Installation Instruction Manual. Low Coolant Shutdown Kit Part No Series 7004C Hobart Engine-Drive Generator Sets

Transcription

1 TO-223 June 18/92 Installation Instruction Manual for Low Coolant Shutdown Kit Part No for use with Series 7004C Hobart Engine-Drive Generator Sets Hobart Brothers Company Airport Systems Grroup Power Systems Division Troy, Ohio U.S.A.

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3 Installation Instruction Manual for Low Coolant Shutdown Kit Part No for use with Series 7004C Hobart Engine-Drive Generator Sets 1. Description The low coolant shutdown kit covered by this manual, and identified by Hobart Part Number , is designed for use with Series 7004C Hobart engine-drive generator sets. Its purpose is to stop the engine before overheating, caused by low coolant, can occur. A liquid-level detector, mounted in the radiator tank, opens the power to the engine fuel valve solenoid when coolant drops to a predetermined level in the radiator. NOTE: Radiator MUST be refilled after a low-coolant shutdown before engine can be restarted. 2. Installation a. Installing the Relay Figure 1 shows where the relay is to be installed on the rear of the generator control box. Proceed as follows to install the relay. (1) Attach the relay socket and relay retainer spring to the relay mounting bracket, using the two rivets provided in the kit. (2) Mount the relay bracket securely to the rear of the control box, using the two #6-32 X 3/8 self-tapping screws provided in the kit. (3) Plug the relay into the socket and snap the relay retainer spring over it. b. Installing the Low Coolant Switch Figure 2 shows where the low coolant switch (provided in the kit) is to be installed on the radiator. This installation can and should be performed at a qualified radiator repair shop. Refer to radiator rework instructions c. Installation of Recovery Tank Figure 3 shows the recovery tank that is to be mounted on a bracket that attaches to the generator canopy top, and Figure 4 shows where holes should be drilled in the canopy top for installing the recovery tank mounting bracket. Proceed as follows with this installation. (1) With a sharp pencil, mark the places on the canopy top where holes are to be drilled for installing the recovery tank mounting bracket. Refer to Figure 4 to see where these holes should be drilled. (2) Using a sharp drill bit, drill two 9/32" holes in the canopy top at the locations marked in step (1). (3) Position the recovery tank mounting bracket just as is shown in Figure 3. Using two 1/4-20 X 1/2-inch self-tap screws, provided in the kit, attach the mounting bracket to the canopy top. (4) As Figure 3 shows, the recovery tank has a flange at the top of it with a screw hole for installing the recovery tank on the mounting bracket. Use the #10-24 X 5/8 sheet metal screw and 1/4-inch flat washer provided in the kit to attach the recovery tank to the mounting bracket. (5) Attach one end of the transfer tube to the bottom of the recovery tank, and secure it to the tank with one of the spring clamps provided in the kit. June 18/92 Page 1

4 TO-223 / Installation Instruction Manual Low Coolant Shutdown Kit / Series 7004C Generator Sets (6) Remove the existing overflow tube from the radiator, and install the other end of the plastic transfer tube (provided in the kit) to the radiator nipple from which the overflow tube was removed. Secure the tube to the nipple with another of the spring clamps provided in the kit. NOTE: It may be necessary to cut off a small portion of the transfer tube if it is too long. 1. Control box 4. Relay socket 2. Relay retainer spring 5. Relay mounting bracket 3. Relay Location for Relay on Generator Control Box Figure 1 d. Wiring the Low Coolant Kit Figure 5 is a wiring diagram which shows how the kit should be wired into the circuitry of the generator set. This diagram is an addition to Diagram , Sheet 5, in manual OM In Figure 5, the low-coolant shutdown switch is identified as S45 and the low-coolant shutdown relay is identified as K28. Wires required are provided in the kit. Refer to Diagram , Sheet 5, in manual OM-2045 to note changes in wiring, and wire the low coolant shutdown circuitry just as is shown in Figure 5. Page 2 June 18/92

5 TO-223 / Installation Instruction Manual Low Coolant Shutdown Kit / Series 7004C Generator Sets Location of Low Coolant Level Switch Figure 2 Location of Recovery Tank Figure 3 June 18/92 Page 3

6 TO-223 / Installation Instruction Manual Low Coolant Shutdown Kit / Series 7004C Generator Sets Hole Locations for Recovery Tank Mounting Bracket Figure 4 3. Checking Operation of the Low Coolant Shutdown Kit As shown in Figure 5, the low coolant shutdown switch (S45) has a TEST terminal, which permits testing of the switch by electrically simulating a low coolant condition. To check operation of the low coolant shutdown switch: a. Turn on the generator set and operate it at idle speed. b. Using a jumper wire with an alligator clip on each end, ground the TEST terminal on the low coolant shutdown switch. The generator set engine should shut off immediately. Page 4 June 18/92

7 TO-223 / Installation Instruction Manual Low Coolant Shutdown Kit / Series 7004C Generator Sets 4. Replacement Parts The following chart is a list of the major items which comprise the low coolant shutdown kit, except for hardware which is available from any hardware store. If it becomes necessary to replace any of the items listed below, these items may be ordered from Hobart Brothers Company using their part numbers as given below. ITEM HOBART PART No. NUMBER REQUIRED Socket, Relay 16DA Mount, Socket, Relay 16DA Relay, Enclosed Retainer, Relay, Spring 16DA Diode 1CZ-93B 1 Switch, Low Coolant Level Tank, Recovery Bracket, Mounting, Tank, Recovery Cap, Radiator Instructions, Rework, Radiator Service Information If you have any questions concerning your Hobart Ground Power Division equipment, you are invited to contact our service department by mail, telephone, or FAX. Write: Hobart Brothers Company Airport Systems Group Service Department 1177 Trade Square East Troy, Ohio U.S.A In U.S.A. Call: (800) (800) From Foreign Countries, Call: (513) (Parts) (513) (Service) Fax: (513) June 18/92 Page 5

8 TO-223 / Installation Instruction Manual Low Coolant Shutdown Kit / Series 7004C Generator Sets Wiring for Low Coolant Shutdown Kit Figure 5 Page 6 June 18/92

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