Hobart 6824A-5 Operation and Maintenance Manual

OM-499

Revised 053194

OPERATION AND MAINTENANCE

MANUAL

with

ILLUSTRATED PARTS LIST

for

ENGINE DRIVEN GENERATOR SETS

60-kVA, 400-Hz, 115/200-V AC, 3-Phase Units

with

PERKINS DIESEL ENGINE

Type 6.3544

HOBART BROTHERS COMPANY

Airport Systems Group

Troy, Ohio 45373 U.S.A.

SPECIFICATION MOUNTING VOLTAGE

REGULATOR

6824-1, 6824A-1 Trailer or Truck 430391C

6824-2, 6824A-2 Tractor 430391C

6824-3, 6824A-3 Stationary: With Fuel Tank & Batteries 430391C

6824-4, 6824A-4 Trailer or Truck, Dual Output 430391C

6824A-5 Trailer or Truck 489812

6824A-6 Tractor 489812

6824A-7 Stationary: With Fuel Tank & Batteries 489812

6824A-8 Trailer or Truck, Dual Output 489812

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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 cables to break load and

prevent tools from causing short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage

this and attache equipment.

Important: Protect all operating personnel. Read, understand, and follow all instructions

in the Operating/Instruction Manual before installing, operating, or servicing

the equipment. Keep the 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. The operator must strictly 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.

1. Shock Prevention

Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live 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 of the body is decreased when wet, permitting dangerous currents to flow

through it. When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubber

mat or dry wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry,

and never work alone

a. 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 National Electrical Code, ANSI/NFPA 70, or 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, as

this makes the equipment frame electrically HOT, which can cause a fatal shock.

Always 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. Ensure 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

correctly mating receptacles.

b. Output Cables and Terminals

Inspect cables frequently 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

equipment is energized.

WARNING

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May 31/94 Revised Safety Warnings

Page 1

c. 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 the supervisor and

discontinue use of the equipment until its safety has been assured. Repairs should be made by

qualified personnel only.

(1)

Before inspecting or servicing electrically-powered equipment, take the following precautions:

(2)

Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the

equipment.

(3)

Lock switch OPEN

(or remove line fuses)

so that power cannot be turned on accidentally.

(4)

Disconnect power to equipment if it is out of service.

(5)

If troubleshooting must be done with the unit energized, have another person present who is

trained in turning off the equipment and providing or calling for first aid.

2. 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.

a. Electrical Short Circuits and Overloads

Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by

causing nearby combustibles to ignite. For electrically-powered equipment, provide primary input

protection to remove short circuited or heavily overloaded equipment from the line.

b. Batteries

Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured

battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or

use open flame near the battery.

c. Engine Fuel

Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank

is not grounded prior to or during fuel transfer. Shut unit DOWN before removing fuel tank cap. DO

NOT completely fill tank, because heat from the equipment may cause fuel expansion overflow.

Remove all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, open

equipment doors and blow fumes away with compressed air.

3. 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 of air

conditioners.

4. Bodily Injury Prevention

Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipment

for inspection and routine maintenance. When equipment is in operation, use extreme care in doing

necessary trouble-shooting and adjustment. Do not remove guards while equipment is operating.

5. 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.

OM-499

Safety Warnings May 31/94 Revised

Page 2

Call physician immediately. Seek additional assistance. 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 ELECTRICAL 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.

6. Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be

easily read.

EMERGENCY

FIRST AID

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May 31/94 Revised Safety Warnings

Page 3

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Safety Warnings May 31/94 Revised

Page 4

Introduction

This manual contains operation and maintenance information for a series of 400-Hertz generator sets

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

This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to

provide information and instructions to experienced operators, electricians, and mechanics who have

never seen or operated this equipment. It is the intent of this 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 contained 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 and 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 a

chapter, section, and paragraph, or figure number. For 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 information in Chapter 6.

Content of the manual is arranged as follows:

Chapter 1. Description/Operation

Chapter 2. Servicing

Chapter 3. Troubleshooting

Chapter 4. Illustrated Parts List

Chapter 5. Optional Equipment

Chapter 6. Manufacturer’s Literature

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May 31/94 Revised Introduction

Page 1

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OM-499

Introduction May 31/94 Revised

Page 2

Table of Contents

SUBJECT CHAPTER/SECTION PAGE

Chapter 1. Description / Operation 1-1 1

Section 1. Description 1-1 1

1. General 1-1 1

2. Orientation 1-1 1

3. Special Features 1-1 1

a. “Roll-Out” Feature (Tow Tractor

-Mounted Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . 1i

b. Protective Monitor . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 2

c. Pull-out Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 2

d. Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 2

e. Test Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 2

f. Electric Governor . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 2

4. Identification 1-1 2

5. Canopy 1-1 5

6. Optional Equipment 1-1 5

a. Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 5

b. Transformer-Rectifier . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 5

c. Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 5

d. Second Output and Control Box . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 5

e. Quick Start Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 5

7. Engine, Generator, and Controls

Assembly 1-1 6

a. Basic Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 6

b. Engine Manufacturer’s Equipment . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 6

c. Hobart Engine Equipment . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 6

d. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 9

e. Control Box Assembly . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . . 9

f. Engine Control Panel . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . 15

g. Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . 17

h. Power Module Panel Assembly . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . 19

8. Test Box 1-1 23

a. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . 23

b. Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . . . . 23

9. Dual Output Units (Specifications 6824-4,

6824A-4 and 6824A-8) 1-1 24

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May 31/94 Revised Table of Contents

Page 1

SUBJECT CHAPTER/SECTION PAGE

Section 2. Preparation For Use,

Storage, Or Shipping 1-2 1

1. Preparation for Use 1-2 1

a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . 1

b. Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . 1

c. Installing Output Cables . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . 2

2. Preparation for Storage 1-2 3

. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . 3

. Temporary Storage . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . 3

. Long Time Storage (Over 30 Days) . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . 4

3. Preparation for Shipment (Tractor-

Mounted Units Only) 1-2 4

Section 3. Operation 1-3 1

1. General 1-3 1

2. Operating the Generator Set 1-3 1

a. Pre-start Inspection . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 1

b. Normal Engine Starting Procedures . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 1

c. Cold Weather Engine Starting Procedures . . . . 1-3 . . . . . . . . . . . . . . . . . 4

d. Preparation for Power Delivery (Normal

Automatic Voltage Control) . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 4

e. Power Delivery (Automatic Voltage Control). . . 1-3 . . . . . . . . . . . . . . . . . 5

f. Preparation for Power Delivery (Manual

Voltage Control) . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 6

g. Power Delivery (Manual Voltage Control) . . . . . 1-3 . . . . . . . . . . . . . . . . . 6

h. Discontinue Power Delivery . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 6

i. Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 6

3. Test Box Operation 1-3 6

4. Transformer-Rectifier Operation 1-3 8

a. Direct Current Power Delivery . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 8

b. Simultaneous 28.5-V DC and 115-V AC

Power Delivery . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 8

5. No. 2 Output Operation (Specifications

6824-4, 6824A-4 and 6824A-8) 1-3 9

a. Power Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 9

b. Discontinue Power Delivery . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 9

6. Trailer Operation 1-3 9

a. Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 9

b. Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . . . . 10

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Page 2

SUBJECT CHAPTER/SECTION PAGE

Chapter 2. Service 2-1 1

Section 1. Maintenance 2-1 1

1. General 2-1 1

2. Operation of Roll-Out Feature (For

Tractor-Mounted Units Only) 2-1 1

a. Roll Generator-Set Out for Service . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 1

b. Roll Generator-Set In to Normal Position . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 1

3. Inspection 2-1 1

4. Lubrication 2-1 3

a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 3

b. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 3

c. Generator Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-1. . . . . . . . . . . . . . . . . . 3

d. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 3

e. Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 4

5. Air Cleaner Service 2-1 4

a. Cartridge Removal. . . . . . . . . . . . . . . . . . . . . . . . . 2-1. . . . . . . . . . . . . . . . . . 4

b. Cartridge Installation . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 4

6. Engine Fuel 2-1 5

. Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 5

. Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 5

7. Engine Cooling System 2-1 6

a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 6

b. Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 6

c. Warm Weather Operation . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 6

d. Cold Weather Operation . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 6

e. Draining the Cooling System . . . . . . . . . . . . . . . . 2-1. . . . . . . . . . . . . . . . . . 8

f. Cleaning the Cooling System . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 8

g. Cleaning the Radiator Core . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 8

h. Filling the Cooling System . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 8

8. Generator Maintenance 2-1 9

a. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 9

b. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. . . . . . . . . . . . . . . . . . 9

9. Drive Belts 2-1 9

a. Checking Belt Tension . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 9

b. Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 9

10. Trailer, Truck and Battery Maintenance 2-1 9

11. Service Helps 2-1 9

a. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . . 9

b. Control Box Trays . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . 10

c. Generator Exciter . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . 10

d. Engine Control Panel . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . . . . 11

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Page 3

SUBJECT CHAPTER/SECTION PAGE

Section 2. Inspection / Check 2-2 1

1. General 2-2 1

2. Engine 2-2 1

a. Fuel (See Fig. 1 for time schedules). . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 1

b. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 1

c. C. Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 1

d. V-Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 1

e. Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 1

3. Electrical System (12-V DC) 2-2 3

a. Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 3

b. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 3

c. Wiring and Connections . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 3

4. Electrical System (115-V AC) 2-2 3

a. Monitoring Instruments . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 3

b. Indicating Lights . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 3

c. Protective Modules . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 3

d. Wiring and Connections . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . . . . . 4

5. Trailer and Truck 2-2 4

Section 3. Adjustment / Test 2-3 1

1. General 2-3 1

2. Test Panels 2-3 1

a. Generator Set Removed from Tractor . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 1

b. Generator Set in Tow Tractor . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 1

3. Generator Set Test 2-3 2

a. Pre-operational Test Procedures . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 2

b. Operational Test Procedures . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 3

4. Generator Set Adjustment 2-3 9

a. Generator Adjustment . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 9

b. Generator Control Adjustments . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 9

c. Basic Engine Adjustments . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 12

d. Engine Accessories Adjustment . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 12

e. Electric Governor System Adjustment . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 12

5. Generator and Exciter Test 2-3 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . . . . . 17

6. Diode Test 2-3 17

7. Additional Test for Dual Output Unit 2-3 18

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Page 4

SUBJECT CHAPTER/SECTION PAGE

Chapter 3. Troubleshooting Procedures 1 1

Section 1. Troubleshooting 3-1 1

1. General 3-1 1

a. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . . . . . . . . . . . . . 1

b. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . . . . . . . . . . . . . 1

c. Use of the Troubleshooting Chart . . . . . . . . . . . . 3-1 . . . . . . . . . . . . . . . . . . 1

2. Equipment for Troubleshooting 3-1 2

3. Safety 3-1 2

3. Parts Replacement 3-1 2

4. Test Values 3-1 2

5. Check Connections and Leads 3-1 3

6. Electric Governor Trouble Shooting 3-1 3

7. Engine Trouble Shooting Procedures 3-1 3

a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . . . . . . . . . . . . . 3

8. Illustrations 3-1 3

Chapter 4. Illustrated Parts List 4-1 1

Section 1. Introduction 4-1 1

1. General 4-1 1

2. Purpose 4-1 1

3. Arrangement 4-1 1

4. Explanation of Parts List 4-1 1

a. Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . . . . . . . . . . . . . 1

b. Parts List Form . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . . . . . . . . . . . . . 1

Section 2. Manufacturer’s Codes 4-2 1

1. Explanation of Manufacturer’s 4-2

(Vendor) Code List 4-2 1

Section 3. Parts List 4-3 1

1. Explanation of Parts List Arrangement 4-3 1

2. Symbols and Abbreviations 4-3 1

Section 4. Numerical Index 4-4 1

1. Explanation of Numerical Index 4-4 1

Chapter 5. Optional Equipment 5-0 1

Chapter 6. Manufacturer’s Literature 6-0 1

Unusual Service Conditions

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Chapter 1. Description / Operation

Section 1. Description

1. General

The basic generator sets

(see Fig. 1)

covered by the manual are identified by Series No. 6824and

Series No. 6824A. The various configurations of the set are identified by adding a dash number

(-1, -2,

etc.)

suffix to the Series number.

The generator sets in the 6824A series feature armatures with Hoover Bearings, Browning Coupler,

and different magnetic pole construction for the generator revolving field. This new armature can be

easily identified by the two copper rings on each end of the field coils and copper wedges between the

magnetic poles.

The basic generator set which includes the engine, generator and all controls is identical for all models.

Differences between models are those required by their respective mounting, such as trailer mounting,

tow tractor mounting, etc. Identification of different models within the Series will be explained later in the

Description.

Information and instructions throughout the manual apply to all models. Information which applies only

to a certain model will be qualified and identified as such.

The purpose of the generator set is to generate and deliver regulated, 400-Hz electrical power to a

parked

(or towed)

aircraft for operation of the aircraft’s electrical equipment when the on-board

generators are not running. The engine, generator, and controls are designed into a compact unit which

is easily removable from a tow tractor. See Figure 2 for specifications and capabilities.

2. Orientation

For purpose of orientation and to familiarize operators and maintenance personnel with the location of

components, the radiator is considered to be at the FRONT of the unit. The generator and controls are

at the REAR. RIGHT and LEFT are determined by standing at the rear end facing the machine. Thus,

the generator control box, output receptacle connector, and engine control panel are mounted on the

LEFT side at the REAR of the unit.

3. Special Features

The generator set has many special features which are later described more fully under the assemblies

in which they appear. Some of the main features are mentioned here and described briefly as follows.

a. “Roll-Out” Feature (Tow Tractor-Mounted Unit)

For a generator set mounted on a tow tractor the generator set is supplied with two-channel-like

tracks which are floor mounted in the generator compartment of the tow tractor. Tracks are

equipped with cam-follower, needle-bearing rollers which support the generator set and allow it to

roll in-and-out easily for servicing and maintenance.

Additional rollers are mounted on each side of the generator set main frame, near the rear, to add

stability and to prevent the unit from tipping downward at the front when it is rolled outward for

service.

(See Figure 21, Section 4-3.)

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The set is secured in mounted position by two retaining brackets attached at the front of the unit

(See 2-1, Fig. 2).

The removal of two screws from the brackets allows the set to be rolled out

approximately 38 inches, where a stop-bar on the main frame contacts a stop-block in the left track

to prevent further outward travel.

b. Protective Monitor

A single, solid-state device

(4, Fig. 8)

receives signals from all of the fault sensing units in the

generator output circuit and functions to cause the load to be disconnected from the generator if an

abnormal condition of voltage, frequency, or load develops.

c. Pull-out Trays

The control box is equipped with pull-out, drawer-type trays

(Fig. 6)

which provide easy access to

controls and equipment mounted in them. Each tray may be removed as an assembly by

disconnecting a single quick-disconnect connector and tripping two safety latches.

d. Voltage Regulator

A solid-state, adjustable voltage regulator

(Fig. 10)

provides automatic voltage regulation at the

aircraft (or distribution panel when applicable). The regulator is also adjustable for a variety of

output cable sizes and lengths.

e. Test Circuitry

A receptacle connector

(19, Fig. 9)

with wiring to various test points throughout the electrical

circuitry is provided for the attachment of a test box manufactured by Hobart Brothers. This test

circuitry allows electricians to perform as many as twenty-four tests and checks from one location,

conveniently and easily.

f. Electric Governor

The engine is equipped with an all electric type governor kit

(5 and 12, Fig. 3)

and other special

equipment more fully described under the engine description.

4. Identification

Generator sets are identified by their Specification number, which consists of a Series number plus a

dash number

(i.e. -1, -2, etc.)

suffix. The suffix number indicates the mounting design of the generator

set. For example, Specification number 6824A-2 identifies a machine designed for mounting on a tow

tractor.

The following identification chart identifies in greater detail the machines covered by this manual.

SPECIFICATION No. CHARACTERISTICS

6824-1, 6824A-1, and

6824A-5

Designed for trailer or truck mounting. 12-V DC electrical power and

fuel to be supplied from facilities on trailer or truck.

6824-2, 6824A-2, and

6824A-6

Designed for mounting on a tow tractor. 12-V DC electrical power

and fuel to be supplied by tow tractor. Furnished with roll-out tracks

for mounting on tow tractor.

6824-3, 6824A-3, and

6824A-7

Designed for stationary mounting. Equipped with two 12-V batteries

and fuel tank.

6824-4, 6824A-4, and

6824A-8

Dual output unit for trailer or truck mounting. 12-V DC electrical

power and fuel to be supplied from facilities on trailer or truck.

Generator Set Identification Chart

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1. Canopy 6. Mounting frame

2. Lifting eye 7. Engine fan exhaust deflectors

3. Windows 8. Engine exhaust pipe

4. Output receptacle cover 9. Radiator cap access cover

5. Output cable horn

Generator Set

Figure 1

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PHYSICAL

Length

(stationary units)

82 inches

(2082.8 mm)

Width 36 inches

(914.4mm)

Height

(overall)

43 inches

(1092.2mm)

Weight

(approximately)

3300 pounds

(1496.8 kg)

GENERATOR CAPABILITIES

Output power rating 60 KVA

Output voltage 115/200 VAC

Rated load capacity 173 A

Frequency/cycles per second 400 Hz

Output Kilowatts 48 KW

Power factor 0.8 PF

Duty cycle 100%

Operating speed 2000 RPM

Overload capacity

(125% of rated load)

216 A

Output cable size 2/0

GENERATOR PROTECTIVE SYSTEM

Overvoltage relay Trips 130 V to 134 V; resets 125 V

Undervoltage relay Trips 93 V to 102 V; resets 110 V

Overfrequency relay Trips 415 Hz to 425 Hz; resets 410 Hz

Underfrequency relay Trips 375 Hz to 385 Hz; resets 385 Hz

Undervoltage time delay 4 to 12 seconds, depending upon adjustment

Overload relay Trips at 125% rated load in less than 5 minutes

ENGINE

Manufacturer Perkins Engines, Inc.

Model T6-3544

Type In-line, 6-cylinder, 4-cycle diesel

Displacement 354 cu. in.

(5.8 liters)

Compression ratio 16:1

Firing order 1 - 5 - 3- 6 - 2 - 4

Number of main bearings 7

Horsepower at 2000 RPM 107

Governed speed 2000 RPM + / - 4.5%

Idle speed 850 + / - 25 RPM

Electrical system 12 volt

Oil Capacity

(W/Filter)

15 Quarts

(14 liters)

Oil Capacity

(W/O Filter)

14 Quarts

(13.6 liters)

Coolant capacity

(approx.)

20 quarts

(19 liters)

Fuel Diesel oil conformint to ASTM Specification

D.975-66T, No. 1-D and 2-D MIL-L-2104B

Specifications and Capabilities

Figure 2

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5. Canopy

A sheet metal enclosure, identified as a canopy

(1, Fig. 1),

provides protection for the engine, generator

and electrical controls. The canopy is designed to reduce the operational noise level in the immediate

area of the machine. Doors and panels are covered on the inside with Fiberglass acoustic material to

reduce reflected and conducted noise, and to absorb noise. Noise producing vibration in most

frequently used doors on the left side is reduced by the use of two-point slam locks. Less frequently

used doors on the right side are equipped with screw-operated latch fasteners which are tightened after

latching to reduce vibration. Insulating strips around all doors also reduce noise. Metal strips are

mounted horizontally across the front grille to deflect engine fan exhaust air and noise upward.

Two large openings in the canopy top provide an entrance for cooling air and an access to internal

components. A hood-type cover is mounted about two inches above each opening. The cover is

flanged downward and extends beyond the edges of the upwardly flanged opening to prevent entrance

of blowing rain while still allowing a good flow of air. Air enters the forward opening into the engine

compartment and is discharged through the radiator by the engine fan. Air enters the rear opening into

the generator compartment. It is then circulated over generator controls and drawn into the rear exciter

and generator housings where it passes over all windings before being discharged by the generator fan.

All generator sets in this Series except the tractor-mounted unit are equipped with a canopy having

doors on both sides. Tractor-mounted units have two large removable panels on the right side mainly

because the right side of the machine is not accessible when mounted on a tow tractor, and secondly

because the thick doors would not allow mounting in the limited space available on the tractor. Panel

mounted instruments may be observed through two Plexiglass windows in the left rear door which

covers the control box and engine control panel. The lower window is slanted outward at the bottom to

provide access to engine controls when the door is closed. A centrally-located lifting eye attached to a

lifting yoke extends through the canopy top to provide an attaching point for chains, cables, or hook

used to lift and move the generator set.

6. Optional Equipment

Several items of optional equipment are available for units covered in this manual . Each piece of

optional equipment is covered by its own Instruction and Parts Manual and will not be covered in this

basic manual. When applicable, information for optional equipment will be located in Chapter 5. Options

are listed as follows:

a. Trailer

A four-wheel trailer with batteries and fuel tank is available.

b. Transformer-Rectifier

A transformer-rectifier

(T-R)

is available for use with the generator set. This T-R receives

115/200-V, 400-Hz, AC power from the generator and converts it to a 28.5 V DC output.

c. Truck

Trucks with special bodies for generator set mounting are available. Compartments in the body are

provided for batteries, cable-storage, etc. Trucks available are Ford, Chevrolet, and GMC.

d. Second Output and Control Box

An auxiliary output and control box is available to provide a second independent 115-V AC output

circuit. This option is for -1, -2 and -3 generator set specification numbers if a second output is

desired for a machine purchased before dual output machines (-4 specification numbers) were

available, or if a second output is desired for a tractor-mount or stationary unit.

e. Quick Start Kit

(See Section 1-3, Para. 2C)

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7. Engine, Generator, and Controls Assembly

This assembly is the basic generator set without canopy. It includes all components required to

generate and regulate 400 Hz, 115/200 V, threephase power, and is operable when provided with fuel

and 12 V DC power. The engine-generator assembly is mounted on a welded steel frame. A

superstructure, attached to the main frame, provides mounting facilities for the canopy, control box, and

electrical equipment and controls.

a. Basic Engine

This generator set is equipped with a 6-cylinder, in-line, turbo-charged Perkins Diesel engine. See

Figure 2 for general specifications, and see Engine Operator’s Handbook in Chapter 6 for more

detailed information.

b. Engine Manufacturer’s Equipment

As received from the engine manufacturer, the engine includes the following equipment which is

described in the Perkins Shop Manual

(Chapter 6)

.

(1)

Electronic stop control.

(2)

Fuel filter.

(3)

Reverse-flow, engine cooling fan to blow air outward through the radiator.

c. Hobart Engine Equipment

The engine is modified at Hobart Brothers by the addition of the following equipment:

(1)

Electric governor system

An electric governor kit is installed on the engine to replace a conventional, mechanical type.

The electric governor was selected for control of engine speed

(and generator output frequency)

because it provides faster engine response to changes in load conditions. This fast response

results in very close frequency control. Refer to the Barber-Colman instruction book in Chapter

6 for a detailed description. A brief description is given below:

a. Magnetic pickup

The magnetic pickup is a device for detecting the speed of the engine. It is mounted in the

flywheel housing directly over the ring gear. It produces an AC signal to the control unit when

the ferrous flywheel teeth pass through the magnetic field at the end of the pickup.

b. Control unit

The control unit

(5, Fig. 3)

is a box containing a compact assembly of solid state

components. It receives an AC signal from the magnetic pickup and senses speed changes

in the engine. It provides a voltage signal to the actuator which causes the actuator to move

the fuel control lever as required to maintain a predetermined engine speed. Its power is

received from the 12-V DC battery system.

c. Actuator

The actuator

(12, Fig. 3)

supplies the force needed to move and position the fuel lever as

required to maintain a constant engine speed. The actuator is operated by a DC signal from

the control unit.

(2)

Engine electrical system

Items in the 12-volt engine electrical system that are provided by Hobart Brothers are:

a. A heavy-duty motor starter

b. Alternator with voltage regulator

c. Starting switch

d. Wiring harness

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Hobart 6824A-5 Operation and Maintenance Manual

Hobart 6824A-5 Operation and Maintenance Manual

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