Hobart 9OC24S Operation Manual

Revised 062574
Rev ised 022278

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL

FOR

SELF-PROPELLED GENERATOR SET

MODE L N 0. 9OC24S

TM-240A

103073

SPECIFICATION NO. 5381A AND VARIATIONS

90KVA, 115/200-V AC, 400 tjZ, 3-PHASE

Manufactured by ,

MOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY

TROY, OH IO 45373

U.S.A.

SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT

ELECTRIC SHOCK can kill. Do not touch live electrical parts.

FUMES AND GASES can be fire and health hazards. Ventilate all fumes and exhaust gases to the outside.

ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible material. Do not

use power cables to break load and be sure tools don’t cause short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.

MOVING PARTS can cause serious injury. Keep clear of moving parts.

iMPORTANT - Protect yourself and others. Read and understand all the instructions in this Operating/Instruction

Manual before installing, operating, or servicing this equipment. Keep this manual available for future
use by all operators.

A. GENERAL

Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions. Safe practices
have developed from past experience in the use of power source equipment. Certain of the practices below apply to

engine driven equipment.

6. SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a

person. Have a competent electrician verify that the equipment is adequately grounded and learn what terminals
and parts are electrically HOT. Use proper safety clothing, procedures, and test equipment.

The electrical resistance of the body is decreased when wet, thus more easily permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas without being extremely careful.
Stand on dry rubber mat or dry wood, use insulating gloves that are effective when dampness or sweat cannot be
avoided. Keep your clothing dry and never work alone.

1. Installation and Grounding of Electrically Powered Equipment - Electrical equipment must be installed

and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, and other applicable codes.
A power disconnect switch or circuit breaker must be located at the equipment. Check the nameplate for voltage,
frequency, and phase requirements. If only 3-phase power is available, connect any single-phase rated equipment to
only two wires of the 3-phase line. DO NOT CONNECT the equipment grounding conductor (lead) to the third live
wire of the 3-phase line, g this makes the eauipment frame electricallv

---

HOT, which can cause a fatal shock

--- ----

Be sure to connect the grounding lead, if supplied in a power line cable, to the grounded switch box or building

ground. If not provided, use a separate grounding lead. Be certain that the current (amperage) capacity of the
grounding lead will be adequate for the worst fault current situation. Refer to the National Electrical Code ANSI/
NFPA 70 for details. Do not remove plug ground prongs. Use correct mating receptacles.

2. Output Cables and Terminals - Inspect cables often for damage to the insulation and the connectors. Replace
or repair cracked or worn cables immediately. Do not overload cables. Do not touch output terminal while equip-

ment is energized.

Instruction 910082
Nov 16182 Revised

Page 1

,--

3. Service and Maintenance - This equipment must be maintained in good electrical and mechanical condition
to avoid hazards stemming from disrepair. Report any equipment defect or safety hazard to your supervisor and
discontinue use of the equipment until its safety has been assured. Repairs should be made by qualified personnel
only. Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the equipment.

Lock switch OPEN (or remove line fuses) so that power cannot be turned ON accidentally. Disconnect power to
equipment if it is out of service. If troubleshooting must be done with the unit energized, have present another per­son trained in turning off the equipment and providing or calling for first aid.

C. FIRE AND EXPLOSION PREVENTION

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust piping, misuse
of batteries and fuel, or unsafe operating or fueling conditions.

1.

Electrical Short Circuits and Overloads - Overloaded or shorted equipment can become hot enough to cause
fires either by self destruction or causing nearby combustibles to ignite. Provide primary input protection to re­move short circuited or heavily overloaded equipment from the line.

2. Battery - Batteries may explode and/or give off flammable hydrogen gas. The acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, causing sparking, or use open flame
near the battery.

3. Enqine Fuel

- Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel
tank is not grounded prior to and during fuel transfer. Shut unit DOWN before removing fuel tank cap. Do not
completely fill tank. Heat from the equipment may cause fuel expansion overflow. Remove all spilled fuel im­mediately including any that penetrates the unit. After cleanup, open equipment doors and blow fumes away with
compressed air.

D. TOXIC FUME PREVENTION

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

E. BODILY INJURY PREVENTION

Serious injury can result from contact with fans, belts, and pulleys inside the equipment. Shut DOWN equipment
for inspection and routine maintenance. When equipment is in operation use extreme care in doing necessary
troubleshooting and adjustment.

F. MEDICAL AND FIRST AID TREATMENT

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

EMERGENCY FIRST AID

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

IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELEC­TRICAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration,
preferably mouth-to-mouth. If no detectable pulse, begin external heart massage. Call Emergency

Rescue Squad immediately.

G. EQUIPMENT PRECAUTIONARY LABELS

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

Page 2

Instruction 910082

Revised Nov 16/82

WARNING!

SAFETY DEVICE BOX

HOBART PART NO. 6FW-4013A

DANGER! FAILURE TO PROPERLY MAINTAIN THE MICRO SWITCH GEARSHIFT
INTERLOCK CAN RESULT IN INJURY OR DEATH DUE TO UNEXPECTED MOVEMENT OF
THE GPU. PERFORM THE FOLLOWING PROCEDURE EVERY 200 OPERATING HOURS OR
3 MONTHS.

1. Remove the GPU to an area free of personnel and equipment. Set the
emergency brake and chock wheels.

2. With the gearshift in any gear (except neutral) and the clutch pedal engaged,
attempt to start the GPU. If the GPU starts, have qualified maintenance
personnel replace the micro switch, Hobart part no. 403982, and repeat this test
procedure prior to returning the GPU to service.

3. With the gearshift in any gear (except neutral) and the clutch pedal engaged,
switch the GPU to “GENERATE” mode. If the GPU engine does not shut down,
have qualified maintenance personnel replace the micro switch, Hobart part no.

403982, and repeat this test procedure prior to returning the GPU to service.

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HOBART BROTHERS COMPANY

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

LIST OF EFFECTIVE PAGES

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

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OPERATION, MAINTENANCE. AND OVERHAUL MANUAL. TM-240A

SELFlPROPELlED GENiRATOR SET, SPEC. NO. 53&A

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OF’ERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

:MOTOR GENERATOR DIVISION
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CHAPTE I?/

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HOBART BROTHERS CCIMPANY

OARATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPECS. NO. 5381A

LIST OF EFFECTIVE PAGES (CONTINUED)

PAGE

D ATE

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I

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Page 6

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Revised June 25/74

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HOBART BROTHERS COMPANY

OPERATION, MAINTENANCE, AND OVERHAUL MAN UAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

INTRODUCTION

1. Genera I

The Introduction has been relocated to the front of the manual because we wish it to
be noticed and read first.

It has also been expanded in an attempt to give the reader

a better understanding of the manual and to make it more helpful and easier to use.

If you expect the manual to be useful to you, please read the introduction.

2.

scope

The manual contains descriptive,

maintenance, trouble shooting and overhaul informa­tion for a basic 400-Hertz, generator set and its different optional Variations.
qualified information throughout the manual will apply to the basic set and all varia­tions.

identified as such. An explanation of “variations”

Any information which applies only to a specific variation will be qualified and

and how to identify all generator

sets is given in the Description, Chapter/Section l-l (Chapter 1, Section 1).

3. P

urpose

The manual’s purpose is to provide information and instructions to experienced operators,

electricians, and mechanics who have never seen or operated this generator set.

the intent of the manual to guide and assist operators and maintenance personnel in the
proper use and maintenance of the equipment.

4. Contents

Immediately following the Introduction is a List of Effective Pages which lists each

page in the manual by its Chapter/Section, and page number. Directly opposite
each page number listing is a date which indicates whether the page is original or
revised.

A complete Table of Contents appears next in sequence. It contains a list of all
Chapters, Sections, and the principal paragraph titles within each Section. The lo­cation of each listing is identified by Chapter/Section and page number. A complete

list of illustrations with their locations is located at the end of the Table of Contents.

Un-

G

It is

The main text of the manual is divided into eight Chapters as follows:

Chapter 1. Description/Operation
Chapter 2. Servicing
Chapter 3. Trouble Shooting
Chapter 4. RemovaI/lnstaI laticn
Chapter 5.

Repairs

act 30/73 Introduction

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HOEIART BROTHERS COMPANY

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

Chapter 6. Overhaul
Chapter 7.
Chapter 8.

II lustrated Parts List

Manufacturer’s Literature

Each Chapter is divided into as many Sections as necessary. Sections are always referred
to by a combination Chapter/Section number. Example, 2-3 refers to Chapter 2, Section

3.

5. Format

A. Paragraphing and Out I in ing

The material within each Section is divided into main subjects with applicable
paragraph headings and subheadings as required. This method not only helps keep

information closely knit, but provides a means of identifying material for reference

purposes.

For example, a portion of the Description Section might logically follow

this arrange men t and paragraph ing :

1. Control Box

A. Interior Panel

(1) Protective devices

(a) Over load relay

(2) Con tactors

Page N umber ing

B.

Page numbers do not run consecutively throughout the manual. Each page is
identified by the Chapter/Section number in which it appears, and by a page

number within the Chapter/Section. Therefore the first page in each Section is

page 1.

These identifying numbers appear in the lower, outside corner of each
page. Each page also bears a date located in the corner opposite the page number.
This date is either that of original issue, or of the latest revision. Any revision

to the original text is identified by a heavy black line in the left-hand margin.

Illustrations follow a numbering system similar to page numbering. The first

Figure in each Section is Figure 1.

6. How to Use the Manual

A. General

There has always been, and probably always will be, some disagreement between

writers, users-,-specification writers, and others, regarding all phases of manual

Introduction
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HOBART BROTHERS COMPANY

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

preparation and how the manual-can best serve the needs of the user.

It is of

course impossible to completely satisfy al I concerned.

This manual follows the format, rules and style proposed by, and generally accepted

by members of the Air Transport Association.

grouped to help the user locate it quickly.

In so far as possible, information is

All tables, charts, diagrams, etc., as

well as illustrations, are identified by Figure Number (i.e., Fig. 2) to avoid con-

’ fusion.

How to Locate Information

B.

Even if you have read the manual completely and thoroughly, the easiest and quick­est way to locate information is by using the Table of Contents. In addition to the
complete Table of Contents in the front of the manual, each Chapter has its own

Table of Contents and List of Illustrations.

(1) Table of Contents

The complete Table of Contents is only five pages long 9 Even if the user has
no idea where a certain bit of information is located, the general location
can be quickly found by running through the Table of Contents. For example,
some adjustment information is needed.

A quick look at the Table of Contents
indicates that “Adjustment/Test” information is located in Chapter/Section 2-3
(Chapter 2, Section 3).

If the specific adjustment being sought is not listed

in the main Table of Contents, turn to Chapter 2 and look in its Table of Con-

tents under “Adiustment/Test” where each adjustment is listed with the page
number location.

, (2) List of Illustrations

Ott 30/73

A complete List of Illustrations follows the Table of Contents and includes the
title, figure number, and Chapter/Section, with page number location of all

illustrations contained in the manual.

Locate the appropriate title in the

List of Illustrations, then turn to the Chapter/Section and page number indicated.

It should be noted here that ALL electrical connection diagrams are located

in Chapter 5, Repair.

(3) References

To avoid repetition and lengthy explanations, references to other material are
used throughout the manual. Both material in the text and illustrations may be
referred to in order to clarify or expand information and instructions. Portions
of the text are referred to by identifying the paragraph in which referenced
material may be found. A reference to other material would be in order right
here by referring to paragraphing information contained in paragraph 5, A

Introduction

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

;MOTOR GENERATOR DIVISION
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HOBART BROTHERS COMPANY

above .
the reference, only the paragraph identification is given.

Example:

When referenced material is located in another Chapter/Section, both the
Chapter/Section number and the paragraph identification are given.

Example :

Components shown in illustrations and illustrations themse Ives are referenced
in a similar manner. When this type reference is made, the item number of

the part and the Figure number in which it appears are given.

Example:

When referenced material is located in the same Chapter/Section as

(Ref. Para.

the same Chapter/Section.

(Ref. 1-2, Para.
Chapter/Section l-2, and identified by paragraph 1, A.

1, A) means the material is to be found in paragraph 1, A, of

1, A) means that the referenced material is located in

(Ref. 2, Fig. 3) f re ers to item number 2 which appears in illustration Figure

3 of the same Chapter/Section.

When the referenced Figure appears in another Chapter/Section, the reference
will include the Chapter/Section number.

Example :

(Ref. 2-3; 1, Fig.

see item 1, in Figure 4.

Once a Figure number reference has been established for a series of instructional
steps, the Figure number is not repeated. Only the item numbers of parts in­volved are referenced.

For example, an instruction might appear like this: “Loosen screw (2, Fig. 6),

slide out connector (4), and remove brush (6)“.

When an item is referenced without a figure number, it will always apply to the

last preceding Figure number mentioned in the text.

NOTE:

The word “See” may appear in some references, as (See Fig. 2). It
means exactly the same thing as “Ref. “, however, its ,usage seems a
little more direct and definite.

4) tel Is the user to refer to Chapter/Section 2-3, and to

Introduction

page 4

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HOBART BROTHERS COMPANY

OPERATION, MAINTENANCE , AND OVERHAUL MAN UAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

7. Abbreviations

The following is a list of abbreviations used throughout the manual. They are not

to be confused with symbols which appear on schematic diagrams.

A - ampere
AC

- alternating current

AR ’ - as required

C
ccw
cw
DC

de!3
F

Fig
GALS
Hz
in .
KG
KVA
KW
MM

No.

Para.
PF
PSI
Pt
Qt

Ref
RPM

Sect
SPEC

- ten tigrade

- counterclockwise

- clockwise

- direct current

- degree

- Fahrenheit

- figure

- gal Ions

- Hertz (cycles per second)

- inch

- kilogram

- kilovolt-ampere

- kilowatt

- millimeter

-number

- paragraph

- power factor

- pounds per square inch

- pint

- quart

- reference (refer to)

- revolutions per minute

- section

- specification

T-R - transformer-rectifier

V - volt

VAR

- variation

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

lntroc+ction Ott 30/73

Page -6.

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

pMDTDR GENERATOR DIVISION

i

TABLE OF CONTENTS

HOBART BROTHERS COMPANY

SUBJECT

Description/Operation

Description

Genera I

Orientation

Spec ia I Features

Optional Equipment and Identification

Engine, Generator and Control Box

Operating Mode Safety Devices

Transformer-Rectifiers (Optional)

Test Box (Optional)

Additional Variations

Preparation for Use

CHAPTER/SECTION

1-o 1

l-l

l-2

PAGE

1

6

6

28

29

32;

1

General

Inspection and Checks

Lubrication

Installing Output Cable

Operation l-3

Genera I 1

Moving the Cklit Without Engine Power

Operating the Unit

Operating Transformer-Rectifier (Optional

Equipment) 11

1

1

2

2

1

June 25/74 Revised

P!zP 1

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

TABLE OF CONTENTS (CONT’D.)

SUBJECT

Operating the Test Box

DC and AC Power Delivery

Servicing

Maintenance Inspection/Check

Genera I

Maintenance Schedule

Inspection/Check

Maintenance Procedures

General

Lubrication 1

Servicing the Air Cleaner

CHAPTER/SECTION

1-3

2-o

2-l

2-2 1

PAGE

:8”

1

1

1

1

5

1

13

Engine Fue I

Engine Cooling System 18

Battery Service 25

Brake Fluid Check

Drive Belts 30

Generator Maintenance 34

Tire Inflation 34

Adjustment/Test

2-3

Genera I

Testing the Generator Set 1

Engine-Generator Components Ad justmen t

14

29

1

1

15

Contents

Page 2

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Revised June 25/74

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO, 538

1A

TABLE OF CONTENTS (CONT’D .)

SUBICT

Chassis Components Adiustment

Trouble Shooting

Theory of Operation

General

Twelve-Volt Electrical System

400-Hz Generator System

Trouble Shooting Procedures

Genera I

Trouble Shooting Chart

Equipment for Trouble Shooting

CHAPTER/SECTION PAGE

2-3 30

3-o 1

3-l 1

1

1

9

3-2

1

1

1

1

Safety

Parts Replacement

Test Values

Trouble Shooting Practices

Electric-Hydraulic Governor Trouble Shooting

Engine Trouble Shooting

II lustrations

Removal/Installation

Engine-Generator Assembly Removal and

Installation

Genera I

4-o

4-l

2

2

2

3

4

5

5

1

1

1

Con tents.

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 538114

TABLE OF CONTENTS (CONT’D.)

SUBJECT

Installation

Individual Components Removal and Installation

General

Generator Control Box Trays

Power Module Panel Assembly

Control Box

Repair

Electrical Repairs

Genera I

Generator Control Box

CHAPTER/SECTION

4-l

5-o

5-l

PAGE

10

1

1

2

4

1

1

1

1

Generator

Engine

Connection Diagrams

Mechanical Repairs

Engine

Generator

Canopy Assembly

Overhaul

Electrical

Genera I

Generator Control Box Assembly

1

1

5-2

1

1

1

1

6-O

1

6-l 1

1

1

Contents

kg9 .~P

act 30/73

GENERATOR DIVISION

HOBART BROTHERS COMPAW

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

TABLE OF CONlENTS (CONT’D.)

SUBJECT

Generator

Mechanical

General

Engine

Generator

I I lustrated Parts List

Introduction

Genera I

Purpose

Arrangement

CHAPTER/SECTION

6-l

6-2

7-o

7-l

PAGE

2

1

1

1

1

1

1

1

1

1

Explanation of Parts List

Manufacturer’s Codes

, Explanation of Manufacturer’s (Vendor)

Code List

Parts List

Explanation of Parts List Arrangement

Symbols and Abbreviations

N umer ica I Index

Explanation of Numerical Index

Manufacturer’s Information

7-2

1

1

7-3 1

1

1

7-4

1

1

8-O 1

1

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HOB/\RT BROTHERS COMPANY

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC-. NO. 5381A

LIST OF ILLUSTRATION S

CHAPTER/

SECTION NUMBER

l-l
l-l
l-l 3
l-l
l-l 5
l-l
l-l
l-l 8
l-l 9
l-l 10
l-l 11

FIGUTE

1

2

4

6
7

TITLE

Self-Propelled Generator Set
Specifications and Capabilities (Sheets 1 and 2)

Component Identification (Sheets 1 and 2)

Air Cleaner and Service Indicator

Control Box
Generator Control Tray
Protective Relay Tray

Voltage Regulator Tray

Voltage Regulator
Power Module
Test Box Assembly (Optional)

l-2 1 Engine Oil Gage Rod and Filler Cap

l-2
l-2 3
l-2
l-2 5

l-3 1

2

4

Output Terminals (Typical)

Opening for Output Cable (Typical)
T-R Output Cable lnsta I lation
T-R Cable Plug Boxes

Engine and Generator Controls and Instruments

(Sheets 1 and 2)
l-3
l-3
l-3

l-3
l-3
l-3
l-3
l-3

Starting Aid
Driver’s Compartment Controls (Typical)
Transformer-Rectifiers (Typical Installation)

28.5-V DC T-R Control Panel

28.5-V DC T-R Output Voltage Adiustment 14
112-V DC T-R Control Panel 16

Test Box Operating Controls
Test Receptacle Connector (Typical) 18

PAGE

NO.

1

3-4

8-9

12
16

18

21

24
25
26
30

2-3

5

8
12
14

17

2-l
2-l
2-l
2-l

2-2
2-2
2-2
2-2
2-2
2-2

Contents

Page 6

1
2
3
4

1
2
3

Maintenance Schedule
Vibration Damper Hub

Lamp Identification Chart 18

Fuse Chart 19

Lubrication Chart
Lubricants and Fluids Chart
Symbols and Time Intervals

4 Oil and Coolant Capacities

5

6

Temperature and Viscosity Chart
Oil Filter

2 thru 4

14

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

LIST OF ILLUSTRATIONS (CONT’D.)

CHAPTER/

FIGURE

SECTION NUMBER

2-2
2-2
2-2 ’

2-2
2-2
2-2
2-2
2-2
2-2
2-2
2-2
2-2

2-2
2-2
2-2

7

8
9

10
11
12
13
14
15
16
17
18

19
20
21

2-3 1
2-3

2

2-3 3
2-3 4
2-3 5
2-3
2-3

6

7

2-3 8
2-3 9
2-3
2-3
2-3

10
11

12
2-3 13
2-3 14
2-3 15
2-3

16
2-3 17
213

18
2-3 19

TITLE

Water Pump Lubrication

Fan Hub Lubrication

Rear Axle, Transmission, and Steering Gear Grease

Filler Plugs

Air Cleaner Cartridge Replacement

Fuel Filter

Fuel Pump Screen and Priming Plug
Coolant Drains
C

orrosion Resistor
Battery Access Doors
Battery Installation

Master Brake Cylinder

Belt Deflection, Tension Check Chart
Belt Deflection Check

Alternator Belt Adjustment

Fan Belt Adjustment

Generator Control Box Interior

Engine and Generator Controls and Instruments

(Sheets 1 and 2)
Terminal Boards
Generator and Exciter Stator Test

Excitation Resistors
Voltage Regulator Adjustments
Voltage Regulator Damping Adjustments
Engine Specifications
Governor Linkage Adjustment
Magnetic Pickup Adjustment
Hydraulic Actuator Adjustment
Governor Electric Control Box and Potentiometer

Acce lerator Linkage Adiustmen t

Clutch Pedal Adiustment
Brake Peda I Ad justmen t
Parking Brake Adjustment
Brake Shoe Adjustment
Brake Bleeder Valve (Rear Wheel)
Gearshift Micro Switch Adjustment

PAGE
NO.

9

10

12
14
16

17
22
24
26
28
29
30
31
33
33

2

4-5

6
14
16
17
19

20
23
24
26
28
30
31
33
34
36
38
40

3-l 1
3-l

w W??

2

Engine Circuit Schematic Diagram

Generator Circuit Schematic Diagram

2
4

Contents

Page 7

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HOBART BROTHERS COMPANY

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

LIST OF ILLUSTRATION S (CON T’D. )

CHAPTER/

FIGURE

SECTION NUMBER

3-l 3
3-l
3-l

3-2

3-2

4

t5

1

2

3-2 3
3-2
3-2
3-2

4

5

6

4-l 1

4-l
4-l

2

3
4-l 4
4-l 5
4-l

6
4-l 7

PAGE

TITLE

Governor Speed Setting Potentiometer Schematic
Governor Actuator Cross-Section

Electric Governor Voltage Values

NO.

7
8
9

Engine and Generator Controls and Instruments

(Sheets 1 and 2)

6-7
Starter and Solenoid Switch 8
Termina I Boards 9

Exe itation Resistors 10
End View of Voltage Regulator Amphenol Connector

10

Trouble Shooting Chart 11 thru 30

Self-Propelled Generator Set 3

Accelerator Control Cable Connection 4

Steering Gear 5

Clutch Shaft and Linkage

7
Peda Is and Master Cylinder 8
Pedals Assembly Attachment

Engine-Generator Hoisting Arrangement (Typical)

8

9

4-2
4-2

5-l
5-l
5-l
5-l
5-l
5-l

5-2

6-l
6-l
6-l
6-l
6-l

6-l

6-l

6-l

1

2

1

2

3

Control Tray Removal (Typical)

Power Module Panel Assembly 3

Generator Circuit Connection Diagram 2

Engine Circuit Connection Diagram

Control Box Connection Diagram 4

4 Generator Control Tray Connection Diagram

5

6

Protective Monitor Tray Connection Diagram
Power Module Connection Diagram

No Illustrations

1
2
3

4

5

6
7

8

Generator Lifting Arrangement (Typica I) 2
Generator-to-Engine Connection
Generator Fan and Coupling (Typical)

Wrench Positioned to Prevent Engine Rotation (Typical) 5

Flexible Coupling (Removal or Installation) (Typical)
Coupling Hub and Bushing
Generator Exploded View

Exciter Rotor (Removal or Installation)

2

3

5
6
7

3
4

6
6

8
9

Contents

Page 8

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Ott 38/73

.-~. .__

GENERATOR DIVISION

HOBART BROTHERS COMPANY

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 538114

LIST OF ILLUSTRATION S (CON T’D , )

CHAPTER/ FIGURE
SECTION NUMBER

TITLE

6-l 9 Positioning Generator Rotor (Removal or Installation)

(Typical)
6-l 10
6-1
6-l

11

12
6-l 13
6-l

6-1
6-l

14

15

16

Preparation for Rotor lnstal lation (Typica I)

Cleaning and Lubricating Hub and Bearing (Typical)

Routing Exciter Leads (Typical)

Installing Exciter Housing (Typical)

Exciter Rotor Installation (Typical)

Pulling Generator Rotor Field Leads (Typical)
Fan Housing-to-Flywheel Adapter Measurement

(Typical)
6-l 17
6-l

18

Torquing Hub Screws (67 ft-lbs)
Measuring Flexible Coupling Location on Generator

Shaft (Typical)

6-l

19

Positioning Generator to Engine (Typical)

6-l 20 Torquing Coupling-to-Flywheel Screws (150 ft-lbs)

6-2

7-3

7-3
7-3
7-3
7-3
7-3
7-3
7-3
7-3
7-3
7-3

7-3
7-3
7-3
7-3
7-3
7-3
7-3
7-3
7-3

7-3

7-3

1
2
3
4
5
6
7

8

9

10
11
12
12A

-13.
14

15
16
17
18
19

‘20

21

No Illustrations

Self-Propelled Generator Set
Canopy Assembly
Generator Set Without Canopy
Control Box Assembly
Generator Control Tray Assembly
Protective Relay Tray Assembly
Voltage Regulator Tray Assembly

Power Module Panel Assembly
Control Box Front Panel Instruments and Controls
Control Box and Internal Components Group

Radiator and Cooling System Group

Floorplate, Pedals, and Brake Group
Floorplate, Pedals and Brake Group
Hydraulic Brake Master Cylinder
Steering Group
Steering Gear

Engine and Drive Train Group

Governor and Accelerator Linkage Group

Governor Oil Lines
Fuet-and Oil Lines Group

Stator Terminal Panel Assembly ‘.-

Gear-shift Safety Box and Back-up Light Switch Group

PAGE

NO.

10
14
15
16
16
17
18

19

21

21
22
23

2
4
6

8
10
14
18

20
24
26
28
32

35A

36

38
40
42
46
48

50
52
54

Oct30/73

June 25/74Revised

Contents

page 9

FOBAR’I:

e
a

t

B. *,,+*’

;MOTOR GENERATOR DIVISION

QD

:

z

HOBART BROTHERS COMPAN”

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO, 5381A

LIST OF ILLUSTRATIONS (CON T’D. 1

CHAPTER/

SECTlObi

7-3
7-3
7-3
7-3
7-3
7-3 27
7-3 28
7-3
7-3
7-3

FIGURE

NUMBER

22

,23

TITLE

Transmission Assembly

Clutch Group

PAGE

NO,

56
66

/ 24 Generator Group 68

25 Seat and Transformer-Rectifier Group
26 Output Terminal Panel Assembly

70
74

Transformer-Rectifier Terminal Pane I Assembly 76

29
30
31

Vehicular Lights Group

Body and Frame Group 80
Battery Group

Axle Group 86

78

84

FOBART

8
5

“c

%

;MOTOR GENERATOR DIVISION

QD

*. B,,I~~

oz

2

HOBART BROTHERS COMPANY

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO, 5381A

CHAPTER 1. DESCRIPTION/OPERATION

TABLE OF CONTENTS

SUBJECT

Description

General

Orientation

Specia I Features

Protective Monitor

Pull-out Trays

Voltage Regulator

Test Circuitry

Electric Hydraulic Governor

Optional Equipment and Identification

CHAPTER/SECTION PAGE

l-l

1

1

5

5

5

5

5

5

5

6

Variation No. 1

Variation No. 2

Combinations of Variations

Future Variations

Engine, Generator and Control Box

Basic Engine

Engine Manufacturer’s Equipment

Electrical system

filter

I

Fue

Oil filter

6

6

6

6

6

6

7

7

7

GENERATOR DIVISION

HOBART BROTHERS COMPANY

OPERATION, MAINTENANCE ,. AND OVERHAUL MANUAL, TM-240A

SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A

TABLE OF CONTENTS (CONTINUED)

SUBJECT

Automatic shut-down system

Fue I shut-off valve

Oil pressure switch

Engine overspeed protection

Engine-cooling fan

Hobart Installed Engine Equipment

Electric-hydraulic governor

Electric control unit

Hydraulic actuator

Magnetic pickup

CHAPTER/SECTION

l-l

PAGE

7

7

7

10

10

10

10

10

11

11

Engine safety device

Coolant temperature switch

Air cleaner

Mufflers

Radiator

Generator

Control Box Assembly

Engine instruments

Ammeter

Temperature gage

Oi I pressure gage

11

11

11

12

12

12

13

13

13

13

14

l-O_

Page 2

- ..~.~_. _

octt30/73