Revised Revised Revised Revised Revised Revised Revised Revised OPERATION and MAINTENANCE MANUAL with ILLUSTRATED PARTS LIST

OM-2017 110185 Revised 092286 Revised 101086 Revised 102886 Revised 061287 Revised 081787 Revised 111887 Revised 040888 Revised 081588

OPERATION AND MAINTENANCE MANUAL

with

ILLUSTRATED PARTS LIST

for

28.5V-DC GENERATOR SETS

SERIES NO. 6878

Specification Mounting

6878-l Stationary

6878-2 On Electric Vehicle (Taylor-Dunn)

HOBART BROTHERS COMPANY POWER SYSTEMS DIVISION TROY, OHIO 45373

. _.

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 below 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, and other a plicable codes. A power disconnect switch or circuit breaker must iie located at the equipment. Check the nameplate for volta e, frequency, and phase requirements. If only 3-phase power is availabf 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, as this makes the equipment frame electrically HOT, which can cause a fataf' SnocK.--- m ----- Alwa s connect the grounding lead if supplied in a power line cable, to tK e grounded switch box or building ground. If not provided, use a separate groundin lead. Ensure that the current (amperage) capacity of the grounding !fead 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. Re lace or repair cracked or worn cables immediately. :Do not overload ca!I les. Do not touch output terminal while equipment is energized. / 3. Service and Maintenance ” - --T~--e$u~~e-n~~-~-.~-~n~a~~~~~-n--go--e-le~t-~i~a~-~~-me~h.an-i~al.j------I. condition to_ -avoid hazards stemming from disrepair. Report any _. . hazard to -.the".-.-.. supervisor .---. _- ._.and ._,.^_ discontinue-R~~6ifs- - ..__. _..-j iX$ZZif?Xy has been assured. .-,_" ,._. ,,- personnel only. .__._.^.^..- -.."...-__-._..-..__-.___._ --__-_ ..__ _. Instruction 910082 Page 1 Feb 25/86 Revised / ‘1 / _./ I . , j -+A, ,s” / \ / /J i 1’ \ I a-.1./- Bef%$einspectidg or servicing electrically-powered equ&ment ,&'h&-.~ r-. . --_-----__d- . . ! /'._. QWPT a+ the dl SC ch ar l&a&?jceaket.______-.i2:.-., ing or servicing-. b. Lock switch OPEN (or remove line fuses) so that power cannot be turned ON accidentally. Disconnect power to equipment if it is out of service. d. If troubleshooting must be done with the unit ener ized, have another person present who is trained in turning of f the equipment and providing or calling for first aid. k. FIRE AND EXPLOSION PREVENTION . Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust pi ing, misuse of batteries and fuel, or unsafe operating or fueling con!I* itions. 1.1 Electrical Short Circuits and Overloads I / Overloaded or shorted equipment can become hot enough to cause fires ' i either by self destruction or causing nearby combustibles to ignite. 1 For electrically-powered equipment, in particular, rovide primary / input protection to remove short circuited or heavi'i y overloaded equipment from the line. 2.1 Batteries

/ Batteries may explode and/or give off flammable hydro3 en adg;ion;;e acid j and arcing from a ruptured battery can cause fires an / 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 1 explosions can occur if the fuel tank is not grounded prior to ;E $;ing j fuel transfer. Shut unit DOWN before removing fuel tank cap. completely fill tank, because heat from the e uipment .may cause fuel j expansion overflow. Remove all spilled fuel 9MMEDIATELY, including any ; that penetrates the unit. After clean-up, open equipment doors and blow 1 fumes away with compressed air. PO TOjIICFUME 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. Nepr locate engine exhausts near intake ducts of air condltloners. E. BODILY INJURY PREVENTION Setiiousinjury can result from contact with fans inside some equipment. Shut DOWN such equipment for inspection and routine maintenance. When I equipment is in o eration use extreme care in doing necessary troubleshooting! and adjustment. ifio 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 fok 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.

1 EMERGENCY FIRST AID Cakl physician immediately. Seek additional assistance and use First Aid tephniques recommended by American Red Cross until medical help arrives. REATHING IS DIFFICULT give oxy en if available, and have victim lie FOR ELECTRICAL SHO&, turn of f iower. Remove victim; if not ihing, begin artificial respiration, preferably mouth-to-mouth. If etectable pulse, begin external heart massage. Call Emergency Rescue -Sqpad immediately. -.__ d

Page 2 Instruction 910082 Revised Feb 25/86 This manual contains operation and service information for 28.5-V DC Generator Sets identified as Jet Ex 4. These units are available as stationary, skid- mounted units, or they may be mounted on electric vehicles as self-propelled units. In addition, the stationary unit may be mounted on an optional trailer for mobility. Both versions are available with 14-V DC output capability.

Most information in the manual applies to the 28.5-V Jet Ex in general. Infor- mation which applies to options and special equipment is identified as such.

The primary purpose of the manual is to provide information and instructions to experienced operators, electricians, and mechanics who are not familiar with this equipment. The intent of the manual is to guide and assist operators ,and maintenance personnel in the proper use and care of the equipment.

Read the instructions before starting the unit. Learn to use the manual and to locate information contained in it.

The Table of Contents, which follows this Introduction, lists all Chapters, Sections, and the paragraph titles within each Section. The location of each listing is identified by Chapter, Section and page number. A complete list of illustrations, with their locations, follows the Table of Contents.

Each Chapter is divided into as many Sections as necessary. Sections are always referred to by a combination Chapter/Section number, for example: 2-3 refers to Chapter 2, Section 3.

The material within each Section is divided into main subjects with applicable paragraph headings and subheadings as required. For example, a portion of.the Description Section might logically follow this arrangement and paragraphing:

1. Control

A. Interior Panel

(1) Protective devices

(a) Overload relay

(2) Contactors

Page numbers do not run consecutively throughout the manual. Each page is identifed by the Chapter/Section number in which it appears, and by a page number within the Chapter/Section . Therefore, the first page in each Sektion is page 1. These identifying numbers appear in the lower, outside corner of each page. Each page also bears a date located in the corner opposite the page' number. This date is either that of original issue, or of the latest revision. Any revision to the original text is identified by a heavy black line in ihe t left-hand margin. Illustrations follow a numbering system similar to page num- 1 bering. The first Figure in each Section is Figure 1. / ! 1 All tables, charts and diagrams, as well as illustrations, are identified:by / Figure numbers to avoid confusion. i L .-. .- - .- ---_- ---_ -- . ..- --.--:- __i '1Nov l/85 Introduction; !_ _.- !.-_..______11--_---, --_._ -..---..- --,. "_--..- ._._- -.-.- ----..----.-. ~-. -.-- I ("_,_.._. _.__,. ___ _ I / --. .- / *> OM-2017 .~_--. -~ _.--...... _" _.___.___._..._._____. _._I_.______.._.__._ The general location of any particular information can be found quickly by running through the Table of Contents. For example: to locate any adjustment information, a quick look at the Table of Contents shows that "Adjustment/ Test",is located in Chapter 2, Section 3, (shown as 2-3).

Portions of the text are referred to by identifying the paragraph in which the referenced material may be found. When referenced material is located in the same Chapter/Section as the reference, only the paragraph identification is given, for example: (Ref. Para. 1, A) means that the material is to be found in paragraph 1, A, of the same Section.

When referenced material is located in another Chapter/Section, both the Chapter and Section numbers and the paragraph identification are given, for example: (Ref. l-2, Para. 1, A) means that the referenced material is located in Chapter/Section l-2, and paragraph 1, A within that Chapter/Section.

Components shown in illustrations, and the illustrations themselves, are referenced in a similar manner. When this type of reference is made, the item number of the part and the Figure number in which it appears are given, for example: (2, Fig.3) refer to item number 2 in illustration Figure 3 of the same Chapter/Section.

When a referenced figure appears in another Chapter/Section, the reference will include the Chapter/Section number, for example: (2-3, 1, Fig. 4) tells the user that the information is in Chapter/Section 2-3, and to refer to item 1 in Figure 4.

Once a Figure number reference has been established, the Figure number is not repeated and only the item numbers of the parts involved are referenced, for example: "Loosen screw (2, Fig.G), slide out connector (4), and remove brush (6)."

When an item number is referenced without a Figure number, it always applies to the last preceding Figure number mentioned in the text.

A collection of manufacturer's literature is supplied as part of the information package.

If you have any questions concerning your Hobart Power Systems Division equipment, you are invited to contact our Service Department by mail, telephone, or TWX.

Write: Hobart Brothers Company Power Systems Division Service Department Troy, Ohio 45373 U.S.A.

Call: Area code (513) 339-6000 Extension 4276

TWX: 810-456-2907

i ,.- _--..--.------..-_------__--.--I-- .-.. -__-.. Introduction Nov l/85: ' ‘.------. -.-. -.~----~. --- -- . .-..-.-..-.I- -...-. - ._...._ -.__ .---.. -...---.--.-.- __-

! P.age..2 _,.._ ._ _., _ OM-2017

TABLE OF CONTENTS

SUBJECT CHAPTER/SECTION PAGE

Description/Operation Description l-l 1 1. General 1 2. Orientation 1 3. Generator Soft-Start Feature 1' 4. Electric Vehicle 4 A. Standard Features 4 B. Vehicle Options 5 5. Generator Options 5 6. Canopy 5 7. Engine, Generator and Controls 5 A. General 5 B. Engine 6 C. Generator 9 D. Control Panel Assembly 9 E. Output Terminals 11 F. Contactor 13 G. Rectifier Assembly 13 H. Ammeter Shunt 13

Preparation for Use, Storage, or Shipping l-2 1 1. Preparation for Use 1 A. General 1 B. Inspection/Check of Generator 1 C. Inspection/Check of Electric Vehicle 2 D. Output Cable Installation 2 2. Preparation for Storage 3 A. General 3 B. Temporary Storage 3 C. Long Time Storage 4 3. Preparation for Shipping 5

Nov l/85 Contents Page 1 OM-2017

TABLE OF CONTENTS

SUBJECT CHAPTER/SECTION

Operation l-3 1 1. General 1 2. Operating the Electric Vehicle 1 3. Operating the Generator Set 1 A. Pre-Start Inspection 1 B. Pre-Start Instructions 1 C. Starting the Engine 3 D. Generator Operation 4 E. Deliver Power 4 F. Stop Operation 4 G. Adverse Weather Precautions 4 H. Operation in Hot and Humid Conditions 6 I. Operation in Extremely Dusty Conditions 6 J. Operation in Salt Water Areas 6 K. Miscellaneous 7

Servicing Maintenance Inspection/Check 2-l 1. General 2. Maintenance Schedule A. General B. Maintenance Schedule Check Sheet C. Time Intervals 3. Engine and Related Components 4. Electric Vehicle 5. Inspection and Cleaning

Maintenance Procedures 2-2 1. General 2. Lubrication A. General B. Engine Lubrication Charts C. Electric Vehicle Lubrication D. Generator ' E. Generator Controls

Contents Nov l/85 Page 2 OM-2017

TABLE OF CONTENTS

SUBJECT CHAPTER/SECTION PAGE

F. Engine 2-2 3 G. Engine Accessories 5 3. Servicing the Air Cleaner and Crankcase Ventilation System 5 A. General 5 B. Clean and Service Air Cleaner 6 C. Clean Crankcase Ventilation System 6 4. Servicing the Fuel Filter 6 5. Drive Belt Service 6 6. Engine Cooling System 7 A. General 7 B. Rust Inhibitor 7 C. Antifreeze 7 7. Battery Service 7 8. Generator Maintenance 7 A. General 7 B. Brush Service 8 C. Generator Revolving Field Brush Replacement 8 9. Electric Vehicle Maintenance 8

Adjustment/Test 2-3 1 1. General 1 2. Testing the Electric Vehicle 1 3. Testing the Generator Set 1 A. Pre-operational Test Procedures 1 B. Operational Tests 3 4. Governor Adjustment 4 A. General 4 B. Troubleshooting 6 5. Overspeed Relay Adjustment 7 A. General 7 6. Voltage Regulator Adjustment 7 A. 28.5 Volt Adjustment 7 B. Line Drop Compensation 7

Contents Nov l/85 Page 3 OM-2017

TABLE OF CONTENTS

SUBJECT CHAPTER/SECTION PAGE

Troubleshooting Troubleshooting Procedures 3-l 1 1. General 2. Troubleshooting Chart A. Description B. Use of the Troubleshooting Chart 3. Equipment for Troubleshooting 4. Safety 5. Diagrams 6. Illustrations 7. Connections and Wiring 8. Electric Vehicle Troubleshooting

Illustrated Parts List Introduction 4-l 1 1. General 1 2. Purpose 1 3. Arrangement 1 4. Explanation of Parts List 1 A. Contents 1 B. Parts List Form 1

Manufacturers' Codes 1. Explanation of Manufacturers (Vendor) Code List 4-2 1

Parts List 4-3 1 1. Explanation of Parts List Arrangement 1 2. Symbols and Abbreviations 1

Numerical Index 4-4 1 1. Explanation of Numerical Index 1

Optional Equipment 5-o 1

Manufacturers' Literature 6-O 1

Contents Nov l/85 Page 4 .’

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CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE

List of 2-l 1 Nov l/85 Effective 2-l 2 Nov l/85 Pages 1 thru 2 Aug 15188 2-l 3 Nov l/85 2-l 4 Nov l/85 Introduction 1 Nov l/85 Introduction 2 Nov l/85 2-2 1 Nov 1 85 2-2 2 Nov 1 85 Contents 1 Nov l/85 2-2 3 Nov 1 85 Contents 2 Nov l/85 2-2 4 Nov 1 85 Contents 3 Nov l/85 2-2 5 Nov 1 85 Contents 4 Nov l/85 2-2 6 Nov 1 85 Contents 5 Nov l/85 2-2 7 Nov 1 85 Contents 6 Nov l/85 2-2 8 Nov 1 85 Contents 7 Nov l/85 2-2 9 Nov 1 85 Contents 8 Nov l/85 2-2 10 Nov 1 85 Contents 9 Nov l/85 Contents 10 Nov l/85 2-3 1 Nov l/85 2-3 2 Nov l/85 l-l 1 Nov l/85 2-3 3 Nov l/85 l-l 2 Nov l/85 2-3 4 Nov l/85 l-l 3 Nov l/85 2-3 5 Nov l/85 l-l 4 Aug 15188 2-3 6 Nov l/85 l-l 5 Nov l/85 2-3 7 Nov l/85 l-l 6 Nov l/85 2-3 8 Nov l/85 l-l 7 Nov l/85 l-l 8 Nov l/85 3-l 1 Nov l/85 l-l 9 Nov l/85 3-l 2 Nov l/85 l-l 10 Nov l/85 3-l 3 Nov l/85 l-l 11 Nov l/85 3-l 4 Nov l/85 l-l 12 Nov l/85 3-l 5 Nov l/85 l-l 13 Nov l/85 3-l 6 Nov l/85 l-l 14 Nov l/85 3-1 7 Nov l/85 3-l 8 Nov l/85 l-2 1 Nov l/85 3-l 9 Nov l/85 1-2 2 Nov l/85 3-l 10 Nov l/85 l-2 3 Nov l/85 3-l 11 Nov l/85 1-2 4 Nov l/85 3-l 12 Nov l/85 l-2 5 Nov l/85 3-l 13 Nov l/85 l-2 6 Nov l/85 3-l 14 Nov l/85 3-l 15 Nov l/85 l-3 1 Nov l/85 3-l 16 Nov l/85 l-3 2 Nov l/85 3-l 17 Nov l/85 1-3 3 Nov l/85 3-1 18 Nov l/85 l-3 4 Nov l/85 3-l 19 Nov l/85 l-3 5 Nov l/85 3-l 20 Nov l/85 1-3 6 Nov l/85 3-l 21 Nov l/85 l-3 7 Nov l/85 3-l 22 ov l/85 1-3 8 Nov l/85

Aug 15/88 Revised l-1

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CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE

4-l 1 Nov l/85 4-3 39 Jun 12/87 4-l 2 Nov l/85 4-3 40 Jun 12187 4-l 3 Nov l/85 4-3 41 Jun 12187 4-l 4 Nov l/85 4-3 42 Nov l/85 4-3 43 Nov l/85 4-2 1 Nov l/85 4-3 44 Nov l/85 4-2 2 Nov l/85 4-3 45 Nov l/85 4-2 3 Nov l/85 4-3 46 Nov l/85 4-2 4 Nov l/85 4-4 1 Nov l/85 4-3 1 Nov l/85 4-4 2 Nov l/85 4-3 2 Nov l/85 4-4 3 Nov l/85 4-3 3 Nov l/85 4-4 4 Nov l/85 4-3 4 Nov l/85 4-4 5 Jun 12/87 4-3 5 Nov l/85 4-4 6 Nov l/85 4-3 6 Aug 17/87 4-4 7 Nov l/85 4-3 7 Jun 12/87 4-4 8 Nov l/85 4-3 8 Nov l/85 4-3 9 Aug 17187 5-o Nov l/85 4-3 10 Nov l/85 5-o Nov l/85 4-3 11 Aug 15188 4-3 12 Nov l/85 6-O Nov l/85 4-3 13 Nov l/85 6-O Nov l/85 4-3 14 Nov l/85 4-3 15 Nov l/85 Unusual Service Conditions 4-3 16 Nov l/85 4-3 17 Nov 18187 4-3 18 Nov l/85 4-3 19 Nov l/85 4-3 20 Nov l/85 4-3 21 Nov l/85 4-3 22 Nov l/85 4-3 23 Nov l/85 4-3 24 Nov l/85 4-3 25 Nov l/85 4-3 26 Nov l/85 4-3 27 Nov l/85 4-3 28 Nov l/85 4-3 29 Nov l/85 4-3 30 Nov l/85 4-3 31 Nov l/85 4-3 32 Nov l/85 4-3 33 Nov l/85 4-3 34 Nov l/85 4-3 35 Nov l/85 4-3 36 Nov l/85 4-3 37 Nov l/85 4-3 38 Jun 12187

Aug 15188 Revised l-l

Page 2 1. General

The Jet-Ex 4 unit covered in this manual (Figure 1) is a gasoline engine driven, self-contained generator set manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio U.S.A. The basic unit is identified by a Specification Number 6878, plus a dash number which defines a specific configuration. The Series number, plus the dash number, make up the Specification Number.

Specification No. 6878-l covers a stationary, skid mounted unit rated at 28.5 Volts DC output. It is equipped with a sheet metal canopy and hinged engine compartment door. The unit is also equipped with a mechanical governor. Various options are available for use with the basic unit. These options are listed in paragraph 2.B. below.

Specification No. 6878-2 covers the same basic 6878 unit, mounted on a Taylor-Dunn electric vehicle to make the unit self-propelled. This unit's generator, when operated at rated speed, provides power for operating the eleCtric vehicle.

In this manual, reference to the "generator set", the "set", or the "unit" is a reference to the ENTIRE piece of equipment. In the case of Spec 6878-2 units, the reference is to the generator set AND electric vehicle.

These generator sets are designed to generate and deliver 28.5 volts DC power to an aircraft when its on-board generators are shut down. In addition to poviding continuous, regulated'power to the aircraft, the units are designed for starting any fixed-wing aircraft or helicopter which is equipped with an external 28.5 volt DC power receptacle. Refer,to Figure 2 for complete 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 is at the REAR of the unit. RIGHT and LEFT are determined by standing at the rear of the unit and facing it.

3. Generator "Soft-Start" Feature

The "Soft-Start" current limiting feature, recommended by most engine manufacturers, provides the operator with a control which limits theiinrush current to the aircraft engine's starter. When the operator presets&this control, the generator will provide constant voltage to the preset currrent value. As more current is applied beyond the preset current value, the voltage will decrease to a minimum of 14 volts DC, after which the voltage' will remain constant as more current may be delivered beyond the preset current value. Limiting inrush current is recommended by most engine t manufacturers to protect the aircraft engine's starter shear sectioni The current limiting control is continuously adjustable from 300 amperes, which . .--.__-__.-- ---..--._---_~ ,.-- Nov l/85 --.:----J+ - .------.---__ .- -...... --- ..-..----..~ .~___. -- -- ...... _ Pageil _",.. --..__. . ..- __ is recommended for helicopter and small turbine starting, to 1600 amperes, required for starting larger aircraft engines when the control is turned fully clockwise.

Additional features include a mechanical governor which maintains the engine speed at 2600 RPM at no load, an all-electric engine overspeed protection device which shuts down the engine by opening the ignition Gircuit if the engine speed reaches 3200 RPM.

STATIONARY UNIT (s-6878-l)

SELF- PROPELLED UNIT (S-6878-2)

Jet-Ex 4 Generator Sets Figure 1 -----._ ---, .m.------.- -~-..--i._____ t Nov l/85; ._-- ," -.- - .-- -- ___ 1 Page 2 ,_._ I .. l__ - _- ._ r . _ ,- -- - .--. . ..-..- -..-______~~. _---_-...I,_..-i OM-2017

STATIoNAm UNIT (WITH CABLE HANGERS)

Length 65.50 inches (1664 mm) Width 34.25 inches (870 mm) Height 46.25 inches (1175 mm) Weight (dry fuel tank) 1365 pounds (619 kg)

VEHICLE-MOUNTED UNIT WITH CAB

Length 119 inches (3023 mm) Width 43 inches (1092 mm) Height 73 inches (1854 mm) Weight, approximate (dry fuel tank) 2800 pounds (1270 kg)

VEHICLE MOUNTED UNIT WITHOUT CAB

Length 119 inches (3023 mm) Width 43 inches (1092 mm) Height 69 inches (1753 mm) Weight, approximate (dry fuel tank) 2500 pounds (1134 kg)

GENERATOR

Output Power Rating 15.7 kW Voltage 28.5 volts DC Rated Load Capacity 550 amperes continuous at 28.5 volts DC Starting Current Capacity 300 to 600 amperes Current Limiting Capability 300 to 1600 amperes, continuously adjustable Operating Speed 2600 RPM

ENGINE

Manufacturer Ford Motor Company Model LSG 4231-6005-A (with special options: SO-2802A) 5Pe Overhead valve, in-line, 4 cylinder Fuel Gasoline, no lead Displacement 140 cubic inches (2.3 liters) Rated Power at 2600 RPM 64 Horsepower Oil Capacity (with filter change) 5 quarts (4.7 liters) Coolant Capacity 2.5 U.S. gallons (9.5 liters) Spark Plugs Type AWSF-52 (.042 - .046 gap)

Specifications and Capabilities Figure 2 (Sheet 1 of 2)

Nov l/85 l-l

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(Ignition System (Distributor-coil type) 12 volt DC, negative ground Governed Speed 2600 + 25 RPM IIdle Speed 900 to iooo RPM IFuel Tank Capacity 21 U.S. gallons (79.5 liters)

IPROTECTIVE DEVICES

i GENERATOR I (28.5 volt overvoltage module trips at 32 to 34 volts. (14 volt overvoltage module trips at 18 to 20 volts. I iENGINE

IOverspeed device trips at 3100 to 3200 RPM. (Low oil pressure switch opens at 10 PSI (69 kPa).

Specifications and Capabilities Figure 2 (Sheet 2 of 2)

4. Electric Vehicle-Mounted Unit (Spec 6878-2)

The electric vehicle used in this Specifcation is a Taylor-Dunn Model B2-48. For operating power, the electric vehicle receives 36-V DC from the Spec 6878 generator which is mounted on it. This is the same generator which provides 28.5-V DC to an an aircraft when driven to the aircraft location. The electric vehicle has a rated speed of 12 MPH, and a motor rated at 10 horsepower at 1400 RPM.

This vehicle is designed to be easy to operate, and requires a minimum of maintenance. Its steering mechanism and short length enables an operator to easily maneuver it in and out of tight places. Many special features of this vehicle are standard, and a number of options are available from Taylor -Dunn Company for it. Refer to Taylor-Dunn Operator's Manual.

5. Optional Equipment

A. Stationary Unit (Spec 6878-l)

(1) Two different models of four-wheel torsional spring trailers are available to add mobility to the stationary unit. These trailers are equipped with pneumatic rubber tires, a drawbar for towing, and drawbar-operated, drum type parking brake. One model (Hobart Part No. 488880-l) is equipped with fenders, bumpers, and cable trays. The other model (Hobart Part No. 488880-2) does not have the latter three items.

(2) A 120-V AC generator kit, which mounts to the unit, receives 28.5-V DC power from the generator, and converts it to 120-V AC, 60-Hz power for operating small tools, electrical instruments, lights and other devices requiring 120-V AC power. This 120-V DC generator kit is available as Hobart Part No. 489100 for mounting to self-propelled units or trailer-mounted units with fenders, and as Part-.-No;--4891-04-for-mon-nti-rrg-to--stationa~~~u~i~-ortrai-ler-mounted units without fenders. l-l Revised Aug 15/88 Page 4 . (3) A 14-V DC output kit, Hobart Part No. 488951, which can be installed in a 28.5-V DC unit to provide 14-V DC to aircraft whose systems re-quire this voltage for starting and maintenance.

(4) A spacer kit for stationary mounting. This kit consists of a set of metal spacers that elevate a stationary unit six inches above the platform to which it is mounted, in order to permit the free flow of air for cooling the unit. This spacer kit is identified as Hobart Part No. 488952.

B. Self-Propelled Unit (Spec 6878-2)

(1) A steel cab and canopy group, identified by Hobart Part No. 408426. This cab is available with or without doors. The set of two metal slam doors are an available option, identified by Hobart Part No. 408427.

(2) An hour meter, which registers the time, in hours, that the electric vehicle is operated. This hour meter is identified as Hobart Part No. 408433.

(3) A side view mirror, Hobart Part No. 408438, which attaches to the cab.

6. Canopy

The canopy of Series 6878 generator sets is a sheet metal enclosure which protects the engine, generator, and electrical controls. It has one large, hinged door at the left front to provide access for service and maintenance. Panels at the rear provide access to the generator. A Plexiglas window is mounted above the control panel to allow observation of the instruments while protecting them from the weather. The right rear panel has a round hole in it to permit viewing the fuel gage mounted in the fuel tank.

7. Engine, Generator, and Controls

A. General

Refer to Figure 3. The engine (3) and generator (15) are mounted on a welded steel frame (10). A fuel tank support (7) located at the rear of the unit supports the fuel tank (13) and provides a mounting frame for. the load contactor and output terminals (2). The radiator (5) is;moun" ted to the front canopy. A heavy U-bolt is attached to the centrally-, located lifting yoke (12) for raising and moving the generator set with a crane or hoist to or from its platform (if it is a stationary unit) or to or from the electric vehicle.

WARNING: DO NOT ATTEMPT TO LIFT AN ENTIRE GENERATOR SET MOUNTED bN AN/ ELECTRIC VEHICLE (Spec 6878-2) BY THE LIFTING YOKE. / i

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B. Engine

(1) General

The in-line four cylinder engine is a Ford Model LSG 4231-6005-A. It has 140 cubic inch (2.3 liters) cylinder displacement and uses no lead gasoline.

The ignition distributor is mounted on the left side of the engine and is driven by a gear on the camshaft. The distributor, in turn, drives the oil pump through a short intermediate drive shaft.

Oil pressure is maintained in the lubrication system by a rotary oil pump located in the crankcase. A spring-loaded relief valve in the pump limits maximum pressure in the system. A full-flow oil filter (16, Figure 3) cleans the entire output of the pump before it enters the oil distributing system. A valve in the filter provides a bypass to an oil gallery in case the filter becomes clogged. A low oil pressure switch is mounted on the engine block as a protective device. The primary ignition circuit is wired through the contacts of this switch, which closes at 10 PSI (69 kPa). This prevents the engine from running if oil pressure will not build up, and also shuts down the engine if oil pressure drops radically during operation. A vacuum switch mounted in the intake manifold prevents energizing of the starter motor once the engine is running. See Figure 2 and.the engine operator's manual for engine specifications.

The generator and engine are mounted on a welded steel skid, and are enclosed by a sheet metal canopy that bolts to the skid. Access to engine serviceable components (oil filter, air cleaner, etc.) is through a gull-wing door at the front left of the machine.

Two removeable panels to the right side and one to the 'leftrear allow access to the other components such as spark plugs, load contactor and output terminals. The rear panel is removeable and permits access to the rectifier assembly.

(2) Cooling fan

The cooling fan on the engine is designed to blow air out through the radiator rather than to draw it in. This prevents hot air, heated by the engine, from entering the generator.

(3) Engine speed governor

The engine speed governor (4, Figure 3) is a constant speed mechanical governor. Its actuator arm is linked to the carburetor fuel control lever by a rod with ball joints threaded on both ends. This governor maintains the engine speed at approximately 2600 RPM when the generator is in operation. l-l Page 6 Nov l/85 OM-2017

6’ I

/ // I6 21 LEFT SIDE 19 17

I / I IO 15 ? --+---dDE 8 3

1. Control Panel 11. Oil Pressure & Coolant Temp. Senders 2. Output Terminals 12. Lifting Yoke 3. Engine 13. Fuel Tank 4. Governor 14. Fuel Shut-off Solenoid Valve 5. Radiator 15. Generator 6. Drain Cock 16. Oil Filter 7. Fuel Tank Support 17. Fuel Pump and Fuel Filter 8. Starter Relay 18. Engine Voltage Regulator 9. Rectifier Assembly 19. Battery 10. Frame 20. Alternator 21. Engine Overspeed Relay

Generator Components Figure 3 Nov l/85 l-l Page 7 OM-2017

: (4) Engine overspeed device

The engine and generator are protected against the danger of overspeed by an overspeed relay (21, Figure 3). This unit is a sealed, solid-state device which is wired into the primary ignition circuit. It senses the distributor pulses, and when they reach a frequency which indicates an engine speed of approximately 3150 RPM, an internal relay shorts the ignition circuit to ground and shuts down the engine.

(5) Crankcase ventilation

This engine is equipped with an open crankcase ventilation system. This open ventilation system consists of a breather cap on the rocker arm cover.

(6) Fuel system

The fuel system consists of an 21-gallon (79.5 liters) tank (13, Figure 3) and a diaphragm type fuel pump (17) with all the :_ necessary fittings and hoses. A 12 volt, solenoid operated ‘> shutoff valve (14) is mounted in the fuel line in front of the tank. It shuts.off the supply of fuel to.the engine when then. .._ ENGINE‘(ignition) switch on the control panel is iin the STOP/SHUTDOWN position (ignition OFF). This keeps the engine from flooding due to the gravity flow or siphoning from the tank when the engine is not running.

Power to open the solenoid valve is supplied when the ENGINE switch is in the START and RUN positions.

(7) Alternator and regulator

The battery charging alternator (20, Figure 3) is rated at 40 amperes. Its voltage regulator (18) is mounted on the side of the left engine support.

(8) Starter relay

The starter relay (8, Figure 3) is mounted on the right side of the lifting yoke near the starter motor.

(9) Carburetor

The carburetor, specially designed for engine governor type applica- tions, is mounted on the engine and adjusted at the Hobart factory. Re- placement carburetor, spare parts, and repair kits are available from Hobart Brothers only.

(10) Spark arrester muffler

This muffler prevents the discharge of sparks from the engine's exhaust.

l-l Page 8 Nov l/85 OM-2017

c. Generator

The generator (15, Figure 3) is a multi-phase, synchronous salient pole, revolving field, AC generator whose output is rectified. The output is reciti- fied by a rectifier assembly (9) made up of twelve rectifiers connected into a full wave configuration. The generator is self-excited and receives excitation from a three phase full wave ret-tified stator winding. One positive and one negative brush in contact with slip rings supply controlled excitation current from the stator winding through the voltage regulator to the ro- tating field winding. The voltage regulator controls the excitation current and maintains a constant output voltage. Access to the brushes is through holes in the anti-drive end bracket.

The rotor is supported at the anti-drive end (slip ring end) by a single-row ball bearing. The drive end is connected to the engine fly-wheel by a flexible disc and hub coupling assembly and is supported by the engine main bearings. A radial-blade fan of formed sheet metal construction is mounted on the coupling hub and draws cooling air over the rectifier assembly and generator windings.

Air enters through the anti-drive end of the generator and is dis-charged through openings in the flywheel housing at the drive end. The generator housing assembly, which contains the generator stator, is bolted to the engine flywheel housing.

D. Control Panel Assembly

(1) General

The control panel (1, Figure 3) is a sheet metal panel which houses and provides mounting facilities for controls and monitoring instruments. The panel 1s mounted at the rear of the canopy. Its control are accessible behind a hinged Plexiglas cover. A small hinged panel (Figure 4) provides mounting for the starting current potentiometer, and also provides access to the voltage regulator and overvoltage relay, etc.

(2) Lights

Two panel lights (7, Figure 4) provide illumination for instruments and controls. One green pilot light (12) glows when the output load contactor is closed, and another one (14) glows green when the engine is running.

(3) Monitoring instruments

The voltmeter (6, Figure 4) indicates generator output voltage, and the ammeter (5) displays generator current.

A tachometer (2) displays the engine speed in RPM. This instrument is operated by pulses from the distributor.

l-1 Nov l/85 Page 9 OM-2017

A water temperature gauge (3) indicates the engine coolant temperature and is actuated by a temperature sender (11, Figure 3) mounted on the engine's water jacket.

An oil pressure gauge (1, Figure 4) displays the pressure in the engine's lubrication system. It is operated by a sender (11, Figure 3) mounted on the engine block.

The ammeter (20, Figure 4) indicates the rate of charge or discharge in the engine's 12 volt DC electrical system.

The hourmeter (15) records the total hours of engine operation for scheduling maintenance.

(4) Potentiometer

The current limiting potentiometer (4) is used to select the starting current recommended for various aircraft. The current limiting setting is continuously adjustable from 300 to 1600 amperes.

(5) Switches

The contactor control switch (11, Figure 4) is a three-position toggle switch used to close and open the output load contactor. The top CLOSE position is spring-loaded and is held momentarily until the contactor closed light (12) glows, then it is released to the center ON position. In this position the switch provides holding current to the load contactor to keep it closed. Protective devices in the load contactor circuit provide protection against overvoltage by opening the load contactor if that condition occurs. In the bottom OFF positi'on,the contactor is opened. The push-to-build-up-voltage switch (10) is a momentary contact pushbutton switch which flashes the generator fields with 12 volt engine circuit when flashing the fields.

The panel lights switch (8, Figure 4) turns the lights (7) on and off. The engine start switch (17) is a momentary contact pushbutton which closes the starter relay (8, Figure 3) and cranks the engine. This switch is operable only when the engine (ignition) switch (19) is held in its top spring-loaded START position.

The engine (ignition) switch (19), when released from its top START position after the engine starts, will return to center RUN position. The engine ON light (14) will glow as long as the switch is in RUN position. In the bottom STOP position, the switch will stop the engine and the light (14) will go out.

Refer to Figure 4. The speed control switch, (13) is a two- position toggle switch wired to an idling device on the engine. In the IDLE position, used for starting, the engine speed is controlled approximately 900-1000 RPM. In the Rated RPM position, engine speed is controlled to approximately 2600 RPM.

l-l Page 10 Nov l/85 OM-2017

(6) Fuses

Three cartridge-type'fuses protect the engine ignition circuit, the panel lights circuit, and the voltage regulator. The engine circuit fuse (16, Figure 4) is rated at 20 amperes, the panel lights fuse (9) at 10 amperes, and the voltage regulator fuse (4, Fig. 5) at 10 amperes.

(7) Voltage regulator

Refer to Figure 5. The voltage regulator (1) is a solid-state device which regulates the 28.5 volt DC generator output after the voltage is built up.

(8) Overvoltage module

The overvoltage relay (2) is a solid-state protective device on a printed circuit board. A normally closed relay in the circuit is wired into the load contactor coil circuit. An overvoltage condition causes the relay contacts to open, which in turn prevents the contactor from closing, or opens the load contactor and discon- tinues the power delivery. The overvoltage module is adjusted to to trip at 32 to 34 volts DC in 2 to 10 seconds.

(9) Resistor and diode assembly

This network which is mounted on a terminal strip behind the control panel, protects the overvoltage module against reverse current when the generator is delivering power.

(10) Choke control

The choke control is connected to the carburetor choke butterfly with a flexible control cable. Pulling it out closes and enriches the fuel mixture. Pushing it in opens the choke.

(11) Excitation Rectifiers

Two diode bridge rectifiers, CR418 and CR417, (3, Fig. 5) convert an AC voltage from the generator armature to the DC voltage needed for the generator revolving field.

(12) Voltage Sensing Relay

Voltage sensing relay K404 (5, Fig. 5) is a safety device which automatically opens the grounding circuit of the revolving field to prevent excessive voltage build-up if the push-to-build-up- voltage switch is held in too long, or if it is pushed in after voltage is built up.

E. Output Terminals

The output terminal panel (2, Figure 3) is mounted on the side of the fuel tank support.

l-l Nov l/85 Page 11 OM-2017

5 6 7

OIL PRESSURE WATER TEMP

/ GENERATOR L 0 6

I 12 18 16 14

LPSD-10611

1. Oil Pressure Gauge 11. Contactor Control Switch 2. Tachometer 12. Contactor Closed Light 3. Water Temperature Gauge 13. Speed Control Switch 4. Current Limit Control 14. Engine On Light 5. Ammeter (Generator) 15. Hourmeter 6. Voltmeter 16. Engine Circuit Fuse 7. Panel Light 17. Engine Start Switch 8. Panel Lights Switch 18. Choke 9. Panel Lights Fuse 19. Engine Ignition Switch 10. Push-To-Build-Up-Voltage Switch 20. Ammeter (Engine)

Control Panel Assembly Figure 4

l-l Page 12 Nov l/85 OM-2017

F. Contactor

The load contactor which is mounted beside the output terminal panel, provides a safe and convenient means of connecting and disconnecting the generator from the load. Initial power for closing the load contactor is supplied by the generator through the spring-loaded momentary contacts of the contactor control switch (11, Figure 4). Holding power, to keep the contactor closed, passes through the normally open auxiliary contacts in the load contactor.

G. Rectifier Assembly

The rectifier assembly (9, Figure 3) is located at the rear of the machine below the control panel. It consists of two aluminum heat sinks with six diodes on each heat sink. The negative rectifier assembly is mounted nearest to the rear frame and the positive rectifier assembly is mounted nearest to the generator. The rectifier assembly converts the AC output of the generator to 28.5 V DC.

H. Ammeter Shunt

The ammeter shunt is connected in the generator's negative output circuit. It supplies a small voltage proportional to output current for operation of the generator ammeter (5, Fig. 4) and for sensing output current for the current limit circuit of the voltage regulator (1, Fig. 5). This shunt is mounted on a bus connected to the negative heat sink of the rectifier assembly (9, Fig. 3).

-I 1. Voltage Regulator 2. Overvoltage Relay 3. Excitation Rectifiers 4. Voltage Regulator Fuse 5. Voltage Sensing Relay

-2

Control Panel Wrapper Figure 5

l-i

Nov l/85 Page 13 OM-2017

This page intentionally left blank.

l-l Page 14 Nov l/85 OM-2017

SECTION 2. PREPARATION FOR USE, -STORAGE, OR SHIPPING- 1. Preparation for Use

A. General

The generator set is shipped with a dry battery and an empty fuel'tank. After the battery is filled with electrolyte and charged, the fuel tank filled and the generator set inspected, the generator set is ready for use.

CAUTION: READ OPERATING INSTRUCTIONS IN SECTION 1-3 BEFORE OPERATING THE UNIT.

B. Inspection/Check of Generator

Inspect the unit completely prior to operation.

(1) Remove crating, blocking, banding, ties, and other securing and protective material. After shipping carton is removed, remove the four carton supports from the bases of the clearance lights. Then install the attached clearance light lenses in their bases.

(2) Inspect exterior for shipping damage such as broken glass, damaged sheet metal, etc.

(3) Open canopy door and inspect interior for foreign material such as rags, tools, shipping papers, etc.

(4) Check fuel, coolant, and oil hoses and connections for visible leaks. If leaks are discovered, correct by tightening hose clamps, tube fittings, etc., as required.

(5) Check security of attaching and retaining hardware.

(6) Check the following for sufficient quantity.

(a) Fuel

Fuel tank capacity is 21 gallons (79.5 liters). Use no lead gasoline.

(b) Engine coolant

The radiator cap is located above the front canopy. Coolant level should be approximately one inch below the filler neck. Allow a sufficient capacity for coolant expansion.

CAUTION: BE SURE THE COOLING SYSTEM ANTIFREEZE SOLUTION IS ADEQUATE TO PROTECT BELOW LOWEST TEMPERATURE EXPECTED.

1-2 Nov l/85 Page 1 OM-2017

The oil level dipstick is located on the left side of the engine. Refer to Ford Maintenance and Operator's Manual for oil recommendations.

(7) Air cleaner

Make sure air cleaner element is installed. Recommended replacement element is United Air Cleaner No. 25OA13.

(8) Battery

Check fluid level in 12 volt battery. Fluid should cover plates.

C. Inspection/Check of Electric Vehicle

(1) Open all packages and examine any accessories which may be shipped detached from vehicle.

(2) Examine wiring for visible evidence of damage. Check all connections to insure that none has loosened during transit.

(3) Check all battery connections and electrolyte level in each cell.

(4) Inspect battery charger in accordance with manufacturer's installation instructions.

(5) Check tires for damage and proper inflation. Check wheel lugs to insure tightness.

(6) If vehicle is equipped with hydraulic brakes, check hydraulic lines for evidence of damage.

(7) Check brake fluid level in master cylinder.

(8) Examine entire vehicle for damage such as dents or cracks.

(9) Check operation of controls to see that they are working freely.

D. Output Cable Installation

Units are normally supplied without a generator-to-aircraft cable.

(1) Cable requirements

Cable length is determined by the customer's requirements. It is recommended that the cable be no longer than 30 feet (9 4. The cable should be two conductor with lug-type terminals on one end and an AN-2551 plug connector on the other.

l-2 Nov l/85 Page 2 OM-2017

The recommended single conductor sizes for 28.5 volt DC, continuous rated amperage and 90°C (194'F) rise is as follows: for 285 amperes use 2/O size for 385 amperes use 4/O size for 530 amperes'use 350 MCM size

NOTE: Some operators may wish to add a second cable assembly with MS-25019 plug connector for starting aircraft such as Jetstar and Sabre liner.

(2) Cable connector

(a) Connect 28 volt conductors to output terminals on output terminal panel (Figure 1). Terminals are identified POSITIVE and NEGATIVE. Tighten terminal nuts securely.

(b) Store cables in cable tray provided on top of fender, or on hangers on side of canopy if fenders are not used.

2. Preparation for Storage

When a generator set is to be stored or removed from operation, special precautions should be taken to protect the internal and external parts from rust and corrosion.

A. General

(1) The unit should be prepared for storage as soon as possible after being removed from service.

(2) Storage should be in a building which is dry and which may be heated during winter months.

(3) Moisture absorbing chemicals are available for use where excessive dampness is a problem, however the unit must be completely packaged and sealed if moisture absorbing chemicals are to be effective.

B. Temporary Storage

When storing the unit for one month, prepare as follows:

(1) Lubricate the unit completely in accordance with instructions in Section 2-2. This will include changing engine oil, and filter elements.

(2) Make certain the cooling system antifreeze solution is adequate to protect below the lowest temperatures expected during the storage period.

(3) Start the engine and operate at idle speed. With air cleaner removed, spray an engine preservative oil into the carburetor air intake for about two minutes. This oil should be SAE No. 10,

Nov l/85 l-2 Page 3 OM-2017

formulated for anti-rust and anti-corrosion protection. It should also be a high detergent-type that meets requirements for most severe (M.S.) service and Ford Specification M-4834-A.

(4) Throw the speed control switch to RATED RPM (up) position for a short burst of speed, then turn the iginition switch off and allow the engine to come to a stop while continuing to spray oil into the carburetor air intake.

(5) Clean the exterior of the engine with fuel oil and dry with clean cloths and compressed air.

(6) Seal all engine openings. Use a waterproof, vaporproof material which is strong enough to resist puncture damage from air pressure.

C. Long Time Storage

(1) Engine operation method

The unit may be stored for long periods with no special preparation if it is possible to operate the engine once each week.

(a) Make certain that the cooling system is adequately protected.

(b) Start the engine once each week and operate at idle speed until coolant temperature has reached at least 140 deg F (60 deg C). Operating time should be sufficiently long to keep the battery in a fully charged condition.

WARNING: MAKE CERTAIN OF ADEQUATE VENTILATION BEFORE STARTING P-eENGINE. (c) Operate normal operating controls.

(2) If weekly operation is not possible, nor convenient, prepare the unit for storage as follows:

(a) Lubricate the unit in accordance with instructions in Section 2-l. Drain the crankcase completely and refill with engine preservative oil Ford Speciffcation M-4834-A

(b) Drain the fuel tank and run the engine until the carburetor is empty. Pour about a gallon of unleaded, undyed gasoline in the fuel tank and operate the engine for at least 10 minutes. With the engine running at idle speed and the air cleaner removed, treat the upper cylinders, valves, etc., by spraying an engine preservative oil into the carburetor air intake for about two minutes. Throw the IDLE/GENERATE switch to GENERATE position for a short burst of speed, turn the ignition off, and continue to spray oil into the carburetor until the engine stops.

l-2 Nov l/85 Page 4 OM-2017

(c) Drain engine oil. Drain fuel tank, carburetor and fuel line. Drain cooling system at bottom of radiator and left side of engine block. Remove radiator cap so coolant will drain completely.

(d) Remove all grease and oil from exterior surfaces of engine.

(e) Seal all engine openings and accessories with water resistant tape.

(f) Remove battery and store in a cool dry place. Store the battery on wood rather than directly on cement or metal.

(g) To protect the generator and other electrical components, the complete unit should be packaged, using moisture proof packaging and sealing materials. Place packages of moisture absorbing chemicals, such as silica-gel, in the unit before packaging.

WARNING: PLACE WARNING TAGS IN SEVERAL PLACES TO MAKE CERTAIN THAT THE INDIVIDUAL WHO TAKES THE UNIT OUT OF STORAGE IS WARNED THAT ENGINE OIL AND COOLANT HAVE BEEN DRAINED.

3. Preparation for Shipping

Prepare the unit for shipping as follows:

A. Seal all engine openings to prevent the entrance of water, dirt, and dust

B. Disconnect battery cables.

c. Drain all fuel from tank, carburetor, and fuel lines as required by carrier rules.

D. Crate the unit solidly to prevent damage to instruments, glass, and sheet metal.

l-2 Nov l/85 Page 5 OM-2017

\ 3 Ipso-10641

1. Positive Output Terminal 2. Negative Output Terminal 3. Load Contactor

28 Volt Output Terminal Panel Figure 1

l-2

Page 6 Nov l/85 3M-2017

SECTION 3. OPERATION

1. General

This section contains information and instructions for the safe and efficient operation of the generator set. Operating instructions are presented in a step-by-step sequence of procedures to be followed in supplying power to an aircraft.

NOTE: Read ALL of the operating instructions before attempting to operate the equipment.

WARNING: EAR PROTECTION MAY BE NECESSARY WHEN WORKING CLOSE TO THIS EQUIPMENT.

2. Operatinq the Electric Vehicle

For instructions on how to properly operate the electric vehicle, refer to Section 3 of Taylor-Dunn Manual No. MB-248-02, which is provided with this manual. Be sure to read these instructions thoroughly and Jo their entirety before attempting to operate the electric vehicle.

(1) Aircraft cable connector must be plugged into switch box to operate vehicle.

(2) Start Engine.

(3) Build-Up voltage by engaging build-Up voltage switch.

(4) Sit on seat to activate seat switch.

(5) Turn key switch on.

(6) Actuate direction control switch.

(7) Release hand brake.

(8) Slowly depress accelerator,bringing vehicle up to desired speed.

WARNING: For vehicle stability, avoid rapid accelleration or sudden braking. Use safe driving practices at all times. Always engage hand brake when vehicle is parked. 3* Operating the Generator Set

A. Pre-start Inspection

(1) Always be sure there is sufficient oil and coolant in the engine.'

(2) Be sure the fuel shutoff valve is open. The valve is located at the fuel tank outlet. Observe the fuel gage. Make certain of sufficient fuel to complete the job to be done.

(3) Open the engine compartment door and inspect interior for rags, tools, and foreign material.

Nov l/85 113 ?age 1 B. Pre-start Instructions OM-2017 In all probability, the unit will be moved from one location to another many times during its lifetime of service. Therefore, the following steps should be taken to optimize maximum efficient operation.

(1) Check the supply of fuel, crankcase oil and radiator coolant. See Maintenance and Operator's Manual for specifications.

(2) Inspect the unit thoroughly to be sure it is in proper working order. Check all fuel lines and wire connections to be certain they are secure. Tighten any loose screws, nuts or bolts.

(3) Wipe off the entire unit and clean the air passages, contrr.1panel and other hard to reach places with compressed air not over 25 psi (172 kPa).

I 6 7

e3 @ llAUllti6 CURREWT OIL PRESSURE WATER TEWP 62

19 / 17 I 15 I I3 Ii ’ ll5 ‘8 II 9 18 I6 I4

1. Oil Pressure Gauge 11. Contactor Control Switch 2. Tachometer 12. Contactor Closed Light 3. Water Temperature Gauge 13. Speed Control Switch 4. Current Limit Control 14. Engine On Light 5. Ammeter (Generator) 15. Hourmeter 6. Voltmeter 16. Engine Circuit Fuse 7. Panel Light 17. Engine Start Switch 8. Panel Lights Switch 18. Choke Control 9. Panel Lights Fuse 19. Engine Ignition Switch 10. Push-To-Build-Up-Voltage Switch 20. Ammeter (Engine)

Operating Controls and Indicators Figure 1

1-3 Nov l/85 Page 2

.- OF?-2017

(4) Make sure that no loose bars, tools, parts, etc., are in or on any part of the engine as they could cause serious damage to the engine, generator, or personal injury to anyone standing nearby.

(5) If the unit is operated indoors, make sure that an exhaust line is properly connected to the engine exhaust system, and discharged out of doors. Avoid short bends or reduction in line sizes in exhaust pipes. Locate the unit so as to necessitate the shortest possible exhaust line to insure the least amount of back-pressure on the engine. Back-pressure can cause engine damage and loss of power.

(6) Check the electrical system to make sure the connections are secure and properly connected. Check the battery electrolyte level.

C. Starting The Engine

Make sure that all Prestarting Instructions have been carried out, and reference to Initial Preparation For Use has been checked for operating details.

(1) Check engine oil, fuel and coolant levels.

(2) Place speed control switch (13) in IDLE (down) position.

(3) If engine is COLD pull out CHOKE (18). Do not choke HOT engine.

(4) Hold IGNITION switch (19) in START position.

(5) Press and hold ENGINE START pushbutton (17). Release as soon as engine starts.

~--CAUTION: IF THE ENGINE STALLS OR FALTERS IN STARTING, WAIT THREE OR FOUR SECONDS BEFORE RE-ENGAGING STARTER. THIS WILL PREVENT POSSIBLE DAMAGE TO STARTER OR THE ENGINE.

DO NOT OPERATE THE STARTER FOR PERIODS LONGER THAN 15 SECONDS AT A TIME. AN INTERVAL OF AT LEAST TWO MINUTES SHOULD BE ALLOWED BETWEEN CRANKING PERIODS TO PROTECT THE STARTER FROM OVERHEATING.

(a) Push the CHOKE control in if the engine does not start after being cranked a few revolutions.

(b) If engine flooding is suspected, push the CHOKE control in and crank the engine again, observing the CAUTION above.

(6) Release IGNITION switch (19), to RUN position when oil pressure builds up.

(7) Adjust CHOKE (18).

(8) As engine warms up, push CHOKE all the way in.

Nov l/85 1-3 Page 3 OM-2017

(9) Allow engine to warm up before applying a load.

WARNING: THE l?NGINE’S ENTIKE EXHAUST SYSTEM WILL GET VEKY HOT AND CAUSE SEVEKE BURNS IF TOUCHED.

NOTE: Be sure that the Choke control is pushed all the way in before operating the engine under load.

D. Generator Operation

(1) DO NOT Attempt to close output contactor when vehicle is n'n 36 volt propelled mode.

(2) Aircraft cable connector must be removed from plug box to actuate 28 volt aircraft mode. WARN1NG: DO NOT CLOSE CONTACTOR WITHOUT AIRCRAFT CABLE CONNECTOR BEING PLUGGED INTO AIRCRAFT.ELECTRJCAL SHOCK COULD RESULT.

(3) At this point output contactor can be closed.

Place speed control switch (13) in RATED RPM (up) position. (4) Engine speed will be 2600 RPM.

Press BUILD UP VOLTAGE pushbutton (10). Generator will produce (5) rated voltage.

Adjust STARTING CURRENT rheostat (4) if necessary. 6) E. Deliver Power

(1) Connect output cable to AIRCRAFT.

(2) Hold CONTACTOR switch (11) in CLOSE position. Release to ON position as soon as green CONTACTOR CLOSED light (12) comes on.

F. Stop Operation Shutdown

(1) Place CONTACTOR switch (11) in OFF position. Light (12) should go off to indicate load contactor has opened and power is no longer available at the aircraft.

(2) Place speed control switch (13) in IDLE (down) position. Allow engine to run for 2 to 3 minutes.

(3) Disconnect output cable from aircraft receptacle and store cable in cable trays or on cable hangers as the case may he. _I (4) Place IGNITION switch (19) in STOP/SHUTDOWN position.

1-3 Nov l/85 Page 4 OM- 2017

G. Adverse Weather Precautions

(1) Cold weather operation

Operation of engine-driven units at sub-zero temperatures requires special precautions and extra servicing from both operation and maintenance personnel if poor performance or total functional failure is to be avoided. Consult .Yaintenanceand Operator's Manual and recommendatfons below.

(2) Fuel system

Keep system clean and free from water which may collect in a low spot in the fuel line and freeze, plugging the line. Fuel tanks should be kept FULL to prevent water condensation from the air above the Fuel.

(3) Fuel

Keep fuel storage tanks or drums as full as possible to avoid condensation of moisture from the air above the fuel. After filling or moving fuel containers, allow fuel to settle before using. Never draw fuel from the extreme bottom of the container. Strain all fuel to remove any foreign matter. When operating outdoors, take steps to prevent the entry of snow, water and Ice into the fuel containers.

(4)-Cooling system --

Prior to cold weather, drain and flush the cooling system to remove accumulations of rust and sediment. Mix and add antifreeze solution, check the cooling system connections for leaks. Add a can of rust inhibitor to the radiator when system is winterized. This will keep system cleaner and furnish lubricati.onfor the water pump.

Nov l/85 l-3 Page 5 OM-2017

(5) Lubrication

Drain the crankcase (preferably when warm after running) and fill with a lighter grade of oil. See Engine Oil Recommendations chart in the Maintenance .and Operator's Manual for recommended viscosity for various atmospheric temperatures. In cold weather, drain oil more frequently. Water condenses and collects quickly, mixes with the oil and increases deposits to form a sludge. Check oil frequently for this condition. Water in crankcase or oil lines may freeze and cause serious damage to the oil pump, or shut off the oil supply.

(6) Electrical system

In cold weather, the most efficient electric;1 system is needed to start the cold engine. Check the entire system for loose connections or indication of bad wiring or shorted conditions. Check spark gaps of the spark plugs, and distributor point gaps, consult the Maintenance and Operator's Manual for the engine.

(7) Battery

Battery efficiency decreases sharply with lower temperatures. Maintain the specific gravity of the battery between 1.275 and 1.300 (fully charged condition). Make sure of full charge before attempting to start engine in sub-zero conditions. H. Operation in Hot and Humid 'Conditions

(1) Cooling system

Maintain a more frequent check of the coolant level in the radiator.

(2) Battery

The specific gravity and proper level of the battery electrolyte should be maintained. Observe recommendations in the Maintenance and Operator's Engine Manual for proper care of the battery.

I. Operation in Extremely Dusty Conditions

If unit is to be operated under dusty, out-of-door conditions, place in a sheltered area. Take advantage of any natural barriers which may offer protection from blowing dust. If the installation is more than temporary, erect a protection shield.

(I) Fuel system

Change the fuel pump filter regularly and keep all fuel containers covered and protected against dust entry. l-3 Nov l/85 Page 6 OM-2017

(2) Oil filter and air cleaner .

These both need more frequent attention under dusty conditions. Check air cleaner daily. Replace oil filter cartridge as needed.

(3) Crankcase

The crankcase oil level will bear close attention. Dusty conditions tend to load crankcase oil with dirt. Watch for dirty and gritty oil conditions, and change oil more frequently as required. 4

J. Operation in Salt Water Areas

(1) Qnow

Wash canopy regularly to remove salt film. Repaint any damaged places and oil the side panel hinges regularly.

(2) Covering

To protect the engine and generator as much as possible from salt water atmosphere, keep the side panels on the canopy closed, when not in use. It is advisable to kef:pthe unit covered with a tarpaulin, if available, while in operation. Salt water should be wiped from the engine, and all terminals and connections in the electrical system wiped dry. Keep all linkage oiled. (3) Brushes

The brushes of the generator should be inspected regular'lyto make certain that they are free in the holders. Lift the brushes in the brushholders about every two days to insure their freedom to slide within the holder. Wipe dry all the parts that can be reached, and use compressed air, if available, to dry the parts of the generator that cannot otherwise be reached. See MAINTENANCE for brush care.

(4) Field coils

The fields should be dried as thoroughly as possible. If they have become damp, proceed with recommended procedure in MAINTENANCE section.

(5) Battery terminals

Thoroughly clean the battery terminals and connections. Coat terminals and connections with petroleum jelly to retard corrosion.

K. Miscellaneous

Once a month, oil hinge on the engine compartment door and the hinged Plexiglas cover, and apply several drops of oil to the choke cable wire at the carburetor (where wire exits from its sheath). Allow each drop to soak back into sheath. l-3

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l-3 Nov l/85 Page 8 OM-2017

CHAPTEK 2. SERVICING

SECTION 1. MAINTENANCE INSPECTION/CHECK

1. General

To make certain that generator set is always in good operating condition, it must be inspected, maintained, and lubricated regularly and systematically.

WARNING: STOP OPERATIONS AT ONCE IF A SERIOUS OR POSSIBLY DANGEROUS FAULT IS DISCOVERED.

2. Maintenance Schedule

A. General

Figure 1 provides a suggested schedule for periodic checks and services. Refer to Section 2-2 for lubrication requirements.

B. Maintenance Schedule Check Sheet

It is strongly recommended that the customer use a maintenance schedule check sheet. The check sheet will provide a record of maintenance operations performed and may also serve to improve scheduling for a specific operation.

C. Time Intervals

The schedule is based on both hours of operation and calendar intervals. These two intervals are not necessarily the same. The calendar period is included to make certain services are performed regularly when equipment is being operated infrequently, or at irregular intervals. Hourly time intervals agree with the engine manufacturer's recommendations. Perform all services on a "whichever comes first" basis.

NOTE: Refer to the Ford Maintenance and Operator's Manual for detailed engine maintenance information.

3. Engine and Related Components

See the Ford Maintenance and Operator's Manual for LSG423, 140 cu. in. engine.

4. Electric Vehicle

See the Taylor-Dunn Operation and Maintenance Manual for maintenance instructions for the electric vehicle.

2-l Nov l/85 Page 1 OM-2017

A/R 10 I-IRS.100 HRS. 200 HRS. 400 FIRS. 800 HRS. OR OR OR OR OR DAILY- 2 WEEKS 1 MONTH 2 MONTHS 6 MONTHS ENGINE

Check oil level X Check coolant level X Check governor oil X Check fuel quantity X Check gages and instruments for proper operation X Clean or replace dry-type . carburetor air cleaner element X X Lubricate distributor X Clean crankcase ventilation system X X Change engine oil X Change engine oil filter X Change governor oil X Lubricate choke linkage X Check and tighten drive belts X X Clean and inspect exterior of radiator X Check exhaust system X Check cooling system X Check and adjust idle speed and mixture X X Check and refill cooling system (Twice yearly, summer and winter) Replace fuel filter X X Clean engine X

ELECTRICAL SYSTEM (12-V DC)

Check lights X Check charging rate X Check battery water level X Check battery state of charge X Charge wiring and connections X Check all instruments and gages X Check battery terminals and connectors X

Inspection/Check/MaintenanceSchedule Figure 1 (Sheet 1 of 2)

2-l Nov l/85 Page 2 OM-2017

A/R 10 HRS. 100 HRS. 200 HRS. i500 HRS. 800 HRS. OR OR OR OR OR DAILY 2 WEEKS 1 MONTH 2 MONTHS 6 MONTHS

ELECTKICAL SYSTEM (28.5-V DC)

Check indicating light X Check operation of all instruments, meters, etc. X Check generator brushes for length, cleanliness, and free operation X Check slip rings for smooth- ness and cleanliness X Check the entire unit X Check overvoltage protection X Check all wiring connections X

Inspection/Check/MaintenanceSchedule Figure 1 (Sheet 2 of 2)

5. Inspection and Cleaning

Every day, check for oil, coolant, or fuel leaks. Also check for loose electrical connection. Check oil pressure with engine running at rated RPM ', -,,. (2600). Do not operate engine if oil pressure is less than 15 psi. Wipe ~ '-: -accumulated water off from all electrical connections and instruments. ; '_I Make sure that the alternator ammeter is not discharging, which indicates '. ' ':.. that the battery is being charged. ._.,,

Every week, wipe off accumulated dust, dirt and oil from the engine and generator. Check all parts for loose connections and wear* If arcing has occurred at any electrical connections, recondition them and securely refasten. Check engine oil and coolan-tlevels.

Every month, check generator for amperage and voltage output. Rlow out generator windings with compressed air, not over 25 psi (172 kPa) pressure or remove with a suction-type cleaner with a non-metalic nozzle. If windings should become slightly damp, use space heaters or electrical light bulbs to effectively dry out the windings. If dampness is excessive, apply external heat under a canvas cover, well vented. Heating should not exceed 194" F (90" C).

Pound out any dents in the canopy. Sand, prime, and repaint any dented or rusted spots.

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SECTION 2. MAINTENANCE PROCEDURES

1. General

A suggested Maintenance Schedule is provided in Section 1 of this Chapter. Each step of the schedule is also covered in general in Section 1. This Section covers maintenance in more detail where necessary.

WARNING: STOP OPERATION IMMEDIATELY IF A SERIOUS OR POSSIBLY DANGEROUS FAULT IS DISCOVERED.

2. Lubrication

A. General

Proper lubrication is one of the most important steps in good maintenance procedure. Proper lubrication means the use of correct lubricants and adherence to a proper time schedule. Lubrication points, frequency of lubrication, and recommended lubricants are indicated in Figure 1 for the engine.

B. Engine Lubrication Charts I Lubrication points are illustrated and identified by name on Lubrication Chart, Figure 1.

Number symbols used to designate the kind of lubricant required and the specification recommended are identified in Figure 2.

Letter symbols used to designate the normal lubrication period are identified in Figure 3.

C. Electric Vehicle Lubrication

Follow the lubrication instructions provided in Taylor-Dunn Operation and Maintenance Manual, Sections 4 and 5.

D. Generator

The 28.5 volt DC generator requires NO lubrication. The armature is supported at the rear by a single, ball bearing which is lubricated and sealed at the factory for lifetime, maintenance free operation. The front end of the armature is supported by the engine main bearings.

E. Generator Controls

Generator controls and instruments require no periodic lubrication. A few drops of oil may be required on door hinges occasionally to insure free and quiet operation.

Nov l/85 2-2 Page 1 Of+2017

L---w-* CRANKCASE D2 i ** OIL FILTER M FUEL FILTER SA

GOVERNOR BW 2

* Check crankcase o 1 daily; change after 200 hours use. ** Change oil filter after 200 hours use.

Engine Lubrication Chart Figure 1

Grease, Automtive Federal Sinclair Litholene and Industrial VV-G-632 Industrial No. 2; Mobil-Mobilplex 47, or equivalent.

Oil, Engine, Heavy Ford spec. Ford Motorcraft, or Duty ESE-M2ClOl-C equivalent. Refer to Figure 4 for recom- ended oil viscosity.

Lubricants Figure 2

2-2 Nov l/85 Page 2 OM-2017

D 10 hours or Daily BW 100 hours or Biweekly M 200 hours or Monthly BM 400 hours or Bimonthly SA 800 hours or Semiannually

Symbols and Time Intervals Figure 3

F. Engine

Although the engine and its accessories require no more attention than any other similar installation, they still inherently require a major portion of the generator set lubrication and maintenance. Recommendations regarding engine lubrication have been taken from the engine manufacturer's "Maintenance and Operator's Manual".

(1) Lubrication schedule

Time schedules indicated on the Lubrication Chart, Figure 1, are approximate. They are based on average operating conditions. It may be necessary to lubricate more frequently under severe operating-conditions such as: low engine temperature, high oil temperature, intermittent operation, or dusty conditions. However, time intervals should not exceed those indicated in the chart without careful evaluation.

The use of quality lubricating oil, combined with proper oil drain and filter change intervals are important factors in extending, engine life.

(2) Oil specification

Engine lubricating oil recommended by the engine manufacturer must meet Ford Specification No. ESE-M2C101-C. Oil that meets this specification is normally marked so on the can and meets API (American Petroleum Institute) classification designation SG or SH. The manufacturer recommends Ford or Motorcraft oils, which meet all specifications for Ford Industrial Engines.

(3) Oil‘viscosity 1, When you change or add oil, you should select oil with the proper specifications and with the viscosity, selected from the following' table, which most closely matches temperature range you expect to encounter for the next 100 hours of operation.

2-2 Nov l/85 Page 3 OM-2017

SINGLE VISCOSITY OILS MULTI-VISCOSITY OILS When Outside Use SAE When Outside Use SAE Temperature is viscosity Temperature is viscosity Consistently Number Consistently Number

-10°F to +32"F Below +32F (*I 5w-30 +lO'F to +6O"F -10°F to +90"F low-30 +32"F to +90"F -10°F to +90"F (or above low-40 Above 60°F Above +lO"F 2OW-40

(*) Where sustained high RPM operation is anticipated, use 2OW20.

Temperature and Oil Viscosity Chart Figure 4

(4) Change engine oil (100 hours) Oil should be changed after each 100 hours of engine operation. The generator set is equipped with an hourmeter which records actual engine operating time. The ideal time to change oil is soon after a power delivery run when the engine is at operating temperature. NOTE: If lubricating oil is drained immediately after the unit has been run for some time, most of the sediment will be in suspension and oil will drain readily without clinging to internal surfaces.

CAUTION: DO NOT USE SOLVENTS AS FLUSHING OILS IN RUNNING ENGINES. Change the oil filter each time the oil is changed.

Change oil as follows: (a) Provide a container for catching used oil. Capacity-should be greater than 2 gallons. (b) Remove drain plug located in oil pan. Allow sufficient time for oil to drain from valve train, timing gear case, etc., before reinstalling plug. (c) ,"i;zz oil filter while oil is draining [see Para. 2, E, (5) . (d) Clean drain plug and reinstall. Do not over-tighten. (e) Remove filler cap on valve cover and refill crankcase with new, clean oil of proper specification and viscosity [see Para. 2, E, (2) and Figure 41. 7 quarts are required when oil filter is changed. (f) Start engine and allow it to idle. Oil pressure should come up to normal quickly. Check for oil leaks at filter and drain plug.

2-2 Nov l/85 Page 4 OM-2017

(g) Stop engine. Allow several minutes for oil to drain to crankcase, then check oil level. It should be at FULL mark on dipstick.

(h) Check hourmeter and record time of oil change.

(5) Change engine oil filter (100 hours)

(a) Place a container under the oil filter (l-l; 23, Figure 3) to catch oil

(b) Loosen filter with a special oil filter removal wrench. Several types are available. Discard oil filter.

(d) Coat the gasket on the new filter with oil.

(e) Place the new filter in position on the cylinder block and spin on until the gasket conta-ctsthe adapter face; then hand tighten another l/2 turn. Do not over-tighten.

(f) Start engine and check filter gasket for leaks.

G. Engine Accessories

(1) Distributor

Place a few drops of SAF 1OW engine oil in the oil cap on the distributor housing each 100 hours operation.

(2) Governor linkage

Lubricate all wear points with one or two drops of SAE 30 engine oil each 200 hours.

(3) Governor

Change governor oil each 800 hours. Add SAE 40 oil to governor.

3. Servicing the Air Cleaner and Crankcase Ventilation System

A. General

It is important that the air cleaner be cleaned and.serviced regularly each 100 hours of engine operation. Service the air cleaner more often under severe dust conditions. Failure to service the cleaner can cause damage to the cylinder walls and rings, excessive oil consumption, and excessive fuel consumption. The recommended filter element for replacement is United Air Cleaner No. 250813.

Nov l/85 2-2 Page 5 OM-2017

B. Clean and Service Air Cleaner

(1) Remove thumb nut and remove air cleaner assembly.

(2) Disassemble air cleaner and discard dry filter element.

(3) Wash all components with solvent and blow dry with compressed air.

(4) Replace air cleaner body on carburetor.

(5) Install a new filter element.

(6) Replace air filter cover.

(7) Reinstall thumb nut and tighten securely.

C. Clean Crankcase Ventilation System

Clean breather cap at each oil change (100 hours).

(1) Remove breather cap from the rocker cover and clean it in a petroleum solvent.

(2) Replace breather cap.

4. Servicing the Fuel Filter

The fuel filter is a disposable in-line type and is mounted on the intake manifold (l-l; 17, Figure 3) on the left side of the engine. The recommended filter element for replacement is Ford No. C2RZ-9155-A, and should be changed every 800 hours.

A. Remove inlet and outlet hose clamps.

B. Disconnect the hoses and discard the filter.

c. Install new filter by connecting the hose from the fuel pump to the inlet side and the hose from the carburetor to the outlet side of the filter.

D. Position the hose clamps and tighten them.

E. Start the engine and check for leaks.

5. Drive Belt Service

Check all drive belts and adjust if necessary each 200 hours. Refer to Ford Maintenance and Operator's Manual in Chapter 5 for proper procedures.

Nov l/85 2-2 Page 6 OM-2017

6. Engine Cooling System

A. General

NOTE: Refer to the Ford Maintenance and Operator's Manual in Chapter 5 for detailed instructions on servicing the engine's cooling system.

During warm weather operation, when plain water is used as a coolant, the cooling system MUST be protected against rust by a rust inhibitor additive. During cold weather operation the system MUST be protected against freezing. The system should NEVER be operated on plain water, without a rust inhibitor or antifreeze.

WARNING: WHEN REMOVING THE CAP FROM A VERY HOT RADIATOR, COVER THE CAP WITH A THICK CLOTH AND TURN IT SLOWLY COUNTERCLOCKWISE TO THE FIRST STOP. WHEN PRESSURE IS COMPLETELY RELEASED, PRESS DOWNWARD AND FINISH REMOVING CAP.

CAUTION: --DO NOT ADD COOLANT TO AN EXTREMELY HOT ENGINE. THIS CAN RESULT IN A CRACKED BLOCK OR CYLINDER HEAD.

B. Rust Inhibitor

The recommended rust inhibitor to use in this engine is Ford Rotunda 8A-19546-C.

c. Antifreeze

The recommended antifreeze for use in this engine is Ford Rotunda 8A19549-A. The coolant, when mixed as equal parts of water and the recommended antifreeze, will provide protection to -35 degrees F (-37 degrees C). If another coolant is used, it must meet Ford Specification ESE-M97B18-C.

7. Battery Service

Refer to the Ford Maintenance and Operator's Manual in Chapter 5 for battery service instructions.

8. Generator Maintenance

A. General I~ The only maintenance service required for the generator will be brush replacement, slip ring cleaning, etc.

Nov l/85 2-2 Page 7 OM-2017

B. Brush Service

(1) Cleaning

If inspection reveals that brushes are gummy or sticking in the brushholders, they should be removed and cleaned. Clean both the brushes and brushholders. Use a good, SAFE, commercial cleaner. DRY ALL PARTS THOROUGHLY. Be sure brushes can move freely in brushholders.

WARNING: DO NOT USE A FLAMMABLE SOLVENT. DO NOT USE STEAM CLEANER, OR SOAPS AND DETERGENTS UNDER PRESSURE.

C. Generator Revolving Field Brush Replacement

See Figure 5

(1) Disconnect leads (A) from connectors on brushholder caps (B).

CAUTION: When removing the lead wires, do so one at a time and replace each brush accordingly, to insure that the lead i wires are put back onto the proper brushes.

(2) Lift brush (D) from brushholder (C) for inspection. If brushes are worn unevenly or are shorter than 7/16 inch (11 mm), replace them,

(3) Inspect slip rings whenever brushes are removed for servicing brushes or brushholders. Note surface conditions of rings. Surface should appear smooth and clean. Scoring or roughness of slip rings may be caused by grit or abrasive substance in brushes, or by oil on the rings. Moderately rough slip rings can be smoothed by holding grade 00 flint paper against their surface while the rings are revolving slowly. If the rings are badly scored, the unit must be sent to an overhaul facility for repair. After cleaning slip rings, blow dirt and grit out of the unit with compressed air. Do not use over 25 psi (172 kPa) air pressure to blow dirt out.

(4) Slip new brushes into brushholder guides, and place caps on top, and screw them into the guides to a "bottomed" position. The spring attached to the brush will determine the pressure at which the brush contacts the slip rings.

(5) To fit new brushes to the slip rings, lay a strip of No. 00 sand- paper, smooth side down, on slip ring surface, and draw the sand- paper in the direction of rotation of the slip ring, lifting the brush on the return stroke. Continue until the brushes have same curvature as the slip rings. Blow all carbon dust out of the machine using not over 25 psi (172 kPa) air pressure. . . 9. Electric Vehicle Maintenance

Refer to Taylor-Dunn Operation and Maintenance Manual. 2-2 Nov l/85 Page 8 OM-2017

*\ .

----l

C------

0’

A-Leads D-Brush B-Brushholder Caps E-Slip Rings C-Brushholder

Generator Revolving Field Brushes Figure 5

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SECTION 3. ADJUSTMENT/TEST

1. --General The adjustments and test procedures presented below are required after major repairs, parts replacement, or long storage.

2. Testing~. the Electric Vehicle

Refer to Taylor-Dunn Operation and Itaintenance Manual for electric vehicle testing procedures. - 3. Testing the Generator Set

Test values listed below will result when the generator set is operating properly. If your test results are not within the limits shown, perform the applicable troubleshooting procedures given in Chapter 3.

If major repairs have been made or if critical components have been replaced, make sure that the applicable adjustments have been made before testing the generator set. Adjustment procedures are described in Para. 3 of this Section.

A. Preoperational Test Procedures

(1) Open engine compartment door and inspect the interior for rags, tools, and other foreign materials.

(2) Check engine oil level.

(3) Check coolant level.

(4) Check battery water level.

(5) Check for suffLc%ent fuel.

(6) Check drive belts. Each belt should have approximately l/2 inch (13 mm) slack.

(7) Inspect all wiring for possible trouble spots such as loose wires or terminals, frayed insulation, obvious shorts, etc.

(8) Check panel lights, panel light switch, and fuse.

(9) Check governor linkage for freedom of travel. Proper control rod length is approximately 7-l/8 inches (181 mm) center-to-center of ball joints.

CAUTION: IF GOVERNOR WAS REPLACED OR LINEAGE WAS DISCONNECTED FOR ANY REASON.,REFER TO ADJUSTMENT PROCEDURES IN PARA. 3 BEFORE TESTING GENERATOR.

(10) Connect cables from generator output terminals to a load bank. Use cables of the same size and length as those used in service, preferably No. 2/O, not more than 30 feet (9 m) long.

Nov l/85 2-3 Page 1 OM-2017

6 7

\ TACHOMETER

\ * s~Amrh3 CURRENT = A OIL PRESSURE WATER TEMP FI @ GENERATOR - 0 0

18 16 14

1. Oil Pressure Gauge 11. Contactor Control Switch 2. Tachometer 12. Contactor Closed Light 3. Water Temperature Gauge 13. Speed Control Switch 4. Current Limit Control 14. Engine On Light 5. Ammeter (Generator) 15. Hourmeter 6. Voltmeter 16. Engine Circuit Fuse 7. Panel Light 17. Engine Start Switch 8. Panel Lights Switch 18. Choke Control 9. Panel Lights Fuse 19. Engine Ignition Switch 10. Push-To-Build-Up-Voltage Switch 20. Ammeter (Engine)

Operating Controls and Indicators Figure 1 2-3 Nov l/85 Page 2 OM-2017

B. Operational Tests

(1) Start the engine as described in l-3; Para. 3 (a), and let it warm at idle speed.

(2) Inspect for oil, fuel and coolant leaks.

(3) Check the engine ammeter (20, Fig. 1) for a slight charge. Check oil pressure gauge (1). It should read 35 to 60 psi (240 to 414 kPa). Check coolant temperature gauge. It should read 180 to 200 deg. F (82 to 93 deg. C.).

(4) Idle speed displayed on the tachometer (2) should be 900 to 1000 RPM.

(5) Check engine rpm's at operating speed:

(a) Governor

Place speed control switch (13) in RATED RPM (up) position. Tachometer (2) should show a reading of 2600 rpm at no load speed.

(6) Depress the PUSH TO BUILD UP VOLTAGE Switch to build up output voltage of gen-erator.

(7) Set current limit control (4, Figure 1) to maximum, full clockwise, position.

(8) Adjust the load bank for a load of 550 amperes.

(9) Place the contactor control switch (11) in the CLOSE position. CONTACTOR CLOSED light (12) will glow and the contactor will close. Release the switch to the center ON position. The tachometer (2) will indicate 2550 + 25 RPM.

(10) Disconnect the load bank and check the overvoltage protection by adjusting voltage regulator potentiometer R46 (1, Fig. 3) to increase the voltage. The overvoltage relay will trip and open the load contactor at 32 to 34 volts in 2 to 10 seconds.

(11) Readjus.tthe voltage to 28.5 volts, connect the load bank, set it at 550 amperes, and close the contactor.

(12~) Remove load bank and check voltage regulation at no load. Voltage will be 28.5 volts. Reconnect load bank and check voltage regulation with load bank set at 137, 275, 413, 550, and 660 amperes and check voltage at each setting. Voltage will be 28.5 + 1 volts at each different load.

(13) Apply 600 to 700 amperes load to the generator and set the current limit control (4) to 400. Current displayed on ammeter (6) will be 400 + 40 amperes.

NOTE: Voltage will not drop below 12 volts. 2-3 Nov l/85 Page 3 OM-2017

(14) Set current li.mitcontrol to 1000. Apply 1200 amperes load. Currentdispalyed on ammeter will be 1000 + 100 amperes and voltage will not drop below 12 volts.

(15) To check the overspeed relay, manually override the governor linkage at the ignition circuit and shut down the engine at 3100 to 3200 RPM.

(16) Restart the engine, check the instruments as directed in step (3), and check the entire generator set for unusual vibration and noises.

4. Governor Adjustment

A; General

(1) Put a slight tension on governor spring (just enough to crank the coils apart) with adjusting screw (A, Fig. 2). Install linkage from governor throttle lever to carburetor lever, adjusting length of linkage so that the throttle arm on the carburetor is l/16 inch off the full throttle stop. Release spring tension and operate throttle lever manually to check for any binding or lost motion in linkage. Make corrections as required.

(2) If governor is equipped with bumper screw (C), back out bumper screw until only three or four threads are engaged and secure with locknut.

(3) Start engine and operate at fast idle until warmed to operating temperature.

(4) Obtain desired no-load speed with adjusting screw (A).

(5) Check regulation by applying and removing engine load. If drop in engine speed between no-load and full-load is too much, adjust regulation screw (B) to draw spring closer to lever hub. If governor surges under load, adjust screw (B) to move spring away from lever hub. Repeat until desired regulation is obtained.

(6) Check speed adjustment after making regulation adjustment.

(7) Bumper screw (C) is used to remove a no-load surge only. If governor surges at no-load, turn screw (C) in slowly until surging stops. Secure adjustment with locknut.

CAUTION: DO NOT TURN BUMPER SCREW IN FAR ENOUGH TO INCREASE NO- LOAD SPEED OF ENGINE.

B. Troubleshooting

When installing the governor, carefully follow the instructions for installation and adjustment. To further aid in checking installation and servicing of the governor after it has been in use, check the following troubleshooting hints.

2-3 Nov l/85 Page 4 OM-2017

OPEN THROTTLE POSITION IDLE POSITION

OIL FILL- II

I L OIL LEVEL HOLE -

Governor Adjustment Figure 2

2-3

Nov l/85 Page 5 _’ I ‘4 .A’ / _ _-’ ’ ! 4 . / .. / ” ’ A.a’ I .-’ -. __. -. __ _ _. _._...-._ - __^_. --.------...-.-.~--.. .- .-.- -~ ‘., ; OM-2017 '.' Troubleshooting

(1) Engine speed lugs down when load is applied

(a) Governor improperly adjusted. (b) Friction in throttle linkage. (c) Load is too great for engine. (d) Engine worn, compression too slow. (e) Timing slow. (f) Governor running too slow. (g) Springs in carburetor or throttle mechanism opposing governor action. (h) Governor worn internally.

(2) Engine over-speeds when load is applied

(a) Governor belt slipping. (b) Governor running too slow. (c) Friction in throttle linkage. (d) Governor improperly adjusted. (e) Friction in carburetor. (f) Springs in carburetor or throttle mechanism opposing governor action. (g) Governor worn internally.

(3) Governor surges at no-load

(a) Friction in throttle linkage. (b) Governor belt slipping. (c) Carburetor mixture too lean or too rich. (d) Timing set too fast. (e) Faulty ignition. (f) Governor worn internally.

(4) Governor surges under-load

Governor improperly adjusted. Friction in throttle linkage. Governor belt slipping. Carburetor mixture too lean or too rich. Timing too fast. Faulty ignition. Governor running too fast. Governor worn internally.

NOTE: The governor has been pre-lubricated at the factory and does not require further attention for the warranty period.' If after the warranty period expires, the governor shows any oil leakage, the oil level can be checked and maintained to the "OIL LEVEL HOLE" depth.

---. ----. ..___ Nov l/85! - . ..---__ .-.... --_--.-- .---. .-._ .__.._ __- .-.._ ..___._____.... .- .-...... _. _-~_--..

6 / 4. Overspeed Relay Adjustment I A. General

I If the overspeed relay has been replaced, the new unit may require adjustment as described below.

(1) Make certain that the speed control switch (13, Figure 1) is in IDLE position. Start the engine and let it run at idle speed until it reaches operating temperature of 180 to 200 deg. F (82 to 93 deg. C).

(2) Manually override the control linkage at the carburetor to increase the engine speed. The overspeed relay should shut down the engine at 3100 to 3200 RPM. If the engine shuts down below 3100 REM or if it does not shut down at 3200 RPM, adjustment is required.

(3) Adjust the screwdriver adjustable pot at the point shown in the illustration. Turn it counter clockwise to increase the speed at which the engine will shutdown. Turn it counterclockwise to decrease the shutdown RPM.

5. Voltage Regulator Adjustment

A. 28.5 Volt Adjustment

The regulating voltage, in the 28.5 volt range, is determined by the position of the wiper arm of the multi-turn potentiometer R45. Clock- wise (CW) rotation increases the voltage level at which the unit operates. Conversely, counterclockwise (CCW) rotation decreases the voltage level.

B. 36-V Adjustment

Regulated voltage for powe,ringthe electric vehicle on Spec 6878-2.units is determined by the position of the wiper arm of the multi-turn potentiometer ~-46. Clockwise (CW) rotation increases the voltage level at which the vehicle operates. Conversely, counterclockwise (CCW) rotation decreases the voltage level.

B. Line Drop Compensation

Line drop compensation allows the voltage at the load end of the output cable to remain constant despite the voltage drop associated with the output cable. Clockwise (CW) rotation of the single-turn potentiometer (~24) increases the compensation. This potentiometer should be set for flat regulation of voltage at the load end of the output cable when delivering rated load current.

:_.,. . 'Nov1...-.. l/85-.~ - _..-. . ..- .^_. .___ - .-.- ..-._. ._ ..__..-_-.-. -...... - ..- .._ .-. _....~2-3 /. ,-...._.. _- .^.. _. ._...^.- .- -- -.___ --.--.__ -..- ___. Page-. 7-’ R624zm== R63 e

1. 28.5-V Voltage Adjustment 2. Line Drop Compensation Voltage Adjustment 3. 36-V Voltage Adjustment I Voltage Regulator Adjustment /^_ -._. ~,L--.------_I______Figure-- -__------.-..-~3 i -----i-----z i....-2-3,!.---_~-.-..--..-----... .- --,.__. . ..._ - -.-.. -..--- .~ ---.- .--..---_..I --._ -__-- -..NoLY .I.&.2 .~._i i..Page-&, __I^_ ,._ I. .-- .--- ."-..- -..- _-_ .__.- -._- - .._,_, OM-2017

CHAPTER 3. TROUBLESHOOTING

SECTION 1. TROUBLESHOOTING PROCEDURES

1. General

Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the exact cause of a trouble is found. . Asarule, the best place to start looking for the cause of a trouble in a circuit is at the source of power, Continue testing and checking the circuit, step-by-step, in an orderly manner, until the cause of trouble is located. See connection and schematic diagrams.

2. Troubleshooting Chart

A. Description

The troubleshooting chart lists information under three headings:

(1) Trouble, symptom, and condition.

(2) Probable cause'

(3) Test, check and remedy

B. Use of the Troubleshooting Chart

Read the trouble symptoms and conditions before proceeding to causes and remedies. For example, at the beginning of the trou-bleshootiug chart under ENGINE, the first trouble listed is: "Engine till not start. Starter will NOT crank engine." If the starter WILL.crank the engine, then obviously this is not your symptom and condition., Go the next trouble and symptom directly below.

If the starter will NOT crank the engine, look to the right u&er PROBABLE CAUSE and TEST, CHECK, AND REMEDY and find the Variousthings which could cause the trouble and what to do to check and remedy them,.

3. Equipment for Troubleshooting

A good quality, multi-scale voltohmmeter is the only instrument required for troubleshooting. At least two jumper leads with "alligator"-,or similar clips, will be required. The 12 volt engine electrical sy-stemmay be used for a 12 volt DC power source.

4. Safety

WARNING: LOOSE GARMENTS, NECKTIES, AND OTHER HANGING ITEMS MUST NOT BE WO-RN BY PERSONNEL NEAR THE FAN OR OTHER EXPOSED MOVING PARTS OF THIS EQUIPMENT WHILE IT IS RUNNING. ALSO, AVOID CONTACT WITH LIVE ELECTRICAL PARTS. DEATH OR SERIOUS INJURY COULD RESULT! ,

3-1 Nov l/85 Page 1 OM-2017

5. Diagrams

A schematic diagram of the generator set is provided in Chapter 6. This diagram can be very helpful1 in troubleshooting. Components shown in the diagram are identified by reference designators (or item names in some instances). A legend appearing on the diagram identifies each reference designator by its full item name. For example, the symbol K403 identifies the overvoltage relay, and M406 identifies the voltmeter.

A connection diagram is also provided in Chapter 6. It also can be very helpful in troubleshooting, parts replacement, etc.

6. Illustrations

To aid maintenance personnel with troubleshooting, three illustrations are provided in this section, showing the locations of various components of the generator set.

7. Connections and Wiring-- Before condemning any electrical component, check all connections and wiring which could affect its operation. In many instances a component may be non-functional simply because it is not receiving power because of a loose connection or a poor ground. In most cases throughout the troubleshooting chart, it will be assumed that connections and wiring have been checked.

8. Electric Vehicle Troubleshooting

Refer to Taylor-Dunn Operation and Maintenance Manual, Section 6, for troubleshooting procedures for the electric vehicle.

3-l Nov l/85 Page 2 OM-2017

LEFT SlDE

, \ \ I IF- ’ I \ \ IO 15 22 RIGHT SIDE 8 3

1. Control Panel Il. Oil Pressure & Coolant Temp, Senders 2. Output Terminals 12. Lifting Yoke 3. En-gine 13.- Fuel Tan-k 4. Governor 14. Fuel Shut-off Solenoid Valve 5. Radiator 15. Generator 6. Drain Cock 16. Oil Filte-r 7. Fuel Tank Support 17. Fuel Pump and Fuel Filter 8. Starter Relay 18. Engine Voltage Regulator 9. Rectifier Assembly 19. Battery 10. Frame 20. Alternator 21. Engine Overspeed Relay

Generator Components Figure 1 3-l Nov l/85 Page 3 OM-2017

6 7

STARTINB CURRENT OIL PRESSURE WATER TEMP 43

i !i,il! 9 18 16 14

[PSD- 106 11

Control Panel Assembly Figure 2 3-l

Page 4 Nov l/85 OM-2017

- 97 ,I /

-2

1. Voltage Regulator 2. Overvoltage Relay 3. Control Winding Rectifier 4. Voltage Regulator Fuse 5. Voltage Sensing Relay

Control Panel Wrapper Figure 3 3-l Nov l/85 Page 5 OUBLE, SYMPTOM I ND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY I GINE AND CONTROL

Engine will not 9. Ignition switch (5404) Momentarily connect large start. Starter or pushbutton start capacity jumper cable between will not crank switch (S401) the hot side of the starter engine. defective. relay (L401) and the start switch terminal on the starter relay (blue wire). If the. starter operates, check ignition switch (19, Fig. 2) and pushbutton start switch (17, Fig. 2). Replace faulty switch. If starter doesn'lt crank, proceed to Step B.

3. Batteries discharged, Check battery connections or loose battery or and check voltage across i ground connection. battery. Voltage should be approximately 13.5 VDC. Be sure this voltage is reaching starter relay input terminal. If battery and connections are good, proceed to Step C.

2. Defective starter Momentarily connect a large relay (L401) capacity jumper cable between the hot side of the starter relay (8, Fig. 1) and the starter input terminal. If the starter attempts to crank the engine, the starter solenoid is defective. Replace it. If engine still won't crank, proceed to Step D.

1. Defective starter. If starter did not attempt (B401) to operate in Step C above, the starter is defective. Replace starter. If starter did attempt to operate, but couldn't turn engine, proceed to Step E.

Figure 4 --.-.__ _ ---_- ___-_-_ -~-- -.--. ..- - I _,-_ - ----.---..--Nov.-l/85 h----.------_-- Page 6 TROUBLE, SYMPTOM AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY I ENGINE AND CONTROL

L. Engine will not E. Internal engine z. CAUTION: MAKE CERTAIN THAT start. Starter seizure. IGNITION IS OFF SO will not crank THAT THE ENGINE DOES engine. (Cont'd) NOT START.

Use a socket wrench on the front crankshaft pulley to try to turn engine by hand. If engine will not turn, internal damage is indicated.

!. Engine will not 4. Engine circuit fuse L. Replace engine circuit fuse start. Starter (F402) blown or- (16, Fig. 2). Use type DOES crank AGC-20 fuse. engine. 3. Fuel valve at tank 5. Check and correct as required. closed, or no fuel tank or-

2. Defective overspeeC :. Disconnect the black wire from relay (K401) or- terminal 4 on the overspeed relay (21, Fig. 1). If engine now starts, replace overspeed relay.

1. Defective component ). Check these components in ignition system: accordance with Ford Mainten- ignition coil (L402 ance and Operator's Manual. distributor (E405), Replace faulty component. ignition module, 01:

I. Defective anti-dies ‘. The anti-diesel solenoid is solenoid (L405). located at the base of the carburetor in front of it. Disconnect the red wire of the solenoid from the engine circuit. With a jumper lead attached to the positive terminal of the battery, check the operation of the solenoid by listening for its opening and closing when the other end of the jumper lead is touched to the terminal of the red solenoid wire. If no sound is heard from the solenoid, it must be replaced.

--I__-_-_.--.II_._- .--I-..

-4CSVJ-L 3-l PROBABLE CAUSE TEST, CHECK, AND REMEDY

I IS ENGINE AND CONTROL

!I Engine will not I JARNING: EXERCISE CARE TO AVOID A FIRE WHEN WORKING WITH THE i start. Starter FUEL SYSTEM. DO NOT PERFORM STEPS F AND G WHEN / DOES crank ENGINE IS HOT. 1 engine. (cont'd)T

F. Defective fuel valve F. Disconnect hose at input side solenoid (L404). of fuel pump (17, Fig. 1). Momentarily apply 12-VDC to the fuel valve solenoid (14, Fig. 1). If fuel valve solenoid is good, fuel should flow from it when voltage is applied. Replace fuel valve solenoid if defective. If solenoid is good, proceed to Step G.

:. Defective fuel pump. 2. Disconnect hose at output, side of fuel pump and crank engine. If fuel does not spurt from pump when engine is cranked, replace pump.

! Engine fires i. Spark plug cables I. Check high tension spark plug and/or backfires incorrectly installed wires. Firing order is l-3-4-2 but will not run on plugs or in Correct as required. If distrubutor cap. firing order is correct, proceed to Step B.

3. Distributor not 3. Time in accordance with correctly timed to instructions in Ford Mainten- engine. ance and Operator's Manual in Chapter 5. If timing is correct, proceed to Step C.

:. Water in gasoline. 2. Check for water in fuel tank and fuel lines. Drain tank and refill if necessary.

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-----_--l__l-_- --. .._._Nov 'l/85 / -...... ’ .~. .

_ OM-2017

TROUBLE, SYMPTOM AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY ENGINE AND CONTR -I $. Engine starts 1. Fuel not turned on. 1I. Turn on fuel shutoff valve. then stops. 3. Defective oil pressure I3. Connect a jumper Twireacross, switch (S403) located T the "C" and "No" terminals on engine block. of oil pressure switch. Start engine and check oil pressure. If it is below 10 PSI (69 kPa) shut do'wnthe engine and check lubrication system for leaks. Check also the oil pump. If oil pressure comes up to normal, and the engine continues to run, the oil pressure switch is defective. Replace oil pressure switch. If oil pressure switch is good, proceed to Step C.

:. Fuel valve solenoid Refer to 2.F. above and check (L404) defective. accordingly.

). Excessive engine speed Check and correct as follows:

(1) Loose or defective (1) Check condition of governor drive governor belt. If belt. excessively worn, replace it. If its condition is good, tighten it in 'accordance with Fdrd Maintenance and Operators Manual in Chapter 5.

(2) Improperly (2) Adjust governor. Refer adjusted governor to Section 2-3, P&a. 3, and Ford Maintenance and Operator's Manual in Chapter 5.

- I .I

- _-...... - -~__ --.-.-. - ~.. . .._ page 9 TROUBLE, SYMPTOM ANI/CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY I ENGI$E AND CONTROLS I 5, Engine runs A. Distributor timing A. Check timing. Set timing roughly, then improperly set. according to Ford Maintenance stalls. and Operator's Manual.

B. Moisture or damaged B. Check distributor according components in to Ford Maintenance and distributor. Operator's Manual. Service or replace items as necessary.

5. Engine does not 9. Idle speed set either A. Adjust idle speed to approx- attain normal too high or too low. imately 900-1000 RPM. idle RPM, or idles too fast.

Engine goes to R. Loose, slipping or 9. Inspect belt. Adjust or overspeed defective drive belt. replace as required. immediately when speed con- 3. Improper setting of B. Set governor for proper engine trol switch is engine RPM at governo' RPM. placed in RATED RPM :. Governor defective. :. Replace governor. Send old poSition. governor to overhaul.

Engine will not 1. Speed control switch I. If engine will not go from run at rated (S406) defective. idle to rated speed when speed spfed (2600 RPM) control switch (13, Fig. 2) is in RATED RPM position, turn ! off engine and take resistance measurements at speed control switch terminals with switch in the RATED SPEED position. Measure for about 15 ohms between terminals having red-blue and orange-yellow wires. Zero resistance should be measured between terminals having brown-red and red wires. Replace speed control switch if any of these measurements are improper.

____---_---~-_.---_~---~-~__ __-____ - - mee..e--.----.~~v.x./.85 ' _ i------Page 10 , -k Y .e’ , ‘.

..,: 4 ,’ : ._’ .’ ~... -. -.-- OM-2017

TROUBLE, SYMPTOM AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY I ENGINE AND CONTROL

3. Engine will not I. Speed control switch I. If engine will not go from run at rated (S406) defective. idle to rated speed when speed speed (2600 RPM) control switch (13, Fig. 2) Cont'd. is in RATED RPM position, turn off engine and take resistance measurements at speed control switch terminals with switch in the RATED SPEED position. Measure for about 15 ohms between terminals having red-blue and orange-yellow wires. Zero resistance should be measured between terminals having brown-red and:red wires. Replace speed control switch if any of these measurements are improper.

3. Carburetor throttle B. Check throttle linkage and linkage improperly make certain the governor can adjusted. actuate the carburetor throttle valve to "wide open" position. Adjust and free linkage as required. Refer to Section 2-3, Para. 2, A, (9), and Para. 3.

2. Governor improperly Z. Adjust governor in accordance adjusted. with Section 2-3, Para. 3.

3. Engine surges i. Governor improperly A. Adjust governor. See Sect. at no load. adjusted. 2-3, Para. 3.

3. Binding in governor-to- B. Free linkage. carburetor linkage.

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-_ ,_-. ._. I. -..___~-- __ .- .-.. . .~ ._ .-Page 11 fl I .. / -. ! ‘1 /’ . -. . / . ,‘ ’ \ // I ‘,.,. ,.- ‘“L I 1 ,Y I.. , ” / . . .A’ \ __ .--._ -, - _- ,i. .._ , L.--..- . _I--^-~------/’ / ‘- ,, I f ,,L” ,- --~-..--- .-- ~----- .I . _ - - r~-._ 2-L _____.. ____-__ ---_-_-.___ OM-2017

/ TROUBLE, SYMPTOM jAND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY /

ENGINE AND CONTROLS (Cont'd)I / 19. Engine surges 1. Governor improperly 1A. Adjust governor. See Sect. I under load. adjusted. T 2-3, Para. 3. 3. Binding in governor-to- 3. Free linkage. carburetor linkage.

2. Governor belt slipping. :. Adjust or replace belt as required.

I. Carburetor mixture I. Check carburetor. Adjust either too lean or for proper mixture according too rich. to Ford Maintenance and Operator's Manual. Replace carburetor if defective.

l. Engine timing too fast. 5. Adjust timing according to instructions in Ford Maintenance and Operator's Manual.

7. Faulty ignition. Check complete ignition system and repair as required.

. Engine lacks 3. Insufficient air 9. Check and service air power. to carburetor. cleaner.

3. Restricted exhaust B. Check exhaust pipe for system. restrictions. Check muffler for clogged condition, Replace as required.

2. Carburetor dirty or 2. Clean and/or adjust or re- improperly adjusted. place carburetor as necessary

1. Low compression. I. Check compression in all cylinders according to Ford Maintenance and Operator's Manual. Engine may need new rings or valves.

~~______-_---- ..--.. ------.-.------. - ---.- __-_.--- -.. .-.. ~__

-- _-._-__.-_--.-.----_--~----~~~~_ _-~-_ -_-..______--~--._ Nov 'l/85

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TROUBLE, SYMPTOM hD CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

ENGINE AND CONTROL:; (Cont'd)

12 Engine "misses"-l----7. iA. Fault in ignition Check and correct as follows: at rated speed system. and under load.

(1) Spark plugs (1) Clean spark plugs and faulty. re-gap them. (.042" to .046"). Replace any plugs found to be defective.

(2 1) Distributor (2) Check distributor accord- (E405) faulty. ing to Ford Maintenance and Operator's Manual. Service or replace items as necessary.

(3) Defective igni- (3) Check ignition coil accord- tion coil. (L402) ing to Ford Maintenance and Operator's Manual. Replace coil if defective.

3. Fault in fuel system. 3. Check and correct as follows:

(1) Defective carbu- (1) Check carburetor. Replace retor, float if necessary and send old level too low, or carburetor to overhaul. dirt in carburetor.

(2) Defective fuel (2) Check fuel pump pressure.

pump l If pressure is low, replace pump.

2. Mechanical fault in 2. Check engine compression to engine such as burned determine fault. Send unit valve, defective pis- to overhaul. ton rings, "blown" head gasket, etc.

-. __-- --

;-/x35- .-- 3-l -----. --.--_-.~-_-~__~~. .-_ .-_ Page 13 TROUBLE, SYMPTOM /AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY ENGINE AND CONTROL:;I (Cont'd) Excessive A. Ignition timing too faxI A. Check ignition timing and "pinging" and advanced. adjust according to Ford detonation Maintenance and Operator's under load. Manual in Chapter 5. TB. Poor grade of gasoline, B. Use good, clean gasoline of 92 to 94 octane rating.

c. Fuel mixture too lean. C. Check carburetor main metering system, float level, etc.. Replace carburetor if defective.

D. Engine overheating. D. If engine is running excessively hot, check entire cooling system. Check f,or dirt in system and for dirt outside of core. Check thermostat. Repair as required.

Engine speed 1. Governor improperly I4. Adjust governor. Refer to drops excess- adjusted. Section 2-3, Para. 3. ively when load is applied. 3. Governor-to-carburetor Ia. Free the linkage where linkage binding. binding.

:. Governor-to-carburetor (:. Adjust linkage. Refer to linkage improperly Section L-3, Para. 2, A,'(9) adjusted. and Para. 3.

1. Excessive load on II. See that load does not exceed generator, or defective generator's rating (550A). governor. Re-check engine speed at approximately rated load. If engine speed still drops excessively, replace governor and send old governor to overhaul.

Engine timing is slow. 5. Adjust timing in accordance with Ford Maintenance and Operator's Manual in Chap. 5.

Governor worn or 7. Remove governor and inspect. defective. Replace if necessary.

___--_._ -..-----_-_-“--. 1.1. --.- ~-- X.._..-.-.------..-.- --.-...-.- .._-_ Nov l/85

L------.--- Page 14 x_ ,.’ j ‘1 ,,’ I -._ . . .., */’ /.- I _ . . I ‘. .-J \ /’ I ‘y-y, ‘,--r I - “..... OM-2017 ‘- ’ ._ '. / 1 I J"./ ,,_+-- ---.-A_ , ___-__-__---- .------.---.J_.-_ - .-_.-- .- -. " '. I

PROBABLE CAUSE TEST, CHECK, AND REMEDY

ENGINE AND CONTROLS (Cont'd)

15. Engine A. Governor-to-carburetor A. Check linkage. Adjust and/or response slow linkage either loose, tighten as necessary. when going binding, or out of from idle to adjustment. rated speed 01 from rated B. Ignition timing slow. B. Check ignition timing and speed to idle, adjust in accordance with Ford Maintenance and Operator's Manual in Chapter 5.

c. Engine needs tune-up. c. Tune up engine as required. Refer to Ford Maintenance and Operator's Manual in Chapter 5,

16. Engine A. Dirt or sludge in A. Drain coolant, flush radiator, overheats. coolant. and put in clean coolant. Refer to Section 2-2, Para. 6 and to Ford Maintenance and Operator's Manual in Chapter 5.

B. Debris and dirt on B. Clean radiator core carefully. radiator core. Refer to Ford Maintenance and Operator's Manual in Chap. 5.

17. Engine does 9. Malfunction of governo:r >A. Stop engine by placing igni- not slow down to-carburetor throttle tion switch in STOP/SHUTDOWN to idle with linkage, speed control position. Check and correct speed control switch (S406), or idle as follows: switch in IDLE solenoid (L403). position. (1) Governor-to- (1) Manually check linkage. carburetor If binding, free up the throttle linkage linkage. ! binding.

(2) Speed control (2) With speed control switch switch (S406) in IDLE (DOWN) position, i defective. take resistance measurements between switch ter- ! ! minals. Measure for ZERO I resistance between termi- I nals having red-blue and I orange-yellow wires. Meas- I ure for INFINITY (OPEN) between terminals wired I with brown-red and red , wires, and terminals wired / with black-yellow and $ black wires. Replace i - -- sw~~-i-~.any.-o.fi.,-these I 4 readings are improper. 1---.- v-l&@-- -_---~____ -l_-l-.------.-----"----- .- - .-.---.--_... ..-- - - 1 ? i----..-----.-..-- - --Page15 .. _j ’ ‘\ ’ i . /NC ; ‘\ ‘._.., ,, /- , , \ , , // ‘I. ,-’ , ‘,< I I / -., _, ” .- . . t , ,.L--.--.---\,_~------._--__-. _. - ._ -/ ..~ /‘I ’ ..__ i : ,.” OM-2017 .-,.-'- - -j+- -.---__^-___--._'..i --.--.-- i

DOUBLE SYMPTOM hND CObDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

ENGINE AND CONTROLS (Cont'd)

Engine does (3) Idle solenoid (3) Idle solenoid is located not slow down (L403) defective. just behind carburetor. to idle with Disconnect idle solenoidls speed control wire leads at the quick- switch in IDLI disconnect clips which position. wire the solenoid to (Cont'd) engine circuitry. With clip leads, attempt to operate the solenoid by putting 12-V DC directly into the solenoid from the engine battery., The white wire is positive and the black wire is negative.

Engine will L. Plunger of anti-diesel I!II. Remove engine circuit fuse to not shut off. solenoid (L405, on stop engine. Replace idle Speed control front of carburetor solenoid. switch in IDLE just above its base) position and becomes stuck while ignition engine is running. switch in OFF/ SHUTDOWN position.

.____ ---.--.- -.__l_-l_.------.-. - --. .-.-. _. ^.. -. ._..__.- __-__ .____ _ -Novl/85 , _a- \ ..- . ’ \, --__. __---- _---__ --... OM-2017

TROUBLE, SYMPTOM AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY I" GENERATOR AND CONTR

1. Generator will 4. Flashing power not 4. Check as follows: not build up reaching generator voltage at all revolving field (L406). when push-to- build-up volt- (1) Defective push-to- (1) Momentarily connect two age switch build-up-voltage jumper leads across the (S407) is switch (S407) push-to-build-up-voltage operated. (contacts stuck in switch; one lead across Engine running open position) the terminals on the left normally side and the other lead across the terminals on the right side. If the voltage builds up, replace switch.

(2) Defective diode (2) Use ohmmeter to check (CR401) diode on back of push-to- build-up-voltage switch. Replace diode if defective.

(3) Excessive brush (3) Check brushes closely for wear, or poor excessive wear and check contact of brushes brush contact with slip to slip rings. rings. Replace brushes if excessively worn, and make sure that brush contact with slip rings is proper.

3. Voltage sensing relay 3. Connect a jumper lead (K404) defective. between pins 1 and 3 on Relay contact l-7 or voltage sensing relay 3-9 stuck in open (5, Fig. 3). If voltage position. then builds up &en switch S407 is pushed, voltage sensing .relay is defective and must be replaced. If voltage sensing relay is good, proceed to Step C.

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-T HJBLE, SYMPTOM JD CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

-G JERATOR AND CONTROLS (Cont'd) T I. Generator will 2. Generator revolving 2. Locate yellow and red-orange not build up field (L406) defective. wires on terminal strip that is voltage at all just beneath base of voltage when push-to- sensing relay (at rear of build-up volt- control panel). Disconnect the age switch yellow and red-orange wires (S407) is which go down to the generator. operated. (Refer to connection diagram Engine running 488860 in Chapter 5). Measure normally. resistance between these two (Cont'd) wires. Should be 6 to 8 ohms. If reading indicates an open, short or lower than normal resistance, proceed to Step D.

1. Defective generator I. If check of the generator armature (G402) revolving field (Step C above) revealed no trouble, the generator armature is defective. Send unit to overhaul.

Generator builds 1. Generator voltage i. Replace voltage regulator up to only a low regulator fuse (F403) fuse (4, Fig. 3). Resume voltage while blown. operation of generator set to push-to-build- see if problem is corrected. up voltage If not, proceed to Step B. switch is depressed. I. Defective control 3. Check control winding rec- winding rectifier tifiers (3, Fig. 3) with an ohmmeter to see if they are good. If either rectifier is defective, replace it. If both rectifiers are good, proceed to Step C.

:. Generator voltage :. Replace voltage regulator regulator (VR402) (1, Fig. 3). defective.

- -&-.1_;- .-.Nov l/85 PROBABLE CAUSE TEST, CHECK, AND REMEDY I GENERATOR AND CONTE .S (Cont'd)

3. Generator volt- \. Voltage sensing relay i. Remove voltage sensing relay age builds too (K404) defective. (5, Fig. 3) from its socket high a voltage. Relay coil is open or and apply 24V DC to the coil contacts l-7 and 3-9 (terminals A and B). Using stuck in closed an ohmmeter, check to see that position. contacts open and close properly. If voltage sensing relay is defective, replace it. If not , proceed to Step B.

5. Defective voltage It3. Replace voltage regulator regulator (VR402). (2, Fig. 3) with a voltage regulator known to be good, and resume operation of generator set. If new voltage regulator produces normal operating voltage, send old voltage regulator to factory for service. t. Load contactor :AUTION: DO NOT OPERATE THE GENERATOR SET TO DELIVER POWER will not close TO AN AIRCRAFT WHEN ANY PROTECTIVE DEVICE OR OTHER when contactor COMPONENT IS JUMPERED. close switch (S408) is L. Defective contactor 9. Momentarily connect a jumper operated. Engine close switch (S408). lead between terminals 4 and 5 running normally (red and yellow-red wires) on voltage normal, the contactor close switch (11, no load applied Fig. 2). If the load contactor to output cable. closes momentarily, replace contactor close switch.

i. Defective load 3. If load contactor (22, Fig. 1) contactor (K402). will not close when contactor close switch is jumpered, it is likely that the contactor is defective. Replace contactor.

I. Overvoltage relay Z. Connect a jumper lead between (K403) defective. terminals T and P on the overvoltage relay (2, Fig. 3). If contactor will now close, replace overvoltage relay.

3-1 Page 19 TROUBLE, SYMPTOM AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

GENERATOR AND CONTR ,S (Cont'd)

5. ,Load contactor L. Defective contactor L. Connect a jumper lead between iopens as soon close switch (S408). terminals 1 and 2 (orange-red ,as contactor and yellow-red wires) on the close switch is contactor close switch (11, released from Fig. 2). If the load contactor its top (spring- now remains closed, replace loaded) position contactor close switch.

i. Defective resistor R406 1. Using an ohmmeter, check (located in back of resistor R406 for proper control panel, on resistance (7.5 ohms). If terminal strip beneath an open circuit is indicated, base of voltage sensing replace resistor. relay. See connection diagram 488860)

:. Defective diode CR402. :. This diode is also located on the terminal strip beneath the voltage sensing relay. Using an ohmmeter, check this diode for an open circuit. If diode is defective, replace it.

1. Load contactor (K402) 1. If no fault was found in steps defective. 4A, B, and C above, 'theload contactor (22, Fig. 1) is defective. Replace load contactor.

3. ,Load contactor 1. Contactor opening could 1. Resume operation and closely iopens during have been normal because observe voltmeter (6, Fig. 2) power delivery. of an overvoltage for evidence of overvoltage. condition. If contactor opens when no overvoltage condition exists, proceed to Step B.

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TROUBLE, SYMPTOM AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

I I GENERATOR AND CONTROLS (Cont'd)

5. Load contactor 3. Overvoltage relay (K403) 3. Check overvoltage relay by opens during defective. operating the machine under power delivery. load and gradually raising (cont'd) voltage at the voltage regulator (1, Fig. 3) while observing voltmeter (6, Fig. 2). Start with a low voltage (25-V DC) and gradually increase voltage until relay functions to open load contactor. If relay trips at less than 32-V DC, replace relay (2, Fig. 3) and return old relay to factory for service.

:. Load contactor (K402) 2. If no fault was found in Step E defective. replace load contacts (22, Fig. 1).

7. Output current L. Defective current limit- 1. Shut down engine and check cannot be limiting potentiometer (R402) current limiting potentiometer ed by operating (4, Fig. 2) with an ohmmeter. current limiting To do this, disconnect plug potentiometer. from generator voltage regulator (1, Fig. 3) and take resistance measurements from pin 2 to pin 9 and then from pin 2 to pin 10 on the plug. For each measurement, slowly turn potentiometer through its entire range, while observing ohmmeter readings. Replace potentiometer if defective. If it isn't defective, proceed to Step B,

I. Defective voltage 1. Replace voltage regulator with regulator (VR4020 one known to be good, and then operate the generator set under sufficient load to observe current limiting. If current limiting potentiometer now controls current properly, send old voltage regulator to factory for service. _a----.l __---II_ ------.. ---.---_--_ ---- 3-l Nov--l&85------__-..-- .-..- ~-- ._I - .___ _-----.- -_.. _ -.. -. ._ _ .__. Page 21 ---. -. - - -.__, _ _ -.--I.-.-- - ,^.___.__-. This page intentionally left blank.

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CHAPTEK 4. ILLUSTRATEU PARTS LIST

SECTION 1. INTRODUCTION

1. General

The illustrated Parts List identifies, describes, and illustrates main assemblies, sub-assemblies, and detail parts of a self-propelled generator set manufactured by Hobart Brothers Company, Power Systems Division,, Troy, Ohio 45373.

2. Purpose

The purpose of this list is to provide parts identiEication and descriptive information to maintenance and provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts.

3. Arrangement

Chapter 4 is arranged as follows:

Section 1 - Introduction Section 2 - Manufacturer's Codes Section 3 - Parts List Section 4 - Numerical Index

4. Exnlanation of Parts List

A. Contents

The parts list contains a breakdown of the equipment into groups, assemblies, subassemblies, and detail parts. All parts of the equipment are listed except:

(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are available commercially.

(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.

(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to other parts, weldments, or assemblies.

B. Parts List Form

This form is divided into six columns. Beginning at the left side of the form and proceeding to the right, columns are identified as follows:

Nov l/85 4-l

Page 1 \ .-.

‘..

,, \.. i ., .. OM-2017

(1) "FIGURE-ITEM NO." Column

This column lists the figure number of the illustration applicable to a particular parts list and also identifies each part in the list by an item number. These item numbers also appear on the illustration. Each item number on an illustration is connected to the part to which it pertains by a leader line. Thus the figure and item numbering system ties the parts list to the illustrations and vice versa. The figure and index numbers,are also used in the numerical index to assist the user in finding the illustration of a part when the part number is known.

(2) "HOBART PART NUMBER" Column

ALL part numbers appearing in this column are Hobart numbers. In all instances where the part is a purchased item, the vendor's identifying five-digit code and his part number will appear in the "NOMENCLATURE" column. Parts manufactured by Hobart reflect no vendor code or part number in the "NOMENCLATURE" column.

(3) "NOMENCLATURE" Column

The item identifying name appears in this column. The indenture method is used to indicate item relationship. Thus, components, of an assembly are listed directly below the assembly and indented one space. Vendor codes and part numbers for purchased parts are shown in this column. Hobart modification to vendor items is also noted in this column.

(4) "EFF" (Effective) Column

This column is used to indicate the applicability of parts to different models of equipment. When more than one model of equipment is covered by a parts list, there are some parts which are used on only one model. This column is used for insertion of a code letter "A", IIBW,etc., to indicate these parts and to identify the particular model they are used on.

Parts coded "A" are used only on Spec 6878-l units. Parts coded "B" are used only on Spec 6878-2 units.

Uncoded parts are usable on all models.

(5) "UNITS PER ASSEMBLY" Column

This column indicates the quantity of parts required for an assembly or subassembly in which the part appears. This column does not necessarily reflect the total used in the complete end ; item.

._i _- --.- _I- ---.------.--- -.--__ 4-l Nov 1185 -. ..--- _._,-...-.. - --.- ..~ _-.- __ ' -Page..2... .i .._ .__.,-._ .- - -_.-...-... -_- -._.-~ __.. -. . - _ -' OM-2017

REF. LOC ---‘ION REF. LOCATION REF. DES. -- ITEP FIG. DES. --ITEM --FIG. DES. i ---_ T - A401 28 5 M406 7 6 A402 NS 5 M407 6 6 B401 37 5 P401-P403 NS 5 BT401 5 5 P404-P405 28 6 c401 9 11 29 6 10 5 R401 NS 5 C402 41 6 R402 4 6 CR401 13 6 5 6 14 6 R403-R405 8 5 15 6 R406 31 6 CR402 32 6 R407 9 14 CR405-CR410 5 14 R408 42 6 CR411-CR416 6 14 s401 22 6 CR417-CR418 26 6 23 6 CR419 NS 21 s402 30 5 CR420 32 6 S4Q3 23 5 DS401,DS402 8 6 S404 6 6 DS403,DS406 9 4 9 6 DS407 19 6 s405 9 6 DS408 9 6 10 6 16 6 S406 9 6 E401-E404 NS 5 18 6 E405 NS 5 s407 13 6 E406 3 20 14 6 F401 11 6 15 6 12 6 S408 9 6 ,: F402 11 6 16 6 12 6 vR401 NS 5 F403 12 6 VR402 28 6 27 6 29 6 G401 NS 5 6402 12 5,21 5401-5403 NS 5 J404,5405 NS 5 K401 1 20 K402 2 7 K403 29 6 30 6 K404 38 6 L401 7 19 L402 5 19 L403 NS 5 L404 NS 5 L405 NS 5 L406 NS 21 M401 24 6 M402 20 6 M403 2 6 M404 3 6 M405 1 6 ._, NS-NOT SHOWN Nov l/85 Reference Designator Index 4-1 Figure 1 Page 3 OM-2017

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4-l Nov l/85

Page 4 1. Explanation of Manufacturer's (Vendor) Code List 1

The following list is a compilation of vendor codes with names and addres- ses for suppliers of purchased parts listed in this publication. Thelcode; are in accordance with the Federal Supply Codes for Manufacturer's Catalog ing Handbook H4-1, and are arranged in numerical order. Vendor codesiare inserted in the nomenclature column of the parts list directly following the item name and description. In case a manufacturer does not have a ven dor code, the name of the manufacturer will be listed in the nomenclaiure / column.

I CODE VENDOR'S NAME AND ADDRESS I

02231 Anchor Rubber Company 840 S. Patterson Blvd. Dayton, Ohio 45402

04713 Motorola Inc. Semiconductor Products Div. Phoenix, Arizona 85008

05277 Westinghouse Electric Corp. Semi Conductor Div., Hill Street Youngwood, Pennsylvania 15697

07575 Blackstone Corp. 111 Allen St. Jamestown, NY 14701

08452 Westinghouse P.O. Box 300 Sykesville, MD 21784

08786 Taylor-Dunn Mfg. Co. 2114 W. Ball Road Anaheim, CA 92804

13445 Cole-Herse 20 Old Colony Ave. Boston, MA 02127

14655 Cornell Dubilier 209 W. Central St. Natick, MA 01760

15605 Eaton Corporation 4201 N. 27th St. Milwaukee, Wisconsin 53216

16476 Datcon Instrument Co. P.O. Box 128 East Petersburg, PA 17520 --A--- --&v-.l.$8~ _ ----___c______~- -.--_ VENDOR'S NAME AND ADDRESS

HB Instrument Co. American and Bristol St. Philadelphia, PA 19140

Deltrol Controls 2745 S. 19th St. Milwaukee, WI 53215

31510 Mainline Supply Co., Inc. 905 E. Third St. Dayton, OH 45402

Facet Ent. Inc. US. No. 1 Bypass South Henderson, NC 27536

3,708b Tridon Limited P.O. Box 1600 Nashville, TN 37202

Modine Mfg. Co. 1500 Dekoven Ave. Racine, WI 53401

Ohmite Mfg. Co. 3601 W. Howard St. Skokie, IL 60076 I 416992 Phoenix Electric 3625 N. Halstead St. Chicago, IL 60613

Protect0 Seal Co. 225 W. Foster Avenue Bensenville, IL 60106 41589 ST - SEMICON, INC. 415 N. College Ave. Bloomington, Indiana 47401

+7448 Allis Chalmers Corp. 275 Ridgeway Avenue, P.O. Box 1367 I Aurora, Illinois 60507 / 70741 Triplett Electrical Instrument Company 286 Harmon Road I Bluffton, Ohio 45817 I 1864 TRW-Inc. United Carr Div. P 31 Burlington Mall Rd. Burlington, MA 01803 b--- 1. I 4- Nov 1183 L-..--ii -----I--_p- L..------______--_- -Y /- 1 ‘i .,..’ . r ‘. I _......

-. OM-2017 '.\*. CODE VENDOR'S NAME AND ADDRESS

70411 Anderson Brass Co. 100 S. Campbell Ave. Detroit, MI 48209

71400 Bussman Division of McGraw-Edison Company 114 Old State Rd. St. Louis, Missouri 63178

74465 Hoof Products 4051 w. 51st St. Chicago, IL 60632

74559 Carling Switch Co. 505 New Park Ave. West Hartford, CT 06110

75175 K-D Lamp Co. 1910 Elm St. Cincinnati, OH 45210

77343 Potter SrBrumfield, Inc. 200 Richland Creek Drive Princeton, IN 47671

77977 Signal-Stat Corp. 1200 Commerce Ave. Union, NJ 11211

78189 Illinois Tool Works Inc. St. Charles Rd. Elgin, IL 60120

78377 SCP Inc. 9115 George Ave. Cleveland, OH 44105

78940 United Air Cleaners 9705 S. Cottage Grove Ave. Chicago, IL 60628

7 9409 Woodhead Daniel Co. 3411 Woodhead Dr. Northbrook, IL 60062

81640 Eaton Corp. 2074 Whitfield Ave. E. Sarasota, FL 33580

83613 Kirkhill Inc. / 12021 S. Woodroof Ave. ” .__ _i-- ..-- __- Do~.ee_y-,-CA---.9.~~~~_--.-.-----..~...-.----: __._._-- 'Nov l/85 4-2

..~.~. . .._~_ __...... _. - ^ .-._..... - ._._ -...- ..,. _.___.__.--.--... ----.--..-.. _..~.. .- ~~ .I-.-. __ Page!3 . ,a’ I ! I..- ,-” -.. i _’ I . . ,:- --. . I

I .- .., : ‘. .._ .OM-2OI7-~. -..._-

CODE VENDOR'S NAME AND ADDRESS

90927 Ford Motor Co. Ind. Engine Operations 300 Renaissance Ctr. P.O. Box 43338 Detroit, MI 48243

91636 Curtis 34999 Curtis Blvd. Eastlake, OH 44094

94222 Southco Inc. 210 N. Brinton Lk. Rd; Concordville, PA 19331

96152 Borg Warner Corp. 2195 S. Elwin Rd. Decatur, IL 62525

N,oNumber Pipe d Supplies Inc. 329 E. Poplar St. Sidney, OH 45365

-. i,z!l- I_--- ______-_ 4-2, Nov l/85: - _ .- ...~.._.-..-.. .--.__ .._.__.__._ _I_- _ -- -.--.------..---. --. -..- . - .. _ __ Bage 4." ..- ,." ",. .-.-----.- - ..--..-.-._ ----.-.-..~- _...... _ -. OM-2017..

SECTION 3. PARTS LIST

1. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a left-hand page and the applicable parts list will appear on the opposite right-hand page. Unless the list is unusually*long, the user will be able to look at the illustration and read the parts list without turning a page.

2. Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list.

* - item not illustrated A, or AMP - ampere AC - alternating current AR - as required DC - direct current Fig. - Figure hd. - head hex - hexagon Hz - Hertz (cycles per second) I.D. - inside diameter IN - inch kVA - kilovolt-amperes IJF - microfarad No. - number NHA - next higher assembly R - Ohm OM - Owners Manual PRV - peak reverse voltage PSI - pounds per square inch Ref - reference (the item has been listed previously) TM - Technical Manual T-R - transformer-rectifier v - volt (when used as a prefix to a five-digit number, indicates vendor code)

NOTE: An item which does not reflect an index number is an assembly which is not illustrated in its assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated

Nov l/85 4-3 Page 1 _’ -_ _ ,- .’ : -‘i.

/,’ -. : *. __\ _. .- -. -...... _’ ’ I.. .. -’ OM-2017.

II 6 2

STATIONARY UNIT (s-6878-1)

7 8

SELF- il PROPELLED UNIT (s-6878-2)

u ’ 23 .

Generator Sets Figure 1 -.. .- .-.~--_-._. -.-._--.-.-~ .------_I__.__~ --____ ~-___ ..-. ~.~ ~-.-~ - --._ 4-3 Revised Jun 22/87 ---,---_-^-.-_.-.-.- "-_-" .-...__. _. _ Page 2. ".,, _ _ -_--.----_-.--_I-~.-.___--.I -.

- OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 EFF ASSY l- 6878-l GENERATOR SET, 28.5-V DC, STATIONARY MTG.A 1 6878-2 GENERATOR SET, 28.5-V DC, SELF-PROPELLED B 1 1 489502 . BODY, VEHICLE, ASSY., V08786,NO.B2-48 B 1 (For Details See fig 20) 1A 485477 . BOX, PLUG ASSY. B 1'

l (F or Details See fig 20) 2 4889418 . CANOPY ASSY. (For Details See Fig.2) A 1 3 489494 . CANOPY ASSY. (For Details See Fig.2) B 1 *4 No Number . GENERATOR SET WITHOUT CANOPY (For Details See Fig. 3) 1 5 489476 . PANEL, CONTROL, ASSY. (For Details See Fig. 4) 1 6 No Number . FRAME, LIFTING YOKE, ASSEMBLY (For Details See Fig. 15) 1 7 408426 . CANOPY, CAB, STEEL, GROUP (OPTION) B 1 8 408427 . DOOR, METAL, SLAM, SET OF TWO (OPTION) B 1 * 9 408438 . MIRROR, RIGHT SIDE NO. V2-008-31 B 1 LEFT SIDE NO. V2-008-30 B 1 10 402987 . NAMEPLATE, HOBART 2 11 6FW-5072 . CAP, FUEL, V49234, NO. 1273 1 * 12 408424 . PAD, VIBRATION B 4 * 13 488880-l . KIT, TRAILER WITH FENDERS, m~mRs, & CABLE TRAYS (OPTION) (For Details See Fig. 16) 1 * 14 488880-2 . KIT, TRAILER, WITHOUT FENDERS, BUMPERS, StCABLE TRAYS (OPTION) (For Details See Fig. 15) 1 15 84B-1078 . LABEL, OPERATING INSTRUCTIONS 1 16 81B-1064 . LABEL, ENGINE DRIVE 1 17 81B-1084 . LABEL, NAMEPLATE, 28-V DC 1 18 408437 . LABEL, WARNING LIFT B 3 19 489795 . PAN, DRAIN ASSY. B 1 20 489830 . SOCKET, ASSY. A 1 401564-3 . . HOUSING, SOCKET, CONNECTOR A 1 21 DDW-495-12 . CAP, RAIN, EXHAUST B 1 * 22 405042-2 . CONTACTOR (LOCATED ON VEHICLE BODY) V50603, NO. HB309AH B 1 23 489473 . WRAPPER, AIR CHAMBER B 1 * 24 489472 . SHIELD, HEAT, ASSY. B 1 488952 . KIT, SPACERS, STATIONARY MOUNTING (OPTIONAL) A 1 25 488904 . . BRACKET, SPACER (OPTIONAL) A 4

* Not Illustrated

Jun 22187 Revised I~ 4-3 / a._ ,,I. _-’ 1 -. ’ ‘.. .I’ -. . . . , ,.’ 1 ‘. ._ -’ ._, , *-’ . +.’ $ ~.~ _ -. -- ---’ 7 OM-2017

Canopy Assembly Figure 2

‘~~4-3. +- -.- __^.. __- .-.. ----..----.- ._-. Nov l/85 I

Lpage.. ‘4 -~ ~...__. -.. _ - . __ ----- .-... --...- .~. ..-----I--..------_ b ._ .,._ . .._ ,... _,.. ..- - ..-. - --.- -.- -. -. - ._ ..- __. -..---. ._-..-.._ -.. UNITS I

FIGURE HOBART ; per / ITEM NO. PART NO. 1234567 EFF ;ASSY I I A i 1 / 2- 488941A CANOPY ASSY (For NHA See Fig. 1) j 489494 CANOPY ASSY (For NHA See Fig. 1) B I1 / 489445 . PANEL, TOP, REAR ASSY. j 1 488939 . PANEL, GEN. INSULATION, LT, ASSY. j 1 488933 . PANEL, CANOPY, ENGINE ASSY. : 1 488938 . PANEL, ENGINE, INSULATION ASSY. j 1 488822 . PLATE, CATCH, DOOR i 1 488820 . PANEL, CENTER RT. CANOPY j 1 488640 . BRACKET, OUTPUT CABLE ASSY. il 488866 . SUPPORT, CONTROL PANEL, RT. ASSY. ; 1 404101-l . LIGHTS, CLEARANCE, V75175, NO. 514-0168 ; 4 j 1 10 488592 . COVER, CONTROLS / 11 84A-1053 . PLATE, ADHESIVE, V94222 NO. 02-14-201-14 i 2 12 403127 . CATCH, MAGNET DOOR, V94222 I

NO. 02-10-201-10 / 2 1 13 488639 . PANEL, LOWER REAR ; 1 14 488865 . SUPPORT, CONTROL PANEL, LEFT ASSY. ; 1 15 488940 . PANEL, GEN. INSULATION RT., ASSY. j 1 16 488799 . COVER, OUTPUT CABLES j 1 17 488631 . PANEL, CENTER, CANOPY ASSY. j 1 18 488858 . PANEL, SIDE, LT, REAR ASSY. i 1

19 488580 . YOKE, LIFTING ASSY. ! 1 j 20 81B-1019 . LATCH, T-HANDLE 12 i 21 488942 . DOOR, ENGINE, INSULATION, LT ASSY : 1 I 22 848-1096 . LATCH, BOLT STEEL / 23 488790 . SPACER, LATCH ;,l 4 24 488632 . PANEL, SIDE, RT. ! 1 25 488791 . ACTUATOR, RELEASE CATCH 11 , 26 489529 . PANEL, FRONT A j 1 489556 . PANEL, FRONT B j 1 1 27 489530 . COVER, TAIL PIPE A I 1 28 488633 . SUPPORT, FRONT PANEL j 4 29 488635 . PANEL, ACCESS BATTERY i 1 Y 30 407366 . LABEL, CAUTION INSUFFICIENT COOLING ! 1 ! 31 81B-1063 . LABEL, HOT WATER Q STEAM 11 32 8411-1071 . LABEL, ACCESS PANEL !j 1 ,

33 406001 . LABEL, DANGER, MOVING PART ; 1 1 34 402987 . NAMEPLATE, HOBART '1 35 406000 . LABEL, ENGINE FUEL z: a1 36 76B-1149 . LABEL, GASOLINE i 1 37 403153-l . FOOT, RUBBER STOP, V83613, NO. B-232A 2 38 75-422-o . CLAMP, OUTPUT CABLE ) 1; 39 41505 . SLEEVING, FIBERGLAS, #5 i 23"; 40 489492 . PANEL, LOUVERED, ASSY. B j 11 * 41 489473 . WRAPPER, AIR CHAMBER B i 1/ * 42 489472 . SHIELD, HEAT, ASSY. B j 11 c----r -_--____~_ -- R 1 .I Nov l/85 T--q i i --^ -.-.b- - -_--.I ~--I..--._.-_-_-- _-__ -_- ...------^ __I_.-_* - _ _. _ _ ~ .--...-L? Page 5 i- 1....- - “..- .-__.-.r “.- __. ------._-__ - 43 I 44

2 _. ._. _ .__“.._.._-..-_.- ~..~.~~ -.-- - .-.- - OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

3- No Number GENERATOR SET WITHOUT CANOPY (For NHA See Fig. 1) REF 1 No Number COOLING SYSTEM (For Details See Fig. 11) 1 2 489534 . GUARD (For Details See Fig. 11) 1 3 408419 . CARBURETOR, V31695, NO. o-14024 MOD. 33AW8 1 3A 84A-1097 . . VALVE, SOLENOID SHUT DOWN V31695, No. B75-22 1 * 3B 408435 . . KIT, CARBURETOR OVERHAUL v31695, REF No. K-2220 3c NO Number . . GASKET, CARBURETOR 1 4 404898 . IDLING DEVICE (For Details See Fig. 7) 1 5 402086-l . BATTERY, 12 V (For Details See Fig. 8) 1 6 488571 . SUPPORT, ENGINE, LEFT ASSY. 1 7 488868 . RELAY, OVERSPEED, (For Details See Fig. 17) 1 8 487050-4 . RESISTOR ASSY., PRELOAD 1 9 405278-6 . CAPACITOR, V56289, NO. 36DX413G075DF2A 1 10 361052-g . CLAMP, MTG., CAPACITOR, V56289, NO. 4586-2 1 11 488800 . SUPPORT, CAPACITOR 1 12 488947 . GENERATOR, (For Details See Fig. 17) 1 13 NO NUMBER . ENGINE EXHAUST (For Details See Fig. 14) 1 14 488613 . SHROUD, FAN ASSY., (For Details See Fig. 11) 1 15 488576 . SUPPORT, ENGINE RIGHT ASSY. 1 16 No Number . FUEL SYSTEM (For Details See Fig. 9) 1 17 488870 . SUPPORT, FUEL TANK, CONTACTOR ASSY. (For Details See Fig. 5) 1 18 488901 . GOVERNOR (For Details See Fig. 6) 1 19 407713 . CLEANER, AIR, V78940, NO. B-lB33 1 20 5CW-2163-2 . HOSE, BREATHER 1 21 W-10869-15 . CLAMP, HOSE, BREATHER, V35708, NO. HS12 1 22 488948 . RECTIFIER ASSY. (For Details See Fig. 12) 1 23 403809-2 . SWITCH, OIL PRESSURE 1 24 78B-1118-1 . SENDER, OIL PRESSURE, V16476, NO. 02504 1 25 488565 . FRAME, MTG. ASSY. (For Details See Fig. 15) 1 26 w-11294-1 . NUT, WING 1 27 492572 . ROD, AIR CLEANER 1 28 78B-1119-1 . TEMPERATURE, SENDER, V16476, NO. 02019 1 29 DELETE 30 400581 . SWITCH, VACUUM, V13445, NO. 9253 1 31 No Number . REGULATOR, VOLTAGE, V90927, (Supplied W/Engine) No. E2P2-10316-A 1 32 w-10909-1 . TEE, STREET, BRS. 1 33 w-10119-1 . COUPLING, PIPE STEEL (PIPE & SUPPLIES, INC.) 1 34 w-10750-1 . NIPPLE, PIPE, l/8, V31510 1 35 W-7814-O . BUSHING, PIPE, STEEL 1

36 _-..W-7814-1-..-. ---._...__ .._.._._.__ -_..~---.~~.--..--J.--.-.-,--.-.--__. BUSHING PIPE STEEL

Jun 1218 7Aeyised ____..____-.._ -__. _.-_I______.__.__ --_ ...-... - ._.__..-_.._.-_._ __ ,__ -...- __ 4-3 .-.------.-_. -.--_----.-.-. _-. Page 7 OM-2017 j

This page intentionally left blank.

14-3 Nov l/85;

I page .& ..- .- , --_--__ OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 EFF ASSY

3-37 No Number . STARTER,v90927 (SUPPLIED WITH ENGINE) NO. E4DF-11001~AA 38 No Number . PUMP, FUEL,v90927, (SUPPLIED WITH ENGINE) NO. EOFZ-9350-A 1 39 No Number . GASKET, CARBURETOR, V90927, SUP- PLIED W/ENGINE) NO. E3TZ-9447-A 1 40 407834 . ENGINE, FORD, V90927, MODEL LSG-423 1 * 41 407835 . KIT, ENGINE PARTS 1 42 489818 . RELAY, ASSY. B 1 43 489658-3 .. DIODE ASSY. B 1 44 408472 .. RELAY B 2 45 489813 .. BRACKET, RELAY SUPPORT B 1

* Not Illustrated

.~ .~~ Aug 17/87 Revised

. - ..- - . -....__...~--.- - Page- --_. 9 .- ! ‘, “a-- _- ‘. ,.’ I . . / . . .’ _, ‘- 1. _,. .’ . .

‘,. : .‘ ’ . . OM-2017 ~

\ \

‘T TACHOMETER@)

OIL PRESSURE WATER TEMfJ

/ RATED RPM

I 24 36

Control Panel Assembly Figure 4

Nov l/85. i Page 10 This page intentionally left blank.

~______Nov ,185 4-i I_-_--__I_ - .-"-.-.-- --.--.._ -..-__' __.__ - Page 12

..-_I_----i.- -..-.._-..-..._ ---_--.-- .._.. - ..^._, NOMENCLATURE UNITS FIGURE HOBART per 'ASSY ITEM NO. PART NO. 1234567

4-36 385765 . CONTROL, CHOKE 37 488598 . COVER, 14V OPTION 38 403056-4 . RELAY, ENCLOSED, DPDT, 24V DC V77343 NO. KUP-llO-15-24VDC 1 1 39 403055-2 . SOCKET, RELAY, V77343, NO. 243067 40 16DA-4253-2 . SPRING, RETAINING RELAY 41 405485-l . CAPACITOR, 0.1 uF, 400 VDC, V14655, NO. DPMS4P1 1' 42 W-9714-25 . RESISTOR, 10 OHM, 2 WATT 1 43 489918 . DOOR, RHEOSTAT, ASSY 1 44 76A-1115 . LATCH, ADJUSTABLE GRIP : 1 2 * 45 405608 . CLIP, WIRE * 46 42543 . INSULATION, SLEEVING, FIBERGLAS 8"

* Not Illustrated

;._ - ..- -. ,,_ I I Support, Fuel Tank, Contactor Assembly I Figure 5 i ,_- ._ .- --.--..-.-._ ..._ - ._-.- . -..._--_ __ _I--.- I / 4-3 I I 1 --._j...------_--- --.. -.. _.- 1--, - -... -.--_---_ ,.-______- _I_-Nov l/8$ i / NOMENCLATURE IUNITS FIGURE HOBART i per ITEM NO. PART NO. 1234567 : ASSY

5- 488870 SUPPORT, FUEL TANK, CONTACTOR ASSY. (For NHA See Fig. 3) 1 1 488601 . SUPPORT, FUEL TANK ASSY. 1 2 84C-1092 . CONTACTOR, V26659, NO. JGA6003A 1 3 488990 . BUS, STUD, CABLE 2 4 5cw-975 . BUSHING, INSULATOR 2 j 5 5CW-2127 . BUSHING 2 ! 6 w-11242-10 . WASHER, FLAT, 3/8, ST. 4

/ 7 w-11254-6 . WASHER, LOCK, 3/8, ST. 4 8 w-11278-5 . NUT, 3/8-16, HEX. ST. 2 9 400435 . NAMEPLATE, 28 VOLTS 1 10 w-11097-8 . SCREW, 3/8-16 X 2 HHC. ST. 2 I 11 5CW-976A . WASHER, INSULATOR 4

_ I - ,-. “.A--- --~-----_--- _-.~- .._ --.----- _---~-__-___~--~. E :, Nov l/85 i 4-f - . -. I, ,_-- ..- _..-_--. .- . . . ..~_. ___._-...__.. .,-. - _.- . . . ..------.--...... L -._. .^_

L ^ ._ ._x. . ._ . _ . . ._ Page 15 Governor Figure 6 /

- . . --.‘-----.-.------. .-- ---.--- __--- -.-. ~~-_---._-. --- .- ~-~_.-_-__I_ --- __._ ---_.. 2 4-3. Nov l/85 ' Page 16 . _ ,^-,, __.-, --..--_^ ,..-....--.-.. -__ _.._--..- .--- ._.-c OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

6- No Number GOVERNOR ASSY. (For NHA See Fig. 3) 1 1 488901 . GOVERNOR, V74465, NO. BD875C 1 2 402908 . JOINT, BALL, V57448, NO. TF-4Y 2 3 488842 . SPACER, GOVERNOR, ROD 1 4 w-9476-39 . ROD, GOVERNOR THROTTLE 1 * 5 180959 . STOP, PULLEY GOVENOR 1

Nov 18/87 Revised

Page 17 p-FiEq

/ I / 1 / Idling Device Assembly I / Figure 7 I.%_ ,.. .-^_--.i-__-_ ---~ -- ---.---.--..----.-_-_-- -..- .__~_ --.-.-___ -___-----.----.A-: Nov 1183 ; II4-3 ---. - .- __-. ..-.. .._--.. -.--- .~-I ., .._ ._. ..~~~~- _.. -..._ -- - -. _. .^_._ ~--.-. _ _ _ _: .. 1 1 Page 18 _-.- ."..-- ...- . _ -.--.---___--_ -,.-._.. - --i CjM-2017 - ..- _--- ~.~_. ~--. .--.-.....-...-... ~------~- --- -.--.- NOMENCLATURE 'UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

7- 489946 IDLING DEVICE ASSY. (FOR NHA SEE FIG. 3) REF 1 404898 . DEVICE, IDLING, V28478, NO. 54699-63 1 2 489947 . ROD, IDLING DEVICE 1 3 493114 . BRACKET MTG, IDLING DEVICE 1 4 No Number . WASHER, FLAT 4 5 No Number . SCREW 4 6 12Cw-908 . CLAMP, FUEL LINE (Separate item not part of assembly) 1 7 (DELETED) 8 16DA-954-O . PIN, SPRING 1 /* .

1 Battery Installation b-_ "--. +------.--F~~e..~.~--~.---.-.-~------i 4-3; Nov l/8$ kE --2o-., _-."- ..^ ._- .---...-.^ -- _.__--. -.-.-_- ____ .___~__...._, _ NOMENCLATURE UNIT? FIGURE HOBART per I ITEM NO. PART NO. 1234567 ASSY / 8- No Number BATTERY INSTALLATION (For NHA See Fig. 3) REF 1 12cw-1915-2 . CABLE ASSEMBLY (NEG.) 1 2 12cw-1914-20 . CABLE ASSEMBLY (POS.) 1 3 No Number . NUT, PLAIN, HEX, 5/16-18 2 4 No Number . WASHER, FLAT, 5/16 IN. 4 5 491687 . ROD, BATTERY CLAMP 2 6 491962-1 . CLAMP, BATTERY 1 7 402086-l . BATTERY, 12V 1 / 8 488614 . TRAY, BATTERY 1' 9 488588 . GUARD 1 * 10 488949 . COVER, BATTERY TERMINAL 1'

* Not Illustrated

3 :, Nov l/85 ; 4-3;

Page 2$ /’ I ! ‘1 -I-, , -5 /,,. .. I . , 2 I -‘.-l ‘.. :<’ I _ .’ ‘-.* / .- .,’ -. I / L-5 -.._. -.-.-> ” ---_ ._. / _) ^ _. ” z . Oi?wDli~ ,_ _.A’ ‘- ._ i ‘H .------._- .------, _.-.__-._-----.-~ -...--.. _)I:- ----. -..- .--- -- _--._ ------..-

6’

Fuel System Figure 9

I , ,_ - .- _- 02 -_- --.- -.___.-__-I~ -_- ..-- -.-.- --.-.--- --...--.-.___-_ .--__ 4-3 ,j Nov l/8.5 NOMENCLATURE /UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

9- No Number FUEL SYSTEM (For NHA See Fig. 3) REF 1 488611 . TANK, FUEL ASSY. 1 2 ~FW-5072 . CAP, FUEL TANK, V49234, NO. 1273 1 3 5Cw-3420-l . GUAGE, FUEL TANK 1 4 486567-2 . STRAP, FUtiLTANK ASSY. 2, 5 483630 . INSULATION STRAP, FUEL TANK 2 6 488870 . SUPPORT, FUEL TANK, CONTACTOR (For Details See Fig. 7) 7 488946 . FUEL LINE ASSY. (For Details See Fig. 12) 8 358493 . SHIELD, SAFETY, FUEL TANK 9 81B-1061 . LABEL, ELECTRIC SHOCK

.~__-__--~-~~~-__-~_-_~-.-.-. _.._ ~_ .---.-. ~~- -_.-- -..- --____ ----___.- . ..-_---_-_.I_ -- 7 E Nov21/85 4-3; .-. :...i _ ,... ,._. .~-._I _ - Page 213 .._ .-. I . ._ .^ .r'_, ~I~-2017: J

TO FUEL TANK

I’ 9 ’

I Fuel Line Assembly TO FUEL PUMP Figure 10

Nov l/d NOMENCLATURE /UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 / ASSY

10- 488946 FUEL LINE ASSY. (For NHA See Fig. 9) i 1 1 402265 . VALVE, SHUT-OFF, V70411, NO. 13OC-J I1 2 w-10750-1 . NIPPLE, PIPE, l/8, V31510 :1 3 403615 . VALVE, SOLENOID, FUEL SHUT-OFF V96152, NO. 4-2314 '1 4 848-1068-l . FITTING, ELBOW, MALE HOSE, VO2231 NO. KFO5-02PS90 i 1 5 w-10869-14 . CLAMP, HOSE, V35708 2 6 56544 . HOSE, FUEL, 5/16 ID /25 l/2" -;,,..c ! , / i, _, ,I_~---.---.>,.T,- .-.-.._-...-I I-. --. _i’ ’ i _j __‘. 4” .- .._ ____....___ ---.--I”--- -______~---____--.------OM-2017

Cooling System Figure 11 NOMENCLATURE UNITS; FIGURE HOBART per I ITEM NO. PART NO. 1234567 ASSY. ll- No Number COOLING SYSTEM (For NHA See Fig. 3) REF / 1 408441-2 . RADIATOR, V41197, NO. lAl3714D t 1 i 2 w-10869-3 . CLAMP, V35708 I 2 i 3 407170 . HOSE, TOP, RADIATOR 1 ,: 4 408445 . HOSE, BOTTOM, RADIATOR, V11288, NO. 81171 j lL i 5 406989 . CAP, FILLER, NO. 58-30689, MODINE MFG. CO. 1 14 LB. PRESSURE / 1 6 489549 . SHROUD, FAN ASSY. I 1 7 489534 . GUARD, BELT , 1 I 8 488814 . BRACKET, GUARD, BELT 1 9 w-10869-2 . CLAMP, RADIATOR NECK, V35708 I 1 1 10 489533 . SUPPORT, RADIATOR, NECK I 1 11 489520 . SUPPORT, RADIATOR, LEFT 1 r 12 489519 . SUPPORT, RADIATOR, RIGHT I 1 13 No Number . VALVE, COCK, SHUT OFF, V41197, I No. 5A40617A 1 I 14 351541 . LABEL, CAUTION, FAN 1 15 w-10869-12 . CLAMP, V35708 I 1 f * 16 401842 . TAG, ATTENTION, ENGINE COOLING / 1 * 17 400902 . ANTI-FREEZE 1 1 1 * 18 489547 . BAFFLE, RADIATOR 2 ! I ! I

* Not Illustrated I

-+--- Nov l/85 I 4-3 -- L..--- --__---I_ Page--- 2 I

Rectifier Assembly Figure 12 &--- I -T--- i 4-3 i Nov l/85 ! -- -.L..- I ------.._ - - .-.-._____ .----!~- k_Eagg -- 28 ----.___ \ * _ I i ; . -. \,’ / ;a ! y-, “4 ,*,* . \ , ,’,’ I j x“,-‘..“” .’ /_” ‘:..c I 1 _“.’ -,------.-.---.i------, ‘1 \ I ____- .._.-. .. __,./. .\ _’ GM-2017 ______.____._-___~__---.-___..- j,,/'- -...-....-.-.. -----.------.-----_ NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

12- 488948 RECTIFIER ASSY. (For NHA See Fig. 3) 1 1 489602 . SHROUD, RECTIFIER ASSY 1 2 488840 . BRACKET, MTG., HEATS-INK 2 3 488841 . BRACKET, MTG., HEATSINK 2 4 .488621 . HEAT SINK, RECTIFIER OUTPUT 2 5 w-10933-3 . DIODE, SILICON ~05277, NO. ~6110328 (NEGATIVE) 6

I / 6 W-10931-3 . DIODE, SILICON ~05277, NO. ~6110328 (POSITIVE) 6 7 400149-l . NUT, SPRING, DISHED, 3/4-16, V78189, NO. 534-750200-52 12 8 488564 . BUS BAR, NEGATIVE 1 9 60FC-405 . SHUNT, 2000A, 50 MV, ASSY. 1 10 488559 . GUARD, RECTIFIER 1 11 A-25 . WASHER, INSULATING, V CELCON NO. M270-04 16 12 5CW-2127 . BUSHING, INSULATING 8 * 13 AAW-3909-10 . INSULATOR, SHOCK 1 * 14 42517 . INSULATION, SLEEVING, FIBERGLAS, SIZE "0" 8"

* Not Illustrated

.-. j- __I __--___,..-_ .~___.. - --~-.---T I Nov l/85 4p3 L __. -. / -I.- .I-- _I_-“-.^------.--..,.-__ - ----._ - __ .-. ..----x-.-- .-..--_- .-- ..--.. . - ..- _ _..___ __._ _.__._ 1 _.-_-.: __ : Page F9 i .- . - ,,,, _ _- .~” ., .“- ,. --..- .- _ _I _I ._..__. __-. __ ._.-._-- _._.. -t I Brushholder Assembly / I Fig. 13

_.^ ._. -..*'-I ---___-_-.- _^---.---.-.____. -...- _-_---_-I____---_-__--___~__ 4-31 Nov l/85 ; . ~.. --._. .~_ ...__ _-_ ~.._ _._~ .._ ._ _ : Page 30 I .__. -,.,.-"_ _., ._ .-..-.- - --. --,_ -.. - __._ __~ _.____. .__ .^ _ OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 EFF ASSY

13- 488784 BRUSHHOLDER, ASSY. (For NHA See Fig. 19) 1 488562 . BRACKET, MTG., BRUSHHOLDER 2 488628 . BRACKET, MTG., DIODE 3 408991-l . DIODE, SILICON, 30A, POS., V08452 4 402531 . CAP, BRUSHHOLDER, V46992, No. DE-55 5 402530 . GUIDE, BRUSHHOLDER, V46992, No. 661-D-23 6 402788 . BRUSH, A.C., V78377, No. 4433 I . -\ I ^,’ . / ‘- ---A -,.I-- __I .’ I ’ _I.< ‘\ t. \ _I / --x __ * -, .. r / ” / I ,r -’ ‘.. / .- ,’ ,I: --.---..--.-’ y-----.-I. _ 4” i ‘-,, ! i _*’ OM-2017 __.'I ,~ ____I__-.-____-.--~---_.--___ .----_- '/-.-.-.-----__-' -..-.------._.~-.-. -...-... I

i /

I 1 , ! Engine, Exhaust System I I { Figure 14 1,~_ - -. ,_ J ..._ --.---______-~______I_- t , 4-3 i Nov l/85 ; .,~ - - -.! .-.-. -I_-.------..-- . . --___ ..-- ..______.___. -.-- .-. ..---. --...... - - -. ..- ._ ..-.- i Page 32 .I..-"..-. ,. "_ i,, I._.I- .., ., - _- .- - . _-_-..-_-__ -.- -...._--..-_. . _; ,_-’

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NOMENCLATURE UNITS ~FIGURE HOBART per I ITEM NO. PART NO. 1234567 EFF ASSY j 14- No Number ENGINE EXHAUST SYSTEM (6878-l SHOWN) (For NHA See Fig. 3) REF 84C-1095 . MUFFLER 1 404154-8 . CLAMP, EXHAUST PIPE 2 488616 . PIPE, MANIFOLD ASSY. 1 488581 . GASKET, MANIFOLD 1 489545 . PIPE, TAIL, EXHAUST, ASSY. A 1 489436 . PIPE, TAIL, EXHAUST, ASSY B 1 6 488615 . BRACKET, MTG., MUFFLER 1 7 488815 . SPACER, BRACKET, MUFFLER 1 "8 3OGH-417 . MOUNT, SHOCK, EXHAUST B 1 * 9 489289 . BRACKET, SHOCK MOUNT, EXHAUST B 1

* Not Illustrated

4-3

.._"..-....--. .-_-. .-. -..-._-.__-.--Page .. - 33-. -\ 26 -6 5,--\P 3- ’ k?a-h

Kit, Trailer Without Fenders (Option) Figure 15 __. ” . ._L- ____... 4-3 Nov l/85 .._..- __. _~ _ - ._. : Page 34 .- ^ - _._-.. _.- - --.- _.__ ._.._-..--. -. _,.- OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

15- 488880-2 KIT, TRAILER, WITHOUT FENDERS, BUMPERS, & CABLE TRAYS (OPTION) (2360 Lb. Capacity) 1 1 84C-1100A . TRAILER - JET EX 4 1 2 84B-1099 . TIRE, 4:80.X 8, WHEEL ASSY. (590 Lb. Capacity) 4 3 12Cw-2146 . YOKE, THROTTLE, ROD, VO3504, NO. 4-J-4200 2 4 w-11563 . PIN, CLEVIS CLARK, VO3504, NO. 4F-04051 5 w-11337-2 . PIN, COTTER 6 84B-1042 . CABLE, BRAKE ASSY. 7 400562-40 . SPRING, TENSION CABLE 8 81B-1062 . LABEL, WARNING, DRAWBAR, (UNDERSIDE) 1 9 DWP-982 . BRACKET, CABLE 2 10 50NH-622 . PLATE, REINFORCING, CABLE HANGER 1 11 408394 . BOLT, 3/4-16 UNF X 5.00 2 12 408397 . WASHER, FL 3/4" 8 13 408387 . SPINDLE, STEERING ARM ASSY., L.H. 1 14 408396 . BOLT, 3/4-16 UNF X 400 1 15 408398 . NUT, SLOTTED, 3/4" - 16 UNF 4 16 408393 . PIN, COTTER 4 17 408388 . DRAWBAR, TUBE ASSY. 1 18 408389 . GREASE, ZURK STRAIGHT 1 19 408391 . LATCH, TONGUE ASSY. 1 20 408390 . TONGUE ASSY. 1 21 408399 . TIE ROD ASSY. LARGE 2 22 408401 . TIE ROD COUPLER ASSY. 2 23 408400 . TIE ROD ASSY., SMALL 2 24 408402 . GREASE, ZURK 90 4 25 408386 . SPINDLE, STEERING ARM, ASSY. R.H. 1 26 408395 . BOLT, 3/4-16 UNF X 6.00 1 27 408403 . HUBS, 5 ON 4 2 28 408410 . GREASE, SEAL 2 29 408408 . OUTER, INNER, BEARING CONE 4 40 408413 . ELECTRICAL BRAKE, RIGHT HAND 7" 1 31 408414 . ELECTRICAL BRAKE, LEFT HAND 7" 1 32 408407 . HUB AND DRUM WITH CUPS 2 33 408406 . SPINDLE, WASHER 2 34 . DELETE 35 408405 . SPINDLE, NUT 2 36 408411 . COVER, DUST 2 * 37 408412 . WHEEL, NUT 5 38 408404 . STUD, PRESS-IN l/2-20 X l-7/8 5 * 39 408415 . COMPLETE BRAKE ASSY. LH. (Rear wheels) 1 * 40 408416 . COMPLETE BRAKE ASSY. RH. (Rear wheels) : 1' * 41 408417 . SECONDARY SHOE & LINING ASSY. (Rear wheels) j 2 :j . * 42 408418 . PRIMARY SHOE & LINING ASSY. (Rear wheels) 1 j 43 408392 . SPINDLE, NUT 2 i-. I. ^ ,_ .-eh.---- .--. -.. .---___

; Nov l/85 4-3. -. ,._.-.. - _-..-.--... .- ---.-- . ..__._ ..--.-_.. .~.,. - .._ -_ -. -

._ “., _ .- .-. . .--. - - . .. ~.-.-.- ____-_ Page 3$ Kit, Trailer With Fenders (Option) Figure 16 1.._.-_ -. -' j__x___ _-__. -___- __.__- __-__-_^ -~-- -___-_-. -.-~___---.2 __._-.A 1 4-3,; Nov 1485 ! _..._...-.._ ..___.____ -._... -. ..-__,.. -._~-..---_- ._ - .-..,_ ._. ____ L : Page 36 , '_. -,.."". . ,-- -- _.- ,... __._.._.- ._. _.-_. ._.__.-..._...... -. _ __ -_ OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

16- 488880-l KIT, TRAILER, WITH FENDERS, BUMPERS, AND CABLE TRAYS, (OPTION) (2360 Lb. Capacity) 1 1 488807 . RAIL, CABLE 2 2 488929 . FENDER, SIDE, RIGHT 1 3 488930 . BUMPER, REAR 1, 4 488931 . BUMPER, FRONT 1 5 84C-1100A . TRAILER - JET-EX 4 1 6 488812 . PANEL, ACCESS, BATTERY '1 7 488928 . FENDER, SIDE, LEFT 1 8 84B-1099 . TIRE, 4:80 X 8, WHEEL ASSY. (590 Lb. Capacity) 4 9 12CW-2146 . YOKE, THROTTLE, ROD, VO3504 NO. 4-J-4200 2 10 w-11563 . PIN, CLEVIS CLARK, VO3504 NO. 4F-04051 2 11 w-11337-2 . PIN, COTTER 2 12 84B-1042 . CABLE, BRAKE ASSY. 2 13 400562-40 . SPRING, TENSION CABLE 2 14 81B-1062 . LABEL, WARNING, DRAWBAR, (UNDERSIDE) 1 15 848-1071 . LABEL, ACCESS PANEL, BATTERY 1

L .- - .-. [email protected] -~_-__-~ -.- i -: i i Nov l/85 4-F I_ I_ - -_ .___ ! R.“- . .-“_“-- . . .-.-.,_. .-----.--,...-_-___ Page 3j7 Lifting Yoke and Frame Assembly Figure 17 ____------._-.- ~.-

4-3. _-______.---___._--.--._._._-~__.___ _,_ .Revi.s.eL ..Jun 12/87 Page 38 .., ..----.------.- . . _ ‘. ,. ._ . . --

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.~.~ .-...-. __... ._ ._ ._ _....._.._..- .-- -. ._--. -..----. .--. OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

17- No Number FRAME, LIFTING YOKE ASSY. (For NHA See Fig. 1) 1 488565 . FRAME, MOUNTING 1 488570 . BAR, MTG., GENERATOR 1 12CW-2234 . MOUNT, SHOCK 4 488580 . YOKE, LIFTING 1 No Number . IGNITION, COIL, V90927, (SUPPLIED W/ENGINE) NO. D5Az-12029-A 1 6 401937-l . TERMINAL BLOCK, 20 AMP, V91636 1 7 No Number . STARTER, SOLENOID, V90927, (Supplied W/Engine) No. B6AZ-11450-A * 8 357909 . WASHER, SHOCK MOUNT 16~~-335 . WASHER, CUP 1 *1; 488868 . RELAY, OVERSPEED

. ---_- -- .- .- -- __...--.._.... - -.-- ._._-.. Page 39 IGNITION MODULE ASSY. Figure 18 __"..-_, ___-- ...--

4-3 -....~_.._,.IR&sed~~ Jun 12/87 Page 40. __.-~-- . .-.- ~. ,I -. ~. __ _.. -___--._ ._.._- .- ---.--_- ----~- .---...-- -.. OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

18- No Number IGNITION MODULE ASSY. REF 1 488813 . SUPPORT, IGNITION MODULE 1 2 No Number . IGNITION, MODULE, V90927, (Supplied W/Engine) No. D9VZ-12A199-A 1

Jun 12187 .Resised-.___n____._ ~-~____._-_-..^__ -_.._--___...... ~.---- _-._... 4-3

Page 41 6 / 7

Generator Assembly Figure 19 ,...__^ .- .-$ .^.--_-_ __ -.---__------..--.--- -...... ----.-...--.--.-.- ~..._--..'------4-3 1 Nov l/85; . - .-..-. - -~-_ .. . ..- -- --__ . -._..__- -. ~_ ...__ .._--.. ..-. - .--.. ., - .- ..-... i Page 42 --.-- .-.- - .._ .. .__-...___ .._~. .-.~ ,- ._ .___., . . . ,: I ., ,/--’ . / : ._

_.. --. .’ ‘. ; OM-2017

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY

19- 488947 GENERATOR SPARE ASSY. 1 1 491758-l . COVER - HOLE, FLYwHEEL HOUSING 1 2 488843-l . HOUSING, FLYWHEEL 1 3 488557-l . HOUSING & STATOR ASSY. 1 4 c-31 . KEY - COUPLING 1 5 488552 . ARMATURE, ASSY. 1 6 488555-l . HOUSING, BEARING ASSY. 1 7 55-260-o . CAP, BEARING 1 8 488784 . musHHoLDERASSY. (FOR DETAILS SEE FIG. 13) 1 9 488560 . COVER, GENERATOR HOUSING 1 10 489420 . COUPLING & FAN ASSY. 1 11 No Number . FLYWHEEL - (SUPPLIED B/ENGINE) V90927, NO. ESJ6-6375-BA 1 12 w-10072-63 . BEARING 1

,_ _ ,__ .r_:.l------.... --_-.-__--

: Nov l/85 4-3 . .- _._.-.. --.--.- --- ._...^ -. _ c ._.....^.-_.- ._--.. ..-..- --._.---- -___Page - 43:__' OM-2017

Vehicle Canopy Assembly Figure 20

~....- 4-3

Page 44 . $ey+sed Jun.22/87 . /- : ,-- . . :’ * ‘. ._ .’ .-. .,. . .

. . ___I- ____._ - .-..--

-c_ ., _---.LL_ _-._-._- ___. -.-__. _-.._- x-_I-.---_-- --.--.- __-- ..-. --~- ..--

NOMENCLATURE UNITS FIGURE HOBART per ITEM NO. PART NO. 1234567 ASSY EFF 20- 489502 CANOPY, VEHICLE ASSY. B 1

*1 489495 . CARRIER, BURDEN ELEC. AY. 1 2 489456 . RAIL, CABLE, RETAINER, RT. AY. 1 3 489457 . RAIL, CABLE, RETAINER, LT. AY. 1' 4 489455 . RAIL, CABLE, RETAINER, REAR 1 5 489469 . PLATE, FLOOR SIDE, RT. AY. 1 6 489470 . PLATE, FLOOR SIDE, LT. AY. 1 7 489466 . PLATE, FLOOR REAR 1 8 489461 . PLATE, FLOOR FRONT 1 "9 77A-1000-1 . BUSHING HOLE PLASTIC 1 10 485477 . BOX, PLUG AY. 1 11 485472 . . WRAPPER, BOX PLUG 1 12 485473 . . PLATE, END 2 13 485474 . . PANEL, INTERIOR 1 14 485475 . . ACTUATOR, SWITCH 1 15 485476 . . BRACKET, MICRO-SWITCH 1 16 83A-1069 . . SWITCH, MICRO, V91929,NO. BZ-AR-A2 1 17 83A-1067 . . ACTUATOR, MICRO-SWITCH, V91929, NO. AD5721~ 1 * 18 400562-39 . . SPRING, TORSION 1

Jun---. .-22187 - _ _._ _.- Revised..--..-. I_.._.-__ __.,."l_--.--- ..-. -.---L _.^.- .,.- .-- "."__..-__._ "._ .._ 4-3 Page 45 .- ._ _” _- -- ...-.- --I.______-__ -- ~..~__~ . . This page intentionally left blank.

4-3 ^- Revised Jun 22/87 Page 46. -. . -. .~...__ -OM-2017

SECTION 4. NUMERICAL INDEX

1. Explanation of Numerical Index

The purpose of this index is to assist the user in finding the illustration and description of a part when the part number is known. Part numbers are arranged in alpha-numerical sequence. Thus, any part number beginning with the letter A would be located at or near the top of the index list. Like- wise, a part number 9 would be listed near the end of the list and far below a part number 1000. The figure number and item number location of the part is directly opposite the part. If the part is used in more than one place, each location is listed commencing with the first location the part is listed.

NUMBERICAL INDEX