140G17P

Hobart 140G17P, 140G17K Operation And Maintenance

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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
1
1
2
2
2
2
2
2
2
314
l-2
1
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
3
3
6
6
7
9
9
10
10
10
10
12
I;
Revised Jan 22/81
I
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
18
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
12
14
14
14
15
15
15
15
15
15
16
18
18
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
20
20
20
20
20
21
21
21
21
21
21
22
22
22
22
22
22
23
23
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
23
23
23
25
25
25
25
25
26
26
26
26
26
28
28
28
1
1
1
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
3/4
l-4
1
1
1
1
1
2
2
2
2
2
2
2
3
3
3
3
4
4
,
4
(#Ii
7 :
Revised Jan 22/81
I
m
I 1
TM-528
I
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
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
10
11
11
11
11
12
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
5
5
s 5
5
5
5
7
7
8
8
8
8
9
9
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
13
13
2-2
13
13
1
1
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
10
El0
11
12
12
12
14
14
14
16
1
1
1
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
l/2
i;
Contents
Page 11
I
j CHAPTER/
j SECTION
l-l
l-2
l-2
l-2
l-2 !
l-2
l-2
l-2
l-2,
l-2
l-2
l-2
l-2
l-3
l-4
l-4
l-4
l-4
2-l
2-l
2-l
2-l
2-l
2-l
2-l
2-l
2-2
2-2
2-2
2-2 1
2-2
2-2
2-2
3-l
3-l I
3-1
3-l
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
1
1
2
3
1
1
2
3
4
5
6
7
1
1
2
3
4
5
6
1
2
3
4
5
6
1
(’
1
‘&
I
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
6
11
12
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
4-3
4-3
4-3
4-3
4-3
4-3
4-3
4-3
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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