OPERATION AND MAINTENANCE MANUAL - · PDF fileom-465 revised 063094 operation and maintenance manual with illustrated parts list for 37.5 kva and 60 kva synchronous motor driven generator

OM-465Revised 063094

OPERATION AND MAINTENANCEMANUAL

with

ILLUSTRATED PARTS LIST

for

37.5 kVA and 60 kVASYNCHRONOUS MOTOR DRIVEN

GENERATOR SETS

400-Hz, 115/200-V AC, 3-Phase

HOBART BROTHERS COMPANYAirport Systems GroupTroy, Ohio 45373 U.S.A.

SPECIFI-CATION

MODELNUMBER

INPUTVOLTS

INPUTHERTZ

OUTPUTPOWER

RATING (KVA)

RATEDSPEED(RPM)

6182A-1 37F-H61 230 / 460 60 37.5 1200

6182A-2 37F-H61 208 / 380 60 37.5 1200

6182A-3 37F-H61 575 60 37.5 1200

6183A-1 37F-H51 220 / 380 50 37.5 1500

6184A-1 60F-H61 230 / 460 60 60 1200

6184A-2 60F-H61 230 / 460 * 60 60 1200

6184A-3 60F-H61 208 / 380 60 60 1200

6184A-4 60F-H61 575 60 60 1200

6185A-1 60F-H51 220 / 380 50 60 1500

6185A-2 60F-H51 415 50 60 1500

* Delta Output

This page intentionally left blank.

Safety Instructions and Warnings for Electrical Power Equipment

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

ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage,and ignite combustible material. DO NOT use power cables to break load andprevent tools from causing short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damagethis and attache equipment.

Important: Protect all operating personnel. Read, understand, and follow all instructionsin the Operating/Instruction Manual before installing, operating, or servicingthe equipment. Keep the manual available for future use by all operators.

1. GeneralEquipment that supplies electrical power can cause serious injury or death, or damage to otherequipment or property. The operator must strictly observe all safety rules and take precautionaryactions. Safe practices have been developed from past experience in the use of power sourceequipment. While certain practices below apply only to electrically-powered equipment, other practicesapply to engine-driven equipment, and some practices to both.

2. Shock PreventionBare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatallyshock a person. Have a certified electrician verify that the equipment is adequately grounded and learnwhat 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 flowthrough it. When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubbermat or dry wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry,and never work alone

a. Installation and Grounding of Electrically Powered Equipment

Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installedand maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or otherapplicable codes. A power disconnect switch or circuit breaker must be located at the equipment.Check the nameplate for voltage, frequency, and phase requirements. If only 3-phase power isavailable, connect any single-phase rated equipment to only two wires of the 3-phase line. DO NOTCONNECT the equipment grounding conductor (lead) to the third live wire of the 3-phase line, asthis makes the equipment frame electrically HOT, which can cause a fatal shock.

Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box orbuilding ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)capacity of the grounding lead will be adequate for the worst fault current situation. Refer to theNational Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs. Usecorrectly mating receptacles.

b. Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the connectors. Replace or repaircracked or worn cables immediately. Do not overload cables. Do not touch output terminal whileequipment is energized.

WARNING

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June 30/94 Revised Safety WarningsPage 1

c. Service and Maintenance

This equipment must be maintained in good electrical and mechanical condition to avoid hazardsstemming from disrepair. Report any equipment defect or safety hazard to the supervisor anddiscontinue use of the equipment until its safety has been assured. Repairs should be made byqualified personnel only.

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

(2) Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing theequipment.

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

(4) Disconnect power to equipment if it is out of service.

(5) If troubleshooting must be done with the unit energized, have another person present who istrained in turning off the equipment and providing or calling for first aid.

3. Fire And Explosion PreventionFire and explosion are caused by electrical short circuits, combustible material near engine exhaustpiping, misuse of batteries and fuel, or unsafe operating or fueling conditions.

a. Electrical Short Circuits and Overloads

Overloaded or shorted equipment can become hot enough to cause fires by self destruction or bycausing nearby combustibles to ignite. For electrically-powered equipment, provide primary inputprotection to remove short circuited or heavily overloaded equipment from the line.

b. Batteries

Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a rupturedbattery can cause fires and additional failures. When servicing, do not smoke, cause sparking, oruse open flame near the battery.

c. Engine Fuel

Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tankis not grounded prior to or during fuel transfer. Shut unit DOWN before removing fuel tank cap. DONOT completely fill tank, because heat from the equipment may cause fuel expansion overflow.Remove all spilled fuel IMMEDIATELY , including any that penetrates the unit. After clean-up, openequipment doors and blow fumes away with compressed air.

4. Toxic Fume PreventionCarbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaustfumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of airconditioners.

5. Bodily Injury PreventionSerious injury can result from contact with fans inside some equipment. Shut DOWN such equipmentfor inspection and routine maintenance. When equipment is in operation, use extreme care in doingnecessary trouble-shooting and adjustment. Do not remove guards while equipment is operating.

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Safety Warnings June 30/94 RevisedPage 2

6. Medical and First Aid TreatmentFirst aid facilities and a qualified first aid person should be available for each shift for immediatetreatment of all injury victims. Electric shock victims should be checked by a physician and taken to ahospital immediately if any abnormal signs are observed.

Call physician immediately. Seek additional assistance. Use First Aidtechniques recommended by American Red Cross until medical helparrives.

IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim liedown. FOR ELECTRICAL SHOCK, turn off power. Remove victim; if notbreathing, begin artificial respiration, preferably mouth-to-mouth. If nodetectable pulse, begin external heart massage. CALL EMERGENCYRESCUE SQUAD IMMEDIATELY.

7. Equipment Precautionary LabelsInspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot beeasily read.

IMPORTANT

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June 30/94 Revised Safety WarningsPage 3


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Safety Warnings June 30/94 RevisedPage 4

Introduction

This manual contains operation and maintenance information for a series of 400-Hertz generator setsmanufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373.

This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is toprovide information and instructions to experienced operators, electricians, and mechanics who havenever seen or operated this equipment. It is the intent of this manual to guide and assist operators andmaintenance people in the proper use and care of the equipment.

Use of the manual should not be put off until a trouble or need for help develops. Read the instructionsbefore starting the unit. Learn to use the manual and to locate information contained in it. Its style andarrangement are very similar to commercial aircraft manuals. The manual is divided into six chapters.Each chapter is divided into as many sections as required. Each new section starts with page 1. Eachpage is identified by chapter, section and page number, which are located in the lower, outside corner.When information located in another portion of the manual is referred to, its location is identified by achapter, section, and paragraph, or figure number. For example, “(See 2-3, Para. B)” refers toinformation located in Chapter 2, Section 3, Paragraph B. If a Chapter and Section are not indicated ina reference, the referenced material is located in the same section as the reference, Example, (SeePara. B).

In addition to operation and maintenance instructions, the manual contains an illustrated parts list inChapter 4, and connection and schematic diagrams in Chapter 6.

Content of the manual is arranged as follows:

Chapter 1. Description/Operation

Chapter 2. Servicing

Chapter 3. Troubleshooting

Chapter 4. Illustrated Parts Lis t

Chapter 5. Optional Equipment

Chapter 6.Manufacturer’s Literature

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June 30/94 Revised IntroductionPage 1


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Introduction June 30/94 RevisedPage 2

Table of Contents

Safety Warnings

Introduction

Table of Contents

Chapter 1. Description / Operation 1-1 1

Section 1. Description 1-1 11. General 1-1 12. Orientation 1-1 13. Optional Equipment 1-1 14. Identification 1-1 45. Special Features 1-1 46. Detailed Description 1-1 4

a. Motor-Generator Assembly . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . 5b. Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . . 5

(1) General 1-1 5(2) Generator Monitor Tray 1-1 7(3) Generator Protection Tray 1-1 9(4) Voltage Regulator Tray 1-1 12(5) Motor And Generator Control Pushbutton Panels 1-1 13(6) Front Panel 1-1 13

c. Interior Panel (Ref. 7, Fig. 4) . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 13(1) Contactors 1-1 13(2) Motor Control Transformer 1-1 13(3) Generator Control And Plug-Interlock Relays 1-1 13(4) Aircraft - Test Bank Switch 1-1 16(5) Motor Overload Relay And Transformer 1-1 16(6) Rectifier 1-1 16(7) Power Supply (12-V DC) 1-1 16(8) Wiring Harness 1-1 18(9) Current Transformer Panel Assembly 1-1 18

d. Test Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 19e. Cabinet Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 19

7. Conduits and Connectors 1-1 23

Subject Chapter/Section Page

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June 30/94 Revised Table of ContentsPage 1

8. Frame And Sheet Metal Covers And Air Ducts 1-1 239. Options 1-1 25

a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 25b. Second Output (Part Number 485211) . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 25c. Convenience Receptacle Panel Assembly, 60-HZ . . 1-1 . . . . . . . . . . . . . 25d. Phase Failure Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 27e. Alternate Voltage Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 27f. Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 27g. Transformer-Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 28h. T-R Mounting Package . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 28i. Convenience Receptacle Panel Assembly,

50-HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . . . . . . . . 28

Section 2. Preparation For Use 1-2 11. Uncrating 1-2 12. Inspection/Check 1-2 13. Lubrication 1-2 14. Generator Set Mounting Installation 1-2 1

a. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 1b. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 1

(1) General 1-2 1(2) Mounting Cautions 1-2 1(3) Recommended Mounting Instructions 1-2 2(4) Mounting Kit 1-2 2(5) Mounting Procedures 1-2 2(6) Alternate Mounting Method 1-2 2

5. Wiring the Generator Set 1-2 4a. Preparation for Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 4

(1) Input Voltage Requirements 1-2 4(2) Cable Horns and Clamps 1-2 5(3) Cable Size Selection for Input Power 1-2 5

b. Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 6(1) Protection 1-2 6(2) Cable Terminations 1-2 6(3) Cable Routing 1-2 6(4) Cable Connections and Armature

Rotation Direction 1-2 6(5) Grounding 1-2 6(6) Check for Proper Phase Sequence Connection 1-2 7

c. Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 8(1) Output Cable Assembly 1-2 8(2) Cable Selection 1-2 8(3) Cable Connection 1-2 8(4) Second Output 1-2 8


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Table of Contents June 30/94 RevisedPage 2

6. Wiring for Alternate Input Voltages 1-2 10a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 10b. Motor Stator Terminal Board . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 10c. Motor Overload Relay Heater Elements . . . . . . . . . . 1-2 . . . . . . . . . . . . . 11d. Motor Control Transformer Alternate

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 13e. Convenience Receptacle Panel Assembly (Option). 1-2 . . . . . . . . . . . . . 14f. Checks and Procedures Following Voltage

Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . 14

Section 3. Operation 1-3 11. General 1-3 12. Preparation for Power Delivery with

AUTOMATIC Voltage Regulation 1-3 1a. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . 1b. Position Switches and Controls. . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . 1

(1) Front Panel 1-3 1(2) Generator Monitor Tray 1-3 1(3) Generator Protection Tray 1-3 1(4) Voltage Regulator Tray 1-3 4(5) Interior Panel 1-3 5

3. Power Delivery with Automatic Voltage Control 1-3 54. Preparation for Power Delivery with

MANUAL Voltage Control 1-3 55. Power Delivery with MANUAL Voltage Control 1-3 76. Discontinue Power Delivery 1-3 77. Optional Equipment Operation 1-3 7

a. Second Output Circuit. . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . 7b. Convenience Receptacle Panel Assembly . . . . . . . . 1-3 . . . . . . . . . . . . . . 7c. Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . 7d. Transformer Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . . . . . . . . . . 8

Chapter 2. Servicing 2-1 1

Section 1. Maintenance 2-1 11. General 2-1 12. Inspection 2-1 13. Lubrication 2-1 14. Parts Replacement 2-1 1

a. Replacements of Lamps and Fuses. . . . . . . . . . . . . . 2-1 . . . . . . . . . . . . . . 2b. Replacement of Minor Electrical Components . . . . . 2-1 . . . . . . . . . . . . . . 2


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Section 2. Inspection Check And Repair 2-2 11. General 2-2 12. Exterior Cables and Connections 2-2 1

a. Input and Output Cables . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 1b. Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 1

3. Controls and Instruments 2-2 1a. Voltmeter and Ammeter . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 1b. Indicating Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 1

(1) Protective Monitor Indicating Lights 2-2 1(2) Motor and Generator Control Indicating lights 2-2 1

c. Overvoltage Protection Circuit . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 3d. Undervoltage Protection Circuit . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 3e. Underfrequency Protection Circuit . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 3f. Overload Protection Circuit . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 3g. Ammeter Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 3h. Voltmeter Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 3i. Internal Wiring and Connections . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 4j. General Overall Inspection. . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 4

4. Motor Generator 2-2 4a. Rotor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 4b. Motor-Generator Temperature . . . . . . . . . . . . . . . . . . 2-2 . . . . . . . . . . . . . 4

5. Check Electrical Components 2-2 4

Section 3. Adjustment / Test 2-3 11. General 2-3 12. Test Panel 2-3 13. Testing The Generator Set 2-3 1

a. Pre-Operational Test Procedures . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 1b. Operational Test Procedures . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 3c. Optional Equipment Testing . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 10

4. Motor-Generator Testing 2-3 11a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 11b. Motor and Generator Stator Windings . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 11

(1) Preparation for test 2-3 11(2) Check generator stator winding resistance 2-3 11(3) Check motor stator winding resistances 2-3 12

c. Motor and Generator Rotor Windings . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 12(1) Preparation For Test 2-3 12(2) Test Generator Rotor Fields on Series 6183A,

Series 6184A and Series 6185A Units 2-3 12(3) Test Motor Rotor Field on Series 6183A,

Series 6184A and Series 6185A Units 2-3 13(4) Test Motor Rotor Field - Generator Rotor Field

on Series 6182A Units 2-3 13


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d. Test Exciter Rotating Field . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 13e. Test Exciter Stationary Fields . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 13f. Check Micro Switches . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 13g. Rotor Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 13

5. Diode Test 2-3 156. Adjustments 2-3 15

a. Adjust Undervoltage Time Delay . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 15b. Adjust Manual Voltage Control Variable Resistor . . 2-3 . . . . . . . . . . . . . 16c. Adjust 12-V DC Power Supply . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 18d. Adjust Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . . . . . . . . 18

Section 4. Removal/Installation ofMotor-Generator Covers

1. General 2-4 12. Generator End Covers 2-4 1

a. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . 1b. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . 1

3. Motor End Covers 2-4 1a. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . 1b. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . . . . . . . . . 1

Section 5. Motor-Generator Servicingand Repair 2-5 11. General 2-5 12. Motor-Generator Removal and Installation 2-5 1

a. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . . . . . . . . . . 1b. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . . . . . . . . . . 5

3. Electrical and Mechanical Repair 2-5 5a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . . . . . . . . . . 5b. Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . . . . . . . . . . 5

(1) Sheet Metal Repair 2-5 5(2) Frame and Structural Repair 2-5 6

c. Wiring the Unit After Repair or Parts Replacement . 2-5 . . . . . . . . . . . . . . 6

Section 6. Overhaul of ElectricalEquipment and Motor-Generator 2-61. Electrical Equipment 2-6 12. Motor-Generator Overhaul 2-6 1

a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . . 1b. Remove Sheet Metal Covers and Ducts . . . . . . . . . . 2-6 . . . . . . . . . . . . . . 1c. Disassembly, General . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . . 1d. Disassemble Motor-Generator . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . . 1e. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . . 6


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f. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . 6(1) Bearings 2-6 6(2) Fan 2-6 8(3) Armature (Rotor) Assembly 2-6 8(4) Motor, Generator and Exciter Stators 2-6 8

g. Assemble Motor-Generator. . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . 83. Remove and Install Exciter Rotor Without

Removing Armature 2-6 15a. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . 15b. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . . . . . . . . 15

Chapter 3. Troubleshooting 3-1 1

Section 1. Troubleshooting Procedures 3-1 11. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . . . . . . . . 1

2. Troubleshooting 3-1 1a. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . . . . . . . . 1

(1) Trouble, Symptom, and Condition 3-1 1(2) Probable cause 3-1 1(3) Test, Check, and/or Remedy 3-1 1

b. Use of the Troubleshooting Chart . . . . . . . . . . . . . . . 3-1 . . . . . . . . . . . . . 13. Equipment for Troubleshooting 3-1 24. Safety 3-1 25. Parts Replacement 3-1 26. Test Values 3-1 27. Check Connections and Leads 3-1 3

Chapter 4. Illustrated Parts List 4-1 1

Section 1. Introduction 4-1 11. General 4-1 12. Purpose 4-1 13. Arrangement 4-1 14. Explanation of Parts List 4-1 1

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

(1) FIGURE-ITEM NO. Column 4-1 2(2) HOBART PART NUMBER Column 4-1 2(3) NOMENCLATURE Column 4-1 2(4) REC. SPARES column 4-1 2(5) “EFF” (Effective) Column 4-1 2(6) UNITS PER ASSEMBLY Column 4-1 2


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Section 2. Manufacturer’s Codes 4-2 11. Explanation of Manufacturer’s (Vendor)

Code List 4-2 1

Section 3. Parts List 4-3 11. Explanation of Parts List Arrangement 4-3 12. Symbols and Abbreviations 4-3 1

Section 4. Numerical Index 4-4 11. Explanation of Numerical Index 4-4 1


Chapter 6. Manufacturer’s Literature

Unusual Service Conditions

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Chapter 1 n Description / Operation

Section 1. Description

1. General The generators covered by this manual are identified by Series Numbers 6182A, 6183A, 6184A and 6185A. These generator sets are manufactured by Hobart Brothers Co., Power Systems Division, Troy, Ohio 45373. All generator sets are electric drive stationary units, fiowever each may be made mobile by mounting on an optional four-wheel trailer.

Unqualified information throughout the manual will apply to all generator sets. Information which applies to a specific machine will be qualified as such. Each machine is identified in Para. 4., Identification.

Specifications and capabilities for each series are contained in Fig. 2.

For purposes of simplification and to avoid confusion when referring to the generator, which is a component of the subject Generator Set, the end item covered by this manual will hereafter be referred to as the set.

All sets are identical in outward appearance because they share the same frame, control box, sheet metal covers, etc. All sets produce 400-HZ, 115/200-V, 3-phase output power for serving the electrical system of parked aircraft or for powering other equipment requiring 400-HZ service. The only difference in the four sets covered here are in the internal electrical components required for either 37.5KVA or 60-KVA output rating and for their input power requirements of either 50-HZ or 60-HZ and optional voltages such as 220-V, 380-V, etc.

NOTE: When we speak of 50HZ or 60HZ we will always be referring to drive motor input requirements. All generators covered by the manual produce 400HZ output power.

As stated above, the general physical configuration of all machines is the same. A welded steel frame provides mounting facilities for a control cabinet and a combination motor-generator complete the unit.

2. Orientation To avoid confusion in the location of components, the control cabinet is located at the FRONT of the unit. Left and right are determined by looking at the unit from the REAR. The motor-generator is mounted with the generator end on the LEFT, the motor on the RIGHT. Cooling air enters on the LEFT or generator end and exits on the RIGHT or motor and fan end.

3. Optional Equipment Some options, by their size, function, etc., lend themselves to inclusion in the basic manual. They are:

Phase Reversal Relay (See Para. 9, D) Second Output (See Para. 9, B) Convenience Receptacle (See Para. 9, C) Alternate Voltage Kit (See Para. 9, E) Transformer-Rectifier and Mounting Kit (See Para. 9, G and H)

Options covered by separate manuals are:

Four-Wheel Trailer (See TM-268A in Chapter 8) Transformer-Rectifier (See TM-597 in Chapter 8)

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3

""'i

3/4 Front View 3/h Rear View

Front View

Motor Driven Generator Set Figure 1

Top View

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PHYSICAL SPECIFICATIONS STATIONARY 6162A-1, 6182A-2 6183A-1 6184A-1, 6184A-2 6185A-I

UNITS 6182A-3 6184A-3, 6184A-4 6185A-2

Weight 2785 lb. 2900 lb. 3125 lb. 3185 lb. (1283 Kg) (1315 Kg) (1417 Kg) (1445 Kg)

Length 60 in. 60 in. 60 in. 60 in. (1524 mm) (1524 mm (1524 mm (1524 mm

Width 40 in. 40 in. 40 in. 40 in. 1016 mm) 1016 mm) 1016 mm) 1016 mm)

Height 46 in. 46 in. 46 in. 46 in. 1168mm 1168 mm 1168 mm 1168 mm

UNITS WITH TRAILER

Weight 3200 lb. 3315 lb. 3540 lb. 3600 lb. (145lKg.) (I 503 Kg.) (I 605 Kg.) (1632 Kg.)

Length 71 in. 71 in. 71 in. 71 in. (1803.4 mm) (1803.4 mm) (1803.4 mm) (I 803.4 mm)

Width 64-518 in. 64-518 in. 64-518 in. 64-518 in. (1641 mm) (1641 mm) (1641 mm) (1641 mm)

Height 57-314 in. 57-3/4 in. 57-314 in. 57-314 in. (1467 mm) (1467 mm) (1467 mm) (1467 mm)

GENERATOR

37F-H61 and 37F-H51 UNITS

60F-H61 and 60F-H51 UNITS

VOLTS LOAD HERTZ KILO- POWER DUTY OVERLOAD AMPS WAlTS FACTOR CYCLE CAPACITY

115/200 108 400 30 .8 100% 125% of rated load

115/200 173 400 48 .8 100% 125% of rated load

Specifications and Capabilities Figure 2

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4. ldentif ication Generator sets covered by the manual are listed below with their Specification Number, Model Number and Characteristics.

For clarification, it should be noted here that a plain four-digit Series number (i.e. 6182A) does not identify a complete machine. It rather represents a group of parts used in ALL 6182A Series machines. To identify a complete functional machine, a dash number suffix (i.e. -1, -3, etc.) must be added to the Series number (i.e. 6182A-1). Dash numbers, added to the Series number, identify certain characteristics of a machine which set it apart from others in a Series.

A Series number plus a dash number becomes a Spec (specification) number which completely identifies a machine without options.

Optional equipment such as a trailer, special instruments, etc. which are usable on more than one Series of machines are identified by a six digit part number and must be ordered by part number. There is no single number which identifies a machine and an option or options.

When an option or options are part of your purchase, applicable Instruction Manuals will be included in your Basic Manual under Manufacturer’s Data, Chapter 8. Otherwise options are covered here.

5. Special Features Generator sets have many special features which are described more fully under the assemblies in which they appear.

Some features are listed as follows:

a. The backward tilted mounting position of instruments and controls allows easier reading and operation from a normal standing position.

b. A hinged Plexiglass cover provides protection for instruments and controls allows easy access to them.

C. Split-winding motor starting is used to simplify the starting sequence and to reduce weight, maintenance and bulk normally associated with Wye-Delta starting, and to provide closed transition starting rather than open transition as in Wye-Delta starting.

d. Controls and instruments, as well as the voltage regulator, are mounted in pull-out, drawer type trays which allow easy access to equipment mounted in them.

e. A test panel with connections to various test points throughout the electrical circuitry is located inside the control cabinet door. The test panel provides safe, convenient test points for checking equipment performance and for troubleshooting.

f. A solid-state, adjustable voltage regulator provides automatic voltage regulation and line drop compensation

The generator protective monitor system consists of solid-state devices (printed circuit boards) which provide maintenance-free operation and quick, easy removal and installation if replacement should become necessary.

h. The complete generator set is designed to be weatherproof.

6. Detailed Description A detailed description of the parts which are used to build the generator set is given here. Main assemblies are listed by part name. Components of each assembly are then described. An attempt will be made to describe each item in a way which will be the most helpful to operators and maintenance personnel.

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a. Motor-Generator Assembly

The motor-generator (Fig. 3) was designed with two main goals in mind. First, to eliminate excessive weight and bulk, and second, to maintain quality, performance and overload capacity. Comparing this motor-generator to previous designs clearly indicates that both goals have been reached.

The drive motor, generator and exciter are combined in a single, compact, brushless unit. Both motor and generator are three-phase synchronous type.

This design incorporates motor, generator and exciter stator windings in a common stator housing.

Rotating field windings for motor and generator, and the exciter armature are mounted on a common shaft which is supported at each end by permanently lubricated ball bearings.

Generator connection is four-wire wye with grounded neutral.

The motor is connected in delta for lower voltages, 208-V to 230-V input, in wye for higher voltages, 380-V and up.

The normal AC output of the exciter is changed to DC for excitation of both the motor and generator. Six diodes, mounted on the generator revolving field spider are provided to make the AC to DC change.

Two normally CLOSED Micro switches also mounted on the generator revolving field spider are connected across the diodes to disable them and prevent excitation of the motor and generator during motor start-up. This design provides better starting characteristics because less power (amperage) is required for starting when motor and generator fields are NOT excited. Since micro switches are sensitive to centrifugal force, they OPEN when armature speed reaches near normal speed and allow excitation to reach motor and generator fields for normal operation.

Motor starting is accomplished by the split-winding or part-winding method in which only half of the motor stator windings are used for starting. After the motor has reached operating speed, the other half of windings are automatically connected for normal running.

A centrifugal, vane type fan mounted by a hub on the armature shaft at the motor end provides air circulation throughout the motor-generator. Air is drawn in at the generator end and is circulated over and around all windings. Air is then discharged from the motor end and is conducted by a sheet metal duct arrangement to an outlet at mounting frame level.

b. Control Cabinet

(7) General

The control cabinet (Fig. 4) is mounted on the frame at the front of the unit. It consists of a weather proof enclosure which houses all electrical controls, protective devices and monitoring instruments.

Two drawer type, slide-out trays (1 and 3) are mounted in the upper part of the cabinet. These trays contain instruments, controls and protective devices. The front panels of these trays are tiled backward at an angle for improved visibility from a standing position in front of the control cabinet. A third tray (9) without a front panel, contains the voltage regulator and is mounted in the lower compartment to the left of the interior panel.

All trays slide in and out easily for adjustment or inspection of internal components. Quick-disconnect wiring connectors allow quick removal and replacement.

Trays are supported by slides and nylon rollers which are mounted on the sides of trays and tray compartments. Slides and rollers mate to form a rigid support for trays and to prevent downward tipping when trays are at the limit of the outward travel.

A gravity-type retainer latch on each compartment slide prevents the tray from being accidentally pulled from a compartment before the latch is released.

The two top trays are retained in their compartments by screw driver operated, adjustable grip latches.

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1 2 3

\

4 5

\ I

d b

-6

-7

-7

-6

1. Motor Stator Windings 7. Diode 2. Armature Shaft 8. Bearing Cap 3. Generator Stator Windings 9. Spacer 4. Stator Housing 10. Ball Bearing 5. Bearing Bracket 11. Fan 6. Micro Switch (not illustrated) 12. Excciter Fields

13. Exciter Rotating Armature 14. Key Washer 15. Round Nut 16. Fan Hub 17. Fan Housing

Motor-Generator Figure 3

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A hinged Plexiglass cover (6) provides protection for trays while allowing observation of instruments, etc.

Motor START-STOP and generator ON-OFF switches and indicating lights are panel mounted just below the trays (See 4, and 10, Fig. 4).

Space is provided for mounted an optional second output control panel (5).

A single door with key-lock handle provides access to electrical components mounted in the large lower compartment of the cabinet. In addition to the voltage regulator tray, the interior panel is located here.

All wiring to and from the panel is routed through quick-disconnect connectors.

Cable hangers (11) are mounted on each side of the cabinet.

(2) Generator Monitor Tray

The generator monitor tray (1, Fig. 4 and Fig. 5) contains generator output monitoring instruments and controls.

a. Wiring Harness

A wiring harness (1, Fig. 5) with receptacle connector mates with another wiring harness which has a plug connector. These mating connectors provide a quick-disconnect point for all wiring to and from the tray.

b. Automatic-Manual Voltage Controls

Items covered here are the switch (2), rectifier (4), variable rheostat (7), and variable resistor (6). Automatic or manual control of the generator output voltage is selected by a 4p dt, two-position, toggle switch (2). The generator set is normally operated with the switch in AUTOMATIC position. in this position the switch serves to connect the voltage regulator (Ref. Fig. 4, Item 9) in the exciter field circuit for automatic regulation of the generator output voltage. When the switch is in AUTOMATIC position, all manual voltage controls are disconnected. When the switch is placed in MANUAL position, it serves to disconnect the voltage regulator from the exciter field circuit and connect the manual control rheostat (7, Fig. 5) in its place. Current to the exciter field is the supplied through a rectifier (4), variable resistor (6), and controlled by the rheostat (7). Voltage may be adjusted by turning the rheostat knob (8) clockwise to increase voltage and counterclockwise to reduce voltage. The variable resistor (6) is used to adjust the effective voltage range controlled by the rheostat.

c. Excitation De-Energize Relay (EDR)

This relay (3, Fig. 5) performs a dual function. It prevents energization of the exciter field and operation of the generator until the motor has reached operating speed. It also stops generator output by removing excitation from the generator and motor fields when the motor STOP switch button is pushed, or when any motor shutdown device functions.

d. Ballast Resistors

Two, 50-ohm, loo-watt resistors (5) are connected in the exciter field circuit and act as ballast. They are connected in parallel and function during both automatic and manual operation.

e. Ammeter

The ammeter (9) is a special rectifier type with voltmeter movement and rectangular 4-l/2 inch face. A zero adjusting screw is accessible through a hole just below the instrument in the front panel of the tray.

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1 2 3 4 5 6

1. Generator Monitor Tray 6. Plexiglass Cover 2. Front Panel 7. Interior Panel 3. Generator Protection Tray 8. Test Panel 4. Generator Control Pushbutton 9. Voltage Regulator

Panel (No. 1 Standard) IO. Motor Control Pushbutton 5. Generator Control Pushbutton Panel

Panel (No. 2 Standard) 11. Cable Hangers

Control Cabinet Figure 4

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f. Voltmeter

The voltmeter (12) is also a rectifier type with rectangular 4-i/2 inch face. It also has a zero adjustment screw accessible through a hole in the front panel.

The same voltmeter is used on all units. Its scale marking range is 0 to 300-VAC. The voltmeter indicated phase-to-phase (A-B, B-C, or C-A) generator output voltage as determined by the position of the meter selector switch (11).

g. Meter Selector Switch

The meter selector switch (11) is a six-position rotary type. It provides a means of selecting and determining which phase amperage or voltage is indicated on the voltmeter and switch phase amperage or load is indicated on the ammeter. Switch positions and equivalent phases monitored by the voltmeter and ammeter are silkscreened on the tray front panel. (See Sect. 1-3, Fig. 2)

(3) Generator Protection Tray

The generator protection tray (3, Fig. 4 and Fig. 6) contains electrical devices designed to protect the aircraft and generator against damage which could result from overvoltage, undervoltage, underfrequency, etc.

A series of indicating lights on the front panel warn the operator when a fault condition exists and also identifies the fault.

a. Voltage And Frequency PC Boards

The over-undervoltage board (3) and underfrequency board (4) are solid-state devices which receive their signals directly from output circuits.

These boards (or modules) sense any abnormal condition of voltage or frequency and signal the solid-state circuitry of the memory and time delay board (2) to open the load contactor and disconnect the generator from the load. Voltage and frequency values at which the boards send a signal are adjustable, however, adjustments must be make ONLY under laboratory conditions. The frequency sensing board is connected for sensing underfrequency. The over-frequency circuitry is not used because it is required only in engine-driven generator sets. A synchronous motor cannot run faster than its designed speed. In this case 1200 RPM for 60-HZ motors and 1500 RPM for 50-HZ motors.

A solid-state overload signaling device (Ref. 4, Fig. 12) is also connected to the memory and time delay board (2, Fig. 6) and performs a function similar to the voltage and frequency sensing modules.

See Para. 6, C, (1 l), (c) for more specific and detailed information regarding overload device.

Factory adjusted trip values for protective circuits are as follows:

Overvoltage trips at 130-V to 134-V; resets at 125-V Undervoltage trips at 93-V to 102-V; resets at 11 O-V Underfrequency trips at 375-HZ to 385-HZ Undervoltage time delay (adjustable) 4 to 12 seconds (set at 5 seconds) Overload circuit trips at any value over 125% rated load capacity in 5 minutes, 150% load in 30 seconds, and 200% in 4 seconds.

b. Memory and Time Delay Board

The memory and time delay board (2, Fig. 6) is sometimes called the protective monitor module. It is a solid-state device with a hermetically-sealed, reed-type relay. The printed circuit board or “card” is connected to a corresponding sensing circuit in the over-undervoltage board, underfrequency board and overload board.

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6

1. Wiring Harness 7. Manual voltage control rheostat 2. Automatic-manual voltage control switch 8. Knob 3. Excitation deenergization relay (EDR) 9. Ammeter 4. Rectifier 10. Adjustable grip latch 5. Ballast resistor, 50-ohm, loo-watt 11. Voltmeter-ammeter selector switch 6. Manual control resistor, 50-ohm, loo-watt 12. Voltmeter

Generator Monitor Tray Figure 5

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12 11 10 9 8 7 6 5

I I I \I I I I

HOBART I ’ GENERATOR PROTECTION

1. Fuse-interlock relay

2. Memory and time delay board

3. Over-undetvoltage board

4. Undetfrequency board

5. Reset switch

6. Test switch

7. Hole plug

8. Overload indicating light

9. Underfrequency indicating light 10. Undervoltage indicating light

11. Overvoltage indicating light

12. Fuse, 2-Amp

13. Adjustable grip latch

14. Terminal Board 15. Wiring harness

Generator Protection Tray Figure 6

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All circuits are connected to the module relay coil, and any one of the circuits can energize the coil to open the relay contacts. Thus, when a sensing device energizes any one of the module circuits, the module relay is also energized to break the load contactor holding circuit and allow the load contactor to open. All circuits, except the undervoltage circuit, function immediately to open the load contactor. A time delay system is designed into the undervoltage circuit to prevent nuisance opening of the output. An undervoltage condition which continues un interrupted for a period of 4 to 12 seconds (adjustable) will cause the time delay circuit to open the load contactor. Each of the four circuits is connected to a corresponding indicating light (8 through 11) which is turned on when a fault occurs.

The module relay will remain energized (OPEN) and the light will remain On until the reset switch (5) is pushed to break the module 12-V DC circuit, and allow the relay to return to normal, CLOSED position.

The overvoltage, undervoltage and underfrequency circuits are self-explanatory and function when one of those faults exist.

NOTE: The overload circuit is activated at any value over 125% rated load on the generator [See Para. 6, C, (11 )I (c)l

c. Indicating Lights (12-15, Fig. 6)

Four identical RED indicating lights (8, 9, 10, and 11) are mounted on the front panel of the tray. Their function is to indicate to the operator the abnormal condition which caused the protective monitor system to function and open the load contactor.

An indicating light will remain ON until the reset switch (5) is pushed.

d. Reset And Test Switches

The reset switch (5) and test switch (6) are identical pushbutton switches.

The reset switch is used to break the 12-V DC protective system circuit and allow the system to return to normal after a fault condition has caused the system to function. Pushing the switch turns off any indicating light(s) which may be on and allows memory and time delay board relays to “reset”.

The test switch is used to apply 12-V DC directly to all SCR (silicon controlled rectifier) memory circuits for testing each circuit in the memory and time delay PC Board and for testing lamps (bulbs) in their respective indicating lights on the tray front panel.

e. Fuse And Fuse-Interlock Relay

The function of the fuse-interlock relay (1) is to interrupt the load contactor holding coil circuit and remove the load in case the 12-V protective system operating circuit is disabled by a “blown” fuse (12).

f. Terminal Board

The terminal board (14) provides wiring connection points between quick-disconnect connectors on PC Boards, internal components and the wiring harness (15).

g. Wiring Harness

A wiring harness (15) with receptacle connector mates with another wiring harness which has a plug connector. These mating connectors provide a quick connect-disconnect point for all wiring to and from the tray.

(4) Voltage Regulator Tray

The voltage regulator (9, Fig. 4 and Fig. 7) is mounted in a pull-out tray similar to the generator monitor and protection trays with the exception that it has no front panel. However, it is protected by the cabinet lower compartment door.

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The regulator is a solid-state device designed to provide automatic voltage regulation of generator output at the aircraft. It will maintain a constant voltage to within plus or minus 1% of the preset value. The regulator controls output voltage by varying the field power of the exciter as required by load conditions. For details, Static Voltage Regulator, Operation and Maintenance Manual No. TM-759, in Chapter 8.

(5) Motor And Generator Control Pushbutton Panels

Pushbutton controls for motor and generator are mounted on small separate panels (4 and 10, Fig. 4) just below the trays. (See Fig. 8 and 9).

Each pushbutton panels contains two momentary contact switches and an indicating light. Panel components are identical with exception of the indicating light color. Motor RUNNING light is AMBER, contactor CLOSED light is GREEN.

When an optional second generator is ordered, a second generator output panel “No. 2” is mounted directly to the right of the “No. I’ control panel. (See 5, Fig. 4).

(6) Front Panel (Ref. 2, Fig. 4)

A fluorescent light (1, Fig. 10) at the top of the front panel provides illumination for instruments and controls mounted in trays. It is controlled by a toggle switch (3).

A time totalizing meter (hourmeter) (2) records actual running time and is useful in maintenance scheduling as well as recording total operating time. It is operated by 12-V DC from the generator protection circuit and is turned ON when the motor has reached operating speed and the start-run timer switches have closed. A terminal board (4) is mounted on the back of the panel. Two openings are provided for trays.

c. Interior Panel (Ref. 7, Fig. 4)

The interior panel (Fig. 11) is mounted on the back panel of the control cabinet. Although it is located in the control cabinet it is not considered to be a part of the cabinet assembly.

(7) Contactors

Three identical electromagnetic switches or relays that are identified as “contactors” by the manufacturer are located on the interior panel. The contactor is a sealed unit. Main contacts are 3 p st. N.O. Auxiliary contacts open before main contacts when coil voltage is, removed.

Two contactors (17 and 18) function as motor switches. One (18) connects input power to half of motor stator windings for motor starting. After normal motor operating speed has been reached, the second contactor (17) connects the second half of stator windings for running. Both contactors of course remain closed for normal operation.

The third contactor (7) serves to connect and disconnect generator output power to or from a load (aircraft, etc.) and is identified as the “load contactor”.

(2) Motor Control Transformer

The step-down transformer (5) is used to reduce motor input power to 115~VAC for operation of motor and generator controls. Multiple input taps provide connections for various input voltages from 208-V to 575-V.

(3) Generator Control And Plug-Interlock Relays

These relays (9 and 10) are magnetic coil operated, enclosed, plug-in type, and are identical except their coil voltage ratings.

The generator control relay (9) is energized when the contactor CLOSE switch (See Fig. 9) is pushed. Its purpose is to by-pass the CLOSE switch and connect power for holding the load contactor closed and operating the contactor CLOSED indicating light when the CLOSE switch is released. The relay is de-energized when the OPEN switch is pushed.

The plug interlock relay (10, Fig. 11) is energized by 28.5~VDC from the aircraft being serviced. Its purpose is to interrupt the load contactor holding circuit and disconnect generator output in the event that the output cable plug should be accidentally disconnected at the aircraft. This relay also prevents power delivery if the output cable is not properly connected.

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I I I

I

:0 I

I 10 I I t

I0 I I I

0 0: 0 I

0 I

01

0 1 f

1. Resistor (1000 ohms, 25 watts) 11. Receptacle connector

2

3 0 8 0

4

5

2. Regulator rheostat 12. Fuse (5 amp) 3. Cable length compensation rheostat 13. Fuseholder 4. Cable size compensation rheostat 14. Receptacle connector 5. On-Off switch, line drop compensation 15. Sensing and preamplifier 6. Chassis assembly, line drop compensation chassis assembly 7. Receptacle connector 16. High-phase sensing board assembly 8. Damping circuit gain potentiometer 17. Reactor 9. Receptacle connector 18. Chassis 10. Damping circuit rate potentiometer 19. Terminal board

Voltage Regulator (Top View) Figure 7

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Motor Control Pushbutton Panel Figure 8

NO. 1 GENERATOR CONTACTOR c

START OPEN CLOSED

Generator Control Pushbutton Panel Figure 9

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1. Flourescent light 3. Toggle switch

2. Time totalizing meter (hourmeter) 4. Terminal board

Front Panel Figure 10

(4) Aircraft - Test Bank Switch

This toggle switch (8) is provided to by-pass the plug interlock relay for servicing an aircraft not equipped with an interlock system, or for supplying power to a load bank used in generator testing.

(5) Motor Overload Relay And Transformer

Any input voltage change necessitates a change in overload relay heater* I elements. I

Three current transformers located on the power input panel (15) lower input current in each input line to a lesser value of definite ratio (500A to 5A) for operation of the motor overload relay (14). The relay is an automatic reset, ambient compensated, bimetallic, thermal, overcurrent type. The reduced current is connected to heater elements in the relay. A set of contact in the relay are connected in series with the motor control transformer (5) which supplies power for operation of motor-generator controls and contactors. Any condition of overload in any input line causes a heater element (elements) to OPEN relay contacts and thus stop the motor by disconnecting the source of power for holding contactors closed.

Heater elements must be matched to input voltage (See Sect. l-2, Fig. 15)

(6) Rectifier

This silicon rectifier (2, Fig. 11) “converts” 115-VAC output of the motor control transformer (5) to direct current for operation of all contactor (7, 17 and 18) coils which require DC for operating and holding contacts closed.

(7) Power Supply (12-DC)

The 12-DC power supply (13) is a compact unit which contains a step-down transformer, printed circuit board, etc. required to change 115-VAC input to 12-V DC output. 12-V DC is used for operation of the protective system relay, lights, etc. and the hourmeter. Power from this source is also used by the optional transformer-rectifier.

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18-

16

1 23 4 5 6

1. Voltage regulator (Not part of interior panel)

2. Rectifier

3. Terminal board

4. Wiring harness

5. Motor control transformer

6. Transformer panel assembly 7. Load contactor

8. Aircraft-test bank switch

9. Generator control relay

Interior Panel Figure I I

10. Plug interlock relay Il. “E” and “F” leads terminal

12. Neutral terminal

13. Power supply

14. Motor overload relay

15. Motor input terminal panel

16. Wiring harness

17. Motor run contactor 18. Motor start contactor

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(8) Wiring Harness

Six wiring harness assemblies (4 and 16) are mounted on brackets at the top and left side of the interior panel. Each wiring harness is provided with a quick disconnect receptacle connector which mates with another harness assembly plug connector. This arrangement provides quick disconnect facilities for wires routed to trays, test panel, etc.

(9) Current Transformer Panel Assembly (Ref. 6, Fig. 11)

The current transformer panel assembly (Fig. 12) is mounted in the upper right corner of the interior panel.. The panel (13) is a three sided, box like configuration which allows mounting of electrical components on the sides, front and back.

a. Time Delay Relays

Two, multi-range, time delay relays (8 and 10, Fig. 12) are bracket mounted on the left front of the panel and are sometimes identified as “TDR’s” or simply “Timers”.

The TDR (Fig. 13) provides a choice of any timing period from 50 ms to 10 hours. It has six switch-selected ranges: 1 second, 10 seconds, 1 minute, IO minutes, I hour, and IO hours. Within each range it is dial-adjustable to any desired timing period.

The numerals on the dial adjustment scale always read directly in the correct second, minute or hour units regardless of the range selected, because the range selector switch automatically adds or removes the decimal point as required. The range selector switch knob may be removed to prevent accidental or unauthorized range change.

The TDR has three-mode capability and provides either on-delay, off-delay or interval control depending upon how the terminal block is wired.

The digital circuit of the TDR makes possible the cycle progress indication through a LED (light emitting diode) annunciator or indicator. It starts to blink immediately as timing begins. It blinks at an ever increasing rate as timing progresses: once every 3-l/2 seconds during the first 10% of the cycle, twice every 3-112 seconds during the second 10% etc. When the TDR times out the LED stays on, pulsing at a high rate. Because of the short time cycles involved, the LED pattern is different for l-second and IO-second time ranges. The LED is OFF before timing; steady ON during timing; and PULSATING at a high rate after timing when operating in 1 -second and 1 O-second ranges.

The exciter time delay relay (IO, Fig. 12) is operated in the I minute range and is set for 0.5 min. (30 second) delay.

The start-run time delay relay (8) is operated in the IO second range and is set for 5 seconds delay.

The excitation TDR (10, Fig. 12) is adjusted to provide a 0.5 minute time delay and has three functions. First, it delays closing of the motor RUN contactor until operating speed has been reached; second, it closes the excitation de-energization relay to connect power to exciter fields to provide excitation to both motor and generator; third, it starts the start-run TDR.

The start-run TDR (8) functions 5 seconds after being started. It functions to connect 12-VDC power for operation of the protection circuit. This delay prevents operation of any protective device until generator output is normal following start-up.

NOTE: Timers may be removed from the front of the panel. By removing two screws which attach the timer support (9, Fig. 12) the timer and support may be lifted out as an assembly.

b. Motor Control Relay

This is a plug-in, enclosed relay (5, Fig. 12)

It is energized when the motor START switch is pushed and functions to by-pass the START switch. This relay is de-energized when the motor STOP switch is pushed and then functions to remove power and disable all motor and generator controls.

c. Overload PC Board

The overload board (4) is similar to voltage and frequency protection devices described in Para. 6, B, (3), (a).

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OM-465

The board is a solid-state device designed to interpret signals from current transformers (12) and send a signal to the memory and time delay board (2, Fig. 6) when an overload condition exists in any phase of generator output. A pull-apart electrical connector is mounted on the overload board to provide a quick-disconnect facility for all wiring to the board.

The overload board is equipped with a hermetically-sealed, reed-type relay, the contacts of which are normally OPEN. The solid-state circuitry is designed to CLOSE the relay contacts when the output current in any phase reaches 125% of normal rated load. The closed relay sends a signal to the memory and time delay board. This signal “gates” the overload SCR (silicon-controlled rectifier) in the memory circuit to open the load contactor.

The following is a list of overload module characteristics:

NOTE: The overload protective system will function when any phase carries 123% to 127% of rated current.

l At 125% load the device will function in 5 minutes.

l At 150% load the device will function in 16 seconds.

l At 200% load the device will function in 4 seconds.

NOTE: All times are plus or minus 25% and are nonadjustable.

d. Overload And Ammeter Current Transformers And Resistors

Three overload current transformers (12, Fig. 12) supply a current signal to resistors (I). These resistors convert the current signal to a voltage signal which is sensed by the overload board (4) and also by the ammeter.

NOTE: Resistors for 60-KVA units are rated 25 ohm, 20 watt. Resistors for 37-l/2 KVA units are rated 40 ohm, 20 watt.

e. Voltage Drop Current Transformers And Resistors

The three “line-drop” current transformers (1 I), in conjunction with the burden resistors (3), detect the magnitude and power factor of current flowing from the generator to the load, and feed a signal to the voltage regulator which interprets the signal and alters the exciter field current as required to maintain a constant predetermined voltage at the load. (See Voltage Regulator Manual No. TM-759 in Chapter 8).

f. Fuse and Fuseholder

A cartridge type, 5 amp fuse (6) is mounted in a fuseholder on the face of the transformer panel. This fuse protects the 115-V motor and generator control circuit.

d. Test Panel

A test panel (8, Fig. 4 and Fig. 14) is mounted on the inside of the cabinet door. It provides identified and conveniently located test points for testing generator, motor and controls circuitry.

A schematic diagram background shows the operator exactly at what point in the circuitry a test connection is being made.

Further information and test values may be found in Adjustment/Test, Section 2-3.

e. Cabinet Fan

A 115VAC fan (Fig. 15) is mounted inside the cabinet on the back panel near the top. The fan draws cooling air from two screened openings in the bottom of the cabinet. Air is drawn upward over electrical components and is discharged by the fan through a box like duct mounted outside the cabinet. Heated air is then directed downward by the duct. The fan is not controlled by a switch. It operates constantly when the motor-generator is running.

June 30194 Revised I-I Page I9

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3

FRONT VIEW

13

REAR VIEW

1. Overload and ammeter resistor (25-ohm 8. Start-run time delay relay for 60-kVA, 40-ohm for 37.5-kVA) (TDR) (Timer) 5-second

2. Grommet 9. Timer support 3. Line drop current resistor (50-ohm, 10. Exciter time delay relay (TDR)

25watt) (Timer) 0.5-minute (30 seconds) 4. Overload PC board 11. Line drop current transformer 5. Motor control relay 12. Overload and ammeter current 6. Fuse, 5-amp transformer 7. Terminal board 13. Panel

Current Transformer Panel Figure 12

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Range Indicator Window

Range Selector Switch

LED Annunciator

Dial Adjustment

Time Delay Relay (Timer) (TDR) Figure I3

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Test Panel Figure I4

Cabinet Fan Figure I5

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7. Conduits and Connectors All wiring between the motor-generator and control cabinet is conducted through two conduits which are attached at the stator housing and rear cabinet panel by weather proof connectors. (See Fig. 16).

Motor stator input cables are routed through one conduit while generator output stator cables are routed through the other.

ELBOW CONNECTORS

‘K \

CONDUIT NUT

Motor-Generator-to-Cabinet Cable Conduits and Connectors Figure 16

8. Frame And Sheet Metal Covers And Air Ducts (See Fig. 17) Cooling air enters the generator end at the bottom of a box like inlet cover and passes through small diamond shaped openings in a protective cover on the generator bearing bracket. The protective cover prevents foreign material and small animals from entering the generator. The fan draws air over all windings and discharges it at the motor end through an exhaust duct. The motor end is also protected by a cover with small openings to prevent entrance of small animals and foreign material. A rectangular cover is mounted over the fork lift access holes on the motor end. This cover prevents recirculation of heated air which is discharged downward from the exhaust duct. Heated air might otherwise circulate back to the intake through fork lift openings.

June 30/94 Revised I-I Page 23

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d

1. Air intake cover 7. support 2. Ground strap 8. Cover 3. support 9. Baffle 4. Shield 10. Panel 5. Air duct 11. Frame 6. Guard 12. Cable hanger

Frame and Sheet Metal Covers and Air Ducts Figure I7

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June 30/94 Revised

9. Options

a. General

Several options are available for machines covered by the manual. They are listed and described below.

b. Second Output (Part Number 48521 I)

The second output option is designed to provide a second independent generator output circuit. This dual-output capability allows the generator set to be used for servicing aircraft having two 400HZ input receptacles.

(7) Components

Second output consists of two principal components, namely the load contactor panel (Fig. 18) and output control panel (Fig. 19) plus necessary cables, etc.

a. Contactor Panel

The contactor panel (Fig. 18) is designed to be mounted on the interior panel at the left of the regular, No. 1. output contactor and associated controls. The contactor panel mounts a load contactor (2), plug interlock relay (3), generator control relay (4) and aircraft-test bank switch (5) which are identical to generator output components described under Para. 6, C.

b. Control Panel

The control panel (Fig. 19) is identical to the generator output control panel described in Para. 6, B, (5).

It is mounted in the front panel just to the right of the regular No. 1, output control panel.

c. Convenience Receptacle Panel Assembly, 60-HZ (Part No. 485240, for use on 60-HZ input machines S-61 82A-I and S-6184A-I)

NOTE: For Convenience Receptacle Panel Assembly used on 50-HZ input machines (6183A-1 and S-6185A-I) see Para. 9, J and Fig. 24.

The convenience receptacle panel assembly (Fig. 20) mounts in an opening provided in the side of the control cabinet. This opening is normally closed by a rectangular cover.

Power to the panel assembly is taken from the motor input circuit. Input power is reduced to 115-VAC and output at the dual receptacle is 60-HZ.

The convenience receptacle provides a usable power supply for extension lights and small hand tools.

(7) Components

a. Transformer

A transformer (1) reduces motor input power to 1 I&VAC.

Several input taps allow adjustment for various input voltages.

b. Circuit Breaker

A 1 O-amp manual-reset, circuit breaker (2) provides protection to the circuit.

c. Receptacle Connector

A dual receptacle connector (3) provides connection facilities for two plug connectors. A cover provides protection when the receptacle is not in use.


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2 1. Terminal board

2. Contactor switch

3. Plug interlock relay

4. Generator control relay 5. Aircraft-test bank switch

Second Output Contactor Panel (Optional)

Figure 18

START

NO. 2 GENERATOR CONTACTOR

OPEN

Second Output Control Panel (Optional) Figure I9

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---

4

1. Transformer 2. Circuit breaker 3. Duplex receptacle 4. Terminal board

Convenience Receptacle Panel (Optional) for 60-Hz

Figure 20

d. Phase Failure Relay (Part Number 485398-I)

This relay (Fig. 21), is a solid-state sensor device with relay output. It will prevent motor starting or stop a motor which is running if one phase is lost, or if the voltage on any phase drops below a preset value. The under-voltage drop-out point is screwdriver adjustable, at the front of the relay from 75% to 100% of nominal line voltage. The NO contacts of the relay are connected in series with them motor starting voltage at proper phase sequence

e. Alternate Voltage Kit (Part Number 485237)

This kit is a package containing all of the various motor overload relay heater elements required for any motor input voltage usable by machines covered in the manual. Instructions for voltage changeover are included in the kit. Heater elements contained in the kit are identified in Chapter 7, Fig. 6.

f. Trailer (Part Number 484331)

The trailer may also be used with many generator sets other than those included in this manual. It is therefore covered by a separate manual, TM-268A. The applicable manual will be included in Chapter 8, when the trailer is ordered as an option.

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g. Transformer-Rectifier (Part Number 482085A-1)

Phase Reversal Relay (Optional) Figure 21

This T-R (Fig. 22) is an option which adds 28.5VDC output capability to any of the machines covered by this manual. Since it is also applicable to many generator sets, a separate manual, TM-597, is supplied in Chapter 8 when the T-R is purchased as an option.

h. T-R Mounting Package (Part Number 485255)

A special kit or group of parts, identified as a mounting package (Fig. 23), is required to mount the T-R.

The T-R is mounted directly above the motor-generator on a fabricated support.

A cable conduit with weatherproof connectors at the T-R and control cabinet protect AC power cables and wiring to the T-R. A cable hanger is provided for storing DC output cables.

i. Convenience Receptacle Panel Assembly, 50-HZ (Part Number 485652, for use on 50-HZ machines S-6183A-1 and S-6185A-1).

This convenience receptacle panel assembly option (Fig. 24) is very similar to the assembly described in Para. 9-C above, and performs the same function of providing a usable power supply for extension lights and small tools.

In this case the output power is 230-VAC, 50-HZ.

The manual-reset circuit breaker is rated at 5 amperes.

The receptacle connector provides a single connection.

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Transformer-Rectifier (T-R) 28.5-V DC (Optional) Figure 22

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1. Grommet 7. Harness

2. Elbow 8. Housing

3. Bushing 9. Sleeving

4. Connector 10. Cable hanger

5. Gasket 11. Cable assembly

6. Conduit 12. support

Transformer-Rectifier Mounting Package (Optional) Figure 23

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I. Transformer 2. Circuit breaker 3. Receptacle 4. Terminal board

Convenience Receptacle Panel (Optional) for 50-Hz

Figure 24


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Section 2. Preparation For Use

1. Uncrating

a. Uncrate the unit carefully.

b. Depending upon packaging level, remove blocking, banding, ties and any other exteriorsecuring material.

c. Open cabinet door and remove door keys which are taped to right side of cabinet.

d. Remove, identify and store any packaged items on the floor of the cabinet, such as motoroverload heater elements and instructions for alternate motor input voltage, and floormounting brackets.

e. The unit may be lifted by attaching hoist, etc. to lifting eye located on the motor-generatorstator housing. Rectangular openings in the frame are to accommodate lift truck forks forlifting and moving.

2. Inspection/CheckInspect the unit thoroughly.

a. Inspect exterior for shipping damage such broken lights, damaged sheet metal, etc.

b. Inspect cabinet interior for foreign material such as tools, papers, etc.

c. Inspect motor-generator air inlet for obstructions to air flow.

3. LubricationNo pre-start lubrication is required. Motor-generator armature bearings are permanently lubricated andsealed.

4. Generator Set Mounting Installation

a. Location

When installing the generator set, avoid locations exposed to high humidity, dust, or corrosivefumes. Provide a clear working area around the complete machine.

b. Mounting

(1) General

No “hard and fast” rules for mounting the generator set can be given because they may vary,depending upon the user’s requirements and facilities. Common sense must be used in allinstallations to achieve a firm mounting which is free from vibration and which does not placeundue stress on the mounting frame and motor-generator.

(2) Mounting Cautions

Before recommending how to mount the generator set, we believe you should first be cautionedabout how NOT to mount it.

(1) Do not bolt the machine to an uneven floor, pad, or pedestal. This can causedamaging stresses in the frame and motor-generator.

CAUTION

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June 30/94 Revised 1-2Page 1

(2) Do not set (and operate) the machine loosely on an uneven surface. Thiscan result in an unstable three-point suspension and cause vibration.

NOTE: In most cases, vibration is caused by mounting the generator set on an uneven surface.

(3) Recommended Mounting Instructions

a. Mounting Surface

The single most important thing in generator set mounting is the mounting surface. Themounting surface must be level and smooth, so that the full length and width of the frame issupported evenly.

b. Vibration Control

Refer to Figure 1. Vibration of the generator set is minimized by mounting the unit directlyon the resilient pads provided. Any lateral movement of the generator set is prevented byinstalling the padded frame-holding brackets as illustrated in Figure 2. The resilient vibrationcontrol pads and the padded brackets are shipped inside the unit’s control cabinet andMUST be installed as shown in the illustrations. An adhesive coating on one side of the floorpads is exposed by stripping away its protective cover. This adhesive secures the strips tothe floor, as shown in Figure 1, until the unit is placed in position.

Do not bolt frame directly to floor.

(4) Mounting Kit (See Fig. 2)

Each mounting kit contains the following parts

• Eight (8) Vibration Control Pads, for under-frame, Part No. 78A-1078

• Four (4) Mounting Brackets, Part No. 485256

• Four (4) Frame Holding Brackets with Pads, Part No. 485258

• Eight (8) 3/8 - 16 X 1 in. Long Hex-Hd Cap Screws with nuts and lockwashers.

(5) Mounting Procedures

a. Open installation kit bags found in cabinet.

b. Determine exact mounting location for generator set, and position 2-inch X 6-inch vibrationcontrol pads (1, Fig. 2) as indicated in Figure 1.

c. Lift and position generator set onto pads.

d. Place a frame holding bracket (2, Fig. 2) and a mounting bracket (3) at each corner of theframe, then assemble each set of brackets so that frame holding bracket pads contact theend frame member and the side frame member as illustrated in Fig. 2. Two bracketassemblies will be assembled one way and two the opposite way.

e. Use 3/8-inch masonry anchor bolts to attach mounting brackets to floor so that both bracketpads contact the frame firmly.

(6) Alternate Mounting Method

An alternate method to the plain pad installation described above is one involving the use ofself-contained leveling mounts such as “Unisorb Level-Rites” or equivalent. These mounts willcompensate for a greater degree of floor unevenness than plain insulating pads.

CAUTION

CAUTION

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1-2 June 30/94 RevisedPage 2

Frame Pads and BracketsMounting Location

Figure 1

1. Vibration control pads

2. Frame holding brackets

3. Mounting brackets

4. Cap screw, 3/8 - 16 X 1 in.

5. Hex nut, 3/8 - 16

6. Lockwasher, 3/8

7. Frame

Frame Mounting BracketsInstallation

Figure 2

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5. Wiring the Generator Set

a. Preparation for Wiring

Several things must be determined before any actual wiring is started.

(1) Input Voltage Requirements

The input voltage for which the machine is internally connected may be determined in either oftwo ways. First, a tag, indicating voltage requirements, is attached to each machine. Second, ifthe tag is lost or destroyed, check the nameplate on the front of the machine to determine thespecification number.

NOTE Spec numbers 6182A-1 and 6184A-1 may also use 208-V and 380-V input. Consult factory foroperation at these voltages.

To determine what voltage the machine is connected for, check the connection of the YELLOWwire on the motor control transformer (Sect. 1-1; Fig. 11, Item 5). Refer to Fig. 3, whichindicates terminal connections for all input voltages.

SPECIFICATIONNUMBER

IS CONNECTABLEFOR

INPUTHERTZ

6182A-1 230-V or 460-V 60

6182A-2 208-V or 380-V 60

6182A-3 575-V 60

6183A-1 220-V or 380-V 50

6184A-1 230-V or 460-V 60

6184A-2 230-V or 460-V * 60

6184A-3 208-V or 380-V 60

6184A-4 575 60

6185A-1 220-V or 380-V 50

6185A-2 415-V 50

* Delta Output

VOLTAGE 208-V 220-V 230-V 380-V 415-V 460-V 575-VYELLOW WIRE ConnectionTerminals on Motor ControlTransformer

H6 H5 H5 H4 H3 H2 H1

Motor Control Transformer Primary Connectionsfor Various Input Voltages

Figure 3

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(2) Cable Horns and Clamps

Entry and exit holes for input and output cables are pre-cut in the control box and are equipped withprotective cable horns and clamps. On single output machines, the second output hole is coveredby a metal plate.

(3) Cable Size Selection for Input Power

Select a cable size which meets Local Electrical Code based on the following tables (Figures 4, 5,6, and 7). Cable length must also be considered in determining voltage at the machine.

INPUT VOLTAGE NORMAL FULL LOADAMPERAGE

STARTING INRUSHAMPERAGE

208-V 114-A 205-A

230-V 103-A 182-A

380-V 62-A 108-A

460-V 52-A 112-A

575-V 41-A 110-A

Normal Operating and Starting Amperages for37.5-KVA, 60-Hz Units

Figure 4



208-V 170-A 340-A

230-V 154-A 375-A

380-V 93-A 210-A

460-V 77-A 260-A

575-V 61-A 325-A

Normal Operating and Starting Amperages for60-KVA, 60-Hz Units

Figure 5



220-V 109-A 245-A

380-V 63-A 155-A

Normal Operating and Starting Amperages for37.5-KVA, 50-Hz Units

Figure 6

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b. Input Wiring

(1) Protection

Always be sure the power source is turned off when working on input leads orconnections.

A disconnect switch and fuses must be installed in the input circuit between the power sourceand generator set. Install to meet local electrical code.

(2) Cable Terminations

No terminals are required for input cables. The only preparation required is removal of1-1/4-inch of insulation from each cable end. A cable attaching hole in the lug will accommodatecable sizes from #2 to 500 CM. A short clamping screw with 3/8-inch Allen head drive providescompression to hold the cable termination firmly in place.

(3) Cable Routing

Route input cables, from their entrance point in the cabinet, neatly to the input terminal board(Sect. 1-1, Fig. 11, Item 17) on the interior panel. Provide sufficient slack to allow easy insertionof cable ends into terminal lug holes.

(4) Cable Connections and Armature Rotation Direction

It is easily possible to connect three-phase input cables in a manner which will result in reversearmature rotation. It is equally easy to correct the connections to rotate the armature in theproper direction.

If input cables are identified as L1, L2 and L3, they may be connected properly the first timesince terminal lugs are identified as L1, L2 and L3 by labels (See Fig. 8). Connect cable L1 tolug L1, cable L2 to lug L2, etc. Use a 3/8-inch Allen wrench to tighten lug clamping screwssecurely.

If cables are not identified, connect at random and check for proper armature rotation later [Para(6) below].

(5) Grounding

a. Connect a No. 2 size (minimum) ground wire from “GND” terminal to earth or to groundconnection at the power source.

b. When conduit or flexible armored cable is used for input, provide an adequate ground as inPara (a) above. Also ground the conduit or armor of the cable.

WARNING



220-V 162-A 427-A

380-V 94-A 275-A

Normal Operating and Starting Amperages for60-KVA, 50-Hz Units

Figure 7

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(6) Check for Proper Phase Sequence Connection

It is necessary to have input power to the machine to make any check for proper phasesequence and armature rotation.

a. Safety Check

Make certain that the machine is properly grounded and that no tools or other foreignmaterial are in or on the unit.

Before turning on power to the machine, make certain that no harm to personnelor damage to the machine will result from connecting input power or fromstarting the motor.

b. Motor Connection Check with Phase Sequence Indicator

• Connect the three leads of a phase sequence indicator to the three input cableconnections. If the indicator shows ABC sequence, cables are connected properly.

• If the instrument indicates an out-of-phase sequence (CBA) connection, EXCHANGE THECONNECTIONS OF ANY TWO INPUT CABLES AT THE INPUT TERMINAL BOARD TOCORRECT THIS.

Always turn off power at the remotely located switch BEFORE exchanging orworking with input cables. This applies to Para. (c) and (d) below as well as toPara. (b) above.

WARNING

WARNING

Input TerminalsFigure 8

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c. Motor Connection Check with Phase Reversal Relay

If the machine is equipped with an optional phase reversal relay, check as follows, after firstdetermining that no injury or damage will result from starting the motor.

• Press motor START button.

• If the motor starts normally, the phase sequence is correct. Press motor STOP button.

• If the motor did NOT start, it indicates that input cables are connected incorrectly.Correction is the same as previously explained - exchange the connections of ANY TWOinput cables.

d. Armature Rotation Check

This is the most time-consuming check to make, because some sheet metal covers must beremoved to observe armature rotation.

• Remove air intake duct cover at generator end (See Sect. 1-1; 1, Fig. 17).

• Start motor and observe armature rotation direction.

• If armature rotation is counter-clockwise when observed from the generator end, inputcables are connected in proper phase sequence. Stop motor.

• If observed rotation was clockwise, stop motor, DISCONNECT input power, and correct byexchanging the connections of any TWO input cables as above.

• Install air intake duct cover.

c. Output Wiring

(1) Output Cable Assembly

Generator sets of this output capacity (37.5-KVA and 60-KVA) normally use an output cableassembly with plug connector which mates with an aircraft receptacle connector. Eachcable and small lead of the cable assembly is identified by an identification band (See Fig.9). Cables are identified as A, B, C, and N. Two small leads are identified as E and F.

(2) Cable Selection

Cable assemblies with four single-conductor 1/0 cables and two #12 control leads are available.In a 115/200-V, 3-phase, 400-Hz system, this cable assembly will carry up to 75-VA of load.Cable length should be held to shortest practical length possible to minimize voltage drop, andshould be NO LONGER THAN 60 FEET.

(3) Cable Connection

a. Cable entrance and exit holes in the cabinet have been located and cut at the factory, andcable horns, clamps, et cetera, have been installed. The cable horn is for cable protectionand the clamp is to hold the cable and protect the load contactor and terminals from damageresulting from pulling or jerking the cable.

b. Route loose cable ends through cable horn and clamp. Remove load contactor terminalshields (See Fig. 10) and connect “A” cable to “A” terminal on load contactor, “B” cable to “B”terminal, and “C” cable to “C” terminal.

c. Connect “N” (neutral) cable to “N” terminal (Fig. 10) on interior panel.

d. Connect “E” and “F” leads to single “E” and “F” terminal beside the “N” terminal. (Fig. 10).

e. Allow some slack in cables and leads inside the cabinet, and tighten cable clamp bolts.Re-install load contactor terminal shields.

f. Coil and store cable assembly on cable hangers.

(4) Second Output

If an optional second output has been installed, follow the same connection procedures asoutlined above.

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Output CableAssemblyFigure 9

(Typical, showingplug connector

and cableterminals. Notpart of the unit)

Output LoadContactor, Cable

and LeadConnectionTerminalsFigure 10

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6. Wiring for Alternate Input Voltages

a. General

Some of the machines covered by this manual may be operated at more than one input voltage bychanging some connections in the control cabinet. Figures 4 through 7 indicate input voltagesusable on each machine.

b. Motor Stator Terminal Board

For operation on lower voltages (208-V, 220-V, or 230-V), links on the motor stator terminal boardare positioned to operate the motor in DELTA connection (See Fig. 11). For operation on highervoltages (380-V and up), links are positioned for WYE motor connection (See Fig. 12). Thus it isnecessary to change stator link connections only when changing from low voltage to high voltageand vice versa. To change stator link connections, proceed as follows:

If input power is not disconnected at a remote point, serious injury could result.

(1) Turn OFF input power at remote disconnect switch.

(2) Open top (Plexiglas) door. Loosen generator monitor tray fastener (2, Fig. 13) and slide trayoutward. Disconnect plug connector (3) at receptacle.

(3) Support tray with hands at each side of the tray near latches (5). Unlock latches by pressingthem DOWN with thumbs, then slide tray out of its compartment.

(4) Remove fiber cover over motor stator terminal board.

(5) Observe and note position of stator cables. Disconnect as required to change links.

NOTE: Cables must be returned to their original connected position.

(6) For low voltages (208-V, 220-V, or 230-V) motor stator links must be positioned as illustrated inFig. 11.

(7) For high input voltages (380-V and up) motor stator links must be connected as illustrated inFig. 12.

WARNING

Motor Stator ChangeoverLinks Connected for

208-V, 220-V, or 230-VInput (Delta Connection)

Figure 11

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c. Motor Overload Relay Heater Elements

Overload relay heater elements must be checked or changed each time input voltage is changed.

(1) Open cabinet door and observe numbers on the three heater elements in overload relay (Fig.14). Compare element numbers with those indicated by chart (Fig. 15) for the voltage you aregoing to use.

(2) If the comparison indicates that a change is necessary, remove old heater elements byremoving attaching screws and replace with proper elements indicated by the chart.

NOTE: All available heater element kits are listed in Chapter 4, Parts List.

Motor Stator ChangeoverLinks Connected for

380-V, 415-V, 460-V, or575-V Input (Wye

Connection)

Figure 12

1. Latch

2. Fastener

3. Connector

4. Rail

Tray Removal (Typical)Figure 13

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SERIES 208-V 220-V 230-V 380-V 415-V 460-V 575-V

6182A AR 2.98 AR 2.71 AR 1.53 AR 1.26 AR .95

6183A AR 2.71 AR 1.53

6184A AR 4.37 AR 3.98 AR 2.24 AR 1.68 AR 1.39

6185A AR 3.98 AR 2.24 AR 2.04

Motor Overload Relay Element and Voltage ChartFigure 15

1. Element mounting location 4. Manual reset button2. Element mounting screws 5. Trip current adjustment3. Automatic-manual (hand) reset control

Motor Overload RelayFigure 14

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d. Motor Control Transformer Alternate Connections

Motor control transformer primary coil connections must be changed also when input voltage ischanged.

(1) Observe connection of YELLOW wire on motor control transformer (Fig. 16).

(2) Compare the top connection observed with tap identifications and voltages shown in chart (Fig.17).

(3) Change tap connection of YELLOW wire as indicated by chart for voltage you are going to use.

Connection for 60-Hz machines.Connect transformer leads per this schematic.

Connection for 50-Hz machines.Connect transformer leads per this schematic.

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e. Convenience Receptacle Panel Assembly (Option)

When changing power input to a different voltage or when adding the convenience receptacleoption to a machine, ALWAYS check connection of convenience receptacle transformer primaryleads to make certain that they are properly connected for the input voltage being used.

f. Checks and Procedures Following Voltage Changeover

(1) Double check to make certain that the changeover process has been completed properly.

(2) Check security of all connections and parts changed.

(3) Install cover over motor stator terminal panel.

(4) Install generator monitor tray and connect harness plug connector. Slide tray in and secure.

(5) When certain that the machine is in a condition to receive input power, close doors and turn ONpower at remote disconnect switch.

VOLTAGE 208-V 220-V 230-V 380-V 415-V 460-V 575-VConnect YELLOW WIRE to thisTerminal

H6 H5 H5 H4 H3 H2 H1

Motor Control Transformer Taps and Voltage ChartFigure 17

Motor Control TransformerTaps Identification

Figure 16

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Section 3. Operation

1. GeneralThis section contains information and instructions for the safe and efficient operation of the equipment.Operating instructions are presented in step-by-step sequence of procedures to be followed insupplying 400-Hz power to an aircraft or other equipment.

NOTE: Read all of this section before attempting to operate the unit.

2. Preparation for Power Delivery with AUTOMATIC Voltage Regulation

a. Safety

Make certain that no tools, rags, or other foreign material are in or on the unit.

b. Position Switches and Controls

Position (or check) switches and controls as follows: (See Fig. 1, which is a composite of allcontrols). Open plexiglas cover to gain access to controls.

(1) Front Panel

If lighting is required, place panel light switch (17, Fig. 1) in ON position.

(2) Generator Monitor Tray

The voltmeter-ammeter selector switch (2, Fig. 1) may be in any position. However, someoperating instructions should be understood.

a. The rotary selector switch (Fig. 2) provides a means of connecting and selecting inputsignals to the ammeter and voltmeter. This enables the operator to select and observe theload (amperes) in any of the three output phases, “A”, “B”, or “C”. It also allows selection ofline-to-neutral voltage in any of the three phases or line-to-line voltage. The switch has sixfunctional positions. Each position is identified by two sets of letter designators (i.e. B-N andPH. B when the knob pointer is straight down as in Fig. 2). The two top letters, separated bya dash, indicate which voltage is connected to the voltmeter. Any combination of line-to-linevoltage (A-B, B-C or C-A) may be selected. Likewise, any line-to-neutral voltage (A-N, B-Nor C-N) may also be selected.

b. The bottom letters (i.e. PH. B) at each position indicate which phase is being monitored bythe ammeter. You will notice that each phase may be monitored in either of two positions.

c. Release tray fastener (3, Fig. 1) and pull monitor tray outward. Unless output voltage is tobe controlled manually for testing, etc., the voltage control, automatic-manual switch (29)should be in AUTOMATIC position. Push tray in and secure.

(3) Generator Protection Tray

a. Press reset switch (13) to reset protective system if any indicating lights (7 through 10) areON.

b. Press light test switch (12). All fault indicating lights should glow if lamps are good.

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1. Voltmeter 13. Reset switch2. Voltmeter and ammeter selector switch 14. Motor START switch3. Tray fastener 15. Motor STOP switch4. Ammeter 16. Motor RUNNING indicating light5. Hourmeter 17. Panel light switch6. Fuse, protective system, 2-amp 18. No. 1 contactor CLOSE switch7. Overvoltage indicating light 19. No. 1 contactor OPEN switch8. Undervoltage indicating light 20. No. 1 contactor CLOSE indicating light9. Underfrequency indicating light 21. No. 2 contactor CLOSE switch (optional)

10. Overload indicating light 22. No. 2 contactor OPEN switch (optional)11. Hole plug 23. No. 2 contactor CLOSE indicating light12. Test switch (optional)

Operating Controls and InstrumentsFigure 1 (Sheet 1 of 2)

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24. Exciter time delay relay (timer) 30-second 32. Automatic voltage control rheostat25. Start-run time delay relay (timer) 5-second 33. Cable length compensation rheostat26. Fuse, motor control transformer 5-amp 34. Cable size compensation rheostat27. No 1 Aircraft-test bank switch 35. Line (voltage) drop compensation28. No 2 Aircraft-test bank switch (optional) ON-OFF switch29. Automatic-manual voltage control switch 36. Damping circuit “gain” potentiometer30. Manual voltage control rheostat 37. Damping circuit “rate” potentiometer31. Fuse, voltage regulator, 5-amp


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(4) Voltage Regulator Tray

a. Open cabinet door and slide voltage regulator outward.

b. Place line-drop compensation switch (35) in ON position.

c. Check the position of the cable compensation rheostats (33 and 34). Output cable size andlength (generator set to aircraft) must be known for this check. Rheostat (33) knob must beset to the cable length (in feet). Rheostat (34) knob must be set to cable size (2/0, 4/0, etc.).(See manual TM-759 in Chapter 6 for details regarding voltage regulator adjustment.

d. The regulator rheostat (32) has been set at the factory to produce 115-V AC output. Do notdisturb this adjustment until the generator is running and a voltage value can be read on thevoltmeter.

e. Push voltage regulator tray into locked position.

Voltmeter-Ammeter Selector Switch PositionsFigure 2

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(5) Interior Panel

a. Place aircraft-test bank switch (27) in AIRCRAFT position if aircraft to be served is equippedwith an interlock system. When supplying power to an aircraft or load bank not equippedwith an interlock system, place the switch in the TEST BANK position.

b. Time delay relays (timers) (24 and 25) are properly adjusted at the factory. If timers havebeen tampered with, reset as follows: (See Fig. 3).

• Set exciter time delay relay (24, Fig. 1) range selector switch (Fig. 3) at 1 minute, and setdial adjustment at 1/2 (0.5) minute.

• Set start-run relay (25, Fig. 1) range switch at 10 seconds, and set dial adjustment at 5.

3. Power Delivery with Automatic Voltage Control

a. Press motor START switch (14) momentarily. Motor RUNNING indicating light (16) shouldglow immediately. Allow approximately 35 seconds for the motor to reach operating speedand the generator to produce power. The hourmeter (5) will start when the generator is incondition to deliver power.

NOTE: A start may be aborted without damage to motor starting contactors.

b. Observe the generator output voltage as indicated on the voltmeter (1). This voltage mustbe 115-V, line-to-neutral. If voltage is not 115-V, use the rheostat (32) to adjust to propervalue. Turn the rheostat knob CLOCKWISE to INCREASE voltage andCOUNTERCLOCKWISE to DECREASE voltage. Use the meter selector switch (2) to checkvoltage in each phase.

NOTE: If the rheostat (32) has been tampered with and is adjusted for too high or too low voltage, a faultindicating light may come on to indicate an abnormal generator output condition. If this happens,observe and note which fault (overvoltage or undervoltage) occurred. Correct the fault condition, asrequired by turning the rheostat knob in accordance with instructions in the paragraph directly above.Press the reset switch (13) when voltage adjustment is completed.

c. Connect generator output cable plug connector to aircraft. Make certain that the plug andreceptacle connectors are securely and fully mated.

d. Press generator load contactor CLOSE button (18). Indicating light (20) glows

e. It is recommended that the operator check output voltage and current in each of the threephases early in the power delivery run. Use meter selector switch (2) to select phaseamperage observed and to select line-to-line or line-to-neutral voltage. If load is changing,it is good operating practice to observe the instruments until load conditions stabilize.

f. A condition of overvoltage, undervoltage, underfrequency or overload in the output circuitwill automatically open the load contactor and turn on the applicable indicating light tosignal the operator as to which of the above faults caused the protective monitor to operate.After the fault has been corrected, press the reset switch (13) to turn off the indicatinglight(s) and reset the protective monitor system. Proceed with power delivery by pressinggenerator load contactor CLOSE button.

4. Preparation for Power Delivery with MANUAL Voltage ControlPower delivery, using manual means for controlling the generator output voltage, is basically anemergency operation and should be used only in case of voltage regulator failure, or for testing the unit.Preparation for power delivery with manual voltage control is exactly the same as for automatic control,except:

a. Place the automatic-manual switch (29) in MANUAL position. This will disconnect thevoltage regulator from the exciter field circuit and connect the manual voltage controlrheostat (30) into the circuit.

b. Set the manual voltage control rheostat (30) knob to near mid-range position.

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Time Delay Relay (Timer) (TDR)Figure 3

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5. Power Delivery with MANUAL Voltage ControlPower delivery procedures are the same as for delivery with automatic control, except:

a. Regulate the output voltage to 115-V by controlling the exciter voltage and current with themanual voltage control rheostat (30). Turn the knob CLOCKWISE to increase voltage andCOUNTERCLOCKWISE to decrease voltage.

b. There is a possibility that the protective monitor system may function to open the loadcontactor (because of overvoltage and undervoltage) before the operator can stabilizevoltage output at 115-V. If this happens, press the reset switch (13) and reconnect thegenerator to the load by pressing CLOSE switch (18).

Caution: The operator must remain with the unit to adjust the manual voltagecontrol rheostat as required by changing load conditions.

6. Discontinue Power Delivery (See Figure 1)

a. Press the red OPEN switch (19) and hold until the indicating light (20) goes off. This indi-cates that the load contactor has opened and that power is no longer being delivered to theoutput cable.

Warning: Never disconnect a power cable while power is on.

b. Disconnect the Power Delivery delivery cable from the aircraft.

c. Stop motor by pressing red STOP switch (15) to open motor input contactors. Theindicating light (16) should go OFF, indicating that input power has been removed from thethe motor. The hourmeter (5) will stop running.

7. Optional Equipment Operation

a. Second Output Circuit

A second generator output circuit adds the capability of serving aircraft such as Boeing 727,Douglas DC-8 and others which require 400-Hz input at two circuits simultaneously. Componentsof the second output option are described in Sect. 1-1, Para. 9, B.

Operation of a second output is exactly the same as operating a single output. A second generatorcontrol panel, with contactor CLOSE and OPEN switches (21 and 22, Fig. 1) and CLOSEDindicating light (23),is added for the second or No. 2 output. A second aircraft-test bank switch (28)is also added along with a second load contactor, generator control relay and plug-interlock relay.

The second or No. 2 output is capable of the same output as No. 1. However, the combined loadsof both outputs CANNOT exceed the the KVA rating of the machine.

b. Convenience Receptacle Panel Assembly

Power is available at the output receptacle at all times when input power is is reaching themachine, and may be used for operation of lights and small tools. Power output for 50-Hzmachines will be 50-Hz, 230-V. For 60-Hz machines it will be 60-Hz, 115-V.

If the circuit breaker is tripped, it must be reset MANUALLY.

c. Trailer

Operation of the trailer is covered in a separate manual, TM-268A, which is included in Chapter 6 ifapplicable.

CAUTION

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d. Transformer rectifier

Operation of the T-R is also covered by a separate manual, TM-433. It is included in Chapter 6when applicable.

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Chapter 2. Servicing

Section 1. Maintenance

1. GeneralTo make certain that the generator set is ready for operation at all times, it must be inspected andmaintained systematically so that defects may be discovered and corrected before they result inserious damage or failure of the equipment. Defects discovered during operation of the unit should benoted for future correction to be made as soon as operation has ceased.

Stop operation immediately if a serious and possibly dangerous fault isdiscovered.

Make certain that the source of motor power is turned off before proceeding withany inspection or maintenance operation which could bring personnel in contactwith high voltage or revolving equipment.

The generator set is designed to be as maintenance free as possible. Therefore there are fewinspection and maintenance requirements.

2. InspectionA periodic inspection should be established and maintained. A suggested inspection/check schedule isprovided in Section 2-2, Figure 1; however it may be changed as required to meet varying operatingconditions and environment. See Section 2, Inspection/Check for inspection and check procedures tobe used in conjunction with Section 2-2, Figure 1 schedule.

3. LubricationThe subject of lubrication is mentioned here mostly to inform maintenance personnel that it has notbeen overlooked. No lubrication is required for the generator set. The motor-generator rotor bearingsare permanently lubricated and sealed at manufacture. Relubrication is not recommended.

A good silicone spray lubricant is recommended for hinges and tray slides if exposure to weathershould make them difficult to operate.

4. Parts ReplacementThere are no high mortality parts which require periodic or regular replacement. The use of thesplit-phase motor starting method has eliminated the need for frequent start switch contactreplacements.

WARNING

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a. Replacements of Lamps and Fuses

Avoid breaking fluorescent lamps. Their gas content is harmful if breathed.

Replacement of mortality items such as lamps, fluorescent lamp starters, fuses, etc., requires nospecial instructions except that the new items should be installed securely and with good electricalcontact. See Fig. 1 for lamp identification chart, and Fig. 2 for fuse identification chart.

b. Replacement of Minor Electrical Components

No special instructions are required for items such as relays, instruments, small switches and othercontrols. Replacements of such items is a matter of disconnecting all wiring attached to the item,removing attaching hardware, taking out the defective item, placing a new item in proper position tomount with the same hardware, and completing the installation by connecting the wiring as notedat removal, or in accordance with the applicable connection diagram.

ITEM PROTECTED LOCATION TYPE SIZEProtective MonitorSystem (12-V DC)

Generator ProtectionTray

AGC-2 2A

Control System (115-V,60-Hz AC)

Current TransformerPanel

AGC-5 5A

Voltage Regulator(230-V, 400-Hz, AC)

Voltage Regulator Tray AGC-5 5A

Fuse Identification ChartFigure 2

LIGHTIDENTIFICATION

LAMPLOCATION

LAMPMANUFACTURER NUMBER

Panel Light(Fluorescent)

Front Panel Lamp Industry TradeNumber

15-T8

Starter for FluorescentLight

Front Panel Lamp Industry TradeNumber

FS-2

Motor “RUNNING”Indicating Light

Motor Control Panel Lamp Industry TradeNumber

120PSB

Contactor ClosedIndicating Light

Generator ControlPanel

Lamp Industry TradeNumber

120PSB

Lamp Identification ChartFigure 1

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Section 2. Inspection Check And Repair

1. GeneralThis section describes inspections and checks to be performed in conjunction with Inspection/CheckSchedule, Figure 1.

2. Exterior Cables and Connections

a. Input and Output Cables

Observe general condition of motor input cables and generator output cables. Inspect for cuts andabrasions in the insulation which could cause a short circuit. Visually inspect the output cable plugconnector for physical damage and evidence of overheating.

b. Cable Connections

High voltage - electric shock can kill! Turn the source of input power off whenchecking these connections.

Check all input and output cable connections for tightness and security.

3. Controls and Instruments

a. Voltmeter and Ammeter

Observe these instruments at each “start-up” to verify that they are operating. If one of theinstruments is suspected of being inaccurate, check it against a master, or test instrument.

b. Indicating Lights

(1) Protective Monitor Indicating Lights

Check the lamps (bulbs) in these lights by pressing test switch (Sect. 1-3; 12, Fig. 1). All lightsshould glow RED when switch is pushed. Replace any defective lamp by unscrewing lensholder to remove and replace.

(2) Motor and Generator Control Indicating lights

Check these lights at each “start-up”. The motor RUNNING indicating light should glow AMBERwhen START button is pushed. Generator contactor CLOSED indicating light should glowGREEN when CLOSE button is pushed. Replace lamp if any light should fail to glow underoperating conditions.

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EACHSTART ASREQUIRED

DAILYOR 8

HOURS

WEEKLYOR 50HOURS

ONEMONTHOR 200HOURS

SIXMONTHSOR 200HOURS

EXTERIOR CABLES

Inspect generator output cables X

Inspect motor input cables X

Check cable connections X

CONTROLS AND INSTRUMENTS

Check voltmeter X

Check ammeter X

Check all indicating lights X

Check over-undervoltage protection circuits X

Check underfrequency protection circuit X

Check overload protection circuit X

Check voltage and ammeter accuracy X

Check all wiring and connections X

Inspect generator set in general X

MOTOR-GENERATOR

Check rotor bearings X

Check temperature X

Inspection/Check ScheduleFigure 1

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c. Overvoltage Protection Circuit

To check the operation of the overvoltage protection circuit, proceed as follows:

(1) Start motor by pressing START switch (Section 1-3; 14, Fig. 1).

(2) Unfasten and pull out the monitor tray.

(3) Place the automatic-manual switch (29) in MANUAL position.

(4) Increase the generator output voltage gradually by turning the rheostat knob (30) slowlyCLOCKWISE. Observe the voltage indicated on the voltmeter and note the voltage at which theovervoltage indicating light (7) comes ON. The relay should function to open the protectivemonitor relay and turn the indicating light ON at an indicated voltage of 130-V to 134-V. Theovervoltage sensing relay is not adjustable and must be replaced if it does not function withinthe specified voltage range.

(5) Adjust generator voltage to normal 115-V AC output.

(6) Push the reset switch (13) to turn the indicating light OFF, and to reset the protective monitor.

d. Undervoltage Protection Circuit

Check operation of undervoltage protection circuit as follows:

(1) The motor must be running, the generator monitor tray open, and the automatic-manual switchmust be in MANUAL position as in Para. 3, C, (1) through (3) above.

(2) Lower the generator voltage in steps of 1-V each by turning the rheostat knob (Section 1-3; 30,Fig. 1) COUNTERCLOCKWISE. Wait at least 12 seconds between steps to allow the timedelay to function after the undervoltage relay has tripped. Observe the voltage indicated on thevoltmeter and note the voltage at which the voltage indicating light (8) comes on. The relayshould function to open the protective monitor relay and turn the indicating light ON at anindicated voltage of 102-V or below. The undervoltage sensing relay is not adjustable and mustbe replaced if it does not function within the specified voltage range.

(3) Adjust generator voltage to normal 115-V AC output.

e. Underfrequency Protection Circuit

To check the underfrequency circuit is a rather complicated procedure. To check this circuit, referto Section 2-3, Para. 3, B, (17), (a) through (e).

f. Overload Protection Circuit

This check should be performed ONLY when the machine is connected to a load bank. Refer to1-3, Para. 3, B, (10) to check overload circuit.

g. Ammeter Accuracy

Ammeter accuracy should be checked when supplying power to a load bank. Use a precision,clamp-on type ammeter on a generator output cable to check panel ammeter accuracy.

NOTE: The panel ammeter movement senses voltage rather than amperage. Therefore aconventional master ammeter cannot be used for testing ammeters used on machines coveredby this manual.

h. Voltmeter Accuracy (See Section 1-1, Fig. 5)

(1) Connect a master voltmeter of known accuracy in test points 218 and 219 on the test panel.

(2) Start the motor and compare the unit voltmeter reading to the master reading. At normal outputof 115-V AC, the voltmeter must not vary from the master meter by more than plus or minus 3%of full scale.

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i. Internal Wiring and Connections

High voltage - electric shock can kill! Turn the source of input power off whenchecking these connections.

(1) Open all doors and trays.

(2) Visually inspect all wiring, leads, and cables. Inspect for cuts, abrasions, and signs ofdeterioration and overheating. Inspect stranded leads for broken strands at terminals. Repairor replace any faulty wiring.

(3) Check all connections and connectors for quality and security.

j. General Overall Inspection

(1) Inspect the entire generator set thoroughly.

(2) Clean the entire unit with dry rags and dry, low-pressure air so that any broken welds, cracks,deformation or other evidence of damage may be observed.

(3) Check all attaching hardware for adequate tightness.

4. Motor Generator

a. Rotor Bearings

(1) Remove motor-generator air inlet and outlet covers and ducts as required to reach bearing hubs.

(2) Start motor.

(3) Check both rotor bearings. Use a stethoscope, or long metal rod, to listen for unusual bearingsounds. If using a metal rod, place one end on a bearing housing and hold the other end nearthe ear. Hold the rod with three fingers and thumb to form a “sounding chamber” between therod and ear. Do not allow the rod to touch the ear. Listen for clicks, whines, or pounding whichwould indicate a defective bearing. Send the unit to overhaul if in doubt of bearing serviceability.

NOTE: Do not misinterpret a “crackling” sound, caused by grease cavitation, as a defective bearing sound.A cavitation noise may be especially noticeable in new bearings.

b. Motor-Generator Temperature

Check the temperature of the motor-generator discharge air at the duct outlet in the top of thecanopy. Use an accurate thermometer with Fahrenheit scale. After one hour of operation at fullload in ambient temperature of 90o F, the discharged air temperature should not exceed 133o F.

5. Check Electrical ComponentsA test panel is provided for checking and testing all electrical components of the electrical controlsystem. See Section 1-1, Para. 6, D, for a description. See Section 2-3, Figures 3 and 4 fornominal test values.

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Section 3. Adjustment / Test

1. GeneralAdjustments and test procedures are most applicable to testing and adjusting the power delivery unitsafter a major repair, replacement of parts, etc.

2. Test PanelA test panel (Fig. 1) provides connections to various selected points throughout the motor-generator setwiring. The panel is located inside the cabinet door where it is easily accessible. It contains a numberof insulated type jacks into which test probes of a voltmeter or ohmmeter fit snugly. These test jacksare referred to as “test points” or “TPs”.

Test points are numbered for identification and a schematic diagram background on the test panelallows the operator to see exactly which points in the wiring are being used.

Figure 2 is a schematic diagram illustrating test point locations and identifying numbers. Figures 3 and4 list normal test values for a number of test point combinations.

NOTE 1: On Figure 3 and 4, in the TEST POINTS columns, “GRD” refers to any good ground within the unit,such as the grounded neutral terminal at the motor input.

NOTE 2: Insulated-tip test plugs, which fit the test jacks, are available from Hobart for making up test leads.Test plug part number is 404208-1.

3. Testing The Generator SetThe following test procedures may be used for testing the unit after major repairs or overhaul.

a. Pre-Operational Test Procedures

Perform the following checks, tests and operations before starting the generator set:

Make certain the remotely located disconnect switch is off and no power isreaching the generator set.

(1) Make certain that motor input and generator output “GRD” and “N” terminals are properlygrounded.

(2) Check all wiring for loose connections.

(3) Polarize exciter field by momentarily applying 12-V DC or 24-V DC between TP201 and TP202.Connect POSITIVE lead to TP201 and NEGATIVE to TP202.

Flashing the field in a reverse direction could result in damage to diodes in thevoltage regulator or manual voltage control rectifier.

(4) Prepare for checking motor starting sequence by disconnecting motor control transformer leadsat terminals X 1 and X2. See Sect. 1-1; 5, Figure 11 for location of transformer. Refer to Fig. 4for location of terminals.

CAUTION

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(5) Connect a source of 115-VAC power to the two transformer leads removed above, so that themotor starting sequence may be completed WITHOUT connecting normal input power to the setand WITHOUT starting the motor.

a. An ordinary 2-wire extension cord with male plug connector on one end may be used.Attach an alligator clip to each wire on the other end.

b. Attach clips to transformer leads disconnected in Para. 4. above.

c. Insert male plug of extension cord into regular 115-VAC wall outlet to provide power to motorcontrol circuits.

(6) With exciter timer (M7) (24, Fig. 5) set at 0.5 minute and start-run timer (M22) (25, Fig. 5) set at5 seconds, check motor start sequence timing by using a stop watch or watch which willindicate seconds.

(7) Press START switch (14, Fig. 5) and observe flashing red LED lights on timers. The excitertimer (24) should time out in 30 seconds to start the start-run timer (25). In 5 more seconds thestart-run timer should also time out to close the motor RUN contactor.

The motor start contactor should close the instant the START switch (14) is pushed. After atotal delay of approximately 35 seconds the motor RUN contactor should close.

An alternate method of checking start sequence is to use a voltmeter to check timing.

a. Connect voltmeter between TP115 and GRD.

b. Press motor START button and start timing sequence with watch. At the end of 30 secondsa voltage value (115-VAC) should appear on voltmeter.

Test PanelFigure 1

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c. Quickly change voltmeter probe from TP115 to TP116. If 5 seconds after voltage appearedat TP115, or a total of 35 seconds after START button was pushed, voltage should beindicated (115-VAC) at TP116.

(8) Observe running time meter (hourmeter) (5, Fig. 5) to be sure it is operating when motorcontactors are closed.

(9) Observe operation of cabinet cooling fan located at the top of cabinet rear panel.

(10) Check 12-V DC power supply (sect. 1-1; 13, Fig. 11)

Check voltage between TP223 and GRD. Voltage should be 12-V DC. If not 12-V DC, adjust inaccordance with instructions in Para. 6,C.

(11) Check lamps in indicating lights (7 through 11, Fig. 5) by pressing test switch (12)

(12) Press motor STOP switch (15). Amber indicating light (16) should go OFF.

(13) Unplug extension cord used for auxiliary power in these tests. Detach clips from controltransformer leads and reconnect leads to terminals X1 and X2 on transformer (Fig. 4).

(14) Check connection of motor stator voltage changeover links, motor control transformer inputconnections and motor overload relay heater elements for proper connection for input voltage tobe used. Refer to Sect. 1-2, Para. 6 for proper connections.

(15) Position automatic-manual reset control (3, Fig. 6) on motor overload relay to AUTO position.Set trip current adjustment to 100%.

(16) Connect generator output to a load bank of sufficient capacity to check generator at 125% ofrated load capacity. Use same size and length cables as those to be used in service.

(17) If input power is not already properly connected at set, connect and check in accordance withSect. 1-2; Para. 5, B, (1) through (6).

With power properly connected and turned ON proceed to operational tests.

b. Operational Test Procedures

(1) Check voltage between TP106 and GRD. Voltage should be 115-VAC indicating a good motorcontrol transformer (T14). Check voltage between TP105 and GRD. Should also be 115-VAC.If no voltage is indicated, replace fuse (F10) (26, Fig. 5)

(2) Attach a clamp-on type ammeter to a power, input cable. Press motor START switch (14, Fig.5). Observe and record starting amperage. Compare to Sect. 1-2; Figs. 4, 5, 6, or 7.

(3) Place panel light switch (17, Fig. 5) in ON position to check operation of panel lamp and starter.

(4) Check operation of load contactor (No. 1) and its operating controls and circuitry.

a. Place aircraft-test bank switch (27) in TEST BANK (ON) position.

b. Press load contactor CLOSE switch (18) momentarily. Load contactor should close andindicating light (20) should glow GREEN.

c. Press load contactor OPEN switch (19). Load contactor should OPEN and indicting light(20) should turn OFF.

(5) Place automatic-manual control switch (29, Fig. 5) in MANUAL position to check manual voltagecontrol circuit and range. Use manual control rheostat (30) to check adjustable voltage, L-N(line-to-neutral). Turn rheostat knob clockwise to INCREASE voltage and counterclockwise toDECREASE voltage. Maximum voltage, as indicated on voltmeter (1) should be 140-VAC.Minimum voltage should be less than 100-VAC. If voltage is not within this range, adjust inaccordance with instructions in Para. 6, B.

(6) Place automatic-manual control switch (29) in AUTO position. Use voltage regulator rheostat(32) to check automatic voltage control range. Turn rheostat knob clockwise to INCREASEvoltage and counterclockwise to DECREASE voltage. Maximum voltage should be 132-VAC,or higher L-N. Minimum voltage should be less than 100-VAC.

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(7) Check plug interlock relay and aircraft test bank switch.

a. Place aircraft test bank switch 927) in TEST BANK position and press load contactor CLOSEswitch 918). Green contactor CLOSED indicating light (20) should glow, indicating that loadcontactor is closed.

b. Place aircraft test bank switch in AIRCRAFT position. Indicating light (20) should go OUTand load contactor should open, indicating that aircraft-test bank switch is functioning andthat plug interlock relay contacts are open as they should be.

c. Apply 24-V DC between terminals N and E, F on interior panel (See Sect. 1-1; Fig. 11).Press load contactor CLOSE switch. Load contactor should close, as indicated by light (20),and remain closed. This indicates that the plug interlock relay (Sect. 1-1; 10, Fig. 11) isfunctioning properly.

d. If machine is equipped with SECOND OUTPUT, repeat above test using second outputcontrols.

(8) Pull voltage regulator tray outward sufficiently to reach regulator controls. Be sure automaticmanual switch (29) is in AUTOMATIC position and that line drop (voltage) compensation switch(35) is ON. Adjust cable length compensation rheostat (33) to length of output cables beingsued. Use an accurate voltmeter to check voltage at the load.

Voltage should vary no more than 1% when load is varied between no load and 125% ratedoutput capacity of generator.

TEST POINTS: POINT-TO-POINT NORMAL VOLTAGE VALUE

101 - 102 Line voltage See Below *




106 - GND 115 +/- 5-V AC

105 - GND 115 +/- 5-V AC

110 - 111 110 +/- 5-V AC

* Series 6182A, Model 37F-H61, 230-V, 460-V, or 575-V

* Series 6183A, Model 37F-H51, 220-V or 380-V

* Series 6184A, Model 60F-H61, 208-V, 230-V, 380-V, 460-V, 575-V

Test Values, Power to Unit, Unit Not RunningFigure 2

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(9) Apply full load, and operate the unit for 20 minutes.

TEST POINTS CONDITION TEST VALUES109 - 111 No Load 110 +/- 5-V DC108 - 111 No Load 110 +/- 5-V DC107 - 111 No Load 110 +/- 5-V DC112 - Ground No Load 115 +/- 5-V AC113 - Ground No Load 115 +/- 5-V AC114 - Ground No Load 115 +/- 5-V AC115 - Ground No Load 115 +/- 5-V AC116 - Ground No Load 115 +/- 5-V AC117 - Ground No Load, Load Contactor Closed 115 +/- 5-V AC201 - 202 No Load, (Series 6182A) AUTOMATIC MODE 15 +/- 3-V DC201 - 202 No Load, (Series 6183A) AUTOMATIC MODE 14 +/- 3-V DC201 - 202 No Load, (Series 6184A) AUTOMATIC MODE 18 +/- 3-V DC201 - 202 No Load, (Series 6185A) AUTOMATIC MODE 16 +/- 3-V DC203 - 204 No Load, (Series 6182A) AUTOMATIC MODE 34 +/- 5-V DC203 - 204 No Load, (Series 6183A) AUTOMATIC MODE 60 +/- 10-V DC203 - 204 No Load, (Series 6184A) AUTOMATIC MODE 40 +/- 5-V DC203 - 204 No Load, (Series 6185A) AUTOMATIC MODE 40 +/- 5-V DC205 - 206 No Load, Operating Mode Switch in MANUAL 103 +/- 3-V DC207 - 208 No Load 200 +/- 2-V AC223 - Ground No Load 12.5 +/- 1-V DC224 - Ground No Load 12.5 +/- 1-V DC225 - Ground No Load, Press Test Switch 12 +/- 1-V DC226 - Ground No Load, Press Test Switch 12 +/- 1-V DC227 - Ground No Load, Press Test Switch 12 +/- 1-V DC228 - Ground No Load, Press Test Switch 12 +/- 1-V DC230 - Ground No Load, Press Test Switch 0-V DC231 - Ground No Load, Press Test Switch 0-V DC232 - Ground No Load, Press Test Switch 0-V DC233 - Ground No Load, Press Test Switch 0-V DC234 - Ground No Load, Press Test Switch 0-V DC209 - 210 No Load 200 +/- 2-V AC209 - 211 No Load 200 +/- 2-V AC210 - 211 No Load 200 +/- 2-V AC209 - Ground No Load 115 +/- 1-V AC212 - 213 Full 100% Rated Load 6.6 +/- 0.5-V AC214 - 215 Full 100% Rated Load 6.6 +/- 0.5-V AC216 - 217 Full 100% Rated Load 6.6 +/- 0.5-V AC220 - 221 Full 100% Rated Load 6.6 +/- 0.5V AC218 - 219 No Load, Meter Selector Switch at A-N 115 +/- 1-V AC222 - Ground With 24-V DC at Terminals E, F to N 24 +/- 1-V AC

Test Values with Unit RunningFigure 3

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Full load for Series 6182A and Series 6183A generator sets is 108 amperes.

Full load for Series 6184A and Series 6185A generator sets is 173 amperes.

a. Check for overheating.

b. Check for unusual noises.

c. Observe instruments for fluctuation.

(10)

Apply 125% rated load and observe overload indicating light (10, Fig. 5). Load contactor shouldopen and O.L. light should be turned ON within 5 minutes. At greater overloads the O.L.protection circuit will function faster.

Use TP212 and TP213, TP214 and TP215, TP216 and TP217 to check for balanced voltagesacross overload burden resistors, R26, R27 and R28. Voltage should be at least 8.25-VAC totrip overload. Press reset switch (13) to turn light OFF and reset protective system.

(11) Check accuracy of voltmeter. Use a master voltmeter. Error should not exceed 3% of full scale.

(12) Check accuracy of ammeter. (See Sect. 2-2, Para. 3, H). Error should not exceed 3% of fullscale.

(13) Check meter selector switch (2), with voltage adjusted to 115-VAC by the voltage controlrheostat (32), L to N (line-to-neutral) in all three phase as selected by the switch (2) should beapproximately the same, 115-VAC, L to L (line-to-line) A-B, B-C, etc. should be approximatelythe same, 200-VAC.

Motor ControlTransformer

Figure 4

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(14) Check overvoltage protective system.

a. Apply a normal load to generator.

b. Use voltage regulator rheostat (32) to increase voltage until overvoltage board functions toopen load contactor and turn On O.V. light (7, Fig. 5). Light should be turned ON at 130 to135-VAC.

c. Return voltage to normal and press reset switch (13).

(15) Check undervoltage protection system.

NOTE: A time delay of 5 to 12 seconds is built into the undervoltage protection circuit to avoid openingof load contactor under conditions of momentary undervoltage.

a. Apply normal load to generator.

b. Use rheostat (32) to lower voltage to 103-VAC. Wait 10 seconds. Undervoltage systemshould NOT function.

c. Continue to lower voltage 1 volt at a time with a wait of 10 seconds between changes. At avoltage between 102 and 93-VAC the undervoltage protective system should function toOPEN the load contactor and turn ON U.V. light (8).

d. Return set to normal operating condition.

(16) Check underfrequency circuit

a. Connect a frequency meter between TP209 and GRD.

b. With unit running at NO LOAD, close load contactor by pressing CLOSE switch (18).

c. Open remote power input switch to remove all power from generator set.

d. Observe meter as frequency slowly decreases from 400-HZ as motor slows down.Underfrequency protective circuit should function to OPEN load contactor and turn ON U.F.indicating light (9) when frequency reaches approximately 380-HZ.

Make certain that motor contactors have opened before restarting.

(17) Use a megger to check for grounds. Reading should be a 3 MEG OHMS or more.

(18) Check wiring to remote START-STOP and CLOSE-OPEN terminals on board located at loweredge of transformer panel (See Fig. 7).

a. Refer to Fig. 7. Use a SAFE jumper test lead with insulated tips to make momentaryconnection between terminals 1 and 2. Motor start sequence should START. Allowsequence to be completed (35 seconds).

b. Carefully disconnect one end of jumper No. 1. Motor contacts should open to STOP motor.Reconnect jumper No. 1.

c. With motor running normally and aircraft-test bank switch (27, Fig. 5) in TEST BANKposition, use the test lead to momentarily connect terminals 6 and 7. Load contactor shouldCLOSE.

d. Carefully disconnect either end of jumper No. 2. Load contactor should OPEN. ReconnectJumper No. 2.

e. If unit is equipped with optional second output check wiring as follows:

• (aa) With motor running and aircraft-test bank switch (28) in TEST BANK position, use thetest lead to connect terminals 11 and 12 momentarily. No. 2 load contactor should CLOSE.

• (bb) Carefully disconnect one end of Jumper No. 3, No. 2 load contactor should open.Reconnect Jumper No. 3.

CAUTION

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c. Optional Equipment Testing

(1) Check second output (No. 2) in the same manner as described in Para. 3, B, (4) and (7) exceptuse controls for second output (No. 2)

(2) Check Convenience Receptacle

Use light or tool rated at 115-v, 60-hz for 60-hz machines. Use light or tool ratedat 230-v, 50-hz for 50-hz machines.

a. Connect the cord plug of a trouble light or small tool at the receptacle. If light or toolfunctions properly, components are good.

b. If light or tool will not function, check the circuit breaker and reset (See Sect. 1-1; Fig. 20 and24).

CAUTION

1. Element mounting location 4. Manual reset button2. Element mounting screws 5. Trip current adjustment3. Automatic-manual (hand) reset control

Motor Overload RelayFigure 6

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(3) Check Phase Reversal Relay

a. Turn input power OFF at remote disconnect switch.

b. Observe and note connections of input cables at input terminal panel (Sect. 1-2, Fig. 7), thenreverse the connection of any two cables.

c. Turn power ON at disconnect switch.

d. Press motor START switch (14, Fig. 5). Motor will NOT start if reverse phase relay (1-1; Fig.21) is functioning properly.

e. Again turn power OFF at disconnect switch, and reconnect input cables in their originalpositions.

4. Motor-Generator Testing

a. General

It may be necessary to check motor, generator, and exciter windings only after major overhaul tomake certain that wiring is properly connected, or during troubleshooting to find a motor-generatorfault.

A “Kelvin” bridge or very sensitive and accurate instrument (volt-ohmmeter) is required for checkingmost windings since many resistances encountered in these tests are very low.

NOTE: The generator set must be “COLD” or at normal ambient temperature when resistance readings aretaken.

b. Motor and Generator Stator Windings

(1) Preparation for test

a. Remove generator monitor tray and generator protective trays, and remove two panelswhich cover motor and generator stator terminal panels (Ref. Sect. 4-2, Para. 2, A, (2)).

b. All stator cables are now accessible for testing. All stator leads are identified by a band typemarking. Terminals are also identified to indicate where each cable must be connected.(See Figs. 8 and 9).

c. It is not necessary to disturb any cable connections or connecting links.

NOTE: The position of stator links does not matter.

(2) Check generator stator winding resistance (See Fig. 8)

Terminal identification numbers (1 through 12) on the generator stator terminal panel (Fig. 8)correspond to cable identifications on appropriate connection diagram in Section 6. Bycomparing (Fig. 8) and the diagram, it is evident that the following is true:

Terminals and cables 1 and 7 are “A” phase

Terminals and cables 2 and 8 are “B” phase

Terminals and cables 3 and 9 are “C” phase

Terminals and cables 4, 5, 6, 10, 11 and 12 are “N” (neutral).

Since terminals and cables 1 and 7, 2 and 8, 3 and 9 are connected by links, LINE-TO-LINEresistance may easily be checked as follows:

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Compare readings observed with normal values in Figure 10.

(3) Check motor stator winding resistances (See Fig. 10).

Terminal identification letters (A, 1A, 2A, etc.) on the motor stator terminal panel (Fig. 9)correspond to cable identification letters on the appropriate connection diagram in Section 6.

Since cables must always be connected to their corresponding terminals and not disturbedwhen changing connecting LINKS for various voltages, resistances are checked the same wayfor all machines.

To check any one of the 6 (six) motor stator windings, refer to appropriate schematic diagram inSection 6 and to terminal panel (Fig. 9). Connect instrument as required. For example to checkwinding “C”-"1C" simply connect instrument between terminal “C” and terminal marked “1C”,“3C”. To check winding “2B”-"3B" connect instrument between terminals marked “2B” andterminal marked “1B”, “3B”.

Compare readings with normal values shown in Fig. 10.

(4) Reinstall panels removed in Para. 4, B, (1) 6 above in reinstall trays.

c. Motor and Generator Rotor Windings

(1) Preparation For Test

a. Refer to Sect. 4-1; Fig. 1, and remove air intake cover (1) and cover support (3) to gainaccess to motor, generator and exciter rotor connections.

b. Rotate rotor so that positive base diodes are at the top as in illustration (Fig. 11). The arrowon positive diode body points toward base.

(2) Test Generator Rotor Fields on Series 6183A, Series 6184A and Series 6185A Units

Motor and generator fields on these machines are connected parallel and consequently may betested separately.

a. Disconnect short wire (with protective sleeving) which exits generator windings and isconnected to diode base opposite top POSITIVE diode.

b. Connect one lead of test instrument to end of wire just disconnected and the other lead ofinstrument to NEGATIVE diode mounting BASE. (See Fig. 13). Compare observedresistance to normal resistance shown in Chart Fig. 10.

c. Reconnect generator wire removed in step (a).

FOR LINE-TO LINEMEASUREMENTS:

CONNECT INSTRUMENTBETWEEN TERMINALS:

A - B 1 and 2

B - C 2 and 3

C - A 3 and 1

FOR LINE-TO-NEUTRALMEASUREMENTS:

CONNECT INSTRUMENTBETWEEN TERMINALS:

A - B 1 and 4 or any “N” terminal

B - N 2 and 5 or any “N” terminal

C - N 3 and 6 or any “N” terminal

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(3) Test Motor Rotor Field on Series 6183A, Series 6184A and Series 6185A Units

a. Disconnect long, sleeving covered motor field wire from POSITIVE diode base. Do notconfuse motor field wire with a smaller non-sleeving covered wire to Micro Switch.

b. Connect one lead of test instrument to end of wire just disconnected. Connect otherinstrument lead to NEGATIVE diode mounting base.

c. Compare observed resistance reading with Chart Fig. 10.

d. Reconnect motor Field Wire.

(4) Test Motor Rotor Field - Generator Rotor Field on Series 6182A Units

The motor and generator rotor fields are connected in series on these machines. The combinedresistances of both fields will be indicated in this text. (See Fig. 12).

NOTE: Undesirable cutting of wires would be required to test each field separately.

a. Disconnect generator wire to POSITIVE diode base the same as instructed in Para. 4, C, (2)(a) above.

b. Connect test instrument the same as instructed in Para. 4, C, (2) (b) above. The resistanceindicated will be the combined resistances of the motor and generator rotating fields.Compare to Chart (Fig. 10).

c. Reconnect generator field wire.

d. Test Exciter Rotating Field

(1) Remove any one of the POSITIVE diodes.

(2) Use a volt-ohmmeter to check resistance between the wire connection of the removed diodeand each of the three NEGATIVE diodes at the wire connection. A O (zero) resistance readingwill be observed at one of the NEGATIVE diodes. Remove that diode.

(3) Use the test instrument to check resistance between the wire connection on the removedNEGATIVE diode and either of the two mounted NEGATIVE diodes. Observed meter readingwill be exciter rotating field resistance. Compare with Chart, Fig. 10.

(4) Reinstall diodes.

e. Test Exciter Stationary Fields

(1) Disconnect RED and BLACK-RED exciter lead wires at terminal board at top edge of interiorpanel (See Fig. 13).

(2) Connect test instrument to disconnected wires and observe indicated resistance reading.Compare to Chart Fig. 10.

(3) Reconnect exciter lead wires.

f. Check Micro Switches

Check both Micro Switches. Contacts must be CLOSED under “at rest” condition.

g. Rotor Bearings

(1) Remove air inlet and outlet panels are required to reach bearings. Ref. Sect. 4-1; Para. 2 and 3.

(2) Start motor.

(3) Check rotor bearings. Use a stethoscope, or long metal rod to listen for unusual bearingsounds. If using a metal rod, place one end on a bearing housing and hold the other near theear. Hold the rod with three fingers using the index finger and thumb to form a “soundingchamber” between the rod and ear. Do not allow the rod to touch the ear. Listen for clicks,whines, or pounding which would indicate a defective bearing.

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No. 1 Jumper is between terminals 2 and 3 for motor remote START-STOP

No. 2 Jumper is between terminals 7 and 8 for No. 1 load contactor CLOSE-OPEN

No. 3 Jumper is between terminals 12 and 13 for No. 2 load contactor CLOSE-OPEN

Jumpers are connected to allow operation without remote controls and are always installed whenmachine leaves factory.

Remote Controls Terminal BoardLocation and Identification

Figure 7

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5. Diode TestTest values for diodes are not given here because they could be misleading. Test values may varyeven between diodes of the same part number, rating, and manufacturer. General instructions fortesting diodes follows:

a. Disconnect diode lead(s).

b. Use a good quality ohmmeter. An instrument which indicates 50 ohms at the center of thescale is preferable.

NOTE: Make certain the battery is in good condition and the pointer is adjusted to zero when the test leadpoints are shorted together. Set the scale selector to RX1.

c. Hold one ohmmeter lead point on the threaded end of the diode. Hold the other lead pointon the wire terminal end. Observe and note the indicated resistance. Now reverse the leadconnections on the diode. Again observe and note the ohmmeter indicated resistance.Generally speaking, if an infinite or very high resistance was indicated with the leadsconnected one way and a low, readable resistance was indicated with the leads connectedthe opposite way, the diode may be considered good.

6. Adjustment

a. Adjust Undervoltage Time Delay

(1) With generator running normally, open generator control tray and place automatic-manualswitch (29, Fig. 5) in MANUAL position. Use manual control rheostat (30) to adjust voltage to115V AC. Observe indicating lights. If any light is ON, press reset switch (13).

Generator Stator Terminal PanelFigure 8

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NOTE: A stop-watch, or sweep-second hand watch is required for timing.

(2) Observe voltmeter and quickly lower voltage, with the manual control (30) to 93V AC. Time thedelay between the instant voltage reaches 93V AC and the instant the undervoltage indicatinglight (8) comes ON.

(3) If adjustment is necessary, open the protection tray and adjust potentiometer (R655) located onthe memory and time delay board (Fig. 14). The potentiometer is mounted just to the left of thelarge capacitor (C617). A small adjusting screw is located in the top of the potentiometer and iseasily accessible. Turn the screw CLOCKWISE to INCREASE time delay orCOUNTERCLOCKWISE to DECREASE time delay. The “pot” has an adjustable range of theone turn from full clockwise to full counterclockwise.

(4) Return generator to 115V AC output and press reset button (13 Fig. 5). Repeat above testingand adjustment procedures, as required, until as satisfactory adjustment has been completed.

(5) Return controls to normal AUTOMATIC operating position.

b. Adjust Manual Voltage Control Variable Resistor

The adjustment of this resistor (Fig. 15

) determines the maximum generator output voltage obtainable when using the manual voltagecontrol rheostat to adjust voltage. To adjust resistor proceed as follows:

Motor Stator Terminal PanelFigure 9

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(1) With unit running normally at no load, place automatic-manual control switch (29, Fig. 5) inMANUAL position. Use manual control rheostat to check voltage range obtainable. Maximumvoltage should be 140-VAC; minimum should be less than 100V AC.

NOTE: Fault indicating lights will be turned ON during above check. Press switch (13, Fig. 5) to resetas required.

(2) If voltage is not within above range, use the variable resistor (Fig. 15) to adjust.

(3) Loosen clamping screw and move slider band toward the end of resistor which has a SINGLEwire connected to INCREASE voltage potential. Move toward the double wire connection endto DECREASE.

(4) Check voltage range after each adjustment of slider band.

(5) When a satisfactory adjustment has been accomplished, return set to normal operating mode.

TEST CONNECTION NOMINAL RESISTANCE IN OHMS6182A 6183A 6184A 6185A

GENERATOR WINDINGSSTATOR (Stationary Fields)

A - B Line to Line 0.0391 0.0396 0.0263 0.0101B - C Line to Line 0.0391 0.0396 0.0263 0.0101C - A Line to Line 0.0391 0.0396 0.0263 0.0101A - N, B - N, or C - N 0.0195 0.0392 0.0132 0.0343

ROTOR (Revolving Fields) N/A 1.32 1.78 1.43

MOTOR WINDINGSSTATOR (Stationary Fields)

A - 1A 0.316 0.267 0.178 0.160B - 1B 0.316 0.267 0.178 0.160C - 1C 0.316 0.267 0.178 0.160


EXCITER WINDINGSSTATOR (Stationary, Across the Fields) 17.5 17.5 17.5 17.5ROTOR (Revolving Fields)

A - B * 0.17 0.17 0.17 0.17B - C * 0.17 0.17 0.17 0.17C - A * 0.17 0.17 0.17 0.17

* (Line-to-Line, (Across 2 Windings)

MOTOR AND GENERATORROTOR (Revolving Fields) 2.17 N/A N/A N/A

Motor, Generator and Exciter Winding Resistance ValuesNominal (70 o F, 21o C) Ambient Temperature

Figure 10

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c. Adjust 12-V DC Power Supply

If tests indicate that the DC power supply unit (Sect. 1-1; 13, Fig. 11) is producing direct current butnot the 12-V desired, the output voltage may be adjusted as follows:

(1) With the unit running normally and a voltmeter connected to the power supply output terminals,use a small screwdriver to adjust potentiometer (Fig. 18). Turn pot adjusting screwCLOCKWISE to INCREASE output voltage and COUNTERCLOCKWISE to DECREASEvoltage.

(2) Adjust pot until 12-V DC is indicated on test instrument.

d. Adjust Voltage Regulator

Refer to Voltage Regulator Manual, TM-759, in Chapter 6 for specific voltage regulator adjustments.

Motor, Generator and Exciter Windings(Series 6183A, Series 6184A and Series 6185A Units) (Parallel)

Figure 11

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Motor, Generator and Exciter Wiring Connections(S-6182A Series )

Figure 12

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Exciter Stationary Field ConnectionsFigure 13

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Undervoltage Time Delay Adjusting PotentiometerFigure 14

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Manual Voltage Range Adjusting ResistorFigure 15

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12-V DC Power Supply AdjustmentFigure 16

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Section 4Removal / Installation of Motor-Generator Covers

1. GeneralThis section contains information and procedures for removal and installation of sheet metal covers, airducts, etc., which route air into and out of the motor-generator.

2. Generator End CoversIt is necessary to remove these covers to gain access to diodes and Micro switches mounted on thegenerator armature.

a. Removal

(1) Remove hex-head, self-tapping screws which attach air intake cover (1, Fig. 1) to cover support(3). Lift off cover.

(2) Remove hex-head screws which attach cover support (3) to generator bearing bracket, and liftoff support. Diodes and Micro switches are now accessible for inspection, test, replacement,etc.

b. Installation

(1) Position cover support (3) properly on generator bearing bracket and align mounting holes.Attach with hex-head, self-tapping screws. Attach ground strap (2) with one of the supportattaching screws.

(2) Position intake cover (1) on cover support (3) and align mounting holes. Attach with hex-head,self-tapping screws. Tighten screws securely.

3. Motor End CoversMotor end covers removal is necessary to gain access to fan, exciter rotor, etc.

a. Removal

(1) Remove screws which attach shield (4, Fig. 1) and guard (6) to frame. Lift off shield (4).

(2) Remove screws which attach air duct (5) and lift off.

(3) Remove screws which attach cover (8), supports (7), and guard (6) and remove.

(4) Remove screws which attach four baffles (9) and panel (10) and remove.

b. Installation

(1) Position panel (10, Fig. 1) and baffles (9) on fan housing. Align mounting holes and attach withself-tapping screws.

(2) Position cover (8) on panel (10) and attach with self-tapping screws.

NOTE: Leave support (7) mounting holes free.

(3) Install two supports (7).

(4) Position and attach guard (6) to support (7).

(5) Install shield (4) over lower edge of guard (6) and secure both to frame (11) with self-tappingscrews.

(6) Position air duct (5) on panel (10). Align holes and attach with self-tapping screws.

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1. Air intake cover 7. Support2. Ground strap 8. Cover3. Support 9. Baffle4. Shield 10. Panel5. Air duct 11. Frame6. Guard 12. Cable hanger

Frame and Sheet Metal Covers and Air DuctsFigure 1

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Section 5.Motor-Generator Servicing and Repair

1. GeneralThe motor-generator may be serviced, maintained and overhauled while mounted on the main frame.About the only circumstance requiring removal would be a requirement for stator replacement.

2. Motor-Generator Removal and Installation

a. Removal

NOTE: If the machine is equipped with an optional T-R package, it must be removed first. DisconnectT-R input power cables and control leads at the T-R. Remove attaching screws and lift off T-R.Disconnect conduit elbow at T-R support. Remove support attaching screws and lift off.

Make certain that power to machine is OFF.

(1) Remove air intake cover and support from generator end of motor-generator and air outlet ductand fan fan housing cover from motor end in accordance with instructions in Sect. 4-1, Para. 2and 3. The ground strap will be disconnected in the process.

(2) Open cabinet Plexiglas cover. Release and pull out generator monitor and protection trays.Disconnect wiring harnesses at quick-disconnect connectors and remove trays. (See Sect. 1-2,Fig. 13). Remove two panels (Fig. 1) which cover motor and generator stator terminal panels(Fig. 2).

(3) Observe and note positions and routing of stator cables. Make certain that each cable is plainlymarked so that cables may be re-connected to their original positions. Disconnect twelve motorstator cables and twelve generator stator leads

(4) Disconnect the two exciter leads (RED and BLACK-RED) from terminal board located oninterior panel just left of the current transformer panel. Exciter leads are the first two at the leftend of the terminal board (See Fig. 3).

(5) Straighten both sets of motor and generator stator cables so that they may be drawn throughconduit connectors in cabinet.

(6) Loosen conduit connector nuts on straight cabinet connectors (See Fig. 4). Conduits will remainwith motor-generator.

(7) Remove four 3/4-10 motor generator mounting screws. Remove top plates and small insulatingpads. (See Fig. 5).

NOTE: In order to reach the two mounting screws on the cabinet side of the motor-generator, it will benecessary to remove six cabinet mounting screws in the bottom of the cabinet and move thecabinet away from the motor-generator far enough to gain access to motor-generator mountingscrews.

(8) Install a 3/4-10 lifting eye in stator housing. Attach a lifting hoist.

Lift the motor-generator sufficiently to clear frame mounting pads, and move carefully away fromcabinet to free conduit from cabinet connector. Move the motor-generator slowly away fromcabinet while observing and arranging stator cables inside cabinet to make certain that they areare withdrawn from cabinet without tangling or damage.

WARNING

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(9) If necessary, detach cable conduit assemblies from stator housing by removing eight screwsfrom each elbow plate. (See Sect. 4-3, Fig. 15). Then slide conduit off of stator cables.

Stator Terminal PanelCoversFigure 1

Motor Stator TerminalPanel

Figure 2

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Generator StatorTerminal Panel

Figure 3

Exciter Field LeadsConnection Diagram

Figure 4

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Motor-Generator-to-Cabinet

Cable ConduitsFigure 5

Motor GeneratorMounting

ComponentsFigure 6

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b. Installation

NOTE: It is assumed that cabinet is loose and moved forward from its mounted position (Ref. NOTEunder Para. (1)(g) above).

(1) If cable conduits were removed, slide cable conduit assemblies over cables and attach elbowmounting plates to stator housing with special washer-type screws. (See Fig. 4).

(2) Install a 3/4-10 lifting eye in stator housing and attach a lifting hoist.

(3) Position bottom insulation pads and plates properly on frame. (See Fig. 5).

(4) Move motor-generator to near its mounted position and route stator cables through theirrespective conduit connectors and into the cabinet.

(5) Move motor-generator slowly to its mounted position, stopping frequently to pull cables intocabinet and to route them properly.

(6) Align mounting pads, plates, and stator mounting feet, and lower motor-generator into itsmounted position.

(7) Install top pads, plates and mounting screws. Tighten securely. (See Fig. 5).

(8) Move cabinet back to its mounted position. In this moving process, continue to pull cables intocabinet and guide cable conduit ends into cabinet connectors. (See Fig. 4). Connect conduit toconnectors with nuts which are part of connector assemblies.

(9) Secure cabinet with six mounting screws.

(10) Route cables and leads to their respective connection points and connect securely. Refer toappropriate connection diagrams in Chapter 6 if necessary.

(11) After making certain that cables and leads are connected properly, stator panel covers may bereplaced. (See Fig. 1).

(12) Install and connect generator monitor and protection trays. Close Plexiglas cover.

(13) Install sheet metal covers, air ducts, etc., in accordance with instructions in Para. 2, B and 3, B

3. Electrical and Mechanical Repair

a. General

Repair of the set will consist mainly of the replacement of parts found defective by inspection andcheck as outlined in Chapter 2, or in Troubleshooting, Chapter 3.

Repair of electrical components such as relays, small switches, contactors, PC boards, etc., shouldnot be attempted. Remove and replace the defective item as a complete unit.

A complete set of connection diagrams is included in Chapter 6 to guide the repairman and makecertain that the new part is properly connected.

It is recommended that spare tray assemblies be stocked so that a tray containing a defective partmay be replaced immediately to get a set back in service with minimum delay. The defective partin the tray may then be replaced in an overhaul facility.

Overhaul of the motor-generator is covered completely in Section 2-6.

b. Cabinet

(1) Sheet Metal Repair

If sheet metal dents, bends, etc., are discovered by inspection, they may be straightened andrepaired by dollying and normal sheet metal practices. When straightening has beencompleted, sand the affected surfaces, clean thoroughly, and apply Gray Polane Sealer,Sherwin-Williams No. E65A4 (Hobart 903359. When sealer is thoroughly dry, apply one or twocoats of Sherwin-Williams, Linear White. “Polane T” No. F63W12 paint (Hobart No. 903864).

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(2) Frame and Structural Repair

Cracks and fissures in any welded junction, longitudinal cracks in the weld itself or in thestructural metal adjacent to the weld should be repaired by welding. Clean and repair the metalto be welded in accordance with good welding practices. Be sure that good penetration isachieved.

c. Wiring the Unit After Repair or Parts Replacement

When reconnecting wires to an electrical component after repair or replacement, make certain thatconnections are made correctly. A complete set of connection diagrams is included in Chapter 6 toguide the repairman in this regard.

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Section 6.Overhaul of Electrical Equipment and Motor Generator

1. Electrical EquipmentOverhaul of electrical subassemblies such as the control cabinet, pushbutton switch panel, transformerpanel, etc., just for the sake of overhaul, is not necessary or practical. It is felt that defective partsreplacement and repair can be accomplished at less cost and with as good results as completeoverhaul. However, overhaul information for the motor-generator is presented in this section becauseof special procedures for disassembly, cleaning, bearing installation, etc.

2. Motor-Generator Overhaul

a. General

Unless the motor-generator stator must be replaced, it is possible to overhaul the motor-generatorwithout removing it from its mounted position on the frame. An exploded view of themotor-generator is illustrated in Fig. 1.

b. Remove Sheet Metal Covers And Ducts]

Remove covers and air ducts in accordance with instructions in Sect. 4-1, Para. 2,A and 3,A.

c. Disassembly, General

NOTE: Is not necessary to disassemble the complete motor-generator in order to reach and replace certainparts such as the bearings, exciter, diodes, micro switches, etc.

(1) Decide what internal part is defective if possible, then disassemble only those parts which arenecessary to reach, remove and replace the part.

(2) Sheet Metal Air Inlet Covers And Ducts

a. It is assumed that all covers and ducts, or as many as necessary have been removed.

b. To reach diodes and switches only the air inlet covers need to be removed. (See Sect. 4-1;Para 2,A).

c. To reach and remove the fan, fan hub, and exciter rotor, only the air outlet ducting, covers,and shrouds need to be removed. (See Sect. 4-1; Para. 3,A).

d. Disassemble Motor-Generator

NOTE: Position the machine under a hoist so that the hoist track is directly over and parallel to themotor-generator armature.

(1) Remove screws which attach bearing caps (1, Fig. 1) then remove bearing caps (1) andspacers (2). Observe and note number of spacers and their location for use at reassembly.

(2) Remove six screws which attach fan housing (3) to stator housing (33), after placing pointerpunch marks on fan housing and stator housing, opposite each other so that housing is properlypositioned at reassembly.

NOTE: If fan housing is not reassembled in its original position, air ducts and covers will not fit.

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1. Cap 12. Insulator 23. Armature

2. Spacer 13. Insulator 24. Polepiece

3. Fan housing 14. Switch 25. Exciter field winding

4. Fan 15. Clamp 26. Insulation

5. Screw 16. Insulator 27. Insulation

6. Bearing bracket 17. Hub 28. Plate

7. Ball bearing 18. Nut 29. Pad

8. Armature 19. Washer 30. Plate

9. Diode 20. Key 31. Pad

10. Bus 21. Exciter rotating field 32. Label

11. Screw 22. Key 33. Housing and stator

Motor-Generator Exploded ViewFigure 1

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(3) On later production machines you will find three, 5/8-11 tapped holes in the fan housingmounting ring. (See Fig. 2) (Some early production units have two holes and a few have none).Install 5/8-11 x 2-1/4 inch cap screws in threaded holes. Tighten screws alternately and evenlyto force fan housing off of stator housing mounting seat and away from stator sufficiently toinsert pry bars and pry fan housing off of bearing. If housing is difficult to remove from bearing,thread a 1/2-13 eyebolt into the tapped hole in the end of armature shaft. Position a pry bar in amanner to PUSH on the eye bolt and force the bearing and armature shaft out of the fanhousing hub.

NOTE: A tool for removing the fan housing (3) and also the generator end bearing bracket (6) may be madefrom one of the bearing caps (1). Locate the center of the cap and drill and tap a hole for a 3/4-10screw. Install the reworked cap on the housing or bracket to be removed. Install a 3/4-10 x 2 in. screwin the cap and tighten to exert pressure on the end of the armature shaft. Further tightening of thescrew will force the shaft and bearing out of the hub.

(4) Use paint or punch marks opposite each other on the fan(4) and fan hub (17) the same asperformed in Para. (2) above, so that the fan may be reassembled in proper position. Removeeight screws (5) which attach fan (4) to fan hub (17). Remove fan (See Fig. 3).

NOTE: If exciter rotor (21, Fig. 1) does not require removal, proceed to step (5). If exciter removal is requiredrefer to Para. 3.

(5) Use paint or punch marks opposite each other on the generator end bearing bracket (6, Fig. 1)and stator housing (33) the same as performed in Para. (2) above, so that bracket may bereassembled in proper position. Remove six bracket attaching screws.

(6) Follow the same general procedures for bearing bracket (6) removal as were given in Par. (3)above for fan housing removal.

(7) The motor-generator armature assembly (8) with fan hub, exciter, rotor, etc. may now beremoved from the generator end of the stator housing. Use a lifting fixture (Fig. 4) and attach toa chain hoist which is mounted on a track running parallel to the armature.

NOTE: To fabricate a fixture refer to Fig. 4.

(8) Carefully position the round lifting rod (4, Fig. 4) of the fixture in a lightening hole in armaturespider as illustrated in Fig. 5. Use a long rod or pipe also inserted in a lightening hole to helpbalance and guide the armature.

(9) Lift the armature until all of its weight is supported by the hoist, then carefully pull armature outof stator housing.

(10) Move the armature away from the stator and lower onto an armature cradle or wooden blocks.Make certain that it cannot roll when released. The armature may now be further disassembledif necessary.

(11) Use a mechanical or hydraulic bearing puller to remove bearings (5, fig. 1). (See Para. ForInspection). Make certain that threads in end of shaft are protected by a special cup or washer.Figure 6 illustrates a hydraulic puller in position for pulling bearing.

NOTE: The motor end bearing must be removed to remove the exciter, however, the generator end bearingneed not be removed if inspection shows it to be in good condition. Never try to re-use a bearingwhich has been removed. The repeated heating required for installation could cause early failure.

(12) Straighten and release tab on keywasher (19, Fig. 1) which is bent into a slot on round nut (18).Use a special round nut wrench (Fig. 7) to remove nut. When attaching the wrench to the nut,place the wrench handle to the RIGHT to TIGHTEN the nut . Place the wrench handle to theLEFT to LOOSEN the nut for removal. Refer to Figure 12 for information on this nut wrench.

(13) Slide off key washer (19, Fig. 1).

(14) Pull off fan hub (17, Fig. 1). Use a rawhide, rubber or brass hammer on hub flange to loosen ifnecessary. Remove machine key (20).

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Fan Housing onMotor EndFigure 2

Fan Ready forRemovalFigure 3

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(15) Exciter Removal

a. Remove varnished glass tape (Fig. 8) which secures all exciter leads to armature shaftbetween exciter rotor and motor rotor.

b. Pull loosened leads outward from shaft. Remove electrical tape from the three leadconnections to expose clamp-on wire connectors. Cut leads as close to clamp-onconnectors as possible to conserve as much wire as possible and to avoid splicing.

NOTE: Clamp-on connectors may be removed after heating with a clamp-on type soldering tool (SeeFig. 19) to melt solder.

c. Observe and check two 5/16-18 puller attaching holes in core of exciter. Make certain thatthey are clean and will accept puller attaching screws freely.

NOTE: At manufacture, varnish may have entered tapped holes and it may be necessary to use a5/16-18 thread tapping tool to clean threads before puller screws can be installed.

d. Mount a puller tool (See Fig. 9) using 5/16-18 screws or threaded screws or threaded rods atleast 8 inches long. Make certain that threaded hole in end of armature is protected by a capon the end of the puller screw or a large washer between the puller screw and armatureshaft.Operate puller to remove exciter.

e. When exciter is removed, remove machine key (22, Fig. 1), and remove puller from exciter.

(16) Remove diodes (9, Fig. 1), Micro switches, etc., Items 9 thru 16 as required. (See Fig. 10)

(17) Before removing exciter field windings (25, Fig. 1), observe and note installed position ofinsulators (26 and 27). Windings are held in place by polepieces (24). Each polepiece issecured by two cap screws. Remove cap screws (a total of eight) and remove polepieces,windings and insulators.

1. Lifting eye (5/8-in. thread)

2. Bar stock, 1/2-in, X 1-in.X 1-1/2-in. long

3. Bar stock, 1-1/2-in, X2-in. X 12-in. long

4. Round stock, 1-1/4-in,die. X 22-in. long

Lifting FixtureFigure 4

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(18) Stator Removal

The stator is removed exactly the same way as a complete motor-generator. Refer to Sect. 4-2,Para. 2,A, (2) thru (8).

e. Cleaning

(1) Steam cleaning of motor-generator components is no longer recommended because team canbe damaging to insulation. Use a good, SAFE, commercial cleaner on all parts except bearings.DRY ALL PARTS THOROUGHLY AFTER CLEANING.

Do not use flammable solvent.

(2) Wipe bearings clean with a dry cloth. Sealed bearings should NOT be washed. A little tarnish,stain and corrosion on the outside surfaces are not detrimental to the operation of the bearingand need not be removed.

f. Inspection

(1) Bearings

Inspection bearings while they are mounted on the rotor shaft.

a. Inspect the bearings for evidence of physical damage, such as cracks, nicks, damagedseals, etc. Inspect for evidence of overheating. Overheated bearings are generallydarkened to a brownish blue or blue-black color. Replace the bearing if damaged in any wayor if it shows evidence of overheating.

b. Check the bearing for excessive looseness between the races and the bearing balls.Replace if worn and loose.

WARNING

Setup for Removal or Installation ofMotor-Generator Armature

Figure 5

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Removing Armature Shaft Bearing With Hydraulic PullerFigure 6

Special Round Nut WrenchFigure 7

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c. Turn the outer race slowly and check for any roughness or sudden stopping. Repeat thecheck while turning the race in the opposite direction. The outer race should rotate smoothlyand without catching. Replace the bearing if rough or catching.

d. Even if no defects are found, or suspected, the age and service of the bearing should beconsidered before passing it for further service. If the hourmeter indicates the bearing hasbeen in operational service approximately 5000 hours, or more, it should be replaced.

(2) Fan

Inspect the fan while it is mounted on the rotor assembly.

a. Inspect for evidence of physical damage such as bent or loose blades, and fatigue cracks inthe blades, disc, or welds.

b. Replace the fan if any of the above defects are discovered.

(3) Armature (Rotor) Assembly

a. Visually inspect the assembly for physical damage. Inspect visible welds for breaks orfatigue cracks.

b. Inspect all lead clamps on the generator end for security.

c. Inspect insulation tape on leads between rotors.

d. Inspection insulation on windings and leads.

e. Check diodes in accordance with Sect. 2-3; Para. 5.

f. Inspect and check Micro switches (See Sect. 2-3; Para. 4,F).

g. Check resistance of motor, generator and exciter windings. (See Sect. 2-3; Para. 4,C, (1)thru (4), and D.

(4) Motor, Generator And Exciter Stators

a. Visually inspect stators for physical damage, and inspect welds for cracks or breaks.

b. Inspect all wire leads for damaged insulation or broken or frayed wires at the terminal ends.

c. Check all stator windings for open or short circuits in accordance with Sect. 2-3; Para. 4,B,(1) thru (3), and E.

g. Assemble Motor-Generator

(1) Equipment

Locate equipment, hoist, etc. the same as for disassembly. Refer to NOTE under Para. Cabove.

(2) Stator Installation

Follow instructions as outlined in Sect. 4-2, Para. 2, B, (1) thru (12), to install stator (33, Fig. 1)on frame if it was removed.

(3) Preparation for exciter installation

a. Clean armature shaft, exciter rotor bore (21, Fig. 1), and machine key (22). Remove all rust,corrosion, etc.

b. Apply “Locquic”* primer Grade T, No. 47-56, to exciter rotor key and keyway (See Fig. 11).Clean excess from rotor bore mounting surface. *Manufacturers of recommended productsare listed in Fig. 12.

c. Apply “Loctite” retaining compound, No. 40-31 to SIDES of machine key (See Fig. 13) andspread evenly. Install key in armature shaft. Remove excess “Loctite” from shaft andkey.

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Remove TapeFigure 8

Puller Tool in Position for Removing Exciter RotorFigure 9

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d. Apply “Never-Seez” compound No. NSBT-8 to bore of exciter rotor (Fig. 14) and to armatureshaft.

e. If exciter is new, route the three long exciter leads backward and through the closest of thetwo larger, unthreaded holes in the exciter core. Pull leads snugly so that there is nolooseness at the front of exciter.

(4) Exciter Installation

a. Place exciter on shaft (The end from which exciter leads emerge from hole in core goes onfirst) (Ref. Para. (e) above).

b. Align keyway in exciter with machine key in shaft and push exciter onto shaft. If force isrequired to push exciter into place, use a brass rod and hammer to drive the exciter intoproper position firmly against its seat on the armature.

Make certain that no leads are caught between exciter and its shaft seat.

c. If new exciter leads are too long for this application, pull the ends of the two groups of diodeleads (Fig. 15) which are taped to the armature shaft, upward. Measure the three exciterleads against these generator leads. Cut exciter leads to match length of six generator leads(Fig. 16). Process ends of all leads for connection with a clamp-on connector.

d. Select one lead from each of the two groups of diode leads and connect any one of the threeexciter leads (See Fig. 17). Twist terminations together and slip on a clamp-on connectorand clamp securely. (See Fig. 18).

CAUTION

Generator End of ArmatureFigure 10

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e. Use a clamp-on type soldering tool to apply solder to connections after clamping (See Fig.19). Wrap connections with electricians tape after soldering.

f. Arrange all connected leads neatly around armature shaft between motor rotor and exciterand tape securely to armature shaft with glass tape, then varnish the tape. (See Fig. 20 and21).

NOTE: Do not use any form of rubber tape for this application.

(5) Fan Hub Installation

a. Clean armature shaft, hub bore (17, Fig. 1), machine key (20). Remove all rust, corrosion,etc.

b. Apply “Locquic” primer, Grade T, No. 47-56, to hub key (20) and Keyway similarly toillustration Fig. 11. Clean excess from rotor bore mounting surface.

c. Apply “Loctite” retaining compound, No. 40-31 to SIDES of machine key (See Fig. 13) andspread evenly. Install key in armature shaft. Remove excess “Loctite” from shaft and key.

d. Apply “Never-Seez” compound, No. NSBT-8, to bore of fan hub and to armature shaft.

e. Install fan hub on shaft and align keyway with key.

f. Push hub onto shaft until it contacts exciter. If forcing is necessary, use a hammer and abrass rod to tap into position.

(6) Key washer and round nut installation.

Install keywasher (19) and round nut (18). Tighten nut securely with special wrench. (See Fig.7). Bend a washer tab as required to lock nut in position.

(7) Bearing Installation

Bearing installation is one of the most critical operations in the overhaul of the generator set.Improper installation practices and procedures can only result in shortened bearing life andpremature failures.

NOTES: 1. New bearings must be heated in 100o C (212o F) prior to installation. Time may be saved ifthe bearings are placed in a thermostatically controlled oven approximately two hours prior toscheduled assembly. Set the thermostat at 100o C.

2. If a bearing is removed for any reason, do NOT try to reuse it. Always use NEW bearings.

After bearing (7, Fig. 1) is properly heated (2 hours at 100o C) use heavy leather gloves toremove from oven and install on shaft as soon as possible.

When properly heated, the bearing will slide onto shaft easily.

NOTE: Allow bearings to cool to ambient temperature before attempting to install bearing bracket andfan housing.

(8) Install diodes (9, Fig. 1), switch (14), and any parts removed from the generator end.

(9) The armature assembly (8) with exciter, fan hub, bearings, etc. may now be installed in thestator housing (33). Installation is made from the generator end with the exciter end enteringthe stator first. Use a lifting fixture (Fig. 4) and attach a chain hoist which is mounted on a trackrunning parallel to the armature and stator.

(10) Carefully position the round lifting rod (4, Fig. 4) of the fixture in a lightening hole in the armaturespider as illustrated in Fig. 5. Use a long rod or pipe also inserted in a lightening hole, to helpbalance and guide the armature.

(11) Lift the armature and guide carefully into stator.

(12) When armature is in place remove lifting fixture and guide rod.

(13) Position fan (4, Fig. 1) on fan hub (17). Align punch marks or paint marks made on fan and hubat disassembly, and secure fan with eight screws.

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Applying "Locquic" PrimerFigure 11

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“LOCQUIC” No. 47-56, Primer Grade T

“LOCTITE” No. 40-31, Retaining Compound

Manufactured byLoctite CorporationNewington Connecticut 06111

“NEVER-SEE”, No. NSBT-8 (8-oz. can) Manufactured byNever-See Compound CorporationBroad view, Illinois 60153

“N) COO” Varnish No. T-211 (clear, air-dry) Manufactured bySterling Division ofReich hold Chemical Inc.,Marysville, Pennsylvania

Special Round Nut WrenchSize 2" - 4.75"Part No. 34-307

Arm strong Bras. Tool Company5273 W. Arm strong Ave.Chicago, Illinois 60646

Recommended Products and Tool ManufacturersFigure 12

Applying"Loctite" to

Machine KeyFigure 13

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Applying "Never-See" to Exciter Rotor BoreFigure 14

Diodes-to-Exciter Rotor Leads(TWO Groups of THREE Each)

Figure 15

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NOTE: Either bearing bracket (6) or fan housing (3) may be installed next.

(14) Lift bearing bracket (6) into position and align punch marks or paint marks on stator and bracketat disassembly. Start bracket hub onto bearing.

(15) Install a 1/2 in. lifting eye in end of armature and use a crowbar to help push bracket ontobearing. (See Fig. 22).

(16) Use a bar between bearing bracket and frame to lift bracket (and armature) to align bracketmounting holes (See Fig. 23). Install six mounting screws. Continue lifting bracket as requiredand tightening screws until alignment ring on bracket enters seat on stator housing. Thentighten screws securely.

Fig. 3 in Sect. 1-1, illustrates a cross-section of alignment rings.

(17) Lift fan housing (3, Fig. 1) into position and align punch or paint marks on housing and stator.Start housing hub onto bearing.

(18) Follow same general installation instructions as for bearing bracket (6) in Para. 15 and 16 aboveto complete installation.

(19) Use lifting eye and crowbar (See Fig. 22) to properly position armature lengthwise, so thatspacers (2) may be returned to their original position(s).

(20) Install bearing caps. (1).

3. Remove And Install Exciter Rotor Without Removing Armature

a. Removal

(1) Remove air duct, covers, etc. on motor end of motor-generator in accordance with instructionsin Sect. 4-1, Para. 3,A, (1) thru (5).

(2) Before removing fan housing (3, Fig. 1), place 3/16 in. thick metal shims between motor rotatingfields and motor stator fields as illustrated in Fig. 24.

NOTE: Shims prevent exciter rotor from resting on exciter stator windings when fan housing isremoved.

(3) Remove bearing cover (1, Fig. 1), fan housing (3) and fan (4) in accordance with instructions inPara. 2,D, (1) thru (4).

(4) Use a suitable puller to remove ball bearing (7). Refer to Para. 2,D, (11).

(5) Remove round nut (18), keywasher (19) and fan hub (17) in accordance with instructions inPara. 2,D, (12) thru (14).

(6) Remove exciter rotor (21) in accordance with instructions in Para. 2, D, (15), (a) thru (e).

b. Installation

(1) Follow instructions in Para. 2, G, (1) thru (4) to install exciter rotor.

(2) Install fan hub, keywasher and round nut, See Para. 2, G, (5) and (6).

(3) Install a new bearing in accordance with Para. 2, G, (7).

(4) Install fan on fan hub and install fan housing bracket in accordance with general instructions inPara. 2, G, (13) thru (16).

NOTE: Above referenced instructions apply to bearing bracket on generator end, however, the sameinstructions apply to fan housing installation.

(5) Remove shims installed in Para. 3, A, (2) above.

(6) Install air duct, etc. See Sect. 4-1, Para. 3, B, (1) thru (6).

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Diode and Exciter Leads Ready to Process and ConnectFigure 16

Connection of Exciter Leads and Diode LeadsFigure 17

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Installing Clamp-on ConnectorsFigure 18

Soldering Connections With Clamp-on Soldering ToolFigure 19

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Binding Leads to Shaft With Glass TapeFigure 20

Applying Varnish to TapeFigure 21

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Using Crowbar to Install Bearing BracketFigure 22

Using Crowbar in Bearing Bracket InstallationFigure 23

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Motor Stator/Rotor Shims in PlaceFigure 24

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Chapter 3. Troubleshooting

Section 1. Troubleshooting Procedures

1. General

a. Troubleshooting is an orderly process of checking and eliminating possible causes of trouble untilthe exact cause is located. When looking for the cause of a trouble in a circuit or system begin atthe source of power or supply. Continue testing and checking the circuit, or system, step-by-step, inan orderly manner, until the cause of trouble is located.

b. The chapter provides information for diagnosing and correcting certain troubles which causeunsatisfactory operation or failure of the equipment.

c. Minor troubles may be remedied by the operator, however, major repairs must be undertaken byexperienced mechanics and electricians only.

2. Troubleshooting

a. Description

The troubleshooting chart lists information under three headings as follows:

(1) Trouble, Symptom, and Condition

(2) Probable cause

(3) Test, Check, and/or Remedy

b. Use of the Troubleshooting Chart

(1) A troubleshooting chart is furnished to provide maintenance and repair personnel with atime-saving guide for locating trouble. To use the chart, proceed as follows:

a. Locate the symptom(s) of trouble in the “Trouble” column.

b. Check the probable causes of trouble in the “Probable Cause” column.

c. Test, check, repair, or correct the trouble as indicated in the “Remedy” column.

(2) If the cause of a trouble is an uncommon one and cannot be located by use of the chart, start atthe source of power or supply and check the affected circuit or system completely. Useschematic and connection diagrams supplied with this manual.

(3) Electrical components mentioned in the troubleshooting chart are identified by a noun name anda corresponding symbol which allows the user to identify the item more easily on schematicdiagrams.

(4) It is assumed that wiring and connections in defective circuits have been thoroughly checkedbefore condemning any other components.

NOTE: Reference symbols (S9, etc.), used in the Troubleshooting Chart, are identified on Schematicand Connections Diagrams.

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3. Equipment for TroubleshootingA good quality multi-scale volt-ohmmeter is the only instrument required for troubleshooting. At leasttwo “jumper” leads with “alligator” clips and test prods will be required. The 12-V, engine electricalsystem may be used as a 12-V DC power source.

If a test box, part number 388318A -2, is available tests may be made more quickly and accurately,however, the test receptacle connector may be used by inserting the test points of a volt-ohmmeter intoproper terminals of the connector. Refer to Fig. 8.

4. Safety

Electric shock and moving parts can kill! Exercise extreme care to avoid contactwith high voltage parts or leads and moving parts when trouble shooting oroperating the equipment. Remove jewelry such as rings and watch.

5. Parts ReplacementTo lessen end item “down” time and to get a faulty machine back “on-the-line” as quickly as possible,the “black-box” concept of parts replacement is reflected in the troubleshooting chart. For example, if acomponent in the protective relay tray is defective, the quickest way to remedy the situation is toreplace the complete tray assembly and send the old tray for repair.

Assemblies which lend themselves to this concept are:

• Generator control tray

• Protective relay tray

• Voltage regulator

• Overload module

• Protective monitor module

• Electric governor control “box”

• Governor actuator

• Over-undervoltage module

• Over-underfrequency module

The above items are in addition to normally replaced items such as fuel pump, injectors, relays, etc.

6. Test ValuesAlthough test values are provided, where applicable, throughout the troubleshooting chart additionalinformation and values are given here.

• Generator output at maximum voltage regulator rheostat setting 134 V or higher

• Generator output at minimum voltage regulator rheostat setting 108 V or lower

• Overload relay trips at any value above 125% load in 5 minutes or less.

• Overload relay trips at 130 to 134 V AC, resets at 125 V AC.

• Undervoltage relay trips at 93 to 102 V AC, resets at 110 V AC.

• Undervoltage time delay circuit functions in 4 to 12 seconds.

• Overfrequency relay trips at 415 to 425 Hz, resets at 410 Hz.

• Underfrequency relay trips at 375 to 385 Hz, resets at 385 Hz.

• Overload relay trips at 125% rated load in 5 minutes.

WARNING

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See 2-3 Fig. 13 for typical test values at test receptacle and test box.

7. Check Connections and LeadsALWAYS make a check of connections and leads to a component suspected of being faulty. With theexception of a few instances, we will assume that connections and wiring have always been checkedfirst and that power has not been lost as a result of defective wiring or connections.

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Operating Controls and Instruments

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Operating Controls and Instruments

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Test Panel

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TEST POINTS: POINT-TO-POINT NORMAL VOLTAGE VALUE





106 - ND 115 +/- 5-V AC

105 - ND 115 +/- 5-V AC

110 - 111 110 +/- 5-V AC


* Series 6183A, Model 37F-H51, 220-V or 380-V

* Series 6184A, Model 60F-H61, 208-V, 230-V, 380-V, 460-V, 575-V


Test Values, Power to Unit, Unit Not Running

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TEST POINTS CONDITION TEST VALUES109 - 111 No Load 110 +/- 5-V DC108 - 111 No Load 110 +/- 5-V DC107 - 111 No Load 110 +/- 5-V DC112 - Ground No Load 115 +/- 5-V AC113 - Ground No Load 115 +/- 5-V AC114 - Ground No Load 115 +/- 5-V AC115 - Ground No Load 115 +/- 5-V AC116 - Ground No Load 115 +/- 5-V AC117 - Ground No Load, Load Contactor Closed 115 +/- 5-V AC201 - 202 No Load, (Series 6182A) AUTOMATIC MODE 15 +/- 3-V DC201 - 202 No Load, (Series 6183A) AUTOMATIC MODE 14 +/- 3-V DC201 - 202 No Load, (Series 6184A) AUTOMATIC MODE 18 +/- 3-V DC201 - 202 No Load, (Series 6185A) AUTOMATIC MODE 16 +/- 3-V DC203 - 204 No Load, (Series 6182A) AUTOMATIC MODE 34 +/- 5-V DC203 - 204 No Load, (Series 6183A) AUTOMATIC MODE 60 +/- 10-V DC203 - 204 No Load, (Series 6184A) AUTOMATIC MODE 40 +/- 5-V DC203 - 204 No Load, (Series 6185A) AUTOMATIC MODE 40 +/- 5-V DC205 - 206 No Load, Operating Mode Switch in MANUAL 103 +/- 3-V DC207 - 208 No Load 200 +/- 2-V AC223 - Ground No Load 12.5 +/- 1-V DC224 - Ground No Load 12.5 +/- 1-V DC225 - Ground No Load, Press Test Switch 12 +/- 1-V DC226 - Ground No Load, Press Test Switch 12 +/- 1-V DC227 - Ground No Load, Press Test Switch 12 +/- 1-V DC228 - Ground No Load, Press Test Switch 12 +/- 1-V DC230 - Ground No Load, Press Test Switch 0-V DC231 - Ground No Load, Press Test Switch 0-V DC232 - Ground No Load, Press Test Switch 0-V DC233 - Ground No Load, Press Test Switch 0-V DC234 - Ground No Load, Press Test Switch 0-V DC209 - 210 No Load 200 +/- 2-V AC209 - 211 No Load 200 +/- 2-V AC210 - 211 No Load 200 +/- 2-V AC209 - Ground No Load 115 +/- 1-V AC212 - 213 Full 100% Rated Load 6.6 +/- 0.5-V AC214 - 215 Full 100% Rated Load 6.6 +/- 0.5-V AC216 - 217 Full 100% Rated Load 6.6 +/- 0.5-V AC220 - 221 Full 100% Rated Load 6.6 +/- 0.5V AC218 - 219 No Load, Meter Selector Switch at A-N 115 +/- 1-V AC222 - Ground With 24-V DC at Terminals E, F to N 24 +/- 1-V AC

Test Values with Unit Running

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TEST CONNECTION NOMINAL RESISTANCE IN OHMS

6182A 6183A 6184A 6185A

GENERATOR WINDINGS

STATOR (Stationary Fields)

A - B Line to Line 0.0391 0.0396 0.0263 0.0101

B - C Line to Line 0.0391 0.0396 0.0263 0.0101

C - A Line to Line 0.0391 0.0396 0.0263 0.0101

A - N, B - N, or C - N 0.0195 0.0392 0.0132 0.0343


MOTOR WINDINGS

STATOR (Stationary Fields)

A - 1A 0.316 0.267 0.178 0.160

B - 1B 0.316 0.267 0.178 0.160

C - 1C 0.316 0.267 0.178 0.160


EXCITER WINDINGS

STATOR (Stationary, Across the Fields) 17.5 17.5 17.5 17.5

ROTOR (Revolving Fields)

A - B * 0.17 0.17 0.17 0.17

B - C * 0.17 0.17 0.17 0.17

C - A * 0.17 0.17 0.17 0.17

* (Line-to-Line, (Across 2 Windings)

MOTOR AND GENERATOR

ROTOR (Revolving Fields) 2.17 N/A N/A N/A

Motor, Generator and Exciter Winding Resistance Values

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Motor, Generator and Exciter Windings Resistance Values

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Motor Controls

Trouble, Symptom andCondition Probable Cause Test, Check and Remedy

1. Motor will not start whenSTART switch is pushed.Indicating light (DS16) doesnot glow.

a. No power reaching input. Restore input power. Checkvoltages between TP101 andGND, TP102 and GND, andTP103 and GND. If no voltage isindicated, remedy as follows.

b. Remotely locateddisconnect switch OFF.

Turn switch ON.

c. Input line fuse(s) “blown”or input circuit breaker istripped.

Replace fuse(s) or reset circuitbreaker.

d. Source of Power is OFF. Correct as required.

e. Overload relay (K5) istripped and has not reset

Relay (K5) may be set forMANUAL (hand) reset. (See 2-3,Fig. 7) set for AUTO reset.

f. Defective overload relay(K5)

Check as follows:

g. Wrong size elementsused, or elements burnedout.

Check elements. Compareelement part number to thoselisted in 1-2, Fig. 15. Installproper elements.

h. Defective relay contacts. If normal input voltage is notindicated between TP104 andGND when elements are OK andrelay is properly set, replace relay.

i. Motor control transformer(T14) improperlyconnected.

Check voltage between TP106and GND, If other than 115-VAC, check connections inaccordance with 1-2; Fig. 17.

j. Motor control transformer(T14) defective.

If voltage was 0 in check step “i”above, replace transformer.

k. Motor control transformerfuse (F10) blown.

Check voltage between TP105and GND. If no voltage isindicated, replace fuse.

l. Defective start switch(S26).

Connect a test lead (jumper)between TP105 and TP112. Ifthe motor starts, replace the startswitch (S26). If motor did notSTART, proceed to step H.

m. Defective stop switch(S27)

Connect test lead betweenTP112 and TP113. PressSTART switch. If motorSTARTS, replace STOP switch(S27).

Motor Controls

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2. Motor will not start whenSTART switch is pressed.Light (DS16) glows.

a. Defective motor controlrelay (K15).

Hold START switch closed andobserve contacts in motor controlrelay (1-1; 5, Fig. 12). If contactsdo not close, relay coil isdefective. Replace relay. Ifcontacts close, make certain thatthey are making good contactbefore accepting relay as good.

b. Defective contactorrectifier (CR6).

Measure DC voltage BetweenTP110 and TP111. Should be atleast 90-V DC. If not, replacerectifier (CR6).

c. Defective start contactor(K20)

If voltage was normal in the stepabove, replace start contactor(K20)

3. Motor starts, stops whenSTART switch is released.

a. Auxiliary contacts inSTART contactor (K20)defective.

Connect a test lead betweenTP113 and TP114. PressSTART switch. If motorcontinues to run when STARTswitch is released, replaceSTART contactor (K20)

4. Motor “bogs down” under load. a. RUN contactor (K21) hasnot closed.

Check as follows with motorrunning.

NOTE: The first indication of an open contactor will probably be lack of power under load since onlyhalf of motor stator windings will be receiving power. Before checking for any faults, makeCERTAIN that exciter timer (M7) and start-run timer (M22) are properly adjusted. [Ref. 1-1;Para. 6,C, (11), (a)].

b. Defective exciter timer(M7) (0.5 minute)

Check voltage between TP115and ND. If no voltage isobserved, the timer (M7) has notoperated. Replace M7. Ifvoltage was 115-V AC, M7 isgood. Proceed to the next step.

c. Defective start-run timer(M22) (5 seconds).

Check voltage between TP108and TP111. If no voltage isobserved, the timer (M22) hasnot operated. Replace M22. Ifvoltage was approximately 90-VDC, the timer is good.

d. Defective RUN contactor(K21).

If voltage observed in theprevious step was approx.-mutely 90-V DC, the RUNcontactor (K21) is defective.Replace it.

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Motor Controls


5. Cabinet cooling fan (B4) doesnot operate when motor isrunning.

a. Defective fan motor. The fan can operate only whenthe motor is running.

b. Defective wiring. Make certain that 115-V AC isreaching fan.

c. Loose connection at fan. Check wiring connections.

d. Bent fan blade. Be certain that fan blades turnfreely.

e. Defective fan (B4). After determining that the abovefaults are not preventing fanoperation, replace fan (B4).

6. Fluorescent panel light (DST)does not operate when switch(S4) is ON.

a. No voltage to light circuit. Check voltage between TP105and GROUND to verify that115-V AC is reaching light circuit.If no voltage is indicated, refer toTROUBLE 1 preceding forcauses which will prevent 115-VAC from reaching light circuit.

b. Fluorescent lamp burnedout.

Replace lamp.

c. Lamp starter defective. Replace lamp starter.

d. Switch (S4) defective. Carefully jumper the panel lightswitch. If light comes ON,replace switch (S4).

e. Defective light fixture. If none of the above remedy thetrouble, replace light fixture (DST).

7. Overload relay (K5) trips whenmotor is started.

a. Improper heater elements. Observe heater element numb-beer and compare with require-menace for input voltage used.See 1-2; Fig. 15.

b. Loose connection or shortin motor input circuit.

Turn off power at remote ids-connect. Check complete inputcircuit to motor stator terminalpanel. Check all connections forsecurity. Check all cables fordamaged insulation and shortcircuited condition. Correct anyfaults found.

c. Defective motor statorwinding(s).

Check motor stator windings inaccordance with instructions in2-3; Para. 4, B, (3). Send unit tooverhaul if defective.

Motor

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1. Motor runs at reduced powerand increased input current.

a. Open or shorted diode inexciter rectifier.

Check diodes in accordance with2-3, Para. 5. Replace diodes ifdefective.

b. Open, shorted orgrounded exciter field.

Check exciter field winding inaccordance with 2-3, Para. 4, Dand E. Send unit to overhaul ifdefective.

2. Input power source hassingle-phased.

a. Motor runs at increasedand unbalanced motorcurrent.

Check input power to confirmsingle-phasing. With motorstopped, check voltage betweenTP101 and TP102, TP102 andTP103, TP101 and TP103.Voltages indicated should benormal input voltage for the set.If single-phasing is indicated,check power source and allcables between power sourceand the set. Correct as required.

b. Motor stator winding isopen or short circuited.

Check stator windings inaccordance with 2-3, Para. 4, B,(3). Send unit to overhaul ifdefective.

3. Motor will not start. (Inputpower reaching motor stator).

a. Open circuit in motor statorwinding.

See remedy 2, B, directly above.

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Generator and Motor Excitation Circuits


NOTE: Before condemning any component in the GENERATOR EXCITATION CIRCUIT as the cause of lowoutput voltage or no output voltage, the GENERATOR AND INDICATING INSTRUMENTS should beeliminated as trouble sources.

It should also be noted that any exciter troubles will be reflected in both motor and generatorperformance.

If the motor operates NORMALLY and generator voltage is below normal, trouble is likely in thegenerator rotating fields or generator stator windings.

First, use a good quality master voltmeter to check output voltages between TP209 and TP210, TP210and TP211, TP209 and TP211. If voltages are found to be normal 200-V AC, refer to troubles underCONTROLS AND INSTRUMENTS.

Second, check voltage between TP201 and TP202. If voltage is approximately 15-V DC in AUTO-MATIC voltage control mode, and if it may be varied between 0 and 35-V DC in MANUAL mode, referto troubles under GENERATOR.

Third, with unit in MANUAL mode, apply a DC voltage between TP201 and TP202 as follows:

15-V DC for Series 6182A 18-V DC for Series 6184A

12V DC for Series 6183A 14-V DC for Series 6185A

If generator output now is normal, we may conclude that the generator is good and that the fault is inthe EXCITATION CIRCUIT. Proceed to TROUBLES and CAUSES following.

1. Low generator voltage in allphases. Motor runs with highinput current. Automatic-manual voltage mode switch(S1) (29, Fig. 1) in AUTO-MATCH position.

a. No DC excitation to exciterfield.

Place Automatic- manual voltageswitch (S1) (29, Fig. 1) inMANUAL position. If a nearnormal voltage appears on thevoltmeter, it indicates that thegenerator, exciter and ballastresistors are good. Proceed tofind trouble in the automaticexcitation circuits as follows, withautomatic- manual voltage modeswitch in AUTOMATIC position.

b. Five-ampere fuse involtage regulator blown.

Voltage will appear normal at NOload, but will drop under load.Inspect fuse (1-1; 12, Fig. 7).Replace if blown.

c. Auto-manual control switch(S1) or EDR (K16)defective.

Observe voltage between TP210and TP211. Check voltagebetween TP207 and TP208. Thetwo voltages should be identical.If they are not the same, opengenerator monitor tray, 1-1; Fig.5. Inspect and check switch (2)and EDR (3). Replace switch orEDR as required.

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Low generator voltage in allphases. Motor runs with highinput current. Automatic-manual voltage mode switch(S1) (29, Fig. 1) in AUTO-MATCH position.

d. Defective voltage regulator(VR1).

Check voltage between TP203and TP204. At NO load, voltageshould be approximately 25 to50-V DC. If voltage is unseats-factory, replace complete voltageregulator tray assembly.

2. Low generator voltage in allphases. Motor runs with highinput current. Automatic-manual voltage mode switch(S1) (29, Fig. 1) in MANUALposition.

a. No excitation to generatorfields through MANUALvoltage controls.

Place voltage mode controlswitch (S1) in AUTOMATICposition. If a normal voltage nowappears on the voltmeter, itindicates that the trouble is in theMANUAL voltage control circuit.Check as follows, with switch(S1) in MANUAL position:

b. Defective auto-manualswitch (S1).

Open generator monitor tray (1-1;Fig. 5) and check connate- uniteof switch (2) in MANUAL position.Replace switch if defective.

NOTE: In checking the auto-manual control switch in Troubles 1 and 2, it must be remembered that this dpdtswitch carries both AC and DC. Although contacts which conduct AC to the regulator or rectifier maybe good, contacts which conduct DC output of regulator or rectifier may be defective, or vice-versa.

c. Rectifier (CR.) defective. Check and note voltage betweenTP211 and ND, then check vol.-age between TP205 and TP206.Voltage between TP205 andTP206 should be approximately90% of voltage observedbetween TP211 and ND. If not,replace rectifier (CR.).

d. Defective manual voltagecontrol rheostat (R61) ordefective manual rangecontrol resistor (R11).

Turn unit OFF. Place automaticswitch (29, Fig. 1) in AUTO-MATCH position. Measurereships- tank of manual controlrheostat (R61) (30, Fig. 1).Resistance should be 75 ohmswhen knob is in clockwiseposition. Replace rheostat (R61)if resistance is not 75 ohms.Measure resistance of manualrange control resistor (R11) (1-1;6, Fig. 5). Total resistance is 50ohms. Read- in should beproportional depending uponwhere the “slide” adjustment isset. If resistance is not normal oran open circuit is indicated,replace resistor (R11).

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NOTE: If output voltage is low in both MANUAL and AUTO control modes, the trouble is likely in the EXCITERor GENERATOR. However, before checking EXCITER and GENERATOR, check the three commoncomponents in the excitation circuit.

3. Low voltage in both MANUALand AUTOMATIC voltagecontrol modes.

a. Defective ballast resistors(R1) or (R2).

Use an ohmmeter to checkresistance across BOTHresistors. Should be 25 ohms. Ifindividual resistor is checked bydisconnecting wires, resistanceshould be 50 ohms for each.Replace as required.

b. Defective AUTO-MANUALcontrol switch (S1).

Check continuity of switchthoroughly. Replace if defective.

c. Defective EDR (K16). Observe operation of EDR (1-1;3, Fig. 5). Replace if defective.

Generator and Exciter


NOTE: Also refer to Motor-Generator Fault and Effect Chart (Figure 8).

1. Low output in all phases.Motor runs with high inputcurrent at no load.

a. Exciter field (L5) defective. Check resistance of exciter fieldwindings in accordance withinstructions in 2-3; Para. 4, e.

b. Exciter rectifier (CR.)defective.

Check rectifier diodes inaccordance with 2-3; Para. 5.

c. Defective windings ingenerator stator (G1).

Check windings in accordancewith instructions in 2-3; Para. 4,B, (1) and (2).

d. Defective exciter orgenerator rotor windings.

Check windings in accordancewith 2-3; Para. 4, C.

e. Defective micro switch orswitches (S42) and (S43).

Inspect switches for mechanicalfailure and stuck contacts.Replace if defective.

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Generator and Exciter


2. Generator overheats a. A loose connection iscausing high resistance.

Check all output connections.Look for discoloration atconnections. Tighten or repair asrequired.

b. Stator windings shortcircuited.

Check stator windings inaccordance with 2-3; Para. 4, B.Overhaul generator as required.

Generator Instruments and Signal Sensing Circuits


1. Low voltmeter readings in allphases.

a. Defective voltmeter (M2). Connect an accurate voltmeterbetween TP218 and TP219.Compare voltage indicated on testmeter to readings observed onmachine voltmeter as selectorswitch (S3) (2, Fig. 1) is rotated toselect phase. If voltage indicatedon test meter and on themachine’s meter vary greatly,replace machine voltmeter. Ifreadings are nearly the same,check TROUBLES underGENERATOR AND EXCITER,AND GENERATOR EXCITATIONCIRCUIT.

2. Low voltage reading in ONEoutput phase.

a. Defective meter selectorswitch (S3).

Identify phase that is indicatinglow voltage. Use a test meter tocheck voltage in affected phase.If test indicates that voltage isactually normal, replace switch(S3). If test confirms a lowvoltage in the phase, checkTROUBLES under GENERATORAND EXCITER.

NOTE: Before checking or condemning instrument, check for unbalanced and correct this condition. If loadis balanced, proceed as follows.

3. Generator ammeter indicatesNO load or low load in onephase.

a. Defective ammeter. The ammeter receives a voltagesignal. If 6.6V AC is observed atammeter terminals at full load,replace ammeter.

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Generator Instruments and Signal Sensing Circuits


Generator ammeter indicatesNO load or low load in onephase. (Continued).

b. Defect in signal sendingcircuit.

Identify defective circuit andproceed as follows:

c. Defective overload PCboard.

Disconnect overload board. Ifammeter now functions properly,replace overload board.

d. Defective meter selectorswitch (S3).

Identify wire leads from affectedcircuit at the meter switch.Disconnect those wires andcheck signal voltage at full load.If 6.6-V AC is observed, replaceswitch. If 6.6-V AC is NOT obi-served, reconnect wires andproceed to the next step.

e. Defective resistor (R26),(R27) or (R28), ordefective currenttransformer (T7), (T8) or(T9).

Identify resistor and transformerin affected circuit. Unsoiled leadsfrom one end of resistor andmeasure resistance. Should be25 ohms for 60 KVA units and 40ohms for 37.5 KVA units. Ifresistor is defective, replace. Ifresistor is good, replace currenttransformer.

Generator Controls and Related Components


1. Protective monitor indicatinglights do not glow whenpress-to-test switch (12, Fig. 1)is pushed. Motor running.

a. Fuse (F2) (26, Fig. 1)blown.

Inspect fuse and replace if blown.Check for cause of fuse blowing.

b. Protective system notreceiving DC power.

Check as follows.

c. 12-V DC power supply(A6) defective.

Check voltage between outputterminals on power supply (1-1;13, Fig. 11). Indicated voltageshould be 12-V DC. If 12-V DC.cannot be obtained byadjustment (See 2-3, Fig. 18)replace power supply (A6).

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Protective monitor indicatinglights do not glow whenpress-to-test switch (12, Fig. 1)is pushed. Motor running.(Continued).

d. Defective reset switch(S23) (13, Fig. 1).

Check voltage between TP223and ND. If no DC voltage isobserved when power supply (A6)and fuse (F2) are known to begood, replace reset switch (S23).

e. Defective test switch (S30)(12, Fig. 1).

Open protective tray and carefullyjumper test switch connections.If indicating lights glow, replacetest switch (S30).

2. Load contactor will not closewhen CLOSE switch (S21) (18,Fig. 1) is pressed. Motorrunning normally. (NOTE: Besure that no fault lights areON).

a. Defective generator controlrelay (K47) (1-1; 9, Fig. 11).

Connect a test lead betweenTP110 and TP107. If contactorcloses, replace generator controlrelay (K47). If contactor does notclose, proceed to CAUSE “B”.

b. Defective CLOSE switch(S21) or OPEN switch(S22).

Check voltage between TP116and ND. If 115-V AC isindicated, power is reaching theCLOSE switch. Check voltagebetween TP117 and ND whilepushing CLOSE switch (S21).No voltage indicates that CLOSEor OPEN switch is defective.Connect a test lead betweenTP116 and TP117. If loadcontactor CLOSES when testlead is connected, remove testlead and carefully inspect andcheck both CLOSE and OPENswitches. Replace defectiveswitch or switches.

c. Power not reachingcontactor CLOSE switch(S21).

Check voltage between TP116and ND. Voltage should beapproximately 115-V AC. If not,Check the following:

d. Defective fuse interlockrelay (K17).

If hourmeter (M4) is running, itindicates that 12-V DC power isreaching the relay, and it shouldbe CLOSED. Check and inspectrelay (K17). Replace if defective.If hourmeter is NOT running,check 12-V DC circuit underTROUBLE 1 above.

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Load contactor will not closewhen CLOSE switch (S21) (18,Fig. 1) is pressed. Motorrunning normally. (NOTE: Besure that no fault lights areON).

e. Defective auxiliarycontacts in motor RUNcontactor (K21) (1-1; 19,Fig. 11).

Carefully jumper small terminals 1and 2 on RUN contactor. If loadcontactor will now CLOSE whenswitch (S21) is pushed, replaceRUN contactor (K21).

f. Defective relay (K14) inmemory and time delayboard.

It is assumed that all causes ofload contactor closing have beeneliminated under precedingsteps. The relay in the memoryand time delay board is the onlyremaining cause. Check andexamine relay carefully. Replacecomplete memory and time delayboard if defective.

Protective Monitor System


1. An indicating light continues toglow after reset switch (S23)(13, Fig. 1) is pushed.

a. The light is doing its joband is indicating a faultcondition.

Inspect and check to discover thefault. Correct fault conditionbefore proceeding with normaleducation.

b. One of the fault sensingboards is defective, or thememory and a time delayboard is defective.

Check voltages between testpoints in accordance with Fig. 7.Replace defective board asrequired.

2. Protective system isinoperative.

a. No DC voltage reachingprotective system.

Check and remedy in accordancewith troubleshooting instructionsunder GENERATOR CON-TROLLS AND RELATEDCOMMA- PENANCE, TROUBLE1, A and B.

b. Memory and time delayboard (1-1; 2, Fig. 6)defective.

Check voltages in accordancewith Fig. 7. Replace memory andtime delay board if defective.

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Protective Monitor System


1. Load contactor opens andoverload indicating light comesON when there is NO overloadfault.

a. One of the resistors R26,R27, or R28 (1-1; 1, Fig.12) in overload sensingcircuit is open.

With full rated load applied to themachine, voltage indicatedbetween each pair of Tap’s belowshould be approximately 6.6-V AC.

CHECK Tap’s TO CHECK

212 - 213 R26214 - 215 R27216 - 217 R28

If voltage indicated between anypair of Tap’s above is 8-V AC ormore, replace the correspondingresistor.

b. Overload sensing board(K4) (1-1; 4, Fig. 12)defective.

If normal signal values werefound in check A above, replaceoverload board.

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Indicating Light WhichRemains ON When Reset

Button is Pushed

To Test, checkVoltage at Tap’s

Indicates DefectiveMemory and Time

Delay Board

Indicates DefectiveSensing Board

OLD Light TP225 - ND 0-DC 12-V DC

OVA Light TP226 - ND 0-DC 12-V DC

UV Light TP227 - ND 12-V DC 0-V DC

UF Light TP228 - GND 0-V DC 12-V DC

NOTE: The 12-V DC value in chart is normal adjusted output voltage of Power Supply (A6).

Protective System Fault Chart

FAULTEFFECT

MOTOR GENERATOR

EXCITER ROTOR

Open diode Motor will run with decreased powerpotential and increased inputcurrent.

Will operate with decreased poweroutput potential.

Shorted diode Motor will run with extremely highinput current and extremely laggingpower factor.

NO VOLTAGE OUTPUT

Open rotor winding Motor will run with decreased powerpotential and increased inputcurrent.

Will operate with decreased poweroutput potential.

Shorted rotor winding Motor will run with extremely highinput current and extremely laggingpower factor.

NO VOLTAGE OUTPUT

EXCITER FIELD

Open circuited Motor will run with decreased powerpotential and increased inputcurrent.

NO VOLTAGE OUTPUT

Short Circuited Motor will run with decreased powerpotential and increased inputcurrent.

NO VOLTAGE OUTPUT

MOTOR ROTOR

Open circuited winding Motor will run with decreased powerpotential.

NONE, except decreased outputpower potential caused by reducedmotor power.

Short circuited Motor will run, heat, and probably“burn out” diodes in exciter.

NONE, except NO VOLTAGEOUTPUT if diodes are “burned out”.

Motor-Generator Fault and Effect Chart

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FAULTEFFECT

MOTOR GENERATOR

MOTOR STATOR

Open circuited winding Motor will continue to run, singlephase, with high input current andlow power. Motor WILL NOTSTART if stopped.

NONE, except low current output.

Short circuited windings Motor will continue to run, singlephase. WILL HEAT. Will probablytrip overload relay.

NONE, except low current output.

GENERATOR ROTOR

Open circuited winding NONE NO VOLTAGE OUTPUT

Short circuited windings NONE, except low power if exciterdiodes are “burned out”.

NO VOLTAGE OUTPUT

GENERATOR STATOR

Open circuited winding NONE Will operate until parallel windings inone phase are burned out byoverload, then operate single phase.

Short circuited windings NONE Will operate single phase, HEAT,and have unbalanced voltageoutput.

Motor-Generator Fault and Effect Chart

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Chapter 4. Illustrated Parts List

Section 1. Introduction

1. GeneralThe Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, anddetail parts of particular engine-driven generator sets manufactured by Hobart Brothers Company,Power Systems Division, Troy, Ohio, 45373. Refer to Section 1-1 for generator set identificationinformation.

2. PurposeThe purpose of this list is to provide parts identification and descriptive information to maintenance andprovisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spareparts.

3. ArrangementChapter 4 is arranged as follows:

Section 1 - Introduction

Section 2 - Manufacturer’s Codes

Section 3 - Parts List

Section 4 - Numerical Index

4. Explanation of Parts List

a. Contents

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

(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which areavailable 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., toother 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 theright, columns are identified as follows:

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(1) FIGURE-ITEM NO. Column

This column lists the figure number of the illustration applicable to a particular parts list and alsoidentifies each part in the list by an item number. These item numbers also appear on theillustration. Each item number on an illustration is connected to the part to which it pertains by aleader line. Thus the figure and item numbering system ties the parts lists to the illustrations andvice versa. The figure and index numbers are also used in the numerical index to assist the userin 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 partis a purchased item, the vendor’s identifying five-digit code and his part number will appear inthe NOMENCLATURE column. Vendor parts which are modified by Hobart will be identified assuch in the NOMENCLATURE column. In case Hobart does not have an identifying partnumber for a purchased part, the HOBART PART NUMBER column will reflect No Number andthe vendor’s number will be shown in the NOMENCLATURE column. Parts manufactured byHobart 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 itemrelationship. Thus, components of an assembly are listed directly below the assembly andindented one space.

Vendor codes and part numbers for purchased parts are shown in this column.

(4) REC. SPARES column

When there is an entry in this column, it shows the quantity of that item recommended forspares to support ONE end item.

(5) “EFF” (Effective) Column

This column is used to indicate the applicability of parts to different models of equipment. Whenmore than one model of equipment is covered by a parts list, there are some parts which areused on only one model. This column is used for insertion of a code letter “A”, “B”, etc., toindicate these parts and to identify the particular model they are used on.

Uncoded parts are usable on all models.

• Parts coded “A” are usable on Spec 6182A-1 only.

• Parts coded “B” are usable on Spec 6182A-2 only.

• Parts coded “C” are usable on Spec 6182A-3 only.

• Parts coded “D” are usable on Spec 6183A-1 only.

• Parts coded “E” are usable on Spec 6184A-1 only.

• Parts coded “F” are usable on Spec 6184A-2 only.

• Parts coded “G” are usable on Spec 6184A-3 only.

• Parts coded “H” are usable on Spec 6184A-4 only.

• Parts coded “J” are usable on Spec 6185A-1 only.

• Parts coded “K” are usable on Spec 6185A-2 only.

(6) UNITS PER ASSEMBLY Column

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

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Section 2. Manufacturer’s Codes

1. Explanation of Manufacturer’s (Vendor) Code ListThe following list is a compilation of vendor codes with names and addresses for suppliers ofpurchased parts listed in this publication. The codes are in accordance with the Federal Supply Codesfor Manufacturer’s Cataloging Handbook H4-1, and are arranged in numerical order. Vendor codes areinserted in the nomenclature column of the parts list directly following the item name and description.In case a manufacturer does not have a vendor code, the full name of the manufacturer will be listed inthe nomenclature column.

CODE VENDOR’S NAME AND ADDRESS

00779 AMP Inc., P.O. Box 3608, Harrisburg, Pennsylvania 17105

01121 Allen-Bradley Company, 1201 South 2nd St., Milwaukee, Wisconsin 53204

02660 Bunker Ramo Corporation, Amphenol-Borg Electronics, North Am. Div.2801 South 25th Ave., Broadview, Illinois 60153

03743 Appleton Electronics Company, 2205 12th Avenue, South Milwaukee,Wisconsin 53172

04009 Crouse-Hinds Arrow Hart, Arrow Hart Div., 103 Hawthorne Street,Hartford, Connecticut 06105

04713 Motorola Semiconductor Products, Inc., 5005 East McDowell Road,Phoeniz, Arizona 85008

05864 Automatic Timing and Controls Company, Div. of American Manufacturing CompanyInc., 201 S. Gulph Road, King of Prussia, Pennsylvania 19406

05469 Bearings, Inc., 3634 Euclid, P.O. Box 6925, Cleveland, Ohio 44101

08108 Lamp Industries For Use With Industry Designations & Abbreviations for Lamps

10983 American Solenoid Company, Inc., 60 New Brunswick Road, P.O. Box 430,Somerset, New Jersey 08873

14280 Square-D Company, Distribution Equipment Division, 1601 Mercer Road,Lexington, Kentucky 40505

15605 Eaton Corporation Cutler-Hammer Div., 4201 N. 27th St.,Milwaukee, Wisconsin 53216

19321 Malco Products, Inc., 361 Fairview Avenue, Barberton, Ohio 44203

21335 The Fafnir Bearing Company, Division of Textron Inc., 37 Booth Street,New Britain, Connecticut 06050

23934 Power Mate Corp., 514 South River St., Hackensack, New Jersey 07601

23978 Technology, Inc., 3821 Coloney Glenn Highway, P.O. Box 3036, Overlook Branch,Dayton, Ohio 45431

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24248 Southco, Inc., 210 N. Brinton Lake Road, Concordville, PA 19331

24493 General Electric COmpany, Meter Business Dept., Instruments Products,40 Federal Street, West Lynn, Massachusetts 01905

25248 Wilmar Electronics, Inc., 2430 Ansler Street, Torrance, California 90505

28488 Raco, Inc., 3902 W. Sample Street, South Bend, Indiana 46619

28520 Heyco Motor Products, P.O. Box 160, Kenilworth, NJ 07033

30882 Micron Industries Corporation, 1830 32nd Avenue, Stone Park, Illinois 60165

44655 Ohmite Manufacturing Company, 3601 West Howard Street,Skokie, Illinois 60076

59730 Thomas and Betts Corporation, Highway 218 South, Iowa City, Iowa 52240

70611 Ark-les Switch Corp., #45 Water, Watertown, Massachusetts 02172

71183 Bryant Division, Westinghouse Electric Corp., 1421 State St., P.O. Box D,Bridgeport. Connecticut 06602

71400 Bussman Manufacturing, Division of McGraw-Edison Company,114 Old State Road, P.O. Box 14460, St. Louis, Missouri 63178

72619 Dialight Div., Amperex Corporation, 203 Harrison Place,Brooklyn, New York 11237

73559 Carlingswitch, Inc., 505 New Park Ave., West Hartford, Connecticut 06110

74063 Figgie International Inc., Hartman Electrical Manufacturing Div.,175 N. Diamond, P.O. Box 8, Mansfield, Ohio 44902

74193 Heinemann Electric Company, 2600 Brunswick Pike, P.O. Box 8428,Trenton, NJ 08650

74400 Hobbs Division, Stewart-Warner Corp., Yale Blvd. and Ash St., Springfield, IL 62705

74829 Ilsco Division, 4730 Madison Road, Cincinnati, Ohio 45227

74970 E. F. Johnson Company, 299 10th Avenue S.W., Waseca, Minnesota 56093

75358 Knape and Vogt Mfg. Co., 2700 Oak Industrial Drive, Grand Rapids, Michigan 49505

77060 Packard Electric Division, General Motors Corporation, 408 Dana St., N.E.,P.O. Box 431, Warren, Ohio 44482

77342 Potter and Brumfield Division, AMF Inc., 200 Richland Creek Drive,Princeton, Indiana 47670

77379 Premier Rubber Manufacturing Company, Division of Eagle-Picher Industries, Inc.No. 1 Edmund St., Dayton, Ohio 45404

81041 Howard Industries Div., MSL Industries Inc., #1 No. Dixie Highway, P.O. Box 287,Milford, Illinois 60953

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81703 Mulberry Metal Products Inc., 2199 Stanley Terrace, Union, NJ 07083

81860 Barry Controls, Barry Wright Corp., 700 Pleasant, Watertown, Massachusetts 02172

84970 ST-Semicon Inc., 415 N. College Avenue, Bloomington, Indiana 47401

91094 Suflex/IWP Division, Essex Grou, Inc., Bay Road, Newmarket, NH 03857

91637 Dale Electronics Incorporated, P.O. Box 609, Columbus, Nebraska 68601

91929 Honeywell, Inc., Buildings Controls & Components Group,Micro Switch Division, 11 W. Spring Street, Freeport, Illinois 61032

98410 E.T.C. - Molex Inc., 5201 Richmond Rd., Bedford Heights, Ohio 44146

No Number Duray Fluorescent Mfg. Co., 5645 N. Ravensword, Chicago, IL 60660

OM-465



OM-465


Section 3. Parts List

1. Explanation of Parts List ArrangementThe parts list is arranged so that the illustration will appear on a left hand page and the applicable partslist will appear on the opposite right-hand page. Unless the list is unusually long, the user will be ableto look at the illustration and read the parts list without turning a page.

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

2. Symbols and AbbreviationsThe 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-ampere

F - microfarad

No. - number

NHA - next higher assembly

Ω - 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)

OM-465


Motor-Driven Generator SetFigure 1

OM-465


NOMENCLATURE UNITSFIGURE HOBART per

ITEM NO. PART NO. 1 2 3 4 5 6 7 EFF ASSY

1 - 6182A-1 GENERATOR SET, MOTOR DRIVEN,230 / 460-V, 37.5-kVA, 60-Hz INPUT A 1

6183A-1 GENERATOR SET, MOTOR DRIVEN,220/380-V, 37.5-kVA, 50-Hz INPUT B 1

6184A-1 GENERATOR SET, MOTOR DRIVEN,230 / 460-V, 60-kVA, 60-Hz INPUT C 1

6185A-1 GENERATOR SET, MOTOR DRIVEN,220 / 380, 60-kVA, 50-Hz INPUT D 1

6184A-3 GENERATOR SET, MOTOR DRIVEN,208 / 380-V, 60-kVA, 60-Hz INPUT E 1

6182A-2 GENERATOR SET, MOTOR DRIVEN,208 / 380-V, 37.5-kVA, 60-Hz INPUT F 1

6182A-3 GENERATOR SET, MOTOR DRIVEN,575-V, 37.5-kVA, 60-Hz INPUT G 1

6184A-2 GENERATOR SET, MOTOR DRIVEN,230 / 460-V, 60-kVA, 60-Hz INPUT,DELTA OUTPUT H 1

6184A-4 GENERATOR SET, MOTOR DRIVEN,575-V, 60-kVA, 60-Hz INPUT J 1

6185A-2 GENERATOR SET, MOTOR DRIVEN,415-V, 60-kVA, 50-Hz INPUT K 1

1 No Number . CONTROL CABINET GROUP (FORDETAILS SEE FIG. 2) A-B 1

No Number . CONTROL CABINET GROUP (FORDETAILS SEE FIG. 2) CDE 1

2 No Number . CONDUIT AND CONNECTORS GROUP

(FOR DETAILS SEE FIG. 15) 13 No Number . MOTOR-GENERATOR GROUP (FOR

DETAILS SEE FIG. 16) A,FG 1No Number . MOTOR-GENERATOR GROUP (FOR

DETAILS SEE FIG. 16) B 1

No Number . MOTOR-GENERATOR GROUP (FORDETAILS SEE FIG. 16) C,E,H,J 1

No Number . MOTOR-GENERATOR GROUP (FORDETAILS SEE FIG. 16) D,K 4

No Number . FRAME AND COVERS GROUP (FOR

DETAILS SEE FIG. 17) 1* 5 485211 . KIT, SECOND OUTPUT (OPTIONAL)

(FOR DETAILS SEE FIG. 18) 1* 6 485240 . KIT, CONVENIENCE RECEPTACLE

(60Hz) (OPTIONAL) (FOR DETAILSSEE FIG. 20) A,C,E-J 1

* Not Illustrated

OM-465



OM-465




1 - (Continued)* 7 482085A . TRANSFORMER-RECTIFIER, 28.5-V DC

(OPTIONAL) (FOR DETAILS SEE TM-597) 1* 8 485255 . KIT, T-R MOUNTING (OPTIONAL)

(FOR DETAILS SEE FIG. 21) 1* 9 485398-1 . KIT, PHASE REVERSAL RELAY

(OPTIONAL) FOR 460V(FOR DETAILS SEE FIG. 22) A-C,E,J 1

*10 485398-2 . KIT, PHASE REVERSAL RELAY(OPTIONAL) FOR 575V(FOR DETAILS SEE FIG. 22) A-C,E,J 1

*11 485398-3 . KIT, PHASE REVERSAL RELAY(OPTIONAL) FOR 230V(FOR DETAILS SEE FIG. 22) A-C,E,J 1

*12 485398-4 . KIT, PHASE REVERSAL RELAY(OPTIONAL) FOR 380V

(FOR DETAILS SEE FIG. 22) B,D,K 1*13 484311 . TRAILER (OPTIONAL) (FOR DETAILS

SEE TM-268A) 1*14 485237 . KIT, ALTERNATE VOLTAGE PKG.

(OPTIONAL) (FOR DETAILS SEE

FIG. 6) 1*15 485652 . KIT, CONVENIENCE RECEPTACLE

(50Hz) (OPTIONAL) (FOR DETAILSSEE FIG. 23) B,D,K 1

* Not Illustrated

OM-465


Control Cabinet GroupFigure 2

OM-465




2 - No Number CONTROL CABINET GROUP(FOR NHA SEE FIG. 1) AB,FG REF

No Number CONTROL CABINET GROUP(FOR NHA SEE FIG. 1) C-E,H-K REF -1

485032-2 . TRAY ASSY, GENERATOR MONITOR(FOR DETAILS SEE FIG. 3) AB,FG 1

485032-1 . TRAY ASSY, GENERATOR MONITOR(FOR DETAILS SEE FIG. 3) C-E,H-K 1

2 488410 . TRAY ASSY, GENERATOR PROTECTION

(FOR DETAILS SEE FIG. 4) 13 485130 . TRAY ASSY, VOLTAGE REGULATOR

(FOR DETAILS SEE FIG. 5) 14 485081-4 . PANEL ASSY, INTERIOR

(FOR DETAILS SEE FIG. 6) AB,FG 1

485081-3 . PANEL ASSY, INTERIOR(FOR DETAILS SEE FIG. 6) C-E,H-K 1

5 485093 . CABINET ASSY, CONTROL(FOR DETAILS SEE FIG. 9) 1

OM-465


Generator Monitor Tray AssemblyFigure 3

OM-465




3 - 485032-2 TRAY ASSY, GENERATOR MONITOR(FOR NHA SEE FIG. 2) AB,FG REF

485032-1 TRAY ASSY, GENERATOR MONITOR(FOR NHA SEE FIG. 2) C-E,H-K REF

1 485163 . HARNESS, RECEPTACLE, GENERATORMONITOR TRAY 1

2 79B-1159-1 . CONNECTOR RECEPTACLE, ELECTRICAL(00779, NO. 206151-1) 1

3 402665-1 . HOUSING, RECEPTACLE, QUICK DIS-

CONNECT (00779, NO. 1-480416-0) 64 402826 . SWITCH, TOGGLE, AUTO-MANUAL

(15605, NO. 8926K425) 15 485153 . BRACKET, SWITCH AND RECEPTACLE

MOUNTING 1

6 404065-2 . RECTIFIER, SILICON(04713, NO. SDA10270-1) 1

7 403765-4 . RESISTOR, BALLAST, 50 OHM, 100WATT(44655, NO. 0602) 2

8 W-2974-L . RESISTOR, MANUAL CONTROL, 50 OHM

100W (44655, NO. 0959) 19 400078 . BRACKET, MTG, RESISTOR 6

10 16DA-4253-1 . RETAINER, SPRING, RELAY(77342, NO. 20C206) 1

11 16DA-4004A-1 . RELAY, ENCLOSED, PLUG-IN,

EXCITATION DEENERGIZATION(77342, NO. KA-4244-1) 1

12 79B-1138 . SOCKET, RELAY (77342, NO. 27E123) 113 16DA-2162 . KNOB, RHEOSTAT, MANUAL CONTROL

(44655, NO. 5150) 1

14 10J-178 . PLATE, INSTRUCTION 115 402157 . RHEOSTAT, MANUAL CONTROL

(44655, MODEL L, 150 WATT, 75 OHM) 116 485154 . BRACKET, MTG, RHEOSTAT 117 79C-1135-2 . AMMETER, AC, 0-160 AMPS AB,FG 1

79C-1135-1 . AMMETER, AC, 0-260 AMPS C-E,H-K 1

18 79C-1158 . SWITCH, ROTARY, METER, SELECTOR(10983, TYPE C11, CODE NO. 2DE483) 1

19 79C-1134-4 . VOLTMETER, AC, 0 TO 300 VOLTS(24493, NO. 50-251430RXRX) 1

OM-465



OM-465




3 - (Continued)20 400828-1 . TIE, WIRE, PLASTIC

(59730, NO. TYB-23M) 40485033 . TRAY, GENERATOR MONITOR 1

21 76A-1115 .. LATCH, ADJUSTABLE GRIP(75358, NO. 48-99-126-11) 1

22 370382A .. HANDLE, TRAY 123 56203 .. STRIP, RUBBER 1/8 BY 3/8 IN 27-IN24 284913 .. SLIDE, TRAY, LEFT (NOT PROCURABLE

SEPARATELY SEE KIT NO. 402383) 125 485034 .. TRAY 1

* 26 402383 KIT, TRAY SLIDES (75358, NO. 1300) ARKIT CONTAINS ONE EACH OF THEFOLLOWING:

384913 SLIDE, TRAY, LEFT384912 SLIDE, TRAY, RIGHT

384911 SLIDE, CABINET, LEFT384910 SLIDE, CABINET, RIGHT

*NOT ILLUSTRATED

OM-465


Generator Protection Tray AssemblyFigure 4

OM-465




4 - 488410 TRAY ASSY, GENERATOR PROTECTION(FOR NHA SEE FIG. 2) REF

1 488415 . HARNESS, RECEPTACLE, GENERATORPROTECTIVE TRAY 1

2 79B-1159-1 .. CONNECTOR, RECEPTACLE, ELECTRICAL(00779, NO. 206151-1) 1

3 485148 . BRACKET, MOUNTING, RECEPTACLE 1

4 401937-3 . TERMINAL BOARD (98410, NO. 35012-3526) 15 16DA-4253-1 . RETAINER, SPRING, RELAY

(77342, NO. 20C260) 16 16DA-4004A-10 . RELAY, ENCLOSED, PLUG-IN FUSE

INTERLOCK (77342, NO. KAP-14DG) 1

7 79B-1138 . SOCKET, RELAY (77342,NO. 27E123) 1-8 401564-5 . HOUSING, SOCKET, CONNECTOR

(00779, NO. 1-480438-0) 19 387736B . BRD ASSY, MEMORY AND TIME DELAY 1

10 401564-4 . HOUSING, SOCKET, CONNECTOR

(00779, NO. 1-480287-0) 211 482038 . BOARD ASSY, OVER-UNDERVOLTAGE 112 482039 . BOARD ASSY, OVER-UNDERFREQUENCY 113 401556 . MOUNT,RESILIENT (81860-NO.SS-01) 1214 403336 . RING, LOCKING, SWITCH

(91929, NO. TS10397) 215 76A-1118 . SWITCH, PUSH, RESET & LIGHT TEST

(15605, NO. SA35BCB34-4) 216 HF-2518-2 . LIGHT, INDICATING, RED

(72619, NO. 26-1310-1191-301) 4

17 404172-1 .. LENS, LIGHT, RED(72619, NO. 16-1191-300) 1

18 400613-4 .. LAMP, INCANDESCENT (08108, NO. 1815) 119 402658 . FUSEHOLDER (71400, NO. HP-HH) 120 W-11166-1 . FUSE, CARTRIDGE, FAST BLOW

(71400, TYPE AGC, 2 AMP) 121 400828-1 . TIE, WIRE, PLASTIC

(59730, NO. TB-23M) 40488411 . TRAY, GENERATOR PROTECTION 1

22 76A-1115 .. LATCH, ADJUSTABLE GRIP

(75358, NO. 48-99-126-11) 123 370382A .. HANDLE, TRAY 124 56203 .. STRIP, RUBBER, 1/8 BY 3/8 IN 27-IN.

OM-465



OM-465




4 - 488410 (Continued)25 284913 .. SLIDE, TRAY, LEFT (NOT PROCURABLE

SEPARATELY, SEE KIT NO. 402383) 1384912 .. SLIDE, TRAY, RIGHT (NOT PROCURABLE

SEPARATELY, SEE KIT NO. 402383) 126 488412 .. TRAY 1

402383 KIT, TRAY SLIDES (75358, NO. 1300) ARKIT CONTAINS ONE EACH OF THEFOLLOWING:



27 403091-6 . PLUG, HOLE, PLASTIC, (28520,NO. DIP-750) 1

OM-465


Voltage Regulator Tray AssemblyFigure 5

OM-465




5 - 485130 TRAY ASSY, VOLTAGE REGULATOR(FOR NHA SEE FIG. 2) REF

1 430391B . REGULATOR, VOLTAGE(FOR DETAILS SEE VOLTAGEREGULATOR MANUAL TM-759) 1

485131 . TRAY, SUB-ASSEMBLY, VOLTAGEREGULATOR 1

2 484913 .. SLIDE, TRAY, LEFT (NOT PROCURABLESEPARATELY, SEE KIT NO. 402383) 1

484912 .. SLIDE, TRAY, RIGHT (NOT PROCURABLESEPARATELY, SEE KIT NO. 402383) 1

3 405132 .. TRAY, VOLTAGE REGULATOR 1

402383 KIT, TRAY SLIDES (75358, NO. 1300) ARKIT CONTAINS ONE EACH OF THEFOLLOWING:



OM-465


Interior Panel AssemblyFigure 6

OM-465




6 - 485081-4 PANEL ASSY, INTERIOR(FOR NHA SEE FIG. 2) A-B,FG REF

485081-3 PANEL ASSY, INTERIOR(FOR NHA SEE FIG. 2) C-E,H-K REF

- 1 404518 . CONTACTOR, MOTOR START ANDGENERATOR LOAD (74063, NOHB200BB) 3

2 485117 . BUS BAR 33 404065-2 . RECTIFIER, SEMICONDUCTOR DEVICE

(04713, NO. MDA 3504) 14 401937-3 . TERMINAL BOARD

(98410, NO. 35012-3526) 1485168 . HARNESS, RECEPTACLE, GENERATOR

MONITOR TRAY 1


6 79A-1164 ..PLUG, KEYING (00779,NO. 200821-1) 1488422 . HARNESS, RECEPTACLE, GENERATOR

PROTECTION TRAY 1


8 79A-1164 ..PLUG, KEYING (00779,NO. 200821-1) 1485170 .HARNESS, RECEPTACLE, CONTROL PANEL 1

9 79B-1159-2 .. CONNECTOR, RECEPTACLE,

ELECTRICAL (00779, NO. 20636-1) 110 79A-1164 ..PLUG, KEYING (00779,NO. 200821-1) 111 485116 . BRACKET, MTG., RECEPTACLE 212 79B-1150 . TRANSFORMER, MOTOR CONTROL

(30882, NO. CX500MBRDTW13) 1

13 485079-1 . PANEL ASSY, CURRENT TRANSFORMER(FOR DETAILS SEE FIG. 7) A-B,FG 1

485079-2 . PANEL ASSY, CURRENT TRANSFORMER(FOR DETAILS SEE FIG. 7) C-E,H-K 1

14 403336 . RING, LOCKING, SWITCH

(91929, TS10020) 115 402662 . SWITCH, TOGGLE (73559,

NO. 2GK71-73) 116 100GH-142 . BRACKET, SWITCH MOUNTING 117 16DA-4252-1 . RETAINER, SPRING, RELAY

(77342, NO. 20G206) 218 16DA-4004A-1 . RELAY, ENCLOSED, PLUG-IN, GENERATOR

CONTROL (77342, NO. KA-4244-1, 115V) 119 16DA-4004A-3 . RELAY, ENCLOSED, PLUG-IN, PLUG

INTERLOCK (77342, NO. KAP-14DG 24V) 1

OM-465




6 - (Continued)20 DELETE21 79B-1138 . SOCKET, RELAY (77342, NO. 27E123) 222 483436 . LABEL, PHASE 123 75GH-50 . PLATE, IDENTIFICATION “F” 124 75GH-49 . PLATE, IDENTIFICATION “E” 1

25 402119-9 . SCREW, CAP, HEX HED, 1/4-20 X 1-3/4 IN. LONG 126 A-25 . INSULATOR, WASHER 127 DW-1704 . INSULATOR, BUSHING 128 75GH-51 . PLATE, IDENTIFICATION “N” 129 DELETE

30 DELETE31 DELETE32 485145 . TERMINAL, INPUT 333 79B-1153 . POWER SUPPLY, 12-VDC (23934,

MODEL NO. EMA-12/15B) 1

34 485264 . PLATE, POWER SUPPLY MOUNTING 135 79B-1155 . RELAY, MOTOR OVERLOAD (14280,

CLASS 9065, TYPE SEO-6B SERIES B) 136 W-9760-174 . CABLE, ASSY, INPUT A-B,FG 2

W-9648-287 . CABLE, ASSY, INPUT C-E,H-K 2

37 W-9760-175 . CABLE, ASSY, INPUT A-B,FG 1W-9648-288 . CABLE, ASSY, INPUT C-E,H-K 1

38 485145 . PANEL ASSY, INPUT(FOR DETAILS SEE FIG. 8) 1

485165 . HARNESS, RECEPTACLE, TEST POINTS

BOTTOM 139 79B-1159-2 .. CONNECTOR, RECEPTACLE, ELECTRICAL

(00779, NO. 206306-1) 140 79A-1164 ..PLUG, KEYING (00779,NO. 200821-1) 1

488420 .HARNESS,RECEPTACLE TEST POINTS TOP 1


42 79A-1164 ..PLUG, KEYING (00779,NO. 200821-1) 1485167 . HARNESS, RECEPTACLE, VOLTAGE REG 1

43 79B-1159-2 .. CONNECTOR, RECEPTACLE, ELECTRICAL

(00779, NO. 206306-1) 144 79B-1164 ..PLUG, KEYING (00779,NO. 200821-1) 145 401937-4 . TERMINAL BOARD (98410, NO. 35018-3426) 146 485177 . PANEL, INTERIOR 1

* 47 485237 KIT, ALTERNATE VOLTAGE HEATER

ELEMENTS (FOR OVERLOAD RELAYNO. 79B-1155) AR

OM-465




6 - (Continued)* 48 485237-3 . KIT, HEATER ELEMENTS, FOR 575V INPUT

ON 6184A-4 J AR* 49 79A-1156-3 . . ELEMENT, THERMAL (14280, NO. AR 1.39 J 3* 50 485237-4 . KIT, OVERLOAD RELAY, HEATER ELEMENTS

FOR 460V INPUT ON S-6184A-1

AND S6184-2 C,H 3* 51 79A-1156-4 . . ELEMENT, THERMAL (14280, NO. AR-1.68) C,H 3* 52 485237-6 . KIT, OVERLOAD RELAY, HEATER ELEMENTS

FOR 230V ON S-6182A-1AND FOR 220V ON S-6183A-1 AB AR

* 53 79A-1156-6 .. ELEMENT, THERMAL (14280, NO. AR 2.71) AB 1* 54 485327-7 . KIT, OVERLOAD RELAY, HEATER

ELEMENTS FOR 208V ON S-6182A-2 F AR* 55 79A-1156-7 .. ELEMENT, THERMAL (14280, NO. AR 2.98) F 3* 56 485327-8 . KIT, OVERLOAD RELAY, HEATER

ELEMENTS FOR 575V INPUT ONS-6182A-3 G AR

* 57 79A-1156-9 .. ELEMENT, THERMAL (14280, NO. AR 0.95) G 3* 58 485237-9 . KIT, OVERLOAD RELAY, HEATER

ELEMENTS FOR 380V INPUT ON

S-6182A-2 AND S-6183A-1 B,F 3* 59 79A-1156-10 .. ELEMENT, THERMAL (14280, NO. AR 1.53) B,F 3* 60 485237-10 . KIT, OVERLOAD RELAY, HEATER

ELEMENTS FOR 380V INPUT ONS-6184A-3, AND S-6185A-1 DE AR

* 61 79A-1156-11 .. ELEMENT, THERMAL (14280, NO. AR 2.24) DE 3* 62 485237-11 . KIT, OVERLOAD RELAY, HEATER

ELEMENTS FOR 230V ONS-6184A-1 AND S-6184A-2, ANDFOR 220V ON S-6185A-1 CD AR

* 63 79A-1156-12 .. ELEMENT, THERMAL (14280, NO. AR 3.98) CD 1* 64 485237-12 . KIT, OVERLOAD RELAY, HEATER

ELEMENTS FOR 208V INPUT ONS-6184A-3 E AR

* 65 79A-1156-13 .. ELEMENT, THERMAL

(14280, NO. AR 4.37) E 3* 66 485237-13 . KIT, OVERLOAD RELAY, HEATER ELE-

MENTS FOR 460V INPUT ON S-6182A-1 A AR* 67 79A-1156-14 .. ELEMENT, THERMAL (14280, NO. AR 1.26) A 3* 68 485237-14 . KIT, OVERLOAD RELAY, HEATER ELE-

MENTS FOR 415V INPUT ON S-6185A-2 K AR* 69 79A-1156-16 .. ELEMENT, THERMAL (14280, NO. AR 2.04) K 3

* NOT ILLUSTRATED

OM-465


Current Transformer Panel AssemblyFigure 7

OM-465




7- 485079-1 PANEL ASSY, CURRENT TRANSFORMER(FOR NHA SEE FIG. 6) AB,FG REF

485079-2 PANEL ASSY, CURRENT TRANSFORMER(FOR NHA SEE FIG. 6) C-E,H-K REF

1 1CZ-148 . TRANSFORMER, CURRENT, LINEDROP 660:1 6

2 484661 . BRACKET, MTG. TRANSFORMER 83 402037-8 . GROMMET, RUBBER (02231, NO. AGW-8301) 54 W-9746-1 . RESISTOR, LINE DROP, 50 OHM 25 WATT

(44655, NO. 0200D) 35 404402-3 . RESISTOR, OVERLOAD, BURDEN (91637,

TYPE RH-25, 40 OHMS) AB,FG 3404402-2 . RESISTOR, OVERLOAD, BURDEN (91637,

TYPE RH-25, 25 OHMS) C-E,H-K 3

6 401564-4 . HOUSING, SOCKET CONNECTOR(00779, NO. 1-480287-0) 1

7 401566-11 . TERMINAL, SOCKET (00779, NO. 60619-1) 108 387738A . BOARD ASSY, OVERLOAD, 12V 19 401556 . MOUNT, SHOCK, RUBBER (81860, NO. SS-01) 4

10 16DA-4253-1 . RETAINER, SPRING, RELAY (77342, NO. 20C260) 111 16DA-4004A-1 . RELAY, ENCLOSED, PLUG-IN MOTOR 112 79B-1138 . SOCKET, RELAY, 11 PIN

(77342, NO. 27E123) 113 402658 . FUSEHOLDER (71400, NO. HKP-HH) 1

14 W-11166-2 . FUSE, CARTRIDGE, 5 AMP (71400,TYPE AGC, 5 AMP) 1

15 77B-1120 . RELAY, TIME DELAY (04864,NO. 328A200Q10XX) 2

16 485431 . SUPPORT, TIME DELAY RELAY 2

17 401937-8 . TERMINAL BOARD (98410, NO. 35014-3526) 118 410539 . TERMINAL, FEMALE, 90 DEG.

(70611, NO. 300DS25) 1419 401937-4 . TERMINAL BOARD 98410, NO. 35018-3526) 220 485080 . PANEL, CURRENT TRANSFORMER 1

OM-465


Input Terminal Panel AssemblyFigure 8

OM-465




8 - 485145 PANEL ASSY, INPUT TERMINAL(FOR NHA SEE FIG. 6) REF

1 79B-1154-1 . TRANSFORMER, CURRENT (14280,NO. 74-501) 3ATTACHING PARTS

2 W-11287-4 . NUT, PLAIN, HEX NO. 10-24 63 W-11254-3 . WASHER, LOCK NO. 10 6

4 W-11245-3 . WASHER, FLAT, BRASS NO. 10 65 W-11112-12 . SCREW, MACHINE, RD, HD

NO. 10-24 x 2-1/4 IN. LONG 66 481515 . BUS BAR, INPUT TERMINAL 37 77A-1141 . LUG, CABLE (59730, NO. 62235) 4

ATTACHING PARTS8 W-11280-6 . NUT, PLAIN, HEX, 3/8-16 89 W-11254-6 . WASHER, LOCK, 3/8 IN. 8

10 W-11242-10 . WASHER, FLAT, 3/8 IN. 14-11 W-11097-7 . SCREW, CAP, HEX HD, 3/8-16 x

2 IN. LONG 612 W-11097-5 . SCREW, CAP, HEX HD, 3/8-16 x

1-1/2 IN. LONG 213 A-25 . INSULATOR, WASHER 614 AW-626 . INSULATOR, BUSHING 6

15 485114 . PANEL, INPUT TERMINAL 116 485112 . BRACKET, INPUT PANEL 1

* 17 77A-1106 . LABEL, “GRD” 1* 18 400092 . LABEL, “L1" 1* 19 400097 . LABEL, “L2" 1

* 20 400098 . LABEL, “L3" 1

* NOT ILLUSTRATED

OM-465


Control Cabinet AssemblyFigure 9

OM-465




9 - 485093-5 CABINET ASSY, CONTROL(FOR NHA SEE FIG. 2) AB,FG REF

485093-4 CABINET ASSY, CONTROL(FOR NHA SEE FIG. 2) C-E,H-K REF

1 80A-1101 . LATCH, ADJUSTABLE GRIP(24248, NO. 69-10-401-11) 2

2 485426 . COVER, TRAYS 13 485210 . DOOR (WINDOW), PLEXIGLAS 14 485976 . PANEL ASSY, FRONT (FOR DETAILS

SEE FIG. 10) 15 485128 . BRACKET, MOUNTING, FRONT PANEL 26 482496-1 . CLAMP, LOOP, STEEL 37 485124 . COVER, TERMINAL PANELS 28 384911 . SLIDE, CABINET, RIGHT

(NOT PROCURABLE SEPARATELY,SEE KIT NO. 402383) REF

9 384910 . SLIDE, CABINET, LEFT(NOT PROCURABLE SEPARATELY,SEE KIT NO. 402383) REF

10 485122 . BRACKET ASSY, MOUNTING,TRAYS, RIGHT 2

11 485123 . BRACKET ASSY, MOUNTING, TRAYS,LEFT 2

12 485100 . BRACKET, MOUNTING, VOLTAGE

REGULATOR TRAY 213 485094 . PANEL ASSY, MOTOR STATOR TERMINALS

(FOR DETAILS SEE FIG. 11) 114 485095 . PANEL ASSY, GENERATOR STATOR

TERMINALS (FOR DETAILS SEE FIG.12) 1

15 485120 . PANEL, MOUNTING, TRAYS 116 401937-4 . TERMINAL BOARD (98410, NO. 35018-3526) 117 485214-1 . PANEL ASSY, MOTOR CONTROL, PUSH-

BUTTON (FOR DETAILS SEE FIG. 13) 118 485214-2 . PANEL ASSY, GENERATOR CONTROL

PUSH-BUTTON (FOR DETAILS SEEFIG. 14) 1

- 19 485219 . COVER, PUSHBUTTON PANEL 1- 20 486006 . HARNESS, PLUG, CONTROL PANEL 1

21 79B-1160-2 .. CONNECTOR, PLUG, ELECTRICAL

(00779, NO. 206305-1) 122 79B-1161-1 .. CLAMP, CABLE (00779, NO. 206138-1) 123 41547 .. SLEEVING, PLASTIC, BLACK 5/8 IN. ID

(91094, ASTRA NO. 703/105) 18-IN.

OM-465




9 - (Continued)24 488397 . PANEL ASSY, TEST POINTS 125 402946 .. JACK, INSULATED TIP

(74970, NO. 105-802) 4926 488413 .. HARNESS, PLUG, TEST POINTS, TOP 127 79B-1160-2 ...CONNECTOR, PLUG, ELECTRICAL

(00779, NO. 206305-1) 128 79B-1161-1 ...CLAMP, CABLE (00779, NO. 206138-1) 129 76A-1132 ...TUBING, “Z-FLEX”, 0.75 IN. I.D.

(77060, NO. 68703R) 14-IN.30 485171 .. HARNESS, PLUG, TEST POINTS,

BOTTOM 131 79B-1160-2 ...CONNECTOR, PLUG, ELECTRICAL

(00779, NO. 206305-1) 132 79B-1161-1 ...CLAMP, CABLE(00779,NO. 206138-1) 133 76A-1132 ...TUBING, “Z-FLEX”, 0.75 IN. I.D.

(77060, NO. 68703R) 14-IN.34 485150-3 .. PANEL, TEST POINTS 135 483918 . COVER, HOLE 236 485225 . COVER, CONVENIENCE RECEPTACLE

MOUNTING OPENING 1

37 485432-1 . STRAP, GROUND 138 79B-1145 . HANDLE, DOOR, KEYLOCK

(24248, NO. 92-21-109-72) 139 485178 . DOOR ASSY, BOTTOM, CONTROL CAB. 140 56205 . STRIP, RUBBER, 1/4 x 3/4 IN.

(TOTAL OF 196 IN. REQUIRED) AR41 W-9760-191 . CABLE ASSY, MOTOR, #180 AB,FG 142 W-9760-191 . CABLE ASSY, MOTOR, #181 AB,FG 143 W-9760-191 . CABLE ASSY, MOTOR, #182 AB,FG 144 W-9760-191 . CABLE ASSY, MOTOR, #183 AB,FG 1

45 W-9760-191 . CABLE ASSY, MOTOR, #184 AB,FG 146 W-9760-191 . CABLE ASSY, MOTOR, #185 AB,FG 147 W-9760-191 . CABLE ASSY, MOTOR, #186 AB,FG 148 W-9760-191 . CABLE ASSY, MOTOR, #187 AB,FG 149 W-9760-191 . CABLE ASSY, MOTOR, #188 AB,FG 1

50 W-9760-317 . CABLE ASSY, GEN., #101 AB,FG 151 W-9760-317 . CABLE ASSY, GEN., #102 AB,FG 152 W-9760-317 . CABLE ASSY, GEN., #103 AB,FG 153 W-9760-318 . CABLE ASSY, NEUTRAL, #110 AB,FG 154 W-9760-192 . CABLE ASSY, NEUTRAL GROUND #111 1

55 W-9648-288 . CABLE ASSY, GROUND INPUT #190 1

OM-465




9 - (Continued)56 W-9648-316 . CABLE ASSY, MOTOR, #180 C-E,H-K 157 W-9648-316 . CABLE ASSY, MOTOR, #181 C-E,H-K 158 W-9648-316 . CABLE ASSY, MOTOR, #182 C-E,H-K 159 W-9648-316 . CABLE ASSY, MOTOR, #183 C-E,H-K 160 W-9648-316 . CABLE ASSY, MOTOR, #184 C-E,H-K 1

61 W-9648-316 . CABLE ASSY, MOTOR, #185 C-E,H-K 162 W-9648-316 . CABLE ASSY, MOTOR, #186 C-E,H-K 163 W-9648-316 . CABLE ASSY, MOTOR, #187 C-E,H-K 164 W-9648-316 . CABLE ASSY, MOTOR, #188 C-E,H-K 165 W-9648-317 . CABLE ASSY, GEN., #101 C-E,H-K 1

66 W-9648-317 . CABLE ASSY, GEN., #102 C-E,H-K 167 W-9648-317 . CABLE ASSY, GEN., #103 C-E,H-K 168 W-9648-318 .CABLE ASSY, NEUTRAL, #110 C-E,H-K 169 408333 . FAN, AXIAL, CABINET COOLING

(81041, NO. 3-9-8010) 1

70 485452 . DUCT, AIR 171 485461 . COVER, VENT 2

* 72 79A-1067 . LABEL, “DANGER-HIGH VOLTAGE” 2* 73 405793 . LABEL, “GROUND” 1* 74 40201 . STRIP, RUBBER 42 IN.

* 75 485585 . COVER, SECOND OUTPUT CABLEEXIT HOLE 1

* 76 5J-422-0 . CLAMP, CABLE 4* 77 100GH-121 . BRACKET, CLAMP MOUNTING 2* 78 100GH-118 . HORN, CABLE 2

* 79 485634 . STRAP, REGULATOR BRACKETSRETAINING 1

80 485193 . BOX, CONTROL CABINET 181 80A-1000 . LUG, CABLE (74829, NO. TA-2) 182 DWP-982 . HANGER, CABLE 2

83 485174 . HARNESS, PLUG, GENERATORMONITOR TRAY 1

84 79B-1160-1 . CONNECTOR, PLUG, ELECTRICAL(00779, NO. 206150-1) 1


* Not Illustrated

OM-465




9 - (Continued)86 79B-1161-1 . CLAMP, CABLE

(00779, NO. 206138-1) 287 79A-1164 . PLUG, KEYING

(00779, NO. 200821-1) 188 41547 . SLEEVING, PLASTIC, BLACK 5/8IN.

ID (91094, ASTRA NO. 703/105) 40-IN.89 488418 HARNESS PLUG, GENERATOR PROTECTION

TRAY 190 79B-1160-1 . CONNECTOR, PLUG, ELECTRICAL

(00779, NO. 206150-1) 1


92 79B-1161-1 . CLAMP, CABLE (00779, NO. 206138-1) 293 79A-1164 . PLUG, KEYING (00779, NO. 200821-1) 194 41547 . SLEEVING, PLASTIC, BLACK, 5/8IN.

ID (91094, ASTRA NO. 703/105) 28-IN.95 485173 HARNESS, PLUG, VOLTAGE REGULATOR 196 79B-1160-2 . CONNECTOR, PLUG, ELECTRICAL

(00779, NO. 206305-1) 197 79B-1161-1 .CLAMP, CABLE

(00779, NO. 206138-1) 198 402377 . CONNECTOR, PLUG, ELECTRICAL

(02660, NO. MS-3106A-22-14.5) 199 16DA-5082 .CLAMP, CABLE

(02660,NO. AN-3057-12) 1

100 41547 . SLEEVING, PLASTIC, BLACK, 5/8 IN. ID(91094, ASTRA NO. 703-105) 28-IN.

* 101 402383 KIT, TRAY SLIDES (SEE FIG. 3) REF

* Not Illustrated

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OM-465


Control Cabinet Front Panel AssemblyFigure 10

OM-465




10 - 485976 PANEL ASSY, FRONT CONTROL CABINET(FOR NHA SEE FIG. 9) 1

1 400344 . LIGHT, FLUORESCENT (DURAYFLUORESCENT MFG. CO. TSW-115) 1

2 No Number . . STARTER, LAMP (08108, NO. FS-2) 13 400345-0 . LAMP, FLUORESCENT(08108, NO. 15-TB) 14 403336 . RING, LOCKING, SWITCH (91929,

NO. TS-10020) 15 402662 . SWITCH, TOGGLE (73559, NO. 2GK71-73) 16 79C-1149-1 . METER, TIME, TOTALIZING (HOURMETER)

(74400, MODEL 15000, TYPE A) 17 401937-2 . TERMINAL BOARD (98410, NO. 35005-3526) 1

8 485975 . PANEL, FRONT, CONTROL CABINET 19 283167 . METER, FREQUENCY 1

OM-465


Motor Stator Terminal Panel AssemblyFigure 11

OM-465




11 - 485094 PANEL, ASSY, MOTOR STATOR TERMINALS(FOR NHA SEE FIG. 9) REF

1 482539 . BUS BAR 3(ATTACHING PARTS)

2 W-11280-6 . NUT, PLAIN, HEX 3/8-16 243 W-11254-6 . WASHER, LOCK 3/8 IN. 244 W-11242-10 . WASHER, FLAT, 3/8 IN. 48

5 W-11097-22 . SCREW, CAP, HEX HD 3/8-16 x2-1/2 IN. 12

6 482535 . PANEL, TERMINAL, STATOR 1

OM-465


Generator Stator Panel AssemblyFigure 12

OM-465




12 - 485095 PANEL ASSY, GENERATOR STATORTERMINALS (FOR NHA SEE FIG. 9) REF

1 482539 . LINK, CHANGEOVER 62 482538 . BUS BAR 1

ATTACHING PARTS3 W-11280-6 . NUT, PLAIN, HEX, 3/8-16 214 W-11254-6 . WASHER, LOCK, 3/8 IN. 24

5 W-11242-10 . WASHER, FLAT, 3/8 IN. 546 W-11097-22 . SCREW, CAP, HEX HD,

3/8-16 x 2-1/2 IN. 127 100NH-422 . CAPACITOR, 0.1 MFD 38 482535 . PANEL, GENERATOR STATOR 1

OM-465


Motor Control Pushbutton Panel AssemblyFigure 13

OM-465




13 - 485214-1 PANEL ASSY, MOTOR CONTROLPUSHBUTTON (For NHA See Fig. 9) REF

1 77A-1167 . CAP, PROTECTIVE, PUSHBUTTON(14280, Class 9001, Type KU7) 2

2 77A-1036-1 . SWITCH, PUSHBUTTON, OPERATOR, STARTBLACK (14280, No. KR-2B-H1) 1

3 77A-1036-2 . SWITCH, PUSHBUTTON, OPERATOR, STOP

BLACK (14280, No. KR-2R-H1) 14 82B-1066-8 . LIGHT, INDICATING, AMBER, MOTOR-

RUNNING, ASSY. (Body, with lens and cap) 15 400613-6 . . LAMP, INCANDESCENT

(08018, No. 120-MB) 1

6 485215-1 . PANEL, PUSHBUTTON, MOTOR CONTROL 1

OM-465


Generator Control Pushbutton Panel AssemblyFigure 14

OM-465




14 - 485214-2 PANEL ASSY, GENERATOR CONTROLPUSHBUTTON (For NHA See Fig. 9) REF


2 77A-1036-1 . SWITCH, PUSHBUTTON, OPERATOR, CLOSE,BLACK (14280, No. KR-2B-H1) 1

3 77A-1036-2 . SWITCH, PUSHBUTTON, OPERATOR, OPEN

BLACK (14280, No. KR-2R-H1) 14 82B-1066-7 . LIGHT, INDICATING,CONTACTOR CLOSED,

GREEN, ASSY. (Body, with lens and cap) 15 400613-6 . . LAMP, INCANDESCENT

(08018, No. 120-MB) 1

6 485215-2 . PANEL, PUSHBUTTON, MOTOR CONTROL 1

OM-465


Conduit and Connectors GroupFigure 15

OM-465




15 - No Number CONDUIT AND CONNECTORS GROUP(For NHA See Fig. 1) REF

1 78A-1075 . BUSHING, INSULATING, PLASTIC(28488, No. 1408) 4

2 79B-1147-1 . ELBOW, CONNECTOR, 90o, 2-IN I.D.(03743, No. ST-90200) 2

3 78B-1080-1 . CONNECTOR, STRAIGHT, 2-IN I.D.

(03743, No. ST-200) 24 78B-1081-1 . GASKET (03743, No. STG-200) 45 57512 . CONDUIT, FLEXIBLE, ALUMINUM

2-IN I.D., 21 INCHES REQUIRED AR6 484936 . PLATE, MOUNTING, CONDUIT 2

ATTACHING PARTS7 77A-1049-1 . SCREW, SELF-TAPPING, HEX-HD WITH

RUBBER WASHER SEALING FEATURE(19321, No. BT-473) 16

OM-465


Motor-Generator GroupFigure 16

OM-465




16 - No Number MOTOR-GENERATOR GROUP(FOR NHA SEE FIG. 1) REF

1 484914 . CAP, BEARING 22 484915 . SPACER, BEARING 23 484913-1 . HOUSING, FAN 14 484942 . FAN 1

ATTACHING PARTS

5 W-11095-1 . SCREW, CAP, HEX HD, 3/8 x5/8 IN. LONG 8

6 484912 . BRACKET, BEARING, GENERATOR END 17 W-10072-1 . BEARING, BALL, ANNULAR

(21335, NO. W31OPP) 2

8 484937-2 . ARMATURE ASSY,37.5KVA,60-HZ A,F,G 1484956-2 . ARMATURE ASSY,37.5 KVA,50 HZ B 1484937-1 . ARMATURE ASSY,60 KVA,60 HZ C,E,H,J 1484956-1 . ARMATURE ASSY,60 KVA,50 HZ D,K 1

9 W-10874-1 .. DIODE, POSITIVE, 35 AMP

(84970, NO. ST-46OP) 3W-10875-1 .. DIODE, POSITIVE, 35 AMP

(84970, NO. 460N) 310 484962 .. BUS, DIODE 2

ATTACHING PARTS

11 W-11236-3 .. SCREW, SELF-TAPPING, HEX, WASHERHEAD, 1/4-20 x 1-1/4 IN. 4

12 A-25 .. INSULATOR, WASHER 813 DW-1704 .. INSULATOR, BUSHING 414 403982 .. SWITCH, MICRO

(91929, NO. BZ-2RD) 215 50GHP-573 .. CLAMP, WIRE 216 HF-3305-2 .. INSULATOR, CLAMP 417 484940 .. HUB, FAN

ATTACHING PARTS

18 W-11282-1 .. NUT, ROUND (05469, NO. N12) 119 W-11264 .. WASHER, KEY (05469, NO. W12) 120 C-30 .. KEY, MACHINE, HUB

3/8 IN. SQ. x 3 IN. LONG 121 485088 .. EXCITER, ROTATING FIELD 1

22 C-30 .. KEY, MACHINE, EXCITER3/8 IN. SQ. x 3 IN. LONG 1

23 NO NUMBER .. ARMATURE, WINDINGS AND SHAFT 124 100NH-2 . POLE PIECE, EXCITER FIELDS 425 D-3169 . WINDINGS, EXCITER FIELD 1 SET

OM-465



OM-465




16 - No Number MOTOR-GENERATOR GROUP(FOR NHA SEE FIG. 1) REF

26 100NH-3 . INSULATION, EXCITER FIELDS 427 385950 . INSULATION, TOE, EXCITER 828 387168 . PLATE, GENERATOR MOUNTING 429 386635A . PAD, VIBRATION INSULATING, TOP 4

- 30 483797 . PLATE, SPACER 4

31 482846 . PAD, VIBRATION INSULATING, BOTTOM 432 A-98 . LABEL, ROTATION 133 484943-2 . HOUSING AND STATOR ASSY A,G 1

484943-3 . HOUSING AND STATOR ASSY B,D 1484943-1 . HOUSING AND STATOR ASSY C,H 1

484943-6 . HOUSING AND STATOR ASSY E 1484943-5 . HOUSING AND STATOR ASSY F 1**484943-8 . HOUSING AND STATOR ASSY J 1484943-9 . HOUSING AND STATOR ASSY K 1

** USED WITH 6184A-4 ONLY.

OM-465


Frame and Covers GroupFigure 17

OM-465




17 - No Number FRAME AND COVERS GROUP (ForNHA See Fig. 1) REF

1 485144 . COVER, AIR INTAKE 12 482599 . STRAP, GROUND, GENERATOR-TO-FRAME 13 485002 . SUPPORT, AIR INTAKE COVER 14 484886 . SHIELD, AIR 15 485004 . DUCT, AIR OUTLET 1

6 485048 . GUARD, AIR EXHAUST 17 485397 . SUPPORT, GUARD 28 485000 . COVER, FAN HOUSING END 19 485433 . BAFFLE, FAN 4

10 485387 . PANEL, AIR OUTLET DUCT 1

11 484977 . FRAME, MOUNTING 112 DWP-982 . HANGER, CABLE 2

OM-465


Second Output Kit (Option)Figure 18

OM-465




18 - 485211 KIT, SECOND OUTPUT (OPTIONAL)(SEE FIG. 1) REF

0 485212 . PANEL ASSY, CONTACTOR 1ATTACHING PARTS

1 402119-2 . SCREW, CAP, HEX HD,1/4-20 BY 1/2 IN. LONG 4

2 W-11254-4 . WASHER, LOCK, 1/4 IN. 4

3 404518 .. CONTACTOR, GENERATOR LOAD(74063, NO. HB-200BB) 1

4 402119-9 .. SCREW, CAP, HEX HD1/4-20 x 1-3/4 IN. LONG 1

5 A-25 .. INSULATOR, WASHER 4

6 DW-1704 .. INSULATOR, BUSHING 17 W-11097-7 .. SCREW, CAP, HEX HD

3/8-16 x 2 IN. LONG 18 5CW-2127 .. INSULATOR, BUSHING 19 75GH-50 .. PLATE, IDENTIFICATION “F” 1

10 75GH-49 .. PLATE, IDENTIFICATION “E” 111 75GH-51 .. PLATE, IDENTIFICATION “N” 112 16DA-4253-1 .. RETAINER, SPRING, RELAY

(77342, NO. 20G206) 213 16DA-4004A-1 .. RELAY, ENCLOSED, PLUG-IN GEN.

CONTROL (77342, NO. KA-4244-1) 114 16DA-4004A-3 .. RELAY, ENCLOSED, PLUG-IN PLUG

INTERLOCK (77342, NO. KAP-14DG) 115 79B-1138 .. SOCKET, RELAY (77342, NO. 27E123) 216 403336 .. RING, LOCKING, SWITCH

(91929, NO. TS 10020) 117 402662 .. SWITCH, TOGGLE (73559, NO. 2GK71-73) 118 100GH-142 .. BRACKET, SWITCH MOUNTING 119 401937-5 .. TERMINAL BOARD (98410 ,NO. 35006-3526) 120 485213 .. PANEL, CONTACTOR 1

* 21 485214-3 . PANEL ASSY, PUSHBUTTON, SECONDOUTPUT (FOR DETAILS SEE FIG. 19) 1

22 W-9648-287 . CABLE ASSY, FOR NO. 104, NO. 105AND NO. 106 GENERATOR CABLES ANDFOR NO. 114 NEUTRAL CABLE 4

* 23 7J-422-0 . CLAMP, CABLE 2* 24 100GH-121 . BRACKET, CLAMP MOUNTING 1* 25 100GH-118 . HORN, CABLE 1

OM-465


Generator Control Pushbutton Panel Assembly (Option)Figure 19

OM-465




19 - 485214-3 PANEL ASSY, GENERATOR CONTROLPUSHBUTTON (OPTION)(For NHA See Fig. 18) REF


2 77A-1036-1 . SWITCH, PUSHBUTTON, OPERATOR,CONTACTOR CLOSE, BLACK(14280, No. KR-2B-H1) 1

3 77A-1036-2 . SWITCH, PUSHBUTTON, OPERATOR, STOPBLACK (14280, No. KR-2R-H1) 1

4 82B-1066-7 . LIGHT, INDICATING,CONTACTOR CLOSED,GREEN, ASSY. (Body, with lens and cap) 1

5 400613-6 . . LAMP, INCANDESCENT

(08018, No. 120-MB) 16 485215-3 . PANEL, PUSHBUTTON, MOTOR CONTROL 1

OM-465


Convenience Receptacle Kit (Option)Figure 20

OM-465




20 - 485240 KIT, CONVENIENCE RECEPTACLE60-Hz (See Fig. 1) A,C,E-J REF

1 402751-6 . CIRCUIT BREAKER, 10-A(14280, No. QOU-110-S-5202) A,C,E-J 1

2 80B-1085 . TRANSFORMER, (30882,No. CX1K13MRBDW013-H) A,C,E-J 1

3 7J-597-6 . PLATE. IDENTIFICATION A,C,E-J 1

4 404277 . COVER, RECEPTACLE(81703, No. 30430) A,C,E-J 1

5 402670 . RECEPTACLE, DUPLEX, 15-A,125-V (04009, No. 10103) A,C,E-J 1

6 401937-1 . TERMINAL BLOCK

(98410, No. 35005-3526) A,C,E-J 17 485239 . PANEL, CONVENIENCE RECEPTACLE A,C,E-J 1

OM-465


Transformer-Rectifier Mounting Kit (Option)Figure 21

OM-465




21 - 485255 KIT, T-R MOUNTING PACKAGE(SEE FIG. 1) REF

1 430278 . GROMMET (77379, NO. 9233) 12 79B-1147-1 . ELBOW, CONNECTOR, 90 DEG. 2 IN.

(03743, NO. ST-90200) 13 78A-1075-1 . BUSHING, PLASTIC, CONDUIT

(28488, NO. 1408) 1

4 78B-1080-1 . CONNECTOR STRAIGHT, 2 IN.(03743, NO. ST-200) 1

5 78B-1081-1 . GASKET, CONNECTOR(03743, NO. STG-200) 1

6 57512 . CONDUIT, FLEXIBLE, ALUMINUM

2 IN. I.D. 29 IN.7 485290 . HARNESS, T-R 18 401564-2 .. HOUSING, SOCKET, CONNECTOR

(00779, NO. 1-480283-0) 19 42517 .. SLEEVING, FIBERGLAS, SIZE 0 40 IN.

10 DWP-982 . HANGER, CABLE 111 W-9648-319 . CABLE ASSY, GENERATOR TO T-R #141 1

W-9648-318 . CABLE ASSY, GENERATOR TO T-R #142 1W-9648-320 . CABLE ASSY, GENERATOR TO T-R #143 1

12 485277 . SUPPORT, T-R MOUNTING 1

OM-465


Phase Reversal Relay Kit (Optional)Figure 22

OM-465




22 - 495398-1 KIT, PHASE REVERSAL RELAY FOR460-V (See Fig. 1) A,C,E,J REF

495398-2 KIT, PHASE REVERSAL RELAY FOR575-V A,C,E,J REF

495398-3 KIT, PHASE REVERSAL RELAY FOR230-V A,C,E,J REF

495398-4 KIT, PHASE REVERSAL RELAY FOR380-V B,D,K REF

1 83B-1030- . RELAY, PHASE FAILURE FOR 460-V,60-Hz A,C,E,J 1

2 83B-1030- . RELAY, PHASE FAILURE FOR 575-V,60-Hz A,C,E,J 1

3 83B-1030- . RELAY, PHASE FAILURE FOR 230-V,

60-Hz A,C,E,J 14 83B-1030- . RELAY, PHASE FAILURE FOR 380-V,

50-Hz B,D,K 15 485399 . PANEL, PHASE REVERSAL RELAY 1

OM-465


Convenience Receptacle Kit (Option) 50-HzFigure 23

OM-465




23 - 485652 KIT, CONVENIENCE RECEPTACLE50-Hz (See Fig. 1) B,D,K REF

1 404899-5 . CIRCUIT BREAKER, 5-A(74193, No. AM1-A3-A-5-2) B,D,K 1

2 485663 . BRACKET, MOUNTING B,D,K3 80B-1131 . TRANSFORMER, (30882,

No. CFX1K15NR18-H) B,D,K 1

4 388328-80 . PLATE. IDENTIFICATION B,D,K 15 404335 . COVER, RECEPTACLE

(81703, No. 30437) B,D,K 16 404336 . RECEPTACLE, (71183, No. 4760) B,D,K 17 401937-1 . TERMINAL BLOCK

(98410, No. 35005-3526) B,D,K 18 485653 . PANEL, CONVENIENCE RECEPTACLE B,D,K 1

OM-465



OM-465


SECTION 4. NUMERICAL INDEX

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

A-25 6-26, 8-13, 16-12, 18-5,

A-98 16-32

ARMATURE, WINDINGS AND SHAFT 16-23

AW-626 8-14

C-30 16-20, 16-22

CONDUIT AND CONNECTORS GROUP 1-2, 15-0

CONTROL CABINET GROUP 1-1, 2-0

D-3169 16-25

DW-1704 6-27, 16-13, 18-6

DWP-982 9-82, 17-12, 21-10

FRAME AND COVERS GROUP 1-3, 17-0

HF-2518-2 4-16

HF-3305-2 16-16

MOTOR-GENERATOR GROUP 1-3, 16-0

W-10072-1 16-7

W-10874-1 16-9

W-10875-1 16-9

W-11095-1 16-5

W-11097-5 8-12

W-11097-7 8-11, 18-7

W-11097-22 11-5, 12-6

W-11112-12 8-5

W-11166-1 4-20

W-11166-2 7-14

W-11236-3 16-11

W-11242-10 8-10, 11-4, 12-5

W-11245-3 8-4

W-11254-3 8-3

FIGURE ANDPART NUMBER ITEM NUMBER

OM-465


W-11254-4 18-2

W-11254-6 8-9, 11-3, 12-4

W-11264 16-19

W-11280-6 8-8, 11-2, 12-3

W-11282-1 16-18

W-11287-4 8-2

W-2974-L 3-8

W-9648-287 6-36, 18-22

W-9648-288 6-37, 9-55

W-9648-316 9-56, 9-57, 9-58, 9-59,

9-60, 9-61, 9-62, 9-63, 9-64

W-9648-317 9-65, 9-66, 9-67

W-9648-318 9-68

W-9648-319 21-11

W-9746-1 7-4

W-9760-174 6-36

W-9760-175 6-37

W-9760-191 9-41, 9-42, 9-43, 9-44

W-9760-191 9-45, 9-46, 9-47, 9-48, 9-49

W-9760-192 9-54

W-9760-317 9-50, 9-51, 9-52

W-9760-318 9-53

W-9916-10 10-9

1CZ-148 7-1

10J-178 3-14

100NH-2 16-24

100NH-3 16-26

100GH-121 9-77, 18-24

100GH-118 9-78, 18-25

100GH-142 6-16, 18-18

100NH-422 12-7

16DA-2162 3-13

16DA-4004A-1 3-11, 6-18, 7-11, 18-13

16DA-4004A-3 6-19, 18-14

16DA-4004A-10 4-6

16DA-4252-1 6-17

16DA-4253-1 3-10, 4-5, 7-10, 18-12

16DA-5082 9-99

284913 3-24


OM-465


370382A 3-22, 4-23

384910 3-26, 4-26, 5-3, 9-9

384911 3-26, 4-26, 5-3, 9-8

384912 3-26, 4-26, 5-3

384913 4-26, 3-26, 5-3

385950 16-27

386635A 16-29

387168 16-28

387736B 4-9

387738A 7-8

388328-801 23-4

400078 3-9

400092 8-18

400097 8-19

400098 8-20

400344 10-1

400345-0 10-3

400613-4 4-18

400828-1 3-20

400828-1 4-21

401556 4-13

401556 7-9

401564-2 21-8

401564-4 4-10, 7-6

401564-5 4-8

401566-11 7-7

401937-1 20-6, 23-7

401937-2 10-7

401937-3 4-4, 6-4

401937-4 6-45, 7-19, 9-16

401937-5 18-19

401937-8 7-17

40201 9-74

402037-8 7-3

402119-2 18-1

402119-9 6-25, 18-4

402157 3-15

402377 9-98

402383 3-26, 4-26, 5-3,9-101


OM-465


402658 4-19, 7-13

402662 6-15, 10-5, 18-17

402665-1 3-3

402670 20-5

402751-6 20-1

402826 3-4

402946 9-25

403091-6 4-27

403336 4-14, 6-14, 10-4, 18-16

403982 16-14

403765-4 3-7

404065-2 3-6, 6-3

404172-1 4-17

404215-1 9-69

404277 20-4

404335 23-5

404336 23-6

404402-2 7-5

404402-3 7-5

404518 6-1, 18-3

404899-5 23-1

405132 5-3

405793 9-73

410539 7-18

41547 9-23, 9-88, 9-94, 9-100

42517 21-9

430278 21-1

430391C 5-1

481515 8-6

482038 4-11

482039 4-12

482085A 1-7

482496-1 9-6

482535 11-6, 12-8

482538 12-2

482539 11-1, 12-1

482599 17-2

482846 16-31

483028-2 13-3


OM-465


483028-3 14-3, 19-3

483436 6-22

483797 16-30

483918 9-35

484311 1-13

484661 7-2

484886 17-4

484912 5-2, 16-6

484913 5-2

484913-1 16-3

484914 16-1

484915 16-2

484936 15-6

484937-1 16-8

484937-2 16-8

484940 16-17

484942 16-4

484943-1 16-33

484943-2 16-33

484943-3 16-33

484943-5 16-33

484943-6 16-33

484943-8 16-33

484943-9 16-33

484956-1 16-8

484956-2 16-8

484962 16-10

484977 17-11

485000 17-8

485002 17-3

485004 17-5

485032-1 3-0, 2-1

485032-2 2-1, 3-0

485033 3-20

485034 3-25

485048 17-6

485079-1 6-13

485079-2 6-13

485079-1 7-0


OM-465


485079-2 7-0

485080 7-20

485081-3 2-4, 6-0

485081-4 2-4, 6-0

485088 16-21

485093 2-5

485093-4 9-0

485093-5 9-0

485094 9-13, 11-0

485095 9-14, 12-0

485100 9-12

485112 8-16

485114 8-15

485116 6-11

485117 6-2

485120 9-15

485122 9-10

485123 9-11

485124 9-7

485128 9-5

485130 2-3, 5-0

485131 5-1

485144 17-1

485145 6-32, 6-38, 8-0

485148 4-3

485150-3 9-34

485153 3-5

485154 3-16

485163 3-1

485165 6-38

485167 6-42

485168 6-4

485170 6-8

485171 9-30

485173 9-95

485174 9-83

485177 6-46

485178 9-39


OM-465


485193 9-80

485210 9-3

485211 1-5, 18-0

485212 18-0

485213 18-20

485214-1 9-17, 13-0

485214-2 9-18, 14-0

485214-3 18-21, 19-0

485215-1 13-8, 14-8

485215-3 19-8

485219 9-19

485225 9-36

485237 1-14, 6-47

485237-3 6-48

485237-4 6-50

485237-6 6-52

485237-9 6-58

485237-10 6-60

485237-11 6-62

485237-12 6-64

485237-13 6-66

485237-14 6-68

485239 20-7

485240 1-6, 20-0

485255 1-8, 21-0

485264 6-34

485277 21-12

485290 21-7

485327-7 6-54

485327-8 6-56

485387 17-10

485397 17-7

485398-1 1-9, 22-0

485398-2 1-10, 22-0

485398-3 1-11, 22-0

485398-4 1-12, 22-0

485399 22-5

485426 9-2

485431 7-16


OM-465


485432-1 9-37

485433 17-9

485452 9-70

485461 9-71

485585 9-75

485634 9-79

485652 1-15, 23-0

485653 23-8

485663 23-2

485975 10-8

485976 9-4, 10-0

486006 9-20

488397 9-24

488410 2-2, 4-0

488411 4-21

488412 4-26

488413 9-26

488415 4-1

488418 9-89

488420 6-40

488422 6-6

5CW-2127 18-8

5J-422-0 9-76

50GHP-573 16-15

56203 3-23, 4-24

56205 9-40

57512 15-5, 21-6

6182A-1 1-0

6182A-2 1-0

6182A-3 1-0

6183A-1 1-0

6184A-1 1-0

6184A-2 1-0

6184A-3 1-0

6184A-4 1-0

6185A-1 1-0

6185A-2 1-0

7J-422-0 18-23

7J-597-6 20-3


OM-465


75GH-49 6-24, 18-10

75GH-50 6-23, 18-9

75GH-51 6-28, 18-11

76A-1115 3-21, 4-22

76A-1118 4-15

76A-1132 9-29, 9-33

77A-1026-2 13-5

77A-1026-3 14-5, 19-5

77A-1027 13-4, 14-4, 19-4

77A-1028-2 13-7, 14-7

77A-1028-2 19-7

77A-1036-1 13-2, 14-2, 19-2

77A-1036-2 13-3, 14-3, 19-3

77A-1049-1 15-7

77A-1106 8-17

77A-1141 8-7

77A-1167 13-1, 14-1, 19-1

77B-1120 7-15

78A-1075 15-1

78A-1075-1 21-3

78B-1080-1 21-4, 15-3

78B-1081-1 15-4, 21-5

79A-1067 9-72

79A-1156-3 6-49

79A-1156-4 6-51

79A-1156-6 6-53

79A-1156-7 6-55

79A-1156-9 6-57

79A-1156-10 6-59

79A-1156-11 6-61

79A-1156-12 6-63

79A-1156-13 6-65

79A-1156-14 6-67

79A-1156-16 6-69

79A-1164 6-6, 6-8, 6-10, 6-40

6-42, 9-87, 9-93

79B-1138 3-12, 4-7, 6-21,

7-12, 18-15

79B-1145 9-38


OM-465


79B-1147-1 15-2, 21-2

79B-1150 6-12

79B-1153 6-33

79B-1154-1 8-1

79B-1155 6-35

79B-1159-1 3-2

79B-1159-1 4-2

79B-1159-2 6-5

79B-1159-2 6-7

79B-1159-2 6-9

79B-1159-2 6-39

79B-1159-2 6-41

79B-1159-2 6-43

79B-1160-1 9-84

79B-1160-1 9-90

79B-1160-2 9-21, 9-27, 9-31, 9-85,

9-91, 9-96

79B-1161-1 9-22, 9-28, 9-32, 9-86,

9-92, 9-97,

79B-1164 6-44

79C-1134-4 3-19

79C-1135-1 3-17

79C-1135-2 3-17

79C-1149-1 10-6

79C-1158 3-18

80A-1000 9-81

80A-1101 9-1

80B-1131 23-3

80B-1085 20-2

83B-1030 22-1, 22-2, 22-3, 22-4


OM-465



This chapter provides documentation covering any optional equipment furnished with your generator.Available options are listed below.

OPTION NAME MANUAL HOBART NO.Second Output Kit In this manual 485211

Generator Control Pushbutton Panel Assembly(Second Output) In this manual 485214-3

Convenience Receptacle Kit, 60-Hz In this manual 485240

Convenience Receptacle Kit, 50-Hz In this manual 485652

Transformer-Rectifier Mounting Kit In this manual 485255

Phase Reversal Relay, for 460-V, 60-Hz Unit in this manual 495398-1




OM-465



OM-465


Unusual Service Conditions

This information is a general guideline and cannot cover all possible conditions of equipment use. Thespecific local environments may be dependent upon conditions beyond the manufacturer’s control. Themanufacturer should be consulted if any unusual conditions of use exist which may affect the physicalcondition or operation of the equipment.

Among such conditions are :

a. Exposure to:

(1) Combustible, explosive, abrasive or conducting dusts.

(2) Environments where the accumulation of lint or excessive dirt will interfere with normalventilation.

(3) Chemical fumes, flammable or explosive gases.

(4) Nuclear radiation.

(5) Steam, salt-laden air, or oil vapor.

(6) Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive tofungus growth.

(7) Abnormal shock, vibration or mechanical loading from external sources during equipmentoperation.

(8) Abnormal axial or side thrust imposed on rotating equipment shafts.

(9) Low and/or high ambient temperatures.

b. Operation at:

(1) Voltages above or below rated voltage.

(2) Speeds other than rated speed.

(3) Frequency other than rated frequency.

(4) Standstill with rotating equipment windings energized.

(5) Unbalanced voltages.

(6) Operation at loads greater than rated.

c. Operation where low acoustical noise levels are required.

d. Operation with:

(1) Parts or elements unauthorized by the manufacturer.

(2) Unauthorized modifications.

e. Operation in poorly ventilated areas.

OM-465

June 30/94 Revised Unusual Service ConditionsPage 1


OM-465

Unusual Service Conditions June 30/94 RevisedPage 2

Documents

OPERATION AND MAINTENANCE MANUAL - · PDF fileom-465 revised 063094 operation and maintenance manual with illustrated parts list for 37.5 kva and 60 kva synchronous motor driven generator