Hobart 9OC24S User manual

TM-240A
103073
Revised062574
Revised 022278
OPERATION, MAINTENANCE, AND OVERHAUL MANUAL
FOR
SELF-PROPELLED GENERATOR SET
MODE L N 0. 9OC24S
SPECIFICATION NO. 5381A AND VARIATIONS
90KVA, 115/200-V AC, 400 tjZ, 3-PHASE
Manufactured by ,
MOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY
TROY, OH IO 45373
U.S.A.

SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT
ELECTRIC SHOCK can kill. Do not touch live electrical parts.
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 don’t 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.
6. 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 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 conductor (lead) to the third live
wire of the 3-phase line, g this makes the eauipment frame electricallv
--- 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/
NFPA 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.
Instruction 910082
Nov 16182 Revised ,--
Page 1

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 your supervisor and
discontinue use of the equipment until its safety has been assured. Repairs should be made by qualified personnel
only. Shut OFF all power at 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 service. If troubleshooting must be done with the unit energized, have present another per-
son 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 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.
D. TOXIC FUME PREVENTION
Carbon Monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust fumes to a
suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts or air conditioners.
E. BODILY INJURY PREVENTION
Serious injury can result from contact with fans, belts, and pulleys inside the equipment. Shut DOWN equipment
for inspection and routine maintenance. When equipment is in operation use extreme care in doing necessary
troubleshooting and adjustment.
F. 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 signsare observed.
EMERGENCY FIRST AID
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.
G. EQUIPMENT PRECAUTIONARY LABELS
Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be easily read.
Page 2 Instruction 910082
Revised Nov 16/82

WARNING!
SAFETY DEVICE BOX
HOBART PART NO. 6FW-4013A
DANGER! FAILURE TO PROPERLY MAINTAIN THE MICRO SWITCH GEARSHIFT
INTERLOCK CAN RESULT IN INJURY OR DEATH DUE TO UNEXPECTED MOVEMENT OF
THE GPU. PERFORM THE FOLLOWING PROCEDURE EVERY 200 OPERATING HOURS OR
3 MONTHS.
1. Remove the GPU to an area free of personnel and equipment. Set the
emergency brake and chock wheels.
2. With the gearshift in any gear (except neutral) and the clutch pedal engaged,
attempt to start the GPU. If the GPU starts, have qualified maintenance
personnel replace the micro switch, Hobart part no. 403982, and repeat this test
procedure prior to returning the GPU to service.
3. With the gearshift in any gear (except neutral) and the clutch pedal engaged,
switch the GPU to “GENERATE” mode. If the GPU engine does not shut down,
have qualified maintenance personnel replace the micro switch, Hobart part no.
403982, and repeat this test procedure prior to returning the GPU to service.

,
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SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
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OF’ERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
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OARATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
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1 Ott 30/73
2 Ott 30/73
LIST OF EFFECTIVE PAGES (CONTINUED)
List of Effective Pages
Page6 act 30/73
RevisedJune 25/74

FOBART
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;MOTOR GENERATOR DIVISION
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OPERATION, MAINTENANCE, AND OVERHAUL MAN UAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
INTRODUCTION
1. GeneraI
The Introduction has beenrelocatedto the front of the manualbecausewe wish it to
benoticed and read first. It has also beenexpandedin an attempt to give the reader
a better understandingof the manualand to makeit morehelpful andeasier to use.
If you expect the manualto be useful to you, pleaseread the introduction.
2. scope
The manualcontains descriptive, maintenance, trouble shooting and overhaul informa-
tion for a basic400-Hertz, generatorset and its different optional Variations. Un-
qualified information throughout the manualwill apply to the basicset andall varia- G
tions. Any information which applies only to a specific variation will bequalified and
identified as such. An explanation of “variations” andhow to identify all generator
sets is given in the Description, Chapter/Section l-l (Chapter 1, Section 1).
3. P
urpose
The manual’spurposeis to provide information and instructions to experiencedoperators,
electricians, and mechanicswho havenever seenor operatedthis generator set. It is
the intent of the manualto guide and assist operatorsand maintenancepersonnel in the
proper useand maintenanceof the equipment.
4. Contents
Immediatelyfollowing the Introduction is a List of Effective Pageswhich lists each
pagein the manualby its Chapter/Section, and pagenumber. Directly opposite
eachpagenumber listing is a date which indicates whether the pageis original or
revised.
A completeTable of Contents appearsnext in sequence. It contains a list of all
Chapters, Sections, andthe principal paragraphtitles within each Section. The lo-
cation of each listing is identified by Chapter/Section and pagenumber. A complete
list of illustrations with their locations is locatedat the end of the Table of Contents.
The main text of the manualis divided into eight Chaptersas follows:
Chapter 1. Description/Operation
Chapter 2. Servicing
Chapter 3. Trouble Shooting
Chapter4. RemovaI/lnstaIlaticn
Chapter 5. Repairs
act 30/73 Introduction
~~~~Page 1

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;MOTOR GENERATOR DIVISION
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4. BL,I’La
OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
Chapter 6. Overhaul
Chapter 7. II lustrated Parts List
Chapter 8. Manufacturer’s Literature
Each Chapter is divided into as manySections as necessary. Sections are always referred
to by a combinationChapter/Section number. Example, 2-3 refers to Chapter 2, Section
3.
5. Format
A. Paragraphingand Out Iining
The material within each Section is divided into main subjects with applicable
paragraphheadingsand subheadingsas required. This methodnot only helps keep
information closely knit, but providesa meansof identifying material for reference
purposes. For example, a portion of the Description Section might logically follow
this arrangement and paragraphing:
1. Control Box
A. Interior Panel
(1) Protective devices
(a) Overloadrelay
(2) Contactors
B. PageN umbering
Pagenumbersdo not run consecutively throughout the manual. Each pageis
identified by the Chapter/Section numberin which it appears, and by a page
numberwithin the Chapter/Section. Therefore the first pagein each Section is
page1. These identifying numbersappearin the lower, outside corner of each
page. Each pagealso bearsa date located in the corner oppositethe pagenumber.
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 numberingsystemsimilar to pagenumbering. The first
Figure in each Section is Figure 1.
6. How to Use the Manual
A. General
There hasalways been, and probablyalways will be, somedisagreementbetween
writers, users-,-specificationwriters, and others, regardingall phasesof manual
Introduction .-~o~t.~o[~~
Page2

FOBART
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;MOTOR GENERATOR DIVISION
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“c z HOBARTBROTHERSCOMPANY
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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
preparationand how the manual-canbest serve the needsof the user. It is of
course impossibleto completelysatisfy al I concerned.
This manualfollows the format, rules and style proposedby, andgenerally accepted
by membersof the Air Transport Association. In so far as possible, information is
groupedto 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 con-
’ fusion.
B. How to Locate Information
Even if you have readthe manualcompletelyand thoroughly, the easiest andquick-
est way to locate information is by using the Table of Contents. In addition to the
completeTable of Contents in the front of the manual, eachChapter has its own
Table of Contents and List of Illustrations.
(1) Table of Contents
The completeTable of Contents is only five pageslong 9 Even if the user has
no ideawhere a certain bit of information is located, the general location
can be quickly found by running through the Table of Contents. For example,
someadjustment information is needed. A quick look at the Table of Contents
indicates that “Adjustment/Test” information is located in Chapter/Section 2-3
(Chapter2, Section 3). If the specific adjustment beingsought is not listed
in the main Table of Contents, turn to Chapter 2 and look in its Table of Con-
tents under “Adiustment/Test” where eachadjustment is listed with the page
number location.
, (2) List of Illustrations
A completeList of Illustrations follows the Table of Contents and includes the
title, figure number, and Chapter/Section, with pagenumberlocation of all
illustrations contained in the manual. Locate the appropriatetitle in the
List of Illustrations, then turn to the Chapter/Section and pagenumber indicated.
It should benoted here that ALL electrical connectiondiagramsare located
in Chapter 5, Repair.
(3) References
To avoid repetition and lengthyexplanations, referencesto other material are
usedthroughout the manual. Both material in the text and illustrations maybe
referred to in order to clarify or expandinformation and instructions. Portions
of the text are referred to by identifying the paragraphin which referenced
material maybe found. A reference to other material would be in order right
here by referring to paragraphinginformation contained in paragraph5, A
Ott 30/73 Introduction

FOBART
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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
above. When referenced material is locatedin the sameChapter/Section as
the reference, only the paragraphidentification is given.
Example:
(Ref. Para. 1, A) meansthe material is to be found in paragraph1, A, of
the sameChapter/Section.
When referencedmaterial is locatedin another Chapter/Section, both the
Chapter/Section numberand the paragraphidentification are given.
Example:
(Ref. 1-2, Para. 1, A) meansthat the referencedmaterial is located in
Chapter/Section l-2, and identified by paragraph1, A.
Componentsshown in illustrations and illustrations themseIves are referenced
in a similar manner. When this type reference is made, the item numberof
the part and the Figure numberin which it appearsare given.
Example:
(Ref. 2, Fig. 3) fre ers to item number2 which appearsin illustration Figure
3 of the sameChapter/Section.
When the referenced Figure appearsin another Chapter/Section, the reference
will include the Chapter/Section number.
Example:
(Ref. 2-3; 1, Fig. 4) tel Is the user to refer to Chapter/Section 2-3, andto
see item 1, in Figure 4.
Once a Figure numberreference has beenestablished for a series of instructional
steps, the Figure numberis not repeated. Only the item numbersof parts in-
volved are referenced.
For example, an instruction might appearlike this: “Loosenscrew (2, Fig. 6),
slide out connector (4), andremovebrush (6)“.
When an item is referencedwithout a figure number, it will always apply to the
last precedingFigure numbermentionedin the text.
NOTE: The word “See” mayappearin somereferences, as (See Fig. 2). It
meansexactly the samething as “Ref. “, however, its ,usageseemsa
little moredirect anddefinite.
Introduction
page4
Ott 30/73

POBARI
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OPERATION, MAINTENANCE , AND OVERHAUL MAN UAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
7. Abbreviations
The following is a list of abbreviations usedthroughout the manual. They are not
to beconfusedwith symbolswhich appearon schematicdiagrams.
A - ampere
AC - alternating current
AR ’ - as required
C - tentigrade
ccw - counterclockwise
cw - clockwise
DC - direct current
de!3 - degree
F - Fahrenheit
Fig - figure
GALS - galIons
Hz - Hertz (cyclesper second)
in. - inch
KG - kilogram
KVA - kilovolt-ampere
KW - kilowatt
MM - millimeter
No. -number
Para. - paragraph
PF - powerfactor
PSI - poundsper square inch
Pt - pint
Qt - quart
Ref - reference (refer to)
RPM - revolutions per minute
Sect - section
SPEC - specification
T-R - transformer-rectifier
V - volt
VAR - variation

FOBART
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gMOTOR GENERATOR DIVISION
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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
lntroc+ction Ott 30/73
Page-6.

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pMDTDR GENERATOR DIVISION
“c i HOBART BROTHERS COMPANY
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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
TABLE OF CONTENTS
SUBJECT CHAPTER/SECTION PAGE
Description/Operation
Description
1-o 1
l-l 1
GeneraI
Orientation
SpeciaI Features
Optional Equipment and Identification 6
Engine, Generator andControl Box 6
Operating Mode Safety Devices 28
Transformer-Rectifiers (Optional) 29
Test Box (Optional)
Additional Variations
Preparation for Use l-2 32;
1
General
Inspectionand Checks
Lubrication 2
Installing Output Cable
Operation l-3
1
1
2
1
GeneraI 1
Moving the Cklit Without Engine Power
Operating the Unit
Operating Transformer-Rectifier (Optional
Equipment) 11
June 25/74 Revised P!zP1

.
OPERATION, MAINTENANCE, AND OVERHAUL MANUAL, TM-240A
SELF-PROPELLED GENERATOR SET, SPEC. NO. 5381A
TABLE OF CONTENTS (CONT’D.)
SUBJECT
Operating the Test Box
DC and AC Power Delivery
Servicing
CHAPTER/SECTION
1-3
2-o
PAGE
:8”
1
Maintenance Inspection/Check 2-l 1
GeneraI 1
Maintenance Schedule 1
Inspection/Check 5
Maintenance Procedures 2-2 1
General 1
Lubrication 1
Servicing the Air Cleaner 13
Engine FueI 14
Engine Cooling System 18
Battery Service 25
Brake Fluid Check 29
Drive Belts 30
Generator Maintenance 34
Tire Inflation 34
Adjustment/Test 2-3 1
GeneraI 1
Testing the Generator Set 1
Engine-Generator ComponentsAdjustment
Contents
Page2
15
act 30/73
RevisedJune 25/74