Hobart 140G17K Operation And Maintenance

TM-528

Revised 032495

OPERATION AND MAINTENANCE

MANUAL

for

TRUCK/TRAILER-MOUNTED GENERATOR SET

140-KVA, 400-HZ, 115/200-V AC, 3-PHASE

with

DETROIT DIESEL ENGINE

TYPE 8V-71N

5566B

Model Numbers

140G17K (Truck Mounted Unit)

140G17P (Trailer Mounted Unit)

140G17P (With Special Accessories)

Manufactured by

L

.!

HOBART BROTHERSCOMPANY "

POWER SYSTEMS DIVISION

j”i

TROY, OHIO 45373

1

U.S.A.

SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT

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

ELECTRIC ARC FLASH can injure eyes burn skin cause equipment damage and

ignite combustible material. Do not use power cabies to

I

brekk load and prevent tools from causing short circuits.

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

equipment.

IMPORTANT: - Protect all oderating personnel.

Read, understand, and follow

ail instructions in the Operating/Instruction Manual before

installing, operating,

or servicing the equipment.

available for future use by all operators.

Keep the manual

A.

B.

GENERAL

Equipment that supplies electrical power can cause serioueinjury or death,

or damage to other equipment or property.

The operator must strictlv

observe all safety rules and take precautionary actions.

Safe practices

have been developed from past experience in the use of power source equipment.

While certain practices below apply only to electrically-powered equipment,

other practices apply to engine-driven equipment,

and some practices to both.

SHOCK PREVENTION

Bare conductors,

electrically-live

or terminals in the output circuit, or ungrounded,

equipment can fatally shock a person.

Have a certified

electrician verify that the equipment is adequately grounded and learn what

terminals and parts are electrically HOT.

Avoid hot spots on machine. Use'

proper safety clothing, procedures, and test equipment.

The electrical resistance

dangerous currents to

of the body is decreased when wet, permitting

flow through it.

equipment, do not work in damp areas.

When inspecting or servicing

Stand on a drv rubber mat or

dry wood,

use insulating gloves when dampness or sweat cannot be avoided.

Keep clothing dry, and never work alone.

1. Installation and Grounding of Electrically Powered Equipment

Equipment driven by electric motors (rather than by diesel or gasoline

engines) must be installed and maintained in accordance with the ?lational

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

A power

disconnect switch or circuit breaker must be located at the equinment.

Check the nameplate for volta e,

only 3-phase power is

F

frequency, and phase requirements.

If

availab e,

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

this makes the eauipment frame electrically HOT, which can cause a fa;aF

-iniT&.--

-m-e-

Always connect the grounding lead

if supplied in a power line cable,

to tne grounded switch box or building ground,

separate groundin

!T

lead.

If not provided, use a

Ensure that the current

of the grounding

(am erage)

ead will be adequate for the worst

P

capacity

ault current

situation.

details.

Refer to the National Electrical Code .ANSI/NFPA 70 for

Do not remove plug ground prongs. Use correctly mating

receptacles.

2.

Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the

connectors.

not overload

Re lace or repair cracked or worn cables immediately. Do

ca les. 1

energized.

Do not touch output terminal while equipment is

./

3.

Service and Maintenance

,

This equipment must be maintained in good elec&?ical and mechanical

condition to avoid hazards stemming from disrepair. Report,any

1

equipment defect or safet

use of the eluigm ent unti its safety has been assured.

1

should be ma e'

hazard to the supervisor and di.z;.z;fmre

y qualified personnel only.

>

Instruction 910082

Feb 25/86 Revised

Page 1

?I.

TC)XIC FUME PREVENTION

E.

c

- .

Before inspecting or servicing eledtricallp-powered equiment,

take the following precautions:

a. Shut OFF all power at the

disconnectin

before inspecting or servicing the

f

switch or line breaker

equ pment.

b.

Lock switch OPEN (or remove line fuses) so that power cannot be

turned ON accidentally.

c. Disconnect power to equipme.nt if it is out of service.

d. If troubleshooting must be 'done with the unit ener

another person present who is trained in turning o

9

zed, have

f the equipment

and'providing or calling far first aid.

FIRE AND EXPLOSION PREVENTION'

Fire and explosion are caused hy electrical short circuits, combustible

material nea,r engine exhaust &ping, misuse of batteries and' fuel, or

unsafe operating or fueling conaitlons.

1.

2.

3.

Electrical Short Circuits and Overloads

Overloaded or shorted equipment can become

hot enough to cause fires

either by self destruction or causing nearby combustibles to ignite.

For electrically-powered equipment, in particular,

"1

rotide primary

~input protection to remove short circuited or heavi y overloaded

equipment from the line.

Batteries

Batteries may explode and/or give off flammable hydro en

and arcing from a ruptured battery can cause fires

an

3 ad%%oni?e acid

failures.

When servicing, do not smoke, cause sparking, or use open

flame near the battery.

Engine Fuel

Use only approved fuel container or fueling system.

Fires and

explosions can occur if the fuel tank is not grounded prior to ;g duping

fuel transfer. Shut unit DOWN before removing fuel tank cap.

completely fill tank, because heat from the eouipment may cause fuel

expansion overflow.

Remove all spilled fuel IMMEDIATELY, including any .

that penetrates the unit. After clean-up,

fumes away with compressed air.

open equipment doors and blow

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 of air conditioners.

BODILY INJURY PREVENTION

Serious inju

Y

can result from contact with fans inside some equipment.

Shut DOWN sue

equipment for inspection and routine maintenance.

When

equipment is in oneration use extreme care in doing necessary troubleshooting

and adjustment.

Do not remove guards while equipment.is operating.

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 ph

sician and taken to a hospital

immediately if any abnormal signs are

o served. i:

EMERGENCY FIRST AID I

Call physician immediately.

Seek additional assistance and use First Aid

techniques recommended by American Red Cross until medical help arrives.

./

;EzREATHING IS DIFFICULT give oxy en,

FOR ELECTRICAL SHOCK, turn o

F

if available, and have victim lie

f power, Remove victim; if not

breaihing, begin artificial respiration, preferably mouth"to-mouth. If

I no detectable pulse,

Squad immediately,.

begin external heart massage. Calll.$mergency Rescue

G.1 EQUIPMENT PRECAUTIONARY LABELS

h:;E:::e 3 YeCau==ona

Order and

abels

ry Aabe's on the equi

that cannot be easily rea

F

ent monthly.

.

!,

Page 2

Instruction 910082

Revised Feb 25/86

TABLE OF CONTENTS

SUBJECT

I

Introduction

,

Description/Operation ,

/

Identification

1.

General

2. Model Number

3.

Optional Equipment

A.

Trucks

B.

Truck Body Kits

C.

Trailer

D.

Transformer-Rectifiers

E.

T-R Mounting Kits

F.

Test Box

G.

Revolving Light

Description

1.

General

2.

Orientation

3.

Special Features

A. Protective Monitor System

B.

Pullout Trays

C. Voltage Regulator

D.

Test Receptacle Connector

1

./

/‘Ii

Jan 22181

1

CHAPTER/SECTION

PAGE

1-o

1

l-l

1

2

314

l-2

1

Contents

Page 1

TABLE OF CONTENTS CONTINUED

SUBJECT

CHAPTER/SECTION

E . Test Box

,

l-2

F. Dual Output

I

).

4., Canopy

5. Engine, Generator and Controlls Assembly

A. General

3. Generator

C. Engine

D. Governor

E. Engine Safety Shutdown System

(1) General

(2) Air shutoff valve

(3) Engine fault sensing devices

(a) General

(b) Emergency-stop solenoid valve

F. Air Cleaner

G. Control Box

(1) Voltage regulator tray

(a) Gantrols

(b) Protection

(c) Components

(2) Protective relay tray

1

Contents

Page 2

) b’i

TM-528

PAGE

3

6

7

9

10

12

I;

Revised Jan 22/81

I

i

/

!

/

I

/

f

I

!

/

I

,

I

/

!&

1

TABLE OF CONTENTS CONTINUED

SUBJECT

CHAPTER/SE CT ION

‘, (a) S

ensing relays 1’

(b) Protective monitor module

I

,I

(c) indicating I ights

(d) Plug interlock relay

(e) Test-bank switch

(f) Resistor

(g) Fuse interlock relay

(h) Connector

(i) Diode,

capacitor and terminal board

(k) Overload relay

(I) Fuses

(3) Generator control tray

(a) Resistors

16

(b) Generator output meters 16

(c) Meter and I ine switches

16

18

(d) Receptacle connect0 r

(4 Tray

(f) Manual voltage control

H. Engine and Generator Control Panel

(1) Engine gages and meters

(a) 0 i I pressure gage and diaphragm switch

l-2

1

Li

I t

TM-528

PAGE

12

14

15

16

18

Jan 22/8 T Revised

Contents

Page 3

.I

!

Contents

Page 4

TABLE OF CONTENTS CONTINUED

SUBJECT

CHAPTE R/SE CT 10 N

I (b) Ammeter : ,

(c) Temperature gage

(d) Hourmeter

!_

(2) Panel lights

,

(3) Indicating I ights

(a) Engine ON indicating light

(b) locd contactor indicating I ights

(4) Switches

(a) Air valve (starting) switch

(b) Starter switch

(c) Speed control switch

(d) Light switch

(e) Load contactor control switches

(f) Push-to-build-up-voltage switch

(5) Excitationtdeenergization relay

(6) Fuse

(7) Test receptacle connector

(8) Speed control cable

(9) Cold weather starting aid

(10) Terminal boards

J. Special Engine and Generator Control Panel

(1

) General

1-2

t

l,‘i

TM-528

PAGE

18

20

21

22

23

Revised Jan 22/81

I

m

1

TABLE OF CONTENTS CONTINUED

SUBJECT

(2) Receptacle, connector and circuit breaker

I

<’

(3) Emergency-stop switch

,(4) Ho urme ter d iaphragm switch

(5) Locd contactor switches operating handle

(6) Low fuel warning and shutdown system

K. Power Module

(1) Capacitor

CHAPTER/SECTION

1-2

(2) Line-drop current transformer

(3) Ammeter current transformer

(4) Locd contactor

(5) Diode panel

(6) Resistors (line drop)

(7) Overload current transformer

(8) Overlood board

(9) Indicating light relc

(10) Terminal board

’ L. Output Terminal Panel

Preparation for Use

,l . Generator Set

A. General

B. Inspection/Check

ys and blocking diode

l-3

C. Output Cables Installation

Jan 22/81 Revised

TM-528

PAGE

23

25

26

28

1

3/4

Contents

Page 5

TM-528

SUBJECT

CHAPTER/SECTION

PAGE

TABLE OF CONTENTS CONTINUED

(l), Cable requirements

3

(2) Cable connection ’

Operation

1. General

2. Operating the Truck

A. General Operating Instructions

8. Starting the Truck Engine

C. Positioning the Truck

3. Operating the Trailer

A. General

B. Operating the Brakes

C. Drawbar

4. Operating the Generator Set

A. General

8. Connecting Output Cables

C. Preparation for Power Delivery

(1) Voltage regulator trcy

(2) Protective relay tray

1 (3) Generator control tray

(4) Engine and generator control panei

D. Normal Engine Starting

1

E. Cold Weather Engine Starting

Contents

Page 6

1-3

3/4

l-4

1

2

3

4

,

4

(#Ii

7 :

Revised Jan 22/81

I

m

I 1

TM-528

I

TABLE OF CONTENTS CONTINUED

SUBJECT

CH APTE R/SE CT IO N

PAGE

--

F., Power Delivery (Automatic Voltage Cantroi)

l-4

9

G. Power Delivery (Manual Voltage Gntrol)

H.. Stop Power Deliver&

10

J. Stop Engine

K. Emergency Stop (Special)

5. Operating Instructions for Optional T-Rs

A. Transformer-Rectifier Operation

(1) Direct current power delivery

(2) Simultaneous 28.5-V and 35-V DC power delivery

(3) Simultaneous 28.5-V DC and 115-V AC power delivery

(4) Simultaneous 35-V DC or 112-V DC

-

Servicing

2-o

Maintenance

2-l

1. General

10

11

12

2. Maintenance Schedule

1

A. General

1

B.

Maintenance Schedule Check Sheet

1

C. Time lntemais

1

D. Identification of Interval Periods

1:

3. Air Cleaner Cartridge Replacement

3

A. Removal

,

3

ii

B. Installation

4

Jan 22/8 1 Revised :

i.

Contents

Page 7

TM-528

TABLE OF CONTENTS CONTINUED

SUBJECT CHAPTER/SE CT ION

PAGE

4. Electrical System (24-‘V and

I

A. Lights

B. Fuses

C. Wiring and Gpnections

D . Battery Service

(1) General

12-W DC) , 2-l 5

(2) Battery location and accessibility

(3) Battery care

(4) Liquid level

(5) Cleaning the battery

5. Electrical System (115-V AC)

A. Monitoring Instruments

B. Indicating Lights

C. Protective Relays

D. Wiring and Connections

6. Lubrication

A. General

B. AC Generator

C. Generator Controls

D. Diesel Engine

(1) Lubrication schedule

t:

ontents

5

s 5

5

7

8

9

1

)“i

9 .

-

!,

Revised Jan 22/81

Page 8

SUBJECT

.

w

1

I

TM-528

TABLE OF CONTENTS CONTINUED

CHAPTER/SE CT IO N

PAGE

I

(2) Oil specification

2-l

9

I

(3) Oil viscosity

10

(4) Changing engine oil

10

(5) Changing oil filter elements

10

(6) Lubrication procedures

7. Generator Maintenance

10

13

A. Cleaning

B . Ad i ustment

8. Engine Mcintenance

A. General

3. Cleaning

Ad iustment/Test

1. General

2. Testing

13

2-2

13

1

A. Preoperational Test Procedures

1

B. Operational Test

4

3. Adjustment

7

A. Engine Governor

7

B. Generator

8

C. Generator Control Adiustments

8

(1) Adjust manual voltage co,ntrol variable $$istor

9

Jan 22/81 Revised

:

i>

Contents

Page 9

TABLE OF CONTENTS CONTINUED

SUBJECT

CHAPTER/SE CT 10 N

I (2) Adjust generator ove?load relay

balast resistor I

(3) Adjust 115-V AC voltage regulator

),

(a) Adiust generator output voltage

(b) Adiust cable length and size

compensation rheostats

(c) Adjust damp and rate potentiometers

D. Basic Engine Adiustrnents

E. Governor Adiustment

F. Covernor Speed Control Linkage Adiustment

(i) Adjust switch operating disc position

(2) Adjust solenoid linkage

(3) Ad just eng ine id le speed

(4) Adjust engine governed (high) speed

Troubleshooting

Troubleshooting Procedures

1. General

2. Troubleshooting Chart

A. Description

8. Use of the Troubleshooting Chart

3. Wiring Diagrams

II lustrated Parts List

c!

ontents

Page 10

2-2

3-o

3-l

4-o ,,ii

TM-528

PAGE

9

10

El0

11

12

14

16

1

j, Revised Jan 22/81

I 1

TM-528

TABLE OF CONTENTS CONTINUED

SUBJECT

Intro#uct ion

1. General

I

2. ,Purpose

3. Arrangement

CHAPTER/SECTION PAGE

1

4-l 1

4. Explanation of Parts List

A. Contents

B. Parts List Form

(1) Figure-Item No. Column

(2) Hobart Part Number Column

(3) Nomenclature Column

(4) Eff (Effective) Column

(5) Units per Assembly Column

Manufacturer’s Codes

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

Parts List

1. Explanation of Parts List Arrangement

2. Symbol s and Abbreviations

Numerical Index

1 1. Explanation of Numerical Index

Optional Equipent

Manufacturer’s Literature

Jan 22/81 Revised :

4-2

4-3

1

4-4

1

5-o

1

6-O

Li

1

l/2

i;

Contents

Page 11

I

j CHAPTER/

j SECTION

l-l

l-2

l-2 !

l-2

l-2,

l-2

l-3

l-4

2-l

2-2

2-2 1

2-2

3-l

3-l I

3-1

3-l

.I

3-l

1 4-3

!

Con tents

Page 12

FIGURE

NUMBER

I

,l

1

2

3

4

5

6

7

8

9

10

11

12

1

2

3

1

2

3

4

5

6

7

1

2

3

4

5

6

1

2

3

4

5

6

1

(’

1

‘&

I

LIST OF ILLUSTRATIONS

TM-528

TITLE

PAGE

NO.

Identification Plate ’

Generator Set

Generator Set Components

Specifications and Capabilities

Engine Safety Shutdown System

Air Cleane,r and Service Indicator

Voltage Regulator

Protective Relay Tray

Generator Control Tray

Engine Control Panel

Engine Control Panel (Special)

Power Module (Contactor) Panel

Output Terminal Panel

Engine Oil Gage Rod and Filler Cap

Operating Controls and Instruments (Sheet 1 of 2)

Operating Controls and Instruments (Sheet 2 of 2)

Cold Weather Starting Aid

Transformer-Rectifiers (Typiccl Installation)

Maintenance Schedule (Sheet 1 of 2)

Maintenance Schedule (Sheet 2 of 2)

Air Cleaner Cartridge Replacement

Lamp Identification Chart

Fuse Identification Chart

Engine Lubrication Points

Diesel Engine Lubricants

Lubrication end Maintenance Chart

Symbols and T ime Intervals

Operating Controls and Instruments (Sheet 1 of 2)

Operating Controls and Instruments (Sheet 2 of 2)

1

2

5

6

8

9

11

13

17

19

24

27

28

2

5

6

8

12

2

3

4

6

11

12

2

3

Normal Test Values at Test Receptacle Connector (7 PL) 8

Excitation Resistors 9

Voltage Regulator Adiustment

11

Voltage Regulator Damping Adiustments 13

Governor Speed Control Linkage Adiustment

15

Troubleshooting Chart (9 sheets) 3

Voltage Regulator

12

Protective Relay Tray 13

Generator Control Tray 14

Engine Control Panel

15

Power Module (Contactor) Panel

/;i

16

Generator Set

2

5

Revised Jan 22/81

./

!

CHAPTER/

FIGURE

SECTION

NUMBER

4-3

11

4-3 12

4-3

13

4-3

14

4-3 15

4-3 16

4-3 17

4-3 17A

4-3

18

4-3 19

4-3 20

1

!/r

I,

LIST OF ILLUSTRATIONS (CONTINUED)

2 ~

3

4

5

6

7

8

9

10

<’

TITLE

I

.

Canopy Assembly

Generator Set Without Canopy

Control Box Assembly

Voltage Regulator Tray Assembly

, Protective Relay Tray Assembly

Generator Control Tray Assembly

Control Box and Internal Components Group

Engine Control Panel Assembly

Engine Controi Panel Assembly

(Special)

‘Power Module Panel Assembly

Output Terminal Panel Assembly

Air Cleaner Group

Generator Group

Red iator and Coo I ing System

Engine Group

Governor Oil Filter Lines Group

Lines, Oil, Emergency Shut Down

Governor Linkage Group

Exhaust System

Frame Group

TM-528

PAGE

NO.

4

6

8

10

12

16

20

22

26

30

34

36

38

40

44

48

50

52

54

56

r

Jan 22/8 1 Revised :

Contents

Page 13/14

id

I

1

TM-528

i,NTRODUCTiON

This manual contains operation and, maintenance information for a 400-Hz Generator Set

which may be either truck or trail&r mounted,.

These units are manufactured by Hobart

Brothers Company,

Power Sjstems Division, Troy, Ohio 45373.

The purpose of the manual is!to provide operators and maintenance personnel with instructions

and information which will guide and ,assist them in the efficient operation and maintenance

of the ground power equipment.

Ail personnel responsible for the equipment should read

these instructions and familiarize’ themselves with the characteristi’cs, capabilities, and

limitations of the unit.

The manual is divided into six chapters. Each chapter is d ivided into as many sections as

required .

Pages and illustrations are not numbered consecutively through the manual. Each

section begins with Page one and the first illustration in each section is Figure 1.

Should this manual contain additional information required to cover optional equipment,

modifications, changes and updated designs, added after the original manual was released,

this information will be added at the end of a Section where it would normally be found.

Added or changed information is indicated by a solid black line in the left-hand margin

of the page, opposite the new or revised material.

Always refer to the Table of Contents, or to the last page (s) of a Section to determine

if special information hcs been added for your particular machine.

Refer to Chapter 1, Section 1 for an explanation of how to identify generator sets.

Chapter 5 lists ail options available for use with the basic generator set.

Chapter 6

lists ail pertinent,manufacturer’s literature which is furnished with this manual, including

schematic and connection diagrams.

!

Jan 22/81 Revised

:

I)

Introduction

Page l/2

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