Engine-Driven Generator Set Operation Manual

OM-2037
113091
042793
OPERATION AND MAINTENANCE

MANUAL
with
ILLUSTRATED PARTS LIST
for
ENGINE-DRIVEN GENERATOR SET
SPECIFICATION NUMBERS
6919A and 6919B
For Truck or Trailer Mounting

MODEL No. 90J20
90-KVA, 400-HZ, 115/200-V AC, 3-PHASE
with
JOHN DEERE DIESEL ENGINE

TYPE 6059TL
(Turbocharged)
Hobart Brothers Company

Airport Systems Group
Ground Power Equipment
Troy, Ohio 45373
U.S.A.
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OM-2037
INTRODUCTION
This manual contains operation and maintenance information for four series of 400-Hertz generator sets
manufactured by Hobart Brothers Company, Power Systems Group, Troy, Ohio 45373.
This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics who have never seen
or operated this equipment. It is the intent of this manual to guide and assist operators and maintenance
people in the proper use and care of the equipment.
Use of the manual should not be put off until a trouble or need for help develops. Read the instructions
before starting the unit. Learn to use the manual and to locate information contained in it. Its style and ar-
rangement are very similar to commercial aircraft manuals. The manual is divided into six chapters.
Each chapter is divided into as many sections as required. Each new section starts with page 1. Each
page is identified by chapter, section and page number, which are located in the lower, outside corner.
When information located in another portion of the manual is referred to, its location is identified by a chap-
ter, section, and paragraph, or figure number.
For example, “(See 2-3, Para. B)” refers to information located in Chapter 2, Section 3, Paragraph B. If a
Chapter and Section are not indicated in a reference, the referenced material is located in the same sec-
tion as the reference, Example, (See Para. B).
In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chap-
ter 4, and a collection of manufacturer’s literature and supplemental information in Chapter 6.
Content of the manual is arranged as follows:
Chapter 1. Description/Operation
Chapter 2. Servicing
Chapter 3. Troubleshooting
Chapter 4. Illustrated Parts List
Chapter 5. Optional Equipment
Chapter 6. Manufacturer’s Literature
November 30/91 Introduction

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Introduction November 30/91

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Table of Contents
SUBJECT CHAPTER/SECTION PAGE
WARNING
INTRODUCTION
Section 1. Description 1-1 1
1. General 1-1 1
2. Orientation 1-1 1
3. Special Features 1-1 1
A. Protective Monitor 1-1 1
B. Voltage Regulator 1-1 2
C. Electric Governor 1-1 2
4. Canopy 1-1 2
5. Optional Equipment 1-1 2
6. Engine, Generator, and Controls Assembly 1-1 2
A. Basic Engine 1-1 2
B. Engine Manufacturer’s Equipment 1-1 2
C.Hobart Engine Equipment 1-1 5
(1) Electric governor system 1-1 5
(a) Magnetic pickup 1-1 5
(b) Control unit 1-1 5
(c) Actuator 1-1 5
(2) Engine electrical system 1-1 5
(3) Engine protective devices 1-1 5
(a) High coolant temperature switch 1-1 5
(b) Oil pressure switch 1-1 5
(4) Air cleaner 1-1 7
(5) Exhaust system 1-1 7
(6) Radiator 1-1 7
D. Generator 1-1 8
E. Control Box Assembly 1-1 9
(1) Front Panel 1-1 9
(a) Generator output monitors (meters) 1-1 9
(b) Meter and line switches 1-1 9
(c) Instrument light 1-1 9
(d) Indicating lights 1-1 9
(2) Control box internal components 1-1 11
(a) Sensing modules 1-1 11
(b) Memory and time delay module 1-1 11
(c) Excitation-deenergization relay 1-1 11
(d) Plug-interlock relay 1-1 12
(e) Test-bank switch 1-1 12
(f) Resistor 1-1 12
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(g) Fuse-interlock relay 1-1 12

(h) Auxiliary underfrequency relay 1-1 12
(j ) Terminal boards 1-1 12
(k) Solid-state voltage regulator 1-1 12
(l) Overload module 1-1 12
(m) Rectifier 1-1 12
F. Engine Control Panel (See Fig. 8) 1-1 14
(1) Engine instruments 1-1 14
(a) Ammeter 1-1 14
(b) Temperature gage 1-1 14
(c) Oil pressure gage and oil pressure switch 1-1 14
(d) Hourmeter 1-1 14
(e) Fuel gage and blocking diodes 1-1 14
(2) Engine and generator controls 1-1 15
(a) Engine-generator control switch 1-1 15
(b) Contactor control switch 1-1 15
(c) Instrument light and switch 1-1 15
(d) Engine starting circuit 1-1 15
(e) Indicating lights 1-1 15
(f) Fuse 1-1 15
G. Load Contactor Circuit Components 1-1 17
(1) Load contactor 1-1 17
(2) Current transformers 1-1 17
(a) Ammeter current transformers 1-1 17
(b) Line-drop current transformers 1-1 17
(c) Overload current transformers 1-1 17
(3) Overload module 1-1 17
(4) Rectifier 1-1 18
Section 2. Preparation For Use,

Storage, Or Shipping 1-2 1
1. Preparation for Use 1-2 1
A. Inspection/Check Inspect the unit
thoroughly prior to operation. 1-2 1
B. Installing Three-phase AC Output Cables 1-2 1
2. Preparation for Storage 1-2 2
A. General 1-2 2
B. Temporary Storage When storing the unit
for 30 days or less, prepare as follows: 1-2 2
C. Long Time Storage (Over 30 Days) 1-2 3
Section 3. Operation 1-3 1

1. General 1-3 1
2. Operating the Generator Set 1-3 1
A. Pre-start Inspection 1-3 1
B. Normal Engine Starting Procedures 1-3 1
C.Preparation for Power Delivery 1-3 3
D. Power Delivery 1-3 4
E. Discontinue Power Delivery 1-3 4
F. Stopping the Engine 1-3 4
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3. Trailer Operation 1-3 5

A. Towing 1-3 5
B. Parking 1-3 5
Chapter 2. Service
Section 1. Maintenance 2-1 1
1. General 2-1 1
2. Inspection 2-1 1
3. Lubrication 2-1 1
A. General 2-1 1
B. Generator 2-1 1
C. Generator Controls 2-1 1
D. Engine 2-1 1
(1) Lubrication schedule 2-1 2
(2) Oil specification 2-1 2
(3) Oil viscosity 2-1 2
(4) Changing engine oil 2-1 2
(5) Changing engine oil filter 2-1 2
E. Starter 2-1 2
F. Trailer 2-1 2
(1) Front axle assembly 2-1 2
(2) Wheel bearings 2-1 3
4. Air Cleaner Service 2-1 3
A. Inspecting the Air Cleaner 2-1 3
B. Cleaning Instructions 2-1 3
C. Disposal 2-1 4
5. Engine Fuel 2-1 4
A. Quality 2-1 4
B. Fuel Filter 2-1 4
6. Engine Cooling System 2-1 4
A. General 2-1 4
B. Radiator Cap 2-1 4
(1) General 2-1 4
(2) Removal 2-1 5
(3) Installation 2-1 5
C. Warm Weather Operation 2-1 5
D. Cold Weather Operation 2-1 5
(1) General 2-1 5
(2) Checking coolant solution 2-1 5
(3) Preparing the coolant solution 2-1 5
(4) Installing the antifreeze solution 2-1 6
E. Draining the Cooling System 2-1 6
F. Cleaning the Cooling System 2-1 7
G. Cleaning the Radiator Core 2-1 7
H. Filling the Cooling System 2-1 7

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7. Generator Maintenance 2-1 8

A. Cleaning 2-1 8
B. Adjustment 2-1 8
8. Drive Belts 2-1 8
A. Checking Belt Tension 2-1 8
B. Belt Adjustment 2-1 8
9. Battery Maintenance 2-1 8
A. General 2-1 8
B. Battery Location and Accessibility 2-1 8
C. Battery Care 2-1 9
D. Liquid Level 2-1 9
E. Cleaning the Battery 2-1 9
F.Testing the Battery 2-1 9
(1) Test with Battery-Starter Tester 2-1 9
(2) Test with Hydrometer 2-1 10
10. Service Helps 2-1 10
A. Wiring 2-1 10
B. Generator Exciter 2-1 10
(1) Preparation for exciter removal. 2-1 10
(2) Exciter removal 2-1 10
(3) Exciter installation 2-1 10
SECTION 2. INSPECTION/CHECK 2-2 1

1. General 2-2 1
2. Engine 2-2 1
A. Fuel 2-2 1
B. Lubrication 2-2 1
C. Coolant 2-2 1
D. V-Belt 2-2 1
E. Exhaust System 2-2 1
3. Electrical System (12-V DC) 2-2 3
A. Lights 2-2 3
B. Fuses 2-2 3
C. Wiring and Connections 2-2 4
4. Electrical System (115-V AC) 2-2 4
A. Monitoring Instruments 2-2 4
B. Indicating Lights 2-2 4
C. Protective Modules 2-2 4
D. Wiring and Connections 2-2 4
5. Trailer 2-2 4
Section 3. Adjustment/Test 2-3 1
1. General 2-3 1
2. Generator Set Test 2-3 1
A. Pre-operational Test Procedures 2-3 1
B. Operational Test Procedures 2-3 2

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3. Generator Set Adjustment 2-3 7

A. Generator Adjustment 2-3 7
B. Voltage Regulator Adjustments 2-3 7
C.Basic Engine Adjustments 2-3 7
D. Engine Accessories Adjustment 2-3 7
(1) Generator and fan belt adjustment 2-3 7
E. Electric Governor System Adjustment 2-3 8
(1) Actuator linkage adjustment 2-3 8
(2) Magnetic pickup adjustment 2-3 9
(a) Preliminary Controller Settings 2-3 10
(b) Checking No-Load Operation of
Controller 2-3 11
(c) Checking Operation of Controller
Under Load 11
(a) Preliminary Controller Settings 2-3 11
(b) Checking No-Load Operation
of Controller 2-3 13
(c) Adjusting for RATED Speed Operation 2-3 13
(d) Checking the Actuator 2-3 13
(e) Checking Operation of Controller
Under Load 13
(5) Checking Magnetic Pick-up signal 2-3 15
4. Generator and Exciter Test 2-3 15
5. Diode Test 2-3 16
Section 1. Troubleshooting Procedures 3-1 1
1. General 3-1 1
2. Trouble Shooting Chart (Figure 5) 3-1 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
10.Illustrations 3-1 3
Section 1. Introduction 4-1 1
1. General 4-1 1
2. Purpose 4-1 1
3. Arrangement 4-1 1
4. Explanation of Parts List 4-1 1

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A. Contents 4-1 1
B. Parts List Form 4-1 2
(1) FIGURE-ITEM NO. Column 4-1 2
(2) HOBART PART NUMBER Column 4-1 2
(3) NOMENCLATURE Column 4-1 2
(4) REC. SPARES Column 4-1 2
(5) “EFF” (Effective) Column 4-1 2
(6) 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
1. Explanation of Numerical Index 4-3 1
Section 4. Numerical Index
1. Explanation of Numerical Index 4-4 1
Unusual Service Conditions

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Section 1. Description
1. General
This manual covers two series of trailer-mounted 90-kVA generator sets manufactured by Hobart Brothers
Company: Specification No. 6919A and Specification No. 6919B.
Generator sets in Series 6919A feature an armature with Hoover Bearings, Browning Coupler, and differ-
ent magnetic pole construction for the generator revolving field. This new armature can be easily identified
by the two copper rings on each end of the field coils and copper wedges between the magnetic poles.
Series 6919A generator sets also feature a wide-type single bearing on the generator.
Generator sets in Series 6919B are virtually identical to Generator sets in Series 6919A, except that the
engine has an improved fuel pump and a dual speed governing system for adjustment of idle speed and
rated speed.
The purpose of the generator set (Fig. 1) is to generate and deliver regulated, 400-Hz electrical power to
a parked (or towed) aircraft for operation of the aircraft’s electrical equipment when the on-board gener-
ators are not running. See Figure 2 for specifications and capabilities.
Within a particular series, the basic generator set - including the engine, generator and all controls - is
identical for all units in the series. However, within a particular series different variations of the basic gen-
erator set are offered. Each variation is identified by a specification number, which is derived by adding a
dash number (-1, -2, etc.) suffix is to the Series number. The specification number generally indicates the
manner in which the particular individual unit is mounted, and it may also indicate some other special fea-
ture of the unit. Identification of different specifications within each series will be explained later in the De-
scription.
Generally, information and instructions throughout the manual apply to all specifications. Information
which applies only to a certain specification will be qualified and identified as such.
2. Orientation
For purpose of orientation and to familiarize operators and maintenance personnel with the location of
components, the radiator is considered to be at the FRONT of the unit. The generator and controls are at
the REAR. RIGHT and LEFT are determined by standing at the rear end facing the machine.
3. Special Features
The generator set has many special features which are later described more fully under the assemblies in
which they appear. Some of the main features are mentioned here and described briefly.
A. Protective Monitor
A single, solid-state device (7, Fig. 7) receives signals from all of the fault sensing units in the gener-
ator output circuit and functions to cause the load to be disconnected from the generator if an abnor-
mal condition of voltage, frequency, or load develops.
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B. Voltage Regulator
A solid-state, adjustable voltage regulator (Items 13 and 17, Fig. 7) provides automatic voltage regula-
tion at the aircraft (or distribution panel when applicable). The regulator is also adjustable for a variety
of output cable sizes and lengths.
C. Electric Governor
The engine is equipped with an all electric type governor kit (13 and 16, Fig. 3) and other special
equipment more fully described under the engine description.
4. Canopy
A sheet metal enclosure, identified as a canopy (2, Fig. 1), provides protection for the engine, generator
and electrical controls. This generator set is equipped with a canopy having doors on both sides. This
canopy is largely of one-piece construction, with the four access doors of the unit attached to the canopy
top by welded-on piano hinges. Hex-head bolts attach the front and back panels to the canopy top assem-
bly and the frame. Air enters the bottom of the unit into the engine compartment and is discharged
through the radiator by the engine fan. Metal strips are mounted horizontally across the front grille to de-
flect engine fan exhaust air and noise downward. Air entering the generator compartment is circulated
over generator controls and drawn into the rear exciter and generator housings where it passes over all
windings before being discharged by the generator fan.
Panel mounted instruments may be observed through two Plexiglas windows in the left rear door which
covers the control box and engine control panel. The lower window is slanted outward at the bottom to
provide access to engine controls when the door is closed. Doors on the unit are equipped with flexible
rubber draw latches (9, Fig. 1) which prevent excessive door vibration when the unit is running.
5. Optional Equipment
Three items of optional equipment are presently available for units covered by this manual: A cold-
weather starting aid kit identified as Hobart Part No. 180961, a four-wheel trailer with fuel tank, identified
as Hobart Part No. 281056, and a second output assembly, identified as Hobart Part No. 281286-1.
6. Engine, Generator, and Controls Assembly

This assembly is the basic generator set without canopy. It includes all components required to generate
and regulate 400 Hz, 115/200 V, threephase power, and is operable when provided with fuel and 12 V DC
power. The engine-generator assembly is mounted on a welded steel frame. A superstructure, attached to
the main frame, provides mounting facilities for the canopy, control box, and electrical equipment and con-
trols.
A. Basic Engine
This generator set is equipped with a 6-cylinder, in-line, turbocharged John Deere engine. See Figure
2 for general specifications, and see Engine Operator’s Handbook in Chapter 6 for more detailed infor-
mation.
B. Engine Manufacturer’s Equipment
As received from the engine manufacturer, the engine includes the following equipment which is de-
scribed in the John Deere shop Manual (Chap. 6)
(1) Fuel filter.
(2) Reverse-flow, engine cooling fan to blow air OUTWARD through the radiator.
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1. Engine fan exhaust deflectors 6. Generator control panel window

2. Radiator cap access hole 7. Engine control panel window
3. Canopy 8. Mounting frame
4. Doors (attached to canopy) 9. Door latches
5. Engine exhaust pipe and cover
Generator Set (Basic Unit)

Figure 1
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PHYSICAL
BASIC GENERATOR SET
Length overall 84 inches (2134 mm)
Width 33 inches (838 mm)
Height 43 inches (1092 mm)
Weight (Approximate) 3655 pounds (1658 kg)
TRAILER-MOUNTED GENERATOR SET

Length overall 90 inches (2286 mm)
Width 66 inches (1676 mm)
Height 57 inches (1448 mm)
Weight (Approximate) 4120 pounds (1868.5 kg)
GENERATOR
Output power rating 90 KVA
Output voltage 115/200 V
Rated load capacity 260 A
Frequency (cycles-per-second) 400 Hz
Output kilowatts 72 KW
Power factor 0.8 PF
Duty cycle 100%
Operating speed at 400 Hz 2000 RPM
Overload capacity (125% of rated load capacity) 325 A
GENERATOR PROTECTIVE SYSTEM

Overvoltage relay trips 130 V to 134 V; resets 125 V
Undervoltage relay trips 102 V or below; resets 110 V
Overfrequency relay trips 415 Hz to 425 Hz; resets 410 Hz
Underfrequency relay trips 375 Hz to 385 Hz; resets 385 Hz
Overload relay trips 112 KVA in less than 5 minutes
Undervoltage time delay relay 4 to 12 seconds
ENGINE
Manufacturer John Deere
Model 6059TL
Type Turbocharged, In-line, 6-cylinder, 4-cycle Diesel
Displacement 359 cu. in. (5.9 liters)
Compression ratio 17.8:1
Firing order 1-5-3-6-2-4
Horsepower at 2000 RPM 123
Governed speed 2000 RPM +/- 4.5%
Idle speed 850 +/- 25 RPM
Electrical system 12 volt
Oil capacity (with filter) 18 quarts (17 liters)
Oil capacity (without filter) 16 quarts (15 liters)
Coolant capacity (approx.) 20 quarts (19 liters)
Fuel Diesel oil conforming to ASTM Specification
D.975-66T, Nos. 1-D and 2-D
Lube oil MIL-L-2104C or MIL-L-2104D
Specifications and Capabilities

Figure 2
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C.Hobart Engine Equipment
The engine is modified at Hobart Brothers by the addition of the following equipment:
(1) Electric governor system
An electric governor 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) be-
cause it provides faster engine response to changes in load conditions. This fast response re-
sults in very close frequency control. Refer to the Barber Colman in Chapter 6 for a detailed
description. A brief description is given below:
The governor system consists of the following main components:
(a) Magnetic pickup, (b) Control unit, and, (c) Actuator
(a) Magnetic pickup
This pickup is a device for detecting engine speed. It is mounted in the flywheel housing di-
rectly over the ring gear. It produces an AC signal to the control unit when the ferrous fly-
wheel teeth pass through the magnetic field at the end of the pickup.
(b) Control unit
The control unit (13, Fig. 3) is a box containing a compact assembly of solid state compo-
nents. It receives an AC signal from the magnetic pickup and senses speed changes in the
engine. It provides a voltage signal to the actuator which causes the actuator to move the fuel
control lever as required to maintain a predetermined engine speed. Its power is received
from the 12-V DC battery system.
(c) Actuator
The actuator (16, Fig. 3) supplies the force needed to move and position the fuel lever as re-
quired to maintain a constant engine speed. The actuator is operated by a DC signal from the
control unit.
(2) Engine electrical system
Items in the 12-volt engine electrical system that are provided by Hobart Brothers are:
(a) A heavy-duty motor starter
(b) Alternator with voltage regulator
(c) Starting switch
(d) Wiring harness
(3) Engine protective devices
(a) High coolant temperature switch

A high coolant temperature switch is mounted in the front of the cylinder block to monitor the
coolant temperature. If the coolant temperature reaches 210 degrees F (99 degrees C), this
normally closed switch opens and de-energizes the fuel valve solenoid which shuts down the
engine.
(b) Oil pressure switch
A diaphragm-type switch monitors the pressure in the lubricating oil system. It is mounted in
the side of the cylinder block (9, Fig. 3). If the pressure in the lube oil system falls to 10 psi
(69 kPa), this switch opens and de-energizes the fuel valve solenoid which shuts down the en-
gine.
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1. Generator 7. Quick-start kit 13. Governor control box

2. Battery 8. Air Cleaner 14. Engine control panel
3. Control box assembly 9. Engine assembly assembly
4. Muffler 10. Cooling fan 15. Exhaust pipe assembly
5. Rain cap 11. Radiator assembly 16. Governor actuator
6. 90o elbow 12. Mounting frame 17. Load contactor
Generator Set Components

Figure 3
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(4) Air cleaner
The diesel-engine air cleaner (Fig. 4) is so constructed that air enters it through the perforated cy-
lindrical body of the air cleaner itself, and is filtered in the process before being passed on to the
engine turbo-charge assembly.
Air Cleaner
Figure 4
(5) Exhaust system
The exhaust system consists of a noise reducing muffler (2, Fig.5) which is connected by a pipe
(1) to the exhaust manifold. The tail pipe (3) directs exhaust and noise upward.
(6) Radiator (11, Fig. 3)
This radiator is a one-piece item designed for long periods of operation without servicing. Refer
to Section 2-1, Para. 7, G, for servicing procedure.
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1. Pipe, manifold-to-muffler 2. Muffler 3. Tail Pipe
Exhaust System
Figure 5
D. Generator
The 400-Hz generator 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 sup-
ported by the fan housing; the rear bearing is mounted in the exciter housing. Both of these housings
are attached to the main generator stator housing. The front end of the rotor shaft extends forward be-
yond the rear bearing and into the exciter stator housing. The exciter rotor is mounted on this shaft ex-
tension with a Woodruff key and is secured by a washer and 1/2"-13 thd, cap screw. A rectifier with
six diodes is mounted on the exciter rotor and converts exciter AC output to DC for excitation of the
generator revolving fields. The exciter DC output to the generator fields, and consequently the gener-
ator output, is controlled by the amount of DC voltage supplied to exciter fields by the static voltage
regulator. A centrifugal, radial-blade fan which is part of the hub and coupling assembly, draws cool-
ing air over all internal windings. Air enters at the exciter end and is discharged at the drive end. The
complete generator is bolted to the engine flywheel housing.
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E. Control Box Assembly
The control box (Fig. 6) is a sheet metal enclosure which houses and provides mounting facilities for
generator controls, and engine and generator monitoring equipment. For access to components
mounted inside the control box, it is necessary to remove two 1/4 X 20 - 1/2-inch hex bolts, and to pull
down the front panel, which is hinged to the control box at the bottom.
(1) Front Panel
(a) Generator output monitors (meters)

The generator output is monitored by three instruments; a frequency meter (2), a voltmeter
(3), and an ammeter (4) The frequency meter is a resonant-reed type, and indicates the fre-
quency of the generator output alternating current in the range of 380 to 420 Hz (cycles per
second). The voltmeter indicates the generator output voltage in each phase-to-neutral (A-N,
B-N and C-N) or phase-to-phase (A-B, B-C and C-A) as selected by the meter selector switch
(5) and the line selector switch (7). (These switches will be described below.) The voltmeter
has a 3-1/2-inch face and the scale is graduated 0 to 300 V. The ammeter is also 3-1/2-inch
size and is graduated 0 to 500 A. The amperage value in each of the three phases may be
read on the ammeter by selecting the desired phase with switch (5). Three ammeter current
transformers, located beneath the generator control box support panel, lower the output load
current to a lesser value, of definite ratio, which will operate the ammeter movement without
damage. The ammeter dial scale is graduated and numbered so that the pointer will indicate
the true load current value rather than the meter movement current.
(b) Meter and line switches
These switches provide a means of selecting and determining which phase of voltage and
current is indicated on the voltmeter and ammeter and whether the voltage is line-to-neutral
or line-to-line The meter switch (5) is a four-position, rotary type. A nameplate (6), located un-
der the switch knob, is marked and lettered to indicate the three functional positions of the me-
ter switch. (When the knob is pointing straight DOWN, the switch is OFF.) The line switch (7)
is a two-position, toggle switch used to select either line-to-neutral or line-to-line voltage to the
voltmeter. The nameplate is also marked to indicate position of this switch.
(c) Instrument light
A shielded, instrument panel light (1) is mounted at the left side of the control panel to illumi-
nate controls, instruments, and indicator lights. It is controlled by a toggle switch on the en-
gine control panel (3, Fig. 8) which also controls instrument light on the engine control control.
(d) Indicating lights
The function of these lights (10, 11, 12, 13 and 14) is to indicate, to the operator, the abnor-
mal condition of overvoltage, underfrequency, etc., which caused the protective monitor sys-
tem to function. Each of the five lights is connected to an actuating circuit within the memory
and time delay module. When one of the circuits is activated, it turns on the applicable indicat-
ing light. The light will remain on until the reset switch (17) is pushed. All lamps in indicating
lights may be tested by pressing switch (16).
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1. Instrument panel light 11. Undervoltage indicating light

2. Frequency meter 12. Overfrequency indicating light
3. Voltmeter 13. Underfrequency indicating light
4. AC ammeter 14. Overload indicating light
5. Meter selector rotary switch 15. Hole plug
6. Instruction plate 16. Light test switch
7. Line selector toggle switch 17. Reset switch
8. Protective system fuse (2-A) 18. Regulated/diagnostic switch
9. Load contactor circuit fuse (2-A) 19. Aircraft/test-bank switch
10. Overvoltage indicating light
Front Panel of Generator Control Box
Figure 6
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(2) Control box internal components (Figure 7)
Internally, the control box contains a solid-state voltage regulator, and electrical and safety de-
vices designed to protect the aircraft electrical system against damage which could result from
overvoltage, undervoltage, overfrequency, or underfrequency. Also contained therein are devices
for the protection and control of the generator output electrical system.
(a) Sensing modules
The voltage sensing module (4) and frequency sensing module (6) are connected to gener-
ator output leads between the generator and load contactor. These solid-state modules sense
any abnormal condition of voltage or frequency and signal the solid-state circuitry of the mem-
ory and time delay module (7) to open the load contactor and disconnect output to the air-
craft. A solid-state overload signaling device (5) is also connected to the protective monitor
module and performs a function similar to the voltage and frequency sensing modules.
Trip values for protective circuits are as follows:
Overvoltage trips at 130 V to 134 V
Undervoltage trips at 102 V or below
Overfrequency trips at 415 Hz to 425 Hz
Underfrequency trips at 390 Hz to 395 Hz
Undervoltage time delay (adjustable)
Overload circuit trips at any value over 125% rated load capacity.
Trip values are adjustable, however, adjustments should be made ONLY under laboratory
conditions.
See Para 6,H, (3) for more specific and detailed information regarding overload device.
(b) Memory and time delay module
The memory and time delay module (7) is sometimes called the protective monitor module. It
is a solid-state device with a hermetically-sealed, reed-type relay. The printed circuit board or
“card” includes five memory circuits and a time delay circuit. Each circuit is connected to a
corresponding sensing circuit in the sensing modules (4, 5, and 6). All memory circuits are
connected to the module relay coil, and any one of the circuits can energize the coil to open
the relay contacts. Thus, when a sensing device energizes any one of the module circuits, the
module relay is also energized to break the load contactor holding circuit and allow the load
contactor to open. The module relay will remain energized (OPEN) and the light will remain
ON until the reset switch (17, Fig. 6) is pushed to break the module 12-V DC cirucit, and allow
the relay to return to normal, CLOSED position. All circuits, except the undervoltage circuit,
function immediately to open the load contactor. A time delay system is designed into the un-
dervoltage circuit to prevent nuisance opening of the contactor under conditions of momen-
tary undervoltage in the generator output. An undervoltage condition which continues
uninterrupted for a period of 4 to 12 seconds (adjustable) will cause the time delay circuit to
open the load contactor. Each of the five circuits is connected to a corresponding indicating
light (10, 11, 12, 13 and 14) which is turned on when a fault occurs.
(c) Excitation-deenergization relay
The purpose of this relay (1) is to allow automatic excitation to be connected to the exciter
field only when engine speed is being controlled by the electric governor.
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(d) Plug-interlock relay

The function of the plug interlock relay (2) is to cause the output load contactor to open in the
event the cable plug connector becomes accidentally disconnected from the aircraft during
power delivery, or if an attempt is made to deliver power when the output cable is not con-
nected to the aircraft. Twenty-eight-volt, direct current for operation of the relay is supplied
from the aircraft either through an on-board transformer-rectifier, or from a twenty-eight-volt,
electrical system. Connection from the aircraft to the interlock relay is made through termi-
nals E and F on the output cable plug connector.
(e) Test-bank switch
A spst, toggle switch (19) provides a means of bypassing the plug interlock relay (2) when
supplying power to a load bank or to an aircraft not equipped with a plug interlock system.
(f) Resistor
A 100-ohm, 25-watt resistor (18) is connected in series with the plug interlock relay to protect
the relay in the event that phase C contacts in the load contactor should fail to close when the
generator ON switch is operated.
(g) Fuse-interlock relay
The function of the fuse-interlock relay (8) is to interrupt the load contactor holding coil circuit
and remove the load in case of a “blown” fuse (8, Fig. 6) in the protective relay coil circuit.
(h) Auxiliary underfrequency relay
The function of the auxiliary underfrequency relay (9) is to automatically open the excitation-
deenergization relay and disconnect the voltage regulator any time generator frequency
drops to 380 Hz or below. This protects the voltage regulator PC board (13, Fig. 7) against
overload which could be caused by high voltage regulator output in its attempt to maintain
voltage when the generator is operating at a speed which cannot produce normal voltage out-
put.
NOTE: If the auxiliary underfrequency relay is tripped, it will be necessary to momentarily
place engine operating mode switch (5, Fig. 8) in BUILD-UP-VOLTAGE position to restore
generator voltage.
(j ) Terminal boards
Two terminal boards (14) provide connection facilities for small leads.
(k) Solid-state voltage regulator
This voltage regulator consists of two assemblies, a line-drop compensation assembly (17)
and a voltage regulator PC board (13). A full and working description of this voltage regulator
is provided in Solid State Regulator Manual OM-2020, which is a part of Chapter 6 of this
manual.
(l) Overload module (5)
See Para. 6, H, (3) for functional description of the overload module.
(m) Rectifier (10)
See Para. 6, H, (4) for functional description of the load contactor rectifier.
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1. Excitation-deenergization relay 12. Bottom interior panel

2. Plug-interlock relay 13. Voltage regulator PC board
3. Rear interior panel 14. Terminal strips
4. Over-undervoltage module 15. Blocking diode assembly
5. Overload module 16. Ballast resistor,
6. Over-underfrequency module 20 ohm, 100 watt
7. Memory and time delay module 17. Line drop compensator
8. Fuse-interlock relay assembly
9. Auxiliary underfrequency relay 18. Resistor, 100 ohm, 25 watt
10. Contactor rectifier 19. Line drop burden resistors,
11. Overload burden resistors, 50 ohm, 25 watt
16.6 ohm, 25 watt
Control Box Internal Components

Figure 7
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F. Engine Control Panel (See Fig. 8)
The engine control panel is mounted directly below the control box. Along with engine controls and in-
struments, generator output controls are mounted here. A plexiglas window in the canopy rear door,
slants outward at the bottom to form an opening for access to controls when the door is closed.
(1) Engine instruments
Engine operation is monitored by an ammeter (4) a coolant temperature gage (8), and an oil pres-
sure gage (10). An hourmeter (6) records engine operating time.
(a) Ammeter
The ammeter (4) indicates the direction and value of current flow in the 12-V DC electrical
system. Its graduated range is from -60 A through 0 A, to +60 A.
(b) Temperature gage
The temperature gage (8) is a mechanical type of unit construction. It consists of a panel
mounted indicating mechanism which is connected by a capillary tube to a bulb mounted in
the engine cooling system. The gage indicates engine coolant temperature in the range of
100F to 220F.
(c) Oil pressure gage and oil pressure switch
The oil pressure gage (10) is a bourdon tube type and indicates engine lubricating oil pres-
sure. It is graduated from 0 PSI to 75 PSI. An oil pressure switch is mounted in a tee fitting di-
rectly behind the gage. This switch connects 12-V DC power to the engine control system
and to the generator 12-V DC control system when the engine is running.
(d) Hourmeter
The hourmeter (6) is electrically driven from the 12-V DC battery system. The hourmeter
measures and records engine running time and will record up to 9999.9 hours on five revolv-
ing drums. The hourmeter operates only when the engine is running and the oil pressure
switch is closed.
(e) Fuel gage and blocking diodes
An electric fuel gage (2, Fig. 8) accurately indicates the quantity of fuel oil in the tank provided
for the generator set. A sending unit mounted in the trailer or truck mounted unit fuel tank sup-
plies the signal to the gage. Twelve-volt DC operating power is supplied to the fuel gage from
two sources. The gage functions when the engine is running, or when the instrument lights
are ON. Since two power sources are connected to the fuel gage system, a blocking diode is
required in each power source circuit. One diode prevents energizing the motor-generator
control circuit when panel lights are ON. Another diode prevents operation of the panel lights
by the engine-generator circuit when the engine is running. (See Connection Diagram in
Chapter 6 for location of these diodes). To check fuel quantity when engine is stopped, use
switch to turn on panel lights.
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(2) Engine and generator controls
(a) Engine-generator control switch

The engine-generator control switch (5) (also identified as the “build-up-voltage, generate,
idle” switch) is a three-position toggle type. It is spring-loaded in one position, BUILD-UP-
VOLTAGE, and will automatically reposition to GENERATE position when released. In
BUILD-UP-VOLTS position it performs a dual function. First, it supplies power to the gover-
nor control box, which allows the engine to operate at normal governed speed; second, it mo-
mentarily supplies current for closing the excitation-deenergization relay (1, Fig. 7) contacts,
to make three-phase, 115-V AC power available to the voltage regulator, or to the regulated-
diagnostic circuit, for excitation of the generator exciter. In GENERATE position, power is
maintained to the governor control box and to the excitation relay (1, Fig. 7). When the switch
is placed in IDLE position, power is disconnected so that the engine returns to idle speed and
the exciter field is deenergized.
(b) Contactor control switch
This is another three-position, toggle switch (7, Fig. 8) identical to the engine-generator con-
trol switch. When placed in the spring loaded CLOSE position, it provides 115-V AC power di-
rectly to a rectifier which supplies DC power for closing the load contactor. When released it
returns to the normal ON position and continues to provide power to the rectifier, but in this
switch position, AC power must pass through the plug interlock and fuse interlock relays. In
OFF position the switch opens the AC circuit to the rectifier, thereby cutting off the source of
DC power to the contactor coil which allows the contactor to open.
(c) Instrument light and switch
A shielded, instrument panel light (1) is mounted at the left side of the control panel. It is con-
trolled by a toggle switch (3), which also controls instrument lights on the control box.
(d) Engine starting circuit
The pushbutton start switch (13) and permissive toggle switch (15) serve to connect power to
the starter solenoid which functions to engage the starter gear with the flywheel ring gear and
apply power to the starter motor to crank the engine. The permissive toggle switch (15) also
stops the engine when the toggle is placed in the STOP (down) position.
(e) Indicating lights
A green indicating light (12) glows to indicate that power is available to the engine protective
system. The light operates only when the engine permissive start switch (15) is in the START
or RUN position. Another green indicating light (9, Fig. 8) glows when the generator output
load contactor is CLOSED and power is available at the generator output cables.
(f) Fuse
A 10-ampere fuse (11) protects the 12-V DC engine control circuit, hourmeter, illuminating
light circuit, and 12-V DC system in the main generator protective system.
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1. Panel light 9.Load contactor indicating light

2. Fuel gage 10. Engine oil pressure gage
3. Light switch 11. Engine circuit fuse (10-A)
4. DC Ammeter 12. Engine “ON” indicating light
5. Engine-generator control switch 13. Engine starter switch
6. Hourmeter 14. Terminal strip (behind panel)
7. Load contactor control switch 15. Permissive start switch
8. Coolant temperature gage
Engine Control Panel

Figure 8
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G. Load Contactor Circuit Components
Load contactor circuit components are located either attached beneath the control box support panel,
on the trailer assembly, or inside the generator control box. The load contactor and its associated cir-
cuit components provide a means of connecting and disconnecting generator output to and from the
load (aircraft).
(1) Load contactor
The load contactor (3, Fig. 9) is a sealed unit which contains a magnetic operating coil and four
sets of contacts. The three larger contacts conduct three-phase AC generator output. A smaller
contact set is connected in the protective monitor circuit and supplies 12-V DC power used by
sensing relays to signal the protective monitor when a fault occurs. Three-phase, 400-Hz gener-
ator output power is conducted to the load contactor by 2/0 cables which pass through 3 sets of
current transformers.
(2) Current transformers
Current transformers are located beneath the control box support panel directly below the control
box.
(a) Ammeter current transformers (2, Fig. 10)
Three current transformers lower the output load current to a lesser value of definite ratio
(500-A to 5-A) which will operate the ammeter (4, Fig. 6) movement without damage. The am-
meter dial scale is graduated and numbered so that the ammeter pointer will indicate the true
load current value rather than the meter movement current.
(b) Line-drop current transformers (3, Fig. 10)
The three line-drop current transformers in conjunction with burden resistors, detect the mag-
nitude and power factor of current flowing from generator to load. They feed a signal to the
voltage regulator which interprets the signal and alters the exciter field current as required to
maintain a constant predetermined voltage at the load.
(c) Overload current transformers (4, Fig. 10)
Three overload current transformers, in conjunction with burden resistors monitor the output
load current in each of the three output phases, and supply a reduced value current signal to
the overload module (5, Fig 7)
(3) Overload module
The overload module is located inside the generator control box. This overload module (5, Fig 7)
is a solid-state device designed to interpret a signal from the current transformers and to send a
signal to the protective monitor module (7, Fig. 7) when an overload condition exists in any gener-
ator output phase. A pull-apart electrical connector is mounted on the overload module to provide
quick-disconnect facilities for all wiring to the module. The overload module is equipped with a
hermetically sealed, reed-type relay. Relay contacts are normally open. The solid-state circuitry is
designed to close relay contacts when output current in ANY phase reaches 125% of normal
rated output capacity. The closed relay sends a signal to the protective monitor. This signal
“gates” the overload SCR (silicone-controlled rectifier) in the protective monitor and interrupts the
load contactor holding circuit, allowing the load contactor to open.
NOTE: The overload protective system will function when any phase carries 123% to 127% of
rated load.
At 125% load the module will function in 4 minutes.
At 150% load the module will function in 16 seconds.
At 200% load the module will function in 4 seconds.
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NOTE: All times are plus or minus 25% and are nonadjustable.
(4) Rectifier
A diode bridge rectifier is located inside the generator control box. (See Fig. 7, item 10). This di-
ode-bridge rectifier receives 400-Hz AC from phase C of the generator output an converts it to a
pulsating, direct current for energization of the load contactor coil only. This DC coil-holding circuit
is controlled indirectly be controlling the 400-Hz AC to the rectifier. The ground circuit for the recti-
fier’s AC supply must pass through the relay contacts in the protective monitor module to ground
cable N. Therefore, any time a protective device functions to open the protective monitor relay,
the rectifier’s AC circuit is opened. No DC is then available for the load contactor coil, hence, the
load contactor opens.
1. Contactor panel 3. Load contactor

2. Neutral terminal 4. E-F terminal
Load Contactor Panel

Figure 9
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1.Bottom of control box 3.Line drop current transformers

2.Ammeter current transformers 4.Overload current transformers
Current Transformers
Figure 10
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Section 2. Preparation For Use, Storage, Or Shipping
1. Preparation for Use

A. Inspection/Check Inspect the unit thoroughly prior to operation.
(1) Remove blocking, banding, ties, and other securing material.

(2) Inspect exterior for shipping damage such broken lights, damaged sheet metal, etc.
(3) Open all canopy doors and inspect interior for foreign material such as rags, tools, shipping pa-
pers, etc.
(4) Check fuel, coolant, and oil hoses and connections for visible leaks. Visually inspect the compart-
ment floor and ground surface under the unit for signs of leakage. If leaks are found, correct by tight-
ening hose clamps, tube fittings, etc., as required.
(5) Check the following for sufficient quantity:
(a) Fuel
Place engine permissive start switch (1-1; 15, Fig. 8) in the RUN position to energize fuel
gage when engine is stopped.
(b) Engine coolant
The radiator cap is accessible by opening the hinged access cover on the front canopy hous-
ing. Coolant level should be approximately one inch below the filler neck. Allow a capacity for
coolant expansion.
CAUTION: BE SURE THE COOLING SYSTEM ANTIFREEZE SOLUTION IS ADEQUATE TO PRO-
TECT BELOW LOWEST TEMPERATURE EXPECTED.
NOTE: For antifreeze protection, use a solution of 50% permanent antifreeze (Ethylene glycol) and 50%
clean water.
(c) Engine lubricating oil
Oil level should be at “FULL” mark on oil level gage rod. See the John Deere Shop Manual
for oil recommendations.
(6) Check air cleaner
The air cleaner (Sect. 1-1, Fig. 3, item 8) is a “dry” type. Be sure there are no papers, tapes, or
other material covering the air inlet area.
B. Installing Three-phase AC Output Cables
Units are generally shipped without generator set-to-aircraft cables. The load contactor, at which ca-
bles must be connected is located on the left side of the unit beside the engine control panel (see 1-1;
2, Fig. 3). To install AC output cables proceed as follows.
(1) Open and raise left rear canopy door of the generator set.
(2) Loosen screws on cable clamp located on the cable tray on the left side of the generator set.
(3) Remove lexan cover over the load contactor.
(4) Route cables through cable clamp, and up to the load side (bottom) of the load contactor.
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NOTE: Conductor size recommended for AC output is 2/0 size. Use No. 12 size for control (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.
(5) Remove the terminal cover on the load side of the contactor and connect the phase cable terminal
lugs to the appropriate terminal studs on the contactor: cable lug “A” to terminal stud “A”, “B” to “B”,
and “C” to “C”.
(6) Connect the cable’s neutral terminal lug securely to the neutral (ground) stud on the side of the
load contactor mounting bracket.
(7) Tighten terminal nuts securely and replace the terminal cover on the load contactor. Connect small
plug interlock leads “E” and “F” to terminal “E-F” on the side of the load contactor mounting bracket.
(8) Tighten clamp screws securely on the left side of the unit, but avoid damage to cable insulation.
(9) Replace lexan cover over load contactor.
2. Preparation for Storage

When a generator set is to be stored or removed from operation, special precautions should be taken to
protect the internal and external parts from rust, corrosion, and gumming in the engine fuel system.
A. General
(1) The unit should be prepared for storage as soon as possible after being removed from service.
(2) The unit should be stored in a building which is dry and which may be heated during winter
months.
(3) Moisture absorbing chemicals are available for use where excessive dampness is a problem, how-
ever the unit must be completely packaged and sealed if moisture absorbing chemicals are to be ef-
fective.
B. Temporary Storage When storing the unit for 30 days or less, prepare as follows:
(1) Lubricate the unit completely in accordance with instructions in Sect. 2-1. This will include chang-
ing engine oil, and all filter elements.
(2) Start the engine and operate for about two minutes so that all internal engine components will be
coated with new oil.
NOTE: Do not drain the fuel system or crankcase after this run.
(3) Make certain the cooling system antifreeze solution is adequate to protect below the lowest tem-
peratures expected during the storage period. See 2-1; Para. 7, D. Be sure the solution is thoroughly
mixed.
(4) Clean the exterior of the engine with fuel oil. Dry with clean rags and compressed air.
(5) Seal all engine openings. Use a waterproof, vaporproof material which is strong enough to resist
puncture damage from air pressures.
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C. Long Time Storage (Over 30 Days)
(1) The unit may be stored for long periods with no special preparation if it is possible to operate the
engine once each week.
(a) Make certain the cooling system is adequately protected
WARNING: MAKE CERTAIN OF ADEQUATE VENTILATION BEFORE STARTING THE ENGINE.
(b) Start the engine and operate at a fast idle (800 to 1000 RPM) until coolant temperature has
reached at least 140 deg F.
(c) Operate normal operating controls.
(2) If weekly operation is not possible, prepare and protect the engine in accordance with instructions
in the John Deere Operator’s Manual.
(3) To protect the generator and other electrical components, the complete unit should be packaged,
using moisture proof packaging and sealing material. Place containers of moisture absorbing chemi-
cals, such as silica-gel, in the unit before packaging.
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Section 3. Operation
1. General
This section contains information and instructions for the safe and efficient operation of the equipment.
Operating instructions are presented in step-by-step sequence of procedures to be followed in supplying
400-Hz power to an aircraft.
WARNING: IMPROPER OPERATION CAN KILL! EAR PROTECTION EQUIPMENT MAY BE NEC-
ESSARY WHEN WORKING IN CLOSE PROXIMITY TO THIS EQUIPMENT. READ AND FOLLOW
ALL OF THE OPERATING INSTRUCTIONS BEFORE ATTEMPTING TO OPERATE THE EQUIP-
MENT.
2. Operating the Generator Set
A. Pre-start Inspection
(1) Open the fuel shut-off valve.

(2) Provide 12-V DC power to the engine starting system.
(3) Check the engine and generator compartments and remove rags or other 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 (13) in ON position.
NOTE: This switch must be ON to check fuel when engine is stopped.
(2) Hold engine start switch (24, Fig. 1) in START position momentarily. Push engine start pushbutton
(23) to crank engine. When engine starts, release pushbutton. Continue to hold engine start switch
(24) in position until oil pressure gage (20) reads at least 20 PSI pressure. Release switch (24).
(3) Check ammeter (3) for charge reading.
(4) Check fuel gage (12) and oil gage (20).
(5) Place engine generator control switch (15) in IDLE position.
(6) Activate generator output contactor switch (17).
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1. Frequency meter 14. DC Ammeter

2. Voltmeter 15. Engine-generator control switch
3. AC Ammeter 16. Hourmeter
4. Meter switch 17. Load contactor control switch
5. Line switch 18. Coolant temperature gage
6. Reset switch 19. Load contactor indicating light
7. Light test switch 20. Oil pressure gage
8. Fault indicating lights 21. Engine circuit fuse (10-A)
9. Load contactor circuit fuse 22. Engine protective circuit
(2-A) indicating light
10. Protective system fuse (2-A) 23. Engine starter switch
11. Instrument panel light 24. Permissive start switch
12. Fuel gage 25. Regulated/diagnostic switch
13. Light switch 26. Aircraft/test-bank switch
Operating Controls and Instruments

Figure 1 (Sheet 1 of 2)
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OM-2037
27. Automatic voltage control potentiometer (R5) 29. Line-drop compensation on/off switch
28. Cable size compensation rheostat 30. Cable length compensation rheostat
31. Voltage regulator fuse (5A)

C.Preparation for Power Delivery
The following are power delivery preparation procedures to be followed after the engine is started.
(1) Check and position switches and controls.
(a) Loosen the two fasteners at the top of engine-generator control panel, and lower the panel to
gain access to the interior component panel.
(b) Place regulated-diagnostic switch (25) in REGULATED position.
(c) Place test bank switch (26) in AIRCRAFT position if the aircraft being serviced is equipped
with 28.5-V DC interlock relay system. (If not, place in TEST BANK position.)
(d) Meter switch (4) may be in any position except pointing straight DOWN.
(e) Raise engine-generator control panel and fasten it as it was previously.
(2) Connect output cable plug connector to aircraft receptacle. Be sure connectors are mated fully
and securely.
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D. Power Delivery
(1) Place engine-generator control switch (15) in BUILD-UP-VOLTAGE position momentarily, then al-
low it to position itself in GEN position. The electric governor will immediately increase engine speed
to 2000 RPM and maintain it.
(2) Observe generator instruments. Frequency meter (1) should indicate exactly 400 Hz. Voltmeter
(2) should indicate 115 V AC when line switch (5) is in ANY line-to-neutral position, A-N, B-N, or C-N,
and should read 200-V AC when it is in any line-to-line position, A-B, B-C, or C-A.
(3) The final step in delivering power is closing the load contactor. When satisfactory frequency and
voltage values are indicated by the instruments, close the load contactor by momentarily placing the
load contactor control switch (17) in the top (spring loaded), CLOSE position. The green indicating
light (19) should glow at once to indicate that the load contactor is closed and power is available at
the aircraft. As soon as the light glows, release the switch. It will automatically return to the center ON
position.
NOTE: If the indicating light (19) should “go-out” as soon as the switch is released, and no fault lights
are ON, it indicates that 28.5-V DC holding current is not being supplied from the aircraft to the
plug-interlock relay.
Correct the condition an again operate the load contactor control switch (17) 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 (4) to select the phase and line-to-line or line-to-
neutral voltage. If the load is changing, it is good operating practice to observe the instruments until
load conditions stabilize.
(5) A condition of overvoltage, undervoltage, underfrequency, overfrequency, or overload in the out-
put circuit will automatically open the load contactor and turn on the applicable indicating light to sig-
nal the operator which of the above faults caused the protective monitor system to operate. After the
fault has been corrected, press the reset switch (6) to turn off the indicating light and reset the protec-
tive relay system. Proceed with power delivery by operating the load contactor switch.
E. Discontinue Power Delivery
(1) Place the load contactor switch (17) in OFF position. Green light (19) should go OFF immediately
to indicate that the load contactor has opened and power is no longer being delivered to the aircraft.
(2) Place engine-generator control switch (15) in IDLE position.
(3) Disconnect output cable from aircraft.
WARNING: HIGH VOLTAGE - ELECTRIC SHOCK OR FIRE CAN KILL! NEVER DISCONNECT THE
OUTPUT CABLE WHILE POWER IS BEING DELIVERED.
F. Stopping the Engine
(1) Allow the engine to idle a few minutes before stopping, to permit cooling.
(2) To stop the engine, move the START-RUN-STOP switch (24) to the STOP (down) position.
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3. Trailer Operation
A. Towing
Observe the following rules when towing the trailer.

(1) Be sure all output cables are disconnected and properly stowed.
(2) Be sure parking brake is released.
(3) Avoid turns which are shorter than the steering linkage will freely allow.
(4) Avoid dangerous speed and sudden turns.
B. Parking Observe the following rules when parking the trailer.
(1) Apply parking brake before disconnecting tow vehicle.

(2) Always place drawbar in an upright, vertical position when trailer is parked.
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Chapter 2. Service
Section 1. Maintenance
1. General
To make certain the generator set is always ready for operation, it must be inspected and maintained
regularly and systematically so that defects may be discovered and corrected before they result in serious
damage or failure of the equipment.
WARNING: ELECTRIC SHOCK, FLYING PARTS, OR FIRE CAN KILL OR INJURE! STOP OPERA-
TION IMMEDIATELY IF A SERIOUS OR POSSIBLY DANGEROUS FAULT IS DISCOVERED.
2. Inspection
A periodic inspection should be established and maintained. A suggested inspection/check schedule is
provided in 2-2, Figure 1, however it may be modified as required to meet varying operating and environ-
mental conditions. If the generator set is mounted on a tow tractor, it is suggested that inspections be co-
ordinated.
3. Lubrication
A. General
Proper lubrication is one of the most important steps in good maintenance procedures. Proper lubri-
cation means the use of correct lubricants and adherence to a proper time schedule. Frequency of lu-
brication and recommended lubricants are indicated in Figure 1.
B. Generator
The 400-Hz generator REQUIRES NO LUBRICATION. The rotor is supported by two ball bearing as-
semblies 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
Generator controls and instruments require no scheduled periodic lubrication. A few drops of oil may
be required on door hinges occasionally to insure free an quiet operation.
D. Engine
Although the engine and its accessories require no more attention than any other similar installation,
they still inherently require a major portion of the generator set lubrication and maintenance. Recom-
mendations regarding engine lubrication have been taken from the engine manufacturer’s “Operator’s
Manual” and incorporated here to make them more readily available to operators and maintenance
personnel.
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(1) Lubrication schedule
Time schedules indicated on the Lubrication Chart, Fig. 1, are approximate. They are based on
average operating conditions. It may be necessary to lubricate more frequently under severe oper-
ating conditions such as: low engine temperatures, excessively heavy loads and high oil tempera-
tures, or intermittent operation. However, time intervals should not exceed those indicated in the
chart without careful evaluation.
(2) Oil specification
Oil recommended by the engine manufacturer is identified by a military specification number, MIL-
L-2104B. Because of the substantial increase in additive concentration in some MIL-L-2104B oils
to meet service “MS” requirements, recommended oil is qualified still further by the following limita-
tions.
(a) Zinc, as zinc diorganodithiophosphate, between a minimum of 0.07 and a maximum of 0.10
percent by weight.
(b) Sulfated ash (ASTM D-874) of 1.00 percent maximum by weight, except lubricants that con-
tain only barium detergent-dispersants where 1.50 percent by weight is allowed.
Diesel lubricating oil specifications are discussed in the John Deere Operator’s Manual in Chapter
6.
(3) Oil viscosity
The use of an SAE-30 grade oil is recommended for year-round service. The engine is equipped
with an ether starting aid to assist in engine starting during cold weather when SAE-30 oil is used.
Multigrade oils are NOT recommended, and should be considered only as a “last resort” to facili-
tate engine starting.
(4) Changing engine oil
Change engine lubricating oil following the instructions in the John Deere Operator’s Manual in
Chapter 6. Lube oil capacity for this engine is 15-1/2 quarts.
(5) Changing engine oil filter
Change the oil filter following the instructions in the John Deere Operator’s Manual in Chapter 6.
E. Starter
The starting motor is lubricated at assembly and should be relubricated only when the starter is re-
moved from the engine or when disassembled. Remove pipe plugs on outside of motor and apply a
few drops of light engine oil to the oil wicks.
F. Trailer
(1) Front axle assembly
The front axle assembly, drawbar, and steering linkage are equipped with high-pressure lubrica-
tion fittings. Lubricate the trailer every 400 hours. Use a good quality chassis lubricant such as
Sinclair Litholene Industrial No. 2, Mobil Mobilplex 47, or equivalent. Clean lube fittings before ap-
plying grease.
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ITEM MAINTENANCE REQUIRED
Lube Oil Check oil level daily or after every 10 hours of use. Change oil after
200 hours or one month of use. Use heavy duty oil such as SAE-30
(MIL-L-2104D). Engine lube oil capacity: 18 quarts.
Lube Oil Filter Change oil filter every 200 hours or 1 month of use.
Fuel Oil Filter Drain filter daily. Change filter element every 600 hours or 4 months of use.
Starter Lubricate as needed, using heavy duty engine oil such as SAE-30
(MIL-L-2104B). Lubricate only when starter is removed from engine.
Coolant Check coolant level daily. Service and maintain coolant system according
to para.6. Engine coolant capacity: 20 quarts.
Air Cleaner Check air cleaner periodically and clean or change it as necessary. (Refer
to Para. 4 for servicing instructions).
AC Generator AC generator bearings are sealed and require no periodic lubrication.
Lubricationand Maintenance Chart

Figure 1
(2) Wheel bearings
Lubricate and check wheel bearing adjustment every 800 hours or semi-annually. Use a good
quality automotive bearing lubricant grease (Specification MIL-G-10924B or equivalent).
Refer also to TO-186 in Chapter 5 of this manual for additional information on trailer lubrication.
4. Air Cleaner Service

Refer to Section 1-1; Fig. 4. This air cleaner is a dry type which may be cleaned as many as six times be-
fore replacing it with a new air cleaner. A definite time schedule for cleaning or changing the air cleaner
cannot be determined because of varying operating conditions. However, since this air cleaner can be re-
moved and replaced without difficulty on this generator set (simply by loosening one metal clamp on each
end of the air cleaner), it may be inspected either at prescribed service intervals or at any time deemed
necessary.
A. Inspecting the Air Cleaner
(1) Make periodic checks of air cleaner inlet screen for obstructions. If any obstructions are present,
remove them.
(2) Check outlet connection for proper seal.
NOTE: DO NOT judge the element’s life just by looking at it, IT SHOULD LOOK DIRTY, or it’s not doing
its job.
B. Cleaning Instructions
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CAUTIONS: (1) DO NOT RAP THE AIR CLEANER ON A HARD SURFACE TO CLEAN IT, AND (2)
NEVER LEAVE THE AIR INLET DUCTING OPEN LONGER THAN NECESSARY DURING THE
SERVICE PROCEDURE.
(1) Pressurized air cleaning
After removing the air cleaner from the generator set, blow air into the outlet neck, causing dust to
flow off the air cleaner filter media.
CAUTIONS: (1) DO NOT USE COMPRESSED AIR HIGHER IN PRESSURE THAN 100 PSI, AND (2)
DO NOT USE COMPRESSED AIR CLEANING WHEN THE FILTER MEDIA IS WET.
(2) Low pressure water flush
(a) Flow low pressure water, warm or cold, into the air cleaner outlet neck, causing dirt to flow off
the filter media. Always be sure not to let any contaminated water back into the outlet neck.
(b) A mild detergent may also be used. However, the filter must then be flushed thoroughly with
clean water. This cleaning method is recommended by the manufacturer.
(c) Always allow filter media to dry before use.
C. Disposal
Normal trash pick-up is acceptable. NEVER burn the air filter for disposal.
5. Engine Fuel
A. Quality
The quality of fuel oil used in the diesel engine is a major factor in long engine life and performance.
Fuel oil must be clean, completely distilled, stable, and non-corrosive. Only distillate fuel No. 1D is rec-
ommended for use both summer and winter.
CAUTION: CONSULT THE “FUEL OIL SELECTING CHART” IN THE ENGINE OPERATOR’S
MANUAL BEFORE SUBSTITUTING ANOTHER GRADE OF FUEL.
B. Fuel Filter
Refer to John Deere Shop Manual in Chapter 6 for instructions on removal and replacement of fuel fil-
ter elements.
6. Engine Cooling System

A. General
Cooling system device requires much more than maintaining the proper coolant level in the radiator.
During warm seasons and in warm climates, plain water can be used as a coolant if the system is pro-
tected against rust by a rust inhibitor additive. During cold seasons and in cold climates, the system
must, of course, be protected against freezing. At no time should the system be operated for any
length of time on plain water, without a rust inhibitor or antifreeze. Draining, cleaning, and filling the
cooling system are covered in Para. 7, E through H.
B. Radiator Cap
(1) General
A pressure valve is built into the radiator cap. It is designed to open at a pressure of approxi-
mately seven pounds per square inch.
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(2) Removal
To remove, turn the cap to the left (counterclockwise) to the safety stop. When all pressure is re-
leased, press down on the cap and continue to turn until the cap is free to be removed.
WARNING: HOT STEAM AND FLUIDS WILL SEVERELY BURN! WHEN REMOVING CAP FROM A
VERY HOT RADIATOR, DO NOT TURN CAP PAST SAFETY STOP UNTIL ALL PRESSURE OR
STEAM HAS ESCAPED. USE PROTECTIVE CLOTHING. ALLOW ENGINE TO COOL BEFORE
ADDING COOLANT.
(3) Installation
When installing the cap be sure it is turned clockwise as far as it will go so that the pressure re-
taining valve will be functional.
C. Warm Weather Operation
During warm weather operation, if water is used in the cooling system instead of an antifreeze solu-
tion, keep the cooling system free of rust and sludge by adding a cooling system conditioner that is
compatible with aluminum. Instructions for use of the conditioner are printed on each can.
CAUTION: USE ONLY A CORROSION INHIBITOR THAT IS COMPATIBLE WITH ALUMINUM. DO
NOT USE INHIBITORS LABELED AS “ACID NEUTRALIZER”.
D. Cold Weather Operation
CAUTIONS: (a) DO NOT USE “METHANOL” OR ALCOHOL AS AN ANTIFREEZE, AND (b) DO NOT
USE TWO DIFFERENT TYPES OF ANTIFREEZE. MIXED SOLUTIONS (TWO TYPES) MAKE IT
IMPOSSIBLE TO DETERMINE IF THE COOLING SYSTEM HAS ADEQUATE PROTECTION
AGAINST FREEZING.
(1) General
A permanent type, (Ethylene Glycol) antifreeze is recommended for use in the cooling system.
(2) Checking coolant solution
Check the solution frequently to be sure the cooling system has sufficient protection against freez-
ing.
NOTE: (a) When testing the solution, be sure the coolant is at operating temperature. (b) Follow
manufacturer’s instructions on tester.
(3) Preparing the coolant solution
The following table (Figure 2) indicates the freezing points of solutions varying from 16% anti-
freeze to 65% antifreeze. Percentages are based on permanent type (Ethylene Glycol) antifreeze.
Most antifreeze containers have a similar table printed on the label.
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FREEZING POINT PERCENTAGE OF ANTI-

(FAHRENHEIT) FREEZE IN SOLUTION
20 16%
+10 25%
0 33-1/3%
-10 40% Antifreeze Solution Table
-20 45% Figure 2
-30 50%
-40 54%
-50 58%
-60 62%
-70 65%
(4) Installing the antifreeze solution
Before installing antifreeze in the system, make the following checks:

(a) Check the system for signs of leaks
(b) Inspect all hoses and tighten all hose clamps. Install new hoses if necessary.
(c) Drain and clean the system. Ref. Paras. 7,E and 7,F.
(d) Check the condition and tension of the engine V-belt. Replace the V-belt if necessary.
(e) Be sure radiator and engine drain valves are closed, and all connections are securely tight-
ened.
(f) Install the required amount of antifreeze: 20 quarts. Fill the system with coolant as outlined un-
der Para. 7, H.
E. Draining the Cooling System
Drain the cooling system immediately after stopping the engine, while most of the sediment is in sus-
pension. Proceed as follows:
(1) Remove radiator cap.
(2) Open radiator drain valve (at bottom of radiator) and engine drain valves. See John Deere Shop
Manual for exact locations of engine coolant drain valves.
NOTE: When draining the system for storage, remove all drain valves and remove drain plug.
(3) Allow the system to drain completely.
NOTE: Be sure the drain valves do not plug-up during draining.
(4) When the system is completely drained, close all drain valves except when draining for storage.
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F. Cleaning the Cooling System
Drain and thoroughly flush the coolng system twice a year or more often if necessary. The appear-
ance of rust in the radiator, or in the coolant is an indication that the inhibitor has become weakened
and it is possible that some sludge has accumulated in the system. When this condition exists, pro-
ceed as follows:
(1) Run the engine until it reaches normal operating temperature; then stop the engine and drain the
cooling system (Ref. Para. 7, E).
(2) Fill the cooling system with clean coolant (Ref. Para. 7, H).
(3) Add a flushing compound, that is compatible with aluminum, to the cooling system in accordance
with the instructions furnished with the compound.
(4) Start the engine and flush the system as directed by the instructions furnished with the compound.
(5) After the system has been flushed and thoroughly cleaned of the compound, refill the clean cool-
ant (Ref. Para. 7, H).
G. Cleaning the Radiator Core
Blow out insects and dirt from the radiator core air passages, using air or water under pressure. En-
gine overheating is often caused by bent or clogged radiator fins. When straightening bent fins, be
careful not to injure the tubes or to break the bond between the fins and tubes.
H. Filling the Cooling System
Add a cooling system corrosion inhibitor (for warm weather operation) or permanent antifreeze (when
the air temperatures expected are at freezing, (+32 deg F or lower). Antifreeze may be premixed if de-
sired. See Fig. 1 for cooling system capacity.
(1) Engine must be STOPPED. Close all drain valves except top water outlet valve. Leave this valve
OPEN to allow air to escape.
(2) Pour coolant into radiator slowly until system is filled to level of top drain valve. Close valve and
continue to fill system until coolant reaches a level approximately 1 inch below the radiator filler neck.
NOTE: If antifreeze solution is not premixed, pour required antifreeze in first. Install corrosion inhibitor
according to directions on container.
(3) Start the engine and allow it to idle. Add coolant if trapped air escapes from the system and the
coolant level falls.
(4) Continue to check coolant level until the engine reaches operating temperature. Add coolant, if
needed, to fill to the required level, 1 inch below filler neck. Install radiator cap.
NOTE: It is good practice to attach a card, indicating the cooling system contents, and the date serviced
to the radiator filler neck.
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7. Generator Maintenance
The 400-Hz generator requires no maintenance or service other than periodic cleaning. The unit is
brushless, and bearings are permanently lubricated and sealed.
WARNING: ELECTRIC SHOCK AND FIRE CAN KILL OR INJURE! BE SURE THE UNIT IS COM-
PLETLY DRY BEFORE OPERATING. DO NOT USE A FLAMMABLE SOLVENT.
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 no longer recommended because the use of steam and
harsh chemical compounds may result in damage to insulation and other generator components.
B. Adjustment
The generator itself requires no adjustment. Adjustment procedures for generator controls will be cov-
ered in Section 2-3.
8. Drive Belts
A single belt from the crankshaft pulley is used to drive the alternator and water pump. For proper engine
operation this belt should be in good condition and at proper tension at all times.
A. Checking Belt Tension
Check belt tension every 200 hours of engine operation, or bi-weekly. A belt which is too tight is de-
structive to bearings of the alternator and water pump. A loose belt will slip and cause inefficient op-
eration of the alternator and/or the water pump.
To check belt tension, press the belt firmly with the thumb at a point halfway between the alternator
pulley and the crankshaft pulley. A properly adjusted belt should deflect about 3/8 inch.
B. Belt Adjustment
To adjust belt tension, loosen the alternator mounting bolts and change the position of the alternator.
Upon obtaining the correct tension, re-tighten both alternator mounting bolts.
When new belt is fitted, it is necessary to run the engine for a short period to allow the new belt to set-
tle into the grooves of the pulleys and thus show any initial stretching that is going to occur. Recheck
belt tension after running the engine and adjust as necessary.
9. Battery Maintenance
A. General
Two 12-volt batteries supply power for operation of the engine electrical system, clearance and panel
lights, and for flashing the generator exciter field.
B. Battery Location and Accessibility
For location of batteries refer to Section 1-1; Figure 3, Item 2. These batteries are easily accessible by
raising the right rear canopy door of the generator set.
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C. Battery Care
(1) Never allow a battery which has been removed from the unit to sit on concrete, ground, or metal
unless proper insulation is provided. A wooden platform or board will provide sufficient insulation.
(2) Maintain stored batteries in a charged condition.
(3) Be sure batteries are fastened securely in their compartment to avoid damage from vibration.
(4) Maintain battery fluid at proper level.
(5) Keep battery terminal posts and lead connectors clean.
WARNING: NEVER ALLOW SPARKS OR OPEN FLAME NEAR BATTERIES. AVOID SPILLING
ELECTROLYTE ON HANDS OR CLOTHING.
D. Liquid Level
The electrolyte in each cell should be above the plates at all times to prevent battery failure. Check
the level of the electrolyte every two weeks. When electrolyte level is low, add pure distilled water. Do
not use hydrant water or any water which has been in contact with a metal container. Acid should
never be added except by a skilled batteryman.
CAUTION: NEVER ADD ANY SPECIAL BATTERY DOPES, SOLUTIONS OR POWDERS.
NOTE: It is especially important to keep the battery at full charge for cold weather operation. Add distilled
water to the battery in freezing temperatures only when the engine is to operate forseveral hours, to
thoroughly mix the water and the electrolyte, or damage to the battery will result from the water freezing.
E. Cleaning the Battery
If the top of the battery is dirty, it may be cleaned with a brush dipped in ammonia or soda solution.
Disconnect lead connectors from battery posts. Vent plugs should be tightened to prevent cleaning so-
lution from entering cells. Clean battery as required, using brush and cleaning solution. Flush off the
battery with clean water. Brighten terminal and post surfaces with steel wool, a wire brush, or special
terminal cleaning tool. Make certain that vent holes in filler caps are not clogged.
F.Testing the Battery
Tests are made on a battery to determine the state of charge and also the condition. The results of
these tests show that the battery is good, needs recharging, or must be replaced. If a battery has
failed, is low in charge, or requires water frequently, the reason for the condition must be found and
corrected. Visually inspect the battery before testing, to determine if it has been damaged. Moisture
on the outside of the case, or low fluid level in one or more cells indicates possible battery damage
(cracked case, etc.). The battery may be tested by two methods. A Battery-Starter Tester may be
used to determine the battery’s ability to deliver current. A battery hydrometer test determines the
charge condition of the battery.
(1) Test with Battery-Starter Tester
Connect battery to the tester according to instructions furnished with the instrument. Test battery
according to tester instructions. If the test determines that battery has acceptable voltage, this indi-
cates that battery has output capacity and will accept a charge, if required.
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(2) Test with Hydrometer
(a) Remove filler caps and check the specific gravity of electrolyte in each cell. If specific gravity is
1.230 or below, add water if necessary and charge the battery until it is fully charged. A fully
charged battery will give a specific gravity reading of from 1.265 to 1.285. The specific gravity of a
fully discharged battery may range from 1.140 down to 1.120.
NOTE: The battery is fully charged when all cells are gassing freely, and specific gravity ceases to rise
for three successive readings taken at hourly intervals.
(b) If the Battery-Starter Test indicated that battery voltage was below the acceptable voltage
value, test each cell with the hydrometer. If specific gravity readings between any two cells is 50
points (0.050) or more, the battery isn’t satisfactory for service and should be replaced.
10. Service Helps

A. Wiring
All small wire leads are routed through plastic flexible conduit which protects them and makes a neat
easily removable and replaceable wiring harness arrangement. This wiring method allows the replace-
ment of a single wire lead with a minimum of difficulty. All wires are color coded.
B. Generator Exciter
Provisions have been made to allow removal of the generator exciter without disturbing or removing
the complete generator.
(1) Preparation for exciter removal.
(a) Remove rear panel of canopy.

(b) Remove air shroud whiich is attached to control box support
(c) Remove main frame rear cross member by removing four attaching bolts (see Fig. 3).
(2) Exciter removal
Refer to TM-360 in Chapter 6 for exciter instructions.
(3) Exciter installation
(a) Install exciter in accordance with TM-360.

(b) Re-install rear frame member and tighten screws securely.
(c) Re-install air shroud.
(d) Re-install rear panel of generator.
NOTE: It may be necessary to use a large “C” clamp or other arrangement to position frame side rails
and align rear frame member mounting holes.
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Removable Rear Frame Cross-Member

Figure 3
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SECTION 2. INSPECTION/CHECK
1. General
This section describes inspections and checks to be performed in conjunction with Inspection/Check
Schedule, Figure 1.
2. Engine
A. Fuel (See Fig. 1 for time schedules)
(1) Check fuel quantity DAILY.

(2) Drain fuel filters and change fuel filter elements in accordance with instructions in John Deere
Shop Manual.
(3) Open fuel tank drain every 500 hours to drain off water and sediment.
B. Lubrication
(1) Check crankcase oil level DAILY.

(2) Lubricate in accordance with Lubrication Chart (Ref. 2-1; Fig. 3).
C. Coolant
(1) Check coolant level DAILY.

(2) Inspect for signs of rust and corrosion. Change coolant if rust and sediment are present. See 2-1;
Para. 7, E, F, and H.
(3) Inspect hoses for cracks and deterioration. Inspect clamps for tightness.
D. V-Belt
(1) Inspect V-belt for proper tension and adjust if necessary after each 200 hours of operation. (See 2-
1; Para. 7, A, B, and C.)
E. Exhaust System
WARNING: EXHAUST FUMES OR FIRE CAN KILL OR INJURE! IMMEDIATELY REPAIR DEFEC-
TIVE EXHAUST SYSTEMS.
(1) Visually inspect muffler and exhaust pipes for signs of approaching failure.
(2) Listen for any gasket or joint leaks.
(3) Replace any defective parts at once.
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Daily Or Every 8 Hours

Inspect air cleaner Check generator ammeter
Check output cable and connector Check frequency meter
Check generator voltmeter Check all lights
Check fuel quantity
Weekly, Or Every 50 Hours

Check crankcase oil level Check all lights
Check coolant level
Monthly, Or Every 200 Hours

Check safety switches Clean battery terminals
Change engine oil filter element Change engine oil
BI-MONTHLY, OR EVERY 400 HOURS

Check cooling system hoses, Check exhaust sys.
tubes, fittings, clamps Check protective relays
Every 6 Months Or 1200 Hours

Check V-belt tension Clean and inspect generally
Change fuel filter elements Drain/refill cooling system
Inspect all wiring and connections
Open Fuel Tank Drain Every 500 Hours

Lubricate (see Lubrication Chart)
Inspection/Check/Maintenance Schedule
Figure 1
3. Electrical System (12-V DC)

A. Lights
Check all lights for proper operation DAILY. Replace any defective lamps (bulbs) as soon as discov-
ered. Figure 2 lists ALL lamps, their location, and part numbers.
B. Fuses
Check and replace fuses as required. See Figure 3 for fuse sizes and locations. Figure 3 includes all
fuses used in both the engine and generator electrical system.
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LIGHT LAMP LAMP (BULB)

IDENTIFICATION LOCATION MANUFACTURER NUMBER
Instrument Panel Control Box and Lamp Industry

Lights Engine Control Panel Trade No. 63
Engine On Indicating Engine Control Lamp Industry 1815

Light Panel Trade No.
Contactor CLOSED Engine Control Lamp Industry 1815

Indicating Light Panel Trade No.
Fault Indicating Control Box Lamp Industry 1815

Lights Trade No.
Lamp Identification Chart

Figure 2
ITEM PROTECTED LOCATION ILLUSTRATION SIZE AND TYPE
Instrument panel Engine Sect. 1-1, 10A Type AGC

lights and engine control panel Fig. 8, item 11
Protective relay Generator Sect. 1-1, 2A Type AGC

system Control Panel Fig. 6, item 8
Voltage regulator Voltage Sect. 1-3, 5A Type AGC

regulator Fig. 1, item 31
Load contactor Generator Sect. 1-1, 2A Type AGC

circuit Control Panel Fig. 6, item 9
Fuse Identification Chart

Figure 3
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C. Wiring and Connections
(1) Inspect all cables and leads for broken, worn, and damaged insulation.
(2) Check electrical connections for looseness.
NOTE: A darkened terminal generally indicates a loose connection.
4. Electrical System (115-V AC)

The 400-Hz generator and controls are designed to be as maintenance free as possible. No lubrication is
necessary and no periodic maintenance adjustments are required. However, some regular checks should
be made to be sure all controls, instruments, etc., are working properly.
A. Monitoring Instruments
Observe operation of voltmeter, ammeter, and frequency meter each time the unit is started.
B. Indicating Lights
Check lamps (bulbs) in all of the indicating lights at each start up. Fault indicating lights on the front
panel of the control box may be tested by pressing test switch (1-1; 16, Fig. 6).
C. Protective Modules
Check operation of all protective modules to make certain they will function if a fault should occur in
the output circuit. (See 2-3; Para. 3, B.)
D. Wiring and Connections
WARNING: STOP OPERATIONS AND STOP ENGINE BEFORE TOUCHING EXPOSED CONDUC-
TORS OR TERMINALS.
(1) Check all cables, leads, and wiring for broken, worn, and damaged insulation.
(2) Check all connections for tightness.
(3) Check the output cable plug connector for damaged contactors in the end of the plug.
5. Trailer
If the generator set comes with the trailer option, perform inspection as follows:
A. Check operation of parking brakes.
B. Check fuel tank for leaks.
C. Check pressure in all four tires. Should be 95 psi.
D. Check reflectors for damage.
E. Check trailer axles, linkage, and wheel bearings for proper lubrication. (Refer to Section 2-1, Para. 3,
F.) Refer also to TO-186 in Chapter 5 of this manual.
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Section 3. Adjustment/Test
1. General
Adjustment and test procedures are most applicable to testing and adjusting the generator set after a ma-
jor repair, replacement of parts, or overhaul.
2. Generator Set Test

A. Pre-operational Test Procedures
(1) Connect cables from the generator output terminals to a load bank. Use cables of the same size
and length as those to be used in service. Be sure the generator output “N” cable is grounded.
(2) Check engine oil level. Oil should be at FULL mark on gage rod.
(3) Check radiator coolant level (Ref. Section 2-1, Para. 7, H).
(4) Check tension of engine V-belt.
(5) If governor throttle linkage was disturbed, check all linkage to make certain engine speed may be
controlled when the engine is started. See Figure 3.
(6) Inspect for oil, fuel, and coolant leaks.
(7) If the setting of the voltage regulator rheostat (27, Fig. 1) has been disturbed, set it at CENTER po-
sition (halfway between full clockwise position and full counterclockwise position).
(8) Check engine circuit fuse (21, Fig. 1) by placing panel light switch (13) in ON position. If panel light
(11) operates, the fuse (21), switch (13), and lamps are good.
(9) Check fault indicating lights (8) by pressing test switch (7). If lights glow, fuse (21) and indicating
lamps are good.
(10) Make a general inspection of all wiring and terminals. Inspect the equipment to be certain no
damage will result from starting the engine.
CAUTION: ENGINE MUST NOT BE RUNNING WHEN FLASHING EXCITER FIELD IF VOLTAGE
REGULATOR DAMAGE IS TO BE PREVENTED. DO NOT LEAVE REGULATED/DIAGNOSTIC
SWITCH IN DIAGNOSTIC POSITION AFTER FLASHING FIELD.
(11) At initial start-up after generator overhaul or repair, “flash” the exciter field by momentarily apply-
ing 12-V DC to the field windings. To flash the exciter field, place the Regulated/Diagnostic switch (25,
Fig. 1) in the DIAGNOSTIC position for 3 to 5 seconds. Then return it to the REGULATED position.
(12) Check position of load contactor “on-off” switch (17, Fig. 1), and engine-generator control switch
(15).
(a) Load contactor switch (17) must be in OFFposition.
(b) Engine-generator control switch (15) must be in IDLE position.
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B. Operational Test Procedures
(1) Start the engine in accordance with instructions in 1-3; Para. 2, A thru C.
(2) Check operation of engine instruments: DC ammeter (14, Fig. 1), coolant temperature indicator
(18), oil pressure gage (20), and hourmeter (16).
(3) Check engine idle speed. Should be 825 to 875 RPM. Adjust, if necessary, in accordance with in-
structions in Engine Operator’s Manual.
NOTE: A stroboscope is required for this check.
(4) Again check for oil, fuel, and coolant leaks and correct any leaking condition.
(5) Position switches and controls for automatic voltage regulation and power delivery as follows:
(a) Place regulated-diagnostic switch (25, Fig. 1) in REGULATED position.
(b) Place test-bank switch (26) in AIRCRAFT position.
(c) Meter switch (4) may be in any position other than the directly downward (OFF) position.
(d) If the adjustment of the voltage regulator rheostat potentiometer (27) has been disturbed, posi-
tion the knob to mid-range position.
(6) Bring the engine up to governed speed and also energize the generator by holding the engine-gen-
erator control switch (15) in BUILD-UP-VOLTS position momentarily. Release switch and allow it to
position in “center” RUN position. If the engine “comes-up” to governed speed and a voltage value ap-
pears on the voltmeter (2), the electric governor and excitationdeenergization relay circuits are func-
tioning.
(7) Observe frequency meter (1). If engine speed is properly adjusted, frequency will be exactly 400
Hz. If not, adjust engine governed speed in accordance with Para. 3, E, (3) (d).
(8) Observe voltmeter (2). Use rheostat (27) to adjust voltage to 115 V AC.
(9) Measure governor actuator input signal. See Para. 3, E, (4), (a).
(10) Measure governor magnetic pickup signal. See Para. 3, E, (4), (b).
(11) Check speed limiting governor
Set engine speed-limiting governor to 2300 +/-25 RPM. See John Deere Diesel Handbook in
Chapter 6 for instructions on how to set the governor.
(12) Check adjustable voltage range
(a) With regulated/diagnostic switch (25) in REGULATED position, observe voltmeter (2, Fig. 1)
and turn voltage regulator potentiometer (27) CLOCKWISE to full clockwise position. Maximum
voltage should be at least 134 V AC, or higher.
NOTE: If voltage should decrease when the potentiometer is turned clockwise, it indicates that the voltage
regulator PC board is defective. Replace the regulator PC board.
(b) Observe voltmeter and turn rheostat knob to full COUNTERCLOCKWISE position. Minimum
voltage should be 108 V AC, or lower.
(13) Observe voltmeter and adjust rheostat to obtain 115-V AC voltmeter reading.
(14) Position load bank switches, etc., to apply a light load to the generator.
(15) Place the load contactor “on-off” switch (17, Fig. 1) in the top, spring loaded, CLOSE position.
Hold in this position momentarily. Hold in this position momentarily. The indicating light (19) should
glow GREEN and an amperage value should appear on the AC ammeter (3).
2-3 November 30/91 Revised

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OM-2037
(16) Release the switch (17) and allow it to return to the center ON position. The load contactor
should open immediately, and the generator “on” indicating light should go OFF. This is because the
plug interlock relay (Ref. 1-1; 1, Fig. 8) is not receiving power from an outside source of 28 V DC. It in-
dicates that the plug interlock contacts are OPEN as they should be when the interlock coil is not re-
ceiving 28-V DC power.
(17) Open and lower the front door panel of the control box and place the test bank switch (26, Fig. 1)
in TEST BANK position.
(18) Again place the load contactor switch (17) in the top, CLOSE position. Light (19) 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 (26) is functioning to bypass the plug interlock relay.
(19) Return the test bank switch to AIRCRAFT position. The load contactor should open at once and
the green indicating light (19) should go off.
(20) Connect a source of 24-V DC power (two twelve-volt batteries connected in series) to terminals
“N” and “E-F” at the output terminal panel.Connection polarity should be: MINUS to terminal “N” and
PLUS to terminal “E-F”.
(21) With test-bank switch in AIRCRAFT position, hold the contactor operating switch (17) in top,
CLOSE position momentarily. The generator “on” indicating light (19) should glow GREEN and re-
main on when the switch is released and allowed to return to the center ON position. This indicates
that the load contactor is closed and the plug interlock relay is functioning properly.
(22) Apply 1/3 to 1/2 load at the load bank and allow the unit to run for 15 to 30 minutes. Observe op-
eration of all monitoring instruments.
(23) Increase load bank resistance to apply a full load.
(24) Check operation of the governor by observing the frequency meter (1, Fig. 1) when generator is
switched from no-load to full-load and vice versa. Use the contactor control switch (17) to apply and
remove load several times. Frequency drop should be no more than 1 Hz. Adjust governor if neces-
sary (See Para. 3, E, (3)).
(25) Follow instructions in Para. 3, B, (2) (b) to set voltage regulator line-drop compensation potenti-
ometers (Ref. Figure 1, items (28) and (30). Set knob pointer on cable size potentiometer (28) to size
(2/0, 4/0, etc.) of cable being used. Set knob pointer on cable length potentiometer (30) to length (20
feet, 40 feet, etc.) of cable being used. See instruction plate (mounted below knobs).
(26) Check voltage regulator, at intervals, from no-load to full load, and on up to 125% load. Observe
and note voltage at various loads. Voltages should vary no more than plus or minus 1% from 115 V.
(27) Check accuracy of voltmeter.
(a) Open and lower the front door panel of the control box and connect a master voltmeter of
known accuracy to terminals of the voltmeter (2).
(b) Compare unit voltmeter reading with master meter. Error must not exceed 2% of full scale.
(28) Check accuracy of AC ammeter.
(a) Connect a master ammeter of known accuracy to the AC ammeter (3) terminals.
(b) Compare unit ammeter reading with master meter under various loads. Error must not exceed
4% of full scale.
(29) Check operation of meter selector switch (4). A voltage value should be shown in each switch po-
sition, except when the switch handle is on the DOWN (OFF) position.
(30) Check operation of the line switch (5). A normal voltage of 115 V AC should be indicated when
the switch is in LINE-TO-NEUTRAL position. A voltage of approximately 200 V AC should be indi-
cated when the switch is placed in LINE-TO-LINE position.

Page 3
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Page 4
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27. Automatic voltage control 29. Line-drop compensation

potentiometer (R5) on/off switch
28. Cable size compensation 30. Cable length compensation
rheostat rheostat

(31) Check accuracy of frequency meter.

(a) Connect a master frequency meter of known accuracy to the frequency meter (1) terminals.
(b) Compare meter readings. Error must not exceed 1% of full scale.
(32) Operate the unit not less than 10 minutes under full load. The overload device (Ref. 1-1; 7, Fig.
11) MUST NOT trip.
(33) Operate at 125% rated load for 5 minutes immediately following the fullload run. The overload de-
vice MUST trip within 5 minutes and the overload indicating light (1-1; must come ON to indicate an
overload condition).
(34) Reduce load to normal. Turn off indicating light by pressing reset switch (6, Fig. 1).
(35) Check engine oil pressure at governed speed (2000 RPM). Gage should indicate at least 38 PSI
when the engine is hot. Check engine coolant temperature. Gage should indicate in the range of 180
degrees to 190 degrees depending upon ambient temperature.
(36) Check operation of fuse interlock (Ref. 1-1; 8, Fig. 7). With unit operating normally under load, re-
move protective relay circuit fuse (10, Fig. 1). The load contactor should open immediately. This indi-
cates that the fuse interlock relay is functioning properly. Replace fuse and apply load.
NOTE: Make all protective relay tests with the unit operating under load.

Page 5
OM-2037
(37) Check operation of overvoltage relay and indicating light.

(a) With the unit running at normal load, adjust the voltage regulator rheostat (27, Fig. 1) to in-
crease voltage (turn clockwise) until the overvoltage sensing relay actuates the protective monitor
to open the load contactor and turn on the overvoltage indicating light. The overvoltage sensing
relay should trip when voltage reaches 130 V to 134 V.
(b) Return unit to normal operating conditions by adjusting voltage regulator rheostat and press-
ing reset switch (6).
(38) Check operation of undervoltage sensing relay, indicating light, and time delay. Before starting
this check, let us understand the sequence of events which should happen when voltage is reduced
to 103 V or lower. At some value between 103 V and 93 V, the undervoltage sensing relay (Ref. 1-1;
4, Fig. 7) should function to activate the undervoltage time delay circuit. Five seconds after the time
delay circuit is activated, (if the undervoltage condition continues) it should function to open the protec-
tive monitor relay which, in turn, will open the load contactor to stop power delivery. As a result of the
action, the undervoltage indicating light should be turned ON. A stopwatch or sweep-second-hand
watch is required for this check. Proceed as follows:
(a) With unit running at normal load, use the voltage regulator rheostat (27, Fig. 1) to reduce volt-
age to 104V. The load contactor should NOT open after a 5-second delay.
(b) Reduce voltage in steps of 1 V, with a delay of at least 5 seconds between steps. Restart stop-
watch or note position of sweep-secondhand each time voltage is reduced. At some voltage value
between 103 V and 93 V, and 4 to 12 seconds after a new voltage setting is made, the load con-
tactor should be opened and the undervoltage indicating light should be turned on by the step-by-
step action of the undervoltage sensing relay, time delay circuit, and protective monitor relay.
NOTE: The 4 to 12 second time delay is generally set at 5 seconds. It may be necessary to switch to
MANUAL control to obtain these low voltages.
(c) If the load contactor is not opened at 103 V to 93 V, refer to the Trouble Shooting Chart, Sec-
tion 3-1, to determine which component of the undervoltage protective circuit is defective.
(d) If the undervoltage circuit performs satisfactorily, return the unit to normal operation by adjust-
ing the voltage to 115 V, pressing the reset switch, and closing the load contactor.
(39) Check underfrequency sensing relay, protective monitor, and indicating light. At some frequency
value (Hz, cycles-per-second) from 385 Hz down to 375 Hz, the underfrequency sensing relay should
function to signal the underfrequency circuit in the protective monitor module to OPEN the load con-
tactor holding circuit, thus OPENING the load contactor. To check the underfrequency protective com-
ponents, proceed as follows:
(a) While the unit is operating normally under load, reduce generator output frequency by reduc-
ing engine speed. Use the governed speed setting potentiometer (Ref. Fig. 5). Turn adjusting
screw COUNTERCLOCKWISE gradually to reduce engine speed until frequency meter indicates
386 Hz. Underfrequency protective relay should not function to open the load contactor at this fre-
quency. Reduce frequency in steps of 1 Hz.
(b) If the protective system functions to open the load contactor and turn on the underfrequency
light after some frequency between 385 Hz and 375 Hz is reached, all components of the system
are functioning properly. If the load contactor is not opened within the above frequency range, re-
fer to Trouble Shooting Chart to determine which component is defective.
(c) Return unit to normal operating condition.
(40) Check overfrequency sensing relay, protective monitor, and indicating light. This protective circuit
operates in exactly the same manner as the underfrequency circuit except its operating range is from
415 Hz to 425 Hz. Its purpose also is to open the load contactor and turn on an indicating light.
(a) Check procedures are the same for overfrequency as for underfrequency (above) except that
engine speed is INCREASED to create a condition of overfrequency.

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OM-2037
(b) If the overfrequency system functions to open the load contactor and turn on the overfre-
quency light after some frequency between 415 Hz and 425 Hz is reached, all compo-nents of the
system are functioning properly. If the load contactor is not opened within the above frequency
range, refer to Trouble Shooting Chart to determine which component is defective.
(41) If the generator is operating under load at this point, place the contactor control switch (17, Fig.
1) in OFF position to open load contactor and disconnect load. There will be no further need for the
load bank in the following checks.
(42) With the engine running at normal governed speed, check the entire unit for vibration and for any
parts which may have become loosened during the above checks. Tighten any loose attaching hard-
ware as required.
WARNING: ELECTRIC SHOCK, MOVING PARTS, AND NOISE CAN KILL OR INJURE! IF A METAL
SOUNDING ROD IS USED TO DETECT BEARING NOISES, EXERCISE EXTREME CARE TO AVOID
INJURY.
(43) Check 400-Hz generator bearings. Use a stethoscope or metal sounding rod to listen for unusual
noises. If using a metal rod, place one end on the generator housing and hold the other end near the
ear. Hold the rod with three fingers and use the index finger and thumb to form a “sounding chamber”
between the rod and the ear. Do NOT allow the rod to touch the ear. Listen for “grinding” or pounding
sounds which would indicate a defective bearing. An engine noise may be “telegraphed” to the gener-
ator and misinterpreted as a generator noise. Send the unit to overhaul if in doubt of bearing service-
ability.
3. Generator Set Adjustment

A. Generator Adjustment
The 400-Hz generator is a brushless type requiring no adjustments of any kind.
B. Voltage Regulator Adjustments
At some time during the life of the equipment, the solid stage voltage regulator may require output volt-
age adjustments and/or line-drop compensation adjustments. Make these adjustments according to
the instructions given in Solid State Regulator Manual OM-2020, which is a part of Chapter 6 of this
manual.
C.Basic Engine Adjustments
Adjustment procedures applicable to the diesel engine are included in the John Deere Handbook
which accompanies this Hobart manual. Specific information for this particular engine is listed in Fig-
ure 2.
D. Engine Accessories Adjustment
(1) Generator and fan belt adjustment
Refer to 2-1; Para. 8 for fan belt adjustment instructions.

Page 7
OM-2037
Manufacturer John Deere

Model 6059TL
Type Turbocharged, In-line, 6-cylider,
4-cycle Diesel
Displacement 359 cu. in. (5.9 liters)
Compression ratio 17 .8:1
Firing order 1-5-3-6-2-4
Horsepower at 2000 RPM 123 Engine Specifications
Governed speed 2000 RPM +/- 4.5% Figure 2
Idle Speed 850 +/- 25 RPM
Electrical System 12 volt
Oil capacity 18 quarts (17 liters)
Coolant capacity (approx.) 20 quarts (19 liters)
Fuel Diesel oil conforming to ASTM
Specification D.975-66T,
Nos. 1-D and 2-D
Lube oil MIL-L-2014C or MIL-L-2014D
E. Electric Governor System Adjustment
Two electric governor system main components, namely the magnetic pickup and controller, have
critical adjustments which can affect engine performance and therefore generator output. The adjust-
ment of the actuator linkage can also affect engine performance.
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 pick-up
Third - Check or adjust electric control box
(1) Actuator linkage adjustment
The proper adjustment of the mechanical linkage between the electric actuator and engine speed
control lever is important to the satisfactory operation of the complete system.
Exact adjustment instructions regarding effective length of rod assembly(items 4,5,6, and 7,Fig.
3), or regarding the proper hole in actuator lever in which to attach ball joint (4) cannot be deter-
mined because of slight variations in brackets, mountings, and engine performance charac-
teristics. However, definite rules must be followed in making the adjustments:
RULE 1. Adjust linkage to use FULL TRAVEL of actuator output shaft (1).
RULE 2. Linkage must move speed control lever from FULL IDLE to FULL SPEED position,
or VERY CLOSE to FULL SPEED position in order for the generator to pull 125% load.
Check and adjust linkage as follows, with engine stopped.
(a) Before making adjustment, observe and note which hole in actuator lever (3) is used to mount
ball joint (4). It does not necessarily have to be the same hole as may have been previously used.
Disconnect ball joint (4) from actuator lever (3).
(b) Be sure neither lever (the actuator lever, 3, or the fuel control lever) has slipped on shafts. If a
lever has slipped, position it correctly and tighten securely.

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OM-2037
(c) Place both levers (3 and 7) in FULL IDLE position an attempt to connect ball joint (4) at the
hole in actuator lever (3) from which it was removed in step (a). If connection cannot be made,
loosen nuts (5) and adjust effective length of rod assembly (4,5,6 and 7, Fig. 4) so that connec-
tion can be made.
(d) Manually operate actuator lever back and forth between FULL IDLE and FULL SPEED. If ad-
justment is unsatisfactory, try another hole in ACTUATOR lever and readjust rod length.
(e) Tighten all parts securely when adjustment is completed.
1. Actuator shaft
2. Signal input connector
3. Actuator lever
4. Ball joint, actuator
5. Nut
6. Rod
7. Ball Joint, Fuel
Control Lever
Governor Actuator Linkage

Figure 3
(2) Magnetic pickup adjustment (Figure 4)
The strength of the magnetic pickup signal to the control box can be weakened if the tip of the
pickup is too far from the flywheel ring gear. If the pickup is to be removed for any reason, or if the
signal is weak (less than 2.5-V AC) as indicated by a voltage test at the pick-up with the engine
running at rated speed, proceed as follows:
(a) Disconnect wiring as necessary to remove magnetic pick-up from engine.
(b) Loosen nut (2) and remove magnetic pickup (1).
(c) Inspect to make certain the tip is not damaged from contact with the ring gear teeth, replace
pickup if damaged.
(d) Rotate the engine as required to locate a ring gear tooth directly below the tapped, pickup
mounting hole. An imaginary line should pass through the center of the mounting hole, the center
of a flywheel tooth and the center of the flywheel.
(e) Install the magnetic pickup into the tapped mounting hole and thread it in until the tip touches
the “in-line” flywheel gear tooth.
CAUTION: THE PICKUP TIP MUST BE DIRECTLY OVER A TOOTH AND NOT BETWEEN TEETH
WHEN ADJUSTMENT IS MADE.
(f) Back the pickup outward (counterclockwise) 1/2 turn. Hold the pickup securely in this position
and tighten nut (2). This adjustment will result in a clearance of approximately 0.028 inch between
the pickup tip and the flywheel teeth and give an operating AC voltage of 4 V to 8 V at controller
terminals 5 and 6 when the engine is running at no load and governed speed, and approximately
2.5-V at cranking speed.

Page 9
OM-2037
NOTE: As little a 1-V is required for operation of governor control box. Magnetic pickup voltage does not
have to be 4-V to 8-V.
(g) Reconnect wiring to magnetic pick-up.
1. Magnetic pick-up
2. Nut
Magnetic Pick-up Adjustment

Figure 4
(3) Adjustment and Test of Controller and Actuator (Series 6919B Generator Sets)
Refer to Figure 5. The controller has three identical control potentiometers (see inset): the GAIN
potentiometer, the DROOP potentiometer, and the potentiometer marked “I”. In addition, a
SPEED control potentiometer is located just next to the GAIN potentiometer. Make controller set-
tings as follows:
(a) Preliminary Controller Settings
• With the engine of the generator set turned OFF, set the “I” adjustment at the FOURTH in-
crement mark from zero.
• Set the GAIN adjustment at the THIRD increment mark from from zero.
• Set DROOP adjustment COUNTERCLOCKWISE to minimum (zero) position as shown in
Figure 6.
• Start the engine and adjust the controller’s SPEED potentiometer until engine is operating
at rated speed (2000 RPM). Turning the adjustment CLOCKWISE increases engine RPM
and turning it COUNTERCLOCKWISE decreases engine RPM.

Page 10
OM-2037
(b) Checking No-Load Operation of Controller

• Turn the GAIN potentiometer control slowly CLOCKWISE until the governor becomes un-
stable and the actuator lever oscillates. (If the actuator lever DOESN’T oscillate at this set-
ting, upset the lever manually to cause it to oscillate).
• Next, turn the same GAIN potentiometer control slowly COUNTERCLOCKWISE until the
governor becomes stable and the oscillations cease.
• Turn the “I” potentiometer control showly CLOCKWISE until the governor agains becomes
unstable and the actuator lever oscillates.
• If the governor DOES NOT become unstable and the lever DOES NOT oscillate, place the
“I” potentiometer control setting at approximately EIGHT increment marks from zero (or
TWO increment marks from maximum setting).
• If the governor DOES become unstable, and the actuator lever DOES oscillate, turn the “I”
potentiometer control slowly COUNTERCLOCKWISE until the governor becomes stable
and the oscillations cease.
• Upset the actuator lever by hand. If the lever oscillates in 3 to 5 diminishing oscillations
and stops, the setting is correct.
NOTE: For more accurate and dependable settings, when making GAIN and “I” adjustments, ALWAYS
adjust GAIN before adjusting “I”.
(c) Checking Operation of Controller Under Load
Apply a load to the generator set, then remove the load and observe the length of time re-
quired for engine speed to again stabilize. Engine speed should stabilize within 3 to 5 dimin-
ishing oscillations. If this does not happen, proceed as follows:
• With the generator set operating at no load, turn the GAIN setting slightly in the COUN-
TERCLOCKWISE direction, and apply load again to the generator set..
• Remove load again and observe length of time required for engine speed to stabilize. It
should now stabilize in 3 to 5 diminishing oscillations.
NOTE: If engine speed STILL doesn’t stabilize, recheck governor linkage. If linkage is set properly,
the governor controller is probably defective.
(4) Adjustment and Test of Controller and Actuator (Series 6919B Generator Sets with
Speed Control PC Board)
Refer to Figure 6. The controller has three control potentiometers used to control the IDLE speed:
the GAIN potentiometer, the DROOP potentiometer, and the potentiometer marked “I”. In addi-
tion, a SPEED control potentiometer is located just next to the GAIN potentiometer. The new
speed control board is used to adjust RPM’s at the RATED speed setting. Make controller set-
tings as follows:
(a) Preliminary Controller Settings
• With the engine OFF, set the “I” adjustment at the FOURTH increment mark from zero.
• Set the GAIN adjustment at the THIRD increment mark from zero.
• Set DROOP adjustment COUNTERCLCKWISE to minimum (zero) position.
• Turn the adjustment pot on the speed control board, all the way COUNTERCLOCKWISE.
Then, turn the pot twelve full turns CLOCKWISE.
• Start engine, leave at IDLE and adjust controller’s SPEED potentiometer until engine is op-
erating at 875 RPM or an output frequency of 175 Hz. Turning the adjustment CLOCK-
WISE increases engine RPM; turning it COUNTERCLOCKWISE decreases engine RPM.

Page 11
OM-2037
Electric Governor Controller and its Connections

for Series 6919A Generator Sets
Figure 5

Page 12
OM-2037
(b) Checking No-Load Operation of Controller

• Turn the GAIN potentiometer control slowly CLOCKWISE until the governor becomes un-
stable and the actuator lever oscillates. (If the actuator lever DOES NOT oscillate at this
setting, upset the lever manually to cause it to oscillate).
• Next, turn the same GAIN potentiometer control slowly COUNTERCLOCKWISE until the
governor becomes stable and the oscillations cease.
• Turn the “I” potentiometer control slowly CLOCKWISE until the governor again becomes
unstable and the actuator lever oscillates.
• If the governor DOES NOT become unstable and the lever DOES NOT oscillate, place “I”
potentiometer control setting at approximately EIGHT increment marks from zero (or TWO
increment marks from maximum setting).
• If the governor DOES become unstable, and the actuator lever DOES oscillate, turn the “I”
potentiometer control slowly COUNTERCLOCKWISE until the governor becomes stable
and the oscillations cease.
• Flip the engine MODE switch to the BUILD-UP VOLTAGE position. Let the engine stabi-
lize, then flip the switch back to IDLE. Engine speed should stabilize within 3 to 5 diminish-
ing oscilllations. If it doesn’t, repeat the first three steps above.
NOTE: For more accurate and dependable settings, when making GAIN and “I” adjustments, ALWAYS
adjust GAIN before adjusting “I” and upset the throttle lever in between adjustments.
NOTE: If engine speed STILL doesn’t stabilize, recheck governor linkage. If linkage is set properly, the
governor controller is probably defective.
(c) Adjusting for RATED Speed Operation
The function of the new speed control board, is to govern the engine at RATED speed. To
check for proper adjustment, proceed with the following steps:
• With the engine running and properly adjusted for IDLE speed, flip the engine MODE
switch to the BUILD-UP VOLTAGE setting. The engine should be running at 2000 RPM
and output frequency should be 400Hz.
• If the reading is high or low, proceed as follows:
With the generator set operating at RATED speed, turn the adjustment pot on the speed
control board in the CLOCKWISE direction to increase RPM’s or COUTERCLOCKWISE
direction to decrease RPM’s.
After making any adjustments, switch to IDLE speed, allow the engine to stabilize, then
switch back to RATED speed.
(d) Checking the Actuator
The actuator does not require any adjustments. An actuator malfunction, when it occurs, will
result in the actuator being totally inoperative, either due to the actuator coil being open or
shorted to the actuator case. Resistance measurements will reveal either of these conditions.
(e) Checking Operation of Controller Under Load
Apply a load to the generator set, then remove the load and observe the length of time re-
quired for engine speed to again stablize. Engine speed should stabilize within 3 to 5 diminish-
ing oscilllations. If this does not happen, proceed as follows:
• With the generator set operating at no load, turn the GAIN setting slightly in the COUNTER-
CLOCKWISE direction.

Page 13
OM-2037
Electric Governor and its Connections

for Series 6919B Generator Sets
(With Speed Control PC Board)
Figure 6

Page 14
OM-2037
• Apply load again to the generator set. Then remove the load again and observe the length
of time required for engine speed to stabilize. It should now stabilize in 3 to 5 diminishing
oscillations.
NOTE: If engine speed STILL doesn’t stabilize, recheck governor linkage. If linkage is set properly, the
governor controller is probably defective.
(5) Checking Magnetic Pick-up signal
Connect a high inpedance voltmeter to magnetic pickup input terminals (10 and 11, Fig. 6) on con-
troller terminal board. The voltage value at no load, governed speed should be 4-V AC MINIMUM.
NOTE: A signal as low as 2.5-V is sufficient to operate the control unit satisfactorily. If a no-voltage
condition is indicated, the magnetic pick-up is too far away from flywheel teeth, or it is defective.
4. Generator and Exciter Test

The generator fields may be tested with a “Kelvin” bridge. This is a double-bridge type instrument required
for the very low resistances encountered in this test. It is understood that 0 resistance indicates a SHORT
CIRCUITED condition. An infinite resistance reading indicates an OPEN CIRCUITED condition. See Fig.
6 below for resistance values.
NOTE: The equipment should be COLD or at normal ambient temperature when tests are made.
A. Disconnect generator stator leads at the power module panel.
B. Disconnect exciter leads from terminal board mounted on rear of engine control panel. Positive
lead is RED. Negative lead is YELLOW-BLACK.
C. Check resistances and compare to values given in Fig. 7.
TEST CONNECTION NOMINAL RESISTANCE IN OHMS

GENERATOR STATOR
Phase A to N 0.008
Phase B to N 0.008
Phase C to N 0.008
NOTE: The two leads of a phase must be connected when test is made.
EXCITER A-B, B-C, A-C 0.1
Field (RED to YELLOW-BLACK) 7.23
Generator and Exciter Stator Test Values

(70F Ambient Temperature)
Figure 7

Page 15
OM-2037
5. Diode Test
Test values for diodes are not given here because they could be misleading. Test values may vary even
between diodes of the same part number, rating, and manufacturer. General instructions for testing di-
odes follows:
A. Disconnect diode lead(s).

B. Use a good quality ohmmeter. An instrument which indicates 50 ohms at the center of the scale is
preferable.
NOTE: Make certain the battery is in good condition and the pointer is adjusted to zero when the test
lead points are shorted together. Set the scale selector to RX1.
C. Hold one ohmmeter lead point on the threaded end of the diode. Hold the other lead point on the
wire terminal end. Observe and note the indicated resistance. Now reverse lead connections on the di-
ode. Again observe and note the ohmmeter indicated resistance. Generally speaking, if an infinite or
very high resistance was indicated with the leads connected one way and a low, readable resistance
was indicated with the leads connected the opposite way, the diode may be considered good.

Page 16
OM-2037
Section 1. Troubleshooting Procedures
1. General
A. Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the
exact cause of a trouble is found. As a rule, the best place to start looking for the cause of a trouble in a
circuit is at the source of power. Continue testing and checking the circuit, step-by-step, in an orderly man-
ner, until the cause of trouble is located.
B. This section provides information useful in diagnosing and correcting certain troubles which cause un-
satisfactory operation or failure of the equipment.
C. Minor troubles may be remedied by the operator; however, major repairs must be undertaken by experi-
enced mechanics and electricians only.
2. Trouble Shooting Chart (Figure 5)

A. Description
The troubleshooting chart lists information under three headings as follows:
(1) Trouble, Symptom, and Condition

(2) Probable Cause
(3) Test, Check, and/or Remedy
B. Use of the Trouble Shooting Chart
(1) A troubleshooting chart is furnished to provide maintenance and repair personnel with a time-sav-
ing 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 and cannot be located by use of the chart, the only
alternative is to start at the source of power or supply and check the affected circuit or system com-
pletely. Use schematic and connection diagrams which are supplied with this manual.
(3) Electrical components mentioned in the trouble shooting chart are identified by a noun name and
corresponding symbol which allows the user to identify the item more easily on schematic diagrams.
(4) It is assumed that wiring and connections in defective circuits have been thoroughly checked be-
fore condemning any other components.
NOTE: Reference symbols (S9, etc.), used in the Trouble Shooting Chart, are identified on Schematic
and Connection Diagrams.
November 30/91 3-1

Page 1
OM-2037
3. Equipment for Troubleshooting

A good quality multi-scale voltohmmeter is the only instrument required for trouble shooting. At least two
“jumper” leads with “alligator” clips and test prods will be required. The 12-V, engine electrical system may
be used as a 12-V DC power source.
4. Safety - WARNING:
WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT WITH HIGH VOLTAGE LEADS AND
COMPONENTS WHICH COULD CAUSE SERIOUS SHOCK AND INJURY IF TOUCHED WHEN
TROUBLE SHOOTING OR OPERATING THE EQUIPMENT.
5. Parts Replacement
To lessen end item “down” time and to get a faulty machine back “on-theline” as quickly as possible, the
“black-box” concept of parts replacement is reflected in the trouble shooting chart. For example, if a com-
ponent in a particular assembly or module is defective, the quickest way to remedy the situation is to re-
place the complete assembly or the module and send the old assembly or module to stock. Assemblies
which lend themselves to this concept are:
Voltage regulator Protective monitor module

Governor actuator Over-underfrequency module
Overload module Electric governor control “box”
Over-undervoltage module
The above items are in addition to normally replaced items such as fuel pump, injectors, relays, etc.
6. Test Values
Although test values are provided throughout the trouble shooting chart, where applicable, additional infor-
mation and values are given here.
Generator voltage output at maximum voltage regulator rheostat setting: 134-V AC or higher
Generator voltage output at minimum voltage regulator rheostat setting: 108-V AC or lower
Overload relay trips at any value above 112-KVA in 5 minutes.
Overvoltage relay: trips at 130 to 134-V-AC, resets at 125-V AC.
Undervoltage relay: trips at 93 to 102-V AC, resets at 110-V AC.
(Undervoltage time delay circuit functions in 4 to 12 seconds.)
Overfrequency relay: trips at 415 to 425-Hz, resets at 410-Hz.
Underfrequency relay: trips at 375 to 380-Hz, resets at 385-Hz.
Overload relay: trips at 125% rated load in 5 minutes.
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7. Checking Connections and Leads

ALWAYS make a check of connections and leads to a component suspected of being faulty. With the ex-
ception of a few instances, we will assume that connections and wiring have always been checked first
and that power has not been lost as a result of defective wiring or connections.
8. Electric Governor Trouble Shooting

The following facts concerning the operation of the electric governor may be helpful in understanding the
system and in determining which unit in the system is faulty in case of troubles.
A. The system requires two sources of power to operate normally.

(1) 12-V DC input power (from engine electrical system)
(2) 4-V AC input power (from magnetic pickup)
B. Assuming other conditions are normal, the actuator will go to, or remain in, IDLE position under the
following conditions.
(1) No 12-V DC power
(2) No voltage from control box to actuator
C. The actuator will “surge” under the following conditions:
(1) “Stability” or “gain” adjustment set too “high”
(2) Throttle linkage binding
9. Engine Trouble Shooting Procedures

The following engine trouble shooting procedures were taken from John Deere Diesel Handbook. Certain
abnormal conditions which may interfere with satisfactory engine operation, together with methods of de-
termining the cause of such conditions, are covered in the Trouble Shooting Chart.
The ability of the engine to start and operate properly depends primarily on two things:
-The presence of an adequate supply of air, compressed to a sufficiently high compression pressure.
-The injection of the proper amount of fuel at the right time.
Lack of power, uneven running, excessive vibration, stalling, and hard starting may be caused by low com-
pression, faulty injection in one or more cylinders, or lack of sufficient air. Refer to John Deere Handbook
for trouble shooting and repair procedures.
10.Illustrations
Illustrations in Figure 1 are referred to throughout the Trouble Shooting Chart.
November 30/91 3-1

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3-1 November 30/91

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27. Automatic voltage control 29. Line-drop compensation

potentiometer (R5) on/off switch
28. Cable size compensation 30. Cable length compensation
rheostat rheostat

November 30/91 3-1

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3-1 November 30/91

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TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
NOTE: Diesel engine trouble shooting is covered in John Deere Shop Manual under Fault Diagnosis.
ENGINE CONTROLS
1. Engine will not A. Batteries discharged, A. Check voltage across bat-
start. Starter will or loose battery or teries. Voltage should be
NOT crank engine. ground connection approximately 13.5 volts DC.
Check all battery terminals.
Be sure 13.5 volts DC is
reaching solenoid input
teminal.
B. Defective starter B. Momentarily connect a large
solenoid capacity jumper cable be-
tween the hot side of the
starter solenoid and the
starter input terminal. If
the starter attempts to
crank the engine, it indi-
cates the starter solenoid
is defective. Replace. If
the starter did not operate,
proceed to step D.
C. Defective starter C. If starter did not operate
in check C above, the
starter is defective. Rplace.
D. Internal seizure D. If all engine starting com-
ponents are good and the
starter is unable to crank
the engine, internal seizure
is indicated. For repair
procedure see John Deere
workshop manual.
2. Engine will not start. A. Low battery output A. Check battery. Recharge or
Cranking speed low. replace.
B. Loose starting cir- B. Check all connections and
cuit connections or cables. Tighten or replace
faulty cables. as required.
C. Improper lubricating C. Check oil. See Sect. 2-1,
oil viscosity Para. 3, D, (3).
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ENGINE AND CONTROLS (CONTINUED)
3. Engine will not A. No fuel A. Before attempting to find
start. Cranking the cause of “no fuel”,
speed normal. 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 the fuel source and
the suction side of the pump
is indicated. Check and/or
remedy as follows.
(1) Insufficient fuel (1) Fill tank.
in tank
(2) Fuel shut-off (2) Make certain valve is
valve closed OPEN.
(3) Loose connections (3) Tighten all fittings and
damaged hoses or connections. Replace any
fuel lines be- damaged hoses or fuel
tween tank and links.
fuel pump
(4) Plugged or defec- (4) Do not overlook the
tive fuel filter possibility of restrict-|
ed flow through the fuel
filters. Also check gas-
kets for leaking or dam-
aged condition.
(5) Faulty installa- (5) Restricted fitting miss-
tion ing from return line.
(6) Faulty fuel pump (6) Check pump.
(a) Relief valve (a) An open relief valve
not seating will cause low out-
put pressure.
(b) Worn pump
gears or dam- (b) Check pump for nor-
aged pump mal operation. Re-
drive place if defective.
(7) Defect in inject- (7) Refer to John Deere Handbook.
or racks or link- Make adjustments and/or repairs
age according to instructions therein.
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3A. Engine will not start. B. 12-V DC power not B. Apply 12-V DC directly to
Cranking speed normal. reaching governor terminal 1 on governor con-
( Specification 6919B control box trol box. If engine does not come
generator set) up to speed, check following:
C. Governor linkage C. Check governor linkage and
binding or governor throttle shaft for binding
throttle sticking and sticking. Repair as required.
D. Defective or mis- D. The control unit may not be
adjusted magnetic receiving a signal from the mag-
pickup (2, Fig. 4, netic pickup and the “fail-safe”
2-3). feature of the unit may be
functioning to prevent any signal
from reaching the actuator. To
check the magnetic pickup, dis-
connect pickup from control unit
and connect a high impedance AC
voltmeter to the pickup output
leads. Crank engine but don’t
start. Voltage reading should be a
minimum of one (1) volt. If no or
low voltage is indicated, check
pickup adjustment [see 2-3,
Para. 3, E, (2)]. If pickup is
properly adjusted and voltage is
still zero, replace pickup.
E. Defective actuator E. Apply 12-V DC to the two
actuator input leads. Actua-
tor lever should move im-
mediately to full speed po-
sition. If lever does not
move, replace actuator.
F. Defective control F. Connect a DC voltmeter to
unit the leads from the control unit
to the actuator. Start the engine
and manually control speed. At
speeds below governed speed
the voltmeter should indicate
within two (2) volts of the system
voltage. If voltage is at near zero,
turn speed adjusting screw
several turns clockwise to be
sure speed setting is not too low
because of tampering. If voltage
remains low or at zero, replace
control unit. Refer to Barber-
Colman Handbook for control
unit bench tests and adjustments.
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4. Engine is hard to A. Low ambient temper- A. Check causes and remedies
start. Cranking ature, or limited under ENGINE, Trouble 3,
speed normal. fuel above.
B. Low compression which B. Check compression in accor-
may be caused by any dance with Para. 9, C and D.
one of the following:
(1) Sticking or (1) Cylinder head must be
burned exhaust removed and overhauled
valves to correct this condi-
tion.
(2) Compression rings (2) Check rings in accor-
worn or broken dance with instructions
in John Deere Handbook.
(3) Cylinder head (3) Check gasket in accor-
gasket leaking dance with instructions
in John Deere Handbook.
(4) Improper valve (4) Check and adjust valve
clearance adjust- clearance in accordance
ment with instructions in
John Deere Handbook.
5. Engine starts.Stops A. The shut-down circuit A. Restart the engine, hold
after a few seconds may have functioned permissive start switch in
by automatic shut- normally to stop the START position, and observe
down. engine because of low oil pressure gage. If oil
lubricating oil pres- pressure is 12 psi or more,
sure. and the engine shuts down
when the permissive start
switch is released to the
run position, put a jumper
wire across oil pressure
switch terminals “C” and
“NO”. Restart engine. If
the engine continues to run
when the permissive start
switch is released to the
RUN position, the oil
pressure switch is defective.
Replace oilpressure switch
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5. Engine starts.Stops B. Defective or incor- B. Check wiring to high temper-
after a few seconds rectly wired high ature switch. One Red-Yellow
by automatic shutdown temperature switch wire should be connected to
(S 49, located on the the C terminal. With wires
engine block on the removed, check resistance
right side). between terminals C and N.C.
A resistance reading of zero
indicates a good temperature
switch. A readable resis-
tance, indicates a defective
switch. Replace switch if
defective.
6. Engine runs at idle speed. A. Lamp defective A. Replace lamp.
Engine “ON” indicating light
(22, Fig. 1) does not glow.
B. Indicating light body B. Be sure light is grounded
poorly grounded properly.
7. Engine will not A. 12-V DC power not A. Apply 12-V DC directly to
come “up” to gov- reaching governor terminal 1 on governor con-
erned speed in GEN control box due to trol box. If engine comes-up
mode. defective operating to speed, check following:
mode switch (15, Fig. 1
B. Governor linkage B. Check governor linkage and
binding or governor throttle shaft for binding
throttle sticking and sticking. Repair as required.
C. Defective or mis- C. The control unit may not be
adjusted magnetic receiving a signal from the mag-
pickup (2, Fig. 4, netic pickup and the “fail-safe”
2-3). feature of the unit may be
functioning to prevent any signal
from reaching the actuator. To
check the magnetic pickup, dis-
connect pickup from control unit
and connect a high impedance AC
voltmeter to the pickup output
leads. Crank engine but don’t
start. Voltage reading should be a
minimum of one (1) volt. If no or
low voltage is indicated, check
pickup adjustment [see 2-3,
Para. 3, E, (2)]. If pickup is
properly adjusted and voltage is
still zero, replace pickup.
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7. Engine will not D. Defective actuator D. Apply 12-V DC to the two
come “up” to gov- actuator input leads. Actua-
erned speed in GEN tor lever should move im-
mode. mediately to full speed po-
sition. If lever does not
move, replace actuator.
E. Defective control E. Connect a DC voltmeter to
unit the leads from the control
unit to the actuator. Start
the engine and manually
control speed. At speeds
below governed speed the
voltmeter should indicate
within two (2) volts of the
system voltage. If voltage
is at near zero, turn speed
adjusting screw several
turns clockwise to be sure
speed setting is not too low
because of tampering. If
voltage remains low or at
zero, replace control unit.
Refer to Barber Colman
Handbook for control unit
bench tests and adjustments.
7A. Engine will not come A. Governor linkage A. Check governor linkage
“up” to governed speed binding or governor and throttle shaft for binding
in GEN mode. ( Specification throttle sticking and sticking. Repair as
6919B generator set) required.
B. Defective Idle-Gen- B. Apply 12-V DC directly to
Build-up-Voltage the quick connect terminal on
switch (S13) PC board A14. If engine comes
up to speed, Idle-Gen-Build-
up-Voltage switch (S13)
is defective. Replace switch.
C. Defective speed adjust- C. Remove PC board. If engine
ment PC board (A14) then comes up to RATED speed
(with Idle-Gen-Build-up-Voltage
switch in IDLE position) the PC
board is defective. Replace
board.
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8. Engine goes to A. Governed speed con- A. Turn speed control adjusting
overspeed when control adjustment set screw fully counterclock-
trol switch (15, too high (see 2-3, wise. Start engine. Place
Fig. 1) is in GEN Fig. 5) control switch (15, Fig. 1)
position. in GEN position. If engine
speed is now well below gov-
erned speed, turn adjusting
screw clockwise until cor-
rect speed (2000 RPM, 400-
Hz). If engine still goes
to overspeed, proceed to
Step B.
B. Defective linkage or B. Check governor linkage and
actuator actuator for sticking or
binding in full-speed posi-
tion. Repair as required.
C. Defective control C. Replace control unit. Check
unit unit in accordance with
Barber Colman Handbook.
9. Engine is unsteady A. Fault in engine A. Before condemning the gover-
(surges) under load nor system for surging, make
certain the fault is not in
the engine. Make certain all
cylinders are firing prop-
erly.
B. Governor system B. Check and adjust as follows:
faulty or mis-
adjusted
(1) Loose or binding (1) Check linkage ball
governor linkage joints and all connec-
tions for looseness or
binding. Be sure linkage
will move from idle
speed to full speed
without lost motion or
binding.
(2) GAIN and STABIL- (2) Adjust GAIN and STABIL-
ITY controls im- ITY controls on control
properly adjusted unit in accordance with
2-3; Para. 3
(3) Magnetic pickup (3) Check and adjust pickup.
signal weak See 2-3, Para. 3, E, (2)
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10. Engine has slow A. Governor control unit A. Adjust. See 2-3; Para. 3
response time improperly adjusted
B. Actuator linkage binding B. Inspect and repair as required.
C. Engine needs tune-up C. Tune-up as required. Refer
to John Deere Handbook
11. Engine “misses”. A. Insufficient fuel A. Check fuel flow in accordance
Runs unevenly. with John Deere Handbook. Repair
or replace parts as required. Also
see Engine, Trouble 3.
B. Fault injector B. Check injectors in accordance
with John Deere Handbook. See
causes of low compression listed
under ENGINE, Trouble 4, B.
C. Low compression C. Check compression in accor-
pressure dance with John Deere Handbook.
See causes of low compression
listed under ENGINE, Trouble 4, B.
12. Engine lacks power A. Improper engine A. “Tune-up” the engine in
adjustments and gear accordance with John Deere
train timing Handbook
B. Insufficient fuel B. See ENGINE, Trouble 3.
C. Insufficient inlet C. Check air cleaner for
air due to damaged “plugging” and/or damage.
air cleaner
D. Restricted exhaust D. Check exhaust pipes for
system restrictions. Check muffler
for clogged condition.
Replace as required.
GENERATOR EXCITATION CIRCUITS

1. No (or low) gen- A. Defective generator A. Place the REGULATED/
erator output volt- or excitation DIAGNOSTIC switch (25,Fig.1) in
age in all phases. circuit. DIAGNOSTIC position. This
Generator operating applies 12-V DC from the
at 400 Hz. battery to the exciter
field, which should produce
an indicated output voltage
of 55 V-DC +/-5 V-DC. If the
voltage produced is within
this range, the generator is
good, and the trouble is in
the voltage regulator
circuit. Proceed to step B.
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GENERATOR EXCITATION CIRCUITS (CONTINUED)
1. No (or low) generator- B. Defect in VOLTAGE B. Check as follows:
output voltage in all phases. REG. excitation circuit.
Generator operating at 400 Hz.
(1) Defective REGULATED/ (1) Check the switch thoroughly
DIAGNOSTIC switch (25, A defective switch may prevent
Fig. 1) current rent reaching and/or
leaving the voltage regulator
Replace switch if defective.
(2) Defective excitation- (2) Check EDR contacts. A
deenergization relay faulty EDR can prevent power
(K16) (1-1; 1, Fig. 7) from reaching the voltage regu-
lator. Replace relay if defective.
(3) Defective ballast (3) If output voltage was pro-
resistor, (See duced when the generator set
1-1; 16, Fig. 7) was operated in DIAGNOSTIC
mode, the resistor is good. If no
voltage was produced in DIAG-
NOSTIC mode, the resistor could
be defective. Connect a jumper
lead across the ballast resistor.
If an output voltage is now pro-
duced, replace resistor if defective.
(4) Defective (4) Disconnect plug from voltage
connector at regulator PC board. Using jumper
voltage regu- leads with clip and prod terminals,
lator, or defec- connect 12-V DC to terminals
. tive wiring from 4 and 5 in loose plug. Connect
regulator to NEGATIVE to terminal 5 and
exciter field. connect POSITIVE lead to termi-
nal 4 (see Schematic/Connection
Diagram in Chapter 6). If the
generator will NOT produce at
least 50 V-AC, replace or repair
connector and wiring between
voltage regulator and exciter field
as required.
(5) Defective voltage (5) All components in the excitation
regulator circuit except the voltage regulator
have been tested in steps (1)
through (4) above. This leaves only
the regulator as a cause of trouble.
Replace voltage regulator PC
board.
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LOAD CONTACTOR OPERATING CIRCUIT
1. Load contactor (K1) A. In addition to de- A. After checking fuse (F1) in
will not close when fective wiring and step (1) below, check all
control switch (20, connections in the AC wiring and connections in
Fig. 1) is held in and DC load contactor the load contactor circuits.
ON position. Gener- actuating circuits, Then check components as
ator running at the load contactor follows:
normal voltage. No may be prevented from
fault lights on. closing for any one
of the following
reasons:
(1) Blown fuse (F1) (1) Remove and inspect fuse.
(1-1; 16, Fig. 8) Replace if blown.
(2) Defective (open) (2) Replace protective
relay in protec- module with a module
tive module (1-1; known to be operating
4, Fig. 8) properly. If contactor still
doesn’t close,proceed to step (3).
(3) Defective load (3) Set Regulated/Diagnos-
contactor control tic switch (S1) in
switch (S5) (20, REGULATED position.
Fig. 1) Check AC voltage input
to contactor rectifier
(CR6). If voltage isn’t
approximately 115-V AC,
contactor control
switch is defective and
must be replaced.
(4) Defective recti- (4) After making certain
fier (CR6) (1-1; that contactor switch
5, Fig. 11) (S5) is providing 115-V
AC to the rectifier
(CR6), measure DC out-
put voltage between
positive (+) and nega-
tive (-) terminals of
rectifier. If voltage
measured isn’t approxi-
mately 90-V DC, replace
rectifier.
(5) Defective load (5) Disconnect leads at load
contactor coil contactor terminals X1 and X2.
(K1) (1-1; 6, Check coil resistance between
Fig. 11) these terminals. Resistance
should be approximately 600
ohms. If coil is defective, replace
the complete load contactor.
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LOAD CONTACTOR OPERATING CIRCUIT (Continued)
2. Load contactor (K1) will close A. 28.5-V DC is not A. Proceed as follows to find
when control switch (20, Fig. 1) reaching plug inter- the cause of this mal-
is held in momentary ON lock relay (K2) from function.
position. Opens immediately aircraft for the
when switch is released to center following reasons:
ON position.
(1) Generator to air- (1) Inspect cable connector
craft cable con- plug thoroughly for dam-
nector defective aged E and F terminals.
or not plugged Be sure the plug is fully mated
into aircraft with the aircraft receptacle con-
receptacle connector. nector and making good contact.
(2) Aircraft reject- (2) Check aircraft on board
ing power electrical equipment and
controls
B. “Blown” protective B. Press the lens housing of
relay fuse (F2) fault indicating lights. If lamps
(1-1; 8, Fig. 6) do not glow, replace fuse (F2).
C. Defective plug- C. Place test-bank switch (S2)
interlock relay (K2) (34, Fig. 1) in ON position. If load
contactor will now remain closed,
replace the plug-interlock relay
(K2) (Sect. 1-1; 2, Fig. 7)
D. Small contacts in D. Connect a jumper lead be-
load contactor (K1) tween small terminal no. 1
defective and no. 2 on the load contactor.
If load contactor will now remain
closed, replace the complete load
contactor (K1).
E. Defective fuse- E. Connect a jumper across
interlock relay (K17) resistor R46) (Sect. 1-1;
or resistor (R46) 21, Fig. 8). If the
contactor will now remain
closed, replace the resistor
(R46). If the contactor will
not remain closed, replace
fuse-interlock relay (K17)
. (Sect. 1-1; 8, Fig. 7).
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GENERATOR CONTROLS AND INSTRUMENTS (CONTINUED)
3. Load contactor A. Fuse (F1 or F2) A. Remove and inspect fuses
opens during power blown. (1-1; 8 and 9, Fig. 6).
delivery. NO fault Replace as required.
indicating lights on.
B. A fault has devel- B. If the load contactor cannot
oped in the load be closed by operation of
contactor holding the control switch (S5) (20,
circuit. Fig. 1), check the circuit
in accordance with instruc-
tions in Trouble 1, above
under LOAD CONTACTOR
OPERATING CIRCUIT. If the
load contactor can be closed, but
opens as soon as control
switch (S5) is released,
check for trouble under
Trouble 2, above.
C. Cable accidentally C. Reconnect cable.
disconnected from
aircraft.
PROTECTIVE CIRCUIT
NOTE: The protective relays and protective monitor are not completely functional until the load
contactor is CLOSED. Since it is not advisable to vary voltages for test purposes while delivering
power to an aircraft, the generator should be connected to a load bank for trouble shooting the
protective circuits.
To avoid repetition, it will be assumed that the reset switch [(6), Fig. 1] has been pushed and the
load contactor has been closed before commencing each test.
1. Load contactor A. The overvoltage con- A. Press reset switch (6,
opens during power dition may have been Fig. 1) and resume power
delivery. Over- the result of a sud- delivery. Observe voltmeter
voltage indicating den drop in the load, (2, Fig. 1) to be certain
light ON or possible tampering voltage is normal 115 V AC.
with voltage regula- Adjust to normal if necessary. If
tor potentiometer the load contactor is opened
(27, Fig. 1), and may again and an over-voltage condi-
have been a normal tion is indicated by OV indicating
action. light, proceed to step B.
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PROTECTIVE CIRCUIT
1. Load contactor opens during B. Defective over-under- B. Use voltage adjusting
power delivery. Overvoltage voltage sensing mod- potentiometer (27, Fig. 1)
indicating light ON ule (K26) to reduce voltage to 110 V
AC. Observe voltmeter and
gradually increase voltage with
potentiometer. If the over-under-
voltage sensing module (K26)
functions to open the load
contactor at any value less than
134 VAC, it is defective. Replace
over-undervoltage module.
2. Load contactor A. An undervoltage con- A. Observe generator voltage on
opens during power dition caused the voltmeter and adjust to normal
delivery. Under- over-undervoltage 115 V AC with voltage
voltage indicating sensing module (K26) regulator potentiometer (27,
light ON. to function normally. Fig. 1). Resume normal oper-
ation. If the load contactor
opens again and an under-
voltage condition is indi-
cated by UV indicating
light, proceed to step B.
2. Load contactor B. Defective over-under- B. Use potentiometer (27, Fig.
opens during power voltage module (K26) 1) to reduce voltage to 104
delivery. Under- V. The undervoltage indi-
voltage indicating cating light should NOT come
light ON (Cont’d) on during a time delay of 4
to 12 seconds. If the light
comes on before a delay of 4
to 12 seconds, the under-
voltage relay is defective.
Replace the module (K26).
C. Defective protective C. With unit running normally,
monitor module (K14) use potentiometer (27, Fig.
1) to reduce voltage quickly
to 90 V. If the undervoltage
indicating light (DS38) is
turned ON immediately, the
protective monitor circuitry
is defective. Replace
protective monitor (K14).
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PROTECTIVE CIRCUIT (CONTINUED)
3. Load contactor opens during A. Electric governor A. Proceed as follows:
power delivery. Overfrequency improperly adjusted,
indi cating light (DS40) ON or malfunctioning
(1) Governor improp- (1) Adjust in accordance
erly adjusted with Sect. 2-3, Para. 3,
E, (3).
(2) Electric governor (2) Check and adjust or re-
system malfunc- pair in accordance with
tioning ENGINE AND CONTROLS,
Troubles 8 and 9.
B. Defective over-under- B. If overfrequency nuisance
frequency sensing tripping continues after the
module (K27) governor system is proven to be
good, and an overfrequency con-
dition does not exist, replace the
over-under frequency module (K27).
4. Load contactor opens A. Electric governor A. Proceed as follows:
during power delivery. Under- improperly adjusted,
frequency light ON. or malfunctioning
(1) Governor improp- (1) Adjust in accordance
erly adjusted with Sect. 2-3, Para. 3, E, (3).
(2) Electric governor (2) Check and adjust or re-
system malfunc- pair in accordance with
tioning ENGINE AND CONTROLS,
Troubles 8 and 9.
B. Defective over-under- B. If overfrequency nuisance
frequency sensing tripping continues after the
module (K27) governor system is proven to
be good, and an underfrequency
condition does not exist, replace
over-under-frequency relay.
5. Load contactor A. There may have been A. Observe ammeter (3, Fig. 1).
opens during power an overload condition Check for abnormal overload
delivery. Over- which caused the condition and correct. If
frequency indi- overload device (K4) overload device functions to
cating light ON. to function normally. open the load contactor when
an overload does not exist,
proceed to step B.
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PROTECTIVE CIRCUIT (CONTINUED)
5. Load contactor B. One of the resistors B. An open resistor will cause
opens during power (R26, R27, or R28) a higher than normal volt-
delivery. Over- across overload age. Refer to Schematic/
frequency indi- transformers is open Connection diagram for exact
cating light ON. circuited. location of these resistors
Check resistors. Replace if
defective.
C. Overload device C. Replace overload module (K4)
printed circuit board (Sect. 1-1; 5, Fig. 7) with
defective an overload module known to
be operating properly.
GENERATOR
1. No (or low) voltage A. Shorted diode in A. Check diodes in accordance
output exciter rectifier with Sect. 2-3, para. 6. If
(CR2). diodes are good, proceed to
step B.
B. Open or shorted exci- B. Use ohmmeter to check for
ter rotor winding open or shorted condition.
(G2) If exciter rotor windings
are good, proceed to step C.
C. Open or shorted exci- C. Check field resistance. See
ter field windings (L2) Sect. 2-3, Fig. 6 for normal values.
D. Open or shorted gen- D. Check resistance with ohm-
erator rotor windings meter to determine if open
(L1) or short circuited.
2. Generator operates A. Open or short cir- A. Check stator winding resis-
single phase cuited winding in tances. See Sect. 2-3, Fig.
generator stator (G1) 6 for normal values.
3. Generator A. Loose connection A. Check all output connec-
overheats causing high resis- tions. Look for discolora-
tance. tion caused by heat. Tighten
or replace as required.
B. Improper or blocked B. Check for foreign material
ventilation. (rags, etc.) blocking air flow.
Provide adequate ventilation.
C. Generator stator C. Check stator windings. See
windings short circuited. Sect. 2-3, Fig. 6.
November 30/91 3-1

Page 21
OM-2037

EXTERNAL LOAD
4. Unbalanced output B. Open or short circuited B. Check stator windings in
phase accordance with 2-3, Para. 5
Repair or replace as re-
quired.
A. Loose connection in A. Check all output connec-
output circuit. tions. Discolored connectors
indicate a loose connection.
Tighten or replace as required.
C. Defective connection C. Check plug and receptacle
in output circuit. connectors at aircraft.
Tighten, repair, or replace
as required.
D. Break or cut in out- D. Inspect. Repair or replace

put cable assembly. as required.
E. Unbalanced load E. Check aircraft 400-Hz compo-

nents.
3-1 November 30/91

Page 22
OM-2037

Section 1. Introduction
1. General
The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail
parts of four series of engine-driven generator sets manufactured by Hobart Brothers Company, Power
Systems Group, Troy, Ohio, 45373. These sets are identified by Hobart Series Numbers 7004, 7004A,
7004B, and 7004C.
2. Purpose
The purpose of this list is to provide parts identification and descriptive information to maintenance and
provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare
parts.
3. Arrangement
Chapter 4 is arranged as follows:
Section 1 - Introduction
Section 2 - Manufacturer’s Codes
Section 3 - Parts List
Section 4 - Numerical Index
4. Explanation of Parts List

A. Contents
The parts list contains a breakdown of the equipment into assemblies, subassemblies, and detail
parts. All parts of the equipment are listed except:
(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are avail-
able 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.
November 1/91 4-1

Page 1
OM-2037
B. Parts List Form
This form is divided into six columns. Beginning at the left side of the form and proceeding to the right,
columns are identified as follows:
(1) FIGURE-ITEM NO. Column
This column lists the figure number of the illustration applicable to a particular parts list and also
identifies each part in the list by an item number. These item numbers also appear on the illustra-
tion. Each item number on an illustration is connected to the part to which it pertains by a leader
line. Thus the figure and item numbering system ties the parts lists to the illustrations and vice
versa. The figure and index numbers are also used in the numerical index to assist the user in
finding the illustration of a part when the part number is known.
(2) HOBART PART NUMBER Column
ALL part numbers appearing in this column are Hobart numbers. In all instances where the part is
a purchased item, the vendor’s identifying five-digit code and his part number will appear in the
NOMENCLATURE column. Vendor parts which are modified by Hobart will be identified as such
in the NOMENCLATURE column. In case Hobart does not have an identifying part number for a
purchased part, the HOBART PART NUMBER column will reflect No Number and the vendor’s
number will be shown in the NOMENCLATURE column. Parts manufactured by Hobart reflect no
vendor code or part number in the NOMENCLATURE column.
(3) NOMENCLATURE Column
The item identifying name appears in this column. The indenture method is used to indicate item
relationship. Thus, components of an assembly are listed directly below the assembly and in-
dented one space. Vendor codes and part numbers for purchased parts are shown in this column.
(4) REC. SPARES Column
When there is an entry in this column, it shows the quantity of that item recommended for spares
to support ONE end item.
(5) “EFF” (Effective) Column
This column is used to indicate the applicability of parts to different specifications of equipment.
When more than one specification of equipment is covered by a parts list, there are some parts
which are used on only one specification. This column is used for insertion of a code letter “A”,
“B”, etc., to indicate these parts and to identify the particular specification they are used on.
Uncoded parts are used on all specifications.
Parts coded “A” are usable on Specification 6919A only.
Parts coded “B” are usable on Specification 6919B only.
(6) UNITS PER ASSEMBLY Column
This column indicates the quantity of parts required for an assembly or subassembly in which the
part appears. This column does not necessarily reflect the total used in the complete end item.
4-1 November 1/91

Page 2
OM-2037
Section 2. Manufacturer’s Codes
1. Explanation of Manufacturer’s (Vendor) Code List

The following list is a compilation of vendor codes with names and addresses for suppliers of purchased
parts listed in this publication. The codes are in accordance with the Federal Supply Codes for Manufac-
turer’s Cataloging Handbook H4-1, and are arranged in numerical order. Vendor codes are inserted in the
nomenclature column of the parts list directly following the item name and description. In case a manufac-
turer does not have a vendor code, the full name of the manufacturer will be listed in the nomenclature col-
umn.
CODE VENDOR’S NAME AND ADDRESS
00779 AMP Inc. P.O. Box 3608 Harrisburg, Pennsylvania 17105
01428 Superior Ball Joint Corporation 1202 South Quality Drive P.O. Box 227
New Haven, IN 46774
02231 Anchor Rubber Company 840 South Patterson Boulevard P.O. Box 832, Dayton, OH 45401
02660 Amphenol Division Bunker-Ramo Electra Corp. 2801 S. 25th Avenue

Broadview, IL 60153
03613 Barber-Colman Co. 1354 Clifford Ave. Loves Park, IL 61132
03924 StratoFlex, Inc. 2nd and Piper Sts., Baer Field Box 9190, Waynedale Station
Ft. Wayne, IN 46809
04713 Motorola Inc. Semiconductor Products Div. Phoenix, Arizona 85008
05277 Westinghouse Electric Corp. Semi Conductor Div., Hill Street

Youngwood, Pennsylvania 15697
08108 Lamp Industries For Use With Industry Designations & Abbreviations for Lamps
15605 Eaton Corporation Cutler-Hammer Div. 4201 N. 27th St., Milwaukee, Wisconsin 53216
16238 Lord Mfg. Co. Inc. Sterling Road South Lancaster, Massachusetts 01561
16764 General Motors, Corp. Delco-Remy Division 2401 Columbus Ave. P.O. Box 2439
Anderson, IN 46018
18265 Donaldson Co. Inc. 400 W. 94th St. P.O. Box 1299 Minneapolis, MN 55440
19220 Eberhard Manufacturing Company 21944 Drake Road Strongsville, OH 44136
November 1/91 4-2

Page 1
OM-2037
20038 ESB Inc. 5 Penn Center Plaza P.O. Box 8109 Philadelphia, Pennsylvania 19101
20598 Tech. Products 105 Willow Ave. Staten Island, N.Y. 10305
21335 Fafnir Bearing Company Division of Textron 37 Booth Street

New Britain, Connecticut 06050
21585 Farr Company, Airport Station P.O. Box 92187 Los Angeles, California 90009
22938 Prototype Development, Inc. 7750 Hub Parkway Cleveland, OH 44125
24248 Southco Inc. 210 N. Brinton Lake Road Concordville, PA 19331
26403 ITT - Grinnell Corp. 260 W. Exchange St. Providence, RI 02901
27192 Eaton Corporation Power Control Operations 4265 N. 30th St., Milwaukee, WI 53216
28520 Heyman Mfg. Co. 147 Michigan Ave. P.O. Box 160 Kenilworth, NJ 07033
30327 Imperial Clevite Inc. Fluid Components Division 6300 W. Howard Street, Chicago, IL 60648
31337 Parker Metal Corp. 85 Prescott Street Worchester, MA. 01605
31356 J-B-T Instruments, Incorporated 394 East Street P.O. Box 1818
New Haven, Connecticut 06508
35708 Tridon Limited P.O. Box 1600 Nashville, TN 37202
41197 Modine Manufacturing Company 1500 Dekoven Avenue Racine, Wisconsin 53401
44655 Ohmite Manufacturing Company 3601 West Howard Street Skokie, Illinois 60076
49234 Protectoseal Co. 225 W. Foster Ave. Bensenville, IL 60106
50508 Magnetic Components Inc. 9520 Ainslie St. Schiller Park, Illinois 60176
50603 H.B. Electrical Mfg. Co. Inc. 1125 National Pky. Mansfield, OH 44906
51377 Kysor of Caddilac 1100 Wright St. Cadillac, MI 49601
51589 ST - SEMICON, INC. 415 N. College Ave. Bloomington, IN 47401
57448 Allis Chalmers Corp. Stevens & Adamson Mfg. Subsidiary 275 Ridgeway Avenue,
P.O. Box 1367 Aurora, IL 60507
57733 Stewart-Warner Corporation 1826 Diversey Parkway Chicago, IL 60614
4-2 November 1/91

Page 2
OM-2037
60741 Triplett Electrical Instrument Company 286 Harmon Road Bluffton, Ohio 45817
61112 Cleanweld Products Co., Turner Div. 821 Park Avenue Sycamore, IL 60178
62295 Butech Pressure Systems Division of Ber-Lo Mfg. Co., Inc. 4928 Pittsburgh Ave.
Erie, PA 16509
70040 General Motors Corp. AC Spark Plug Division 1300 N. Dort Highway
Flint, MI 48556
70485 Atlantic India Rubber Works Inc. 571 W. Polk Street Chicago, IL 60607
71400 Bussman Mfg. Division of McGraw Edison Company 114 Old State Rd.
P.O. Box 14460 St. Louis, Missouri 63178
71744 General Instrument Corp. Miniature Lamp Div., Worldwide 443 N. Ravenswood Ave.
Chicago, IL 60640
72582 General Motors Corp. Detroit Diesel Allison Div. 13400 W. Outer Dr.
Detroit, MI 48228
73559 Carlingswitch, Inc. 505 New Park Ave. West Hartford, Connecticut 06110
74400 Stewart Warner Corp, Hobbs Div. Ash Street & Yale Boulevard
Springfield, Illinois 62705
75175 K-D Lamp Company 1910 Elm St. Cincinnati, OH 45210
75358 Knape & Vogt Manufacturing Company 2700 Oak Industrial Drive
Grand Rapids, Michigan 49505
77342 Potter and Brumfield Division AMF Inc. 200 Richland Creek Drive
Princeton, Indiana 47670
78225 Stant Manufacturing Company Inc. 1620 Columbia Avenue.

Connersville, Indiana 47331
78388 Synchro - Start Products, Inc. Sub. of Knowles Electronics, Inc. 8109 N. Lawndale Ave.
P.O. Box 147 Skokie, IL 60076
79470 Dana Corp., The Weatherhead Division 767 Beta Drive Cleveland, OH 44143
80183 Sprague Products 87 Marshall Street North Adams, MA. 01247
81074 ITT - Holub Industries 413 Elm Street Sycamore, Illinois 60178
81518 Flexaust Co. Div. of Callahan Mining Co. 11 Chestnut St. Amesbury, MA 01913
November 1/91 4-2

Page 3
OM-2037
81860 Barry Controls Division of Barry Wright Corp. 700 Pleasant Street
Watertown, Massachusetts 02172
82121 Electro - Switch Corp. 180 King Ave. Weymouth, MA 02188
82372 Huntington Rubber Company Los Angeles, CA
85925 Emico Inc. (Electro Mechanical Instrument Company, Inc.) 123 N. Main St.,
P.O. Box 368 Dublin, Pennsylvania 18917
89110 AMP Inc. Capitron Div. 1595 South Mt. Joy Street Elizabethtown, Pennsylvania 17022
89616 Uniroyal Inc. Plastic Products Division 312 N. Hill St. Mishawaka, Indiana 46544
90201 Emhart Ind. Inc. Mallory Capacitor Co. 4760 Kentucky Ave. P.O. Box 372
Indianapolis, Indiana 46206
90763 TRW Inc. United-Carr Div. 10544 West Lunt Ave. Rosemont, Illinois 60018
91637 Dale Electronics Incorporated P.O. Box 609 Columbus, Nebraska 68601
91929 Micro Switch Division Honeywell Inc. 11 W. Spring Street Freeport, Illinois 61032
92563 McGill Manufacturing Company, Inc. Bearing Division 909 N. Lafayette

Valparaiso, Indiana 46383
94222 Southco Inc. 210 N. Brinton Lake Road Concordville, PA 19331
95879 Alemite Instrument Division of Stewart-Warner Corporation 1826 Diversey Parkway

Chicago, IL 60614
98738 Stewart-Warner Electronics Div. of Stewart-Warner Corp. 1300 N. Kostner

Chicago, IL 60651
98991 Worchester Controls Corp. Worchester Valve Division 125 Hartwell Street
West Boyleston, Massachusetts 01583
No Number Modine Manufacturing Co. 1500 Dekoven Avenue Racine, WI 53401
4-2 November 1/91

Page 4
OM-2037
SECTION 3. PARTS LIST
1. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a lefthand page and the applicable parts list
will appear on the opposite righthand page. Unless the list is unusually long, the user will be able to look
at the illustration and read the parts list without turning a page.
2.Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list.
* - item not illustrated
A, or AMP - ampere
AC - alternating current
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 vendor code)
NOTE: An item which does not reflect an index number is an assembly which is not illustrated in its
assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated.
November 31/91 4-3

Page 1
OM-2037
Generator Set
Figure 1
4-3 November 31/91

Page 2
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY
1- 6919A1 GENERATOR SET FOR TRAILER OR TRUCK

MOUNTING A REF
6919B-1 GENERATOR SET FOR TRAILER OR TRUCK
MOUNTING B REF
1 No Number . CANOPY ASSEMBLY (For Details See Fig. 2) 1
2 No Number . GENERATOR SET WITHOUT CANOPY
(For Details See Fig. 3) 1
3 281080 . FRAME, MOUNTING 1
4 402987 . LABEL, HOBART 3
*5 281056 . TRAILER, FENDERS, FUEL TANK (OPTION)
*6 76B-1150 . LABEL, OPERATING INSTRUCTIONS 1
* NOT ILLUSTRATED
November 31/91 4-3

Page 3
OM-2037
Canopy Assembly
Figure 2
4-3 November 31/91

Page 4
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
2- NO NUMBER CANOPY ASSEMBLY (For NHA See Fig. 1) REF

1 281074 . PANEL, FRONT 1
2 281115 . PANEL, REAR 1
3 281114 . SUPPORT, CNTR., CANOPY 1
4 281103 . TOP, CANOPY 1
5 280591 . PANEL, LOUVERED, ASSY. 1
6 281071 . DOOR, CANOPY, ASSY. 2
7 281096 . DOOR, CANOPY,LEFT REAR 1
8 281093 . COVER, GENERATOR CONTROL 1
9 281574 . COVER, ENGINE CONTROL 1
10 281109 . DOOR, CANOPY, RIGHT REAR 1
11 181125 . LATCH, DOOR 8
* 12 280606 . CLAMP, CABLE, OUTPUT 1
*13 281086 . SHROUD, AIR, GENERATOR 1
*14 281102 . BAFFLE, HEAT 1
*15 351683 . GROMMET, STATOR LEADS 1
*16 78A-1000 . LABEL, ID 1
*17 79A-1110 . LABEL, OPTION 1
*18 76B-1148 . LABEL, DIESEL FUEL 1
*19 430077-2 . LABEL, HANDLING 1
*20 403153-1 . BUMPER, RUBBER 1
* NOT ILLUSTRATED
November 31/91 4-3

Page 5
OM-2037
Generator Set Without Canopy

Figure 3
4-3 November 31/91

Page 6
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
3- No Number GENERATOR SET WITHOUT CANOPY

(For NHA See Fig. 1) REF
1 408786 . FAN, COOLING 1
2 No Number . RADIATOR AND COOLING SYSTEM GROUP
3 280544 . KIT, AIR CLEANER, ASSY. (For Details See Fig. 5) 1
4 408589 . ENGINE ASSEMBLY, JOHN DEERE DIESEL,
V72582, No. 6359TL (For Components of this
assembly see Print 408589 in Chapter 6) 1
5 100GHP-1157 . FLANGE, CONNECTOR, MANIFOLD, ASSY. 1
6 280518 . PIPE, EXHAUST, ASSY 1
7 DDW-495-1 . CAP, RAIN 1
8 280517 . PIPE, ELBOW 1
9 280519 . MUFFLER, ASSEMBLY 1
10 180404 . SUPPORT, MUFFLER, LH 1
*10A 180405 . SUPPORT, MUFFLER, RH 1
11 280543-3 . BOX ASSEMBLY, CONTROL, GENERATOR
12 280542-1 . PANEL ASSEMBLY, CONTROL, ENGINE
13 281118 . PANEL, SUPPORT, CONTROL BOX 1
14 281116 . LEG, SUPPORT, CONTROL BOX 2
15 281080 . FRAME, MOUNTING 1
16 281117 . LEG, SUPPORT, CONTROL BOX 1
17 280722B . PANEL, CONTACTOR, ASSY.
184 281098 . KIT, ELECTRICAL GOVERNOR, ASSY.
(For Details See Fig. 6) A 1
282949 . KIT, ELECTRICAL GOVERNOR, ASSY.
(For Details See Fig. 6A) B 1
180961 . KIT, QUICK-START, ASSY. (OPTION)
19 180960 . . BRACKET, MOUNTING, QUICK-START 1
20 402096 . . QUICK-START, ASSY. 1
21 281871-1 . BATTERY, 12-VOLTS (For Details See Fig. 9) 1
22 281086 . SHROUD, AIR, ASSY. 1
23 181582 . GENERATOR ASSY. (For Details See Fig. 13) 1
*24 404151 . CLAMP, EXHAUST 1
*25 404154-15 . CLAMP, FULL CIRCLE 2
*26 100GHP-1158 . GASKET, EXHAUST 1
*27 480603-1 . MOUNT, SHOCK 2
* NOT ILLUSTRATED
November 31/91 4-3

Page 7
OM-2037
4-3 November 31/91

Page 8
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
3- (CONTINUED)
*28 HF-2752 . MOUNT, RUBBER, (4 For mounting control
box to control box support panel, and 4 for
mounting muffler assembly) V16238,
No. 4624-105 8
*29 280015 . MOUNT, ENGINE, LEFT 1
*30 280018 . MOUNT, ENGINE, RIGHT 1
*31 280621A . LINES, FUEL, ASSEMBLY
*32 180434 . LINE, OIL, ASSEMBLY (For Details See Fig. 8) 1
*33 406254-1 . MOUNT, SHOCK 4
* NOT ILLUSTRATED
November 31/91 4-3

Page 9
OM-2037
Radiator and Cooling System Group

Figure 4
4-3 November 31/91

Page 10
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
4- No Number RADIATOR AND COOLING SYSTEM GROUP

1 180954 . RADIATOR 1
2 280054 . SUPPORT, RADIATOR 2
3 181269 . HOSE, RADIATOR, INLET 1
4 180928 . SHROUD, FAN 1
5 405743 . CAP, RADIATOR, V78225, No. AAX-4018 1
6 181042 . PIPE, HOSE COUPLING 1
7 W-10869-7 . CLAMP, HOSE, RADIATOR, V35708, NO. HS-12 6
8 181040 . HOSE, ENGINE INLET 1
9 56531 . HOSE RADIATOR OUTLET 11-1/2"
10 281462A . GUARD, FAN 2
11 404154-11 . CLAMP, HOSE, RADIATOR, V31337, NO.2020 1
12 280742 . SUPPORT, RADIATOR HOSE 1
13 181042 . PIPE, HOSE COUPLING 1
* 14 351541 . LABEL, CAUTION, FAN 2
* 15 403782-2 . SWITCH, SHUTDOWN, TEMPERATURE, V51377,
NO. 1002-04880-34 1
* 16 W-7814-4 . BUSHING, PIPE, STEEL 1
* 17 386751 . CLAMP, HOSE, OVERFLOW 2
* NOT ILLUSTRATED
November 31/91 4-3

Page 11
OM-2037
Air Cleaner Assembly

Figure 5
4-3 November 31/91

Page 12
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
5- 280544 KIT, AIR CLEANER, ASSY

1 181128 . CLEANER, AIR 1
2 403483 . CLAMP, HOSE 2
3 280538 . PIPE, ELBOW, AIR CLEANER, ASSY. 1
4 85A-1045 . REDUCER, RUBBER 1
5 W-10869-6 . CLAMP, HOSE 3
6 280541 . PIPE, AIR CLEANER 1
7 77A-1166 . ELBOW, RUBBER, 90 , 3" ID 1
*8 280535 . BRACKET, MOUNTING, AIR CLEANER 1
*9 181129 . CLAMP, AIR CLEANER 1
* Not Illustrated
November 31/91 4-3

Page 13
OM-2037
Electric Governor Kit

Figure 6
4-3 November 31/91

Page 14
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
6- 281098 KIT, ELECTRIC GOVERNOR, ASSY

(For NHA See Fig. 3) A REF
282949 KIT, ELECTRIC GOVERNOR, ASSY
(For NHA See Fig. 3) B REF
1 281774-2 . SENSOR, MAGNETIC GOVERNOR
V03613, No. DYNT-17200 1
2 181020 . CONTROLLER, GOVERNOR, ELECTRIC
V03613, No. DYN1-10654-000-0-12 1
3 280447 . GOVERNOR, ACTUATOR, ELECTRIC
V03613, No. DYNC-11021-300-12 1
4 84A-1091 . ARM, THROTTLE, GOVERNOR 1
5 402908 . JOINT, BALL, GOVERNOR LINKAGE 2
6 W-9476-41 . ROD, THREADED, 1/4-28 X 4 1
7 W-11280-3 . NUT, HEX, 1/4-28 5
8 181891-1 . BOARD, PC, SPEED CONTROL B 1
*9 84A-1075 . MOUNT, SHOCK, RUBBER, V20598,
No. 51083, 50-DURO 4
*10 482989 . STRAP, WIRE, GROUND 2
*11 280460 . BRACKET, GOVENOR MTG 1
*12 281751-1 . ADAPTER 1
*13 482496-2 . CLAMP 2
*15 400829-5 . TERMINAL, SPADE 3
* NOT ILLUSTRATED
Revised 4-3
March 22/93 Page 15
OM-2037
Fuel Lines Assembly

Figure 7
4-3 November 31/91

Page 16
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
7- 280621A LINES, FUEL, ASSEMBLY (For NHA See Fig. 3) REF

1 400818-1 . NIPPLE, HEX, 1/2 X 3/8 1
2 400819-2 . VALVE, BALL 1
3 W-10886-8 . CONNECTOR, MALE 1
4 W-10891-6 . ELBOW, MALE 1
5 W-10893-0 . FITTING, HOSE, SWIVEL, FEMALE 2
6 56535 . HOSE, LOW PRESSURE, 3/8 ID 24"
7 78B-1019-3 . TUBE, RIGID, HOSE, END 1
8 W-10893-2 . FITTING, HOSE, SWIVEL, FEMALE 1
9 56534 . HOSE, LOW PRESSURE 31"
10 W-10886-2 . CONNECTOR, MALE 1
11 W-7814-3 . BUSHING, PIPE 1
12 56587 . HOSE, RUBBER 40"
13 W-10051-6 . CLAMP, HOSE 2
14 84A-1007-1 . FITTING, HOSE, MALE 1
15 W-10869-14 . CLAMP, HOSE 1
November 31/91 4-3

Page 17
OM-2037
Oil Line Assembly

Figure 8
4-3 November 31/91

Page 18
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
8- 180434 LINE, OIL, ASSEMBLY (For NHA See Fig. 3) REF

1 403809-1 . SWITCH, LOW OIL PRESSURE V51377,
No. C-25900-10 1
2 W-10910-0 . TEE, STREET, BRASS V79470, No.3700 X 6 1
3 W-10886-1 . CONNECTOR, MALE, WEATHERHEAD
V79470, No. 48 X 4 1
4 403590-1 . SWIVEL, FEMALE, 7/16-20 SAE THDS
V03924 No. 7115-4S 2
5 56548 . HOSE, #4, 3/16 ID 51"
*6 W-10750-2 . PIPE 1
*NOT ILLUSTRATED
November 31/91 4-3

Page 19
OM-2037
Battery Installation
Figure 8
4-3 November 31/91

Page 20
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
9- No Number BATTERY INSTALLATION REF

1 281871-1 . BATTERY, 12-VOLTS 1
2 181825 . TRAY, BATTERY 1
* 2A A-25 . SPACER, BATTERY TRAY 8
3 181831 . FRAME, HOLDDOWN, BATTERY 1
4 388827-15 . CABLE, POSITIVE 1
5 388828-9 . CABLE, NEGATIVE 1
*6 5CW-2048 . ROD, BATTERY, SUPPORT, ASSEMBLY 2
*7 482496-1 . CLAMP, HARNESS, WIRE 1
*8 W-9407-138 . CABLE, ENGINE TO GROUND 1
* Not Illustrated
November 31/91 4-3

Page 21
OM-2037
Control Box Assembly

Figure 10
4-3 November 31/91

Page 22
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
10- 280543-3 BOX, CONTROL, ASSEMBLY

1 401937-3 . STRIP, TERMINAL V98410, No. 35012-3526 2
2 401564-4 . HOUSING, SOCKET, CONNECTOR, V89110,
No. 1-480287-0 4
3 489811 . BOARD, PC, VOLTAGE REG., 400 HZ 1
4 404065-2 . RECTIFIER, SILICON, V04713, No. SDA-10270-2 1
5 404402-1 . RESISTOR, OVERLOAD BURDEN, 25 WATT,
V91637, No. RH-25 3
6 16DA-4004A-10 . RELAY, PLUG-IN, 12 V. DC, V77342,
No. KAP-14D G-12 3
7 16DA-4052-0 . SOCKET, RELAY, V02660, No. 77-MIP-11 4
8 370891 . BRACKET, MTG., SOCKET, RELAY 2
9 16DA-4253-1 . RETAINER, SPRING, RELAY,
V77342, No. (KAP)20C206 4
10 400785-7 . RIVET, BLIND, DOMED HEAD, ST. 8
11 484689-1 . SLEEVING, PLASTIC, 1/8 I.D. 12"
12 484690-2 . SLEEVING, PLASTIC, 3/16 I.D. 9"
13 ICZ-93B . DIODE, SILICON, FLY-BACK, V05277,
No. IN4820 4
14 400030-1 . CAPACITOR, TANTALUM, 6.8 MFD, 35 V.,
V80183, No. 150D685X9035B2 1
15 16DA-4004A-3 . RELAY, PLUG-IN, 24 VOLT D.C., V77342,
No. K10-14DG-24 1
16 280534 . BOTTOM, CONTROL BOX 1
17 482038 . BOARD, PC, OVER-UNDERVOLTAGE, ASSY. 1
18 401556 . MOUNT, SHOCK, RUBBER, V81860, No. SS-01 16
19 387738A . BOARD, PC, OVERLOAD, 12 VOLT, ASSY. 1
20 404460-1 . SUPPORT, LOCKING, PC BOARD 4
21 482039 . BOARD, PC, OVER-UNDERFREQUENCY, ASSY. 1
22 387736C . BOARD, PC, MEMORY & TIME DELAY, ASSY. 1
No. 1-480438-0 1
24 280531 . PANEL, CONTROL, BOX 1
25 W-9916-10 . METER, FREQUENCY, V31356, No. 36-FX 1
26 W-8105A-4 . VOLTMETER, V60741, No. 331LH 1
27 W-8095A-9 . AMMETER, V60741, No. 331LH 1
28 15GH-433 . NAMEPLATE, METER SELECTOR SWITCH 1
29 HF-1459 . SWITCH, METER SELECTOR, V82121,
No. 101904LN 1
30 400400 . SWITCH, LINE, DPDT, V73559, No. 26L61TABS 1
31 180913-4 . LIGHT, PILOT, FAULT, RED, 12 V., ASSY. 5
404172-1 . . LENS (RED) 1
400613-4 . . BULB, 12-16 VOLTS 1
November 31/91 4-3

Page 23
OM-2037
4-3 November 31/91

Page 24
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
10 - (CONTINUED)
32 76A-1118 . SWITCH, SNAP, PUSHBUTTON, V27192,
No. SA35BCB34-9 2
33 482291 . NAMEPLATE, PROTECTIVE SYSTEM 1
34 ICZ-148 . TRANSFORMER, CURRENT, LINE DROP &
OVERLOAD, V50508, No. E-6170 6
35 (DELETED)
36 430340 . CHASSIS, LINE DROP COMPENSATION 1
No. 1-480285-0 1
38 W-9746-3 . RESISTOR, 100 OHM, 25 WATT, V44655,
No. 0200F 1
39 W-9746-1 . RESISTOR, LINE DROP BURDEN, 50 OHM,
25 W, V44655, No. 0200D 3
40 363136-5 . TRANSFORMER, CURRENT, AMMETER 3
41 402037-9 . GROMMET, RUBBER, V02231, No. AGW-4211 1
42 402658 . HOLDER, FUSE, V71400, No. HKP-HH 2
43 W-11166-1 . FUSE, AGC., 2 AMP 2
44 82B-1047 . LIGHT, PANEL, V74400, No. MI-3216 1
400613-4 . BULB, V74400, No. 3271 1
45 402662 . SWITCH, AIRCRAFT/TEST BANK, DPST, V73559,
No. 2GK71-73 1
46 402826 . SWITCH, REGULATOR/DIAGNOSTIC, 4PDT,
V15605, No. 8926K425 1
47 280590 . BRACKET, MTG., SWITCHES 1
48 (DELETED)
49 403336 . RING, LOCKING, SWITCH, V91929, No. TS10397 2
50 403091-6 . BUTTON, PLUG, HOLE 1
51 402665-1 . HOUSING, RECEPTACLE, V00779, No. 1-480416-0 6
52 489658-5 . DIODE, ASSY. 1
November 31/91 4-3

Page 25
OM-2037
Engine Control Panel Assembly

Figure 11
4-3 November 31/91

Page 26
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
11- 280542-1 PANEL ASSEMBLY, CONTROL, ENGINE

1 280545 . PANEL, CONTROL, ENGINE 1
2 280612 . NAMEPLATE, CONTROLS 1
3 82B-1047 . LIGHT, PANEL, 12 VOLT 1
4 FW-1312 . SWITCH, TOGGLE, DPST V27192, No. 7320K3 1
5 Y-680 . AMMETER 1
6 403189 . SWITCH, TOGGLE, V91929, No. 312TS1-59 3
7 W-9917-18 . METER, ENGINE, HOUR V16476, No. 771-8/50 1
8 30GH-764 . GAUGE, TEMPERATURE, WATER 1
9 180913-1 . LIGHT, PILOT, ENGINE & GENERATOR,
GREEN, 12 VOLT 2
10 82A-1030 . GAUGE, PRESSURE OIL 1
11 403091-5 . BUTTON, PLUG, HOLE 1
12 400701 . CONNECTOR, RIGHT ANGLE 2
13 401937-2 . STRIP, TERMINAL, V98410, No. 35008-3526 1
14 404100 . SWITCH, PUSHBUTTON, STARTER,
V70040, No. 1996097 1
15 25MS-156 . BUS, JUMPER 1
16 20RT-353-1 . DIODE, NEGATIVE BASE, 16 AMP 1
17 406910-6 . FUSE, 10 AMP 1
18 402658 . HOLDER, FUSE, V71400, No. HKP-HH 1
19 12CW-1320A-5 . GAUGE, FUEL, ELECTRIC, V57733, No. 455-BK 1
20 400059-3 . FITTING, TUBE, CONNECTOR 1
21 12CW-2125 . FITTING, PIPE, STREET ELL, 45o 1
November 31/91 4-3

Page 27
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
12- 280722C CONTACTOR PANEL ASSEMBLY

1 280723C . PANEL, CONTACTOR 1
2 402119-4 . SCREW, 1/4 - 20 X 3/4, HHC, ST. 3
3 282130-1 . CONTACTOR, 3-POLE 1
4 402119-8 . SCREW, 1/4 - 20 x 1-1/2, HHC, ST. 1
5 A-25 . WASHER, INSULATING 2
6 DW-1704 . BUSHING 1
7 W11242-5 . WASHER, FLAT, ST., 1/4 5
8 W-11254-4 . WASHER, LOCK, 1/4, ST. 5
9 W-11280-2 . NUT, HEX, 1/4 - 20, ST 2
10 W-11097-8 . SCREW, 3/8 - 16 x 2, HHC, ST. 1
11 W-11242-10 . WASHER, FLAT, ST., 3/8 1
12 W-11254-8 . WASHER, LOCK, ST., 3/8 1
13 W-11278-5 . NUT, HEX, 3/8 - 16 2
14 W-11263-6 . WASHER, LOCK, , IET, ST., 3/8 2
Revised 4-3
March 25/93 Page 29
OM-2037
Generator Group
Figure 13
4-3 November 31/91

Page 30
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
13- 181582 GENERATOR ASSY (For NHA See Fig. 3) REF

1 281658 . HOUSING & STATOR, GENERATOR 1
2 181584 . ARMATURE, ASSY. 1
*3 W-10874-1 . DIODE, SILICON, 35-A, POSITIVE BASE,
(Located on exciter armature assembly) 3
4 181581 . HOUSING & COILS, EXCITER 1
5 W-10072-1 . BEARING
6 484914 . CAP, BEARING 1
7 180608 . COVER, EXCITER HOUSING 1
8 180691 . COVER, GENERATOR HOUSING, TOP 1
9 180687 . COVER, GENERATOR HOUSING, BOTTOM 1
181267 . KIT, FLEX-COUPLING, ASSY. 1
10 283130 . . SCREW, 3/8-16 X 3/4, SKT-HD,
CAP, ST, NK 6
11 85B-1039 . . KEY, COUPLING 1
12 85C-1004-1 . . BUSHING, SPLIT-TAPER 1
13 489111 . . DISK, COUPLING, FLEXIBLE 4
14 489124 . . FAN, COUPLING, ASSY. 1
* 15 480669 . ADAPTER, FOOT, GEN. 1
* Not Illustrated
November 31/91 4-3

Page 31
OM-2037
Trailer Assembly
Figure 14
4-3 November 31/91

Page 32
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
14- 281056 TRAILER GROUP (OPTION) REF

1 181077A . TRAILER, ASSY., V22938, No. 747 1
2 85B-1013 . TIRE, 5:30 X 12 4
3 181079 . BRAKE, ASSY. 1
4 280597 . . LEVER, BRAKE MOUNT, ASSY. 1
5 280602 . . SHOE, BRAKE, ASSY. 1
6 280607 . . ROD, ADJUSTING, BRAKE 2
7 400954 . . CLEVIS, ADJUSTING, BRAKE 2
8 401468 . . PIN, CLEVIS 2
9 W-11338-5 . . PIN, COTTER, 1/8 X 1", ST. 4
10 280604 . . SPACER, GUIDE, SHOE, BRAKE 2
11 280605 . . GUIDE, SHOE, BRAKE 2
* 11A 280725 . SPACER, BOTTOM, BRAKE 2
* 12 484634 . BLOCK, CHOCK 1
* 13 486270-10 . LABEL, WARNING, COMPOSITE 1
14 280581 . FENDER, LEFT 1
15 280582 . FENDER, RIGHT 1
* 16 280588 . SUPPORT, FENDER 4
17 280587 . TRAY, CABLE 2
* 18 281058 . TANK, FUEL, ASSY. 1
* 19 76A-1152 . CAP, TANK, FUEL 1
* 20 280564 . STRAP, MTG., FUEL TANK 2
* 21 280608 . INSULATOR, FUEL TANK 2
22 280585 . PANEL, SIDE 3
23 280724 . PANEL, SIDE, LEFT REAR 1
24 280727 . BUMPER, REAR 1
25 79A-1075 . DRAWBAR, ASSY., V22938, No. 19-3500 1
26 79A-1057 . . PIN, HINGE, V22938, No. 5416 1
27 76A-1171 . . PIN, COTTER, V22938, No. 4800-6 2
79A-1045 . CENTER ARM, ASSY., V22938, No. 15-3854 1
284399-6 . . BUSHING W/G GROOVES., V22938, No. 5282-44 1
29 404529 . . PEDAL, LATCH, V22938, No. 3855 1
30 404530 . . PIN, ROLL, V22938, No. 5000-1 1
31 404528 . . SPRING, V22938, No. 4006 1
32 79A-1047 . WASHER, FLAT, V22938, No. 4701-3 1
33 79A-1048 . PIN, CENTER, V22938, No. 5400-5 1
284399-4 . AXLE, REAR, ASSY., V22938, No. 747-2001 1
34 284399-5 . . AXLE, REAR, BEAM WELDMENT, V22938, No. 747-4286 1
85A-1019 . . HUB ASSEMBLY, REAR AXLE, V22938, No. 7-3601 2
35 85A-1020 . . . CAP, GREASE, V22938, No. 6301 2
* NOT ILLUSTRATED
April 27/93 Revised 4-3

Page 33
OM-2037
4-3 November 31/91

Page 34
OM-2037
NOMENCLATURE UNITS
FIGURE HOBART PER
14 - (CONTINUED)
36 85A-1022 . . . BEARING, CONE, OUTER, V22938, No. 6151 2
37 85A-1021 . . . BEARING, CONE, INNER, V22938, No. 6050 2
38 85A-1023 . . . SEAL, GREASE, V22938, No. 6300 2
39 85A-1024 . . . NUT, STUD, V22938, No. 4603-1 10
. . . HUB, STUD AND CUP ASSY., V22938, No. 3601-7 2
41 85A-1025 . . . . HUB, V22938, No. 3601-1 2
42 85A-1027 . . . . STUD, WHEEL, V22938, No. 6251-1 10
43 85A-1028 . . . . CUP, BEARING, INNER, V22938, No. 6155 2
44 85A-1029 . . . . CUP, BEARING, OUTER, V22938, No. 6156 2
45 85A-1030 . . WASHER, SPINDLE, V22938, No. 4701-10 2
46 85A-1031 . . NUT, SPINDLE, V22938, No. 4600 2
47 80A-1052 . . PIN, COTTER, V22938, No. 4800-5 2
284399-1 . AXLE, FRONT ASSY., V22938, No. 747-2051 1
48 284399-2 . . AXLE, FRONT BEAM ASSY., V22938, No. 747-2051-1 1
49 85A-1034 . . SPINDLE & KNUCKLE ASSY.(LEFT), V22938, No. 27-3800 1
284399-3 . . . BUSHING, V22938, No. 5282-43 4
50 84A-1035 . . SPINDLE & KNUCKLE ASSY.(RIGHT), V22938, No. 28-3800 1
51 84A-1081 . . PIN, KING, V22938, No. 5401 2
52 84A-1082 . . PIN, ROLL, V22938, No. 5000-6 2
85A-1026 . . HUB ASSY. FRONT AXLE, V22938, No. 7-3601 2
53 85A-1020 . . . CAP, GREASE, V22938, No. 6301 2
54 85A-1022 . . . BEARING, CONE, OUTER, V22938, No. 6051 1
55 85A-1021 . . . BEARING, CONE, INNER, V22938, No. 6050 1
56 85A-1023 . . . SEAL, GREASE, V22938, No. 6300 1
57 85A-1024 . . . NUT, STUD, V22938, No. 4603-1 10
85A-1019 . . . HUB, STUD & CUP ASSY., V22938, No. 7-3601 2
59 85A-1025 . . . . HUB, V22938, No. 3601-1 2
60 85A-1027 . . . . STUD, WHEEL, V22938, No. 6251-1 10
61 85A-1028 . . . . CUP, BEARING, INNER, V22938, No. 6155 2
62 85A-1029 . . . . CUP, BEARING, OUTER, V22938, No. 6156 2
63 85A-1030 . . WASHER, SPINDLE, V22938, No. 4710-10 2
64 85A-1031 . . NUT, SPINDLE, V22938, No. 4600-1 2
65 80A-1052 . . PIN, COTTER, V22938, No. 4800-5 2
85A-1037 . TIE, ROD ASSY., V22938, No. 3906-2354 1
67 79A-1051 . . NUT, JAM, R.H., V22938, No. 4602-1 2
68 79A-1052 . . NUT, JAM, L.H., V22938, No. 4602-2 2
69 79A-1053 . . JOINT, BALL, R.H. W/NUT, V22938, No. 3950-1 2
70 79A-1054 . . JOINT, BALL, L.H. W/NUT, V22938, No. 3950-2 2
*71 79A-1055 . . PIN, COTTER, 3/32 X 1, NO. 4800-4 4
*72 80A-1052 . . PIN, COTTER, NO. 4800-5 2
* 73 79A-1035 . FITTING, LUBE, V22938, No. 5801 4
* NOT ILLUSTRATED
August 03/93 Revised 4-3

Page 35
OM-2037
4-3 November 31/91

Page 36
OM-2037
1. Explanation of Numerical Index

The purpose of this index is to assist the user in finding the illustration and description of a part when the
part number is known. Part numbers are arranged in alpha-numerical sequence. Thus, any part number
beginning with the letter A would be located at or near the top of the index list. Likewise a part number 9
would be listed near the end of the list and far below a part number 1000. The figure number and item
number location of the part is directly opposite the part. If the part is used in more than one place, each lo-
cation is listed commencing with the first location the part is listed.
FIGURE & ITEM

PART NUMBER NUMBER
A-25 9-2A, 12-4
BATTERY INSTALLATION 3-2
CANOPY ASSEMBLY 1-1, 2-0
DDW-495-1 3-7
DW-1704 12-5
FRAME GROUP 1-3
FW-1312 11-4
GENERATOR SET W/O CANOPY 1-2
HF-1459 10-29
HF-2752 3-28
RADIATOR AND COOLING SYSTEM GROUP 3-10
W-10051-6 7-13
W-10072-1 13-5
W-10750-2 8-6
W-10869-6 5-5
W-10869-7 4-7
W-10869-14 7-15
W-10874-1 13-3
W-10886-1 8-3
W-10886-2 7-10
W-10886-8 7-3
W-10891-6 7-4
W-10893-0 7-5
W-10893-2 7-8
W-10910-0 8-2
W-11097-7 12-10
W-11166-1 10-43
W-11242-5 12-7
W-11242-10 12-11
W-11254-4 12-8
W-11254-8 12-12
W-11263-6 12-14
W-11278-5 12-13
W-11280-2 12-9
W-11280-3 6-7
W-11338-5 14-9
W-7814-3 7-11

Page 1
OM-2037
FIGURE & ITEM

PART NUMBER NUMBER
W-7814-4 4-16
W-8095A-9 10-27
W-8105A-4 10-26
W-9407-138 9-8
W-9746-1 10-39
W-9746-3 10-38
W-9476-41 6-6
W-9916-10 10-25
W-9917-18 11-7
Y-680 11-5
ICZ-148 10-34
ICZ-93B 10-13
100GHP-1157 3-5
100GHP-1158 3-26
12CW-1320A-5 11-19
12CW-2125 11-21
15GH-433 10-28
16DA-4004A-3 10-15
16DA-4004A-10 10-6
16DA-4052-0 10-7
16DA-4253-1 10-9
180404 3-10
180405 3-10A
180434 3-32, 8-0
180608 13-7
180687 13-9
180691 13-8
180913-1 11-9
180913-4 10-31
180928 4-4
180954 4-1
180960 3-19
181020 6-2
181125 2-11
181040 4-8
181042 4-6, 4-13
181077A 14-1
181079 14-3
181128 5-1
181129 5-9
181267 13-9
181269 4-3
181581 13-4
181582 3-23, 13-0
181584 13-2
4-4 April 27/93 Revised

Page 2
OM-2037
FIGURE & ITEM

PART NUMBER NUMBER
181825 9-2
181831 9-3
181584 13-3
181891-1 6-8
20RT-353-1 11-16
25MS-156 11-15
280015 3-29
280018 3-30
280054 4-2
280447 6-3
280460 6-11
280517 3-8
280518 3-6
280519 3-9
280531 10-24
280534 10-16
280535 5-8
280538 5-3
280541 5-6
280542-1 3-12, 11-0
280543-3 3-11, 10-0
280544 3-3, 5-0
280545 11-1
280564 14-20
280581 14-14
280582 14-15
280585 14-22
280587 14-17
280588 14-16
280590 10-47
280591 2-5
280597 14-4
280602 14-5
280604 14-10
280605 14-11
280606 2-12
280607 14-6
280608 14-21
280612 11-2
280621A 3-31, 7-0
280722B 3-17, 12-0
280723C 12-1
280724 14-23
280725 14-11A
280727 14-24

Page 3
OM-2037
FIGURE & ITEM

PART NUMBER NUMBER
280742 4-12
281056 1-5, 14-0
281058 14-18
281071 2-6
281074 2-1
281080 1-3, 3-15
281086 2-13, 3-22
281093 2-8
281096 2-7
281098 3-18, 6-0
281102 2-14
281103 2-4
281109 2-10
281114 2-3
281115 2-2
281116 3-14
281117 3-16
281118 3-13
281132 12-2
281462A 4-10
281574 2-9
281658 13-1
281751-1 6-12
281774-2 6-1
281871-1 3-21, 9-1
282949 3-18, 6-0
283130 13-10
284399-1 14-0
284399-2 14-48
284399-4 14-0
284399-5 14-34
30GH-764 11-8
351683 2-15
351541 4-14
363136-5 10-40
370891 10-8
386751 4-17
387736C 10-22
387738A 10-19
388827-15 9-4
388828-9 9-5
400030-1 10-14
400059-3 11-20
400400 10-30
400613-4 10-31, 10-44

Page 4
OM-2037
FIGURE & ITEM

PART NUMBER NUMBER
400701 11-12
400785-7 10-10
400818-1 7-1
400819-2 7-2
400829-5 6-15
400954 14-7
401468 14-8
401556 10-18
401564-3 10-37
401564-4 10-2
401564-5 10-23
401937-2 11-13
401937-3 10-1
402037-9 10-41
402096 3-20
402119-8 12-6
402658 10-42, 11-18
402662 10-45
402665-1 10-51
402826 10-46
402908 6-5
402987 1-4
403091-5 11-11
403091-6 10-50
403153-1 2-20
403189 11-6
403336 10-49
403483 5-2
403590-1 8-4
403782-2 4-15
403809-1 8-1
404065-2 10-4
404100 11-14
404151 3-24
404154-11 4-11
404154-15 3-25
404172-1 10-31
404402-1 10-5
404460-1 10-20
404518 12-3
404528 14-31
404529 14-29
404530 14-30
405743 4-5
406254-1 3-33

Page 5
OM-2037
FIGURE & ITEM

PART NUMBER NUMBER
406910-6 11-17
408589 3-4
408786 3-1
430077-2 2-19
430340 10-36
480603-1 3-27
480669 13-15
482038 10-17
482039 10-21
482291 10-33
482496-1 9-7
482496-2 6-13
482989 6-10
484634 14-12
484689-1 10-11
484690-2 10-12
484914 13-6
486270-10 14-13
489111 13-13
489124 13-14
489658-5 10-52
489811 10-3
5CW-2048 9-6
56531 4-9
56534 7-9
56535 7-6
56548 8-5
56587 7-12
6919A1 1-0
6919B-1 1-0
76A-1118 10-32
76A-1152 14-19
76A-1171 14-27
77A-1166 5-7
76B-1148 2-18
76B-1150 1-6
78A-1000 2-16
78B-1019-3 7-7
79A-1110 2-17
79A-1035 14-71
79A-1045 14-27
79A-1047 14-32
79A-1048 14-33
79A-1051 14-67
79A-1052 14-68

Page 6
OM-2037
FIGURE & ITEM

PART NUMBER NUMBER
79A-1053 14-69
79A-1054 14-70
79A-1057 14-26
79A-1075 14-25
80A-1052 14-47, 14-65
82A-1030 11-10
82B-1047 10-44, 11-3
84A-1007-1 7-14
84A-1075 6-9
84A-1091 6-4
85A-1019 14-40, 14-58
85A-1020 14-35, 14-53
85A-1021 14-37, 14-55
85A-1022 14-36, 14-54
85A-1023 14-38, 14-56
85A-1024 14-39, 14-57
85A-1025 14-41, 14-59
85A-1026 14-34, 14-52
85A-1027 14-42, 14-60
85A-1028 14-43, 14-61
85A-1029 14-44, 14-62
85A-1030 14-45, 14-63
85A-1031 14-46, 14-64
85A-1034 14-49
85A-1035 14-50
85A-1037 14-0
85A-1045 5-4
85A-1081 14-51
85A-1082 14-52
85B-1013 14-2
85B-1039 13-11
85C-1004-1 13-12

Page 7
OM-2037

Page 8
OM-2037

This chapter provides documentation covering any optional equipment furnished with your generator.
Available options are listed below.
OPTION NAME HOBART NO. MANUAL

Trailer, Fenders, Fuel Tank, and Parts 281056 OM-2037
Cold Weather Starting Aid Kit 180961 OM-2037
Second Output Assembly Kits 281286-1 TO-203
November 30/91 5-0

Page 1
OM-2037
5-0 November 30/91

Page 2
OM-2037

Voltage Regulator Hobart Brothers Company
Operation and Maintenance Manual OM-2020
Electric Governor Barber Colman Company
Electrically-Powered Governor
Engine Detroit Diesel-John Deere
Operators Manual No. OM-RG-16407DD
Flexible Coupling Hobart Brothers Company
Coupling Manual TO-216
Exciter Rotor Hobart Brothers Company
Rotor Manual TM-360
HOBART DIAGRAMS:
280624 Schematic and Connection, Engine and Generator, S-6919A
(5 Diagrams)
282950 Schematic and Connection, Engine and Generator, S-6919B
(5 Diagrams)
November 30/91 6-0

Page 1
OM-2037
6-0 November 30/91

Page 2
OM-2037
Unusual Service Conditions

This information is a general guideline and cannot cover all possible conditions of equipment use. The
specific local environments may be dependent upon conditions beyond the manufacturer’s control. The
manufacturer should be consulted if any unusual conditions of use exist which may affect the physical con-
dition or operation of the equipment.
Among such conditions are :
1. Exposure to:
A. Combustible, explosive, abrasive or conducting dusts.

B. Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation.
C. Chemical fumes, flammable or explosive gases.
D. Nuclear radiation.
E. Steam, salt-laden air, or oil vapor.
F. Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus
growth.
G. Abnormal shock, vibration or mechanical loading from external sources during equipment opera-
tion.
H. Abnormal axial or side thrust imposed on rotating equipment shafts.
I. Low and/or high ambient temperatures.
2. Operation at:
A. Voltages above or below rated voltage.

B. Speeds other than rated speed.
C. Frequency other than rated frequency.
D. Standstill with rotating equipment windings energized.
E. Unbalanced voltages.
F. Operation at loads greater than rated.
3. Operation where low acoustical noise levels are required.
4. Operation with:
A. Improper fuel, lubricants or coolant.

B. Parts or elements unauthorized by the manufacturer.
C. Unauthorized modifications.
5. Operation in poorly ventilated areas.
November 30/91 Unusual Service Conditions

Page 1
OM-2037
Unusual Service Conditions November 30/91

Page 2
OM-2037
Wet-Stacking in Generator Set

Diesel Engines
All diesel engines operated for extended periods under light load may develop a condi-
tion commonly referred to as wet-stacking. This condition results from the accumulation
of unburned fuel in the exhaust system. It is recognizable by fuel oil wetness around
the exhaust manifold, pipes, and muffler. Liquid fuel, in the form of droplets, may be
spewed from the exhaust outlet.
Wet-stacking is common, and may be expected in diesel engines operated under light
load. Light loads do not allow the engine to reach most efficient operating temperature
for complete combustion of fuel. The unburned fuel collects in the exhaust system to
create the wet condition known as wet-stacking.
To alleviate wet-stacking in lightly loaded engines, it is recommended that the machine

be connected to a load bank after each 200 hours of use and operated under full rated
load for one hour. This will burn away and evaporate the accumulation of fuel in the ex-
haust system. This clean-out procedure should be considered as a regular mainte-
nance operation for machines operated under light load. The time schedule of 200
hours may be changed as required to suit each user’s particular needs and operating
conditions.
November 30/91 Wetstacking

Page 1
Wetstacking November 30/91

Page 2

Engine-Driven Generator Set Operation Manual

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OM-2037

OPERATION AND MAINTENANCE

ILLUSTRATED PARTS LIST

For Truck or Trailer Mounting

90-KVA, 400-HZ, 115/200-V AC, 3-PHASE

JOHN DEERE DIESEL ENGINE

Hobart Brothers Company

Content of the manual is arranged as follows:

November 30/91 Introduction

This page intentionally left blank.

Introduction November 30/91

November 30/91 Table of Contents

SUBJECT CHAPTER/SECTION PAGE

(g) Fuse-interlock relay 1-1 12

Section 2. Preparation For Use,

Section 3. Operation 1-3 1

Table of Contents November 30/91

SUBJECT CHAPTER/SECTION PAGE

3. Trailer Operation 1-3 5

November 30/91 Table of Contents

SUBJECT CHAPTER/SECTION PAGE

7. Generator Maintenance 2-1 8

SECTION 2. INSPECTION/CHECK 2-2 1

Table of Contents November 30/91

SUBJECT CHAPTER/SECTION PAGE

3. Generator Set Adjustment 2-3 7

November 30/91 Table of Contents

SUBJECT CHAPTER/SECTION PAGE

Section 2. Manufacturer’s Codes 4-2 1

Chapter 5. Optional Equipment

Chapter 6. Manufacturer’s Literature

Unusual Service Conditions

Table of Contents November 30/91

November 30/91 1-1

6. Engine, Generator, and Controls Assembly

B. Engine Manufacturer’s Equipment

1-1 November 30/91

1. Engine fan exhaust deflectors 6. Generator control panel window

Generator Set (Basic Unit)

November 30/91 1-1

TRAILER-MOUNTED GENERATOR SET

GENERATOR PROTECTIVE SYSTEM

Specifications and Capabilities

1-1 November 30/91

C.Hobart Engine Equipment

(1) Electric governor system

(2) Engine electrical system

(3) Engine protective devices

(a) High coolant temperature switch

November 30/91 1-1

1. Generator 7. Quick-start kit 13. Governor control box

Generator Set Components

1-1 November 30/91

(4) Air cleaner

(5) Exhaust system

(6) Radiator (11, Fig. 3)

November 30/91 1-1

1. Pipe, manifold-to-muffler 2. Muffler 3. Tail Pipe

1-1 November 30/91

E. Control Box Assembly

(1) Front Panel

(a) Generator output monitors (meters)

November 30/91 1-1