TM-297 080673 OPERATION AND MAINTENANCE MANUAL with ...
Transcript of TM-297 080673 OPERATION AND MAINTENANCE MANUAL with ...
TM-297
080673
OPERATION AND MAINTENANCE MANUAL
with
ILLUSTRATED PARTS LIST
for
GENERATOR SET
Hobart Model MG 1028
28.5 V DC, 28.5 KW, 1000 A.
Specification 5651
and Variations
Manufactured by
MOTOR GENERATOR DIVISION
HOBART BROTHERS COMPANY
TROY, OHIO 45373
U.S.A.
SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT
A WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts.
FUMES &ND GASES can be fire and health hazards. Ventilate all fumes and exhaust gases to the outside.
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible material. Do not
use power cables to break load and be sure tools don’t cause short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.
MOVING PARTS can cause serious injury. Keep clear of moving parts.
IMPORTANT - Protect yourself and others. Read and understand all the instructions in this Operating/Instruction
Manual before installing, operating, or servicing this equipment. Keep this manual available for future
use by all operators.
A.
6.
GENERAL
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions. Safe practices
have developed from past experience in the use of power source equipment. Certain of the practices below apply to
engine driven equipment.
SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a
person. Have a competent electrician verify that the equipment is adequately grounded and learn what terminals
and parts are electrically HOT. Use proper safety clothing, procedures, and test equipment.
The electrical resistance of the body is decreased when wet, thus more easily permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas without being extremely careful.
Stand on dry rubber mat or dry wood, use insulating gloves that are effective when dampness or sweat cannot be
avoided. Keep your clothing dry and never work alone.
1. Installation and Grounding of Electrically Powered Equipment - Electrical equipment must be installed
and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, and other 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 S-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 -- --- ---*
Be sure to connect the grounding lead, if supplied in a power line cable, to the grounded switch box or building
ground. If not provided, use a separate grounding lead. Be certain that the current (amperage) capacity of the
grounding lead will be adequate for the worst fault current situation. Refer to the National Electrical Code ANSI/
NFPA 70 for details. Do not remove plug ground prongs. Use correct mating receptacles.
2. Output Cables and Terminals - Inspect cables often for damage to the insulation and the connectors. Replace
or repair cracked or worn cables immediately. Do not overload cables. Do not touch output terminal while equip-
ment is energized.
Instruction 910082
Nov 16182 Revised
Page 1
C.
D.
E.
F.
G.
1 I 3. Service and Maintenance - This equipment must be maintained in good electrical and mechanical condition
to avoid hazards stemming from disrepair. Report any equipment defect or safety hazard to your supervisor and
discontinue use of the equipment until its safety has been assured. Repairs should be made by qualified personnel
only. Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the equipment.
Lock switch OPEN (or remove line fuses) so that power cannot be turned ON accidentally. Disconnect power to
equipment if it is out of service. If troubleshooting must be done with the unit energized, have present another per-
son trained in turning off the equipment and providing or calling for first aid.
’ FIRE AND EXPLOSION PREVENTION
Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust piping, misuse
of batteries and fuel, or unsafe operating or fueling conditions.
1. Electrical Short Circuits and Overloads - Overloaded or shorted equipment can become hot enough to cause
fires either by self destruction or causing nearby combustibles to ignite. Provide primary input protection to re-
move short circuited or heavily overloaded equipment from the line.
2. Battery - Batteries may explode and/or give off flammable hydrogen gas. The acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, causing sparking, or use open flame
near the battery.
3. Enoine Fuel - Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel
tank is not grounded prior to and during fuel transfer. Shut unit DOWN before removing fuel tank cap. Do not
completely fill tank. Heat from the equipment may cause fuel expansion overflow. Remove all spilled fuel im-
mediately including any that penetrates the unit. After cleanup, open equipment doors and blow fumes away with
compressed air.
TOXIC FUME PREVENTION
Carbon Monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust fumes to a
suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts or air conditioners.
BODILY INJURY PREVENTION
Serious injury can result from contact with fans, belts, and pulleys inside the equipment. Shut DOWN equipment
for inspection and routine maintenance. When equipment is in operation use extreme care in doing necessary
troubleshooting and adjustment.
MEDICAL AND Fl RST AID TREATMFN
First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of ail
injury victims. Electric shock victims should be checked by a physician and taken to a hospital immediately if any
abnormal signs are observed.
EMERGENCY FIRST AID
Call physician immediately. Seek additional assistance and use First Aid techniques recommended
by American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELEC-
TRICAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration,
preferably mouth-to-mouth. If no detectable pulse, begin external heart massage. Call Emergency
Rescue Squad immediately.
EQUIPMENT PRECAUTIONARY LABELS
Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be easily read.
Page 2 Instruction 910082
Revised Nov 16182
INTRODUCTION
This manual contains operation and service information and instructions for a Hobart Induction
Motor Driven 28.5-V DC Generator Set, specification number 5651 (S-5651).
In addition to the standard unit, the manual also covers variations to the basic specifications,
which are designated by a numerical suffix to the specification number, on the nameplate.
A sub-section entitled “VARIATION,S” in Chapter 1 explains these variations, and will in-
clude any such new variations as they are added in the future.
The manual in no way is presented as a text-book on electricity or electronics. Its primary
purpose is to provide information and instructions to experienced operators, electricians
and mechanics who have never seen, nor operated this particular generator set. It is the
intent of the manual to guide and assist operators and maintenance personnel 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 con -
tained in it. Each page is identified in the lower outside corner by the chapter and section
number in which it appears. Each new section starts with page 1. The first figure in each
section is Figure No. 1 .
In addition to operation and maintenance instructions, the manual contains an Illustrated Parts
List in Chapter 4. A collection of manufacturer’s literature is supplied as part of the infor-
mation package.
Aug 6/“73 Introduction
Page 1
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
Description/Operation
Description
q General
Special Features
Standard Unit and Variations
Physical Data
Control Box Assembly
Genera I
Control Pane I
Controls
Lights
Monitoring Instruments
Switches
Control Rheostats
Interior Pane I Assembly
Resistors
Overvoltage Module
Ammeter Shunt
Over load Re lay
Automatic Flash Relay
Load Con tactor
Voltage Regulator
Aug 6/73
1-o 1
l-l 1
1
8
Contents
Page 1
SUBXCT
Genera I
Theory of Operation
, lnstal lation,
Preparation for Use
Genera I
Inspection/Check
Installation of Unit
Genera I
Wiring
Output Cable lnstal lation
Cable Requirements
Cable Connections
Portable Mounting
Preparation for Storage
Operation
Genera I
Starting
Power Del ivery
Constant 28.5-V DC Power Delivery
Limited Current Power Delivery
Power Delivery For Helicopter Starting
Power Delivery With Manual Voltage Control 3
Contents
Page 2
Aug 6/73
CHAPTER/SECTION PAGE
l-l 8
9
l-2 1
1
1
1
1
1
1
3
3
3
3
4
l-3 1
1
1
1
1
2
2
SUBJECT CHAPTER/SECTION
TABLE OF CONTENTS (CONT’D.)
Discontinue Power Delivery
Servicing
Majntenance Inspection/Check
Genera I
Maintenance Schedule
Genera I
Maintenance Schedule Check Sheet
Time Intervals
Maintenance Procedures
Genera I
Lubrication
Genera I
Generator Bearing Lubrication
Generator Brush and Commutator Maintenance
General
Brush Service
Loss of Magnetism
Generator Controls Maintenance
Genera I
Over load Re lay
Overvoltage Module
Adjustment and Test
PAGE
l-3 3
2-o 1
2-l 1
1
1
2-2
2-3
4
4
4
4
7
1
Aug 6/‘73 Con tents
Page 3
SUBJECT CHAPTER/SECTION
Genera I 2-3
Testing the Generator Set
,
Pre-Operational Test Procedures
Operational Test
Adjusting the Generator Set
Generator Adjustment
Brushholder Adjustment
Initial Adjustment of Brushholder
Brush Spring Adjustment
Generator Controls Adiustment
Adjust Range of 700-1300 A Current Limiting
Rheostat
Adjust 400 A Current Limit Resistor
Adjust Automatic Mode Resistor
Adiust 60 Hz Operation Resistor
Trouble Shooting
Trouble Shooting Procedures
Genera I
Trouble Shooting Chart
Equipment for Trouble Shooting
Safety
Diagrams
Connections and Wiring
Contents
Page 4
3-o
3-1
PAGE
3
3
5
5
5
5
5
1
1
1
1
1
1
2
2
Aug 6/73
SUBJECT
Chart
II lustrated Parts List
Introduction
Genera I
Purpose
Explanation of Parts List
Contents
Parts List Form
“Figure-Item No. ” Column
“Part Number” Column
“Nomenclature” Column
“EFF” (Effectivity) Column
“Units per Assembly” Column
Parts List
Genera I
Parts List
Generator Set
Control Box Group
Interior Panel Group
Motor Switch Panel
Across-The-Line Switch Assembly
Motor Generator Group
Aug 6/‘73
CHAPTER/SECTION PAGE
3-l
4-o
4-l
4-2
3 thru 7
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
3
5
7
11
13
17
Contents
Page 5
CHAPTER/
SECTION
TABLE OF CONTENTS (CONT’D.)
SUBJECT CHAPTER/SECTION
Brushholder Group 4-2
Exciter Brushholder Assembly
Trailer Group
FIGURE
NUMBER
,
LIST OF ILLUSTRATION S
TITLE
PAGE
19
21
23
PAGE
NO.
l-l
l-l
l-l
l-2
l-2
2-l
2-2
2-2
2-2
2-2
2-3
2-3
1
2
3
1
2
1
1
2
3
4
1
2
Outline, MG-1028 2
Control Pane I Assembly 5
Interior Pane I Assembly 6
Across-The-Line Switch Assembly
Output Cable Connections
2
4
Ma in tenance Schedu le 2
Generator Brush Installation 3
Overload Re lay lnsta I lation 5
Over load Relay Dashpot Assembly 7
Overvoltage P.C. Board Schematic Diagram 8
Brushholder Assembly 4
Current Limiting Adjusting Resistors 6
Contents
Page 6
Aug 6/73
CHAPTER 1. DESCR IPTlON/OPERATION
SECTION 1. DESCRIPTION
1. General
The electric motor-driven aircraft energizer is a se If-contained un it powered by a
squirre I cage induction motor. 1 All of the rotating parts are mounted on a steel shaft,
supported on both ends by ball bearings. The generator and motor housings are bolted
together at the middle of the machine for ease in disassembly. The controls are all
located on top of the generator in a sheet metal control cabinet. The front cabinet
panel contains a hinged door on which are mounted the controls and instruments normally
used by the operator while the machine is in operation. This hinged door opens out
and down, to reveal the inner control panel which contains resistors, relays, etc.,
which are not used by the operator while the machine is in operation. A lifting eye
protrudes through the top of the cabinet to facilitate handling the unit with a crane
or hoist.
2. Special Features
The Model MG 1028 features a current limiting, “Soft-Start” control, recommended
by most turbine-powered aircraft and helicopter engine manufacturers, for protection
of the engine starter shear section. The inrush current may be preset to any limited
value between 700 and 1300 amperes, as recommended by the engine manufacturers.
A special 400-ampere “low” current limiting system is provided for helicopter and
small turbine starting.
3. Standard Unit and Variations
As stated previously, the standard Model MG 1028 is a self-contained, stationary unit,
identified as Specification Number 5651 (S-5651). It is equipped with two “feet”
on the generator housing, and a “pad” on the motor housing, which may be bolted
onto a base or floor configuration.
An optional type of mounting is available, as supplied for Variation 4, which provides
a portable mounting, with towing tongue for tractor towing. Shoe type brakes lock
the front wheels when towing handle is in the upright position.
Another option available as a variation is a change in the electric motor for 50-Hertz
operation at 1450 RPM. This is covered in Variation Number 3. If other variations
become available, or if changes are made, new information will be added at the end
of sections in which the information would normally be located.
Aug 6/73 l-l
Page 1
Outline MG 1028
Figure 1
4. Physical Data
A. Stationary Unit - See Figure 1
Length overa II
Width
Height overall
We’ight
Bolt-down dimensions (length)
Bolt-down dimensions (width)
(A)
(B)
K>
CD)
w
B. Portable Mounted Unit
Length overa I I
Width (outside of wheels)
54-l/4 inches (1378 mm) approx.
32-3/4 inches (832 mm)
Height overall 52-5/8 inches (1337 mm)
Weight 2000 pounds (910 kg)
Tread 28-3/4 inches (730 mm)
Whee I base 32-7/8 inches (835 mm)
Ground clearance 6-3/4 inches (172 mm)
Tires 4.80/4.00x 8
Tire pressure 60 P.S. I.
46-3/4 inches (1187 mm)
18-l/2 inches (470 mm)
44-5/8 inches (1133 mm)
1800 pounds (816 kg)
30-l/2 inches (775 mm)
15-l/2 inches (394 mm)
l-l Aug 6/73
Page 2
C. Generator
Output power rating
Vo I tage
Rated load capacity
Current limiting capability
28.5 KW
28.5 V DC
1000 A @ 100% duty cycle (1250 A for 3 min .)
700 A to 1300 A as required
400 A for helicopter starting
Operating speed 1 1750 RPM
D. Motor
Manufacturer
Type Motor volts
Motor amps
Hobart Brothers Company
Squirre I cage induction
230/460 volts
119/60 amps
E. Protective Devices
Overvoltage relay trips at 32-34 V DC, in 2-10 seconds.
Overload relay trips at 1250 A after 3 minutes.
5. Control Box Assembly
A. General
The control box is a sheet metal enclosure which houses and provides mounting
facilities for generator controls and monitoring instruments. The box is mounted
atop the generator, with a hinged instrument panel which swings down to provide
access to the interior panel, which is mounted inside the control box.
‘B. Control Panel See Figure 2
(1) Controls
The controls are all located on the front panel of the control box. The
panel contains a voltmeter, ammeter, pilot lights, generator ON/OFF
switch, motor ON/OFF switch, voltage adiustment rheostat, starting
current adjustment rheostat and current limiting switch.
(2) Lights
(a) Amber pilot light (2) d in icates that the electric motor driving the gen-
erator is running , when light is lighted.
(b) Green pilot light (1) d in icates that output load contactor is closed. See
(4) (c) below for reference to contactor control switch function.
Aug 6/73 l-l
Page 3
(3) Monitoring Instruments
(a) Voltmeter (8). Th e voltmeter is located in the upper right-hand corner
of the control panel. The purpose of the voltmeter is to indicate the
voltage generated by the energizer. The voltmeter is scaled O-50 V DC.
(b) Ammeter (6). The ammeter is in the upper left-hand corner of the control
panel. The purpose of the ammeter is to measure the amount of current that
I is being supplied by the energizer, and it will indicate only when current
is being delivered. The ammeter is scaled O-1600 amps.
(4) Switches
(4
09
(4
(4
Current Selection Switch (4). A three-position toggle switch used to select
the value of the energizer output current.
Position 1: High current, in the range of 700 to 1300 A. UP position.
Position 2: Constant DC voltage supply at 28.5 volts. CENTER position.
Position 3: Low current (400 A) for helicopter starting. DOWN position. :.,
Automatic/Manual Switch (9). A two-position toggle switch. Its function
is to select the mode of generator operation by applying either automatically
controlled (voltage regulator) or manually controlled (rheostat) excitation
to the generator fields.
Ccntactor Control Switch (10). A three-position toggle-type switch with
positions identified as CLOSE-ON-OFF. Its purpose is to connect or dis-
connect the generator output to or from the output cables to the aircraft.
The top (CLOSE) p OSI eon is spring-loaded and is used only momentarily ‘t’
for closing the load contactor. When in the center (ON ) position, the
switch conducts holding current to the load contactor to maintain it in
the closed position.
Motor ON/OFF Switch (3). A three-position toggle switch with positions
identified as START-RUN-STOP. Its purpose is to start and stop the
energizer motor. The top (START) position is spring-loaded, and is used
only momentarily for motor start-up. The switch returns to center (RUN)
position when it is given freedom to do so.
(5) Control Rheostats
(a) Starting Current Rheostat (5) is used to select the recommended starting
current for various aircraft . Output current is adjustable within a range
of 700 A to 1300 A when the current limit switch (4) (a) is in the “UP”
position.
l-l
Page 4
Aug 6/73
4’
3’
2’
6 7 8 I 7
1. Pilot light - Green 6. Ammeter
2. Pilot light - Amber 7. Manual Adjust Rheostat
3. Motor ON/OFF Switch 8. Voltmeter
4. Current Selection Switch 9. Automatic/Manual Switch
5. Starting Cur ‘r-1 ent Rheostat 10. Contactor Control Switch
Control Panel Assembly
Figure 2
(b) Manua I Adjust Rheostat (7) is used to manually control the generator
field current and thereby adjust the generator output voltage. The
rheostat is connected in the field circuit only when the automatic/
manual switch (9) is in the MANUAL position.
,9
-10
‘I
6. Interior Panel Assembly
The interior panel assembly is mounted vertically inside the control box near the
rear panel. Components are described as follows:
A. Resistors
There are five resistors, (2) (3) (4) (7) and (8) mounted on the interior panel.
Aug 6/73 l-l
Page 5
5 6 7 8 9
2-3-4
I i-------i I I I I 1 I 1 It
I I I-------\ I4 \I3
1. Voltage Regulator 8. Resistor - 20 ohm, 25 watt
2. Resistor - 4 ohm, 100 watt (outer) 9. Automatic Field Flash
3. Resistor - 20 ohm, 100 watt (center)
Relay
10. Arc Suppression Capacitor
4. Resistor - 30 ohm, 100 watt (inner) 11. Overload Relay
5. Terminal Board 12. Load Contactor
6. Overvoltage Module 13. Ammeter Shunt
7. Resistor - 100 ohm, 25 watt 14. Terminal Board
Interior Panel Assembly
Figure 3
(1) Variable resistor (2) 4 ohm, 100 watt is used to adjust field current for automatic
mode operation.
(2) Variable resistor (3) 20 ohm, 100 watt reduces exciter current for 60 Hertz
operation of electric motor.
(3) Variable resistor (4) 30 ohm, 100 watt isused to adjust generator output to
400 A for helicopter starting. This resistor is connected into the voltage regulator
signal circuit when the current selector switch (4, Figure 2) is in the 400 A
position.
l-l
Page 6
Aug 6/“/3
(4)
(5)
Resistor (7) (not adiustable) is connected across the generator output leads
and provides a very small load required to close the differential relay contacts
in the load contactor to make the contactor closing circuit functional and
allow the main contacts to close when desired.
Variable resistor (8) 20 ohm, 25 watt is connected in series with the starting
current rheostat (5, Figure 2) and is used to adjust the operating range of the
rheostat at 700 A to (1300 A.
B. Overvo I tage Modu le
The overvoltage module (6) is a protective device with solid state circuitry which
causes a normally CLOSED relay with the device to OPEN during a condition
of overvoltage in the generator output circuit. The relay contacts are connected
in the circuit which holds the load contactor closed. When an overvoltage con-
dition causes the relay to OPEN, the holding circuit is broken and the load con-
tactor opens automatically to disconnect the load from the generator. The over-
voltage module is adjusted to trip at 32 to 34-V DC, in 2-10 seconds.
C . Ammeter Shunt
The ammeter shunt (13) is connected in the generator POSITIVE output circuit.
Its function is to supply a greatly reduced current for operation of ammeter (6,
Figure 2).
D . Overload Re lay
The solenoid operated, dashpot-type relay (11) protects the generator and output
circuit against overload. The relay contacts are connected in series with the load
contactor holding circuit and are normally CLOSED when the generator is operating
normally. Th ey may be opened mechanically by action of the solenoid plunger
(or armature). A bus bar in the generator positive output circuit acts as a coil
to supply magnetic force for actuation of the plunger. An overload condition
in the output circuit provides sufficient magnetism to lift the plunger against
the retaining force of the dashpot piston and open the relay contacts, thus
breaking the load contactor holding circuit and automatically opening the
load contactor.
The resistive force of the dashpot on the plunger provides a delaying action and
prevents nuisance tripping when the generator is overloaded for short periods of
time, such as aircraft starting, etc.
The overload relay will function to open the load contactor if a load of 1250
amps continues for 3 minutes. Larger load wi II trip the relay in a much shorter
time.
Aug 6/73 l-l
Page 7
E. Automatic Field Flash Relay
The automatic field flash relay (9) and arc suppression capacitor (10) are provided
to adjust field current for the automatic mode. If the exciter output current is too
low, the relay contacts wi II remain closed until the generator voltage reaches
24 V, then the coil in the relay wil I become energized, opening the contacts and
permitting resistor (1Res) to function to control the exciter current. The arc suppression
capacitor (10) prevents the relay,contacts from arcing when opening and closing.
F. Load Con tat tor
The load contactor (12) providesa safe and convenient means of connecting or
disconnecting the generator from the load. Initial power for closing the load con-
tactor is supplied by the generator through the spring-loaded momentary contacts
of the contactor control switch (10, Figure 2).
Holding power to maintain the load cantactor in closed position passes through the
stationary contacts of the control switch, and also through the closed contacts of
the overload relay and the overvoltage module. By this circuitry arrangement, the
holding circuit is broken and the load contactor opened by either fault condition
which causes one of the protective devices to function.
G. Voltage Regulator - See Diagram 430338
(1) General
(a) The voltage regulator (1) is a solid state device designed to provide
regulation of 28-V output on self-excited, DC generators. Means are
also provided for current limiting and line drop compensation.
’ (b) The DC generator voltage is controlled by varying the average generator
field power with what is known as time-ratio control. A power transistor
in series with the field is turned cyclicly on and off, varying the average
field power by controlling the ratio of “on” time to “off” time. The
switching cycle is kept short compared to the field time constant, making
negligible the effect of the switching on the generator voltage.
The switching rate is controlled by varying, with a transistor, the rate at
which a capacitor charges to the firing voltage of a four-layer diode, in
response to the output of a reference amplifier comparing the generator
voltage with a reference voltage.
NOTE: A detailed schematic of the regulator is shown on d-iagram
430338, as applied to a separately excited DC generator.
See theory of operation, which follows.
l-l
Page 8
Aug 6/73
GENERATOR DIVISION HOw.RT BHOTtrtRS COMPAN”
(2) Theory of Operation - Transistor Ql , the series control transistor, is driven
into saturation by transistor Q2, which is biased into saturation through resistor
R8 whenever transistor Q3 is not conducting. This allows current to flow from
the exciter into the generator field through transistor Ql , and at the same time
through diode D5, transistor Q5 and resistor R5 to charge capacitor Cl at
a rate determined by the base drive of transistor Q5. When the voltage across
capacitor Cl reaches the firing voltage of 4-layer diode 02, this diode switches
from a blocking to a conducting state. When diode D2 conducts, current flows
through resistor R7 and the base to emitter junction of transistor Q4, turning
transistor Q4 on. Current then flows from the base of transistor Q3 through
resistor R6 and the col lector of transistor Q4, turning on transistor Q3, and
shunting the emitter-base junction of transistor Q2. Transistor Q2 then turns
off, turning off transistor Ql . The generator field current, sustained by the
inductance of the field, continues to flow through the path provided by diode
D4. After transistor Ql turns off, capacitor Cl discharges through 4-layer diode
D2, resistor R7 and the base of transistor Q4 until the diode current decreases
to below the value required to hold it in its conducting state. Diode D2, tran-
sistor Q4, and resistor R6 are so chosen that transistor Q4 is still saturated
at the minimum holding current of the diode. When the 4-layer diode reverts to
its blocking state, transistors Q4 and Q3, turn off, al lowing transistors Q2 and
Ql to turn on and begin the next switching cycle. The time required for capac-
itor Cl to discharge below the voltage required to sustain the 4-layer diode
current above its holding level, determines the “off” time of the Ql transistor.
The time required for capacitor Cl to charge to the firing voltage of the
4-layer diode is determined by the current passed by the transistor Q5 in response
to its base current through transistor Q6. Transistor Q6 is controlled by tran -
sistor Q8, which compares generator voltage tapped from potentiometer R13
to the voltage of reference diode Dl through its emitter and base. The time
period for which transistor Ql remains “on” between “off” periods is thus
determined by the magnitude of that part of the generator which is compared
to the reference voltage. If the generator voltage rises above the level
at which the regulator is set to regulate, the base potential of transistor Q8
decreases with respect to its emitter, which is clamped by reference diode Dl
at a fixed potential below the generator positive terminal. The current
through the transistor Q8 into the base of transistor Q6 increases, causing
the base current of transistor Q5 to increase through the collector of transistor
Q6. Transistor Q5 conducts a higher charging current to capacitor Cl,
decreasing the time required for the capacitor voltage to reach the firing
voltage of 4-layer diode D2 and the time period for which transistor Ql
conducts becomes shorter. The resulting decrease in the “on ” time of tran-
sistor Ql , with respect to its “off” time, reduces the average generator
field power to the level required to maintain generator voltage at its reg-
u lated leve I. If the generator voltage decreases be low its regulated value,
the base potential of transistor Q8 rises with respect to its emitter, resulting
in a decrease in the current of transistors Q8, Q6, and Q5. Thecharging
Aug 6/73
,
l-l
Page 9
rate of capacitor Cl decreases, resulting in longer “on” time intervals for
transistor Ql , and an increase in average generator field power to the level
required for the generator voltage to return to its rated value.
The regulating voltage may be adiusted with potentiometer R13, since the
regulator acts to keep the voltage constant between generator positive and the
slider of the potentiometer. Moving the slider towards the positive end of the
potentiometer increases generator voltage, toward the negative end decreases
generator voltage. Resistor R14 serves to bias the current in reference diode
Dl above its threshold or “knee ” current, even if transistor Q8 is biased com-
plete ly off. Line drop compensation is obtained by subtracting generator
interpole winding voltage drop from the sensed voltage through potentiometer
R9. Since the interpole winding drop and output cable drop are both pro-
portional to current, this circuit permits flat voltage regulation at the load
end of the ‘cables, by causing generator terminal voltage to rise to an amount
equal to cable drop voltage, when a load is applied.
Generator current limiting is also derived from the interpole winding voltage
drop. Part of this voltage drop is applied through resistors RlO and R 11 to the
emitter to base junction of transistor Q7. When the generator current reaches
a magnitude such that the voltage between the generator positive brush and the
slider of Rll exceeds the threshold voltage of its emitter-base diode the tran-
sistor conducts, allowing current to flow through resistor R3 into the base of
transistor Q6. This results in a decreased regulator output and a steeply dropping
generator output characteristic when the generator current exceeds a preset
value.
Provisions have been made to allow dual voltage operation of the regulator.
When the slider potentiometer R15 is connected to machine negative, the
voltage regulating range is shifted to its 14-volt range.
l-l
Page 10
Aug 6/73
SECTION 2. INSTALLATION
1. Preparation for Use
A. General
The generator set is shipped in operating condition and ready for use after inspec-
tion and checking for possible damage in shipping. Power supply cables and
I generator output cables must be suppliedand connected to the unit prior to use.
These are not supplied with the unit.
CAUTION : READ OPERATING INSTRUCTIONS IN SECTION l-3, BEFORE
OPERATING THE UN IT.
B. Inspection/Check
(1) Remove crating, blocking, banding, ties and other securing and protective
materia I.
(2) Inspect exterior for shipping damage such as broken meters, damaged sheet
meta I, etc.
C. Installation of Unit
(1) General
When installing the machine avoid, whenever possible, locations exposed
to high humidity or dust. Moisture condenses on generator parts and electrical
controls, causing corrosion which can seriously affect operation and efficiency.
Dust and dirt cause needless extra wear on all moving parts. Care should,
therefore, be taken to locate the machine so that there will be as little
opportunity as possible for excessive moisture, dust or corrosive fumes to be
drawn into the energizer.
(2) Wiring
(a) Remove the top of the control cabinet, after unscrewing the lifting
eyebolt, and removing it.
(b) Locate the connection terminals Ll, L2 and L3, on the across-the-line
switch assembly (see Figure 1) and ground (GND) stud.
(c) Check the position of the changeover (stator) links, located below the
switch assembly (above, paragraph (b) for voltage supply. See wiring
diagram in Chapter 3 of this manual.
Aug 6/73 l-2
Page 1
; QO
_... _.I.. --..-..e..I.. - ._.-._. 2 Y . *OHAH, B”“,,<, “S COMP&NI “0 c‘ +, 9. s,,+c
NOTE: Links are positioned in a vertical arrangementfor 230-V power supply;
and in horizontal arrangement for 460-V supply.
CAUTION : BE SURE THAT THE POWER SUPPLY IS CONNECTED THROUGH
A FUSED DISCONNECT SWITCH (FURNISHED BY THE CUS-
TOMER) AND THAT THE WIR IN G TO THE MOTOR IS OF
SUFFICIENT SIZE TO CARRY THE LOAD. CHECK THE FOLLOW-
ING DATA,:
Motor Size: 50 HP
Approx. Line Fuse Rating:
230 V 400 Amp
460v 200 Amp
Min. Size Wire - Rubber Insulation:
230 V #3/o
460v #3
CONNECTION TERMINALS
Ll, L2 AND L3
GROUNDING
/
STUD
Across-The-Line Switch Assembly
Figure 1
l-2 Aug 6/‘73
Page 2
(d) Power supply cables enter the cabinet through holes near the top, on the
right-hand end panel of the cabinet (facing instrument panel). Pass the
cables through the holes before connecting onto the terminals, to allow
the top of the control cabinet to be replaced in position.
D. Output Cable Installation
Units are normally supplied without a generator-to-aircraft cable.
(1) Cable requirements
Cable length is determined by the customer’s requirements. It is recommended
that the cable be no longer than 40 feet. The cable should be two conductor
with lug-type terminals on one end and an AN-2551 plug connector on the
other end.
Recommended conductor size for 28.5-V DC and continuous rated amperage
(1000 A) is #4/O size.
NOTE: Some operators may wish to add a second cable assembly with
MS-25019 plug connector for starting aircraft such as Jetstar
and Sa bre I iner .
(2) Cable connections - See Figure 2
Connect the two conductors to the bus bar connections on the backside of the
interior pane I. Use capscrews, washers and nuts, and tighten securely to the
connections.
Store the cable assembly on hangers at rear of the control cabinet.
NOTE: Output cables exit from the cabinet through elongated holes in
left-hand end panel of the cabinet (facing instrument panel).
E. Portable Mounting
Mount the energizer on the portable mounting as follows:
(1) Remove the wooden skid from under the energizer unit.
(2) Lift the energizer with a hoist until the rear axle assembly, with wheels
can be fitted under the feet of the generator housing.
(3) Securely fasten the rear axle to the feet of the generator housing.
Aug 6/73 l-2
Page 3
rPOSITIVE CONNECTION
-NEGATIVE
CONNECTION
Output Cable Connections
Figure 2
(4) Locate the front axle, with wheels, under the front mounting plate on the
motor housing. Attach the front axle to the plate by means of the bolt, nut,
and cotter key provided.
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 externa I parts from rust and corrosion.
A. The unit should be prepared for storage as soon as possible after being removed from
service.
B. Storage should be in a building which is dry and which may be heated during
winter months.
C. Moisture absorbing chemicals 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.
1-2
Page 4
Aug 6/73
SECTION 3. OPERATION
1. Genera I
This section contains information and instructions for the safe and efficient operation
of the generator set. Operating instructions are presented in a step-by-step sequence
of procedures to be followed in supplying 28.5-V DC to an aircraft.
NQTE: Read ALL of the operating instructions before attempting to operate
the equipment.
2. Startina
A. To start the electric motor-driven energizer, place the MOTOR, 3-position
switch in START (Up) position.
NOTE: This toggle switch is momentary contact type switch. Hold it UP
until motor starts, and then release it to the RUN position. Amber
light (2, l-l, Figure 2) should glow.
B. The armature of the machine should rotate in the direction indicated by the
arrow on the front panel below the nameplate. lf it does not, place the motor
switch in STOP (Down) position, throw the disconnect switch (see CAUTION,
Section 2, page 1, under C (2).
C. To reverse the direction of rotation, reverse the connections of any two of the
incoming power lines, either at the disconnect switch or at the motor switch.
(See Figure 1 and text under (2) Wiring, Section 2, page 1.)
3. Power De livery
There are several methods of power delivery including (1) Constant 28.5-V DC Voltage,
(2) Limited Current (Soft-start), (3) Helicopter Starting and (4) Manual Voltage Con-
trol. Each mode of operation will be described below.
NOTE: Refer to l-l, Figure 2 for reference to item call-out numbers, if not
otherwise identified.
A. Constant 28.5-V DC Power Delivery
Output voltage to the aircraft (power consuming end-item) will be automatically
regulated at approximately 28.5-V DC by the voltage regulator. (Ref. Section
l-l, Figure 3, item 1)
(1) Place the current selection switch (4) in CONSTANT VOLTAGE (Center)
position for this mode of operation.
Aug 6/73 l-3
Page 1
(2) Place the automatic-manual switch (9) in AUTOMATIC (Up) position.
(3) Check to make sure that the aircraft (power consuming end-item) is ready
to receive power from the energizer.
NOTE: Current selection switch (4) and fie Id rheostat (7) are non -functiona I
in the constant voltage mode.
(4) <Place the MOTOR switch (3) in START position, and hold momentarily
until pilot light (2) glows amber. Release switch to RUN position.
(5) To apply power to the aircraft, close the load contactor control switch (10)
(Generator) by holding the switch in CLOSE (Top) position momentarily, until
indicator light (1) glows green. Release switch and a I low it to return to ON
(Center) position. Light (1) should continue to glow, indicating that the load
contactor is closed, and that power is available at the generator output.
B. Limited Current Power Delivery
Not all aircraft engine starters require the same cranking current. In the limited
current mode, the current output is adiustable from 700 A to 1300 A, by means
of the current selection switch.
(1) Place the current control switch (4, l-l, Fig. 2) in CURRENT LIMITING (Up)
position.
(2) Place the automatic-manual switch (9, l-l, Fig. 2) in AUTOMATIC (Up)
position.
NOTE: A voltage value of approximately 28.5-V DC should be indicated
on the voltmeter.
(3) Check to make sure that the aircraft is in ready condition to receive power
from the generator.
(4) Place the MOTOR switch (3) in START position, and hold it momentarily
until pilot light (2) glows amber. Release switch to RUN position.
(5) Adiust starting current rheostat to current required, within the range of 700 A
to 1300 A. Set to maximum current desired.
(6) To apply power to the aircraft, follow instructions in A, (5), above.
C. Power Delivery for Helicopter Starting (400 A)
Helicopter and small turbine starting requires a low current limiting capability
not possible by using the current limiting rheostat (5). For helicopter starting,
proceed as follows:
l-3 Aug 6/73
Page 2
(1) Place automatic-manual switch (9) in AUTOMATIC (Up) position.
(2) Place the current limiting switch (4) in 400 A (Down) position. In this switch
position, the current limiting rheostat (5) is by-passed and the maximum out-
put of the generator is limited to approximately 400 A.
(3) To apply power to the aircraft, follow instructions in A, (5), above.
D, Power Delivery With Manual Voltage Control
This mode of operation is recommended for generator testing, or for emergency
use in case of voltage regulator trouble only. For manual control of generator
output voltage, use normal operating procedures, except:
(1) Place automatic-manual switch (9) in MAN UAL position.
(2) Use the rheostat (7) to manually regulate voltage at 28.5-V DC. Turn knob
clockwise to increase voltage, and counterclockwise to reduce voltage.
4. Discontinue Power Delivery
A. Place load contactor control switch (10) in OFF (Down) position. Light (1)
should go off to indicate load contactor has opened, and power is no longer
available at the energizer output cables.
B. Place motor switch (3) in STOP (Down) position.
C. Disconnect cable plug from the aircraft receptacle and store cable on hangers
at rear of control cabinet.
Aug 6/73 l-3
Page 3
l-3
Page 4
Aug6,'73
CHAPTER 2. SERVICING
SECTION 1. MA INTENANCE INSPECTION/CHECK
1. Genera I
To make certain the generator set is always in good operating condition,
spected, maintained and lubricated regularly and systematically.
WARN ING: STOP OPERATION AT ONCE IF A SER IOUS OR POSSIBLY
DANGEROUS FAULT IS DISCOVERED.
it must be in-
2. Maintenance Schedule
A. General
A periodic maintenance schedule should be established and maintained. A suggested
schedule is provided in Figure 1. It may be modified as required to meet varying
operating and environmental conditions.
B. Maintenance Schedule Check Sheet
It is strongly recommended that the customer use a maintenance schedule check
sheet. The check sheet will provide a record of maintenance operations performed
and may also serve to improve scheduling for a specific operation.
C . Time Intervals
The schedule is based on both hours of operation and calendar intervals. These
two interva Is are not necessarily the same. The calendar period is included to
make certain services are performed regularly when equipment is being operated
less than normally. Perform all services on a “whichever comes first” basis.
CAUTION: WHEN CLEANING THE UNIT, DO NOT USE A HIGH PRESSURE
SPRAY WITH SOAP OR DETERGENT, OR STEAM CLEANER ON
THE GENERATOR OR OTHER ELECTRICAL EQUIPMENT. IF
SOAP ENTERS THE GENERATOR BEARING, ITS LIFE WILL BE
SHORTENED. DETERGENT AND STEAM MAY ALSO PENETRATE
OTHER E LECTR ICAL EQUIPMENT AND CAUSE CORROSION,
RUST, SHORTING, ETC.
Aug 6/73 2-l
Page 1
Check indicating I ight
Check operation of all instruments,
meters, etc.
Check generator brushes for length,
clean I iness, and free operation
Check commutator for smoothness
and cleanliness
Check overload relay dashpot
Clean the entire unit
Check overload protection
Check overvoltage protection
Check all wiring and connections
10 Hrs.
or
Daily
X
X
100 Hrs.
2 ;ks.
X
Maintenance Schedule
Figure 1
LOO Hrs.
I Go.
400 Hrs.
2 Go.
X
X
t 300 Hrs.
6’;o.
X
X
X
X
2-l
Page 2
Aug 6/73
SECTION 2. MAINTENANCE PROCEDURES
1. Genera I
A suggested Maintenance Schedule was provided in Section 1 of this Chapter. This
Section covers maintenance in more detail where necessary.
WARN ING: STOP OPERATION Af ONCE IF A SERIOUS OR POSSIBLY SERIOUS
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 the adherence to the
proper time schedule.
B. Generator Bearing Lubrication
There are only two places on the generator unit which require lubrication. These
places are the two end bearings which support the armature shaft. These bearings
are packed withenough grease when the machine leaves the factory to last 6 to
8 months under most severe use. After this initial period, the manufacturer suggests
that the bearings be lubricated twice yearly.
(1) Procedure
(a) To lubricate the bearings, remove the bearing caps from both motor and
generator housings. Remove the three bolts that hold the bearing caps
in place.
(b) Remove as much old grease as possible, and wash out the bearing and cap
with kerosene or warm diesel fue I. DO NOT use gasoline.
(c) Fill clean bearing cap about l/3 full, and fill the bearings 50 to 75%
full of recommended bearing grease. See paragraph (3) be low. Place cap
in position and tighten bolts securely.
(2) Cleanliness
DO NOT inspect or lubricate the bearings more often than every six months.
Always wipe area clean around the bearing cap before removing it.
Aug 6/73
__. _,_,
2-2
Page 1
(3) Lubricant
Ordinary cup grease is not a satisfactory lubricant for ball bearings. Use only
a clear, non-corrosive, heat-resistant, medium-bodied grease recommended for
ball bearings. Such a grease, H B-354, is available from Hobart Brothers in
l- and 5-pound containers. DO NOT use a graphite lubricant.
3. Generator Brush and Commutator Maintenance
A. General
The only maintenance service required for the generator will be brush replacement,
commutator clean ing , etc.
B. Brush Service
(1) Cleaning
If inspection reveals that brushes are gummy or sticking in the brushholders, they
should be removed and cleaned. Clean both the brushes and brushholders. Use
a good, SAFE, commercial cleaner. DRY ALL PARTS THOROUGHLY. Be sure
brushes can move freely in brushholders.
WARN IN G: DO NOT USE A FLAMMABLE SOLVENT. DO NOT USE STEAM
CLEANER, OR SOAPS AND DETERGENTS UNDER PRESSURE.
(2) Replacement
Brushes for this application are l-3/4 inches long when new. They should be
replaced when worn to one-half their original length, or 7/8 inch.
(4
04
(4
(4
(4
2-2
Page 2
Remove pigtail attaching screw.
Move brush spring (1, Fig. 1) aside and remove old brush (3).
Check new brushes before installation. Size must be 3/4 x 1 x l-3/4
inches long.
Move brush spring aside and install new brush.
NOTE: Check position of brush pigtail and install so that pigtail
is on the forward side of the brush.
Check the clearance between brush and brushholder. The brush should
move up and down freely in the holder, yet without excessive side-to-side
or fore-and-aft movement.
Aug 6/73
1 . Spring
2. Pigtail
3. Brush
4. Nut
5. Spring mounting
adapter
6. Wrench
6 4’
Generator Brush lnsta I lation
Figure 1
(f) Connect the pigtail. A single screw attaches two brush pigtails.
(g) Repeat steps (a) through (f) for other brushes.
(3) Brush seating
When replacing brushes, it is important that they be carefully fitted to the
commutator ring. The seating stone method of brush seating is recommended
for this installation.
Seating stones are fine-grain, abrasive blocks made especially for brush
seating. When applied to the commutator, fine particles from the stone
drift under the brush and shape its face to the same curve as the commutator.
(a) Start the motor and operate the generator with no power output.
(b) Hold the stone against the commutator immediately behind the brushholder
so that stone particles will be carried directly under the brush. Steady the
stone by holding it against the brushholder.
(c) Seating may be speeded up by applying extra pressure on the brush.
WARN IN G: EXERCISE CARE TO AVOID IN JURY BY THE ROTAT-
IN G EQUIPMENT OR E LECTR ICAL ‘SHOCK,.
Aug 6/73 2-2
Page 3
(d) Use only dry compressed air to blow out any grit or foreign material.
CAUTION: DO NOT APPLY A FULL LOAD UNTIL BRUSHES HAVE
RUN-IN FOR APPROXIMATELY ONE HOUR AT 300 TO
400 A LOAD.
(4) Brush springs
Refer to Section 2-3, Page 4, Para. 3, A, (3) for brush spring adjustment instruc-
tions.
(5) Commutator cleaning
One of the best ways of cleaning the commutator is to use a piece of clean,
hard-woven canvas, attached to, or folded cn a wooden stick. Hold the
canvas against the rotating commutator until dirt and smudge are removed.
Another effective method of cleaning and smoothing the commutator is the
use of a flexible abrasive block especially manufactured for commutator
cleaning. When held against the revolving commutator, the block wil I
quickly remove deposits of dirt and grease.
Operate the generator at 300 to 400 A load for approximately one hour to
allow a film to form on the commutator after cleaning.
C . Loss of Magnetism
In isolated cases, the exciter loses its residual magnetism in shipment, with the
result that no voltage is generated. This condition is corrected by raising the exciter
brushes and applying an outside source of DC voltage, not in excess of 110 V, for a
few seconds, to the exciter brushes of opposite polarity. This sets up a magnetic
field which leaves enough residual magnetism to cause the exciter to build up by
itself when the brushes are again lowered on the commutator. If, after the outside
DC voltage has been applied, the exciter still fails to generate voltage, again
raise the brushes and reverse the outside voltage through the exciter brushes.
4. Generator Controls Maintenance
A. General
The overload relay dashpot (2, Fig. 3) is the only component of the control system
which requires periodic inspection and maintenance.
B. Overload Relay
The entrance of water into the dashpot or the use of improper fluid may cause operating
troubles requiring disassembly and repair of the dashpot assembly. The foIlawing
instructions include repair procedures in the recommended sequence of steps.
2-2 Aug 6/73
Page 4
(1) Disassemble
(a) Hold the dashpot and unlatch the spring clamp (4) by prying with a screw-
driver to swing the clamp forward. Lower and remove the complete dash-
pot assembly.
(b) Lift the core (l), cover (2),
an assembly.
and valve plate (6) out of the dashpot (3) as
(c) Pour the dashpot fluid into a clean glass container and inspect for signs
of water.
NOTE: Moisture may condense in the dashpot to form water which
wil I cause corrosion of the valve plate and dashpot.
CONTACTS
BUS BAR
(28.5 V OU
PLUNGER
DASHPOT
Over load Re lay lnstal lation
Figure 2
Aug 6/73
TPUT)
2-2
Page 5
(2) Inspection
Inspect the valve plate (6) and the dashpot (3) for evidence of corrosion. Discard,
if corroded, and replace with new parts. Observe the position of the two valve
plate covers. One is diamond shaped and retains two steel balls (5). This cover
should not be disturbed. The other plate serves to cover the valve plate by-pass
holes, and MUST be positioned to completely COVER and CLOSE the holes.
(3) Assemble *
(4
(b)
(4
(4
(e )
( f )
Pour a sufficient quantity of new fluid into the dashpot to cover the
circular ridges in the bottom. Use a silicon fluid witha viscosity rating
of 100 centistokes at 25OC.
Approved fluids are:
Dow-Corning No . 200 ( 100 ten tistokes)
Allen-Bradley No. 810-N9B, Series A
Allen-Bradley No. X-106518
NOTE: Allen-Bradley numbers indicate different container sizes.
Install the valve plate (6) and core (1) as an assembly. Make certain that
the valve plate “bottoms” in the dashpot.
Add fluid until the surface of the fluid is leve I with the tops of the three
cylindrical projections on top of the valve plate. Actuate the piston a
short distance up and down to expel any air trapped below the plate. Re-
check the fluid level and add fluid if required.
Install the dashpot cover (2).
Make certain the valve plate (6) is “bottomed” in the dashpot and measure
the height that the core protrudes above the rim of the dashpot. The core
must extend 3/4 inch above the dashpot rim. Increase the height by turn-
ing the core in a counterclockwise direction. Decrease the height by turn-
ing the core in a clockwise direction. Turn the core a full turn at a time
and be sure the lock spring (7) is seated in the valve plate stud groove when
the adjustment is completed.
Position the dashpot assembly in the overload relay and lock in place with
the spring clamp (4).
Aug 6/“73
Rev. Apr 26/74
I
1. Core (plunger)
2. Cover ,
3. Dashpot
4. Spring clamp
5. Steel balls
6. Va Ive plate
7. Lock spring
2
LEVEL
Overload Relay Dashpot Assembly
Figure 3
C. Overvoltage Module
The overvoltage relay contacts are part of the solid state module, and in case of
malfunction, the printed circuit board should be replaced. (Module-PC Over-
voltage Board 389522A is listed in Parts List. )
To test overvoltage module:
(1) Supply fused and filtered DC power, 20 to 40 volts (adiustable), to plus (+)
and minus (-) terminals on P.C. Board.
(2) Connect ohmmeter across terminals P and T, Figure 4.
(3) Adjust (Pl) potentiometer to trip relay at 32 volts in 2-10 seconds. No trip
at 31 volts.
(4) With 35 volt input, check for trip time to be approximately 1 second.
NOTE: See Trouble Shooting Chart, Chapter 3, Section 1, for test on
overvoltage relay.
Aug 6/73 2-2
Page 7
R2 I.2Kn
PI IKll
R3 4.7Kr
--
1 cI+Tg 1 I I
R6 22Kn
. -lA 2N-3903
4 .W F
R8 270n 02 TD----J
RIO 15Odl.
Overvoltage P. C. Board Schematic Diagram
Figure 4
.c.;
2-2
Page 8
Aug 6/73
SECTION 3. AD JUSTMEN T/TEST
1. Genera I
These adjustment and test procedures are most applicable to testing and adiusting the
generator set after major repair, replacement of parts, long storage, etc.
2. Testing the Generator Set ,
A. Pre-operationa I Test Procedures
Perform the following checks, tests, and operations before starting the unit.
(1) Connect cables from the generator output terminals to a load. Use cables
of the same size and length as those to be used in service, preferably size 2/O,
and not more than 30 feet long.
(2) Make a general inspection of all wiring and connections to find any obvious
incorrect wiring, loose wires, and loose or shorted terminal lugs.
(3) Set manual control rheostat (7, Sect. l-l, Fig. 2) to MIN IMUM position *
(4) Set automatic-manual switch (9, Sect. l-1, Fig. 2) to MANUAL position.
(5) Check panel lights (1 and 2, Sect. l-l, Fig. 2).
B. Operationa I Test
(1) Start electric motor as described in Chapter 1, Section 3, Page 1, Sub-section
2.
(2) Check and record manual rheostat range which should be approximately 2 V DC
minimum to 49 V DC maximum as observed on voltmeter (8, Sect. l-l, Fig. 2).
Reset rheostat at 28.5-V DC.
(3) Place contactor switch (10) in top CLOSE position momentarily. Release, and
allow switch to return to center ON position. Load contactor should CLOSE
and indicating light (10) should glow green.
(4) If brushes have been replaced, proceed as follows:
(a) Use brush-seating stone to seat brushes.
(b) Apply a load of 300 to 400 A and allow brushes to “run-in” for a minimum
of 1 hour.
Aug 6/73 2-3
Page 1
(5) Adjust brushholder to give 27.5 to 28.5 V at 750 A load when no-load voltage
is set at 28.5 with manual control rheostat. (See Para. 3, A, (1) for adjustment
procedures. )
(6) Check overload relay trip time at 1250 A. Should trip in approximately 3
minutes. (See Sect. 2-2, Page 4.)
(7) Check overvoltage relay. Should trip at 32 to 34 V DC. (See Sect. 2-2,
Page 7.)
(8) Place automatic-manual switch (9, Sect. l-l, Fig. 2) in AUTOMATIC
position. Adjust rheostat on voltage regulator to 28.5 V DC (see attached
voltage regulator instructions).
(9) Place current-limiting rheostat (5, Sect. l-l, Fig. 2) in MAXIMUM position
and current-limiting selector switch (4) in 700-1300 A position.
(10) With a 900-1000A I d oa applied, turn current-limiting rheostat counterclockwise
until ammeter indicates 700 A. The knob pointer should be at 700 A on the dial.
If not, set the movable pointer to 700 A on dial.
(11) Check current limiting at 700, 1000, and 1300 A.
(12) Place current-limiting switch (4, Sect. l-l, Fig. 2) in 400 A position. Check
current limiting at 400 A for helicopter service.
(13) Check voltmeter accuracy. Error must not exceed 2% full scale.
(14) Check ammeter accuracy. Error must not exceed 4% full scale.
3. Adjusting the Generator Set
A. Generator Adjustment
The brushholder assembly and the brush hold-down springs may require adiustment if
the generator is disassembled, or if parts are replaced.
WARNING: DO NOT MAKE ADJUSTMENTS WHEN THE GENERATOR IS RUNNING.
(1) Brushholder adiustment
The brushholder assembly is mounted in a machined, circular seat in the rear of
the generator housing. The brushholder mounting ring is held in the seat by clamps
and the entire brushholder assembly may be rotated when the clamps are loosened.
To adjust, proceed as follows:
2-3 Aug 6/73
Page 2 Rev. Apr 26/74
(a) With generator running at no load and automatic-manual switch (9, Sect.
l-l, Fig. 2) in MAN UAL position, use manual control rheostat (12) to
adiust voltage to 28.5 V.
(b) Apply a load of 750 A and check output voltage. If voltage is 27.5 to
28.5 V, the brushholder is properly adjusted. If voltage is below 27.5
V, or above 28.5 V, adjustment is required.
(c) Stop generator and scribe a mark on the brushholder mounting ring, and
on one of the seat bars to determine a starting point for adjustment.
(d) Loosen brushholder clamping screws (2, Sect. 2-3, Fig. 1) and rotate the
brushholder (1) in the direction of armature rotation to REDUCE voltage,
or opposite the direction of rotation to INCREASE voltage. Do not rotate
the brushholder more than l/8 inch without rechecking voltage. Tighten
clamping screws (2) before starting generator.
(e) Start generator and repeat steps (a), (b), (c), and (d) as required until a
satisfactory adjustment has been made.
(f) Be sure clamping screws (2) are securely tightened at conclusion of
adjustment.
(2) Initial adjustment of brushholder
In the event that the generator is disassembled and the brushholder assembly is
removed, locate the brushholder as follows:
(a) Rotate armature so that an armature slot is directly under an interpole
piece. Carefully observe and trace the wires which lead from the winding
in the slot to a commutator segment (5, Sect. 2-3, Fig. 1). Rotate the
brushholder ring (1) so that a row of 4 brushes is directly over this segment.
Tighten brushholder clamping screws (2).
N OTE: Exercise care in tracing the armature to commutator wire
because the wires run at an angle and not directly to a
commutator segment . It may be possible to detect yellow
paint marks on the armature slot and the commutator riser
which were used to position the brushholder originally. If
these marks can be found, it will make brushholder adjust-
ment easier.
(b) Make final adjustment in accordance with Para. 3, A, (l), above.
(3) Brush spring adiustment
Recommended spring pressure is 18 to 30 ounces measured along an imaginary
line which passes through the center of the brush and the center of the com-
Aug 6/73 mutator. 2-3
Page 3
Brush spring pressure is very difficult to measure accurately. Since spring
pressure is not critical as long as it is sufficient to prevent brush bouncing
and not great enough to cause excessive mechanical, brush wear, it is recom-
mended that springs be adjusted by feel. Adjust as follows:
(a) Make certain that the brush is free to move in the holder.
(b) Lift the spring away from the brush with the finger. If the spring is exerting
firm, but not excessive pressure on the brush, adjustment is not required.
(c) If spring pressure feels weak on the brush, loosen nut (Sect. 2-2; 3, Fig. 7)
and turn spring adapter (5) toward the brush (arrow direction). Tighten
nut (4).
(d) If spring pressure feels excessive, loosen nut (4) and turn adapter (5) away
from brush (opposite arrow direction).
NOTE: The adapter (5) must be held in its new adiusted position while
tightening (or loosening) the nut (4).
RMATURE OTAT ION
1. Brushholder mounting
2. Clamp screw
3. Clamp
4. Seat bar
5. Commutator segment
ring
Brushholder Assembly
Figure 1
Aug 6/73
4. Generator Controls Ad justmen t
Various generator controls may require adjustment following replacement of parts, repair,
etc. Adjustment procedures are listed as follows:
A. Adjust Range of 700-1300 A Current Limiting Rheostat
The resistor (3RES) (8, Seot. 2-3, Fig. 2) is used to adjust the current limiting
I range of the rheostat (5, Sect. l-l, Fig. 2) to 700 to 1300 A. Adjust as follows:
(1) To increase the current range value, move slider (9, Sect. 2-3, Fig. 2)
to right.
(2) To decrease current range value, move slider (9) to the left.
(3) Recheck voltage range after each adjustment.
NOTE: When adiustment is completed as indicated by the ammeter,
it may be necessary to readjust the rheostat (5, Sect. l-l,
Fig. 2) pointer so that it will point to the same amperage
value as indicated by the ammeter.
B. Adjust 400 A Current Limit Resistor (4RE S) (I nner of three stacked resistors)
This resistor (5, Sect. 2-3, Fig. 2) is used to adjust the 400 A current limiting
system so that the maximum generator output power will be 400 A when the current
limiting selector switch (4, Fig. 2) is in 400 A position, for helicopter starting.
The normal initial setting of the slider (6, Sect. 2-3, Fig. 2) on this resistor
is l/8 inch (3.2 mm) from the top end.
(1) Move the slider (6, Sect. 2-3, Fig. 2) DOWN to increase current.
(2) Move the slider (6) UP to decrease current output.
C. Adjust Automatic Mode Resistor (2RES) (Outer of three stacked resistors)
This resistor performs the function of limiting current in the generator field circuit.
Setting is in mid-position for 2 ohm resistance.
D. Adiust 60 Hz Operation Resistor (1RES) (Center one of three stacked resistors)
This resistor is factory-set for 10 ohms, in the exciter field circuit. Used when
generator set is in use on 60 Hertz power.
Aug 6/73 2-3
Page 5
1. Automatic mode resistor (2RES)
2. Slider
3. 60 Hz operation resistor (IRES)
4. Slider
5. 400 A current limiting resistor (4RE S>
6. Slider
7 8: Non-adjusting resistor (5RE S) 700 to 1300 A current limiting resistor (3RES)
9. Slider
10. Interior panel
Current Limiting Adiusting Resistors
Figure 2
Aug 6/73
2-3
&age 6
CHAPTER 3. TROUBLE SHOOTING
1.
SECTION 1. TROUBLE SHOOTING PROCEDURES
Genera I
2.
3.
4.
Trouble shooting is an orderly process of checking and eliminating possible causes of
trouble until the exact cause ‘of a trouble is found. As a rule, the best place to start
looking for the cause of a trouble in a circuit is at the source of power. Continue
testing and checking the circuit, step-by-step, in an orderly manner, until the cause
of trouble is located. See connection and schematic diagrams.
Trouble Shooting Chart
A. Description
The trouble shooting chart lists information under three headings:
(1) Trouble, symptom, and condition
(2) Probable cause
(3) Test, check, and remedy
B. Use of the Trouble Shooting Chart
Read the trouble symptoms and conditions before proceeding to causes and remedies.
With problem known, locate trouble in TROUBLE, SYMPTOM and CONDITION
column, and check PROBABLE CAUSE and TEST, CHECK and REMEDY columns.
Equipment for Trouble Shooting
A good quality multi-scale voltohmmeter is the only instrument required for trouble
shooting. At least two “iumper” leads with “alligator”, or similar clips, will be
required. The 12-V, engine electrical system may be used for a 12-V DC power
source.
Safety
WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT WITH ELECTRICAL
CIRCUITS AND REVOLVING EQUIPMENT WHICH COULD CAUSE
SERIOUS IN JURY IF TOUCHED WHEN TROUBLE SHOOTING OR
OPERATING THE EQUIPMENT.
Aug 6/73 3-l
Page 1
5. Diagrams
A schematic diagram of the generator set is provided, following the Trouble Shooting
Chart. This diagram can be very helpful in trouble shooting. Components shown in the
diagram are identified by symbols (or item names in some instances). A legend appearing
on the diagram identifies each electrical symbol by its full item name. For example,
the symbol, “OV” identifies the overvoltage relay, and “VM” identifies the voltmeter. ,
6. Connections and Wiring
Before condemning any electrical component, check all connections and wiring which
could affect its operation. In many instances a component may be non-functional simply
because it is not receiving power because of a loose connection or a poor ground. In
most cases throughout the trouble shooting chart, it will be assumed that connections
and wiring have been checked.
A Connection Diagram follows the Trouble Shooting Chart, also. Consult it for reference
to power supply and output.
3-1
Page 2
Aug 6/“73
GENERATOR DIVISION “OB*HT “ROIU~RS COMPI\N”
TROUBLE JYMPTOM
AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY
GENERATOR AND ( >NTROLS
1. Generator will
not build-up-volt
age I
Automatic-manua
control switch in
the AUTOMATIC
position. Motor
running normally.
A. Defective field flash relay
,
B. Defective automatic-
manual switch
C. Defective voltage reg-
u lator
A. Replace relay (FFR)
NOTE: If voltage does not build-up
by replacing the relay above, the
trouble may be in the generator, or in
the voltage regulator and excitation
circuit.
B. Place automatic-manual control
switch (9, l-l, Fig. 2) in
MANUAL position. If voltage will
now build-up, it proves that the
generator is good, and that the
trouble is in automatic section of
automatic-manual switch, or in the
voltage regulator. Return switch
to AUTOMATIC position. Connect
a jumper lead across the contacts
on the automatic side of the switch
If voltage will now build-up, re-
place the automatic-manual control
switch.
Z. If voltage would not build-up when
automatic contacts of switch were
jumpered (in step B, above) trouble
is in the voltage regulator. Re-
place the voltage regulator.
3
Aug 6/73 3-l
Page 3
GENERATOR DIVISION HOBART BROI,ILRS COMPPlN”
TROUBLE, SYMPTOM,
AND CON D ITION PROBABLE CAUSE
GENERATOR AND CONTROLS (CONTINUED)
TEST, CHECK, AND REMEDY
2. Generator will not A. Defective automatic- A. Connect a jumper lead across
bui Id-up voltage manual switchI MANUAL contacts of switch
(1s). If generator will now
Automatic-manual bui Id-up voltage, replace
control switch in switch (1s) (9, l-l, Fig. 2).
MANUAL position. If voltage will NOT build-up,
Motor running proceed to step B.
normally.
B. Defective manual control B. Connect a jumper lead across the
rheostat (1RH) manual control rheostat. If gen-
erator will now build-up, re-
place the rheostat (9, l-l, Fig.
2). If not, proceed to step C.
C. Defect in generator C. If generator would not build-up
voltage during steps 2, A and B
above , it indicates the generator
is defective. Check for open
circuited shunt fie Ids.
3. Load contactor will A. Defective resistor (SRES) A. The load contactor requires a
not close when gen - slight load on the output circuit
erator (load con - to close the differential contacts
tactor) switch (10, and allow the ccntactor to be
l-l, Fig: 2) is closed. Resistor (!5RE S) provides
placed in CLOSE this load when output cables are
position. Motor not connected to a load. Check
running, NO load this resistor (Sect. l-l, Page 7)
applied to output and replace if defective.
cable.
B. Defective contactor con- B. Momentarily connect a jumper
trol switch (4s) lead between terminals 1 and 2
on the control switch (4s). If
the load contactor closes momen,
tarily, replace switch (4s) (10,
l-l, Fig. 2).
C. Defective load contactor
U-C)
C. If load contactor will not close
when control switch (4s) is
jumpered, it is, likely that the
con tactor is defective .’
3-l
Page 4
Aug 6/73
HOBART ;MOTOR GENERATOR DIVISION
HORAHT BROTHt “S COMI’AN”
TROUBLE, SYMPTOM
AND CONDITION PROBABIE CAlJSF TFST; CHFCK; AND RFMFDY
GENERATOR AND CONTROLS (CONTINUED)
4. Load contactor A. Defective control switch A. Connect a jumper lead between
OPENS as soon (4S) ’ termina Is 4 and 5 on the control
as control switch switch (4s). If contactor will now
is released from remain closed after initial closing,
the CLOSE replace the control switch (4s)
position. (10, l-l, Fig. 2).
B. Overload relay (20L) B. Connect a jumper lead across the
defective over load re lay (20L) contacts.
If contactor will now remain
closed, replace overload relay
(20L) (Sect. 2-2, pages 4-7).
CAUTION: DO NOT OPERATE THE GENERATOR SET TO DE LIVER
POWER WHEN AN,Y PROTECTIVE DEVICE IS JUMPERED.
C. Overvoltage relay (OV)
defective
C. Connect a jumper lead between
terminals “T” and “P” on the over-
voltage relay (OV). If con tactor
will now remain closed, replace
overvoltage module (Sect. 2-2,
page 7).
D. Load contactor (LC) defec- D. If a fault was not found in steps
tive 4, A, B or C above, the load con-
tactor is defective. Replace load
contactor (LC) (12, l-l, Fig. 3).
5. Load contactor A. Contactor opening could A. Resume operation and closely ob-
opens during have been normal due to an serve ammeter and voltmeter for
power de I ivery overload or overvoltage evidence of overload and over-
run. condition. voltage. If contactor opens when
it is known that there were no over
load or overvoltage conditions,
proceed to step B.
B. Overload relay (20L) defec- B. Oi I in the overload relay dashpot
tive may be low, allowing the plunger
to operate too freely. Check dash.
pot in accordance with instructions
in Sect. 2-2, pages 4-7. Also
Aug 6/73 3-l
GENERATOR DIVISION HOEWRT BROIHLRS COMPAN”
ROUBLE,SYMPTOM,
AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY
GENERATOR AND CONTROLS (CONTINUED)
5. (Continued) B. (Continued)
C. Overvoltage reiay (OV)
defective
B. check overload relay contacts.
C. Check overvoltage relay by
operating the machine under loac
and controlling voltage manually
Start with a low voltage (25.0 V
DC) and gradually increase unti I
the relay functions to open the
load contactor. If relay trips at
less than 32 V DC, replace relay
and return old relay to factory
for service.
D. Load contactor defective D. If no fault was found in checks
B and C above, the load con-
tactor is at fault. Replace load
contactor (LC) (12, l-l, Fig. 3)
5. Generator voltage A. Defective voltage regula- A. Use automatic-manual switch
will not build up to tor (9, l-l, Fig. 2) to change to
normal operating MAN UAL control. If normal
voltage in AUTO- operating voltage (28.5 V DC)
MATIC control mode. can be selected with manual
control, replace the voltage
regulator module.
7. Generator voltage A. Defective voltage regula- A. Switch to MANUAL control.
builds too high in tor If normal operating voltage can
AUTOMATIC con- be selected with manual control,
trol . replace the voltage regulator.
3. Output current can - A. Defective current I imiting A. Change current limit control
not be limited by rheostat (lRH), or defective switch (2s) to 400 A current
operating current or improperly adjusted limit position. If current is now
limit rheostat when resistor (3RE S). limited to 400 A, check rheostat
selector switch is in and resistor. (See Sect. 2-3,
700 to 1300 A sub-sect. 3, B, (1) for resistor
position. adjustment.) Replace parts as
required.
3-l
Page 6
Aug 6/73
GENERATOR DIVISION HOBART BROlHfRS COMPAN”
TROUBLE, SYMPTOM] I AND CGNDITION 1 PROBABLE CAUSE 1 TEST, CHECK, AND REMEDY
GENERATOR AND
8. (Continued)
9. Output current
is not limited
when current
selector switch
is in 400 A
position.
CONTROLS (CONTINUED)
I B. Defective voltage regulator
4. Resistor (4RES) is defective
or improperly adjusted
B. Defective voltage
regulator
B. If current is not limited in eithc
700-1300 A or 400 A switch
position, a defective voltage n
ulator is indicated. Replace at
return old regulator to the fact,
for service.
A. Change current selector switch
700 to 1300 A limiting position
current can be limited in this
position, adjust or replace resi:
(4RES). (See Sect. 2-3, sub-s
3, B (2) for resistor adjustment.
Replace parts as required.
B. If current is not limited in eithc
selector switch (2s) position,
replace voltage regulator and
return old regulator to factory
service.
II
Aug 6/73 3-l
Page 7
3-l
Page 8
Aug 6/73
CHAPTER 4. ILLUSTRATED PARTS LIST
SECTION 1. INTRODUCTION
1. Genera I
The illustrated Parts List identifies, describes, and illustrates main assemblies, and
detail parts of a 28.5-volt, lOOO-ampere, 28.5-KW electric motor-driven Aircraft
Energizer, manufactured by Motor Generator Division, Hobart Brothers Company,
Troy, Ohio 45373. The unit is identified by Specification Number (SPECS) 5651.
2. Purpose
The purpose of the list is to provide parts identification and descriptive information to
maintenance and provisioning personne I for use in provisioning, requisitioning, purchas-
ing and issuing of spare parts.
3. Exolanation 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 h ar d ware 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 five columns. Beginning at the left side of the form
and proceeding to the right, columns are identified as follows:
(1) “FIGURE-ITEM NO. I’ 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
list to the illustration and vice versa.
July 6/‘73
TM-297
4-l
Page 1
(2) “PART NUMBER ‘I Column
All part numbers appearing in this column are Hobart numbers. If a Hobart
number has not been assigned to a part, “NO NUMBER” will appear in the
column and a vendor number will be listed 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. Sizes, ratings, or vendor part
numbers may also appear in this column.
(4) “EFF” (Effectivity) Column
This column is used to indicate applicability of parts when two or more models
of equipment are covered by the parts list. Code letters are used to indicate
parts which are used only on a certain model or models. Parts in the list are
coded as follows:
Uncoded parts are usable on all machines.
Parts coded “A” are usable onbasic Specs 5651 only.
Parts coded “B” are usable on Specs 5651, Var. 3 only.
Parts coded “C” are usable on Specs 5651, Var. 4 only.
(5) “UNITS PER ASSEMBLY” Column
This column indicates the quantity of parts required of an assembly or subassembly
in which the part appears. This column does not necessarily reflect the total
used in the complete end item.
4-l July 6/73
Page 2 TM-297
SECTION 2. PARTS LIST
1. General
Illustrations appear on left-hand pages, and parts lists appear on opposite right-hand
pages for the convenience of the user.
July 6/73
TM-297
4-2
Page 1
4-2
Page 2
Generator Set
Figure 1
July 6/“73
TM-297
. . 0”
@
ZMOTOR GENERATOR DlVlSfON : :: 0 . HOflARl BHOTHtHS COMPAN” “0 d *< 4. e,,\ $
FIGURE PART
ITEM N 0. NUMBER
NOMENCLATURE UN ITS
1234567 EFF A!&
l- s5651 GENERATOR SET, 28.5 V DC,
1000 AMPS, 60 HZ A
S565 1 -V3 GENERATOR SET, 28.5 V DC,
11000 AMPS, 50 HZ B
s5651 -v4 GENERATOR SET, 28.5 V DC,
1000 AMPS, TRAILER MOUNTED C
1 No Number . CONTROL BOX GROUP (For
Details See Fig. 2)
2 No Number . MOTOR GENERATOR GROUP
(For Details See Fig. 6)
3 W-4460(67C) . TRAILER GROUP (For Details
See Fig. 9)
Ju I y 6/73
TM-297
REF
REF
REF
4-2
Page 3
;MulOR GENERATOR DIVISION HOClAHl BHOIHLRS COMPAN”
Control Box Group
Figure 2
July 6/73
TM-297
SMOTOR GENERATOR DIVISION
N OME NC IATURE
FIGURE PART
ITEM NO. NUMBER 1234567
2- No Number
1 481096
2 481083
3 481099
4 No Number
CONTROL BOX GROUP (For NHA
See Fig. 1)
. PANEL, COVER
. PANE L, FRONT ASSEMBLY
PANE L, H INGED ASSEMBLY
: PANE L, INTER IOR GROUP
(For Details See Fig. 3)
5 481093
6 481088
7 481091
8 5C w-3405
9 3 89535- 1
10 W-8061A-11
11 W-8063A-3
12 480911
. PANEL,SIDE, LEFT,ASSEMBLY
. PANEL, SIDE, RIGHT, ASSEMBLY
. PANEL, REAR, ASSEMBLY
. EM, LIFTING
. ROPE, SUPPORT
. AMMETER
. VOLTMETER ’
13 400400
14 402159
15 403 189
16 H F-25 18-7
17 W-97 12-7
18 HF-2518-11
19 402855
20 403189
21 AAW-83%
2? 16DA-2162
23 DWP-1815
24 382818
25 W-l 1250
26 403336
27 DW-4701A-0
28 DWP-1186-O
29 7J -422
30 w-10051-4
31 w-10051-5
32 401864
33 A-98
. PANEL, SWITCH, MOTOR
ASSEMBLY (For Details See Fig. 4)
. SWITCH, TOGGLE, AUTO, MAN.
. RHE OSTAT, VvLTAGE
. SWITCH, TOGGLE, GENEKATOR
. LIGHT, PILOT, GREEN
RHE OSTAT, CURRE NT
: LIGHT, PILOT, AMBER
. SWITCH, TOGGLE, CL-CV
. SWITCH, TOGGLE, MOTOR
. RHEOSTAT, KNOB
. RHEOSTAT, KNOB
. STRAP, GROUNDING
. SCREW, FASTENING, HINGED PANEL
. WASHEK, SOUTHCO
. RING, LOCKING SWITCH
. HANGER, CAt3lE
. BRACKET, CLAMP, CABLE
. CIAMP, CABLE, MAIN STARTING
. CLAMP, WIRE
. CLAMP, WRE
. NAMEPLATE, IDENTIFICATION
. IABE L, ROTATION
NHA NEXT HIGl+K ASSEMBLY
UN ITS
E FF A&
RE F
1
1
1
PEF
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
4
2
2
2
1
1
1
1
July 6/73
TM-297
4-2
Page 5
r- -
\.
Inter ior Panel Group
Figure 3
4-2
Page 6
July 6/73
TM-297
FIGURE PAR T
ITEM NO. NUMBER
3- No Number
1
2 t
3
4
480903
w-454 1 -c
W-4541-D
APY-34
W-2974-D
5 W-2974-N
6 W-2974-M
7 400589-3
8 401556
9 403763- 1
10 3 89522A
11 400589-5
12 FW-2 13 1
13 6FW-2845
14 6FW-2087A
15 6FW-2085
16 6FW-1799
17 6FW-2714
18 Y-10
19 DWP-1653
20’ 480904
21 389466
22 6FW-2091
23 40 1564-2
24 401566-l
25 A-25
26 480993
27 481087
28
29
30
430336
6FW-2537
6FW-2532
6FW-2536
NHA
July 6/‘73
TM-297
NEXT H IGHER ASSEMBLY
NOMENCLATURE
1234567
PANEL, INTERIOR GROUP (For
NHA See Fig. 2)
. PANE L, INTER IOR ASSEMBLY
. ‘. RESISTOR, 20 OHM, 25 W
. . RESISTOR, 100 OHM, 25 W
. . BRACKET, MTG., RESISTORS
. . RESISTOR, 4 OHM, 100 W
(OUTER)
. . RESISTOR, 20 OHM, 100 W
(CENTER)
. . RESISTOR, 30 OHM, 100 W
(INNER)
. . BLOCK, TERMINAL
. . MOUNT, SHOCK
. . WASHER, FIBER
. . BOARD, P. C. OVERVOLTAGE
. . BLOCK, TERMINAL
. . RE LAY, OVER LOAD
. . BUS, POSITIVE TERMINAL RELAY
. . RE LAY, HARTMAN, A791M
. . BUS, SHUNT TO REV. CURRENT
RELAY
. . SHUNT, 50 MV
. . BUS, TERMINAL TO SHUNT
. . SPACER
. . BUS, CON TACTOR
. . PANE L, INTER IOR
. . BRACKET, RELAY
. . PLATE, TERMINAL, NEGATIVE
. . HOUSING, SOCKET,
CONNECTOR
. . TERMINAL, SOCKET
. . WASHER, FIBER
. . LABE L, OPERATING FREQlIN CY
. BRACKET, MOUNTING, INTERNAL
PANEL
. REGULATOR, VOLTAGE ASSEMBLY
. RESISTOR, CURRENT REGULATOR
f . BUS, TERMINAL BLOCK TO
RESISTANCE
. . RESISTOR, ELEMENT, CURRENT
UN ITS
per EFF ASSY
REF
1
1
1
2
1
1
1
1
3
3
1
1
1
1
1
2
1
1
1
8
1
4-2
Page 7
4-2
Page 8
July 6/73
TM-297
FIGURE PART
ITEM NO, NUMBER
3- 31
32
33 t 3 87725
34 16DA-4004A-3
35 16DA-4052-O
36 16DA-4253-1
37 W-10051-8
38 16DA-3731
6FW-2535
6FW-2929
480590
NOMENCLATURE UN ITS
1234567
. . BUS, CABLE TO RESISTANCE
BUS, BANK RESISTOR
,: KIT, RE LAY, PLUG-IN, 24 V.
ASSEMBLY
. . BRACKET, MTG., SOCKET,
RE IAY
. . RELAY, PLUG-IN, 24 V.
. . SOCKET, RELAY
. . RETAINER, SPRING, RE LAY
. CLAMP, WIRE, PLASTIC
. CAPAC ITOR, 15 MFD, 200 V
EFF A&
1
July 6/73
TM-297
4-2
Page 9
0 0 ii
\ 7 0 A
0
\Q
/
Motor Switch Panel Assembly
Figure 4
4-2
Page 10
6
July 6/73
TM-297
FIGURE PART
ITEM NO. NUMBER
4- 4809 11
1 480922
2 402949
3 I 402948
4 430114-6
9
402947
400589-l
400533
25MS-302-4
357678
402677
10 No Number
11 36 1922
12 No Number
13 35753 1
14 16DA-4252-16
15 400651
16 400670
17 CW-811
18 404083- 1
19
20
21
42517
400828-l
AW-367
NOMENCLATURE
1234567
PANEL, SWITCH, MOTOR,
ASSEMBLY (For NHA See Fig. 2)
.
I.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
PANEL, MTG., MOTOR iWITCH
NAMEPLATE, L3
NAMEPLATE, L2
SWITCH, ACROSS LINE ASSEMBLY
(For Details See Fig. 5)
NAMEPLATE, Ll
BLOCK, TERMINAL
NAMEPLATE, GROUND
ELEMENT, HEAT, OVERLOAD
BLOCK, OVERLOAD, ASSEMBLY
. SWITCH, MICRO SPNC., 250
TAB
. SCREW, #6-32 x 3/8, SET,
SOCKET, OVAL POINT
. BAR, ACTUATING
. SCREW, #6-32 x 5/8, SET, SKT.,
HD., ST.
BLOCK, OVERLOAD
&SE, SLOW BLOWING
HOLDER, FUSE
TRAN SFORMER , CONTROL
STRAP, CONNECTING
TERMINAL, R IN G TONGUE,
#8 WIRE, #8 STUD
INSULATION, SLEEVING, FIBER-
GLAS, YELLOW, SIZE 0
TIE, WIRE, PLASTIC
SPACER, PANE L
NHA NEXT HIGHER ASSEMBLY
July 6/73
TM-297
UN I TS
Per
EFF ASSY
REF
1
1
1
1
6
4-l/2"
3
4
4-2
Page 11
V
\
\
100 Amp Across Line Switch Assembly
Figure 5
4-2
Page 12
FIGURE
ITEM NO.
5-
1
2 I
3
4
5 DATA 1330A
6 1 OOMS-6
7 1 OOMS-8
8 1 OOMS-79
9 1 OOMS-9A
10
11
12
13
14
15
16
17 430076-2
18 200MS- 116
19 1 OOMS-466
20 1 OOMS-238A
21 430047-O
22 lOOMS-14
23 25MS-323
24 25MS-324
25 1 OOMS-449
26 W-l 1245-8
27 25MS-309
28 lOOMS-137
29
NHA
PART
NUMBER 1234567
430114-6
430111
50MS-28
lOOMS-141
43 0048
1 OOMS-358
SWITCH, 100 AMP, ACROSS LINE,
ASSEMBLY (For N HA See Fig. 4)
PANEL, MOLDED, ACROSS LINE
1. SWITCH
. HOLDDOWN, COIL
. YOKE, MOVABLE, MAGNETIC,
SA
. STOP, MOVABLE, MAGNETIC,
YOKE
. COIL, NVR
. WASHER, MAGNETIC, BLOWOUT
COIL
. CYLINDER, BLOWOUT COIL
ASSEMBLY
. . CYLINDER
. . INSULATOR
. SPRING, MAGNETIC BLOWOUT
COIL
lOOMS-122-1
lOOMS-146
1 OOMS-122-0
50MS-300
1 OOMS-336 - 1
50MS-472
430113
430075-2
. HOLDER, ARC SH IE LD
. SHIELD, ARC
. HOLDER, ARC SH IE LD
. STRAP, CONNECTING
. MOUNT, CONTACT, STATIONARY
. SUPPORT, SINGLE BEARING
. INSULATOR, BETWEEN PHASE
. SHAFT, ARMATURE & CONTACT
ASSEMBLY
. . CONTACT, MT. SA
f . . CON TACT
. . . LEAD, PIGTAIL
. . SHAFT, ARM ASSEMBLY
. . INSULATION , SHAFT, ARMA-
TURE
. . CLAMP, SHAFT, ARMATURE
. BRACKET, MTG., MICRO SWITCH
I ARM, LEVER
. SWITCH, MICRO
. WASHER, FLAT, 3/8 BRS
. INSULATION , PANEL
. YOKE, STATIONARY, MAG-
NETIC, SA
. LEAD, CLAMP 5CW-529
NEXT HIGHER ASSEMBLY
NOMENCLATURE UN ITS
Per EFF ASSY
REF
1
2
1
6
3
1
1
3
3
3
3
2
3
1
3
1
3
1
1
1 ’
July 6/73
TM-297
July 12/76 Kevised
4-2
Page 13
4-2
Page 14
FIGURE PAR T
ITEM N 0. NUMBER
N OMEN CLATURE
1234567
5- 30 No Number . TUBING, VINYL-FLEX, 4000
I 31 33 32 200MS-116 lOOMS-132 25MS-156 ,. . . MOUNT CONTACT BUS, JUMPER
Ott 19/76 Revised
July 6/73
TM-297
UN ITS
Per EFF ASSY
REF
1
3
3
4-2
Page 15
I i
P
( : -
;
FIGURE PART
ITEM NO. NUMBER 1234567 EFF
6- No Number
1 6FW-5734- 1
MOTOR GENERATOR GROUP (For
NHA See Fig. 1)
. ARMATURE, 28.5V, 1000 A., DC
, ELEC. ASSEMBLY
2 I
3
4
5
6
W- 10072-8
DW-882A
DW-883
5B-48
6FW-858B
. BEARING, BALL, SINGLE ROW,
RADIAL
. CAP, BEARING
. GASKET, CAP, BEARING
. NUT, l-9/16-14
7 430278
8 6FW-2442
. BRUSHHOLDER GROUP (For Details
See Fig. 7)
. BUSHING, LEAD
. COIL, INTERPOLE, 1000 A, 6 POLE,
GEN.
9 6FW-1896
10 DATA 1888- 1
11 6FW-1501-2
W-10126-6
AW-720B
6FW-2453
. COVER, LOUVER, GENERATOR
. COIL, FIELD, SHUNT, GENERATOR
HOUSING, GENERATOR, 600 A.,
‘6 POLE, ASSEMBLY
. INSULATION
12
13
. . WRAPPING, POLEPIECE EXCITER
. . COLLAR, INSULATING, GENERA-
TOR
14
15
16
6FW-4033
6FW-2770
6FW-889
. . INSULATOR, FLUX RING TO POLE
PIECE, GENERATOR
. . INSULATION, 7” PLUG HAT,
WRAPPER, GENERATOR
. . INSULATION, INTERPOLE,
WRAPPER, GENERATOR
17 6FW-2771
18 6FW-2455
19 6FW-2769
. . INSULATION, 7” PLUG HAT,
TOE, GENERATOR
POLEPIECE, INTERPOLE, GEN-
- ERATOR
. POLEPIECE, PLUG HAT, GEN-
ERATOR
20 6FW-1488
21 430015-l
. GUARD, OUTLET, AIR, ASSY
. HOUSING & STATOR, MOTOR
ASSEMBLY
22 DW-4414 . BRUSHHOLDER ASSEMBLY I
EXCITER (For Details See Fig. 8)
23 6FW-220 . COVER, LOUVER, EXCITER END
24 DATA 491 . COIL, FIELD, EXCITER
25 BW-97 . POLEPIECE, EXCITER
NHA
July 6/73
TM-297
NEXT HIGHER ASSEMBLY
NOMENCLATURE UN ITS
Per ASSY
REF
1
1
4
6
1
6
1
REF
4
12
36
6
6
12
6
6
1
1
1
1
1 SET
4
4-2
Page 17
F8
I
i. ..-. .-. _. ___ . . . .
Brushholder Group
Figure 7
July 6/73
TM-297
--
a e z QD
$MOTOR GENERATOR DIVISION e
> G % *. ,,,I‘++
FIGURE
ITEM NO.
PART
NUMBER
7- No Number
6FW-858B
1 t 6FW-864
2 W-10855-4
3 6FW-862
4 AW-740
5 6FW-5719
6 AW-1156
7 AW-734
8 AW-638C
9 W-799F-#113
10 AW-667A
11 A W-732
12 A-25
13 BW-107
14 AW- 1470
15 6FW-1480
16 24FW-23
17 24FW-27
18 SAY-84
19 W-9234-4
20 W-9234-2 1
2i W-9234-l 8
22 6FW-3351
NOMENCLATU?E
1234567
BRUSHHOLDER GROUP (For NHA
See Fig. 6)
. BR USHH OLDER ASSEMBLY,
’ 6 POLE
. . MOUNT, BRUSHHOLDER
. . CONDENSER,.25 MFD, 100 V
. . PLATE, BRUSHHOLDER, SUPPORT
. . SPACER, BRUSHHOLDER
. . SPACER, BRUSHHOLDER
. . PLATE, GUIDE & FINGER,
BRUSHHOLDER, ASSEMBLY
. . . PLATE & GUIDE, BRUSHHOLDER
. . . WASHER, SPR IN G AD JUSTIN G
. . . SPR IN G, TEN SION
. . . BUSHING, LEVER SCW,
TENSION
. . . FINGER, BRUSHHOLDER, SA
. . WASHER, FIBER
. . BUSH IN G, BRUSHHOLDER
. . BRUSH , COPPER GRAPH ITE
. . BRACE
. . BUS BAR
. . BUS
. . SPACER
. LEAD, BRUSHHOLDER
. LEAD, BRUSHHOLDER
. LEAD, BRUSHHOLDER
. STRAP, POSITIVE, ASSEMBLY
NHA NEXT HIGHER ASSEMBLY
UN ITS
Per EFF ASSY
REF
1
1
6
6
30
12
24
1
1
1
1
1
24
12
24
6
6
3
3
1
1
1
2
July 6/‘?‘3 4-2
TM-297 Page 19
Exciter Brushholder Assembly
Figure 8
4-2
Page 20
July 6/73
TM-297
FIGURE PAR T
ITEM NO. NUMBER
8- DW-4414
1 AW-671
2 AW-626
3 AW-63 1
4
5
6 AW-696
7 AW-638C
8 AW-667A
9 400562-5
10 AW-634
11 4DW-423
AW-630
W-l 0753-4
AW-700
NOMENCLATURE
1234567
BRUSHHOLDER, EXCITER ASSEMBLY
(For NHA See Fig. 6)
. MOUNT, BRUSHHOLDER
. BUSH IN G, BRUSHHOLDER
‘. RING, OUTER, EXCITER,
BR USHHOLDER
. RING, INNER, EXCITER,
BRUSHHOLDER
. CON DENSER
. PLATE, MTG., BRUSHHOLDER
ASSEMBLY
. . PLATE & GUIDE, BRUSHHOLDER
SA
. . WASHER, SPRING, ADJUSTlNG
. . BUSH IN G, LEVER, TENSION
. . SPRING, TENSION
. . FINGER, BRUSHHOLDER, SA
. BRUSH , CAR BON
NHA NEXT HIGHER ASSEMBLY
July 6/‘73
TM-297
UN ITS
Per EFF ASSY
REF
1
4
1
1
2
4
4-2
Page 21
1) z .z QD
;MOTOR GENERATOR DIVISION .
-, ,’ HOB*“I 8H”iHLRS COMPAN” 5 Q. 8.11 8
Trailer Group
Figure 9
4-2 July 6/73
Page 22 TM-297
FIGURE PART
ITEM NO. NUMBER
9-
1
2
3
NOMENCLATU?E
1234567 EFF
W-4460(67C)
35566 1
DW-6641
cw-773
5CW-5125
5CW-3466
5C W-5083
DW-3860
5CW-3208
TRAILER GROUP (For NHA See Fig. 1) C
. AXLE, REAR ASSEMBLY C
WHEEL, PNEUMATIC, 4:00 X 8
I* (Geneva Metal Wheel Co., Geneva,
Ohio. DC305-1 KW224-D16. 3”xl”
Durex Bearing Axle) C
. CAP, HUB C
. AXLE, FRONT, ASSEMBLY C
. . AXLE & TONGUE, ASSEMBLY C
. . YOKE & FIFTH WHEEL, ASSY C
. . SHAFT, YOKE PLATE C
. . SHOE, BRAKE C
UN ITS
Per ASSY
REF
1
NHA
July 6/73
TM-297
NEXT HIGHER ASSEMBLY
4-2
Page 23
4-2
Page 24
July 6/73
TM-297
-
r 23
0 O
R 46
0 V.
AC
(4
60
V C
ON
N.
SHO
WN
) 50
UR
60
HZ.
IN
PUT
POW
ER
- SW
IN
D
(
r”
0
5RES
26.5
I!
DC
OU
TPU
T PO
WEf
L JU
MPE
R
INST
ALL
ED
FOR
50
H
Z.
OPE
RA
TIO
N
EI
REM
OVE
D
FOR
60
H
Z.
OPE
RA
TIO
N.
LEG
END
AM
BER
IN
DIC
ATI
NG
LI
GH
T (M
OTO
R
RU
NN
ING
) IO
L A
MM
ETER
, G
ENER
ATO
R
2OL
AM
MET
ER
SHU
NT,
16
00A
.. 50
MV.
ov
CA
PAC
ITO
R,
0.1
MFD
, 10
0 V.
IP
L2-7
CA
PAC
ITO
R,
0.25
M
FD.
IOO
V.
REI
CA
PAC
ITO
R,
1.5
MFD
, 20
0 V.
RE
G
CO
MPO
UN
DS
IRES
EXC
ITER
A
RM
ATU
RE
2RES
FIEL
D
FLA
SH
REL
AY,
A
UTO
MA
TIC
3R
ES
EXC
ITER
FI
ELD
4R
ES
GEN
ERA
TOR
FI
ELD
5R
ES
FUSE
, SL
OW
B
LOW
ING
, 2A
IR
H
GRE
EN
IND
ICA
TIN
G
LIG
HT
(LO
AD
O
N)
2RH
G
ENER
ATO
R
AR
MA
TUR
E IS
INTE
RPO
LES
2s
LOA
D
CO
NTA
CTO
R
3s
MO
TOR
SW
ITC
H
4s
MO
TOR
ST
ATO
R
(460
V
CO
NN
. SH
OW
N)
IT
VM
IA
AM
AS
l.2C
AP
3-6C
AP
9CA
P
CO
MP
EXC
FFR
IFLD
2FLD
IFU
IG
GEN
INT
LC
MS
MTR
OVE
RLO
AD
, M
OTO
R
OVE
RLO
AD
R
ELA
Y,
GEN
ERA
TOR
OVE
RVO
LTA
GE
REL
AY
CO
NN
ECTO
R,
VOLT
AG
E R
EGU
LATO
R
RES
ISTA
NC
E BA
NK
REG
ULA
TOR
, VO
LTA
GE
RES
ISTO
R,
20
OH
M,
100
WA
TT
RES
ISTO
R,
4 O
HM
, 10
0 W
ATT
RES
ISTO
R,
20
OH
M,
25
WA
TT
RES
ISTO
R,
30
OH
M,
100
WA
TT
RES
ISTO
R.
100
OH
M,
25
WA
TT
RH
EOST
AT,
C
UR
REN
T
RH
EOST
AT,
VO
LTA
GE,
M
AN
UA
L F
A.0
SU
P 6
FFP
SWIT
CH
, A
UTO
MA
TIC
-MA
NU
AL
a’P‘
r*.lc
LI
t
11
3 C
O”.
‘il
,SL,
(
&PC
, To
D.I.
ll.l
s,o<
‘1
. A
5
SWIT
CH
, C
UR
REN
T LI
MIT
PH
OTC
CTI
V~ Il
.dilS
Y SW
ITC
H,
MO
TOR
ST
AR
T-ST
OP
CM
AN
GC
Li
i( CO
””
SWIT
CH
, C
ON
TAC
TOR
O
N-O
FF
.~
v.,
lpi”
,I “i
l,E
*..,
s*i,t
x ::b
irl
TRA
NSF
OR
MER
, C
ON
TRO
L (4
6OV
CO
NN
. SH
OW
?&
‘:I
.::,‘A
- ’
’ /-
‘8,’
VOLT
MET
ER
/-- ---
w 22;
:A:
P :-----
- -----7
R2 1.2KA
--
330n 31/qw.
K7 IOKA
RS 47on
R8 27OA D2
RIO 15On
L
:: Dl, D2 Pl
If:
:: R2 R3 R4 R5, R6
%I RV RlO
LEGEND
CAPACITOR 1.5/35 CAPACITOR SO/25 DIODE POTENTIOMETER 1K OHM, l/2 WATT TRANSISTOR 2N-3903 TRANSISTOR 2N-3904 TRANSISTOR PROGRAMMABLE UNIJ-2N-6027 RESISTOR 330 OHM, 3-l/4 WATT RESISTOR 1200 OHM, l/2 WATT RESISTOR 4700 OHM, l/2 WATT 1
RESISTOR 5600 OHM, l/2 WATT RESISTOR 22K OHM, l/2 WATT RESISTOR 10K OHM, l/2 WATT RESISTOR 270 OHM, l/2 WATT RESISTOR 470 OHM, l/2 WATT RESISTOR 150 OHM. l/2 WATT RELAY ZENER 22 VOLT E, 22