PDF Service Manual Bobcat HG40 Heater Generator Set - 3 MB
Perform expert service and repairs on your Bobcat Heater Generator Set HG40 with this comprehensive manual.
It contains detailed procedures for troubleshooting, disassembly, and reassembly of all major components.
Essential for technicians aiming to maintain the reliability and performance of this equipment, especially for models with serial numbers B14F00101 and above.
This guide will help you get the job done right.
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--- Page 1 ---
Service Manual
Heater Generator Set
(HG40) S/N B14F00101 & Above
6990758 (8-13) Printed in U.S.A. © Bobcat Company 2013
--- Page 3 ---
FEATURES AND ACCESSORIES
Standard Items
The heater generator set is equipped with the following
standard items:
• Control Panel Mounted Voltage Selector Switch
(VSS).
• Safety Shutdown System.
• EPA Certified Engine.
• Advanced Engine Controller.
• Remote Auto Start / Stop Control.
• Hard Wire Panel.
• Twist Lock Receptacles.
• Individual Circuit Breakers.
• Easy To Read Analog Gauges.
• Corrosion Resistance Enclosure.
• High Capacity On Board Fuel System.
• Sound Reducing Insulated Enclosure.
1-9 Heater Generator Set Service Manual
--- Page 4 ---
ENGINE AIR CLEANER NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Replacing Air Filter Element
Install new air filter element. Push all the way in until it
contacts the base of the housing.
WARNING Install the air cleaner cover (Item 2) and secure the three
latches (Item 1) [Figure 10-40-1].
UNEXPECTED ENGINE STARTUP CAN CAUSE
SERIOUS INJURY OR DEATH
Never inspect or service unit without first
disconnecting battery cables to prevent accidental
starting.
W-2950-1112
Open the back panel door (right hand side if facing
control panel).
Figure 10-40-1
1
2
1
1 P108253
Open the three latches (Item 1). Remove the air cleaner
cover (Item 2) [Figure 10-40-1].
Figure 10-40-2
1
P108254
Remove the air filter element (Item 1) [Figure 10-40-2].
10-40-1 Heater Generator Set Service Manual
--- Page 5 ---
FUEL SYSTEM (CONT’D) Replacing Fuel / Water Separator Filter
Fuel Filter(s) See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-30-1.)
Replace the fuel filter(s) every 500 hours of operation.
Stop engine and open the front panel door.
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-30-1.) Remove the fuel / water separator filter element (Item 2)
[Figure 10-60-2].
Stop engine and open the front panel door.
Clean the area around the fuel / water separator filter
Removing Water housing. Apply a small amount of fuel to the seal of the
new fuel / water separator filter. Install fuel / water
Figure 10-60-2 separator filter and hand tighten.
NOTE: Do not add fuel to the new fuel / water
separator filter before installing.
Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-60-4.)
2 Fuel Filter
Figure 10-60-3
1
P108244
Loosen the drain (Item 1) [Figure 10-60-2] at the bottom
of the fuel / water separator filter element to remove
trapped water.
Securely tighten the drain.
1
WARNING P108247
Remove the fuel filter element (Item 1) [Figure 10-60-3].
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames, Clean the area around the fuel filter housing. Apply a
sparks or lighted tobacco away from fuel and oil. small amount of fuel to the seal of the new fuel filter.
Failure to use care around combustibles can cause Install the fuel filter, and hand tighten.
explosion or fire.
W-2103-0508
NOTE: Do not add fuel to the new fuel filter before
installing.
Close the front panel door.
Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-60-4.)
10-60-3 Heater Generator Set Service Manual
--- Page 6 ---
MAINFRAME
ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Roof Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Side Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-2
Control Panel Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-3
Side Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-3
Left Rear Corner Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Right Rear Corner Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
20-01 Heater Generator Set Service Manual
--- Page 8 ---
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Asphalt Heater Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Infrared element not heating. 1, 2, 3, 4, 5
KEY TO CORRECT THE CAUSE
1. Broken element.
2. Loose / broken wire connection.
3. Asphalt heater circuit breaker tripped.
4. Heater generator set main breaker tripped.
5. Blown fuse.
30-10-6 Heater Generator Set Service Manual
--- Page 9 ---
CHARGE ALTERNATOR (CONT'D) Low Voltage Testing
Alternator Voltage Testing Figure 30-30-8
Figure 30-30-7
1
P108479
P108521
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 30-30-8] from the alternator.
Open rear panel door.
Turn the battery disconnect switch to the ON position.
Turn the engine on and run at idle. With a voltmeter,
check the voltage between the B+ terminal and ground at Figure 30-30-9
the starter [Figure 30-30-7].
2
The voltage must be higher than 13.5 volt but lower than
14.7 volt at 21°C (70°F) (Alternator Temperature).
If the voltage is higher that 14.7 volt, proceed to the 1
following high voltage test.
If the voltage is lower than 13.5 volt, run the engine at
high idle and recheck voltage. If voltage is still below 13.5
volt, proceed with the following low voltage test.
P108481
Check the voltage across the “L” terminal (Item 1) and
ground (Item 2) [Figure 30-30-9]. The voltage should be
what the battery voltage is. If not, check wire harness,
relay and fuses. If the wire harness, relay and fuses are
okay remove alternator for replacement or repair.
30-30-4 Heater Generator Set Service Manual
--- Page 11 ---
INSTRUMENT PANELS (CONT’D) Amperage Output Switch Removal And Installation
Voltage Output Switch Removal And Installation Figure 30-50-9
Figure 30-50-7
2
1
1
2
P108522
P108522
Remove the screw (Item 1) [Figure 30-50-9] and knob.
Remove the screw (Item 1) [Figure 30-50-7] and knob. Figure 30-50-10
Figure 30-50-8
1
1
P108395
P108395
Remove the nut (Item 2) [Figure 30-50-9] and remove
the amperage output switch assembly (Item 1) [Figure
Remove the nut (Item 2) [Figure 30-50-7] and remove 30-50-10] from the control panel.
the voltage output switch assembly (Item 1) [Figure 30-
50-8] from the control panel. NOTE: Service work on the amperage output switch
assembly should only be performed by a
NOTE: Service work on the voltage output switch qualified technician. Use only genuine Bobcat
assembly should only be performed by a parts if repair is necessary.
qualified technician. Use only genuine Bobcat
parts if repair is necessary.
30-50-4 Heater Generator Set Service Manual
--- Page 12 ---
TRANSFORMER (CONT’D) Figure 30-60-5
Continuity Testing
WARNING
UNEXPECTED ENGINE STARTUP CAN CAUSE
SERIOUS INJURY OR DEATH
Never inspect or service unit without first
disconnecting battery cables to prevent accidental
starting.
W-2950-1112
P108530
Use a test meter to test transformer continuity [Figure
WARNING 30-60-5].
NOTE: Set meter to read ohm. With robes not
ELECTRICAL SHOCK CAN CAUSE touching anything, the meter should see a
SERIOUS INJURY OR DEATH reading of infinity or OL.
• Always treat electrical circuits as if they were
energized. Open the front panel door (left hand side if facing control
• Disable start control before attempting any repair panel).
service. Disconnect all leads to electrical power
requirements and disconnect battery to prevent Remove transformer wires. (See [Figure 30-60-3].)
startup.
W-2953-1112
Figure 30-60-6
Turn engine off and disconnect the battery.
Open the front panel door (left hand side if facing control
panel).
Remove the transformer cover. (See [Figure 30-60-1].)
With robes not touching anything, the meter should see a
reading of infinity or OL.
X1
Open circuit: When the circuit is not complete, meaning
that no voltage is able to flow through. This can be X2
caused by a blown fuse, resistor or a switch.
P108473
Closed circuit: When the circuit is complete, meaning that
voltage is able to flow through it.
Test for continuity between X1 and X2 [Figure 30-60-6]
A simple continuity test on a light switch that is not wired of the transformer. The meter should have a reading of
to anything. With the switch off, probe the terminals. You infinity or OL.
should not get a reading on your tester. But, when you
NOTE: If the meter is showing a reading above
turn the switch on, you will notice that the tester will read
infinity or OL, replace the transformer.
zero and the beep should be heard, signaling that the
circuit is closed or complete.
30-60-2 Heater Generator Set Service Manual
--- Page 13 ---
GENERATOR (CONT’D) Install the side panel(s). (See Side Panel Removal And
Installation on Page 20-10-3.)
Installation (Cont’d)
Install roof panel. (See Roof Panel Removal And
Figure 40-10-17 Installation on Page 20-10-1.)
Install the side door panel(s). (See Side Door Removal
And Installation on Page 20-10-2.)
Install and connect the battery. (See Removal And
Installation on Page 30-20-1.)
1
P108489
Align and install the two mounting bolts (Item 1) [Figure
40-10-17], nuts and washers.
Figure 40-10-18
1
P108467
Install the ground strap (Item 1) [Figure 40-10-18].
Install the control panel. (See Control Panel Removal
And Installation on Page 30-50-7.)
Install the right rear corner panel. (See Right Rear
Corner Panel Removal And Installation on Page 20-10-
5.)
Install the left rear corner panel. (See Left Rear Corner
Panel Removal And Installation on Page 20-10-4.)
Install the control panel door. (See Control Panel Door
Removal And Installation on Page 20-10-3.)
40-10-6 Heater Generator Set Service Manual
--- Page 14 ---
GENERATOR (CONT’D) Figure 40-10-25
R438 Adjustments (AREP System)
WARNING
MODIFICATION OR ALTERATION OF THIS MACHINE
CAN RESULT IN SERIOUS INJURY OR DEATH
Never alter or modify this machine without approval
from the manufacturer.
W-2949-1112
P108278
WARNING R438 (AREP System) [Figure 40-10-25].
1. Initial potentiometer settings (See Factory Rated No-
AVOID INJURY OR DEATH Load Values on Page 40-10-19.).
Voltage selection, adjustment, and electrical
connections shall be performed only by qualified NOTE: Remote voltage adjustment potentiometer:
personnel. center (ST4 strap removed).
Do not turn voltage selector switch while engine is 2. Install a D.C. analogue voltmeter (needle dial) cal.
running. 50V on terminals E+, E- and an A.C. voltmeter cal.
W-2955-1112 300 - 500 or 1000V on the alternator output terminals.
NOTE: The generator must be stopped (or the power 3. Make sure that the ST3 strap is positioned on the
switched off) in order to reset the protection. desired frequency (50 or 60 Hz).
• Fuse F1 on input side (X1, X2). 4. Voltage potentiometer P2 at minimum, fully to anti-
clockwise (CCW).
• Voltage detection: 5 VA isolated via transformer. 0-
110V terminals = 95 to 140V, 0-220V terminals = 170 5. Turn the V/Hz potentiometer P4, fully to clockwise (if
to 260V, 0-380V terminals = 340 to 520V. equipped with P4).
• Voltage regulation ± 1% (R448: ± 0.5%). 6. Stability potentiometer P3 approximately 1/3 of travel
anti-clockwise (CCW).
• Rapid or normal response time via strap ST2.
7. Start the engine and set its speed to a frequency of 48
• Voltage adjustment via potentiometer P2. Other Hz for 50 Hz, or 58 for 60 Hz.
voltages via step down transformer.
8. Adjust the output voltage to the desired value using
• Current detection: (parallel operation): C.T. 2.5VA P2.
cl1, secondary 1A (Option).
• Quadrature droop adjustment via potentiometer P1.
• Under speed protection (U/f) and LAM. Frequency
threshold adjustable via potentiometer P4 on older
models. Strap ST5 is connected for LAM operation.
25% or 13% voltage drop via strap ST10.
• Potentiometer P5, Max. excitation current adjustment
via P5: 4.5 to 10A.
• 50/60 Hz selection via strap ST3.
40-10-16 Heater Generator Set Service Manual
--- Page 15 ---
GENERATOR (CONT’D) Mechanical Checks Prior to First Use
Electrical Checks Prior to First Use Before starting the machine for the first time, check that:
NOTE: Under no circumstances should an alternator, • All bolts and screws are tight.
new or otherwise, be operated if the isolation
is less than 1 mega ohm for the stator and • The cooling air is drawn in freely.
100,000 ohm for the other windings.
• The protective grilles and housing are correctly in
There are three possible methods for restoring the place.
minimum values.
• The standard direction of rotation is clockwise as
Method #1 seen from the shaft end (phase rotation in order 1 - 2
- 3).
Dry out the machine for 24 hours in a drying oven at a
temperature of approximately 110°C (230°F). • For counterclockwise (CCW) rotation, swap 2 and 3.
Method #2 • The winding connection corresponds to the site
operating voltage. (See Checking The Winding on
Blow hot air into the air input, having made sure that the Page 40-10-20.)
machine is rotating with the exciter field disconnected.
Method #3
Run in short-circuit mode (disconnect the AVR).
• Short-circuit the output phases using connections
capable of supporting the rated current (try not to
exceed 6A / mm2).
• Insert a clamp ammeter to monitor the current
passing through the short-circuit connections.
• Connect a 48 volt battery in series with a rheostat of
approximately 10 ohm (50 watts), to the exciter field
terminals, respecting the polarity.
• Open fully all the alternator orifices.
• Run the alternator at rated speed. Adjust the exciter
field current using the rheostat to obtain the rated
output current in the short-circuit connections.
NOTE: Prolonged Standstill - The use of space
heaters, as well as turning over the machine
from time to time is recommended to avoid
these problems.
NOTE: Space heaters are only effective if they are
working continuously while the machine is
stopped.
40-10-26 Heater Generator Set Service Manual
--- Page 16 ---
ENGINE INFORMATION (CONT’D)
Specifications (Cont’d)
Thermostat
Valve Opening Temperature 76,5 ± 2°C (169 ± 35°F) (Standard)
Valve Lift (@9 mm (0.354 in) or more) 90°C (194°F)
Relief Valve
Valve Opening Pressure 304 - 402 kPa (3 - 3,96 bar) (44.09 - 58.32 psi)
Safety Valve
Valve Opening Temperature 1078,38 kPa (10,64 bar) (156.4 psi)
Fuel Injection Nozzle
Valve Opening Pressure (Swirl Chamber) 11769,77 - 12748,86 kPa (116,14 - 125,81 bar)
(1707 - 1849 psi)
Spray Cone Angle (Swirl Chamber) 0 degrees
Oil Tightness Of Needle Valve Seat Seat shall not hold test pressure 1965,1 kPa (19,4
bar) (285 psi) lower than valve opening pressure for
10 seconds.
Starter
No-Load Characteristics
Terminal Voltage 11V
Current 130A or less
Rotation Speed 3800 min-1
Brush Length 18,0 mm (0.71 in)
Brush Spring Load (@ 26.5 - 36.3 N) 26,5 - 36,3 N
(2,7 - 3,7 kgf)
(6.0 - 8.2 lbf)
Allowable Limit 14.7 N (1.5 kgf) (3.3 lbf)
Commutator Radial Runout Allowable Limit 0,10 mm (0.004 in)
Commutator Diameter 32,0 mm (1.26 in)
Allowable Limit 31,4 mm (1.24 in)
Under Cutting Depth 0,4 - 0,6 mm (0.016 - 0.024 in)
Allowable Limit 0,2 mm (0.008 in)
IC Regulator Controlled Voltage @20°C (68°F) A7TA0483A / 14,7 ± 0.3V
Alternator
IC Regulator Controlled Voltage @20°C (68°F) A7TA0483A / 14,7 ± 0.3V
-1
Output Characteristics (When Hot) 2500 min or less (Current) 33A above
Output Characteristics (When Hot) 5000 min-1 or less (Current) 47A above
Brush Length 18,5 mm (0.73 in)
Allowable Limit 5,0 mm (0.20 in)
Magnetic Plug
Resistance Of Stop Solenoid ETR Type (RUN-ON) @12V 8 - 10.7 ohm
Resistance Of Stop Solenoid ETR Type (RUN-ON) @24V 33 - 43.4 ohm
50-10-6 Heater Generator Set Service Manual
--- Page 17 ---
50-20-2 Heater Generator Set Service Manual
--- Page 18 ---
TECHNICAL SERVICE GUIDE SPECIFICATIONS (CONT’D)
Lubricating System Torques
Oil Gear Pump 28,0 - 38,0 N•m (21.0 - 28.2 ft-lb)
Oil Pan 10,0 - 13,0 N•m (7.2 - 9.4 ft-lb)
Oil Pan Drain Plug 34,0 - 44,0 N•m (25.3 - 32.5 ft-lb)
Relief Valve 44,1 - 53,9 N•m (32.5 - 39.8 ft-lb)
Safety Valve 64,0 - 74,0 N•m (47.0 - 54.2 ft-lb)
NOTE: For additional engine torques, (See Torque Values on Page 50-10-7.)
Inlet And Exhaust System Torques
Exhaust Manifold (Bolt Only) 27,5 - 33,3 N•m (20.3 - 24.6 ft-lb)
Exhaust Manifold (With Spacer) 15,0 - 22,0 N•m (10.8 - 15.9 ft-lb)
Electrical System Torques
Starter Terminal B 9,8 - 11,8 N•m (7.2 - 8.7 ft-lb)
Glow Plug (Swirl Chamber) 15,0 - 20,0 N•m (10.8 - 14.5 ft-lb)
Cooling System Torques
Thermostat Case 17,0 - 20,0 N•m (12.3 - 14.5 ft-lb)
NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 10-50-1.)
Cooling System
Coolant Type and Mix 50% Water and 50% Ethylene Glycol
Radiator Cap Pressure 97 kPa (1 bar) (14 psi)
Thermostat Fully Open at 90°C (194°F)
NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 10-50-1.)
SPEC-20-2 Heater Generator Set Service Manual