f. Insert the tie rod end ball studs (29) into thespiiidles and steering knuckles (30).Secure with theslotted hex nuts (28).Recheck thewheel alignment as directed aboveand%heck the toe-in as directed in p a r a g r a p h 4 - 3 7 .If both are correct, tighten the nuts (26) between tierods(25) and tie rodends (29)andinstall the cotterpins (27) that secure the ball stud nuts (28).4 - 3 7 . F r o n t W h e e l T o e - I n A d j u s t m e n t .See f i g u r e 4 - 1 0 andcheck andadjust the front wheeltoe-in as follows:a. Position the vehicle on a flat, hard, evensur~ace, with the wheels positioned in the straight-ahead position. Check wheel alignment ( p a r a g r a p h4 - 3 6 ) .b. Using yellow crayon, mark the front center ofthe~ire tread at each front wheel. Carefully measurethe distance between themarks.S e c t i o n V .4 - 3 8 . G e n e r a l .a. (See f i g u r e 4 - 1 3 ) . The load bank is a balancedthr~e phase, four wire resistive type load which isused to maintain the generator set load at approxi-mately half-load at 120/208 volts and240/416 volts,at 50/60 HZ and 400 Hz. The generator set is pro-tected against overloadsby the load bank reject con-trol system.b. The load bank special purpose cable connectsthe-automatic load bank reject control system intothe load measuring system. The load bank is con-nected to thegenerator setload terminal board viathe load bankfour wire power cable. A load bankpower on indicator lamp indicates when ac power isapplied to load bankheatingelements.c. The load bank rotary selector switches permitch@es in load from O to 50 percent of the generatorset KW ra$ing (60 KW) in four 7.5 KW increments of2! percent of the load capacity (30KW) and permitoperation at either 120/208 or 240/416 volts.~. A load reject toggle switch provides forselection of automatic load reject or manual modereject mode of operation. During automatic mode,the load measuring unit senses thegenerator setout-put (utility load plus load bank).If the combined loadexceeds 509+of the generator setcapacity of 60”KW,the load measuring unit applied to theload rejectrelay via the tactical relay boxtrips the load rejectrelaywhich trips the over temperature reset switchtrip coil (3 phase magnetic circuit breaker) removingthe selected load from the generator set.(The loadreject relaytrips when the total current in anyphaseof the generatorsetrises to and remains at 125 per-cent plusor minus five percent of the maximum loadc.Pushthe vehicle backwards in a straight lineunt~l the marks are positioned at theback of thewheel. Again measure the distance between marks.The measured distance between marks when at therear must exceed the distance between the markswhen at the front of the wheel by 1/4inch.d. If the toe-in is not correct, remove the cotterp i n _ ( 2 7 , f i g . 4 - 1 0 ) and nut (28) that secure each tierodendball stud (29)to the spindles and knuckles(30).Disengage the tie rod endball studs (29)andtie rods(25).e. Using a straightedge along the sides of thefro fit and rear wheels, position the front wheels sothey are correctly aligned with just sufficient toe-in(refer to s t e p c. above).f. Adjust the tie rod ends (29) on the tie rods (25)as directed in p a r a g r a p h 4 - 3 6 above and reconnectthe tie rods.L O A D B A N K.bank capacity. ) Thus, the utility load continues to besupplied without risk of generator set overload.When the generator set load diminishes the load bankis reconnected by manually resetting the over tem-perature reset switch. During the manual modeprotection of the generator set against overloads isthe responsibilityof the operator by monitoring thegenerator set control panel KW meter. If setsrated load capacity is exceeded, the operator reducesor removes the load bank load with the ‘% load selectorrotary switch.e. A fan and motor assembly provides for coolingthe~oad bank resistive load (heater elements).f. The thermostatic switch operates the trip coilof t~e over temperature reset switch removing theselected load from the generator set when tempera-ture within load bank reaches 450° F +- 15° F. Theswitch closes with temperature at 450m F +- 15° Fand opens with temperature at 3510F + 15~F.g. The purpose of the resistive load (heater ele-mefits) is to provide a partial load for the generatorset if the normal utility load is too low to keep setoperating without carbonization of the engine.h. For load bank operating instructions, refer top a r a g r a p h 2 - 2 7 .4 - 3 9 . I n s t a l l a t i o n .See f i g u r e s 1 - 1 , 1 - 2 , 1 - 2 1 , 1 - 2 6 o r 1 - 2 7 , a n d 4 - 1 3and proceed as follows:~. Stop generator set.b Set % LOAD SELECTOR switch to OFF.—“C h a n g e 14 - 2 9
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