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Hobart Brothers 90 GT 20 Operation And Maintenance Manual With Illustrated Parts List

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OPERATION AND MAINTENANCE
ILLUSTRATED PARTS LIST
ENGINE-DRIVEN GENERATOR SET
Series Numbers 6910, 6910A, 6910B, 6910C
90-KVA, 400-HZ, 115/200-V AC, 3-PHASE
Specification Number
6910-1, 6910A-1, 6910B-1
6910C-1
6910A-2, 6910B-2, 6910C-2
6910A-3, 6910B-3, 6910C-3
6910B-4, 6910C-4
6910B-5, 6910C-5
MANUAL
with
for
MODEL 90 GT 20
Mounting
Trailer or Truck
Trailer or Truck
Fixed Unit W/Fuel
Tank & Batteries
4-Wheel trailer, 5th Wheel
Trailer, or Truck
Tractor
Hobart Brothers Company
Airport Systems Group
Ground Power Equipment
Troy, Ohio 45373
U.S.A.
OM-2028
010187
Revised 042393
Revised 071596
Voltage Regulator Used
430391C
489812A
489812A
489812A
489812A

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  • Page 1 Revised 071596 OPERATION AND MAINTENANCE MANUAL with ILLUSTRATED PARTS LIST ENGINE-DRIVEN GENERATOR SET Series Numbers 6910, 6910A, 6910B, 6910C MODEL 90 GT 20 90-KVA, 400-HZ, 115/200-V AC, 3-PHASE Specification Number Mounting Voltage Regulator Used 6910-1, 6910A-1, 6910B-1 Trailer or Truck...
  • Page 2 This page intentionally left blank...
  • Page 3 SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT WARNING ELECTRIC SHOCK can KILL. Do not touch live electrical parts. ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible material. DO NOT use power cables to break load and prevent tools from causing short circuits. IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.
  • Page 4 a. Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the equipment. b. Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally. c. Disconnect power to equipment if it is out of service. d.
  • Page 5 OM-2028 LIST OF EFFECTIVE PAGES CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE List of May 1/91 Aug 31/90 Effective May 1/91Aug 31/90 Aug 31/90 Pages Aug 31/90 Aug 31/90 Introduction Aug 31/90 Aug 31/90 Aug 31/90 Contents 1 thru 6 Aug 31/90 Aug 31/90 May 1/91...
  • Page 6 OM-2028 LIST OF EFFECTIVE PAGES (CONT’D) CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE Jun 20/89 May 1/91 May 1/91 Jun 20/89 May 1/91 Jun 20/89 May 1/91 Jun 20/89 May 1/91 Jun 20/89 May 1/91 Jun 20/89 May 1/91 Jun 20/89 May 1/91 Jun 20/89...
  • Page 7 OM-2028 Table of Contents SUBJECT CHAPTER/SECTION PAGE WARNING LIST OF EFFECTIVE PAGES INTRODUCTION CHAPTER 1. DESCRIPTION/OPERATION SECTION 1. DESCRIPTION ..1-1 ..1 1.
  • Page 8 OM-2028 SUBJECT CHAPTER/SECTION PAGE E. Control Box Assembly ....1-1 ... . . 12 (1) Generator control tray (a) Resistors (b) Generator output monitors (meters) (c) Meter and line switches...

  • Page 9: Table Of Contents

    OM-2028 SUBJECT CHAPTER/SECTION PAGE 2. Preparation for Storage ... 1-2 ... 3 A. General ..... . . 1-2 ... . . 3 B.
  • Page 10 OM-2028 SUBJECT CHAPTER/SECTION PAGE 4. Air Cleaner Service ....2-1 ..3 A. Air Cleaner with Replaceable Filter ..2-1 ... . . 3 (1) Cartridge Removal (2) Cartridge Installation B.
  • Page 11 OM-2028 SUBJECT CHAPTER/SECTION PAGE E. Exhaust System ....2-2 ... . . 1 3.
  • Page 12 OM-2028 SUBJECT CHAPTER/SECTION PAGE 4. Safety ..... 3-1 ..2 5. Parts Replacement ....3-1 .
  • Page 13 This manual contains operation and maintenance information for a series of 400-Hertz generator sets manufactured by Hobart Brothers Company, Power Systems Group, Troy, Ohio 45373. This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to pro- vide information and instructions to experienced operators, electricians, and mechanics who have never seen or operated this equipment.
  • Page 14 OM-2028 This page intentionally left blank Introduction June 20/89 Revised Page 2...
  • Page 15 OM-2028 CHAPTER 1. DESCRIPTION/OPERATION SECTION 1. DESCRIPTION 1. General Four series of generator sets are covered by this manual: Series 6910, Series 6910A, Series 6910B, and 6910C. Generator sets in Series 6910A are an improved version of the original Series 6910 generator sets. Series 6910A generator sets feature armatures with Hoover Bearings, Browning Coupler, and differ- ent magnetic pole construction for the generator revolving field.
  • Page 16 OM-2028 1. Canopy 6. Output cable horn 2. Access-vent covers 7. Mounting frame 3. Lifting eye 8. Engine fan exhaust deflectors 4. Windows 9. Engine exhaust pipe 5. Output receptacle cover 10. Radiator cap access cover Generator Set Figure 1 May 1/91 Revised Page 2...
  • Page 17 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 al- lows electricians to perform as many as twenty-four tests and checks from one location, conveniently and easily.
  • Page 18 OM-2028 PHYSICAL BASIC UNIT 88 inches (2235 mm) Length overall Width 36 inches (914.4 mm) Height overall 43 inches (1092.2 mm) 3500 pounds (1496.8 kg) Weight FOUR-WHEEL TRAILER-MOUNTED UNIT Length overall 100 inches (2540 mm) 78 inches (1981.2 mm) Width Height 72 inches (1828.8 mm) Weight...

  • Page 19: General

    OM-2028 ENGINE Manufacturer/Model John Deere, Model 6059TL Type Turbocharged, In-line, 6-cylinder, 4-cycle Diesel Displacement 359 cu. in. (5.9 liters) Compression ratio 16.8:1 Firing order 1-5-3-6-2-4 Number of main bearings Horsepower at 2000 RPM Governed speed 2000 RPM +/- 4.5% Idle speed 850 RPM +/- 25 RPM Electrical system 12 volt...
  • Page 20 OM-2028 5. Optional Equipment Several items of optional equipment are available for units covered by this manual. Each optional item is covered by its own Instruction and Parts Manual and will not be covered in this basic manual. When appli- cable, information for optional equipment will be located in Chapter 5.
  • Page 21 (2) 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. The electric governor was selected for control of engine speed (and generator output frequency) be- cause it provides faster engine response to changes in load conditions.
  • Page 22 OM-2028 1. Mounting frame 8. Air cleaner 14. Engine control panel 2. Generator 9. Lifting yoke 15. Cable horn and clamp 3. Power module 10. Engine 16. Radiator 4. Control box 11. Engine exhaust pipe 17. Fuel valve solenoid 5. Governor control box 12.
  • Page 23 The actuator is operated by a DC signal from the control unit. (2) Engine electrical system Items in the 12-volt engine electrical system that are provided by Hobart Brothers are: (a) A heavy-duty motor starter (b) Alternator with voltage regulator...
  • Page 24 OM-2028 1. Viewing chamber 2. Indicating “flag” 3. Reset button Air Cleaner and Service Indicator Figure 4 May 1/91 Revised Page 10...
  • Page 25 OM-2028 Exhaust System Figure 5 (6) Radiator The radiator (16, Fig. 3) is a one-piece item designed for long periods of operation without servic- ing. Refer to Section 2-1, Para. 7, G, for servicing procedure. D. Generator The 400-Hz generator is a brushless, revolving field, three-phase, alternating current type. The rotor assembly is mounted by two, permanently lubricated, sealed, ball bearings: the front bearing sup- ported by the fan housing;...
  • Page 26 OM-2028 E. Control Box Assembly The control box (Fig. 6) is a sheet metal enclosure which houses and provides mounting facilities for generator and engine controls and monitoring equipment. The box is equipped with two, drawer type trays which contain generator output control devices and monitoring instruments. Trays slide in and out on nylon rollers for easy access to internally mounted components.
  • Page 27 OM-2028 (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. A variable resistor (1) is connected in series between the manual control rec- tifier (14) and rheostat (13) .
  • Page 28 OM-2028 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 29 OM-2028 (2) Protective relay tray (see Figure 8) The bottom tray in the control box is identified as the protective relay tray and contains electrical and safety devices designed to protect the aircraft electrical system against damage which could result from overvoltage, undervoltage, overfrequency, or underfrequency. The tray also contains devices for the protection and control of the generator output electrical system.
  • Page 30 OM-2028 Each of the five circuits is connected to a corresponding indicating light (10, 11, 13, 14 and 15) which is turned on when a fault occurs. The module relay will remain energized (OPEN) and the light will remain ON until the reset switch (7) is pushed to break the module 12-V DC circuit, and allow the relay to return to normal, CLOSED position.
  • Page 31 OM-2028 1. Plug-interlock relay 12. Tray fastener 2. Fuse-interlock relay 13. Overfrequency indicating light 3. Auxiliary underfrequency 14. Undervoltage indicating light relay 15. Overvoltage indicating light 4. Memory and time delay module 16. Load contactor circuit fuse 5. Over-undervoltage module (2 A) 6.
  • Page 32 OM-2028 F. Engine Control Panel (See Fig. 9) The engine control panel is mounted directly below the control box. In addition to engine controls and instruments, generator output controls are mounted here. A plexiglass window in the canopy rear door, slants outward at the bottom to form an opening for access to controls when the door is closed. (1) Engine instruments Engine operation is monitored by an ammeter (4) , a coolant temperature gage (8) , and an oil pres- sure gage (10) .
  • Page 33 OM-2028 In GENERATE position, power is maintained to the governor control box and to the excitation relay (3, Fig. 7) . When the switch is placed in IDLE position, power is disconnected so that the engine returns to idle speed and the exciter field is deenergized. (b) Contactor control switch This is another three-position, toggle switch (7, Fig.
  • Page 34 OM-2028 (4) Test receptacle connector This Amphenol connector (19) provides an attaching point for leads which are connected to se- lected test points throughout the engine and generator electrical systems. Connections and sche- matic diagrams indicate points at which the leads are connected. The receptacle connector is designed to mate with a test box plug connector (see Fig.
  • Page 35 OM-2028 G. Power Module Panel Assembly The power module panel assembly (Fig. 10) sometimes referred to as the “contactor panel”, is lo- cated at the right rear of the machine behind the control box. On all models except the tow tractor mounted unit, it is accessible by removing rear access-vent cover (2, Fig.
  • Page 36 OM-2028 (3) Overload module The overload module (7) is a solid-state device designed to interpret a signal from transformers (3) and to send a signal to the protective monitor module (4, Fig. 8) when an overload condition exists in any generator output phase. A pull-apart electrical connector is mounted on the overload module to provide quick-disconnect facilities for all wiring to the module.
  • Page 37 OM-2028 1. Overload resistor (16.6 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 38 OM-2028 8. Test Box The test box is an optional accessory item used for testing the generator set. All generator sets are wired to accommodate a test box, however, the box is supplied only when ordered (Part Number 388318A-1). A. Description (See Fig. 11) The test box assembly consists of a rotary selector switch, momentary contact pushbutton switch, and two, insulated-tip test jacks, mounted in a small metal box.
  • Page 39 OM-2028 9. Water Heater Kit Generator set Specifications 6910B-4, 6910C-4, 6910B-5 and 6910C-5 are equipped with a water heater kit to heat the engine block and thus keep the coolant warm when the engine is shut down for ex- tended periods of time in cold weather. This permits the engine to start more quickly. The water heater kit is installed inside the enclosure of the generator set, and is connected to the cooling system of the die- sel engine which drives the unit.
  • Page 40 OM-2028 This page intentionally left blank. May 1/91 Revised Page 26...

  • Page 41: General

    OM-2028 SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING 1. Preparation for Use A. General Hobart Generator sets, when ordered with truck or trailer, are mounted at the Hobart factory and are shipped in running condition and ready for operation after inspection and check. WARNING: IMPROPER OPERATION CAN KILL, INJURE, OR CAUSE DAMAGE! READ AND UNDERSTAND OPERATING INSTRUCTIONS IN SECTION 1-3 BE- FORE OPERATING THE UNIT.
  • Page 42 OM-2028 C. Installing Output Cables Units are generally shipped without generator set-to-aircraft cables. NOTE: Generator sets Specification 6810B-4 is equipped with a generator output receptacle connector. No output cable wiring is required. An output cable assembly with plug connector on each end is required, (1) Three-phase, AC output cable assembly installation The AC output terminal panel is located on the left side, below the air cleaner and left of the en- gine control panel (see Fig.

  • Page 43: Preparation For Storage

    OM-2028 (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 Installa- tion Figure 2 2. Preparation for Storage When a generator set is to be stored or removed from operation, special precautions should be taken to protect the internal and external parts from rust, corrosion, and gumming in the engine fuel system.

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

    OM-2028 (3) Make certain the cooling system antifreeze solution is adequate to protect below the lowest tem- peratures expected during the storage period. See 2-1; Para. 7, D. Be sure the solution is thoroughly mixed. (4) Clean the exterior of the engine with fuel oil. Dry with clean rags and compressed air. (5) Seal all engine openings.

  • Page 45: Section 3. Operation

    OM-2028 SECTION 3. OPERATION 1. General This section contains information and instructions for the safe and efficient operation of the equipment. Operating instructions are presented in step-by-step sequence of procedures to be followed in supplying 400-Hz power to an aircraft. WARNING: IMPROPER OPERATION CAN KILL! EAR PROTECTION EQUIP- MENT MAY BE NECESSARY WHEN WORKING IN CLOSE PROXIMITY TO THIS EQUIPMENT.
  • Page 46 OM-2028 1. Frequency meter 18. Engine-generator control 2. Voltmeter 18. Engine-generator control switch 3. Fastener 19. Hourmeter 4. AC Ammeter 20. Load contactor control 5. Meter switch switch 6. Line switch 21. Coolant temperature gage 7. Reset switch 22. Load contactor indicating 8.
  • Page 47 OM-2028 32. Manual voltage control rheostat 37. Automatic voltage control rheostat 33. Automatic-manual voltage control 38. Cable length compensation rheostat switch 39. Cable size compensation rheostat 34. Test bank switch 40. Line drop compensation on/off switch 35. Light test switch 41.

  • Page 48: Cold Weather Engine Starting Procedures

    OM-2028 C. Cold Weather Engine Starting Procedures Two optional starting aids are available for installation on generator sets covered by this manual to as- sist in starting the engine at low temperatures. The starting aid identified by Hobart Part Number 488913 and illustrated as Figure 2 must be pre- pared for operation as explained in sub-paragraph (1) following.
  • Page 49 OM-2028 WARNING: DO NOT “FLOOD” THE ENGINE WITH STARTING FLUID. A SERIOUS EXPLOSION COULD RESULT. (e) In extremely cold weather it may be necessary to repeat steps (a) and (b) above.C. Cold Weather Engine Starting Procedures CAUTION: USE STARTING AID ONLY FOR STARTING. DO NOT OPERATE WHILE ENGINE IS RUNNING.

  • Page 50: Preparation For Power Delivery

    OM-2028 D. Preparation for Power Delivery (Normal Automatic Voltage Control) The following are power delivery preparation procedures to be followed after the engine is started. (1) Check and position switches and controls. (a) Loosen fastener (3, Fig. 1) and pull generator control tray outward. Place automatic-manual switch (33) in AUTOMATIC position.

  • Page 51: Power Delivery (Manual Voltage Control)

    OM-2028 G. Power Delivery (Manual Voltage Control) Power delivery using manual voltage control is the same as automatic delivery [Para. E, (1) thru (5) above] except: (1) Control generator output voltage by adjusting the rheostat (32) to maintain a steady 115-V AC reading on the voltmeter (2).
  • Page 52 OM-2028 Test Box Operating Ccntrols Figure 3 Test Receptacle Connector Figure 4 August 31/90 Revised Page 8...

  • Page 53: Transformer-Rectifier Operation

    OM-2028 4. Transformer-Rectifier Operation (Optional Equipment) (See Fig. 5) Transformer-Rectifier operating instructions are contained in its operating manual, however some gener- ator set instructions are required here. A. Direct Current Power Delivery NOTE: If the customer adds a Transformer-Rectifier to a standard machine which was NOT equipped with a T-R when it left the factory, he must remove the jumper lead which will be found on the small terminal strip in the generator set voltage regulator (see 1-1;...

  • Page 54: Trailer Operation (Optional)

    OM-2028 Transformer-Rectifier Figure 5 5. Trailer Operation (Optional) A. Towing Observe the following rules when towing the trailer. (1) Be sure all output cables are disconnected and properly stowed. (2) Be sure parking brake is released. (3) Avoid turns which are shorter than the steering linkage will freely allow. (4) Avoid dangerous speed and sudden turns.

  • Page 55: Chapter 2. Service

    OM-2028 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: Engine

    OM-2028 (1) Lubrication schedule Time schedules indicated on the Lubrication Chart, Fig. 1, are approximate. They are based on average operating conditions. It may be necessary to lubricate more frequently under severe oper- ating conditions such as: low engine temperatures, excessively heavy loads and high oil tempera- tures, or intermittent operation.

  • Page 57: Air Cleaner Service

    OM-2028 ITEM MAINTENANCE REQUIRED Lube 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: 18 quarts. Lube Oil Filter Change oil filter every 200 hours or 1 month of use.

  • Page 58: Disposable Air Cleaner

    OM-2028 (2) Cartridge Installation (See Fig. 2) (a) Carefully install the new cartridge into the housing. Avoid bumping the cartridge tubes against the housing sealing flange. Seat the cartridge properly within the housing. Press all edges and corners of the cartridge firmly with fingers to effect a positive air seal against the sealing flange of the housing.

  • Page 59: Disposal

    OM-2028 (2) Cleaning Instructions CAUTIONS: (1) DO NOT RAP THE AIR CLEANER ON A HARD SURFACE TO CLEAN IT, AND (2) NEVER LEAVE THE AIR INLET DUCTING OPEN LONGER THAN NECESSARY DURING THE SERVICE PROCEDURE. (a) Pressurized air cleaning After removing the air cleaner from the generator set, blow air into the outlet neck, causing dust to flow off the air cleaner filter media.

  • Page 60: Radiator Cap

    OM-2028 B. Radiator Cap (1) General A pressure valve is built into the radiator cap. It is designed to open at a pressure of approxi- mately seven pounds per square inch. (2) Removal To remove, turn the cap to the left (counterclockwise) to the safety stop. When all pressure is re- leased, press down on the cap and continue to turn until the cap is free to be removed.

  • Page 61: Draining The Cooling System

    OM-2028 (3) Preparing the coolant solution The following table (Figure 3) indicates the freezing points of solutions varying from 16% anti- freeze to 65% antifreeze. Percentages are based on permanent type (Ethylene Glycol) antifreeze. Most antifreeze containers have a similar table printed on the label. (4) Installing the antifreeze solution Before installing antifreeze in the system, make the following checks: (a) Check the system for signs of leaks.

  • Page 62: Cleaning The Cooling System

    OM-2028 (4) When the system is completely drained, close all drain valves except when draining for storage. F. Cleaning the Cooling System Drain and thoroughly flush the cooling system twice a year or more often if necessary. The appear- ance of rust in the radiator, or in the coolant is an indication that the inhibitor has become weakened and it is possible that some sludge has accumulated in the system.

  • Page 63: Cleaning

    OM-2028 A. Cleaning The generator may be cleaned by careful use of compressed air and/or a good, SAFE commercial cleaner. Steam cleaning of the generator is no longer recommended because the use of steam and harsh chemical compounds may damage insulation and other generator components. WARNING: ELECTRIC SHOCK AND FIRE CAN KILL OR INJURE! BE SURE THE UNIT IS COMPLETELY DRY BEFORE OPERATING.

  • Page 64: B.control Box Trays

    OM-2028 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. 4) (b) Slide tray outward and disconnect Amphenol connector (3). (c) Support tray with hands at each side of tray near latches (1).

  • Page 65: Engine Control Panel

    OM-2028 (3) Exciter installation (a) Install exciter in accordance with TM-360. (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. Removable Rear Frame Cross-Member Figure 5 D.
  • Page 66 OM-2028 Engine Control Panel in Tilt-out Position Figure 6 August 31/90 Revised Page 12...

  • Page 67: Section 2. Inspection/Check

    OM-2028 SECTION 2. INSPECTION/CHECK 1. General This section describes inspections and checks to be performed in conjunction with Inspection/Check Schedule, Figure 1. 2. Engine A. Fuel (See Fig. 1 for time schedules) (1) Check fuel quantity DAILY. (2) Drain fuel filters and change fuel filter elements in accordance with instructions in John Deere Shop Manual.
  • Page 68 OM-2028 Daily Weekly Weekly Monthly Monthly 6 Mo. 8 Hrs. 50 Hrs. 100 Hrs. 200 Hrs. 400 Hrs. 1200 Hrs. ENGINE Check fuel quantity Check crankcase oil level Check coolant level Change engine oil filter element Change engine oil Replace air cleaner cartridge Inspect cooling system hoses, tubes, fittings &...

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

    OM-2028 (3) Replace any defective parts at once. WARNING: EXHAUST FUMES OR FIRE CAN KILL OR INJURE! IMMEDIATELY REPAIR DEFECTIVE EXHAUST SYSTEMS. 3.Electrical System (12-V DC) A. Lights Check all lights for proper operation DAILY. Replace any defective lamps (bulbs) as soon as discovered. Figure 2 lists ALL lamps, their location, and part numbers.

  • Page 70: Electrical System (115-V Ac)

    OM-2028 (2) Check electrical connections for looseness. NOTE: A darkened terminal generally indicates a loose connection. 4. Electrical System (115-V AC) The 400-Hz generator and controls are designed to be as maintenance free as possible. No lubrication is necessary and no periodic maintenance adjustments are required. However, some regular checks should be made to be sure all controls, instruments, etc., are working properly.

  • Page 71: Wiring And Connections

    OM-2028 D. Wiring and Connections (1) Check all cables, leads, and wiring for broken, worn, and damaged insulation. (2) Check all connections for tightness. WARNING: STOP OPERATIONS AND STOP ENGINE BEFORE TOUCHING EX- POSED CONDUCTORS OR TERMINALS. (3) Check the output cable plug connector for damaged contactors in the end of the plug. 5.
  • Page 72 OM-2028 This page intentionally left blank June 20/89 Revised Page 6...

  • Page 73: Section 3. Adjustment/Test

    OM-2028 SECTION 3. ADJUSTMENT/TEST 1. General djustment and test procedures are most applicable to testing and adjusting the generator set after a major repair, replacement of parts, or overhaul. 2. Generator Set Test A. Pre-operational Test Procedures (1) Connect cables from the generator output terminals to a load bank. Use cables of the same size and length as those to be used in service.
  • Page 74 OM-2028 (cc) Momentarily pressing pushbutton switch (Sect. 1-3, Fig. 3, item 2) will flash the exciter field. (dd) Disconnect jumper leads. (b) Flashing exciter field without test box. (aa) Remove test receptacle cover (1-3; Fig. 4). Use two test leads equipped with a test prod on one end and an “alligator”...
  • Page 75 OM-2028 1. Frequency meter 17. DC Ammeter 2. Voltmeter 18. Engine-generator control switch 3. Fastener 19. Hourmeter 4. AC Ammeter 20. Load contactor control switch 5. Meter switch 21. Coolant temperature gage 6. Line switch 22. Load contactor indicating light 7.
  • Page 76 OM-2028 32. Manual voltage control rheostat 33. Automatic-manual voltage control switch 34. Test bank switch 35. Light test switch 36. Reset switch Operating Controls and Instruments Figure 1 (Sheet 2 of 2) June 20/89 Revised Page 4...

  • Page 77: Operational Test Procedures

    OM-2028 Test Receptacle Connector Terminals Identification Figure 2 B. Operational Test Procedures (1) Start the engine in accordance with instructions in 1-3; Para. 2, A thru C. (2) Check operation of engine instruments: DC ammeter (17, Fig. 1), coolant temperature indicator (21), oil pressure gage (23), and hourmeter (19).
  • Page 78 OM-2028 (9) Measure governor actuator input signal. See Par. 3, E, (4), (a). (10) Measure governor magnetic pickup signal. See Para. 3, E, (4), (b). (11) Check speed limiting governor Set engine speed-limiting governor to 2300 + 25 RPM. See John Deere Diesel Handbook in Chapter 6 for instructions on how to set the governor.
  • Page 79 OM-2028 (22) With test-bank switch in AIRCRAFT position, hold the contactor operating switch (20) in top, CLOSE position momentarily. The generator “on” indicating light (22) should glow GREEN and re- main on when the switch is released and allowed to return to the center ON position. This indicates that the load contactor is closed and the plug interlock relay is functioning properly.
  • Page 80 OM-2028 (36) Check engine oil pressure at governed speed (2000 RPM). Gage should indicate at least 38 PSI when the engine is hot. Check engine coolant temperature. Gage should indicate in the range of 180 degrees to 190 degrees depending upon ambient temperature. (37) Check operation of fuse interlock (Ref.
  • Page 81 OM-2028 (a) While the unit is operating normally under load, reduce generator output frequency by reduc- ing engine speed. Use the governed speed setting potentiomete. Turn adjusting screw COUN- TERCLOCKWISE gradually to reduce engine speed until frequency meter indicates 386 Hz. Underfrequency protective relay should not function to open the load contactor at this frequency.

  • Page 82: Generator Set Adjustment

    OM-2028 3. Generator Set Adjustment A. Generator Adjustment The 400-Hz generator is a brushless type requiring no adjustments of any kind. B. Generator Control Adjustments The following items may require adjustment at some time during the life of the equipment. (1) Adjust manual voltage control, variable resistor.

  • Page 83: Electric Governor System Adjustment

    OM-2028 E. Electric Governor System Adjustment Two electric governor system main components, namely the magnetic pickup and controller, have critical adjustments which can affect engine performance and therefore generator output. The adjustment of the actuator linkage can also affect engine performance. When the complete system is to be checked and/or adjusted, a definite sequence of procedures should be followed: First - Check or adjust actuator linkage...
  • Page 84 OM-2028 1. Actuator shaft 5. Nut 2. Signal input connector 6. Rod 3. Actuator lever 7. Ball Joint, Fuel Control Lever 4. Ball joint, actuator Governor Actuator Linkage Figure 4 (2) Magnetic pickup adjustment The strength of the magnetic pickup signal to the control box can be weakened if the tip of the pickup is too far from the flywheel ring gear.
  • Page 85 OM-2028 (d) Rotate the engine as required to locate a ring gear tooth directly below the tapped, pickup mounting hole. An imaginary line should pass through the center of the mounting hole, the center of a flywheel tooth and the center of the flywheel. (e) Install the magnetic pickup into the tapped mounting hole and thread it in until the tip touches the “in-line”...

  • Page 86: Adjustment And Test Of Controller And Actuator

    OM-2028 (3) Adjustment and Test of Controller and Actuator (Series 6910, 6910A, and 6910B Generator Sets) Refer to Figure 6. The controller has three identical control potentiometers (see inset): the GAIN potentiometer, the DROOP potentiometer, and the potentiometer marked “I”. In addition, a SPEED control potentiometer is located just next to the GAIN potentiometer.
  • Page 87 OM-2028 Electric Governor Controller and its Connections for Series 6910, 6910A, and 6910B Generator Sets Figure 6 May 1/91 Revised Page 15...
  • Page 88 OM-2028 (4) Adjustment and Test of Controller and Actuator (Series 6910C Generator Sets with Speed Control PC Board) Refer to Figure 7. The controller has three control potentiometers used to control the IDLE speed: the GAIN potentiometer, the DROOP potentiometer, and the potentiometer marked “I”. In addi- tion, a SPEED control potentiometer is located just next to the GAIN potentiometer.

  • Page 89: (D) Checking The Actuator

    OM-2028 (c) Adjusting for RATED Speed Operation The function of the new speed control board, is to govern the engine at RATED speed. To check for proper adjustment, proceed with the following steps: • With the engine running and properly adjusted for IDLE speed, flip the engine MODE switch to the BUILD-UP VOLTAGE setting.
  • Page 90 OM-2028 Electric Governor Controller With Speed Control PC Board And its Connections for Series 6910C Generator Sets Figure 7 June 20/89 Revised Page 18...

  • Page 91: Generator And Exciter Test

    OM-2028 5. Generator and Exciter Test The generator fields may be tested with a “Kelvin” bridge. This is a double-bridge type instrument required for the very low resistances encountered in this test. It is understood that 0 resistance indicates a SHORT CIRCUITED condition.
  • Page 92 OM-2028 TEST BOX TEST POINTS POINTER CONNECTOR TEST CONDITION VOLTAGE POSITION TERMINALS DESCRIPTION Phase “A” input for Unit in “GEN” mode 115-V AC reg. and trays & auto-man sw. in 400-Hz Phase “B” input for Unit in “GEN” mode 115-V AC reg.

  • Page 93: Chapter 3. Troubleshooting

    OM-2028 CHAPTER 3. TROUBLESHOOTING SECTION 1. TROUBLE SHOOTING PROCEDURES 1. General A. Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the exact cause of a trouble is found. As a rule, the best place to start looking for the cause of a trouble in a circuit is at the source of power.

  • Page 94: Equipment For Troubleshooting

    OM-2028 (4) It is assumed that wiring and connections in defective circuits have been thoroughly checked be- fore condemning any other components. NOTE: Reference symbols (S9, etc.), used in the Trouble Shooting Chart, are identified on Schematic and Connection Diagrams. 3.

  • Page 95: Test Values

    OM-2028 6. Test Values Although test values are provided throughout the trouble shooting chart, where applicable, additional infor- mation and values are given here. Generator output at maximum voltage regulator rheostat setting 134 V or higher Generator output at minimum voltage regulator rheostat setting 108 V or lower Depending on customer requirements, two over-undervoltage PC boards and four over-under fre- quency PC boards are available.

  • Page 96: Engine Trouble Shooting Procedures

    OM-2028 B. Assuming other conditions are normal, the actuator will go to, or remain in, IDLE position under the following conditions. (1) No 12-V DC power (2) No voltage from control box to actuator C. The actuator will “surge” under the following conditions: (1) “Stability”...
  • Page 97 OM-2028 1. Frequency meter 17. DC Ammeter 2. Voltmeter 18. Engine-generator control switch 3. Fastener 19. Hourmeter 4. AC Ammeter 20. Load contactor control switch 5. Meter switch 21. Coolant temperature gage 6. Line switch 22. Load contactor indicating light 7.
  • Page 98 OM-2028 32. Manual voltage control rheostat 33. Automatic-manual voltage control switch 34. Test bank switch 35. Light test switch 36. Reset switch Operating Controls and Instruments Figure 1 (Sheet 2 of 2) June 20/89 Revised Page 6...
  • Page 99 OM-2028 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 June 20/89 Revised Page 7...
  • Page 100 OM-2028 Test Receptacle Connector Termi- nals Identification Figure 4 June 20/89 Revised Page 8...
  • Page 101 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY NOTE: Diesel engine trouble shooting is covered in Perkins Engine Shop Manual under Fault Diagnosis. ENGINE CONTROLS 1. Engine will not A. Batteries discharged, A. Check voltage across bat- start.
  • Page 102 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 3. Engine will not A. No fuel A. Before attempting to find start. Cranking the cause of “no fuel”, speed normal.prime the fuel filters by removing pipe plug in thecover of each.
  • Page 103 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 3. Engine will not (6) Faulty fuel pump (6) Check pump. start. Cranking speed normal. (a) Relief valve (a) An open relief valve not seating will cause low out- put pressure.
  • Page 104 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 5. Engine starts.Stops A. The shut-down circuit A. Restart the engine, hold after a few seconds may have functioned permissive start switch in by automatic shut- normally to stop the START position, and observe down.
  • Page 105 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 7. Engine will not A. 12-V DC power not A. Apply 12-V DC directly to come “up” to gov- reaching governor terminal 1 on governor con- erned speed in GEN control box due to trol box.
  • Page 106 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 7. Engine will not E. Defective control E. Connect a DC voltmeter to come “up” to gov- unit the leads from the control erned speed in GEN unit to the actuator.
  • Page 107 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 9. Engine is unsteady A. Fault in engine A. Before condemning the gover- (surges) under load nor system for surging, make certain the fault is not in the engine.
  • Page 108 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 11. Engine “misses”. A. Insufficient fuel A. Check fuel flow in accor- Runs unevenly. dance with John Deere Diesel Handbook. Repair or replace parts as required. Also see Engine, Trouble 3.
  • Page 109 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS (CONTINUED) 1. No (or low) gener- A. Defective generator A. The first check is an easy ator output voltage or excitation circuit one which will allow the in all phases.
  • Page 110 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR EXCITATION CIRCUITS (CONTINUED) 1. No (or low) genera- C. Defect in VOLTAGE C. Check as follows: tor output voltage REG. excitation cir- in all phases. Gen- cuit. erator operating at 400 Hz in AUTOMATIC (1) Defective AUTO- (1) Check the switch thor-...
  • Page 111 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR AND EXCITATION CIRCUIT (CONTINUED) 1. No (or low) gen- (4) Defective Amph- (4) Disconnect voltage reg- erator output volt- enol connector at ulator Amphenol connec- age in all phases. voltage regu- tor (See TM-759 or OM-2020).
  • Page 112 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR CONTROLS AND INSTRUMENTS (CONTINUED) 2. No (or low) output B. Defect in manual voltage A. Check as follows: voltage when operating control portion in MANUAL mode of excitation circuit (Continued) (1) Defective AUTO- (1) Check contacts and oper-...
  • Page 113 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY NO. 1 LOAD CONTACTOR OPERATING CIRCUIT (CONTINUED) 1. Load contactor (K1) (2) Defective (open) (2) Use a jumper with clip will not close when relay in protective and prod terminals to control switch (20, module (1-1;...
  • Page 114 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY N0. 1 LOAD CONTACTOR OPERATING CIRCUIT (CONTINUED) 2. Load contactor (K1) A. 28.5-V DC is not A. Check voltage at terminal Z will close when reaching plug interlock on test receptacle. Voltage control switch (20, relay (K2) from should be 28.5-V DC.
  • Page 115 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR CONTROLS AND INSTRUMENTS (CONTINUED) 2. Load contactor will E. Defective fuse- E. Open protective relay tray close when control interlock relay (K17) and connect a jumper across switch (20, Fig. 1) or resistor (R46) the resistor R46) (Sect.
  • Page 116 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY PROTECTIVE CIRCUIT NOTE: The protective relays and protective monitor are not completely functional until the load contactor is CLOSED. Since it is not advisable to vary voltages for test purposes while delivering power to an aircraft, the generator should be connected to a load bank for trouble shooting the protective circuits.
  • Page 117 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY PROTECTIVE CIRCUIT (CONTINUED) 2. Load contactor B. Defective over-under B. Use rheostat to reduce opens during power voltage module (K26) voltage to 104 V. The delivery. Under- undervoltage indicating voltage indicating light should NOT come on light ON (Cont’d)
  • Page 118 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY PROTECTIVE CIRCUIT (CONTINUED) 4. Load contactor A. Electric governor B. Proceed as follows: opens during power improperly adjusted, delivery. Under- or malfunctioning frequency light ON. (1) Governor improperly (1) Adjust in accordance adjusted with Sect.
  • Page 119 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR 1. No (or low) voltage A. Shorted diode in A. Check diodes in accordance output exciter rectifier with Sect. 2-3, para. 6. If (CR2). diodes are good, proceed to step B.
  • Page 120 OM-2028 TROUBLE, SYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY EXTERNAL LOAD 4. Unbalanced output C. Defective connection A. Check plug and receptacle (Continued) in output circuit. connectors at aircraft. Tighten, repair, or replace as required. D. Break or cut in out- D.

  • Page 121: Chapter 4. Illustrated Parts List

    The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail parts of the engine-driven generator sets manufactured by Hobart Brothers Company, Power Systems Group, Troy, Ohio, 45373. These sets are identified as Hobart Series No. 6910, 6910A, 6910B, and 6910C.
  • Page 122 OM-2028 (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 modified by Hobart will be identified as such in the NO- MENCLATURE column.

  • Page 123: Section 2. Manufacturer's Codes . 4-2

    OM-2028 SECTION 2. MANUFACTURER’S CODES 1. Explanation of Manufacturer’s (Vendor) Code List The following list is a compilation of vendor codes with names and addresses for suppliers of purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes for Manufac- turer’s Cataloging Handbook H4-1, and are arranged in numerical order.
  • Page 124 OM-2028 CODE VENDOR’S NAME AND ADDRESS 20038 ESB Inc. 5 Penn Center Plaza P.O. Box 8109 Philadelphia, Pennsylvania 19101 21335 Fafnir Bearing Company Division of Textron 37 Booth Street New Britain, Connecticut 06050 21585 Farr Company, Airport Station P.O. Box 92187 Los Angeles, California 90009 24248 Southco Inc.
  • Page 125 OM-2028 CODE VENDOR’S NAME AND ADDRESS 61112 Cleanweld Products Co., Turner Div. 821 Park Avenue Sycamore, IL 60178 62295 Butech Pressure Systems Division of Ber-Lo Mfg. Co., Inc. 4928 Pittsburgh Ave. Erie, PA 16509 70040 General Motors Corp. AC Spark Plug Division 1300 N. Dort Highway Flint, MI 48556 70485 Atlantic India Rubber Works Inc.
  • Page 126 OM-2028 CODE VENDOR’S NAME AND ADDRESS 82372 Huntington Rubber Company Los Angeles, CA 85925 Emico Inc. (Electro Mechanical Instrument Company, Inc.) 123 N. Main St., P.O. Box 368 Dublin, Pennsylvania 18917 89110 AMP Inc. Capitron Div. 1595 South Mt. Joy Street Elizabethtown, Pennsylvania 17022 89616 Uniroyal Inc.

  • Page 127: Section 3. Parts List

    OM-2028 SECTION 3. PARTS LIST 1. Explanation of Parts List Arrangement The parts list is arranged so that the illustration will appear on a left-hand page and the applicable 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 128 OM-2028 Generator Set Figure 1 May 1/91 Revised Page 2...
  • Page 129 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 6910-1 GENERATOR SET FOR TRAILER OR TRUCK MOUNTING 6910A-1 GENERATOR SET FOR TRAILER OR TRUCK MOUNTING 6910-A-2 GENERATOR SET FOR TRAILER OR TRUCK MOUNTING 6910A-3 FIXED UNIT W/FUEL TANK & BATTERIES 6910B-1 GENERATOR SET FOR TRAILER OR TRUCK MOUNTING...
  • Page 130 OM-2028 Canopy Assembly Figure 2 May 1/91 Revised Page 4...
  • Page 131 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 180416 CANOPY ASSEMBLY (For NHA See Fig. 1) A-G,K-M 282322 CANOPY ASSEMBLY (For NHA See Fig. 1) 181035 . PANEL ASSEMBLY, SIDE, RIGHT, FRONT, CANOPY 482320 . DOOR ASSEMBLY, LEFT & RIGHT, FRONT, CANOPY DELETED 482322...
  • Page 132 OM-2028 This page intentionally left blank May 1/91 Revised Page 6...
  • Page 133 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY CANOPY ASSEMBLY (CONTINUED) 7J-422-0 . . CLAMP, CABLE 100GH-121 . . BRACKET, MTG., CLAMP 482442 . . HORN ASSY., CABLE ENTRANCE 403091-8 . PLUG, PLASTIC, 1-3/4", V28520, NO. DP-1750 482482 .
  • Page 134 OM-2028 Generator Set Without Canopy Figure 3 May 1/91 Revised Page 8...
  • Page 135 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number GENERATOR SET WITHOUT CANOPY (For NHA See Fig. 1) 489341 . GENERATOR ASSY. (For Details see Fig. 17) 489331 . GENERATOR ASSY. (For Details See Fig. 17) 280783A .
  • Page 136 OM-2028 This page intentionally left blank May 1/91 Revised Page 10...
  • Page 137 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number GENERATOR SET WITHOUT CANOPY 180407 . MUFFLER, ASSEMBLY 280519 . MUFFLER, ASSEMBLY 180409 . PIPE, EXHAUST, ASSY. 280518 . PIPE, EXHAUST, ASSY. *14A 100GHP-1158 . GASKET 180404 .
  • Page 138 OM-2028 Radiator and Cooling System Group Figure 4 May 1/91 Revised Page 12...
  • Page 139 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number RADIATOR AND COOLING SYSTEM GROUP (For NHA See Fig. 3) 180954 . RADIATOR 280054 . SUPPORT, RADIATOR ASSY. DELETED 181269 . HOSE, RADIATOR, INLET DELETED 404154-11 . CLAMP, HOSE, RADIATOR, V31337, NO2020 180928 .
  • Page 140 OM-2028 Air Cleaner Assembly (For units manufactured before and during August, 1990) Figure 5 May 1/91 Revised Page 14...
  • Page 141 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 180417 KIT, AIR CLEANER, ASSY (For units Manufactured before and during August, 1990) (For NHA See Fig. 3) 84A-1011 . AIR CLEANER V18265, No. FHG09-0024 84A-1010 . CLAMP, MOUNTING, AIR CLEANER V18265, No.
  • Page 142 OM-2028 Electric Governor Kit Figure 6 May 1/91 Revised Page 16...
  • Page 143 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 280459 KIT, ELECTRIC GOVERNOR, ASSY (For NHA See Fig. 3) 282948 . KIT, ELECTRICAL GOVERNOR, ASSY, (For NHA See Fig. 3) 281774-2 . SENSOR, MAGNETIC GOVERNOR, V03613 181020 . CONTROLLER, GOVERNOR, ELECTRIC V03613 280447 .
  • Page 144 OM-2028 Fuel Lines Assembly Figure 7 May 1/91 Revised Page 18...
  • Page 145 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 280983 LINES, FUEL, ASSEMBLY (For NHA See Fig. 3) REF 56535 . HOSE, LOW PRESSURE, 3/8 68" W-10893-0 . FITTING, HOSE, SWIVEL, FEMALE, 3/8 W-10886-11 . CONNECTOR, MALE, 1/2 X 5/8 W-10119-4 .
  • Page 146 OM-2028 Oil Line Assembly Figure 8 May 1/91 Revised Page 20...
  • Page 147 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 180434 LINE, OIL, ASSEMBLY (For NHA See Fig. 3) 403809-1 . SWITCH, LOW OIL PRESSURE, V51377, No. C-25900-10 W-10909-1 . TEE, STREET, BRASS V79470, No. 3750 X 2 W-10886-1 .
  • Page 148 OM-2028 Stator Terminal Panel Assembly Figure 9 May 1/91 Revised Page 22...
  • Page 149 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 482319 PANEL ASSY, TERMINAL, STATOR (For NHA See Fig. 3) 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. 482446 .
  • Page 150 OM-2028 Power Module Panel Assembly Figure 10 May 1/91 Revised Page 24...
  • Page 151 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 10 - 482075-2 PANEL ASSEMBLY, POWER MODULE (For NHA See Fig. 3) 401937-3 . STRIP, TERMINAL V98410, No. 35012-3526 401937-2 . STRIP, TERMINAL V98410, No. 35008-3526 W-9746-1 . RESISTOR, LINE DROP BURDEN, 50 OHM, 25 WATT, V44655, No.
  • Page 152 OM-2028 Control Box Assembly Figure 11 May 1/91 Revised Page 26...
  • Page 153 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 11 - 482235-2 CONTROL BOX ASSY (For NHA see Fig. 3) A-G,J-M,P 482235-10 CONTROL BOX ASSY (For NHA see Fig. 3) 482278-2 . TRAY ASSY, GENERATOR CONTROLS (For Details see Fig. 12) 482285-1 .
  • Page 154 OM-2028 Generator Controls Tray Assembly Figure 12 May 1/91 Revised Page 28...
  • Page 155 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 12 - 482278-2 TRAY ASSEMBLY, GENERATOR CONTROLS (For NHA See Fig. 11) 482355 . HARNESS, WIRE, RECEPTACLE 482284-1 . BRACKET, MOUNTING, RECEPTACLE & SWITCH 402826 . SWITCH, AUTOMATIC, MANUAL V15605, No.
  • Page 156 OM-2028 Protective Relays Tray Assembly Figure 13 May 1/91 Revised Page 30...
  • Page 157 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 13 - 482285-1 TRAY ASSEMBLY, PROTECTIVE RELAYS (For NHA See Fig. 11) 402662 . SWITCH, TEST BANK 482284-2 . BRACKET, MTG., RECEPTACLE & SWITCH 482356 . RECEPTACLE, HARNESS, WIRE 16DA-4052-0 .
  • Page 158 OM-2028 Control Box and Internal Components Group Figure 14 May 1/91 Revised Page 32...
  • Page 159 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 14 - No Number CONTROL BOX AND INTERNAL COMPONENTS GROUP (For NHA See Fig. 11) REF 402037-9 . GROMMET, RUBBER V02231, No. AGW-4211 82B-1047 . LIGHT, PANEL V74400, No. MI-3216 400613-4 .
  • Page 160 OM-2028 Engine Control Panel Assembly Figure 15 May 1/91 Revised Page 34...
  • Page 161 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 482296-17 PANEL ASSEMBLY, CONTROL, ENGINE (For NHA See Fig. 3) 482296-21 PANEL ASSEMBLY, CONTROL, ENGINE (For NHA See Fig. 3) B-G,K-M 482296-27 PANEL ASSEMBLY, CONTROL, ENGINE (For NHA See Fig. 3) 482296-28 .
  • Page 162 OM-2028 This page intentionally left blank May 1/91 Revised Page 36...
  • Page 163 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 15 - PANEL ASSEMBLY, CONTROL, ENGINE (CONTINUED) No Number . NAMEPLATE, START-RUN-STOP (Furnished with Engine) 403380 . CAP & CHAIN ASSEMBLY, V02660, No. 9760-28 482304 . HARNESS, WIRE, TEST RECEPTACLE ASSY. 280510 .
  • Page 164 OM-2028 Output Terminal Board Assembly Figure 16 May 1/91 Revised Page 38...
  • Page 165 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 16 - 482317 BOARD ASSEMBLY, TERMINAL, OUTPUT (For NHA See Fig. 3) 280515 BOARD ASSEMBLY, TERMINAL, OUTPUT (For NHA See Fig. 3) B-G,K-M 50MS-732-0 . NUT, HEX, 1/4-20, KEPS, MH, STEEL W-11242-5 .
  • Page 166 OM-2028 Generator Assembly Figure 17 May 1/91 Revised Page 40...
  • Page 167 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 17 - 489341 GENERATOR ASSY. (For NHA See Fig. 3) 489331 GENERATOR ASSY. (For NHA See Fig. 3) 280783A GENERATOR ASSY. (For NHA See Fig. 3) 387617A . COVER, FAN, HOUSING 387621 .
  • Page 168 OM-2028 Mounting Frame Assembly and Lifting Yoke Figure 18 May 1/91 Revised Page 42...
  • Page 169 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 18 - No Number FRAME ASSEMBLY, MOUNTING & LIFTING YOKE (For NHA See Fig. 1) 488785 . YOKE, LIFTING 180414 . PANEL, SUPPORT, CONTROL BOX 482316 . BRACKET, MOUNTING, SUPPORT, BOX, CONTROL 481113 .
  • Page 170 OM-2028 Water Heater Figure 19 May 1/91 Revised Page 44...
  • Page 171 OM-2028 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 19 - 282321 WATER HEATER KIT H,J,N,P 408503 . HEATER, WATER JACKET H,J,N,P 1 181713 . BRACKET, MTG. WATER HEATER H,J,N,P 1 56537 . HOSE, CONNECTION OUTLET 5/8 I.D. H,J,N,P 34"...
  • Page 172 OM-2028 This page intentionally left blank. May 1/91 Revised Page 46...

  • Page 173: Chapter 5. Optional Equipment

    OM-2028 CHAPTER 5. OPTIONAL EQUIPMENT This chapter provides documentation covering any optional equipment furnished with your generator. Available options are listed below. OPTION NAME MANUAL HOBART Trailer, Fenders and Parts (Four-Wheel Trailer) TO-136 482731-7 Trailer, Fenders and Parts (Fifth-Wheel Trailer) TO-209 282288-1 Transformer-Rectifier, 28.5-V DC...
  • Page 174 OM-2028 This page intentionally left blank. May 1/91 Revised Page 2...

  • Page 175: Chapter 6. Manufacturer'sliterature

    Barber Coleman Governor Company Electrically Powered Governor Engine John Deere Operators Manual No. OM-RG-18293 6910 Flexible Coupling Hobart Brothers Company Coupling Manual TM-736 6910A /6910B/6910C Flexible Coupling Hobart Brothers Company Coupling Manual OM-2019 Exciter Rotor Hobart Brothers Company Rotor Manual TM-360 Hobart Diagrams...
  • Page 176 OM-2028 This page intentionally left blank. June 20/89 Revised Page 2...

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