i il · Delete Figure 12 and substitute Hobart drawing no. 485498 included as part of this addendum. E. Engine Assembly - Refer to Figure 3 Engine Assembly (4) is part no. 80B-‘l’T0.7

i il

TM-630 090178

Revised 101981 Revised 102282 Revised 031284 Revised 042188

OPERATION AND MAINTENANCE MANUAL

with

ILLUSTRATED PARTS LIST

covering

JET-EX DII

GENERATOR SETS

Specification Series No. 5961

28.5 V DC, 21.4 kW, 750A

Diesel Engine Driven

by

Perkins Model 6-354

HOBART BROTHERS COMPANY POWER SYSTEMS DIVISION

TROY, OHIO 45373 " ._ --_ - -- _.---._.--.____ _____-..-- - U.S.A.

’ ‘\ ./’ :

/

‘“-,..

/- I

r --_

P . .’

‘\ ,/.’

.--.-

\ _.*”

.-\ --.

c ._ . .

,, ” ‘,

_--_____ -___--.L.- .- _.. _. -.- ---- ----‘----.-S~.~-I~-TT~~~~D WARNINGS FOR ELECTRICAL PQWER EQUIPMENT I_

.' ,. ,.. .._ ___.. -.--.- .._ ----.A _--..- -.-. -- ~---__ _-- ..__ - -..--.--....--..... -.---. --'

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 cabies to ' break 1

TII d 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. available for future use by all operators.

Keep the manual

A. GENERAZ,

Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or property. The operatormust 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 below apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and some practices to both.

B. SHOCK PREVENTION

Bare conductors, electrically-live

or terminals in the output circuit, or ungrounded, 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. equipment, do not work in damp areas.

When inspecting or servicing

dry wood, Stand on a dry rubber mat or

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 1

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, and other a plicable disconnect switch or circuit breaker must %

codes. A power

Check the nameplate for volta e, only 3-phase power is availab e, P

frequency, e located at the equipment. and phase requirements. If

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 fataf- ShoCg.- -----

Alwa K s connect the grounding lead

to e grounded switch box or bui -1 if supplied in a power line cable,

t separate groundin lead.

ding ground. If not provided, use a

'i Ensure that the current

of the grounding (am erage)

ead will be adequate for the worst ! capacity

ault current situation. details.

Refer to the National Electrical Code ANSI/NFPA 70 for Do not remove plug ground prongs.

receptacles. Use correctly mating

2.. Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the connectors. Re lace or repair cracked or worn cables immediately. Do

fi (

not overload ca les. Do not touch output terminal while equipment is energized.

3. Service and Maintenance

1.. ..-. .'-,--------.Th-ls-e~u~-n-t--mu~~~.~~~~~n~~e-~~r-~a~-a~~~e~h~~i~-a~' ---- condition to avoid hazards stemming from disrepair. Report any I

._ _ ,.-_-- .._. ~_.._ ewi.me-at, _defect2xde_t-m lmsd- .t~_+~e...supervi.s_or-_and~_dl~~ue .-l_._, use of the e ui ent unti -its safety has been assured. should be ma%e c qualif zd personnel only.__.,._-"..,_,_..,.__-._-_

Repairs _.. ._ . .,_, .- ..- .- ~ ." ._

Instruction 910082 Feb 25186 Revised

Page 1

. I ‘.. /’ I / I \ \ i I \ , ‘- I

Before inspecting or servicing electrically-powered -<&ake th> ,followi!na B recautions:

"- ; i ,. ". * ' 4. Shut-CFFahE Rower at the 4. -a. -

before inspecting or

b. Lock switch OPEN (or remove line fuses) so that power cannot be turned ON accidentally.

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

d. If troubleshooting must be done with the unit ener ized, another person present who is Frained in turning o H

have f

and providing or callpn$ for first aid.

FIRE AND EXPLOSION PREVENTION

the equipment

Fi?/e and explosion are caused by electrical short circuits, combustible material near engine exhaust pi

?I ing, misuse of batteries and fuel, or

unsafe operating or fueling con itions.

1. Electrical Short Circuits and Overloads

Overloaded or shorted equipment can become hot enough to cause fires either by self destruction or causing nearby combustibles to ignite. For electrically-powered equipment, in particular,

*B rovide primary

input protection to remove short circuited or heave y overloaded equipment from the line.

,

2. Batteries .

Batteries may explode and/or give off flammable hydro en and arcing from a ruptured battery can cause fires an % ad%?zionzle acid failures. When servicing, do not smoke, cause sparking, or use open flame near the battery.

3.1 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. completely fill

Shut unit DOWN before removing fuel tank cap. Do not tank,

expansion overflow. because heat from the e uipment may cause fuel Remove all spilled fuel 4

that penetrates the unit. After clean-up, MMEDIATELY, including any

fumes away with compressed air. open equipment doors and blow

D. TO$IC 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. Nerer locate engine exhausts near intake ducts of air conditioners.

b. BODILY INJURY PREVENTION

Sekious injury can result from contact with fans inside some equipment. / Shbf DOWN such equipment for inspection and routine maintenance. When 1

equipment is in o eration use extreme care in doing necessary troubleshooting/ and adJustment. I? o not remove guards while equipment is operating.

;

P* MEDICAL AND FIRST AID TREATMENT I

Fikst aid facilities and a qualified first aid person should be available foi each shift for immediate treatment of all injury victims. Electric sh ck victims should be checked by a ph sician and taken to a hospital i: immediately if any abnormal signs are o served. x I

EMERGENCY FIRST AID

Cahl physician immediately. Seek additional assistance and use First Aid tekhniques recommended by American Red Cross until medical help arrives.

if available, and have victim lie Remove victim; if not

preferably mouth-to-mouth. If massage. Call Emergency Rescue

--- R

F.. EQ&?MEN~~l%CAHTIQNAR.Y-LABELS Ins ect a

I._.-rep % YTecau=lona ry iabels on the-equi~n~nthlyl~-

~+.~i-&-.&-.--J .____.

wall abels that cannot be easily rea -- ._I _- I I _.-.____ ___ -.--. ---__^ "- -

Page 2 Instruction 910082 Revised Feb 25/86

I 1.

2.

General

This addendum extends the coverage of Hobart ManuaI No. TM-630 to include the generator set manufactured as Specification No. 59618-l. This unit is the same as 5961-1 except for the minor. differences described below. Operation and performance of units manufactured under both specifications is identical.

Engine Changes

The Perkins Diesel engine used in this unit is Model No. 6.3544 ’ (Hobart part number 80B-1107) . It differs from the Model No. ’ 6.354 used on Specification 5961-1 as follows:

A. Water Trap

Refer to the basic manual TM-630, Section l-l, Figure 3. On, this unit, the water trap,in the fuel line (19) has been relocated from the position shown, to the right rear of the engine. It is mounted on a mounting plate, Hobart part no. 485496.

B. Fuel Filters

Fuel filters (12) have been relocated from the front of the engine to the rear, on the left side, next to the ether start kit (15).

3. Hobart Changes

ADDENDUM NO. 1

to

OPERATION AND MAINTENANCE MANUAL

1 6 TM-630

covering

JET-EX DII

GENERATOR SET

Specification No. 596 lA- 1

Changes in Hobart equipment due to interface requirements for this Perkins engine affect the IIIustrated Parts List Section of the manual only. Refer to the basic manual, Section 4-3, for the Figure and Index numbers referenced below.

Ott 19/81 Revised Sept 18180 Page 1

A. Cooling System - Refer to Figure 6

Radiator Inlet Hose (2) is part no. 402141-20.

Delete : Inlet Hose Elbow,. , * i ‘I

Radiator Outlet Hose is part no. 402141-19.

Radiator Assembly is part no. 485495.

Radiator Supply Hose is part no. 485497.

B. Exhaust System - Refer to Figure 11

Manifold Exhaust Pipe (8) is part no. 485501.

Gasket (9) is part no. 480621.

C. Air Cleaner - Refer to Figure 3

Air Cleaner Kit is part no. 485499.

Replacement Filter Cartridge is part no. 404196.

D. Fuel and Oil Lines

Delete Figure 12 and substitute Hobart drawing no. 485498 included as part of this addendum.

E. Engine Assembly - Refer to Figure 3

Engine Assembly (4) is part no. 80B-‘l’T0.7.

Page 2 Sept 18180 Revised Ott 19/81

ADDENDUM No. 2

to

OPERATION AND MAINTENANCE MANUAL TM-630

covering

GENERATOR SET

SpeFification No. 5961A-1

1. Scope

This addendum increases the coverage of Hobart Manual TM-630 to include changes made in the output cables and buses of the basic generator set for one special customer generator order.

2. Description

The changes made in output cables and copper buses were made to reduce voltage drop within the generator set and thereby increase voltage at the set's output terminals during aircraft starting. Mainly, the steps taken to reduce voltage drop were to reduce the number of connections and to increase the capacity of power cables in the generator set.

3. Manual Changes

For the special customer generator order covered by this addendum, and for this order ONLY, the following changes are required in the manual:

A. Section 4-3, Paqe 12. Eliminate item 9 from the illustration.

B. Section 4-3, Page 13.

(1) Delete item 9 from the list.

(2) Add, at bottom of list:

* W-9218-175 . CABLE, POSITIVE, (No. 134) 2

C. Section 4-3, Page 24. Item 2 of illustration is changed to extend farther downward by approximately 2 inches.

D. Section 4-3, Page 25.

(1) Item 5

(a) Change Hobart Part No. from W-11097-8 to W-11097-3.

(b) Change screw description to:

"SCREW, 3/8-16 x l-1/4, HHC, STEEL"

(2) Items 6 and 7. Change UNITS PER ASSEMBLY from 4 to 2 for both flat washers and lock washers.

Page 1

(3) Add at bottom of list:

* W-9218-188 . CABLE, POSITIVE, (No. 130) * W-9218-137 . CABLE, POSITIVE, (No. 131) :

E. Section 4-3, Page 17. Add at bottom of list:

* W--9218-126 1

~.;~cA;~E,~;;;ATIVE, (NO. 132 and . 2

F. Section 4-4, Page 2.

(1) Change Part No. W-11097-8 to W-11097-3.

(2) After Part No. W-8061A-11, add the following Part Numbers:

PART FIGURE AND NUMBER ITEM NUMBER

PART NUMBER

FIGURE AND ITEM NUMBER

W-9218-126 7-o W-9218-175 5-o

W-9218-137 10-O W-9218-188 10-O

G. Section 6-O

Replace generator Set Connection Diagram No. 483657 with Connection Diagram No. 489563.

4. Customer Service

If you have any questions concerning your Hobart Power Systems Division equipment, you are invited to contact our Service Department by mail, telephone, or TWX:

Write: Hobart Brothers Company Power Systems Division Service Department Troy, Ohio 45373, U.S.A.

Call: Area Code (513) 339-6000, Extension 4276

TWX: 810-456-2907

Page 2

w

1 TM-630

INTRODUCTION

I

This manual contains operation and service information and instructions for 28.5 volt DC Generator Sets, identified .

as Jet-Ex DII.

I The Jet-Ex Dll is unit, or it may be trailer-mounted for portability. Both ver-

sions are available with output capability.

The manual is not a text book on electricity or electronics. Its primary purpose is to provide information and instruc- 1

tions to experienced operators, electricians, and mechanics who have never seen, nor operated this particular generator

set. It is the intent of the manual to guide and assist operators and maintenance personnel 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 before starting the unit. Learn to use the manual and to locate information contained in it. Each page is identified in the lower outside corner by the chapter and section number in which it appears. Each new section starts with page 1. The first figure

in each section is Figure No. 1.

In addition to operation and maintenance instructions, the manual contains an Illustrated Parts List in Chapter 4. A

collection of manufacturer’s literature is supplied as part of the information package.

If, and when additional options and models become available, any new instructions and parts list required will be added

to the manual. Look for new and added information at the end of a Section in which it would normally be found. Use

the Table of Contents and List of Illustrations to find information.

If you have any questions concerning your Hobart Power Systems Division equipment, you are invited to contact our

Service Department by mail, telephone or TWX.

Write: Hobart Brothers Company Power Systems Division Service Department Troy, Ohio 45373 U.S.A.

Call: Area Code (513) 339-6011

Extension 4276

TWX: 810-456-2907

Ott 19/81 Revised Introduction ,,

Page 1

SUBJECT

Description/Operation

Description i i,

1. General

2. Special Features 1

3. Orientation

4. Identification 1

5. Canopy 1

6. Engine, Generator, and Controls

A. General

B. Engine

(I) General

(2) Cooling fan

(3) Engine protective devices

C. Generator

D. Control Box Assembly

(I) General

(2) Panel light

(3) Monitoring instruments

(4) Switches

(5) Control rheostats

(6) Hinged panel

E. Interior Panel Assembly

(I) Resistors

(2) Overvoltage module

(3) Ammeter shunt

Sept II78

TABLE OF CONTENTS

TM-630

CHAPTER/SECTION PAGE

1-o 1

l-l 1

1

1

1

1

4

9

9

9

IO

10

IO

Contents

Page 1

SUBJECT

(4) Overload relay

(5) Load contactor

(6) Voltage regulator

F. Engine Control Panel

(1) Panel light

(2) Switches

(3) Fuse

(4) Throttle control

(5) Output terminals

(6) Engine monitoring instruments

(7) Cold weather starting aid control

G. RFI Suppression

7. Optional Trailer

8. Optional 14-Volt DC Output Kit

A. 14 Volt Contactor Panel

(1) Overload relay

(2) Control relays

(3) Load contactor


(5) Resistors


(7) Capacitor

B. 14 Volt Control Panel

(1) Control switch

(2) Mode indicating light

(3) Contactor closed light

Contents Page 2

‘4 TM-630

TABLE OF CONTENTS (CONTINUED)


l-l IO

12

i \I 12

12

12

12

12

12

12

14

15

15

15

15

15

15

16

16

16

16

16

16

16

18

18

18

Revised Ott 22182

SUBJECT

I


CHAPTER/SECTION

TM-630

PAGE

Preparation for Use, Storage, or Shipqi,ng

1. Preparation for Use

A. General

B. Inspection/Check

C. Output Cable Installation

(1) Cable requirements

(2) Cable connection

2. Preparation for Storage

3. Preparation for Shipping

Operation

1. General

2. Operating the Generator Set

A. Prestart Inspection

l-2 1

1

1

1

2

2

2

2

2

1-3 1

1 _, .

1

1

B. Starting the Engine 1

C. Cold Weather Engine Qarting Procedures 3

D. Preparation for Power Delivery 4

E. Power Delivery 4

(1) Normal power delivery with automatic voltage control 4

(2) Power delivery for aircraft engine starting (700 to 2000 amperes ) 5

(3) Power delivery for helicopter starting (400 amperes) 5

(4) Power delivery with manual voltage control 5

’ F. Discontinue Power Delivery 6

Ott 22182 Revised Contents Page 3

1 TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION

3. Operation of 14 Volt DC Output Option l-3

A. Preparation for Power Delivery

i iI B. Power Delivery

(1) Normal 14 volt power delivery

(2) Power delivery for aircraft engine starting (706 to 2000 amperes)

(3) Power delivery for helicopter starting (400 amperes)

(4) Power delivery with manual voltage control

C. Discontinue Power Delivery

D. Switching Power from Mode-to-Mode

(1) Switch from 14 volt to 28.5 volt delivery

(2) Switch from 28.5 volt to 14 volt delivery

4. Trailer Operation

A. Towing

B. Parking

Servicing

Maintenance Inspection/Check

1. General

2. Maintenance Schedule

A. General

B. Maintenance Schedule Check Sheet

C. Time Intervals

3. Inspection/Check

Maintenance Procedures

1. General

2. Lubrication I

2-o

2-l

2-2

TM-630

PAGE

6

6

6

9

9

9

10

10

IO

10

1

1

1

' 1

1

1

1

1

1

1

1

Contents

Page 4

Revised Ott 22182

‘4 I TM-630


SUBJECT CHAPTER/SECTION PAGE

A. General 2-2 1

B. Lubrication Chart 1

C. Generator 1 1

D. Generator Controls 1

E. Engine 1

(1) Lubrication schedule 1

(2) Oil specification

(3) Oil viscosity

(4) Change engine oil

(5) Change engine oil filter

F. Trailer

(1) Front axle assembly

(2) Wheel bearings

3. Air Cleaner Service

A. Cartridge Removal

B. Cartridge Installation

4. Battery Service

A. General

B. Battery Location and Accessibility

C. Battery Care

D. Liquid Level

E. Cleaning the Battery

5. Generator Maintenance

6

6

6

6

A. General 6

Ott 22/82 Revised Contents Page 5

I 1

m I 1 I I TM-630

SUBJECT

B. Brush Service

(1) Cleaning I

(2) Replacement

(3) Brush seating

(4) Brush springs

(5) Commutator cleaning

I 6. Generator Controls Maintenance

/

A. General

B. Overload Relay

(1) Disassemble

(2) Inspection

(3) Assemble

7. Testing the Battery

A. Test with Battery-Starter Tester

B. Test with Hydrometer

Adjustment/Test

1. General

2. Testing the Generator Set

A. Preoperational Test Procedures

B. Operational Test

3. Adjusting the Generator Set

A. Generator Adjustment



2-2 6

i iI 6

7

8

9

9

10

10

11

11

11

2-3 1

1

1

Contents Page 6

(1) Brushholder adjustment

(2) Initial adjustment of brushholder

(3) Brush spring adjustment

2

4

5

5

Revised Ott 22182

I I m

I I I I TM-630



B. Generator Controls Adjustment , 2-3 7

(I) i 4

Adjust 700-1300 ampere range of current limiting rheostat 7

(2) Adjust 900-2000 ampere range of current limiting rheostat 8 1

(3) Adjust 400 ampere current limit resistor 8

C. Engine Adjustment 9

D. Voltage Regulator Adjustment 9

E. Fuel Valve Solenoid Adjustment .9

Troubleshooting

Troubleshooting Procedures

1. General

2. Troubleshooting Chart

A. Description

B. Use of Troubleshooting Chart

3. Equipment for Troubleshooting

4. Safety

5. Diagrams

6. Connections and Wiring

Illustrated Parts List

Introduction

1. General

2. Purpose

3. Arrangement

4. Explanation of Parts List

A. Contents

B. Parts List Form

Ott 22182 Revised

3-O

3-l

4-o

4-1

Contents

Page 7

‘& 3 TM-630



(I) Figure-Item No. column i 6

4-l

(2) Hobart Part Number column

(3) Nomenclature column

(4) Recommended Spares column

(5) EFF (Effectivity) column

(6) Units per Assembly column

Manufacturer’s Codes

1. Explanation of Manufacturer’s (Vendor) Code List

Parts List

1. Explanation of Parts List Arrangement

2. Symbols and Abbreviations

Numerical Index 4-4

1. Explanation of Numerical Index

Optional Equipment

Manufacturer’s Literature

4-2

4-3

6-O

. . ..,.

2

2

2

2

2

31

1

1

1

1

1

1

1

Contents

Page 8

Revised Ott 22182

CHAPTER/ FIGURE SECTION NUMBER TITLE

PAGE

NO L

l-l 1 Jet-Ex*DI I Generator Set 2

l-l 2 Spqcifications and Capabilities (2 Sheets) 3-4

l-l I 3 Generator Set Components 5

l-l 4 Control Box Assembly 8

l-l 5 Interior Panel Assembly 11 ’

l-l 6 Engine Control Panel 13

l-l 7 Air Cleaner and Service Indicator 14

l-l 8 14 Volt Output Contactor Panel 17

l-l 9 14 Volt Output Control Panel 19

l-3 1 Operating Controls and Instruments 2

l-3 2 Cold Weather Starting Aid 3

l-3 3 14 Volt Output Control Panel 7

2-l 1 Inspection/Check/Maintenance Schedule 2

2-2 1 Lubrication Chart 2

2-2 2 Lubricants 3

2-2 3 Symbols and Time Intervals 3

2-2 4 Air Cleaner Cartridge Replacement 5

2-2 5 Generator Brush Installation 7

2-2 6 Overload Relay Installation 9

2-2 7 Overload Relay Dashpot Assembly 10

2-3 1 Operating Controls and Instruments 3 2-3 2 Brushholder Assembly 4 2-3 3 Measuring Spring Pressure 6 2-3 4 Generator Brushes 7 2-3 5 Current Limit Adjusting Resistors 8 2-3 6 Fuel Valve Solenoid Linkage 10

3-l 1 Operating Controls and Instruments 3-1 2 Troubleshooting Chart (6 Sheets)

2

4-9

4-3 1 Generator Set 4-3 2 Canopy Assembly 4-3 3 Generator Set, Without Canopy 4-3 4 Control Box Assembly 4-3 5 Interior Panel Group 4-3 6 Cooling System 4-3 7 Generator and Drive Group 4-3 8 Brushholder Assembly 4-3 9 Trailer Group 4-3 10 Engine Control Panel 4-3 11 Frame Group 4-3 12 Fuel and Oil Lines Assembly

4-3 13 14 Volt Output Kit (Optional)

2 4

6

8

12

14

16

18

20

24

26

28

30

Ott 22182 Contents

Page 9

I I

LIST OF ILLUSTRATIONS

TM-630

TM-630

CHAPTER 1. DESCRIPTION/OPERATION

SECTION 1. DESCRIPTION

1. General - I

i iI

I All Jet-Ex DI I generator sets (Figure 1) covered by this manual are engine-driven, self-contained units, enclosed by ,

a sheet metal canopy. They are manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373, and are identified by a specification series number 5961, plus a dash number -1, -2, etc., to identify a

specific machine. Each machine is designed to produce and deliver regulated 28.5 volt DC power to a parked aircraft for operation of the aircraft’s on-board electrical equipment. 14 volt DC output capability is available as an

I option. The Jet-Ex DI I output power characteristics meet the requirements of Turbo-Jet, Turbo-Prop, and piston engine executive aircraft with 28.5 volt DC electrical systems. (Refer to Figure 2 for specifications and capabili-

ties.)

2. Special Features

I The Jet-Ex DII features a current limiting, soft-start control, which is recommended by most engine manufacturers

for the protection of the engine starter shear section. With soft-start control, the inrush current to the engine

starter may be preset to any value between 700 and 2000 amperes as recommended by the engine manufacturer.

Another special control limits output current to 400 amperes for helicopter and small turbine engine starting.

3. Orientation

I The radiator end of the Jet-Ex DI I is the front. Right and left are determined by standing at the rear of the ma-

chine and facing the unit. The control box and engine control panel are located on the right side.

4. Identification

I All Jet-Ex Dllsare identified by a specification series number 5961 (S-5961 ). To identify any specific machine, a dash number, -1, or -2, etc., must.be added to the specification number. The series number 5961 does not identify a complete machine. Only the series number, 5961, PLUS a dash number forms a specification number and

identifies a complete machine. Only a single dash number is used with the series number to form a specification

number. Dash numbers are NEVER used in combination, such as S5961-1 and -2.

5. Canopy

The canopy is a sheet metal enclosure which protects the engine, generator and controls. It has two large doors on each side to provide easy access to the equipment for service and maintenance. The right rear door has two smaller

doors, each equipped with a Plexiglass window, which provides access to controls on the generator control panel

and the engine control panel. The Plexiglass windows permit observation of instruments and control settings with-

out opening the doors. These two smaller doors are held in the closed position by magnets mounted on the larger

6. Engine, Generator, and Controls

A. General

Ott 19/81 Revised I-1

Page 1

TM-630

Jet-Ex DII with Canopy Removed

--- -._. . ----~,

Trailer-Mounted Jet-Ex DI I

Jet-Ex DII Generator §et

Figure 1

l-l

Page 2 Revised Ott 19/81

TM-630

PHYSICAL

STATIONARY UN IT

Length overall

Width

Height overall

Weight

i 4

80 inches (2033 mm)

36 inches (914 mm)

56 inches (1422 mm)

2980 pounds (I 352 kg)

TRAILER-MOUNTED UNIT

Length overall 93 inches (2362 mm) Width 66 inches (1676 mm) Height 61 inches (I 549 mm) Weight 3400 pounds (1542 kg)

TRAILER

Tread Wheelbase

Ground clearance Tires

Tire pressure

58 inches (1473‘mm) 60 inches (1524 mm)

5 inches (127 mm)

6.90/6.00 x 9 (6 ply) 60 psi (413 kPa)

GENERATOR

Output power rating Voltage

Rated load capacity

Current limiting capability

Operating speed

21.4 kW 28.5 V DC

750 A at 50% duty cycle 530 A continuous at 28.5 V DC

2000 A maximum 700 to 2000 A as requiredl

400 A for helicopter starting.

2400 RPM

ENGINE

Manufacturer Model

We

Displacement

Compression .ratio Firing order

Number of main bearings Horsepower at 2400 RPM

Governedspeed Idle speed

Electrical system Batteries

Perkins Engines Inc.

6-354

In-line, 6cylinder, 4-cycle Diesel 354 cu. in. (5.8 liters)

16:l

I-5-3-6-2-4 7

107 2400 RPM ? 4.5%

909 RPM

12 volt Two 6-volt in series

Specifications and Capabilities (Sheet 1 of 2)

Figure 2

Ott 19/8l Revised I-1

Page 3

ENGINE (Continued)

Oil capacity (with filter)

Oil capacity (without filter)

Coolant capacity (approx.)

Fuel capacity Fuel ’

15 quarts (14 liters)

14 quarts (13.6 liters)

i il 20 quarts (19 liters)

30 gallons (I 14 liters)

Diesel oil conforming to ASTM Specification

D.975-66T, Nos. I-D and 2-D

Lube oil MIL-L-2104B

PROTECTIVE DEVICES

GENERATOR

28.5 V overvoltage relay trips at 32 to 34 V in 2 to 10 seconds. Overload relays trip at 1000 A in 1 minute.

ENGINE

Governor limits to 2400 RPM 2 4.5%.

TM-630

Specifications and Capabilities (Sheet 2 of 2) Figure 2

Refer to Figure 3. The engine (4) and generator (18) are mounted on a welded, steel frame (5). A sub-frame

(17) located at the rear of the unit supports the control box (I) and fuel tank (16) and provides a mounting frame for the engine control panel (IO). The radiator (24) is mounted on the main frame at the front of the

unit. A lifting eye is attached to a centrally located lifting yoke (3) and provides a convenient attaching point for chains, cables, or hooks used to lift and move the generator set.

B. Engine

(1) General

The Perkins Diesel Engine, model 6-354, is a six cylinder, four stroke, direct injection power unit. The cylinder block is cast integrally with the crankcase, the sides of the cylinder block extending below the

crankshaft axis to form a stiffening skirt. The cylinder head is secured to the cylinder block by steel

studs and nuts, the joint being made by a composite type gasket. Two valves per cylinder operate in un- shouldered cast iron guides fitted into the cylinder head and two springs (inner and outer) are provided

for each valve.

Being a direct injection engine, the combustion chamber is formed in the crown of the piston. The

atomizers are fitted into the left-hand side of the cylinder head and are cooled by jets of water directed

onto the nozzle bosses and valves through cored deflectors cast in the cylinder head. These deflectors are

in direct communication with the water rail on the side of the cylinder block. The fuel is injected by means of multi-hole nozzles.

l-l

Page 4

Sept II78

I 1

Sept 1178

‘-

& I 1

\

24

I I I I I I I \ I / I I II I \

23 i2 il 20 14 is 1.1 - __- - -- .-

y5 ,

TM-630

i [5-596_1_1 1. Control Box 13. Flyback Diode (CR4061 2. Air Cleaner 14. Solenoid (L403) 3. Lifting Yoke 15. Ether,Start Kit 4. Engine :,, 16.,zFuel Tank 5. Frame : ! .;. l7. Support Frame 6. Alternator (G403) ‘, ._I 18. Generator -; 7. Muffler and‘Exhaust System i: ,I. : 19. .Wa’ter Trap (Fuel Line) 8 Blocking Diode (CR401) ,I ’ 20. Oil Pressure Switch (S417) .’ 9. Fuel Lift Pump 21.. Lube Oil Filter

IO. Engine Control Panel - 22. Fuel Injection Pump 11. Battery 23. Tachometer Sender (R413) : 12. Fuel Filters 24. Radiator

.

Generator Set Components .

Figure.3 ..‘.: .. ___ .:A,~ -- .-~--~-- ~~ /-A--’

*

i-1 -j_

Page 5 - -_I

TM-630

The valves are operated by cast iron mushroom type tappets with chill hardened tappet faces, located in

guides machined in the cylinder block, through push rods with hardened ends to cast iron rocker levers.

The rockers and valve assembly are lubricated by an intermittent feed, taken from the second camshaft

bearing via a drilled oil way in the cylinder block and head to the hardened hollow rocker shaft.

The crankshaft is forged steel. The r

c

ar of’the shaft is machined to provide an oil thrower and oil return

scroll. Crankshaft end float is contr ll’dd by four thrust washers, located on both sides of the centre main

bearing housing and centre main bearing cap. Oil seals are provided at the front and rear of the crankshaft.

The front seal is a synthetic rubber lip seal, fitting into the timing case cover; the rear main oil seal is a

rubber core, woven asbestos rope, retained in a split housing.

Seven main bearings are provided, lined with aluminum tin. Each half bearing is located by a tab which fits into a slot in the bearing housing. The main bearing caps are secured to the crankcase by two set- screws and located by ring dowels.

The camshaft is mounted in a low position on the right-hand side of the cylinder block, supported in four bearings machined directly in the cylinder block, all the bearings being lubricated by a full pressure feed.

The camshaft and auxiliary drive shaft are driven from the front end of the crankshaft through a train of

gears. The timing gears are enclosed by a cover secured to the front face of the cylinder block. The camshaft is located axially by a collar locating in a groove at the front end of the camshaft. The timing gears

are lubricated by an intermittent feed from the idler gear hubs.

The rotary oil pump, secured to the cylinder block, is driven through a serrated extension of the fuel

pump worm gear. The oil is delivered by the pump through a full flow filter, to the main oil gallery,

lengthwise through the crankcase. Holes through the main bearing housings carry oil from the main

gallery to the main bearings, through the crankshaft to the big end bearings.

An impeller type water pump is fitted to the front of the cylinder block and is driven by a Vee belt from the front of the engine crankshaft. The cooling system is thermostatically controlled.

The crankcase and cylinder head cover is vented to the atmosphere by a breather pipe.on the left-hand side of cylinder head cover.

The fuel injection pump is of the distributor type, mounted vertically on the left-hand side of the engine, driven via a worm gear from the auxiliary drive shaft. Engine speed is controlled by a mechanical gov-

ernor in the fuel injection pump. A fuel lift pump of the diaphragm type, equipped for hand priming, is mounted on the cylinder block and operated by an eccentric on the camshaft.

A 12 volt electrical system is used. The alternator is mounted on the right-hand side of the engine, belt

driven from the front of the crankshaft. Belt tension is adjusted by a slotted link.

(2) Cooling fan

The cooling fan is designed to blow air outward through the radiator rather than to draw it in as a con- ventional fan does. This modification is to prevent engine-heated, hot air from entering the 28.5 volt DC generator.

(3) Engine protective devices

A high coolant temperature switch is mounted in the rear of the cylinder block to monitor the coolant temperature. If the coolant temperature reaches 205 deg F (96 deg C), this normally closed switch opens

and actuates the fuel valve solenoid (14, Fig. 3) which shuts down the engine.

l-l

Page 6

Sept l/78

TM-630

Two diaphragm-type switches monitor the pressure in the lubricating oil system. One is mounted in the side of the cylinder block (20, Fig. 3) and the other is located behind the oil pressure gage on the engine

control panel (16, Fig. 6). If the pressure in the lube oil system falls to 10 psi (69 kPa), these switches

open and actuate the fuel valve solenoid (14, Fig. 3) which shuts down the engine.

C. Generator 1 il

The 28.5 volt DC generator (18, Fig. 3) is a self-excited, shunt-wound type with interpoles to improve com-

mutation. Excitation voltage is taken from the main generator output at the brushes and is controlled at the ,

option of the operator either by a manual voltage control rheostat (12, Fig. 4) or by an automatic voltage

regulator (1, Fig. 5). Sixteen brushes, mounted in four stacks of four brushes each, conduct the 28.5 volt DC generator output from the armature commutator to the two output cables (one positive, one negative). A

two-piece cover protects the brushholder assembly and allows access for brush service.

The armature is supported at the rear, commutator end by a single-row ball bearing. The front (drive) end is connected to the engine flywheel by a flexible disc and hub coupling assembly and is supported,by the engine

main bearings. A radial-blade fan of spot-welded construction is mounted on the coupling hub and draws cooling air over all of the generator windings.

Air enters through louvers in the rear (brushholder) cover and is discharged through openings in the flywheel

housing. An expanded-metal cover surrounds the flywheel housing. The generator housing assembly contains

a set of main shunt coils, and a set of interpole coils which are mounted alternately between the shunt coils. The generator housing is bolted directly to the engine flywheel housing.

D. Control Box Assembly

(I) General

The control box (Fig. 4) is a sheet metal enclosure which houses and provides mounting facilities for

generator controls and monitoring instruments. The box is mounted on a support frame over the generator on the right side of the machine. A Plexiglass window in the right-rear canopy door provides

protection for surface mounted instruments (Ref. Fig. 1).

A hinged panel (15, Fig. 4) provides a mounting facility for monitoring instruments and controls, and also provides access to the interior panel (Fig. 5) which is mounted inside the control box at the rear.

(2) Panel light

A panel mounted light (3, Fig. 4) provides illumination for instruments and controls during night-time operation. It is controlled by the light switch on the engine control panel (12, Fig. 6).

An indicating light (6, Fig. 4) glows green when the output load contactor is closed.

(3) Monitoring instruments

An ammeter (14) indicates generator output current in a range of 0 to 1600 amperes. The voltmeter (2) indicates generator voltage in a range of 0 to 50 volts DC.

Engine speed is indicated by an electric tachometer (5) actuated by the tachometer sender (23, Fig.

3). An internal light is provided to illuminate the dial. The tachometer’s indicating range is 0 to

4000 RPM.

Sept II78 l-l

Page 7

TM-630

,5-J?y-------#/+ \

14

1. Panel Fastener 2. Voltmeter

3. Panel Light 4. Hourmeter 5. Tachometer 6. Contactor Closed Light 7. Automatic/Manual Switch 8. Current Range Switch

9. Current Limiting Switch

10. Push To Build Up Volts Switch

11. Contactor Control Switch

12. Field Rheostat Control 13. Current Limiting Control 14. Ammeter

15. Hinged Panel 16. Interior Panel

Control Box Assembly

Figure 4

I-l

Page 8

Sept II78

I TM-630

The hourmeter (4) is operated from the 12-volt DC primary ignition circuit and records the total hours of engine operation. It is used in servicing to determine when maintenance operations should be performed.

(4) Switches

The automatic-manual switch (7) is a two-position toggle switch. Its function is to select the mode of generator operation by applying either automatically controlled (voltage regulator) or manually controlled (rheostat) excitation to th/e knerator fields.

The current limiting switch (9) is a two-position toggle switch used to select the value of the generator output current. Low current (400 amperes) for helicopter starting may be selected, or high current (in , the range of 700 to 2000 amperes) may be selected with this switch. In the up, current limiting position, the current range switch (8) and the current limiting rheostat, controlled by knob (13). are switched into the output circuit network.

When the current range switch (8) is in the down position, output current in the range of 700 to 1300 amperes is available. The exact current desired must be adjusted with the current limiting control (13), using the INNER dial scale. In the up position, this switch makes available an output current range of 900 to 2000 amperes also adjustable with the control (13). but using the OUTER dial scale.

The contactor control switch (11) is a three-position toggle switch with positions identified as ON and OFF. Its purpose is to connect, or disconnect the generator output to, or from the output cables. The top ON position is spring-loaded and is used only momentarily for closing the load contactor. When in center position the switch conducts holding current to the load contactor to maintain it in closed position. The holding circuit contains protective devices (overload and overvoltage) which open the contactor in the event of abnormal load or voltage in the output circuit. The load contactor is normally opened by placing the control switch in OFF position.

CAUTION: DO NOT HOLD THE CONTACTOR CONTROL SWITCH (11) IN THE TOP ON POSITION -- TO DELIVER POWER TO AN AIRCRAFT. IN THIS POSITION, THE CONTACTOR CLOSES BUT ALL PROTECTIVE DEVICES ARE BYPASSED AND SERIOUS DAMAGE TO THE AIRCRAFT’S ELECTRICAL CIRCUITS MAY RESULT.

A push-to-build-up-voltage switch (IO) is used to flash the generator fields with 12-volts DC at initial start-up of the generator to build up magnetism. Use this switch at start-up only if the generator fails to build up voltage by itself. A diode mounted on the switch prevents 28.5 volt DC generator output from entering the 12 volt DC engine circuit when flashing the field.

(5) Control rheostats

The field rheostat (12) is used to manually control the generator field current and thereby adjust the generator output voltage. The rheostat is connected in the field circuit only when the automatic-manual switch (7) is in MANUAL position.

The current limiting rheostat (13) is used to select the recommended starting current for various aircraft. Output current is adjustable within a range of 700 to 2000 amperes.

(6) Hinged panel

The hinged panel (15) is held in closed position by two, threaded fasteners (1). The fasteners have a round, knurled, knob-like head. When opened, the panel is supported in a near horizontal position by a nylon rope.

E. Interior Panel Assembly

The interior panel assembly (Fig. 5) is mounted vertically inside the control box near the rear panel. Com- ponents are described as follows:

Sept 1 l/81 Revised I-l

Page 9

(1) Resistors

TM-630

There are four resistors (3,4, 5, and 8, Fig. 5) mounted on the interior panel.

A 30 ohm, 100 watt, variable resistor (3) is used to adjust generator output to 400 amperes for helicopter

starting. This resistor is connected in the v’oltage regulator signal circuit when the current limiting switch

(9, Fig. 4) is in 400 amperes positio ll ‘1 .

A variable resistor (5, Fig. 5) rated at 20 ohms, 25 watts is connected in series with the current SeleCtOr

rheostat (13, Fig. 4), and is used to adjust the operating range of the rheostat between 700 and 1300

amperes.

The variable resistor (8, Fig.,5), rated at 100 ohms, 25 watts, is connected in series with the current selector rheostat (13, Fig. 4) and is used to adjust the operating range of the rheostat between 900 and

2000 amperes.

The resistor (4, Fig. 5) is not adjustable. It is connected across the generator output leads and provides a very small load required to close the differential relay contacts in the load contactor to make the contactor closing circuit functional and allow the main contacts to be closed when desired.


The overvoltage module (6) is a protective device with solid state circuitry which causes a normally CLOSED relay within the device to OPEN during a condition of overvoltage in the generator output cir-

cuit. The relay contacts are connected in the circuit which holds the load contactor closed. When an

overvoltage condition causes the relay to OPEN, the holding circuit is broken and the load contactor

opens automatically to disconnect the load from the generator. The overvoltage module is adjusted to

trip at 32 to 34 volts DC in 2 to 10 seconds.

(3) Ammeter shunt

The ammeter shunt (7) is connected in the generator POSITIVE output circuit. Its function is to supply a greatly reduced current for operation of ammeter (14, Fig. 4). A diode (9, Fig. 5), mounted in a bus bar

on the generator side of the shunt prevents field flashing power of the 12 volt battery from entering any part of the generator circuit except the shunt field, and thus prevents build-up of reverse polarity.

(4) Overload relay

The solenoid operated, dashpot-type relay (IO) protects the generator and output circuit against overload. The relay contacts are connected in series with the load contactor holding circuit and are normally CLOSED when the generator is operating normally. They may be opened mechanically by action of the

solenoid plunger (or armature). A bus bar in the generator positive output circuit acts as a coil to supply

magnetic force for actuation of the plunger. An overload condition in the output circuit provides suf-

ficient magnetism to lift the plunger against the retaining force of the dashpot piston and open the relay

contacts, thus breaking the load contactor holding circuit and automatically opening the load contactor.

The resistive force of the dashpot on the plunger provides a delaying action and prevents nuisance tripping when the generator is overloaded for short periods of time, such as aircraft starting, etc.

The overload relay will function to open the load contactor if a load of 1000 amperes continues for

1 minute. A larger load will trip the relay in a much shorter time.

l-l

Page IO

Sept II78

hii - . - Fl TM-630

IO

1. Voltage Regulator 6. Overvoltage Module

2. Load Contactor 7. Ammeter Shunt

3. Resistor, 30 ohm, 100 watt 8. Resistor, 100 ohm, 25 watt

4. Resistor, 100 ohm, 25 watt 9. Diode

5. Resistor, 20 ohm, 25 watt 10. Overload Relay

Interior Panel Assembly

Figure 5

Sept l/78 l-l

Page 11

I TM-630

(5) Load contactor

The load contactor (2, Fig. 5) provides a safe and convenient means of connecting, or disconnecting the

generator and the load.

Initial power for closing the load contactor is supplied by the generator through the spring-loaded momentary contacts of the contactor controlswitch (11, Fig. 4). Holding power to maintain the load contactor

in closed position passes through th$ &tionary contacts of the control switch and also the closed con-

tacts of the’ overload relay and the overvoltage module. By this circuitry arrangement the holding circuit is broken and the load contactor opened by either fault condition which causes one of the protective

devices to function.

(6) Voltage regulator

The voltage regulator (1, Fig. 5) is a solid state device designed to provide regulation of 28 volt output on self-excited, DC generators. Means are also provided for current limiting and line drop compensation.

Refer to TM-313, Instructions for Voltage Regulator No. 430090, which is part of the Jet-Ex DII in-’

formation package. Voltage Regulator Instructions contain detailed information and an Illustrated Parts

List.

F. Engine Control Panel

The engine control panel (Fig. 6) is mounted below the control box on the fuel tank and box support frame.

Controls are accessible by opening the lower door with the Plexiglass window in the right rear canopy door.

(1) Panel light

A panel light (6) provides illumination for panel mounted instruments and controls.

(2) Switches

The engine start switch (11) is a momentary contact pushbutton which is used to close the starter solenoid switch and crank the engine.

The ignition switch (9) is spring-loaded in the top START position. Released, it returns to RUN. The light

switch (12) turns the panel lights (3, Fig. 4 and 6, Fig. 6) ON and OFF.

(3) Fuse

The cartridge-type fuse (14), rated at 10 amperes, protects the panel light circuit.

(4) Throttle control

The throttle control (5) is a push-pull cable assembly with T-handle and locking feature. Operation is

covered in detail in the Operation Section (l-3).


Two stud-type terminals provide insulated mounting connections for 28.5 volt DC output cables. The left terminal (1) is negative; the right terminal (3) is positive.

A single capacitor (2) is connected to the positive output circuit. The capacitor is to eliminate radio

frequency interference before it is transmitted to the positive output cable.

l-l

Page 12

Revised Ott 19/81

TM-630

I 2 3 4 5 6 7

8

I3 16

1. Negative Output Terminal 2. Capacitor, R. I. Filter 3. Positive Output Terminal 4. Air Cleaner Service Indicator 5. Throttle Control 6. Panel Light 7. Engine Running Light 8. Cold Weather Start Aid

9. Ignition Switch

10. Ammeter, Battery Charge 11. Starter Pushbutton

12. Panel Light Switch 13. Oil Pressure Gage

14. Fuse, Light Circuit

15. Coolant Temperature Gage

16. Oil Pressure Switch (Panel Rear)

,?

Engine Control Panel

Figure 6

Sept l/78 l-l

Page 13

TO

‘-.

(6) Engine monitoring instruments

TM-630

The ammeter (IO) indicates the rate of charge or discharge in the 12 volt DC engine electrical system.

It is graduated from -30 amperes on the left, through 0 at the center to +30 amperes on the right.

The oil pressure gage (13) is a bourdon tube type and indicates pressure in the engine lubrication

system. It is graduated from 0 to 79 PSI. A diaphragm-type pressure switch is mounted in the oil line

behind the pressure gage by a tee fitting. Switch contacts are connected in the 12 volt DC hourmeter and generator flashing circuit and are held in closed position by oil pressure. The switch allows opera-

tion of the hourmeter and flashing of the generator field only when the engine is running.

The temperature gage (15) 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 cylinder head. The gage indicates engine coolant temperature in the range of 100 to 220 deg. F.

The air cleaner service indicator (4) provides a signal to the operator when the cartridge in the air cleaner (2, Fig. 3) needs changing. Refer to Figure 7. A red cylinder flag (2) is forced upward in the glass vietiing chamber (I) when air pressure inside the air cleaner drops below the outside air pressure due to fouling

of the filter cartridge. As the air pressure in the system drops, the flag rises higher until it locks in place at the highest position. This signals the operator that the air cleaner cartridge MUST be changed to avoid

possible engine shutdown. The flag is released from the locked position by pushing the reset button (3).

ENGINE

-.

AIR CLEANER

-* ~~~~$y,s ~~~~

’ .: ..‘.

INDICATOR ON ’ ..‘+J

3,. ,f

ENGINE CONTROL PANEL .I-

(SEE FIG. II ) 1. :. __

VACUUM’li(O!3E (l/4 IN. I.D.) TO INDICATOR

1. Viewing chamber

2. Indicating flag 3. Reset button

Air Cleaner and Service Indicator

Figure 7

l-l

Page 14

Sept II78

I

7.

8.

I I TM-630

(7) Cold weather starting aid control

The push-pull control (8) operates a cold weather starting aid (15, Fig. 3). The starting aid consists of a

group of items designed to inject a highly combustible fluid into the engine air intake system to assist

ignition of fuel when air temperature is too low for the heat of compression to ignite a normal fuel mix-

ture. The starting aid consists of.a cylindrical fluid container and a valve (see 1-3, Fig. 2) which are

mounted on the lifting yoke.fThe valve is operated by the control (8, Fig. 6). Pulling the control outward

allows fluid to flow into the valve. Pushing the control IN forces fluid through a small tube and an atomiz-

ing nozzle into the air inlet manifold. The addition of atomized, highly combustible fuel into the inlet

air assists in igniting the diesel fuel mixture.

G. RFI Suppression

Four capacitors are mounted on the rear end of the generator housing. They are connected between the generator brushes and ground to suppress any radio frequency interference generated by the brushes. These four capacitors, and the capacitor on the positve output terminal (2, Fig. 6), provide positive RFI suppression for

the generator set.

Optional Trailer

The portable Jet-Ex DII is mounted on a four-wheel trailer (see Fig. 1) which consists of front and,rear axle assemblies. Axles are mounted directly to the main frame of the generator set.

c

The front axle is a solid beam type pivoted at the center to allow up-and-down wheel movement. All wheel hubs

are mounted on roller bearings. Front wheels are mounted on spindles which are operated by tie rods connected

to the hitch and drawbar assembly. Any side-to-side movement of the drawbar turns the wheels in the direction

of travel. The drawbar can be folded upward when the trailer is parked.

The rear axle is also a solid beam type. The parking brake consists of a bar mounted across the underside of the frame ahead of the rear wheels. Metal pads are located on each end of the bar just ahead of each tire. When the bar

is actuated by a hand lever and brake operating rods, the pads are pulled against the tire tread with sufficient pressure to prevent wheel rotation. The actuating mechanism works on an over-center locking principle which will

not unlock until the hand lever is pushed to release position. This trailer is available from Hobart Brothers and is identified by part number 484331.

Optional 14-Volt DC Output Kit

. :

All Jet-Ex D I I units are available with optional 14 volt DC output capability. The 14 volt DC output kit consists

of a contactor panel (Figure 8), a control panel (Figure 9). and miscellaneous cables, wiring, and hardware. This option is available from Hobart Brothers and is identified by part number 483656.

A. 14 Volt Contactor Panel

The 14 volt contactor panel (Figure 8) is located on the left side of the machine below the fuel tank (19,

Figure 3). Its function in the 14 volt DC output circuit is similar to that of the interior panel assembly (Fig

ure 5) in the 28.5 volt DC output circuit.

(1) Overload relay

This solenoid-operated, dashpot-type relay (IO, Figure 8) opens the load contactor (4) if a load of 1000

amperes continues for 1 minute. A larger load will trip the relay in a shorter time.

Ott 22182 Revised l-l Page 15

TM-630

(2) Control relays

The two control relays (1 and 3, Figure 8) are identical. They are identified as 14 volt and 28.5 volt

relays because of the voltage values of their coil circuits. Their function is to prevent operation of both output circuits (14 volt and 28.5 v+lt\ at the same time. They also prevent closing of the 14 volt circuit

while the 28.5 volt circuit is in operation. When the 14 volt system is in operation, they allow the 28.5

volt system to be closed by the operator and at the same time automatically open the 14 volt circuit.

The 14 volt relay (I) energizes the 14 volt control circuit when the 14 volt load contactor is closed.

(3) Load contactor

The 14 volt load contactor (4, Figure 8) performs the same function as the one in the 28.5 volt output circuit. See para. 6. E. (5) for description.


The 14 volt, overvoltage module (7, Figure 8) is similar to the module used on the rear panel assembly

of the control box. See Para. 6, E, (2) for description. The 14volt module is adjusted by a resistor (11) to trip at 18 to 20 volts DC in 2 to IO seconds. The relay resets at 14.5 to 15.5 volts DC.

(5) Resistors

The 300 ohm, 25 watt variable resistor (11, Figure 8) is used to adjust the trip point of the overvoltage

module (7). Adjust the resistor to give 20 volts at the overvoltage module input.

The 100 ohm, 25 watt resistor (9) is not adjustable. It is connected across the 14 volt output leads to pro-

vide a small load required to close the differential relay contacts in the load contactor to make the contactor closing circuit functional and allow the main contacts to be closed when desired.

The 120 ohm, 2 watt resistor (2) is connected in series with the 28.5 volt control relay coil to reduce

power to the coil and protect it when the 28.5 volt output circuit is in operation.


Cables for the 14 volt output circuit are connected to the two terminal studs provided: positive cable to

terminal (6, Figure 8) and negative to terminal (8).

(7) Capacitor

A capacitor (5, Figure 8) is wired into the output circuit to help suppress radio frequency interference

at the output.

B. 14 Volt Control Panel

The 14 volt control panel (Figure 9) is located on the right side of the unit, mounted in front of the air cleaner (2, Figure 3).

l-l

Page 16

Revised Ott 22182

‘& I I TM-630

IO 9 8 7 IpsD-o480(

1. Control Relay, 14 Volt

2. Resistor 3. Control Relay, 28 Volt 4. Load Contactor

5. Capacitor

6. Positive Output Terminal

7. Overvoltage Module

8. Negative Output Terminal

9. Resistor

10. Overload Relay

11. Resistor

14 Volt Output Contactor Panel Figure 8

Ott 22182 Revised l-l

Page 17

I TM-630

(1) Control switch

In the ON position, this three-position toggle switch (2, Figure 9) connects power to the 14 volt control

relay and to the amber mode indicating light. In the CLOSE CONTACTOR position, it connects power to

the load contactor coil for initial clpsing of the contactor. When released from the CLOSE CONTACTOR

position, it returns automatically t& bN and maintains power to the 14 volt control relay. Power to the load contactor coil is maintained through contacts in the 14 volt control relay, the 28 volt control relay,

the overload relay, and the overvoltage module. Placing the control switch in OFF position opens the load

contactor by disconnecting power to the 14 volt control relay, which opens the contactor coil holding circuit.

(2) Mode indicating light

This light (1, Figure 9) glows amber when the 14 volt output circuit is functional. If the light does not come on when the switch (2) is placed in the ON position, it indicates to the operator that the 14 volt

circuit is not functional and the 14 volt contactor cannot be closed.

(3) Contactor closed light

This light (3, Figure 9) glows green when the 14 volt contactor is closed and power is available at the 14

volt output terminals.

I-l Page 18

Revised Ott 22182

Ott 22182 Revised

0 0

TM-630

1 PSD-0481 1

1. Circuit On Light

2. Circuit Control Switch 3. Contactor Closed Light

14 Volt Output Control Panel

Figure 9

I-l

Page 19

i 6

.

TM-630

SECTION 2. PREPARATION FOR USE, STORAGE. OR SHIPPING

1. Preparation for Use

A. General

The generator set is shipped in operating condition and is ready for use after inspection and check.

CAUTION: READ OPERATING INSTRUCTIONS IN SECTION 1-3 BEFORE OPERATING THE

UN IT.

B. Inspection/Check

Inspect the unit completely prior to operation.

(I) Remove crating, blocking, banding, ties, and other securing and protective material. ’

(2) Inspect exterior for shipping damage such as broken glass, damaged sheet metal, etc.

(3) Open all canopy doors and inspect interior for foreign material such as rags, tools, shipping papers, etc.

(4) Check fuel, coolant, and oil hoses and connections for visible leaks. Check the ground surface under the

unit for evidence of leaks. If leaks are discovered, correct by tightening hose clamps, tube fittings, etc., as required.

(5) Check security of attaching and retaining hardware.

(6) Check the following for sufficient quantity.

(a) Fuel

Fuel tank capacity is 30 gallons (114 liters). The recommended fuel is diesel oil conforming to

ASTM Specs D.975-66T No. I-D or No. 2-D.

(b) Engine coolant

The radiator cap is accessible by opening the hinged access cover on the front canopy housing.

Coolant level should be approximately one inch below the filler neck. Allow a sufficient capacity

for coolant expansion.

CAUTION: BE SURE THE COOLING SYSTEM ANTIFREEZE SOLUTION IS ADEQUATE TO

PROTECT BELOW LOWEST TEMPERATURE EXPECTED.

(c) Engine lubricating oil

The oil level dipstick is located on the left side of the engine. The engine manufacturer recommends

the use of lubricating oil conforming to U.S. Ordnance Specification Ml L-L-2104B.

(7) Battery

Check fluid level in both 6-volt batteries. Fluid stiould cover plates.

Sept l/78 1-2

Page 1

I 1

m I 1 TM-630 I J

C. Output Cable Installation

Units are normally supplied without a generator-to-aircraft cable.

(1) Cable requirements i;r ’

Cable length is determined by the customer’s requirements. It is recommended that the cable be no longer

than 30 feet (9 meters). The cable should be two conductor with lug-type terminals on one end and an

AN-2551 plug connector on the other.

Recommended conductor size for 28.5 volts DC and continuous rated amperage (530 amperes) is 2/O size.

NOTE: Some operators may wish to add a second cable assembly with MS-25019 plug connector for starting aircraft such as Jetstar and Sabre liner.

(2) Cable connection

(a) Connect 28 volt conductors to output terminals on engine control panel (l-l, Fig. 6). Terminals are identified POSITIVE and NEGATIVE. Tighten terminal nuts securely. ,_ :. ~~ _._..__ ._ _ ,. . . ‘..‘.i..Il . . . . ..: .., _ ._

(b) Connect 14 volt conductors, if optional kit is used, to output terminals on the 14 volt contactor

panel (l-l; Figure 8). Terminals are labeled POSITIVE and NEGATIVE. Tighten terminal nuts securely.

(c) Store cables on hangers provided at the rear of canopy.

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 and corrosion. Refer to the Perkins Engine Manual for proper procedures

to be followed.

3. Preparation for Shipping

Prepare the unit for shipping as follows:

A. Seal all engine openings to prevent the entrance of water, dirt, and dust.

8. Disconnect battery cables.

C. Drain all fuel from tank and fuel lines as required by carrier rules.

D. Crate the unit solidly to prevent damage to instruments, glass, and sheet metal.

l-2 Page 2

Revised Ott 22/82

TM-630

SECTION 3. OPERATION

1. General

This section contains information and instructions for the safe and efficient operation of the generator set. Operat- ing instructionsare presented in a step-by-step sequence of procedures to be followed in supplying 28.5 volts DC

to an aircraft. I ‘I

NOTE: Read ALL of the operating instructions before attempting to operate the equipment.

WARNING: EAR PROTECTION MAY BE NECESSARY WHEN WORKING IN CLOSE PROXIMITY TO THIS

EQUIPMENT.

2. Operating the Generator Set

A. Prestart Inspection

(1) Always be sure there is sufficient oil and coolant in the engine.

(2) Be sure the fuel shutoff valve is OPEN. The valve is located at the fuel tank outlet. Observe fuel gage.

Make certain of sufficient fuel to complete the job to be done.

(3) If the unit is trailer-mounted and is not connected to a tow vehicle, be sure the parking brake is applied. The brake lever operates on an over-center locking principle. Pull the lever backward until it snaps into

locked position. To unlock, push the lever forward to full OFF position.

(4) Open doors and inspect interior for rags, tools, and foreign material.

B. Starting the Engine

(I) Refer to Figure 1. Be sure contactor control switch (11) is in OFF position.

(2) Pull throttle (21) out approximately one quarter of full travel and lock by turning control clockwise.

(3) Position ignition switch (25) to top START position and hold.

(4) Press starter pushbutton (27) and hold until engine starts. Green engine running light (23) will glow.

(5) Continue to hold ignition switch (25) in START position, after engine starts, until oil pressure gage (29)

indicates 10 psi or over; then release to RUN position.

CAUTION: (a) IF THE ENGINE FAILS TO START WITHIN 30 SECONDS, RELEASE THE START

SWITCH AND ALLOW THE STARTING MOTOR TO COOL FOR A FEW MINUTES. IF THE ENGINE FAILS TO START AFTER FOUR ATTEMPTS, AN INSPECTION

SHOULD BE MADE TO DETERMINE THE CAUSE.

(b) IF THE ENGINE FIRES SUFFICIENTLY TO DISENGAGE THE STARTER GEAR,

BUT DOES NOT START, RELEASE THE START BUTTON AND ALLOW THE

STARTING MOTOR TO COME TO A COMPLETE STOP BEFORE ATTEMPTING

TO ENGAGE THE STARTER AGAIN.

(6) After engine starts, slowly push throttle control all the way in. Engine will idle at approximately 900

RPM. Allow the engine to warm approximately five minutes before applying load.

Ott 19/81 Revised 1-3

Page 1

16 \

1 I 2 3 4 5 I 6 TM-630

17 18 19 20 21 22 23

1. Panel Fastener 2. Voltmeter, 28.5 Volt System 3. Panel Light 4. Hourmeter 5. Tachometer 6. Contactor Closed Light 7. Automatic/Manual Switch 8. Current Range Switch 9. Current Limiting Switch

24

25

26

27

28

10. Push To Build Up Volts Switch 21. Throttle Control 11. Contactor Control Switch 22. Panel Light 12. Field Rheostat Control 23. Engine Running Light 13. Current Limiting Control 24. Cold Weather Start Control 14. Ammeter, 28.5 Volt System 25. Ignition Switch 15. Hinged Panel 26. Ammeter, 12 Volt System 16. Interior Panel 27. Starter Pushbutton 17. Negative Output Terminal 28. Panel Light Switch 18. Capacitor 29. Oil Pressure Gage 19. Positive Output Terminal 30. Fuse, Light Circuit 20. Air Cleaner Service Indicator 31. Coolant Temperature Gage

1-3

Operating Controls and Instruments Figure 1

Page 2

Sept II78

C. Cold Weather Engine Starting Procedures

TM-630

A cold weather starting-aid kit (Fig. 2) is provided to assist in starting the engine at temperatures below 50 deg F (IO deg C). To start the engine, using the starting aid, proceed as follows:

(I) Position switches and conty/; as’instructed in paragraph 2, B, above.

(2) Prepare starting aid for use. The starting aid is shipped in a safe condition and is not operable until assembled. Assemble as follows:

WARNING:

-. _

STARTING FLUID IS EXTREMELY FLAMMABLE. IT IS UNDER PRESSURE.

USE CAUTION WHEN HANDLING. AVOID CONTACT WITH SKIN AND AVOID

BREATHING VAPOR.

Cold Weather Starting Aid

Figure 2

1. Clamp nut

2. Fluid cylinder

3. Cylinder cap

4. Plug

5. Valve 6. Control cable

(a) Loosen clamp nuts (1, Fig. 2) and slide the cylinder (2) upward sufficiently to remove protective

cap (3) and plug (4).

(b) Use bottle opener to remove cylinder cap (3). Unscrew and remove plug (4).

(c) Slide the cylinder (2) downward and thread into the valve (5). Tighten securely. The starting aid is

now ready for use.

Sept l/78 1-3

Page 3

TM-630

(3) Cold weather starting procedures are exactly the same as for normal starting except:

(a) Before cranking the engine, pull the starting aid control (24, Fig. 1) OUT to the full extent of its travel. Hold for 2 to 3 seconds. (This allows the starting aid valve chambers to fill with pressurized ethyl ether.)

i 6 (b) Push,the control IN. (This step sprays starting fluid into the engine intake manifold.)

(c) Follow normal starting procedures and CAUTIONS in para. 2, B, above.

(d) In extremely cold weather it may be necessary to repeat steps (a) and (b) above.

CAUTION: USE STARTING AID ONLY FOR STARTING. DO NOT OPERATE WHILE ENGINE IS RUNNING.

WARNING: DO NOT FLOOD THE ENGINE WITH STARTING FLUID. A SERIOUS EXPLOSION COULD RESULT.

D. Preparation for Power Delivery

(I) Remove the output cable from its stored position on the cable hangers at the rear of the canopy.

(2) Connect the cable plug to the aircraft receptacle connector.

E. Power Delivery

CAUTION: NEVER HOLD THE CONTACTOR CONTROL SWITCH (11, FIG. 1) IN THE TOP ON POSITION TO DELIVER POWER TO AN AIRCRAFT. IN THIS POSI- TION, THE CONTACTOR CLOSES BUT ALL PROTECTIVE DEVICES ARE BYPASSED AND SERIOUS DAMAGE TO THE AIRCRAFT’S ELECTRICAL CIRCUITS MAY RESULT.

There are several methods of power delivery including normal automatic voltage control, manual voltage control, limited current engine starting, and helicopter starting. Each method is covered below. For each method it is assumed that the engine has been started and warmed and is running at IDLE speed.

(I) Normal power delivery with automatic voltage control

(a) If lighting is required, place light switch (28, Fig. 1) in ON position.

(b) Place automatic-manual switch (7) in AUTOMATIC position.

(c) Place current limiting switch (9) in CUR. LIM. (up) position.

(d) Unlock throttle control (21) (turn to left counterclockwise) and,pull OUT to full throttle position and turn right to lock. Observe tachometer. Engine speed should be approximately 2400 RPM.

(e) Check engine gages.

Ammeter should indicate a slight charge. It may be near zero if the battery is fully charged.

Normal oil pressure is 30 to 60 psi hot.

Normal coolant temperature is 165 to 195 deg F. depending on ambient temperature, load, etc.

1-3

Page 4

Revised Sept 1 l/81

TM-630

(f) Press the push-to-build-up voltage switch (IO) to flash the generator field coils.

NOTE: It is necessary to press this switch only when the generator has insufficient residual magnetism.

A voltage value of approximately 28.5 volts DC will be observed on the voltmeter (2). If value is other than 28.5 volts DCb adjust voltage regulator according to instructions in TM-313 under AD-

1 JUSTMENTS.

(g) Check to be certain that the aircraft is in condition to receive power.

(h) If current limiting in the range of 700 to 1300 amperes is required, push current range switch (8) to down position and adjust current with control (13) reading INNER scale.

(j) If current limiting in the range of 900 to 2000 amperes is required, push current range switch (8) to up position and adjust current with control (13) reading OUTER scale.

(k) To apply power to the aircraft, close the load contactor by holding the contactor control switch (11) in top ON position momentarily until indicating light (6) glows green. Release switch and allow it to position to center ON position. Light (6) will continue to glow, indicating that the load con-

tactor is CLOSED and power is available at the aircraft.

Voltage will be automatically regulated at approximately 28.5 volts DC by the voltage regulator.


Not all aircraft engine starters require the same cranking current.

(a) Refer to the aircraft engine manual to find engine starter current requirements.

(b) Follow power delivery procedures as outlined in Para. 2, E, (I), (a) through (k) above,


Helicopter and small turbine starting requires a low current limiting capability not possible by using the

current limiting rheostat (13). For helicopter starting proceed as follows:

(a) Prepare the machine for normal power delivery as instructed in Para. 2, D, (I) (a thru g) above,

except:

Place current limiting switch (9) in 400 amperes (bottom) position. In this switch position the current limiting rheostat (13) is by-passed and maximum output of the generator is limited to approximately

400 amperes.

(b) Close load contactor by holding control switch (11) in top ON position, then release to center ON position. Light (6) will glow, indicating contactor is closed.


This mode of operation is recommended for generator testing, or for emergency use in case of voltage regulator trouble only. For manual control of generator output voltage, use normal operating procedures

except:

Sept II78 1-3

Page 5

r I

TM-630

(a) Place automatic-manual switch (7) in MANUAL position.

(b) Use the rheostat (12) to manually regulate voltage at 28.5 volts DC as indicated on voltmeter (2).

Turn knob clockwise to INCREASE voltage. Turn counterclockwise to reduce voltage.

F. Discontinue Power Delivery

I i i,

(1) Place load contactor control switch (11) in OFF position.

Light (6) will go off to indicate load contactor has opened and power is no longer available at the air-

craft.

(2) Push throttle control (21) IN to IDLE position.

(3) Disconnect cable plug from aircraft receptacle and store cable on hangers at the rear of canopy.

(4) Stop engine by placing ignition switch (25) in OFF position.

NOTE: If the engine has been under heavy load for a long period, allow it to idle and cool for a few

minutes before stopping.

3. Operation

When the 14 volt DC output option is used with the generator set, operate the unit in accordance with the follow-

ing instructions to deliver 14 volt DC output power.

A. Preparation for Power Delivery

(1) Prepare the unit for 14 volt operation following the same procedure used for 28 volt operation, and

described in Para. 2. A, B, and C above.

(2) Remove 14 volt output cable from its stored position.

(3) Connect cable plug to aircraft receptacle connector.

NOTE: Both 14 volt and 28 volt output cables may be connected to aircraft (or loads) at the same

time, but 14 volt and 28 volt DC power CANNOT BE DELIVERED AT THE SAME TIME.

B. Power Delivery

All of the power delivery modes used with the 28 volt output circuit may be used with the 14 volt output

option. For each power delivery mode described below, it is assumed that the engine has been started and

warmed and is running at IDLE speed.

NOTE: For 14 volt power delivery, the 28 volt contactor control switch (11, Figure 1) MUST be

positioned to OFF.

CAUTION: NEVER HOLD THE CONTACTOR CONTROL SWITCH (2, FIG. 3) IN THE TOP ON

POSITION TO DELIVER POWER TO AN AIRCRAFT. IN THIS POSITION, THE CON-

TACTOR CLOSES BUT ALL PROTECTIVE DEVICES ARE BYPASSED AND SERIOUS

DAMAGE TO THE AIRCRAFT’S ELECTRICAL CIRCUITS MAY RESULT.

1-3

Page 6

Revised Ott 22182

TM-630

I 2

\

3

\ \

0 0

1. Circuit On Light

2. Circuit Control Switch 3. Contactor Closed Light

14 Volt Output Control Panel Figure 3


Page 7

TM-630

(1) Normal 14 volt power delivery with automatic voltage control

(a) If lighting is required, place light switch (28, Fig. 1) in ON position.

(b) Place automatic-manual switc \{) in AUTOMATIC position.

(c) Place’current limiting switch (9) in CUR. LIM. (up) position.

(d) Unlock throttle control (21) (turn to left counterclockwise) and pull OUT to full throttle position

and turn right to lock. Observe tachometer. Engine speed should be approximately 2400 RPM:

(e) Check engine gages.

Ammeter should indicate a slight charge. It may be near zero if the battery is fully charged.

Normal oil pressure is 30 to 60 psi hot.

Normal coolant temperature is 165 to 195 deg F. depending on ambient temperature, load, etc.

(f) Press the push-to-build-up voltage switch (10) to flash the generator field coils.

It is necessary to press this switch only when the generator has insufficient residual NOTE:

magnetism.

A voltage value of approximately 28.5 volts DC will be observed on the voltmeter (2). If value is

other than 28.5 volts DC, adjust voltage regulator according to instructions in TM-313 under AD-

JUSTMENTS.

(g) Check to be certain that the aircraft is in condition to receive power.

(h) If current limiting in the range of 700 to 1300 amperes is required, push current range switch (8) to down position and adjust current with control (13) reading INNER scale.

(j) If current limiting in the range of 900 to 2000 amperes is required, push current range switch (8) to

up position and adjust current with control (13) reading OUTER scale.

(k) To deliver power to the aircraft, position contactor control switch (2, Fig. 3) to center ON position.

14 Volt MODE light (1) will glow amber to indicate that the 14 volt output circuit is functional. Voltmeter (2, Fig. 1) will indicate 14 volts DC. Position the switch (2, Fig. 3) to the top CLOSE CONTACTOR position momentarily, then release it to the center ON position. CONTACTOR

CLOSED light (3) will glow to indicate that the contactor is closed and 14 volt DC power is avail-

able at the aircraft. Voltage will be regulated automatically at 14 volts DC by the voltage regulator.


Not all aircraft engine starters require the same cranking current.

(a) Refer to the aircraft engine manual to find engine starter current requirements.

(b) Follow power delivery procedures as outlined in Para. 3, E, (I), (a) through (k) above.

I-3

Page 8

Revised Ott 22/81

TM-630


Helicopter and small turbine starting requires a low current limiting capability not possible by using the

current limiting rheostat (13, Fig. 1). For helicopter starting proceed as follows:

(a) Prepare the machine for normal power delivery as instructed in Para. 3, E. (I) (a thru g) above,

except: i ;, I

Place current limiting switch (9) in 400 amperes (bottom) position. In this switch position the current

limiting rheostat (13) is by-passed and maximum output of the generator is limited to approximately ,

400 amperes.

(b) Close load contactor by holding control switch (2, Fig. 3) in top ON position, then release to center ON position. Light (3) will glow, indicating contactor is closed.


This mode of operation is recommended for generator testing, or for emergency use in case of voltage regulator trouble only. For manual control of generator output voltage, use normal operating procedures

except:

(a) Place automatic-manual switch (7, Fig. 1) in MANUAL position.

(b) Use the rheostat (12) to manually regulate voltage at 14 volts DC as indicated on voltmeter (2).

Turn knob clockwise to INCREASE voltage. Turn counterclockwise to reduce voltage.

C. Discontinue Power Delivery

(1) Place load contactor control switch (2, Fig. 3) in OFF position.

Lights (1 and 3) will go off to indicate load contactor has opened and power is no longer available at the

aircraft.

(2) Push throttle control (21, Fig. 1) IN to IDLE position.

(3) Disconnect cable plug from aircraft receptacle and store cable on hangers at the rear of canopy.

(4) Stop engine by placing ignition switch (25) in OFF position.

NOTE: If the engine has been under heavy load for a long period, allow it to idle and cool for a few minutes before stopping.

D. Switching Power from Mode-to-Mode

Power delivery can be switched from one mode to the other without stopping the machine and without

making major control changes.

(1) Switch from 14 volt to 28.5 volt delivery

For this change, place 28.5 volt DC load contactor control switch (11, Figure 1) in top CLOSE position

momentarily, then release to center ON position. The 28.5 volt DC load contactor will close and the

14 volt DC load contactor will be automatically opened.

Ott 22/82 Revised l-3

Page 9

TM-630

(2) Switch from 28.5 volt to 14 volt delivery

(a) Place 28.5 volt DC load contactor control switch (11, Figure 1) in OFF position.

(b) Hold 14 volt DC control switcj [f, Figure 3) in top CLOSE CONTACTOR position until both

indicating lights (1 and 3) are on. Release switch to center ON position.

NOTE: Switching from 14 volt DC to 28.5 volt DC can be made simply by operating the 28.5 volt DC contactor switch (11, Figure 1); however, the 28.5 volt DC switch must be turned ,off

first to change from 28.5 volt to 14 volt power.

4. 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.

1-3

Page IO

Revised Ott 22182

I I TM-630

CHAPTER 2. SERVICING

SECTION 1. MAINTENANCE INSPECTION/CHECK

I- - General i 4

To make certain the generator set is always in good operating condition, it must be inspected, maintained, and lub-

ricated regularly and systematically.

WARNING: STOP OPERATIONS AT ONCE IF A SERIOUS OR POSSIBLY DANGEROUS FAULT IS

DISCOVERED.

2. Maintenance Schedule

A. General

A periodic maintenance schedule should be established and maintained. A suggested schedule is provided in

Figure 1. It may be modified as required to meet varying operating and environmental conditions.

B. Maintenance Schedule Check Sheet

It is strongly recommended that the customer use a maintenance schedule check sheet. The check sheet will provide a record of maintenance operations performed and may also serve to improve scheduling for a specific

operation.

C. Time Intervals

The schedule is based on both hours of operation and calendar intervals. These two intervals are not neces-

sarily the same. The calendar period is included to make certain services are performed regularly when equipment is being operated infrequently. Hourly time intervals agree with the engine manufacturer’s recommenda-

tions. Perform all services on a whichever comes first basis.

3. Inspection/Check

Inspections, checks, and maintenance operations are listed in Figure 1. More specific and detailed information is contained in Sections 2 and 3 of this Chapter.

CAUTION: DO NOT USE A HIGH PRESSURE SPRAY WITH SOAP OR DETERGENT, OR STEAM CLEANER ON THE GENERATOR OR OTHER ELECTRICAL EQUIPMENT. IF SOAP

ENTERS THE GENERATOR BEARING, ITS LIFE WILL BE SHORTENED. DETERGENT AND STEAM MAY ALSO PENETRATE OTHER ELECTRICAL EQUIPMENT AND CAUSE

CORROSION, RUST, SHORTING, ETC.

Sept l/78 2-I

Page 1

TM-630

ENGINE

10 Hrs. 100 Hrs. 200 Hrs. 400 Hrs. 800 Hrs. AIR or

Daily 2 ;ks. 1 i-0. 2:o. 6:o.

Check oil level i 4 X

Check coolant level X

Check fuel quantity X

Check gages and instruments for proper operation X

_* Change engine oil X

Change engine oil filter X

Lubricate throttle linkage X

Check and tighten fan belt X X

Clean and inspect exterior of radiator X

Check exhaust system X

Check cooling system X

Check compression X X

Check and refill cooling system (Twice yearly, summer and winter) X

Replace fuel filter X

Replace air cleaner cartridge X

Clean engine X

ELECTRICAL SYSTEM (12 volts DC)

Check lights Check charging rate Check battery water level Check battery state of charge Check wiring and connections Check all instruments and gages Clean battery terminals and connectors

ELECTRICAL SYSTEM (28.5 volts DC)

X X

X X X

x I X

Check indicating light Check operation of all instruments, meters, etc. Check generator brushes for length, cleanliness,

and free operation Check commutator for smoothness and

cleanliness Check overload relay dashpot Clean the entire unit Check overload protection Check overvoltage protection Check all wiring and connections

TRAILER

X X

x

X X X X

X X

Lubricate X

Check tire inflation X

Check and adjust wheel bearings X

Lubricate wheel bearings X

Inspection/Check/Maintenance Schedule Figure 1

2-I

Page 2

Revised Ott 19/81

1. General

w

I I

SECTION 2. MAINTENANCE PROCEDURES

TM-630

A suggested Maintenance Schedule is provided in Section 1 of this Chapter. This Section covers maintenance in

more detail where necessary. i 4 WARNING: STOP OPERATION IMMEDIATELY IF A SERIOUS OR POSSIBLY DANGEROUS FAULT IS

DISCOVERED.

2. Lubrication

A. General

Proper lubrication is one of the most important steps in good maintenance procedure. Proper lubrication means the use of correct lubricants and adherence to a proper time schedule. Lubrication points, frequency of lubrication, and recommended lubricants are indicated in Figure I.

B. Lubrication Chart

Lubrication points are illustrated and identified by name on Lubrication Chart, Figure 1.

Number symbols used to designate the kind of lubricant required and the specification rcommended are identified in Figure 2.

Letter symbols used to designate the normal lubrication period are identified in Figure 3.

C. Generator

The 28.5 volt DC generator requires NO lubrication. The armature is supported at the rear by a single, ball bearing which is lubricated and sealed at the factory for lifetime, maintenance free operation. The front end

of the armature is supported by the engine main bearings.

D. Generator Controls

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

E. 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. Recommendations

regarding engine lubrication have been taken from the engine manufacturer’s Maintenance and Operator’s

Manual.

(I 1 Lubrication schedule

Time schedules indicated on the Lubrication Chart, Figure 1, are approximate . They are based on average

operating conditions. It may be necessary to lubricate more frequently under severe operating conditions

such as: low engine temperature, high oil temperature, intermittent operation, or dusty conditions. How-

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

Sept II78 2-2

Page 1

TM-630

Steering pinion ‘BM 1 BM 1 Draw bar

Axle pin BM 1

Tie rod j3M 1

King pin BM 1

Wheel bearing SA 3

BM 1 Tie rods r

,‘.

BM 1 Tie rods ‘:I: *’ ,

BM 1 Kingpins --ei: L

SA 3 Wheel beaiings;, I$.

Fuel filters SA

Throttle linkage M2

** Oil filter M

* Crankcase D2

SA 3 Wheel bearings *,

2-2

Page 2

Lubrication Chart Figure 1

Sept II78

TM-630

SYMBOL NAME SPECIFICATION NOTES

1 Grease, Automotive and Federal Sinclair Litholene Industrial

lndustridl ’ 1 VV-G-632 No. 2; Mobile-Mobilplex 47, I or equivalent.

2 Oil, Engine

3 Grease, Automotive

Military

MIL-L-2104B

Military

MI L-G-1 0924B

See Perkins Engine Shop

Manual.

Wheel bearings.

Lubricants Figure 2

SYMBOL TIME INTERVAL

D 10 hours or Daily

BW 100 hours or Biweekly M 200 hours or Monthly

BM 400 hours or Bimonthly SA 800 hours or Semiannually

Symbols and Time Intervals

Figure 3

(2) Oil specification

Engine lubricating oil recommended by the engine manufacturer must meet the requirements of U.S.

Ordnance Specification MIL-L-2104B.

The use of quality lubricating oil, combined with proper oil drain and filter change intervals are important

factors in extending engine life.

(3) Oil viscosity

Lubricating oil should have a minimum viscosity index of 80.

(4) Change engine oil

Change engine lubricating oil following the instructions in the Perkins Engine Shop Manual.

Sept II78 2-2

Page 3

TM-630

(5) Change engine oil filter

Change the oil filter following the instructions in the Perkins Engine Shop Manual.

F. Trailer

(1) Front axle assembly

The front axle assembly, drawbar, and steering linkage are equipped with high-pressure lubrication

fittings. Lubricate the trailer each 400 hours. Use a good quality chassis lubricant (see Fig. 2). Clean

lube fittings before applying grease.

(2) Wheel bearings

Lubricate and check wheel bearing adjustment each 800 hours or semiannually. Use a good quality bearing lubricant (see Fig. 2).

3. Air Cleaner Service

The air cleaner is a dry type with replaceable filter cartridge. A definite time schedule for changing the filter cartridge cannot be determined because of varying operating conditions. Change the filter cartridge when the red indicator flag reaches the top of the viewing chamber and locks in that position. Change the cartridge as follows:

A. Cartridge Removal

(1) Refer to Figure 4. Loosen the four nuts (I), unlatch clamps (3) and swing the tee bolts (4) outward away from the moisture eliminator (7).

(2) Remove the moisture eliminator (7).

(3) Remove the filter cartridge (6) and discard.

CAUTION: DO NOT CLEAN OR REUSE CARTRIDGE.

(4) Inspect the interior of the cleaner housing (5). Make certain it is free from all foreign material.

B. Cartridge Installation

(1) Carefully insert the new cartridge into the housing. Avoid hitting the cartridge tubes against the housing

sealing flange. Make certain the cartridge is seated properly within the housing. Press all edges and corners

of the cartridge firmly with the fingers to effect a positive air seal against the sealing flange of the housing.

CAUTION: UNDER NO CIRCUMSTANCES SHOULD THE CARTRIDGE BE POUNDED OR STRUCK IN THE CENTER TO EFFECT A SEAL.

(2) Lock the cartridge in place by installing the moisture eliminator (7) and clamping in place with four tee bolts, clamps and nuts.

(3) Nuts must be tightened evenly, crisscrossing from corner to corner. After tightening the nuts as tight as

possible by hand, tighten them two full turns with a small wrench.

NOTE: Check the nuts three or four days later and retighten if required.

2-2

Page 4

Sept II78

TM-630

;I 5 6

I

113-5961)

- -.

1. Nut 5. Housing

2. Spring washer 6. Cartridge

3. Clamp 7. Moisture eliminator

4. Tee bolt

Air Cleaner Cartridge Replacement (Typical) Figure 4

4. Batterv Service

A. General

Two 6 volt batteries supply power for operation of the engine electrical system, clearance and panel lights, and

for flashing the 28.5 volt generator field.

B. Battery Location and Accessibility

The two batteries are mounted inside the generator frame, one on each side, at the rear of the unit. They are accessible by opening the rear doors of the enclosure and may be removed by disconnecting the cables, removing the lower side panels, and removing the holddown clamps.

Sept II78 2-2

Page 5

id - . - Pl I I

C. Battery Care

TM-630

(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 chargt#d;Fondition.

(3) Be sure batteries are fastened securely in the vehicle to avoid damage from vibration.

(4) Maintain battery fluid at proper level.

(5) Keep battery terminal posts and lead connectors clean.

WARNING: (a) NEVER ALLOW SPARKS OR OPEN FLAME NEAR THE BATTERIES.

(b) AVOID SPILLING ELECTROLYTE ON HANDS OR CLOTHING.

NOTE: See Para. 7 for battery testing information.

D. Liquid Level

The electrolyte in each cell should be above the plates at all times to prevent battery failure. Check the

level of the electrolyte every 2 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.

CAUTION: NEVER ADD ANY SPECIAL BATTERY DOPES, SOLUTIONS, OR POWDERS.

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 for ,

several 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. Disconnect lead connectors from battery posts. Brighten terminal and post

surfaces with steel wool, a wire brush, or special terminal cleaning tool. Make certain that the vent holes in filler caps are not clogged.

5. Generator Maintenance

A. General

The only maintenance service required for the generator will be brush replacement, commutator cleaning, etc.

B. Brush Service

(1) Cleaning

2-2

Page 6

Sept l/78

I w

TM-630

If inspection reveals that brushes are gummy or sticking in the brushholders, they should be removed and

cleaned. Clean both the brushes and brushholders. Use a good, SAFE, commercial cleaner. DRY ALL PARTS THOROUGHLY. Be sure brushes can move freely in brushholders.

WARNING: DO NOT USE A FLAMMABLE SOLVENT. DO NOT USE STEAM CLEANER, OR

SOAPS AND/DETERGENTS UNDER PRESSURE.

(2) Replacement

Brushes for this application are l-3/4 inches (44 mm) long when new. They should be replaced when

worn to one-half their original length, or 7/8 inch (22 mm).

(a) Remove pigtail attaching screw.

(b) Move brush spring (1, Fig. 5) aside and remove old brush (3).

(c) Check ne.w brushes before installation. Size must be 3/4 x 1 x l-3/4 inches (19 x 25.4 x 44 mm).

(d) Move brush spring aside and install new brush.

Check position of brush pigtail and install so that pigtail is on the forward side of the NOTE: brush.

(e) Check the clearance between brush and brushholder. The brush should move up and down freely

in the holder, yet without excessive side-to-side or fore-and-aft movement.

Sept l/78

Generator Brush Installation

Figure 5

1. 2.

3. 4.

5.

6.

Spring Pigtail Brush

Nut

Spring mounting

adapter

Wrench

2-2

Page 7

1 (f) Connect the pigtail. A single screw attaches two brush pigtails.

TM-630

(g) Repeat steps (a) through (f) for other brushes.

(3) Brush seating

When replacing brushes, it is importart that they be carefully fitted to the commutator ring. The seating

stone method of brush seating is re L ommended for this installation. I

Seating stones are fine-grain, abrasive blocks made especially for brush seating. When applied to the

commutator, fine particles from the stone drift under the brush and shape its face to the same curve

as the commutator.

(a) Start the motor and operate the generator with no power output.

(b) Hold the stone against the commutator immediately behind the brushholder so that stone particles will be carried directly under the brush. Steady the stone by holding it against the ,

brushholder.

(c) Seating may be speeded up by applying extra pressure on the brush.

WARNING: EXERCISE CARE TO AVOID INJURY BY THE ROTATING EQUIPMENT

OR ELECTRICAL SHOCK.

(d) Use dry compressed air to blow out any grit or foreign material.

CAUTION: DO NOT APPLY A FULL LOAD UNTIL BRUSHES HAVE RUN-IN FOR

APPROXIMATELY ONE HOUR AT 300 TO 400 AMPERE LOAD.

(4) Brush springs

Refer to Section 2-3, Para. 3, A, (3) for brush spring adjustment instructions.

(5) Commutator cleaning

One of the best ways of cleaning the commutator is to use a piece of clean, hard-woven canvas, attached

to, or folded on a wooden stick. Hold the canvas against the rotating commutator until dirt and smudge

are removed.

Another effective method of cleaning and smoothing the commutator is the use of a flexible abrasive

block especially manufactured for commutator cleaning. When held against the revolving commutator,

the block will quickly remove deposits of dirt and grease.

Operate the generator at 300 to 400 ampere load for approximately one hour to allow a film to form on

the commutator after cleaning.

6. Generator Controls Maintenance

A. General

The overload relay dashpot (Fig. 6) is the only component of the control system which requires periodic

inspection and maintenance. It is located on the interior panel (I-l ; IO, Fig. 5).

When the 14 volt output option is used with the generator set, a second, identical relay is mounted on its

contactor panel (1-I; 10, Fig. 8).

2-2 Revised Ott 22/82

Page 8

I I

m TM-630

B. Overload Relay

The entrance of water into the dashpot or the use of improper fluid may cause operating troubles requiring disassembly and repair of the dashpot assembly. The following instructions include repair procedures in the

recommended sequence of steps.

(1) Disassemble I (a) Hold the dashpot and unlatch the spring clamp (4, Fig. 7) by prying with a screwdriver to swing the ,

clamp forward. Lower and remove the complete dashpot assembly.

_ Contacts

/ L\- Plunger

5 Ill - Dashpot

Overload Relay Installation

Figure 6

(b) Lift the core (I), cover (2), and valve plate (6) out of the dashpot (3) as an assembly.

(c) Pour the dashpot fluid into a clean glass container and inspect for signs of water.

NOTE: Moisture may condense in the dashpot to form water which will cause corrosion

of the valve plate and dashpot.

Sept II78 2-2

Page 9

(2) Inspection

I TM-630

Inspect the valve plate (6, Fig. 7) and the dashpot (3) for evidence of corrosion. Discard, if corroded,

and replace with new parts. Observe the position of the two valve plate covers. One is diamond shaped

and retains two steel balls (5). This cover should not be disturbed. The other plate serves to cover the valve plate by-pass holes, and MUST be positioned to completely COVER and CLOSE the holes.

(3) Assemble

(a) Pour a sufficient quantity of new fluid into the dashpot to cover the circular ridges in the bottom.

Use a silicon fluid with a viscosity rating of 100 centistokes at 77 deg F (25 deg Cl.

Approved fluids are:

Dow-Corning No. 200 (100 centistokes) Allen-Bradley No. 810-N9B, Series A

Allen-Bradley No. X-106518

NOTE: Allen-Bradley numbers indicate different container sizes.

(b) Install the valve plate (6) and core (1) as an assembly. Make certain that the valve plate bottoms in

the dashpot.

(c) Add fluid until the surface of the fluid is level with the tops of the three cylindrical projections on top of the valve plate. Actuate the piston a short distance up and down to expel any air trapped below the plate. Recheck the fluid level and add fluid if required.

1. Core (plunger

2. Cover

3. Dashpot

4. Spring clamp

5. Steel balls 6. Valve plate

7. Lock spring

I I l-l/8 INCH

(29rTv-d

-7

,OL LEVEL 1;

‘6

Overload Relay Dashpot Assembly

Figure 7 2-2

Page 10

Sept l/78

I I ._- m

I I TM-630

(d) Install the dashpot cover (2).

(e) Make certain the valve plate (6) is bottomed in the dashpot and measure the height that the core ex-

tends above the rim of the dashpot. Adjust core (I) so that it extends I-118 inch (29 mm) above the

dashpot rim. This adjustment should cause the overload relay to trip at IOOO-ampere load in 1 minute. Increase the heig l-i t t$v turning the core in a counterclockwise direction. Decrease the height by

I turning the core in a clockwise direction. Turn the core a full turn at a time and be sure the lock

spring (7) is seated in the valve plate stud groove when the adjustment is completed.

(f) Position the dashpot assembly in the overload relay and lock in place with the spring clamp (4).

7. 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. The presence of 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.

A. Test with Battery-Starter Tester

Connect the battery to the tester according to instructions furnished with the instrument. Test the battery in accordance with tester instructions. If the test determines that the battery has acceptable voltage, it in-

dicates that the battery has output capacity and will accept a charge, if required.

B. Test with Hydrometer

(1) 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 .I40 down to 1.120.

NOTE: The battery is fully charged when all cells are gassing freely, and the specific gravity ceases to

rise for three successive readings taken at hourly intervals.

(2) If the Battery-Starter Test indicated the battery voltage was below the acceptable voltage value, test each cell with the hydrometer. If the difference in specific gravity readings between any two cells is 50 points (0.050) or more, the battery is not satisfactory for service and should be replaced.

Sept I/78 2-2

Page 11

SECTION 3. AD.iUSTMENT/TEST

TM-630

I. ___ General

These adjustment and test procedures are most applicable to testing and adjusting the generator set after major repair, replacement of parts, long storage;etc.

i ‘I 2. Testing the Generator Set

A. Preoperational Test Procedures

Perform the following checks, tests, and operations before starting the unit.

(1) Open all access doors and inspect interior for foreign material (rags, tools, etc.).

(2) Check engine oil and governor oil levels.

(3) Check coolant level.

(4) Check battery water level.

(5) Check fuel tank quantity.

(6) 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, preferably size 2/O, and not more than 30 feet (9 meters) long.

(7) Make a general inspection of all wiring and connections to find any obviously incorrect wiring, loose

wires, and loose or shorted terminal lugs.

(8) Check V-belt tension. Belt should have approximately l/2 inch (13 mm) slack.

(9) Set manual control rheostat (12, Fig. 1) to MINIMUM position.

(10) Set automatic-manual switch (7, Fig. 1) to MANUAL position.

(11) Check panel lights.

B. Operational Test

(1) Start engine in accordance with Sect. 1-3, Para. 2, B.

(2) Engine should idle at 900 RPM with throttle control (21) pushed IN.

(3) Inspect for oil, fuel, and coolant leaks.

(4) Check 12 volt DC ammeter (14), oil pressure gage (29), and temperature indicator (31).

(5) Pull throttle control OUT to full speed position. Tachometer should indicate 2450 RPM at no load.

(6) Check and record manual rheostat range which should be approximately 2 volts DC minimum to 49 volts DC maximum as observed on voltmeter (2). Reset rheostat at 28.5 volts DC.


Page 1

(7) Place contactor switch (11) in top ON position momentarily. Release, and allow switch to return to center ON position. Load contactor should CLOSE and indicating light (6) should glow green.

(8) If brushes have been replaced, proceed as follows:

(a) Use brush-seating stone to seat brushes.

i ‘I (b) Applyla load of 300 to 400 amperes and allow brushes to run-in for a minimum of 1 hour.

(9) Adjust brushholder to give 27.5 to 28.5 volts at 750 amperes load when no-load voltage is set at 28.5

with manual control rheostat. (See Para. 3, A, [I I for adjustment procedures.)

(IO) Check speed regulation at no-load and full-load. Adjust governor as required to limit droop to 100 RPM

or less.

(11) Check overload relay trip time at 1000 amperes. Should trip in approximately 1 minute. (See 2-2, Para.

5, B, [3], [el for adjustment.)

(12) Check overvoltage relay. Should trip at 32 to 34 volts DC, in 2 to 10 seconds.

(13) Check reverse current protection by connecting the output to a 24 volt DC source (two - 12 volt

batteries). Reduce generator voltage until load contactor opens.

(14) Place automatic-manual switch (15, Fig. 1) in AUTOMATIC position. Adjust rheostat on voltage regu-

lator to 28.5 volts DC. (See attached Voltage Regulator Instructions, TM-313.)

(15) Place current-limiting rheostat (13) in MAXIMUM position, current-limiting selector switch (9) in top position and current range switch (8) in 700-1300 ampere position.

(16) With a 900-1000 amperes load applied, turn current limiting rheostat counterclockwise until ammeter

indicates 700 amperes. The knob pointer should be at 700 on the dial. If not, set the movable pointer to 700 on dial.

(17) Check current limiting at 700, 1000, 1300, and 2000 amperes.

(18) Place current-limiting switch (9) in 400 ampere position. Check current limiting at 400 amperes for

helicopter service.

(19) Check voltmeter accuracy. Error must not exceed 2% full scale.

(20) Check ammeter accuracy. Error must not exceed 4% full scale.

(21) Check oil pressure at rated speed. Should be 30 to 60 psi when hot.

(22) Check coolant temperature. Should be 185OF to 1950F depending upon ambient temperature.

(23) Check complete unit for vibration and unusual noises.

3. Adjusting the Generator Set

A. Generator Adjustment

The brushholder assembly and the brush holddown springs may require adjustment if the generator is dis-

assembled, or if parts are replaced. 2-3 Sept II78

Page 2

TM-630

. . .

/ I / I

\ I I / / 0

I I I

I3 I2 II

I7 18 19 20 21 22 23

1. 2. 3. 4. 5.

6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Sept II78

Panel Fastener Voltmeter, 28.5 Volt System Panel Light Hourmeter Tachometer Contactor Closed Light Automatic/Manual Switch I -I

Current Range Switch 31 30

Current Limiting Switch [3--J

-~_-

Push To Build Up Volts Switch 21. Throttle Control Contactor Control Switch 22. Panel Light Field Rheostat Control 23. Engine Running Light Current Limiting Control 24. Cold Weather Start Control Ammeter, 28.5 Volt System 25. Ignition Switch Hinged Panel 26. Ammeter, 12 Volt System Interior Panel 27. Starter Pushbutton Negative Output Terminal 28. Panel Light Switch Capacitor 29. Oil Pressure Gage Positive Output Terminal 30. Fuse, Light Circuit Air Cleaner Service Indicator 31. Coolant Temperature Gage

Operating Controls and Instruments Figure 1

2-3

Page 3

bd Fl TM-630

2-3

Page 4

1 I

WARNING: DO NOT MAKE ADJUSTMENTS WHEN THE GENERATOR IS RUNNING.

(I 1 Brushholder adjustment

The brushholder assembly is mounted in a machined, circular seat in the rear of the generator housing. The brushholder mounting ring is held in the seat by clamps and the entire brushholder assembly may be

rotated when the clamps are loosened, To’adjust, proceed as follows:

(a)

(b)

k-1

(4

(4 Start generator and repeat steps (a), lb), (cl, and (d) as required until a satisfactory adjustment has been made.

(f) Be sure clamping screws (2) are securely tightened at conclusion of adjustment.

I ‘I With generator running at no load and automatic-manual switch (7, Fig. 1) in MANUAL position, use manual control rheostat (12) to adjust voltage to 28.5 volts.

Apply a load of 750 amperes and check output voltage. If voltage is 27.5 to 28.5 volts, the brush-

holder is properly adjusted. If voltage is below 27.5 volts, or above 28.5 volts, adjustment is required.

Stop generator and scribe a mark on the brushholder mounting ring, and on one of the seat bars to

determine a starting point for adjustment.

Loosen brushholder clamping screws (2, Fig. 2) and rotate the brushholder (I) in the direction of

armature rotation to REDUCE voltage, or opposite the direction of rotation to INCREASE voltage.

Do not rotate the brushholder more than l/8 inch (3 mm) without rechecking voltage. Tighten

clamping screws (2) before starting generator.

1. Brushholder mounting ring

2. Clamp screw

3. Clamp

4. Seat bar

5. Commutator segment

Brushholder Assembly Figure 2

Sept II78

TM-630

(2) Initial adjustment of brushholder

In the event that the generator is disassembled and the brushholder assembly is removed, locate the brushholder as follows: ,

(a) Rotate armature so tkat ‘kl n armature slot is directly under an interpole piece. Carefully observe

and trace the wires which lead from the winding in the slot to a commutator segment (5, Fig. 2).

Rotate the brushholder ring (1) so that a row of 4 brushes is directly over this segment. Tighten ,

brushholder clamping screws (2).

NOTE: Exercise care in tracing the armature to commutator wire because the wires run

at an angle and not directly to a commutator segment. It may be possible to detect yellow paint marks on the armature slot and the commutator riser which were used

to position the brushholder originally. If these marks can be found, it will make

brushholder adjustment easier.

(b) Make final adjustment in accordance with Para. 3, A, (I), above.

(3) Brush spring adjustment

Recommended spring pressure is 18 to 30 ounces (5 to 8 N) measured along an imaginary line which

passes through the center of the brush and the center of the commutator.

Spring pressure is critical to long brush life and generator performance in that it must be sufficiently

strong to maintain stable brush-commutator contact, yet not strong enough to cause mechanical

wear. Insufficient spring pressure can cause excessive surface film build-up on the commutator, arcing,

heat, and more rapid brush wear than excessive brush pressure. For these and other reasons it is best to use the higher recommended brush pressures.

It is difficult to measure brush pressure accurately. Take the following precautions to reduce chances

of error.

1. Be sure brush can move freely in brush-box.

2. Be sure brush finger and spring are not corroded or sticking.

3. Make certain the scale to be used is accurate.

The following is a suggested method of measuring brush pressure.

(a) A leather loop and an ordinary tension scale which is graduated in ounces are required. The leather

loop gives firmer contact with the brush spring or finger than the scale hook (see Fig. 3).

(b) Place a strip of paper between the brush and commutator.

(c) Place a leather loop over the brush spring (or finger) and position it under the point where the spring (or finger) touches the brush. Attach scale to leather loop.

(d) Pull lightly outward on scale ring. The direction of pull must be parallel to the brush length. At the

same time, pull gently on the paper strip.

Sept l/78 2-3

Page 5

TM-630

Measuring Spring Pressure

Figure 3

(e) Increase pull on the scale until paper strip slips free. Read scale to the nearest ounce.

(f) Pressure should be within recommended range, preferably at, or near, the high limit.

(g) Adjust pressure as required.

To adjust spring pressure, loosen nut (5, Fig. 4) and turn spring adapter (5) toward the brush (arrow direction) to increase pressure. Turn the opposite direction to decrease pressure. Tighten nut (4).

NOTE: The adapter must be held in its new adjusted position while tightening nut.

2-3

Page 6

Sept II78

w I 1 TM-630

,

6 4

1.

2. 3. 4. 5.

Spring

Pigtail Brush Nut Spring mounting I

adapter Wrench 6.

Generator Brushes Figure 4

B. Generator Controls Adjustment

Various generator controls may require adjustment following replacement of parts, repair, etc. Adjustment procedures are listed as follows:

(1) Adjust 700-1300 ampere range of current limiting rheostat.

The resistor (3, Fig. 5) is used to adjust the 700 to 1300 ampere range of the current limiting rheostat

(13, Fig. 1). Adjust as follows:

(a) To increase the current range value, move slider (4, Fig. 5) upward.

(b) To decrease current range value, move slider (4) downward.

(c) Recheck voltage range after each adjustment.

Sept II78 2-3

Page 7

Interior Panel -/ 6

TM-630

16-59611

1. 400 A current limiting resistor (helicopter starting)

2. Slider

3. 700 to 1300 A range current limiting resistor

4. Slider

5. 900 to 2000 A range current limiting resistor

6. Slider

Current Limit Adjusting Resistors Figure 5

NOTE: When adjustment is completed as indicated by the ammeter, it may be necessary to readjust

the rheostat (13, Fig. I) pointer so that it will point to the same amperage value as indicated

by the ammeter.

(2) Adjust 900-2000 ampere range of current limiting rheostat

The resistor (5) is used to adjust the 900 to 2000 ampere range of the current limiting rheostat. Adjust as follows:

(a) To increase current range value, move slider (6) upward.

(b) To decrease current range value, move slider downward.

(c) Recheck voltage range after each adjustment.

NOTE: Adjust this resistor to the high end of the range (2000 amperes).

(3) Adjust 400 ampere current limit resistor

2-3

Page 8

This resistor (1, Fig. 5) is used to adjust the 400 ampere current limiting system so that the maximum generator output power will be 400 amperes when the current limiting selector switch (9, Fig. I) is in 400

ampere position. Sept II78

I I TM-630

The normal initial setting of the slider (2, Fig. 5) on this resistor is l/8 inch (3 mm) from the right end.

(a) Move the slider (2) to the left to increase current output.

(b) Move slider (2) to the right to decrease current output.

C. Engine Adjustment i ‘I

Refer to the Perkins Engine Shop Manual for details regarding engine adjustments.

D. Voltage Regulator Adjustment

Refer to Voltage Regulator Instructions, TM-313, for adjustment procedures.

E. Fuel Valve Solenoid Adjustment

CAUTION: THIS ADJUSTMENT IS CRITICAL. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE IRREPARABLE DAMAGE TO THE SOLENOID.

Connection of the solenoid to the fuel valve control MUST allow the solenoid plunger to bottom when the

solenoid is holding the fuel valve open (plunger pulled into solenoid body). If plunger does not bottom and

disconnect the low-resistance coil in the solenoid, EXCESSIVE HEAT results which will damage the solenoid

in 30 seconds.

If solenoid (l-l; 14, Fig. 3) is replaced or disconnected, proceed as follows:

(1) Make sure solenoid linkage is connected as shown in Figure 6.

(2) Loosen round-head screw in throttle pivot so that control wire slides freely through pivot head.

(3) Manually push solenoid plunger into solenoid body until it BOTTOMS, and HOLD it in that position. An alternate method is to apply 12 volts DC to the solenoid terminals (observe polarity shown in

Figure 6). With voltage applied, plunger will bottom in solenoid body and remain there.

(4) Manually tilt the end of the fuel control lever which has the return spring attached as far as it will go toward the solenoid, and HOLD it in that position.

(5) Tighten the round-head screw in the pivot to secure the control wire and let the spring return the fuel valve to the OFF position. Remove 12 volts DC if it was applied in step (3) above.

June 26180 Revised 2-3

Page 9

2-3

rNegative Terminal

1 w

1

a ,-Solenoid Locknut

Fuel Valve Control Lever-\ Hex Nut-, \ /

Return Spring

L-Round Head Screw

TM-630

Fuel Valve Solenoid Linkage

Figure 6

Revised June 26180

Page 10

TM-630 I I

CHAPTER 3. TROUBLESHOOTING

SECTION 1. TROUBLESHOOTING PROCEDURES

1. General

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 b&t 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 manner, until the cause of trouble

is located. See connection and schematic diagrams.

2. Troubleshootinq Chart

A. Description

The troubleshooting chart lists information under three headings:

(I) Trouble, symptom, and condition

(2) Probable cause

(3) Test, check, and remedy

B. Use of the Troubleshooting Chart

Read the trouble symptoms and conditions before proceeding to causes and remedies. For example, at the beginning of the troubleshooting chart under ENGINE, the first trouble listed is: “Engine will not start.

Starter will NOT crank engine.” If the starter WILL crank the engine, then obviously this is not your

symptom and condition. Go to the next trouble and symptom directly below.

If the starter will NOT crank the engine, look to the right under PROBABLE CAUSE and TEST, CHECK, AND REMEDY and find the various things which could cause the trouble and what to do to check and

remedy them.

3. Equipment for Troubleshooting

A good quality multi-scale voltohmmeter is the only instrument required for troubleshooting. At least two jumper

leads with alligator, or similar clips, will be required. The 12 volt engine electrical system may be used for a 12

volt DC power source.

4. Safety

WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT WITH ELECTRICAL CIRCUITS AND

REVOLVING EQUIPMENT WHICH COULD CAUSE SERIOUS INJURY IF TOUCHED WHEN

TROUBLESHOOTING OR OPERATING THE EQUIPMENT.

5. Diagrams

A schematic diagram of the generator set is provided in Chapter 6. This diagram can be very helpful in troubleshooting. Components shown in the diagram are identified by reference designators (or item names in some in-

stances). A legend appearing on the diagram identifies each reference designator by its full item name. For example, the symbol K406 identifies the overvoltage relay, and M402 identifies the voltmeter.

A connection diagram is also provided in Chapter 6. It also can be very helpful in troubleshooting, parts replace-

ment, etc.

Sept II78 3-I

Page 1

17 18 19 20 21 22 23

24 ;

25

26 1

!

27 ‘.

28 ) ‘, 1. Panel Fastener 2.. Voltmeter, 28.5 Volt System 3. Panel Light 4. Hourmeter 5. Tachometer

: “6. Contactor Closed Light 7. Automatic/Manual Switch 8. Current Range Switch $1

v. 9. Current Limiting Switch pzGi-J

10. Push To Build Up Volts Switch 21. Throttle Control 1 j : Contactor Control Switch 22. Panel Light 12. .Field Rheostat Control 13. Cut’ren? Limiting Control

23. Engine Running Light 24. Cold Weather Start Control ..

14. Ammeter:285 Volt System IS. .Hirfged Panel

‘, . . i ,, 25. Ignition Switch h : .,; ‘:,” I’- ..;

: c -. . ,:. ‘, 16. ,lnterior Panel ‘* 1’ ; ,.

‘26 ..,, Am~e~~!:!a’Volt~~~stem~ I_ ’

17.. Negaijve Output Tkmin ,I 18; Capaciltor : __ “‘.I -, ,;-. : 19. Positive Qutput~Ter$I 20. Air .C+aner Set-vi* In

;

3-1

Page 2

Sept l/78

TM-630

6. Connections and Wiring

Before condemning any electrical component, check all connections and wiring which could affect its operation.

In many instances a component may be non-functional simply because it is not receiving power because of a loose connection or a poor ground. In most cases throughout the troubleshooting chart, it will be assumed that connections and wiring have been checkecl(. 1,

Sept II78 3-1

Page 3

I . TM-630

TROUBLE, SYMPTOM, AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

I I

NOTE: Diesel engine troubleshooting is covere$ ir) Perkins Engine Shop Manual under Fault Diagnosis.

ENGINE CONTROLS’ .-

1. Engine will not start.

Starter will NOT crank

engine.

A. Ignition switch (25, Fig. 1) is not A. The ignition switch MUST be ON before ON current can be supplied to the start’

switch and starter solenoid. If the starter

will not operate.when the ignition switch is ON, momentarily connect a jumper lead between the hot side of the starter solenoid and the start switch terminal on the

solenoid (yellow-red wire). If the starter

operates, check the ignition switch (S419)

and the pushbutton start switch (S413).

Replace as required. If starter did not

operate when jumper was connected

above, proceed to step B.

B. Batteries discharged, or loose

battery or ground connection B. Check voltage across batteries. Voltage

should be approximately 13.5 volts DC.

Check all battery terminals. Be sure 13.5

volts DC is reaching solenoid input terminal.

C. Defective starter solenoid C. Momentarily connect a largecapacity

jumper cable between the hot side of the

starter solenoid and the starter input terminal. If the starter attempts to crank the engine, it indicates the starter sole-

noid is defective. Replace. If the starter

did not operate, proceed to step D.

D. Defective starter D. If starter did not operate in check C

above, the starter is defective. Replace.

2. Engine will not start.

Starter cranks engine. A. Fault in fuel system

(1) Fuel valve at tank closed, or

no fuel in tank

(2) Defective fuel pump

A. Check fuel system as follows:

(I 1 Check and correct as required.

(2) Check fuel pump by disconnecting

output line at pump and cranking

engine. If fuel does not spurt from

pump when engine is cranked, re-

place pump.

WARNING: EXERCISE CARE TO

AVOID A FIRE WHEN WORKING WITH THE FUEL SYSTEM.

Troubleshooting Chart (Sheet 1 of 6) Revised Ott 22/82

Figure 2

TM-630

TROUBLE, SYMPTOM,

AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

ENGINE CONTROLS (CONTINUED)

3. Engine lacks power. A. InsuffiTieni air to engine 1 I

I B. Restricted exhaust system

GENERATOR AND CONTROLS

A. Check and service air cleaner.

Bl Check exhaust pipes for restrictions.

Check muffler for clogged condition.

Replace as required.

1. Generator will not buildup voltage when push-to-build-up-volt-

age switch (S414) is

operated. Automatic-

manual control switch in AUTOMATIC posi-

tion. Engine running

normally.

A. Flashing power not reaching shunt field (L407)

(1) Defective oil pressure switch

(S416 or S417) located on oil

pressure gage and engine

block

A. Check as follows:

(1) Connect a jumper lead between oil

pressure switch terminals. If generator

will now build-up-voltage when switch

(10, Fig. 1) is pushed, replace oil pres-

sure switch (l-l ; 20, Fig. 3 and 16,

Fig. 6). If voltage did not build-up, pro-

ceed to step (2).

(2) Defective push-to-build-up-

voltage switch (S414)

(2) Momentarily connect a jumper lead

across push-to-build-voltage switch

(10, Fig. I) terminals. If voltage

builds-up, replace switch.

(3) Defective diode (CR402) (3) Use ohmmeter to check diode on back

of switch (10, Fig. I). Replace if defective.

NOTE: If voltage did not build-up during the above three checks, the trouble is

either in the generator, or in the voltage regulator and excitation circuit.

To determine which, proceed to step B.

B. Defective automatic-manual switch (S401)

B. Place automatic-manual control switch (7, Fig. 1) in MANUAL position. If voltage will now build-up, it proves that the gen-

erator is good and trouble is in automatic

section of ‘automatic-manual switch or in thf

voltage regulator. Return switch to AUTO-

MATIC position. Connect a jumper lead across the contacts on the automatic side

of the switch. If voltage will now build-up,

replace the automatic-manual control switch.

. _,.^,..^.-. . * - . . . . ^. ,-. - - -. a.3 Ict zz/ijz newsea I roubieshootmg C;hart (sheet 2 ot 8) .5- I

Figure 2 Page 5

TM-630

TROUBLE, SYMPTOM,


GENERATOR AND CONTROLS (CONTINUED)

1. (Continued) C. Defective vfltfge regulator C. If voltage would not build-up when

I (VR401) automatic contacts of switch (S401)

were jumpered in step B above, trouble

is in the voltage regulator (l-l; 1, Fig. 5).

Replace.

2. Generator will not A. Flashing power not reaching A. Perform checks 1, A, (1) and 1, A, (2) build up voltage when shunt field to make certain’flashing power is reach- push-to-build-up-voltage ing field. switch (S414) is operated. Automatic-manual B. Defective automatic-manual B. Connect a jumper lead across MANUAL switch in MANUAL switch (S401) contacts of switch (S401). If generator position. Engine running will now build-up voltage when flashed, normally. replace switch (7, Fig. 1). If voltage will

not build up, proceed to step C.

C. Defective manual control C. Connect a jumper lead across the manual rheostat (R411) control rheostat. If generator will now

build up when flashed, replace the rheo-

stat (12, Fig. 1). If not, proceed to step

D.

D. Defect in generator D. If generator would not build-up voltage

during steps 2, A through C above, it

indicates the generator is defective. Check for open circuited shunt fields. ’

3. Load contactor will not A. Defective resistor (R401) A. The load contactor requires a slight load close when contactor on the output circuit to close the dif- control switch (S402) ferential contacts and allow the con- is placed in top ON tactor to be closed. Resistor (R401) position. Engine running provides this load when output cables are normally. Voltage nor- not connected to a load. Check this mal. NO load applied to resistor (Sect. I-l ;4, Fig. 5) and replace output cable. if defective.

B. Defective contactor control B. Momentarily connect a jumper lead switch (S402) between terminals 1 and 2 on the con-

trol switch. If the load contactor closes

momentarily, replace switch (11, Fig. 1).

C. Defective load contactor C. If load contactor will not close when (K401) control switch (S402) is jumpered, it

is likely that the contactor is defective.

3-I Trou bleshootinFgiIuramrt2 (Sheet 3 of 6) Revised Ott 22182

Page 6

TM-630

Ict 22182 Revised

TROUBLE, SYMPTOM,



4. Load contactor

OPENS as soon as

control switch is re-

leased from top ON

position.

A. Defe F I tjve control switch (S402) A. Connect a jumper lead between terminals

4 and 5 on the control switch. If con-

tactor will now remain closed after

initial closing, replace the control

switch (11, Fig. I).

B. Overload relay (K403) defective B. Connect a jumper lead across the over-

load relay contacts. If contactor will

now remain closed, replace overload relay (Sect. l-l; 10, Fig. 5).

C. Overvoltage relay (K406) defec-

tive

C. Connect a jumper lead between terminals

T and P on the overvoltage relay. If con-

tactor will now remain closed, replace overvoltage relay (Sect. I-l ; 6, Fig. 5).

CAUTION: DO NOT OPERATE THE GENERATOR SET TO DELIVER POWER

WHEN ANY PROTECTIVE DEVICE IS JUMPERED.

D. Load contactor (K401) defec-

tive

D. If a fault was not found in steps 4, A

through C above, the load contactor

is defective. Replace load contactor

(Sect. l-l ; 2, Fig. 5).

5. Load contactor opens A. Contactor opening could have

during power been normal because of an delivery run overload or overvoltage

A. Resume operation and closely observe

ammeter and voltmeter for, evidence

of overload and overvoltage. If con-

tactor opens when it is known that

there was no overload or overvoltage,

proceed to step B.

B. Overload relay (K403) defective B. Oil in the overload relay dashpot may be

low allowing the plunger to operate too

freely. Check dashpot in accordance with instructions in Sect. 2-2, Para. 6, B,

(I) through (3). Also check overload

relay contacts.

C. Overvoltage relay (K406)

defective C. Check overvoltage relay by operating the

machine under load and controlling volt-

age manually. Start with a low voltage

(25.0 volts DC) and gradually increase until the relay functions to open the load contactor. If relay trips at less than 32 volts DC, replace, and return old relay

to factory for service (I-l; 6, Fig. 5).

Troubleshooting Chart (Sheet 4 of-61 a- I

Figure 2 Page 7

TM-630

TROUBLE, SYMPTOM,



5. (Continued) D. Load contgcjpr defective D. If no fault was found in checks B and C (K401) above, the load contactor is at fault. I

Replace load contactor (Sect. l-l ; 2, Fig. 5).

6. Generator voltage will A. Defective voltage regulator A. Use automatic-manual switch (7, Fig. I) not build up to normal (VR401) to change to MANUAL control. If normal operating voltage in operating voltage (28.5 volts DC) can be AUTOMATIC control. selected with manual control, replace the

voltage regulator (I-l ; 1, Fig. 5).

7. Generator voltage builds A. Defective voltage regulator A. Switch to MANUAL control. If normal too high in AUTOMATIC operating voltage can be selected with control manual control, replace the voltage

regulator.

8. Output current cannot be A. Defective current limiting rheo- A. Change current limit control switch limited by operating cur- stat (R412), or defective or im- (S405) to 400 A current limit position. rent limit rheostat when properly adjusted resistor If current is now limited to 400 A, check range is in 700 to 1300 (R406 or R414) rheostat and resistor. (See Sect. 2-3, Para. ampere or 900 to 2000 3, B, [II and [21 for resistor adjustment.) ampere position. Replace parts as required.

B. Defective voltage regulator B. If current is not limited in either 700-1300

ampere or 400 ampere switch position, a defective voltage regulator is indicated.

Replace and return old regulator to factory for service.

9. Output current is not A. Resistor (R407) is defective or A. Change current limit switch to 700 to 130C limited when current limit improperly adjusted ampere limiting position. If current can be switch is in 400 ampere limited in this position, adjust or r,eplace position. resistor (I -1; 3, Fig. 5).

B. Defective voltage regulator B. If current is not limited in either selector

switch (S405) position, replace voltage

regulator and return old regulator to

factory for service.

3-l Troubleshooting Chart (Sheet 5 of 6) Revised Ott 22/82

Page 8 Figure 2

TM-630

TROUBLE, SYMPTOM,


14 VOLTOUTPUT (OPTION) , , . 7

I ‘I 1. 14 Volt load contactor A.

will not close.

B.

Defective resistor (l-l; 9, Fig. 8)

28 Volt load contactor control

ON (11, Fig. 1)

2. Load contactor closes, but opens when con-

trol switch returns to

ON position.

3. Load contactor opens

during power delivery.

A. Replace resistor (5 RES).

B. Position switch to OFF.

C.

D.

E.

F.

G.

H.

A.

A.

B.

C.

D.

I

E.

28 Volt control relay (I-l ;

3, Fig. 8) defective

C. Replace defective relay (1 CR).

14 Volt control relay (l-l; 1,

Fig. 8) defective D. Replace defective relay (2 CR).

Overvoltage module (l-l; 7, E. Replace faulty overvoltage module

Fig. 8) faulty (2 OV).

Overload relay (l-l; 10, Fig. 8) faulty

F. Replace faulty relay (2 OL).

Contactor control switch (l-l ; 2, Fig. 9) defective

G. Replace defective switch (6 S).

Load contactor (l-l ; 4. Fig. 8) defective

H. Replace defective load contactor

(2 LC).

14 Volt control relay (l-l ; 1, Fig. 8) defective

A. Replace defective relay (2 CR).

Overload relay (I-l;.lO, Fig. 8)

faulty

A. Replace faulty relay (2 OL).

Overvoltage module (l-l ; 7,

Fig. 8) defective

B. Replace defective module (2 OV).

Resistor (l-l ; 11, Fig. 8) out of

adjustment

C. Adjust or replace resistor (6 RES).

One of the two control relays

(I-l ; 1 and 3, Fig. 8) defective

D. Replace defective relay (2 CR or 1 CR).

Load contactor (l-l ; 4, Fig. 8)

defective.

E. Replace defective load contactor (2 LC).

kt 22/82 Revised Troubleshooting Chart (Sheet 6 of 6)

Figure 2

3-1

Page 9

TM-630

CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION

1. General

i ; The Illustrated Parts List identifies, deicribes, and illustrates main assemblies, subassemblies, and detail parts of an engine-driven generator set manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio

45373. The set is identified as a Jet-Ex Dll Specification No. 5961-1

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:

(I 1 Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are available 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.

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:

(I) 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 appear on the illustration. 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.


Page 1

I TM-630

(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 NOMEN-

CLATURE column. Vendor parts which are modified by Hobart will be identified as such in the NO-

MENCLATURE column. In case Ho,bart does not have an identifying part number for a purchased part, the HOBART PART NUMBEd dblumn 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 re- lationship. Thus, components of an assembly are listed directly below the assembly and indented

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. No coding is required for this manual.

(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

Page 2

NovIOl

SECTION 2. MANUFACTURER’S CODES

TM-630

1. Explanation of Manufacturer’s (Vendor) Code List

The following list is a compilation of vendor codes with names and addresses for suppliers of purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes for Manufacturer’s Catalog-

ing Handbook H4-1, and are arran&d jn numerical order. Vendor codes are inserted in the nomenclature column

of the parts list directly following the item name and description. In case a manufacturer does not have a vendor

code, the full name of the manufacturer will be listed in the nomenclature column.

CODE VENDOR’S NAME AND ADDRESS

01428 Superior Ball Joint Corporation

1202 S. Quality Drive P. 0. Box 227 New Haven, Indiana 46774

05277

16238

21335

Westinghouse Electric Corporation Semi & Conductor Department

Youngwood, Pennsylvania 15697

Lord Manufacturing Company, Inc.

Sterling Road South Lancaster, Massachusetts 01561

The Fafnir Bearing Company

Division of Textron

37 Booth Street

New Britain, Connecticut 06050

21585

22938

24248

Farr Company 2301 E. Rosecrans El Segundo, California 90245

Prototype Development Inc.

7750 Hub Parkway

Cleveland, Ohio 44125

South Chester Corporation South Company Division 3rd Street and Governor Printz Boulevard

Lester, Pennsylvania 19113

26992

30327

33955

Hamilton Watch Company

Columbia &West End Avenue

Lancaster, Pennsylvania 17604

Imperial-Eastman Corporation 6300 W. Howard Street Chicago, Illinois 60648

Teleflex Inc.

1816 57th Street

Sarasota, Florida 33580

4-2

Page 1

Nov IO/78

June 9179 Revised

CODE

41197

41625

44655

49234

57733

58849

60038

60741

61112

66295

70040

71400

I I

VENDOR’S NAME AND ADDRESS

Modine Manufacturing Company

1500 DeKoven Avenue

Racine, Wisconsin 53401

Morse Controls, Inc.

25 Clinton Street

Hudson, Ohio 44236

Ohmite Manufacturing Company

3601 W. Howard Street

Skokie, Illinois 60076

Protectoseal Company 1920 S. Western

Chicago, Illinois 60608

Stewart-Warner Corporation 1826 Diversey Parkway


Syntron Company

1938 Black Street Homer City, Pennsylvania 15748

Timken Roller Bearing Company

1835 Dueber Avenue SW

Canton, Ohio 44706

Triplett Electrical Instr. Company

Harmon Road

Bluffton, Ohio 45817

Turner Corporation

821 Park Avenue

Sycamore, Illinois 60178

Wittek Manufacturing Company 4309 W. 24th


AC Spark Plug Division of General Motors Corporation

1300 N. Dort Highway

Flint, Michigan 48556

Bussmann Mfg. Division

of McGraw & Edison Company 2536 W. University Street

St. Louis, Missouri 63017

TM-630

4-2

Page 2

Nov IO/78

TM-630

CODE

73559

74400

75175

75418

78225

78388

79260

79470

81082

82240

85925

89616

L I

VENDOR’S NAME AND ADDRESS

Carling Electric Inc. 505 New Park Avenue West Hartford, Connecticut 06110

Hobbs Division Stewart-Warner

Yale Blvd. and Ash Street

Springfield, Illinois 62705

The Duplan Corporation

KD Lamp Division

1910 Elm Street Cincinnati, Ohio 45210

Kysor Industrial Corporation

1100 W. Wright Street

Cadillac, Michigan 49601

Stant Manufacturing Company, Inc.

1620 Columbia

Connersville, Indiana 47331

Syncro-Start Products, Inc.

8151 N. Ridgeway Avenue

Skokie, Illinois 60076

Walker Manufacturing Company 1201 Michigan Blvd. Racine, Wisconsin 53402

The Weatherhead Company 300 East 131st Street

Cleveland, Ohio 44108

Electric Auto Lite Company

Lebanon Road Cincinnati, Ohio 45241

Simmons Fastener Corporation

North Broadway

Albany, New York 12204

Electra Mechanical Instrument Company, Inc.

8th & Chestnut Streets

Perkasie, Pennsylvania 18944

Uniroyal Inc. Consumer Industrial and Plastic Products

312 N. Hill Street

Mishawaka, Indiana 46544

Nov 10178 4-2

Page 3

CODE VENDOR’S NAME AND ADDRESS

90201 Mallory Capacitor Company

3029 E. Washington Street

91929

98410

4-2

Page 4

m I I I 1

i 4

P. 0. Box 372

Indianapolis, Indiana 46206

TM-630

Honeywell Inc. Building Controls and Components Group

Micro Switch Division

Freeport, Illinois 61032

E.T.C. Inc.

990 E. 67th Street Cleveland, Ohio 44103

Nov IO/78

w TM-630

SECTION 3. PARTS LIST

1. Explanation of Parts List Arrangement b

The parts list is arranged so that thejiliystration will appear on a left-hand page and the applicable parts list will appear on the opposite right-hand page. Unless the list is unusually long, the user will be able to look at the illustra-

tion 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 1

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 e

kVA - kilovolt-ampere .!’ :; B uF - microfarad ‘ai

c 5 No. - number / I NHA - next higher assembly

PRV - peak reverse voltage PSI - pounds per square inch

Ref - reference (the item has been listed previously)

TM - Technical Manual

T-R - transformer-rectifier

v - volt (when used as a prefix to a five-digit number, indicates vendor code)

NOTE: ..r

An item which does not reflect an index number is an assembly which is not illustrated in its a,&e&ed’ _. state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated. : ,

Nov IO/78 4-3

Page 1

imid r5 TM-630

4-3

Page 2

Generator Set

Figure 1 Nov IO/78

FIGURE HOBART

ITEM NO. PART NO.

I l- 5961-I

1 483554

2 DdW-155

3 402987

4 No Number

I 5 484331 * IOOGH-117

Ott 19/81 Revised

NOMENCLATURE

1234567

GENERATOR SET, 28.5 V DC JET-EX DII

;gA;Eh MOUNTED

A OPY ASSEMBLY (For Details See Fig. 2) . EYE, LIFTING YOKE

. NAMEPLATE, HOBART

. GENERATOR SET, WITHOUT CANOPY (For

Details See Fig. 3)

. TRAILER ASSEMBLY (For Details See Fig. 9)

. HORN, CABLE ASSEMBLY

TM-630

UNITS REC. per

SPARES EFF ASSY

REF

1

1

2 ,

4-3

Page 3

w

I I I I TM-630

4-3

Page 4

Canopy Assembly

Figure 2

Nov IO/78

FIGURE HOBART

ITEM NO. PART NO.

2-

1 2

3 4

5

6 7

8 9

10

II

12

13

483554

352281

16DA-4131-1

16DA-4117 W- 11242-6

352275-O

352289

402809

483569 483581

483586 483555

483574

483577

30GHP-391

14 15

16

17 18

19

20

21 22 23 24

25 * *

*

*

*

483567 DWP-982

483636

480109

483576

483635 483599

483638 483637 483639 DWP-1804-1

404101-1

400613-10 403127

387859

386751

HJ-129A

I * 486270-8 * 26 400435

NOMENCLATURE

1234567

CANOPY ASSEMBLY (For NHA See Fig. 1)

, CPVER, HOLE, RADIATOR, ASSEMBLY

. . k+UD, POSITIVE LOCK

. . WASHER, STUD LOCK

. . WASHER, FLAT, 5/16 IN.

, . COVER

, SPACER, HINGE

. RECEPTACLE, STUD, RIVET TYPE

. PANEL, END, FRONT, ASSEMBLY

. DOOR, LEFT FRONT, ASSEMBLY

. DOOR, RIGHT FRONT, ASSEMBLY

. PANEL, CENTER, CANOPY

. TOP, CANOPY, ASSEMBLY

. DOOR, LEFT REAR, ASSEMBLY

. LATCH, DOOR CANOPY V82240, No. 2 LINK

LOCK FASTENER

. PANEL, END, REAR, ASSEMBLY

. BRACKET, CABLE

. DOOR, RIGHT REAR, ASSEMBLY

. PANEL, ACCESS, REAR

. PANEL, SIDE, CANOPY

. PANEL, SIDE, RIGHT FRONT

. WINDOW, DOOR, LARGE, ASSEMBLY

. COVER, WINDOW, LARGE

. WINDOW, DOOR, SMALL, ASSEMBLY

. COVER, WINDOW, SMALL

. REFLECTORS, RED V75175, No. KD-333

. LIGHTS, CLEARANCE V75175, No. 514-0168

. . LAMP, CLEARANCE LIGHT, 12 V

. CATCH, MAGNETIC V24248, No. 02-10-201-10

. ROD, HOOK, DOOR

. CLAMP, RETAINER, ROD

. JOINT, BALL, DOOR ROD V01428

No. SPSI 002CP . LABEL, WARNING, COMP. . NAMEPLATE, 28 VOLT

TM-630

UNITS REC. per

SPARES EFF ASSY

REF

1

1

1

1 ! 1

1

1

1

1 1 2

1

1

4

1 2

1

1

3

1

1

1 1

1 2 1 4 2 4

6 1

2

4

4

4

:

APR 21/88 Revised 4-3

Page 5

TM-630

4-3

Page 6

I I / I I I’

d

?

5

Generator Set, Without Canopy

Figure 3

Nov 10178

TM-630

FIGURE HOBART

ITEM NO. PART NO.

3- No Number

1 389967A-2 I

GENERATOR SET, WITHOUT CANOPY (For

N II

q See’ Fig. 1) . B ti, CONTROL, GENERATOR, ASSEMBLY

2 485499 3 483549

4 80B-1107 5 No Number 6 No Number

(For Details See Fig. 4) . KIT,AIR CLEANER , uses 404196 filter

. YOKE, LIFTING, ASSEMBLY (For Details See

Fig. 11)

. ENGINE ASSEMBLY

. FRAME GROUP (For Details See Fig. 11)

. MUFFLER & EXHAUST SYSTEM (For Details See Fig. 11)

7 483536 . PANEL, CONTROL, ENGINE, ASSEMBLY (For

8 403492- 1 9 1 CZ-93B

**10 404124

Details See Fig. IO)

. BATTERY (For Details See Fig. 11)

. DIODE, FLYBACK V05277, No. IN4820

. SOLENOID, ASSEMBLY V78388,

NO. 1500-12/C2UIB 11 12 13

14

15 *

w *

*

1 : *

*

*

*

* *

402096 483502 No Number

78A-1001

No Number

482312 403782-o W-781 4-4

483608

78A-1002

484533 5cw-794

4836 11

. KIT, QUICK START V61112, NO. OS-3267-207

. TANK, FUEL, ASSEMBLY (For Details See Fig. 11) GENERATOR GROUP (For Details See Fig. 7)

: SENDER, TACHOMETER V33955, NO. 9604276

. COOLING SYSTEM (For Details See Fig. 6) BRACKET MOUNTING QUICK START

: SWITCH, HI-TEMP V75418, NO. 33080-205

. BUSHING, SWITCH HI-TEMP

. BRACKET, MOUNTING SOLENOID

. TIP, DRIVE SENDER V33955, NO. 5933572

. KIT, TACH, DRIVE

. ADAPTER, SOLENOID

. LINES, FUEL & OIL ASSEMBLY (For Details

See Fig. 12) 403171

403194

403716 483656

. PIVOT, THROTTLE

. CLIP, PIVOT

. PIVOT, THROTTLE CONT.

. KIT, 14 VOLT OUTPUT, ASSEMBLY (OPTIONAL) (For Details See Fig. 13) 1

1234567

NOMENCLATURE UNITS REC. per

SPARES EFF ASSY

REF

1

1 ,

1 1

1 2

1 1

1 1 1 1

1

1

1

1 1

1 1 1

1

1

** Beginning with S/N 85PSOl.346 Solenoid on Perkins Engine.

Pay lo/86 Revised 4-3

Page 7

TM-630

4-3

Page 8

Control Box Assembly

Figure 4

Nov IO/78

FIGURE HOBART

ITEM NO. PART NO.

4- 389967A-2

1 404329- 1

2 506 HP-206

3 H F-530

4 W-l 1250

5 W-8061A-11

6 78A- 1005

7 W-991 7-18

8 400642-3 9 400400

IO 78A-1004

11 388328- 17

12 DW-1777B

13 20RT-353-1

14 25MS-156

15 IOOGH-138

16 H F-251 8-7

17 400613-3

18 403189

19 16DW-538-0

20 w-10051-4

21 w-10051-1

22 HF-1638

23 H F-743

24 BW-161A

25 BW-9 16

26 78B-1013

27 W-971 2-7

28 DW-4324

29 389535-l

30 483588

31 483666

32 480010 33 No Number

34

35 *

480006 . BODY, CONTROL BOX 78A-1012 . NAMEPLATE, 900-2000

480616 . STRAP, GROUND

I TM-630

NOMENCLATURE

1234567

REC.

SPARES EFF

UNITS

per ASSY

BOX ASSEMBLY, CONTROL (For NHA

See rig. 3)

. L/lGtlT, PANEL V74400, NO. Ml-3216

. . LAMP (Lamp Industry No. 313)

. SCREW, PANEL FASTENER

. WASHER, PANEL FASTENER

. AMMETER, 0 to 1600-A DC V60741

NO. 321 LH

1

6

REF

1

1

2

2 ’

1

. TACHOMETER V33955, NO. 1136075

. HOURMETER V26992, NO. 771-4/50

. VOLTMETER, 0 to 50 V DC V60741

. SWITCH, TOGGLE V73559,

NO. 26L61TABS

1

. PLATE, IDENTIFICATION

. PLATE, IDENTIFICATION, CURRENT

LIMITING

. SWITCH, PUSHBUTTON

. DIODE, NEGATIVE BASE, 250 PRV

V58849, NO. 92429-CF

. BUS

1

1

1

1

. PLATE, IDENTIFICATION, PUSH-TO-BUILD-

UP-V0 LTAG E

. LIGHT, INDICATING, GREEN

. . LAMP (Lamp Industry No. 313)

. SWITCH, TOGGLE V91929, NO. 312TSl-59

6

1

. PLATE, IDENTIFICATION, CONTACTOR ON-OFF

. CLAMP, WIRE

. CLAMP, WIRE

. KNOB, RHEOSTAT

. PLATE, IDENTIFICATION, VOLTAGE CONTROL

RHEOSTAT

. RHEOSTAT, MANUAL VOLTAGE CONTROL

V44655, Model N 300 WATT

. KNOB, RHEOSTAT

. DIAL, RHEOSTAT

. RHEOSTAT, CURRENT CONTROL V44655,

Model H,25 OHM, 25 WATT

. PLATE, IDENTIFICATION, AUTOMATIC-

MANUAL SWITCH

. CHAIN, SUPPORT, HINGED PANEL

. PANEL ASSEMBLY, HINGED

. PANEL, FRONT, CONTROL BOX

. PANEL, REAR CONTROL BOX

. PANEL GROUP, INTERIOR (For Details See

Fig. 5)

1

1

1

Nov IO/78 4-3

Page 9

4-3

Page 10

TM-630

Nov 10178

TM-630

Interior Panel Group

Figure 5

4-3

Page 12

Nov IO/78

TM-630

FIGURE HOBART

ITEM NO. PART NO.

5-

1

2

3

4

5 389522A 6 403763- 1

7 401556

8 389466

9 6FW-6113

10 6FW-6116

11 6FW-2087A

12 6FW-6117

13 FW-2131

14 20RT-353-1

15

16

17

18 7 ‘

19 *

*

*

*

*

*

*

Nov IO/78

No Number

483768

W-?974M

400078

W-454 1 D

w-4541 c

6FW-6115

6FW-1799

430090B

400589-5

389966

400591

8TRY-17

402900

402665-I

400701

403068

403069

NOMENCLATURE UNITS

REC. per SPARES EFF ASSY 1234567

PANEL, INTERIOR, GROUP (For NHA See

Fig. 4) ,

. Pj9qEL ASSEMBLY, INTERIOR

. . RESISTOR, VARIABLE, 30 OHM, 100 WATT

V44655

. . BRACKET, MOUNTING, RESISTOR


V44655


V44655

. . BOARD ASSEMBLY, OVERVOLTAGE

. . WASHER, SHOULDER, FIBER

. . MOUNT, SHOCK

. . BRACKET, MOUNTING, OVERLOAD BOARD

. . BUS, LOAD CONTACTOR, POSITIVE TERMINAL

. . BUS, LOAD CONTACTOR TO SHUNT

. . CONTACTOR, LOAD 1

. . BUS, LOAD CONTACTOR TO SHUNT

. . RELAY, OVERLOAD VOI 121 1

. . DIODE, NEGATIVE BASE V58849,

No. 92429~CF 1

. . BUS, SHUNT POSITIVE TERMINAL

. . SHUNT, 1600 AMPERES

. . REGULATOR ASSEMBLY, VOLTAGE 1

. . BOARD, TERMINAL V98410,

No. 38012-3820

. . PANEL, INTERIOR

. . TAB, DOUBLE

. . HOUSING, TAB

. . TERMINAL, QUICK-CONNECT

. . CONNECTOR, RECEPTACLE

. . CONNECTOR, RIGHT ANGLE



REF

1

1

2 ’

2

1

1 1

3

3

1

1

1

1

1 1

2

1

24

1

4

2

4

11

3

4-3

Page 13

TM-630

14

‘a?

I

,

ji

Cooling System

Figure 6 4-3

Page 14

Nov IO/78

NOMENCLATURE

FIGURE HOBART

ITEM NO. PART NO. 1234567

6-

I 1

*

2 *

9

10

11

12

13

14

15

16 *

* * *

I *

No Number

403034

W-l 0869-3

402’141- 2 0 402141-16

402141- 19

989909 485495 483438

387881

483439

402958

387313

50GHP-89

50G HP-82

483440

5cw-1932-o

386751

56555

355194 485897 483614

351541

483612 W-l 0869-7

COOLING SYSTEM (For NH-A See Fig. 3)

. CAP, RADIATOR V78225, No. AAX-OB48

. C&/hP, RADIATOR HOSE V66295

. HOSE, RADIATOR INLET

. HOSE, ELBOW INLET

. HOSE, RADIATOR OUTLET

. GUARD, FAN RADIATOR

. RADIATOR ASSEMBLY

. . HEAD, RADIATOR ASSEMBLY

. . ANGLE, MOUNTING SHROUD

. . SHROUD, RADIATOR

. . CORE, RADIATOR V41197, Size 26 in.

x 28 in. x 2-11 I32 in.

. . RAIL, SIDE RADIATOR ASSEMBLY

. . STRIP, REINFORCING

. . GASKET, RADIATOR

. . BASE, RADIATOR, ASSEMBLY

. . VALVE, DRAIN, RADIATOR V79470, No. 145

. . CLAMP, RETAINER

. . TUBING, NEOPRENE

. . PIPE, OVERFLOW, RADIATOR

. HOSE, SUPPLY RADIATOR

. HOSE, VENT RADIATOR

. LABEL, CAUTION FAN

. PIPE, ELBOW RADIATOR

. CLAMP, RADIATOR HOSE, V66295

TM-630

UNITS

REC. per SPARES EFF ASSY

REF

1 1 4

1 1

1 1 , 1 1

2

1

1

1

1

1 2

4

2

1

1

2

45”

1

1

1

2

1 2

July l/87 Revised 4-3

Page 15

-_

I

FIGURE HOBART

ITEM NO. PART NO.

I

I -~ * * * K 1 * * * I * * * * *

7-

1 483449

2 483598

3 W-l 0855-4

4 DW-882A

5 DW-883

6 FW-446

7 W-l 0072-8

8 16DW-967

9 358221-32

10 358830-14

11 380706

12 380707

13 DW-1045

14 1361

15 430278

16 484810-I

17 480646

18 483277

19

20 485893& 484685

21 483293-l

w-9234-142

16DW-246

w-9234-3 1

W-9234-l 67

480603-I

483511

483798 350330-I 82

20A 483286 20B W-11095-1

W-11102-18 W-11254-10

No Number I

NOMENCLATURE

REC.

1234567 SPARES EFF

GEklkRATOR AND DRIVE GROUP (For NHA

See Fig. 3)

. COVER, END

. COVER, FAN HOUSING

. CAPACITOR, 0.25 /.IF, 100 V DC V90201,

No. B-20601 1

. CAP, BEARING

. GASKET, BEARING CAP

. NUT, BEARING

. BEARING, BALL V21335, No. 310NP

. C,LAMP, BRUSHHOLDER

. BRUSHHOLDER (For Details See Fig. 8)

. POLEPIECE, INTERPOLE

. COIL, INTERPOLE

. COIL, INTERPOLE

. POLEPIECE, PLUG HAT

. COIL SET, SHUNT FIELD

. GROMMET, GENERATOR HOUSING V89616,

No. TPR No. 1812

. HOUSING, GENERATOR

. KEY, FLEXIBLE COUPLING

. ARMATURE ASSEMBLY

. FAN, GENERATOR ASSEMBLY

. COUPLIk, GENERATOR-TO ENGINE ASSY

. HOUSING, FAN ASSEMBLY

. LEAD, BRUSHHOLDER

. BUS, EQUALIZER

. LEAD, INTERPOLE

. LEAD, INTERPOLE

. MOUNT, sHOCk

. PLATE, MTG. GENERATOR FOOT

. LEAD, CAPACITOR . INSULATION

-DISC, .BOLT 3/8-16 x 5/8 HHC -BOLT Z-3/4" GR.5 .LOCK WASHER 810

TM-630

UNITS

per ASSY

REF

1 ! 1

4

1

1

1

1

2

1

4

2

2

4

1 SET

4

1

1

1

1

1

1

2

1

1

1

6

2

4 1

4 8 ' 6 6

May lo/86 ReviseJ 4-3

- Page 17

,

-_ -_

I 1

m

I I TM-630

NOMENCLATURE UNITS

FIGURE HOBART REC. per ITEM NO. PART NO. 1234567 SPARES EFF ASSY

8- 358221-32

1 Ay-1470

2 W-l 1236-7

3 16DW-200

4 SBW-12-3

5 402119-25 6 W- 11280-2

7 W-l 1242-5

8 W-l 1254-4

9 352413

10 AW-1156B

11 W-799H-173

12 AW-1719

13 W- 11280-2

14 AW-734

15 AW-740

16 AW- 1683

17 12CW-962

BRUSHHOLDER ASSEMBLY (For NHA See

.I!

Fi .i7)

RkiH

. SCREW, TAPPING, THREAD FORMING,

1/4-20x 718 IN. TYPE F

. BUS

. BOLT, CARRIAGE, 1/4-20x 4-l/2 IN.

. BOLT, CARRIAGE, 1/4-20x 5 1'

. NUT, HEX, l/4-20

. WASHER, FLAT, l/4 IN.

. WASHER, LOCK, 114 IN.

. SPACER, BRUSH BOX

. PLATE ASSEMBLY, BRUSH GUIDE

. . SPRING, BRUSH

. . ADAPTER, SPRING

. . NUT, HEX

. . GUIDE

. SPACER

. SPACER

. RING, MOUNTING

16

REF

16

8 ,

4

10

4

14

8

14

4

16

1

1

1

20

8

1

May lo/86 Revise< 4-3

Page 19

TM-630

26 28 ---7

.36

Trailer Group

Figure 9

4-3 Nov IO/78

Page 20 Revised June 9179

FIGURE

ITEM NO.

HOBART

PART NO.

9- 484331 ;k

1

2

3

4

5

6

7

8

9

10

11

400238

484259

484255

484256

HF-1882

484250

484254

W-l 1242-l 2

400954

W-l 1338-5

401468

78B-1123

79A-1075

12

13

79A-1057

76A-1171

79A-1045

14

15

16

17

18

19

79A-1046

404529

404530

404528

79A-1047

79A-1048

79A-1074

20 79A-1078

76A-1184

21

22

404539

404540

23 404541

24

25

26

404543

404544

404545

76A-1185

27 404551

28 404552

29 404553

NOMENCLATURE

1234567

TRAILER, WITH STANDARD 6.00 x 9

TIRES +SSEMBLY

.

.i

IPE, 6.00 x 9 6-PLY

RkKE, ASSEMBLY

. . LEVER, BRAKE MOUNT ASSEMBLY

. . BRAKE, SHOE ASSEMBLY

. . SHOE, BRAKE ASSEMBLY

. . ROD, ADJUSTING, BRAKE

BRACKET, MTG., BRAKE SHOE ANGLE

: : WASHER, FLAT, l/2”, STEEL

. . CLEVIS, ADJUSTING, BRAKE

. . PIN, COTTER, 1/8x 1, STEEL

. . PIN, CLEVIS

. TRAILER ASSEMBLY

. . DRAWBAR ASSEMBLY V22938

No. 6-3502

. . . HINGE PIN V22938, No. 5416

. . . COTTER PIN V22938, No. 4800-6

. . CENTER ARM ASSEMBLY V22938,

No. l-3854

. . . CENTER ARM V22938, No. 3854

. . . LATCH PEDAL V22938, No. 3855

. . . ROLL PIN V22938, No. 5000-I

. . . SPRING V22938, No. 4006

. . FLAT WASHER V22938, No. 4701-3

. . CENTER PIN V22938, No. 5400-5

. . AXLE, REAR, ASSEMBLY V22938,

No. 363-2006

. . . AXLE, REAR, BEAM WELDMENT

V22938, No. 363-2006-3

. . . HUB ASSEMBLY, REAR AXLE

V22938, No. 1-3612

. . . . CAP, GREASE V22938, NO. 6312

. . . . BEARING, CONE, OUTER V22938,

No. 6058

. . . . BEARING, CONE, INNER V22938,

No. 6057

. . . . SEAL, GREASE V22938, No. 6311

. . . . NUT, STUD V22938, No. 4601-6

. . . . LOCKWASHER V22938. No. 4700-5

. . . . HUB, STUD AND CUP ASSEMBLY

V22938, No. 3603-I

. . . . . HUB V22938, No. 3603

. . . . . STUD, WHEEL V22938, No. 6251-10

. . . . . CUP, BEARING, INNER V22938,

No. 6152 2

*NOTE: All Units Shipped After Sept./85 will have new trailer 489048

(TO-155 In Back Of Manual).

Nov IO/78

June 9179

TM-630

UNITS


4

REF.

4

1

1

4

2

2

2

2

4

t 2

1

1

1

2

1

1

2

1

1

1

1

5

1

4-3

Page 21

FIGURE

ITEM NO.

9-30

31

32

33

HOBART

PART NO.

404554

404537

404538

76A-1182

404546

34

35

76A-1219

76A-1220

36 76A-1221

37 76A-1223

38

39

76A-1222

400599

79A-1073

40 79A-1076

41 404533

42

43

44

404534

404535

404536

76A-1184

45 404539

46 404540

47 404541

48

49

50

404543

404544

404545

76A-1185

51 404551

52 404552

53 404553

4-3

Page 22

NOMENCLATURE

REC.

1234567 SPARES

. . . . . CUP, BEARING, OUTER V22938,

No. 6/l5j

. . . WASHER, SPINDLE V22938, No. 4702-2

. . . NUT, SPINDLE V22938, No. 4600-2

. . . PIN, COTTER V22938, No. 4800-5

. . WHEEL ASSEMBLY (For 6.00 x 9 in. IO

Ply Tire) V22938, No. 3712

. . . DISC, WHEEL (Without valve hole)

V22938, No. 3712-2

. . . DISC, WHEEL (With valve hole) V22938,

No. 3712-I

. . . BOLT, 318 in. 24N F, 314 in. Lg. Hex Hd.

V22938, No. 4901-8

. . . LOCKWASHER, 318 in. V22938,

No. 47004

. . . NUT, 318 in. 24 UNFV22938, No. 4601-5

. . TUBE, INNER V22938, No. 3600-200

* . AXLE, FRONT ASSEMBLY V22938,

No. 363-2056

. . . AXLE, FRONT BEAM ASSEMBLY V22938,

No. 363-205X-l

. . . SPINDLE & KNUCKLE ASSEMBLY (Left)

V22938, No. 3-3806

. . . SPINDLE & KNUCKLE ASSEMBLY (Right)

V22938, No. 4-3806

. . . PIN, KING V22938, No. 5401

. . . PIN, ROLL 3116 x l-314 in. V22938,

No. 5000-6

. . . HUB ASSEMBLY FRONT AXLE,

V22938, No. 1-3612

. . . . CAP, GREASE V22938, No. 6312

. . . . BEARING, CONE, OUTER V22938,

No. 6058

. . . . BEARING, CONE, INNER V22938,

No. 6057

. . . . SEAL, GREASE V22938, No. 6311

. . . . NUT, STUD V22938, No. 4601-6

. . . . LOCKWASHER V22938, No. 4700-5

. . . . HUB, STUD & CUP ASSEMBLY

V22938, No. 3603-I

. . . . . HUB V22938, No. 3603

. . . . . STUD, WHEEL V22938, No. 6251-10

. . . . . CUP, BEARING, INNER V22938,

No. 6152

TM-630

UNITS

per EFF ASSY

1 r: 2

2

2

4

1

1

8

8

8

4

1

1

1

1

1

1

2

1

1 ,

1

1

5

1

I

Revised June 9179

FIGURE HOBART

ITEM NO. PART NO.

9- 54 404554

55

56

57

404537

404538

76A-1182

79A-1049

58 79A-1077

59 79A-1051

60 79A-1052

61 79A-1053

62 79A- 1054

*

* 79A-1035

79A-1183

1234567

NOMENCLATURE UNITS


. * .a. . 6UP BEARING, OUTER V22938,

1 ‘1 No.6151

. . . WASHER, SPINDLE V22938, No. 4702-2

. . . NUT, SPINDLE V22938, No. 4600-2

. . . PIN, COTTER V22938, No. 4800-5

. . TIE, ROD ASSEMBLY V22938,

No. 3906-235

. . . TUBE V22938, No. 3600-200

. . . JAM NUT, R.H. V22938, No. 4602-I

. . . JAM NUT, L.H. V22938, No. 4602-2

. . . BALL JOINT, R.H. W/NUT V22938,

No. 3950-I

. . . BALL JOINT, L.H. W/NUT V22938,

No. 3950-2

. . LUBE FITTING V22938, No. 5801

. . LUBE FITTING V22938, No. 5800

1

2 2

1 2

1 2

1 2

1 2

4

5

June 9179 Revised 4-3

Page 23

TM-630

-- ~-.-- --

Engine Control Panel

Figure IO

4-3

Page 24

Nov IO/78

I

FIGURE HOBART

ITEM NO. PART NO.

IO- 483536

1 5cw-975

2 IOOGH-I 12

3 5CW-2127

4 5CW-976A

5 W-l 1097-8

6 W- 11254-6 7 W-l 1242-10

8 W-l 1278-5

9 401937-3

IO 402435

11 483537

12 402889-2

13 *

14

15 *

16

17

18

19

404329-I

400613-10

DW-6080

H F-251 8-8

4006 13-4

DW-4304

402658

W-II 166-3

404100

20

21

22

402662

y&-&097-1

23 W- 10853-4

* *

4836 IO No Number

m

TM-630

1234567

NOMENCLATURE UN ITS


PAN,EL,CONTROL, ENGINE, ASSEMBLY

(F/xi F\JHA See Figure 3)

BUSHING, INSULATOR

: TERMINAL, OUTPUT

. BUSHING

WASHER, INSULATOR

: SCREW, 3/8-16x 2, HHC, (STEEL)

. WASHER, LOCK, 3/8 (STEEL)

. WASHER, FLAT, 3/8 (STEEL)

. NUT, 3/8-16, HEX (STEEL)

. STRIP, TERMINAL V98410, No. 35012-3526

. INDICATOR, SERVICE, FILTER AIR CLEANER

V21585, No. L-14440-25

. PANEL, ENGINE CONTROL

. AMMETER, BATTERY CHARGING V85925

No. 730D5

. LIGHT, PANEL V74400, No. Ml-3216

. . LAMP 12 V (Lamp Industry Type 1895)

. GAUGE, OIL PRESSURE V81082

. LIGHT, PILOT, ENGINE GREEN 12 V

. . LAMP 12 V (Lamp Industry Type 1815)

. GAUGE, WATER TEMPERATURE V57733

. HOLDER, FUSE V71400 TYPE HKP-HH

. FUSE, AGC IOA V71400

. SWITCH, PUSHBUTTON STARTER V70040

No. 1996027

. SWITCH, TOGGLE V73559 No. 2GK71-73-DPST

. CONTROL, THROTTLE V41625 No. D43141

. SWITCH, TOGGLE, 3 POS., 2 POLE V91929,

No. 312TSl-59

. CAPACITOR, 0.5 pF, 100 V, DC V90201,

No. B-206020

. BRACKET, THROTTLE CABLE . CABLE;-ASSY QUICK START (PART OF QUICK

START KIT, FIG 3-11)

2

5

1 t 1

1

1 REF

REF

2

2

2 t

4

2

4

4

2

1

REF

1

1

1

1

May lo/86 Revised 4-3

Page 25

-_

--

“.Z

’..’

i -:.

,, ”

“,

FIGURE HOBART

ITEM NO. PART NO.

ll-

1

2

3

4

5

6

7

8

9

IO 5)

11

12 t

13

14

15

16

17

18

19

20

21

22

23 *

*

*

No Number

483384

483549

482918

12CW-2077-I

W- 10750-6

483524

404154-I 1

485501 480621 480618

30GH-417

483526

483451

403037-g

HF-2752

403492-I

483542

5CW-2048

483502

5CW-3420-I

76A-1152

483630

483540

483423

483420

388827-6

388828-5

483593

NOMENCLATURE

1234567

FRAME,GROUP (For NHA See Fig. 3)

.

.3

‘R’QME, MOUNTING, ASSEMBLY

OKE, LIFTING, ASSEMBLY

. MUFFLER, ASSEMBLY (Includes 4 and 5 below)

. . ELL, STREET, 90°

. . NIPPLE, PIPE, l/8”

. PIPE, EXHAUST, MUFFLER, ASSEMBLY

. CLAMP, FULL CIRCLE V79260, No. 35414

. PIPE, EXHAUST, MANIFOLD, ASSEMBLY

. GASKET, EXHAUST, MANIFOLD

. BRACKET, MOUNTING, EXHAUST

. MOUNT, SHOCK

. BRACKET, MOUNTING, MUFFLER, ASSEMBLY

. SUPPORT, CONTROL BOX, ASSEMBLY

. GROMMET, RUBBER

. MOUNT, RUBBER V16238, No. 4624-105

. BATTERY

. CLAMP, BATTERY HOLDDOWN

. ROD, BATTERY CLAMP

. TANK, FUEL, ASSEMBLY

. . GAUGE, FUEL

. CAP, FUEL TANK V49234, No. 1275

INSULATION, STRAP, FUEL TANK

: STRAP, FUEL TANK

. MOUNT, ENGINE, RIGHT FRONT, ASSEMBLY

. MOUNT, ENGINE, LEFT FRONT, ASSEMBLY

. CABLE, BATTERY FEED

. CABLE, BATTERY TO GROUND

. CABLE, BATTERY CONN.

TM-630

UNITS


REF

1

REF

1

1 1

1

1

1

1

4

REF

2

4

1 1 ' 1 1 1

2

2

1

1

1

1

1

M&y lo/86 Pevised 4-3

P?Zge 27

TM-630

Line, Fuel Supply

Line,Fuel Supply

Line,Fuel Return

l- &+=&&Qj&- Line Oil

Fuel and Oil Lines Assembly

Figure 12 4-3

Page 28

Nov IO/78

FIGURE HOBART

ITEM NO, PART NO.

12- 483611

1 w-1,0901-3

2 W-l 0905-6

3 78B-1019-2

4 56534

5 W- 10893-2

6 400225-2

7 W-7814-O

8 78B-1024-1

9 30523

IO 78A-1020-I

11

12

w-10901-1

w-10905-1

13 78B-1019-I

14 W-10891-1

15 W-10886-1

16 w-10909-1

17 403809-I

18

19 *

*

*

w-10910-0 . TEE, If8 PIPE V79470, No. 3700 x 2

W-10891-7 . ELBOW, MALE V79470, No. 49 x 4

78B-1021 . FITTING, CONNECTION, BANJO

78B-1022 . BOLT, BANJO CONNECTION

78B-1023 . WASHER, BANJO CONNECTION

NOMENCLATURE

1234567

LINES, FUEL AND OIL ASSEMBLY (For NHA

Seq qig. 3)

. Nd, COMPRESSION V79470, No. 61 x 5

. SLEEVE, COMPRESSION V79470, No. 60 x 5

. TUBE, RIGID, HOSE END, V79470,

No. 10004B-X05

. HOSE, LOW PRESSURE l/4” I.D.

. SWIVEL, FEMALE, SAE 45O FLARED V30327,

No. KA04-04NS

. VALVE, SHUT-OFF S.A.E. ANGLE V79470,

No. 320

. BUSHING, l/4 TO l/8 PIPE

. UNION, COMPRESSION, 5/16 OD TUBE

V79470, No. 62 x 5

. TUBING, COPPER 5/16 OD x .032 WALL .

. NUT, THREADED SLEEVE V79470,

No. 6100 x 5

. NUT, COMPRESSION V79470, No. 61 x 3

. SLEEVE, COMPRESSION V79470,

No.60~3

. TUBE, RIGID, HOSE END V79470, No.

10004B-X03

. ELBOW, MALE V79470 No. 49 x 4 x 4

. CONNECTOR, MALE V79470, No. 48 x 4

. TEE, STREET V79470, No. 3750 x 2

. SWITCH, OIL PRESSURE V75108,

No. C-25900-10

TM-630

UNITS


REF

2

2

3

98”

4

1

1

1

7 I,

1

1

1

1

1

1

1

2 ’ 2

1

1

2

2

4

4-3

Page 29

Nov IO/78

TM-630

\

34’

I’

/ 6

331 .’ c!c

4-3

Page 30

26

14 Volt Output Kit (Optional)

Figure 13

Revised Ott 22182

TM-630

FIGURE HOBART

ITEM NO. PART NO.

13- 483656

484836

481224

481225

387725

16DA-4253-I

5 16DA-4004A-IO

6 16DA-4052-0 7 W-97 14-22

8 400785-7

9 6 FW-6423A

IO

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36 *

*

A-896- 1 . . NAMEPLATE, POSITIVE

401937-2 . . STRIP, TERMINAL V98410, No. 35008-3526

401556 . . MOUNT, SHOCK, RUBBER

400434 . . NAMEPLATE, 14 VOLTS

481231 . . BOARD, P.C., OVERVOLTAGE, ASSEMBLY

W-9746-3 . . RESISTOR, 100 OHM, 25 WATT

400701 . . CONNECTOR, RIGHT ANGLE

FW-2131 . . RELAY, OVERLOAD VOI 121, No. X-10,000

w-10051-7 . . CLAMP, WIRE, PLASTIC

W-4541-L . . RESISTOR, 300 OHM, 25 WATT

1 cz-74 . * INSULATOR, TOP, RESISTOR

484265-3 . . SPACER

A-897-l . . NAMEPLATE, NEGATIVE

481226 . , BAR, BUS, OUTPUT

W- 10853-4 . . CAPACITOR, 0.5 pF 100 V. DC

484834 . PANEL, CONTROL, 14 V., ASSEMBLY

484835 . . PANEL, CONTROL, 14 V.

HF-2518-4 . . LIGHT, PILOT, AMBER, 14 V., ASSEMBLY

404 173 . . . BASE

404 172-2 . . . LENS (AMBER)

400613-3 . . . BULB

403189 . . SWITCH, TOGGLE, 3 POS., 2 POLE

HF-2518-8 . . LIGHT, PILOT, GREEN, 14 V., ASSEMBLY

404173 . . . BASE

404 172-3 . . . LENS (GREEN)

400613-4 . . . BULB

484833 . BRACKET, MTG. 14 V. PANEL

30GH-417 . MOUNT, SHOCK, RUBBER

483791 . PLATE, MTG. 14 V., CONTACTOR PNL.

H F-2962 . CLAMP, CABLE

400434 . NAMEPLATE, 14 VOLT

400435 . NAMEPLATE, 28 VOLT

NOMENCLATURE

1234567

KIT, 14 VOLT OUTPUT, ASSEMBLY (For

NH,+ See Fig. 3)

. PjAQEL, CONTACTOR, 14 V. ASSEMBLY

. . PANEL, CONTACTOR, 14 VOLT

. . BUS, INPUT

. . BRACKET, MTG., SOCKET, RELAY

. . RETAINER, SPRING, RELAY V77342,

No. 2OC206

. . RELAY, PLUG-IN, 12 VOLT V77342,

No. KAP-14DG

. . SOCKET, RELAY VO2660, No. 77-MIP-11

. . RESISTOR, 120 OHM, 2 WATT

* . RIVET, BLIND, STEEL, DOMED HEAD

. . LOAD CONTACTOR, 14 VOLT V74063,

No. A-791 N

UNITS


REF

1

1

3 /

1

2

1

1

1

1

1

1

1

1

1

4

1

1

1

Ott 22182 Revised 4-3

Page 31

FIGURE HOBART

ITEM NO. PART NO.

*13- IOOGH-117 *

481236 *

481235 ’ *

W-92 18-75 *

W-9218-131

4-3

Page 32

I I

NOMENCLATURE

1234567

. HORN &C BLE’CLAMP, ASSEMBLY

. wmwss, oh RE, ASSEMBLY P

. BAR, BUS, POSITIVE CONNECTION

. CABLE, NEGATIVE, ASSEMBLY

. CABLE, POSITIVE, ASSEMBLY

TM-630

UNITS


Revised Ott 22182

1

m

TM-630

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 ar arranged in alpha-numerical sequence. Thus, any part number beginning with

the letter A would be located at or n&r the top of the index. Likewise a part number 9 would be listed near the ‘i

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 location is listed commencing with the , first location the part is listed.

NUMERICAL INDEX

PART NUMBER

AW-1156B

AW-1470

AW-1683

AW-1719

AW-734

AW-740

BW-161A

BW-916

COOLING SYSTEM

DDW-155

DW-1045

DW-177B

DW-4304

D W-4324

DW-6080

DW-882A 7-4

DW-883 7-5

DWP-1804-1 2-24

DWP-982 2-15

FRAME GROUP 3-5

FW-2131 5-13

FW-446 7-6

GENERATOR GROUP 3-13

GENERATOR SET WITHOUT CANOPY I-4

HF-1638 4-22

HF-1882 9-4

HF-2518-7 4-16

HF-2518-8 IO-15

H F-2752 1 I-13

H F-530 4-3

H F-743 4-23

HJ-129A 2-o MUFFLER & EXHAUST SYSTEM 3-6

PANEL GROUP, INTERIOR 4-33

June 26/80 Revised

FIGURE AND

ITEM NUMBER

8-10

8-I

8-16

8-I 2

8-14

8-15

4-24

4-25

3-I 5

I-2

7-13

4-I 2

IO-16

4-28

IO-14

Numerical Index

4-4

Page 1

TM-630

b PART NUMBER

w-10051-1

w-10051-4

W-l 0072-B

W-l 0750-6 ’

W-10853-4

W-l 0855-4

W- 10869-3

W-10886-1

W-10891-1

W-10891-7

W- 10893-2

w-10901-1

w-10901-3

W-l 0905-I

W-l 0905-6

w-10909-1

w-10910-0

W-l 1097-8

w-11100-1

W-l 1166-3

W- 11236-7

W-l 1242-5

W-l 1242-6

W-11242-10

W-l 1242-12

W-l 1250

W-l 1254-4

W- 11254-6

W-l 1278-l

W-l 1278-5

W- 11280-2

W-l 1338-5

W-2974M

w-454 1 c

w-4541 0

W-781 O-O

W-7814-4

W-799H-173

W-8061A-I 1

w-9234-31

W-9234-l 42

W-9234- 167

W-97 12-7

W-9917-18

1 CZ-93B

IOOGH-112

Numerical Index

4-4

Page 2

NUMERICAL INDEX (CONTINUED)

i 6

FIGURE AND

ITEM NUMBER

4-21

4-20

7-7

11-5

1 O-23

7-3

6-O

12-15

12-14

12-19

12-5

12-11

12-1

12-12

12-2

12-16

12-18

1 o-5

1-44

IO-18

8-2

8-7

2-3

1 o-7

9-7

4-4

8-8

1 O-6

1-45

1 O-8

8-6

8-13

9-9

5-I

5-4

5-3

12-7

3-o

8-11

4-5

7-o

7-o

7-o

4-27

4-7

3-9

1 o-2

Revised June 26180

I I TM-630

PART NUMBER

IOOGH-117

IOOGH-138

12CW-2077-I

12cw-962

16DW-200

16DW-246

16DW-4117

16DW-538-0

16DW-967

1361

20RT-353-1

25MS-156

30G H-4 17

30GHP-391

30523

351541

352275-O

352281

352289

352413

355194

358221-32

358830-I 4

380706

380707

386751

387313

387859

38788 1

388328- 17

388827-6

388828-5

389466

389522A

389535-l

389909 389966

389967A-2

400078

400225-2

400238

400400 400435

APR 21/88 Revised-


FIGURE AND

ITEM NUMBER

1-o

4-15

II-4

8-17

8-3

7-o

2-2

4-19

7-8

7-14

4-I 3

5-14

4-14

11-o

2-13

12-9

6-O

2-4

2-o

2-5

8-9

6-16

7-9

8-O

7-10

7-I 1

7-12

2-o

6-14

6-9

2-o

6-6

4-l 1

11-o

11-o

5-8

5-5

4-29

6-4

5-19

3-l

4-o

5-2

12-6

9-1

4-9 2-26

Numerical Index

4-4

Page 3

PART NUMBER

400589-5

400591

400599 I

400613-3

4006 13-4

400613-10

400642-3

400701

400954

401468

401556

401937-3

402096

402141-16

402141-17

402141-18

402435

402658

402662

402665-I

402809

402889-2

402900

402958

402987

403034

403037-g

403068

403069

403127

403171

403 189

403194

403492-I

403648

4037 16

403763-I

403782-o

403809- 1

404100

404101-1

Numerical Index

4-4

Page 4

TM-630


i 4

FIGURE AND

ITEM NUMBER

5-18

5-o

9-39

4-17

1 o-o

2-o

1 o-o

4-8

5-o

9-8

9-10

5-7

1 o-9

3-11

6-O

6-2

6-3 1040:

IO-17

1 O-20

5-o

2-6

IO-12

4-o

5-o

6-8

1-3

6-1

II-O

4-o

5-o

4-o

5-o

2-o

3-o

4-18

1 o-22

3-o

3-8

II-14

4-o

3-o

5-6

3-o

12-17

IO-19

2-25

Revised June 26180

PART NUMBER

404 124

404154-I 1

404329-a

404528

404529

404530

404533

404534

404535

404536

404537

404538

404539

404540

404541

404543

404544

404545

404546

404551

404552

404553

404554

404603-2

430090B

430278

480006

480010

480026

480030

480109

480603-I

480616

480618

480646

482313

482918

483277

June 26180 Revised

I 1 NUMERICAL INDEX (CONTINUED)

i 4

FIGURE AND

ITEM NUMBER

3-10

11-7

4-1

IO-13

9-17

9-15

9-16

9-41

9-42

9-43

9-44

9-31

9-32

9-21

9-45

9-22

9-46

9-23

9-47

9-24

9-48

9-25

9-49

9-26

9-50

9-o

9-27

9-51

9-28

9-52

9-29

9-53

9-30

IO-21

5-17

7-15

4-34

4-32

4-o

7-19

2-17

7-o

4-o

II-10

7-17

3-o

11-3

7-18

\ TM-630

Numerical lhdex

4-4

Page 5

PART NL JMBER

483293- 1

483384

483420

483423

483437

483438

483439

483440

483449

483451

483460

483502

4835 11

483516

483524

483526

483529

483536

483537

483540

483542

483549

483654

483555

483567

483569

483574

483576

483577

483581

483586

483588

483593

483598

483599

483608

483610

4836 11

483612

483614

483615

483630

483635

Numerical Index

4-4

Page 6


i 4

FIGURE AND

ITEM NUMBER

7-22

11-I

11-23

11-22

6-O

6-5

6-7

6-12

7-1

11-12

3-2

3-12

II-17

7-o

11-8

II-6

II-II

II-9

3-7

10-I 1

11-21

11-15

3-3

11-2

I-1

2-o

2-I 0

2-14

2-7

2-11

2-18

2-12

2-8

2-9

4-30

11-O

7-2

2-20

3-o

1 o-o

3-o

12-o.

6-O

6-O

6-O

II-20

2-19

TM-630

Revised June 26/80

PART NUMBER

483636

483637

483638 ’

483639

483666

483768

483798

484250

484254

484255

484256

484259

48433 1

484533

484685

484810-I

5cw-1932-o

5CW-2048

5CW-2127

5CW-3420-I

5cw-794

5cw-975

5CW-976A

50GHP-206

50GHP-82

50GHP-89

56534

56555

5961-1

6FW-1799

6FW-2087A

6FW-6113

6FW-6115

6FW-6116

6FW6117

76A-1152

76A-1171

76A-1182

76A-1184

76A-1185

76A-1219

76A-1220

76A-1221

76A-1222

76A-1223

I 77B-1195

June 26180 Revised


i 6

FIGURE AND

ITEM NUMBER

2-16

2-22

2-21

2-23

4-31

5-o

7-o

9-5

9-6

9-2

9-3

9-o

I-5

9-o

3-o

7-20

7-16

6-13

11-16

1 o-3

II-18

3-o

10-I

1 o-4

4-2

6-11

6-10

12-4

6-15

1-O

5-16

5-11

5-9

5-15

5-10

5-12

II-19

9-13

9-33

9-o

9-o

9-34

9-35

9-36

9-38

9-37

3-4

TM-630

Numerical Index

4-4

Page 7

w 1 TM-630

I I

PART NUMBER

78A-1001

78A-1002 ’

78A- 1004

78A-1005

78A-1012

78A-1020-1

x78B-1013

78B-1019-I

78B-1019-2

78B-1021

78B-1022

78B-1023

788-1024-1

78B-1123

79A-1045

79A-1046

79A-1047

79A-1048

79A-1057

79A-1073

79A-1074

79A-1075

79A- 1076

79A-1078

8BW-12-3

8BW-12-8

8TRY-17


i i!

The following parts were added to update this parts list:

A-896-l

A-897-l

FW-2131

HF-2518-4

HF-2618-8

H F-2962

W-921 8-75

W-9218-131

w-9714-22

W-9746-3

w-10051-7

W- 10853-4

W-454 1-6

1 cz-74

IOOGH-117

W-10869-7 350330-182 486270-8

$kyerical Index

Page 8

FIGURE AND

ITEM NUMBER

3-14

3-o

4-10

4-6

4-35

12-10

4-26

12-13

12-3

12-o

12-o

12-o

12-8

9-10

9-o

9-14

9-18

9-19

9-12

9-o

9-o

9-11

9-40

9-20

8-4

8-5

5-o

13-10

13-22

13-17

13-o

13-o

13-36

13-o

13-o

13-7

13-15

13-18

13-24

13-19

13-20

13-o

76:;

2-o

Revised Mar 12/84

PART NUMBER

16DA-4004A-10

16DA-4052-0

16DA-4253-1

30GH-417

387725

400434

400435

4006 13-3

400613-4

40070 1

400785-7

401556

401937-2

403189

404172-2

404172-3

404173

481224

481225

481226

481231

481235

481236

483656

483791

484265-3

484833

484834

484835

484836

6FW-6423A

Ott 22182 Revised

w r 1


i 4

FIGURE AND

ITEM NUMBER

13-5

13-6

13-4

13-34

13-3

13-o

13-13

13-o

13-28

13-32

13-16

13-8

13-12

13-I 1

13-29

13-27

13-31

13-26

13-30

13-1

13-2

13-23

13-14

13-o

13-o

3-o

13-35

13-21

13-33

13-o

13-25

13-o

13-9

TM-630

Numerical Index

4-4

Page 9

OPTION NAME

Trailer

14 Volt output

Sept l/78

June 9179 Revised

CHAPTER 5. OPTIONAL EQUIPMENT

i i,

HOBART PART NO.

48433 1

TM-630

483656

5-o

Page 1

i iI

::

CHAPTER 6. MANUFACTURER'S LITERATURE

Voltage Regulator

i i,

Hobart Brothers Company Operation and Maintenance Manual TM-313

Engine, tiodel 6-354

Flexible Coupling

Hobart Diagrams

483657 Connection, Generator Set

483658 Schematic, Generator Set

Perkins Engines, Inc. Perkins Engine Shop Manual 601 SER 1080

Hobart Brothers Company Coupling Manual TM-350

481237 Connection, 14 Volt Output Option

Ott 22182 Revised - ----~- --.- -.-.._--___-~ .._. -.-_ ._~.._~_---__ 6-O ----- -___ -.--..- --- -- -..- ~ -.~-- ..__

_ .- _- - --_----

i iI

m-313 Revbed 081078

6th

D.C. FiEGULATOR hIgOB

manufacturedby

HOBARTBROTHF,RSCOMPANY POWER SYSTEMS DIVISION

TROY, OHIO 45373 U.S.A.

CONTENTS PAGE

SECTION 1 - INTRODUCTION

1. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 - SIQUENCE OF OPERATION

1. General ........................................................ 1

2. 14 Volt Operation .............................................. 2

3. Line Drop Compensation ......................................... (2

4. Current Limiting ...............................................

5. Stabilizing ....................................................

SECTION 3 - ADJUSTMENTS

1. Locations ...................................................... 2. 28 Volt Adjustment .............................................

14 Volt Adjustment 43: Li

............................................. ne Drop Compensation .........................................

5. Stabilizing or Damping ......................................... 6. Current Limiting ...............................................

SEXTION 4 - MAINTENANCE

1. Trouble Chart .................................................. 2. Diagrams .......................................................

SECTION 5 - PARTS LIST

1. General ........................................................ 2. Parts list Form ................................................

2

2 I

3 3 3 3 3 3

)+ 4

7 7

SECTION 1 - s ..- .,, . . ..L :.‘ ..Y y"

;-' : 1. GENERAL DESCRIPTION

The 43009OB regulator is designed to provide 2% regulation with l/2 second recoveky time on 28 volt self excited D.C. generators requiring no more than 7 amperes shunt field excitation. Means are provided for current limiting and line drop compensation. For 28 volt/l4 volt dual voltage,machines means are provided for regulation at either voltage level. i 'I

The regulator consists of a 3 stage direct coupled transistor smplifier drawing power from the generator and providing shunt field excitation as required to hold the gen- ' erator voltage constant. Generator voltage is compared with a constant voltage reference diode. If the generator voltage changes the amplifier output changes, varying the generator excitation in such a manner as to return the voltage to it$::original value. Dine drop compensation and current limiting are obtained by sensing the voltage drop across the generator interpole snd using the signal thus obtained to change the regulator output such as to provide the desired generator characteristics.

SECTION 2 - SEQUENCE OF OPERATION

1. GENERAL

When the generator is rotating at or near normal operating speed, voltage build up begins from residual magnetism and is applied to the generator shunt field through a h&gh power transistor (Q4). The power transistor base is connected to the positive generator terminal through a smaller power transistor (Q3) and a resistor (~8). Transistor Q3 is biased on through a resistor (R5) and allows sufficient current to flow through the base to emitter junction of power transistor Q4 to turn it full on. This causes nearly full generator voltage to be applied to'the shunt field and the resulting self excitation increases the generator voltage. When the generator voltage rises to such a level that the voltage between the positive generator terminal and the slider of the voltage adjustment potentiometer (R2) exceed the voltage at which the reference diode (Dl) conducts, a low power signal tranListar'~(Ql)~is'biased on through the reference diode. This transistor shunts current past the.base to emitter junction of medium power transistor (Q3), partially turning it off. The high power transistor (Qk), its base drive reduced by (Q3), decreases the generator shunt field current to the level required for generation of the nominal regulated voltage.

When a generator load or speed change causes the generator voltage to decrease, the reference diode (Dl) holds constant the voltage between the base of low power trsns- istor (Ql) and slider of the voltage adjustment potentiometer (R2). Most of the voltage decrease appears between the potentiometer slider and generator negative; causing a decrease in the base current of the low power transistor (Ql). The resulting increase in the collector current of the high power transistor (Q4) increases the generator excitation until the generator voltage returns to its regulated value.

When a load or speed change causes the generator terminal voltage to increase, the voltage between the slider of voltage adjustment potentiometer (R2) and generator negative increases, causing an increase in the base current of low power transistor (al). The collector current of this transistor causes a decrease in the base current

1.

of medium power transistor (Q3). The collector current of transistor (Q3) decreases, causing a similar reduction of the base and collector currents of power transistor , (Q4). The shunt field current of the generator decreases until the generator termin voltage return5 to normal.

2. 14 VOLT OPERATION

The regulating level is change 7 ,from 28 volts to 14 volts by shorting the slider of a

potentiometer (R3) in the sensing circuit to generator negative with an external switch(s). This increases the percentage of generator voltsge compared with the reference and shifts the regulating ruyg down to the 14 volt level.

3. LINE DROP COMPENSATION

The line drop compensation circuit causes the regulator to increase the generator voltage with load such that the voltage at the load end of the generator output cables remains constant despite the load cable voltage dron. This is done by sensjnp the generator interpole voltage drop and rttbtract$ng a part of,this voltage:'fr$!m!the sensed voltage such that the regulator senses a voltage lower than actually appears across the generator output terminals. This causes the regulated voltage to rise as generator load current increases. Proper adjustment of the line drop compensation potentiometer (RlO) causes the generator terminal voltage to increase enough with increasing load to exactly compensate for load cable drop, maintaining a constant voltage at the 1Osd.

4. CURRENT LIMITING

Generator output current is limited to a pre-set value by sensing the inter-pole voltI, age drop through a pair of resistor (Rll, R13) and using this voltage to drive a 2 ' stage transistor amplifier (Q2, 85). When the sensed voltage exceed the base to .emitter threshold voltage of transistor 85, the transistor conducts allowing current to flow through the base of transistor (Q2). Transistor (Q2) shunts the base to emitter junction of medium power transistor (Q3), causing a reduction in the base drive of output transistor (Q4). The current flowing to the shunt field through transistor Q4 decreases and the generated voltage drops in value. Any further increase in generator current causes further reduction of shunt field excitation, causing the generator to operate in a constant current mode.

5. STABILIZING

The stabilizing circuit prevents hunting and reduces over and undershoot of generator voltage following abrupt load changes. The regulator output voltage is coupled through a capacitor (C2), rheostat (R4) and limiting resistor (R7) to the base of low power transistor (Ql). A sudden change in the regulator output causes a transient current to flow in this circuit which opposes the sensed voltage causing the change.

2.

. SECTION 3 - ADJUSTMENTS

t 1. IDCATIONS ,

There are four locking screw driver adjustable potentiometers located below the transistor heat sink on the regulator assembly. Looking at the regulator in its normal mounting position, with the plug at the bottom, these are from left to right the 14 volt adJustme&, the line dr

R cbmpensation adjustment, the damping adjustment;

and the 28 volt adjustment.

2. 28 VOLT ADJUS!MENT

The exact regulating voltage in the 28 volt range is determined by the positdon of thcslider of this potentiometer (R2), which is located at the bottom of the regulator immediately to the right of the regulator power plug. Turning the slider clockwise increases the regulating voltage. Any adjustment of this potentiometea~.also:‘affeats the 14 volt level adjustment

3. 14 VOLT ADJUSTMENT

The exact adjustment of this voltage is normally made after the 28 volt range voltage is set. With the generator voltage range switch in the 14 volt position; the exact voltage is set by adjusting potentiometer R3 located at the bottom of the regulator immediately to the left of the regulator power plug. Turning the shaft clockwise increases voltage. Adjustment of this voltage does not require resetting of the 28 volt voltage.

( 4. LINE DROP COMPENSATION

.The line drop compensation potentiometer is located above and to the left of the regulator power plug. Clockwise rotation of the potentiometer shaft increases compensrtr tion. This potentiometer should be set for flat regulation of voltage at the load end of the output cables with the generator delivering rated continuous 1oad:current.

5. STABILIZING OR DAMPING

The damping circuit adjustment is located above and to the right of the regulator power plug. Clockwise rotation of the potentiometer shaft increases the stabilizing signal, making the system more stable but increasing the system response time.

6. CURRENT LIMITING

The current limiting adjustment is made with a rheostat on the generator ccont?ol panel. A calibrated dial is provided which indicated the approximate current value at which the generator output current is limited. There is a second adjustment in this circuit located inside the control box, a 25 watt slide wire tapped resistor with which the range of current limiting may be set. The range adjustment is factory set and should not normally need adjusting in the field.

3.

SECTION 4 -MAINTENACNE

1. TROUBLE CNART c . . ----- * . . . -..w_.. . . . .

symptom 1. .

I

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Generator voltage will not Shorted build up to normal operatilag Check For

,QL 62, 65, Dl

voltage lR2, Rl, RlO, D3 Open ' I 1 -I

' Generator voltage builds up 63, Q4, Cl Shorted too high, not controllable Check For ' with R2 \Ql, Dl, R6, R2, R3 open

1 I

----.P.... . ” ..-.-. ___ . --I

Generator voltage oscillates Check For '

R4, R-I', Open

1.Gen. brushholder set for too much compounding i

I ____- ,

2. DIAGRAMS

Connection diagram number 430529 and schematic diagram number 430099 are included in this section. They are especially useful for trouble shooting and repair,

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. . . UNUBUAL SERVICE CONDITIONS

This’infonnatiou is a general mideline and caunot cover al& possible couditioas of equipment use. The specific local environmelits may be dependent upon conditions beyond the mauufacturer's coatrol. The manufacturer should be

consulted if any unusual couditions of use exist which may affect the physical couditioa or operation of the equipment.

Among such conditions arq:;,

1. Exposure to:

A.

B.

c.

D.

E.

F.

G.

H.

I.

J.

Combustible, explosive, abrasive or coaductiug dusts.

Euviroumnts where the accumulatiou of lint or excessive dirt -will interfere with normal veutilatiou.

Chemical fumes, flammable or explosive gases.

Nuclear radiatioa.

Steam, salt-laden air, or oil vapor.

Damp or very dry locations, radiant heat, vermin iufestatidu, or atmospheres conducive to fungus growth.

Abnormal shock, vibratiqu or mechanical loading from enema1 sources duriw equipment operation.

Abuormal axial or side thrust imposed on rotating equipment shafts. I

Low and/or high smbient temperatures.

High electromagnetic fields.

2. Operation ati

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 thau 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.

Documents

i il · Delete Figure 12 and substitute Hobart drawing no. 485498 included as part of this addendum. E. Engine Assembly - Refer to Figure 3 Engine Assembly (4) is part no. 80B-‘l’T0.7