60g20

OM-2011B
060192
Revised 030896
Operation and Maintenance Manual

for
Model No. 60G20 Series No. 5384E
Trailer and Truck-Mounted
Generator Sets
60 kVA, 400 Hz, 3-Phase, 115/200 V AC
SPEC No. MOUNTING VOLTAGE SPECIAL FEATURES

(ORDER ENTRY No.) REGULATOR
5384E-1 (-50, -51) Trailer or Truck 430391C Basic unit in Series
5384E-4 (-50, -51) Trailer or Truck 430391C 28.5-V T-R; 2 duplex receptacles
5384E-5 (-50, -51) Trailer or Truck 430391C SGX governor
5384E-9 (-50) Trailer 430391C Dual output unit
5384E-10 (-50) Trailer 430391C Fuel pressure gage and output receptacle
5384E-11 (-52, -53) Trailer or Truck 489812A Basic unit in series with solid state voltage
regulator
5384E-14 (-52, -53) Trailer or Truck 489812A 28.5-V T-R; 2 duplex receptacles, and solid
state voltage regulator
5384E-15 (-52, -53) Trailer or Truck 489812A SGX governor and solid state voltage
regulator
5384E-16 (-52, -53) Trailer or Truck 489812A Dual output unit, solid state voltage regulator
5384E-17 (-52) Trailer 489812A Fuel pressure gage, output receptacles and
solid state voltage regulator
Hobart Brothers Company

Airport Systems Group
Troy, OH 45373
U.S.A.
This page intentionally left blank.
OM-2011B / Operation and Maintenance Manual
Series 5384E / Trailer & Truck Mounted Generator Sets
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.
1. 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 below apply only to electrically-powered equipment, other practices
apply to engine-driven equipment, and some practices to both.
2. 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
a. Installation and Grounding of Electrically Powered Equipment
This equipment 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 voltage, frequency, and phase requirements. If
only 3-phase power is available, connect any single-phase rated equipment to only two wires of the
3-phase line. DO NOT CONNECT the equipment grounding conductor (lead) to the third live wire of
the 3-phase line, as this makes the 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
building 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.
b. 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.
June 1/92 Safety Warnings

Page 1
3. Service and Maintenance

This equipment must be maintained in good electrical condition to avoid hazards stemming 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 this 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.
4. Fire And Explosion Prevention

Fire and explosion are caused by electrical short circuits, combustible material near this equipment, or
unsafe operating conditions. 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.
5. Bodily Injury Prevention

Serious injury can result from contact with live circuit components inside this equipment. Shut DOWN
this equipment for inspection and routine maintenance. When equipment is in operation, use extreme
care in doing necessary trouble-shooting and adjustment.
6. Medical and First Aid Treatment

First aid facilities and a qualified first aid person should be available for each shift for immediate
treatment of all injury victims. Electric shock victims should be checked by a physician and taken to a
hospital immediately if any abnormal signs are observed.
EMERGENCY
Call physician immediately. Seek additional assistance. Use First Aid
FIRST AID
techniques recommended by American Red Cross until medical help
arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie

down. FOR ELECTRICAL 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.
7. Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be
easily read.
Safety Warnings June 1/92

Page 2
Introduction
This manual contains operation and maintenance information for 400-Hertz generator sets manufactured by
Hobart Brothers Company, Hobart Airport Systems Group, Troy, Ohio 45373.
The basic generator sets covered by the manual are rated at 90 KVA. The machines are described and
identified in Chapter 1, Description/Operation.
When applicable, manuals for sub-vendor equipment are included in Chapter 5.
The primary purpose of the manual is to provide information and instructions to experienced operators,
electricians, and mechanics who are not familiar with this equipment. The intent of the manual is to guide and
assist operators and maintenance personnel in the proper use and care of the equipment.
Read the instructions before starting the unit. Learn to use the manual and to locate information contained in
it.
The Table of Contents, which follows this introduction, lists all Chapters, Sections, and the paragraph titles
within each Section. The location of each listing is identified by Chapter, Section and page number. A
complete list of illustrations, with their locations, follows the Table of Contents.
Each chapter is divided into as many Sections as necessary. Sections are always referred to by a
combination Chapter/Section number, for example: 2-3 refers to Chapter 2, Section 3.
The material within each Section is divided into main subjects with applicable paragraph headings and
subheadings as required. For example, a portion of the Description Section might logically follow this
arrangement and paragraphing:
1. Control
a. Interior Panel
(1) Protective devices
a. Overload relay
(2) Contactors
Page numbers do not run consecutively throughout the manual. Each page is identified by the
Chapter/Section number in which it appears, and by a page number within the Chapter/Section. Therefore,
the first page in each Section is page 1. These identifying numbers appear in the lower, outside corner of
each page. Each page also bears a date located in the corner opposite the page number. This date is either
that of original issue, or of the latest revision. Any revision to the original text is identified by a heavy black
line in the left-hand margin. Illustrations follow a numbering system similar to page numbering. The first
Figure in each Section is Figure 1.
All tables, charts and diagrams, as well as illustrations, are identified by Figure numbers to avoid confusion.
The general location of any particular information can be found quickly by running through the Table of
Contents. For example: to locate any adjustment information, a quick look at the Table of Contents shows
that “Adjustment/Test” is located in Chapter 2, Section 3 (shown as 2-3).
Portions of the text are referred to by identifying the paragraph in which the referenced material may be found.
When referenced material is located in the same Chapter/Section as the reference, only the paragraph
identification is given, for example: (Ref. Para 1, A) means that the material is to be found in paragraph 1, A,
of the same Section.
June 1/92 Introduction

Page 1
When referenced material is located in another Chapter/Section, both the Chapter and Section numbers and
the paragraph identification are given, for example: (Ref. 1-2, Para 1, A) means that the referenced material
is located in Chapter/Section 1-2, and paragraph 1, A within that Chapter/Section.
Components shown in illustrations, and the illustrations themselves, are referenced in a similar manner.
When this type of reference is made, the item number of the part and the Figure number in which it appears
are given, for example: (2, Fig. 3) refers to item number 2 in illustration Figure 3 of the same Chapter/Section.
When a referenced figure appears in another Chapter/Section, the reference will include the Chapter/Section
number, for example: (2-3; 1, Fig. 4) tells the user that the information is in Chapter/Section 2-3, and to refer
to item 1 in Figure 4.
Once a Figure number reference has been established, the Figure number is not repeated and only the item
numbers of the parts involved are referenced, for example: “Loosen screw (2, Fig. 6), slide out connector (4),
and remove brush (6).”
When an item number is referenced without a Figure number, it always applies to the last preceding Figure
number mentioned in the text.
A collection of manufacturer’s literature is supplied as part of the information package in Chapter 6.
If you have any questions concerning your Hobart Airport Systems Group equipment, you are invited to
contact our Service Department by mail, telephone or FAX.s
Write: Hobart Brothers Company

Service Department
1177 Trade Square East
Troy, Ohio 45373
U.S.A
In U.S.A. Call: (800) 422-4166

(800) 422-4177
From Foreign Countries, Call: (937) 332-5050 (Parts)

(937) 332-5060 (Service)
Fax: (937) 332-5121
Introduction June 1/92

Page 2
Table of Contents
Chapter - Section Page
Chapter 1. Description/Operation
Section 1. Description 1-1 1
General 1-1 1
Orientation 1-1 1
Special Features 1-1 1
Protective Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1
Pull-out Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1
Voltage Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1
Test Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 3
Electric Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 3
Identification: Mounting Design
and Additional Equipment 1-1 3
Canopy 1-1 3
Engine, Generator and Controls Assembly 1-1 4
Basic Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 4
Engine Manufacturer’s Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 5
Hnobart Engine Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 7
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 10
Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 10
Engine Control Panel (See Fig. 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 16
Power Module Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 19
Voltage Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 21
Test Box 1-1 22
Description (See Fig. 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 22
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 22
Units with SGX Governor 1-1 23
Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 23
Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 23
Dual Output Machines 1-1 23
Generator Set Specifications: Series 5384E 1-1 27
Section 2. Preparation For Use, Storage, Or Shipping 1-2 1

Preparation for Use 1-2 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1
Inspection/Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1
Installing Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2
June 1/92 Table of Contents

Page 1
Preparation for Storage 1-2 2

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2
Temporary Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 3
Long Time Storage (Over 30 days) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 3
Preparation for Shipment 1-2 3
Section 3. Operation 1-3 1

General 1-3 1
Operating the Generator Set 1-3 1
Pre-start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1
Normal Engine Starting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1
Preparation for Power Delivery (Normal
Automatic Voltage Control)
Power Delivery (Automatic Voltage Control) . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 5
Preparation for Power Delivery (Manual Voltage Control) . . . . . . . . . . . . . . . 1-3 6
Power Delivery (Manual Voltage Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 6
Discontinue Power Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 6
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 6
Test Box Operation 1-3 7
Chapter 2. Service
Section 1. Maintenance 2-1 1
General 2-1 1
Inspection 2-1 1
Lubrication 2-1 1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 1
AC Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 1
Generator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 1
Engine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 3
Air Cleaner Service 2-1 6
Inspecting the Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 6
Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 6
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 7
Engine Fuel 2-1 7
Quailty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 7
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 8
Engine Cooling System 2-1 8
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 8
Radiator Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 9
Warm Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 9
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 9
Table of Contents June 1/92

Page 2
Drain the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 10

Cooling System Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 11
Radiator Core Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 11
Cooling System Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 12
Generator Maintenance 2-1 12
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 12
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 12
Drive Belts 2-1 12
Check Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 12
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 13
Service Helps 2-1 14
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 14
Control Box Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 14
Generator Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 15
Engine Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 16
Section 2. Inspection / Check 2-2 1

General 2-2 1
Engine 2-2 1
Fuel (See Fig. 1 for time schedules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1
V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1
Electrical System (12-V DC) 2-2 1
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1
Wiring and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 3
Electrical System (115-V AC) 2-2 3
Monitoring Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 3
Indicating Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 3
Protective Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 4
Wiring and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 4
Section 3. Adjustment / Test 2-3 1

General 2-3 1
Generator Set Test 2-3 1
Pre-operational Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 1
Operational Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2
Generator Set Adjustment 2-3 10
Generator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 10
Generator Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 10
Basic Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 11
Engine Accessories Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 11

Page 3
Electric Governor System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 12

Engine Shut-Down Devices Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 16
Generator and Exciter Test 2-3 18
Diode Test 2-3 19
Section 4. Troubleshooting 2-4 1

General 2-4 1
Troubleshooting 2-4 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 1
Use of the Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 1
Equipment for Troubleshooting 2-4 2
Safety 2-4 2
Parts Replacement 2-4 2
Test Values 2-4 2
Check Connections and Leads 2-4 3
Electric Governor Trouble Shooting 2-4 3
Engine Trouble Shooting Procedures 2-4 3
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 3
Locating a Misfiring Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 3
Checking Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 4
Interpretation of Compression Pressure Records. . . . . . . . . . . . . . . . . . . . . . 2-4 4
Causes of Low Cylinder Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 4
Fuel Flow Test (see Fig. 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 4
Illustrations 2-4 5
Troubleshooting Chart 2-4 5
Engine & Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 13
Generator and Excitation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 19
Protective Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 24
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 27
Section 5. Voltage Regulator 430391C

(Used on Specs 5384E-1, -4,
-5, -9, -10) 2-5 1
Unit Assembly 2-5 1
Components 2-5 1
Detailed Circuit Descriptions 2-5 1
Voltage Detection Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 1
The Voltage Comparison Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 3
The transistor Pre-Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 3
The Power State Full-wave, Single-phase
Magnetic Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 3
The damping circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 3
The Line Voltage Drop Compensation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4

Page 4
The Voltage Build-Up Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4

Terminal Board Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4
Installation And Preparation For Use 2-5 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4
Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 5
Operating Procedures 2-5 5
Adjustment Procedures 2-5 5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 5
Adjust generator output voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 5
Adjust Line Drop Compensation for Cable Length. . . . . . . . . . . . . . . . . . . . . 2-5 6
Adjust Line Drop Compensation for Cable Size . . . . . . . . . . . . . . . . . . . . . . . 2-5 6
Adjust Damping Gain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 6
Adjust Damping Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 7
Test the Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 7
Maintenance Procedures 2-5 9
Inspection 2-5 9
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 9
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 9
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 10
Troubleshooting 10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 10
Use of the Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 10
Checking the Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 13
Illustrated Parts List 2-5 17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 17
Explanation of Parts List Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 19
Symbols and Abbreviations 2-5 19
Section 5. Voltage Regulator 489812A

(Used on Specs 5384E-14,
-15, -16, -17, -18) 2-5 1
General 2-5 1
Components 2-5 1
Line Drop Compensator Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 1
Voltage Regulator PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 3
Installation and Preparation for Use 2-5 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4
Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4
Operating Procedures 2-5 4
Sequence and Theory of Operation 2-5 4
Troubleshooting 2-5 5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 5
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 5

Page 5
Troubleshooting the Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 5

Voltage Regulator Removal and Installation 2-5 6
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 6
Removal of Voltage Regulator from Generator Set . . . . . . . . . . . . . . . . . . . . . 2-5 6
Replacement of Assemblies on the Voltage Regulator. . . . . . . . . . . . . . . . . . 2-5 6
Installation of Voltage Regulator on Generator Set. . . . . . . . . . . . . . . . . . . . . 2-5 6
Adjustment and Test 2-5 6
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 6
Inspection and Check 2-5 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 7
Check the Voltage Regulator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 7
Cleaning and Painting 2-5 7
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 7
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 8
Repair 2-5 8
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 8
Removal/Replacement of Line Drop
Compensator Assembly 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal/Replacement of Voltage
Regulator PC Board Assembly 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Introduction 2-5 9
Chapter 3. Overhaul / Major Repair

Section 1. Table of Contents 3-1 1
Section 2. Flexible Couplings 3-2 1
General 3-2 1
Coupling Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 2
Disassembly 3-2 3
Seperate Engine and Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3
Remove Coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3
Coupling Service 3-2 4
Coupling Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 5
Bushing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 5
Coupling Installation 3-2 6
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 7
Reassemble Engine and Generator 3-2 10
Run-in and Periodic Check 3-2 10

Page 6
Section 3. Exciter Armature Removal and Installation 3-3 1

General 3-3 1
Exciter Armature 3-3 1
Exciter Armature Replacement 3-3 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1
Conditions for Exciter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1
Tools for Exciter Armature Removal and Installation. . . . . . . . . . . . . . . . . . . 3-3 1
Preparation for Exciter Armature Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3
Exciter Armature Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 5
Installing the Exciter Armature 3-3 6
Preparation for Exciter Armature Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 6
Exciter Armature Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 8
Recommended Products Manufacturers 3-3 14
Section 4. Four Wheel Trailer (When Used) 3-4 1

General 3-4 1
Description 3-4 1
Hydraulic (Surge) Crakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 1
Mechanical Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Additional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Preparation for Use 3-4 4
Check reflectors for broken glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Check sheet metal for dents and deformation. . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Check pressure in all four tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Check batteries for proper fluid level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Check operation of parking brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Check hydraulic brake system.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Check Fuel Quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4
Operation 3-4 4
Trailer Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 5
Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 5
Disconnect Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 6
Maintenance 3-4 6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 6
Hydraulic Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 7
Bleeding Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 9
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 9
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 10
Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 10
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 10
Customer Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 12
Running Gear Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 12

Page 7

Manufacturers Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 15
Parts Identification Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 15
Chapter 4. Illustrated Parts List

Section 1. Introduction 4-1 1
General 4-1 1
Purpose 4-1 1
Arrangement 4-1 1
Explanation of Parts List 4-1 1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1
Parts List Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 1
Section 2. Manufacturer’s Codes 4-2 1

Explanation of Manufacturer’s (Vendor) Code List 4-2 1
Section 3. Illustrated Parts List 4-3 1

Explanation of Parts List Arrangement 4-3 1
Symbols and Abbreviations 4-3 1
Section 4. Numerical Index 4-4 1

Explaation of Numerical Index 4-4 1
Numerical Index 4-4 1
Chapter 5. Manufacturers Literature

Page 8
Chapter 1. Description/Operation
Section 1. Description
1. General
This manual describes, first, a basic 60-kVA diesel-powered generator set (Fig. 1) , identified by Hobart
Specification Number 5384E-1, and designed for trailer or truck mounting. Secondly, this manual
describes, if necessary, the specific variation of this basic generator set purchased by the customer.
Refer to Paragraph 10 for information on the particular generator set Specification purchased if it is a
Specification other than Specification Number 5384E-1.
Depending on customer requirements, within the 5384E generator set series, there are 10 variations
(specifications) of generator sets, for trailer or truck mounting, based in design on the Specification
5384E-1 unit.
The purpose of one of this generator set is to produce and deliver regulated 400-Hz, 115/200-V AC
power to a parked aircraft for operation of the aircraft’s electrical equipment when the on-board
generators are not running. See Fig. 2 for basic generator set 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 described more fully under the assemblies in
which they appear. Some of the main features are mentioned here and described briefly.
a. Protective Monitor
A single, solid-state device (4, Fig. 9) receives signals from all of the fault sensing units in the
generator 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 which provide easy access to controls
and equipment mounted in them. Each tray may be removed as an assembly by disconnecting a
single quick-disconnect connector and tripping two safety latches.
c. Voltage Regulator
A solid-state, adjustable voltage regulator provides automatic voltage regulation at the aircraft. The
regulator is also adjustable for a variety of output cable sizes and lengths.
June 1/92 Chapter 1-1

Page 1
1. Canopy 6. Frame assembly

2. Access - vent covers 7. Engine fan exhaust deflectors
3. Lifting eye 8. Engine exhaust pipe
4. Windows 9. Radiator cap access cover
5. Output receptacle cover 10. Truck mounting body (when ordered
by customer for truck mounting)
Generator Set
Figure 1
Chapter 1-1 June 1/92

Page 2
d. Test Circuitry
A receptacle connector with wiring to various test points throughout the electrical circuitry is provided
for the attachment of a test box manufactured by Hobart Brothers. This test circuitry allows
electricians to perform as many as twenty-four tests and checks from one location, conveniently and
easily.
e. Electric Governor
The engine is equipped with an all electric type governor kit and other special equipment more fully
described under the engine description.
4. Identification: Mounting Design and Additional Equipment

To further enhance the capabilities of Series 5384E generator sets, a customer, when ordering the
generator set, may select a unit designed for trailer and/or truck mounting with particular additional items
of equipment for installation on the unit.
In regard to mounting design and particular items of equipment, generator sets manufactured by Hobart
Brothers Company are identified by their Specification Number, which consists 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 and also indicates which of one or more items of special or extra equipment are a part of
the unit.
Information on this additional equipment, when selected, is provided in pertinent sections of this manual.
Included in Paragraph 8 in this Section is list of the Specifications available. Encircled on this list is the
Specification covered by this manual, describing its mounting design and additional items of equipment.
5. Canopy
A sheet metal enclosure, identified as a canopy (1, Fig. 1), provides protection for the engine, generator
and electrical controls. The canopy is designed to reduce the operational noise level in the immediate
area of the generator set. Doors and panels are covered on the inside with fiberglass acoustic material
to reduce reflected and conducted noise, and to absorb noise. Noise caused by vibration is most
commonly found on doors and movable panels. This has been reduced with the use of two-point slam
locks on the most commonly opened doors on the left side of the unit. 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 downward.
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 entrance
of blowing rain while still allowing a good flow of air. Air enters the forward opening into the engine
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 the generator controls and drawn into the rear
exciter and generator housings, where it passes over all windings before being discharged by the fan.
Because this unit is designed to be tractor-mounted, it has two large removable panels on the right side.
This is mainly because the right side of the machine is not accessible when mounted on a tow tractor,
and secondly, the thick doors would not allow mounting in the limited space available on a tractor.
Panel mounted instruments may be observed through two Plexiglass windows in the left rear door which
covers the control box and engine control panels. The lower window is slanted outward at the bottom to
provide access to engine 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.

Page 3
6. Engine, Generator and Controls Assembly

This assembly includes all components required to generate 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 superstructure, attached to the main frame, provides
mounting facilities for the canopy, control box and electrical equipment and controls.
a. Basic Engine
This unit is equipped with a three-cylinder, in-line diesel engine, manufactured by Detroit Diesel
Corporation, Detroit, Michigan. See Figure 2, Sheet 2 for general specifications.
Physical
Basic Generator Set
Length (approx.) 82 inches (2083 mm)
Width (approx.) 36 inches (914 mm)
Height (approx.) 43 inches (1092 mm)
Weight (approx.) 4360 pounds (1979 kg)
Generator Capabilities
Output power rating 60 KVA
Output voltage 115/200 V-AC
Rated load capacity 173 A
Frequency (cycles-per-second) 400 Hz
Output kilowatts 48 KW
Power factor 0.8 PF
Duty cycle 100%
Operating speed at 400 Hz 2000 RPM
Overload capacity 216 A
(125% of rated load capacity)
Output cable size required 2/0
Generator Protective System

Overvoltage relay trips 130 V to 134 V; resets 125 V
Undervoltage relay trips 100 V or below; resets 102 V
Overfrequency relay trips 415 Hz to 425 Hz; resets 410 Hz
Underfrequency relay trips 375 Hz to 385 Hz; resets 385 Hz
Generator Specifications & Capabilities
(Sheet 1 of 2)
Figure 2

Page 4
Engine
Manufacturer Detroit Diesel Corporation
Model 3-71N
Type 3-cylinder, 2-cycle Diesel
Bore 4.25 inches (108 mm)
Stroke 5.00 inches (127 mm)
Displacement 213 cu. in. (3491.1 cc)
Compression ratio (nominal) 17:1
Firing order 1-3-2
Horsepower at 2000 RPM 148
Governed speed 2000 RPM ±2%
Idle speed 900 RPM ± 25 RPM
Electrical system 12 volt DC
Oil capacity (with filter) 15 quarts (14.2 liters)
Oil capacity (without filter) 13 quarts (12.3 liters)
Coolant capacity (approx.) 8-1/2 gallons (32.18 liters)
Generator Specifications & Capabilities
(Sheet 2 of 2)
Figure 2
b. Engine Manufacturer’s Equipment
As received from the engine manufacturer, the engine includes the following equipment which is
described in the Engine Operator’s Manual (Chapter 6).
(1) Twelve volt electrical system includes starter and alternator with built-in voltage regulator.
(2) Ether starting aid system.
(3) Fuel strainer and fuel filter.
(4) Full-flow oil filter.
(5) Automatic shutdown system including temperature and pressure sensing switches, a “hot-wire”
relay, and a solenoid-operated, cam-and-latch type shutdown valve in the blower air intake.
(6) Speed limiting governor.
(7) Reverse-flow, engine-cooling fan to blow air outward through the radiator.
All the above equipment, except the fan, is described in the Detroit Diesel Operator’s Manual.

Page 5
1. Radiator 10. Engine control panel

2. Engine 11. Engine oil filler pipe
3. Lifting Yoke 12. Generator
4. Overspeed Governor 13. Governor magnetic pick-up
5. Voltage Regulator 14. Starter cut-out switch
6. Power Module 15. Mounting frame
7. Air Cleaner 16. Governor actuator
8. Governor control box 17. Engine exhaust pipe
9. Generator Control box 18. Output receptacle (when used)
Generator Set Components
Figure 3

Page 6
c. Hobart Engine Equipment
The engine is modified at Hobart Brothers by the addition of the following equipment:
(1) Electric governor system
The electric governor was selected for control of engine speed (and generator output frequency)
because it provides faster engine response to changes in load conditions. This fast response
results in very close frequency control. Refer to the Barber-Colman literature in Chapter 6 for a
detailed description. As described briefly below, the governor system consists of the following
main components:
Magnetic pickup Control unit Actuator
a. Magnetic pickup
The magnetic pickup (13, Fig. 3) 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 (8, Fig. 3) is a box containing a compact assembly of solid state
components. 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 two 12-V DC battery system.
c. Actuator
The actuator (16, 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 Safety devices
a. Overspeed governor
The overspeed governor (4, Fig. 3) is a mechanical fly-weight type, mounted at the rear of
the engine and driven through an adapter by the camshaft. Electrical contacts in the governor
are connected in parallel with other engine shutdown devices. The governor is adjusted to
close the contacts and actuate the shutdown solenoid when an engine speed of 2400 RPM is
reached. The governor must be manually reset, after tripping, by pushing a button located on
the governor head.
b. Temperature sensing safety switch
This switch (10, Fig. 4) is mounted in the engine water manifold and is identified as an
“Alarmstat”. It is very sensitive to temperature changes and functions to protect the engine
against overheating caused by low coolant level, broken fan belt, etc. It sends a signal which
activates the shut-down solenoid to stop the engine when temperature in the cooling system
reaches 205 deg. F.
c. Start circuit cut-out switch
This is a Micro-type switch (7, Fig. 4), mounted just below the air-valve operating lever. The
switch is electrically connected in series with the starter switch. In normal operation the switch
is CLOSED. In the event the shutdown solenoid is actuated to stop the engine, the shutdown
switch is OPENED to prevent operation of the engine starter until the shutdown air valve is
LATCHED in OPEN position.
d. Start circuit solenoid switch
This solenoid type switch (4, Fig. 4) functions to conduct 12-V DC power to the engine starter
solenoid when the panel mounted pushbutton start switch is pushed. The solenoid switch
serves to by-pass and protect the pushbutton starter switch against heavy load current in
case the starter gear should fail to engage the flywheel ring gear properly.

Page 7
1. Overspeed governor 6. Air shut-off valve

2. Oil filler tube 7. Start circuit cut-off switch
3. Oil level gage rod 8. Shut-down solenoid
4. Start circuit auxiliary solenoid switch 9. Low-oil-pressure switch
5. Fuel pressure switch 10. High temperature switch
Engine Shut-down Set Components
Figure 4

Page 8
(3) Air Cleaner

The diesel-engine air cleaner (Fig. 5) is a dry-cartridge type. It is equipped with a service
indicator which signals the operator when it needs cleaning. A cylindrical “flag” (2) is forced
upward in a glass enclosed viewing chamber (1) when air pressure within the air cleaner drops
below the outside air pressure. As the cartridge becomes loaded with dirt and air, pressure
within the cleaner lessens, the “flag” gradually rises higher in the glass viewing chamber. When
the “flag” reaches the top of the chamber, it locks in that position to warn the operator that the
cartridge must be changed. The “flag” is reset (unlocked) by pushing the reset button (3)
located on the indicator.
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.
1. Viewing chamber 2. Indicator “flag” 3. Reset button

Air Cleaner and Service Indicator
Figure 5
(4) Exhaust system

The exhaust system consists of a special noise reducing muffler (3, Fig. 6) which is connected
by a flexible pipe (2) to a conventional exhaust manifold (1). Baffles in the tail pipe outlet direct
exhaust out and noise downward.
(5) Radiator
The radiator (1, Fig. 3) is a tube type with bolted-on, top and bottom tanks which permit
disassembly for cleaning and repair.

Page 9
1. Exhaust manifold 2. Exhaust pipe 3. Muffler and tailpipe
Noise Reduction Exhaust System
Figure 6
d. Generator
The 400-Hz generator is a brushless, revolving field, three-phase, alternating current type. The rotor
assembly is mounted by two, permanently lubricated, sealed ball bearings. The front bearing is
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 extends
forward beyond the bearing and is attached to the engine flywheel by a hub and flexible disc coupling
assembly. The rear end of the rotor shaft extends rearward beyond the rear bearing into the exciter
stator housing. The exciter rotor is mounted on this shaft extension with a standard key and is
secured by a washer and 1/2" - 13 thread., cap screw. A rectifier with six diodes is mounted on the
exciter rotor and converts exciter AC output to DC for excitation of the generator revolving fields.
The exciter DC output to the generator fields, and consequently, the generator output is control led
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. 7) 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 and are
easily removable by disconnecting an “Amphenol” connector and unlocking safety latches.
A shielded, instrument panel light is mounted on the left side of the control box front panel to
illuminate controls and instruments within the trays.

Page 10
Control Box
Figure 7
(1) Generator control tray (see Figure 8)

The generator control tray contains instruments and controls for
monitoring and controlling the generator output.
a. Resistors
Two, 20-ohm, 100-watt, ballast resistors (2) are connected in series in the generator exciter
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.
b. Generator output monitors (meters)
The generator output is monitored by three instruments; a frequency meter (10), a voltmeter
(9), and an ammeter (7). The frequency meter is a resonant-reed type which 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 described below). The voltmeter
has a 3-1/2-inch face and the scale is graduated 0 to 300 V. The ammeter is graduated 0 to
250-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.

Page 11
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 positions 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 control
box components.
e. Tray
The tray (15) slides in and out on nylon rollers. It is secured in place by a twist-lock, screw
fastener (8).
f. Manual voltage control
When the automatic-manual switch (11) is placed in MANUAL position, AC power is
supplied to the rectifier (14) rather than to the automatic voltage regulator. The DC output of
the rectifier is routed to the exciter field through a rheostat (13). The generator output voltage
is 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 exciter
field only when the engine speed is being controlled by the electric governor.
(2) Protective relay tray (see Figure 9)
The bottom of the control box is the protective relay tray and contains electrical and electronic
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 system.
a. Sensing modules
The voltage sensing module (5) and frequency sensing module (6) are connected to
generator 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 the
generator output 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. 121 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 375 Hz to 385 Hz.
• Undervoltage time delay (adjustable) 4 to 12 seconds.
• Overload circuit trips at any value over 125% rated load capacity.
See Para. 6, G, (3) for more specific and detailed information regarding overload device.

Page 12
1. Resistor, 50-ohm, 100 watt 9. Voltmeter

2. Resistor, 20-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 8

Page 13
b. Memory and time delay module

The memory and time delay module (4) is sometimes called the protective monitor module. It
is a solid-state device with a hermetically-sealed, reed-type relay. The printed circuit board or
“card” includes five memory circuits and a time delay circuit. Each circuit is connected to a
corresponding sensing module (5 and 6). All memory circuits are connected to the module
relay coil, and any one of the circuits can energize the coil to open the relay contacts. Thus,
when a sensing device energizes any one of the module circuits, the module relay is also
energized to break the load contactor holding circuit and allow the load contactor to open. All
circuits, except the undervoltage circuit, 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 conditions 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 occurs. The module relay will remain energized (OPEN) until the
reset switch (7) is pushed to allow the relay to return to normal, CLOSED position.
c. Indicating lights
The function of these lights (10, 11, 13, 14, and 15) is to indicate to the operator the
abnormal condition of overvoltage, underfrequency, etc., which caused the protective monitor
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
through terminals E and F on the output plug connector.
e. Test bank switch
A single-pole single-throw 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 protect
the relay in the event that phase “C” contacts in the load contactor should fail to close when
the generator ON switch is operated.
g. Fuse-interlock relay
The function of the fuse-interlock relay (2) is to interrupt the load contactor holding coil circuit
and remove the load in case of a “blown” fuse (17) in the protective relay coil circuit.
h. Connector
A twenty-six contact connector (19) provides a quick-disconnect facility for all wiring to tray
electrical components so that the complete tray assembly may be removed quickly and easily.
i. Auxiliary underfrequency relay
The function of the auxiliary underfrequency relay (3) is to automatically open the excitation-
deenergization relay and disconnect the voltage regulator anytime generator frequency drops
to 375-385 Hz. This protects the voltage regulator (Fig.12) and ballast resistors (2, Fig. 8)
against overload which could be caused by very high voltage regulator output in its attempt to
maintain voltage when the generator is operating at a speed which cannot produce normal
voltage output.

Page 14
1. Plug-interlock relay 12. Tray fastener

2. Fuse-interlock relay 13. Overfrequency indicating light
3. Auxiliary underfrequency relay 14. Undervoltage indicating light
4. Memory and time delay module 15. Overvoltage indicating light
5. Over-undervoltage module 16. Load contactor circuit fuse (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 light 22. Tray
Protective Relay Tray
Figure 9

Page 15
NOTE: fI the auxiliary underfrequency relay is tripped, it will be necessary to place engine operating
mode switch (5, Fig. 10) in BUILD-UP-VOLTAGE position to restore generator voltage.
f. Engine Control Panel (See Fig. 10)
The engine control panel is mounted directly below the control box. In addition to engine controls
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 electric
system. Its graduated range is from - 60-A through 0 A, to +60-A
b. Temperature gage
The temperature gage (8) is a mechanical type of unit construction. It consists of a panel
mounted indicating mechanism which is connected by a capillary tube to a bulb mounted in
the engine cooling system. The gage indicates engine coolant temperature in the range of
100oF to 220oF.
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 12-V DC control
system to the generator when the engine is running.
d. Hourmeter
The hourmeter (6) is electrically driven from the 12 V-DC battery system. The hourmeter
measures and records engine running time and will record up to 9999.9 hours on five
revolving drums. The hourmeter operates only when the engine is running and the oil
pressure switch is closed.
(2) Engine and generator controls
a. 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.
b. 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
GENERATE position the switch brings engine up to rated speed.
In BUILD-UP-VOLTAGE 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 which closes the
excitation-deenergization relay, (3, Fig. 8) 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. 8). When the switch is placed in IDLE, power is disconnected so that the engine
returns to idle speed and the exciter field is deenergized.

Page 16
c. Contactor control switch

This is another three-position toggle switch (7, Fig. 10) 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.
d. Instrument light and switch
A shielded, instrument light (1) is mounted on the left side of the control panel. It is controlled
by a toggle switch (3), which also controls instrument lights on the control box and canopy
light.
e. Engine starting circuit
The start switch (15) serves to connect power for closing an auxiliary solenoid switch (4, Fig.
4). The auxiliary switch then connects power to the starter solenoid which functions to
engage the starter gear with the flywheel ring gear and apply power to the starter motor to
crank the engine. The auxiliary solenoid switch is necessary because the start 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 start switch (15) is functional only when
the shutdown air valve is in latched (open) position, which places the start-circuit, cut-out
switch (7, Fig. 4) in CLOSED position.
f. Indicating lights
A green indicating light (14) glows to indicate that power is available to the engine operating
system. The light operates only when the engine is running and fuel pressure is sufficiently
high to close a fuel pressure switch (5, Fig. 4). 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. 10) glows when the generator output load contactor is
CLOSED and power is available at the generator output .
g. Fuel gage and blocking diodes
An electric fuel gage (2, Fig. 10) is required on all units except tractor-mounted, since fuel for
the tractor mounted unit is supplied by the tow tractor fuel system. A sending unit mounted in
the trailer or truck mounted unit fuel tank supplied the signal to the panel mounted 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 (19) 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.
h. Engine stop control
The engine is normally stopped by use of the mechanical stop control (14) which is a
push-pull control cable connected to the engine fuel rack lever. Pulling the control outward
places the rack in “no-fuel” position to stop the engine.
(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. 5).
(4) Test receptacle connector
This amphenol connector (18) provides an attaching point for leads which are connected to
selected test points throughout the engine and generator electrical systems. Connections and
schematic diagrams indicate points at which the leads are connected. The receptacle connector
is designed to mate with a test box plug connector (See Fig. 13).

Page 17
1. Panel light 11. Hole plug

2. Fuel gage 12. Air cleaner indicator
3. Light switch 13. Engine circuit fuse (10-A)
4. DC Ammeter 14. Engine “ON” indicating light
5. Engine-generator control switch 15. Engine starter switch
6. Hourmeter 16. Terminal board
7. Load contactor control switch 17. Engine stop control
8. Coolant temperature gage 18. Test receptacle
9. Load contactor indicating light 19. Blocking diodes
10. Engine oil pressure gage
Engine Control Panel
Figure 10

Page 18
g. Power Module Panel Assembly
The power module panel assembly (Fig. 11), sometimes referred to as the “contactor panel”, is
located at the right rear of the machine behind the control box. On this 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 circuit and provides a means of connecting
and disconnecting generator output to and from the load (aircraft).
(1) Load contactor
The load contactor (6, Fig. 11) is a sealed unit which contains a magnetic operating coil and four
sets of contacts. The three larger contacts conduct three-phase AC generator output. A smaller
contact set is connected in the protective monitor circuit and supplies 12-V DC power used by
sensing relays to signal the protective monitor when a fault occurs. Three-phase, 400-Hz
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 contactors used in earlier 60 kVA machines.
This note is for the benefit of those users who may have old style contactors Part no. 75GH-566
(Hartman No. A-874C) or No. 404518 (Prestolite No. HB-200-B) 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 (7, Fig. 8) movement without damage. The
ammeter dial scale is graduated and numbered so that the ammeter pointer will indicate the
load current value rather than the meter movement current.
b. Line-drop current transformers
The three line-drop current transformers (9, Fig. 11), in conjunction with burden resistors (8),
detect the magnitude and power factor of current flowing from generator to load. They feed a
signal to the voltage regulator which interprets the signal and alters the exciter field current as
required to maintain a constant predetermined voltage at the load. (See voltage regulator
Manual information in Section 2-5 of this manual).
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).
(3) Overload module
The overload module (7) is a solid-state device designed to interpret a signal from transformers
(3) and to send a signal to the protective monitor module (4, Fig. 9) when an overload 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. Relay contacts are normally
open.
The solid-state circuitry is designed to close the 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 (silicon-controlled rectifier) in the
protective monitor and causes 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
current.
At 125% load the module will function in 5 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.

Page 19
(4) Rectifier
A diode-bridge rectifier (5) receives 400-Hz AC from phase C of the generator output and
converts it to a pulsating, direct current for energization of the load contactor holding coil only.
This DC coil-holding circuit is controlled indirectly by 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 protective device functions to open the protective monitor relay, the
rectifier’s circuit is opened. No DC is then available for the load contactor holding coil, hence, the
load contactor opens.
(5) Terminal boards
Three terminal boards (2) provide connection facilities for small leads.
1. Overload resistor (16.6 ohm, 25 watt) 6. Load contactor

2. Terminal board 7. Overload module
3. Overload current transformer 8. Line drop resistor (50 ohm, 25 watt)
4. Ammeter current transformer 9. Line drop current transformer
5. Rectifier 10. Blocking diode
Power Module Panel
Figure 11

Page 20
h. Voltage Regulator
The voltage regulator provides field excitation power for the rotary exciter, and regulates generator
output voltage by varying the exciter field power as required to meet varying load conditions. Thus,
the generator output is held at a constant voltage.
The voltage regulator is located on the right side of the machine just back of the engine compart-
ment near the lifting yoke. (See 5, Fig. 3). On trailer or truck mounted units the regulator is
accessible for adjustment by opening rear doors on the right side.
Depending on which specification number a customer selects, the voltage regulator may be either a
magnetic amplifier type (Part No. 430391C) or a solid-state type (Part No. 489812A). Both voltage
regulators are shown in Figure 12. The regulator used on the particular generator set for which this
manual is provided is described and illustrated in detail in Section 2-5.
Voltage Regulators
Figure 12

Page 21
7. Test Box
The test box is an accessory item used for testing the generator set. All generator sets in this Series are
wired to accommodate a test box. However, the box is supplied only when ordered. (Part Number
388318A-2).
a. Description (See Fig. 13)
The test box assembly consists of a rotary selector switch, momentary contact pushbutton 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 connector which mates with a
receptacle connector.
b. Theory of Operation
Wire leads are connected to the electrical circuitry of the generator set at various points and routed
to a Receptacle connector mounted on the engine control panel. They are connected to the test box
rotary switch by a plug connector and wiring harness.
The rotary selector switch is wired in such a manner that for any switch position, two pre-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 positions and component tested in each position.
Normal voltage for each test is also indicated.
Two test jacks are provided for connection of the test prods of a voltmeter. After the voltmeter 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 arrangement 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.
1. Test box
2. Cable
3. Plug connector
Test Box Assembly
Figure 13

Page 22
8. Units with SGX Governor

Two of the units covered by this manual have engines equipped with a Woodward Type SGX governor -
Specification 5384E-5 and Specification 5384E-15. To accommodate the SGX governor, units having
this governor differ from other units as follows:
a. Governor System
The electric governor system is removed and replaced by a Woodward Type SGX governor,
furnished with the engine.
b. Throttle Control
The engine control panel (Fig. 14) is modified by the addition of the throttle control (16) to replace the
STOP control, and by changing two of the functions of the MODE switch (13). The center position
has been changed to RUN, and the bottom position has been changed to STOP. The BUILD-UP-
VOLTAGE function (top position) remains the same. Refer to Figure 14. The THROTTLE control is
connected is connected by a flexible cable to the hydraulic governor’s fuel control linkage. Pulled all
the way out, this control operates the engine at 2000 RPM through the hydraulic governor. Pushed
all the way in, it runs the engine at idle speed of 900 RPM.
When the throttle control is pulled all the way out, a disk on the control cable depresses the plunger
on a microswitch and closes its normally-open contacts. The closed contacts, wired in series with
the excitation-deenergization relay (3, Fig. 8), complete a circuit which closes that relay’s contacts.
This arrangement insures that the generator will deliver output power ONLY when the engine is
running at 2000 RPM and insures the delivery of RATED output power only.
Placing the MODE switch in RUN position closes a solenoid valve which is mounted behind the oil
reservoir. This solenoid valve uses the engine’s lube oil to maintain the hydraulic pressure required
for proper operation of the hydraulic governor. When the mode switch is positioned to OFF, the
solenoid valve is opened, oil which maintains hydraulic pressure in the governor is dumped to the
crankcase, and the engine is stopped since this shuts off the fuel supply.
9. Dual Output Machines

Two of the units covered by this manual - Specification 5384E-9 and Specification 5384E-16 - have dual
outputs for servicing two aircraft simultaneously, or for servicing a single aircraft with two input
receptacles. The output terminal boards for these units are arranged as illustrated in Figure 15, with
output No. 1 at the rear terminal board and output No. 2 in front. This dual output assembly is mounted
in the same location as the single output terminal board on a single output unit.
Components of the dual output circuits are identical to the components of the comparable single output
units, but are grouped separately as follows:
a. The contactor switch of the second output is located on the control nameplate of the engine
control panel. See Fig. 16. Located beside this switch is the No. 2 contactor closed light,
which glows green when the No. 2 contactor is closed. These parts are identical to items 7
and 9 on Fig. 9.
b. The power module panel for output No. 2 (Fig. 17) is mounted on brackets directly above the
power module panel for output No. 1. (See Fig.11 ). The load contactor, rectifier and blocking
diode are identical to items 6, 5, and 10, Figure . The two relays, TEST BANK switch and
resistor are identical to items 1, 2, and 21, Figure 9.
c. The protective circuits described in Para. 6, E. (2) (a) and (b) monitor and protect output No. 2
as well as output No. 1. The output cable clamp for the No. 2 output is mounted next to the
cable clamp for the No. 1 output, just to the left of it, as viewed from the side of the unit. See
Fig. 15.
d. A flashback diode has been added to the No. 2 output circuit across pins 2 and 10 of the fuse
interlock relay socket. This diode prevents any inductive voltage discharge into the circuit
when the relay coil is deenergized.

Page 23
1. SGX hydraulic governor 9. Actuator plunger

2. Fuel rod knob (emergency shutdown 10. Micro switch (S41)
3. Oil reservoir 11. Mounting bracket (on engine)
4. Solenoid valve (L2) 12. Throttle control cable
5. Idle screw 13. Mode switch
6. Maximum speed limit screw 14. Engine control panel
7. Throttle control shaft 15. Locking ring
Throttle Control and Hydraulic Governor System
Figure 14

Page 24
Dual Output
Terminal Boards
Figure 15
No. 2 Output Control
Figure 16

Page 25
Output No. 2 Power Module Panel
(Located atop Output No. 1 Power Module Panel)

Figure 17

Page 26
10. Generator Set Specifications: Series 5384E

Generator sets in Series 5384E are listed below. In addition to the basic features of the Specification
5384E-1 generator set, additional features are listed. Encircled on this list is the generator set covered
especially by this manual.
Voltage
Specification Mounting Regulator Features
5384E-1 Trailer/Truck 430391C Basic generator set in Series 5384E.
5384E-4 Trailer/Truck 430391C Has 28.5-V transformer-rectifier, 35-V
transformer rectifier, and two duplex
receptacles. Differs from Spec. 5384E-1
only in regard to these features.
5384E-5 Trailer/Truck 430391C Has SGX GOVERNOR and special
features for United Airlines. Differs from
Spec. 5384E-1 only in regard to these
features.
5384E-9 Trailer 430391C Has DUAL OUTPUTS. Differs from Spec.
5384E-1 only in regard to this feature.
5384-10 Trailer 430391C Has FUEL PRESSURE GAGE and OUT-
PUT RECEPTACLE. Differs from Spec.
5384E-1 only in regard to these features.
5384E-11 Trailer/Truck 489812A Has SOLID STATE VOLTAGE
REGULATOR . Differs from Spec.
5384E-1 only in regard to this feature.
5384E-14 Trailer/Truck 489812A Has 28.5-V transformer-rectifier, 35-V
transformer rectifier, and two duplex
receptacles. Differs from Spec. 5384E-4
only in regard to SOLID STATE
VOLTAGE REGULATOR 489812A
5384E-15 Trailer/Truck 489812A Has SGX GOVERNOR, SPECIAL
FEATURES for UNITED AIRLINES.
Differs from Spec.5384E-5 only in regard
to SOLID STATE VOLTAGE REGU-
LATOR 489812A
5384E-16 Trailer 489812A Has DUAL OUTPUTS. Differs from Spec.
5384E-9 only in regard to SOLID STATE
VOLTAGE REGULATOR 489812A
5384E-17 Trailer 489812A Has FUEL PRESSURE GAGE and
OUTPUT RECEPTACLE. Differs from
Spec. 5384E-10 only in regard to SOLID
STATE VOLTAGE REGULATOR
489812A
5384E-18 Trailer 489812A Has special trailer for FEDERAL

EXPRESS and SOLID STATE VOLTAGE
REGULATOR 489812A. Differs from Spec.
5384E-1 only in regard to these features.

Page 27

Page 28
Section 2. Preparation For Use, Storage, Or Shipping
1. Preparation for Use

a. General
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 DAMAGE! 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 as broken lights, damaged sheet metal, etc.
(3) Open all canopy doors and inspect interior for foreign material such as rags, tools, shipping
paper, etc.
(4) Check fuel, coolant, and oil hoses and connections for visible leaks. Visually inspect the
compartment floor and ground surface under the unit for signs of leakage. If leaks are found,
correct by tightening hose clamps, tube fittings, etc., as required.
(5) Check the following for sufficient quantity:
a. Fuel
Turn ON engine controls to energize fuel gage when engine is stopped.
b. Engine coolant
The radaitor cap is accessible by opening the hinged access cover on the front canopy
housing. Coolant level should be approximately one inch below the filler neck. Allow a
capacity for coolant expansion.
CAUTION
Be sure the cooling sysyem antifreeze solution is adequate to protect below
lowest temperature expected.
Note: For antifreeze protection, use a solution of 50% permanent antifreeze (Ethylene glycol) an 50%
clean water.
c. Engine lubricating oil
Oil level should be at “full” mark on oil level gage rod (see Fig. 1). See Sect. 2-1, Fig. 2 or the
attached Detoit Diesel Operator’s Manual for oil recommendations.

Page 1
1. Oil level gage rod

2. Oil filler cap
Engine Oil Gage Rod
and Filler Cap
Figure 1
(6) Check air cleaner

The air cleaner (Sect. 1-1, Fig.3, item 7) is a “dry type. Be sure there are papers, tapes or other
material covering the air inlet area.
(7) Check battery
c. Installing Output Cables
Units are gennerally shipped without generator set-to-aircraft cables.
Conductor size recommended for AC output is 2/0 size.
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 when excessive dampness is a problem,
however the unit must be completely packaged and sealed if moisture absorbing chemicals are
to be effective.

Page 2
b. Temporary Storage
(1) When storing the unit for 30 days or less, prepare as follows:
(2) Lubricate the unit completely in accordance with instructions in Sect. 2-1. This will include
changing engine oil, and all filter elements.
(3) 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.
(4) Make certain the cooling system antifreeze solution is adequate to protect below the lowest
temperatures expected during the storage period. See 2-1; Para. 6, D. Be sure the solution is
thoroughly mixed.
(5) Clean the exterior of the engine with fuel oil. Dry with clean rags and compressed air.
(6) 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
FUMES AND OXYGEN DEFICIENCY CAN KILL! Make certain of adequate
ventilation before starting the engine.
c. Operate normal operating controls.

(2) If weekly operation is not possible, prepare and protect the engine in accordance with
instructions in Detroit 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
chemicals, such as silica-gel, in the unit before packaging.
3. Preparation for Shipment

During long shipments by rail (and other), the generator set retaining hardware may become loosened
by vibration, jolting, etc.
WARNING
LOOSE OR FALLING PARTS CAN KILL, INJURE OR DAMAGE! 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 3

Page 4
Section 3. Operation
1. General
This section contains information and instructions for safe, efficient equipment operation. Operating
instructions are presented in step-by-step sequence for supplying 400-Hz power to an aircraft.
WARNING
Noise can damage hearing; improper operation can kill! Ear protection
equipment may be necessary when working in close proximity to this equipment.
Read and understand all of the operating instructions before attempting to
operate the equipment.
2. Operating the Generator Set

a. Pre-start Inspection
(1) Be sure the fuel shut-off valve (if used) if OPEN.
(2) Make certain 12-VDC power is available to the engine starting system.
(3) Check the engine and generator compartments to make certain they are free of 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) Be sure engine stop control (30) is at IN position.
(3) Be sure engine air shut-off is in LATCHED, open position (See Fig. 2).
NOTE: Push lever (3, Fig. 2) DOWN to LATCH valve OPEN.
(4) Place engine-generator control switch (18) in IDLE position.
(5) Activate engine start switch (28) to crank engine. Release start switch as soon as engine starts.
When engine starts, observe engine protective system light (27). When this light glows green it
indicates that the fuel pressure switch is closed and the engine protective system is functional.
CAUTION
(a) If the engine fails to start within 30 seconds, Release the start switch and
allow the starting motor to cool for a few minutes. If the engine fails to start after
four attempts, an inspection should be made to determine the cause.
(b) If the engine fires sufficiently to disengage the starter gear, but does not
start, release the start button and allow the starting motor to come to a complete
stop before attempting to engage the starter again.
(6) Observe oil presure gage (23). The engine wil be automatically stopped if pressure does not
build-up quickly to normal.
(7) Allow the engine to idle and warm for about 5 minutes before applying load.
Note: (a) If the shutdown valve is tripped for any reason during start-up, it will be necessary to latch the
valve mechanism by pushing latch lever (3, Fig. 2) down to reset.

Page 1
1. Frequency Meter 17. DC Ammeter

2. Voltmeter 18. Mode 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. Hole plug
9. Fault Indicating Lights 25. Air Cleaner Indicator
10. Load Contactor Circuit Fuse (2A) 26. Engine Circuit Fuse (10-A)
11. Protective System Fuse (5A) 27. Engine Protective Circuit Indicating Light
12. Protective Relay Tray 28. Engine Starter Switch
13. Instrument Panel Light 29. Blocking Diodes
14. Generator Control Tray 30. Engine stop switch
15. Fuel gage 31. Test Receptacle Connector
16. Light Switch
Operating Controls and Instruments
Figure 1 (Sheet 1 of 2)

Page 2
32. Manual Voltage Control Rheostat 38. Cable Length Compensation Rheostat
33. Automatic-manual Voltage Control Switch 39. Cable Size Compensation Rheostat
34. Test Bank Switch 40. Line-Drop Compensation On-Off Switch
35. Light Test Switch 41. Fuse (5-A)
36. Reset Switch 42. Fuse (10-A)

Page 3
(b) If the shutdown valve cannot be latched, check the overspeed govenor (see Fig. 3). It may have
been tripped by an overspeed condition.Press reset button on overspeed govenor immediately after
an overspeed trip, because the shutdown solenoid will remain energised and discharge the batteries
until overspeed govenor is reset.
1. Starter safety switch 2. Shutdown valve latch 3. Latch reset lever
Shutdown Valve Latch and Starter Safety Switch

Figure 2
CAUTION
Do not allow the engine to idle for long periods of time. See SB-41 at end of
manual.
c. 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
AIRCRAFT position, if the aircraft being serviced is equipped with a 28.5-VDC 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.

Page 4
Overspeed Governor
Figure 3
d. 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.
Voltmeter (2) should indicate 115 VAC when line switch (6) is in LINE-TO-NEUTRAL position.
(3) The final step in delivering power is closing the load contactor. When satisfatory 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), ON 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.
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 and 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 observe the instruments until load conditions stabilize.
(5) A condition of overvoltage, undervoltage, underfrequency, overfrequency or overload in the
output circuit will automatically open the load contactor and turn on the applicable indicating light
to signal 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 protective relay system. Proceed with power delivery by operating the load contactor
switch.
(6)

Page 5
e. Preparation for Power Delivery (Manual Voltage Control)

Preparation for power delivery using manual voltage is exactly the same as for automatic control
(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.
f. Power Delivery (Manual Voltage Control)
Power delivery using manual voltage control is the same as automatic delivery (para. D, (1) thru (5)
above except:
(1) Control generator output voltage by adjusting the rheostat (32) to maintain a steady 115-VAC
reading on the voltmeter (2). Turn the rheostat knob (32) CLOCKWISE to INCREASE voltage
and COUNTERCLOCKWISE to DECREASE voltage.
(2) Adjust voltage to 115 VAC.
(3) During manual power delivery the operator must remain with the generator set to adjust output
voltage for varying loads and conditions.
g. 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.
h. Stopping the Engine

(1) Allow the engine to idle a few minutes before stopping to permit cooling.
(2) To stop the engine, pull the stop control (30) OUT and hold until the engine stops. This control is
spring-loaded and should return to the IN position when released.

Page 6
3. Test Box Operation

The test box is useful and convenient in testing the generator set after repair or overhaul and also in
troubleshooting. To operate the test box, proceed as follows:
a. Open left, rear canopy doors and connect the test box plug connector (see 1-1; 18, Fig. 10) to the
test receptacle connector (Fig. 5).
b. Connect the test prods of a voltmeter at the test jacks (3 and 4, Fig. 4). Test jacks are color coded.
Red indicated 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. 4) 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 pushbuttons switch (2) and observe voltage indicated by the voltmeter. Compare to normal
voltage indicated in VOLTAGE column.
g. Release pushbutton switch.
h. Repeat steps A thru G for other tests as required.
i. When tests are completed, disconnect the test equipment and close canopy doors.
1. Selector switch
2. Pushbutton switch
3. Positive test jack (red)
4. Negative test jack (black)
Test Box Operating Controls

Figure 4

Page 7
Test Receptacle Connector (with protective cap

installed)
Figure 5

Page 8
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. Inspection
A periodic inspection should be estabilshed 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.
3. 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. Lubrication
points, recommended lubricants, and frequency of lubrication, are indicated in Figures 1, 2, and 3
respectively.
b. AC Generator
The 400-Hz generator requires NO lubrication. The rotor is supported by two ball bearing assemblies
which are lubricated and sealed at the factory for lifetime, maintenance-free operation. It is
suggested that generator bearings be checked after 5000 hours of operation.
c. Generator Controls
Generator controls and instruments require no scheduled periodic lubrication. A few drops of oil may
be required on door hinges occasionally to insure free and 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
“Operation Manual” and incorporated here to make them more readily available to operators and
maintenance personnel.

Page 1
(1) Lubrication schedule

Time schedules indicated on the Lubrication Chart, Fig. 1, are approximate. They are based on
average operating conditions. It may be necessary to lubricate more frequently under severe
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 further in the Detroit Diesel, “Operator’s Manual”.
(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 during cold weather when SAE-30 oil is used.
Multigrade oils are NOT recommended, and should be considered only as a “last resort” to
facilitate engine starting.
(4) Change engine oil
The following oil change recommendations are taken from Detroit Diesel Operator’s Manual. “It is
recommended that new engines be started with 100 hour oil change periods. The drain period
may then be gradually increased, or decreased, following the recommendations of an
independent oil analysis laboratory, or oil supplier (based upon the sample analysis) until the
most practical oil change period for the particular service has been established.
The generator set is equipped with an hourmeter to record actual engine operating time. The
ideal time to change oil is soon after a power delivery “run”, when the engine is at operating
temperature.
NOTE: If lubricating oil is drained immediately after the unit has been run for some time, most of the
sediment will be in suspension and will drain readily.
CAUTION
Do not use solvents as flushing oils in running engines.
Change the oil filter cartridge each time the oil is changed.
Change oil as follows:
a. Provide a container for catching used oil. Capacity should be greater than 17 quarts.
b. Remove drain plug located in oil pan.
c. While oil is draining, proceed to change the oil filter. See Para. 3, D, (5) below, for
instructions.
d. Clean the drain plug and install securely when engine oil has drained.

Page 2
e. Remove oil filler cap (Sect. 1-2, Fig. 1) and refill the crankcase with new, clean oil which
meets engine manufcturer’s recommendations. (See para. 3,D, (2) above, or Detroit Diesel
Operator’s Manual.) See Fig. 4 for engine oil capacities.
CAUTION
1. Always use clean container, funnels, Etc.
2. Don’t forget to :
• Drain oil oil
• Reinstall drain plug.
• Install new oil before starting engine.
f. Install filler cap and check oil level on gage rod. (Sect. 1-2, Fig 1). The gage rod should
indicate over FULL until the engine is started and oil is circulated to fill the oil filter.
g. Start engine and check oil pressure at once. Normal pressure should be indicated within 15
seconds. Allow engine to idle for about 5 minutes , then stop.
h. After the engine has been stopped for about 5 minutes, recheck the oil level. Add oil, if
required, to bring the level up to the FULL mark on the gage rod.
(5) Change oil filter
a. Unscrew filter cartridge (4, Fig. 5) from filter head casting (1, Fig. 5) , and discard cartridge.
b. Clean filter head.
c. Prime the new cartridge with lubricating oil, allowing time for the oil to filter through the filter
element (3, Fig. 5).
d. Using clean engine oil, liberally lubricate the oil filter seal (2, Fig. 5) of the replacement
cartridges.
e. Screw replacement cartridge onto the filter head until the seal just touches the head, and then
tighten securely by hand. If an oil filter tool is available, tighten to 15 ft/lbs (20 Nm).
f. Run engine and check for leaks.
e. Engine Accessories
See Figure 1 for identification of engine and accessories lubrication points, lubrication intervals and
lubricants.
(1) Starter
The starting motor is lubricated at assembly and should be re-lubricated only when the starter is
removed from the engine or disassembled
Remove pipe plugs on outside of motor and applt a few drops of light engine oil to the oil wicks.
(2) Overspeed governor and drive
See manufacturer’s service instructions in Chapter 5 for lubrication of overspeed governor (1-1;
1, Fig. 4).

Page 3
Lubrication and Maintenance Chart

Figure 1

Page 4
Symbol Name Specification Notes

1 Grease, General Shell “Alvania” No. 2 or
Purpose equivalent. (use No. 1 grade at
temperature below +30 deg. F.)
2 Oil, Engine, Military Mil-L-2104B SAE 30, use for all
Heavy Duty temperatures
3 Grease, Aircraft Military Mil-G-23827A Enco Beacon No. 325 or
and Instrument Equivalent.
Lubricants
Figure 2
Symbol Time Interval

S Daily 7 hours
W Weekly, or 50 hours
BW Biweekly, or 100 hours
M Monthly, or 200 hours
SA Semiannually, or 1200 hours
A Annually, or 2400 hours
Lubrication Chart Symbols and Time Intervals

Figure 3
Coolant Capacity 8-1/2 gallons (32.18s liters)

Oil Capacity (Including Filter) 15 quarts
(14.2 liters)
Oil Capacity (without filter) 13 quarts
(12.3 liters)
Oil and Coolant Capacities

Figure 4

Page 5
1. Head casting
2. Oil filter seal
3. Filter element
4. Oil filter canister
Oil Filter
Figure 5
4. Air Cleaner Service

The air cleaner is a dry type with replaceable filter cartridge. A definite time schedule for changing the
filter cartridge cannot be determined because of the varying operating conditions. Change the filter
cartridge when the red indicator “flag” reaches the top of the viewing chamber and locks in that position.
Proceed as follows to change the cartridge.
a. Cartridge Removal (See Fig. 6)
(1) Loosen the four nuts (1), unlatch clamps (3), and swing the tee bolts (4) outward away from the
moisture eliminator (7).
(2) Remove the moisture eliminator (7).
(3) Remove the filter cardtridge (6) and discard.
(4) Inspect the interior of the cleaner housing (5). Make certain that it is free from all foreign material.
b. Cartridge Installation (See Fig. 6)
(1) Carefully insert the new cartridge into the housing. Avoid hitting the cartridge tubes against the
housing flange. Make certain that the cartridge is seated properly within the housing. Press all
edges and corners of the cartridge firmly with the fingers to affect 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 affect a seal.
(2) Lock the cartridge in place by installing the moisture eliminator (7) and clamping in place with the
four tee bolts, clamps, and nuts.
(3) Nuts must be tightened evenly, criss-crossing from corner to corner. After tightening the nuts as
tightly as possible by hand, turn them two full turns with a small wrench.
NOTE: Check the nuts three or four days later and retighten if required.

Page 6
1. Nut
2. Spring washer
3. Clamp
4. Tee bolt
5. Housing
6. Cartridge
7. Moisture eliminator
Air Cleaner Cartridge

Replacement
Figure 6
5. Engine Fuel
CAUTION
Consult the “fuel oil selection chart” in the engine operator’s manual before
substituting another grade of fuel.
a. Quailty
The quality of fuel 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. Only distillate fuel No. 1D is
recommended for use both summer and winter.
b. Fuel Filters
A primary fuel filter and a secondary fuel filter are used in the fuel system to remove impurities from
the fuel. The primary fuel filter is located between the fuel supply tank and the fuel pump. It operates
under vacuum and removes larger particles from the fuel. The secondary fuel filter, which removes
small particles from the fuel, is located between the fuel pump and fuel inlet manifold. Both of these
filters are replaceable cartridgess. Change both filters after each 300 hours of engine operation.
This is done as follows, with engine STOPPED:
(1) If generator set’s fuel tank is at a higher level than the filters, close the fuel cock on the fuel tank.
(2) Provide a container for catching fuel oil, and position it beneath each filter as it is being removed.
(3) Unscrew the filters, using a filter wrench if necessary, and discard them.
(4) Fill a new replacement cartridge approximately two-thirds full with clean fuel oil.
(5) Coat the seal gasket lightly with clean fuel oil.
(6) Screw the new cartridge in place by hand until gasket is evenly seated, then give cartridge a final
half-turn. If a filter wrench is used, do not overtighten.
(7) Open fuel cock on fuel tank.
(8) Start the engine and check the fuel filter(s) to make certain there are no leaks.

Page 7
1. Primary fuel filter

2. Secondary fuel filter
Fuel Filters
Figue 7
6. Engine Cooling System

a. General
Cooling system service 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 acoolant if the system is
protected against rust by a rust inhibitor additive. During cold seasons and in cold climates, the
system must, of corse be protected against freezing. At no time sholud 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. 6, E through H.
b. Radiator Cap
(1) General
A pressure valve is built into the radiator cap. It is designed to open at a pressure of
approximately seven pounds per square inch.
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.
(2) Removal
To remove, turn the cap to the left (counterclockwise) to the safety stop. When all pressure is
released, press down the cap and continue to turn until the cap is free to be removed.
Note: Do not attempt to repair the valve in a radiator cap. Replace with a new cap.
(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.

Page 8
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 compatable 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) Coolant solution check

Check the solution frequently to be sure that 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.
(3) Coolant solution preparation
The following table (Figure 8) indicates the freezing points of solutions varying from 16%
antifreeze to 65% antifreeze. Most antifreeze containers have a similar table printed on the label.
FREEZING POINT PERCENTAGE OF ANTI-

(FAHRENHEIT) FREEZE IN SOLUTION
20 16%
+10 25%
0 33-1/3%
-10 40%
-20 45%
-30 50%
-40 54%
-50 58%
-60 62%
-70 65%
Antifreeze Solution Table

Figure 8

Page 9
(4) Antifreeze solution installation

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. 6, E amd 6, 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 (Ref. Fig. 9) are closed, and all connections are
securely tightened.
f. Install the required amount of antifreeze (Ref. Fig. 8). Fill the system with coolant as outlined
under Para. 7, H.
e. Drain 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 and engine drain valves (See Fig. 9).
Note; When draining the systen for storage, remove all drain valves and remove drain plug located in
the left side of the engine block near the rear end of the blower.
(3) Allow the systen 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.
f. Cooling System Cleaning
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, procede as follows:
(1) Run the engine until it reaches normal operating temperature; then stop the engine and drain the
cooling system (Ref. Para. 6, E).
(2) Fill the cooling system with clean coolant (Ref. Para. 6, H).
(3) Add a flushing compound, that is compatable 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 with clean
coolant.
g. Radiator Core Cleaning
Blow out insects and dirt from the radiator core air passages, using air or wates under pressure.
Engine overheating often caused by bent or clogged radiator fins. When straightening bent fins, be
careful not to damage the tubes or to break the bond between the fins and tubes.
h. Cooling System Filling
Add a cooling system corrosion inhibitor (for warm weather opreation) or permanent antifreeze when
the air temperatures expected are at freezing, +32 deg F or lower). Antifreeze may be desired. See
Fig. 4 for cooling system capacity.

Page 10
1. Top engine water outlet

drain valve
2. Water pump drain valve
3. Oil cooler housing drain
valve
Coolant Drain Valve

Location
Figure 9
(1) Engine must be stopped. Close all drain valves except top water outlet valve (1, Fig. 9). 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 (1, Fig. 9). Close
valve and continue to fill system until coolant reaches a level, approximatey 1 inch below the
radiator filler neck.
Note: If antireeze 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 fron 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 rediator 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 11
7. Generator Maintenance
The 400 -Hz generator requires no maintenance or service other than periodic cleaning. The unit is
brushless, and bearings are permanently lubricated and sealed.
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 components.
WARNING
Electiric shock and fire can kill or injure! Be sure the unit is completely dry before
operating. Do not use a flammable solvent.
b. Adjustment
The generator itself requires no adjustment. Adjustment procedures for generator controls will be
covered in Section 2-3.
8. Drive Belts
The Engine cooling fan is driven by a matched-set of V-belts, which must be replaced as a matched-set.
The 12-V DC alternator is driven by a single V-belt.
a. Check Belt Tension
Check belt tension every 200 hours, or bi-weekly. A belt which is too tight is destructive to the
bearings of the driven part. A loose belt will slip and cause innefficient opreation of the part being
driven. Belts may be checked with a belt tension gage, Detroit Diesel No. BT-33-73FA, or
equivalent. (See Fig. 10 for tension values.) Check at midpoint between pulleys. Belt tension may
also be checked by a firm push witht the thumb, at a point midway between two pulleys. A properly
adjusted belt should be depressed 1/2 to 3/4 inch.
Fan Drive Alternator Drive

50-60 50-70
Belt Tension Chart (lbs./belt)

Figure 10
b. Belt Adjustment
(1) Alternator belt
Adjust alternator belt drive as follows: (See Fig. 11)
CAUTION
Exercise care to prevent damage to any component.
a. loosen pivot screw and nut (3).

b. Loosen adjusting bracket screw (1) and use a lon screwdriver (or pry bar) to pry the alternator
(4) outward to increase belt tension.
c. Tighten adjusting bracket screw (1) and check belt tension (See Para. 8, A, above).
d. Repeat steps (b) and (c) until belt (2) is properly adjusted.
e. Tighten pivot screw and nut (3) and retighten adjusting bracket screw (1).

Page 12
1. Adjusting Bracket Screw

2. Alternator drive belt
3. Alternator pivot nuts and
screws
4. Alternator
Alternator Belt
Adjustment
Figure 11
(2) Fan Belts

Adjust fan drive belt as folows:(See Fig. 12)
a. Loosen four adjusting bracket screws (2) sufficiently to allow adjusting bracket (4) to slide on
support bracket (5).
b. Turn adjusting screw (1) clockwise to tighten fan belts (counterclockwise to loosen belts).
c. Check belt tension in accordance with Para. 8, B.
d. Repeat steps (b) and (c) untill belts are properly adjusted.
e. Tighten adjusting bracket screws (2).
9. 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.

Page 13
1. Adjusting screw
2. Bracket screws
3. Fan belts
4. Adjusting bracket
5. Support bracket
Fan Belt Adjustment

Figure 12
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. 13).
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).
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 rear canopy panel.
b. Remove main frame rear cross member by removing four attaching cap screws (see Fig.14).
(2) Exciter removal
Refer to Section 3-3 for exciter removal instructions.
(3) Exciter installation
Install exciter in accordance with instructions in Section 3-3, and reinstall rear frame member and
tighten screws securely.

Page 14
1. Latch
2. Fastener
3. Connector
4. Rail
5. Track
Tray Removal (Typical)

Figure 13
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.
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.
15). 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 capscrews 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.

Page 15
Removable Rear Frame Cross-Member

Figure 14
Engine Control Panel in Tilt-out Position

Figure 15

Page 16
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 in accordance with 2-1; Para. 5, B.
(3) Change fuel filter elements in accordance with 2-1, Para. 5, B.
(4) 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. 1, 2, 3, and 4).
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. 6, 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. 8, A, B, & C).
WARNING
Exhaust fumes or fire can kill or injure! Immediately repair defective exhaust
systems.
e. Exhaust System
(1) Visually inspect muffler and exhaust pipes for signs of approaching failure.
(2) Listen for gasket or joint leaks.
(3) Replace any defective parts at once.
3. Electrical System (12-V DC)
a. Lights
Inspect 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
Inspect 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.

Page 1
Daily Weekly Bi weekly Monthly Bi- Six

or or or or Monthly Months
AR 8 Hrs 50 Hrs 100 Hrs 200 Hrs or or
400 Hrs 1200 Hrs
Engine
Check fuel quantity X
Check crankcase oil level X
Check coolant level X
Change engine oil filter X
element
Change engine oil X
Replace air cleaner cartridge X
Check cooling system X
hoses, tubes, fittings, clamps
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 hours
ELECTRICAL (12-V SYSTEM)
Check all lights X
Clean battery terminals X
Check wiring X
Check connections X
400-HZ GENERATING AND CONTROLS SYSTEM
Check output cable and X
connector
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 and X
connections
Clean and inspect generally X
Inspection/Check/Maintenance Schedule
Figure 1

Page 2
Light Identification Location Lamp Manufacturer Lamp (bulb)

Number
Instrument Panel Lights Control Box Lamp Industry 63
Trade Number
Engine “ON” Indicating Light Engine Control Panel Lamp Industry 1815
Trade Number
Contactor CLOSED Engine Control Panel Lamp Industry 1815
Indicating Light (Output No. 1) Trade Number
Contactor CLOSED No. 2 Control Lamp Industry 1815
Indicating Light (Output No. 2) Trade Number
Fault Indicating Lights Protective Relay Tray Lamp Industry 1815
Trade Number
Clearance Lights Canopy Lamp Industry 57
Trade Number
Lamp Identification Chart

Figure 2
Item Protected Location Illustration Size and Type

Instrument Panel light Engine control panel Sect. 1-1, Fig. 11 item 15 10 A Type AGC
and engine circuit
Protective relay system Protective relay tray Sect. 1-1, Fig. 10 item 17 2 A Type AGC
Voltage regulator Voltage regulator tray Sect. 1-1, Fig. 12 item 12 5 A Type AGC
Load contactor circuit Protective relay tray Sect. 1-1, Fig. 10 item 16 2 A Type AGC
Fuse Identification Chart

Figure 3
c. Wiring and Connections
(1) Inspect all cables and leads for broken, worn, and damaged insulation.
(2) Check electrical connections for loose connection.
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 or periodic maintenance adjustments are required. However, some regular checks should
be made to be sure all controls, instruments, etc., are working properly.
a. Monitoring Instruments
Observe operation of voltmeter, ammeter, and frequency meter each time the unit is started.
b. Indicating Lights
Check lamps (bulbs) in all of the indicating lights of each start up. Fault indicating lights in the
protective relay tray may be tested by pressing test switch (1-1, 8, Fig. 9).

Page 3
c. Protective Modules
Check operation of all protective modules to make sure they will function if a fault should occur in the
output circuit. (see 2-3; Para. 2, B).
d. Wiring and Connections
WARNING
High voltage: Electric shock can kill! Stop operations and stop engine before
touching exposed conductors or terminals.
(1) Check all cables, leads, and wiring for broken, worn and damaged insulation.
(2) Check all connections for tightness.
(3) Check the output cable plug connector for damaged contactors in the end of the plug.

Page 4
Section 3. Adjustment / Test
1. General
These adjustments and test procedures are applicable to testing and adjusting the generator set after
major repair, major parts replacement, 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 coolant level. (Sect. 2-1, Para. 6, H).
(4) Check tension of fan and fan generator V-belts. (Sect. 2-1, Figure 11 and 12).
(5) If governor throttle linkage was disturbed, check all linkage to make certain engine speed may be
controlled when the engine is started. (Figure 7).
(6) Inspect for oil, fuel and coolant leaks.
(7) If the setting of the voltage regulator adjustment potentiometer (37, Fig. 1) has been disturbed,
set it at CENTER position (approximately 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 certain the air shut-off valve is latched OPEN by pressing the latch lever (8, Fig. 2) DOWN.
(11) Make a general inspection of all wiring and terminals. Inspect the equipment to be certain
damage will result from starting the engine.
Check operation of the shut-down solenoid (1, Fig. 2) by momentarily connecting a jumper wire
between the “hot” terminal (4, Fig. 3) on the starter solenoid and the left terminal (2, Fig. 2) on
the shut-down solenoid. The solenoid should unlatch the air valve as soon as connection is
made.
(12) While the air valve is unlatched, check operation of the starter “cut-out” switch (10, Fig. 2). Press
engine start switch (28, Fig. 1). Starter should not crank engine if starter cut-out switch is
operating properly. See Para. 3, F, (1) if starter cutout-out switch adjustment is necessary.
(13) At initial start-up after generator overhaul or repair, “flash” the exciter field by momentarily
applying 12-V DC to the field windings as follows:
CAUTION
Engine must not be running when field flashing if voltage regulator damage is to
be prevented.
a. Flashing exciter field using test box.

If a test box (see Sect. 1-3, Fig. 4) is available, connect it to receptacle connector (Sect. 1-3.,
Fig. 5).
• Rotate the selector knob (Sect. 1-3, Fig. 4, item 1) to position 8.

Page 1
CAUTION
Flashing the field in a reverse direction could cause damage to voltage regulator
diodes.
• Use two jumper leads, each equipped with alligator test clip and a test prod, to connect
12-V DC power to test jacks (Sect. 1-3, Fig. 4, items 3 and 4) on the box. Connect positive
jumper from input terminal (4, Fig. 5) on starter solenoid to red test jack. Connect negative
lead from starter ground terminal to black test jack.
• Momentarily pressing pushbutton switch (sect. 1-3, Fig. 4, item 2) will flash the exciter field.
• Disconnect jumper leads.
b. Flashing exciter field without test box.
Remove test receptacle cover (1-3; Fig 5). 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 terminal “D” of the test
receptacle (see Fig. 4), and connect the other end of the lead to a good GROUND. insert the
test prod of the second lead in the terminal “P” of the test receptacle and momentarily touch
the other end (alligator clip) to the “hot” terminal (4, Fig. 3) on the starter solenoid to flash the
field. After flashing exciter field, disconnect leads and install receptacle cover.
NOTE: If test leads with test prods are not available, insert short pieces of wire in proper test terminals
to make connections.
(14) 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.
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 875 to 925 RPM. Adjust, if necessary, in accordance with
instructions 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 conditions.
(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 adjustment potentiometer (37) has been disturbed,
position the knob to mid-range position.
(6) Bring the engine up to governed speed, and also energize the generator by holding the
engine-generator control switch (18) in BUILD-UP-VOLTS position momentarily. Release switch
and allow it to position in “center” GENERATE 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 in accordance with Para. 3, E, (3). See Fig. 11.
(8) Observe voltmeter (3). Use voltage regulator adjustment potentiometer (37) to adjust voltage to
115 V AC line-to-neutral.

Page 2
(9) Measure governor actuator input signal. See Para. 3, E, (4), (a).
(10) Measure governor magnetic pickup signal. See Para. 3, E,(4),(b).
(11) Check high-speed limiting governor.
Engine limiting speed governor should limit engine speed to just below trip point of overspeed
governor. Overspeed device should trip at 2400 RPM. See Synchro-Start Products, Inc.
instructions in Chapter 5.
(12) Check adjustable voltage range in automatic operating mode.
a. Observe voltmeter (2, Fig. 1) and turn voltage regulator adjustment potentiometer (37)
CLOCKWISE to full clockwise position. Maximum voltage should be at least 134 V AC, or
higher.
NOTE: If voltage should decrease when the potentiometer adjustment is turned clockwise, it indicates
that internal wiring of the voltage regulator is incorrect. Replace the complete regulator.
b. Observe voltmeter and turn adjustment potentiometer (37) to full COUNTERCLOCKWISE
position. Minimum voltage should be 108 V AC, or lower.
(13) Observe voltmeter and turn adjustment potentiometer (37) 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
position. Maximum voltage should be 160 V AC.
c. Observe voltmeter and turn rheostat (32) to full COUNTER CLOCKWISE 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. The indicating light (22) should glow GREEN and an amperage
value should appear on the AC ammeter (4).
(17) Release the switch (20) and allow to return to the center ON position. The load contactor should
open immediately, and the contactor “on” indicating light should go OFF. This is because the
plug interlock relay (Ref. 1-1; 1, Fig. 9) is not receiving power from an outside source of 28 V DC.
It indicates that the plug 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
remain 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.

Page 3

14. Generator Control Tray 30. Engine Stop Control
16. Light Switch

Page 4

Page 5
1. Shut-down solenoid
2. Solenoid terminal (input)
3. Solenoid terminal (ground)
4. Latch arm adjusting nuts
5. Switch bar attaching nut
6. Latch actuating arm
7. Latch
8. Latch reset lever
9. Air shut-off valve shaft
10. Switch
11. Switch adjusting nuts
12. Switch actuating rod
13. Switch actuating bar
14. Latch cam
15. Solenoid plunger rod
Shut-down Solenoid with

Linkage and Starter Cut-out
Switch
Figure 2
(23) Apply 1/3 to 1/2 load at the load bank and allow the unit to run for 15 to 30 minutes. Observe
operation 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 droop should be no more than 1 Hz. Adjust
governor if necessary (see Para. 3, E, (3).
(26) Follow instructions in Section 2-5 to set voltage regulator line-drop compensation potentiometers
[(Ref. Figure 1, items (38) and (39)]. Set knob pointer on cable size potentiometer (39) to size
(2/0, 4/0, etc.) of cable being used. Set knob pointer on cable length potentiometer (38) 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. Voltage should be 115-V +/- 1%.
(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.

Page 6
1. Starter
2. Starter solenoid switch to
starter terminal
3. Solenoid coil ground
terminal
4. Solenoid switch input
terminal
5. Starter solenoid switch
6. Solenoid coil terminal
7. Battery cable
8. Starter ground cable
Starter and Solenoid

Switch
Figure 3
(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
position (except straight down).
(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
indicated 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 for not less than 10 minutes under full load. The overload device (Ref. 1-1; 7,
Fig. 12) 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
indicate an overload condition.
(35) Reduce load to normal. Turn off indicating light by pressing reset switch (7, Fig. 1).
(36) Check engine oil pressure at governor 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.

Page 7
Test Receptacle
Connector Terminals
Identification
Figure 4
(37) Check operation of fuse interlock (Ref. 1-1; 2, Fig. 9). With unit operating normally under load,
remove protective relay circuit fuse (Ref. 11, Fig. 1). The load contactor should open immediate-
ly, indicating 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 in the manual mode, adjust the manual rheostat (32, Fig.
1) to increase voltage (turn clockwise), until the overvoltage sensing relay actuates the
protective monitor to open the load contactor and turn on the overvoltage indicating light. The
overvoltage sensing relay should trip when voltage reaches 130-V to 134-V.
b. Return unit to normal operating conditions by adjusting manual rheostat and pressing reset
switch (7), and switching to AUTOMATIC mode.
(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. 9) 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 protective 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 operating at normal load in the MANUAL mode, use the manual rheostat (32, Fig. 1)
to reduce voltage to 104 V. 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
stopwatch, or note position of sweep-second hand each time voltage is reduced. At some volt
age value between 103 V and 93 V, and 4 to 12 seconds after a new voltage setting is made,
the load contactor should be opened and the undervoltage indicating light should be turned
on by the step-by-step action of the undervoltage sensing re lay, time delay circuit, and
protective monitor relay.
NOTE: The 4 to 12 second time delay is generally set at 5 seconds.

c. If the load contactor is not opened at 103 V to 93 V, it will be necessary to refer to the
Troubleshooting Chart, Section 2-4, to determine which component of the undervoltage
protective circuit is defective.

Page 8
d. If the undervoltage circuit performs satisfactorily, return the unit to normal operation by
adjusting the voltage to 115 V, pressing the reset switch, and switching to AUTOMATIC mode.
(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 contactor holding circuit, thus OPENING the load contactor. To check the
underfrequency protective components, proceed as follows:
a. While the unit is operating normally under load, reduce generator output frequency by
reducing engine speed. Use the governor speed setting potentiometer (Ref. Fig. 11). Turn
adjusting screw COUNTERCLOCKWISE gradually to reduce engine speed until frequency
meter indicates 386 Hz. Underfrequency protective relay should not function to open the load
contactor at this frequency. Reduce frequency in steps of 1 Hz.
b. If the protective system functions to open the load contactor, turn off the voltage regulator,
and turn on the underfrequency light after some frequency between 385 Hz and 375 Hz is
reached, all components of the system are functioning properly. If the load contactor is not
opened within the above frequency range, refer to Troubleshooting 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
overfrequency 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 Troubleshooting 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
hardware as required.
CAUTION
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.
(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 generator and misinterpreted as a generator noise. Send the unit to
overhaul if in doubt of bearing serviceability.

Page 9
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.
The adjustment of this resistor (Ref. 1-1; 1, Fig. 8) determines the maximum generator output
voltage obtainable when using the manual control rheostat for voltage control. To adjust
maximum voltage potential (160-V AC line-to-neutral) proceed as follows:
a. Loosen slider-band clamping screw.
b. Move the slider-band toward the single wire end of the resistor to increase voltage potential.
Move the band towards the double wire end (two wires connected) to decrease voltage
potential.
c. Tighten slider-band clamping screw.
(2) Adjust 400-Hz voltage regulator.
When a voltage regulator is first put into service, or when output (generator-to-aircraft) cables
are changed, the regulator may require adjustment. Depending on specification, the voltage
regulator may be either the magnetic-amplifier type voltage regulator (Part No. 430391C), shown
in Figure 5, or the solid state voltage regulator (Part No. 489812A). Refer to Section 2-5 of this
manual for regulator adjustment instructions.
1. Voltage adjusting rheostat

2. Cable length compen-
sation rheostat
3. Cable size compensation
rheostat
4. On-Off switch, line-drop
compensation
5. Fuse (5-Amp)
6. Fuseholder
7. Damp (gain) adjusting
potentiometer
8. Rate adjusting
potentiometer
Voltage Regulator
Adjustments
Figure 5

Page 10
c. Basic Engine Adjustments

Specific information for this particular engine application is listed in Figure 6 Adjustment procedures
applicable to the following items of the diesel engine are included in the Detroit Diesel Operator’s
Manual, which is located in Chapter 5.
(1) Exhaust valve adjustment.
(2) Exhaust valve bridge adjustment.
(3) Fuel injector timing adjustment.
(4) Idle speed, speed limiting and overspeed adjustment
Refer to speed limiting mechanical governor adjustment instructions with the Detriot Diesel
Operator’s Manual. Use instructions which apply to a single weight governor.
Recommended idle speed for this application is 875 to 925 RPM.
NOTE: A stroboscope is required for engine speed tests.

The limiting speed governor should be set at a speed just below the overspeed governor trip
point, or approximately 2300 RPM. Refer to manufacturer’s instructions in Chap. 5 for
“Synchro-Srart” overspeed governor adjustment.
d. Engine Accessories Adjustment
(1) Generator and fan belt adjustment
Refer to 2-1; Para. 9 for belt adjustment instructions.
Engine
Type engine 4-cylinder, 2-cycle Diesel
Manufacturer Detroit Diesel Corporation
Model 4-71N
Governed speed 2000 RPM ±4.5%
Idle speed 900 RPM ± 25 RPM
Overspeed governor trip point 2400 RPM
Limiting speed governor 2300 RPM
Firing order 1-3-4-2
Type of cylinder head 4 valve
Bore 4.25 inches (108 mm)
Stroke 5.00 inches (127 mm)
Displacement 284 cu. in. (4640.5 cc)
Compression ratio (nominal) 18.71:1
Horsepower at 2000 RPM 148
Electrical system 12 volt DC
Oil capacity (with filter) 17 quarts (16 liters)
Oil capacity (without filter) 15 quarts (14.2 liters)
Coolant capacity (approx.) 9-1/2 gallons (36 liters)
Engine Specifications
Figure 6

Page 11
NOTE: Replace fan belts with a matched set.
e. Electric Governor System Adjustment

Two electric governor system main components, namely the magnetic pickup, and control box, have
critical adjustments which can affect engine performance and generator output. Actuator-to-fuel
control lever adjustment 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 pickup.
Third - Check or adjust electric governor controller.
(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. In making
the adjustment, make certain that the following rules are observed:
* Adjust linkage to use the FULL TRAVEL of actuator lever (3).
* Linkage must move speed control lever (7) from FULL IDLE to FULL SPEED position, to allow
engine to pull 125% load.
With engine stopped, refer to Figure 7 and adjust linkage as follows:
a. Place the ball joint that attaches to the actuator lever (3) in the FOURTH hole from the
mounted end of this lever, and place the ball joint that attaches to the fuel control lever (7) in
the LAST hole (the hole nearest the mounted end of the lever).
b. Disconnect ball joint (4) from actuator lever (3), and make sure that the levers (3 and 7) have
not slipped on shafts. If a lever has slipped, position it correctly and tighten it securely.
c. Place both levers (3 and 7) in FULL IDLE position and attempt to connect ball joint (4) at hole
in actuator lever (3) from which it was removed in step (a). If connection cannot be made,
loosen nuts, (8) and adjust effective length of rod assembly so that connection may be made.
NOTE: When this adjustment is properly made, the effective length of the rod assembly (items 4, 6, and
8, Fig. 7), - measured between ball joint centers - is generally 6-3/16 inches +/- 1/8 inch (See
Fig. 8). When this adjustment is made properly, an angle of approximately 60 degrees is formed
between the engine speed control lever (7) and the side of the engine block at idle.
d. Manually operate actuator lever (3) back and forth between FULL IDLE and FULL SPEED
positions. With the actuator lever being moved approximately its entire range of travel, speed
control lever (7) should move freely through its entire range between FULL IDLE and FULL
SPEED. If adjustment is unsatisfactory, try another hole mounting in ACTUATOR lever and
readjust rod length.
e. Tighten all parts securely when adjustment is completed.

Page 12
1. Actuator
2. Mounting bracket
3. Actuator lever
4. Ball joint
5. Fuel shut-off lever
6. Rod
7. Engine speed control
lever
8. Nut
Actuator Linkage
Figure 7
Length Adjustment of
Linkage Rod Assembly
Figure 8

Page 13
(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, as indicated by test in Para. 3, E, (4), (b), refer to Fig. 9 and adjust as follows:
a. Wires from the magnetic pickup to the governor controller are contained in a shielded cable.
Separate this shielded cable from other wiring by cutting the plastic wire ties binding it to the
other wiring.
b. Disconnect the magnetic pickup at terminals 10 and 11 on the governor controller (Fig. 10).
c. Loosen nut (2) and remove magnetic pickup (1).
d. Inspect to make certain the tip is not damaged from contact with the ring gear teeth (replace
pickup if damaged).
e. 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.
f. Install the magnetic pickup and thread into the mounting hole 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.
g. 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
10-V at control box terminals 10 and 11 when the engine is running at no load and governed
speed.
NOTE: As little as 1-V is required for operation of governor control box. Magnetic pickup voltage does
not have to be as much as 4-V to 10-V.
h. Tighten nut (2) to firmly attach magnetic pickup (1) to engine flywheel housing.
i. Reconnect terminals of magnetic pickup wires at the controller, and use plastic wire ties to
bind the magnetic pickup shielded cable to the other wiring from which it was removed.
1. Magnetic pick-up
2. Nut
Magnetic Pickup
Figure 9

Page 14
(3) Governor Controller Adjustment

Before making an adjustment to the controller (Fig. 10), make certain that linkage between
actuator and fuel control lever (Fig. 8) is free and properly adjusted. There must be no lost
motion or “play” in the linkage. Be sure magnetic pickup is producing a strong, normal output.
The controller has three identical control potentiometers: the GAIN potentiometer, the DROOP
potentiometer, and the potentiometer marked “I”. In addition, a SPEED control potentiometer is
located just next to the GAIN potentiometer. Make controller settings as follows:
a. Preliminary Controller Settings
• With the engine of the generator set turned off, Set the “I” ADJUSTMENT one division
mark from zero.
• Set GAIN adjustment at the third division mark from zero.
• Set DROOP adjustment COUNTERCLOCKWISE to minimum position as shown in Figure
11.
• Start the engine and adjust the controller’s SPEED potentiometer until the engine is
operating at rated speed (2000 RPM). Turning the adjustment CLOCKWISE increases
engine RPM, and turning it COUNTER-CLOCKWISE decreases engine RPM.
• If the governor system is unstable, reduce slightly the “I” and GAIN settings.
b. Checking No-Load Operation of Controller
• Turn the GAIN adjustment CLOCKWISE until the actuator lever oscillates (a faster
oscillation than was observed when the “I” adjustment was first made).
• Reduce the GAIN adjustment slowly COUNTERCLOCKWISE until the actuator lever is
stable.
• Upset the lever by hand. If the lever oscillates in 3 to 5 diminishing oscillations and stops,
the setting is correct.
c. Checking Operation of Controller Under Load
• Apply a load to the generator set, then remove the load and observe the length of time
required for the engine speed to again stabilize. Engine speed should stabilize within 3 to
5 oscillations. If engine speed does not stabilize at the above setting, proceed as follows.
• With generator set operating at no load, reduce GAIN setting COUNTER CLOCKWISE one
division mark and turn “I” adjustment fully CLOCKWISE while observing the actuator lever.
• If the lever does not become unstable, upset it by hand. When the lever slowly oscillates,
turn the adjustment COUNTERCLOCKWISE slowly until the lever is stable.
• Upset the lever again. It should oscillate 3 to 5 times and then become stable for optimum
response.
(4) Electric governor test values
a. Signal to actuator
Refer to Figure 11. With the generator set operating at governed speed (2000 RPM,
400-Hz), check actuator signal voltage, measuring this voltage between terminals 4 and 5 on
the control box terminal board. Voltage measured should be approximately 5.2-V DC at no
load, and 5.8-V DC at full load.
b. Magnetic pickup signal
Connect a high impedance voltmeter to magnetic pickup input terminals (10 and 11) on
control box terminal board. The voltage value at governed speed, no load should be 4-V AC
MINIMUM to 10-V AC MAXIMUM.
NOTE: A signal as low as 1-V is sufficient to operate the control unit satisfactorily. If a condition exists
wherein no voltage at all is measured, this indicates either that the magnetic pickup is too far
from flywheel teeth or that it is defective.

Page 15
Electric Governor Control Box Location

Figure 10
f. Engine Shut-Down Devices Adjustment

(1) Starter cut-out switch adjustment (see Fig. 2). Engine must be stopped.
a. Lift latch (7) to UNLATCH the shut-down mechanism.
b. Check clearance between switch actuating rod (12) and switch actuating bar (13). Actuating
rod (12) must not touch bar (13) when the mechanism is UNLATCHED. Acceptable clearance
may be 0.010 to 0.020 inch.
c. If adjustment is required, loosen nuts (11) and adjust to position switch (10) to get acceptable
clearance. Tighten nuts securely. Reset mechanism by pressing lever (8) down.
NOTE: Pushing the start switch should operate the starter when the shut-down linkage is latched. It
should not operate the starter when linkage is UNLATCHED.
(2) Shut-down linkage adjustment
This linkage should require adjustment only if disassembled or if a shut-down solenoid is
replaced. (See Figure 2). Engine must be stopped.
a. Adjustment is required if the latch (7) does not fully seat in cam notch (14) when the
mechanism is in LATCHED position with air shutoff valve fully open, or if the solenoid plunger
rod (15) is at the end of its downward travel and the air shut-off valve is fully open.
b. If adjustment is required, remove nut (5) and bar (13). Loosen nuts (4) and adjust so that the
latch (7) is fully seated in the cam notch (14) when the solenoid plunger rod (15) is at the end
of its downward travel and the air shut-off valve is fully open. Tighten nuts. (4).

Page 16
Electric Governor Control Box

Figure 11

Page 17
c. To check operation, momentarily apply 12-V DC to terminal (2). Plunger rod (15) must
actuate mechanism to lift latch (7) out of notch in cam (14) and allow blower air-valve to close.
d. Install bar (13) and attach with nut (5).
e. Check adjustment of starter cut-off switch (10). Adjust in accordance with Para. 3, F, (1) if
necessary
4. Generator and Exciter Test
The generator fields may be tested with a “Kelvin” bridge. This is a double bridge type instrument
required for the very low resistances encountered in this test. Zero resistance indicates a SHORT
CIRCUITED condition. An infinite resistance reading indicates an OPEN CIRCUITED condition. See
Fig. 12 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 resistance and compare to values given in Fig. 12.
TEST CONNECTION NOMINAL RESISTANCE IN OHMS

GENERATOR STATOR
Phase A to N 0.008
Phase B to N 0.008
Phase C to N 0.008
NOTE: The two leads of a phase must be connected when test is made.
EXCITER A-B, B-C, A-C 0.1
Field (RED to YELLOW-BLACK) 7.23
L1 Field 2.2 +/- 5%
Generator and Exciter Stator Test Values

(70F Ambient Temperature)
Figure 12

Page 18
5. Diode Test
Test values for diodes are not given here because they could be misleading.
Test values may vary even between diodes of the same part number, rating, and manufacturer.
General instructions for testing diodes follow:
(1) Disconnect diode lead(s).
CAUTION
The regulator output must never be grounded when the generator is turning.
(2) Use a good quality ohmmeter. An instrument which indicates 50 ohms at the center of the scale is
preferable.
NOTE; Make certain the battery is in good condition and the pointer is adjusted to zero when the test
lead points are shorted together. Set the scale selector to RX1.
(3) Hold one ohmmeter lead point on the threaded end of the diode. hold the other lead point on the
wire terminal end. Observe the note and 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 19
TEST BOX TEST POINTS TEST CONDITION VOLTAGE

POINTER CONNECTOR DESCRIPTION
POSITON TERMINALS
1 K-M Phase “A” input for reg. and Unit in “GEN” mode 115-V AC
trays 400 HZ
2 K-P Phase “B” input for reg.and Unit in “GEN mode & 115-V AC
trays auto-man sw. in ”AUTO" 400HZ
3 K-S Phase “C” input for reg. and Unit in “GEN mode & 115-V AC
trays auto-man sw. in ”AUTO" 400HZ
4 K-A Protective monitor fuse Battery voltage 12-VDC
5 K-B Fuse interlock relay Test bank sw. Closed & 12-V DC
contactor closed
6 H-S Protective monitor contacts Auto-man sw. in “AUTO 115-V AC
position
7 K-Z Plug interlock relay Plug in aircraft 28-V DC
8 D-F Exciter input Unit in “GEN mode 8-12 VDC
9 V-X Regulator output** Unit in “GEN mode & 50-70 V
auto-man sw.in ”AUTO" DC*
10 K-B Contactor operation Test bank sw. Closed & 115-V AC
contactor closed
11 K-E Overload contacts at less than Test bank sw. Closed & O-V DC
125% load contactor closed
12 K-R Contactor switch Test bank sw. closed & 115-V AC
contactor sw. closed in
“ON” position
13 K-N Battery voltage and engine All conditions 12-V DC
circuit fuse
14 K-J Shut-down solenoid Engine running O-V DC
15 K-G Governor and EDR Unit in “GEN” mode 12-V DC
16 U-W Governor actuator Unit at idle speed O-V DC
Unit in “GEN” mode, 2-4 V DC
no load
* For units with 20 ohm, 100 watt ballast resistors in protective relay tray.
** Caution: The regulator output must never be grounded when the generator is turning.
Typical Test Values at Test Receptacle Connector or Test Box

Figure 13

Page 20
Section 4. Troubleshooting
1. General
a. Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the
exact cause is located. When looking for the cause of a trouble in a circuit or system begin at the
source of power or supply. Continue testing and checking the circuit, or system, step-by-step, in an
orderly manner, until the cause of trouble is located.
b. The chapter provides information for diagnosing and correcting certain troubles which cause
unsatisfactory operation or failure of the equipment.
c. Minor troubles may be remedied by the operator, however, major repairs must be undertaken by
experienced mechanics and electricians only.
2. Troubleshooting
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 Troubleshooting Chart
(1) A troubleshooting chart is furnished to provide maintenance and repair personnel with a
time-saving guide for locating trouble. To use the chart, proceed as follows:
a. Locate the symptom(s) of trouble in the “Trouble” column.
b. Check the probable causes of trouble in the “Probable Cause” column.
c. Test, check, repair, or correct the trouble as indicated in the “Remedy” column.
(2) If the cause of a trouble is an uncommon one and cannot be located by use of the chart, start at
the source of power or supply and check the affected circuit or system completely. Use
schematic and connection diagrams supplied with this manual.
(3) Electrical components mentioned in the troubleshooting chart are identified by a noun name and
a 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
before condemning any other components.
NOTE: Reference symbols (S9, etc.), used in the Troubleshooting Chart, are identified on Schematic
and Connections Diagrams.

Page 1
3. Equipment for Troubleshooting

A good quality multi-scale volt-ohmmeter is the only instrument required for troubleshooting. 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 388318A -2, is available tests may be made more quickly and accurately,
however, the test receptacle connector 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
Electric shock and moving parts can kill! Exercise extreme care to avoid contact
with high voltage parts or leads and moving parts when trouble shooting or
operating the equipment. Remove jewelry such as rings and watch.
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 troubleshooting chart. For example, if a
component 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 for repair.
Assemblies which lend themselves to this concept are:
• Generator control tray
• Protective relay tray
• Voltage regulator
• Overload module
• Protective monitor module
• Electric governor control “box”
• Governor actuator
• Over-undervoltage module
• Over-underfrequency module
The above items are in addition to normally replaced items such as fuel pump, injectors, relays, etc.
6. Test Values
Although test values are provided, where applicable, throughout the troubleshooting chart additional
information 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 125% load in 5 minutes or less.
• Overload 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.

Page 2
• Underfrequency relay trips at 375 to 385 Hz, resets at 385 Hz.

• Overload relay trips at 125% rated load in 5 minutes.
See 2-3 Fig. 13 for typical test values at test receptacle and test box.
7. Check Connections and Leads

ALWAYS make a check of connections and leads to a component suspected of being faulty. With the
exception 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) 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 to control box.
(2) No voltage from control box to actuator.
(3) No signal from magnetic pickup.
c. The actuator will “surge” under the following conditions:
(1) “Stability” or “gain” adjustment set too “high”.
(2) Throttle linkage binding.
9. Engine Trouble Shooting Procedures
a. General
The following engine troubleshooting procedures were taken from Detroit Diesel’s “Field Service
Data Book”. Certain abnormal conditions which may interfere with satisfactory engine operation,
together with methods of determining the cause of such conditions, are covered in the Trouble
Shooting Chart.
The ability of the engine to start and operate properly depends primarily on two things:
(1) The presence of an adequate supply of air, compressed to a sufficiently high compression
pressure.
(2) The injection of the proper amount of fuel at the right time.
Lack of power, even running, excessive vibration, stalling, and hard starting may be caused by
low compression, faulty injection in one or more cylinders, faulty timing or valves, or lack of
sufficient air.
Since proper compression, fuel injection, and the proper amount of air are important to good
engine performance, procedures for checking them are given here.
b. Locating a Misfiring Cylinder
(1) Start engine and allow it to run until it reaches normal operating temperatures.
(2) Remove valve cover.
(3) Run engine at IDLE speed and check valve clearance.
(4) Hold the No. 1 injector follower down with a screwdriver, or with a special injector cut-out tool,
thus preventing operation of the injector.

Page 3
If the cylinder has been misfiring, there will be no noticeable difference in the sound and
operation of the engine. If the cylinder has been firing properly there will be a noticeable
difference in the sound and operation when the plunger is held down. This is similar to
short-circuiting a spark plug in a gasoline engine.
(5) If cylinder No. 1 is firing properly, repeat the procedure on the other cylinders until the faulty one
has been located.
(6) Providing that the injector operating mechanism of the faulty cylinder is functioning satisfactorily,
remove the fuel injector and install a new injector.
c. Checking Compression Pressure
(1) Start engine and run until normal operating temperature is reached.
(2) With engine stopped, remove fuel pipes from the injector and fuel connectors of No. 1 cylinder.
(3) Remove the injector from No. 1 cylinder and install the proper adapter of the pressure gage (tool
J6692) in its place.
(4) Use one of the two fuel pipes as a jumper connection between the fuel inlet and return manifold
to permit fuel to flow directly to the return manifold. On some cylinder heads it is necessary to
fabricate a jumper connection from a fuel pipe.
(5) Start the engine and run at idle speed.
CAUTION
Do not crank the engine with cranking (starting) motor to obtain compression
pressure.
Record compression pressure indicated.
NOTE: A guide to minimum compression pressures to be expected is included in Sect. 2-3, Fig. 6.
(6) Remove pressure gage, install injector, and reinstall fuel lines.
(7) Repeat steps (2) through (6) for each cylinder.
d. Interpretation of Compression Pressure Records
Compression pressure in any one cylinder should not be less than specified in Sect. 2-3, Fig. 6.
Variation in compression pressures between cylinders must not exceed 25 PSI. A low compression
pressure in one cylinder indicates that something unusual has occurred and that a pressure leak has
developed.
e. Causes of Low Cylinder Pressure
Low cylinder pressures may result from any one of several causes:
(1) Piston rings may be stuck or broken. To determine the condition of the rings, remove the air box
cover and press on the compression rings with a blunt tool. A broken or stuck ring will not have a
spring-like action.
(2) Compression pressure may be leaking past the cylinder head gasket, valves and valve seals,
injector tube, or through a hole in the piston or combustion chamber.
To correct any of these conditions, consult your Detroit Diesel Service Outlet.
f. Fuel Flow Test (see Fig. 7)
Check fuel pump and fuel flow as follows:
(1) Disconnect the fuel return tube at, or near, the tank. Hold the open end in a convenient container
of over 1-gallon capacity.
(2) Start and run the engine at governed speed 2000 RPM. Measure the fuel flow from the return
tube for 1 minute. Flow should be 0.8 gallon (based on 0.080 restriction). If fuel flow is below this
amount, it indicates that the fuel strainer, fuel filter or fuel pump requires servicing or repair.

Page 4
(3) To check suction side of the pump, immerse the end of the return tube in a container of fuel. If air
bubbles rise to the surface of the fuel, it indicates that air is being drawn into the fuel system on
the suction side of the pump. If air is present, tighten all fuel connections between the fuel tank
and the fuel pump. Check for defective tubes, hoses, etc.
10. Illustrations
Illustrations, Figures 1 through 8, are referred to throughout the Trouble Shooting Chart
11. Troubleshooting Chart

The troubleshooting chart is provided on pages 13 through 27.

Page 5

14. Generator Control Tray 30. Engine Stop Control


Page 6

Page 7
1. Starter
2. Starter solenoid switch to
starter terminal
3. Solenoid coil ground
terminal
4. Solenoid switch input
terminal
5. Starter solenoid switch
6. Solenoid coil terminal
7. Battery cable
8. Starter ground cable
Starter and Solenoid

Switch
Figure 2

Page 8
1. Shut-down solenoid
2. Solenoid terminal (input)
3. Solenoid terminal (ground)
4. Latch arm adjusting nuts
5. Switch bar attaching nut
6. Latch actuating arm
7. Latch
8. Latch reset lever
9. Air shut-off valve shaft
10. Switch
11. Switch adjusting nuts
12. Switch actuating rod
13. Switch actuating bar
14. Latch cam
15. Solenoid plunger rod
Shut-down Solenoid with

Linkage and Starter Cut-out
Switch
Figure 3

Page 9
1. Low-oil-pressure switch 5. Fuel pressure switch

2. High temperature switch 6. Air shut-off valve latch
3. “Hot wire” shut-down relay 7. Shut-down solenoid
4. Overspeed governor
Switch Contact Positions
Switch Engine Stopped Engine Running Under Fault Condition

1 Closed Open Closed
2 Open Open Closed
3 Open Open Closed
4 Open Open Closed
5 Open Closed Cpen
Engine Shut-Down and Safety Devices

Figure 4

Page 10
1. Manual control voltage potential adjusting resistor 2. Exciter field ballast resistors
Excitation Resistors
Figure 5
End View of Voltage Regulator Amphenol Connector

Figure 6

Page 11
Fuel Flow Schematic (Typical)

Figure 7
Test ReceptacleConnector
Terminals Identification
Figure 8

Page 12
Engine and Controls
Trouble, Symptom & Condition Test or Inspection Corrective Action
1. Engine will not start. Starter a. Battery or batteries Check battery voltage and
will not crank engine. discharged or faulty. specific gravity. Recharge or
replace.
12-V DC power not reaching
starter solenoid.
Check voltage at starter
solenoid input terminal (4, Fig.
2). Voltage should be
approximately 13.5 V. If no
voltage, check cables and
connections between starter
solenoid and power source.
Replace or repair cables and
connectors as required.
b. Batteries or starter not Check cable and all
properly grounded. connections.
c. Air shut-off valve unlatched Latch air shut-off valve by
and holding starter cut-out pushing latch lever (8, Fig. 3)
switch open (see Fig. 3). down. If valve will not latch,
check for tripped overspeed
governor.
d. Starter cut-out switch Adjust in accordance with Sect.
improperly adjusted, or 2-3, Para.34, F, (1), or replace
defective. switch.
e. Defective start switch (S24) Check voltage at terminal (6,
or defective auxiliary Fig. 2) while operating start
solenoid (L10). switch (28, Fig. 1). If no voltage
is indicated, replace switch
(S24) or solenoid switch (L10)
as required.
f. Defective starter solenoid, Momentarily connect a large
or starter. size starter cable between
terminals 2 and 4, Fig. 2.
If the starter cranks the engine,
the solenoid (5, Fig. 2) is
defective. If the starter does not
crank the engine, the starter (1)
is defective. In either case,
replace starter and solenoid as
an assembly.

Page 13
Engine and Controls (cont.)
Engine will not start. Starter g. Internal seizure If all engine starting components
will not crank engine are good and the starter is
(continued). unable to crank the engine,
internal seizure is indicated.
Attempt to hand-crank the
engine, using a socket wrench
with long flex handle on the
crank shaft pulley screw. If the
engine cannot be turned a
complete revolution, remove
engine and disassemble to find
damage and cause.
2. Engine will not start. Cranking a. Low battery output or faulty Check battery and starter.
speed low. starter. Recharge, repair, or replace.
b. Loose starting circuit Check all connections and
connections or faulty cables. cables. Tighten or replace as
required.
c. Improper lubricating oil Check oil. See Sect. 2-1, Para.
viscosity. 3, D, (3).
3. Engine will not start. Cranking a. No fuel. Before attempting to find the
speed normal. cause of “no fuel”, prime the
fuel filters by removing pipe
plug in the cover of each. Fill
each filter with fuel oil. If the
engine will not start after
priming, mechanical pump
trouble is indicated. If the
engine starts and then stops
after a short time, trouble
between the fuel source and
the suction side of the pump is
indicated. Check and/or remedy
as follows (see Fig. 7).
b. Low compression which Check compression in
may be caused by any of accordance with Para. 9, C and
the following: D.
c. Sticking or burned exhaust Cylinder head must be removed
valves . and overhauled to correct this
condition.
d. Compression rings worn or Check rings in accordance with
broken. Para. 9, E, (1).
e. Cylinder head gasket Check gasket in accordance
leaking. with Para. 9, E, (2).

Page 14
Engine and Controls (cont).
Engine will not start. Cranking f. Improper valve clearance Check and adjust valve
speed normal. (cont.) adjustment. clearance in accordance with
instructions in Detriot Diesel
Operator’s Manual.
g. Blower not functioning. Inspect blower drive shaft and
drive coupling. Replace parts as
required.
4. Engine starts. Stops after a a. The shut-down circuit may Reset shut-down valve latch (7,
few seconds by automatic have functioned normally to Fig. 3). Start the engine and
shut-down. stop the engine because of observe oil pressure gage. if
low lubricating oil pressure. pressure is less than 12 PSI,
stop engine at once and check
for cause of low pressure.
Repair as required..
b. Defective low oil pressure Reset shut-down valve latch (7,
switch (1, Fig. 4). Fig. 3). Disconnect ORANGE
wire at low oil pressure switch.
Start engine. Observe oil
pressure. If pressure is 38 PSI,
or more, check voltage from oil
pressure switch terminal (one
which had ORANGE wire
removed) to ground. If
approximately 12-V DC is
indicated, the oil pressure
switch is defective. Stop engine
and replace switch (1, Fig. 4).
c. Defective or incorrectly Check wiring to high
wired high temperature temperature switch. Two
switch (2, Fig. 4) yellow-blue wires should be
connected to N.O. terminal.
Yellow wire should be
connected to C terminal. Check
resistance between terminals N.
O. and C with wires removed.
Infinite resistance indicates a
good temperature switch. A
readable resistance indicates a
defective switch. Replace
switch.
5. Engine runs at idle speed. a. Lamp defective. Replace lamp.
Engine “ON” indicating light
(27, Fig. 1) does not glow.
b. Indicating light body poorly Be sure light is grounded
grounded. properly.
c. Defective fuel pressure Check switch. Replace if
switch (5, Fig. 4). defective.

Page 15
Engine and Controls(cont.)
6. Engine will not come “up” to a. 12-V DC power not Apply 12-V DC directly to
governed speed in GEN mode. reaching governor control terminal “1" on governor control
box for following reasons: box. If engine comes-up to
speed, check
following:
b. Engine circuit fuse (26, Fig. Replace fuse (10 Amp).
1) is blown.
c. Oil pressure switch (S53) Check switch and replace if
(located behind oil gage) is defective.
defective.
d. Defective operating mode Check switch. Replace if
switch (18, Fig. 1) defective.
e. Governor linkage binding or Check governor linkage and
governor throttle sticking. throttle shaft for binding and
sticking. Repair as required.
f. Defective or mis-adjusted The control unit may not be
magnetic pickup. receiving a signal from the
magnetic pickup and the “fail
-safe” feature of the unit may be
functioning to prevent any
signal from reaching the
actuator. To check the mag-
netic pick-up, disconnect pickup
from control unit and connect a
high impedance AC voltmeter to
the pickup output leads. Crank
engine but don’t start. Voltage
reading should be a minimum of
(1) volt. If no voltage or low
voltage is indicated, check
pickup adjustment [See 2-3,
Para. 4, E, (2)]. If pickup is
properly adjusted and voltage is
still zero, replace pickup.
g. Defective actuator. Apply 12-V DC to the two
actuator input leads. Actuator
lever should move immediately
to full speed position. If lever
does not move, replace actuator

Page 16
Engine will not come “up” to h. Defective control unit. Connect a DC voltmeter to the
governed speed in GEN mode. leads from the control unit to the
(Continued) actuator. Start the engine and
manually control speed. At
speeds below governed speed
the voltmeter should indicate
within two (2) volts of the
system voltage. If voltage is at or
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 the
Barber-Coleman Handbook for
control unit bench tests and
adjustments.
7. Engine goes to overspeed a. Governed speed control Turn speed control adjusting
when control switch (18, Fig. 1) adjustment set too high screw 22 turns counterclock-
is in GEN position. (see 2-3, Fig. 11). wise. Start engine. Place
control switch (18, Fig. 1) in
GEN position. If engine speed
is now well below governed
speed, turn adjusting screw
clockwise until correct speed
(2000 RPM, 400 Hz) is
reached. If engine still goes to
overspeed, proceed to step B.
b. Defective linkage or Check governor linkage and
actuator. actuator for sticking or binding
in full-speed position. Repair as
required.
c. Defective control unit. Replace control unit. Check unit
in accordance with Barber-
Colman operating instructions.
8. Engine is unsteady (surges) a. Fault in engine. Before condemning the
under load. governor system for surging,
make certain the fault is not in
the engine. Make certain all
cylinders are firing properly and
air and fuel supply is proper.
b. Governor system faulty or Check and adjust as follows:
mis-adjusted.

Page 17
c. Loose or binding governor

d. Check linkage ball joints and all
linkage. connections for looseness or
binding. Be sure linkage will
move from idle speed to full
speed without lost motion or
binding.
e. GAIN and STABILITY Adjust GAIN and STABILITY
controls improperly controls on control unit in accor-
adjusted. dance with 2-3; Para. 4, E, (3).
f. Magnetic pickup signal Check and adjust pickup. See
weak. 2-3, Para. 3, E, (2).
9. Engine has slow response time. a. Governor control unit Adjust. See 2-3; Para. 3, E, (3).
improperly adjusted.
b. Actuator linkage binding. Inspect and repair as required.
c. Engine needs tune-up. Tune up as required. Refer to
Detroit Diesel Operator’s
Manual.
10. Engine “misses”. Runs a. Insufficient fuel. Check fuel flow in accordance
unevenly. with Para. 9, F. Repair or
replace parts as required. Also
see ENGINE, Trouble 3.
b. Faulty injector. Check injectors in accordance
with Para. 9, B.
c. Low compression pressure. Check compression in accor-
dance with Para. 9, C. See
causes of low compression
listed under ENGINE, Trouble
3, B, above.
11. Engine lacks power. a. Improper engine “Tune-up” the engine in
adjustment and gear train accordance with Detroit Diesel
timing. Operator’s Manual.
b. Insufficient fuel. See ENGINE, Trouble 3.
c. Insufficient inlet air. Check as follows:
d. Damaged air cleaner. Check air cleaner for “plugging”
and/or other damage.
e. Defective blower to-cylinder Replace the gasket if
block gasket necessary. If the blower is
removed, install a new gasket.
f. Plugged cylinder liner ports. Clean ports if they are over
50% obstructed.
g. Faulty air blower. Repair or replace.
h. Worn Engine. See engine overhaul
instructions in engine manual.

Page 18
Generator and Excitation Circuit
1. No (or low) generator output a. Defective generator or The first check is an easy one
voltage in all phases. excitation circuit. which will allow the mechanic to
Generator operating at 400 Hz reach some definite conclusions
in AUTOMATIC mode. about where the trouble is. Place
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
circuit. Proceed to step C. If
switching to MANUAL control did
not affect generator output, the
trouble is likely in the generator,
but to prove the generator is
defective, proceed to step B.
b. Defective generator. Use the test receptacle (31,
Fig.. 1) to connect ungrounded
CAUTION: DO NOT use 12-V DC to the exciter field.
battery on unit to flash field Using leads with alligator clips
with generator turning and test prods, connect 12-V
voltage regulator. Damage DC NEGATIVE lead to terminal
results from the introduced “D”. Terminal identifying letters
ground are plainly visible on the face of
the test receptacle. Connect
POSITIVE lead to terminal “F”.
If no output voltage change is
indicated when the exciter field
is energized, the generator is
defective.
Stop operations and see 2-3,
Para. 4 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.
c. Defect in VOLTAGE REG. Check as follows:
excitation circuit.
d. Defective AUTO-MANUAL Check the switch thoroughly. A
switch (33, Fig. 1) defective switch may prevent
current reaching and/or leaving
the voltage regulator. Replace
switch if defective.
e. Defective excitation Check EDR contacts. A faulty
deenergization relay (K16) EDR can prevent power from
(1-1; 3, Fig. 8). reaching the voltage regulator.
Replace relay if defective.

Page 19
Generator and Excitation Circuit (cont.)
No (or low) generator output f. Defective ballast resistor(s), If output voltage was produced
voltage in all phases. (See Fig. 5). when the generator set was
Generator operating at 400 Hz operated in MANUAL mode, the
in AUTOMATIC mode. resistors are good. If no voltage
(Continued) was produced in MANUAL
mode, resistors could be
defective. Refer to Fig. 5 and
connect a jumper lead across
the ballast resistors. If an output
voltage is now produced,
replace resistor(s) as required.
g. Defective Amphenol Disconnect voltage regulator
connector at voltage Amphenol connector (see 1-1;
regulator, or defective Fig. 12). Using jumper leads
wiring from regulator to with clip and prod terminals,
exciter field. connect ungrounded 12-V DC
to terminals “E” and “C” in loose
plug. Connect NEGATIVE to
terminal “E”. Connect
POSITIVE lead to “C” terminal
(See Fig. 6).
If the generator will NOT
produce a normal voltage,
replace or repair Amphenol
connector and wiring between
voltage regulator and exciter
field as required.
h. Defective voltage regulator. All components in the 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 if the
magnetic amplifier regulator
430391C is used. If solid state
amplifier 489812A is used,
replace PC board.

Page 20
Generator and Excitation Circuit
2. No (or low) output voltage a. Defective generator Place AUTO-MANUAL control

when operating in MANUAL manual control excitation switch (33, Fig. 1) in AUTO
mode. circuit. position. If a normal voltage is
NOT produced, perform checks
as instructed in GENERATOR
AND EXCITATION CIRCUIT
TROUBLE 1, above. If a normal
voltage is produced, proceed to
step “B” below
b. Defect in manual voltage Check as follows:
control portion of excitation
circuit.
c. Defective AUTO-MANUAL Check contacts and operation
switch (33, Fig. 1). of AUTO- MANUAL switch.
Replace if defective.
d. Defective rectifier (CR3) Check diodes (see 2-3, Para..
(Sect. 1-1; 14, Fig. 8). 6). Replace rectifier if defective.
e. Defective resistor (R11) Jumper resistor (1, Fig. 5). If
(See 1, Fig. 5). normal voltage (depending on
rheostat) is produced, replace
resistor.
f. Defective rheostat (R61) Connect a jumper across
(32, Fig. 1) rheostat. If maximum (manual
control) voltage is produced,
replace rheostat.
3. Load contactor (K1) will not a. In addition to defective After checking fuse (F1) in step
close when control switch (20, wiring and connections in (1) below, check all wiring and
Fig. 1 is held in CLOSE the AC and DC load connections in the load
position. Generator running at contactor actuating circuits, contactor circuits on the engine
normal voltage. No fault lights the load contactor may be control panel, the protective
on. prevented from closing for relay tray and power module.
any of the following reasons: Then check components as
follows:
b. Blown fuse (F1) )1-1; 16, Remove and inspect fuse.
Fig. 9) Replace if blown.
c. Defective (open) relay in Use a jumper with clip and prod
protective module (1-1; 4, terminals to GROUND terminal
Fig. 9). “H” in the test receptacle. If
contactor will now close,
replace module or complete
protective relay tray (12, Fig. 1)

Page 21
Load contactor (K1) will not d. Defective load contactor Set AUTO-MANUAL switch (S1)
close when control switch (20, control switch (S5) to AUTO position. connect a
Fig. 1 is held in CLOSE (20, Fig. 1). jumper with test prods between
position. Generator running at terminals “S” and “R” on the test
normal voltage. No fault lights receptacle. If the contactor
on. (cont.) closes, replace control switch.
e. Defective rectifier (CR6) Check rectifier output as follows:
1-1; 5, Fig. 11).
With test receptacle terminals
“S” and “R” connected as above,
check voltage to rectifier
between terminals “R” and “H”.
Voltage should be 115-V AC.
With test receptacle terminals
“S” and “R” connected as above,
check rectifier output at load
contactor terminals X and Y. If
voltage is not at least 90 V DC,
replace rectifier.
Defective load contactor coil
(K1) )1-1; 6, Fig. 11)
Disconnect leads at load
terminals W and V. Check coil
resistance between these
terminals. Resistance should be
approximately 50 ohms. If coil is
defective, replace the complete
load contactor.
4. Load contactor (K1) will close a. 28.5-V DC is not reaching Check voltage at terminal Z on
when control switch (20, Fig. 1 plug-interlock relay (K2) test receptacle. Voltage should
is held in momentary CLOSE from aircraft for the be 28.5-V DC. If not, voltage is
position. Opens immediately following reasons: not being supplied from aircraft.
when switch is released to Check causes as follows:
center ON position.
b. Generator to aircraft cable Inspect cable connector plug
connector defective or not thoroughly for damaged E and
plugged into aircraft F terminals. Be sure the plug is
receptacle connector. fully mated with the aircraft
receptacle connector and
making good contact.
c. Aircraft rejecting power. Check aircraft on board
electrical equipment and
controls.

Page 22
Load contactor (K1) will close d. “Blown” fuse (F2) (1-1; 17, Press lamp test switch (8, Fig.
when control switch (20, Fig. 1 Fig. 9) in protective relay 1). If lamps do not glow, replace
is held in momentary CLOSE tray. fuse (F2).
position. Opens immediately
when switch is released to
center ON position. (cont.)
e. Defective plug-interlock Place test-bank switch (S2) (34,
relay (K2). Fig. 1) in ON position. If load
contactor will now remain
closed, replace the
plug-interlock relay (K2) (Sect.
1-1; 1, Fig. 9) or the complete
protective relay tray.
f. Small contacts in load Connect a jumper lead between
contactor (K1) defective. small terminals N.O. and C on
the load contactor. If the load
contactor will now remain
closed, replace the complete
load contactor (K1).
g. Defective fuse interlock Open protective relay tray and
relay (K 17) or resistor connect a jumper across the
(R46). resistor (R46) (Sect. 1-1; 21
Fig. 9). If the contactor will now
remain closed, replace fuse
interlock relay (K17) (Sect. 1-1;
2, Fig 9) or replace the
protective relay tray assembly.
5. Load contactor opens during a. Fuse (F1 or F2) blown. Remove and inspect fuses (1-1;
power delivery. NO fault 16 and 17, Fig. 9.) Replace as
indicating lights on. required.
b. A fault has developed in the If the load contactor cannot be
load contactor holding closed by operation of the
circuit. control switch (S5) (20, Fig. 1),
check the circuit in accordance
with instructions 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 Reconnect cable.
disconnected from aircraft.

Page 23
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 troubleshooting 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 before commencing each test.
1. Load contactor opens during a. The over voltage condition Use voltage adjusting rheostat
power delivery. Overvoltage may have been the result of (37, Fig. 1) to reduce voltage to
indicating light ON. a sudden drop in the load, 110-V AC. Observe voltmeter
or possible tampering with and gradually increase voltage
voltage regulator with rheostat. If the
adjustment potentiometer over-under-voltage sensing
(37, Fig. 1 ), and may have module (K26) functions to open
been a normal action. the load contactor at any value
less than 130-V AC, it is
defective. Replace
over-under-voltage module or
complete protection relay tray.
b. Defective protective monitor If overvoltage light comes on at
module (K14). 110-V, unplug over-under
voltage module and close
contactor. If the Overvoltage
light comes on, the protective
monitor module (K14) is
defective.
NOTE: it is normal for the

undervoltage light to come on
during this test.
2. Load contactor opens during a. An undervoltage condition Observe generator voltage on
power delivery. Undervoltage caused the over-under- voltmeter and adjust to normal
indicating light ON. voltage sensing module 115-V AC with voltage regulator
(K26) to function normally. adjustment potentiometer (37,
Fig. 1). Resume normal
operation. If the load contactor
opens again and an under-
voltage condition is indicated by
light (DS38) proceed to step B.
b. Defective over-under- Use voltage regulator
voltage module (K26). adjustment potentiometer(38,
Fig. 1) to reduce voltage to
104-V. Wait 12 seconds. The
undervoltage indicating light
should NOT be turned on. If the
light is turned on, the
undervoltage relay is defective.
Replace the module (K26) or
the protective relay tray.

Page 24
Protective Circuit (Continued)
Load contactor opens during c. Defective protective monitor With unit running normally, use
power delivery. Undervoltage module (K14). voltage regulator adjustment
indicating light ON. (Continued) potentiometer ( 37, Fig. 1 ) to
reduce voltage quickly to 90-V. If
the light is turned ON
immediately, the protective
monitor circuitry is defective.
Replace the protective relay tray.
3. Load contactor opens during a. Electric governor Proceed as follows:
power delivery. Overfrequency improperly adjusted, or
indicating light (DS 40) ON. malfunctioning.
b. Governor improperly Adjust in accordance with Sect.
adjusted. 2-3, Para. 3, E, (3).
c. Electric Governor System Check and adjust or repair in
Malfunctioning. accordance with ENGINE AND
CONTROLS Troubles 8 and 9.
d. Defective If overfrequency nuisance
over-under-frequency tripping continues after
sensing module (K27). governor system is proven to
be good, and an overfrequency
condition does not exist,
replace over- underfrequency
module (K27), or complete
protective relay tray.
4. Load contactor opens during a. Electric governor Proceed as follows:
power delivery. Under- improperly adjusted, or
frequency light (DS39) ON. malfunctioning.
b. Governor Improperly Adjust in accordance with Sect.
adjusted. 2-3. Para. 3, E, (3).
c. Electric governor system Check and adjust or repair in
malfunctioning. accordance with ENGINE AND
CONTROLS Troubles 8 and 9.
d. Defective over-under If overfrequency nuisance
frequency sensing module tripping continues after
(K27). governor system is proven to
be good, and an under
frequency condition does not
exist, replace over- under
frequency module (K27), or
complete protective relay tray.
5. Load contactor opens during a. There may have been an Observe ammeter ( 4, Fig. 1 ).
power delivery. Indicating light overload condition which Check for abnormal overload
ON. caused the overload device condition and correct. If
(k4) to function normally. overload device functions too
open the load contactor when
an overload does not exist,
proceed to step B.

Page 25
Protective Circuit (Continued)
Load contactor opens during a. One of the resistors (R26, An open resistor will cause a
power delivery. Indicating light R27 or R28) across higher than normal Voltage.
ON overload transformer is Check Resistors (Sect. 1-1; 1,
open Circuited. Fig. 13). Replace if defective.
b. Overload device printed With unit off, measure
circuit board defective. resistance between terminals B
and E, Fig. 8. If zero ohms
resistance is measured, replace
Overload device (K4)(Section
1-1; 7, Fig. 11).
Generator
1. No (or low) voltage output. a. Shorted diode in exciter Check diodes in accordance
rectifier (CR2). with sect. 2-3, Para. 6 If diodes
are good, proceed to step B.
b. Open or shorted exciter Use ohmmeter to check for
rotor winding (G2). open or shorted condition. If
rotor windings are good,
proceed to step C.
c. Open or shorted exciter Check for field resistance. See
field windings (L2). Sect. 2-3. Fig. 14 for normal
values.
d. Open or shorted generator Check resistance with
rotor windings (L1). ohmmeter to determine if open
or short circuited.
2. Generator operates single a. An open or short circuited Check stator winding
phase. winding in generator stator resistances. See Sect. 2-3, Fig.
(G1). 12 for normal values.
3. Generator overheats. a. Loose connection causing Check all output connections for
high resistance. looseness. Look for
discoloration caused by heat.
Tighten or replace as required.
b. Improper or blocked Check for foreign materials
ventilation. (rags, etc.) blocking air flow.
Provide adequate ventilation.
c. Check Stator windings Check Stator windings. See
short circuited. Sect. 2-3, Fig 12.

Page 26
Generator
1. Unbalanced output. a. Loose connection in output Check all output connections,

circuit. Discolored connectors indicate a
loose connection. Tighten or
replace as required.
b. Open or short circuited Check stator windings in
stator Phase. accordance with Sect. 2-3,
Para. 4. Repair or replace as
required.
c. Defective connection in Check plug and receptacle
output circuit. connectors at aircraft. Tighten,
Repair or replace as required.
d. Unbalanced load. Check aircraft 400-Hz
components.

Page 27

Page 28
Section 5. Voltage Regulator
1. Unit Assembly
The 430391C voltage regulator (Figure 1) is designed to provide 1% voltage regulation with 0.25 second
recovery time for all loads up to 100% of rated load on a three-phase, four-wire 115/200 volt, 400-Hz
brushless alternator. This regulator provides field excitation power for a rotary exciter and regulates
alternator voltage by varying the exciter field power as required to meet varying alternator load
conditions to hold the alternator voltage constant. The maximum continuous rating of this regulator is
4.0 amperes at 125-V DC. The voltage regulator consists of seven basic interconnected circuits. They
are:
(1) Voltage detection circuit
(2) Voltage comparison circuit
(3) Transistorized pre-amplifier
(4) Power stage full-wave single-phase magnetic amplifier
(5) Damping circuit
(6) Line drop compensation circuit
(7) Voltage build-up circuit
Any deviation of the alternator voltage from its set, regulated level is sensed by the voltage detection
and comparison circuits. A signal is fed from the comparison circuit into the transistorized pre- amplifier,
amplified, and used to drive the magnetic amplifier. The magnetic amplifier output changes in response
to this signal, changing the field power of the rotary exciter long enough to return the alternator voltage
to its regulated value. The voltage at which the alternator is regulated may be adjusted with the voltage
adjustment rheostat.
2. Components
Refer to Figure 1. Components of these basic circuits are mounted in two major subassemblies which
are the line drop compensation chassis assembly (6) and the sensing and pre-amplifier chassis
assembly (15). Receptacle connectors (7, 9, and 11) provide quick connect-disconnect facilities for
interconnecting wire leads. The two subassemblies are mounted on a chassis (18) along with other
main components of the regulator, which include a resistor (1), voltage adjusting rheostat (2), fuse (12)
and fuseholder (13), nineteen-pin receptacle connector (14), and reactor (17). (Field ballast resistors
and line drop current transformer loading resistors are located at a point remote from the voltage
regulator and are not supplied with the regulator).
3. Detailed Circuit Descriptions

a. Voltage Detection Circuit
Refer to schematic and connection diagrams at the end of this section. This circuit consists of three
single-phase transformers (T501, T502, T503), three diodes (CR501, CR502, CR503) connected as
a three-phase, half-wave rectifier, six diodes (CR504 through CR509) connected as three
single-phase, full wave center-tap rectifiers, and four blocking diodes (CR510 through CR513). The
transformer primaries are connected as a three-phase, four wire Y to the alternator output voltage.
The transformer secondaries are center-tapped with the center taps joined together to for a common
negative for the three single-phase rectifiers and the three-phase, half-wave rectifier. The filtered
output of each of the single-phase rectifiers is pro- portioned to a given phase voltage. The output of
the three-phase, half-wave rectifier is pro- portioned to the average of the three generator phase
voltages. The positive outputs of the three single-phase rectifiers are connected to a common point
through blocking diodes (CR511 and CR513). Part of the three-phase, half-wave rectifier voltage, as
determined by the ratio of the resistors (R501 and R502) is connected through blocking diode CR510
to this same point. The blocking diodes prevent current flow from one of the four rectifiers into the
filter circuit of any other rectifier.

Page 1
The functions of the voltage detection circuit are to provide a filtered DC voltage proportional to the
alternator voltage and to sense the highest single alternator phase voltage if the phase voltages are
not balanced. The three-phase, half-wave rectifier senses the average phase voltage, and the three
single-phase, full-wave rectifiers each sense a single phase. Resistors (R501 and R502) are scaled
such that the portion of the three-phase half-wave fed through the blocking diode (CR510) is slightly
higher than the three single-phase outputs when the alternator phase voltages are balanced. If the
three phase voltages are not equal, the rectifier voltage corresponding to the highest phase voltage
is higher than the average voltage signal. The output of the voltage detection circuit is thus a filtered
DC voltage proportional to the average alternator phase voltage if the voltages are not balanced.
1. Resistor 11. Receptacle connector

2. Regulator 12. Fuse
3. Cable length compensation rheostat 13. Fuseholder
4. Cable size compensation rheostat 14. Receptacle connector
5. On-off switch 15. Sensing and pre-amplifier chassis assembly
6. Line drop compensation chassis assembly 16. High-phase sensing board assembly
7. Receptacle connector 17. Reactor
8. Damping circuit gain potentiometer 18. Chassis
9. Receptacle connector 19. Terminal board
10. Damping circuit rate potentiometer 20. Instruction label
Static Voltage Regulator
Figure 1

Page 2
b. The Voltage Comparison Circuit

The comparison circuit is a simple voltage reference bridge consisting of three fixed resistors (R506,
R508, R509), a potentiometer (R571) and a reference diode (VR501). These components are
connected to form a bridge in which the DC output of the voltage detection circuit is compared to a
fixed voltage reference. A voltage proportional to the difference between the reference and the input
voltage to the bridge appears between the slider of the potentiometer and the positive side of the
reference diode. This voltage is a function both og the generator voltage and the position of the
potentiometer slider.
The function of the voltage comparison circuit is to compare part of the DC output voltage of the
detection circuit with a fixed DC reference voltage and derive from their difference a signal suitable
for driving a DC amplifier. It is in this circuit that the voltage at which the alternator regulates is
established. Varying the position of the slider on the potentiometer changes the fraction of the
voltage compared to the reference and varies the driving signal to the DC amplifier.
c. The Transistor Pre-Amplifier
The pre-amplifier consists of two transistors (Q501, Q501), two resistors (R507, R511), a zener
diode (VR502), a ‘freewheeling" diode (CR514) and a filter capacitor (C505). These components are
connected in a two-stage DC amplifier circuit obtaining power from the three-phase, half-wave
rectifier of the voltage detection circuit and using the power to drive the control winding of the
magnetic amplifier in response to a signal from the voltage comparison bridge. Resistors (R507 and
R511) limit the transistor currents to safe levels, the filter capacitor keeps the ripple low in the input
signal, and the zener diode and “freewheeling” diode protect the output transistor from the voltage
spikes from the reactor control coil. The transistorized pre-amplifier amplifies the output signal from
the voltage comparison circuit and drives the magnetic amplifier with this amplifier output.
d. The Power State Fule-wave, Single-phase Magnetic Amplifier
This circuit consists of a single-phase, full-wave reactor (L505) and a full rectifier (CR531 through
CR534) connected to a self-saturating magnetic amplifier. The saturable reactor has two load
windings (1-2, 3-4) on separate cores and two control windings (5-6, 7-8) linking both cores.
The load windings are connected with the rectifiers in such a manner that only one of the load
windings conducts for each half cycle of alternator voltage. This results in a net DC voltage on each
reactor load winding, causing the reactor cores to saturate in the absence of a control signal. The
control winding is driven with DC power in such a manner to oppose this self saturation, partially or
completely desaturating the amplifier cores in response to the pre-amplifier output.
The magnetic amplifier rectifies AC voltage from the alternator and uses the DC voltage thus
obtained to excite the rotary exciter in response to a control signal from the DC pre-amplifier. The
impedence of the reactor load windingsin series with the magnetic amplifier rectifier, is varied by the
control signal to control exciter field power.
e. The damping circuit
The damping circuit includes a transformer (T504), a limiting resistor (R510), a variable resistor
(R551), a potentiometer (R572), and two capacitors (C506 and C507). The transformer primary is
connected to the regulator output through resistors (R510 and R551). The transformer secondary is
connected across the potentiometer. That part of the potentiometer between the slider and one end
is in series with the input of the transistor pre-amplifier and is filtered by one of the capacitors. The
other capacitor connects from the positive side of the voltage comparison circuit to the potentio-
meter.
The damping circuit detects changes in the regulator output and feeds energy pulses opposing the
changes into the transistor pre-amplifier. The damping circuit affects the transient behavior of the
regulated alternator system, preventing hunting, oscillation, and excessive overshoot of the alternator
voltage following load changes. The damping rheostat affects mostly the amplitude of the damping
signal. The rate potentiometeraffects both phasing and amplitude of the signal. Capacitor (C506)
serves to shift the phase of the sensing signal, reducing the system response time.

Page 3
f. The Line Voltage Drop Compensation Circuit

The line drop compensation circuit consists of a current transformer (T1, T2, T3) on each phase of
the load circuit, a fixed inductance (L506, L507, L508) and variable resistance (R553) in series with
each of the three phase lines leading to the voltage detection circuit, a toggle switch (S502) for
bypassing the line drop compensation, a variable resistance (R554) in series with each current
transformer input to the regulator and fixed resistance in parallel with each current transformer. Each
of the three current transformer secondaries are connected through a variable resistor to the fixed
inductance and other variable resistors.
The current transformers detect the magnitude and power factor of current flowing through the power
cables from the alternator to its load and feed a signal into the resistance with inductance ahead of
the voltage detection circuit opposing the voltage sensed by that circuit. The voltage actually sensed
by the detection circuit is therefore lower than the actual alternator voltage by an amount proportional
to the magnitude and power factor of the load current and thus proportional to the voltage drop
between the alternator and its load. The regulator output increases slightly so that the alternator
output voltage is equal to the regulated voltage plus the voltage drop in the liness. The variable
resistances may be adjusted to match exactly the impedance of the power cables carrying the load
current.
g. The Voltage Build-Up Circuit
The voltage build-up circuit of a relay (K501) with normally closed contacts connected across the
load windings of the power reactor and a resistor (R12) in series with the relay coil. When the
machine is first started, the alternator voltage from residual magnetism is applied through the relay
contacts and the magnetic amplifier rectifier to the exciter field circuit. This causes the exciter
voltage to increase and makes the alternator voltage build up. When the alternator voltage rises high
enough to power the regulator, the relay coil, connected to the voltage detection circuit, is energized.
This actuates the relay and opens the normally closed contacts shunting the reactor load coils,
allowing the magnetic amplifier to control the exciter field power.
h. Terminal Board Circuit
This terminal board circuitry allows a signal from a Transformer-Rectifier (T-R), when used, to enter
the regulator and control generator output as required by the T-R load when the jumper lead (Shown
in Fig. 2) is disconnected. When the jumper lead is connected, the regulator functions normally as
controlled by signals from the line drop current transformer at the generator.
4. Installation And Preparation For Use

a. Installation
(1) General
a. This voltage regulator is designed primarily for drawer-type mounting. However, it is not
attitude sensitive and may be mounted in any position without affecting its operation. In some
installations it is mounted in what appears to be a backward position, which may make
reading the instruction plate for cable compensation adjustment somewhat difficult.
b. The regulator does not dissipate large amounts of power, but certain components, especially
the line drop compensator rheostats and regulator power transistor, need a reasonable
amount of air for convection cooling. For this reason, the regulator should not be mounted in
a small airtight enclosure which would prevent air circulation around the line drop chassis
assembly.
c. Four mounting holes (one in each corner of the main chassis) are provided for attaching the
regulator.
d. Position the regulator in its mounted location and install with appropriate attaching hardware
(nuts and/or screws, and washers)
(2) Connections
All electrical connections to the regulator are made through a nineteen pin receptacle connector
(14, Fig. 1) which is bracket mounted on the chassis.

Page 4
Terminal Board
Figure 2
b. Preparation for Use

No special preparation is necessary to place the regulator in service other than the following checks
and inspections:
(1) Check all terminal lug type connections for security.
(2) Check all plug and receptacle type connectors to make certain they are firmly mated.
(3) It may be necessary to adjust a new regulator at initial start-up after installation.
5. Operating Procedures
This voltage regulator requires no start, stop, or extensive operating instructions. For initial start-up
procedures, refer to Section 1-3 of this manual.
6. Adjustment Procedures
a. General
When a voltage regulator is first put into service, or when output (generator-to-aircraft) cables are
changed, the regulator may require as many as five separate adjustments. The five adjustments are
for (1) generator output voltage value, (2) cable length line drop compensation, (3) cable size line
drop compensation, (4) “rate” adjustment, and (5) “damp” adjustment. See Figure 3 for identification
of components used for regulator adjustment.
b. Adjust generator output voltage.
Perform this adjustment with the generator set operating at rated speed with no load applied. Rotate
the rheostat knob (1) CLOCKWISE to INCREASE voltage and COUNTERCLOCKWISE to
DECREASE voltage. Observe the AC voltmeter and adjust output voltage to 115 V AC.

Page 5
c. Adjust Line Drop Compensation for Cable Length

Adjustment of line drop compensation magnitude is made with the knob marked “Foot
Compensation” (2) on the line drop compensation module. The knob dial is calibrated for
approximate cable length in feet. The “Foot Compensation” knob controls a rheostat which limits the
current flowing in the compensation circuit. The setting of the rheostat resistance determines the
magnitude of the compensation. Rotating the knob clockwise increases the magnitude of the
compensation, and rotating it counterclockwise decreases the magnitude. To adjust the line drop
compensation gain, proceed as follows:
(1) Connect the generator output cables to a balanced, three-phase load of 30 kilowatts.
(2) Make sure that the line drop compensation switch (4, Fig. 3) is in the ON position.
(3) Set the “Foot Compensation” knob to a dial setting corresponding to the length of the output
cables being used.
d. Adjust Line Drop Compensation for Cable Size
The compensation circuit must be adjusted to match not only the voltage drop in the power cables to
the load, but must be adjusted to match the phase of the voltage drop. This is done by adjusting the
relative magnitude of the reactive and resistive compensation with the “Cable Size” knob (3). This
knob is calibrated incable sizes and controls a varied resistance in series with a fixed reactance. The
power factor of the compensation circuit is varied by varying the resistance and leaving the
reactance constant. Rotating the knob clockwise increases the resistive component of the
compensation circuit and simulates a smaller cable. Rotating the knob counterclockwise decreases
the resistive component of the compensation. Adjust line drop compensation phase as follows:
(1) Set the “cable size” knob (3) to a dial setting corresponding to the size of the output cables.
(2) Re-adjust the generator voltage control (2) to the desired value if the line drop compensation
adjustments have affected the no-load voltage output.
(3) Load the machine the machine with the largest available three-phase load of rated power factor
not exceeding the maximum rating of the machine. If the load voltage rises or drops more than
one percent (1%) at the load end of the cables, decrease or increase the setting of the load “Foot
Compensation” knob until the regulation is flat.
(4) Load the machine the machine with the largest available three-phase unity power factor load
within the rating of the machine. IF the voltage rises or drops more than one percent (1%) at full
load, adjust the “Cable Size” setting until flat regulation is obtained. If it is necessary to adjust
the cable setting, repeat step (3) above.
e. Adjust Damping Gain
The gain adjustment for the damping circuit is a 1500 ohm variable resistance (R551) in series with
the primary winding of the damping transformers. This resistor is in the form of a screwdriver-
adjustable potentiometer (7, Fig. 3) with a locking nut, located on the right side of the end of the
sensing andd preamplifier assembly. Turning the potentiometer screw clockwise increases the
resistance, decreasing the system damping, and making the regulator less stable. Turning the
adjustment screw counterclockwise decreases the resistance, improving regulator stability, but
slowing regulator response. This resistance is set at the factory for satisfactory response times, and
should not ordinarily require adjustment. However, if adjustment becomes necessary, proceed as
follows:
(1) Loosen the potentiometer adjusting screw locknut.
(2) Connect the generator output to a balanced, three-phase load of 30 kilowatts.
(3) With generator running at 115-V AC no load, operate the contactor “on-off” switch on the engine
control panel.
(4) Turn the adjusting screw counterclockwise with a screwdriver to improve generator output
stability.
(5) Turn the adjusting screw clockwise to decrease regulator response time. Best adjustment is
approximately 3/4 of full travel clockwise.
(6) Tighten the locknut securely after the adjustment has been completed.

Page 6
f. Adjust Damping Rate

The rate adjustment is a potentiometer (8) is a potentiometer connected across the secondary oo the
damping transformer. Both the amplitude of the damping signal and its phasing are affected by this
potentiometer. Because of this, a relatively large change in system performance is obtained with a
relatively small change in its setting. When the screw is turned fully counterclockwise, the amplitude
of the damping signal fed into the transistor preamplifier is at a minimum. When the screw is set fully
clockwise, the signal is at maximum. The system may be unstable with this potentiometer set at
either maximum or minimum because of the phase shift. The potentiometer is set and locked at the
factory for good system transient response and should not need further adjustment. If the
potentiometer does need adjustment, proceed as follows:
(1) Loosen the adjusting screw locknut.
(2) With a dcrewdriver, turn the adjusting screw to near its full counterclockwise position.
(3) Turn the adjusting screw slowly clockwise while observing generator output voltage on the
generator voltmeter. The generator output voltage will oscillate until a certain point of adjustment
is reached, at which it will abruptly become steady. The best adjustment for the system will
usually be reached when the screw is turned just slightly (5o to 10o) beyond this point in a
clockwise position.
(4) Tighten the locknut securely after the adjustment has been completed.
g. Test the Voltage Regulator
After necessary adjustments have been completed, test the regulator as follows:
(1) Connect a voltmeter at the load end of the generator output cables.
(2) Operate the machine at no load and observe voltage reading.
(3) Operate the machine under load and observe voltage reading. Voltage under load and no load
should vary no more than 1% at the load end of the cables.
NOTE: The panel mounted voltmeter will indicate a higher voltage than indicated by a voltmeter at the
load end of the output cables. The amount of variance will depend upon cable length and size.
1. Voltage adjusting rheostat

2. Cable length compen-
sation rheostat
3. Cable size compensation
rheostat
4. On-Off switch, line-drop
compensation
5. Fuse (5-Amp)
6. Fuseholder
7. Damp (gain) adjusting
potentiometer
8. Rate adjusting
potentiometer
Voltage Regulator
Adjustments
Figure 3

Page 7
Voltage Regulator Damping Adjustments

Figure 4

Page 8
7. Maintenance Procedures
a. Inspection
(1) General
Inspect the voltage regulator periodically, at the same time other inspections of the generator set
are made.
(2) Inspect Connectors and Terminals
a. Inspect connectors for full engagement.
b. Inspect terminals for security.
(3) Inspect Wiring
Inspect wire insulation for cracks and damage.
(4) Inspect Attaching Parts
Inspect attaching hardware for security
(5) Inspect regulator fuse. When replacing this fuse, replace it with the EXACT SAME type and
rating of fuse.
b. Cleaning
WARNING
Electric shock can kill! Remove power before cleaning regulator.
A. Make certain that compressed air is clean and dry.
B. Do not use flammable or conductive cleaners.
C. Exercise care to avoid damage to components.
Under normal operating conditions, very little cleaning is required; however, when operating
under dusty conditions, it may be necessary to periodically clean the regulator with compressed
air.
c. Painting
(1) General
Only the sheet metal components of the voltage regulator are painted. Electrical and electronic
components should never be painted.
(2) Preparation for Painting
a. Remove regulator from control box (or from its mounted position) and place it on a clean
workbench.
b. Disassemble as required to remove the component (s) to be painted.
c. Prepare the surface to be painted by sanding. Remove all rust.
d. Use tape to mask any electronic or electrical components not removed in step (2) above.
e. Prime all bare metal surfaces with red oxide primer, Hobart No. 903318, or equivalent.

Page 9
(3) Painting the Unit

a. Make certain that all surfaces are clean and dry.
b. Paint all prepared surfaces with gray enamel paint, Hobart No. 903316, or equivalent.
d. Repair
For the convenience of maintenance personnel, this voltage regulator is designed to be trouble-free
and simple to put back into service once it has malfunctioned or if it is not functioning properly. Flight
line repair is usually limited to removal and replacement of the entire voltage regulator assembly, and
adjustments of the newly-installed voltage regulator if necessary.
For customers that have facilities that permit repair of voltage regulators, the regulators may be
repaired according to malfunctions disclosed through troubleshooting. Refer to the troubleshooting
procedure that follows:
8. Troubleshooting
Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the
exact cause is located. When looking for the cause of a trouble in a circuit or system begin at the
source of power or supply. Continue testing and checking the voltage regulator, step-by-step, in an
orderly manner, until the cause of trouble is located.
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 Troubleshooting Chart
The troubleshooting chart that follows is furnished to provide maintenance and repair personnel with
a time-saving guide for locating trouble. To use the chart, proceed as follows:
(1) Locate the symptom(s) of trouble in the “Trouble” column.
(2) Check the probable causes of trouble in the “Probable Cause” column.
(3) Test, check, repair, or correct the trouble as indicated in the “Remedy” column.
If the cause of a trouble is an uncommon one and cannot be located by use of the chart, start at the
source of power or supply and check the affected circuit or system completely. Use schematic and
connection diagrams supplied with this manual.
Electrical components mentioned in the troubleshooting chart are identified by a noun name and a
corresponding symbol which allows the user to identify the item more easily on schematic diagrams.
It is assumed that wiring and connections in defective circuits have been thoroughly checked before
condemning any other components.
NOTE: Reference symbols (S9, etc.), used in the Troubleshooting Chart, are identified on Schematic
and Connections Diagrams at the end of this section.
Following the troubleshooting chart is a list of electrical checks which may be performed to locate
defective components in the regulator. Use the list in conjunction with the schematic and connection
diagrams at the end of this section.

Page 10
1. Generator voltage will not build a. Fuse (F1) open. Replace fuse.
up to normal.
b. Shorted diode (CR531 Replace the shorted diode.
through C534).
c. Exciter field circuit shorted Repair as necessary.
or grounded.
d. Sensing and pre-amplifier Connect plug.
plug (P503 or P504) not
connected.
e. Generator field circuit open Restore continuity to field circuit.
f. Generator field circuit Replace defective resistor.
ballast resistor open.
g. Voltage build-up circuit Replace relay.
relay (K501) normally-
closed contacts open.
h. Generator residual voltage “Flash” exciter fields with 12-V
too low, or reversed. DC from a storage battery.
i. Shorted or open power
j. Replace defective diode.
diode (CR531 through
CR534).
2. Generator voltage builds up a. Voltage reference diode Replace diode.
until relay actuates, then falls (VR501) shorted.
back.
b. Pre-amplifier transistor Replace transistor.
(Q501 or Q502) shorted
c. Pre-amplifier diode (VR502) Replace diode.
shorted
d. Stability capacitor (C507) Replace capacitor.
shorted
3. Generator voltage builds to a a. Voltage build-up relay: Replace relay.
dangerously high level. 1. Coil open
Flashing relay does not 2. Contacts “welded”
actuate.
b. Line-drop coupling plug Connect plug securely.
(P502) not in socket.
c. Sensing diode (CR501, Replace diode and check
CR502, CR503) shorted. sensing trtansformers for
damage.

Page 11
4. Generator voltage builds to a a. Magnetic amplifier reactor Replace reactor.

dangerously high level; (L505) winding open.
flashing relay actuated, but
voltage is not controllable with
voltage adjusting potentio-
meter.
b. Line drop coupling plug Connect plug.
(P502) not in socket.
c. Damping potentiometer Replace potentiometer
(R572) open.
d. Voltage comparison Restore continuity.
potentiometer (R571) circuit
open.
e. Voltage comparison resistor Replace resistor.
(R509) open.
f. Voltage comparison Replace diode.
reference diode (VR501)
open.
g. Pre-amplifier transistor Replace transistor.
(Q501, Q502) open.
h. Pre-amplifier resistor (R507 Replace resistor.
or R511) open.
i. Pre-amplifier diode Replace diode and check
(CR514) shorted. transformers (T501, T502,
T503) for damage.
5. Poor voltage regulation when a. Voltage comparison resistor Replace resistor
generator is loaded (droop at (R506 or R508) open.
regulator input terminals more
than 1%).
b. Voltage sensing choke Replace choke.
(L501, L502, L503 or L504)
partially shorted.
c. Voltage sensing diode Replace diode.
(CR501 through CR509)
open.
d. Voltage comparison Replace diode.
reference diode (VR501)
has high dynamic
resistance.
e. Pre-amplifier transistor Replace transistor.
(Q501 or Q502) low gain.

Page 12
6. Generator voltage unstable. a. Damping transformer Replace transformer.

(T504) open.
b. Damping rheostat (R551) Adjust or replace rheostat.
incorrectly adjusted or open.
c. Damping resistor (R510) Replace resistor.
open.
d. Damping potentiometer Check continuity. If good,
(R572) incorrectly adjusted adjust. If not, replace
or open. potentiometer.
7. Voltage on one phase rises a. Voltage detection resistor Replace resistor.
above 130 volts, (R502) open.
line-to-neutral, with balanced
load.
b. Voltage detection trans- Replace transformer.
former (T501, T502, T503)
coils shorted or open.
c. Voltage detection choke Replace choke.
(L502, L503, L504) coil
open.
d. Voltage detection diode Replace diode.
(CR511, CR512, or CR513)
shorted.
8. Generator voltage becomes a. Voltage detection diode Replace capacitor and trans-
erratic. Smoke comes from (CR501 throuugh CR509) formers (T501, T502, and T503).
voltage detection transformers. shorted.
b. Voltage detection capacitor Replace capacitor and trans-
(C501 through C504) formers (T501, T502, and T503).
shorted
c. Checking the Voltage Regulator

(1) General
The following pages provide electrical checks which may be performed to locate defective
components in the regulator. Use the list in conjunction with the schematic and connection
diagrams at the end of this section.
(2) Conditions for Check
a. The generator must have no load other than the regulator.
b. Rhe voltage regulator must be regulated at 120 volts, with four-wire, three-phase voltage at
400-Hz.
c. A Triplett No. 630 volt-ohmmeter or equivalent is recommended for measuring voltages.
NOTE: The operating voltages listed in the chart were observedwhen the regulator was supplying low
amperes of direct current to the generator exciter fields. This current value may be different for
some installations of the regulator and, consequently, the voltage check values may vary slightly.

Page 13
Reference Location for

Designator Component Voltage Measurement Voltage Value
C501 Capacitor, 3mF, 50-Volt Across Capacitor 16.0 V-DC
C507 Capacitor, 20mF, 50-Volt Across Capacitor Too low to read
CR501 Diode, IN4820 Across Diode 16.8 V-DC
CR531 Diode, S2040 Across Diode 33 V-DC
K501 Relay Across Relay Coil 13-0 V-DC
L501 Choke, 1CZ-93 Across Choke Coil 0.60 V-DC
L505 Reactor Accross Winding 1-2 140 V-AC, 0.4 V-DC
Accross Winding 3-4 140 V-AC, 0.4 V-DC
Accross Winding 5-6 6.0 V-AC, 0.38 V-DC
Accross Winding 7-8 11V-AC
L506 Choke, Line Drop Across Choke Coil 0.70 V-DC

Page 14

Q501 Transistor, 2N3904 Emitter to Base 0.55 V-DC
Base to Collector 9.2 V-DC
Emitter to Collector 9.8 V-DC
Q502 Transistor, 2N-5416 Emitter to Base 0.55 V-DC
Base to Collector 12.0 V-DC
Emitter to Collector 12.6 V-DC
R501 Resistor 150-Ohm, 5-Watt Across Resistor 1.8 V-DC
R502 Resistor 1000-Ohm, 5-Watt Across Resistor 12.5 V-DC
R503 Resistor, 1000-Ohm, 5-watt Across Resistor 12.5 V-DC
R510 Resistor, 1000-Ohm, 25-watt Across Resistor 65 V-AC, 44 V-DC
R511 Resistor, 100-Ohm, 5-Watt Across Resistor 3.4 V-DC
R512 Resistor, 47-Ohm, 1-Watt Across Resistor 7.2 V-AC, 3.3 V-DC
R513 Resistor, 1000-Ohm, 1/2-Watt Across Resistor 7.2 V-DC
R514 Resistor, 470-Ohm, 1/2-Watt Across Resistor 0 V-DC
R551 Rheostat, 1500-Ohm, 25-Watt Across Rheostat 20 V-AC, 15 V-DC
R553 Rheostat, (Triple Tandem)
10-Ohm, 25-Watt Across Rheostat 0.15 V-AC
R554 Rheostat, (Triple Tandem)
250-Ohm, 25-Watt Across Rheostat 0.55 V-AC
R571 Potentiometer, 500-Ohm, 2-Watt R509 End to Slider 2.4 V-DC
R506 End to Slider 0.7 V-DC
Across Potentiometer 3.1 V-DC
R572 Potentiometer, 2500-Ohm, 2-Watt Slider to R571 Too Low to Read
Across Potentiometer 3.1 V-DC
T501 Transformer, High Phase Green to Black 120 V-AC
Red to Orange 30 V-AC
Red to Blue 15 V-AC
Red to Blue 15 V-AC

Page 15

Red to Blue 15 V-AC
T504 Transformer, Damping Orange to Blue 6.0 V DC
Red to Brown 11.0 V-AC, 1.1 V-DC
VR501 Diode, Zener, 6.2-Volt, 1-Watt Across Diode 6.1 V-DC
VR502 Diode, Zener, 80-Volt, 1-Watt Across Diode 0.25 V-DC

Page 16
9. Illustrated Parts List

a. Introduction
(1) Scope
The Illustrated Parts List identifies, describes, and illustrates all components of the Static Voltage
Regulator, Hobart Part No. 430391C, with the exception of attaching hardware.
(2) Purpose
The purpose of the Illustrated Parts List is to provide maintenance and provisioning personnel
with identification and descriptive data for use in the provisioning, requisitioning, storing, and
issuing of spare parts.
(3) Explanation of Parts List Form
This form is divided into five columns. Beginning at the left side of the form and proceeding to the
right, columns are identified as follows:
a. “FIGURE/ITEM NO.” Column
This column lists the figure number of the illustration applicable to the list and also identifies
each part in the illustration by an item number which appears on the illustration. Assemblies
and subassemblies which are illustrated in their disassembled state will not be identified by
an item number.
b. “HOBART PART NUMBER” Column
ALL part numbers appearing in this column are Hobart numbers. In all instances where the
part is a purchased item, the vendor’s identifying five-digit code and his part number will
appear in the “NOMENCLATURE” column. Vendor parts which are modified by Hobart
Brothers will be identified as such in the “NOMENCLATURE” column. In case Hobart
Brothers does not have an identifying part number for a purchased part, the “HOBART
PART NUMBER” column will reflect “NO NUMBER” and the vendor’s mumber will be shown
in the “NOMENCLATURE” column. Parts manufactured by Hobart Brothers reflect no
vendor code or vendor part number in the “NOMENCLATURE” column.
c. “NOMENCLATURE” Column
The item identifying name appears in this column. The indenture method is used to indicate
item relationship. Thus, components of an assembly are listed directly below the assembly
and indented one space. Vendor codes and part numbers for purchased parts are shown in
this column. Hobart modification to vendor items is also noted in this column.
d. “EFF” (Effectivity) Code
Code letters (“A”, “B”, “C”, etc.) are used in this column to indicate the use of parts where
more than one model or type of machine is covered by the parts list. Since this manual
covers only one model of voltage regulator, this column is not used in this manual.
e. “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 17
(4) Manufacturer’s Codes

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 Manufacturers’ Cataloging Handbook H4-1, and are arranged in numerical order.
Code Vendor’s Name And Address
01746 Electronics Engineers, Inc., 5615 Division, Chicago, Illinois 60651
02660 Amphenol Corporation, 2801 S. 25th Avenue, Broadview, Illinois 60153
15605 Cutler-Hammer, 1391 W. St. Paul Avenue, Milwaukee, Wisconsin 53223
44655 Ohmite Manufacturing Co. 3601 W. Howard St. Skokie, IL 60076
50508 Magnetic Components, Inc. 9520 Ainslie St. Schiller Park, IL 60176
71044 Bussmann Manufacturing, Division of McGraw-Edison Company,

2536 W. University Street, St. Louis, Missouri 63017
77342 Potter & Brumfield Division, AMF Company, 1200 E. Broadway,

Princeton, Indiana 47570
96682 Genisco Technology Corporation, 18435 Susana Road,

Compton, California 90221

Page 18
b. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a left hand 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.
c. 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
Ω - Ohm
OM - Owners Manual
PRV - peak reverse voltage
PSI - pounds per square inch
Ref - reference (the item has been listed previously) TM - Technical Manual
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.

Page 19
Voltage Regulator Assembly

Figure 5

Page 20
NOMENCLATURE UNITS
FIGURE HOBART per
ITEM NO. PART NO. 1 2 3 4 5 6 7 EFF ASSY
5- 430391C REGULATOR, VOLTAGE (MAG-AMP)

(For NHA See Fig. 3) REF
1 430469 CHASSIS, REGULATOR 1
430340 . CHASSIS, LINE DROP COMPENSATION
ASSEMBLY 1
2 430470 . CHASSIS 1
3 402373 . NAMEPLATE, LINE DROP COMPENSATION 1
4 W-11597 . KNOB, POINTER, V75376, No. S-292-3L 2
5 1CZ-70 . SWITCH, ON-OFF, V15605, No. 7610K2 1
6 1CZ-97 . REACTOR, LINE-DROP, V86151, No. E3963 3
7 401563-3 . HOUSING, PIN CONNECTOR 1
8 1CZ-105 . RHEOSTAT, TRIPLE TANDEM,
V44655, No. H-10-F2-T3 1
9 1CZ-128 . . RHEOSTAT, TRIPLE TANDEM,
V44655, No. 6610 1
10 430476 . INSULATION, BOTTOM, RESISTOR 1
11 W-9746-9 . RESISTOR, V44655, No. 0205 1
12 1CZ-74 . INSULATOR, TOP, RESISTOR 1
13 402342 . REACTOR, REGULATOR, V96682,
No. 70-8532 1
14 16DA-2162 . KNOB, RHEOSTAT, V44655, No. 5150 1
15 HF-745 . NAMEPLATE 1
16 30GH-734 . BRACKET, MOUNTING, RHEOSTAT 1
17 W-9712-13 . RHEOSTAT, REGULATOR, 750-OHM,
25-WATT, V44655, MODEL H 1
18 370141 . BRACKET, MOUNTING, PLUG 1
19 25MS-328 . SPACER 2
20 402376 . RECEPTACLE, V02660, No. MS-1302A-22-14P 1
21 400782-1 . FUSE, 5-AMP, FAST-ACTING, GLASS
TUBE, MTH 1
22 HF-2407 . FUSEHOLDER, V71400, No. HKP 1
23 401911-3 . TERMINAL BOARD, V88223, No. 441-3 1
24 W-10827-8 . RESISTOR, 470-OHM, 1/2-WATT 1
430472A CHASSIS, SENSING & PRE-AMP, ASSEMBLY 1
25 430341 . BRACKET, MOUNTING, CHASSIS 1
26 485053 . BOARD, PC, HIGH PHASE SENSING 1
27 79B-1140 . RELAY, V77342, No. KHU17D11 1
28 79A-1142 . SPRING, RETAINING, RELAY,V77342 1
29 404460-1 . SUPPORT, PC BOARD, LOCKING 3
30 485282 . BRACKET, MOUNTING, PC BOARD, FRONT 1
31 485283 . BRACKET, MOUNTING, PC BOARD, REAR 1

Page 21
NOMENCLATURE UNITS
FIGURE HOBART per
5- 430391C REGULATOR, VOLTAGE (MAG-AMP)

(Continued) REF
34 400698-2 . POTENTIOMETER, 2500-OHM, 2-WATT,
V44655, No. CLU-2521 1
35 W-9712-30 . RHEOSTAT, 1500-OHM, 25-WATT,
V44655, No. H 1
36 1CZ-60 . TRANSFORMER, DAMPING, V50508
No. E3196-A 1
37 402357 . TRANSFORMER, HIGH PHASE, V50508,
No. 40-8583 3
38 430473 . PANEL, CHASSIS 1
39 1CZ-63 . REACTOR, FILTER, HIGH PHASE, V50508
No. E3661-A 4
40 402358 . NAMEPLATE, ADJUST 1
41 480725 . LABEL, INSTRUCTION 1
* 401564-2 . HOUSING, SOCKET CONNECTOR 1
* 401564-3 . HOUSING, SOCKET CONNECTOR 2
* Not Illustrated

Page 22
Section 5. Voltage Regulator
1. General
This section contains information and instructions for a solid state voltage regulator, Part No. 489812A,
manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373, U.S.A.
An illustrated parts list is contained at the end of this section.
This voltage regulator (Figure 1) is designed to provide 1% voltage regulation for all loads up to 100%
of rated load on a three-phase, four-wire, 115/200-volt, 400-Hz brushless alternator. This regulator
provides field excitation power as required to meet varying alternator load conditions to hold the
alternator voltage constant. The voltage regulator consists of two basic interconnected assemblies, the
Line Drop Compensator Assembly and the Voltage Regulator PC Assembly
Any deviation of the alternator voltage from its set, regulated level is sensed at the voltage regulator PC
board. The sensing signal is compared to a reference signal, and, with associated circuitry, varies the
field power supplied to the rotary exciter.
2. Components
Refer to Figure 1. The line drop compensator assembly (5) and the voltage regulator PC board
assembly, (4) and (2), are mounted on a chassis along with a terminal board (10) and 19-pin receptacle
connector (11). The PC board assembly consists of the PC board itself (4) and its protective cover (2).
a. Line Drop Compensator Circuit Components
Refer to Schematic Diagram 280003 and Connection Diagram 181440 at the end of this section.The
line drop voltage compensation circuit consists of:
(1) A current transformer (T1, T2, T3) on each phase of the load circuit.
(2) A fixed inductance (L6, L7, L8), and variable resistance (R6) in series with each of the phase
lines leading to the voltage detection circuit.
(3) A toggle switch (S1) for bypassing the line drop compensator.
(4) A variable resistance (R7) in series with each current transformer input to the regulator.
(5) A fixed resistance (R3, R4, R5) in parallel with each current transformer.
The current transformers detect the magnitude and power factor of current flowing through the power
cables from the alternator to its load and feed a signal into the resistance and inductance ahead of
the voltage detection circuit opposing the voltage sensed by that circuit. The voltage actually sensed
by the voltage detection circuit is therefore lower than the actual alternator voltage by an amount
proportional to the magnitude and power factor of the load current and thus proportional to the
voltage drop between the alternator and its load. The regulator output increases slightly so that the
alternator output voltage is equal to the regulated voltage plus the voltage drop in the lines. The
variable resistances may be adjusted to match exactly the impedence of the power cables carrying
the load current.

Page 1
1. Voltage Regulator Chassis 7. Cable size compensation rheostat

2. Cover, Regulator PC Board 8. On-Off switch
3. Regulator PC Bord (under item 2) 9. Nameplate
4. Voltage Control Potentiometer 10. Receptacle Connector (19-pin)
5. Line Drop Compensator Assembly 11. Terminal Strip
6. Cable length compensation rheostat 12. Connector Housing (10-pin)
Solid State Voltage Regulator

Figure 1

Page 2
b. Voltage Regulator PC Board (3, Fig. 1, and Fig. 2))

The voltage regulator PC board assembly is a non-reparable assembly, and includes circuitry for
voltage build-up, voltage regulation, voltage recovery, and line drop compensation using signals from
the line drop compensator assembly.
Voltage Regulator PC Board

Figure 2

Page 3
3. Installation And Preparation For Use

a. Installation
(1) General
This voltage regulator is designed primarily for drawer-type mounting. However, it is not attitude
sensitive and may be mounted in any position without affecting its operation. In some
installations it is mounted in what appears to be a backward position, which may make reading
the instruction plate for cable compensation adjustment somewhat difficult.
The regulator does not dissipate large amounts of power, but certain components, especially the
line drop compensator rheostats and regulator power transistor, need a reasonable amount of air
for convection cooling. For this reason, the regulator should not be mounted in a small airtight
enclosure which would prevent air circulation around the line drop chassis assembly.
Four mounting holes (one in each corner of the main chassis) are provided for attaching the
regulator. Position the regulator in its mounted location and install with appropriate attaching
hardware (nuts and/or screws, and washers).
(2) Connections
All electrical connections to the regulator are made through a nineteen pin receptacle connector
(1-2, Fig. 1) which is bracket mounted on the chassis.
b. Preparation for Use
No special preparation is necessary to place the regulator in service other than the following checks
and inspections.
(1) Check all terminal lug type connections for security.
(2) Check all plug and receptacle type connectors to make certain they are firmly mated.
It may be necessary to adjust a new regulator at initial start-up after installation. (See Chapter 2,
Section 4).
4. Operating Procedures
Operating procedures, as such, are not applicable to the solid state voltage regulator because it requires
no start, stop, or operating instructions. See Section 1-3 for initial start-up adjustments and procedures.
Make certain that the line drop compensator switch (1-2; 5, Fig. 1) is in the ON position when operating
the generator set.
5. Sequence and Theory of Operation

A description of the sequence of events, which occur when the solid state regulator is in operation, is
presented here to give maintenance personnel a better understanding of how and why the unit operates,
and thus assist them in the adjustment and troubleshooting of the equipment.
When the machine is started, the rotary exciter is excited from alternator residual magnetism through
the starting relay and the half-wave rectifier bridge, both located on the voltage regulator PC board
assembly. As the rotary exciter voltage increases, alternator excitation increases and the alternator
voltage builds up. When this voltage becomes high enough, the build-up relay switches the voltage
regulator into the circuit. The sensing circuit of the voltage regulator PC then compares the input voltage
to a reference voltage and adjusts the field power of the rotary exciter to bring the voltage into regulation
limits.
The voltage at which the alternator is regulated may be varied by changing the position of the slider on
the “Volts Adjust” potentiometer.
When the alternator is loaded, its terminal voltage decreases, lowering the rectified three-phase
voltage of the voltage sensing circuit. The sensing voltage is low in respect to its referencce voltage,
causing the voltage regulator PC circuitry to increase the power to the field of the rotary exciter. The
alternator voltage increases until the voltage returns to its regulated value.

Page 4
When a load is removed from the alternator, the alternator voltage rises. The rectified three-phase
voltage sensing signal increases, causing this signal to be larger than the reference signal. The
associated voltage regulator circuitry causes the field power of the rotary exciter to decrease,
lowering the alternator voltage until the voltage returns to regulated value.
6. Troubleshooting
a. General
and simple to put back into service once it has malfunctioned or if it is not functioning properly. The
heart of the solid state voltage regulator is the regulator PC board (Section 1-2, 4, Fig. 1, and Fig. 2).
Most malfunctions of the voltage regulator will be corrected by (1) removing and replacing the PC
board, and (2) making voltage and line-drop adjustments after installing the new board.
b. Preliminary Checks
Before determining that the voltage regulator is defective, perform the following checks:
(1) Check the 5A fuse on the regulator PC board to be certain that it is good.
(2) Check all connections on the regulator to make certain that they are tight and secure.
(3) Make certain also that the line drop compensator switch (1-2; 8, Fig. 1) is in the ON position for
checking line drop compensation.
c. Troubleshooting the Voltage Regulator
Troubleshooting of the solid-state voltage regulator begins logically with a check of the regulator PC
board. In most instances this check can be made without removing the voltage regulator from the
generator set. This is simply a matter of disconnecting the suspect PC board from the regulator
wiring assembly and connecting in its place a PC board which works properly. Proceed as follows:
CAUTION
Shut off the generator set before working on the voltage regulator.
(1) A. Carefully disconnect the rectangular plug connector of the regulator wiring assembly from the
suspect PC board. This can be done, if done carefully, without removing the regulator PC cover
(Section 1-2; 2, Fig. 1).
(2) B. Connect a properly working PC board to the regulator wiring assembly.
(3) C. Place a piece of insulating material between the properly working PC board and the metal PC
board cover (Section 1-2; 2, Fig. 1). Do this to avoid short circuiting the bottom of the properly
working PC board to the cover
(4) D. Start the generator set and perform the tests and adjustments according to instructions in
Section 2-4.
(5) E. If the generator set works properly with the properly working PC board temporarily connected
to the voltage regulator, shut off the generator set and replace the defective PC board with one
that is properly working. On most Hobart generator sets, it is possible to remove and replace the
PC board quickly without removing the voltage regulator from the generator set. See Section 2-7,
Para. 3 for removal and replacement instructions.
NOTE: Preferably, the defective PC board should be replaced with the same PC board used for this
troubleshooting check. This would eliminate the need for again doing tests and adjustments, as
would be required with another PC board.
(6) F. If these tests and adjustments with the properly working PC board fail to correct the regulator
malfunction, follow the same procedure as above for checking the line drop compensator
assembly. Refer to Section 2-4 for test and adjustment procedure, and to Section 2-7, Para. 2
for removal and replacement procedure.

Page 5
7. Voltage Regulator Removal And Installation

a. General
Due to the design of this solid state voltage regulator, and because of its compact size,
troubleshooting and repair can often be done without removing it from the generator set. This
on-the-unit troubleshooting and repair is explained in Sections 2-2 and 2-4. However, if removal and
replacement of the entire voltage regulator is necessary, follow the procedure given below.
b. Removal of Voltage Regulator from Generator Set
(1) Disconnect the 19-pin connector (1-2; 11, Fig. 1).
(2) Remove the regulator’s attaching hardware, and exercise care to avoid dropping the unit.
(3) Place the unit on a clean workbench, allowing enough room to work on it.
c. Replacement of Assemblies on the Voltage Regulator
Refer to repair instructions in Section 2-7 for procedures for replacement of assemblies on the
voltage regulator.
d. Installation of Voltage Regulator on Generator Set
(1) Place the voltage regulator in its proper mounting position.
(2) Fasten the voltage regulator in place with its attaching hardware, and make certain that it is
mounted securely.
(3) Re-connect the 19-pin connector, and make certain that this connection is securely made.
8. Adjustment And Test
a. Adjustment
(1) General
When a voltage regulator is first put into service, it may require an adjustment of the regulated
output voltage. The generator set must be running at rated RPM, under no-load conditions,
when voltage regulation adjustment is made. Adjust the regulator as follows:
(2) Adjust Voltage Control
The output voltage at which the generator is regulated is adjust table by the PC board
potentiometer adjustment (Fig. 2).
a. Turn the potentiometer adjustment counterclockwise (CCW) to increase generator output
voltage, and clockwise (CW) to decrease voltage.
b. Observe the output voltage as indicated by the voltmeter which is located on the control panel
of the generator set.
c. Set output voltage at 115-V AC line-to-neutral (200-V AC line-to-line).
(3) Adjust Line Drop Compensation Gain
Adjustment of line drop compensation magnitude is made with the knob marked “Foot
Compensation” (6) on the line drop compensator module. The knob dial is calibrated for
approximate cable length in feet. The “Foot Compensation” knob controls a rheostat which limits
the current flowing in the compensation circuit. The setting of the rheostat resistance determines
the magnitude of the compensation. Rotating the knob clockwise increases the magnitude of the
compensation, and rotating counterclockwise decreases the magnitude. To adjust the line drop
compensation gain, proceed as follows:
a. Connect the generator set output cables to a load.
b. Make certain that the line compensation switch (8) is in the ON position.

Page 6
c. Set the “Foot Compensation” knob to a dial setting corresponding to the length of the output
cables being used.
(4) Adjust Line Drop Compensation Phase
The compensation circuit must be adjusted to match not only the voltage drop in the power
cables to the load, but must be adjusted to match the phase of the voltage drop. This is done by
adjusting the relative magnitude of the reactor and resistive compensation with the “Cable Size”
knob (7). This knob is calibrated in cable sizes, and controls a varied resistance in series with a
fixed reactance. The power factor of the compensation circuit is varied by varying the resistance
and leaving the reactance constant. Rotating the knob clockwise increases the resistive
component of the compensation circuit, and simulates a smaller cable. Rotating the knob
counterclockwise decreases the resistive component of the compensation. Adjust the line drop
compensation phase as follows:
a. Set the “Cable Size” knob (7) to a dial setting corresponding to the size of the output cables.
b. Adjust the generator voltage control potentiometer (13) to the desired value if the line drop
compensator adjustments have affected the no-load voltage output.
9. Inspection and Check
a. Inspection
(1) General
Inspect the voltage regulator periodically, at the same time other inspections of the generator set
are made.
(2) Inspect Connectors and Terminals
a. Inspect connectors for full engagement.
b. Inspect terminals for security.
(3) Inspect Wiring
Inspect wire insulation for cracks and damage.
(4) Inspect Attaching Parts Inspect attaching hardware for security
(5) Inspect Regulator Fuse on PC Board
When replacing this fuse, replace it with the EXACT SAME type and rating of fuse.
b. Check the Voltage Regulator Unit
If it is necessary to check electrical operation of the voltage regulator, refer to Section 2-4 for the test
and adjustment procedure to be used.
10. Cleaning And Painting

a. Cleaning
WARNING
Electric shock can kill! Remove power before cleaning regulator.
A. Make certain that compressed air is clean and dry.
B. Do not use flammable or conductive cleaners.
C. Exercise care to avoid damage to components.
Under normal operating conditions, very little cleaning is required; however, when operating under
dusty conditions, it may be necessary to periodically clean the regulator with compressed air.

Page 7
b. Painting
(1) General
Only the sheet metal components of the voltage regulator are painted. Electrical and electronic
components should never be painted.
(2) Preparation for Painting
a. Remove regulator from control box (or from its mounted position) and place it on a clean
workbench.
b. Disassemble as required to remove the component (s) to be painted.
c. Prepare the surface to be painted by sanding. Remove all rust.
d. Use tape to mask any electronic or electrical components not removed in step (2) above.
e. Prime all bare metal surfaces with red oxide primer, Hobart No. 903318, or equivalent.
(3) Painting the Unit
a. Make certain that all surfaces are clean and dry.
b. Paint all prepared surfaces with gray enamel paint, Hobart No. 903316, or equivalent.
11. Repair
a. General
and simple to put back into service once it has malfunctioned or if it is not functioning properly. Flight
line repair is limited to removal and replacement of either the Voltage Regulator PC Board assembly
or the Line Drop Compensator assembly, depending on whether the malfunction of the voltage
regulator is poor voltage regulation or poor line drop compensation. Refer to Figure 1, Section 1-2.
It is not recommended that repairs be attempted on the voltage regulator PC board, because voltage
regulation could be seriously affected if replacement parts are not identical to the original parts.
Therefore a defective PC board assembly should be replaced with a PC board assembly known to
be good.
The line drop compensator assembly, like the PC board, does not lend itself to flight line repair. To
put the voltage regulator back into service after a line drop malfunction, the line drop compensator
assembly should be replaced with an assembly known to be good.
b. Removal/Replacement of Line Drop Compensator Assembly
Removal of this assembly (1-2; 5, Fig. 1) from the voltage regulator requires only that one disconnect
the 10-pin connector housing (1-2; 12, Fig. 1) and remove the four screws which fasten the assembly
to the regulator. Replacement of this assembly with one known to be good is simply a matter of
mounting the replacement assembly in place, re-installing the four attaching screws securely, and
re-connecting the 10-pin amphenol connector, making certain that the this connection is secure.
Refer to Section 2-3, Para. 4 for instructions on installing the voltage regulator on the generator set
after replacement of the line drop compensator assembly. Install the voltage regulator accordingly.

Page 8
c. Removal/Replacement of Voltage Regulator PC Board Assembly

(1) To remove this assembly (1-2; 5, Fig. 1) from the voltage regulator, proceed as follows:
a. Remove the attaching hardware (four hex nuts, lock-washers and flat washers) which fasten
the PC board cover (2) to the voltage regulator (on 489812 Regulator’s).
b. Disconnect the regulator wiring assembly from the PC board. The wiring assembly attaches
to the PC board at a socket connector on the board similar to the one which is mounted on
the line drop compensator assembly.
c. The voltage regulator PC board is fastened to the voltage regulator unit with four plastic PC
locking supports, one in each corner of the board. To remove the PC board, use a small
screwdriver to push in the tab of each PC support, one at a time, while lifting the PC board
from the supports.
(2) To install the replacement PC board on the voltage regulator, proceed as follows:
a. Make certain that the PC board is positioned properly (such that the 12-pin connector of the
PC board is close to the line drop compensator assembly) and press the PC board gently
down onto the plastic locking PC supports.
b. Connect the regulator wiring assembly to the newly-installed PC board. Make certain that this
connection is securely made.
c. Re-mount the PC board cover, and tighten it down onto the voltage regulator with its
attaching hardware (hex nuts, locknuts, and flat washers).
d. Make compensation and voltage adjustments, if required, in accordance with instructions in
Section 2-4.
e. Refer to Section 2-3, Para. 4 for instructions on installing the voltage regulator on the
generator set after the replacement of the PC board. Install the voltage regulator accordingly.
12. Illustrated Parts List

a. Introduction
(1) Scope
The Illustrated Parts List identifies, describes, and illustrates all components of the Solid State
Voltage Regulator, Hobart Part No. 489812A, with the exception of attaching hardware.
(2) Purpose
The purpose of the Illustrated Parts List is to provide maintenance and provisioning personnel
with identification and descriptive data for use in the provisioning, requisitioning, storing, and
issuing of spare parts.
(3) Explanation of Parts List Form
a. “FIGURE/ITEM NO.” Column
This column lists the figure number of the illustration applicable to the list and also identifies
each part in the illustration by an item number which appears on the illustration. Assemblies
and subassemblies which are illustrated in their disassembled state will not be identified by
an item number.

Page 9
b. “HOBART PART NUMBER” Column

ALL part numbers appearing in this column are Hobart numbers. In all instances where the
part is a purchased item, the vendor’s identifying five-digit code and his part number will
appear in the “NOMENCLATURE” column. Vendor parts which are modified by Hobart
Brothers will be identified as such in the “NOMENCLATURE” column. In case Hobart
Brothers does not have an identifying part number for a purchased part, the “HOBART
PART NUMBER” column will reflect “NO NUMBER” and the vendor’s mumber will be shown
in the “NOMENCLATURE” column. Parts manufactured by Hobart Brothers reflect no
vendor code or vendor part number in the “NOMENCLATURE” column.
c. “NOMENCLATURE” Column
The item identifying name appears in this column. The indenture method is used to indicate
item relationship. Thus, components of an assembly are listed directly below the assembly
and indented one space. Vendor codes and part numbers for purchased parts are shown in
this column. Hobart modification to vendor items is also noted in this column.
d. “EFF” (Effectivity) Code
Code letters (“A”, “B”, “C”, etc.) are used in this column to indicate the use of parts where
more than one model or type of machine is covered by the parts list. Since this manual
covers only one model of voltage regulator, this column is not used in this manual.
e. “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 10
(4) Manufacturer’s Codes

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 Manufacturers’ Cataloging Handbook H4-1, and are arranged in numerical order.
Code Vendor’s Name And Address
02660 Bunker-Ramo Eltra Corp. Amphenol Division 2801 S. 25th Avenue

Broadview, Il 60153
15605 Eaton Corporation Operations and Technical Center 4201 N.

27th St. Milwaukee, WI 53216
44655 Ohmite Manufacturing Co. 3601 W. Howard St. Skokie, IL 60076
50508 Magnetic Components, Inc. 9520 Ainslie St. Schiller Park, IL 60176
52238 Richlok Corporation 5825 N. Tripp Avenue Chicago, IL 60646
75376 Kurz-Kash, Inc. 2271 Arbor Blvd., P.O. Box 1246 Dayton, OH 45401
88223 General Products Corp. 107 Salem St. Union Springs, NY 13160

Page 11

Page 12
b. Parts List
(1) Explanation of Parts List Arrangement
The parts list is arranged so that the illustration will appear on a left hand 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.
This parts list is all-inclusive, in that it covers parts for all sixteen of the trailer and/or
truck-mounted generator set specifications available in generator set Series 5359F. For
parts used only on one particular generator set, refer to the effectivity (EFF) code in this parts list
for that generator set.
(2) Symbols and Abbreviations
A, or AMP - ampere
AR - as required
DC - direct current
Fig. - Figure
hd. - head
hex - hexagon
IN - inch
F - microfarad
No. - number
Ω - Ohm
OM - Owners Manual

Page 13
Solid State Voltage Regulator Assembly

Figure 3

Page 14
NOMENCLATURE UNITS
FIGURE HOBART per
3- 489812A REGULATOR, VOLTAGE (SOLID STATE)

1 180075 CHASSIS, REGULATOR 1
430340 . CHASSIS, LINE DROP
COMPENSATION, ASSY 1
2 430470 . . CHASSIS 1
3 402373 . . NAMEPLATE, LINE COMPENSATION 1
4 W-11597 . . KNOB, POINTER, V75376, NO. S-292-3L 2
5 1CZ-70 . . SWITCH, ON-OFF, V15605, NO. 7610K2 1
6 1CZ-97 . . REACTOR, LINE DROP, V50508,
NO. E-3963 3
7 401563-3 . . HOUSING, PIN CONNECTOR 1
8 1CZ-105 . . RHEOSTAT, TRIPLE TANDEM, V44655,
NO. H-10-F2-T3 1
9 1CZ-128 . . RHEOSTAT, TRIPLE TANDEM, V44655,
NO. 6610 1
10 370141 . BRACKET, MOUNTING, PLUG 1
11 402376 . RECEPTACLE, V02660,
NO. MS-1302A-22-14P 1
12 401911-3 . TERMINAL BOARD, V88223, NO. 441-3 1
13 180074 . NAMEPLATE, MODEL, SERIAL NO. 1
14 181419 . BOX, P.C. BOARD, ASSEMBLY 1
15 408537 . LABEL, CAUTION 1
16 489811 . BOARD, PC, VOLTAGE REGULATOR, 1
17 400647-8 . . FUSE, TYPE ABC-10, 10-A, 250-V 1
*18 408542-1 . GUARD, STRIP TERMINAL 4
* Not Illustrated

Page 15

Page 16
Chapter 3. Overhaul / Major Repair
Section 1. Table of Contents
Section 2 Flexible Coupling
Section 3 Exciter Armature Removal and Installatrion
Section 4 Four-Wheel Trailer

Page 1
This page intentionally left blank

Page 2
Section 2. Flexible Coupling
1. General
This section provides basic instructions for removal, service and installation of a flexible coupling
assembly, with fan attached, manufactured by Hobart Brothers Company as Part Number 488908.
This assembly is illustarted in Figure 1. The primary function of this assembly is to couple a Hobart
Generator Set to a Diesel engine. The flexible coupling assembly compensates for slight misaligment
between the engine and the generator, due to manufacturing tolerances. A tapered bushing and hub
secures the coupling to the generator shaft.
Coupling Assembly
Figure 1

Page 1
a. Coupling Bolts
CAUTION
Failure to verify proper coupling bolt installation may result in coupling failure
and damage equipment.
NOTE: It is not necessary to seperate the engine and generator if all that is being done is checking and
replacing the coupling bolts. Removal of the perforated cover over the fan housing provides access
to the coupling bolts for removal and installation.
(1) Refer to Figure 2. Use a long-handled, reversible ratchet drive with a 15/16-inch hex socket
wrench to remove one coupling bolt. Measure its length. If it is 2-3/4 inches (70mm) long,
reinstall it and torque ALL of the coupling bolts to 85 foot-pounds (115 N-m).
(2) Use of the proper coupling bolts for replacement is VERY IMPORTANT. Replacement bolts
MUST be 5/8-11, SAE Grade 5, hex-head bolts, 2-3/4-inches (70 mm) long, reinstall it and
torque ALL of the coupling bolts to 85 foot-pounds (115 N-m). There is NO ACCEPTABLE
SUBSTITUTE for these bolts. Hobart Brothers stocks these bolts as Part Number W-11102-18.
Access to Coupling Bolts

(for Removal and Installation)
Figure 2

Page 2
2. Disassembly
Removal of the flexible coupling is required for servicing the generator armature, generator bearings, or
the coupling itself. To remove the coupling, for any reason, it is necessary to seperate the engine and
generator. On self-propelled units, many mechanics prefer to remove the engine and generator as an
assembly, and then seperate them. Others may prefer to remove the engine or the generator seperately
to reach the coupling. However, seperating the engine and generator while they are installed in the
Ground Power Unit is VERY DIFFICULT because of the limited working space.
During removal DO NOT cut any cables or wires. Disconnect and tag them for reassembly.
a. Seperate Engine and Generator
(1) (1) Install a lifting eye with 1/2-13 threads in the tapped hole on top of the generator frame, and
attach a hoist to it. Lifting eyes are available from Hobart as Part Number CTW-116A.
(2) (2) Remove the fan housing cover from the generator fan housing.
(3) (3) Refer to Figure 2. Use a 15/16-inch socket ona long-handled ratchet and remove the
hex-head bolts which attach the coupling to the engine flywheel.
NOTE: These bolts were torqued to 85-foot pounds (115 N-m) at installation. Therefore it may be necessary
to block the armature against counterclockwise rotation to remove them.
(4) Remove bolts attaching the generator fan housing to the engine flywheel housing.
(5) Seperate the generator from the engine with a hoist and move it to a clear working area.
b. Remove Coupling Assembly
(1) Refer to Figure 3. Using a socket wrench, remove all three of the 3/8-16 bolts (1) that secure the
bushing (2) to the hub (3).
(2) To separate the housing from the hub, lubricate two of the 3/8-16 bolts and insert them into the
threaded holes (4) in the bushing. With socket wrench, screw these bolts into the bushing such
that the bushing pops loose from the hub.
(3) Using a 3/16-inch Allen wrench, loosen the set screw (7) in the bushing to release pressure on
the key (5).
(4) When the bushing (2) is loose in the hub (3), use a mallet to GENTLY tap the bushing out of the
hub.
(5) Slide the coupling assembly off the shaft and remove the key (5).
(6) Inspect the coupling assembly components carefully as follows:
a. Check for deformed fan blades and damage to the disk.
b. Check the rubber exposed at both ends of the bushings for signs of deterioration.
c. Check hub and split bushing for cracks, evidence of galling, and rust pits. Light rust is
permissible on the split bushing and the tapered bore of the hub.
d. Check the shaft for any damage or deformation where the coupling was mounted on it.
e. Check bushing alignment to make sure that the dimension illustarted in Figure 6 is maintained.

Page 3
1. Bolts, 3/8 - 16 (3)

2. Bushing
3. Hub
4. Tapped holes (2)
5. Key
6. Set screw
7. Coupling disk
Hub and Bushing
Figure 3
3. Coupling Service
When ordering coupling kits or other parts from your Hobart Brothers Company Distributor, be sure to
include all pertinent information from the unit’s identification plate: Specification No., Model No., and unit
rating.
If you have any questions concerning your Hobart Power Systems Group equipment, you are invited
to contact our Service Department by mail, telephone or FAX.
Write: Hobart Brothers Company
Service Department
1177 Trade Square East
Troy, Ohio 45373
U.S.A
In U.S.A. Call: (800) 422-4166

(800) 422-4177
From Foreign Countries, Call: (937) 332-5050 (Parts)

(937) 332-5060 (Service)
Fax: (937) 332-5121

Page 4
a. Coupling Kits
A replacement coupling kit is available from your Hobart Brothers Company Distributor. This kit
provides a replacement coupling assembly with attaching hardware and installation instructions. The
Part Number for this kit is 488908. This kit is illustarted in Figure 4.
b. Bushing Kit
A bushing kit is available from Hobart Brothers Company for replacing the rubber bushing only in the
coupling assembly. However, it should be noted that the finished coupling assembly must be
balanced to 1/2 inch-ounce (360 mg-m) minimum, which may be a problem in the field. If bushing
replacement only is required, the kit part number is 480290. Each kit contains the required number of
bushings, a container of lubrication, and installation instructions. To replace bushings only, proceed
as follows:
(1) Press out ALL old bushings.
(2) Refer to Figure 5. Clean each bushing socket thoroughly, removing all traces of old rubber. DO
NOT scratch or deform the bore of the bushing socket.
(3) Shake the container of lubricant vigorously and pour it into a small shallow dish.
(4) Roll a bushing in the lubricant to coat it thoroughly, and press it into a socket (from the
chamfered end) to the dimension shown in Figure 5: 3/32 +/- 1/64th-inch (2.381 +/- 0.397 mm)
from the face of the bushing socket to the face of the bushing, on the side opposite the fan
blades.
(5) Repeat step 4 until all new bushings are installed.
(6) Balance the complete coupling assembly to 1/2 inch-ounce (360 mg-m) minimum.
Coupling Kit
Figure 4

Page 5
Bushing Installation
Figure 5
4. Coupling Installation
CAUTION
Improper installation of the coupling assembly can result in serious damage to
the equipment. Follow these installation instructions exactly.
a. Cleaning
Refer to Figure 6. It is VERY IMPORTANT that the shaft, the bore and the outside of the split
bushing, and the tapered inside of the hub be thoroughly CLEANED FREE OF DIRT AND GRIT.

Page 6
CAUTION
Do not lubricate any of the surfaces listed above. Lubrication of these surfaces
can cause the coupling to fail and damage the generator set. Slight traces of
rust are permissible on the surfaces marked “x”, but nothing else.
b. Assembly
(1) (1) If an adaptor ring must be replaced, remove the 8 bolts which secure it to the flywheel.
Discard the old adaptor ring and bolts. Install the new adaptor ring Part No. 386612 using the
new bolts Part No. W-11097-34 (Kit 489166) or Part No. W-11259-6 (Kit 180504). The new
adaptor ring and bolts are included in the kits.
(2) Torque all 8 bolts to 30 foot-pounds (41 N-m).
(3) Refer to Figure 3. Assemble the split bushing (2) into the hub (3).
CAUTION Make certain that only the bolts are lubricated, and that no lubricant is permitted
to get inside the bushing where the armature shaft will enter the bushing.
(4) Lubricate the three 3/8-16 bolts SPARINGLY and start them into the three (unthreaded) holes
finger-tight.
(5) Slide the generator armature as far as it will go toward the fan housing. Block the armature to
maintain this forward position throughout the installation procedure. Block the armature with a
wooden block or wedge, being careful not to damage any components of the armature or exciter.
CAUTION
Do not rotate the armature while this block is installed.
(6) Install the key in the shaft keyway.

(7) Place the bushing in the hub over the installed key (5), and install the coupling assembly on the
shaft, with the split bushing approximately flush with the end of the shaft.
(8) Using a 3/16-inch Allen wrench, tighten the set screw (7) in the bushing (2) to apply pressure on
the key (5).
(9) Refer to Figure 9. Place a straightedge across the two adjacent bushings and measure the
distance from the bushings to the mounting face of the generator fan housing. Slide the coupling
assembly on the shaft until this dimension is 1/16-inch (1.6 mm) LESS than the dimension
recorded in step 7 above. The tapered hub will be pulled onto the split bushing 1/16-inch (1.6
mm) when the 3/8-16 bolts are completely tightened.
(10) Tighten the 3/8-16 bolts (1, Figure 3) alternately and evenly as follows:
a. Set a torque wrench to 30 foot-pounds (41 N-m) and tighten all three 3/8-16 bolts to that
value. Block the coupling against clockwise rotation with a bar, as illustrated in Figure 10.
Observe the CAUTION above when it is necessary to rotate the shaft.
b. Repeat step (a) above until 3/8-16 bolts can no longer be tightened.
c. Recheck the dimension in Figure 9 to be sure it is the same as the dimension in (7) above.
CAUTION
Remove armature block installed in para. 4, b, (3). Otherwise, damage to the
armature could result.

Page 7
Assembly Procedure
Figure 6
Flywheel Adaptor
Figure 7

Page 8
Engine Measurement
(Measuring from mounting face to adaptor ring)
Figure 8
Measuring from Mounting Face to Bushing

Figure 9

Page 9
5. Reassemble Engine and Generator
CAUTION
Use of the proper coupling bolts is very important. Failure to use the proper
bolts, as outlined below, can result in coupling failure and damage to the
generator set.
Use 5/8-11 SAE GRADE 5 hex-head bolts 2-3/4 inches (70 mm) long. These bolts are included in the
coupling kit, and are available from Hobart Brothers as Part No. W-11102-18.
a. Insert the proper coupling bolts with lockwashers through the bushings from the FAN side of
the coupling.
b. Using a hoist, align the generator fan housing flange with the flange on the engine flywheel
housing and insert two of the attaching bolts, one on each side of the flange. Start the bolts
into the tapped holes in the flywheel housing just enough to ensure thread engagement. DO
NOT TIGHTEN.
c. Turn all of the coupling bolts into the tapped holes in the flywheel, finger tight. DO NOT
tighten with a wrench.
d. Insert all remaining attaching bolts (two installed in Step B, above) through the generator
flange, engaging the tapped holes in the flywheel housing, and tighten them all securely.
e. Refer to Figure 2. Insert a long piece of wood through the fan housing to block the armature
against clockwise rotation. Torque all of the coupling bolts to 85 foot-pounds (115 N-m).
6. Run-in and Periodic Check

a. Mount the engine-generator assembly in a suitable test area and operate it for a 2-hour run-in.
b. Shut down the engine after 2 hours and re-torque all coupling bolts to 85 foot-pounds (115
N-m) to compensate for normal torque relaxation.
c. Return the unit to normal service.
d. After 200 hours of operation, check all coupling bolts with a torque wrench set at 85
foot-pounds (115 N-m).
e. Return the unit to normal service.
f. After each additional 2,000 hours of operation (or every year) recheck all coupling bolts to
maintain the same torque value.

Page 10
Blocking Coupling Assembly Against Rotation

Figure 10

Page 11

Page 12
Section 3. Exciter Armature Removal and Installation
1. General
This section provides information and instructions for removal and installation of the exciter armature
used on this generator set. Through design improvements, the exciter and main bearing can now be
removed without removing the generator from the generator set. The name exciter armature refers to
the shaft-mounted, revolving three-phase windings of the exciter.
The exciter armature covered by the manual is mounted on the rear portion of the main generator
armature shaft which extends rearward, beyond the rear generator bearing, into the exciter housing
(See Fig. 1). Because of its location on the shaft, the exciter armature must be removed for main
bearing replacement.
Since the removal and installation of exciter armatures can be rather complicated, this manual has been
prepared to assist mechanics in the operation. It may be necessary to remove the exciter armature
several times for bearing replacement during the life of a generator set.
2. Exciter Armature
The exciter armature used in this generator set consists of a revolving winding assembly on a laminated
core, a rectifier assembly (diode mounting plate with diodes), and a one-piece flywheel and mounting
sleeve (or hub) casting. See Figure 2. The field core and rectifier are mounted on the sleeve of the
flywheel casting.
3. Exciter Armature Replacement

a. General
As stated earlier, exciter armature removal is often required for rear bearing replacement rather than
for replacement of the exciter armature itself. Other reasons for exciter armature removal are:
generator armature replacement, general overhaul, etc.
b. Conditions for Exciter Removal
The mechanics performing the work must decide upon the best and most convenient method of
removing the exciter armature. If the exciter armature is being replaced, then the work may be
performed without removing the generator from the machine. In a great majority of cases, exciter
removal will be for the replacement of bearings. This operation can also be accomplished without
removing the generator.
c. Tools for Exciter Armature Removal and Installation
In addition to the standard mechanic’s hand tools such as wrenches, etc., you will need only the
following items for removing the exciter armature: A small lightweight sling-hammer puller, and a
gear puller with pilot plug and 5/16 - 18 puller attaching screws.
The sling-hammer puller (Fig. 3) is required for removing the threaded machine key (8, Fig.2) from
the exciter armature. If the technician doesn’t have such a puller in his equipment, Figure 3 also
shows components and dimensions for fabricating such a tool. Figure 4 shows a gear puller with
pilot plug and 5/16 - 18 puller attaching screws such as will be needed for pulling the exciter
armature from the generator armature shaft.
To install an armature, in most cases, a fabricated tool for pushing the armature onto the generator
shaft is required. The armature should NEVER be hammered onto the shaft. If only a single
machine is being maintained, a a simple installation tool such as shown in Fig. 10 may be sufficient.
If several machines are being maintained, it may be feasable to fabricate a tool which will make
armature installation easier and faster. Figue 11 illustrates a typical tool of this type, and gives
dimensions, materials, and instructions for fabricating such a tool.

Page 1
1. Armature shaft 9. Rear bearing snap ring

2. Flexible coupling and hub 10. Generator rear bearing
3. Flywheel adapter 11. Exciter stator
4. Engine flywheel 12. Exciter armature revolving fields
5. Fan 13. Rectifier
6. Front bearing 14. Exciter armature flywheel
7. Generator stator (clutch mounts here)
8. Generator revolving field 15. Armature locating snap ring
Generator (Top Half Sectioned)
Figure 1
d. Preparation for Exciter Armature Removal

(1) Remove louvered exciter cover from end of canopy.
(2) Remove exciter housing cover as required. Then remove the 1/2-13 cap screw which holds the
exciter armature on the generator shaft.
(3) Refer to Figure 3. Disconnect the two rectifier-to-generator field leads (1) from diodes (9) to
which they are attached. Cut off terminal lugs (2) from the two leads so that leads will pass
through routing holes in rectifier body and armature core as armature is removed. CUT AS
CLOSE TO LUGS AS POSSIBLE to conserve leads and to prevent the need for splicing.
(4) Cut and remove tape (3) which binds generator field leads to rotor sleeve. EXERCISE CARE to
prevent damage to leads. Remove kinks in the two generator leads as much as possible before
starting removal operation.

Page 2
1. Rotor windings 5. Negative heat sink

2. Rotor core 6. Leads routing holes
3. Positive heat sink 7. Rectifier
4. Diode 8. Threaded machine key
Exciter Armature
Figue 2
e. Exciter Armature Removal

(1) Removing the Threaded Key With Sling-Hammer Puller
Attachment of the assembled puller to the threaded key (8, Fig.2) in one operation is not
recommended because the weight and bulk of the assembly make threading the 1/4-inch stud
into the key rather clumsy. To do so could result in cross-threading and damage to the key and
stud. It is safer and easier to attach as follows:
a. Thread stud (1, Fig. 3) into adapter (2, Fig. 3) until it bottoms, then thread this assembly (1)
and (2) into key until stud bottoms in key threads. Tighten securely.
b. If hammer (5) and rod (4) are not already assembled, thread one nut (3) onto addapter end of
rod (4). Thread rod into adapter until it bottoms, then tighten nut securely against adapter.
Slide hammer (5) onto rod and install washer (6) and two nuts (3). Thread nuts onto rod until
both nuts are fully threaded, then lock together.
WARNING
Be very careful during removal process (slide-hammering) to avoid injury to
hands.

Page 3
CAUTION
Exercise care to prevent breaking or damaging stud.
c. Position hammer at adapter end of rod.

d. Quickly move hammer to outer end of rod with a rapid, slinging motion. HOLD the hammer
through the entire motion. If hammer is allowed to slide free on the rod, the stud could be
DAMAGED or BROKEN.
e. Repead steps (c) and (d) as required to loosen key, then remove key and slide hammer and
puller.
f. After key is removed, apply penetrating oil in the armature and shaft keyways.
1. Stud, 1/4-28 UNF 2A, grade 5 or 8 only 4. Rod, 1/2" round, CR steel
2. Adapter, 3/4" round CR steel 5. Hammer, 2"round CR steel
3. Nut, 1/2-13 hex, steel (3 required) 6. Washer, flat, 1/2: steel
Sling-Hammer Puller
Figure 3

Page 4
(2) Removing the Armature with Gear Puller

Figure 5 shows the location of the holes into which gear puller screws must be inserted for
removing the exciter armature from the generator armature shaft. This figure also shows the
gear puller installed for pulling the exciter armature. Proceed as follows to remove the exciter
armature.
a. Attach gear puller (Fig. 4) to the exciter armature using 5/16 - 18 puller attaching screws, just
as shown . BE CERTAIN to install a plug in the end of the generator shaft to protect threads
and pilot bushing.
b. Attach puller attaching screws so that pulling force is equally divided between them and so
that the puller is mounted squarely.
c. Turn the main puller screw to apply pulling pressure. If the armature does not break loose,
strike the end of the main puller screw with a heavy hammer. Continue to alternately tighten
puller screw and strike the screw head until the armature breaks loose from the shaft.
d. When exciter armature is loosened, use the puller to remove it slowly from the shaft and at
the same time observe the following CAUTION.
CAUTION
Pay close attention to field leads (1, Fig. 3) while pulling exciter rotor from shaft.
One mechanic should watch them constantly while another mechanic operates
the puller. Make certain that leads do not catch and be sure that they slide
smoothly through tubes (6, Fig. 3). Straighten leads and remove kinks to avoid
damage to insulation.
Typical Gear Puller

Figure 4

Page 5
Pulling the Exciter Armature

Figure 5

Page 6
4. Installing the Exciter Armature

a. Preparation for Exciter Armature Installation
(1) Clean generator shaft, exciter armature bore, and machine key. Remove all rust, corrosion, etc.
(2) Apply LOCQUIC primer, No. 47-56 grade T to exciter armature key and keyway (See Fig. 6).
Clean excess from armature bore mounting surface.
(3) Apply LOCQUIC retaining compound, No. 40-31 to SIDES of machine key (See Fig. 7) and
spread evenly. Remove excess LOCQUIC from shaft and key.
NOTE Manufacturers of recommended products are listed on the last page in this section.
(4) Remove 3/8 inch of insulation from ends of revolving field leads (See Fig. 8) and attach a 2-foot
length of small soft wire to each. Attachment may be made by wrapping wire tightly around lead
by soldering. These wires are necessary to start and pull leads through routing holes (6, Fig. 2)
in rotor core.
(5) Install rotor locating snap ring (if used) on generator shaft.
NOTE: Application of LOCTITE is to compensate for any looseness in machine key and keyway (up to
0.005 inch).
Applying "Locquic" Primer

Figure 6

Page 7
Applying "Loctite" to
Machine Key
Figure 7
b. Exciter Armature Installation

After exciter armature has been prepared for installation according to preceding instructions, proceed
with installation as follows:
(1) Align armature keyway with keyway in armature shaft and start armature onto shaft.
(2) Route the revolving field “pull” wires (installed in step 4 preceding) through routing holes (6, Fig.
2) and carefully pull leads into these routing holes. Figure 9 shows how this should be done.
(3) If the armature-to-generator shaft fit is such that the armature may be pushed on by hand, push
it on very slowly while another mechanic carefully watches and pulls the field leads through the
routing holes. Continue installation until armature core contacts the shoulder of the shaft.
If the rotor cannot be pushed by hand, mount an installation tool on the generator shaft. (See
Figures 10, 11, and 12). Push the armature on slowly and, at the same time, pull field leads
through armature tubes. Stop pushing as soon as armature core contacts the shoulder of the
shaft. Remove installation tool.
(4) Route field leads through holes in rectifier base. Remove “pull” wires and clamp ring type
terminals on field leads (See Fig. 13). Attach one lead to the nearest diode in the POSITIVE
group of three and attach the other lead to the nearest diode in the NEGATIVE group of three
(See Fig. 14). It makes no difference to which group of diodes (POSITIVE or NEGATIVE) a lead
is attached. The important thing is - DO NOT ATTACH BOTH LEADS TO DIODES INTHE
SAME GROUP. BE SURE ONE LEAD IS ATTACHED TO THE POSITIVE GROUP AND THE
OTHER TO THE NEGATIVE GROUP.

Page 8
(5) When field leads are properly attached to diodes, pull the excess lead back through the rectifier
body so that any looseness is between the rectifier and exciter armature windings. Press loose
part of leads down against rotor shaft between rectifier and exciter armature windings. Wrap 4
or 5 turns of linen tape around the armature shaft (See Fig.15 ) to position and secure leads.
Tie tape ends together in a secure knot and cut off excess tape ends. Apply a coat of clear,
air-drying varnish to the tape wrap. (See Fig. 16).
CAUTION
Do not use adhesive tape for securing leads. It may come loose and cause
damage to exciter armature.
(6) Insert UNTHREADED end of machine key (8, Fig. 2) in the keyway to tighten the exciter
armature to the generator shaft, then tap it lightly until the threaded end of the key is flush with
the end of the shaft.
(7) Secure the exciter armature on generator shaft with the 1/2-13 cap screw.
(8) Install exciter housing cover.
(9) Install louvered exciter cover on end of canopy.
CAUTION
Allow at least 6 hours for complete cure and set up of Loctite before operating
machine.
Generator
Revolving Field
Leads
Figure 8

Page 9
Pulling Generator
Field Leads Through
Armature
Figure 9
Simple Tool for Armature Installation

Figure 10

Page 10
Instructions for Making Exciter Armature Installation Tool

Figure 11

Page 11
Pushing Armature
onto Shaft With
Special Tool
Figure 12
Attaching Field Lead

Terminals
Figure 13

Page 12
Armature installed, Field

Leads Attached, and
Armature
Retainer Installed
Figure 14
Securing Leads to
Shaft with Tape
Figure 15

Page 13
Applying Varnish to
Tape
Figure 16
5. Recommended Products Manufacturers

“LOCQUIC” No. 47-56, Primer Grade T, Manufactured by Loctite Corporation, Newington, Connecticut
06111
“LOCTITE” No. 40-31, Retaining Compound, Manufactured by Loctite Corporation, Newington,
Connecticut 06111
“NOCO10" Varnish No. T-211 (clear, air dry), Manufactured by Sterling Division of Reichhold Chemical
Incorporated, Marysville, Pennsylvania 17053

Page 14
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 Series 5384E trailer and/or truck-mounted Diesel Engine Generator Sets manufactured by
Hobart Brothers Company, Power Systems Division, Troy, Ohio, 45373.
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
available commercially.
(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.
(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to
other parts, weldments, or assemblies.
b. Parts List Form
(1) “FIGURE-ITEM NO.” Column
This column lists the figure number of the illustration applicable to a particular parts list and also
identifies each part in the list by an item number. These item numbers also appear on the
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.
March 08/96 Revised Chapter 4-1

Page 1
(2) “HOBART PART NUMBER” Column

ALL part numbers appearing in this column are Hobart numbers. In all instances where the part
is a purchased item, the vendor’s identifying five-digit code and his part number will appear in the
“NOMENCLATURE” column. Vendor parts which are modified by Hobart will be identified as
such in the “NOMENCLATURE” column. In case Hobart does not have an identifying part
number for a purchased part, the “HOBART PART NUMBER” column will reflect “No Number”
and the vendor’s number will be shown in the “NOMENCLATURE” column. Parts manufactured
by Hobart reflect no vendor code or part number in the “NOMENCLATURE” column.
(3) “NOMENCLATURE” Column
The item identifying name appears in this column. The indenture method is used to indicate item
relationship. Thus, components of an assembly are listed directly below the assembly and
indented one space. Vendor codes and part numbers for purchased parts are shown in this
column. Hobart modification to vendor items is also noted in this column.
(4) “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 items are used on all models.
Items coded A are used on Speficication 5384E-1 (-50, -51) units.
Items coded B are used on Speficication 5384E-4 (-50, -51) units.
Items coded C are used on Speficication 5384E-5 (-50, -51) units.
Items coded D are used on Speficication 5384E-9 (-50) units.
Items coded E are used on Speficication 5384E-10 (-50) units.
Items coded F are used on Speficication 5384E-11 (-52, -53) units.
Items coded G are used on Speficication 5384E-14 (-52, -53) units.
Items coded H are used on Speficication 5384E-15 (-52, -53) units.
Items coded J are used on Speficication 5384E-16 (-52, -53) units.
Items coded K are used on Speficication 5384E-17 (-52) units.
Items coded L are used on Speficication 5384E-18 (-52) units.
(5) “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.
March 08/96 Revised Chapter 4-1

Page 2
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
Manufacturer’s Cataloging Handbook H4-1, and are arranged in numerical order. Vendor codes are
insert ed in the nomenclature column of the parts list directly following the item name and description. In
case a manufacturer does not have a vendor code, the full name of the manufacturer will be listed in the
nomenclature column.
Code Vendor’s Name & Address Code Vendor’s Name & Address
00779 AMP Inc. 07088 Kelvin Electric Co.

P.O. Box 3608 5907 Noble Avenue
Harrisburg, Pennsylvania 17105 Van Nuys, California 91411
01428 Tuthill Corporation - Linkage Div. 08108 Lamp Industry for use with Industry
2110 Summit Street P.O. Box 227 Designations and Abbreviations
New Haven, Indiana 46774 for Lamps
01843 American Bosch Marketing 13445 Cole-Hersee Company

Division of Ambac Industries Inc. 20 Old Colony Avenue
3664 Main Street Boston, Massachusetts 02127
Springfield, Mass. 01107
14101 Sprague Electric Company
02231 Anchor Rubber Company 87 Marshall St.
840 South Patterson Boulevard North Adams, Mass. 01247
P.O. Box 832
Dayton, Ohio 45401 14831 Magnetic Components, Inc.
5907 Noble Avenue
02660 Bunker Ramo Corporation Van Nuys, California 91411
Borg Electronics North Am. Div.
2801 South 25th Ave. 15434 Cummins Engine Company
Broadview, Illinois 60153 1000 Fifth St.
Columbus, IN 47201
03924 STRATOFLEX, INC.
Ft. Wayne, Indiana 15605 Eaton Corp., Cutler-Hammer Div.
4201 N. 27th St.
04009 Crouse-Hinds Arrow-Hart Corporation Milwaukee, Wisconsin 53216
Arrow Hart Division
103 Hawthorne Street 16238 Lord Manufacturing Co, Inc.
Hartford, Connecticut 06105 Sterling Road
South Lancaster, Mass. 01561
04713 Motorola, Inc.
Semiconductor Products Division 16764 Delco Remy
Phoenix, Arizona 85008 Div. of General Motors Corp.
2401 Columbus Avenue
05277 Westinghouse Electric Corp. P.O. Box 2439
Semiconductor Div. Hill St. Anderson, Indiana 46018
Youngwood, PA 15697

Page 1
OM-2011BA / Operation and Maintenance Manual
19220 Eberhard Manufacturing Company 30327 Imperial Clevite Inc.

21944 Drake Road Fluid Components Division
Strongsville, Ohio 44136 6300 W. Howard Street
Chicago, Illinois 60648
20038 ESB Inc.
5 Penn Center Plaza 31356 J-B-T Instruments, Inc.
P.O. Box 8109 394 East Street
Philadelphia, Penn. 19101 P.O. Box 1818
New Haven, CT 06508
21335 Fafnir Bearing Company
Div. of Textron 31510 Main Line Supply Co.
37 Booth Street 905 E. 3rd St.
New Britain, Connecticut 06050 Dayton, OH 45402
21585 Farr Company, Airport Station 35738 Charles Lentz & Sons
P.O. Box 92187 3330 N. Broad
Los Angeles, California 90009 Philadelphia, Pennsylvania 19140
21678 Uniroyal Inc. 41197 Modine Manufacturing Company

Plastic Products Division 312 N. Hill St. 1500 Dekoven Avenue
Mishawaka, Indiana 46544 Racine, Wisconsin 53401
24161 The Gates Rubber Co. 41625 INCOM International Inc.

999 S. Broadway P.O. Box 5887 Morse Controls Division
Denver, CO 80217 21 Clinton Street
Hudson, Ohio 44236
24248 Southco Inc.
210 N. Brinton Lake Road 44655 Ohmite Manufacturing Company
Concordville, PA 19331 3601 W. Howard Street
Skokie, Illinois 60076
24617 General Motors Corp.
General Motors Bldg. 49234 Protectoseal Company
3044 Grand Blvd. W. 225 W. Foster Avenue
Detroit, Michigan 48202 Bensenville, Illinois 60106
26403 ITT-Grinnell Corp. 51589 Sarkes Tarzian Semicon Inc.

260 W. Exchange Street Broadcast Equipment Division
Providence, RI 02901 415 N. College Avenue
Bloomington, Indiana 47401
26992 Hamilton Watch Company
941 Wheatland Avenue 56289 Sprague Electric Company
P.O. Box 3420 87 Marshall St.
Lancaster, Pennsylvania 17604 North Adams, Mass. 01247
27191 Cutler-Hammer Inc. 57448 Allis Chalmers Corp.

Power Distribution & Control Division Stephens & Adamson Mfg. Subsidiary
4201 N. 27th Street 275 Ridgeway Avenue
Milwaukee, Wisconsin 53216 P.O. Box 1367
Aurora, Illinois 60507
28520 Heyman Mfg. Company
147 Michigan Avenue 57733 Hobbs Division,
P.O. Box 160 Stewart-Warner Corporation
Kenilworth, N.J. 07033 1826 Diversey Parkway
Chicago, IL 60614

Page 2
58849 FMC Corp. 74063 Figgie International Inc.

Material Handling Equipment Division Hartman Electrical Manufacturing Div.
446 Lexington Avenue 175 N. Diamond
Homer City, Pennsylvania 15748 P.O. Box 8
Mansfield, Ohio 44902
59730 The Thomas & Betts Company Hwy.
218 South 74400 Stewart Warner Corp, Hobbs Division
Iowa City, Iowa 52240 Ash Street & Yale Boulevard
Springfield, Illinois 62705
60741 Triplett Electrical Instrument Company
Harmon Rd. 75175 K-D Lamp Company
Bluffton, Ohio 45817 1910 Elm St.
Cincinnati, Ohio 45210
61112 Cleanweld Products Co., Turner Division
821 Park Avenue 75358 Knape & Vogt Manufacturing Co.
Sycamore, Illinois 60178 2700 Oak Industrial Drive
Grand Rapids, Michigan 49505
66295 Wittek Microdot Fastening Systems
Special Components Division 75418 Kysor Industrial Corporation
1421 Barnsdale Road One Madison Avenue
La Grange Park, Illinois 60525 Cadillac, Michigan 49601
70040 AC Spark Plug Division 77342 American Machine & Foundry Inc.
General Motors Corporation Potter & Brumfield Division
1300 N. Dort Highway 200 Richland Creek Dr.
Flint, Michigan 48556 P.O. Box 522
Princeton, Indiana 47670
70485 Atlantic India Rubber Works, Inc.
571 W. Polk Street 77910 Speareflex Flexible Controls Div.
Chicago, Illinois 60607 CR Industries Inc.
241 E. Kalamazoo Avenue
71400 Bussman Manufacturing Division of Kalamazoo, Michigan 49007
McGraw & Edison Company
114 Old State Road P.O. Box 14460 78225 Stant Manufacturing Company Inc.
St. Louis, Missouri 63178 1620 Columbia Avenue
Connersville, Indiana 47331
71744 General Instrument Corp, Lamp Division
443 North Ravenswood Avenue 78553 Eaton Corp, Tinnerman Products Div.
Chicago, Illinois 60640 8700 Brookpark Road
P.O. Box 6688
72582 Detroit Diesel Allison Division Cleveland, Ohio 44101
General Motors Corporation
13400 W. Outer Drive 79470 Dana Corp., The Weatherhead Division
Detroit, Michigan 48228 767 Beta Drive
Cleveland, Ohio 44143
72619 Dialight Division Amperex Corp.
203 Harrison Place 80996 ITT-Grinnel Corp.
Brooklyn, New York 11237 260 W. Exchange St.
Providence, RI 02901
73559 Carlingswitch Inc.
505 New Park Avenue
West Hartford, Connecticut 06110

Page 3
OM-2011BA / Operation and Maintenance Manual
81074 ITT_Holub Industries, Inc. 89616 Uniroyal Inc.

413 Elm St. Plastic Products Division
Sycamore, Illinois 60178 312 N. Hill St.
Mishawaka, Indiana 46544
81082 Electric Auto-Lite Company
Lebanon Road 90201 Emhart Ind. Inc., Mallory Capacitor
Cincinnati, Ohio 45241 4760 Kentucky Ave.,
P.O. Box 372
81703 Mulberry Metal Products, Inc. Indianapolis, Indiana 46206
2199 Stanley
Terrace Union, NJ 07083 90763 TRW Inc., United Carr Division
10544 W. Lunt Avenue
81860 Barry Wright Corp. Rosemont, Illinois 60618
Barry Controls Div.
700 Pleasant St. 91637 Dale Electronics, Inc.
Watertown, Mass. 02172 P.O. Box 609
Columbus, Nebraska 68601
81861 Wyle Laboratories
Burton Electrical Engineering Div 91929 Honeywell, Inc.
111 Maryland St. Buildings Controls & Components Group
El Segundo, CA 90245 Micro Switch Division
Freeport, Illinois 61032
81872 Olympic Plastics Co.
Sub. of Intercontinental Diamond Corp. 92563 McGill Manufacturing Company, Inc.
5800 W. Jefferson Blvd. Bearing Division
Los Angeles, CA 90016 909 N. Lafayette
Valparaiso, Indiana 46383
83315 Hubbel Corporation
407 E. Howly 94222 Southco Inc.
Mundetein, Ill. 60060 210 N. Brinton Lake Road
Concordville, PA 19331
84970 Sarkes Tarzian Semicon Inc.
Broadcast Equipment Division 95879 Alemite Instrument Division of
415 N. College Avenue Stewart-Warner Corporation
Bloomington, Indiana 47401 1826 Diversey Parkway
Chicago, Illinois 60614
85925 Emico Inc. (Electro Mechanical
Instrument Company, Inc.) 98110 Naval Air Facility
123 N. Main St. El Centro, California 92243
P.O. Box 368
Dublin, PA 18917 98410 E.T.C.- Molex Inc.
5201 Richmond Rd.
89110 AMP Inc., Capitron Div. Bedford Heights, Ohio 44146
1595 South Mt. Joy Street
Elizabethtown, Pennsylvania 17022 98738 Stewart-Warner Electronics
Div. of Stewart-Warner Corp.
89373 United States Rubber Tire Company 1300 N. Kostner Chicago, Illinois 60651
Division of Uniroyal Inc.
3920 Big Beaver Rd., Suite 200 98991 Worchester Controls Corporation
P.O. Box 3939 Worchester Valve Division
Troy, Michigan 48084 125 Hartwell Street
West Boyleston, Massachusetts 01583

Page 4
Section 3. Parts List
1. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a left hand 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.
This parts list is all-inclusive, in that it covers parts for all sixteen of the trailer and/or truck-mounted
generator set specifications available in generator set Series 5384E. For parts used only on one
particular generator set, refer to the effectivity (EFF) code in this parts list for that generator set.
2. Symbols and Abbreviations

A, or AMP - ampere
AR - as required
DC - direct current
Fig. - Figure
hd. - head
hex - hexagon
IN - inch
F - microfarad
No. - number
Ω - Ohm
OM - Owners Manual
July 18/96 Revised Chapter 4-3

Page 1
Generator Set
Figure 1

Page 2
NOMENCLATURE UNITS
FIGURE & HOBART per
ITEM NO. PART NO. 1234567 EFF ASSY
1- 5384E-1 GENERATOR SET, TRAILER/TRUCK

MOUNTING A 1
5384E-4 GENERATOR SET, TRAILER/TRUCK
MTG, WITH 28.5V TRANSFORMER-
RECTIFIER , 35-V TRANSFORMER
RECTIFIER, AND TWO DUPLEX
RECEPTACLES B 1
MOUNTING, WITH SGX GOVERNOR C 1
5384E-9 GENERATOR SET, TRAILER MOUNTING
WITH DUAL OUTPUTS D 1
WITH FUEL PRESSURE GAGE AND
OUTPUT RECEPTACLE E 1
5384E-11 GENERATOR SET, TRAILER/TRUCK MTG F 1
MOUNTING WITH 28.5V TRANSFORMER-
RECTIFIER , 35-V TRANSFORMER-
RECTIFIER AND TWO DUPLEX
RECEPTACLES G 1
5384E-15 GENERATOR SET, TRAILER/TRUCK MTG,
WITH SGX GOVERNOR H 1
MOUNTING, WITH DUAL OUTPUTS J 1
5384E-17 GENERATOR SET, TRAILER MOUNTING,
WITH FUEL PRESSURE GAGE AND
OUTPUT RECEPTACLE K 1
WITH SPECIAL TRAILER FOR FEDERAL
EXPRESS L 1
1-1 DDW-155 . EYE, LIFTING 1
1-2 489825 . CANOPY ASSY (For Details See Fig. 2) A,C,E,F
H,K,L 1
489823 . CANOPY ASSY (For Details See Fig. 2) D,J 1
489868 . CANOPY ASSY (For Details See Fig. 2) B,G 1
1-3 No Number . GENERATOR SET WITHOUT CANOPY
(For Details See Fig. 3) 1
1-4 No Number . FRAME ASSY, MOUNTING & LIFTING YOKE
1-5 402987 . NAMEPLATE, HOBART 3
1-6 481386-5 . BODY, TRUCK (For Details See Fig. 20) 1

Page 3
Canopy Assembly
Figure 2

Page 4
NOMENCLATURE UNITS
FIGURE & HOBART AIRLINE per
ITEM NO. PART NO. PART NO. 1234567 EFF ASSY
2- 489825 . CANOPY ASSY (For NHA see Fig. 1) A,C,E,F,

H,K,L REF
489823 . CANOPY ASSY (For NHA see Fig. 1) D,J REF
489868 . CANOPY ASSY (For NHA see Fig. 1) B,G REF
2 -1 482333 . PANEL ASSY, SIDE, RIGHT, FRONT
CANOPY 1
2 -2 482320 . DOOR ASSY, LEFT & RIGHT, FRONT
CANOPY 2
2 -3 482321 . DOOR ASSY, RIGHT, FRONT, CANOPY 1
2 -4 482322 . DOOR ASSY, RIGHT, REAR, CANOPY 1
2 -5 482376 . COVER ASSY, OPENING, TOP 2
2 -6 482323 . DOOR ASSY, RIGHT REAR, CANOPY 1
2 -7 482327 . BRACKET, MTG., LATCH, DOOR 3
2 -8 76A-1115 . LATCH, ADJUSTABLE GRIP, V94222
NO. 48-99-126-11 4
2 -9 481418 . TOP ASSY, REAR, CANOPY 1
2 -10 481419 . SUPPORT, MTG., REAR, CANOPY 1
2 -11 482469 . PANEL ASSY, END, REAR, CANOPY 1
489443 . PANEL ASSY, END, REAR, CANOPY 1
2 -12 482401 . COVER, PLEXIGLASS, GENERATOR
CONTROLS 1
2 -13 489032 . DOOR ASSY, LEFT, REAR, CANOPY 1
2 -14 489030 . COVER, PLEXIGLASS, ENGINE
CONTROLS 1
2 -15 482426 . PANEL ASSY, SIDE, LEFT, REAR, A,C,E,F,
CANOPY H,K,L 1
482029 . PANEL ASSY, SIDE, LEFT, REAR,
CANOPY D,J 1
482877 . PANEL ASSY, SIDE, LEFT, REAR,
CANOPY B,G 1
2 -16 480695 . DOOR ASSY, ACCESS, RECEPTACLE 1
2 -17 403127 . CATCH, MAGNETIC, V94222,
NO. 02-10-201-10 2
2 -18 482386 . DOOR ASSY, LEFT, REAR, CANOPY 1
484076 . DOOR ASSY, LEFT, REAR, CANOPY 1
2 -19 489052 . LATCH, DOOR, RECESSED, V19220,
NO. 3-4886 2
2 -20 482372 . DOOR ASSY, LEFT, FRONT, CANOPY 1
2 -21 482328 . PANEL ASSY, SIDE, RIGHT, REAR,
CANOPY 1
2 -22 481417 . TOP ASSY, FRONT, CANOPY 1

Page 5

Page 6
NOMENCLATURE UNITS
FIGURE & HOBART AIRLINE per
ITEM NO. PART NO. PART NO. 1234567 EFF ASSY
2- (CONTINUED)
2 -23 387450 . COVER ASSY, HOLE, RADIATOR 1
2 -24 482437 . FRONT ASSY, CANOPY 1
2 -25 482429 . PANEL ASSY, LOUVERED, FRONT,
CANOPY 1
2 -26 389284 . COVER, HOLE, FRONT, CANOPY 1
2 -27 481416 . SUPPORT ASSY, MTG. FRONT 1
2 -28 HJ-129A . JOINT, BALL, V01428, NO. SPS1002CP 8
2 -29 482407 . ROD, STOP, DOOR 6
2 -31 482424 . PANEL ASSY, SIDE, LEFT, FRONT 1
* 2 -31 480701 . SPACER, LATCH, DOOR 5
2 -32 482428 . PLATE, COVER 1
2 -33 482482 . BRACKET, MTG., LATCH, DOOR 1
* 2 -34 76A-1125 . LABEL, HAND, TACH 1
* 2 -35 482507 . ROD, STOP, DOOR 1
* 2 -36 488863 . ROD, STOP, DOOR 1
* 2 -37 403091-8 . PLUG, PLASTIC, 1-3/4, V28520, NO. P-1750 6
* 2 -38 404101-1 . LIGHT CLEARANCE, V75175,
NO. 514-0168 4
* Not Illustrated

Page 7
Generator Set Without Canopy

Figure 3

Page 8
NOMENCLATURE UNITS
FIGURE & HOBART per
3 - No Number GENERATOR SET WITHOUT CANOPY

(For NHA see Fig. 1) REF
3-1 No Number . RADIATOR AND COOLING SYSTEM GROUP
3-2 No Number . ENGINE AND AIR CLEANER GROUP
(For Details see Fig. 5) 1
** 3 - 3 430391C . REGULATOR ASSY, VOLTAGE
(For Details See Section 2-5) A-G,R 1
489812A . REGULATOR ASSY, VOLTAGE
(For Details See Section 2-5) H-Q 1
** 3 - 4 482319 . PANEL ASSY, TERMINAL, STATOR
*3-5 482075-1 . PANEL ASSY, POWER MODULE
(For Details See Fig.12) 1
* 3 -6 482235-4 . GENERATOR CONTROL BOX GROUP A,B,D-G,
(For Details see Fig. 12) J-L
482235-3 . GENERATOR CONTROL BOX GROUP
(For Details see Fig. 12) C,H
3-7 482296-2 . PANEL ASSY, CONTROL, ENGINE
(For Details See Fig. 17) A,F 1
482296-8 . PANEL ASSY, CONTROL, ENGINE
(For Details See Fig. 17) B,G 1
(For Details See Fig. 17) C,H 1
(For Details See Fig. 17) D,J 1
(For Details See Fig. 17) E,K 1
(For Details See Fig. 17) L 1
3-8 482325 . BRACKET, MOUNTING, PANEL, CONTROL 2
3-9 482314 . BRACKET, MOUNTING, RECEPTACLE E,K 1
3 -10 400162 . RECEPTACLE, V81861, NO. AN-3114-1B E,K 1
3 -11 482318 . COVER, PANEL, OUTPUT TERMINAL
AND STATOR TERMINAL 2
3 -12 482317 . PANEL ASSEMBLY, OUTPUT
TERMINAL (For Details See Fig. 10) A-C,F-H,L 1
484107 . PANEL ASSEMBLY, OUTPUT
TERMINAL (For Details See Fig. 10) D,J 1
3 -13 280786A . GENERATOR ASSY (For Details
See Fig. 18) 1
* Not Illustrated

Page 9

Page 10
NOMENCLATURE UNITS
FIGURE HOBART per
3- No Number GENERATOR SET WITHOUT

CANOPY (Continued)
* 3 -14 HF-2752 . MOUNT, RUBBER (Used to mount
electrical panels on control box
support panel) V16238, No. 4624-105 12
3 -15 No Number . FRAME ASSY, MOUNTING & LIFTING
YOKE (For Details See Fig. 19) REF
484066-1 . SECOND OUTPUT D,J 1
3 -16 484067 . . PANEL, POWER MODULE ASSY.
3 -17 484070 . . SUPPORT, POWER MODULE,
MOUNTING D,J 4
484086 . . BRACKET, SWITCH & LIGHT ASSY D,J 1
3 -18 482326 . . HORN, CABLE CLAMP, ASSY D,J 1
3 -19 403127 . . CATCH, MAGNETIC, V94222,
No. 02-10-201-10 D,J 1
3 -20 480695 . . DOOR, ACCESS, RECEPTACLE,
ASSY D,J 1
* 3 -21 484244A . . HARNESS, WIRE, SECOND OUTPUT D,J 1
* 3 -22 76B-1127 . LABEL, OPERATING INSTRUCTIONS 1
* 3 -23 286629 . SWITCH, FUEL PRESSURE 1

Page 11
Radiator and Cooling System Group

Figure 4

Page 12
NOMENCLATURE UNITS
FIGURE HOBART per
4- No Number RADIATOR AND COOLING SYSTEM

388425 . RADIATOR ASSEMBLY 1
4-1 387878 . . HEAD ASSEMBLY, RADIATOR 1
4-2 50GHP-89 . . STRIP, REINFORCING 4
4-3 50GHP-82 . . GASKET, RADIATOR 2
4-4 387913 . . SHROUD, RADIATOR 1
4-5 5CW-1932-0 . . VALVE, DRAIN, V79470, NO. 145 1
4-6 387914 . . BASE ASSEMBLY, RADIATOR 1
4-7 387313 . . RAIL ASSEMBLY, SIDE, RADIATOR 2
4-8 402958 . . CORE, RADIATOR, V41197,
SIZE 26 In. X 28 In. X 2-11/32 In. 1
4- 9 387881 . . ANGLE, MOUNTING 1
4 -10 355194 . . PIPE, OVERFLOW 1
* 4 -11 56555 . . HOSE, OVERFLOW, (LENGTH 45 IN.) 1
* 4 -12 386751 . . CLAMP, RETAINER 2
4 -13 403034 . CAP, RADIATOR, V78225, NO. AAX-0B48 1
388219-1 . LINE ASSEMBLY, SUPPLY 1
4 -14 W-10869-2 . . CLAMP, HOSE, V66295, NO. C52P 4
4 -15 56501 . . HOSE, RUBBER, RADIATOR, 3 PLY 1 IN. I.D. 34"
4 -16 W-10890-6 . . ELBOW, PIPE 2
4 -17 385275 . . PIPE, LINE 2
4 -18 W-7814-5 . . BUSHING, PIPE, 3/4 O.D. X 1/2 I.D. 1
4 -19 W-10760-1 . . NIPPLE, PIPE, 1/2-14 1
4 -20 56532 . HOSE, RADIATOR, INLET 11"
4 -21 W-10869-3 . CLAMP, HOSE, RADIATOR, V66295,
NO. C32P 4
* 4 -22 W-10869-2 . CLAMP, HOSE, RADIATOR, V66295,
NO. C20P 2
4 -23 56532 . HOSE, RADIATOR, OUTLET 14"
* 4 -24 389421 . BRACE, LINE, SUPPLY 1
4 -25 HF-2962 . CLAMP, HOSE, BRACE 1
* 4 -26 12CW-908 . CLAMP, LINE, VENT 1
4 -27 W-7814-2 . . BUSHING, PIPE, 3/8 O.D. TO 1/4 I.D. 2
4 -29 W-10893-2 . . SWIVEL, FEMALE, SAE-45, V30327,
NO. KA04-04NS 2
4 -30 402499-1 . . CLAMP, HOSE, V35738, NO. J340 2
4 -31 56534 . . HOSE, LOW-PRESSURE, HIGH-TEMP
1/4 I.D. LENGTH 18-1/2 IN. 1
4 -32 389909 . GUARD, FAN, LEFT 1
4 -33 180132 . GUARD, FAN, RIGHT 1
* 4 -34 351541 . LABEL, CAUTION, FAN 2
* NOT ILLUSTRATED

Page 13
Engine and Air Cleaner Group

Figure 5

Page 14
NOMENCLATURE UNITS
FIGURE HOBART per
5- No Number ENGINE & AIR CLEANER GROUP

5- 1 404006 . ENGINE, DETROIT DIESEL, 3- A,B,D-G,
CYLINDER, MODEL NO. 3-71N J-L 1
78B-1076 . ENGINE, DETROIT DIESEL, 3-CYLINDER
WITH SGX GOVERNOR, MODEL
NO. 3-71N C,H 1
5- 2 403782-0 . DEVICE, TEMPERATURE, HIGH, V75418,
NO. 33080-205 1
5- 3 387607A . PIPE, AIR CLEANER 1
388535 . KIT, ASSY, AIR CLEANER 1
5- 4 403064 . . CLAMP, FITTING, V21585, NO. L-4690-11 1
5- 5 403065 . . COUPLING, RUBBER, V21585,
No. A-19054-10 1
5- 6 387629 . . HOUSING, CLEANER, AIR, V21585,
No. C24625-7 1
5- 7 403156 . . CARTRIDGE, FILTER, V21585,
No. P-24 1
5- 8 83A-1026 . . INDICATOR, SERVICE FILTER, CARTRIDGE
V21585, NO.L-14440-001 1
5- 9 403157 . . ELIMINATOR, MOISTURE, V21585,
No. D56519-16 1
5 -10 403774 . . FASTENER
* 5 -11 402436 . . KIT, INSTALLATION, INDICATOR,
SERVICE, V21585, No. L-14439 1
5 -12 403264 . GOVERNOR ASSY, OVERSPEED, V78388,
NO. SA503A-P 1
* 5 -13 W-7814-9 . BUSHING, HIGH TEMP. DEVICE 1
5 -14 403412 . ADAPTER, TACH, DRIVE, V72582,
NO. 1565170 1
5 -15 482529 . PIPE, OIL FILL 1
5 -16 403409 . CAP, OIL FILL, V24617, NO. 5117362 1
5 -17 480629 . GASKET, MANIFOLD 1
5 -18 480630 . PIPE, MUFFLER TO MANIFOLD 1
5 -19 480621 . GASKET, MUFFLER 1
5 -20 480648 . MUFFLER 1
* Not Illustrated
** Located or connected at rear of engine control panel

Page 15
NOMENCLATURE UNITS
FIGURE HOBART per
5- No Number ENGINE & AIR CLEANER GROUP (Continued)

5 -21 480618 . BRACKET, MOUNTING, EXHAUST, OUTLET 1
5 -22 480619 . BRACKET, MOUNTING, MUFFLER 1
* 5 -23 30GH-417 . MOUNT, SHOCK, V21678, NO. 314C 2
5 -24 404568 . SOLENOID, STARTER, AUX. V16764,
NO. 1114537 1
5-25 482093 . BRACKET, MOUNTING, SOLENOID 1
5-26 387293 . SWITCH ASSY, STARTER CUT-OUT
5-27 181018 . KIT ASSEMBLY, GOVERNOR, A,B,D-G,
ELECTRIC (For Details See Fig.7) J-L 1
5-28 402908 . JOINT, BALL, THROTTLE CONTROL,
V57448, No. TF-4Y C,H 1
5-29 483991 . DISK, ACTUATOR, MICRO-SWITCH C,H 1
5-30 78A-1085 . ARM, LEVER, THROTTLE, V72582 C,H 1
5-31 483989 . BRACKET, MOUNTING, THROTTLE
CONTROL C,H 1
5-32 483990 . PLATE, MOUNTING, MICRO-SWITCH C,H 1
5-33 DW-4866 . SWITCH, MICRO THROTTLE, V91929,
No. BZ-2RA2 C,H 1
5-34 78A-1092 . VALVE, SHUTDOWN, ENGINE C,H 1
5-35 484014 . BRACKET, MOUNTING, VALVE C,H 1
5-36 30GH-1189-1 . CONTROL, THROTTLE, V41625,
No. D44196 C,H 1
* 5-37 483914 . BRACKET, MOUNTING, FILTER
GOVERNOR C,H 1
* 5-38 483916 . LINES, OIL FILTER, GOVERNOR, ASSY C,H 1
* 5-39 483958 . SPACER, AIR CLEANER, PIPE C,H 1
* 5-40 388437 . GASKET, INTAKE MANIFOLD C,H 1
* 5-41 483959 . SPACER, AIR CLEANER C,H 1
* 5-42 483992 . ADAPTER, THROTTLE CONTROL C,H 1
* 5-43 5AW-989 . NAMEPLATE, THROTTLE C,H 1
* 5-44 78A-1093 . TOP, GOVERNOR C,H 1
* 5-45 484265-1 . SPACER, TUBING, 1/4 C,H 1
* 5-46 484015 . LINES, VALVE, SHUTDOWN C,H 1
* 5-47 79A-1015 . COVER, CYLINDER HEAD, GOVERNOR C,H 1
* 5-48 12CW-908 . CLAMP, FUEL LINE C,H 1
* 5-49 30GH-1259 . CLAMP, MOUNTING, THROTTLE C,H 1
* 5-50 402119-30 . SCREW, 1/4 - 20 X 1 HHC, GRADE 8 C,H 3
* 5-51 483971 . COLLAR, SHAFT THROTTLE C,H 1
* 5-52 79A-1000 . LEVER, THROTTLE SHAFT C,H 1
* Not Illustrated

Page 16
NOMENCLATURE UNITS
FIGURE HOBART per
5- No Number ENGINE & AIR CLEANER GROUP (Continued)

* 5-53 79A-1001 . LEVER, THROTTLE SHAFT C,H 1
* 5-54 79A-1002 . LINK, GOVERNOR LEVER-TO-
THROTTLE ARM C,H 1
* 5-55 484464-1 . SHAFT, THROTTLE C,H 1
* 5-56 79A-1003 . BRACKET, THROTTLE SHAFT C,H 1
* 5-57 W-11563 . PIN, CLEVIS C,H 1
* 5-58 486192 . SCREW, SGX GOVERNOR C,H 1
* 5-59 486191 . TUBE, OUTLET, ASSEMBLY C,H 1
* 5-60 6FW-5047 . SPACER, FUEL FILTER 6
* 5-61 W-9234-55 . CABLE, STARTER TO GROUND 1
* 5-62 484838 . KEY, TACH DRIVE V24617, NO. 6478641 1
* 5-63 482506 . LINES ASSEMBLY, FUEL (For
Details See Fig. 8 ) 1
* 5-64 482494 . LINES ASSEMBLY, OIL (For Details See Fig. 9) 1
* 5-65 60GHP-416 . BRACKET, MTG., FUEL LINES 2
* 5-66 60GHP-424 . BRACKET, MTG., FUEL LINES 2
* Not Illustrated

Page 17
Starter Cut-out Switch Assembly

Figure 6

Page 18
NOMENCLATURE UNITS
FIGURE HOBART per
6- 387293 SWITCH ASSEMBLY, STARTER CUT-OUT

6 -1 No Number . SOLENOID (For details See Engine
Operator’s Manual) 1
6 -2 No Number . ARM SUPPORT (Furnished with engine) 1
6 -3 387295 . ACTUATOR, SWITCH 1
6 -4 387294 . BRACKET, MOUNTING, SWITCH 1
6 -5 DW-4866 . SWITCH, MICRO V91929, No. BZ-2RA2
WITH ACTUATOR No. MC-7711 1

Page 19
Electric Governor Assembly

Figure 7

Page 20
NOMENCLATURE UNITS
FIGURE HOBART per
7- 181018 KIT, ASSEMBLY, GOVERNOR, A,B,D-G,

ELECTRIC (For NHA See Fig.3) J-L REF
** 7 - 1 181020 . CONTROLLER, ELECTRIC GOVERNOR 1
7- 2 84A-1075 . MOUNT, SHOCK, RUBBER 4
7- 3 404595 . SENSOR, MAGNETIC, GOVERNOR 1
7- 4 181019 . ACTUATOR, ELECTRIC GOVERNOR 1
7- 5 404594 . ARM, THROTTLE, ENGINE 1
7- 6 402908 . JOINT, BALL, GOVERNOR LINKAGE V57448,
No. TF-4Y 2
7- 7 W-9476-16 . ROD, THREADED, 1/4-28 X 3-7/8 1
7- 8 85A-1047 . LEVER, ACTUATOR 1
7- 9 482152 . BRACKET, MOUNTING, ACTUATOR 1
* 7 -10 482989 . STRAP, WIRE, GROUND 2
* 7 -11 482170 . SPACER, HOLE, BALL JOINT 1
* 7 -12 W-799F-110 . SPRING, THROTTLE CONTROL 1
* Not Illustrated
** This unit is mounted to back of generator control box.

Page 21
Fuel Lines Assembly

Figure 8

Page 22
NOMENCLATURE UNITS
FIGURE HOBART per
8- No Number LINES, FUEL, ASSEMBLY (For NHA

See Fig.5) REF
8- 1 403592 . VALVE, CHECK V72582, No. 5122279 1
8- 2 400059-1 . CONNECTOR, FEMALE V79470,
No. 46 X 6 1
8- 3 403590-3 . FITTING, SWIVEL, FEMALE V03924,
No. 7115-6S 2
8- 4 56550 . HOSE, #6, 5/16 I.D. Length 65" 1
8- 5 W-10891-10 . ELBOW, MALE V79470, No. 2
8- 6 W-11608-3 . TEE, PIPE, 1/2 IN. 1
8- 7 W-10760-1 . NIPPLE, CLOSE 1/2 IN. 1
8- 8 W-10893-0 . SWIVEL, FEMALE V30327, No. KA 06-06NS 1
8- 9 56535 . HOSE, LOW PRESSURE 3/8 IN. I.D.
Length 33-inch 1
8 -10 W-10891-10 . ELBOW MALE V79470, No. 49 X 8 X 4 5
8 -11 403590-4 . FITTING, SWIVEL, FEMALE V03924,
No. 7115-8S 8
8 -12 56551 . HOSE #8, 13/32 In. I.D. 53.5"
8 -13 W-10891-9 . ELBOW, MALE V79470, No. 49 X 8 X 8 1
8 -14 W-7814-5 . BUSHING, PIPE 3/4 X 1/2 2
8 -15 400819-1 . VALVE, MALE (ECON-O-MITE) V98991,
No.4211B 1
8 -16 12CW-2077-3 . ELBOW, STREET, 1/2IN. V26403, 90 1
8 -17 W-10760-3 . NIPPLE, PIPE, 1/2 IN. 1
8 - 18 W-10892-2 . ELBOW, STREET, 3400 X 4, V26403,
#3400 X 4 1
8 - 19 W-10886-4 . CONNECTOR, MALE, WEATHERHEAD 1
8 - 20 W-10886-6 . CONNECTOR, MALE, WEATHERHEAD 1
* Not Illustrated

Page 23
Oil Line Assembly

Figure 9

Page 24
NOMENCLATURE UNITS
FIGURE HOBART per
9- 482494 . LINE ASSEMBLY, OIL (For NHA See Fig.5) REF

9 -1 W-10886-1 . CONNECTOR, MALE, V79470,
48 X 4 1
9 -2 403590-1 . SWIVEL, FEMALE, SAE 45, FLARED, V03924,
NO. 7115-4S 2
9 -3 DELETED
9 -4 56548 . HOSE, 3/16 IN. I.D. 51"
9 -5 W-10891-7 . ELBOW, MALE, V79470, #49 X 4 1

Page 25
Output Terminal Panel Assembly

Figure 10

Page 26
NOMENCLATURE UNITS
FIGURE HOBART per
10 - 482317 PANEL, TERMINAL, OUTPUT,

ASSEMBLY(For NHA See Fig. 3) A-C,F-H,LREF
10 - 484107 PANEL, TERMINAL, OUTPUT,
ASSEMBLY (For NHA See Fig. 3) D,J REF
10 - 1 50MS-732-0 . NUT, HEX, 1/4-20, KEPS, MH, STEEL A-C,F-H,L 12
50MS-732-0 . NUT, HEX, 1/4-20, KEPS, MH, STEEL D,J 30
10 - 2 W-11242-5 . WASHER, FLAT, 1/4 IN., STEEL A-C,F-H,L 12
W-11242-5 . WASHER, FLAT, 1/4 IN., STEEL D,J 30
10 - 3 W-9549-19 . ROD, TERMINAL 1/4-20 X 2-1/4 A-C,F-H,L 2
W-9549-19 . ROD, TERMINAL 1/4-20 X 2-1/4 D,J 6
10 - 4 482445 . BRACKET, MOUNTING, BOARD, TERM.,
OUTPUT 2
10 - 5 W-11097-18 . SCREW, HHC, STEEL, 3/8-16 X 3/4 A-C,F-H,L 8
W-11097-18 . SCREW, HHC, STEEL, 3/8-16 X 3/4 D,J 16
10 - 6 W-11254-6 . WASHER, LOCK, STEEL, 3/8 IN. A-C,F-H,L 8
W-11254-6 . WASHER, LOCK, STEEL, 3/8 IN. D,J 16
10 - 7 W-11242-10 . WASHER, FLAT, STEEL, 3/8 IN. A-C,F-H,L 8
W-11242-10 . WASHER, FLAT, STEEL, 3/8 IN. D,J 16
10 - 8 482446 . RETAINER, CABLE A-C,F-H,L 8
482446 . RETAINER, CABLE D,J 16
10 - 9 482443 . BAR, BUS, PHASE A-C,F-H,L 4
482443 . BAR, BUS, PHASE D,J 8
10 -10 W-11112-3 . SCREW, RD. HD., MH, STEEL, 10-24 X 3/4 A-C,F-H,L 4
W-11112-3 . SCREW, RD. HD., MH, STEEL, 10-24 X 3/4 D,J 8
10 -11 W-11254-3 . WASHER, 10, LOCK, STEEL A-C,F-H,L 4
W-11254-3 . WASHER, 10, LOCK, STEEL D,J 8
10 -12 W-11245-3 . WASHER, 10, FLAT, BRASS A-C,F-H,L 4
W-11245-3 . WASHER, 10, FLAT, BRASS D,J 8
10 -13 482444 . BOARD, TERMINAL, OUTPUT A-C,F-H,L 1
482444 . BOARD, TERMINAL, OUTPUT D,J 2
10 -14 484071 . BRACKET, MOUNTING, BOARD,
TERMINAL, OUTPUT 2
10 -15 75NH-307 . NAMEPLATE, #2 OUTPUT D,J 1
10 -16 75NH-306 . NAMEPLATE, #1 OUTPUT A-C,F-H,L 1
* 482400 . COVER, OUTPUT TERMINALS 1
* Not Illustrated

Page 27
Terminal Stator Panel Assembly

Figure 11

Page 28
NOMENCLATURE UNITS
FIGURE HOBART per
11 - 482319 PANEL ASSEMBLY, TERMINAL, STATOR

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

Page 29
Power Module Panel Assembly

Figure 12

Page 30
NOMENCLATURE UNITS
FIGURE HOBART per
12 - 482075-1 . PANEL, ASSY, POWER MODULE

12 - 1 401937-3 . STRIP, TERMINAL, V98410, NO. 35012-3536 2
12 - 2 401937-2 . STRIP, TERMINAL, V98410, NO. 35008-3536 1
12 - 3 W-9746-1 . RESISTOR, LINE DROP BURDEN, 50 OHM,
25 WATT, V44655, NO. 0200D 3
12 - 4 404402-2 . RESISTOR OVERLOAD BURDEN, 25 OHMS
V91637, NO. RH-25, 20 WATT 3
12 - 5 1CZ-148 . TRANSFORMER, CURRENT LINE DROP
& OVERLOAD, V14831, NO. E-6170 6
12 - 6 404065-2 . RECTIFIER, SILICON, V04713,
NO. SDA 10270-2 1
12 - 7 282130-1 . CONTACTOR, LOAD, Furnas Electric Co.,
NO. 421F109137R 1
12 - 8 387738A . BOARD ASSEMBLY, PC OVERLOAD 1
12 - 9 401564-4 . HOUSING, SOCKET, CONNECTOR,
V89110, NO. 1-480287-0 1
12 -10 401566-11 . TERMINAL, SOCKET, V89110, NO. 60619-1 10
12 -11 403763-1 . WASHER, FIBER, SHOULDER 4
12 -12 401556 . MOUNT, SHOCK, RUBBER, V89616, NO. B-323
OR V81860, NO. SS-01 4
12 -13 363136-2 . TRANSFORMER, CURRENT, AMMETER 3
12 -14 400701 . CONNECTOR, RIGHT ANGLE V59730,
NO. TA-250-8 5
12 -15 401939 . ADAPTER, TERMINAL, V98410, NO. VWA-0 1
12 -16 400830-15 . TERMINAL, RING TONGUE, V89110,
NO. 31159 3
12 -17 402197-1 . TERMINAL, QUICK CONNECT, PIGGYBACK,
V89110, NO. 61944-2 1
12 -18 400480-2 . TERMINAL, QUICK CONNECT,
V00779, NO. 41274 5
12 -19 400480-3 . TERMINAL, QUICK CONNECT,
V00779, NO. 42640-2 2
* 12 -20 1CZ-93B . DIODE, SILICON, V05277, NO. IN4820 1
12 -21 482076 . PANEL, POWER MODULE 1
* 12 -22 W-9060-279 . CABLE ASSEMBLY, POWER ELECTRICAL
(No. 101) “A” Stator Terminal Panel to
“A” Contactor; (No. 102) “B” Stator Terminal
Panel “B” Contactor; (N0. 103 “C” Stator
Terminal Panel to “C” Contactor; (No. 110)
“N” Terminal to “N” Output Terminal Panel 4
* Not Illustrated

Page 31

Page 32
NOMENCLATURE UNITS
FIGURE HOBART per
12 - 482075-1 . PANEL, ASSY, POWER MODULE

(Continued) REF
* 12 -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
*12 -24 W-9360-278 . CABLE ASSEMBLY, POWER ELECTRICAL
(No. 111) “N” Terminal to Ground 1
484067 PANEL ASSEMBLY, POWER MODULE
(for NHA See Fig. 4) D,J REF
12 -25 482069 . PANEL, POWER MODULE ASSY. D,J 1
12 -26 401937-3 . STRIP, TERMINAL, V98410,
NO. 35012-3526 D,J 1
12 -27 404065-2 . RECTIFIER, SILICON, V04713
NO. SDA10270-2 D,J 1
12 -28 16DA-4052-0 . SOCKET, RELAY, V02660,
NO. 77-MIP-11 D,J 2
12 -29 1CZ-93B . DIODE, SILICON, V05277, NO. IN4820 D,J 1
12 -30 282130-1 . CONTACTOR, LOAD, Furnas Electric Co.,
No. 421F109137R D,J 1
12 -31 402037-14 . GROMMET, RUBBER D,J 3
12 -32 402662 . SWITCH, TOGGLE, DPST, V74559,
NO. 2GK71-73 D,J 1
12 -33 16DA-4004A-3 . RELAY, PLUG INTERLOCK, 24V DC
V77342, NO. KAP-14DG D,J 1
12 -34 16DA-4253-1 . RETAINER, SPRING, RELAY V77342,
NO. 20C206 D,J 2
12 -35 16DA-4004A-10 . RELAY, FUSE INTERLOCK, 12V
V77342, NO. KAP-14DG D,J 1
12 -36 W-9746-3 . RESISTOR, 100 OHM, 25 WATT
V44655, NO. 0200F D,J 1
*12 -37 1CZ-93B . DIODE, SILICON, V05277, NO. IN4820 D,J 1
*12 -38 400480-3 . TERMINAL, QUICK CONNECT, V00779,
NO. 42640-2 D,J 2
* Not Illustrated

Page 33
Generator Control Box Group

Figure 13

Page 34
NOMENCLATURE UNITS
FIGURE HOBART per
13 - 482235-4 GENERATOR CONTROL BOX GROUP A,B,D-G

(For NHA see Fig. 3) J-L REF
13 - 482235-3 GENERATOR CONTROL BOX GROUP
(For NHA see Fig. 3) C,H REF
13 - 1 482278-4 . TRAY ASSEMBLY, GENERATOR A,B,D-G
CONTROLS (For details see Fig. 14) J-L 1
13 - 1 482278-5 . TRAY ASSEMBLY, GENERATOR
CONTROLS (For details see Fig. 14) C,H 1
13 - 2 482285-1 . TRAY ASSEMBLY, PROTECTIVE
RELAYS (For details see Fig. 15) 1
13 - 3 NO NUMBER . CONTROL BOX AND INTERNAL
COMPONENTS ASSY. (For details
see Fig. 16) 1
* Not Illustrated

Page 35
Generator Controls Tray Assembly

Figure 14

Page 36
NOMENCLATURE UNITS
FIGURE HOBART per
14 - 482278-4 TRAY ASSEMBLY, GENERATOR A,B,D-G

CONTROLS (For NHA see Fig. 13) J-L REF
482278-5 TRAY ASSEMBLY, GENERATOR
CONTROLS (For NHA see Fig. 13) C,H REF
14 - 1 482355 . HARNESS, WIRE, RECEPTACLE A,B,D-G
J-L 1
14 - 1 484501 . HARNESS, WIRE, RECEPTACLE C,H
14 - 2 482284-1 . BRACKET, MTG., RECEPTACLE &
SWITCH 1
14 - 3 402826 . SWITCH, AUTOMATIC, MANUAL,
V15605, NO. 8926K425 1
* 14 - 4 402665-1 . HOUSING, RECEPTACLE, V00779,
NO. 1-480416-0 6
14 - 5 404065-2 . RECTIFIER, SILICON, V04713,
NO. SDA10270-2 1
14 - 6 W-2974-L . RESISTOR, MANUAL, 50 OHM, 100 WATT
V44655, NO. 0959 1
14 - 6A 400078 . BRACKET, MOUNTING, RESISTOR 6
14 - 7 W-2974-N . RESISTOR, BALLAST, V44655, 100 WATT 2
14 - 8 16DA-4253-1 . RETAINER, SPRING, RELAY, V77342,
NO. 20C206 1
14 - 9 16DA-4004A-10 . RELAY, EXCITATION, DEENERGIZATION
12V, V77342, NO. KAP-14DG 1
14 -10 16DA-4052-0 . SOCKET, RELAY, V02660, NO. 77-MIP-11 1
*14 -11 363771-5 . SLEEVING, PLASTIC, 1/8 IN. I.D. 6
*14 -12 363770-1 . SLEEVING, PLASTIC, 3/16 IN. I.D. 2
14 -13 16DA-4029 . BRACKET, MOUNTING, SOCKET, RELAY 1
14 -14 16DA-2162 . KNOB, RHEOSTAT, V44655, NO. 5150 1
14 -15 10J-178 . NAMEPLATE, FIELD, RHEOSTAT 1
14 -16 381439 . BRACKET, MOUNTING, RHEOSTAT 1
14 -17 402218 . RHEOSTAT, MANUAL, MODEL L,
V44655, 100 OHMS, 150 WATTS 1
14 -18 HF-1459 . SWITCH, METER SELECTOR,
V04009, NO. 81579-FT 1
14 -19 15GH-433 . NAMEPLATE, METER, SELECTOR
SWITCH 1
14 -20 400400 . SWITCH, TOGGLE, V74559,
NO. 26L61TABS 1
14 -21 W-8095A-8 . AMMETER, V60741, NO. 331LH 1
* Not Illustrated

Page 37

Page 38
NOMENCLATURE UNITS
FIGURE HOBART per
14 - (Continued) REF
14 -22 W-8105A-4 . VOLTMETER, V60741, NO. 331LH 1
14 -23 W-9916-10 . METER, FREQUENCY, V31356,
NO. 36-FX 1
14 -24 388328-51 . NAMEPLATE, IDENTIFICATION A,B,D-G
J-L 1
14 -24 388328-65 . NAMEPLATE, IDENTIFICATION C,H 1
482279 . TRAY, SUB-ASSY, GENERATOR
CONTROL 1
14 -25 370382A . . HANDLE, TRAY 1
14 -26 404028 . . NAMEPLATE, HOBART 1
14 -27 76A-1115 . . LATCH, ADJUSTABLE GRIP, V94222,
NO. 48-99-126-11 1
14 -28 402383 . . SLIDE ASSY, TRAY, (Consists of four
parts marked CR, CL, DR, & DL) V75358,
NO. 1336-12 1 SET
14 -29 482280 . . TRAY ASSEMBLY 1
*14 -30 400030-1 . CAPACITOR, TANTALUM 6.8 F, 35V,
V56289, NO. 150D685X9035B2 1
*14 -31 482306 . HARNESS ASSY, WIRE, GEN. CONTROL TRAY 1
*14 -32 402379 . . PLUG, STRAIGHT, 20 CONTACT V02660,
NO. MS-3106A-28-16S 1
*14 -33 402382 . . CLAMP, CABLE, V02660, NO. MS-3057-16 1
*14 -34 484689-1 . . SLEEVING, SHRINKABLE, 1/8 ID AR
* Not Illustrated

Page 39
Protective Relays Tray Assembly

Figure 15

Page 40
NOMENCLATURE UNITS
FIGURE HOBART per
15 - 482285-1 . TRAY ASSEMBLY, PROTECTIVE

RELAYS (For NHA see Fig. 13) REF
15 - 1 402662 . SWITCH, TEST BANK, V73559,
NO. 2GK71-73 1
15 - 2 492284-2 . BRACKET, MTG., RECEPTACLE & SWITCH 1
15 - 3 482356 . RECEPTACLE, HARNESS, WIRE 1
15 - 4 16DA-4052-0 . SOCKET, RELAY V02660, NO. 77-MIP-11 3
15 - 5 16DA-4004A-3 . RELAY, PLUG INTERLOCK, 24 VDC 1
15 - 6 16DA-4253-1 . RETAINER, SPRING, RELAY V77324, NO. 20C206 3
15 - 7 16DA-4004A-10 . RELAY, FUSE INTERLOCK, NO. KAP-14DG 2
15 - 8 W-9746-3 . RESISTOR, 100 OHM, 25 WATT, V44655, NO. 0200F 1
15 - 9 401937-1 . STRIP TERMINAL, V98410, NO. 35005-3526 1
15 -10 401556 . MOUNT, SHOCK, RUBBER, V98373,
NO. B-323 OR SS-01 12
15 -11 387736C . BOARD, ASSY, MEMORY AND TIME DELAY 1
15 -12 401563-5 . . HOUSING, PIN, CONNECTOR 1
15 -13 482038 . BOARD ASSY, OVER-UNDERVOLTAGE 1
15 -14 401563-4 . . HOUSING, PIN, CONNECTOR 1
15 -15 482039A . BOARD, ASSY, OVER-UNDERFREQUENCY 1
15-16 401563-4 . . HOUSING, PIN, CONNECTOR 1
15-17 76A-1118 . SWITCH, SNAP, PUSHBUTTON, V27191,
NO. SA35BCB34-9 2
15-18 403336 . RING, LOCKING SWITCH V91929, TS10020 2
15-19 HF-2518-2 . LIGHT, PILOT, FAULT, 12-V, RED 5
15-19A 404172-1 . . LENS, RED, V72619, NO. 26-1101-300 1
15-20 400613-4 . . BULB, V7144, TYPE 1815 1
15- 21 402658 . HOLDER, FUSE, V71400, NO. HKP-HH 2
15-22 W-11166-1 . FUSE, AGC, 2A. 1
15-23 W-11166-1 . FUSE, AGC, 2A. 1
15-24 403091-6 . BUTTON, PLUG, HOLE 1
15-25 402037-9 . GROMMET, RUBBER, V02231, NO. AGW-4211 1
*15-26 388328-52 . NAMEPLATE, IDENTIFICATION 1
*15-27 401566-11 . TERMINAL, SOCKET, V89110, N. 60619-1 35
*15-28 401564-4 . HOUSING, SOCKET, CONNECTOR, V89110
NO. 1-480287-0 2
* Not Illustrated

Page 41

Page 42
NOMENCLATURE UNITS
FIGURE HOBART per
15 - (Continued) REF
* 15 -29 401564-5 . HOUSING, SOCKET, CONNECTOR, V89110
NO. 1-480438-0 2
15 -30 482291 . NAMEPLATE, PROTECTIVE SYSTEM 1
482286 . TRAY, ASSY, PROTECTIVE RELAYS 1
15 -31 402383 . . SLIDE ASSY, TRAY, (Consists of four
parts marked CR, CL, DR & DL)
V75358, NO. 1336-12 1 Set
15 -32 404028 . . NAMEPLATE, HOBART 1
15 -33 370382A . . HANDLE, TRAY 1
15 -34 76A-1115 . . LATCH, ADJUSTABLE GRIP, V94222
NO. 48-99-126-11 1
15 -35 482287 . . TRAY ASSEMBLY 1
* 15 -36 482307 . HARNESS ASSY, WIRE, PROTECTIVE
RELAYS TRAY 1
* Not Illustrated

Page 43
Control Box and Internal Components Group

Figure 16

Page 44
NOMENCLATURE UNITS
FIGURE HOBART per
16 - No Number CONTROL BOX AND INTERNAL COMPONENTS

ASSEMBLY (For NHA see Fig. 13) REF
16 - 1 402037-9 . GROMMET, RUBBER V02231, NO. AGW-4211 2
16 - 2 82B-1047 . LIGHT ASSY, PANEL V75175, NO. 261-3306 2
16 -2A 82A-1048 . . LENS, CLEAR, V75175, NO. 40944-001 1
16 - 3 50GHP-206 . . BULB V08108, NO. 67 OR T631 1
16 - 4 W-10051-10 . CLAMP, WIRE, PLASTIC V81074, NO. EC-10 3
16 - 5 W-10051-13 . CLAMP, WIRE, PLASTIC V81074, NO. EC-14 2
16 - 6 402383 . SLIDE ASSY, TRAY
(For Details see Tray Assemblies, Fig. 17 or 18) REF
16 - 7 482236 . BOX ASSY, CONTROL 1
16 - 8 401937-3 . STRIP, TERMINAL V98410,
NO. 35012-3526 1
* 16 - 9 401556 . MOUNT, SHOCK, RUBBER V81860,
NO. SS-01 OR V89373, NO. B-323 REF

Page 45
Engine Control Panel

Figure 17

Page 46
NOMENCLATURE UNITS
FIGURE HOBART per
17 482296-2 PANEL ASSY, CONTROL, ENGINE

(For NHA see Fig. 3) A,F REF
(For NHA see Fig. 3) B,G REF
(For NHA see Fig. 3) C,H REF
(For NHA see Fig. 3) D,J REF
(For NHA see Fig. 3) E,K REF
(For NHA see Fig. 3) L REF
17 - 1 482297 . PANEL, CONTROL, ENGINE A,D,F,J,L 1
17 - 1 482855 . PANEL, CONTROL, ENGINE B,G 1
17 - 1 484016 . PANEL, CONTROL, ENGINE C,H 1
17 - 1 485660 . PANEL, CONTROL, ENGINE E,K 1
17 - 2 482300 . NAMEPLATE, CONTROLS ABEFGKL 1
17 - 2 485388 . NAMEPLATE, CONTROLS D,J 1
17 - 3 82B-1047 . LIGHT ASSY, PANEL, V75175,
NO. 261-3306 1
82A-1048 . . LENS, CLEAR, V75175,
NO. 40944-001 1
50GHP-206 . . BULB, V08108, NO. 67 FOR 12V 1
17 - 4 12CW-1320A-5 . GAUGE, FUEL V98738, NO. 301-4 1
17 - 5 FW-1312 . SWITCH, TOGGLE V27191,
NO. 7320K3 1
17 - 6 402889-2 . AMMETER V85925, NO. 730-D-5 A-D,F-J,L 1
17 - 7 403189 . SWITCH, TOGGLE V91929,
NO. 312TS1-59 A-C,E-H,KL 2
403189 . SWITCH, TOGGLE V91929,
NO. 312TS1-59 D,J 3
17 - 8 W-9917-18 . METER, ENGINE, HOUR V26992,
NO. 771-4/50 A-K 1
17 - 8 181358 . METER, ENGINE, HOUR V57733,
NO. 80001 L 1
17 - 9 DW-4304 . GAUGE, TEMP, WATER V81082,
NO. 8585A 1
17-10 HF-2518-8 . LIGHT, PILOT, ENGINE & GEN. (GRN) 2
400613-4 . . BULB, V08108 NO. 1815 1
404172-3 . . LENS, GREEN V72619,
NO. 26-1192-300 1
* Not Illustrated

Page 47

Page 48
NOMENCLATURE UNITS
FIGURE HOBART per
17 - (Continued)
17 -11 DW-6080 . GAUGE, PRESSURE, OIL V81082,
NO. 75, TYPE “C” 1
* 17 -12 W-10910-0 . TEE, PIPE V79470, NO. 3700 X 2 1
* 17 -13 402130 . SWITCH, PRESSURE, OIL, V74400,
NO. M-4006 1
17 -14 403091-4 . BUTTON, PLUG, HOLE 1
17 -15 83A-1026 . INDICATOR, SERVICE FILTER, AIR
CLEANER, V21585, NO. L-14440-001 REF
17 -16 76B-1129 . CONTROL, ENGINE STOP V41625
NO. B048701-000-0108 AB,D-G,J-L 1
17 -17 W-11166-3 . FUSE, AGC, 10 AMP. 1
17 -18 402658 . HOLDER, FUSE V71400,
NO. HKP-HH 1
17-19 401937-3 . STRIP, TERMINAL V98410,
NO. 35012-3526 1
17 -20 404100 . SWITCH, PUSHBUTTON, STARTER
V700400, NO. 1996027 A,C-F,H-L 1
17 -21 1CZ-93B . DIODE, SILICON V05277, NO. IN4820 2
17 -24 401937-2 . STRIP, TERMINAL V98410,
NO. 35008-3526 1
17 -22 400480-3 . TERMINAL, QUICK CONNECT V00779,
NO. 42640-2 3
17 -23 400701 . CONNECTOR, RT. ANGLE, V59730,
NO. TA-250-8 5
17 -25 403091-2 . BUTTON, PLUG, HOLE 1
17 -26 403380 . CAP & CHAIN ASSEMBLY
V02660, NO. 9760-28 1
17 -27 482304 . HARNESS ASSY, WIRE TEST
RECEPTACLE 1
17 -28 W-10051-13 . CLAMP, WIRE, PLASTIC 1
* Not Illustrated

Page 49
Generator Assembly
Figure 18

Page 50
NOMENCLATURE UNITS
FIGURE HOBART per
18 - 280786A GENERATOR ASSY (For NHA See Fig. 3) REF

18 - 1 387617A . COVER, FAN, HOUSING 1
18 - 2 387621 . COVER, EXCITER HOUSING 1
18 - 3 488908 . FAN & COUPLING ASSEMBLY 1
**18 -3A W-11102-18 . SCREW, FLEXIBLE COUPLING 6*
* 18 - 4 482483 . SCREW, RETAINING 1
18 - 5 480669 . ADAPTER, FOOT, GEN. 2
* 18 - 6 W-11102-8 . SCREW, GEN. MTG. 6
18 - 7 488755 . COVER, END, EXCITER HOUSING 1
18 - 8 100GHP-66 . WASHER, RETAINING 1
18 - 9 387623-1 . CORE, ARMATURE ASSEMBLY 1
18 - 10 W-10875-1 . . DIODE, SILICON, 35 AMP, NEGATIVE
BASE, V51589, #ST460N 3
18 - 11 W-10874-1 . . DIODE, SILICON, 35 AMP, POSITIVE
BASE, V51589, #ST460P 3
18 - 12 386612 . RING, SPACER, COUPLING 1
*18 -12A W-11097-34 . . SCREW, SPACER RING 8
18 - 13 481379 . KEY, EXCITER 1
18 - 14 387624A-1 . HOUSING, EXCITER 1
18 - 15 100NH-2 . POLEPIECE, EXCITER 4
18 - 16 100NH-3 . INSULATION, EXCITER, WRAPPER 4
18 - 17 DATA 3190 . COIL, FIELD, EXCITER 1 SET
18 - 18 387620A-1 . HOUSING, FAN ASSEMBLY 1
18 - 19 85B-1039 . KEY, FLEXIBLE, COUPLING 1
18 - 20 W-10072-68 . BEARING, FRONT 1
18 - 21 W-10072-1 . BEARING, REAR 1
18 - 22 181786 . ARMATURE, AC/DC 1
18 - 23 387748-2 . HOUSING & STATOR ASSEMBLY 1
18 - 24 483993 . BRACKET, RETAINING BEARING 1
*18 - 25 385950 . INSULATION, TOE 16
*18 - 26 480603-1 . MOUNT, RUBBER 6
s*18 - 27 480628 . WASHER, MOUNT 6
* Not Illustrated
** Do Not Substitute - Requires 5/8 - 11 X 2-3/4 Sae Grade 5 For Safety.

Page 51
Frame Assembly, Mounting & Lifting Yoke

Figure 19

Page 52
NOMENCLATURE UNITS
FIGURE HOBART per
19 - No Number FRAME ASSEMBLY, MOUNTING &

LIFTING YOKE (For NHA See Fig. 1) REF
19 - 1 482316 . BRACKET, MOUNTING, SUPPORT,
BOX, CONTROL 2
19 - 2 482315 . PANEL, SUPPORT, CONTROL BOX 1
19 - 3 482311A . YOKE, LIFTING 1
19 - 4 480586A . FRAME, MOUNTING 1
19 - 5 481113 . PLATE, END, REAR, (Part of Item 4 Assembly) 1

Page 53
Truck Body Assembly

Figure 20

Page 54
NOMENCLATURE UNITS
FIGURE HOBART per
20 - 481386-5 BODY, TRUCK, ASSEMBLY FOR

TRUCK-MOUNTING OF GENERATOR
SET BY CUSTOMER (For NHA See Fig. 1) REF
20 - 1 482741 . FRAME, MOUNTING 1
20 - 2 482706 . TANK, FUEL, ASSEMBLY 1
20 - 3 481032 . PLATE, COVER, REAR 1
20 - 4 76A-1152 . CAP, PROTECTOSEAL, FILL 1
20 - 5 485477 . BOX, PLUG 1
20 - 6 83A-1069 . . SWITCH, MICRO 1
20 - 7 485474 . . PANEL, INTERIOR, PLUG BOX 1
20 - 8 485475 . . ACTUATOR, SWITCH 1
20 - 9 281871-1 . BATTERY, 12-V 1
20 -10 181831 . CLAMP, BATTERY, HOLD-DOWN 1
20 -11 5CW-2048 . ROD, BATTERY, HOLD-DOWN 2
20 -12 480711 . SUPPORT, BOX BATTERY, ASSEMBLY 1
* 20 -13 76B-1149 . LABEL, GASOLINE 1
* 20 -14 HF-530 . KNOB, PANEL, BATTERY BOX 1
* Not Illustrated

Page 55

Page 56
Section 4. Numerical Index
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 know. Part numbers are arranged in numeric-alpha sequence. Thus, any number
beginning with the letter “A” would be located toward the end of the index list. Likewise a part number
“1" would be listed near the end of the list. The figure number and item number location of the part is
directly opposite the part. If the part is used more than one place, each location is listed commencing
with the first location the part is listed.
PART NUMBER FIGURE - ITEM No.

ARM SUPPORT 6-2
CONTROL BOX AND INTERNAL COMPONENTS ASSY. 13-3, 16-0
DATA 3190 18-17
DDW-155 1-1
DW-4304 17-9
DW-4866 6-5
DW-4866 5-33
DW-6080 17-11
ENGINE AND AIR CLEANER GROUP 3-2, 5-0
FRAME ASSY, MOUNTING & LIFTING YOKE 1-4, 3-15, 19-0
FW-1312 17-5
GENERATOR SET WITHOUT CANOPY 1-3, 3-0
HF-1459 14-18
HF-2518-2 15-19
HF-2518-8 17-10
HF-2752 3-14
HF-2962 4-25
HF-530 20-14
HJ-129A 2-28
LINES, FUEL, ASSEMBLY 5-63, 8-0
RADIATOR AND COOLING SYSTEM GROUP 3-1, 4-0
SOLENOID 6-1
W-10051-10 16-4
W-10051-13 16-5, 17-28
W-10072-1 18-21
W-10072-68 18-20
W-10760-1 8-7
W-10760-1 4-19
W-10760-3 8-17

Page 1

W-10854-4 11-6
W-10869-2 4-14, 4-22
W-10869-3 4-21
W-10874-1 18-11
W-10875-1 18-10
W-10886-1 9-1
W-10886-4 8 - 19
W-10886-6 8 - 20
W-10890-6 4-16
W-10891-7 9-5
W-10891-9 8-13
W-10891-10 8-5
W-10891-10 8-10
W-10893-0 8-8
W-10893-2 4-29, 5-8
W-10910-0 17-12
W-11097-18 10-5, 11-1
W-11097-34 18-12A
W-11102-8 18-6
W-11102-18 18-3A
W-11166-1 15-22, 15-23
W-11166-3 17-17
W-11112-3 10-10, 11-10,
W-11242-5 10-2
W-11242-10 10-7, 11-3
W-11245-3 10-12, 11-12
W-11254-3 10-11, 11-11
W-11254-6 10-6, 11-2
W-11608-3 8-6
W-2974-L 14-6
W-2974-N 14-7
W-7814-2 4-27
W-7814-5 4-18, 8-14
W-7814-9 5-13
W-799F-110 7-12
W-8095A-8 14-21
W-8105A-4 14-22
W-9060-279 12-22

Page 2

W-9234-55 5-61
W-9360-211 12-23
W-9360-278 12-24
W-9476-16 7-7
W-9549-19 10-3
W-9746-1 12-3
W-9746-3 12-36, 15-8
W-9916-10 14-23
W-9917-18 17-8
1CZ-148 12-5
1CZ-93B 12-20, 12-29,12-37, 17-21
10J-178 14-15
100GHP-66 18-8
100NH-2 18-15
100NH-3 18-16
12CW-1320A-5 17-4
12CW-2077-3 8-16
12CW-908 4-26, 5-50
15GH-433 14-19
16DA-2162 14-14
16DA-4004A-3 12-33, 15-5
16DA-4004A-10 12-35, 14-9, 15-7
16DA-4029 14-13
16DA-4052-0 12-28, 14-10, 15-4
16DA-4253-1 12-34, 14-8, 15-6
180132 4-33
181018 5-27, 7-0
181019 7-4
181020 7-1
181358 17-8
181786 18-22
181831 20-10
280786A 3-13, 18-0
281871-1 20-9
282130-1 12-7, 12-30
30GH-1189-1 5-36
30GH-1259 5-49
30GH-417 5-23

Page 3

351541 4-34
355194 4-10
363136-2 12-13
363770-1 14-12
363771-5 14-11
370382A 14-25, 15-33
381439 14-16
385275 4-17
385950 18-25
386612 18-12
386751 4-12
387293 5-26, 6-0
387294 6-4
387295 6-3
387313 4-7
387450 2-23
387607A 5-3
387617A 18-1
387620A-1 18-18
387621 18-2
387623-1 18-9
387624A-1 18-14
387629 5-6
387736C 15-11
387738A 12-8
387748-2 18-23
387878 4-1
387881 4-9
387913 4-4
387914 4-6
388219-1 4-13
388328-51 14-24
388328-52 15-26
388328-65 14-24
388425 4-0
388437 5-40
388535 5-3
389284 2-26

Page 4

389421 4-24
389909 4-32
400030-1 14-30
400059-1 8-2
400162 3-10
400078 14-6A
400400 14-20
400480-2 12-18
400480-3 12-19, 12-38, 17-22
400613-4 15-20, 17-10
400701 12-14, 17-23
400819-1 8-15
400830-15 12-16
401556 12-12, 15-10, 16-9
401563-4 15-14, 15-16
401563-5 15-12
401564-4 12-9, 15-28
401564-5 15-29
401566-11 12-10, 15-27
401937-1 11-9, 15-9,
401937-2 12-2, 17-24
401937-3 12-1, 12-26,
16-8, 17-19
401939 12-15
402037-9 15-25
402037-9 16-1
402037-14 12-31
403091-6 15-24
402119-30 5-50
402130 17-13
402197-1 12-17
402218 14-17
402379 14-32
402382 14-33
402383 14-28
402383 16-6
402436 5-11
402499-1 4-30

Page 5

402658 15-21
402658 17-18
402662 12-32
402662 15-1
402665-1 14-4
402826 14-4
402889-2 17-6
402908 5-28, 7-6
402958 4-8
402987 1-5
403034 4-13
403064 5-4
403065 5-5
403091-2 17-25
403091-4 17-14
403091-8 2-37
403127 2-17, 3-19
403156 5-7
403157 5-9
403189 17-7
403264 5-12
403336 15-18
403380 17-26
402383 15-31
403409 5-16
403412 8-11
403590-1 9-2
403590-3 8-3
403592 8-1
403763-1 12-11
403774 5-10
403782-0 5-2
404006 5-1
404595 7-3
404028 14-26, 15-32
404065-2 12-6, 12-27, 14-5
404100 17-20
404101-1 2-38

Page 6

404172-1 15-19A
404172-3 17-10
404402-2 12-4
404568 5-24
404594 7-5
430391C 3-3
456548 9-4
480586A 19-4
480603-1 18-26
480618 5-21
480619 5-22
480621 5-19
480628 18-27
480629 5-17
480630 5-18
480648 5-20
480669 18-5
480695 2-16, 3-20
480701 2-31
480711 20-12
481032 20-3
481113 19-5
481379 18-13
481386-5 1-6, 20-0
481416 2-27
481417 2-22
481418 2-9
481419 2-10
482029 2-15
482038 15-13
482039A 15-15
482069 12-25
482075-1 3-5, 12-0
482076 12-21
482093 5-25
482152 7-9
482170 7-11
482235-3 3-6, 13-0

Page 7

482235-4 3-6, 13-0
482236 16-7
482278-4 13-1, 14-0
482278-5 13-1, 14-0
482279 14-24
482280 14-29
482284-1 14-3
492284-2 15-2
482285-1 13-2, 15-0
482286 15-30
482287 15-35
482291 15-30
482296-2 3-7
482296-2 17-0
482296-8 3-7
482296-8 17-0
482296-9 3-7
482296-9 17-0
482296-11 3-7
482296-11 17-0
`482296-15 3-7
482296-15 17-0
482296-23 3-7
482296-23 17-0
482297 17-1
482300 17-2
482304 17-27
482306 14-31
482307 15-36
482311A 19-3
482314 3-9
482315 19-2
482316 19-1
482317 3-12
482317 10-0
482318 3-11
482319 3-4
482319 711-0

Page 8

482320 2-2
482321 2-3
482322 2-4
482323 2-6
482325 3-8
482326 3-18
482327 2-7
482328 2-21
482333 2-1
482355 14-1
482356 15-3
482372 2-20
482376 2-5
482386 2-18
482400 10-16
482401 2-12
482407 2-29
482424 2-31
482426 2-15
482428 2-32
482429 2-25
482437 2-24
489443 2-11
482443 10-9
482443 11-5
482444 10-13
482445 10-4
482446 10-8
482446 11-4
482449 11-8
482450 11-13
482469 2-11
482471 11-7
482482 2-33
482483 18-4
482494 5-64, 9-0
484501 14-1
482506 5-63

Page 9

482507 2-35
482529 5-15
482706 20-2
482741 20-1
482855 17-1
482877 2-15
482989 7-10
483914 5-37
483916 5-38
483958 5-39
483959 5-41
483971 5-51
483989 5-31
483990 5-32
483991 5-29
483992 5-42
483993 18-24
484014 5-35
484015 5-46
484016 17-1
484066-1 3-15
484067 3-16, 12-24
484070 3-17
484071 10-14
484076 2-18
484086 3-17
484107 3-12, 10-0
484244A 3-21
484265-1 5-45
484464-1 5-55
484689-1 14-34
484838 5-62
485388 17-2
485474 20-7
485475 20-8
485477 20-5
485660 17-1
486191 5-59

Page 10

486192 5-58
488755 18-7
488863 2-36
488908 18-3
489030 2-14
489032 2-13
489052 2-19
489812A 3-3
489825 1-2, 2-0
489823 1-2, 2-0
489868 1-2, 2-0
5AW-989 5-43
5CW-1932-0 4-5
5CW-2048 20-11
50GHP-89 4-2
50GHP-82 4-3
50GHP-206 16-3, 17-3
50MS-732-0 10-1
5384E-1 1-0
5384E-4 1-0
5384E-5 1-0
5384E-9 1-0
5384E-10 1-0
5384E-11 1-0
5384E-14 1-0
5384E-15 1-0
5384E-16 1-0
5384E-17 1-0
5384E-18 1-0
56501 4-15
56532 4-20
56532 4-23
56534 4-31
56534 5-7
56535 8-9
56550 8-4
56551 8-12
56555 4-11

Page 11

6FW-5047 5-60
60GHP-416 5-65
60GHP-424 5-66
75NH-306 10-16
75NH-307 10-15
76A-1115 2-8
76A-1115 14-27
76A-1115 15-34
76A-1118 15-17
76A-1125 2-34
76B-1127 3-22
76B-1129 17-16
76A-1152 20-4
76B-1149 20-13
78A-1085 5-30
78A-1092 5-34
78A-1093 5-44
78B-1076 5-1
79A-1000 5-52
79A-1001 5-53
79A-1002 5-54
79A-1003 5-56
79A-1015 5-47
82A-1048 16-2A, 17-3
82B-1047 16-2, 17-3
83A-1026 5-6, 17-15
83A-1069 20-6
84A-1075 7-2
85A-1047 7-8
85B-1039 18-19

Page 12
Chapter 5. Manufacturer’s Literature
Voltage Regulator Hobart Brothers Company

OM-2011B, Section 2-5
Electric Governor Barber-Colman Electric Governor Instructions
Engine Detroit Diesel Corporation

In-Line Engine Operator’s Manual
Overspeed Governor Synchro-Start Products

Instructions for Overspeed Governor
Flexible Coupling Hobart Brothers Company

Exciter Rotor Hobart Brothers Company

Hobart Diagrams
482360 Schematic, Generator (All units except S-5384E- 4 & -14), or

482856 Schematic, Generator (S-5384E-4 & -14)
180894 Connection, Generator (All units except S-5384E-4, -5, -14, -15), or
181073 Connection, Generator (S-5384E-4 & -14), or
484017 Connection, Generator (S-5384E-5 & -15)
181071 Schematic, Engine (All units except S-5384E-5, -10, -15, -17), or
483973 Schematic, Engine (S-5384E-5 & -15), or
486658 Schematic, Engine (S-5384E-10 & -17)
482362 Connection, Engine (All units except S-5384E-5, -10, -15, -17), or
483974 Connection, Engine (S-5384E-5 & -15), or
486657 Connection, Engine (S-5384E-10 & -17)
482365 Connection, Generator Control Tray (All units except S-5384E-5, -15), or
484018 Connection, Generator Control Tray (S-5384E-5 & -15), or
482366 Connection, Protective Relays Tray (All units)
482099 Connection, Power Module (All units)
484226 Connection, Second Output (S-5384E-9, -16)

Page 1

Page 2
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 :
a. Exposure to:
(1) Combustible, explosive, abrasive or conducting dusts.
(2) Environments where the accumulation of lint or excessive dirt will interfere with normal
ventilation.
(3) Chemical fumes, flammable or explosive gases.
(4) Nuclear radiation.
(5) Steam, salt-laden air, or oil vapor.
(6) Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus
growth.
(7) Abnormal shock, vibration or mechanical loading from external sources during equipment
operation.
(8) Abnormal axial or side thrust imposed on rotating equipment shafts.
(9) Low and/or high ambient temperatures.
b. Operation at:
(1) Voltages above or below rated voltage.
(2) Speeds other than rated speed.
(3) Frequency other than rated frequency.
(4) Standstill with rotating equipment windings energized.
(5) Unbalanced voltages.
(6) Operation at loads greater than rated.
c. Operation where low acoustical noise levels are required.
d. Operation with:
(1) Improper fuel, lubricants or coolant.
(2) Parts or elements unauthorized by the manufacturer.
(3) Unauthorized modifications.
e. Operation in poorly ventilated areas.
June 1/92 Unusual Service Conditions

Page 1
Unusual Service Conditions June 1/92

Page 2

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OM-2011B

Operation and Maintenance Manual

SPEC No. MOUNTING VOLTAGE SPECIAL FEATURES

Hobart Brothers Company

Safety Instructions and Warnings for Electrical Power Equipment

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage

June 1/92 Safety Warnings

3. Service and Maintenance

4. Fire And Explosion Prevention

5. Bodily Injury Prevention

6. Medical and First Aid Treatment

IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie

7. Equipment Precautionary Labels

Safety Warnings June 1/92

June 1/92 Introduction

Write: Hobart Brothers Company

In U.S.A. Call: (800) 422-4166

From Foreign Countries, Call: (937) 332-5050 (Parts)

Fax: (937) 332-5121

Introduction June 1/92

Chapter - Section Page

Section 2. Preparation For Use, Storage, Or Shipping 1-2 1

June 1/92 Table of Contents

Chapter - Section Page

Preparation for Storage 1-2 2

Section 3. Operation 1-3 1

Table of Contents June 1/92

Chapter - Section Page

Drain the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 10

Section 2. Inspection / Check 2-2 1

Section 3. Adjustment / Test 2-3 1

June 1/92 Table of Contents

Chapter - Section Page

Electric Governor System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 12

Section 4. Troubleshooting 2-4 1

Section 5. Voltage Regulator 430391C

Table of Contents June 1/92

Chapter - Section Page

The Voltage Build-Up Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4

Section 5. Voltage Regulator 489812A

June 1/92 Table of Contents

Chapter - Section Page

Troubleshooting the Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 5

Chapter 3. Overhaul / Major Repair

Table of Contents June 1/92

Chapter - Section Page

Section 3. Exciter Armature Removal and Installation 3-3 1

Section 4. Four Wheel Trailer (When Used) 3-4 1

June 1/92 Table of Contents

Illustrated Parts List 3-4 15

Chapter 4. Illustrated Parts List

Section 2. Manufacturer’s Codes 4-2 1

Section 3. Illustrated Parts List 4-3 1

Section 4. Numerical Index 4-4 1

Chapter 5. Manufacturers Literature

Table of Contents June 1/92

June 1/92 Chapter 1-1

1. Canopy 6. Frame assembly

Chapter 1-1 June 1/92

4. Identification: Mounting Design and Additional Equipment