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Hobart 6824-1 Operation And Maintenance Manual

Engine driven generator sets 60-kva, 400-hz, 115/200-v ac, 3-phase units with perkins diesel engine type 6.3544
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OM-499
Revised 053194
OPERATION AND MAINTENANCE
ENGINE DRIVEN GENERATOR SETS
60-kVA, 400-Hz, 115/200-V AC, 3-Phase Unit
SPECIFICATION
6824-1, 6824A-1
6824-2, 6824A-2
6824-3, 6824A-3
6824-4, 6824A-4
6824A-5
6824A-6
6824A-7
6824A-8
MANUAL
ILLUSTRATED PARTS LIST
PERKINS DIESEL ENGINE
Type 6.3544
MOUNTING
Trailer or Truck
Tractor
Stationary: With Fuel Tank & Batteries
Trailer or Truck, Dual Output
Trailer or Truck
Tractor
Stationary: With Fuel Tank & Batteries
Trailer or Truck, Dual Output
HOBART BROTHERS COMPANY
Airport Systems Group
Troy, Ohio 45373 U.S.A.
with
for
with
s
VOLTAGE
REGULATOR
430391C
430391C
430391C
430391C
489812
489812
489812
489812

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Summary of Contents for Hobart 6824-1

  • Page 1 ENGINE DRIVEN GENERATOR SETS 60-kVA, 400-Hz, 115/200-V AC, 3-Phase Unit with PERKINS DIESEL ENGINE Type 6.3544 SPECIFICATION MOUNTING VOLTAGE REGULATOR 6824-1, 6824A-1 Trailer or Truck 430391C 6824-2, 6824A-2 Tractor 430391C 6824-3, 6824A-3 Stationary: With Fuel Tank & Batteries 430391C 6824-4, 6824A-4...
  • Page 2 This page intentionally left blank.
  • Page 3 OM-499 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.
  • Page 4 OM-499 c. Service and Maintenance This equipment must be maintained in good electrical and mechanical condition to avoid hazards stemming from disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the equipment until its safety has been assured. Repairs should be made by qualified personnel only.
  • Page 5 OM-499 EMERGENCY FIRST AID Call physician immediately. Seek additional assistance. Use First Aid techniques recommended by American Red Cross until medical help arrives. IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration, preferably mouth-to-mouth.
  • Page 6 OM-499 This page intentionally left blank. Safety Warnings May 31/94 Revised Page 4...
  • Page 7 This manual contains operation and maintenance information for a series of 400-Hertz generator sets manufactured by Hobart Brothers Company, Power Systems Division, 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 8 OM-499 This page intentionally left blank. Introduction May 31/94 Revised Page 2...
  • Page 9 Hobart Engine Equipment ....1-1 ....

  • Page 10: Table Of Contents

    OM-499 SUBJECT CHAPTER/SECTION PAGE Section 2. Preparation For Use, Storage, Or Shipping 1. Preparation for Use a. General ....... . . 1-2 ....1 b.
  • Page 11 OM-499 SUBJECT CHAPTER/SECTION PAGE Chapter 2. Service Section 1. Maintenance 1. General 2. Operation of Roll-Out Feature (For Tractor-Mounted Units Only) a. Roll Generator-Set Out for Service ... 2-1 ....1 b.
  • Page 12 OM-499 SUBJECT CHAPTER/SECTION PAGE Section 2. Inspection / Check 1. General 2. Engine a. Fuel (See Fig. 1 for time schedules) ..2-2 ....1 b.
  • Page 13 OM-499 SUBJECT CHAPTER/SECTION PAGE Chapter 3. Troubleshooting Procedures 1 Section 1. Troubleshooting 1. General a. Troubleshooting ......3-1 ....1 b.
  • Page 14 OM-499 This page intentionally left blank. Table of Contents May 31/94 Revised Page 6...
  • Page 15 OM-499 Chapter 1. Description / Operation Section 1. Description 1. General The basic generator sets (see Fig. 1) covered by the manual are identified by Series No. 6824and Series No. 6824A. The various configurations of the set are identified by adding a dash number (-1, -2, etc.) suffix to the Series number.
  • Page 16 A receptacle connector (19, Fig. 9) 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, conveniently and easily.
  • Page 17 OM-499 1. Canopy 6. Mounting frame 2. Lifting eye 7. Engine fan exhaust deflectors 3. Windows 8. Engine exhaust pipe 4. Output receptacle cover 9. Radiator cap access cover 5. Output cable horn Generator Set Figure 1 May 31/94 Revised Page 3...
  • Page 18 OM-499 PHYSICAL Length (stationary units) 82 inches (2082.8 mm) Width 36 inches (914.4mm) Height (overall) 43 inches (1092.2mm) Weight (approximately) 3300 pounds (1496.8 kg) GENERATOR CAPABILITIES Output power rating 60 KVA Output voltage 115/200 VAC Rated load capacity 173 A Frequency/cycles per second 400 Hz Output Kilowatts...
  • Page 19 OM-499 5. Canopy A sheet metal enclosure, identified as a canopy (1, Fig. 1), provides protection for the engine, generator and electrical controls. The canopy is designed to reduce the operational noise level in the immediate area of the machine. Doors and panels are covered on the inside with Fiberglass acoustic material to reduce reflected and conducted noise, and to absorb noise.
  • Page 20 (3) Reverse-flow, engine cooling fan to blow air outward through the radiator. 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 21 OM-499 1. Mounting frame 7. Voltage regulator 13. Output cable terminal board 2. Generator 8. Air cleaner 14. Engine control panel 3. Power module 9. Lifting yoke 15. Cable horn and clamp 4. Control box 10. Engine 16. Radiator 5. Governor control box 11.
  • Page 22 OM-499 (3) Engine protective devices a. High coolant temperature switch A high coolant temperature switch is mounted in the front of the cylinder block to monitor the coolant temperature. If the coolant temperature reaches 210 degrees F (99 degrees C) , this normally closed switch opens and actuates the fuel valve solenoid which shuts down the engine.
  • Page 23 OM-499 (5) Exhaust system The exhaust system consists of a special noise reducing muffler (3, Fig. 5) which is connected by a pipe (2) to a conventional exhaust manifold (1) . Baffles in the tail pipe outlet direct exhaust and noise downward. Noise Reduction Exhaust System Figure 5 (6) Radiator...
  • Page 24 OM-499 Control Box Figure 6 (1) Generator control tray (See Figure 7) The generator control tray contains instruments and controls for monitoring and controlling the generator output. a. Resistors Two, 10-ohm, 100-watt, ballast resistors (2) are connected in series in the generator exciter DC field circuit.
  • Page 25 OM-499 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 positions of the meter switch.
  • Page 26 OM-499 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 27 OM-499 b. Memory and time delay module The memory and time delay module (4) is sometimes called the protective monitor module. It is a solid-state device with a hermetically-sealed, reed-type relay. The printed circuit board or “card” includes five memory circuits and a time delay circuit. Each circuit is connected to a corresponding sensing circuit in the sensing modules (5 and 6) .
  • Page 28 OM-499 1. Plug-interlock relay 12. Tray fastener 2. Fuse-interlock relay 13. Overfrequency indicating light 3. Auxiliary underfrequency relay 14. Undervoltage indicating light 4. Memory and time delay module 15. Overvoltage indicating light 5. Over-undervoltage module 16. Load contactor circuit fuse (2-A) 6.
  • Page 29 OM-499 i. Auxiliary underfrequency relay The function of the auxiliary underfrequency relay (3) is to automatically open the excitation-deenergization relay and disconnect the voltage regulator anytime generator frequency drops to 380 Hz or below. This protects the voltage regulator (Fig. 10) and ballast resistors (2, Fig.
  • Page 30 OM-499 (2) Engine and generator controls a. Engine-generator control switch The engine-generator control switch (5) (also identified as the “build-up-voltage, generate, idle” switch) is a three-position toggle type. It is spring-loaded in one position, BUILD-UPVOLTAGE, and will automatically reposition to GENERATE position when released.
  • Page 31 OM-499 g. Fuse A 10-ampere fuse (13) protects the 12-V DC engine control circuit, hourmeter, illuminating light circuit, and 12-V DC system in the main generator protective system. (3) Air cleaner indicator The air cleaner indicator (12) is mounted on the engine control panel for easy viewing. Its function was explained in Para.
  • Page 32 OM-499 1. Panel light 11. Cold weather starting aid control 2. Fuel gage 12. Air cleaner indicator 3. Light switch 13. Engine circuit fuse (10-A) 4. DC Ammeter 14. Engine “ON” indicating light 5. Engine-generator control switch 15. Engine starter switch 6.
  • Page 33 OM-499 (1) Voltage Regulator Controls The rheostat (2, Fig. 10) 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). Cable compensation may be turned ON or OFF by a toggle switch (5).
  • Page 34 OM-499 1. Resistor (1000 ohms, 25 watts) 10. Damping circuit rate potentiometer 2. Regulator rheostat 11. Receptacle connector 3. Cable length compensation rheostat 12. Fuse (5 amp) 4. Cable size compensation rheostat 13. Fuseholder 5. On-off switch, line drop 14. Receptacle connector compensation 15.
  • Page 35 OM-499 b. Line-drop current transformers The three line-drop current transformers (9), in conjunction with burden resistors (8), detect the magnitude and power factor of current flowing from generator to load. They feed a signal to the voltage regulator which interprets the signal and alters the exciter field current as required to maintain a constant predetermined voltage at the load (see Voltage Regulator Manual No.
  • Page 36 OM-499 1. Overload resistor (25 ohm, 25 watt) 6. Load contactor 2. Terminal board 7. Overload module 3. Overload current transformer 8. Line drop resistor 50 ohm, 25 watt 4. Ammeter current transformer 9. Line drop current transformer 5. Rectifier 10.
  • Page 37 OM-499 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. 12) The test box assembly consists of a rotary selector switch, momentary contact pushbutton switch, and two, insulated-tip test jacks, mounted in a small metal box.
  • Page 38 OM-499 9. Dual Output Unit (Specification 6824-4) This generator set has two output circuits for servicing two aircraft simultaneously, or for servicing a single aircraft with two input receptacles. The output terminal boards for this unit are arranged as illustrated in Figure 13, with output No. 1 at the rear, lower terminal board and output No.
  • Page 39 OM-499 No. 2 Output Control Figure 14 No. 2 Power Module Panel Figure 15 May 31/94 Revised Page 25...
  • Page 40 OM-499 This page intentionally left blank. May 31/94 Revised Page 26...

  • Page 41: Section 2. Preparation For Use, Storage, Or Shipping

    Hobart Brothers Company does not build an aircraft tow tractor. Generator sets for tractor mounting are installed by the customer, or tractor manufacturer. 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.

  • Page 42: Installing Output Cables

    OM-499 (7) Check air cleaner The air cleaner (Sect. 1-1, Fig. 3, item 8) is a “dry” type. Be sure there are no papers, tapes, or other material covering the air inlet area. c. Installing Output Cables Units are generally shipped without generator set-to-aircraft cables. NOTE: Generator sets designed for tractor mounting are equipped with a generator output receptacle connector.

  • Page 43: Preparation For Storage

    OM-499 (2) Transformer-rectifier (DC) output cable installation (optional equipment) . Install DC output cables as illustrated in Figure 2. Use 4/0 size cables. T-R Output Cable Installation Figure 1 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.

  • Page 44: Long Time Storage (Over 30 Days)

    OM-499 (4) Clean the exterior of the engine with fuel oil. Dry with clean rags and compressed air. (5) Seal all engine openings. Use a waterproof, vaporproof material which is strong enough to resist puncture damage from air pressures. c. Long Time Storage (Over 30 Days) (1) The unit may be stored for long periods with no special preparation if it is possible to operate the engine once each week.

  • Page 45: Section 3. Operation

    OM-499 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 equipment may be necessary when working in close proximity to this equipment.
  • Page 46 OM-499 1. Frequency meter 12. Protective relay tray 22. Load contactor indicating light 2. Voltmeter r 13. Instrument panel light 23. Oil pressure gage 3. Fastener 14. Generator control tray 24. Cold weather starting aid control 4. AC Ammeter 15. Fuel gage 25.

  • Page 47: Automatic Voltage Control

    OM-499 32. Manual voltage control rheostat 38. Cable length compensation 33. Automatic-manual voltage control rheostat switch 39. Cable size compensation 34. Test bank switch rheostat 35. Light test switch 40. Line-drop compensation on-off 36. Reset switch switch 37. Automatic voltage control 41.
  • Page 48 OM-499 c. Cold Weather Engine Starting Procedures A cold weather starting-aid kit (Fig. 2) is provided to assist in starting the engine at temperatures below 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 49: Power Delivery (Automatic Voltage Control)

    OM-499 1. Clamp screw 2. Fluid cylinder 3. Cap 4. Plug 5. Valve Cold Weather Starting Aid (Optional) Figure 2 e. Power Delivery (Automatic Voltage Control) (1) Place engine-generator control switch (18, Fig. 1) in BUILD-UP-VOLTAGE position momentarily, then allow it to position itself in GEN position. The electric governor will immediately increase engine speed to 2000 RPM and maintain it.

  • Page 50: Preparation For Power Delivery

    OM-499 (5) A condition of overvoltage, undervoltage, underfrequency, overfrequency, or overload in the output circuit will automatically open the load contactor and turn on the applicable indicating light to signal the operator which of the above faults caused the protective monitor system to operate.
  • Page 51 OM-499 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. 4). b. Connect the test prods of a voltmeter at the test jacks (3 and 4, Fig. 3). Test jacks are color coded.

  • Page 52: 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...

  • Page 53: No. 2 Output Operation (Specifications 6824-4, 6824A-4 And 6824A-8)

    To open the load contactor in the No. 2 output circuit, place the No. 2 contactor switch (Fig. 6) in OFF position. The indicator light beside the switch will go out. For engine shutdown procedures, refer to para. 2. H. For generator sets having the optional second output, refer to Hobart Manual TO-128 in Chapter 6.

  • Page 54: Parking

    OM-499 b. Parking Observe the following rules when parking the trailer. (1) Apply parking brake before disconnecting tow vehicle. (2) Always place drawbar in an upright, vertical position when trailer is parked. No. 2 Output Control Figure 6 May 31/94 Revised Page 10...

  • Page 55: Chapter 2. Service

    OM-499 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 56 OM-499 Roll-out Stop-bar (For tractor-mounted units only) Figure 2 1. Attaching hardware; nuts, screws, and lockwashers 2. Retaining brackets Generator Set Retaining Components (Tractor-mounted units only) Figure 2 May 31/94 Revised Page 2...

  • Page 57: Lubrication

    OM-499 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 58: Starter

    OM-499 ITEM MAINTENANCE REQUIRED Lubricating Oil Check oil level daily or after every 10 hours of use. Change oil after 200 hours or one month of use. Use heavy duty oil such as SAE-30 (MIL-L-2104B). Engine lube oil capacity: 15 quarts. Lube Oil Filter Change oil filter every 200 hours or one month of use.

  • Page 59: Engine Fuel

    OM-499 CAUTION Under no circumstances should the cartridge be pounded or struck in the center to effect a seal. (2) Lock the cartridge in place by installing the baffle assembly (7) and clamp assembly (3) with cup assembly (8) in place. Tighten clamp (3) down in place. 1.

  • Page 60: Engine Cooling System

    OM-499 7. Engine Cooling System a. General Cooling system device requires much more than maintaining the proper coolant level in the radiator. During warm seasons and in warm climates, plain water can be used as a coolant if the system is protected against rust by a rust inhibitor additive. During cold seasons and in cold climates, the system must, of course, be protected against freezing.
  • Page 61 OM-499 (2) Checking coolant solution Check the solution frequently to be sure the cooling system has sufficient protection against freezing. NOTE: When testing the solution, be sure the coolant is at operating temperature. (b) Follow manufacturer’s instructions on tester. (3) Preparing the coolant solution The following table (Figure 5) indicates the freezing points of solutions varying from 16% antifreeze to 65% antifreeze.

  • Page 62: Draining The Cooling System

    OM-499 e. Draining the Cooling System Drain the cooling system immediately after stopping the engine, while most of the sediment is in suspension. Proceed as follows: (1) Remove radiator cap. (2) Open radiator drain valve (at bottom of radiator) and engine drain valves. See Perkins Shop Manual for exact locations of engine coolant drain valves.

  • Page 63: Generator Maintenance

    OM-499 NOTE: It is good practice to attach a card, indicating the cooling system contents, and the date serviced to the radiator filler neck. 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. a.

  • Page 64: Control Box Trays

    OM-499 b. Control Box Trays Control box trays may be removed easily and moved to a work bench for service or replacement of parts. (1) Tray removal a. Loosen screw-lock fastener (2, Fig. 6) b. Slide tray outward and disconnect Amphenol connector (3). c.

  • Page 65: Engine Control Panel

    OM-499 Removable Rear Frame Cross-Member Figure 7 (3) Exciter installation a. (a) Install exciter in accordance with TM-360. b. (b) Reinstall rear frame member and tighten screws securely. NOTE: It may be necessary to use a large “C” clamp or other arrangement to position frame side rails and align rear frame member mounting holes.
  • Page 66 OM-499 Engine Control Panel in Tilt-out Position Figure 8 May 31/94 Revised Page 12...

  • Page 67: Section 2. Inspection / Check

    OM-499 Section 2. Inspection / Check 1. General This section describes inspections and checks to be performed in conjunction with Inspection/Check Schedule, Figure 1. 2. 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 Perkins Shop Manual.
  • Page 68 OM-499 HOURLY INTERVAL Daily Bi-Weekly Monthly Bi-Monthly CALENDAR INTERVAL Required 8 Hrs 100 Hrs 200 Hrs 400 Hrs ENGINE Check fuel quantity Check crankcase oil level Check coolant level Check engine oil filter element Change engine oil Replace air cleaner cartridge Inspect cooling system hoses, tubes, fittings and clamps Check V-belt tension...

  • Page 69: Electrical System (12-V Dc)

    OM-499 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. b. Fuses Check and replace fuses as required. See Figure 3 for fuse sizes and locations. Figure 3 includes all fuses used in both the engine and generator electrical systems.

  • Page 70: Wiring And Connections

    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 inspection procedure. Both manuals cover batteries, as, when either option is used, the batteries are installed within it.

  • Page 71: Section 3. Adjustment / Test

    OM-499 Section 3. Adjustment / Test 1. General Adjustment and test procedures are most applicable to testing and adjusting the generator set after a major repair, replacement of parts, or overhaul. 2. Test Panels (See Figure 1) a. Generator Set Removed from Tractor Tests and adjustments may be performed more conveniently while the generator set is out of the tow tractor.

  • Page 72: Generator Set Test

    OM-499 (3) Remove power module and voltage regulator access panels (Ref. 1-1; 2, Fig. 1). 3. 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 73: Operational Test Procedures

    OM-499 Test Receptacle Connector Terminals Identification Figure 2 b. Flashing exciter field without test box. CAUTION Flashing the field in a reverse direction could cause damage to voltage regulator diodes. • (aa) Remove test receptacle cover (1-3; Fig. 4). Use two test leads equipped with a test prod on one end and an “alligator”...
  • Page 74 OM-499 1. Frequency meter 12. Protective relay tray 22. Load contactor indicating light 2. Voltmeter 13. Instrument panel light 23. Oil pressure gage 3. Fastener 14. Generator control tray 24. Cold weather starting aid control 4. AC Ammeter 15. Fuel gage 25.
  • Page 75 OM-499 32. Manual voltage control rheostat 38. Cable length compensation 33. Automatic-manual voltage control rheostat switch 39. Cable size compensation 34. Test bank switch rheostat 35. Light test switch 40. Line-drop compensation on-off 36. Reset switch switch 37. Automatic voltage control 41.
  • Page 76 OM-499 a. Place automatic-manual switch (33, Fig. 2) in AUTOMATIC position. b. Place test-bank switch (34) in AIRCRAFT position. c. Meter switch (5) may be in any position except pointing straight down. d. If the adjustment of the voltage regulator rheostat (37) has been disturbed, position the knob to mid-range position.
  • Page 77 OM-499 (18) Open the protective relay tray and place the test bank switch (34, Fig. 2) in TEST BANK position. (19) Again place the load contactor switch (20) in the top, CLOSE position. Light (22) should glow GREEN and remain ON when the switch is released and allowed to return to the center ON position.
  • Page 78 OM-499 a. Connect a master frequency meter of known accuracy to the frequency meter (1) terminals. b. Compare meter readings. Error must not exceed 1% of full scale. (33) Operate the unit not less than 10 minutes under full load. The overload device (Ref. 1-1; 7, Fig. 11) MUST NOT trip.

  • Page 79: Generator Set Adjustment

    OM-499 (40) Check underfrequency sensing relay, protective monitor, and indicating light. At some frequency value (Hz, cycles-per-second) from 385 Hz down to 375 Hz, the underfrequency sensing relay should function to signal the underfrequency circuit in the protective monitor module to OPEN the load contactor holding circuit, thus OPENING the load contactor.
  • Page 80 NOTE: The following adjustments are for the magnetic amplifier type voltage regulator, identified by Hobart Part Number 430491C, illustrated herein, and covered by manual number TM-759 in Chapter 6. For units having the newer solid state voltage regulator, refer to manual number OM-2020 in Chapter 6.
  • Page 81 OM-499 • (bb) Connect the generator output to a balanced, three-phase load of 30 kilowatts. • (cc) With generator running at 115 V AC no load, operate the contactor “on-off” switch (20, Fig. 2). If the average phase voltage changed more than 1. volt, or if output is unsteady, adjust “damp”...

  • Page 82: Basic Engine Adjustments

    Figure 5 c. Basic Engine Adjustments Adjustment procedures applicable to the diesel engine are included in the Perkins 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;...
  • Page 83 OM-499 Manufacturer Perkins Engines, Inc. Model 6-3544 Type In-line, 6-cylinder, 4-cycle diesel Displacement 354 cubic inches (5.8 liters) Compression ratio 16:1 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 + / - 25 RPM Electrical system...
  • Page 84 OM-499 c. While holding the removed ball joint in its mounting hole in the engine speed control lever, compare the TRAVEL of the ACTUATOR SHAFT (2) with the travel of the engine speed control lever (6). d. At FULL IDLE position, the actuator shaft should be pulled ALL THE WAY DOWNWARD. e.
  • Page 85 OM-499 i. Make a preliminary setting of engine idle speed by adjusting the idle speed set screw, which is located on the engine speed control lever. See that this screw is turned INWARD about 3 to 5 turns, to force the engine speed control lever downward slightly from the full upward position.
  • Page 86 OM-499 g. Connect the pick-up wires to a voltmeter. The signal should read between 4 and 8 VAC. h. If the signal is weaker than 4-V AC, check connections. If necessary, check magnetic pick-up continuity or idle speed setting on the fuel pump. i.

  • Page 87: Generator And Exciter Test

    OM-499 d. Upset the engine speed control lever by hand. If the lever oscillates in 3 to 5 diminishing oscillations and stops, the setting is correct. e. Apply a load to the generator set, then remove the load and observe the length of time required for the engine speed to again stabilize.

  • Page 88: Additional Test For Dual Output Unit

    OM-499 TEST CONNECTION NOMINAL RESISTANCE IN OHMS GENERATOR STATOR Phase A to N * 0.00827 Phase B to N * 0.00835 Phase C to N * 0.00840 EXCITER A-B, B-C, A-C 7.23 Field (RED to YELLOW-BLACK) ROTATING FIELD 2.19 Measure resistance at revolving field rectifier (CR2) with exciter armature leads removed from rectifier.
  • Page 89 OM-499 TEST BOX TEST POINTS TEST CONDITION VOLTAGE POINTER CONNECTOR DESCRIPTION POSITON TERMINALS Phase “A” input for reg. and Unit in “GEN” mode 115-V AC trays 400 HZ Phase “B” input for reg.and Unit in “GEN mode & 115-V AC trays auto-man sw.
  • Page 90 OM-499 No. 2 Output on Dual Output Units Figure 13 May 31/94 Revised Page 20...
  • Page 91 OM-499 Chapter 3. Troubleshooting Procedures Section 1. Troubleshooting 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 92 OM-499 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. If a test box, part number 388318A -2, is available tests may be made more quickly and accurately, however, the test receptacle connector may be used by inserting the test points of a volt-ohmmeter into proper terminals of the connector.
  • Page 93 OM-499 See 2-3 Fig. 13 for typical test values at test receptacle and test box. 7. Check Connections and Leads ALWAYS make a check of connections and leads to a component suspected of being faulty. With the exception of a few instances, we will assume that connections and wiring have always been checked first and that power has not been lost as a result of defective wiring or connections.
  • Page 94 OM-499 1. Frequency meter 12. Protective relay tray 22. Load contactor indicating light 2. Voltmeter r 13. Instrument panel light 23. Oil pressure gage 3. Fastener 14. Generator control tray 24. Cold weather starting aid control 4. AC Ammeter 15. Fuel gage 25.
  • Page 95 OM-499 32. Manual voltage control rheostat 38. Cable length compensation 33. Automatic-manual voltage control rheostat switch 39. Cable size compensation 34. Test bank switch rheostat 35. Light test switch 40. Line-drop compensation on-off 36. Reset switch switch 37. Automatic voltage control 41.
  • Page 96 OM-499 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 May 31/94 Revised Page 6...
  • Page 97 OM-499 Test Receptacle Connector Terminals Identification Figure 4 May 31/94 Revised Page 7...
  • Page 98 OM-499 This page intentionally left blank. May 31/94 Revised Page 8...
  • Page 99 OM-499 Engine and Controls Trouble, Symptom & Condition Test or Inspection Corrective Action 1. Engine will not start. Starter a. Batteries discharged or Check voltage across batteries. will NOT crank engine. loose battery or ground Voltage should be approximately connection 13.5-V DC.
  • Page 100 OM-499 Engine and Controls Trouble, Symptom & Condition Test or Inspection Corrective Action Engine will not start. Cranking c. Fuel shut-off valve closed Make certain that fuel shut-off speed normal. (Continued) valve is open d. Loose connections, Tighten all fittings and connec- damaged hoses or fuel tions.
  • Page 101 OM-499 Engine and Controls(cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action 5. Engine starts. Stops after a a. The shut-down circuit may Re-start the engine, hold few seconds by automatic have functioned normally permissive start switch in shut-down. to stop the engine because START position, and observe oil of low lubricating oil...
  • Page 102 OM-499 Engine and Controls(cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action Engine will not come “up” to c. Defective or mis-adjusted The controller may not be governed speed in GEN magnetic pickup. receiving a signal from the mode.(Continued) magnetic pickup and the “fail -safe”...
  • Page 103 OM-499 Engine and Controls (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action 8. Engine goes to overspeed a. Governed speed control Turn speed control adjustment when control switch (18, Fig. 1) adjustment set too high. screw fully counterclockwise. is in GEN position.
  • Page 104 OM-499 Engine and Controls (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action 11. Engine “misses”. Runs a. Insufficient fuel. Check fuel flow in accordance unevenly. with Perkins Diesel Handbook. Repair or replace parts as required. Also see ENGINE, Trouble 3.
  • Page 105 OM-499 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. excitation circuit. which will allow the mechanic to Generator operating at 400 Hz reach some definite conclusions in AUTOMATIC mode.
  • Page 106 OM-499 Generator and Excitation Circuit (cont.) Trouble, Symptom & Condition Test or Inspection Corrective Action No (or low) generator output f. Defective ballast If output voltage was produced voltage in all phases. resistor(s), (See Fig. 5). when the generator set was Generator operating at 400 Hz operated in MANUAL mode, the in AUTOMATIC mode.
  • Page 107 OM-499 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. 1) in AUTO mode. circuit.
  • Page 108 OM-499 No. 1 Load Contactor Operating Circuit (Continued) 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. connect a Fig.
  • Page 109 OM-499 No. 1 Load Contactor Operating Circuit (Continued) Trouble, Symptom & Condition Test or Inspection Corrective Action Load contactor (K1) will close f. Small contacts in load Connect a jumper lead between when control switch (20, Fig. 1 contactor (K1) defective. small terminals No.
  • Page 110 OM-499 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. To avoid repetition, it will be assumed that the reset switch [(36), Fig.
  • Page 111 OM-499 Protective Circuit (Continued) Trouble, Symptom & Condition Test or Inspection Corrective Action Load contactor opens during c. Defective protective With unit running normally, use power delivery. Undervoltage monitor module (K14). voltage regulator adjustment indicating light ON. (Continued) potentiometer ( 37, Fig. 1 ) to reduce voltage quickly to 90-V.
  • Page 112 OM-499 Protective Circuit (Continued) Trouble, Symptom & Condition Test or Inspection Corrective Action 5. Load contactor opens during a. There may have been an Observe ammeter ( 4, Fig. 1 ). power delivery. Overfrequency overload condition which Check for abnormal overload indicating light ON.
  • Page 113 OM-499 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. b. Open or short circuited Check stator windings in stator Phase.
  • Page 114 OM-499 This page intentionally left blank. May 31/94 Revised Page 24...
  • Page 115 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 Division, Troy, Ohio, 45373. These sets are identified as Hobart Series No. 6810 & 6810A. 2. Purpose...
  • Page 116 OM-499 (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 NOMENCLATURE column. Vendor parts which are modified by Hobart will be identified as such in the NOMENCLATURE column.
  • Page 117 OM-499 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 118 OM-499 CODE VENDOR’S NAME AND ADDRESS 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. 260 W. Exchange St. Providence, RI 02901 27192 Eaton Corporation Power Control Operations 4265 N.
  • Page 119 OM-499 CODE VENDOR’S NAME AND ADDRESS 73559 Carlingswitch, Inc. 505 New Park Ave. West Hartford, Connecticut 06110 74400 Stewart Warner Corp, Hobbs Div. Ash Street & Yale Boulevard Springfield, Illinois 62705 75175 K-D Lamp Company 1910 Elm St. Cincinnati, OH 45210 75358 Knape &...
  • Page 120 OM-499 CODE VENDOR’S NAME AND ADDRESS 95879 Alemite Instrument Division of Stewart-Warner Corporation 1826 Diversey Parkway Chicago, IL 60614 98738 Stewart-Warner Electronics Div. of Stewart-Warner Corp. 1300 N. Kostner Chicago, IL 60651 98991 Worchester Controls Corp. Worchester Valve Division 125 Hartwell Street West Boyleston, Massachusetts 01583 No Number Tech Products Corporation 5030 Linden Avenue Dayton, Ohio 45432...
  • Page 121 OM-499 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 122 OM-499 Generator Set Figure 1 May 31/94 Revised Page 2...
  • Page 123 FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY S-6824-1, A-1, A-5, GENERATOR SET FOR TRAILER OR B-1, and B-5 TRUCK MOUNTING S-6824-2, A-2, A-6, GENERATOR SET FOR TRACTOR B-2 and B-6 MOUNTING S-6824-3, A-3, A-7, GENERATOR SET, FIXED UNIT WITH...
  • Page 124 OM-499 Canopy Assembly Figure 2 May 31/94 Revised Page 4...
  • Page 125 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 489860 CANOPY ASSEMBLY (For NHA See Fig. 1) 489112 CANOPY ASSEMBLY (For NHA See Fig. 1) 481416 . SUPPORT ASSY, MTG., FRONT 387450 . COVER ASSEMBLY, HOLE, RADIATOR 482429 .
  • Page 126 OM-499 This page intentionally left blank. May 31/94 Revised Page 6...
  • Page 127 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY CANOPY ASSEMBLY (CONTINUED) 389284 . COVER, HOLE, FRONT, CANOPY 482326 . HORN & CABLE CLAMP ASSEMBLY 7F-422 . . CLAMP, CABLE 100GH-121 . . BRACKET, MTG., CLAMP 482442 . . HORN ASSEMBLY, CABLE ENTRANCE...
  • Page 128 OM-499 Canopy Assembly Figure 3 May 31/94 Revised Page 8...
  • Page 129 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 489861 CANOPY ASSEMBLY (For NHA See Fig. 1) 481416 . SUPPORT ASSY, MTG., FRONT 387450 . COVER ASSEMBLY, HOLE, RADIATOR 482429 . PANEL ASSEMBLY, LOUVERED, FRONT, CANOPY 482437 . FRONT ASSEMBLY, CANOPY 488871 .
  • Page 130 OM-499 This page intentionally left blank. May 31/94 Revised Page 10...
  • Page 131 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 489861 CANOPY ASSEMBLY (CONTINUED) * 27 403091-8 . PLUG, PLASTIC, 1 3/4-INCH V28520, No. DP-1750 * 28 482482 . BRACKET, MTG. DOOR LATCH * 29 482507 . ROD, STOP, DOOR...
  • Page 132 OM-499 Generator Set Without Canopy Figure 4 May 31/94 Revised Page 12...
  • Page 133 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number GENERATOR SET WITHOUT CANOPY (For NHA See Fig. 1) No Number . GENERATOR GROUP (For Details see Fig. 20) 482319 . PANEL ASSEMBLY, TERMINAL, STATOR (For Details See Fig. 12) 482075-2 .
  • Page 134 OM-499 This page intentionally left blank. May 31/94 Revised Page 14...
  • Page 135 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY GENERATOR SET WITHOUT CANOPY (CONTINUED) 482296-17 . PANEL ASSEMBLY, CONTROL, ENGINE (For Details See Fig. 18) 482296-18 . PANEL ASSEMBLY, CONTROL, ENGINE (For Details See Fig. 18) 482296-19 . PANEL ASSEMBLY, CONTROL, ENGINE (For Details See Fig.
  • Page 136 OM-499 Radiator PN 486773 Radiator and Cooling System Group Figure 5 May 31/94 Revised Page 16...
  • Page 137 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number RADIATOR AND COOLING SYSTEM GROUP (For NHA See Fig. 4) 403034 . CAP, RADIATOR, V78225, No. AAX-0B48 W-10869-3 . CLAMP, HOSE, RADIATOR, V 62295 No. C32P 488697 .
  • Page 138 OM-499 Air Cleaner Assembly Figure 6 May 31/94 Revised Page 18...
  • Page 139 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488694 KIT, AIR CLEANER, ASSY (For NHA see Fig. 4) REF 84A-1011 . AIR CLEANER V18265, No. FHG09-0024 84A-1010 . CLAMP, MOUNTING, AIR CLEANER V18265, No. POO-4073 488741 . PLATE, MOUNTING, AIR CLEANER 489291 .
  • Page 140 OM-499 Electric Governor Assembly Woodward Governor Kit - Part No. 488701 Figure 7 May 31/94 Revised Page 20...
  • Page 141 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488701 KIT, ELECTRIC GOVERNOR, ASSY * * (WOODWARD GOVERNOR) (For NHA See Fig. 4) 281774-2 . SENSOR, MAGNETIC, GOVERNOR 84A-1009 . CONTROLLER, GOVERNOR, ELECTRIC V31361, No. 8290-040 84A-1020 . ACTUATOR, GOVERNOR, ELECTRIC V31361, No.
  • Page 142 OM-499 Fuel Lines Assembly Figure 8 May 31/94 Revised Page 22...
  • Page 143 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488702 LINES, FUEL, ASSEMBLY (For NHA See Fig. 4) REF W-10760-3 . NIPPLE, PIPE, 1/2 12CW-2077-3 . STREET, ELL, 90 V26403, No. 1/2-INCH, 90 W-7814-5 . BUSHING, PIPE, STEEL 400819-1 .
  • Page 144 OM-499 Oil Line Assembly Figure 9 May 31/94 Revised Page 24...
  • Page 145 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488695 LINE, OIL, ASSEMBLY (For NHA See Fig. 4) 403809-1 . SWITCH, LOW OIL PRESSURE V51377, No. C-25900-10 1 W-10909-1 . TEE, STREET, BRASS V79470, No. 3750 X 2 W-10886-1 .
  • Page 146 OM-499 Fuel Oil Lines Figure 10 May 31/94 Revised Page 26...
  • Page 147 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 10 - 388763 LINES, FUEL OIL (For NHA See Fig. 4) W-10891-8 . ELBOW, MALE V79470, 49 X 8 403590-4 . FITTING, SWIVEL, FEMALE 3/4 SAE, THD. V03924 56551 .
  • Page 148 OM-499 Fuel Oil Lines Figure 11 May 31/94 Revised Page 28...
  • Page 149 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 11 - 488764 LINES, FUEL OIL, ASSY. W-7814-11 . BUSHING, PIPE, STEEL W-10891-7 . ELBOW, MALE V79470, No. 49 X 4 W-10893-2 . FITTING, HOSE, SWIVEL, FEMALE V30327, No. KA04-04NS 56534 .
  • Page 150 OM-499 Stator Terminal Panel Assembly Figure 12 May 31/94 Revised Page 30...
  • Page 151 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 12 - 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 152 OM-499 Power Module Panel Assembly Figure 13 May 31/94 Revised Page 32...
  • Page 153 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 13 - 482075-2 PANEL ASSEMBLY, POWER MODULE (For NHA See Fig. 4) 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.
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  • Page 155 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 13 - PANEL ASSEMBLY, POWER MODULE (CONTINUED) W-9360-279 . CABLE ASSEMBLY, POWER ELECTRICAL (No. 101) “A” Stator Terminal Panel to “A” Contactor; (No. 102) “B” Stator Terminal Panel to “B” Contactor; (No. 103) “C” Stator Terminal to “C”...
  • Page 156 OM-499 Control Box Assembly Figure 14 May 31/94 Revised Page 36...
  • Page 157 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 14 - 482235-2 CONTROL BOX ASSY (For NHA see Fig. 4) 482278-2 . TRAY ASSY, GENERATOR CONTROLS (For Details see Fig. 15) 482285-1 . TRAY ASSEMBLY, PROTECTIVE RELAYS (For Details see Fig. 16) No Number .
  • Page 158 OM-499 Generator Controls Tray Assembly Figure 15 May 31/94 Revised Page 38...
  • Page 159 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 15 - 482278-2 TRAY ASSEMBLY, GENERATOR CONTROLS (For NHA See Fig. 14) 482355 . HARNESS, WIRE, RECEPTACLE 482284-1 . BRACKET, MOUNTING, RECEPTACLE AND SWITCH 402826 . SWITCH, AUTOMATIC, MANUAL V15605, No.
  • Page 160 OM-499 This page intentionally left blank. May 31/94 Revised Page 40...
  • Page 161 CONTROLS (CONTINUED) 482279 . TRAY SUB-ASSEMBLY, GENERATOR CONTROL 370382A . . HANDLE, TRAY 404028 . . NAMEPLATE, HOBART 76A-1115 . . LATCH, ADJUSTABLE GRIP V94222 No. 48-99-126-11 . . SLIDE ASSEMBLY, TRAY (Consists of four parts 402383 marked CR, CL, DR, & DL) V75358, No. 1335-12...
  • Page 162 OM-499 Protective Relays Tray Assembly Figure 16 May 31/94 Revised Page 42...
  • Page 163 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 16 - 482285-1 TRAY ASSEMBLY, PROTECTIVE RELAYS (For NHA See Fig. 14) 402662 . SWITCH, TEST BANK V73559, No. 2GK71-73 482284-2 . BRACKET, MTG., RECEPTACLE & SWITCH 482356 . RECEPTACLE, HARNESS, WIRE 16DA-4052-0 .
  • Page 164 OM-499 This page intentionally left blank. May 31/94 Revised Page 44...
  • Page 165 . TRAY ASSEMBLY, PROTECTIVE RELAYS . . SLIDE ASSEMBLY, TRAY (Consists of four 402383 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 166 OM-499 Control Box and Internal Components Group Figure 17 May 31/94 Revised Page 46...
  • Page 167 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 17 - No Number CONTROL BOX AND INTERNAL COMPONENTS GROUP (For NHA See Fig. 14) 402037-9 . GROMMET, RUBBER V02231, No. AGW-4211 82B-1047 . LIGHT, PANEL V74400, No. MI-3216 400613-4 .
  • Page 168 OM-499 Engine Control Panel Assembly Figure 18 May 31/94 Revised Page 48...
  • Page 169 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 18 - 482296-17 PANEL ASSEMBLY, CONTROL, ENGINE (For NHA See Fig. 4) 482296-18 PANEL ASSEMBLY, CONTROL, ENGINE (For NHA See Fig. 4) 482296-19 PANEL ASSEMBLY, CONTROL, ENGINE (For NHA See Fig. 4) 484016 .
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  • Page 171 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 18 - 482296-17 PANEL ASSEMBLY, CONTROL, ENGINE(Cont’d) 400701 . CONNECTOR, RIGHT ANGLE, V59730, No. TA-250-8 No Number . SWITCH, PERMISSIVE START (Furnished with Engine) No Number . NAMEPLATE, START-RUN-STOP...
  • Page 172 OM-499 Output Terminal Board Assembly Figure 19 May 31/94 Revised Page 52...
  • Page 173 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 19 - 482317 BOARD ASSEMBLY, TERMINAL, OUTPUT (For NHA See Fig. 4) 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 174 OM-499 Generator Group Figure 20 May 31/94 Revised Page 54...
  • Page 175 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 20 - No Number GENERATOR GROUP (For NHA See Fig. 4) 387617A . COVER, FAN, HOUSING 387621 . COVER, EXCITER HOUSING 480235A . FAN & COUPLING ASSEMBLY (Series 6824) 488908 .
  • Page 176 OM-499 Mounting Frame and Lifting Yoke Assembly Figure 21 May 31/94 Revised Page 56...
  • Page 177 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 21 - No Number FRAME ASSEMBLY, MOUNTING & LIFTING YOKE (For NHA See Fig. 1) 482316 . BRACKET, MOUNTING, SUPPORT, BOX, CONTROL 482315 . PANEL, SUPPORT, CONTROL BOX 482311 .
  • Page 178 OM-499 Auxiliary Frame and Components Group Figure 22 May 31/94 Revised Page 58...
  • Page 179 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 22 - No Number AUXILIARY FRAME & COMPONENTS 403492-1 . BATTERY, 6 VOLT, AABM GROUP 7D, V20038, #HHD-70, or equiv. 480674 . BOX, BATTERY, ASSEMBLY 480675 . . LID, BATTERY, BOX 402037-23 .
  • Page 180 OM-499 Electric Governor Assembly May 31/94 Revised Page 60...
  • Page 181 OM-499 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 7A - 282671 KIT, ELECTRIC GOVERNOR, ASSY. *** (For NHA See Fig. 4) 281772 . ACTUATOR, GOVERNOR, ELECTRIC V03613,No.DYNC-10502-000-0-12 282501 . CONTROLLER, GOVERNOR, ELECTRIC V03613,No. DYN1-10704 282673 . BRACKET, MTG. ACTUATOR 282674 .
  • Page 182 OM-499 This page intentionally left blank. March 31/74 Revised Page 21A...
  • Page 183 OM-499 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 184 OM-499 FIGURE & PART NUMBER ITEM NUMBER W-10072-1 20-21 W-10072-48 20-20 W-10119-4 8-24 W-10750-3 6-12 W-10760-3 W-10760-11 8-23 W-10854-4 12-6 W-10869-1 5-22 W-10869-3 W-10869-5 W-10875-1 20-10 W-10874-1 20-11 W-10886-1 8-25, 9-3 W-10886-2 8-20 W-10891-1 11-16 W-10891-7 8-6, 11-2 W-10891-8 10-1 W-10891-11 10-4 W-10893-0...
  • Page 185 OM-499 FIGURE & PART NUMBER ITEM NUMBER W-11254-6 12-2, 19-6 W-11254-10 7A-14 W-11280-3 7-7, 7A-17 W-11278-7 7A-19 W-11287-3 7A-15 W-11330 4-39 W-11608-3 8-22 W-2974A 18-28 W-2974-L 15-6 W-2974-N 15-7 W-7814-2 11-18 W-7814-4 8-21 W-7814-5 W-7814-9 5-24 W-7814-10 W-7814-11 11-1 W-8095A-9 15-21 W-8105A-4 15-22...
  • Page 186 OM-499 FIGURE & PART NUMBER ITEM 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 13-32, 16-5 16DA-4004A-10 13-34, 15-9, 16-7 16DA-4029 15-13 16DA-4052-0 13-27, 15-10, 16-4 16DA-4133-2 22-4 16DA-4253-1 13-33, 15-8, 16-6 180132 181343 20-22 281772 7A-1 281774-2 281774-2...
  • Page 187 OM-499 FIGURE & PART NUMBER ITEM NUMBER 387617A 20-1 387620A-1 20-18 387621 20-2 387623-1 20-9 387624A-1 20-14 387736B 16-11 387738A 13-8 387748-1 20-23 387881 387915 21-5 387916 21-4 387947 21-10 388328-49 15-24 388328-52 16-26 388763 4-30, 10-0 388828-1 22-7 389284 2-27 389909 400059-3...
  • Page 188 OM-499 FIGURE & PART NUMBER ITEM NUMBER 401939 13-14 402037-9 16-25, 17-1 402037-14 13-30 402037-23 22-3 402096 402194 21-8 402197-1 13-16 402218 15-17 402383 15-28, 16-31, 17-6 402658 16-21, 18-16 402662 13-31, 16-1 402665-1 15-4 402826 15-3 402889-2 18-5 402908 7-5, 7A-23 402958 5-10...
  • Page 189 OM-499 FIGURE & PART NUMBER ITEM NUMBER 404124 4-17 404402-2 13-4 404518 13-7, 13-29 405015 4-34 405071-1 7-13 405099 4-35 430278 21-12 430391C 480235 20-3 480603-1 20-26 480618 4-23 480619 4-24 480621 4-12 480628 20-27 480646 20-19 480669 20-5 480674 22-1 480675 22-2...
  • Page 190 OM-499 FIGURE & PART NUMBER ITEM NUMBER 482284-1 15-2 482284-2 16-2 482285-1 14-2, 16-0 482286 16-30 482287 16-35 482291 16-30 482296-17 4-18, 18-0 482296-18 4-18, 18-0 482296-19 4-18, 18-0 482298 18-27 482304 18-25 482305 4-27 482306 15-30 482307 16-36 482311 21-3 482315 21-2...
  • Page 191 OM-499 FIGURE & PART NUMBER ITEM NUMBER 482429 2-3, 3-3 482437 2-4, 3-4 482442 2-31 482443 12-5, 19-9 482444 19-13 482445 19-4 482446 12-4, 19-8 482449 12-8 482450 12-13 482458 3-19 482459 3-21 482464 3-20 482468 3-22 482469 2-24 482482 2-34, 3-28 482471 12-7...
  • Page 192 OM-499 FIGURE & PART NUMBER ITEM NUMBER 488698 488699 5-19 488700 4-13 488701 488702 4-28, 8-0 488735-1 4-36 488735-2 4-37 488741 488755 20-7 488764 4-31, 11-0 488863 2-26, 3-25 488871 2-5, 3-5 488872 2-10, 3-10 488908 20-3 488993 20-24 489029 2-17 489030 2-13, 3-13...
  • Page 193 OM-499 FIGURE & PART NUMBER ITEM NUMBER 56551 10-3 56552 10-6 56555 5-17 7F-422 2-29 75NH-306 19-16 75NH-307 19-15 76A-1115 2-21A, 15-27, 16-34 76A-1118 16-17 76A-1130 14-4 76A-1152 22-12 78A-1021 8-12 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-1021 11-10...
  • Page 194 OM-499 This page intentionally left blank. May 31/94 Revised Page 12...
  • Page 195 Truck, Chevrolet TO-109 404137 Truck, Ford, Std. TO-109 403757 Truck, GMC TO-109 404238 Second Output, TR Box Mounted, for Specifications 6824-1, 6824A-1, 6824-2, 6824A-2, 6824-3, 6824A-3, TO-128 481428A Quick Start Kit OM-499 488913 * Kit, Water Heater Assembly TO-177 180483...
  • Page 196 OM-499 This page intentionally left blank. May 31/94 Revised Page 2...
  • Page 197 Barber-Colman Governor Company Electrically Powered Governor Manual Engine Perkins Engines, Inc. Handbook for Diesel Engines T6.3544 and 6.3544 Flexible Coupling Hobart Brothers Company Coupling Manual OM-2019 Exciter Rotor Hobart Brothers Company Rotor Manual TM-360 Hobart Diagrams 482360 - Schematic, Generator...
  • Page 198 OM-499 This page intentionally left blank. May 31/94 Revised Page 2...
  • Page 211 OM-499 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 212 OM-499 This page intentionally left blank. Unusual Service Conditions May 31/94 Revised Page 2...

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