Om 2076D

OM-2076D
080604 Original
Operation and Maintenance Manual

with
Illustrated Parts List
for
90DZ20
90 kVA, 3 Phase, 115/200 Volt,
400 Hz. Generator Set
Series 500047D
ITW GSE Group
Hobart Ground Power
Troy, Ohio 45373
U.S.A.
Warranty
Data Sheet 165

Index: 990223
Replaces: 980601
HOBART GROUND POWER

TROY, OHIO 45373
1.
Hobart Brothers Company (hereinafter called HOBART) warrants that each new and unused Hobart Ground Power
Equipment, (hereinafter called the PRODUCT) is of good workmanship and is free from mechanical defects,
provided that (1) the PRODUCT is installed and operated in accordance with the printed instructions of HOBART,
(2) the PRODUCT is used under the normal operating conditions for which it is designed, (3) the PRODUCT is not
subjected to misuse, negligence or accident, and (4) the PRODUCT receives proper care, lubrication, protection,
and maintenance under the supervision of trained personnel.
2. This warranty expires 15 months after shipment by HOBART to the first user, or 12 months after installation,
whichever first occurs.
3. This warranty does not apply to: primary and secondary switch contacts, cable connectors, carbon brushes, fuses,
bulbs, and filters unless found to be defective prior to use.
4. Hobart DOES NOT WARRANT THE FOLLOWING COMPONENTS: Engines, engine components ; such as:
starters, alternators, regulators, governors, etc., and cable retrieving devices. Many of the foregoing components
are warranted directly by the manufacturer to the first user and serviced by a worldwide network of distributors and
others authorized to handle claims for component manufacturers. A first users claim should be presented directly
to such an authorized component service outlet. In the event any component manufacturer has warranted its
component to HOBART and will not deal directly with a first user then HOBART will cooperate with the first user
in the presentation of a claim to such manufacturer. Under NO circumstances does HOBART assume any liability
for any warranty claim against or warranty work done by or in behalf of any manufacturer of the foregoing
components.
5. This warranty is extended by HOBART only to the purchaser of new PRODUCTS from HOBART or one of its
authorized distributors. The PRODUCTS purchased under this warranty are intended for use exclusively by the
buyer and his employees and by no other persons and, therefore, there shall be no third party beneficiary to this
warranty.
6. A claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and
judgment. HOBARTS liability is limited to repair of any defects found by HOBART to exist, or at HOBARTS
option the replacement of the defective product, F.O.B. factory, after the defective product has been returned by the
purchaser at its expense to HOBARTS shipping place. Replacement and exchange parts will be warranted for the
remainder of the original Warranty, or for a period of ninety (90) days, whichever is greater.
7. UNDER NO CIRCUMSTANCES whatsoever shall HOBART and its authorized distributors be liable for any
special or consequential damages, whether based on lost goodwill, lost resale profits, work stoppage impairment
of other goods or otherwise, and whether arising out of breach of any express or implied warranty, breach of
contract, negligence or otherwise, except only in the case of personal injury as may be required by applicable law.
8. Continued use of the PRODUCT(S) after discovery of a defect VOIDS ALL WARRANTIES.
9. Except as authorized in writing, this warranty does not cover any equipment that has been altered by any party
other than HOBART.
10. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE
OF. HOBART MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
11. HOBART neither assumes nor authorizes any person to assume for HOBART any liability in connection with the
PRODUCTS sold, and there are no oral agreements or warranties collateral to or affecting this written Warranty.
This warranty and all undertakings of HOBART thereunder shall be governed by the laws of the State of Ohio,
United States of America.
WARNING
AT ALL TIMES, SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE INSTALLATION,
SERVICING AND OPERATION OF THE PRODUCT, AND SKILLED, TECHNICALLY QUALIFIED
PERSONNEL SHOULD ALWAYS BE EMPLOYED FOR SUCH TASKS.
OM-2076D / Operation and Maintenance Manual

90DZ20/ Series 500047D/ 400 Hz. Generator Set
Safety Warnings and Cautions

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
WARNING
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.
CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine exhaust and

some of its constituents are known to the State of California to cause cancer, birth
defects and other reproductive harm.
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, 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,
and 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
Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed and
maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or other applicable
codes. A power disconnect switch or circuit breaker must be located at the equipment. Check the
nameplate for 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.
August 6, 2004
Safety Warnings
Page 1

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.
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, or by disconnecting battery, 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 engine exhaust
pipes, misuse of batteries and fuel, or unsafe operating or fueling conditions.
a) Electrical Short Circuits and Overloads
Overloaded or shorted equipment can become hot enough to cause fires by self-destruction or by
causing nearby combustibles to ignite. For electrically powered equipment, provide primary input
protection to remove short circuited or heavily overloaded equipment from the line.
b) Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or use
open flame near the battery.
c) Engine Fuel
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is
not grounded prior to or during fuel transfer. Shut unit DOWN before opening fuel tank cap. DO NOT
completely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove
August 6, 2004
Safety Warnings
Page 2

all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, open equipment
doors and blow fumes away with compressed air.
5) Toxic Fume Prevention

Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust
fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air
conditioners.
6) Bodily Injury Prevention

Serious injury can result from contact with fans or hot spots inside some equipment. Shut DOWN such
equipment for inspection and routine maintenance. When equipment is in operation, use extreme care in
doing necessary trouble-shooting and adjustment. Do not remove guards while equipment is operating.
7) 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
FIRST AID
Call physician immediately. Seek additional assistance. Use First Aid techniques
recommended by American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down.
FOR 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.
8) Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be
easily read.
August 6, 2004
Safety Warnings
Page 3

This page intentionally left blank.
August 6, 2004
Safety Warnings
Page 4

Introduction
This manual contains operation and maintenance information for a 90DZ20, 400 Hz Generator Set
manufactured by ITW GSE Group, Hobart Ground Power, Troy, Ohio 45373.
This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics who have never operated
this equipment. It is the intent of this manual to guide and assist operators and maintenance people in the
proper use and care of the equipment.
Use of the manual should not be put off until a trouble or need for help develops. Read the instructions
before starting the unit. Learn to use the manual and to locate information contained in it. Its style and
arrangement are very similar to commercial aircraft manuals.
The manual is divided into five chapters plus an appendix. Each chapter is divided into as many sections as
required. Each new section starts with page 1. Each page is identified by chapter, section and page number,
which are located in the lower, outside corner. When information located in another portion of the manual is
referred to, its location is identified by a chapter, section, and paragraph or figure number.
For example: (see Section 2-3, Paragraph 1.a.) refers to information located in Chapter 2, Section 3,
Paragraph 1.a. If a chapter and section are not indicated in a reference, the referenced material is located in
the same section as the reference, for example: (see Paragraph 1.a.).
The Appendix is the last section. Its contains a list of available options that may be purchased with that unit.
Items on the list with check marks next to them, have been added to the standard unit per the customers
order. Literature for each option follows. The Appendix will help control the information in the manual:
making it unique to the unit purchased.
In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chapter
4, and a collection of manufacturers literature and supplemental information in Chapter 5.
Contents of the manual is arranged as follows:
Chapter 1. Description/Operation
Chapter 2. Servicing/Troubleshooting
Chapter 3. Overhaul/Major Repair
Chapter 4. Illustrated Parts List
Chapter 5. Manufacturers Literature
Appendix A Options
August 6, 2004
Introduction
Page 1

If you have any questions concerning your Hobart Ground Power equipment, immediately contact our Service
Department by mail, telephone, FAX, or E-Mail.
Write:
ITW GSE Group

Hobart Ground Power
Service Department
1177 Trade Road East
Troy, Ohio 45373
U.S.A.
Call Inside U.S.A.:
(800) 422-4166 (Parts)

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

(937) 332-5060 (Service)
FAX Inside U.S.A.
(800) 367-4945
FAX From Foreign Countries:
(937) 332-5121
E-Mail :
service@itwgsegroup.com
Web Page :
www.itwgsegroup.com
August 6, 2004
Introduction
Page 2

Table of Contents
Chapter 1
Description/Operation
Section 1
Description
1-1/1
General
1-1/1
Optional Equipment - Appendix A
1-1/1
Orientation
1-1/1
Special Features
1-1/1
Canopy
1-1/2
Engine and Generator
1-1/3
Control Box Assembly
1-1/10
Power Module Panel Assembly
1-1/21
Cold Weather Start System
1-1/22
Section 2
Section 3
Chapter-Section/Page#
Preparation for Use, Storage or Shipping
1-2/1
Preparation For Use
1-2/1
Preparation for Storage
1-2/3
Preparation for Shipment
1-2/4
Operation
1-3/1
General
1-3/1
400 Hz. Operation Procedure
1-3/1
DC Operation Procedure
1-3/6
Chapter 2
Servicing / Troubleshooting
Section 1
Maintenance Inspection/Check
2-1/1
General
2-1/1
Maintenance Schedule
2-1/1
Inspection / Check
2-1/3
Maintenance Procedures
2-2/1
General
2-2/1
Lubrication
2-2/1
Servicing The Air Cleaner
2-2/5
Engine Fuel
2-2/6
Engine Fuel System
2-2/7
Section 2
August 6, 2004
Table of Contents
Page 1

Section 2
(cont.)
Section 3
Section 4
Engine Cooling System
2-2/10
Generator Maintenance
2-2/13
Drive Belt
2-2/13
Adjustments / Tests
2-3/1
General
2-3/1
Testing the 400 Hz. Generator Set
2-3/1
Generator Set Adjustments
2-3/12
Generator and Exciter Test
2-3/15
Diode Test
2-3/16
Testing the Transformer-Rectifier
2-3/16
Troubleshooting Procedures
General
2-4/1
Equipment for Troubleshooting
2-4/1
Parts Replacement
2-4/1
400 Hz. Test Values
2-4/2
Check Connections and Leads
2-4/2
Engine Troubleshooting
2-4/2
Illustrations
2-4/2
Connection and Schematic Diagrams
2-4/2
GPU Control Monitoring
2-4/3
Troubleshooting Charts
2-4/10
Engine Controls
2-4/10
Generator Excitation Circuits
2-4/13
No. 1 Load Contactor Operating Circuit
2-4/14
2-4/16
Protective Circuit
2-4/18
Generator
2-4/19
Troubleshooting Tables GPU Commands
2-4/21
Troubleshooting Tables GPU Faults
2-4/25
Chapter 3
Overhaul / Major Repair
Section 1
Exciter Armature
3-1/1
General
3-1/1
Exciter Armature
3-1/2
Exciter Armature Replacement
3-1/3
Exciter Armature Installation
3-1/6
August 6, 2004
Table of Contents
Page 2

Section 2
Section 3
Dual Bearing Flexible Coupling

General
3-2/1
Disassembly
3-2/1
Coupling Service
3-2/4
Coupling Installation
3-2/5
Reassemble Engine and Generator
3-2/6
Run-in and Periodic Check
3-2/7
Generator Assembly
General
3-3/1
Generator Assembly Removal
3-3/1
Generator Assembly Installation
3-3/3
Chapter 4
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
Manufacture's Codes
4-2/1
Explanation of Manufacture's (Vendor) Code List
4-2/1
4-3/1
Explanation of Parts List Arrangement
4-3/1
Symbols and Abbreviations
4-3/1
Figure 1: General Assembly
4-3/2
Figure 2: Frame Assembly
4-3/4
Figure 3: Canopy Assembly
4-3/6
Section 2
Section 3
Figure 4: Internal Components
4-3/8
Figure 5: Control Box Door Panel Assembly
4-3/10
Figure 6: Control Box Interior Components
4-3/12
Figure 7: Control Switch Panel Components
4-3/14
Figure 8: Push-Buttons Details
4-3/16
Figure 9: 400 Hz. Power Module Assembly
4-3/18
Figure 10: Cooling System Components
4-3/20
August 6, 2004
Table of Contents
Page 3

Section 3
(cont.)
Section 4
Chapter 5
Figure 11: Engine Ground Plate and Cables
4-3/22
Figure 12: Fuel System Components
4-3/24
Figure 13: Engine Exhaust Components
4-3/26
Figure 14: 12 VDC Battery System
4-3/28
Figure 15: Air Cleaner Components
4-3/30
Figure 16: Engine Electrical Panel Components
4-3/34
Figure 17: Generator Assembly
4-3/36
Numerical Index
4-4/1
Explanation of Numerical Index
4-4/1
Manufacture's Literature
Appendix A Options/Features
Wet Stacking
Unusual Service Conditions
August 6, 2004
Table of Contents
Page 4

Chapter 1 Description/Operation
Section 1
Description
1) General
The basic generator set covered in this manual, manufactured by ITW GSE Group, Hobart Ground Power
is rated at 90 kVA and designed to produce and deliver 115/200-volt, 400 Hz, 3-phase AC power to a
parked aircraft or other load.
The number 500047D identifies the model or series of the GPU. The part number is followed by a
different dash number that separates the basic units available. Figure 1 uses the part number to identify
the variations covered in this manual.
Part & Dash Number
500047D-001
500047D-002
500047D-003
500047D-004
500047D-005
500047D-006
500047D-007
500047D-008
500047D-009
Model Description
Single Output, Trailer Mounted
Single Output, Fixed/Truck Mounted
Dual Output, Trailer Mounted
Dual Output, Fixed/Truck Mounted
Single Output, Trailer Mounted, 28.5 VDC TR
Single Output Fixed Mounted, 28.5 VDC TR
Dual Output, Trailer Mounted, 28.5 VDC TR
Dual Output, Fixed/Truck Mounted, 28.5 VDC TR
Single Output, Trailer Mounted (Special Configuration)
Series 500047D Generator Set Part Number Descriptions

Figure 1
2) Optional Equipment - Appendix A

Chapters 1 through 5 of this Operation and Maintenance Manual identifies only the strip down version of
the 90DZ20 generator set. A list of optional equipment which make this manual unique to the generator
set that you have purchased, appears in Appendix A. A few items included in Appendix A are cable trays,
trailers, 28-volt DC power transformer-rectifiers, etc.
3) Orientation
For purpose of orientation, the radiator is considered to be at the REAR of the unit. The generator and
controls are at the FRONT. RIGHT and LEFT are determined by standing at the REAR end facing the
machine. Thus, the control box is mounted on the LEFT FRONT side of the unit.
4) Special Features
The generator set has special features that are described more fully under the assemblies in which they
appear.
August 6, 2004
Chapter 1-1
Page 1

a) Protective Monitoring
The protective monitoring system receives signals from 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) Voltage Regulator
A microprocessor-type, adjustable voltage regulator provides automatic voltage regulation at the
aircraft. The regulator is also adjustable for a variety of output cable sizes and lengths.
c) Engine Electronic Control Module
The engine is equipped with an electronic control module that monitors, records, and controls engine
performance.
5) Canopy
A sheet metal enclosure, identified as a canopy, 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 machine.
Physical
Basic Unit (Fixed Mount)
With Trailer
Length
Width
Height
Weight
Weight with 28.5 VDC T-R
105 in. (2667 mm)

45 in. (1143 mm)
52 in. (1321 mm)
5600 lb. (2540 kg.)
5900 lb. (2676 kg.)
150 in. (3810 mm)

77 in. (1956 mm)
62 in. (1575 mm)
6000 lb. (2722 kg.)
6300 lb. (2858 kg.)
AC GENERATOR
Output power rating
Output voltage
Rated load capacity
Frequency
Power factor
Duty Cycle
Operating speed
Overload capacity, both outputs
125% rated load
Output cable size
90 kVA
115 / 200 VAC
261 Amps
400 Hz.
0.8
100%
2000 RPM
326 Amps
72 kW
2/0
Specifications and Capabilities
Figure 2 (sheet 1 of 2)
August 6, 2004
Chapter 1-1
Page 2

GENERATOR PROTECTIVE SYSTEM

Over voltage
Trips at 126 volts after a 1 second time delay.

Trips at 140 volts in 160 milliseconds.
Trips at any voltage below 100 volts after 7 seconds.
Trips at any value between 420 Hz and 480 Hz after a 5 second time
delay. Trips immediately at any frequency exceeding 480 Hz.
Trips at 380 Hz. or less after a 7 second time delay.
Trips in approximately 5 minutes at 125% load of 90 kVA on either
output or 125% of 120 kVA on both outputs combined.
Under voltage
Over frequency
Under frequency
Overload time delay
DC OUTPUT (OPTIONAL, SEE APPENDIX A)

Output Voltage
Amps (Continuous)
Amps (Peak/Starting/Overload)
28.5 VDC
600 A
2700 A for 2 seconds
1200 A 90 seconds
750 A 600 seconds
ENGINE
Manufacturer
Model No.
Type
Bore and Stroke
Displacement
Horsepower
Idle speed
High speed limiting
Normal governed speed
Firing Order
Electrical system
Ground
Lubricating oil capacity (w/ filter)
Coolant capacity system
Deutz Corporation
BF06M1013EC
6 cylinder, 4 cycle diesel, electronic controlled
4.25 in. x 5.12 in. (108 mm x 130 mm)
436 in 3 (7146 cm3)
218 hp (163 kW)
1000 50 rpm
2350 75 rpm
2000 rpm
1-5-3-6-2-4
12 VDC
Negative
22 quarts (21 liters)
40 quarts (37.8 liters)
Figure 2 (sheet 2 of 2)
6) Engine and Generator

The engine and generator comprise the principal components of the generator set. They are mounted on
the welded steel frame of the chassis. The engine coolant radiator is also mounted on the frame just
forward of the engine-generator combination. Figures 4 and 5 are illustrations showing the location of all
major components and sub-assemblies.
August 6, 2004
Chapter 1-1
Page 3

a) Basic Engine
The basic engine is direct injected, 6-cylinder, electronically controlled, diesel rated at 218
horsepower. See Figure 2 for specifications and capabilities.
b) Engine Manufacturers Equipment
As received from the engine manufacturer, the engine includes the following equipment, which is
more fully described in the engine manufacturers operation manual.
(1) Electrical System
The 12 VDC electrical generating and starting system include an alternator, voltage regulator,
and starter with solenoid switch.
(2) Fuel Filter
The fuel filter is a spin-on disposable type, located on interior bulkhead located in the middle of
the unit.
(3) Oil Filter
The engine oil filter is a spin-on, full-flow type, located on the left side of the engine near the front.
(4) Pre-programmed Electronic Engine Governor (EMR)
The EMR is a pre-programmed engine control module, mounted remotely on the interior
bulkhead.
c)
Engine-cooling fan
The engine fan is designed to blow air outward through the radiator, rather than pulling the air inward
as a conventional fan does.
d) Factory Installed Equipment

This generator set is modified at the factory by the addition of the following equipment:
(1) Shut Down/Reset device
In addition to the other devices provided by the engine manufacturer, the factory also added an
engine shutdown/reset feature.
a
EMERGENCY SHUTDOWN/RESET SWITCH (S28)

The emergency shutdown switch has two purposes. One is to reset the starting circuit
following a failed starting sequence. The other is to provide instant manual shut off of the
generator set by disconnecting power to the EMR through the control box. It is located on the
left side of the generator set near the control box (See Figure 3)
August 6, 2004
Chapter 1-1
Page 4

To operate the EMERGENCY SHUTDOWN/RESET SWITCH:
Push button in until engine stops or until button travel stops

Pull the button back out to reset
Coolant high temperature shutdown system

The coolant temperature shutdown system consists of a factory supplied temperature switch.
This switch is monitored by the microprocessor on the EIB (Engine Interface Board) PC
Board, which will stop the engine if the temperature reaches 230 F (110 C).
Oil pressure shutdown system

The oil pressure shutdown system consists of a factory supplied oil pressures switch. This
switch is monitored by the microprocessor on the EIB (Engine Interface Board) PC Board,
which will stop the engine if the oil pressure is under 12 PSI (82.7 kPA).
(2) Radiator and Charge-Air-Cooler (CAC)

The radiator and charge-air-cooler is a two-piece type designed for long periods of operation
without servicing. Refer to Section 2-1 for servicing procedure.
(3) Air cleaner (Figure 6)
The diesel engine air cleaner is so constructed that air enters through its cylindrical body, and
then is filtered in the process before being passed onto the engine turbo-charger assembly. An
air cleaner service indicator device is mounted on the air cleaner assembly to monitor the airflow
into the air cleaner. As the air cleaner becomes filled with dust, dirt, and carbon, the intake
system airflow becomes increasingly restricted. This restriction causes a diaphragm inside the
indicator to move toward an electrical contact. When the maximum allowable restriction level is
reached, the circuit closes and the air cleaner indicator fault appears on the control panel fault
display to warn the operator that the air cleaner must be changed. The electrical indicator
automatically resets when the restriction level drops sufficiently.
e) Engine faults
The following is a table listing faults, which may occasionally occur. Column two of the table explains
what happens in the engines circuitry when the fault occurs, and column three tells how to return the
generator set to service once the problem is solved. Refer to Chapter 2 for more details on all other
faults.
August 6, 2004
Chapter 1-1
Page 5

ENGINE FAULTS
Engine Fault Condition
What Occurs
How To Reset
Over temperature or low oil

pressure
Shuts down the engine, and will be

indicated will appropriate fault
code.
Low fuel warning and shutdown
Turns on the low fuel indication on

the fault code meter. The GPU is
programmed at the factory to warn
1
1
at /4 tank and to shutdown at /8
tank.
Clogged air cleaner or other

restriction in the combustion air
inlet.
Turns on the air cleaner restriction

indicating fault code.
a) Press the engine stop button to

reset the fault code and reset the
protective system.
b) Or use E-STOP button for
immediate reset.
a) The low fuel fault indicating
function must be reset by
pressing the engine stop button
Fuel must be added prior to
attempting another engine start.
immediate reset.
a) Press the engine stop button.
The restriction must be removed
prior to attempting another engine
start.
immediate reset.
August 6, 2004
Chapter 1-1
Page 6

10
5
7
1.
2.
3.
4.
5.
Control Panel
Operators Push-Button Panel
Output Cable Location
Front Axle Assembly
Rear Axle Assembly
6.
7.
8.
9.
10.
Emergency Stop Switch (S28)

Exhaust Outlet
Canopy
CAC/Radiator End
Generator End
General Assembly of Generator Set

Figure 3
August 6, 2004
Chapter 1-1
Page 7

1.
2.
3.
4.
5.
10
Radiator / Charge-Air-Cooler
Deutz 1013E Engine
Air Cleaner
Control Box
Fuel Tank
6.
7.
8.
9.
10.
Exhaust System
Generator
Inlet/Oulet Radiator Hoses
Rear Axle
Air Intake Heater (BH1)
Main Components of Generator Set (Right Side)

Figure 4
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10
1
1.
2.
3.
4.
5.
Single Output Power Module (Dual Output Shown)

12 VDC Batteries (BT1, BT2)
CAC Piping
Engine Pre-Heater
Fuel/Water Separator Pre-Filter
8,9
5
6.
7.
8.
9.
10.
Top and Bottom Fan Shroud

Alternator Fan/Belt Guard
Engine Cooling Fan
Fan Guard
Control Box
Main Components of Generator Set (Left Side)

Figure 5
August 6, 2004
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Page 9

Service Indicator
Air Cleaner and Service Indicator

Figure 6
Air Cleaner
f)
Generator
The 400 Hz generator is a brushless, revolving field, three-phase, alternating current type. The
generator set covered by this manual is a dual-bearing type. The front end of the rotor shaft extends
forward beyond the front bearing and is attached to the engine flywheel by a flexible coupling
assembly. The rear end of the rotor shaft extends rearward beyond the rear bearing and into the
exciter stator housing. The exciter rotor is mounted on this shaft extension with a 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 controlled voltage regulator
PC board (REG). A centrifugal, radial-blade fan, which is part of the flexible 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 assembly is bolted to the engine flywheel housing.
7) Control Box Assembly

The control box is a sheet metal enclosure that houses and provides mounting facilities for engine and
generator controls and monitoring equipment.
a) Control Panel (Figure 7 and 8)
The control system is divided into two sections. On the left side of the control panel, as one faces it,
are engine meters. On the right side of the control panel are generator meters. Below the control
panel are push-button switches for operating the engine and generator.
(1) Panel lights and panel light push-button switch (S74)
Meters are lighted from inside the control panel. The LAMPS push-button switch controls the
lights.
(2) Engine hour meter (M4)
The hour meter is electrically driven from the 12 VDC battery system. The hour meter measures
and records the engines running time and will record up to 9999.9 hours on five revolving drums.
It is only functional when the engine is running.
August 6, 2004
Chapter 1-1
Page 10

1.
2.
3.
4.
5.
6.
7.
8.
9.
7,10
Fuel Gage (M13)

Front Panel
Engine Coolant Temperature Gauge (M24)
Running Time Meter (M4)
Oil Pressure Gage (M25)
Battery Voltmeter (M5)
Frequency Meter (M3)
Control Panel Label
Fault Code Meter (M6)
10,12
15
10.
11.
12.
13.
14.
15.
16.
17.
17
11,10
16
13
Strip Lights (DS60-DS62) (3) [Not Shown]

AC Generator Ammeter (M1)
AC Voltmeter (M2)
Adjustable Grip Latch
Control Panel Door Hinge [Not Shown]
DC Voltmeter [Optional with TR]
DC Ammeter [Optional with TR]
Front LED PC Board (A5) [Shown Opposite Side]
Control Panel Door

Figure 7
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10
1.
2.
3.
4.
5.
Meter Selector Switch (S3)

Test/Reset Switch (S77)
Engine Stop Switch (S76)
DC Starting Current Switch (S431) [Optional with TR]
DC Output Contactor Switch (S430) [Optional with TR]
6.
7.
8.
9.
10.
AC Output No. 2 (S275) [if applicable]

AC Output No. 1 (S75)
Engine Start Switch (S24)
Air Intake Heater Switch (S79)
Panel Light Switch (S74)
Control Push-Button Switch Panel

Figure 8
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2
5
6
3
4
10
1.
2.
3.
4.
5.
6.
11
Control Box Wrapper

Engine Specific PC Board [ESB] (A1)
Engine Interface PC Board [EIB] (A2)
Digital Control PC Board [CTL] (A3)
Voltage Regulator PC Board [REG] (A4)
Transformer-Rectifier PC Board [TRB] (A404) {Optional}
7.
8.
9.
10.
11.
+5, -12 VDC Power Supply (PS1)

Circuit Breaker Support Bracket
Marker Lights Circuit Breaker, 10 A (CB1)
Engine Circuit Breaker, 10 A (CB4)
Controls Circuit Breaker, 5 A (CB7)
Control Box Interior Components

Figure 9
August 6, 2004
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Page 13

(3) Engine oil pressure gage (M24)
The oil pressure gage is an electrical type that is connected by a wire to an oil pressure sensor
installed in the engine lubricating system. The range is 0 to 125 PSI (0 to 862 kPA).
(4) Engine ON indicating light (DS58)
When the engine is running at idle speed, a green indicating light, within the ENGINE START
push button switch, flashes at a rate of 1 second on, 1 second off. When the engine is running at
rated speed, the light will stay on continuously.
(5) Engine coolant temperature gage
The temperature gage is an electrical type that is connected by a wire to a water temperature
sensor installed in the engine cooling system. The gage indicates engine coolant temperature in
the range of 100-280 F (38-138 C).
(6) ENGINE START push-button switch (S24)
The ENGINE START push-button switch, when pressed, connects 12 VDC power to the starter
solenoid coil, which actuates the solenoid switch to connect power to the engine starting motor.
The 12 VDC power is supplied directly to the engine EMR and the oil pressure shutdown switch is
bypassed (This bypass is necessary for engine starting because the low oil pressure switch is
CLOSED until the engine is running normally). The green indicator light with blink.
When pressed a second time, this push-button switch provides a signal to the EMR to adjust the
engine speed to 2000 RPM. The green indicator light will glow continuously. At the same time, a
ground signal is provided to the regulator, enabling the generator to build up voltage for 400-Hz
generator output. Pressing the push-button switch once more removes these signals and the
engine reverts to idle speed and a blinking green indicator light.
(7) ENGINE HEATER push-button switch (S79)
The ENGINE HEATER push-button switch activates the standard cold starting aid (manifold air
intake heater), which is totally controlled by the engines EMR. Once the heater is activated, the
engines EMR will control the operation. The heater typically stays on for a period of
approximately 30 seconds, which is indicated by the light on the push-button. When the light
goes out, the engine is ready to start. Starting a cold engine without first warming the engine will
lead to excessive white smoke exhaust and the engine may be hard to start.
(8) ENGINE STOP push-button switch (S76)
When the ENGINE STOP push-button switch is pressed, the red indicator will glow. Then a 3 5 minute delay will occur to permit the turbo and other engine components to cool evenly. After
the delay, power is disconnected from the engine EMR causing the engine to shut down.
(9) Engine voltmeter (M5)
The ammeter indicates the direction and value of current flow from or to the 12 VDC battery. Its
graduated 10 V to 16 V.
August 6, 2004
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Page 14

(10) Engine fuel gage (M13)
An electric fuel gauge receives its controlling signal from a sending unit in the fuel tank. 12 VDC
operating power is supplied to the fuel gauge when the ENGINE START push-button switch is
pressed. The fuel level can also be checked when the unit isnt running by pressing the panel
light LAMPS push-button switch.
(11) Fault Code meter and TEST/RESET push-button switch (M6, S77)
The function of the fault code meter is to indicate to the operator, that an abnormal condition of
over voltage, under frequency, etc. occurred, which caused the protective monitoring system to
function. When one of the circuits are activated, it shows the code on the fault code meter. The
fault will remain on for a short period of time or until the TEST/RESET push-button switch is
pressed. Pressing the TEST/RESET push-button switch can also test the fault code meter
operation. A meter test should be performed only when disconnected from a load, as the
contactor(s) will open during the test cycle.
(12) Engine systems fault codes
Fault codes will be shown to warn the operator of abnormal engine operations that must be
corrected. These indicators are over temperature, air cleaner restriction, low oil pressure, and
low fuel indication.
(13) AC Generator output monitors (meters)
Three instruments, a frequency meter, a voltmeter, and an ammeter monitor the generator output.
The frequency meter is an analog type and indicates the frequency of the generator output
alternating current in the range of 360 to 440 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, BC and C-A) as selected by the METER SELECT switch. The voltmeter has a scale of 0 to 300
V. The ammeter has a scale of 0 to 500 A. The amperage value in each of the three phases
may be read on the ammeter by selecting the desired phase with METER SELECT switch. The
ammeter current transformers, located in the output power module circuit, lower the output load
current to a lesser value, of definite ratio, which is sent to the Voltage Regulator PC Board (REG).
The ammeter dial scale is numbered so that the pointer will indicate the true load current value.
(14) Load contactor indicating lights [Yellow # 1 and Orange # 2] (S75, S275)
Indicating lights within the respective contactor control push-button switches (OUTPUT NO. 1
and or OUTPUT NO. 2, if applicable) glow when the circuit is energized, indicating that power
is available at the plug. When the load contactor opens for any reason, the light is turned OFF.
(15) Front LED Display (A5)
The front LED display signifies to the operator which voltage (A-N, A-B, etc) and amperage are
shown on the meters, as well as, when EF BY-PASS is present or bypassed. This EF BYPASS indicator serves to warn the operator that if the plug interlock system was by-passed any
exposed cable may be live.
August 6, 2004
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Page 15

(16) DC Generator output monitors (meters) [Optional with TR, Reference Appendix A]
Two instruments, a voltmeter and an ammeter, monitor and display the transformer-rectifiers
output. The voltmeter and ammeter meters are both analog type and indicate the output voltage
from 0 to 50 VDC and the amperage from 0 to 2500 A.
(17) STARTING CURRENT Switch (S431) [Optional with TR, Reference Appendix A]
Each time the STARTING CURRENT push-button switch is pressed, the BLUE indicator will
glow. The present current limiting amperage setting will be displayed on the fault code meter for
a short time delay, before incrementing, at 100 A increments, up to 2500 A. Once 2500 A has
been reached, the incrementing will start over from the beginning.
(18) DC OUTPUT Contactor Switch (S430) [Optional with TR, Reference Appendix A]
Each time the DC OUTPUT push-button switch is pressed, the BLUE indicator will glow when
the circuit is energized, indicating that power is available at the plug. When the load contactor
opens for any reason, the light is turned OFF.
b) Control Box Interior Components (Figure 9)
(1) EF Bypass switches (located on CTL)
For each load contactor circuit, a single-pole, single-throw EF1 BYPASS for OUTPUT 1 (or
EF2 BYPASS for OUTPUT 2, if applicable) provides a means of bypassing the 28 VDC
interlock circuit for the contactor when supplying power to a load bank or to an aircraft not
equipped with a plug interlock system.
(2) Regulated-diagnostic switch (located on the REG)
When the REGULATED/DIAGNOSTIC switch is in the REGULATED (down) position, the
generator output voltage is regulated by the PC board for 115/200 VAC output to an aircraft.
When this switch is placed in the DIAGNOSTIC (up) position, 12 VDC is applied to the
generator exciter with the engine running at rated RPM, in order to check the operation of the
generator. This is done to determine if a particular power output malfunction is caused by a
defective generator or by a defective voltage regulator. When this switch is in the
MAINTENANCE position, no current is supplied to the generator exciter. In this condition, a lowlevel, unregulated voltage of approximately 30 VAC will be produced at the generator output
terminals due to the residual magnetism of the exciter.
(3) Circuit breakers (CB1, CB4, CB7)
A 10-ampere ENGINE circuit breaker, protects the 12 VDC engine electrical and fault circuits,
and another 10-ampere MARKER LIGHTS circuit breaker protects the 12 VDC lighting system.
A 5-ampere CONTROL circuit breaker protects the 12 VDC control system.
(4) Digital Control PC Board [CTL] (A3)
The digital control PC board (see Figure 10) is the center for all communications throughout the
entire control system. All push-button panel commands run through the digital control PC board
and communicates the commands to the appropriate area (i.e. other PC boards) in the control
system. The digital control PC board also controls the real time clock, monitors the over/under
voltage and overload protection, push-button panel indicator lights, generator output meters, EF
bypass switches, and communicates with the optional service tool.
August 6, 2004
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(5) Engine Interface PC Board [EIB] (A2)
The EIB (see figure 11) is common between all engine models and monitors coolant temperature,
oil pressure, battery voltage, and fuel tank level monitoring. The EIB is also responsible for the
monitoring the warning switches for high coolant temperature, low oil pressure, high air
restriction, and low coolant level (optional). The warning switches signal the EIB when a fault
occurs, which then the EIB relays this information to the CTL. The CTL will issue the command
to the system that fits the fault event.
The EIB also controls the power distribution in the control system, hour meter, lights, and the
engine starter operation.
J54 Connector
PC Board Software
EF1 Bypass
EF2 Bypass (if applicable)
Service Tool Connector
Digital Control PC Board

Figure 10
(6) Engine Specific PC Board [ESB] (A1)
The ESB (see figure 12) is unique only to the engine model used in the GPU purchased. The
ESB is the primary interface between the control system and the engines electronic control
module. When the CTL senses the engine start button has been pressed it signals to the ESB,
which then communicates to the engine control module what mode of operation is required (idle
or rated speed).
The ESB controls the FREQUENCY ADJUST switch that is used to enable the FREQUENCY
ADJUST ENABLE/DISABLE potentiometer to test the over/under frequency fault limits of the
generator set system. The ESB also controls the DATA REQUEST button and diagnostic
indicator light to read the engines EMR diagnostic error codes.
August 6, 2004
Chapter 1-1
Page 17

Starter Disable/Enable
J51 Connector
PC Board Software
Engine Interface PC Board
Figure 11
Engine Status Switch
Frequency Adjustment &

Enable/Disable Switch
Engine Status Light
J52 Connector
PC Board Software
Engine Specific PC Board

Figure 12
August 6, 2004
Chapter 1-1
Page 18

Regulated/Diagnostic
J53 Connector
Voltage Adjustment, Coarse

Voltage Adjustment, Fine
PC Board Software
LDC Control
Voltage Regulator PC Board
Figure 13
(7) Voltage regulator PC board [REG] (A4)

This voltage regulator PC board (see Figure 13) is designed to provide voltage regulation for 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. In addition, the voltage regulator PC board circuitry provides line drop
compensation. 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.
a
When the machine is started, and the engine is at rated speed, the rotary exciter is excited
from alternator residual magnetism through the half-wave rectifier-bridge, located on the
voltage regulator PC board assembly. As the rotary exciter voltage increases, alternator
excitation increases and the alternator voltage builds up. The sensing circuit of the voltage
regulator PC board 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.
August 6, 2004
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b
When the alternator is loaded, its terminal voltage decreases, lowering the rectified threephase voltage of the voltage sensing circuit. The sensing voltage is low in respect to its
reference 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.
When a load is removed from the alternator, the alternator voltage rises. The rectified threephase voltage-sensing signal increases, causing this signal to be higher 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. The
line drop voltage compensation circuit consists of a current transformer on each phase of the
load circuit, and fixed resistance in parallel with each current transformer. The current
transformers detects the magnitude of current flowing through the power cables from the
alternator to its load and feeds a signal into the voltage regulator PC board. The PC board
processes this signal to change the output voltage proportional to the current draw. 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 line drop compensation
potentiometer may be adjusted to match exactly the voltage drop of the power cables
carrying the load current.
The under/over frequency protection, EF signal, and lost neutral detection are also monitored by
the REG and will signal the CTL when a fault has occurred. The CTL issues the appropriate
command that corresponds to the fault.
(8) Transformer-Rectifier PC Board [TRB] (A404) {Optional with TR, Reference Appendix A}
The TRB PC Board (see Figure 15) is only used when the optional 28.5 VDC transformer-rectifier
assembly is installed. The TR monitors the output voltage, output current, controls the input and
output contactors, and monitors all fault events associated with the DC output. When a fault event
does occur the TRB relays this information to the CTL. The CTL will issue the command to the
system that fits the fault event.
(9) +5, -12 VDC Power Source (PS1)
Supplies the internal power distribution of +5 VDC and 12 VDC into the control system.
Control System Power Source

Figure 14
August 6, 2004
Chapter 1-1
Page 20

J401 Connector
PC Board Software
Transformer-Rectifier PC Board
Figure 15
8) Power Module Panel Assembly (Figure 16)

The power module panel assembly sometimes referred to as the contactor panel, is located at the left
front of the machine under the control box. The panel assembly provides a means of connecting and
disconnecting generator output to and from the load (aircraft).
a) Load contactor(s)
The load contactor(s) each contain a magnetic operating coil and four sets of contacts. The three
larger contacts conduct three-phase AC generator output. A small contact set is connected to the
Digital Control PC Board (CTL) to activate the protective monitor circuit. Three-phase, 400-Hz
generator output power is conducted to the load contactors by 2/0 cables that pass through current
transformers.
nd
b) Current transformers (CT1-CT3 or CT6 if 2
output installed)
On each individual output a set of current transformers are used to monitor and control the line-drop
compensation, ammeter, and overload circuit.
August 6, 2004
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(1) Line-Drop Compensation
The current transformers detects the magnitude and power factor of current flowing from
generator to load. They feed a signal to the voltage regulator that interprets the signal and alters
the exciter field current as required to maintain a constant predetermined voltage at the load.
(2) Ammeter
The current transformers convert a current signal to a voltage signal, which is sent to the Voltage
Regulator PC Board (REG). The ammeter is really a voltmeter graduated and numbered in
amperes to show current proportional to the voltage signal received.
When there is overload on the output for more than 5 minutes (load exceeding 326 amperes per
output or 125% of rated load), the main overload sensing circuit sends signals the load the
contactor(s) circuit to open both load contactors.
(3) Overload, No 1 and/or No. 2 output (if applicable)
On each individual output the current transformers converts a current signal to a voltage signal.
The voltage signal is sent to the ammeter and to the overload monitoring circuit for that output.
The overload monitoring circuit will open the contactors when the output current reaches 125% of
the normal rated output current. The monitoring circuit moniters each individual output, as well
as, the overall current for a dual output machines.
The following is a list of overload module characteristics:
At 125% load the module will function in 5 minutes.

At 150% load the module will function in 30 seconds.
AT 200% load the module will function in 10 seconds.
NOTE: The overload protective system will function when any phase carries 123% to 127% of
rated load. All times are plus or minus 25% and are non-adjustable.
9) Cold Weather Starting System (BH1)

The intake air heater (see Figure 17), located on the intake manifold, is used for starting the engine at
very cold temperatures and reduces the white smoke associated with a cold start. This cold weather
starting system is a fully automatic once engaged by the operator (Chapter 1, Section 3). The intake air
heater (or grid heater) is energized or de-energized from a power relay controlled by the EMR. The
amount of time the air intake heaters stay on, in the preheat phase, is a function of the intake manifold
temperature at start up. (The pre-heat time increases with colder intake manifold temperatures). The
maximum duration of the pre-heat phase is around 30 seconds. During cranking, the intake air heater is
turned off to allow maximum current to be used by the starter.
CAUTION
Never use an ether start system in conjunction with the air intake heater.
August 6, 2004
Chapter 1-1
Page 22

Generator Lead Connection Point
Output Contactor # 1 (S75)
Current Transformers (CT1-CT3)
Output Contactor # 2 (S275)

Location (if applicable)
Output Cable Connection Points
Output Power Module Components

Figure 16
August 6, 2004
Chapter 1-1
Page 23

CAC Intake End
Air Intake Heater

Figure 17
Intake Heater
August 6, 2004
Chapter 1-1
Page 24

Section 2
Preparation for Use, Storage, or Shipping
1) Preparation for Use

a) Inspection/Check
Inspect the unit thoroughly prior to operation.
(1) Remove blocking, banding, ties, and other securing material.
(2) Inspect exterior for shipping damage such as broken lights, damaged sheet metal, etc.
(3) Open all canopy doors and inspect interior for foreign material such as rags, tools, shipping
papers, etc.
(4) Check fuel, coolant, 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 fitting, etc., as required.
(5) Check security of generator set retaining components.
(6) Check the following for sufficient quantity:
a
Fuel
Press LAMPS push-button button to energize fuel gage when engine is stopped. Fuel is
supplied from a customer-furnished source.
NOTE: For recommended fuel specifications refer to the Engine Manufacturers Operation and
Maintenance Manual provided with this manual.
b
Engine coolant
Remove radiator cap to check coolant level. Coolant level should be at the bottom of the filler
neck.
CAUTION
BE SURE the cooling system antifreeze solution is adequate to protect below the
lowest temperature expected.
NOTE: For antifreeze protection, use a solution of 50% permanent antifreeze (Ethylene glycol) and
50% clean water.
ENGINE OIL AND COOLANT CAPACITIES


Figure 1
August 6, 2004
Chapter 1-2
Page 1

c
Engine lubricating oil level

The oil gage rod has H high mark and L low level marks to indicate the operating
lubrication oil supply. Oil level should be kept as near the high mark as possible, without
going over it. See Figure 1 for capacity.
CAUTION
NEVER operate the engine with oil level below the L level mark or above the H
level mark.
NOTE: See the Engine Manufacturers Operation Maintenance Manual for oil recommendations.
Oil Fill and Oil Level Check Locations

Figure 2
Check Batteries
Inspect the batteries for proper connection of the terminals and also check the electrolyte
level (if possible). Service or replace if necessary.
b) Installing Three-Phase AC Output Cables

The generator set may be shipped without aircraft cables. The load contactors, to which cables must
be connected, are located on the power module assembly (left side of the unit beneath the engine
control panel).
The conductor size recommended for AC output cables is 2/0 AWG. Use No. 12 size for control (E
and F) terminals. Large cables (A, B, C, and N) should be equipped with terminals having at least a
3/8-inch diameter mounting hole. Mounting hole in small leads (E and F) should be at least 1/4-inch
diameter.
August 6, 2004
Chapter 1-2
Page 2

To install AC output cables proceed as follows:
(1) Open control box door of the generator set and remove the lower panel.
(2) Remove Plexiglas cover in front of the power module assembly.
(3) Remove the cover panel on the cable tray covering the cable clamps.
(4) Loosen screws on cable clamps.
(5) Route cables through cable clamps, and up to the load side of the load contactor(s).
(6) Connect the phase cable terminal lugs to the appropriate terminal studs on the contactor(s): cable
lug A to terminal stud A, B to B, and C to C.
(7) Connect the cables neutral terminal lug securely to the neutral (ground) stud on the power
module assembly.
(8) Connect the E and F cables to the E and F studs on the power module assembly.
(9) Tighten clamp screws securely, but avoid damage to cable insulation.
(10) Replace Plexiglas cover panel, lower panel, and close canopy door.
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
Pull all circuit breakers and/or disconnect battery negative terminal.
(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 (Factory Part No. 76A1354-001) are available for use where
excessive dampness is a problem; however, the unit must be completely packaged and sealed if
moisture absorbing chemicals are to be effective.
b) Temporary Storage
When storing the unit for 30 days or less, prepare as follows:
(1) Lubricate the unit completely in accordance with instructions in Section 2-2. This will include
changing engine oil, and all filter elements.
(2) Start the engine and operate for about two minutes so that all internal engine components will be
coated with new oil.
NOTE: Do not drain the fuel system or crankcase after this run.
August 6, 2004
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Page 3

(3) Make certain the cooling system antifreeze solution is adequate to protect below the lowest
temperatures expected during the storage period. Be sure the solution is thoroughly mixed.
(4) Clean the exterior of the engine. Dry with clean rags and compressed air.
(5) Seal all engine openings. Use a waterproof, vapor proof material that is strong enough to resist
puncture damage from air pressures.
c) Long Time Storage (Over 30 Days)
To protect the generator and other electrical components, the complete unit should be packaged
using moisture proof packaging material and sealing material. Place containers of moisture
absorbing chemicals (Factory Part No. 76A-1354-001) in the unit before packaging. The unit may be
stored for long periods with no special preparation if it is possible to operate the engine once each
week. When starting once a week proceed as follows:
(1) Make certain the cooling system is adequately protected.
WARNING
ENSURE adequate ventilation before starting the engine.
(2) Start the engine and operate under full load until coolant temperature has reached at least 176F
(80C).
(3) While the engine is running, ensure that normal operating controls are in good working condition
before shutdown and storage. If weekly operation is not possible, contact the nearest engine
manufacturer distributor for instructions.
3) Preparation for Shipment

a) Disconnect battery negative terminal before shipping.
b) During long shipments, vibration, jolting, etc may loosen the generator set retaining hardware.
CAUTION
When shipping the unit, provide sufficient retaining materials to ensure the generator
set cannot roll out or off the vehicle in which it is being transported.
NOTE: It is suggested that strong banding be used to secure the generator set, or a strong steel bar
be either welded or bolted across the front of the generator set frame.
August 6, 2004
Chapter 1-2
Page 4

Section 3
Operation
1) General
This section contains information and instructions for the safe and efficient operation of the equipment.
Operating instructions are presented in step-by-step sequence of procedures to be followed in supplying
400-Hz power.
NOTE: Read ALL of the operating instructions before attempting to operate the equipment.
WARNING
Ear protection equipment may be necessary when working close to this equipment.
2) 400 Hz. Operating Procedure

a) Pre-start inspection
(1) Be sure the fuel shutoff valve on the unit is open.
(2) Ensure 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.
(4) Make certain there is sufficient lubricating oil and coolant in the engine.
(5) Check that all circuit breakers are reset.
(6) Make certain the STARTER ENABLE/DISABLE switch is enabled, and the FREQUENCY
ADJUST switch is disabled.
b) Normal Engine Starting Procedures
Engine starting procedures are outlined below. The engines operating controls and monitoring
instruments are illustrated in Figure 1 and 2.
CAUTION
Refer to operating instructions in the engine manufacturers operation manual, when

starting engine for the first time.
NOTE: The engine manufacturers operation manual is provided with this manual.
(1) If illumination is required, press LAMPS push-button switch one time. Pressing this button
switch also activates the fuel gage.
(2) On days when the ambient temperatures are below 60 F, press the ENGINE HEATER pushbutton to engage the air intake heater prior to starting the engine. The light in the button will
illuminate when the intake heater is engaged (if the light does not illuminate, the engine is ready
to start) and will go off when the intake heater is disengaged, thus signifying the engine is ready
to start.
August 6, 2004
Chapter 1-3
Page 1

1.
2.
3.
4.
5.
6.
7.
8.
9.
7,10
Fuel Gage (M13)

Front Panel
Control Panel Label
10,12
15
10.
11.
12.
13.
14.
15.
16.
17.
17
11,10
16
13

AC Voltmeter (M2)
Control Panel Door

Figure 1
August 6, 2004
Chapter 1-3
Page 2

10
1.
2.
3.
4.
5.

6.
7.
8.
9.
10.


Figure 2
August 6, 2004
Chapter 1-3
Page 3

CAUTION
Never use an ether start system in conjunction with the air intake heater.
(3) Press the green ENGINE START push-button switch and hold until engine starts. The engine
will start at idle speed, and the green light in the ENGINE START push-button switch will flash
to indicate that power is available to the engines ECM circuit.
CAUTION
CAUTION
Do not attempt to bring to rated speed for at least 5 seconds after engine starts.
Damage to the starter and flywheel will result.
If the engine fails to start within 5 seconds, the control system will automatically
disable the starting motor and indicate a low oil pressure fault. The emergency stop
switch must be pressed to reset the control system and allow another starting attempt.
If the engine fails to start after four attempts, an inspection should be made to
determine the cause.
If the engine fires sufficiently to disengage the starter gear, but does not start, allow
the starting motor to come to a complete stop before attempting to engage the starter
again, then press the start push button switch.
(4) Check oil pressure to make certain that it is normal, and observe all other engine instruments for
normal operation.
(5) Allow engine to idle and warm for 3 - 5 minutes before bringing it up to rated speed.
CAUTION
To eliminate the possibility of wet stacking (See Appendix A), DO NOT allow the
engine to idle for long periods of time.
c) Failed Starting Procedure

In the event that the engine fails to start, the circuitry must be reset before the next attempt. To do
this:
(1) Push the red EMERGENCY STOP/RESET BUTTON on the control box door to the right of the
control panel.
(2) Pull the red EMERGENCY STOP/RESET BUTTON back out before the next attempt to start
the generator set.
d) Power Delivery
(1) Press ENGINE START push button switch a second time to bring engine from idle speed to
rated speed. The ECM will immediately increase engine speed to 2000 RPM and maintain it.
The voltage build-up will occur automatically. Also the green indicating light in the ENGINE
START push-button switch will glow continuously.
August 6, 2004
Chapter 1-3
Page 4

(2) Observe generator instruments. The frequency meter should indicate exactly 400 Hz. With the
METER SELECT push button switch set to read any line-to-neutral position, (A-N, B-N, or CN), the voltmeter should read 115 volts. With the METER SELECT push button switch set to
any line-to-line position, (A-B, B-C, or C-A), the voltmeter should read 200 volts.
(3) The final step in delivering power is closing one or both of the load contactors. When the
instruments indicate satisfactory frequency and voltage values, close either load contactor (or
both load contactors) by momentarily pressing the load contactor(s) (OUTPUT NO. 1 or
OUTPUT NO. 2, if applicable) push button switch. The yellow or orange indicating light of the
push button switch that is pressed will glow continuously, indicating that the load contactor is
closed and power is available at the aircraft.
(4) Early in the power delivery run it is recommended that the operator check output voltage and
current in each of the three phases. Use the METER SELECT push button switch to select the
either the 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.
CAUTION
NEVER press the test/reset push button switch while power is being delivered.
The contactors will open and power to the aircraft will be suddenly interrupted.
(5) A condition of over-voltage, under-voltage, under-frequency, over-frequency, or overload in the

output circuit will automatically open the load contactor and display a fault code to signal the
operator which of the above faults caused the protective monitor system to operate. After the
fault has been corrected, press the TEST/RESET push-button switch to reset the protective
relay system. Proceed with power delivery by operating the load contactor push button switch.
WARNING
CAUTION
NEVER disconnect the output cable while power is being delivered. Output
contactors must be open prior to removal of the cable from the aircraft.
The generator set must be shut down so that the failed power delivery problems can
be diagnosed. Only licensed technicians should work on this generator set.
e) Failed Power Delivery

If the contactor indicating light should go out as soon as the push button switch is released, and a
fault code is displayed indicating that 28.5 VDC interlock signal is not being supplied from the aircraft
to the plug interlock relay, correct the condition and again press the load contactor(s) (OUTPUT NO.
1 or OUTPUT NO. 2, if applicable) push button switch.
The REGULATED/DIAGNOSTIC switch (located on the VR1) must be set to NORMAL for power
delivery.
The OUTPUT NO. 1 (or OUTPUT NO. 2, if applicable) EF BY-PASS ON/OFF switch (located
on the CTL) must be set to ON position.
See section 2-4 for other No. 1 (or No. 2, if applicable) Load Contactor Operating Circuit for additional
troubleshooting procedures.
August 6, 2004
Chapter 1-3
Page 5

f)
Discontinue Power Delivery with Unit Shutdown

(1) Normal conditions
a
Push the load contactor(s) (OUTPUT NO. 1 or OUTPUT NO. 2, if applicable) push
button switch to open the contactor. The indicating light (yellow or orange depending on the
contactor used) on that switch will go OFF immediately to indicate that the load contactor has
opened and power is no longer being delivered to the aircraft. The engine will remain at
rated speed.
Push the red ENGINE STOP push-button switch once to bring the engine down to idle
speed. This will begin the automatic shutdown sequence to shut off the engine, gauges,
lights, etc., after approximately 3 - 5 minutes.
Disconnect output cable from aircraft after engine is at idle speed only.
(2) Emergency conditions

a
CAUTION
Depress the EMERGENCY STOP BUTTON located on the control box door to the right of
the control panel. When pushed this button instantly shuts the generator set off and must be
pulled back out to reset itself for restarting the generator set.
Do not use the EMERGENCY STOP BUTTON button as a normal shutdown device.
Damage to the engine turbo charger may result without proper cooling time. Use the
ENGINE STOP push-button for all normal engine shutdowns.
3) DC Operating Procedure (Optional, See Appendix A)

The 28.5 VDC transformer-rectifier is an optional add-on to the GPU. See Appendix A for more details on
the operation of the transformer-rectifier.
August 6, 2004
Chapter 1-3
Page 6

Chapter 2 Service and Troubleshooting

Section 1
Maintenance Inspection/Check
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 to components, or failure of the equipment.
WARNING
STOP operations at once if a serious or possibly dangerous fault is discovered.
2) Maintenance Schedule
a) General
A periodic maintenance schedule should be established and maintained. A suggested schedule is
provided in Figure 1 on the following pages. It may be modified, as required to meet varying
operating and environmental conditions. It is suggested that generator set and vehicle inspections be
coordinated as much as possible.
b) Maintenance Schedule Check Sheet
It is strongly recommended that the customer use a maintenance schedule check sheet such as the
one in engine manufactures operation manual. The check sheet will provide a record and serve as a
guide for establishment of a schedule to meet the customers maintenance requirements for his
specific operation.
c) Time Intervals
The schedule is based on both hours of operation and calendar intervals. These two intervals are not
necessarily the same. For example, in normal operation the oil change period, based on hours of
operation, will be reached long before the three months calendar period. The calendar period is
included to make certain services are performed regularly when the equipment is stored, or being
operated infrequently. Lubricating oil standing in engines that are stored, or used very little, may tend
to oxidize and may require changing although it is not dirty. Perform all services on whichever-comesfirst basis.
d) Identification of Interval Periods
Each interval period is identified by a letter A, B, C, etc. For example, services under B schedule
should be performed at the end of each 250 hours of operation, or every three months, BR service is
performed during the BREAK IN period (first 50-150 hours) and AR service is performed AS
REQUIRED.
August 6, 2004
Chapter 2-1
Page 1

Hourly Interval
Calendar Interval
Symbol
AR
AR
50-150
10
250
500
1000
1500
2000
Once
Daily
3 Mo.
6 Mo.
1 Yr.
1.5 Yr.
2 Yr.
BR
Engine
Change Air Cleaner Cartridge
Check Coolant Hose and Clamps
Check Crankcase Oil Level
Drain Fuel PreFilter Elements
Check Coolant Level
Check for Leaks and Correct
Check Air Cleaner Indicator

Check Exhaust System
X
X
Charge-Air-Cooler (CAC) and Piping
Change Fuel Filter Element
Change Fuel Pre-Filter Element
Check Fuel Pump
Check Radiator Core and Hoses
Check Oil Pressure and Record
Change Crankcase Oil
Change Oil Filter Element
Check Engine and Generator Mounts
Check Coolant, Additive-Concentration
Check Fan Hub and Drive Pulley

Check Hose Clamps on Air Intake Side
X
X
Check Belts Conditions and Tensioner
Check and/or Adjust Valve Clearance
Check Water Pump
Steam Clean Engine
X
X
Clean Fuel System
Check Alternator
Check Cranking Motor
Check Vibration Damper
Check Cooling and CAC systems
X
Figure 1 (Sheet 1 of 2)
August 6, 2004
Chapter 2-1
Page 2

Hourly Interval
AR
Calendar Interval
Symbol
AR
50-150
10
250
500
1000
1500
2000
Once
Daily
3 Mo.
6 Mo.
1 Yr.
1.5 Yr.
2 Yr.
BR
Engine (continued)
Flush and Change Coolant
Check Fan Mounting
Spring & Fall
Clean Cooling System
Spring & Fall
Check Hoses
Spring & Fall
Clean Electrical Connections
Spring & Fall
Check Thermostats and Seals
Fall
Electrical (12 VDC System)

Check All Lights
Check Alternator Charging Rate
Check Battery and Fluid Level

Clean Battery Terminals
X
X
Check Wiring and Connections
Check All Engine Meters
Electrical (400-Hz System)

Check E-F By-Pass Operation
Check Output Cable and Connectors
Check Volt, Amp & Frequency Meters
Check and/or Adjust Output Voltage
Inspect Wiring and Connectors
Clean and Inspect Generally
X
Figure 1 (Sheet 2 of 2)
3) Inspection/Check
a) General
Inspections, checks, and maintenance are described in general and more specific and detailed
information can be found in Section 2-2 and 2-3, when applicable.
b) AR Checks and Operations (As Required)
(1) Engine
a
Change Air Cleaner
August 6, 2004
Chapter 2-1
Page 3

A definite time schedule for changing the air cleaner cannot be established. This filter should
not be washed more then six times or retained for more than one year of service, which ever
comes first.
b
Check and tighten, as required, all coolant hose clamps, air intake hose clamps and exhaust
clamps. Check all coolant hoses, air intake hoses and exhaust pipes for leaks.
(2) Electrical System (12 VDC)

a
Check Battery Terminals

Anytime the compartment doors are opened for any reason, visually check battery cable
connectors and battery posts. If corrosion is observed, disconnect cables and clean battery
posts and connectors with a wire brush or special battery post-cleaning tool. Coat posts and
connectors with a light film of petroleum lubricant before reconnecting cables.
(3) Electrical (400 Hz System)

a
Check the output voltage and be sure it is set for 115 VAC 1 V. Adjustment can be made
using the fine adjustment located on the Voltage Regulator PC Board (REG).
c) BR Checks and Operations (Break-In Period, Once After 50-150 hrs.)

The following procedures are precautionary measures taken on most new engines. If a problem
occurs with any of the following issues be sure to recheck it after the next 50-150 hours.
(1) Engine
a
Check for leaks and correct. This involves an overall inspection of the engine and may
require some maintenance if leaks are found. Refer to the engine manufacturers operations
manual for assistance.
Change all fuel filter elements. Metal shavings from the new fuel tank can clog the filter.
Change crankcase oil. New engines often release metal shavings more frequently. Therefore
the crankcase oil must be changed as a precautionary measure.
Change oil filter element. The oil filter should be changed with the oil.
Check engine and generator mounts to ensure they are properly installed and they have not
worked loose. (Torque is set at 122 N-m, 90 ft-lb.).
Check coolant additive concentration. Refer to the engine manufacturers operations manual
for assistance.
Steam clean the engine to free it of oil and dirt to prevent uneven engine cooling hot spots.
The oil and dirt can also fall into the engine and fuel system when covers are removed during
repair work.
Inspect the water pump weep hole for indication of a steady leak. If a steady flow of coolant
or oil is observed, replace the water pump with a new or rebuilt unit. Refer to the engine
manufacturers operations manual for assistance.
August 6, 2004
Chapter 2-1
Page 4

d) A Checks and Operations (10 Hours or Daily)
(1) Engine
a
Check Crankcase Oil Level
CAUTION
DO NOT overfill. DO NOT operate the engine with oil level below the lower bar or
above the upper bar on the dipstick.
(i)
Check oil level daily with oil gage dipstick.
(ii)
Oil level should not be checked until 3 to 5 minutes after engine shutdown. Keep oil
level as near the upper bar as possible.
Drain Fuel Pre-Filter Element

The life of the fuel pump and injectors can be extended if the operator drains about a cup of
fuel from the fuel pre-filter element to remove water and sediment before starting the engine
each day.
CAUTION
BE SURE to prime and bleed the fuel system after draining the filters, replacing filter
element, or if the fuel tank has run empty. Failure to do so can cause engine starting
problems.
(i)
Provide a container for catching drained fuel.
(ii)
Open the drain valve on the fuel/water filter by turning it counterclockwise.
(iii)
Drain the filter until clear fuel is visible.
(iv)
Tighten the drain valve.
(v)
Safely dispose of drained fuel.
(vi)
Purge air from fuel system if necessary.
Check Coolant Level

Check coolant level daily or at each fuel fill interval. Investigate for cause of any coolant loss.
WARNING
Cooling system is pressurized. To avoid personal injury, DO NOT remove radiator

cap when engine is hot.
Check for Leaks and Correct
At each daily start-up, check for coolant, fuel, and oil leaks. Coolant leaks may be more
noticeable when components are cold. Observe pumps, hoses, fittings, gasket connections,
etc., for signs of leakage. Correct as required.
August 6, 2004
Chapter 2-1
Page 5

Fuel Pre-Filter and Drain

Figure 2
Fuel Drain
e
Check Air Cleaner Indicator

At each daily start-up, observe the air cleaner indicator light. If this light comes ON, it
indicates that the air cleaner should be changed.
Check Exhaust System

Visually inspect muffler and exhaust pipes for rust and signs of approaching failure. Listen for
any gasket or joint leaks.
WARNING
A leaking and defective exhaust system could be a fire hazard.
(2) Electrical System (12 VDC)
a
Check All Lights

Check all indicating lights to be sure they will operate when they should. If any light fails to
operate, check both the lamp and its protective circuit breaker. Figure 5 lists all lamps with
their location and part number. Figure 6 lists all circuit breakers.
Check Alternator Charging Rate

Observe the 12 VDC ammeter each time the engine is started. A zero amperage reading or
extremely high reading for any length of time indicates trouble in the alternator, regulator,
battery, or interconnecting wiring.
Check the operation of all the engine meters.
August 6, 2004
Chapter 2-1
Page 6

b
Check Output Cables and Connector

Check the output cable plug connection for damaged insulation and contacts each time the
connector is detached from the aircraft.
Monitoring Instruments
Check operation of voltmeter, ammeter and frequency meter each time the unit is started.
e) B Check and Operations (250 Hours or 3 Months)

(1) Engine
a
Charge-Air-Cooler and Piping

Inspect the charge-air-cooler for dirt and debris blocking the fins. Check for cracks, holes, or
other damage.
Inspect the pipes and hoses for leaks, holes, cracks, or loose connections. Tighten the hose
clamps if necessary.
Change oil and oil filters
Check and record oil pressure

After each oil change, check and record oil pressure at idle speed after oil has warmed to
approximately 140 F. Record oil pressure under identical conditions at each oil change
interval. A comparison of pressure at idle speed with previous readings will give an indication
of progressive wear of oil pump, bearings, shafts, etc. Investigate any abnormal change in
pressure readings.
Change all fuel filters.
Check Radiator Core and Hoses

Inspect the radiator core for dirt and debris blocking the fins. Clean as necessary. Check for
cracks, holes, or other damage.
Check Fuel Pump

Inspect the fuel injection pump mounting nuts for loose are damaged hardware.
(2) Electrical (12 VDC system)

NOTE: The battery furnished with this generator set is MAINTENANCE FREE.
a
Battery Electrolyte Level (if applicable)

Battery electrolyte level must be maintained above top of plates. Add distilled water as
required.
August 6, 2004
Chapter 2-1
Page 7

CAUTION
DO NOT overfill.
b
Check Battery
If battery requires water frequently, or is low in charge, the reason for the condition must be
found and corrected.
Check battery terminals and clean, if necessary.

a
f)
Check the operation of the E-F bypass system.
C Checks and Operations (500 Hours or 6 Months)

(1) Engine
a
Check Engine and Generator Mounts
CAUTION
An unstable or loosely mounted engine can create hazardous environment and may
also damage equipment.
(i)
Engine mount bolts must be torqued to 122 N-m (90 ft-lb.).
(ii)
Generator mount bolts must be torqued to 122 N-m (90 ft-lb.).
Check Coolant Additive Concentration

The cooling system protective liquid (nitrite-, amine- and phosphate free) provides effective
protection against corrosion, cavitation, and freezing. See engine manufacturers operation
manual for ordering and mixture details.
(2) Electrical (12 VDC system)

a
Wiring
Inspect all cables and leads for worn or damaged insulation.
Connections
Inspect connectors for damaged or corroded condition.

a
Protective Monitoring Circuits

Check operation of all protective monitoring circuits to make certain they will function if a fault
should occurs in the output circuit. Procedures for testing these circuits are contained in the
Adjustment/Test section of this manual.
August 6, 2004
Chapter 2-1
Page 8

b
Inspect Wiring and Connections

Check all cables, leads, and wiring for broken, worn and damaged insulation. Check all
connections for tightness.
Clean and inspect generally
g) D Checks and Operations (1000 Hours or 1 Year)

(1) Engine
a
Check Fan Hub and Drive Pulley

Inspect for loose bolts or worn features. Tighten bolts and replace parts if necessary. Refer
to the engine manufacturers operations and maintenance manual for assistance and the
most update to date information.
Check Hose Clamps on Air Intake Side

Be sure that all clamps are properly secured to prevent leaks and all hose are in good
condition.
Check Belt Condition and Tensioner

Refer to the engine manufacturers operations and maintenance manual for assistance and
the most update to date information.
Check and/or Adjust Valve Clearance

Check Water Pump

Inspect the water pump weep hole for indication of a steady leak. If a steady flow of coolant
or oil is observed, replace the water pump with a new or rebuilt unit. Refer to the engine
manufacturers operations manual for assistance.
h) E Checks and Operations (1500 Hours or 1.5 Year)

(1) Engine
a
Steam Clean Engine

There are several reasons why the engine exterior should be kept clean. Dirt on the outside
will enter fuel and oil filter cases and rocker housings when covers are removed, unless dirt is
removed first. A clean engine will run cooler and develop fewer hot-spots. Steam cleaning is
one of the most satisfactory methods of cleaning and engine; however, there are some
CAUTIONS to be observed:
August 6, 2004
Chapter 2-1
Page 9

WARNING
Exercise care to avoid injury and damage to eyes and skin.
CAUTION
1. If a cleaning compound is used, select one that is free from acid and will not
remove paint.
2. Protect (or remove) all electrical accessories, such as voltage regulator, alternator,
and electrical wiring.
3. Seal all openings. DO NOT use a flammable solvent.
4. DO NOT use mineral spirits or solvents on a hot engine.
5. Remove or protect bottom panel of unit (belly pan) to protect insulation.
Clean Fuel System
See engine manufacturers operation manual for instructions.
Check Alternator and Cranking Motor.

The alternator and cranking motor on this particular engine require no periodic lubrication.
i)
F Checks and Operations (2000 Hours or 2 Years)

(1) Engine
a
Check Vibration Damper.

Check vibration damper for looseness, wobble, chunking and streaking. Also verify the hub
bolts are tightened to the engine manufacturers specifications.
c
j)
Check Charge-Air-Cooler and Radiator Systems

(i)
Check for damaged hoses and loose or damaged hose clamps.
(ii)
Check the radiator for leaks, damage, and build up of dirt in the fins. Clean or
replace as necessary.
Flush cooling system and change coolant.
Seasonal Maintenance Checks Spring/Fall (Engine)

(1) Check Fan Mounting
a
Check fan to be sure it is securely mounted.
Check for fan wobble and/or broken/cracked blades.
Check fan hub and crankshaft pulley for secure mounting.
August 6, 2004
Chapter 2-1
Page 10

5
1
4
3
1.
2.
3.
4.
5.
Water Pump
Fan Pulley
Vibration Damper
Alternator
Starter Motor
Engine Accessories
Figure 3
(2) Check cooling system each spring and fall. Clean if necessary.
(3) Check All Hoses.
In addition to daily checks of hoses for leaks, inspect hoses thoroughly each time the cooling
system is cleaned and serviced.
Inspect for signs of deterioration and collapse. Inspect for cracks and cuts. Inspect for cutting
and deformation caused by hose clamps. Replace hoses as required.
(4) Check thermostat and seals each fall when cooling system is serviced.
k) Lamps Circuit breakers, and Fuses
(1) Check all lamps daily
(2) Check circuit breakers and fuses as required.
August 6, 2004
Chapter 2-1
Page 11

(3) The lamp chart lists all lamps with their location and identifying trade number in table below.
(4) The circuit breaker chart lists all circuit breakers with their location, size, and type.
(5) The fuse chart lists all fuses with their location, size, and type.
Item Protected
Location
Quantity
Size
Engine Air Intake Heater
Top of Inside Bulkhead
100 A
Load Contactor Circuit
Voltage Regulator PCB
1A
1A
Field Voltage Circuit
5A
Transformer-Rectifier PCB
1A
Transformer-Rectifier [Optional]
Fuse Identification Chart

Figure 4
Location
Lamp (Bulb) as per Lamp

Industry Trade Number or
Description
Instrument Panel Lights
Switch Panel
67
Engine Start Indicator
Switch Panel
1815
Engine Stop Indicator
Switch Panel
1815
No. 1 Load Contactor Indicator
Switch Panel
1815
No. 2 Load Contactor Indicator
Switch Panel
1815
Test/Reset Indicator
Switch Panel
1815
Pre-heater Indicator
Switch Panel
1815
Clearance Lights (optional)
Canopy Top
57
Inside Each Gauge
53
Light Identification
Engine Gauge Lights
Lamp Identification Chart

Figure 5
Item Protected
Location
Quantity
Size
Engine Circuit and Instrument Panel
Inside Control Box
10 A
Controls
Inside Control Box
5A
Marker Lights (optional)
Inside Control Box
10 A
Circuit Breaker Identification Chart

Figure 6
August 6, 2004
Chapter 2-1
Page 12

Section 2
Maintenance Procedures
1) General
A suggested maintenance schedule was provided in Section 1 of this Servicing Chapter. Each step of the
schedule was also covered in general in Section 1. This Section covers maintenance in more detail,
where necessary.
WARNING
STOP operations at once if a serious or possibly dangerous fault is discovered.
2) Lubrication
a) General
Proper lubrication is one of the most important steps in good maintenance procedure. Proper
lubrication means the use of correct lubricants and adherence to a proper time schedule. Lubrication
points, frequency of lubrication, and recommended lubricants are indicated in Figures 1 and 2.
b) AC Generator
The 400 Hz generator requires NO lubrication.
c) Generator Controls
Generator controls and instruments require no 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 manufacturers
Operation and Maintenance Manual and incorporated here to make them more readily available to
operators and maintenance personnel.
(1) Lubrication schedule
Time schedules indicated on the Lubrication Chart, Figure 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, high oil temperatures, or intermittent
operation. However, time intervals should not exceed those indicated in the chart without careful
evaluation.
August 6, 2004
Chapter 2-2
Page 1

(2) Oil specification
Engine lubricating oil, recommended by the engine manufacturer, is identified by an API
(American Petroleum Institute) classification designation. The manufacturer does not recommend
any specific brand of lubricating oil.
The use of quality lubricating oil, combined with a appropriate lubricating oil drain and filter
change intervals, are important factors in extending engine life.
Oil recommended for the diesel engines in this application is API Class CCMC.
Lubricating oil is discussed in detail in the engine manufacturers operation manual.
(3) Oil viscosity
A temperature and oil viscosity index chart is shown below. For operation at temperatures
consistently below -13F (-25C), refer to the engine manufacturers operation manual.
(4) Changing engine oil
Oil should be changed once after the first 50 - 150 hrs. of use, then every 500 hrs of engine
operation thereafter. The generator set is equipped with an hour meter to record actual engine
operating time. The ideal time to change engine oil is soon after a power delivery run, when the
engine is at operating temperature.
Change the oil filter element each time the oil is changed.
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
High ash oils may produce harmful deposits on valves that can cause valve burning.
CAUTION
Do not use solvents as flushing oils in running engines.
Change oil as follows:
a
Provide an open container for catching the old oil below the oil drain plug. Container capacity
must be greater than 30 quarts (28.4 liters).
The oil drain tube can be attained though a hole in the access panel underneath the
generator set.
Open drain plug located in oil pan.
August 6, 2004
Chapter 2-2
Page 2

Item
Maintenance Required
Lube Oil
Check oil level daily or after every 10 hours of use. Change oil and the oil filter
after the first 50 to 150 hours of use, then at 250 hour or 3 month intervals
thereafter. Use oil specification API CF-4, HT/HS Viscosity 3.7cP minimum.
Capacity
Oil Filter Replacement
Oil Filter Replacement Hobart Ground Power No. 286897-013

Oil Filter Replacement Engine Manufacturer No. 117-4421
Lube Oil Viscosity

Required as per
Ambient Temperatures
VISCOSITY AMBIENT
TEMPERATURE CONDITIONS
SAE
SAE
SAE
SAE
0F (-18C) and above for most climates

-10F to +50F (-23C to +10C) Winter conditions
-20F to +50F (-29C to +10C) Artic Conditions
-20F and below to +50F (-29C and Below to +10C)
15W40 (Preferred)
10W30
5W30
0W30
Synthetic Oils
See the engine manufacturers operations manual for usable synthetic oils and
instructions.
Fuel Pre-filter
Drain Filter Daily. Change filter element every 250 hours or 3 months of use.
Coolant
Check coolant level daily. Service and maintain coolant system according to
Section 2-2, paragraph 6. Engine coolant capacity (system): 40 quarts (37.8
liters)
Coolant hoses and

connections
Check coolant hoses and connections daily for leaks.
Air Cleaner
Change air cleaner filter as required when air cleaner indicator (on engine control
panel) shows that it should be changed.
Fan Belt
Check fan belt condition and tension every 500 hours or 6 months of use.
AC Generator
AC generator bearings are sealed and require no periodic lubrication.
Alternator
Alternator bearings are sealed and require no periodic lubrication.
Starter
Starter motor bearings are sealed and require no periodic lubrication.
Water Pump
The water pump is packed at assembly and requires no periodic lubrication.
Fan Hub
The fan hub is lubricated at assembly and requires no periodic lubrication.

Lubrication and Maintenance Chart
Figure 1
August 6, 2004
Chapter 2-2
Page 3

Symbol
Name
Specification
Grease, General Purpose
MIL-G-3545
Notes
Excludes those of sodium or soda
soap thickness.
Lubricants Chart
d
While oil is draining, change the oil filter element. See instructions below.
(i)
Provide a container for catching spilled oil from the filter.
(ii)
Remove the oil filter by twisting counter-clockwise and inspect it.
NOTE: The gasket can stick to the filter head. Make sure it is removed before installing a new filter.
CAUTION
If bearing metal particles are found on the element or in the shell, the source should
be determined before a failure.
CAUTION
Determine source of moisture, internal leaks, defective seals, gaskets, etc.
(iii)
Fill the new filter with clean lubricating oil before installation.
(i)
Apply a light coating of lubricating oil to the gasket sealing surface and install the
filter. DO NOT over tighten the filter.
Oil Filter
Oil Fill Location
Lubrication System
Figure 2
Oil Level Check Location
August 6, 2004
Chapter 2-2
Page 4

e
Clean the drain plug and install when engine oil has completely drained. Torque the drain
plug to 50 foot-pound (68 Nm).
Use the oil refill tube to refill the crankcase with new, clean oil that meets engine
manufacturers recommendations.
NOTE: Using a funnel to fill the oil crankcase will help prevent spills.
CAUTION

1. Always use clean containers, funnels, etc.

2. Dont forget to close the drain plug valve, and install the new oil, before starting the
engine.
Start engine and check oil pressure at once. Allow engine to idle for 5 minutes, check for
leaks, than stop the engine.
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 high bar on the oil dipstick.
e) Engine Accessories Lubrication

(1) Alternator
Most alternators contain sealed bearings and require no periodic lubrication, however, CHECK to
make certain there are no lubrication points on your particular alternator.
(2) Starter
Most starting motors are lubricated at assembly and should be re-lubricated only when the starter
is removed and disassembled, however, INSPECT the starter to make certain it has no
lubrication points.
(3) Water Pump
The water pump is packed at assembly and requires no periodic lubrication. Replace pump if
signs of lubricant leakage are found.
(4) Fan Pulley
The fan hub is also lubricated at assembly and requires no periodic lubrication. Replace hub if
lubricant is leaking.
3) Servicing the Air Cleaner

This air cleaner is a disposable type which, when dirty may be discarded. A definite time schedule for
cleaning or changing the air cleaner cannot be determined because of varying operating conditions. This
air cleaner filter can be removed from the air cleaner housing and replaced by unfastening the three metal
clamps on the end of the air cleaner housing. It may be inspected either at prescribed service intervals or
at any time deemed necessary.
August 6, 2004
Chapter 2-2
Page 5

Air Cleaner
Service Indicator
Air Cleaner Assembly

Figure 3
a) Inspecting the Air Cleaner

(1) Make periodic checks of air cleaner inlet screen for obstructions. If any obstructions are present,
remove them.
(2) Check outlet connection for proper seal.
b) Changing the Air Filter
(1) Unfasten the three metal clamps on the end of the air cleaner housing.
(2) Remove end cover of housing
(3) Pull out air filter element and replace.
(4) Replace end cover on housing, making certain that the filter is centered in the housing.
(5) Refasten the three metal clamps on the end of housing.
c) Disposal
Normal trash pick-up is acceptable. NEVER burn the air filter for disposal.
4) Engine Fuel
a) How to select FuelQuality
The quality of fuel oil used in the diesel engine is a major factor in engine performance and life. Fuel
oil must be clean, completely distilled, stable and non-corrosive.
August 6, 2004
Chapter 2-2
Page 6

CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely important that
the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause
severe damage to both the injection pump and the injection nozzles.
Use commercially available diesel fuel with less than 0.5% sulfur content. If the sulfur content is
higher than 0.5%, oil change intervals should be reduced (See engine manufacturers operation
manual).
In general, fuels meeting the properties of ASTM designation D 975 (grades 1-D and 2-D) have
provided satisfactory performance. For more information regarding the selection of fuel to use, refer
to publication Engine RequirementsLubricating Oil, Fuel, and Filters available from authorized
engine manufacturers service outlets.
b) Cold Weather Operation
In cold weather, diesel fuel will form wax crystals, which can restrict flow and clog filters. Fuel oil
suppliers approach this problem several ways. Some provide a specially refined product, while
others may use flow-improving additives or winter blends. Winter blended fuel will likely contain
kerosene or 1-D fuel, which provide good cloud point temperatures, but result in a lighter fuel with a
lower heat content. These fuels may be used, but they may result in reduced engine power and/or
fuel mileage.
In most cases, adequate resistance to cold can be obtained by adding an additive. For further
assistance contact the nearest engine manufacturers service representative.
5) Engine Fuel System

The fuel system consists of five primary components: Fuel tank, Fuel Water Separator (Pre-Filter), Fuel
Lift Pump, Fuel Filter, and the Fuel Return Line. The following are maintenance procedures for each of
these items.
a) Fuel Tank
Be sure that no foreign objects are permitted in the fuel tank. The fuel tank must be removed and
flushed out if objects are found in the Fuel Water Separator
b) Fuel Water Separator
Hobart Ground Power has mounted a fuel water separator on the inner wall of the canopy. Its
function is to remove foreign material and extract water from the fuel before it enters the fuel lift
pump. Daily draining of the filter water separator bowl is required.
August 6, 2004
Chapter 2-2
Page 7

(1) Draining the fuel water separator bowl.
a
Open drain valve
Drain accumulated water and contaminants.
Close drain valve.
(2) Priming fuel water separator (when applicable).

a
Loosen the vent plug.
Pump until fuel purges at the vent plug.
Close the vent plug, start the engine and check for leaks,
Correct as necessary with the engine off.
(3) Changing the fuel water separator element (when applicable).

a
The filter element replacement part number.
Hobart Part No. 286897-027

Deutz Part No. 1340130
Drain off some fuel by loosening the vent plug and opening the drain valve.
Spin the element and bowl off together. Remove the bowl and clean the O-ring gland.
Apply a coating of clean fuel or motor oil to the new O-ring and element seal. Spin the bowl
onto the new element and the spin them both onto the filter head snugly by hand only. DO
NOT USE TOOLS TO TIGHTEN!
With the vent plug still loosened, pump knob until fuel purges at the vent plug. Close the vent
plug, start the engine and check for leaks, correct as necessary with the engine off.
NOTE: The priming pump in the filter assembly is in tended for priming fuel into the Racor filter only
and not the entire fuel system.
c) Fuel Pump
The fuel pump supplies pressure to the fuel system so the diesel fuel can circulate freely. A
consistent check of the fuel pressure is necessary. Loss in fuel pressure in the fuel line may indicate
a faulty fuel pump.
d) Engine Fuel Filter
The forth item in the fuel line system is the factory installed fuel filter. The filter function is to remove
foreign material from the fuel under pressure before it enters the engine. The filament element is a
throwaway type in which the case and element are made as one disposable part.
August 6, 2004
Chapter 2-2
Page 8

Fuel Water Separator and Drain

Figure 4
Fuel Filter Drain
(1) Changing fuel filter

a
Replacement fuel filter part number.
Hobart Part No. 286897-014

Engine Manufacturer Part No. 118-0597
Change fuel filter after each 200 hours of operation unless a restriction test indicates the time
period should be extended.
Shut off fuel valve.
Place a pan underneath the fuel filter to catch spilled fuel
Undo fuel filter with commercial tool and spin off.
Catch any fuel.
Clean any dirt from the filter carrier rim
Apply a light film of oil or diesel on the rubber seal on the new filter.
CAUTION
When installing new element, do not over tighten it; mechanical tools may distort or
crack filter head.
Fill new filter with diesel fuel
August 6, 2004
Chapter 2-2
Page 9

j
Screw in the new fuel filter snug. Check that the cartridge is seated correctly against the
gasket and tighten with a final half turn.
Open fuel valve.
e) Fuel Return
The fuel return is a fuel line (tube) that takes unused fuel from the engine, and delivers it to the fuel
tank. No maintenance is required.
f)
Priming Fuel System (when applicable)

If this generator set has been run out of fuel, the fuel system must be manually primed with diesel fuel
up to the fuel water separator before the generator set can be started again. See Paragraph 5, b, (2)
for instructions for priming the fuel water separator system. Once the fuel has reached the fuel water
separator, close all open valves (i.e. filter vent plug) and cranked the engine until the fuel reaches the
injectors and the engine starts.
CAUTION
CAUTION
Make sure that all rags, or absorbent sheets, are clear of moving engine parts and
cannot be drawn in to the radiator fan.
Do not crank the engine for more then 15 seconds continuously. Allow the starter to
cool for 15 seconds between attempts.
6) Engine Cooling System

a) General
Cooling system service requires more than maintaining the proper coolant level in the radiator and
protecting the system against freezing. Water should by clean and free of any corrosive chemicals
such as chloride, sulfate, and acids. It should be kept slightly alkaline with a pH value in the range of
8.0 to 9.5. Any water which is suitable for drinking can be used in the engine when properly treated
as described in Engine manufacturers operation manual. The engine manufacturers representative
should be consulted regarding the selection of satisfactory brand, permanent-type antifreeze for use
in the cooling system.
b) Radiator Cap
(1) General
A pressure relief valve is built into the radiator cap. It is designed to open at a pressure of
approximately 10 psi (68.9 Kpa).
WARNING
When removing cap from a very hot radiator, do not turn cap past safety stop until the
pressure or steam has escaped.
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Chapter 2-2
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(2) Removal
To remove, turn the cap to the left (counterclockwise) to the safety stop. When all pressure is
released, press down on the cap and continue to turn until the cap is free to be removed.
CAUTION
Allow engine to cool before adding coolant.
CAUTION
Do not attempt to repair the valve in a radiator cap in case of failure. 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.
c) Coolant
The preparation and maintenance of the coolant solution is important to engine life and is completely
covered in the engine manufacturers operation manual. For information regarding coolant
specifications, testing equipment, antifreeze, etc., refer to engine manufacturers operation manual
that accompanies the Hobart manual or consult the local engine manufacturers representative.
CAUTION
Never use soluble oil in the cooling system.
(1) General
A permanent type antifreeze is recommended for use in the cooling system.
CAUTION
1. DO NOT use methanol or alcohol as antifreeze.

2. DO NOT mix brands or type of antifreeze. A solution containing two or more
types of antifreeze is impossible to test accurately.
(2) Selecting antifreeze

a
Select a permanent type antifreeze known to be satisfactory for use with chromate corrosion
resistor.
When it is not known if the antifreeze is satisfactory for use with chromate resistor, check with
local engine manufacturers representative for a list of compatible antifreezes.
(3) Checking antifreeze solution

Check the solution with a reliable tester when in doubt about antifreeze protection.
August 6, 2004
Chapter 2-2
Page 11

d) Draining the Cooling System
To completely empty the cooling system requires draining the engine block and the radiator
assembly. Both of the drain valves (radiator and block drain), CAN BE opened/closed at the same
time but they DO NOT need to be.
To drain the cooling system, proceed as follows:
(1) Remove radiator cap.
(2) Place a drain pan with at least a 40 quart (28.4 liters) capacity under radiator to catch coolant.
(3) Place the radiator drain hose that comes off the two radiator drain valves, into the drain pans.
(4) Open the radiator drain valves.
(5) Allow the system to drain completely.
NOTE: Be sure the drain valves do not clog during draining.
(6) When the system is completely drained, close the drain valves and replace engine drain plug.
e) Flushing the Cooling System
Flushing the cooling system should be a yearly maintenance procedure. By flushing the system,
clean water is forced through the engine block to remove expired coolant and other contaminants.
f)
Cleaning the Radiator Core

Blow out accumulated dirt from the radiator core air passages, using water. Engine overheating is
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 fins and tubes.
NOTE: Direct the water in a reverse direction to normal air flow. Normal flow on this installation is
from the engine compartment out ward.
g) Filling the Cooling System

The preparation and monitoring of coolant in liquid-cooled engines is especially important because
corrosion, cavitation, and freezing can lead to engine damage. For coolant system protection details
see the engine manufacturers operations manual.
(1) Install coolant
a
Remove radiator cap. Be sure that both radiator drain valves are closed.
Pour coolant into radiator very slowly until it reaches the bottom of fill neck. Allow time for
trapped air to escape from the system then continue filling until the coolant level remains at
the bottom of the fill neck.
Start the engine and bring up to rated speed and allow the thermostat to open. Add coolant
as trapped air escapes from the system and the coolant level falls.
August 6, 2004
Chapter 2-2
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d
Continue to check coolant level until all trapped air escapes. Add coolant if needed to fill to
the bottom of fill neck. Install radiator cap.
(2) Inspection/Check
a
Check system for evidence of leaks.
Inspect all hoses. Install new hoses as necessary. Tighten hose clamps as required.
Check the condition of fan and water pump belts. Replace belts if necessary.
NOTE: It is good practice to attach a card, indicating the cooling system contents and date serviced,
to the radiator filler neck.
h) Thermostat
The thermostat should be checked each fall, or as required. Refer to engine manufacturers
operations manual for recommended instructions.
7) Generator Maintenance
The 400 Hz generator requires no maintenance or service other than periodic cleaning. The unit is
brushless and has bearings that are permanently lubricated and sealed.
a) Cleaning
The generator may be cleaned by careful use of compressed air and/or a good, SAFE commercial
cleaner. Steam cleaning of the generator is not recommended because the use of steam and harsh
chemical compounds may result in damage to insulation and other generator components.
CAUTION
Do not use a flammable solvent. Be sure the unit is completely dry before operating.
b) Adjustment
The generator itself requires no adjustment. Adjustment procedures for generator controls are
covered in Section 2-3.
8) Drive Belt
a) General
The engine cooling fan, alternator, and water pumps are driven by one serpentine belt, which must be
replaced if worn or damaged.
b) Preparation for Belt Check and Adjustment
All driven assemblies must be securely mounted in operating position before checking belt tension.
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Chapter 2-2
Page 13

c) Checking Belt Tension
CAUTION
Checking the tension and changing the serpentine belt should only be performed with
the engine off.
Check belt tension every 500 hours, or once a half-year, whichever comes first. A belt that is too tight
is destructive to bearings of the driven part. A loose belt will slip and cause inefficient operation of the
part being driven as well as wear to the belt.
CAUTION
Inspect and replace the belt if it has unacceptable cracks, is frayed, or has pieces of
material missing.
Belt tension may be checked by hand. To do so, manually depress the belt with an index finger to
determine the amount of belt deflection obtained. When a force is applied at a point halfway between
pulleys on the longest span of a belt, there should be no more than 1/2 inch of deflection attained.
Refer to the engine manufacturers operation manual for checking belt tension and changing worn
belts.
August 6, 2004
Chapter 2-2
Page 14

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 replacements, or overhaul.
IMPORTANT
In order to perform most of the following test, a load bank with an EF interlock circuit
is required. But if no EF interlock is available on a load bank, see special procedure
in the EF Bypass section for testing the EF circuit.
2) Testing the 400 Hz. Generator Set

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 high bar on the dipstick.
(3) Check radiator coolant level (See 2-2, Paragraph 6)
(4) Check tension of drive belt (See 2-2, Paragraph 8).
(5) Inspect for oil, fuel and coolant leaks.
(6) If the setting of the output voltage coarse adjustment potentiometer (Figure 8) on the voltage
regulator has been disturbed, set it at center position (halfway between full clockwise position and
full counterclockwise position).
(7) Check control panel lights circuit breaker (Figure 3) by pressing panel LAMPS push button
switch (Figure 2). If panel lights operate, the circuit breaker, switch, and lamps are good.
(8) Check fault indication lights by pressing TEST/RESET push button switch (Figure 2). If fault
code display lights up, the control circuit breaker (Figure 3) is good.
(9) Make a general inspection of all wiring, and terminals. Inspect the equipment to be certain no
damage will result from starting the engine.
b) Operational Test Procedures
(1) Start the engine in accordance with instructions in Section 1-3, Paragraph 2.
(2) Check operation of engine instruments: ammeter, coolant temperature indicator, oil pressure
gage and hour meter (all shown in Figure 1).
(3) Check engine idle speed. Should be 1000 +/- 25 RPM.
NOTE: A stroboscope may be required for this check.
(4) Again check for oil, fuel, and coolant leaks and correct any leaking condition.
August 6, 2004
Chapter 2-3
Page 1

1.
2.
3.
4.
5.
6.
7.
8.
9.
7,10
Fuel Gage (M13)

Front Panel
Control Panel Label
10,12
15
10.
11.
12.
13.
14.
15.
16.
17.
17
11,10
16
13

AC Voltmeter (M2)
Control Panel Door

Figure 1
August 6, 2004
Chapter 2-3
Page 2

10
1.
2.
3.
4.
5.

6.
7.
8.
9.
10.
AC Output No. 2 Contactor Switch (S275)

AC Output No. 1 Contactor Switch (S75)

Figure 2
August 6, 2004
Chapter 2-3
Page 3

2
5
6
3
4
10
1.
2.
3.
4.
5.
6.
11
Control Box Wrapper

7.
8.
9.
10.
11.


Figure 3
August 6, 2004
Chapter 2-3
Page 4

(5) Position switches and controls for automatic voltage regulation and power delivery as follows:
a
Place regulated-diagnostic switch (Figure 8) in REGULATED position.
Place EF Bypass switches (Figure 4) in BYPASS / OFF position.
If the output voltage coarse adjustment potentiometer (Figure 8) on the voltage regulator has
been disturbed, place the knob at mid-range position.
(6) Bring the engine up to rated speed, which also energize the generator, by pressing the ENGINE
START push button switch (Figure 2) a second time. If the engine comes up to rated speed and
a 115 V voltage value appears on the voltmeter (Figure 1), the engine EMR and excitation circuits
are functioning.
(7) After generator overhaul or repair, the Regulated/Diagnostic switch (Figure 8) must be placed in
the DIAGNOSTIC position for 3 to 5 seconds to re-magnetize the exciter. Then return the switch
to the REGULATED position after voltage has built-up.
(8) Observe frequency meter (Figure 1). If engine speed is properly set, frequency should read 400
Hz.
(9) Observe voltmeter (Figure 1). Use output fine voltage coarse adjustment potentiometer (Figure 8)
to adjust voltage to 115 V AC.
(10) Check adjustable voltage range.
a
Observe voltmeter (Figure 1) and turn output voltage coarse adjustment potentiometer
(Figure 8) to full clockwise position. Maximum voltage should be 134 volts or higher.
NOTE: If voltage should decrease when regulator potentiometer is turned clockwise, it indicates that
internal wiring in the voltage regulator is incorrect. Replace complete voltage regulator assembly.
b
Observe voltmeter and turn regulator potentiometer knob to full counterclockwise position.
The minimum voltage should be 95 volts or lower.
(11) Position load bank switches, etc., to apply a light load to the generator.
c) Testing the No. 1 Output Circuit
(1) Place EF Bypass switch (Figure 4) in BYPASS / OFF position turn the EF signal ON on the
load bank. Then press the yellow No. 1 load contactor push button switch (Figure 2) to close
contactor, which is indicated when its internal indicating light glows.
(2) Place EF switch on the load bank in the off position. The No. 1 load contactor should open
immediately, and the indicating light within the push button switch should go off. The fault code
display should also read EF 1, indicating an EF warning. This is because the interlock circuit of
the control PC board is not receiving 28.5 VDC signal from an outside source. It indicates that
the No. 1 interlock circuit is OPEN, as it should be when the interlock circuit is not receiving a 28
VDC signal. Reset the fault by pressing the TEST/RESET push button (Figure 2).
August 6, 2004
Chapter 2-3
Page 5

PC Board Software
EF1 Bypass
EF2 Bypass
Service Tool Connector
Digital Control PC Board

Figure 4
(3) Verify that when the EF Bypass switch (Figure 4) is in the BYPASS / ON position or the
BYPASS / OFF position, that the appropriate LED indication on the control panel display (Figure
5) is correct.
(4) Place EF bypass switch (Figure 4) in BYPASS / ON position. Press the No. 1 load contactor
push button switch. The No. 1 contactor power indicating light within the push button switch
should glow and remain on when the push button switch is released. This indicates that EF
bypass switch is functioning correctly. The corresponding LED (Figure 5) should also indicate the
bypass mode.
(5) Place the No. 1 EF bypass switch to BYPASS / OFF position. The No. 1 load contactor should
open at once and the yellow indicating light within the No. 1 load contactor push button switch
should go off and the fault code display should also read EF 1, indicating a EF warning. The
corresponding LED (Figure 5) should also indicate the EF present mode. Reset the fault by
pressing the TEST/RESET push button (Figure 2).
(6) Proceed to step 12.
August 6, 2004
Chapter 2-3
Page 6

(Steps 8 - 11 are only required if EF interlock system is not available on a load bank.)
(7) Connect a source of 24 V-DC power (two twelve-volt batteries connected in series) to terminals
N, F (or E) at the output terminal panel. Connection polarity is important. Connect plus (+) to
terminals E or F, and minus (-) to terminal N.
(8) Verify that when the EF Bypass switch (Figure 4) is in the BYPASS / ON position or the
BYPASS / OFF position, that the appropriate LED indication on the control panel display (Figure
5) is correct during the following steps 9 and 10.
(9) Place the No. 1 EF bypass switch to BYPASS / OFF position. Press the No. 1 contactor
operating push button switch (Figure 2). The No. 1 contactor power on indicating light, within the
push button switch, should glow and remain on when the push button switch is released. This
indicates that the load contactor is closed and the plug interlock circuit is functioning properly.
(10) Disconnect the 24 V-DC power source and the No. 1 load contactor should open immediately,
and the indicating light within the push button switch should go OFF. The fault code display
should also read EF 1, indicating an EF warning. This is because the interlock circuit of the
control PC board is not receiving 28.5 VDC signal from an outside source. It indicates that the
No. 1 interlock circuit is OPEN, as it should be when the interlock circuit is not receiving a 28 VDC
signal. Reset the fault by pressing the TEST/RESET push button (Figure 2).
EF Bypass Indication
Figure 5
EF Bypass Indication
(11) In EF bypass mode, 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.
(12) Increase load at the load bank to full load.
(13) Check operation of the engine EMR by observing the frequency meter (Figure 1) when generator
is switched from no load to full load, and vice versa. Use the No. 1 contactor control push button
switch to apply and remove load several times. Steady-state frequency droop should be no more
than 1 Hz.
(14) Follow instructions in Paragraph 3 to set voltage regulator line drop compensation for the length
and size of cable being used.
August 6, 2004
Chapter 2-3
Page 7

(15) Check voltage regulator, at intervals, from no load to full load. Observe and note voltage at
various loads. Steady-state voltages should vary no more than +/- 1% from normal output
voltage.
(16) Operate the No. 1 output circuit of the unit no less than 10 minutes under full load. The overload
protection MUST NOT trip.
(17) Operate the No. 1 output circuit of the unit at 125% load (325 amperes) for 5 minutes immediately
following the full load run. The overload device MUST trip within 5 minutes, and the fault code
display should read 70.18 indicating an overload condition in OUTPUT NO 1 (Reference fault
chart in Section 2-4).
(18) Reset the fault by pressing TEST/RESET push button (Figure 2).
d) Testing the No. 2 output circuit
(1) Repeat steps (1) through (18) in the previous section Testing the No. 1 Output Circuit for
testing the No. 2 output circuit.
e) Testing and checking meters, switches, protective monitoring circuits, and fault code display
(1) Check accuracy of AC voltmeter
a
Open door of control box and connect a master voltmeter of known accuracy to terminals of
the AC voltmeter (Figure 1).
Compare the units voltmeter reading with master meter. Error must not exceed 2% of full
scale.
(2) Check accuracy of AC ammeter

a
Connect a master ammeter of known accuracy to the AC ammeter (Figure 1).
Compare the units ammeter reading with master meter under various loads. Error must not
exceed 4% of full scale.
(3) Check operation of the METER SELECT switch (Figure 2).

a
In any LINE-TO-NEUTRAL position, the voltmeter reading should be 115 volts when the LED
under the voltmeter indicates one of the 3 phase being check (Figure 5).
In any LINE-TO-LINE position, voltmeter reading should be 200 volts when the LED under
the voltmeter indicates two of the phases being checked (Figure 5).
(4) Check accuracy of frequency meter

a
Connect a master frequency meter of known accuracy to the terminals of the frequency meter
(Figure 1).
Compare meter readings. Error must not exceed 1% of full scale.
August 6, 2004
Chapter 2-3
Page 8

NOTE: Make all protective system tests with the unit operating under a load for the following steps.
Reference Chapter 2, Section 4, for all fault codes.
(5) Check operation of over-voltage circuit and fault code display.
a
With the unit running at a normal load, adjust the coarse adjustment potentiometer (Figure 8)
on the voltage regulator clockwise to increase voltage until the over-voltage sensing circuit
actuates the protective monitor. After the protective monitor is activated, the load contactor
will open and the fault code display will display fault 70.16. At 125 volts, the circuit will trip
after a 1-second time delay. At higher values of voltage, time delays for over voltage trips are
as follow:
At 140 volts, the circuit will trip within 160 milliseconds.
At 180 volts, the circuit will trip within 50 milliseconds.
If the load contactor does not open under the conditions described in step (a), refer to the
Troubleshooting Chart in Section 2-4.
Return unit to normal operating conditions by adjusting coarse adjustment potentiometer

(turning it counterclockwise) and pressing TEST/RESET button switch to clear the fault
code (Figure 2).
(6) Check operation of under-voltage circuit and fault code display.

With the unit running at a normal load, adjust the coarse adjustment potentiometer (Figure 8) on
the voltage regulator counterclockwise to decrease voltage until the under-voltage sensing circuit
actuates the protective monitor. After the protective monitor is activated, the load contactor will
open and the fault code display will display fault 70.17. Follow the following steps below to
activate the under-voltage protective monitor. A stopwatch is required for this check.
a
With the unit running at normal load, use the output voltage coarse adjustment potentiometer
on the voltage regulator to reduce the voltage to 104 volts. The load contactor should NOT
open.
Reduce voltage in increments of 1 volt, with a time delay of 7 seconds between steps. At a
setting of 100 volts, the load contactor will open and the under voltage light will glow after a 7second time delay.
If the load contactor does not open under the conditions described, refer to the
Troubleshooting Chart in Section 2-4.
If the under voltage circuit performs satisfactorily, return unit to normal operation by adjusting
output voltage coarse adjustment potentiometer for normal output voltage, pressing the
TEST/REST push button switch to clear the fault code.
(7) Check under-frequency circuit and fault code display.

At some frequency value 380 Hz or less, after 7 seconds, the frequency condition should signal
the under-frequency circuit protective monitor to OPEN the load contactor and display 70.23 on
fault code display. To check the under-frequency protective components, proceed as follows:
August 6, 2004
Chapter 2-3
Page 9

a
While the unit is operating normally under load, set the frequency adjust switch (Figure 6) to
TEST. Use the frequency adjust potentiometer (Figure 6) to adjust frequency to 400 HZ.
Reduce frequency in steps of 1 Hz, with a time delay of 7 seconds between steps.
If the protective circuit opens the load contactor and displays fault 70.23 on the fault code
display after 7 seconds, at 380 Hz or less, all components of the system are functioning
properly.
If the load contactor is not opened at 380 Hz or less after 7 seconds, refer to Troubleshooting
Chart in Chapter 2, Section 4.
Return unit to normal operating condition by setting the frequency adjust switch to
NORMAL and pressing TEST/RESET button switch (Figure 2) to clear fault code.
Engine Status Switch
Frequency Adjustment &

Enable/Disable Switch
Engine Status Light
J52 Connector
PC Board Software
Engine Specific PC Board

Figure 6
(8) Check over-frequency circuit and fault code display.

At some frequency value 420 Hz to 440 Hz, after 5 seconds, the over frequency sensing circuit
should signal the over-frequency circuit protective monitor to OPEN the load contactor and
display 70.22 on fault code display.
At any frequency value exceeding 440 Hz, the over-frequency circuit should immediately signal
the protective monitor to OPEN the load contactor and display 70.22 on fault code display..
To check the under frequency protective components, proceed as follows:
a
While the unit is operating normally under load, set the frequency adjust switch (Figure 6) to
TEST. Use the frequency adjust potentiometer (Figure 6) to adjust frequency to 400 HZ.
Increase frequency in steps of 1 Hz, with a time delay of 5-7 seconds between steps.
August 6, 2004
Chapter 2-3
Page 10

If the protective circuit opens the load contactor and displays fault 70.22 on the fault code
after 5 seconds at 426 Hz, all components of the system are functioning properly.
If the load contactor is not opened at 426 Hz after 5 seconds, refer to Troubleshooting Chart
in Chapter 2, Section 4.
Return unit to normal operating condition by setting the frequency adjust switch to
NORMAL and pressing TEST/RESET button switch (Figure 2) to clear fault code.
NOTE: If the generator is operating under load at this point, open the contactors. There will be no
further need for the load bank in the following checks.
f)
Testing for engine EMR faults

(1) Set the starter disable switch to DISABLE.
(2) Press the green engine start push button switch. The engine will not start and the green light in
the engine start switch will flash to indicate that power is available to the engine EMR.
Starter Disable/Enable
PC Board Software
Engine Interface PC Board

Figure 7
August 6, 2004
Chapter 2-3
Page 11

(3) If no active codes are recorded the Engine Diagnostic Indicator lamp will stay off.
If active codes are recorded the lamps will flash or stay on continuously signifying the severity of
the fault code. A continuous light is the most severe and may prevent the engine from operating
until the fault is corrected and cleared.
(4) If active codes exist, press the data request button for 2 seconds and release. The light will blink
the present error codes. See engine manufactures manual for code meanings.
g) Re-checking the entire unit after testing
(1) With the engine running at normal rated speed, check the entire unit for vibration and for any
parts that may have become loosened during the above checks. Tighten any loose hardware as
required.
(2) Check engine oil pressure at rated speed (2000 RPM). The oil pressure gage should indicate at
least 44.9 psi (3.1 bar) when engine is hot. Also at rated speed, check the engine coolant
temperature. The temperature gage should indicate in the range of 180 to 190 F (82 to 88 C),
depending upon operating conditions.
WARNING
If a metal sounding rod is used to detect bearing noises, exercise extreme care to
avoid injury from moving components.
(3) Check 400 Hz generator bearings. Use a stethoscope or metal sounding rod to listen for unusual
noises. If using a metal rod, place on 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. Contact the equipment
manufacturer if in doubt of bearing serviceability.
3) Generator Set Adjustment

a) Generator Adjustment
The 400 Hz generator is a brushless type requiring no adjustments of any kind.
b) 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 adjustments of output voltage value and line-drop compensation.
For making these adjustments, the voltage regulator has three potentiometers:
A coarse output voltage potentiometer (Figure 8).
A fine output voltage potentiometer (Figure 8)
A line-drop compensation potentiometer (Figure 8).
For the following adjustment, the generator set must be running at rated speed (2000 RPM), under
no-load conditions. Adjust the regulator as follows:
August 6, 2004
Chapter 2-3
Page 12

Regulated/Diagnostic
Voltage Adjustment, Coarse

Voltage Adjustment, Fine
PC Board Software
LDC Control
Voltage Regulator PC Board
Figure 8
(1) Output Voltage Adjustment

a
Adjust Voltage Control

The output voltage, at which the generator is regulated, is adjustable by the fine voltage
adjustment potentiometer (Figure 8). Turn the potentiometer adjustment clockwise to
increase generator output voltage, and counterclockwise to decrease voltage.
Observe the output voltage as indicated by the voltmeter, located on the control panel of the
generator set. Set output voltage at 115-V AC line-to-neutral (200-V AC line-to-line).
August 6, 2004
Chapter 2-3
Page 13

b
Adjust Line Drop Compensation

Adjustment of line drop compensation is made with the line drop compensation potentiometer
(Figure 8). Turning the potentiometer knob clockwise increases the magnitude of the
compensation, and turning the potentiometer knob counterclockwise decreases the
magnitude (A graduated nameplate for specified cable lengths is included for quick
reference.). To adjust the line drop compensation, proceed as follows:
Connect the generator set output cables to a load. Load the generator set with the
largest available three-phase load of rated power factor not exceeding the maximum
rating of the generator set.
Measure output voltage at the load end of the cables. If the load voltage rises or drops
more than 1% at the load end of the cables, decrease or increase the line drop
compensation until the regulation is flat (115-V AC line-to-neutral and 200-V AC line-toline).
If the line drop compensation adjustments have affected the no-load voltage output,
adjust the fine output voltage control potentiometer to the desired value.
(2) Test the Voltage Regulator

After necessary adjustments have been completed, re-test the voltage regulator as follows:
a
b
c
d
Connect a voltmeter at the load end of the generator output cables.

Operate the generator set at no-load and observe voltage reading.
Operate the generator set 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.
c) Basic Engine Adjustments

Adjustment procedures applicable to the diesel engine are included in the engine manufacturers
operation manual, which is referenced in Chapter 5. Specific information for these engines is listed in
Figure 2. Refer to the engine operation manual for detailed information on the following engine
adjustments.
(1) Exhaust valve adjustment
(2) Fuel injector timing adjustment
(3) Engine idle speed adjustment
Engine idle speed is programmed at the factory. If adjustment is required, contact the local
engine distributor. The recommended idle speed is 1000 RPM, +/- 25 RPM.
NOTE: A stroboscope is required for engine idle speed checks.
(4) Engine speed limiting adjustment
The speed limiting adjustment is also set and sealed at the factory. Speed should be limited to
approximately 2350 RPM. If adjustment is required, contact your local engine distributor.
August 6, 2004
Chapter 2-3
Page 14

d) Engine Accessories Adjustment
(1) Alternator and fan belt adjustment
Refer to Section 2-1 and engine manufacturers manual.
ENGINE
Manufacturer
Model No.
Type
Horsepower
Idle speed
High speed limiting
Normal governed speed
Deutz Corporation
BF06M1013EC
Rotary, 6 cylinder, 4 cycle diesel, electronic controled
218 hp (163 kW)
850 or 1000 50 rpm
2350 75 rpm
2000 rpm

Figure 9
4) Generator and Exciter Test

The generator fields and exciter stator may be tested with a Kelvin bridge. This is a double-bridge type
instrument required for the very low resistances encountered in this test. It is understood that zero (0)
resistance indicates a SHORT CIRCUITED condition. An infinite resistance reading indicates an OPEN
CIRCUITED condition. See Figure 10 for resistance values.
a) Disconnect generator stator leads at the output module panel.
b) Disconnect the two black exciter field leads from terminal block mounted on output module panel.
c) Check resistance and compare to values given in Figure 5.
Test Connection
Resistance (Ohms)
Generator Stator Phase A to N (G1)*

Generator Stator Phase B to N (G1)*
Generator Stator Phase C to N (G1)*
Exciter Stator Field (L2)
A - B, B - C, C - A Exciter Armature (G2)
Generator Revolving Field (L1)
0.0026
0.0026
0.0026
29
0.041
2.1
*NOTE: The two leads of a phase must be connected when test is made. Take readings when unit
is cold and in an ambient temperature of 70 F (21C.).
Generator and Exciter Test Readings
Figure 10
August 6, 2004
Chapter 2-3
Page 15

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 are as follows:
a) Disconnect exciter windings from diode lead(s).
b) Use a good quality ohmmeter. An instrument, which indicates 50 ohms at the center of the scale, is
preferable.
NOTE: Make certain the battery is in good condition and the pointer is adjusted to zero when the test
lead points are shorted together.
c) Hold one ohmmeter lead point on the threaded end of the diode. Hold the other lead point on the
wire terminal end. Observe and note the indicated resistance. Now reverse the lead connection 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.
6) Testing the Transformer-Rectifier (Optional, See Appendix A)

The 28.5 VDC transformer-rectifier is an optional add-on to the GPU. See Appendix A for more details on
the adjustment and test of the transformer-rectifier.
August 6, 2004
Chapter 2-3
Page 16

Section 4
Troubleshooting Procedures
1) General
The Troubleshooting Chart (See Appendix A for the 28.5 VDC Transformer-Rectifier troubleshooting
information.) and Fault Code Chart, located in this section, covers the common faults and malfunctions
that you may find during operation or maintenance of this equipment. The charts may not list all faults
and malfunctions that may occur. If a fault of malfunction is not listed in the chart, start looking for the
cause at the source of power in the affected circuit. Refer to the schematic and connection diagrams in
Chapter 5. Test the circuit, step by step, until the source of the malfunction is isolated.
The Fault Code Chart is arranged under 2 headings: Commands and Faults. Commands display the
operation mode at the time a fault code is triggered.
The Troubleshooting Chart is arranged under 3 headings: Trouble Symptom and Condition, Probable
Cause, and Test Check and/or Remedy. Trouble(s), Symptom(s), and Condition(s) are described and
numbered. Probable Cause(s) are indented to the right and listed in numbered steps below Probable
Cause. Test Check and/or Remedy provides instructions for correcting the malfunction, and is listed
below each Test or Inspection procedure. Tests and inspections called for in the Troubleshooting Chart
are to be performed as described in Chapter 2, Section 1-3, of this manual.
2) Equipment for Troubleshooting

WARNING
CAUTION
Exercise extreme care to avoid contact with high voltage leads and components.
High voltage can kill!
Maintenance personnel must be very careful when performing terminal-to-terminal

checks to be certain the proper terminals are being used, especially when using
jumper leads. Damage to electrical components may result from the application of
improper voltage and current.
A good quality multi-scale voltmeter is the only instrument required for troubleshooting. At least two
jumper leads with alligator, or similar clips, will be required. The engine electrical system may be
used as a 12 VDC power source.
3) Parts Replacement
To lessen end item down time, and to get a faulty machine back on line as quickly as possible, the black
box concept of parts replacement is reflected in the Troubleshooting and Fault Code Chart. For example,
if a component on a control box PC board is defective, the quickest way to remedy the situation is to
replace the complete PC board and send the old to stock. Some of the assemblies that tend to lend
themselves to this concept are:
Voltage regulator PC Board (REG)

Control PC board (CTL)
Engine Specific PC Board (ESB)
Enigne Interface PC Board (EIB)
LED PC Board (LED)
28.5 VDC Transformer-Rectifier PC Board (TRB) [Optional, See Appendix A]
August 6, 2004
Chapter 2-4
Page 1

4) 400 Hz. Test Values

Although test values are provided throughout the troubleshooting chart, additional information and values
are given here.
Generator output voltage at maximum voltage regulator potentiometer setting:
120 volts or higher.
Generator output voltage at minimum voltage regulator potentiometer setting:
110 volts or lower.
Over voltage relay
Trips at 126 volts after a 1-second time delay.

Under voltage relay
Trips at 100 volts after 7 seconds.
Over frequency relay
Trips at any value between 426-Hz and 480-Hz

after a 5-second time delay. Trips immediately at
any frequency exceeding 480-Hz.
Under frequency relay
Trips at 375 Hz or less after a 5-second time delay.
Overload time delay
Trips in approximately 5 minutes at 125% load of

GPU rating or at 90 kVA on either output.
Frequency at rated speed of 2000 RPM is 400 +/- 2 Hz at no load and rated load.
Engine oil pressure (warm and at rated speed 2000 RPM) 45 to 90 PSI (445 to 621 kPa).
Engine coolant temperature (normal operation) 160 to 200 F (71 to 93 C).
5) 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.
6) Engine Troubleshooting
The ability of the engine to start and run properly depends upon a number of things.
a) An adequate supply of 12 VDC power reaching a good starter and starter button
b) An adequate supply of air, compressed to a sufficiently high pressure.
c) The injection of the correct amount of clean fuel at the proper time
NOTE: When trouble shooting the engine, keep these requirements in mind.
7) Illustrations
Illustrations, Figures 1, 2, 3 and 4, are referred to throughout the Troubleshooting Chart
8) Connection and Schematic Diagrams

All connection and schematic diagrams for generator, engine, lights, and all controls are located in
Chapter 5.
August 6, 2004
Chapter 2-4
Page 2

9) GPU Control Monitoring

The GPU control system performs complete diagnostic testing and continuous monitoring of all critical
circuits and operating electrical values. If the control system senses a problem with one of the circuits or
if any of the electrical values exceeds its safe operating limit, the control system will shut the GPU down,
or may allow the GPU to continue operation depending on the severity of the condition.
a) Commands
The ongoing operations conducted by the GPU are driven by the list of commands in Table 1. The
control PC board communicates these commands to all of the PC boards in the GPU. The first half of
the fault code identifies the command that was present when the fault occurred.
Commands
01.
\
39.
Self-Test Mode
40.
Engine Start Mode
50.
Engine Idle Mode
70.
Engine Run Mode
80.
Engine Shutdown Mode
90.
Engine Stop Mode
99.
System Off Mode

Operating Commands
Table 1
(1) Self-Test Mode

When power is first applied to the control circuit, the GPU performs complete self diagnostics of
the internal circuitry. During this self test, the GPU will perform the commands listed in the
enclosed charts. When a fault is detected during the self test, the current COMMAND and
detected FAULT are displayed on the fault code display.
(2) Engine Start Mode
When the ENGINE START push-button is activated, the engines starter and the engines ECM
will be energized.
August 6, 2004
Chapter 2-4
Page 3

(3) Engine Idle Mode
When the engine has been started, the engine will begin in the idle mode. The ENGINE
START push-button will flash indicating the engine is in the idle mode.
(4) Engine Run Mode
After the engine has been warmed up properly in the Engine Idle Mode, pressing the ENGINE
START push-button again will bring the GPU up to rated speed. The ENGINE START pushbutton light will no longer flash, but instead become continuously illuminated. The GPU is now
ready for aircraft loading.
(5) Engine Shutdown Mode
When shutting the GPU down, pressing the ENGINE STOP push-button will start the 3-5
minutes delayed shutdown period. The ENGINE STOP push-button will flashed and the engine
will return to idle speed. The shutdown period is required to sufficiently cool the engines
turbocharger.
(6) Engine Stop Mode
After the 3-5 minutes delayed shutdown period, the engine will stop running.
(7) System Off Mode
The power will be removed from the GPUs entire control system.
b) Faults
Faults result when any of the fault limits are exceeded, when an internal problem occurs, or under
certain conditions that would cause injury to personnel or damage to an aircraft or the GPU. Faults
are also stored in memory as event records. The fault limits and conditions are preset at the factory.
Faults
.01
\
.09
.10
\
.39
.40
\
.59
.60
\
.79
.80
\
.99
Warning (no operation changes)
Run Mode (minor fault)
Idle Mode (moderate fault)
Stop Mode (major fault)
Special Configuration (reserved)

Fault Codes
Table 2
August 6, 2004
Chapter 2-4
Page 4

(1) Warning
Warning faults are faults that occur and have no effect on the operation of the GPU. An example
would be an intake air restriction fault due to a dirty filter. Although the GPU will continue to
operate, the fault will appear on the fault code display. Pressing the TEST/RESET push button
or shutting down the GPU will reset the fault.
(2) Run Mode
Run mode faults that occur will remove power form the aircraft but will not change the operating
speed of the engine. An example would be an over voltage fault. Although the contactors will
open and remove power from the aircraft, the engine will remain at rated speed, and the fault will
appear on the fault code display, along with the appropriate command. Pressing the
TEST/RESET push button or shutting down the GPU will reset the fault.
(3) Idle Mode
Idle mode faults that occur will remove power form the aircraft and drop the operating speed of
the engine to the idle setting. A possible example (depending on customer configuration) would
be a high temperature fault. The contactors will open and remove power from the aircraft, the
engine will drop to its idle speed, and the fault will appear on the fault code display, along with the
appropriate command. Pressing the TEST/RESET push button or shutting down the GPU will
reset the fault.
(4) Stop Mode
Stop mode faults that occur will remove power form the aircraft and shut the engine down. An
example would be a low oil pressure fault. The contactors will open and remove power from the
aircraft, the engine will shut down, and the fault will appear on the fault code display, along with
the appropriate command. Pressing the TEST/RESET push button or shutting down the GPU
will reset the fault.
(5) Special Configuration
These fault codes are reserved for special customer configurations. Contact the factory for
information.
c) Fault Code Display
The numbers that appear in the FAULT CODE display are used for troubleshooting the GPU. To
read the four-digit fault code properly, it must be understood that the first two digits represent one half
of the fault code and the last two digits represent the other half.
The first two digits on the left side of the Fault Code represent the Command.
The two digits on the right side of the Fault Code represent the Fault Condition.
August 6, 2004
Chapter 2-4
Page 5

Command
Fault
70.67
Fault Codes
Fault Meter Display
Figure 1
d) Operation Monitoring
While applying power to an aircraft, the GPU continually monitors all critical circuits and operating
electrical values.
During 400 Hz AC and 28.5 VDC (if supplied) operation, the GPU continually performs Command
70 (Engine Run Mode). When a fault is detected during operation, this Command and the detected
Fault are indicated in the FAULT CODE display.
By referencing the Command and Fault Code chart, the GPU state and exact fault can be
determined. When the fault is reset, and the GPU restarted, the GPU may often detect the fault again
revealing additional information. This method yields a high degree of troubleshooting accuracy.
Fault meter display example shown above: If the engine shuts down with the above fault code,
70.67, the engine ceases operation due to high coolant temperatures in the engine. The 70
represents the command the GPU was executing at the time of the fault and shutdown (Command
70 indicates an Engine Run Mode command.). The 67 represents the fault code that indicates the
action taken by the control system upon faulting (Fault 67 indicates a Stop Mode fault which shuts
the GPU down.).
August 6, 2004
Chapter 2-4
Page 6

1.
2.
3.
4.
5.
6.
7.
8.
9.
7,10
Fuel Gage (M13)

Front Panel
Control Panel Label
10,12
15
10.
11.
12.
13.
14.
15.
16.
17.
17
11,10
16
13

AC Voltmeter (M2)
Control Panel Door

Figure 2
August 6, 2004
Chapter 2-4
Page 7

10
1.
2.
3.
4.
5.

6.
7.
8.
9.
10.


Figure 3
August 6, 2004
Chapter 2-4
Page 8

2
5
6
3
4
10
1.
2.
3.
4.
5.
6.
11
Control Box Wrapper

7.
8.
9.
10.
11.


Figure 4
August 6, 2004
Chapter 2-4
Page 9

Trouble, Symptom, Condition
Probable Cause
Test, Check, and/or Remedy
a. Battery discharged, or loose

battery or ground connection.
Check voltage across batteries.

Voltage should be approximately
12.8 volts DC. Check all battery
terminals. Be sure 12.8 volts DC
is reaching solenoid input terminal.
b. Electrical defect in starter.
Momentarily connect a large

capacity jumper cable (No. 1/0
minimum) between hot side of
starter solenoid and starter input
terminal. If starter does not crank
engine, proceed to step c. If
starter does crank engine, proceed
to step e.
Remove starter motor from engine
and apply 12 VDC to test it. If it
doesnt operate, it is defective.
Replace it. If starter motor does
operate, proceed to step d.
Engine Controls
1. Engine will not start. Starter
will NOT crank engine.
c. Mechanical defect in starter.
d. Internal seizure.
e. Defective starter solenoid.
f. Defective auxiliary starter

solenoid.
August 6, 2004
If battery and starter are good and

starter is unable to crank the
engine, internal seizure is
indicated. Attempt to hand crank
engine with a -inch square drive
on a long flex handle on
crankshaft pulley. If engine cannot
be turned one complete revolution,
internal seizure is indicated.
Remove engine and contact the
engine manufacturer and/or
nearest dealer.
Momentarily connect a large
capacity jumper cable (No. 1/0
minimum) between the auxiliary
solenoid terminals (one on each
side). If engine does not crank,
replace starter solenoid. If engine
cranks, proceed to step f below.
Momentarily connect a small lug
jumper on front of auxiliary
solenoid to the battery terminal of
the auxiliary starter If engine does
not crank, replace auxiliary starter
solenoid. If engine cranks,
proceed to step g below.
Chapter 2-4
Page 10

Probable Cause
Engine Controls (continued)

1. Engine will not start. Starter
will NOT crank engine (continued).
g. Defective EIB Board.

h. Defective engine start button.
2. Engine will not start. Cranking

speed low.
a. Low battery output check

battery.
b. Loose starting circuit
connections or faulty cables.
c. Improper lubricating oil
viscosity
3. Engine cranks, but will not start.
a. No fuel or insufficient fuel level

in tank. Low FUEL indication
appears 3 seconds after cranking
is initiated.
b. Fuel shutoff valve closed.

c. Loose connections, damaged
hoses or fuel lines between tank
and fuel pump
d. Plugged or defective filter.
4. Engine cranks, but will not

start. Over-temperature indication
appears immediately.
e. Defective EIB board.

a. Defective or incorrectly wired
high temperature switch, located
on the top of the engine block.
b. Defective EIB board
August 6, 2004
Replace EIB board.

Depress button and check
continuity between button
contacts. If no continuity exists,
replace button. If there is
continuity, replace EIB board.
Recharge or replace.
Check all connections and cables.
Tighten or replace as required.
Check oil, Section 2-2.
Remove and replace oil as
necessary.
Fill fuel tank if it is empty or if
amount of fuel in it is low. If
necessary, fill each filter with fuel.
If engine will not start after priming
filters, fuel pump trouble is
indicated. If engine starts and
stops after a short time, trouble
between fuel source and suction
side of pump is indicated. Check
and/or remedy as follows.
Open shutoff valve on fuel tank.
Tighten all fittings and
connections. Replace any
damaged hoses or fuel links.
Do not overlook the possibility of
restricted flow through the fuel
filters. Also check gaskets for
leaking or damaged condition.
Replace EIB board.
Check wiring to high temperature
switch according to connection
diagram in Chapter 5, and see that
wiring is correct. If wiring is
correct, remove wires and check
resistance between terminals C
and N.O. A resistance of less than
10 ohms indicates a defective
switch. Replace switch if
defective.
Replace EIB board.
Chapter 2-4
Page 11

Probable Cause

5. Engine is hard to start.
Cranking speed normal, fuel
supply adequate.
6. Engine starts. Stops after a

few seconds by automatic
shutdown.
a. Low compression, which may

be caused by any one of following:
Sticking or burned exhaust valves,
worn or broken compression rings,
leaking cylinder head gasket, or
improper valve clearance
adjustment.
a. Shutdown circuit may have
functioned normally to stop engine
because of low lubricating oil
pressure or due to a defective oil
pressure switch.
Check compression in accordance

with instructions in engine
manufacturers operation manual.
Overhaul engine to make repairs
as necessary.
b. Defective EIB board

a. Marker light circuit breaker,
(CB1) wont close.
b. Defective CTL board
Restart engine, and observe oil

pressure gage. If oil pressure is
12 psi or more, disconnect wire
from oil pressure switch terminal
N.C. Restart engine. If engine
continues to run, oil pressure
switch is defective. Replace oil
pressure switch. If engine stops,
check for following malfunctions:
Replace EIB board.
Replace marker lights circuit
breaker (CB1) if defective.
Replace CTL board.
8. Engine either goes from rated

speed to idle speed, or shuts
down.
9. Engine has slow response
time.
a. Low fuel was detected or the

EIB board could be defective.
Add No. 2 diesel fuel.

Replace EIB board.
a. Engine needs tune-up
Tune-up as required. Refer to

engine manufacturers operation
manual.
10. Engine misses. Runs

unevenly.
a. Insufficient fuel
Check low fuel level in accordance

with engine manufacturers
operation manual. Repair or
replace parts as required.
Check injectors in accordance with
engine manufacturers operation
manual. See causes of low
compression listed under ENGINE
CONTROLS.
Check compression in accordance
operation manual. See causes of
low compression listed under
ENGINE CONTROLS.
Check all fittings to be sure they
are tight and the thread sealant is
still present. Tight the fittings and
add new thread sealant as
required.
7. All panel and clearance lights

are either always ON or always
OFF.
b. Faulty injector
c. Low compression pressure
d. Air in fuel system
August 6, 2004
Chapter 2-4
Page 12

Probable Cause

11. Engine lacks power
a. Improper engine adjustments

and gear train timing
b. Insufficient fuel
c. Insufficient inlet air due to

damaged or dirty air cleaner.
d. Restricted exhaust system
Probable Cause
Tune-up engine in accordance

operation manual.
Check low fuel level in accordance
operation manual. Repair or
replace parts as required.
Check air cleaner for plugging
and/or damage.
Check exhaust pipes for
restrictions. Check muffler for
clogged condition. Replace as
required.
Generator Excitation Circuits

1. No (or low) generator output
voltage in all phases. Generator
operating at 400 Hz.
a. Defective generator or
excitation circuit.
b. Defective voltage regulator

(REG)
c. Open fuse on REG.
August 6, 2004
On REG place Regulated/

Diagnostic switch in Diagnostic
position. This applies 12 VDC
from battery to exciter field, which
should produce an indicated
output voltage of 100 +/- 20 VAC
line to neutral. If voltage produced
is within this range, the generator
is good, and trouble is in voltage
regulator circuit. Proceed to Step
b.
Connect a properly working REG
board to regulator wiring
assembly, avoid short circuiting
bottom of properly working REG
board. Then start generator set
and perform tests and adjustments
according to instructions in Section
2-3. If generator set works
properly with a properly working
REG board temporarily connected,
shut off generator set and replace
defective REG board with one that
is properly working (preferably,
same REG board used for this
troubleshooting check).
Check fuses thoroughly. Replace
fuses if defective.
Chapter 2-4
Page 13

Probable Cause
Generator Excitation Circuits (continued)

1. No (or low) generator output
voltage in all phases. Generator
operating at 400 Hz. (continued).
e. Defective connector at voltage

regulator, or defective wiring from
regulator to exciter field
Disconnect exciter wires at

terminal strip. Using jumper leads
with clip terminals, connect 12
VDC to wires. If generator will
produce at least 80 V-AC, replace
or repair connector and wiring
between voltage regulator and
exciter field as required.
Probable Cause

1. Load contactor (K1) will not
close when output No. 1 push
button switch is held in close
position. Generator running at
normal voltage. Rectifier circuit
breaker CB2 closed. No fault
indicated
a. Defective circuit breaker (CB2).
b. In addition to defective wiring

and connections in AC and DC
load contactor actuating circuits,
load contactor may be prevented
from closing for any one of
following reasons:
c. Defective REG board.
d. Defective output No. 1 push

button switch (S75).
e. Defective voltage regulator

(REG).
August 6, 2004
Remove terminal leads from circuit

breaker, press circuit breaker
button to close circuit breaker, and
use an ohmmeter. Replace circuit
breaker if defective.
Check all wiring and connections
in load contactor circuits.
Replace REG board with a board

known to be operating properly. If
contactor still doesnt close,
proceed to step d.
At rated speed, measure the
voltage across the switch. The
voltage should read approximately
5 VDC. Press the switch again
and the voltage should go to 0 V.
If voltage does not go to 0 V, the
switch is defective and needs to
be replaced.
After making certain that output
No. 1 push button switch (S75) is
working, measure DC output
voltage at contactor coil. If voltage
measured isnt approximately 90-V
DC, replace REG.
Chapter 2-4
Page 14

Probable Cause
No. 1 Load Contactor Operating Circuit (Continued)

button switch is held in CLOSE
breaker (CB2) closed. No fault
indicated. (continued)
f. Defective coil in load contactor

(K1).
Disconnect leads at load contactor

terminals V and W. Check coil
resistance between these
terminals. Resistance should be
approximately 50 ohms. If coil is
defective, replace complete load
contactor.
2. Load contactor (K1) will close

when output No. 1 push button
switch is held in CLOSE position.
Opens immediately when switch is
released.
a. No. 1 plug interlock EF1 circuit

on CTL board could be defective
Place EF Bypass switch, No. 1

output in ON position. If load
contactor remains closed, proceed
to step b.
Proceed as follows to find the
cause of this malfunction.
b. 28.5-V DC is not reaching the

No. 1 plug interlock EF1 circuit
from aircraft for following reasons
d & e:
d. Generator to aircraft cable
connector defective or not plugged
into aircraft receptacle connector.
e. Aircraft rejecting power.

f. Defective contacts in N.O.
auxiliary push button switch
mounted on right side of contactor
(K1).
3. Load contactor opens during
power delivery. No fault indicated.
a. A fault has developed in load

contactor holding circuit.
c. Cable accidentally
disconnected from aircraft.
August 6, 2004
Inspect cable connector plug

thoroughly for damaged E and F
terminals. Be sure plug is fully
mated with aircraft receptacle
connector and making good
contact.
Check aircraft on-board electrical
equipment and controls.
Connect a jumper lead between
terminals of N.O. auxiliary switch.
If load contactor will now remain
closed, replace N.O. auxiliary
switch or complete load contactor.
If load contactor cannot be closed
by operation of output No. 1 push
button switch (S75), check circuit
in accordance with instructions in
Trouble, Symptom, Condition 1. If
load contactor can be closed, but
opens as soon as power accepted
switch (S75) is released, check for
trouble under Trouble 2, above.
Reconnect cable.
Chapter 2-4
Page 15

Probable Cause
No. 2 Load Contactor Operating Circuit (if applicable)

breaker CB2 closed. No fault
indicated.
a. Defective circuit breaker (CB2).
b. In addition to defective wiring

and connections in AC and DC
load contactor actuating circuits,
load contactor may be prevented
from closing for any one of
following reasons:
c. Defective REG board.
d. Defective output No. 1 push

button switch (S75).
e. Defective voltage regulator

(REG).
August 6, 2004
Remove terminal leads from circuit

breaker, press circuit breaker
button to close circuit breaker, and
use an ohmmeter. Replace circuit
breaker if defective.
Check all wiring and connections
in load contactor circuits.
Replace REG board with a board

known to be operating properly. If
contactor still doesnt close,
proceed to step d.
At rated speed, measure the
voltage across the switch. The
voltage should read approximately
5 VDC. Press the switch again
and the voltage should go to 0 V.
If voltage does not go to 0 V, the
switch is defective and needs to
be replaced.
After making certain that output
No. 1 push button switch (S75) is
working, measure DC output
voltage at contactor coil. If voltage
measured isnt approximately 90-V
DC, replace REG.
Chapter 2-4
Page 16

Probable Cause
No. 2 Load Contactor Operating Circuit (if applicable) [continued]

button switch is held in close
breaker (CB2) closed. No fault
indicated. (continued)
f. Defective coil in load contactor

(K201).
Disconnect leads at load contactor

terminals V and W. Check coil
resistance between these
terminals. Resistance should be
approximately 50 ohms. If coil is
defective, replace complete load
contactor.
2. Load contactor (K201) will

position. Opens immediately when
switch is released.
a. No. 2 plug interlock EF2 circuit

on CTL board could be defective
Place EF Bypass switch, No. 1

output in ON position. If load
contactor remains closed, proceed
to step b.
Proceed as follows to find the
cause of this malfunction.
b. 28.5-V DC is not reaching the

No. 1 plug interlock EF2 circuit
from aircraft for following reasons
d & e:
d. Generator to aircraft cable
connector defective or not plugged
into aircraft receptacle connector.
e. Aircraft rejecting power.

f. Defective contacts in N.O.
auxiliary push button switch
mounted on right side of contactor
(K1).
power delivery. No fault indicated.
a. A fault has developed in load

contactor holding circuit.
c. Cable accidentally
disconnected from aircraft.
August 6, 2004
Inspect cable connector plug

thoroughly for damaged E and F
terminals. Be sure plug is fully
mated with aircraft receptacle
connector and making good
contact.
Check aircraft on-board electrical
equipment and controls.
Connect a jumper lead between
terminals of N.O. auxiliary switch.
If load contactor will now remain
closed, replace N.O. auxiliary
switch or complete load contactor.
If load contactor cannot be closed
by operation of output No. 1 push
button switch (S275), check circuit
in accordance with instructions in
Trouble, Symptom, Condition 1. If
load contactor can be closed, but
opens as soon as power accepted
switch (S275) is released, check
for trouble under Trouble 2, above.
Reconnect cable.
Chapter 2-4
Page 17

Probable Cause
Protective Circuit
NOTE: Protective monitoring is not completely functional until load contactor is CLOSED. Since it is not
advisable to vary voltages for test purposes while delivering power to an aircraft, the GPU should be
connected to a load bank for trouble shooting protective circuits. To avoid repetition, it will be assumed that
TEST/RESET push-button switch has been pressed and the load contactor has been closed before
commencing each test.
a. Over voltage condition may
Press TEST/RESET push-button
power delivery. Over voltage fault
have been result of a sudden drop
switch and resume power delivery.
indicated.
in load, or possible tampering with Observe voltmeter to be certain
REG potentiometer, and may have voltage is normal 115 V-AC.
been a normal action.
Adjust to normal if necessary. If
load contactor is opened again
and the fault code meter indicates
an over-voltage condition, proceed
to step b.
b. Defective CTL board.
Use REG potentiometer to reduce
voltage to 110 V AC. Observe
voltmeter and gradually increase
voltage with potentiometer. If
sensing circuit CTL board
functions to open load contactor at
any value less than 125-VAC, it is
defective. Replace CTL board.
a. Under voltage condition may
Press TEST/RESET push-button
power delivery. Under voltage
have been result of a sudden
switch and resume power delivery.
fault indicated.
shock load, or possible tampering
Observe voltmeter to be certain
with REG potentiometer, and may
voltage is normal 115 V-AC.
have been a normal action.
Adjust to normal if necessary. If
load contactor is opened again
and the fault code meter indicates
an under-voltage condition,
proceed to step b.
Use REG potentiometer to reduce
voltage to 100 V AC. Observe
voltmeter and gradually decrease
voltage with potentiometer. If
sensing circuit CTL board
functions to open load contactor at
any value great than 100-VAC, it is
defective. Replace CTL board.
a. Frequency adjust switch is
Set frequency adjust switch to
power delivery. Over frequency
enabled.
DISABLE
fault indicated.
b. Defective REG board.
If over-frequency faults continue
after engines ECM is proven to be
good, and an over-frequency
condition does not exist, replace
REG board.
August 6, 2004
Chapter 2-4
Page 18

Probable Cause
Protective Circuit (continued)

NOTE: Protective monitoring is not completely functional until load contactor is CLOSED. Since it is not
advisable to vary voltages for test purposes while delivering power to an aircraft, the GPU should be
connected to a load bank for trouble shooting protective circuits. To avoid repetition, it will be assumed that
TEST/RESET push-button switch has been pressed and the load contactor has been closed before
commencing each test.
a. Frequency adjust switch is
Set frequency adjust switch to
power delivery. Under frequency
enabled.
DISABLE
fault indicated.
b. Defective REG board.
If under-frequency faults continue
after engines ECM is proven to be
good, and an under-frequency
condition does not exist, replace
REG board.
a. There may have been an
Observe ammeter. Check for
power delivery. Overload fault
overload condition.
abnormal overload condition and
indicated.
correct. If overload device
functions to open load contactor
when an overload does not exist,
proceed to step B.
Replace CTL board.
Probable Cause
a. Shorted diode in exciter rectifier

(CR2).
Check diodes in accordance with

Section 2-3. If diodes are good,
proceed to step B.
Use ohmmeter to check for open
or shorted condition diodes in
accordance with Section 2-3. If
exciter rotor windings are good,
proceed to step C.
Check field resistance. See
Section 2-3 for normal values.
Check resistance with ohmmeter
to determine if open or short
circuited diodes in accordance
with Section 2-3
Check stator-winding resistances.
See Section 2-3 for normal values.
Generator
1. No (or low) voltage output
b. Open or shorted exciter rotor

winding (G2)
c. Open or shorted exciter field

windings (L2)
d. Open or shorted generator
rotor windings (L1)
2. Generator operates single
phase.
a. Open or short circuited winding

in generator stator (G1)
3. Generator overheats
a. Loose connection causing high

resistance.
August 6, 2004
Check all output connections.

Look for discoloration caused by
heat. Tighten or replace as
required.
Chapter 2-4
Page 19

Probable Cause
b. Improper or blocked ventilation.
Check for foreign material (rags,

etc.) blocking air-flow. Provide
adequate ventilation.
Check stator windings. See
Section 2-3.
Generator (continued)
3. Generator overheats
(continued)
c. Generator stator windings short

circuited.
4. Unbalanced output
a. Loose connection in output

circuit.
b. Open or short circuited phase
c. Defective connection in output

circuit.
b. Break or cut in output cable
assembly.
c. Unbalanced load
August 6, 2004
Check all output connections.

Discolored connectors indicate a
loose connection. Tighten or
replace as required.
Check stator windings in
accordance with Section 2-3.
Repair or replace as required.
Check plug and receptacle
connectors at aircraft. Tighten,
repair, or replace as required.
Inspect. Repair or replace as
required.
Check aircraft 400-Hz
components.
Chapter 2-4
Page 20

Troubleshooting Table
GPU Commands
Cmd
code
00. _ _
Invalid Command
01. _ _
ENGINE SELF TEST CMD
Name
Description
All boards test the communication between each other.
02. _ _
03. _ _
04. _ _
05. _ _
06. _ _
07. _ _
08. _ _
09. _ _
10. _ _
11. _ _
12. _ _
13. _ _
14. _ _
15. _ _
16. _ _
17. _ _
18. _ _
19. _ _
20. _ _
21. _ _
22. _ _
23. _ _
24. _ _
25. _ _
26. _ _
27. _ _
28. _ _
29. _ _
30. _ _
August 6, 2004
Chapter 2-4
Page 21

GPU Commands
Cmd
code
31. _ _
Name
Description
32. _ _
33. _ _
34. _ _
35. _ _
36. _ _
37. _ _
38. _ _
39. _ _
40. _ _
ENGINE START MODE
Engine starter and engines ECM is activated.
ENGINE IDLE MODE
Engine idles at approximately 1000 RPM
ENGINE RAMP UP
Period when engine goes from idle to rate speed.
41. _ _
42. _ _
43. _ _
44. _ _
45. _ _
46. _ _
47. _ _
48. _ _
49. _ _
50. _ _
51. _ _
52. _ _
53. _ _
54. _ _
55. _ _
56. _ _
57. _ _
58. _ _
59. _ _
60. _ _
61. _ _
August 6, 2004
Chapter 2-4
Page 22

GPU Commands
Cmd
code
62. _ _
63. _ _
Name
Description
REG TEST OUTPUT FREQUENCY
Check for 400 Hz. output frequency.
TRB REGULATE DC
Check for DC regulation.
CTL TEST OUTPUT
Checks the CTL communications.
ENGINE RUN MODE
The engine is at rated speed and ready for aircraft load.
ENGINE RAMP DOWN
Period when engine goes from rated to idle speed.
ENGINE SHUTDOWN MODE
Allows the turbocharger to cooling properly.
ENGINE STOP MODE
Engine is brought to a complete stop.
64. _ _
65. _ _
66. _ _
67. _ _
68. _ _
69. _ _
70. _ _
71. _ _
72. _ _
73. _ _
74. _ _
75. _ _
76. _ _
77. _ _
78. _ _
79. _ _
80. _ _
81. _ _
82. _ _
83. _ _
84. _ _
85. _ _
86. _ _
87. _ _
88. _ _
89. _ _
90. _ _
91. _ _
92. _ _
August 6, 2004
Chapter 2-4
Page 23

GPU Commands
Cmd
code
93. _ _
Name
Description
94. _ _
95. _ _
96. _ _
97. _ _
98. _ _
99. _ _
System Off Mode
August 6, 2004
All electrical circuits have been turned off.
Chapter 2-4
Page 24

Faults
Fault
code
_ _.00
Name
Possible Cause(s)
Corrective Action
Invalid Fault
_ _.01
_ _.02
_ _.03
CTL MEMORY FAULT
_ _.04
REG EF1 LOSS FAULT
EF1 voltage signal not present.

CTL board defective.
_ _.05
REG EF2 LOSS FAULT
EF2 voltage signal not present.

EIB AIR RESTRICTION FAULT
Air filter is obstructed or dirty.

Bad air restriction indicator
_ _.16
CTL OUTPUT OVER VOLTAGE

FAULT
Voltage set too high.

LDC set too high.
_ _.17
CTL OUTPUT UNDER

VOLTAGE FAULT
Voltage set too low.

Switch the EF1 switch to ON

Check cable contacts.
Replace the CTL board.
Switch the EF2 switch to ON
Check cable contacts.
Replace the CTL board.
_ _.06
_ _.07
_ _.08
Check for obstructions.

Change air filter cartridge or
air restriction indicator.
_ _.09
_ _.10
_ _.11
_ _.12
_ _.13
_ _.14
_ _.15
_ _.18
_ _.19
_ _.20
_ _.21
_ _.22
CTL OUTPUT 1 OVERLOAD

FAULT
CTL OUTPUT 2 OVERLOAD
FAULT
CTL MACHINE OVERLOAD
FAULT
CTL OUTPUT VOLTAGE
IMBALANCE FAULT
REG OUTPUT OVER FREQ
FAULT
August 6, 2004
Adjust voltage or the LDC on

the REG board.
Replace CTL board.
Adjust voltage on the REG
board.
Replace CTL board.
Overload on Output 1
Reset and restart GPU.
Overload on Output 2
Total overload on Output 1 & 2.
Defective engine ECM.

Defective REG board.
Replace engine ECM.

Replace REG board.
Chapter 2-4
Page 25

Faults
Fault
code
Name
_ _.23
REG OUTPUT UNDER FREQ

FAULT
_ _.24
REG CONTACTOR1 FAULT
_ _.25
REG CONTACTOR 2 FAULT
Possible Cause(s)
Corrective Action
Defective engine ECM.

Defective output contactor.
Replace engine ECM.

Replace REG board.
Replace output contactor.
Replace REG board.
Replace REG board.
Defective CTL board.
Replace CTL board.
Replace CTL board.
Voltage set too high.

TRB board defective.
Voltage set too low.
TRB board defective.

Replace TRB board.
Replace TRB board.
DC load over rating of GPU.
TRB DC CONTACTOR FAULT

Defective TRB board.

Replace TRB board.
_ _.40
CTL ID FAULT
Replace CTL board.
_ _.41
TRB ID FAULT
Replace TRB board.
_ _.42
ESB ID FAULT
Defective ESB board.
Replace ESB board.
_ _.43
REG ID FAULT
TRB HEATSINK OVERTEMP
FAULT
TRB TRANSFORMER
OVERTEMP FAULT
TRB INPUT CONTACTOR
FAULT

Obstructed cooling air path.
Defective thermal switch
Obstructed cooling air path.
Defective thermal switch
Defective input contactor.
Replace REG board.

Clear air obstruction.
Replace switch.
Clear air obstruction.
Replace switch.
Replace input contactor.
Replace TRB board.
_ _.26
_ _.27
_ _.28
_ _.29
_ _.30
_ _.31
CTL DC OVER VOLTAGE

FAULT
CTL DC UNDER VOLTAGE
FAULT
TRB OUTPUT OVER VOLTAGE
FAULT
TRB OUTPUT UNDER
VOLTAGE FAULT
TRB OUTPUT OVERLOAD
FAULT
_ _.32
_ _.33
_ _.34
_ _.35
_ _.36
_ _.37
_ _.38
_ _.39
_ _.44
_ _.45
_ _.46
_ _.47
_ _.48
August 6, 2004
Chapter 2-4
Page 26

Faults
Fault
code
_ _.49
Name
Possible Cause(s)
Corrective Action
_ _.50
_ _.51
_ _.52
_ _.53
_ _.54
_ _.55
_ _.56
_ _.57
_ _.58
_ _.59
_ _.60
CTL COMM FAULT
Replace CTL board.
_ _.61
EIB COMM FAULT
Defective EIB board.
Replace EIB board.
_ _.62
ESB COMM FAULT
Defective ESB board.
Replace ESB board.
_ _.63
REG COMM FAULT
Replace REG board.
_ _.64
TRB COMM FAULT
Replace TRB board.
_ _.65
REG EF1 VOLTAGE TOO HIGH

FAULT
_ _.66
REG EF2 VOLTAGE TOO HIGH

FAULT

EF voltage being sent from
aircraft on output 1 to the GPU
is too high.
Output cable is defective.
EF voltage being sent from
aircraft on output 2 to the GPU
is too high.
Output cable is defective.
Engine is over-heated.
Coolant level is too low.
Radiator is dirty or obstructed.
Defective temperature switch.
Engine oil level is too low.
Defective oil pressure switch.
_ _.67
EIB ENGINE OVERTEMP

FAULT
_ _.68
EIB LOW OIL PRESSURE

FAULT

Check output cable.

Check output cable.
Let engine cool then restart.
Check coolant level and add.
Clean radiator.
Replace EIB board.
Replace switch.
Check oil level and add.
Replace EIB board.
Replace switch.
_ _.69
_ _.70
_ _.71
_ _.72
August 6, 2004
Chapter 2-4
Page 27

Faults
Fault
code
_ _.73
Name
Possible Cause(s)
Corrective Action
_ _.74
_ _.75
_ _.76
_ _.77
_ _.78
_ _.79
_ _.80
_ _.81
_ _.82
_ _.83
_ _.84
_ _.85
_ _.86
_ _.87
_ _.88
_ _.89
_ _.90
_ _.91
_ _.92
_ _.93
_ _.94
_ _.95
_ _.96
_ _.97
_ _.98
_ _.99
August 6, 2004
Chapter 2-4
Page 28

Chapter 3 Overhaul/Major Repair

Section 1
Exciter Armature
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 rear main bearing can 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.
1, 2
5,6,7,8
4
9
1.
2.
3.
4.
5.
Coupling Key (Not Shown)

Flex Coupling Assembly
Generator Housing & Stator Assembly
Armature Assembly
Exciter Housing & Coils Assembly
6.
7.
8.
9.
10.
Exciter Cover
Exciter Armature Assembly
Exciter Key (Not Shown)
Front Bearing (Located Inside Housing Shown)
Rear Bearing (Located In Exciter Housing)
General Assembly
Figure 1
August 6, 2004
Chapter 3-1
Page 1

2
1. Exciter Core Flange
2. Exciter Core Lamination
Revolving Field
Leads
Key Removal
3. Diode Mounting Plate

4. Silicon Diode
Exciter Armature
Figure 2
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
Figure 1). Because of its location on the shaft, the exciter armature must be removed for rear main
bearing replacement. The exciter armature has two M10-1.5 tapped holes in its diode mounting plate to
accommodate pulling it off the shaft.
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 mounting flange. The flange, core,
and diode mounting plate are bolted together to make the complete exciter armature.
August 6, 2004
Chapter 3-1
Page 2

The exciter armature is mounted on the main generator armature shaft with a 3/8-inch square machine
key that held in place by a key retainer, and an M12-1.75 hex head cap screw in the center of the diode
mounting plate.
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) Tools needed for Exciter Armature Removal and Installation
In addition to the standard mechanics hand tools such as wrenches, etc., you will need only the
following items for removing the exciter armature:
A small, lightweight, sling-hammer puller

Two M10-1.5 x 127 mm long fully-threaded hex-head bolts
A small, lightweight, sling-hammer puller is shown in Figure 3. This tool is necessary for removing
the threaded machine key, which keeps the exciter armature from spinning on the generator armature
shaft. You may have such a puller in your equipment inventory. If not, Figure 3 also illustrates
components and dimensions for fabricating such a tool. Sling-hammer pullers are also commercially
available. Instructions for using tool are provided in this manual.
Once the threaded machine key is removed, No other special tools are required for removing the
exciter from the generator shaft. This can be done using the two M10-1.5 fully-threaded hex-head
bolts. Instructions for doing this are provided in this manual.
c) 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 the rear bearing. This operation can also be accomplished
without removing the generator. Replacement of the front bearing requires removal of the generator
from the unit.
d) Preparation for Exciter Armature Removal
(1) Remove exciter cover from end canopy and the exciter armature cover from the end of the
generator.
(2) Place a block bar (pry bar) into the generator fan assembly to keep the generator armature from
rotating.
WARNING
To prevent personal injury, keep fingers and hands clear of generator assembly until
the armature is block into place to prevent rotation.
(3) Remove exciter housing cover as required. Remove the M12-1.75 cap screw, which holds the
exciter armature and key retainer on the generator shaft.
August 6, 2004
Chapter 3-1
Page 3

(4) Refer to Figures 1 and 2. Disconnect the two rectifier-to-generator field leads. One lead, with a
ring type terminal, is attached to the rectifier mounting plate with a screw and the other lead goes
into a splice type connector with three other leads coming from the exciter armature windings. Cut
the leads at the connector for removal of the one field lead. Cut as close as possible to the
connection as to preserve lead length for reconnection later during exciter armature installation.
(5) Take EXERCISE CARE to prevent damage to leads. Remove kinks in the two generator leads
as much as possible before starting removal operation (The exciter armature will be sliding over
these leads.).
e) Exciter Armature Removal
(1) Removing the Threaded Key with Sling-Hammer Puller
Refer to Figure 2 for location of threaded machine key. Attachment of the assembled puller to the
key 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. This could result in cross-threading and
damage to key and stud. It is safer and easier to attach as follows:
a
Thread stud (1, Figure 3) into adapter (2) until it bottoms, then thread this assembly (1) and
(2) into key until stud bottoms in key threads. Tighten securely.
If hammer (5) and rod (4) are not already assembled, thread one nut (3) onto adapter 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 full threaded and locked together.
WARNING
Be very careful during removal process (slide-hammering) to avoid injury to hands.
CAUTION
Exercise care to prevent breaking or damaging stud.
c
Position hammer at adapter end of rod.
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.
Repeat step (c) and (d) as required to loosen key, then remove key and slide-hammer puller.
After key is removed, apply penetrating oil in the armature and shaft keyways.
(2) Removing the Exciter Armature

CAUTION
Leads may be damaged if armature is turned too far in either direction.
August 6, 2004
Chapter 3-1
Page 4

a
WARNING
Place a block bar (pry bar) into the generator fan assembly to keep the generator armature
from rotating.
Attempt to loosen exciter armature on shaft by rotating it slightly back and forth. If armature
cannot be loosened by hand, use two M10-1.5 hex-head bolts as shown in Figure 4 to force
the exciter armature off the shaft. Turn each of the two screws a few turns at a time into the
threaded holes of the diode mounting plate until the exciter armature is sufficiently loosened
from the shaft to be removed from it by hand. Remove it slowly from the shaft and at the
same time observe the following CAUTION.
Sling Hammer Assembly
.421 Drill 1.25 in. Deep; Tap -13 UNC-2B, 1 in. Deep
.578 in. Diameter
Sling Hammer Components
1. Stud, 1/4-28 UNF 2A, Grade 5 or 8 ONLY

2. Adapter, 3/4" Round CR Steel
3. Nut, 1/2-13 Hex, Steel (3 required)
4. Rod, 1/2" Round, CR Steel

5. Hammer, 2" Round, CR Steel
6. Washer, Flat, 1/2" Steel
Sling Hammer Puller

Figure 3
August 6, 2004
Chapter 3-1
Page 5

CAUTION
Pay close attention to field leads while pulling exciter armature from shaft. Make
CERTAIN that the leads stay in the 1/2" keyway. One mechanic should watch them
constantly while another operates the puller. Make certain that leads do not catch and
be sure that they slide smoothly through the hole (Figure 2). Straighten leads and
remove kinks as required to avoid damage to insulation.
4) Installation Exciter Armature

a) Preparation for Exciter Armature Installation
(1) Clean generator shaft and exciter armature bore. Remove all rust, corrosion, etc.
(2) Make CERTAIN that the leads are tucked into the 1/2" keyway, which is opposite from the 3/8"
keyway in the generator armature shaft.
Threaded hole in the

diode mounting plate
Generator
Armature
Shaft
(2) M10-1.5 x 127 mm lg. Bolts
Threaded hole in the

diode mounting plate
Screw the two M10-1.5 bolts into the
threaded holes of the diode mounting plate to
force the exciter armature off the generator
armature shaft.
Exciter Armature Removal

Figure 4
(3) Route the revolving field leads (step 2 above) through exciter armature hole (Figure 2), which is
opposite the keyway.
August 6, 2004
Chapter 3-1
Page 6

(4) Align armature keyway with key in shaft and start armature on shaft.
b) Exciter Armature Installation
(1) If the exciter armature-to-generator shaft fit is such that the exciter armature may be pushed on
by hand, push it on very slowly while another mechanic carefully watches and pulls field leads
through hole in the exciter armature diode mounting plate. Continue installation until the diode
mounting plate contacts the end of the generator shaft. If the exciter armature cannot be pushed
on by hand, use a M12-1.75 hex-head bolt and M12-1.75 nut as shown in Figure 5 to pull the
exciter armature onto the generator shaft. Put the exciter armature on slowly and at the same
time pull field leads through the hole (Figure 2) in the diode mounting plate. Screw the nut onto
the bolt until it is near the head of the bolt. Insert the bolt through the hole in the center of the
diode mounting plate as far as it will go, and screw it into the end of the armature shaft. Screw the
nut up against the diode mounting plate. Continue turning the nut until the diode mounting plate
contacts the end of the generator shaft, just as is shown in the lower portion of Figure 5. After
installation, remove the bolt and nut.
(2) Connect the two generator field leads to the exciter armature as follows:
a
Connect lead with ring type terminal to the screw provided to the mounting plate (Figure 2).
Connect the other field lead to the three leads coming off of the exciter armature windings.
Use parallel splice connector, crimp and solder for a good connection.
Insulate with sleeving material or wrap with electrical tape.
(3) Install the Machine Key

a
Clean the machine key thoroughly. All mounting surfaces must be free of rust, corrosion, oil,
grease, etc.
Apply LOCQUIC primer, No. 47-56 grade T to SIDES of machine key. Do not over prime. A
thin film is best. Allow to dry three to four minutes.
Apply a thin coating of LOCTITE, No. 242 adhesive to SIDES of keyways in shaft and
armature. Be certain to remove any excess from mounting surfaces on shaft and bore of
armature.
NOTE: Application of Loctite is to compensate for any looseness in machine key and keyway (up to
0.005 inch). Manufacturers of LOCTITE and other recommended products are listed below.
When exciter armature removal is for the replacement of bearings and no kit is involved, be sure that
LOCTITE is used (No. 242 is recommended), which is a milder adhesive than that recommended in
the manual.
When kits are involved, the correct grade of LOCTITE is included in the Kit.
The application of NEVER-SEEZ to the shaft and armature bore is NOT recommended because there
is a danger that it may mix with and contaminate the LOCTITE. Application of NEVER-SEEZ will be
at the customers risk. LOCTITE can lose its adhesive and tightening properties if contaminated by
rust preventatives, oil, or other lubricants and antirust products.
August 6, 2004
Chapter 3-1
Page 7

Recommended Products Manufacturers:
LOCQUIC No. 47-56, Primer Grade T

LOCTITE No. 40-31, Retaining Compound, Manufactured by Loctite Corporation, Newington,
Connecticut 06111
NEVER-SEEZ No. NSBT-8 (8 oz. can), Manufactured by Never-Seez Compound Corporation,
Broadview, Illinois 60153
NOCO10" Varnish No. T-211 (clear, air dry), Manufactured by Sterling Division of Reichhold
Chemical Incorporated, Marysville, Pennsylvania 17053
d
Apply LOCTITE, No. 242 to SIDES of new type threaded machine key. A thin film 0.005 to
0.010 inch thick is adequate and desirable.
Ensure keyways in the generator armature shaft and exciter armature are aligned.
Insert UNTHREADED end of key in keyways, and then tap lightly until threaded end is flush
with end of shaft.
(4) Secure the exciter armature and key retainer on generator shaft with the M12-1.75 hex head cap
screw.
f
CAUTION
Allow at least 6 hours for complete cure and set up of Loctite before operating
machine.
August 6, 2004
Chapter 3-1
Page 8

Diode Mounting
Plate
Generator
Armature
M12-1.75 threaded
hole in armature
M12-1.75
bolt and nut
Exciter armature after installation on shaft
Remove the M12-1.75 bolt and the nut after

installing the exciter armature on the generator
armature shaft.
Exciter Armature Installation

Figure 5
August 6, 2004
Chapter 3-1
Page 9

August 6, 2004
Chapter 3-1
Page 10

Section 2
Dual Bearing Flexible Coupling
1) General
This manual provides basic instructions for removal, service and installation of a flexible coupling
assembly, with generator fan, manufactured by Hobart Ground Power as Part Number 288481. This
assembly is illustrated in Figure 1. The primary function of this assembly is to couple a Hobart 2000 RPM
Generator to a Diesel engine. The flexible coupling assembly compensates for slight misalignment
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
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 separate the engine and
generator. However, separating 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 re-assembly.
a) Separate Engine and Generator
(1) Refer to Chapter 3, Section 3 for generator assembly removal.
August 6, 2004
Chapter 3-2
Page 1

Access To Coupling Bolts

(for removal or installation)
Figure 2
b) Remove Coupling Assembly

WARNING
(1) Refer to Figure 3. Using a socket wrench, remove all three of the 3/8-16 bolts that secure the
bushing to the hub.
(2) Using a 3/16-inch Allen wrench, loosen the set-screw in the bushing to release pressure on the
key.
(3) To separate the bushing from the hub, lubricate two of the 3/8-16 bolts and insert them into the
two threaded holes in the bushing flange. With socket wrench, screw these bolts into the bushing
such that the bushing pops loose from the hub, alternating from bolt to bolt.
(4) When the bushing is loose in the hub, use a mallet to GENTLY tap the bushing out of the hub.
(5) Slide the coupling assembly off the shaft and remove the key.
(6) Inspect the coupling assembly components carefully as follows:
a
Check for deformed fan blades and damage to the disk.
Check the rubber exposed at both ends of the bushings for signs of deterioration.
Check hub and bushing for cracks, evidence of galling, and rust pits. Light rust is permissible
on the bushing and the tapered bore of the hub.
August 6, 2004
Chapter 3-2
Page 2

d
Check the shaft for any damage or deformation where the coupling was mounted on it.
Check rubber bushing alignment to make sure that the dimension illustrated in Figure 4 is
maintained.
6
1
5
8
3
4
2
7
1.
2.
3.
4.
Bolt, 3/8-16 UNC (3)

Taper Lock Bushing
Taper Lock Hub
Tapped holes (2)
5. Key
6. Set Screw
7. Fan/Coupling Disk
8. Armature Shaft
Hub and Bushing

Figure 3
August 6, 2004
Chapter 3-2
Page 3

3) Coupling Service
When ordering coupling kits or other parts from your ITW GSE Group Distributor, be sure to include all
pertinent information from the units identification plate: Specification No., Model No., and unit rating.
If you have any questions concerning your ITW GSE Group equipment, immediately contact our Service
Department by mail, telephone, e-mail, or FAX.
Write:
ITW GSE Group

Hobart Ground Power
Service Department
Troy, Ohio 45373
U.S.A.
Call Inside U.S.A.:
(800) 422-4166 (Parts)

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

(937) 332-5060 (Service)
FAX Inside U.S.A.
(800) 367-4945
FAX From Foreign Countries:
(937) 332-5121
E-Mail :
service@itwgsegroup.com
Web Page :
www.itwgsegroup.com
a) Replacement Coupling Kit

A replacement coupling kit is available from your ITW GSE Group Distributor. This kit provides a
replacement coupling assembly with attaching hardware and installation instructions.
b) Bushing Kit
A bushing kit is available from the ITW GSE Group 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.
c) Bushing Replacement
To replace bushings only, proceed as follows:
(1) Press out ALL old bushings.
(2) Refer to Figure 4. Clean each bushing socket thoroughly, removing all traces of old rubber. DO
NOT scratch or deform the bore of the bushing socket.
August 6, 2004
Chapter 3-2
Page 4

(3) Shake the container of lubricant (supplied with kit) vigorously and poor it into a small shallow dish.
(4) Roll a bushing in the lubricant to coat it thoroughly. Press it into a socket (from the chamfered
end) to the dimension shown in Figure 4.
(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.
4) Coupling Installation
WARNING
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 5. 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.
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.
b) Assembly
(1) If an adapter ring must be replaced, remove the bolts that secure it to the flywheel. Discard the
old adapter ring and bolts. Install the new adapter ring (see Chapter 4) using the new socket head
bolts.
Torque all bolts to 100 ft-lbs (135 N-m).
The new adapter ring and bolts are included in the kit, when required.
(2) Refer to Figure 3. Assemble the bushing into the hub.
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.
(3) Lubricate the three 3/8-16 bolts SPARINGLY and start them into the three (unthreaded) holes
finger-tight.
(4) 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.
August 6, 2004
Chapter 3-2
Page 5

CAUTION
Do not rotate the armature while this block is installed.
(5) Install the key in the shaft keyway.
(6) Place the bushing in the hub over the installed key, and install the coupling assembly on the
shaft, with the bushing approximately flush with the end of the shaft.
(7) Using a 3/16-inch Allen wrench, tighten the set screw in the bushing to apply pressure on the key.
(8) Refer to Figure 7. 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 Figure 6 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.
(9) Tighten the 3/8-16 bolts 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 2.
Observe the CAUTION above when it is necessary to rotate the shaft.
Repeat step (a) above until 3/8-16 bolts can no longer be tightened.
Recheck the dimension in Figure 7 to be sure it is the same as the dimension in Figure 6.
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.
a) Insert the new coupling bolts (see Chapter 4) with lock washers 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) Block rotation of generator and turn all of the coupling bolts into the tapped holes in the flywheel until
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) Torque all coupling bolts to 85 ft-lbs (115 N-m).
CAUTION
Remove all armature blocks, otherwise, damage to the armature could result.
August 6, 2004
Chapter 3-2
Page 6

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.
August 6, 2004
Chapter 3-2
Page 7

Bushing
(8) Required
Fan and Coupling

Assembly
(1) Required
Taper Bushing
(1) Required
Press bushing in
from this side.
Bushing Installation
Figure 4
August 6, 2004
Chapter 3-2
Page 8

Assembly Procedure
Figure 5
Measure from mounting face to adapter ring.

Figure 6
August 6, 2004
Chapter 3-2
Page 9

Measuring From Mounting Face To Bushing

Figure 7
August 6, 2004
Chapter 3-2
Page 10

Section 3
Generator Assembly
1) General
This section provides information and instructions for removal and installation of the generator set.
2) Generator Assembly Removal (Refer to Figure 2)

a) Procedure for Gaining Access to the Generator
WARNING
Before starting removal of the generator assembly, position the front section of the
generator set under a hoist, which is capable of lifting at least 1500 pounds (560 kg),
which is the weight of the generator assembly.
When removing generator assembly, refer to Figure 2 and Connection Diagram in Chapter 5 and
proceed as follows:
(1) Disconnect battery leads from the generator set.
(2) If a transformer-rectifier (T-R) assembly is mounted on the generator set, remove T-R assembly.
(3) Disconnect clearance light wires from the top canopy (1), if installed.
(4) Remove top canopy panel (1).
(5) Remove the left front (2) and right front (3) doors.
(6) Remove the following: right front lower panel (5) and left front lower panel (4). Disconnect the
clear power module cover (6) from the angle bracket on the frame and loosen cable clamps to so
that the aircraft cables can be disconnected from the load contactors on the power module (7).
(7) Disconnect plug connectors from the back of the control box (8).
(8) Remove the control box (8).
(9) Remove the air cleaner (9) and the pipe/hoses connecting it to the engine.
Note: cover the turbo inlet while the air cleaner is removed.
(10) Remove the generator stator leads from the power module (7).
(11) Route wire harness through the bulkhead panel (10) towards the engine compartment, so that the
front canopy panel (11), the control box support panel (12), power module assembly (7), and the
bulkhead panel (10) can be lifted off the unit in a one piece assembly.
(12) Remove generator housing cover (13).
b) Removing the generator Assembly
(1) Remove the four 5/8 - 11 x 4-1/2 bolts that mount the generator assembly to the frame of the
generator set.
August 6, 2004
Chapter 3-3
Page 1

(2) Support the engine at the flywheel housing with wooden blocks, or second hoist if available.
(3) Using the hoist, support the generator assembly. For lifting convenience, a M12-1.75 threaded
hole is drilled in the top of the generator housing. Insert a M12-1.75 eyebolt in the hole and attach
the hoist chain to the eyebolt as shown in Figure 1.
(4) Remove the M12-1.75 bolts generator-to-flywheel coupling bolts.
(5) Detach the generator housing from the engine. Do this by removing the six M10 - 1.5 x 35 metric
bolts.
(6) Carefully lift and separate the generator from the engine.
Hoist
Lifting Eye
Generator
Generator Lifting Arrangement
Figure 1
August 6, 2004
Chapter 3-3
Page 2

2
5
8
10
9
11
6
12
13
1.
2.
3.
4.
5.
6.
7.
Canopy Top Assembly

Right Front Door
Control Box Door (Left Front Door)
Left Front Lower Panel
Right Front Lower Panel
Power Module Cover
Power Module Assembly
8.
9.
10.
11.
12.
13.
Control Box Assembly

Air Filter Assembly
Bulkhead Panel
Front Canopy Panel
Control Box Support
Generator Cover
Component Removal Required for Access to Generator

Figure 2
August 6, 2004
Chapter 3-3
Page 3

3) Generator Assembly Installation

Installation of a generator assembly is essentially a reversal of the procedure for removal of the generator
assembly: the re-mounting of the generator assembly to the frame of the generator set, and the
remounting of the assemblies that were removed to gain access to the generator assembly. To install the
generator assembly, refer to Connection Diagram, and proceed as follows:
a) Remounting the Generator Assembly
(1) Support engine at flywheel housing with wooden blocks, or second hoist if available.
(2) Using the hoist, support the generator assembly and lower it carefully and slowly into position for
attachment to the engine.
(3) While still supporting the generator assembly with the hoist, attach the generator housing to the
engine, using the six M10 - 1.5 x 35 metric bolts. Torque bolts to 30 ft-lb (41 N-m).
(4) Attach the generator to the flywheel coupling, using the eight M12-1.75 bolts. Torque bolts to 85
ft-lb (115 N-m).
(5) Mount the generator housing to the frame of the generator set, using the four 5/8 - 11 x 4-1/2
bolts.
(6) Install the generator wrapper on the generator assembly, using 1/4 - 20 x 1/2 tap-tite screws.
b) Remounting the previously removed assemblies
(1) Remount the remaining pieces of the unit in reverse order of disassembly procedure.
August 6, 2004
Chapter 3-3
Page 4

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 an Engine-Generator Set manufactured by ITW GSE Group, Hobart Ground Power.
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 - Manufacturers 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
This form is divided into six columns. Beginning at the left side of the form and proceeding to the
right, columns are identified as follows:
(1) FIGURE-ITEM NO. Column
This column lists the figure number of the illustration applicable to a particular parts list and also
identifies each part in the list by an item number. These item numbers also appear on the
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
August 6, 2004
Chapter 4-1
Page 1

vice-versa. The figure and index numbers are also used in the numerical index to assist the user
in finding the illustration of a part when the part number is known.
(2) FACTORY PART NUMBER Column
All part numbers appearing in this column are Hobart numbers. In all instances where the part is
a purchased item, the vendors 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 FACTORY PART NUMBER column will reflect No Number
and the vendors number will be shown in the NOMENCLATURE column. Parts manufactured
by Hobart will reflect no vendor 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 also listed in this
column when applicable. 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 that 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. Since this manual covers more than
one generator set specification, this column is used as follows:
Parts coded A are usable on Part Number 500047D-001 only.
Parts coded B are usable on Part Number 500047D-002 only.
Parts coded C are usable on Part Number 500047D-003 only.
Parts coded D are usable on Part Number 500047D-004 only.
Parts coded E are usable on Part Number 500047D-005 only.
Parts coded F are usable on Part Number 500047D-006 only.
Parts coded G are usable on Part Number 500047D-007 only.
Parts coded H are usable on Part Number 500047D-008 only.
Parts coded J are usable on Part Number 500047D-009 only (Special Configuration).
(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.
August 6, 2004
Chapter 4-1
Page 2

Section 2
Manufacturer's Codes
1) Explanation of Manufacturers (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
Manufacturers Cataloging Handbook H4-1, (CAGE CODES) and are arranged in numerical order.
Vendor codes are inserted in the nomenclature column of the parts list directly following the item name
and description. In case a manufacturer does not have a code, the full name of the manufacturer will be
listed in the nomenclature column.
Code
Vendors Name and Address
Code
00779
Amp Inc.
2800 Fulling Mill Rd.
P.O. Box 3608
Harrisburg, PA 17105-3608
05HB5
Magnecomp Inc
161 Eagles Nest Dr
Pickens Sc 29671-7808
01XD4
Contact Industries Inc

25 Lex-Industrial Dr
P.O. Box 3086
Mansfield OH 44904-3086
05YB3
Acon Inc.
22 Bristol Dr.
South Easton, MA 02375
01428
Tuthill Corp.
Superior Linkage Div.
2110 Summit St.
New Haven, IN 46774-9524
0E8J0
Emka Inc.
1961 Fulling Mill Rd.
Middletown, PA 17057-3125
016T7
Amaton Inc.
446 Blake St.
New Haven, CT 06515
0HZP9
Diesel Radiator Co.

1985 Janice Ave.
Melrose Park, IL 60160
01989
Dana Corp
Weatherhead Div
U.S. 24 E.
Antwerp, OH 45813
0H8R0
Magnetics
200 10TH St.
P.O. Box 391
Butler, PA 16003-0391
02660
Amphenol Corp.
720 Sherman Ave
Hamden, CT 06514-1146
0MR72
Power Devices Inc.

26941 Cablot Rd
Suite 124
Laguna Hills, CA 92653-7006
02768
Illinois Tool Works Inc.

Fastex Division
19 S. Algonguin Rd.
Des Plaines, IL 60016
0ZW45
KHD Deutz Of America Corp

3883 Steve Reynolds Blvd
Norcross Ga 30093
05277
Westinghouse Electric Company

Semiconductor Division
Hill Street
Youngwood, PA 15697
1AA44
Collmer Semiconductor Inc.

C/O NA-NA Co.
14368 Protopn Rd.
Dallas, TX 75244-3511
054W1
Talema Electronic Inc.

3 Industrial Park Dr.
P.O. Box 306
Saint James, MO 65559
1DG36
E. M. Products Inc.
220 W. 90th St.
Minneapolis, MN 55420
August 6, 2004
Chapter 4-2
Page 1

Code
Code
1E045
Austin Hardware and Supply Co.

10220 E. 65TH St.
P.O. Box 9550
Kansas City, MO 64133-5205
14552
Microsemi Corp
2830 S. Fairview St.
Santa Ana, CA 92704-5948
1E222
Furnas Electric Co.

Richmond, VA 23200
14799
Square D Co.
Chicago Assembly Plant
9522 W. Winona
Schiller Park, IL 60176-1025
1FQ83
Newark Electronics Div

3033 Kettering Blvd
Dayton OH 45439
14604
Elmwood Sensors, Inc.

Subsidary Fasco Ind.
1655 Elmwood Avenue
Cranston, RI 02907
1PAM0
DAVCO Manfacturing
1600 Woodland Dr.
Saline MI 48176
14892
Bendix Corp.
The Brake And Steering Div.
401 N Bendix Dr
South Bend IN 46634
1SPJ9
Hobart Ground Power

Troy, OH 45373
16238
Lord Mfg. Co. Inc.

Sterling Road
South Lancaster, Mass 01561
1W134
Eaton Corp.
4201 N. 27TH Ave.
Milwaukee, WI 53216-1807
16476
Datcon Instrument Co.

P.O. Box 128
East Petersburg, PA 17520
1Y498
F B Wright
100 E Wilson Bridge Rd
Columbus Oh 43085-2334
17284
Mercury Metal Company

1201 S. Mercury Dr.
Schaumburg, IL 60193
12662
Peterson Mfg Co.

4200 E 135th St
Grandview MO 64030-2821
18265
Donaldson Co. Inc.

1400 W. 94th St.
P.O. Box 1299
Minneaplis, MN 55440-1299
12687
Trilectron Industries
11001 U.S. Hwy. 41 North
Palmetto, Florida 34221
2B664
All-Phase Electric Supply Co

1620 W Main St
P.O. Box 149
Springfield OH 45501-0149
13445
Cole-Herse
20 Old Colony Ave.
Boston, MA 02127
2B928
Barber Colman Co.

Pasadena, TX 77501
13902
Smith Valve Corp.

1 Apple HL Suite 316
Natick, MA 01760-2072
2N562
Power Transmission Sales Inc.

351 Washington
P.O. Box 229
Chagrin Falls, OH 44022-4446
August 6, 2004
Chapter 4-2
Page 2

Code
Code
23803
N T N Bearing Corp of America

650 Pennsylvania Dr
Exton PA 19341
30327
Imperial Eastman Corporation

6300 W. Howard Street
Chicago, IL 60648
23826
Furnas Electric Company

1004 McKee Street
Batavia, IL 60510
30430
Marathon Electric Mfg. Corp.

398 Beach Rd.
Burlingame, CA 94010-2004
24161
Gates Rubber Co
900 S Broadway
Denver CO 80217-5887
38151
Marathon Electric Mfg. Co.

100 E. Randolph St.
P.O. Box 8003
Wausau, WI 54401-2568
24446
General Electric Co.

3135 Easton Tpke.
Fairfield, CT 06431
40121
Peterson Mfg. Co. Inc.

700 W. 143rd St.
P.O. Box 8
Plainfield, IL 60544-9733
25710
Deka Plastics Inc.

914 Westfield Ave.
Elizabeth, NJ 07208-1222
44655
Heico Ohmite LLC

3601 W. Howard St.
Skokie, IL 60076-4014
26794
Connectron Inc.
12 Industrial Dr.
South Amboy, NJ 08879
46922
Crawford Electric Co
445 E 32 Mile Rd
Romeo MI 48065-0120
27410
Harris Corp.
1025 Nasa Blvd.
Melbourne, FL 32919
49234
Protectoseal Company
1920 S. Western
Chicago, Illinois 60608
28520
Heyco Molded Products Inc.

1800 Industrial Way N.
P.O. Box 517
Toms River, NJ 08755
5E599
NVF Company
Primary Products Div
Yorklyn Rd
Yorklyn, DE 19736
3A054
McMaster Carr Supply Co.

9630 Norwalk Blvd.
Santa Fe Springs, CA 90670-2932
5P059
Tech Products Corp.

2348 Sandridge Dr.
Dayton, OH 45439
3Y208
Taylor And Summerville Battery Co

3485 Successful Way
Dayton Oh 45414-4319
5U553
Wes-Garde Components Group Inc

300 Enterprise Dr
Westerville OH 43081-8840
30104
Automotive Controls Corp.

1300 W. Oak St.
P.O. Box 788
Independence, KS 67301-2347
50508
Magnetic Components Inc.

9520 Ainslie St.
Schiller Park, IL 60176-1116
August 6, 2004
Chapter 4-2
Page 3

Code
Code
52793
Saginaw Products Corp.

68 Williamson St.
Saginaw, MI 48601-3246
60038
Timken Corp
1835 Dueber Ave Sw
Canton, OH 44706-2798
55752
Parker Hannifin Corp.

Racor Div.
3400 Finch Rd.
Modesto, CA 95353-3208
61706
EAO Switch Corp.

198 Pepes Farm Rd.
P.O. Box 552 M O
Milford, CT 06460-3670
56289
Sprague Electric Company

87 Marshall St.
North Adams, MA, 01247
66180
Automatic Timing and Controls

3312 Bloomingdale
Melrose Park, IL 60160-1030
57347
Wall Industries Inc.

5 Watson Brook Rd.
Exeter, NH 03833
66844
Powerex Inc.
E. Hillis St.
Youngwood, PA 15697-1176
57448
Stephens & Adamson Mfg. Company

275 Ridgeway Avenue
Aurora, Illinois 60507
62292
EBM Industries Inc.

110 Hyde Rd.
P.O. Box 4009
Farmington, CT 06034-4009
57733
Stewart-Warner Corporation
1826 Diversey Parkway
Chicago, Illinois 60614
67529
All-Phase Electric Supply Co.

875 Riverview Dr.
P.O. Box 67
Benton Harbor, MI 49022-0067
59993
International Rectifier Corp

233 Kansas St.
El Segundo, CA 90245
7M613
Wright F.B. Co. of Cincinnati

4689 Ashley Dr.
Hamilton, Oh 45011-9706
6H359
Hobbs Div., of Stewart Warner Corp.

Highway 6
Spring Valley, IL 61362
71382
Seal Master Bearings

1901 Bilter Rd.
Aurora, IL 60504-9620
6S553
Wes-Garde Components Group Inc

300 Enterprise Dr
Westerville, OH 43081-8840
71400
Bussman Manufacturing
Division of McGraw-Edison Company
114 Old State Road
St. Louis, MO 63178
6Y440
Micron Technologies Inc.

8000 S. Federal Way
Boise, ID 83707
71774
General Electric Corp. Lamp Division

4433 N. Ravenswood Ave.
Chicago, IL 60640
6Y481
Hamilton Avnet Electronics Corp

777 Brooksedge Blvd
Westerville, OH 43081-2821
72582
Detroit Diesel Corp

13400 W. Outer Dr.
Redford, MI 48239-4001
August 6, 2004
Chapter 4-2
Page 4

Code
Code
72619
Amperex Electronic Corp.

Dialight Division
203 Harrison Place
Brooklyn, NY 11237
8A334
Cummins Interstate Power Inc

4000 Lyman Dr
Hilliard OH 43026
74829
Ilsco Corp.
4730 Madison Rd.
Cincinnati, OH 45227-1426
8T246
Whitesell RO & Associates, Inc.

4133 S. Dixie Ave.
Dayton, OH 45439
77166
Pass and Seymour

P.O. Box 4822
Syracuse, NY 13221
81074
Holub Industries, Inc.

413 DeKalb Avenue
Sycamore, Illinois 60178
74542
Hoyt Electrical Instruments

P.O. Box 8798
Penacook, NH 03303
81703
Mulberry Metal Products Inc.

2199 Stanley Terrace
Union , NJ 07083
74545
Hubbell Harvey Inc.

584 Derby Milford Rd.
Orange, CT 06477
82866
Research Products Corp.

1015 E. Washington Ave.
Madison, WI 53701
75418
Kysor Industrial Corporation

1100 W. Wright Street
Cadillac, Michigan 49601
83330
Dialight Corp.
1913 Atlantic Ave.
Manasquan, NJ 08736-1005
74559
Electrical Enclosures
Div Of Hoover Systems
12118 Corporate Dr
Dallas TX 75228
86797
Rogan Corp
3455 Woodhead Dr.
Northbrook, IL 60062-1812
77342
Potter and Brumfield Inc

200 S. Richland Creek Dr.
Princeton, IN 47671-0001
90201
Emhart Ind., Inc.

Mallory Capacitor Co.
4760 Kentucky Ave.
Indianapolis, IN 46206
78377
Superior Carbon Products Inc

Cleveland OH 44100
91637
Dale Electronics Inc.

1122 23RD St.
Columbas, NE 68601-3647
78388
Synchro-Start Products Inc

Sub of Knowles Electronics Inc
6250 W Howard St
Niles, Il 60714
91929
Honeywell Inc.
Microswitch Div.
11 W. Spring St.
Freeport, IL 61032
79497
Western Rubber Co.

620 E. Douglas
Goshen, IN 46526-4035
94222
Southco Inc.
210 N. Brinton Lake Rd.
Concordville, PA 19331
August 6, 2004
Chapter 4-2
Page 5

Code
97520
Basler Electric Company

Route 143
P.O. Box 269
Highland, IL 62249
D0024
Semikron International
Sigmundstrasse 200
P.O. Box 820251
Nuerengerg, Germany 90253
E0615
Kraus and Naimer

42 Miramar Avenue
P.O. Box 15-009
Wellington, New Zealand
S7023
Bossard LTD Fasteners

Steinhauserstrasse 70
Zug
Switzerland, CH-6300
August 6, 2004
Code
Chapter 4-2
Page 6

Section 3
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.
2) Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list:
*
A, or AMP
AC
AR
DC
Fig.
hd.
hex
Hz
I.D.
IN or
KVA
uF
No.
NHA
PRV
PSI
Ref
RH
LH
TM
T-R
V
Item not illustrated

Ampere
Alternating current
As required
Direct current
Figure
Head
Hexagon
Hertz (cycles-per-second)
Inside diameter
Inch
Kilovolt-ampere
Microfarad
Number
Next higher assembly
Peak reverse voltage
Pounds per square inch
Reference (the item has been listed previously)
Right Hand
Left Hand
Technical Manual
Transformer-rectifier
Volt or used as a prefix indicating 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.
August 6, 2004
Chapter 4-3
Page 1

4,5,6,19
37
7,8
27
28
13 20
22
21
32,33
1
17 29
24
26
34
31
Fixed Mount Bracket

General Assembly
Figure 1
August 6, 2004
Chapter 4-3
Page 2

FIGURE
ITEM NO.
1*
*
*
*
*
*
*
*
*
*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
*
*
28
*
*
29
*
*
*
*
*
*
30
31
32
33
34
35
36
37
38
FACTORY
PART NO.
285125
288300
77A1157
408665-1
408665-2
4025987
289177-2
287696
76B1148
287459
287460
287461
287462
287463
287464
287466
282658
288866
288862
287465
287571
283714-2
285418
282667
282727
280763
408781-1
288697
288698
288694
288696
288695
288695
288694
7J422-0
287808
287376
287377
288967
288703
287120
286956
100GH121
100GH121
100GH121
August 6, 2004
NOMENCLATURE
Frame Assembly (See Figure 2)
Canopy Assembly (See Figure 3)
Generator Set Internal Components (See Fig. 4)
Guard, Mushroom Button (V14799 # K564M)
Plate, Legend, Emergency Stop
Switch, Maintained, Push-Pull (V14799 #KR-9R-H6)
Reflector. Red (V12662 #B491)
Reflector, Amber (V12662 #B491A)
Label, Hobart
Instructions, Operating
Label, Hearing Protection
Label, Diesel Fuel
Label, General
Label, High Voltage
Label, Fuel
Label, Radiator
Label, Hot Muffler
Label, Moving Parts
Label, Emergency Stop
Label, Warning Clearance
Label, Support Center
Label, Caution, Engine Speed
Label, Warning Drawbar
Label, Tire Pressure
Label, kVA Rating
Wheel, Ay. 20.5 x 8.00 10
th
Bracket, 5 Wheel Assembly
Plate, Cover
Plate, Bearing
Pin, Spring
Tray, Cable, Right
Cover, DC Cable
Panel, Cable Guide
Tray, Cable, Left
Cover, AC Cable
Cover, AC Cable
Panel, Cable Guide
Clamp, Cable
Clamp, Cable (when DC is supplied)
nd
Clamp, Cable (with 2 output)
Kit, Fixed Mount Support
Bumper, Side
Support, Fender
Shield, Heat, Tray, Cable
Rear, Axle
Front, Axle
Drawbar
Bracket, Mounting Clamp
Bracket, Mounting Clamp (when DC is supplied)
nd
Bracket, Mounting Clamp (with 2 output)
EFF
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
E,F,G,H
A,C,E,G,J
E,F,G,H
C,D,G,H
B,D,F,H
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
A,C,E,G,J
E,F,G,H
C,D,G,H
UNIT PER
ASSY.
Ref.
Ref.
Ref.
1
1
1
8
24
2
1
1
1
1
1
1
1
2
2
1
1
1
1
2
4
2
4
1
1
1
2
1
1
1
1
1
2
1
2
3
4
1
2
4
1
1
1
1
1
2
3
Chapter 4-3
Page 3

15
12
16
12
13
8
14
11
1
4
9
10
Frame Assembly
Figure 2
August 6, 2004
Chapter 4-3
Page 4

FIGURE
ITEM NO.
FACTORY
PART NO.
NOMENCLATURE
2*
*
*
*
*
288879
287738-25
287738-30
287738-31
287738-32
287738-29
288691A
288835A
288722
282562
287781
288507
287739
287738-3
287437
288701
288702-7
288704
288882
288699
288692
288693
Panel, Front Canopy

Insulation, Top
Insulation, Left
Insulation, Left
Insulation, Right
Insulation, Right
Support, Control Box
Panel, Bulkhead, Center
Tray, Battery
Cap, Fuel (V49234 #1275/0003)
Tank, Fuel, 65 Gallon
Support, Engine, Front
Panel, Bottom
Insulation, Bottom Panel
Cover, Panel, Bottom
Panel, Bottom, Generator
Insulation, Noise, Bottom, Generator
Frame Assembly
Cover, Power Module
Cover, Frame, Exhaust
Leg, Control Box Support, Left
Leg, Control Box Support, Right
2
3
4
5
6
7
8
*
9
10
*
11
12
13
14
15
August 6, 2004
EFF
UNIT
PER
ASSY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Chapter 4-3
Page 5

4
1
8
9
3
7
1
9
12
13
14
2
10
11
Canopy Assembly
Figure 3
August 6, 2004
Chapter 4-3
Page 6

FIGURE
ITEM NO.
FACTORY
PART NO.
3*
287701
287738-1
283597
283824
287542-1
287542-2
287526-2
288880
288881
287738-28
283597
287542-1
287542-2
287526-2
288544
287738-20
288547
287738-21
287738-22
403091-2
288919
403127
287819
287805
287806
287793
287889
287703
287738-4
287785
2
*
3
*
4
*
*
*
5
6
*
7
*
*
*
8
9
*
10
288878
287738-27
287785
11
12
13
14
15
403091-8
287808
288700
288694
287489-1
*
*
*
August 6, 2004
NOMENCLATURE
Door, Assembly
Insulation, Noise, Door
Hinge, LH Access Door (V94222 #96-10-510-50)
Hinge, RH Access Door (V94222 #96-10-520-50)
Latch, Door (V94222 #E3-16-15)
Latch, Door (V94222 #E3-11-15)
Tab, Pull, Door Latch (V94222 #E3-27-1)
Door, Control Box
Cover, Controls (V1Y498)
Insulation, Noise, Door
Hinge, LH Access Door (V94222 #96-10-510-50)
Latch, Door (V94222 #E3-16-15)
Latch, Door (V94222 #E3-11-15)
Tab, Pull, Door Latch (V94222 #E3-27-1)
Panel, Support Door
Insulation, Panel, Door Support
Top, Canopy Assembly
Insulation, Noise, Canopy Top, Rear
Insulation, Noise, Canopy Top, Front
Cover, Canopy Exhaust
Door, Radiator Access
Catch, Magnetic (V94222 #02-10-201-10)
Panel, Rear Assembly
Deflector, Radiator, Left
Deflector, Radiator, Right
Bracket, Mounting Plenum
Cover, Louver Panel
Panel, Side, Lower
Insulation, Noise, Lower Panel
Fastener, Panel, Access
(VA5733 #7800-00 & #263-000006-00-0017)
Panel, Side, Lower (Control Box Side)
Insulation, Noise, Lower Panel
Fastener, Panel, Access
(VA5733 #7800-00 & #263-000006-00-0017)
Plug, Hole, Plastic (V28520 #DP-1750)
Cover, Opening, Front Canopy
Cover, Opening, Front Canopy
Panel, Cable Guide
Light, 12 V. Strobe
EFF
J
A TO H
J
A TO H
UNIT PER
ASSY.
3
3
2
4
3
3
3
1
1
1
2
1
1
1
2
2
1
1
1
2
1
1
1
1
1
2
1
3
3
12
1
1
4
A,C,E,G,J
B,D,F,H
J
1
1
1
1
1
Chapter 4-3
Page 7

11
10
7
16
9
15
Right Side
14
18
1
8
17
6
3
Left Side
Internal Components
Figure 4
August 6, 2004
Chapter 4-3
Page 8

FIGURE
ITEM NO.
FACTORY
PART NO.
288840-1
288840-2
No Number
No Number
No Number
No Number
Left Side
Control Box Assembly [No T-R] (See Figures 5 & 6)
Control Box Assembly [With T-R] (See Figures 5 & 6)
Mount, Rubber (V5P059 #51225)
Control Switch Panel Assembly [1 Output & No T-R]
(See Figure 7 & 8)
Control Switch Panel Assembly [2 Outputs & No T-R]
(See Figure 7 & 8)
Control Switch Panel Assembly [1 Outputs & T-R]
(See Figure 7 & 8)
Control Switch Panel Assembly [2 Outputs & T-R]
(See Figure 7 & 8)
400 Hz. Power Module Components (See Figure 9)
400 Hz. Power Module Components (See Figure 9)
Cooling System Components (See Figure 10)
Engine Ground Plate and Cables (See Figure 11)
Fuel System Components (See Figure 12)
Engine Exhaust Components (See Figure 13)
No Number
288460-1
480603-1
288457
No Number
No Number
288952
288964
288555
287438
056535
284371-5
283873
056534
286903
Right Side
12 VDC Battery Components (See Figure 14)
Generator Assembly (See Figure 17)
Mount, Shock, Generator
Ring, Spacer, Flex Coupling
Air Cleaner Components (See Figure 15)
Engine Electronic Panel Components (See Fig. 17)
Wire Harness, Engine
Wire Harness, Engine Electronics
Engine, Deutz, BF06M1013EC, 218 HP (V 0ZW45)
Valve, Oil, Drain
3
Hose, /8, ID
Mount, Shock, Engine
Valve, Drain, Radiator
Hose, 3/8 ID
Adapter, M14 1.5 x NPT
288692
288693
288691A
288835A
288895
289127
Miscellaneous
Leg, Control Box Support, Left
Leg, Control Box Support, Right
Support, Control, Box
Panel, Bulkhead, Center
Support, Option Terminal Block
Label, Option
41
*
*
289019-3
289019-4
288847-1
289012-1
289012-2
289012-3
289012-4
3
4
5
6
7
8
9
*
*
*
10
11
12
13
14
15
16
17
18
19
NOMENCLATURE
August 6, 2004
EFF
A,B,C,D,J
E,F,G,H
UNIT PER
ASSY.
A,B,J
1
1
4
1
C,D
E,F
G,H
A,B,E,F,J
C,D,G,H
1
1
Ref.
Ref.
Ref.
Ref.
Ref.
1
4
1
Ref.
Ref.
1
1
1
1
8 in.
2
1
42 in.
1
1
1
1
1
1
1
Chapter 4-3
Page 9

7,10
11,12
16
17
10,12
15
12
Control Box Door Panel Assembly

Figure 5
August 6, 2004
Chapter 4-3
Page 10

FIGURE
ITEM NO.
FACTORY
PART NO.
NOMENCLATURE
5-
289018-1
289018-3
494134-1
288995
286936-1
181358
286937-1
288819-1
283167
289017
288858-4
288814-2
W8105A-9
288999-1
285172
285172
288836-2
288836-1
400641-15
400642-8
288806
288820
Door, Control Panel, Assembly [No T-R]

Door, Control Panel, Assembly [With T-R]
Gauge, Fuel Level (V16476 #06339-01)
Panel, Door, Control Box
Gauge, Water Temperature (V61712 #310504)
Meter, Running Time (6H359 #85101)
Gauge, Oil Pressure (V61712 #350516)
Gauge, Voltmeter (V16476 #06351-01)
Meter, Frequency (V74542 #D-1255119311)
Label, Control Box
Meter, Fault, Digital
Ammeter, AC (V74542 #D-1500122163)
Voltmeter, AC (V74542 #D-1497222103)
Latch, Control Box (V94222 #62-20-25)
Light, Strip
Light, Strip
Hinge, Offset, Bottom (V94222 # 96-142 Type B)
Hinge, Offset Top (V94222 # 96-141Type A)
Ammeter, DC [See TR Manual]
Voltmeter, DC [See TR Manual]
Board, P.C., Front Panel, Led
Gasket, LED PC Board
*
*
*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
August 6, 2004
EFF
A,B,C,D,J
E,F,G,H
A,B,C,D,J
E,F,G,H
E,F,G,H
E,F,G,H
UNIT
PER
ASSY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
5
1
1
1
1
1
1
Chapter 4-3
Page 11

4
6
14
5
7
10 11
10 12

Figure 6
August 6, 2004
Chapter 4-3
Page 12

FIGURE
ITEM NO.
FACTORY
PART NO.
NOMENCLATURE
6-
288994
288993
288992
288742
288813
288937
288791
288940
288876
288896
W11166-9
W11166-2
289026
288875
288818-1
288605
289059
289060
283978-2
283978-1
289073
289072
288914
W11166-9
288917-2
288918-2
Side, Left, Control Box

Side, Right, Control Box
Wrapper, Control Box
Board, PC, ESB
Label, ESB [Engine Control]
Board, PC, EIB
Label, EIB [Starter Control]
Board, PC, Regulator
Label, Regulator [Generator Control]
Label, Regulator [LDC & Voltage Control]
Fuse, 1 A, 250 V (V2B664)
Fuse, 5 A, 250 V (V2B664)
Board, PC, Digital Controls
Label, Control [EF Bypass Control]
Power Supply (V05YB3 # M30T1205-12TS)
Support, Power Supply
Support, Circuit Breakers
Label, Circuit Breakers
Circuit Breaker, 10A (V77342 #W23-X1A16-10)
Circuit Breaker, 5A (V77342 #W23-X1A16-5)
Harness, Wire
Harness, Wire, DC [See TR Manual]
Board, PC, T-R [See TR Manual]
Fuse, 1 A, 250 V (V2B664)
Label, I.D. (Inside Control Box)
Label, Options (Inside Control Box)
1
2
3
4
*
5
*
6
*
7
*
8
9
*
*
*
*
10
11
12
13
14
15
16
August 6, 2004
EFF
E,F,G,H
E,F,G,H
E,F,G,H
UNIT
PER
ASSY.
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Chapter 4-3
Page 13

14
15
11
Item #s 12 & 13 are bolted to item # 11.

Item # 18 is located on item # 13
10
Control Switch Panel Components

Figure 7
August 6, 2004
Chapter 4-3
Page 14

FIGURE
ITEM NO.
7-
1
2
3
4
5
6
7
*
*
*
*
*
8
9
10
11
12
13
14
15
16
17
18
PART NO.
NOMENCLATURE
No Number
No Number
No Number
No Number
No Number
287038-1
No Number
287038-1
No Number
287038-1
No Number
No Number
No Number
288773
288772
288771
289004
289014
W10079-3
289015
288872
Lamps Pushbutton, Yellow (See Figure 8)

Pre-Heater Pushbutton, Orange (See Figure 8)
Engine Start Pushbutton, Green (See Figure 8)
Output # 1 Pushbutton, Yellow (See Figure 8)
Output # 2 Pushbutton, Orange (See Figure 8)
Plug, Hole (when output # 2 is not used)
DC Output Pushbutton, Blue [See T-R Manual]
Plug, Hole (when TR in not used)
Starting Current Pushbutton, Blue [See T-R Manual]
Plug, Hole (when TR in not used)
Engine Stop Pushbutton, Red (See Figure 8)
Test/Reset Pushbutton, Red (See Figure 8)
Meter Select Pushbutton, Green (See Figure 8)
Panel, Switch Box
Wrapper, Switch Box
Top, Switch Box
Panel, Switch
Label, Panel, Switch
Connector, Box Straight
Harness, Wire
Label, Fault and Command
August 6, 2004
EFF
C,D,G,H
E,F,G,H
E,F,G,H
UNIT
PER
ASSY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Chapter 4-3
Page 15

Switch Panel
Control Panel
6
2
3
1
11
9
9
7
8
7
10
Lamps Push-Button
Test/Reset Push-Button
Control Panel
Control Panel
6
6
3
11
2
1
7
10
11
7
10
Engine Stop Push-Button
Output # 1 Push-Button
Control Panel
Control Panel
6
6
4
11
5
1
7
10
11
7
10
Engine Start Only
Output # 2 & Pre-Heater Push-Button
Engine Start & Meter Select Push-Button
Push-Buttons Details
Figure 8
August 6, 2004
Chapter 4-3
Page 16

FIGURE
ITEM NO.
8-
PART NO.
NOMENCLATURE
1
2
3
4
285029-1
285030-2
285030-1
285030-4
5
6
7
8
9
10
11
285030-3
285031-1
285032-1
285033
284475-1
400613-4
285034-1
Frame, Bezel (V61706 #704-701.0)

Lens, Yellow (V61706 #704-702.4)
Lens, Red (V61706 #704-702.2)
Lens, Orange (V61706 #704-702.3)
Lens, Orange [Pre-Heater] (V61706 #704-702.3)
Lens, Green (V61706 #704-702.5)
Holder, Lens (V61706 #704-709.7)
Actuator, Sleeve (V61706 #704-731.0)
Flange, Mounting (V61706 #704-950.5)
Block, Contact, N.O. (V61706 #704-900.3)
Bulb, Type 1815 (V1FQ83)
Lamp Holder (V61706 #704-950.0)
EFF
C,D,G,H
UNIT
PER
ASSY.
1
1
1
1
1
1
1
1
1
1
1
1
[See TR Manual for DC operator pushbuttons.]
August 6, 2004
Chapter 4-3
Page 17

12
11
12
400 Hz. Power Module Assembly

Figure 9
August 6, 2004
Chapter 4-3
Page 18

FIGURE
ITEM NO.
9-
PART NO.
NOMENCLATURE
12
288709
AW626
A25
AW626
A25
282130-1
282130-1
286266
286266
401911-10
288829
288832
282089-10
288892-1
285102-1
285102-1
288829
13
288832
Panel, Power Module

Bushing, Insulating [A-B-C] (V1Y498)
Washer, Insulating
Bushing, Insulating [N] (V1Y498)
Washer, Insulating
Contactor, Line, 3-Pole
Contactor, Line, 3-Pole
Standoff, Short [E-F]
Standoff, Short [E-F]
Block, Terminal
Harness, Wire
Harness, Wire, 2nd Output
Diode, Flyback
Resistor, GPU ID
Current, Transformer (V05HB5 # 20130)
Current, Transformer (V05HB5 # 20130)
Cable, Power, Ay.
(No. 101) A Stator Terminal to K1, # 1 Output
(No. 102) B Stator Terminal to K1, # 1 Output
(No. 103) C Stator Terminal to K1, # 1 Output
(No. 110) N Stator Terminal to N, Neutral
Cable, Power, Ay.
(No. 104) A Stator Terminal to K201, # 2 Output
(No. 105) B Stator Terminal to K201, # 2 Output
(No. 106) C Stator Terminal to K201, # 2 Output
1
2
3
4
*
5
*
*
*
6
7
8
9
10
11
August 6, 2004
EFF
C,D,G,H
C,D,G,H
C,D,G,H
C,D,G,H
UNIT
PER
ASSY.
1
3
6
2
4
1
2
2
4
1
1
1
1
1
3
6
Ref.
1
1
1
1
C,D,G,H
1
1
1
Chapter 4-3
Page 19

3,4
10
14
12
13
Cooling System Components

Figure 10
August 6, 2004
Chapter 4-3
Page 20

FIGURE
ITEM NO.
10 -
1
2
3
4
5
6
7
8
PART NO.
NOMENCLATURE
288433
288435
287249
288509
288432
288431
288562
288503
W10869-3
287662
W10869-5
Radiator Assembly (V0HZP9)

Charge-Air-Cooler Assembly (V0HZP9)
Fan, Cooling, 26
Guard, Spiral, Fan
Shroud, Fan, Top
Shroud, Fan, Bottom
Guard, Fan Belt
Hose, Radiator, Upper (V24161)
9
Clamp, Hose (1 /16 2 )
Hose, Radiator, Lower (V24161)
5
Clamp, Hose (2 /16 3 )
Line, De-Aeration
Bushing, Pipe, Steel, 1/8
Connector, Male
Hose, , ID
7
5
Clamp, Hose ( /32 /8)
Valve, Drain, Radiator
Hose, 3/8 ID, Low Pressure
Pipe, CAC, Inlet
Bracket, Support, CAC, Pipe
Hose, CAC, (V0ZW45)
Clamp, Hose, CAC (V0ZW45)
Pipe, CAC, Outlet, 90
Hose, CAC, Inlet (V0ZW45)
Clamp, Hose, CAC (V0ZW45)
Hose, Radiator Fill
Hose, Radiator, 7/8: ID
Clamp, Hose, (13/16 x 1-3/4)
Clamp, Shield
Kit, Low Coolant Shutdown
Valve, Radiator, Drain
Connector, Male, 1/4 NPT, 3/8 Tube
Clamp, Hose, Stainless Steel
Hose, Low Press, Lube Oil, 1/4 I.D.
Gage, Low Coolant
Connector, Male, 1/2 NPT, 3/8 Tube
Tee, Street, 1/4 NPT
Tee, Street, Male Branch, 1/4 NPT
Kit, Block Heater, 120v.
Fitting, Reducer, M22-1.5 To 1/2 NPT
Fitting, Elbow, 1/2" NPT X 3/4" Barb
Hose, 3/4" I.D., Radiator
Hose, 3/4" I.D., Radiator
Block Heater (Hardware Included)
10
11
12
13
W7814-0
402927-3
056534
W10869-14
283873
056535
288450
288454
288687
404154-15
288500
288687
404154-15
14
15
16
058521
W10869-2
HF2962
288074
283873
288123-1
W10869-14
056534
288077-1
288123-2
288071-1
288126-1
288596-1
287055
287056
213502
213502
287566-1
August 6, 2004
EFF
UNIT PER
ASSY.
1
1
1
1
1
1
2
1
2
1
2
Ref.
1
1
23
2
2
48
1
1
1
2
1
1
2
Ref.
42
2
1
Ref.
1
3
4
5.3 ft
1
1
1
1
Ref
2
2
33 in.
28 in.
1
Chapter 4-3
Page 21

Engine Ground Plate and Cables

Figure 11
August 6, 2004
Chapter 4-3
Page 22

FIGURE
ITEM NO.
11 -
1
2
3
4
PART NO.
NOMENCLATURE
288735
W9407-446
W9360-289
288952
Plate, Ground
Cable, Engine to Ground
Cable, #111, Power Mod. To Ground
Wire Harness, Engine
August 6, 2004
EFF
UNIT PER
ASSY.
1
1
1
1
Chapter 4-3
Page 23

7
9
3,5
6
4
8
1
Fuel System Components

Figure 12
August 6, 2004
Chapter 4-3
Page 24

FIGURE
ITEM NO.
12 -
1
2
3
4
5
6
7
PART NO.
NOMENCLATURE
No Number
286897-13
288585
12CW2077-3
400819-3
W10760-3
288586
Filter, Fuel/Water, Separator (V0ZW45 # 1340130)

.Filter, Fuel, Replacement (V0ZW45 # 117-4421)
Line, Fuel, Tank to Filter
Elbow, NPT, ST., 90
Valve, Ball, NPT
Nipple, Pipe,
Line, Fuel, Filter to Pump
Line, Fuel, Return
Hose, 3/8 ID
7
5
Clamp, Hose ( /32 /8)
Fitting, Hose, Barbed, Brass
Fitting, Fuel Return Straight
Tubing, Z-Flex, ID
Bracket, Engine Fuel Filter
Tank, Fuel, 65 Gallon
Cap, Fuel Neck (V49234 #1275G/12T)
Filter, Fuel/Water, Separator
(V1PAM0 # 382050CMDV)
Line, Fuel, Tank to Filter
Line, Fuel, Filter to Pump
Bracket, Engine Fuel Filter
*
*
8
9
10
11
056535
W10869-14
286851
288248
76A1132
288587
287781
282562
288188
*
*
*
12
13
14
289166
289165
289188
August 6, 2004
EFF
UNIT PER
ASSY.
Ref.
1
1
1
1
1
1
Ref.
72
2
1
1
66
1
1
1
1
J
J
J
1
1
1
Chapter 4-3
Page 25

5,6
2,3
Engine Exhaust Components

Figure 13
August 6, 2004
Chapter 4-3
Page 26

FIGURE
ITEM NO.
13 -
*
*
*
*
1
2
3
4
5
6
7
8
9
PART NO.
NOMENCLATURE
288968
287431
287431
287432
287691
288969
404154-16
287406
287644
287647
287645
287370
287643
Muffler and Exhaust Ay.

Bracket, Muffler Mounting, Front
Bracket, Muffler Mounting, Front
Bracket, Muffler Mounting, Rear
Spring, Muffler, Mounting
Pipe, Turbo, Ay.
Clamp, Pipe, 4
Shield, Heat, Muffler
Shield, Heat, Muffler
Shield, Heat, Muffler [End]
Support, Exhaust Pipe
Pipe, Exhaust Ay.
Pipe, Exhaust Ay.
August 6, 2004
EFF
A,C,E,G,J
B,D,F,H
A,C,E,G,J
B,D,F,H
B,D,F,H
B,D,F,H
A,C,E,G,J
B,D,F,H
UNIT PER
ASSY.
1
1
2
1
4
1
3
1
1
1
1
1
1
Chapter 4-3
Page 27

12 VDC Battery System

Figure 14
August 6, 2004
Chapter 4-3
Page 28

FIGURE
ITEM NO.
14 -
1
2
3
4
5
6
PART NO.
NOMENCLATURE
281881-1
287740
287797
288722
287796
494295
Battery, 12 V (V3Y208 #724 DT)

Cable, Battery, Positive (V3Y208)
Cable, Battery, Negative (V3Y208)
Tray, Battery
Hold Down, Battery (V3Y208)
Bolt, Hold Down, Battery (V3Y208)
August 6, 2004
EFF
UNIT PER
ASSY.
2
1
1
1
2
2
Chapter 4-3
Page 29

9
8
10
Air Cleaner Components

Figure 15
August 6, 2004
Chapter 4-3
Page 30

FIGURE
ITEM NO.
15 -
1
2
3
4
5
6
7
8
9
10
PART NO.
NOMENCLATURE
286061
284923
282918
288588
287371
284925
280732-6
280732-7
403484
288054-3
Air Cleaner (V18265 #EBB12-0271)

Mount, Band, Air Cleaner (V18265 #AAH00-0349)
Indicator, Restriction, Electric (V18265 #REX77-0062)
Pipe, Air Inlet, Ay.
Elbow, Rubber, 90 (V55752 # 4014-03002)
Reducer, Rubber, 90 Elbow (V18265 # P12-1482)
Clamp, T-Bolt (V18265 # P148343)
Clamp, T-Bolt (V18265 # P148345)
Reducer, Hump, Rubber
Elbow, Steel, 90
August 6, 2004
EFF
UNIT PER
ASSY.
1
2
1
1
1
1
4
1
1
1
Chapter 4-3
Page 31

Engine Electronic Panel Components

Figure 16
August 6, 2004
Chapter 4-3
Page 32

FIGURE
ITEM NO.
16 -
1
2
3
5
6
7
8
PART NO.
NOMENCLATURE
286850
288973
Not Available
Not Available
Not Available
Not Available
Not Available
288964
Not Available
Not Available
Not Available
Not Available
287145-001
287144-001
Starter Solenoid (V13445 # 24059)

Diode, Flyback
Electronic Module (EMR II) [Supplied by Engine]
Electronic Module Harness [Supplied by Engine]
Connector, 25 Socket (V00779 #281810-2)
Cover, Connector (V00779 #281812)
Plug, Socket (V00779 # 929938)
Harness, Wire, Engine, Electronic
Connector, 25 Socket (V00779 # 281810-2)
Cover, Connector (V00779 # 281812)
Plug, Socket (V00779 # 929938)
Relay, Grid Heater, Power [Supplied by Engine]
Fuse Holder (V71400 # T30100-1CR)
Fuse, Fast Acting (V71400 # JJN-100)
Deutz Service Tool Adapter
Connector, 23 Pin (V9U703 # 192900-0324)
Cover, Connector (V9U703 # 192900-0378)
Extension, Connector (V9U703 # 192900-0286)
Pins Connector (V9U703 # 192990-0110)
Harness, Engine
(No. 150) K6-A [Power Relay] to F111-A [Fuse]
(No. 151) K6-B [Power Relay] to AIH [Heater]
(No. 152) BT + [Battery] to F111-B [Fuse]
Call Factory
Call Factory
Call Factory
Call Factory
288952
August 6, 2004
EFF
UNIT PER
ASSY.
1
1
1
1
1
1
AR
1
1
1
AR
1
1
1
Ref.
1
1
1
1
1
1
1
1
Chapter 4-3
Page 33

3
2
5
13
7
6
12
11
8
10
Generator Assembly
Figure 17
August 6, 2004
Chapter 4-3
Page 34

FIGURE
ITEM NO.
17 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NO.
NOMENCLATURE
288486
288494
180696-003
288440
288471
W-10072-68
288447-001
288461
288481
480290
85B-1039
85C1004-1
288457
288458
288478
Exciter Cover
Exciter Armature
Exciter Key
Exciter Housing and Coils Assembly
Generator Housing and Coils Assembly
Bearing
Generator Rotor
Front Bearing Support
Flexible Coupling Kit
Coupling Bushing
Coupling Key
Split Taper Bushing
Flywheel Adapter Ring
Generator Air Deflector
Generator Cover
August 6, 2004
EFF
UNIT PER
ASSY.
1
1
1
1
1
2
1
1
1
8
1
1
1
6
1
Chapter 4-3
Page 35

August 6, 2004
Chapter 4-3
Page 36

Section 4
Numerical Index
1) Explanation of Numerical Index

The purpose of this index is to assist the user in finding the illustration and description of a part when the
part number is known. Part numbers are arranged in alphanumerical sequence. Thus, any part number
beginning with the letter A would be located at or near the top of the index list. Likewise, a part number
9 would be listed near the end of the list and far below a part number 1000. The figure number and
item number location of the part is directly opposite the part. If the part is used in more than one place,
each location is listed commencing with the first location the part is listed.
FIGURE ITEM NO.
9-2
9-3
991017-6
11-2
11-3
1010125-11
66101012-5
7-16
6101041010410121012-3
17-3
5-4
101015-8
15-7
114-1
9-9
9-4
August 6, 2004
HOBART PART NO.

AW626
AW626
A25
A25
HF2962
W-10072-68
W9407-446
W9360-289
W10869-14
W10869-14
W10869-14
W8105A-9
W11166-9
W11166-9
W10869-5
W10869-3
W10760-3
W10079-3
W11166-2
W10869-2
W7814-0
056534
056534
056534
056535
056535
056535
058521
12CW2077-3
180696-003
181358
213502
213502
280732-7
280732-6
280763
281881-1
282089-10
282130-1
FIGURE ITEM NO.

92-5
12-10
1-20
1-27
115-3
5-7
331-25
3410-11
106-10
6-11
48-9
15-2
15-6
8-4
8-5
8-2
8-1
8-3
8-6
8-7
8-11
8-8
9-11
91-4
5-13
51-26
15-1
9-5
9-
HOBART PART NO.

282130-1
282562
282562
282658
282667
282727
282918
283167
283597
283597
283714-2
283824
283873
283873
283873
283978-2
283978-1
284371-5
284475-1
284923
284925
285030-4
285030-3
285030-2
285029-1
285030-1
285031-1
285032-1
285034-1
285033
285102-1
285102-1
285125
285172
285172
285418
286061
286266
286266
Chapter 4-4
Page 1

FIGURE ITEM NO.
16-1
121245-3
5-5
1-37
77710101-36
16-7
16-6
10-3
13-9
15-5
1-32
1-33
13-7
13-2
1313-3
2-9
41-13
1-14
1-15
1-16
1-17
1-18
1-23
1-19
3-15
333333101-24
131313-8
1310-9
13-4
1-11
3-1
August 6, 2004
HOBART PART NO.

286850
286851
286897-13
286903
286936-1
286937-1
286956
287038-1
287038-1
287038-1
287055
287056
287120
287144-001
287145-001
287249
287370
287371
287376
287377
287406
287431
287431
287432
287437
287438
287459
287460
287461
287462
287463
287464
287465
287466
287489-1
287526-2
287526-2
287542-2
287542-2
287542-1
287542-1
287566-1
287571
287643
287644
287645
287647
287662
287691
287696
287701
FIGURE ITEM NO.

3-9
22223323333232-8
14-2
2-6
12-9
33314-5
14-3
331-31
3-12
3-7
3-8
15-10
1010-15
1010101012-11
121-5
10-6
10-5
10-1
10-2
17-4
17-7
10-12
10417-12
17-13
4-9
HOBART PART NO.

287703
287738-32
287738-31
287738-30
287738-29
287738-28
287738-27
287738-25
287738-22
287738-21
287738-20
287738-4
287738-3
287738-1
287739
287740
287781
287781
287785
287785
287793
287796
287797
287805
287806
287808
287808
287819
287889
288054-3
288071-1
288074
288077-1
288123-2
288123-1
288126-1
288188
288248
288300
288431
288432
288433
288435
288440
288447-001
288450
288454
288457
288457
288458
288460-1
Chapter 4-4
Page 2

FIGURE ITEM NO.
17-8
17-5
17-14
17-9
17-1
17-2
10-13
10-8
2-7
10-4
3-3
3-4
4-14
10-7
12-2
12-6
12-8
15-4
10-16
610102-2
4-17
2-14
4-15
2-15
4-16
113-14
2111-29
1-28
12-13
3-13
2-10
1-35
2-11
9-1
2-4
14-4
11-1
6-4
7-13
7-12
7-11
6August 6, 2004
HOBART PART NO.

288461
288471
288478
288481
288486
288494
288500
288503
288507
288509
288544
288547
288555
288562
288585
288586
288587
288588
288596-1
288605
288687
288687
288691A
288691A
288692
288692
288693
288693
288694
288694
288694
288702-7
288695
288695
288696
288697
288698
288699
288700
288701
288703
288704
288709
288722
288722
288735
288742
288771
288772
288773
288791
FIGURE ITEM NO.

5-17
5-10
66-8
5-6
59-7
9-12
9-8
9-13
5-14
52-3
4-18
44-3
45-9
1-22
1-21
7-18
663-10
2-1
3-2
32-12
9-10
4-19
66-14
6-15
6-16
3-6
6-5
6-6
4-12
11-4
16-9
4-13
16-4
1-34
13-1
13-5
166-3
6-2
6-1
5-2
5-12
HOBART PART NO.

288806
288814-2
288813
288818-1
288819-1
288820
288829
288829
288832
288832
288836-2
288836-1
288835A
288835A
288840-2
288840-1
288847-1
288858-4
288862
288866
288872
288875
288876
288878
288879
288880
288881
288882
288892-1
288895
288896
288914
288917-2
288918-2
288919
288937
288940
288952
288952
288952
288964
288964
288967
288968
288969
288973
288992
288993
288994
288995
288999-1
Chapter 4-4
Page 3

FIGURE ITEM NO.
7-14
4444-2
7-15
457-17
4-1
55-8
6-7
6-9
66-13
6-12
412-13
12-12
1-10
12-14
8-10
5-15
5-16
12-4
9-6
103-11
3-5
315-9
13-6
10101-8
1-7
11745-1
14-6
1-9
1-30
1-12
121-6
17-10
17-11
August 6, 2004
HOBART PART NO.
FIGURE ITEM NO.
HOBART PART NO.
289004
289012-4
289012-3
289012-2
289012-1
289014
289019-4
289018-3
289015
289019-3
289018-1
289017
289026
289059
289060
289072
289073
289127
289165
289166
289177-2
289188
400613-4
400641-15
400642-8
400819-3
401911-10
402927-3
403091-8
403091-2
403127
403484
404154-16
404154-15
404154-15
408665-2
408665-1
408781-1
480290
480603-1
494134-1
494295
4025987
7J422-0
76B1148
76A1132
77A1157
85B-1039
85C1004-1
Chapter 4-4
Page 4

Chapter 5 Manufacturers Literature

Vendor Literature
Type
Diagram Description
Engine
Operation and Maintenance Manual

Parts Catalog
Diagram Number
Diagram Description
289117
Diagram, Schematic & Connection
289022
Diagram, Connection, Control Box
289002
Diagram, Connection, Power Module
289013
Diagram, Connection, Switch Box
See Appendix A
Diagram, Connection, Transformer-Rectifier
Contact Hobart Ground Power if either copy of these drawings or manuals are not with this manual (unless
otherwise noted above). Refer to Appendix A for specific information on 90DZ20, 400 Hz. Generator Set,
optional equipment.
August 6, 2004
Chapter 5-1
Page 1

August 6, 2004
Chapter 5-1
Page 2

Appendix A Options / Features

Option/Features Available
Description
Part Number
Trailer, with Tongue Actuated Brakes/Cable Trays

Trailer, with Lever Actuated Brakes/Cable Trays
Kit, Noise Reduction
Kit, Spotlight
Kit, Block Heater, 120V
Kit, Block Heater, 240V
Kit, Fire Extinguisher
Kit, Pin Hitch
Kit, Pintle Hitch
Kit, Fixed Mounting
Support, Fork Lift Assembly
Kit, Tie-Down
*Kit, Unit Operating, Non-Flashing Beacon
*Kit, Low Fuel, Flashing/Non-Flashing Beacon
*Kit, Low Fuel Strobe Beacon
Kit, Battery Blanket, 120V
Drawbar, 1-1/2 Eye
Kit, T-Handle Latch
Wheel Chocks
Kit, Clearance Lights
Kit, Transformer-Rectifier, 28 VDC
Standard
Call Factory
288865
287122
288596-1
288596-2
283012
381441
76A1361
287892
287694
284706
288909-XXX
Call Factory
Call Factory
287917
286944
287546-2
287609
288912
Call Factory
Document
Number
TO-257
TO-241
n/a
n/a
288596
288596
TO-252
381441
76A1361
n/a
TO-281
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
TO-297
OM-2136
In This
Section
* A large number of variations exist under this part number. Call the factory for details.
n/a Not Available, call the factory for details.
The following is a list of options/features available for the 90DZ20, 400 Hz. Generator Set. This chart
contains the description, part number, and document number (if applicable) of the option/feature. There is
also a column to identify which option/feature document is contained in this Appendix.
August 6, 2004
Appendix A
Page 1

August 6, 2004
Appendix A
Page 2

Wet-Stacking in Generator Set

1) Diesel Engines
All diesel engines operated for extended periods under light load may develop a
condition commonly referred to as wet-stacking. This condition results from the
accumulation of unburned fuel in the exhaust system. It is recognizable by fuel oil
wetness around the exhaust manifold, pipes, and muffler. Liquid fuel, in the form of
droplets, may be spewed from the exhaust outlet.
Wet-stacking is common, and may be expected in diesel engines operated under light
load. Light loads do not allow the engine to reach the most efficient operating
temperature for complete combustion of fuel. The unburned fuel collects in the exhaust
system to create the wet condition known as wet-stacking.
To alleviate wet-stacking in lightly loaded engines, it is recommended that the machine
be connected to a load bank after each 200 hours of use and operated under full rated
load for one hour. This will burn away and evaporate the accumulation of fuel in the
exhaust system. This clean-out procedure should be considered as a regular
maintenance operation for machines operated under light loads. The time schedule of
200 hours may be changed as required to suit each users particular needs and
operating conditions.
August 6, 2004
Appendix A
Page 3

August 6, 2004
Appendix A
Page 4

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 manufacturers control. The
manufacturer should be consulted if any unusual conditions of use exist which may affect the physical
condition or operation of the equipment.
Among such conditions are:

1) Exposure to:
a) Combustible, explosive, abrasive or conducting dusts.
b) Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation.
c) Chemical fumes, flammable, or explosive gases.
d) Nuclear radiation.
e) Steam, salt-laden air, or oil vapor.
f)
Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus
growth.
g) Abnormal shock, vibration or mechanical loading from external sources during equipment operation.
h) Abnormal axial or side thrust imposed on rotating equipment shafts.
i)
Low and/or high ambient temperatures.
j)
High electromagnetic fields
2) Operation at:
a) Voltages above or below rated voltage.
b) Speeds other than rated speed.
c) Frequency other than rated frequency.
d) Standstill with rotating equipment windings energized.
e) Unbalanced voltages.
f)
Operation at loads greater than rated.
3) Operation where low acoustical noise levels are required.
August 6, 2004
Appendix A
Page 5

4) Operation with:
a) Improper fuel, lubricants or coolant.
b) Parts or elements unauthorized by the manufacturer.
c) Unauthorized modifications.
5)
Operation in poorly ventilated areas.
August 6, 2004
Appendix A
Page 6

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OM-2076D

Operation and Maintenance Manual

Data Sheet 165

HOBART GROUND POWER

OM-2076D / Operation and Maintenance Manual

Safety Warnings and Cautions

ELECTRIC SHOCK can KILL. Do not touch live electrical parts.

CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine exhaust and

OM-2076D / Operation and Maintenance Manual

3) Service and Maintenance

4) Fire And Explosion Prevention

OM-2076D / Operation and Maintenance Manual

5) Toxic Fume Prevention

6) Bodily Injury Prevention

7) Medical and First Aid Treatment

8) Equipment Precautionary Labels

OM-2076D / Operation and Maintenance Manual

This page intentionally left blank.

OM-2076D / Operation and Maintenance Manual

OM-2076D / Operation and Maintenance Manual

ITW GSE Group

Call Inside U.S.A.:

(800) 422-4166 (Parts)

Call From Foreign Countries:

(937) 332-5050 (Parts)

FAX Inside U.S.A.

FAX From Foreign Countries:

OM-2076D / Operation and Maintenance Manual

Optional Equipment - Appendix A

Engine and Generator

Control Box Assembly

Power Module Panel Assembly

Cold Weather Start System

Preparation for Use, Storage or Shipping

Preparation For Use

Preparation for Storage

Preparation for Shipment

400 Hz. Operation Procedure

Servicing The Air Cleaner

Engine Fuel System

OM-2076D / Operation and Maintenance Manual

Engine Cooling System

Testing the 400 Hz. Generator Set

Generator Set Adjustments

Generator and Exciter Test

Testing the Transformer-Rectifier

Equipment for Troubleshooting

400 Hz. Test Values

Check Connections and Leads

Connection and Schematic Diagrams

GPU Control Monitoring

Generator Excitation Circuits

No. 1 Load Contactor Operating Circuit

No. 2 Load Contactor Operating Circuit

Troubleshooting Tables GPU Commands

Troubleshooting Tables GPU Faults

Overhaul / Major Repair

Exciter Armature Replacement