Hobart 60F24 Operation and Maintenance Manual

TM-493

070176

Rev ised 100780

OPERATION AND MAINTENANCE MANUAL

with

ILLUSTRATE D PARTS LIST

for

ENGINE-DRIVEN GENERATOR SET

SER ES 5625A, MODE L 6OF24

60-KVA , 4OO-Hz,

115/200-V AC, 3 Phase

Specification Number 5625A-1, For truck or trailer mounting

Specification Number 5625A-2, For tractor mounting

Specification Number 5625A-3, For stationary mounting

with

FORD V-8 (361

cubic inch) GASOLINE ENGINE

Manufactured by

HOBART BROTHERS COMPANY

POWER SYSTEMS DIVISION

TROY, OH IO 45373

U.S.A.

“I

SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT

ELECTRIC SHOCK can kill. Do not touch live electri,cal 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

thraugh 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 equipment frame electrically HOT, which can cause a fatal

---

--- --

shock.

Be sure ta 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/

N FPA 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 r(,ot touch output terminal while equip-

ment is energized.

“I

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 don,e 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. Encine 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

1

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

Pm+ 2

Instruction 910082

Revised Nov 16182

INTKODUCT ION

This manual contains operation and maintenance information for a 400-Hertz, generator set

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

The ma&l is not intended to be ,a text book on e lectric ity or electronics . Its primary purpose

is to provide information and instructions to experienced operators, electriciarp, and mechanics

who have never seen or operated this generator set.

It is the intent of the manua I to guide

and assistoperators and maintenance people in the proper use and care of the equipment.

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

instruct ions 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 manua k.

The manual is divided into six chapters.

as required. Each

Each chapter is divided into as many sections

new section starts with page 1.

Each page is identified by chapter,

section and page number which are located in the lower, outside corner. When in fcrmation

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

section, and paragraph, cr figure number. Fcr example, “(See 2-3, Para. B)” refers to

information located in Chapter 2, Section 3, paragraph B.

If a Chapter and Section are

not indicated in a reference, the referenced material is located in the same section as the

reference, Example, (See Para. B).

In addition to operation and maintenance instructions,

the manual contains an illustrated

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

informat ion in Chapter 6.

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

I

July l/76

Introduction

Page 1

TABLE OF CONTENTS

SUBJECT

Descr ipt,ion/Operation

Description

,’

I j

CHAPTER/SECTION PAGE

1-o 1

1-l 1

1.

.GeneraI 1

2.

Orientation

3.

Special Features

A.

“Roil-Out” Feature

B.

Protective Monitor

C . Pull-out Trays

D. Voltage Regulator

E.

Test Circuitry

F. Electric Governor

4.

Identification

A. General

B.

Generator Sets Available in 56254 Series

5.

Optional Equipment

A. Trailer

B.

True k

C. Transformer-Rectifier

6. Canopy

7. Engine, Generator, and Controls Assembly

A. Basic Engine

B,

E ng ine Manufacturer 5 Equ ipment

i

July l/76

1

3

6

7

8

Contents

Page 1

TABLE OF CONTENTS (CONTINUED)

SUBJECT’ CHAPTER/SECTION

PAGE

, (1) Electrical system

a 1

(2) Fuel filter

(3) Oil filter

(4) Carburetor air intake heater

C. Hobart Installed Engine Equipment

(1) Electric governor system

(a) Magnetic pickup

(b) Control unit

(c) Actuator

(d) Throttle valve assembly

(2) Engine safety shut-down devices

(a) Coolant temperature switch

(b) Oil pressure switch

(c) Engine overspeed device

(3) Air c leaner

D. Generator

E.

Control Box Assembly

(1) Generator control tray

(a) Resistors

(b) Generata output monitors (meters)

(c) Meter and line switches

(d) Receptacle connector

Contents

Page 2

i

:

l-l 8

e

8

10

11

12

13

14

1

14

“I

16

July l/76

TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

L

(4 Tray (

l-l

16

a 1

(f) Manual voltage control

16

(g) Excitation-deenergization relay

(2) Protective relays tray

(a) Sensing modules

(b) Memory and time delay module

(c) Indicating lights

(d) Plug-interlock relay

(e) Test-bank switch

(f) Resistor

(g) Fuse-interlock relay

(h) C onnectcr

(k) Auxiliary underfrequency relay

F. Engine Control Panel

(1) Engine instruments

(a) Ammeter

(b) Temperature gage

(c) Oil pressure gage

(d) Hourmeter

(2) Fuse

16

17

19

!9

19

20

21

(3) Switches 21

1

(a) Ignition switch

“I

?l

‘.

C onte nis

Page 3

CEI

m

r

1

TABLE OF CONTENTS (CONTINUED)

SUBJECT

CHAPTER/SECT ION

1 (b) Starter switch ,:

l-l

a s

(c) Light switch

w

(d) Push-to-build

-up-voltage switch

(e) Contactcr control switch

(4) Indicating I ights

(a) Contactor indicating light

(b) Ignition indicating light

(5) Pane I light

(6) Choke control

(7) Throttle control

(8) Diode

(9) Test receptacle connector

(10) Charging circuit resistor

(11) A

ir cleaner indicator

G . Voltage Regulator

(1) Controls

(2) Protection

(3) C ompone nts

l-l.

Power Module Panel Assembly

(1) Load contactcr

(2) Current transfcrmers 1

)‘I

(a) Ammeter current transformers

PA GE

21

23

24

25

27

dohe nts

Page 4

t>

July l/76

TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECT ION PAGE

(b) Line-drop current transformers

l-l

27

L

9

(c) Overload c‘urrent transformers

28

(3) Overload module

29

(4) Rectifier

(5) Terminal boards

29

8. Test Box

30

A. Description

30

B.

Theory of Operation

31

Preparation for Use, Storage, or Shipping

l-2

1

1.

Preparation for Use

1

A. General

1

B.

Inspection/Check

1

C.

Install Output Cables

3

(1) Three-phase AC

output cable insta I lat ion

3

(2) Transformer-rectifier (DC) output cable installation

(opt iona I equ ipment)

4

2.

Preparation fcr Storage

5

A. General

B.

Temporary Storage

5

C.

Long Time Storage (Over 30 Days)

3.

Preparation for Shipping

6

4. Shipping the Tractor-Mounted Unit

1

7

“I

July l/76

.’

;* I’ _’ .

,,~..

C onte nts

Page 5

TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION

\

Operation L

l-3

9

I <

1.

Genera I

2.

Operating the Unit

A. Pre-start Inspection

B.

Engine Starting Procedures

C. Preparation for Power De livery (Normal Automatic

Voltage Control)

D. Power De livery (Automatic Voltage Control)

E.

Preparation for Power Delivery (Manual Voltage Control)

F.

Power Delivery (Manual Voltage Control)

G. Discontinue Power Delivery

H. Stop Engine

3.

Operation of Trailer-Mounted Unit (Optional Equipment)

A. General

B.

Towing and Positioning the Trailer

4. Test Box Operation (Optional Equipment)

5.

Transfcrmer-Rectifier Operation (Optional Equipment)

A. Direct Current Power Delivery

B.

Simultaneous 28.5-V and 35-V DC Power Delivery

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

D. S imu Itaneous 35-V DC cr 112-V DC and 115-V AC

Power De livery

-

1

“I

1 C onte nts

Page 6

_.- I

,, ,. .,../

PAGE

1

2

5

6

7

9

10

July l/76

TABLE OF CONTENTS (CONTINUED)

SUBJECT

CHAPTER/SECTION

Servicing.

2-o

1 3

Ma inte na nce , Inspect ion&he; k

2-l

1.

General

2.

Ma i nte nance Sc hedu le

A. General

B.

Maintenance Schedule Check Sheet

C . Time Intervals

3.

Inspection/Check

A.

10 Hours or Daily Checks and Operations

(1) Engine

(2) Electricalsystem (12-V DC)

(3) Electrical system (115-V AC)

B.

100 Hours Checks and Operations

(1) Engine

C.

200 Hours or Monthly Checks and Operations

(1) Engine

(2) Electrical system (12-V DC)

D. 300 Hours cr Bi-Monthly Checks and Operations

(1) Engine

(2) E lectrical system (12-V DC)

(3) Electrical system (115-V AC)

(4) Trailer (Optional Equipment)

“I

1

July l/76

PAGE

1

3

4

6

C onte nts

Page 7

m ”

Ei?)J

1

TABLE OF CONTENTS (CONTINUED)

SUBJECT’

CHAPTER/SECT ION

E.

900.Hours cr 6-Months Checks and Operations

2-l

1

,(

(1) Engine

/ s

(2)

E lectrical system (T 15-V AC)

(3) Trailer (Optional Equipment)

.

F. Seasonally

Maintenance Procedures

2-2

1.

General

2.

Operation of Roll-Out Feature (For tractor-mounted units only)

A. Roll Generator Set Out for Service

B.

Roll Generator Set In to Normal Position

3.

Lubrication

A. General

B.

Lubrication

C. Generator

D. Generator Controls

E.

E ng ine

(1) Lubrication schedule

(2) Oil specification

(3) Oil viscosity

(4) Change engine oil (100 hours)

(5) Change engine oil filter (100 hours)

F. E ng ine Access or ies

PAGE

6

7

1

3

6

7

Contents

July l/76

Page 8

t>

,.

,/’ .‘: _:

TABLE OFCONTENTS (CONTINUED)

SUBJECT

CHAPTER/SECTION PAGE

(1) Distrib,utor

2-2

1

7

3

(2) Thr ott le I inkage

7

G. Trailer

8

4. Servicing the Air C leaner

8

A. Cartridge Re mova I

8

B.

Cartridge Installation

8

5. Engine Fuel System

9

A. Fuel

9

B.

Fue I Filter

9

(1) General

9

(2) Replace filter element

9

6. V-Belt Service

9

A. General

9

B.

V-Belt Adjustment

9

7. Engine Cooling System

10

A. General

10

B.

Radiator Cap

11

(1) General

11

(2)

Re mow I

11

(3) Installation

11

C . Warm Weather Operation

11

1

D. Cold Weather Operation

“I

11

I

July l/76

C onte nis

Page 9

T,,.‘

TABLE’ OF CONTENTS (CONTINUED)

SUBJECT’

(I) General

t

/ *

(2) Checking coolant solution

CHAPTER/SECTION PAGE

2-2

11

12

(3) Preparing the solution

12

(4) Installing antifreeze solution

12

E.

Draining the Cooling System

12

F. Cleaning the Cooling System

13

G. Cleaning the Radiator Core

14

H. Filling the Cooling System

14

8. Battery Service

14

A. General

14

B.

Battery Location

C . Battery Care

D.

Liquid Leve I

15

E.

Battery Cleaning

16

F. Testing the Battery

16

9.

Ge neratcr Ma intenance

A. C leaning

10. Service He Ips

A. Wiring

17

18

B.

Control Box Trays

18

(1) Tray removal

(2) Tray installation

1

18

Ii,

18

C ante nts

July l/76

Page 10

7. _..

:’

,C.

SUBJECT CHAPTER/SECTION

TABLE OF CONTENTS (CONTINUED)

Engine Control Panel

2-2

I 1

(1) Tilt out engine control panel

(2) Reinstall engine control panel

Adjustmnt/Test

2-3

1.

Genera I

2.

Preparation for Test

3.

Testing the Generator Set

A. Pre -0perat iona I Test Procedures

B.

Operationa I Test Procedures

4. Generator Set Adjustment

A. Generator Adiustment

B.

Generator Control Adjustment

(1) Adjust manua I voltage control variable

resistor

(2) Adjust 115-V voltage regulator

(a) Adjust generator output voltage

(b) Adjust cable length and cable size

compensation rheostats

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

potentiometers

C. Engine Adjustment

(1) Spark plug adjustment

(2) Replace spark plugs

July l/76

PAGE

19

1

4

8

9

10

11

13

15

Contents

Page 11

TABLE. OF CONTENTS (CONTINUED)

SUBJECT

CHAPTER/SECT ION

(3) Adjust distr ibutcr contacts

2-3

1

3

I .

(4) Re place d istr ibut cr contacts

(5) Adjust ignition timing

D. E lectric Governor System Adjustment

(1) Governor linkage adjustment

(2) Magnetic pickup adjustment

(3) Control unit adjustment

(4) Electric governor test values

(a) S igna I t 0 actuat cr

(b) Magnetic pickup signal

E.

Adjust Overspeed Device

5. Generator and Exciter Test

6.

Diode Test

Trouble Shooting

3-o

Trouble Shooting Procedures

3-l

1.

General

2. Trouble Shooting Chart

A. Description

B.

Use of Trouble Shooting Chart

3. Equipment for Trouble Shooting

4. Safety

1

5.

Parts Replaceme nt

,‘I

PAGE

15

16

17

19

20

23

25

1

2

,2

2

Contents

Page 12

July l/76

TABLE OF CONTENTS (CONTINUED)

SUBJECT

CHAPTER/SECTION PAGE

6., ,Test Values

3-l

3

4

7. Check Connections and Leads

3

8., Electric Governor Trouble Shooting

Illustrated Parts List

3

4-o

1

Introduction

1.

Ge nera I

2.

Purpose

4-l

1

3. Arrange n-tent

4. Explanation of Parts List

A. Contents

B.

Parts List Form

1

(1) “Figure-Item” Column

2

(2) “Hobart Part Number” Column

2

(3) “Nomenclature ” Column

2

(4) ‘Eff” (Effective) Column

2

(5)

“Units Per Assembly” Column

2

Manufacturer’s

Codes

4-2 1

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

1

Parts List

4-3 1

1. Explanation of Parts List Arrangement

1

2. Symbok and Abbreviations

1

I

/

July l/i’6

Contents

i.

Page 13

TABLE OF CONTENTS (CONTINUED)

SUBJECT

CHAPTER/SECTION

PAGE

<*

4-4

Numerical, Index

/ s

1.

Explanation of Numerical Index

1

Optional Equipment

Manufacturer’s Literature

CHAPTER/ FIGURE

SECTION

NUMBER

l-l 1

l-l

2

l-l 3

l-l 4

l-l

5

l-l

6

l-l 7

l-l

8

l-l

9

l-l 10

l-l

11

l-l

12

l-2 1

l-2 2

l-2

3

l-3 1

Fuel Shut-Off Valve (All except tractor mounted)

1

1-3

2

Operating Controls and Instruments (Sheets 1 and 2)

3-4

l-3

3

Test Box Operating Controls

8

l-3 4

Test Receptacle Connector

8

l-3

5

Transformer-Rectifier (Optional) (Typical Installation)

9

2-l 1

2-l

2

2-l

3

2-2 1

2-2 2

Contents

Page 14

5-o

6-O

LIST OF ILLUSTRATIONS

TITLE

Generator Set

Specifications and Capabilities (Sheet 1 and 2)

Generator Set Identification Chart

Ge nerat or Set C ompone nts

Air Cleaner and Service Indicator

Control Box

Generator Control Tray

Protective Relay Tray

Engine Control Panel

Voltage Regulator

Power Module Pane I Assembly

Test Box Assembly (Optional)

Engine Oil Gage Rod and Filler Cap

AC Output Terminal Pane I (Used on all units

except tractor mounted)

T-R Output Cable Installation

Inspection/Check/Maintenance Schedule (2 Sheets)

Lamp ,ldentification Chart

Fuse Identification Chart

Rol I-Out Stop-Bar

1

Generator Set Retaining Components

“I

i,

1

PAGE

NO.

2

4-5

6

9

12

14

15

18

22

26

28

30

1

4

2-3

5

2

July l/76

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Hobart 60F24 Operation and Maintenance Manual

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