Hobart 5359D Operation and Maintenance Manual

OM 2012

082585

Revised 042188

OPERATION AND MAINTENANCE MANUAL

with

ILLUSTRATED PARTS LIST.

for

E.N G INE -DRIVEN* GENERATOR SET

SERIES 5359P, MODE L 9OG20

909KVA , 400-H z, 115/200-V AC, 3 Phase

with

DETROIT DlEsELENGINE, TYPE 4-71N

.

Specification Number 5359&l, For truck or trailer mounting

Speciftiation Number 53590-2, For tracta mounting

Specification Number 5359@-3, For stationary mounting

Specification Number 5359s 9,; For truck or trailer mounting

(Special features for ‘AF)

.

Manufactured by

HOBART BROTHERS COMPANY

POWRSYSTEMS DNISION

TROY, OHIO 45373

U.S.A.

,

.--

_ -

L

i

.-

SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTKFCAL POWER EQUIPMENT I

WARNING

I

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

I

ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and

ignite combustible material.

Do not use power cables to

break load and be sure tools don't cause short circuit+.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attach{d

equipment.

I

IMPORTANT: - Protect yourself and others.

Read and understand all the

instructions in this Operating/Instruction Manual before

j

!

A.

B.

installing, operating,

or servicing this equipment.

manual available for future use by all operators.

Keep th{s

I

GENERAL

Equipment that supplies electrical power can cause serious injury or death,

or damage to other equipment or property,

if the operator does not str$ctly

observe all safety rules and take precautionary actions.

Safe practides

have developed from past experience in the use of power source equipmt&t.

SHOCK PREVENTION

I

Bare'conductors, or terminals in the output circuit, or ungrounded,

I

electrically-live equipment can fatally shock a person.

Have a tiompei&nt

electrician verify that the equipment is adequately grounded and learn what

terminals and parts are electrically HOT.

Use proper safety clothing;

procedures,

and test equipment.

\

I

The electrical resistance of the body is decreased when wet, thus more

easily permitting dangerous currents to flow through It. When fnspecting OF

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.

,

!

I. Installation and Grounding of Electrically Powered Equipment -Elet$tricab

equipment must be installed and maintained in accordance with the NatJonal j

Electrical Code, ANSI/NFPA 70, and other applicable codes.

A power discon-!

nect switch or circuit breaker must be located at the equipment.

nameplate for voltage, frequency, and phase requirements.

If only

Cheek the;

power is available,

3-phase j

of the 3-phase line.

connect any single-phase rated equipment to only two wipes

DO NOT CONNECT the equipment grounding &onductor (lea/d)

to the third live wire of the 3-phase line, as this makes the equipmelfit frame

electrically HOT, which can cause a fatal shGky--

l

1

-w-e--

!

I

I ;

- ..-. m-t-.- ._ -.. .1

I

1

Dee 41184

I-. -, - _- __ _ _ - -_ -.. __ _..

I

c

C.

I

1 D.

I

j E.

F.

+- _. ^_ ‘.’

Be sure to.connect the grounding lead,

if supplied $,,aXpower line cabIe;~..:.,,--

to the grounded -s&t&-box or.building ground;.

-Ifs-t&--provided, use a:- ;

separate grounding lead.

Be certain that the current (amperage) capacity j

of the grounding lead will be adequate for the worst fault current sltua-

'

tion. Refer to the National Electrical Code ANSI/NFPA 70 for detai1s.i Do

not remove plug ground prongs.

Use correct mating receptacles.

I

2.

Output Cables and Terminals

- Inspect cables often for damage to the !

insulation and the connectors.

Replace or repair cracked or worn cables !

Immediately.

Do not overload cables.

equipment is energized.

Do not touch output terminal whfle

FIRE PREVENTION

Overloaded or shorted equipment can become hot enough to cause fires e+ther

by self destruction or causing nearby combustibles to ignite. Provide!

primary input protection to remove short circuited or heavily overload+d

i

!

equipment from the line.

I

!

,

BODILY INJURY PREVENTION

/

Serious injury can result from contact with fans inside the equipment.:

b

Shut DOWN equipment for Inspection and routine maintenance. When. equ;pment

is in operation use extreme care in doing necessary troubleshooting and

adjustment.

t

1

Inspect all precautionary labels on the equipment monthly.

Order and 1

_,~_ ~. -

replace all labels that cannot be easily read. -- -

~- --I

I

. . .._ ..- .-

.-- - -_ - _-..-..-_.. ..- _.._ .-... _ .._ __ ..-_.

/

.-- -_.-. _ ._ _.

w-2

3. Service and Maintenance -

This equipment must be maintained in good

electrical and mechanical condition to avoid hazards stemming from dis+

repair. Report any equipment defect or safety hazard to your supervisor ant

discontinue use of the equipment until its safety has been assured. Re-

pairs.should be made by qualified personnel only. Shut OFF all power gt

the disconnecting switch or line breaker before inspecting or servicing the

equipment. Lock switch OPEN (or remove line fuses) so that power cannot be

turned ON accidentally.

Disconnect power to equipment If it is out of;ser-

vice.

If troubleshooting must be done with the unit energized, have pre-

sent another person trained in turning off the equipment and provldlng,or

calling for first aid.

4

MEDICAL AND FIRST AID TREATMENT

First aid facilities and a qualified first aid person should be available

for each shift for immediate treatment of all Injury victims. Electric

shock victims should be checked by a physician and taken to a hospital/

immediately if any abnormal signs are observed.

I-

EMERGENCY FIRST AID

Call physician immediately. Seek additional assistance and use First hd

techniques recommended by American Red Cross until medical help arrive6.

IF BREATHING IS DIFFICULT, give oxygen,

if available, and have victim jfe

down.

FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not

breathing, begin artificial respiration, preferably mouth-to-mouth. I!f

no detectable pulse, begin external heart massage. Call Emergency Res)cue

Squad immediately.

I

EQUIPMENT PRECAUTIONARY LABELS

.I

OM 2012

ItiTR ODUCT ION

This manual contains operation and maintenance information for a 4OO+Iertz, generator set

manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373.

The manual is not intended to be a text book on electricity cr electronics.

Its primary purpose is

to provide information and instructions to experienced operators, electricians, and mechanics

who have never seen or operated this generator set.

It is the intent of 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

instructions before starting the unit.

Learn to use the manual and to locate information con-

tained in it. Its style and arrangement are very similar to commercial aircraft manuals.

The manual is divided into six chapters.

Each chapter is divided into as many sections

as required.

Each new section starts with page 1.

Each page is identified by chapter,

section qnd page number which are located in the lower, outside corner. When information

located in another portion of the manual is referred to, its location is identified by chapter,

section, and paragraph, or figure number. For example, “(See 2-3, Para. B) ‘I refers

to information located in Chapter 2, Section 3, paragraph 8.

If a Chapter and Section are

not indicated in a reference, the referenced material is l&ted in the same section as the

reference, Example, (See Para. B).

In addition to operation and maintenance instructions,

the manual contains an illustrated

parts list iri Chapter 4, and a collection of manufacturer’s literature and supplemental

info-pen in Chapter 6.

\

.

1

-_.-..

Content of the manual is arranged as follows :

Chapter

1. Description/Operation

Chapter

2. Servicing

Chapter 3. Trouble Shooting

Chapter 4. Illustrated Parts List

Chapter 5. Optional Equipment

Chapter 6. Manufacturer’s Literature

Aug 25 185

lntroduc t ion

Page 1

OM 2012

TABE OF c O~TEblTS

SUBJECT

--

CkiAPT&‘SECTi01\!

PA GE

.

ink o&c t ion

1

Table of Contents

1

Description/Operation

1

1-O

l-1

Descr i@ ion

1

1. General

1

2. Orientation

1

3. S pet ia 1 Features

1

A.

‘Roll-Out” Feature Ji’ractor-Mounted Unib)

6

9. Protective Monitor

6

,

6

C. Pull-out Trays

.

D. Voltage Regulator

E. Test Circuiky .

F. Electric Governor

6

4. Ident if icat ion

7

A. Genera6

7

9.

Generatcr Sets Available in 5359C Series

7

5. Optional Equipment

7

A. Trailer

a

9. Truck

8

C. Transfcrmer-Rectifier

8

6. Canopy

8

Contents

Page 1

Avg 25%5

OH 2012

TABLE OF COhTZfiTS (COiuT’D)

SUBJECT

CHAP-fEl:/‘SECTiC~

7. Engine, Generator and Controls Assembly

l-1

A. Basic Engine

fi.

Engine Manufacturer s Equipment

C. Hobart’ Engine Equipment

(1) Electric governor system

(a) Magnetic pickup

(b) Control unit

(c) Actuator

(2> Engine safety devices

(a) Overspeed governor

(b)

Temperature sensing safety switch

(c) Start circuit cut-out switch

(d)

Start circuit solenoid switch

(3) Air cleaner

(4) Exhaust system

(5) Rad iat or

D. Generator

E. Control Box Assembly

(1) Generator control tray

(a) Resistors

(b) Generator output monitors (meters)

.

PAGE

9 :

9

10

11

11 *

11

13

14

15

16

Contents

Page 2

Aug 25 &i

.

c

OM 2012

TABLE OF CO!~‘TEt’JTTS (CONT’D)

SlJBJECT

--

(c) M2ter and line switches

CHAPTER/SECTION

PA GE

l-l

’ 16

(d)

Rece ptac 13 c onnec t cr

18

(e) Tray

18

(f) Manual voltage control

18

(9)

EXC itation-deenerg ization re lay

18

(2) Protective relay fray

18

‘(a) S

ens ing modu Ies

18

(b) Memory and time-de!ay module

19

(c) indicating lights

19

(d) Plug-inter lock relay

.

21

(e) Test-bank switch

’ 21

(f) Res istor

(g) Fuse-interlock relay

21

.

(h) Connector

21

(k) Auxiliary underfrequency relay

;

22

F. Engine Control Panel

22

(1) Engine instruments

(4 A

mmeter

22

(b) Temperature gage

22

(c) Oil pressure gage and oil pressure switch

23

(d) Hourmeter

23

Aug 2545

Contents

Page 3

OM 2012

TABLE OF COiuTEN IS (CONT’D)

--

SUBJECT

CHAPTER/SECT ;Cti

PA GE

-

(2) Engine und generator contrck

l-l

23

(a) Fuse

23

@) Engine-generator control switch

23

(c) Contactcr control switch

24

(d) Instrurrcnt light and switch

24

(e) Engine starting circuit

24

(f) Indicating lights

24

(9) f%e 1 9ase

(h) Coid weather starting aid control

(k) Engine stop control

(3) Air c leaner indicator

(4) Test receptacle connector

(5) Charging circuit resistor

G. Voltage Kegulatar

(1) Controls

26

26 ’

27

(2) Protection

27

(3) C omponenfs

27

H. Power Module Panel Assembly

30

(1) Load contactor

30

(2) Current transformers

30

Contents

Page 4

.

Aug 25185

OM 2012

TABLE OF CONTENTS (CONTiNUED)

SUBJECT

CHAPTER/SECTION

PAGE

(a) Ammeter current transformen

l-l

30

(b) Line-drop current transformers

30

(c) Overload current transfoners

31

(3) Overload module

32

’ (4) Rectifier

32

(5) Terminal boards

32

8. Test Box

33

A. Description

9. Theory of Operation

9. 5359G

A. RFI Suppression Kit

9. , 24 Volt DC Power Supply Kit

Preparation for Use, Storage, or Shipping

33

34

l-2

.

1

1.

Preparation for Use

1

A. Genemi

1

9. Inspection/Check

1

C. Installing Output Cables

(1) Three-phase, AC output cable ossembl y

installation

(2) Transformer-rectifier (DC) output cable

installation

4

2.

Prepamtion for Storage

5

A. Geneml

5

9. Tempomry Skmge

5

C. Long Time Storage (Over 30 Days)

5

Aug 25 185

Contents

Page 5

TABIE OF CONTENTS (CONT’D)

OM 2012

SUD.JECT

CHAPTEI:/SECT~O~~

PAGE

3,

Preparation for Shipnx?nt

l-2

Operaf ion

l-3

1.

Gcr,era I

2. Operatir~g’tile’Generatcr Set

A. Pre-start Inspection

9. N mna I Engine Starting Procedures

C. Cold Weather Engine Starting Procedures

D. Preparation for Power Delivery (Normal Automatic

Voltage Control)

E. Power De I ivery (Automatic V&age Control)

.

F. Prewation for Power Delivery (Manual Voltage

Control)

G . Power De livery (Manual Voltage Control)

H. Discontinue Power Delivery

K. Stopping the Engine

3. Test Box Operation

4. Transfamer-Rectifier Operation (Optional Equipmznt)

A. Direct Current Power Delivery

9. Simultaneous 28.5-V and 35-V DC Power Delivery

C. Simultaneous 28.5-V DC and 115-V AC Power Delivery

D. Simultaneous 35-V DC, CT 112-V DC and 115-VAC

-

I

Power De livery

5.

24 Volt DC Power Supply

Contents

Page 6

7

8

9

1.0

11

12

13

Aug 25,/85

OM 2012

SWJECT

CHAPTEiR,/SECTIOju

-----

Scrv ice

2-o -

h{a in te nance

Z-1

1.

Genera I

2. Operation of Roll-OUF Feature (Tractcr-Momled Units)

A. Roll Generotor Set Out for Service

B.

Roll Generator Set In to Normal Position

3.

Inspect ion

4. lubrication

A. General

B. AC Generator

C. Generator Controls

D. Engine

(1) Lubrication schedule

(2) Oil specification

(3) Oil viscosity

(4) Change engine oil

(5) Change oil filter element

E .

E ng ine Access cc ies

(1) A lternatrx

(2) Siarter

(3) Overspeed governor arld drive

,

3

6

7

8

9

Aug 25%

Contents

Page 7

OM 2012

TAB!E OF CONTENTS (CONT’D)

SUBJECT

CI-IAPKI!/SECTlO~

PAGE

5. Air Cleaner Service

A.

Car-jr idge Re mova I

B.

Cartr idye

Ins ta I lat ion

6. Engine Fuel

A. Qua1 ity

B.

Fue I Filters

(1) Daily service

I

(2) Change strainer and filter elements

(3) Ctwngespin-on strainer and filter

7. Engine Cooling System

A. General

3.

Radiatoh Cap

(1) General

(2) Removal

(3)

lnsta I lat ion

C. Warm Weather Operation

D . Cold Weather Operation

(1) General

(2) Coolant solution check

(3) Coolant solution preparation

(4) Antifreeze solution installation

b

C onknts

Page 8

-.__

6 ;

2-l

Aug 25185

9

10

11

13

13,

13

14

15

c

OM 2012

TABLE OF CCb!-fETuTS (CC&T’D)

SUBJECT

CHAPTER ,‘%CTICIV

PAGE

_- -_I

E.

Drain the Cooling System

2--l l

15

F. Coaling System Cleaning

16

G. Radiator Core Cleaning

H.’ Cdoling System Filling

16

8. Generator Maintenance

18

A. C isaning

18

B.

Adiustment

18

9. Drive Belts

19

.

19

A.

Preparation for Belt Check and Adjustment

.

B.

Check Be It Tens ion

.

C. Be it Adjustmzznt

(1) Alternatcc belt

(2) Fanbeiis’

20

10. Service Helps

22

A. Wiring

22

B.

Control Box Trays

(1) Tray removal

22

(2) Tray insta I iat ion

C . Generator Exciter

22

23

(1) Preparation for exciter removal

23

(2) Exe iter remova I

23

Aug 25,/8!5

Contenb

Page 9

TABLE OF COIU-ENTS (CL?1Uf’D)

SWJECT

---

CHAPEL/‘SECTlCt~ FAGE

(3) Exe i:er insfai lation

2-l

D. Engine Control Panel

(1) Ti!t out engine control pawi

(2) t&instuII engine control panel

InspectiwjCheck

1.

.Genera I

2-2

2. Engine

A’. Fuel

B.

Lcl br icat ion

C. Coolant

.

De V-Belts

E . Exhaust-System

3. Electric System (12-V DC)

A. Lights

B. Fuses

C. Wiring Connections

4. E iectrical System (115-V AC)

A. Monita ing Instrurtznts

B.

Ind icat ing Lighb

C. Protective Modules

D. Wiring and Connections

Contents

Page 10

OM 2012

24

1

1’

1

3

4

Au g 25 I85

OM 2012

.

TABLE OFCO!uTEtiTS (CONT’D)

SUGXCI

--

CHAPTiXf,/SECTiON

--

.

Adjustment/Tesi

2-3

1.

General

2.

Preparation for Test for Tractor-Mounted Units

<

A. Generator Set Removed from Tractor

B.

Generator Set in Tow Tractor

3. Generator Set Test

A. Pre-opzrationa I Test Procedures

B.

Operat iona I Test Procedures

4. Generator Set Adjustment

A. Generator Adjustmnt

8.

Generator Controls Adjustment

(1) Adjust manual voltage control variable resistor

(2) Adjust 400-l-i

2 voltage regulator

(a) Adjust generator output voltage

(b) Adjst cable length and cable size

compensation rheostats

(c) Adjust “damp” and “rate “ adjusting

potentiometers

C. Basic Engine Adjustment

(1) Exhaust valve adjustment

(2) Exhaust valve bridge adjustment

(3) Fuel injector timing adjustment

PAGE

--

1

2

9

15

16

17

19

,

Contents

Page 11

OM 2012

TABLE- OF C9NTf3luTS (CO;%-‘D)

SUBJECT

CHkl’i-EK/SECT ION

PAGE

(4) Idle speed, speed limiting, and overspzed

adjustment

2-3

D. Engine Accessories Adjustment

E . E IectriF Governor System Adiustment

(1) Actuator linkage adjustment

(2) Magnetic pickup adjustment

23

(3) Governor control unit adjustment

24

(4) Electric governor test values

(a)

S igna I to actuatcf

(b) Magnetic pickup signal

F. Engin& Shut-Down Devices Adjrrstment

.

(1) Starter cut-out switch adjustment

(2) Shut-down linkage adjustment

28

5. Generator and Exciter Test

6. Diode Test

I

7. 24 Volt DC Power Supply Test

Trouble Shooting

Trouble Shooting Procedures

1. General

2. Trouble Shooting Chart

A. Description

I

B. Use of Trouble Shooting Chart

Conh?llts

Page 12

3-o

3-l

.

20

21

26

28

29

31

1

Aug 25 &i

OM 2012

.

TABLE OF CONTE~YTS (CONT’n)

----__

SUBJECT

--

CHAP-lXR/SECffON

PA GE

3. Equipmnt for Trouble’Shooting 3-l -

2

4. Safety

2

5. Parts Replacemznt

2

6. T&t Va fues

7. Check Connections and Leads

3

8. Electric Governor Trouble Shooting

3

9. Engine Trouble Shooting Procedures

4

A. General

B.

Locating a N&firing Cylinder

4

C . Checking Compress ion

5

D.

Interpretation of Compress ion Pressure Chart

,

6

E.

Causes of Low Cylinder Pressure

6

F. Fuel Flow Test

10. Illustrations

II lustrated Parts List

introduction

1.

General

2. Purpose

3. Arrangement

4. Explanation of Parts List

6

4-o

1

4-1 1

1

Aug 25’85

C cntenis

Page 13

OM 2012

SUGJFCI- CHAPTER/‘SECT (09. PAGE

.

A .

C OntC il iS

4-1

1

B.

PUitS Li;t Form 1

(1) “Figure-Item No. ” Column

2

(2) “Hobart Part No. ” Column

(3) “N omenc lature ” Column

(4)

‘E FF” @ Ffective) Column

(5) “Units Per Assembly” Column

Manufacturer’s Codes

4-2

1. Explanation of Manufacturer’s (Vendor’s) Code List

I

.

Park List .

4-3

1. Explanation of Parts List Arrangement

,

2. Symbols and Abbreviations

Optional Equipment

5-o

Manufacturer’s Literature

LIST OF ILLUSTRATIONS

6-O

2

3

1

1’

1

CHAPTER/ FIGURE

PAGE

SECTION NUMBER

TITLE

NO.

l-l 1

Generator Set

2

l-l 2

Specifications and Capabilities (Two Sheets)

3-4

l-l 3

Generatcr Set Components

5

l-l

4

Generator Set Identification Chart

7

Contents

Aug 25 0%

Page 14

OM 2012

LIST OF ILLUSTRATIONS (CONT’D)

CHAPTER/

l-l

I

l-l

l-2

l-3

2-l

Aug 25185

FIGURE

NUMBER

TlTLE

5

6

7

8

9

10

11

12

13

14

15

16

1

2

3

Engine Shut-Down and Safety Devices

Air Cleaner and Service indicator

Noise Reduction Exhaust System

Control Box

Generator Control Tray

Protective Relay Tray

Engine Control Panel

Voltage Regulator

Power Module Panel Assembly

Test Box Assembly

RF I Suppression Network

24 Volt DC Power Supply Kit

Engine Oil Gage Rod and Filler Cap

AC Output Terminal Panel

T-R Output Cable installation

Operating Controts and lnstrunents (Two Sheets)

Shut-down Valve Latch and Starter Safety Switch

Overspeed Governor

Cold Weather Starting Aid

Test Box Operating Controls

Test Receptacle Connector

Transformer-Rectifier

--

PAGE

NO.

12

13

14

16

17

20

25

29

31

33

35

37

2

4

-4

2-3

4

5

6

10

’ 11

12

1

Roll-out Stop-bar

2

Generator Set Retaining Camponents 2

3

Lubrication and Maintenance Chart 4

4

Lubricants 5

5 Lubrication Chart Symbols ad Time Intervals

5

6 Oil and Coolant Capacities

5

* 7 Oil Filter 8

8 Air Cleaner Cartridge Replacement

10

9

Fuel Filter and Strainer

12

10 Antifreeze Solution Table 15

11

Coolant Drain Valve Locution

17

12 Belt Tension Chart

19

13 Alternator BeIt Adjustment

20

14

Fan Belt Adjustment

21

15

Tray Removal 22

16

Removable Rear Frame Cross-Member 23

17

Eqine Control Panel in Tilt-Out Position 25

Contents

Page 15

CHAPTER/

FIGURE

SECTlO!\!

fuUMGER

2-2 1

2-2

2

2-2

3

2-3 ld

Fue I and Battery Connect ions

2-3

2

Operating C 0ntr 01s

and Instruments (Two S beets)

2-3 3

Engine Shut-Down Solenoid with Linkage and

2-3

3-l

3-1’

3-l

4

5

6

7

8

9

10

11

12

13

14

15

44:;

:

4-l 3

11;

4

5

4-l 6’

4-l

7

LIST OF fLf~JSTftATiOi~.S (CCX’JP’D)

TSi-LE

ltap~ction/Check/N~aintenance Schcdulo

Lamp Identification Chart

Fuse Identification Chart

Starter Cut-Out Switch

Starter and Solenoid Switch

Test Receptacle Connector Terminals Identification

Voltage Kegulatpr Adjustments

Voltage Regulator Damping Adjustment

E ng ine S pet if icat ions

Governor Linkage

Magnetic Pie kup

Electric Governor Control Box Lcoation

Electric Governor Control Bcx Adjustment

Electric Governor Connection Diagram

Generator and Exciter Statcr Test

Typical Test Values at Test Receptacle Connector

or Test Box

Operating Gontrols and lnstrurr-ents (Two Sheets)

Starter and Solenoid Switch

Engine Shut-Down Solenoid and Linkage

Engine Shut-Down and Safety Devices

Exe itaticn Resistors

End View of Voltage Regulatcr Amphe’nol Connector

Fuel Flow Schematic (Typical)

Test Receptacle Connector Terminals Identification

Trcuble Shooting Chart (21 Sheets)

Generatcr Set

Canopy Assembly

Generator Set Without Canopy

Radiator and Cooling System Group

Engine & Air C leaner Group

Starter Cut-Out Switch Assembly

OM 2012

PAGE

NO:

2

3

4

1

4-5

4

8

;;

20

22

24

25

27

29

.

30

7-8

9

10

11

12

13

14

15 thru 35

2

4

8

12

16

20

24

Contents

Page 16

Aug 25,‘85

OM 2012

c

Ct-iAPTEt~,'

FIGURE

SECT ION I\( u MBE R

--

-

4-l

4-1

4-l

4-j

4-1

4-I

4-1

4-l

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I

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8

9

10

11

12

.

13

14

15

16

17

18

17

20

21

22

23

24

25

26

27

TiTLE

E lectiic Governor Kit Assembly

Fuel Lines Assembly

Oil Lint Assembly

Fuel Lines Assembly

Fuel Oil Linzs

Fuel Lines Assembly

Stator Terminal Pane i Assembly

Power Module Panel Assembly

Control BGX Group

GeneratE Controls Tray Assembly

Protective Relays Tray A<jcmbIy

Contra! Box and Inferna! Compo;lenh Group

Engine Ccnfrof Paw I Assembly

Output Terminal Board Assembly

Generutor Group

Mounfhg Framz and Lifting Yoke Assembly

Auxiliary Frame and Ccmponents

Fue 1 Tank Fift ings Assembly

Suppress ion Kit

24 Volt GC Power Supply Kit

PAGE

tu0.

--

3/

2

30

32

34

36

38

40

44

46

50

54 .

56

60

62

64

66

68

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2

Aug 25’85

Contents

Page 17

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CHAPTER 1. DESCR IPTION/OPERAT ION

SECTION 1. DESCRlPTlOlv

1.

Genera I

The basic generator set (see Fig. 1) covered by the manual is identified as Series 5355KD

The various configurations of the set are identified by adding a dash number (-1, -2,

etc.) suffix to the Series number.

The basic generator set which includes the engine, generatcr and ail controk is identical

for ail mode k. Differences between mode k are those required by their respective mount-

ing, such as trailer mounting, tow tractor mounting, etc.

Identification of different

mode k with in the Series wil I be explained later in the Description.

Information and instructions throughout the manual apply to ail mode k.

infcrmation

which applies only to a certain model will be qualified and identified as such.

The purpose of the generator set ‘a to generate and de liver regulated, 400-H~ e iectrica I

power to a parked (or towed) aircraft for operation of the aircraft’s electrical equipment

when the on-board generators are not running. The engine, generator, and ccntrok

are designed into a compact unit which is easily removable from a tow.tractor. See

Figure 2 fcr specifications and capabilities.

2. Orientation

.

For purpose of orientation and to familiarize operatars and maintenance personnel with

the location of components, the radiator k considered to be at the FRONT of the unit.

The generator and controk are at the REAR. RIGHT and LEFT are determined by stand-

ing at the rear end facing the machine. Thus, the generator control box, output recep-

tat ie connecta, and engine control pane I are mounted on the LE FT side at the REAR

of the unit.

3. Soeciai Features

The generator set has many special features which are later described mare fully under

the assemblies in which they appear. Some of the main features are mentioned here

and described briefly.

Aug 25,‘85

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1. Canopy

2. Access

- vent covers

3. Lifting eye

4. Windows

5. Output receptacle cover

6. Output cable horn

7. Koii-out tracks (for tractor-

mounted un its on I y)

8. Engine fan exhaust deflectors

9. Engine exhaust pipe

10. Radiator cap access cover

Generator Set

Figure 1

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Aug 25435

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PHYSiCAL (Bas ic Generator Set)

Length

Width (without tracks)

Height (without i ifting eye)

Weight (without tracks )

82 INCHES (2082.8 MM)

35 INCHES (889 0 MM)

40 INCHES (1016.0 MM)

Approx. 3980 POUNDS (1805 KG)

GENERATOR

Output power rating

Output voltage

Rated load capacity

Frequency (cycles-per-second)

Output kilowatts .

Power factor

D* cycle

Operating speed at 400 Hz

Gve’rload capacity

(125% of rated load capacity)

90 KVA

115/200 v

260 A

400 Hz

72 KW

0.8 PF

100%

2000 RPM

325 A

GENERATOR PROTECTIVE SYSTEM

Overvoltage relay

trips 130 V to 134 V;resdts 125 V

Undervohage relay

trips 102 V 0~ below; resets 110 V

Overfrequency t-e lay

trips 415 Hz to 425 Hz;resets 410 Hz

Underfrequency relay

trips 375 Hz to 385 Hqresets 385 Hz

Overload relay

trips 112 KVA in less than 5 minutes

Undervo itage

time delay relay

4 to 12 seconds

Specifications and Capabilities

Figure 2 ( Sheet 1 of 2)

Aug 25 ‘85

Page 3

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I

ENGINE

Manufacturer

Model

Type

Number: of cylinders

aare

Stroke

Compression ratio (Nominal)

Displacement

Firing order (R. H. Rotation)

Number of main bearings

Horsepower (at 2000 RPM)

Governed speed

jdie speed

Electrical system.

Ground

Oil capacity (w/filter)

Oil cdpacity (pan)

Coolant capacity

Detroit Diesel Engine Division

General Motors Corporation

4-71N Modified 004QSSC (4-71)

Diesel

4

4-l/4 tN.

5 IN.

18.71 to 1

284 CU. IN.

l-3-4-2

5

148

2000 RPM

Approx. 875 RPM

12-V DC

Negative

21-l/2 quarts

(20.344 liters)

20 quarts

(18.925 liters)

9-l/2 gallons

(35.957 liters)

.

STATIONARY UN IT (5359&3) Same as above except:

Battery

Fue I tank capac it y (approx imate Oy

Two, 6 volt

50 gallons

(189 liters)

TRAILER

(See Manual in Chapter 5 when applicable)

Specifications and Capabilities

Figure 2 (Sheet 2 of 2)

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Aug 25185

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#Used on S3!59D-9 only.

1. Kadiator

2. Engine

3. Lifting yoke

4. Starting fluid container

5. Overspeed governor

6. Voltage regu Iator

7. Power module

8. Air cleaner

9. Governor control box

10. Generator control box

11. Engine control panel

13. Cable horn and clamp (Used on all

units except tracts mounted)

14. Output cable terminal board (Used on

all units except tractor mounted)

15. Engine oil filler pipe

16. Generator

17. Governor magnetic pickup

18. Sturter cut-out switch

19. Roli-out rails (Used on tractor mounted

units only)

20. Governor actuator

I

12. Output cable receptacle connector

21. Engine exhaust pipe

(Used on tractor mounted units)

l 22. 24 Volt power supply

Generator Set Components

Figure 3

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Aug 25+35

Page. 5

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A.

“Roil-Out” Fea;urc

(TGW Tracts-Evlo:Jnted Unit)

Th:: s;cnerator set is supp!icd With two-channel-like tracks(JT,Fig. J) which arc

floor mounted in the gc!neraIor Ccrtmp~r’rmCnt of ths tC:v tractor.

Tracks arc cquippzd

with cam-follower, ne:;-die-bearing rollers which support the generator set ur+rlj al-

low it to roli in-and-au,

+ easily for servicing and maintenance.

Additiona! rollers

are mounkd on each

side of iho generator set main frame,

near the rear, to add

stability and to p;-cvet!t- the unit from tipping downward at ihe front when it is

rolled outward for service.

The set is secured in mounted position by two retaining bra&is attached at the front

of the unit (see 2-J, Fig. 2). The removal of twoscrews from the brackets allows the

set to be rolled out approximately38 inches,

wh.ere a stop-bar on the main frame

contacts a stop-block in the left track to prevent further outwardtravel.

B.

Protective Monitor

Asingle, solid-state device (4, Fig. JO) receives signals from a]1 of the fault sensing

units in t-he generator output circuit and functions to cause the load to be disconnected

from the generator if an abnormal ccndition of voltage, frequency, or load develops.

C. Pull-cut Trays

.

The control box is equipped with pul!-out, drawer-type trays (Fig. 8)

which provide ‘easy access to controls and equipment mounted in them. Each t&y

*

may be removed as an assembly bydi:;connecting a single quick-disconnect connector

and tripping. two safety latches.

D. Voltage Regulator

A solid-state, adjustable voltage regulator (Fig.

12) provides automatic voltage regula-

tion at the aircraft (or distribution panel when applicable). The regulator is also ad-

justable for a variety of output cable sizes and lengths.

E. Test Circuitry

A receptacle connector (Jo, Fig l

JJ) with wiring to various test points throughout the

electrical circuitry is provided for the attachment of a test box manufactured by Hobart

Brothers.

This test circuitry allows electricians to perform as many as twenty-four tests

and che,cks from one location, conveniently and easily.

F. Electric Governor

The engine is equipped with an all electric type governor kit (9, 17, and 20,

Fig. 3) and other speciai equipment more fully described under the engine description.

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Page 6

Aug 2545

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4.

5.

identification

A. General

Generator sets are identified by their Specification number which consists of the

Series number plus a dash number (i.e.

-1, -2, etc.) suffix. The suffix number

indicates the mounting design of the generator set. For example, Specification

number 5359@-2 identifies a machine designed for mounting on a tow tractor.

0.

Generator Sets Avai fable in 53590 Ser’ies

(I) The identification chart (Fig. 4) lists machines current/y available in 53590

*

Series.

Specification

Number

5359::p. 1

5359rp 2

5359B-3

5359& q

Characteristic

Designed for trailer or truck mounting. 12-V DC

electrical power and fuel to be supplied from

facilities on trailer or truck.

Designed for mounting on a tow tractor. 12-V DC

electrical mer and fuel supplied by tow tractor.

Furnished with roll-out tracks for mounting in a

tow tractor.

Designed for stationary mounting. Equipped with

two 12-V batteries and fuel tank.

Sune as 5359C-1 except with RFI Suppression and

24 Volt Power Supply (Refer to para. 9)

Generator Set ldentif ication Chart

Figure 4

(2)

The stationary unit (53590-3) is the same as the tractor mounted unit except

that is equipped with a fuel tank and batteries.

The 50-gallon tank is mounted

in the main frane below the generator.

Batteries are mounted in a box directly

behind the generator.

Roll-out tracks are not supplied with this unit.

Optional Equipment

Several items of optional equipment are available for the 53590 Series. Each piece of

optional equipment is covered by its own Instruction and Parts Manual and wi II not be

covered in this basic manual, When applicable, information for optional equipment

wil I be located in Chapter 5.

Options are listed as follows:

Aug 25185

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A. Tr-ui!zr

A foilr-whee

B.

True I-,

! tank is avoilal:!~.

.

Truc!:s with spzcicl bodks for mounding thn generotor set ore avai!abk . Compr-fil;cnts

in the body arc provided for b:*t:eries, cable storage, etc. Trucks ava i lablz are

Ford, Chevrolet, a,,d GtiC.

I

C. Transformer-Rectifier

Three different T-Rs are avai!able for use with the generator set. T-k op;“rate from

the 400-Hz, 115-V AC

genzrcrtor output and produce a DC output of 28.5-V, 35-V,

or 112-V depnding upon the T-K selected.

6. Canopy

A sheet rretal enclosure, identified as a canopy (1, Fig. l),provides protection fti the

engine, generator and electrical controls.

The canopy is designed to reduce the operational noise level in the immediate area of

the moo h ine .

Doors and panels are covered on the inside with Fiberglas acoustic material

to reduce rcf lekted and conducted noise, and to abscb noise.

Noise prodvc ing vibration

in most freqtient ly used doors on the left side is reduced by the use of two-point s Iani locks.

.

Less frequently used doors on the right side are equipp&d with screw-operated latch fasteners

which are tightened after latching to reduce vibration.

Insulating strip around all doors

also reduce noise.

ktal strip. are mounted ho;izontaIly acras the front grille to deflect

.

engine fun exhaust air and noise upward.

Two large openings in the canopy top provide an entrance for cooling air and an access

to internal components. A hood-type cover is mounted about two inches above each open-

ing . The cover is flanged downward and extends beyond the edges of the upwardly flanged

opening to prevent entrance of blowing rain while still allowing a good flow of air. Air

enters the forward opening into the engine compartment and is discharged through the

radiator by the engine fan.

Air enters the rear opening into the generator compartment.

It is then circulated over generator controls and drawn into the rear exciter and genera-

tor housings where it passes over all windings before king discharged by the generator

fan.

All generator sets in this Series except the tractor-mounted unit are equipped with a canopy

having dotis on both sides. Tractor-mounted units have two large removable panels on

the right side mainly because the right side of the machine is not accessible when mounted

on a tow tractor, and secondly because the thick doors would not allow mounting in the

limited space available on the tractor.

Panel mounted instruments may be observed through

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Aug 25185

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.‘TC . . .* .z ,+$‘,““ll*r~

OM. 2012

two Plcxisiass wirtdoe:; in the ICI-> rcclr dnc; which covers the control 1:~ and engine

C ontr 0 I p:lnD I .

Tilt lower vfi:>dcJ?*/ is slclnted outward at fr?e bsticm tc p<-svidz UCCCT,S

to engine co::tro!s v:h::n the doLtr is closed. A centruily-loeu

:cd tift+ eye nita::hc:d

to a IiR ing yoke exf-c,:ds througij the canopy top to provide a;, Giiachii:s point for clonic-:;,

cables, chr hook uSed ;o lift or:d move t!,lc gcncrcrto; set.

This assenlbiy is the basic generotor set without canopy and rol!-out tracks.

lt includes

all components required to generate and regulate 4QO Hz, 11.5/?00 V, three-p!lase p3’.*:cr,

and is operabie when provided with fuel and 12 V DC power. The engine-generator

assembly is mounted on a welded steel frame. A supcrstructurc, attached to the main

frame, provides mounting facilities 5x the canopy,

contrcl box, and eleciricc! equip-

ment and controls.

A. Basic Engine

The engine is a four-cylinder, in-line, diesel type (d-71 N), identified US Model

No. 004055C with “N” features, by the moncrfacturer, Detroit Diesel Engine Divi-

sion, General Motors Corporation, Detroit, Michigan. See Fig. 2 for general

specifications.

e

8.

Engine Manufacturer’s Equipment

-As received from the engine manufacturer, the engine includes the fo.ifoking equip-

.ment which is described in the Engine Operator’s Manual (Chapter 6).

(1) Twelve-volt electrical system includes starter and alternator with built-in

voltage regu later .

(2) Ether starting aid s&m

(3) Fuel strainer and fuel filter

(4) Full-flow oil filter

(5) Automatic shutdown system including temperature and pressure sensing

switches, a “hot-wire” relay, and a solenoid-operated, cam-and-latch

type shutdown valve in the blower air intake.

(6) Speed limiting governor

(7) Reverse-flow, engine-cooling fan to blow air outward through the radiator

Alf of the above equipment, except the fan,

is described in the Detroit Diesel

Operator’s Manual.

Aug 254~5

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C. ii&art Ensine Equlpmzn!

(1) Electric governor sy:tirn

An e lec:r;

c yo*cerrtor kit is instolltid on the engine

to rcp!ace a CcnWii~icnCJI,

rnzchirnicai typz. The electric governor was se/ectcd for con;-rol of ensir;

speed (and generator output freqczncy) because it provides faster engill?

respdze

to changes in load conditio!r, .

This fast rcsponcc resufts in very

close frequ0icy control.

Refer to the American Bozch t-ian&rmk in Chapter 6

for a detailed description. A brief description is given below:

The governor system consists of th

e fol lowing ri;u in components :

Magnetic pickup

Control unit

Actuator

(a) Magnetic pit kup

The magnetic pickup (17, Fig. 3j is a device for detecting the spzcd of

* the engine. It is mounted in the flywheel housing directly over the ring

gear. It produces an AC signal to the control unit when the ferret-s fly- ,

wheel teeth pass through the rnagnztic field at the end of the pickup.

(b) Control unit

The control unit (9, Fig. 3) is a box containing a compact assembly of

solid state components.

It receives an AC signal from the magnetic pick-

up and senses speed changes in the engine.

It provides o voltage signal

to the actuator which causes the actuat,or to move the fuel control lever

as required to maintain a predetermined engine speed. Ifs power is re-

ce ived from the 12-V DC battery system.

(c) Actuator

The actuator (20, Fig. 3) supplies the force needed to move and position

the fuel lever as required to maintain a corstant engine speed. The actuator

is operated by a DC signal from the control unit.

(2) Engine safety devices

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Page 10

Aug 25’85

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(a) Overspccd ~~o~crnor .

The overspzed governor (5, Fig. 3)

is a rfecharlica I fly-we i&t i’ypr: ,

mounted ot the rear of the engine alrd driven throL!gh an adai:.:e: by the

canahcrft.

E Irctrical contacir, in the governor are connected in pxa lict I

with other engine shutdcwn devices. The gol;srnDr i; adiustcd to c;lcze

the ~otlfu~t- ond actuate the shutdown solnnoid when an enginz stxed of

2250 to 2300 KPM is reached.

The governor must tx manually reset, after

tr ipp ing ,

by pushing a button located on the governor head.

(b) Temperature sensing safety switch

This switch (IO, Fig. 5) is mounted in the engine water outlet manifold

and is identified as an “Alarmtut”.

It is very sensitive to temperature

changes and functions to protect the engine against overheating caused

by low coolant level, brcken fan belt, etc.

It sends a signal which

activates the shut-down solenoid to stop the engine when temperature

in the cooling system reaches 205 deg F.

(c) Start circuit cut-out switch

.

This is a Micro-type switch (7, Fig. 5),

mounted just be lciw the air-va Ive ,

shutdown solenoid. It is mechanically actuated by the air-valve operating

lever. The switch is electrically connected in series with the .starter

switch.

In the event t’he

In normal opzration the.switch is CLOSED.

shutdown solenoid is actualed to stop the engine, the switch is OPEIqED

to prevent operation of the engine starter until the shutdown air valve

is LATCHED in OPEN position.

(d) Start circuit solenoid switch

This solenoid type switch (4, Fig. 5) f

unctions to conduct 12-V DC power

to the engine starter switch when the panel mounted pushbutton start switch

is pushed. Th

e solenoid switch serves to by-pass and protect the push-

button starter switch against heavy load current in case the starter device

gear should fail toengage the flywheel ring gear proprly.

Aug 25 ‘85

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Left front engine

Right rear engine

1. Overspeed governor

2. Oil filler tube

3. Oil level gage rod

4. Start circuit auxiliary

solenoid switch

5. Fue I pressure switch

Left rear engine

Right front engine

6. Air shut-off valve latch

7. Start circuit cut-off switch

8. Shut-down solenoid

9. Low-oil-pressure switch

10. High temperature switch

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Page 12

Engine Shut-Down Components

Figure 5

Aug 25 /85

OM 2012

(3) A ii. cleaner

The dksz I-ci:sinc air ckaner (Fig. 6)

is a dt-y-ccirtrirlge tylx. I!- is equi*Qwd

with u moi;turc climinatti and a service indica:ci.

Tl~e ind ica; C: funct ltiia to

s igna I t IW operatm when the cart&-idge ncc& chang ir,g .

A red cy Iin& ice I

“fl33” (2) i; forced upward in a g!cx: cnc Io;ed ~:i~.wing cham!xr (1) when air

pressure wi: h in 1,I-13 a i:- c 1,

‘xaner hex Irrg drop bz 1:~ the 01~;s j(.k air piessu~z .

As the coriridgc kco;n~s loaded v/ith dirt and air pressure within the cleaner

lessens,

the “flag” gradually rises higher in the glcss viewing chamber. When

the “flag” reaches the top of the chamber,

it leeks in that PCjition to warn

the operator that ihe cartridge must be changed. The “flag” is resrt (unlocked)

by pushing the reset button (3) located on the bottom of the indicaf-or.

NOTE:

The service indicator is mounted cn the engine control pane I

and connecled 10 thz air cleaner by a rub!ser hose. The ii\-

dicatcc flag is visible only wheti the engine is running, or

when the flag is locked in WAl?N NG position.

TO ENGINE

INOIC4TOR ON

ENGINE CONTROL PANEL

(SEE FIG. II 1

- L VACUUM tiOSE (I,4 IN. I.D.)

AIR CLEANER

TO INDICATOR

1. Viewing chamber

2. lnd.icat ing “flag ”

3. Reset button

Air Cleaner and Service lndicatcr

Figure 6

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Aug 2545

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The cxh~,~t sr;tem cons is

k of a s pc ia I noi,e redtic ing muff Ic:r (3, Fig . 7) wli ich i;

connec:c~d by a Ilcxib!c

pipz (2) to a co9ven:ionai exha~t manifold (I).*

6aff!es in d-e f-c:il pie; outIct direct exhavsi- and no&e dowrlw,erd.

(5) Rad iatti

The radia:or (I, Fig. 3) is a tube type with bolted-on, top a!?d bottom ta;l!s

which permit disassembly fee cleaning and repair.

,

1. Exhaust rnanifold

2. Exhaust pipe

3. Muffler and tailpipe

Noise Reduction ixhaust System

Figure 7

.

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Aug 25 I05

OM 2012

ThC 400-l-Jz c~Cnr?rato:. is a brushless,

revolviny field, three-phase, alternating cur-

rcn; type. The PC~CJT

c;;emllly is mounted by INQ, p~~mcrt~r,:ly fub;icutcd, Seafed,

bal I bearings.

The front bearing is supported by the fan housing; thr? rear beo;ing

is mounted in the exciter housing. Both of ther,e housings ore attached to t!lo main

generat-or stator hcusin~. The front end of the roior shafi extends forwai.c.l !>c:yond

the bearing and is attached to tI:e engine flyv+huel by a hub and flexible r!isc

COU~!iliJ @‘ss~!l?bl~.

The rear end of the rotor shaft extends rearword beyond the

rear bearing and into the exciter stutor housing.

The exciter rotor is mounted on

t!lis shaft extension with a Woodruff key and is secured by a washer and J/2”-13

thd, cap screw.

A rectifier with six diodes is mounted on the exciter rotor and

converts exciter AC ou~tput to DC for excitation 0

f the generotor revolvirrg fields.

The exciter DC output to t-he generator fields, and consequently the generator

output,

is controlled by the amount of DC voftcge supplied to exciter fields by

the static voffage regu!ator.

A centrifugal, radial-blade fan which is par: ,_

of the hub and coupling assembly, draws cooling air over c!l internal wirdiags.

Air enters at the exciter end and is dischcrgrd at the drive end. The complete

generator is bolted to the engine flywheel ,housing.

E.

Control Box Assembly

The control box (Fig. 8)

is a shect.metal enclosure which houses and provides

mounting facilities for generator and engine controls and monitoring equipment.

The box is equipped with two,

drawer type trays which contain generator output

control devices and monitoring instruments. Troys slide in and cut on nylon rollers

for easy access to internally mounted components. Each tray is ecsily remcvable

by disconnecting an

“Amphenol” connector, unlocking safety latches, and sliding

the complete tray assembly out of the control box.

A

shielded, instrument panel light is

mounted on the left side of the control

box front pcnel, to illuminate controls and instruments in the trays.

(1) Generator control tray (See Figure 9)

The generator control tray contains instruments and controls for monitoring

and controlling the generator output.

(a) Res iston

Two, JO-ohm, loo-watt, ballast resistors (2) are connected in series

in the generator exe iter DC fie Id c ircuit.

Au g 25 I85

A variable resistor (1) is connected in series between the manual control

rectifier (14) and rheostut (13). Its purpose is to adjust the DC voltage

to the rheostat and thus determine the voltage range through which the

--heostat can controt generator output voltage.

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Page 1.5

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-------_

Generator

control ira)

Pr ate c t ive

rclaF tra)

Control Box

Figure 8

(b) Generator output monitors (meters)

The generator output is monitored by three instruments; a frequency meter

(lO),a voltmeter (9), and an ammeter (7). The frequency meter is a

resonant-reed type,,

and indicates the frequency of th- generator output

alternating current in the rcnge of 380 to 420 Hz (cycles per second). The

voitmeter indicates the’ geflerator 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 se!ector switch (6)

and the line selector switch (5). (These

switches will be described below.) The voltmeter has a 3-l/!-inch face ’

and the scale is graduated 0 to 300 V. The ammeter is also 3-l/2-inch

size ond is graduated 0 to 500 A. The amperage value in each of the

three phases may be read on the ammeter by sefecting the desired phase

with switch (6). Three ammeter current transformers (Ref. 4, Fig. 13)

lower the output load current to a lesser value, of definite ratio, which

will operate the ammeter movement without damage. The ammeter dial

scale is graduated and numbered so that the pointer will indicate the true

load current value rather than the meter movement current.

(c) Meter and line switches

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Page 16

These ,witches provide a means of selecting and determining 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

(6) is a four-position, rotary type. A namep!ate (4), located under the

switch knob,, is marked and lettered to indicate the three functional

positions of the meter switch.

(When the knob is pointing straight down,

the switch is OFF.) The line switch (5) is a two-position, toggle switch

used to select either line-to-neutral or line-to-line voltage to the volt-

meter.

The nameplate is also marked to indicate the position of this

switch.

Aug 25,&5

OH 2012

1. Resistor (50 ohm,

100 watt)

2. Resist@ (10 ohm,

100 watt)

3. Excitation-decnergization relay

4.

Instruction plate

5. Line selector ioggle switch

6. Meter selector rotary switch

7. AC Ammeter

8. Tray fastener

9. Voltmeter

10. Frequency meter

11. Automat ic-manua I switch

12. Receptacle connector

13. Manual voliage control rheostat

14. Manual control rectifier

15. Tray .

Aug 25’85

Gencrqtor Control Tray

Figure 9

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OM 2012

Al

“imq;!~er~oI” co!~:~ccl-or (12) pr-ovidcs a me:j:;s of quickly disconn~ctir:;7

all Wires to control box cc’mpsnerits.

(e) Tray

T/-,5 Iray (15) slides in und out on nylon rolizrs .

It i; WcurXl in p2cK~2

by a twist-lock, screw fastener (6).

(f) Manual voltage control

We-11 the automatic manual switch (1 7) is placed in MWUAL position,

AC power is supplied to the rectifier (14) rafhcr than to thz automstic

vohage regu!ator . The DC output of the rectifier is routed to the exciter

field through a rheostat (13j.

Tb ,e gensratcjc- output voltage is thereby

manually controlled by adjustmnt of the rheostat.

(g) Excii,ation-deenergization relay

The purpose of this re lay (3) is to allow automatic excitation to be

connected to the exciter field cnly when engitle sEed is btiing controlled

by the e let tr ic governor.

(2) Protective relay tray (see Figure 10)

The bottom tray in the control box is identified as tile protecfivc relay tray and

contains electrical and electronic safety devices designed to protect the air-

craft electrical sFtem against damage which could result from overvoltage,

undervo I tage ,

overfrequency, or underfrequency. The tray also contains

devices for the protection and control of the generator output electrical sptem.

(a) Sensing modules

The voltage sensing module (5)

and frequency scns ing modu ie (6) are connected

to generate output leads between the generotcr and load contactor. These

solid-state modules sense any abnormal condition of voltage DT frequency and

signal the solidstate circuitry of the memory and time delay module (4) to

open the load contactor and disconnect output to the aircraft. Trip values

are adjustabl&, however, adjustments should be made ONLY under laboratory

conditions.

A solid-state overload signaling device (Ref. 7, Fig. 13) is ako connected

to the protective monitu module and perfwms a function similar to the

voltage and frequency sensing modules .

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Page 18

Aug 25’85

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Trip values fcr protective circuits arc @s follow::

OVerVG!?‘Ug2 trips ai 130 V to 134 V

Undervo!ta~,;s ir ips at 102 V or bc: low

Overfr~quency trips at $15 Hz to 125 Hz

Undcrfrcquoncy trip; at 390 Hz to 395 Hz

Under-voltage til;>2 delay (adjustab!c) 4 to 12 !;oco:;d;

Overload circuit trips at any valtie over 125% rated loud capacity.

See Para. 7, H, (3) fcr more specific and detailed information regarding

over foad device.

(b) Memcry and time delay module

The memcry and time delay module (4)

is sometimes ca!Ied the protective

mon itor module. It is a solid-state device with a herrnet~cally-seaied,

reed-typa relay. The printed circuit board or “card” includes five

memory circuits and a time defcy circuit. Each circuit k connected to a

corresponding sensing circuit in the sensing modules (5 and 6). Ali memory

circuit-s are connected to the module relay coil, and any one of the cir-

cuits can energize the coil to open the relay contacts. Thus, when a

sensing device energizes any one of the module circuits, the module relay

is also energized to break the load contactcr holding circuit and allow the

load contactoc’ to opan. All circuits, except the undervol:age circuit,

function immediately to open the load contactor. A time deiaysplkm

is designed into the undervoltage circuit to prevent nuisance opening

of the contact= under conditions of momentary undervoltage in the gen-

erator output. An undervoltage condition which cant inues uninterrupted

for a period of 4 to 12second.s (adjustable) wiil cause the time delay

circuit to open the load contacts. Each of the five circuits is connected

to a corresponding indicating light (10, 11, 13, 14 and 15) which is turned

on when a fault occurs.

The module relay will remain energized (OPEN) and the light will remain

ON until the reset switch (7) is pushed to break the module 12-V DC

circuit, and allow the relay to return to normal, CLOSED position.

(c) Indicating lights

The function of these lights (10, 11, 13, 14 and 15) is to indicate, to the

operator, the abnormal condition of overvoltage, undert?equency, etc.,

which caused the protective monitcc system’to function. Each of the five

lights is connected to an actuating circuit within the memory and time

de lay module. When one of the circuiti is activated, it turns on the

Aug 25,185

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-6

1. Plug-inter lock relay

12. Under-frequency indicating light

2. Fuse-inter lock re lay

13. Overfrequency indicating light

3. Auxiliary underfrequency relay 14. Undervoitage indicating light

4. Memory and tirnc delay module

15. Overvobage ind icat ing I ight

I

5. Over-undervoltage module 16. Load contactor circuit fuse (2 A)

6. Over-underfrequency module

17. Protective system fuse (2 A)

’ 7. Reset switch

18. Test bank switch

8. Light test switch

19. Receptacle connector

9. Hole plug ‘20. Terminal board

10. Over load indicating light

21. Resistor (100 ohm, 25 watt)

11. Tray fastener

22. Tray

Protective Relay Tray

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Figure 10

Page 20

Aug 25 ‘85

.-, - -

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(4

(9)

04

The flJf7CtiW d the ph~g i:it:?rlock relay (:>

is to ccc!se 1.1;e output load

contuctor to c\jen in the cvont the cat!e plug corlnccio: become; accidental])

di;sonnectcd from the aircraft during power delivery; or if an citenpt is

Made to defivar power when the output cable is not connected to the air-

craft. Twenty-tight-volt, direct current for operation of the relay is

supplied from the aircraft either through an on-boanl tran=fom;cr-rectifier,

or from a twenty-eight-voIt, c!ectrical system. Connection from the air-

craft to the interlock relcy is made through terminals E a,nd F 0;; the

otltput Cclbk plug connzct~x.

Test-bank switch -

Asp st, toggle switch

(18)~ rovides a means of by-passing the inter-

lock relay (1) when supplying power to a load bank or to an aircraft

not equipped with a plug interlocl: system.

.

Resistor

,

A Too-ohm, 25-w&t resistor (21) is connected in series with the plug

interlock reiay to protect the relay in the event that phase C contacts

in the load contactor should fail to close when the generator ON

switch is operated.

Fuse-interlock relay

The function of the fuse-interlock relay ‘(2) is to interrupt the load con-

tactor holding coil circuit and remove the load in case of a “blown!’

fuse (17) in the protective relay coil circuit.

Connector

A twenty-six contact connector (19) provides a quick-disconnect

facility for all wiring to the tray electrical components so that the

COMplete tray assembly may be removed quickly and easily.

Aug 25185

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(k) Au;:i ij(::;y utl&riiccjucncy relay

The fu;;r:ticn of i-he auxiliary ui-&rircqucnc y rc: lny (3) is to autcmclt isc I I;;

open i!:c e):Cjt~Cltion-d~energii_ati!,n rc lay Clild c]ijCoilneCt th-? vollugc i-c31;1’1-

tcf anytire 9F:ncl’atcr frequency drop f-o 389 t!z c; kIo*.~. This p~uic-.;s

the vi.:l!~~;;c i’egulatc: (Fig.

12) and lxiiozt re;istoi-s (2, i:iy. 3) again:t

over load wh iCh could be caused by very high vo!)age regulntor- output in

its cttempi to maintain voltage cv!len the gene:‘atcz is o;~fo: ir:g at a sp~cd

which Cannot produce normal voltage output.

NOTE: if the auxifiary underfrequency relay ‘r, tripp~cl, it will be

necessary to momentarily place engine oprating mo& switch

(5, Fig. 11) in BUILD-UP-VOLTAGE po;Ition to restcre gen-

erator voltage.

F.

Engine Contro I

Panel (See Fig. 11)

The engine control panel is mounted dire.ctly below the ccntro! box.

In odd it ion

to engine controls end instruments, generator output controls are mounted here.

A plexiglass window in the canopy rear door,

slants outward .at the botfom to form

cm opening for access to controls when the door is closed.

(I) Engine instruments

,

Engk operation is monitored by an ammeter cd>, a coolant temperature gage

(8)

, and an oil pressure gage (10). An hourmeter (6) records engine operating

time.

(a) Ammeter

The ammeter (4) indicates the direction and value of current flow in the

12-V DC electrical system.

Its graduated range is from -60 A through

0 A, to 360 A.

(b) Temperature gage

The temperature gage (8) is a mechanical type of unit construction.

It

consists of a panel mounted indicating mechanism which is connected by

a capillary tube to a bulb mounted in the engine cooling system. The

gage indicates engine coolant temperature in the range of lOOoF to

2200F.

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Aug 25 /a5

OM 2012

The swi>ch connccis 12-V DC p3wcr to the et?l;‘in.-

0 cc~trcl sptem and to

the g~neratc.~ 1 2-V LX c0nfiOi system when tlx engine is funning.

(d) liourmztter

The hwrmetcr (6) is electrically driven from the 12-V DC bgi+ery sFtcm.

The hourmzter n-eo;ures and reca.Q engine rur!ning line rind wili rcccrd

up to ?9?9.9 hours on five revolving drums. The hourmzief operates o:ily

when the engine is running and the oil pressure switch (II) is closed.

(2) Engine and generator controls

(a) Fuse

A IO-amperefuse (15) protects the 12-V DC engine control circuit, hour-

meter, illuminating fight circuit, and 12-V DC system in the main gen-

erator protective system.

(b) Engine-generator control switch

,

Aug 2545

The engine-generator control switch (5) (

aiso identified as the “build-up-

voltage, generate, idle” switch) is a three-position toggle type. It is

spring-loaded in one position, BUILD-UP-VOLTAGE, and will auto-

matically reposition to GENERATE position when released. In BUILD-

UP-VOLTS position it perform a dual function. First, it supplies power

to the governor control box, which allow the engine to operate at

norma I governed speed; set ond , it momentarily supplies current for

clcsing the excitation-deenergization relay (3, Fig. 9) contacts, to make

three-phase, 115-V AC power available to the voltage regulator, or to

the manual voltage control circuit for excitation of the generator exciter.

In GENERATE pcsition, power is maintained to the governs control box

and to the excitation relay (3, Fig. 9). When the switch is placed in

IDLE position, power is disconnected so that the engine returns to idle

speed and the exciter fie’ld is deenergized,

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(c) Cmhxtor control switch

This is another tllrec-position, toggle ;v:itch (7, Fig.

11 ) id::n!,icaI f 0 the

eng it-,2 -genzrci-or control switch.

\‘d;.zn placed Tn the SF): rng loaded CLOSE

position, it prcvIdos 115-V AC

power directty to a reci ifinr wl~ich supp1I.o;

DC povdcr for

clG;ing iho icad contocic’. W&n r-2 Ie~~?d it returns to the

normal ON position and continues to p:ovide po:v.zr to the rectifier, but

in this switch position, AC

power must IXISS through the pl”g iniorl ock

and fuse interlock relays.

In OFF position the switch opens’ the AC

circuit to the rectifier, thereby cuttln

C-J off the source of DC power to the

contactor coil which allows the contactcr to open.

(d) Instrument light and switch

A shie Ided, instrument pancl light (1)

is mounted at the left si-Jc of the

control pane I.

It is ccntrol!ed by a toggle switch (I;), which trI;o control;

instrument lights on the control box.

(e) Engine starting circuit

The pushbutton start switch (17)

serves to connect power for closing an

auxiliary solenoid switch (4, Fig. 5). The auxiliar;/ switch then connects

power to the starter solenoid which functions to engage the starter gear

with the flywheel ring gear and apply power to the starter motor to crank

the engine. The auxiliary solenoid switch is necessary because the start

’

pushbutton switch is not capable of carrying the high amperage flow to the

starter solenoid which wolrld result if the starter gear and ring gear should

fa ii to engage. The pushbutton start switch (17, Fig. 11 ) is functional

only when the shutdown air valve is in latched (opn) position, which

places the start-z ircuit,

cut-out switch (7, Fig. 5) in CLOSED pcsition.

(f) Indicating lights

A green indicating I ight (16) g I ows to indicate that po:$‘er is available

to the engine protective system. The light operates only when the engine

is running and fuel pressure is sufficiently high to close a fuel fxessure

switch (5, Fig. 5). The purpose of the pressure switch is to deactivate

the protective circuit when the engine is stopped and prevent battery

discharge.

Another green indicating light (9, Fig. 11) glows when the generator

output load contact-or is CLOSED and power is available at the generator

output terminal panel (14, Fig.‘3).

Aug 25185

OM 2012

2b

I9 *2r I8 17

16 14

* Used on 5359C-lOonly.

~pso--o195

1. Panel light

2. Fue I gage

3. Light switch

4. Ammeier (DC)

5. Engine-generutcr control switch

6. Hourmeter

7. Load contactor control switch

8. Coolant temperature gage

9. Load contactor indicating light

10. Engine oil pressure gage

11. Operating circuit oil pressure switch

12. Cold kather starting uid control

13. Air cleaner indicator

14. Engine STOP control

15. Engine circuit fuse (10-A)

16. Engine protective circuit indicating

I ight

17. Engine starter switch

18. Blocking diodes (400 PVR, 1.5-A)

19. Test receptacle

20. Battery charging circuit resistor (used

only on tractor mounted units)

* 21 o 24 volt power supply switch

Aug 25185

Engine Control Panel

Figure 11

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An eI?cfric fue I sake (2, Fig. 11) is required r:n al I unil5 except f;ac;~r.-

rnvJn?cd,

s irice f(laI for the ii’acir>: rnounticd \!:\it i: supp!izd by the tow

tracto: fuzl syicm.

A sending vnik rnourited in ;,IIc trailer or i-ruck mcvn{cd

unit fuel tank sup;>lI.~s ihc signal to tile pnzi :ncxJtjted gaze. Twelve-voli

DC op:ruting powc

r is suppi izd to the fue I go<jc from two :oc;rccs . The gogc

functions when the engine i; running,

or when the instruir,3nt iig!it: are OX .

Since two power sources are connected to the fuel gage sksttem, a blEI::ng

diode (16) is required in each power source circuit.

One d io& prevcn!;

. .

energrztng \I e

‘4 motor-generator control circuif- when panel lights are ON.

Another diode prevents opration of the panel lights by tllc engine-gene-

erator circuit when the engine is running. To check fue I qucntity when

e ng irie

is stopped, use switch (3) to turn ON punel lights.

(h) Cold wealher starting aid control

The push--pull control (12)

contro!s operation of a cold weather starting cid

(4, Fig. 3). The starting aid consists of a group of items designed to’ inject

a highly volatile fluid into the engine air intake system to ass!st igniticn

of fuel when air temperature is too low for the heat of comprezsian to

ignite a normal fuel mixture. The starting aid cons&& of a cylindrical,

fluid container and a valve (see l-3, Fig. 4) which are mount,zd on the

iifting yoke. The valve is opzrated by the control (12, Fig. 11). PuHing

the control outward allows fluid to flow into the valve.

Pushing the ’

control IN forces fluid through a small tube end an atomizing nozzle into

the inlet manifoid. The addition of atomized, highly volutile fuel into

the inlet air assists in igniting the diesel fuel mixture.

(k) Engine stop control

.

The engine is normally stopped by use of the mechanical stop control (14)

which is a push-pull control cable connected to the engine fuel rack

lever.

Pulling the control outward places the rack in “no-fuel” pr~ition

to stop the engine.

(3) Air cleaner indicator

The air cleaner indicator (13) is mounted on the engine control panel fcr easy

viewing.

Ifs function was explained in Para. 7, C , (3) (see Fig. 6).

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Aug 2545

OM 2012

(5) Charg’ing circuit resistti

This 0.5 ohm, 100 watt resistor (20) is requivq-’

LL~ on tractor-mounted uni:s crjly.

Its purpc~e is to allow the battery charging alternator to maintain a nea; ncrn-tal

voltage in th

e c lcctric go;erncr co;ltrol box supply circuit when the TOW

TRACTOR ENGINE is bzing started. Witho;rt !hb resister in tl\z circuit,

cranking ihe tow tractti engine can cause a sufficiznt voltage d;op in ihe

system to influence operation of the electric governor control box and cause

an overspeed condition which will curve the overfrequency relal, to oFrate

and shut off power to an aircraft.

With the resistor in the circuit, alternator

charging copability is limited to approximately 4 urnperes at ol I times, and

battery charging will be done mostly by the tow fructor generator or alternatcr.

G . Voltage Regu latcjr

0

Th’e voltage regulator (Fig.

12) is located on the right side of the machi,ne iust back

of the engine compartment near the lifting yoke. On tractor and truck moutited

units, 0~ sfationory units the regulator is accessible fo: adjrr;tment by opening

rear doors on the right side.

On tractor mounted units, which have a large panel on

the right side, the regulator is reached by removing the rear hood-type vent cover

on top of the canopy.

Although a separate regulator manual is supplied with the generator set, a biief,

working description is given here.

The voltage regulator is designed to provide 1% voltage regulation with .25-seccnd

recovery time for all loads up to 100% of rated load on a three-phase, four-wire,

115/200-volt, 400-Hz, brushless generator.

This regulator provides field excita-

tion power for the rotary exciter,

and regulates generator output voltage by vary-

ing the exciter field power as required to meet varying load conditions. Thus,

the generator output is held ot a constant voltage. The maximum continwous rat-

ing of this regulator is 4.0 amperes at 140 volts DC.

Aug 25/s

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The rheosl-at (2, Fig. 12)

is used to adiust the regu!ated voltage value

of the 3enerafor OufpiJt. Compensa! ion for cable sizr is cdjusted by a

potenfiorrctcr (4).

Ca!:,k length is compensated for by adiustmcnt c?f

another pstcntiometer (3). Cable compensation n;ay be tlrrned ON or GF~:

by a toggle c

,*,\fifch (5). For this application the switch must ahvc,ys be ON.

An instruction plate under the potentiometer kncbs indicates proper setting

for various cable sizes and lengths.

Regulator stabilii-y is adjusted by the

damping circuit gain potentiotmeter (S).

Regulator response time is adjusted

by the da:nping circuit rate potentiometer (IO).

(2) Protecticn .

Intkrnaf circuitry of the voltage regulator is protected by a cartridge type,

5-amcere fuse (12).

(3) Components (See Fig. 12)

Components of the basic circuits are mounted in two maior subassemblies

which are the line drop compensation chassis assembly (6), and the sensing

and pre-amplifier chassir

a assembly (15). Receptacle connectors (7, 9, and

1 I) provide quick connect-disconnect facilities for interconnecting wire

leads. The two subassemblies are mounted on a chassis (?a) along with

other main components of the regulator, which include a resistor (l),

voltage adjusting rl-,eostat (2), fuse (12) and fuseholder (13), nineteen-pin,

receptacle connector (14),

and reactor (17). Field bcilast resistors and

line drop current transformer loading resistors ore located at a point remote

from the voltage regulator and ore not supplied with the regulator.

The two field ballast resistors are located in the generatcc control tray (iief.

2, Fig. 9). Transformer loading resistox are located on the power module

panel assembly (Ref. 8, Fig. 13).

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Page 28

Aug 25185

OM 2012

Front of Gencrutor Set

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Resistor (1000 ohms, 25 watts) . ,,

Regulator rheostat

Cable length compensation rheostat

Cable size compensation rheostat

Gn-off switch, line drop compensation

Line drop compensation, chassis assembly

Receptacle connector

Damping circuit gain potentiometer

Receptacle connector

Damping circuit rate potentiometer

Voltage Regu la tar

Figure 12

Aug 25 ‘85

Il. Receptacle connector

12. Fuse (5 amp)

13. Fuseholder

14. Receptacle connector

15. Sensing ond preamplifier chassis

assembly

16. High-phase sensing board assembly

17. Reactor

18. Chassis

19. Terminal board

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The p

3 we f

m 02

‘vk IXIWI u~cn?bly (FiJ. 13),

sorriztii7-:cs ieefrt4YCd to C: the ‘%oi~ta::t~

pale I I’,

is lozotod at the right rear of ~IIC machine behind the con:~o! box. On uii

mod, I; e>:cept th,

Q tow tractcr mounted unit, it is cccc:: ible by opening right r::tii

clocn .

017 tracts mout~kd unils it is ClCCeSS ible by i~Cf?20Vii7g rfar CCccss-;*enf.

Ccs;ef (2, Fig. 1) on the cancpy.

The pnel assembly provides sensing and OL’.‘:‘-

load p:o:ection

fcr the OUtpUt CiiCUit and provides a freans of connect irtg and dis-

ccnnecting generator outpu,

+ to and from the load (aiiccaft).

(1) Load contactcz

The load contactor (6, Fig. 13) is a sealed unit which contains a magnetic

operating coil and fm sets of contacts.

The three larger contacfs conduct

three -phase AC

generutor output. A smaller contact set is connected in t-he

protective monitor circuit and suppI ies 12-V DC power used by sen; ing rc !n)~

to signal the protective monitor when a fault occurs. Three-phcie, 400-Hz

generator output power is conducted to the load contactor by 2/O cables which

pass through 3 sets of current transformers (3, 4, and 9).

NOTE:

This contacts may.be replaced by the old style contactc~ u;ed

in previous 60-WA mychines.

This nore is fti the benefit of

those users who may have old style contact@s Part number

75GH-566 (Hartman No. A-87&I) in stock.

,

(2) Current trcnzformers

(a) Ammeter current transformers

Three current transformers (4) lower the output load current to a lesser

.valuz of definite ratio (250-A to 5-A) which will operate the ammeter

(4, Fig. 11) movemznt without damage. The a,mrrzter dial scale is

graduated and numbered so that the ammeter pointer will indicate the

true load current value rather than the meter movement current.

(b) Line-drop current transforrrers

The three line-drop current transformers (9), in coniunction with burden

resistors (8), detect the magnitude and power factor of current flowing

from generator to load.

They feed a signal to the voltage regulutor

which interprets the signal and alters the exciter field currentas required

to maintain a constant predetermined voltage at the load (see Voltage

Regulator Manual No. TM-232).

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Aug 25&i

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.

._.-

-

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L’

.

1

21

3.

4.

5.

6. -

7.

8.

9.

Overload resistor (16.6 ohm, 25 watt)

Terminal board

Over load current transformer

Ammeter current transformer

Rectifier

I*

Load contactor

Overt oad module

Line drop resistor (50 ohm, 25 watt)

Line drop current transformer

Power Module Pane I Assembly

Figure 13

(c) Over load current transformers

Three overload current tramforrnzrs (3), in coniunction with burden te-

sistcxs (I), monitcr the output load current in each of the three output

phases, and supply a reduced value current signal to the overload

module (7).

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Page 31

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(3) Overload module

’ -

The over load module (7)

is a solid-state device designed to interpret a signal

from transfamers (3)and to send a signal to the protective monitor module

(4, Fig. 10) when an overload condition exists in any generator output phase.

A pull-apart electrical connector is mounted on the overload module to provide

_ -.

quick-dbconnect facilities for all wiring to the module. The overload module

- is equipped with a hermetically-sealed, reed-type relay. Relay contacts are

ncmal ly open.

The solid-state circuitry is designed to close relay contacts

--when output curre;lt in ANY phase reaches 125% of normal rated output capacity.

The closed relaysen& a signal to the protective monitor. This signal “gates”

the overload SCR (silicone-controlled rectifier) in the protective monitcr

and interrupts the load contactor holding circuit, allowing the load contactcr

to open.

The following k a list of overload module characteristics:

NOTE:

The overload protective system will function when any phase

carries 123% to 127% of rated load.

At 125% load the moduk will function in 4 minutes -

At 150% load the module will function. in 16 seconds. ’

At 200% load the module will function in 4 seconds.

NOTE:

All times are plus cc minus 25%and are nonadjustable.

(4) Rectifier

A diode-bridge ret tif ier (5) rece ives 400-H~ AC from phase C of the generatcr

output and converts it to a pulsating, direct current for energiration of the

load contacta holding coil only.

Thb DC coil-holding circuit is controlled

indirectly by controlling the 400-H~ AC to the rectifier. The ground circuit

for the rectifier’s AC supply must pass through the relay contacts in the pro-

tective monitcr module to ground cable N. Therefore, any time a protective

device functions to open the protective monitcr relay, the rectifier’s AC cir-

cuit k opened.

No DC is then available for the load contactcr holding coil,

hence, the load contactor opens.

(5) Terminal boards

Three terminal boards (2) provide connection facilities fcr small leads.

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Aug 25’85

OM 2012

8. Test Box

The test box is an optional accessory item used fcr testing the generator set. All S-53590

sets are wired to accommodate a test box, however, the box b supplied only when ordered

(Part Number 388318A-2)

A. Description (See Fig. 14)

The test box assembly consists of a rotary selector switch, mokentary contact push-

button switch, and two, insulated-tip test jccks, mounted in a small metal box. Con-

nection to the generator set is made through a wiring harness equipped with a 26-con-

tact plug connector which mates with a receptacle connector.

1.

Test box

2.

Cable

3.

Plug connector

Test Box Assembly (Optiona I)

Figure 14

Aug 2545

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33

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9.

8.

Theory of Operation

Wire leads are connected to the electrical circuitry of the generator set at various

points and routed to a receptacle connector,

mounted on the engine control panel.

They are connected to the test box rotary switch by a plug connector and wiring

harness.

The rotary selector switch is wired in such a manner that for any switch position, two

pre-selected test points in the generator set circuitry are connected for testing. The

selector switch may be rotated to any one of 22 positions, however not all positions

are used in this installation. An instruction plate mounted under the switch knob in-

dicates switch positions and component tested’ in each position. Normal voltage for

each test is also indicated.

Two test jacks are provided for connection of the test prods of a voltmeter. After

the voltmeter is connected and selector switch positioned, the test circuit is closed

by pressing the pushbutton switch.

A voltage value may then be observed on the

voltmeter. This arrarlgement prevents energization of test circuitry and equipment

for extended periods and allows the operator to reset and adjust the voltmeter with-

out disconnecting it from the box.

For operating instructionr, see Sect. T-3, Para. 3.

53590-q)

The generator*& identified as Specification Nunber 5359&q is the same as 5359@1

except for the addition of a Rodio Frequency Interference (RF I) Suppression Kit, Hobart

Part Number 482337, and a 24 Volt Power Supply Kit, Hobart Part Nunber 435262. ’

A. RFI Suppression Kit

The RFI suppression kit is attached to the engine’s governor control vnit (9, Fig. 3)

as shown in Figure 15.

6. 24 Volt DC Power Supply Kit

NOTE: Generator sets with Serial Number 8OPSO1501 and higher, have

had the power supply kit installed at the factory. Units with

Serial Nunbers lower than80PS01501 were shipped from the

factory without the power supply. However, these units may

be modified in the field to include the kit. Order Hobart

Part Number 435262.

Certain aircraft require a 24 volt DC signal on their input power receptacle (Pin E)

as a condition for receiving 115 volt AC, 400 Hz input from the ground power gen-

erator set.

This power supply furnishes that 24 volt DC signal.

The fzower supply

(22, Fig. 3) is mounted on support brackets directly above the power modvie panel

(7). All components except the fuse are enclosed within a sheet metal cover. The

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I

Governor Control Unit

I

RFI Suppression Network

Figure 15 -

Aug 25 %5

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power supply is turned ON and OFF by a toggle switch (21, Fig. 11) mounted on

the engine control panel.

The toggle switch is equipped with o hinged guard which

insures that the power supply is OFF when the guard is closed, covering the switch.

The guard may be safety-wired In the closed position to prevent inadvertent operation

of the switch.

Refer to Figure 16.

When the toggle switch (7) is in the UP position, 24 volts DC

is present on terminal E of the generator’s output terminal panel (14, Fig. 3) through

the following circuitry.

Refer to diagrans in Chapter 6 as required.

115 volts AC

power into‘the power supply is topped off the generator output line, on the input

side of the load contactor. The per supply is protected by the fuse (6) in the

input line. This 115 volts input is reduced by the transformer (3), rectified by the

diode bridge (2), and filtered by the capacitor (4) and resistor (5), so that an un-

regulated 24 volts DC is provided to terminal E on the output terminal panel.

In

addition, the plug interlock relay (1, Fig. 10) is energized to penit power delivery

to the aircraft.

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Aug 25, ‘85

OH 2012

Engine Control Panel

1. Cover

2. Rectifier

3. Transfoner

4. Capacitor

24 Volt DC Power Supply

Figure 16

Aug 25%

5. Resistor

6. Fuse

7. Switch

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SECTION 2. PREPARATION FOR USE, SiOKAGE , OR SH JPPlt\(G

1. Preparation far Use

A. General

.

These instructiora are based on the assumption that the tow tractor-mounted unit

b properly installed on the tractor and that all necessary fuel and electrical con-

nections have been mode.

Hobart Brothers Company do& not build on aircraft

tow tractor.

Generator sets fcr tractor mounting are installed by the customer,

or ‘trac’tor manufacturer. Other generatar sets,

when ordered with truck or trailer,

are moimted at the Hobart factory and are shipped in running condition and ready

for operation after inspection and check.

’

CAUTION :

READ OPERATING IMlXUCTlOf’JS IN SECTION l-3 BEFORE

OPERATIluG THE UN IT.

B.

Inspection/Check

Inspect the unit thoroughly prior to oFration..

(1) Remove blacking, banding, ties, and- othei securing

i2) inspect exterior for shipping damage such as broken

metal, etc.

material.

I ighk , damaged sbee t

(3). Open all canopy doors and inspect intericr foe foreign n#teriaI such as rags,

too&, shipping papers, etc.

.

(4) Check fuel, coolant, and oil hoses and connections for vkible leak. Visually

inspect the compartment fioor and ground surface under the unit fcr signs of

leakoge. If leaks ore found, ccrrect by tightening hose clomps, tube fittings,

etc.,

os required.

(5) Check s&urity of tracts mounted getieratcr set retaining components (Sect.

2-1, Fig, 2) .

(6) Check rh e 0 owing for sufficient quantity: f II

(a) Fuel

Turn ON panel lights to energize fuel gage when engine is stopped.

(Tractor-mounted units ore rupplied from the tow tractor tank.)

Aug 25’85

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. .

.

04

(4

Engine coolant - .

The radiator cop is accessible by opening the hinged access cover on the

front canopy housing.

Coolant level should be approximately one inch

below the filler-neck. AJJow a capacity for coolant expansion.

CAUTION: BE SURE THE COOLJNG SYSTEM ANTJFREEZE SOWTJON

is ADEQUATE TO PROTECT BELOW LOWEST TEMPERATURE

EXPECTED,. _

.

For antifreeze protection, use a &Jution of 5a permanent NOTE:

antifreeze (Ethylene glycol) and 50% clean water.

Engine lubricating oil

OJI level should be at “FULL” mark on oil level gage rod (see Fig. J). See

Sect. 2-1, Fig. 4 or the attached Detroit Diesel Operatar’s

Manual for oil recommendations.

Check air dieoner

The air cIeaner.(Sect. I-1, Fig. 3, item 8) is a “dv” type.

papers, tapes, or other material covering the air inlet area.

n

1. Oil feei gage rod

2. Oif filler cop

Engine Oil Gage Rod and Filler Cop

Figure 1

Be sure there ore no .I

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(8) Check batteries . .

12-V DC power for tractor-mounted units k supplied by tow trocta batteries .

C. InstaIling Output Coblei

Units are generally shipped without generator set-to+ircraft cables.

Generotcr sets designed for tracta mounting are eqvipped NOTE :

4

with 9 generator output receptacle connect@. No output

* cable wiring is required.

An output cable assembly with

plug-connector on each end is required fa troctos-mounted

machines (see l-l; 12, Fig. 3).

(1) Three-phase, AC output cable assembly installation

The AC output terminal pane J is located on the left side, be low the air cleaner

and Jeft of the engine control pan61 (see Fig. 2).

(a) Open left rear canopy docrs and loosen cable clamp screws at cable hcen

‘fjee I-1; 13, Fig. 3),

(b) Rwte cables through cable horn and clamp and upward to terminaf board.

NOTE :

Conductor size recommended for AC cutput b 2/O s ize .’

Use No. 12 size fcr cotitrol (E ond F terminak),

. .

+rge cables (A, 8, C, N) should be equipped with

terminals having at Jeast a 3/8-inch diameter mounting

hole. Mounting hole in small leads (E and F) shwld be

at least l/4-inch diameter.

(c) Each‘terminal stud is identified by on identification plate. Each cable

should be identified by a band-type marker. Connect cable “A” to

terminal “A”,

“B ” to “B “, etc.

Tighten terminal nuts securely. Connect

small ‘plug interlock lead “E ” IX “F” to terminal ‘F “ OT “F”.

(d) Tighten clamp scre- securely, but ovoid damage to cab Je insulation.

Aug 25&j

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.

AC Output Terminai Panel (Used on all

units except tractor mounted)

Figure 2

(2) Transformer-Rectifier (DC) Output Cabfe Installation (Optional Equipment)

(a) Install’DC output cables as ilk&rated in Fig. 3. ‘Use 4/Osire cables

* for 28.5-V and 35-V DC. Use 2/O size cables for 112-V DC.

.

‘1-2

Pago 4

T-R Output Cable Installation

Figure 3

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2. Preparation for Storage

.

When a generator set is to be stored or removed from operation, special precautions

should be taken to protect the internal and external parts From rust, corrosion, and

gumming in the engine fuel system.

A. General.

.

(1) The unit should be prepared for storage as soon as possible after being removed

from service.

(2) The unit should bestored in a building which is dry and which may be heated

during winter months. ’

(3) Mo$ture absorbing chemicals are available for use where excessive.dampnes,t

is a problem, however the unit m&t be completely packaged and sealed if

moisture absorbing chemicals are to be effective,

8. Temporary Storage

When storing the unit fa.r 30 days or less, prepare as follws:

’

* (1)

: (2,

@I

. -

(4

(5)

Lubricate the unit completely in accordance wih instructions in Sect. 2-l.

This will include ohanging engine oil, and all Filter elements.,

,

Start the engine and operate for about two minutes so that .all internal

engine components will be coated with new oil e

‘.

NOTE: Do not drain the fuel system or crankcase after this run.

.-- -.-

Make &tain the cooling system antifreeze solution is adequate to protect

below the lowest temperatures expected duripg the storage period. See

271; Para. 7, D . Be sure the solution ‘a thaoughly mixed 0

Clean the exterior of the engine with Fuel oil.

Dry with clean rags and

compressed air.

Seal all engine openings.

Use a,waterproof, vaporproof material which is

strong enough to resist puncture damage From air pressures.

C. Long Time Storage (Over 30 Days)

.

(I) The unit may be stored for long periods with no special preparation if it is

possible to operate the engine once each week..

Avg 25 ‘85

Page 5

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(a) Make certain the cooling system is adequately protected.

(b)

Start the engine and operate at a fast idle (800 to 1000 RPM) until coolart

temperature has reached at least 140 deg F.

.

WARNING:

MAKE CERTAIN OF ADEQUATE VENTILATION BEFORE

.

STARTING THE ENGINE.

(c) Operate normal operating controls.

*

(2) If weekly operation is not possible, prepare and protect the engine in accordance

with instructions in Detroit Diesel Operatar’s Manual.

(3) To protect the generator and other electrical components, the complete unit

. . should be packaged, using moisture proof packaging and sealing material. Place

containers of moisture absorbing chemicals, such as silica-gei, in the unit before

packaging.

Preparation for Shipment (Tractor-Mounted Units Only)

During long shipments by rail (and other), the generator set retaining hardware may be-

come loosened by vibration, -iolting, etc.

.

‘:

i

CAUTION: WHEN SHfPPfNG THE UNIT (MOUNTED IN A T.OWTRACTOR),

’

JpROVIDE ADDITIONAL RETAINING MATERIALS TO MAKE CER-

TAIN THE GENERATOR SET CANNOT ROLL OUT OF THE TOW

TRACTOR.

NOTE:

It is suggested that strong bandi’ng may be used to secure the generator set,

or a strong steel bar may be welded or bolted across the Front of the gen-

erata set frame.

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Aug 25,/I%

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1.

General

SECTION 3. OPERAiION

**This section contains information and instructions for the safe and efficient operation

of the equipment.

Operating instructions are presented in step-by-step sequence of

procedures to be followed in supplying 4000Hz power to an aircraft.

Read ALL of the operating instructions before attempting to operate the NOTE:

equipment.

.

WARNING:

EAR PROTECTION EQUfPMENT MAY BE NECESSARY WHEN WORK-

ING IN CLOSE PROXIMITY TO THfS EQUIPMENT.

2. Operating the Generator Set

A. Pre-start Inspection

(7) Be sure the fuel shut-off valve (if used) b OPEN.

.

:

‘(2) Mak c

certain 12-V DC power is available to the engine starting system;

(3) Check the engine and generator compartments t& make certain they are free

of rags or other foreign materials.

B. Normal Engine Starting Procedures

.

Eirgine starting procedures are outlined below. Engine operating controls and

monitoring instruments are illustrated in Fig. 1.

. .

(1) If iilumination is required, place light switch (16) in ON position.

NOTE: This switch must be ON to check fuel when engine is stopped.

(2) Be sure engine stop control (26) is at IN position.

(3) Be sure engine air shut-off valve is in IATCHED, open parition bee Fig. 2).

NOTE: Push lever (3, F

ig. 2) DOWN to LATCH valve OPEN.

(4) Place engine-generator control s.witch (18) in IDLE position.

(5)

Press start switch button (29) to crank engine, Rc lease the start switch as

soon as the engine starts. When engine starts, observe engine protective

Avg 25185.

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1’1

io

I3

IS

16 If r8

I9 20 21 22

23 24 29

*lJsed on as96q-

only

CONTKOL

BOX

ENGINE CONTROL

PA&E 1

.

50 29 28 27 26

1. Frequency meter

2. vottrneter

17. DC Ammeter

3. Fastener

18. Engine-generator control switch

19. Hourmeter

4. AC Ammter

5. Meter switch

20. .Lcad cdntactcs control switch

6. Line swiich

21. Coolant temperature gage

7. Reset switch

22. Load contactor indicating light

8. Light test switch

23. Oil pressure gage

9. f%uJt indicating lights

24. Cold weather starting aid control

10. Load cantactor circuit fuse (2-A)

25. Air c leaner indicator

I

? ? .

Protective s ys tern fuse (2-A)

26. Engine STOP control

12. Protective relay tray

27. ,Engine circuit fuse (10-A)

13. Instrument panel light

28. Engine protective circuit indicating

14. Generator control tray

light ’

15. Fuel gage

29. Engine starter switch

16. Light switch

30. Blocking diodes

31. Test receptacle connecter

l-3

Page 2

Operating Controls arid Instruments

Figure 1 (Sheet ? of 2)

Avg 25 ‘85

‘I

GENERATOR CONTKOL TRAY

PKOTECTM KE tit TtiY

32. Manual voltage control rheostat

33. Automatic-manual voltage control switch

34. Test bank switch

35. Light test switch

36. t&set switch

37. Automatic voltage control rheozfat

38. Cable length compensation rheastat

39. ‘Cable size compensation rheostat

40. Line-drop compensation on-off switch

41. Fuse (5-A)

*42,

24 Volt power supply switch

-

I

Aug25& i

_ Operating Controls and Instrumznts

Figure 1 (Sheet 2 of 2) .

VOtTAGE REGULATOPI

143

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Page 4

q&em light (28). When this fight glows green it indicates that the fuel pressure

switch is closed and the engine protective system k functional.

NOTE: (a) If the shutdown valve is tripped for anyreuson during start--up, it

will be necessary to latch the valve mechanism by pushing latch

lever (3, Fig. 2) down to reset.

Press DOWN to latch

Urilatched View

Latched View

(Shutdown valve closed)

(Shutdown valve open)

(Micro switch (1) open)

(Micro switch (1) closed)

.

1. Starter safety switch

2. Shutdown valve *latch ’

3. Latch reset lever

Shutdown Valve Latch and Starter Safety Switch

Figure 2

(bj If the shutdown valve cannot be latched, check the overspeed

governa (see Fig. 3). It may have been tripped by an over-

speed condition.

Press reset button an ov?rspeed governor

head, then latch shutdown valve open. Always reset the

ovenpeed governor immediately after an averspeed trip,

because the shutdown soicnoid will remain energkd and

/’

dkcharge the batter& until overspeed governa is reset.

Aug 25 ‘85

OM 2012

.

Rese

tbutton

.0verspeed Governor

Figure 3

.

CAUTION: (a)

IF THE ENGINE FAILS TO START WtTHfN 30 SECONDS,

RELEASE THE START SWITCH AND ALLOW THE STARTJNG

MOTOR TO COOL FOR A FEW MINUTES.

JF THE ENGINE

FAILS TO START AFTER FOUR ATTEMPTS, AN INSPECTION

SHOULD BE MADE TO DETERMINE THE CAUSE,

., (b) IF THE ENGfNE FIRES SUFFICIENTLY TO DISENGAGE

THE STARTER GEAR, BUT DOES NOT START, RELEASE

THE START BUTTON AND ALLOW THE STARTING MOTOR

TO COME TO A COMPLETE STOP BEFORE ATTEMPTING

TO ENGAGE THE STARTER AGAIN.

. (6) ObseNe oil pressure gage (23). Theenglne will be automatically stopped if

pressure does not build-up quickly to normal.

. (7) Allow the engine to ‘die and warm for about 5 minutes before applying load.

CAUTIO’N: DO NbT ALLOW THE ENGINE Td IDLE FOR LONG PERIODS

OF TIME,

Aug 25 ‘85

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C. Cold Weather Engine Starting Procedures

.

A cold weather starting-aid kit (Fig. 4) b provided to assist in starting t,he engine’

at temperatures below 50 deg.F. Tostart the engine, using the starting aid,.pro-

teed as follows:

(1) Position switches and controls as instructed in step (1) thraugh (4), paragraph

.

B, Normal Engine Starting Procedures, above.

(2) Prepare starting aid for use.

The starting aid is shipped in a sad condition

and ‘k not operable until assembled. Assemble as follows:

WAKNlNG: STARTING FLUID IS EXTREMELY FNMMABLE. IT lS

UNDER PRESSURE. USE CAUTION WHEN HANDLING.

AVOID CONTACT WlTH SKIN AND AVOID BREATHING

I

VAPOR.

.

7.

Clamp nut

2.

Fluid cylinder

3.

Cylinder cap

4.

Plug

5.

Valve

6.

Control cable

Cold Weather Starting Aid

Figure 4

.

(a) Lo-en clamp nuts (7, Fig. 4) and slide the cylinder (2) upward sufficiently

‘to remove protective cap (3) and plug (4).

i

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.

Aug 25’85

Pug&3 6

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(b) Use bottle opener to remove cylinder cup (3). Unscrew and remove plug

(4).

(c) Slide the cylinder (2) d

ownward and thread into the valve (3). Tighten

securely. The starting aid is now ready fcr use.

(3) Cold weather starting pacedures are exactly thesame as for normal starting

except:

‘

d (a) Before cranking the engine ,’ puil the starting aid control (24, Fig. 1)

OUT to the full extent of ifs travel. Hold for 2 to 3 seconds. (This

allows the starting aid valve chamber to fill with pessurized ethyl

ether..)

(b) Push the control IN. (This stepsprays starting fluid into the engine intake

manifold .)

~.

(c) Push starter switch (29) to crank engine.

(d) Foildw normal starting procedures and CAUTIONS above [;teps (5) through ’

(7), para. 2, BJ.

.

(e) Jn extreme iy cold weather it may be necessary to repeat step (a) and (b)

above.

*

CAUTION: USE STARTING AID ONLY FOR STARTtNG. DO E\rOT

OPERATE WHILE ENGlNE 1s RUfvNlNG.

WARNlNG:DO NOT “FLOOD” ME ENGlNE WlTH STARTING

FLUID. A SERIOUS EXPLOSION COULD RESULT.

D. eeparation fa Power Delivery (Normal Automcrtic Voltage Control)

The following are power delivery preparation procedures to be followed after the

eng he b started a

(1) Check and pcs ition switches and controk.

(a) Loosen fastener (3, Fig. 7) and pull generator control tray a&ward.

Place.automatic-manuaI switch (33) in AUTOMATIC pasition. Close

tray and secure.

. I

(b) Loosen fastener (3) and pull protective relay tray outward. Place test-

‘--

bank switch (34) in AIRCRAFT position if the aircraft being serviced is

equipped with 28.5-V DC interlock relay system. (If not, piace in

TEST BANK position,.) Slide tray in and secure.

Aug 25 ‘85

l-3

_ Page 7

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(c) Meter switch (5) may be in any pcsition except pointing straight DOWN. ’

(2) Connect output cable plug connects to aircraft receptacle. Be sure ctinnectas

are mated fully and secue ly.

.

E.

Power Delivery (Automatic Voltage Co&of)

(1)

Place engine-generator control switch (18, Fig. 1) in Bu I LD-U P-VOLTAGE pas it ion

momentarily, then allow it to position itself in GEN pbsition. The electric gov-

erncr will. immediately increase engine speed fo 2000 RPM and maintain it.

(2) Observe generator instruments.

Frequency meter (1, Fig. 1) should indicate

exactly 400 Hr. Voltmeter (2) should indicate 115 V AC when line switch (6)

is in LINE-TO-NEUTRAL position.

(3) The final step in delivering power is closing the load contactor. When satisfacto~

frequency and voltage values are indicated by the instruments, close the load con-

.’

tactor by momentarily placing the load contactor control switch (20) in the-tap

(jprirlg kxded), CLOSE position.

The green indicating light (22) should glow at .

once to indicate that the foad cantactor is closed ad power is available at the

aircraft. Ps soon OS the light gbws, release the switch.

It will automatically

ret,um to the center ON position.

NOTE:

If the indicating light (22) should “go-out” as saon as the switch

’

is released, and no fault jighis are ON, it indicates that 28.5-V

DC holding current is not being supplied from the aircraft ta the

plugtinteriock relay.

Correct the’ condition and again operate the

load contactor control switch (20) as above.

.

(4).

It is recommended that the operator check output voltage and current in each

of the three phases early in the power delivery run.

Use the meter switch (5)

to select the phose.

Use the line switch (6) to select line-to-line or iine-ta-

neutral voltage.

if the food is changing, it is goad operating practice to ob-

seme the instruments until toad conditions stabilize.

(5) A condition of overvoltage, undervoltage, under-frequency, averfrequency, or

overload in the output circuit will automatically open the load contactor and

turn on the applicable indicating light to signal the operator which of the

abave fau!ts caused the protective monito’r system to operate. After the fault

has been corrected, press the reset switch (7) to turn off the indicating light

and reset the protective relay system.

Proceed with power delivery by operating

the load contactor switch.

.I

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I

F. Prepamtion for Power Delivery (Manual Voltage Control)

Preparation for power-delivery using manual voltage control is exactly the same as

far automatic control para. 2, 0, (1) thru (2) above1 except:

-

(1) Piace automatic-manual switch (33) in. MANUAL position.

(2) Set the manual voltage contrai rheostat (32) near its mid-range position.

G. Wwer’Deiivety (Manual Voltage Control)

Power delivery using manual voltage contra! is. the same as automatic delivery

Clara. E, (1) thru (5) above1 except:

(1) Gntrai generator output voltage by adjusting the rheostat (32) to maintain a

steady 115-V AC reading on the voltmeter (2). Turn the rheostat (32) knob

CLOCKWISE to INCREASE voltage and COUNTERCLOCKWISE to DECREASE

voltage.

(2) Adjust voltage to 115 V AC..

(3) During manual power delivery the operator mus; remain with the generator set to

adiust output voltage for varying loads and conditions.

H. Discontinue Power Delivery

9

(1) tiace thd’ioad contactor switch (20)’ in OFF position. Green light (22) should

go OFF immediately to indicate that the load contactor .has opened and power

is na longer being delivered to the aircraft.

. (2) Place engine-generatorcontroi switch (18) in IDLE pasition.

,

.

(3) Disconnect output’ cable from aircraft .

WARNING: NEVER DISCONNECT THE OUTPUT CABti WHILE POWER IS

BEING DELIVERED.

K. Stopping the Engine

(1) Allow theicngine to id/c a few minutesbefore stopping, to permit coaling.

._. ’

(2) To stop the engine pull the siop control (24 OUT and hold until the engine

.

stops. This control is spring-loaded and should return to the IN position when

released.

Aug 25’85

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l-3

Test Box Opration

The,test‘ box is useful and convenient in testing the generator set after ‘repair or overhaul

and also in+roubte shooting.

To opemte the test bo& proceed as folfows:

A.

B.

c.

0.

E.

F..

G.

ii.

1.

Open left, rear canopy doors and connect the test box plug connector (see 1-l;

3, Fig. 14)’ to the test receptacle connector (Fig. 6).

Connect the test prods of a voltmeter at the test jacks (3 and 4, Fig. 5).

Test iacks

are coiol: cod*. RED indicates POSITIVE. BLACK indicates NEGATIVE,

Locate the component or circuit to be-tested in the DESCRlPTlON column on the

instruction plate and set the selector switch (1, Fig. 5) to the number indicated

.

opposite the description.

.

Note the normal voltage value and kind of current (AC or DC) to be expected at

the position and set voltmeter accordingly. ’

:

Campiy with conditions indicated in CONDITIONS column for the particular test

being performed. .,

\

Press the pushbutton swifch (2) and observe voltage indicate+ by the v&meter. Cow

par8 to rtcrm~f voitage indicated in VOLTAGE cofumn,

,j

Release pushbutton switch.

,

Repeat steps A thru G for other tests as required.

men tests are compieted, disconnect the test equipment and close canopy doas.

Page ‘10

Test Box Operating Controls

Figure 5

. .

1.

Se lectca switch

2,

Pushbutton switch

3.

Positive test jack (red)

4.

Negative test jack (black)

5. Instruction plate

J

Aug 25 ‘85

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.

Test Receptacle Connectcc

(with protective cap installed)

Figure 6

4. TransformerT7ectifier Operation (Optional Equipment) (See Fig. 7)

Transformer-Rectifier operating instructions ore contained in their respective manual ,

hov.ever some generator set instructions are required here.

\

‘- .

A. Direct Current Power Delivery

.

NOIE: If the customer adds a Transfornsr-Rectifier to a standard

machine which was NOT equipped with a T-R when it left ’

the factcry, he must remove the jumper lead-which will be

found on the small terminal strip in the generator set voit-

age regulator (see l-l; 19, Fig. 12). if your generator

set.has a factory installed T-R, the jumper will have been

removed.

(1) When delivering paver from a SINGLE T-R.(?8.5-V, 35-V, or 112-V DC)

4

prepare the generator set for DC power de livery the same 0s for AC de livery,

except dd not connect AC output cable and do not close AC load contactor

(see Para. 2, D and E).

(2) Fa T-R operating instructions:

.

See TM-197 for 28.5-V DC T-!! Operating Instructions

See TM-422 for 35-V DC T-K Operating Instructions

See TM-237 fa 112-V DC T+ Operating Instructions

-’

Aug 25185

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112-v DC a- 35-V DC

ransfarmer-Rectifier

Transfarmer-Re&ifiers (Typical Inrtallatiar)

Figure 7

.

B. Simultaneous 28.5-V and 35-V DC Power Delivery

2 8.5-V and 35-V DC T-KS

may be operated at the same tirrre without special

pcecaut ions .

Prepare the generatcr set for power delivery in accbdance with

Para. 4, A, (1) above.

TM,

Operate each T-K according to Instructions in applicable

NOTE:

-

It is EuORN\Al. for T-K output to become S LIGH’TLY unstable

(indicated by blinking contactcr light on either T-R) when

operating with current limiting. When output is unstable,

observe DC voltmeter.

Fluctuation of one or two volts is

normal. If fluctuation is violent (several volts), adjust

voltage regulator RATE potentiometer (see 2-3; 2, Fig. 7)

to correct.

C , S imu Jtane ous 28.5-V DC and 115-V AC Power De I ivery

If both 28.5-V DC and 115-V AC

must be de Iivered at the some time, the follow-

ing rules and precautions must be observed.

I-3

Page 12

Aug ‘5’85

OM 2012

(1) Place T-R current limiting switch in OFF position. Thk will eliminate the

soft start feature of the T-R, but will prevent AC voltage from dropping low

enough to trip the AC load contactar.

(2) Line-drop compensation on the T-R must be REDUCED or turned.DOWN

completely to prevent opening of the AC load contactor by an overvoltage

condition.

Readjust T-R line-drop compensation so that AC voltage (as

indicated by the generator set voltmeter) does not exceed 118-V AC when

the DC toad is 500 Amperes.

If higher DC voltage is needed, adjust T-K

line-drop compensation as required. Observe AC voltage while making

this adjustment to be certain that it does not go TOO H IGH with DC load.

(3) During simultaneous, continuous operation, foods on either circuit are

limited mly by the capacities of their respective circuits, however, the

combined loads should not exceed the rated capacity of the generator set

(90 WA cf 72 W).

0. Simultaneous 35-V DC a 112-V DC and 115-V AC Power Delivery

Since no ither of these T-Rs have line-drop compensation capabilify, no special

adjustment to the T-R will be required.

Combined loads shculd not exceed the

rated capacity of the generator set (90 KVA OT 72 Kw).

I

5.

24 Volt DC Power Supply

.

This power supply is furnished with generator set 5359&q; U NLY. .It is to be

used ONLY on aircraft which require a 24 volt DC signal standing on power receptacle

pin E as a condition for receiving 115 volt AC, 400 Hz ground power.

To operate the power supply, position the power supply switch (42, Fig. 1) to UP

position BEFORE closing load contactor for nonal pChrJer delivery.

CAUTION: DO NOT USE THIS POWER SUPPLY ON F-4 OR F-15 AIRCRAFT.

ETISE, DAMAGE TO AIRCRAFT ON-BCJARD EQUIPMENT

WILL RESULT.

Aug 25’85 J

1-3

Page. 13

.

OM 2012

*

\AjkRj\(!NG:

STOP OFEEATlON lM\4EDi,+:XL’i’ IF A SERIOUS OR POSSIDLY

-m-I_

DANGEROUS FAULT IS DISCOVERED.

2. @p~rdtion of RsI!-Out Feature (Fcr Tractclr-/douGted Uni!T Only)

.-

One of tf~e first things to learn cbout the service operation is hew to roll fhn senerctor

partia!ly out of the tow tractor so that components on the rig!lt side and bo:tom of th%

unit cre more accessible.

A. Roll Generator-Set Out for Service

(1) Make CERTA!N the stop-bar (Figure 1) is down as Tar as it wllf go in

SAFETY position.

.

(2) Remove two each attaching nuts,

screws, and lockwashers (1, Fig. 2) frcm

retaining brackets (2) at the front of the machine.

.

(3) Roll the generator set cutward carefully, until the stop-bar (Fig&e l).cont~cts

the stop-block in the left track, This will allow access to ihe right side and

underside of *the engine.

B.

Roll Generator-Set In to Nonnai Position

To return the generator-set to normal operating position, proceed as follows:

(1) Roll the machine inward carefully until the retaining brackets (2, Figure 2)

contact the end gussets in the tracks.

(2) Install attaching screws, nuts, and lo&washers and tighten securely.

3.

Inspect ion

A periodic inspection should be established und maintained. A suggested inspection/

check schedule is provided in

2-2, Figure 1, however it may bc modified as

required to mee.t varying operating and environmenta! conditions.

If the generator

set is mounted on a tow tructor, it is suggested that irlspcctions be coordinated.

Aug 25 ‘85

2-l

Page 1

OM 2012

Roll-out Stop-ba: (For tractti-mounied units only)

-Figure 1

1 I-5-

- .

/

1. Attaching hardware; nuts, screws, .and lockwashers

2. Retaining brackets

Generator Set Retaining Components (Tractor-mounted units only)

Figure 2

Aug 25’85

.

2-1

Page 2

OM 2012

4. Lubricoticn

FTOPW ItibrIcation is one of the most important steps in go<;d malntenurico p;-occdures.

Proper lubricatio- ,, means the use of con-ect lubricants and adherence to a prai?er

time scitcdulc. Lubrication point!:, frequency of fu!>ricat ion, and reccm~;.~en:ied

lubricants are indicated in Figure 3.

B.

AC Generator

The 400-i+ generator requires NO lubrication. The rotor is supported by two,

ball bearings which are lubricated and sealed at the factory For lifetime,

main-

tenance-free operation.

It is suggested t-hat generator bearings be rep!aced after

5000 hours of operaf ion.

C. Generator Controls

Generaror controls ad instruments require no periodic lubrication. A few drops

of oil muy be required on door hinges occasionally to insure free and quiet opera-

tion.

D. Engine

D

Although the engine and its accessories require no more attention than any other

similar installation, they still inherently require a major’portion of the g&rator

set Iubricotion and maintenance. Recommendations regarding engine lubrication

have been taken from the engine manufacturer’s “Operator’s Manual” and in-

corporated here to make them more readily available to operators and main-

tenance penonne I.

(1) Lubrication schedule

Time schedules indicated on rhe Lubrication Chart, Pig. 3, are approximate.

They are based on average operating conditions.

It may he necessary fo

lubricate more frequently under severe operating conditions such as: low

engine temperatures,

excessively heavy loads and high oil temperatures,

or intermittent operation. However, time intervals should not exceed those

indicated in the chart without careful evaluation.

’ (2) Oil specification

Oil recommended by the engine manufacturer is identified by a military

specification number, MIL-L-2104B. Because of the substantial increase

in additive concentration in some MIL-L-21048 oifs to meet service “MS”

requirements, recommended oil is qualified still further by the following

/imitations.

Au925335 ;

2-1

I

Page 3

OM 2012

FLJ~ I Filter

D~*c;i,-t Daily D”

Oil Fitter

Starter

Fue I Filter

Drain Daily

Engine Oil

Check I-eve I

M2 E ngine A Iternator

D”

D2

Check Daily

Change Oil ***

Air Cleaner ++

-

Refer to Dotro!t D iese I

Operator ‘s Manua I

- BWl Overspeed Governor

DF ive

.

** AC Generator

SAl Cam followers

Used on tractor-mounted

units only (not illustrated)

* Change elements 300 hours.

** AC Generator bearings

are sea led. Require no periodic lubrication.

***Change engine oil after each 100 hours, or as recommended in Para.

4, D, (4); pge 6.

+ Lubricate starter when removed only.

++Change air cleaner cartridge as required by indicator.

2-l

Page 4

Lubrication and Maintenance Chart

Figure 3

Aug 25’35

,

OM 2012

--

Symbo I

I

2

I

Specifica! ion

Greusc,

Gcnercf

Purpose

OiJ, Engine,

Military

Heuvy D&y t?,iL-L-2!04B

Notes

‘. I

ShC3ll “klvonia” No. 2

0: eqtf iva!er?t .

(USC NO. ? g :*adc ct

temperatures be faw -i-33

deg F.)

SAE-30, ure for all

temperature;.

Lubricants

Figure 4

-

D

W

BW

M

SA

A

Daily

Weekly, or

Bi-weekly, or

Monthly, or

Semi-annual iy, or

Annual ly , or

7 hburs

50 hour?i

100 hourc

200 hours

1200 hours

2400 hours

.

Lubrication Chart Symbols and Time Intervals

Figure 5

Coo lant capacity

9-l/2 gal Ions

Oil capacity (incl(Kling fiiter) 20-I/2 quarts

Oil capacity (without filter)

20 quarts

Gil and Coolant Capacities

Figure 6 .

Aug 25%

2-1

Page 5

OM 2012

(3)

2-1

Page 6

,

Dies:1 lui~~icctirg oi!

zpzcificatlons are discuxxi f&her in the

Detroit Giesel,

*‘opfxc!I.c)r’s r;rfanual”.

Oil viscosity

The use of an SkE-30 grade oil is recommended for year-round service. The

engine is equipped with an ether starting aid to assist in en2ir.e sturting durrng

cold wcathcr when SAE-30 oil is used. MultiStade oi!s an NOT rccommzr&d,

and should be considered only as a

“lost resort” io facilitate engine starting.

Change engine oil

The following oil change recomFendations are taken from Detroit Diesel Qxrator’s

Manual .

“It is recommended that new engines be started with 109 hcur

oil change periods.

The drain p&cd may then be gradualty increased, or dc-

creased, following the recommendations of an izldependent Oil analysis Iaborato;y,

or oil supplier (based upon the sample analysis) until the m.ost practical +I

change period for the particular service has been establishzci. ”

-

1

The genarator set is equipped with an hourmeter to record actucl engine operating.,

time. The ideal time to change oil is soon after a power delivery “run“, when

the engine, is at operating temperature.

NOTE: If lubricating oil is drained immediately after the unit has been run

for some time, most of the sediment will be in suspension and will

drain readily.

CAUTION: DO NOT USE SOLVENTS ASFLUSHING OILS IN RUNNiNG

ENGINES.

Change the oil filter element euch time the oil’ is changed.

Change oil as foilows:

(a) Provide a container for catching used oil. Capacity should be greater

than 21 quarts.

(b) Remove drain plug located in oil pan.

(c) While oil is draining, proceed to change the oil filter clement. See Para..

4, 0, (5) below, for instructions.

(d) Clean the drain plug and instail securely when engine oil has drained.

Aug 25%

OM 2012

(5)

(e) Remove oil filler cap (Sect. 1-2, Fig. 1) and refill the crankcase with

new, clean oil which meets engine manufacturer’s recommendations.

(See Para. 4, D, (2) aba

ve, or Detroit Diesel Operator’s Manual.)

Engine oil capacity is as follows:

21-l/2 quarts - including filter.

20 quarts - not including filter.

CAUTION: 1. ALWAYS USE CLEAN CONTAINER, FUNNELS, ETC.

2. DON’T FORGET TO:

- DRAIN OLD OIL.

- RE INSTALL DRAIN PLUG o

- INSTALL MW OIL BEFORE STARTING ENGINE.

(f) lnstaii fiile r cap and check oil level on gage rod (Sect. l-2, Fig. 1).

The gage rod should indicate over FULL until the engine is started and

oil is circulated to fill the oii filter.

(a) Start engine and check oil pressure at once. Normal pressure should be

indicated within 15 seconds. Allow engine to idle for about 5 minutes,

then stop.

.

(h) After the engine has been stopped for about 5 minutes, recheck the oil

level. Add oil, if required, to bring the level up to the FULLmark

onthegagerod.

Change oil filter element

Replacement oil filter elements are available from AC Delco NOTE:

as part nunber 25OTo495.

(a) Provide a container for catching used oil if the vessel used for draining

the crankcase is not sufficiently wide to serve both operations.

(b) Remove drain plug (6, Fig. 7), and allow oil to drain.

(c) loosen center stud (5) and remove stud (5), shell (4), element (3), and

gasket (2) as an assembly.

Discard the gasket and element.

(d) Clean the filter base (1).

(e) Wipe out the interior of the shell (4) with a clean, lint-free cloth.

Aug ~5035

Install a new element (3) on the center stud (5) and in the shell (4).

2-l

Page 7

r

OM 2012

1.

Base

2.

Gasket

3.

Element

4.

Shell

.

5.

Center stud

6.

Drain plug

Oil Filter

Figwe 7

.

(f) Place a ne:~ gcsket in the filter Lax (1).

(9) Position the shell and element carefully. on the base.. Be sure the shell

fits perfectly on the gasket.

Start the stud threads into the base while

holding the shell in position.

Tighten stud carefully to prevent damage

to the gasket and/or stud threads. Torque stud to 50-60 foot-pods

(68 - 81 Nom).

(h) &an the drain plug (6) and install securely.

(i) When the engine is fint started after completing the oil change and filter

change operations,

check the shell-to-gasket joint for possible oil leak.

E. Engine Accessories

See Figure 3 for identification of engine and accessories lubrication points, lubricction

intervals, and lubricants.

.’ .

(1) Alternator

Apply 5 or.6 drops of engine oil in each hinged cap oiler every 200 hours.

2-l

Page 8

Aug 25’85

OM 2012

(3)

Overspeed govcrnoc and dr ive

8 Lubricate :he overspeed governor d;iw

lubricator every 100 hours.

(l-1; Fig. 5) wilh a p-essurc-typz hanc!

Use a Ef2iler-Gl plJrpCSf2 grease such a; She 11 AIvai\ia

No. 2, or equivalent.

At kmperatur-es be low GO deg F, use b!o. 1 grade .

See manuracturer ‘s service instruct icn:

in Chap. 6 for lubricction of ovcrspxd

governor.

5. Air Cleaner Service

The air cleaner is a dry type with replaceable filter cartridge. A definite time schedule

for chunging the filter cartridge cannot be determined because of varying operating con-

ditions. Change the filter carfridge when the red indicate: “flag” reaches the top of

the viewing chamber art4 locks in that position.

Change the cartridge as foilows:

.

A. CaTtridge Kemova! (See Fig. 8)

(1) Loosen the four nuts (11,

unlatch clamps (3)

and swing the tee ‘bolts (4)

outward away from the moisture elirnii~ator (7).

(2) Remove the mqisture eliminator (7).

(3) Remove the filter cartridge (6) and discard.

CAUTION: .DO NOT CLEAN OR RE-USE CARTRIDGE.‘

(4)

Inspect the interior of the cleaner housing (5). Make certain it is free from

all foreign mcterial.

8. Cartridge lnsta llation (See Fig. 8)

(1) Carefully insert the new cartridge into the housing. Avoid hitting the cartridge

tubes against the housing sealing flange. Make certain the cartridge is seated

properly within the housing.

Press all edges and corners of the cartridge firmly

with the fingers to effect a positive air seal against the sealing flange of the

housing.

CAUTION:

UNDER NO CIRCUMSTANCES SHOULD THE CARTRIDGE BE

POUNDED OR STRUCK IN THE CENTER TO EFFECT A SEAL.

Aug 25’85

2-l

Page 9

OM 2012

1. Nut

2. Spring washer

3. Clamp

4. Tee bolt

5. Housing

6. Cartridge

7. Moisture e I imjnator

Air Cleaner Cartridge Repfccement (Typical)

Figure 8

,

(2)

Lock the cartridge in place by instcfling the moizture eliminctor (7) and clamp-

ing in place with the four tee bolts, clamps and nuts.

. *

(3) Nuts

must be tightened evenly, crisscrossing from corner to corner.

After

tightening the n&s as tight as possible by.band, tighten them two full turns with

a smal I wrench.

NOTE: Check the nuts

three or four days later and retighten if required.

6. Engine ‘Fuei

A. Qualify

The quality of fuel oil usdd in the diesel.engine is a major.factor in engine performance

and life.

Fuel oil must be clean, completely distilled, stable, and non-corrosive.

Only distillute fuel No. 1D is recommended for use bath summer and winter.

2-l

Page 10

Aug 251135

OM 2012

A fuel s:rcincr aild aI:c cl

fuel flit::: are uc-zd in the fuel systcrrr to rerwv? impuri:ies

from f,hc fuel.

Each is a replcceoblc element type.

The fuel strainer is iczated

between the fuel supply tcnk and the fuel pump.

It operates under VQC~U~T! and re-

moves larger particles fram the fuel.

The fuei Filter is Ioccted between t!;c fuei

pump a,ncJ fuel inlet manifold. This filter opc”mtes under p:cmre and rer!isvss smaIl

particles from he fuel.

Engines delivered after January 1980 have spin-on strainer

and filter shetls, and NO DRAIN VALVES,

(1) Daily service

Drain fuel frrjm both the fuef strainer and filter daily, to remove sediment

and water.

(a) Provide a container for catching drained fuel.

(b) Open drain valves (2, Fig. 9)

and allow cpproximately l/i’pint of

fuel to drain from each filter.

(c) Close drain valves. Do not over-tighten.

.

(2) Change strainer and filter efernents

-.These instructions apply to both the strainer and filter. Change elements

after each 300 houw of engine operation.

(a) Place a new element in a container of clean fuel oil and allow it to

soak while removing old element.

(b) Provide container for catching fuel oil.

(c) With engine STOPPED, open drain valve (2, Fig. 9) and allow filter

to drain.

NOTE: The filter will drain more freely if the cover bolt is

loosened slightly.

(d) Support the shell and unscrew the cover bolt.

(e) Remove shell, element, and gasket as an assembly.

Aug 25&i

2-1

Page 11

c

ON 2012

*Fuel filters and stminers

furnished after December

have NO OFCAIN VALVES.

1. Fuel filter

* 2. Drain valve

3. Fuel strainer

Fue I Filter and Strainer (Typical)

Figure 9

(f)

Discard the element and gasket.

(g) Wash the she/I with f I ‘I

ue 01 and dry with a lint-free cloth and/or com-

pressed air.

(h)

Place the new element, which has been’thoroughly soaked in clean fuel

oil (step (a) above), in the shell and push it down on the seat.

(i)

Close the drain valve and fill the shell about two-thirds full of clean

fuel oil.

(i)

Jnstaif a new gasket and position the shell and element to the cover. In-

stall the cover bolt. Be sure the gasket, cover, and shell mate perfectly.

Tighten the bolt only enough to.prevent fuel leakage.

2-1

Page 12

Aug 25, /85

OM 2012

(k) Remove the pipe plug in the cover and fill the filter (strainer) with clean

fuel oil. This step is known as “priming” the filter.

(1) Start the engine and check the fuel filter(s) to make certain there are no

leak.

(3) Change spin-on strainer and filter

Replacement cartridges are available from AC Delco under NOTE:

(4

04

(4

id)

the following part nunben;

Fuel Strainer - 25011011

Fuel Filter - 8921410

Change both cartridges after each 300 hours of engine operation.

Unscrew the filter (or strainer) and discard.

Fill a new replacement cartridge approximately two-thirds full with clean

fuel oil. Coat the seal gasket lightly with clean fuel oil.

install the new cartridge and tighten it two-thirds of a turn beyond gasket

contact.

Start the engine and check for leak. *

7. Engine Cooling System

A. Ge’neral

.

Cooling system service requires much more than maintaining the proper coolant

level ,in the radiator.

During warm seasOns and in warm climates, when plain water

is used as a coolant, the system must be protected against rust by a rust inhibitor

odd itive.

During cold seasons and in cold climates, the system must, of course,

be protected against freezing. At no time should the system be operated for any

length of time on plain water, without a rust inhibitor or antifreeze.

Draining,

cleaning, and filling the cooling system are covered in Para. 7, E thmugh H.

B. Radiator Cap

(1) General

A pressure valve is built into the radiator cap.

It is designed to open at a

pressure of approxhately seven pounds per square inch.

(2) Removal

To remove, turn the cap to the left (counterclockwise) to the safety stop.

When all pressure is released, press down on the cap and continue to turn

until the cap is free to be removed.

c

Au g 25 65

2-l

Page 13

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WARNING: WHEN REMOVING CAP FROM A VERY HOT RADIATOR, DO NOT

TURN CAP PAST SAFETY STOP UNTIL ALL PRESSURE OR STEM

HAS ESCAPED.

CAUTION: ALLOW ENGJNE TO COOL BEFORE ADDING COOLANT.

NOTE: Do not attempt to repair the valve in a radiator cap. Replace with a new

cap.

(3) I&al lat ion

When installing the cap be sure it is turned clockwise as far as it will go so that

the pressure retaining valve will be functional.

C. Warm Weather Operation

The engine will run cooler during warm weather operation if water is used in the cool-

ing system instead of an antifreeze solution.

To keep the cooling system free of rust and

sludge during warm weather opemtion,

odd a cooling system conditioner that is compat-

ible with alwninun. instructions for use of the conditioner are printed on each can.

CAUTION: USE ONLY A CORROSION INHISITOR THAT IS COMPATIBLE WITH

ALUMINUM. DO NOT USE INHJBITORS LABELED AS “ACID NEU-

TRALIZE R”.

D. Cold Weather Operation

(1)

(2)

(3)

2-1

Page 14

General

A permanent type, gthylene Glycol) antifreeze is recommended for use in the

cooling system.

,

CAUT10N: (a) DO NOT USE “METHANOL” OR ALCOHOL AS AN ANTI-

FREEZE.

(b) DO NOT USE TWO DIFFERENT TYPES OF ANTIFREEZE.

MIXED SOLUTIONS (TWO TYPES) MAKE IT IMPOSSIBLE

TO DETERMIN IF THE COOLING SYSTEM HAS ADEQUATE

PROTECTION AGAINST FREEZING.

Coolant solution check

Check the solution frequently to be sure the cooling system has sufficient pro-

tection against freezing.

NOTE: (a) When testing the solution, be sure the coolant is atoperating

temperature.

(b) Follow manufacturer‘s instructions on tester.

Coolant solution preparation

The following table (Figure 10) indicates the freezing points of solutions vary-

ing from 16% antifreeze to 65% antifreeze.

Percentages are based on permanent

type (Ethylene Glycol) antifreeze.

Most antifreeze containers hove a similar

table printed on the label.

Aug 25,/85

OM 2012

r

Freezi~.;a Pi>inf

Percentogr-: of anfiirr:cze

(FcxCd~eii)

in so!ution

------

-

-:-2(p

16%

4-I CO

25%

O0

33- ?/3%

-10”

4036

-20”

45%

-30°

50% I

-400

54%

-500

58%

-6OO

62%

-700

65%

_.

Antifreeze Solution Table

Figure IO

(4) Antifreeze solution installation

.

Before installing antifreeze in the system, make the foI!owing checks:

l

. (a> Check the system for signs.of leaks.

(b) Inspect a! I hoses and tighten a! I hose clamps.

Install new hoses if ’

necessary.

(c) Drain and clean the system. Ref. Parcr. 7, E and 7, F.

(d) Check the condition and tension of the fan and water pump belts and

alternator beIts. Replace the belts if necessary.

(e). Be sure radiator and engine drain.valves (Ref. Fig. 11) are closed,

and al! connections are securely tightened.

(f) J&a! I the required amount of antifreeze (Ref. Fig. 10). Fi!f the

system with coolant as out! ined under Para. 7, H.

E. Drain the Cooling System

Drain the cooling system immediately after stopping the engine, while most of the

sediment is in suspension. Proceed as follows: .

(7) Remove radiator cap.

Aug 25185

2-l

Page 15

OM 2012

(3) Ai!cPf th-,

d system to d!-r;in compfetk!y .

t\!CTE:

Ce sure the drain valves do net plug-up during draining,

.

(4) When the &stem is completely drained,

close a!! dmin vafves except .&en drain-

ing for storage.

F- Cooling System C Iconing

.

Drain end thoroughly flush the cooJ!ng system twice a year or mere often if necessary.

The appearance of rust in the rudiator, or in the coo!c;nt is an indication that the

inhibItor has become weakened and it is possible that some sludge bus cccumulated

in the system. When this condit.ion exists, proceed as foI!ows:

(I) fun the enginc until .it reaches nprmal opercting temperature; then stop the

engine and drain the cooling system (Ref. Para. 7, E).

(2) Fiji the coo!ing system with clean coojunt (Ref. Pora. 7,’ 6).

(3) Add a flushing compound, that is compatible with aluminum, to the cooling

system in accordance with the instructions furnished with the compound.

(4) Start the engine and flush the system as directed by the instructions furnished

with the compound.

(5) After the system has been flushed and thorotighly cleaned of the compound,

refill with clean coolant (Ref. Para. 7, 1-i).

G. Radiator Ccre Cleaning

Blow out insects and dirt from the radiator core air passages, using air or water

under pressure.

Engine overheating is often caused by bent or clogged radiutor

fins. When straightening bent fins,

be careful not to injure the tubes or to break

the bond between the fins and tubes.

J-I* Cooling Sysiem Filling

2-1

Add a cooling system corrosion inhibitor (for warm weather operation) or permanent

antifreeze (when the air temperatures expected ure at freezing, +32 deg F or lower).

Antifreeze may be premixed if desired.

Cooling system capacity is approximately

9-l/2 gaJionS.

-

Page 76,

AJJ, 2545

OF1 2012

4’

1. Top engine water outlet drain valve

2. Water pump drain valve

3. Oil cooler housing drain valve

4. Radiator dra in valve

Coolant Drain Valve Location

Figure ‘I 1

Aug 25 ‘85 2-l

Page 17

OM 2012

NOTE:

if arrtificeze So!lJtiSl is not P’emhd, pour requii:cd antifreeze

in first. hstult corrcsion inhibits cccording to directions on

a container.

(3) Start the er?ginc ynd allow it to idle. Add cooiant if trappd air escapes from

the system and the coziant level falls.

‘(4 c

anti:-iue to check coolant leve! until the engine reaches operating temperature.

Add coolant, if needed, to fili to.the required level, 1 inch below filler neck.

InstaIl radiatti cap.

.

NOlE :

It is good practice to attach a card,

indicating the cooling system

contenb, and the date serviced to the rudiator filter neck.

.

8. Generator biainfenarce

-

.

The 400-Hz generator requires no maintenance or service other than periodic cleaning.

Clean the complete generator set wl~cn other compwxrh of the tow tractor are cleaned.

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 commercial cleaner.

Steam cleaning of the generator is no longer recom-

mended because the use of steam and harsh chemical compounds may result in

damage to insulation and other generator components.

CAUTION: BE SURE THE UNIT IS COMPLETELY DRY BEFORE ORRATlNG.

WARNING: DO NOT USE A FLAMMABLE SOLVENT.

9.

Adiustment

The generator itself requires no adjustment.

controls will be covered in Section 2-3.

Adiustment procedures for generator

-u ‘-- --

. 2-1

Aua 25185

Page 18

0

, . Drive Colts

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B. -Chick BeIt Tcnsicn

Check belt tension every ZOO hours, or bi-week!y.

A l~eit whIvh is too !ight is

destructive to t-he bearings of the driven pert.

A locsc beit will slip and cause

inefficient operation of the part being driven.

Belts may be checked with a belt tension gage, Detr0i.t DieseI No. Bi-33-73FA,

or equivulen:. (See Fig. 12 for tension values.) Check at midpoint between

puf Icys.

- .

7

Fan Drive Aiternatcc . Drive

50-60

50-70

,

Belt Tension Chart (lbs.,&eit)

Figure 12

Belt tension may also be checked by a firm push with the thumb, at a point mid-

way between two put leys.

A properly adjusted belt should be depressed l/2 to

3/4 inch.

C. Belt Adiustment

(1) Alternator belt

Mjustalternatcr drive belt as follows: (See Fig. 13)

.(a) Loosen pivot screw ond nut (3).

(b) Loosen adjusting bracket screw (1) and use a long screwdriver (or pry

bar) to pry the alternatcr’(4) outward to increase belt tension.

CAUTION:

EXERCISE CARE TO PREVENT DAMAGE TO ANY

COMPONENT.

Aug 25’85

2-l

Page 13

OM 2012

(not in view)

1. Adjusting bracket screw

2.

A Iternatar dr ive be It

3. Alternator pivot nuts and screw

4. Alternator

A lternattx EeJt Adjustment

..Figure 13

(c) Tighten adjusting bracket screw (1) and check belt tension (see Para. 9, B,

above).

(d) Repeat steps (b) and (c) until belt (2) is properly adiusted.

(e) Tighten pivot screw and nut (3) and retighten adjusting bracket screw (1).

(2) Fan belts

Adjust fan drive belts as follows: (See Fig. 14)

(a) Loosen four adjusting bracket screws (2) sufficiently to allow adjusting

bracket (4) to slide on support bracket (5).

2-1

Page 20

(b) Turn adjusting screw (1) clockwise to tighten fan belts (counterclockwise

to loosen hefts).

AW 25’85

.

1 . Ad justimJ screw

2. Bracket screws

3. Fan belts

4. Adjusting track&

5. Support bracket

Fan Belt Adjustment

Figure 14

(c) Check belt tension in accordance with Para. 9, B.

(d) Repeat steps (b) and (c) until belts (3) are properly adjusied.

(e) Tighten adjusting bracket screws (2).

0. if no other maintenance operations are to be performed on a trailer-mounted set

after be Its are checked and adiusted,

install the right front access pane1 and roll

the generatcx set back into opcrating position and secure‘ (see Sect. 2-1, Para. 2,

BL

Aug 25 ‘85

2-1

Page 2’1

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c

10. Scrvke Help

--

A .

Wir ins

Contra! box traF may be removed easily and moved to a wwl: bench fcr service o:

replacerr2nt of park.

(1) Tray re mow I

(a) Lomen screw-lock fastener (2, Fig. 15).

(b) Slide tray outward and disconnect Amphenol connecta’ (3).

(c) Support tray with honds,at each side of tray near latches (I). Unlrxk lutches

(1) by pressing down with thumbs, then slide tray out of box.

(2) Tray iktallation

.

(a) Use both hands to support tray as in removal above.

(b) Align rails (4) with tracks (5) and slide tray into box. Latch wit1 lock

automatic01 ly.

I

5

/

2-1

Page 22

Tray Ke mova I (Typica I)

Figure 15

i. Latch

2. Fastrner

3. Connecfor

4. Rail

5; Track

Aug 254%

c

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(C) C O~lX?Ct Afliplle:iol Cc)\nnectc:r (3).

(I) Frcjzai~ion f

s exe iter re mova I.

’ (a) Re mcvc rear canopy pane I.

(b) Remove main frame rear croz, mzmbcr by removing four c!+aching cap

screws (see Fig. 16).

(2) Exe iter re mova I

Refer to TM-360 in Chapter 0 fof exciter inStilJCti@nS.

.

Attach ina

Screws ”

Attaching

Scrdws

/

Kemovab le frame member

Aug 25./85 ;

Removable Kear Franz Cress-Member

Figure 16

2-l

Page 23

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(3) Exe iter i!lstul la: ion

(a)

in5tuII 2xc ifer in accordance with TM.-360.

(b) Kcin:;ia

II rear frarr~ mem!zr and tighton straws securely.

N O-E :

--

It may be necessury to use a iarge

“C ” c lamp or, other cxrang?-

r-rent to pi;l;ition frun;:: side rails end align rccr frame r;izriibci

mount ing holes .

D . Engine Co&-o1 Pane t

Tllc engine control panel is designed and mounfed in such a monnqr ihat it may Lz

re leased from Its mounted PCS it ion and tilted outward fcx access to components

mounted cn the back s Tde (see Fig. 17).

(1) Tilt out engine control panel

,

(a) Remove clamp screw which supports w’ire conduit above output terminal

panel.

(b} Remove four capscrews which attach engine cot&o! pznei to frame sup%-

strut ture .

.

(c) Maneuver panel to tilt it inward at the bottom and outward at the top.

’

(2) Reinstall engine control panel

(a) Maneuver panel into po5 ition and align mounting holes. Install mounting

screw and secure.

(b) Secure wire conduit in its original pcxition with clamp and screw.

2-1

Aug2sa

Page 24

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Flex ib

C cndu

.

Engine Control Panel in Tilt-Out Pujitim

Figure 17

Aug 2545

2-1

Page 25

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2. Engine

A.

Fuel (See Fig. 1 for time schedules)

(lj Chok fuel quantity DAILY.

(2) Drain fuel filters in accordance with 2-1; Para. 6, B, (1).

.~_.

(3) Change fuei filter elements in a&dance with 2-l; Para. 6, B, (2).

I

(4) Open fuel tank drain every 500 hours to drain off water or sediment.

B. Lubrication

(1) Check crankcase oil level DAfLY.

(2) Lubricate in accordance with !,ubrication Chart (Ref. 2-1; Fig. 3, 4, 5, and

’ , 6).

.

C. Coolant

v

(1) Check coolant Ievel DAlLY.

.(2) Inspect for signs of rust and corrosion.

Change coolant if rust and sediment

are present. See 2-l; Para. 7, E , F and !-! .

(3) Inspect hoses for cracks and deterioration.

Inspect clamps for tightness.

D. V-Belts

(I) Inspect V-belts for proper tension and adjust if necessary after each 200 hours

of operation. (See 2-l; Para. 9, A, B, and C .>

E. Exhaust System

(1) Visually inspect muffler end exhaust pipes for signs of approaching faiture.

(2) Listen for any gasket or joint leaks.

Aug 25 I85

2-2

Page 1

-...--__

.--

--

.--

--

ENGiNE

--

----

Check fuel q :rant ity

Ch::ck crcnkccsc: oif level

Check coofcnt level ’

Change engine oil CiIter element

Change erig inc oi I

Rspluce air cleaner carlrid~2

hspect CGPJ ir:fi syf3um hoses,

tubes, fittings, and clcmps

Check V-belts tension

Diain Qrld PZFiil CO0ling SystC%l

Change fuel .fi!ier elements

Lubricate

Check exhuust system

Open fuel tank drain

ELECTRKAL (12-V SYSTEM)

.-

4R

-

Caify

or

2 firs.

X

TWICE ANNUALLY

See Lubrication Chart

fvew 500 hours

X

’

Check all I ;ghts

CIeon bcrttety terminals

Check c/irina

Check connections

400 Hz GENERATING AND CONTROLS SYSTEM

Check output cable and

connector

Check voJtmeter

Check animeie r

Check frequency meter

Check all lights

Check protective relays

Chcclc safC ty swt icires

inspect all wiring and connection

Ctecn and inspect generally

X

i.nspection/Check/Maintenance Schedule

Figure 1

2-2

Page 2

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-- .- --

l-T--

. .

X

Aug 25’85

.

OM 2012

(3) Repfccc any dcfcctlvc pGftS a! once.

A. Lights

Check aIl lights forproper operation DAILY.

Replace any ddfcctive Tcmp; (bulbs)

as soon as discovered. Figure 2 lists AL1 lamps, their locution, and pcti numbrjr~.

B. Fuses

Check end r~p!~ce fuses as required.

See Figure 3 for fuce sizs and locutions.

Figure 3 includes all fuses used in bath the engine and gencxtor cfuctritol

systems.

-

Light

Identification

Loccition

Lamp

Manufacturer

.

Lamp (bulb)

Nurnbe r

Instrument Panel

Lights

Engine ON Indicat-

ing Light

Contactor CLOSED

indicating Light

Fault Indicating

Lights

Clearance Lights

Control Box

Lamp Industry

Trade No.

Engine Control

Lamp Industry

Panel Trade No.

Engine Control Lamp Industry

Panel

.Trade No.

Protective Relay tamp Industry

Tray Trcde’ No.

Canopy

Lbmp Industry

Trade No.

.

67

1815

57

Lamp Identification Chart

Figure 2

C. Wiring and Cdnnections

(1)’ Inspect al I

cables and leads for broken, worn, and damaged insulation.

Aug 25’85

2-2

Page 3

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OM 2012

(2) Check electrical connections for looseness.

NOTE: Adarkened tenirxrl generally indicates a loose connection.

4. Electrical System (115-V AC)

The 400-Hz generator and controls are designed to be as maintenance free as possible.

No lubrication is necessary and no periodic maintenance adjustments are required. How-

ever, some regular checks should be mode to be sure all controls, instrunents, etc., are

working properly;

A. Monitoring lnstrunents

Observe operation of voltmeter, ammeter,

and frequency meter each time the unit

is started.

Engine control panel

Sect. l-l, Fig. 11,

Sect. l-l, Fig. 10,

load contactor

Sect. l-l, Fig. 10,

*24 Volt power Power supply

Sect. l-l, Fig. 16, 2ATypeIvtDL

supply

item 6

Wsed on 5359Fg; only.

Fuse kfentification Chart

Figure 3

8. Indicating Lights

Check lamps (bulbs)

in all of the indicating lights at each start up. Fault indicating

lights in the protective relay tray may be tested by pressing the lens housing.

C. Protective Modules

Check operation of all protective modules to make certain they will Function if a

2-2

fault should occur in the output circuit.

Page 4

Aug 25,!85

D. Wiring and Connections

(1) Ch k II bl

ec a ca

es,

leads, and wiring for broken, worn, and dcrnaged insulation.

(2) Check all connections for tightness.

WARNING: STOP OPERATIONS AND STOP ENGINE EJEFOf?E

TOUCHING EXPOSED CONDUCTORS OR TERMINALS.

(3)

Check the output cable plug corm ctor for danaged contactors in the end of

the plug.

Aug 25435

2-2

Page 5

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2.

Preparation for Ttist fcr Tractcr-h4ountcc~ Unifx

A. Generator Set Removed from Tractor

Tests and cdjvstments rngy be performed more conveniently whifc thr! ger?erator set

is out of the tow tractor.

Prepare for fcst aS foflows:

(1) Connect a source of Dl diesel fuel to the engiwc: fuel system. Provide for

Fuel feed-bat!< (Ref. Fig. I).

-2

1. Fuel drain hose (to tractor tank)

2. Twelve-volt input terminal

3. Fuel input hose (from tractor tank)

4. Twelve-Loft input cable (from tractor)

Fuel and Battery Connections (Tractor-Mounted Unit)

Figure 1

Aug 25’85 2-3

Page 1

OM 2012

B.

Generator Set in Tow Tractor

If the generator set is to be tested while mounted in the :o~ tractor, proceed cs

fol lows:

(1) Roll the unit out in accordcnce with instructions in Sect. 2-1, Fara. 2, A.

(2) Open uccess doors and remove right front engine accesr pcnei.

(3) Remove power module and voltage regulator access panels (Ref. l-l; 2, Fig. 1).

3. Generatar Set Test

.

A. Pre-operational Test Procedures

,

(1) 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.

Be sure the

generator output’ “N” cable’ is grounded.

(2) Check engine oil level. Oil should be at FIJI& mark on gage rod.

(3) Check radiator coolant level (Ref. Section 2-1, Fara. 7, H).

(4) Check tension of fan and generator V-belts. (See Section 2-1, Figure 12.)

(5) If governor throttle. linkage was disturbed, check ail linkage to make certain

engine speed may be controlled when the engine is started. See Figure 9.

(6) inspect for oil, fuel, and coolant leaks.

(7) if the setting of the voltage regulator rheostat (37, Pig. 2) has been disturbed,

set it at CENTER position (halfway between full clockwise position and Full

counterclockw isc position).

2-3

Page 2

Aug 25 ‘85

OM 2012

(9) Ch.i;ck fault indicating ii&h (9) by pESSitr3 b2S.f SVJjkh (8). If 1 i&b glow,

fuse (11) and indicating lamps are good.

(10) Make a g encrol inspection of all wiring, and terminals. ’ Inspect the ccpipment

to be certain no damage will result from starting the engine.

(11) Make certain the air shut-off valve is latched OPEN by pressing t!>e latch

lever (8, Fig. 3) DOWN.

Check operat

ion of the shut--down solenoid (I) by momentarily connecting

a jumper wire between the

“hot” terminal (4, Fig. 4) on tile starter solenoid

and the left terminaJ (2, Fig. 3) on the s!-;ut-down solenoid. The solenoid

should unlatch the air valve as soon as ccnnection is made.

(12) While the air valve is unlatched, check operation of the starter “cut-out”

switch (10, Fig. 3)‘. P

ress engine start switch (29, Fig. 2). Starter should

not crank engine if starter cut-out switch is operating properly. See Para.

4, F, (1) if starter cut-out switch adiustment is necessary.

(13) At initial start-up after generator overhaul or repair, “flash” the exciter

field by momentarily applying 12-V DC to the field w.indings as follcv~s:

(a} Flashing exciter field using test box.

‘. If a test box (see Sect. T-3, Fig. 5) is available, connect it to

receptacle connector (Sect. T-3, Fig. 6).

. .

(aa) Rotate the selector knob (Sect. T-3, Fig. 5, item 1) to position

8.

(bb) U

se wo. ‘urn er ea

t 1 p I d

s, each equipped with an alligator clip and

a test prod, to connect 12 V DC power to test jacks (2 and 3) on

the box. Connect positive jumper from input terminal (4, Fig. 5)

on starter solenoid to red test iack. Connect negative lead from

starter ground terminal to black test jack.

(cc) Momentarily pressing pushbutton switch (Sect. l-3, Fig. 5, item 2)

will flash the exciter field.

Aug 25185

2-3

page 3

OM 2012

CONTt:O I_

BOX

il

io 3

13

IS

16 I7 I8 I9 20

21 22 23 24 25

ENGINE CONXOL

PANE L

*used on 53590-q

only

1. Frequency meter

2. Voltmeter

3. Fastener

4. AC Ammeter

5. A4zter switcl7

6. Line switch

7. Reset switch

8. Light test switch

9. Fault indicating lights

I

10. Load contacts circuit fuse (2-A)

11. Protective system fuse (2-A)

12. Protective relay tray

13. Instrument panel light

14. Generator control tray

15. Fuel gage

16. Light switch

17. DC Ammeter

18. Engine-generator controi switch

19. Hourmeter

20. Load contactor control switch

21. Coolant temperature gage

22. Load contactOF indicating light

23. Oi I pressure gage

24. Cold weather starting aid control

25. Air cleaner indicator

26. Engine STOP control

27. Engine circuit fuse (10-A)

28. Engine protective circuit indicating

I ight

.

I’

29. Engine starter switch

30. Blocking diodes

31. Test receptacle connector

Operating Conirols and Instruments

2-3

Figure

2 (Sheet

1’ of

2)

Aug 25/85

Pap 4

.

OM 2012

32.

GENERATOK CONTROL TRAY

PROTECTIVE KE LAY Ti<AY

32. Manual voltage control rheostat

33. Automatic-manual voltage control switch

34. Test bank switch

35. Light test switch

36. Keset switch

37. Automatic voltage control rheostat

38. Cable length compensation rheatat

39. Cable size compensation rhecstat

40: Line-drop compensation on-off switch

4 1. Fuse (5-A)

.

pt

l 41

VOLTAGE REG1JLATOR

* 42. 24 Volt power supply switch

Aug 25/e

Operating Controls and Instruments

Figure 2 (Sheet 2 of 2).

2-3

Page 5

L

OM 2012

.

1. Shut-down solenoid

9. Air shut-off valve shaft

2. Solenoid termina! (input)

10. Starter cut-out switch

3. Solenoid terminal (gramd) 11. Switch adjusting nuts

4. Latch crm adjusting nuts

12. Switch actuating rod

5. Switch bar attaching nut

13. Switch actuating bar

6. Latch actuating arm

14. Latch can a

7.’ Latch

15. Solenoid plunger rod

8. Latch reset lever

.

Engine Shut-Down Solenoid with Linkage, and Starter Cut-out Switch

Figure 3

(dd) Disconnect jumper leads.

(b)

Flashing exciter field without test box.

ba)

Remove test receptacle cover (1-3; Fig. 6). Use two test leads

equipped with a test prod on one end and an “alligator” clipon

the other.

insert the test prod of one lead in terminal “D” of the

test receptacle (see Fig. 5), and connect the other end of the lead

to a good GROUND.

tnsert the test prod of the second lead in

terminal “F” of the test receptacle and momentarily touch the

other end (alligator clip) to the “hot” terminal (4, Fig. 4) on the

starter soleno id to flash the field.

CA1JTlON: FWSHING THE FIELD IN A REVERSE DIRECTION

COULD CAUSE DAMAGE TO VOLTAGE REGULATOR

DIODES.

2-3

Aug 25 185

Page 6

OM 2012

.

7

-.

’

1.

2.

3.

4.

5;

6.

7.

8.

I

6

.

Starter

Starter solenoid stiifch. to starter terminal

Solenoid coil ground terminal

Solenoid switch input terminal

Starter solenoid switch

Solenoid coil terminal

Battery cable

Starter ground cable

Starter and Solenoid Switch

Figure 4

NOTE: If test ieods with test prods are nol available, insert

short pieces of wire in pqxr test terminals to make

connections.

(bb) Disconnect iecds and install receptacle cover.

(14)

Check position of load contactor “on-off” switch (20, Fig. 2), and engine-

generator control switch (18).

(a) Load contactor switch (20) must be in OFF position.

(b) Engine-generator control switch (18) must be in IDLE pcsition.

Aug 25’85

2-3

Page 7

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Test Receptacle Connector Terminals Identification

Figure 5

2-3

Page 8

Aug 25’85

I.

/

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(I) S1-xt ffi:: engifz in accordmse with ins!wcticmt in I-3; Purer. 2, A

fhr:s c.

.

(3) Check engine idle speed. Sfi~ouid be 875 to 925 RPAd. Aciust, if necessury,

in accordance with instruction5 in Engine Opera{ds Mcncrll .

NOTE:

A sirobcscope is required for this check.

(4) Agcin check for oil, fuel, and coolant Icc!<s ci:!d correct any leckir,g coniiticn.

(5) Position switches and controls for automatic voltage regulc,iIcr~ and power

de1 ivery as fol iows:

(a) Place automatic-manual switch (33, Fig. 2) in AUTOMATfC position.

.

_ I

(b) Place test-bank switch (34) in AIRCRAFT position.

.

1 (c) CSetcr switch (5) may be inany position except pointing straight down.

‘..

.

(d) If the adiustment of the voltage, regulator i’heostat (37) has been distuked,

position the knob to mid-range position.

(6) Bring the engine up to governed speed and also energize the generator by

holding the engine-generator control switch (18) in BUILD-UP-VOLTS

posit ion momentarily .

Release switch and allow it to position in “center”

.

RUN position.

.

If the engine “comes-up” to governed speed and a voltage value appears on

the voitmeter(2) , the electric governor and exe itation-deenerg izo-

tion relay circuits are functioning.

(7) Observe frequency meter (1).

If engine speed is properly odiusted; frequency

wiil be exactly 400 Hz.

If not, adjust engine governed speed in accordcnce

with Para. 4, E, (3) (d). See Fig. 12.

(8)

Observe voltmeter (2). Use rheostat (37’) to adjust voltage to 115 V AC.

(9)

Measure governor actuator input signa!. See Para. 4, E , (4), (a).

.*

Aug25G5

2-3

Page 9

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(16)

. tw

w

Check adjustable voltugc range in automatic opet-cting mode.

tw

(16)

MeCjUre governor magzfic pickup.:ignc!. See Po!.o. 4, E, (4j, (b).

Check hi&-speed !imiting governor.

.

Engine Iimiting speed governor shoufd limit et!yiiic +

K?d t0 jLJ:t CbOVc trip ;?oinf

of overspfzed governor.

Ovcnpecd device.shoLt!d trip at 2250 to 23GG RT’I\+i. See

Synchro*-Start Products Inc. instructIons in Chapter 6.

(a)

Observe voltmeter (2, Fig. 2) one! turn rheostat (37) CLC.C!<W!SE to fcli!

clockwise position. Maximum voltage shoutd be at ieact 134 V AC, or

higher.

NOTE: If vo!tagc shou!d decrease when the knob is turned clockwise,

-I

it indicates that interna wiring of the vo!tage regum

r

correct.

Replace the complete regulator tray assembly,.

(b)

Observe voltmeter and turn rheostat knob to full COUNTERCLOCKWISE

position. Minimum voltage shou!d be 108 V AC, or lower.

Observe voltmeter and adjust rheosjat to obtain 115-V AC vo!tmeti:r reading.

.

Check adiustable voltage range in manual oparcting mode.

(a)

Open the generotor .controJ tray .( 14, F

ig. 2)..and place the automatic-

manual switch (33)

in MANUAL position.

(b) Observe voltmeter (2) and turn manual control rheostat (32) CLOCKWISE

to full clockwise position.

Maximum voltage should be at least 160 V AC.

(c)

Observe voltmeter and turn rheostat (32) to full COUNTERCLOCKWISE

position. Minimum voltage should be 95 V AC or less.

(d) Adjust voltage to 115 V AC, then return the atiomotic-manual switch

to AUTOMATIC position.

Position load bank switches, etc.,

to apply a light ioad to the generator.

Place the load contactor “on-off” switch (20, Fig. 2) in the top, spring loaded,

CLOSE position.

Hold in this position momentarily. The indicatiag light (22)

should glow GREEN and an amperage value should appear on tfle AC ammeter

(4). -

2-3

Page 10

Aug 25%

(20)

(23)

(26)

OM 2012

.

Oven the protective relay tray and place the test bon!: switch (34,. Fig.

2) in TEST BANK position.

&in place the load contactor switch (20) in the top, CLOSE position.

Light (22) show Id glow GREEN und remain 01

u when the switch is released

and c/lowed to rcturn to the center ON position. This indicu?es that the

load bank switch (34) is f unc,roning to by-pass the plug intcrlcck ielcy. t’

Return the load bank switch to AIRCRAFT position. The load contactor shoujd

open at once and the green indicating tight (22)should go off.

Connect a soufce of 24-V DC power (two twelve-volt Imi!.e:ics connected

in’series) to terminals “IN” and “I-” (or “E”) at the output terminal pane!.

Connection polarity shoukl be: MINUS to terminal N and PLUS to temrinal

E orF.

Place test-bank switch in AIRCRAFT position. Hold the contactor operqting

switch (20) in top, CLOSE position momentarily, The generator “on”

indicating light (22) should glow GREEN and remain on when the switch

is released and allowed to return to the center ON position. This In-

dicates that the ioad contactor is closed and the plug interlock relay is

functicning properly.

.Apply l/3 to l/2 (90 A to 130 A) load at the load bank and al low the unit

to fun for 15 to 30 minutes. Observe operation of all monitoring instru-

merits.

Increase load bank resistance to apply a full load (260 A).

Check operation of the governor by observing the frequency meter (1,

Fig. 2) when generator is switched from no-load to full-load and vice versa.

Use the contactor control switch (20) t

o apply and remove load several times.

Frequency droop should be no more thun 1 Hz. Adiust governor if necessary

(see Para. 4, E, (3).

.

Follow instructions in Para. 4, B, (2) (b) t

o set voltage regulator, line-drop

comp,ensation potentiometers (Ref. Figure 2, items (38bnd (39). Set knob

pointer on cable size potentiometer (39) to size (2/O, 4/O, etc.) of cable

j being used. Set knob pointer on cable length potentiometer(38) to length

Aug 25/85

2-3

Page 11

OM 2012

(26) Check accuracy of voltmeter.

(a} Open generator control trcy (14, Fig. 2).

(b)

Connect a master voitmcter of known accuracy to terminais of the voltm:tzr

(2).

i(d)

Compare unit voltmeter recding with master meter. Error must not exceed

2% of

FuII scale.

(29) Check accuracy of AC ammeter.

(a) Connect a muster ammeter of knotin accuracy to the AC amme>er (4)

tenina!s.

l

(b) ibmpare unit ammeter reading with master meter under varioti; toads.

Error must not exceed 4% of full scale.

.

(30) Check operation of meter selector switch (5).

A voltage value should be shunin ’

‘in each switch positiqn.

131) Ch

ec o era ion of the line switch (6). A normal voltage of I15 V AC shou!d be

k p. t

indicated when the switch is in LINE-TO-NEUTRAL position.

A voltage of

-approximately 200 V AC sftould be indicated when the switch is placed in LINE-

TO-LINE position.

(32) .Check accuracy of frequency meter.

(a) Connect a master frequency meter of known accuracy to the frequency

meter (1) terminals.

(b) Compare meter readings.

Error must not exceed 1% of ful i scale.

(33) Operate the unit not less than 10 minutes under full load (260 A). The over-

load device (Ref. l-1; 7, Fig. 13) MUST NOT trip.

2-3

Page 12

Aug 25 /*

OM 2012

load iridicatirlg Jisht (9, Fig. 21 mus

dition.

(35) i!.ecJcrce Joad tc normcl. Turn off ind

Fig. 2).

icGtirt3 ligltt by prcxing reset s:,:?ch (7,

(36). Check engin e oil pressure at govemed speed (2000 Rr?l~<).’ Gage slroufd indicate

at Jeust 38 PSI when the engine is hot.

Check engine cotilant ten+xture.

Gage should indicate in the range of .I80 degrees to l?G degrees dependins

upon an?bient temperature.

(37) Check operation of fuse interlock (Ref. 7-J; 2, Fig. 10). W{fJl

unit 0pera:ic-g normaliy under load, remove protective relay circuit fuse (Ref.

11, Fig. 2).

The load contactor sllould open immediately. This indicates

that the fuse interlock reJay is functioning properly. Rep&e fuse and appiy

load.

NOTE: Make all protective refay tests with the unit operating urder load.

_ .

(38)

Check operation of overvoltage relay and indicating fight.

. (a) With tho unit running ct normal loud, adjust’ the voltage regulator rheo-

stat (37, Fig. 2) to increase voltage (turn cfock\h:isc) until the,overvoltage

sensing re!ay actuates the protective monitor to open the load conthctor

and turn on the overvoitagc indicating light. The ovetvoltase xnsing

relay should trip when voltage reaches 130 V to 134 V.

(b) Return unit to normal operating conditions by adjusting voltcge regulator

rheostut and pressing reset switch (7).

/

’ (39) Ch

ec. o era ion of undervoltage sensing relay, indicating light, und time delay.

k p t

Before starting this check, Jet 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. J-J; 5, Fig. JO)

should function to activate the undervoltcge time delay circuit. Five seconds

after the time delay circuit is activated, (if the under-voltage condition con-

tinues) it should function to open the protective monitor relay which, in turn,

will open the load contactor to stop powerdelivery. As a resuJt of the action,

the undervoltage indicating JiglIt (9) should be turned ON. A stopwatch or

sweep-second-hand watch is required for this check.

Proceed as fof Jaws:

(a) With unit running at normal load, use the voltage regulator rheostat (37,

Fig. 2) to reduce voltage to 104 V. The load contactor should NOT

open after a Ssecond dalay .

Aug 25105

2-3

Page 13

OM 2012

It may be necc NQTE:

ssary to switch to MANUAL contrcl to obtain thc:re

low voltages.

(c) If the load contactor is not opened at 103 \I to 93 V, it will be necessay

to refer to the Troub!e Shcoting Chart, Section 3-1, to d&ermine

which COV~OilCtlt of the undervoI:uge protective circuit is defective.

(d) If the undervoltage circuit performs satisfactorily, return the unit to norma!

operaticn by adjusting the voltage to 115 V, pressing the reset switch, and

closing the foad contactor.

(40) c!eck d is ‘I

un c *rc uency sensing relay, protective monitor, and indiccjting light.

At some frequency value (Hi:, cyc!es-per-second) from 385 Hz down to 375 Hz,

the underfrequency sensing relay should function to signal the underfrequency

circuit’in the protective monitor module to OPEN the load contact07 holding

”

circuit, thus OFENING the load contactor. To check the underfre.quency

*

.

,protoctive components, proceed as follows:

la) Whi !e the unit is. operat ing normally under load, reduce ,generator output

frequency. by reduding engine speed. Use the governed speed setting

potentiometer (Ref. Fig. 12). Turn adjusting screw COUNTERCtOCKWlSE

gradually to reduce engine speed until frequency meter indicates 386 Hz.

Underfrequency protective relay should not function to open the load con-

tactor at this frequency.

Reduce frequency in steps of 1 Hz.

.jb) ff the protective system functions to open the load contactor and turn on

the underfrequency light after sarnf: frequency between 385 Hz and-375 Hz

is reached, all components of the system are functioning properly.

If the

load contactor is not opened with in the above frequency range, refer to

Trouble Shooting Chart to determine which component is defective.

(c) Return unit to normal operating condition.

(41) Check overfrequency sensing.relay, protective monitor, and indicating light.

2-3

Aug 25/85

Page 14

OM 2012

(b) If the overfrequency system functicns to open the (cad contcctor and turn

on the overfrequency light after some frequency between 415 Hz und 425

Hz is reached, all components of the

system are functioning prOpCi4y. If

the load contactor is not opened within the above frequency rcnge, tefer

to Trouble Shcoting Chcrt to determir;e which compc~ent i; defc.st-lve.

(42)

if the generctor is operating under load at this point, place the contircior

control switch (20, Fig. 2) in OFF position to ok*

q-n load co.ntactor c?nd disconnect

load. There wifl be no further need for the load bank in the following checks .

4

(43)

With the engine running at normal governed speed, check ihe entire unit for

vibration and for any parts which may have become loosened during the above

checks. Tighten any locse citaching ha.rdware a; required.

(44)

Check &O-Hz generator hecrings.

USC a stethoscope or metcl 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 one! use the indes finger ard thumb to form a “sounding chamber”

z between the rod and the ear. Do NOT allow the rod to touch the ear.

Listen

for “grinding” or pounding. sounds which would indicate a defective bearing.

An engine noise may be “telegraphed” to the generator and misinterpreted as

a generator noise. Send the unit to overhcul if in doubt of bearing setvice-

ability.

WARNiNG: IF A METAL SOUNDING ROD IS USED TO DETECT BEARING

NOISES, EXERCISE EXTREME CARE TO AVOID INJURY.

4. Generator Set Adjustment

A. Generator Adjustment

The 400-Hz generator is a brushless type requiring no adiustments of any kind.

B. Generator Control Adjustments

The following items may require adjustment at some time during the life of the

ea LJ inme nt .

Au3 25’85

2-3

Page 15

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(b} Idove ‘ ‘he slider-band toward #re single wi:e end of i&e

rrrk~r to i~t~im.5~

voltage poknl id.

I\/iove the band toward the double wire end (two \~1:1-.s

connecied) to decrease voitage potential .

(c) F&e;: slider-band cfamping screw.

(Zj Adif.ef 4X-k voliagc regulator.

When c vcltcge reyufctor is first put into service, or when ou:put (gcnerai-x-

to-aircraft) cabJes cte changed, the regulator may require up to five scparafe

s

adjustmer:fs. The five adiustmenfs are for generator output voltage value,

damping gain, damping rate, line drop compensation gain, and line drop

comper.sation rate.

See Figure 6 for ider.tification of components used for

reguJator adiustment.

.

(a) Adiust generator output voltage.

This is a reJativeJy ecsy adjustment to make. Witlt the generator running

at a rated speed (2000 RPM) end rated cycles-per-second (400 Hz}, rotate

the rheostat knob (7) CLOCKWISE to INCREASE voltage and COL!NTER-

CLOCKWJSE to DECREASE voltcge.

Obse,rve the AC voltmeter and adjust

output vohcge to 115 V AC.

(b) Adiust cable length and cabfs size compensation rheostats.

These’ two adjustments should be made together. Switch (4., Fig. 6) must lx

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) Adjust rheostat (3) to point to the size of cable being used. Various

cable sizes are also indicated on a plate behind the rheostat knob.

2-3

Page 16

(cc) With generator running (no load), check output voltage value, which

should be oxactJy 115 V AC.

If not, adjust in accordance with Pam.

4, B, (2), (a) above.

Au g 25 435

OM 2012

* 8

1.

2.

3.

4.

5.

6.

7.

8.

V.oJtagc adjusting rheostat

Cable iength compensation rheostat

Cable s ize compensation rheas tct

On-off switch, Jine-drop compensation

Fuse (5 Amp)

Fuse h older

Damp (gain) adjusting potentiometer

Rate adjusting potentiometer

Voitage Regulator Adjustments

Figure 6

,

(dd) Apply a full load (90 KVA, 260 A) to the generator. Observe AC

voltmeter.

If the voltage observed varies more than 1% (plus or

minus) from 115 V AC, adjust rheostats (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 COUtdTERCL@CI<WJSE

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 adiustment.

Aug 25,%

(c) Miust “damp” and “rate” adjusting potentiometers (see Figure 7).

Damping adiustments are very delicate and should not be attempted unfess

the generator output average phase value varies more than 1 volt, or

output voltage is unstable. “Damp” and “rate” adiustments must be mcde

in coniunction with each other because the adiustment of one may affect

the other.

For example, improving the response by .adjusting the “damp“

potentiometer (1) may affect the stability as adjusted by the “rate”

potentiometer (2). Adjust as follows:

2-3

Page 17

OM 2012

STAr3tE (ICSS steady) I

COUi+TE?ICLOCI\‘Wv’SE - iV,~ke;

regufctor ,V,OIZE STACLE (si.eodicr),

LESS RESPONS IVC.

Best adjustment approximatcfy 3/4

of full travel CLOCKW 1% o

i

RATE - (Affects stability)

- . .

ADJUSTING SCREW DISECTION

OF ROTATION

Regulator will likely bs UNSTABLE

if adjusting screw is at either limit

of odju5tment -

CLQCKWISE or

COUNTERCLOCKW (SE. From a

point near full COUNTERCLOCK-

WISE position, turn the screw

CLOCKWISE unfil a point is

reached where the voltage regula-

t ion abruptly becomes STEADY.

Best adjustment for the system is

usually 5 deg to 10 deg beyond

this point in a CLOCKWISE direc-

tion.

2-3

Page 18

Voltage Regulator Damping Adiustments

Figure 7

Aug 25’85

OM 2012

(bb) Coiinect t!;e genergtor output !

o c buianced, three-phase load of 30

kilowatts.

(CC) Witfl gerierator running at 115 \I AC no load, &perate the contactor

“on-off” switch (20, Fig. 2). if the average phase voit~gc: charged

more than 1. volt, or if outpuf is unsteady, adjust “damp” and “rate”.

(dd) Turn the “damp” (1, Fig. 7) arlj3stir.g screw CLOCK\;r’ISE io Improve

response. Turn COUNTERCLOCKWiSE to improve STABltiTY. Gen-

erally the best adjustment is approximutely 3/4 of full CLOCKWISE

travel.

(ee) Turn the “rate” (2) adjusting ‘screw to near full COUNTERCLOCKWISE

posit ion.

Turn the screw siowly CLOCKWISE until the vollcge output

abruptly becomes STEADY. Continue turning the screw CLOCKWISE

5 deg to 10 deg past this point for bcst.‘“rote” adjustment.

L

(ff) Tighten adju:ting screw locknuts after adjustment is compteted.

C. Basic Engine Ad justmcnts

Adjustment procedures applicable to the diesel engine are included in the Detroit

Diesel OpcrGtor’s Manual, which is located in Chapter 6. Specific information

for this particular engine cpplication is listed in Figure 8.

(1) Exhaust valve adjustment

Refer to the Detroit Diesel Operator’s Manual.

(2) Exhaust valve bridge adjustment

Refer to the Detroit Diesel Operator’s Manual.

(3) Fuel injector timing adjustment

Refer to the Detroit Diesel O’perator’s Manual.. Injector NOS.

Timing Gage Tool No. J1242.

OM 2012

--.-I--_-.

-

Type eiig iw

4-7 1 i;:

Erqirt-rr govc:;i;r;d :pxx~

2Q3g 1: y’i,q

Id!c speed

875 to 925 kI‘M

CJvCt:pCCf! gcw2r:?cc t;ip ;zoir:i .

2400 !? ?!itl

Lirnii-ins sp?cd ~O;~C?ffm: 2 300 i< PAi

Firing cfdcr

l-3-4-2

Typ of cyIixk!r head 4 Valve

Type of I iinit Ing speed governor

Sirigte Weight

Type of injcciors N65

injcckx timing toof pati civmher

*

J1242

(For engiiS

es with advanced camsh:& timing)

Exhaust valve cl’earanca (cotd)

0.015 in. GO

0.017 in. NO GO

Exha& v&e clearance (hzt)

0.013 in. GO

0.015 in. NO GO

Lubricating Oil Przssurz

Normal

@ 20%) R PM

4.0 to 60 l’s !

Minimum far safe operation @ 2100 RPM

30 PSI

Fuel kessure, Inlet Manifofd

Normuf @ 2oco

45-70 PSI

Engine Coofant Temperature

Normal

160 to.185 deg F.

Minimum Compression Pressures @ idtc speed

Sea level approx.

515 PSI

2500 ft.. cpprox .

480 PSI

5000 ft. approx.

440 PS:

’ Eng ine Spec if icat ions

Figure 8

(4) Idle speed,sped 1’

imiting, and overspeed adiustment.

Refer to sped limiting mechanical governor adjustment instructions

in the Detroit Diesel OFrats’s Manual. Use instructions which

apply to a single weight governor.

Recommended idle speed for this application is 875 to 925 RPM.

NOTE: A stroboscope is required for engine speed tests.

The limiting speed governor should be set at a speed just below the ovenpeed

governor trip point,

or approximately 2300 RPM,

Refer ta manufac’turer’s instructions, in Chap. 6 for ‘!Synchro-Start” overspeed

governor adiustment.

2-3

Page 20

-*.

-*p

--

Au g 25.46

’ .

f

OM 2012

.

Refer to 2-1; Pora. 8 for lx It adiusirtzi;t insifuctior,:.

E. E lectric Governs; System Adjustment

All of the electric governor system main com~~o:~ents, namely the magnetic pickup,

actuate-, and conk01 bcx, have critical adjustii2nts which can affect c+n.lIne

performarlce and t-hzrefore, generrc!,or output. Actuator-to-fuoi control icver

adjustment can ai;o affect engIrl prfornancz.

When ihe complete system is to be checked, and/or adjusted, a definite sequence

of prozcdures should bz followed:

First -Check ar adizt actuator linkage

Second - Check OT adjust magnetic pickup

Third -Check OT adjust electric cantrat box

(I) Actuator lin koge adiustment

.

_.

The proper adjustment of the mechanical linkage between the electric dctuator

and engine speed control lever is important to the satisfucfcry o,peratior;l of other

‘electric-hydraulic governor components.

The mast important thing to remember about this adjustment is that the actuator

and linkage mu

st move speed control lever through its compleic rcnge of trab-el

from full idle (fuel off) positiorr to fuil speed (fuel on) position. An adjustment

which does not provid,

0 ful I travel of the spzod control lever can caue sluggish

operation and slow response time under load. Check and adjust linkage as

foliovd, with engine stopped.

(a) Disconnect but1 joint (3, Fig. 9 ) from actuator lever (2).

(b) A spring in the speed limiting governor will hold the speed control lever

‘. (6) in full IDLE position.

In this position it should point almost straight

outward at approximately 10 degrees toward the rear of the engine.

Aug 2545

2-3

Page 21

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(4

,

With sped CCX-I:.F~)~ lever (6)

and actuator iever (2) bo!h in fu!l IDLE posi?icn,

aitcjn-,;.3f to conw~

t boll joint (3) to lever (2).

If hli joini~ mom!‘irrg mew

and mounting ~G!C

in the lever do not line-up, locscn nxts (7) and

adlust length of rod (5) so that the bull joil:t may bc attaclied to iever (2)

when bcih fevers ore in full IDLE position.

ivOo!‘E:

Bati joint attaches to last hole in actvats lever (2) and first ho/e

in speed control lever (6), as iilv;.tiatcd.

Governor Linkage

Figure 9

.

1. Actuator

2. Actuator lever

3. Ball joint

4. Fuel shut-off iever

5. Rod

6. Speed conirol lever

7. Nut

8. Actuutor shaft

Aug 25 ‘85

.2-3

Page

c

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(2) Magrl.?tic pickup ad~~.fii;!ient

The sjrrength 0; the magnetic pict:r_tp signal to the controi box can be weakened

’ if the tip of the pit kup is

too far from the flywhze 1 ring gear. If the pickup

is to be removed for any reason,

or if the signa! is weak, OS indicatzd by i-est

in Para. 4, E, (4, (bj, adjGt as follova:

(a) Disccnnect magnetic pickup ut puIl-apo:t co:lnecta (1, Fig. IO).

(b) Loosen nut (3) and remove mzgnetic pit kup (2).

(c) lnspct to make certain the tip is not damogcd from contact with the ring

gear teeth (replace pickup if damaged).

(d) Rotate the engine as required to locate a ring gear tooth directly bs,lcw

the tapped, pickup mounting hole.

An imaginary line should pass through

the center of the mounting hoIc, the center of a flywheel tooth or.4 the

cenfer of the flywheel.

,

,(e) Install th e magnetic pickup and thread info the mountyng hole until the

tip touches the “in line ” flywhee I gear tooth.

CAUTION: THE PICKUP TIP MUST BE DKECTLY OVER A TOOTH

AND NOT BeEN TEETH WHEI\I ADJUST/&NT IS

MADE.

(f) Back the pickup outward (countcrclockwZe) l/Z turn. Hold the pickup

securely in this prxition and tighten nut (3). This adjustrrent 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 (S and T, Fig. 13), when the engine is running

at no load and governed speed.

Reconnect pull+part connecter (1).

NOTE: As little as 1-V is required fw operation of governor

control box. Magnetic pickup vo,ltage does not have to

be 4-V to 8-V.

Aug 25435

2-3

Page 23

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1. Connector

2. Magnci-ic pickup

Magnetic Pickup

Figure IG

.

(3) Governor control unit cdjustment

.

Before making on adjustment to the control unit (Fig. I?), make certain that

linkage batween actuator and fue I control iever (Fig. 9 ), is free and proper/y

adjusted. There must be no lost motion or “play” in the linkage. Be sure mag-

netic pickup is producing a strong, normal output.

There are three adjustnant controls on the unit (see Fig. 12). They are identified

US:

FREQ. ADJUST - Adiusts engine speed and gcneratos frequency.

GAIN and STABILITY -Adjust engine response time end stability.

To adjust control unit, proceed as foiiow,:

(a) If the control box is being adjusted fcx the first time, set adjustment controL 05

folloVV5:

FtIE Q. control

- Turn adjusting screw at least 22 turns counterclcckwise. This

will pasitiveiy insure that its adjusied position will be at MiNIMUM

speed.

2-3

Paae 24

Aug 25 ‘85

OM 2012

STAB tLlTY control

- Loaen Iocknut and adjczt sfabiliiy con!-;a! tc ik fufi

c ounterc ioclcw~e pc6 it ion.

(b) Start engine and a!low if to warm.

(c) Piace operating mode switch (18, Fig. 2) in GEN pclsition to nxrke e&i-ic

governa system.func~ionaI,

- Governcr

c ontr

,ol box

Aug 25,‘85

Electtic Governor Control Box Location

Figure 11

2-3

Page 25

OM 2012

if th? engine hecomes unstab!:? Lofore 4GG HZ is ICClCh2d, turn GA:?! control

counterclockwise until engine s,pccd stabiii-as and ad’juif FI;EQ coi::rc! by

turning c I ockw/i:~:

to increase speed or counierc!ockv/i;e to decrea;c spzed

untii 490 Hz is indicated 0;7 the frequency meter.

(e) Turn GAiN control clockwise until the engine becomes just unstobl~z (scre:-;s).

Back the GAfN control sliyfitiy coun:ercIockwbe until the engin: is again

stab le.

(f)

Turn the STAG lLfTY control slowly c icckwise until the engine becom-+s

uns tab ie .

Back the STABiLiTY

counterclockwise utltif

the engine k crgain stable,

control siighti

Then turn STAB1

I

COUNTERCLOCKWISE.

ITY control two graduations

(g)

The electric governor is now set to a nomincliy good operating point.

.

(h) Tighten all adjustment control lociinuts.

(4) Electric governor test values

(a) Signal to actuator

f

Check amperage value of the signal to actuatcz by disconnecting iecd at

terminal (5, or 0, Fig. 12) at control box terminal board. Connect an

accurate ammeter in the circuit.

Current value when operating at govcrred

speed (2000 RPM, 4OG-Hz) should be 2. I-A to 3.0-A at 4-V to 6-V. At

full load, current value shodid be 0.974 to 1.3-A HIGHER than no-load

value. Voltage should be approximately 4 to 6-V DC at no load.

(b) Magnetic pickup signal

Connect a high impedance voltmeter to magnetic pickup input terminais

(S and T, Fig. 13) on control box terminal board. The voltage vaiuo at

governed speed, no load should be 4-V AC MIN iMUM.

NOTE:

A signal as low as 1-V is sufficknt to operate the control unif

satisfactorily,

No voltage indicates the pickup is too fur from

flywhec I teeth, or it is defectivc.

2-3

Aug 25 %fi

Page 26

,:

=-?c

<

-a*<~

r,w

_

.,_..

_,

bPEED ADJUSTING

SCREW

GAIN kDJUSTlNG

12-V DC ’

-------I)

.

1

/

e

E lectric Governor Control Box Adjustment

Figure 72

TO TEST

RECEPTACLE

EXCITATIDN

DE-ENERGIZATION

.

1 A B C D E ‘TG-H- ’

I

OM 2012

-

.

3l---ll

I I I I

_ _ _

CONTROL 80X

MAGNETIC

PICKUP

CONNECTOR

E lectr ic Governor C onnec t ion D iagram

Figure 13

Aug 25 ‘85

2-3

Page 27

OM 2012

(I)) C!iJdI CIL'Ci@l!CZ t ChvCei-~ Switch actuai-ins I-od (13)

cd GxitcIr actua: ir;g

bar (13). Acluci-ing rod (12) must not to:+ch bar. (13) V.&X tile mzchcnism

is UNLATCfiED. Acceptab!e clearunce may be 0.010 to 0.020 inch.

(c) ff adjustment is required, !c m-en nuts (:I) and adjust to position swiich

(10) to get acceptable clearance. Tighten nuts securely. Rext mechanism

by pressing fever (8) down.

NOTE: Pushing the start switch should o;xrate the stcrter when

the shut-dcwn linkage is LATCHED. it should NQT

operate the starter when linkage is UNLATCH~E.

(2) Shut-down linkage adiustment

This linkage should rcquIre adjustment only if disassembled CT if a shut-down

solenoid is replaced.

(See Figure 3.) Engine must be stopped.

,

(a) Adiustment is required if the latch (7) doos not fully seat in cam notch *

(14) when the mechanism is in LATCHED position with air shut-off va!ve

fully open, or if the solenoid plunger rod (15) does no.2 have enough

travel to lift the latch (7) out of the cam notch when the solenoid is

energized .

.(b) If adjustment is required, remove nut (5) and bar (13). Loosen nuts (4}

and adjust so that the latch (7) is fully seated in the cam notch (14) when

the solenoid plunger rod (15) is at the end of its downward travel and the

air shut-off valve is fu I ly open. Tighten nuts (4).

(c) To check operation, momentarily apply 12-V DC to terminal (2). Plunger

rod (15) must actuate mechanism to lift latch (7) out of notch in cam (14)

and allow blower air-valve to close.

(d) Install bar (13) and attach with nut (5).

(e) Check adjustment of starter cut-off switch (TO). Adjust in accordance

with Para. 4, F, (1) if necessary.

2-3

Page 28

Aug 25’05

OM 2012

5.

A. Disccnnect generator stc;tor leads at the power module pane!.

B.

Disconnect exciter ieads from tenninai board mounted cn rcar,c,f engine contrc!

panel. Positive /cad is PED. Negative lead is YELLOW-BLACK.

.

C. Check resistances and compare to values given in fig. 14.

t

TEST CONNECTION

NOMNAL RESiSTANCE fN WfMS

.._I---.

-.

GENERATOR STATOR

.

_I-

7

Phase A to N ’

0.00827

Phase B to N

*

0.00835

Phase C to N

0.00840

NOTE: The two leads of a phase must be connected when test is made.

.-

EXCJTER A-B, B-C, A-C

0.1

Field (RED to YELLOW BLACK)

7.23

L

Generator and Exciter Stator Test

Values (700 F Ambient Temperature)

Figure 14

6.

Diode Test

Test values for diodes are not given here because they could be misleading. Test values

may vary even between diodes of the same part number, rating, and manufacturer.

General instructions for testing diodes follow:

A. Disconnect diode lead(s).

Au g 25 ‘85

2,3

c

OM 2012

Phati I’,” inp:Jt for reg. Cs, tray<.

Chit in ‘rG2r(‘r mot:2 t:

--.,-

Phase “C” input for rey. 8, trays

Prot?ctive ,rr(an if or fuse

m--.-e

Fuse infer lock rc lay

Protective mcnifoi c~7tocts

8

D-F

9

v-x

10

K-b

11

K-E

12 K-R .

13

14 .-

IS

- ----

16

K-Pi

17

K-J

18

K-G

19

u-w

20

21

22

I

Plug in:.zrlocl: re!oy

Exciter input

Regulator output .

auto-man SW. in

CWtCCtOi operation

Test bark SW. closed &

cantactor c losod

.

Overload contacts at less than

.-

Test bank SW. closed 8,

0 V DC

125% load

--

con:ioc tar closed

Contactor switch

I-est bank sw. closed &

115 V AC

cantactor SW. in “On” pos.

Bet. vol toge & eng . circ. fuse

AI I conditicns

Shut-down solenoid

_12VDC

Engine runnina

. OVDC

Governor & ext. de-energ. relay Unit in “Gen” mode

12 V DC

Governor actuator

Unit at idle spacd

0 V DC

Unit in “Gen” mode, no load

4-6V DC

Typical Test Values at Test Receptocie

Connector or Test Box

Figure 15

2-3

Aug 25,/85

Page 30

a.

c.

Hold one ohmmet2:. ICad point on the

threc!Jc

d

end of the dicdr .

Ho!d ih~: other

L

lead poirrt on the wi:a terminal end.

Gbservc .and note the indicated resk~ance.

Now reverse the lead connectioris on the diode. Aguin o!xzrve and noiz the ohm-

meter indicated rF:jistunce. Gmcratly spzaking.,

if an infinite of very hi& Fe-

sistance was inllicatzd with the Icads connected me way ai,J a low, rckgbie

resistance was ir;dicated with the leads conxcf~~d the opposite way, the diodz

may be consider& good.

7. 24 Vo It DC Power Supply Test

CAUTION:

MAKE SURE GENERATOR OUTPUT IS NOT CONNECTED TO

--

A.

B.

c.

D.

E.

F.

AN AIRCRAFT.

Start the generator set and operate it for normal power delivery without closing

the output load contactor.

.

’ Place test bank switch (34, Fig. 2) in AIRCRAFT position.

,

Lift red cover on 24 volt Power supply switch (42) and place switch in UP

position.

Measure DC voltage between temrinafs E (+) and N (-) on the output terminal

panel. Voltage should be 27 z 2 volts DC, with no load on the power supply.

Close the output load co&actor with contactor control switch (20). It should

close and remain ciosed.

Position power supply switch (42) to the DOWN position. Contactor should

open, and remain open even when contactor control switch (20) is actuated.

Au g 25. .035 .

2-3

Page 31

OM 2012

A . Trouble shooting is an orderly process

sf checking and clin;%-~u~Tng pos:.i&ic causes

of trouh!e until the exact cause of CI trou!>le is fozld. As u rukz, the b:;t place

to start looking for the cause

of a trouble in a circuit or system is at the source

of*power or supply.

Continue testing or checking the circuit or systern, sivp-by-

step,

in an orderly manner,

until the CCJcJSe of trouble is locnkd.

B. The chapter provides infcrmatioo useful in diagi;osing and carrzcting certain

.

troubles v.hich cause unsatisfactory operation or failure of ihe equipment.

C. Minor troubles may & remedied by the operator; however, maior repairs ,nust

be undertaken by experienced mechan its and c lectricians on iy.

2.

Trouble Shooting Chart (Figure 9)

A.

Description

The trouble shooting ‘chart lists information under th’ree headings as follows:

,

(1) Trouble, Symptom, and Ccnditicn

.

(2) Probable Cause

(3) Test, Check ; and/or Remedy

B. Use of the Trouble Shooting Chart

(1) A trouble shooting chart is furnished to provide maintenance and repair

personnel with Q time-saving guide for locating trouble. To use the chart,

proceed as follows:

(a) Locate the symptom(s) of trouble in the “Trouble ” column.

(b) Check the probabl

e causes of trouble in the “Probable Cause ” column.

(c) Test, check, repair, or correct the trouble as indicated in the “Remedy”

column.

(2) If the cause of a trouble is an uncommon one and cannot be located by use

of the chart, the only alternative is to start at the source of power or supply

and check the affected circuit or system completely.

[Jse schematic and

Aug 25 ‘85

connection diagrams which are supplied with fhis manual.

3-1

Page -1

OM 2012

NOTE:

RCfC.?feiTCe symbols

1 (SF, etc. ), used in the Trouble Shooting

--

Chart-, are identified on Schematic and Connection Diagrams.

3. E~&~,ertt far Trouble Shooting

A go& quality multi-scale VO~~I!I~WW~~ is ihe

n!y instrument fequifcd for trcub1e

shooting. At lazasf two “jumpor” leads with “clligutor”

clips and test prods will be

required. The 12-V,

engine e1ectricuI sy:tzm may be used as a 12-V DC power

sour-ce .

if a test box, part num&r 388318-2, is avoiiabie tests may b made more quickly

and accmate ly,

however, the test recepfacie connector (3 1, Fig. 1) may be ‘used by

inserting the test points of a voltohmmeter into prop& terminals of thz cormector.

Refer to Fig. 8.

.

- 4. Safety ,

WARN IN G: EX!ZRCISE EXTRE~,‘~ CARE TO AVOID CONTACT WITH HIGH VOLTAGE ’

--

.

LEAD’S AND COMPONENTS WHICH COULD CAUSE SERIOUS SHOCK

AND INJURY IF TOUCHED WHEN TROUBLE SHOOTING OR OPiZRATIKG

THE EQUIPMENT.

5.

Parts Replacement

To lessen end item “down” time and to get a faulty machine back “on-the-line“ as

quickly OS possible, the “black-box” concept of, parts replucement isreflected in the

trouble shooting chart. For example,

if a component in the protective relay trcy is

defective, fhe quickest way to remedy the situation is to replace the complete tray

assembly. and send the old tray to stock.

Assemblies which lend themselves to this concept are:

Generator control tray

Over-undervoltage module

Protective relay troy

Over-underfrequency modu ie

Voltage regulator.

Over lcad module

Pfofective monitor module

.

Electric governor ccntrol “box”

Governor actuator

3-1

Page 2

c

OM 2012

The c~hcvco ifnm: arc in addition to normally rcplcccd

I

‘!CrtlS SllCh CCi fur: i pump, in jeCtc;s,

re lays, etc.

6.

Test Valuzs

Aithough test valuzs carp provide J

a$ ihioughcx~t ihe troiil~le shcding chart, wh:.:re app!iccbIs,

udditional information and values are given I1er.e.

Generate: output at maximum

voltage regulator rheoztnt setting

134 V or higher

Generator output at n~inimxn

voltage regulator rheostat setting

108 v or lov”er

Overload relay trips at any value above 112 KYA in 5 minutes.

Overvoltage relay trips at 13O’to 134 V AC, resets at 125 V AC.

Uldervoltcge reiay trips at 93 to 102 V AC, resets at 110 V AC.

Utdervolfcge tire delay circuit functions in 4 to 12 seconds.

Overfreqbency relay trips at 415 to 425 Hz, resets at 410 Hz.

Underfreqency relay trips at’3?5 to 380 Hz, resets at 385 Hz.

Overload relay trips at 125% rated load in 5 minutes.

*

See 2-3, Fig. 15 for typical test values at test receptacle and test box.

7. Check Connections and Leads

ALWAYS mak.z a check ofconnections and leads to a component suspected of being

faulty. With the exception of a few instances,

we will ossumz that connections

and wiring have atwa\/s been checked first and that power has not been lost as a

.

resuit of defective wiring OT connections.

8. E fectric Governor Trouble Shooting

The following fccts concerning the operation of the electric governor may be

helpful in understanding the system and in determining which unit in the system is

faulty in case of troubles.

A. The system requires two sources of power to operate normally.

(1)

12-V DC input power (from engine electrical sytem)

(2) 4-V AC input power (from magnetic pickup)

3-l

Page .3

Au g 25 I85

c

OM 2012

(1) No 12-Y DC POM’W

.

(2) No vofta~~ fr

om co~tro! box to actuator

C. The actuator wilf “surge”

uz&r the foI Io;‘(ing conditions:

(1) “Stability” cr “gain” adjustmzntset too “high“

(2) II-u-cttlc I iu!rage binding

9. Enc:ine Trouble ShoFfing Procedures

A. General

The following engine trouble shooting procedures were taken from Detroit Diesel’s

“Field Service Data Bookli

. Certain abnormal conditic;ls which may interfere with

satisFactory engine operation,

toget~ier with method; of determining the cause of

such conditims, are covered in the Trouble Shooting Chart.

.

The ability of the engine to star: and operate properly depends primarily on two

things: .

(1) The presence of an adequate supply of air, compressed to a sufficiently

high compression pressure.

(2) The injection of the proper amount of fuel at the right time.

Lack of power

, uneven running,

excessive vibration, stalling, and hard starting

may be caued by low compress&,

faulty injection in one or more cylinders,

or lack of sufficient air.

Since proper compression, fue I injection ,

and the proper .amount of air are imporl,ant

to good engine performance, procedures for checking them are given here.

B.

locating a Misfiring Cylinder

(I) Start cnginc’and allow it to run mtil it reaches normal operating temperatures.

3-l

Page 4

” --- -

Aua 25’85

c

OM 2012

If the cy!inc!cr has keen misfiring,

there will b;> no noticeuble difference

in the sound and opcraticn of the engi:>e.

If the cylinder has been firing

propzrfy there will Lx a noticeable difkrence in the sound and oFration

when the plunger is held down.

This is simi!ar to short-ci:cuiting a spark

plug in a gasoline engine.

(5) If cylinder No. 1 is firing properly,

repat the procedure on the of.her

cylinders untii the faulty c*re has been located.

(6) Providing that the injector operating mechunizm of the faulty cylinder is

functioning satisfactorily, remove the fuel in

$ctor and instull a new injector.

C. Checking Compression Pressure

(1) Sfart engine and run until normal oFrating temperature is rea$ied,

(2) With engine stopped, remove fml pipe-s from the injector and fue I calnectcrs

*.

of No. 1 cylinder.

(3) Remove the injector from No.

1 cylinder aqd install the proper adaptor of

the pressure gauge (tool J6692) in its place.

(4) Use one of the two fuel pipes as a jumper connection ktween the fuel in let

and return manifold to prmit fuel to flow directly to the return manifold.

On some cylinder heads it is necessary to fabricate a itimper connection

from a fuel pipe.

(5) Start the engine and run at idle speed.

CAUTION: DO NOT CRANK THE ENGINE WITH CRANKING (STARTING)

MOTOR TO OBTAIN COMPRESSION PRESSURE.

Record compression pressure indicated.

NOTE: A guide to minimum compression pressures to be expected is in-

cluded in Sect. 2-3, Fig. 8.

(6) Remove pressure gage, install injector, and reinstall fuel lines.

Aug 25, ‘85

3-1

Page 5

OM 2012

(7) Rc;:I;aat si-ops (2) tlil-CtXJ!l (6) for each cylin&r.

E.

Causes of tow Cylinder Pressure

Low cylinder presr.uras may result from any one of several

fauSCs:

(1) Pistcxl r ings may b2 :tuck or broken .

To determine the conditial of thz

rings, remove t!m air bsx cover end press a7 the compressi-,:; rings with

a blunt tool.

A broken or stuck ring will net have a spring-like acticn.

(2) Compression pressure may ‘be leaking past i-he cylinder head gasket, valves

and valve seals, injector tube, or through a hole in the piston.

To aorrzct any of these ccnditians, consult your Detroit Diesel Srvice Outle?.

.

F..

Fue I Flow,Test (see Fig. 7)

Cljeck fue I pump and fuel flow as foiiows:

(1) Disconnect the fuel return tuto at, or near, the tank. Hold the open end

over, or in, a convenient container of over 1 -gal Ian capccity .

(2) Start and run the engine at governed speed 2000 RPM. Measure the fuel

flow from the return tube for 1 minute. Flow should be 0.8 galfon (based

or? O-.080 restriction). If fuel flow is be low this amount, it indicates that

the fuel strainer, fuel filter or fue I pump requires servicing or repair.

(3) To chacksuction side of the pump, immerse the end of the return tube in

a ccntainer of fuel.

if air bubbles rise to the surface of the fuel, it indi-

cates that air is being drawn into the fuel sy:tem on the suction side of the

pump. If air is present,

tighten all fuel connections between the fuel tank

and the fuel pump. Check for defective t&s, hoses, etc.

10. Illustrations

Illustrations, Figures 1 through 8, arc referred to throughout the Trouble Shooting

Chart, Figure 9.

3-l

Page 6

4 25435

OM 2012

it

io

I3 IS

16

17 I8 19

ENG!t’!E CCNTROL

PANEL

si

27 26

1. Frequency meter

2. Voltmeter

3. Fastener

4. AC Ammeter

5. h4eter switch

6. Line switch

7. Reset switch

8. Light test switch

9. Fault indicating lights

10. Load contactor circuit fuse (Z-A)

11. Protective system fuse (2-A)

12. Protective relay tray

13. Instrument panel light

14. Generator control tray

15. Fuel gage

16. Light switch

17. DC Ammeter

18. . Engine-gencratcr control switch

19. Hourmeter

20. Load contactcr control switch

21. Coolant temperature gage

22. Load contactcx indicating light

23. Oil pressure gage

24. Cold weather starting aid control

25. Air cleaner indicatcr

26, Engine STOP control

27. Engine circuit fuse (10-A)

28. Engine protective circuit indicating

I ight

29. Engine starter switch

30. Blocking diodes

31. Test receptacle connectar

Operating Controls and Instruments

Figure 1 (Sheet 1 of 2)

3-l

Page 7

OM 2012

34,

I

IJ

GENEl?ATOR CONit< TRAY

PROTECT

IVE KE MY -WAY

32. Manual voltage control rheostat

33. Automatic-manual voltage control switch

34. T&t bank switch

35. Light test switch

36.

Reset switch

37. Automatic voltage control rhecstat

38. Cable length compensation rheatat

39. Cable size compensation rheostat

40. Line-drop compensation on-off switch

41. Fuse (5-A)

* 42.

24 Vob

power

supply

switch

3-1

Operating Controls and Instrutxnts

Figure

1 (Sheet

2

of 2)

Page 8

41

VOLTAGE REGWATCR ,’ ,,

Aug 25185

OM 2012

7

8

1. Starter

2. Starter solenoid switch tc starter terminal

3. Solenoid coil ground terminal

4. Solenoid switch input terminal

5. Starter solenoid switch

6. Solenoid coil term’inai

7. Battery cable

8. Starter ground cable

Starter and Solenoid Switch

Figure 2

Aug 25 185

3-1

Page .9

OM 2012

.

1.

2.

3.

4.

5.

6.

7.

8.

3-l

Page 10

Shut-down solenoid

9. Air shut-off valve shaft

Solenoid terminal (input)

10. Starter cut-out switch

Solenoid terminal (ground)

11. Switch adiusting nuts

Latch arm adjusting nuts

12. Syitch actuating rod

Switch bar attaching nut

13. Switch actuating bar

Latch actuating arm

14. Latch cam

Latch

15. Solenoid plunger rod

Latch reset lever

Engine Shut-down Solenoid and Linkage

Figure 3

Aug 25%

OM 2012

1. Low-oil-pressure switch

2. High temperature switch

3.

“Hot wire “ shut-down relay

4. Oversped governs

5. Fuel pressure switch

6. Air shui--off va ive latch

. 7. Shut-down solenoid

SWI JCH CON TACT POSITIONS

SWITCH

ENGINE

STOPPED

ENGINE

UNDER FAULT

RUNNING

CONDITION

--._.

1

2

3

4

5

Avg 25’85

CLOSED

OPEN CLOSED

OPEN OPEN

. CLOSED

OPEN

CLOSED

OPEN OPEN

CLOSED

OPEN

. CLOSED

OPEN

-.--

Engine Shut-Down and Safety Devices

Figure 4

,

3-1

Page 11

.

OM 2012

1. Manual control voltage potential adiustifig resistor

2. Exciter field baflar:t resistors

Excitation Resistors

Figure 5

.

+ To

exciter

field

To exciter

-

ficl4

3-1

Page 12

End View of Voltage Regulator Amphenol Connector

Figure 6

Aug 25,‘s

OM 2012

---

c

FROM TANK

e

Fuel Flow Scflematic (Typical)

Figure 7

-RESThlCTO3

FUEL PRESSLJRE

P

SWITCH

--

Q

-

.

Au a 75 45

3-1

Puge 13

OM 2012

Test Receptacle Connector Terminafs Identification

Figure 8

3-l

Page I4

Aug 25435

c

OM 2012

a “trip”.

Push reset b

3. 12-v DC p

OMZi- no? reach-

ing stcrter solenoid

:. Batteries cx starter not

propr ly groundad

1. Airshutioff valve unlafc’k

and holding starter cut-owt

switch open (see Fig. 3)

.

Starter cut-out swifch im-

E . Adjust in accordance ‘with Sect.

properly adiusted, or &fec

2-3, Para. 4, F, (I), or repfocc

t ive

switch.

‘. Defective start switch (S24)

OT defective auxiliary

solenoid (l.10)

; .Defective starter solenoid,

or starter

B. Check v~!;age at stcrter solenoid

input termlnol (4, Fig. 2).

Volt

age she=, Id t-x: opproxirx:z Iy

13.5 V. If no v&cgc:, chrtk

i

cables and co::nectio;x bziw:cn

starter soienoX and po~~hzr scorch

Rep&e cr re;~ir ccbi’:‘s and

cot-inectc;s u; q:!ired.

I

2.1

I

C. Check cable and cll co:x~ctici~

D. latch air shut-off vclve by push.

ing latch ien:r (8, Fig. 3) down

If valve will not latch, check fc

tripped overs;ced gov&rnw,

F. Check voltage at terminal (6,

Fig. 2) while operating start

switch (29, Fig. 1). If no volt-

age is indicated, replace

switch (S24) or solenoid switch

(LiG) as required.

I

G. Momzntarily connect a large s izc

starter cable between terminals

2 and 4, Fig. 2. If the: starter

cranks he engine, the solenoid

(5, Fig. 2) is defective. tf the

starter does not crank the eng ine

the starter (1) is defective. In

either co:c , replace stortcr and

solenoid as an assemtaly.

- A_.

xbJ~3 Shooting Chart (Sheet 1 of ill)

Figure 9

J-I

Page 15

OM 2012

2. Er-,+w will not

star:-. Cranking

speed Ibw.

3. Engine wifl not

start.

Gunk ing

speed norma 1.

A. Low battery output

B. Loose starting c ircvit con-

nections or faulty cab Jes

C. Imprcper lubricating oiJ

VisCcG ity

D. Ambient temperature too

low for normai starting

procedures .

4. No fuel

1. Check batPcry. Recharge or

replace.

.

Check cIJ connections and cables

Tighten or rcp!ace as required. ’

i . Clleck oil.

See Sect. 2-1, Fort,

4, JL (3).

1. Use engine starting aid. See

Sect. 1-3, Para. 2,C.

. Before.attempting to find the

cause of “no fuel ‘I, prime the

fuel filters by removing pip2 plug

in the cover of each. Fill each

fiber with fuei oil. If the engine

wiil not start after priming,

mechanical pump trouble is indi-

cated.

If the engine starts ond

then stops after a short time,

trouble between the fue I source

and the suctiot-r side of the pump

is indicated. Check and/or rem-

edy as foJJov,r (see Fig. 7):

Au g 25 105

Trouble Shooting Chart (Sheet 2 of 2 J)

Figure 9

Oil 2012

, Engine is hard to

start. Cranking

speed normal.

Aug 25’85

(i) lnsuf:ici?nt fuel in tan!

(2) Fuz I shut-off valve

closed

(3) Loose co.7nections,

damaged hoses or fur:1

lines titwcn tank utid

fuel pump

(4) Plugged or defective

fuel filter

(5) Faulty installation

(6) Faulty fue I pump

(a)RelIef valve not

seating

(b) Worn pump gears or

damaged pump drive

(7)Defect in injector racks

or linkage

5. Low ambient temperature,

or limited fuel

A. (C on:-had)

(1)~ill tank.

(2)Make certain vclve is Oi?i:i’xi.

(3) Tighten a

Ii fitfir,gs and con-

nectiaqs.

Reploce any

damaged hoses or fuz I links.

(4)Dc not overlook the FOSSibiIiiy

of restricted flow through the

fuel filters. Also check gaskets

for leakiny CT dcrnagcd condi-

tion.

.

(5)Restr icted fitting missing from

ret1Jrr-I I ine .

,

(6) Check pump.

(a)An open relief valve will

cause low output pressure.

(b)Check pump for normal

operation. Replace if dc-

feet ive .

(7)Check position of fw?l shut-off

lever (Sect. 2-3, Fig. 9, item

4). Should lx in full CLOCK-

WISE position. Check all fuel

control linkcge to make certain

injectors are functional.

.

Check causes and remedies under

EN G INE , Trouble 3, above.

wble Shooting Chart (Sheet 3 of 21)

Figure 9

3-1

Page 17

OM 2012

Et.! G I.! E At\; D c:>tq I-T

---- _-.___--

---

4. Engine is ho:.d to

sturt. Crank iny

speeti normal.

(Continued)

J.

Engine starts. Stops

after a few seconds

by automatic shut-

down. *

3-l

Page 18

LS (CONTiiJ ED)

--

B. LOW co&presioo;> wI1Ic11

may lz ccruxd by any ow

of the fol I owirig :

(1) Sticking or burned

exhaust valves

(2) Compression rings

worn or broken

(3) Cylinder heud gasket

leaking

(4) Improper vaive

clearance adjustment

(5) Blower not function-

ing

A. The shut-down circuit

may’have functioned

normally to stop the

engine because of law

lubricating oil pressure.

B. Defective low oil pres-

sure switch (1, Fig. 4)

ruble Shooting Chart (Sheet 4 of

Figure 9

.

B. Check co:nprc::ion in accordc~;.,cc

wil I-I Partr . 9, C and D .

(1 ) Cylinder head mu:: TV re-

moved and’ overhauled to

correct this condition.

(2

(3

Check rings in accordance

with Para. 9, E, (I).

Check gasket in ccccrdance

with Para. 9, E, (2).

(4) Check andadjuzt valve

clearance in accorduzce

with instructims in Detroit

DiFsel Operator’s Manuti!.

(5) Inspect blower drive shaft

and drive coupling. ,Replgc

parts as required.

A. Reset shut-down valve latch

(7, Fig. 3). Start the engine

and observe oil pressure gage .

If pressure is less than 12 PSI,

stop engine at once and check

for cause of low pressure.

Repair as required.

B. Reset shut-down valve latch

(7, Fig. 3). Disconnect

ORANGE wire at low oil pres-

sure switch. Start engine. Ob-

serve oil pressure.

If pressure

is 38 PSI, or more, check voltage

at oil pressure switch terminal

from which ORAN GE wire was

removed.

If approximately 12-V

DC is indicated, the oil pressure

21)

Aug 25’85

.

I

5. Engine runs at

id!e speed.

E ng ine “ON ”

indicating 1 ight

(28, Fig. 1)

does not gfow.

7. Engine will not

con-e ‘IJp” to

governed speed

in GEN mode.

Aug 25,‘s

D. Defective shutdown relay

D. Check relay (3, Fig. 4). Replace

(3, Figa 4

if defective.

A. Lamp defective

B. Indicating light body

poor iy grounded

C . Defective fue I pressure

switch (5, Fig.41

A. 12-V DC power not reach-

ing governor control box

fee following reasons:

(1)Engine circuit fcbe (27,

Fig. 1) is blown

c . Check

wi;in(; to higil fer::pefsi-u:T

switcll.

Two ye I low-b 12.2 wirei

should be coni:ec!ed to N .O.

terminal. Yellow wire should be

con;;i:cicd to C terminal. Check

resistance between termit.la15 N.

0.

and C. with wires removed.

In fin i!e res L tcince Ind icctcs a

900d (erpCOtUiC? :witch. A

readabic resistance indTcatcs a

defective s:;litch. Replace switch

A. Replace lamp.

.

B. Be sure light b grounded

propSly.

C . Check switch. Replace if defec-

tive.

A. Apply 12-V DC directly to

terminal E

on governor con-

trol box. If engine comes-up to

speed, check following:

(1)Replace fuse (10 up).

Trouble Shooting Chart (Sheet 5 of 21)

Figure 9

3-l

Page 19

.

B. Governs linkage binding

cK gcwcrncr thrott!e

sticking

3. Defective c-Y m&-adjusted

magnetic pit kup

3 7

Trouble Shooting Chart (Sheet 6 o

‘f 21)

B.

Check go-terasr I inlqe end

throttle shaft icr bindlog and

.

sticking. I<epoiir as req:;!r,: c! .

C.

The control unit my not bo rc

ceiving a signa! from ilie n-ng-

netic pickup and the “fail-

safe” feature of tile unit rfxy

be functioning to prevent cny

s ignal from reach Ing the

actuatcr . To check the nag-

netic pickup, disconnect pick-

up from control unit and

connect a high impedcnce AC

voltmeter to the pickup output

leads. Crank engine but don’t

start. Voltage reading should

be ci minimum of one (1) volt.

If no or low voltage is indicate

check pickup adjustment

Isee 2-3, Para. 4, E , @)I.

(3) chccl< switCl?. ccplocc

if defect&e.

-.-_-__

--

---I .-

3-1

Page 20

Figure 9

Aug 25 ‘85

OM 2012

--N-.-e -.--I--

7.

(Contlcc?*l)

. Engine goes to

ovenpeed when

control switch

(18, Fig. i) is in

GEN position.

Aug 25,‘85 ;

D. Defective actuator

D. Apply !2-V DC to iI.s two

I. Defective control unit

k. Governed speed control

adjrr;tment set too high

(see 2-3; Fig. 12)

wbk Shooting Chart (Sheet 7 of 21)

Figure 9

F

-.

A?

Connect a DC voltmstcr to the

leads from the control unit to

the actuator. Start thz engine

and mnually control spzed.

At speech be low govztncd speec

the voltmzter shoJ!d indicate

within two (2) vofk of the sys-

tern voltcge.

if VO!tGp. is at

‘or near zero, turn spzzed cfd-

justing screw several turns

clockwise to be sure speed

setting is not too low beccuse

of tampering. If voltage rc-

mains low Oi at 2x3-0, replocc

control unit. Refer to Arrxxi-

can Bcsch Handbook for con-

trol unit bench tests and ad-

justmnts.

Turn speed control adjusting

screw 22 turns counterclockwise

Start engine. Place control

switch (18, Fig. 1) in GEN

position. If engine srxed is

now we II be low govemed

speed, turn adjusting screw

clockwise until coxcct speed

(2000 RPM, 400 Hz) is

3-1 .

Page 21

OM 2012

9. Engine !s cnsffeadI

(ssw) u&r

B. Defcctitrz linko,gc

or actuator

c. Cefectivo control M-Ii:

A, Fcuit in engine

B. Governor sj5fern faulty

OT mis-adjL%ted

(1) Locee or binding

.governor linkage

(2) GAIN and STAB ILITY

controls improperly

adjusted

(3) Magnetic pickup

signal weak

B.

Cheek govzmc~ I i:~f:c;~z and

actuator for sFp:k-

ing or binding in fuil~peerl

position. Repsir Q; required.

C. Rep1ace control unit. Check

unit in accordatxe with

American Bach I-andbook.

A. Bcfcre condemning the governrz

S )S te m fOi Sury ifq, make Ct?riU in

the fault is no: in tk.a engine.

Make certain all cylinders are

firing prdpzrfy,

B. Chock and adjust as folIcv,o :’ ,

(?)Check linkage boll join6 and

all corxectiom for loajeness

or binding.

Be sure linkage

will move from idle speed to

full sped without loct motion

or’ b.ind ing .

(2)Aditst GAIN and STABILITY

controh on control unit in

accordance with 2-3; Para.

4, E, (3).

(3) Check and adjust pickup. See

2-3, Para. 4, E , (2).

3-l

Page 22

Trouble Shooting Chart (Sheet 8 of 21)

Figure 9

Aug 2545

c

OM 2012

2, Engin!: lacks

power

-.

--

4. Gov;;tl.i7x control unit

irnprcp~r ly adju;tzd

3. Actuatcr 1inkagr: bi;Tdi\lg

1. Engine needs tutln-up

4. Insufficient fuel

. Faulty injector

: . Low compress ion pressure

,. lmpropzr engine adjust-

4. “Tune-up” the engine in

ments and gear train

accordance with Detroit Diesel

t im ing

Operator’s Manual.

.

Insufficient fuel

.

A.Adjv;t. 5.x 2-3; Parom 4, E,

(3).

C. Tune-up a: required.

Ik fe L’

De trait D itxe I Opero/.or ‘s

MmJaI. )

A. Check fuz t F!CW ii> acccrdansc

with Para. 9, F. Repair CT

replace parts US required. Also

see ENGINE, Trouble 3.

B. Check injectors in accordance

with Para. 9, B.

C . Cliec k compress ion in acccrdanct

with Para. 9, C . See causes

of low compress ion I k.kd under

ENGlNE, Trouble 4, 6, ’

ab eve .

d. See ENGINE, Trouble 3.

_ -_.

Trouble Shooting Chart (Sheet 9 of 2 I)

Figure 9

Aug 25,‘s

3-l

Page 23

OM 2012

-

(WJ

amag:~c! air c 12anet

.

(2) Defective blowcr-to-

cylin&r block gasket

(3) Pluga2d cylinder finer

ports

;EbiERATQR AND EXCITATION CIRCUH-

---

I

.

No (or low) yen.

erotor output

voltage in a/l

phases. ‘Gen-

erator operating

at400Hz in *

A UTOM~TIC

mode.

A. Defecti= generator or

excitation circuit.

B. Defective generator

1

I’ouo e . ootmg Chart (S

!V?C

1

Figure 9

c. Clvxl~:. OS ro!iov/::

(2)fkpi~~ the gasket if necessar

If the blower is removed,

instcll a new gasket.

(3)CIean ports if they are 0vc.r

50% oh::-ructcd.

A. The first check is an easy one

wh[ch will ci!ow the me&an ic

to reach some definite conclusinl

about where the trouble is. Piacc

the A UT@-MAN switch

(33, Fig

1) in MANUAL position. If a

normal volfage (for the rheostat

setting) is now produced, the

generator is good, and the troubl

is in the voitage regulator circuit

Proceed to step C. if switching

to MANUAL control did not affec

generator output, the trouble is

likely in the generator, but to

prove the generator is defective,

proceed to step B.

B. Use the test receptacie (31, Fig. I

to connect 12-V DC to the ex-

citer field. Using leads wit11

alligator clips and test prods,

connect 12-V DC NEGATIX

lead to terminal “D”.

Terminal

identifyirig letters are plainly

visible cn the face of the test.

receptacle,. Connect POSITIVE

,‘Aug 25435

OM 2012

i . 3!0 (LX low) ~~txxc;

tor oulpyi- \~Ol!q$!

in Of I F!lnX?::. Gcfi

erator oil”rCIting ai

400 Hz in AU’fG-

MATIC moc:c.

(Continucc.)

i

.

,. :

. .

Aug 25435

1. Defect in VOLTAGE RE G.

excitation circuit.

(1)Defective AUTO-

MANUAL switch (33,

Fig. 1)

(2) Defective excitation-

deenergizaticn relay

- (Kl6) (l-1; 3, Fig. 9)

(3) Defective ballast re-

sistor(s),(See Fig. 5)

D)

--_-

w--w-

.

R. (CcnfinU:rc!)

!CC~ fo tcrmina 1 “F”.

1; no cut.

put Voitag? Chr;r;gC is indicated

when the e::citer fie!d is crier-

gizcd,

the gei7efatW is defec-

tivc. Stop cperations and sea

2-3, Para. 5 for :&her generoff

testing. If the generator pro-

duces approximately 14%v AC

when the exciter field is e:ler-

gized , the troub!e is in the

voltage rcgulat or -exe itaticn

circuit. Proceed to step C.

C. Check as follows:

.

(1)Check the switch thorough-lly.

A defective switch, may pre-

vent current reaching ahd/or

leaving the voltage regulator,

Replace switch if defective.

(2) Check EDR

contacts.

A faulty EDR can

prevent power from reaching

the voltage regulator. Re-

place relay if defective.

(3) If output voltage was pro-

duced when the generator set

was operated in MAN&L

mode, the resistors are good.

If no voltage was produced

in MANUAL mode, resistors

could be defective. Refer to

Fig. 5 ond connect a jumper

lead across the looI last rc-

sistors. If an output voltage

Trouble Shooting Chart (Sheet 11 of 21)

Figure 9 ,.

3-l

Page 25

OM 2012

1 . No (or low) g2l-l.

erafor culf,uf WI

apz in 0 l I phc~s

Gonerot-or O+I CJ

ing at 400 Hz in

AUTOh~L4TIC

’ (Cont’dj

moae .

1. No (or low)

odpt voltage

when operating

in MANUAL

mode.

(4) Defective Ampheno!

conf~ecto~ ai volticgz

regulctor , or defect&

wirincj from rcgulatc:. to

exci:l-r field.

ive voltage reg- (5)Defect

uttitcr

. Defective generator manual

control excitaticxl circuit.

--___

---

.

(3j (c:

GI-l?i~lUd)

(4.j 0 ISC 0nilec t

VO!~G~Z i-03~ la: <:;

Amphenol co:-~t?cc:~cr

(see 1-l; 14, Fig. ‘12). U:hg

jumper leads v,,Ith cfip and pi od

terminal;,

ca.mect 12-V DC to

terminu!s “El’ and “C” in loois

plug. Connect NEGAT WE to

terminal ‘E I’.

COlliXX~ PCS IT 1’~

load to “C” terminal (see Fig.

6). If the generator will NOT

produce a normcl voltage, re-

place or repair Atr,pheno! COriilcI‘C-

tor and wiring betv,een voltage

regulator and exciter field as

required.

l

(5)AII components in the excitation

circuit except the voltage reg-

ulator have been tested in steps

(1) through (4) cbove. This

leaves only the regulator as a

cause of trouble. Replace com-

plete voltage regu!ator .

4. Place AUTO-MANUAL control

switch (33, Fig. I) in AUTO

position. If 0 normal voltage is

NOT produced, perform checks

as instructed in GENERATOR AND

EXCITATION CIRCUIT TROUBLE

1,

above. If a normal voltage is

produced, proceed to step “B”

below.

3-l

Page 26

Trouble Shooting Chart (Sheet 12 of 21)

Figure 9

Aug 25@5

OM 2012

(1) Defective AUTO-

(1)Chcck contacts and opcrc-

MANUAL switch (33,

tion of AUTO-Mki~I UAL

Fig. 1) switch. Replace i; defeci ive

(2) Clefective rectifier

(CR3j (Sect. l-l;

14, Fig. 9)

(3) Defective resisto:

(Rll) (See 1, Fig. 5)

(4) Defectike rheostat

Wl) (32, Fig. I)

\dO. 1 LOAD CONTACTOR OPERATING CIRCUiT

.

Load contcctor (K 1)

will not close when

control switch (20,

Fig. I) is he Id in

ON position .

Generator running

at normal voltage .

No fault lights on.

Avg 25%

4. In addition to defective

wiring and connections

in the AC and DC load

contactor actuating cir-.

cvits, the lioad contactor

may be prevented from

closing for any one of the

following reasons:

(J

)Blown fuse (Fl) (l-

16, Fig. 10)

1;

(2)Check diodes (see 2-3, Para,

6). Repiace rectifier if

defective.

(3)Jvmper resistor (1, Fig. 5).

If normal voltage (depending

on rheostat setting) is pro-

duced, replace resistor.

(43Connect a jvmper across

rheostat. If maximum (manuc

control) voltage is produced,

replace rheostat.

.

Trouble Shooting, Chart (Sheet 13 of 21)

Figure 9

A. Afier checking fuse (Fl) in

step (1) below, check ail wiring

and connections in the load con-

tactor circuits on the engine

control pane I, protective reiay

tray, and power module. Then

check components as foilows:

(1)Remove and inspect fuse.

Replace if blown.

3-1

Page 27

TROUBLE SYMPTOM

AND CONDITION

PROBABLE CAUSE

TEST, CECK, AND/OR REMEDY

NO. 1 LOAD CONTACTOR OPERATING CIRCUIT (CONTINUED)

1. Load contactar

(2) Defective (open) relay

(K?) will not

(2) Use a junper with clip and

in protect.ive module

prod ten inals to GRCIJ ND

close when con-

(l-l; 4, Fig. 10)

terminal “H” in the test

trol switch (20,

receptacle. If contactar will

Fig. 1) is held in

naw close, replace module or

ON position.

complete protective relay tray

Generabr running

(12, Fig. 1).

at normal volt&e.

Na fault lights (3) Defective load con-

(3) Set AUTO/MANUAL switch

on. (Continued)

tactor control switch

(S?) to AUTO position.

(95) (20, Fig. 1)

Connect a jumper with test

prods Between terminals “S”

and “R” on the test receptacle,

If the contactor closes, replace

contra I sw itch.

(4) Defective rectifier

(4) With test receptacle terminals

((36) (l-l; 5, Fig. 13)

‘5” and “R” connected as

above, check voltage at load

contactor coil terminal X2.

If voltage is not approximately

90-V DC, replace rectifier.

(5) Defective lo& con-

(5) Disconnect leads at load con-

tactor coil (Kl)

tactor terminals Xl and X2.

(l-l; 6, Fig. 13)

Check coil resistance between

these terminals. Resistance

shoukl be approximately 600

ohms. If coil is defective,

replace the complete load

contactor.

Trouble Shooting Chart (Sheet 14 of 21)

Figure 9

3-l

Page 28

AUg 25185

c

OM 2012

-I--

.-- -----

---.---A

A. 2E.5-\I DC is not v:OS!iinl

plug-ir,kr!eck rc!cry (K2)

froln oircmft Tar the

following rccsons:

(1) Generator to aircraft

cable ccnnectc: deiec-

tive or not plugged into

a ircruft receptacie

co:xiector

(2) A ircrafi re jetting

power

B. “Blown” fuse (F2) (l-l; 17,

Fig. 10) in protective relay

hay

C,. Defective plug-interlock

relay (K2).

1. Small contacts in load

contactor (KJ) defective

.

Defective fuse -in tcr lock

relay (KJ7)or resistor

W)

Aug 25’85 I

(1) Inspcf cabie conncctcr

plug i.h~roughly for dzmx:gc

E and F terniinalr.

Be sure

the plug is fully rn::;~d wi;!

the o ircraft recc ptcx !c

ccnnector and making

good contact.

(2) Check aircraft onboard

electrIcal equipn?ent and

control:.

.

13. Press the lens housing of fault

indicating lights. If ,lamps do

not glow, repluce fue (F2).

C. Pface test-bcnk. switch $2) (34,

Fig. J) in ON position. If loac

cantactor will nowremain closet

replace the plug-interlock relay

(K2) (Sect. J-1; 1, Fig. 10)

or the complete protective

re lay tray.

D. Connect a jumper lead between

small terminals no. J and no. 2

an the load contactor. If load

contactor will now remain

closed, replace the complete

load contactor (KJ).

E. Open protective relay tray and

connect a jumper across the re-

sistor 846) (Sect. l-l; 2J I

Fig. IO). If the contactor will

-

Trouble Shooting Chart (Sheet 15 of 21)

Figure 9

3-J

-a.

.-.

I

Page 29,

OM 2012

3. Load c.zitacior

opens durin_n

power iie I ivcry.

NO fault indi-

cating Iighis on.

3-1

Page 30

,.-- ---

-._

E . (Conrinxc:)

A. Fuse (if= or 2F) blown.

6. A fau It has de~eiopad in

the load c cntac tcr ho id-

ing circuit.

C. Cable accidentally

disconnected from air-

craft

4. Remcve and ir,spct fcxs (l-1; 16

and 77, F;g.

10). Koplace as

required.

B. if the Load contcctcr cannot be

clcxd by operation of the contrt!

switch (S5) (20, Fig. I),.check

the circu?t in cccordance with in-

structioii:

in Trouble 1, above’ S

under LOAD CONTACTCiZ

OPERATtNG CIRCUIT. If the

load contcctar can be cIox+d, but

opens as soon as control switch

(S5) is released, check for trouble

under Trouble 2, above.

Z. Reconnect cub!e .

Figure 9

Aug 25 &i

I

/

OM 2012

To avoid repetition,

it wi:! he a<sunxd that th.:: reset svritcl~t(M), Fig. ?? \,t>s beer-1

pushcd and the load contactor has been closed brfoce commzncir-q each tc-c!:t.

1. Load confactrv

opxs dur i:>g

power de livery.

Overvoli-a3c in-

dicoting light ON

.

!. Load contactcr

opens dur ing

power de livery.

Undervoltage in-

dicating light ON

A. The overvoltage condition

may have been the resu!t

of a sudden drcp in the

load, OT po,silie tampr-

ing with voltage regulate

rheastat (37, Fig. l),

and may have been a

norma I action.

B. Defective over-undervolt-

age scns ing module (K26)

A.An undervottagc condition

caused the over-undervolt-

age sensing moduk (K26)

to function ncxmally.

\ * Press reset switch (3C>, Fig. 1) and

resuri- pcv,c: de I ivory . Obxrvc

voltmeter (2, Fig. 1) to be cer-

tain volta& is normal 1’15 V AC.

Adjust to nocrxrl if necessary. If

the load co;;tuctor is opened aguin

and an overvoltage- co:;dition is

indicated by light (DS37), proceed

to step B ,

1. Use yoltagz adjusting rhecstat (37,

Fig. 1) 10 reduce voltage to 110 V

AC. Okerve voltrxter and grod-

ually increase voltage +ith rhec-

stat. if thz over-unc’xvoltcge scns~

ing moduk (K26) funct icns to opn

the load contactor at cny value

less than 134 V AC, it is defective ,

Replace over-undervoito~e module

tx complete protective re luy troy.

i. Observe generator voltage on volt-

rnzter and adjust to nOiiT?Cll 115 V

AC with voltage reguluto: rheaztat

(37, Fig. 1). Resurnz normaI cpero.

tion. If the load coniuctw opens

again and on undervoltage condi-

tion is indicated by light (DS38),

ptxeed to step B.

Aug 25185 :

Trouble Shooting Chart (Sheet li

Figure 9

3-l

Page 31

.

Loud cr,nklctcf

open: c&x ing pcW!r

de I ivory. Over-

frequsncy indicating

light (DS40) CN

T

1. Defective protective

monitor module (KI4)

. E lectric governor improper I;

adiL5ted, oh nutfunctioning

(1) Gavernor improperly

adi usted

(2) E lectr’ic governor

system malfunctioning

Defective over-under-

’ frequency sensing module

(K27)

---

~.- -me--

13. UX J:ccztat (37, F& 1) tr> re-

duz vrol:ugz to IOr, V. I’!:e

unc!zrvoI!~qc indicutlng I ir;!,t

sh XI Id N 01’ come on during

a I-imr! de lay of 4. to 12 secc.nd< .

If the light comes on before a

delay of 4 to 12 seccnds, thy’

underltoltage relay is defect;l:e.

Replclce the module (K26) cz- the

protective relay tray.

C. With unit running nH:imIty, use

rheostat (37, Fig. 1) to reduce

voltage quickly to 90 V. If the

undervoltage indicating 1 i&t

(DS38) is turned ON immediateI>

the protective monifor circuitry

is defective. Replace the pro-

tective mpnitor (Kl4) or rep!cce

the potective relay trajr.

A. Proceed as foIlows:

’ (1) Adjust in accordance with

Sect. 2-3, Para. 4, E, (3).

(2)Check and adjust or repair

in act ordance with E NG IblE

AND CONTKOLS, Tro&!es

8 and 9.

3. If overfrequency nuisance trippi%

continues after the governor

system is proven to be good, and

an overfrequency condition does

not exist, replac,.

0 the over-under

frequency module (K27), or com-

plete protective relay tray.

-_.

Trouble Shooting Chart (She&t 18 of 21)

-

3-1

Page 32

Figure 9

Aug 25%

.

OM 2012 :.

I.

light (DS3Y) ON

j. Load contactor

O~RS durii>g

power delivery.

Overlmd indi-

cating Ii&t ON,

A. E fzc:i.iG gavcrllor impra;->-

er ly *di!,st?d, or ma I-

fun& ion ing

.

(1) Governor improper Iy

adjusted

(2) E lectrtc governor

system rna!functioning

6. Defective over-undzr-

frequency sensing module

627)

A. Thkre may have been an

over load condition which

caused .the over load

device (K4) to functicn

normally.

B. One of the res ktcrs (1X26,

R27, OF R28) acrrxs over-

load transformers is open

circuited.

/

C. Over load device printed

circuit board defective

Trouble Shooting Chart (Sheet 1’

Figure 9

--

-

(1) Adjls;st In accc;:d,rncc with

Sect. 2-3, Fora. 4., E, (3).

(2) Check and odjusf o: repsir

in accordance with E N G !i\? E

AND COl\rTGO1S, Troubles

8 and 9.

3. If underfrequency nuisance tr ippins

continues after the governar system

is proven to be good, and an under

frequency condition does not exist,

replace over-uaderfrcqrrency relay,

or complete protective relay tray.

.

4. Observe ammeter (4, Fig. 1).

Check fcr abncrmai overload con-

dition and correct. If overlbad

device functions to open the load

contactor when an overtaad dces

not exist, proceed to step 8.

I. An open resistor wiii case a

higher than normal voltage. Check

resistors (Sect. l-l; 1, Fig. 13).

Replace if dafective.

1. Check voltcge at terminal E, Fig.

8. If 12-V DC, replace over load

device (K4) (Sect. l-l; 7, Fig. 1;3

3f 21)

3-1

Page 33

OM 2012

!. Generator operates

5 ing le ,phase

.

Unbalanced output

3-l

Page 34

.----

A . Sii rX?;:d <.I Fo::c in c ):c itcr

rcctificr (CR2)

B. 0~217 o- shoe-ted exe iter

rota;’ winding (G2)

C. Open a- shorted e>:cIter

fiaid wi:,>dings (L.2)

D. Open cr shorted generator

rotor windings (Li)

4. An open M shcrt circuited

winding in generctar

stator (Gl)

4. Loose connect ion causing

h igh res is tance

3. Improper cr bloc&d

ventilation

:. Generator stator windings

short circuited

4. Loose connection in output

circuit

1. Open or short circuited

stator phase

rouble Shooting Chart (Sheet ;

Figure 9

B. Use ollmr-rla!er to chick far cpen

or shori.eb condition. If cxc iteer

rotor winding: are goad, ~a-

cccd to sicp C.

C . Chock fie Id rcs istcncc . See

Sect. 2-3, Fig. 14 f~ nHmal

va tues .

D . Check res;:tanse with ohmmater

to determine if open or short

c ircu ited.

A. Cheek stator winding r-es istances,

See Sect: 2-3, Fig. 14 for nor-

mal values.

A.Check ail output connections

for loaeness. Look far dis-

coloration caused by heat.

Tighten CT replace as required.

B . Check for fore ign mater ia Is (rags

etc.) blacking air flow. Pro-

vide.adequata ventilation.

C. Check stator windings. See

Sect. 2-3, Fig. 14.

A.Check all output connections.

Discolored connectors indicate

a locse connection. Tighten

ar replace as required.

B. Check stbtcc windings in acccrd-

ante with Sect. 2-3, Para. 5.

Repair or replace as required.

ofl)

Aug 25&i

OH 2012

.

output c ircuii

0. ha!: c? Cut in cxui

cable osscmb!i/

E. Uxbaianced load E . Check oircraf t 4CO-#z

c 0mponen.b .

24 Volt DC Power Supply (53596 9 Only)

I. Loss of 24 Volt D(

signal at output

tetminai pane1 -

temrinal E.

-

Trouble Slloot ing Chart (Sheet 21

A’Jg 25 185

A. Open fuse Fl8

A. Check fuse (l-l; 6, Fig. 16). Re-.

plade if open.

8. Defective coniponent:

8. Check power supply (l-l; Fig. 16).

T15, CR7, C20, R49 or S69

Repair or replace, as required.

,

3-l

Page 35

Figure 9

c

OM 2012

CHAF’TFR 4. ILLUSTtXATED PARTS LIST

SECTfON 1. WTRODUCTiOfu

1.

I

2.

3.

Arrange me nt

4.

I

General

.

The Illustrated Parts List identifies,

describes, and illustrates main assemblies, sub-

assemblies, and detail parts of the Diesei Engine-Generator Set manufactured by

Hobart Brothers Company, Power Systems Division, Troy, Ohio, and identified

as Speclficatian 53590-1, -2, ‘3, and -9 l

Purpose

The purpose of this list is to provide parts identification and descriptive information to

mainirnance and provisioning personnel for use in provisioning, requisitioning, pur-

chasing, stcriing,

and issuing of spare parts.

Chapter 4 is arranged as folIo&s:

Section 1 - Introduction

Section 2 - Manufacturer ‘s Codes

Section 3 - Parts List

.

*

Explanation of Parts List

A. Contents

The parts list contains a breakdown of the equipment into assemblies, subassemblies,

and detail parts. A11 parts of the equipment are fisted except:

(I) Standard hardware items (attaching parts) such as nuts, screws, washers, etc.,

which are available commercially.

(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are al.so

commercially available.

(3)

Permanently attached parts which lose their identity by being welded, soldered,

riveted, etc.,

to other parts, weldments, or assemblies.

6. Parts List Form

This form is divided into five columns. Beginning at the left side of the form and

proceeding to the right, columns are identified as follows:

.

._ ,. . ^

Aug ~‘85

4-l

(7) “FIGURE-l7EM NO .” +mn

This column lists the figure number of the illustration applicable to a particular

: ’ parts fist and also identifies each part in the list by an item number. These item

numbers also appear on the illustration.

Each item number on an illustration is

connected ta the part to which it pertains by a ieader tine. Thus the figure and

item nunbering system ties the parts lists to the illustrations and vice versu. The

figure and index numbers a@ also used in the numerical index to assist the user

in finding the illustrationof a part when the part number is krpwn.

. (2) “HOBART PART’NUMBER” Column

ALi part nunben appearing in this column are Hobart numbers.

In all instances

where the part is a purchased item, the vendor’s identifying five-digit code and

his part number will appear in the “NOMENCLATURE” column. Vendor parts

which are modified by Hobart will be identified as such in the “NOMENClATURE”

cqlumn, In case Hobart 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 will tiflect na vendor code or part number in the “NOMEN-

. UATURE “ column.

.

(3) ,“NOMENCLATUk” Cotmn

.

The item identifying ncrne appears in this column. ‘The indenture &thod is used

to indicate item relationship.

Thus, components of an assembly are listed directly

below the assembly and indented one space . -Vendor cades,and part numbers. for

purchased parts are shown in -this column. -. Hobart modification to vendor items

is also noted in this’column.

‘(4) “EFF” (Effective) Column

.

This column is used to indicate the applicability of parts to different models of

equipment. When more than one modei of equipment is covered by a parts

list, there ate same parts which are used on only one model.

This column is

used br insertion of a code letter “A”, “B”, etc. , to indicate these pcrts and

to identify the particular model they are used on.

Parts in this manual are

coded as follows:

.

Uncoded ports are usable an all made k.

Parts coded “A” are usable on Specs 5359Q-1 only.

Parts coded “8” are usable on Specs 53594-Z only.

.

Parts coded “C” are usable an Specs 53590-3 only.

Parts coded “D” are usable on Specs 5359Q- 9’ only.

4-l

Page 2

Aug 254~

_____-

OM 2012

.*: :

, t

..?

i : *.__ ..

(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 des not necessarily re-

flect the total aed in the complete end item.

Aug 24185

,

4-1

Page 3

OM 2012

SECT ION 2. MANUFACTURER’S CODES

1. Explanation of Manufacturer’s (Vendor) Code List

The following list is a compilation of vendor codes with rimes and addresses for suppliers

of purchased parts listed in this publication.

The codes are in accordance with the Federal

Supply Codes for Manufacturer’s Cataloging Handbook H4-1, and are arranged in numerical

order. Vendor codes are inserted in the nomenclature column of the parts list directly

following the item name and description.

In case a manufacturer does not have a code,

the full riune of the manufacturer will be listed in the nomenclature colunn.

CODE

VENDOR’S NAME AND ADDRESS

00779

I

01428

AMP inc.

P.O.Box3608

Harrisburg, Pennsylvania 17105

Superior Linkage Division

2110 Summit Street

New Haven, Indiana 46774

01843 ,

American Bosch Marketing

Div. of Ambac industries inc.

3664 Main Street

Springfield, Mass. 01107

02231.

Anchor Rubber Gmpany

840 S. Patterson Blvd.

Dayton, Ohio 45402

02660

Pmphenoi Corporation

2801 S. 25th Avenue

Broadview, Illinois 60153

I

03924

STRATOFLEX, INC.

Box 9190, Waynedale Sta.

Ft. Wayne, Indiana 46809

04009

Arrow-Hart and Hegeman Electric Company

103 Hawthorne Street

Hartford, Connecticut 06106

4-2

Page 1

c

CO DE

VENDOR’S NM AND ADDRESS

04713

85277

15605

16476

.

16764

I

19220

20038

21335

OM 2012

Motorola, inc.

Semiconductor Products Division

5005 E . McDowell Rd.

Phoenix, Arizona 85008

Westinghouse Electric Corp.

Semi & Conductor Dept.

Armbunt Rd.

Youngwood, Pennsylvania 15697

Smith Valve Corporation

125 Fisher Street

Westbom, Massachusetts 01581

Cutler-Hcamer

4201 N. 27th Street

Milwaukee, Wisconsin 53216

Dotcon instrument company

P. 0. Box 128

Et Petersburg, Pennsylvania 17520

Delco & Remy

Div. of General Motors 6rp.

2401 Colunbus Avenue

Anderson, Indiana 46011

Eberhard Manufacturing Company

21944 Drake Road

Stmngsville, Ohio 44136

ES6 inc. Philadelphia Pa. 2

Penn Center Plaza

P. 0. Box 8109

Philadelphia, Pennsylvania 19101

Fafnir Bearing Compcmy

Div. of Textron

37 Booth Street

New Britain, Connecticut 06050

,

4-2

Page 2

Aug 25.185

OM 2012

CODE

VENDOR’S NAME AND ADDRESS

21678

Uniroyal inc.

24617

26992

27192

30327

31356

35738

41197

44655

49234

Consumer industrial and Plastic Products

Misland Duraleather Gmpany

Philadelphia, Pennsylvania

General Motors Corp.

3044 Grand Blvd.

W. Detroit, Michigan 48202

Huniiton Watch Company

941 Wheatland Avenue

Lancaster, Pennsylvania 17604

Cutler-Hammer Inc.

Power Distribution & Control Division

4265 N. 3Otb Street

Milwaukee, Wisconsin 53216

I-T-E imperial Corp.

6300 W. Howard Street

Chicago, Illinois 60648

J-B-T instruments, Inc .’

261 Putnan Avenue

New Haven, Connecticut 06517

Charles lmtz & Sons

3330 N. Brocd

Phiiadeiphia, Pennsylvania 19140

Modine Manufacturing Company

1500 Dekoven Avenue

Racine, Wisconsin 53401

Ohmite Manufacturing Company

3601 W. Howard Street

Skokie, Illinois 60076

Protectoseal Company

225 W. Foster Avenue

Bensenville, Illinois 60106

.

Aug 25185

4-2

Page 3

OM 2012

CODE

50508

50603

51106

5 7589

57448

57733

.

60741

66295

70040

VENDOR’S NAME AND ADDRESS

Magnetic Components Inc.

9520 Ainslie Street

Schiller Park, Illinois 60176

H. B.ElectricaI Mfg. Co., inc.

1125 National Pky .

Mansfield, Ohio 44901

Standard Power Inc.

1400 S. .Village Way

Santa Ana, California 92705

St-Sem icon inc.

415 N . Gilege Avenue

Bloomington, Indiana 47401

Stephens & Munson Mfg. Company

275 Ridgeway Avenue

Aurom, Illinois 60507

-

Stewart-Warner Corporation

1826 Diversey Parkway

Chicago, Illinois 60614

The Thomas 8, Betts Company

920 Route 202

Raritan, New Jersey 08869

Tripiett Electrical instrument Company

Harmon Road

Bluffton, Ohio 45817

Microdot Manufacturing Inc.

1421 Barnsdale Rd.

Lo Grange Park, Illinois 60525

AC Spark Plug

Givision of General Motors Corporation

1300 N. Doti. Highway

Flint, Michigan 48556

70485

4-2

Page 4

Atlantic India Rubber Works Inc.

571 W. Polk Street

Chicago, Illinois

60607

Aug 25 &j

c

OM 2012

‘.

CODE

71400

71744

72582

73559

I

74063

74400

I

75358

75418

b

76599

77342

Aug25&

VENDOR’S NAME AND ADDRESS

Bussmann Mfg. Division

of McGraw & Edison Company

502 Earth City Plaza

P.O.Box14460

St. Louis, Missouri 63178

Chicago Miniature Lamp Works

4433 Ravenswood Avenue

Chicago, Hlinois 60640

Detroit Diesel Engine Division of

General Motors Corpomtion

13400 W. Outer Drive

Detroit, Michigan 48239

Carling E lectric, Inc.

505 New Park Avenue

Hartford, Connecticut 06110

.Hartman Electrical Manufacturing Company

175 N. Diamond St.

Mansfield, Ohio 44902

John W. Hobbs Corporation

Ash Street & Yale Boulevard

Springfield, Illinois 62705

Knape & Vogt Mfg. Company

2700 Oak Industrial Drive

Grand Rapids, Michigan 49505

Kysor Industrial Corporation

One Madison Avenue

Cadillac, Michigan 49601

Murray Corporation

Greater Baltimore industrial Park

Schilling Circle

Cockeysville, Maryland 21030

AMF inc.

Potter & Brutnfield Division

200 Richland Creek Dr.

Princeton, Indiana 47670

4-2

Page 5

c

OM 2012

I

‘I

I

CODE

VENDOR’S NA&tE AND ADDRESS

77910

Shakespeare Products Division of

Shakespeare Company, Inc.

241 E . Kalamazoo Ave.

Kalamazoo, Mich igan 49001

78225

78553

79470

80996

81074

81082

81860

81861

82121

Stant Manufacturing Company Inc.

1620 Colunbia

Connersville, Indiana 47331

Eaton Corporation

8700 Brookpark Road

Cleveland, Ohio 44101

The Weather-head Company

300 EC& 13lst Street

Cleveland, Ohio 44108

Grinnell Company Inc.

260 W. Exch.

Providence, Rhode Island 02901

Holub Industries, Inc.

413 E Im Street

Sycamore, Illinois 60178

Electric Auto tite Company

Lebanon Road

Cincinnati, Ohio 45241

Barry Controls

700 Pleasant

Watertown, Massachusetts 02172

Burton Electrical Engineering Company

Ill Maryland Street

El Segundo, Calii%mia 90245

Electto Switch Corporation

King Avenue

Weymouth, Massachusetts 02188

4-2

Page 6

Aug 25 ‘85

OM 2012

CODE

VENDOR’S NAME AND ADDRESS

85925

89110

I

*

89373

89616

’ I

90201

I

90763 ’

91637

91929

92563

I

94222

E lectm Mechanical Instrunent Company, Inc.

123 N. Main St.

Dublin, Pennsylvania 18917

AMP Incorporated

1595 S. Mt. Joy St.

E lizabethtown, Pennsylvania 17022

Uniroyal Tire Company

6600 E. Jefferson Avenue

Detroit, Michigan 48232

Uniroyal. Inc.

Consumer Industrial and Plastics Pmducts Div.

312 N. Hill Street

Mishawaka, Indiana 46544

Mallory Capacitor Company

4760 Kentucky Avenue

Ind ianapol is, Ind iana 46206

United-Carr Inc.

10544 W .

Lunt Avenue

Rosemont, Illinois 60018

Dale E lectroniu, Inc.

P. 0. Box609

Columbus, Nebraska 68601

Honeywell, Inc.

Buildings Controls & Components Group

Micro Switch Division

Freeport, Illinois 61032

McGill Manufacturing Company, Inc.

Bearing Division

909 Lafayette

Valparaiso, Indiana 46383

Southco Inc.

Lester, Pennsylvania 19113

.

Aug 25 I85

1

4-2

Page 7

c

OM 2012

CODE

95879

98110

98410

98738

98991

VENDOR’S NAME AND ADDRESS

Alemite Instrument Division of

Stewart-Warner Corporation

1826 Diversey Parkway

Chicago, Illinois 60614

Naval Air Facility

El Centm, California 92243

E.T.C.

29000 Aurora Rd.

Solon, Ohio 44139

Stewart-Warner Corp.

1300 N . Kostner

Chicogo, Illinois 60651

Worcester ContmIs Corpration

125 Hartwell Street

W. Boylston, Massachusetts 01583

4-2

Aug 25,‘85

Page 8

. _ - - _ ,

-- -

I

.

OM 2012

SECTION 3. PARTS LIST

.

1. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a left-hand page

and the applicable pat-is list will appear on the opposite right-hand page. Unless

the list is unusually long, the user will be able to look at the illustration and read

the parts list without turning a page.

2. Symbols and Abbreviations

The following is .a list of symbols and abbreviations used in the parts list.

* - Item not illustrated

A, or AMP -ampere

AC -

a ltemat ing current

AR - as required

DC - direct current

Fig.

- Figure

hd. -head

.

hex - hexagon

Hz - Hertz (cyc les-per-secad)

I.D. -

ins ide diameter

IN - inch

WA - kilovolt-ampere

NtfD - microfarad .

No. -

number

NHA - next higher assembly

PRV - peak reverse voltage

PSI - pounds per square inch

Ref - reference (the item has been listed previously)

TM -Technical Manual

T-R - transformer-rectifier

._.

v- volt (when used as a prefix to a five-digit number, indicates

vendor code)

NOTE: An item which does not reflect an index number is an assembly which

is not illustrated in its assembledstate, or it is similar (right-hand,

left-hand, top, etc .) to an item which is illustrated.

Aug 25’85

5

OM 2012

3

Generat or Set

Figure 1

4-3

Page 2

Aug 25,&s

c

OM 2012

FIGURE

HCI BART

ITEM NO.

PART NO.

l-

53590-l

53590-2

5359D-3

I

1

2

I

3

I

4

5

I

*

* 5359% fv

DDW-155

482262

482467

No Number

.

402987

482337

78A-1112

NOMENCLATURE

1234567

EFF

GENERATOR SET FOR TRAILER OR TRUCK

MOUNTING

GENERATOR SET FOR TRACTOR MOUNT-

ING

GENERATOR SET, FIXED UNIT WITH

FUEL TANK AND BATTERIES

GENERATOR SET FOR TRAILER OR

TRUCK MOUNTING

A

B

C

D

.

EYE, LJFTING

CANOPY ASSEMBLY (For Details See

’ Fig. 2)

. CANOPY ASSEMBLY (For Details See

Fig. 3)

GENERATOR SET WITHOUT CANOPY

l (For Details See Fig. 4)

FRAME GROUP (For Detai Is See Fig. 23)

: NAMEPLATE, HOBART

.

NAME PLATE, HO BART

KIT, SUPPRESSl0N (For Details See

l Fig. 26)

.

NAMEPLATE, RATING

AD

BC

ACD

B

D

UNITS

ii&

A’ug 25’185

4-3

Page 3

.

OM 2012

Canopy Assembly

Figure 2

4-3

Page 4

Aug 25.&G

OM 2012

FIGUI?E’

H OBAR T

ITEM NO. PART NO.

1234567

EFF

2-

482262

1 482333

2 482320

3 48232 1

4 482322

5 482376

6 482323

7

482327

8

76A-1115

9 481418

10 482470

11

481419

12 482469

13 ‘482401

14 482389

15

482400

16 482426

17 480695

18 403127

19

482386

20 404036

21 482372

22

482328

23

481417

24

3 87450

25 482437

26 482429

27

389284

28 481416

29 HJ-129A

Aug 25,‘85

NOMEtKiATURE

CAh OPY ASSE MB LY (For NHA See Fig. 1)

PANE L ASSE MB LY, S IDE , t: lGHT,

l FRONT, CANOPY

DOOR ASSEMBLY, LEFT 8, RIGHT,

l FRONT, CANOPY

. DOOR ASSEMBLY, RIGHT, FRONT, ’

CAN OPy

DOOR ASSEMBLY, RIGHT, REAR,

’ CANOPY

COVER ASSEMBLY OPENING TOP

: DOOR ASSEMBLY,‘RIGHT, REAh,

CAN OPY

BRACKET, MTG., LATCH, DQOR

: LATCH, ADJUSTABLE GR IP V94222

No. 48-99-126-11

TOP ASSE MB LY, REAR, CAN OPY

: COVER, OPENING, PANEL, REAR

SUPPORT, MTG., REAR, CANOPY

: PANELASSY, END, REAR, CANOPY

COVER, PLEXIGLASS, GENERATOR

l COhTROl5

.

DOORASSY, LEFT, REAR, CANOPY

UN ITS

AF;Y

ACD

‘REF.

ACD

1

ACD

2

ACD

1

ACD

1

2

ACD

1

4

ACD

ACb

qcD

‘1

1

COVER, PlEXIGlASS, ENGiNECONTROlS ACD

: PANELASSY, SIDE, LEFT, REAR,CAIUOPY ACD

.

DOOR ASSY, ACCESS, RECEPTACLE

ACD

CATCH ,MAGNET fC

l N 0. M-1s201-10

V94222

ACD

DOOR ASSY, LEFT, REAR., CANOPY

: LATCH, DOOR, RECESSED. V19220,

ACD

No. 3-49735s U ACD

.

DOOR ASSY, WT, R,ONT, CANOPY

ACD

PANE t ASSY, S IDE, R IGHT ,REAR ,CAN OPY

: TOPASSEMBLY, FRONT, CANOPY

AC D

ACD

COVER ASSEMBLY, HOLE, RADLATOR

: FRONT ASSEMBLY, CAN OPY

. PANELASSEMBLY, LOUVERED, FRCXUT,

CAtvow

. COVER, HOLE, FRONT, CANOPY

, SUPPORT ASSY, MTG ., FRONT

.

JOINT, BALL VO1428, No.SPS1002CP

ACD

2

1

4-3

Page 5

OM 2012

-

4-3

6

FlGURE H OBART

ITEM NO. PART tu0.

2- 30 482407

31 482424

* 32 480701

482326

33 75-422

34 lOOGH-121

1234567

ROD, STOP, DOOR

: PANELASSY, SIDE, IEFT, FRONT

.

SPACER, IATCH , DOOR

HORtu &CABLE CiAMP ASSEMBLY

: . CtAMP, CABLE

. .

BKACMT, MTG., CLAMP

OM 2012

EFF

ACD

l

ACD

Ufu iTS

AEY

'8

1

AR

1

2

1

35

482442

HORlv ASSEMBLY, CABLJi

EikTt?$dwCE

ACD

1

* 36 7&A-7125 : iABEL, HA&D, TACH ACD 1

.

Aug 25435

I

4

.

,

4-3

Page 7

c

OM 2012

28

Canopy Assembly

Figure 3

4-3

Page 8

Aug 25435

UM 2012

FIGURE

H OBAKT

ITE M tw 0. PART N 0

3-

482467

1

482429

2

482468

3

482459

4

481417

5 482458

6 482464

7 482376

8 481418

9 482470

10

481419

11

482469

.I2 * 482401

13

482389

14 482403

15 482386

16 480695

17 403 127

. .

18

19

20

21 404036

22 482407

23 HJ-129A

24 482372

25 482320

26

481416

482426

482428

482424

tu OMENC 1ATUKE

1234.567 EFF

CANOPY ASSEMBLY (For NHA See Fig. I>

.

PANEL ASSEMBLY, LOUVERED, FI!OI\JT,

CANOPY

PAtuELASSEMBLY, LOWER, KiGHT,

l FRONT, CAhOPY

.

PAIvELASSEMBLY, UPFfR, RIGHT,

FROhT, CAh OPY

TOP ASSEMBLY, FRONTT, CANOPY

: BRACKET, M0Ul’~Tll\rG, RIGHTS IDE,

PANELS

.

PAI’JELASSEMBLY, UPPER, RIGHT,

REAR, CANOPY

. COVER ASSEMBLY, OFEFV IhG, TOP,

CANOPY

TOP ASSEMBLY, REAR, CAtuOPY

: COVER, OFEblbG, REAR, CANOPY

SUPPORT ASSY, MOU~JTII’JG, REAR

l CANOPY

PAtLEL, END, REAR, CAlLO&

: COVER, PLEXIGLASS, GENERATOR

COIVTROLS

. DOOR ASSEMBLY, LEFT, REAR

B

6

B

.

COVER, PLEXIGLASS, ENGIbE COfuTROLS B

. DOORkSSEMBLY, LE-FT, REAR

DOOR ASSEMBLY, ACCESS, RECEPTACLE

: CATCH, MAGNETIC V94222,

No. 02-10-201-10

PAhEPASSEMBLY, SIDE, LEFT, REAR,

l CAhOPY

.

COVER, OPElulEuG, PANEL, SIDE,

KEAR, LEFT

PAfvELASSEMBLY, SIDE, LEFT, FROluT,

l CAtvOW

LATCH, DOOR, RECESSED V19220,

l No. 3-4973SslJ

. ROD, STOP, DOOR

JOlht, BALL V01428, No. SP-S 1002CP

: DOOWASSY, LEFT, FRO~T,~A~JOPY

.

DOO!bASSY, LEFT, FRObT, CANOPY

B

B,

B

.

SUPPORT ASSY., MTG., FROhT,CAhOf’Y B

Utu ITS

AK

RE F

1

2

1

2

1

‘1 I

1

2

1

Aug 25%

4-3

Page .9

.

OM 2012

.

4-3

Page 10

Aug 25 '85

OM 2012

. Iv Oh% NC IATURE

FIGURE

HOBART

ITEM h0. PAKT NO.

1234557

3- 27

482437

FROf\lT ASSEMBLY, CAbOPY

28 3 87450

: COVER, HOLE, RADiATOR

*

29

480701

. SPACEK, LATCH, DOOK

*

30

481503

LABEL, ACCESS, PAhE L “REMOVE FOR

l ACCESS TO VOLTAGE REGULATOR .

AND COfuTACTOR”

*

31

‘76/b1125

. LABEL, HA&D, TACH

UN ITS

EFF

Ay;Y

B

:1

B

1

B

AR

B

2

B

1

.

Aua 25’85

4-3

Page I!

c

OM 2012

43

Page 12

Generator Set Without Canopy

Figure 4

Aug-25 0%

OM 2012

FiGURE

ITEM NO.

4-

1

2

3

4

*

5

*

6

7

'8

9

10

.

11

12

13

14

*

15

16

hotuumber

*

17

482305

18

ho luumber

Aug 35 ‘85

H OBART

PART tu 0.

t\ro humber

ho humber

ho t\cumber

402096

482312

Y-10

W-7814-0

482319

43039lA

482075-2

482235

482296-2

482325

482317

4823 18

H F-2752

- t\c OMEhC iATURE

Uh ITS

1234567

EFF A!;Y

.

l

.

e

.

PA~ELAs~EMBLY, TERMINAL,

STATOR (For Details See Fig. 14)

REGUlATOR ASSEMBLY, VOLTAGE

(For Detaik See Technicai Manual

No . TM-232)

GEhERATOK SET WITHOUT CAhOPy

(For t\rHA See Fig. 1)

l

RADIATOR AfuD COOLlhG SYSTEM

GROUP (For Detaik See Fig. 5)

.

EhGiEuE AhD AIR CEAE\rER GROUP

(For Details See Fig. 6)

KIT, QUiCK START V61112,

l ho. QS-3267-207

BRACKET, MOUhTlkG, QUICK

l START

SPACER, QUICK START BRACKET

: BUSH IhuG, QU lC K START

PAt\rELASSEMBLY, POWER MODULE

(For Details See Fig. 15)

BOX ASSEMBLY, COhTROL GEh-

ERATOR (Fcr Detaik See Fig. 16)

PAtLELASSEMBLY, COhTROL,

EhGlhE (For Details See Fig. 20)

BRACKET, MOlJhTfiG, PhEL,

CaTROL

PAhE L ASSEMBLY, OUTPUT

TERMffuAL (For Detaik See Fig. 21)

COVER, PAhEL, OUTPUT TERMll\rAL

At\r D STATOR TE RMIhA L

MOUihT, RUBBER (Used to mount

electrical panek on control box

support pane I) V 16238,

ho. 4624-105

GEhERATOR GROUP (For Detaik

See Fig. 22)

HARbESS , WIRE, KE GU LATOR ,

VOLTAGE

FRAME, MOUhTIl\cG’Af\cD LIFT-

IhG YOE ASSEMBLY (For Details

See Fig. 23)

REF.

1

2

1

.

1

2

1

2

12

1

REF.

4-3

Page 13

c

OM 2012

.

4-3

Page 14

Aug 25185

OM 2012

FIGURE

H OBARI

ITEM ho.

PART h0.

4- 19

20

*

21

*

22

*

23

*

24

4823 14

400162

400078

W-2974-A

403594

485262

f\c OME hC LATUKE

F 234567

EFF

Aug 25% I

BRAC KET , MOUluT lh G ,

l RECE PTAC LE

RECEPTACLE, V81861,

l ho. Ah-3114-18

BRACKET, RES ISTOR V44655, ’

l ho. 12

RESISTOR V44655, 100 Watts

: TERMhAL, BATTERY V81872,

ho, MS27212-5-.l

KIT, 24 V DC

l ASSEktBlY

POWER SUPPLY

BC

B

D

Ut\r ITS

per

ASSY

1

2

1

.

4-3

Page 15

.

OM 2012

4-3

Page 16

Radiata and Cooling Sysiem Group

Figure 5

Aug 25 ‘85

FIGURE

HOBART

ITEM ho. PART rU0.

5-

No Number

387614

387878

50GHP-89

<5OGH P-82

387913

5CW-1932-O

3879 14

387313

402958

9

10

*

11

*

12

13

14

15

387881

355194

56555

386751

403034

388219

W-10869-2

5650 1

16

w- 10890-d

17

385275

18 W-7814-5

19 W-10760-1

20 388943

21 w-108693

*

22

23

*

24

25

*

26

W-10869-2

27

28

402141-15

389421

H F-2962

12CW-908

387917

W-78 14-2

w-10891-1

29

W-l 0893-2

Aug 75 215

OM 2012

. .

N OMElvC LATURE

1234567

RADlATOR AhD COOLII’JG SYSTEM

GROUP (Far NHA See Fig. 4)

RAD fATOR ASSEMBLY

: . HEAD ASSEMBLY, KADtATOR

. . STRIP, REINFORCING

GASKET, RADIATOR

: : SHROUD, RADIATOR

. .

VALM , DRAIN V79470, ho. 145

. . BASE ASSEMBLY, RADIATOR

RAILASSEMBLY, SIDE, RADIATOR

I I CORE, RADIATOR V41197, Size

26 in. x 28 in. x 2-l l/32 in.

ANGLE, MOUNTING

: : PIPE, OVERFLOW

HOSE, OVERFLOW (LENGTH 45 IN .)

: : CLAMP, RETA IhER

CAP, RAD IATOR V78225, b o. A,4X-O848

: LINE ASSE MB LY, SUPPLY

CLAMP, HOSE V76599, No. G-20

: : HOSE, RUBBER, RADIATOR, 3 PLY

1 IN. I.D.

ELBOW, PIPE

: : PIPE, LINE

BUSHihG, PIPE 3/4 O.D. x l/2 I.D.

: : N IPPLE , PIPE l/2-14

HOSE, RADIATOR, INLET

: CLAMP, HOSE, RADlATOR V76599,

No. GS32

CIAMP, HOSE, RADIATOR ~76599,

l No. G-20

.

HOSE, RADIATOR, OUTLET

BRACE, LINE, SUPPLY

: CLUMP, HOSE, BRACE

CLAMP, LIhE, VENT

: LINE ASSEMBLY, VENT, RADIATOR

BUSHING, PIPE, 3/8 O.D. to l/4 I.D.

l : E LBOW MA LE

’

V79470,

No. 49: 4A (4’~ 4)

SWIVEL, KM&E, SAE 45, V30327,

’ l No. KA04-04NL

EFF

c

uturrs

A:;,(

REF.

1

4

2

1

2

28 lb.

2

1

2

4-3

Page 17

43

Page 18

OM 2012

. .

Aug25'85

L

OM 2012

FIGURE H OBART

ITEM ho. PART k0.

h OME hC LATURE

1234567

EFF

5- 30 402499- 1

31 56534

32 389898

33 482499

*34 -351541

CLAMP, HOSE V35738, No. J340

: : HOSE, LOW PRESS., HIGH TEMP.,

l/4 I.D. LEhGTH 18-l/2 lI\(.

. GUARD, FAh, LEFT

:

GUARD, FAb

, RIGHT

lABE L, CAUTIOb FAt\r

,

Uh ITS

i&Y

Aug 25.%5

4-3

Page 19

4-3

Page 20

Engine & Air Cleaner Group

Figure 6

Aug 25 &j

.

OM 2012

8

OM 2012

FIGURE

H OBART

IlEM tu0. PART EUO.

6-

No Number

1 404008

2

3

4

403782-O

‘3876~7~

387606

403064

5

403065

6

387629

7

403156

8 402435

9

403157

10 403774

*

11

402436

12

403264

*

13

14

W-7814-9

403412

15

388217

16

403409

17

480629

18

480630

19

480621

20

480648

21

480618

22 480619

*

23 30GH-417

24

404568

25

482093

Aug 24’85 \,

twOMENCL4TURE

1234567

ENGIbE &AIR CWWJER GROUP (For

NHA See Fig. 4)

.

EhG&E, DETROIT DIESEL, 4 CYLIluDER

MODELtuO.4-71N

DEVICE, TEMPERATURE, HIGH V75418,

’ No. 1002-0488-33

. PlPE,A~ClEANER

KIT ASSEMBLY, AIR ClEAtuER

: . ClAMP, FITTING V21585,

b4 0, L-4690-1 1

COUPLII’JG, RUBBER V21585,

l l No. A- 15094-10

. . HOUSlt’dG, CLEANER,

AIR

CARTRIDGE , FILTER V21585, No. P-24

: : INDICATOR, SERVICE FILTER, CART-

RIDGE V21585, Iv o, L-14440-25

. . ELIMIbATOR, MOISTURE V21585,

two. D-56519-16

FASTENER, AIR ClEAhER V21585,

l l ho. A-42586

. . KIT, IfvSTALlATlOfv, IhDlCATOR,

SERVICE V21585, Ej o. L-14439

GOVERhOR ASSY, OVERSPEED

l V78388, ho. SA503A-P

BUSHIhG, HIGH TEMP. DEVICE

: ADAPTER, TACH. DRIVE V72582,

No. 1565170

. PIPE, OIL FILL

.

CAP, OIL FILL V24617, I’Jo. 5117362

GASKET, MAh IFOLD

: PIPE, MUFFLER TO MANIFOLD

GASKET, MUFFLER

: MUFFlER

BRACKET, MTG. ,EXHAUiiT , OUTLET

: BRACKET, MTG., MUFFLER

MOUhT, SHOCK, V21678, ho. 314C

: SOLENOID, STARTER, AUX., 12 V.

V16764, ho. 1486

.

BRAC#ET, MOU~JTING SOLENOID

Ut\c ITS

EFF A?;Y

REF.

1

4

1

I

1

4

1

2

1

4-3

Page 21

4-3

Page 22

OM 2012

Aug25&

-, _.

-i

i

FIGURE

HOBART

ITEMNO. PART NO.

6- 26

*

27

28

*

29

30

387293

6FW-5047

W-9234-55

181018

484949

I

*

31

*

32

*

33

* 34.

I

*

35

*

36

403413

482493

482494

482506

388763

*

37

*

38

482495

482405

56553

*

39 56544

*

40

56544

OM 2012

b OMEt\rC LATURE

1234567

.

SWITCH ASSEMBLY, STARTER CUT-OUT

(For Details See Fig. 7)

SPACER, FUE L FILTER

l DElETED

. CABIf, STARTER TO GROUND

.

KITASSEMBLY, GOVERNOR,

ELECTRIC (For Detaik See Fig. 8)

.

KIT ASSEMBLY, GOVERNOR, ELECTRIC

(For Details See Fig. 8)

. KEY, TACH DRIVE V24617,

ho. 6478641

.

LlIbES ASSEMBLY, FUEL (For Detaik

See Fig . 9)

.

LlhES ASSEMBLY, OIL (For Details

See Fig. 10)

Llt\rES ASSEMBLY, IUE L (For Detaik

* See Fig. 11)

LlhES ASSE MB LY, FUE L (For Detai k

l see Fig. 12)

.

LlhES ASSEMBLY, IUEL (For Details

See Fig. 13)

. BRACKET, JUI’CTlOt\(, FUEL LIhES

.

HOSE, BREATHER, GOVERhOR (Length

20”)

.

HOSE, TUBE, 1E FT FRONT (Length 18”)

UN ITS

EFF A:;Y

1

6

1

ABC 1

D 1

1

ACD 1

B 1

B I

B 1

.

1

.

HOSE, TUBE, RIGHT REAR (imgth 10”)

1

Apr 21/88 Revised 4-3

Page 23

OM 2012

4-3

Page 24

Starbr Cut-0ut Switch Assembly

Figure 7

,

Aug 2.5&i

OM 2012

FIGURE

ITEM NO.

7-

387293

1 No Number

3’

4

5

HOBART

PART NO.

No Number

387295

3 87294

DW-4866

NOMENCLATURE

1234567

SWITCH ASSEMBLY, STARTER CUT-OUT

(For NHA See Fig. 6)

.

SOLENOID (For Details See Engine

Operators Manua I)

ARM, SUPPCRT

(F

urnishc-d

: ACTUATOR, SWITCH

with engine)

BRACMT, MOUNTING, SWITCH

: SWITCH, MICRO V91P29, No. BZ-2RA2

WITH ACTUATOR NO. MC-771 1

UN ITS

‘per

EFF ASSY

REF

1

Aug 35 '85

4-3

Page 25

r

OM 2012

12

I3

.

Electric Governor Kit Assembly

Figure 0

43

Page 26

Aug 25035

OM 2012

FIGURE

iTEM ho.

8-

1

2

I

8

9

10

* 11

12

13

I

* 14

**

This unit is mounted to back of, generator control box.

HOBART

PART ho.

181018

484949

ho kumber

402908

W-9476- 16

404594

482335

482152

404112-l

401556

482157-1

402595

482170

403716

ho Number

Iho Number

482337

1234567

E FF

KIT ASSEMBLY, GOVElifuOR, ELJZCTK:C

(For N-tA See Fig. 6)

KIT ASSEMBLY, GOVERNOR,

ELECTRIC (For NHA See Fig. 6)

ARM, ACTUATOR (Port of Item ho. 5)

: JOINT, BALL, GOVERbOR LlfuKAGE

V57448, No. TF-4Y

ROD, THREADED 1/4-28x 3-7/8 ’

: ARM, THKOTTLE V725E2, No. 5164318

. ACTUATOR, GOVERNOR, ELECTRIC

. BRACKET, MOUNTING, ACTUATOR

. UNIT, CONTROL, ELECTRIC, GOV-

ERNOR V01843, No. CU673C7 **

MOUNT, SHOCK,

’ V81860, No. SS-01

RUBBER

. HARNESS, WfRE, ACTUATOR

. SENSOR, hnAGhETiC, GOVERtuOR

V01843, ho. MP675

. SPACER, HOLE, BALLJOIkT

PNOT, ARM, THROTTLE

.

. SCREW V72582, ho. 100659

. NUT V72582, No. 5168374

KIT, SUPPRESSION (For Details

l See Fig 0 26)

t

ABC

D

Ub ITS

AS&

REF.

1

2

1

4

1

* 1

1

Apr 21/88 Revised

4-3

Page 27

. .

OM 2012

.

4-3

page 28

i

PfWWw OR (LONG)

WEL FILTER-OUTLET

&WARY OR (SHORT)

FUEL FILTER- OUTLET

be1 Lines Assembly

Figure 9

Aug 25'85

OM 2012

FIGURE HOBART

ITEM NO. PART NO.

9-

482493

1

W- 10892-2

2

W- 10886-4

3

4

5655 1

5 W-10891-10

6

w- 10886-6

403590-4

Aug 25,!85

NOMENCLATURE

1234567

Llt\rES ASSEMBLY, FUE L

ELBOW, STREET

l 13400 x 4

3400 x 4 v79470,

.

CONNECTOR, MALE, WEATHER-

HEAD V79470, #48 x 8 x 4

SWIVEL, FEMALE 3/4-16 SAE,

l THDS. V03924, *7115-85

.

HOSE, 88, 13/32 I.D.

.

ELBOW, MALE, WEATHERHEAD

v7947q, 49 x a x 4

.

CONNECTOR, MALE r WEATHER-

HEAD v79470, 848 x 8

.

UN ITS

EFF.

AZ

REF.

1

.

1

6

94”

4

1

4-3

Page 29

c

OM 2012

TO ENGINE

43

Page 30

TO TEE ON

OIL PRESSURE

Oil line Assembly

Figure 10

Aug 25'85

OM 2012

FlGU RE

tTEM lu0.

lo-

1

2

3

4 .

5

Aug 25 1’85

HOBART

PART tu0.

. Eu OhrEf~CfATUtiE

UTU ITS

1234567

E FF A’;“s’v

482494

LltvE ASSEMBLY, OIL

W-10886-1 .

CON’JECTOR, MALE V79470,

48x4

403590-l .

SWIVEL, FEMALE, SAE 45’ FLARED

V03924, h0. 7115-4s

DELETED

56548

HOSE, 3/16 It\c. I.D.

W-10891-7

: ELBOW, M4f.E V79470, f49x 4

REF.

1

2

51 ”

1

4-3

Page 31

OM 2012

I

1

ff f’

I

I 2

3

4 3

e/

5

FUEL RETURN Fi VENT LINES

7

FUEL RETURN CONN.

IN TOP OF TANK

FUEL STRAINER CONN.

/I5

FUEL SUPPLY LINE

&i-LET CONN. IN

FUEL TANK

Fue I Lines Assemb ly

Figure 11

4-3

Page 32

Aug 25’85

tuOMEI\rClATURE

FIGURE

H OSART

ITEM k0.

PAtiT I\( 0. 1234567

EFF

ll-

482506

1

403592

2

400059- 1

LI&ES ASSE MB LY, FUE L

VALVE, CHECK V72582, l’io. 5122279

: COt\rf\lECTOR, FEMALE V79470,

ko.46X6

3

403590-3

4 56550

5 w-10891-4

6

W-11608-3

7

W-10760-7

a

W- 10893-o

9

56535

10

W-10891-10

11 403590-4

12

56551

13

14

15

w-.10891-9

w-7814-5

400819-i

FITTIhG, SWIVEL, FEMALE V03924, *

l ho. 7115-6s

HOSE, #6, 5/16 I.D. Length 65”

: ELBOW, MALE V79470,No. 49 x 6C (6 x 8)

TEE, PIPE, l/2 IN.

: I\r IPPLE , C LOSE l/2 lb .

SWIVEL, FEMALE V30327, ho. KAO6-06kS

: HOSE, LOW PRESSURE 3/8 ib. I.D.

Len& 27 In.

.

ELBOW, MALE V79470, No. 49 x 8 x 4

. FITTlbG, SWIVEL, FEMAlE V03924,

No. 7115-8s

HQSE #a, 13/32 In. I.D., Length 53-l/2

l In.

.

. ELBOW, hAAlE v79470, No. 49 x a x a

BUSHlEuG, PIPE 3/4 x l/2

: VALVE, MALE V13902

No. F-125R

16

lXW-2077-3

.

E LBOW, STREET, l/2 IN. V80996, 900

17 W- 10760-3

. IwPPtE, PIPE, l/2 IN.

OM 2012

ACD

REF.

ACD

1

ACD

ACC

ACG

ACC

ACD

AC,D

ACD

Uk ITS

A;‘Y

1

2

1

2

1

2

1

2

.

1

Aug 25 ‘85

4-3

Page 33

c

OM 2012

TO

ON

.

4-3

PC& 34

TO TRACTOR

DISCONNECT

Aug 25’85

OM 2012

FiGURE

HOBART

ITEM NO.

P&T NO.

NOMENCLATURE

UNiTTS

,per

ASSY

1234567

EFF

12-

388763

LINES, FUEL 0 IL

B

Ref.

1

w-10891-8 .

ELBOW, MALE V79470, 49 x 8

B

1

2 1

403590-4

.

FITTING, SWIVEL, FEMALE

3/4 SAE, THD . V03924

.

HOSE, #8, 13/32 I.D.

, B

5

B

2

46 ”

3

5655 1

4

W-10891-1 1

.

ELBOW, MALE ~79470, 49 x 10

1

5 403590-5

.

FITTING, SWIVEL, FEMALE,

7/8- 14, SAE, THD. V03924

.

HOSE, #?O, l/2” I.D.

B

2

46”

6 56552

.

Aug 25,‘&

4-3

Page 35

OM 2012

TO FUEL RETURN

LINE

4-3

Page 36

TO l/2” COUPLING

ON UFfiNG YOKE

Fuel Lines Assembly

Figure 13

.6

3/8” COUPLING

LIFTING YOKE

Aug 25,/85

oty 2012

.

FIGURE

HOBART

ITEM I’iO.

PART t\rO. 123456?

13- 4 82495

1

403570-3

2

56550

3

W-10871-2

4 ’ 403572

5 W-7814-2

6 W-10871-9

hOMEtuCLATUKE

Lli\rES , FUE L 0 IL, ASSE MB LY

FITTIfuG, SWIVEL, RMALE, 5/8-18

l THD. V03924

c7115-6s

.

HOSE #6, 5;16 I.D.

ELBOW, MALE, WEATHERHEAD

l 47 x 6 V79470, #47 x 6 ..

Uh ITS

EFF A:&’

8

REF.

8 2

8 28-l/2”

8 2

: VALVE, BUSH ffvG CHECK, PIPE V72582, to

#5122279

, l/4 3/8

. ELBOW, MALE, WEATHERHEAD

~79470, 49 x 8 x a

8 8 1 1

8 1

I

.7

12CW-2077-2 . E LBOW, STREET, 90 V80996, f3/8”

15/16x l-7/16 (or equiv.)

8 1

8 403590-4 ’ FITTiNG, SWIVEL, FEMALE 3/4-16

THDS, V03924, #7115-8s

8 2

I 9 10

5655 W-10891-‘10 1 : E HOSE IBO’iV, #8 MALE 13/32 y79470, I.D. 49 x 8 x 4

8 8 88-l/2” 1

11

W-101 19-2 . COUPLIhG, PIPE l/4

6 1

Aug 25 035

4-3

Puge 37

OM 2012

Stata Terminal Panel Assembly

Figure 14

4-3.

Page 38

4% 251~

-

FIGURE

HOBART

ITEM 1\10.

PART h0.

1234567

EFF

14-

4823 17

1

W-11077-18

2

W-l 1254-6

3

W-l 1242-10

4

482446 ,

5

482443

6

W-10854-4

7

482471

8 482449

9

401737-l

10 W-11112-3

11

W-l 1254-3

12

W- 11245-3

13

482450

OM 2012

Eu OAElKL4m?E

PAhELASSEMBLY, TERMIhAL, STATOR

(For T\IHA See Fig. 4)

SCREW, STEEL, 3/8-16 x 3/4, HHC

: WASHER, LOCK, S’iEE L, 3/8 Ih.

WASHER, FLAT, 3/8 Ih .

.

: RETAIlhER, CABLE

. BAR, BUS

CAPACITOR, 0.1 MFD, 500 V. V90201,

’ ho. 8-206143

STRAP, COf\rhECTIbtG, CAPAC ITORS

: BRACKET, MOUhTIhG, BOARD

BLOCK, TERMhAL V78410,

’ by o. 35005-3526

.

SCREW, ROUhD HEAD, MH, STEEL,

#lo-24 x 3/4

WASHER, LOCK, #TO, STEE L

: WASHER, FIAT, BRASS

.

PAbE 1, TERMlf\tAL, OUTPUT.

Aug 25 ‘85

.

ul\r ITS

A&

REF.

7

9

6

3

1

2

1

3

1

,

4-3

Page 37

OM 2012

Power Module Panel Assembly

Figure 15

4-3

Page 40

Aug 25dZi

OM 2012

NOMENClATURE

WITS

A%

FIGURE

HOBART

fTEM NO.

PART NO.

1234567

EFF

15-

482075-2

PANEL ASSEMBLY, POWER MODULE (For NHA

See Fig. 4)

.

STRIP, TERMINAL V98410, No. 350123526

STRIP, TERMINAL V98410, No. 35008-3526

: RESISTOR, LINE DROP BURDEN, 50 OHM,

25 WATT, V44655, No. 02OoD

RESfSTOR, OVERLOAD BURDEN 25 WAT7,

l V91637, No. RH-25, 20 WATT

. TRANSFORNER, CURRENT, LINE DROP &

OVERLOAD V50508, No. E-6170

RECTIFIER, SILKON VO4713, No. SDA10270-1

: CONTACTOR, LOAD V50603, No. H820088

BOARD ASSEMBLY, PC OVERLOAD

: HCXJSING, SOCKET, CONNECTOR V89110,

No, l-480287-0

TEftbAINAL, SOCKET V89110, No. 60619-l

1 WASHER, FIBER, SHOULDER

MCUNT, SHOCK, RUBBER V81860

l No. ss-01

TfIANSFORtiR, CURRENT, AMMETER

: CONNECTOR, RIGHT ANGLE V59730,

No. TA-250-8

ADAPTER, TERMINAL ~98410, No. VWA-0

: TERMINAL, RING TONGUE V89110,

No. 31159

TERMlfJAL,QUlCK CONNECT, PIGGYBACK

l V89110, No. 61944-2

TERMINAL, QUKK CONNECT VOO779,

’ No. 41274

TERMINAL,

‘No.42640-2

QU KK CONNECT VO0779,

DIODE, SILKON VO5277, No. IN4820

: PANEL, POWER MODULE

REF

2

1

I

401937-3

2 401937-2

3 *w-9746-1

3

4 404402- 1

3

I

5

I

6

7

8

9

lCZ-148

404065-l

404518

38773&4

401564-4

1

10

4

10

11

I

l2 4

401566-l 1

403763-l

401556

4

3

363 136-5

~400701

13

14

5

1 15

401939

16 4oo830-15

3

17 402197-l

1

18 400480-2

5

19 400480-3

2

1

* 20

1C Z-938

21 482076

4-3

Page 41

Aug 25d3!j

4-3

Page 42

OM 2012

Aug 35%5

c

OM 2012

FIGURE HOBART

l7EM I\rO. PART ho.

*15- 22

*

23

*

24

W-9360-279

*W-9360-2 11

W-9360-278

1234567

UTU ITS

Per

EFF

ASSY

CABLE ASSEM6LY, PO\‘iER E LECTRKAL

--

‘(ho. 101) “A” Stator Terminal Panel to

“A” Contactor; (No. 102) “B” Stats TerminaI

Panel to “B”Contacta; (No. 103) Y”Stator

Terminal Panel to “C” Contacts; (No. ,110)

‘lb ” Terminal to “N ” Output Terminal Pane i

.

CABLE ASSEtv’iBLY, POWER ELECTRICAL

(NO. 104) ‘A” Contactti to “A” Output

Terminal Panel; (No. 105) “8” Conlactcr

to “8” Output Terminal Pane I; (nt o. 106)

‘Y: ” Contacts to “C” Output Tecminal

Pane I

.

CABLE ASSEMBLY, POhER ELECTRICAL

(lu o. 111) “h ” Termina I to Ground

Aug 25%

.

,

4-3

Page 43

.

OM 2012

. *

Control Box Group

Fhure 16

4-3

Page 44

Aug 25/&i

ON 2012

FIGURE H OBART

ITEMNO. PART NO.

16-

No Number

1

482278-2

2

482285- 1

3

N 0 Number

4 401556 .

5

404112-l UNIT, CONTROL, Ei.ECTRlC,GOVERhOR

l V01843, No. CU673C7 **

* 6

76x4-1 130

.

CLAMP, TUBE V78553, No. C-4362S-031

I’J O/v‘E NC tATURE

1234567

EFF

CONTROL BOX GROUP (For NHA See

Fig. 4)

.

TRAY ASSEMBLY, GENERATOR

COtVTROLs (For Detaik See Fig. 17)

.

TRAY ASSEMBLY, PROTECTIVE RELAYS

(Fa Detaik See Fig. 18)

.

CONTROL BOX AND INTERNAL

COMPONENTS GROUP (For Details

See Fig. 19)

.

MOUNT, SHOCK, RUBBER V81860,

No. ss-01

**

This unit is pert of electric governor kit assembly (fa details

see Fig. 8).

UN ITS

Ap;;‘v

REF.

1

REF.

2

Aug 25&

4-3

Page 45

OM 2012

4-3

Page 46

Generator Controls Tray Assembly

Figure 17

Aug 25/&j

OM 2012

FIGURE HOBART

ITEM NO. PART NO.

17-

1

2

3

*

4

5

6 W-2974-L

6A

7

I

8

9

I

10

*

11

*

, 12

13

14

15

16

17

I

18

HF -1459

19

20

21

W-8095A-9

22 W-8105A-4

23 W-9916-10

*

24

388328 -49

.

NAMEPLATE, IDENTIFICATION

482278-2

482355

482284-l

4.02826

402665- 1

404065-I

400078

W-2974-N

16DA-4253- 1

1234567’

EFF

TRAY ASSEMBLY, GEhERATOR CONTROLS

(FOF NHA See Fig, 16)

.

HARbuEsS , WIRE , RECE PTAC 1E

.

BRACKET, MOlJNTIhG, RECEPTACLE

AND SWITCH

SWITCH, AUTOMATIC, MANUAL ’

l V15605, No. 8926K425

H OUS ING , RECE PTAC LE VO0779,

l No. [email protected]

RECTlFlER, SILtCON

’ SDA 10270-l

V04713, No.

RES ISTOR , MANUA L, 50 OHM, 100 WATT

l V44655, No. 0959

BRACKET, MOUNTING, RESISTOR

: RES ISTOR, BALLAST V4-4655, 100 WATT

.

RETAINER, SWING, KE IAY V77342,

No. (KUP) 2OC206

16DA-4004A-10 . RE LAY, EXC ITATIOh , DEEbERG IZATION

d 16DA-4052-O

363771-5

363770-I

16DA -4029

16DA-2162

lOJ-178

381439

4022 18

15GH -433

400400

Aug 25185

12V. V77342; No. KAP-14DG-12

.

SOCKET, RE LAY VO2660, No. 77-MIP-11

SLEEVING, PIASTIC, l/8 IN. I.D.

: SLEEVING, PLASTIC, 3/16 IN. I.D.

.

BRACET, MOUNTING, SOCKET,

RELAY

KNOB, RHEOSTAT V4-4655, No. 5150

: NAMEPLATE, FIELD, KHEOSTAT

BRACKET, MOUNTiNG, RHEOSTAT

: RHE OSTAT, MANUAL, MODE L L

V44655,

100 Ohm, 1.50 Watts

, SWITCH, METER SElECTOR V82121,

No. 10 1904LN

NAMEPLATE, METER, SELECTOR

l SWITCH

. SWITCH, TOGGLE V73559,

No. 26L61TABS

, AMMETER V60741, No. 331 LH

VOLTMETER V60741, No. 331LH

: METER, FREQUENCY, V31356,

No. 36-FX

.

UN ITS

A:;Y

REF.

1

6

1

6

2

1

.6

2

4-3

Page 47

4-3

Page 48

OM 2012

.

Aug25B5

FIGURE

HOBART

ITEM NO. PART IhO.

17- 482279

25

370382A

I

27 26 404028 7&4-l 115

28

‘402383

29

482280

* 30

482306

1

:

I

OM 2012

/

.

a:_ ,I’ .

!

*,.

, - ,.

. a.

L : .- ._.

!

t\r OMENC IATURE

UN ITS

1234567

EFF

Ap;‘s’v

TRAY SUB-ASSEMBLY, GEhERATOR

l COtvTROt

HANDlE , TRAY

: : MMPLATE, HOBART

JATCH , ADJUSTABLE GRIP V94222

l l No. 48-99-126-11

SLIDE ASSEMBLY, TRAY (Consists of

l ’ four p&n marked CR, CL, IX, 8, DL)

V75358, No. 1336-12

TRAY ASSEMBLY

~%RNESS ASSEMBLY, WIRE, GE~\(.

COhTROC TRAY

1

1 set

1

Aug25’85 i

43

Page 49

. .

:

,

Q

Q f

NOMENCLATURE

FIGURE HOBART

ITEM NO. PART NO.

1234567

18-

5

6

I

7

8

9

.

‘-.

: 10

:I

11

12

13

14

.iM 2012

EFF

482285-l TRAY ASSEMBLY, PROTECTIVE RJZLAYS

(For NHA See Fig. 16)

402662 l

SWITCH, TEST BANK V73559,

No. 2GK71-73

482284-2

BRACKET, MTG., RECEKACLE h SWITCH

482356

: RECEPTACLE, HARNESS, WIRE

16DA-4052-O . SOCKET, RELAY

MDA-4004A-3 . RELAY, PLUG, INTERLOCK 24 V. DC

V77342, No. KAP-14DG-24

16DA-4253-1 . RETAINER, SPRING, RELAY V77342,

No. Q<UP) 2oc206

REF.

1

3

16DA-4004A-10 . RELAY, FUSE, INTERLOCK V77342,

No. KAP-14DG12

w-9746-3

RESISTOR, 100 OHM, 25 W., V44#5,

l No. 02OOF

401937-l STRIP, TERMINAL V%410, No. 35005-3526

‘401556: : MOUNT, SHOCK, RUl&R V81860,

No. ss-01.

3877368 ‘. -)

BOARD ASSY I MEMORY AND T IME DE LAY

401563-5

HOUSING, PIN, CONNECTOR

482038

’ iOARD ASSEMBLY OVER-UNDERVOLTAGE

40 1363-4 : . HOUSING, ?lN; CONNECTOR

482039 BOARD ASSEMBLY, OVER-UNDER-

* FREQUENCY

40 1563-4 HOUSING, PIN, CONNECTOR

76A-1118 l &ITCH SNAP PUSHBUTTON ~27192,

l No. S&BCB34:9

403336 RING, LOCKING, SWITCH V91929,

’ No. TS10397

HF-2518-2 . LIGHT, PILOT, FAULT, RED, 12 V.

400613-4

BULB, V71744, Type 1815

402658

l IkLDER, FUSE V71400, NO. HKP-HH

w-11166-1 :

FUSE, AGC, 2 A.

w-11166-1 FUSE, AGC, 2 A.

16DA-1997-6

: BUTTON, PLUG, HOLE V90763,

No. SS-51026

402037-9 GROMM T, RUBBER V02231,

l No. AGW-4211

2

1

12

1

15

.1

1.

1

16

1

17

18

19

2

20

21

22

23

24

25

1

Aug 25,‘85 1

4-3

UN ITS

EiY

Page 51

.

I

4-3

Page 52

Aug 25105 ;

. i

. .

_..

.N OME NC IATURE

UN ITS

FIGURE

4-l OBAR T

IIEMNO. PART NO.

1234567

EFF A&

* 18-26 388328-52

NAIv’EPIATE, IDENTlFfCATION

C

*

27 407566-11

: TERMINAL, SOCKET V89110,

No. 60619-l

* 28 401564-d

HOUSING, SO&T

35

CONNECTOR

’ V89110, No. 1-480;87-0

2

*

29.

A01564-5

HOUSING, SOCKET, CONNECTOR

l v89110, N

o. l-480438-0

1

30 482291

NAMEPLATE, PROTECTIVE SYSTEM

1

482286

: TRAY ASSEMBLY, PROTECTIVE RE LAYS

1

31 402383

S LIDE ASSEMBLY, TRAY (Cons ists of

l l four parts marked CR, CL, DR & D L)

V75358,No. 1336-12

1 set

32

404028

NAMEmATE, HOBART .

1

I

33 370382A

: : HAhDLE, TRAY

1

34

76A-1115

tATCH , ADJUSTABLE GRIP V94222

’ l No. 48-99-126-l 1

1

482287 TRAY ASSE MB LY

1

482307

l&NESS ASSEMBLY, WIRE, PROTECTIVE

RELAYS TRAY 1

.

Aug 25/85 :

/

Page 53

Control Box and Internal Components Group

Figure 19

4-3

Aug 25105

Pase~

~ ’

FIGURE

HOBART

ITEM ho. PART lu0.

J9-

No humber

1

402037-9

I

3"

404329-l

'400613-4

4

W-JOO5J-JO

5

W-10051-13

6'

402383

7

482236

.

~~O~~JCLATURE

1234567

C&TROL BOX AND 1NTERNAL

COMPOhENTS GROUP (For hHA See

Fig. 16)

GROMMET, RUBBER V02231,

l No. AGW-4211

LIGHT, PAtLEL V74400, ho. MI-321:

: . BULB V744d0, ho. 3271

.

CLAMP,’ WfRE, PLASTIC V81074,

ho. EC-10 -

w

CiAMP, WIRE, PLASTIC V81074,

Iwo. EC-14

SLIDE ASSEMBLY, TRAY (For Details

See Tray Assembl ies , Fig . 17 or 18)

BOX ASSEMBLY, CONTROL

*

--

‘._.,

EFF

.

Uh t-l-s

Ac;“s’v

REF.

2

1

2

1

REF.

J

.

Aug 25'85

I

1. \

4-3

Page 55

.

1

2

I

2A

3 4

IO

II

13

5 8

9

I I

12 13A

14

24

I

20 19

9

Ii3 16

I

I7

Engine Control Panel Assembly

Figure 20

4-3

Page 56

Aug 25,‘s ;

.

I“., i

*.

OM 2012

NOMENCLATUf?E

FIGURE

HOBART

ITEM NO. PART NO.

1234567

EFF

zo- 482296-2 PANEL ASSEMBLY, CONTROL, ENGINE

(For NHA See Fig. 4)

1

404329- 1

LIGHT ASSY, PANEL V74400, No. Ml-3216

: . B&B Vd400, No. 3271

2 12CW-J32OA-5 .

GAUGE, FUEL (OPTIONAL)

2A 16DA-1997-16 .

BUTTON, PLUG, HOLE V90763,

I

No. ss-48175

3 FW-1312

SWITCH, TOGGLE V27192, No. 732OK3

4

402889-Z

: AMMETER, V85925, No. 730-D-5

5 403189

SWITCH, TOGGLE V91929, No. 312TSl-59

6

403336 : RING, LOCKING, SWITCH V91929,

No. TS10397

7 W-9917-18

METER, ENGINE, HOUR V16476,

l No. 771-8/50

.

a DW-4304

*

GAUGE, TEMPERATURE, WATER

l v57733, .,No. 2100

9

W-2518-8

: . LIGHT,. PILOT, ENGINE & GENERATOR

I

GREEN

400613-4

BULB, ‘V74400, No. 3271

10

DW-6080

: ;jAUGE, PRESSURE, OIL V57733, No.

3529AW

11

w-10910-0

TEE, PlFE, V79470, No. 3700x2

12

402130 : SWITCH, PRESSURE, OIL, V74400,

No. M-4006

13 DELETED

13A

J6DA- 1997-5 .

BUTTON, PLUG, HOLE V90763,

No. SS-48172

14 402435 INDICATOR, SERVICE FILTER, AIR

I

l CLEANER V21585, No. L-14440-25

15

385765

CONTROL, ENGINE STOP OR CHOKE

’ V77574, No. R21PBK

16

W-J J 166-3

FUSE, AGC, JO AMP.

17 402658

: HOLDER, FUSE V71400, No. HKP-HH

ia 401937-3 STRIP, 7ERMlNAL V98410,

l No. 35012-3526

19

404100

SWITCH, PUSHBUTTON, STARTER

’ V70040, No. 1996027

,

Aug 25)s~

i *

UN ITS

AEt

REF.

J

1

‘1

1

J

REF.

1

J

4-3

I

Page57 . .

!

4-3

Aug 25,/&j i

,Puge 58

i

.

. NOMEhC MTURE

FIGURE

H OBAKT

ITEM I\rO.

PART t\c 0.

1234567

20- 20

21

JC Z-938

’ DIODE, S ILlCON V05277, I\lo. lb4820

401937-Z

: STRIP, TEKMlfuALV9&$10, kc,. 35008-

3526

403380

CAP & CHAltv ASSEMBLY VO2660,

l ho. 9760-28

4

482304

HARbESS ASSEMBLY, WIRE, TEST

l RECE.PTAC LE

482300

kAMEPLATE, COtuTROLs

400480-3

: TERMIhAL, QUICK COktvECT VO0779,

No. 42640-Z

J6DA-1997-4

BUTTON, PLUG, HOLE V90763,

l No. SS-48152

400701

COb&ECTOR, RIGHT At\r G lE V59730,

l No. TA-250-8

22

23

24

*

25

26

27

28

29

!

Uh ITS ’

EFF &

2

1

3

1

2

1

482297

W-2974-A

PANEL, COhTROL, EtuGlbE

1 RESISTOR -VARIABLE, 0.5 OHMS,

.

. lO@NATTs

B 1

*

.

Aug 25 ‘85

4-3

Page 59

Output Terminal Board Assembly

Figure 21

4-3

Page 60

Aug 25@ ’

.

. .

FIGURE

HOBART

ITEM ho. PART ho.

21-

4823 17

1

5OMS -732-O

2

W- i 1242-5

3

w-9549-19

4

482445

5 W-11097-18

6

W- J J 254-6

7

W-11242-10

8

482446

9 482443

10

w-11112-3

11 W-l 1254-3

12

W-l 1245-3

13 482444

OM 2012

c

1234567

EFF

BOARD ASSEMBLY, TERMlhAL, OUTPUT

(Fck &HA See Fig. 4)

. &UT, HEX, l/4-20, KEPS, MH, STEEL

.

WASHER, FLAT, l/4 ltu., STEE L

ROD, TERMIbAL l/4-20 X 2-l/4

: BRACKET, MOUt\(TIfuG, BOARD,

TERM., OUTPUT

AD

RE F

AD

12

AD

12

AD

2

. SCREW, HHC, STEEL, 3/8-16 X 3/4

WASHER, LOCK, STEE L, 3/8 IEU .

: WASHER, FLAT, STEE L, 3/S lb.

RETA IhER, CABLE

: BAR, BUS, PitASE

SCREW, RD. HD., MH, STEEL, JO-24

l x 3/4

. WASHER, JO, LOCK, STEEL

. WASHER, JO, FIAT, BRASS

AD

2

AD

8

AD

8

AD

8

AD

4

AD

4

.

BOARD, TERMNA L, OUTPUT

AD

.

mm

A&

e

I

Aug 25,‘85

I

4-3

I

Page 61

.

,-

FIGURE HOBART

ITEM NO.

PART NO.

22-

489331

481613

1

2

3

* 3A

*4

5

*6

7

a

9

10

387617A

387621

480235A

w-11102-18

482483

480669

w-11102-a

488755

lOOGHP-66

387623-l

w-loa75-i

GENERATOR ASSY (For NHA

See Fig. 4)

GENERATOR ASSY (For NRA

See Fig. 4)

< COVER, FAN, HOUSING

. COVER, EXCITER HOUSING

. FAN & COUPLING ASSEMBLY

. SCREW, FLEXIBLE COUPLING

. SCREW, RETAINING

. ADAPTER, FOOT, GEN.

. SCREW, GEN. MTC.

. COVER, END, EXCITER HOUSING

. WASHER, RETAINING

. CORE, ARMATURE ASSEMBLY

REF

1

1'

1

6"

1

2

6

1

w-10874-i

. .

DIODE, SILICON, 35 AMP,

NEGATIVE BASE, V51589, #ST460N

3

11

12

* 12A

13

14

15

.16

17

18

19

20

21

22

. .

DIODE, SILICON, 35 AMP,

POSITIVE BASE, v51589, #~~460~

. RING, SPACER, COUPLING

. .

SCREW, SPACER RING

. KEY, EXCITER

. HOUSING, EXCITER

. POLEPIECE, EXCITER

. INSULATION, EXCITER, WRAPPER

. -COIL, FIELD, EXCfTER

. HOUSING, FAN ASSEMBLY

. KEY, FLEXIBLE, COUPLING

23

24

* 2s

* 26

* 27

* 28

* 29

386612

w-11097-34

481379

387624A-1

LOONH-2

POONH-3

DATA 3190

38762OA-1

85B-ro3q

W-10072-& !

W-10072-69 :

489047 ii

388362B-1

387748-l

387748-2

488 993

385950

480603-l

480628

79A-1144

482305

.

BEARING, FRONT, V53035 7%~314~DuW’~fd *

. BEARING, REAR,

Vsxo~s #631oDDu~E3’,5RkS

ARMATURE, AC/DC

: ARMATURE, AC/DC

. HOUSING & STATOR ASSEMBLY

. HOUSING 8 STATOR ASSEMBLY

\\

I

. BRACKET, RETAINING BEARING

I

. INSULATION, TOE

. MOUNT, RUBBER

. WASHER, MOUNT

. NAMEPLATE, FAN 6 COUPLING

. HARNESS, REGULATOR

3

1

8

1

4

1 SET

1

16

6

1

REF

*

DO NOT SUBSTITUTE - REQUIRES 5/a - 11 X 2-3/4 GRADE 5 FOR SAFETY.

*

NOT ILLUSTRATED

NOMENCLATURE

-1234567

EFF

UNITS

per

ASSY

Auq 25/85

4-3

Page 63

P

Y

., r:

OM 2012

~-,

. .

‘:

I.-

FIGURE

HOBART

ITEM I’JO. PART h0.

230

ho &umber

4823 16

1

2

3

4

5

1

6

7

8

9

* 10

* 11

* 12

* 13

*

?4

* 15

4823 15

482311

387916

387915

480587A

401898-2

402194

481113

3 87947

387600

430278

ho rwmber

A-25

AW-626

.

_’

lu OMEfkClATURE

Uf\c JiS

1234567

EFF A%

l%Ah% ASSEMBLY, MCUhTlT\cG & LlFTlfvG

YOKE (For hHA See Fig. 1)

e

BRACKET, MOUhTIhG, SUPPORT, BOX,

COtvTROL

PAtwE L, SUPPORT, COhTROL BOX

: YOKE, LfFTIf\rG

.

TRAC K, RO LL-OUT , R IGHT

B

TRACK;ROLL-OUT, ‘LEFT

: FRAM, MOUtvTfhG

B

CAM, FOLLOWER V92563, ho. CF-?-l/2

: FITTfhG, GREASE V95879, ho. 1728-J

B

PLATE, EtuD, REAR (Part of Item 6 Assembly)

: STOP, fRAME, MOUhThG B

BRACKET, RETAItuIhG, FRAME

: GROMMET, RUBBER V89616, ho. TPR#?8?2

B

.

AUXMARY FRAME B COMPOtuEfwlI

(For Detaib See Fig. 24) .

WASHER, ff’NlATOR

: BUSHfhG .-,

C

REF.

2

1

10

1

2

3

:

1

Aug 25185

i

4-3

Page 65

4-3

Page 66

Auxiliary Frame and Components

Figure 24

Aug 25 ‘85

I

oy 2012

c

FIGURE HOBART

. NOMENCLATUPZ.

ITEM NO.

PART NO. 1234567

E.FF

w

24-

No Number

AUXJLIARY FRAME & COMPONENTS

C

1

403492-1 .

BATTERY, 6 VOLT, AABM GROUP 7D,

V20038, #HHD-70, or equiv.

C

480674 .

2

480675

BOX, BATTERY, AS;EMBLY

C

. . LID, BATTERY, BOX

* c

*

3 , 402037-23 ‘. .

GROMMET, RUBBER V70485, t1877 C

4 - ?6DA-4133-2 . .

STUD, FASTENER, l/4 TURN

V24248, #5-RA-300 C

5 480676 . .

BOX, BATTERY, SUB-ASSEMBLY C

* 6

?OOGH-664 .

CABlE, BATTERY, CONNECTIONS C

*. 7

388828-5 .

CABLE, BATTERY, NEGATNE

C

* 8

357177-2 .

CABLE, BATTERY, POSITIVE

C

9

480733 .

CLAMP, BATTERY

c

*

. 10

480776

FITTINGS, FUEL TANK ASSY

* (For Details See Fig. 25)

c

?1

480652

. FRPME, MTG. ASSEMBLY

C

12

13 Eiw-2048 .

Deleted

ROD, BATTERY, CLAMP

C

*

14 .‘,

6FW-5072

0

:. PROTECTOSEAL FfLL UNiT Vk9234,

1273A

c

15

480711

SUPPORT, BATTERY, ASSY.

16 480764

: TANK, FUEL ASSEMBLY

C

17 .

404030-2 . .

SENDER, FUEL, *GAUGE V57733,

8385-C

C

18

DE i&D

19

480662

* 20

?2CW-?32OA-5 :

PLATE, END, REAR

c

GAUGE, FUEL, ELECTRIC

V98738 f301 -H

C

UN ITS

AEC

Ref

2

1

2

1

2

1

v.

1:

1

.

!

Aug 25,/s \

4-3

Page 67

_i

:

.

TO OUTLET Sf’W

IN FUEL TANK

TO RETURN SPUD

IN FUEL TANK

x-

‘TO FUEL

RETURN UNE

~6 FUEL

SUCTION LINE

Fuel Tank Fittings Assembly

Figure 25

4-3

Page 68

.

FIGURE

ITEM NO.

250

1

2

W-l 07603

3

12CW-2077-3 :

4 ’

5

6

W-10891-1 1 .

I

OM : 2012

. .

._

H&ART

N?MENCLATURE

PART NO.

1234567

480776

FITTINGS Am’, FUEL TANK

W-10891-10 .

.

EFF

;:

ELBOW, MALE t WEATHERIiEAD,,

V79470, #49 x 8 x 8

NIPPLE, PIPE, l/2

ELBOW, STREET ELF

#l/2 x ?-l/8 x l-518

V80996

BUSHING, PIPE 3/4x l/2

VALVE, BALL Vi3902

F-125R

ELBOW, MALE, WEATHERHEAD

V79470, g49 x 10

W-7814-5

400819-1 :

C

UNIiS

i&Y

Ref

1

2

Avg 25185

i

4-3

Page 69

v-----------------

F

-------w-e---------

11

I

.

I

f

I

i

L

Governor Control Unit

----se-----m-----e-

;

§ T

3

TY

{I]

‘1

.

. .

4-3

Page 70

Suppression Kit

Figum 26

Aug 25 ‘85

FIGURE HOBART

ITEM NO.

PART NO.

26-

482337

1

401427-7

2

482338

3

400829-5

+

Aug 25185

I

NOMENCLATURE

1234567

KIT, SUPPRESSKIN (For NHA See Fig.

CAPACITOR, 0.01 pF t- ?OY’o, 100 W’

l VDC

BOARD, MOUNTING,

: LUG, TERMINAL

! c

I

j

UNITS .-’

EFF

81

D REF

4

1 :

6

4-3

Page 71

. .

,I.(

:-

,.

Q

3:

c

OM 2012

:.

.’

FIGURE

HOBART

ITEM NO. PART NO.

27-

485262

1

485260

2

400400

3 400585

4

485291

5

485235

*

485261

485259

6

485244

7

402037-5

8

w-10051-5

9

402658

10 ?6DA-4252-16

11

‘8044-7096

12

8oGm92

_,I s

.I

i :‘. a:~

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NOMENCLATURE

1234567

KIT, 24 V DC POWER SUPPLY ASSEMBLY

(For NHA See Fig. 4)

COVER, MODUI+, ASSEMBLY

: SWITCH, TOGGLE, DPDT V73559,

No. 2GLGl TABS

‘GUARD, TOGGLE, SWITCH V27192

l No. 8497K-1

TAB, TE DOWN, SWITCH GUARD

: NAME PLATE, SWITCH

HARNESS, WIRING POWER SUPPLY

: MODULE, POWER SUPPLY 24 V A

EFF

D

SUPPORT, PO’hER MODULE, ASSY

: : GROMMET, RUBBER VO2231,

D

No. wGW-2511

6

CLAMP, WIRE, PLASTIC 3/8 V81074

l l No. EC-6.

:

HOLDER;.FUSE ‘V71400, No. HKP-HH

0’

: FUSE, 2 AM?, MDL. V71400,

D

*y&v;- ;. .:

0

LABEI., FU% MDL. 2 AMP

: : SUPPLY, POWER, DC, 10 AMP

D

UNITS

SY

1

2

1

1’

1

.

CHAPTER 6. MANUFACTURER5 INFORMATION

Detroit Diesel In-Line Engine (4971N) Operator 5 Manual

American Bosch Electric Speed Control Governor Srtem HANDBOOK, Edition C

(or later)

Hobart Voltage Regulator Manual TM-232

.I

Hobart Coupling Manua I TM-736

I

Hobart Exciter Rotor Manual TM-360

Ovenpeed Governor

- Synchro-Start Products Inc.

Adjustment, Maintenance, Service Instructions

Hobart Drawings (Reduced)

482099 -Connection Power Module

181071- Schematic Engine

482360 -Schematic Generator

482362 .-Connection Engine

1’80894 - Connect ion Generator

482365 - Connection Genera& Tray

.

&32366-c

onnection P.R. Tray

485292 - Schematic, Generator @3!5?1%9- only)

485293 - Connection, Generator (535$@-,S’ only)

Apg 21/88 Revised

6-O

.y+

.:

,_

‘,..’

:: .,. ..,

1.

.

Hobart 5359D Operation and Maintenance Manual

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Hobart 5359D Operation and Maintenance Manual

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