Hobart 5359D Operation and Maintenance Manual

OM 2012

082585

Revised 042188

OPERATION AND MAINTENANCE MANUAL

with

ILLUSTRATED PARTS LIST.

for

E.N G INE -DRIVEN* GENERATOR SET

SERIES 5359P, MODE L 9OG20

909KVA , 400-H z, 115/200-V AC, 3 Phase

with

DETROIT DlEsELENGINE, TYPE 4-71N

.

Specification Number 5359&l, For truck or trailer mounting

Speciftiation Number 53590-2, For tracta mounting

Specification Number 5359@-3, For stationary mounting

Specification Number 5359s 9,; For truck or trailer mounting

(Special features for ‘AF)

.

Manufactured by

HOBART BROTHERS COMPANY

POWRSYSTEMS DNISION

TROY, OHIO 45373

U.S.A.

,

.--

_ -

L

i

.-

SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTKFCAL POWER EQUIPMENT I

WARNING

I

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

I

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 circuit+.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attach{d

equipment.

I

IMPORTANT: - Protect yourself and others.

Read and understand all the

instructions in this Operating/Instruction Manual before

j

!

A.

B.

installing, operating,

or servicing this equipment.

manual available for future use by all operators.

Keep th{s

I

GENERAL

Equipment that supplies electrical power can cause serious injury or death,

or damage to other equipment or property,

if the operator does not str$ctly

observe all safety rules and take precautionary actions.

Safe practides

have developed from past experience in the use of power source equipmt&t.

SHOCK PREVENTION

I

Bare'conductors, or terminals in the output circuit, or ungrounded,

I

electrically-live equipment can fatally shock a person.

Have a tiompei&nt

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.

\

I

The electrical resistance of the body is decreased when wet, thus more

easily permitting dangerous currents to flow through It. When fnspecting OF

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.

,

!

I. Installation and Grounding of Electrically Powered Equipment -Elet$tricab

equipment must be installed and maintained in accordance with the NatJonal j

Electrical Code, ANSI/NFPA 70, and other applicable codes.

A power discon-!

nect switch or circuit breaker must be located at the equipment.

nameplate for voltage, frequency, and phase requirements.

If only

Cheek the;

power is available,

3-phase j

of the 3-phase line.

connect any single-phase rated equipment to only two wipes

DO NOT CONNECT the equipment grounding &onductor (lea/d)

to the third live wire of the 3-phase line, as this makes the equipmelfit frame

electrically HOT, which can cause a fatal shGky--

l

1

-w-e--

!

I

I ;

- ..-. m-t-.- ._ -.. .1

I

1

Dee 41184

I-. -, - _- __ _ _ - -_ -.. __ _..

I

c

C.

I

1 D.

I

j E.

F.

+- _. ^_ ‘.’

Be sure to.connect the grounding lead,

if supplied $,,aXpower line cabIe;~..:.,,--

to the grounded -s&t&-box or.building ground;.

-Ifs-t&--provided, use a:- ;

separate grounding lead.

Be certain that the current (amperage) capacity j

of the grounding lead will be adequate for the worst fault current sltua-

'

tion. Refer to the National Electrical Code ANSI/NFPA 70 for detai1s.i Do

not remove plug ground prongs.

Use correct mating receptacles.

I

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.

equipment is energized.

Do not touch output terminal whfle

FIRE PREVENTION

Overloaded or shorted equipment can become hot enough to cause fires e+ther

by self destruction or causing nearby combustibles to ignite. Provide!

primary input protection to remove short circuited or heavily overload+d

i

!

equipment from the line.

I

!

,

BODILY INJURY PREVENTION

/

Serious injury can result from contact with fans inside the equipment.:

b

Shut DOWN equipment for Inspection and routine maintenance. When. equ;pment

is in operation use extreme care in doing necessary troubleshooting and

adjustment.

t

1

Inspect all precautionary labels on the equipment monthly.

Order and 1

_,~_ ~. -

replace all labels that cannot be easily read. -- -

~- --I

I

. . .._ ..- .-

.-- - -_ - _-..-..-_.. ..- _.._ .-... _ .._ __ ..-_.

/

.-- -_.-. _ ._ _.

w-2

3. Service and Maintenance -

This equipment must be maintained in good

electrical and mechanical condition to avoid hazards stemming from dis+

repair. Report any equipment defect or safety hazard to your supervisor ant

discontinue use of the equipment until its safety has been assured. Re-

pairs.should be made by qualified personnel only. Shut OFF all power gt

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;ser-

vice.

If troubleshooting must be done with the unit energized, have pre-

sent another person trained in turning off the equipment and provldlng,or

calling for first aid.

4

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.

I-

EMERGENCY FIRST AID

Call physician immediately. Seek additional assistance and use First hd

techniques recommended by American Red Cross until medical help arrive6.

IF BREATHING IS DIFFICULT, give oxygen,

if available, and have victim jfe

down.

FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not

breathing, begin artificial respiration, preferably mouth-to-mouth. I!f

no detectable pulse, begin external heart massage. Call Emergency Res)cue

Squad immediately.

I

EQUIPMENT PRECAUTIONARY LABELS

.I

OM 2012

ItiTR ODUCT ION

This manual contains operation and maintenance information for a 4OO+Iertz, generator set

manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373.

The manual is not intended to be a text book on electricity cr electronics.

Its primary 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 people in the proper use and care of the equipment.

Use of the manual should not be put off until a trouble or need for help develops.

Read the

instructions before starting the unit.

Learn to use the manual and to locate information con-

tained in it. Its style and arrangement are very similar to commercial aircraft manuals.

The manual is divided into six chapters.

Each chapter is divided into as many sections

as required.

Each new section starts with page 1.

Each page is identified by chapter,

section qnd page number which are located in the lower, outside corner. When information

located in another portion of the manual is referred to, its location is identified by chapter,

section, and paragraph, or figure number. For example, “(See 2-3, Para. B) ‘I refers

to information located in Chapter 2, Section 3, paragraph 8.

If a Chapter and Section are

not indicated in a reference, the referenced material is l&ted in the same section as the

reference, Example, (See Para. B).

In addition to operation and maintenance instructions,

the manual contains an illustrated

parts list iri Chapter 4, and a collection of manufacturer’s literature and supplemental

info-pen in Chapter 6.

\

.

1

-_.-..

Content of the manual is arranged as follows :

Chapter

1. Description/Operation

Chapter

2. Servicing

Chapter 3. Trouble Shooting

Chapter 4. Illustrated Parts List

Chapter 5. Optional Equipment

Chapter 6. Manufacturer’s Literature

Aug 25 185

lntroduc t ion

Page 1

OM 2012

TABE OF c O~TEblTS

SUBJECT

--

CkiAPT&‘SECTi01\!

PA GE

.

ink o&c t ion

1

Table of Contents

1

Description/Operation

1

1-O

l-1

Descr i@ ion

1

1. General

1

2. Orientation

1

3. S pet ia 1 Features

1

A.

‘Roll-Out” Feature Ji’ractor-Mounted Unib)

6

9. Protective Monitor

6

,

6

C. Pull-out Trays

.

D. Voltage Regulator

E. Test Circuiky .

F. Electric Governor

6

4. Ident if icat ion

7

A. Genera6

7

9.

Generatcr Sets Available in 5359C Series

7

5. Optional Equipment

7

A. Trailer

a

9. Truck

8

C. Transfcrmer-Rectifier

8

6. Canopy

8

Contents

Page 1

Avg 25%5

OH 2012

TABLE OF COhTZfiTS (COiuT’D)

SUBJECT

CHAP-fEl:/‘SECTiC~

7. Engine, Generator and Controls Assembly

l-1

A. Basic Engine

fi.

Engine Manufacturer s Equipment

C. Hobart’ Engine Equipment

(1) Electric governor system

(a) Magnetic pickup

(b) Control unit

(c) Actuator

(2> Engine safety devices

(a) Overspeed governor

(b)

Temperature sensing safety switch

(c) Start circuit cut-out switch

(d)

Start circuit solenoid switch

(3) Air cleaner

(4) Exhaust system

(5) Rad iat or

D. Generator

E. Control Box Assembly

(1) Generator control tray

(a) Resistors

(b) Generator output monitors (meters)

.

PAGE

9 :

9

10

11

11 *

11

13

14

15

16

Contents

Page 2

Aug 25 &i

.

c

OM 2012

TABLE OF CO!~‘TEt’JTTS (CONT’D)

SlJBJECT

--

(c) M2ter and line switches

CHAPTER/SECTION

PA GE

l-l

’ 16

(d)

Rece ptac 13 c onnec t cr

18

(e) Tray

18

(f) Manual voltage control

18

(9)

EXC itation-deenerg ization re lay

18

(2) Protective relay fray

18

‘(a) S

ens ing modu Ies

18

(b) Memory and time-de!ay module

19

(c) indicating lights

19

(d) Plug-inter lock relay

.

21

(e) Test-bank switch

’ 21

(f) Res istor

(g) Fuse-interlock relay

21

.

(h) Connector

21

(k) Auxiliary underfrequency relay

;

22

F. Engine Control Panel

22

(1) Engine instruments

(4 A

mmeter

22

(b) Temperature gage

22

(c) Oil pressure gage and oil pressure switch

23

(d) Hourmeter

23

Aug 2545

Contents

Page 3

OM 2012

TABLE OF COiuTEN IS (CONT’D)

--

SUBJECT

CHAPTER/SECT ;Cti

PA GE

-

(2) Engine und generator contrck

l-l

23

(a) Fuse

23

@) Engine-generator control switch

23

(c) Contactcr control switch

24

(d) Instrurrcnt light and switch

24

(e) Engine starting circuit

24

(f) Indicating lights

24

(9) f%e 1 9ase

(h) Coid weather starting aid control

(k) Engine stop control

(3) Air c leaner indicator

(4) Test receptacle connector

(5) Charging circuit resistor

G. Voltage Kegulatar

(1) Controls

26

26 ’

27

(2) Protection

27

(3) C omponenfs

27

H. Power Module Panel Assembly

30

(1) Load contactor

30

(2) Current transformers

30

Contents

Page 4

.

Aug 25185

OM 2012

TABLE OF CONTENTS (CONTiNUED)

SUBJECT

CHAPTER/SECTION

PAGE

(a) Ammeter current transformen

l-l

30

(b) Line-drop current transformers

30

(c) Overload current transfoners

31

(3) Overload module

32

’ (4) Rectifier

32

(5) Terminal boards

32

8. Test Box

33

A. Description

9. Theory of Operation

9. 5359G

A. RFI Suppression Kit

9. , 24 Volt DC Power Supply Kit

Preparation for Use, Storage, or Shipping

33

34

l-2

.

1

1.

Preparation for Use

1

A. Genemi

1

9. Inspection/Check

1

C. Installing Output Cables

(1) Three-phase, AC output cable ossembl y

installation

(2) Transformer-rectifier (DC) output cable

installation

4

2.

Prepamtion for Storage

5

A. Geneml

5

9. Tempomry Skmge

5

C. Long Time Storage (Over 30 Days)

5

Aug 25 185

Contents

Page 5

TABIE OF CONTENTS (CONT’D)

OM 2012

SUD.JECT

CHAPTEI:/SECT~O~~

PAGE

3,

Preparation for Shipnx?nt

l-2

Operaf ion

l-3

1.

Gcr,era I

2. Operatir~g’tile’Generatcr Set

A. Pre-start Inspection

9. N mna I Engine Starting Procedures

C. Cold Weather Engine Starting Procedures

D. Preparation for Power Delivery (Normal Automatic

Voltage Control)

E. Power De I ivery (Automatic V&age Control)

.

F. Prewation for Power Delivery (Manual Voltage

Control)

G . Power De livery (Manual Voltage Control)

H. Discontinue Power Delivery

K. Stopping the Engine

3. Test Box Operation

4. Transfamer-Rectifier Operation (Optional Equipmznt)

A. Direct Current Power Delivery

9. Simultaneous 28.5-V and 35-V DC Power Delivery

C. Simultaneous 28.5-V DC and 115-V AC Power Delivery

D. Simultaneous 35-V DC, CT 112-V DC and 115-VAC

-

I

Power De livery

5.

24 Volt DC Power Supply

Contents

Page 6

7

8

9

1.0

11

12

13

Aug 25,/85

OM 2012

SWJECT

CHAPTEiR,/SECTIOju

-----

Scrv ice

2-o -

h{a in te nance

Z-1

1.

Genera I

2. Operation of Roll-OUF Feature (Tractcr-Momled Units)

A. Roll Generotor Set Out for Service

B.

Roll Generator Set In to Normal Position

3.

Inspect ion

4. lubrication

A. General

B. AC Generator

C. Generator Controls

D. Engine

(1) Lubrication schedule

(2) Oil specification

(3) Oil viscosity

(4) Change engine oil

(5) Change oil filter element

E .

E ng ine Access cc ies

(1) A lternatrx

(2) Siarter

(3) Overspeed governor arld drive

,

3

6

7

8

9

Aug 25%

Contents

Page 7

OM 2012

TAB!E OF CONTENTS (CONT’D)

SUBJECT

CI-IAPKI!/SECTlO~

PAGE

5. Air Cleaner Service

A.

Car-jr idge Re mova I

B.

Cartr idye

Ins ta I lat ion

6. Engine Fuel

A. Qua1 ity

B.

Fue I Filters

(1) Daily service

I

(2) Change strainer and filter elements

(3) Ctwngespin-on strainer and filter

7. Engine Cooling System

A. General

3.

Radiatoh Cap

(1) General

(2) Removal

(3)

lnsta I lat ion

C. Warm Weather Operation

D . Cold Weather Operation

(1) General

(2) Coolant solution check

(3) Coolant solution preparation

(4) Antifreeze solution installation

b

C onknts

Page 8

-.__

6 ;

2-l

Aug 25185

9

10

11

13

13,

13

14

15

c

OM 2012

TABLE OF CCb!-fETuTS (CC&T’D)

SUBJECT

CHAPTER ,‘%CTICIV

PAGE

_- -_I

E.

Drain the Cooling System

2--l l

15

F. Coaling System Cleaning

16

G. Radiator Core Cleaning

H.’ Cdoling System Filling

16

8. Generator Maintenance

18

A. C isaning

18

B.

Adiustment

18

9. Drive Belts

19

.

19

A.

Preparation for Belt Check and Adjustment

.

B.

Check Be It Tens ion

.

C. Be it Adjustmzznt

(1) Alternatcc belt

(2) Fanbeiis’

20

10. Service Helps

22

A. Wiring

22

B.

Control Box Trays

(1) Tray removal

22

(2) Tray insta I iat ion

C . Generator Exciter

22

23

(1) Preparation for exciter removal

23

(2) Exe iter remova I

23

Aug 25,/8!5

Contenb

Page 9

TABLE OF COIU-ENTS (CL?1Uf’D)

SWJECT

---

CHAPEL/‘SECTlCt~ FAGE

(3) Exe i:er insfai lation

2-l

D. Engine Control Panel

(1) Ti!t out engine control pawi

(2) t&instuII engine control panel

InspectiwjCheck

1.

.Genera I

2-2

2. Engine

A’. Fuel

B.

Lcl br icat ion

C. Coolant

.

De V-Belts

E . Exhaust-System

3. Electric System (12-V DC)

A. Lights

B. Fuses

C. Wiring Connections

4. E iectrical System (115-V AC)

A. Monita ing Instrurtznts

B.

Ind icat ing Lighb

C. Protective Modules

D. Wiring and Connections

Contents

Page 10

OM 2012

24

1

1’

1

3

4

Au g 25 I85

OM 2012

.

TABLE OFCO!uTEtiTS (CONT’D)

SUGXCI

--

CHAPTiXf,/SECTiON

--

.

Adjustment/Tesi

2-3

1.

General

2.

Preparation for Test for Tractor-Mounted Units

<

A. Generator Set Removed from Tractor

B.

Generator Set in Tow Tractor

3. Generator Set Test

A. Pre-opzrationa I Test Procedures

B.

Operat iona I Test Procedures

4. Generator Set Adjustment

A. Generator Adjustmnt

8.

Generator Controls Adjustment

(1) Adjust manual voltage control variable resistor

(2) Adjust 400-l-i

2 voltage regulator

(a) Adjust generator output voltage

(b) Adjst cable length and cable size

compensation rheostats

(c) Adjust “damp” and “rate “ adjusting

potentiometers

C. Basic Engine Adjustment

(1) Exhaust valve adjustment

(2) Exhaust valve bridge adjustment

(3) Fuel injector timing adjustment

PAGE

--

1

2

9

15

16

17

19

,

Contents

Page 11

OM 2012

TABLE- OF C9NTf3luTS (CO;%-‘D)

SUBJECT

CHkl’i-EK/SECT ION

PAGE

(4) Idle speed, speed limiting, and overspzed

adjustment

2-3

D. Engine Accessories Adjustment

E . E IectriF Governor System Adiustment

(1) Actuator linkage adjustment

(2) Magnetic pickup adjustment

23

(3) Governor control unit adjustment

24

(4) Electric governor test values

(a)

S igna I to actuatcf

(b) Magnetic pickup signal

F. Engin& Shut-Down Devices Adjrrstment

.

(1) Starter cut-out switch adjustment

(2) Shut-down linkage adjustment

28

5. Generator and Exciter Test

6. Diode Test

I

7. 24 Volt DC Power Supply Test

Trouble Shooting

Trouble Shooting Procedures

1. General

2. Trouble Shooting Chart

A. Description

I

B. Use of Trouble Shooting Chart

Conh?llts

Page 12

3-o

3-l

.

20

21

26

28

29

31

1

Aug 25 &i

OM 2012

.

TABLE OF CONTE~YTS (CONT’n)

----__

SUBJECT

--

CHAP-lXR/SECffON

PA GE

3. Equipmnt for Trouble’Shooting 3-l -

2

4. Safety

2

5. Parts Replacemznt

2

6. T&t Va fues

7. Check Connections and Leads

3

8. Electric Governor Trouble Shooting

3

9. Engine Trouble Shooting Procedures

4

A. General

B.

Locating a N&firing Cylinder

4

C . Checking Compress ion

5

D.

Interpretation of Compress ion Pressure Chart

,

6

E.

Causes of Low Cylinder Pressure

6

F. Fuel Flow Test

10. Illustrations

II lustrated Parts List

introduction

1.

General

2. Purpose

3. Arrangement

4. Explanation of Parts List

6

4-o

1

4-1 1

1

Aug 25’85

C cntenis

Page 13

OM 2012

SUGJFCI- CHAPTER/‘SECT (09. PAGE

.

A .

C OntC il iS

4-1

1

B.

PUitS Li;t Form 1

(1) “Figure-Item No. ” Column

2

(2) “Hobart Part No. ” Column

(3) “N omenc lature ” Column

(4)

‘E FF” @ Ffective) Column

(5) “Units Per Assembly” Column

Manufacturer’s Codes

4-2

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

I

.

Park List .

4-3

1. Explanation of Parts List Arrangement

,

2. Symbols and Abbreviations

Optional Equipment

5-o

Manufacturer’s Literature

LIST OF ILLUSTRATIONS

6-O

2

3

1

1’

1

CHAPTER/ FIGURE

PAGE

SECTION NUMBER

TITLE

NO.

l-l 1

Generator Set

2

l-l 2

Specifications and Capabilities (Two Sheets)

3-4

l-l 3

Generatcr Set Components

5

l-l

4

Generator Set Identification Chart

7

Contents

Aug 25 0%

Page 14

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