Om 436

OM-436
062984
Revised083189
Revised051890
INSTRUCTION MANUAL
with
ILLUSTRATED PARTS LIST
for
ENGINE DRIVEN GENERATOR SETS
Series 6760 Series 67606 *
Series 6760A Series 7001 A
90=kVA, 400=Hz, 115/200-V AC, 3-Phase

with
DEUTZ DIESEL ENGINE
Type BF6L913
HOBART BROTHERS GROUP
Airport Systems Division
Troy, Ohio 45373 U.S.A.
This page intentionally left blank.
SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT
WARNING
ELECTRIC SHOCK can KILL. Do not touch live electrical parts.
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible
material. DO NOT use power cables to break load and prevent tools from causing short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached
equipment.
IlTlpOttRflt: - Protect all operating personnel. Read, understand, and follow all instructions
in the Operating/Instruction Manual before installing, operating, or servicing the equipment.
Keep the manual available for future use by all operators.
A. GENERAL
Equipment that supplies electrical power can cause serious injury or death, or damage to other e uaig-
ment or property. The operator must strictly observe all safety rules and take precautionary actions. ?i
practices have been developed from past experience in the use of power source equipment. While certain
practices below apply only to electrically-powered equipment, other practices apply to engine-driven
equipment, and some practices to both.
R. SHOCK PRWFNTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatal-
ly shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn
what terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,
procedures, and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubber
mat or dry wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry,
and never work alone
1. Instz&jjon and Grounding of Flectrically Powered Equipment
Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed and
maintained in accordance with the National Electrical Code, ANSVNFPA 70, or other applicable codes. A
power disconnect switch or circuit breaker must be located at the equipment. Check the nameplate for
voltage, frequency, and phase requirements. If only 3-phase power is available, connect any single-phase
rated equipment to only two wires of the 3-phase line. DO NOT CONNECT the equipment grounding con-
ductor (lead) to the third live wire of the 3-phase line, as this makes the equipment frame electrically HOT,
which can cause a fatal shock.
Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or
building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)
capacity of the grounding lead will be adequate for the worst fault current situation. Refer to the National
Electrical Code ANSVNFPA 70 for details. Do not remove plug ground prongs. Use correctly mating
receptacles.
3 Output Cables and Terminals
Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked
or worn cables immediately. Do not overload cables. Do not touch output terminal while equipment is
energized.
3. Service and Maintenance
This equipment must be maintained in good electrical and mechanical condition to avoid hazards
stemming from disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue
use of the equipment until its safety has been assured. Repairs should be made by qualified personnel
only.
Before inspecting or servicing electrically-powered equipment, take the following precautions
b. Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally.
c. Disconnect power to equipment if it is out of service.
d. If troubleshooting must be done with the unit energized, have another person present who is
trained in turning off the equipment and providing or calling for first aid.
C . FIRE AND EXPLOSION PREVENTION

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust
piping, misuse of batteries and fuel, or unsafe operating or fueling conditions.
1. Electrical Short Circuits and Overloads
Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by
causing nearby combustibles to ignite. For electrically-powered equipment, provide primary input protec-
tion to remove short circuited or heavily overloaded equipment from the line.
2. Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured bat-
tery can cause fires and additional failures. When servicing,do not smoke, cause sparking, or use open
flame near the batten/.
3. Enaine Fuel -
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank ._is
not grounded prior to or during fuel transfer. Shut unit DOWN before removing fuel tank-. can. --I--
DC
-3
NOT completely fill tank, because heat from the equipment mav ...--J canse
----- flu4
.--. exnanninn
-~pI. .-.-. . c
Jverflow. Remove
all spilled fuel IMMEDIATELY, including any that penetrate:: the unit. After clean-uo, .I ooen
. eauioment
I I
doors and blow fumes away with compressed air.
Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the ex-
haust fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air
conditioners.
F. BODlt Y INJURY PREVENTION

Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipment
for inspection and routine maintenance. When equipment is in operation, use extreme care in doing I
necessary trouble-shooting and adjustment. Do not remove guards while equipment is operating.
First aid facilities and a qualified first aid person should be available for each shift for immediate treat-
ment of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital
immediately if any abnormal signs are observed.
EMERGENCY FIRST AID

Call physician immediately. Seek additional assistance. Use First Aid techniques recom-
mended by American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELECTRI-
CAL SHOCK, turn off power. Remove victim.; If not breathing, begin artificial respiration, preferably
mouth-to-mouth. If no detectable pulse, begrn external heart massage. CALL EMERGENCY RESCUE
SQUAD IMMEDIATELY.
G. EQUIPMENT PRECAUTIONARY LABELS

Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be
easily read.
CM-436
Table of Contents
SUBJECT CHAPTER/SECTION
WARNING
LIST OF EFFECTIVE PAGES
ADDENDUMS
INTRODUCTION
CHAPTER 1. DESCRIPTION/OPERATION
SECTION 1. DESCRIPTION . . . . . . . . .1-l . . . . . . : . . 1

1. General ................... .1-l .......... .I
2. Special Features .............. .1-l .......... .4
A. Trailer Mounted ................ .1-l ............ .4
B. Protective Monitor ............... .1-l ............ .4
C. Pull-out Trays .................. l-l ............ .4
D. Voltage Regulator ................ l-l ............ .4
E. Test Circuitry .................. .1-l ............ .4
F. Electric Governor ................. l-l ............ .4
G. Transformer-Rectifiers (Optional) ....... .1-l ............ .4
3. Optional Equipment ............. I-l .......... .4
A.QuickStartKit ................. .1-l ............ .4
4. Canopy ................... .1-l .......... .6
5. Engine, Generator and Controls
Assembly ................... J-1 .......... .6
A. Basic Engine .................. .1-l ............ .6
B. Engine Manufacturers Equipment ....... l-l ............ .6
C. Hobart Engine Equipment ........... .1-l ............ .6
(1) Electric governor system l-l 6
(a) Magnetic pickup l-l 6
(b) Control unit 1-I 8
(c) Actuator 1-l 8
(2) Air Cleaner l-l 8
(3) Exhaust System l-l 9
D. Generator ................... .1-l ............ 10
E. Control Box Assembly .............. l-l ............ 10
(1) Generator control tray (see Figure 8) 1-l 10
(a) Resistors l-l 10
(b) Generator output monitors (meters) 1-l 10
(c) Meter and line switches l-1 11
(d) Receptacle connector l-l 11
(4 Tray l-l 11
(f) Manual voltage control l-l 13
(g) Excitation-deenergization relay l-l 13
May 18/90 Revised Table of Contents

Page 1
OM-436
SUBJECT CHAPTER/SECTION PAGE
(2) Protective relay tray (Figure 9) l-l 13

(a) Sensing modules l-l 13
(b) Memory and time delay module l-l 13
(c) Indicating lights l-l 14
(d) Plug interlock relay l-1 14
(e) Test bank switch l-l 14
(f) Resistor l-l 14
(g) Fuse-interlock relay l-l 14
(h) Connector l-l 14
(j) Auxiliary underfrequency relay l-l 14
F. Engine Control Panel (Fig. 10) . . . . . . . . . 1-l . . . . . . . . . . . . 16
(1) Engine Instruments l-l 16
(a) Ammeter l-l 16
(b) Oil Temperature Gage l-l 16
(c) Oil Pressure gage and oil
pressure switch l-1 16
(d) Hourmeter l-l 16
(2) Engine and generator controls l-l 16
(a) Fuse l-l 16
(b) Engine-generator control switch l-l 16
(c) Contactor control switch l-l 17
(d) Indicating lights l-l 17
(e) Fuel gage and blocking diodes l-l 17
(f) Cold weather starting aid
control (Optional) l-l 17
(g) Engine stop control l-l 17
(h) Air cleaner indicator l-l 17
(j) Test receptacle connector l-l 17
G. Voltage Regulator . . . . . . . . . . . . . . . l-1 . . . . . . . . . . . . i9
(1) Controls l-l 19
(2) Protection l-l 20
(3) Components (See Fig. 12) l-l 20
H. Power Module Panel Assembly . . . . . . . . l-l . . . . . . . . . . . . 20
(1) Load contactor l-l 20
(2) Current transformers l-l 20
(a) Ammeter current transformers l-l 20
(b) Line-drop current transformers l-l 20
(c) Overload current transformers l-l 22
(3) Overload module l-l 22
(4) Rectifier l-l 22
6. Test Box . . . . . . . . . . . . . . . . . . . I-1 . . . . . . . . . . 22
A. Description (See Fig. 14) . . . . . . . . . . . . l-l . . . . . . . . . . . . 22
B. Theory of Operation 0 . . . . . . . . . . . . . l-l . . . . . . . . . . . . 24
7. Dual Output Machine . . . . . . . . . . . . 1-I . . . . . . . . . . 25
Table of Contents May 18/90 Revised

Page 2
OM-436
SECTION 2. PREPARATION FOR USE,

STORAGE, OR SHIPPING 1-2 1
1. Preparation for Use l-2 1
A. General l-2 1
B. Inspection/Check l-2 1
C. Installing Output Cables l-2 1
(1) Three-phase, AC output cable
assembly installation. l-2
(2) Transformer-rectifier (T-R) cable
assembly installation
2. Preparation for Storage ;:2
A. General l-2
B. Temporary Storage l-2
C. Long Time Storage (Over 30 days)
3. Preparation for Shipment ;:2
SECTION 3. OPERATION I-3

1. General l-3
2. Operating the Generator Set l-3
A. Pre-start Inspection l-3
B. Normal Engine Starting Procedures l-3
C. Cold Weather Engine Starting Procedures l-3
D. Preparation for Power Delivery
(Normal Automatic Voltage Control) 1-3
E. Power Delivery (Automatic Voltage Control) l-3
F. Preparation for Power Delivery (Manual
Voltage Control) l-3
G. Power Delivery (Manual Voltage Control) 1-3
H. Discontinue Power Delivery l-3
J. Stopping the Engine
3. Transformer-Rectifier Operation ::3
A. Direct Current Power Delivery l-3
B. Simultaneous Operation of 28.5-V T-Rs l-3
C. Simultaneous 28.5-V DC and
115-V AC Power Delivery l-3
D. Simultaneous 112-V DC and 115-V AC
Power Delivery l-3 7
4. Test Box Operation l-3 8
5. No. 2 Output Operation
(Specification 6687-5) l-3 9
A. Power Delivery l-3 9
B. Discontinue Power Delivery l-3 9
Aug 31189 Table of Contents

Page 3
CM-436
CHAPTER 2. SERVICING
SECTION 1. MAINTENANCE 2-1 1
1. General 2-1 1
2. Inspection 2-1 1
3. Lubrication 2-1 1
A. General 2-l 1
B. AC Generator 2-l 1
C. Generator Controls 2-l 1
D. Trailer 2-l 1
E. Engine 2-l 2
(1) Lubrication schedule 2-l 2
(2) Oil specification 2-l 3
(3) Oil viscosity 2-1 3
(4) Change engine oil 2-l 5
(5) Change oil filter element 2-l 6
F. Engine Accessories 2-l 7
(1) Starter 2-l 7
4. Air Cleaner Service 2-1 7
A. Cartridge Removal 2-l 7
B. Cartridge Installation 2-l 7
5. Engine Fuel 2-1 7
A. Quality
6. Generator Maintenance ;:I B
A. Cleaning 2-l 8
B. Adjustment 2-l $8
7. Drive Belts 2-1 9
A. Fan Belts 2-l 9
B. Check Belt Tension 2-l 9
C. Adjusting Alternator Belt Tension 2-l 9
D. Belt Replacement 9
8. Service Helps ;:I 10
A. Wiring 2-l 10
B. Control Box Trays 2-l 10
(1) Tray removal 2-l 10
(2) Tray installation 2-l 10
C. Generator Exciter 2-1 11
(1) Preparation for exciter removal. 2-l 11
(2) Exciter removal: 2-l 11
(3) Exciter installation: 2-l 11
D. Engine Control Panel 2-l 11
(1) Tilt out engine control panel 2-l 11
(2) Reinstall engine control panel
9. Transformer-Rectifier Maintenance ;:I
Table of Contents Aug 31189

Page 4
SECTION 2. INSPECTION / CHECK 2-2 1

1. General 2-2 1
2. Engine 2-2 1
A. Fuel (See Fig. 1 for time schedules) 2-2 1
B. Lubrication 2-2 1
C. V-Belts 2-2 1
D. Exhaust System
3. Electrical System (12-V DC) ;:2 ;
A. Lights 2-2 1
B. Fuses 2-2 1
C. Wiring and Connections 2-2
4. Electrical System (115-V AC) 2-2 i
A. Monitoring Instruments 2-2 3
B. Indicating Lights 2-2 3
C. Protective Modules 2-2 3
D. Wiring Connections 2-2 3
5. Inspection of Transformer-Rectifiers 2-2 4
SECTION 3. ADJUSTMENT/TEST 2-3 1

1. General 2-3 1
2. Generator Set Test 2-3 1
A. Pre-operation Test Procedures 2-3 1
(a) Flashing exciter field using test box. 2-3 1
(b) Flashing exciter field without test box. 2-3 4
B. Operational Test Procedures 2-3
3. Generator Set Adjustment 2-3 ii
A. Generator Adjustment 2-3 9
B. Generator Control Adjustments 2-3 9
(1) Adjust manual voltage control, variable resistor. 2-3 9
(2) Adjust 400-Hz voltage regulator 2-3 9
C. Basic Engine Adjustments 2-3 10
(1) Exhaust valve adjustment. 2-3 10
(2) Exhaust valve bridge adjustment. 2-3 10
(3) Fuel injector timing adjustment. 2-3 10
(4) Idle speed, speed limiting, and
overspeed adjustments. 2-3 10
D. Alternator and fan belt adjustment 2-3 10
E. Electric Governor System Adjustment 2-3 10
(1) Actuator linkage adjustment 2-3 11
(2) Magnetic pickup adjustment 2-3 13
(3) Governor Control Unit Adjustment 2-3 14
(4) Magnetic pickup signal 2-3
4. Generator and Exciter Test 2-3 E5

Page 5
OM-436
5. Diode Test 2-3 16

6. Test and Adjustment of Transformer-
Rectifiers 2-3 17
7. Additional Tests for Dual Output Units 2-3 17
CHAPTER 3. TROUBLESHOOTING
SECTION I. TROUBLE SHOOTING
PROCEDURES 3-l 1
1. General 3-1 1
2. Trouble Shooting Chart (Figure 2) 3-1 i
A. Description 3-l 1
B. Use of the Trouble Shooting Chart 1
3. Equipment for Troubleshooting ;:I 2
4. Safety - WARNING: 3-1 2
5. Parts Replacement 3-1 2
6. Test Values 3-1 3
7. Checking Connections and Leads 3-1 3
8. Electric Governor Trouble Shooting 3-1 3
9. Engine Trouble Shooting Procedures 3-1 4
A. General 3-l 4
B. Locating a Misfiring Cylinder 3-l 4
C. Checking Compression Pressure 3-l .4
D. Interpretation of Compression
Pressure Records 3-l 5
E. Causes of Low Cylinder Pressure 3-l 5
F. Fuel Flow Test (see Fig. 7) 5
1O.lllustrations il.!-: 5
11. Troubleshooting Transformer-
Rectifiers (T-Rs) 3-1
CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION I. INTRODUCTION 4-I
1. General 4-1
2. Purpose 4-1
3. Arrangement 4-1
4. Explanation of Parts List 4-1
A. Contents 4-l
Table of Contents Aug 31/89

Page 6
B. Parts List Form 4-l 1

(1) FIGURE-ITEM NO. Column 4-l 2
(2) HOBART PART NUMBER Column 4-l 2
(3) NOMENCLATURE Column 4-l 2
(4) EFF (Effective) Column 4-l 2
(5) UNITS PER ASSEMBLY Column 4-l 2
SECTION 2. MANUFACTURERS
CODES 4-2 1
1. Explanation of Manufacturers
(Vendor) Code List 4-2 1
SECTION 3. PARTS LIST 4-3

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

1. Explanation of Numerical Index 4-4 1
CHAPTER 5. OPTIONAL EQUIPMENT
CHAPTER 6. MANUFACTURERS LITERATURE
UNUSUAL SERVICE CONDITIONS

Page 7
_ ----~-z-T. :. :.:, ,. _. > x/_ _

^ *_,.
Table of Contents Aug 31189

Page 8
OM-436
INTRODUCTION
1. General
The following information is provided for the operator to familiarize himself with using the manual
properly. THE MANUAL MUST BE READ AND UNDERSTOOD BEFORE PERSONNEL AT-
TEMPTS TO OPERATE, INSTALL, OR REPAIR THIS EQUIPMENT.
2. Scope
The manual covers a series of synchronous Motor-Generator Sets identified by the Specification Num-
bers listed. A detailed description of the equipment and information covering operation, maintenance,
troubleshooting, repair, and overhaul is included.
3. Purpose
The manual provides information and instructions to guide and assist operator and maintenance per-
sonnel in the proper use and maintenance of the equipment.
4. Contents
The Introduction is a List of Effective Pages which lists each page in the manual by its Chapter/Sec-
tion, and page number. Directly opposite each page number listing is a date which indicates whether
the page is original or revised.
The Table of Contents contains a list of all Chapters, Sections, and the principal paragraph titles within
each Section. The location of each listing is identified by Chapter/Section and page number. A com-
plete list of illustrations with their location is provided at the end of the Table of Contents.
The main text of the manual is divided into four Chapters as follows:
Chapter 1. Description/Operation
Chapter 2. Servicing
Chapter 3. Troubleshooting
Chapter 4. Illustrated Parts List
Each Chapter is divided into as many Sections as necessary. Sections are referred to by a combina-
tion Chapter/Section number. Example, 2-3 refers to Chapter 2, Section 3.
Aug 31189 Introduction

Page 1
5. Format
A. Paragraphing and Outlining
The material within each Section is divided into main subjects with applicable paragraph headings
and sub-headings as required. This method provides a means of identifying material for reference
purposes. For example;
1. Control
A. Interior Panel
(1) Protective devices
(a) Overload relay
(2) Contactors
B. Page Numbering
Page numbers do not run consecutively throughout the manual. Each page is identified by the
Chapter/Section number in which it appears, and by a page number within the Chapter/Section.
Therefore, the first page in each Section is page 1. These identifying numbers appear in the lower,
outside corner of the page. Each page also bears a date located in the corner opposite the page
number. This date is either that of original issue, or of the latest revision. Any revision to the
original text is identified by a heavy black line in the left-hand margin. Illustrations follow a number-
ing system similar to page numbering. The first Figure in each Section is Figure 1.
6. How to Use the Manual
A. General
This manual follows the format, rules and style proposed by members of the Air Transport Associa-
tion. Insofar as possible, information is grouped to help the user locate it quickly. All tables,
charts, diagrams, etc., as well as illustrations, are identified by Figure Number (i.e., Fig. 2) to avoid
confusion.
B. How to Locate Information
Refer to the Table of Contents for information required and where to locate it within the manual.
l (1) Table of Contents
The Table of Contents provides information for easy location of all subjects contained
within the manual. The chapter and section numbers are together, e.g. 2-3, indicating
Chapter 2, Section 3.
0 (2) List of Illustrations
The list of Illustrations follows the Table of Contents and includes the title, figure number,
and Chapter/Section, with page number location of the illustrations contained in the
manual. Locate the appropriate title in the List of Illustrations, refer to the Chapter/Section
and page number indicated.
Introduction Aug 31189

Page 2
OM-436
l (3) References
References are used throughout the manual. Both material in the text and illustrations
may be referred to in order to clarify or expand information and instructions. Portions of
the text are referred to by identifying the paragraph in which that material may be found.
When referenced material is located in the same Chapter/Section as the reference, only
the paragraph identification is given. For more information concerning references, refer to
paragraph 5, A on page 2.
Example:
(Ref. Para. 1, A) means the material is to be found in paragraph 1, A of the same
Chapter/Section.
When referenced material is located in another Chapter/Section, both the Chapter/Section
number and the paragraph identification are given.
Example:
(Ref. l-2, Para. 1, A) means that the referenced material is located in ChaptedSec-
tion l-2, and identified by paragraph 1, A.
Components shown in illustrations, and illustrations themselves, are referenced in a
similar manner. When this type reference is made, the item number of the part and the
Figure number in which it appears are given.
Example:
(Ref. 2, Fig. 3) refers to item number 2 which appears in illustration Figure 3 of the
same Chapter/Section.
When the referenced Figure appears in another Chapter/Section, the reference will in-
clude the Chapter/Section number.
Example:
(Ref. 2-3; 1, Fig. 4) tells the user to refer to Chapter/Section 2-3, and to see item 1, in
Figure 4.
Once a Figure number reference has been established for a series of instructional steps,
the Figure number is not repeated. Only the item numbers of parts involved are refer-
enced.
For example, Loosen screw (2, Fig. 6), slide out connector (4), and remove brush (6).
When an item is referenced without a figure number, it will always apply to the last preced-
ing Figure number mentioned in the text.
NOTE 7: The word See may appear in some references, as (See Fig. 2). It means exactly the same
thing as Ref., however, its usage is more direct and definite,
NOTE 2: When an output cable is mentioned in the manual, itrefers to a multiconductor cable
assembly. A five-conductor (A, B, C, N, and E or F) cable is required when delivering power directly
to an aircraft. A four-conductor (A, B, C, and N) cable may be used on a single output machine when
delivering power to a distribution box.
Aug 31189 Introduction

Page 3
OM-436
7. Customer Service
If you have any questions concerning your Hobart Power Systems Group equipment, you are invited
to contact our service department by mail, telephone, or FAX.
Write: Hobart Brothers Company

Airport Systems Group
Service Department
Troy, Ohio 45373, U.S.A.
Telephone: (513) 332-5060 (Service)
(513) 332-5050 (Parts)
FAX: (513) 332-5121
Introduction May la/90 Revised

Page 4
OM-436
CHAPTER 1. DESCRIPTION/OPERATION
SECTION 1. DESCRIPTION
1. General
Four different series of generator sets are covered by this manual. All generator sets in these series
are driven by a Deutz Diesel engine and have 90-kVA, 400-Hz output power ratings. The seven series
of generator sets covered by this manual are as follows:
Series 6760 Trailer-mounted, truck-mounted, or stationary units.
Series 6760A Trailer-mounted, truck-mounted, or stationary units, featuring armatures

with Hoover Bearings, Browning Coupler, and improved magnetic pole construction
for the generator revolving field.
Series 6760B Trailer-mounted, truck-mounted, or stationary units, with wide generator bearings.
Series 7001A Mounted on 5th Wheel type trailers, with fuel fill necks out the SIDE of the unit.
,
Generator sets are identified by a Specification Number which includes the Series Number and a dash
number suffix (i.e. -7, -2, etc.). The suffix number indicates either the mounting design of the gener-
ator set and/or one or more other major distinguishing features. Refer to the chart at the end of this
section and to Addendums 1 through 6 at the beginning of this manual to identify a particular unit.
Generator sets are commonly referred to as ground power units, however, the equipment will be
identified in the manual as generator sets. Generator output power is principally used for operation of
an aircrafts electrical equipment when the on-board generators are not operating. For voltage and
current requirements, physical dimensions, weight and general output characteristics of a typical gen-
erator set covered by this manual, refer to Figure 2.
Refer to Fig. 1 for identification of the main components . The equipment is a combination motor-gen-
erator unit mounted on a welded steel frame. A superstructure supports the control box, motor
switch, load contactors, and other equipment. The output terminal is located to the rear at the engine
end, and the input panel is located to the front at the motor switch end. Right and left are determined
by standing at the rear and facing the machine. A sheet metal housing, or canopy, protects electrical
components. Removable panels and covers provide access for servicing and maintenance.
May la/90 Revised l-l

Page 1
6
1. Voltage Panel & Contactor 8. Canopy

Access Door 9. Left Side Engine Access Door
2. Engine Exhaust Pipe 10. Output Receptacle
3. Battery Storage Compartment 11. Engine Controls & Panel
4. Alternator & Motor Starter Access Door
Access Door 12. Window
5. Air Filter Access Door 13. Trailer Hitch
6. Fuel Fill Pipe 14. Trailer Frame
7. Lights 15. Lifting Yoke
Generator Set
Figure 1
l-1 May 18190 Revised

Page 2
PHYSICAL
Weight (approximately) 5800 pounds (2627 kg)

Length (stationary units) 106 inches (2692 mm)
Width 78 inches (1987 mm)
Height (overall) 65 inches (1666 mm)
GENERATOR CAPABILITIES
Output power rating 90 KVA

Output voltage 115/200 VAC
Rated load capacity 260 A
Frequency/cycles per second 400 Hz
Output Kilowatts 72 KW
Power factor 0.8 PF
Duty cycle 100%
Operating speed 2000 RPM
Overload capacity (725% of rated load, 325 A
Output cable size 2/o
GENERATOR PROTECTIVE SYSTEM
Overvoltage relay Trips 130 V to 134 V; resets 125 V

Under-voltage relay Trips 93 V to 102 V; resets 110 V
Over-frequency relay Trips 415 Hz to 425 Hz; resets 410 Hz
Underfrequency relay Trips 375 Hz to 385 Hz; resets 385 Hz
Undervoltage time delay 4 to 12 seconds, depending upon adjustment
Overload relay Trips at 125% rated load in less than 5 minutes
ENGINE
Manufacturer Deutz
Manufacturers Specification No. DO 693-738*
Number of Cylinders 6
Bore 4.02 inches (102 mm)
Stroke 4.92 inches (125 mm)
Displacement (Piston) 374Cu. In. (6128~~)
Firing Order l-5-3-6-2-4
Oil Capacity (W/Fj/ter) 18.5 Quarts (17 l/2 liters)
Oil Capacity (W/O Filter) 16.5 Quarts (75.67 liters)
Battery Two 12 volts
Fuel Tank Capacity (approx.) 50 gallon (189.25 liters)
*This engine is purchased from Deutz under this specification especially for Hobart Brothers
Specifications and Capabilities

Figure 2
May 18/90 Revised l-l

Page 3
CM-436
2. Special Features
The generator set has many special features which are described in detail under the assemblies in
which they appear. Some of the features are as follows:
A. Trailer Mounted
The generator set is a trailer mounted type with the engine and generator shock mounted to the
trailer frame (74, Fjg. 7).
B. Protective Monitor
A single, solid-state device (7, Fig, 3) receives signals from all of the fault sensing units in the gen-
erator output circuit and disconnects the load from the generator if an abnormal condition of volt-
age, frequency, or load develops.
C. Pull-out Trays
The control box is equipped with pull-out, drawer-type trays (15, Fig.3) which provide easy access
to controls and equipment mounted in them. Each tray may be removed as an assembly by dis-
connecting a single quick-disconnect connector and tripping two safety latches.
D. Voltage Regulator
A solid-state, adjustable voltage regulator (3, Fig. 3) provides automatic voltage regulation of the
aircraft. The regulator is adjustable for a variety of output cable sizes and lengths.
E. Test Circuitry
A receptacle connector (70, Fjg. 7), with wiring to various test points throughout the electrical cir-
cuitry is provided for the attachment of a test box manufactured by Hobart Brothers. This test cir-
cuitry allows electricians to perform as many as twenty-four tests and checks from one location.
F. Electric Governor
The engine is equipped with an all electric type governor (4 and 76, Fig. 3) and other special
equipment described under the engine description.
G. Transformer-Rectifiers (Optional)
Generator sets covered by this manual may be equipped with one or two transformer-rectifiers
(76, Fig. 7). A transformer-rectifier, or T-R, receives 115/200-V AC power from the generator out-
put and converts it to DC power for starting and maintenance of aircraft having DC electrical sys-
tems. Two different T-Rs are available for installation on generator sets covered by this manual;
one with 28.5-V DC power output and another with 112-V DC power output. A generator set may
be ordered with one or two of either of these T-Rs or with one 28.5-V DC T-R and one 112-V DC T-
R.
3. Optional Equipment
A. Quick Start Kit
(See Para. 2, F, /tern (2) (f) and Section 7-3, Para. 2, C.)
l-l Mav 18/90 Revised

OM-436
1. Generator Control Box 9. Belts Access Panel

2. Engine Control Panel 10. Output Terminal Panel
3. Voltage Regulator 11. Diesel Fuel Inlet
4. Control Box Governor 12. Panel Power Module
5. Relay 13. Battery Storage Compartment
6. Starter Aid Assembly (Option) 14. Mumer
7. Lights 15. Tray Control Box
8. Air Filter Access 16. Governor
Generator Set Components

Figure 3

Page 5
OM-436
4. Canopy
A sheet metal enclosure, or canopy (8, Fig. 71,provides protection for the engine, generator and
electrical controls. It has two large, hinged doors on each side to provide access for service and main-
tenance. A large panel at the rear provides access to the air filter. A plexiglass window is mounted in
the left front door to allow observation of the instruments. The window is mounted at an angle and is
open at the bottom to permit access to the controls without opening the door.
5. Engine, Generator and Controls Assembly
The generator set includes all components required to generate and regulate 400 Hz, 115/200 V, three-
phase power, and is operable when provided with fuel and 12-V DC power. The engine-generator as-
sembly is mounted on a welded steel frame which provides mounting facilities for the canopy, control
box and electrical equipment and controls.
A. Basic Engine
The 90 kVA generator sets covered by this manual are equipped with a six cylinder, in-line diesel
engine, and is manufactured by KHO Deutz, 5000 Koln, Deutz-MulheimerStrabe 111.
B. Engine Manufacturers Equipment
As received from the engine manufacturer, the engine includes the following equipment which is
described in the Deutz Diesel Operators Manual.
(1) Twelve volt electrical system includes starter and alternator with built-in voltage regulator.
(2) Fuel strainer and fuel filter.
(3) Full-flow oil filter.
(4) Automatic shutdown system including high oil temperature and low oil pressure sensing
switches.
(5) Speed limiting governor.
C. Hobart Engine Equipment
The engine is modified at Hobart Brothers by the addition of the following equipment:
l (1) Electric governor system
An electric governor kit is installed on the engine to replace a conventional, mechanical

type. The electric governor was selected for control of engine speed (and generator out-
put frequency) because it provides faster engine response to changes in load conditions.
The governor system consists of (a) the Magnetic pickup (b) the Control unit, and (c)
the Actuator. A brief description is given below:
(a) Magnetic pickup
The magnetic pickup (77, Fig, 4) is a device for detecting the speed of the engine.
It is mounted in the flywheel housing directly over the ring gear. It produces an AC
signal to the control unit when the ferrous flywheel teeth pass through the magnetic
field at the end of the pickup.
l-l May 18/90 Revised

Page 6
1. Oil Filter Cartridge 11. Filler Neck Oil
2. Cooling Fins 12. Drain Plug
3. Rocker Chamber Cover 13. Oil Sump
4. Hydro Controller 14. Oil Microfilter
5. V-Belt Blower 15. Fuel Feed Pump
6. Injection Pump 16. Oil Level Dip Stick
7. V-Belt Alternator 17. Magnetic Pickup
8. Oil Pump 18. Starter Motor
9. Electric Switch 19. Alternator
10. Push Idler Pulley
Engine Components
Figure 4

Page 7
CM-436
(b) Control unit

The control unit (4, Fig. 3) is a box containing a compact assembly of solid state
components. It receives an AC signal from the magnetic pickup and senses speed
changes in the engine. It provides a voltage signal to the actuator which causes the
actuator to move the fuel control lever as required to maintain a predetermined en-
gine speed. Its power is received from the two 12-V DC battery system.
(c) Actuator
The actuator (1, Fig. 75) supplies the force needed to move and position the fuel
lever as required to maintain a constant engine speed. The actuator is operated by
a DC signal from the control unit.
l (2) Air Cleaner
The diesel-engine air cleaner (Fig. 5) is a dry-cartridge type. It is equipped with a service
indicator which signals the operator when the cartridge needs changing. A green cylindri-
cal flag (2) is forced upward in a glass enclosed viewing chamber (1) when air pressure
within the air cleaner housing drops below the outside air pressure. As the cartridge be-
comes loaded with dirt and air, pressure within the cleaner lessens, the flag gradually
rises higher in the glass viewing chamber. When the flag reaches the top of the cham-
ber, it locks in that position to warn the operator that the cartridge must be changed. The
flag is reset (unlocked) by pushing the reset button (3) located on the indicator.
NOTE: The service indicatoris mounted on the engine controlpaneland connected to the air cleaner
by a rubber hose.
The indicator flag is visible only when the engine is running or when the flag is locked in
WARNING position.
1. Viewing Chamber
2. Indicator Flag
3. Reset Button
kir Cleaner and Service

Indicator
Figure 5

Page 8
OM-436
l (3) Exhaust System
The exhaust system consists of a special noise reducing muffler (3, Fjg. 6) which is con-
nected by a rigid pipe (2) to a conventional exhaust manifold (1). The tail pipe outlet
directs exhaust out the right side of trailer frame. Specification 6760B-1 provides the muf-
fler as shown below. Specification 67608-l provides an optional vertical mounting (nor
shown).
1. Exhaust Flange
2. Exhaust Pipe
3. Muffler and Tailpipe
Noise Reduction Exhaust System

Figure 6

Page 9
CM-436
D. Generator
The 400-Hz generator is a brushless, revolving field, three-phase, alternating current type. The
rotor assembly is mounted by two, permanently lubricated, sealed ball bearings. The front bear-
ing is supported by the fan housing; the rear bearing is mounted in the exciter housing and both of
these are attached to the main generator stator housing. The front end of the rotor shaft extends
forward beyond the bearing and is attached to the engine flywheel by a hub and flexible disc cou-
pling assembly. The rear end of the rotor shaft extends rearward beyond the rear bearing into the
exciter stator housing. The exciter rotor is mounted on the shaft extention with a standard key
and is secured by a washer and l/2 -13 thd., cap screw.
A rectifier with six diodes is mounted on the exciter rotor and converts exciter AC output to DC for
excitation of the generator revolving fields. The exciter DC output to the generator fields, and con-
sequently, the generator output is controlled by the amount of DC voltage supplied to exciter
fields by the static voltage regulator. A centrifugal, radial-blade fan, which is part of the hub and
coupling assembly, draws cooling air over all internal windings. Air enters at the exciter end and is
discharged at the drive end. The complete generator is bolted to the engine flywheel housing.
E. Control Box Assembly
The control box (Fjg. 7) is a sheet metal enclosure which houses and provides mounting facilities
for generator and engine controls and monitoring equipment. The box is equipped with two,
drawer-type trays which contain generator output control devices and monitoring instruments.
Trays slide in and out on nylon rollers for easy access to internally mounted components and are
easily removable by disconnecting an Amphenol connector, unlocking safety latches.
Two, shielded, instrument panel lights are mounted on top of the control box front panel to il-
luminate controls and instruments within the trays.
l (1) Generator control tray (see Figure 8)
The generator control tray contains instruments and controls for monitoring and control-
ling the generator output.
(a) Resistors
Two, 20-ohm, loo-watt, ballast resistors (2) are connected in series in the generator
exciter DC field circuit.
A variable resistor (1) is connected in series between the manual control rectifier
(14) and rheostat (73). Its purpose is to adjust the DC voltage to the rheostat and
thus determine the voltage range through which the rheostat can control generator
output voltage.
(b) Generator output monitors (meters)
The generator output is monitored by three instruments; a frequency meter (70, Fig,
8) a voltmeter (9), and an ammeter (7). The frequency meter is a resonant-reed type
which indicates the frequency of the generator output alternating current in the
range of 380 to 420 Hz (cycles per second). The voltmeter indicates the generator
output voltage in each phase-to-neutral (A-N, B-N and C-N) or phase-to-phase (A-B,
B-C and C-A) as selected by the meter selector switch (6) and the line selector
switch (5). The voltmeter scale is graduated 0 to 300 V and the ammeter is
graduated 0 to 500 A on 90-kVA units. The amperage value in each of the three
phases may be read on the ammeter by selecting the desired phase with switch (6).
Three ammeter current transformers, (Ref. 4, F/g. 13), lower the output load current
to a lesser value of definite ratio, which will operate the ammeter movement without
damage. The ammeter dial scale is graduated and numbered so that the pointer will
indicate the true load current value rather than the meter movement current.

Page 10
OM-436
ONTROL TRAY
PROTECTIVE
RELAY TRAY
/
PANEL LIGHT
Control Box
Figure 7
(c) Meter and line switches

These switches provide a means of selecting and determining which phase of volt-
age and current is indicated on the voltmeter and ammeter and whether the voltage
is line-to-neutral or lineto-line. The meter switch (6, Fig. 8) is a four-position, rotary
type. An instruction plate (41, located under the switch knob is marked and lettered
to indicate the three functional positions of the meter switch. (When the knob is
pointing straight down, the swirch is OFF). The line switch (5) is a two-position, tog-
gle switch used to select either line-to-neutral or line-to-line voltage to the voltmeter.
The instruction plate is also marked to indicate the position of this switch.
(d) Receptacle connector
An Amphenol connector (72, Fig* 8) provides a means of quickly disconnecting all
wires to control box components.
(4 Tray
The tray (75) slides in and out on nylon rollers. It is secured in place by a twist-lock,
screw fastener (8).

Page 11
OM-436
1. Resistor (50 Ohm, 100 Watt) Variable 9. Voltmeter

2. Resistor (20 012175 100 Watt) Ballast 10. Frequency Meter
3. Excitation-de-energization Relay 11. Automatic-Manual Switch
4. Instruction Plate 12. Receptacle Connector
5. Line Selector Toggle Switch 13. Manual Voltage Control Rheostat
6. Meter Selector Rotary Switch 14. Manual Control Rectifier
7. AC Ammeter 15. Tray
8. Tray Fastener 16. Flyback Diode
Generator Control Tray

Figure 8
1-l May 18/90 Revised

Page 12
OM-436
(f) Manual voltage control

When the automatic-manual switch (77) is placed in MANUAL position, AC power is
supplied to the rectifier (74) rather than to the automatic voltage regulator. The DC
output of the rectifier is routed to the exciter field through a rheostat (73). The gener-
ator output voltage is manually controlled by adjustment of the rheostat.
(g) Excitation-deenergization relay
The purpose of this relay (3) is to allow automatic excitation to be connected to the
exciter field only when the engine speed is being controlled by the electric governor.
0 (2) Protective relay tray (Figure 9)
In the bottom of the control box is the protective relay tray which contains electrical and
electronic safety devices. These devices are designed to protect the aircraft electrical sys-
tem against damage resulting from over or under-voltage, over or underfrequency. The
tray also contains devices for the protection and control of the generator output electrical
system.
(a) Sensing modules
The voltage sensing module (5) and frequency sensing module (6) are connected to
the generator output leads between the generator and load contactor. These are
the solid-state circuitry of the memory and time delay module (4) which open the
load contactor and disconnect the generator output to the aircraft.
A solid-state overload signaling device (Ref. 7, Fig. 73) is also connected to the
protective monitor module and performs a function similar to the sensing relays.
Trip values for the protective circuits are as follows:
Overvoltage - at 130 V to 134 V Undervoltage - at 102 V or below Over-frequency - at
415 Hz to 425 Hz Underfrequency - at 390 Hz to 395 Hz Undervoltage time delay
(adjustable) 4 to 12 seconds Overload circuit trips at any value over 125% rated
load capacity.
(b) Memory and time delay module
The memory and time delay module (4, Fig. 9) or the protective monitor module, is a
solid-state device with a hermeticallysealed, reed-type relay. The printed circuit
board or card includes five memory circuits and a time delay circuit. Each circuit
is connected to a corresponding sensing module (5 and 6). All memory circuits are
connected to the module relay coil, and any one of the circuits can energize the coil
to open the relay contacts. When a sensing device energizes any one of the module
circuits, the module relay is also energized to break the load contactor holding cir-
cuit and allow the load contactor to open. All circuits, except the undervoltage cir-
cuit, function immediately to open the load contactor. A time delay system of the
contactor under conditions the momentary undervoltage in the generator output.
An undervoltage condition which continues uninterrupted for a period of 4 to 12
seconds (adjustable) will cause the time delay circuit to open the load contactor.
Each of the five circuits is connected to a corresponding indicating light (70, 77, 13,
74, and 75) which is turned on when a fault occurs.
The module relay will remain energized (OPEN) until the reset switch (7) is pushed
to allow the relay to return to normal, (CLOSED).

Page 13
(c) Indicating lights
The function of lights (70, 77, 73, 74, and 75) is to indicate to the operator the abnor-
mal condition of overvoltage, under-frequency, etc., which caused the protective
monitor system to function. Each of the five lights is connected to an actuating cir-
cuit within the memory and time delay module. When one of the circuits is activated,
it turns on the applicable indicating light. The light will remain on until the reset
switch (7) is pushed. All lamps in indicating lights may be tested by pressing switch
(8).
(d) Plug interlock relay
The function of the plug interlock relay (7) is to open the output load contactor in the
event the cable plug connector becomes disconnected during power delivery. The
output load contactor will also be opened if an attempt is made to deliver power
when the output cable is not connected. The relay receives 28-V DC for operation
supplied through the on-board transformer-rectifier, or from the 28-Volt electrical
system.
Connection to the interlock relay is through terminals E and F on the output plug
connector.
(e) Test bank switch
A test bank toggle switch (78, Fig. 9) provides a means of bypassing the interlock
relay (7) when supplying power to a load bank, or to an aircraft not equipped with a
plug-interlock system.
(f) Resistor
A loo-ohm, 25watt resistor (27) is connected in series with the plug interlock relay
to protect it in the event that phase c contacts in the load contactor should fail to
close when the generator control ON switch is operated.
(g) Fuse-interlock relay
The function of the fuse-interlock relay (2) is to interrupt the load contactor holding
coil circuit and remove the load in case of a blown fuse (77) in the protective relay
coil circuit.
(h) Connector
A 26-contact connector (79) provides a quick-disconnect facility for all wiring to the
tray electrical components so that the complete tray assembly may be removed
quickly and easily.
(j) Auxiliary underfrequency relay
The auxiliary underfrequency relay (3) automatically opens the excitation-deener-
gization relay disconnecting the voltage regulator whenever the frequency drops to
380 Hz or below. This protects the voltage regulator (Fig. 72) and ballast resistors
(2, Fig. 8) against overloading.
NOTE: If the auxiliary underfrequency relay is tripped, it will be necessary to place engine operating
mode switch (5, Fig. 8) in BUILD-UP-VOLTAGE position to restore generator voltage.

Page 14
1. Plug Interlock Relay 12. Tray Fastener
2. Fuse Interlock Relay 13. Overfrequency Indicating Light (Red)
3. Auxiliary Underfrequency Relay 14. Undervoltage Indicating Light (Red)
4. Memory and Time Delay Module 15. Overvoltage Indicating Light (Red)
5. Over-undervoltage Module 16. Load Contactor Circuit Fuse (2A)
6. Over-underfrequency Module 17. Protective Systems Fuse (2)
7. Reset Switch 18. Test Bank Switch
8. Light Test Switch 19. Receptacle Connector
9. Ground Fault 20. Terminal Board
10. Overload Indicating Light (Red) 21. Resistor (100Olzng 25 Watt)
11. Underfrequency Indicating 22. Tray
Light (Red)
Protective Relay Tray

Figure 9
May 18190 Revised l-l

Page 15
OM-436
F. Engine Control Panel (Fig, 70)
The engine control panel is mounted into the side of the control box. The engine controls and in-
struments and generator output controls are included. A plexiglass window in the engine control
panel door slants outward at the bottom to form an opening for access to controls when the door
is closed.
l (1) Engine Instruments
Engine operation is monitored by an ammeter (4), an oil pressure gage (2), and an oil
temperature gage (5). An hourmeter (3) records engine operating time.
(a) Ammeter
The ammeter (4, Fig. 70) indicates the direction and value of current flow in the 12
VDC electric system. Its graduated range is from - 60 A through 0 A, to +60 A.
(b) Oil Temperature Gage
This gage (5) indicates engine temperature. Its graduated range is 150 to 300 F
(50 Oto 750 C).
(c) Oil Pressure gage and oil pressure switch
The oil pressure gage (2, Fig. 70) is a bourdon tube type and indicates engine
lubricating oil pressure. It is graduated from 0 PSI to 75 PSI. An oil pressure switch
is mounted in a tee fitting directly behind the gage. The switch connects 12-V DC
power to the engine control system and 12-V DC control system to the generator
when the engine is running.
(d) Hourmeter
The hourmeter (3) is electrically driven from the 12 VDC battery system. The hour-
meter measures and records engine running time and will record up to 9999.9 hours
on five revolving drums. The hourmeter operates only when the engine is running
and the oil pressure switch (2) is closed.
l (2) Engine and generator controls
(a) Fuse
A 15ampere fuse (76, Fig. 9) protects the 12-VDC engine control circuit hourmeter,
illuminating light circuit, and 12-VDC system in the main generator protective sys-
tem.
(b) Engine-generator control switch
The generator mode control switch (9, Fig. 70) is a three-position toggle type. It is
spring-loaded in BUILD-UP-VOLTAGE position, and will automatically reset to
GENERATE position when released. The switch supplies power to the governor
control box allowing the engine to operate at normal governed speed. It also
momentarily supplies current which closes the excitation-deenergization relay, (3,
Fig. 8).
When the switch is in GENERATE position, power is maintained to the governor

control box and to the excitation relay. When the switch is in IDLE, power is discon-
nected so the engine returns to idle speed and the exciter field is deenergized.

Page 16
OM-436
(c) Contactor control switch

The engine start switch is a three-position toggle type (75, Fig. 70) identical to the en-
gine-generator control switch. When placed in the spring loaded ON position, it
provides 115-VAC power directly to a rectifier which supplies DC power for closing
the load contactor. When released, it returns to the normal ON position and con-
tinues to provide power to the rectifier. In this switch position, AC power must pass
through the plug interlock and fuse interlock relays. In OFF position the switch
opens the AC circuit to the rectifier, cutting off the source of DC power to the contac-
tor coil which allows the contactor to open.
(d) Indicating lights
A green indicating light (73,Fig. 70) glows to indicate that power is available to the
engine protective system. The light operates only when the engine is running and
fuel pressure is sufficiently high to close a fuel pressure switch (79, Fig. 4). The pur-
pose of the pressure switch is to deactivate the protective circuit when the engine is
stopped and prevent discharge.
(e) Fuel gage and blocking diodes
An electric fuel gage (7, Fig. 70) receives a signal from the sending unit mounted on
the fuel tank. Twelve-Volt DC operating power is supplied to the fuel gage system.
To check fuel quantity while engine is stopped, use switch (6) to turn ON panel
lights.
A blocking diode (70, Fig. 731,located on the back of the fuel
gage, prevents feedback from the alternator into the engine circuitry.
(f) Cold weather starting aid control (Optional)
The push-button control (77, Fig. 70) operates a cold weather starting aid. The start-
ing aid consists of a group of items designed to inject a highly volatile fluid into the
engine air intake system. This assists ignition of fuel when air temperature is too low
for the heat of compression to ignite a normal fuel mixture. The starting aid consists
of a cylindrical fluid container and a valve (see 6, Fig. 3) which are mounted on the
panel separating the generator from the engine. The valve is operated tiy the con-
trol (77, Fig. 70) allowing fluid to flow into the valve. Pushing the button IN forces
fluid through a small tube and an atomizing nozzle into the inlet manifold. The addi-
tion of atomized, highly volatile fuel into the inlet air assists in igniting the diesel fuel
mixture.
(g) Engine stop control
The engine is normally stopped by use of the 3 position switch. Top position is
START, middle is RUN and bottom position is STOP.
(h) Air cleaner indicator
The air cleaner indicator (See 7, Fig. 77) is mounted on the engine test panel. Its
function was explained in Para. 5, (3), See Fig. 5.
(j) Test receptacle connector
This amphenol connector (7, Fig. 77) provides an attaching point for leads which are
connected to selected test points throughout the engine and generator electrical
systems. Connections and schematic diagrams indicate points at which the leads
are connected. The receptacle connector is designed to mate with a test box plug
connector (See Fig. 74).

Page 17
1. Panel 9. Generator Mode Control
2. Oil Pressure Gage 10. Output Contactor Light
3. Hourmeter 11. Cold Weather Starting
4. Ammeter (DC) Battery 12. Fan Belt Fault Indicating
5. Oil Temperature Gage Light
6. Switch, Panel Lights 13. Light, Engine Operating
7. Fuel Gage 14. Engine Start Pushbutton
8. Generator Output Contactor Switch 15. Switch Engine Start
Engine Control Panel

Figure 10
l-1 May 18/90 Revised

Page 18
OM-436
Engine Test Panel

Figure 11
G. Voltage Regulator
The voltage regulator (Fig. 72) is located on the left side of the machine behind the engine com-
partment. The regulator is accessible for adjustment by opening the door on the left side. Al-
though a separate regulator manual is supplied with the generator set, a brief, working description
is given here.
The voltage regulator is designed to provide 1% voltage regulation with 25second recovery time
for all loads up to 100% of rated load on a three-phase, four-wire, 115/200-volt, 400-Hz, brushless
generator. This regulator provides field excitation power for the rotary exciter and regulates gener-
ator output voltage by varying the exciter field power as required to meet varying load conditions.
Thus, the generator output is held at a constant voltage. The maximum continuous rating of this
regulator is 4.0 amperes at 140 volts DC.
Any deviation of the generator output voltage from its set level is sensed by the voltage detection
and comparison circuits. A signal is fed from the comparison circuit into the transistorized,
preamplifier, preamplified, and used to drive the magnetic amplifier. The magnetic amplifier output
changes in response to this signal, changing the field power of the rotary exciter enough to return
the generator voltage to its regulated value. The voltage at which the generator is regulated may
be adjusted with the voltage adjustment rheostat (2, Fig. 72).
0 (1) Controls
The rheostat (2, Fig. 12) is used to adjust the regulated voltage value of the generator out-
put. Compensation for cable size is adjusted by a potentiometer (4). Cable length is com-
pensated for by adjustment of another potentiometer (3). Cable compensation may be
turned ON or OFF by a toggle switch (5). For this application, the switch must always be
ON. An instruction plate under the potentiometer knobs indicates proper setting for
various cable sizes and lengths. Regulator stability is adjusted by the damping circuit
gain potentiometer (8). Regulator response time is adjusted by the damping circuit rate
potentiometer (70).

Page 19
0 (2) Protection
Internal circuitry of the voltage regulator is protected by a cartridge type 5-ampere fuse
(72).
0 (3) Components (See Fig. 12)
Components of the basic circuits are mounted in two major subassemblies which are the
line drop compensation chassis assembly (S), and the sensing and preamplifier chassis
assembly (15).
Receptacle connectors (7, 9, and 11) provide quick connect-disconnect facilities for inter-
connecting wire leads. The two subassemblies are mounted on chassis (18), along with
other main components of the regulator. These include a resistor (l), voltage adjusting
rheostat (2), fuse (12) and fuseholder (13), nineteen-pin receptacle connector (14), and
reactor (17). Field ballast resistors and line drop current transformer loading resistors are
located at a point remote from the voltage regulator and are not supplied with the
regulator. The two field ballast resistors are located in the generator control tray (Ref. 2,
Fig.8). Transformer loading resistors are located on the power module panel assembly
(Ref. 8, Fig. 13).
H. Power Module Panel Assembly
The power module panel assembly (Fig. 13), or contactor panel, is located at the right front of
the machine behind the control box and is accessible by opening the left front door. The panel as-
sembly provides a means of connecting and disconnecting generator output to and from the load
(aircraB).
l (1) Load contactor
The load contactor (6, F/g. 13) is a sealed unit which contains a magnetic operating coil
and four sets of contacts. The three larger contacts conduct three-phase AC generator
output. A smaller contact set is connected in the protective monitor circuit and supplies
12-VDC power used by sensing relays to signal the protective monitor when a fault oc-
curs. Three-phase, 400-Hz generator output power is conducted to the load contactor by
2/O cables which pass through 3 sets of current transformers (3, 4, and 9).
NOTE: This contactor may be replaced by the old style contactor used in earlier 60 and 90 kVA
machines, (part no. 75GH-566 [Hartman No. A-874C]) in stock.
0 (2) Current transformers
(a) Ammeter current transformers

Three current transformers (4) lower the output load current to a lesser value of
definite ratio (250-A to 5-A) which operates the ammeter (7, fig. 8) movement
without damage. The ammeter pointer indicates the true load current value rather
than the meter movement current.
(b) Line-drop current transformers
Three current transformers (4), lower the output load current to a lesser value of
definite ratio (250-A to 5-A) which operates the ammeter (7, Fig, 8), in conjunction
with the burden resistors (8, Fig. 13), detect the magnitude and power factor of cur-
rent flowing from generator to load. They 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).

Page 20
17 I8
f------L _____:
\
1. Resistor (1000 Ohms, 25 Watts) 11. Receptacle Connector

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 & Preamplifier Chassis
6. Line Drop Compensation, Chassis Assy. Assembly
7. Receptacle Connector 16. High-Phase Sensing Board Assembly
8. Damping Circuit Gain Potentiometer 17. Reactor, Regulator
9. Receptacle Connector 18. Chassis
10. Damping Circuit Rate Potentiometer 19. Terminal Board
Voltage Regulator
Figure 12

Page 21
CM-436
(c) Overload current transformers

Three overload current transformers (3), in conjunction with burden resistors (I),
monitor the output load current in each of the three output phases, and supply a
reduced value current signal to the overload module (7).
l (3) Overload module
The overload module (7) is a solid-state device designed to interpret a signal from trans-
formers (3) and to send a signal to the protective monitor module (4, Fig. 9) when an
overload condition exists in any generator output phase. A pull-apart electrical connector
is mounted on the overload module to provide quick-disconnect facilities for all wiring to
the module. The overload module is equipped with a hermetically-sealed, reed-type relay.
Relay contacts are normally open.
The solid-state circuitry is designed to close the relay contacts when output current in
ANY phase reaches 125% of normal, rated output capacity. The closed relay sends a sig-
nal to the protective monitor. This signal gates the overload SCR (silicon-controlled rec-
tifier) in the protective monitor and interrupts the load contactor to open.
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.
At 125% load the device will function in 5 minutes.

At 150% load the device will function in 16 seconds.
NOTE: All times are plus or minus 25% and are nonadjustable.
l (4) Rectifier
A diode-bridge rectifier (5, Fig. 73) receives 400-Hz AC from phase C of the generator out-
put and converts it to a pulsating, direct current for energization of the load contactor
holding coil only. This DC coil-holding circuit is controlled indirectly by the 400-Hz AC to
the rectifier. The ground circuit for the rectifiers AC supply must pass through the relay
contacts in the protective monitor module to ground cable N. Therefore, any time a
protective device functions to open the protective monitor relay, the rectifiers circuit is
opened. No DC is then available for the load contactor holding coil, hence, the load con-
tactor opens.
6. Test Box
The test box is an optional accessory item used for testing the generator set. All generator sets are
wired to accommodate a test box, however, the box is supplied only when ordered. (Part Number
3883 18A-2).
A. Description (See Fig. 74)
The test box assembly consists of a rotary selector switch, momentary contact pushbutton switch,
and two insulated-tip test jacks, mounted in a small metal box. Connection to the generator set is
made through a wiring harness equipped with a 26-contact plug connector which mates with a
receptacle connector.

Page 22
OM-436
1. Overload Resistor (16.6 Ohm, 25 Watt 6. Load Contactor

for 90-kVA) 7. Overload Module
2. Terminal Board 8. Line Drop Resistor (50 Oh,
3. Overload Current Transformer 25 Watt)
4. Ammeter Current Transformer 9. Line Drop Current Transformer
5. Rectifier 10. Blocking Diode
Power Module Panel Assembly

Figure 13

Page 23
B. Theory of Operation
Wire leads are connected to the electrical circuitry of the generator set at various points and
routed to a receptacle connector mounted on the engine control panel. They are connected to
the test box rotary switch by a plug connector and wiring harness.
The rotary selector switch is wired in such a manner that for any switch position, two pre-selected
test points in the generator set circuitry are connected for testing.
The selector switch may be rotated to any one of 22 positions, however, not all positions are used
in this installation. An instruction plate mounted under the switch knob indicates switch positions
and component tested in each position. Normal voltage for each test is also indicated.
Two test jacks are provided for connection of the test prods of a voltmeter. After the voltmeter is
connected and selector switch positioned, the test circuit is closed by pressing the pushbutton
switch. A voltage value may then be observed on the voltmeter. This arrangement prevents ener-
gization of test circuitry and equipment for extended periods and allows the operator to reset and
adjust the voltmeter without disconnecting it from the box.
For operating instructions, see Sect. l-3, Para. 3.
1. Test box
2. Cable
3. Plug connector
Test Box Assembly (Optional)

Figure 14

Page 24
OM-436
1. Actuator
2. Rod
3. Speed Control Lever
4. Bracket Mounting
Throttle Control and Electric

Governor System
Figure 15
7. Dual Output Machine
When a machine is equipped with the second output option, the unit has two output circuits for servic-
ing two aircraft simultaneously, or for servicing a single aircraft with two input receptacles. The output
terminal boards for this unit are arranged as illustrated in Figure 16, with output No. 1 at the rear ter-
minal board and output No. 2 at the front. This dual output assembly is mounted in the same location
as the single output terminal board on the single output unit (IO, Fig. 3). Components of the dual out-
put circuits are identical to the components of the comparable single output units, but are grouped
separately as follows:
A. Contactor switch for the second output is located in a small box attached to the frame in front of
the engine control panel (Fig, 77). This box also includes the No. 2 contactor CLOSED light which
glows green when the No. 2 contactor is closed. These parts are identical to items 8 and 10 on Fig. 10.
B. The power module panel for output No. 2 (Fig. 78) is mounted on brackets directly above the
power module panel for output No. 1 (72, Fig. 3). The load contactor, rectifier and blocking diode are
identical to items 5, 6, and 8, Figure 13. The two relays, TEST BANK switch and resistor are identical
to items 1, 2, 18, and 21, Figure 9.
C. A flyback diode has been added to the No. 2 output circuit across pins 2 and 10 of the fuse inter-
lock relay socket. This diode prevents any inductive voltage discharge into the circuit when the relay
coil is deenergized. Its counterpart in the No. 1 output circuit is an integral part of the over-undervol-
tage relay (5, Fig. 9).
D. Protective circuits described in Para. 2 monitor and protect output No. 2 as well as output No. 1.

Page 25
01111-436
No. output
No. output
Dual Output Terminal
Boards
Figure 16
V Output Cable Horns
Second Output Control Panel Engine Control Panel
- ----..--_ \
No. 2 Output Control

Figure 17

Page 26
OM-436
Indicating Light Blocking Diode
Diode
tor
L-Hold Circuit LTest Bank Switch

Resistor
Output No. 2 Power Module Panel

Figure 18

Page 27
OM-436
Voltage
Specification Location of Regulator
Number Mounting Exhaust on Unit Used Note C!:
6760-1, 676OA-1,6760B-1 Trailer Right Fender 430391c (1)
6760-2, 6760A-2,6760B- 2 Trailer Top of Unit 430391c (2)
6760-3 Trailer Top of Unit 430391c (3)
6760-4, 6760A-4,6760B-4 Stationary Top of Unit 430391c (4)
6760-5, 676OA-5,6760B-5 Stationary Top of Unit 430391c (5)
6760-6, 6760A-6,6760B-6 Truck Top of Unit 430391c (6)
6760A-7,6760B-7 * Trailer Right Fender 489812 (7)
6760A-8,6760B-8 * Trailer Top of Unit 489812 (8)
676OA-9,6760B-9 Stationary Top of Unit 489812 (9)
676OA-10,6760B-10 i: Stationary Top of Unit 489812 (10)
6760A-11,6760B-ll * Truck Top of Unit 489812 (11)
7001A-1 5th Wheel Trailer Top of Unit 430391c (12)
7001A-2 5th Wheel Trailer Top of Unit 489812 (13)
*Covered by addendums at front of manual after table of contents.

** See sheet 2 for additional descriptive information.
Generator Set Identification

Sheet 1 of 2 Sheets

Page 28
Note
No. Additional Descriptive Information
(1) Batteries included.
(2) Fenders and batteries included.
(3) Fenders and special batteries included.
(4) Without trailer, fenders, and batteries.
(5) Without trailer, fenders, batteries, but with 65-A alternator and glow-plug quick start.
(6) Identical to Spec 6760-2,6760A-2, or 6760B-2, except that it is for truck mounting.
(7) Batteries included.
(8) Fenders and batteries included.
(9) Without trailer, fenders, and batteries.
(10) Without trailer, fenders, batteries, but with 65-A alternator and glow-plug quick start.
(11) Very similar to Spec 6760B-8, except that it is for truck mounting.
(12) Very similar to Spec 6760B-2, except the fuel fill neck is out the SIDE of the unit, and
the generator of this unit has wide bearings.
(13) Identical to Spec 7001A-1, except for control panel support assembly: Part No. 181101.
(14) Very similar to Spec 7001A-1, except for trailer kit: Part No. 280359-2
(15) Very similar to Spec 7001A-1, except for fuel tank: Part No. 281263, and control panel
support: Part Number 181718
Generator Set Identification

Sheet 2 of 2 Sheets

Page 29
OM-436
1-l May 18190 Revised

Page 30
SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING
1. Preparation for Use
A. General
WARNING: IMPROPER OPERATION CAN KILL, INJURE OR DAMAGE!

BEFORE OPERATING THE UNIT. READ AND FOLLOW OPERATING IN-
STRUCTIONS IN SECTION 1-3
B. Inspection/Check
Inspect the unit thoroughly prior to installation or use.

(1) Remove blocking, banding, ties, and other securing material.
(2) Inspect exterior for shipping damage such as broken lights, damaged sheet metal, etc.
(3) Open all canopy doors and inspect interior for foreign material such as rags, tools, shipping
paper, etc.
(4) Check fuel, oil bases, and connections for visible leaks. Visually inspect the compartment
floor and ground surface under the unit for signs of leakage. If leaks are found, correct by tighten-
ing hose clamps, tube fittings, etc., as required.
(5) Check the following for sufficient quantity:
(a) Fuel
Turn ON panel lights to energize fuel gage when engine is stopped.
(b) Engine lubricating oil
Oil level should be at FULLmark on oil level gage rod (I, Fig. I).
(6) Check air cleaner
The air cleaner (Sec. 7-7, Fig. 5) is a dry type. Be sure there are no papers, tapes, or
other material covering the air inlet area.
(7) Check batteries
Two 12-VDC batteries are provided in the decking of the trailer.
C. Installing Output Cables
Units are generally shipped without generator set-to-aircraft cables.
l (1) Three-phase, AC output cable assembly installation.
The AC output terminal panel is located on the left side, below the generator control box.
(See Fig. 2).
(a) Open left front canopy door and loosen cable clamp screws at cable horn.
Aug 31189 1-2

Page 1
CM-4362
1. Oil Level Gage Rod

2. Oil Filler Cap
Engine Oil Gage Rod and
Filler Cap
Figure 1
(b) Route cables through cable horn and clamp and upward to terminal board.
NOTE: Conductor size recommended for AC output is 2/O. Use No. 12 size for control (E and F
terminals).
Large cables (A, B, C, N) should be equipped with terminals having at least a 3/8-inch
diameter mounting hole. Mounting hole in small leads (E and F) should be at least l/4
inch diameter.
(c) Each terminal stud is identified by an identification plate. Each cable should be iden-
tified by a band-type marker. Connect cable A to A, B to B, etc. Tighten terminal
nuts securely. Connect small plug interlock lead E or F to terminal El or F respective-
ly.
(d) Tighten clamp screws securely, but avoid damage to cable insulation.
l (2) Transformer-rectifier (T-R) cable assembly installation
If the generator set is provided with one or more transformer-rectifiers, refer to Hobart
manual OM-433 in Chapter 6 of this manual for instructions on installing the T-R output
cable assembly or assemblies.
1-2 Aug 31189

Page 2
OUTPUT TERMINAL PANEL
/-
i- CABLE HORN
Output Terminal Panel Arrangements

Figure 2
2. Preparation for Storage
When a generator set is to be stored or removed from operation, special precautions should be taken
to protect the internal and external parts from rust, corrosion, and gumming in the engine fuel system.
A. General
(1) The unit should be prepared for storage as soon as possible after being removed from service.
(2) During winter months the unit should be stored in a dry, heated building.
(3) Moisture absorbing chemicals are available for use when excessive dampness is a problem.
The unit must be completely packaged and sealed if moisture absorbing chemicals are to be effec-
tive.
B. Temporary Storage
When storing the unit for 30 days or less, prepare as follows:

(1) Lubricate the unit completely in accordance with instructions in Sect. 2-1. This will include
changing engine oil, and all filter elements.
(2) Start the engine and operate for about two minutes so that all internal engine components will
be coated with new oil.
Aug 31189 l-2

Page 3
OM-4364
NOTE: Do not drain the fuel system or crankcase after this run.
(3) Clean the exterior of the engine with fuel oil. Dry with clean rags and compressed air.
(4) Seal all engine openings. Use a waterproof, vaporproof material which is strong enough to
resist puncture damage from air pressures.
C. Long Time Storage (Over 30 days)
IWARNING: FUMES AND OXYGEN DEFICIENCY CAN KILL! PROVIDE ADE-

QUATE VENTILATION BEFORE STARTING THE ENGINE. I
(1) The unit may be stored for long periods with no special preparation if the engine is operated at
least once each week.
(2) If weekly operation is not possible, prepare and protect the engine in accordance with instruc-
tions in KHD Deutz diesel operation instructions.
(3) To protect the generator and other electrical components, the complete unit should be padk-
aged, using moisture packaging and sealing material. Place containers of moisture absorbing
chemicals, such as silica-gel, in the unit before packaging.
3. Preparation for Shipment
During long shipments by rail (and other means), the generator set retaining hardware may become
loosened by vibration, jolting, etc.
1-2 Aug 37189

Page 4
SECTION 3. OPERATION
1. General
This 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 in supply-
ing 400-Hz power to an aircraft.
WARNING: IMPROPER OPERATION CAN KILL! EAR PROTECTION EQUIP-

MENT MAY BE NECESSARY WHEN WORKING IN CLOSE PROXIMITY TO
THIS EQUIPMENT. READ AND FOLLOW ALL OF THE OPERATING IN-
STRUCTIONS BEFORE ATTEMPTING TO OPERATE THE EQUIPMENT.
2. Operating the Generator Set
A. Pre-start Inspection
(7) Open the fuel shut-off valve (if used).

(2) Provide 12-VDC power to the engine starting system.
(3) Check the engine and generator compartments and remove rags or other foreign materials,
B. Normal Engine Starting Procedures
Engine starting procedures are outlined below. Engine operating controls and monitoring instru-
ments are illustrated in Fig. 1.
(7) If illumination is required, place light switch (24) in ON position.
NOTE: This switch must be ON to check fuel when engine is stopped.
(2) Set parking brake.

(3) Hold engine start switch (26, Fig. I) in START position momentarily. Push engine start push-
button (27) to crank engine. When engine starts, release pushbutton. Continue to hold engine
start switch (26) in position until oil pressure gage (16) reads 40 Ibs. pressure. Release switch
(26).
(4) Check ammeter (79) for charge reading.
(5) Check fuel gage (20) and oil gage (76).
(6) Place generator mode control switch (77) in IDLE position.
(7) Activate generator output contactor switch (27).
Aug 37189 7-3

Page 7
OM-436
I2 II io
CONTROiBOX
ENGINECONTROL PANEL
1. Frequency Meter 16. Oil Pressure Gage

2. Instrument Panel Lights 17. Generator Mode Control Switch
3. Voltmeter 18. Hourmeter (,??JzgiJze)
4. Fastener 19. Ammeter (DC) Battery
5. AC Ammeter 20. Fuel Gage
6. Meter Switch 21. Switch, Generator Output Contactor
7. Line Switch 22. Fan Belt Fault Indicator Light
8. Test Switch 23. Output Contactor Light
9. Reset Switch 24. Switch, Panel Lights
10. Fault Indicating Lights 25. Light, Engine Operating
11. Load Contactor Circuits Fuse (2) 26. Switch, Engine Start
12. Protective System Fuse (2.4) 27. Engine Start, Pushbutton
13. Protective Relay Tray 28. Cold Weather Start
14. Fastener 29. Oil Temperature Gage
15. Generator Control Tray
Operating Controls and Instruments

Figure 1 (Sheet 1 of 2)
7-3 Aug 37189

Page 2
35 36 37 38
38.
GENERATOR CONTROL TRAY
VOLTAGE REGULATOR
PROTECTIVE RELAY TRAY
30. Manual Voltage Control Rheostat 35. Automatic Voltage Control Rheostat *
31. Automatic-manual Voltage 36. Cable Length Compensation Rheostat *
Control Switch 37. Cable Size Compensation Rheostat *
32. Test Bank Switch 38. Line-Drop Compensation
33. Light Test Switch On-Off Switch *
34. Reset Switch 39. Fuse (5-A) *
* (Voltage regulator No. 430391C corltrols illustrated)

Aug 31189 1-3

Page 3
OM-436
C. Cold Weather Engine Starting Procedures
WARNING: THIS KIT MUST NOT BE USED IN TANDEM WITH A GLOW-PLUG

STARTING AID. AN EXPLOSION AND SERIOUS INJURY COULD RESULT. I
A cold weather stat-tin%-aidkit (Fig. 2) is an option available for starting the engine at tempera-
tures below 50 F (70 C) . To start the engine, using the starting aid, proceed as follows:
(1) Position switches and controls as instructed in steps (I) through (4), paragraph B, Normal En-
gine Starting Procedures, above.
FIRES, FUMES, AND FLYING PARTS CAN KILL OR INJURE!

FLUID IS EXTREMELY FLAMMABLE. IT IS UNDER PRESSURE.
AVOID CONTACT WITH SKIN AND
(2) Prepare starting aid for use. The starting aid is shipped in a safe condition and is not operable
until assembled. Assemble as follows:
(a) Loosen clamp screws (1, Fig. 2) and slide the cylinder (2) upward sufficiently to
remove protective cap (3) and plug (4).
(b) Use bottle opener to remove cylinder cap (3). Unscrew and remove plug (4).
(c) Slide the cylinder (2) downward and thread into the valve (5). Tighten securely. The
starting aid is now ready to use.
1. Clamp Screw
2. Fluid Cylinder
3. Cap
4. Plug
5. Valve
Cold Weather Starting Aid

(Optional)
Figure 2

Page 4
OM-436
(3) Cold weather starting procedures are the same as for normal starting except:
(a) Activate Engine Starter button (27) and engine start switch (26) to crank engine.
(b) Follow normal starting procedures and CAUTIONS above steps (1) through (5), para.
2, B).
(c) In extremely cold weather it may be necessary to repeat steps (a) and (II) above.
WARNING: FIRE OR EXPLOSION CAN KILL OR INJURE! DO NOT FLOOD

THE ENGINE WITH STARTING FLUID. A SERIOUS EXPLOSION COULD
RESULT. USE STARTING AID ONLY FOR STARTING. DO NOT OPERATE
WHILE ENGINE IS RUNNING.
D. Preparation for Power Delivery (Normal Automatic Voltage Control)
The following power delivery preparation procedures are to be followed after the engine is started.
(1) Check and position switches and controls.
(a) Loosen fasteners (4, Fig. 7) and pull generator control tray outward. Place automatic-
manaual switch (31) in AUTOMATIC position. Close tray and secure.
(b) Loosen fastener (4) and pull protective relay tray outward. Place test-bank switch
(32) in AIRCRAFT position, if the aircraft being serviced is equipped with a 28.5-VDC inter-
lock relay system. (/f not, place in TEST BANK position.) Slide tray in and secure.
(c) Meter switch (6) may be in any position except pointing straight DOWN.
(2) Connect output cable plug connector to aircraft receptacle. Ensure connectors are mated
fully and securely.
E. Power Delivery (Automatic Voltage Control)
(1) Place generator mode control switch (77, Fig, 7) in BUILD-UP-VOLTAGE position momentari-
ly then allow it to position itself in GEN position. The electric governor will immediately increase
engine speed to 2000 RPM and maintain it.
(2) Observe generator instruments. Frequency meter (7, Fig. 7) should indicate exactly 400-Hz;
voltmeter (3) should indicate 115 VAC when line switch (7) is in LINE-TO-NEUTRAL position.
(3) The final step in delivering power is closing the load contactor.When satisfactory frequency
and voltage values are indicated by the instruments, close the load contactor by momentarily plac-
ing the load contactor control switch (27) in the top (spring-loaded) ON position. The green in-
dicating light (23) should glow at once to indicate that the load contactor is closed and power is
available at the aircraft. As soon as the light glows, release the switch. It will automatically return
to the center ON position.
NOTE: If the indicating light (23) should go-out as soon as the switch is released, and no fault
lights are ON, it indicates that 28.5-VDC holding current is not being supplied from aircraft to the
plug-interlock relay. Correct the condition and again operate the load contactor control switch (2 1)
as above.
(4) It is recommended that the operator check output voltage and current in each of the three
phases early in the power delivery run.Use the meter switch (6) to select the phase. Use the line
switch (7) to select line-to-line or line-to-neutral voltage. If the load is changing, it is good operat-
ing practice to observe the instruments until load conditions stabilize.
Aug 31189 1-3

Page 5
Ohi-436
(5) The load contactor will automatically open when a condition of over or undervoltage, over or
under frequency, or overload exists in the output circuit. The applicable indicating light will signal
the operator which fault caused the protective monitor system to operate. Reset switch (9) after
the fault has been corrected. The indicator light will turn off, and the protective relay system will
reset. Proceed with power delivery by operating the load contactor switch.
F. Preparation for Power Delivery (Manual Voltage Control)
Preparation for power delivery using manual voltage is exactly the same as for automatic control
[Para. 2, B, (1) thru (2) above] except:
(1) Place automatic-manual switch (37) in MANUAL position.

(2) Set the manual voltage control rheostat (30) near its mid-range position.
G. Power Delivery (Manual Voltage Control)
Power deliver using manual voltage control is the same as automatic delivery [para. E, (7) thru (5)
above] except:
(1) Control generator output voltage by adjusting the rheostat (30, Fig, 7) to maintain a steady
115VAC reading on the voltmeter (3). Turn the rheostat (30) knob CLOCKWISE to INCREASE
voltage and COUNTERCLOCKWISE to DECREASE voltage.
(2) Adjust voltage to 115 VAC.
(3) During manual power delivery the operator must remain with the generator set to adjust out-
put voltage for varying loads and conditions.
H. Discontinue Power Delivery
(1) Place the load contactor switch (27) in OFF position. Green light (23) should go OFF imme-
diately to indicate that the load contactor has opened and power is no longer being delivered to
the aircraft.
(2) Place engine-generator control switch (21) in IDLE position.
(3) Disconnect output cable from aircraft.
WARNING: HIGH VOLTAGE! ELECTRIC SHOCK OR FIRE CAN KILL!

NEVER DISCONNECT THE OUTPUT CABLE WHILE POWER IS BEING
DELIVERED.
J. Stopping the Engine
(1) Allow the engine to idle a few minutes before stopping to permit cooling.
(2) To stop the engine, move switch to stop position (26).
1-3 Aug 31189

Page 6
OM-436
3. Transformer-Rectifier Operation
Tranformer-Rectifier operating instructions are contained in their respective manuals, however, some
generator set instructions are required here.
A. Direct Current Power Delivery
NOTE: If the customeradds a Tranformer-Rectifier to a standard machine which was NOTequipped

with a T-R when it left the factory, he must remove the jumper lead which will be found on the small
terminal strip in the generator set voltage regulator (see l- 1; 19, Fig. 12). If your generator set has
a factory installed T-R, the jumper will have been removed.
(1) When delivering power from only one T-R (28.5-V, 35-V, OR 772-VDC) prepare the generator
set for DC power delivery the same as for AC delivery, except do not connect AC output cable and
do not close AC load contactor.
(2) For T-R operating instructions:
See OM-433 for 28.5 V DC T-R Operating Instructions
See TM-598 for 112-V DC T-R Operating Instructions
B. Simultaneous Operation of 28.5-V T-Rs
Two 28.5 V T-Rs may be operated at the same time without special precautions. Prepare the gen-
erator set for power delivery in accordance with Para. 2, D. above. Operate each T-R according to
Instructions in applicable TM.
NOTE: It is NORMAL for T-R output to become SLIGHTLY unstable indicated by blinking contactor
light on either T-R) when operating with current limiting. When output is unstable, observe DC
voltmeter. Fluctuation of one or two volts is normal.
If fluctuation is violent (several volts), adjust voltage regulator RATE potentiometer to correct.
C. Simultaneous 28.5-V DC and 115-V AC Power Delivery
If both 28.5-V DC and 115-V AC must be delivered at the same time, the following rules and
precautions must be observed.
(1) Place T-R current limiting switch in OFF position. This will eliminate the soft start feature of
the T-R, but will prevent AC voltage from dropping low enough to trip the AC load contactor.
(2) Line-drop compensation on the T-R must be REDUCED or TURNED DOWN completely to
prevent opening of the AC load contactor by an overvoltage condition. Readjust T-R line-drop
compensation so that AC voltage (as indicated by the generator set voltmeter) does not exceed
118-V AC when the DC load is 500 Amperes. If higher DC voltage is needed, adjust T-R line-drop
compensation as required. Observe AC voltage while making this adjustment to be certain that it
does not go TOO HIGH with DC load.
(3) During simultaneous, continuous operation, loads on either circuit are limited only by the
capacities of their respective circuits, however, the combined loads should not exceed the rated
capacity of the generator set (90 kVA or 72 KW).
D. Simultaneous 112-V DC and 115-V AC Power Delivery
Since 112-V T-Rs dont have line-drop compensation capability, no special adjustment to the T-R
will be required. Combined loads should not exceed the rated capacity of the generator set (90
kVA or 72 KW).
Aug 31189 l-3

Page 7
4. Test Box Operation
The test box is useful and convenient in testing the generator set after repair or overhaul and also in
troubleshooting. To operate the test box, proceed as follows:
A. Open left, front canopy doors and connect the test box plug connector (see 7-7; 3, Figure 74) to
the test receptacle connector (Fig. 4).
B. Connect the test probes of a voltmeter of the test jacks (3 and 4, Fig.3). Test jacks are color
coded. Red indicates POSITIVE. BLACK indicates NEGATIVE.
C. Locate the component or circuit to be tested in the DESCRIPTION column on the instruction plate
and set the selector switch (I, Fig. 3) to the number indicated opposite the description.
D. Note the normal voltage value and kind of current (AC or DC) to be expected at the position and
set voltmeter accordingly.
E. Comply with conditions indicated in CONDITIONS column for the particular test being performed.
F. Press the pushbutton switch (2, Fig, 3) and observe voltage indicated by the voltmeter. Compare
to normal voltage indicated in VOLTAGE column.
G. Release pushbutton switch.
H. Repeat steps A thru G for other tests as required.
J. When tests are completed, disconnect the test equipment and close canopy doors.
1. Selector Switch
2. Pushbutton Switch
3. Positive Test Jack (Red)
4. Negative Test Jack (Black)
5. Instruction Plate
Test Box Operating Controls
Figure 3
l-3 Aug 31189

Page 8
OM-436
Test Receptacle Connector

(with protective cap)
Figure 4
5. No. 2 Output Operation
When a machine is equipped with a second output option, each output may be operated inde-
pendently of the other. Each output has the same rating as the generator when operated alone; how-
ever, when operated simultaneously, the total load of both circuits should not exceed the rated
capacity of the generator.
A. Power Delivery
Output No. 2 on the dual output machines is operated in the same manner as output No. 1 (see
para. 2. E) using the duplicate contactor switch shown in Figure 5. When the No. 2 cdntactor is
closed, the contactor CLOSED light beside that switch will glow green.
NOTE: Make sure that No. 2 TEST BANK switch (7- 1; Fig. 18) is positioned properly (see para. 2. D.
(1) (b) for proper position).
B. Discontinue Power Delivery
To open the load contactor in the No. 2 output circuit, place the No. 2 contactor switch (Fig. 5) in
OFF position. The indicator light beside the switch will go out.
For engine shudown procedures, refer to para.2, J.
May 18/90 Revised 1-3

Page 9
OM-436

Figure 5
1-3 Aug 31189

Page 10
I_ ..:.-. _ - ._ - , > _ i
-. .
CM-436
CHAPTER 2. SERVICING
SECTION 1. MAINTENANCE
1. General
To ensure the generator set is ready for operation at all times, inspect and maintain it regularly and sys-
tematically. Locate and correct problems before they result in serious damage or failure of the equip-
ment.
WARNING: ELECTRIC SHOCK, FLYING PARTS, OR FIRE CAN KILL OR

INJURE! STOP OPERATION IMMEDIATELY IF A SERIOUS OR POSSIBLE
DANGEROUS PROBLEM EXISTS.
2. Inspection
A periodic inspection schedule should be established and maintained. A suggested inspection/check

schedule is provided in Section 2-2, Figure 1. However, it may be modified as required to meet vary-
ing operating and environmental conditions.
3. Lubrication
A. General
Lubricating the equipment is one of the most important steps in good maintenance procedures.
Proper lubrication is the use of correct lubricants and adherence to a proper time schedule.
Lubrication points, frequency, and recommended lubricants are indicated in Fig. 1.
B. AC Generator
The 400-Hz generator requires NO lubrication. The rotor is supported by two ball bearing as-
semblies which are lubricated and sealed at the factory for lifetime, maintenance-free operation. It
is suggested that generator bearings be checked after 5000 hours of operation.
C. Generator Controls
Generator controls and instruments require no scheduled periodic lubrication. A few drops of oil
may be required on door hinges occasionally to insure free and quiet operation.
D. Trailer
The trailer illustrated as Figure 2 is a standard four-wheel trailer. For 5th-wheel type trailers used
on some of the generator sets covered by this manual, refer to TO-1 80 in Chapter 5.
On either four-wheel or 5th wheel trailers, most lubrication points, such as spring shackle bolts, tie
rod ends, etc. are equipped with high-pressure lubrication fittings.
May 18/90 Revised 2-l

Page 1
OM-436
I
l Check w Clean A Change
I Maintenance point
iSeepage
I ,^I.
Maintenance point
ours I
91 93 94 See page
A l l Job
i ---
Maintenance point
I! ~%er~l Maintenance point
100 101 See page

A Inh
Lubrication & Maintenance Chart

Figure 1
E. Engine
The engine and its accessories require a major portion of the generator set lubrication and main-
tenance. The following recommendations are taken from the engine manufacturers operation
manual.
l (1) Lubrication schedule
Time schedules indicated on the Lubrication Chart, Fig. 1, are approximate. They are
based on average operating conditions. It may be necessary to lubricate more frequently
under severe operating conditions such as: low engine temperatures, excessively heavy
loads, and high oil temperatures, or intermittent operation. However, time intervals should
not exceed those indicated in the chart without careful evaluation.
2-l Aug 31189

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OM-436
l (2) Oil specification
Oil recommended by the engine manufacturer is identified by a military specification

number, MIL-L-2104B. Because of the substantial increase in additive concentration in
some MIL-L-21048 oils to meet service MS requirements, recommended oil is qualified
still further by the following limitations.
(a) Zinc: between a minimum of 0.07 and a maximum of 0.10 percent by weight.
(b) Sulfated ash: (ASTM D-874) of 1.OOpercent maximum by weight, (except lubricants
that contain only barium detergent-dispersants where 1.50 percent by weight is allowed).
NOTE: Diesel lubricating oil specifications are discussed further in the Deutz Diesel, Operators
Manual.
0 (3) Oil viscosity
The viscosity of the oil being greatly influenced by the ambient temperature, the choice of
the SAE grade should be governed by the ambient temperature at engine site. (See page
86 of Deutz Operation Manual). If temperatures temporarily fall below the limit of the SAE-
grade selected, this will merely affect the starting performance but cause no engine
damage. Since too viscous an oil causes starting difficulties, the choice of the viscosity
grade during winter operation should be governed by the ambient temperature prevailing
at the time of starting the engine. Oil changes as a function of ambient temperatures can
be avoided by using multigrade oils.
MIL-G-10924B
Trailer Lubricants
SYMBOL TIME INTERVAL
D Daily 7 hours
W Weekly, or 50 hours
BW Bi-weekly, or 100 hours
M Monthly, or 200 hours
SA Semi-annually, or 1200 hours
A Annually, or 2400 hours
Lubrication Chart Symbols and Time Intervals
Aug 31169 2-l

Page 3
Brake Linkage M2 Ml Drawbar
Ml .Tierod
Tie Rod Ml Ml Shackle,
Wheel Bearings A3 Ml Tie rod
A3 Wheel Bearings
Ml King Pin
Ml Shackle
I \ Ml Pivot Pin
Wheel Bearings A3
A3 Wheel Bearings
Break Linkage M2
-Ml Shackle
Shackle Ml w
[ps
Lubrication Chart
Figure 2
2-1 Aug 31189

Page 4
OM-436
l (4) Change engine oil
The following oil change recommendations are taken from Duetz Diesel Operators
Manual.
Imoortant: Should the engine run less than the hours stated in the following table, the oil
must be changed in any case once a year.
Engine Application Category Oil Change Intervals

of oil (running hours)
stressing
Oil Grade Oil Grade
API:CC/SE APJ:CD/SE
Tractors, Lift trucks A 250 500

Cranes, Construction Mach.
Rail traction units, Ships
Base-load gensets, Pumps
Farm Equipment (Seasonal) B 125 250

Undergroud Mining,
Road Sweepers, Winter
service, Emergency
gensets, Emergency Pumps
Important: The above intervals are based on the use of diesel fuel containing max. 0.5%
b. w. of sulphur and Central European or similar climatic conditions. Periods should be
cut by half for each of the following heavy duty factors:
- Diesel fuel with more than 0.5% b.w. of sulphur.
- Permanent ambient temperatures above + 30 C or below - 10 C.
The generator set is equipped with an hourmeter to record actual engine operating time.
The ideal time to change oil is soon after a power delivery run, when the engine is at
operating temperature.
NOTE: If lubricating oil is drained immediately after the unit has been run for some time, most of the
sediment will be in suspension and will drain readily.
CAUTION: DO NOT USE SOLVENTS AS FLUSHING OILS IN RUNNING ENGINES.

Change the oil filter element each time the oil is changed.
Change oil as follows:
(a) Remove bolted oil drain cover on bottom of air duct.
(b) Provide a container for catching used oil. Capacity should be greater than 17 quarts.
(c) Remove drain plug located in oil pan.
(d) While oil is draining, proceed to change the oil filter element.See Para. 3, D, (5) below,
for instructions.
(e) Clean the drain plug and install securely when engine oil has drained.
Aug 31189 2-l

Page 5
CAUTION: WHEN REFILLING CRANKCASE, TO AVOID POSSIBLE FUTURE ENGINE DAMAGE,
ALWAYS USE CLEAN OIL CONTAINER AND FUNNEL.
(f) Remove oil filter cap (Sect. I-7, Fig. 4) and refill the crankcase with new, clean oil
which meets engine manufacturers recommendations. [See Para. 3, 0, (2)] above, or
Deutz Diesel Operators Manual). See Fig. 3 below for engine oil capacities.
Oil capacity (Including filter) 17 Quarts (16 Liters)

Oil capacity (Without filter) 15 Quarts (74 Liters)
Oil Capacities
Figure 3
(g) Install filler cap and check oil level on gage rod (Sect. I-7 Fig. 4). The gage rod
should indicate over FULL mark.
l (5) Change oil filter element
(a) Provide a container for catching used oil if the vessel used for draining the crankcase
is not sufficiently wide to serve both operations.
(b) Release cartridge (7,Fig. 3) with a wrench and screw off by hand.
(c) Clean sealing surface (3).
(d) After slightly oiling the rubber gasket (2), screw new cartridge in place by hand until
gasket is evenly seated. Give the cartridge a final half turn.
(e) After the oil change is complete and the filter replaced, start the engine and check the
shell-to-gasket joint for possible oil leaks.
1. Cartridge
2. Gasket
3. Sealing surface
4. Filter Element
Main Cartridge Oil Filter

Figure 4
2-1 Aug 31169

Page 6
F. Engine Accessories
See Figure 1 for identification of engine and accessories lubrication points, intervals, and
lubricants.
0 (1) Starter
The starting motor is lubricated at assembly and should be re-lubricated only when the
starter is removed from the engine or when disassembled.
Remove pipe plugs on outside of motor and apply a few drops of light engine oil to the oil
wicks.
4. Air Cleaner Service
The air cleaner is a dry type with replaceable filter cartridges. A definite time schedule for changing
the filter cartridge cannot be determined because of varying operating conditions. Change, the filter
cartridge when the green indicator flag reaches the top of the viewing chamber and locks in that posi-
tion. Change the cartridge as follows:
A. Cartridge Removal (See Fig, 4)
(1) Remove air cleaner access panel from rear of unit.

(2) Remove clamp assembly (2) from air cleaner.
(3) Remove baffle assembly (3).
(4) Remove primary element (4), and replace with new element.
CAUTION: DO NOT CLEAN OR RE-USE CARTRIDGE.
(5) Inspect the interior of the cleaner housing (7). Make certain it is free from all foreign material.
B. Cartridge Installation (See Fig, 4)
(1) Carefully install the new cartridge into the housing. Avoid bumping the cartridge tubes
against the housing sealing flange. Seat the cartridge properly within the housing. Press all edges
and corners of the cartridge firmly with fingers to effect a positive air seal against the sealing
flange of the housing.
CAUTION: UNDER NO CIRCUMSTANCES SHOULD THE CARTRIDGE BE POUNDED OR
STRUCK IN THE CENTER TO EFFECT A SEAL.
(2) Lock the cartridge in place by installing the baffle assembly (3) and clamp assembly (2) with
cup assembly (7) in place. Tighten clamp (2) down in place.
5. Engine Fuel
A. Quality
The quality of fuel oil used in the diesel engine is a major factor in long engine life and perfor-
mance. Fuel oil must be clean, completely distilled, stable, and non-corrosive. Only distillate fuel
No. 1d is recommended for use both summer and winter.
CAUTION: CONSULT THE FUEL OIL SELECTING CHART IN THE ENGINE OPERATORS
MANUAL BEFORE SUBSTITUTING ANOTHER GRADE OF FUEL.
Aug 31189 2-l

Page 7
OM-436
1 2 3 4 5 6 7
1. Cup Assembly 5. Safety Element

2. Clamp Assembly 6. 0 Ring
3. Raffle Assembly 7. Body Assembly
4. Primary Element 8. Nut Assy RrWasher Gasket
Air Cleaner Components
Figure 5
6. Generator Maintenance
The 400-Hz generator requires no maintenance or service other than periodic cleaning. The unit is
brushless, and bearings are permanently lubricated and sealed.
A. Cleaning
The generator may be cleaned by careful use of compressed air and/or a good, SAFE commercial
cleaner. Steam cleaning of the generator is not recommended because steam and harsh chemi-
cal compounds may damage insulation and other generator components.
WARNING: ELECTRIC SHOCK AND FIRE CAN KILL OR INJURE! BE SURE

THE UNIT IS COMPLETELY DRY BEFORE OPERATING. DO NOT USE A
FLAMMABLE SOLVENT. I
B. Adjustment
The generator itself requires no adjustment. Adjustment procedures for generator controls are
covered in Section 2-3.
2-1 Aug 31/89

Page 8
CM-436
7. Drive Belts
To check V-belts, it is necessary to remove rear access panel cover on left side of canopy. The engine
cooling fan is driven by a matched set of V-belts. The 12 V-DC alternator is driven by a single V-belt.
A. Fan Belts
No adjustment is necessary for fan belts. Proper tension is maintained on these belts by the idler
pulley (Section l-l, Item IO, Fig. 4).
B. Check Belt Tension
Check tension by pressing the thumb (Fig. 6) midway between the pulleys. Maximum allowable
inward deflection of this belt is 15mm (0.6 in.)
I -a 1Smm I
Checking Alternator Belt Tension

Figure 6
C. Adjusting Alternator Belt Tension
See Fig. 7. Slacken hex-bolts (items I, 2, and 3). Pull alternator (4) in direction A until correct
belt tension is obtained. Then securely re-tighten hex bolts, 1, 2, and 3.
D. Belt Replacement
Replace V-belts according to instructions in Deutz Diesel Instruction Manual in Chapter 6.
Aug 37189 2-7

Page 9
Adjusting Alternator Belt Tension
Figure 7
8. Service Helps
A. Wiring
Wiring leads are covered with a flexible conduit for protection and easy removal and replacement.
All wire leads are color coded.
B. Control Box Trays
Control box trays may be removed easily and moved to a work bench for service or replacement
of parts.
l (7) Tray removal
(a) Loosen screw-lock fastener (2, Fig. 8)

(b) Slide tray outward and disconnect Amphenol Connector (3).
(c) Support tray at each side of tray near latches (7). Unlock latches (I) by pressing
down with thumbs, then slide tray out of box.
l (2) Tray installation
(a) Use both hands to support tray as in removal above.

(b) Align rails (4) with tracks (5) and slide tray into box. Latches will lock automatically.
(c) Connect Amphenol Connector (3).
2-7 Aug 37189

Page 70
OM-436
1. Latch
2. Fastener
3. Connector
4. Rail
5. Track
Typical Tray Removal
Figure 8
C. Generator Exciter
Provisions have been made to allow removal of the generator exciter without disturbing or remov-
ing the complete generator.
0 (7) Preparation for exciter removal.
Remove front access panel to remove generator exciter.
l (2) Exciter removal:
Refer to TM-360 in Chapter 6 for exciter instructions.
l (3) Exciter installation:
(a) Install exciter in accordance with TM-360.

(b) Reinstall front access panel.
D. Engine Control Panel
The engine control panel is designed and mounted so that it may be released and tilted outward
for access to components on the back side (see Fig. 7).
l (7) Tilt out engine control panel
(a) Remove clamp screw which supports wire conduit above output terminal panel.
(b) Remove two cap screws which attach engine control panel to frame of control box.
(c) Maneuver panel to tilt it inward at the bottom and outward at the top.
Aug 37189 2-7

Page 77
OM-436
0 (2) Reinstall engine control panel
(a) Maneuver panel into position and align mounting holes. Install mounting screws and
secure.
(b) Secure wire conduit in its original position with clamp and screw.
,ENGINECONTROL
PANEL
Engine Control Panel in Tilt-Out Position

Figure 9
9. Transformer-Rectifier Maintenance
Though transformer-rectifiers should be periodically inspected, they require no scheduled main-

tenance and should operate for long periods of time without servicing. When servicing is required, it
will usually be limited to replacement of lamps and fuses.
2-7 Aug 37169

Page 72
SECTION 2. INSPECTION / CHECK
1. General
This section describes inspections and checks to be performed in accordance with inspection/checks
schedule, Figure 7.
2. Engine
A. Fuel (See Fig. 1 for time schedules)
(7) Check fuel quantity DAILY
(2) Drain fuel filters in accordance with 2-1; Para. 5.
(3) Change fuel filter elements in accordance with 2-1, Para. 5.

(4) Drain fuel tank of water and sediment every 500 hours.
B. Lubrication
(7) Check crankcase oil level DAILY.

(2) Lubricate in accordance with Lubrication Chart (Ref. 2-7; Fig. I).
C. V-Belts
inspect V-belts for proper tension and adjust if necessary after each 200 hours of operation. (See
2-l; para. 7, A, B, & C).
D. Exhaust System
(7) Visually inspect muffler and exhaust pipes for signs of approaching failure.
(2) Inspect for gasket or joint leaks.
(3) Replace any defective parts at once.
IWARNING: EXHAUST FUMES OR FIRE CAN KILL OR INJURE!

ATELY REPAIR DEFECTIVE EXHAUST SYSTEMS.
IMMEDI-
I
3. Electrical System (12-V DC)
A. Lights
Inspect all lights for proper operation DAILY. Replace any defective lamps (bulbs) as soon as dis-
covered. Figure 2 lists ALL lamps, their location, and part numbers.
B. Fuses
Inspect and replace fuses as required. See Figure 3 for fuse sizes and locations. Figure 3 in-
cludes all fuses used in both the engine and generator electrical systems.
Aug 37/89 2-2

Page 7
OM-436
Bi- Bi-
Daily Weekly Weekly Monthly Monthly 6 MO.
or or or or
AR 8 Hrs. 50 Hrs. 100 Hrs. ior0 Hrs. 400 Hrs. y:OO Hrs.
ENGINE
Check fuel quantity X

Check crankcase oil level X
Check coolant level X
Change engine oil filter
element X
Change engine oil X
Replace air cleaner cartridge X
Inspect cooling system hoses,
tubes, fittings & clamps X
Check V-belt tension X
Drain/refill cooling system TWICE ANNUALLY
Change fuel filter elements X
Lubricate SEE LUBRICATION CHART
Check exhaust system I X
Open fuel tank drain EVERY 500 HRS.
ELECTRICAL
Check all lights X

Clean battery terminals X
Check wiring X
Check connections X
400 Hz GENERATING AND CONTROL SYSTEM
Check output cable &

connector X
Check voltmeter X
Check ammeter X
Check frequency meter X
Check all lights X
Check protective relays X
Check safety switches X
Inspect all wiring &
connections X
Clean & inspect generally X
Inspection/Check/Maintenance Schedule
Figure 1
2-2 Aug 31189

Page 2
OM-436
LIGHT LAMP LAMP

IDENTIFICATION LOCATION MANUFACTURER NUMBER
Instrument Panel Control Box Lamp Industry 63

Lights Trade No.
Engine ON Indicating Engine Control Lamp Industry 1815

Light Panel Trade No.
.
Contactor CLOSED Engine Control Lamp Industry 1815
Indicating Light Panel Trade No.
Fault Indicating Protective Relay Lamp Industry 1815

Lights Tray Trade No.
Clearance Lights Canopy Lamp Industry 37

Trade No.
Lamp Identification Chart

Figure 2
C. Wiring and Connections
(1) Inspect all cables and leads for broken, worn, and damaged insulation.
(2) Check for loose connections and tighten.
NOTE: A darkened terminal generally indicates a loose connection.
4. Electrical System (115-V AC)
The 400-Hz generator and controls are designed to be as maintenance free as possible. No lubrica-
tion or periodic maintenance adjustments are required. However, some regular checks should be
made to be sure all controls, instruments, etc., are working properly.
A. Monitoring Instruments
Observe operation of voltmeter, ammeter, and frequency meter each time the unit is started.
B. Indicating Lights
Check lamps (bolbs) in all of the indicating lights of each start up. Fault indicating lights in the
protective relay tray may be tested by pressing test switch (7-7, 8, Fig. 9).
C. Protective Modules
Check operation of all protective modules to ensure they will function if a fault should occur in the
output circuit. (see 2-3; Para. 3, B).
D. Wiring Connections
(1) Check all cables, leads, and wiring for broken, worn and damaged insulation.
(2) Inspect connections for tightness.
Aug 31189 2-2

Page 3
OM-436
ITEM PROTECTED LOCATION ILLUSTRATION SIZE & TYPE
Instrument panel Engine control Sect. l-l, Fig. 11, 15A Type AGC
lights & engine item 15
panel circuit
Protective relay Protective relay Sect. 1-1, Fig.lO, 2A Type AGC

system tray item 17
Voltage regulator Voltage regulator Sect. l-l, Fig. 12, 5A Type AGC
tray item 12
Load contactor Protective relay Sect. l-l, Fig. 10, 2A Type AGC
circuit tray item 16
Fuse Identification Chart

Figure 3
WARNING: HIGH VOLTAGE: ELECTRIC SHOCK CAN KILL! STOP OPERA-

TIONS AND STOP ENGINE BEFORE TOUCHING EXPOSED CONDUCTORS
OR TERMINALS.
(3) Check the output cable plug connector for damaged contactors in the end of the plug.
5. Inspection of Transformer-Rectifiers
A periodic inspection schedule should be established and maintained for T-Rs. Inspections should be
scheduled to coincide with similar inspections for the generator set. Inspect as follows:
A. Open front control panel and rear access panel. Remove top cover.
WARNING: BE SURE NOT INPUT POWER CAN REACH THE T-R. LETHAL
ELECTRICAL SHOCK HAZARD EXISTS.
B. Inspect leads and cables for deteriorated or damaged insulation.
C. Check all accessible terminals and connectors for security.
D. Visually inspect all components, terminals, etc., for discoloration and evidence of overheating
caused by loose connections, etc.
E. Check both fuses located on control panel.
F. Use dry, compressed air to clean the interior of the T-R each time it is inspected.
2-2 Aug 31189

Page 4
OM-436
SECTION 3. ADJUSTMENT/TEST
1. General
These adjustment and test procedures are applicable to testing and adjusting the generator set
after major repair, major parts replacement, or overhaul.
2. Generator Set Test
A. Pre-operation Test Procedures
(1) Connect cables from the generator output terminals to a load bank. Use cables of the same
size and length as those to be used in service. Be sure the generator output N cable is
grounded.
(2) Check engine oil level. Oil should be at FULL mark on gage rod.
(3) Check tension of fan and generator V-belts. (See Section 2-7, Figure 5 and 6).
(4) If governor throttle linkage was changed, check all linkage to make certain engine speed may
be controlled when started. See Figure 15.
(5) Inspect for oil and fuel leaks.
(6) If the setting of the voltage regulator rheostat (37, Fig. 7) has been changed, set at CENTER
position (halfway between full clockwise position and full counterclockwise position.)
(7) Check engine circuit fuse (47, F/g. 7) by placing panel light switch (37) in ON position. If
panel lights (2) operate, the fuse (41) switch (31) and lamps are good.
(6) Check fault indicating lights (70) by pressing test switch (8). If lights glow, fuse (47) and in-
dicating lamps are good.
(9) Make a general inspection of all wiring, and terminals. Inspect the equipment to be certain no
damage will result from starting the engine.
(10) At initial start-up after generator overhaul or repair, flash the exciter field momentarily with
12-V DC to the field windings as follows:
CAUTION: ENGINE MUST NOT BE RUNNING WHEN FIELD FLASHING TO PREVENTVOLTAGE
REGULATOR DAMAGE.
l (a) Flashing exciter field using test box.
If a test box (see Sect. 7-3, F/g, 3) is available, connect it to receptacle connector (Sect. l-
3, Fig. 4).
(aa) Rotate the selector knob (Sect. 7-3, Fig. 3, /tern 7) to position 8.
(bb) Use two jumper leads, each equipped with an alligator clip and a test prod, to con-
nect 12 V DC power to test jacks (2 and 3) on the box. Connect positive jumper from
input terminal on starter solenoid (2, F/g. 2) to red test jack. Connect negative lead from
starter ground terminal (3, F/g. 2) to black test jack.
(cc) Momentarily pressing pushbutton switch (Sect. 7-3, Fig. 3, item 2) will flash the ex-
citer field.
(dd) Disconnect jumper leads.
Aug 31189 2-3

Page 1
OM-436
CONTROL BOX
ENGINE CONTROL PANEL

3. Voltmeter lg. Hourmeter (Engine)
11. Load Contactor Circuits Fuse (2A) 26. Switch, Engine Start
12. Protective System Fuse (2A) 27. Engine Start, Pushbutton

OM-436
\
35
\
36
\I
37
GENERATOR CONTROL TRAY
VOLTAGE REGULATOR
33 34
PROTECTIVE RELAY TRAY
30. Manual Voltage Control Rheostat 35. Automatic Voltage Control Rheostat*
Control Switch 37. Cable Size Compensation Rheostat*
33. Light Test Switch On-Off Switch*
34. Reset Switch 39. Fuse (5-A)
:k (Voltage regulator No. 430391C controls illustrated)

Figure 1 (Sheet 2 of2)
Aug 31189 2-3

Page 3
OM-436
l (b) Flashing exciter field without test box.
Remove test receptacle cover (I-3; Fig. 3). Use two test leads equipped with a test prod
on one end and an alligator clip on the other. Insert the test prod of one lead in terminal
ID of the test receptacle and momentarily touch the other end (alligator clip) to the hot
terminal (4, Fig. 4) on the starter solenoid to flash the field.
CAUTION: FLASHING THE FIELD IN A REVERSE DIRECTION COULD CAUSE DAMAGE TO
VOLTAGE REGULATOR DIODES.
(11) Check position of load contactor on-off switch (27 Fig. I), and generator control mode
switch (77).
(a) Load contactor switch (27) must be in OFF position.
(b) Generator mode control switch (77) must be in IDLE position.
1. Starter Connection to Solenoid 4. Positive Battery Cable

2. Solenoid 5. Starter Solenoid Switch
3. Negative Battery Cable Connection 6. Starter
Starter and Solenoid Switch
Figure 2
2-3 Aug 31189

Page 4
Test Receptacle Connector
Terminals Identification
Figure 3
B. Operational Test Procedures
(1) Start the engine in accordance with instructions in 1-3; Para 2,A thru C.
(2) Check operation of engine instruments; DC ammeter (19, Fig. 7), Oil pressure gage (76), and
hourmeter (78).
(3) Check engine idle speed. It should read 650 to 700 RPM. Adjust, if necessary, in accordance
with instructions in Engine Operators manual.
NOTE: A stroboscope is required for this check.
(4) Check for oil and fuel leaks, and correct any leaking conditions.
(5) Position switches and controls for automatic voltage regulation and power delivery as follows:
(a) Place automatic-manual switch (37, Fig. 7) in AUTOMATIC position.
(b) Place test-bank switch (32) in AIRCRAFT position.
(c) Meter switch (6) may be in any position except pointing straight down.
(d) If the adjustment of the voltage regulator rheostat (35) has been altered, position the
knob to mid-range position.
(6) Bring the engine up to governed speed, and energize the generator by holding the generator
mode control switch (77, Fig. 7) in BUILD-UP-VOLTS position momentarily. Release switch and
allow it to position in center RUN position. The governor and excitation-deenergization relay cir-
cuits are functioning properly when engine comes up to governed speed [voltage value appears
on voltmeter (3, Fig. 7)].
(7) Observe the Frequency meter (7). If engine speed is properly adjusted, frequency will be ex-
actly 400 Hz. If not, adjust engine governed speed in accordance with Para. 4, E, (3) (d). See Fig.
12.
(8) Observe voltmeter (3). Use rheostat (35) to adjust voltage to 115 V AC.
(9) Measure governor actuator input signal. See Para. 4, E, (4), (a).
(10) Measure governor magnetic pickup signal, See Para. 4, E, (4), (b).
Aug 31189 2-3

Page 5
(11) Check high-speed limiting governor. Engine limiting speed governor should limit engine
speed to just below trip point of overspeed governor. Overspeed device should trip at 2400 RPM.
(12) Check adjustable voltage range in automatic operating mode.
(a) Observe voltmeter (3, Fig. 7) and turn rheostat (35) CLOCKWISE to full clockwise
position. Maximum voltage should be at least 134 V AC, or higher.
NOTE: If voltage should decrease when the knob is turned clockwise, it indicates that internal wiring
of the voltage regulator is incorrect. Replace the complete regulator tray assembly.
(b) Observe voltmeter and turn rheostat knob to full COUNTERCLOCKWISE position.
Minimum voltage should be 108 V AC, or lower.
(13) Observe voltmeter and adjust rheostat to obtain 115-V AC voltmeter reading.
(14) Check adjustable voltage range in manual operating mode.
(a) Open the generator control tray (75, Fig. I) and place the automatic manual switch
(31) in MANUAL position.
(b) Observe voltmeter (3) and turn manual control rheostat (30) CLOCKWISE to full
clockwise position. Maximum voltage should be 160 V AC.
(c) Observe voltmeter (3) and turn rheostat (30) to full COUNTERCLOCKWISE position.
Minimum voltage should be 95 V AC or less.
(d) Adjust voltage to 115 V AC, then return automanual switch to AUTOMATIC position.
(15) Position load bank switches, etc., to apply a light load to the generator.
(16) Place the load contactor on-off switch (27, Fig. I) in the top, spring loaded, CLOSE posi-
tion. Hold in this position momentarily. The indicating light (23) should glow GREEN and an
amperage value should appear on the DC ammeter (19).
(17) Release switch (27) and allow to return to center ON position. Load contactor should open
immediately, and generator on indicating light should go OFF. This indicates that the plug inter-
lock contacts are OPEN as they should be when the interlock coil is not receiving 28-V DC power.
(18) Open protective relay tray and place the test bank switch (32, Fig. 7) in TEST BANK position.
(19) Again place load contactor switch (27) in the top, CLOSE position. Light (23) should glow
GREEN and remain ON when the switch is released and allowed to return to the center ON posi-
tion. This indicates that the test bank switch (32) is functioning to by-pass the plug interlock relay.
(20) Return the test bank switch to AIRCRAFT position. The load contactor should open at once
and the green indicating light (23) should go off.
(21) Connect a source of 24-V DC power (two 72-volt batteries connected in series) to terminals
N and F (or YE>at the output terminal panel. Polarity connection should be: MINUS to ter-
minal N and PLUS to terminal E or F.
(22) With test-bank switch in AIRCRAFT position, hold the contactor operating switch (27) in top,
CLOSE position momentarily. The generator ON indicating light (23) should glow GREEN and
remain ON when the switch is released and allowed to return to the center ON position. This indi-
cates that the load contactor is closed and the plug interlock relay is functioning properly.
(23) Apply l/3 to i/2 load at the load bank and allow the unit to run for 15 to 30 minutes. Observe
operation of all monitoring instruments.
(24) Increase load bank resistance to apply a full load.
(25) Check operation of the governor by observing the frequency meter (7, Fig. 1) when gener-
ator is switched from no-load to full-load and vice versa frequency drop should be no more than 1
Hz. Adjust governor as necessary [(see Para. 4, f, (3)].
2-3 Aug 31189

Page 6
OM-436
(26) Follow instructions in Para. 4, B, (2), (b) to set voltage regulator line-drop compensation
potentiometers [(Ref. Figure 7, items (36) and (37)]. Set knob pointer on cable size potentiometer
(37) to size (2/O, 4/O, etc.) of cable being used. Set knob pointer on cable length potentiometer
(36) to length (20 feet, 40 feet, etc.) of cable being used. See instruction plate (mounted below
knobs).
(27) Check voltage regulator, at intervals, from no-load to full load, and on up to 125% load. Ob-
serve and note voltage at various loads. Voltages should vary no more than plus or minus 1%
from 115V.
(28) Check accuracy of voltmeter.
(a) Open generator control tray (75, Fig. 1).
(b) Connect a master voltmeter of known accuracy to terminals of the voltmeter (3).
(c) Compare unit voltmeter reading with master meter. Error must not exceed 4% of full
scale.
(29) Check accuracy of AC ammeter.
(a) Connect a master ammeter of known accuracy to the AC ammeter (4) terminals.
(b) Compare unit ammeter reading with master meter under various loads. Error must
not exceed 4% of full scale.
(30) Check operation of meter selector switch (6). A voltage value should be shown in each
switch position.
(31) Check operation of the line switch (7). A normal voltage of 115 V AC should be indicated
when the switch is in LINE-TO-NEUTRAL position. A voltage of approximately 200 V AC should
be indicated when the switch is placed in LINE-TO-LINE position.
(32) Check accuracy of frequency meter.
(a) Connect an accurate master frequency meter to the frequency meter (7) terminals.
(b) Compare meter readings. Error must not exceed 1% of full scale.
(33) Operate the unit for a full 10 minutes under full load. The overload device (Ref. 7-7; 7, Fig.
73) MUST NOT trip.
(34) Operate at 125% rated load for 5 minutes immediately following the full-load run. The over-
load device MUST trip within 5 minutes and the overload indicating light (70, Fig. 9) must come
ON to indicate an overload condition.
(35) Reduce load to normal. Turn off indicating light by pressing reset switch (7, Fig. 9).
(36) Check engine oil pressure and oil temperature at rated operating speed (2000 RPM). Oil
pressure gage should indicate at least 38 PSI when the engine is hot. Oil temperature gage
should indicate 190 F (88 C) 5 F (3 C) when engine is hot.
(37) Check operation of fuse interlock (Ref. 7-7; 2, Fig. 9). With unit operating normally under
load, remove protective relay circuit fuse (Ref. 77, Fig. 9). The load contactor should open immedi-
ately. This indicates that the fuse interlock relay is functioning properly. Replace fuse and apply
load.
NOTE : Perform all protective relay tests with the unit operating under load.
(38) Check operation of overvoltage relay and indicating light.

(a) With the unit operating at normal load, adjust the voltage regulator rheostat (37, F/g,
7) to increase voltage (clockwise), until the overvoltage sensing relay activates the protec-
tive monitor. This will open the load contactor and turn on the overvoltage indicating light.
The overvoltage sensing relay should trip when voltage reaches 130V to 134V.
Aug 31189 2-3

Page 7
OM-436
(b) Return unit to normal operating conditions by adjusting voltage regulator rheostat
and pressing reset switch (9).
(39) Check operation of undervoltage sensing relay, indicating light, and time delay. At some
value between 103 V and 93 V, the undervoltage sensing relay (Ref. I-7; 5, Fig. 9) should function
to activate the undervoltage time delay circuit. Five seconds after the time delay circuit is ac-
tivated, (if the undervoltage condition continues) it should function to open the protective monitor
relay. Which, in turn will open the load contactor to stop power delivery. As a result of the action,
the undervoltage indicating light (74) should be turned ON. A stopwatch or sweep-second hand
watch is required for this check. Proceed as follows:
(a) With unit operating at normal load, use the voltage regulator rheostat (37, Fig. 7) to
reduce voltage to 104V. The load contactor should NOT open after a 5-second delay.
(b) Reduce voltage in steps of 1-V, with a delay of at least 5 seconds between steps. Res-
tart stopwatch, or note position of sweep-second hand, each time voltage is reduced. At
some voltage value between 103 V and 93 V, and 4 to 12 seconds after a new voltage set-
ting is made, the load contactor should be step-by-step action of the undervoltage sens-
ing relay, time delay circuit, and protective monitor relay.
NOTE: The 4 to 72 second time delay is generally set at 5 seconds. It may be necessary to switch
to MANUAL control to obtain these low voltages.
(c) If the load contactor is not opened at 103 V to 93 V, it will be necessary to refer to the
Troubleshooting Chart, Section 3-1, to determine which component of the undetvoltage
protective circuit is defective. If the undervoltage circuit performs satisfactorily, return the
unit to normal operation by adjusting the voltage to 115 V, pressing the reset switch, and
closing the load contactor.
(40) Check under-frequency sensing relay, protective monitor, and indicating light. At some fre-
quency value from 385 Hz down to 375 Hz, (Hz = cycles-per-second) the under-frequency sensing
relay should function to signal the under-frequency circuit in the protective monitor module to
OPEN the load contactor holding circuit. To check the under-frequency protective components,
proceed as follows:
(a) While the unit is operating normally under load, reduce generating or output frequen-
cy by reducing engine speed. Use the governor speed setting potentiometer (Ref. Fig. 4).
Gradually turn adjusting screw COUNTERCLOCKWISE to reduce engine speed until fre-
quency meter indicates 386 Hz. Under-frequency protective relay should not function to
open the load contactor. Reduce frequency in steps of 1 Hz.
(b) If protective system functions to open load contactor and turn on the under-frequency
light after some frequency between 385 Hz and 375 Hz is reached, all components of the
system are functioning properly. If the load contactor is not opened within the above fre-
quency range, refer to Troubleshooting Chart to determine which component is defective.
(c) Return unit to normal operating condition.
(41) Check over-frequency sensing relay, protective monitor and indicating light. This protective
circuit operates exactly as the underfrequency circuit except the operating range is from 415 Hz to
425 Hz. Its purpose is to open the load contactor and turn on an indicating light.
(a) Check procedures are the same for overfrequency as for under-frequency (above) ex-
cept that engine speed is INCREASED to create a condition of overfrequency.
(b) If the over-frequency system functions to open load contactor and turn on over-frequen-
cy light after some frequency between 415 Hz and 425 Hz is reached, all components of
the system are functioning properly. If load contactor is not opened within the above fre-
quency range, refer to Troubleshooting Chart to determine which component is defective.
(42) If the generator is operating under load at this point, place the contactor control switch (29,
Fig. 7) in OFF position to open load contactor and disconnect load. There will be no further need
for the load bank in the following checks.
2-3 Aug 31189

Page 8
, ; __ ._
OM-436
(43) With the engine running at normal governor speed; check the entire unit for vibration and
parts which may have become loosened during the above checks. Tighten any loose attaching
hardware as required.
(44) Check 400-Hz generator bearings. Use a stethoscope or metal sounding rod to listen for un-
usual noises. If using a metal rod, place one end on the generator housing and hold the other end
near the ear. Hold the rod with three fingers and use the index finger and thumb to form a sound-
ing chamber between the rod and the ear. Do NOT allow the rod to touch the ear. Listen for
grinding or pounding sounds which would indicate a defective bearing. An engine noise may be
telegraphed to the generator and misinterpreted as a generator noise. If in doubt of bearing ser-
vice ability, send unit to be overhauled.
WARNING: ELECTRIC SHOCK, MOVING PARTS, AND NOISE CAN KILL OR

INJURE! IF A METAL SOUNDING ROD IS USED TO DETECT BEARING
NOISES. EXERCISE EXTREME CARE TO AVOID INJURY.
3. Generator Set Adjustment
A. Generator Adjustment
The 400 Hz generator is a brushless type requiring no adjustments of any kind.
B. Generator Control Adjustments
The following items may require adjustment of some time during life of the equipment.
l (1) Adjust manual voltage control, variable resistor.
The adjustment of this resistor (Ref. l-7; 7, Fig. 8) determines the maximum generator
output voltage obtainable when using the manual control rheostat for voltage control. To
adjust maximum voltage potential, proceed as follows:
(a) Loosen slider-band clamping screw.
(b) Move the slide-band toward the single wire end of the resistor to increase voltage
potential. Move the band towards the double wire end (fwo wires connected) to decrease
voltage potential.
(c) Tighten slider-band clamping screw.
l (2) Adjust 400-Hz voltage regulator
The voltage regulator used with this generator set may be either of two models, depend-
ing on the generator set specification. The older magnetic amplifier-type regulator il-
lustrated in this manual (Hobart Part No. 430397C) is covered by Hobart manual TM-759.
The newer solid state regulator (Hobart Part No. 489872) is covered by Hobart Manual
OM-2020. Both of these manuals are included in Chapter 6 of this manual. Make
adjustments according to instructions provided in the applicable manual. Refer to the
Deutz Diesel Operators Manual for instructions on how to make the following adjustments.
Aug 31189 2-3

Page 9
OM-436
C. Basic Engine Adjustments
Adjustment procedures applicable to the diesel engine are included in the Deutz Diesel Operators
Manual, which is located in Chapter 6. Specific information for this particular engine application is
listed in Figure 4.
l (1) Exhaust valve adjustment
l (2) Exhaust valve bridge adjuskent.
l (3) Fuel injector timing adjustment.
l (4) Idle speed, speed limiting, and overspeed adjustments.
Use instructions which apply to a single weight governor. Recommended idle speed for
this application is 650 to 700 RPM.
NOTE: A stroboscope is required for engine speed test.
The limiting speed governor should be set at a speed just below the overspeed governor
trip point, or approximately 2350-2400 RPM.
D. Alternator and fan belt adjustment
Refer to 2-1; Para. 8 for belt adjustment instructions.

NOTE: Replace fan belts with a matched set.
E. Electric Governor System Adjustment
The magnetic pickup and control box have critical adjustments which can affect engine perfor-
mance and generator output. Actuator-to-fuel control lever adjustment can also affect engine per-
formance.
WARNING: THE ENGINE SHOULD BE EQUIPPED WITH A SEPARATE

OVERSPEED (OVERTEMPERATURE, OR OVERPRESSURE) SHUTDOWN
DEVICE, TO PROTECT AGAINST RUNAWAY OR DAMAGE TO THE EN-
GINE, WITH POSSIBLE PERSONAL INJURY OR LOSS OF LIFESHOULD
THE MECHANICAL GOVERNOR, OR ELECTRIC CONTROL, ACTUATOR,
FUEL CONTROLS, DRIVING MECHANISM, LINKAGE, OR THE CONTROL-
LER .DEVICE FAILS.
When the complete system is to be checked, and /or adjusted, a definite sequence of procedures
should be followed:
First - Check or adjust actuator linkage.
Second - Check or adjust magnetic pickup.
Third - Check or adjust electric control box
2-3 Aug 31189

Page 10
OM-436
Engine Type &cylinder turbocharged four

cycle air-cooled diesel
direct injected
Bore/Stroke 4f4.9 in. (1021125 mnz)
Displacement 374 in. 3 (6.12 L)
Compression Ratio 15S:l
Maximum Output 160 HP @ 2800 RPM

DIN 6270 (118 Iov @ 2800 RPM)
Maximum Torque 3613 lb. ft. @ 1500 RPM

DIN 6270 (490 NM @ 1500 RPM)
-.____- _-
Min. Idling Speed 650-700 RPM
Specitlc Fuel 365 Ibs. HPh

Consumption at (215 glKwlt)
Max. Torque
Rotation Counterclockwise (view

toward flywheel)
Net Weight 1133 lhs. (515 Kg)
Engine Specifications
Figure 4
l (1) Actuator linkage adjustment
The proper adjustment of the mechanical linkage between the electric actuator and en-
gine speed control lever is important to the satisfactory operation of the complete system.
Exact adjustment instructions such as effective length of rod assembly (6, Fig. 5), or
which hole in actuator lever to attach ball joint (4) cannot be determined because of slight
variations in brackets, mountings, and engine performance characteristics. However,
definite rules must be followed in making the adjustment:
1. First, adjust linkage to use the FULL TRAVEL of actuator output shaft (2).
2. Second, make certain that linkage is adjusted such that it can move speed con-
trol lever (8) from FULL IDLE to FULL SPEED position, or VERY CLOSE to FULL
SPEED position to allow engine to pull 125% load.
Check and adjust linkage as follows, with engine stopped.
(a) Before making adjustment, observe and note which hole in actuator lever (3) is used
to mount ball joint (4). It does not necessarily have to be the same hole as shown in il-
lustration (Fig. 5), however, rod connection to fuel control lever (8) is always in the upper
hole (the hole nearest the fuel pump).
Aug 31189 2-3

Page 11
(b) Be sure levers (3 and 8) have not slipped on shafts. In IDLE position actuator lever
(3) should point forward and upward at an angle of 15 to 20 degrees. Speed control lever
(8) should point forward in a near horizontal position. If a lever has slipped, position cor-
rectly and tighten securely.
(c) Place both levers (3 and 8) in FULL IDLE position and attempt to connect ball joint (4)
at hole in lever (3) from which it was removed in step (a). If connection cannot be made,
loosen nuts, (5) and adjust effective length of rod so that connection may be made.
(d) Manually operate actuator lever back and forth between FULL IDLE and FULL SPEED
positions. Speed control lever (8) should be moved freely through its full range between
FULL IDLE AND FULL SPEED. If adjustment is unsatisfactory, try another hole mounting
in ACTUATOR lever and readjust rod length.
(e) Tighten all parts securely when adjustment is completed.
1. Actuator
FULL SPEED
POSITION 2. Actuator shaft
3. Speed control lever
IDLE 4. Ball joint, control end
P#STTrnti
- - - - -. 5. Nut
6. Rod
7. Ball joint, pump end
8. Fuel pump lever
9. Signal input connector
Governor Linkage
Adjustment
Figure 5
2-3 Aug 37189

Page 72
l (2) Magnetic pickup adjustment
The strength of the magnetic pickup signal to the control box can be weakened if the tip
of the pickup is too far from the flywheel ring gear. If the pickup is to be removed for any
reason, or if the signal is weak, as indicated by test [see Para. 4, E, (4), (b)].
(a) Disconnect pull-apart connector (7, Fig. 6).
(b) Loosen nut (3) and remove magnetic pick-up (2).
(c) Inspect to make certain the tip is not damaged from contact with the ring gear teeth
(replace pickup if damaged).
(d) Rotate the engine as required to locate a ring gear tooth directly below the tapped,
pickup mounting hole. An imaginary line should pass through the center of the mounting
hole, the center of a flywheel tooth and the center of the flywheel.
(e) Install the magnetic pickup and thread into the mounting hole until the tip touches the
in-line flywheel gear tooth.
CAUTION: THE PICKUP TIP MUST BE DIRECTLY OVER A TOOTH AND NOT BETWEEEjTEETH
WHEN ADJUSTMENT IS MADE.
(f) Back the pickup outward (COUNTERCLOCKWISE) l/2 turn. Hold the pickup securely
in this position and tighten nut (3). This adjustment will result in a clearance of ap-
proximately 0.028 inch between the pickup tip and the flywheel teeth and give an operat-
ing AC voltage of 4 V to 8 V at the control box terminals 5 and 6 when the engine is
running at no load and governed speed.
NOTE: As little as 1-V is required for operation of governor control box. Magnetic pickup voltage
does not W to be 4-V to 8-V.
u. /
2
1. Connector
2. Magnetic Pickup
3. Nut
Magnetic Pickup
Adjustment
Figure 6
Aug 37189 2-3

Page 73
OM-436
l (3) Governor Control Unit Adjustment
Before making an adjustment to the control unit (F/g. 7), make certain that linkage be-
tween actuator and fuel control lever (Fig. 5) is free and properly adjusted. There must
be no lost motion or play in the linkage. Be sure magnetic pickup is producing a strong,
normal output.
There are three adjustment controls on the unit (see F/g. 7). They are identified as:
RATED SPEED - Adjusts engine speed and generator frequency.
GAIN, and STABILITY - Adjust engine response time and stability.
To adjust control unit, proceed as follows:
(a) If the control box is being adjusted for the first time, set adjustment controls as fol-
lows:
RATED SPEED control - set the rated speed control screw 6 to 8 turns
counterclockwise. This causes the engine to run below 2000 RPM when started.,
NOTE: A very small screwdriver is required for this adjustment.
GAIN control - Adjust the gain control to its approximate midrange position.
STABILITY control - Adjust stability control to its full counterclockwise position.
(b) Start engine and allow it to warm.
(c) Place engine-generator control switch (78, Kg. 2) in GEN position to make electric
governor functional.
(d) Turn RATED SPEED adjusting screw (7, Fig. 7) clockwise to increase engine speed
to 2000 RPM. At 2000 RPM the frequency meter (7, Fig. 2) will indicate 400-Hz.
(e) Turn the GAIN control screw (3, Fig. 7) clockwise until the engine becomes unstable.
Then turn this control counterclockwise until the engine becomes just barely stable.
(f) Turn the STABILITY control screw (2, fig. 7) slightly clockwise.
(g) Repeat step (e) above, then repeat step (I).
(h) Continue this procedure until the engine is no longer stable. At this point, it is neces-
sary to set both the gain and stability controls back to the last position at which the engine
was stable. At this position, check to see if engine stability is set properly. Do this by
momentarily shorting terminals 3 and 4 on the control box. The engine will start to go to
idle and then return to operating speed, either stable or unstable. If the engine is still un-
stable, it may be necessary to turn either the gain control or the stability control slightly
counterclockwise until the engine is stable.
(j) The electric governor is now set. If the engine becomes unstable when load is ap-
plied, it may be necessary to turn either the gain control or the stability control slightly
more counterclockwise until the engine again becomes stable.
NOTE: The best setting of speed, gain, and stability controls is the setting at which the frequency
settles at 400-Hz as fast as possible when a load is applied, and remains stable when the load is
removed.
l (4) Magnetic pickup signal
Connect a high impedance voltmeter to magnetic pickup input terminals (5 and 6, Fig. 8)
on control box terminal board. The voltage value at governed speed, no load, should be
4-V AC MINIMUM.
2-3 Aug 37189

Page 74
NOTE: A signal as low as 1-V is sufficient to operate the control unit satisfactorily. No voltage
indicates the pickup is too far from flywheel teeth, or it is defective. For additional information, refer
to Woodward Governor Catalog No. 82493C in Chapter 6 of this manual.
1. Speed control
2. Stability control
3. Gain control
Electric Governor
Control Box
Figure, 7
12-V DC IDLE/RATE SPEED
Electric Governor
Connection Diagram
Figure 8
GOVERNOR- w u
ACTUATOR TO TEST
RECEPTACLE
MAGNETIC
PICK-UP
ilug 31189 2-3

Page 15
OM-436
4. Generator and Exciter Test
The generator fields may be tested with a Kelvin bridge. This is a double bridge type instrument re-
quired for the very low resistances encountered in this test. It is understood that 0 resistance indicates
a SHORT CIRCUIT condition. An infinite resistance reading indicates an OPEN CIRCUITED condi-
tion. See Fig. 9 below for resistance values.
NOTE: The equipment should be COLD or at normal ambient temperature when tests are made.
A. Disconnect generator stator leads at the power module panel.
8. Disconnect exciter leads from terminal board mounted on rear of engine control panel. Positive
lead is RED. Negative lead is YELLOW-BLACK.
C. Check resistance and compare to values given in Fig. 9.
TEST CONNECTION NOMINAL RESISTANCE IN OHMS
GENERATOR STATOR
Phase A to N 0.00827
Phase B to N 0.00835
Phase C to N 0.00840
NOTE: The two leads of a phase must be connected when test is made.
EXCITER A-B, B-C, A-C 0.1
Field (RED to YELLOW-BLACK) 7.23
ROTATING FIELD
(Measure resistance at revolving field rectifier (CR2) 2.19
with exciter armature leads removed from rectifier.
(See Connection Diagram)
Generator and Exciter Stator Test Values

(70FAmbient Temperature)
Figure 9
5. Diode Test
Test values for diodes are not given here because they could be misleading. Test values may vary
even between diodes of the same part number, rating, and manufacturer. General instructions for test-
ing diodes follows:
A. Disconnect diode lead(s).
CAUTION: THE REGULATOR OUTPUT MUST NEVER BE GROUNDED WHEN THE GENER-
ATOR IS TURNING.
NOTE: For units with 70 ohm, 700 watt ballast resistors (before Jan. 1976) voltage is 30-40 V DC.
2-3 Aug 31189

Page 16
OM-436
B. Use a good quality ohmmeter. An instrument which indicates 50 ohms at the center of the scale is
preferable.
NOTE: The battery must be in good condition and the pointer adjusted to zero when the test lead
points are shorted together. Set the scale selector to RX7 and zero the ohmmeter before testing
diodes.
C. Hold one ohmmeter lead point on the threaded end of the diode. Hold the other lead point on the
wire terminal end. Observe and note the indicated resistance. Now reverse the lead connections on
the diode. Again observe and note the ohmmeter indicated resistance. If an infinite or very high resis-
tance is indicated with the leads connected one way and a low, readable resistance was indicated with
the leads connected the opposite way, the diode may be considered good.
6. Test and Adiustment of Transformer-Rectifiers
For testing and adjusting transformer-rectifiers, refer to the appropriate transformer-rectifier manual in-
cluded in Chapter 6 of this manual.
7. Additional Tests for Dual Output Units

Perform the tests outlined in para. 2, B, (76) through (22) substituting the controls and indicators
illustrated in Figures 10 and Il.
load
Contactor
Output No. 2 Power

No. 2 Module Panel
Test Bank
Switch Figure 10
Aug 31189 2-3

Page 17
OM-436

Figure 11
OM-436
CHAPTER 3. TROUBLESHOOTING
SECTION 1. TROUBLE SHOOTING PROCEDURES
1. General
A. Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until
the exact cause of a trouble is found. As a rule, the best place to start looking for the cause of a
trouble in a circuit is at the source of power. Continue testing and checking the circuit, step-by-step, in
an orderly manner, until the cause of trouble is located.
B. This section provides information useful in diagnosing and correcting certain troubles which cause
unsatisfactory operation or failure of the equipment.
C. Minor troubles may be remedied by the operator; however, major repairs must be undertaken by
experienced mechanics and electricians only.
2. Trouble Shooting Chart (Figure 2)
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 Trouble Shooting Chart
(1) A troubleshooting chart is furnished to provide maintenance and repair personnel with a time-
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, the
only alternative is to start at the source of power or supply and check the affected circuit or sys-
tem completely. Use schematic and connection diagrams which are supplied with this manual.
(3) Electrical components mentioned in the trouble shooting chart are identified by a noun name
and corresponding symbol which allows the user to identify the item more easily on schematic
diagrams.
(4) It is assumed that wiring and connections in defective circuits have been thoroughly checked
before condemning any other components.
NOTE: Reference symbols (S9, etc.), used in the Trouble Shooting Chart, are identified on Schematic
and Connection Diagrams.
Aug 31189 3-l

Page 1
CM-436
3. Equipment for Troubleshooting
A good quality multi-scale voltohmmeter is the only instrument required for trouble shooting. At least
two jumper leads with alligator clips and test prods will be required. The. 12-V, engine electrical sys-
tem may be used as a 12-V DC power source.
If a test box, Hobart part number 388318A, is available, tests may be made more quickly and accurate-
ly. However, the test receptacle connector may be used by inserting the test points of a volt-
ohmmeter into proper terminals of the connector. Refer to figure 8.
4. Safety - WARNING:
WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT WITH HIGH

VOLTAGE LEADS AND COMPONENTS WHICH COULD CAUSE SERIOUS
SHOCK AND INJURY IF TOUCHED WHEN TROUBLE SHOOTING OR
OPERATING THE EQUIPMENT.
5. Parts Replacement
To 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 trouble shooting chart. For example, if
a component in the protective relay tray is defective, the quickest way to remedy the situation is to
replace the complete tray assembly and send the old tray assembly for repair
Assemblies which lend themselves to this concept are:
Generator control tray Electric governor control box

Protective relay tray Governor actuator
Voltage regulator Over-undervoltage module
Overload module Over-underfrequency module
Protective monitor module
The above items are in addition to normally replaced items such as fuel pump, injectors, relays, etc.
3-1 Aug 31189

Page 2
OM-436
6. Test Values
Although test values are provided throughout the trouble shooting chart, where applicable, additional
information 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 112 KVA in 5 minutes.
Overvoltage 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.
Over-frequency relay trips at 415 to 425 Hz, resets at 410 Hz.
Under-frequency relay trips at 375 to 380 Hz, resets at 385 Hz.
Overload relay trips at 125% rated load in 5 minutes.
7. Checking Connections and Leads
ALWAYS make a check of connections and leads to a component suspected of being faulty. With the
exception of a few instances, we will assume that connections and wiring have always been checked
first and that power has not been lost as a result of defective wiring or connections.
8. Electric Governor Trouble Shooting
The following facts concerning the operation of the electric governor may be helpful in understanding
the system and in determining which unit in the system is faulty in case of troubles.
A. The system requires two sources of power to operate normally.

(1) 12-V DC input power (from engine electrical system)
(2) 4-V AC input power (from magnetic pickup)
B. Assuming other conditions are normal, the actuator will go to, or remain in, IDLE position under
the following conditions.
(1) No 12-V DC power
(2) No voltage from control box to actuator
(3) No signal from magnetic pick-up.
C. The actuator will surge under the following conditions:
(1) Stability or gain adjustment set too high
(2) Throttle linkage binding
Aug 31189 3-1

Page 3
OM-436
9. Engine Trouble Shooting Procedures
A. General
The following engine trouble shooting procedures were taken from Deutz Diesel Handbook. Cer-
tain abnormal conditions which may interfere with satisfactory engine operation, together with
methods of determining the cause of such conditions, are covered in the Trouble Shooting Chart.
The ability of the engine to start and operate properly depends primarily on two things:
-The presence of an adequate supply of air, compressed to a sufficiently high compres-
sion pressure.
-The injection of the proper amount of fuel at the right time.
Lack of power, uneven running, excessive vibration, stalling, and hard starting may be caused by
low compression, faulty injection in one or more cylinders, or lack of sufficient air. Refer to Detroit
Handbook for trouble shooting and repair procedures.
Since proper compression, fuel injection, and the proper amount of air are important to good en-
gine performance, procedures for checking them are given here.
B. Locating a Misfiring Cylinder
(1) Start engine and allow it to run until it reaches normal operating temperatures.
(2) Remove valve cover.
(3) Operate engine at IDLE speed and check valve clearance.
(4) Hold the No. 1 injector follower down with a screwdriver, or with a special injector cut-out tool,
preventing operation of the injector. If the cylinder has been misfiring, there will be no noticeable
difference in the sound and operation of the engine. If the cylinder has been firing properly, there
will be a noticeable difference in the sound and operation when the plunger is held down. This is
similar to short-circuiting a spark plug in a gasoline engine.
(5) If cylinder No. 1 is firing properly, repeat the procedure on the other cylinders until the faulty
cylinder has been located.
(6) Providing that the injector operating mechanism of the faulty cylinder is functioning satisfac-
torily, remove the fuel injector and install a new one.
C. Checking Compression Pressure
(1) Start engine and run until normal operating temperature is reached.
(2) With engine stopped, remove fuel pipes from the injector and fuel connectors of the No. 1
cylinder.
(3) Remove the injector from the No. 1 cylinder and install the proper adapter of the pressure
gage (tool J6692) in its place.
(4) Use one of the two fuel pipes as a jumper connection between the fuel inlet and return
manifold to permit fuel to flow directly to the return manifold. On some cylinder heads, it is neces-
sary to fabricate a jumper connection from a fuel pipe.
3-l Aug 31169

Page 4
(5) Start the engine and runit at idle speed.
CAUTION: DO NOT CRANK THE ENGINE WITH CRANKING (STARTING) MOTOR TO OBTAIN
COMPRESSION PRESSURE.
Record compression pressure indicated.
Note: A guide to minimum compression pressure expected is included in Section 2-3, Figure 6.
(6) Remove pressure gage, install injector, and reinstall fuel lines.
(7) Repeat steps (2) through (6) for each cylinder.
D. Interpretation of Compression Pressure Records
Compression pressure in any one cylinder should not be less than specified in Section 2-3, Figure
6. Variation in compression pressures between cylinders must not exceed 25 PSI. A low com-
pression pressure in one cylinder indicates that a problem has occurred and that a pressure leak
has developed.
E. Causes of Low Cylinder Pressure
Low cylinder pressures may result from any one of several causes:
(1) Piston rings may be stuck or broken. To determine the condition of the rings, remove the air
box cover and press on the compression rings with a blunt tool. A broken or stuck ring will not
have a spring-like action.
(2) Compression pressure may be leaking past the cylinder head gasket, valves, and valve seals,
injector tube, or through a hole in the piston or combustion chamber.
To correct any of these conditions, consult the Deutz Diesel Service Outlet.
F. Fuel Flow Test (see Fig. 7)
Check fuel pump and fuel flow as follows:

(1) Disconnect the fuel return tube at or near the tank. Place the open end in a convenient con-
tainer of over 1-gallon capacity.
(2) Start and run the engine at governed speed speed (2000 RPM). Measure the fuel flow from
the return tube for 1 minute. Flow should be 0.8 gallon (based on 0.080 restriction. If fuel flow is
below this amount, it indicates that the fuel strainer, fuel filter, or fuel pump requires servicing or
repair.
(3) To check suction side of the pump, immerse the end of the return tube in a container of fuel.
If bubbles rise to the surface of the fuel, it indicates that air is being drawn into the fuel system on
the suction side of the pump. If air is present, tighten all fuel connections between the fuel tank
and the fuel pump. Check for defective tubes, hoses, etc.
1O.lllustrations
Illustrations in Figure 1 are referred to throughout the Trouble Shooting Chart, Figure 9.
Il.. Troubleshooting Transformer-Rectifiers, (T-Rs)
Instructions for troubleshooting and repair of transformer-rectifiers are provided in the appropriate
transformer-rectifier manuals included with Chapter 6 of this manual.
Aug 31189 3-1

Page 5
OM-436
CONTROL BOX 0 0 0
ENGINE CONTROL PANEL

3. Voltmeter 18. Hourmeter (Engine)
11. Load Contactor Circuits Fuse (2,4) 26. Switch, Engine Start
12. Protective System Fuse (2,4) 27. Engine Start, Pushbutton
3-1 Aug 31169

Page 6
30
31
GENERA,TOR CONTROL TRAY
VOLTAGE REGULATOR
\\
PROTECTIVE RELAY TRAY 33 34
30. Manual Voltage Control Rheostat 35. Automatic Voltage Control Rheostat *
Control Switch 37. Cable Size Compensation Rheostat *
33. Light Test Switch On-Off Switch *
34. Reset Switch 39. Fuse (5-A) *
k (Voltage regulator No. 430391C controls illustrated)

Figure 1 (Sheet 2 of2)
Aug 31189 3-1

Page 7
OM-436
1. Starter Connection to Solenoid

2. Solenoid
3. Negative Battery Cable Connection
4. Positive Battery Cable Connection
5. Starter Solenoid Switch
6. Starter
Starter and solenoid Switch
Figure 2
1. Manual Control Voltage

Adjusting Resistor
2. Exciter Field Ballast
Resistors
Excitation Resistors
Figure 3
mg 37189
3-1
Page a
+ To exciter
End View of Voltage Regulator

Amphenol Connector
Figure 4
field
1. Fuel Tank
2. Fuel Suppli Line
3. Fuel Feed Pump
4. Injector Pump
5. Injector Lines
6. Injector
7. Backleakage Lines
8. Overflow Lines
9. Overflow Valve
10. Fuel Return Line
Fuel Flow
Figure 5
Aug 31189 3-1

Page 9
Test Receptacle Connector Terminals Identification
Figure 6
3-l Aug 31189

Page 10
OM-436
TROUBLE, SYMPTOM TEST, CHECK, AND

AND CONDITION PROBABLE CAUSE REMEDY
ENGINE AND CONTROLS
1. Engine will not A. Battery or batteries A. Check battery voltage and

start. Starter will discharged or faulty. specific gravity. Recharge
not crank engine. or replace.
B. 12-V DC power not B. Check voltage at starter

reaching starter solenoid input terminal (4,
solenoid. Fig. 2). Voltage should be
approximately 13.5 V. If no
voltage, check cables and
connections between starter
solenoid and power source.
Replace or repair cables and
connectors as required.
C. Batteries or starter C. Check cable and all

not properly grounded. connections.
D. Delective start D. While operating start switch

switch (S24). (27, Fig. I), measure voltage
at terminal where brown-blue
wire connects to starter
solenoid. If no voltage is
indicated, replace switch.
E. Defective starter E. If, in steps A through D,

solenoid, or starter. the components checked are
in good condition and all
connections are secure,
either the starter solenoid
or the starter is defective.
Replace starter and solenoid
as an assembly.
2. Engine will not A. Low battery output A. Check battery and starter.
start. Cranking or faulty starter. Recharge, repair, or
speed low. replace.
B. Loose starting B. Check all connections and

circuit connections cables. Tighten or replace
or faulty cables. as required.
C. lmproper lubricating C. Check oil. See Sect. 2-1,

oil viscosity. Para. 3, D, (3). Take correc-
tive action as necessary.
Electrical Troubleshooting Chart

Aug 31189 3-l

Page 11
OM-436

ENGINE AND CONTROLS (Continued)
2. Engine will not start D. Ambient temperature D. Use engine starting aid.
start. Cranking too low for normal See Sect. 13, Para. 2, C.
speed low starting procedures.
3. Engine will not A. Fuel tank empty or A. Make certain that valve
start. Cranking fuel shut-off valve is open. Fill fuel tank
speed normal. closed. if necessary.
(1) Insufficient (1) Fill tank.

fuel in tank.
(2) Fuel shut-off (2) Make certain valve is

valve closed. OPEN.
(3) Loose connections, (3) Tighten all fittings and

damaged hoses or fuel connections. Replace any
lines between tank and damaged hoses or fuel
fuel pump. links.
(4) PIrIgged or defec- (4) Do not overlook the

tive fuel litter possibility of restricted-
or air filter. flow through fuel filters.
Also check gaskets for
leaking or damaged
condition. Check air
filter indicator.
(5) Faulty installation. (5) Restricted fitting miss-

ing from return line.
(6) Faulty fuel pump. (6) Check pump.
(a) Relief valve (a) An open relief valve

not seating. will cause low
output pressure.
(b) Worn pump (b) Check pump for

gears or normal operation.
damaged pump Replace if defec-
drive. tive.

3-1 Aug 31189

Page 12
OM-436

3. Engine will not (7) Defect in injector (7) Check position of fuel
start. Cranking racks or linkage. shut-off lever (Sect. 2-3, Fig.
speed normal. 7, item 4). Should be in full
(Continued) CLOCKWISE position.
Check all fuel control
linkage to make certain
injectors are functional.
4. Engine is hard to A. Low ambient tempera- A. Check causes and remedies

start. Cranking true, or limited fuel. under ENGINE, Trouble 3,
speed normal. above.
B. Low compression which B. Check compression in accor-

may be caused by any dance with Para. 9, C and D.
one of the following:
(1) Sticking or (1) Cylinder head must be

burned exhaust removed and overhauled
valves. to correct this con-
dition.
(2) Compression rings (2) Check rings in accor-

worn or broken. dance with Deutz Diesel
Instruction Manual.
(3) Improper valve (3) Check and adjust valve

clearance clearance in accordance
adjustment. with instructions in
Deutz Diesel Instruction
Manual.
5. Engine starts. A. The shut-down circuit A. Start the engine and observe
Stops after a few may have functioned oil pressure gage. If
seconds by auto- normaily to stop the pressure is less that 12
matic shut-down. engine because of low PSI, stop engine at once and
lubricating oil check for cause of low
pressure. pressure. Correct as
required.

Aug 37/89 3-7

Page 73
matic shut-down. sure If pressure is 38 PSI, or

more, check voltage between
terminal C of oil pressure
switch (the terminal with
YELLOW-BLUE wires) and
ground. If approximately
12-V DC is indicated, the
engine and replace switch.
6. Engine runs at A. Lamp defective. A. Replace lamp.

idle speed. Engine
ON indicating B. Indicating light body B. Be sure light is grounded
light (25, Fig. 1) poorly grounded.
does not glow.
7. Engine will not A. 12-V DC power not A. Apply 12-V DC directly to

come up to reaching governor terminal # 1 on governor
governed speedin comes-up to speed, check
GEN mode.
B. Governor linkage B. Check governor linkage and

binding or governor throttle shaft for binding
throttle sticking. and sticking. Repair as
.
C. Defective or mis- C. The control unit may not be

adjusted magnetic receiving a signal from the
magnetic pickup and the
fail-safe feature of the
unit may be functioning to
prevent any signal from
reaching the actuator.

3-7 Aug 37189

Page 74
7. Engine will not C. Defective or mis- C. To check the magnetic

come up to adjusted magnetic pick-up, disconnect pickup
governed speed pick-up (continued) from control unit and
in GEN mode. connect a high impedance
(Continued) AC voltmeter to the pickup
output leads. Crank engine
but dont start. Voltage
reading should be a minimum
of (1) volt. If no or low )
voltage is indicated, check
pickup adjustment [See 2-3,
Para. 4, E, (2)]. If pickup is-
properly adjusted and voltage
is still zero, replace pick-up.
D. Defective actuator. D. Apply 12-V DC to the two

actuator input leads.
Actuator lever should move
immediately to full speed
position. If lever does
not move, replace actuator.
E. Defective control E. See Woodward Manual.
8. Engine goes to A. Governed speed A. Turn speed control adjusting

overspeed when control adjustment screw 22 turns counterclock-
control switch set too high (see wise. Start engine. Place
(17, Fig. 1) is 2-3, Fig 11). control switch (17, Fig. 1)
in GEN position. in GEN position. If engine
speed is now well below
governed speed, turn adjust-
ing screw clockwise until
correct speed (2000 RPM,
400 Hz) is reached. If
engine still goes to over-
speed, proceed to step B.
B. Defective linkage B. Check governor linkage and

or actuator. actuator for sticking or binding
in full-speed position. Repair
as required.
C. Defective control C. Replace control unit. Check

unit. unit in accordance with
American Bosch Handbook.

Aug Wa9 3-7

Page 75
9. Engine is unsteady A. Fault in engine; A. Before condemning the gov-

surges under load. ernor system for surging,
make certain the fault is
not in the engine. Make
certain all cylinders are
firing properly and air and
fuel supply is proper.
B. Governor system B. Check and adjust as follows:

faulty or mis-adjusted.
(1) Loose or binding (1) Check linkage ball joints

governor linkage. and all connections for
looseness or binding. Be
sure linkage will move from
idle speed to full speed
without lost motion or binding.
(2) GAIN and (2) Adjust GAIN and STA-

STABILITY con- BILITY controls on control
trols improperly unit in accordance with 2-3;
adjusted. Para. 3, E, (3).
(3) Magnetic pickup (3) Check and adjust pickup.

signal weak. See 2-3, Para. 3, E. (2).
10. Engine has slow A, Governor control unit A. Adjust. See 23; Para.
response time. improperly adjusted. 3, E, (3).
B. Acutator linkage B. Inspect and repair as

binding. required.
C. Engine needs tune-up. C. Tune up as required. Refer

to Deutz Manual.
11. Engine misses. A. Insutlicient fuel. A. Check fuel flow in accord-

Runs unevenly. ante with Para. 9, F. Repair
or replace parts as required.
Also see ENGINE, Trouble 3.
B. Faulty injector. B. Check injectors in accord-

ance with Para. 9, B.

Figure (Sheet 6 of 1.9)
3-7 Aug 3ua9

Page 76
OM-436

11. Engine misses C. Low compression C. Check compression in accord-

runs unevenly pressure. ante with Para. 9, C. See
(continued) causes of low compression
listed under ENGINE, Trouble
4, B, above.
12. Engine lacks A. Improper engine A. Tune-up the engine in

power. adjustment and gear accordance with Deutz
train timing. Manual.
B. Insufficient fuel. B. See ENGINE, Trouble 3.
C. Insufficient inlet C. Check as follows:

air.
(1) Damaged air (1) Check air cleaner for

cleaner. plugging and/or
damage.
(2) Defective blower-to- (2) Replace the gasket if

cylinder block gasket. necessary. If the
blower is removed,
install a new gasket.
(3) Plugged cylinder (3) Clean ports if they are

liner ports. over 50% obstructed.
(4) Faulty air (4) Repair or replace.

blower.
D. Worn Engine. D. See engine overhaul instruc-

tions in engine manual.

Figure 7 (Sheet 7 of 19 )
Aug 37189 3-7

Page 77
GM-436

GENERATOR AND EXCITATION CIRCUIT
1. No (or low) gen- A. Defective generator A. The first check is an easy

erator output or excitation one which will allow the
voltage in all circuit. mechanic to reach some
phase. Generator definite conclusions about
operating at 400 where the trouble is. Place
Hz in AUTOMATIC the AUTO-MAN switch (31,
mode. Fig. 1) in MANUAL position.
If a normal voltage (for the
rheostat setting) is now
produced, the generator is
good, and the trouble is in
the voltage regulator circuit.
Proceed to step C. If swltch-
ing to MANUAL control
did not affect generator
output, the trouble is likely
in the generator, but to
prove the generator is
defective, proceed to step B.
B. Defective generator. *B. Use the test receptacle (31,

Fig. 6) to connect unground-
* CAUTION: DO NOT ed 12-V DC to the exciter field.
USE BATTERY ON Using leads with alligator clips
UNIT TO FLASH FIELD and test prods, connect 12-V
WITH GENERATOR DC NEGATIVE lead to I
TURNING. VOLTAGE terminal D. Terminal identi-
REGULATOR DAMAGE fying letters are plainly visible
RESULTS FROM THE on the face of the test recep-
INTRODUCED tacle. Connect POSITIVE lead
GROUND to terminal F. If no output
voltage change is indicated
when the exciter field is
energized, the generator is
defective. Stop operations
and see 2-3, Para. 4 for
further generator testing.
If the generator produces
approximately 140-V AC
when the exciter field is
energized, the trouble is in
the voltage regulator
excitation circuit. Proceed
to step C.

Figure 7 (Sheet 8 of 19 )
3-l Aug 31189

Page 18
OM-436

GENERATOR AND EXCITATION CIRCUIT (Continued)
1. No (orlow) gen- C. Defect in VOLTAGE C. Check as follows:

erator output REG. excitation
voltage in all circuit.
phases. Generator
operating at 400 (1) Defective AUTO- (1) Check the switch
Hz in AUTOMATIC MANUAL switch thoroughly. A defective
mode. (Continued) (31, Fig 1) switch may prevent current
reaching and/or leaving the
voltage regulator. Replace
switch if defective.
(2) Defective (2) Check EDR contacts. A

excitation- faulty EDR can prevent
deenergization power from reaching the
relay (K16) voltage regulator. Replace
(l-l; 3, Fig. 8). relay if defective.
(3) Defective ballast (3) If output voltage was

resistor(s), produced when the gen-
(See Fig. 3). erator set was operated
in MANUAL mode, the
resistors are good. If no
voltage was produced in
MANUAL mode, resistors
could be defective. Refer to
Fig. 5 and connect aejumper
lead across the ballast resis-
tors. If an output voltage is
now produced, replace resis-
tor(s) as required.
(4) Defective (4) Disconnect voltage

Amphenol connec- regulator Amphenol con-
tor at voltage nectar (see l-l; 14,
regulator, or Fig. 12). Using jumper
defective wiring leads with clip and
from regulator prod terminals, connect
to exciter field. ungrounded 12-V DC to
terminals E and C in
loose plug. Connect
NEGATIVE to terminal
E. Connect POSITIVE
lead to C terminal

Aug 31189 3-1

Page 19
OM-436

1. No (or low) gen- (4) Defective Amphenol (4) If the generator will NOT
erator output connector at voltage produce a normal voltage,
voltage in all regulator, or defective replace or repair Amphenol
phases. Generator wiring from regulator connector and wiring between
operating at 400 to exciter field, voltage regulator and exciter
Hz in AUTOMATIC (Continued) field as required.
mode. (Continued)
* AUTION: A GROUN-
DED DC VOLTAGE
SOURCE SUCH AS
FROM THE GENERATOR
SET MUST NOT BE USED
FOR APPLYING TEST
VOLTAGE. DAMAGE
WILL RESULT TO THE
VOLTAGE REGULATOR
CIRCUITRY.
(5) Defective voltage (5) All components in the

regulator. excitation circuit
except the voltage
regulator have been
tested in steps (1)
through (4) above. This
leaves only the reg-
ulator as a cause of
trouble. Replace com-
plete voltage regulator.
2. No (orlow) output A. Defective generator A. Place AUTO-MANUAL

voltage when operating manual control ex- switch (32, Fig. 1) in AUTO
in MANUAL mode. citation circuit. position. If a normal volt-
age is NOT produced, per-
form checks as instructed
in GENERATOR AND
EXCITATION CIRCUIT
TROUBLE 1, above. If a
normal voltage is produced,
proceed to step B below.

3-1 Aug 31189

Page 20
2. No (or low) output B. Defect in manual B. Check as follows:

voltage when operating voltage control por-
in MANUAL mode. tion of excitation
(Continued) circuit.
(1) Defective AUTO- (1) Check contacts and

MANUAL switch operation of AUTO-
(31, Fig. 1). MANUAL switch. Replace
if defective.
(2) Defective rec- (2) Check diodes (see 2-3,

tifier (CR-j) Para.5). Replace recti-
(Sect. l-l; 14, fier if defective.
Fig. 8).
(3) Defective resis- (3) Jumper resistor (I, Fig. 3)

tor (Rll) (See 1, If normal voltage (depending
Fig. 3). 011rheostat)is produced,
replace resistor.
(4) Defective (4) Connect a jumper across

rheostat (R61) rheostat. If maximum
(30, Fig. I) (manual control) voltage is
produced, replace rheostat.
LOAD CONTACTOR OPERATING CIRCUIT
1. Load contactor (Kl) will A. In addition to defec- A. After checking fuse (Fl) in
not close when control switch tive wiling and con- step (1) below, check all
(21, Fig.I) is held in CLOSE nections in the AC wiring and connections in
position. Generator running and DC load contac- the load contactor circuits
at normal voltage. No fault tor actuating cir- on the engine control panel,
lights on. cuits, the load con- the protective relay tray,
tactor may be pre- and power module. Then check
vented from closing components as follows:
for any oue of the
. following reasons:
(1) Blown fuse (FI) (1) Remove and inspect fuse.

(l-l; 16, Fig. 9) Replace if blown.

Aug 3lia9 3-1

Page 21
LOAD CONTACTOR OPERATING CIRCUIT (CONTINUED)
1. Load contactor (Kl) will (2) Defective (open) (2) Connect a jumper with
not close when control relay in memory clip and prod terminals
switch (21, Fig. 1) is held and time delay between terminal H of the
in CLOSE position. module (l-1, 4, test receptacle and ground.
Generator running at Fig. 9). If contactor will now close,
normal voltage. No replace memory-time delay
fault lights on. module.
(3) Defective load (3) Set AUTO/MANUAL

contactor control switch (Sl) to AUTO posi-
switch (S5) (21, tion. Connect a jumper with
Fig. I). test prods between terminals
S and R on the test
receptacle. If the contactor
closes, replace control
switch.
(4) Defective recti- (4) Check rectifier input

fier (CR6) (1-l; and output voltage as
5, Fig. 13). follows:
(a) With test receptacle

terminals S and R
connected as above, check
voltage to rectifier between
terminals R and H. Vol- ,
tage should be 115 VAC.
(b) With test receptacle

terminals S and R
connected as above, check
rectifier output at load
contactor terminals X and Y.
If voltage is not approximately
90 V DC, replace rectifier.
(5) Defective load (5) Disconnect leads at load

contactor coil (KI) contactor terminals X and Y.
(I-I; 6, Fig. 13). Check coil resistance between
these terminals. Resistance
should be approximately 100
ohms. If coil is defective,
replace the complete load
contactor.

3-l Aug 31189

Page 22
AND CONDITION PROBABLE CAUSE
2. Load contactor (Kl) will A. 28.5 V DC is not A. Check voltage at terminal Z

close when control interlock reaching plug- on test receptacle. Voltage
relay (K2) switch (21, Fig. 1) should be 28.5 V DC. If not,
is held in momentary CLOSE from aircraft for the voltage not bei
position. Opens immediately following reasons: from ai raft. C
when switch is released to as follows:
center ON position.
(1) Generator to (1) Inspect cable connector
aircraft cable plug thoroughly for damaged
connector defec- E and F terminals. Be sure
tive or not plug- the plug is fully mated with
ged into aircraft the aircraft receptacle
receptacle con- connector and making good
nectar. contact.
(2) Aircraft (2) Check aircraft on board

rejecting power. electrical equipment and
controls.
B. Blown fuse (F2) B. Press lamp test switch (8,

(l-l; 17, Fig. 9) in Fig. 1). If lamps do not
protective relay glow, replace fuse (F2).
tray.
C. Defective plug C. Place test-bank switch (S2)

interlock relay (IQ). (32, Fig. I) in ON position.
If load contactor will now
remain closed, replace the
. plug-interlock relay (K2)
(Sect. l-l; 1, Fig. 9) or
the complete protective
relay tray.
I). Small contacts in D. Connect a jumper lead be-

load contactor (Kl) tween small terminals no. 1
defective. and no. 2 on the load
contactor. If load contactor
will now remain ciosed,
replace the complete load
contactor (Kl).

Aug 31189 3-1

Page 23
OM-436

2. Load contactor E. Defective fuse- E. Open protective relay tray

will close when control interlock relay (K17) and connect a jumper across
switch (21, Fig. 1) is or resistor (R46). the resistor (R46) (Sect.
held in momentary l-l; 21, Fig. 9). If the
CLOSE position. Opens contactor will now remain
immediately when switch closed, replace fuse inter-
is released to center ON lock relay (K17) (Sect. l-l;
position. (Continued)
3. Load contactor A. Fuse (FI o1F2) A. Remove and inspect fuses

opens during power (l-l; 16 and 17, Fig. 9). ,
delivery. NO Replace as required.
fault indicating
lights on. B. A fault has developed B. If the load contactor cannot
in the load contactor be closed by operation of
the control switch (SS)
(21, Fig. I), check the
circuit in accordance with
instructions in Trouble 1,
above under LOAD
CONTACTOR OPERATING
CIRCUIT. If the load
contactor can be closed
but opens as soon as control
switch (S.5) is released,
check for trouble under ,
Trouble 2, above.
C. Cable accidentally C. Reconnect cable.

disconnected from

3-1 Aug 31169

Page 24
AND CONDITION - PROBABLE CAUSE
NOTE: 7lzeprotective relays and protective monitor are not completely firnctional until the load
contactor is CLOSED. Since it is not advisable to vary voltages for test purposes wltile delivering
power to an aircraft, the generator should be connected to a load bank for trouble shooting the
protective circuits.
To avoid repetition, it will be assumed that the reset switch [(34), Fig. 1] has been pushed and
the load contactor has been closed before commencing each test.
1. Load contactor opens A. The overvoltage A. Press reset switch (34, Fig.
during power delivery. condition may have 1) and resume power
Overvoltage indicating been the result of delivery. Observe voltmeter
light ON. (3, Fig. 1) to be certain
voltage is normal 115 V AC.
Adjust to normal if
necessary. If the load
contactor is opened again
and an overvoltage condition
a normal action. is indicated by light (DS37)
proceed to step B.
B. Defective over-under- B. Use voltage adjusting

voltage sensing module rheostat (35, Fig. 1) to
(K26) ; failure in its -. reduce voltage to 110 V AC.
mvoltage circuit) Observe voltmeter and grad-
ually increase voltage with
rheostat. If the overqnder-
voltage sensing module (E6)
functions to open the load
contactor at any value less
than 130 V AC, it is defec-
tive. Replace over-under-
voltage module or complete
protection relay tray.
2. Load contactor A. An undervoltage A. Observe generator voltage

opens during power condition caused the on voltmeter and adjust
delivery. Under- over-under-voltage to normal 115 V AC with
voltage indicating sensing module (k26) voltage regulator rheostat
light ON. to function normally. (35, Fig. 1). Resume normal
operation. If the load con-
tactor opens again and an
undervoltage condition
is indicated by light (DS38)
proceed to step B.

Aug 31/89 3-1

Page 25
OM-436

PROTECTIVE CIRCUIT
2. Load contactor opens B. Defective over-under- B. Use rheostat (35, Fig. I) to

during power delivery. voltage sensing module. reduce voltage to 104 V.
Undervoltage indicating (K26); failure in its Wait 12 seconds. The under-
light ON. (Continued) Undervoltage circuit. voltage indicating light
should NOT be turned on.
If the light is turned on,
the undervoltage relay is
defective. Replace the
C. Defective protective C. With unit running normally,

monitor module (Kl#}. use rheostat (35, Fig. 1) to
reduce voltage quickly to 90 V.
If the undervoltage indicating
light (DS38) is turned ON
immediately, the protective
monitor circuitry is defective.
Replace the protective
monitor (K14) or replace the
protective relay tray.
3. Load contactor A. Electric governor A. Proceed as follows:

opens during improperly adjusted,
power delivery. or malfunctioning.
Overfrequency
indicating light 1) Governor impro- (1) Adjust in accordance
(DS40) ON. with Sect. 2-3, Para. 3, E, (3).
(2) Check and adjust or

repair in accordance
with ENGINE AND
CONTROLS, Troubles 8 and 9.
B. Defective over-under- B. If overfrequency nuisance

frequency sensing tripping continues after the
governor system is proven to
be good, and an overfrequency
condition does not exist, replace
the over-underfrequency
module (K27), or complete
protective relay tray.

3-1 hg 31189
Page 26
Olvl-436

PROTECTIVE CIRCUIT (Continued)
power delivery. or malfunctioning.

Underfrequency
light (DS39) ON. (1) Adjust in accordance
with Sect. 2-3, Para.
(2) Electric governor (2) Check and adjust or

system malfunc- repair in accordance
with ENGINE AND CON-
TROLS Troubles 8 and 9.
B. Defective over-under- B. If overfrequency nuisance

frequency sensing tripping continues after
the governor system is
proven to he good, and an
underfrequency condition
does not exist, replace the
over-underfrequency relay,
or complete protective
5. Load contactor A. There may have heen A. Observe ammeter (5, Fig. 1).
opens during an overload condition Check for abnormal overload
power delivery. which caused the condition and correct. If
Overload indi- overload device to overload device functions
eating light ON. function normally. to open the load contactor
when an overload does not
exist, proceed to step B.
B. One of the resistors B. An open resistor will cause

(R21j,R27, orR2S) a higher than normal voltage
across overload trans- Check resistors (Sect. (I-l;
former is open circuited. I, Fig. 13). Replace if defective
C. Overload device C. Check voltage at terminal E,

Fig. 6. If 12-V DC, replace
overload device (K4) (Sect.

3-l
Page 27
GENERATOR
B. Open or shorted ex- B. Use ohmmeter to check for

titer rotor winding open or shorted condition.
If exciter rotor windings
are good, proceed to step C.
C. Open or shorted ex- C. Check for field resistance.

titer field windings See Sect. 23, Fig. 12 for
normal values.
I). Open or shorted gen- D. Check resistance with ohm-

erator windings (Ll). meter to determine if open
or short circuited.
2. Generator operates A. An open or short A. Check stator winding resis-

single phase. circuited winding in tances. See Sect. 2-3, Fig.
generator stator ((il) 12 for normal values.
3. Generator over- A. Loose connection A. Check all output connections

heats. for looseness. Look for dis-
coloration caused by heat.
B. Improper or blocked B. Check for foreign materials

(rags, etc.) blocking air
flow. Provide adequate
C. Generator stator C. Check stator windings. See

Sect. 2-3, Fig. 12.
4. Unbalanced out- A. Loose connection in A. Check all output connec-

put. tions. Discolored connectors
indicate a loose connection.
Tighten or replace as

3-1 Aug 31189

Page 28
OM-436

AND CONDITION PROBABLE CAUSE
GENERATOR (Continued)
4. Unbalanced output B. Open or short B. Check stator windings in
(Continued) circuited stator accordance with Sect. 23,
Para. 4. Repair or replace
C. Defective connection C. Check plug and receptacle

in output circuit. connectors at aircraft.
Tighten, repair, or replace
D. Break or cut in out- D. Inspect. Repair or,replace

put cable assembly.
E. Unbalanced load. E. Check aircraft 400-Hz

Aug 31189 3-l

Page 29
This page intentionally leti blank.
3-1 Aug 31189

Page 30
OM-436
CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION
PART NUMBERS ARE SUBJECT TO CHANGE WITHOUT NOTICE
1. General
The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and
detail parts of seven series of Diesel Engine Generator Sets manufactured by Hobart Brothers Com-
pany, Airport Systems Division, Troy, Ohio, 45373.
2. Purpose
This list provides parts identification and descriptive information to maintenance and provisioning per-
sonnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts.
3. Arrangement
Chapter 4 is arranged as follows:
Table of Contents
Section 1 - Introduction
Section 2 - Manufacturers 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 detail
parts. All parts of the equipment are listed except:
(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are
available commercially.
(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.
(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc.,
to other parts, weldments, or assemblies.
B. Parts List Form
This form is divided into five columns. Beginning at the left side of the form and proceeding to the
right, columns are identified as follows:
May la/90 Revised 4-l

Page 1
OM-436
l (1) FIGURE-ITEM NO. Column
This column lists the figure number of the illustration applicable to a particular parts list
and also identifies each part in the list by an item number. These item numbers also ap-
pear on the illustration. Each item number on an illustration is connected to the part to
which it pertains by a leader line. Thus the figure and item numbering system ties the
parts lists to the illustrations and vice versa. The figure and index numbers are also used
in the numerical index to assist the user in finding the illustration of a part when the part
number is known.
l (2) HOBART PART NUMBER Column
ALL part numbers appearing in this column are Hobart numbers. In all instances where
the part is a purchased item, the vendors identifying five-digit code and his part number
will appear in the NOMENCLATURE column. Vendor parts which are modified by Hobart
will be identified as such in the NOMENCLATURE column. In case Hobart does not
have an identifying part number for a purchased part, the HOBART PART NUMBER
column will reflect No Number and the vendors number will be shown in the
NOMENCLATURE column. Parts manufactured by Hobart reflect no vendor code or part
number in the NOMENCLATURE column.
a (3) NOMENCLATURE Column
The item identifying name appears in this column. The indenture method indicates item
relationship. Thus, components of an assembly are listed directly below the assembly
and indented one space. Vendor codes and part numbers for purchased parts are
shown in this column. Hobart modification to vendor items is also noted in thi column.
l (4) EFF (Effective) Column
This column is used to indicate the applicability of parts to different models of equipment.
When more than one model of equipment is covered by a parts list, there are some parts
which are used on only one model. This column is used for insertion of a code letter A,
B, etc., to indicate these parts and to identify the particular model they are used on. ,Un-
coded parts are usable on all models.
Parts in this manual are coded as follows:

Parts coded A are used on Spec 6760-l) 6760A-1, and 6760B-1
Parts coded B are used on Spec 6760-2,6760A-2, and 6760B-2
Parts coded C are used on Spec 6760-3
Parts coded D are used on Spec 6760-4,6760A-4,6760B-4
Parts coded E are used on Spec 6760-5, 676OA-5, 67608-5
Parts coded F are used on Spec 6760-6,6760A-6,6760B-6
Parts coded Gare used on Spec 6760A-7,6760B-7

Parts coded H are used on Spec 6760A-8,6760B-8
Parts coded J are used on Spec 6760A-9,6760B-9
Parts coded K are used on Spec 6760A-10,6760B-10
Parts coded L are used on Spec 6760A-11,6760B-11
Parts coded M are used on Spec 7001A-1
Parts coded N are used on Spec 7001 A-2

Page 2
QM-436
Parts coded P are used on Spec 7001A-3
Parts coded Q are used on Spec 7001A-4
l (5) UNITS PER ASSEMBLY Column
This column indicates the quantity of parts required for an assembly or subassembly in
which the part appears. This column does not necessarily reflect the total used in the
complete end item.
May 18/90 Revised 4-l

Page 3
OM-436

Page 4
SECTION 2. MANUFACTURERS CODES
1. Explanation of Manufacturers (Vendor) Code List
The following list is a compilation of vendor codes with names and addresses for suppliers of pur-
chased parts listed in this publication. The codes are in accordance with the Federal Supply Codes
for Manufacturers Cataloging Handbook H4-1, and are arranged in numerical order. Vendor codes
are inserted in the nomenclature column of the parts list directly following the item name and descrip-
tion. In case a manufacturer does not have a vendor code, the full name of the manufacturer will be
listed in the nomenclature column.
CODE VENDORS NAME AND ADDRESS
00779 AMP Inc., P.O. Box 3608, Harrisburg, Pennsylvania 17105
02231 Anchor Rubber Company, 840 South Patterson Boulevard, P.O. Box 832,
Dayton, Ohio 45401
02660 Bunker Ramo Corporation, Amphenol-Borg Electronics, North Am. Div.

2801 South 25th Ave., Broadview, Illinois 60153
03924 Stratoflex, Inc., Ft. Wayne, Indiana
04009 Grouse-Hinds Arrow Hart, Arrow Hart Div., 103 Hawthorne Street,
Hartford, Connecticut 06105
04713 Motorola Inc., Semiconductor Products Div., Phoenix, Arizona 85008
05277 Westinghouse Electric Corp., Semiconductor Div. Hill St., Youngwood, PA 15697
08108 Lamp Industries For Use With Industry Designations &Abbreviations for Lamps
14831 Magnetic Components, Inc., 5907 Noble Avenue, Van Nuys, CA 91411
14892 Bendix Corp., The Brake and Steering Div., 401 North Bendix Dr., P.O. Box 4001,
Southbend, Indiana 46634
15605 Eaton Corporation Cutler-Hammer Div., 4201 N. 27th St.,

Milwaukee, Wisconsin 53216
16238 Lord Manufacturing Co., Inc., Sterling Road South, Lancaster, Mass. 01561
18265 Donaldson Co., Inc., 329 East Poplar St., Sidney, OH 45365
21335 The Fafnir Bearing Company, Division of Textron Inc., 37 Booth Street,
New Britain, Connecticut 06050
2293s Prototype Dev. Inc., 7750 Hub Park Way, Cleveland, OH 44125
23826 Furnas Electric Company, 1004 Mckee Street, Batavia, Illinois 60510
26992 Hamilton Watch Company, 941 Wheatland Avenue, P.O. Box 3420,
Lancaster, PA 17604
Aug 31189 4-2

Page 1
OM-436
27191 Cutler-Hammer Inc., Power Distribution & Control Div., 4201 N. 27th Street,
Milwaukee, Wisconsin 53216
31356 J-B-T Instruments, Inc., 394 East Street, P.O. Box 1818, New Haven, CT 06508
31510 Main Line Supply, 905 East Third St., Dayton, OH 45402
35708 Tridon Limited, P.O. Box 1600, Nashville, Tennessee 37202
44655 Ohmite Manufacturing Company, 3601 West Howard Street,

Skokie, Illinois 60076
49234 Protectoseal Co., 225 W. Foster Ave., Bensenville, IL 60106
50508 Magnetic Components Inc., 9520 Ainslie St., Schiller Park, Illinois 60176
51589 Sarkes Tarzian Semicon Inc., Broadcast Equipment Division, 415 N. College Ave.,
Bloomington, Indiana 47401
56289 Sprague Electric Company, 87 Marshali St., North Adams, Mass 01247
59197 VDO-ARGO Instruments, Inc., 980 Brook Road, P.O. Box 2630,
Winchester, VA 22601
59730 The Thomas & Betts Company, Hwy 218 S., Iowa City, Iowa 52240
60741 Triplett Electrical Instrument Company, 286 Harmon Road,

Bluffton, Ohio 45817
62445 Deutz Corporation, 7585 Ponce De Leon Cir., Atlanta, GA 30340
66503 Woodward Governor Co., 5001 N. Second St., P.O. Box 7001, Rockford, IL 61101
70040 AC Spark Plug Div., General Motors Corp., 1300 N. Dort Highway,
Flint, Michigan 48556
71400 Bussman Manufacturing, Division of McGraw-Edison Company,

114 Old State Road, P.O. Box 14460, St. Louis, Missouri 63178
71774 General Instrument Corp., Lamp Division, 443 N. Ravenswood Ave.,

Chicago, Illinois 60640
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
75358 Knape & Vogt Mfg. Co., 2700 Oad Industrial Dr., Grand Rapids, Michigan 49505
4-2 Aug 31189

Page2
75376 Kurz-Kasch Inc., 2271 Arbor Blvd., P.O. Box 1246, Dayton, OH 45401
76870 Ohio Nut &Washer Co., P.O. Box 66, Mingo Junction, OH 43938
77342 American Machine & Foundry Inc., Potter RrBrumiield Division,

200 Richland Creek Drive, P.O. Box 522, Princeton, Indiana 47670
79470 Dana Corp., The Weatherhead Division, 767 Beta Drive, Cleveland, OH 44143
81082 Electric Auto-Lite Company, Lebanon Road, Cincinnati, OH 45241
81860 Barry Wright Corp., Barry Controis Div., 700 Pleasant St., Watertown, Mass. 02172
82372 Huntington Rubber Co., Los Angeles, CA 82372
86151 Genisco Technology Corp, Illinois Div., 9367 William Street, Rosemont, IL 60018
87930 Tower Manufacturing Corp., 25 Reservoir Avenue, Providence, RI 02907
88223 General Products Corp., A Gulf And Western Systems Co., 107 Salem St.,
Union Springs, NY 13160
89110 AMP Inc., Capitron Div., 1595 South Mt. Joy St., Elizabethtown, PA 17022
89373 United States Rubber Tire Company, Division of Uniroyal Inc.,

3920 W. Big Beaver Rd., Suite 200, P.O. Box 3939, Troy, Michigan 48084
89616 Uniroyal Inc., Plastic Products Division ,312 N. Hill St., Mishawaka, IN 46544
90763 TRW Inc., United-Carr Div., 10544 West Lunt Ave., Rosemont, Illinois 60018
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
94222 Southco Inc., 210 N. Brinton Lake Road, Concordviiie, PA 19331
96682 Genisco Technology Corp., Memory Products Div., 10874 Hope Street,
Cypress, California 90630
98410 E.T.C. - Moiex Inc.5201 Richmond Rd., Bedford Heights, Ohio 44146
98738 Stewart-Warner Electronics Div. of Stewart-Warner Corp., 1300 N. Kostner,

Chicago, IL 60651
No Number Bamai Fasteners Corp., 23240 Industrial Park Dr.,

Farmington Hills, Michigan 48024
No Number Mid State Bolt B Nut Co. Inc., 1575 Alum Creek Dr., Columbus, OH 43216
No Number Pipe & Supplies Inc., 329 East Poplar St., Sidney, Ohio 45365
Aug 31189 4-2

Page3
Ohl-436
4-2 Aug 31189

Page 4
OM-436
SECTION 3. PARTS LIST
1. Explanation of Parts List Arrangement
The parts list is arranged so that the illustration will appear on a lefthand page and the applicable parts
list will appear on the opposite righthand page. Unless the list is unusually long, the user will be able to
look at the illustration and read the parts list without turning a page.
2.Symbols and Abbreviations
The following is a list of symbols and abbreviations used in the parts list.
* - item not illustrated
A, or AMP - ampere
AC - alternating current
AR - as required
DC - direct current
Fig. - Figure
hd. - head
hex - hexagon
HZ - Hertz (cycles-per-second)
I.D. - inside diameter
IN - inch
WA - kilovolt-ampere
UF - microfarad
No. - number
NHA - next higher assembly
OM - Owners Manual
PRV - peak reverse voltage
PSI - pounds per square inch
Ref - reference (the item has been listed previously)
T-R - transformer-rectifier
V - volt (when used as a prefix to a five-digit number, indicates vendor code)
NOTE: An item which does not reflect an indexnumber is an assembly which is not illustrated in its
assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated.
August 31189 Revised 4-3

Page 1
OM-436
Generator Set
Figure 1
4-3 August 31/89 Revised

Page 2
OM-436
NOMENCLATURE UNIT!
FIGURE & HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY
l- S-6760B-1 GENERATOR SET, TRAILER -MOUNT, [R] A 1

S-6760B-2 GENERATOR SET, TRAILER-MOUNT B 1
S-6760-3 GENERATOR SET, TRAILER-MOUNT C 1
S-6760B-4 GENERATOR SET, STATIONARY-MOUNT D 1
S-6760B-5 GENERATOR SET, STATIONARY-MOUNT E 1
S-6760B-6 GENERATOR SET, TRUCK-MOUNT F 1
S-676OB-7 ** GENERATOR SET, TRAILER-MOUNT, [R] G 1
S-6760B-8 ** GENERATOR SET, TRAILER-MOUNT H 1
S-6760B-9 ** GENERATOR SET, STATIONARY-MOUNT J 1
S-6760B 10 ** GENERATOR SET, STATIONARY-MOUNT K 1
S-676OB-11 ** GENERATOR SET, TRUCK-MOUNT L 1
S-7001A-1 GENERATOR SET WITH 5th-WHEEL M 1
S-7001A-2 GENERATOR SET WITH 5th-WHEEL N 1
S-7001A-3 GENERATOR SET WITH 5th-WHEEL P 1
S-700lA-4 GENERATOR SET WITH 5th-WHEEL Q 1
1 488738 . CANOPY ASSY (For Details See Fig. 2) A-L 1
181117 CANOPY ASSY (For Details See Fig. 2) M-Q 1
2 402987 . NAMEPLATE, HOBART 4
3 76A-1152 . CAP, FUEL TANK, V49234 1
4 406000 . LABEL 1
5 768-l 148 . LABEL, DIESEL FUEL 1
6 No Number GENERATOR SET WITHOUT CANOPY (For e
Details See Fig. 3) 1
7 No Number .TRAILER ASSY. (For Details See Fig. 18) 1
8 81B-1064 . LABEL 2
9 404101-l . LIGHTS, CLEARANCE, V75175, NO. 514-0168 4
10 84A-1047 . LABEL 1
* Not Illustrated
** These units covered by addendums at front of manual, after table of contents.
[R] Exhaust at right side fender of generator set, instead of at the top.
NOTE: This manual also covers earlier model generator sets in Series 6760 and Series 6760A.
Except for the generator assemblies, virtually all components are identical for all three generator set
groups, Series 6760, Series 676OA, and Series 67608. Whereas Series 6760 units use the standard
generator assembly, Series 6760A features armatures with Hoover Bearings, Browning Coupler, and
improved magnetic pole constructionfor the generator revolving field. Generator sets in Series
6760B feature wide bearings in the generator assembly.

Page 3
OM-436
4-3 August 31189 Revised

Page 4
OM-436
NOMENCLATURE UNITS
FIGURE & HOBART PER
l- GENERATOR SETS (Continued)

11 84A-1048 .LABEL. I
12 84B-1045 .LABEL 1
13 84A-1054-I REFLECTOR, LIGHT, RED 4
14 79A-1127-2 : GUARD, FILLER NECK 1
*15 81B-1062 . LABEL 1
*I6 76A-1125 . LABEL (LOCATED ON FRONT OF UNIT) 1
17 84B-1046 . LABEL 2
18 84A-1049 . LABEL 1
19 DDW-155 . EYEBOLT, LIFTING 1
* 20 78A-1000 . NAMEPLATE, IDENTIFICATION 1
* 21 84B-1067 . LABEL 1
* 22 489127-1 . KIT, MTG., T-R AY, SINGLE T-R (For Details
See Fig. 28)(Shown) 1
489127-2 . KIT, MTG., T-R, AY, TWO T-Rs (For Details
See Fig. 28) 1
489943 . KIT, MOUNTING, T-R, AY, BACK-MOUNTING (For
281745-1 KIT, MOUNTING, T-R, ASSY. (For Details See
Figure 30) 1
281745-2 KIT, MOUNTING, T-R. ASSY. (For Details See
Figure 30) 1
* 23 484066-3 KIT, SECOND OUTPUT (For Details See
big. 27) 1
* Not Illustrated

Page 5
Canopy Assembly
Figure 2

Page 6
OM-436
NOMENCLATURE UNITS
FIGURE & HOBART PER
2- 488738 CANOPY ASSY (For NHA see Fig. I) A-L 1

181117 CANOPY ASSY (For NHA see Fig, I) M-Q 1
1 DELETED
488739 TOP CANOPY ASSY. (shown) 1
2 488325 DOOR ASSY. LEFT FRONT 1
3 488182 : COVER, PLEXIGLASS, ENGINE CONTROLS 1
4 489481 . PANEL ASSY., LEFT SIDE 1
5 488150 SUPPORT, MTG. DOORS 2
6 488756 : YOKE, LIFTING 1
7 488322 . DOOR ASSY, RIGHT FRONT 1
8 488323 . DOOR ASSY, LEFT REAR 1
9 488327 . PANEL ASSY, RIGHT SIDE 1
10 81B-1019 . LATCH, T-HANDLE, DOOR 4
11 7J-422-O . CLAMP, CABLE 2
12 lOOGH-121 . BRACKET, MTG. CLAMP 1
13 482442 HORN ASSY, CABLE ENTRANCE 1
14 482447 1 FLANGE, HORN CABLE ENTRANCE I
15 404101-1 . LIGHTS CLEARANCE, V75175, NO. 515-0168 4
"16 387859 . ROD, HOOK DOOR 4
*17 HJ-129A BALL JOINT, SLIP JOINT 4
18 488324 . DOOR ASSY, RIGHT REAR 1
* 19 181113 . PANEL, FUEL FILL OUTLET, ASSY M-Q 1
*20 403091-8 . PLUG, HOLE M-Q 1
* Not Illustrated

Page 7
OM-436
Generator Set Without Canopy

Figure 3

Page 8
NOMENCLATURE UNITS
FIGURE & HOBART PER
3- No Number GENERATOR SET WITHOUT CANOPY

(For NHA see Fig. 1) (6760-l shown) REF
No Number . ENGINE AND AIR CLEANER GROUP
(For Details See Fig. 4) 1
488279 . GENERATOR CONTROL BOX GROUP
488301 . ENGINE CONTROL PANEL ASSY.
488262 . ENGINE CONTROLS (For Details See Fig. 7) 1
488296 ELECTRIC GOVERNOR ASSY.
482075-2 . POWER MODULE PANEL ASSY.
430391 c . VOLTAGE REGULATOR ASSY.
(For Details See Fig. 70) A-F,M,PQ 1
489812A . VOLTAGE REGULATOR ASSY. (For
Details See Manual OM-2020 in ChaDter 6) G-L,N 1
8 280783 . GENERATOR (For Details See Fig. 15) 1
** 9 84B-1038 . KIT, COLD START ASSY, V62445,
NO. BF6L913 (For Details See Fig. 16) 1
10 408524 . UNIT, CONTROL ELECTRIC GOV.
(For Details See Fig. 16), V66503 1
11 482317 . OUTPUT TERMINAL BOARD ASSY.
12 81 B-l 061 LABEL 2
13 488222 : SUPPORT PANEL CONTROL ASSY.
- (For Details See Fig. 5, 6, 9, 70, 16) A-F,M,N 1
181101 SUPPORT PANEL CONTROL ASSY.
(For Details See Fig. 5, 6, 9, 70, 16) G-L,N 1
181718 SUPPORT PANEL CONTROL ASSY.
(For Details See Fig, 5, 6, 9, 10, 16) Q 1
14 482318 . COVER, TERMINAL OUTPUT 1
15 404595 . SENSOR MAGNETIC GOVERNOR 1
16 No Number . STATOR ASSY. (For Details See Fig. 16) REF
** Optional Item

Page 9
OM-436
Engine and Air Cleaner Group

Figure 4

Page 10
OM-436
NOMENCLATURE UNITS
FIGURE & HOBART PER
4- No Number ENGINE AND AIR CLEANER GROUP

(For NHA See Fig. 3) (6760-I shown) 1
1 838-l 109A . ENGINE, DEUTZ DIESEL, V62445 1
2 488193 . EXTENSION, AIR INTAKE 1
3 488194 PAD, VIBRATION, AIR INTAKE 2
4 488289 . RING, EXTENSION, AIR INTAKE 1
5 488330 . PANEL, WALL FRONT ASSY. 1
6 488333 . CANOPY, REAR ASSY. A-L 1
181106 . CANOPY, REAR ASSY. M-Q I
7 488192 COVER, SHORT AIR INTAKE 1
8 488191 : COVER, LONG AIR INTAKE 2
9 488329 . COVER, ACCESS 1
10 488525 BAFFLE, AIR INTAKE 1
11 489005 : COVER, ACCESS 1
12 84A-1011 AIR CLEANER ASSY. 1
13 84A-1010 . BRACKET, MTG, AIR CLEANER VI 8265,
......_.__..___._
......_______.._
......_._._
___.
__.._
......_.._ NO. POO-4073 2
___.______.__._....__---.--............------.---------.--..............-.........--...............................
___._.....................~.~.~.~
_________
14 403483 CLAMP, FITTING 1
15 488201 : TANK, FUEL ASSY. 1
16 DELETE
17 488334 . BAFFLE, AIR INTAKE ASSY. 2
18 488303 . PLATE, MTG. EXHAUST PIPE AG 1
19 84A-1006 . REDUCER, V82372, AIR CLEANER 1
20 W-l 0869-5 . CLAMP FITTING 1
21 488277 PIPE MANIFOLD ASSY. 1
22 404154-13 CLAMP PIPE 1
23 488265 . MUFFLER ASSY. AG 1
488742 . MUFFLER ASSY. B-F,H-Q
24 488233-2 STRAP, MTG. MUFFLER 2
25 488232 : STRAP, MTG, MUFFLER ASSY. 2
26 30GH-417 . MOUNT, SHOCK MUFFLER 4
30GH-417 . MOUNT, SHOCK MUFFLER AG 2
27 488205 SUPPORT, MUFFLER ASSY. 2
28 488743 . PIPE, EXHAUST ASSY. AG 1
488760 . PIPE, EXHAUST ASSY. B-F,H-Q 1

Page 11
oM-436

Page 12
oM-436
NOMENCLATURE UNITS
FIGURE HOBART per
29 488293 COVER, ALTERNATOR ASSY. 1

30 488304 : BRACKET, MTG, EXHAUST PIPE A 1
31 30GH-417 SPACER, MTG, EXHAUST PIPE, V81860 2
32 404154-l 5 : CLAMP, MUFFLER A 2
404154-l 5 CLAMP, MUFFLER BDE 1
33 488314 :BRACKET, MTG., FUEL FILTER 1
34 488318 PAN, FUEL DRIP 1
35 No Number : FUEL FILTER (DEUTZ ENGINE) 1
36 DDW-495-1 . CAP, RAIN BDE 1
37 488780 . HOSE, OVERFLOW ENGINE 1
August 31/89 Revised 4-3

Page 13
OM-436
-3
Generator Control Box Group

Figure 5
43 August 31189 Revised

Page 14
OM-436
NOMENCLATURE UNITS
FIGURE HOBART per
5- 488279 GENERATOR CONTROL BOX GROUP
1 NoNumber . CONTROL BOX AND INTERNAL

COMPONENTS ASSY. (For Details See
Fig. 13) 1
2 482278-2 . TRAY ASSY, GENERATOR CONTROLS
3 482285-l . TRAY ASSY, PROTECTIVE RELAYS, (For
4 HF-2752 . SPACER, SHOCK MTG., V16238,
NO. 4624-l 05 4
August 31 I89 Revised 4-3

Page 15
OM-436
2 3 4
Engine Control Panel Assembly

Figure 6

Page 16
OM-436
NOMENCLATURE UNITS
FIGURE & HOBART PER
6- 488301 PANEL ASSY. CONTROL ENGINE

1 488188 PANEL, ENGINE CONTROL 1
2 82A-1030 : GAUGE OIL, PRESSURE, V81082
NO. 75 TYPE C
3 W-991 7-l 8 . ENGINE, HOUR METER, AC DC,
V26992, NO. 771-4150 1
4 400889-2 . AMMETER, BATTERY, V23826 1
5 84A-1019 , GAUGE, OIL TEMPERATURE, V59197
NO. 3105041231015207 1
6 403189 . SWITCH, TOGGLE, V91929,
NO. 312, TSl-59 3
7 12CW-1320A-5 GAUGE FUEL, V98738, NO. 301-4 1
8 404172-3 LENS, GREEN, V72619,
NO. 26-l 192-300 2
9 DW-1777B SWITCH, PUSHBUTTON, STARTER,
V87930, NO. 5570-8 1
10 404172-l LENS, RED, V72619 1
11 404100 1 PUSHBUTTON, ENGINE, ~70040,
NO. 1996027 1
12 488183 . HINGE, PANEL, ENGINE 1
13 HF-2752 . SPACER, V16238, NO. 4624-105 1
14 25Ms-156 . BUS MTG. DIODE 2
15 20RT-353-1 . DIODE CONTROLLED AVALANCHE,
V51589, NO. ST23OECAN 2
16 404173 BASE, LIGHT, PILOT, V72619,
NO. 26-1310-11-301 3
17 400613-4 BULB, 12V, LIGHT, VO8108, NO. 1815 3
18 4053651 : SWITCH, TOGGLE, SPST, V73559,
NO. 2FA53-73 1

Page 17
OM-436
Engine Control
Figure 7
43 August 31189 Revised

Page 18
NOMENCLATURE UNITS
FIGURE HOBART per
7- 488262 PANEL, ENGINE TEST ASSY.
(For NHA See Fig. 3) 1
1 488207 . PANEL, ENGINE TEST 1

2 403379 . RECEPTACLE, BOX 26 CONTACT 1
3 405797-3 . INDICATOR, SERVICE AIR FILTER 1
4 400698-5 POTENTIOMETER, 50K OHM, 1
5 W-l 1166-4 : FUSE, 15A, FAST BLOW, AGC 1
6 402658 HOLDER, FUSE 1
7 84A-1008-l : ADAPTER, BULKHEAD, FILTER 1
8 W-11231-1 SCREW, # 8-l 8 X 318 SELF TAP 1
9 403380 : CAP AND CHAIN ASSY. 1
* 10 W-l 0886-l CONNECTOR, MALE, SAE, 45
DARED v79470, ~0.48 x 4 1
* Not Illustrated

Page 19
OM-436
Electric Governor Assembly

Figure 8

Page 20
NOMENCLATURE UNITS
HOBART PER
PART NO. 1234567 EFF ASSY.
8- 488296 ELECTRIC GOVERNOR ASSY.

1 488294 . BRACKET MTG. GOVERNOR 1
2 84A-1020 . GOVERNOR, ELECTRIC, V66503 1
3 84A-1050 . ARM, THROTTLE 1
4 402908 . JOINT, BALL GOVERNOR LINKAGE 2
5 W-l 1280-3 . NUT 2
6 W-9476-33 . ROD, THREADED, l/4-28 X 3-718 1
*7 281774-2 . SENSOR, MAGNETIC GOVERNOR
(See Fig. 3 for location) 1
*8 408524 . GOVERNOR, CONTROLLER (See
Figure 76, Item I) 1
9 489951 . BRACKET, GOVERNOR 1
* Not Illustrated
Dee 18/93 Revised 43

Page 21
OM-436
14
Power Module Panel Assembly

Figure 9

Page 22
NOMENCLATURE UNITS
FIGURE HOBART per
9- 482075-2 . PANEL, ASSY, POWER MODULE
1 482076 PANEL, POWER MODULE 1

2 1CZ-148 : TRANSFORMER, CURRENT LINE
DROP & OVERLOAD, Vl4831, NO. E-61 70 6
3 404402-l RESISTOR OVERLOAD BURDEN,
i 6.6 OHMS V91637, NO. RH-25,
20 WATT 3
4 401937-3 STRIP, TERMINAL, V98410,
ho. 35012-3536 2
5 401939 . ADAPTER, TERMINAL, V98410,
NO. VWA-0 1
6 402197-l . TERMINAL, QUICK CONNECT,
PIGGYBACK, V89110, NO. 61944-2 1
7 400830-15 . TERMINAL, RING TONGUE,
V89110, NO. 31159 3
8 400701 . CONNECTOR, RIGHT ANGLE
V59730, NO. TA-250-8 11
9 400480-2 . TERMINAL, QUICK CONNECT,
VOO779, NO. 41274 5
10 400480-3 . TERMINAL, QUICK CONNECT,
V00779,NO.42640-2 2
11 401937-2 . STRIP, TERMINAL, V98410,
NO.35008-3526 1
12 W-9746-l . RESISTOR, LINE DROP BURDEN,
50 OHM, 25 WATT, V44655, NO. 0200D 3
13 404065-2 . RECTIFIER, SILICON, VO4713,
NO. SDA 10270-2 1
14 404518 . CONTACTOR, LOAD, V74063,
NO. HB 200B 1
15 387738A . BOARD, PC OVERLOAD 1
16 401556 . MOUNT, SHOCK, RUBBER, V89616,
NO. B-323 OR V81860, NO. SS-01 4
17 363136-5 . TRANSFORMER, CURRENT AMMETER 3
18 1CZ-93 B . DIODE, SILICON, V05277, NO. IN4820 1
19 401564-4 HOUSING, SOCKET, CONNECTOR,
i89110, NO. 1-480287-O 1
20 401566-l 1 . TERMINAL, SOCKET, V89110, NO. 60619 10
21 HF-2752 . SPACER 4
* Not Illustrated

Page 23
OM-436
37
Voltage Regulator Assembly

Figure 10

Page 24
NOMENCLATURE UNITS
FIGURE & HOBART PER
lo- 430391c 0 REGULATOR, VOLTAGE, ASSY

(Refer to manual TM-759 in ChaDter 6) 1
1 485530 CHASSIS, REGULATOR 1
430340 : CHASSIS, LINE DROP COMPENSATION, ASSY. 1
2 430470 . . CHASSIS 1
3 402373 . . NAMEPLATE, LINE COMPENSATION 1
4 w-11597 . . KNOB, POINTER, V75376, NO. S-292-3L 2
5 ICZ-70 . . SWITCH, ON-OFF, VI 5605, NO. 761 OK2 1
6 1cz-97 . . REACTOR, LINE DROP, V86151,
NO. E-3963 3
7 401563-3 . . HOUSING, PIN CONNECTOR 1
8 ICZ-105 . . RHEOSTAT, TRIPLE TANDEM, V44655,
--__-_-_
NO. H-l 0-F2-T3 1
9 lCZ-128 RHEOSTAT, TRIPLE TANDEM, V44655,
NO. 6610 1
10 430476 INSULATOR, BOTTOM, RESISTOR 1
11 W-9746-9 . RESISTOR, V44655, NO. 0205 1
..._...__
.-.._......_...__.._._
.........._.__...__
...._..___.__
_______.................~~
___.___________
- _____
________
__
-__I-
_____________
._..__
__.___
_________
______._
_...._
__.____...........___...............~.......................~..
12 ICZ-74 . INSULATOR, TOP, RESISTOR 1
13 402342 REACTOR, REGULATOR, V96682,
NO.70-8532 1
14 16DA-2 162 . KNOB, RHEOSTAT, V44655, NO. 5150 1
15 H F-745 . NAMEPLATE 1
16 30GH-734 . BRACKET, MOUNTING, RHEOSTAT 1
17 w-9712-13 . RHEOSTAT, REGULATOR, 750 OHM,
25 WATT, V44655, MODEL H, 1 TURN 1
18 370141 . BRACKET, MOUNTING PLUG 1
19 25fvlS-328 . SPACER 2
20 402376 . RECEPTACLE, VO2660,
NO. MS-l 302A-22-14P 1
21 400782-l . FUSE, 5 AMP, FAST ACTING, GLASS TUBE, MTH 1
22 HF-2407 . FUSEHOLDER, V71400, NO. HKP 1
23 401911-3 . TERMINAL BOARD, V88223, NO. 441-3 1
24 W-l 0827-8 RESISTOR, 470 OHM, l/2 WATT 1
430472A : CHASSIS SENSING & PRE AMP, ASSY 1
25 430341 . BRACKET, MOUNTING, CHASSIS 1
0 This magnetic-amplifier type voltage regulator, comprised of all of the parts

on this list, is used on generator sets having Effectivity Codes A-F, M, PQ.
For generator sets covered by this manual that are equipped with the solid-
state voltage regulator (Part No. 489812A) refer to Manual OM-2020 in
Chapter 6.

Page 25

Page 26
OM-436
NOMENCLATURE UNITS
FIGURE & HOBART PER
lo- 430391c 0 REGULATOR, VOLTAGE, ASSY (Continued)

26 485053 . . BOARD, PC, HIGH PHASE SENSING 1
27 79B-1140 . . . RELAY, V77342, NO. KHU17Dll 1
28 79A-1142 SPRING, RELAY RETAINING, V77342 1
29 404460-I I : SUPPORT, PC BOARD, LOCKING 3
30 485282 . . BRACKET, MTG, PC BOARD, FRONT 1
31 485283 . . BRACKET, MTG, PC BOARD, REAR 1
32 40 1563-2 HOUSING, PIN CONNECTOR 1
33 401563-3 . HOUSING, PIN CONNECTOR 1
34 400698-2 . . POTENTIOMETER, 2500 OHM,
2 WATT V44655, NO. CLU-2521 1
35 W-971 2-30 RHEOSTAT, 1500 OHM, 25 WATT,
V44655, NO. H 1
36 1CZ-60 . . TRANSFORMER, DAMPING, V50508,
NO. E3196-A 1
37 402357 . . TRANSFORMER, HIGH PHASE,
V50508, NO. 40-8587 3
38 430473 . PANEL, CHASSIS 1
39 1CZ-63 REACTOR, FILTER, HIGH PHASE,
V50.508, NO. E3661 -A 4
.....-------.
40..............
............402358 _________.__..........~~.~~.~~
:..:N~~EP-~~~~.~~~~-~~- _______________.
- .._._
________
._._.
__.______
____________________________
........1_______
41 480725 . LABEL, INSTRUCTION 1
* 40 1564-2 . HOUSING, SOCKET CONNECTOR 1
* 401564-3 HOUSING, SOCKET CONNECTOR 2
42 HF-2752 : SPACER MOUNTING 4
* Not Illustrated
0 This magnetic-amplifier type voltage regulator, comprised of all of the parts

on this list, is used on generator sets having Effectivity Codes A-F, M, PQ.
For generator sets covered by this manual that are equipped with the solid-
state voltage regulator (Part No. 489812A) refer to Manual OM-2020 in
Chapter 6.

Page 27
OM-436
Protective Relays Tray Assembly

Figure 11

Page 28
OM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
ll- 482285-l TRAY ASSY, PROTECTIVE RELAYS

(For NHA see Fig. 5) REF
1 402662 . SWITCH, TEST BANK, V73559,
NO. 2GK71-73 1
2 492284-2 . BRACKET, MTG., RECEPTACLE & SWITCH 1
3 482356 . RECEPTACLE, HARNESS, WIRE 1
4 16DA-4052-0 . SOCKET, RELAY VO2660, #77-MIP-11 3
5 16DA-4004A-3 . RELAY, PLUG INTERLOCK, 24 V DC
V77342, #KAP-14DG 1
6 16DA-4253-1 RETAINER, SPRING, RELAY V77324,
#2OC206 3
7 16DA-4004A-10 RELAY, FUSE INTERLOCK, NO. KAP-14DG 2
____--___-
8 W-9746-3 RESISTOR, 100 OHM, 25 WATT, V44655,
NO. 02OOF 1
9 401937-l STRIP, TERMINAL, V98410, NO. 35005-3526 1
10 401556 . MOUNT, SHOCK, RUBBER, V89373,
____________________.~.~.......
_.__
__..........________..~.~.......
_.___._
_____ NO.
_.__._......_.~... B-323 OR V81860,
_....._..___.___
_____ NO. _---------.--..-...-.-..---...........
________________
____ SS-01
_______._.I__-.-- 12
_.--.............--.............-...........
11 387736C . BOARD, ASSY, MEMORY AND TIME DELAY 1
12 401563-5 . . HOUSING, PIN, CONNECTOR 1
13 482038 . BOARD ASSY, OVER-UNDERVOLTAGE 1
15 482039 BOARD, ASSY, OVER-UNDERFREQUENCY 1
17 76A-1118 . SWITCH, SNAP, PUSHBUTT,ON, V27191,
NO. SA35BCB34-9 2
18 403336 . RING, LOCKING SWITCH V91929, TSlOO20 2
19 HF-2518-2 LIGHT, PILOT, FAULT, 12V, RED 5
19A 404172-l . . LENS, RED, V72619, NO. 26-1191-300 1
20 400613-4 . . BULB, V71744, TYPE 1815 1
21 402658 . HOLDER, FUSE, V71400, NO. HKP-HH 2
22 W-l 1166-l FUSE, AGC, 2A. 1
23 W-l 1166-l .FUSE, AGC, 2A. 1
_----
24 16DA-1997-6 BUTTON, PLUG, HOLE, V90763, NO. SS-51026 1
25 402037-g GROMMET, RUBBER, V02231, NO. AGW-4211 1
* 26 388328-52 . NAMEPLATE, IDENTIFICATION 1
* 27 401566-l 1 . TERMINAL, SOCKET, V89110, NO. 60619-l 35
* 28 40 1564-4 . HOUSING, SOCKET, CONNECTOR, V891 IO
NO. l-480287-0 2
* 29 401564-5 . HOUSING, SOCKET, CONNECTOR, V891 IO
NO. 1-480438-O 2
* Not Illustrated

Page 29
OM-436

Page 30
NOMENCLATURE UNITS
FIGURE HOBART per
30 482291 NAMEPLATE, PROTECTIVE SYSTEM 1

482286 : TRAY, ASSY, PROTECTIVE RELAYS 1
31 402383 . . SLIDE ASSY, TRAY, (Set consists of fourparts
marked CR, CL, DR, & DL) V75358, NO. 1336-12
32 404028 . NAMEPLATE, HOBART
33 370382A . . HANDLE, TRAY
34 76A-1115 . . LATCH, ADJUSTABLE GRIP, V94222
NO. 48-99-126-11
35 482287 TRAY ASSEMBLY
* 36 482307 HARNESS ~ss~, WIRE, PROTECTIVE
RELAYS TRAY
* Not Illustrated

Page 31
Generator Controls Tray Assembly
Figure 12
4-3 May 18/90 Revised

Page 32
NOMENCLATURE UNITS
FIGURE HOBART per
12- 482278-2 TRAY ASSY, GENERATOR CONTROLS
1 482355 . HARNESS, WIRE, RECEPTACLE 1

2 482284-i BRACKET, MTG., RECEPTACLE & SWITCH 1
3 402826 : SWITCH, AUTOMATIC, MANUAL, V15605
NO. 8926K425 1
*4 402665-l HOUSING, RECEPTACLE, VO0779,
&-480416-O 6
5 404065-2 . RECTIFIER, SILICON, V04713,
NO. SDA10270-2 1
6 W-2974-L . RESISTOR, MANUAL, 50 OHM, 100 WATT
V44655,NO.0959 1
6 400078 . BRACKET, MOUNTING, RESISTOR 6
7 W-2974-N RESISTOR, BALLAST, 100 WATT 2
8 16DA-4253-1 : RETAINER, SPRING, RELAY, V77342,
NO.20C206 1
9 16DA-4004A-10 RELAY, EXCITATION, DEENERGIZATION
i 2V, V77342, NO. KAP-14DG 1
10 16DA-4052-0 . SOCKET, RELAY, VO2660, NO. 77-MIP-11 1
*11 363771-5 SLEEVING, PLASTIC, l/8 IN. I.D. 6
"12 363770-l : SLEEVING, PLASTIC, 3/16 IN. I.D. 2
13 16DA-4029 . BRACKET, MOUNTING, SOCKET, RELAY 1
14 16DA-2162 . KNOB, RHEOSTAT, V44655, NO. 5150 1
15 1OJ-178 . NAMEPLATE, FIELD, RHEOSTAT 1
16 381439 . BRACKET, MOUNTING, RHEOSTAT 1
17 402218 . RHEOSTAT, MANUAL, MODEL L, V44655,
100 OHMS, 150 WATTS 1
18 HF-1459 . SWITCH, METER SELECTOR, VO4009,
NO. 81579-FT 1
19 15GH-433 NAMEPLATE, METER, SELECTOR SWITCH 1
20 400400 : SWITCH, TOGGLE, V74559, NO. 26L61TABS 1
21 W-8095A-9 . AMMETER, V60741, NO. 331 LH 1
22 W-8105A-4 . VOLTMETER, V60741, NO. 331 LH 1
23 W-991 6-l 0 . METER, FREQUENCY, V31356, NO. 36-FX 1
24 388328-49 NAMEPLATE, IDENTIFICATION 1
482279 : TRAY, SUB-ASSY, GENERATOR CONTROL 1
25 370382A . . HANDLE, TRAY 1
26 404028 . . NAMEPLATE, HOBART 1
* Not Illustrated

Page 33
OM-436

Page 34
CM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
12- TRAY ASSY, GENERATOR CONTROLS (Contd)

27 76A-1115 . LATCH, ADJUSTABLE GRIP, V94222,
NO. 48-99-l 26-l 1
28 402383 . SLIDE ASSY, TRAY, (Set consists of four parts
marked CR, CL, DR, & DL) V75358, NO. 1336-I 2
29 482280 . . TRAY ASSEMBLY
30 408999-I . DIODE, RECTIFIER, POWER, VO4713, No. MR1396 1
*31 400030-1 . CAPACITOR, TANTALUM 6.8 F, 35V, V56289,
NO. 150D685X9035B2 1
*32 482306 . HARNESS ASSY, WIRE, GEN. CONTROL TRAY 1
33 402379 . .PLUG, STRAIGHT, 20 CONTACT VO2660,
NO. MS-3106A-28-1 SS 1
*34 402382 . CLAMP, CABLE, VO2660, NO. MS-3057-1 6 1
*35 484689-l SLEEVING, SHRINKABLE, l/8 ID AR

Page 35
OM-436
Control Box And Internal Components Assembly

Figure 13

Page 36
CM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
13- NO NUMBER CONTROL BOX AND INTERNAL

COMPONENTS ASSY. (For NHA see Fig, 5) REF
1 82B-1047 . LIGHT, ASSY, PANEL V75175, NO. 261-3306 2
1A 82A-1048 . . LENS, CLEAR, V75175, NO. 40944-001 1
2 50GHP-206 . . BULB, VO8108, NO. 67 OR T631 1
3 401937-2 . STRIP, TERMINAL, V98410, NO. 35012-3526 1
4 488180 . BOX, CONTROL ASSY. 1
402383 . SLIDE ASSY. TRAY (For Details
See Fig. 11 or 72) REF
402037-g . GROMMET, RUBBER, VO2231, NO. AGW-4211 2
w-10051-13 CLAMP, WIRE, PLASTIC, V81074, NO. EC-14 2
w-10051-10 . CLAMP, WIRE, PLASTIC, V81074, NO. EC-10 3
9 16DA-4253-1 . RETAINER SPRING RELAY, V77342, NO. 2OC206 2
10 16DA-4004A-10 RELAY, FUSE INTERLOCK, 12V, V77342,
NO. KAP-14DG 2
11 370891 . BRACKET, MTG. RELAY 1
12 401937-3 STRIP, TERMINAL, V98410, NO. 35012-3526 2
13 16DA-4052-0 S OCKET, RELAY, VO2660, NO. 77-MIP-11 2
14 488280 HARNESS, WIRE GEN. CONTROL TRAY 1
*15 488281 . HARNESS, WIRE PROTECTIVE RELAY TRAY 1
*16 484689-l SLEEVING, PLASTIC l/8 ID 2
*17 484690-2 : SLEEVING, PLASTIC 3/l 6 ID 4

Page 37
OM-436
-5
-6
8CD-7
-8
Output Terminal Board Assembly

Figure 14

Page 38
NOMENCLATURE UNITS
FIGURE HOBART per
482317 PANEL ASSY, TERMINAL OUTPUT
1 50MS-732-0 NUT, HEX, l/4-20, KEPS, MH, STEEL 12

2 W-l 1242-5 : WASHER, FLAT, l/4 IN. STEEL 12
3 w-9549-19 . ROD, TERMINAL, l/4-20 X 2-l/4 2
4 482445 BRACKET, MOUNTING, BOARD,
TERM. OUTPUT 2
5 W-11097-18 . SCREW, HHC, STEEL, 3/8-16 X 3/4
(BAMAL FASTENERS CORP) 8
6 W-l 1254-6 WASHER, LOCK, STEEL, 3/8 IN. 8
7 W-l 1242-l 0 : WASHER, FL, STEEL, 3/8 IN.
(MID STATE NUT & BOLT) 8
8 482446 . RETAINER, CABLE 8
9 482443 BAR, BUS, PHASE 4
10 W-11112-3 : SCREW, RD., HD., MH, ST.
1O-24 X 314 4
11 W-l 1254-3 WASHER, 10, LOCK, ST.
(MID STATENUT & BOLT) 4
12 W-l 1245-3 . WASHER, lo, FLAT, BRA& 4
13 482444 BOARD, TERMINAL, OUTPUT 1
* 14 W-9360-261 : CABLES, OUTPUT 3

Page 39
OM436
Generator Assembly
Figure 1.5
4-3 May 18/90 Revised

Page 40
NOMENCLATURE UNITS
FIGURE HOBART PER
15- 280783 GENERATOR ASSY (For NHA See Fig. 3) REF
1 488295 . COVER, FAN, HOUSING 1
2 DELETED
3 488908 FAN & COUPLING ASSEMBLY 1
*3A W-l 1102-l 8 : SCREW, FLEXIBLE COUPLING 6
*4 482483 . SCREW. RETAINING 1
5 480669 . ADAPTER, FOOT, GEN. REf

*6 W-l 1102-8 SCREW, GEN. MTG. 10
7 488755 : COVER, END, EXCITER HOUSING 1
8 1OOGHP-66 WASHER, RETAINING 1
9 387623-l ICORE, ARMATURE ASSEMBLY 1
10 W-l 0875-l DIODE, SILICON, 35 AMP, NEGATIVE BASE,
i51589, #ST460N 3
11 W-l 0874-l DIODE, SILICON, 35 AMP, POSITIVE BASE,
i51589, #ST460P 3
12 386612 . RING, SPACER, COUPLING 1
13 481379 . KEY, EXCITER 1
14 387624A-1 . HOUSING, EXCITER 1
15 1OONH-2 . POLEPIECE, EXCITER 4
16 1OONH-3 INSULATION, EXCITER, WRAPPER 4
*17 DATA 3190 : COIL, FIELD, EXCITER SF
18 387620A-1 . HOUSING, FAN ASSEMBLY 1
19 85B-1039 . KEY, FLEXIBLE, COUPLING 1
20 281536 . BEARING, FRONT 1
21 W-l 0072-l BEARING, REAR 1
22 181343 : ARMATURE, AC/DC 1
23 387748-l . HOUSING & STATOR ASSEMBLY 1
24 488993 . BRACKET, RETAINING BEARING 1
25 385950 . INSULATION, TOE 16
*26 480603-l MOUNT, RUBBER 6
*27 480628 : WASHER, MOUNT 6
*28 79A-1144 NAMEPLATE, FAN & COUPLING 1
* NOT ILLUSTRATED

Page 41
ohi-436
Panel Support, Controls

Figure 16

Page 42
NOMENCLATURE UNITS
FIGURE HOBART per
lb NO NUMBER PANEL, SUPPORT CONTROLS 1
1 408524 .UNIT CONTROL ELECTRIC GOV., V66503,
**2 848-1038 KIT, COLD START ASSY, V62445
NO. BF6L913 1
3 401556 MOUNT, ----
SHOCK, RUBBER 4
4 W-10854-4 : CAPACITOR, 0.1 F, 500 V, AC/DC 3
5 1OOGH-112 . TERMINAL OUTPUT 3
6 5cw-975 BUSHING, INSULATOR, CABLE STUD 3
7 5CW-976A : WASHER, INSULATOR, CABLE STUD 6
8 W-l 1242-l 0 . WASHER, FL, STD. 3/8, V76870 6
9 W-l 1254-6 . WASHER, LOCK, STD, 3/8
(MIDSTATE NUT & BOLT CO.) 6
10 W-l 1097-8 . SCREW, 3/8-16X2, HHC, ST.
(BAMAL FASTENERS CORP.) 3
11 482989 STRAP, WIRE GROUND 2
12 W-l 1278-5 . NUT, 3/8-16 HEX FULL ST.
(BAMAL FASTENERS CORP.) 3
** Optional Item

Page 43
Oi&436
FUEL
Mounting Frame and Control Support Assembly

Figure 17

Page 44
OM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
17- NO NUMBER MOUNTING FRAME AND SUPPORT

CONTROL ASSY. (For NHA see Fig. 3) REF
1 488328 . PANEL, SUPPORT CONTROL ASSY. 1
2 488331 . COVER, ASSY. A-L 1
280367 COVER, ASSY. M-Q 1
3 488222 . PANEL, SUPPORT ASSY A-F,M 1
181101 . PANEL, SUPPORT ASSY G-L,N 1
181718 PANEL, SUPPORT, ASSY Q 1
4 488267 PANEL, BULKHEAD, REAR ASSY. 1
5 488756 : YOKE, LIFTING 1
6 488201 . TANK, FUEL ASSY. 1
7 480669 . ADAPTER, FOOT GENERATOR 2
8 480603-l . MOUNT, SHOCK, V81860 20
9 480628 . PLATE, MTG., ENGINE, GENERATOR IO
10 488124 . SUPPORT, ENGINE FRONT 4
11 430278 . GROMMET, RUBBER 4
12 488150 . SUPPORT, MTG. DOOR 2

Page 45
OM-436
Trailer Group With Parking Brake

Figure 18

Page 46
NOMENCLATURE UNITS
FIGURE & HOBART PER
18- No Number TRAILER GROUP WITH PARKING BRAKE

(For NHA See Fig. 1) REF
1 489725-l . FENDER FRAME AND UNDER CARRIAGE
W/ EXHAUST OUT TOP (For Details See
Fig. 19) BC,H 1
489725-2 . FENDER FRAME AND UNDER CARRIAGE
W/ EXHAUST OUT SIDE (For Details See
Fig. 79) A,G 1
2 404088A-1 . TRAILER ASSEMBLY WITH PARKING
BRAKE (For Details See Fig. 20) A-C,GH 1
3 280359-l . KIT, TRAILER & FENDER ASSY. W/ EXHAUST
OUT TOP (For Details See TO- 780) N-b 1
280359-2 . KIT, TRAILER & FENDER ASSY. W/ EXHAUST
OUT TOP (For Details See TO- 780) M 1

Page 47
01\11-436
Fenders, Frame Accessories and Under Carriage

Figure 19
4-3
Page 48 August 31/89 Revised
OM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
19- 489725-l FENDER, FRAME AND UNDERCARRIAGE

(For NHA See Fig. 18) BC,H,P REF
489725-2 FENDER, FRAME AND UNDERCARRIAGE
(For NHA See Fig. 18) A,G REF
1 488125 . FRAME, MTG., GEN. SET + 1
2 488176 RAIL, CABLE SUPPORT + 2
3 488736 . FENDER, RIGHT SIDE REAR BC,H 1
488154 . FENDER, RIGHT SIDE REAR AG 1
4 488171 PANEL, COVER BATTERIES + 1
5 488170 . PANEL, COVER BATTERIES + 1
6 488155 PANEL, CENTER ASSY. + 2
7 488156 : SUPPORT, BATTERY DOOR 4 2
8 488165 . SUPPORT, BATTERIES + 1
9 488174 . RAIL, CABLE SUPPORT + 2
.......------...-...-._----____
......_._.-
--..--.
_._--_--_
--------............-.-..----
_---_-_
________________
______.__.-.-..__-..__I__________________---...
__
....._________ .............__.._.
_._....____.__........~..~
_.._ ____________
10 488251 FENDER, RIGHT SIDE FRONT t 1
11 488166 : SIDE, BATTERY BOX + 1
12 488152 FENDER, LEFT SIDE, REAR + 1
13 488163 SUPPORT, FENDER + 2
14 488172 PANEL, CENTER COVER + 1
** 15 488247 . BRACKET, MTG. DEFLECTOR + 2
16 488253 FENDER, LEFT SIDE, FRONT + 1
17 488164 . FENDER, REAR GUARD t 1
** 18 488313 . PANEL, BELOW GEN. ASSY. 1
** 19 488312 . PANEL, BELOW GEN. 1
** 20 488249 . AIR DEFLECTOR ASSY. 1
** 21 488238 . PANEL, DUCT, ENG. ASSY. 1
""22 488526 . COVER, OIL DRAIN 1
**23 488231 . PANEL, LOWER ENGINE FRONT 1
24 402086-3 . BATTERY, 12 VOLT AB,GH,M-Q 2
84C-1061 . BATTERY, 12 VOLT, 580-A C 2
25 488245 . HOLD DOWN, BATTERY ASSY. AB,GH,M-Q 2
489160 . HOLD DOWN, BATTERY ASSY. C 2
26 5CW-2048 . ROD, HOLD DOWN BATTERY t 2
27 76A-1131 . GUARD, EDGE + 6"
*28 488302-l CABLE, BATTERY, POS. + 1
*29 488302-2 : CABLE, BATTERY, NEG. + 1
**30 488184 . PANEL, SEAL, GEN. 1
* Not Illustrated
** Only these items of the Fender, Frame and Undercarriage apply to

Specification Numbers 67608-4 and 6760B-5.
+ These parts used on all regular four-wheel trailers.

Page 49
OM-436

Page 50
oM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
19 - FENDER, FRAME AND UNDERCARRIAGE (Continued)

**31 488204 PANEL, LOWER, ENGINE, FRONT 1
**32 402037-12 : GROMMET, RUBBER 3
*33 488246 . STRIP, MTG. PANEL + 2
*34 80A-1035 PIN, YOKE + 6
*35 80A-1036 : YOKE + 6
"36 W-9234-362 . CABLE, BATTERY, CONNECTION,
NEGATIVE-TO NEGATIVE C 1
*37 W-9234-363 CABLE, BATTERY-TO-STARTER C 1
"38 W-9234-38 . CABLE, BATTERY-TO-GROUND C 1
*39 w-9234-112 CABLE, BATTERY-TO-POSITIVE C 1
*40 489812 ROD, RIGGING BRAKE REWORK + 1
* Not Illustrated
** Only these items of the Fender, Frame and Undercarriage apply to

Specification Numbers 6841-1, 6760-4 and 6760-5.
+These parts used on all regular four-wheel trailers.

Page 51
Trailer Assembly
Figure 20

Page 52
oM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
20 - 404088A-1 TRAILER ASSEMBLY WITH STANDARD

PNEUMATIC TIRES (For NHA See
Fig. 18) A-C,GH REF.
1 76A- 1140 . TIRE, PNEUMATIC, 6:00 X 9, 10 PLY 4
2 400599 . TUBE, 6:00 X 9 4
404088-l RUNNING GEAR ASSY, V22938, NO. 2-383 1
408532 . . AXLE ASSY, FRONT, V22938,
NO. 2-383-2056 1
---
3 79A-1044 . AXLE, FRONT, V22938, NO. 383-205-l 1
79A-1049 . . . ROD ASSY, TIE, RIGHT, V22938,
NO. 3906-265 2
4 79A-1051 . . . NUT, ROD, TIE, V22938, NO. 4602-l 2
5 79A-1052 . . . . NUT, ROD, TIE, V22938, NO. 4602-2 2
........._______.....~.~.~~~~~~........~..~
____..........
_.___
____.
__..................._
____._________
___________
_____
----------------------.-...--.-------------~----..--
......_-.-__
.......------.-...........-..-.-...........-.........--
6 79A-1053 . . . . END, ROD, TIE, RIGHT, V22938,
NO. 3950-l 2
7 79A-1054 . . . . END, ROD, TIE, V22938, NO. 3950-2 2
8 79A-1050 . ROD, TIE, V22938, NO. 3900-230 2
* 79A-1055 . . . . COTTER PIN, V22938, NO. 4800-4 4
79A-1045 ARM ASSY, CENTER, V22938, NO. l-3854 1
9 79A-1046 . . ARM, CENTER, V22938, NO. 3854 1
10 404528 . . . . SPRING, LATCH, V22938, NO. 4006 1
11 404529 . . . . LATCH, DRAW BAR, V22938, NO. 3855 1
12 404530 PIN, ROLL, 3/8X l-1/2 IN, V22938,
....._________..
- _.____.._............~~~...~...~.......~~~~~~~~~~.~~....................~..~..~~~..~
_-_____.___
_____-
_----_---_--_--.-
_---..-.-..-.---------
_---.--.....-.------.--.......---.---.............-.....................
_.....
NO. 5000-l 1
13 79A-1048 . . . PIN, CENTER, V22938, NO. 5400-5 1
14 76A-1171 . PIN, COTTER, CENTER, V22938,
NO. 4800-6 1
408533 BAR ASSY, DRAW, V22938, NO. 9-3500 1
-_--__--
15 79A-1057 . . . PIN, HINGE, V22938, NO. 12-3502 1
16 76A-1171 . . . PIN, COTTER, V22938, NO. 4800-6 2
* 79A-1047 . . . WASHER, FLAT, V22938, NO. 4701-3 1
17 76A-1172 BAR, DRAW, V22938, NO. 3502-012 1
18 482746 1: TONGUE, TOWING ASSY. 1
76A-1173 . . RIGGING ASSY, BRAKE V22938,
NO. 383-5901 1
19 40453 1 . . . LEVER ASSY, HAND BRAKE, V22938, NO. l-591 9 1
20 76A-1174 . . . PIN, COTTER 3/32 X 3/4 IN, V22938,
NO. 4800-2
... .........._____...........~~..~~..........~.~~~.~..~~.~.................~...~~~.. ............ .......... . . ... .. ...5.. .
....____________________________________-.-..-..-.....-.------..............-.-....-...........-..-..
21 76A-1175 . . PIN, YOKE, 3/8 X 13/32 IN, V22938,
NO. 5206 6
22 404532 . . . YOKE, 3/8-24 NF, V22938, NO. 5205 6
* 76A-1222 . NUT, YOKE, V22938, NO. 4601-5 6
23 488269-2 . . . ROD, HAND BRAKE LEVER TO CROSS
SHAFT LEVER 1
24 488269-l . . . ROD, BRAKE 2

Page 53
OM-436
NOMENCLATURE UNITS
FIGURE HOBART per
76A-l 178 . . . ROLL, PIN 5/16X l-1/4 IN.

V22938, NO. 5000-2 3
25 76A-1179 . . . LEVER, V22938, NO. 5909 3
26 76A-1180 . . . BEARING, PILLOW BLOCK, V22938,
NO. 5908 - ----_ 3
26A 79A-1062 . . . COLLAR, SET SCREW, V22938, NO. 6319-2 2
27 76A-1181 . . . SHAFT, CROSS, V22938, NO. 591 O-383 1
28 480989 . . PLATE, MOUNTING, HAND BRAKE 1
29 404533 . . . SPINDLE & KNUCKLE ASSY, (LEFT)
V22938, NO. 3-3806 1
30 404534 . . SPINDLE & KNUCKLE ASSY, (RIGHT)
V22938, NO. 4-3806 1
31 404536 . . PIN, ROLL, 3/16 X l-3/4 IN.
V22938, NO. 5000-6 2
32 404535 . . . PIN, KING, V22938, NO. 5401 2
33 404537 WASHER, SPINDLE, V22938, NO. 4702-2 2
34 404538 . . . NUT, SPINDLE, V22938, NO. 4600-2 2
35 76A-1182 . . PIN, COTTER, V22938, NO. 4800-5 2
* 79A-1035 4
. FITTING, LUBE, V22938, NO. 4800-5
* 76A-1183 . . . FITTING, LUBE, V22938, NO. 5800 5
76A-1184 . . HUB ASSY, FRONT AXLE, V22938,
NO. l-361 2 2
36 404539 . . CAP, GREASE, V22938, NO. 6312 1
37 404540 . . BEARING, CONE, OUTER, V22938,
NO. 6058 --____ 1
38 404541 . . . BEARING, CONE, INNER, V22938,
NO. 6057 1
39 404543 ... SEAL, GREASE, V22938, NO. 6311 1
40 404544 . . . NUT, WHEEL, V22938, NO. 4601-6 5
41 404545 . WASHER, LOCK V22938 NO 4700-5
- ------__-A- 5
* 76A-1183 . . . FITTING, LUBE, V22938, NO. 5800 5
76A-1185 . . . HUB SUB-ASSY, V22938, NO. 3603-l 1
42 404551 . . . . HUB, V22938, NO. 3603 1
43 404552 . . . . STUD, WHEEL, V22938, NO. 6251-10 5
44 404553 . . . CUP, BEARING,
--.-~ INNER, V22938,
NO. 6152 1
45 404554 . . . CUP, BEARING, OUTER, V22938,
NO. 6151 1
404546 . . WHEEL ASSY, (For 6:UU X 9 in. 70 ply tire)
.__ ________ V22938, ._.....
NO. 3712
. .___ 4
46 76A-1219 . . DISC, WHEEL, (Without valve hole) V22938,
NO. 3712-2
76A-1220 . . . DISC, WHEEL (With valve hole) V22938,
NO. 3712-1, NO. l-4251

Page 54
NOMENCLATURE UNITS
FIGURE HOBART per
48 76A-1221 . BOLT, 3/8 IN. 24 NF, 3/4 IN. LG.

HEX HD, V22938, NO. 4901-8 8
49 76A-1222 . NUT, 3/8 IN. - 24 UNF, HEX V22938,
NO. 4601-5 8
50 76A-1223 . LOCKWASHER,
.--, 3/8 IN, V22938,
NO. 4700-4 8
76A-1186 BRACKET ASSY. HANGER SPRING
(HOOK END) V22938, NO. l-4251 4
51 76A-1187 BRACKET, SPRING (HOOK END) V22938,
NO. 4251 1
52 76A-1188 . . . PIN, STRAIGHT HEADED V22938,
NO. 5403-l 1
76A-1189 PIN, COTTER, V22938, NO. 4800-3 1
76A-1190 . BRACKET ASSY., HANGER, SPRING,
FRONT .-..
~-_-.-. AXLE
-. (Eye End), V22938, NO. 1-4261 2
76A-1191 BRACKET, SPRING, FRONT AXLE (Eye End)
V22938, NO. 4261 1
55 76A-1192 . . BOLT, HEX HEAD, g/16-12 NF X 3-3/4 lg.
V22938, NO. 4901-19 1
56 76A-1193 . . . --~--___-
NUT, 9/16 - 12 NF HEX V22938,
NO. 4601-33 1
76A-1194 . . BRACKET ASSY., HANGER, SPRING,
REAR AXLE (Eye End) V22938, NO. 4-4251 2
76A-1187 . . BRACKET, SPRING, REAR AXLE, (Eye End), I
V22938, NO. 4251 1
58 76A-1192 . BOLT, HEX HEAD, g/16-12 NF X 3-3/4 lg.,
V22938, NO. 4901-l 9 1
59 76A-1193 . NUT, 9/16 - 12 NF HEX V22938, NO. 4601-33 1
60 76A-1195 CLAMP, SPRING & AXLE, FRONT V22938,
NO.
--.- 5601-l
___---- 2
61 76A-1196 . . CLAMP, SPRING & AXLE, REAR V22938,
NO. 5601-2 2
62 76A-1197 . . SPRING ASSY., V22938, NO. l-4010-3 4
63 404549 . . BOLT U, SPRING FRONT, V22938,
NO. 5100-14
---.-_-__-___ 8
64 404550 . NUT, HEX, l/2-20 UNF, V22938, NO. 4601-7 16
76A-1212 . AXLE ASSY., REAR,
V22938, NO. 383-2146 1

Page 55
NOMENCLATURE UNITS
FIGURE HOBART per
65 76A-1198 . AXLE ASSY., REAR, v22938, NO. 383-2146-2 1

76A-1199 . HUB & DRUM ASSY., v22938, NO. 2-3612 1
76A-1200 . . HUB & DRUM SUB-ASSY.
V22938, NO. 3612-2 1
66 404551 . . . . HUB, V22938, NO. 3603 1
67 79A-1064 . . . STUD, WHEEL, V22938, NO. 6251-9 5
68 404553 . . . . CUP, BEARING, INNER v22938, NO. 6152 1
69 404554 . . . CUP, BEARING, OUTER V22938, NO. 6151 1
70 76A-1201 . . . . DRUM, BRAKE, V22938, NO. 8221 1
71 404544 . . . NUT, WHEEL, l/2-20 NF, HEX V22938,
NO. 4601-6 5
72 404545 . . . WASHER, LOCK, v22938, NO. 4700-5 5
73 404541 . . . CONE, BEARING, INNER, V22938,
NO.6057 1
74 404540 . . CONE, BEARING,
---. -..-._OUTER, v22938,
NO.6058 1
75 404543 ... SEAL, GREASE,V22938, NO. 6311 1
76 404539 .. CAP, GREASE, V22938, NO. 6312 1
77 404538 NUT, SPINDLE, V22938, NO. 4600-2 2
78 404537 - : : WASHER, SPINDLE,
.-.. .--- -v22938,
_--.-.-__--
NO. 4702-2 2
79 76A-1182 PIN, COTTER, V22938, NO. 4800-5 2
80 76A-1203 1 BRAKE ASSY., MECHANICAL, v22938,
NO. l-8209 (For Details See Fig. 22) * 2
81 488275 . . SUPPORT, BRAKE ---- RIGGING - 1
82 488270 . . . SUPPORT, ROD BRAKE ASSY. 1
83 488268 . . BRACKET, SUPPORT, PARKING BRAKE 1
4-3 August31/89 Revised

Page56

Page 57
5
4 i
Brake Assembly Prototype Development Inc.
Figure 21

Page 58
OM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
21- 76A-l 203 BRAKE ASSEMBLY, MECHANICAL V22938,

NO. l-8209 (For NHA see Fig. 20) A-C,GH REF
1 76A-1204 . SHIELD, DUST, V22938, NO. 8210 2
2 76A-1211 . LEVER & BOLT, CAMSHAFT, V22938, NO. 8225 1
3 76A-1216 . BOLT, MTG. BRAKE ASSY.
V22938, NO. 4901-7 8
4 76A-1217 . LOCKWASHER, V22938, NO. 4700-4 8
5 76A-1218 . NUT, V22938, NO. 4601-5 8
76A-1205 . BRAKE ASSY., V14892, NO. 4-8209 2
** 6 76A-1206 PLATE, BACKING, V14892, NO. 310949 1
7 76A-1207 SHOE & LINING, V14892, NO. 317849 2
8 76A-1208 . . SPRING, RETURN, V14892, NO. 4150098 1
----_____
9 76A-1209 CAMSHAFT, V14892, NO. 312853 1
10 76A-1210 : : SPRING, HOLDDOWN, V14892, NO. 310959 2
** NOT REPLACEABLE. IF BACKING PLATE IS DAMAGED, COMPLETE

BRAKE ASSY.NO. l-8209 (76A-1205) WILL BE FURNISHED.

Page 59
OM-436
8
I \ o
TO FUEL
TANK
6,
Q@ (-@t!L.
@D(fJ
\6
n
5,Ll
:I
I.
1
3-. c!
Fuel Tank Fitting Assembly

Figure 22

Page 60
obl-436
NOMENCLATURE UNITS
FIGURE HOBART per
22- 488178 FUEL TANK FITTING ASSY. REF 1
400819-2 . VALVE, BALL (ECON-O-MITE), V31510,

NO.70-102 1
2 W-10886-8 . CONNECTOR, MALE, V79470, NO. 48 X 6 X 6 2
3 W-l 0893-O . FITTING, HOSE, SWIVEL, FEMALE V03924,
NO.442-6-6 2
56535 . RUBBER, HOSE, LOW PRESSURE 17"
w-10917-5 . NIPPLE, PIPE, 3/8 TAPERED THREAD 2
12cW-2077-2 . STREET, ELL, 90, (PIPE & SUPPLIES, INC.) 2
W-10917-6 NIPPLE, PIPE 1
w-10119-3 : COUPLING, PIPE, (PIPE & SUPPLIES, /NC.) 1
-.-.--
84A-1055 FITTING, BANJO, FUEL FILTER, V62445,
NO. 129-0579 1

Page 61
TO OILm.PBE.SSURE...GAU.GE
4
TO OIL
FILTER
Oil Line Assembly

Figure 23

Page 62
NOMENCLATURE UNITS
FIGURE HOBART per
-~
23 - 488685 OIL LINE ASSY. REF
1 400059-3 CONNECTOR, FEMALE, SAE 45, FLARED, 1

2 403590-l . SWIVEL, FEMALE, SAE 45, FLARED,
V03924, NO. 71 lS-4s 2
3 56548 HOSE, DIESEL, SIZE 4, 3/16 4F
4 W-l 0909-l : TEE, STREET, BRASS 2
5 403809-l SWITCH, OIL PRESSURE, ENGINE
GENERATOR 1
6 W-l 0886-l CONNECTOR, MALE, SAE, 45 FLARED 1
7 403809-3 : SWITCH, OIL PRESSURE, STARTER
CUT-OUT 1

Page 63
OM-436
TO
FUEL
TANK
Fuel Line Assembly

Figure 24

Page 64
NOMENCLATURE UNITS
FIGURE HOBART per
24 - 488178 FUEL LINE ASSEMBLY 2
W-l 0886-l CONNECTOR, MALE, V79470, NO. 48 X 4 2

W-l 0893-O : SWIVEL, FEMALE, SAE 45 FLARED V03924,
NO. 442-6-6 2
56535 . HOSE, LOW PRESSURE 110
84A-1055 . COUPLING, PIPE, l/4, V62445, NO. 129-0579 2

Page 65
OM-436
TO
ENGINE
TO FUEL
TANK
Fuel Return Line Assembly

Figure 25

Page 66
NOMENCLATURE UNITS
FIGURE HOBART per
488178 FUEL RETURN LINE ASSY. REF 1
l- 56587 . HOSE, LOW PRESSURE 120

2 W-l 0869-l 4 . CLAMP, FITTING, V35708 2
3 84A-1007-l . CONNECTOR, MALE, V79470,
NO. 310504 1231 015207 1
4 W-l 0892-4 ELBOW, MALE, V79470, NO. 3400X2 1
5 W-l 0119-l : CO~~i:~;?~~E, (PIPE & SUPPLIES, INC.) 1
6 W-l 0750-l . NIPPLE, PIPE, V31510 1

Page 67
OM-436
TO AIR CLEANER
TO AIR
CLEANER
INDICATOR
Air Cleaner Hose Assembly

Figure 26

Page 68
NOMENCLATURE UNITS
4
FIGURE HOBART per
AIR CLEANER HOSE ASSY. REF
1 56534 . HOSE, LOW PRESSURE 12 F

2 400333-l . ELBOW, FEMALE, SAE 45, V03924,
NO. 7115-4s 2
3 W-l 0893-2 FITTING, HOSE, SWIVEL, FEMALE,
SAE 45, FLARED, V03924, NO. 71 lS-4s 2
4 W-l 0886-l . CONNECTOR, MALE, V79470, NO. 48 X 4 1

Page 69
Second Output Kit
Figure 27

Page 70
OM-436
NOMENCLATURE UNITS
FIGURE HOBART per
27 - 484066-3 KIT, SECOND OUTPUT (For NHA See Fig. 7) REF
484067 . PANEL ASSY, POWER MODULE

(For NHA See Fig. 4) REF
482069 . . PANEL, POWER MODULE ASSY. 1
401937-3 . . STRIP, TERMINAL, V98410,
NO. 35012-3536
-.-___- 1
404065-2 . . RECTIFIER, SILICON, VO4713,
NO. SDA 10270-2 1
16DA-4052-0 . . SOCKET, RELAY VO2660,
NO. 77-MIP-11 2
5 1CZ-93B . . DIODEL SILICON, V05277, NO. IN4820 1
6 404518 . CONTACTOR, LOAD, V74063, NO. HB 200B 1
7 402037-14 . GROMMET, RUBBER 3
8 402662 . . SWITCH, TOGGLE DPST, V74559,
NO. 2GK71-73 1
9 16DA-4004A-3 RELAY,
__-_-- PLUG
._._.__ INTERLOCK, 24V-DC
-.-----___.---
. V77342, NO. KAP-14DG 1
10 16DA-4253-1 RETAINER, SPRING, RELAY,
V77342,NO.20C206 2
11 16DA-4004A-10 . RELAY, FUSE INTERLOCK, 12V.
V77342
-....!-_ NO. KAP-14DG 1
12 W-9746-3 . . RESISTOR, 100 OHM, 25 WATT,
V44655,NO.O200F 1
* 13 1CZ-93B DIODE, SILICON, V05277, NO. IN4820 1
* 14 400480-3 : : TERMINAL, QUICK CONNECT
V00779,NO.42640-2 2
15 484070 SUPPORT, POWER MODULE, ASSY. 4
16 489479 PANEL, CONTROL, SECOND OUTPUT 1
17 403189 SWITCH, TOGGLE, 3-POSITION
V91929, NO. 312TSl-59 1
18 404173 . BASE, LIGHT, PILOT, V72619,
NO.26-1310-11-301 1
19 404613-4 . BULB, 12-V, LIGHT, VO8108, NO. 1815 1
20 404172-3 . LENS, LIGHT, PILOT, GREEN,
V72619, NO. 26-l 192-300 1
*21 W-1 1236-4 . SCREW, l/4-20 X l/8, HWH, SF-TAP,
TYPE F 4
482326 HORN, CABLE CLAMP, ASSY. 1
22 7J-422-O . . CLAMP, CABLE 2
23 lOO-GH-121 BRACKET, MOUNTING, CLAMP 1
24 482442 . HORN ASSY, CABLE ENTRANCE 1

Page 71
OM-436

Page 72
OM-436
NOMENCLATURE UNITS
FIGURE HOBART per
27-
25 482447 FLANGE, HORN, CABLE ENTRANCE

*26 484244A 1 HARNESS, WIRE, SECOND OUTPUT
"27 W-9360-278 CABLE, CONTACTOR INPUT, PHASE A (#707)
*28 W-9360-278 : CABLE, CONTACTOR INPUT, PHASE B (#702)
* 29 W-9360-278 CABLE, CONTACTOR INPUT, PHASE c (# 703)
"30 W-9360-261 : C~~,C?%%TACTOR INPUT, PHASE A
*31 W-9360-261 . CABLE, CONTACTOR INPUT, PHASE B 1
*32 W-9360-261 . CABLE, CONTACTOR INPUT, PHASE C 1
* 33 W-9360-278 . CABLE, NEUTRAL (#I 12) 1
* Not Illustrated

Page 73
OM-436
Kit, Mounting, T-R Assembly

Figure 28

Page 74
OM436
NOMENCLATURE UNITS
FIGURE & HOBART PER
28 - 489127-1 Kit, MOUNTING, T-R, ASSY. (For NHA See Fig. 7)

SINGLE T-R MTG. (OPTIONAL) 1
489127-2 Kit, MOUNTING, T-R, ASSY. (For NHA See Fig. 7)
(OPTIONAL) DOUBLE T-R MTG. 1
* 489127-3 Kit, MOUNTING, T-R, ASSY. (For NHA See Fig, 7)
DOUBLE T-R W/EXHAUST OUT TOP 1
1 489132 . BRACKET, MTG. T-R LEFT ASSY. 1 1
489132 . BRACKET, MTG. T-R LEFT ASSY. 2c
2 489133 BRACKET, MTG. T-R RIGHT ASSY. 1 4
489133 . BRACKET, MTG. T-R RIGHT ASSY. 2c
3 430278 GROMMET 1 4
._...........__._........................~~~~~.~~.............~.~~...~.........................~~~~~~~~~~~~~~~~~~~~~~~~~~.~.~~~~~
___.._............_._.~~~~~~~~~~......................................................
L................______
430278 . GROMMET 2c
*4 DWP-982 HANGER, CABLE 4
5 60GHP-416 : BRACKET, CLAMP CABLE 1
6 60GHP-424 CLAMP, CABLE OUTPUT 1
7 489134 : SHIELD, RAIN T-R OPENING 1 0
489134 . SHIELD, RAIN T-R OPENING 2c
8 280005 EXTENSION, PIPE EXHAUST ASSY. 1A
9 404154-I 5 : CLAMP, FULL CIRCLE 1A
+ This number of items used on Part No. 489127-1

0 This number of items used on Part No. 489127-2
A These items used on Part No. 489127-3 only

Page 75
T-R Mounting Kit Assembly
(Back-Mounting Unit)
Figure 29

Page 76
NOMENCLATURE UNITS
FIGURE HOBART per
29 - 489943 KIT, MOUNTING, T-R, ASSY. (Mounted on

Rear of Unit) REF
1 489897 . BRACKET, MOUNTING, T-R, LEFT ASSY 1
2 489919 BRACKET, MOUNTING, T-R, RIGHT ASSY 1
3 489899 . BRACE, T-R, ASSY 2
4 489906 . SUPPORT, T-R, MOUNTING, ASSY 1
*5 404154-l 1 . CLAMP, CONDUIT -- 3
6 408523 ELBOW, 90,2-INCH 2
*7 489952 . CONDUIT, 2-INCH 1
* Not Illustrated

Page 77
OM436
-3
T-R Mounting Kit Assembly

(For Sth-Wheel Trailer)
Figure 30

Page 78
NOMENCLATURE
FIGURE & HOBART
ITEM NO. PART NO. 1234567
30- 281745-1 KIT, MOUNTING, T-R, ASSY. (For unit having

one T-R on 5th~Wheel Trailer) REF
281745-2 KIT, MOUNTING, T-R, ASSY. (For unit having
two T-Rs on Sth-Wheel Trailer) REF
1 281743 . SUPPORT, T-R, MOUNTING, LOWER, ASSY. 1
2 281744 SUPPORT, T-R, MOUNTING, UPPER, ASSY. 1A
3 402037-14 : GROMMET, RUBBER 1+
402037-14 . GROMMET, RUBBER 20
*4 281437 . HARNESS, WIRE, T-R, ASSY. 1
*5 w-9407-324 . CABLES 3+
w-9407-324 . CABLES 60
*6 489190 . WIRE, NEUTRAL, T-R, ASSY. IA
*7 282354 . BUMPER, RUBBER, T-R SUPPORT 1
* Not Illustrated
+ This number of items used on Part No. 2812451
0 This number of items used on Part No. 281245-2
A This item used on Part No. 281745-2 only

Page 79

Page 80
OM-436
CHAPTER 5. OPTIONAL EQUIPMENT

This chapter provides documentation covering - any_ optional
. equipment furnished with your generator.
Available options are listed below.
OPTION NAME MANUAL HOBART NO.
Quick Start Kit In this manual 488898
Kit, Second Output In this manual 484066-3
Kit, T-R Mtg. (Sing/e, for 4-Wheel Trailers) In this manual 489127-l
Kit, T-R Mtg. (Double, for 4-Wheel Trailers) in this manual 489127-2
Kit, T-R Mtg. (Sing/e, rear-mounting) In this manual 489943-l
Kit, T-R Mtg. (Sing/e, for 5th-Wheel Trailers) In this manual 281745-l
Kit, T-R Mtg. (Double, for Sth-Wheel Trailers) In this manual 281745-2
Truck & Truck Body (For Specs 6760-6, 676OA-6

676OB-6, and 6760B- 11) TO-1 76 280099-l
Kit, Fifth-Wheel Trailer (For Specs 7007A-7 through

700 IA-4) TO-1 80 280359-l and -2
* Kit No. 488898 consists of Part Numbers 84B-1038 and DW-1777B.
May 18/90 Revised 5-o

Page 1
5-o Aug 31189

Page 2
OM-436
CHAPTER 6. MANUFACTURERS LITERATURE

COMPONENT DESCRIPTION & COMPONENT MANUFACTURER, &
HOBART PART NUMBER MANUAL COVERING THIS COMPONENT
Engine KHO Deutz Company

Deutz Spec. No. DO 693-738 Operators Manual No. 297-3917cle/en
Hobart Part No. 83B-1109A Spare Parts Catalog No. 297-4221
Voltage Regulator Hobart Brothers Company

Hobart Part No. 430391 C Operation and Maintenance Manual No. TM-759
Voltage Regulator HobartBrothersCompany

Hobart Part No. 489812A Operation and Maintenance Manual No. OM-2020
Electric Governor Assembly WoodwarclGovernorCompany

Hobart Part No. 488296 Installation Manual No. 82329E
Trailer Group with Parking Brake HobartBrothersCompany

Hobart Part No. 489725-l Operation and Maintenance Manual No. OM-436
Trailer Group with Parking Brake HobartBrothersCompany

Hobart Part No. 489725-2 Operation and Maintenance Manual No. OM-436
DIAGRAMS
488351 Generator Connection Diagram

482360 Generator Schematic Diagram
488352 Engine Connection Diagram
488350 Engine Schematic Diagram
482365 Control Tray Connection Diagram
482366 Protective Relay Tray Connection Diagram
482099 Power Module Connection Diagram
488250 Dimensional Layout Diagram
489542 Engine Connection Diagram (Specs 676UB5, 6760B7 7)
489543 Engine Schematic Diagram (Specs 6 760B5,676OB7 7)
PC BOARDS
387738A Overload Board

387736C Memory and Time Delay Board
482038 Over-UndervoltageBoard
482039 Over-UnderfrequencyBoard
May la/90 Revised 6-O

Page1
6-O Aug 3iia9

Page 2
GROUND TERMINAL
LOWlEO ON LEFT
FRONT Of MTG FRAME
REAR OF OUTPUT
GROUND TERMINAL
L&;;,;hX OF FLYWHEEL
c----------------t'-- A-------- ---- - ___- --__---_- -------.---------- -

, ,_--
...._..._.. _.___--- ..,.f--..,-~~... ..__ -.-- ..___. . .._... _..__ --_._----_------- ..... . ..---...
..__ FACING REAR OF CONTROL BOX
--I i
1 ! rt-
i.
GROUtiD TERMINAL
LOXTED IN CENTER OF
CONTRX BOX SKLF
(6611J6-LlR(I-BK. , 1
1 } ; L ~ FACING TOP OF VOLTAGE REGULATQR ,
I
I
I
I
I
I
I NOTE;
ALL WlRES ARE NO.,BF-T UNLESS
I
OTHERWISE SPECIFIEO.
I
I
I
I
I
TRANSFORMER-RECTIFIER, 28.5 V. (WHEN FURNISHED)
TRANSFORMER-RECTIFIER, 112 V. (WHEN FURNISHED)
Cl-C3 CAPACITOR, GENERATOR, 0.1 MFD, 500 V.
CR2 RECTIFIER, GENERATOR REVOLVING FIELD
Gl GENERATOR, STATOR
G2 EXCITER ARMATURE, GENERATOR
57 RECEPTACLE, T-R CONTROL, 28.5 v. (WHEN FURNISHED)

58 RECEPTACLE, TEST
Kl LOAD COFITACTOR
Ll FIELD, REVOLVING GENERATOR

L2 FIELD, EXCITER GENERATOR
PLUG, VOLTAGE REGULATOR

;; PLUG, PROTECTIVE RELAY TRAY
P3 PLUG, GENERATOR CONTROL TRAY
P7 PLUG, T-RCONTROL, 28.5 V. (WHEN FURNISHED)
Tl-T3 TRANSFORMER CURRENT, AMMETER

T4-T6 TRANSFORMER, CURRENT, LINE DROP
T7-T9 TRANSFORMER, CURRENT, OVERLOAD GENERATOR
I
I 1! !
-._ .-
____--_- _______________
----. - ____-- ____-------- _____ _
I9R-RR I - II 52BK-WT I
I II
MO- .lll3MXMVIS 3UnSS3tld110 39111 HXIMS fbSS
1138 Ntj HXIMS fLS
31nl~3dW31 110 38l-11HXIMS ZLS
(03HSINLlnjN3HM) 1llWlS kl3H13 HUMS Ifs 0
(-NM-IA Ni'HM)AUjWS 3tinlYti3dW31MO1 HXIMS OLSQ
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(I'ON) (-NMllj N3HM) !43ntll 'Wnn3WA H31IMS ZSS
'N35-'9N3 '31nSS31d 110 38111 H31IMS 9bS
('NMllj N3HM) ZH OOP XOe 5nld 013IW 'H31IMS LES
230-I 13X 1IwlS 3NI9N3 H31IMS 91s
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isnraw a33ds 3iaI ~3ukioI~N3Lod LLI
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i AZ1 3NI9N3 tl31kJWlS za
a13931
LEoEFm
82 swfTER,ENGM.l2v
ETI , 812 EArrERY. 12v.
CS cbpIcIIDR.aem.,3sv.
CR4 CR13 BODE.FLY-BACK

CR28
CR24cRX) i%E: %W
LmMT. FnNEL.wmE ,---\ MTD ON DASH SOARD
TO~CKK~N.~- ---_---____ &cf~IRvac ____ -_,
FS ~.tDGlNE CIRWIT. IOA. :
i%%$ifi% .?i%%#i WEATMR START

RECEPTACLE. PROTkTIVE RELAY TRAY
RECEPTACLE. GEMRATOR CONTROL TRAY
RECEPTACLE, T-R CONTROL.28dV.MlEN FURN.)
RECEPTACLE, TEST
RECEPTACLE, FAN BELT SWITCH
K16 RELAY, EXClTAToN DE-ENERGIZATION

K23 RELAY, UNDERFECUENCY AUXLIARY
Kb5 RELAY. GOVERNOR i&E SPEED
K66 RELAY. HIGH OIL TEMPERATURE
L9 SOLENOID. STARTER, 12V

L13 YXENOIO. COLD WEATMR START
04
M4 RUNNING TIME METER

AMMETER, BATTERY
g RUNNING TIME METER, TRUCKIWHEN FURN.)
GAGE, FUEL, ELECTRlC
M24 GAGE, OIL TEMPERATURE
P2 PLUG. PROTECTIVE RELAY TRAY

P3 PLUG. GENERATOR CONTRO!. TRAY
P43 PLUG, FAN BELr SW.

R52 RESISTER, PRE-HEAT
R55 SENDER, ELECTRIC FUEL GAGE
R77 POTENTIOMETER, IDLE SPEED ADJUSl
ELECTRIC GOVERNOR
54 SWITCH, FdNEL LIGHT CONTROL BOX
SWITCH, PERMISSIVE START
E3 SWITCH. ICLE-GM-BUILD UP VOLTS
s37 SWITCH. MICRO. PLUG BOX ,4OOHZ(WHEN FURN.)(NO.Il
S46 SWITCH. LUBE Oh PRESSURE, ENG-GEN.
S52 SWITCH, VACUUM TRUCK (WHEN FURN.)
s72 SWITCH, LUBE OIL TEMPERATURE
573 SWITCH, MN BELT
SWITCH, MICRO. PLUG BOX 400 HZ.(W?4EN FURN.)(NO.Z)
%63 SWITCH, ENGME START, KEI) LOCK
S47 SWITCH .LUBE OIL PRESSURE, ST RTER CUT-OUT
L II CE I
ELECTRIC -
GOVERNOR -I-
ACTUATOR _ _ _ __.. ------
_--- -------.
__---
-.. _A-
TITLE DIAGRAM *
Schematic
-STAlriP 011 CIRCUIT six:
-.IP~,O.C. I N0.30773rA
I
--.-y5 I
-----G
Q
e
~---
I----- -. ~- -1
oloot, ZfNf*, IN. ,ow*n

DIWE, ZtNEL, 6.N.. ,cahw.
DIcm, .?.fNfI, P.W., 1 WATT
I_
09
08
0 IO
07
0 II
s
06
d
P 0 12
05
ru 0 13
F (6)
04
ab
0 14
& II) CAPACITOR. .022 UF, 600.
03 :: speck% 220 F, lrJOC
a-c7 CAPACnOR, 33 "F, ,WDC
8 0 15 CR,-CR, DIOCE. SItICON, 00 KC, 1.5 AMP
02 Kl RELAY. FOUM 18, 12. K

Y
06 m 01 TL4NSISTOR, 2N39a
0 16 QZ-P6 RECTIFIER, SILICON CoNmotttD
CR7=@== 0 RI RESISTOR, ISO OHM, I/Z w.
0 I 12
- POTENTlOkWER, M K OHM, I,? W.
R3 RESISTOR, lo K OHM, I,? w.
CL- R4.u RESISTOR, 2.2 OHM, 1,-z w.
16 RESISTOR. 2.2 K OHM, ,,*w.
R7 RESISTOR, 680 OHM, I w.
n&i?9,Lll,
R14,R1S RESISTOR, 330 Ow.4, I,? w.
110.112.113,
RI6 RESISTOI, ,ul OHM, I,? w.
TO I6 TAN
TO I5
13 BROWN _a .,
TO I4 I I3
TO I2 TO II
TO IO TO 9
RI4 CR6 RI I CR5 TO 6 TO 7
330n 33ol-l TO 6
TO 4
TO 2
Pi P
-- 6C. BOARD
95 04
NOTES:
I. PRINT LABEL, ITEM 22. PER MANUFACTURING
INSTRUCTIONS 910351. ADD I2 VOLTS AS SHOWN
I .
M-M
OVERVOLTAGE UNOERVOLTAGE OVERFREOUENCY UNDERFREQUENCY OVERLOAO
1m
LEGENO
TO TO TO CAPACITOR. 2FO. 300

PHASE C CAPACITOR. 6.8MFO. 35"
N IAL PHASE A PHASE B DIODE. SILICON, 600P~v. I.3
-. -___--_--_------ ---
RELAY. OYERYOLTb.tE. REEO. FORM IA. 24v
3 4
RELAY. "NOER"OLTdCE. REEO, FORM 1.4. 24v
r TRANSlSTOR. OVERVOLTAGE. 2N3904
L- ---------~------- ------ TRANSISTOR. UNDERVOLTAGE. 213904
RESISTOR. 100 OHM. 112w
3 5 RESISTOR. 27K OH". 2w
m RESISTOR. IOK OHM, IW
P RESISTOR. 1% OHM, 3w
:: RESISTOR. S.BK OH". ow
RESISTOR, 2.2K OHM. I!4
POTENTIOHETER. OYERYOLTAGE. 5K OH", l,ZW
CR6Gi CR 602
POTENTIOMETER. "NOER"OLTAGE. SK WM. 1/m
0100~. ZENER, 6.2V
I t
CR 604
i R607
C604
6.6/36
22K IW
R609
J
Y Y
OVERVOLTAGE UNDERVOLT=
HOeARTBROTHERSCO.
TROYJMiIO45373 Usa
SCHEMATIC DIAGRAM ---. .._ --
^. - - -. - .
cONFIbENTlAL - Thlr drewlng, Including aJtinlottnetlon contained thereon, is (he exclusive endconfidential property of Hobart BrothersCompany
of Ttov, Ohio, end 1snot to be copied, reproduced or delivered or disclosed to others, in whole or In part, except wlth expresswritten petmission.
,.___ -.
_,_/
i
,
7
io
!
C609
i-7 A- --.- ---- &?A QP ,C6lO ,-.
TO *,I1
TO IO TO 9
TO 6 TO *7
TO *s TO 5
TO 4 TO 3
TO 2 TO I
@NOTE RESISTOR5 1w 01 ABOVE SHOULC BE MOUNTED INSTA UCTIONS. TEST - 482423.

I oFFTt!fe.OALD.
--..___
CAPACITOR. 6.8MFo. 35" l...
-I \ _-
----
-.__.- C605.C606
CWACITOR. ."22"fO, 200" --..__
C607,C608
z ---48 --+-----
.---.-.
__
--.--.____ ~~~~,I CAPACITOR.
CAPACITOR.
33"FD. 10"
3.3HF0, 35"
---.-.--.__ _. ;;;;'-"""I" DIOOE. SILICON. 600 PR". 1.5A
RELAY. OVER FREQUENCY. REED. FOR" ,A. 24V
E
l-----------l
2 I
---_..~... . ..._ .__-- i
K604 RELAY. UNDER FREQUENC". REED. FORM IA. 24"
Q603 TRANSISTOR. OVER FREQUENCY. 2N3904
iII
Q604 TRANSISTOR. UNDER FKEQ"ENCY. 2N3904
R605.R606 RESISTOR. IfJK OHM. 3w
R610.R611 RESISTOR. 33K OHM. 5w
0) R61Z.R613 RESISTOR. 4.7K OHH.3.25W
R653 POTENTIOMETER, OVER FREQUENC". 5K OH". ,134
R654 POTENTlOHETER. UNDER FREQUENCY, 5K OHM. ,,ZW
SK 1/2W
5K V2W
rl CR606 I I
n
CW 2N3904
33/lO
T
1a6o3 7 0 GROUND
SCHEMATIC DIAGRAM
TITLEBO~~.PC,,,Q~R-
UNDERFREQ. AY!
I I
REV. owe. Ho.
{SHT :
2 482039;
UNUSUAL E CONDITIONS
This information is a general guideline and cannot cover all possible conditions of equipment use. The
specific local environments may be dependent upon conditions beyond the manufacturers control.
The manufacturer should be consulted if any unusual conditions of use exist which may affect the
physical condition or operation of the equipment.
Among such conditions are:
1. Exposure to:
A. Combustible, explosive, abrasive or conducting dusts.
B. Environments where the accumulation of lint or excessive dirt will interfere with normal ventila-
tion.
C. Chemical fumes, flammable or explosive gases.
D. Nuclear radiation.
E. Steam, salt-laden air, or oil vapor.
F. Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fun-
gus growth.
G. Abnormal shock, vibration or mechanical loading from external sources during equipment
operation.
H. Abnormal axial or side thrust imposed on rotating equipment shafts.
1. Low and/or high ambient temperatures.
J. High electromagnetic fields.
2. Operation at:
A. Voltages above or below rated voltage.
B. Speeds other than rated speed.
C. Frequency other than rated frequency.
D. Standstill with rotating equipment windings energized.
E. Unbalanced voltages.
F. Operation at loads greater than rated.
3. Operation where low acoustical noise levels are required.
4. Operation with:
A. Improper fuel, lubricants or coolant.
B. Parts or elements unauthorized by the manufacturer.
C. Unauthorized modifications.
5. Operation in poorly ventilated areas.

This page intentionally left blank
Wet-Stacking in Generator Set
Diesel Engines
All diesel engines operated for extended periods under light load may develop
a condition commonly referred to as wet-stacking. This condition results from
the accumulation of unburned fuel in the exhaust system. It is recognizable by
fuel oil wetness around the exhaust manifold, pipes, and muffler. Liquid fuel, in
the form of droplets, may be spewed from the exhaust outlet.
Wet-stacking is common, and may be expected in diesel engines operated

under light load. Light loads do not allow the engine to reach most efficient
operating temperature for complete combustion of fuel. The unburned fuel col-
lects in the exhaust system to create the wet condition known as wet-stacking.
To alleviate wet-stacking in lightly loaded engines, it is recommended that the

machine be connected to a load bank after each 200 hours of use and operated
under full rated load for one hour. This will burn away and evaporate the ac-
cumulation of fuel in the exhaust system. This clean-out procedure should be
considered as a regular maintenance operation for machines operated under
light load. The time schedule of 200 hours may be changed as required to suit
each users particular needs and operating conditions.

Om 436

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ILLUSTRATED PARTS LIST

ENGINE DRIVEN GENERATOR SETS

Series 6760 Series 67606 *

Series 6760A Series 7001 A

90=kVA, 400=Hz, 115/200-V AC, 3-Phase

C . FIRE AND EXPLOSION PREVENTION

F. BODlt Y INJURY PREVENTION

EMERGENCY FIRST AID

G. EQUIPMENT PRECAUTIONARY LABELS

SECTION 1. DESCRIPTION . . . . . . . . .1-l . . . . . . : . . 1

May 18/90 Revised Table of Contents

SUBJECT CHAPTER/SECTION PAGE

(2) Protective relay tray (Figure 9) l-l 13

Table of Contents May 18/90 Revised

SUBJECT CHAPTER/SECTION PAGE

SECTION 2. PREPARATION FOR USE,

SECTION 3. OPERATION I-3

Aug 31189 Table of Contents

SUBJECT CHAPTER/SECTION PAGE

Table of Contents Aug 31189

SECTION 2. INSPECTION / CHECK 2-2 1

SECTION 3. ADJUSTMENT/TEST 2-3 1

Aug 31189 Table of Contents

SUBJECT CHAPTER/SECTION PAGE

5. Diode Test 2-3 16

CHAPTER 4. ILLUSTRATED PARTS LIST

Table of Contents Aug 31/89

B. Parts List Form 4-l 1

SECTION 3. PARTS LIST 4-3

SECTION 4. NUMERICAL INDEX 4-4 1

CHAPTER 5. OPTIONAL EQUIPMENT

CHAPTER 6. MANUFACTURERS LITERATURE

UNUSUAL SERVICE CONDITIONS

Aug 31189 Table of Contents

_ ----~-z-T. :. :.:, ,. _. > x/_ _

Table of Contents Aug 31189

Aug 31189 Introduction

A. Paragraphing and Outlining

6. How to Use the Manual

B. How to Locate Information

l (1) Table of Contents

0 (2) List of Illustrations

Introduction Aug 31189

Aug 31189 Introduction

Write: Hobart Brothers Company

Telephone: (513) 332-5060 (Service)

(513) 332-5050 (Parts)

FAX: (513) 332-5121

Introduction May la/90 Revised

Series 6760 Trailer-mounted, truck-mounted, or stationary units.

Series 6760A Trailer-mounted, truck-mounted, or stationary units, featuring armatures

May la/90 Revised l-l

1. Voltage Panel & Contactor 8. Canopy

l-1 May 18190 Revised

Weight (approximately) 5800 pounds (2627 kg)

Output power rating 90 KVA

GENERATOR PROTECTIVE SYSTEM

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

Specifications and Capabilities

May 18/90 Revised l-l

A. Quick Start Kit

l-l Mav 18/90 Revised