Hobart 90c20

OM-2031
080187
Revised 080589
Revised 032293
Revised 100195
Revised 043096
OPERATION AND MAINTENANCE

MANUAL
with
ILLUSTRATED PARTS LIST
for
ENGINE-DRIVEN GENERATOR SET
Series Numbers 6911 and 6911A
MODEL 90 C 20
90-KVA, 400-HZ, 115/200-V AC, 3-PHASE
SPECIFICATION MOUNTING VOLTAGE REGULATOR
NUMBER USED
6911-1, 6911A-1 Trailer or Truck 430391C
6911-2, 6911A-2 Trailer or Truck 489812A
6911-3, 6911A-3 Tractor 489812A
6911A-4 Fixed Unit With Fuel
Tank and Batteries 430391C
6911A-5* Trailer or Truck 489812A
Hobart Brothers Company

Ground Power Division
Troy, Ohio 45373
U.S.A.
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SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT
WARNING
ELECTRIC SHOCK can KILL. Do not touch live electrical parts.
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible
material. DO NOT use power cables to break load and prevent tools from causing short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached
equipment.
Important: - Protect all operating personnel. Read, understand, and follow all instructions in
the Operating/Instruction Manual before installing, operating, or servicing the equipment. Keep
the manual available for future use by all operators.
A. GENERAL
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment
or property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices
have been developed from past experience in the use of power source equipment. While certain practices be-
low apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and some
practices to both.
B. SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally
shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn what
terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing, procedures,
and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubber mat
or dry wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and
never work alone
1. Installation and Grounding of Electrically Powered Equipment
Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed and
maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or other applicable codes. A
power disconnect switch or circuit breaker must be located at the equipment. Check the nameplate for volt-
age, frequency, and phase requirements. If only 3-phase power is available, connect any single-phase rated
equipment to only two wires of the 3-phase line. DO NOT CONNECT the equipment grounding conductor
(lead) to the third live wire of the 3-phase line, as this makes the equipment frame electrically HOT, which can
cause a fatal shock.
Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or build-
ing ground. If not provided, use a separate grounding lead. Ensure that the current (amperage) capacity of
the grounding lead will be adequate for the worst fault current situation. Refer to the National Electrical Code
ANSI/NFPA 70 for details. Do not remove plug ground prongs. Use correctly mating receptacles.
2. Output Cables and Terminals
Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked or
worn cables immediately. Do not overload cables. Do not touch output terminal while equipment is energized.
3. Service and Maintenance
This equipment must be maintained in good electrical and mechanical condition to avoid hazards stem-
ming from disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of
the equipment until its safety has been assured. Repairs should be made by qualified personnel only.
Before inspecting or servicing electrically-powered equipment, take the following precautions:
a. Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the
equipment.
b. Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally.
c. Disconnect power to equipment if it is out of service.
d. If troubleshooting must be done with the unit energized, have another person present who is trained in
turning off the equipment and providing or calling for first aid.
C . FIRE AND EXPLOSION PREVENTION

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust pip-
ing, misuse of batteries and fuel, or unsafe operating or fueling conditions.
1. Electrical Short Circuits and Overloads
Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by causing
nearby combustibles to ignite. For electrically-powered equipment, provide primary input protection to remove
short circuited or heavily overloaded equipment from the line.
2. Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured battery
can cause fires and additional failures. When servicing,do not smoke, cause sparking, or use open flame
near the battery.
3. Engine Fuel
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is not
grounded prior to or during fuel transfer. Shut unit DOWN before removing fuel tank cap. DO NOT com-
pletely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove all spilled fuel
IMMEDIATELY, including any that penetrates the unit. After clean-up, open equipment doors and blow fumes
away with compressed air.
D. TOXIC FUME PREVENTION

Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust
fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air condition-
ers.
E. BODILY INJURY PREVENTION

Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipment for
inspection and routine maintenance. When equipment is in operation, use extreme care in doing necessary
trouble-shooting and adjustment. Do not remove guards while equipment is operating.
F. MEDICAL AND FIRST AID TREATMENT

First aid facilities and a qualified first aid person should be available for each shift for immediate treat-
ment of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital im-
mediately if any abnormal signs are observed.
EMERGENCY FIRST AID

Call physician immediately. Seek additional assistance. Use First Aid techniques recommended
by American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELECTRI-
CAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration, preferably
mouth-to-mouth. If no detectable pulse, begin external heart massage. CALL EMERGENCY RESCUE
SQUAD IMMEDIATELY.
G. EQUIPMENT PRECAUTIONARY LABELS

Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be
easily read.
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Table of Contents
SUBJECT CHAPTER/SECTION PAGE

WARNING
LIST OF EFFECTIVE PAGES
INTRODUCTION
CHAPTER 1. DESCRIPTION/OPERATION
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 3
B.Pull-out Trays 1-1 3
C.Voltage Regulator 1-1 3
D.Test Circuitry 1-1 3
E.Electric Governor 1-1 3
F. “ROLL-OUT” FEATURE
(TOW TRACTOR-MOUNTED UNIT) 1-1 3
4. Identification 1-1 5
A. General 1-1 5
B. Generator Sets Available in 6911 Series. 1-1 5
5. Optional Equipment 1-1 6
A. Trailer 1-1 6
B. Transformer-Rectifier 1-1 6
C. Truck 1-1 6
D. Second Output and Control Box 1-1 6
E. Quick Start Kit 1-1 6
6. Canopy 1-1 6
7. Engine, Generator, and Controls
Assembly 1-1 7
A. Basic Engine 1-1 7
B. Engine Manufacturer’s Equipment 1-1 7
C. Hobart Engine Equipment 1-1 9
(1) Electric governor system 1-1 9
(a) Magnetic pickup 1-1 9
(b) Control unit 1-1 9
(c) Actuator 1-1 9
(2) Engine electrical system 1-1 9
(3) Engine protective devices 1-1 9
(4) Air cleaner 1-1 10
(5) Exhaust system 1-1 12
(6) Radiator 1-1 12
August 5/89 Revised Table of Contents

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D. Generator 1-1 13
E. Control Box Assembly 1-1 13
(1) Generator control tray 1-1 13
(a) Resistors 1-1 13
(b) Generator output monitors (meters) 1-1 14
(c) Meter and line switches 1-1 15
(d) Receptacle connector 1-1 15
(e) Tray 1-1 15
(f) Manual voltage control 1-1 15
(g) Excitation-deenergization relay 1-1 15
(2) Protective relay tray 1-1 15
(a) Sensing modules 1-1 17
(b) Memory and time delay module 1-1 17
(c) Indicating lights 1-1 18
(d) Plug-interlock relay 1-1 18
(e) Test-bank switch 1-1 18
(f) Resistor 1-1 18
(g) Fuse-interlock relay 1-1 18
(h) Connector 1-1 20
(k) Auxiliary underfrequency relay 1-1 20
F. Engine Control Panel 1-1 20
(1) Engine instruments 1-1 20
(2) Engine and generator controls 1-1 21
(3) Air cleaner indicator 1-1 22
(4) Test receptacle connector 1-1 22
G. Voltage Regulator 1-1 24
H. Power Module Panel Assembly 1-1 24
(1) Load contactor 1-1 24
(2) Current transformers 1-1 24
(3) Overload module 1-1 25
(4) Rectifier 1-1 25
(5) Terminal boards 1-1 25
8. Test Box 1-1 27
A. Description 1-1 27
B. Theory of Operation 1-1 28
SECTION 2. PREPARATION FOR USE,

STORAGE, OR SHIPPING 1-2 1
1. Preparation for Use 1-2 1
A. General 1-2 1
B. Inspection/Check 1-2 1
(a) Fuel 1-2 1
(b) Engine coolant 1-2 2
(c) Engine lubricating oil 1-2 2
C. Installing Output Cables 1-2 2
Units are generally shipped without generator
set-to-aircraft cables. 1-2 2
Table of Contents August 5/89 Revised

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2. Preparation for Storage 1-2 4
A. General 1-2 4
B. Temporary Storage 1-2 5
C. Long Time Storage (Over 30 Days) 1-2 5
3. Preparation for Shipment
(Tractor-Mounted Units Only) 1-2 6
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. Cold Weather Engine Starting Procedures 1-3 4
D. Preparation for Power Delivery 1-3 5
E. Power Delivery 1-3 6
F. Preparation for Power Delivery
(Manual Voltage Control) 1-3 6
G. Power Delivery (Manual Voltage Control) 1-3 7
H. Discontinue Power Delivery 1-3 7
K. Stopping the Engine 1-3 7
3. Test Box Operation 1-3 8
4. Transformer-Rectifier Operation 1-3 9
A. Direct Current Power Delivery 1-3 9
B. Simultaneous 28.5-V DC and 115-V AC
Power Delivery 1-3 10
6. Trailer Operation 1-3 11
A. Towing 1-3 11
B. Parking 1-3 11
CHAPTER 2. SERVICE
SECTION 1. MAINTENANCE 2-1 1
1. General 2-1 1
2. Operation of Roll-Out Feature
(For Tractor-Mounted Units Only) 2-1 1
A. Roll Generator-Set Out for Service 2-1 1
B. Roll Generator-Set In to Normal Position 2-1 1
3. Inspection 2-1 1
4. Lubrication 2-1 3
A. General 2-1 3
B. Generator 2-1 3
C. Generator Controls 2-1 3

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D. Engine 2-1 3
(1) Lubrication schedule 2-1 3
(2) Oil specification 2-1 3
(3) Oil viscosity 2-1 3
(4) Changing engine oil 2-1 4
(5) Changing engine oil filter 2-1 4
E. Starter 2-1 4
5. Air Cleaner Service 2-1 5
A. Cartridge Removal 2-1 5
B. Cartridge Installation 2-1 5
6. Engine Fuel 2-1 6
A. Quality 2-1 6
B. Fuel Filter 2-1 6
7. Engine Cooling System 2-1 6
A. General 2-1 6
B. Radiator Cap 2-1 6
(1) General 2-1 6
(2) Removal 2-1 6
(3) Installation 2-1 7
C. Warm Weather Operation 2-1 7
D. Cold Weather Operation 2-1 7
(1) General 2-1 7
(2) Checking coolant solution 2-1 7
(3) Preparing the coolant solution 2-1 7
(4) Installing the antifreeze solution 2-1 7
E. Draining the Cooling System 2-1 8
F. Cleaning the Cooling System 2-1 8
G. Cleaning the Radiator Core 2-1 9
H. Filling the Cooling System 2-1 9
8. Generator Maintenance 2-1 9
A. Cleaning 2-1 9
B. Adjustment 2-1 10
9. Drive Belts 2-1 10
A. Checking Belt Tension 2-1 10
B. Belt Adjustment 2-1 10
10. Trailer, Truck and Battery Maintenance 2-1 10
11. Service Helps 2-1 10
A. Wiring 2-1 10
B.Control Box Trays 2-1 10
C. Generator Exciter 2-1 11
D. Engine Control Panel 2-1 12
SECTION 2. INSPECTION/CHECK 2-2 1

1. General 2-2 1
2. Engine 2-2 1
A. Fuel (See Fig. 1 for time schedules) 2-2 1
B. Lubrication 2-2 1

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C. Coolant 2-2 1
D. V-Belts 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 3
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 and Truck 2-2 5
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 5
3. Generator Set Adjustment 2-3 10
A. Generator Adjustment 2-3 10
B. Generator Control Adjustments 2-3 10
C. Basic Engine Adjustments 2-3 10
D. Engine Accessories Adjustment 2-3 10
E. Electric Governor System Adjustment 2-3 11
(1) Actuator linkage adjustment 2-3 11
(2) Magnetic pickup adjustment 2-3 12
(3) Adjustment and Test of Controller and Actuator 2-3 14
(4) Checking Magnetic Pick-up signal 2-3 16
5. Generator and Exciter Test 2-3 16
6. Diode Test 2-3 17
A. Disconnect diode lead(s). 2-3 17
CHAPTER 3. TROUBLESHOOTING
SECTION 1. TROUBLE SHOOTING
PROCEDURES 3-1 1
1. General 3-1 1
2. Trouble Shooting Chart 3-1 1
3. Equipment for Troubleshooting 3-1 2
4. Safety 3-1 2
5. Parts Replacement 3-1 2

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6. Test Values 3-1 3
7. Checking Connections and Leads 3-1 3
8. Electric Governor Trouble Shooting 3-1 3
9. Engine Trouble Shooting Procedures 3-1 4
A. General 3-1 4
CHAPTER 4. ILLUSTRATED PARTS LIST
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
A. Contents 4-1 1
B. Parts List Form 4-1 1
SECTION 2. MANUFACTURER’S CODES 4-2 1

1. Explanation of Manufacturer’s (Vendor)
Code List 4-2 1
SECTION 3. PARTS LIST 4-3 1

1. Explanation of Parts List Arrangement 4-3 1
2. Symbols and Abbreviations 4-3 1
SECTION 4. NUMERICAL INDEX 4-4 1

1. Explanation of Numerical Index 4-4 1
CHAPTER 5. OPTIONAL EQUIPMENT
CHAPTER 6. MANUFACTURER’S LITERATURE
UNUSUAL SERVICE CONDITIONS

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INTRODUCTION
This manual contains operation and maintenance information for a 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 arrangement
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 chapter, 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 section as the reference, Example, (See Para. B).
In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chapter
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
August 5/89 Revised Introduction

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Introduction August 5/89 Revised

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CHAPTER 1. DESCRIPTION/OPERATION
SECTION 1. DESCRIPTION
1. General
The generator sets (see Fig. 1) covered by the manual are identified by Series No. 6911 & 6911A.
The various configurations of the set are identified by adding a dash number (-1, -2, etc.) suffix to the
Series number.
The generator sets in the 6911 series feature armatures with Hoover Bearings, Browning Coupler,
and different 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 6911A generator sets feature the same magnetic pole construction for the generator revolving
field as Series 6911 generator sets. In addition, Series 6911A generator sets also feature wide-type
Fafnir bearings on the generator.
The basic generator set which includes the engine, generator and all controls is identical for all mod-
els. Differences between models are those required by their respective mounting, such as trailer
mounting, tow tractor mounting, etc. Identification of different models within the Series will be ex-
plained later in the Description.
Information and instructions throughout the manual apply to all models. Information which applies only
to a certain model will be qualified and identified as such.
The purpose of the generator set 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. The engine, generator, and controls are designed into a compact unit which is
easily removable from a tow tractor. See Figure 2 for specifications and capabilities.
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. Thus, the generator
control box, output receptacle connector, and engine control panel are mounted on the LEFT side at
the REAR of the unit.
3. Special Features
The generator set has many special features which are later described more fully under the assem-
blies in which they appear. Some of the main features are mentioned here and described briefly.
April 30/96 Revised 1-1

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1. Canopy 6. Output cable horn

2. Access-vent covers 7. Mounting frame
3. Lifting eye 8. Engine fan exhaust deflectors
4. Windows 9. Engine exhaust pipe
5. Output receptacle cover 10. Radiator cap access cover
Generator Set
Figure 1
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A. Protective Monitor
A single, solid-state device (4, Fig. 8) receives signals from all of the fault sensing units in the gen-
erator output circuit and functions to cause the load to be disconnected from the generator if an
abnormal condition of voltage, frequency, or load develops.
B. Pull-out Trays
The control box is equipped with pull-out, drawer-type trays (Fig. 6) which provide easy access to
controls and equipment mounted in them. Each tray may be removed as an assembly by discon-
necting a single quick-disconnect connector and tripping two safety latches.
C. Voltage Regulator
A solid-state (used on 6911-2, 6911-3, 6911A-2, 6911A-3 units), adjustable voltage regulator
(See OM-2020 in Chapter 6) provides automatic voltage regulation at the aircraft (or distribution
panel when applicable). The regulator is also adjustable for a variety of output cable sizes and
lengths.A magamp type voltage regulator is used on Specs. 6911-1, 6911A-1, 6911A-4 units
(See TM-759 in Chapter 6).
D. Test Circuitry
A receptacle connector (19, Fig. 9) with wiring to various test points throughout the electrical cir-
cuitry is provided for the attachment of a test box manufactured by Hobart Brothers. This test cir-
cuitry allows electricians to perform as many as twenty-four tests and checks from one location,
conveniently and easily.
E.E lectric Governor
The engine is equipped with an all electric type governor kit (5 and 12, Fig. 3) and other special
equipment more fully described under the engine description.
F. “ROLL-OUT” FEATURE (TOW TRACTOR-MOUNTED UNIT)
For a generator set mounted on a tow tractor (Spec. 6911-2) the generator set is supplied with
two-channel-like tracks which are floor mounted in the generator compartment of the tow tractor.
Tracks are equipped with cam-follower, needle-bearing rollers which support the generator set
and allow it to roll in-and-out easily for servicing and maintenance. Additional rollers are mounted
on each side of the generator set main frame, near the rear, to add stability and to prevent the
unit from tipping downward at the front when it is rolled outward for service. (See Figure 21, Sec-
tion 4-3).

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PHYSICAL
BASIC UNIT
Length overall 82 inches (2082.8 mm)
Width 36 inches (914.4 mm)
Height overall 43 inches (1092.2 mm)
Weight 3050 pounds (1383.2 kg)
TRAILER-MOUNTED UNIT
Length overall 100 inches (2540 mm)
Width 78 inches (1981.2 mm)
Height overall 72 inches (1828.8 mm)
Weight 4950 pounds (2244.9 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 325 A
(125 % of rated lad capacity
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 at 112-kVA in less than 5 minutes
Undervoltage time delay relay trips 4 to 12 seconds
Specifications and Capabilities

Figure 2 (Sheet 1 of 2)

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Engine
Manufacturer Cummins
Model 6BTA5.9
Type Turbocharged, in-line, 6-cylinder, 4-cycle diesel
Displacement 359 cu. in. (5.8 liters)
Compression ratio 16.5:1
Firing order 1-5-3-6-2-4
Number of Main bearings 7
Horsepower at 2000 RPM 167
Governed speed 2000 RPM +/- 4.5%
Idle Speed 850 RPM +/- 25 RPM
Electrical System 12-volt
Oil capacity (with filter) 17.3 quarts (16.4 liters)
Oil capacity (without filter) 16.3 quarts (13.6 liters)
Coolant capacity 15.3 quarts (14.5 liters)
Fuel Diesel oil conforming to ASTM Spec.
D.975-66T, Nos. 1-D and 2-DD
Lube oil MIL-L-2104C or MIL-L-2104D
Specifications and Capabilities
4. Identification
A. General
Generator sets are identifaied by their Specification numbers which consist of the Series number
plus a dash number (i.e. -1,-2, etc.) suffix. The suffix number indicates the mounting design of
the generator set. For example, Specification No. 6911 identifies a machine designed for mount-
ing on a trailer or truck.
B. Generator Sets Available in 6911 and 6911A Series
The following identification chart lists machines currently available in each series.
SPECIFICATION MOUNTING VOLTAGE

NUMBER REGULATOR
USED
6911-1, 6911A-1 Trailer or Truck 430391C
6911-2, 6911A-2 Trailer or Truck 489812A
6911-3, 6911A-3 Tractor 489812A
6911A-4 Fixed, Fuel Tank and Batteries 430391C
6911A-5* Trailer or Truck 489812A

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5. Optional Equipment
Several items of optional equipment are available for the 6911 Series unit. Each piece of optional
equipment is covered by its own Instruction and Parts Manual and will not be covered in this basic
manual. When applicable, information for optional equipment will be located in Chapter 5.
Options are listed as follows:
A. Trailer
A four-wheel trailer with batteries and fuel tank is available.
B. Transformer-Rectifier
A transformer-rectifier (T-R) is available for use with the generator set. This T-R receives 115/200-
V, 400-Hz, AC power from the generator and converts it to a 28.5 V DC output.
C. Truck
Trucks with special bodies for mounting the generator set are available. Compartments in the
body are provided for batteries, cable-storage, etc. Trucks available are Ford, Chevrolet, and
GMC.
D. Second Output and Control Box
An auxiliary output and control box is available to provide a second independent 115-V AC output
circuit.
E. Quick Start Kit
(See Section 1-3, Para. 2C)
6. Canopy
A sheet metal enclosure, identified as a canopy (1, Fig. 1), provides protection for the engine, gener-
ator and electrical controls.
The canopy is designed to reduce the operational noise level in the immediate area of the machine.
Doors and panels are covered on the inside with Fiberglass acoustic material to reduce reflected and
conducted noise, and to absorb noise. Noise producing vibration in most frequently used doors on the
left side is reduced by the use of two-point slam locks. Less frequently used doors on the right side
are equipped with screw-operated latch fasteners which are tightened after latching to reduce vibra-
tion. Insulating strips around all doors also reduce noise. Metal strips are mounted horizontally across
the front grille to deflect engine fan exhaust air and noise upward.
Two large openings in the canopy top provide an entrance for cooling air and an access to internal
components. A hood-type cover is mounted about two inches above each opening. The cover is
flanged downward and extends beyond the edges of the upwardly flanged opening to prevent en-
trance of blowing rain while still allowing a good flow of air. Air enters the forward opening into the en-
gine compartment and is discharged through the radiator by the engine fan. Air enters the rear
opening into the generator compartment. It is then 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.

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This generator set is equipped with a canopy having doors on both sides. Panel mounted instruments
may be observed through two Plexiglass 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 en-
gine controls when the door is closed. A centrally-located lifting eye attached to a lifting yoke extends
through the canopy top to provide an attaching point for chains, cables, or hook used to lift and move
the generator set.
7. Engine, Generator, and Controls Assembly

This assembly is the basic generator set without canopy. It includes all components required to gener-
ate and regulate 400 Hz, 115/200 V, three phase 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 superstruc-
ture, attached to the main frame, provides mounting facilities for the canopy, control box, and electri-
cal equipment and controls.
A. Basic Engine
This generator set is equipped with a 6-cylinder, in-line, turbo-charged Cummins Diesel engine. See
Figure 2 for general specifications, and see Engine Operator’s Handbook in Chapter 6 for more de-
tailed information.
B. Engine Manufacturer’s Equipment
As received from the engine manufacturer, the engine includes the following equipment which is
described in the Cummins Shop Manual (Chapter 6).
(1) Electronic stop control.
(2) Fuel filter.
(3) Reverse-flow, engine cooling fan to blow air outward through the radiator.

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1. Mounting frame 8. Air cleaner 14. Engine control panel

2. Generator 9. Lifting yoke *15. Cable horn and clamp
3. Power module 10. Engine 16. Radiator
4. Control box 11. Engine exhaust pipe *17. Fuel valve solenoid
*5. Governor control box 12. Governor actuator 18. Oil pressure switch
*6. Starting fluid container 13. Output cable terminal 19. Muffler
7. Voltage regulator board
* NOT ILLUSTRATED
Generator Set Components
Figure 3

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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 fre-
quency) because it provides faster engine response to changes in load conditions. This fast
response results in very close frequency control. Refer to the Barber Coleman Handbook in
Chapter 6 for a detailed description. A brief description is given below:
The governor system consists of the following main components:

Magnetic pickup
Control unit
Actuator
(a) Magnetic pickup

The magnetic pickup is a device for detecting the speed of the engine. It is mounted in
the flywheel housing directly over the ring gear. It produces an AC signal to the control
unit when the ferrous flywheel teeth pass through the magnetic field at the end of the
pickup.
(b) Control unit
The control unit (5, 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 (12, Fig. 3) supplies the force needed to move and position the fuel lever as
required 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 actuates the fuel valve solenoid which shuts
down the engine.

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(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 (18, Fig. 3). If the pressure in the lube oil system falls to
10 psi (69 kPa), this switch opens and actuates the fuel valve solenoid which shuts down
the engine.
(4) Air cleaner
The diesel-engine air cleaner (Fig. 4) is a dry-cartridge type. It is equipped with a moisture
eliminator and a service indicator. The indicator functions to signal the operator when the car-
tridge needs changing. A red cylindrical “flag” (2) is forced upward in a glass enclosed view-
ing chamber (1) when air pressure within the air cleaner housing drops below the outside air
pressure. As the cartridge becomes loaded with dirt and air pressure within the cleaner less-
ens, the “flag” gradually rises higher in the glass viewing chamber. When the “flag” reaches
the top of the chamber, it locks in that position to warn the operator that the cartridge must be
changed. The “flag” is reset (unlocked) by pushing the reset button (3) located on the bottom
of the indicator.
NOTE: The service indicator is mounted on the engine control panel and connected to the air cleaner
by a rubber hose. The indicator flag is visible only when the engine is running, or when the flag is
locked in WARNING position.

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1. Viewing chamber
2. Indicating “flag”
3. Reset button
Air Cleaner and Service Indicator

Figure 4

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(5) Exhaust system
The exhaust system consists of a special noise reducing muffler (3, Fig. 5) which is con-
nected by a pipe (2) to a conventional exhaust manifold (1). Baffles in the tail pipe outlet di-
rect exhaust and noise downward.
(6) Radiator
The radiator (16, Fig. 3) is a tube-type with bolted-on, top and bottom tanks which permit dis-
assembly for cleaning and repair.
1. Exhaust Manifold
2. Exhaust Pipe
3. Muffler
Exhaust System
Figure 5

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D. Generator
The 400-Hz generator is a brushless, revolving field, three-phase, alternating current type. The ro-
tor assembly is mounted by two, permanently lubricated, sealed, ball bearings. The front bearing
is supported by the fan housing; the rear bearing is mounted in the exciter housing. Both of these
housings are attached to the main generator stator housing. The front end of the rotor shaft ex-
tends forward beyond the rear bearing and into the exciter stator housing. The exciter rotor is
mounted on this shaft extension 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 out-
put to DC for excitation of the generator revolving fields. The exciter DC output to the generator
fields, and consequently the generator 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 cooling 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.
E. Control Box Assembly
The control box (Fig. 6) is a sheet metal enclosure which houses and provides mounting facilities
for generator and engine controls and monitoring equipment. The box is equipped with two,
drawer type trays which contain generator output control devices and monitoring instruments.
Trays slide in and out on nylon rollers for easy access to internally mounted components. Each
tray is easily removable by disconnecting an “Amphenol” connector, unlocking safety latches, and
sliding the complete tray assembly out of the control box.
A shielded, instrument panel light is mounted on the left side of the control box front panel, to illu-
minate controls and instruments in the trays.
(1) Generator control tray (See Figure 7)
The generator control tray contains instruments and controls for monitoring and controlling
the generator output.
(a) Resistors
Two, 10-ohm, 100-watt, ballast resistors (2) are connected in series in the generator ex-
citer DC field circuit.
A variable resistor (1) is connected in series between the manual control rectifier (14) and
rheostat (13). Its purpose is to adjust the DC voltage to the rheostat and thus determine
the voltage range through which the rheostat can control generator output voltage.

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Control Box
Figure 6
(b) Generator output monitors (meters)

The generator output is monitored by three instruments; a frequency meter (10), a voltme-
ter (9), and an ammeter (7). The frequency meter is a resonant-reed type, and indicates
the frequency 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 (6) and the line selector switch (5). (These switches will be de-
scribed 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 (6). Three ammeter current transformers (Ref. 4, Fig. 11) 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.

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(c) 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 (6) is a four-position, rotary type. A nameplate (4),
located under the switch knob, is marked and lettered to indicate the three functional posi-
tions of the meter switch. (When the knob is pointing straight down, the switch is OFF.)
The line switch (5) 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 the position
of this switch.
(d) Receptacle connector

An “Amphenol” connector (12) provides a means of quickly disconnecting all wires to con-
trol box components.
(e) Tray
The tray (15) slides in and out on nylon rollers. It is secured in place by a twist-lock,
screw fastener (8).
(f) Manual voltage control

When the automatic manual switch (11) is placed in MANUAL position, AC power is sup-
plied to the rectifier (14) rather than to the automatic voltage regulator. The DC output of
the rectifier is routed to the exciter field through a rheostat (13). The generator output volt-
age is thereby manually controlled by adjustment of the rheostat.
(g) Excitation-deenergization relay

The purpose of this relay (3) is to allow automatic excitation to be connected to the ex-
citer field only when engine speed is being controlled by the electric governor.
(2) Protective relay tray (see Figure 8)
The bottom tray in the control box is identified as the protective relay tray and contains electri-
cal and safety devices designed to protect the aircraft electrical system against damage
which could result from overvoltage, undervoltage, overfrequency, or underfrequency. The
tray also contains devices for the protection and control of the generator output electrical sys-
tem.

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1. Resistor (50 ohm, 100 watt) 9. Voltmeter

2. Resistor (25 ohm, 100 watt) 10. Frequency meter
3. Excitation-deenergization relay 11. Automatic-manual switch
4. Instruction plate 12. Receptacle connector
5. Line selector toggle switch 13. Manual voltage control rheostat
6. Meter selector rotary switch 14. Manual control rectifier
7. AC ammeter 15. Tray
8. Tray fastener
Generator Control Tray

Figure 7

Page 16
OM-2031
(a) Sensing modules

The voltage sensing module (5) and frequency sensing module (6) are connected to gen-
erator 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 memory and time delay module (4) to open the load contactor and disconnect out-
put to the aircraft. Trip values are adjustable, however, adjustments should be made
ONLY under laboratory conditions.
A solid-state overload signaling device (Ref. 7, Fig 11) 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.
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 (4) is sometimes called the protective monitor mod-
ule. It is a solid-state device with a hermetically-sealed, reed-type relay. The printed cir-
cuit 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 (5 and 6). All mem-
ory circuits are connected to the module relay coil, and any one of the circuits can ener-
gize 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 hold-
ing circuit and allow the load contactor to open. All circuits, except the undervoltage cir-
cuit, function immediately to open the load contactor. A time delay system is designed
into the undervoltage circuit to prevent nuisance opening of the contactor under condi-
tions of momentary 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, 13, 14 and 15) which is turned on when a fault oc-
curs.
The module relay will remain energized (OPEN) and the light will remain ON until the re-
set switch (7) is pushed to break the module 12-V DC circuit, and allow the relay to return
to normal, CLOSED position.

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(c) Indicating lights

The function of these lights (10, 11, 13, 14 and 15) is to indicate, to the operator, the ab-
normal condition of overvoltage, underfrequency, etc., which caused the protective moni-
tor system 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 indicating light. The light will remain on until the reset switch (7) is pushed. All
lamps in indicating lights may be tested by pressing switch (8).
(d) Plug-interlock relay

The function of the plug interlock relay (1) 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 connected 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 terminals E and F on the output cable plug connector.
(e) Test-bank switch

A spst, toggle switch (18) provides a means of by-passing the interlock relay (1) 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 (21) is connected in series with the plug interlock relay to pro-
tect 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 (2) is to interrupt the load contactor holding coil cir-
cuit and remove the load in case of a “blown” fuse (17) in the protective relay coil circuit.

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1. Plug-interlock relay 12. Tray fastener

2. Fuse-interlock relay 13. Overfrequency indicating light
3. Auxiliary underfrequency 14. Undervoltage indicating light
relay 15. Overvoltage indicating light
4. Memory and time delay module 16. Load contactor circuit fuse
5. Over-undervoltage module (2 A)
6. Over-underfrequency module 17. Protective system fuse (2 A)
7. Reset switch 18. Test bank switch
8. Light test switch 19. Receptacle connector
9. Hole plug 20. Terminal board
10. Overload indicating light 21. Resistor (100 ohm, 25 watt)
11. Underfrequency indicating 22. Tray
light
Protective Relay Tray

Figure 8

Page 19
OM-2031
(h) Connector
A twenty-six contact connector (19) provides a quick-disconnect facility for all wiring to
the tray electrical components so that the complete tray assembly may be removed
quickly and easily.
(k) Auxiliary underfrequency relay

The function of the auxiliary underfrequency relay (3) is to automatically open the excita-
tion-deenergization relay and disconnect the voltage regulator anytime generator fre-
quency drops to 380 Hz or below. This protects the voltage regulator (Fig. 10) and ballast
resistors (2, Fig. 7) against overload which could be caused by very high voltage regula-
tor output in its attempt to maintain voltage when the generator is operating at a speed
which cannot produce normal voltage output.
NOTE: If the auxiliary underfrequency relay is tripped, it will be necessary to momentarily place
engine operating mode switch (5, Fig. 9) in BUILD-UP-VOLTAGE position to restore generator
voltage.
F. Engine Control Panel (See Fig. 9)
The engine control panel is mounted directly below the control box. In addition to engine con-
trols and instruments, generator output controls are mounted here. A Plexiglass 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 pressure 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 in-
dicating mechanism which is connected by a capillary tube to a bulb mounted in the engine cooling sys-
tem. 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 pressure. It is
graduated from 0 PSI to 75 PSI. An oil pressure switch is mounted in a tee fitting directly behind the gage.
The 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.

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(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 revolving drums. The hourme-
ter 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. 9) 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 supplies 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 (18) 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. To check fuel quantity when engine is stopped, use switch (3) to turn ON panel lights.
(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 governor control box, which allows the engine to operate at
normal governed speed; second, it momentarily supplies current for closing the excitation-deenergization
relay (3, Fig. 7) contacts, to make three-phase, 115-V AC power available to the voltage regulator, or to
the manual voltage control circuit for excitation of the generator exciter. In GENERATE position, power is
maintained to the governor control box and to the excitation relay (3, 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 deen-
ergized.
(b) Contactor control switch

This is another three-position, toggle switch (7, Fig. 9) identical to the engine-generator control switch.
When placed in the spring loaded CLOSE position, it provides 115-V AC power directly 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 controlled by
a toggle switch (3), which also controls instrument lights on the control box.

Page 21
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(d) Engine starting circuit

The pushbutton start switch (15) and permissive toggle switch (18) serve to connect power for closing
an auxiliary solenoid switch. The auxiliary switch then connects power to the starter solenoid which func-
tions to engage the starter gear with the flywheel ring gear and apply power to the starter motor to crank
the engine. The auxiliary solenoid switch is necessary because the start pushbutton switch is not capable
of carrying the high amperage flow to the starter solenoid which would result if the starter gear and ring
gear should fail to engage. The permissive toggle switch (18) also stops the engine when the toggle is
placed in the down (STOP) position.
(e) Indicating lights

A green indicating light (14) glows to indicate that power is available to the engine protective system.
The light operates only when the engine is running and fuel pressure is sufficiently high to close a fuel
pressure switch. The purpose of the pressure switch is to deactivate the protective circuit when the engine
is stopped and prevent battery discharge.
Another green indicating light (9, Fig. 9) glows when the generator output load contactor is CLOSED
and power is available at the generator output terminal panel (13, Fig. 3).
(f) Cold weather starting aid control

The push-pull control (11) controls operation of a cold weather starting aid (Fig. 3). The starting aid
consists of a group of items designed to inject a highly volatile fluid into the engine air intake system to as-
sist ignition of fuel when air temperature is too low for the heat of compression to ignite a normal fuel mix-
ture. The starting aid consists of a cylindrical, fluid container and a valve (see 1-3, Fig. 4) which are
mounted on the lifting yoke. The valve is operated by the control (11, Fig. 9). Pulling the control outward
allows fluid to flow into the valve. Pushing the control IN forces fluid through a small tube and an atomiz-
ing nozzle into the inlet manifold. The addition of atomized, highly volatile fuel into the inlet air assists in ig-
niting the diesel fuel mixture.
(g) Fuse
A 10-ampere fuse (13) protects the 12-V DC engine control circuit, hourmeter, illuminating light circuit,
and 12-V DC system in the main generator protective system.
(3) Air cleaner indicator

The air cleaner indicator (12) is mounted on the engine control panel for easy viewing. Its
function was explained in Para. 6, C, (3) (see Fig. 6).
(4) Test receptacle connector

This Amphenol connector (19) provides an attaching point for leads which are connected
to selected test points throughout the engine and generator electrical systems. Connec-
tions and schematic diagrams indicate points at which the leads are connected. The re-
ceptacle connector is designed to mate with a test box plug connector (see Fig. 12).

Page 22
OM-2031
1. Panel light 12. Air cleaner indicator

2. Fuel gage 13. Engine circuit fuse (10-A)
3. Light switch 14. Engine “ON” indicating light
4. DC Ammeter 15. Engine starter switch
5. Engine-generator control switch 16. (Deleted)
6. Hourmeter 17. Terminal board
7. Load contactor control switch 18. Permissive start switch
8. Coolant temperature gage 19. Test receptacle
9. Load contactor indicating light 20. Charging circuit resistor
10. Engine oil pressure gage
11. Cold weather starting aid control
Engine Control Panel

Figure 9

Page 23
OM-2031
G. Voltage Regulator
Mag-Amp type, Hobart Part No. 430391C, See TM-759 in Chapter 6 of this manual.
Solid-State type, Hobart Part No. 489812A, See OM-2020 in Chapter 6 of this manual.
H. Power Module Panel Assembly
The power module panel assembly (Fig. 10) sometimes referred to as the “contactor panel”,
is located at the right rear of the machine behind the control box. On all models except the
tow tractor mounted unit, it is accessible by removing rear access-vent cover (2, Fig. 1) on
the canopy. The panel assembly provides sensing and overload protection for the output cir-
cuit and provides a means of connecting and disconnecting generator output to and from the
load (aircraft).
(1) Load contactor
The load contactor (6, Fig. 10) 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 oc-
curs. Three-phase, 400-Hz generator output power is conducted to the load contactor by
2/0 cables which pass through 3 sets of current transformers (3, 4, and 9).
NOTE: This contactor may be replaced by the old style contactor used in previous 60-KVA machines.
This note is for the benefit of those users who may have old style contactors Part number 75GH-566
(Hartman No. A-874C) in stock.
(2) Current transformers

(a) Ammeter current transformers
Three current transformers (4) lower the output load current to a lesser value of definite ratio (250-A
to 5-A) which will operate the ammeter (4, Fig. 9) movement without damage. The ammeter 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

The three line-drop current transformers (9), in conjunction with burden resistors (8), detect the magni-
tude and power factor of current flowing from generator to load. They feed a signal to the voltage regula-
tor which interprets the signal and alters the exciter field current as required to maintain a constant
predetermined voltage at the load (see Voltage Regulator Manuals No. TM-759 for a Mag-Amp type or
OM-2020 for a Solid-State type regulator).
(c) Overload current transformers

Three overload current transformers (3), in conjunction with burden resistors (1), monitor the output
load current in each of the three output phases, and supply a reduced value current signal to the overload
module (7).

Page 24
OM-2031
(3) Overload module

The overload module (7) is a solid-state device designed to interpret a signal from trans-
formers (3) and to send a signal to the protective monitor module (4, Fig. 8) when an over-
load condition exists in any generator 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. Re-
lay contacts are normally open. The solidstate 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 contac-
tor holding circuit, allowing the load contactor to open.
The following is a list of overload module characteristics:
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.
NOTE: All times are plus or minus 25% and are nonadjustable.
(4) Rectifier
A diode-bridge rectifier (5) 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 holding coil
only. This DC coil-holding circuit is controlled indirectly be controlling the 400-Hz AC to
the rectifier. The ground circuit for the rectifier’s AC supply must pass through the relay
contacts in the protective monitor module to ground cable N. Therefore, any time a protec-
tive device functions to open the protective monitor relay, the rectifier’s AC circuit is
opened. No DC is then available for the load contactor holding coil, hence, the load con-
tactor opens.
(5) Terminal boards

Three terminal boards (2) provide connection facilities for small leads.

Page 25
OM-2031
1. Overload resistor (16.6 ohm, 25 watt)

2. Terminal board
3. Overload current transformer
4. Ammeter current transformer
5. Rectifier
6. Load contactor
7. Overload module
8. Line drop resistor (50 ohm, 25 watt)
9. Line drop current transformer
10. Blocking diode
Power Module Panel Assembly

Figure 10

Page 26
OM-2031
8. Test Box
The test box is an optional accessory item used for testing the generator set. All generator
sets are wired to accommodate a test box, however, the box is supplied only when ordered
(Part Number 388318A-1).
A. Description (See Fig. 11)
The test box assembly consists of a rotary selector switch, momentary contact pushbut-
ton switch, and two, insulated-tip test jacks, mounted in a small metal box. Connection to
the generator set is made through a wiring harness equipped with a 26-contact plug con-
nector which mates with a receptacle connector.
1. Test box
2. Cable
3. Plug connector
Test Box Assembly (Optional)

Figure 11

Page 27
OM-2031
B. Theory of Operation
Wire leads are connected to the electrical circuitry of the generator set at various points
and routed to a receptacle connector, mounted on the engine control panel. They are con-
nected to the test box rotary switch by a plug connector and wiring harness.
The rotary selector switch is wired in such a manner that for any switch position, two pre-
selected test points in the generator set circuitry are connected for testing. The selector
switch may be rotated to any one of 22 positions, however not all positions are used in
this installation. An instruction plate mounted under the switch knob indicates switch posi-
tions and component tested in each position. Normal voltage for each test is also indi-
cated.
Two test jacks are provided for connection of the test prods of a voltmeter. After the volt-
meter is connected and selector switch positioned, the test circuit is closed by pressing
the pushbutton switch. A voltage value may then be observed on the voltmeter. This ar-
rangement prevents energization of test circuitry and equipment for extended periods and
allows the operator to reset and adjust the voltmeter without disconnecting it from the box.
For operating instructions, see Sect. 1-3, Para. 3.
9. Special Equipment for Specification 6911A-5 Generator Sets
The assemblies below, which are optional on other units covered by this manual, are stand-
ard equipment for Specification 6911A-5 generator sets, and are installed at the factory when
a generator set of this specification is ordered by the customer.
A. Low-Fuel Shutdown Assembly with Pilot Light
This low fuel shutdown assembly, Hobart Part Number 285953, stops the engine when
the fuel level in the fuel tank becomes low before the unit runs out of fuel. A liquid-level
detector, mounted in the fuel tank, opens the power to the engine governor system when
fuel drops to a predetermined level in the fuel tank, and the pilot light that is a part of this
assembly comes on.
B. The Low Coolant Shutdown Kit
The low coolant shutdown kit on this generator set stops the engine before overheating,
caused by low coolant, can occur. A liquid-level detector, mounted in the radiator tank,
opens the power to the engine fuel valve solenoid when coolant drops to a predetermined
level in the radiator.
NOTE: Radiator MUST be refilled after a low-coolant shutdown before engine can be restarted.
C. Emergency Stop Switch
This switch, Hobart Part Number 285958, on the generator set control panel, is used
manually by the operator to stop the engine quickly and safely in the event of an emer-
gency observed by the operator.
D. Forklift Support Assembly
This assembly, Hobart Part Number 482743, permits the safe lifting of the generator set
with a forklift of sufficient lifting capacity. The forklift used should have a lifting capacity of
at least 5000 pounds (2267.6 kg).

Page 28
OM-2031
SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING
1. Preparation for Use

A. General
These instructions are based on the assumption that the tow tractor mounted unit is properly installed on
the tractor and that all necessary fuel and electrical connections have been made. Hobart Brothers Com-
pany does not build an aircraft tow tractor. Generator sets for tractor mounting are installed by the cus-
tomer, or tractor manufacturer. Other generator sets, when ordered with truck or trailer, are mounted at
the Hobart factory and are shipped in running condition and ready for operation after inspection and check.
WARNING: IMPROPER OPERATION CAN KILL, INJURE, OR CAUSE DAM-

AGE! READ AND UNDERSTAND OPERATING INSTRUCTIONS IN SECTION 1-
3 BEFORE OPERATING THE UNIT.
B. 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 security of tractor mounted generator set retaining components (Sect. 2-1, Fig. 2).
(6) Check the following for sufficient quantity:
(a) Fuel
Turn ON panel lights to energize fuel gage when engine is stopped. (Tractor-mounted units are sup-
plied from the tow tractor tank.)
August 5/89 Revised 1-2

Page 1
OM-2031
(b) Engine coolant
The radiator cap is accessible by opening the hinged access cover on the front canopy housing. Cool-
ant level should be approximately one inch below the filler neck. Allow a capacity for coolant expan-
sion.
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 Perkins Shop Manual for oil recom-
mendations.
(7) 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.
C. Installing Output Cables
Units are generally shipped without generator set-to-aircraft cables.
NOTE: Generator sets designed for tractor mounting are equipped with a generator output receptacle
connector. No output cable wiring is required. An output cable assembly with plug connector on each
end is required for tractor-mounted machines (see 1-1; 12, Fig. 3).
(1) Three-phase, AC output cable assembly installation

The AC output terminal panel is located on the left side, below the air cleaner and left of the engine
control panel (see Fig. 1).
(a) Open left rear canopy doors and loosen cable clamp screws at cable horn (see 1-1; 13, Fig. 3).
(b) Route cables through cable horn and clamp and upward to terminal board.
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.
1-2 August 5/89 Revised

Page 2
OM-2031
(c) Each terminal stud is identified by an identification plate. Each cable should be identified by a
band-type marker. Connect cable “A” to terminal “A”, “B” to “B”, etc. Tighten terminal nuts se-
curely. Connect small plug interlock lead “E” or “F” to terminal “E” or “F”.
(d) Tighten clamp screws securely, but avoid damage to cable insulation.
(2) Transformer-rectifier (DC) output cable installation (optional equipment). Install DC output cables
as illustrated in Figure 2. Use 4/0 size cables.
AC Output Terminal Panel

Figure 1

Page 3
OM-2031
T-R Output Cable Installation

Figure 2
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.

Page 4
OM-2031
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.
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.

(b) Start the engine and operate at a fast idle (800 to 1000 RPM) until coolant temperature has
reached at least 140 deg F.
WARNING: MAKE CERTAIN OF ADEQUATE VENTILATION BEFORE START-

ING THE ENGINE.
(c) Operate normal operating controls.

(2) If weekly operation is not possible, prepare and protect the engine in accordance with instructions
in Perkins Diesel 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.

Page 5
OM-2031
3. Preparation for Shipment (Tractor-Mounted Units Only)

During long shipments by rail (and other) the generator set retaining hardware may become loosened by
vibration, jolting, etc.
CAUTION: WHEN SHIPPING THE UNIT (MOUNTED IN A TOW TRACTOR), PROVIDE ADDITIONAL
RETAINING MATERIALS TO MAKE CERTAIN THE GENERATOR SET CANNOT ROLL OUT OF THE
TOW TRACTOR.
NOTE: It is suggested that strong banding may be used to secure the generator set, or a strong steel
bar may be welded or bolted across the front of the generator set frame.

Page 6
OM-2031
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 EQUIP-

MENT MAY BE NECESSARY WHEN WORKING IN CLOSE PROXIMITY TO
THIS EQUIPMENT. READ AND FOLLOW ALL OF THE OPERATING INSTRUC-
TIONS BEFORE ATTEMPTING TO OPERATE THE EQUIPMENT.
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 (16) in ON position.
NOTE: This switch must be ON to check fuel when engine is stopped.
(2) Hold engine start switch (30, Fig. 1) in START position momentarily. Push engine start pushbut-
ton (28) to crank engine. When engine starts, release pushbutton. Continue to hold engine start
switch (30) in position until oil pressure gage (23) reads at least 20 PSI pressure. Release switch (30).
(3) Check ammeter (17) for charge reading.
(4) Check fuel gage (15) and oil gage (23).
(5) Place engine generator control switch (18) in IDLE position.
(6) Activate generator output contactor switch (20).
October 1/95 Revised 1-3

Page 1
OM-2031
1. Frequency meter 18. Engine-generator control switch

2. Voltmeter 19. Hourmeter
3. Fastener 20. Load contactor control switch
4. AC Ammeter 21. Coolant temperature gage
5. Meter switch 22. Load contactor indicating light
6. Line switch 23. Oil pressure gage
7. Reset switch 24. Cold weather starting aid control
8. Light test switch 25. Air cleaner indicator
9. Fault indicating lights 26. Engine circuit fuse (10-A)
10. Load contactor circuit fuse (2-A) 27. Engine protective circuit indicating light
11. Protective system fuse (2-A) 28. Engine starter switch
12. Protective relay tray 29. Blocking diodes
13. Instrument panel light 30. Permissive start switch
14. Generator control tray 31. Test receptacle connector
15. Fuel gage
16. Light switch
17. DC Ammeter
Operating Controls and Instruments

1-3 October 1/95 Revised

Page 2
OM-2031
32. Manual voltage control rheostat 35. Light test switch

33. Automatic-manual voltage control 36. Reset switch
switch
34. Test bank switch


Page 3
OM-2031
C. Cold Weather Engine Starting Procedures

A cold weather starting-aid kit (Fig. 2) is provided to assist in starting the engine at temperatures be-
low 50 degree F. To start the engine, using the starting aid, proceed as follows:
(1) Position switches and controls as instructed in steps (1) through (4), paragraph B, Normal Engine
Starting Procedures, above.
(2) Prepare starting aid for use. The starting aid is shipped in a safe condition and is not operable un-
til assembled. Assemble as follows:
WARNING: FIRES, FUMES, AND FLYING PARTS CAN KILL OR INJURE!

STARTING FLUID IS EXTREMELY FLAMMABLE. IT IS UNDER PRESSURE.
USE CAUTION WHEN HANDLING. AVOID CONTACT WITH SKIN AND AVOID
BREATHING VAPOR.
(a) Loosen clamp screws (1, Fig. 2) and slide the cylinder (2) upward sufficiently to remove pro-
tective cap (3) and plug (4).
(b) Use bottle opener to remove cylinder cap (3). Unscrew and remove plug (4).
(c) Slide the cylinder (2) downward and thread into the valve (5). Tighten securely. The starting
aid is now ready to use.
1. Clamp screw
2. Fluid cylinder
3. Cap
4. Plug
5. Valve
Cold Weather Starting Aid

(When Provided)
Figure 2

Page 4
OM-2031
(3) Cold weather starting procedures are exactly the same as for normal starting except:
(a) Before cranking the engine, pull the starting aid control (24, Fig. 1) OUT to the full extent of its
travel. Hold for 2 to 3 seconds. (This allows the starting aid valve chamber to fill with pressurized
ethyl ether.)
(b) Push the control IN. (This step sprays starting fluid into the engine intake manifold.)
(c) Push starter switch (28) to crank engine.
(d) Follow normal starting procedures and CAUTIONS above [steps (5) through (7), para. 2, B].
(e) In extremely cold weather it may be necessary to repeat steps (a) and (b) above.
CAUTION: USE STARTING AID ONLY FOR STARTING. DO NOT OPERATE

WHILE ENGINE IS RUNNING.
WARNING: DO NOT “FLOOD” THE ENGINE WITH STARTING FLUID. A SERI-

OUS EXPLOSION COULD RESULT.
D. Preparation for Power Delivery (Normal Automatic Voltage Control)

The following are power delivery preparation procedures to be followed after the engine is started.
(1) Check and position switches and controls.
(a) Loosen fastener (3, Fig. 1) and pull generator control tray outward. Place automatic-manual
switch (33) in AUTOMATIC position. Close tray and secure.
(b) Loosen fastener (3) and pull protective relay tray outward. Place test bank switch (34) in AIR-
CRAFT position if the aircraft being serviced is equipped with 28.5-V DC interlock relay system.
(If not, place in TEST BANK position.) Slide tray in and secure.
(c) Meter switch (5) may be in any position except pointing straight DOWN.
(2) Connect output cable plug connector to aircraft receptacle. Be sure connectors are mated fully
and securely.
E. Power Delivery (Automatic Voltage Control)

(1) Place engine-generator control switch (18, Fig. 1) in BUILD-UP-VOLTAGE position momentarily,
then allow 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, Fig. 1) should indicate exactly 400 Hz. Volt-
meter (2) should indicate 115 V AC when line switch (6) is in LINE-TO-NEUTRAL position.
(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 (20) in the top (spring loaded), CLOSE position. The green indicating
light (22) 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.

Page 5
OM-2031
NOTE: If the indicating light (22) 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 (20) 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 (5) to select the phase. Use the line switch (6) to
select line-to-line or line-to-neutral voltage. If the load is changing, it is good operating practice to ob-
serve 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 (7) to turn off the indicating light and reset the protec-
tive relay system. Proceed with power delivery by operating the load contactor switch.
F. Preparation for Power Delivery (Manual Voltage Control)

Preparation for power delivery using manual voltage control is exactly the same as for automatic con-
trol [Para. 2, D, (1) thru (2) above] except:
(1) Place automatic-manual switch (33) in MANUAL position.
(2) Set the manual voltage control rheostat (32) near its mid-range position.
G. Power Delivery (Manual Voltage Control)
Power delivery using manual voltage control is the same as automatic delivery [Para. E, (1) thru (5)
above] except:
(1) Control generator output voltage by adjusting the rheostat (32) to maintain a steady 115-V AC
reading on the voltmeter (2). Turn the rheostat (32) knob CLOCKWISE to INCREASE voltage and
COUNTERCLOCKWISE to DECREASE voltage.
(2) Adjust voltage to 115 V AC.
(3) During manual power delivery the operator must remain with the generator set to adjust output
voltage for varying loads and conditions.
H. Discontinue Power Delivery

(1) Place the load contactor switch (20) in OFF position. Green light (22) 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 (18) 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.
K. 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 (30) to the STOP(down) position.

Page 6
OM-2031
3. Test Box Operation

The test box is useful and convenient in testing the generator set after repair or overhaul and also in
trouble shooting. To operate the test box, proceed as follows:
A. Open left, rear canopy doors and connect the test box plug connector (see 1-1; 3, Fig. 14) to the
test receptacle connector (Fig. 4).
B. Connect the test prods of a voltmeter at the test jacks (3 and 4, Fig. 3). Test jacks are color coded.
RED indicates POSITIVE. BLACK indicates NEGATIVE.
C. Locate the component or circuit to be tested in the DESCRIPTION column on the instruction plate
and set the selector switch (1, Fig. 3) to the number indicated opposite the description.
D. Note the normal voltage value and kind of current (AC or DC) to be expected at the position and
set voltmeter accordingly.
E. Comply with conditions indicated in CONDITIONS column for the particular test being performed.
F. Press the pushbutton switch (2) and observe voltage indicated by the voltmeter. Compare to nor-
mal voltage indicated in VOLTAGE column.
G. Release pushbutton switch.
H. Repeat steps A thru G for other test as required.
J. When test are completed, disconnect the test equipment and close canopy doors.
Test Box Operating Controls

Figure 3

Page 7
OM-2031
Test Receptacle
Connector
Figure 4
4. Transformer-Rectifier Operation (Optional Equipment) (See Fig. 5)

Transformer-Rectifier operating instructions are contained in its operating manual, however some gener-
ator set instructions are required here.
A. Direct Current Power Delivery

NOTE: If the customer adds a Transformer-Rectifier to a standard machine which was NOT equipped
with a T-R when it left the factory, he must remove the jumper lead which will be found on the small
terminal strip in the generator set voltage regulator (see 1-1; 19, Fig. 12). If your generator set has a
factory installed T-R, the jumper will have been removed.
(1) When delivering power from a T-R, prepare the generator set for DC power delivery the same as
for AC delivery, except do not connect AC output cable and do not close AC load contactor (see Para.
2, D and E).
(2) For T-R operating instructions, see Hobart Manual No. OM-433.
B. Simultaneous 28.5-V DC and 115-V AC Power Delivery

If both 28.5-V DC and 115-V AC must be delivered at the same time, the following rules and precau-
tions must be observed.
(1) Place T-R current limiting switch in OFF position. This will eliminate the soft start feature of the T-
R, but will prevent AC voltage from dropping low enough to trip the AC load contactor.
(2) Line-drop compensation on the T-R must be REDUCED or turned DOWN completely to prevent
opening of the AC load contactor by an overvoltage condition. Readjust T-R line-drop compensation
so that AC voltage (as indicated by the generator set voltmeter) does not exceed 118-V AC when the
DC load is 500 Amperes. If higher DC voltage is needed, adjust T-R line-drop compensation as re-
quired.Observe AC voltage while making this adjustment to be certain that it does not go TOO HIGH
with DC load.
(3) During simultaneous, continuous operation, loads on either circuit are limited only by the capaci-
ties of their respective circuits, however, the combined loads should not exceed the rated capacity of
the generator set (90 KVA or 72KW).

Page 8
OM-2031
Transformer-Rectifier
Figure 5
6. Trailer Operation (Optional)

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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7. Low Fuel Shutdown Assembly

A. Description
The low fuel shutdown assembly, when requested as an option by a customer, may be used with all
generator set specifications covered by this manual. It is identified by Hobart Part Number 285953 .
Its purpose is to stop the engine when the fuel level in the fuel tank becomes low before the unit runs
out of fuel. A liquid-level detector, mounted in the fuel tank, opens the power to the engine fuel valve
solenoid when fuel drops to a predetermined level in the fuel tank.
NOTE: Fuel tank MUST be refilled after a low-fuel shutdown before engine can be restarted.
B. Location of Relay and Low Fuel Sensor

Figure 6 shows where the low fuel relay is installed on the rear of the generator control box., and Fig-
ure 7 shows where the low fuel sensor is installed on the fuel tank. Engine schematic diagram
281886 in Chapter 6 identifies the low fuel shutdown sensor as item S54, and the low fuel relay as
K65.
1. Control box
2. Relay retainer spring
3. Relay
4. Relay socket
5. Relay mounting bracket
Location for Relay on

Generator Control Box
Figure 6

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Location of Low Fuel Level Switch

Figure 7
C. Checking Operation of the Low Fuel Shutdown Assembly

The low fuel shutdown sensor (S54) has a TEST terminal, which permits testing of the sensor by elec-
trically simulating a low fuel condition. To check operation of the low fuel shutdown sensor:
(1) Turn on the generator set and operate it at idle speed.
(2) Using a jumper wire with an alligator clip on each end, ground the TEST terminal on the low fuel
shutdown sensor. The generator set engine should shut off immediately.

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D. Replacement Parts
The following chart is a list of the major items which comprise the low fuel shutdown assembly, except
for hardware which is available from any hardware store. If it becomes necessary to replace any of
the items listed below, these items may be ordered from Hobart Brothers Company using their part
numbers as given below.
ITEM HOBART NUMBER

DESCRIPTION
PART No. REQUIRED
1 Socket, Relay 16DA-4052-0 1
2 Mount, Socket, Relay 16DA-4029 1
3 Screw, #6-32 X 3/8, W-11223-2 2

SF-TAP, PAN HD, ST
4 Relay, Enclosed 283000-1 1
5 Retainer, Relay, Spring 16DA-4253-0 1
6 Diode 1CZ-93B 1
7 Sensor, Low Fuel Level 285954-1 1
8 Harness, Connector, 285955-1 1

Sensor
9 Splice, Butt 400161-1 4
10 Sleeving, Heat-Shrink, 1/8" 484689-1 2
11 Sleeving, Heat-Shrink, 484690-2 4

3/16"
12 Sleeving, Wire, Yellow 41501 86"
13 Clamp, Wire 12CW-908 2
14 Tubing, 1/2", Z-Flex 76A-1131 30"
15 End, 1/2", Z-Flex 76A-1135 2
16 Screw, M10-1.5 X 20 mm, 405061-8 1

HEX-HD CAP
17 Washer, Flat, M10, ST 281929-6 1
18 Washer, Lock, M10, ST 281930-6 1
19 Washer, Lock, M10, IET 283467-6 1

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8. Low Coolant Shutdown Assembly

A. Description
The low coolant shutdown assembly, when provided, is used with Specification 6911A-5 Hobart en-
gine-drive generator sets. Its purpose is to stop the engine before overheating, caused by low cool-
ant level, can occur. A liquid-level detector, mounted in the radiator, opens the power to the engine
coolant level solenoid when coolant drops to a predetermined level in the radiator.
NOTE: Radiator MUST be refilled after a low-coolant shutdown before engine can be restarted.
B. Location of Low Coolant Relay and Low Coolant Sensor

Figure 6 shows where the low coolant relay is installed on the rear of the generator control box., and
Figure 8 shows where the low coolant sensor is installed on the radiator. Engine schematic diagram
281886 in Chapter 6 identifies the low coolant shutdown sensor as item S45, and the low coolant re-
lay as K28.
C. Checking Operation of the Low Coolant Shutdown Assembly

The low coolant shutdown sensor, shown in Figure 8, has a TEST terminal, which permits testing of
the sensor by electrically simulating a low coolant condition. To check operation of the low coolant
shutdown sensor:
(1) Turn on the generator set and operate it at idle speed.
(2) Using a jumper wire with an alligator clip on each end, ground the TEST terminal on the low cool-
ant shutdown sensor. The generator set engine should shut off immediately.
Location of Low
Coolant Level
Switch
Figure 8

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D. Replacement Parts
The following chart is a list of the major items which comprise the low coolant shutdown assembly, ex-
cept for hardware which is available from any hardware store. If it becomes necessary to replace any
of the items listed below, these items may be ordered from Hobart Brothers Company using their part
numbers as given below.
ITEM DESCRIPTION HOBART NUMBER

PART No. REQUIRED
1 Socket, Relay 16DA-4052-0 1
2 Mount, Socket, Relay 16DA-4029 1
3 Screw, #6-32 X 3/8, W-11223-2 2

SF-TAP, PAN HD, ST
4 Relay, Enclosed 283000-1 1
5 Retainer, Relay, Spring 16DA-4253-0 1
6 Diode 1CZ-93B 1
7 Radiator, Assembly 285961 1
8 Harness, Connector, 285955-1 1

Sensor
9 Splice, Butt 400161-1 4
10 Sleeving, Heat-Shrink, 1/8" 484689-1 2
11 Sleeving, Heat-Shrink, 484690-2 4

3/16"
12 Sleeving, Wire, Yellow 41501 55"
13 Clamp, Wire 12CW-908 2
14 Tubing, 1/2", Z-Flex 76A-1131 55"
15 End, 1/2", Z-Flex 76A-1135 2
16 Screw, M10-1.5 X 20 mm, 405061-8 1

HEX-HD CAP
17 Washer, Flat, M10, ST 281929-6 1
18 Washer, Lock, M10, ST 281930-6 1
19 Washer, Lock, M10, IET 283467-6 1
20 Cap, Radiator 181930 1

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9. Emergency Stop Assembly

A. Description of the Emergency Stop sensor
The emergency stop assembly, when requested as an option by a customer, may be used with all
generator set specifications covered by this manual. It is identified by Hobart Part Number 285958 .
Its purpose is to stop the engine in the event that a condition develops which could damage the gener-
ator set or endanger personnel, such as uncontrolled overspeed or an open flame in the interior of the
unit.
B. Location of the Emergency Stop sensor

The emergency stop switch is a red mushroom-shaped switch installed on the left side of the unit, on
the door that is just left of the engine control panel door. Engine schematic diagram 281886 in Chap-
ter 6 identifies the emergency stop switch as item S28.
C. Checking Operation of the Emergency Stop sensor

To check operation of the emergency stop switch:
(1) Turn the generator set ON and operate it at idle speed.
(2) Press the emergency stop switch. The engine should shut off immediately.
D. Replacement Parts for the Emergency Stop sensor

The following chart is a list of the major items which comprise the emergency stop sensor assembly,
except for hardware which is available from any hardware store. If it becomes necessary to replace
any of the items listed below, these items may be ordered from Hobart Brothers Company using their
part numbers as given below.
HOBART NUMBER
ITEM
PART No. REQUIRED
Plate, Legend 285681 1
sensor, Operator, PB, Mushroom 77A-1157 1
Guard, Mushroom Button 285125 1
Sleeving, Yellow 41502 60"
Tie, Anchor, Cable, Plastic 400826-1 3
Screw, M3.5 X 9.5 mm, 282909-1 2

PAN-HD, SF-TAP

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10. Service Information

If you have any questions concerning your Hobart Ground Power Division equipment, you are in-
vited to contact our Service Department by mail, telephone or FAX.
Write: Hobart Brother Company
Ground Power Division
Service Department
1177 Trade Square East
Troy, Ohio 45373
U.S.A.
In U.S.A. Call: (800) 422-4166 (Parts)

(800) 422-4177 (Service)
From Other Countries Call: (513) 332-5050 (Parts)

(513) 332-5060 (Service)
FAX: (513) 332-5335 (Parts)

(513) 332-5121 (Service)

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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
operation immediately if a serious or possibly dangerous fault is discovered.
2. Operation of Roll-Out Feature (For Tractor-Mounted Units Only)

One of the first things to learn about the service operation is how to roll the generator partially out of the
tow tractor so that components on the right side and bottom of the unit are more accessible.
A. Roll Generator-Set Out for Service

(1) Make CERTAIN the stop-bar (Figure 1) is down as far as it will go in SAFETY position.
(2) Remove two each attaching nuts, screws, and lockwashers (1, Fig. 2) from retaining brackets (2)
at the front of the machine.
(3) Roll the generator set outward carefully, until the stop-bar (Figure 1) contacts the stop-block in the
left track. This will allow access to the right side and underside of the engine.
B. Roll Generator-Set In to Normal Position

(1) Roll the machine inward carefully until the retaining brackets (2, Figure 2) contact the end gussets
in the tracks.
(2) Install attaching screws, nuts, and lockwashers and tighten securely.
3. 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
environmental conditions. If the generator set is mounted on a tow tractor, it is suggested that inspections
be coordinated.
November 18/91 Revised 2-1

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Roll-Out Stop-Bar (For tractor-mounted units only)

Figure 1
1. Attaching hardware: nuts,

screws, and lockwashers
2. Retaining brackets
Generator Set Retaining Components

(Tractor-mounted unit only)
Figure 2
2-1 November 18/91 Revised

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4. Lubrication
A. General
Proper lubrication is one of the most important steps in good maintenance procedures. Proper
lubrication means the use of correct lubricants and adherence to a proper time schedule. Frequency
of lubrication and recommended lubricants are indicated in Figure 3.
B. Generator
The 400-Hz generator requires NO lubrication. The rotor is supported by two ball bearing assemblies
which are lubricated and sealed at the factory for lifetime, maintenance-free operation. It is suggested
that generator bearings be checked after 5000 hours of operation.
C. Generator Controls
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.
Recommendations 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.
(1) Lubrication schedule
Time schedules indicated on the Lubrication Chart, Fig. 3, are approximate. They are based on
average operating conditions. It may be necessary to lubricate more frequently under severe
operating conditions such as: low engine temperatures, excessively heavy loads and high oil
temperatures, 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
limitations
(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
contain only barium detergent-dispersants where 1.50 percent by weight is allowed.
Diesel lubricating oil specifications are discussed in the Cummins Handbook for Diesel Engines.
(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.
Multi-grade oils are NOT recommended, and should be considered only as a “last resort” to
facilitate engine starting.

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(4) Changing engine oil
Change engine lubricating oil following the instructions in the Cummins Engine Shop Manual
(Chapter 6). Lube oil capacity for this engine is 17.3 QUARTS.
(5) Changing engine oil filter
Change the oil filter following the instructions in the Cummins Engine Shop Manual (Chapter 6).
E. Starter
The starting motor is lubricated at assembly and should be relubricated only when the starter is
removed 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.
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-2104B).
Engine lube oil capacity: 17.3 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 800 hours or 6 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: 15.3 QUARTS.
Air Cleaner Change air cleaner cartridge as required by air cleaner indicator (on engine
control panel).
AC Generator AC generator bearings are sealed and require no periodic lubrication.
Lubrication and Maintenance Chart

Figure 3

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5. Air Cleaner Service

The air cleaner is a dry type with replaceable filter cartridges. A definite time schedule for changing the
filter cartridge cannot be determined because of varying operating conditions. Change the filter cartridge
when the red indicator “flag” reaches the top of the viewing chamber and locks in that position. Change
the cartridge as follows:
A. Cartridge Removal (See Fig. 4)

(1) Open canopy door and remove clamp assembly (3) from air cleaner
(2) Remove baffle assembly (7).
(3) Remove primary element (4), and replace with new element.
Caution: Do not clean or re-use cartridge.
(4) Inspect the interior of the cleaner housing (1). Make certain it is free from all foreign material.
B. Cartridge Installation (See Fig. 4)

(1) Carefully install the new cartridge into the housing. Avoid bumping the cartridge tubes against the
housing sealing flange. Seat the cartridge properly within the housing. Press all edges and corners of
the cartridge firmly with fingers to effect a positive air seal against the sealing flange of the housing.
Caution: Under no circumstances should the cartridge be pounded or struck

in the center to effect a seal.
(2) Lock the cartridge in place by installing the baffle assembly (7) and clamp assembly (3) with cup
assembly (8) in place. Tighten clamp (3) down in place.
1. Body Assembly 5. Washer Gasket

2. “O” Ring 6. Wing Nut
3. Clamp Assembly 7. Baffle Assembly
4. Primary Element 8. Cup Assembly
Air Cleaner Cartridge Replacement

Figure 4

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6. Engine Fuel
A. Recommendations/Specifications
The quality of fuel oil used in the diesel engine is a major factor in engine performance and life. Fuel
oil must be clean, completely distilled, stable and non-corrosive. Use low sulphur content fuel having
a cloud point that is at least 10o below the lowest expected fuel temperature. Cloud point is the
temperature at which crystals begin to form in diesel fuel. The viscosity of the fuel must be kept
above 1.3 centistrokes to provide adequate fuel system lubrication.
WARNING ! Do not mix gasoline or alcohol with diesel fuel. This mixture can
cause an explosion.
Caution: Due to the precise tolerances of diesel injection systems, it is

extremely important that the fuel be kept clean and free of dirt or water. Dirt
or water in the system can cause severe damage to both the injection pump
and the injection nozzles.
Use ASTM No. 2D fuel with a minimum Cetane number of 40. No. 2 diesel fuel gives the best
economy and performance under most operating conditions. Fuels with Cetane numbers higher than
40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and
excessive smoke.
At operating temperatures below 0o C (32o F), use a blend of No. 1D and No. 2D fuels, also known as
“winterized” No. 2D.
NOTE: No. 1D fuels can be used, but fuel economy wil be reduced.
Caution: Low viscosity fuel such as Jet-A fuel, will cause excessive wear on
the engine fuel pump and reduce its life expectancy unless lubricating oil is
added to the Jet A fuel.
Jet-A fuel - which is a low viscosity fuel - may be used, provided that lubricating oil is added to the
diesel fuel in the amount of 5% of the fuel mixture. Use one quart of lubricating oil per 5 gallons of Jet-
A fuel.
B. Fuel Filter
Refer to Cummins Shop Manual in Chapter 6 for instructions on removal and replacement of fuel filter
elements.
7. 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
protected 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.

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B. Radiator Cap
(1) General
A pressure valve is built into the radiator cap. It is designed to open at a pressure of
approximately seven pounds per square inch.
(2) Removal
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.
To remove, turn the cap to the left (counterclockwise) to the safety stop. When all pressure is
released, press down on the cap and continue to turn until the cap is free to be removed.
(3) Installation
When installing the cap be sure it is turned clockwise as far as it will go so that the pressure
retaining valve will be functional.
C. Warm Weather Operation

During warm weather operation, if water is used in the cooling system instead of an antifreeze
solution, 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
(1) General
A permanent type, (Ethylene Glycol) antifreeze is recommended for use in the cooling system.
Caution: (a) Do not use “methanol” or alcohol as an antifreeze.
(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.
(2) Checking coolant solution
Check the solution frequently to be sure the cooling system has sufficient protection against
freezing.
NOTE: (a) When testing the solution, be sure the coolant is at operating temperature.
(b) Follow manufacturer’s instructions on tester.

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(3) Preparing the coolant solution
The following table (Figure 5) indicates the freezing points of solutions varying from 16%
antifreeze to 65% antifreeze. Percentages are based on permanent type (Ethylene Glycol)
antifreeze. Most antifreeze containers have a similar table printed on the label.
(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 fan and water pump belts and alternator belts. Replace
the belts if necessary.
(e) Be sure radiator and engine drain valves are closed, and all connections are securely
tightened.
(f) Install the required amount of antifreeze: 15.3 QUARTS. Fill the system with coolant as
outlined under Para. 7, H.
FREEZING POINT PERCENTAGE OF ANTI-

(FAHRENHEIT) FREEZE IN SOLUTION
20 16%
+10 25%
0 33-1/3%
-10 40%
-20 45% Antifreeze Solution Table
-30 50%
Figure 5
-40 54%
-50 58%
-60 62%
-70 65%
E. Draining the Cooling System

Drain the cooling system immediately after stopping the engine, while most of the sediment is in
suspension. 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.

Page 8
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F. Cleaning the Cooling System

Drain and thoroughly flush the cooling system twice a year or more often if necessary. The
appearance 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, proceed 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
coolant (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.
Engine 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
desired. See Fig. 3 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.

Page 9
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8. 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
completely 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
covered in Section 2-3.
9. Drive Belts
Twin belts from the crankshaft pulley are used to drive the alternator and water pump. For proper engine
operation these belts 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 biweekly. Belts which are too tight are
destructive to bearings of the alternator and water pump. A loose belt will slip and cause inefficient
operation of the alternator and/or the water pump.
To check belt tension, press each 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 belts are fitted, it is necessary to run the engine for a short period to allow the new belts to
settle 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. Twin drive belts should be
changed in pairs.
10. Trailer, Truck and Battery Maintenance

If the generator set comes with either the trailer or truck option, refer to Chapter 5 for the number of the
manual which covers the particular option. The manual referred to will provide the appropriate
maintenance procedure. Both manuals cover battery maintenance, as, when either option is used, the
batteries are installed within it.

Page 10
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11. 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
replacement of a single wire lead with a minimum of difficulty. All wires are color coded.
B.Control Box Trays

Control box trays may be removed easily and moved to a work bench for service or replacement of
parts.
(1) Tray removal
(a) Loosen screw-lock fastener (2, Fig. 6)
(b) Slide tray outward and disconnect Amphenol connector (3).
(c) Support tray with hands at each side of tray near latches (1).Unlock latches (1) by pressing
down with thumbs, then slide tray out of box.
(2) Tray installation
(a) Use both hands to support tray as in removal above.
(b) Align rails (4) with tracks (5) and slide tray into box. Latches will lock automatically.
(c) Connect Amphenol connector (3).
1. Latch
2. Fastener
3. Connector
4. Rail
5. Track
Tray Removal (Typical)

Figure 6

Page 11
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C. 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 main frame rear cross member by removing four attaching cap screws (See Fig. 7).
(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) Reinstall rear frame member and tighten screws securely.
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.
Removable Rear Frame Cross-Member

Figure 7

Page 12
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D. Engine Control Panel

The engine control panel is designed and mounted in such a manner that it may be released from its
mounted position and tilted outward for access to components mounted on the back side (see Fig. 8).
Do not disconnect the wires.
(1) Tilt out engine control panel
(a) Remove clamp screw which supports wire conduit above output terminal panel.
(b) Remove four cap screws which attach engine control panel to frame superstructure.
(c) Maneuver panel to tilt it inward at the bottom and outward at the top.
(2) Reinstall engine control panel
(a) Maneuver panel into position and align mounting holes. Install mounting screws and secure.
(b) Secure wire conduit in its original position with clamp and screw.
Engine Control Panel in Tilt-out Position

Figure 8

Page 13
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Page 14
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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 Cummins 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-Belts
(1) Inspect V-belts 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
(1) Visually inspect muffler and exhaust pipes for signs of approaching failure.
(2) Listen for any gasket or joint leaks.

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Bi- Bi-
Daily Weekly Weekly Monthly Monthly 6 Mo.
or or or or or or
AR 8 Hrs. 50 Hrs. 100 Hrs. 200 Hrs. 400 Hrs. 1200 Hrs.
ENGINE
Check fuel quantity X

Check crankcase oil level X
Check coolant level X
Change engine oil filter
element X
Change engine oil X
Replace air cleaner cartridge X
Inspect cooling system hoses,
tubes, fittings & clamps X
Check V-belt tension X
Drain/refill cooling system TWICE ANNUALLY
Change fuel filter elements X
Lubricate SEE LUBRICATION CHART
Check exhaust system X
Open fuel tank drain EVERY 500 HRS.
ELECTRICAL
Check all lights X

Clean battery terminals X
Check wiring X
Check connections X
400 Hz GENERATING AND CONTROL SYSTEM
Check output cable &

connector X
Check voltmeter X
Check ammeter X
Check frequency meter X
Check all lights X
Check protective relays X
Check safety switches X
Inspect all wiring &
connections X
Clean & inspect generally X
Inspection/Check/Maintenance Schedule
Figure 1

Page 2
OM-2031
(3) Replace any defective parts at once.
WARNING: EXHAUST FUMES OR FIRE CAN KILL OR INJURE! IMMEDIATELY

REPAIR DEFECTIVE EXHAUST SYSTEMS.
3.Electrical System (12-V DC)

A. Lights
Check all lights for proper operation DAILY. Replace any defective lamps (bulbs) as soon as discovered.
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 systems.
Light Lamp Lamp

Identification Location Manufacturer Number
Instrument Panel Control Box Lamp Industry 63

Lights Trade No.
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 Protective Relay Lamp Industry 1815

Lights Tray Trade No.
Clearance Lights Canopy Lamp Industry 57
Lamp Identification Chart

Figure 2
C. Wiring and Connections

(1) Inspect all cables and leads for broken, worn, and damaged insulation.

Page 3
OM-2031
(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.
Item Protected Location Illustration Size & Type
Instrument panel Engine control Sect. 1-1, Fig.9, 10A Type AGC
lights & engine panel item 13
circuit
Protective relay Protective relay Sect. 1-1, Fig.8, 2A Type AGC

system tray item 17
Voltage regulator Voltage regulator Sect. 1-1, Fig. 10, 5A Type AGC
item 12
Load contactor Protective relay Sect. 1-1, Fig. 8, 2A Type AGC

circuit tray item 16
Fuse Identification Chart

Figure 3
B. Indicating Lights
Check lamps (bulbs) in all of the indicating lights at each start up. Fault indicating lights in the protective
relay tray may be tested by pressing test switch (1-1; 8, Fig. 8)
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

(1) Check all cables, leads, and wiring for broken, worn, and damaged insulation.
(2) Check all connections for tightness.
WARNING: STOP OPERATIONS AND STOP ENGINE BEFORE TOUCHING EX-

POSED CONDUCTORS OR TERMINALS.

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OM-2031
(3) Check the output cable plug connector for damaged contactors in the end of the plug.
5. Trailer and Truck

If the generator set comes with either the trailer or truck option, refer to Chapter 5 for the number of the
Hobart manual which covers the particular option. The manual referred to will provide the appropriate in-
spection procedure. Both manuals cover batteries, as, when either option is used, the batteries are in-
stalled within it.

Page 5
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OM-2031
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 fan and generator V-belts.
(5) If governor throttle linkage was disturbed, check all linkage to make certain engine speed may be
controlled when the engine is started.
(6) Inspect for oil, fuel, and coolant leaks.
(7) If the setting of the voltage regulator rheostat (See TM-759 or OM-2020 for your particular regula-
tor) has been disturbed, set it at CENTER position (halfway between full clockwise position and full
counterclockwise position).
(8) Check engine circuit fuse (26, Fig. 1) by placing panel light switch (16) in ON position. If panel
lights (13) operate, the fuse (26), switch (16), and lamps are good.
(9) Check fault indicating lights (9) by pressing test switch (8). If lights glow, fuse (11) 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.
(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 as follows:
CAUTION: ENGINE MUST NOT BE RUNNING WHEN FLASHING FIELD IF VOLTAGE REGULATOR
DAMAGE IS TO BE PREVENTED.
(a) Flashing exciter field using test box.
If a test box (see Sect. 1-3, Fig. 3) is available, connect it to receptacle connector (Sect. 1-3, Fig.
4).
(aa) Rotate the selector knob (Sect. 1-3, Fig. 3, item 1) to position 8.
(bb) Use two jumper leads, each equipped with an alligator clip and a test prod, to connect
12-V DC power to test jacks (2 and 3) on the test box. Connect positive jumper from input ter-
minal on starter solenoid to red test jack. Connect negative lead from starter ground terminal
to black test jack.
(cc) Momentarily pressing pushbutton switch (Sect. 1-3, Fig. 3, item 2) will flash the exciter
field.

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OM-2031
(dd) Disconnect jumper leads.

(b) Flashing exciter field without test box.
(aa) Remove test receptacle cover (1-3; Fig. 4). Use two test leads equipped with a test prod
on one end and an “alligator” clip on the other. Insert the test prod of one lead in terminal “D”
of the test receptacle (see Fig. 1), and connect the other end of the lead to a good GROUND.
Insert the test prod of the second lead in terminal “F” of the test receptacle and momentarily
touch the other end (alligator clip) to the “hot” terminal on the starter solenoid to flash the field.
CAUTION: FLASHING THE FIELD IN A REVERSE DIRECTION COULD CAUSE DAMAGE TO

VOLTAGE REGULATOR DIODES.
NOTE: If test leads with test prods are not available, insert short pieces of wire in proper test terminals
to make connections.
(bb) Disconnect leads and install receptacle cover.
(12) Check position of load contactor “on-off” switch (20, Fig. 1), and engine-generator control switch
(18).
(a) Load contactor switch (20) must be in OFF position.
(b) Engine-generator control switch (18) must be in IDLE position.

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1. Frequency meter 17. DC Ammeter

2. Voltmeter 18. Engine-generator control switch
3. Fastener 19. Hourmeter
4. AC Ammeter 20. Load contactor control switch
5. Meter switch 21. Coolant temperature gage
6. Line switch 22. Load contactor indicating light
7. Reset switch 23. Oil pressure gage
8. Light test switch 24. Cold weather starting aid control
9. Fault indicating lights 25. Air cleaner indicator
10. Load contactor circuit fuse (2-A) 26. Engine circuit fuse (10-A)
11. Protective system fuse (2-A) 27. Engine protective circuit
12. Protective relay tray indicating light
13. Instrument panel light 28. Engine starter switch
14. Generator control tray 29. (Deleted)
15. Fuel gage 30. Permissive start switch
16. Light switch 31. Test receptacle connector


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32. Manual voltage control rheostat

33. Automatic-manual voltage
control switch
35. Light test switch
36. Reset switch


Page 4
OM-2031
Test Receptacle Connector Terminals Identification

Figure 2
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 (17, Fig. 1), coolant temperature indicator
(21), oil pressure gage (23), and hourmeter (19).
(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 automatic-manual switch (33, Fig. 1) in AUTOMATIC position.
(b) Place test-bank switch (34) in AIRCRAFT position.
(c) Meter switch (5) may be in any position except pointing straight down.
(d) If the adjustment of the voltage regulator rheostat (See TM-759/OM-2020) has been dis-
turbed, position 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 (18) 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 appears on the voltmeter (2), the
electric governor and excitation deenergization relay circuits are functioning.
(7) Observe frequency meter (1). If engine speed is properly adjusted, frequency will be exactly 400
Hz. If not, adjust engine governed speed. See Fig. 8.
(8) Observe voltmeter (2). Use rheostat to adjust voltage to 115 V AC.

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(9) Measure governor actuator input signal. See Par. 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 in automatic operating mode.
(a) Observe voltmeter and turn rheostat CLOCKWISE to full clockwise position. Maximum volt-
age should be at least 134 V AC, or higher.
NOTE: If voltage should decrease when the knob is turned clockwise, it indicates that internal wiring of
the voltage regulator is incorrect. Replace the complete regulator tray assembly.
(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) Check adjustable voltage range in manual operating mode.
(a) Open the generator control tray (14, Fig. 1) and place the automatic-manual switch (33) in
MANUAL position.
(b) Observe voltmeter (2) and turn manual control rheostat (32) CLOCKWISE to full clockwise po-
sition. Maximum voltage should be at least 160 V AC.
(c) Observe voltmeter and turn rheostat (32) to full COUNTERCLOCKWISE position. Minimum
voltage should be 95 V AC or less.
(d) Adjust voltage to 115 V AC, then return the automatic-manual switch to AUTOMATIC position.
(15) Position load bank switches, etc., to apply a light load to the generator.
(16) Place the load contactor “on-off” switch (20, Fig. 1) in the top, spring loaded, CLOSE position.
Hold in this position momentarily. Hold in this position momentarily. The indicating light (22) should
glow GREEN and an amperage value should appear on the AC ammeter (4).
(17) Release the switch (2) 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 in-
terlock relay (Ref. 1-1; 1, Fig. 8) is not receiving power from an outside source of 28 V DC. It indicates
that the plug interlock contacts are OPEN as they should be when the interlock coil is not receiving 28-
V DC power.
(18) Open the protective relay tray and place the test bank switch (34, Fig. 1) in TEST BANK position.
(19) Again place the load contactor switch (20) in the top, CLOSE position. Light (22) 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 (34) is functioning to by-pass the plug interlock relay.
(20) Return the test bank switch to AIRCRAFT position. The load contactor should open at once and
the green indicating light (22) should go off.
(21) Connect a source of 24-V DC power (two twelve-volt batteries connected in series) to terminals
“N” and “F” (or “E”) at the output terminal panel. Connection polarity should be: MINUS to terminal N
and PLUS to terminal E or F.
(22) With test-bank switch in AIRCRAFT position, hold the contactor operating switch (20) in top,
CLOSE position momentarily. The generator “on” indicating light (22) should glow GREEN and re-

Page 6
OM-2031
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.
(23) 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.
(24) Increase load bank resistance to apply a full load.
(25) 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 (20) to apply and
remove load several times. Frequency drop should be no more than 1 Hz. Adjust governor if neces-
sary (see Para. 4, E, (3)).
(26) Follow instructions in Para. 4, B, (2) (b) to set voltage regulator line drop compensation potenti-
ometers. Set knob pointer on cable size potentiometer to size (2/0, 4/0, etc.) of cable being used. Set
knob pointer on cable length potentiometer to length (20 feet, 40 feet, etc.) of cable being used. See
instruction plate (mounted below knobs).
(27) 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.
(28) Check accuracy of voltmeter.
(a) Open generator control tray (14, Fig. 1).
(b) Connect a master voltmeter of known accuracy to terminals of the voltmeter (2).
(c) Compare unit voltmeter reading with master meter. Error must not exceed 2% of full scale.
(29) Check accuracy of AC ammeter.
(a) Connect a master ammeter of known accuracy to the AC ammeter (4) terminals.
(b) Compare unit ammeter reading with master meter under various loads. Error must not exceed
4% of full scale.
(30) Check operation of meter selector switch (5). A voltage value should be shown in each switch po-
sition.
(31) Check operation of the line switch (6). 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.
(32) 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.
(33) Operate the unit not less than 10 minutes under full load. The overload device (Ref. 1-1; 7, Fig.
11) MUST NOT trip.
(34) Operate at 125% rated load for 5 minutes immediately following the full load run. The overload
device MUST trip within 5 minutes and the overload indicating light (9, Fig. 1) must come ON to indi-
cate an overload condition.
(35) Reduce load to normal. Turn off indicating light by pressing reset switch (7, Fig. 1).

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OM-2031
(36) 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.
(37) Check operation of fuse interlock (Ref. 1-1; 2, Fig. 8). With unit operating normally under load, re-
move protective relay circuit fuse (Ref. 11, Fig. 1). The load contactor should open immediately. This
indicates 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.
(38) Check operation of overvoltage relay and indicating light.

(a) With the unit running at normal load, adjust the voltage regulator rheostat to increase voltage
(turn clockwise) until the over-voltage 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 (7).
(39) 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;
5, Fig. 8) 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 (9) 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 to reduce voltage 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: 1. The 4 to 12 second time delay is generally set at 5 seconds.
2. 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, it will be necessary to refer to the Trouble
Shooting Chart, Section 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.
(40) 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:

Page 8
OM-2031
(a) While the unit is operating normally under load, reduce generator output frequency by reduc-
ing engine speed. Use the governed speed setting potentiometer. Turn adjusting screw COUN-
TERCLOCKWISE gradually to reduce engine speed until frequency meter indicates 386 Hz.
Underfrequency protective relay should not function to open the load contactor at this frequency.
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 37 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.
(41) 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.
(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 components 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.
(42) If the generator is operating under load at this point, place the contactor control switch (20, 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.
(43) 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.
(44) 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.
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.

Page 9
OM-2031
3. Generator Set Adjustment

A. Generator Adjustment
The 400-Hz generator is a brushless type requiring no adjustments of any kind.
B. Generator Control Adjustments
The following items may require adjustment at some time during the life of the equipment.
(1) Adjust manual voltage control, variable resistor.

See TM-759 or OM-2020 for your particular Regulator.
(2) Adjust 400-Hz voltage regulator.
See TM-759 or OM-2020 for your particular Regulator.
C. Basic Engine Adjustments
Adjustment procedures applicable to the diesel engine are included in the John Deere Diesel Handbook
which accompanies this Hobart manual. Specific information for this particular engine is listed in Figure 6.
D. Engine Accessories Adjustment

(1) Generator and fan belt adjustment Refer to 2-1; Para. 8 for fan belt adjustment instructions.
NOTE: Replace fan belts as a matched set.
Manufacturer Cummins
Model 6BTA5.9
Type Turbocharged, In-line, 6-cylinder,
4-cycle Diesel
Displacement 359 cu. in. (5.88 liters)
Compression ratio 16.5 : 1
Firing order 1-5-3-6-2-4
Number of main bearings 7
Horsepower at 2000 RPM 167
Governed speed 2000 RPM +4.5%
Idle Speed 850 +25 RPM
Electrical System 12 volt
Oil capacity 17.3 QUARTS (16.4 LITERS)
Coolant capacity (approx.) 15.3 QUARTS (14.5 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
Engine Specifications
Figure 3

Page 10
OM-2031
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 adjustment 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. 4), or
regarding the proper hole in actuator lever in which to attach ball joint (4) cannot be determined be-
cause of slight variations in brackets, mountings, and engine performance characteristics. 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.
(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.

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1. Actuator shaft 5. Nut

2. Signal input connector 6. Rod
3. Actuator lever 7. Ball Joint, Fuel Control Lever
4. Ball joint, actuator
Governor Actuator Linkage

Figure 4
(2) Magnetic pickup adjustment
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 “pull-apart” connector (1, Fig. 5).
(b) Loosen nut (3) and remove magnetic pickup (2).
(c) Inspect to make certain the tip is not damaged from contact with the ring gear teeth, replace
pickup if damaged.

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OM-2031
(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 (3). 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.
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.
1. Connector
2. Magnetic pick-up
3. Nut
Magnetic Pickup Adjustment
Figure 5

Page 13
OM-2031
(3) Adjustment and Test of Controller and Actuator
Refer to Figure 6. The controller has three identical control potentiometers See inset): the GAIN po-
tentiometer, the DROOP potentiometer, and the potentiometer marked “I”. In addition, a SPEED con-
trol potentiometer is located just next to the GAIN potentiometer. Make controller settings as follows:
(a) Preliminary Controller Settings
(1) With the engine of the generator set turned OFF, set the “I” adjustment at the FOURTH in-
crement mark from zero.
(2) Set the GAIN adjustment at the THIRD increment mark from zero.
(3) Set DROOP adjustment COUNTERCLOCKWISE to minimum (zero) position as shown in
Figure 6.
(4) 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.
(b) Checking No-Load Operation of Controller
(1) Turn the GAIN potentiometer control slowly CLOCKWISE until the governor becomes un-
stable and the actuator lever (3,Fig.4) oscillates. (If the actuator lever DOESN’T oscillate at
this setting, upset the lever manually to cause it to oscillate).
(2) Next, turn the same GAIN potentiometer control slowly COUNTERCLOCKWISE until the
governor becomes stable and the oscillations cease.
(3) Turn the “I” potentiometer control slowly CLOCKWISE until the governor again becomes
unstable and the actuator lever (3, Fig. 4) 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.
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:
(1) With the generator set operating at no load, turn the GAIN setting slightly in the COUN-
TERCLOCKWISE direction.
(2) 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 oscil-
lations.
NOTE: If engine speed STILL doesn’t stabilize, recheck governor linkage. If linkage is set properly, the
governor controller is probably defective.

Page 14
OM-2031
Electric Governor Controller: Illustration and Connection Diagram

Figure 6

Page 15
OM-2031
(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.
(4) Checking Magnetic Pick-up signal
Connect a high impedance voltmeter to magnetic pickup input terminals (10 and 11, Fig. 6) on control-
ler 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.
5. 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.
7 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 0.00827
Phase B to N 0.00835
Phase C to N 0.00840
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 16
OM-2031
6. 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 pref-
erable.
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 the lead connections on the diode.
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 17
OM-2031
TEST BOX TEST POINTS

POINTER CONNECTOR TEST CONDITION VOLTAGE
POSITION TERMINALS DESCRIPTION
1 K-M Phase “A” input for Unit in “GEN” mode 115-V AC

reg. and trays & auto-man sw. in 400-Hz
2 K-P Phase “B” input for Unit in “GEN” mode 115-V AC
“AUTO”
3 K-S Phase “C” input for Unit in “GEN” mode 115-V AC
“AUTO”
4 K-A Protective monitor Battery voltage 12-V DC
fuse
5 K-B Fuse interlock relay Test bank sw. closed 12-V DC
& contactor closed
6 H-S Protective monitor Auto-man sw. in 115-V AC
contacts “AUTO” position
7 K-Z Plug interlock relay Plug in aircraft 28-V DC
8 D-F Exciter input Unit in “GEN” mode 8-12 V DC
9 V-X Regulator output * Unit in “GEN” mode 50-70V
& auto-man sw. in -DC
“AUTO”
10 K-b Contactor operation Test bank sw. closed 115-V AC
& contactor closed
11 K-E Overload contacts at Test bank sw. closed 0-V DC
less than 125O% load & contactor closed
12 K-R Contactor switch Test bank sw. closed 115-V AC
& contactor sw. in
“ON” position
13 K-N Battery voltage and All conditions 12-V DC
engine circuit fuse
14 K-J Shut-down solenoid Engine running 0-V DC
15 K-G Governor actuator Unit in “GEN” mode 0-V DC
16 U-W Governor actuator Unit at idle speed 0-V DC
Typical Test Values at Test Receptacle

Connector or Test Box
Figure 8

Page 18
OM-2031
CHAPTER 3. TROUBLESHOOTING
SECTION 1. TROUBLE SHOOTING 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.

Page 1
OM-2031
NOTE: Reference symbols (S9, etc.), used in the Trouble Shooting Chart, are identified on Schematic
and Connection Diagrams.
3. Equipment for Troubleshooting

A good quality multi-scale volt ohmmeter 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. If a test box, part number 388318-2, is available, tests may be made
more quickly and accurately, however, the test receptacle connector (31, Fig. 1) may be used by inserting
the test points of a volt ohmmeter into proper terminals of the connector. Refer to Fig. 8.
4. Safety
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 OPER-
ATING THE EQUIPMENT.
5. Parts Replacement
To lessen end item “down” time and to get a faulty machine back “on-the-line” 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 the protective relay tray is defective, the quickest way to remedy the situation is to replace the
complete tray assembly and send the old tray to stock.
Assemblies which lend themselves to this concept are:
Generator control tray

Over-undervoltage module
Protective relay tray
Over-underfrequency module
Voltage regulator
Overload module
Protective monitor module
Electric governor control “box”
Governor actuator
The above items are in addition to normally replaced items such as fuel pump, injectors, relays,
etc.

Page 2
OM-2031
6. Test Values
Although test values are provided throughout the trouble shooting chart, where applicable, additional infor-
mation and values are given here.
Generator output at maximum

voltage regulator rheostat setting 134 V or higher
Generator output at minimum

voltage regulator rheostat setting 108 V 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.
See 2-3, Fig. 8 for typical test values at test receptacle and test box.
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

Page 3
OM-2031
9. Engine Trouble Shooting Procedures

A. General
The following engine trouble shooting procedures were taken from Cummins 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:
(1) The presence of an adequate supply of air, compressed to a sufficiently high compression pres-
sure.
(2) 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 Perkins Diesel Handbook
for trouble shooting and repair procedures.
10.Illustrations
Illustrations, Figures 1 through 4, are referred to throughout the Trouble Shooting Chart.

Page 4
OM-2031
1. Frequency meter 17. DC Ammeter

2. Voltmeter 18. Engine-generator control switch
3. Fastener 19. Hourmeter
4. AC Ammeter 20. Load contactor control switch
5. Meter switch 21. Coolant temperature gage
6. Line switch 22. Load contactor indicating light
7. Reset switch 23. Oil pressure gage
8. Light test switch 24. Cold weather starting aid
9. Fault indicating lights control
10. Load contactor circuit fuse (2-A) 25. Air cleaner indicator
11. Protective system fuse (2-A) 26. Engine circuit fuse (10-A)
12. Protective relay tray 27. Engine protective circuit
13. Instrument panel light indicating light
14. Generator control tray 28. Engine starter switch
15. Fuel gage 29. (Deleted)
16. Light switch 30. Permissive start switch
31. Test receptacle connector


Page 5
OM-2031
32. Manual voltage control rheostat

33. Automatic-manual voltage control switch
35. Light test switch
36. Reset switch


Page 6
OM-2031
1. Manual control voltage potential adjusting resistor

2. Exciter field ballast resistors
Excitation Resistors
Figure 2
End View of Voltage Regulator Amphenol Connector

Figure 3

Page 7
OM-2031
Test Receptacle Connector Terminals Identification

Figure 4

Page 8
OM-2031
TROUBLE, SYMPTOM TEST, CHECK, AND/OR

AND CONDITION PROBABLE CAUSE REMEDY
NOTE: Diesel engine trouble shooting is covered in Perkins Engine 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
terminal.
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. Re-
place.
D. Internal seizure E. 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 Perkins Diesel
workshop manual.
2. Engine will not A. Low battery output A. Check battery. Recharge or

start. Cranking replace.
speed low.
B. Loose starting cir- B. Check all connections and
cuit connections or cables.Tighten or replace
faulty cables. as required.
C. Improper lubricating D. Check oil. See Sect. 2-1,
Troubleshooting Chart (Sheet 1 of 20)

Figure 5

Page 9
OM-2031

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 thecover 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 between damaged hoses or fuel
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 installation (5) Restricted fitting missing

from return line.
Trouble Shooting Chart (Sheet 2 of 20)

Figure 5

Page 10
OM-2031

3. Engine will not (6) Faulty fuel pump (6) Check pump.
start. Cranking
speed normal. (a) Relief valve (a) An open relief valve
not seating will cause low out-
put pressure.
(b) Worn pump
gears or damaged pump (b) Check pump for normal
drive operation. Re-
place if defective.
(7) Defect in inject- (7) Refer to Cummins Diesel

or racks or linkage Handbook. Make adjust-
ments and/or repairs
according to instruc-
tions therein.
4. Engine is hard to A. Low ambient temperature, A. Check causes and remedies

start. Cranking or limited fuel under ENGINE, Trouble 3,
speed normal. 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 Cummins Diesel Hand-
book.
(3) Cylinder head (3) Check gasket in accor-

gasket leaking dance with instructions
in Cummins Diesel Hand-
book.
(4) Improper valve (4) Check and adjust valve

clearance adjust- clearance in accordance

Figure 5

Page 11
OM-2031

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 oil
pressure switch
B. Defective or incor- B. Check wiring to high temper-

rectly wired high ature switch. One Red-Yellow
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 A. Lamp defective A. Replace lamp.

speed. Engine “ON”
indicating light B. Indicating light body B. Be sure light is grounded
(27 Fig. 1) does poorly grounded properly.
not glow.

Figure 5

Page 12
OM-2031

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:
ode switch (18, 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
pickup (2, Fig. 5, magnetic pickup and the
2-3). “fail-safe” feature of the
unit may be functioning to
prevent any signal from
reaching the actuator. To
check the magnetic pickup,
disconnect pickup from con-
trol 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 volt-
age is indicated, check
pickup adjustment.
If pickup is
properly adjusted and
voltage is still zero,
replace pickup.
D. Defective actuator D. 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.

Figure 5

Page 13
OM-2031

7. Engine will not E. Defective control E. Connect a DC voltmeter to

come “up” to gov- unit the leads from the control
erned speed in GEN unit to the actuator. Start
mode. (Continued) 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 Woodward Handbook
for control unit bench tests
and adjustments.
8. Engine goes to A. Governed speed con- A. Turn speed control adjusting

overspeed when control adjustment set screw fully counterclock-
trol switch (18, too high (see 2-3, wise. Start engine. Place
Fig. 2) is in GEN Fig. 6) control switch (18, Fig. 2)
position. in GEN position. If
engine speed is now well below
governed 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

Figure 5

Page 14
OM-2031

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 properly.
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, E, (3).
(3) Magnetic pickup (3) Check and adjust pickup.

signal weak See 2-3, Para. 3, E, (2)
10. Engine has slow A. Governor control unit A. Adjust. See 2-3; Para. 3, E,
response time improperly adjusted (3).
B. Actuator linkage B. Inspect and repair as re-

binding quired.
C. Engine needs tune-up C. Tune-up as required. Refer

Figure 5

Page 15
OM-2031

11. Engine “misses”. A. Insufficient fuel A. Check fuel flow in accor-

Runs unevenly. dance with Cummins Diesel
Handbook. Repair or replace
parts as required. Also see
Engine, Trouble 3.
B. Fault injector B. Check injectors in accor-
dance with Cummins Diesel
Handbook. See causes of low
compression listed under
ENGINE, Trouble 4, B, above.
C. Low compression C. Check compression in accor-

pressure dance with Cummins Diesel
Handbook. See causes of low
compression listed under
ENGINE, Trouble 4, B, above.
12. Engine lacks power A. Improper engine A. “Tune-up” the engine in

adjustments and gear accordance with Cummins
train timing Diesel 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.

Figure 5

Page 16
OM-2031

1. No (or low) gener- A. Defective generator A. The first check is an easy

ator output voltage or excitation circuit one which will allow the
in all phases. Gen- mechanic to reach some
erator operating at definite conclusions about
400 Hz in AUTOMATIC where the trouble is. Place
mode. the AUTO-MAN switch (33,
Fig. 1) in MANUAL position.
If a normal voltage (for the
rheostat setting) is now
produced, the generator is
good, and the trouble is in
the voltage regulator cir-
cuit. Proceed to step C. If
switching to MANUAL control
did not affect generator
output, the trouble is like-
ly in the generator, but to
prove the generator is de-
fective, proceed to step B.
B. Defective generator B. Use the test receptacle (31,

Fig. 1) to connect 12-V DC
to the exciter field. Using
leads with alligator clips
and test prods, connect 12-V
DC NEGATIVE lead to terminal
“D”. Terminal identifying
letters are plainly visible
on the face of the test receptacle.
Connect POSITIVE lead to
terminal “F”. If no output voltage
change is indicated when the
exciter field is energized, the gen-
erator is defective. Stop
operations and see 2-3, Para. 5
for further generator testing. If
the generator produces
approximately 140-V AC when
the exciter field is energized, the
trouble is in the voltage
regulator-excitation circuit.
Proceed to step C.

Figure 5

Page 17
OM-2031

GENERATOR EXCITATION CIRCUITS (CONTINUED)
1. No (or low) genera- C. Defect in VOLTAGE C. Check as follows:

tor output voltage REG. excitation cir-
in all phases. Gen- cuit.
erator operating at
400 Hz in AUTOMATIC (1) Defective AUTO- (1) Check the switch thor-
mode. (Continued) MANUAL switch oughly. A defective
(33, Fig. 1) switch may prevent cur-
rent reaching and/or
leaving the voltage reg-
ulator. Replace switch
if defective.
(2) Defective exci- (2) Check EDR contacts. A

tation-deenergi- faulty EDR can prevent
zation relay power from reaching the
(K16) (1-1; 3, voltage regulator. Re-
Fig. 7) place relay if defective
(3) Defective ballast (3) If output voltage was

resistor(s), (See produced when the gener-
Fig. 2) ator set was operated in
MANUAL mode, the resis-
tors are good. If no
voltage was produced in
MANUAL mode, resistors
could be defective.
Refer to Fig. 5 and con-
nect a jumper lead a-
cross the ballast resis-
tors. If an output volt-
age is now produced,
replace resistors as

Figure 5

Page 18
OM-2031

GENERATOR AND EXCITATION CIRCUIT (CONTINUED)
1. No (or low) gen- (4) Defective Amph- (4) Disconnect voltage reg-
erator output volt- enol connector at ulator Amphenol connec-
age in all phases. voltage regu- tor (See TM-759 or OM-2020).
Generator operating lator, or defec- Using jumper leads
at 400 Hz in AUTOMATIC tive wiring from with clip and prod terminals,
mode. regulator to connect 12-V DC
(Cont’d) exciter field. to terminals “E” and “C”
in loose plug. Connect
NEGATIVE to terminal “E”
Connect POSITIVE lead to
“C” terminal (see Fig.
6). If the generator
will NOT produce a normal
voltage, replace or
repair Amphenol connector
and wiring between
voltage regulator and
exciter field as re-
quired.
(5) Defective voltage (5) All components in the

regulator excitation 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 complete
voltage regulator
2. No (or low) output A. Defective generator A. Place AUTO-MANUAL control

voltage when operating manual control excitation switch (33, Fig. 1) in AUTO
in MANUAL mode circuit. position. If a normal voltage
is NOT produced, perform
checks as instructed in GEN-
ERATOR AND EXCITATION
CIRCUIT TROUBLE 1, above.
If a normal voltage is produced,
proceed to step “B” below.

Figure 5

Page 19
OM-2031

GENERATOR CONTROLS AND INSTRUMENTS (CONTINUED)
2. No (or low) output B. Defect in manual voltage A. Check as follows:

voltage when operating control portion
in MANUAL mode of excitation circuit
(Continued)
(1) Defective AUTO- (1) Check contacts and oper-
MANUAL switch (33, ation of AUTO-MANUAL
Fig. 1) switch. Replace if de-
fective.
(2) Defective rectifier (2) Jumper resistor (1, Fig.

(CR 3) (Sect 2). If normal voltage
1-1; 14, Fig. 7) (depending on rheostat
setting) is produced,
replace resistor.
(3) Defective resistor (3) Jumper resistor (1, Fig.

(R11) (See, 2). If normal voltage
Fig. 2) (depending on rheostat
setting) is produced,
replace resistor.
(4) Defective rheostat (4) Connect a jumper across

(R61) (32, rheostat. If maximum
Fig. 1) (manual control) voltage
is produced, replace
rheostat.
NO. 1 LOAD CONTACTOR OPERATING CIRCUIT
2. Load contactor (K1) A. In addition to defective A. After checking fuse (F1) in

will not close when 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. Generator actuating circuits, on the engine control panel,
running at the load contactor protective relay tray, and
normal voltage. No may be prevented from power module. Then check
fault lights on. closing for any one components as follows:
of the following
reasons:
(1) Blown fuse (F1) (1) Remove and inspect fuse.

Figure 5

Page 20
OM-2031

NO. 1 LOAD CONTACTOR OPERATING CIRCUIT (CONTINUED)
1. Load contactor (K1) (2) Defective (open) (2) Use a jumper with clip
will not close when relay in protective and prod terminals to
control switch (20, module (1-1; GROUND terminal “H” in
Fig. 1) is held in 4, Fig. 8) the test receptacle. If
ON position. Generator contactor will now
running at close, replace module or
normal voltage. No complete protective
fault lights on. relay tray (12, Fig. 1)
(Continued)
(3) Defective load (3) Set AUTO/MANUAL switch
contactor control (S1) to AUTO position.
switch (S5) (20, Connect a jumper with
Fig. 1) test prods between terminals
“S” and “R” on the
test receptacle. If the
contactor closes, re-
place control switch.
(4) Defective rectifier (4) With test receptacle

(CR6) (1-1; terminals “S” and “R”
5, Fig. 11) connected as above,
check voltage at load
contactor coil terminal
X2. If voltage is not
approximately 90-V DC,
replace rectifier.
(5) Defective load (5) Disconnect leads at load

contactor coil contactor terminals X1
(K1) (1-1; 6, and X2. Check coil resistance
Fig. 11) between these
terminals. Resistance
should be approximately
600 ohms. If coil is
defective, replace the

Figure 5

Page 21
OM-2031

N0. 1 LOAD CONTACTOR OPERATING CIRCUIT (CONTINUED)
2. Load contactor (K1) A. 28.5-V DC is not A. Check voltage at terminal Z

will close when reaching plug interlock on test receptacle. Voltage
control switch (20, relay (K2) from should be 28.5-V DC. If not,
Fig. 1) is held in aircraft for the voltage is not being supplied
momentary ON position. following reasons: from aircraft. Check
Opens immediately causes as follows:
when switch
is released to center (1) Generator to aircraft (1) Inspect cable connector
ON position. cable connector plug thoroughly for damaged
defective E and F terminals.
or not plugged Be sure the plug is
into aircraft fully mated with the
receptacle connector aircraft receptacle connector
and making good
contact.
(2) Aircraft rejecting (2) Check aircraft on board

power electrical equipment and
controls
B. “Blown” fuse (F2) B. Press the lens housing of

(1-1; 17, Fig. 8l) in fault indicating lights. If
protective relay tray lamps 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; 1, Fig. 8) or
the complete protective
relay tray.
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

Figure 5

Page 22
OM-2031

GENERATOR CONTROLS AND INSTRUMENTS (CONTINUED)
2. Load contactor will E. Defective fuse- E. Open protective relay tray

close when control interlock relay (K17) and connect a jumper across
switch (20, Fig. 1) or resistor (R46) the resistor R46) (Sect.
is held in momentary 1-1; 21, Fig. 8). If the
ON position. contactor will now remain
Opens immediately closed, replace the resistor
when switch is released (R46). If the contactor will
to center ON position. not remain closed, replace
fuse-interlock relay (K17)
(Sect. 1-1; 2, Fig. 8) or
replace the protective relay
tray assembly.
3. Load contactor A. Fuse (1F or 2F) blown A. Remove and inspect fuses
opens during power (1-1; 16 and 17, Fig. 8).
delivery. NO fault Replace as required.
indicating lights
on.
B. A fault has developed B. If the load contactor cannot

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

Figure 5

Page 23
OM-2031

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 [(36), Fig. 1] has been pushed and the load
contactor has been closed beforecommencing each test.
1. Load contactor A. The overvoltage con- A. Press reset switch (36,

opens during power dition may have been Fig. 1) and resume power
delivery. Overvoltage the result of a sudden delivery. Observe voltmeter
indicating light ON drop in the load, (2, Fig. 1) to be certain
or possible tampering voltage is normal 115 V AC.
with voltage regulator Adjust to normal if necessary.
rheostat, and If the load contactor
may have been a is opened again and an over-
normal action. voltage condition is indicated
by light (DS 37), proceed
to step B.
B. Defective over-under- B. Use voltage adjusting rheostat

voltage sensing module to reduce voltage
(K26) to 110 V AC. Observe
voltmeter and gradually
increase voltage with rheostat.
If the over-under-
voltage sensing module (K26)
functions to open the load
contactor at any value less
than 134 V AC, it is defective.
Replace over-undervoltage
module or complete
protective relay tray.
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 rheostat.
light ON. to function normally. Resume normal operation.
If the load contactor
opens again and an undervoltage
condition is indi-
cated by light (DS38), proceed

Figure 5

Page 24
OM-2031

PROTECTIVE CIRCUIT (CONTINUED)
2. Load contactor B. Defective over-under B. Use rheostat to reduce

opens during power voltage module (K26) voltage to 104 V. The
delivery. Under- undervoltage indicating
voltage indicating light should NOT come on
light ON (Cont’d) 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) or
the protective relay tray.
C. Defective protective C. With unit running normally,

monitor module (K14) use rheostat to reduce
voltage quickly to
90 V. If the undervoltage
indicating light (DS38) is
turned ON immediately, the
protective monitor circuitry
is defective. Replace pro
tective monitor (K14) or replace
3. Load contactor A. Electric governor A. Proceed as follows:

opens during power improperly adjusted,
delivery. Over- or malfunctioning
frequency ind
cating light (DS40) (1) Governor improperly (1) Adjust in accordance
ON adjusted with Sect. 2-3, Para. 3.
(2) Electric governor (2) Check and adjust or re-

system malfunctioning pair in accordance with
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 overfre-
quency condition does not
exist, replace the over-

Figure 5

Page 25
OM-2031

PROTECTIVE CIRCUIT (CONTINUED)
4. Load contactor A. Electric governor B. Proceed as follows:

opens during power improperly adjusted,
delivery. Under- or malfunctioning
frequency light ON.
(1) Governor improperly (1) Adjust in accordance
adjusted with Sect. 2-3, Para. 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 underfre-
quency condition does not
exist, replace over-under-
frequency relay, or complete
5. Load contactor A. There may have been A. Observe ammeter (4, Fig. 1).
opens during power an overload condition Check for abnormal overload
delivery. Overload which caused the condition and correct. If
indi cating overload device (K4) overload device functions to
light ON. to function normally. open the load contactor when
an overload does not exist,
proceed to step B.
B. One of the resistors B. An open resistor will cause

(R26, R27, or R28) a higher than normal volt-
across overload age. Check resistors (Sect.
transformers is open 1-1; 1, Fig. 11). Replace if
circuited. defective.
C. Overload device C. Check voltage at terminal E,

printed circuit board Fig. 8. If 12-V DC, replace

Figure 5

Page 26
OM-2031

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.

ter field windings for normal values.
(L2)
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 2-3, Fig. 12)
generator stator (G1) for normal values.
3. Generator A. Loose connection A. Check all output connec-

overheats causing high resis- tions. Look for discoloration
tance. 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.

windings short cir-
cuited
5. Unbalanced output A. Loose connection in A. Check all output connections.

output circuit. Discolored connectors
indicate a loose connection.
Tighten or replace as
required.
B. Open or short cir- B. Check stator windings in

Figure 5

Page 27
OM-2031

EXTERNAL LOAD
4. Unbalanced output C. Defective connection A. Check plug and receptacle

(Continued) 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-

Figure 5

Page 28
OM-2031
CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION
1. General
The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail
parts of the engine-driven generator sets manufactured by Hobart Brothers Company, Power Systems
Group, Troy, Ohio, 45373. These sets are identified as Hobart Series No. 6911, 6911A.
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.
B. Parts List Form
This form is divided into six columns. Beginning at the left side of the form and proceeding to the right, col-
umns are identified as follows:

Page 1
OM-2031
(1) FIGURE-ITEM NO. Column
This column lists the figure number of the illustration applicable to a particular parts list and also identi-
fies each part in the list by an item number. These item numbers also appear on the illustration. 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 NOMEN-
CLATURE column. Vendor parts which are modified by Hobart will be identified as such in the NO-
MENCLATURE 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 rela-
tionship. Thus, components of an assembly are listed directly below the assembly and indented 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 models of equipment. When more
than one model of equipment is covered by a parts list, there are some parts which are used on only
one model. This column is used for insertion of a code letter “A”, “B”, etc., to indicate these parts and
to identify the particular model they are used on.
Uncoded parts are usable on all models.
Parts coded “A” are usable on Specs 6911-1 only.
Parts coded “B” are usable on Specs 6911-2 only.
Parts coded “C” are usable on Specs 6911-3 only.
Parts coded “D” are usable on Specs 6911A-1 only.
Parts coded “E” are usable on Specs 6911A-2 only.
Parts coded “F” are usable on Specs 6911A-3 only.
Parts coded “G” are usable on Specs 6911A-4 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.

Page 2
OM-2031
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
01843 American Bosch Marketing Div. of Ambac Industries Inc. 3664 Main Street
Springfield, Mass. 01107
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
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
15434 Cummins Engine Company, Defense Products, 1000 Fifth St., P.O.Box 3005,
Columbus, INdiana 47201
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

20038 ESB Inc. 5 Penn Center Plaza P.O. Box 8109 Philadelphia, Pennsylvania 19101

Page 1
OM-2031

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
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
31211 Motorolla Automotive 1303 E. Algonquin Road Schaumburg, IL 60196
31356 J-B-T Instruments, Incorporated 394 East Street P.O. Box 1818
New Haven, Connecticut 06508
31361 Woodward Governor Co. 1000 E. Drake Rd. P.O. Box 1519 Ft. Collins, CO 80522
35708 Tridon Limited P.O. Box 1600 Nashville, TN 37202
41197 Madine 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 Cadilac 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
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

Page 2
OM-2031

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
81074 ITT - Holub Industries 413 Elm Street Sycamore, Illinois 60178
81518 Flexaust Co. Div. of Callahan Mining Co. 11 Chestnut St. Amesbury, MA 01913
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

Page 3
OM-2031

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 Tech Products Corporation 5030 Linden Avenue Dayton, Ohio 45432

Page 4
OM-2031
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 right-hand 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
F - 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.
July 11/96 Revised 4-3

Page 1
OM-2031
Generator Set
Figure 1

Page 2
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY
1- 6911-1 GENERATOR SET FOR TRAILER OR
TRUCK MOUNTING A 1
6911-2 GENERATOR SET FOR TRAILER OR
TRUCK MOUNTING B 1
6911-3 GENERATOR SET FOR TRACTOR MOUNTING C 1
6911A-1 GENERATOR SET FOR TRAILER OR
TRUCK MOUNTING D 1
TRUCK MOUNTING E 1
6911A-3 GENERATOR SET FOR TRACTOR MOUNTING F 1
6911A-4 FIXED UNIT W/FUEL TANK & BATTERIES G 1
TRUCK MOUNTING H 1
1 DDW-155 . EYE, LIFTING 1
2 280342 . CANOPY ASSEMBLY (For Details See Fig. 2) A,B,D,
E,G,H 1
* 180894 . CANOPY ASSEMBLY C,F 1
3 No Number . GENERATOR SET WITHOUT CANOPY
(For Details See Fig. 4) 1
4 280269 . FRAME 1
5 402987 . NAMEPLATE, HOBART 3
*6 76B-1148 . LABEL, DIESEL FUEL 1
*7 79A-1110 . NAMEPLATE, OPTION 1
*8 78A-1000 . NAMEPLATE 1
* NOT ILLUSTRATED

Page 3
OM-2031
Canopy Assembly
Figure 2

Page 4
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
2- 280342 CANOPY ASSEMBLY (For NHA See Fig. 1) A,B,D,
E,G,H REF
181345 CANOPY ASSEMBLY (For NHA See Fig.1) C, F REF
1 488719 . PANEL ASSEMBLY, SIDE, RIGHT, FRONT,
CANOPY A,B,D,
E,G,H 1
2 482320 . DOOR ASSEMBLY, LEFT & RIGHT, FRONT,
CANOPY 2
3 482321 . DOOR ASSEMBLY, RIGHT, FRONT, CANOPY A,B,D,
E,G,H 1
4 482322 . DOOR ASSEMBLY, RIGHT, REAR, CANOPY A,B,D,
E,G,H 1
5 482376 . COVER ASSEMBLY, OPENING, TOP 1
E,G,H 1
7 482327 . BRACKET, MTG., LATCH, DOOR A,B,D,
E,G,H 3
8 76A-1115 . LATCH, ADJUSTABLE GRIP V94222
No. 48-99-126-11 4
9 280338 . TOP ASSEMBLY, REAR, CANOPY 1
10 181049 . COVER, OPENING, PANEL, REAR A,B,D,
E,G,H 1
11 481419 . SUPPORT, MTG., REAR, CANOPY 1
12 181048 . PANEL ASSY, END, REAR, CANOPY A,B,D,
E,G,H 1
13 482401 . COVER, PLEXIGLASS, GENERATOR
CONTROLS 1
14 489032 . DOOR ASSY, LEFT, REAR, CANOPY 1
15 489030 . COVER, PLEXIGLASS, ENGINE CONTROLS 1
16 482426 . PANEL ASSY, SIDE, LEFT, REAR, CANOPY 1
17 480695 . DOOR ASSY, ACCESS, RECEPTACLE 1
18 403127 . CATCH, MAGNETIC V94222
No. 02-10-201-10 2
19 482386 . DOOR ASSY, LEFT, REAR, CANOPY 1
20 404036 . LATCH, DOOR, RECESSED V19220,
No. 3-4973SSU 2
21 482372 . DOOR ASSY, LEFT, FRONT, CANOPY 1
22 482328 . PANEL ASSY, SIDE, RIGHT, REAR, CANOPY A,B,D,
E,G,H 1
23 481417 . TOP ASSEMBLY, FRONT, CANOPY 1
24 387450 . COVER ASSEMBLY, HOLE, RADIATOR 1
25 180669 . FRONT ASSEMBLY, CANOPY 1
* NOT ILLUSTRATED

Page 5
OM-2031

Page 6
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
2- CANOPY ASSEMBLY (CONTINUED)
26 280053 . PANEL ASSEMBLY, LOUVERED, FRONT,
CANOPY 1
27 389284 . COVER, HOLE, FRONT, CANOPY A,B,D,
E,G,H 1
28 481416 . SUPPORT ASSY, MTG., FRONT 1
29 HJ-129A . JOINT, BALL V01428, No. SPS1002CP 8
30 482407 . ROD, STOP, DOOR 7
31 482424 . PANEL ASSY., SIDE, LEFT, FRONT 1
*32 480701 . SPACER, LATCH, DOOR AR
482326 . HORN & CABLE CLAMP ASSEMBLY 1
33 7F-422 . . CLAMP, CABLE 2
34 100GH-121 . . BRACKET, MTG., CLAMP 1
35 482442 . . HORN ASSY., CABLE ENTRANCE 1
*36 403091-8 . PLUG, PLASTIC, 1-3/4", V28520, NO. DP-1750 6
*37 482482 . BRACKET, MTG., DOOR LATCH A,B,D,
E,G,H 1
*38 482507 . ROD, STOP, DOOR (RT. REAR) 1
488863 . ROD, STOP, DOOR (LT. FRONT) 1
*39 404101-1 . LIGHT, CLEARANCE, V75175, NO.514-0168 4
*40 400613-10 . . LAMP, 12V 4
*41 280345 . COVER, OPENING TOP ASSY. (REAR) 1
*42 489052 . ROD & DOOR LATCH ASSY. 2
*43 281088 . FLANGE A,B,D,
E,G,H 1
*44 84A-1047 . LABEL, ACCESS PANEL 1
*45 482428 . COVER, OPENING, LEFT REAR SIDE PNL. C, F 1
*46 482458 . BRACKET, MTG., RIGHT SIDE PNLS. C, F 2
*47 482464 . PANEL, UPPER, RIGHT REAR CANOPY ASSY. C, F 1
*48 482459 . PANEL, UPPER, RIGHT FRONT CANOPY ASSY. C, F 1
*49 482468 . PANEL, LOWER, RIGHT FRONT CANOPY ASSY. C, F 1
*50 485380 . PANEL, END REAR CANOPY ASSY. C, F 1
*51 180911 . FLANGE C, F 1
* NOT ILLUSTRATED

Page 7
OM-2031
Generator Set Without Canopy

Figure 3

Page 8
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
3- No Number GENERATOR SET WITHOUT CANOPY
(For NHA See Fig. 1) REF
1 489331 . GENERATOR ASSY. (For Details See Fig. 17) A,B,C REF
280783 . GENERATOR ASSY. (For Details See Fig. 17) D,E,F,
G,H REF
2 482319 . PANEL ASSEMBLY, TERMINAL, STATOR
3 482075-2 . PANEL ASSEMBLY, POWER MODULE
4 482235-2 . BOX ASSEMBLY, CONTROL, GENERATOR
5 430391C . REGULATOR ASSEMBLY, VOLTAGE
(For Details See Technical Manual TM-759) A,D,G,H 1
* 489812 A . REGULATOR ASSEMBLY, VOLTAGE
(For Details See Technical Manual OM-2020) B,C,E,F 1
* 181442 . LEAD, REGULATOR, SOLID STATE
(Jumper wire for R2 ballast resistor) B,C,E,F 1
6 280264 . KIT, AIR CLEANER, ASSY. (For Details See Fig. 5) 1
7 280269 . FRAME, MOUNTING A-F 1
483203 . FRAME, MOUNTING G,H 1
*8 482305 . HARNESS, WIRE, VOLTAGE REGULATOR 1
280505 . PIPE, EXHAUST, ASSEMBLY 1
9 280335 . . PIPE, EXHAUST-TO-MUFFLER 1
9A W-10869-6 . . CLAMP, EXHAUST 2
10 180912 . MUFFLER ASSEMBLY 1
11 180404 . SUPPORT, MUFFLER LH 1
12 180405 . SUPPORT, MUFFLER, RH 1
13 30GH-417 . MOUNT, RUBBER 4
*14 DDW-495-1 . CAP, RAIN 1
15 NO NUMBER . RADIATOR AND COOLING SYSTEM GROUP
(For Details See Figure 4) 1
16 482296-21 . PANEL ASSEMBLY, CONTROL ENGINE
17 482325 . BRACKET, MOUNTING, PANEL, CONTROL 2
18 482317 . PANEL ASSEMBLY, OUTPUT TERMINAL A,B,D,
(For Details See Figure 16) E,G,H 1
19 482318 . COVER, PANEL, OUTPUT TERMINAL AND A,B,D
STATOR TERMINAL E,G,H 1
*20 HF-2752 . MOUNT, RUBBER (For mounting electrical
panels on Control Box) 12
* NOT ILLUSTRATED

Page 9
OM-2031

Page 10
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
3- GENERATOR SET WITHOUT CANOPY (CONTINUED)
21 408773 . ENGINE ASSEMBLY, CUMMINS DIESEL,
V15434, No. 6BTA5.9 (For Components of
this Assy See Print 408773 in Chapter 6) 1
22 No Number . . STARTER, 12V 1
23 No Number . . ALTERNATOR 1
24 No Number . . FAN, ALTERNATOR 1
*25 180615 . MOUNT, ENGINE LT 1
*26 180614 . MOUNT, ENGINE RT 1
*27 280506 . GUARD, FAN, RT. 1
*28 180981 . GUARD, FAN, LT. 1
29 280454 . KIT, ELECTRICAL GOVERNOR ASSY.,
*30 281220 . LINES, FUEL ASSEMBLY A,B,D,
*31 180895 . LINE, OIL ASSEMBLY A,B,D,
*32 404154-12 . CLAMP, MUFFLER 1
*33 404154-13 . CLAMP, MUFFLER 1
34 280489 . YOKE, LIFTING ASSEMBLY 1
*35 282435 . FAN 1
*36 181331 . SHIELD, RAIN 1
*37 387600 . BRACKET, RETAINING, FRAME C,F 2
*38 401898-2 . CAM, FOLLOWER BEARING C,F 10
*40 387915 . TRACK, ROLL-OUT, LEFT ASSY. C,F 1
*41 387916 . TRACK, ROLL-OUT, RIGHT ASSY. C,F 1
*42 483870 . BLOCK, MTG., CAM FOLLOWER C,F 4
*43 388763 . LINES, FUEL OIL ASSY. C,F 1
488764 . LINES, FUEL OIL ASSY. C 1
284659 . LINES, FUEL OIL ASSY. F 1
*44 403594 . BLOCK, TERMINAL C,F 1
*45 180414 . PANEL, SUPPORT CONTROL BOX 1
*46 482316 . BRACKET, MTG., SUPPORT CONTROL BOX 2
*47 AW-626 . BUSHING, BRUSHHOLDER 1
* NOT ILLUSTRATED

Page 11
OM-2031
Radiator and Cooling System Group

Figure 4

Page 12
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
4- No Number RADIATOR AND COOLING SYSTEM GROU
1 180954 . RADIATOR ASSEMBLY 1
2 405743 . CAP, RADIATOR, V78225, NO. AAX-4018 1
3 280054 . SUPPORT, RADIATOR ASSY. 1
4 W-10869-3 . CLAMP, HOSE, RADIATOR, V62295, NO.C32P 2
6 280339 . SHROUD, RADIATOR 1
7 56532 . HOSE, INLET, RADIATOR 8"
8 280461 . ELBOW, HOSE INLET 1
9 56533 . HOSE, INLET RADIATOR 15"
10 W-10869-7 . CLAMP, HOSE, RADIATOR, V35708, NO.HS-12 4
*11 400902 . ANTI-FREEZE AR
*12 403782-2 . SWITCH, SHUTDOWN, TEMPERATURE,
V51377, NO. 1002-04880-34 1
*13 W-7814-4 . BUSHING, PIPE 1
*14 386751 . CLAMP, HOSE, OVERFLOW 2
* NOT ILLUSTRATED

Page 13
OM-2031
Air Cleaner Assembly

Figure 5

Page 14
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
5- 180417 KIT, AIR CLEANER, ASSY (For NHA See Fig. 3) REF
1 84A-1011 . AIR CLEANER V18265, No. FHG09-0024 1
No. POO-4073 2
*3 180398 . PLATE, MOUNTING, AIR CLEANER 1
4 280265 . PIPE, INTAKE, ASSY. 1
5 403483 . CLAMP, HOSE V21585, No. L-4690-6 3
6 W-10869-5 . CLAMP, HOSE V35708, No. HS-32 1
7 400059-3 . CONNECTOR, FEMALE, SAE-45 V79470, No. 46 X 4 2
8 W-10893-2 . FITTING, HOSE, SWIVEL, FEMALE V30327,
No. KA04-04NS 2
9 56534 . HOSE, LOW PRESSURE, 1/4 ID 48"
10 84A-1045 . REDUCER, RUBBER, V82372, NO. 40R30SL 1
11 83A-1026 . INDICATOR, SERVICE, FILTER, AIR CLEANER,
V21585, No 14440-001 (Mounted on Engine
Control Panel, See Fig. 15, Item 13). 1
12 W-10750-3 . NIPPLE, PIPE, 1/8 1
13 83A-1029 . NUT, PIPE, 1/8-27 V79470, No C3059 X 2 1
*14 85A-1002 . FILTER, AIR CLEANER 1
15 403065 . COUPLING, RUBBER, V21585, NO.A-15094-10 1
* NOT ILLUSTRATED

Page 15
OM-2031
Electric Governor Kit

Figure 6

Page 16
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
6- 280454 KIT, ELECTRIC GOVERNOR, ASSY
1 281774-2 . SENSOR, MAGNETIC GOVERNOR 1
2 280448 . CONTROLLER, GOVERNOR, ELECTRIC 1
3 280447 . GOVERNOR, ACTUATOR, ELECTRIC 1
4 84A-1091 . ARM, THROTTLE, GOVERNOR V03613 1
5 402908 . JOINT, BALL, GOVERNOR LINKAGE
V57448, No. TF-4Y 2
6 W-9476-40 . ROD, THREADED, 1/4-28 X 4 1
7 W-11280-3 . NUT, HEX, 1/4-28 5
*8 84A-1075 . MOUNT, SHOCK, RUBBER TECH PRODUCTS
CORP., NO. 50-DURO 4
*9 482989 . STRAP, WIRE, GRND. 2
*10 280449 . BRACKET, GOVERNOR, MTG. 1
*11 180889 . BRACKET, MTG., CONTROLLER 2
*12 280456 . ADAPTER 1
*13 482496-2 . CLAMP 2
*14 400829-5 . TERMINAL, SPADE 3
* NOT ILLUSTRATED

Page 17
OM-2031
Fuel Lines Assembly

Figure 7

Page 18
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
7- 281220 LINES, FUEL, ASSEMBLY (For NHA See Fig. 3) REF
2 W-10893-0 . FITTING, HOSE, SWIVEL, FEMALE 3
3 W-10886-11 . CONNECTOR, MALE 1
4 W-10119-4 . COUPLING, PIPE 1
5 W-1-760-3 . NIPPLE, PIPE 2
6 W-11608-3 . TEE, PIPE, BLACK 1
7 W-7814-3 . BUSHING, PIPE 1
9 W-10893-2 . FITTING, HOSE, SWIVEL, FEMALE 1
10 56534 . HOSE, LOW PRESSURE 60"
11 78B-1019-3 . TUBE, RIGID, HOSE END, 1/4" 1
12 W-10901-2 . NUT, FITTING 1
13 W-10905-2 . SLEEVE, COMPRESSION 1
15 W-10869-14 . CLAMP, HOSE 2
16 280990 . TUBE, FUEL LINE, 3/8" 2
17 181204 . FILTER, FUEL 1
18 W-10891-4 . ELBOW, MALE 1
19 W-7814-5 . BUSHING, PIPE 2
20 400819-1 . VALVE, BALL, 3/4" 1
21 12CW-2077-3 . STREET ELL, 90 DEG., 1/2" 1
22 W-10760-1 . NIPPLE, PIPE 1

Page 19
OM-2031
Oil Line Assembly

Figure 8

Page 20
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
8- 180895 LINE, OIL, ASSEMBLY (For NHA See Fig. 3) REF
1 W-10750-4 . NIPPLE, PIPE, 1/8 1
2 W-10910-0 . TEE, STREET, BRASS 1
3 403809-1 . SWITCH, LOW OIL PRESSURE, V51377,
NO. C-25900-10 1
4 W-10886-1 . CONNECTOR, MALE, WEATHERHEAD,
V79470, NO. 48 X 4 1
5 403590-1 . SWIVEL, FEMALE, 7/16-20 SAE THDS,
V03924, NO. 7115-4S 2
6 56548 . HOSE, #4, 3/16 ID 60"

Page 21
OM-2031
Stator Terminal Panel Assembly

Figure 9

Page 22
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
9- 482319 PANEL ASSY, TERMINAL, STATOR
1 W-11097-18 . SCREW, STEEL, 3/8-16 X 3/4, HHC 9
2 W-11254-6 . WASHER, LOCK, STEEL, 3/8 IN. 9
3 W-11242-10 . WASHER, FLAT, 3/8 IN. 9
4 482446 . RETAINER, CABLE 6
5 482443 . BAR, BUS 3
6 W-10854-4 . CAPACITOR, 0.1 MFD, 500 V. V90201,
No. B-206143 3
7 482471 . STRAP, CONNECTING, CAPACITORS 1
8 482449 . BRACKET, MOUNTING, BOARD 2
9 401937-1 . BLOCK, TERMINAL V98410, No. 35005-3526 1
10 W-11112-3 . SCREW, ROUND HEAD, MH, STEEL,
#10-24 X 3/4 3
11 W-11254-3 . WASHER, LOCK, #10, STEEL 3
12 W-11245-3 . WASHER, FLAT, BRASS 3
13 482450 . PANEL, TERMINAL, OUTPUT 1

Page 23
OM-2031
Power Module Panel Assembly

Figure 10

Page 24
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
10- 482075-2 PANEL ASSEMBLY, POWER MODULE
1 401937-3 . STRIP, TERMINAL V98410, No. 35012-3526 2
2 401937-2 . STRIP, TERMINAL V98410, No. 35008-3526 1
3 W-9746-1 . RESISTOR, LINE DROP BURDEN, 50 OHM,
25 WATT, V44655, No. 0200D 3
4 404402-1 . RESISTOR, OVERLOAD BURDEN, 16.6 OHM
25-WATT V91637, No. RH-25 3
5 1CZ-148 . TRANSFORMER, CURRENT, LINE DROP &
OVERLOAD V50508, No. E-6170 6
6 404065-1 . RECTIFIER, SILICON V04713, No. SDA10270-1 1
7 404518 . CONTACTOR, LOAD V50603, No. HB200BB 1
9 401564-4 . HOUSING, SOCKET, CONNECTOR V89110,
No. 1-480287-0 1
10 401566-11 . TERMINAL, SOCKET V89110, No. 60619-1 10
11 403763-1 . WASHER, FIBER, SHOULDER 4
12 401556 . MOUNT, SHOCK, RUBBER V81860 No. SS-01 4
13 363136-5 . TRANSFORMER, CURRENT, AMMETER 3
14 400701 . CONNECTOR, RIGHT ANGLE V59730,
No. TA-250-8 5
15 401939 . ADAPTER, TERMINAL V98410, No. VWA-0 1
16 400830-15 . TERMINAL, RING TONGUE V89110, No. 31159 3
17 402197-1 . TERMINAL, QUICK CONNECT, PIGGYBACK
V89110, No. 61944-2 1
18 400480-2 . TERMINAL, QUICK CONNECT V00779, No. 41274 5
19 400480-3 . TERMINAL, QUICK CONNECT V00779, No. 42640-2 2
*20 1CZ-93B . DIODE, SILICON V05277, No. IN4820 1
21 482076 . PANEL, POWER MODULE 1
22 W-9360-279 . CABLE ASSEMBLY, POWER ELECTRICAL
(No. 101) “A” Stator Terminal Panel to “A”
Contactor; (No. 102) “B” Stator Terminal Panel
to “B” Contactor; (No. 103) “C” Stator Terminal
to “C” Contactor; (No. 110) “N” Terminal to “N”
Output Terminal Panel 4
*23 W-9360-211 . CABLE ASSEMBLY, POWER ELECTRICAL
(No. 104) “A” Contactor to “A” Output Terminal
Panel; (No. 105) “B” Contactor to “B” Output
Terminal Panel; (No. 106) “C” Contactor to “C”
Output Terminal Panel 3
*24 W-9360-278 . CABLE ASSEMBLY, POWER ELECTRICAL
(No. 111) “N” Terminal to Ground 1
* NOT ILLUSTRATED

Page 25
OM-2031
Control Box Assembly

Figure 11

Page 26
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
11 - 482235-2 CONTROL BOX ASSY. (For NHA See Fig. 3) REF
1 482278-2 . TRAY ASSY, GENERATOR CONTROLS
(For Details see Fig. 12) 1
2 482285-1 . TRAY ASSEMBLY, PROTECTIVE RELAYS
(For Details see Fig. 13) 1
3 No Number . CONTROL BOX AND INTERNAL COMPONENTS
GROUP (For Details See Fig. 14) 1
*4 76A-1130 . CLAMP, TUBE V78553, No. C-4362S-031 2
* NOT ILLUSTRATED

Page 27
OM-2031
Generator Controls Tray Assembly

Figure 12

Page 28
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
12- 482278-2 TRAY ASSEMBLY, GENERATOR CONTROLS
1 482355 . HARNESS, WIRE, RECEPTACLE 1
2 482284-1 . BRACKET, MOUNTING, RECEPTACLE AND
SWITCH 1
3 402826 . SWITCH, AUTOMATIC, MANUAL V15605,
No. 8926K425 1
*4 402665-1 . HOUSING, RECEPTACLE V00779,
No. 1-480416-0 6
5 404065-1 . RECTIFIER, SILICON V04713, No. SDA10270-1 1
6 W-2974-L . RESISTOR, MANUAL, 50 OHM, 100 WATT
V44655 No. 0959 1
6A 400078 . BRACKET, MOUNTING, RESISTOR 6
7 W-2974-N . RESISTOR, BALLAST V44655, 100 WATT 2
8 16DA-4253-1 . RETAINER, SPRING, RELAY V77342, No.
(KUP) 20C206 1
9 16DA-4004A-10 . RELAY, EXCITATION, DEENERGIZATION 12V.
V77342, No. KAP-14D G-12 1
10 16DA-4052-0 . SOCKET, RELAY V02660, No. 77-MIP-11 1
* 11 363771-5 . SLEEVING, PLASTIC, /8 IN. I.D. 6
* 12 363770-1 . SLEEVING, PLASTIC, 3/16 IN. I.D. 2
13 16DA-4029 . BRACKET, MOUNTING, SOCKET, RELAY 1
14 16DA-2162 . KNOB, RHEOSTAT V44655, No. 5150 1
15 10J-178 . NAMEPLATE, FIELD, RHEOSTAT 1
16 381439 . BRACKET, MOUNTING, RHEOSTAT 1
17 402218 . RHEOSTAT, MANUAL, MODEL L V44655,
100 Ohms, 150 Watts 1
18 HF-1459 . SWITCH, METER SELECTOR V82121,
No. 101904LN 1
19 15GH-433 . NAMEPLATE, METER, SELECTOR SWITCH 1
20 400400 . SWITCH, TOGGLE V73559, No. 26L61TABS 1
21 W-8095A-9 . AMMETER V60741, No. 331LH 1
22 W-8105A-4 . VOLTMETER V60741, No. 331LH 1
23 W-9916-10 . METER, FREQUENCY, V31356, No. 36-FX 1
*24 388328-49 . NAMEPLATE, IDENTIFICATION 1
482279 . TRAY SUB-ASSEMBLY, GENERATOR CONTROL 1
25 370382A . . HANDLE, TRAY 1
26 404028 . . NAMEPLATE, HOBART 1

Page 29
OM-2031
This page intedntionally left blank.

Page 30
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
12- 482278-2 TRAY ASSEMBLY, GENERATOR CONTROLS
Continued REF
27 76A-1115 . . LATCH, ADJUSTABLE GRIP V94222
No. 48-99-126-11 1
28 402383 . . SLIDE ASSEMBLY, TRAY (Consists of four parts
marked CR, CL, DR, & DL) V75358, No. 1335-12 1 set
29 482280 . . TRAY ASSEMBLY 1
*30 482306 . HARNESS ASSEMBLY, WIRE, GEN. CONTROL TRAY 1
* NOT ILLUSTRATED

Page 31
OM-2031
Protective Relays Tray Assembly

Figure 13

Page 32
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
13- 482285-1 TRAY ASSEMBLY, PROTECTIVE RELAYS
1 402662 . SWITCH, TEST BANK V73559, No. 2GK71-73 1
2 482284-2 . BRACKET, MTG., RECEPTACLE & SWITCH 1
3 482356 . RECEPTACLE, HARNESS, WIRE 1
4 16DA-4052-0 . SOCKET, RELAY 3
5 16DA-4004A-3 . RELAY, PLUG, INTERLOCK 24 V. DC V77342,
No. K10-14DG-24 1
6 16DA-4253-1 . RETAINER, SPRING, RELAY V77342,
No. (KUP) 20C206 3
7 16DA-4004A-10 . RELAY, FUSE, INTERLOCK & K23 V77342,
No. KAP-14DG-12 2
8 W-9746-3 . RESISTOR, 100 Ohm, 25 W., V44655, No. 0200F 1
10 401556 . MOUNT, SHOCK, RUBBER V81860, No. SS-01 12
11 387736B . BOARD ASSY, MEMORY AND TIME DELAY 1
12 401563-5 . HOUSING, PIN, CONNECTOR 1
13 482038 . BOARD ASSEMBLY, OVER-UNDERVOLTAGE 1
15 482039 . BOARD ASSEMBLY, OVER-UNDERFREQUENCY 1
17 76A-1118 . SWITCH, SNAP, PUSHBUTTON V27192,
No. SA35BCB34-9 2
18 403336 . RING, LOCKING, SWITCH V91929, No. TS10397 2
19 HF-2518-2 . LIGHT, PILOT, FAULT, RED, 12 V. 5
20 400613-4 . BULB, V71744, Type 1815 1
21 402658 . HOLDER, FUSE V71400, No. HKP-HH 2
22 W-11166-1 . FUSE, AGC, 2 A. 1
23 W-11166-1 . FUSE, AGC, 2 A. 1
24 16DA-1997-6 . BUTTON, PLUG, HOLE V90763, No. SS-51026 1
25 402037-9 . GROMMET, RUBBER V02231, No. AGW-421 1
26 388328-52 . NAMEPLATE, IDENTIFICATION 1
*27 401566-11 . TERMINAL, SOCKET V89110, No. 60619-13 5
*28 401564-4 . HOUSING, SOCKET, CONNECTOR V89110,
No. 1-480287-0 2
*29 401564-5 . HOUSING, SOCKET, CONNECTOR V89110,
No. 1-480438-0 1
30 482291 . NAMEPLATE, PROTECTIVE SYSTEM 1
482286 . TRAY ASSEMBLY, PROTECTIVE RELAYS 1
* NOT ILLUSTRATED

Page 33
OM-2031
This page intentionally left blank.

Page 34
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
13- CONTINUED TRAY ASSEMBLY, PROTECTIVE RELAYS
REF
1 402383 . . SLIDE ASSEMBLY, TRAY (Consists of four parts
marked CR, CL, DR & DL),V75358, No. 1336-12 1set
32 404028 . .NAMEPLATE, HOBART 1
33 370382A . . HANDLE, TRAY 1
34 76A-1115 . . LATCH, ADJUSTABLE GRIP,V94222,No. 48-99-126-11 1
35 482287 . . TRAY ASSEMBLY 1
*36 482307 . HARNESS ASSEMBLY, WIRE,
PROTECTIVE RELAYS TRAY 1
* NOT ILLUSTRATED

Page 35
OM-2031
Control Box and Internal Components Group

Figure 14

Page 36
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
14- No Number CONTROL BOX AND INTERNAL
COMPONENTS GROUP (For NHA See Fig. 11) REF
1 402037-9 . GROMMET, RUBBER V02231, No. AGW-4211 2
2 82B-1047 . LIGHT, PANEL V74400, No. MI-3216 1
3 50GHP-206 . BULB V74400, No. 67 1
4 W-10051-10 . CLAMP, WIRE, PLASTIC V81074, No. EC-10 2
5 W-10051-13 . CLAMP, WIRE, PLASTIC V81074, No. EC-14 1
6 402383 . SLIDE ASSEMBLY, TRAY (For Details See
Tray Assemblies, Fig. 17 or 18) REF
7 482236 . BOX ASSEMBLY, CONTROL 1

Page 37
OM-2031
Engine Control Panel Assembly

Figure 15

Page 38
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
15- 482296-17 PANEL ASSEMBLY, CONTROL, ENGINE
(For NHA See Fig. 3) A REF
482296-21 PANEL ASSEMBLY, CONTROL, ENGINE
(For NHA See Fig. 3) B,C,D,E,
F,G,H REF
1 482297 . PANEL, CONTROL, ENGINE 1
2 82B-1047 . LIGHT, PANEL, 12-V V75175, No. 261-3306 1
3 12CW-1320A-5 . GAUGE, FUEL, ELECTRIC V98738, No. 301-4 1
4 FW-1312 . SWITCH, TOGGLE, DPST V27192, No. 7320K3 1
5 402889-2 . AMMETER, V85925, No. 730-D-5 1
6 403189 . SWITCH, TOGGLE, V91929, No. 312TS1-59 A 4
403189 . SWITCH, TOGGLE, V91929, No. 312TS1-59 B,C,D,
E,F,G,H 3
7 W-9917-18 . METER, ENGINE, HOUR V16476, No. 771-8/50 1
8 DW-4304 . GAUGE, TEMPERATURE, WATER V57733,
No. 2100 1
9 HF-2518-8 . LIGHT, PILOT, ENGINE & GENERATOR,
GREEN 2
400613-4 . . BULB, V74400, No. 3271 1
10 DW-6080 . GAUGE, PRESSURE OIL V57733, No. 352-AW 1
12 No Number . CONTROL, COLD WEATHER, STARTING AID
(Part of Item 3, Fig. 3) 1
13 83A-1026 . INDICATOR, SERVICE, FILTER, AIR CLEANER
(Part of Air Cleaner Kit. See Fig. 6, Item 11
for vendor data). REF
15 W-11166-3 . FUSE, AGC, 10-AMP 1
16 402658 . HOLDER, FUSE, V71400, No. HKP-HH 1
17 401937-3 . STRIP, TERMINAL, 12-STATION V98410,
No. 35012-3526 1
* NOT ILLUSTRATED

Page 39
OM-2031

Page 40
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
15- PANEL ASSEMBLY, CONTROL,
ENGINE (CONTINUED) REF
18 404100 . SWITCH, PUSHBUTTON, STARTER, V70040,
No. 1996027 1
19 Delete
20 401937-2 . STRIP, TERMINAL, 8-STATION V98410,
No. 35008-3526 1
21 400701 . CONNECTOR, RIGHT ANGLE, V59730,
No. TA-250-8 2
22 No Number . SWITCH, PERMISSIVE START
(Furnished with Engine) 1
23 No Number . NAMEPLATE, START-RUN-STOP
(Furnished with Engine) 1
24 403380 . CAP & CHAIN ASSEMBLY, V02660, No. 9760-28 1
25 482304 . HARNESS, WIRE, TEST RECEPTACLE ASSY. A 1
280510 . HARNESS, WIRE, TEST
RECEPTACLE ASSY. B,C,D,
E,F,G,H 1
26 W-10051-13 . CLAMP, WIRE, PLASTIC 1
27 482298 . NAMEPLATE, CONTROLS 1
*28 400059-3 . CONNECTOR, FEMALE, SAE-45, V79470,
No. 46 X 4 1
*29 12CW-2125 . FITTING, PIPE, STREET ELL, 45, V79470,
No. 3350 X 2 1
* NOT ILLUSTRATED

Page 41
OM-2031
Output Terminal Board Assembly

Figure 16

Page 42
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
16- 482317 BOARD ASSEMBLY, TERMINAL, OUTPUT A,B,D,
(For NHA See Fig. 3) E,G,H REF
1 50MS-732-0 . NUT, HEX, 1/4-20, KEPS, MH, STEEL 12
2 W-11242-5 . WASHER, FLAT, 1/4 IN., STEEL 12
3 W-9549-19 . ROD, TERMINAL 1/4-20 X 2-1/4 2
4 482445 . BRACKET, MOUNTING, BOARD, TERM.,
OUTPUT 2
5 W-11097-18 . SCREW, HHC, STEEL, 3/8-16 X 3/4 8
6 W-11254-6 . WASHER, LOCK, STEEL, 3/8 IN. 8
7 W-11242-10 . WASHER, FLAT, STEEL, 3/8 IN. 8
8 482446 . RETAINER, CABLE 4
9 482443 . BAR, BUS, PHASE 4
10 W-11112-3 . SCREW, RD. HD., MH, STEEL, 10-24 X 3/4 4
11 W-11254-3 . WASHER, 10, LOCK, STEEL 4
12 W-11245-3 . WASHER, 10, FLAT, BRASS 4
13 482444 . BOARD, TERMINAL, OUTPUT 1
*14 W-11097-2 . SCREW, HHC, STEEL, 3/8-16 X 1 4
*15 402119-5 . SCREW, HHC, STEEL, 1/4-20 X 7/8 4
* NOT ILLUSTRATED

Page 43
OM-2031
Generator Assembly
Figure 17

Page 44
OM-2031
NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO PART NO. 1234567 EFF ASSY
17- 489331 GENERATOR ASSY. (For NHA See Fig. 3) A,B,C REF
280783 GENERATOR ASSY. (For NHA See Fig. 3) D,E,F,
G,H REF
1 387617A . COVER, FAN, HOUSING 1
2 387621 . COVER, EXCITER HOUSING 1
3 488908 . FAN & COUPLING ASSEMBLY 1
4 482483 . SCREW, RETAINING 1
5 480669 . ADAPTER, FOOT, GENERATOR 2
7 488755 . COVER, END, EXCITER HOUSING 1
8 100GHP-66 . WASHER, RETAINING 1
9 387623-1 . CORE, ARMATURE ASSEMBLY 1
10 W-10875-1 . . DIODE, SILICON, 35 AMP, NEGATIVE
BASE V51589 #ST46ON 3
11 W-10874-1 . . DIODE, SILICON, 35AMP, POSITIVE
BASE V51589 #ST460P 3
12 386612 . RING, SPACER, COUPLING 1
13 481379 . KEY, EXCITER 1
14 387624A-1 . HOUSING, EXCITER 1
15 100NH-2 . POLEPIECE 4
16 100NH-3 . INSULATION, EXCITER 4
17 Data 3190 . COIL, FIELD, EXCITER 1SET
18 387620A-1 . HOUSING, FAN, ASSEMBLY 1
19 85B-1039 . KEY, FLEXIBLE, COUPLING 1
20 W-10072-68 . BEARING, FRONT, V53035,
#6314DDUG3E1SR1S 1
21 W-10072-69 . BEARING, REAR, V53035,
#6310DDUC3ESR1S 1
22 489047 . ARMATURE, AC/DC A,B,C,D 1
181343 . ARMATURE, AC/DC E,F,G,H 1
23 387748-1 . HOUSING & STATOR ASSEMBLY 1
24 481940 . BRACKET, RETAINING BEARING D,E,F,
G,H 1
488993 . BRACKET, RETAINING, BEARING A,B,C 1
*25 385950 . INSULATION, TOE 16
*26 480603-1 . MOUNT, RUBBER 8
*27 480628 . WASHER, MOUNT 8
*28 408999-1 . DIODE, RECTIFIER, POWER 1
*29 181757 . BRACKET, MOUNTING, DIODE 1
* NOT ILLUSTRATED

Page 45
OM-2031

Page 46
OM-2031
SECTION 4. NUMERICAL INDEX
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 location is listed commencing with the first location the part is listed.

Page 1
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
A-25 21-14
AUXILIARY FRAME AND COMPONENTS 4-32, 22-0
AW-626 21-15
CONTROL BOX AND INTERNAL COMPONENTS GROUP 14-3, 17-0
DATA-3190 20-17
DDW-155 1-1
DW-4304 18-8
DW-6080 18-10
ENGINE ASSEMBLY 4-9
FW-1312 18-4
GENERATOR GROUP 4-1
GENERATOR SET WITHOUT CANOPY 1-3, 4-0
HF-1459 15-18
HF-2518-2 16-19
HF-2518-8 18-9
HF-2752 4-26
HJ-129A 2-29, 3-23
MOUNTING FRAME AND LIFTING YOKE ASSY 1-4, 4-10, 21-0
RADIATOR AND COOLING SYSTEM 4-16, 5-0
W-10051-10 17-4
W-10051-13 17-5, 18-26
W-10072-1 20-21
W-10072-48 20-20
W-10072-68 20-20
W-10072-69 20-21
W-10119-4 8-24
W-10750-3 6-12
W-10760-1 8-23
W-10760-3 8-1
W-10854-4 12-6
W-10869-1 5-22
W-10869-3 5-2
W-10869-5 6-6
W-10874-1 20-11
W-10875-1 20-10
W-10886-1 8-25, 9-3
W-10886-2 8-20
W-10891-1 11-16
W-10891-7 8-6, 11-2
W-10891-8 10-1
W-10891-11 10-4
W-10893-0 8-26
W-10893-2 6-8, 8-7, 11-3
W-10900-3 8-16, 11-12
W-10901-1 8-18, 11-14
W-10901-3 8-14, 11-3

Page 2
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
W-10905-1 8-17, 11-3

W-10905-6 8-13, 11-7
W-10909-1 9-2
W-11097-18 12-1, 19-5
W-11112-3 12-10, 19-10
W-11166-1 16-22, 16-23
W-11166-3 18-15
W-11242-5 19-2
W-11242-10 12-3, 19-7
W-11245-3 12-12, 19-12
W-11254-6 12-2, 19-6
W-11280-3 7-7
W-11330 4-39
W-11608-3 8-22
W-2974-A 30-18
W-2974-L 15-6
W-2974-N 15-7
W-7814-2 11-18
W-7814-4 8-21
W-7814-5 8-3
W-7814-9 5-24
W-7814-10 8-5
W-7814-11 11-1
W-8095A-9 15-21
W-8105A-4 15-22
W-9360-211 13-23
W-9360-278 13-24
W-9360-279 13-22
W-9549-19 19-3
W-9746-1 13-3
W-9746-3 13-36, 16-8
W-9746-11 7-6
W-9916-10 15-23
W-9917-18 18-7
1CZ-148 13-5
1CZ-93B 4-38, 13-20,
13-29, 13-37
10J-178 15-15
100GH-121 2-34
100GH-664 22-6
100GHP-66 20-8
100NH-2 20-15
100NH-3 20-16
12CW-1320A-5 18-3, 22-17
12CW-2077-2 11-19
12CW-2077-3 8-2
12CW-2125 18-30

Page 3
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
15GH-433 15-19
16DA-1997-3 18-14
16DA-1997-5 18-11
16DA-1997-6 16-24
16DA-2162 15-14
16DA-4004A-3 13-33, 16-5
16DA-4004A-10 13-35, 15-9,
16-7
16DA-4029 15-13
16DA-4052-0 13-28, 15-10,
16-4
16DA-4133-2 22-4
16DA-4253-1 13-34, 15-8,
16-6
180132 5-6
181343 20-22
30GH-417 4-25
30523 8-15, 11-11
351541 5-21
355194 5-18
357177-3 22-8
363136-5 13-13
363770-1 15-12
363771-5 15-11
386612 20-12
370382A 15-25, 16-33
381439 15-24
385950 20-25
386751 5-16
387313 5-11
387450 2-24, 3-28
387600 21-11
387602B-1 20-22
387617A 20-1
387620A-1 20-18
387621 20-2
387623-1 20-9
387624A-1 20-14
387736B 16-11
387738A 13-8
387748-1 20-23
387881 5-8
387915 21-5
387916 21-4
387947 21-10
388328-49 15-24

Page 4
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
388328-52 16-26
388763 4-30, 10-0
388828-1 22-7
389284 2-27
389909 5-5
400059-3 6-7, 18-29
400078 15-6A
400333-1 6-14
400400 15-20
400480-2 13-18
400480-3 13-19, 13-38,
400613-4 16-20, 17-3,
18-9
400613-10 2-40
400701 13-14, 18-21
400819-1 8-4
400830-15 13-16
401556 13-12, 16-10
401563-4 16-14, 16-16
401563-5 16-12
401564-4 13-9, 16-28
401564-5 16-29
401566-7 13-10
401566-11 16-27
401898-2 21-7
401937-1 12-9, 16-9
401937-2 13-2, 18-20
401937-3 13-1, 13-26,
18-17
401939 13-15
402037-9 16-25, 17-1
402037-14 13-31
402037-23 22-3
402096 4-7
402194 21-8
402197-1 13-17
402218 15-17
402262 16-1
402383 15-28, 16-31,
17-6
402658 16-21, 18-16
402662 13-32
402665-1 15-4
402826 15-13
402889-2 18-5
402908 7-5
402958 5-10

Page 5
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
402987 1-5
403034 5-1
403091-8 2-36
403127 2-18, 3-17
403189 18-6
403336 16-18
403380 18-24
403483 6-5
403492-1 22-1
403590-1 9-4
403590-4 10-2
403590-5 10-5
403592 11-17
403763-1 13-1
403782-2 5-23
403809-1 9-1
404028 15-26, 16-32
404030-2 22-15
404036 2-20, 3-21
404065-1 13-6, 15-5
404065-2 13-27
404100 18-18
404101 2-39
404124 4-17
404402-1 13-4
404518 13-7, 13-30
404595 7-1
405015 4-34
405071-1 7-13
405099 4-35
430278 21-12
430391C 4-8
480235A 20-3
480603-1 20-26
480618 4-23
480619 4-24
480621 4-12
480628 20-27
480646 20-19
480669 20-5
480674 22-1
480675 22-2
480676 22-5
480695 2-17, 3-16
480701 2-32, 3-29
480711 22-13
480733 22-9

Page 6
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
481032 22-16
481113 21-9
481379 20-13
481416 2-28, 3-26
481417 2-23, 3-4
481418 2-9, 3-8
481419 2-11, 3-10
481503 3-20
481940 20-24
482038 16-13
482039 16-15
482069 13-25
482075-2 4-3, 13-0
482076 13-21
482235-2 4-4, 14-0
482236 17-7
482278-2 14-1, 15-0
482279 15-0
482280 15-29
482284-1 15-2
482284-2 16-2
482285-1 14-2, 16-0
482286 16-30
482287 16-35
482291 16-30
482296-17 4-18, 18-0
482296-18 4-18, 18-0
482296-19 4-18, 18-0
482298 18-27
482304 18-25
482305 4-27
482306 15-30
482307 16-36
482311 21-3
482316 21-1
482317 4-20, 19-0
482319 4-2, 12-0
482320 2-2, 3-25
482321 2-3
482322 2-4
482323 2-6
482325 4-19
482326 2-32
482327 2-7
482328 2-22

Page 7
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
482355 15-1
482356 16-3
482372 2-21, 3-24
482376 2-5, 3-7
482386 2-19, 3-15
482389 2-14, 3-13
482400 2-15, 3-14,
19-0
482401 2-13, 3-12
482407 2-30, 3-22
482424 2-31, 3-19
482426 2-16, 3-18
482428 3-19
482429 2-26, 3-1
482437 2-25, 3-27
482442 2-35
482443 12-5, 19-9
482444 19-13
482445 19-4
482446 12-4, 19-8
482449 12-8
482450 12-13
482458 3-5
482459 3-3
482464 3-6
482469 2-12
482470 2-10, 3-9
482471 12-7
482482 2-37
482483 20-4
482507 2-38
482918 4-15
482989 7-11
483203 22-10
484016 18-1
484067 4-3, 13-0
484071 19-14
484265-3 4-40
485379 1-2, 3-0
485880 3-11
487720 1-
488538 5-14
488539 5-7
488540 5-0
488541 5-9

Page 8
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
488661 4-6
488686-1 4-14
488689 21-6
488692 7-8
488693 7-9
488694 4-9, 6-0
488695 4-29, 9-0
488697 5-4
488698 5-3
488699 5-19
488700 4-13
488701 4-15, 7-0
488702 4-28, 8-0
488719 2-1
488720 2-0
488735-1 4-36
488735-2 4-37
488741 6-3
488755 20-7
488764 4-31, 11-0
488908 20-3
488993 20-24
489047 20-22
489291 6-4
489812 4-8
5CW-1932-0 5-15
5CW-2048 22-11
50GHP-82 5-13
50GHP-89 5-12
50MS-732-0 7-12, 19-1
56501 5-20
56534 6-9, 8-8, 11-4
56535 8-27
56540 6-15
56548 9-5
56551 10-3
56552 10-6
56555 5-17
6810-1 1-0
6810-2 1-0
6810-3 1-0
7J-422 2-33
75NH-306 19-16
75NH-307 19-15
76A-1115 2-8, 16-34
76A-1118 16-17
76A-1125 3-31

Page 9
OM-2031
FIGURE &
ITEM
PART NUMBER NUMBER
76A-1130 4-14
76A-1152 22-12
78A-1021 8-12, 11-0
78A-1023 8-11, 11-9
78B-1010 4-33
78B-1019-1 8-19, 11-15
78B-1019-2 8-9, 11-5
78B-1022 8-10, 11-8
82B-1047 17-2, 18-2
83A-1026 6-11, 18-13
83A-1029 6-13
85A-1002 6-16
84A-1006 6-10
84A-1009 7-2
84A-1010 6-2
84A-1011 6-1
84A-1020 7-3
84A-1050 7-4
84A-1075 7-10
84A-1101 4-41
84B-1066 4-11
85A-1007 4-22
85B-1039 20-19

Page 10
OM-2031
CHAPTER 5. OPTIONAL EQUIPMENT

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

Trailer, Fenders and Parts TO-136 482731
Transformer-Rectifier, 28.5-V DC OM-433 487750-1
Transformer-Rectifier Mounting Kit TO-105 481387
Truck Body Package TO-109 481386
Truck, Chevrolet TO-109 404137
Truck, Ford, Std. TO-109 403757
Truck, GMC TO-109 404238
Quick Start Kit OM-2031 402096
Kit, 24VDC Power Supply TO-219 181657
Low Coolant Shutdown Kit OM-2031 No Number
Low Fuel Shutdown Kit OM-2031 285953
Emergency Shutdown Switch OM-2031 285958
Fork Lift Support Assembly OM-2031 482743

Page 1
OM-2031

Page 2
OM-2031
CHAPTER 6. MANUFACTURER’S
LITERATURE
Voltage Regulator (430391C) Hobart Brothers Company
Operation and Maintenance Manual TM-759
Voltage Regulator (489812A) Hobart Brothers Company

Operation and Maintenance Manual OM-2020
Electric Governor Barber Coleman Governor Company

Electrically Powered Governor
Engine Cummins Engines, Inc.

Handbook for Diesel Engine 6BTA5.9
Flexible Coupling Hobart Brothers Company Coupling Manual OM-2019
Exciter Rotor Hobart Brothers Company Rotor Manual TM-360
The following items of equipment, which are options for other specifications
covered by this manual, are standard equipment on Specification 6911A-5
Low Fuel Level Kit (285953) Hobart Brothers Company Manual No. OM-2031
Emergency Stop Kit (285958) Hobart Brothers Company Manual No. OM-2031
Fork Lift Support Assembly (482743 Hobart Brothers Company Manual No. OM-2031
Hobart Diagrams
482099 - Connection Power Module

180893 - Schematic, Engine
181654 - Schematic, Engine (6911A-3, 6911A-4 ONLY)
281886 - Schematic, Engine (6911A-1, 6911A-5)
482360 - Schematic, Generator
488704 - Connection, Engine (6911-1 thru 6911-4)
181653 - Connection, Engine (6911A-1, 6911A-2, 6911A-3, 6911A-4 ONLY)
180894 - Connection, Generator
482365 - Connection Generator Control Tray
482366 - Connection Protective Relays Tray
408773 - Engine, Cummins Diesel, Model 6BTA5.9
280500 - Outline, Dimensional

Page 1
OM-2031

Page 2
OM-2031
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 condition 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 ventila-
tion.
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 fun-
gus growth.
G. Abnormal shock, vibration or mechanical loading from external sources during equipment op-
eration.
H. Abnormal axial or side thrust imposed on rotating equipment shafts.
I. Low and/or high ambient temperatures.
J. High electromagnetic fields.
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.
August 5/89 Revised Unusual Service Conditions

Page 1
OM-2031
Unusual Service Conditions August 5/89 Revised

Page 2

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OM-2031

OPERATION AND MAINTENANCE

6911A-5* Trailer or Truck 489812A

Hobart Brothers Company

C . FIRE AND EXPLOSION PREVENTION

D. TOXIC FUME PREVENTION

E. BODILY INJURY PREVENTION

F. MEDICAL AND FIRST AID TREATMENT

EMERGENCY FIRST AID

G. EQUIPMENT PRECAUTIONARY LABELS

LIST OF EFFECTIVE PAGES

1-1 1 Aug 5/89 1-3 1 Aug 5/89

August 5/89 Revised List of Effective Pages

LIST OF EFFECTIVE PAGES (CONTINUED)

2-1 13 Aug 5/89 3-1 8 Aug 5/89

List of Effective Pages August 5/89 Revised

LIST OF EFFECTIVE PAGES (CONTINUED)

4-3 13 Aug 5/89 4-4 1 Aug 5/89

August 5/89 Revised List of Effective Pages

This page intentionally left blank

List of Effective Pages August 5/89 Revised

SUBJECT CHAPTER/SECTION PAGE

August 5/89 Revised Table of Contents

SUBJECT CHAPTER/SECTION PAGE

SECTION 2. PREPARATION FOR USE,

Table of Contents August 5/89 Revised

SUBJECT CHAPTER/SECTION PAGE

SECTION 3. OPERATION 1-3 1

August 5/89 Revised Table of Contents

SUBJECT CHAPTER/SECTION PAGE

SECTION 2. INSPECTION/CHECK 2-2 1

Table of Contents August 5/89 Revised

SUBJECT CHAPTER/SECTION PAGE

August 5/89 Revised Table of Contents

SUBJECT CHAPTER/SECTION PAGE

CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION 4-1 1

SECTION 2. MANUFACTURER’S CODES 4-2 1

SECTION 3. PARTS LIST 4-3 1

SECTION 4. NUMERICAL INDEX 4-4 1

CHAPTER 5. OPTIONAL EQUIPMENT

CHAPTER 6. MANUFACTURER’S LITERATURE

UNUSUAL SERVICE CONDITIONS

Table of Contents August 5/89 Revised

Content of the manual is arranged as follows:

Chapter 4. Illustrated Parts List

Chapter 5. Optional Equipment

Chapter 6. Manufacturer’s Literature

August 5/89 Revised Introduction

This page intentionally left blank

Introduction August 5/89 Revised

April 30/96 Revised 1-1

1. Canopy 6. Output cable horn

1-1 April 30/96 Revised

E.E lectric Governor

F. “ROLL-OUT” FEATURE (TOW TRACTOR-MOUNTED UNIT)

April 30/96 Revised 1-1

GENERATOR PROTECTIVE SYSTEM

Specifications and Capabilities

1-1 April 30/96 Revised

B. Generator Sets Available in 6911 and 6911A Series

SPECIFICATION MOUNTING VOLTAGE

April 30/96 Revised 1-1

Options are listed as follows: