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FOEBAR;

P ; MOTOR GENERATOR DIVISION


8 s HOBART BROTHERS COMPANY
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OPERATION - MAINTENANCE - OVERHAUL

TM-133

GROUND POWER UNIT 400 CYCLE 115/200 VOLT 160 KVA - TRUCK MOUNTED
with
DETROIT DIESEL ENGINE MODEL 8V-71N
(GENERATOR PRIME MOVER) -

SPECS 4795 VAR. 3

MOTOR GENERATOR DIVISION


HOBART BROTHERS COMPANY
TROY, OHIO 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 dont cause short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.

MOVING PARTS can cause serious injury. Keep clear of moving parts.

IMPORTANT - Protect yourself and others. Read and understand all the instructions in this Operating/Instruction
Manual before installing, operating, or servicing this equipment. Keep this manual available for future
use by all operators.

A. GENERAL
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions. Safe practices
have developed from past experience in the use of power source equipment. Certain of the practices below apply to
engine driven equipment.

B. SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a
person. Have a competent electrician verify that the equipment is adequately grounded and learn what terminals
and parts are electrically HOT. Use proper safety clothing, procedures, and test equipment.

The electrical resistance of the body is decreased when wet, thus more easily permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas without being extremely careful.
Stand on dry rubber mat or dry wood, use insulating gloves that are effective when dampness or sweat cannot be
avoided. Keep your clothing dry and never work alone.

1. Installation and Grounding of Electrically Powered Equipment - Electrical equipment must be installed
and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, and other appiicable codes.
A power disconnect switch or circuit breaker must be located at the equipment. Check the nameplate for voltage,
frequency, and phase requirements. If only 3-phase power is available, connect any single-phase rated equipment to
only two wires of the 3-phase line. DO NOT CONNECT the equipment grounding conductor (lead) to the third live
wire of the 3-phase line, -as ---
this makes the eouipment frame electrically HOT, which
------ can cause a fatal shock.

Be sure to connect the grounding lead, if supplied in a power line cable, to the grounded switch box or building
ground. If not provided, use a separate grounding lead. Be certain that the current (amperage) capacity of the
grounding lead will be adequate for the worst fault current situation. Refer to the National Electrical Code ANSI/
N FPA 70 for details. Do not remove plug ground prongs. Use correct mating receptacles.

2. Output Cables and Terminals - Inspect cables often for damage to the insulation and the connectors. Replace
or repair cracked or worn cables immediately. Do not overload cables. Do not touch output terminal while equip-
ment is energized.

Instruction 910082 Page 1


Nov 16182 Revised
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 TRFATMFNT


First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of all
injury victims. Electric shock victims should be checked by a physician and taken to a hospital immediately if any
abnormal signs are observed.

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 16182
FOi3AR1:
e E MOTOR GENERATOR DIVISION
% : HOBART BROTHERS COMPANY
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GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133


.

TABLE OF CONTENTS

CHAPTER
SUBJECT SECTION PAGE

OPERATION' 1 1

GENERAL l-l 1

SUPPLEMENTARY MANUALS l-l 1

TERMINOLOGY l-l 1

DESCRIPTION AND DATA l-2 1

CONTROLS AND INSTRUMENTS l-3 1

OPERATING PROCEDURES l-4 1

MAINTENANCE 2 1

SERVICING '2-l 1

TROUBLE SHOOTING 2-2 1

OVERHAUL 3 1

DISASSEMBLY INSPECTION AND REPAIR 3-l 1

REASSEMBLY 3-2 1

i
.MOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

CHAPTER 1 OPERATION

SECTION 1

1. General

A. Scope

(1) The purpose of these instructions is to inform the operator of the


characteristics, capabilities, and limitations of this equipment and
i to assist maintenance personnel in installation, trouble shooting,
I and maintenance.
/
(2) Best results will be obtained ONLY if the personnel responsible for
I this equipment have access to, and are familiar with, these instruc-
tions.

2. Supplementary Manuals

A. Supplementary manuals included with these instructions:

(1) The regulated static exciter manual covers theory of operation, line
drop compensation, and maintenance of the static voltage regulator,
Hobart #lCZ-65D.

(2) The engine operator's manual outlines operation, inspection, and


maintenance for the GM diesel, Model 8V-71N.

(3) The truck owner's manual explains features of the truck, upon which
the power unit is mounted.

(4) Parts lists are provided for the power unit and the GM diesel engine.,

Additional copies of the ground power unit manual and the regulated static
exciter manual are available by writing to:

MOTOR GENERATOR DIVISION


HOBART BROTHERS COMPANY
TROY, OHIO 45373
U.S.A.
I
giving the SPECS, SERIAL, and MODEL numbers of your equipment and the
number of copies needed.

July 23168 l-l


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HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

I-
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3. Terminology

A. The space relationships "right", "left!', etc., are determined by the


driver's position in the truck cab.

B* The engine operator's manual will be abbreviated EOM, generally followed


by a reference to the subject heading of the EOM.

C. The ground power unit will be abbreviated to read GPU.

l-l
Page 2
MOTOR GENERATOR DIVISION

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133


.-

CHAPTER 1 OPERATION

SECTION 2 - DESCRIPTION AND DATA

1. Unit Assembly

A. Description

(1) The power generator, its prime mover, control components, and several
sub-assemblies are attached to a common frame and superstructure,
covered with a sheet metal canopy, and mounted on the chassis of a
truck. The truck frame has been customized to include a combination
battery and output cable box on the left side and a lOO-gallon fuel
tank on the right side.

2. Detailed Description of Major Components

A. Generator

(1) This unit utilizes a 3-phase, revolving field, static excited and
regulated generator to develop the 400-cycle output current. The
generator is driven by an 8-cylinder, diesel engine which is flexibly ~
coupled to the rotor shaft. A centrifugal fan, attached to the flex-
ible coupling, draws cooling air in at the open end of the generator,
passes it over the revolving fields, slip rings, and stator, and then
expels the warm air at the opening next to the coupling.

B. Static Voltage Regulator

(1) Voltage regulator function:

(a) Provides excitation voltage for the generator revolving fields.

(b) Provides 1% voltage regulation for all loads up to 100% of rated


power factor. Regulation is achieved by varying the revolving
field power of the alternator as required by load conditions.
The maximum continuous rating of the regulated static exciter is
150-volt DC.

(c) Provides line drop compensation by increasing the generator


voltage in proportion to load increases to compensate for volt-
age drop in the cables to the aircraft.

(2) Operation, adjustment, and servicing

(a) Instructions for the static regulator, Model lCZ-65D, are given
in a separate manual supplied with the ground power unit in-
struction package.

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e 1 MOTOR GENERATOR DIVISION
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: GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

C. Generator Prime Mover

(1) A GM diesel engine, flexibly coupled to the armature shaft, serves as


the generator prime mover. In this manual, engine performance and
procedures are restricted to that information essential to getting
' the engine into service, and that which directs the operator in oper-
ating and lubricating techniques. Specific engine servicing, trouble
shooting, and repair information is contained in the engine operator's
manual. The engine warranty is printed on the inside of the EOM
front cover.

(2) Special emphasis is given in both this manual and in the EOM concern-
ing the engine shutdown system.

(a) The engine shutdown system, as described in the engine manual,


is used to stop the engine in case an abnormal condition, such
as high engine coolant temperature, loss of engine coolant, low
lubrication oil pressure, or engine overspeeding, arises. In
case an immediate shutdown is required, a normally closed mag-
netic valve is connected between the oil pressure bellows and
the engine oil sump. To energize this valve for immediate shut-
down, break the seal on the emergency switch (located on the
front of the control box) and hold the switch in the UP position
until the engine stops. This results in the oil pressure being
removed from the oil pressure bellows, allowing the air flapper
valve to close, thus stopping the engine.

(b) In this shutdown system, a coolant-temperature sensing valve and


an adapter and copper plug assembly are mounted on the exhaust
manifold with the plug extending into the manifold. Coolant
from the engine is directed through the adapter assembly, in
which the bulb of the temperature sensing valve assembly is lo-
cated, to the suction side of the water pump. Oil under pres-
sure from the engine is directed through a restricted fitting
to the oil pressure bellows. A line attached to the discharge
side of the temperature valve directs any oil that passes through
the valve to the engine crankcase. Oil under pressure entering
the oil pressure bellows, works through the bellows against a
spring, overcomes the spring tension, and permits the latch to
retain the air shutdown valve assembly in the OPEN position.
Should the oil pressure drop below a predetermined value, the
spring in the oil pressure bellows will release the latch per-
mitting the air shutdown valve to close, stopping the engine.
The oil pressure bellows can be adjusted to release the latch at
pressures ranging from approx=tely 5 to 25 psi.

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GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(c) The overspeed governor consists of a small plunger and valve


actuated by a set of spring loaded weights. An outlet in the
valve is connected to the engine oil sump. Whenever engine
speed exceeds the overspeed setting, the valve plunger is lifted
from its seat permitting the oil to flow to the engine sump.
This results in a drop of oil pressure to the oil pressure bel-
lows, thus actuating the shutdown mechanism and stopping the
engine.

(d) During operation, should the lube oil pressure drop to 12 psi,
the engine coolant rise to 200'F to 210F, the engine lose,its
coolant, or should the engine speed exceed 1975-2025 rpm,-the
corresponding valve opens, allowing the oil to return to the
engine oil sump, resulting in a decrease in oil pressure on the
bellows. The oil pressure bellows will then release the latch
permitting the air shutdown to close, stopping the engine.

(e) After the engine has been shut down due to the action of pro-
tective device, it cannot be run until the particular device
which actuated the shutdown has returned to its normal position.
The abnormal condition which stopped the engine must be cor-
rected before again attempting to start the engine.

D. Truck

(1) All material regarding the truck features, with the exception of the
manifold vacuum switch, the lOO-gallon fuel tank, and the battery
and output cable box, is covered in the truck manuals. The excepted
items above are thoroughly explained in this manual. Other infor-
mation is tabulated in paragraph E.

(2) In addition to the items listed in the preceding paragraph, an hour-


meter has been installed on the truck dash panel. This meter records
the cumulative truck engine operating hours, in reference to which
engine servicing may be scheduled.

E. Tabulated Data

(1) General (Truck included)

Weight ............. 12, 540 lbs, gross


Length ............. 238-l/8 in.
Width ............. 86 in.
Height ............ 90 in.

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GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(2) Performance I

(a) Engine (Generator Prime Mover)

Type ............ Diesel


Make ............ General Motors
Model ........... 8V-71N
No. of Cylinders ...... 8
HP ............ 253 e-1714
--- RPM
Displacement ........ 567 cu. in.

(3) Capacities (Generator Prime Mover)

Cooling System (approximate) . . 13 gals.


Crankcase (w/filters) . . . . . . 20 qts.

NOTE: The unit should be operated in as near a normal horizontal


position as possible and never at a tilt greater than 15"
from horizontal.

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MOTOR GENERATOR DIVISION


HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

CHAPTER 1 OPERATION

SECTION 3 - CONTROLS AND INSTRUMENTS

1. Control Panel

A. Panel Location

(1) The control panel is located behind the left front door of the canopy.
Engine controls are on the stationary portion of the panel; generator
controls are on the hinged portion (See Figure 1).

B. Description of Controls and Instruments

(1) The fluid starting aid (1) consists of an ether cartridge container,
a cartridge puncturing tool, and a hand pump. It is used at tempera-
tures below 40'F to promote fuel ignition by pumping ether into the
engine intake manifold (see EOM, Initial Start Procedure).

(2) The Throttle Control (2) is used to adjust the engine speed when
starting and warming the engine. The electric speed control switch
(22) must be in the MANUAL position for this control to function.

(3) The idle stop lever (3) permits adjustment of the throttle to the
IDLE position, simultaneously preventing an inadvertent shutdown.
If, after the engine has been idled sufficiently, normal shutdown is
desired, lift the idle stop lever and push the throttle control fully
in.

(4) The water temperature gage (4) indicates the engine coolant tempera-
ture. This gage must indicate 160-200'F after engine warmup. A
temperature appreciably higher or lower than cited here is an indi-
cation/of cooling system difficulties.

(5) The oil pressure gage (5) at operating speed, should register 50-70
psi. If it should fall below 30 psi at operating speed, shut down
the engine and determine cause of pressure failure. During idle
speed operation, engine oil pressure may drop below 30 psi, in which
event, it may be assumed that conditions are normal, unless the low
oil pressure causes an automatic engine shutdown.

(6) The battery ammeter _~~~


(6) should register a charge of 15-30 amperes if :
the battery is below full charge state. Charging rate decreases as -
the battery charge state increases , so that a charge rate of less

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GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

L 1

---l;- Fluid Starting Aid 14. Frequency Meter


(Container and Pump) 15. Engine Hourmeter
2. Throttle Control 16. Push to Build-up Voltage Button
3. Idle Stop 17. Panel Release Cap Screws
4. Coolant Temperature Gage 18. Output Voltage Adjustment Screw
5. Oil Pressure Gage 19. Panel Light
6. Battery Charging Ammeter 20. Utility Receptacles
7. Starter Control 21. Circuit Breakers
8. Panel and Clearance Light Switch 22. Switch - Electric Throttle Control
9. Generator ON-OFF Pushbutton 23. Emergency Stop Switch
10. Red Pilot Lights 24. Electric Fuel Gage
11. Meter Selector Switch 25. Low Fuel Warning Light
12. AC Ammeter 26. Fuel Gage Pushbutton
13. AC Voltmeter
Control Box
Figure 1 i ~~
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e ; MOTOR GENERATOR DIVISION

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GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

than 10 amperes is normal for a new or fully charged battery.

NOTE: Charge the four batteries before putting them into service.
If the ammeter shows a discharge while engine is at operating
speed, it is likely an indication of a circuit malfunction.

(7) The starter control switch (7) controls the electric starting motor
and the air intake valve. The control bypasses the low oil pressure
engine shutdown switch' during starting, by use of the HOLD position.
When the switch is moved to START position the starter motor solenoid
is actuated causing the electric motor to crank the engine. When
the starter control switch is in HOLD or START position the air intake
valve solenoid is actuated permitting the engine to start. (See
Figure 2.) After oil pressure builds up the hydraulic latch holds
the air intake valve open.

Air Intake Valve Solenoid


Figure 2

(8) The panel and clearance light switch (8) controls operation of the ~
panel illuminating light (19) and the clearance (or marker) lights.

(9) The generator ON-OFF pushbutton (9) serves to actuate the load con-
tactors to connect or disconnect the generator output and the load.

(10) The red pilot lights (10) glow when the generator output is being de-
livered to the load.
~~-
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GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(11) The voltage and amperage of each phase can be read on the meters by
turning the meter selector sgch (11) handle to the phase indicated
on the nameplate. One position shows line-to-neutral voltages.

(12) The output current is indicated on the AC ammeter (12) whenever the
generator is loaded. Operation of the meter selector switch (11)
permits reading the current in each of the three phases. Load bal-
ance should be maintained for best operating characteristics and
least possibility of protective device nuisance tripping.

(13) The~generated 400-cycle output voltageis registered on the AC volt- '


_-
meter (13) after the initial turn-up and field-flashing procedures
have been completed. Line-to-line and single line-to-neutral voltage
may be read, as determined by the meter selector switch (11) position.

(14) The frequency meter (14) registers the output current frequency with-
in a range of 380 to 420 cps, as indicated by the reed with the
greatest amplitude of vibration. No-load frequency should be 385-
__I. 390 cps in manual throttle mode and 406-408 cps in automatic throttle
mode.

(15) The engine hourmeter (15) records the cumulative elapsed operating
time on the engine. Lubrication, periodic inspection, and preven-
tive maintenance schedules should be forecast and effected with re-
gard to the hourmeter records.

(16) The push-to-buildup voltage switch (16) is used during turn-up proce-
dures to flash the generator revolving fields. The engine, and thus
the generator, speed must have attained-approximately 80% of full
speed before this switch is closed in order for the circuit to func-
tion.

(17) The panel release cap screws (17) must be loosened to gain access to
the interior panel and the voltage regulator rheostat adjustment
screw.

(18) The output voltage adjustment screw (18), located behind the hinged
panel, serves to adjust the regulated generator output.

(19) The panel light (19) serves to illuminate the control panel.

(20) The utility receptacles (20) provide 115 volt, single phase, 400 cycle
current for operation of lights and/or small tools.

(21) The 20-ampere circuit breakers (21) limit the current drain on the
utility receptacles. I

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GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(22) The electric speed control switch (22) actuates a 6-volt solenoid
coil to set the governor throttle arm at a fixed position for auto-
matic full throttle control. When this switch is in the MANUAL posi-
tion, the hand throttle position determines the engine speed. The
automatic speed circuit will not function until the engine oil pres-
sure reaches 5 psi.

(23) In an emergency, break the wire seal on the emergency stop switch
(23) switch cover, lift the cover, and hold the switch in the UP
position until the engine stops. Holding this switch up energizes
a normally closed magnetic valve to release the oil pressure on the
oil pressure bellows, allowing the air flapper valve to close, and
stop the engine.

(24) The electrical Fuel gage (24) serves to indicate the fuel level in
the tank. The fuel level is indicated in l/4 tank increments. A
low fuel detector attached to the back of the gage senses the voltage
across a rheostat in the tank. When a predetermined level is reached,
(approximately 10% of tank level),-it-actuates a flashing pilot light.
t ---~-g- ~

1. Load ~~._.
Contactors 6. Undervoltage Timer
2. Current Limiting Resistors 7. Undervoltage Relay
3. Diode Panels 8. Overvoltage Relay
4. Plug Interlock (Control) Relays 9. Terminal Strips
5. Underfrequency Relay

Interior Panel
Figure 3

July 23168 l-3


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GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

The detector may be adjusted for other tank levels by turning an


adjustment screw on a potentiometer located on the lower right side
of the detector.

(25) The low fuel warning light (25) flashes to warn of a low fuel con-
dition.

(26) The fuel gage pushbutton serves to test the fuel level when the
engine is not running. When the pushbutton is depressed the indi-
cator gage is actuated and if the fuel level is low the warning
light will flash.

2. Interior Panel

A. Panel Location

(1) The interior panel (Figure 3) is located inside the control box on
the left front side of the unit.

B. Description of Interior Panel and Instruments

(1) The load contactors (1) one in each output circuit, are actuated by
the generator ON-OFF pushbuttons on the control panel (see paragraph
1, item 9) and serve to connect and disconnect the generator output
and the load(s). See trouble shooting chart VI.

I (2) The current limiting resistors (2) are loo-ohm, 25-watt resistors
which serve to prevent damage to the plug interlock relay contacts
should the phase "C" contacts of the load contactor fail to close
when the generator ON pushbutton is pressed.

(3) The diode panels (3) rectify a portion of the generator output to
supply the load contactor with approximately 90-volts DC when the
generator ON pushbutton is pressed, thereby closing the load con-
tactor(

(4) The plug interlock relays are energized by the transformer-rectifier


or battery circuits in the aircraft being serviced (connection is
made through extra wires E and F in the output cables). By this
interlock arrangement, the load contactors are held closed (after
the ON button is released) as long as the voltage returns from-t-he11
aircraft circuit. In the event the cables and aircraft circuits
are not properly connected or become disconnected, the load contac-
tors open. See trouble shooting chart VII.

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GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(5) The underfrequency relay (5) actuates to open the load contactors
when a condition of underfrequency (375 cycles or under), exists.
See trouble shooting chart VIII.

(6) The undervoltage timer (6) after being actuated by the undervoltage
relay, and after a 5-second delay, opens the load contactors. See
trouble shooting chart IX.

(7) The undervoltage relay (7) contacts close when the voltage of any
phase drops below 103 volts. This starts the undervoltage timer
which, after timing out, opens the load contactors.

(8) If the voltage of any phase exceeds 130 volts line-to-neutral, the
contacts of the overvoltage relay (8) open, opening the load con-
tactors. See trouble shooting chart X.

(9) Control wiring connections are conveniently made at the terminal


strips (9), simplifying voltage checks and ensuring against wiring
damage due to vibration.

3. Current Transformer Panel (See Figure 4 and regulated static exciter manual
lCZ-65D)

A. Description of Current Transformer Panel Parts

(1) The ammeter current transformers (1) sense the load current and
reduce it to a lower value of definite ratio, suitable for reading
directly on the ammeter.

Current Transformer Panel (Top View)


Figure 4
July 23168 l-3
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GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133


~~ --

(2) The line drop compensation transformers (2) sense any change in the
load current and apply this information to the static voltage
regulator sensing circuit where the relayed sensing current is used
by the regulator to compensate for the line drop.

(3) 'The filter capacitors (3) are used to by-pass to ground any radio
interference before it is transmitted along the 400-cycle output
cables.

4. Current Sensing Overload Panel (See Figure 5)

A. Panel Description

(1) This panel provides overcurrent protection in all three phases of


both output circuits ensuring that damage to the load and to the
generator will not result should an excessive overcurrent occur.
This panel should carry a minimum of- 231 amperes in any one phase
~_~~~~~~
-----;---
and should trip the appropriate relay (s) in the event of an over-
.. current (in excess of-25&%peres) lasting from 30-60 seconds.

1 9
I I II I ,
I I I I I
I I
I I
-----

1. Current Sensing Transformers


2. Current Sensing Relays
3. Terminal Strip
4. Overload Timer

Current Sensing Overload Panel


(Located beneath the control box)
Figure 5

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GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

5. Output Terminal Panel (See figure 6 and Schematic Diagram)

A. Output Panel Description

(1) There are two sets of output terminals, one set for each of the two
output circuits. The four large terminal posts in each set are for
load application and are marked N, A, B, and C. The "N' post is the
II
generator neutral. A II , "B", and "C" are the three phases of the
generator.

(2) Three-phase, 400-cycle voltage is obtained from the three posts A,


B, and C when the load contactor is closed. This voltage is 200
volts line-to-line when the unit is operating in proper regulation.

(3) Single-phase, 400-cycle, 115-volt power is available from N-A, N-B,


or N-C. Single-phase, 400-cycle, 200-volt power is available from
A-B, A-C, or B-C. The current on any phase, whether a 3-phase load
or combined single-phase and 3-phase load, must not exceed the cur-
rent rating of 462 amperes. Note that 462 amperes is the total cur-
rent rating, whether you are using one or both of the output cir-
cuits.

(4) Since the voltage regulator senses the average of the three line-to-
line voltages, a heavily loaded phase will drop in voltage, while
the unloaded phases will rise. Keep 3-phase loads balanced for best
regulation.

(5) The two terminal posts marked E and F in each set of output terminals
,are interlock terminal posts. Leads from aircraft utilizing plug
interlock circuits are connected to these posts. The leads connected
to "E" and "F" return 24-volt DC from the aircraft when the generator
output plug is plugged into the aircraft and the load contactor is
closed. The contactor will not remain closed unless the 24-volt DC
from the aircraft is being returned to the contactor.

Output Terminal Panel


Figure 6

July 23168 l-3


Page 9

.
FOBART
e E MOTOR GENERATOR DIVISION
z 5 HOBART BROTHERS COMPANY I
c 2
QD
480 $
. BAT

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

CHAPTER 1 OPERATING

SECTION 4 - OPERATING PROCEDURES

1. Operation As A Mobile Unit

For 'detailed truck operating procedures, consult the truck owner's manual.

CAUTION: THE OPERATOR MUST GUARD AGAINST DANGER TO HIMSELF AND THE POWER
UNIT WHEN MANEUVERING AMONG CABLES, ROPES, OR OTHER ZONES OF POSSI-
BLE LOW CLEARANCE, AS THE POWER UNIT EXTENDS ABOVE THE TRUCK-CAB.
WHILE FULLY MOBILE AND RUGGEDLY BUILT, THIS TRUCK HAS THE CONSID-
ERABLE WEIGHT OF THE POWER UNIT AT A HIGH CENTER OF GRAVITY, THERE- ~
FORE MUST NOT BE SUBJECTED TO VIOLENT STARTS, STOPS, OR TURNS AS
A MATTER OF SAFETY;

2. Preparing For Use

A. Preparation Procedure

(1) Once the unit is properly positioned, set the manual parking brake
on the truck, shut down the truck engine, open the side door panels
on the power unit canopy, and, if necessary, turn the panel and
clearance marker lights switch ON. Next proceed with the engine
prestart checklist outlined below:

WARNING: IF THIS SET IS TO BE OPERATED IN AN ENCLOSED SPACE FOR


OVER 5 MINUTES, CONDUCT THE DIESEL ENGINE AND/OR TRUCK
ENGINE EXHAUST OUTSIDE THE BUILDING. BOTH ENGINES DEVELOP
CARBON MONOXIDE WHICH CAN BUILD UP TO A POISONOUS LEVEL.
FAILURE TO OBSERVE THIS PRECAUTION INVOLVES RISK OF LIFE.

(a) Open the fuel line cutoff valve.

(b) Place the electric throttle switch in the MANUAL position.

(c) Check the entire electrical system to make sure all connections
are secure and correct.

(d) Make certain that there are no loose parts, tools, etc., on or
near the engine.

(2) After you are satisfied that the area and the unit are clear of
hazards, the engine may be started. Above all else, SAFETY is the
most important consideration regarding the operation of Ithis-ground
power unit.

I
July 23168 l-4
Page 1
MOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

3. Starting The Engine

A. Starting Preparation

(1) Before starting the engine, refer to the EOM and follow the lubri-
cating and pre-starting instructions contained therein.

B. Engine Starting Procedure

(1) Starting when engine is warm or air temperature is above 40'F.

(a) Pull the throttle control to its stop and observe that the idle
stop rests on the throttle rod.

(b) Turn the starter control knob to START position and hold until
engine starts.

CAUTION: DO NOT ENGAGE THE STARTER FOR MORE THAN 30 SECONDS AT


ATIME. IF THE ENGINE DOES NOT START DO NOT ATTEMPT
TO RE-ENGAGE THE STARTER UNTIL THE ENGINE HAS STOPPED
ROTATING, AS DAMAGE TO THE STARTER DRIVE MAY RESULT.
IF THE ENGINE DOES NOT START IN FOUR TRIALS, CONSULT
THE EOM TROUBLE SHOOTING SECTION.

(c) When the engine starts move the starter control knob to HOLD
position, and hold until oil pressure builds up.

(d) After the engine starts and oil pressure gage reads 25 psi,
release the starter control and return the throttle control
slowly to idle position against the idle stop.

(2) Starting when air temperature is below 40'F.

(a) Remove the cap of the fluid starting aid fluid cartridge con-
tainer and insert a starting fluid cartridge.

(b) Pull the piercing shaft knob fully out before replacing the cap.

(c) Push the piercing shaft knob down firmly to puncture the cap-
sule.

(d) Repeat steps (a) and (b) of procedure (1).

(e) Pull the air heater knob fully out and slowly push it back as
you hold the engine starter control knob.

(f) After start repeat steps (c) and (d) of procedure (1).

l-4 July 23168


Page 2
FOBARZ
B g MOTOR GENERATOR DIVISION
B HOBART BROTHERS COMPANY
c d
QD
b . m .,8

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(g) If the air heater knob is not returned to the completely IN


position, return it very slowly. Remove the capsule puncturing
container cap and remove the empty capsule. Replace the cap
and push the piercing shaft down until it stops.

(3) Preparation for Power Delivery

(a) Bring engine to full speed by pulling the throttle rod fully
out after allowing the engine to warm up at idle speed.

(b) Flash the generator revolving fields by pressing the "push-to-


build-up-voltage" pushbutton as the engine is accelerating.

(c) When the fields "build-up", the AC voltmeter should register


200 volts.

(d) When the frequency meter indicates 385 + 5 cps, place the elec-
tric throttle switch in the AUTOMATIC position; the frequency
meter should now read 406-408 cps.

4. Power Delivery (See Figure 1)

A. Power Delivery Procedure

(1) Before the generator can be set up for power delivery, the output
cable(s) must be connected to the aircraft receptacles.

(2) When ready to deliver power, press and hold the black ON button (9)
until the red pilot light(s) (10) come on, then release the ON button.
The generator is under load as long as the red pilot lights are on;
the AC ammeter (12) will show current drain while the load is on.
When both the light(s) and the meter indicate the set is under load,
check the frequency to be 400 to 408 cycles. Check that the voltage
holds at 200 volts. It is desirable that each generator phase be
checked for voltage output and for current load by use of the meter
-~
selector switch (ll), at this stage. The voltage output checks
should be made during a stabilized load condition.

NOTE: If the run is prolonged, it is advisable to check the water


temperature gage (4) and the oil pressure gage (5), occa-
sionally. Observe the DC ammeter (6) at the same time to see
that the DC generator is charging at a rate appropriate to the
battery condition. Check the air cleaner service indicator
if the red signal is in view the air cleaner filter must be
serviced. See the EOM air cleaner servicing section.

)(

July 23168 l-4


Page 3
,
HOBART i

QQ
I ~IMOTOR GENERATOR DIVISION
J HOBART BROTHERS COMPANY
% d
% . B &.

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

5. Stopping The Engine

A. Normal Engine Shutdown

(1) Any generator load must be removed by pressing the generator OFF
pushbutton, before the engine may be properly shut down. To stop the
engine-, make sure the idle stop is resting on the throttle rod, then
push the throttle rod in against the idle stop and place the electric
throttle switch in the MANUAL position; the engine speed will de-
crease to idle immediately. Allow a 3-5 minute cooling period before
raising the idle stop and pushing the throttle rod in to the cutoff
position.

CAUTION: DO NOT DISCONNECT THE OUTPUT CABLES FROM THE AIRCRAFT WHILE
POWER IS ON. BE SURE THE OUTPUT CABLES ARE PROPERLY STORED
BEFORE RELEASING THE TRUCK EMERGENCY BRAKE.

NOTE: Average lube oil consumption of the engine for 10 hours running
is 2-l/4 quarts per the manufacturer's data.

B. Emergency Stop Procedures

(1) Use this procedure ONLY if a significant, uncontrollable condition,


such as personal injury, fire, extreme electrical difficulties, or
eminent possibility of one of these dictates or warrants such action.
If the generator is loaded and time permits remove the load by pres-
sing the generator OFF pushbotton. Break the wire seal on the
emergency stop switch cover, lift the cover, then hold the switch in
the UP position until the engine stops.

l-4 July 23/68


Page 4
!
FoBART
QD
g MOTOR GENERATOR DIVISION

R.B.8
P
B 5 HOBART BROTHERS COMPANY
c z
c

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

CHAPTER 2 MAINTENANCE

SECTION 1 - SERVICING

1. Periodic Inspection Table

A. Generator Drive Engine

(1) Check any change in operating noise or smoothness at once and stop i
unit if change is abrupt or pronounced. Sudden change in engine
instrument readings normally indicates acute trouble requiring
immediate attention.

B. Daily'or 8 Hours

(1) Check fuel and lubricating oil level. Keep fuel tank filled to min-
imize condensation. Keep oil level full to prevent unnecessary
engine shutdown. Drain l/4 pint of fuel from fuel strainer and
filter (on right rear side of unit frame) to remove sediment and
water.

(2) Clean the air cleaner dust cup (on left center portion of power
unit). Check filter service indicator. If red flag appears, service
the air cleaner.

(3) Observe operation of engine and electrical instruments. If any


excessive or unusual noise is heard or abnormal operation observed,
stop the engine and check for cause of abnormality.

C. Weekly or 25 Hours

(1) Check electrolyte levels; refill batteries if required.

(2) Check engine coolant level (and antifreeze strength, when appli-
cable); refill as required.

(3) Inspect condition of output cables. Cable insulation must not be


broken and connections to the output terminals must be tight.

D. Tri-Monthly or 300 Hours

(1) Check the undervoltage relay tripping characteristics (Chapter l-3,


2B 7).
--
(2) Check the undervoltage time delay relay characteristics (Chapter
l-3, 2B 6).
--

July 23168 2-l


Page 1
FOBART

QD
e I MOTOR GENERATOR DIVISION
z z HOBART BROTHERS COMPANY
0 E
464 P
* BAI

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(3) Check the underfrequency relay tripping characteristics (Chapter


l-3, 2B 5).

(4) Check the overcurrent sensing panel tripping characteristics


(Chapter l-3, 4A).

(5) Check the engine overspeed governor tripping characteristics per


engine operator's manual.

(6) Check the 15 psi low oil pressure tripping characteristics. With
throttle idle stop raised, slowly push in throttle until engine oil
pressure drops below 15 psi.

(7) Check the low fuel warning system. The warning light should flash
when the fuel level drops below 10%.

(8) Check overvoltage relay tripping characteristics (Chapter l-3, item


8).

(9) Check the water temperature device tripping characteristics. The


device trips when temperature exceeds 205'F.

(10) Change fuel filter and strainer elements.

E. Six Months or 500 Hours

(1) Ensure fan belts have 3/4-inch deflection from a straight line over
outer diameter of pulleys. Check coolant hose;-condition.

(2) Drain water and sediment from fuel tank.

(3) Check overspeed governor for proper operation.

(4) Lubricate the engine starter oilers with 5-6 drops of engine oil.

(5) Clean complete unit, tighten all hardware, inspect wiring for good
condition and solid connections, examine for cracks, broken welds,
and deformation.

(6) Bearing noises may be detected by placing one end of a metal rod or
large screwdriver against the bearing housing and placing the ear
against the other end of the rod or screwdriver while the generator
shaft is rotating. If the bearing is found defective, replace it.

2-l July 23168


Page 2
GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(7) Check the 400-cycle generator slip rings for roughness, pitting, or
dirt. Clean slip rings with an abrasive pad formed of heavy canvas,
held against the slip ring with a stick. For repair of roughness or
pitting see overhaul section. Replace the brushes if they have worn
to 3/4-inch or less.

F. Yearly or 1000 Hours

(1) Clean radiator with radiator cleaning compound per directions on


compound package.

(2) Remove radiator shroud side panels and blow out excessive dirt behind
radiator.

(3) Clean air box drain tubes.

2. Lubrication

A. Engine Oil (Consult EOM recommendations)

B. Truck Engine and Chassis (See truck owner's manual)

3. Air Cleaner Servicing and Cleaning

A. Servicing

(1) The air cleaner should be inspected frequently. A damaged air


cleaner can seriously affect the performance and life of the engine.
The following simple service steps are easily made while the engine
is being serviced in the field.

(a) Check all connections for mechanical tightness. Be sure clean-


er outlet pipe is not fractured.

(b) If cleaner has been dented or damaged, check all connections


immediately.

(c) In case of leakage and if adjustment does not correct the


trouble, replace necessary parts or gaskets.

(2) 1The Donaldson dry air cleaner used on this unit employs both a dry,
paper filter and a centrifugal pre-cleaner. The pre-cleaner fins
give high speed rotation to the intake air, separating a large por-
tion of the dust from the air by centrifugal action, after which,
the dust is carried into the dust cup. The dust cup should be ser-
viced daily. The small portion of the dust remaining in the pre-
cleaned air is removed by the filter element.

July 23168 2-l


Page 3
rOBART

QD
e iMOTOR GENERATOR DIVISION
z :: HOBART BROTHERS COMPANY
% 2
4Q. gAJ-

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

B. Cleaning

(1) Direct dry, clean air up and down pleats on the clean air side of
the Duralife filter.

CAUTION: AIR PRESSURE AT NOZZLE MUST NOT EXCEED 100 PSI. MAINTAIN
REASONABLE DISTANCE BETWEEN NOZZLE AND DURALIFE FILTER.

(2) Wash the filter with 2 ounces of Donaldson D1400 Filter Cleaner
mixed with 1 gallon of warm water (appr. lOOoF). For best mixing
results, use a small amount of cool water, add the cleaner, then
add warm water. Soak the filter in the cleaning solution for 15
minutes. Rinse the filter thoroughly with clean water, then air
dry the filter completely before reuse.

CAUTION: WATER PRESSURE USED FOR CLEANING .__.


MUST NOT EXCEED 40 PSI.

(3) After cleaning and drying the filter, inspect for damage by placing
a bright light inside the filter. Slightest rupture requires
replacement of filter.

NOTE: Reassemble in reverse order of disassembly for servicing. If


air cleaner is horizontally mounted, be sure dust cup is posi-
tioned so arrows point up.

CAUTION:DO NOT USE OIL IN DUST-CUP.


_
4. Throttle Linkage Adjustment i

A. Speed Settings

(1) If, for any reason, the engine speed, either manual or automatic, is
altered, the following steps must be taken to reset the speed to the
original values. See figure 1.

(2) With the electric throttle switch in the MANUAL position, and the
throttle rod pushed in against the idle stop on the control panel,
set the idle-speed at 700-800 rpm. To make this adjustment, loosen
the set screw on the governor throttle arm (1) and adjust the screw
in the top center of the arm until the idle-speed is correctly set
(it may be necessary to adjust the stop nuts on the idle adjusting
rod (2) to finish this adjustment).

NOTE: After the idle-speed is set, the remainder of the linkage


adjustment is based on the control panel frequency meter
indications.

2-l July 23168


Page 4

: / :
GENERATOR DIVISION I
HOBART BROTHERS COMPANY I

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

,,. f---

, Throttle Linkage Adjustment


Figure 1

(3) To set the throttle for full speed with automatic throttle control,
first observe the frequency meter indication with the electric
throttle switch in the AUTOMATIC position; it should read 406-408
cps, no load. Next, place the switch in the MANUAL position and
idle the engine (to make the speed adjustment, it is not necessary
to idle the engine, but noise and vibration are not as great at
idle speed as they are at full speed). Proceed with the adjustment
in this manner: Back off the nut locking the plunger stud (3).
Placing a wrench on the stud flat, turn the stud a few turns in
either direction, then place the electric--throttle
_- ~~. switch in the
AUTOMATIC position (throttle rod must be extended to its full speed
stop) and again observe the frequency meter indication. If the
frequency is correctly set, lock the plunger stud in place with the
nut previously loosened. If the frequency does not read 406-408
cps, repeat the plunger stud adjustment until the correct frequency
is obtained. Do not forget to lock the stud in place once the ad-
justment is completed. After the "automatic" full speed is set,
adjustment of the "manual" full speed throttle setting may be
performed.

July 23/68 2-l


Page 5
HOBART
e a MOTOR GENERATOR DIVISION
I HOBART BROTHERS COMPANY
I
QD
0
B- q,+*2 .____- . ..-

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(4) The "manual" full speed adjustment may be made after the idle and
"automatic" full speed settings have been corrected. To set the
"manual" full speed, the electric throttle switch must remain in
the MANUAL position. Pull the throttle rod out --
to-its full speed
stop and observe the frequency meter; it should read 385 25 cps,
no load. If the frequency is not correct, loosen the set screw
on the throttle stop clamp (4), move the throttle rod in or out
as required until the frequency meter indicates 385 55 cps, and then
lock the throttle stop clamp against the throttle control (guide
tube).

(5) After completing the throttle linkage adjustment, recheck the idle
speed and the "automatic" and "manual" full speed settings. As a
final check, allow the engine to idle long enough to cool the valves
and pistons, then lift the idle stop and push the throttle rod in
to the SHUTDOWN position; the engine should stop.

July 23168 _
___~
FOBARZ
e +OTOR GENERATOR DIVISION .
a 2 /
E
HOBART BROTHERS COMPANY

1 QD
64. . ..B I

-~GPU 400 CYCLE 160 KVA TRUCK MOUNTB TM-133-l

CHAPTER 2 MAINTENANCE

SECTION 2

.-

Control Panel
Figure 1

CHART1

TROUBLE PROBABLE CAUSE REMEDY

Voltmeter reads zero when Voltmeter circuit is open Check voltage to the load
the voltage buildup push- contactor input; if
button is pressed (it present, replace the volt-
should, show approximately meter. If the meter
100 volts, then advance still reads zero volts,
immediately to 200 volts) check the complete meter
circuit and replace,the-
defective wiring or part.

If voltage is not present


at the load contactor,
check for battery voltage
into the static exciter
while holding the voltage
build pushbutton in; if
no voltage present,
locate open in the bat-
tery - to - exciter
circuit.

July 23168 2-2


Page 1
FOBAI??
P $lOTOR GENERATOR DIVISION
z 9 HOBART BROTHERS COMPANY
c 2
+e*
QD. m,8

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

TROUBLE PROBABLE CAUSE REMEDY

If the DC voltage is
present at the exciter
in the test above,
check for DC voltage
to the slip rings with
the buildup button
pressed in; if none,
refer to the static
exciter manual.

If DC voltage is present
at the slip rings in the
test above, disconnect
external leads to the
slip rings and check for
open or shorted circuit.

If still no voltage,
check for worn brushes
or very weak brush
spring, then check for
dirty slip rings.

Voltage kicks, but Faulty static exciter Refer to the regulated


falls to zero static exciter manual,
lCZ-65D.

Faulty slip rings or Check and correct


brushes faulty parts.

Voltage rises, but the Incorrect engine speed Adjust the engine speed
voltmeter does not read to obtain the correct
200 volts reading on the frequency
meter.

If the engine speed is


correct, adjust the
regulator rheostat across
the range of 165-240
volts. If the rheostat
is not in control consult
the regulated static
exciter manual.

1
2-2 July 23168
Page 2
----I

, I
.~
GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

CHART11

TROUBLE PROBABLE CAUSE REMEDY

One or both pilot lamps Open bulb filamentT Repair or replace as


fail to come on when the socket, or wiriiig required.
generator pushbutton is
pressed to close the load No voltage into load con- Check for go-volt DC into
contactors. (If just one tactor coil(s) or the Xl and X2.of the load
output cable is in use, coil(s) is defective contactor( if voltage
both pilot lamps should is present, coil(s) is
flash when the ON button (are) defective. If no
is pressed, but only the voltage at coil(s), check
pilot lamp for the cir- for 115-volt AC at the
cuit in use should re- AC terminals of the
main on after the ON diode panel(s).
button is released.
When the aircraft Generator ON pushbutton Check for continuity
being serviced has a defective or protective throughout the con-
transformer-rectifier, circuit has operated to tactor coil holding
the pilot lamp glows prevent closing the load circuit.
only when the load con- contactors (only if both
tactor has closed. When pilot lamps remain off,
the aircraft has a bat- may the protective system
tery, the pilot lamp will be suspected)
glow when the ON button
is pressed, but will re-
main on only if the con-
tactor remains closed.

Pilot lamp comes on A protective device has Check for open contacts
briefly, but goes out operated to open the load in one of the protective
within 1-15 seconds contactor relays. Correct the
faulty power condition
that prompted the relay
to open.

CHART III

One or both pilot lamps ~-. One of the overcurrent Aircraft load is exces-
go off with a load applied sensring-relays open sive; reduce the load.
to the generator: Ammeter
zeros (Load contactor Output cable is shorted
has (have) opened; engine or grounded; repair or
is still running; replace the cable (s) as
voltmeter reads 200 volts) needed to remove the
fault.

2-2
Page 3
FOBART
-,MOTOR GENERATOR DIVISION
I 8
B :: HOBART BROTHERS COMPANY
c 2
QD
4## e+
* BAT

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

TROUBLE PROBABLE CAUSE REMEDY

Relay too sensitive;


replace with a less
sensitive relay if the
load is normal and the
output cables are good.

One of the protective Determine and remedy


relays on the interior the power fault. If a
panel opens protective relay remains
open after the fault has
been corrected, replace
the relay.

CHARTIV

(MISCELLANEOUS GENERATOR PROBLEMS)

Generator noisy Loose drive coupling Tighten the flexible


coupling mounting bolts
and set screws.

Armature rubbing the Determine the cause and


stator correct. Determine ex-
tent of damage to arma-
ture and/or stator and
repair or replace as
necessary.

Defective bearing Replace the bearing.

Generator overheats Poor ventilation Provide adequate venti-


lation.

Overcurrent sensing cir- Replace the defective


cuit defective current transformer or
sensing relay.

Short circuit in either Check the generator out-


the load or the put cables, and the load
generator for shorts; repair or
replace defective
component.

2-2 July 23/68


Page 4
GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

TROUBLE PROBABLE CAUSE REMEDY

No voltage or current Output cable or load Repair or replace the


in one of the three contactor is open in defective item.
phases (single-phase one phase
condition)'

One phase of the stator Shut down the unit and


is defective check the generator
stator for continuity.
If the stator is inter-
nally defective, the
unit must be sent to an
overhaul facility for
replacement of the stator.

CHARTV
(See Figure 1)

No hour meter reading Poor ground, open circuit Clean and tighten ground
lead.

Oil pressure switch bad If the switch is open a-


bove 5 psi, replace it.

Meter bad If meter does not work


with voltage present, jar
it with palm of hand.
If this does not start
meter, replace it.

No frequency meter May be out of range Adjust engine speed thru


reading meter range.

Open circuit to meter Repair.

Meter faulty Replace meter.

~Wrong voltage or amperage If low or no voltage (or If no power to switch,


~reading. (Note: A to N amperage) is shown, see if trouble is in generator
lmeter switch position voltage (or amperage) is or exciter. If okay to
:gives no ammeter present up to the meter switch, locate open to
reading.) selector switch meter. If okay to meter,
replace the meter.

2-2
Page 5
GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK ECUrJTED-TM-133

TROUBLE PROBABLE CAUSE REMEDY

Wrong voltage or amperage Sticking needle If tapping the meter


reading (Note: A to N does not free the needle,
meter switch position replace the meter.
gives no (ammeter
reading.)
~~~~ (Cont'd.)

,'No~ammeter reading in Open in ammeter circuit Check continuity from


one phase (voltage current transformer
okay) through switch to am-
meter. Check for cor-
rect connections.

Voltage cannot be ad- Rheostat circuit open Check continuity of cir-


justed across the range cuit and through rheo-
~ 165-240 volts stat.
I
Static exciter faulty Consult exciter manual.

Panel light out Bulb burned'out Replace bulb.


(switch ON)
Open circuit Trace circuit through
switch to bulb. Locate
and repair the open
circuit.

Generator on-off switch Loose, broken, or Locate and correct.


faulty stuck connections

Dirty contacts Sand lightly to clean.

i Hand throttle stiff Bent wire Pull out to clean and


coat with graphite.
No control when the elec- Broken wire in holding Check continuity of 24-
tric throttle switch is in coil circuit of electric volt circuit to the
the AUTOMATIC position solenoid solenoid.

Defective lube oil pres- Replace lube oil pres-


sure switch (switch set at sure switch.
5 psi) mounted in back of
the oil pressure gage

Engine stops when start Air shutdown valve has Starter control must be
switch is released closed. Starter control held in START position
was not held in START until oil pressure
position long enough for reaches 15 psi.
oil pressure to build up
sufficiently
2-2 July 23168
Page 6
QQ
8 ; MOTOR GENERATOR DIVISION
3
d
HOBART BROTHERS COMPANY
0
I
*;* . ,,R

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

TROUBLE PROBABLE CAUSE REMEDY

Engine stops when start Low oil pressure Locate cause and correct.
switch is released
Cont'd

Electric'fuel gage does Open circuit Trace circuit through


not register the meter to sending
unit. Repair the cir-
cuit.

Defective sending unit Repair or replace.

Defective lube oil pres- Replace lube oil pres-


sure switch (switch set at sure switch.
5 psi) mounted in back of
the lube oil pressure gage

Low fuel level warning. Bulb burned out Replace bulb.


light out (with less than
10% fuel level remaining) Open circuit Trace circuit through the
bulbl,to the sensor.

Defective sensor Replace.

Defective lube oil pres- Replace the switch.


sure switch (switch set at
5 psi) mounted in back of
the lube oil pressure gage

CHART VI

(LOAD CONTACTOR)

Load contactor won't No voltage at Xl and X2 Check voltage at recti-


close (see schematic) when push- fier, check output of
button is pushed rectifier.

-Contactor closes but only Contactor burned out Replace.


2 of-':3phases supplying
voltage

July 23168
Page 7
FOBART

QQ
$MOTOR GENERATOR DIVISION
e
a HOBART BROTHERS COMPANY
c I
I
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GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

NO.

XI x2

CHART VII

(INTERLOCK CONTROL RELAY)

TROUBLE PROBABLE CAUSE RBMBDY

Coil will not cause Open coil Check across Xl and X2


relay to close for open (machine down).
See schematic. Repair
open circuit.

No voltage (28 volts DC Determine cause of no ~


-~---7
from aircraft) voltage from aircraft and
correct as necessary.

Contacts Cl and C2 do not Burned out Replace relay.


close.' See schematic

2-2 July 23168


Page 8
~~ ~~~

~MOTOR GENERATOR DIVISION


HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

CHART VIII

(UNDERFREQUENCY RELAY)

TROUBLE PROBABLE CAUSE REMEDY

Will not close under nor- Defective relay Replace relay.


mal voltage and frequency

Trips even though speed Defective relay Replace relay.


is normal

CHARTIX

(TIME DELAY RELAY)

Timer contacts stuck Defective relay Replace relay.


"open" or "closed"

Heat element open Defective relay Replace relay.

/
July 23168 2-2
Page 9
-.____~-
-___-..__
GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133
CHARTX

(OVERVOLTAGE RELAY)
(See Schematic)

TROUBLE PROBABLE CAUSE

Inoperative relay Contacts stuck "open" or Replace relay.


"closed"

9 0

-2-5/B ___r

i
I
f------w
TOP BOTTOM
DECK DECK
\ _ ,'.
\\ _-'
'-_, /-
-.
---'.
----.__---

July 23168
.-
GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

CHAPTER 3 - OVERHAUL

SECTION 1

1. Disassembly Inspection and Repair

A. '
Truck

(1) Consult truck owner's manual. For major overhaul procedures, contact
truck dealer or representative.

B. Diesel Engine

(1) Consult the General Motors operator's manual and parts book. For
major overhaul, contact a GM-service depot or a factory representa-
tive. -

I I
Canopy Removal
Figure 1

1
July 23/68 3-l
Page 1
-8

---
GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

C. Regulated Static Exciter

(1) Overhaul instructions for the regulated static exciter are furnished
in a separate manual, lCZ-65D, shipped with this generator set.
--
NOTE: Personnel assigned to this work must be qualified in the fieldr
~~_-
of electronics.

D. Canopy

(1) Disassembly (See Figure 1)

(a) Unlatch and remove doors from hangers.

(b) Remove radiator cap.

(c) Remove nuts and washers from lifting eye, pull the lifting eye
up out of the lifting yoke but not through the canopy top. Re-
install nuts and washers on the lifting eye directly under the
canopy top.

(d) Remove mufflers and attaching parts.

(e) Disconnect and remove clearance lights.

(f) Remove attaching parts from end panels at base.

(g) Attach hoist to lifting eye, lift the canopy and store in a
clean area.

(2) Inspection and repair.

(a) Inspect doors, handles, latches, and cams, repair or replace dam-
aged parts, clean doors and parts with a clean cloth moistened
with a suitable solvent.

(b) Inspect end panels and canopy top for cracks, dents, and areas
where paint has been removed. Repair damaged areas using stand-
ard sheet metal practices. Remove rust and/or dirt from damaged
areas and apply rust preventive paint.

(c) Inspect exhaust system pieces and replace if damaged.

E. Cooling System

(1) Disassembly (See Figure 2 "A" and "B")

(a) Drain cooling system.

3-l July 23168


Page 2

--
i
/ I
FOBART
iMOTOR GENERATOR DIVISION
e
x ; HOBART BROTHERS COMPANY

QD
0
cQ. aAI+*

400 CYCLE 160 KVA TRUCK MOUNTED TM-I.33


-

Cooling System
Figure 2A

Cooling System
Figure 2B

3-l
Page 3
GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(b) Remove radiator hoses and pipes.

(c) Remove fan guard and radiator shrouds.

(d) Attach hoist lifting hooks under extension of flange at top of


radiator side panels.

(e) Remove radiator attaching bolts from frame.

(f) Lift radiator with hoist.

(2) Inspection and Repair

(a) Clean by reverse flushing.

(b) Inspect for clogged tubes, cracked, bent, or corroded parts.

(c) If excessive solid deposits are present, dismantle the radiator 1


and clean by passing a metal rod through each core tube.

(d) Clean corroded parts and paint with corrosion resistant paint. (I

NOTE: It is necessary to use all new gaskets to reassemble the


radiator.

(e) Reassemble the cooling system, inspect the pressure cap to


ensure that it will maintain proper coolant pressure.

F. Superstructure Group

(1) Removal (See Figure 3)

Superstructure Group
Figure 3
,' 1
3-l July 23/68
Page 4
___~ ~~
FOBART
e ;MOTOR GENERATOR DIVISION ~ ~
I
E
HOBART BROTHERS COMPANY
8
QD
*c
Q. Ba++

GPU 400 CYCLE 160


~~ KVA TRUCK
~~~~~~ MOUNTED -T&i:133
~~ ~~

(a) Remove all leads from output term panel; remove ground lead
from stator housing.

(b) Remove attaching hardware and remove the panel.

Disconnect all engine control leads at the engine which run from
engine to control panel. Remove oil pressure hose, quick start to
air intake valve tubing - starter leads. Remove leads from stator
to current transformer panel (at panel). Remove hold down connecting
bars from top of panels. Remove attaching bolts and lift ~~
Control
~___~
Panel and Current Transformer Panel off together.

(3) Remove all leads from front of Regulated Static Exciter panel. Re-
move bolts and lift panel from frame. See Figure 4.

#II.

Regulated&Static Exciter
Figure 4

(4) Remove connections from ballast resistors and remove the resistor
panel.

(5) Disconnect air tubing from Air Cleaner Tank then 4 bolts and remove
the tank. See Figure 5.

(6) Disconnect support from frame (six bolts). Remove bolts from lifting
yoke to frame (eight bolts). Remove support and yoke - leaves gen-
erator completely accessible.

July 23168 3-l


Page 5
-
MOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

Air Cleaner Tank


Figure 5

G. AC Generator

(1) Remove the generator (See Figure 6)

Generator Removal
Figure 6

3-l July 23168


Page 6
FOBART
: iMOTOR GENERATOR DIVISION
a HOBART BROTHERS COMPANY
8 i
QD
+Q 6
- BAT
~ .____ -..- ~~ - ~~
GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(a) Remove six large bolts holding generator to base.

(b) Remove screws from engine brackets and lift engine at generator
end. Tilt engine until generator mounting brackets are at __
least one inch off the frame. Put blocks under engine fly:
wheel housing mounting brackets.

(c) Remove screen from fan housing.

(d) Remove screws from fan to flex coupling.

(e) Remove screws attaching generator housing to engine casting.

(f) Attach hoist to generator housing and lift generator from base.

CAUTION: BEFORE REMOVING THE FLEX COUPLING AND HUB, MARK POSI-
TION OF HUB FLANGE AND FLEX COUPLING AS SHOWN IN
FIGURE 7 ENSURE REASSEMBLY AS ORIGINALLY BALANCED.

(g) Remove set screws from coupling.

-
Balance Mark Removing Bushing
Figure 7 Figure 8

July 23168 3-l


Page 7
iMOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(h) Use the set screw to push the bushing out of the hub by insert-
ing it in threaded holes provided on the bushing side of the
hub. See figure 8.

NOTE: When the bushing is free of the hub it should loosen


enough to be pulled from the shaft by hand. If not, the
use of a screwdriver forced into the expansion slot will
loosen the bushing.

(i) Remove fan.

(j) Remove fan housing.

(k) Remove all brushes.

(1) Pull armature out of stator.

CAUTION: WHEN REMOVING ARMATURE USE WOOD BLOCKING TO MAKE


SURE SHAFT DOES NOT DROP DOWN ON STATOR WINDINGS.
~~~
~~
~~
(2) Clean and inspect armature

(a) Remove all dust and dirt with compressed air and mineral
spirits (Stoddard Solvent).

(b) Check armature for grounds using an ohmmeter.

(c) Clean the stator with compressed air and mineral spirits
(Stoddard Solvent).

(d) Check stator windings for opens and shorts.

(e) Check bearings and replace if worn or damaged.

(3) Reassembly

CAUTION: MAKE SURE ARMATURE AND STATOR ARE COMPLETELY DRY BEFORE
REASSEMBLING.

(a) Attach hoist straps around center of armature and around arma-
ture shaft at engine coupling end.

(b) Lift armature and align with stator.

(c) Slide armature carefully into stator as far as possible with


hoist attached.

I
*.--
3-l- July 23168
P.age 8 i
GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

(d) Place block under armature, remove hoist, and slide the arma-
ture completely into place.

(e) Install new brushes in brushholder.

(f) Inspect flex coupling flexible inserts and replace if deter-


iorated.

(g) Replace fan housing.

(h) To ensure proper alignment of the armature, move the armature


forward or back by using a heavy soft faced mallet, until the
brushes ride on the center portion of the slip rings. See
figure 9.

Armature Alignment
Figure 9

(i) Reassemble the taper-lock bushing in the hub and secure by


tightening the set screws.

(j) Attach the flex coupling to the hub with 8 screws.

CAUTION: MAKE SURE THE BALANCE MARKS ON HUB FLANGE AND ON THE
FLEX COUPLING ARE ALIGNED.

.. _

i:
MOTOR GENERA
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160...~__~


KVA TRUCK
~.____MOUNTED TM-133
-__-.-~

(k) Attach the fan to the flex coupling with 2 bolts and nuts. See
figure 10.

Assembling Coupling
Figure 10

(1) Loosen the bushing set screws, insert a screwdriver blade in the
bushing slot to open the bushing enough to start the assembly
onto the generator shaft.

flywheel to the
rface. See

Flywheel Measurement
Figure 11
3-l July 23168
Page 10

,,
Ti
$/MOTOR GEhlERATOR DIVISION
HOBART BROTHERS COMPANY

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133.

(n) Tap the flex coupling in place on the generator shaft with a
soft face mallet. Measure from the face of the generator
housing attaching surface to the end of the flexible mount
using the exact measurement taken in step (m). See figure 12.

Coupling Measurement
Figure 12

(0) Tighten the taper-lock bushing set screws to a torque value


of 67 Ft. Lbs. See figure 13.

Tightening Bushing
Figure 13

July 23168 3-l


Page 11
__--
GENERATOR D
HOBART BROTHERS COMPANY

GPU CYCLE 160 KVA TRUCK MOUNTED TM-133

(p) Tighten the 8 screws attaching the flex coupling.to the hub and
secure with safety wire. See figure 7.

(q) Remove the nuts from the two fan mounting screws and push the
remaining 8 screws through the fan and through the flex
mountings.

3-l July 23168


Page 12
I./~ x- ,- W,%.

-----4 1
$.lOTOl? GENERATOR DIVISIONa; ,
,
HOBART BROTHERS COMPANY

/
,.
-----_

GPU 400 CYCLE 160 KVA TRUCK MOUNTED TM-133

CHAPTER 3 - OVERHAUL

SECTION 2

2. Reassembly

A. <Generator

(1) Lift generator with hoist and lower carefully into place on frame.

(2) Attach generator housing to engine casting, 12 screws.

(3) Insert screws through fan and flex coupling into the engine flywheel,
tighten securely.

(4) Reinstall fan guard.

(5) Secure generator to frame with six bolts and tighten the bolts.

(6) Remove lifting eye from top of generator housing.

B. Lifting Yoke and Support Assembly

(1) Place lifting yoke and support assembly on the frame. Replace bolts.

C. Superstructure Group

(1) Attach control panel, current transformer panel, ballast resistors,


regulated static exciter, and output terminal panel to the super-
structure.

(2) Reconnect all electrical and other control leads.

(3) Install the air cleaner tank and connect all tubing.

D. Cooling System (See 3-l Figure 2A)

(1) Lift the radiator into place with hoist, attach to frame.

(2) Install fan guard and radiator shrouds.

(3) Attach radiator hoses and pipes. ,

(4) Fill radiator with distilled or mineral free water, (approximately


13 gallons).

July 23168 3-2


Page 1

/--
i
TOR DIVISIO

-
GPU -400
~~~CYCLE 160 KVA TRUCK MOUNTED TM-133

E. Canopy

(1) Remove radiator cap.

(2) Lift canopy with hoist and lower it carefully into place on the
G.P.U.

(3) Install all attaching hardware on canopy and end panels.

(4) Install mufflers.

(5) Attach and connect clearance lights.

(6) Replace the radiator cap.

(7) Install and latch canopy doors.

F. Operational Check

(1) Start the engine, (Ref. l-4, paragraph 3B).

(2) Check generator operation.

(a) Ref. l-4, paragraph 3B (3).

(b) After the engine warms up and the generator output shows normal
in step (a), connect 24 volt leads from engine battery or any
24 volt DC source to terminal posts E and F on the Output
Terminal Panel, (Ref. l-3, Figure 1). The system is a negative
ground type, connect ground lead from battery to the GPU frame.
Plug output cable into a load bank and simulate a normal load,
all meters and equipment should operate as noted in l-4, para-
graph 4A.

(c) If the unit does not operate normally, trouble shoot as shown
in Chapter 2, Section 2.

/
3-2 July 23/68 '
Page 2
~______