Professional Documents
Culture Documents
TM-133
GROUND POWER UNIT 400 CYCLE 115/200 VOLT 160 KVA - TRUCK MOUNTED
with
DETROIT DIESEL ENGINE MODEL 8V-71N
(GENERATOR PRIME MOVER) -
FUMES AND GASES can be fire and health hazards. Ventilate all fumes and exhaust gasesto the outside.
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible material. Do not
use power cables to break load and be sure tools dont cause short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.
MOVING PARTS can cause serious injury. Keep clear of moving parts.
IMPORTANT - Protect yourself and others. Read and understand all the instructions in this Operating/Instruction
Manual before installing, operating, or servicing this equipment. Keep this manual available for future
use by all operators.
A. GENERAL
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions. Safe practices
have developed from past experience in the use of power source equipment. Certain of the practices below apply to
engine driven equipment.
B. SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a
person. Have a competent electrician verify that the equipment is adequately grounded and learn what terminals
and parts are electrically HOT. Use proper safety clothing, procedures, and test equipment.
The electrical resistance of the body is decreased when wet, thus more easily permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas without being extremely careful.
Stand on dry rubber mat or dry wood, use insulating gloves that are effective when dampness or sweat cannot be
avoided. Keep your clothing dry and never work alone.
1. Installation and Grounding of Electrically Powered Equipment - Electrical equipment must be installed
and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, and other appiicable codes.
A power disconnect switch or circuit breaker must be located at the equipment. Check the nameplate for voltage,
frequency, and phase requirements. If only 3-phase power is available, connect any single-phase rated equipment to
only two wires of the 3-phase line. DO NOT CONNECT the equipment grounding conductor (lead) to the third live
wire of the 3-phase line, -as ---
this makes the eouipment frame electrically HOT, which
------ can cause a fatal shock.
Be sure to 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. Be certain that the current (amperage) capacity of the
grounding lead will be adequate for the worst fault current situation. Refer to the National Electrical Code ANSI/
N FPA 70 for details. Do not remove plug ground prongs. Use correct mating receptacles.
2. Output Cables and Terminals - Inspect cables often 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 equip-
ment is energized.
1. Electrical Short Circuits and Overloads - Overloaded or shorted equipment can become hot enough to cause
fires either by self destruction or causing nearby combustibles to ignite. Provide primary input protection to re-
move short circuited or heavily overloaded equipment from the line.
2. Battery - Batteries may explode and/or give off flammable hydrogen gas. The acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, causing sparking, or use open flame
near the battery.
3. Enqine Fuel - Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel
tank is not grounded prior to and during fuel transfer. Shut unit DOWN before removing fuel tank cap. Do not
completely fill tank. Heat from the equipment may cause fuel expansion overflow. Remove all spilled fuel im-
mediately including any that penetrates the unit. After cleanup, open equipment doors and blow fumes away with
compressed air.
Call physician immediately. Seek additional assistance and use First Aid techniques recommended
by American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELEC-
TRICAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration,
preferably mouth-to-mouth. If no detectable pulse, begin external heart massage. Call Emergency
Rescue Squad immediately.
TABLE OF CONTENTS
CHAPTER
SUBJECT SECTION PAGE
OPERATION' 1 1
GENERAL l-l 1
TERMINOLOGY l-l 1
MAINTENANCE 2 1
SERVICING '2-l 1
OVERHAUL 3 1
REASSEMBLY 3-2 1
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.MOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY
CHAPTER 1 OPERATION
SECTION 1
1. General
A. Scope
2. Supplementary Manuals
(1) The regulated static exciter manual covers theory of operation, line
drop compensation, and maintenance of the static voltage regulator,
Hobart #lCZ-65D.
(3) The truck owner's manual explains features of the truck, upon which
the power unit is mounted.
(4) Parts lists are provided for the power unit and the GM diesel engine.,
Additional copies of the ground power unit manual and the regulated static
exciter manual are available by writing to:
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3. Terminology
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MOTOR GENERATOR DIVISION
CHAPTER 1 OPERATION
1. Unit Assembly
A. Description
(1) The power generator, its prime mover, control components, and several
sub-assemblies are attached to a common frame and superstructure,
covered with a sheet metal canopy, and mounted on the chassis of a
truck. The truck frame has been customized to include a combination
battery and output cable box on the left side and a lOO-gallon fuel
tank on the right side.
A. Generator
(1) This unit utilizes a 3-phase, revolving field, static excited and
regulated generator to develop the 400-cycle output current. The
generator is driven by an 8-cylinder, diesel engine which is flexibly ~
coupled to the rotor shaft. A centrifugal fan, attached to the flex-
ible coupling, draws cooling air in at the open end of the generator,
passes it over the revolving fields, slip rings, and stator, and then
expels the warm air at the opening next to the coupling.
(a) Instructions for the static regulator, Model lCZ-65D, are given
in a separate manual supplied with the ground power unit in-
struction package.
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(2) Special emphasis is given in both this manual and in the EOM concern-
ing the engine shutdown system.
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(d) During operation, should the lube oil pressure drop to 12 psi,
the engine coolant rise to 200'F to 210F, the engine lose,its
coolant, or should the engine speed exceed 1975-2025 rpm,-the
corresponding valve opens, allowing the oil to return to the
engine oil sump, resulting in a decrease in oil pressure on the
bellows. The oil pressure bellows will then release the latch
permitting the air shutdown to close, stopping the engine.
(e) After the engine has been shut down due to the action of pro-
tective device, it cannot be run until the particular device
which actuated the shutdown has returned to its normal position.
The abnormal condition which stopped the engine must be cor-
rected before again attempting to start the engine.
D. Truck
(1) All material regarding the truck features, with the exception of the
manifold vacuum switch, the lOO-gallon fuel tank, and the battery
and output cable box, is covered in the truck manuals. The excepted
items above are thoroughly explained in this manual. Other infor-
mation is tabulated in paragraph E.
E. Tabulated Data
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GENERATOR DIVISION
HOBART BROTHERS COMPANY
(2) Performance I
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CHAPTER 1 OPERATION
1. Control Panel
A. Panel Location
(1) The control panel is located behind the left front door of the canopy.
Engine controls are on the stationary portion of the panel; generator
controls are on the hinged portion (See Figure 1).
(1) The fluid starting aid (1) consists of an ether cartridge container,
a cartridge puncturing tool, and a hand pump. It is used at tempera-
tures below 40'F to promote fuel ignition by pumping ether into the
engine intake manifold (see EOM, Initial Start Procedure).
(2) The Throttle Control (2) is used to adjust the engine speed when
starting and warming the engine. The electric speed control switch
(22) must be in the MANUAL position for this control to function.
(3) The idle stop lever (3) permits adjustment of the throttle to the
IDLE position, simultaneously preventing an inadvertent shutdown.
If, after the engine has been idled sufficiently, normal shutdown is
desired, lift the idle stop lever and push the throttle control fully
in.
(4) The water temperature gage (4) indicates the engine coolant tempera-
ture. This gage must indicate 160-200'F after engine warmup. A
temperature appreciably higher or lower than cited here is an indi-
cation/of cooling system difficulties.
(5) The oil pressure gage (5) at operating speed, should register 50-70
psi. If it should fall below 30 psi at operating speed, shut down
the engine and determine cause of pressure failure. During idle
speed operation, engine oil pressure may drop below 30 psi, in which
event, it may be assumed that conditions are normal, unless the low
oil pressure causes an automatic engine shutdown.
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NOTE: Charge the four batteries before putting them into service.
If the ammeter shows a discharge while engine is at operating
speed, it is likely an indication of a circuit malfunction.
(7) The starter control switch (7) controls the electric starting motor
and the air intake valve. The control bypasses the low oil pressure
engine shutdown switch' during starting, by use of the HOLD position.
When the switch is moved to START position the starter motor solenoid
is actuated causing the electric motor to crank the engine. When
the starter control switch is in HOLD or START position the air intake
valve solenoid is actuated permitting the engine to start. (See
Figure 2.) After oil pressure builds up the hydraulic latch holds
the air intake valve open.
(8) The panel and clearance light switch (8) controls operation of the ~
panel illuminating light (19) and the clearance (or marker) lights.
(9) The generator ON-OFF pushbutton (9) serves to actuate the load con-
tactors to connect or disconnect the generator output and the load.
(10) The red pilot lights (10) glow when the generator output is being de-
livered to the load.
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(11) The voltage and amperage of each phase can be read on the meters by
turning the meter selector sgch (11) handle to the phase indicated
on the nameplate. One position shows line-to-neutral voltages.
(12) The output current is indicated on the AC ammeter (12) whenever the
generator is loaded. Operation of the meter selector switch (11)
permits reading the current in each of the three phases. Load bal-
ance should be maintained for best operating characteristics and
least possibility of protective device nuisance tripping.
(14) The frequency meter (14) registers the output current frequency with-
in a range of 380 to 420 cps, as indicated by the reed with the
greatest amplitude of vibration. No-load frequency should be 385-
__I. 390 cps in manual throttle mode and 406-408 cps in automatic throttle
mode.
(15) The engine hourmeter (15) records the cumulative elapsed operating
time on the engine. Lubrication, periodic inspection, and preven-
tive maintenance schedules should be forecast and effected with re-
gard to the hourmeter records.
(16) The push-to-buildup voltage switch (16) is used during turn-up proce-
dures to flash the generator revolving fields. The engine, and thus
the generator, speed must have attained-approximately 80% of full
speed before this switch is closed in order for the circuit to func-
tion.
(17) The panel release cap screws (17) must be loosened to gain access to
the interior panel and the voltage regulator rheostat adjustment
screw.
(18) The output voltage adjustment screw (18), located behind the hinged
panel, serves to adjust the regulated generator output.
(19) The panel light (19) serves to illuminate the control panel.
(20) The utility receptacles (20) provide 115 volt, single phase, 400 cycle
current for operation of lights and/or small tools.
(21) The 20-ampere circuit breakers (21) limit the current drain on the
utility receptacles. I
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(22) The electric speed control switch (22) actuates a 6-volt solenoid
coil to set the governor throttle arm at a fixed position for auto-
matic full throttle control. When this switch is in the MANUAL posi-
tion, the hand throttle position determines the engine speed. The
automatic speed circuit will not function until the engine oil pres-
sure reaches 5 psi.
(23) In an emergency, break the wire seal on the emergency stop switch
(23) switch cover, lift the cover, and hold the switch in the UP
position until the engine stops. Holding this switch up energizes
a normally closed magnetic valve to release the oil pressure on the
oil pressure bellows, allowing the air flapper valve to close, and
stop the engine.
(24) The electrical Fuel gage (24) serves to indicate the fuel level in
the tank. The fuel level is indicated in l/4 tank increments. A
low fuel detector attached to the back of the gage senses the voltage
across a rheostat in the tank. When a predetermined level is reached,
(approximately 10% of tank level),-it-actuates a flashing pilot light.
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1. Load ~~._.
Contactors 6. Undervoltage Timer
2. Current Limiting Resistors 7. Undervoltage Relay
3. Diode Panels 8. Overvoltage Relay
4. Plug Interlock (Control) Relays 9. Terminal Strips
5. Underfrequency Relay
Interior Panel
Figure 3
(25) The low fuel warning light (25) flashes to warn of a low fuel con-
dition.
(26) The fuel gage pushbutton serves to test the fuel level when the
engine is not running. When the pushbutton is depressed the indi-
cator gage is actuated and if the fuel level is low the warning
light will flash.
2. Interior Panel
A. Panel Location
(1) The interior panel (Figure 3) is located inside the control box on
the left front side of the unit.
(1) The load contactors (1) one in each output circuit, are actuated by
the generator ON-OFF pushbuttons on the control panel (see paragraph
1, item 9) and serve to connect and disconnect the generator output
and the load(s). See trouble shooting chart VI.
I (2) The current limiting resistors (2) are loo-ohm, 25-watt resistors
which serve to prevent damage to the plug interlock relay contacts
should the phase "C" contacts of the load contactor fail to close
when the generator ON pushbutton is pressed.
(3) The diode panels (3) rectify a portion of the generator output to
supply the load contactor with approximately 90-volts DC when the
generator ON pushbutton is pressed, thereby closing the load con-
tactor(
(5) The underfrequency relay (5) actuates to open the load contactors
when a condition of underfrequency (375 cycles or under), exists.
See trouble shooting chart VIII.
(6) The undervoltage timer (6) after being actuated by the undervoltage
relay, and after a 5-second delay, opens the load contactors. See
trouble shooting chart IX.
(7) The undervoltage relay (7) contacts close when the voltage of any
phase drops below 103 volts. This starts the undervoltage timer
which, after timing out, opens the load contactors.
(8) If the voltage of any phase exceeds 130 volts line-to-neutral, the
contacts of the overvoltage relay (8) open, opening the load con-
tactors. See trouble shooting chart X.
3. Current Transformer Panel (See Figure 4 and regulated static exciter manual
lCZ-65D)
(1) The ammeter current transformers (1) sense the load current and
reduce it to a lower value of definite ratio, suitable for reading
directly on the ammeter.
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(2) The line drop compensation transformers (2) sense any change in the
load current and apply this information to the static voltage
regulator sensing circuit where the relayed sensing current is used
by the regulator to compensate for the line drop.
(3) 'The filter capacitors (3) are used to by-pass to ground any radio
interference before it is transmitted along the 400-cycle output
cables.
A. Panel Description
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(1) There are two sets of output terminals, one set for each of the two
output circuits. The four large terminal posts in each set are for
load application and are marked N, A, B, and C. The "N' post is the
II
generator neutral. A II , "B", and "C" are the three phases of the
generator.
(4) Since the voltage regulator senses the average of the three line-to-
line voltages, a heavily loaded phase will drop in voltage, while
the unloaded phases will rise. Keep 3-phase loads balanced for best
regulation.
(5) The two terminal posts marked E and F in each set of output terminals
,are interlock terminal posts. Leads from aircraft utilizing plug
interlock circuits are connected to these posts. The leads connected
to "E" and "F" return 24-volt DC from the aircraft when the generator
output plug is plugged into the aircraft and the load contactor is
closed. The contactor will not remain closed unless the 24-volt DC
from the aircraft is being returned to the contactor.
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CHAPTER 1 OPERATING
For 'detailed truck operating procedures, consult the truck owner's manual.
CAUTION: THE OPERATOR MUST GUARD AGAINST DANGER TO HIMSELF AND THE POWER
UNIT WHEN MANEUVERING AMONG CABLES, ROPES, OR OTHER ZONES OF POSSI-
BLE LOW CLEARANCE, AS THE POWER UNIT EXTENDS ABOVE THE TRUCK-CAB.
WHILE FULLY MOBILE AND RUGGEDLY BUILT, THIS TRUCK HAS THE CONSID-
ERABLE WEIGHT OF THE POWER UNIT AT A HIGH CENTER OF GRAVITY, THERE- ~
FORE MUST NOT BE SUBJECTED TO VIOLENT STARTS, STOPS, OR TURNS AS
A MATTER OF SAFETY;
A. Preparation Procedure
(1) Once the unit is properly positioned, set the manual parking brake
on the truck, shut down the truck engine, open the side door panels
on the power unit canopy, and, if necessary, turn the panel and
clearance marker lights switch ON. Next proceed with the engine
prestart checklist outlined below:
(c) Check the entire electrical system to make sure all connections
are secure and correct.
(d) Make certain that there are no loose parts, tools, etc., on or
near the engine.
(2) After you are satisfied that the area and the unit are clear of
hazards, the engine may be started. Above all else, SAFETY is the
most important consideration regarding the operation of Ithis-ground
power unit.
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July 23168 l-4
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MOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY
A. Starting Preparation
(1) Before starting the engine, refer to the EOM and follow the lubri-
cating and pre-starting instructions contained therein.
(a) Pull the throttle control to its stop and observe that the idle
stop rests on the throttle rod.
(b) Turn the starter control knob to START position and hold until
engine starts.
(c) When the engine starts move the starter control knob to HOLD
position, and hold until oil pressure builds up.
(d) After the engine starts and oil pressure gage reads 25 psi,
release the starter control and return the throttle control
slowly to idle position against the idle stop.
(a) Remove the cap of the fluid starting aid fluid cartridge con-
tainer and insert a starting fluid cartridge.
(b) Pull the piercing shaft knob fully out before replacing the cap.
(c) Push the piercing shaft knob down firmly to puncture the cap-
sule.
(e) Pull the air heater knob fully out and slowly push it back as
you hold the engine starter control knob.
(f) After start repeat steps (c) and (d) of procedure (1).
(a) Bring engine to full speed by pulling the throttle rod fully
out after allowing the engine to warm up at idle speed.
(d) When the frequency meter indicates 385 + 5 cps, place the elec-
tric throttle switch in the AUTOMATIC position; the frequency
meter should now read 406-408 cps.
(1) Before the generator can be set up for power delivery, the output
cable(s) must be connected to the aircraft receptacles.
(2) When ready to deliver power, press and hold the black ON button (9)
until the red pilot light(s) (10) come on, then release the ON button.
The generator is under load as long as the red pilot lights are on;
the AC ammeter (12) will show current drain while the load is on.
When both the light(s) and the meter indicate the set is under load,
check the frequency to be 400 to 408 cycles. Check that the voltage
holds at 200 volts. It is desirable that each generator phase be
checked for voltage output and for current load by use of the meter
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selector switch (ll), at this stage. The voltage output checks
should be made during a stabilized load condition.
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(1) Any generator load must be removed by pressing the generator OFF
pushbutton, before the engine may be properly shut down. To stop the
engine-, make sure the idle stop is resting on the throttle rod, then
push the throttle rod in against the idle stop and place the electric
throttle switch in the MANUAL position; the engine speed will de-
crease to idle immediately. Allow a 3-5 minute cooling period before
raising the idle stop and pushing the throttle rod in to the cutoff
position.
CAUTION: DO NOT DISCONNECT THE OUTPUT CABLES FROM THE AIRCRAFT WHILE
POWER IS ON. BE SURE THE OUTPUT CABLES ARE PROPERLY STORED
BEFORE RELEASING THE TRUCK EMERGENCY BRAKE.
NOTE: Average lube oil consumption of the engine for 10 hours running
is 2-l/4 quarts per the manufacturer's data.
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CHAPTER 2 MAINTENANCE
SECTION 1 - SERVICING
(1) Check any change in operating noise or smoothness at once and stop i
unit if change is abrupt or pronounced. Sudden change in engine
instrument readings normally indicates acute trouble requiring
immediate attention.
B. Daily'or 8 Hours
(1) Check fuel and lubricating oil level. Keep fuel tank filled to min-
imize condensation. Keep oil level full to prevent unnecessary
engine shutdown. Drain l/4 pint of fuel from fuel strainer and
filter (on right rear side of unit frame) to remove sediment and
water.
(2) Clean the air cleaner dust cup (on left center portion of power
unit). Check filter service indicator. If red flag appears, service
the air cleaner.
C. Weekly or 25 Hours
(2) Check engine coolant level (and antifreeze strength, when appli-
cable); refill as required.
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(6) Check the 15 psi low oil pressure tripping characteristics. With
throttle idle stop raised, slowly push in throttle until engine oil
pressure drops below 15 psi.
(7) Check the low fuel warning system. The warning light should flash
when the fuel level drops below 10%.
(1) Ensure fan belts have 3/4-inch deflection from a straight line over
outer diameter of pulleys. Check coolant hose;-condition.
(4) Lubricate the engine starter oilers with 5-6 drops of engine oil.
(5) Clean complete unit, tighten all hardware, inspect wiring for good
condition and solid connections, examine for cracks, broken welds,
and deformation.
(6) Bearing noises may be detected by placing one end of a metal rod or
large screwdriver against the bearing housing and placing the ear
against the other end of the rod or screwdriver while the generator
shaft is rotating. If the bearing is found defective, replace it.
(7) Check the 400-cycle generator slip rings for roughness, pitting, or
dirt. Clean slip rings with an abrasive pad formed of heavy canvas,
held against the slip ring with a stick. For repair of roughness or
pitting see overhaul section. Replace the brushes if they have worn
to 3/4-inch or less.
(2) Remove radiator shroud side panels and blow out excessive dirt behind
radiator.
2. Lubrication
A. Servicing
(2) 1The Donaldson dry air cleaner used on this unit employs both a dry,
paper filter and a centrifugal pre-cleaner. The pre-cleaner fins
give high speed rotation to the intake air, separating a large por-
tion of the dust from the air by centrifugal action, after which,
the dust is carried into the dust cup. The dust cup should be ser-
viced daily. The small portion of the dust remaining in the pre-
cleaned air is removed by the filter element.
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B. Cleaning
(1) Direct dry, clean air up and down pleats on the clean air side of
the Duralife filter.
CAUTION: AIR PRESSURE AT NOZZLE MUST NOT EXCEED 100 PSI. MAINTAIN
REASONABLE DISTANCE BETWEEN NOZZLE AND DURALIFE FILTER.
(2) Wash the filter with 2 ounces of Donaldson D1400 Filter Cleaner
mixed with 1 gallon of warm water (appr. lOOoF). For best mixing
results, use a small amount of cool water, add the cleaner, then
add warm water. Soak the filter in the cleaning solution for 15
minutes. Rinse the filter thoroughly with clean water, then air
dry the filter completely before reuse.
(3) After cleaning and drying the filter, inspect for damage by placing
a bright light inside the filter. Slightest rupture requires
replacement of filter.
A. Speed Settings
(1) If, for any reason, the engine speed, either manual or automatic, is
altered, the following steps must be taken to reset the speed to the
original values. See figure 1.
(2) With the electric throttle switch in the MANUAL position, and the
throttle rod pushed in against the idle stop on the control panel,
set the idle-speed at 700-800 rpm. To make this adjustment, loosen
the set screw on the governor throttle arm (1) and adjust the screw
in the top center of the arm until the idle-speed is correctly set
(it may be necessary to adjust the stop nuts on the idle adjusting
rod (2) to finish this adjustment).
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(3) To set the throttle for full speed with automatic throttle control,
first observe the frequency meter indication with the electric
throttle switch in the AUTOMATIC position; it should read 406-408
cps, no load. Next, place the switch in the MANUAL position and
idle the engine (to make the speed adjustment, it is not necessary
to idle the engine, but noise and vibration are not as great at
idle speed as they are at full speed). Proceed with the adjustment
in this manner: Back off the nut locking the plunger stud (3).
Placing a wrench on the stud flat, turn the stud a few turns in
either direction, then place the electric--throttle
_- ~~. switch in the
AUTOMATIC position (throttle rod must be extended to its full speed
stop) and again observe the frequency meter indication. If the
frequency is correctly set, lock the plunger stud in place with the
nut previously loosened. If the frequency does not read 406-408
cps, repeat the plunger stud adjustment until the correct frequency
is obtained. Do not forget to lock the stud in place once the ad-
justment is completed. After the "automatic" full speed is set,
adjustment of the "manual" full speed throttle setting may be
performed.
(4) The "manual" full speed adjustment may be made after the idle and
"automatic" full speed settings have been corrected. To set the
"manual" full speed, the electric throttle switch must remain in
the MANUAL position. Pull the throttle rod out --
to-its full speed
stop and observe the frequency meter; it should read 385 25 cps,
no load. If the frequency is not correct, loosen the set screw
on the throttle stop clamp (4), move the throttle rod in or out
as required until the frequency meter indicates 385 55 cps, and then
lock the throttle stop clamp against the throttle control (guide
tube).
(5) After completing the throttle linkage adjustment, recheck the idle
speed and the "automatic" and "manual" full speed settings. As a
final check, allow the engine to idle long enough to cool the valves
and pistons, then lift the idle stop and push the throttle rod in
to the SHUTDOWN position; the engine should stop.
July 23168 _
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CHAPTER 2 MAINTENANCE
SECTION 2
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Control Panel
Figure 1
CHART1
Voltmeter reads zero when Voltmeter circuit is open Check voltage to the load
the voltage buildup push- contactor input; if
button is pressed (it present, replace the volt-
should, show approximately meter. If the meter
100 volts, then advance still reads zero volts,
immediately to 200 volts) check the complete meter
circuit and replace,the-
defective wiring or part.
If the DC voltage is
present at the exciter
in the test above,
check for DC voltage
to the slip rings with
the buildup button
pressed in; if none,
refer to the static
exciter manual.
If DC voltage is present
at the slip rings in the
test above, disconnect
external leads to the
slip rings and check for
open or shorted circuit.
If still no voltage,
check for worn brushes
or very weak brush
spring, then check for
dirty slip rings.
Voltage rises, but the Incorrect engine speed Adjust the engine speed
voltmeter does not read to obtain the correct
200 volts reading on the frequency
meter.
1
2-2 July 23168
Page 2
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GENERATOR DIVISION
HOBART BROTHERS COMPANY
CHART11
Pilot lamp comes on A protective device has Check for open contacts
briefly, but goes out operated to open the load in one of the protective
within 1-15 seconds contactor relays. Correct the
faulty power condition
that prompted the relay
to open.
CHART III
One or both pilot lamps ~-. One of the overcurrent Aircraft load is exces-
go off with a load applied sensring-relays open sive; reduce the load.
to the generator: Ammeter
zeros (Load contactor Output cable is shorted
has (have) opened; engine or grounded; repair or
is still running; replace the cable (s) as
voltmeter reads 200 volts) needed to remove the
fault.
2-2
Page 3
FOBART
-,MOTOR GENERATOR DIVISION
I 8
B :: HOBART BROTHERS COMPANY
c 2
QD
4## e+
* BAT
CHARTIV
CHARTV
(See Figure 1)
No hour meter reading Poor ground, open circuit Clean and tighten ground
lead.
2-2
Page 5
GENERATOR DIVISION
HOBART BROTHERS COMPANY
Engine stops when start Air shutdown valve has Starter control must be
switch is released closed. Starter control held in START position
was not held in START until oil pressure
position long enough for reaches 15 psi.
oil pressure to build up
sufficiently
2-2 July 23168
Page 6
QQ
8 ; MOTOR GENERATOR DIVISION
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HOBART BROTHERS COMPANY
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Engine stops when start Low oil pressure Locate cause and correct.
switch is released
Cont'd
CHART VI
(LOAD CONTACTOR)
July 23168
Page 7
FOBART
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c I
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NO.
XI x2
CHART VII
CHART VIII
(UNDERFREQUENCY RELAY)
CHARTIX
/
July 23168 2-2
Page 9
-.____~-
-___-..__
GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133
CHARTX
(OVERVOLTAGE RELAY)
(See Schematic)
9 0
-2-5/B ___r
i
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f------w
TOP BOTTOM
DECK DECK
\ _ ,'.
\\ _-'
'-_, /-
-.
---'.
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July 23168
.-
GENERATOR DIVISION
HOBART BROTHERS COMPANY
CHAPTER 3 - OVERHAUL
SECTION 1
A. '
Truck
(1) Consult truck owner's manual. For major overhaul procedures, contact
truck dealer or representative.
B. Diesel Engine
(1) Consult the General Motors operator's manual and parts book. For
major overhaul, contact a GM-service depot or a factory representa-
tive. -
I I
Canopy Removal
Figure 1
1
July 23/68 3-l
Page 1
-8
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GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133
(1) Overhaul instructions for the regulated static exciter are furnished
in a separate manual, lCZ-65D, shipped with this generator set.
--
NOTE: Personnel assigned to this work must be qualified in the fieldr
~~_-
of electronics.
D. Canopy
(c) Remove nuts and washers from lifting eye, pull the lifting eye
up out of the lifting yoke but not through the canopy top. Re-
install nuts and washers on the lifting eye directly under the
canopy top.
(g) Attach hoist to lifting eye, lift the canopy and store in a
clean area.
(a) Inspect doors, handles, latches, and cams, repair or replace dam-
aged parts, clean doors and parts with a clean cloth moistened
with a suitable solvent.
(b) Inspect end panels and canopy top for cracks, dents, and areas
where paint has been removed. Repair damaged areas using stand-
ard sheet metal practices. Remove rust and/or dirt from damaged
areas and apply rust preventive paint.
E. Cooling System
--
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FOBART
iMOTOR GENERATOR DIVISION
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Cooling System
Figure 2A
Cooling System
Figure 2B
3-l
Page 3
GENERATOR DIVISION
HOBART BROTHERS COMPANY
(d) Clean corroded parts and paint with corrosion resistant paint. (I
F. Superstructure Group
Superstructure Group
Figure 3
,' 1
3-l July 23/68
Page 4
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FOBART
e ;MOTOR GENERATOR DIVISION ~ ~
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HOBART BROTHERS COMPANY
8
QD
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Q. Ba++
(a) Remove all leads from output term panel; remove ground lead
from stator housing.
Disconnect all engine control leads at the engine which run from
engine to control panel. Remove oil pressure hose, quick start to
air intake valve tubing - starter leads. Remove leads from stator
to current transformer panel (at panel). Remove hold down connecting
bars from top of panels. Remove attaching bolts and lift ~~
Control
~___~
Panel and Current Transformer Panel off together.
(3) Remove all leads from front of Regulated Static Exciter panel. Re-
move bolts and lift panel from frame. See Figure 4.
#II.
Regulated&Static Exciter
Figure 4
(4) Remove connections from ballast resistors and remove the resistor
panel.
(5) Disconnect air tubing from Air Cleaner Tank then 4 bolts and remove
the tank. See Figure 5.
(6) Disconnect support from frame (six bolts). Remove bolts from lifting
yoke to frame (eight bolts). Remove support and yoke - leaves gen-
erator completely accessible.
G. AC Generator
Generator Removal
Figure 6
(b) Remove screws from engine brackets and lift engine at generator
end. Tilt engine until generator mounting brackets are at __
least one inch off the frame. Put blocks under engine fly:
wheel housing mounting brackets.
(f) Attach hoist to generator housing and lift generator from base.
CAUTION: BEFORE REMOVING THE FLEX COUPLING AND HUB, MARK POSI-
TION OF HUB FLANGE AND FLEX COUPLING AS SHOWN IN
FIGURE 7 ENSURE REASSEMBLY AS ORIGINALLY BALANCED.
-
Balance Mark Removing Bushing
Figure 7 Figure 8
(h) Use the set screw to push the bushing out of the hub by insert-
ing it in threaded holes provided on the bushing side of the
hub. See figure 8.
(a) Remove all dust and dirt with compressed air and mineral
spirits (Stoddard Solvent).
(c) Clean the stator with compressed air and mineral spirits
(Stoddard Solvent).
(3) Reassembly
CAUTION: MAKE SURE ARMATURE AND STATOR ARE COMPLETELY DRY BEFORE
REASSEMBLING.
(a) Attach hoist straps around center of armature and around arma-
ture shaft at engine coupling end.
I
*.--
3-l- July 23168
P.age 8 i
GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133
(d) Place block under armature, remove hoist, and slide the arma-
ture completely into place.
Armature Alignment
Figure 9
CAUTION: MAKE SURE THE BALANCE MARKS ON HUB FLANGE AND ON THE
FLEX COUPLING ARE ALIGNED.
.. _
i:
MOTOR GENERA
HOBART BROTHERS COMPANY
(k) Attach the fan to the flex coupling with 2 bolts and nuts. See
figure 10.
Assembling Coupling
Figure 10
(1) Loosen the bushing set screws, insert a screwdriver blade in the
bushing slot to open the bushing enough to start the assembly
onto the generator shaft.
flywheel to the
rface. See
Flywheel Measurement
Figure 11
3-l July 23168
Page 10
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Ti
$/MOTOR GEhlERATOR DIVISION
HOBART BROTHERS COMPANY
(n) Tap the flex coupling in place on the generator shaft with a
soft face mallet. Measure from the face of the generator
housing attaching surface to the end of the flexible mount
using the exact measurement taken in step (m). See figure 12.
Coupling Measurement
Figure 12
Tightening Bushing
Figure 13
(p) Tighten the 8 screws attaching the flex coupling.to the hub and
secure with safety wire. See figure 7.
(q) Remove the nuts from the two fan mounting screws and push the
remaining 8 screws through the fan and through the flex
mountings.
-----4 1
$.lOTOl? GENERATOR DIVISIONa; ,
,
HOBART BROTHERS COMPANY
/
,.
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CHAPTER 3 - OVERHAUL
SECTION 2
2. Reassembly
A. <Generator
(1) Lift generator with hoist and lower carefully into place on frame.
(3) Insert screws through fan and flex coupling into the engine flywheel,
tighten securely.
(5) Secure generator to frame with six bolts and tighten the bolts.
(1) Place lifting yoke and support assembly on the frame. Replace bolts.
C. Superstructure Group
(3) Install the air cleaner tank and connect all tubing.
(1) Lift the radiator into place with hoist, attach to frame.
/--
i
TOR DIVISIO
-
GPU -400
~~~CYCLE 160 KVA TRUCK MOUNTED TM-133
E. Canopy
(2) Lift canopy with hoist and lower it carefully into place on the
G.P.U.
F. Operational Check
(b) After the engine warms up and the generator output shows normal
in step (a), connect 24 volt leads from engine battery or any
24 volt DC source to terminal posts E and F on the Output
Terminal Panel, (Ref. l-3, Figure 1). The system is a negative
ground type, connect ground lead from battery to the GPU frame.
Plug output cable into a load bank and simulate a normal load,
all meters and equipment should operate as noted in l-4, para-
graph 4A.
(c) If the unit does not operate normally, trouble shoot as shown
in Chapter 2, Section 2.
/
3-2 July 23/68 '
Page 2
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