Hobart 5359D User manual

OM 2012
082585
Revised 042188
OPERATION AND MAINTENANCE MANUAL
with
ILLUSTRATED PARTS LIST.
for
E.N G INE -DRIVEN* GENERATOR SET
SERIES 5359P, MODE L 9OG20
909KVA , 400-H z, 115/200-V AC, 3 Phase
with
DETROIT DlEsELENGINE, TYPE 4-71N
.
Specification Number 5359&l, For truck or trailer mounting
Speciftiation Number 53590-2, For tracta mounting
Specification Number 5359@-3, For stationary mounting
Specification Number 5359s 9,; For truck or trailer mounting
(Special features for ‘AF) .
Manufactured by
HOBART BROTHERS COMPANY
POWRSYSTEMS DNISION
TROY, OHIO 45373
U.S.A.
,

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_ -
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SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTKFCAL POWER EQUIPMENT I
WARNING I I
ELECTRIC SHOCK can kill. Do not touch live electrical parts. I
I
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 don't cause short circuit+.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attach{d
equipment. I
IMPORTANT: - Protect yourself and others. Read and understand all the
instructions in this Operating/Instruction Manual before j
!
A.
B.
installing, operating, or servicing this equipment.
manual available for future use by all operators. Keep th{s
I
GENERAL
Equipment that supplies electrical power can cause serious injury or death,
or damage to other equipment or property, if the operator does not str$ctly
observe all safety rules and take precautionary actions. Safe practides
have developed from past experience in the use of power source equipmt&t.
SHOCK PREVENTION I
Bare'conductors, or terminals in the output circuit, or ungrounded, I
electrically-live equipment can fatally shock a person. Have a tiompei&nt
electrician verify that the equipment is adequately grounded and learn what
terminals and parts are electrically HOT. Use proper safety clothing;
procedures, and test equipment. \
I
The electrical resistance of the body is decreased when wet, thus more
easily permitting dangerous currents to flow through It. When fnspecting OF
servicing equipment, do not work in damp areas without being extremely
careful. Stand on dry rubber mat or dry wood, use Insulating gloves that
are effective when dampness or sweat cannot be avoided. Keep your clothing,
dry and never work alone. , !
I. Installation and Grounding of Electrically Powered Equipment -Elet$tricab
equipment must be installed and maintained in accordance with the NatJonal j
Electrical Code, ANSI/NFPA 70, and other applicable codes. A power discon-!
nect switch or circuit breaker must be located at the equipment.
nameplate for voltage, frequency, and phase requirements. If only
Cheek the;
power is available, 3-phase j
of the 3-phase line.
connect any single-phase rated equipment to only two wipes
DO NOT CONNECT the equipment grounding &onductor (lea/d)
to the third live wire of the 3-phase line, as this makes the equipmelfitframe
electrically HOT, which can cause a fatal shGky-- l 1
-w-e-- !
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-..-.m-t-.-._-...1
I 1
Dee 41184
I-. -, - _- __ _ _ - -_ -.. __ _.. I

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C.
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1 D.
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F.
+- _. ^_‘.’
Be sure to.connect the grounding lead, if supplied $,,aXpower line cabIe;~..:.,,--
to the grounded -s&t&-box or.building ground;. -Ifs-t&--provided,use a:- ;
separate grounding lead. Be certain that the current (amperage) capacity j
of the grounding lead will be adequate for the worst fault current sltua- '
tion. Refer to the National Electrical Code ANSI/NFPA 70 for detai1s.i Do
not remove plug ground prongs. Use correct mating receptacles. I
I
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.
equipment is energized. Do not touch output terminal whfle
FIRE PREVENTION
Overloaded or shorted equipment can become hot enough to cause fires e+ther
by self destruction or causing nearby combustibles to ignite. Provide!
primary input protection to remove short circuited or heavily overload+d i
!
equipment from the line. I
!
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BODILY INJURY PREVENTION /
/
Serious injury can result from contact with fans inside the equipment.: b
Shut DOWN equipment for Inspection and routine maintenance. When.equ;pment
is in operation use extreme care in doing necessary troubleshooting and
adjustment.
t
1 Inspect all precautionary labels on the equipment monthly. Order and 1
_,~_ ~. -
replace all labels that cannot be easily read. --- ~---I
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. . .._ ..- .- .--- -_ - _-..-..-_....- _.._.-... _ ..___..-_. /
.---_.-._ ._ _.
w-2
3. Service and Maintenance - This equipment must be maintained in good
electrical and mechanical condition to avoid hazards stemming from dis+
repair. Report any equipment defect or safety hazard to your supervisor ant
discontinue use of the equipment until its safety has been assured. Re-
pairs.should be made by qualified personnel only. Shut OFF all power gt
the disconnecting switch or line breaker before inspecting or servicing the
equipment. Lock switch OPEN (or remove line fuses) so that power cannot be
turned ON accidentally. Disconnect power to equipment If it is out of;ser-
vice. If troubleshooting must be done with the unit energized, have pre-
sent another person trained in turning off the equipment and provldlng,or
calling for first aid.
4
MEDICAL AND FIRST AID TREATMENT
First aid facilities and a qualified first aid person should be available
for each shift for immediate treatment 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.
I-
EMERGENCY FIRST AID
Call physician immediately. Seek additional assistance and use First hd
techniques recommended by American Red Cross until medical help arrive6.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim jfe
down. FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not
breathing, begin artificial respiration, preferably mouth-to-mouth. I!f
no detectable pulse, begin external heart massage. Call Emergency Res)cue
Squad immediately. I
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EQUIPMENT PRECAUTIONARY LABELS
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OM 2012
ItiTR ODUCT ION
This manual contains operation and maintenance information for a 4OO+Iertz, generator set
manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373.
The manual is not intended to be a text book on electricity cr electronics. Its primary purpose is
to provide information and instructions to experienced operators, electricians, and mechanics
who have never seen or operated this generator set. It is the intent of the manual to guide
and assist-operators and maintenance people in the proper use and care of the equipment.
Use of the manual should not be put off until a trouble or need for help develops. Read the
instructions before starting the unit. Learn to use the manual and to locate information con-
tained in it. Its style and arrangement are very similar to commercial aircraft manuals.
The manual is divided into six chapters. Each chapter is divided into as many sections
as required. Each new section starts with page 1. Each page is identified by chapter,
section qnd page number which are located in the lower, outside corner. When information
located in another portion of the manual is referred to, its location is identified by chapter,
section, and paragraph, or figure number. For example, “(See 2-3, Para. B) ‘I refers
to information located in Chapter 2, Section 3, paragraph 8. If a Chapter and Section are
not indicated in a reference, the referenced material is l&ted in the same section as the
reference, Example, (See Para. B).
In addition to operation and maintenance instructions, the manual contains an illustrated
parts list iri Chapter 4, and a collection of manufacturer’s literature and supplemental
info-pen in Chapter 6. \
. 1
-_.-..
Content of the manual is arranged as follows :
Chapter 1. Description/Operation
Chapter 2. Servicing
Chapter 3. Trouble Shooting
Chapter 4. Illustrated Parts List
Chapter 5. Optional Equipment
Chapter 6. Manufacturer’s Literature
Aug 25 185 lntroduc t ion
Page 1

OM 2012
TABE OF c O~TEblTS
SUBJECT
-- CkiAPT&‘SECTi01\! PA GE
.
ink o&c t ion 1
Table of Contents 1
Description/Operation 1
1-O
l-1
Descr i@ ion 1
1. General 1
2. Orientation 1
3. Spet ia 1 Features 1
A. ‘Roll-Out” Feature Ji’ractor-Mounted Unib) 6
9. Protective Monitor 6
6
, 6
6
C. Pull-out Trays
.
D. Voltage Regulator
E. Test Circuiky .
F. Electric Governor 6
4. Ident if icat ion 7
A. Genera6 7
9. Generatcr Sets Available in 5359C Series 7
5. Optional Equipment 7
A. Trailer a
9. Truck 8
C. Transfcrmer-Rectifier 8
6. Canopy 8
Contents
Page 1
Avg 25%5

OH 2012
TABLE OF COhTZfiTS (COiuT’D)
SUBJECT CHAP-fEl:/‘SECTiC~
7. Engine, Generator and Controls Assembly l-1
A. Basic Engine
fi. Engine Manufacturer s Equipment
C. Hobart’ Engine Equipment
(1) Electric governor system
(a) Magnetic pickup
(b) Control unit
(c) Actuator
(2> Engine safety devices
(a) Overspeed governor
(b) Temperature sensing safety switch
(c) Start circuit cut-out switch
(d) Start circuit solenoid switch
(3) Air cleaner
(4) Exhaust system
(5) Rad iat or
D. Generator
E. Control Box Assembly
(1) Generator control tray
(a) Resistors
(b) Generator output monitors (meters)
.
PAGE
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9
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10
10
10
10
11
11 *
11
11
13
14
14
15
15
15
15
16
Contents
Page 2
Aug 25 &i
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TABLE OF CO!~‘TEt’JTTS (CONT’D)
SlJBJECT
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(c) M2ter and line switches
CHAPTER/SECTION PA GE
l-l ’ 16
(d) Rece ptac 13 c onnec t cr 18
(e) Tray 18
(f) Manual voltage control 18
(9) EXC itation-deenerg ization re lay 18
(2) Protective relay fray 18
‘(a)S
ens ing modu Ies 18
(b) Memory and time-de!ay module 19
(c) indicating lights 19
(d) Plug-inter lock relay . 21
(e) Test-bank switch ’ 21
(f) Resistor
(g) Fuse-interlock relay
21
21
. (h) Connector 21
(k) Auxiliary underfrequency relay ; 22
F. Engine Control Panel 22
(1) Engine instruments
(4 A mmeter
22
22
(b) Temperature gage 22
(c) Oil pressure gage and oil pressure switch 23
(d) Hourmeter 23
Aug 2545 Contents
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OM 2012
TABLE OF COiuTEN IS (CONT’D)
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SUBJECT CHAPTER/SECT ;Cti PA GE
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(2) Engine und generator contrck l-l 23
(a) Fuse 23
@) Engine-generator control switch 23
(c) Contactcr control switch 24
(d) Instrurrcnt light and switch 24
(e) Engine starting circuit 24
(f) Indicating lights 24
(9) f%e19ase
(h) Coid weather starting aid control
(k) Engine stop control
(3) Air c leaner indicator
(4) Test receptacle connector
(5) Charging circuit resistor
G. Voltage Kegulatar
(1) Controls
26
26
26
26 ’
27
27
27
27
(2) Protection 27
(3) C omponenfs 27
H. Power Module Panel Assembly 30
(1) Load contactor 30
(2) Current transformers 30
Contents
Page 4
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OM 2012
TABLE OF CONTENTS (CONTiNUED)
SUBJECT CHAPTER/SECTION PAGE
(a) Ammeter current transformen l-l 30
(b) Line-drop current transformers 30
(c) Overload current transfoners 31
(3) Overload module 32
’ (4) Rectifier 32
(5) Terminal boards 32
8. Test Box 33
A. Description
9. Theory of Operation
9. 5359G
A. RFI Suppression Kit
9. , 24 Volt DC Power Supply Kit
Preparation for Use, Storage, or Shipping
33
34
34
34
34
l-2 . 1
1. Preparation for Use 1
A. Genemi 1
9. Inspection/Check 1
C. Installing Output Cables
(1) Three-phase, AC output cable ossembl y
installation
(2) Transformer-rectifier (DC) output cable
installation 4
2. Prepamtion for Storage 5
A. Geneml 5
9. Tempomry Skmge 5
C. Long Time Storage (Over 30 Days) 5
Aug 25 185 Contents
Page 5

TABIE OF CONTENTS (CONT’D)
OM 2012
SUD.JECT CHAPTEI:/SECT~O~~ PAGE
3, Preparation for Shipnx?nt l-2
Operaf ion l-3
1. Gcr,era I
2. Operatir~g’tile’Generatcr Set
A. Pre-start Inspection
9. N mna I Engine Starting Procedures
C. Cold Weather Engine Starting Procedures
D. Preparation for Power Delivery (Normal Automatic
Voltage Control)
E. Power De I ivery (Automatic V&age Control) .
F. Prewation for Power Delivery (Manual Voltage
Control)
G . Power De livery (Manual Voltage Control)
H. Discontinue Power Delivery
K. Stopping the Engine
3. Test Box Operation
4. Transfamer-Rectifier Operation (Optional Equipmznt)
A. Direct Current Power Delivery
9. Simultaneous 28.5-V and 35-V DC Power Delivery
C. Simultaneous 28.5-V DC and 115-V AC Power Delivery
D. Simultaneous 35-V DC, CT 112-V DC and 115-VAC
-
I
Power De livery
5. 24 Volt DC Power Supply
Contents
Page 6
7
8
9
9
9
9
1.0
11
11
12
12
13
13
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OM 2012
SWJECT CHAPTEiR,/SECTIOju
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Scrv ice 2-o -
h{a inte nance Z-1
1. Genera I
2. Operation of Roll-OUF Feature (Tractcr-Momled Units)
A. Roll Generotor Set Out for Service
B. Roll Generator Set In to Normal Position
3. Inspect ion
4. lubrication
A. General
B. AC Generator
C. Generator Controls
D. Engine
(1) Lubrication schedule
(2) Oil specification
(3) Oil viscosity
(4) Change engine oil
(5) Change oil filter element
E . Eng ine Access ccies
(1) A lternatrx
(2) Siarter
(3) Overspeed governor arld drive
, 3
3
3
3
6
6
7
8
8
9
9
Aug 25% Contents
Page 7

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TAB!E OF CONTENTS (CONT’D)
SUBJECT CI-IAPKI!/SECTlO~ PAGE
5. Air Cleaner Service
A. Car-jr idge Remova I
B. Cartr idye Insta I lat ion
6. Engine Fuel
A. Qua1 ity
B. Fue I Filters
(1) Daily service
I
(2) Change strainer and filter elements
(3) Ctwngespin-on strainer and filter
7. Engine Cooling System
A. General
3. Radiatoh Cap
(1) General
(2) Removal
(3) lnsta I lat ion
C. Warm Weather Operation
D . Cold Weather Operation
(1) General
(2) Coolant solution check
(3) Coolant solution preparation
(4) Antifreeze solution installation
b
C onknts
Page 8 -.__
6 ;
2-l
Aug 25185
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9
9
10
10
11
11
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13
13
13
13,
13
13
13
14
14
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15

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TABLE OF CCb!-fETuTS (CC&T’D)
SUBJECT CHAPTER ,‘%CTICIV PAGE
_- -_I
E. Drain the Cooling System 2--l l 15
F. Coaling System Cleaning 16
G. Radiator Core Cleaning
H.’ Cdoling System Filling
16
16
8. Generator Maintenance 18
A. C isaning 18
B. Adiustment 18
9. Drive Belts 19
19
19
. 19
19
A. Preparation for Belt Check and Adjustment .
B. Check Be It Tens ion
. C. Be it Adjustmzznt
(1) Alternatcc belt
(2) Fanbeiis’ 20
10. Service Helps 22
A. Wiring 22
B. Control Box Trays
(1) Tray removal
22
22
(2) Tray insta I iat ion
C . Generator Exciter
22
23
(1) Preparation for exciter removal 23
(2) Exe iter remova I 23
Aug 25,/8!5 Contenb
Page 9

TABLE OF COIU-ENTS (CL?1Uf’D)
SWJECT
--- CHAPEL/‘SECTlCt~ FAGE
(3) Exe i:er insfai lation 2-l
D. Engine Control Panel
(1) Ti!t out engine control pawi
(2) t&instuII engine control panel
InspectiwjCheck
1. .Genera I
2-2
2. Engine
A’. Fuel
B. Lclbr icat ion
C. Coolant
.
De V-Belts
E . Exhaust-System
3. Electric System (12-V DC)
A. Lights
B. Fuses
C. Wiring Connections
4. E iectrical System (115-V AC)
A. Monita ing Instrurtznts
B. Ind icat ing Lighb
C. Protective Modules
D. Wiring and Connections
Contents
Page 10
OM 2012
24
24
24
24
1
1
1
1
1
1
1’
1
3
3
4
4
4
Au g 25 I85

OM 2012
.
TABLE OFCO!uTEtiTS (CONT’D)
SUGXCI
-- CHAPTiXf,/SECTiON
-- .
Adjustment/Tesi 2-3
1. General
2. Preparation for Test for Tractor-Mounted Units
<
A. Generator Set Removed from Tractor
B. Generator Set in Tow Tractor
3. Generator Set Test
A. Pre-opzrationa I Test Procedures
B. Operat iona I Test Procedures
4. Generator Set Adjustment
A. Generator Adjustmnt
8. Generator Controls Adjustment
(1) Adjust manual voltage control variable resistor
(2) Adjust 400-l-i 2 voltage regulator
(a) Adjust generator output voltage
(b) Adjst cable length and cable size
compensation rheostats
(c) Adjust “damp” and “rate “ adjusting
potentiometers
C. Basic Engine Adjustment
(1) Exhaust valve adjustment
(2) Exhaust valve bridge adjustment
(3) Fuel injector timing adjustment
PAGE
--
1
1
1
1
2
2
2
9
15
15
15
16
16
16
16
17
19
19
19
19
,
Contents
Page 11

OM 2012
TABLE- OF C9NTf3luTS (CO;%-‘D)
SUBJECT CHkl’i-EK/SECT ION PAGE
(4) Idle speed, speed limiting, and overspzed
adjustment 2-3
D. Engine Accessories Adjustment
E . E IectriF Governor System Adiustment
(1) Actuator linkage adjustment
(2) Magnetic pickup adjustment 23
(3) Governor control unit adjustment 24
(4) Electric governor test values
(a) Signa I to actuatcf
(b) Magnetic pickup signal
F. Engin& Shut-Down Devices Adjrrstment
. .
. (1) Starter cut-out switch adjustment
(2) Shut-down linkage adjustment 28
5. Generator and Exciter Test
6. Diode Test
I 7. 24 Volt DC Power Supply Test
Trouble Shooting
Trouble Shooting Procedures
1. General
2. Trouble Shooting Chart
A. Description
I
B. Use of Trouble Shooting Chart
Conh?llts
Page 12
3-o
3-l
.
20
21
21
21
26
26
26
28
28
29
29
31
1
1
Aug 25 &i

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TABLE OF CONTE~YTS (CONT’n)
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SUBJECT
-- CHAP-lXR/SECffON PA GE
3. Equipmnt for Trouble’Shooting 3-l - 2
4. Safety 2
5. Parts Replacemznt 2
6. T&t Va fues
7. Check Connections and Leads 3
8. Electric Governor Trouble Shooting 3
9. Engine Trouble Shooting Procedures 4
A. General
B. Locating a N&firing Cylinder
4
4
C . Checking Compress ion 5
D. Interpretation of Compress ion Pressure Chart , 6
E. Causes of Low Cylinder Pressure 6
F. Fuel Flow Test
10. Illustrations
II lustrated Parts List
introduction
1. General
2. Purpose
3. Arrangement
4. Explanation of Parts List
6
6
4-o 1
4-1 1
1
1
1
1
Aug 25’85 C cntenis
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SUGJFCI- CHAPTER/‘SECT (09. PAGE
.
A . C OntC il iS 4-1 1
B. PUitSLi;t Form 1
(1) “Figure-Item No. ” Column 2
(2) “Hobart Part No. ” Column
(3) “N omenc lature ” Column
(4) ‘E FF” @Ffective) Column
(5) “Units Per Assembly” Column
Manufacturer’s Codes 4-2
1. Explanation of Manufacturer’s (Vendor’s) Code List I .
Park List . 4-3
1. Explanation of Parts List Arrangement
,
2. Symbols and Abbreviations
Optional Equipment 5-o
Manufacturer’s Literature
LIST OF ILLUSTRATIONS
6-O
2
2
2
3
1
1’
1
1
1
CHAPTER/ FIGURE PAGE
SECTION NUMBER TITLE NO.
l-l 1 Generator Set 2
l-l 2 Specifications and Capabilities (Two Sheets) 3-4
l-l 3 Generatcr Set Components 5
l-l 4 Generator Set Identification Chart 7
Contents Aug 25 0%
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