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Hobart 90 C 20 Operation And Maintenance Manual

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OM-2031
080187
Revised 080589
Revised 032293
Revised 100195
Revised 043096
OPERATION AND MAINTENANCE
ENGINE-DRIVEN GENERATOR SET
90-KVA, 400-HZ, 115/200-V AC, 3-PHASE
SPECIFICATION
NUMBER
6911-1, 6911A-1
6911-2, 6911A-2
6911-3, 6911A-3
6911A-4
6911A-5*
MANUAL
ILLUSTRATED PARTS LIST
Series Numbers 6911 and 6911A
MODEL 90 C 20
MOUNTING
Trailer or Truck
Trailer or Truck
Tractor
Fixed Unit With Fuel
Tank and Batteries
Trailer or Truck
Hobart Brothers Company
Ground Power Division
Troy, Ohio 45373
with
for
VOLTAGE REGULATOR
USED
430391C
489812A
489812A
430391C
489812A
U.S.A.

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  • Page 1 Revised 100195 Revised 043096 OPERATION AND MAINTENANCE MANUAL with ILLUSTRATED PARTS LIST ENGINE-DRIVEN GENERATOR SET Series Numbers 6911 and 6911A MODEL 90 C 20 90-KVA, 400-HZ, 115/200-V AC, 3-PHASE SPECIFICATION VOLTAGE REGULATOR MOUNTING NUMBER USED 6911-1, 6911A-1 Trailer or Truck...
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  • Page 3 SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT WARNING ELECTRIC SHOCK can KILL. Do not touch live electrical parts. ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible material. DO NOT use power cables to break load and prevent tools from causing short circuits. IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.
  • Page 4 a. Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the equipment. b. Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally. c. Disconnect power to equipment if it is out of service. d.
  • Page 5 OM-2031 LIST OF EFFECTIVE PAGES CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE List of Aug 5/89 Aug 5/89 Effective Aug 5/89 Aug 5/89 Pages Aug 5/89 Aug 5/89 29 Aug 5/89 Introduction Aug 5/89 Aug 5/89 31 Aug 5/89 Contents Aug 5/89 Aug 5/89...
  • Page 6 OM-2031 LIST OF EFFECTIVE PAGES (CONTINUED) CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE Aug 5/89 Aug 5/89 Aug 5/89 Jun 20/89 15/16 Jun 20/89 10 Jun 20/89 11 Jun 20/89 Jun 20/89 12 Jun 20/89 Jun 20/89 13 Jun 20/89 Aug 5/89 14 Aug 5/89 Aug 5/89...
  • Page 7 OM-2031 LIST OF EFFECTIVE PAGES (CONTINUED) CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89 Aug 5/89...
  • Page 8 OM-2031 This page intentionally left blank List of Effective Pages August 5/89 Revised Page 4...

  • Page 9: Table Of Contents

    E. Quick Start Kit 6. Canopy 7. Engine, Generator, and Controls Assembly A. Basic Engine B. Engine Manufacturer’s Equipment C. Hobart Engine Equipment (1) Electric governor system (a) Magnetic pickup (b) Control unit (c) Actuator (2) Engine electrical system (3) Engine protective devices...
  • Page 10 OM-2031 SUBJECT CHAPTER/SECTION PAGE D. Generator E. Control Box Assembly (1) Generator control tray (a) Resistors (b) Generator output monitors (meters) (c) Meter and line switches (d) Receptacle connector (e) Tray (f) Manual voltage control (g) Excitation-deenergization relay (2) Protective relay tray (a) Sensing modules (b) Memory and time delay module (c) Indicating lights...
  • Page 11 OM-2031 SUBJECT CHAPTER/SECTION PAGE 2. Preparation for Storage A. General B. Temporary Storage C. Long Time Storage (Over 30 Days) 3. Preparation for Shipment (Tractor-Mounted Units Only) SECTION 3. OPERATION 1.General 2. Operating the Generator Set A. Pre-start Inspection B. Normal Engine Starting Procedures C.
  • Page 12 OM-2031 SUBJECT CHAPTER/SECTION PAGE D. Engine (1) Lubrication schedule (2) Oil specification (3) Oil viscosity (4) Changing engine oil (5) Changing engine oil filter E. Starter 5. Air Cleaner Service A. Cartridge Removal B. Cartridge Installation 6. Engine Fuel A. Quality B.
  • Page 13 OM-2031 SUBJECT CHAPTER/SECTION PAGE C. Coolant D. V-Belts E. Exhaust System 3.Electrical System (12-V DC) A. Lights B. Fuses C. Wiring and Connections 4. Electrical System (115-V AC) A. Monitoring Instruments B. Indicating Lights C. Protective Modules D. Wiring and Connections 5.
  • Page 14 OM-2031 SUBJECT CHAPTER/SECTION PAGE 6. Test Values 7. Checking Connections and Leads 8. Electric Governor Trouble Shooting 9. Engine Trouble Shooting Procedures A. General 3-1 4 CHAPTER 4. ILLUSTRATED PARTS LIST SECTION 1. INTRODUCTION 1. General 2. Purpose 3. Arrangement 4.
  • Page 15 This manual contains operation and maintenance information for a series of 400-Hertz generator sets manufactured by Hobart Brothers Company, Power Systems Group, Troy, Ohio 45373. This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide information and instructions to experienced operators, electricians, and mechanics who have never seen or operated this equipment.
  • Page 16 OM-2031 This page intentionally left blank Introduction August 5/89 Revised Page 2...

  • Page 17: Section 1. Description

    OM-2031 CHAPTER 1. DESCRIPTION/OPERATION SECTION 1. DESCRIPTION 1. General The generator sets (see Fig. 1) covered by the manual are identified by Series No. 6911 & 6911A. The various configurations of the set are identified by adding a dash number (-1, -2, etc.) suffix to the Series number.
  • Page 18 OM-2031 1. Canopy 6. Output cable horn 2. Access-vent covers 7. Mounting frame 3. Lifting eye 8. Engine fan exhaust deflectors 4. Windows 9. Engine exhaust pipe 5. Output receptacle cover 10. Radiator cap access cover Generator Set Figure 1 April 30/96 Revised Page 2...

  • Page 19: A.protective Monitor

    A receptacle connector (19, Fig. 9) with wiring to various test points throughout the electrical cir- cuitry is provided for the attachment of a test box manufactured by Hobart Brothers. This test cir- cuitry allows electricians to perform as many as twenty-four tests and checks from one location, conveniently and easily.
  • Page 20 OM-2031 PHYSICAL BASIC UNIT Length overall 82 inches (2082.8 mm) Width 36 inches (914.4 mm) Height overall 43 inches (1092.2 mm) Weight 3050 pounds (1383.2 kg) TRAILER-MOUNTED UNIT Length overall 100 inches (2540 mm) Width 78 inches (1981.2 mm) Height overall 72 inches (1828.8 mm) Weight 4950 pounds (2244.9 kg)

  • Page 21: Identification

    OM-2031 Engine Manufacturer Cummins Model 6BTA5.9 Type Turbocharged, in-line, 6-cylinder, 4-cycle diesel Displacement 359 cu. in. (5.8 liters) Compression ratio 16.5:1 Firing order 1-5-3-6-2-4 Number of Main bearings Horsepower at 2000 RPM Governed speed 2000 RPM +/- 4.5% Idle Speed 850 RPM +/- 25 RPM Electrical System 12-volt...

  • Page 22: Optional Equipment

    OM-2031 5. Optional Equipment Several items of optional equipment are available for the 6911 Series unit. Each piece of optional equipment is covered by its own Instruction and Parts Manual and will not be covered in this basic manual. When applicable, information for optional equipment will be located in Chapter 5. Options are listed as follows: A.

  • Page 23: Engine, Generator, And Controls Assembly

    OM-2031 This generator set is equipped with a canopy having doors on both sides. Panel mounted instruments may be observed through two Plexiglass windows in the left rear door which covers the control box and engine control panel. The lower window is slanted outward at the bottom to provide access to en- gine controls when the door is closed.
  • Page 24 OM-2031 1. Mounting frame 8. Air cleaner 14. Engine control panel 2. Generator 9. Lifting yoke *15. Cable horn and clamp 3. Power module 10. Engine 16. Radiator 4. Control box 11. Engine exhaust pipe *17. Fuel valve solenoid *5. Governor control box 12.

  • Page 25: Hobart Engine Equipment

    OM-2031 C. Hobart Engine Equipment The engine is modified at Hobart Brothers by the addition of the following equipment: (1) Electric governor system An electric governor kit is installed on the engine to replace a conventional, mechanical type. The electric governor was selected for control of engine speed (and generator output fre- quency) because it provides faster engine response to changes in load conditions.

  • Page 26: Air Cleaner

    OM-2031 (b) Oil pressure switch A diaphragm-type switch monitors the pressure in the lubricating oil system. It is mounted in the side of the cylinder block (18, Fig. 3) . If the pressure in the lube oil system falls to 10 psi (69 kPa) , this switch opens and actuates the fuel valve solenoid which shuts down the engine.
  • Page 27 OM-2031 1. Viewing chamber 2. Indicating “flag” 3. Reset button Air Cleaner and Service Indicator Figure 4 April 30/96 Revised Page 11...

  • Page 28: Exhaust System

    OM-2031 (5) Exhaust system The exhaust system consists of a special noise reducing muffler (3, Fig. 5) which is con- nected by a pipe (2) to a conventional exhaust manifold (1). Baffles in the tail pipe outlet di- rect exhaust and noise downward. (6) Radiator The radiator (16, Fig.

  • Page 29: Generator

    OM-2031 D. Generator The 400-Hz generator is a brushless, revolving field, three-phase, alternating current type. The ro- tor assembly is mounted by two, permanently lubricated, sealed, ball bearings. The front bearing is supported by the fan housing; the rear bearing is mounted in the exciter housing. Both of these housings are attached to the main generator stator housing.

  • Page 30: (B) Generator Output Monitors (Meters)

    OM-2031 Control Box Figure 6 (b) Generator output monitors (meters) The generator output is monitored by three instruments; a frequency meter (10) , a voltme- ter (9) , and an ammeter (7) . The frequency meter is a resonant-reed type, and indicates the frequency of the generator output alternating current in the range of 380 to 420 Hz (cycles per second) .

  • Page 31: (C) Meter And Line Switches

    OM-2031 (c) Meter and line switches These switches 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 nameplate (4) , located under the switch knob, is marked and lettered to indicate the three functional posi- tions of the meter switch.

  • Page 32: (D) Receptacle Connector

    OM-2031 1. Resistor (50 ohm, 100 watt) 9. Voltmeter 2. Resistor (25 ohm, 100 watt) 10. Frequency meter 3. Excitation-deenergization relay 11. Automatic-manual switch 4. Instruction plate 12. Receptacle connector 5. Line selector toggle switch 13. Manual voltage control rheostat 6.
  • Page 33 OM-2031 (a) Sensing modules The voltage sensing module (5) and frequency sensing module (6) are connected to gen- erator output leads between the generator and load contactor. These solid-state modules sense any abnormal condition of voltage or frequency and signal the solid-state circuitry of the memory and time delay module (4) to open the load contactor and disconnect out- put to the aircraft.

  • Page 34: (F) Resistor

    OM-2031 (c) Indicating lights The function of these lights (10, 11, 13, 14 and 15) is to indicate, to the operator, the ab- normal condition of overvoltage, underfrequency, etc., which caused the protective moni- tor system to function. Each of the five lights is connected to an actuating circuit within the memory and time delay module.

  • Page 35: (G) Fuse-Interlock Relay

    OM-2031 1. Plug-interlock relay 12. Tray fastener 2. Fuse-interlock relay 13. Overfrequency indicating light 3. Auxiliary underfrequency 14. Undervoltage indicating light relay 15. Overvoltage indicating light 4. Memory and time delay module 16. Load contactor circuit fuse 5. Over-undervoltage module (2 A) 6.
  • Page 36 OM-2031 (h) 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. (k) Auxiliary underfrequency relay The function of the auxiliary underfrequency relay (3) is to automatically open the excita- tion-deenergization relay and disconnect the voltage regulator anytime generator fre- quency drops to 380 Hz or below.
  • Page 37 OM-2031 (d) Hourmeter The hourmeter (6) is electrically driven from the 12-V DC battery system. The hourmeter measures and records engine running time and will record up to 9999.9 hours on five revolving drums. The hourme- ter operates only when the engine is running and the oil pressure switch is closed. (e) Fuel gage and blocking diodes An electric fuel gage (2, Fig.
  • Page 38 OM-2031 (d) Engine starting circuit The pushbutton start switch (15) and permissive toggle switch (18) serve to connect power for closing an auxiliary solenoid switch. The auxiliary switch then connects power to the starter solenoid which func- tions to engage the starter gear with the flywheel ring gear and apply power to the starter motor to crank the engine.

  • Page 39: Engine Control Panel

    OM-2031 1. Panel light 12. Air cleaner indicator 2. Fuel gage 13. Engine circuit fuse (10-A) 3. Light switch 14. Engine “ON” indicating light 4. DC Ammeter 15. Engine starter switch 5. Engine-generator control switch 16. (Deleted) 6. Hourmeter 17. Terminal board 7.

  • Page 40: Voltage Regulator

    OM-2031 G. Voltage Regulator Mag-Amp type, Hobart Part No. 430391C, See TM-759 in Chapter 6 of this manual. Solid-State type, Hobart Part No. 489812A, See OM-2020 in Chapter 6 of this manual. H. Power Module Panel Assembly The power module panel assembly (Fig. 10) sometimes referred to as the “contactor panel”, is located at the right rear of the machine behind the control box.
  • Page 41 OM-2031 (3) Overload module The overload module (7) is a solid-state device designed to interpret a signal from trans- formers (3) and to send a signal to the protective monitor module (4, Fig. 8) when an over- load condition exists in any generator output phase. A pull-apart electrical connector is mounted on the overload module to provide quick-disconnect facilities for all wiring to the module.

  • Page 42: Power Module Panel Assembly

    OM-2031 1. Overload resistor (16.6 ohm, 25 watt) 2. Terminal board 3. Overload current transformer 4. Ammeter current transformer 5. Rectifier 6. Load contactor 7. Overload module 8. Line drop resistor (50 ohm, 25 watt) 9. Line drop current transformer 10.

  • Page 43: Test Box

    OM-2031 8. Test Box The test box is an optional accessory item used for testing the generator set. All generator sets are wired to accommodate a test box, however, the box is supplied only when ordered (Part Number 388318A-1). A. Description (See Fig. 11) The test box assembly consists of a rotary selector switch, momentary contact pushbut- ton switch, and two, insulated-tip test jacks, mounted in a small metal box.

  • Page 44: Theory Of Operation

    NOTE: Radiator MUST be refilled after a low-coolant shutdown before engine can be restarted. C. Emergency Stop Switch This switch, Hobart Part Number 285958, on the generator set control panel, is used manually by the operator to stop the engine quickly and safely in the event of an emer- gency observed by the operator.

  • Page 45: Storage, Or Shipping

    Other generator sets, when ordered with truck or trailer, are mounted at the Hobart factory and are shipped in running condition and ready for operation after inspection and check. WARNING: IMPROPER OPERATION CAN KILL, INJURE, OR CAUSE DAM- AGE! READ AND UNDERSTAND OPERATING INSTRUCTIONS IN SECTION 1- 3 BEFORE OPERATING THE UNIT.

  • Page 46: (B) Engine Coolant

    OM-2031 (b) Engine coolant The radiator cap is accessible by opening the hinged access cover on the front canopy housing. Cool- ant level should be approximately one inch below the filler neck. Allow a capacity for coolant expan- sion. CAUTION: BE SURE THE COOLING SYSTEM ANTIFREEZE SOLUTION IS ADEQUATE TO PRO- TECT BELOW LOWEST TEMPERATURE EXPECTED.
  • Page 47 OM-2031 (c) Each terminal stud is identified by an 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 se- curely. Connect small plug interlock lead “E” or “F” to terminal “E” or “F”. (d) Tighten clamp screws securely, but avoid damage to cable insulation.

  • Page 48: Preparation For Storage

    OM-2031 T-R Output Cable Installation Figure 2 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.

  • Page 49: Temporary Storage

    OM-2031 B. Temporary Storage When storing the unit for 30 days or less, prepare as follows: (1) Lubricate the unit completely in accordance with instructions in Sect. 2-1. This will include chang- ing engine oil, and all filter elements. (2) Start the engine and operate for about two minutes so that all internal engine components will be coated with new oil.

  • Page 50: Preparation For Shipment (Tractor-Mounted Units Only)

    OM-2031 3. Preparation for Shipment (Tractor-Mounted Units Only) During long shipments by rail (and other) the generator set retaining hardware may become loosened by vibration, jolting, etc. CAUTION: WHEN SHIPPING THE UNIT (MOUNTED IN A TOW TRACTOR), PROVIDE ADDITIONAL RETAINING MATERIALS TO MAKE CERTAIN THE GENERATOR SET CANNOT ROLL OUT OF THE TOW TRACTOR.

  • Page 51: Section 3. Operation

    OM-2031 SECTION 3. OPERATION 1.General 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 400-Hz power to an aircraft. WARNING: IMPROPER OPERATION CAN KILL! EAR PROTECTION EQUIP- MENT MAY BE NECESSARY WHEN WORKING IN CLOSE PROXIMITY TO THIS EQUIPMENT.
  • Page 52 OM-2031 1. Frequency meter 18. Engine-generator control switch 2. Voltmeter 19. Hourmeter 3. Fastener 20. Load contactor control switch 4. AC Ammeter 21. Coolant temperature gage 5. Meter switch 22. Load contactor indicating light 6. Line switch 23. Oil pressure gage 7.
  • Page 53 OM-2031 32. Manual voltage control rheostat 35. Light test switch 33. Automatic-manual voltage control 36. Reset switch switch 34. Test bank switch Operating Controls and Instruments Figure 1 (Sheet 2 of 2) October 1/95 Revised Page 3...

  • Page 54: Cold Weather Engine Starting Procedures

    OM-2031 C. Cold Weather Engine Starting Procedures A cold weather starting-aid kit (Fig. 2) is provided to assist in starting the engine at temperatures be- low 50 degree F. To start the engine, using the starting aid, proceed as follows: (1) Position switches and controls as instructed in steps (1) through (4), paragraph B, Normal Engine Starting Procedures, above.

  • Page 55: Preparation For Power Delivery 1-3

    OM-2031 (3) Cold weather starting procedures are exactly the same as for normal starting except: (a) Before cranking the engine, pull the starting aid control (24, Fig. 1) OUT to the full extent of its travel. Hold for 2 to 3 seconds. (This allows the starting aid valve chamber to fill with pressurized ethyl ether.) (b) Push the control IN.

  • Page 56: Preparation For Power Delivery (Manual Voltage Control) 1-3

    OM-2031 NOTE: If the indicating light (22) should “go-out” as soon as the switch is released, and no fault lights are ON, it indicates that 28.5-V DC holding current is not being supplied from the aircraft to the plug-interlock relay. Correct the condition an again operate the load contactor control switch (20) as above.

  • Page 57: Test Box Operation

    OM-2031 3. Test Box Operation The test box is useful and convenient in testing the generator set after repair or overhaul and also in trouble shooting. To operate the test box, proceed as follows: A. Open left, rear canopy doors and connect the test box plug connector (see 1-1; 3, Fig. 14) to the test receptacle connector (Fig.

  • Page 58: Transformer-Rectifier Operation

    AC delivery, except do not connect AC output cable and do not close AC load contactor (see Para. 2, D and E). (2) For T-R operating instructions, see Hobart Manual No. OM-433. B. Simultaneous 28.5-V DC and 115-V AC Power Delivery If both 28.5-V DC and 115-V AC must be delivered at the same time, the following rules and precau-...

  • Page 59: Trailer Operation

    OM-2031 Transformer-Rectifier Figure 5 6. Trailer Operation (Optional) A. Towing Observe the following rules when towing the trailer. (1) Be sure all output cables are disconnected and properly stowed. (2) Be sure parking brake is released. (3) Avoid turns which are shorter than the steering linkage will freely allow. (4) Avoid dangerous speed and sudden turns.
  • Page 60 The low fuel shutdown assembly, when requested as an option by a customer, may be used with all generator set specifications covered by this manual. It is identified by Hobart Part Number 285953 . Its purpose is to stop the engine when the fuel level in the fuel tank becomes low before the unit runs out of fuel.
  • Page 61 OM-2031 Location of Low Fuel Level Switch Figure 7 C. Checking Operation of the Low Fuel Shutdown Assembly The low fuel shutdown sensor (S54) has a TEST terminal, which permits testing of the sensor by elec- trically simulating a low fuel condition. To check operation of the low fuel shutdown sensor: (1) Turn on the generator set and operate it at idle speed.
  • Page 62 The following chart is a list of the major items which comprise the low fuel shutdown assembly, except for hardware which is available from any hardware store. If it becomes necessary to replace any of the items listed below, these items may be ordered from Hobart Brothers Company using their part numbers as given below.
  • Page 63 8. Low Coolant Shutdown Assembly A. Description The low coolant shutdown assembly, when provided, is used with Specification 6911A-5 Hobart en- gine-drive generator sets. Its purpose is to stop the engine before overheating, caused by low cool- ant level, can occur. A liquid-level detector, mounted in the radiator, opens the power to the engine coolant level solenoid when coolant drops to a predetermined level in the radiator.
  • Page 64 The following chart is a list of the major items which comprise the low coolant shutdown assembly, ex- cept for hardware which is available from any hardware store. If it becomes necessary to replace any of the items listed below, these items may be ordered from Hobart Brothers Company using their part numbers as given below.
  • Page 65 The following chart is a list of the major items which comprise the emergency stop sensor assembly, except for hardware which is available from any hardware store. If it becomes necessary to replace any of the items listed below, these items may be ordered from Hobart Brothers Company using their part numbers as given below.

  • Page 66: Service Information

    OM-2031 10. Service Information If you have any questions concerning your Hobart Ground Power Division equipment, you are in- vited to contact our Service Department by mail, telephone or FAX. Write: Hobart Brother Company Ground Power Division Service Department 1177 Trade Square East Troy, Ohio 45373 U.S.A.

  • Page 67: Chapter 2. Service

    OM-2031 CHAPTER 2. SERVICE SECTION 1. MAINTENANCE 1. General To make certain the generator set is always ready for operation, it must be inspected and maintained regularly and systematically so that defects may be discovered and corrected before they result in serious damage or failure of the equipment.
  • Page 68 OM-2031 Roll-Out Stop-Bar (For tractor-mounted units only) Figure 1 1. Attaching hardware: nuts, screws, and lockwashers 2. Retaining brackets Generator Set Retaining Components (Tractor-mounted unit only) Figure 2 November 18/91 Revised Page 2...

  • Page 69: Lubrication

    OM-2031 4. Lubrication A. General Proper lubrication is one of the most important steps in good maintenance procedures. Proper lubrication means the use of correct lubricants and adherence to a proper time schedule. Frequency of lubrication and recommended lubricants are indicated in Figure 3. B.

  • Page 70: Changing Engine Oil

    OM-2031 (4) Changing engine oil Change engine lubricating oil following the instructions in the Cummins Engine Shop Manual (Chapter 6). Lube oil capacity for this engine is 17.3 QUARTS. (5) Changing engine oil filter Change the oil filter following the instructions in the Cummins Engine Shop Manual (Chapter 6). E.

  • Page 71: Air Cleaner Service

    OM-2031 5. Air Cleaner Service The air cleaner is a dry type with replaceable filter cartridges. A definite time schedule for changing the filter cartridge cannot be determined because of varying operating conditions. Change the filter cartridge when the red indicator “flag” reaches the top of the viewing chamber and locks in that position. Change the cartridge as follows: A.

  • Page 72: Engine Fuel

    OM-2031 6. Engine Fuel A. Recommendations/Specifications The quality of fuel oil used in the diesel engine is a major factor in engine performance and life. Fuel oil must be clean, completely distilled, stable and non-corrosive. Use low sulphur content fuel having a cloud point that is at least 10 below the lowest expected fuel temperature.

  • Page 73: General

    OM-2031 B. Radiator Cap (1) General A pressure valve is built into the radiator cap. It is designed to open at a pressure of approximately seven pounds per square inch. (2) Removal WARNING ! Hot steam and fluids will severely burn! When removing cap from a very hot radiator, do not turn cap past safety stop until all pressure or steam has escaped.

  • Page 74: Preparing The Coolant Solution

    OM-2031 (3) Preparing the coolant solution The following table (Figure 5) indicates the freezing points of solutions varying from 16% antifreeze to 65% antifreeze. Percentages are based on permanent type (Ethylene Glycol) antifreeze. Most antifreeze containers have a similar table printed on the label. (4) Installing the antifreeze solution Before installing antifreeze in the system, make the following checks: (a) Check the system for signs of leaks.

  • Page 75: Cleaning The Cooling System

    OM-2031 F. Cleaning the Cooling System Drain and thoroughly flush the cooling system twice a year or more often if necessary. The appearance of rust in the radiator, or in the coolant is an indication that the inhibitor has become weakened and it is possible that some sludge has accumulated in the system.

  • Page 76: Generator Maintenance

    OM-2031 8. Generator Maintenance The 400-Hz generator requires no maintenance or service other than periodic cleaning. The unit is brushless, and bearings are permanently lubricated and sealed. WARNING ! Electric shock and fire can kill or injure! BE sure the unit is completely dry before operating.

  • Page 77: Service Helps

    OM-2031 11. Service Helps A. Wiring All small wire leads are routed through plastic flexible conduit which protects them and makes a neat easily removable and replaceable wiring harness arrangement. This wiring method allows the replacement of a single wire lead with a minimum of difficulty. All wires are color coded. B.Control Box Trays Control box trays may be removed easily and moved to a work bench for service or replacement of parts.

  • Page 78: Generator Exciter

    OM-2031 C. Generator Exciter Provisions have been made to allow removal of the generator exciter without disturbing or removing the complete generator. (1) Preparation for exciter removal. (a) Remove main frame rear cross member by removing four attaching cap screws (See Fig. 7). (2) Exciter removal Refer to TM-360 in Chapter 6 for exciter instructions.

  • Page 79: Engine Control Panel

    OM-2031 D. Engine Control Panel The engine control panel is designed and mounted in such a manner that it may be released from its mounted position and tilted outward for access to components mounted on the back side (see Fig. 8). Do not disconnect the wires.
  • Page 80 OM-2031 This page intentionally left blank November 18/91 Revised Page 14...

  • Page 81: Section 2. Inspection/Check

    OM-2031 SECTION 2. INSPECTION/CHECK 1. General This section describes inspections and checks to be performed in conjunction with Inspection/Check Schedule, Figure 1. 2. Engine A. Fuel (See Fig. 1 for time schedules) (1) Check fuel quantity DAILY. (2) Drain fuel filters and change fuel filter elements in accordance with instructions in Cummins Shop Manual.
  • Page 82 OM-2031 Daily Weekly Weekly Monthly Monthly 6 Mo. 8 Hrs. 50 Hrs. 100 Hrs. 200 Hrs. 400 Hrs. 1200 Hrs. ENGINE Check fuel quantity Check crankcase oil level Check coolant level Change engine oil filter element Change engine oil Replace air cleaner cartridge Inspect cooling system hoses, tubes, fittings &...

  • Page 83: Electrical System (12-V Dc)

    OM-2031 (3) Replace any defective parts at once. WARNING: EXHAUST FUMES OR FIRE CAN KILL OR INJURE! IMMEDIATELY REPAIR DEFECTIVE EXHAUST SYSTEMS. 3.Electrical System (12-V DC) A. Lights Check all lights for proper operation DAILY. Replace any defective lamps (bulbs) as soon as discovered. Figure 2 lists ALL lamps, their location, and part numbers.

  • Page 84: Electrical System (115-V Ac)

    OM-2031 (2) Check electrical connections for looseness. NOTE: A darkened terminal 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. However, some regular checks should be made to be sure all controls, instruments, etc., are working properly.

  • Page 85: Trailer And Truck

    If the generator set comes with either the trailer or truck option, refer to Chapter 5 for the number of the Hobart manual which covers the particular option. The manual referred to will provide the appropriate in- spection procedure. Both manuals cover batteries, as, when either option is used, the batteries are in- stalled within it.
  • Page 86 OM-2031 This page intentionally left blank August 5/89 Revised Page 6...

  • Page 87: Section 3. Adjustment/Test

    OM-2031 SECTION 3. ADJUSTMENT/TEST 1. General Adjustment and test procedures are most applicable to testing and adjusting the generator set after a ma- jor repair, replacement of parts, or overhaul. 2. Generator 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.
  • Page 88 OM-2031 (dd) Disconnect jumper leads. (b) Flashing exciter field without test box. (aa) Remove test receptacle cover (1-3; Fig. 4). Use two test leads equipped with a test prod on one end and an “alligator” clip on the other. Insert the test prod of one lead in terminal “D” of the test receptacle (see Fig.
  • Page 89 OM-2031 1. Frequency meter 17. DC Ammeter 2. Voltmeter 18. Engine-generator control switch 3. Fastener 19. Hourmeter 4. AC Ammeter 20. Load contactor control switch 5. Meter switch 21. Coolant temperature gage 6. Line switch 22. Load contactor indicating light 7.
  • Page 90 OM-2031 32. Manual voltage control rheostat 33. Automatic-manual voltage control switch 34. Test bank switch 35. Light test switch 36. Reset switch Operating Controls and Instruments Figure 1 (Sheet 2 of 2) August 5/89 Revised Page 4...

  • Page 91: Operational Test Procedures

    OM-2031 Test Receptacle Connector Terminals Identification Figure 2 B. Operational Test Procedures (1) Start the engine in accordance with instructions in 1-3; Para. 2, A thru C. (2) Check operation of engine instruments: DC ammeter (17, Fig. 1), coolant temperature indicator (21), oil pressure gage (23), and hourmeter (19).
  • Page 92 OM-2031 (9) Measure governor actuator input signal. See Par. 3, E, (4), (a). (10) Measure governor magnetic pickup signal. See Para. 3, E, (4), (b). (11) Check speed limiting governor Set engine speed-limiting governor to 2300 + 25 RPM. See John Deere Diesel Handbook in Chapter 6 for instructions on how to set the governor.
  • Page 93 OM-2031 main on when the switch is released and allowed to return to the center ON position. This indicates that the load contactor is closed and the plug interlock relay is functioning properly. (23) Apply 1/3 to 1/2 load at the load bank and allow the unit to run for 15 to 30 minutes. Observe op- eration of all monitoring instruments.
  • Page 94 OM-2031 (36) Check engine oil pressure at governed speed (2000 RPM). Gage should indicate at least 38 PSI when the engine is hot. Check engine coolant temperature. Gage should indicate in the range of 180 degrees to 190 degrees depending upon ambient temperature. (37) Check operation of fuse interlock (Ref.
  • Page 95 OM-2031 (a) While the unit is operating normally under load, reduce generator output frequency by reduc- ing engine speed. Use the governed speed setting potentiometer. Turn adjusting screw COUN- TERCLOCKWISE gradually to reduce engine speed until frequency meter indicates 386 Hz. Underfrequency protective relay should not function to open the load contactor at this frequency.

  • Page 96: Generator Set Adjustment

    C. Basic Engine Adjustments Adjustment procedures applicable to the diesel engine are included in the John Deere Diesel Handbook which accompanies this Hobart manual. Specific information for this particular engine is listed in Figure 6. D. Engine Accessories Adjustment (1) Generator and fan belt adjustment Refer to 2-1; Para. 8 for fan belt adjustment instructions.

  • Page 97: Electric Governor System Adjustment

    OM-2031 E. Electric Governor System Adjustment Two electric governor system main components, namely the magnetic pickup and controller, have critical adjustments which can affect engine performance and therefore generator output. The adjustment of the actuator linkage can also affect engine performance. When the complete system is to be checked and/or adjusted, a definite sequence of procedures should be followed: First - Check or adjust actuator linkage...
  • Page 98 OM-2031 1. Actuator shaft 5. Nut 2. Signal input connector 6. Rod 3. Actuator lever 7. Ball Joint, Fuel Control Lever 4. Ball joint, actuator Governor Actuator Linkage Figure 4 (2) Magnetic pickup adjustment The strength of the magnetic pickup signal to the control box can be weakened if the tip of the pickup is too far from the flywheel ring gear.

  • Page 99: Magnetic Pickup Adjustment

    OM-2031 (d) Rotate the engine as required to locate a ring gear tooth directly below the tapped, pickup mounting hole. An imaginary line should pass through the center of the mounting hole, the center of a flywheel tooth and the center of the flywheel. (e) Install the magnetic pickup into the tapped mounting hole and thread it in until the tip touches the “in-line”...

  • Page 100: Adjustment And Test Of Controller And Actuator

    OM-2031 (3) Adjustment and Test of Controller and Actuator Refer to Figure 6. The controller has three identical control potentiometers See inset): the GAIN po- tentiometer, the DROOP potentiometer, and the potentiometer marked “I”. In addition, a SPEED con- trol potentiometer is located just next to the GAIN potentiometer. Make controller settings as follows: (a) Preliminary Controller Settings (1) With the engine of the generator set turned OFF, set the “I”...
  • Page 101 OM-2031 Electric Governor Controller: Illustration and Connection Diagram Figure 6 August 5/89 Revised Page 15...

  • Page 102: Checking Magnetic Pick-Up Signal

    OM-2031 (d) Checking the Actuator The actuator does not require any adjustments. An actuator malfunction, when it occurs, will result in the actuator being totally inoperative, either due to the actuator coil being open or shorted to the actuator case. Resistance measurements will reveal either of these conditions. (4) Checking Magnetic Pick-up signal Connect a high impedance voltmeter to magnetic pickup input terminals (10 and 11, Fig.

  • Page 103: Diode Test

    OM-2031 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 di- odes follows: A. Disconnect diode lead(s). B.
  • Page 104 OM-2031 TEST BOX TEST POINTS POINTER CONNECTOR TEST CONDITION VOLTAGE POSITION TERMINALS DESCRIPTION Phase “A” input for Unit in “GEN” mode 115-V AC reg. and trays & auto-man sw. in 400-Hz Phase “B” input for Unit in “GEN” mode 115-V AC reg.

  • Page 105: Chapter 3. Troubleshooting

    OM-2031 CHAPTER 3. TROUBLESHOOTING SECTION 1. TROUBLE SHOOTING PROCEDURES 1. General A. Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the exact cause of a trouble is found. As a rule, the best place to start looking for the cause of a trouble in a circuit is at the source of power.

  • Page 106: Equipment For Troubleshooting

    OM-2031 NOTE: Reference symbols (S9, etc.), used in the Trouble Shooting Chart, are identified on Schematic and Connection Diagrams. 3. Equipment for Troubleshooting A good quality multi-scale volt ohmmeter is the only instrument required for trouble shooting. At least two “jumper”...
  • Page 107 OM-2031 6. Test Values Although test values are provided throughout the trouble shooting chart, where applicable, additional infor- mation and values are given here. Generator output at maximum voltage regulator rheostat setting 134 V or higher Generator output at minimum voltage regulator rheostat setting 108 V or lower Overload relay trips at any value above 112 KVA in 5 minutes.
  • Page 108 OM-2031 9. Engine Trouble Shooting Procedures A. General The following engine trouble shooting procedures were taken from Cummins Diesel Handbook. Certain abnormal conditions which may interfere with satisfactory engine operation, together with methods of de- termining the cause of such conditions, are covered in the Trouble Shooting Chart. The ability of the engine to start and operate properly depends primarily on two things: (1) The presence of an adequate supply of air, compressed to a sufficiently high compression pres- sure.
  • Page 109 OM-2031 1. Frequency meter 17. DC Ammeter 2. Voltmeter 18. Engine-generator control switch 3. Fastener 19. Hourmeter 4. AC Ammeter 20. Load contactor control switch 5. Meter switch 21. Coolant temperature gage 6. Line switch 22. Load contactor indicating light 7.
  • Page 110 OM-2031 32. Manual voltage control rheostat 33. Automatic-manual voltage control switch 34. Test bank switch 35. Light test switch 36. Reset switch Operating Controls and Instruments Figure 1 (Sheet 2 of 2) August 5/89 Revised Page 6...
  • Page 111 OM-2031 1. Manual control voltage potential adjusting resistor 2. Exciter field ballast resistors Excitation Resistors Figure 2 End View of Voltage Regulator Amphenol Connector Figure 3 August 5/89 Revised Page 7...
  • Page 112 OM-2031 Test Receptacle Connector Terminals Identification Figure 4 August 5/89 Revised Page 8...
  • Page 113 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY NOTE: Diesel engine trouble shooting is covered in Perkins Engine Shop Manual under Fault Diagnosis. ENGINE CONTROLS 1. Engine will not A. Batteries discharged, A. Check voltage across bat- start.
  • Page 114 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 3. Engine will not A. No fuel A. Before attempting to find start. Cranking the cause of “no fuel”, speed normal.prime the fuel filters by removing pipe plug in thecover of each.
  • Page 115 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 3. Engine will not (6) Faulty fuel pump (6) Check pump. start. Cranking speed normal. (a) Relief valve (a) An open relief valve not seating will cause low out- put pressure.
  • Page 116 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 5. Engine starts.Stops A. The shut-down circuit A. Restart the engine, hold after a few seconds may have functioned permissive start switch in by automatic shut- normally to stop the START position, and observe down.
  • Page 117 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 7. Engine will not A. 12-V DC power not A. Apply 12-V DC directly to come “up” to gov- reaching governor terminal 1 on governor con- erned speed in GEN control box due to trol box.
  • Page 118 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 7. Engine will not E. Defective control E. Connect a DC voltmeter to come “up” to gov- unit the leads from the control erned speed in GEN unit to the actuator.
  • Page 119 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 9. Engine is unsteady A. Fault in engine A. Before condemning the gover- (surges) under load nor system for surging, make certain the fault is not in the engine.
  • Page 120 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 11. Engine “misses”. A. Insufficient fuel A. Check fuel flow in accor- Runs unevenly. dance with Cummins Diesel Handbook. Repair or replace parts as required. Also see Engine, Trouble 3.
  • Page 121 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 1. No (or low) gener- A. Defective generator A. The first check is an easy ator output voltage or excitation circuit one which will allow the in all phases.
  • Page 122 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR EXCITATION CIRCUITS (CONTINUED) 1. No (or low) genera- C. Defect in VOLTAGE C. Check as follows: tor output voltage REG. excitation cir- in all phases. Gen- cuit. erator operating at 400 Hz in AUTOMATIC (1) Defective AUTO- (1) Check the switch thor-...
  • Page 123 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR AND EXCITATION CIRCUIT (CONTINUED) 1. No (or low) gen- (4) Defective Amph- (4) Disconnect voltage reg- erator output volt- enol connector at ulator Amphenol connec- age in all phases. voltage regu- tor (See TM-759 or OM-2020).
  • Page 124 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR CONTROLS AND INSTRUMENTS (CONTINUED) 2. No (or low) output B. Defect in manual voltage A. Check as follows: voltage when operating control portion in MANUAL mode of excitation circuit (Continued) (1) Defective AUTO- (1) Check contacts and oper-...
  • Page 125 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY NO. 1 LOAD CONTACTOR OPERATING CIRCUIT (CONTINUED) 1. Load contactor (K1) (2) Defective (open) (2) Use a jumper with clip will not close when relay in protective and prod terminals to control switch (20, module (1-1;...
  • Page 126 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY N0. 1 LOAD CONTACTOR OPERATING CIRCUIT (CONTINUED) 2. Load contactor (K1) A. 28.5-V DC is not A. Check voltage at terminal Z will close when reaching plug interlock on test receptacle. Voltage control switch (20, relay (K2) from should be 28.5-V DC.
  • Page 127 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR CONTROLS AND INSTRUMENTS (CONTINUED) 2. Load contactor will E. Defective fuse- E. Open protective relay tray close when control interlock relay (K17) and connect a jumper across switch (20, Fig. 1) or resistor (R46) the resistor R46) (Sect.
  • Page 128 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY PROTECTIVE CIRCUIT NOTE: The protective relays and protective monitor are not completely functional until the load contactor is CLOSED. Since it is not advisable to vary voltages for test purposes while delivering power to an aircraft, the generator should be connected to a load bank for trouble shooting the protective circuits.
  • Page 129 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY PROTECTIVE CIRCUIT (CONTINUED) 2. Load contactor B. Defective over-under B. Use rheostat to reduce opens during power voltage module (K26) voltage to 104 V. The delivery. Under- undervoltage indicating voltage indicating light should NOT come on light ON (Cont’d)
  • Page 130 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY PROTECTIVE CIRCUIT (CONTINUED) 4. Load contactor A. Electric governor B. Proceed as follows: opens during power improperly adjusted, delivery. Under- or malfunctioning frequency light ON. (1) Governor improperly (1) Adjust in accordance adjusted with Sect.
  • Page 131 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR 1. No (or low) voltage A. Shorted diode in A. Check diodes in accordance output exciter rectifier with Sect. 2-3, para. 6. If (CR2). diodes are good, proceed to step B.
  • Page 132 OM-2031 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY EXTERNAL LOAD 4. Unbalanced output C. Defective connection A. Check plug and receptacle (Continued) in output circuit. connectors at aircraft. Tighten, repair, or replace as required. D. Break or cut in out- D.
  • Page 133 The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail parts of the engine-driven generator sets manufactured by Hobart Brothers Company, Power Systems Group, Troy, Ohio, 45373. These sets are identified as Hobart Series No. 6911, 6911A. 2. Purpose...
  • Page 134 (2) HOBART PART NUMBER Column ALL part numbers 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 NOMEN- CLATURE column.
  • Page 135 OM-2031 SECTION 2. MANUFACTURER’S CODES 1. Explanation of Manufacturer’s (Vendor) Code List The following list is a compilation of vendor codes with names and addresses for suppliers of purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes for Manufac- turer’s Cataloging Handbook H4-1, and are arranged in numerical order.
  • Page 136 OM-2031 CODE VENDOR’S NAME AND ADDRESS 21335 Fafnir Bearing Company Division of Textron 37 Booth Street New Britain, Connecticut 06050 21585 Farr Company, Airport Station P.O. Box 92187 Los Angeles, California 90009 24248 Southco Inc. 210 N. Brinton Lake Road Concordville, PA 19331 26403 ITT - Grinnell Corp.
  • Page 137 OM-2031 CODE VENDOR’S NAME AND ADDRESS 70485 Atlantic India Rubber Works Inc. 571 W. Polk Street Chicago, IL 60607 71400 Bussman Mfg. Division of McGraw Edison Company 114 Old State Rd. P.O. Box 14460 St. Louis, Missouri 63178 71744 General Instrument Corp. Miniature Lamp Div., Worldwide 443 N. Ravenswood Ave. Chicago, IL 60640 72582 General Motors Corp.
  • Page 138 OM-2031 CODE VENDOR’S NAME AND ADDRESS 91929 Micro Switch Division Honeywell Inc. 11 W. Spring Street Freeport, Illinois 61032 92563 McGill Manufacturing Company, Inc. Bearing Division 909 N. Lafayette Valparaiso, Indiana 46383 94222 Southco Inc. 210 N. Brinton Lake Road Concordville, PA 19331 95879 Alemite Instrument Division of Stewart-Warner Corporation 1826 Diversey Parkway Chicago, IL 60614...
  • Page 139 OM-2031 SECTION 3. PARTS LIST 1. Explanation of Parts List Arrangement The parts list is arranged so that the illustration will appear on a lefthand page and the applicable parts 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.
  • Page 140 OM-2031 Generator Set Figure 1 April 30/96 Revised Page 2...
  • Page 141 180894 . CANOPY ASSEMBLY No Number . GENERATOR SET WITHOUT CANOPY (For Details See Fig. 4) 280269 . FRAME 402987 . NAMEPLATE, HOBART 76B-1148 . LABEL, DIESEL FUEL 79A-1110 . NAMEPLATE, OPTION 78A-1000 . NAMEPLATE * NOT ILLUSTRATED July 11/96 Revised...
  • Page 142 OM-2031 Canopy Assembly Figure 2 April 30/96 Revised Page 4...
  • Page 143 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 280342 CANOPY ASSEMBLY (For NHA See Fig. 1) A,B,D, E,G,H 181345 CANOPY ASSEMBLY (For NHA See Fig.1) C, F 488719 . PANEL ASSEMBLY, SIDE, RIGHT, FRONT, CANOPY A,B,D, E,G,H 482320 .
  • Page 144 OM-2031 This page intentionally left blank April 30/96 Revised Page 6...
  • Page 145 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY CANOPY ASSEMBLY (CONTINUED) 280053 . PANEL ASSEMBLY, LOUVERED, FRONT, CANOPY 389284 . COVER, HOLE, FRONT, CANOPY A,B,D, E,G,H 481416 . SUPPORT ASSY, MTG., FRONT HJ-129A . JOINT, BALL V01428, No. SPS1002CP 482407 .
  • Page 146 OM-2031 Generator Set Without Canopy Figure 3 April 30/96 Revised Page 8...
  • Page 147 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number GENERATOR SET WITHOUT CANOPY (For NHA See Fig. 1) 489331 . GENERATOR ASSY. (For Details See Fig. 17) A,B,C . GENERATOR ASSY. (For Details See Fig. 17)
  • Page 148 OM-2031 This page intentionally left blank April 30/96 Revised Page 10...
  • Page 149 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY GENERATOR SET WITHOUT CANOPY (CONTINUED) 408773 . ENGINE ASSEMBLY, CUMMINS DIESEL, V15434, No. 6BTA5.9 (For Components of this Assy See Print 408773 in Chapter 6) No Number . . STARTER, 12V No Number .
  • Page 150 OM-2031 Radiator and Cooling System Group Figure 4 April 30/96 Revised Page 12...
  • Page 151 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number RADIATOR AND COOLING SYSTEM GROU (For NHA See Fig. 3) 180954 . RADIATOR ASSEMBLY 405743 . CAP, RADIATOR, V78225, NO. AAX-4018 280054 . SUPPORT, RADIATOR ASSY. W-10869-3 .
  • Page 152 OM-2031 Air Cleaner Assembly Figure 5 April 30/96 Revised Page 14...
  • Page 153 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 180417 KIT, AIR CLEANER, ASSY (For NHA See Fig. 3) 84A-1011 . AIR CLEANER V18265, No. FHG09-0024 No. POO-4073 180398 . PLATE, MOUNTING, AIR CLEANER 280265 . PIPE, INTAKE, ASSY.
  • Page 154 OM-2031 Electric Governor Kit Figure 6 April 30/96 Revised Page 16...
  • Page 155 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 280454 KIT, ELECTRIC GOVERNOR, ASSY (For NHA See Fig. 3) 281774-2 . SENSOR, MAGNETIC GOVERNOR 280448 . CONTROLLER, GOVERNOR, ELECTRIC 280447 . GOVERNOR, ACTUATOR, ELECTRIC 84A-1091 . ARM, THROTTLE, GOVERNOR V03613 402908 .
  • Page 156 OM-2031 Fuel Lines Assembly Figure 7 April 30/96 Revised Page 18...
  • Page 157 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 281220 LINES, FUEL, ASSEMBLY (For NHA See Fig. 3) W-10893-0 . FITTING, HOSE, SWIVEL, FEMALE W-10886-11 . CONNECTOR, MALE W-10119-4 . COUPLING, PIPE W-1-760-3 . NIPPLE, PIPE W-11608-3 . TEE, PIPE, BLACK W-7814-3 .
  • Page 158 OM-2031 Oil Line Assembly Figure 8 April 30/96 Revised Page 20...
  • Page 159 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 180895 LINE, OIL, ASSEMBLY (For NHA See Fig. 3) W-10750-4 . NIPPLE, PIPE, 1/8 W-10910-0 . TEE, STREET, BRASS 403809-1 . SWITCH, LOW OIL PRESSURE, V51377, NO. C-25900-10 W-10886-1 .
  • Page 160 OM-2031 Stator Terminal Panel Assembly Figure 9 April 30/96 Revised Page 22...
  • Page 161 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 482319 PANEL ASSY, TERMINAL, STATOR (For NHA See Fig. 4) W-11097-18 . SCREW, STEEL, 3/8-16 X 3/4, HHC W-11254-6 . WASHER, LOCK, STEEL, 3/8 IN. W-11242-10 . WASHER, FLAT, 3/8 IN.
  • Page 162 OM-2031 Power Module Panel Assembly Figure 10 April 30/96 Revised Page 24...
  • Page 163 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 482075-2 PANEL ASSEMBLY, POWER MODULE (For NHA See Fig. 3) 401937-3 . STRIP, TERMINAL V98410, No. 35012-3526 401937-2 . STRIP, TERMINAL V98410, No. 35008-3526 W-9746-1 . RESISTOR, LINE DROP BURDEN, 50 OHM, 25 WATT, V44655, No.
  • Page 164 OM-2031 Control Box Assembly Figure 11 April 30/96 Revised Page 26...
  • Page 165 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 11 - 482235-2 CONTROL BOX ASSY. (For NHA See Fig. 3) 482278-2 . TRAY ASSY, GENERATOR CONTROLS (For Details see Fig. 12) 482285-1 . TRAY ASSEMBLY, PROTECTIVE RELAYS (For Details see Fig. 13) No Number .
  • Page 166 OM-2031 Generator Controls Tray Assembly Figure 12 April 30/96 Revised Page 28...
  • Page 167 . AMMETER V60741, No. 331LH W-8105A-4 . VOLTMETER V60741, No. 331LH W-9916-10 . METER, FREQUENCY, V31356, No. 36-FX 388328-49 . NAMEPLATE, IDENTIFICATION 482279 . TRAY SUB-ASSEMBLY, GENERATOR CONTROL 1 370382A . . HANDLE, TRAY 404028 . . NAMEPLATE, HOBART July 11/96 Revised Page 29...
  • Page 168 OM-2031 This page intedntionally left blank. April 30/96 Revised Page 30...
  • Page 169 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 482278-2 TRAY ASSEMBLY, GENERATOR CONTROLS Continued 76A-1115 . . LATCH, ADJUSTABLE GRIP V94222 No. 48-99-126-11 402383 . . SLIDE ASSEMBLY, TRAY (Consists of four parts marked CR, CL, DR, & DL) V75358, No. 1335-12...
  • Page 170 OM-2031 Protective Relays Tray Assembly Figure 13 April 30/96 Revised Page 32...
  • Page 171 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 482285-1 TRAY ASSEMBLY, PROTECTIVE RELAYS (For NHA See Fig. 11) 402662 . SWITCH, TEST BANK V73559, No. 2GK71-73 482284-2 . BRACKET, MTG., RECEPTACLE & SWITCH 482356 . RECEPTACLE, HARNESS, WIRE 16DA-4052-0 .
  • Page 172 OM-2031 This page intentionally left blank. April 30/96 Revised Page 34...
  • Page 173 TRAY ASSEMBLY, PROTECTIVE RELAYS 402383 . . SLIDE ASSEMBLY, TRAY (Consists of four parts marked CR, CL, DR & DL) ,V75358, No. 1336-12 1set 404028 . .NAMEPLATE, HOBART 370382A . . HANDLE, TRAY 76A-1115 . . LATCH, ADJUSTABLE GRIP,V94222,No. 48-99-126-11 482287 .
  • Page 174 OM-2031 Control Box and Internal Components Group Figure 14 April 30/96 Revised Page 36...
  • Page 175 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number CONTROL BOX AND INTERNAL COMPONENTS GROUP (For NHA See Fig. 11) 402037-9 . GROMMET, RUBBER V02231, No. AGW-4211 82B-1047 . LIGHT, PANEL V74400, No. MI-3216 50GHP-206 . BULB V74400, No. 67 W-10051-10 .
  • Page 176 OM-2031 Engine Control Panel Assembly Figure 15 April 30/96 Revised Page 38...
  • Page 177 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 482296-17 PANEL ASSEMBLY, CONTROL, ENGINE (For NHA See Fig. 3) 482296-21 PANEL ASSEMBLY, CONTROL, ENGINE (For NHA See Fig. 3) B,C,D,E, F,G,H 482297 . PANEL, CONTROL, ENGINE 82B-1047 . LIGHT, PANEL, 12-V V75175, No. 261-3306 12CW-1320A-5 .
  • Page 178 OM-2031 This page intentionally left blank April 30/96 Revised Page 40...
  • Page 179 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY PANEL ASSEMBLY, CONTROL, ENGINE (CONTINUED) 404100 . SWITCH, PUSHBUTTON, STARTER, V70040, No. 1996027 Delete 401937-2 . STRIP, TERMINAL, 8-STATION V98410, No. 35008-3526 400701 . CONNECTOR, RIGHT ANGLE, V59730, No. TA-250-8 No Number .
  • Page 180 OM-2031 Output Terminal Board Assembly Figure 16 April 30/96 Revised Page 42...
  • Page 181 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 482317 BOARD ASSEMBLY, TERMINAL, OUTPUT A,B,D, (For NHA See Fig. 3) E,G,H 50MS-732-0 . NUT, HEX, 1/4-20, KEPS, MH, STEEL W-11242-5 . WASHER, FLAT, 1/4 IN., STEEL W-9549-19 . ROD, TERMINAL 1/4-20 X 2-1/4 482445 .
  • Page 182 OM-2031 Generator Assembly Figure 17 April 30/96 Revised Page 44...
  • Page 183 OM-2031 NOMENCLATURE UNITS FIGURE HOBART ITEM NO PART NO. 1234567 ASSY 489331 GENERATOR ASSY. (For NHA See Fig. 3) A,B,C 280783 GENERATOR ASSY. (For NHA See Fig. 3) D,E,F, 387617A . COVER, FAN, HOUSING 387621 . COVER, EXCITER HOUSING 488908 .
  • Page 184 OM-2031 This page intentionally left blank April 30/96 Revised Page 46...
  • Page 185 OM-2031 SECTION 4. NUMERICAL INDEX 1. Explanation of Numerical Index The purpose of this index is to assist the user in finding the illustration and description of a part when the part number is known. Part numbers are arranged in alpha-numerical sequence. Thus, any part number beginning with the letter A would be located at or near the top of the index list.
  • Page 186 OM-2031 FIGURE & ITEM PART NUMBER NUMBER A-25 21-14 AUXILIARY FRAME AND COMPONENTS 4-32, 22-0 AW-626 21-15 CONTROL BOX AND INTERNAL COMPONENTS GROUP 14-3, 17-0 DATA-3190 20-17 DDW-155 DW-4304 18-8 DW-6080 18-10 ENGINE ASSEMBLY FW-1312 18-4 GENERATOR GROUP GENERATOR SET WITHOUT CANOPY 1-3, 4-0 HF-1459 15-18...
  • Page 187 OM-2031 FIGURE & ITEM PART NUMBER NUMBER W-10905-1 8-17, 11-3 W-10905-6 8-13, 11-7 W-10909-1 W-11097-18 12-1, 19-5 W-11112-3 12-10, 19-10 W-11166-1 16-22, 16-23 W-11166-3 18-15 W-11242-5 19-2 W-11242-10 12-3, 19-7 W-11245-3 12-12, 19-12 W-11254-6 12-2, 19-6 W-11280-3 W-11330 4-39 W-11608-3 8-22 W-2974-A 30-18...
  • Page 188 OM-2031 FIGURE & ITEM PART NUMBER NUMBER 15GH-433 15-19 16DA-1997-3 18-14 16DA-1997-5 18-11 16DA-1997-6 16-24 16DA-2162 15-14 16DA-4004A-3 13-33, 16-5 16DA-4004A-10 13-35, 15-9, 16-7 16DA-4029 15-13 16DA-4052-0 13-28, 15-10, 16-4 16DA-4133-2 22-4 16DA-4253-1 13-34, 15-8, 16-6 180132 181343 20-22 30GH-417 4-25 30523 8-15, 11-11...
  • Page 189 OM-2031 FIGURE & ITEM PART NUMBER NUMBER 388328-52 16-26 388763 4-30, 10-0 388828-1 22-7 389284 2-27 389909 400059-3 6-7, 18-29 400078 15-6A 400333-1 6-14 400400 15-20 400480-2 13-18 400480-3 13-19, 13-38, 400613-4 16-20, 17-3, 18-9 400613-10 2-40 400701 13-14, 18-21 400819-1 400830-15 13-16...
  • Page 190 OM-2031 FIGURE & ITEM PART NUMBER NUMBER 402987 403034 403091-8 2-36 403127 2-18, 3-17 403189 18-6 403336 16-18 403380 18-24 403483 403492-1 22-1 403590-1 403590-4 10-2 403590-5 10-5 403592 11-17 403763-1 13-1 403782-2 5-23 403809-1 404028 15-26, 16-32 404030-2 22-15 404036 2-20, 3-21 404065-1...
  • Page 191 OM-2031 FIGURE & ITEM PART NUMBER NUMBER 481032 22-16 481113 21-9 481379 20-13 481416 2-28, 3-26 481417 2-23, 3-4 481418 2-9, 3-8 481419 2-11, 3-10 481503 3-20 481940 20-24 482038 16-13 482039 16-15 482069 13-25 482075-2 4-3, 13-0 482076 13-21 482235-2 4-4, 14-0 482236...
  • Page 192 OM-2031 FIGURE & ITEM PART NUMBER NUMBER 482355 15-1 482356 16-3 482372 2-21, 3-24 482376 2-5, 3-7 482386 2-19, 3-15 482389 2-14, 3-13 482400 2-15, 3-14, 19-0 482401 2-13, 3-12 482407 2-30, 3-22 482424 2-31, 3-19 482426 2-16, 3-18 482428 3-19 482429 2-26, 3-1...
  • Page 193 OM-2031 FIGURE & ITEM PART NUMBER NUMBER 488661 488686-1 4-14 488689 21-6 488692 488693 488694 4-9, 6-0 488695 4-29, 9-0 488697 488698 488699 5-19 488700 4-13 488701 4-15, 7-0 488702 4-28, 8-0 488719 488720 488735-1 4-36 488735-2 4-37 488741 488755 20-7 488764 4-31, 11-0...
  • Page 194 OM-2031 FIGURE & ITEM PART NUMBER NUMBER 76A-1130 4-14 76A-1152 22-12 78A-1021 8-12, 11-0 78A-1023 8-11, 11-9 78B-1010 4-33 78B-1019-1 8-19, 11-15 78B-1019-2 8-9, 11-5 78B-1022 8-10, 11-8 82B-1047 17-2, 18-2 83A-1026 6-11, 18-13 83A-1029 6-13 85A-1002 6-16 84A-1006 6-10 84A-1009 84A-1010 84A-1011...
  • Page 195 OM-2031 CHAPTER 5. OPTIONAL EQUIPMENT This chapter provides documentation covering any optional equipment furnished with your generator. Available options are listed below. OPTION NAME MANUAL HOBART No. Trailer, Fenders and Parts TO-136 482731 Transformer-Rectifier, 28.5-V DC OM-433 487750-1 Transformer-Rectifier Mounting Kit...
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  • Page 197 Engine Cummins Engines, Inc. Handbook for Diesel Engine 6BTA5.9 Flexible Coupling Hobart Brothers Company Coupling Manual OM-2019 Exciter Rotor Hobart Brothers Company Rotor Manual TM-360 The following items of equipment, which are options for other specifications covered by this manual, are standard equipment on Specification 6911A-5 Low Fuel Level Kit (285953) Hobart Brothers Company Manual No.
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  • Page 223 OM-2031 UNUSUAL SERVICE CONDITIONS This information is a general guideline and cannot cover all possible conditions of equipment use. The specific local environments may be dependent upon conditions beyond the manufacturer’s control. The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical condition or operation of the equipment.
  • Page 224 OM-2031 Unusual Service Conditions August 5/89 Revised Page 2...

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