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Hobart 6921 Series, Operation And Maintenance Manual

The Hobart 6921 Series is a high-performance appliance that requires proper handling and care. Ensure the longevity and efficiency of your equipment by downloading the user-friendly "Operation And Maintenance Manual" for free from 88.208.23.73:8080. This manual provides comprehensive instructions and guidelines for optimal operation and maintenance.

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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 numbering 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
Association. 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.

(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.

(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.

(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. 1-2, Para. 1, A) means that the referenced material is located in Chapter/Section 1-2,
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 include
the Chapter/Section number.

OM-2040 / Operation and Maintenance Manual

90D20 / Generator Sets

Introduction

February 28/94 Revised

Page 2

Summary of Contents for 6921 Series

Page 1: ...ILLUSTRATED PARTS LIST for ENGINE DRIVEN GENERATOR SETS 90 kVA 400 Hz 115 200 V AC 3 Phase Units Series 6921 Series 6921A Series 6922 Series 6922A Series 6922B 100 kVA 400 Hz 115 200 V AC 3 Phase Unit Specification 7126 1 with DEUTZ DIESEL ENGINE Type DO 693 738 HOBART BROTHERS COMPANY Ground Power Division Troy Ohio 45373 U S A ...

Page 2: ...This page intentionally left blank ...

Page 3: ...an cause serious injury or death or damage to other equipment or property The operator must strictly observe all safety rules and take precautionary actions Safe 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...

Page 4: ...alified personnel only Before inspecting or servicing electrically powered equipment take the following precautions a Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the equipment 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 do...

Page 5: ... 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 Call physician immediately Seek additional assistance 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 ELECTRICAL...

Page 6: ...This page intentionally left blank OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Safety Warnings Revised Page 4 August 01 95 ...

Page 7: ...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 complete 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 O...

Page 8: ...ncludes 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 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 ...

Page 9: ...its usage is more direct and definite NOTE 2 When an output cable is mentioned in the manual it refers 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 7 Customer Service If you have any questions...

Page 10: ...This page intentionally left blank OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Introduction February 28 94 Revised Page 4 ...

Page 11: ...6 5 Engine Generator and Controls Assembly 1 1 7 A Basic Engine 1 1 7 B Engine Manufacturer s Equipment 1 1 7 C Hobart Engine Equipment 1 1 7 1 Electric governor system 1 1 7 a Magnetic pickup 1 1 7 b Control unit 1 1 7 c Actuator 1 1 7 2 Air Cleaner 1 1 9 3 Exhaust System 1 1 10 D Generator 1 1 10 E Control Box Assembly 1 1 11 1 Generator control tray see Figure 8 1 1 11 a Resistors 1 1 11 b Gene...

Page 12: ...gine generator control switch 1 1 16 c Contactor control switch 1 1 16 d Indicating lights 1 1 17 e Fuel gage and blocking diodes 1 1 17 f Cold weather starting aid control Optional 1 1 17 g Engine stop control 1 1 17 h Air cleaner indicator 1 1 17 j Test receptacle connector 1 1 17 G Voltage Regulator 1 1 19 1 Controls 1 1 20 2 Protection 1 1 20 3 Components See Fig 12 1 1 20 H Power Module Panel...

Page 13: ... Cold Weather Engine Starting Procedures 1 3 4 D Preparation for Power Delivery Normal Automatic Voltage Control 1 3 4 E Power Delivery Automatic Voltage Control 1 3 5 F Preparation for Power Delivery Manual Voltage Control 1 3 6 G Power Delivery Manual Voltage Control 1 3 6 H Discontinue Power Delivery 1 3 6 J Stopping the Engine 1 3 6 3 Transformer Rectifier Operation 1 3 6 A Direct Current Powe...

Page 14: ...Cartridge Removal 2 1 8 B Cartridge Installation 2 1 9 5 Engine Fuel 2 1 9 A Quality 2 1 9 6 Generator Maintenance 2 1 9 A Cleaning 2 1 9 B Adjustment 2 1 9 7 Drive Belts 2 1 9 A Fan Belts 2 1 9 B Check Belt Tension 2 1 9 C Adjusting Alternator Belt Tension 2 1 10 D Belt Replacement 2 1 10 8 Service Helps 2 1 10 A Wiring 2 1 10 B Control Box Trays 2 1 10 1 Tray removal 2 1 10 2 Tray installation 2...

Page 15: ...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 5 3 Generator Set Adjustment 2 3 9 A Generator Adjustment 2 3 9 B Generator Control Adjustments 2 3 9 1 Adjust manual voltage control variable...

Page 16: ...1 1 A Description 3 1 1 B Use of the Trouble Shooting Chart 3 1 1 3 Equipment for Troubleshooting 3 1 2 4 Safety WARNING 3 1 2 5 Parts Replacement 3 1 2 6 Test Values 3 1 2 7 Checking Connections and Leads 3 1 3 8 Electric Governor Trouble Shooting 3 1 3 9 Engine Trouble Shooting Procedures 3 1 3 A General 3 1 3 B Locating a Misfiring Cylinder 3 1 3 C Checking Compression Pressure 3 1 4 D Interpre...

Page 17: ...tive Column 4 1 2 5 UNITS PER ASSEMBLY Column 4 1 2 SECTION 2 MANUFACTURER S CODES 4 2 1 1 Explanation of Manufacturer s Vendor Code List 4 2 1 SECTION 3 PARTS LIST 4 3 1 1 Explanation of Parts List Arrangement 4 3 1 2 Symbols and Abbreviations 4 3 1 SECTION 4 NUMERICAL INDEX 4 4 1 1 Explanation of Numerical Index 4 4 1 CHAPTER 5 OPTIONAL EQUIPMENT CHAPTER 6 MANUFACTURER S LITERATURE UNUSUAL SERVI...

Page 18: ...This page intentionally left blank OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Table of Contents February 28 94 Revised Page 8 ...

Page 19: ...lar 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 aircraft s 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 ge...

Page 20: ...Air Filter Access Door 6 Fuel Fill Pipe 7 Lights 8 Canopy 9 Left Side Engine Access Door 10 Output Receptacle 11 Engine Controls Panel Access Door 12 Window 13 Trailer Hitch 14 Trailer Frame 15 Lifting Yoke Generator Set Figure 1 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 1 1 February 28 94 Page 2 Revised ...

Page 21: ...ay 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 Manufacturer s Specification No DO 693 738 Number of Cylinders 6 Bore 4 02 inches 102 mm Stroke 4 92 inches 125 mm Displacement Piston 374 Cu In 612...

Page 22: ...7 Lights 8 Air Filter Access 9 Belts Access Panel 10 Output Terminal Panel 11 Diesel Fuel Inlet 12 Panel Power Module 13 Battery Storage Compartment 14 Muffler 15 Tray Control Box 16 Governor Generator Set Components Figure 3 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 1 1 February 28 94 Page 4 Revised ...

Page 23: ...included Special features for SAS 6922 1 6922A 1 6922B 1 90 KVA 430391C Trailer Standard unit without canopy insulation with top exhaust fenders and batteries 6922 2 6922A 2 6922B 2 90 KVA 430391C Stationary Standard unit without canopy insulation Batteries NOT included Top exhaust 6922 3 6922A 3 6922B 3 90 KVA 489812A Trailer Standard unit without canopy insulation With top exhaust fenders and ba...

Page 24: ...n e Electric Governor The engine is equipped with an all electric type governor 4 and 16 Fig 3 and other special equipment described under the engine description f Transformer Rectifiers Optional Generator sets covered by this manual may be equipped with one or two transformer rectifiers 16 Fig 1 A transformer rectifier or T R receives 115 200 V AC power from the generator output and converts it t...

Page 25: ...overnor kit is installed on the engine to replace a conventional mechanical type The electric governor was selected for control of engine speed and generator output 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 mag...

Page 26: ...8 Oil Pump 9 Electric Switch 10 Push Idler Pulley 11 Filler Neck Oil 12 Drain Plug 13 Oil Sump 14 Oil Micofilter 15 Fuel Feed Pump 16 Oil Level Dip Stick 17 Magnetic Pickup 18 Starter Motor 19 Alternator Engine Components Figure 4 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 1 1 February 28 94 Page 8 Revised ...

Page 27: ...ithin the cleaner lessens the flag gradually rises higher in the glass viewing chamber When the flag reaches the top of the chamber 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 1 Acutator 2 Rod 3 Speed Control Lever 4 Mounting Bracket Throttle Control and Electric Governor System ...

Page 28: ...or is a brushless revolving field three phase alternating current type The rotor assembly is mounted by two permanently lubricated sealed ball bearings The front bearing 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 atta...

Page 29: ...ator 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 illuminate controls and instruments within the trays 1 Generator control tray...

Page 30: ...ns of quickly disconnecting all wires to control box components e Tray The tray 15 slides in and out on nylon rollers It is secured in place by a twist lock screw fastener 8 f Manual voltage control When the automatic manual switch 11 is placed in MANUAL position AC power is supplied to the rectifier 14 rather than to the automatic voltage regulator The DC output of the rectifier is routed to the ...

Page 31: ...ter Selector Rotary Switch 7 AC Ammeter 8 Tray Fastener 9 Voltmeter 10 Frequency Meter 11 Automatic Manual Switch 12 Receptacle Connector 13 Manual Voltage Control Rheostat 14 Manual Control Rectifier 15 Tray 16 Flyback Diode Generator Control Tray Figure 9 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 1 1 Revised Page 13 ...

Page 32: ...g switch 8 d Plug interlock relay The function of the plug interlock relay 1 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 transforme...

Page 33: ...rfrequency Indicating Light Red 12 Tray Fastener 13 Overfrequency Indicating Light Red 14 Undervoltage Indicating Light Red 15 Overvoltage Indicating Light Red 16 Load Contactor Circuit Fuse 2A 17 Protective Systems Fuse 2A 18 Test Bank Switch 19 Receptacle Connector 20 Terminal Board 21 Resistor 100 Ohm 25 Watt 22 Tray Protective Relay Tray Figure 10 OM 2040 Operation and Maintenance Manual 90D20...

Page 34: ... switch 2 is closed 2 Engine and generator controls a Fuse A 15 ampere fuse 16 Fig 10 protects the 12 VDC engine control circuit hourmeter illuminating light circuit and 12 VDC system in the main generator protective system b Engine generator control switch The generator mode control switch 9 Fig 11 is a three position toggle type It is spring loaded in BUILD UP VOLTAGE position and will automatic...

Page 35: ... 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 by the control 11 Fig 11 allowing fluid to flow into the valve Pushing the button IN forces fluid through a small tube and an atomizing nozzle into the inlet ...

Page 36: ...Contactor Switch 9 Generator Mode Control 10 Output Contactor Light 11 Cold Weather Starting 12 Fan Belt Fault Indicating Light 13 Light Engine Operating 14 Engine Start Pushbutton 15 Switch Engine Start Engine Control Panel Figure 11 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 1 1 February 28 94 Page 18 Revised ...

Page 37: ...r 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 generator 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 ...

Page 38: ... assembly Fig 14 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 assembly provides a means of connecting and disconnecting generator output to and from the load aircraft 1 Load contactor The load contactor 6 Fig 14 is a sealed unit which contains a magnetic operating coil and four sets of contacts The...

Page 39: ...l wiring to the module The overload module is equipped with a hermetically sealed reed type relay Relay contacts are normally open 1 Resistor 1000 Ohms 25 Watts 2 Regulator Rheostat 3 Cable Length Compensation Rheostat 4 Cable Size Compensation Rheostat 5 On Off Switch Line Drop Compensation 6 Line Drop Compensation Chasses Assy 7 Receptacle Connector 8 Damping Circuit Gain Potentiometer 9 Recepta...

Page 40: ...em 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 1 Overload Resistor 16 6 Ohm 25 Watt for 90 kva 2 Terminal Board 3 Overload Current Transformer 4 Ammeter Current Transformer 5 Rectifier 6 Load Contactor 7 Overload Module ...

Page 41: ...tes with a receptacle connector I 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 s...

Page 42: ...ED 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 18 is mounted on brackets directly above the power module panel for output No 1 12 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 t...

Page 43: ...Dual Output Terminal Boards Figure 16 No 2 Output Control Figure 17 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 1 1 Revised Page 25 ...

Page 44: ...Output No 2 Power Module Panel Figure 18 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 1 1 February 28 94 Page 26 Revised ...

Page 45: ... 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 tightening 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 FULL mark on oil leve...

Page 46: ...trol 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 1 4 inch diameter c Each terminal stud is identified by an identification plate Each cable should be identified by a band type marker Connect cable A to A B to B etc Tighten terminal nuts securely Connect small plug ...

Page 47: ...hould 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 effective b Temporary Storage When storing the unit for 30 days...

Page 48: ...tored 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 instructions in KHD Deutz diesel operation instructions 3 To protect the generator and other electrical components the complete unit should be packaged using moisture packaging and sealing material Place contain...

Page 49: ...r foreign materials b Normal Engine Starting Procedures Engine starting procedures are outlined below Engine operating controls and monitoring instruments are illustrated in Fig 1 1 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 1 in START position momentarily Pu...

Page 50: ...h 23 Output Contactor Light 9 Reset Switch 24 Switch Panel Lights 10 Fault Indicating Lights 25 Light Engine Operating 11 Load Contactor Circuits Fuse 2A 26 Switch Engine Start 12 Protective System Fuse 2A 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 O...

Page 51: ... 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 Operating Controls and Instruments Figure 1 Sheet 2 of 2 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Revised Chapter 1 3 Page 3 ...

Page 52: ...g 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 b above 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 ...

Page 53: ...d 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 21 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 ...

Page 54: ...tion 3 Disconnect output cable from aircraft High voltage Electric shock or fire can kill Never disconnect the output cable while power is being delivered i 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 3 Transformer Rectifier Operation Tranformer Rectifier operating instructions are contained in ...

Page 55: ...er 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 R s don t 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 ...

Page 56: ...e same manner as output No 1 see para 2 E using the duplicate contactor switch shown in Figure 5 When the No 2 contactor is closed the contactor CLOSED light beside that switch will glow green NOTE Make sure that No 2 TEST BANK switch 1 1 Fig 18 is positioned properly see para 2 D 1 b for proper position 1 Selector Switch 2 Pushbutton Switch 3 Positive Test Jack Red 4 Negative Test Jack Black Test...

Page 57: ...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 No 2 Output Control Figure 5 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Revised Chapter 1 3 Page 9 ...

Page 58: ...This page intentionally left blank OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 1 3 February 28 94 Revised Page 10 ...

Page 59: ...me 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 assemblies 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 Genera...

Page 60: ...Lubrication and Maintenance Chart Figure 1 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 2 1 February 28 94 Revised Page 2 ...

Page 61: ... Duty Military MIL L 2104B or equivalent SAE 30 Summer SAE 10 Winter 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 Lubrication Chart Symbols and Time Intervals OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Revised Chapter 2 1 Page 3 ...

Page 62: ...Trailer Lubrication Chart Figure 2 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 2 1 February 28 94 Revised Page 4 ...

Page 63: ...further in the Deutz Diesel Operator s Manual 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 ...

Page 64: ...ed 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 When refilling crankcase to avoid possible future engine da...

Page 65: ...er replaced start the engine and check the shell to gasket joint for possible oil leaks f Engine Accessories See Figure 1 for identification of engine and accessories lubrication points intervals and lubricants 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 moto...

Page 66: ...g 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 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 CAUTION 1 Cup Assembly 5 Safety Element 2 Clamp Assembly 6 O Ring 3 Baffle Assembly 7 B...

Page 67: ...r 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 chemical compounds may damage insulation and other generator components Electric shock and fire can kill or injure B...

Page 68: ...sy 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 1 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 1 Unlock latches 1 by pressing down with thumbs then slide tra...

Page 69: ...citer 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 1 Tilt out engine control panel a Remove clamp screw which supports wire conduit above output terminal panel b Remove two cap screws whi...

Page 70: ...Maintenance Though transformer rectifiers should be periodically inspected they require no scheduled maintenance 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 Engine Control Panel in Tilt Out Position Figure 9 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 2 1 February 28 ...

Page 71: ...ach 200 hours of operation See 2 1 para 7 A B C d Exhaust System 1 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 Exhaust fumes or fire can kill or injure Immediately repair defective exhaust systems 3 Electrical System 12 V DC a Lights Inspect all lights for proper operation DAILY Replace any de...

Page 72: ...sion X Drain refill cooling system Change fuel filter elements X Lubricate Check exhaust system X Open fuel tank drain X ELECTRICAL Check all lights X Clean battery terminals X Check wiring X Check connections X 400 Hz GENERATING 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...

Page 73: ...y Lamp Industry Trade Number 57 Lamp Identification Chart Figure 2 ITEM PROTECTED LOCATION ILLUSTRATION SIZE TYPE Instrument Panel Lights and Engine Circuit Engine Control Panel Sect 1 1 Fig 11 item 15 15A Type AGC Protective relay system Protective Relay Tray Sect 1 1 Fig 10 item 17 2A Type AGC Voltage regulator Voltage Regulator Tray Sect 1 1 Fig 12 item 12 5A Type AGC Load contactor circuit Pro...

Page 74: ... cables leads and wiring for broken worn and damaged insulation 2 Inspect connections for tightness High voltage electric shock can kill Stop operations 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 m...

Page 75: ...itch 31 and lamps are good 8 Check fault indicating lights 10 by pressing test switch 8 If lights glow fuse 41 and indicating 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 ...

Page 76: ...h 23 Output Contactor Light 9 Reset Switch 24 Switch Panel Lights 10 Fault Indicating Lights 25 Light Engine Operating 11 Load Contactor Circuits Fuse 2A 26 Switch Engine Start 12 Protective System Fuse 2A 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 O...

Page 77: ... 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 Operating Controls and Instruments Figure 1 Sheet 2 of 2 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Revised Chapter 2 3 Page 3 ...

Page 78: ...he field in a reverse direction could cause damage to voltage regulator diodes 11 Check position of load contactor on off switch 21 Fig 1 and generator control mode switch 17 a Load contactor switch 21 must be in OFF position b Generator mode control switch 17 must be in IDLE position CAUTION 1 Starter Connection to Solenoid 2 Solenoid 3 Negative Battery Cable Connection 4 Positive Battery Cable 5...

Page 79: ...rned speed and energize the generator by holding the generator mode control switch 17 Fig 1 in BUILD UP VOLTS position momentarily Release switch and allow it to position in center RUN position The governor and excitation deenergization relay circuits are functioning properly when engine comes up to governed speed voltage value appears on voltmeter 3 Fig 1 7 Observe the Frequency meter 1 If engine...

Page 80: ...ch 32 Fig 1 in TEST BANK position 19 Again place load contactor switch 21 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 position 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 on...

Page 81: ...d device Ref 1 1 7 Fig 13 MUST NOT trip 34 Operate at 125 rated load for 5 minutes immediately following the full load run The overload device MUST trip within 5 minutes and the overload indicating light 10 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 rate...

Page 82: ... circuit in the protective monitor module to OPEN the load contactor holding circuit To check the underfrequency protective components proceed as follows a While the unit is operating normally under load reduce generating or output frequency by reducing engine speed Use the governor speed setting potentiometer Ref Fig 4 Gradually turn adjusting screw COUNTERCLOCKWISE to reduce engine speed until f...

Page 83: ...wire end of the resistor to increase voltage potential Move the band towards the double wire end two wires connected to decrease voltage potential c Tighten slider band clamping screw 2 Adjust 400 Hz voltage regulator When a voltage regulator is first put into service or when output generator to aircraft cables are changed the regulator may require adjustment To make these adjustments refer to the...

Page 84: ...g mechanism linkage or the controller 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 WARNING Engine Type 6 cylinder turbocharged four cycle air cooled diesel direct injected Bore Stroke 4 4 9 in 102 125...

Page 85: ... 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 com...

Page 86: ...ator 2 Actuator shaft 3 Speed control lever 4 Ball joint control end 5 Nut 6 Rod 7 Ball joint pump end 8 Fuel pump lever Governor Linkage Adjustment Figure 5 1 Connector 2 Magnetic Pickup 3 Nut Magnetic Pickup Adjustment Figure 6 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 2 3 February 28 94 Revised Page 12 ...

Page 87: ...ol screw 2 Fig 7 slightly clockwise g Repeat step e above then repeat step f h Continue this procedure until the engine is no longer stable At this point it is necessary 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 contro...

Page 88: ...rol 2 Stability control Electric Governor Control Box Figure 7 Electric Governor Connection Diagram Figure 8 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 2 3 February 28 94 Revised Page 14 ...

Page 89: ...d manufacturer General instructions for testing diodes follows a Disconnect diode lead s The regulator output must never be grounded when the generator is turning NOTE For units with 10 ohm 100 watt ballast resistors before Jan 1976 voltage is 30 40 V DC 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 con...

Page 90: ...posite way the diode may be considered good 6 Test and Adjustment of Transformer Rectifiers If this generator set specificication is equipped with a transformer rectifier option refer to the appropriate transformer rectifier manual included in Chapter 6 of this manual for T R test and adjustment procedures 7 Additional Tests for Dual Output Units Perform the tests outlined in para 2 B 16 through 2...

Page 91: ...No 2 Output Control Figure 5 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Revised Chapter 2 3 Page 17 ...

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Page 93: ...ting 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 an...

Page 94: ...defective the quickest way to remedy the situation is to replace the complete tray assembly and send the old tray for repair Assemblies which lend themselves to this concept are Generator control tray Protective relay tray Voltage regulator Overload module Protective monitor module Electric governor control box Governor actuator Over undervoltage module Over underfrequency module The above items a...

Page 95: ... Throttle linkage binding 9 Engine Trouble Shooting Procedures a General The following engine troubleshooting procedures were taken from Detroit Diesel s Field Service Data Book Certain 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 st...

Page 96: ...he engine and run at idle speed Do not crank the engine with cranking starting motor to obtain compression pressure Record compression pressure indicated NOTE A guide to minimum compression pressures to be expected is included in Sect 2 3 Fig 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 Reco...

Page 97: ...d of the return tube in a container of fuel If air 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 10 Illustrations Illustrations Figures 1 through 8 are referred to throughout the Trouble Shooti...

Page 98: ...h 23 Output Contactor Light 9 Reset Switch 24 Switch Panel Lights 10 Fault Indicating Lights 25 Light Engine Operating 11 Load Contactor Circuits Fuse 2A 26 Switch Engine Start 12 Protective System Fuse 2A 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 O...

Page 99: ... 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 Operating Controls and Instruments Figure 1 Sheet 2 of 2 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Revised Chapter 3 1 Page 7 ...

Page 100: ...Cable 5 Starter Solenoid Switch 6 Starter Starter and Solenoid Switch Figure 2 1 Manual Control Voltage Potential Adjusting Resistor 2 Exciter Field Ballast Resistors Excitation Resistors Figure 3 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 3 1 February 28 94 Revised Page 8 ...

Page 101: ...uel Supply Line 3 Fuel Feed Pump 4 Injection Pump 5 Injection Lines 6 Injector 7 Backleakage Lines 8 Overflow Lines 9 Overflow Valve 10 Fuel Return Line Fuel Flow Figure 5 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Revised Chapter 3 1 Page 9 ...

Page 102: ...Test Receptacle Connector Terminals Identification Figure 6 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 3 1 February 28 94 Revised Page 10 ...

Page 103: ...Latch air shut off valve by pushing latch lever 8 Fig 3 down If valve will not latch check for tripped overspeed governor d Starter cut out switch improperly adjusted or defective Adjust in accordance with Sect 2 3 Para 34 F 1 or replace switch e Defective start switch S24 or defective auxiliary solenoid L10 Check voltage at terminal 6 Fig 2 while operating start switch 28 Fig 1 If no voltage is i...

Page 104: ...g oil viscosity Check oil See Sect 2 1 Para 3 D 3 3 Engine will not start Cranking speed normal a No fuel Before attempting to find the cause of no fuel prime the fuel filters by removing pipe plug in the cover of each Fill each filter with fuel oil If the engine will not start after priming mechanical pump trouble is indicated If the engine starts and then stops after a short time trouble between...

Page 105: ...w oil pressure switch Start engine Observe oil pressure If pressure is 38 PSI or more check voltage from oil pressure switch terminal one which had ORANGE wire removed to ground If approximately 12 V DC is indicated the oil pressure switch is defective Stop engine and replace switch 1 Fig 4 c Defective or incorrectly wired high temperature switch 2 Fig 4 Check wiring to high temperature switch Two...

Page 106: ... Repair as required f Defective or mis adjusted magnetic pickup The control unit may not be 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 To check the mag netic pick up disconnect pickup from control unit and connect a high impedance AC voltmeter to the pickup output leads Crank engine but don t...

Page 107: ...ent set too high see 2 3 Fig 11 Turn speed control adjusting screw 22 turns counterclock wise Start engine Place control switch 18 Fig 1 in GEN position If engine speed is now well below governed speed turn adjusting screw clockwise until correct speed 2000 RPM 400 Hz is reached If engine still goes to overspeed proceed to step B b Defective linkage or actuator Check governor linkage and actuator ...

Page 108: ...flow in accordance with Para 9 F Repair or replace parts as required Also see ENGINE Trouble 3 b Faulty injector Check injectors in accordance with Para 9 B c Low compression pressure Check compression in accor dance with Para 9 C See causes of low compression listed under ENGINE Trouble 3 B above 11 Engine lacks power a Improper engine adjustment and gear train timing Tune up the engine in accord...

Page 109: ... 1 to connect ungrounded 12 V DC to the exciter field Using leads with alligator clips and test prods connect 12 V DC NEGATIVE lead to terminal D Terminal identifying letters are plainly visible on the face of the test receptacle Connect POSITIVE lead 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 Pa...

Page 110: ...er field Disconnect voltage regulator Amphenol connector see 1 1 Fig 12 Using jumper leads with clip and prod terminals connect ungrounded 12 V DC to terminals E and C in loose plug Connect NEGATIVE to terminal E Connect POSITIVE lead to C terminal See Fig 6 If the generator will NOT produce a normal voltage replace or repair Amphenol connector and wiring between voltage regulator and exciter fiel...

Page 111: ... f Defective rheostat R61 32 Fig 1 Connect a jumper across rheostat If maximum manual control voltage is produced replace rheostat 3 Load contactor K1 will not close when control switch 20 Fig 1 is held in CLOSE position Generator running at normal voltage No fault lights on a In addition to defective wiring and connections in the AC and DC load contactor actuating circuits the load contactor may ...

Page 112: ...ntactor coil K1 1 1 6 Fig 11 Disconnect leads at load terminals W and V Check coil resistance between these terminals Resistance should be approximately 50 ohms If coil is defective replace the complete load contactor 4 Load contactor K1 will close when control switch 20 Fig 1 is held in momentary CLOSE position Opens immediately when switch is released to center ON position a 28 5 V DC is not rea...

Page 113: ...ntactor K1 g Defective fuse interlock relay K 17 or resistor R46 Open protective relay tray and connect a jumper across the resistor R46 Sect 1 1 21 Fig 9 If the contactor will now remain closed replace fuse interlock relay K17 Sect 1 1 2 Fig 9 or replace the protective relay tray assembly 5 Load contactor opens during power delivery NO fault indicating lights on a Fuse F1 or F2 blown Remove and i...

Page 114: ...less than 130 V AC it is defective Replace over under voltage module or complete protection relay tray b Defective protective monitor module K14 If overvoltage light comes on at 110 V unplug over under voltage module and close contactor If the Overvoltage light comes on the protective monitor module K14 is defective NOTE it is normal for the undervoltage light to come on during this test 2 Load co...

Page 115: ...equency condition does not exist replace over underfrequency module K27 or complete protective relay tray 4 Load contactor opens during power delivery Under frequency light DS39 ON a Electric governor improperly adjusted or malfunctioning Proceed as follows b Governor Improperly adjusted Adjust in accordance with Sect 2 3 Para 3 E 3 c Electric governor system malfunctioning Check and adjust or rep...

Page 116: ... exciter rotor winding G2 Use ohmmeter to check for open or shorted condition If rotor windings are good proceed to step C c Open or shorted exciter field windings L2 Check for field resistance See Sect 2 3 Fig 14 for normal values d Open or shorted generator rotor windings L1 Check resistance with ohmmeter to determine if open or short circuited 2 Generator operates single phase a An open or shor...

Page 117: ...ace as required b Open or short circuited stator Phase Check stator windings in accordance with Sect 2 3 Para 4 Repair or replace as required c Defective connection in output circuit Check plug and receptacle connectors at aircraft Tighten Repair or replace as required d Unbalanced load Check aircraft 400 Hz components OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Re...

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Page 119: ...s 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 t...

Page 120: ...d as follows Parts coded A are used only on Spec 6921 1 or 6921A 1 Parts coded B are used only on Spec 6921 2 or 6921A 2 Parts coded C are used only on Spec 6921 4 or 6921A 4 Parts coded D are used only on Spec 6921 5 or 6921A 5 Parts coded E are used only on Spec 6921 6 or 6921A 6 Parts coded F are used only on Spec 6921 7 or 6921A 7 Parts coded G are used only on Spec 6921 8 or 6921A 8 Parts cod...

Page 121: ...cut 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 4...

Page 122: ...rt 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 ...

Page 123: ...emont 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 Concordville PA 19331 96682 Genisco Technology Corp Memory Products Div 10874 Hope Street Cypress California 90630 98410 E T C Molex Inc 5201 Ri...

Page 124: ...This page intentionally left blank OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 2 February 28 94 Revised Page 4 ...

Page 125: ...rent AR as required DC direct current Fig Figure hd head hex hexagon Hz Hertz cycles per second I D inside diameter IN inch kVA 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 ...

Page 126: ...Generator Set Figure 1 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 2 Revised ...

Page 127: ...6922 3 S 6922A 3 GENERATOR SET TRAILER MOUNTED S 6922B 3 TOP EXHAUST FENDERS BATTERIES P 1 S 6922 4 S 6922A 4 GENERATOR SET STATIONARY MOUNTED S 6922B 4 Q 1 S 7126 1 GENERATOR SET STATIONARY OR TRUCK MOUNTED 100 KVA R 1 1 181111 CANOPY ASSY For Details See Fig 2 A L 1 No Number CANOPY ASSY For Details See Fig 2 M Q 1 181797 CANOPY ASSY For Details See Fig 2 R 1 NOTES Series 6921A generator sets wi...

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Page 129: ... 1 13 84A 1054 1 REFLECTOR LIGHT RED 4 14 79A 1127 2 GUARD FILLER NECK 1 15 81B 1062 LABEL 1 16 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 ...

Page 130: ...Canopy Assembly Figure 2 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 6 Revised ...

Page 131: ...RONT A L R 1 180089 DOOR ASSY RIGHT FRONT M Q 1 8 488323 DOOR ASSY LEFT REAR A L R 1 180094 DOOR ASSY LEFT REAR M Q 1 9 488327 PANEL ASSY RIGHT SIDE A L R 1 180091 PANEL ASSY RIGHT SIDE M Q 1 10 81B 1019 LATCH T HANDLE DOOR 4 11 7J 422 0 CLAMP CABLE 2 12 100GH 121 BRACKET MTG CLAMP 1 13 482442 HORN ASSY CABLE ENTRANCE 1 14 482447 FLANGE HORN CABLE ENTRANCE 1 15 404101 1 LIGHTS CLEARANCE V75175 NO ...

Page 132: ...Generator Set Without Canopy Figure 3 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 8 Revised ...

Page 133: ...s See Fig 15 A Q 1 280790A GENERATOR ASSY For Details See Fig 15 R REF 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 For Details See Fig 14 1 12 81B 1061 LABEL 2 13 488222 SUPPORT PANEL CONTROL ASSY For Details See Fig 5 6 9 10 16 A E 1 181101 SUPPORT PANEL CONTROL A...

Page 134: ...Engine and Air Cleaner Grooup Figure 4 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 10 Revised ...

Page 135: ... 11 489005 COVER ACCESS 1 12 84A 1011 AIR CLEANER ASSY 1 13 84A 1010 BRACKET MTG AIR CLEANER V18265 NO P00 4073 2 14 403483 CLAMP FITTING 1 15 181094 TANK FUEL ASSY 1 16 DELETE 17 488334 BAFFLE AIR INTAKE ASSY 2 18 488303 PLATE MTG EXHAUST PIPE A F 1 19 84A 1006 REDUCER V82372 AIR CLEANER 1 20 W 10869 5 CLAMP FITTING 1 21 488277 PIPE MANIFOLD ASSY 1 22 404154 13 CLAMP PIPE 1 23 488265 MUFFLER ASSY...

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Page 137: ... 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 B E G L R 1 37 488780 HOSE OVERFLOW ENGINE 1 181113 PANEL FUEL FILL OUTLET ASSY 1 38 181112 PANEL FUEL FILL OUTLET 1 39 181112 PANEL FUEL FILL OUTLET 1 40 408440 ALTERNATOR 65 AMP 12 VOLT V62445 No SA 0027 1333 D 1 41 408439 PLUG GLOW ASSY V62445 No SA 270823 D 1 OM 2040 Operation and...

Page 138: ...Generator Control Box Group Figure 5 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 14 Revised ...

Page 139: ...ONTROL BOX AND INTERNAL COMPONENTS ASSY For Details See Fig 13 1 2 482278 2 TRAY ASSY GENERATOR CONTROLS For Details See Fig 12 1 3 482285 1 TRAY ASSY PROTECTIVE RELAYS For Details See Fig 11 1 4 HF 2752 SPACER SHOCK MTG V16238 NO 4624 105 4 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 15 ...

Page 140: ...Engine Control Panel Assembly Figure 6 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 16 Revised ...

Page 141: ...A 5 GAUGE FUEL V98738 NO 301 4 1 8 404172 3 LENS GREEN V72619 NO 26 1192 300 2 9 DW 1777B SWITCH PUSHBUTTON STARTER V87930 NO 5570 8 1 10 404172 1 LENS RED V72619 1 11 404100 PUSHBUTTON ENGINE V70040 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 ST230ECAN 2 16 404173 BASE LIGHT PILOT...

Page 142: ...Engine Test Panel Assembly Figure 7 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 18 Revised ...

Page 143: ...R SERVICE AIR FILTER 1 4 400698 5 POTENTIOMETER 50K OHM 1 5 W 11166 4 FUSE 15A FAST BLOW AGC 1 6 402658 HOLDER FUSE 1 7 84A 1008 1 ADAPTER BULKHEAD FILTER 1 8 W 11231 1 SCREW 8 18 X 3 8 SELF TAP 1 9 403380 CAP AND CHAIN ASSY 1 10 W 10886 1 CONNECTOR MALE SAE 45 FLARED V79470 NO 48 X 4 1 Not Illustrated OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised...

Page 144: ...Electric Governor Assembly Figure 8 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 20 Revised ...

Page 145: ...03 1 3 84A 1050 ARM THROTTLE 1 4 402908 JOINT BALL GOVERNOR LINKAGE 2 5 W 11280 3 NUT 2 6 W 9476 33 ROD THREADED 1 4 28 X 3 7 8 1 7 281774 2 SENSOR MAGNETIC GOVERNOR See Fig 3 for location 1 8 408524 GOVERNOR CONTROLLER See Figure 16 Item 1 1 9 489951 BRACKET GOVERNOR 1 Not Illustrated OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 21 ...

Page 146: ...Power Module Panel Assembly Figure 9 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 22 Revised ...

Page 147: ...9 400480 2 TERMINAL QUICK CONNECT V00779 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 1 RESISTOR LINE DROP BURDEN 50 OHM 25 WATT V44655 NO 0200D 3 13 404065 2 RECTIFIER SILICON V04713 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 3...

Page 148: ...Voltage Regulator Assembly Part No 430391C Figure 10 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 24 Revised ...

Page 149: ... 1 13 402342 REACTOR REGULATOR V96682 NO 70 8532 1 14 16DA 2162 KNOB RHEOSTAT V44655 NO 5150 1 15 HF 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 25MS 328 SPACER 2 20 402376 RECEPTACLE V02660 NO MS 1302A 22 14P 1 21 400782 1 FUSE 5 AMP FAST ACTING GLASS TUBE MTH 1 22 HF 2407 FUSE...

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Page 151: ...ONNECTOR 1 34 400698 2 POTENTIOMETER 2500 OHM 2 WATT V44655 NO CLU 2521 1 35 W 9712 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 V50508 NO E3661 A 4 40 402358 NAMEPLATE ADJUST 1 41 480725 LABEL INSTRUCTION 1 401564 2 HOUSING SOCKET CONNE...

Page 152: ...Protective Relay Tray Assembly Figure 11 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 28 Revised ...

Page 153: ...OR 1 13 482038 BOARD ASSY OVER UNDERVOLTAGE 1 14 401563 4 HOUSING PIN CONNECTOR 1 15 482039 BOARD ASSY OVER UNDERFREQUENCY 1 16 401563 4 HOUSING PIN CONNECTOR 1 17 76A 1118 SWITCH SNAP PUSHBUTTON V27191 NO SA35BCB34 9 2 18 403336 RING LOCKING SWITCH V91929 TS10020 2 19 HF 2518 2 LIGHT PILOT FAULT 12V RED 5 19A 404172 1 LENS RED V72619 NO 26 1191 300 1 20 400613 4 BULB V71744 TYPE 1815 1 21 402658 ...

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Page 155: ...TRAY Set consists of four parts marked CR CL DR DL V75358 NO 1336 12 1 32 404028 NAMEPLATE HOBART 1 33 370382A HANDLE TRAY 1 34 76A 1115 LATCH ADJUSTABLE GRIP V94222 NO 48 99 126 11 1 35 482287 TRAY ASSEMBLY 1 36 482307 HARNESS ASSY WIRE PROTECTIVE RELAYS TRAY 1 Not Illustrated OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 31 ...

Page 156: ...Generator Controls Tray Assembly Figure 12 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 32 Revised ...

Page 157: ... V02660 NO 77 MIP 11 1 11 363771 5 SLEEVING PLASTIC 1 8 IN I D 6 12 363770 1 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 10J 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 V04009 NO 81579 FT 1 19 15GH 433...

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Page 159: ...6 12 1 29 482280 TRAY ASSEMBLY 1 30 408999 1 DIODE RECTIFIER POWER V04713 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 V02660 NO MS 3106A 28 16S 1 34 402382 CLAMP CABLE V02660 NO MS 3057 16 1 35 484689 1 SLEEVING SHRINKABLE 1 8 ID AR OM 2040 Operation and Maintenance Manual 90D20 Ge...

Page 160: ...Control Box and Internal Components Assembly Figure 13 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 36 Revised ...

Page 161: ... V02231 NO AGW 4211 2 7 W 10051 13 CLAMP WIRE PLASTIC V81074 NO EC 14 2 8 W 10051 10 CLAMP WIRE PLASTIC V81074 NO EC 10 3 9 16DA 4253 1 RETAINER SPRING RELAY V77342 NO 20C206 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 V02660 NO 77 MIP 11 2 14 488280 HARNESS WIRE GEN CO...

Page 162: ...Output Terminal Board Assembly Figure 14 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 38 Revised ...

Page 163: ...1097 18 SCREW HHC STEEL 3 8 16 X 3 4 BAMAL FASTENERS CORP 8 6 W 11254 6 WASHER LOCK STEEL 3 8 IN 8 7 W 11242 10 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 10 24 X 3 4 4 11 W 11254 3 WASHER 10 LOCK ST MID STATE NUT BOLT 4 12 W 11245 3 WASHER 10 FLAT BRASS 4 13 482444 BOARD TERMINAL OUTPUT 1 14 W 9360 261 CABLES OUTPU...

Page 164: ...Generator Assembly Figure 15 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 40 Revised ...

Page 165: ...FOOT GEN REF 13 DATA 3190 COIL FIELD EXCITER SET 14 100NH 3 INSULATION EXCITER WRAPPER 4 15 100NH 2 POLEPIECE EXCITER 4 16 387624A 1 HOUSING EXCITER 1 17 W 10875 1 DIODE SILICON 35 AMP NEGATIVE BASE V51589 ST460N 3 18 W 10874 1 DIODE SILICON 35 AMP POSITIVE BASE V51589 ST460P 3 19 387623 1 CORE ARMATURE ASSEMBLY 1 20 387621 COVER HOUSING EXCITER 1 21 488755 COVER END EXCITER HOUSING 1 22 482483 SC...

Page 166: ...Panel Support Controls Figure 16 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 42 Revised ...

Page 167: ... V AC DC 3 5 100GH 112 TERMINAL OUTPUT 3 6 5CW 975 BUSHING INSULATOR CABLE STUD 3 7 5CW 976A WASHER INSULATOR CABLE STUD 6 8 W 11242 10 WASHER FL STD 3 8 V76870 6 9 W 11254 6 WASHER LOCK STD 3 8 MIDSTATE NUT BOLT CO 6 10 W 11097 8 SCREW 3 8 16X2 HHC ST BAMAL FASTENERS CORP 3 11 482989 STRAP WIRE GROUND 2 12 W 11278 5 NUT 3 8 16 HEX FULL ST BAMAL FASTENERS CORP 3 Optional Item OM 2040 Operation and...

Page 168: ...Mounting Frame and Control Support Assembly Figure 17 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 44 Revised ...

Page 169: ...PPORT PANEL CONTROL ASSY N P Q 1 180098 SUPPORT PANEL CONTROL ASSY MN 1 181718 SUPPORT PANEL CONTROL ASSY L 1 4 488267 PANEL BULKHEAD REAR ASSY A L 1 180097 PANEL BULKHEAD REAR ASSY M Q 1 180752 PANEL BULKHEAD REAR ASSY R 1 5 488756 YOKE LIFTING 1 6 488201 TANK FUEL ASSY 1 7 480669 ADAPTER FOOT GENERATOR 2 8 480603 1 MOUNT SHOCK V81860 20 9 480628 PLATE MTG ENGINE GENERATOR 10 10 488124 SUPPORT EN...

Page 170: ...Trailer Group with Parking Brake Figure 18 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 46 Revised ...

Page 171: ...TOP For Details See Fig 19 B G L 1 489725 2 FENDER FRAME AND UNDER CARRIAGE W EXHAUST OUT SIDE For Details See Fig 19 A F 1 180153 FENDER FRAME AND UNDER CARRIAGE W EXHAUST OUT TOP For Details See Fig 19 M P 1 2 404088A 1 TRAILER ASSEMBLY WITH PARKING BRAKE For Details See Fig 20 AB FG LM P1 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 47 ...

Page 172: ...Fenders Frame Accessories and Undercarriage Figure 19 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 48 Revised ...

Page 173: ... 488174 RAIL CABLE SUPPORT 2 10 488251 FENDER RIGHT SIDE REAR 1 11 488166 SIDE BATTERY BOX 1 12 488152 FENDER LEFT SIDE FRONT 1 13 488163 SUPPORT FENDER 2 14 488172 PANEL CENTER COVER 1 15 488247 BRACKET MTG DEFLECTOR 2 16 488253 FENDER LEFT SIDE REAR 1 17 488164 FENDER REAR GUARD 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...

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Page 175: ...R 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 E K 1 37 W 9234 363 CABLE BATTERY TO STARTER E K 1 38 W 9234 38 CABLE BATTERY TO GROUND E K 1 39 W 9234 112 CABLE BATTERY TO POSITIVE E K 1 40 489812 ROD RIGGING BRAKE REWORK 1 Not Illustrated Only these items of the Fender Frame and Undercarriage apply to Specifica...

Page 176: ...Trailer Assembly Figure 20 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 52 Revised ...

Page 177: ... V22938 NO 4800 4 4 79A 1045 ARM ASSY CENTER V22938 NO 1 3854 1 9 DELETED 10 181840 SPRING LATCH V22938 NO 4006 1 11 404529 LATCH DRAW BAR V22938 NO 3855 1 12 404530 PIN ROLL 3 8 X 1 1 2 IN V22938 NO 5000 1 1 13 79A 1048 PIN CENTER V22938 NO 5400 5 1 14 284399 36 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 C...

Page 178: ...22938 NO 28 3800 1 31 404536 PIN ROLL 3 16 X 1 3 4 IN V22938 NO 5000 6 2 32 85A 1030 PIN KING V22938 NO 5401 2 33 404537 WASHER SPINDLE V22938 NO 4701 10 2 34 404538 NUT SPINDLE V22938 NO 4600 2 2 35 80A 1052 PIN COTTER V22938 NO M524665 360 2 79A 1035 FITTING LUBE V22938 NO 4800 5 4 76A 1183 FITTING LUBE V22938 NO 5800 5 76A 1184 HUB ASSY FRONT AXLE V22938 NO 1 3612 2 36 85A 1020 CAP GREASE V2293...

Page 179: ...38 NO 1 4251 4 51 76A 1187 BRACKET SPRING HOOK END V22938 NO 4251 1 52 76A 1188 PIN STRAIGHT HEADED V22938 NO 5403 1 1 53 76A 1189 PIN COTTER V22938 NO 4800 3 1 76A 1190 BRACKET ASSY HANGER SPRING FRONT AXLE Eye End V22938 NO 1 4261 2 54 76A 1191 BRACKET SPRING FRONT AXLE Eye End V22938 NO 4261 1 55 76A 1192 BOLT HEX HEAD 9 16 12 NF X 3 3 4 lg V22938 NO 4901 19 1 56 76A 1193 NUT 9 16 12 NF HEX V22...

Page 180: ... 6155 1 69 85A 1029 CUP BEARING OUTER V22938 NO 6156 1 70 76A 1201 DRUM BRAKE V22938 NO 8221 1 71 85A 1024 NUT WHEEL 1 2 20 NF HEX V22938 NO 4603 1 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...

Page 181: ...This page intentionally left blank OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 57 ...

Page 182: ...Brake Assembly Prototype Development Inc Figure 21 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 58 Revised ...

Page 183: ...38 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 1 8209 76A 1205 WILL BE FURN...

Page 184: ...Fuel Tank Fitting Assembly Figure 22 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 60 Revised ...

Page 185: ...ONNECTOR MALE V79470 NO 48 X 6 X 6 2 3 W 10893 0 FITTING HOSE SWIVEL FEMALE V03924 NO 442 6 6 2 4 56535 RUBBER HOSE LOW PRESSURE 17 5 W 10917 5 NIPPLE PIPE 3 8 TAPERED THREAD 2 6 12CW 2077 2 STREET ELL 90 PIPE SUPPLIES INC 2 7 W 10917 6 NIPPLE PIPE 1 8 W 10119 3 COUPLING PIPE PIPE SUPPLIES INC 1 9 84A 1055 FITTING BANJO FUEL FILTER V62445 NO 129 0579 1 OM 2040 Operation and Maintenance Manual 90D2...

Page 186: ...Oil Line Assembly Figure 23 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 62 Revised ...

Page 187: ...EL FEMALE SAE 45 FLARED V03924 NO 711S 4S 2 3 56548 HOSE DIESEL SIZE 4 3 16 4 FT 4 W 10909 1 TEE STREET BRASS 2 5 403809 1 SWITCH OIL PRESSURE ENGINE GENERATOR 1 6 W 10886 1 CONNECTOR MALE SAE 45 FLARED 1 7 403809 3 SWITCH OIL PRESSURE STARTER CUT OUT 1 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 63 ...

Page 188: ...Fuel Line Assembly Figure 24 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 64 Revised ...

Page 189: ...FUEL LINES ASSY FUEL PUMP TO ENGINE SECTION R 1 1 W 10886 1 CONNECTOR MALE V79470 NO 48 X 4 2 2 W 10893 0 SWIVEL FEMALE SAE 45 FLARED V03924 NO 442 6 6 2 3 56535 HOSE LOW PRESSURE 110 4 84A 1055 COUPLING PIPE 1 4 V62445 NO 129 0579 2 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 65 ...

Page 190: ...Fuel Return Line Assembly Figure 25 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 66 Revised ...

Page 191: ...7 HOSE LOW PRESSURE A Q 90 56587 HOSE LOW PRESSURE R 120 2 W 10869 14 CLAMP FITTING V35708 2 3 84A 1007 1 CONNECTOR MALE V79470 NO 310504 1231 015207 1 4 W 10892 4 ELBOW MALE V79470 NO 3400X2 1 5 W 10119 1 COUPLING PIPE PIPE SUPPLIES INC 1 6 W 10750 1 NIPPLE PIPE V31510 1 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 67 ...

Page 192: ...Air Cleaner Hose Assembly Figure 26 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 68 Revised ...

Page 193: ... 1 56534 HOSE LOW PRESSURE 12 Ft 2 400333 1 ELBOW FEMALE SAE 45 V03924 NO 7115 4S 2 3 W 10893 2 FITTING HOSE SWIVEL FEMALE SAE 45 FLARED V03924 NO 711S 4S 2 4 W 10886 1 CONNECTOR MALE V79470 NO 48 X 4 1 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 69 ...

Page 194: ...Second Output Kit Figure 27 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 70 Revised ...

Page 195: ... 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 0200F 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 CONTRO...

Page 196: ...This page intentionally left blank OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 72 Revised ...

Page 197: ...HORN CABLE ENTRANCE 1 26 484244A HARNESS WIRE SECOND OUTPUT 1 27 W 9360 278 CABLE CONTACTOR INPUT PHASE A 101 1 28 W 9360 278 CABLE CONTACTOR INPUT PHASE B 102 1 29 W 9360 278 CABLE CONTACTOR INPUT PHASE C 103 1 30 W 9360 261 CABLE CONTACTOR INPUT PHASE A 1 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 112 1 Not Illustrated ...

Page 198: ...Kit Mounting T R Assembly Figure 28 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 74 Revised ...

Page 199: ... 489133 BRACKET MTG T R RIGHT ASSY 1 489133 BRACKET MTG T R RIGHT ASSY 2 3 430278 GROMMET 1 430278 GROMMET 2 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 489134 SHIELD RAIN T R OPENING 2 8 280005 EXTENSION PIPE EXHAUST ASSY 1 9 404154 15 CLAMP FULL CIRCLE 1 This number of items used on Part No 489127 1 This number of...

Page 200: ...Kit Mounting T R Assembly Back Mounting Unit Figure 29 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 3 February 28 94 Page 76 Revised ...

Page 201: ... 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 11 CLAMP CONDUIT 3 6 408523 ELBOW 90 2 INCH 2 7 489952 CONDUIT 2 INCH 1 OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Chapter 4 3 Revised Page 77 ...

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Page 203: ...ncing with the first location the part is listed CONTROL BOX AND INTERNAL COMPONENTS ASSY 5 1 13 0 DATA 3190 15 13 DDW 155 1 19 DDW 495 1 4 36 DW 1777B 6 9 DWP 982 28 4 ENGINE AND AIR CLEANER GROUP 3 1 4 0 FUEL FILTER DEUTZ ENGINE 4 35 GENERATOR SET WITHOUT CANOPY 1 6 3 0 HJ 129A 2 17 HF 1459 12 18 HF 2407 10 22 HF 2518 2 11 19 HF 2752 5 4 6 13 9 21 10 42 HF 745 10 15 MOUNTING FRAME AND SUPPORT CO...

Page 204: ...1102 18 15 26 W 11112 3 14 10 W 11166 1 11 22 11 23 W 11166 4 7 5 W 11231 1 7 8 W 11236 4 27 21 W 11242 5 14 2 W 11242 10 14 7 16 8 W 11245 3 14 12 W 11254 3 14 11 W 11254 6 14 6 16 9 W 11278 5 16 12 W 11280 3 8 5 W 11597 10 4 W 2974 L 12 6 W 2974 N 12 7 W 8095A 9 12 21 W 8105A 4 12 22 W 9234 38 19 38 W 9234 112 19 39 W 9234 363 19 37 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenanc...

Page 205: ... 10 12 1CZ 93B 9 18 27 5 27 13 1CZ 97 10 6 1CZ 105 10 8 1CZ 128 10 9 1CZ 148 9 2 10J 178 12 15 100GH 12 27 23 100GH 112 16 5 100GH 121 2 12 100GHP 66 15 23 100NH 3 15 14 100NH 2 15 15 12CW 1320A 5 6 7 12CW 2077 2 22 6 15GH 433 12 19 16DA 2162 10 14 12 14 16DA 4004A 3 11 5 27 9 16DA 4004A 10 11 7 12 9 13 10 27 11 16DA 1997 6 11 24 16DA 4029 12 13 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and...

Page 206: ...98 3 13 180153 18 1 19 0 181094 4 15 181101 3 13 17 3 181103 3 13 17 3 181106 4 6 181111 1 1 2 0 181112 4 38 4 39 181113 4 37 181118 1 1 2 0 181119 4 7 181343 15 8 181718 3 13 17 3 181797 1 1 2 0 181831 19 25 181840 20 10 20RT 353 1 6 15 25MS 156 6 14 25MS 328 10 19 280005 28 8 280783A 3 8 15 0 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 4...

Page 207: ... 386612 15 1 387620A 1 15 5 387621 15 20 387623 1 15 19 387624A 1 15 16 387736C 11 11 387738A 9 15 387748 1 15 11 387859 2 16 388328 49 12 24 388328 52 11 26 400030 1 12 31 400078 12 6 400059 3 23 1 400333 1 26 2 400400 12 20 400480 2 9 9 400480 3 9 10 27 14 400599 20 2 400613 4 6 17 11 20 400698 2 10 34 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets F...

Page 208: ...27 401911 3 10 23 401937 1 11 9 401937 2 9 11 13 3 401937 3 9 4 13 12 27 2 401939 9 5 402037 9 11 25 13 6 402037 12 19 32 402037 14 27 7 402197 1 9 6 402218 12 17 402342 10 13 402357 10 37 402358 10 40 402373 10 3 402376 10 20 402379 12 33 402382 12 34 402383 11 31 12 28 13 5 402658 7 6 11 21 402662 11 1 27 8 402665 1 12 4 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D...

Page 209: ...15 404154 11 29 5 404154 13 4 22 404154 15 4 32 28 9 404172 1 6 10 11 19A 404172 3 6 8 27 20 404173 6 16 27 18 404402 1 9 3 404460 1 10 29 404518 9 14 27 6 404529 20 11 404530 20 12 404531 20 19 404532 20 22 404536 20 31 404537 20 33 20 78 404538 20 34 20 77 404539 20 76 404540 20 74 404541 20 73 404543 20 75 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator S...

Page 210: ... 30 430278 17 11 28 3 430340 10 1 430341 10 25 430391C 3 7 10 0 430470 10 2 430472A 10 24 430473 10 38 430476 10 10 480603 1 17 8 15 27 480628 15 28 17 9 480669 15 12 17 7 480725 10 41 480989 20 28 481379 15 9 482038 11 13 482039 11 15 482069 27 1 482075 2 3 64 9 0 482076 9 1 482278 2 5 2 12 0 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 4 ...

Page 211: ...444 14 13 482445 14 4 482446 14 8 482447 2 14 27 25 482483 15 22 482746 20 18 482989 16 11 484066 3 1 23 27 0 484067 27 0 484070 27 15 484689 1 12 35 13 16 484690 2 13 17 485530 10 1 485053 10 26 485282 10 30 485283 10 31 488124 17 10 488125 19 1 488150 2 5 17 12 488152 19 12 488154 19 3 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Rev...

Page 212: ... 19 30 488188 6 1 488191 4 8 488192 4 7 488193 4 2 488194 4 3 488201 17 6 488204 19 31 488205 4 27 488207 7 1 488222 3 13 488222 17 3 488231 19 23 488232 4 25 488233 2 4 24 488238 19 21 484244A 27 26 488246 19 33 488247 19 15 488249 19 20 488251 19 10 488253 19 16 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 4 February 28 94 Revised Page 10...

Page 213: ...93 4 29 488294 8 1 488295 15 4 488296 3 5 488296 8 0 488301 3 3 6 0 488302 1 19 28 488302 2 19 29 488303 4 18 488304 4 30 488312 19 19 488313 19 18 488314 4 33 488318 4 34 488322 2 7 488323 2 8 488324 2 18 488325 2 2 488327 2 9 488328 17 1 488329 4 9 488330 4 5 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February 28 94 Revised Chapter 4 4 Page 11 ...

Page 214: ...1 22 489127 1 28 0 489127 2 1 22 489127 2 28 0 489127 3 28 0 489132 28 1 489133 28 2 489134 28 7 489160 19 25 489479 27 16 489481 2 4 489525 3 3 489541 6 0 489725 1 18 1 19 0 489725 2 18 1 19 0 489744 2 19 489745 2 20 489812A 3 7 19 40 489897 29 1 489899 29 3 489906 29 4 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 4 February 28 94 Revised ...

Page 215: ... 28 6 7J 422 0 2 11 7J 422 0 27 22 76A 1115 11 34 12 27 76A 1118 11 17 76A 1125 1 16 76A 1131 19 27 76A 1140 20 1 76A 1152 1 3 76A 1171 20 16 76A 1172 20 17 76A 1173 20 18 76A 1174 20 20 76A 1175 20 21 76A 1178 20 24 76A 1179 20 25 76A 1180 20 26 76A 1181 20 27 76A 1182 20 79 76A 1183 20 35 20 41 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets February ...

Page 216: ...20 65 76A 1201 20 70 76A 1203 20 80 21 0 76A 1204 21 1 76A 1205 21 5 76A 1206 21 6 76A 1207 21 7 76A 1208 21 8 76A 1209 21 9 76A 1210 21 10 76A 1211 21 2 76A 1212 20 64 76A 1216 21 3 76A 1217 21 4 76A 1218 21 5 76A 1219 20 46 76A 1220 20 47 76A 1221 20 48 76A 1222 20 22 20 49 76A 1223 20 50 76B 1148 1 5 78A 1000 1 20 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Gen...

Page 217: ...9A 1127 2 1 14 79A 1144 15 29 79B 1140 10 27 80A 1035 19 34 80A 1036 19 35 80A 1052 20 35 81B 1019 2 10 81B 1061 3 12 81B 1062 1 15 81B 1064 1 8 82A 1030 6 2 82A 1048 13 1A 82B 1047 13 1 83B 1109A 4 1 84A 1006 4 19 84A 1007 1 25 3 84A 1008 1 7 7 84A 1010 4 13 84A 1011 4 12 84A 1019 6 5 84A 1020 8 2 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Februar...

Page 218: ... 19 24 85A 1019 20 41 85A 1020 20 36 85A 1021 20 38 85A 1022 20 37 85A 1023 20 39 85A 1024 20 40 20 71 85A 1025 20 42 85A 1027 20 43 85A 1028 20 44 20 68 85A 1029 20 45 20 69 85A 1030 20 32 85B 1034 20 29 85B 1035 20 30 85B 1039 15 7 PART NUMBER FIGURE ITEM NUMBER OM 2040 Operation and Maintenance Manual 90D20 Generator Sets Chapter 4 4 February 28 94 Revised Page 16 ...

Page 219: ...In this manual 484066 3 Kit T R Mtg Single for 4 Wheel Trailers In this manual 489127 1 Kit T R Mtg Double for 4 Wheel Trailers In this manual 489127 2 Kit T R Mtg Single rear mounting In this manual 489943 1 Truck Truck Body Used on Specs 6921A 6 6921A 11 and 7126 1 TO 176 280099 1 Kit No 488898 consists of Part Numbers 84B 1038 and DW 1777B OM 2040 Operation and Maintenance Manual 90D20 Generato...

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Page 221: ...25 1 Hobart Brothers Company Operation and Maintenance Manual No OM 2040 Trailer Group with Parking Brake Hobart Part No 489725 2 Hobart Brothers Company Operation and Maintenance Manual No OM 2040 488351 Generator Connection Diagram 2 sheets 482360 Generator Schematic Diagram 488352 Engine Connection Diagram 2 sheets 488350 Engine Schematic Diagram 482365 Control Tray Connection Diagram 482366 Pr...

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Page 261: ... locations radiant heat vermin infestation or atmospheres conducive to fungus growth 7 Abnormal shock vibration or mechanical loading from external sources during equipment operation 8 Abnormal axial or side thrust imposed on rotating equipment shafts 9 Low and or high ambient temperatures b Operation at 1 Voltages above or below rated voltage 2 Speeds other than rated speed 3 Frequency other than...

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