Hobart 283782 User manual

TO-221
051592
INSTRUCTION MANUAL FOR
POWER GENERATOR PACKAGE
Part Number 283782
Rated for
28.5-V DC Input and
120-V AC, 60-Hz, 1600-Watt
Single-Phase Output
Optional Accessory for
Specification 6914G
Hobart Jet-Ex
28.5-V DC Generator Set
Hobart Brothers Company
Power Systems Group
Troy, Ohio 45373

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INSTRUCTION MANUAL FOR
POWER GENERATOR PACKAGE
Part Number 283782
1. Description
a. General
The 120-V Power Generator Package covered by this manual, and identified by Hobart Part No.
283782, is an optional kit for use with Specification 6914G trailer-mounted ground power units. This
power generator package mounts on the right rear side of the mounting frame between the wheels.
(See Fig. 2)
NOTE:In this manual, the word “generator” applies to the 120-V AC power generator, and not to the ground
power unit on which it is installed. The term “generator package” applies to the kit as a whole, of which
the generator is just one part. The ground power unit willbe referred to herein as such or as “the unit”.
The main items which comprise the generator package are: the power generator, a
weather-resistant protective cover, a mounting bracket, two No. 6 AWG power input cables in Z-flex
protective tubing, and attaching hardware
(screws, nuts and washers) . See Paragraph 4 for a
detailed list of parts used in this kit.
The power generator
(Fig. 1) , when installed on a ground power unit, receives 28.5-V DC power
from the unit and converts it to 120-V AC, 60-Hz, single-phase power for operating small tools, test
equipment, soldering irons, vacuum cleaners, and other such items. The power generator may also
be used for extension lights and standby power. Two grounding type outlets
(3, Fig. 1) are mounted
on the power generator to receive extension cord plugs, and the power generator has a capacity of
1600 watts.
This generator package is compact in size, weighing approximately 55 pounds
(25 kg.) and
measuring 18 inches
(457 mm) in length, 10-9/16 inches (268 mm) in height, and 10 inches (254
mm)
in width.
b. Special Features of Power Generator
For efficient, economical, and safe operation, the power generator has the following special features:
(1) Demand-start feature
The power generator saves energy by operating only when power is required. It is designed to
operate only when there is a tool, appliance, instrument, or other LOAD plugged into it. It ceases
operation as soon as the tool, appliance, instrument, or other load is unplugged from it.
(2) Overload protection
A built-in circuit breaker, rated at 18 amperes, prevents overloads from damaging the power
generator or electrical equipment that is plugged into the power generator.
(3) Momentary surge-current capacity
This power generator has the capacity to deliver surge current 50% above its rated output
(up to
22.5 amperes)
when momentary starting power is required.
(4) Reverse polarity protection
Because of internal reverse polarity protection, incorrect connections to power input terminals
(1
and 2, Fig. 1)
will not damage the power generator.
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120-V Power Generator Package - Part No. 283782
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(5) Wide temperature range of operation
The power generator will operate efficiently and safely at temperatures ranging between -
30oF
(- 34
o
C) and 130oF (54
o
C) .
1. Input terminal, negative 6. Brush access plate
2. Input terminal, positive 7. Generator cover
3. 120-V AC output receptacles 8. Magnetic door catch
4. Overload reset button 9. Access door
5. Identification nameplate 10. Mounting bracket
120-V AC Power Generator Package
Figure 1
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2. Installation
A Specification 6914G ground power unit may be ordered from the factory with the 120-V AC power
generator package installed. Or, the power generator package may be purchased separately and
installed in the field on a machine previously purchased. Figure 2 shows where the power generator is
to be mounted on the ground power unit: on the right rear side of the mounting frame between the
wheels.
For installing the power generator package, it will be necessary to drill six holes in the right side of the
mounting frame
To install the power generator package, proceed according to the instructions provided on the following
pages of this manual.
Power Generator Package Location
Figure 2
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120-V Power Generator Package - Part No. 283782
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a. Drill Holes for Mounting Generator and Generator Cover
(1) Refer to Figure 3. Mark points for drilling holes on ground power unit as indicated in this
diagram. Drill 5/16-inch holes at these points - a total of six holes.
(2) Mount the generator bracket (10, Fig. 1) securely to the unit, using six 3/8-inch self-tap screws
provided in the kit.
b. Connect Input Cables to Generator and Mount the Generator
(1) Apply the two POSITIVE vinyl lead tags to each end of the shorter No. 6 AWG cable (Part No.
W-9760-271). Apply the two NEGATIVE vinyl tag leads to each end of the longer No. 6 AWG
cable (Part No. W-9760-329).
(2) Connect the No. 6 AWG power input cables (provided in the kit) to the generator input terminals
according to polarity as marked at the generator terminals and on the cables. Make these
connections using the SMALLER of the two terminal lugs on each cable
(the lugs having the
5/16-inch holes).
Location of Holes for Mounting Generator Bracket
Figure 3
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(3) Place the generator in proper mounting position (as shown in Figure 2) , and make certain that
holes in generator base and holes in the mounting bracket are lined up properly for inserting
mounting screws.
(4) Place a 1/4-inch flat washer on each of six 1/4-20 X 1-1/4 hex head cap screws. Then insert the
screws down through the holes in the generator base and the holes in the mounting bracket.
Assemble the six 1/4-inch lock washers and six 1/4-20 hex nuts to these screws and tighten all
six nuts securely.
(5) In preparation for connecting input cables to the output of the ground power unit, put the loose
ends of the power input cables in Z-flex protective tubing
(provided in the kit) . Then route these
cables through the rectangular hole in the mounting bracket, and slide the rubber grommet over
the cables so that it is between the generator and the mounting bracket.
c. Connect Generator Input Cables to Output of Ground Power Unit
Input power for the generator will come from the “hot” side of the load contactor, which is located
just behind the battery on the right side of the ground power unit. Connections for the generator are
to be made at the load contactor and at the output terminal panel. The No. 6 AWG generator
power input cables each have one 3/8-inch terminal lug, and these cables are marked for polarity
per paragraph 2, b, (1). Connect the input cables as follows:
(1) Remove the 3/8-16 hex-head cap screw, lock washer, and flat washer that connect the two short
cables (from the heat sink) to the angle bus at the rear of the load contactor.
(2) Place the 3/8-inch terminal lug of the POSITIVE (+ ) generator input cable ON TOP OF the two
cable lugs loosened in the step above. Then re-install and re-tighten the 3/8-16 hex-head cap
screw, lock washer, and flat washer.
(3) Remove the hex-nut, lock washer, and flat washer that connect the large negative power output
cable to the negative output connection on the output terminal panel, but do not remove the
terminal lug of the negative power output cable from the terminal.
(4) Place the 3/8-inch terminal lug of the NEGATIVE (-) generator input cable ON TOP OF the
terminal lug where the negative power output cable connects to the negative terminal of the
ground power unit. Figure 4 shows how this should be done.
(5) Re-install and re-tighten the hex-nut, lock washer, and flat washer.
d. Mount the Generator Cover
(1) Place the generator cover in proper mounting position over the generator, such that it is mounted
as shown in Figure 2, and such that the rubber grommet on the power input cables fits in the slot
in the rear of the cover. Make certain that holes in the base of the generator cover and holes in
the mounting bracket are lined up properly for inserting mounting screws.
(2) Insert the six 1/4-20 X 1/2 self-tap screws down through the holes in the base of the generator
cover and into the holes in the mounting bracket. Tighten all six screws securely.
e. Install the Generator Cover Access Door
To install this small access door
(9,Fig.1) on the generator cover (7, Fig. 1), usethethree1/4-20X
5/8-inch hex head screws, the three remaining 1/4-inch flat washers, and the three remaining
1/4-inch lock washers, and the three remaining 1/4-inch hex nuts. Make this installation such that
the nuts and washers are INSIDE the generator cover, and make certain that the nuts are tightened
down securely.
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120-V Power Generator Package - Part No. 283782
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3. Operation of the Power Generator Kit
No special instructions are required for using the power generator kit, once input power is provided to
the kit from the ground power unit. However, for using the power generator kit, the engine of the
ground power unit must be running at rated speed, and the operator must push the build up voltage
switch of the ground power unit.
Connecting Negative Power Generator Cable
at Unit’s Output Terminal Panel
Figure 4
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4. Parts Replacement
a. Replacement Items that can be Purchased from Hobart Brothers
The following items may be purchased from Hobart Brothers Company. When ordering, use Hobart
Brothers part numbers.
b. Attaching Hardware
The power generator kit, as received from Hobart Brothers, contains all hardware necessary for the
initial mounting of the power generator package. In the event that it becomes necessary to replace
items of hardware - such as after a repair is made - screws, nuts, and washers needed for mounting
the generator package are available at most hardware stores.
QUANTITY HOBART
ITEM REQUIRED PART NO.
Generator, Electric, Redi-Line 1 85C-1010
Generator Cover 1 489094
Access Door, Generator Cover 1 489099
Bracket, Mounting, Electric Generator 1 283793
Magnetic Door Catch 1 403127
Rubber Grommet, 1-1/4-inch 1 402037-23
Access Panel Label, 120-V AC 1 85A-1014
No. 6 AWG Input Cable, Positive 1 W-9760-271
No. 6 AWG Input Cable, Negative 1 W-9760-329
Z-Flex Protective Tubing 33 inches 76A-1132
Vinyl Lead Tag (+) 2 12RT-662-10
Vinyl Lead Tag ( — ) 2 12RT-662-11
QUANTITY
ITEM REQUIRED
Screws, 1/4 - 20 X 1-1/4-inch 6
Screws, 1/4 - 20 X 5/8-inch (Access Door Mounting) 3
Screws, 1/4 - 20 X 1/2-inch, self-tap (Cover Mounting) 6
Screws, 3/8-12 X 7/8-inch, self-tap (Bracket Mounting) 6
Flat Washers, 1/4-inch 9
Lock Washers, 1/4-inch 9
Nuts, Full, Hex, 1/4 - 20 9
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5. Service Information
If you have any questions concerning your Hobart Ground Power Division equipment, you are invited to
contact our service department by mail, telephone, or FAX.
Write: Hobart Brothers Company
Airport Systems Group
Service Department
1177 Trade Square East
Troy, Ohio 45373
U.S.A
In U.S.A. Call: [phone]
[phone]
From Foreign Countries, Call: [phone] (Parts)
[phone] (Service)
Fax: [phone]
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