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Hobart 6921 Series Operation And Maintenance Manual

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OM-2040
062984
Revised 073188
Revised 093089
Revised 013190
Revised 022894
Revised 093095
OPERATION AND MAINTENANCE
ILLUSTRATED PARTS LIST
ENGINE DRIVEN GENERATOR SETS
90-kVA, 400-Hz, 115/200-V AC, 3-Phase Units
100-kVA, 400-Hz, 115/200-V AC, 3-Phase Unit
MANUAL
Series 6921
Series 6922
Series 6922B
Specification 7126-1
with
DEUTZ DIESEL ENGINE
Type DO 693-738
HOBART BROTHERS COMPANY
Ground Power Division
Troy, Ohio 45373 U.S.A.
with
for
Series 6921A
Series 6922A

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  • Page 1 90-kVA, 400-Hz, 115/200-V AC, 3-Phase Units Series 6921 Series 6921A Series 6922 Series 6922A Series 6922B 100-kVA, 400-Hz, 115/200-V AC, 3-Phase Unit Specification 7126-1 with DEUTZ DIESEL ENGINE Type DO 693-738 HOBART BROTHERS COMPANY Ground Power Division Troy, Ohio 45373 U.S.A.
  • Page 2 This page intentionally left blank.
  • Page 3 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Safety Warnings and Cautions WARNING CALIFORNIA PROPOSITION 65 - GASOLINE ENGINES. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING CALIFORNIA PROPOSITION 65 - DIESEL ENGINES.
  • Page 4 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets a. Installation and Grounding of Electrically Powered Equipment Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or other applicable codes.
  • Page 5 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 5. Toxic Fume Prevention Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air conditioners.
  • Page 6 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Safety Warnings Revised Page 4 August 01/95...
  • Page 7 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Introduction 1. General The following information is provided for the operator to familiarize himself with using the manual properly. THE MANUAL MUST BE READ AND UNDERSTOOD BEFORE PERSONNEL ATTEMPTS TO OPERATE, INSTALL, OR REPAIR THIS EQUIPMENT. 2.
  • Page 8 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets b. Page Numbering Page numbers do not run consecutively throughout the manual. Each page is identified by the Chapter/Section number in which it appears, and by a page number within the Chapter/Section. Therefore, the first page in each Section is page 1.
  • Page 9 A four-conductor (A, B, C, and N) cable may be used on a single output machine when delivering power to a distribution box. 7. Customer Service If you have any questions concerning your Hobart Power Systems Group equipment, you are invited to contact our service department by mail, telephone, or FAX. Write:...
  • Page 10 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Introduction February 28/94 Revised Page 4...

  • Page 11: Table Of Contents

    C. Hobart Engine Equipment ......1-1 ... .
  • Page 12 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets SUBJECT CHAPTER/SECTION PAGE (e) Tray (f) Manual voltage control (g) Excitation-deenergization relay (2) Protective relay tray (Figure 9) (a) Sensing modules (b) Memory and time delay module (c) Indicating lights (d) Plug interlock relay (e) Test bank switch (f) Resistor...
  • Page 13 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets SUBJECT CHAPTER/SECTION PAGE SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING 1. Preparation for Use A. General ....... . . 1-2....1 B.
  • Page 14 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets SUBJECT CHAPTER/SECTION PAGE CHAPTER 2. SERVICING SECTION 1. MAINTENANCE 1. General 2. Inspection 3. Lubrication A. General ....... . 2-1 ....1 B.
  • Page 15 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets SUBJECT CHAPTER/SECTION PAGE D. Engine Control Panel ..... 2-1....11 (1) Tilt out engine control panel (2) Reinstall engine control panel 9.
  • Page 16 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets SUBJECT CHAPTER/SECTION PAGE E. Electric Governor System Adjustment ..2-3 ....10 (1) Actuator linkage adjustment (2) Magnetic pickup adjustment (3) Governor Control Unit Adjustment...
  • Page 17 B. Parts List Form ......4-1....1 (1) “FIGURE-ITEM NO.” Column (2) “HOBART PART NUMBER” Column (3) “NOMENCLATURE” Column (4) “EFF”...
  • Page 18 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Table of Contents February 28/94 Revised Page 8...

  • Page 19: Section 1. Description

    Section 1. Description 1. General The Hobart generator sets covered by this manual are designed to provide power for maintenance and startup of aircraft having 115/200-V AC, 3-phase, 400-Hz electrical systems. Five different series of generator sets are covered by this manual. All generator sets in these series are driven by a Deutz Diesel engine.
  • Page 20 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Voltage Panel & Contactor 8. Canopy Access Door 9. Left Side Engine Access Door 2. Engine Exhaust Pipe 10. Output Receptacle 3. Battery Storage Compartment 11. Engine Controls & Panel 4.
  • Page 21 16.5 Quarts (15.61 liters) Battery Two 12 volts Fuel Tank Capacity (approx.) 50 gallon (189.25 liters) *This engine is purchased from Deutz under this specification especially for Hobart Brothers Company power applications. Specifications and Capabilities Figure 2 February 28/94 Chapter 1-1...
  • Page 22 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Generator Control Box 9. Belts Access Panel 2. Engine Control Panel 10. Output Terminal Panel 3. Voltage Regulator 11. Diesel Fuel Inlet 4. Control Box Governor 12. Panel Power Module 5.
  • Page 23 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets POWER VOLTAGE SPEC. RATING REGULATOR MOUNTING OTHER INFORMATION 6921-1, 90 KVA 430391C Trailer Right side exhaust. Batteries included. 6921A-1 6921-2, 6921A-2 90 KVA 430391C Trailer Top exhaust. Batteries included. 6921-4, 6921A-4 90 KVA 430391C Stationary...

  • Page 24: Special Features

    A receptacle connector (10, Fig. 1) , 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 checks from one location.

  • Page 25: Engine, Generator And Controls Assembly

    (5) (5) Speed limiting governor. 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.

  • Page 26: (A) Magnetic Pickup

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Oil Filter Cartridge 11. Filler Neck Oil 2. Cooling Fins 12. Drain Plug 3. Rocker Chamber Cover 13. Oil Sump 4. Hydro Controller 14. Oil Micofilter 5. V-Belt Blower 15.
  • Page 27 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Acutator 2. Rod 3. Speed Control Lever 4. Mounting Bracket Throttle Control and Electric Governor System Figure 5 (2) Air Cleaner The diesel-engine air cleaner (Fig. 6) is a dry-cartridge type. It is equipped with a service indicator which signals the operator when the cartridge needs changing.
  • Page 28 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOTE: The service indicator is mounted on the engine control panel and connected to the air cleaner by a rubber hose. The indicator flag is visible only when the engine is running or when the flag is locked in WARNING position.

  • Page 29: Control Box Assembly

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets A rectifier with six diodes is mounted on the exciter rotor and converts exciter AC output to DC for excitation of the generator revolving fields. The exciter DC output to the generator fields, and consequently, the generator output is controlled by the amount of DC voltage supplied to exciter fields by the static voltage regulator.

  • Page 30: (E) Tray

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets b. Generator output monitors (meters) The generator output is monitored by three instruments; a frequency meter (10, Fig. 9) a voltmeter (9) , and an ammeter (7) . The frequency meter is a resonant-reed type which indicates the frequency of the generator output alternating current in the range of 380 to 420 Hz (cycles per second) .
  • Page 31 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Resistor (50 Ohm, 100 Watt) Variable 9. Voltmeter 2. Resistor (20 Ohm, 100 Watt) Ballast 10. Frequency Meter 3. Excitation-De-energization Relay 11. Automatic-Manual Switch 4. Instruction Plate 12. Receptacle Connector 5.

  • Page 32: (B) Memory And Time Delay Module

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets b. Memory and time delay module The memory and time delay module (4, Fig. 10) or the protective monitor module, is a solid-state device with a hermeticallysealed, reed-type relay. The printed circuit board or “card”...
  • Page 33 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Plug Interlock Relay 12. Tray Fastener 2. Fuse Interlock Relay 13. Overfrequency Indicating Light (Red) 3. Auxiliary Underfrequency Relay 14. Undervoltage Indicating Light (Red) 4. Memory and Time Delay Module 15.
  • Page 34 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets f. Engine Control Panel (Fig. 11) The engine control panel is mounted into the side of the control box. The engine controls and instruments and generator output controls are included. A plexiglass window in the engine control panel door slants outward at the bottom to form an opening for access to controls when the door is closed.
  • Page 35 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets d. Indicating lights A green indicating light (13, Fig. 11) glows to indicate that power 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 pressure switch (19, Fig.

  • Page 36: Engine Control Panel (Fig. 10) 1-1

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Panel 9. Generator Mode Control 2. Oil Pressure Gage 10. Output Contactor Light 3. Hourmeter 11. Cold Weather Starting 4. Ammeter (DC) Battery 12. Fan Belt Fault Indicating Light 5.

  • Page 37: Voltage Regulator 1-1

    Figure 12 g. Voltage Regulator NOTE: The following references to the voltage regulator are to the Hobart magnetic-amplifier type voltage regulator, Part No. 430391C, which is used on many of the generator set specifications covered by this manual. Some generator set specifications covered by this manual employ a newer solid state voltage regulator, Part No.

  • Page 38: Controls

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (1) Controls The rheostat (2, Fig. 13) is used to adjust the regulated voltage value of the generator output. Compensation for cable size is adjusted by a potentiometer (4) . Cable length is compensated for by adjustment of another potentiometer (3) .

  • Page 39: (C) Overload Current Transformers

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Resistor (1000 Ohms, 25 Watts) 11. Receptacle Connector 2. Regulator Rheostat 12. Fuse (5 Amp) 3. Cable Length Compensation Rheostat 13. Fuseholder 4. Cable Size Compensation Rheostat 14. Receptacle Connector 5.

  • Page 40: Overload Module

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets The solid-state circuitry is designed to close the relay contacts when output current in ANY phase reaches 125% of normal, rated output capacity. The closed relay sends a signal to the protective monitor.

  • Page 41: Test Box

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (4) Rectifier A diode-bridge rectifier (5, Fig. 14) receives 400-Hz AC from phase C of the generator output and converts it to a pulsating, direct current for energization of the load contactor holding coil only.

  • Page 42: Dual Output Machine

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Test box 2. Cable 3. Plug connector Test Box Assembly (Optional) Figure 15 7. Dual Output Machine When a machine is equipped with the second output option, the unit has two output circuits for servicing two aircraft simultaneously, or for servicing a single aircraft with two input receptacles.
  • Page 43 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Dual Output Terminal Boards Figure 16 No. 2 Output Control Figure 17 February 28/94 Chapter 1-1 Revised Page 25...
  • Page 44 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Output No. 2 Power Module Panel Figure 18 Chapter 1-1 February 28/94 Page 26 Revised...

  • Page 45: Section 2. Preparation For Use, Storage, Or Shipping

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Section 2. Preparation for Use, Storage, or Shipping 1. Preparation for Use a. General WARNING Improper operation can kill, injure or damage! Before operating the unit. read and follow operating instructions in section 1-3 b.

  • Page 46: Installing Output Cables

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine Oil Gage Rod and Filler Cap Figure 1 c. Installing Output Cables Units are generally shipped without generator set-to-aircraft cables. (1) Three-phase, AC output cable assembly installation. The AC output terminal panel is located on the left side, below the generator control box. (See Fig.

  • Page 47: Preparation For Storage

    Figure 2 (2) Transformer-rectifier (T-R) cable assembly installation If the generator set is provided with one or more transformer-rectifiers, refer to Hobart manual OM-433 in Chapter 6 of this manual for instructions on installing the T-R output cable assembly or assemblies.

  • Page 48: Long Time Storage (Over 30 Days)

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (2) Start the engine and operate for about two minutes so that all internal engine components will be coated with new oil. NOTE: Do not drain the fuel system or crankcase after this run. (3) Clean the exterior of the engine with fuel oil.

  • Page 49: Section 3. Operation

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 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.
  • Page 50 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Frequency Meter 16. Oil Pressure Gage 2. Instrument Panel Lights 17. Generator Mode Control Switch 3. Voltmeter 18. Hourmeter (Engine) 4. Fastener 19. Battery Ammeter, (DC) 5. AC Ammeter 20.
  • Page 51 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 30. Manual Voltage Control Rheostat 35. Automatic Voltage Control Rheostat * 31. Automatic-manual Voltage 36. Cable Length Compensation Rheostat * Control Switch 37. Cable Size Compensation Rheostat * 32. Test Bank Switch 38.

  • Page 52: Cold Weather Engine Starting Procedures

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets c. Cold Weather Engine Starting Procedures WARNING This kit must not be used in tandem with a glow-plug starting aid. An explosion and serious injury could result. A cold weather starting-aid kit (Fig. 2) is an option available for starting the engine at temperatures below 50 F (10 C) .

  • Page 53: Power Delivery (Automatic Voltage Control)

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Clamp Screw 2. Fluid Cylinder 3. Cap 4. Plug Cold Weather Starting Aid (Optional) Figure 2 e. Power Delivery (Automatic Voltage Control) (1) Place generator mode control switch (17, Fig. 1) in BUILD-UP-VOLTAGE position momentarily then allow it to position itself in GEN position.

  • Page 54: Preparation For Power Delivery

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets f. Preparation for Power Delivery (Manual Voltage Control) Preparation for power delivery using manual voltage is exactly the same as for automatic control [Para. 2, B, (1) thru (2) above] except: (1) Place automatic-manual switch (31) in MANUAL position.

  • Page 55: Simultaneous Operation Of 28.5-V T-R's

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets b. Simultaneous Operation of 28.5-V T-R’s Two 28.5 V T-R’s may be operated at the same time without special precautions. Prepare the generator set for power delivery in accordance with Para. 2, D. above. Operate each T-R according to Instructions in applicable TM.

  • Page 56: 2 Output Operation

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Selector Switch 2. Pushbutton Switch 3. Positive Test Jack (Red) 4. Negative Test Jack (Black) Test Box Operating Controls Figure 3 Test Receptacle Connector (with protective cap installed) Figure 4 5.
  • Page 57 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets b. Discontinue Power Delivery To open the load contactor in the No. 2 output circuit, place the No. 2 contactor switch (Fig. 5) in OFF position. The indicator light beside the switch will go out. For engine shudown procedures, refer to para.2, J.
  • Page 58 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 1-3 February 28/94 Revised Page 10...

  • Page 59: Chapter 2. Servicing

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Chapter 2. Servicing Section 1. Maintenance 1. General To ensure the generator set is ready for operation at all times, inspect and maintain it regularly and systematically. Locate and correct problems before they result in serious damage or failure of the equipment.
  • Page 60 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Lubrication and Maintenance Chart Figure 1 Chapter 2-1 February 28/94 Revised Page 2...
  • Page 61 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets SYMBOL NAME SPECIFICATION NOTES Grease, Automotive and Federal V V-G-632 Sinclair Litholene Industrial Industrial No. 2; “Mobile-Mobilplex” 47 or equivalent Oil, Engine, Heavy Duty Military MIL-L-2104B SAE-30, Summer or equivalent SAE-10 Winter Trailer Lubricants SYMBOL...
  • Page 62 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Trailer Lubrication Chart Figure 2 Chapter 2-1 February 28/94 Revised Page 4...

  • Page 63: Engine

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets e. Engine The engine and its accessories require a major portion of the generator set lubrication and maintenance. The following recommendations are taken from the engine manufacturer’s operation manual. (1) Lubrication schedule Time schedules indicated on the Lubrication Chart, Fig.
  • Page 64 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Important: T he above intervals are based on the use of diesel fuel containing max. 0.5% b. w. of sulphur and Central European or similar climatic conditions. Periods should be cut by half for each of the following heavy duty factors: - Diesel fuel with more than 0.5% b.w.

  • Page 65: Engine Accessories

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (5) Change oil filter element 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. Release cartridge (1,Fig. 3) with a wrench and screw off by hand. c.

  • Page 66: Air Cleaner Service

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 4. 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 green indicator “flag”...

  • Page 67: Cartridge Installation

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets b. Cartridge Installation (See Fig. 4) (1) Carefully install the new cartridge into the housing. Avoid bumping the cartridge tubes against the housing sealing flange. Seat the cartridge properly within the housing. Press all edges and corners of the cartridge firmly with fingers to effect a positive air seal against the sealing flange of the housing.

  • Page 68: Adjusting Alternator Belt Tension

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets c. Adjusting Alternator Belt Tension See Fig. 7. Slacken hex-bolts (items 1, 2, and 3) . Pull alternator (4) in direction “A” until correct belt tension is obtained. Then securely re-tighten hex bolts, 1, 2, and 3. d.

  • Page 69: Generator Exciter

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (2) Tray installation a. Use both hands to support tray as in removal above. b. Align rails (4) with tracks (5) and slide tray into box. Latches will lock automatically. c.

  • Page 70: Transformer-Rectifier Maintenance

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine Control Panel in Tilt-Out Position Figure 9 (2) Reinstall engine control panel a. Maneuver panel into position and align mounting holes. Install mounting screws and secure. b. Secure wire conduit in its original position with clamp and screw. 9.

  • Page 71: Section 2. Inspection / Check

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Section 2. Inspection / Check 1. General This section describes inspections and checks to be performed in accordance with inspection/checks schedule, Figure 1. 2. Engine a. Fuel (See Fig. 1 for time schedules) (1) Check fuel quantity DAILY (2) Drain fuel filters in accordance with 2-1;...
  • Page 72 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Bi-Weekl HOURLY INTERVAL Daily Weekly Monthly Bi-Month lyor Required CALENDAR INTERVAL 8 Hrs 50 Hrs 200 Hrs 400 Hrs 100 Hrs ENGINE Check fuel quantity Check crankcase oil level Check coolant level Check engine oil filter element Change engine oil Replace air cleaner cartridge...
  • Page 73 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets LIGHT LAMP LAMP IDENTIFICAION LOCATION MANUFACTURER NUMBER Instrument Panel Control Box Lamp Industry Trade Lights Number Engine ON Indicating Engine Control Panel Lamp Industry Trade 1815 Light Number Contactor CLOSED Engine Control Panel Lamp Industry Trade 1815...

  • Page 74: Wiring And Connections

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets c. Wiring and Connections (1) Inspect all cables and leads for broken, worn, and damaged insulation. (2) Check for loose connections and tighten. NOTE: A darkened terminal generally indicates a loose connection. 4.

  • Page 75: Section 3. Adjustment/Test

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Section 3. Adjustment/Test 1. General These adjustment and test procedures are applicable to testing and adjusting the generator set after major repair, major parts replacement, or overhaul. 2. Generator Set Test a.
  • Page 76 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Frequency Meter 16. Oil Pressure Gage 2. Instrument Panel Lights 17. Generator Mode Control Switch 3. Voltmeter 18. Hourmeter (Engine) 4. Fastener 19. Battery Ammeter, (DC) 5. AC Ammeter 20.
  • Page 77 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 30. Manual Voltage Control Rheostat 35. Automatic Voltage Control Rheostat * 31. Automatic-manual Voltage 36. Cable Length Compensation Rheostat * Control Switch 37. Cable Size Compensation Rheostat * 32. Test Bank Switch 38.

  • Page 78: (B) Flashing Exciter Field Without Test Box

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets b. Flashing exciter field without test box. Remove test receptacle cover (1-3; Fig. 3) . 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 and momentarily touch the other end (alligator clip) to the “hot”...

  • Page 79: Operational Test Procedures

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Test Receptacle Connector Terminals Identification Figure 3 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 (19, Fig. 1), Oil pressure gage (16) , and hourmeter (18) .
  • Page 80 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (12) Check adjustable voltage range in automatic operating mode. a. Observe voltmeter (3, Fig. 1) and turn rheostat (35) CLOCKWISE to full clockwise position. Maximum voltage should be at least 134 V AC, or higher. NOTE: If voltage should decrease when the knob is turned clockwise, it indicates that internal wiring of the voltage regulator is incorrect.
  • Page 81 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (27) Check voltage regulator, at intervals, from no-load to full load, and on up to 125% load. Observe and note voltage at various loads. Voltages should vary no more than plus or minus 1% from 115 V.
  • Page 82 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets b. Return unit to normal operating conditions by adjusting voltage regulator rheostat and pressing reset switch (9). (39) Check operation of undervoltage sensing relay, indicating light, and time delay. At some value between 103 V and 93 V, the undervoltage sensing relay (Ref.

  • Page 83: Generator Set Adjustment

    Hobart Manual TM-759 covers the magnetic-amplifier type voltage regulator, Part No. 430391C, which is used on many of the generator set specifications covered by this manual. Hobart Manual OM-2020 covers the newer solid state voltage regulators, Part Numbers 489812 and 489812A.

  • Page 84: Alternator And Fan Belt Adjustment

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets d. Alternator and fan belt adjustment Refer to 2-1; Para. 8 for belt adjustment instructions. NOTE: Replace fan belts with a matched set. Engine Type 6-cylinder turbocharged four cycle air-cooled diesel, direct injected Bore/Stroke 4/4.9 in.
  • Page 85 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (1) Actuator linkage adjustment The proper adjustment of the mechanical linkage between the electric actuator and engine speed control lever is important to the satisfactory operation of the complete system. Exact adjustment instructions such as effective length of rod assembly (6, Fig.
  • Page 86 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOTE: As little as 1-V is required for operation of governor control box. Magnetic pickup voltage does not have to be 4-V to 8-V. 1. Actuator 2. Actuator shaft 3. Speed control lever 4.
  • Page 87 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets (3) Governor Control Unit Adjustment Before making an adjustment to the control unit (Fig. 7), make certain that linkage between actuator and fuel control lever (Fig. 6) is free and properly adjusted. There must be no lost motion or “play”...
  • Page 88 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Speed control 2. Stability control Electric Governor Control Box Figure 7 Electric Governor Connection Diagram Figure 8 Chapter 2-3 February 28/94 Revised Page 14...

  • Page 89: Generator And Exciter Test

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 4. Generator and Exciter Test The generator fields may be tested with a “Kelvin” bridge. This is a double bridge type instrument required for the very low resistances encountered in this test. It is understood that 0 resistance indicates a SHORT CIRCUIT condition.

  • Page 90: Test And Adjustment Of Transformer-Rectifiers

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets c. Hold one ohmmeter lead point on the threaded end of the diode. Hold the other lead point on the wire terminal end. Observe and note the indicated resistance. Now reverse the lead connections on the diode.
  • Page 91 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets No. 2 Output Control Figure 5 February 28/94 Revised Chapter 2-3 Page 17...
  • Page 92 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 2-3 February 28/94 Revised Page 18...

  • Page 93: Chapter 3. Troubleshooting

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Chapter 3. Troubleshooting Section 1. Troubleshooting Procedures 1. General a. Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the exact cause is located. When looking for the cause of a trouble in a circuit or system begin at the source of power or supply.

  • Page 94: Equipment For Troubleshooting

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 3. Equipment for Troubleshooting A good quality multi-scale volt-ohmmeter is the only instrument required for troubleshooting. At least two “jumper” leads with “alligator” clips and test prods will be required. The 12-V, engine electrical system may be used as a 12-V DC power source.

  • Page 95: Checking Connections And Leads

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets • Underfrequency relay trips at 375 to 385 Hz, resets at 385 Hz. • Overload relay trips at 125% rated load in 5 minutes. See 2-3 Fig. 13 for typical test values at test receptacle and test box. 7.

  • Page 96: Checking Compression Pressure

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets If the cylinder has been misfiring, there will be no noticeable difference in the sound and operation of the engine. If the cylinder has been firing properly there will be a noticeable difference in the sound and operation when the plunger is held down.

  • Page 97: Fuel Flow Test (See Fig. 7)

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets f. Fuel Flow Test (see Fig. 7) Check fuel pump and fuel flow as follows: (1) Disconnect the fuel return tube at, or near, the tank. Hold the open end in a convenient container of over 1-gallon capacity.
  • Page 98 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Frequency Meter 16. Oil Pressure Gage 2. Instrument Panel Lights 17. Generator Mode Control Switch 3. Voltmeter 18. Hourmeter (Engine) 4. Fastener 19. Battery Ammeter, (DC) 5. AC Ammeter 20.
  • Page 99 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 30. Manual Voltage Control Rheostat 35. Automatic Voltage Control Rheostat * 31. Automatic-manual Voltage 36. Cable Length Compensation Rheostat * Control Switch 37. Cable Size Compensation Rheostat * 32. Test Bank Switch 38.
  • Page 100 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 1. Starter Connection to Solenoid 2. Solenoid 3. Negative Battery Cable Connection 4. Positive Battery Cable 5. Starter Solenoid Switch 6. Starter Starter and Solenoid Switch Figure 2 1. Manual Control Voltage Potential Adjusting Resistor 2.
  • Page 101 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets End View of Voltage Regulator Amphenol Connector Figure 4 1. Fuel Tank 2. Fuel Supply Line 3. Fuel Feed Pump 4. Injection Pump 5. Injection Lines 6. Injector 7. Backleakage Lines 8.
  • Page 102 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Test Receptacle Connector Terminals Identification Figure 6 Chapter 3-1 February 28/94 Revised Page 10...
  • Page 103 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine and Controls Trouble, Symptom & Condition Test or Inspection Corrective Action 1. Engine will not start. Starter a. Battery or batteries Check battery voltage and will not crank engine. discharged or faulty.
  • Page 104 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine and Controls (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action Engine will not start. Starter g. Internal seizure If all engine starting components will not crank engine are good and the starter is (continued).
  • Page 105 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine and Controls (cont). Trouble, Symptom & Condition Test or Inspection Corrective Action Engine will not start. Cranking f. Improper valve clearance Check and adjust valve speed normal. (cont.) adjustment. clearance in accordance with instructions in Detriot Diesel Operator’s Manual.
  • Page 106 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine and Controls(cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action 6. Engine will not come “up” to a. 12-V DC power not Apply 12-V DC directly to governed speed in GEN mode. reaching governor control terminal “1"...
  • Page 107 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine and Controls (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action Engine will not come “up” to h. Defective control unit. Connect a DC voltmeter to the governed speed in GEN mode. leads from the control unit to the (Continued) actuator.
  • Page 108 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine and Controls (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action c. Loose or binding governor Check linkage ball joints and all linkage. connections for looseness or binding. Be sure linkage will move from idle speed to full speed without lost motion or binding.
  • Page 109 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator and Excitation Circuit Trouble, Symptom & Condition Test or Inspection Corrective Action 1. No (or low) generator output a. Defective generator or The first check is an easy one voltage in all phases.
  • Page 110 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator and Excitation Circuit (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action No (or low) generator output f. Defective ballast resistor(s), If output voltage was produced voltage in all phases. (See Fig.
  • Page 111 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator and Excitation Circuit Trouble, Symptom & Condition Test or Inspection Corrective Action 2. No (or low) output voltage a. Defective generator Place AUTO-MANUAL control when operating in MANUAL manual control excitation switch (33, Fig.
  • Page 112 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator and Excitation Circuit (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action Load contactor (K1) will not d. Defective load contactor Set AUTO-MANUAL switch (S1) close when control switch (20, control switch (S5) to AUTO position.
  • Page 113 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator and Excitation Circuit (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action Load contactor (K1) will close d. “Blown” fuse (F2) (1-1; 17, Press lamp test switch (8, Fig. when control switch (20, Fig.
  • Page 114 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 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 troubleshooting the protective circuits.
  • Page 115 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Protective Circuit (Continued) Trouble, Symptom & Condition Test or Inspection Corrective Action Load contactor opens during c. Defective protective monitor With unit running normally, use power delivery. Undervoltage module (K14). voltage regulator adjustment indicating light ON.
  • Page 116 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Protective Circuit (Continued) Trouble, Symptom & Condition Test or Inspection Corrective Action Load contactor opens during a. One of the resistors (R26, An open resistor will cause a power delivery. Indicating light R27 or R28) across higher than normal Voltage.
  • Page 117 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator Trouble, Symptom & Condition Test or Inspection Corrective Action 1. Unbalanced output. a. Loose connection in output Check all output connections, circuit. Discolored connectors indicate a loose connection. Tighten or replace as required.
  • Page 118 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 3-1 February 28/94 Revised Page 26...

  • Page 119: Section 1. Introduction

    PART NUMBERS ARE SUBJECT TO CHANGE WITHOUT NOTICE 1. General The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail parts of seven series of Diesel Engine Generator Sets manufactured by Hobart Brothers Company, Airport Systems Division, Troy, Ohio, 45373. 2. Purpose This list provides parts identification and descriptive information to maintenance and provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts.

  • Page 120: Nomenclature" Column

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 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 “NOMENCLATURE”...

  • Page 121: Section 2. Manufacturer'scodes

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 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 Manufacturer’s Cataloging Handbook H4-1, and are arranged in numerical order.
  • Page 122 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets CODE VENDOR’S NAME AND ADDRESS 31510 Main Line Supply, 905 East Third St., Dayton, OH 45402 35708 Tridon Limited, P.O. Box 1600, Nashville, Tennessee 37202 44655 Ohmite Manufacturing Company, 3601 West Howard Street, Skokie, Illinois 60076 49234 Protectoseal Co., 225 W.
  • Page 123 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets CODE VENDOR’S NAME AND ADDRESS 82372 Huntington Rubber Co., Los Angeles, CA 82372 86151 Genisco Technology Corp, Illinois Div., 9367 William Street, Rosemont, IL 60018 87930 Tower Manufacturing Corp., 25 Reservoir Avenue, Providence, RI 02907 88223 General Products Corp., A Gulf And Western Systems Co., 107 Salem St., Union Springs, NY 13160...
  • Page 124 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-2 February 28/94 Revised Page 4...

  • Page 125: Section 3. Parts List

    OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 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 righthand 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 126 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator Set Figure 1 Chapter 4-3 February 28/94 Page 2 Revised...
  • Page 127 Units 6921A-1 thru 6921A-6, along with 6922-1 and 6922-2, use Hobart Voltage Regulator Part No. 430391C. Units 6921A-7 thru 6921A-11, along with 6922-3 and 6922-4, use Hobart Voltage Regulator Part No. 489812. Refer to manuals TM-759 and OM-2020, respectively, in Chapter 6 for detailed information on these regulators.
  • Page 128 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-3 February 28/94 Page 4 Revised...
  • Page 129 UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY (CONTINUED) 402987 . NAMEPLATE, HOBART 76A-1152 . CAP, FUEL TANK, V49234 406000 . LABEL 76B-1148 . LABEL, DIESEL FUEL No Number . GENERATOR SET WITHOUT CANOPY (For Details See Fig. 3) .TRAILER ASSY.
  • Page 130 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Canopy Assembly Figure 2 Chapter 4-3 February 28/94 Page 6 Revised...
  • Page 131 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 181111 CANOPY ASSY (For NHA see Fig. l) CANOPY ASSY (For NHA see Fig. l) No Number 181797 CANOPY ASSY (For NHA see Fig.
  • Page 132 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator Set Without Canopy Figure 3 Chapter 4-3 February 28/94 Page 8 Revised...
  • Page 133 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY No Number GENERATOR SET WITHOUT CANOPY (For NHA see Fig 1)(S-6921A shown) No Number . ENGINE AND AIR CLEANER GROUP (For Details See Fig.
  • Page 134 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine and Air Cleaner Grooup Figure 4 Chapter 4-3 February 28/94 Page 10 Revised...
  • Page 135 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLTURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY No Number ENGINE AND AIR CLEANER GROUP (For NHA See Fig. 3) (6921-1 shown) 83B-1109A . ENGINE, DEUTZ DIESEL, V62445 488193 .
  • Page 136 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-3 February 28/94 Page 12 Revised...
  • Page 137 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLTURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY (CONTINUED) 488293 . COVER, ALTERNATOR ASSY. 488304 . BRACKET, MTG, EXHAUST PIPE 30GH-417 . SPACER, MTG, EXHAUST PIPE, V81860 404154-15 .
  • Page 138 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator Control Box Group Figure 5 Chapter 4-3 February 28/94 Page 14 Revised...
  • Page 139 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 488279 GENERATOR CONTROL BOX GROUP (For Details See Fig. 3) No Number . CONTROL BOX AND INTERNAL COMPONENTS ASSY. (For Details See Fig. 13) 482278-2 .
  • Page 140 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine Control Panel Assembly Figure 6 Chapter 4-3 February 28/94 Page 16 Revised...
  • Page 141 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 488301 PANEL ASSY., CONTROL, ENGINE (For Details See Fig. 3) A-C, E-R 489541 PANEL ASSY., CONTROL, ENGINE (For Details See Fig. 3) 488188 .
  • Page 142 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Engine Test Panel Assembly Figure 7 Chapter 4-3 February 28/94 Page 18 Revised...
  • Page 143 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 488262 PANEL, ENGINE TEST ASSY. (For NHA See Fig. 3) 488207 . PANEL, ENGINE TEST 403379 . RECEPTACLE, BOX 26 CONTACT 405797-3 .
  • Page 144 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Electric Governor Assembly Figure 8 Chapter 4-3 February 28/94 Page 20 Revised...
  • Page 145 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY. 488296 ELECTRIC GOVERNOR ASSY. (For NHA See Fig. 3) 488294 . BRACKET MTG. GOVERNOR 84A-1020 . GOVERNOR, ELECTRIC, V66503 84A-1050 .
  • Page 146 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Power Module Panel Assembly Figure 9 Chapter 4-3 February 28/94 Page 22 Revised...
  • Page 147 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 482075-2 . PANEL, ASSY, POWER MODULE (For NHA See Fig. 3) 482076 . PANEL, POWER MODULE 1CZ-148 . TRANSFORMER, CURRENT LINE DROP &...
  • Page 148 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Voltage Regulator Assembly (Part No. 430391C) Figure 10 Chapter 4-3 February 28/94 Page 24 Revised...
  • Page 149 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 430391C ◊ 10 - REGULATOR, VOLTAGE, ASSY (Refer to manual TM-759 in Chapter 6) 485530 . CHASSIS, REGULATOR 430340 .
  • Page 150 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-3 February 28/94 Page 26 Revised...
  • Page 151 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 10 - 430391C (CONTINUED) 485053 . . BOARD, PC, HIGH PHASE SENSING 79B-1140 . . . RELAY, V77342, NO. KHU17D11 79A-1142 .
  • Page 152 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Protective Relay Tray Assembly Figure 11 Chapter 4-3 February 28/94 Page 28 Revised...
  • Page 153 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 482285-1 TRAY ASSY, PROTECTIVE RELAYS (For NHA see Fig. 5) 402662 . SWITCH, TEST BANK, V73559, NO. 2GK71-73 492284-2 .
  • Page 154 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-3 February 28/94 Page 30 Revised...
  • Page 155 . TRAY, ASSY, PROTECTIVE RELAYS . . SLIDE ASSY, TRAY, (Set consists of four parts 402383 marked CR, CL, DR, & DL) V75358, NO. 1336-12 404028 . . NAMEPLATE, HOBART 370382A . . HANDLE, TRAY 76A-1115 . . LATCH, ADJUSTABLE GRIP, V94222 NO.
  • Page 156 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator Controls Tray Assembly Figure 12 Chapter 4-3 February 28/94 Page 32 Revised...
  • Page 157 . VOLTMETER, V60741, NO. 331LH W-9916-10 . METER, FREQUENCY, V31356, NO. 36-FX 388328-49 . NAMEPLATE, IDENTIFICATION 482279 . TRAY, SUB-ASSY, GENERATOR CONTROL 370382A . . HANDLE, TRAY 404028 . . NAMEPLATE, HOBART * Not Illustrated February 28/94 Chapter 4-3 Revised Page 33...
  • Page 158 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-3 February 28/94 Page 34 Revised...
  • Page 159 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 12 - TRAY ASSY, GENERATOR CONTROLS (Cont’d) 76A-1115 . . LATCH, ADJUSTABLE GRIP, V94222, NO. 48-99-126-11 . . SLIDE ASSY, TRAY, (Set consists of four parts 402383 marked CR, CL, DR, &...
  • Page 160 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Control Box and Internal Components Assembly Figure 13 Chapter 4-3 February 28/94 Page 36 Revised...
  • Page 161 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 13 - NO NUMBER CONTROL BOX AND INTERNAL COMPONENTS ASSY. (For NHA see Fig. 5) 82B-1047 . LIGHT, ASSY, PANEL V75175, NO. 261-3306 82A-1048 .
  • Page 162 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Output Terminal Board Assembly Figure 14 Chapter 4-3 February 28/94 Page 38 Revised...
  • Page 163 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 14 - 482317 PANEL ASSY, TERMINAL OUTPUT (For NHA see Fig. 3) 50MS-732-0 . NUT, HEX, 1/4-20, KEPS, MH, STEEL W-11242-5 .
  • Page 164 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Generator Assembly Figure 15 Chapter 4-3 February 28/94 Page 40 Revised...
  • Page 165 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 EFF ASSY 15 - 280783A GENERATOR ASSY (For NHA See Fig. 3) GENERATOR ASSY (For NHA See Fig. 3) 280790A 386612 .
  • Page 166 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Panel Support, Controls Figure 16 Chapter 4-3 February 28/94 Page 42 Revised...
  • Page 167 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 16 - NO NUMBER PANEL, SUPPORT CONTROLS 408524 .UNIT CONTROL ELECTRIC GOV., V66503, (For NHA See Fig. 3)
  • Page 168 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Mounting Frame and Control Support Assembly Figure 17 Chapter 4-3 February 28/94 Page 44 Revised...
  • Page 169 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 17 - NO NUMBER MOUNTING FRAME AND SUPPORT CONTROL ASSY. (For NHA see Fig. 3) 488328 . PANEL, SUPPORT CONTROL ASSY.
  • Page 170 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Trailer Group with Parking Brake Figure 18 Chapter 4-3 February 28/94 Page 46 Revised...
  • Page 171 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 ASSY 18 - No Number TRAILER GROUP WITH PARKING BRAKE (For NHA See Fig. 1) 489725-1 . FENDER FRAME AND UNDER CARRIAGE W/ EXHAUST OUT TOP (For Details See Fig.
  • Page 172 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Fenders, Frame Accessories and Undercarriage Figure 19 Chapter 4-3 February 28/94 Page 48 Revised...
  • Page 173 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 489725-1 FENDER, FRAME AND UNDERCARRIAGE (For NHA See Fig. 18) B,G,L REF 489725-2 FENDER, FRAME AND UNDERCARRIAGE (For NHA See Fig. 18) 180153 .
  • Page 174 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-3 February 28/94 Page 50 Revised...
  • Page 175 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 19 - FENDER, FRAME AND UNDERCARRIAGE (Continued) 5CW-2048 . ROD, HOLD DOWN BATTERY 76A-1131 . GUARD, EDGE 6"...
  • Page 176 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Trailer Assembly Figure 20 Chapter 4-3 February 28/94 Page 52 Revised...
  • Page 177 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 20 - 404088A-1 TRAILER ASSEMBLY WITH STANDARD PNEUMATIC TIRES (For NHA See AB,FG, Fig. 18) LM,P REF. 76A-1140 .
  • Page 178 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 20 - (CONTINUED) 404532 . . . YOKE, 3/8-24 NF, V22938, NO. 5205 76A-1222 . . . NUT, YOKE, V22938, NO. 4601-5 488269-2 .
  • Page 179 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 ASSY 20 - (CONTINUED) 85A-1027 ..STUD, WHEEL, V22938, NO. 6251-1 85A-1028 ..CUP, BEARING, INNER, V22938, NO.
  • Page 180 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 20 - (CONTINUED) 76A-1196 . . CLAMP, SPRING & AXLE, REAR V22938, NO. 5601-2 76A-1197 . . SPRING ASSY., V22938, NO. 1-4010-3 404549 .
  • Page 181 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. February 28/94 Chapter 4-3 Revised Page 57...
  • Page 182 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Brake Assembly - Prototype Development, Inc. Figure 21 Chapter 4-3 February 28/94 Page 58 Revised...
  • Page 183 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 21 - 76A-1203 BRAKE ASSEMBLY, MECHANICAL, V22938, No. 1-8209 (For NHA see Fig. 13) 76A-1204 . SHIELD, DUST, V22938, NO. 8210 76A-1211 .
  • Page 184 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Fuel Tank Fitting Assembly Figure 22 Chapter 4-3 February 28/94 Page 60 Revised...
  • Page 185 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 22 - 488178 FUEL LINES ASSY. (FUEL TANK-TO-FUEL PUMP SECTION) 181405 FUEL LINES ASSY. (FUEL TANK-TO-FUEL PUMP SECTION) 400819-2 .
  • Page 186 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Oil Line Assembly Figure 23 Chapter 4-3 February 28/94 Page 62 Revised...
  • Page 187 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 23 - 488685 OIL LINE ASSY. 400059-3 . CONNECTOR, FEMALE, SAE 45, FLARED, 403590-1 . SWIVEL, FEMALE, SAE 45, FLARED, V03924, NO.
  • Page 188 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Fuel Line Assembly Figure 24 Chapter 4-3 February 28/94 Page 64 Revised...
  • Page 189 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 24 - 488178 FUEL LINES ASSY. (FUEL PUMP-TO-ENGINE SECTION) 181405 FUEL LINES ASSY. (FUEL PUMP-TO-ENGINE SECTION) W-10886-1 . CONNECTOR, MALE, V79470, NO. 48 X 4 W-10893-0 .
  • Page 190 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Fuel Return Line Assembly Figure 25 Chapter 4-3 February 28/94 Page 66 Revised...
  • Page 191 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 25 - 488178 FUEL LINE ASSY. (RETURN LINES SECTION) 181405 FUEL LINE ASSY. ( RETURN LINES SECTION) 56587 .
  • Page 192 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Air Cleaner Hose Assembly Figure 26 Chapter 4-3 February 28/94 Page 68 Revised...
  • Page 193 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 26 - 488261 AIR CLEANER HOSE ASSY. 56534 . HOSE, LOW PRESSURE 12 Ft. 400333-1 . ELBOW, FEMALE, SAE 45, V03924, NO.
  • Page 194 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Second Output Kit Figure 27 Chapter 4-3 February 28/94 Page 70 Revised...
  • Page 195 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 27 - 484066-3 KIT, SECOND OUTPUT (For NHA See Fig. 1) KIT, SECOND OUTPUT (For NHA See Fig. 1)
  • Page 196 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-3 February 28/94 Page 72 Revised...
  • Page 197 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 27 - 484066-3 KIT, SECOND OUTPUT W-11236-4 . SCREW, 1/4-20 X 1/8, HWH, SF-TAP, TYPE F 482326 . HORN, CABLE CLAMP, ASSY.
  • Page 198 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Kit, Mounting, T-R Assembly Figure 28 Chapter 4-3 February 28/94 Page 74 Revised...
  • Page 199 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 28 - 489127-1 Kit, MOUNTING, T-R, ASSY. (For NHA See Fig. 1) SINGLE T-R MTG. (OPTIONAL) 489127-2 Kit, MOUNTING, T-R, ASSY. (For NHA See Fig. 1) (OPTIONAL) DOUBLE T-R MTG.
  • Page 200 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Kit, Mounting, T-R Assembly (Back-Mounting Unit) Figure 29 Chapter 4-3 February 28/94 Page 76 Revised...
  • Page 201 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets NOMENCLATURE UNITS FIGURE & HOBART ITEM NO. PART NO. 1234567 EFF ASSY 29 - 489943 KIT, MOUNTING, T-R, ASSY. (Mounted on Rear of Unit) 489897 . BRACKET, MOUNTING, T-R, LEFT ASSY 489919 .
  • Page 202 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 4-3 February 28/94 Page 78 Revised...
  • Page 203 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets Section 4. 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 number beginning with the letter “A”...
  • Page 204 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER W-10854-4 16-4 W-10869-5 4-20 W-10869-14 25-2 W-10874-1 15-18 W-10875-1 15-17 W-10886-1 7-10, 23-6, 24-1, 26-4 W-10886-8 22-2 W-10892-4 25-4 W-10893-0 22-3, 24-2 W-10893-2 26-3 W-10909-1 23-4 W-10917-5...
  • Page 205 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER W-9360-261 14-14, 27-30, 27-31, 27-32 W-9360-278 27-27, 27-28, 27-29, 27-33 W-9234-362 19-36 W-9476-33 W-9549-19 14-3 W-9712-13 10-17 W-9712-30 10-35 W-9746-1 9-12 W-9746-3 11-8, 27-12 W-9746-9 10-11 W-9916-10...
  • Page 206 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 16DA-4052-0 11-4, 12-10, 13-13, 27-4 16DA-4253-1 11-6, 12-8, 13-9, 27-10 180077 180083 180084 180089 180084 180087 180089 180091 180092 180093 2-18 180094 180095 17-2 180096 17-1 180097...
  • Page 207 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 280790A 3-8, 15-0 281536 15-6 281774-2 281871-1 19-24 284399-3 20-29 284399-36 20-14 30GH-417 4-26, 4-31 30GH-734 10-16 363136-53 9-17 363770-1 12-12 363771-5 12-11 370141 10-18 370382A 11-33, 12-25...
  • Page 208 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 400698-5 400701 400782-1 10-21 400819-2 22-1 400830-15 400889-2 401556 9-16, 11-10, 16-3 401563-2 10-32 401563-3 10-7, 10-33 401563-4 11-14, 11-16 401563-5 11-12 401564-2 10-41 401564-3 10-41 401564-4...
  • Page 209 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 402826 12-3 402908 402987 403189 6-6, 27-17 403336 11-18 403379 403380 403483 4-14 403590-1 23-2 403809-1 23-5 403809-3 23-7 404028 11-32, 12-26 404065-2 9-13, 12-5, 27-3 404088-1 20-2 404088A-1...
  • Page 210 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 404545 20-41, 20-72 404549 20-63 404550 20-64 404551 20-66 404595 3-15 404613-4 27-19 405365-1 6-18 405797-3 406000 408439 4-41 408440 4-40 408443 6-19 408523 29-6 408524 3-10, 8-8, 16-1...
  • Page 211 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 482279 12-24 482280 12-29 482284-1 12-2 482285-1 5-3, 11-0 482286 11-30 482287 11-35 482291 11-30 482306 12-32 482307 11-36 482317 3-11, 14-0 482318 3-14 482326 27-21 482355...
  • Page 212 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 488155 19-6 488156 19-7 488163 19-13 488164 19-17 488165 19-8 488166 19-11 488170 19-5 488171 19-4 488172 19-14 488174 19-9 488176 19-2 488178 22-0, 24-0, 25-0 488180 13-4 488182...
  • Page 213 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 488261 26-0 488262 3-4, 7-0 488265 4-23 488267 17-4 488268 20-83 488269-2 20-23 488269-1 20-24 488270 20-82 488275 20-81 488277 4-21 488279 488279 488280 13-14 488281 13-15...
  • Page 214 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 488331 17-2 488334 4-17 488526 19-22 488525 4-10 488685 23-0 488736 19-3 488739 488742 4-23 488743 4-28 488755 15-21 488756 2-6, 17-5 488760 4-28 488780 4-37 488908...
  • Page 215 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 489919 29-2 489943 1-22 489943 29-0 489951 489952 29-7 492284-2 11-2 494295 19-25 5CW-2048 19-26 5CW-975 16-6 5CW-976A 16-7 50GHP-206 13-2 50MS-732-0 14-1 56534 26-1 56535 22-4, 24-3...
  • Page 216 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 76A-1184 20-35 76A-1186 20-50 76A-1187 20-51, 20-57 76A-1188 20-52 76A-1189 20-53 76A-1190 20-53 76A-1191 20-54 76A-1192 20-55, 20-58 76A-1193 20-56, 20-59 76A-1194 20-56 76A-1195 20-60 76A-1196 20-61...
  • Page 217 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 79A-1035 20-35 79A-1044 20-3 79A-1045 20-8 79A-1047 20-16 79A-1048 20-13 79A-1049 20-3 79A-1050 20-8 79A-1051 20-4 79A-1052 20-5 79A-1053 20-6 79A-1054 20-7 79A-1055 20-8 79A-1057 20-15 79A-1062...
  • Page 218 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets PART NUMBER FIGURE / ITEM NUMBER 84A-1055 24-4 84A-1047 1-10 84A-1048 1-11 84A-1049 1-18 84A-1050 84A-1054-1 1-13 84A-1055 22-9 84B-1038 3-9, 16-2 84B-1045 1-12 84B-1046 1-17 84B-1067 1-21 84C-1061 19-24 85A-1019 20-41 85A-1020...
  • Page 219 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. Quick Start Kit In this manual 488898 * Kit, Second Output In this manual 484066-3 Kit, T-R Mtg.
  • Page 220 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 5-0 February 28/94 Revised Page 2...
  • Page 221 COVERING THIS COMPONENT Engine KHO Deutz Company Deutz Spec. No. DO 693-738 Operator’s Manual No. 297-3917de/en Hobart Part No. 83B-1109A Spare Parts Catalog No. 297-4221 Voltage Regulator Hobart Brothers Company Hobart Part No. 430391C Operation and Maintenance Manual No. TM-759...
  • Page 222 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Chapter 6-0 February 28/94 Revised Page 2...
  • Page 261 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets 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 262 OM-2040 / Operation and Maintenance Manual 90D20 / Generator Sets This page intentionally left blank. Unusual Service Conditions February 28/94 Revised Page 2...

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