Hobart 9OC24S Operating instructions

TM-240A

103073

Revised 062574

Rev ised 022278

OPERATION, MAINTENANCE, AND OVERHAUL MANUAL

FOR

SELF-PROPELLED GENERATOR SET

MODE L N 0. 9OC24S

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 per-

son 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 re-

move 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 im-

mediately 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 ELEC-

TRICAL 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.

,

CHAPTER/

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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

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

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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

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

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

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;MOTOR GENERATOR DIVISION

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HOBART BROTHERS COMPANY

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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 informa-

tion for a basic 400-Hertz, generator set and its different optional Variations.

Un-

qualified information throughout the manual will apply to the basic set and all varia-

G

tions.

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

identified as such. An explanation of “variations”

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.

It is

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 lo-

cation 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.

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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4. BL,I’La

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

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

Chapter 6. Overhaul

Chapter 7.

II lustrated Parts List

Chapter 8.

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

B.

Page N umber ing

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

.-~o~t.~o[~~

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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.

In so far as possible, information is

grouped to help the user locate it quickly.

All tables, charts, diagrams, etc., as

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

’ fusion.

B.

How to Locate Information

Even if you have read the manual completely and thoroughly, the easiest and quick-

est 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

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

Ott 30/73

Introduction

FOBART

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

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

above .

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

the reference, only the paragraph identification is given.

Example:

(Ref. Para.

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

the same Chapter/Section.

When referenced material is located in another Chapter/Section, both the

Chapter/Section number and the paragraph identification are given.

Example :

(Ref. 1-2, Para.

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

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

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:

(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.

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

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 in-

volved 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.

Introduction

page 4

Ott 30/73

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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

- ten tigrade

ccw

- counterclockwise

cw

- clockwise

DC

- direct current

de!3

- degree

F

- Fahrenheit

Fig

- figure

GALS

- gal Ions

Hz

- Hertz (cycles per second)

in .

- inch

KG

- kilogram

KVA

- kilovolt-ampere

KW

- kilowatt

MM

- millimeter

No.

-number

Para.

- paragraph

PF

- power factor

PSI

- pounds per square inch

Pt

- pint

Qt

- quart

Ref

- reference (refer to)

RPM

- revolutions per minute

Sect

- section

SPEC

- specification

T-R - transformer-rectifier

V - volt

VAR

- variation

FOBART

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HOBART BROTHERS COMPANY

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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

TABLE OF CONTENTS

SUBJECT

CHAPTER/SECTION

PAGE

Description/Operation

Description

1-o 1

l-l

1

Genera I

Orientation

Spec ia I Features

Optional Equipment and Identification

6

Engine, Generator and Control Box

6

Operating Mode Safety Devices

28

Transformer-Rectifiers (Optional)

29

Test Box (Optional)

Additional Variations

Preparation for Use

l-2

32;

1

General

Inspection and Checks

Lubrication

2

Installing Output Cable

Operation l-3

1

2

1

Genera I 1

Moving the Cklit Without Engine Power

Operating the Unit

Operating Transformer-Rectifier (Optional

Equipment) 11

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

CHAPTER/SECTION

1-3

2-o

PAGE

:8”

1

Maintenance Inspection/Check

2-l

1

Genera I

1

Maintenance Schedule

1

Inspection/Check

5

Maintenance Procedures

2-2 1

General

1

Lubrication 1

Servicing the Air Cleaner

13

Engine Fue I

14

Engine Cooling System 18

Battery Service 25

Brake Fluid Check

29

Drive Belts 30

Generator Maintenance 34

Tire Inflation 34

Adjustment/Test

2-3

1

Genera I

1

Testing the Generator Set 1

Engine-Generator Components Ad justmen t

Contents

Page 2

15

act 30/73

Revised June 25/74

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