OM-2053

032089
Revised 050693
Revised 050994

OPERATION AND MAINTENANCE MANUAL

with

ILLUSTRATED PARTS LIST

for

ENGINE-DRIVEN GENERATOR SET

SPECIFICATION NUMBER 7009 , 7009A, & 7009B

For Truck or Trailer Mounting

MODEL No. 60PL20

60-KVA, 400-HZ, 115/200-V AC, 3-PHASE

with

PERKINS DIESEL ENGINE

TYPE 6.3544

Hobart Brothers Company

Airport Systems Group
Ground Power Equipment
Troy, Ohio 45373
U.S.A.

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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.

Important: - Protect all operating personnel. Read, understand, and follow all instructions in
the Operating/Instruction Manual before installing, operating, or servicing the equipment. Keep
the manual available for future use by all operators.
A. GENERAL
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment
or property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices
have been developed from past experience in the use of power source equipment. While certain practices be-
low apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and some
practices to both.

B. SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally
shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn what
terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing, procedures,
and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubber mat or
dry wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and never
work alone
1. Installation and Grounding of Electrically Powered Equipment
Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed and
maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or other applicable codes. A
power disconnect switch or circuit breaker must be located at the equipment. Check the nameplate for volt-
age, frequency, and phase requirements. If only 3-phase power is available, connect any single-phase rated
equipment to only two wires of the 3-phase line. DO NOT CONNECT the equipment grounding conductor
(lead) to the third live wire of the 3-phase line, as this makes the equipment frame electrically HOT, which can
cause a fatal shock.
Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or build-
ing 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. Refer to the National Electrical Code
ANSI/NFPA 70 for details. Do not remove plug ground prongs. Use correctly mating receptacles.
2. Output Cables and Terminals
Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked or
worn cables immediately. Do not overload cables. Do not touch output terminal while equipment is energized.
3. Service and Maintenance
This equipment must be maintained in good electrical and mechanical condition to avoid hazards stem-
ming from disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of
the equipment until its safety has been assured. Repairs should be made by qualified personnel only.
Before inspecting or servicing electrically-powered equipment, take the following precautions:
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.

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c. Disconnect power to equipment if it is out of service.

d. If troubleshooting must be done with the unit energized, have another person present who is trained in
turning off the equipment and providing or calling for first aid.

C . FIRE AND EXPLOSION PREVENTION

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust pip-
ing, misuse of batteries and fuel, or unsafe operating or fueling conditions.
1. Electrical Short Circuits and Overloads
Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by causing
nearby combustibles to ignite. For electrically-powered equipment, provide primary input protection to remove
short circuited or heavily overloaded equipment from the line.
2. Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured battery
can cause fires and additional failures. When servicing,do not smoke, cause sparking, or use open flame
near the battery.
3. Engine Fuel
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is not
grounded prior to or during fuel transfer. Shut unit DOWN before removing fuel tank cap. DO NOT com-
pletely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove all spilled fuel
IMMEDIATELY, including any that penetrates the unit. After clean-up, open equipment doors and blow fumes
away with compressed air.

D. TOXIC FUME PREVENTION

Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust
fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air condition-
ers.

E. BODILY INJURY PREVENTION

Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipment for
inspection and routine maintenance. When equipment is in operation, use extreme care in doing necessary
trouble-shooting and adjustment. Do not remove guards while equipment is operating.

F. MEDICAL AND FIRST AID TREATMENT

First aid facilities and a qualified first aid person should be available for each shift for immediate treat-
ment of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital im-
mediately if any abnormal signs are observed.

EMERGENCY FIRST AID

Call physician immediately. Seek additional assistance. Use First Aid techniques recommended
by American Red Cross until medical help arrives.

IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELECTRI-
CAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration, prefer-
ably mouth-to-mouth. If no detectable pulse, begin external heart massage. CALL EMERGENCY
RESCUE SQUAD IMMEDIATELY.

G. EQUIPMENT PRECAUTIONARY LABELS

Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be
easily read.

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INTRODUCTION
This manual contains operation and maintenance information for a 400-Hertz generator set manufactured
by Hobart Brothers Company, Power Systems Group, Troy, Ohio 45373.

This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics who have never seen
or operated this equipment. It is the intent of this manual to guide and assist operators and maintenance
people in the proper use and care of the equipment.

Use of the manual should not be put off until a trouble or need for help develops. Read the instructions be-
fore starting the unit. Learn to use the manual and to locate information contained in it. Its style and ar-
rangement are very similar to commercial aircraft manuals. The manual is divided into six chapters. Each
chapter is divided into as many sections as required. Each new section starts with page 1. Each page is
identified by chapter, section and page number, which are located in the lower, outside corner. When infor-
mation located in another portion of the manual is referred to, its location is identified by a chapter, sec-
tion, and paragraph, or figure number.

For example, “(See 2-3, Para. B)” refers to information located in Chapter 2, Section 3, Paragraph B. If a
Chapter and Section are not indicated in a reference, the referenced material is located in the same sec-
tion as the reference, Example, (See Para. B).

In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chap-
ter 4, and a collection of manufacturer’s literature and supplemental information in Chapter 6.

Content of the manual is arranged as follows:

Chapter 1. Description/Operation
Chapter 2. Servicing
Chapter 3. Troubleshooting
Chapter 4. Illustrated Parts List
Chapter 5. Optional Equipment
Chapter 6. Manufacturer’s Literature

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Introduction December 31/91 Revised

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LIST OF EFFECTIVE PAGES

CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE

List of 1 Mar 20/89 1-3 1 Mar 20/89

Effective 2 Mar 20/89 1-3 2 Mar 20/89
Pages 1-3 3 Mar 20/89
1-3 4 Mar 20/89
Introduction 1 Mar 20/89 1-3 5 Mar 20/89
Introduction 2 Mar 20/89 1-3 6 Mar 20/89

Contents 1 Mar 20/89 2-1 1 Mar 20/89

Contents 2 Mar 20/89 2-1 2 Mar 20/89
Contents 3 Mar 20/89 2-1 3 Mar 20/89
Contents 4 Mar 20/89 2-1 4 Mar 20/89
Contents 5 Mar 20/89 2-1 5 Mar 20/89
Contents 6 Mar 20/89 2-1 6 Mar 20/89
Contents 7 Mar 20/89 2-1 7 Mar 20/89
Contents 8 Mar 20/89 2-1 8 Mar 20/89
Contents 9 Mar 20/89 2-1 9 Mar 20/89
Contents 10 Mar 20/89 2-1 10 Mar 20/89
Contents 11 Mar 20/89 2-1 11 Mar 20/89
Contents 12 Mar 20/89 2-1 12 Mar 20/89
2-1 13 Mar 20/89
1-1 1 Mar 20/89 2-1 14 Mar 20/89
1-1 2 Mar 20/89
1-1 3 Mar 20/89 2-2 1 Mar 20/89
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1-2 3 Mar 20/89 2-3 17 Mar 20/89
1-2 4 Mar 20/89 2-3 18 Mar 20/89

March 20/89 List of Effective Pages

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LIST OF EFFECTIVE PAGES

CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE

3-1 1 Mar 20/89 4-3 6 Mar 20/89

3-1 2 Mar 20/89 4-3 7 Mar 20/89
3-1 3 Mar 20/89 4-3 8 Mar 20/89
3-1 4 Mar 20/89 4-3 9 Mar 20/89
3-1 5 Mar 20/89 4-3 10 Mar 20/89
3-1 6 Mar 20/89 4-3 11 Mar 20/89
3-1 7 Mar 20/89 4-3 12 Mar 20/89
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4-3 30 Mar 20/89
4-1 1 Mar 20/89 4-3 31 Mar 20/89
4-1 2 Mar 20/89 4-3 32 Mar 20/89
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4-3 1 Mar 20/89 5-0 1 Mar 20/89

4-3 2 Mar 20/89 5-0 2 Mar 20/89
4-3 3 Mar 20/89
4-3 4 Mar 20/89 6-0 1 Mar 20/89
4-3 5 Mar 20/89 6-0 2 Mar 20/89

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Table of Contents
SUBJECT CHAPTER/SECTION PAGE

WARNING
INTRODUCTION
Chapter 1. Description/Operation
Section 1. Description 1-1 1
1. General 1-1 1
2. Orientation 1-1 1
3. Special Features 1-1 1
A. Protective Monitor 1-1 1
B. Voltage Regulator 1-1 1
C. Electric Governor 1-1 1
4. Canopy 1-1 4
5. Optional Equipment 1-1 4
6. Engine, Generator, and Controls Assembly 1-1 4
A. Basic Engine 1-1 4
B. Engine Manufacturer’s Equipment 1-1 4
C.Hobart Engine Equipment 1-1 6
(1) Electric governor system 1-1 6
(a) Magnetic pickup 1-1 6
(b) Control unit 1-1 6
(c) Actuator 1-1 6
(2) Engine electrical system 1-1 6
(3) Engine protective devices 1-1 6
(a) High coolant temperature switch 1-1 6
(b) Oil pressure switch 1-1 6
(4) Air cleaner 1-1 7
(5) Exhaust system 1-1 7
(6) Radiator 1-1 7
D. Generator 1-1 8
E. Control Box Assembly 1-1 9
(1) Front Panel 1-1 9
(a) Generator output monitors (meters) 1-1 9
(b) Meter and line switches 1-1 9
(c) Instrument light 1-1 9
(d) Indicating lights 1-1 9
(2) Control box internal components 1-1 9
(a) Sensing modules 1-1 10
(b) Memory and time delay module 1-1 11
(c) Excitation-deenergization relay 1-1 11
(d) Plug-interlock relay 1-1 11
(e) Test-bank switch 1-1 11
(f) Resistor 1-1 11
(g) Fuse-interlock relay 1-1 12
(h) Auxiliary underfrequency relay 1-1 12
(j ) Terminal boards 1-1 12

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Table of Contents
SUBJECT CHAPTER/SECTION PAGE

(k) Solid-state voltage regulator 1-1 12

(l) Overload module 1-1 12
(m) Rectifier 1-1 12
F. Engine Control Panel 1-1 12
(1) Engine instruments 1-1 12
(a) Ammeter 1-1 12
(b) Temperature gage 1-1 12
(c) Oil pressure gage and oil
pressure switch 1-1 14
(d) Hourmeter 1-1 14
(e) Fuel gage and blocking diodes 1-1 14
(2) Engine and generator controls 1-1 14
(a) Engine-generator control switch 1-1 14
(b) Contactor control switch 1-1 14
(c) Instrument light and switch 1-1 14
(d) Engine starting circuit 1-1 15
(e) Indicating lights 1-1 15
(f) Fuse 1-1 15
G. Load Contactor Circuit Components 1-1 15
(1) Load contactor 1-1 15
(2) Current transformers 1-1 15
(a) Ammeter current transformers 1-1 15
(b) Line-drop current transformers 1-1 15
(c) Overload current transformers 1-1 15
(3) Overload module 1-1 17
(4) Rectifier 1-1 17

Section 2. Preparation For Use,

Storage, Or Shipping 1-2 1
1. Preparation for Use 1-2 1
A. Inspection/Check 1-2 1
B. Installing Three-phase AC Output Cables 1-2 1
2. Preparation for Storage 1-2 2
A. General 1-2 2
B. Temporary Storage 1-2 2
C. Long Time Storage 1-2 2

Section 3. Operation 1-3 1

1. General 1-3 1
2. Operating the Generator Set 1-3 1
A. Pre-start Inspection 1-3 1
B. Normal Engine Starting Procedures 1-3 1
C.Preparation for Power Delivery 1-3 3
D. Power Delivery 1-3 4
E. Discontinue Power Delivery 1-3 4
F. Stopping the Engine 1-3 4

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Table of Contents
SUBJECT CHAPTER/SECTION PAGE

3. Trailer Operation 1-3 5

A. Towing 1-3 5
B. Parking 1-3 5

Chapter 2. Service
Section 1. Maintenance 2-1 1
1. General 2-1 1
2. Inspection 2-1 1
3. Lubrication 2-1 1
A. General 2-1 1
B. Generator 2-1 1
C. Generator Controls 2-1 1
D. Engine 2-1 1
(1) Lubrication schedule 2-1 2
(2) Oil specification 2-1 2
(3) Oil viscosity 2-1 2
(4) Changing engine oil 2-1 2
(5) Changing engine oil filter 2-1 2
E. Starter 2-1 2
F. Trailer 2-1 2
(1) Front axle assembly 2-1 2
(2) Wheel bearings 2-1 3
4. Air Cleaner Service 2-1 3
A. Inspecting the Air Cleaner 2-1 3
B. Cleaning Instructions 2-1 4
C. Disposal 2-1 4
5. Engine Fuel 2-1 4
A. Quality 2-1 4
B. Fuel Filter 2-1 4
6. Engine Cooling System 2-1 4
A. General 2-1 4
B. Radiator Cap 2-1 5
(1) General 2-1 5
(2) Removal 2-1 5
(3) Installation 2-1 5
C. Warm Weather Operation 2-1 5
D. Cold Weather Operation 2-1 5
(1) General 2-1 5
(2) Checking coolant solution 2-1 5
(3) Preparing the coolant solution 2-1 5
(4) Installing the antifreeze solution 2-1 6
E. Draining the Cooling System 2-1 6
F. Cleaning the Cooling System 2-1 6
G. Cleaning the Radiator Core 2-1 7
H. Filling the Cooling System 2-1 7

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Table of Contents
SUBJECT CHAPTER/SECTION PAGE

7. Generator Maintenance 2-1 7

A. Cleaning 2-1 7
B. Adjustment 2-1 7
8. Drive Belts 2-1 8
A. Checking Belt Tension 2-1 8
B. Belt Adjustment 2-1 8
9. Battery Maintenance 2-1 8
A. General 2-1 8
B. Battery Location and Accessibility 2-1 8
C. Battery Care 2-1 8
D. Liquid Level 2-1 9
E. Cleaning the Battery 2-1 9
F.Testing the Battery 2-1 9
(1) Test with Battery-Starter Tester 2-1 9
(2) Test with Hydrometer 2-1 9
10. Service Helps 2-1 10
A. Wiring 2-1 10
B. Generator Exciter 2-1 10
(1) Preparation for exciter removal. 2-1 10
(2) Exciter removal 2-1 10
(3) Exciter installation 2-1 10

Section 2. Inspection/Check 2-2 1

1. General 2-21 1
2. Engine 2-2 1
A. Fuel 2-2 1
B. Lubrication 2-2 1
C. Coolant 2-2 1
D. V-Belt 2-2 1
E. Exhaust System 2-2 1
3. Electrical System (12-V DC) 2-2 2
A. Lights 2-2 2
B. Fuses 2-2 2
C. Wiring and Connections 2-2 3
4. Electrical System (115-V AC) 2-2 4
A. Monitoring Instruments 2-2 4
B. Indicating Lights 2-2 4
C. Protective Modules 2-2 4
D. Wiring and Connections 2-2 4
5. Trailer 2-2 4

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Table of Contents
SUBJECT CHAPTER/SECTION PAGE

Section 3. Adjustment/Test 2-3 1

1. General 2-3 1
2. Generator Set Test 2-3 1
A. Pre-operational Test Procedures 2-3 1
B. Operational Test Procedures 2-3 1
3. Generator Set Adjustment 2-3 7
A. Generator Adjustment 2-3 7
B. Voltage Regulator Adjustments 2-3 7
C.Basic Engine Adjustments 2-3 7
D. Engine Accessories Adjustment 2-3 8
(1) Generator and fan belt adjustment 2-3 8
E. Electric Governor System Adjustment
(Woodward Governor Kit) 2-3 8
(1) General 2-3 8
(2) Actuator linkage adjustment 2-3 9
(3) Magnetic pickup adjustment 2-3 10
(4) Governor Control Unit Adjustment 2-3 11
F. Electric Governor System Adjustment
(Barber-Colman Governor Kit) 2-3 13
(1) General 2-3 13
(2) Actuator Linkage Adjustment 2-3 13
(3) Magnetic Pick-up Inspection / Adjustment 2-3 15
(4) Governor Controller Adjustment 2-3 16
(5) Re-checking Actuator Linkage 2-3 16
(6) Checking the Actuator 2-3 16
(7) Troubleshooting 2-3 18
4. Generator and Exciter Test 2-3 19
5. Diode Test 2-3 19
Chapter 3.Troubleshooting
Section 1. Trouble Shooting
Procedures 3-1 1
1. General 3-1 1
2. Troubleshooting Chart 3-1 1
A. Description 3-1 1
B. Use of the Trouble Shooting Chart 3-1 1
3. Equipment for Troubleshooting 3-1 2
4. Safety - WARNING: 3-1 2
5. Parts Replacement 3-1 2
6. Test Values 3-1 2
7. Checking Connections and Leads 3-1 3
8. Electric Governor Trouble Shooting 3-1 3
9. Engine Trouble Shooting Procedures 3-1 3
10.Illustrations 3-1 3

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Table of Contents
SUBJECT CHAPTER/SECTION PAGE

Chapter 4. Illustrated Parts List

Section 1. Introduction 4-1 1
1. General 4-1 1
2. Purpose 4-1 1
3. Arrangement 4-1 1
4. Explanation of Parts List 4-1 1
A. Contents 4-1 1
B. Parts List Form 4-1 2
(1) FIGURE-ITEM NO. Column 4-1 2
(2) HOBART PART NUMBER Column 4-1 2
(3) NOMENCLATURE Column 4-1 2
(4) REC. SPARES Column 4-1 2
(5) “EFF” (Effective) Column 4-1 2
(6) UNITS PER ASSEMBLY Column 4-1 2

Section 2. Manufacturer’s Codes 4-2 1

1. Explanation of Manufacturer’s
(Vendor) Code List 4-2 1
Section 3. Parts List 4-3 1
1. Explanation of Parts List Arrangement 4-3 1
2. Symbols and Abbreviations 4-3 1
Section 4. Numerical Index 4-4 1
1. Explanation of Numerical Index 4-4 1

Chapter 5. Optional Equipment

Chapter 6. Manufacturers Literature

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CHAPTER 1. DESCRIPTION/OPERATION
SECTION 1. DESCRIPTION

1. General
This manual covers two trailer-mounted 60-kVA generator sets manufactured by Hobart Brothers Com-
pany and identified respectively as Specification No. 7009-1, Specification No. 7009A-1, and Specifi-
cation No. 7009B-1

All three generator sets feature an armature with Hoover Bearings, Browning Coupler, and different mag-
netic pole construction for the generator revolving field. This new armature can be easily identified by two
copper rings on each end of the field coils and copper wedges between magnetic poles.

The difference between Specification No. 7009-1and Specification No. 7009A-1 is that Specification No.
7009A-1 features new-style doors on the canopy assembly. Specification 7009B-1 is physically and electri-
cally identical toSpecification 7009A-1, except that a Barber-Colman engine speed governor is used in-
stead of the Woodward governor used on Specification No. 7009-1and Specification No. 7009A-1.

The purpose of these generator sets (Fig. 1) is to generate and deliver regulated, 400-Hz electrical power
to a parked (or towed) aircraft for operation of the aircraft’s electrical equipment when the on-board gener-
ators are not running. See Figure 2 for specifications and capabilities.

2. Orientation
For purpose of orientation and to familiarize operators and maintenance personnel with the location of
components, the radiator is considered to be at the FRONT of the unit. The generator and controls are at
the REAR. RIGHT and LEFT are determined by standing at the rear end facing the machine.

3. Special Features
These generator sets have many special features which are later described more fully under the assem-
blies in which they appear. Some of the main features are mentioned here and described briefly.

A. Protective Monitor
A single, solid-state device (7, Fig. 7) receives signals from all of the fault sensing units in the gener-
ator output circuit and functions to cause the load to be disconnected from the generator if an abnor-
mal condition of voltage, frequency, or load develops.

B. Voltage Regulator
A solid-state, adjustable voltage regulator (Items 13 and 17, Fig. 7) provides automatic voltage regula-
tion at the aircraft (or distribution panel when applicable). The regulator is also adjustable for a variety
of output cable sizes and lengths.

C. Electric Governor
The engine is equipped with an all electric type governor kit (13 and 16, Fig. 3) and other special
equipment more fully described under the engine description.

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1. Engine fan exhaust deflectors 6. Generator control panel window

2. Radiator cap access hole 7. Engine control panel window
3. Canopy 8. Mounting frame
4. Doors (attached to canopy) 9. Door latches
5. Engine exhaust pipe and cover

Generator Set
Figure 1

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PHYSICAL
BASIC GENERATOR SET
Length overall 84 inches (2134 mm)
Width 33 inches (838 mm)
Height 43 inches (1092 mm)
Weight (Approximate) 3655 pounds (1658 kg)

TRAILER-MOUNTED GENERATOR SET

Length overall 90 inches (2286 mm)
Width 66 inches (1676 mm)
Height 57 inches (1448 mm)
Weight (Approximate) 4120 pounds (1868.5 kg)
GENERATOR
Output power rating 60 KVA
Output voltage 115/200 V
Rated load capacity 173 A
Frequency (cycles-per-second) 400 Hz
Output kilowatts 48 KW
Power factor 0.8 PF
Duty cycle 100%
Operating speed at 400 Hz 2000 RPM
Overload capacity (125% of rated load capacity) 216 A

GENERATOR PROTECTIVE SYSTEM

Overvoltage relay trips 130 V to 134 V; resets 125 V
Undervoltage relay trips 102 V or below; resets 110 V
Overfrequency relay trips 415 Hz to 425 Hz; resets 410 Hz
Underfrequency relay trips 375 Hz to 385 Hz; resets 385 Hz
Overload relay trips 112 KVA in less than 5 minutes
Undervoltage time delay relay 4 to 12 seconds

ENGINE
Manufacturer Perkins Diesel
Model 6.3544
Type In-line, 6-cylinder, 4-cycle Diesel
Displacement 354 cu. in. (5.8 liters)
Compression ratio 16:1
Firing order 1-5-3-6-2-4
Horsepower at 2000 RPM 107
Governed speed 2000 RPM +/- 4.5%
Idle speed 850 +/- 25 RPM
Electrical system 12 volt
Oil capacity (with filter) 15 quarts (14 liters)
Oil capacity (without filter) 14quarts (13.6 liters)
Coolant capacity (approx.) 20 quarts (19 liters)
Fuel Diesel oil conforming to ASTM Specification
D.975-66T, Nos. 1-D and 2-D
Lube oil MIL-L-2104C or MIL-L-2104D

Specifications and Capabilities

Figure 2

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4. Canopy
A sheet metal enclosure, identified as a canopy (2, Fig. 1), provides protection for the engine, generator
and electrical controls. This generator set is equipped with a canopy having doors on both sides. This
canopy is largely of one-piece construction, with the four access doors of the unit attached to the canopy
top by welded-on piano hinges. Hex-head bolts attach the front and back panels to the canopy top assem-
bly and the frame. Air enters the bottom of the unit into the engine compartment and is discharged
through the radiator by the engine fan. Metal strips are mounted horizontally across the front grille to de-
flect engine fan exhaust air and noise downward. Air entering the generator compartment is circulated
over generator controls and drawn into the rear exciter and generator housings where it passes over all
windings before being discharged by the generator fan.

Panel mounted instruments may be observed through two Plexiglas windows in the left rear door which
covers the control box and engine control panel. The lower window is slanted outward at the bottom to
provide access to engine controls when the door is closed.

Doors on the unit are equipped with flexible rubber draw latches (9, Fig. 1) which prevent excessive door
vibration when the unit is running.

5. Optional Equipment
Two items of optional equipment are presently available for the 7009 & 7009A units: a cold-weather start-
ing aid kit identified as Hobart Part No. 488913 , and a four-wheel trailer with fuel tank, identified as Ho-
bart Part No. 280718 (7009) or Hobart Part No. 281056 (7009A). Refer to TO-186 in Chapter 5 for
information on the four-wheel trailer.

6. Engine, Generator, and Controls Assembly

This assembly is the basic generator set without canopy. It includes all components required to generate
and regulate 400 Hz, 115/200 V, threephase power, and is operable when provided with fuel and 12 V DC
power. The engine-generator assembly is mounted on a welded steel frame. A superstructure, attached to
the main frame, provides mounting facilities for the canopy, control box, and electrical equipment and con-
trols.

A. Basic Engine
This generator set is equipped with a 6-cylinder, in-line, turbocharged Perkins Diesel engine. See Fig-
ure 2 for general specifications, and see Engine Operator’s Handbook in Chapter 6 for more detailed
information.

B. Engine Manufacturer’s Equipment

As received from the engine manufacturer, the engine includes the following equipment which is de-
scribed in the Perkins Diesel shop Manual (Chap. 6)
(1) Fuel filter.
(2) Reverse-flow, engine cooling fan to blow air OUTWARD through the radiator.

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1. Generator7. Quick-start kit 13. Governor control box

2. Batteries (2) 8. Air cleaner 14. Engine control panel
3. Control box assembly 9. Engine assembly assembly
4. Muffler 10. Cooling fan 15. Exhaust pipe assembly
5. Rain cap 11. Radiator assembly 16. Governor actuator
6. 90o elbow 12. Mounting frame 17. Load contactor

Generator Set Components

Figure 3

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C.Hobart Engine Equipment

The engine is modifiee 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. This fast response re-
sults in very close frequency control. Refer to the Woodward Governor manual in Chapter 6 for a
detailed description. A brief description is given below:
The governor system consists of the following main components:
(a) Magnetic pickup, (b) Control unit, and, (c) Actuator
(a) Magnetic pickup
This pickup is a device for detecting engine speed. It is mounted in the flywheel housing di-
rectly over the ring gear. It produces an AC signal to the control unit when the ferrous fly-
wheel teeth pass through the magnetic field at the end of the pickup.
(b) Control unit
The control unit (13, Fig. 3) is a box containing a compact assembly of solid state compo-
nents. It receives an AC signal from the magnetic pickup and senses speed changes in the
engine. It provides a voltage signal to the actuator which causes the actuator to move the fuel
control lever as required to maintain a predetermined engine speed. Its power is received
from the 12-V DC battery system.
(c) Actuator
The actuator (16, Fig. 3) supplies the force needed to move and position the fuel lever as re-
quired to maintain a constant engine speed. 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
(c) Starting switch
(d) Wiring harness

(3) Engine protective devices

(a) High coolant temperature switch

A high coolant temperature switch is mounted in the front of the cylinder block to monitor the
coolant temperature. If the coolant temperature reaches 210 degrees F (99 degrees C), this
normally closed switch opens and de-energizes the fuel valve solenoid which shuts down the
engine.
(b) Oil pressure switch
A diaphragm-type switch monitors the pressure in the lubricating oil system. It is mounted in
the side of the cylinder block (9, Fig. 3). If the pressure in the lube oil system falls to 10 psi
(69 kPa), this switch opens and de-energizes the fuel valve solenoid which shuts down the en-
gine.

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(4) Air cleaner

The diesel-engine air cleaner (Fig. 4) is so constructed that air enters it through the perforated cy-
lindrical body of the air cleaner itself, and is filtered in the process before being passed on to the
engine intake manifold assembly.

(5) Exhaust system

The exhaust system consists of a noise reducing muffler (2, Fig.5) which is connected by a pipe
(1) to the exhaust manifold. The tail pipe (3) directs exhaust and noise upward.

(6) Radiator (11, Fig. 3)

This radiator is a one-piece item designed for long periods of operation without servicing. Refer
to Section 2-1, Para. 7, G, for servicing procedure.

Air Cleaner
Figure 4

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1. Pipe, manifold-to-muffler
2. Muffler
3. Tail Pipe

Exhaust System
Figure 5

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 is sup-
ported by the fan housing; the rear bearing is mounted in the exciter housing. Both of these housings
are attached to the main generator stator housing. The front end of the rotor shaft extends forward be-
yond the rear bearing and into the exciter stator housing. The exciter rotor is mounted on this shaft ex-
tension with a Woodruff key and is secured by a washer and 1/2"-13 thd, cap screw. A rectifier with
six diodes is mounted on the exciter rotor and converts exciter AC output to DC for excitation of the
generator revolving fields. The exciter DC output to the generator fields, and consequently the gener-
ator output, is controlled by the amount of DC voltage supplied to exciter fields by the static voltage
regulator. A centrifugal, radial-blade fan which is part of the hub and coupling assembly, draws cool-
ing air over all internal windings. Air enters at the exciter end and is discharged at the drive end. The
complete generator is bolted to the engine flywheel housing.

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E. Control Box Assembly

The control box (Fig. 6) is a sheet metal enclosure which houses and provides mounting facilities for
generator controls, and engine and generator monitoring equipment. For access to components
mounted inside the control box, it is necessary to remove two 1/4 X 20 - 1/2-inch hex bolts, and to pull
down the front panel, which is hinged to the control box at the bottom.

(1) Front Panel

(a) Generator output monitors (meters)

The generator output is monitored by three instruments; a frequency meter (2), a voltmeter
(3), and an ammeter (4) The frequency meter is a resonant-reed type, and indicates the fre-
quency of the generator output alternating current in the range of 380 to 420 Hz (cycles per
second). The voltmeter indicates the generator output voltage in each phase-to-neutral (A-N,
B-N and C-N) or phase-to-phase (A-B, B-C and C-A) as selected by the meter selector switch
(5) and the line selector switch (7). (These switches will be described below.) The voltmeter
has a 3-1/2-inch face and the scale is graduated 0 to 300 V. The ammeter is also 3-1/2-inch
size and is graduated 0 to 500 A. The amperage value in each of the three phases may be
read on the ammeter by selecting the desired phase with switch (5). Three ammeter current
transformers, located beneath the generator control box support panel, lower the output load
current to a lesser value, of definite ratio, which will operate the ammeter movement without
damage. The ammeter dial scale is graduated and numbered so that the pointer will indicate
the true load current value rather than the meter movement current.
(b) Meter and line switches
These switches provide a means of selecting and determining which phase of voltage and
current is indicated on the voltmeter and ammeter and whether the voltage is line-to-neutral
or line-to-line The meter switch (5) is a four-position, rotary type. A nameplate (6), located un-
der the switch knob, is marked and lettered to indicate the three functional positions of the me-
ter switch. (When the knob is pointing straight DOWN, the switch is OFF.) The line switch (7)
is a two-position, toggle switch used to select either line-to-neutral or line-to-line voltage to the
voltmeter. The nameplate is also marked to indicate position of this switch.
(c) Instrument light
A shielded, instrument panel light (1) is mounted at the left side of the control panel to illumi-
nate controls, instruments, and indicator lights. It is controlled by a toggle switch on the en-
gine control panel (3, Fig. 8) which also controls instrument light on the engine control control.
(d) Indicating lights
The function of these lights (10, 11, 12, 13 and 14) is to indicate, to the operator, the abnor-
mal condition of overvoltage, underfrequency, etc., which caused the protective monitor sys-
tem to function. Each of the five lights is connected to an actuating circuit within the memory
and time delay module. When one of the circuits is activated, it turns on the applicable indicat-
ing light. The light will remain on until the reset switch (17) is pushed. All lamps in indicating
lights may be tested by pressing switch (16).

(2) Control box internal components (Figure 7)

Internally, the control box contains a solid-state voltage regulator, and electrical and safety de-
vices designed to protect the aircraft electrical system against damage which could result from
overvoltage, undervoltage, overfrequency, or underfrequency. Also contained therein are devices
for the protection and control of the generator output electrical system.

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(a) Sensing modules

The voltage sensing module (4) and frequency sensing module (6) are connected to gener-
ator output leads between the generator and load contactor. These solid-state modules sense
any abnormal condition of voltage or frequency and signal the solid-state circuitry of the mem-
ory and time delay module (7) to open the load contactor and disconnect output to the air-
craft. A solid-state overload signaling device (5) is also connected to the protective monitor
module and performs a function similar to the voltage and frequency sensing modules.

1. Instrument panel light 11. Undervoltage indicating light

2. Frequency meter 12. Overfrequency indicating light
3. Voltmeter 13. Underfrequency indicating light
4. AC ammeter 14. Overload indicating light
5. Meter selector rotary switch 15. Hole plug
6. Instruction plate 16. Light test switch
7. Line selector toggle switch 17. Reset switch
8. Protective system fuse (2-A) 18. Regulated/diagnostic switch
9. Load contactor circuit fuse (2-A) 19. Aircraft/test-bank switch
10. Overvoltage indicating light

Front Panel of Generator Control Box

Figure 6

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Trip values for protective circuits are as follows:

Overvoltage trips at 130 V to 134 V
Undervoltage trips at 102 V or below
Overfrequency trips at 415 Hz to 425 Hz
Underfrequency trips at 390 Hz to 395 Hz
Undervoltage time delay (adjustable)
Overload circuit trips at any value over 125% rated load capacity.
Trip values are adjustable, however, adjustments should be made ONLY under laboratory
conditions.
See Para 6,H, (3) for more specific and detailed information regarding overload device.
(b) Memory and time delay module
The memory and time delay module (7) is sometimes called the protective monitor module. It
is a solid-state device with a hermetically-sealed, reed-type relay. The printed circuit board or
“card” includes five memory circuits and a time delay circuit. Each circuit is connected to a
corresponding sensing circuit in the sensing modules (4, 5, and 6). All memory circuits are
connected to the module relay coil, and any one of the circuits can energize the coil to open
the relay contacts. Thus, when a sensing device energizes any one of the module circuits, the
module relay is also energized to break the load contactor holding circuit and allow the load
contactor to open. The module relay will remain energized (OPEN) and the light will remain
ON until the reset switch (17, Fig. 6) is pushed to break the module 12-V DC cirucit, and allow
the relay to return to normal, CLOSED position. All circuits, except the undervoltage circuit,
function immediately to open the load contactor. A time delay system is designed into the un-
dervoltage circuit to prevent nuisance opening of the contactor under conditions of momen-
tary undervoltage in the generator output. An undervoltage condition which continues
uninterrupted for a period of 4 to 12 seconds (adjustable) will cause the time delay circuit to
open the load contactor. Each of the five circuits is connected to a corresponding indicating
light (10, 11, 12, 13 and 14) which is turned on when a fault occurs.
(c) Excitation-deenergization relay
The purpose of this relay (1) is to allow automatic excitation to be connected to the exciter
field only when engine speed is being controlled by the electric governor.
(d) Plug-interlock relay
The function of the plug interlock relay (2) is to cause the output load contactor to open in the
event the cable plug connector becomes accidentally disconnected from the aircraft during
power delivery, or if an attempt is made to deliver power when the output cable is not con-
nected to the aircraft. Twenty-eight-volt, direct current for operation of the relay is supplied
from the aircraft either through an on-board transformer-rectifier, or from a twenty-eight-volt,
electrical system. Connection from the aircraft to the interlock relay is made through termi-
nals E and F on the output cable plug connector.
(e) Test-bank switch
A spst, toggle switch (19) provides a means of bypassing the plug interlock relay (2) when
supplying power to a load bank or to an aircraft not equipped with a plug interlock system.
(f) Resistor
A 100-ohm, 25-watt resistor (18) is connected in series with the plug interlock relay to protect
the relay in the event that phase C contacts in the load contactor should fail to close when the
generator ON switch is operated.

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(g) Fuse-interlock relay

The function of the fuse-interlock relay (8) is to interrupt the load contactor holding coil circuit
and remove the load in case of a “blown” fuse (8, Fig. 6) in the protective relay coil circuit.
(h) Auxiliary underfrequency relay
The function of the auxiliary underfrequency relay (9) is to automatically open the excitation-
deenergization relay and disconnect the voltage regulator any time generator frequency
drops to 380 Hz or below. This protects the voltage regulator PC board (13, Fig. 7) against
overload which could be caused by high voltage regulator output in its attempt to maintain
voltage when the generator is operating at a speed which cannot produce normal voltage out-
put.
NOTE: If the auxiliary underfrequency relay is tripped, it will be necessary to momentarily
place engine operating mode switch (5, Fig. 8) in BUILD-UP-VOLTAGE position to restore
generator voltage.
(j ) Terminal boards
Two terminal boards (14) provide connection facilities for small leads.
(k) Solid-state voltage regulator
This voltage regulator consists of two assemblies, a line-drop compensation assembly (17)
and a voltage regulator PC board (13). A full and working description of this voltage regulator
is provided in Solid State Regulator Manual OM-2020, which is a part of Chapter 6 of this
manual.
(l) Overload module (5)
See Para. 6, H, (3) for functional description of the overload module.
(m) Rectifier (10)
See Para. 6, H, (4) for functional description of the load contactor rectifier.

F. Engine Control Panel (See Fig. 8)

The engine control panel is mounted directly below the control box. Along with engine controls and in-
struments, generator output controls are mounted here. A plexiglas 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). An hourmeter (6) records engine operating time.
(a) Ammeter
The ammeter (4) indicates the direction and value of current flow in the 12-V DC electrical
system. Its graduated range is from -60 A through 0 A, to +60 A.
(b) Temperature gage
The temperature gage (8) is a mechanical type of unit construction. It consists of a panel
mounted indicating mechanism which is connected by a capillary tube to a bulb mounted in
the engine cooling system. The gage indicates engine coolant temperature in the range of
100F to 220F.

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1. Excitation-deenergization relay 12. Bottom interior panel

2. Plug-interlock relay 13. Voltage regulator PC board
3. Rear interior panel 14. Terminal strips
4. Over-undervoltage module 15. Blocking diode assembly
5. Overload module 16. Ballast resistor,
6. Over-underfrequency module 20 ohm, 100 watt
7. Memory and time delay module 17. Line drop compensator
8. Fuse-interlock relay assembly
9. Auxiliary underfrequency relay 18. Resistor, 100 ohm, 25 watt
10. Contactor rectifier 19. Line drop burden resistors,
11. Overload burden resistors, 50 ohm, 25 watt
16.6 ohm, 25 watt

Control Box Internal Components

Figure 7

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(c) Oil pressure gage and oil pressure switch

The oil pressure gage (10) is a bourdon tube type and indicates engine lubricating oil pres-
sure. It is graduated from 0 PSI to 75 PSI. An oil pressure switch is mounted in a tee fitting di-
rectly behind the gage. This switch connects 12-V DC power to the engine control system
and to the generator 12-V DC control system when the engine is running.
(d) Hourmeter
The hourmeter (6) is electrically driven from the 12-V DC battery system. The hourmeter
measures and records engine running time and will record up to 9999.9 hours on five revolv-
ing drums. The hourmeter operates only when the engine is running and the oil pressure
switch is closed.
(e) Fuel gage and blocking diodes
An electric fuel gage (2, Fig. 8) accurately indicates the quantity of fuel oil in the tank provided
for the generator set. A sending unit mounted in the trailer or truck mounted unit fuel tank sup-
plies the signal to the gage. Twelve-volt DC operating power is supplied to the fuel gage from
two sources. The gage functions when the engine is running, or when the instrument lights
are ON. Since two power sources are connected to the fuel gage system, a blocking diode is
required in each power source circuit. One diode prevents energizing the motor-generator
control circuit when panel lights are ON. Another diode prevents operation of the panel lights
by the engine-generator circuit when the engine is running. (See Connection Diagram in
Chapter 6 for location of these diodes). To check fuel quantity when engine is stopped, use
switch to turn on panel lights.

(2) Engine and generator controls

(a) Engine-generator control switch

The engine-generator control switch (5) (also identified as the “build-up-voltage, generate,
idle” switch) is a three-position toggle type. It is spring-loaded in one position, BUILD-UP-
VOLTAGE, and will automatically reposition to GENERATE position when released. In
BUILD-UP-VOLTS position it performs a dual function. First, it supplies power to the gover-
nor control box, which allows the engine to operate at normal governed speed; second, it mo-
mentarily supplies current for closing the excitation-deenergization relay (1, Fig. 7) contacts,
to make three-phase, 115-V AC power available to the voltage regulator, or to the regulated-
diagnostic circuit, for excitation of the generator exciter. In GENERATE position, power is
maintained to the governor control box and to the excitation relay (1, 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. 8) identical to the engine-generator con-
trol switch. When placed in the spring loaded CLOSE position, it provides 115-V AC power di-
rectly to a rectifier which supplies DC power for closing the load contactor. When released it
returns to the normal ON position and continues to provide power to the rectifier, but in this
switch position, AC power must pass through the plug interlock and fuse interlock relays. In
OFF position the switch opens the AC circuit to the rectifier, thereby cutting off the source of
DC power to the contactor coil which allows the contactor to open.
(c) Instrument light and switch
A shielded, instrument panel light (1) is mounted at the left side of the control panel. It is con-
trolled by a toggle switch (3), which also controls instrument lights on the control box.

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(d) Engine starting circuit

The pushbutton start switch (13) and permissive toggle switch (15) serve to connect power to
the starter solenoid which functions to engage the starter gear with the flywheel ring gear and
apply power to the starter motor to crank the engine. The permissive toggle switch (15) also
stops the engine when the toggle is placed in the STOP (down) position.
(e) Indicating lights
A green indicating light (12) glows to indicate that power is available to the engine protective
system. The light operates only when the engine permissive start switch (15) is in the START
or RUN position. Another green indicating light (9, Fig. 8) glows when the generator output
load contactor is CLOSED and power is available at the generator output cables.
(f) Fuse
A 10-ampere fuse (11) protects the 12-V DC engine control circuit, hourmeter, illuminating
light circuit, and 12-V DC system in the main generator protective system.

G. Load Contactor Circuit Components

Load contactor circuit components are located either attached beneath the control box support panel,
on the trailer assembly, or inside the generator control box. The load contactor and its associated cir-
cuit components provide a means of connecting and disconnecting generator output to and from the
load (aircraft).

(1) Load contactor

The load contactor (3, Fig. 9) is a sealed unit which contains a magnetic operating coil and four
sets of contacts. The three larger contacts conduct three-phase AC generator output. A smaller
contact set is connected in the protective monitor circuit and supplies 12-V DC power used by
sensing relays to signal the protective monitor when a fault occurs. Three-phase, 400-Hz gener-
ator output power is conducted to the load contactor by 2/0 cables which pass through 3 sets of
current transformers.

(2) Current transformers

These current transformers are located beneath the control box support panel directly below the
control box.
(a) Ammeter current transformers (2, Fig. 10)
Three current transformers lower the output load current to a lesser value of definite ratio
(250-A to 5-A) which will operate the ammeter (4, Fig. 6) movement without damage. The am-
meter dial scale is graduated and numbered so that the ammeter pointer will indicate the true
load current value rather than the meter movement current.
(b) Line-drop current transformers (3, Fig. 10)
The three line-drop current transformers in conjunction with burden resistors, detect the mag-
nitude and power factor of current flowing from generator to load. They feed a signal to the
voltage regulator which interprets the signal and alters the exciter field current as required to
maintain a constant predetermined voltage at the load.
(c) Overload current transformers (4, Fig. 10)
Three overload current transformers, in conjunction with burden resistors monitor the output
load current in each of the three output phases, and supply a reduced value current signal to
the overload module (5, Fig 7)

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1. Panel light 9.Load contactor indicating light

2. Fuel gage 10. Engine oil pressure gage
3. Light switch 11. Engine circuit fuse (10-A)
4. DC Ammeter 12. Engine “ON” indicating light
5. Engine-generator control switch 13. Engine starter switch
6. Hourmeter 14. Terminal strip (behind panel)
7. Load contactor control switch 15. Permissive start switch
8. Coolant temperature gage

Engine Control Panel

Figure 8

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(3) Overload module

The overload module is located inside the generator control box. This overload module (5, Fig 7)
is a solid-state device designed to interpret a signal from the current transformers and to send a
signal to the protective monitor module (7, Fig. 7) when an overload condition exists in any gener-
ator output phase. A pull-apart electrical connector is mounted on the owerload module to provide
quick-disconnect facilities for all wiring to the module. The overload module is equipped with a
hermetically sealed, reed-type relay. Relay contacts are normally open. The solid-state circuitry is
designed to close relay contacts when output current in ANY phase reaches 125% of normal
rated output capacity. The closed relay sends a signal to the protective monitor. This signal
“gates” the overload SCR (silicone-controlled rectifier) in the protective monitor and interrupts the
load contactor holding circuit, allowing the load contactor to open.
The following is a list of overload module characteristics:
NOTE: The overload protective system will function when any phase carries 123% to 127% of
rated load.
At 125% load the module will function in 4 minutes.
At 150% load the module will function in 16 seconds.
At 200% load the module will function in 4 seconds.
NOTE: All times are plus or minus 25% and are nonadjustable.

(4) Rectifier

A diode bridge rectifier is located inside the generator control box. (See Fig. 7, item 10). This di-
ode-bridge rectifier receives 400-Hz AC from phase C of the generator output an converts it to a
pulsating, direct current for energization of the load contactor coil only. This DC coil-holding circuit
is controlled indirectly be controlling the 400-Hz AC to the rectifier. The ground circuit for the recti-
fier’s AC supply must pass through the relay contacts in the protective monitor module to ground
cable N. Therefore, any time a protective device functions to open the protective monitor relay,
the rectifier’s AC circuit is opened. No DC is then available for the load contactor coil, hence, the
load contactor opens.

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1. Contactor panel 3. Load contactor

2. Neutral terminal 4. E-F terminal

Load Contactor Panel

Figure 9

1. Bottom of control box

2. Ammeter current transformers
3. Line drop current transformers
4. Overload current transformers

Current Transformers
Figure 10

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SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING

1. Preparation for Use

A. Inspection/Check Inspect the unit thoroughly prior to operation.
(1) Remove blocking, banding, ties, and other securing material.
(2) Inspect exterior for shipping damage such broken lights, damaged sheet metal, etc.
(3) Open all canopy doors and inspect interior for foreign material such as rags, tools, shipping pa-
pers, etc.
(4) Check fuel, coolant, and oil hoses and connections for visible leaks. Visually inspect the compart-
ment floor and ground surface under the unit for signs of leakage. If leaks are found, correct by tight-
ening hose clamps, tube fittings, etc., as required.
(5) Check the following for sufficient quantity:
(a) Fuel
Place engine permissive start switch (1-1; 15, Fig. 8) in the RUN position to energize fuel
gage when engine is stopped.
(b) Engine coolant
The radiator cap is accessible by opening the hinged access cover on the front canopy hous-
ing. Coolant level should be approximately one inch below the filler neck. Allow a capacity for
coolant expansion.

CAUTION: Be sure the cooling system antifreeze solution is adequate to protect below lowest
temperature expected.

NOTE: For antifreeze protection, use a solution of 50% permanent antifreeze (Ethylene glycol)
and 50% clean water.
(c) Engine lubricating oil
Oil level should be at “FULL” mark on oil level gage rod. See the John Deere Shop Manual
for oil recommendations.
(6) Check air cleaner
The air cleaner (Sect. 1-1, Fig. 3, item 8) is a “dry” type. Be sure there are no papers, tapes, or
other material covering the air inlet area.

B. Installing Three-phase AC Output Cables

Units are generally shipped without generator set-to-aircraft cables. The load contactor, at which ca-
bles must be connected is located on the left side of the unit beside the engine control panel (see 1-1;
2, Fig. 3). To install AC output cables proceed as follows.
(1) Open and raise left rear canopy door of the generator set.
(2) Loosen screws on cable clamp located on the cable tray on the left side of the generator set.
(3) Remove lexan cover over the load contactor.
(4) Route cables through cable clamp, and up to the load side (bottom) of the load contactor.

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NOTE: Conductor size recommended for AC output is 2/0 size. Use No. 12 size for control (E and
F terminals).
Large cables (A, B, C, N) should be equipped with terminals having at least a 3/8-inch diameter
mounting hole. Mounting hole in small leads (E and F) should be at least 1/4-inch diameter.
(5) Remove the terminal cover on the load side of the contactor and connect the phase cable terminal
lugs to the appropriate terminal studs on the contactor: cable lug “A” to terminal stud “A”, “B” to “B”,
and “C” to “C”.
(6) Connect the cable’s neutral terminal lug securely to the neutral (ground) stud on the side of the
load contactor mounting bracket.
(7) Tighten terminal nuts securely and replace the terminal cover on the load contactor. Connect small
plug interlock leads “E” and “F” to terminal “E-F” on the side of the load contactor mounting bracket.
(8) Tighten clamp screws securely on the left side of the unit, but avoid damage to cable insulation.
(9) Replace lexan cover over load contactor.

2. Preparation for Storage

When a generator set is to be stored or removed from operation, special precautions should be taken to
protect the internal and external parts from rust, corrosion, and gumming in the engine fuel system.

A. General
(1) The unit should be prepared for storage as soon as possible after being removed from service.
(2) The unit should be stored in a building which is dry and which may be heated during winter
months.
(3) Moisture absorbing chemicals are available for use where excessive dampness is a problem, how-
ever the unit must be completely packaged and sealed if moisture absorbing chemicals are to be ef-
fective.

B. Temporary Storage When storing the unit for 30 days or less, prepare as follows:
(1) Lubricate the unit completely in accordance with instructions in Sect. 2-1. This will include chang-
ing engine oil, and all filter elements.
(2) Start the engine and operate for about two minutes so that all internal engine components will be
coated with new oil.
NOTE: Do not drain the fuel system or crankcase after this run.
(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. Use a waterproof, vaporproof material which is strong enough to resist
puncture damage from air pressures.

C. Long Time Storage (Over 30 Days)

(1) The unit may be stored for long periods with no special preparation if it is possible to operate the
engine once each week.

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(a) Make certain the cooling system is adequately protected

WARNING: Make certain of adequate ventilation before starting the engine.

(b) Start the engine and operate at a fast idle (800 to 1000 RPM) until coolant temperature has
reached at least 140 deg F.
(c) Operate normal operating controls.
(2) If weekly operation is not possible, prepare and protect the engine in accordance with instructions
in the Perkins Diesel Operator’s Manual.
(3) To protect the generator and other electrical components, the complete unit should be packaged,
using moisture proof packaging and sealing material. Place containers of moisture absorbing chemi-
cals, such as silica-gel, in the unit before packaging.

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SECTION 3. OPERATION

1. General
This section contains information and instructions for the safe and efficient operation of the equipment.
Operating instructions are presented in step-by-step sequence of procedures to be followed in supplying
400-Hz power to an aircraft.

WARNING: Improper operation can kill! Ear protection equipment may be

necessary when working in close proximity to this equipment. Read and follow
all of the operating instructions before attempting to operate the equipment.

2. Operating the Generator Set

A. Pre-start Inspection
(1) Open the fuel shut-off valve.
(2) Provide 12-V DC power to the engine starting system.
(3) Check the engine and generator compartments and remove rags or other foreign materials.

B. Normal Engine Starting Procedures

Engine starting procedures are outlined below. Engine operating controls and monitoring instruments
are illustrated in Fig. 1.
(1) If illumination is required, place light switch (13) in ON position.
NOTE: This switch must be ON to check fuel when engine is stopped.
(2) Hold engine start switch (24, Fig. 1) in START position momentarily. Push engine start pushbutton
(23) to crank engine. When engine starts, release pushbutton. Continue to hold engine start switch
(24) in position until oil pressure gage (20) reads at least 20 PSI pressure. Release switch (24).
(3) Check ammeter (3) for charge reading.
(4) Check fuel gage (12) and oil gage (20).
(5) Place engine generator control switch (15) in IDLE position.
(6) Activate generator output contactor switch (17).

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1. Frequency meter 14. DC Ammeter

2. Voltmeter 15. Engine-generator control switch
3. AC Ammeter 16. Hourmeter
4. Meter switch 17. Load contactor control switch
5. Line switch 18. Coolant temperature gage
6. Reset switch 19. Load contactor indicating light
7. Light test switch 20. Oil pressure gage
8. Fault indicating lights 21. Engine circuit fuse (10-A)
9. Load contactor circuit fuse 22. Engine protective circuit
(2-A) indicating light
10. Protective system fuse (2-A) 23. Engine starter switch
11. Instrument panel light 24. Permissive start switch
12. Fuel gage 25. Regulated/diagnostic switch
13. Light switch 26. Aircraft/test-bank switch
Operating Controls and Instruments
Figure 1 (Sheet 1 of 2)

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27. Automatic voltage control potentiometer (R5) 30. Cable length compensation rheostat
28. Cable size compensation rheostat 31. Voltage regulator fuse (5A)
29. Line-drop compensation on/off switch

Operating Controls and Instruments

Figure 1 (Sheet 2 0f 2)

C.Preparation for Power Delivery

The following are power delivery preparation procedures to be followed after the engine is started.
(1) Check and position switches and controls.
(a) Loosen the two fasteners at the top of engine-generator control panel, and lower the panel to
gain access to the interior component panel.
(b) Place regulated-diagnostic switch (25) in REGULATED position.
(c) Place test bank switch (26) in AIRCRAFT position if the aircraft being serviced is equipped
with 28.5-V DC interlock relay system. (If not, place in TEST BANK position.)
(d) Meter switch (4) may be in any position except pointing straight DOWN.
(e) Raise engine-generator control panel and fasten it as it was previously.
(2) Connect output cable plug connector to aircraft receptacle. Be sure connectors are mated fully
and securely.

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D. Power Delivery
(1) Place engine-generator control switch (15) in BUILD-UP-VOLTAGE position momentarily, then al-
low it to position itself in GEN position. The electric governor will immediately increase engine speed
to 2000 RPM and maintain it.
(2) Observe generator instruments. Frequency meter (1) should indicate exactly 400 Hz. Voltmeter
(2) should indicate 115 V AC when line switch (5) is in ANY line-to-neutral position, A-N, B-N, or C-N,
and should read 200-V AC when it is in any line-to-line position, A-B, B-C, or C-A.
(3) The final step in delivering power is closing the load contactor. When satisfactory frequency and
voltage values are indicated by the instruments, close the load contactor by momentarily placing the
load contactor control switch (17) in the top (spring loaded), CLOSE position. The green indicating
light (19) should glow at once to indicate that the load contactor is closed and power is available at
the aircraft. As soon as the light glows, release the switch. It will automatically return to the center ON
position.
NOTE: If the indicating light (19) should “go-out” as soon as the switch is released, and no fault
lights are ON, it indicates that 28.5-V DC holding current is not being supplied from the aircraft
to the plug-interlock relay.
Correct the condition an again operate the load contactor control switch (17) as above.
(4) It is recommended that the operator check output voltage and current in each of the three phases
early in the power delivery run. Use the meter switch (4) to select the phase and line-to-line or line-to-
neutral voltage. If the load is changing, it is good operating practice to observe the instruments until
load conditions stabilize.
(5) A condition of overvoltage, undervoltage, underfrequency, overfrequency, or overload in the out-
put circuit will automatically open the load contactor and turn on the applicable indicating light to sig-
nal the operator which of the above faults caused the protective monitor system to operate. After the
fault has been corrected, press the reset switch (6) to turn off the indicating light and reset the protec-
tive relay system. Proceed with power delivery by operating the load contactor switch.

E. Discontinue Power Delivery

(1) Place the load contactor switch (17) in OFF position. Green light (19) should go OFF immediately
to indicate that the load contactor has opened and power is no longer being delivered to the aircraft.
(2) Place engine-generator control switch (15) in IDLE position.
(3) Disconnect output cable from aircraft.

WARNING: HIGH VOLTAGE - Electric shock or fire can kill! Never disconnect
the output cable while power is being delivered.

F. Stopping the Engine

(1) Allow the engine to idle a few minutes before stopping, to permit cooling.
(2) To stop the engine, move the START-RUN-STOP switch (24) to the STOP (down) position.

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3. Trailer Operation
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.

B. Parking Observe the following rules when parking the trailer.

(1) Apply parking brake before disconnecting tow vehicle.
(2) Always place drawbar in an upright, vertical position when trailer is parked.
Refer also to TO-186 in Chapter 5 of this manual for additional information on the trailer.

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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.

WARNING: Electric shock, flying parts, or fire can kill or injure! Stop operation
immediately if a serious or possibly dangerous fault is discovered.

2. Inspection
A periodic inspection should be established and maintained. A suggested inspection/check schedule is
provided in 2-2, Figure 1, however it may be modified as required to meet varying operating and environ-
mental conditions. If the generator set is mounted on a tow tractor, it is suggested that inspections be co-
ordinated.

3. Lubrication
A. General
Proper lubrication is one of the most important steps in good maintenance procedures. Proper lubri-
cation means the use of correct lubricants and adherence to a proper time schedule. Frequency of lu-
brication and recommended lubricants are indicated in Figure 1.

B. Generator
The 400-Hz generator REQUIRES NO LUBRICATION. The rotor is supported by two ball bearing as-
semblies which are lubricated and sealed at the factory for lifetime, maintenance-free operation. It is
suggested that generator bearings be checked after 5000 hours of operation.

C. Generator Controls
Generator controls and instruments require no scheduled periodic lubrication. A few drops of oil may
be required on door hinges occasionally to insure free an quiet operation.

D. Engine
Although the engine and its accessories require no more attention than any other similar installation,
they still inherently require a major portion of the generator set lubrication and maintenance. Recom-
mendations regarding engine lubrication have been taken from the engine manufacturer’s “Operator’s
Manual” and incorporated here to make them more readily available to operators and maintenance
personnel.

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(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. However, time intervals should not exceed those indicated in the
chart without careful evaluation.

(2) Oil specification

Oil recommended by the engine manufacturer is identified by a military specification number, MIL-
L-2104B. Because of the substantial increase in additive concentration in some MIL-L-2104B oils
to meet service “MS” requirements, recommended oil is qualified still further by the following limita-
tions.
(a) Zinc, as zinc diorganodithiophosphate, between a minimum of 0.07 and a maximum of 0.10
percent by weight.
(b) Sulfated ash (ASTM D-874) of 1.00 percent maximum by weight, except lubricants that con-
tain only barium detergent-dispersants where 1.50 percent by weight is allowed.
Diesel lubricating oil specifications are discussed in the Perkins Diesel Operator’s Manual in
Chapter 6.

(3) Oil viscosity

The use of an SAE-30 grade oil is recommended for year-round service. The engine is equipped
with an ether starting aid to assist in engine starting during cold weather when SAE-30 oil is used.
Multigrade oils are NOT recommended, and should be considered only as a “last resort” to facili-
tate engine starting.

(4) Changing engine oil

Change engine lubricating oil following the instructions in the Perkins Diesel Operator’s Manual in
Chapter 6. Lube oil capacity for this engine is 15-1/2 quarts.

(5) Changing engine oil filter

Change oil filter following the instructions in the Perkins Diesel Operator’s Manual in Chapter 6.

E. Starter
The starting motor is lubricated at assembly and should be relubricated only when the starter is re-
moved from the engine or when disassembled. Remove pipe plugs on outside of motor and apply a
few drops of light engine oil to the oil wicks.

F. Trailer

(1) Front axle assembly

The front axle assembly, drawbar, and steering linkage are equipped with high-pressure lubrica-
tion fittings. Lubricate the trailer every 400 hours. Use a good quality chassis lubricant such as
Sinclair Litholene Industrial No. 2, Mobil Mobilplex 47, or equivalent. Clean lube fittings before ap-
plying grease.

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(2) Wheel bearings

Lubricate and check wheel bearing adjustment every 800 hours or semi-annually. Use a good
quality automotive bearing lubricant grease (Specification MIL-G-10924B or equivalent). Refer
also to TO-186 in Chapter 5 of this manual for additional information on trailer lubrication.

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-2104D). Engine lube oil capacity: 18 quarts.

Lube Oil Filter Change oil filter every 200 hours or 1 month of use.

Fuel Oil Filter Drain filter daily. Change filter element every 600 hours or 4 months of use.

Starter Lubricate as needed, using heavy duty engine oil such as SAE-30
(MIL-L-2104B). Lubricate only when starter is removed from engine.

Coolant Check coolant level daily. Service and maintain coolant system according
to para.6. Engine coolant capacity: 20 quarts.

Air Cleaner Check air cleaner periodically and clean or change it as necessary. (Refer
to Para. 4 for servicing instructions).

AC Generator AC generator bearings are sealed and require no periodic lubrication.

Lubricationand Maintenance Chart

Figure 1

4. Air Cleaner Service

Refer to Section 1-1; Fig. 4. This air cleaner is a dry type which may be cleaned as many as six times be-
fore replacing it with a new air cleaner. A definite time schedule for cleaning or changing the air cleaner
cannot be determined because of varying operating conditions. However, since this air cleaner can be re-
moved and replaced without difficulty on this generator set (simply by loosening one metal clamp on each
end of the air cleaner), it may be inspected either at prescribed service intervals or at any time deemed
necessary.

A. Inspecting the Air Cleaner

(1) Make periodic checks of air cleaner inlet screen for obstructions. If any obstructions are present,
remove them.
(2) Check outlet connection for proper seal.
NOTE: DO NOT judge the element’s life just by looking at it, IT SHOULD LOOK DIRTY, or it’s not
doing its job.

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B. 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.

(1) 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.

CAUTIONS: (1) Do not use compressed air higher in pressure than 100 psi, and (2) Do not use
compressed air cleaning when the filter media is wet.

(2) Low pressure water flush

(a) Flow low pressure water, warm or cold, into the air cleaner outlet neck, causing dirt to flow off
the filter media. Always be sure not to let any contaminated water back into the outlet neck.
(b) A mild detergent may also be used. However, the filter must then be flushed thoroughly with
clean water. This cleaning method is recommended by the manufacturer.
(c) Always allow filter media to dry before use.

C. Disposal
Normal trash pick-up is acceptable. NEVER burn the air filter for disposal.

5. Engine Fuel
A. Quality
The quality of fuel oil used in the diesel engine is a major factor in long engine life and performance.
Fuel oil must be clean, completely distilled, stable, and non-corrosive. Only distillate fuel No. 1D is rec-
ommended for use both summer and winter.

CAUTION: Consult the “fuel oil selecting chart” in the engine operator’s manual before
substituting another grade of fuel.

B. Fuel Filter
Refer to Perkins Diesel Shop Manual in Chapter 6 for instructions on removal and replacement of fuel
filter elements.

6. Engine Cooling System

A. General
Cooling system device requires much more than maintaining the proper coolant level in the radiator.
During warm seasons and in warm climates, plain water can be used as a coolant if the system is pro-
tected against rust by a rust inhibitor additive. During cold seasons and in cold climates, the system
must, of course, be protected against freezing. At no time should the system be operated for any
length of time on plain water, without a rust inhibitor or antifreeze. Draining, cleaning, and filling the
cooling system are covered in Para. 7, E through H.

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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.

WARNING: Hot steam and fluids will severely burn! when removing cap from a
very hot radiator, do not turn cap past safety stop until all pressure or steam
has escaped. use protective clothing. Allow engine to cool before adding
coolant.

(3) Installation

When installing the cap be sure it is turned clockwise as far as it will go so that the pressure re-
taining valve will be functional.

C. Warm Weather Operation

During warm weather operation, if water is used in the cooling system instead of an antifreeze solu-
tion, keep the cooling system free of rust and sludge by adding a cooling system conditioner that is
compatible with aluminum. Instructions for use of the conditioner are printed on each can.

CAUTION: Use only a corrosion inhibitor that is compatible with aluminum. do not use
inhibitors labeled as “acid neutralizer”.

D. Cold Weather Operation

CAUTIONS: (a) Do not use “methanol” or alcohol as an antifreeze, and (b) Do not use two
different types of antifreeze. Mixed solutions (two types) make it impossible to determine if the
cooling system has adequate protection against freezing.

(1) General

A permanent type, (Ethylene Glycol) antifreeze is recommended for use in the cooling system.

(2) Checking coolant solution

Check solution frequently to be sure the cooling system has sufficient protection against freezing.
NOTE: (a) When testing the solution, be sure the coolant is at operating temperature. (b) Follow
manufacturer’s instructions on tester.

(3) Preparing the coolant solution

The following table (Figure 2) 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.

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FREEZING POINT PERCENTAGE OF ANTI-

(FAHRENHEIT) FREEZE IN SOLUTION
20 16%
+10 25%
0 33-1/3%
-10 40% Antifreeze Solution Table
-20 45% Figure 2
-30 50%
-40 54%
-50 58%
-60 62%
-70 65%

(4) Installing the antifreeze solution

Before installing antifreeze in the system, make the following checks:

(a) Check the system for signs of leaks
(b) Inspect all hoses and tighten all hose clamps. Install new hoses if necessary.
(c) Drain and clean the system. Ref. Paras. 7,E and 7,F.
(d) Check the condition and tension of the engine V-belt. Replace the V-belt if necessary.
(e) Be sure radiator and engine drain valves are closed, and all connections are securely tight-
ened.
(f) Install the required amount of antifreeze: 20 quarts. Fill the system with coolant as outlined un-
der Para. 7, H.

E. Draining the Cooling System

Drain the cooling system immediately after stopping the engine, while most of the sediment is in sus-
pension. Proceed as follows:
(1) Remove radiator cap.
(2) Open radiator drain valve (at bottom of radiator) and engine drain valves. See Perkins Diesel
Shop Manual for exact locations of engine coolant drain valves.
NOTE: When draining the system for storage, remove all drain valves and remove drain plug.
(3) Allow the system to drain completely.
NOTE: Be sure the drain valves do not plug-up during draining.
(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 coolng 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. When this condition exists, pro-
ceed as follows:
(1) Run the engine until it reaches normal operating temperature; then stop the engine and drain the
cooling system (Ref. Para. 7, E).

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(2) Fill the cooling system with clean coolant (Ref. Para. 7, H).
(3) Add a flushing compound, that is compatible with aluminum, to the cooling system in accordance
with the instructions furnished with the compound.
(4) Start the engine and flush the system as directed by the instructions furnished with the compound.
(5) After the system has been flushed and thoroughly cleaned of the compound, refill the clean cool-
ant (Ref. Para. 7, H).

G. Cleaning the Radiator Core

Blow out insects and dirt from the radiator core air passages, using air or water under pressure. En-
gine overheating is often caused by bent or clogged radiator fins. When straightening bent fins, be
careful not to injure the tubes or to break the bond between the fins and tubes.

H. Filling the Cooling System

Add a cooling system corrosion inhibitor (for warm weather operation) or permanent antifreeze (when
the air temperatures expected are at freezing, (+32 deg F or lower). Antifreeze may be premixed if de-
sired. See Fig. 1 for cooling system capacity.
(1) Engine must be STOPPED. Close all drain valves except top water outlet valve. Leave this valve
OPEN to allow air to escape.
(2) Pour coolant into radiator slowly until system is filled to level of top drain valve. Close valve and
continue to fill system until coolant reaches a level approximately 1 inch below the radiator filler neck.
NOTE: If antifreeze solution is not premixed, pour required antifreeze in first. Install corrosion
inhibitor according to directions on container.
(3) Start the engine and allow it to idle. Add coolant if trapped air escapes from the system and the
coolant level falls.
(4) Continue to check coolant level until the engine reaches operating temperature. Add coolant, if
needed, to fill to the required level, 1 inch below filler neck. Install radiator cap.
NOTE: It is good practice to attach a card, indicating the cooling system contents, and the date
serviced to the radiator filler neck.

7. Generator Maintenance
The 400-Hz generator requires no maintenance or service other than periodic cleaning. The unit is
brushless, and bearings are permanently lubricated and sealed.

A. 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 result in damage to insulation and other generator components.

WARNING: Electric shock and fire can kill or injure! Be sure the unit is completly
dry before operating. Do not use a flammable solvent.

B. Adjustment
The generator itself requires no adjustment. Adjustment procedures for generator controls will be cov-
ered in Section 2-3.

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8. Drive Belts
A single belt from the crankshaft pulley is used to drive the alternator and water pump. For proper engine
operation this belt should be in good condition and at proper tension at all times.

A. Checking Belt Tension

Check belt tension every 200 hours of engine operation, or bi-weekly. A belt which is too tight is de-
structive to bearings of the alternator and water pump. A loose belt will slip and cause inefficient op-
eration of the alternator and/or the water pump.
To check belt tension, press the belt firmly with the thumb at a point halfway between the alternator
pulley and the crankshaft pulley. A properly adjusted belt should deflect about 3/8 inch.

B. Belt Adjustment
To adjust belt tension, loosen the alternator mounting bolts and change the position of the alternator.
Upon obtaining the correct tension, re-tighten both alternator mounting bolts.
When new belt is fitted, it is necessary to run the engine for a short period to allow the new belt to set-
tle into the grooves of the pulleys and thus show any initial stretching that is going to occur. Recheck
belt tension after running the engine and adjust as necessary.

9. Battery Maintenance
A. General
Two 12-volt batteries supply power for operation of the engine electrical system, clearance and panel
lights, and for flashing the generator exciter field.

B. Battery Location and Accessibility

For location of batteries refer to Section 1-1; Figure 3, Item 2. These batteries are easily accessible by
raising the right rear canopy door of the generator set.

C. Battery Care
(1) Never allow a battery which has been removed from the unit to sit on concrete, ground, or metal
unless proper insulation is provided. A wooden platform or board will provide sufficient insulation.
(2) Maintain stored batteries in a charged condition.
(3) Be sure batteries are fastened securely in their compartment to avoid damage from vibration.
(4) Maintain battery fluid at proper level.
(5) Keep battery terminal posts and lead connectors clean.

WARNING: Never allow sparks or open flame near batteries. Avoid spilling
electrolyte on hands or clothing.

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D. Liquid Level

CAUTION: Never add any special battery dopes, solutions or powders.

The electrolyte in each cell should be above the plates at all times to prevent battery failure. Check
the level of the electrolyte every two weeks. When electrolyte level is low, add pure distilled water. Do
not use hydrant water or any water which has been in contact with a metal container. Acid should
never be added except by a skilled batteryman.
NOTE: It is especially important to keep the battery at full charge for cold weather operation. Add
distilled water to the battery in freezing temperatures only when the engine is to operate forseveral
hours, to thoroughly mix the water and the electrolyte, or damage to the battery will result from
the water freezing.

E. Cleaning the Battery

If the top of the battery is dirty, it may be cleaned with a brush dipped in ammonia or soda solution.
Disconnect lead connectors from battery posts. Vent plugs should be tightened to prevent cleaning so-
lution from entering cells. Clean battery as required, using brush and cleaning solution. Flush off the
battery with clean water. Brighten terminal and post surfaces with steel wool, a wire brush, or special
terminal cleaning tool. Make certain that vent holes in filler caps are not clogged.

F. Testing the Battery

Tests are made on a battery to determine the state of charge and also the condition. The results of
these tests show that the battery is good, needs recharging, or must be replaced. If a battery has
failed, is low in charge, or requires water frequently, the reason for the condition must be found and
corrected. Visually inspect the battery before testing, to determine if it has been damaged. Moisture
on the outside of the case, or low fluid level in one or more cells indicates possible battery damage
(cracked case, etc.). The battery may be tested by two methods. A Battery-Starter Tester may be
used to determine the battery’s ability to deliver current. A battery hydrometer test determines the
charge condition of the battery.

(1) Test with Battery-Starter Tester

Connect battery to the tester according to instructions furnished with the instrument. Test battery
according to tester instructions. If the test determines that battery has acceptable voltage, this indi-
cates that battery has output capacity and will accept a charge, if required.

(2) Test with Hydrometer

(a) Remove filler caps and check the specific gravity of electrolyte in each cell. If specific gravity is
1.230 or below, add water if necessary and charge the battery until it is fully charged. A fully
charged battery will give a specific gravity reading of from 1.265 to 1.285. The specific gravity of a
fully discharged battery may range from 1.140 down to 1.120.
NOTE: The battery is fully charged when all cells are gassing freely, and specific gravity ceases
to rise for three successive readings taken at hourly intervals.
(b) If the Battery-Starter Test indicated that battery voltage was below the acceptable voltage
value, test each cell with the hydrometer. If specific gravity readings between any two cells is 50
points (0.050) or more, the battery isn’t satisfactory for service and should be replaced.

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10. Service Helps

A. Wiring
All small wire leads are routed through plastic flexible conduit which protects them and makes a neat
easily removable and replaceable wiring harness arrangement. This wiring method allows the replace-
ment of a single wire lead with a minimum of difficulty. All wires are color coded.

B. Generator Exciter
Provisions have been made to allow removal of the generator exciter without disturbing or removing
the complete generator.

(1) Preparation for exciter removal.

(a) Remove the rear bumper from the generator set. Do this by removing the four 3/8" bolts on
the back of the bumper and the two 1/4" bolts underneath at either end.
(b) Remove the back canopy panel from the generator set. Do this by removing:
• The four 1/4" bolts on top of the panel.
• The three 1/4" bolts at the bottom on the back of the panel.
• The two 1/4" bolts underneath.
• The three 1/4" bolts on each side holding the side panels.
• The one 1/4" bolt on each side holding the cable rails.
• The one 1/4" bolt on each side (underneath) holding fenders.
(c) Remove main frame rear cross member by removing four attaching bolts (see Fig. 3).
(d) Remove generator back plate. Do this by removing the six 1/4" bolts around the circumfer-
ence of the back plate,

(2) Exciter removal

Refer to TM-360 in Chapter 6 for exciter instructions.

(3) Exciter installation

(a) Install exciter in accordance with TM-360.

(b) Re-install generator back plate.
(c) Re-install rear frame member and tighten screws securely.
(d) Re-install the back canopy panel.
(e) Re-install the rear bumper on the generator set.
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.

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Removable Rear Frame Cross Member

Figure 3

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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 Perkins Diesel
Shop Manual.
(3) Open fuel tank drain every 500 hours to drain off water and sediment.

B. Lubrication
(1) Check crankcase oil level DAILY.
(2) Lubricate in accordance with Lubrication Chart (Ref. 2-1; Fig. 3).

C. Coolant
(1) Check coolant level DAILY.
(2) Inspect for signs of rust and corrosion. Change coolant if rust and sediment are present. See 2-1;
Para. 7, E, F, and H.
(3) Inspect hoses for cracks and deterioration. Inspect clamps for tightness.

D. V-Belt
(1) Inspect V-belt for proper tension and adjust if necessary after each 200 hours of operation. (See 2-
1; Para. 7, A, B, and C.)

E. Exhaust System

WARNING: Exhaust fumes or fire can kill or injure! Immediately repair defective
exhaust systems.

(1) Visually inspect muffler and exhaust pipes for signs of approaching failure.
(2) Listen for any gasket or joint leaks.
(3) Replace any defective parts at once.

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Daily Or Every 8 Hours

Inspect air cleaner Check generator ammeter
Check output cable and connector Check frequency meter
Check generator voltmeter Check all lights
Check fuel quantity

Weekly, Or Every 50 Hours

Check crankcase oil level Check all lights
Check coolant level

Monthly, Or Every 200 Hours

Check safety switches Clean battery terminals
Change engine oil filter element Change engine oil

BI-MONTHLY, OR EVERY 400 HOURS

Check cooling system hoses, Check exhaust sys.
tubes, fittings, clamps Check protective relays

Every 6 Months Or 1200 Hours

Check V-belt tension Clean and inspect generally
Change fuel filter elements Drain/refill cooling system
Inspect all wiring and connections

Open Fuel Tank Drain Every 500 Hours

Lubricate (see Lubrication Chart)

Inspection/Check/Maintenance Schedule
Figure 1

3. Electrical System (12-V DC)

A. Lights
Check all lights for proper operation DAILY. Replace any defective lamps (bulbs) as soon as discov-
ered. Figure 2 lists ALL lamps, their location, and part numbers.

B. Fuses
Check and replace fuses as required. See Figure 3 for fuse sizes and locations. Figure 3 includes all
fuses used in both the engine and generator electrical system.

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LIGHT LAMP LAMP (BULB)

IDENTIFICATION LOCATION MANUFACTURER NUMBER

Instrument Panel Control Box and Lamp Industry

Lights Engine Control Panel Trade No. 63

Engine On Indicating Engine Control Lamp Industry 1815

Light Panel Trade No.

Contactor CLOSED Engine Control Lamp Industry 1815

Indicating Light Panel Trade No.

Fault Indicating Control Box Lamp Industry 1815

Lights Trade No.

Lamp Identification Chart

Figure 2

ITEM PROTECTED LOCATION ILLUSTRATION SIZE AND TYPE

Instrument panel Engine Sect. 1-1, 10A Type AGC

lights and engine control panel Fig. 8, item 11

Protective relay Generator Sect. 1-1, 2A Type AGC

system Control Panel Fig. 6, item 8

Voltage regulator Voltage Sect. 1-3, 5A Type AGC

regulator Fig. 1, item 31

Load contactor Generator Sect. 1-1, 2A Type AGC

circuit Control Panel Fig. 6, item 9

Fuse Identification Chart

Figure 3

C. Wiring and Connections

(1) Inspect all cables and leads for broken, worn, and damaged insulation.
(2) Check electrical connections for looseness.
NOTE: A darkened terminal generally indicates a loose connection.

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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.

A. Monitoring Instruments
Observe operation of voltmeter, ammeter, and frequency meter each time the unit is started.

B. Indicating Lights
Check lamps (bulbs) in all of the indicating lights at each start up. Fault indicating lights on the front
panel of the control box may be tested by pressing test switch (1-1; 16, Fig. 6).

C. Protective Modules
Check operation of all protective modules to make certain they will function if a fault should occur in
the output circuit. (See 2-3; Para. 3, B.)

D. Wiring and Connections

WARNING: Stop operations and stop engine before touching exposed conduc-
tors or terminals.

(1) Check all cables, leads, and wiring for broken, worn, and damaged insulation.
(2) Check all connections for tightness.
(3) Check the output cable plug connector for damaged contactors in the end of the plug.

5. Trailer
If the generator set comes with the trailer option, perform inspection as follows:

A. Check operation of parking brakes.

B. Check fuel tank for leaks.

C. Check pressure in all four tires. Should be 95 psi.

D. Check reflectors for damage.

E. Check trailer axles, linkage, and wheel bearings for proper lubrication. (Refer to Section 2-1, Para. 3,
F.) Refer also to TO-186 in Chapter 5 of this manual.

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SECTION 3. ADJUSTMENT/TEST

1. General
Adjustment and test procedures are most applicable to testing and adjusting the generator set after a ma-
jor repair, replacement of parts, or overhaul.

2. Generator Set Test

A. Pre-operational Test Procedures
(1) Connect cables from the generator output terminals to a load bank. Use cables of the same size
and length as those to be used in service. Be sure the generator output “N” cable is grounded.
(2) Check engine oil level. Oil should be at FULL mark on gage rod.
(3) Check radiator coolant level (Ref. Section 2-1, Para. 7, H).
(4) Check tension of engine V-belt.
(5) If governor throttle linkage was disturbed, check all linkage to make certain engine speed may be
controlled when the engine is started. See Figure 3.
(6) Inspect for oil, fuel, and coolant leaks.
(7) If the setting of the voltage regulator rheostat (27, Fig. 1) has been disturbed, set it at CENTER po-
sition (halfway between full clockwise position and full counterclockwise position).
(8) Check engine circuit fuse (21, Fig. 1) by placing panel light switch (13) in ON position. If panel light
(11) operates, the fuse (21), switch (13), and lamps are good.
(9) Check fault indicating lights (8) by pressing test switch (7). If lights glow, fuse (21) and indicating
lamps are good.
(10) Make a general inspection of all wiring and terminals. Inspect the equipment to be certain no
damage will result from starting the engine.

CAUTION: Engine must not be running when flashing exciter field if voltage regulator damage
is to be prevented. Do not leave regulated/diagnostic switch in diagnostic position after
flashing field.

(11) At initial start-up after generator overhaul or repair, “flash” the exciter field by momentarily apply-
ing 12-V DC to the field windings. To flash the exciter field, place the Regulated/Diagnostic switch (25,
Fig. 1) in the DIAGNOSTIC position for 3 to 5 seconds. Then return it to the REGULATED position.
(12) Check position of load contactor “on-off” switch (17, Fig. 1), and engine-generator control switch
(15).
(a) Load contactor switch (17) must be in OFFposition.
(b) Engine-generator control switch (15) must be in IDLE position.

B. Operational Test Procedures

(1) Start the engine in accordance with instructions in 1-3; Para. 2, A thru C.

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(2) Check operation of engine instruments: DC ammeter (14, Fig. 1), coolant temperature indicator
(18), oil pressure gage (20), and hourmeter (16).
(3) Check engine idle speed. Should be 825 to 875 RPM. Adjust, if necessary, in accordance with in-
structions in Engine Operator’s Manual.
NOTE: A stroboscope is required for this check.
(4) Again check for oil, fuel, and coolant leaks and correct any leaking condition.
(5) Position switches and controls for automatic voltage regulation and power delivery as follows:
(a) Place regulated-diagnostic switch (25, Fig. 1) in REGULATED position.
(b) Place test-bank switch (26) in AIRCRAFT position.
(c) Meter switch (4) may be in any position other than the directly downward (OFF) position.
(d) If the adjustment of the voltage regulator rheostat potentiometer (27) has been disturbed, posi-
tion the knob to mid-range position.
(6) Bring the engine up to governed speed and also energize the generator by holding the engine-gen-
erator control switch (15) in BUILD-UP-VOLTS position momentarily. Release switch and allow it to
position in “center” RUN position. If the engine “comes-up” to governed speed and a voltage value ap-
pears on the voltmeter (2), the electric governor and excitationdeenergization relay circuits are func-
tioning.
(7) Observe frequency meter (1). If engine speed is properly adjusted, frequency will be exactly 400
Hz. If not, adjust engine governed speed in accordance with Para. 3, E, (3) (d).
(8) Observe voltmeter (2). Use rheostat (27) to adjust voltage to 115 V AC.
(9) Measure governor actuator input signal. See Para. 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 Perkins Diesel Handbook in Chapter
6 for instructions on how to set the governor.
(12) Check adjustable voltage range
(a) With regulated/diagnostic switch (25) in REGULATED position, observe voltmeter (2, Fig. 1)
and turn voltage regulator potentiometer (27) CLOCKWISE to full clockwise position. Maximum
voltage should be at least 134 V AC, or higher.
NOTE: If voltage should decrease when the potentiometer is turned clockwise, it indicates that
the voltage regulator PC board is defective. Replace the regulator PC board.
(b) Observe voltmeter and turn rheostat knob to full COUNTERCLOCKWISE position. Minimum
voltage should be 108 V AC, or lower.
(13) Observe voltmeter and adjust rheostat to obtain 115-V AC voltmeter reading.
(14) Position load bank switches, etc., to apply a light load to the generator.
(15) Place the load contactor “on-off” switch (17, Fig. 1) in the top, spring loaded, CLOSE position.
Hold in this position momentarily. Hold in this position momentarily. The indicating light (19) should
glow GREEN and an amperage value should appear on the AC ammeter (3).

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(16) Release the switch (17) and allow it to return to the center ON position. The load contactor
should open immediately, and the generator “on” indicating light should go OFF. This is because the
plug interlock relay (Ref. 1-1; 1, Fig. 8) is not receiving power from an outside source of 28 V DC. It in-
dicates that the plug interlock contacts are OPEN as they should be when the interlock coil is not re-
ceiving 28-V DC power.
(17) Open and lower the front door panel of the control box and place the test bank switch (26, Fig. 1)
in TEST BANK position.
(18) Again place the load contactor switch (17) in the top, CLOSE position. Light (19) should glow
GREEN and remain ON when the switch is released and allowed to return to the center ON position.
This indicates that the test bank switch (26) is functioning to bypass the plug interlock relay.
(19) Return the test bank switch to AIRCRAFT position. The load contactor should open at once and
the green indicating light (19) should go off.
(20) Connect a source of 24-V DC power (two twelve-volt batteries connected in series) to terminals
“N” and “E-F” at the output terminal panel.Connection polarity should be: MINUS to terminal “N” and
PLUS to terminal “E-F”.
(21) With test-bank switch in AIRCRAFT position, hold the contactor operating switch (17) in top,
CLOSE position momentarily. The generator “on” indicating light (19) 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.
(22) Apply 1/3 to 1/2 load at the load bank and allow the unit to run for 15 to 30 minutes. Observe op-
eration of all monitoring instruments.
(23) Increase load bank resistance to apply a full load.
(24) Check operation of the governor by observing the frequency meter (1, Fig. 1) when generator is
switched from no-load to full-load and vice versa. Use the contactor control switch (17) to apply and
remove load several times. Frequency drop should be no more than 1 Hz. Adjust governor if neces-
sary (See Para. 3, E, (3)).
(25) Follow instructions in Para. 3, B, (2) (b) to set voltage regulator line-drop compensation potenti-
ometers (Ref. Figure 1, items (28) and (30). Set knob pointer on cable size potentiometer (28) to size
(2/0, 4/0, etc.) of cable being used. Set knob pointer on cable length potentiometer (30) to length (20
feet, 40 feet, etc.) of cable being used. See instruction plate (mounted below knobs).
(26) Check voltage regulator, at intervals, from no-load to full load, and on up to 125% load. Observe
and note voltage at various loads. Voltages should vary no more than plus or minus 1% from 115 V.
(27) Check accuracy of voltmeter.
(a) Open and lower the front door panel of the control box and connect a master voltmeter of
known accuracy to terminals of the voltmeter (2).
(b) Compare unit voltmeter reading with master meter. Error must not exceed 2% of full scale.
(28) Check accuracy of AC ammeter.
(a) Connect a master ammeter of known accuracy to the AC ammeter (3) terminals.
(b) Compare unit ammeter reading with master meter under various loads. Error must not exceed
4% of full scale.
(29) Check operation of meter selector switch (4). A voltage value should be shown in each switch po-
sition, except when the switch handle is on the DOWN (OFF) position.

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(30) Check operation of the line switch (5). A normal voltage of 115 V AC should be indicated when
the switch is in LINE-TO-NEUTRAL position. A voltage of approximately 200 V AC should be indi-
cated when the switch is placed in LINE-TO-LINE position.
(31) Check accuracy of frequency meter.
(a) Connect a master frequency meter of known accuracy to the frequency meter (1) terminals.
(b) Compare meter readings. Error must not exceed 1% of full scale.
(32) Operate the unit not less than 10 minutes under full load. The overload device (Ref. 1-1; 7, Fig.
11) MUST NOT trip.
(33) Operate at 125% rated load for 5 minutes immediately following the fullload run. The overload de-
vice MUST trip within 5 minutes and the overload indicating light (1-1; must come ON to indicate an
overload condition).
(34) Reduce load to normal. Turn off indicating light by pressing reset switch (6, Fig. 1).
(35) 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.
(36) Check operation of fuse interlock (Ref. 1-1; 8, Fig. 7). With unit operating normally under load, re-
move protective relay circuit fuse (10, Fig. 1). The load contactor should open immediately. This indi-
cates that the fuse interlock relay is functioning properly. Replace fuse and apply load.
NOTE: Make all protective relay tests with the unit operating under load.
(37) Check operation of overvoltage relay and indicating light.
(a) With the unit running at normal load, adjust the voltage regulator rheostat (27, Fig. 1) to in-
crease voltage (turn clockwise) until the overvoltage sensing relay actuates the protective monitor
to open the load contactor and turn on the overvoltage indicating light. The overvoltage sensing
relay should trip when voltage reaches 130 V to 134 V.
(b) Return unit to normal operating conditions by adjusting voltage regulator rheostat and press-
ing reset switch (6).
(38) Check operation of undervoltage sensing relay, indicating light, and time delay. Before starting
this check, let us understand the sequence of events which should happen when voltage is reduced
to 103 V or lower. At some value between 103 V and 93 V, the undervoltage sensing relay (Ref. 1-1;
4, Fig. 7) should function to activate the undervoltage time delay circuit. Five seconds after the time
delay circuit is activated, (if the undervoltage condition continues) it should function to open the protec-
tive monitor relay which, in turn, will open the load contactor to stop power delivery. As a result of the
action, the undervoltage indicating light should be turned ON. A stopwatch or sweep-second-hand
watch is required for this check. Proceed as follows:
(a) With unit running at normal load, use the voltage regulator rheostat (27, Fig. 1) to reduce volt-
age to 104V. The load contactor should NOT open after a 5-second delay.
(b) Reduce voltage in steps of 1 V, with a delay of at least 5 seconds between steps. Restart stop-
watch or note position of sweep-secondhand each time voltage is reduced. At some voltage value
between 103 V and 93 V, and 4 to 12 seconds after a new voltage setting is made, the load con-
tactor should be opened and the undervoltage indicating light should be turned on by the step-by-
step action of the undervoltage sensing relay, time delay circuit, and protective monitor relay.
NOTE: The 4 to 12 second time delay is generally set at 5 seconds. It may be necessary to switch
to MANUAL control to obtain these low voltages.

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(c) If the load contactor is not opened at 103 V to 93 V, refer to the Trouble Shooting Chart, Sec-
tion 3-1, to determine which component of the undervoltage protective circuit is defective.
(d) If the undervoltage circuit performs satisfactorily, return the unit to normal operation by adjust-
ing the voltage to 115 V, pressing the reset switch, and closing the load contactor.
(39) Check underfrequency sensing relay, protective monitor, and indicating light. At some frequency
value (Hz, cycles-per-second) from 385 Hz down to 375 Hz, the underfrequency sensing relay should
function to signal the underfrequency circuit in the protective monitor module to OPEN the load con-
tactor holding circuit, thus OPENING the load contactor. To check the underfrequency protective com-
ponents, proceed as follows:
(a) While the unit is operating normally under load, reduce generator output frequency by reduc-
ing engine speed. Use the governed speed setting potentiometer (Ref. Fig. 5). Turn adjusting
screw COUNTERCLOCKWISE gradually to reduce engine speed until frequency meter indicates
386 Hz. Underfrequency protective relay should not function to open the load contactor at this fre-
quency. Reduce frequency in steps of 1 Hz.
(b) If the protective system functions to open the load contactor and turn on the underfrequency
light after some frequency between 385 Hz and 375 Hz is reached, all components of the system
are functioning properly. If the load contactor is not opened within the above frequency range, re-
fer to Trouble Shooting Chart to determine which component is defective.
(c) Return unit to normal operating condition.
(40) Check overfrequency sensing relay, protective monitor, and indicating light. This protective circuit
operates in exactly the same manner as the underfrequency circuit except its operating range is from
415 Hz to 425 Hz. Its purpose also is to open the load contactor and turn on an indicating light.
(a) Check procedures are the same for overfrequency as for underfrequency (above) except that
engine speed is INCREASED to create a condition of overfrequency.
(b) If the overfrequency system functions to open the load contactor and turn on the overfre-
quency light after some frequency between 415 Hz and 425 Hz is reached, all components of the
system are functioning properly. If the load contactor is not opened within the above frequency
range, refer to Trouble Shooting Chart to determine which component is defective.
(41) If the generator is operating under load at this point, place the contactor control switch (17, Fig.
1) in OFF position to open load contactor and disconnect load. There will be no further need for the
load bank in the following checks.
(42) 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 hard-
ware as required.

WARNING: Electric shock, moving parts, and noise can kill or injure! If a metal
sounding rod is used to detect bearing noises, exercise extreme care to avoid
injury.

(43) Check 400-Hz generator bearings. Use a stethoscope or metal sounding rod to listen for unusual
noises. If using a metal rod, place one end on the generator housing and hold the other end near the
ear. Hold the rod with three fingers and use the index finger and thumb to form a “sounding chamber”
between the rod and the ear. Do NOT allow the rod to touch the ear. Listen for “grinding” or pounding
sounds which would indicate a defective bearing. An engine noise may be “telegraphed” to the gener-
ator and misinterpreted as a generator noise. Send the unit to overhaul if in doubt of bearing service-
ability.

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1. Frequency meter 14. DC Ammeter

2. Voltmeter 15. Engine-generator control switch
3. AC Ammeter 16. Hourmeter
4. Meter switch 17. Load contactor control switch
5. Line switch 18. Coolant temperature gage
6. Reset switch 19. Load contactor indicating light
7. Light test switch 20. Oil pressure gage
8. Fault indicating lights 21. Engine circuit fuse (10-A)
9. Load contactor circuit fuse 22. Engine protective circuit
(2-A) indicating light
10. Protective system fuse (2-A) 23. Engine starter switch
11. Instrument panel light 24. Permissive start switch
12. Fuel gage 25. Regulated/diagnostic switch
13. Light switch 26. Aircraft/test-bank switch

Operating Controls and Instruments

Figure 1 (Sheet 1 of 2)

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27. Automatic voltage control potentiometer (R5) 30. Cable length compensation rheostat
28. Cable size compensation rheostat 31. Voltage regulator fuse (5A)
29. Line-drop compensation on/off switch

Operating Controls and Instruments

Figure 1 (Sheet 2 of 2)

3. Generator Set Adjustment

A. Generator Adjustment
The 400-Hz generator is a brushless type requiring no adjustments of any kind.

B. Voltage Regulator Adjustments

At some time during the life of the equipment, the solid stage voltage regulator may require output volt-
age adjustments and/or line-drop compensation adjustments. Make these adjustments according to
the instructions given in Solid State Regulator Manual OM-2020, which is a part of Chapter 6 of this
manual.

C.Basic Engine Adjustments

Adjustment procedures applicable to the diesel engine are included in the Perkins Diesel Handbook
which accompanies this Hobart manual. Specific information for this particular engine is listed in Fig-
ure 2.

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D. Engine Accessories Adjustment

(1) Generator and fan belt adjustment

Refer to 2-1; Para. 8 for fan belt adjustment instructions.

Manufacturer Perkins
Model 6.3544
Type In-line, 6-cylider,
4-cycle Diesel
Displacement 354 cu. in. (5.8 liters)
Compression ratio 16 :1
Firing order 1-5-3-6-2-4
Horsepower at 2000 RPM 107
Governed speed 2000 RPM +/- 4.5%
Idle Speed 850 +/- 25 RPM
Electrical System 12 volt
Oil capacity 15 quarts (14 liters)
Coolant capacity (approx.) 20 quarts (13.5 liters)
Fuel Diesel oil conforming to ASTM
Specification D.975-66T,
Nos. 1-D and 2-D
Lube oil MIL-L-2014C or MIL-L-2014D

Engine Specifications
Figure 2

E. Electric Governor System Adjustment (Woodward Governor Kit)

(1) General

The Hobart electric governor kit, used on units built before November, 1990 is identified as Hobart
Part No. 488701, and consists of Woodward governor parts with brackets and hardware added by
Hobart Brothers to install the governor system on generator sets in this series. The Woodward
governor system consists of (1) an electric controller, (2) an actuator, and (3) a magnetic-pick-
up that is installed in the flywheel housing, which senses engine speed off the flywheel teeth.
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 ad-
justment 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
Second - Check or adjust magnetic pick-up
Third - Check or adjust electric control box

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(2) Actuator linkage adjustment

The proper adjustment of the mechanical linkage between the electric actuator and engine speed
control lever is important to the satisfactory operation of the complete system.
Exact adjustment instructions regarding effective length of rod assembly (6, Fig. 3), or regarding
the proper hole in actuator lever in which to attach ball joint (4) cannot be determined because of
slight variations in brackets, mountings, and engine performance characteristics. However, defi-
nite rules must be followed in making the adjustments:
RULE 1. Adjust linkage to use FULL TRAVEL of actuator output shaft (1).
RULE 2. Linkage must move speed control lever (7) from FULL IDLE to FULL SPEED position,
or VERY CLOSE to FULL SPEED position in order for the generator to pull 125% load.
Check and adjust linkage as follows, with engine stopped.
(a) Before making adjustment, observe and note which hole in actuator lever (3) is used to
mount ball joint (4). It does not necessarily have to be the same hole as may have been pre-
viously used. Disconnect ball joint (4) from actuator lever (3).
(b) Be sure neither lever (the actuator lever (3), or the fuel control lever (7) has slipped on
shafts. If a lever has slipped, position it correctly and tighten securely.
(c) Place both levers (3 and 7) in FULL IDLE position an attempt to connect ball joint (4) at
the hole in actuator lever (3) from which it was removed in step (a). If connection cannot be
made, loosen nuts (5) and adjust effective length of rod assembly (6, Fig. 4) so that connec-
tion can be made.
(d) Manually operate actuator lever back and forth between FULL IDLE and FULL SPEED. If
adjustment is unsatisfactory, try another hole in ACTUATOR lever and readjust rod length.
(e) Tighten all parts securely when adjustment is completed.

1. Actuator shaft
2. Signal input connector
3. Actuator lever
4. Ball joint, actuator
5. Nut, 1/4 x 28
6. Rod
7. Fuel pump lever
8. Ball joint, fuel pump

Governor Actuator Linkage

(Woodward Governor)
Figure 3

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(3) 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. If the pickup is to be removed for any reason, or if the
signal is weak (less than 2.5-V AC) as indicated by a voltage test at the pick-up with the engine
running at rated speed, proceed as follows:
(a) Disconnect “pull-apart” connector (1, Fig. 4).
(b) Loosen nut (3) and remove magnetic pickup (2).
(c) Inspect to make certain the tip is not damaged from contact with the ring gear teeth, replace
pickup if damaged.
(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” flywheel gear tooth.

CAUTION: The pickup tip must be directly over a tooth and not between teeth when adjustment
is made.

(f) Back the pickup outward (counterclockwise) 1/2 turn. Hold the pickup securely in this position
and tighten nut (3). This adjustment will result in a clearance of approximately 0.028 inch between
the pickup tip and the flywheel teeth and give an operating AC voltage of 4 V to 8 V at controller
terminals 5 and 6 when the engine is running at no load and governed speed, and approximately
2.5-V at cranking speed.
NOTE: As little a 1-V is required for operation of governor control box. Magnetic pickup voltage
does not have to be 4-V to 8-V.

1. Connector
2. Magnetic Pick-up (used on
earlier generator sets)
3. Nut

Magnetic Pick-up Adjustment

Figure 4

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(4) Governor Control Unit Adjustment

Before making an adjustment to the control unit (Fig. 5), make certain that linkage between actua-
tor lever (3, Fig. 3) and fuel control lever (7, Fig. 3) is properly adjusted. There must be no lost
motion or “play” in the linkage. Be sure magnetic pickup is producing a strong, normal output.
There are three adjustment controls on the unit (see Fig. 5). They are identified as:
RATED SPEED - Adjusts engine speed and generator frequency.
GAIN and STABILITY - Together, these adjust engine response time and engine stability.
To adjust control unit, proceed as follows:
(a) If the control box is being adjusted for the first time, set adjustment control as follows:
RATED SPEED control - Set the rated speed control screw fully counterclockwise (to mini-
mum speed setting).
GAIN control - Set this control screw to mid position.
STABILITY control - Set this control screw to mid position.
NOTE: A VERY shall screwdriver is required for these adjustments.
(b) Start engine and allow it to warm up.
(c) Place engine-generator control switch (23, Fig. 1) in GEN position to make electric governor
functional.
(d) Turn RATED SPEED adjusting screw clockwise to increase engine speed to 2000 RPM. At
1714 RPM, the frequency meter (9, Fig. 1) will indicate 400-Hz.
(e) Adjust GAIN control screw to the stable region between low frequency and high frequency os-
cillation.
(f) If there is a low frequency oscillation which does not stop when the gain control is adjusted,
turn the STABILITY control screw slightly clockwise and try the GAIN control adjustment again.
Continue adjusting the STABILITY control screw slightly clockwise, then re-adjusting the GAIN
control screw until the engine runs at a steady speed. If there is a high frequency oscillation
which does not stop, even when the GAIN control screw is turned fully counterclockwise, adjust
the STABILITY control screw slightly counterclockwise until the high frequency oscillation stops.
(g) The electric governor is now set to a nominally good operating point. Trim adjustments as de-
sired or required.

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1. Gain asjustment
2. Stability adjustment
3. Rated speed
adjustment

Electric Governor Control

Box (Woodward)
Figure 5

Electric Governor Controller Terminal Strip Connections

(Woodward Governor)
Figure 6

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F. Electric Governor System Adjustment (Barber-Colman Governor Kit)

(1) General

The Hobart electric governor kit, used on units built after November, 1990 is identified as Hobart
Part No. 282671, and consists of Barber-Colman governor parts with brackets and hardware
added by Hobart Brothers to install the governor system on generator sets in this series. The Bar-
ber-Colman governor system consists of (1) an electric controller, (2) an actuator, and (3) a
magnetic-pick-up that is installed in the flywheel housing, which senses engine speed off the fly-
wheel teeth.
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 ad-
justment 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
Second - Check or adjust magnetic pick-up
Third - Check or adjust electric control box

(2) Actuator Linkage Adjustment

The proper adjustment of the mechanical linkage between the governor actuator and engine
speed control lever is important to the satisfactory operation of the complete system. Two definite
rules must be followed in making the adjustment:
Adjust linkage must use the FULL TRAVEL of the actuator output shaft.
Linkage must move engine speed control lever from FULL IDLE to RATED SPEED posi-
tion, or VERY CLOSE to FULL SPEED position to allow the engine to pull maximum load.
With the engine stopped, refer to Figure 3 and proceed with linkage adjustments as follows:
(a) At the engine speed control lever (6), loosen the jam nut (5) that fastens the ball joint (7) to
the threaded rod, and remove the ball joint from the engine speed control lever.
(b) Rotate the ball joint - outward or inward - on the threaded rod (8), as necessary, to acheive a
distance of 6 inches (152 mm) from center to center on the swiveling portions of the two ball
joints (4 and 7).
(c) While holding the removed ball joint in its mounting hole in the engine speed control lever,
compare the TRAVEL of the ACTUATOR SHAFT (2) with the travel of the engine speed control
lever (6).
(d) At FULL IDLE position, the actuator shaft should be pulled ALL THE WAY DOWNWARD.
(e) For RATED SPEED, the actuator shaft should come out far enough to force the engine
speed control lever to use ALL OF ITS TRAVEL as it moves upward.
(f) Re-attach the ball joint to the engine speed control lever with the lockwasher and nut.
(g) Tighten the two jam nuts on the threaded rod firmly against their respective ball joints.

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(h) Check governor linkage for freedom of travel. Move the rod assembly manually to see that
there isn’t any binding or lost motion in linkage. Make corrections if and as required.
(j) Make a preliminary setting of engine idle speed by adjusting the idle speed set screw, which is
located on the engine speed control lever. See that this screw is turned INWARD about 3 to 5
turns, to force the engine speed control lever downward slightly from the full upward position.
(k) Start the engine, and set the idle speed to 850 RPM + / - 25 RPM. Operate engine at idle
speed until it is warmed to operating temperature. Then re-adjust idle speed set screw, if neces-
sary, to obtain the original 850 RPM + / - 25 RPM.

1. Actuator
2. Actuator shaft
3. Clevis, actuator shaft
4. Ball joint, actuator
5. Jam nuts
6. Engine speed control lever
7. Ball joint, engine speed control
8. Rod
9. Mounting brackets, actuator

Governor Actuator Linkage

Figure 7

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(3) Magnetic Pick-up Inspection / Adjustment

Figure 8 shows how the magnetic pick-up is mounted. Typically, this area of the generator set
can be seen by opening the door on the front left side of the generator set and viewing the side of
the flywheel housing. The strength of the magnetic pick-up signal to the controller can be weak-
ened if the tip of the pick-up is too far from the flywheel ring gear or if it becomes damaged.. If
the pick-up is removed for any reason, or if the signal is weak, adjust the magnetic pick-up as fol-
lows:
(a) Loosen the jam nut on the pick-up, by turning it toward the wire end of the pick-up.
(b) Remove the magnetic pick-up and inspect for damage, replace if necessary. Clean the tip
and reinstall.

CAUTION: The pickup tip must be directly over a tooth and not between teeth when adjustment
is made.w

(c) Continue turning pick-up CLOCKWISE until it bottoms out (it has hit the ring gear teeth).
(d) Back the magnetic pick-up out 1/4 to 3/4 of a turn COUNTERCLOCKWISE. This creates a
gap between the magnetic pick-up and the ring gear.
(e) Disconnect magnetic pick-up wires at the terminal strip (Figures 4 & 5)
(f) Start the engine and run at idle speed..
(g) Connect the pick-up wires to a voltmeter. The signal should read between 4 and 8 VAC.
(h) If the signal is weaker than 4-V AC, check connections. If necessary, check magnetic pick-
up continuity or idle speed setting on the fuel pump.
(j) Tighten the jam nut when the pick-up is properly adjusted.
(k) Reconnect the wires to the terminal strip.

1. Magnetic pick-up
2. Adjustment nut

Magnetic Pick-up Adjustment

(Typical)
Figure 8

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(4) Governor Controller Adjustment

The governor controller is located on the large panel to the left of the generator control box, as
viewed from the left side of the generator set. Before making an adjustment to the controller,
make sure the linkage between the actuator and the engine speed control is free and properly ad-
justed. There must be no lost motion or “play” in the linkage. Be sure the magnetic pick-up is pro-
ducing a strong, normal output.
The controller has two control potentiometers: the SPEED control potentiometer and the GAIN
potentiometer. Make the controller settings as follows:
NOTE: A very small screwdriver is required for this adjustment.
(a) With the engine warmed to operating temperature, use operating mode switch to bring the gen-
erator set from idle to rated speed.
(b) Adjust the SPEED potentiometer on the controller until the engine is operating at rated speed
(2000 RPM). To INCREASE engine speed when making this setting, turn the potentiometer
CLOCKWISE. To DECREASE engine speed when making this setting, turn the potentiometer
COUNTERCLOCKWISE.
(c) If the governor oscillates, causing the governor-actuator linkage rod to move in an unstable
manner, adjust the GAIN control on the governor controller until the oscillation and subsequent
instability is just barely eliminated. Then re-adjust the SPEED if necessary.
(d) Upset the engine speed control lever by hand. If the lever oscillates in 3 to 5 diminishing oscil-
lations and stops, the setting is correct.
(e) Apply a load to the generator set, then remove the load and observe the length of time re-
quired for the engine speed to again stabilize. Engine speed should stabilize within 3 to 5 oscilla-
tions.
(f) If engine speed does not stabilize at the above setting, continue making slight adjustments to
the GAIN control, and checking stability and engine speed between no-load and full-load, until the
engine speed stabilizes.

(5) Re-checking Actuator Linkage

Perform this check ONLY if the engine doesn’t come up to rated speed from idle speed, or
doesn’t maintain rated speed under load. If either of these conditions exist, check and adjust link-
age as follows, with engine stopped.
Disconnect the ball joint from the actuator shaft clevis .
Be sure the engine speed control lever is not slipping on its shaft. If it is slipping, position it cor-
rectly and tighten it securely.
Place the engine speed control lever in FULL IDLE position and attempt to connect the ball joint
at the hole in the lever from which it was removed (Step 1). If the holes don’t align correctly,
loosen the ball joint nut and adjust the effective length of the rod assembly - shorter or longer -
and re-connect it to the actuator clevis.
Tighten the ball joint nuts securely and operate the generator set to check governor’s control of
idle speed, rated at no-load speed, and full-load speed.
Repeat this procedure until generator set operates at proper speeds, with and without load.

(6) Checking the Actuator

The actuator does not require any adjustments. An actuator malfunction, when it occurs, will re-
sult in the actuator being totally inoperative, either due to the actuator coil being open or shorted
to the actuator case. Resistance measurements will reveal either of these conditions.

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Electric Governor Control Box

(Barber-Colman Governor)
Figure 9

Electric Governor Controller

Terminal Strip Connections
(Barber-Coleman Governor)
Figure 10

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(7) Troubleshooting

When installing the governor, carefully follow the instructions for installation and adjustment. To
further aid in checking installation and servicing of the governor after it has been in use, check the
following troubleshooting hints.
Engine speed lugs down when load is applied
Governor controller improperly adjusted.
Friction in throttle linkage.
Load is too great for engine.
Engine worn, compression too slow.
Timing slow.
Springs in engine speed control mechanism opposing governor action.
Governor actuator worn internally.
Magnetic pick-up improperly adjusted.
Engine over-speeds when load is applied
Magnetic pick-up improperly adjusted.
Friction in throttle linkage.
Governor improperly adjusted.
Friction in engine speed control mechanism.
Springs in engine speed control mechanism opposing governor action.
Governor actuator worn internally.
Governor surges at no-load
Friction in throttle linkage.
Magnetic pick-up improperly adjusted.
Timing set too fast.
Governor actuator worn internally.
Governor surges under-load
Governor improperly adjusted.
Friction in throttle linkage.
Magnetic pick-up improperly adjusted.
Governor running too fast.
Governor actuator worn internally.

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4. Generator and Exciter Test

The generator fields may be tested with a “Kelvin” bridge. This is a double-bridge type instrument required
for the very low resistances encountered in this test. It is understood that 0 resistance indicates a SHORT
CIRCUITED condition. An infinite resistance reading indicates an OPEN CIRCUITED condition. See Fig.
11 below for resistance values.

NOTE: The equipment should be COLD or at normal ambient temperature when tests are made.

A. Disconnect generator stator leads at the power module panel.

B. Disconnect exciter leads from terminal board mounted on rear of engine control panel. Positive lead is
RED. Negative lead is YELLOW-BLACK.

C. Check resistances and compare to values given in Fig. 11.

TEST CONNECTION NOMINAL RESISTANCE IN OHMS

GENERATOR STATOR
Phase A to N 0.008
Phase B to N 0.008
Phase C to N 0.008

NOTE: The two leads of a phase must be connected when test is made.
EXCITER A-B, B-C, A-C 0.1
Field (RED to YELLOW-BLACK) 7.23

Generator and Exciter Stator Test Values

(70F Ambient Temperature)
Figure 11

5. Diode Test
Test values for diodes are not given here because they could be misleading. Test values may vary even
between diodes of the same part number, rating, and manufacturer. General instructions for testing di-
odes follows:

A. Disconnect diode lead(s).

B. Use a good quality ohmmeter. An instrument which indicates 50 ohms at the center of the scale is
preferable.
NOTE: Make certain the battery is in good condition and the pointer is adjusted to zero when the
test lead points are shorted together. Set the scale selector to RX1.
C. Hold one ohmmeter lead point on the threaded end of the diode. Hold the other lead point on the
wire terminal end. Observe and note the indicated resistance. Now reverse the lead connections on
the diode. Again observe and note the ohmmeter indicated resistance. Generally speaking, if an infi-
nite or very high resistance was indicated with the leads connected one way and a low, readable resis-
tance was indicated with the leads connected the opposite way, the diode may be considered good.

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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. Continue testing and checking the circuit, step-by-step, in an orderly man-
ner, until the cause of trouble is located.

B. This section provides information useful in diagnosing and correcting certain troubles which cause un-
satisfactory operation or failure of the equipment.

C. Minor troubles may be remedied by the operator; however, major repairs must be undertaken by experi-
enced mechanics and electricians only.

2. Troubleshooting Chart (Figure 2)

A. Description

The troubleshooting chart lists information under three headings as follows:

(1) Trouble, Symptom, and Condition

(2) Probable Cause
(3) Test, Check, and/or Remedy

B. Use of the Trouble Shooting Chart

(1) A troubleshooting chart is furnished to provide maintenance and repair personnel with a time-sav-
ing guide for locating trouble. To use the chart, proceed as follows:
(a) Locate the symptom(s) of trouble in the “Trouble” column.
(b) Check the probable causes of trouble in the “Probable Cause” column.
(c) Test, check, repair, or correct the trouble as indicated in the “Remedy” column.
(2) If the cause of a trouble is an uncommon one and cannot be located by use of the chart, the only
alternative is to start at the source of power or supply and check the affected circuit or system com-
pletely. Use schematic and connection diagrams which are supplied with this manual.
(3) Electrical components mentioned in the trouble shooting chart are identified by a noun name and
corresponding symbol which allows the user to identify the item more easily on schematic diagrams.
(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.

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3. Equipment for Troubleshooting

A good quality multi-scale voltohmmeter is the only instrument required for trouble shooting. At least two
“jumper” leads with “alligator” clips and test prods will be required. The 12-V, engine electrical system may
be used as a 12-V DC power source.

4. Safety - WARNING:
WARNING: Exercise extreme care to avoid contact with high voltage leads and
components which could cause serious shock and injury if touched when
trouble shooting or operating the equipment.

5. Parts Replacement
To lessen end item “down” time and to get a faulty machine back “on-theline” as quickly as possible, the
“black-box” concept of parts replacement is reflected in the trouble shooting chart. For example, if a com-
ponent in a particular assembly or module is defective, the quickest way to remedy the situation is to re-
place the complete assembly or the module and send the old assembly or module to stock. Assemblies
which lend themselves to this concept are:

Voltage regulator Protective monitor module

Governor actuator Over-underfrequency module
Overload module Electric governor control “box”
Over-undervoltage module

The above items are in addition to normally replaced items such as fuel pump, injectors, relays, etc.

6. Test Values
Although test values are provided throughout the trouble shooting chart, where applicable, additional infor-
mation and values are given as follows.

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. Trip values, trip times and reset values for these PC boards are
shown in the table on the following page.

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Trip PC Board Trip Value Trip Time Within: Reset Value

Overload 387738A 112 KVA 5 Minutes ——————
—-
Overvoltage 482038 130 - 134 V-AC ———————- 125 V-AC

482038A 125.5 - 126.6 V-AC 1 - 2 seconds 120 V-AC

Undervoltage 482038 93 - 102 V-AC 4 - 12 seconds 110 V-AC
482038A 95 - 100 V-AC 7 - 8 seconds 105 V-AC
Overfrequency 482039 415 - 425 Hz ———————- 410 Hz

482039A 415 - 425 Hz ———————- 410 Hz

482039B 425 - 430 Hz 5 - 6 seconds 415 Hz

482039C 420 - 425 Hz 5 - 6 seconds 415 Hz

PC Board Trip Values, Trip Times, and Reset Values

Table 1

7. Checking Connections and Leads

ALWAYS make a check of connections and leads to a component suspected of being faulty. With the ex-
ception of a few instances, we will assume that connections and wiring have always been checked first
and that power has not been lost as a result of defective wiring or connections.

8. Electric Governor Trouble Shooting

The following facts concerning the operation of the electric governor may be helpful in understanding the
system and in determining which unit in the system is faulty in case of troubles.

A. The system requires two sources of power to operate normally.

(1) 12-V DC input power (from engine electrical system)
(2) 4-V AC input power (from magnetic pickup)
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” or “gain” adjustment set too “high”
(2) Throttle linkage binding

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1. Frequency meter 14. DC Ammeter

2. Voltmeter 15. Engine-generator control switch
3. AC Ammeter 16. Hourmeter
4. Meter switch 17. Load contactor control switch
5. Line switch 18. Coolant temperature gage
6. Reset switch 19. Load contactor indicating light
7. Light test switch 20. Oil pressure gage
8. Fault indicating lights 21. Engine circuit fuse (10-A)
9. Load contactor circuit fuse 22. Engine protective circuit
(2-A) indicating light
10. Protective system fuse (2-A) 23. Engine starter switch
11. Instrument panel light 24. Permissive start switch
12. Fuel gage 25. Regulated/diagnostic switch
13. Light switch 26. Aircraft/test-bank switch

Operating Controls and Instruments

Figure 1 (Sheet 1 of 2)

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27. Automatic voltage control potentiometer (R5) 30. Cable length compensation rheostat
28. Cable size compensation rheostat 31. Voltage regulator fuse (5A)

Operating Controls and Instruments

Figure 1 (Sheet 2 of 2)

9. Engine Trouble Shooting Procedures

The following engine trouble shooting procedures were taken from Perkins Diesel Handbook. Certain ab-
normal conditions which may interfere with satisfactory engine operation, together with methods of deter-
mining the cause of such conditions, are covered in the Trouble Shooting Chart.

The ability of the engine to start and operate properly depends primarily on two things:

-The presence of an adequate supply of air, compressed to a sufficiently high compression pressure.
-The injection of the proper amount of fuel at the right time.

Lack of power, uneven running, excessive vibration, stalling, and hard starting may be caused by low com-
pression, faulty injection in one or more cylinders, or lack of sufficient air. Refer to Perkins Handbook for
trouble shooting and repair procedures.

10.Illustrations
Illustrations in Figure 1 are referred to throughout the Trouble Shooting Chart, Figure 2.

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
NOTE: Diesel engine trouble shooting is covered in John Deere Shop Manual
under Fault Diagnosis.
ENGINE CONTROLS
1. Engine will not A. Batteries discharged, A. Check voltage across bat-
start. Starter will or loose battery or teries. Voltage should be
NOT crank engine. ground connection approximately 13.5 volts DC.
Check all battery terminals.
Be sure 13.5 volts DC is
reaching solenoid input
teminal.
B. Defective starter B. Momentarily connect a large
solenoid capacity jumper cable be-
tween the hot side of the
starter solenoid and the
starter input terminal. If
the starter attempts to
crank the engine, it indi-
cates the starter solenoid
is defective. Replace. If
the starter did not operate,
proceed to step D.
C. Defective starter C. If starter did not operate
in check C above, the
starter is defective. Rplace.
D. Internal seizure D. If all engine starting com-
ponents are good and the
starter is unable to crank
the engine, internal seizure
is indicated. For repair
procedure see Perkins
workshop manual.
2. Engine will not A. Low battery output A. Check battery. Recharge or
start. Cranking replace.
speed low.
B. Loose starting cir- B. Check all connections and
cuit connections or cables. Tighten or replace
faulty cables. as required.

C. Improper lubricating C. Check oil. See Sect. 2-1,

oil viscosity Para. 3, D, (3).

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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 the
cover of each. Fill each
filter with fuel oil. If the
engine will not start after
priming, mechanical pump
trouble is indicated. If the
engine starts and then stops
after a short time, trouble
between the fuel source and
the suction side of the pump
is indicated. Check and/or
remedy as follows.

(1) Insufficient fuel (1) Fill tank.

in tank
(2) Fuel shut-off (2) Make certain valve is
valve closed OPEN.
(3) Loose connections (3) Tighten all fittings and
damaged hoses or fuel connections. Replace any
lines between tank and damaged hoses or fuel
fuel pump links.
(4) Plugged or defective (4) Do not overlook the
fuel filter possibility of restricted
flow through the fuel
filters. Also check gaskets
for leaking or damaged
condition.
(5) Faulty installation (5) Restricted fitting missing
from return line.
(6) Faulty fuel pump (6) Check pump.

(a) Relief valve not (a) An open relief valve will

seating cause low output pressure.
(b) Worn pump gears (b) Check pump for normal
or damaged pump operation. Replace if defective.
drive

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
ENGINE AND CONTROLS (CONTINUED)
3. Engine will not (7) Defect in inject- (7) Refer to Perkins
start. Cranking or racks or link- Handbook. Make adjust-
speed normal (Continued). age ments and/or repairs
according to instruc-
tions therein.
4. Engine is hard to A. Low ambient temper- A. Check causes and remedies
start. Cranking ature, or limited under ENGINE, Trouble 3,
speed normal. fuel above.
B. Low compression which B. Check compression in accor-
may be caused by any dance with Para. 9, C and D.
one of the following:
(1) Sticking or (1) Cylinder head must be
burned exhaust removed and overhauled
valves to correct this condi-
tion.
(2) Compression rings (2) Check rings in accor-
worn or broken dance with instructions
in Perkins Handbook.
(3) Cylinder head (3) Check gasket in accor-
gasket leaking dance with instructions
in Perkins Handbook.
(4) Improper valve (4) Check and adjust valve
clearance adjust- clearance in accordance
ment with instructions in
John Deere Handbook.
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. engine because of low oil pressure gage. If oil
lubricating oil pressure. pressure is 12 psi or more,
and the engine shuts down
when the permissive start
switch is released to the
run position, put a jumper
wire across oil pressure
switch terminals “C” and
“NO”. Restart engine. If
the engine continues to run
when the permissive start
switch is released to the
RUN position, the oil
pressure switch is
defective. Replace oil
pressure switch

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
ENGINE AND CONTROLS (CONTINUED)
5. Engine starts. Stops after B. Defective or incor- B. Check wiring to high temper-
a few seconds by automatic rectly wired high ature switch. One Red-Yellow wire
shutdown. temperature switch should be connected to the C ter-
(S 49, located on the minal. With wires removed, check
engine block on the resistance between terminals C and
right side). N.C. A resistance reading of zero
indicates a good temperature
switch. A readable resistance
indicates a defective switch.
Replace switch if defective.
6. Engine runs at idle speed. A. Lamp defective A. Replace lamp.
Engine “ON” indicating light
(22, Fig. 1) does not glow.
B. Indicating light body B. Be sure light is grounded
poorly grounded properly.
7. Engine will not come “up” A. 12-V DC power not A. Apply 12-V DC directly to
to governed speed in GEN reaching governor terminal 1 on governor controller’s
mode. controller due to terminal strip. If engine comes-up
defective operating to speed, check following:
mode switch (15, Fig. 1)
B. Governor linkage B. Check governor linkage and
binding or governor throttle shaft for binding
throttle sticking and sticking. Repair as required.
C. Defective or mis- C. The controller may not be
adjusted magnetic receiving a signal from the mag-
pickup (2, Fig. 4, netic pickup and the “fail-safe”
2-3). feature of the controller may be
functioning to prevent any signal
from reaching the actuator. To
check the magnetic pickup, refer
to connection and schematic diagram
in Chapter 6 and disconnect pickup
input leads controler’s terminal
strip. Connect a high impedance
AC voltmeter to the pickup output
leads. Crank engine but don’t
start. Voltage reading should be
a minimum of one (1) volt. If no
or low voltage is indicated, check
pickup adjustment as per Section 2-3,
Para. 4, E, (3) for ungrounded
magnetic pickup or Para. 4, F, (3)
for grounded magnetic pickup. If
magnetic pickup is properly adjusted
and voltage is still zero, replace
pickup.

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
ENGINE AND CONTROLS (CONTINUED)
7. Engine will not come “up” D. Defective actuator D. Refer to connection and sche-
to governed speed in GEN matic diagram in Chapter 6 and
mode. (continued) apply 12-V DC to the two
actuator input lead terminals.
Actuator lever should move im-
mediately to full speed position.
If lever does not move, replace
actuator.
E. Defective governor E. Refer to connection and sche-
controller matic diagram in Chapter 6 and
connect a DC voltmeter to the
controller’s terminal strip. Start
the engine and manually control
engine speed. At speeds below
governed speed, the voltmeter
should indicate within two (2) volts
of the system voltage. If voltage
is at near zero, turn speed
adjusting screw several turns
clockwise to be sure speed
setting is not too low because
of tampering. If voltage
remains low or at zero, replace
controller. Refer to governor
instruction booklet in Chapter 6
for controller bench tests and
adjustments.
8. Engine goes to A. Governed speed con- A. Turn speed control adjust-
overspeed when con- trol adjustment set ing screw fully counterclock-
trol switch (15, too high (see 2-3, wise. Start engine. Place con-
Fig. 1) is in GEN mode. Fig. 5) trol switch (15, Fig. 1) in GEN
position. If engine speed is
now well below governed
speed, turn adjusting screw
clockwise until correct speed
(2000 RPM, 400-Hz) is attained.
If engine still goes to over-
speed, proceed to Step B.
B. Defective linkage or B. Check governor linkage and
actuator actuator for sticking or
binding in full-speed position.
Repair as required.
C. Defective controller C. Replace controller. Check
it in accordance with governor
instruction booklet in Chapter 6.

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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. Make certain all
cylinders are firing properly.
B. Governor system B. Check and adjust as follows:
faulty or misadjusted
(1) Loose or binding (1) Check linkage ball joints and all
governor linkage connections for looseness or binding.
Be sure linkage will move from idle
speed to full speed without lost
motion or binding.
(2) GAIN and STABILITY (2) Adjust GAIN and STABILITY
controls improperly controls on controller in accordance
adjusted (Woodward with Section 2-3, Para. 4, E, (4).
controller)
(2A) GAIN control im- (2) Adjust GAIN and STABILITY
properly adjusted (Barber- controls on controller in accordance
Colman controller) with Section 2-3, Para. 4, F, (4).
(3) Magnetic pickup (3) Check and adjust pickup as per
signal weak Section 2-3, Para. 4, E, (3) for
ungrounded magnetic pickup or
Para. 4, F, (3) for grounded
magnetic pickup.
10. Engine has slow A. Governor controller A. Adjust. See 2-3; Para. 4, E, (4).
response time improperly adjusted
B. Actuator linkage binding B. Inspect and repair as required.
C. Engine needs tune-up C. Tune-up as required. Refer
to Perkins Handbook
11. Engine “misses”. A. Insufficient fuel A. Check fuel flow in accordance
Runs unevenly. with Perkins Diesel Handbook.
Repair or replace parts as required.
Also see Engine, Trouble 3.
B. Fault injector B. Check injectors in accordance
dance with Perkins Handbook.
See causes of low compression
listed under ENGINE, Trouble 4, B,
above.
C. Low compression C. Check compression in accor-
pressure dance with Perkins Diesel
Handbook. See causes of low
compression listed under
ENGINE, Trouble 4, B, above.

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
ENGINE AND CONTROLS (CONTINUED)
12. Engine lacks power A. Improper engine A. “Tune-up” the engine in
adjustments and gear accordance with Perkins Diesel
train timing Handbook
B. Insufficient fuel B. See ENGINE, Trouble 3.
C. Insufficient inlet C. Check air cleaner for
air due to damaged “plugging” and/or damage.
air cleaner
D. Restricted exhaust D. Check exhaust pipes for
system restrictions. Check muffler
for clogged condition.
Replace as required.

GENERATOR EXCITATION CIRCUITS

1. No (or low) gen- A. Defective generator A. Place the REGULATED/
erator output volt- or excitation DIAGNOSTIC switch (25,Fig.1) in
age in all phases. circuit. DIAGNOSTIC position. This
Generator operating applies 12-V DC from the
at 400 Hz. battery to the exciter
field, which should produce
an indicated output voltage
of 55 V-DC +/-5 V-DC. If the
voltage produced is within
this range, the generator is
good, and the trouble is in
the voltage regulator
circuit. Proceed to step B.
B. Defect in VOLTAGE B. Check as follows:
REG. excitation cir-
cuit.
(1) Defective REGU- (1) Check the switch thor-
LATED/DIAGNOSTIC oughly. A defective
switch (25, switch may prevent cur-
Fig. 1) rent reaching and/or
leaving the voltage reg-
ulator. Replace switch
if defective.
(2) Defective exci- (2) Check EDR contacts. A
tation-deenergi- faulty EDR can prevent
zation relay power from reaching the
(K16) (1-1; 1, voltage regulator. Re-
Fig. 7) place relay if defective

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
GENERATOR EXCITATION CIRCUITS
1. No (or low) gen- (3) Defective ballast (3) If output voltage was
erator output volt- resistor, (See produced when the gener-
age in all phases. 1-1; 16, Fig. 7) ator set was operated in
Generator operating DIAGNOSTIC mode, the
at 400 Hz. (continued) resistor is good. If no
voltage was produced in
DIAGNOSTIC mode, the
resistor could be defec-
tive. Connect a jumper
lead across the ballast
resistor. If an output
voltage is now produced,
replace resistor as
required.

(4) Defective (4) Disconnect plug from

connector at voltage regulator PC
voltage regu- board. Using jumper
lator, or defec- leads with clip and prod
tive wiring from terminals, connect 12-V
regulator to DC to terminals 4 and 5
exciter field. in loose plug. Connect
NEGATIVE to terminal 5
Connect POSITIVE lead to
terminal 4 (see Sche-
matic/Connection Diagram
in Chapter 6). If the
generator will NOT pro-
duce at least 50 V-AC,
replace or repair
connector and wiring
between voltage regula-
tor and exciter field as
required.
(5) Defective voltage (5) All components in the
regulator excitation circuit ex-
cept the voltage regula-
tor have been tested in
steps (1) through (4)
above. This leaves only
the regulator as a cause
of trouble. Replace
voltage regulator PC
board.

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
LOAD CONTACTOR OPERATING CIRCUIT
1. Load contactor (K1) A. In addition to de- A. After checking fuse (F1) in
will not close when fective wiring and step (1) below, check all
control switch (20, connections in the AC wiring and connections in
Fig. 1) is held in and DC load contactor the load contactor circuits.
ON position. Gener- actuating circuits, Then check components as
ator running at the load contactor follows:
normal voltage. No may be prevented from
fault lights on. closing for any one
of the following
reasons:
(1) Blown fuse (F1) (1) Remove and inspect fuse.
(1-1; 16, Fig. 8) Replace if blown.
(2) Defective (open) (2) Replace protective
relay in protec- module with a module
tive module (1-1; known to be operating
4, Fig. 8) properly. If contactor still
doesn’t close,proceed to step (3).
(3) Defective load (3) Set Regulated/Diagnos-
contactor control tic switch (S1) in
switch (S5) (20, REGULATED position.
Fig. 1) Check AC voltage input
to contactor rectifier
(CR6). If voltage isn’t
approximately 115-V AC,
contactor control
switch is defective and
must be replaced.
(4) Defective recti- (4) After making certain
fier (CR6) (1-1; that contactor switch
5, Fig. 11) (S5) is providing 115-V
AC to the rectifier
(CR6), measure DC out-
put voltage between
positive (+) and nega-
tive (-) terminals of
rectifier. If voltage
measured isn’t approxi-
mately 90-V DC, replace rectifier.
(5) Defective load (5) Disconnect leads at load
contactor coil contactor terminals X1 and X2.
(K1) (1-1; 6, Check coil resistance between
Fig. 11) these terminals. Resistance
should be approximately 600
ohms. If coil is defective, replace
the complete load contactor.

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
LOAD CONTACTOR OPERATING CIRCUIT (Continued)
2. Load contactor (K1) A. 28.5-V DC is not A. Proceed as follows to find
will close when reaching plug inter- the cause of this mal-
control switch (20, lock relay (K2) from function.
Fig. 1) is held in momentary aircraft for the
ON position. Opens immediately following reasons:
when switch is released to center
ON position.
(1) Generator to air- (1) Inspect cable connector
craft cable con- plug thoroughly for dam-
nector defective aged E and F terminals.
or not plugged Be sure the plug is fully mated
into aircraft with the aircraft receptacle con-
receptacle connector. nector and making good contact.
(2) Aircraft reject- (2) Check aircraft on board
ing power electrical equipment and
controls
B. “Blown” protective B. Press the lens housing of
relay fuse (F2) fault indicating lights. If lamps
(1-1; 8, Fig. 6) do not glow, replace fuse (F2).
C. Defective plug- C. Place test-bank switch (S2)
interlock relay (K2) (34, Fig. 1) in ON position. If load
contactor will now remain closed,
replace the plug-interlock relay
(K2) (Sect. 1-1; 2, Fig. 7)
D. Small contacts in D. Connect a jumper lead be-
load contactor (K1) tween small terminal no. 1
defective and no. 2 on the load contactor.
If load contactor will now remain
closed, replace the complete load
contactor (K1).
E. Defective fuse- E. Connect a jumper across
interlock relay (K17) resistor R46) (Sect. 1-1;
or resistor (R46) 21, Fig. 8). If the contactor
will now remain closed,
replace the resistor (R46). If
the contactor will not rwmain
closed, replace fuse-interlock
relay (K17) (Sect. 1-1; 8, Fig. 7).
3. Load contactor A. Fuse (F1 or F2) A. Remove and inspect fuses
opens during power blown. (1-1; 8 and 9, Fig. 6).
delivery. NO fault Replace as required.
indicating lights on.

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
LOAD CONTACTOR OPERATING CIRCUIT (Continued)
3. Load contactor B. A fault has devel- B. If the load contactor cannot
opens during power oped in the load be closed by operation of
delivery. NO fault contactor holding the control switch (S5) (20,
indicating lights on circuit. Fig. 1), check the circuit
in accordance with instruc-
tions in Trouble 1, above
under LOAD CONTACTOR
OPERATING CIRCUIT. If the
load contactor can be closed, but
opens as soon as control
switch (S5) is released,
check for trouble under
Trouble 2, above.
C. Cable accidentally C. Reconnect cable.
disconnected from
aircraft.

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. To avoid repetition, it will be assumed that the reset switch [(6), Fig. 1] has been
pushed and theload contactor has been closed before commencing each test.
1. Load contactor A. The overvoltage con- A. Press reset switch (6,
opens during power dition may have been Fig. 1) and resume power
delivery. Over- the result of a sud- delivery. Observe voltmeter
voltage indicating den drop in the load, (2, Fig. 1) to be certain
light ON or possible tampering voltage is normal 115 V AC.
with voltage regula- Adjust to normal if necessary. If
tor potentiometer the load contactor is opened
(27, Fig. 1), and may again and an over-voltage condi-
have been a normal tion is indicated by OV indicating
action. light, proceed to step B.
B. Defective over-under- B. Use voltage adjusting
voltage sensing mod- potentiometer (27, Fig. 1)
ule (K26) to reduce voltage to 110 V
AC. Observe voltmeter and
gradually increase voltage with
potentiometer. If the over-under-
voltage sensing module (K26)
functions to open the load
contactor at any value less than
134 VAC, it is defective. Replace
over-undervoltage module.

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
PROTECTIVE CIRCUIT (CONTINUED)
2. Load contactor A. An undervoltage con- A. Observe generator voltage on
opens during power dition caused the voltmeter and adjust to normal
delivery. Under- over-undervoltage 115 V AC with voltage
voltage indicating sensing module (K26) regulator potentiometer (27,
light ON. to function normally. Fig. 1). Resume normal oper-
ation. If the load contactor
opens again and an under-
voltage condition is indi-
cated by UV indicating
light, proceed to step B.
B. Defective over-under- B. Use potentiometer (27, Fig.
voltage module (K26) 1) to reduce voltage to 104
V. The undervoltage indi-
cating light should NOT come
on during a time delay of 4
to 12 seconds. If the light
comes on before a delay of 4
to 12 seconds, the under-
voltage relay is defective.
Replace the module (K26).
C. Defective protective C. With unit running normally,
monitor module (K14) use potentiometer (27, Fig.
1) to reduce voltage quickly
to 90 V. If the undervoltage
indicating light (DS38) is
turned ON immediately, the
protective monitor circuitry
is defective. Replace
protective monitor (K14).
3. Load contactor opens A. Electric governor A. Proceed as follows:
during power delivery. improperly adjusted,
Overfrequency indicating or malfunctioning
light (DS40) ON
(1) Governor improp- (1) Adjust in accordance with
erly adjusted Sect. 2-3, Para. 3, E, (3).
(2) Electric governor (2) Check and adjust or re-
system malfunc- pair in accordance with
tioning ENGINE AND CONTROLS,
Troubles 8 and 9.
B. Defective over-under- B. If overfrequency nuisance
frequency sensing tripping continues after the
module (K27) governor system is proven to be
good, and an overfrequency con-
dition does not exist, replace the
toverunder frequency module (K27).

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
PROTECTIVE CIRCUIT (CONTINUED)
4. Load contactor A. Electric governor A. Proceed as follows:
opens during power improperly adjusted,
delivery. Under- or malfunctioning
frequency light ON.
(1) Governor improp- (1) Adjust in accordance
erly adjusted with Sect. 2-3, Para. 3, E, (3).
(2) Electric governor (2) Check and adjust or re-
system malfunc- pair in accordance with
tioning ENGINE AND CONTROLS,
Troubles 8 and 9.
B. Defective over-under- B. If overfrequency nuisance
frequency sensing tripping continues after the
module (K27) governor system is proven to
be good, and an underfrequency
condition does not exist, replace
over-under-frequency relay.
5. Load contactor A. There may have been A. Observe ammeter (3, Fig. 1).
opens during power an overload condition Check for abnormal overload
delivery. Over- which caused the condition and correct. If
frequency indi- overload device (K4) overload device functions to
cating light ON. to function normally. open the load contactor when
an overload does not exist,
proceed to step B.
B. One of the resistors B. An open resistor will cause
(R26, R27, or R28) a higher than normal volt-
across overload age. Refer to Schematic/
transformers is open Connection diagram for exact
circuited. location of these resistors
Check resistors. Replace if
defective.
C. Overload device C. Replace overload module (K4)
printed circuit board (Sect. 1-1; 5, Fig. 7) with
defective an overload module known to
be operating properly.

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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.
B. Open or shorted exci- B. Use ohmmeter to check for
ter rotor winding open or shorted condition.
(G2) If exciter rotor windings
are good, proceed to step C.
C. Open or shorted exci- C. Check field resistance. See
ter field windings (L2) Sect. 2-3, Fig. 6 for normal values.
D. Open or shorted gen- D. Check resistance with ohm-
erator rotor windings meter to determine if open
(L1) or short circuited.
2. Generator operates A. Open or short cir- A. Check stator winding resis-
single phase cuited winding in tances. See Sect. 2-3, Fig.
generator stator (G1) 6 for normal values.
3. Generator A. Loose connection A. Check all output connec-
overheats causing high resis- tions. Look for discolora-
tance. tion caused by heat. Tighten
or replace as required.
B. Improper or blocked B. Check for foreign material
ventilation. (rags, etc.) blocking air flow.
Provide adequate ventilation.
C. Generator stator C. Check stator windings. See
windings short circuited. Sect. 2-3, Fig. 6.
4. Unbalanced output A. Loose connection in A. Check all output connec-
output circuit. tions. Discolored connectors
indicate a loose connection.
Tighten or replace as required.
B. Open or short circuited B. Check stator windings in
phase accordance with 2-3, Para. 5
Repair or replace as required.

EXTERNAL LOAD
4. Unbalanced output C. Defective connection C. Check plug and receptacle
(Continued) in output circuit. connectors at aircraft.
Tighten, repair, or replace
as required.
D. Break or cut in out- D. Inspect. Repair or replace
put cable assembly. as required.
E. Unbalanced load E. Check aircraft 400-Hz compo-
nents.

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CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION

1. General
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 Specification No. 7009-1, Specification No.
7009A-1, and Specification No. 7009B-1.

2. 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.

3. Arrangement
Chapter 4 is arranged as follows:

Section 1 - Introduction

Section 2 - Manufacturer’s Codes

Section 3 - Parts List

Section 4 - Numerical Index

4. Explanation of Parts List

A. Contents

The parts list contains a breakdown of the equipment into assemblies, subassemblies, and detail parts.
All parts of the equipment are listed except:

(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are avail-
able commercially.
(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.
(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to
other parts, weldments, or assemblies.

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B. Parts List Form

This form is divided into six columns. Beginning at the left side of the form and proceeding to the right,
columns are identified as follows:

(1) FIGURE-ITEM NO. Column

This column lists the figure number of the illustration applicable to a particular parts list and also
identifies each part in the list by an item number. These item numbers also appear on the illustra-
tion. Each item number on an illustration is connected to the part to which it pertains by a leader
line. Thus the figure and item numbering system ties the parts lists to the illustrations and vice
versa. The figure and index numbers are also used in the numerical index to assist the user in
finding the illustration of a part when the part number is known.

(2) HOBART PART NUMBER Column

ALL part numbers appearing in this column are Hobart numbers. In all instances where the part is
a purchased item, the vendor’s identifying five-digit code and his part number will appear in the
NOMENCLATURE column. Vendor parts which are modified by Hobart will be identified as such
in the NOMENCLATURE column. In case Hobart does not have an identifying part number for a
purchased part, the HOBART PART NUMBER column will reflect No Number and the vendor’s
number will be shown in the NOMENCLATURE column. Parts manufactured by Hobart reflect no
vendor code or part number in the NOMENCLATURE column.

(3) NOMENCLATURE Column

The item identifying name appears in this column. The indenture method is used to indicate item
relationship. Thus, components of an assembly are listed directly below the assembly and in-
dented one space. Vendor codes and part numbers for purchased parts are shown in this column.

(4) REC. SPARES Column

When there is an entry in this column, it shows the quantity of that item recommended for spares
to support ONE end item.

(5) “EFF” (Effective) Column

This column is used to indicate the applicability of parts to different models of equipment. When
more than one model of equipment is covered by a parts list, there are some parts which are
used on only one model. This column is used for insertion of a code letter “A”, “B”, etc., to indicate
these parts and to identify the particular model they are used on. Since this manual covers only
one model, this column is not used in this manual.
UNCODED PARTS ARE USABLE ON ALL MODELS:
Parts coded “A” are usable on Specification 7009-1 only
Parts coded “B” are usable on Specification 7009A-1 only
Parts coded “C” are usable on Specification 7009B-1 only

(6) UNITS PER ASSEMBLY Column

This column indicates the quantity of parts required for an assembly or subassembly in which the
part appears. This column does not necessarily reflect the total used in the complete end item.

4-1 December 31/91 Revised

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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. Vendor codes are inserted in the
nomenclature column of the parts list directly following the item name and description. In case a manufac-
turer does not have a vendor code, the full name of the manufacturer will be listed in the nomenclature col-
umn.

CODE VENDOR’S NAME AND ADDRESS

00779 AMP Inc. P.O. Box 3608 Harrisburg, Pennsylvania 17105

01428 Superior Ball Joint Corporation 1202 South Quality Drive P.O. Box 227
New Haven, IN 46774

01843 American Bosch Marketing Div. of Ambac Industries Inc. 3664 Main Street
Springfield, Mass. 01107

02231 Anchor Rubber Company 840 South Patterson Boulevard P.O. Box 832
Dayton, OH 45401

02660 Amphenol Division Bunker-Ramo Electra Corp. 2801 S. 25th Avenue

Broadview, IL 60153

03613 Barber-Colman Co. 1354 Clifford Ave. Loves Park, IL 61132

03924 StratoFlex, Inc. 2nd and Piper Sts., Baer Field Box 9190, Waynedale Station
Ft. Wayne, IN 46809

04713 Motorola Inc. Semiconductor Products Div. Phoenix, Arizona 85008

05277 Westinghouse Electric Corp. Semi Conductor Div., Hill Street

Youngwood, Pennsylvania 15697

08108 Lamp Industries For Use With Industry Designations & Abbreviations for Lamps

13446 Perkins Engines Inc., 32500 Van Bon Road, P.O. Box 697, Wayne, Michigan 48184

15605 Eaton Corporation Cutler-Hammer Div. 4201 N. 27th St.

Milwaukee, Wisconsin 53216

16238 Lord Mfg. Co. Inc. Sterling Road South Lancaster, Massachusetts 01561

16764 General Motors, Corp. Delco-Remy Division 2401 Columbus Ave. P.O. Box 2439
Anderson, IN 46018

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CODE VENDOR’S NAME AND ADDRESS

18265 Donaldson Co. Inc. 400 W. 94th St. P.O. Box 1299 Minneapolis, MN 55440

19220 Eberhard Manufacturing Company 21944 Drake Road Strongsville, OH 44136

20038 ESB Inc. 5 Penn Center Plaza P.O. Box 8109 Philadelphia, Pennsylvania 19101

20598 Tech. Products 105 Willow Ave. Staten Island, N.Y. 10305

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

22938 Prototype Development, Inc. 7750 Hub Parkway Cleveland, OH 44125

24248 Southco Inc. 210 N. Brinton Lake Road Concordville, PA 19331

26403 ITT - Grinnell Corp. 260 W. Exchange St. Providence, RI 02901

27192 Eaton Corporation Power Control Operations 4265 N. 30th St.

Milwaukee, WI 53216

28520 Heyman Mfg. Co. 147 Michigan Ave. P.O. Box 160 Kenilworth, NJ 07033

30327 Imperial Clevite Inc. Fluid Components Division 6300 W. Howard Street
Chicago, IL 60648

31337 Parker Metal Corp. 85 Prescott Street Worchester, MA. 01605

31356 J-B-T Instruments, Incorporated 394 East Street P.O. Box 1818
New Haven, Connecticut 06508

31361 Woodward Governor Company, 1000 E. Drake Road, P.O. Box 1519,
Ft. Collins, Colorado 80522

35708 Tridon Limited P.O. Box 1600 Nashville, TN 37202

41197 Modine Manufacturing Company 1500 Dekoven Avenue Racine, Wisconsin 53401

44655 Ohmite Manufacturing Company 3601 West Howard Street Skokie, Illinois 60076

49234 Protectoseal Co. 225 W. Foster Ave. Bensenville, IL 60106

50508 Magnetic Components Inc. 9520 Ainslie St. Schiller Park, Illinois 60176

50603 H.B. Electrical Mfg. Co. Inc. 1125 National Pky. Mansfield, OH 44906

4-2 December 31/91

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CODE VENDOR’S NAME AND ADDRESS

51377 Kysor of Caddilac 1100 Wright St. Cadillac, MI 49601

51589 ST - SEMICON, INC. 415 N. College Ave. Bloomington, IN 47401

57448 Allis Chalmers Corp. Stevens & Adamson Mfg. Subsidiary 275 Ridgeway Avenue,
P.O. Box 1367 Aurora, IL 60507

57733 Stewart-Warner Corporation 1826 Diversey Parkway Chicago, IL 60614

60741 Triplett Electrical Instrument Company 286 Harmon Road Bluffton, Ohio 45817

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. 571 W. Polk Street Chicago, IL 60607

71400 Bussman Mfg. Division of McGraw Edison Company 114 Old State Rd.
P.O. Box 14460 St. Louis, Missouri 63178

71744 General Instrument Corp. Miniature Lamp Div., Worldwide 443 N. Ravenswood Ave.
Chicago, IL 60640

73559 Carlingswitch, Inc. 505 New Park Ave. West Hartford, Connecticut 06110

74400 Stewart Warner Corp, Hobbs Div. Ash Street & Yale Boulevard
Springfield, Illinois 62705

75175 K-D Lamp Company 1910 Elm St. Cincinnati, OH 45210

75358 Knape & Vogt Manufacturing Company 2700 Oak Industrial Drive
Grand Rapids, Michigan 49505

77342 Potter and Brumfield Division AMF Inc. 200 Richland Creek Drive
Princeton, Indiana 47670

78225 Stant Manufacturing Company Inc. 1620 Columbia Avenue.

Connersville, Indiana 47331

78388 Synchro - Start Products, Inc. Sub. of Knowles Electronics, Inc. 8109 N. Lawndale Ave.
P.O. Box 147 Skokie, IL 60076

December 31/91 4-2

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CODE VENDOR’S NAME AND ADDRESS

79470 Dana Corp., The Weatherhead Division 767 Beta Drive Cleveland, OH 44143

80183 Sprague Products 87 Marshall Street North Adams, MA. 01247

81074 ITT - Holub Industries 413 Elm Street Sycamore, Illinois 60178

81518 Flexaust Co. Div. of Callahan Mining Co. 11 Chestnut St. Amesbury, MA 01913

81860 Barry Controls Division of Barry Wright Corp. 700 Pleasant Street
Watertown, Massachusetts 02172

82121 Electro - Switch Corp. 180 King Ave. Weymouth, MA 02188

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. Plastic Products Division 312 N. Hill St. Mishawaka, Indiana 46544

90201 Emhart Ind. Inc. Mallory Capacitor Co. 4760 Kentucky Ave. P.O. Box 372
Indianapolis, Indiana 46206

90763 TRW Inc. United-Carr Div. 10544 West Lunt Ave. Rosemont, Illinois 60018

91637 Dale Electronics Incorporated P.O. Box 609 Columbus, Nebraska 68601

91929 Micro Switch Division Honeywell Inc. 11 W. Spring Street Freeport, Illinois 61032

92563 McGill Manufacturing Company, Inc. Bearing Division 909 N. Lafayette

Valparaiso, Indiana 46383

94222 Southco Inc. 210 N. Brinton Lake Road Concordville, PA 19331

95879 Alemite Instrument Division of Stewart-Warner Corporation 1826 Diversey Parkway

Chicago, IL 60614

98738 Stewart-Warner Electronics Div. of Stewart-Warner Corp. 1300 N. Kostner

Chicago, IL 60651

98991 Worchester Controls Corp. Worchester Valve Division 125 Hartwell Street
West Boyleston, Massachusetts 01583

No Number Modine Manufacturing Co. 1500 Dekoven Avenue Racine, WI 53401

4-2 December 31/91

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SECTION 3. PARTS LIST

1. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a lefthand page and the applicable parts list
will appear on the opposite righthand page. Unless the list is unusually long, the user will be able to look
at the illustration and read the parts list without turning a page.

2.Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list.
* - item not illustrated
A, or AMP - ampere
AC - alternating current
AR - as required
DC - direct current
Fig. - Figure
hd. - head
hex - hexagon
Hz - Hertz (cycles-per-second)
I.D. - inside diameter
IN - inch
kVA - kilovolt-ampere
uF - microfarad
No. - number
NHA - next higher assembly
OM - Owners Manual
PRV - peak reverse voltage
PSI - pounds per square inch
Ref - reference (the item has been listed previously)
T-R - transformer-rectifier
V - volt (when used as a prefix to a five-digit number, indicates vendor code)

NOTE: An item which does not reflect an index number is an assembly which is not illustrated in
its assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated.

July 16/96 Revised 4-3

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Generator Set
Figure 1

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

1- 7009-1 GENERATOR SET FOR TRAILER OR

TRUCK MOUNTING A 1
7009A-1 GENERATOR SET FOR TRAILER OR
TRUCK MOUNTING B 1
7009B-1 GENERATOR SET FOR TRAILER OR
TRUCK MOUNTING C 1
1 No Number . CANOPY ASSEMBLY
(For Details See Fig. 2) A 1
No Number . CANOPY ASSEMBLY
(For Details See Fig. 2) BC 1
2 No Number . GENERATOR SET WITHOUT
CANOPY (For Details See Fig. 3) 1
3 No Number . FRAME GROUP (For Details See Fig. 3) 1
4 402987 . LABEL, HOBART 3
*5 280718 . TRAILER, FENDERS, FUEL TANK
(OPTION) A 1
281056 . TRAILER, FENDERS, FUEL TANK
(OPTION) BC 1

* NOT ILLUSTRATED

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Canopy Assembly
Figure 2

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

2- NO NUMBER CANOPY ASSEMBLY (For NHA See Fig. 1) A REF

NO NUMBER CANOPY ASSEMBLY (For NHA See Fig. 1) BC REF
1 280583 . PANEL, FRONT A 1
281074 . PANEL, FRONT BC 1
2 280635 . PANEL, REAR A 1
281115 . PANEL, REAR BC 1
3 280559 . SUPPORT, CNTR., CANOPY A 1
281114 . SUPPORT, CNTR., CANOPY BC 1
4 281040 . TOP, CANOPY A 1
281104 . TOP, CANOPY BC 1
5 280591 . PANEL, LOUVERED, ASSY. 1
6 280575 . DOOR, CANOPY, ASSY. A 3
281071 . DOOR, CANOPY, ASSY. BC 2
7 280579 . DOOR, CANOPY, L.R. A 1
* 281096 . DOOR, CANOPY, L.R. BC 1
8 482401 . COVER, GENERATOR CONTROL A 1
281093 . COVER, GENERATOR CONTROL BC 1
9 489030 . COVER, ENGINE CONTROLS A 1
281574 . COVER, ENGINE CONTROLS BC 1
10 281109 . DOOR, CANOPY, R.R. BC 1
11 181125 . LATCH, DOOR A 7
181125 . LATCH, DOOR BC 8
*12 280646 . BAFFLE, HEAT A 1
*13 281102 . BAFFLE, HEAT BC 1
*14 403153-1 . BUMPER, RUBBER 1
*15 78A-1000 . LABEL, ID 1
*16 79A-1110 . LABEL, OPTION 1
*17 76B-1148 . LABEL, DIESEL FUEL 1
*18 430077-2 . LABEL, HANDLING 1
*1 9 280606 . CLAMP, CABLE, OUTPUT 1

* NOT ILLUSTRATED

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Generator Set Without Canopy

(Specification 7009B-1 Illustrated)
Figure 3

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

3- No Number GENERATOR SET WITHOUT CANOPY

(For NHA See Fig. 1) REF

1 No Number . GENERATOR GROUP (For Details See Fig. 13) 1

2 282871-1 . BATTERY,12 VOLTS (For Details See Fig. 9A) BC 1
* 402086-2 . BATTERY,12 VOLTS (For Details See Fig. 9) A 2
3 280543-2 . BOX ASSEMBLY, CONTROL, GENERATOR
(For Details See Fig. 10) 1
4 282671 . KIT, ELECTRICAL GOVERNOR, ASSY,
(For Details See Fig. 6A) BC 1
* 488701 . KIT, ELECTRICAL GOVERNOR, ASSY,
(For Details See Fig. 6) A 1
*5 386612 . RING, SPCR., COUPLING 1
6 281035 . KIT, AIR CLEANER, ASSY.
(For Details See Fig. 5) 1
7 280861 . FRAME, MOUNTING 1
8 80B-1107 . ENGINE ASSEMBLY, PERKINS DIESEL,
V13446, No. 6.3544 1
9 No Number . RADIATOR AND COOLING SYSTEM GROUP
(For Details See Fig. 4) 1
10 281050 . MUFFLER, ASSEMBLY 1
11 281041-1 . PIPE, EXHAUST, ASSY 1
12 180404 . SUPPORT, MUFFLER, LH 1
*13 180405 . SUPPORT, MUFFLER, RH 1
14 DDW-495-1 . CAP, RAIN 1
*15 488908 . FAN & FLEX. COUPLING ASSY. 1
*16 404154-15 . CLAMP, FULL CIRCLE 1
17 280542-1 . PANEL ASSEMBLY, CONTROL, ENGINE
(For Details See Fig. 11) 1
18 281118 . PANEL, SUPPORT, CONTROL BOX 1
19 281116 . LEG, SUPPORT, CONTROL BOX 2
*20 HF-2752 . MOUNT, RUBBER, (4 For mounting control
box to control box support panel, and 4
for mounting muffler assembly), V16238,
No. 4624-105 4
*21 488735-1 . MOUNT, ENGINE, LEFT 1
*22 488735-2 . MOUNT, ENGINE, RIGHT 1
*23 281013 . LINES, FUEL, ASSEMBLY (For Details See
Fig. 7) A 1
281013A . LINES, FUEL, ASSEMBLY (For Details See
Fig. 7) BC 1
*24 488695 . LINE, OIL, ASSEMBLY (For Details See Fig. 8) 1

* Not Illustrated

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4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

3- (CONTINUED)
25 280722B . PANEL, CONTACTOR, ASSY.
(For Details See Fig. 12) 1
26 281117 . LEG, SUPPORT, CONTROL BOX BC 1
27 280914 . SHROUD, AIR, ASSY. 1
*28 84A-1101 . KIT, STARTER, SPACER 1

* NOT ILLUSTRATED

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Radiator and Cooling System Group

Figure 4

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

4- No Number RADIATOR AND COOLING SYSTEM GROUP

(For NHA See Fig. 3) REF
1 180954 . RADIATOR 1
2 280054 . SUPPORT, RADIATOR 2
3 405743 . CAP, RADIATOR, 7 LB., V78225, NO.AAX-4018 1
4 281031 . SHROUD, FAN, ASSEMBLY 1
5 280942 . GUARD, FAN, LEFT 1
6 280941 . GUARD, FAN, RIGHT 1
7 W-10869-3 . CLAMP, HOSE 2
8 W-10869-7 . CLAMP, HOSE, V35708, NO. HS-12 2
9 56531 . HOSE, RADIATOR, OUTLET 46"
10 56532 . HOSE, RADIATOR, INLET 17"
*11 386751 . CLAMP, OVERFLOW HOSE 2
* 12 402433 . CLAMP, HOSE 1
* 13 403782-2 . SWITCH, SHUTDOWN, TEMPERATURE,
V51377, NO. 1002-04880-34 1
*14 W-7814-4 . BUSHING, PIPE, STEEL 1

* NOT ILLUSTRATED

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Air Cleaner Assembly

Figure 5

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

5- 281035 KIT, AIR CLEANER, ASSY

(For NHA See Fig. 3) REF
1 181128 . CLEANER, AIR 1
2 403483 . CLAMP, HOSE 2
3 281036 . PIPE, AIR INTAKE, ASSY. 1
4 85A-1045 . REDUCER, RUBBER 1
5 W-10869-6 . CLAMP, HOSE 1
6 181129 . CLAMP, AIR CLEANER 2
*7 281034 . BRACKET, MTG., AIR CLEANER 2
*8 402321-1 . SCREW, 1/4-20 X 1/2, HWH, TAP TITE 3
*9 402119-2 . SCREW, 1/4-20 X 1/2, HHC, ST. 2
* 10 W-11254-4 . WASHER, LK, STD, 1/4 2
* 11 W-11278-7 . NUT, 1/4-20, HEX, FULL, ST. 2

* Not Illustrated

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Electric Governor Kit (Woodward Governor)

Figure 6

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

6- 488701 KIT, ELECTRIC GOVERNOR, ASSY * *

(WOODWARD GOVERNOR)
(For NHA See Fig. 3) REF
1 281774-2 . SENSOR, MAGNETIC, GOVERNOR 1
2 84A-1009 . CONTROLLER, GOVERNOR, ELECTRIC
V31361, No. 8290-040 1
3 84A-1020 . ACTUATOR, GOVERNOR, ELECTRIC
V31361, No. 8256-017 1
4 84A-1091 . ARM, THROTTLE, GOVERNOR, V31361
No. 3952027 1
5 DELETED
6 W-9476-11 . ROD, THREADED 1/4-28 x 4-3/4" 1
7 W-11280-3 . NUT, JAM, HEX, 1/4-28 5
8 488692 . BRACKET, MTG. ACTUATOR 1
*9 285202 . PLATE, MOUNTING, LINKAGE 1
*10 84A-1075 . MOUNT, SHOCK, RUBBER 4
*11 482989 . STRAP, WIRE, GROUND 2
*12 50MS-732-0 . NUT, 1/4-20, HEX, KEPS, ST. 1
*13 405071-1 . SCREW CAP, HEX-HEAD, M8 1

* NOT ILLUSTRATED

* * This governor assembly used on units manufactured prior to November, 1991.

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Electric Governor Kit (Barber-Colman Governor)

Figure 6A

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

6A - 282671 GOVERNOR ASSY. (For NHA See Fig. 3) * * REF

1 281772 . ACTUATOR, GOVERNOR, ELECTRIC
V03613,No. DYNC-10502-000-0-12 1
2 282501 . CONTROLLER, GOVERNOR, ELECTRIC
V03613,No. DYN1-10704 1
3 282673 . BRACKET, MTG. ACTUATOR 1
4 282674 . BRACKET, MTG. ACTUATOR 1
5 281776 . JOINT, BALL, GOVERNOR LINKAGE 2
6 281775 . CLEVIS, ACTUATOR ROD 1
7 281774-2 . SENSOR, MAGNETIC, GOVERNOR 1
8 W-9476-11 . ROD, THREADED 1/4-28 x 4-3/4" 1
9 401937-2 . BLOCK, TERMINAL 1
10 W-11280-3 . NUT, JAM, HEX, 1/4-28 3
*11 84A-1075 . MOUNT, SHOCK, RUBBER 4
*12 482989 . STRAP, WIRE, GROUND 2

* Not Illustrated

* * This governor assembly used on units manufactured after November, 1991.

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Fuel Lines Assembly

Figure 7

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

7- 281013 LINES, FUEL, ASSEMBLY (For NHA See Fig. 3) A REF

281013A LINES, FUEL, ASSEMBLY (For NHA See Fig. 3) BC REF
1 400818-1 . BUSHING, PIPE, STEEL 1
2 400819-2 . VALVE, BALL (ECON-O-MITE) 1
3 W-7814-1 . BUSHING, PIPE, STEEL, 3/4 X 1/8 BC 1
4 W-10891-7 . ELBOW, MALE, WEATHERHEAD, V79470,
No. 49 X 4 1
5 W-10893-2 . FITTING, HOSE, SWIVEL, FEMALE SAE 45
FLARED, V30327, No. KAO4-04NS 2
6 56534 . HOSE, LOW PRESSURE, 1/4 I.D. A 83"
56534 . HOSE, LOW PRESSURE, 1/4 I.D. BC 92"
7 78B-1019-2 . TUBE, RIGID, HOSE, END 1
8 84A-1007-1 . FITTING, HOSE, MALE 1
9 W-10869-14 . CLAMP, HOSE BC 1
*10 W-10051-6 . CLAMP, HOSE BC 2
11 56587 . HOSE, RUBBER BC 40"
12 78B-1019-3 . TUBE, RIGID, HOSE END 1
13 W-10886-2 . CONNECTOR, MALE, SAE-45, FLARED BRASS 1
14 W-7814-3 . BUSHING, PIPE, STEEL 1
*15 W-7814-10 . BUSHING, PIPE, STEEL, 3/4 X 1/8 A 1
*16 W-10901-3 . NUT, COMPRESSION, BRASS A 2
*17 W-10905-6 . SLEEVE, COMPRESSION, BRASS A 2
*18 79B-1022 . BOLT, BANJO CONNECTION A 2
*19 78A-1023 . WASHER, BANJO CONNECTION A 4
*20 78B-1021 . FITTING, CONNECTION, BANJO A 2
*21 30523 . TUBING, COPPER, BARE A 25"
*22 W-10905-2 . SLEEVE, COMPRESSION, BRASS A 1
*23 W-10901-2 . NUT, COMPRESSION, BRASS A 1

* Not Illustrated

All parts unmarked are furnished with engine.

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Oil Line Assembly

Figure 8

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

8- 488695 LINE, OIL, ASSEMBLY (For NHA See Fig. 3) REF

1 403809-1 . SWITCH, LOW OIL PRESSURE V51377,
No. C-25900-10 1
2 W-10909-1 . TEE, STREET, BRASS V79470 1
3 W-10886-1 . CONNECTOR, MALE, WEATHERHEAD
V79470, No. 48 X 4 1
4 403590-1 . SWIVEL, FEMALE, 7/16-20 SAE THDS
V03924 No. 7115-4S 2
5 56548 . HOSE, #4, 3/16 ID 51"

*NOT ILLUSTRATED

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Battery Installation
For units having
TWO batteries
Figure 9

Battery Installation
For units having
ONE battery
Figure 9A

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

9- NO MUMBER BATTERY INSTALLATION (For NHA See Fig. 3)

(For units having TWO batteries) A REF
1 402086-2 . BATTERY, 12 VOLTS 2
2 280952 . TRAY, BATTERY 2
*2A A-25 . SPACER, BATTERY TRAY 8
3 280951 . CLAMP, HOLDOWN, BATTERY 2
4 280619-1 . CABLE, POSITIVE 1
5 280618-1 . CABLE, NEGATIVE 1
6 5CW-2048 . ROD, BATTERY, SUPPORT, ASSY 3
*7 482496-1 . CLAMP, HARNESS, WIRE 1
*8 W-9407-138 . CABLE, ENGINE TO GROUND 1

* NOT ILLUSTRATED

NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

9A- NO MUMBER BATTERY INSTALLATION (For NHA See Fig. 3)

(For units having ONE battery) BC REF
1 281871-1 . BATTERY, 12 VOLTS 1
2 181825 . TRAY, BATTERY 1
*2A A-25 . SPACER, BATTERY TRAY 8
3 181831 . FRAME, HOLD-DOWN, BATTERY 1
4 388827-14 . CABLE, POSITIVE 1
5 388828-9 . CABLE, NEGATIVE 1
*6 5CW-2048 . ROD, BATTERY, SUPPORT, ASSY 2
*7 482496-1 . CLAMP, HARNESS, WIRE 1
*8 W-9407-138 . CABLE, ENGINE TO GROUND 1

* NOT ILLUSTRATED

July 16/96 Revised 4-3

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Control Box Assembly

Figure 10

4-3 December 31/91 Revised

Page 24

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

10- 280543-2 BOX, CONTROL, ASSEMBLY

(For NHA See Fig. 3) REF
1 401937-3 . STRIP, TERMINAL V98410, No. 35012-3526 2
2 401564-4 . HOUSING, SOCKET, CONNECTOR, V89110,
No. 1-480287-0 4
3 489811 . BOARD, PC, VOLTAGE REG., 400 HZ 1
4 404065-2 . RECTIFIER, SILICON, V04713, No. SDA-10270-2 1
5 404402-2 . RESISTOR, OVERLOAD BURDEN, 25 WATT,
V91637, No. RH-25 3
6 16DA-4004A-10 . RELAY, PLUG-IN, 12 V. DC, V77342,
No. KAP-14D G-12 3
7 16DA-4052-0 . SOCKET, RELAY, V02660, No. 77-MIP-11 4
8 370891 . BRACKET, MTG., SOCKET, RELAY 2
9 16DA-4253-1 . RETAINER, SPRING, RELAY, V77342, No.
(KAP)20C206 4
10 400785-7 . RIVET, BLIND, DOMED HEAD, ST. 8
11 484689-1 . SLEEVING, PLASTIC, 1/8 I.D. 12"
12 484690-2 . SLEEVING, PLASTIC, 3/16 I.D. 9"
13 ICZ-93B . DIODE, SILICON, FLY-BACK, V05277,
No. IN4820 4
14 400030-1 . CAPACITOR, TANTALUM, 6.8 MFD, 35 V.,
V80183, No. 150D685X9035B2 1
15 16DA-4004A-3 . RELAY, PLUG-IN, 24 VOLT D.C., V77342,
No. K10-14DG-24 1
16 280534 . BOTTOM, CONTROL BOX 1
17 482038 . BOARD, PC, OVER-UNDERVOLTAGE, ASSY. 1
18 401556 . MOUNT, SHOCK, RUBBER, V81860, No. SS-01 16
19 387738A . BOARD, PC, OVERLOAD, 12 VOLT, ASSY. 1
20 404460-1 . SUPPORT, LOCKING, PC BOARD 4
21 482039 . BOARD, PC, OVER-UNDERFREQUENCY, ASSY. 1
22 387736C . BOARD, PC, MEMORY & TIME DELAY, ASSY. 1
23 401564-5 . HOUSING, SOCKET, CONNECTOR, V89110,
No. 1-480438-0 1
24 280531 . PANEL, CONTROL, BOX 1
25 W-9916-10 . METER, FREQUENCY, V31356, No. 36-FX 1
26 W-8105A-4 . VOLTMETER, V60741, No. 331LH 1
27 W-8095A-8 . AMMETER, V60741, No. 331LH 1
28 15GH-433 . NAMEPLATE, METER SELECTOR SWITCH 1
29 HF-1459 . SWITCH, METER SELECTOR, V82121,
No. 101904LN 1
30 400400 . SWITCH, LINE, DPDT, V73559, No. 26L61TABS 1
31 180913-4 . LIGHT, PILOT, FAULT, RED, 12 V., ASSY. 5
404172-1 . . LENS (RED) 1
400613-4 . . BULB, 12-16 VOLTS 1

July 16/96 Revised 4-3

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4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

10- (CONTINUED)
32 76A-1118 . SWITCH, SNAP, PUSHBUTTON, V27192,
No. SA35BCB34-9 2
33 482291 . NAMEPLATE, PROTECTIVE SYSTEM 1
34 ICZ-148 . TRANSFORMER, CURRENT, LINE DROP &
OVERLOAD, V50508, No. E-6170 6
35 405154-5 . RESISTOR, BALLAST, 100 WATT 1
36 430340 . CHASSIS, LINE DROP COMPENSATION 1
37 401564-3 . HOUSING, SOCKET, CONNECTOR, V89110,
No. 1-480285-0 1
38 W-9746-3 . RESISTOR, 100 OHM, 25 WATT, V44655,
No. 0200F 1
39 W-9746-1 . RESISTOR, LINE DROP BURDEN, 50 OHM,
25 W, V44655, No. 0200D 3
40 363136-2 . TRANSFORMER, CURRENT, AMMETER 3
41 402037-9 . GROMMET, RUBBER, V02231, No. AGW-4211 1
42 402658 . HOLDER, FUSE, V71400, No. HKP-HH 2
43 W-11166-1 . FUSE, AGC., 2 AMP 2
44 82B-1047 . LIGHT, PANEL, V74400, No. MI-3216 1
400613-4 . BULB, V74400, No. 3271 1
45 402662 . SWITCH, AIRCRAFT/TEST BANK, DPST, V73559,
No. 2GK71-73 1
46 402826 . SWITCH, REGULATOR/DIAGNOSTIC, 4PDT,
V15605, No. 8926K425 1
47 280590 . BRACKET, MTG., SWITCHES 1
48 400078 . BRACKET, MTG., RESISTOR 2
49 403336 . RING, LOCKING, SWITCH, V91929, No. TS10397 2
50 403091-6 . BUTTON, PLUG, HOLE 1
51 402665-1 . HOUSING, RECEPTACLE, V00779, No. 1-480416-0 6
52 489658-5 . DIODE, ASSY. 1

July 16/96 Revised 4-3

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Engine Control Panel Assembly

Figure 11

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

11- 280542-1 PANEL ASSEMBLY, CONTROL, ENGINE

(For NHA See Fig. 3) REF
1 280545 . PANEL, CONTROL, ENGINE 1
2 280612 . NAMEPLATE, CONTROLS 1
3 82B-1047 . LIGHT, PANEL, 12 VOLT 1
4 FW-1312 . SWITCH, TOGGLE, DPST V27192, No. 7320K3 1
5 Y-680 . AMMETER 1
6 403189 . SWITCH, TOGGLE, V91929, No. 312TS1-59 3
7 W-9917-18 . METER, ENGINE, HOUR V16476, No. 771-8/50 1
8 30GH-764 . GAUGE, TEMPERATURE, WATER 1
9 180913-1 . LIGHT, PILOT, ENGINE & GENERATOR,
GREEN, 12 VOLT 2
10 82A-1030 . GAUGE, PRESSURE OIL 1
11 403091-5 . BUTTON, PLUG, HOLE 1
12 400701 . CONNECTOR, RIGHT ANGLE 2
13 401937-2 . STRIP, TERMINAL, V98410, No. 35008-3526 1
14 404100 . SWITCH, PUSHBUTTON, STARTER,
V70040, No. 1996097 1
15 25MS-156 . BUS, JUMPER 1
16 20RT-353-1 . DIODE, NEGATIVE BASE, 16 AMP 1
17 W-11166-3 . FUSE, AGC, 10 AMP 1
18 402658 . HOLDER, FUSE, V71400, No. HKP-HH 1
19 12CW-1320A-5 . GAUGE, FUEL, ELECTRIC, V57733, No. 455-BK 1
20 400059-3 . FITTING, TUBE, CONNECTOR 1
21 12CW-2125 . FITTING, PIPE, STREET ELL, 45 1

July 16/96 Revised 4-3

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Contactor Panel Assembly

Figure 12

4-3 Revised
Page 30 March 30/93

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

12- 280722C CONTACTOR PANEL ASSEMBLY

(For NHA See Fig. 3) REF
1 280723C . PANEL, CONTACTOR 1
2 402119-4 . SCREW 1/4 - 20 X 3/4, HHC, ST. 3
3 282130-1 . CONTACTOR, 3-POLE 1
4 402119-8 . SCREW, 1/4 - 20 x 1-1/2, HHC, ST. 1
5 A-25 . WASHER, INSULATING 2
6 DW-1704 . BUSHING 1
7 W11242-5 . WASHER, FLAT, ST., 1/4 5
8 W-11254-4 . WASHER, LOCK, 1/4, ST. 5
9 W-11280-2 . NUT, HEX, 1/4 - 20, ST 2
10 W-11097-8 . SCREW, 3/8 - 16 x 2, HHC, ST. 1
11 W-11242-10 . WASHER, FLAT, ST., 3/8 1
12 W-11254-8 . WASHER, LOCK, ST., 3/8 1
13 W-11278-5 . NUT, HEX, 3/8 - 16 2
14 W-11263-6 . WASHER, LOCK, , IET, ST., 3/8 2

Revised 4-3
March 25/93 Page 31

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Generator Group
Figure 13

4-3 December 31/91 Revised

Page 32

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

13- 280786 GENERATOR ASSY (For NHA See Fig. 3) REF

1 387617A . COVER, FAN, HOUSING 1
2 DELETED
3 488908 . FAN & COUPLING ASSEMBLY 1
** 3A W-11102-19 . SCREW, FLEXIBLE COUPLING 6
**4 482483 . SCREW, RETAINING 1
5 480669 . ADAPTER, FOOT, GEN. REF
*6 W-11102-8 . SCREW, GEN. MTG. 6
7 488755 . COVER, END, EXCITER HOUSING 1
8 100GHP-66 . WASHER, RETAINING 1
9 387623-1 . CORE, ARMATURE ASSEMBLY 1
10 W-10875-1 . . DIODE, SILICON, 35 AMP, NEGATIVE BASE,
V51589, #ST460N 3
11 W-10874-1 . . DIODE, SILICON, 35 AMP, POSITIVE BASE,
V51589, #ST460P 3
12 180927 . RING, SPACER, COUPLING 1
12A 402789-3 . . SCREW, SPACER RING 8
13 481379 . KEY, EXCITER 1
14 387624A-1 . HOUSING, EXCITER 1
15 100NH-2 . POLEPIECE, EXCITER 4
16 100NH-3 . INSULATION, EXCITER, WRAPPER 4
17 489180 . COIL, FIELD, EXCITER 1 SET
18 387620A-1 . HOUSING, FAN ASSEMBLY 1
19 85B-1039 . KEY, FLEXIBLE, COUPLING 1
20 W-10072-48 . BEARING, FRONT, V53035, #6314DDUG3E1SR1S 1
21 W-10072-1 . BEARING, REAR, V53035, #6310DDUC3ESR1S 1
22 181346 . ARMATURE, AC/DC 1
23 387748-1 . HOUSING & STATOR ASSEMBLY 1
24 481940 . BRACKET, RETAINING BEARING 1
*25 385950 . INSULATION, TOE 16
*26 480603-1 . MOUNT, RUBBER 6
*27 480628 . WASHER, MOUNT 6
*28 79A-1144 . NAMEPLATE, FAN & COUPLING 1

* NOT ILLUSTRATED
** DO NOT SUBSTITUTE - REQUIRES 5/8 - 11 X 2-3/4 SAE GRADE 5 FOR SAFETY. MUST
USE ONLY 3 EQUALLY SPACED SCREWS.

July 16/96 Revised 4-3

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Trailer Assembly
Figure 14

4-3 December 31/91 Revised

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

14- 280718 TRAILER GROUP (OPTION) A REF

281056 TRAILER GROUP (OPTION) B REF
1 181077A . TRAILER, ASSY., V22938, No. 747 1
2 85B-1013 . TIRE, 5:30 X 12 4
3 181079 . BRAKE, ASSY. 1
4 280597 . . LEVER, BRAKE MOUNT, ASSY. 1
5 280602 . . SHOE, BRAKE, ASSY. 1
6 280607 . . ROD, ADJUSTING, BRAKE 2
7 400954 . . CLEVIS, ADJUSTING, BRAKE 2
8 401468 . . PIN, CLEVIS 2
9 W-11338-5 . . PIN, COTTER, 1/8 X 1", ST. 4
10 280604 . . SPACER, GUIDE, SHOE, BRAKE 2
11 280605 . . GUIDE, SHOE, BRAKE 2
* 11A 280725 . SPACER, BOTTOM, BRAKE 2
* 12 484634 . BLOCK, CHOCK 1
* 13 486270-10 . LABEL, WARNING, COMPOSITE 1
14 280581 . FENDER, LEFT 1
15 280582 . FENDER, RIGHT 1
* 16 280588 . SUPPORT, FENDER 4
17 280587 . TRAY, CABLE 2
* 18 280565 . TANK, FUEL, ASSY. A 1
281058 . TANK, FUEL, ASSY. B 1
* 19 280611 . CAP, TANK, FUEL A 1
76A-1152 . CAP, TANK, FUEL B 1
* 20 280564 . STRAP, MTG., FUEL TANK 2
* 21 280608 . INSULATOR, FUEL TANK 2
22 280585 . PANEL, SIDE A 3
23 280724 . PANEL, SIDE, LEFT REAR A 1
24 280727 . BUMBER, REAR 1
25 79A-1075 . DRAWBAR, ASSY., V22938, No. 19-3500 1
26 79A-1057 . . PIN, HINGE, V22938, No. 5416 1
27 76A-1171 . . PIN, COTTER, V22938, No. 4800-6 2
79A-1045 . CENTER ARM, ASSY., V22938, No. 15-3854 1
284399-6 . . BUSHING W/G GROOVES, V22938, No. 5282-44 1
29 404529 . . PEDAL, LATCH, V22938, No. 3855 1
30 404530 . . PIN, ROLL, V22938, No. 5000-1 1
31 404528 . . SPRING, V22938, No. 4006 1
32 79A-1047 . WASHER, FLAT, V22938, No. 4701-3 1
33 79A-1048 . PIN, CENTER, V22938, No. 5400-5 1
284399-4 . AXLE, REAR, ASSY., V22938, No. 747-2001 1
34 284399-5 . . AXLE, REAR, BEAM WELDMENT, V22938, No. 747-4286 1
85A-1019 . . HUB ASSEMBLY, REAR AXLE, V22938, No. 7-3601 2
35 85A-1020 . . . CAP, GREASE, V22938, No. 6301 2

* NOT ILLUSTRATED

May 6/93 Revised 4-3

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4-3 December 31/91 Revised

Page 36

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NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

14- (CONTINUED)
36 85A-1022 . . . BEARING, CONE, OUTER, V22938, No. 6151 2
37 85A-1021 . . . BEARING, CONE, INNER, V22938, No. 6050 2
38 85A-1023 . . . SEAL, GREASE, V22938, No. 6300 2
39 85A-1024 . . . NUT, STUD, V22938, No. 4603 10
40 404545 . . . LOCKWASHER 5
. . . HUB, STUD AND CUP ASSY., V22938, No. 3601-7 2
41 85A-1025 . . . . HUB, V22938, No. 3601-1 2
42 85A-1027 . . . . STUD, WHEEL, V22938, No. 6251-1 10
43 85A-1028 . . . . CUP, BEARING, INNER, V22938, No. 6155 2
44 85A-1029 . . . . CUP, BEARING, OUTER, V22938, No. 6156 2
45 85A-1030 . . WASHER, SPINDLE, V22938, No. 4701-10 2
46 85A-1031 . . NUT, SPINDLE, V22938, No. 4600-1 2
47 80A-1052 . . PIN, COTTER, V22938, No. M524665-360 2
284399-1 . AXLE, FRONT ASSY., V22938, No. 747-2051 1
48 284399-2 . . AXLE, FRONT BEAM ASSY., V22938, No. 747-2051-1 1
49 85A-1034 . . SPINDLE & KNUCKLE ASSY.(LEFT),V22938,No. 27-3800 1
50 85A-1035 . . SPINDLE & KNUCKLE ASSY.(RIGHT),V22938,No. 28-3800 1
51 84A-1081 . . PIN, KING, V22938, No. 5401 2
52 84A-1082 . . PIN, ROLL, V22938, No. 5000-6 2
85A-1026 . . HUB ASSY. FRONT AXLE, V22938, No. 7-3601 2
53 85A-1020 . . . CAP, GREASE, V22938, No. 6301 2
54 85A-1022 . . . BEARING, CONE, OUTER, V22938, No. 6051 1
55 85A-1021 . . . BEARING, CONE, INNER, V22938, No. 6050 1
56 85A-1023 . . . SEAL, GREASE, V22938, No. 6300 1
57 85A-1024 . . . NUT, STUD, V22938, No. 4603-1 10
58 . . . LOCKWASHER 5
85A-1019 . . . HUB, STUD & CUP ASSY., V22938, No. 7-3601 2
59 85A-1025 . . . . HUB, V22938, No. 3601-1 2
60 85A-1027 . . . . STUD, WHEEL, V22938, No. 6252-1 10
61 85A-1028 . . . . CUP, BEARING, INNER, V22938, No. 6155 2
62 85A-1029 . . . . CUP, BEARING, OUTER, V22938, No. 6151 1
63 85A-1030 . . WASHER, SPINDLE, V22938, No. 4701-10 2
64 85A-1031 . . NUT, SPINDLE, V22938, No. 4600-1 2
65 80A-1052 . . PIN, COTTER, V22938, No. M524665-360 2
85A-1037 . TIE, ROD ASSY., V22938, No. 3906-234 1
66 79A-1077 . . TUBE, V22938, No. 2
67 79A-1051 . . NUT, JAM, R.H., V22938, No. 4602-1 2
68 79A-1052 . . NUT, JAM, L.H., V22938, No. 4602-2 2
69 79A-1053 . . JOINT, BALL, R.H. W/NUT, V22938, No. 3950-1 2
70 79A-1054 . . JOINT, BALL, L.H. W/NUT, V22938, No. 3950-2 2
* 71 79A-1035 . FITTING, LUBE, V22938, No. 5801 4
* 72 76A-1183 . FITTING, LUBE, V22938, No. 5800 5

* NOT ILLUSTRATED

May 6/93 Revised 4-3

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4-3 December 31/91 Revised

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SECTION 4. NUMERICAL INDEX

1. Explanation of Numerical Index

The purpose of this index is to assist the user in finding the illustration and description of a part when the
part number is known. Part numbers are arranged in alpha-numerical sequence. Thus, any part number
beginning with the letter A would be located at or near the top of the index list. Likewise a part number 9
would be listed near the end of the list and far below a part number 1000. The figure number and item
number location of the part is directly opposite the part. If the part is used in more than one place, each lo-
cation is listed commencing with the first location the part is listed.

FIGURE & ITEM

PART NUMBER NUMBER
A-25 9-2A, 9A-2A, 12-5
BATTERY INSTALLATION 9-0, 9A-0
CANOPY ASSEMBLY 1-1, 2-0
DW-1704 12-6
DDW-495-1 3-14
FRAME GROUP 1-3
FW-1312 11-4
GENERATOR GROUP 3-1
GENERATOR SET WITHOUT CANOPY 1-2, 3-0
HF-1459 10-29
HF-2752 3-20
RADIATOR AND COOLING SYSTEM GROUP 3-9, 4-0
W-10051-6 7-10
W-10072-1 13-21
W-10072-48 13-20
W-10869-3 4-7
W-10869-6 5-5
W-10869-7 4-8
W-10869-14 7-9
W-10874-1 13-11
W-10875-1 13-10
W-10886-1 8-3
W-10886-2 7-13
W-10891-7 7-4
W-10893-2 7-5
W-10901-2 7-23
W-10901-3 7-16
W-10905-2 7-22
W-10905-6 7-17
W-10909-1 8-2
W-11097-8 12-10
W-11102-8 13-6
W-11102-19 13-3A
W-11166-1 10-43
W-11166-3 11-17

Revised 4-4
March 25/93 Page 1

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FIGURE & ITEM

PART NUMBER NUMBER
W-11242-5 12-7
W-11242-10 12-11
W-11254-4 5-10, 12-8
W-11254-8 12-12
W-11263-6 12-14
W-11278-5 12-13
W-11278-7 5-11
W-11280-2 12-9
W-11280-3 6-7, 6A-10
W-11338-5 14-9
W-7814-1 7-3
W-7814-3 7-14
W-7814-4 4-14
W-7814-10 7-15
W-8095A-8 10-27
W-8105A-4 10-26
W-9407-138 9-8, 9A-8
W-9476-11 6-6, 6A-8
ICZ-93B 10-13
ICZ-148 10-34
W-9746-1 10-39
W-9746-3 10-38
W-9916-10 10-25
W-9917-18 11-7
Y-680 11-5
100GHP-66 13-8
100NH-2 13-15
100NH-3 13-16
12CW-1320A-5 11-19
12CW-2125 11-21
12CW-2146 6A-6
15GH-433 10-28
16DA-4004A-3 10-15
16DA-4004A-10 10-6
16DA-4052-0 10-7
16DA-4253-1 10-9
180404 3-12
180405 3-13
180913-1 11-9
180913-4 10-31
180927 13-12
180954 4-1
181077A 14-1
181079 14-3
181125 2-11
181128 5-1

4-4 Revised
Page 2 May 6/93

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FIGURE & ITEM

PART NUMBER NUMBER
181129 5-6
181346 13-22
181825 9A-2
181831 9A-3
20RT-353-1 11-16
25MS-156 11-15
280054 4-2
280488 6-2
280531 10-24
280534 10-16
280542-1 3-17, 11-0
280543-2 3-3, 10-0
280545 11-1
280559 2-3
280564 14-20
280565 14-18
280575 2-6
280579 2-7
280581 14-14
280582 14-15
280583 2-1
280585 14-22
280587 14-17
280588 14-16
280590 10-47
280591 2-5
280597 14-4
280602 14-5
280604 14-10
280605 14-11
280606 2-19
280607 14-6
280608 14-21
280611 14-19
280612 11-2
280618-1 9-5
280619-1 9-4
280635 2-2
280646 2-12
280718 1-5
280718 14-0
280722B 3-25
280722C 12-0
280723C 12-1
280724 14-23
280725 14-11A

Revised 4-4
March 25/93 Page 3

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FIGURE & ITEM

PART NUMBER NUMBER
280727 14-2
280786A 13-0
280861 3-7
280914 3-27
280941 4-6
280942 4-5
280951 9-3
280952 9-2
281013 3-23, 7-0
281013A 3-23, 7-0
281031 4-4
281034 5-7
281035 3-6, 5-0
281036 5-3
281040 2-4
281041-1 3-11
281050 3-10
281056 1-5, 14-0
281058 14-18
281071 2-6
281074 2-1
281093 2-9
281096 2-7
281102 2-13
281104 2-4
281109 2-10
281114 2-3
281115 2-2
281116 3-19
281117 3-26
281118 3-18
281574 2-9
281774-2 6A-7
281776 6A-5
281871-1 3-2, 9A-1
282130-1 12-3
282671 3-4, 6A-0
282500 6A-1
282501 6A-2
282673 6A-3
282674 6A-4
284399-1 14-47
284399-2 14-48
284399-4 14-33
284399-5 14-25
284399-6 14-27

4-4 Revised
Page 4 May 6/93

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FIGURE & ITEM

PART NUMBER NUMBER
30GH-764 11-8
30523 7-21
363136-2 10-40
370891 10-8
385950 13-25
386612 3-5
386751 4-11
387617A 13-1
387620A-1 13-18
387623-1 13-9
387624A-1 13-14
387736C 10-22
387738A 10-19
387748-1 13-23
388827-14 9A-4
388828-9 9A-5
400030-1 10-14
400059-3 11-20
400078 10-48
400400 10-30
400613-4 10-31, 10-44
400701 11-12
400785-7 10-10
400818-1 7-1
400819-2 7-2
400954 14-7
401468 14-8
401556 10-18
401564-3 10-37
401564-4 10-2
401564-5 10-23
401937-2 6A-9, 11-13
401937-3 10-1
402037-9 10-41
402086-2 3-2, 9-1
402119-2 5-9
402119-4 12-2
402119-8 12-4
402321-1 5-8
402433 4-12
402658 10-42, 11-18
402662 10-45
402665-1 10-51
402789-3 13-12A
402826 10-46
402908 6-5

Revised 4-4
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FIGURE & ITEM

PART NUMBER NUMBER
402987 1-4
403091-5 11-11
403091-6 10-50
403153-1 2-14
403189 11-6
403336 10-49
403483 5-2
403590-1 8-4
403782-2 4-13
403809-1 8-1
404065-2 10-4
404100 11-14
404154-15 3-16
404172-1 10-31
404402-2 10-5
404460-1 10-20
404528 14-31
404529 14-29
404530 14-30
04595 6-1
405071-1 6-13
405154-5 10-35
405743 4-3
430077-2 2-18
430340 10-36
480603-1 13-26
480628 13-27
480669 13-5
481379 13-13
481940 13-24
482038 10-17
482039 10-21
482291 10-33
482401 2-8
482483 13-4
482496-1 9-7, 9A-7
484634 14-12
484689-1 10-11
484690-2 10-12
486270-10 14-13
488692 6-8
488693 6-9
488695 3-24, 8-0
488735-1 3-21
488735-2 3-22
488701 3-4, 6-0

4-4 Revised
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FIGURE & ITEM

PART NUMBER NUMBER
488755 13-7
488908 3-15, 13-3
489030 2-9
489180 13-17
489658-5 10-52
489811 10-3
482989 6-11, 6A-2
5CW-2048 9-6, 9A-6
50MS-732-0 6-12
56531 4-9
56532 4-10
56534 7-6
56548 8-5
56587 7-11
7009-1 1-0
7009A-1 1-0
7009B-1 1-0
76A-1118 10-32
76B-1148 2-17
76A-1152 14-19
76A-1171 14-27
76A-1183 14-72
78A-1000 2-15
78A-1023 7-19
78B-1019-2 7-7
78B-1019-3 7-12
78B-1021 7-20
79A-1035 14-71
79A-1045 14-27
79A-1046 14-28
79A-1047 14-32
79A-1048 14-33
79A-1051 14-67
79A-1052 14-68
79A-1053 14-69
79A-1054 14-70
79A-1057 14-26
79A-1077 14-66
79A-1078 14-34
79A-1110 2-16
79A-1144 13-28
79B-1022 7-18
80A-1052 14-47, 14-65
80B-1107 3-8
82A-1030 11-10
82B-1047 10-44, 11-3

Revised 4-4
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FIGURE & ITEM

PART NUMBER NUMBER
84A-1007-1 7-8
84A-1020 6-3
84A-1050 6-4
84A-1075 6-10, 6A-11
84A-1081 14-51
84A-1082 14-52
84A-1101 3-28
85A-1019 14-34, 14-52, 14-57
85A-1020 14-35, 14-53
85A-1021 14-37, 14-55
85A-1022 14-36, 14-54
85A-1023 14-38, 14-56
85A-1024 14-39, 14-57
85A-1025 14-41, 14-59
85A-1026 15, 52
85A-1027 14-42, 14-60
85A-1028 14-43, 14-61
85A-1029 14-44, 14-62
85A-1030 14-45, 14-63
85A-1031 14-46, 14-64
85A-1034 14-49
85A-1035 14-50
85A-1037 14-65
85A-1045 5-4
85B-1013 14-2
85B-1039 13-19

4-4 Revised
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CHAPTER 5. OPTIONAL EQUIPMENT

This chapter provides documentation covering any optional equipment furnished with your generator.
Available options are listed below.

OPTION NAME MANUAL HOBART NO.

7009 - Trailer, Fenders, Fuel Tank, and Parts OM-2053 280718

7009A - Trailer, Fenders, Fuel Tank, and Parts OM-2053 281056
Quick Start Kit OM-2053 181867
Kit, Water Heater TO-192 181714

March 20/89 5-0

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CHAPTER 6. MANUFACTURER’S LITERATURE

Voltage Regulator Hobart Brothers Company
Operation and Maintenance Manual OM-2020

Electric Governor Woodward Governor Company

for Specifications 7009 and Electrically-Powered Governor
7009A units Instruction Manual

Electric Governor Barber-Colman Governor Company

for Specification 7009B units Electrically-Powered Governor
Instruction Manual

Engine Perkins Diesel Engine

Operators Manual No. 6.3544

Flexible Coupling Hobart Brothers Company

Coupling Manual OM-2019

Exciter Rotor Hobart Brothers Company

Rotor Manual TM-360

HOBART DIAGRAMS:

281025 Schematic and Connection, Engine and Generator,

Specifications 7009 and 7009A (5 sheets)

282682 Schematic and Connection, Engine and Generator,

Specification 7009B (5 sheets)

December 31/91 Revised 6-0

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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 con-
dition or operation of the equipment.

Among such conditions are :

1. Exposure to:
A. Combustible, explosive, abrasive or conducting dusts.
B. Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation.
C. Chemical fumes, flammable or explosive gases.
D. Nuclear radiation.
E. Steam, salt-laden air, or oil vapor.
F. Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus
growth.
G. Abnormal shock, vibration or mechanical loading from external sources during equipment opera-
tion.
H. Abnormal axial or side thrust imposed on rotating equipment shafts.
I. Low and/or high ambient temperatures.

2. Operation at:
A. Voltages above or below rated voltage.
B. Speeds other than rated speed.
C. Frequency other than rated frequency.
D. Standstill with rotating equipment windings energized.
E. Unbalanced voltages.
F. Operation at loads greater than rated.

3. Operation where low acoustical noise levels are required.

4. Operation with:
A. Improper fuel, lubricants or coolant.
B. Parts or elements unauthorized by the manufacturer.
C. Unauthorized modifications.

5. Operation in poorly ventilated areas.

December 31/91 Revised Unusual Service Conditions

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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. It is recognizable by fuel
oil wetness around the exhaust manifold, pipes, and muffler. Liquid fuel, in the
form of droplets, may be spewed from the exhaust outlet.

Wet-stacking is common, and may be expected in diesel engines operated under

light load. Light loads do not allow the engine to reach most efficient operating
temperature for complete combustion of fuel. The unburned fuel collects in the
exhaust system to create the wet condition known as wet-stacking.

To alleviate wet-stacking in lightly loaded engines, it is recommended that the ma-

chine be connected to a load bank after each 200 hours of use and operated un-
der full rated load for one hour. This will burn away and evaporate the
accumulation of fuel in the exhaust system. This clean-out procedure should be
considered as a regular maintenance operation for machines operated under
light load. The time schedule of 200 hours may be changed as required to suit
each user’s particular needs and operating conditions.

December 31/91 Revised Wetstacking

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