Hobart 60PL20 Operation and Maintenance Manual

OM-2053

032089

Revised 050693

Revised 050994

OPERATION AND MAINTENANCE MANUAL

with

ILLUSTRATED PARTS LIST

for

ENGINE-DRIVEN GENERATOR SET

SPECIFICATION NUMBER 7009 , 7009A, & 7009B

For Truck or Trailer Mounting

MODEL No. 60PL20

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

with

PERKINS DIESEL ENGINE

TYPE 6.3544

Hobart Brothers Company

Airport Systems Group

Ground Power Equipment

Troy, Ohio 45373

U.S.A.

This page intentionally left blank.

SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT

WARNING

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 attached

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 be-

low apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and some

practices to both.

B. 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

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 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 volt-

age, 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 build-

ing 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.

2. 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.

3. Service and Maintenance

This equipment must be maintained in good electrical and mechanical condition to avoid hazards stem-

ming 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.

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

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

equipment.

b. Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally.

OM-2053

December 31/91 Revised Page 1

c. Disconnect power to equipment if it is out of service.

d. 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.

C . FIRE AND EXPLOSION PREVENTION

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust pip-

ing, 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 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.

2. 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.

3. 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 com-

pletely 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.

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 of air condition-

ers.

E. 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.

F. MEDICAL AND FIRST AID TREATMENT

First aid facilities and a qualified first aid person should be available for each shift for immediate treat-

ment of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital im-

mediately if any abnormal signs are observed.

EMERGENCY FIRST AID

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 ELECTRI-

CAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration, prefer-

ably mouth-to-mouth. If no detectable pulse, begin external heart massage. CALL EMERGENCY

RESCUE SQUAD IMMEDIATELY.

G. EQUIPMENT PRECAUTIONARY LABELS

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

easily read.

OM-2053

Page 2 December 31/91 Revised

INTRODUCTION

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

by Hobart Brothers Company, Power Systems Group, 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 be-

fore starting the unit. Learn to use the manual and to locate information contained in it. Its style and ar-

rangement 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 infor-

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

tion, 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 sec-

tion as the reference, Example,

(See Para. B).

In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chap-

ter 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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WARNING

INTRODUCTION

Chapter 1. Description/Operation

Section 1. Description 1-1 1

1. General 1-1 1

2. Orientation 1-1 1

3. Special Features 1-1 1

A. Protective Monitor 1-1 1

B. Voltage Regulator 1-1 1

C. Electric Governor 1-1 1

4. Canopy 1-1 4

5. Optional Equipment 1-1 4

6. Engine, Generator, and Controls Assembly 1-1 4

A. Basic Engine 1-1 4

B. Engine Manufacturer’s Equipment 1-1 4

C.Hobart Engine Equipment 1-1 6

(1) Electric governor system 1-1 6

(a) Magnetic pickup 1-1 6

(b) Control unit 1-1 6

(c) Actuator 1-1 6

(2) Engine electrical system 1-1 6

(3) Engine protective devices 1-1 6

(a) High coolant temperature switch 1-1 6

(b) Oil pressure switch 1-1 6

(4) Air cleaner 1-1 7

(5) Exhaust system 1-1 7

(6) Radiator 1-1 7

D. Generator 1-1 8

E. Control Box Assembly 1-1 9

(1) Front Panel 1-1 9

(a) Generator output monitors (meters) 1-1 9

(b) Meter and line switches 1-1 9

(c) Instrument light 1-1 9

(d) Indicating lights 1-1 9

(2) Control box internal components 1-1 9

(a) Sensing modules 1-1 10

(b) Memory and time delay module 1-1 11

(c) Excitation-deenergization relay 1-1 11

(d) Plug-interlock relay 1-1 11

(e) Test-bank switch 1-1 11

(f) Resistor 1-1 11

(g) Fuse-interlock relay 1-1 12

(h) Auxiliary underfrequency relay 1-1 12

(j ) Terminal boards 1-1 12

Table of Contents

SUBJECT CHAPTER/SECTION PAGE

OM-2053

December 31/91 Revised Table of Contents

Page 1

(k) Solid-state voltage regulator 1-1 12

(l) Overload module 1-1 12

(m) Rectifier 1-1 12

F. Engine Control Panel 1-1 12

(1) Engine instruments 1-1 12

(a) Ammeter 1-1 12

(b) Temperature gage 1-1 12

(c) Oil pressure gage and oil

pressure switch 1-1 14

(d) Hourmeter 1-1 14

(e) Fuel gage and blocking diodes 1-1 14

(2) Engine and generator controls 1-1 14

(a) Engine-generator control switch 1-1 14

(b) Contactor control switch 1-1 14

(c) Instrument light and switch 1-1 14

(d) Engine starting circuit 1-1 15

(e) Indicating lights 1-1 15

(f) Fuse 1-1 15

G. Load Contactor Circuit Components 1-1 15

(1) Load contactor 1-1 15

(2) Current transformers 1-1 15

(a) Ammeter current transformers 1-1 15

(b) Line-drop current transformers 1-1 15

(c) Overload current transformers 1-1 15

(3) Overload module 1-1 17

(4) Rectifier 1-1 17

Section 2. Preparation For Use,

Storage, Or Shipping 1-2 1

1. Preparation for Use 1-2 1

A. Inspection/Check 1-2 1

B. Installing Three-phase AC Output Cables 1-2 1

2. Preparation for Storage 1-2 2

A. General 1-2 2

B. Temporary Storage 1-2 2

C. Long Time Storage 1-2 2

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.Preparation for Power Delivery 1-3 3

D. Power Delivery 1-3 4

E. Discontinue Power Delivery 1-3 4

F. Stopping the Engine 1-3 4

Table of Contents

SUBJECT CHAPTER/SECTION PAGE

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Table of Contents December 31/91 Revised

Page 2

3. Trailer Operation 1-3 5

A. Towing 1-3 5

B. Parking 1-3 5

Chapter 2. Service

Section 1. Maintenance 2-1 1

1. General 2-1 1

2. Inspection 2-1 1

3. Lubrication 2-1 1

A. General 2-1 1

B. Generator 2-1 1

C. Generator Controls 2-1 1

D. Engine 2-1 1

(1) Lubrication schedule 2-1 2

(2) Oil specification 2-1 2

(3) Oil viscosity 2-1 2

(4) Changing engine oil 2-1 2

(5) Changing engine oil filter 2-1 2

E. Starter 2-1 2

F. Trailer 2-1 2

(1) Front axle assembly 2-1 2

(2) Wheel bearings 2-1 3

4. Air Cleaner Service 2-1 3

A. Inspecting the Air Cleaner 2-1 3

B. Cleaning Instructions 2-1 4

C. Disposal 2-1 4

5. Engine Fuel 2-1 4

A. Quality 2-1 4

B. Fuel Filter 2-1 4

6. Engine Cooling System 2-1 4

A. General 2-1 4

B. Radiator Cap 2-1 5

(1) General 2-1 5

(2) Removal 2-1 5

(3) Installation 2-1 5

C. Warm Weather Operation 2-1 5

D. Cold Weather Operation 2-1 5

(1) General 2-1 5

(2) Checking coolant solution 2-1 5

(3) Preparing the coolant solution 2-1 5

(4) Installing the antifreeze solution 2-1 6

E. Draining the Cooling System 2-1 6

F. Cleaning the Cooling System 2-1 6

G. Cleaning the Radiator Core 2-1 7

H. Filling the Cooling System 2-1 7

Table of Contents

SUBJECT CHAPTER/SECTION PAGE

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December 31/91 Revised Table of Contents

Page 3

7. Generator Maintenance 2-1 7

A. Cleaning 2-1 7

B. Adjustment 2-1 7

8. Drive Belts 2-1 8

A. Checking Belt Tension 2-1 8

B. Belt Adjustment 2-1 8

9. Battery Maintenance 2-1 8

A. General 2-1 8

B. Battery Location and Accessibility 2-1 8

C. Battery Care 2-1 8

D. Liquid Level 2-1 9

E. Cleaning the Battery 2-1 9

F.Testing the Battery 2-1 9

(1) Test with Battery-Starter Tester 2-1 9

(2) Test with Hydrometer 2-1 9

10. Service Helps 2-1 10

A. Wiring 2-1 10

B. Generator Exciter 2-1 10

(1) Preparation for exciter removal. 2-1 10

(2) Exciter removal 2-1 10

(3) Exciter installation 2-1 10

Section 2. Inspection/Check 2-2 1

1. General 2-21 1

2. Engine 2-2 1

A. Fuel 2-2 1

B. Lubrication 2-2 1

C. Coolant 2-2 1

D. V-Belt 2-2 1

E. Exhaust System 2-2 1

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

A. Lights 2-2 2

B. Fuses 2-2 2

C. Wiring and Connections 2-2 3

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

A. Monitoring Instruments 2-2 4

B. Indicating Lights 2-2 4

C. Protective Modules 2-2 4

D. Wiring and Connections 2-2 4

5. Trailer 2-2 4

Table of Contents

SUBJECT CHAPTER/SECTION PAGE

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Table of Contents December 31/91 Revised

Page 4

Section 3. Adjustment/Test 2-3 1

1. General 2-3 1

2. Generator Set Test 2-3 1

A. Pre-operational Test Procedures 2-3 1

B. Operational Test Procedures 2-3 1

3. Generator Set Adjustment 2-3 7

A. Generator Adjustment 2-3 7

B. Voltage Regulator Adjustments 2-3 7

C.Basic Engine Adjustments 2-3 7

D. Engine Accessories Adjustment 2-3 8

(1) Generator and fan belt adjustment 2-3 8

E. Electric Governor System Adjustment

(Woodward Governor Kit) 2-3 8

(1) General 2-3 8

(2) Actuator linkage adjustment 2-3 9

(3) Magnetic pickup adjustment 2-3 10

(4) Governor Control Unit Adjustment 2-3 11

F. Electric Governor System Adjustment

(Barber-Colman Governor Kit) 2-3 13

(1) General 2-3 13

(2) Actuator Linkage Adjustment 2-3 13

(3) Magnetic Pick-up Inspection / Adjustment 2-3 15

(4) Governor Controller Adjustment 2-3 16

(5) Re-checking Actuator Linkage 2-3 16

(6) Checking the Actuator 2-3 16

(7) Troubleshooting 2-3 18

4. Generator and Exciter Test 2-3 19

5. Diode Test 2-3 19

Chapter 3.Troubleshooting

Section 1. Trouble Shooting

Procedures 3-1 1

1. General 3-1 1

2. Troubleshooting Chart 3-1 1

A. Description 3-1 1

B. Use of the Trouble Shooting Chart 3-1 1

3. Equipment for Troubleshooting 3-1 2

4. Safety - WARNING: 3-1 2

5. Parts Replacement 3-1 2

6. Test Values 3-1 2

7. Checking Connections and Leads 3-1 3

8. Electric Governor Trouble Shooting 3-1 3

9. Engine Trouble Shooting Procedures 3-1 3

10.Illustrations 3-1 3

Table of Contents

SUBJECT CHAPTER/SECTION PAGE

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December 31/91 Revised Table of Contents

Page 5

Chapter 4. Illustrated Parts List

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 2

(1) FIGURE-ITEM NO. Column 4-1 2

(2) HOBART PART NUMBER Column 4-1 2

(3) NOMENCLATURE Column 4-1 2

(4) REC. SPARES Column 4-1 2

(5) “EFF” (Effective) Column 4-1 2

(6) UNITS PER ASSEMBLY Column 4-1 2

Section 2. Manufacturer’s Codes 4-2 1

1. Explanation of Manufacturer’s

(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

Chapter 6. Manufacturers Literature

Table of Contents

SUBJECT CHAPTER/SECTION PAGE

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Table of Contents December 31/91 Revised

Page 6

CHAPTER 1. DESCRIPTION/OPERATION

SECTION 1. DESCRIPTION

1. General

This manual covers two trailer-mounted 60-kVA generator sets manufactured by Hobart Brothers Com-

pany and identified respectively as Specification No. 7009-1, Specification No. 7009A-1, and Specifi-

cation No. 7009B-1

All three generator sets feature an armature with Hoover Bearings, Browning Coupler, and different mag-

netic pole construction for the generator revolving field. This new armature can be easily identified by two

copper rings on each end of the field coils and copper wedges between magnetic poles.

The difference between Specification No. 7009-1and Specification No. 7009A-1 is that Specification No.

7009A-1 features new-style doors on the canopy assembly. Specification 7009B-1 is physically and electri-

cally identical toSpecification 7009A-1, except that a Barber-Colman engine speed governor is used in-

stead of the Woodward governor used on Specification No. 7009-1and Specification No. 7009A-1.

The purpose of these generator sets

(Fig. 1)

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 gener-

ators are not running. 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.

3. Special Features

These generator sets have many special features which are later described more fully under the assem-

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

A. Protective Monitor

A single, solid-state device

(7, Fig. 7)

receives signals from all of the fault sensing units in the gener-

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

mal condition of voltage, frequency, or load develops.

B. Voltage Regulator

A solid-state, adjustable voltage regulator

(Items 13 and 17, Fig. 7)

provides automatic voltage regula-

tion at the aircraft

(or distribution panel when applicable).

The regulator is also adjustable for a variety

of output cable sizes and lengths.

C. Electric Governor

The engine is equipped with an all electric type governor kit

(13 and 16, Fig. 3)

and other special

equipment more fully described under the engine description.

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December 31/91 Revised 1-1

Page 1

1. Engine fan exhaust deflectors 6. Generator control panel window

2. Radiator cap access hole 7. Engine control panel window

3. Canopy 8. Mounting frame

4. Doors (attached to canopy) 9. Door latches

5. Engine exhaust pipe and cover

Generator Set

Figure 1

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1-1 December 31/91 Revised

Page 2

PHYSICAL

BASIC GENERATOR SET

Length overall 84 inches (2134 mm)

Width 33 inches (838 mm)

Height 43 inches (1092 mm)

Weight (Approximate) 3655 pounds (1658 kg)

TRAILER-MOUNTED GENERATOR SET

Length overall 90 inches (2286 mm)

Width 66 inches (1676 mm)

Height 57 inches (1448 mm)

Weight (Approximate) 4120 pounds (1868.5 kg)

GENERATOR

Output power rating 60 KVA

Output voltage 115/200 V

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 at 400 Hz 2000 RPM

Overload capacity (125% of rated load capacity) 216 A

GENERATOR PROTECTIVE SYSTEM

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

Undervoltage relay trips 102 V or below; 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

Overload relay trips 112 KVA in less than 5 minutes

Undervoltage time delay relay 4 to 12 seconds

ENGINE

Manufacturer Perkins Diesel

Model 6.3544

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

Horsepower at 2000 RPM 107

Governed speed 2000 RPM +/- 4.5%

Idle speed 850 +/- 25 RPM

Electrical system 12 volt

Oil capacity (with filter) 15 quarts (14 liters)

Oil capacity (without filter) 14quarts (13.6 liters)

Coolant capacity (approx.) 20 quarts (19 liters)

Fuel Diesel oil conforming to ASTM Specification

D.975-66T, Nos. 1-D and 2-D

Lube oil MIL-L-2104C or MIL-L-2104D

Specifications and Capabilities

Figure 2

OM-2053

December 31/91 Revised 1-1

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4. Canopy

A sheet metal enclosure, identified as a canopy

(2, Fig. 1)

, provides protection for the engine, generator

and electrical controls. This generator set is equipped with a canopy having doors on both sides. This

canopy is largely of one-piece construction, with the four access doors of the unit attached to the canopy

top by welded-on piano hinges. Hex-head bolts attach the front and back panels to the canopy top assem-

bly and the frame. Air enters the bottom of the unit into the engine compartment and is discharged

through the radiator by the engine fan. Metal strips are mounted horizontally across the front grille to de-

flect engine fan exhaust air and noise downward. Air entering the generator compartment is 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.

Panel mounted instruments may be observed through two Plexiglas 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.

Doors on the unit are equipped with flexible rubber draw latches

(9, Fig. 1)

which prevent excessive door

vibration when the unit is running.

5. Optional Equipment

Two items of optional equipment are presently available for the 7009 & 7009A units: a cold-weather start-

ing aid kit identified as Hobart Part No. 488913 , and a four-wheel trailer with fuel tank, identified as Ho-

bart Part No. 280718 (7009) or Hobart Part No. 281056 (7009A). Refer to TO-186 in Chapter 5 for

information on the four-wheel trailer.

6. 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 con-

trols.

A. Basic Engine

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

ure 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 de-

scribed in the Perkins Diesel shop Manual

(Chap. 6)

(1) Fuel filter.

(2) Reverse-flow, engine cooling fan to blow air OUTWARD through the radiator.

OM-2053

1-1 December 31/91 Revised

Page 4

1. Generator7. Quick-start kit 13. Governor control box

2. Batteries (2) 8. Air cleaner 14. Engine control panel

3. Control box assembly 9. Engine assembly assembly

4. Muffler 10. Cooling fan 15. Exhaust pipe assembly

5. Rain cap 11. Radiator assembly 16. Governor actuator

6. 90

o

elbow 12. Mounting frame 17. Load contactor

Generator Set Components

Figure 3

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December 31/91 Revised 1-1

Page 5

C.Hobart Engine Equipment

The engine is modifiee 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) be-

cause it provides faster engine response to changes in load conditions. This fast response re-

sults in very close frequency control. Refer to the Woodward Governor manual in Chapter 6 for a

detailed description. A brief description is given below:

The governor system consists of the following main components:

(a) Magnetic pickup, (b) Control unit, and, (c) Actuator

(a) Magnetic pickup

This pickup is a device for detecting engine speed. It is mounted in the flywheel housing di-

rectly over the ring gear. It produces an AC signal to the control unit when the ferrous fly-

wheel teeth pass through the magnetic field at the end of the pickup.

(b) Control unit

The control unit

(13, Fig. 3)

is a box containing a compact assembly of solid state compo-

nents. 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

(16, Fig. 3)

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

quired 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

(3) Engine protective devices

(a) High coolant temperature switch

A high coolant temperature switch is mounted in the front of the cylinder block to monitor the

coolant temperature. If the coolant temperature reaches 210 degrees F

(99 degrees C),

this

normally closed switch opens and de-energizes the fuel valve solenoid which shuts down the

engine.

(b) Oil pressure switch

A diaphragm-type switch monitors the pressure in the lubricating oil system. It is mounted in

the side of the cylinder block

(9, Fig. 3)

. If the pressure in the lube oil system falls to 10 psi

(69 kPa)

, this switch opens and de-energizes the fuel valve solenoid which shuts down the en-

gine.

OM-2053

1-1 December 31/91 Revised

Page 6

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Hobart 60PL20 Operation and Maintenance Manual

Hobart 60PL20 Operation and Maintenance Manual

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