Hobart 90CU24 Operation And Maintenance Manual
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Hobart 90CU24 Operation And Maintenance Manual

Hobart 90CU24 Operation And Maintenance Manual

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OM-2084
112797
Revised 10/98
Operation and Maintenance Manual
Model 90CU24 Generator Sets
Series 500392
Hobart Brothers Company
Ground Power Division
Troy, OH 45373
U.S.A.

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  • Page 1 OM-2084 112797 Revised 10/98 Operation and Maintenance Manual Model 90CU24 Generator Sets Series 500392 Hobart Brothers Company Ground Power Division Troy, OH 45373 U.S.A.
  • Page 2 In the event any component manufacturer has warranted its component to HOBART and will not deal directly with a first user then HOBART will cooperate with the first user in the presentation of a claim to such manufacturer. Under NO circumstances does HOBART assume any liability for any warranty claim against or warranty work done by or in behalf of any manufacturer of the foregoing components.
  • Page 3 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Safety Warnings and Cautions WARNING CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
  • Page 4 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage) capacity of the grounding lead will be adequate for the worst fault current situation.
  • Page 5 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Medical and First Aid Treatment First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital immediately if any abnormal signs are observed.
  • Page 6 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets This page intentionally left blank. Safety Warnings November 27/1997 Page 4...
  • Page 7 90CU24 / Series 500392 Generator Sets Introduction This manual contains operation and maintenance information for a Hobart generator set manufactured by Hobart Brothers Company, Ground Power 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 operated this equipment.
  • Page 8 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets This page intentionally left blank. November 27/1997 Introduction Page 2...
  • Page 9 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Table of Contents Chapter-Section Page Chapter 1. Description / Operation Section 1. Description General Orientation Optional Equipment Special Features Protective Monitor Voltage Regulator Electric Governor Canopy Engine, Generator, and Control Box Basic Engine Engine Manufacturer’s Equipment...
  • Page 10 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Section 3. Operation General Operating the Unit Pre-start inspection Normal Engine Starting Procedures Failed Starting Procedures Power Delivery Discontinue Power Delivery with Unit Shutdown Chapter 2. Servicing Section 1. Maintenance Inspection/Check...
  • Page 11 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Engine Fuel How to Select Fuel—Quality Cold Weather Operation Engine Fuel System Fuel Tank Fuel Pre-Filter/Separator Fuel Pump Fuel Filter and Pre-filter Straining Screen Fuel Return Priming Fuel System...
  • Page 12 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Testing the No. 2 output circuit Testing and checking meters, switches, relays, and indicating lights Re-checking the entire unit after testing Generator Set Adjustment Generator Adjustment Adjust 400 Hz voltage regulator...
  • Page 13 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Installing the Exciter Armature Preparation for Exciter Armature Installation Exciter Armature Installation Section 2. Dual Bearing Flexible Coupling General Coupling Bolts Disassembly Separate Engine and Generator Remove Coupling Assembly...
  • Page 14 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Chapter 4. Illustrated Parts List Section 1. Introduction General Purpose Arrangement Explanation of Parts List Contents Parts List Form Section 2. Manufacturer’s Codes Explanation of Manufacturer’s (Vendor) Code List Section 3.
  • Page 15 Chapters 1 through 5 of this Operation and Maintenance Manual identifies only the “strip down” version of the 90CU24 generator set. A list of optional equipment which make this manual unique to the generator set that you have purchased, appears in Appendix A. A few items included in Appendix A are cable trays, trailers, 28-volt DC power transformer-rectifiers, etc.
  • Page 16 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Control Panel 4. Emergency Stop Switch 2. Output Cable Clamps 5. Canopy 3. Frame 6. Radiator Access Door Generator Set Figure 1 Chapter 1-1 November 27/1997 Page 2...
  • Page 17 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets c. Electric Governor The engine is equipped with an electric governor kit and other special equipment more fully described under the engine description. Canopy A sheet metal enclosure, identified as a canopy, provides protection for the engine, generator, and electrical controls.
  • Page 18 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Engine Manufacturer Cummins Engine Company, Inc. Columbus, Ohio 47201 Model No. 6BT5.9C165 Type In-line 6 cylinder 4 Cycle Diesel Bore and Stroke 4.02 x 4.72 inches (10.2 x 11.9 cm) Displacement 359 c.i.
  • Page 19 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Radiator 6. Output Module Panel 2. Engine 7. Engine-Generator Control Panel 3. Generator 8. Mounting Frame 4. Air Cleaner 9. Muffler 5. Control Box Generator Set Components...
  • Page 20 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (4) Engine over-speed protection The engine is protected against over-speed by a speed-limiting mechanism in the mechanical governor. c. Engine-cooling fan The engine fan is designed to blow air outward through the radiator, rather than pull the air inward as a conventional fan does.
  • Page 21 90CU24 / Series 500392 Generator Sets e. Hobart Installed Equipment This generator set is modified at Hobart Brothers by the addition of the following equipment: (1) Shut Down/Reset device In addition to the other devices provided by the engine manufacturer, an engine shutdown/reset feature is added by Hobart Brothers.
  • Page 22 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (4) Radiator The radiator is a one-piece type designed for long periods of operation without servicing. Refer to Section 2-1 for servicing procedure. (5) Air cleaner The diesel-engine air cleaner (fig. 4) is so constructed that air enters through its cylindrical body, and then is filtered in the process before being passed onto the engine turbo-charge assembly.
  • Page 23 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Control Box Assembly The control box is a sheet metal enclosure which houses and provides mounting facilities for engine and generator controls and monitoring equipment. a. Control Panel (Fig. 5) On the door of this control box is the control panel.
  • Page 24 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Fuel Gage 15. Over Voltage Indicator Light 2. Front Panel 16. Adjustable Grip Latch 3. Engine Coolant Temperature Meter 17. Under Voltage Indicator Light (Red) 4. Over Temperature Indicator Light (Red) 18.
  • Page 25 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (8) Engine ammeter The ammeter (8) indicates the direction and value of current flow from or to the 12-V DC battery. Its graduated range is from -60 A through O A to + 60 A.
  • Page 26 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Control Box Wrapper 11. Panel Lights (2) 2. Control Box Top 12. Engine Circuit Breaker (10A) 3. Receptacles (4) 13. Controls Circuit Breaker (5A) 4. Memory and Time Delay PC Board 14.
  • Page 27 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets b. Control Box Interior Components (Fig. 6) (1) Test bank aircraft switches For each load contactor circuit, a single-pole, single-throw toggle switch (16 or 17) provides a means of bypassing the interlock circuit for that contactor when supplying power to a load bank or to an aircraft not equipped with a plug interlock system.
  • Page 28 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Trip values for protective circuits are as follows: Over voltage relay Trips at 126 volts after 1-second time delay. Trips at 140 volts in 160 milliseconds. Trips at 180 volts in 50 milliseconds.
  • Page 29 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Master Relay (K69) 7. No. 2 Plug-Interlock Relay (K202) 2. Idle-Excitation Relay (K68) 8. No. 1 Plug-Interlock Relay (K2) 3. Over Temperature Fault Relay (K67) 9. Bypass Relay (K73)) 4.
  • Page 30 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets • Relays K65, K66, K67 and K71 are fault relays. Each receives a signal from engine sensors, and illuminate panel lights to indicate the presence of a fault. Activation of the over temperature relay, K67, or low oil pressure relay, K71, result in interruption of 12-V DC power to the governor controller, causing the engine to shut down.
  • Page 31 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Output Voltage Adjustment (Course) 3. Line Drop Compensation Adjustment 2. Output Voltage Adjustment (Fine) Voltage Regulator PC Board Figure 8 November 27/1997 Chapter 1-1 Page 17...
  • Page 32 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 400 Hz. Output Module Panel Assembly Single Output 500392-001 (See Fig. 9) The output module panel assembly, sometimes referred to as the contactor panel, is located at the left front of the machine under the control box.
  • Page 33 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Overload PC Board 6. Overload Current Transformer (T30, T31, T32) 2. Resistor, 50 ohm, 20 watt (R16, R17, R18) 7. Flyback Diode, Exciter 3. Line Drop Current Transformer (T4, T5, T6) 8.
  • Page 34 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 400 Hz. Output Module Panel Assembly, Dual Output 500392-2 The dual output generator set (500392-2) can provide 400 Hz. service on two output cables simultaneously. To make this possible, certain components are added to single output module panel (Fig.
  • Page 35 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Section 2. Preparation for Use, Storage or Shipping Preparation for Use a. Inspection/Check Inspect the unit thoroughly prior to operation. (1) Remove blocking, banding, ties, and other securing material.
  • Page 36 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Oil Level Gauge Oil Fill Oil Fill and Check Location Figure 1 Lubricating oil capacity with filter 24 Quarts (22.7 liters) Coolant capacity including radiator 38 Quarts (36 liters)

  • Page 37: Preparation For Storage

    (2) The unit should be stored in a building which is dry and which may be heated during winter months. (3) Moisture absorbing chemicals (Hobart Brothers Part No. 76A-1354-001) are available for use where excessive dampness is a problem; however, the unit must be completely packaged and sealed if moisture absorbing chemicals are to be effective.
  • Page 38 Place containers of moisture absorbing chemicals, Hobart Brothers Part No. 76A-1354-001, in the unit before packaging. The unit may be stored for long periods with no special preparation if it is possible to operate the engine once each week.
  • Page 39 Refer to Operating Instructions in the Cummins Operation Manual, when starting engine for the first time. NOTE: The Cummins Operation Manual is provided with this Hobart manual (OM-2084) . (1) If illumination is required, press lamps push-button switch (28) one time. Pressing this button switch also activates the fuel gage.
  • Page 40 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Fuel gage 15. Overvoltage indicator light (red) 2. Front panel 16. Adjustable grip latch 3. Engine coolant temperature meter 17. Undervoltage indicator light (red) 4 . Over temperature indicator light (red) 18.
  • Page 41 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 29. Regulated-diagnostic switch 34. Circuit Breaker, control (5-amp) 30. Test bank-aircraft switch No. 1 output 35. Engine circuit breaker (10-amp) 31. Test bank-aircraft switch, No. 2 output 36. Output voltage adjustment (coarse) 32.
  • Page 42 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets CAUTION If the engine fails to start within 5 seconds, the control system will automatically disable the starting motor and indicate a low oil pressure fault. The emergency stop switch must be pressed to reset the control system and allow another starting attempt.
  • Page 43 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (4) 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 44 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets This page intentionally left blank. Chapter 1-3 November 27, 1997 Page 6...
  • Page 45 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Chapter 2. Servicing/Troubleshooting Section 1. Maintenance Inspection/Check 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 to components, or failure of the equipment.
  • Page 46 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Once 1000 1500 2000 HOURLY INTERVAL after Req. Daily 6Mo. 1-1/2 CALENDAR INTERVAL Year Years Years SYMBOL ENGINE Change Air Cleaner Cartridge Tighten Manifold Hardware Check Crankcase Oil Level...
  • Page 47 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Once 1000 1500 2000 HOURLY INTERVAL after Req. Daily 6Mo. 1-1/2 CALENDAR INTERVAL Year Years Years SYMBOL ENGINE Clean/Calibrate/Replace Injectors Check Fuel Pump Calibration Change Coolant Inspect Cylinder Heads...
  • Page 48 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Time Intervals Symbols Hours Calendar 50-150 None As Required None 10 Hours Daily 250 Hours 3 Months 500 Hours 6 Months 1000 Hours 1 Year 1500 Hours 1-½ Years...
  • Page 49 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (4) Change oil filter element. The oil filter should be changed with the oil. See 2-2, Para 2, d, (4) for details. (5) Check engine mounts to ensure they are properly installed and that they have not worked loose.
  • Page 50 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets a. Check oil level daily with oil gage dipstick (see 1-2, Fig. 1). b. Oil level should not be checked until 3 to 5 minutes after engine shutdown. Keep oil level as near the upper bar as possible.
  • Page 51 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets a. Output cable plug connector Check the output cable plug connection for damaged insulation and contacts each time the connector is attached to an aircraft. b. Monitoring instruments Check operation of voltmeter, ammeter and frequency meter each time the unit is started.
  • Page 52 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (3) Check engine mounts WARNING An unstable or loosely mounted engine can create hazardous environment and may also damage equipment. a. Engine mount bolts must be torqued to 285 Nm (210 ft-lb.).
  • Page 53 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets h. “E” Checks and Operations (1500 Hours or 1.5 Year) (1) Engine a. Steam clean engine There are several reasons why the engine exterior should be kept clean. Dirt on the outside will enter fuel and oil filter cases and rocker housings when covers are removed, unless dirt is removed first.
  • Page 54 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Alternator Fan Hub Water Pump Vibration Damper Cranking Motor Engine Accessories Figure 5 i. “F” Checks and Operations (2000 Hours or 2 Years) (1) Engine These checks should determine whether the engine requires a complete overhaul or whether it may be operated for another service period.
  • Page 55 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets c. Change coolant d. Inspect cylinder heads for the possibility of overhaul e. Inspect pistons and piston rings f. Inspect bearings and Journals j. Seasonal Maintenance Checks Spring/Fall (Engine) (1) Inspect engine cooling fan each spring and fall.
  • Page 56 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Lamp (Bulb): as per Lamp Industry Light Identification Location Trade Number Instrument Panel Lights Control box Interior (1-1; Figure 6, Item 11) 1815 Engine Start Indicator Engine-Generator Control Panel (1-1;...
  • Page 57 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (4) Cylinder, or its replacement, should be reinstalled by turning cylinder clockwise until the o-ring contacts the valve. Tighten an additional 1-1/2 turns. DO NOT OVER TIGHTEN CYLINDER! b.
  • Page 58 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets This page intentionally left blank. Chapter 2-1 Page 14...
  • Page 59 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Section 2. Maintenance Procedures General A suggested Maintenance Schedule was provided in Section 1, of this Servicing Chapter. Each step of the schedule was also covered in general in Section 1. This Section covers maintenance in more details where necessary.
  • Page 60 Use oil that conforms to API specification CE/SG. Capacity Engine lube oil capacity with filter: 16 quarts (15.1 liters) Oil Filter Replacement Oil Filter Replacement Hobart Brothers Part No. 286987-006 Oil Filter Replacement Cummins Part No. 3908615 VISCOSITY AMBIENT TEMPERATURE CONDITIONS...
  • Page 61 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Ambient Temperature SAE Viscosity -13ºF to +95°F (-25 to +20°C) 10W-30 +14°F and above (0°C and above) 15W-40 -40°F to 68°F (-40°C to 20°C) 5W-40 Temperature and Viscosity Chart...
  • Page 62 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Change oil as follows: a. Provide a container for catching used oil. Capacity must be greater than 24 quarts. b. Remove drain plug located in oil pan. c. While oil is draining, change the oil filter element. See instructions below.
  • Page 63 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Right Side of Unit Left Side of Unit Oil Filter Oil Fill Location Oil Level Gauge Changing Oil Filter Figure 6 Alternator Fan Hub Water Pump Vibration Damper...

  • Page 64: Servicing The Air Cleaner

    OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets e. Engine Accessories Lubrication (Fig. 7) (1) Alternator Most alternators contain sealed bearings and require no periodic lubrication, however, CHECK to make certain there are no lubrication points on your particular alternator.

  • Page 65: Engine Fuel

    Change elements after each 200 hours of operation unless a restriction test indicates the time period should be extended. • Replacement primary fuel filter elements are Hobart No. 286897-004. • Replacement secondary fuel filter elements are Hobart No. 286897-005. a. Unscrew element and discard.
  • Page 66 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets b. Fill NEW element with CLEAN fuel. CAUTION When installing new element, do not over tighten it. Tightening it with mechanical tools may distort or crack filter head.
  • Page 67 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets CAUTION When removing cap from a very hot radiator, do not turn cap past safety stop until all pressure or steam has escaped. (2) Removal To remove, turn the cap to the left (counterclockwise) to the safety stop. When all pressure is released, press down on the cap and continue to turn until the cap is free to be removed.
  • Page 68 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets d. Draining the Cooling System To drain the cooling system, proceed as follows: WARNING Check temperature gage; coolant temperature must be no higher than 120º F (50º C) before removal of radiator cap.

  • Page 69: Drive Belts

    OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Drive Belts a. General The engine cooling fan, alternator, fuel pump, and water pump are driven by a timing belt which must be replaced if it becomes worn or damaged.
  • Page 70 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Checking Belt Tension Figure 9 Removing and Inspecting Drive Belts Figure 10 Chapter 2-2 November 27/1997 Page 12...
  • Page 71 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Voltage Regulator Maintenance/Repair When the voltage regulator is working properly, no maintenance is necessary. However, if the generator set is used in a dusty environment, the regulator should be periodically cleaned with compressed air.
  • Page 72 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets NOTE: To check system for proper operation, the Engine Temperature Sensor (ETS) must be below 40º F (4º C) or be bypassed by connecting the valve’s black lead directly to a good ground.
  • Page 73 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Section 3. Adjustment/Test General These adjustment and test procedures are applicable to testing and adjusting the generator set after major repair, major parts replacements, or overhaul. Testing the Generator Set a.
  • Page 74 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Fuel gage 15. Overvoltage indicator light (red) 2. Front panel 16. Adjustable grip latch 3. Engine coolant temperature meter 17. Undervoltage indicator light (red) 4 . Over temperature indicator light (red) 18.
  • Page 75 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 29. Regulated-diagnostic switch 34. Circuit Breaker, control (5-amp) 30. Test bank-aircraft switch No. 1 output 35. Engine circuit breaker (10-amp) 31. Test bank-aircraft switch, No. 2 output 36. Output voltage adjustment (coarse) 32.
  • Page 76 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 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 (8, Fig. 1) , coolant temperature indicator (3) , oil pressure gage (7) and hourmeter (5).
  • Page 77 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets c. Testing the No. 1 Output Circuit (See Fig. 1) (1) Make certain that the orange No. 2 contactor on-off push button switch (22, Fig. 1) is in the OFF position, which is indicated when its internal indicating light doesn’t glow.
  • Page 78 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets d. Testing the No. 2 output circuit (See Fig. 1) (500392-002 and -004 Only) (1) Make certain that the No. 1 contactor on-off push button switch (24, Fig. 1) is in the OFF position, which is indicated when its internal indicating light doesn’t glow.
  • Page 79 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets e. Testing and checking meters, switches, circuits, and indicating lights (See Fig. 1) (1) Check accuracy of voltmeter a. Open door of control box and connect a master voltmeter of known accuracy to terminals of the voltmeter (13).
  • Page 80 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets sevensecond time delay. c. If the load contactor does not open under the conditions described in step (b), refer to the Troubleshooting Chart in Section 2-4. d. If the under voltage circuit performs satisfactorily, return unit to normal operation by adjusting output voltage coarse adjustment potentiometer for normal output voltage, pressing the reset push button switch, and closing the load contactor.
  • Page 81 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets f. Re-checking the entire unit after testing (1) With the engine running at normal governed speed, check the entire unit for vibration and for any parts which may have become loosened during the above checks. Tighten any loose attaching hardware as required.
  • Page 82 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets • Connect the generator set output cables to a load. Load the generator set with the largest available three-phase load of rated power factor not exceeding the maximum rating of the generator set.
  • Page 83 The engine run lever (6) is a factory preset throttle control that should not be tampered with. It is set to run wide open. The engine stop control lever (3) linkage along with the hobart installed governor actuator (1) is used to control the engine speed only. These two items (1 and 3) should be used for governor adjustment only.
  • Page 84 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Actuator 4. Ball Joint 2. Stop Lever 5. Nuts 3. Stop Lever Bracket 6. Actuator Rod Governor Actuator Linkage Figure 3 Chapter 2-3 November 27/1997 Page 12...
  • Page 85 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Refer to figure 3 while making linkage adjustments. with engine stopped, check and adjust linkage as follows: a. Before making adjustment, observe and note the hole that the engine stop lever (3) uses to mount the ball joint (4) .
  • Page 86 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Magnetic Pick-Up Adjustment Figure 4 d. Rotate the engine as required to locate a ring gear tooth directly below the tapped, pickup mounting hole. Continue turning pick-up CLOCKWISE until it bottoms out (hits a ring gear tooth).
  • Page 87 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Electric Governor Control Box Figure 5 • Set the “DROOP” potentiometer (1) COUNTER CLOCKWISE to minimum 0 (zero). • Turn the rated speed potentiometer (5) all the way COUNTER CLOCKWISE. Then count twelve full turns CLOCKWISE.
  • Page 88 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets • Slowly turn the “D” potentiometer COUNTER CLOCKWISE until the oscillations stop. Turn the “D” potentiometer ½ an increment past a point where the oscillations stop. • Turn the “I” potentiometer (2) full CLOCKWISE. The frequency meter gage and governor should become unstable and oscillate.
  • Page 89 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets c. Checking Magnetic Pick-up Signal Connect a high impedance voltmeter to magnetic pick-up input terminals (terminals 10 and 11, Fig. 5) on controller terminal board. The voltage value at no load, governed speed should be 4-V AC MINIMUM.
  • Page 90 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets This page intentionally left blank. Chapter 2-3 November 27/1997 Page 18...
  • Page 91 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Section 4. Troubleshooting Procedures General The Troubleshooting Chart, beginning on Page 6, covers the common malfunctions which you may find during operation or maintenance of this equipment. It cannot list all malfunctions that may occur. If a malfunction is not listed in the chart, start looking for the cause at the source of power in the affected circuit.
  • Page 92 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Test Values Although test values are provided throughout the troubleshooting chart , additional information and values are given here. Generator output voltage at maximum voltage regulator potentiometer setting: 134 volts or higher.
  • Page 93 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (2) The actuator will surge under the following conditions: a. Stability or gain adjustment set too high b. Actuator linkage loose c. Actuator linkage binding Engine Troubleshooting The ability of the engine to start and run properly depends upon a number of things.
  • Page 94 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Fuel gage 15. Overvoltage indicator light (red) 2. Front panel 16. Adjustable grip latch 3. Engine coolant temperature meter 17. Undervoltage indicator light (red) 4 . Overtemperature indicator light (red) 18.
  • Page 95 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 29. Regulated-diagnostic switch 34. Circuit Breaker, control (5-amp) 30. Test bank-aircraft switch, 35. Engine circuit breaker (10-amp) No. 1 output 36. Output voltage adjustment (coarse) 31. Test bank-aircraft switch, No. 2 37.
  • Page 96 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Master Relay (K69) 7. No. 2 Plug-Interlock Relay (K202) 2. Idle-Excitation Relay (K68) 8. No. 1 Plug-Interlock Relay (K2) 3. Over Temperature Fault Relay (K67) 9. Bypass Relay (K73)) 4.
  • Page 97 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Engine Controls Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy NOTE: Diesel engine trouble shooting is covered in Cummins Operation Manual. 1. Engine will not start. Starter a.

  • Page 98: Engine Controls

    OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Engine Controls Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy Engine will not start. Starter g. Either of two defective Press lamps button. If clearance will NOT crank engine.
  • Page 99 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Engine Controls Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy Engine WILL NOT start. b. Defective or misadjusted The control unit may not be Cranking speed normal. LOW...
  • Page 100 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy Engine WILL NOT start. g. Faulty fuel pump. Replace fuel pump if defective. Cranking speed normal. LOW OIL indicating lamp on after 5 seconds.
  • Page 101 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Engine Controls Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy 8. Engine starts. Stops after a a. Shut-down circuit may have Restart engine, and observe oil...
  • Page 102 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Engine Controls Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy 12. Engine “misses”. Runs a. Insufficient fuel Check fuel flow in accordance unevenly. with Cummins Operation Manual.
  • Page 103 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Generator Excitation Circuits Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy 1. No (or low) generator output a. Idle-excitation relay (K68) Replace relay K68, bring unit up voltage in all phases.
  • Page 104 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Generator Excitation Circuits Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy No (or low) generator output e. Defective connector at Disconnect plug from voltage voltage in all phases.
  • Page 105 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets No. 1 Load Contactor Operating Circuit Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy 1. Load contactor (K1) will not a. Defective circuit breaker Remove terminal leads from close when output No.
  • Page 106 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets No. 1 Load Contactor Operating Circuit Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy Load contactor (K1) will not e. Defective rectifier (CR6) After making certain that output close when output No.
  • Page 107 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets No. 1 Load Contactor Operating Circuit Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy Load contactor (K1) will close f. Defective contacts in N.O. Connect a jumper lead between when No.
  • Page 108 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets No. 2 Load Contactor Operating Circuit (500392-002 and -004 only) Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy 1. Contactor (K201) will not close a. Contactor circuit breaker Remove terminal leads from when No.
  • Page 109 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets No. 2 Load Contactor Operating Circuit (500392-002 and -004 only) Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy 2. Contactor (K201) will close a. No. 2 plug interlock relay Place test bank/aircraft push when No.
  • Page 110 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets No. 2 Load Contactor Operating Circuit (500392-002 and -004 only) Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy 3. Contactor opens during power a. No. 2 load contactor relay Replace relay K272 and again delivery.
  • Page 111 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Protective Circuit Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy Load contactor opens during b. Defective over-under- Use course voltage adjusting power delivery. Over voltage voltage PC board (K26) potentiometer (36, Fig.
  • Page 112 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Protective Circuit Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy 4. Load contactor opens during a. Electric governor system Check and adjust or repair in power delivery. Over frequency...
  • Page 113 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Protective Circuit Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy Load contactor opens during d. Faulty overload resistors in Replace faulty resistors—R33, power delivery. Overload main overload circuit.
  • Page 114 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Generator Trouble, Symptom Test, Check, And/or and Condition Probable Cause Remedy Unbalanced output a. Defective connection in Check plug and receptacle output circuit. connectors at aircraft. Tighten, repair, or replace as required.
  • Page 115 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Chapter 3. Overhaul/Major Repair Section 1. Exciter Armature General This section provides information and instructions for removal and installation of the exciter armature used on this generator set. Through design improvements, the exciter and rear main bearing can now be removed without removing the generator from the generator set.
  • Page 116 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Exciter Core Flange 4. Diode Mounting Plate 2. Exciter Core Lamination 5. Silicon Diode 3. Banding Glass Tape Exciter Armature Figure 2 The exciter armature covered by the manual is mounted on the rear portion of the main generator armature shaft which extends rearward, beyond the rear generator bearing, into the exciter housing (See Fig.
  • Page 117 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets b. Tools needed for Exciter Armature Removal and Installation In addition to the standard mechanic’s hand tools such as wrenches, etc., you will need only the following items for removing the exciter armature:...
  • Page 118 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets d. Preparation for Exciter Armature Removal (1) Remove louvered exciter cover from end canopy. (2) Remove exciter housing cover as required. Remove the 1/2-13 cap screw which holds the exciter armature on the generator shaft.
  • Page 119 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Location of Exciter Armature Machine Key Figure 4 (2) Removing the Exciter Armature CAUTION Leads may be damaged if armature is turned too far in either direction. Attempt to loosen exciter armature on shaft by rotating it slightly back and forth. If armature cannot be loosened by hand, use two 3/8 - 16 X 5-inch hex-head bolts as shown in Figure 5 to force the exciter armature off the shaft.
  • Page 120 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Removing Exciter Armature from Generator Armature Shaft Figure 5 Installing the Exciter Armature a. Preparation for Exciter Armature Installation (1) Clean generator shaft and exciter armature bore. Remove all rust, corrosion, etc.
  • Page 121 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets (2) Connect the two generator field leads to the exciter armature as follows: a. Connect lead with ring type terminal with screw provided to the rear mounting plate (“A”, Fig.
  • Page 122 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Installing the Exciter Armature Figure 6 Chapter 3-1 November 27/1997 Page 8...
  • Page 123 Hobart Brothers Company as Part Number 281701. This assembly is illustrated in Figure 1. The primary function of this assembly is to couple a Hobart Generator Set to a Diesel engine. The flexible coupling assembly compensates for slight misalignment between the engine and the generator, due to manufacturing tolerances.
  • Page 124 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets b. Remove Coupling Assembly (1) Refer to Figure 3. Using a socket wrench, remove all three of the 3/8-16 bolts (1) that secure the bushing (2) to the hub (3).
  • Page 125 90CU24 / Series 500392 Generator Sets Coupling Service When ordering coupling kits or other parts from your Hobart Brothers Company Distributor, be sure to include all pertinent information from the unit’s identification plate: Specification No., Model No., and unit rating.
  • Page 126 Figure 3 b. Bushing Kit A bushing kit is available from Hobart Brothers Company for replacing the rubber bushing only in the coupling assembly. However, it should be noted that the finished coupling assembly must be balanced to 1/2 inch-ounce (360 mg-m) minimum, which may be a problem in the field. If bushing replacement only is required, the kit part number is 480290.
  • Page 127 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Coupling Installation CAUTION Improper installation of the coupling assembly can result in serious damage to the equipment. Follow these installation instructions exactly. a. Cleaning Refer to Figure 6. It is VERY IMPORTANT that the shaft, the bore and the outside of the split bushing, and the tapered inside of the hub be thoroughly CLEANED FREE OF DIRT AND GRIT.
  • Page 128 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Coupling Kit Figure 4 (8) Refer to Figure 9. Place a straightedge across the two adjacent bushings and measure the distance from the bushings to the mounting face of the generator fan housing. Slide the coupling assembly on the shaft until this dimension is 1/16-inch (1.6 mm) LESS than the dimension...
  • Page 129 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Bushing Installation Figure 5 November 27/1997 Chapter 3-2 Page 7...
  • Page 130 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Assembly Procedure Figure 6 Flywheel Adapter Figure 7 Chapter 3-2 November 27/1997 Page 8...
  • Page 131 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Engine Measurement Figure 8 Measuring from Mounting Face to Bushing Figure 9 November 27/1997 Chapter 3-2 Page 9...
  • Page 132 Use 5/8-11 SAE GRADE 5 hex-head bolts, 2-3/4 inches (70 mm) long. These bolts are included in the coupling kit, and are available from Hobart Brothers as Part No. W-11102-18. a. Insert the proper coupling bolts with lock washers through the bushings from the FAN side of the coupling.
  • Page 133 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Section 3. Generator Assembly General This section provides information and instructions for removal and installation of the generator assembly used on Part Number 500051 generator sets. Procedure for Generator Assembly Removal a.
  • Page 134 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets 1. Lifting Eye (If Supplied) 10. Generator Assembly 2. Canopy Top Assembly 11. Generator Wrapper 3. Right Front Door 12. Front Left Bottom Panel and Cable Clamps 4. Control Box Assembly 13.
  • Page 135 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets b. Removing the generator Assembly (1) Remove the four 5/8 - 11 x 4-1/2 bolts which mount the generator assembly to the frame of the generator set. (2) Support the engine at the flywheel housing with wooden blocks.
  • Page 136 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Sets Installing a Generator Assembly Installation of a generator assembly is essentially a reversal of the procedure for removal of the generator assembly: the re-mounting of the generator assembly to the frame of the generator set, and the re-mounting of the assemblies that were removed to gain access to the generator assembly.
  • Page 137 Section 1. Introduction General The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail parts of a Diesel Engine-Generator Set manufactured by Hobart Brothers Company, Ground Power Division, Troy, Ohio. Purpose The purpose of this list is to provide parts identification and descriptive information to maintenance and provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts.
  • Page 138 90CU24 / Series 500392 / 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 139 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set 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.
  • Page 140 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set Code Vendor’s Name & Address Code Vendor’s Name & Address 2N562 Power Transmission Sales Inc. 61706 EAO Switch Corp. 351 Washington 198 Pepes Farm Rd. P.O. Box 229 P.O.
  • Page 141 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Section 3. Illustrated Parts List 1. Explanation of Parts List Arrangement The parts list is arranged so that the illustration will appear on a left-hand page and the applicable parts list will appear on the opposite right-hand page.
  • Page 142 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Generator Set Figure 1 Chapter 4-3 November 27/1997 Page 2 Revised 10/98...
  • Page 143 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 500392-001 GENERATOR SET FOR TRAILER MOUNTING, SINGLE OUTPUT...
  • Page 144 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Frame Assembly Figure 2 Chapter 4-3 November 27/1997 Page 4 Revised 10/98...
  • Page 145 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY No Number FRAME ASSEMBLY 2 - 1 283634 .
  • Page 146 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Canopy Assembly Figure 3 Chapter 4-3 November 27/1997 Page 6 Revised 10/98...
  • Page 147 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY No Number CANOPY ASSEMBLY 3 - 1 287536 .
  • Page 148 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Interior Components (Left Side) Figure 4A Interior Components (Right Side) Figure 4B Chapter 4-3 November 27/1997 Page 8 Revised 10/98...
  • Page 149 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 4A - No Number INTERIOR COMPONENTS (LEFT SIDE)
  • Page 150 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Control Box Door Assembly Figure 5 Chapter 4-3 November 27/1997 Page 10 Revised 10/98...
  • Page 151 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 286968-003 CONTROL BOX ASSEMBLY 5- 1 286969-003 .
  • Page 152 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Control Box Interior Components Figure 6 Chapter 4-3 November 27/1997 Page 12 Revised 10/98...
  • Page 153 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 286968-003 CONTROL BOX ASSEMBLY INTERIOR COMPONENTS 6- 1 284970 .
  • Page 154 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Control Box Dual Output Kit (Figure 6a) Chapter 4-3 November 27/1997 Page 14 Revised 10/98...
  • Page 155 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 287087 DUEL OUTPUT CONTROL BOX KIT 6a - 1 285029-001 .
  • Page 156 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Governor Kit Figure 7 Chapter 4-3 November 27/1997 Page 16 Revised 10/98...
  • Page 157 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 287532-002 KIT, GOVERNOR (Also See Fig. 8)
  • Page 158 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Governor Controler (Left Side of Unit) Magnetic Pickup (Right side of Engine) Governor Kit (Continued) Figure 8 Chapter 4-3 November 27/1997 Page 18 Revised 10/98...
  • Page 159 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 287532-002 KIT, GOVERNOR (CONTINUED) 8 - 1 283990-001 .
  • Page 160 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Fuel System Components Figure 9 Chapter 4-3 November 27/1997 Page 20 Revised 10/98...
  • Page 161 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY No Number FUEL SYSTEM COMPONENTS Note: All fuel lines (items 2 and 3) are supplied with fittings on each end as one complete assembly.
  • Page 162 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Cooling System Components Figure 10 Chapter 4-3 November 27/1997 Page 22 Revised 10/98...
  • Page 163 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY No Number COOLING SYSTEM COMPONENTS 10 - 1 287618 .
  • Page 164 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Power Module Assembly (Single Output) Figure 11 Chapter 4-3 November 27/1997 Page 24 Revised 10/98...
  • Page 165 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 11 - 285987-001 OUTPUT MODULE PANEL ASSEMBLY...
  • Page 166 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Grounding Plate and Cables Figure 12 Chapter 4-3 November 27/1997 Page 26 Revised 10/98...
  • Page 167 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 12 - No Number GROUND PLATE COMPONENTS...
  • Page 168 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Top Front of Engine Right Side of Engine Engine Components Figure 13 Chapter 4-3 November 27/1997 Page 28 Revised 10/98...
  • Page 169 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 13 - No Number ENGINE COMPONENTS 13 - 1 78B-1118-2 .
  • Page 170 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Battery Components Figure 14 Chapter 4-3 November 27/1997 Page 30 Revised 10/98...
  • Page 171 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 14 - No Number BATTERY COMPONENTS 14 - 1 287741 .
  • Page 172 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Air Cleaner Components (Viewed from the top front of unit) Figure 15 Chapter 4-3 November 27/1997 Page 32 Revised 10/98...
  • Page 173 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 15 - No Number AIR CLEANER COMPONENTS...
  • Page 174 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Muffler and Exhaust Components Figure 16 Chapter 4-3 November 27/1997 Page 34 Revised 10/98...
  • Page 175 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 16 - No Number MUFFLER & EXHAUST COMPONENTS...
  • Page 176 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Generator Assembly Figure 17 Chapter 4-3 November 27/1997 Page 36 Revised 10/98...
  • Page 177 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 17 - 285120-006 GENERATOR, 2400 RPM, 90kVA, DUAL BEARING...
  • Page 178 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set This page intentionally left blank. Chapter 4-3 November 27/1997 Page 38 Revised 10/98...
  • Page 179 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 17 - 285120-006 GENERATOR, 2400 RPM, 120kVA,...
  • Page 180 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Power Module Second Output Kit Figure 18 Chapter 4-3 November 27/1997 Page 40 Revised 10/98...
  • Page 181 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 18 - 284244 KIT, SECOND OUTPUT, POWER MODULE...
  • Page 182 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set Quick Start fuel line into head of engine Quick start temperature sensor Quick Start Components Figure 19 Chapter 4-3 November 27/1997 Page 42 Revised 10/98...
  • Page 183 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set NOMENCLATURE UNITS FIGURE & HOBART AIRLINE ITEM NO. PART NO. PART NO. 1 2 3 4 5 6 EFF ASSY 19 - No Number COLD WEATER START COMPONENTS...
  • Page 184 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 / Generator Set This page intentionally left blank. Chapter 4-3 November 27/1997 Page 44 Revised 10/98...
  • Page 185 OM-2084/ Operation and Maintenance Manual 90CU24 /Series 500392 Generator Set 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.
  • Page 186 OM-2084/ Operation and Maintenance Manual 90CU24 /Series 500392 Generator Set Figure & Figure & Item Number Part Number Item Number Part Number 11-15 286084 17- 39 284312-003 14-4 286219 15 - 10 284461 10-8 286654 6a- 5 284475-001 3-20 286834...
  • Page 187 OM-2084/ Operation and Maintenance Manual 90CU24 /Series 500392 Generator Set Figure & Figure & Item Number Part Number Item Number Part Number 10-4 287453 2- 4 287693 1 - 24 287454 1 - 25 287696 1 - 9 287459 7 - 1...
  • Page 188 OM-2084/ Operation and Maintenance Manual 90CU24 /Series 500392 Generator Set Figure & Figure & Item Number Part Number Item Number Part Number 5- 7 78A-1117-2 11-11 404065-2 13-1 78B-1118-2 16-3 404154-013 13- 9 78B-1119-1 5- 5 404172-001 1 - 10...
  • Page 189 OM-2084/ Operation and Maintenance Manual 90CU24 /Series 500392 Generator Set Figure & Figure & Item Number Part Number Item Number Part Number 17- 32 W11097-035 13-9 W7814-004 17-3 W11100-003 10-1 W7814-011 17-24 W11102-018 5-13 W8105A-004 17-33 W11102-018 11-21 W9350-301 17-1...
  • Page 190 OM-2084/ Operation and Maintenance Manual 90CU24 /Series 500392 Generator Set This page intentionally left blank. Chapter 4-4 November 27/1997 Page 50...
  • Page 191 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set Chapter 5. Manufacturers’ Literature VENDOR LITERATURE Engine Cummins Engine Operation Manual HOBART DIAGRAMS: Part No. 500392 DIAGRAM # DIAGRAM 287655 Schematic and Connection, Engine, Generator, and Options 286998...
  • Page 192 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set This page intentionally left blank. Chapter 5-1 November 27/1997 Page 2...
  • Page 209 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set Appendix A. Options/Features The following is a list of options available for series 500392 generator sets. This chart contains the description, part number, and document number of the option. There is also a column to identify which option is contained in this Appendix.
  • Page 210 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set This page intentionally left blank November 27/1997 Appendix A Page 2...
  • Page 211 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set 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-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set This page intentionally left blank Unusual Service Conditions November 27/1997 Page 2...
  • Page 213 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set Wet-Stacking in Generator Set Diesel Engines All diesel engines operated for extended periods under light load may develop a condition commonly referred to as wet-stacking. This condition results from the accumulation of unburned fuel in the exhaust system.
  • Page 214 OM-2084 / Operation and Maintenance Manual 90CU24 / Series 500392 Generator Set This page intentionally left blank Wet Stacking November 27/1997 Page 2...

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