Operation and Maintenance ManualIntroduction This manual contains operation and service information...

OM-2094A080101

1. Hobart Brothers Company (hereinafter called HOBART) warrants that each new and unused Hobart Ground

Power Equipment, (hereinafter called the PRODUCT) is of good workmanship and is free from mechanical defects,

Operation and Maintenance Manual

Hobart Brothers CompanyGround Power Division

Troy, Ohio 45373U.S.A.

Jet-Ex 5D Generator Sets

Series 500285A

provided that (1) the PRODUCT is installed and operated in accordance with the printed instructions of HOBART,

(2) the PRODUCT is used under the normal operating conditions for which it is designed, (3) the PRODUCT is not

subjected to misuse, negligence or accident, and (4) the PRODUCT receives proper care, lubrication, protection,

and maintenance under the supervision of trained personnel.

2. This warranty expires 15 months after shipment by HOBART to the first user, or 12 months after installation,

whichever first occurs.

3. This warranty does not apply to: primary and secondary switch contacts, cable connectors, carbon brushes, fuses,

bulbs, and filters unless found to be defective prior to use.

4. Hobart DOES NOT WARRANT THE FOLLOWING COMPONENTS: Engines (gasoline or diesel),storage

batteries, engine starters generators, alternators, regulators, governors, tires, axles,transmissions, and cable

retrieving devices. Many of the foregoing components are warranted directly by the manufacturer to the first user

and serviced by a worldwide network of distributors and others authorized to handle claims for component

manufacturers. A first user’s claim should be presented directly to such an authorized component service outlet.

In the event any component manufacturer has warranted its component to HOBART and will not deal directly with

a first user then HOBART will cooperate with the first user in the presentation of a claim to such manufacturer.

Under NO circumstances does HOBART assume any liability for any warranty claim against or warranty work

done by or in behalf of any manufacturer of the foregoing components.

5. This warranty is extended by HOBART only to the purchaser of new PRODUCTS from HOBART or one of its

authorized distributors. The PRODUCTS purchased under this warranty are intended for use exclusively by the

buyer and his employees and by no other persons and, therefore, there shall be no third party beneficiary to this

warranty.

6. A claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and

judgment. HOBART’S liability is limited to repair of any defects found by HOBART to exist, or at HOBART’S

option the replacement of the defective product, F.O.B. factory, after the defective product has been returned by

the purchaser at its expense to HOBART’S shipping place. Replacement and exchange parts will be warranted for

the remainder of the original Warranty, or for a period of ninety (90) days, whichever is greater.

7. UNDER NO CIRCUMSTANCES whatsoever shall HOBART and its authorized distributors be liable for any special

or consequential damages, whether based on lost goodwill, lost resale profits, work stoppage impairment of other

goods or otherwise, and whether arising out of breach of any express or implied warranty, breach of contract,

negligence or otherwise, except only in the case of personal injury as may be required by applicable law.

8. Continued use of the PRODUCT(S) after discovery of a defect VOIDS ALL WARRANTIES.

9. Except as authorized in writing, this warranty does not cover any equipment that has been altered by any party

other than HOBART.

10. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE OF.

HOBART MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR FITNESS FOR

A PARTICULAR PURPOSE.

11. HOBART neither assumes nor authorizes any person to assume for HOBART any liability in connection with the

PRODUCTS sold, and there are no oral agreements or warranties collateral to or affecting this written Warranty.

This warranty and all undertakings of HOBART thereunder shall be governed by the laws of the State of Ohio,

United States of America.

HOBART BROTHERS COMPANY, TROY, OHIO, U.S.A.GROUND POWER DIVISION

WARRANTY

WARNINGAT ALL TIMES, SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE INSTALLATION,

SERVICING AND OPERATION OF THE PRODUCT, AND SKILLED, TECHNICALLY QUALIFIED PERSONNELSHOULD ALWAYS BE EMPLOYED FOR SUCH TASKS.

Safety Warnings and Cautions

CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine exhaust

and some of its constituents are known to the State of California to cause

cancer, birth defects and other reproductive harm.

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

ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage,

and ignite combustible material. DO NOT use power cables to break load and

prevent tools from causing short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage

this and attached equipment.

Protect all operating personnel. Read, understand, and follow all instructions in

the Operating/Instruction Manual before installing, operating, or servicing the

equipment. Keep the manual available for future use by all operators.

1. General

Equipment that supplies electrical power can cause serious injury or death, or damage to otherequipment or property. The operator must strictly observe all safety rules and take precautionaryactions. Safe practices have been developed from past experience in the use of power sourceequipment. While certain practices below apply only to electrically-powered equipment, other practicesapply to engine-driven equipment, and some practices to both.

2. Shock Prevention

Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatallyshock a person. Have a certified electrician verify that the equipment is adequately grounded and learnwhat terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,procedures, and test equipment.

The electrical resistance of the body is decreased when wet, permitting dangerous currents to flowthrough it. When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubbermat or dry wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry,and never work alone

a. Installation and Grounding of Electrically Powered Equipment

Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installedand maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or other applicablecodes. A power disconnect switch or circuit breaker must be located at the equipment. Check thenameplate for voltage, frequency, and phase requirements. If only 3-phase power is available,connect any single-phase rated equipment to only two wires of the 3-phase line. DO NOTCONNECT the equipment grounding conductor (lead) to the third live wire of the 3-phase line, asthis makes the equipment frame electrically HOT, which can cause a fatal shock.

August 01, 2001 Safety WarningsPage 1

OM-2094 A/ Operation and Maintenance Manual

Jet-Ex 5D / Series 500285A / Generator Set

IMPORTANT

WARNING

WARNING

Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box orbuilding ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)capacity of the grounding lead will be adequate for the worst fault current situation. Refer to theNational Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs. Usecorrectly mating receptacles.

b. Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the connectors. Replace or repaircracked or worn cables immediately. Do not overload cables. Do not touch output terminal whileequipment is energized.

3. Service and Maintenance

This equipment must be maintained in good electrical and mechanical condition to avoid hazardsstemming from disrepair. Report any equipment defect or safety hazard to the supervisor anddiscontinue use of the equipment until its safety has been assured. Repairs should be made byqualified personnel only.

Before inspecting or servicing electrically-powered equipment, take the following precautions:

a. Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing theequipment.

b. Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally.

c. Disconnect power to equipment if it is out of service.

d. If troubleshooting must be done with the unit energized, have another person present who is trainedin turning off the equipment and providing or calling for first aid.

4. Fire And Explosion Prevention

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaustpiping, misuse of batteries and fuel, or unsafe operating or fueling conditions.

a. Electrical Short Circuits and Overloads

Overloaded or shorted equipment can become hot enough to cause fires by self destruction or bycausing nearby combustibles to ignite. For electrically-powered equipment, provide primary inputprotection to remove short circuited or heavily overloaded equipment from the line.

b. Batteries

Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a rupturedbattery can cause fires and additional failures. When servicing, do not smoke, cause sparking, oruse open flame near the battery.

c. Engine Fuel

Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tankis not grounded prior to or during fuel transfer. Shut unit DOWN before removing fuel tank cap. DONOT completely fill tank, because heat from the equipment may cause fuel expansion overflow.Remove all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, openequipment doors and blow fumes away with compressed air.

5. Toxic Fume Prevention

Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaustfumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of airconditioners.

6. Bodily Injury Prevention

Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipmentfor inspection and routine maintenance. When equipment is in operation, use extreme care in doingnecessary trouble-shooting and adjustment. Do not remove guards while equipment is operating.

Safety Warnings August 01, 2001Page 2

OM-2094A / Operation and Maintenance Manual


7. Medical and First Aid Treatment

First aid facilities and a qualified first aid person should be available for each shift for immediatetreatment of all injury victims. Electric shock victims should be checked by a physician and taken to ahospital immediately if any abnormal signs are observed.

Call physician immediately. Seek additional assistance. Use First Aid techniques

recommended by American Red Cross until medical help arrives.

IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie

down. FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not

breathing, begin artificial respiration, preferably mouth-to-mouth. If no detectable

pulse, begin external heart massage. CALL EMERGENCY RESCUE SQUAD

IMMEDIATELY.

8. Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot beeasily read.

August 01, 2001 Safety WarningsPage 3

OM-2094A/ Operation and Maintenance Manual


EMERGENCY

FIRST AID

This page intentionally left blank.

Safety Warnings August 01, 2001Page 4



Introduction

This manual contains operation and service information for 28.5 V DC Generator sets identified as Jet-Ex 5D.These units are available as stationary, skid- mounted units, or they may be trailer-mounted for portability.Both versions are available with 14 V DC output capability.

Most information in the manual applies to the 28.5 V Jet-Ex 5D in general. Information which applies tooptions and special equipment are listed in Appendix A.

The primary purpose of the manual is to provide information and instructions to experienced operators,electricians, and mechanics who are not familiar with this equipment. The intent of the manual is to guideand assist operators and maintenance personnel in the proper use and care of the equipment.

Read the instructions before starting the unit. Learn to use the manual and to locate information contained init.

The Table of Contents, which follows this Introduction, lists all Chapters, Sections, and the paragraph titleswithin each Section. The location of each listing is identified by Chapter, Section and page number.

Each Chapter is divided into as many Sections as necessary. Sections are always referred to by acombination Chapter-Section number, for example: 2-3 refers to Chapter 2, Section 3.

The material within each Section is divided into main subjects with applicable paragraph headings andsub-headings as required. For example, a portion of the Description Section might logically follow thisarrangement and paragraphing:

Section 1. Description

1. Engine, Generator and Controls

a. Interior Panel

(1) Protective devices

a. Overload relay

(2) Contactors

Page numbers do not run consecutively throughout the manual. Each page is identified by theChapter-Section number in which it appears, and by a page number within the Chapter-Section. Therefore,the first page in each Section is page 1. These identifying numbers appear in the lower, outside corner ofeach page. Each page also bears a date located in the corner opposite the page number. This date is eitherthat of original issue, or of the latest revision. Any revision to the original text is identified by a heavy black linein the left-hand margin. Illustrations follow a numbering system similar to page numbering. The first Figure ineach Section is Figure 1.

All tables, charts, as well as illustrations, are identified by Figure numbers to avoid confusion.

The general location of any particular information can be found quickly by running through the Table ofContents. For example: to locate any adjustment information, a quick look at the Table of Contents shows that“Adjustment / Test” is located in Chapter 2, Section 3, (shown as 2-3).

August 01, 2001 IntroductionPage 1



Portions of the text are referred to by identifying the paragraph in which the referenced material may befound. When referenced material is located in the same Chapter/Section as the reference, only the paragraphidentification is given, for example: (Ref. Para. 1, A) means that the material is to be found in paragraph 1, A,of the same Section.

When referenced material is located in another Chapter/Section, both the Chapter and Section numbers andthe paragraph identification are given, for example: (Ref. 1-2, Para. 1, A) means that the referenced materialis located in Chapter-Section 1-2, and paragraph 1,a. within that Chapter-Section.

Components shown in illustrations, and the illustrations themselves, are referenced in a similar manner.When this type of reference is made, the item number of the part and the Figure number in which it appearsare given, for example: (2, Fig.3) refer to item number 2 in illustration Figure 3 of the same Chapter/Section.

When a referenced figure appears in another Chapter/Section, the reference will include the Chapter/Sectionnumber, for example: (2-3, 1, Fig. 4) tells the user that the information is in Chapter/Section 2-3, and to referto item 1 in Figure 4.

Once a Figure number reference has been established, the Figure number is not repeated and only the itemnumbers of the parts involved are referenced, for example: “Loosen screw (2, Fig.6) slide out connector (4),and remove brush (6).

When an item number is referenced without a Figure number, it always applies to the last preceding Figurenumber mentioned in the text.

A collection of manufacturer’s literature is supplied as part of the information package.

If you have any questions concerning your Hobart Ground Power equipment, immediately contact ourService Department by mail, telephone or FAX.

Write: Hobart Brother Company

Ground Power Division

Service Department

1177 Trade Road East

Troy, Ohio 45373

U.S.A.

In U.S.A. Call: (800) 422-4166 (Parts)

(800) 422-4177 (Service)

From Foreign Countries Call: (937) 332-5050 (Parts)

(937) 332-5060 (Service)

FAX: (937) 332-5121(800) 367-4945 Toll Free in U.S.A.

Introduction August 01, 2001Page 2


Jet-Ex 5D / Series 500285 A/ Generator Set

Table of Contents

Chapter 1. Description/Operation

Section 1. Description 1

General 1

Special Features 1Standard 1

Options 1

Orientation 4

Identification 4

Canopy 4

Engine, Generator, and Controls 4General 4

Engine 4

Generator 9

Rectifier Assembly 9

Ammeter Shunt 9

Contactor 9

Control Box Assembly (Front) 11

Control Box Assembly (Inside) 15

Emergency Sutdown Device 15

Section 2. Preparation for Use, Storage or Shipping 1

Preparation for Use 1General 1

Inspection/Check 1

Output Cable Requirements and Installation 1

Preparation for Storage 3General 3

Temporary Storage 3

Long Time Storage 3

Preparation for Shipping 3

Section 3. Operation 1

General 1

Operating the Generator Set 1Pre-start Inspection 1

Pre-start Instructions 1

Starting The Engine 3

August 01, 2001 Table of ContentsPage 1



Generator Operation 3

Deliver Power 3

Stop Operation (Shutdown) 3

Adverse Weather Precautions 4

Chapter 2. Servicing / Troubleshooting

Section 1. Maintenance Inspection/Check 1

General 1

Maintenance Schedule 1General 1

Maintenance Schedule Check Sheet 1

Time Intervals 1

Engine and Related Components 1

Inspection and Cleaning 3

Section 2. Maintenance Procedures 1

General 1

Lubrication 1General 1

Lubrication Chart 1

Generator 1

Generator Controls 1

Engine 1

Servicing the Air Cleaner 4Air Filter Cartridge Removal 4

Air Filter Cartridge Installation 4

Servicing the Fuel Filter 4

Drive Belt Service 4

Engine Cooling System 4Radiator Cap Removal 5

Rust Inhibitor 5

Antifreeze 5

Battery Service 5General 5

Battery Location and Accessibility 5

Battery Care 5

Liquid Level (If Battery is not Maintenance Free) 5

Cleaning the Battery 6

Testing a Battery 6

Generator Maintenance 7General 7

Brush Service 7

Generator Revolving Field Brush Replacement 7

Table of Contents August 01, 2001Page 2



Section 3. Adjustment/Test 1

General 1

Testing the Generator Set 1Pre-operational Test Procedures 1

Operational Tests 3

Voltage Regulator Adjustment 428.5 Volt Adjustment 4

Line Drop Compensation 4

Section 4. Troubleshooting Procedures 1

General 1

Troubleshooting Chart 1Description 1

Use of the Troubleshooting Chart 1

Equipment for Troubleshooting 1

Safety Precautions 1

Diagrams 1

Connections and Wiring 1

Section 5. Troubleshooting Charts 1-8

Chapter 3. Major Overhaul

Section 1. Flexible Coupling 1

General 1

Coupling Screws (Routine Coupling Maintenance) 2

Disassembly 3Separate Engine and Generator 3

Remove Coupling Assembly 3

Coupling Service 4

Coupling Installation and Reassembly of Engine Generator 5Cleaning 5

Assembly 5

Run-In and Periodic Check 7

Chapter 4. Illustrated Parts List

Section 1. Introduction 1

General 1

Purpose 1

Arrangement 1

August 01, 2001 Table of ContentsPage 3



Explanation of Parts List 1Contents 1

Parts List Form 1

Section 2. Manufacturer’s Codes 1

Explanation of Manufacturer’s (Vendor) Code List 1

Section 3. Parts List 1

Explanation of Parts List Arrangement 1

Symbols and Abbreviations 1

Section 4. Numerical Parts List 1

Explanation of Numerical Parts List 1

Chapter 5. Manufacturer’s Literature

Appendix A. Options / Features

Table of Contents August 01, 2001Page 4



Chapter 1. Description/Operation

Section 1. Description

1. General

The Jet-Ex 5D units (Figure 1) covered in this manual are diesel engine driven, self-containedgenerator sets manufactured by Hobart Brothers Company, Ground Power Division, Troy, Ohio U.S.A.A basic unit is identified by a Series Number - 500285A - plus a dash number which defines a specificconfiguration. The Series Number, plus the dash number, make up the Specification Number.

Part Number Mounting Configuration

500285A-001 Trailer Mounted with CableTrays

500285A-002 Stationary Mounted withCable Hangers

Specification No. 500285A-001 covers a trailer mounted unit rated at 28.5 Volts DC output. It isequipped with a sheet metal canopy and four hinged engine compartment doors. Various options areavailable for use with the basic unit. A few of these options are listed in paragraph 2.B below, but thecomplete list of options are located in Appendix A.

The basic generator set is designed to generate and deliver 28.5 Volts DC power to an aircraft when itson-board generators are shut down. In addition to providing continuous, regulated power to the aircraft,the unit is also designed for starting any fixed-wing aircraft or helicopter which is equipped with anexternal 28.5 Volts DC power receptacle.

2. Special Features

a. Standard

The “Soft-Start” current limiting feature, recommended by most aircraft engine manufacturers,provides the operator with controls to limit the inrush current to the aircraft engine’s starter. Whenthe operator presets this control, the generator will provide constant voltage to the preset currentvalue. The more current is increased beyond the preset current value, the voltage will decrease to aminimum of 14 volts DC, after which the voltage will remain constant as more current may bedelivered beyond the preset current value. Limiting inrush current is recommended by most enginemanufacturers to protect the aircraft engine’s starter shear section. The current limiting control iscontinuously adjustable from 300 amperes, which is recommended for helicopter and small turbinestarting, to 2000 amperes, required for starting larger aircraft engines when the control is turnedfully clockwise.

b. Options (See Appendix A for complete list)

Chapters 1-5 of this manual describes a basic “no options” generator set. Appendix A lists theoptions available for this unit. Below are the mounting configurations.

August 01, 2001 Chapter 1-1Page 1



Chapter 1-1 August 01, 2001Page 2



Jet-Ex 5D Generator Set(Stationary Mounted Unit Shown)

Figure 1

Unit with Stationary Mount (500285A-002)

Length 68” (172.7 cm)

Width 37” (94 cm)

Height 46” (116.8 cm)

Weight (dry fuel tank) 2400 lbs (1088.6 kg) Approx.

Unit with Trailer and Cable Trays (500285A-001)

Length (with tow-bar up) 94.5” (240 cm)

Width 67” (170.1 cm)

Height 62” (157.5 cm)

Weight (dry fuel tank) 2670 lbs (1211 kg) Approx.

Ground Clearance 14” (35.6 cm)

Generator

Output Power Rating 17.1 kW

Voltage 28.5 volts DC

Rated Load Capacity 800 amperes continuous at 28.5 volts DC

Starting Current Capacity 2000 amperes maximum

Current Limiting Capability 300 to 2000 amperes, continuously adjustable

Operating Speed 2500 +/-50 RPM

Engine

Manufacturer Cummins Diesel

Model 4BT3.9

Type 4-cylinder, 4-stroke, direct injection

Fuel-Diesel recommended ASTM D975 66T Numbers 1D or 2D

Displacement 238 cubic inches (3.9 liters)

Rated Power at 2200 RPM 100 Horsepower (75 kW)

Oil Capacity (without filter change) 11.5 quarts (10.9 liters)

Coolant Capacity - engine only 7.4 U.S. Quarts (7 liters)

Coolant Capacity - system 4.5 U.S Gallons (17 liters)

Electrical System 12 volt DC, negative ground

Governed Speed at No Load 2500 +/- 50 RPM

Idle Speed 1000 +/- 50 RPM

Fuel Tank Capacity 20.5 U.S. gallons (77.6 liters)

Protective Devices

Generator 28.5 volt over voltage module trips at 32 to 34 volts.

EngineWater Temperature Switch opens engine circuit at 210º F(98.8º C)

Low Oil Pressure Switch opens at 20 PSI (138 kPa).




3. Orientation

The radiator end of the Jet-Ex 5D is the front. Right and left are determined by standing at the rear ofthe unit, facing it. The control panel is located at the rear.

4. Identification

The Jet-Ex 5D unit is identified by Specification numbers as described in paragraph 1. There may beany number of Generator sets with the same Specification number. Individual machines are identifiedby a Serial number, assigned to one machine only.

Each generator set has an Identification plate attached inside the control box. This nameplate lists themachines Model No. (Jet-Ex 5D), Specification No., Serial No., and electrical rating.

If any of the options described in paragraph 2.b. are included, they will be listed by name and partnumber on a separate option nameplate located next to the Identification plate.

5. Canopy

The standard canopy is a sheet metal enclosure which protects the engine, generator, and electricalcontrols. It has four hinged doors to provide access for service and maintenance. A bolted on panel atthe rear (below the control box) provide access to the rectifier assembly. A Lexan window is mounted infront of the control panel to allow observation of the instruments while protecting them from theweather.

6. Engine, Generator, and Controls

a. General

The engine (7, Figure 2) and generator (5) are mounted on a welded steel frame (6). A fuel tanksupport (1) located at the rear of the unit supports the fuel tank (2) and provides a mounting framefor the load contactor (10) and output terminals. The radiator (7, Figure 4) is mounted to the frontcanopy and frame.

b. Engine

(1) General

The engine used in the Jet-Ex 5D generator set is a Cummins Model 4BT3.9 four-cylinder,four-stroke, direct injection diesel engine. It has a 238 cubic inch (3.9 liter) cylinder displacementand a 17.5:1 compression ratio. Engine firing order is 1-3-4-2.

A spring-loaded relief valve in the oil pump limits maximum pressure in the system. A full-flow oilfilter (3, Figure 3) cleans the oil before it enters the oil distributing system. A low oil pressureswitch is mounted on the engine block as a protective device. The fuel valve solenoid circuit iswired through the contacts of this switch, which closes at 20 PSI (138 kPa). This prevents theengine from continuing operation if oil pressure will not build up, and also shuts down the engineif oil pressure drops radically during operation.

See the engine operator’s manual for additional engine specifications.

The generator and engine are mounted on a welded steel skid, and are enclosed by a sheetmetal canopy that bolts to the skid. Access to engine serviceable components (oil filter, aircleaner, etc.) is through the doors on each side of the machine.

The rear panel is removable and permits access to the rectifier assembly.







7 2 1

3

4

569

8

10

1. Fuel Tank Support

2. Fuel Tank

3. Control Panel

4. Rectifier Assembly

5. Generator

6. Frame

7. Engine

8. Air Cleaner

9. Battery

10. Contactor

Generator Set Components

Figure 2




4

5

2

1

3

1. Muffler

2. Alternator

3. Oil filter

4. Starter

5. Starter solenoid

Generator Set Components(Left Side)Figure 3




4

5

1

267

3

1. Fuel filter2. Air cleaner3. Throttle control assembly4. Oil pressure sender5. Oil pressure switch 20 psi (138 kPA)6. Water Temp. Switch7. Radiator

Generator Set Components(Right Side)

Figure 4

(2) Cooling fan

The cooling fan on the engine is designed to blow air out through the radiator rather than to drawit in. This prevents hot air, heated by the engine, from entering the generator.

(3) Fuel system

The fuel system consists of a 20.5-gallon (77.6 liters) plastic fuel tank (2, Figure 2) with all thenecessary fittings and hoses.

(4) Alternator

The battery charging alternator (2, Figure 3) is rated at 65 amperes. The alternatorsresponsibility is to produce/regulate 12V DC for the generator sets internal electrical system.

(5) Starter solenoid

The starter solenoid (5, Figure 3) is mounted on the starter motor (4), on the right side of theengine.

(6) Exhaust muffler (1, Figure 3)

This muffler helps deaden audible noise from the engine’s exhaust.

(7) Engine faults

The following is a table listing faults which may occasionally occur. Column two of the tableexplains what happens in the engine’s circuitry when the fault occurs, and column three tells howto return the generator set to service.

ENGINE FAULTS

Engine Fault Condition What This Fault Condition DoesTo Put the Generator Set Back

into Service:

Over Temperature Automatically removes powerfrom the fuel valve solenoid andshuts down the engine

a) Let the engine cool downenough to check for low coolantlevel and or faulty overtemperature switch. Restartengine.

Low Oil Pressure Automatically removes powerfrom the fuel valve solenoid andshuts down the engine

a) Let the engine cool downenough to check for low oil leveland or faulty oil pressure switch.Restart engine.

Clogged air cleaner orother restriction in thecombustion air inlet.

Turns on the air cleanerrestriction indicating light(16, Figure 5)

a) Replace clogged air filter ifneeded; clean out the air intakechamber. Restart engine.




c. Generator

The generator (5, Figure 2) is a multi-phase, synchronous salient pole, revolving field, AC generatorwhose output is rectified. The output is rectified by a rectifier assembly (4) made up of twelverectifiers connected into a full wave configuration. The generator is self-excited, receiving excitationfrom a three phase full wave rectified stator winding. One positive and one negative brush in contactwith slip rings supply controlled excitation current from the stator winding through the voltageregulator to the rotating field winding. The voltage regulator, controls the excitation current andmaintains a constant output voltage. Access to the brushes is through holes in the anti-drive endbracket. The rotor is supported at the anti-drive end (slip ring end) by a single-row ball bearing. Thedrive end is connected to the engine fly-wheel by a flexible disc and hub coupling assembly and issupported by the engine main bearings. A radial-blade fan of formed and welded sheet metalconstruction is mounted on the coupling hub and draws cooling air over the generator windings.

Air flows over the rectifier assembly (4, Figure 2) and then enters through the anti-drive end of thegenerator and is discharged through openings in the flywheel housing at the drive end. Thegenerator housing assembly, which contains the generator stator, is bolted to the engine flywheelhousing.

d. Rectifier Assembly

The Rectifier Assembly (4, Figure 2) consists of two aluminum heat sinks with six diodes on eachheat sink. The rectifier assembly converts the AC output of the generator to 28.5 Volts DC.

e. Ammeter Shunt

The ammeter shunt is connected in the generator’s negative output circuit. It supplies a smallvoltage proportional to output current for operation of the AMMETER (4, Figure 5), and to thecurrent limit circuit of the voltage regulator (2, Figure 6). This shunt is mounted on the negative heatsink of the rectifier assembly (4, Figure 2).

f. Contactor K402 (10, Figure 2)

The load contactor, which is mounted on the right side of the unit below the fuel tank, provides asafe and convenient means of connecting and disconnecting the generator from the load. Initialpower for closing the load contactor is supplied by the generator through the spring-loadedmomentary contacts of the CONTACTOR CONTROL toggle switch (7, Figure 5). Holding power, tokeep the contactor closed, passes through the normally open auxiliary contacts in the loadcontactor. Output power connection is made by attaching the positive lead to the top terminal of theload contactor, and the negative lead to the negative output terminal located above the loadcontactor.







1. TACHOMETER (M403)

2. HOUR METER (M402)

3. VOLTMETER (generator) (M406)

4. AMMETER M407

5. PANEL LIGHTS FUSE (10 amp) (F401)

6. PANEL LIGHTS toggle switch (S405)

7. CONTACTOR CONTROL toggle switch (S408)

8. CONTACTOR CLOSED lamp (DS408)

9. CURRENT LIMITING CONTROLpotentiometer (R402)

10. SPEED CONTROL toggle switch (S406)

11. ENGINE ON lamp (DS407)

12. ENGINE START push button switch(S401)

13. ENGINE CIRCUIT toggle switch (S404)

14. ENGINE CIRCUIT FUSE (20 Amp) (F402)

15. WATER TEMPERATURE gauge (M404)

16. AIR FILTER RESTRICTIONINDICATOR lamp (DS412)

17. OIL PRESSURE gauge (M405)

18. FUEL gauge (M408)

19. VOLTMETER (battery) (M401)

Control Box Assembly

(Front View)

Figure 5

g. Control Box Assembly (Front) (Figure 5)

The Control Box Assembly (Figure 5) houses and provides mounting facilities for controls,monitoring instruments, voltage regulator, relays, etc. The box is mounted at the rear of thecanopy. Its control are accessible behind a hinged plastic cover.

(1) TACHOMETER (M403)

This instrument receives its operating signal from the alternator to display the engine speed inRPM.

(2) HOUR METER (M402)

The HOUR METER records the total hours of engine operation for scheduling maintenance.

(3) VOLT METER, generator (M406)

The VOLT METER indicates generator output voltage.

(4) AMMETER (M407)

The AMMETER displays generator current output.

(5) PANEL LIGHTS FUSE (F401)

This protects the panel lights circuit.

(6) PANEL/CLEARANCE LIGHTS toggle switch (S405)

The PANEL/CLEARANCE LIGHTS toggle switch turns the panel and clearance lamps on andoff.

(7) CONTACTOR CONTROL toggle switch (S408)

The CONTACTOR CONTROL toggle switch is a three-position toggle switch used to close andopen the output load contactor. The top CLOSE position is spring-loaded and is heldmomentarily until the CONTACTOR CLOSED lamp (8) glows, then it is released to the centerON position. In this position the switch provides holding current to the load contactor to keep itclosed. Protective devices in the load contactor circuit provide protection against over voltage byopening the load contactor if that condition occurs. In the bottom OFF position, the contactor isopened.

(8) CONTACTOR CLOSED lamp (DS408)

The CONTACTOR CLOSED lamp glows green when the output load contactor is closed.

(9) CURRENT LIMITING CONTROL POTENTIOMETER (R402)

The CURRENT LIMITING CONTROL POTENTIOMETER is used to select the starting currentrecommended for various aircraft. The current limiting setting is continuously adjustable from300 to 2000 amperes.

(10) SPEED CONTROL toggle switch (S406)

The SPEED CONTROL toggle switch is a two position switch wired to a throttle solenoid on theengine. In the IDLE position, used for starting, the engine speed is controlled to approximately1000 RPM. In the Rated RPM position, engine speed is controlled to approximately 2500 RPM.

(11) ENGINE ON lamp (DS407)

The ENGINE ON lamp glows green when the engine is running.




(12) ENGINE START push button switch (S401)

The ENGINE START push button switch is a momentary contact switch which closes the startersolenoid (5, Figure 3) circuit and cranks the engine. This switch is operable only when theENGINE CIRCUIT toggle switch (13, Figure 5) is held in its top spring-loaded START position.

(13) ENGINE CIRCUIT toggle switch (S404)

The ENGINE CIRCUIT toggle switch must be held in the top START position and the ENGINESTART push button (12) must be depressed TO START THE GENERATOR SET. Whenreleased from its top START position after the engine starts, this toggle switch will return tocenter RUN position. The ENGINE ON lamp (11) will glow as long as the switch is in RUNposition. In the bottom STOP position, this switch will stop the engine and the lamp (11) will goout.

(14) ENGINE CIRCUIT fuse (F402)

The ENGINE CIRCUIT fuse (20 amp.) protects the engine circuitry.

(15) WATER TEMPERATURE gauge (M404)

The WATER TEMPERATURE gauge indicates the engine coolant temperature and is actuatedby a temperature sender (6, Figure 4) mounted on the engine’s water jacket.

(16) AIR FILTER RESTRICTION lamp (DS412)

The AIR FILTER RESTRICTION lamp glows red when the air filter needs changed.

(17) OIL PRESSURE gauge (M405)

The OIL PRESSURE gauge displays the pressure in the engine’s lubrication system. It isoperated by a sender (4, Figure 4) mounted on the engine block.

(18) FUEL gauge (M408)

The FUEL gauge indicates the amount of fuel remaining in the fuel tank.

(19) VOLTMETER (battery) (M401)

The battery VOLTMETER indicates the voltage of the engine’s 12 volt DC electrical system.







1. Over voltage relay (K403)

2. Voltage regulator (VR402)

3. Excitation rectifiers (CR417 & CR418)

4. Control windings fuses (10 Amp.) (F406 - F408)

5. Voltage build-up fuse (10 Amp.) (F405)

6. Voltage regulator fuse (10 Amp.) (F403)

7. Throttle solenoid fuse (20 Amp. Slo-Blo) (F409)

8. Control Panel Lights (DS401, DS402 & DS420)

9. Rectifier Harness Connector (J43)

10. Engine Harness Connectors (J46 & J47)

11. Rectifier (CR401)

12. Capacitor (C403)

Control Box Assembly(Interior View)

Figure 6

h. Control Box Assembly (Interior)

Numbers in parentheses below can be crossed referenced in Figure 6

(1) Over voltage relay (K403)

The over voltage relay is a solid-state protective device on a printed circuit board. A normallyclosed relay in the circuit is wired into the load contactor coil circuit. An over voltage conditioncauses the relay contacts to open, which in turn prevents the contactor from closing, or opensthe load contactor and discontinues the power delivery. The over voltage module is adjusted totrip at 32 to 34 volts DC in .5 seconds ±.2 seconds.

(2) Voltage regulator (VR402)

The voltage regulator is a solid-state device which regulates the 28.5 Volts DC generator outputafter the voltage is built up.

(3) Excitation rectifiers (CR417 and CR418)

Two diode bridge rectifiers, convert an AC voltage from the generator armature to the DCvoltage needed for the generator revolving field.

(4) 3 Control Windings Fuses—cartridge-type—10 amp each (F406 - F408)

(5) Voltage Build-up Fuse—cartridge-type—10 amp (F405)

(6) Voltage Regulator Fuse—cartridge-type—10 amp (F403)

(7) Throttle Solenoid Fuse—cartridge-type—20 amp (F409)

(8) Control Panel Lights (DS401, DS402, & DS420)

Three control panel lights provide illumination for instruments and controls.

(9) Rectifier Harness Connector (J43)

Provides connections between the control box and the Rectifier assembly.

(10) Engine Harness Connectors (J46 & J47)

Provides connections between the control box and engine compartment components.

(11) Rectifier (CR401)

Automatic Voltage Build-Up.

(12) Capacitor (C403)

A 100mfd, 350V DC Capacitor, that filters the DC excitation volts produced by rectifiers CR417and CR418.

i. EMERGENCY SHUT DOWN DEVICE

In addition to the other devices provided by the engine manufacturer, an engine shutdown feature isadded by Hobart Brothers. Since diesel engines typically require several minutes of running at idlespeed before shutdown, this push button switch is intended for use in emergencies only.

(1) EMERGENCY SHUTDOWN push button switch S413

This push button switch has one purpose: To provide immediate shut off of the generator set bydisconnecting power to the fuel solenoid through the control box. Once pushed, it must bepulled back out to restart the generator set. It is located on the rear panel, below the control box.

To operate the EMERGENCY SHUTDOWN push button switch:

� Push button in until engine stops or until button travel stops.

� Pull the button back out to reset.




Section 2. Preparation for Use, Storage or Shipping

1. Preparation for Use

a. General

The generator set is shipped with an empty fuel tank. After the fuel tank is filled and the generatorset is inspected, the generator set is ready for use.

Read operating instructions in Section 1-3 before operating the unit.

b. Inspection/Check

Inspect the unit completely prior to operation.

(1) Remove crating, blocking, banding, ties, and other securing and protective material.

(2) Inspect exterior for shipping damage such as broken glass, damaged sheet metal, etc.

(3) Open canopy doors and inspect interior for foreign material such as rags, tools or shippingpapers.

(4) Check the fuel and coolant systems, also the oil hoses and their connections for visible leaks. Ifleaks are discovered, correct by tightening hose clamps, tube fittings, etc., as required.

(5) Check security of attaching and retaining hardware.

(6) Check the following for sufficient quantity.

a. Fuel

Fuel tank capacity is 20.5 gallons (77.6 liters).

b. Engine coolant

The radiator cap is located under the hinged door, at the front of the unit, on the top canopy.The coolant level should be approximately one inch below the filler neck to allow for sufficientcapacity for coolant expansion.

Be sure the cooling system antifreeze solution is adequate to protect below

lowest temperature expected.

c. Engine lubricating oil

The oil level dipstick is located on the left side of the engine. Refer to the EngineManufactures User’s handbook for oil recommendations.

c. Output Cable Requirements and Installation

Jet-Ex 5D units are normally supplied with a 30ft. generator-to-aircraft output cable. This outputcable consists of two single conductor 4/0 cables.

(1) Cable requirements

� Cable length is determined by the customer’s requirements. It is recommended that thecable be no longer than 30 feet (9 m). It should be two conductor with lug-type terminalson one end and an AN-2551 plug connector on the other.




CAUTION

CAUTION

� The recommended cable size for 28.5 volt DC is determined by the maximum starting loadamperage expectations. A maximum starting load of 1500 amps. requires two singleconductor 4/0 cables. A maximum starting load of 600 amps. requires two singleconductor 2/0 cables.

NOTE: Some operators may wish to add a second cable assembly with MS-25019 plug connector forstarting aircraft such as Jetstar and Sabre liner.

(2) Cable connection (See Figure 1)

� Open and remove the right rear door and the panel below the door. Set aside.

� Loosen the output cable clamp and thread the lugged end of the output cable through theopening in the right side of the unit.

� Connect the POSITIVE cable lead to the output terminal on the contactor. Connect theNEGATIVE cable lead to the negative output terminal located above the load contactor.ALWAYS place the lead under the flat washer shown.




Positive Cable Connection

Negative Cable Connection

Output Cable Connections(Right Side of Unit)

Figure 1

� Tighten the cable clamp and install the lower panel, and the door.

� Store cables in cable tray or on hangers on side of canopy if fenders are not used.

2. Preparation for Storage

When a generator set is to be stored or removed from operation, special precautions should be takento protect the internal and external parts from rust and corrosion.

a. General

The unit should be prepared for storage as soon as possible after being removed from service.

Storage should be in a building which is dry and which may be heated during winter months.

b. Temporary Storage

When storing the unit for one month, prepare as follows:

(1) Lubricate the unit completely in accordance with instructions in Section 2-2; Para. 2. This willinclude changing engine oil, and filter elements.

(2) Make certain the cooling system antifreeze solution is adequate to protect below the lowesttemperatures expected during the storage period.

(3) Clean the exterior of the engine with fuel oil and dry with clean cloths and compressed air.

(4) Seal all engine openings. Use a vapor and waterproof proof material that is strong enough toresist puncture damage from air pressure.

c. Long Time Storage

(1) Engine Protection

The Jet-Ex 5D generator set may be stored for long periods if the engine is given properprotection from rust and corrosion. Refer to the Engine Manufactures Users Handbook for properprocedures to be followed.

(2) Generator Protection

To protect the generator and other electrical components, the complete unit should bepackaged, using moisture proof packaging and sealing materials. Place packages of moistureabsorbing chemicals, such as silica-gel, in the unit before packaging.

(3) Battery Care

Remove battery and store in a cool dry place. Store the battery on wood rather than directly oncement or metal.

3. Preparation for Shipping

Prepare the unit for shipping as follows:

� Disconnect battery cables.

� Seal all engine openings to prevent the entrance of water, dirt, and dust.

� Drain all fuel from tank and fuel lines as required by carrier rules.

� Crate the unit solidly to prevent damage to instruments, glass, and sheet metal.


OM-2094A/ Operation and Maintenance Manual


Section 3. Operation

1. General

This section contains information and instructions for the safe and efficient operation of the generatorset. Operating instructions are presented in a step-by-step sequence of procedures to be followed insupplying power to an aircraft.

NOTE: Read ALL of the operating instructions before attempting to operate the equipment.

Ear protection may be necessary when working close to this equipment.

2. Operating the Generator Set

a. Pre-start Inspection

(1) Always be sure there is sufficient oil and coolant in the engine.

(2) Be sure the fuel shutoff valve is open. The valve is located at the fuel tank outlet. Observe thefuel gage. Make certain of sufficient fuel to complete the job to be done.

(3) If the unit is trailer mounted and is not connected to a tow vehicle, be sure the parking brake isapplied and that the drawbar is raised and locked in the vertical position.

(4) Open the engine compartment doors and inspect interior for rags, tools, and foreign material.

b. Pre-start Instructions

In all probability, the unit will be moved from one location to another many times during its lifetime ofservice. Therefore, the following steps should be taken to optimize maximum efficient operation.

(1) Check the supply of fuel, crankcase oil and radiator coolant. See the Engine ManufacturesUser’s Manual for specifications.

(2) Inspect the unit thoroughly to be sure it is in proper working order. Check all fuel lines and wireconnections to be certain they are secure. Tighten any loose screws, nuts or bolts.

(3) Wipe off the entire unit and blowout air passages, control box, and other hard to reach placeswith compressed air not over 25 psi (172 kPa).

(4) Make sure that no loose bars, tools, parts, etc., are in or on any part of the engine, as they couldcause serious damage to the engine, generator, or personal injury to anyone standing nearby.

(5) If the unit is operated indoors, make sure that an exhaust line is properly connected to theengine exhaust system, and discharged outside. Avoid short bends or reduction in line sizes inexhaust pipes. Locate the unit so as to necessitate the shortest possible exhaust line to insurethe least amount of back-pressure on the engine. Back-pressure can cause engine damage andloss of power.

(6) Check the electrical system to make sure the connections are secure and properly connected.

(7) If applicabled, check the battery electrolyte level. The factory installed battery is maintenancefree.




WARNING




1. TACHOMETER M403

2. HOUR METER M402

3. VOLTMETER (generator) M406

4. AMMETER M407

5. PANEL LIGHTS FUSE (10 amp) F401

6. PANEL LIGHTS toggle switch S405

7. CONTACTOR CONTROL toggle switch S408

8. CONTACTOR CLOSED lamp DS408

9. CURRENT LIMITING CONTROLpotentiometer R402

10. SPEED CONTROL toggle switch S406

11. ENGINE ON lamp DS407

12. ENGINE START push button switch S401

13. ENGINE CIRCUIT toggle switch S404

14. ENGINE CIRCUIT FUSE (20 Amp.) F402

15. WATER TEMPERATURE gauge M404

16. AIR FILTER RESTRICTIONINDICATOR lamp DS412

17. OIL PRESSURE gauge M405

18. FUEL gauge M408

19. VOLTMETER (battery) M401


(Front View)Figure 1

c. Starting The Engine (Figure 1)

Make sure that all Prestarting Instructions have been carried out, and reference to Initial Preparationfor Use has been checked for operating details.

(1) Check engine oil, fuel and coolant levels.

(2) Check AIR CLEANER SERVICE INDICATOR lamp (16, Figure 1). If lamp is glowing, replace airfilter element and/or remove other objects that obstruct air flow.

(3) Place SPEED CONTROL toggle switch (10) in the IDLE (down) position.

If the engine stalls or falters in starting, wait three or four seconds before

re-engaging starter. This will prevent possible damage to starter or the engine.

DO NOT Operate the starter for periods longer than 15 seconds at a time. An

interval of at least two minutes should be allowed between cranking periods to

protect the starter from overheating.

(4) Hold engine ENGINE CIRCUIT toggle switch (13) in START position.

(5) Press and hold ENGINE START push-button switch (12). Release as soon as engine starts.

(6) Release engine ENGINE CIRCUIT toggle switch (13) to RUN position when oil pressure buildsup.

(7) Observe engine RPM on the TACHOMETER (1), idle speed should be 1000 RPM +/- 50 RPM.

(8) Allow engine to warm up before applying a load.

The engine’s entire exhaust system will get very hot and cause severe burns if

touched.

d. Generator Operation (Figure 1)

(1) Place speed control switch (10) in RATED RPM (up) position. Engine speed will be 2500 RPM,and the generator will automatically build up to produce rated voltage.

(2) Adjust CURRENT LIMITING CONTROL potentiometer (9) if necessary. Refer to Proper Aircraftdocumentation for proper setting.

e. Deliver Power

(1) Connect output cable to AIRCRAFT.

(2) Hold CONTACTOR CONTROL toggle switch (7) in CLOSE position. Release to ON position assoon as green CONTACTOR CLOSED lamp (8) comes on.

f. Stop Operation (Shutdown)

(1) Normal Conditions

a. When power delivery is completed (aircraft discontinues drawing current), placeCONTACTOR CONTROL toggle switch (7) in OFF position. The CONTACTOR CLOSEDlamp (8) should go off to indicate load contactor has opened and power is no longer availableat the aircraft.

b. Place SPEED CONTROL toggle switch (10) in IDLE (down) position. Allow engine to run for2 to 3 minutes.

c. Disconnect output cable from aircraft receptacle and store cable in cable trays or on cablehangers as the case may be.

d. Place ENGINE CIRCUIT toggle switch (13) in STOP position.




WARNING

CAUTION

THE BATTERY WILL DRAIN if the ENGINE CIRCUIT toggle switch (13), is not

placed in STOP position after shutdown,

(2) Emergency Conditions

To prevent personal damage or damage to generator set, use of the EMERGENCY SHUTDOWN (E-STOP) push button switch will provide immediate shut down of the engine. Oncepushed in, the E-STOP button must be pulled back out to restart the generator set.

� Depress E-STOP button; engine will shut down

� Pull E-STOP button back out to restart.

g. Adverse Weather Precautions

(1) Cold weather operation

Operation of this engine-driven unit at sub-zero temperatures requires special precautions andextra servicing from both operation and maintenance personnel, if poor performance or totalfunctional failure is to be avoided. Consult the Engine Manufactures Maintenance and Operator’sManual and recommendations below.

a. Fuel system

Keep system clean and free from water which may collect in a low spot in the fuel line andfreeze, plugging the line. Fuel tanks should be kept FULL to prevent water condensation fromthe air above the fuel.

b. Fuel Storage

Keep fuel storage tanks or drums as full as possible to avoid condensation of moisture fromthe air above the fuel. After filling or moving fuel containers, allow fuel to settle before using.Never draw fuel from the extreme bottom of the container. Strain all fuel to remove anyforeign matter. When operating outdoors, take steps to prevent the entry of snow, water, andice into the fuel containers.

c. Cooling system

Prior to cold weather, drain and flush the cooling system to remove accumulations of rust andsediment. Mix and add antifreeze solution, check the cooling system connections for leaks.Add a can of rust inhibitor to the radiator when system is winterized. This will keep systemcleaner and furnish lubrication for the water pump.

d. Lubrication

Drain the crankcase (preferably when warm after running) and fill with a lighter grade of oil.See Engine Oil Recommendations chart in the Engine Manufactures User’s Manual forrecommended viscosity for various atmospheric temperatures. In cold weather, drain oil morefrequently. Water condenses and collects quickly, mixes with the oil and increases depositsto form a sludge. Check oil frequently for this condition. Water in crankcase may freeze andcause serious damage to the oil pump, or shut off the oil supply.

e. Electrical system

In cold weather, the most efficient electrical system is needed to start the cold engine. Checkthe entire system for loose connections or indication of bad wiring or shorted conditions.

f. Battery

Battery efficiency decreases sharply with lower temperatures. Make sure of full charge beforeattempting to start engine in sub-zero conditions.




CAUTION

(2) Operation in Hot and Humid Conditions

a. Cooling system

Maintain a more frequent check of the coolant level in the radiator.

(3) Operation in Extremely Dusty Conditions

If unit is to be operated under dusty, out-of-door conditions, place it in a sheltered area. Takeadvantage of any natural barriers which may offer protection from blowing dust. If the installationis more than temporary, erect a protection shield.

a. Fuel system

Change the fuel filter at prescribed intervals and keep fuel containers covered and protectedagainst dust entry.

b. Air Cleaner

This filter needs more frequent attention under dusty conditions. Check Air Filter RestrictionLamp located on control panel daily.

c. Crankcase Oil

The crankcase oil level will require close attention. Dusty conditions tend to load crankcaseoil with dirt. Watch for dirty and gritty oil conditions, and change oil more frequently asrequired.

(4) Operation in Salt Water Areas

a. Canopy

Wash canopy regularly to remove salt film. Repaint any damaged places and oil the hingesregularly.

b. Covering

To protect the engine and generator as much as possible from salt water atmosphere, keepthe side doors on the canopy closed, when not in use. It is advisable to keep the unit coveredwith a tarpaulin, if available, when not in use. Salt water should be wiped from the engine,and all terminals and connections in the electrical system wiped dry. Keep all linkage oiled.

c. Brushes

The brushes of the generator should be inspected regularly to make certain that they are freein the holders. Lift the brushes in the brush holders about every two days to insure theirfreedom to slide within the holder. Wipe dry all the parts that can be reached, and usecompressed air, if available, to dry the parts of the generator that cannot otherwise bereached. See MAINTENANCE for brush care.

d. Field coils

The fields should be dried as thoroughly as possible. If they have become damp, proceedwith recommended procedure in MAINTENANCE section.

e. Battery terminals

Thoroughly clean the battery terminals and connections. Coat terminals and connections withpetroleum jelly to retard corrosion.

(5) Miscellaneous

Once a month, oil the hinged plexiglass cover.




Chapter 2. Servicing / Troubleshooting

Section 1. Maintenance Inspection/Check

1. General

To make certain that generator set is always in good operating condition, it must be inspected,maintained, and lubricated regularly and systematically.

Stop operations at once if a serious or possibly dangerous fault is discovered.

2. Maintenance Schedule

a. General

Figure 1 provides a suggested schedule for periodic checks and services. Refer to Section 2-2 forlubrication requirements.

b. Maintenance Schedule Check Sheet

It is strongly recommended that the customer use a maintenance schedule check sheet. The checksheet will provide a record of maintenance specific operation.

c. Time Intervals

The schedule is based on both hours of operation and calendar intervals. These two intervals arenot necessarily the same. The calendar period is included to make certain services are performedregularly when equipment is being operated infrequently, or at manufacturer’s recommendations.Perform all services on a “whichever comes first” basis.

3. Engine and Related Components

Refer to the Engine Manufactures User’s Handbook for detailed engine maintenance information.




WARNING

Recommended Service Intervals

First

Service

at

20/40

Hrs

8 hrs.or

Daily 250 hrs.or

6 Months

500 hrs.or12

Months

2000Hours

Engine

Check oil level X

Check coolant level X X

Check fuel quantity X

Check gages and instruments for proper operation X

Drain Fuel Filter Element X X

Change engine oil X X

Change oil filter X X

Check and tighten drive belts X X

Clean and inspect exterior of radiator X

Check exhaust system X

Check cooling system concentration X

Atomizer Maintenance X

Replace fuel filters X

Clean engine X

Check valve tip clearance, adjust if necessary X X

Electrical System (12V DC)

Check lights X

Check charging rate X

Check battery state of charge (alternator) X

Check wiring and connections X

Check starter motor X

Check battery terminals and connectors X

Electrical system (28.5V DC)

Check indicating light X

Check operation of all instruments, meters, etc. X

Check generator brushes for length, cleanlinessand free operation

X

Check slip rings for smoothness and cleanliness X

Check the entire unit X

Check overvoltage protection X

Check all wiring connections X

Trailer (500285A-001 only)

Lubricate X

Check tire inflation X

Check and adjust wheel bearings X

Lubricate wheel bearings X

Check brake tension X

Inspection/Check/Maintenance ScheduleFigure 1




4. Inspection and Cleaning

Every day, check for oil, coolant, or fuel leaks. Also check for loose electrical connection. Check oilpressure with engine running at rated RPM (2500). Do not operate engine if oil pressure is less than20 psi (138 kPA). Wipe accumulated water off from all electrical connections and instruments. Makesure that the battery voltmeter reads proper voltage.

Every week, wipe off accumulated dust, dirt and oil from the engine and generator. Check all parts forloose connections and wear. If arcing has occurred at any electrical connections, recondition them andsecurely refasten. Check engine oil and coolant levels.

Every month, check generator for amperage and voltage output. Blow out generator windings withcompressed air, not over 25 psi (172 kPa) pressure or remove with a suction-type cleaner with anon-metallic nozzle. If windings should become slightly damp, use space heaters or electrical lightbulbs to effectively dry out the windings. If dampness is excessive, apply external heat under a canvascover, well vented. Heating should not exceed 194º F (90º C).

Pound out any dents in the canopy. Sand, prime, and repaint any dented or rusted spots.




This page intentionally left blank




Section 2. Maintenance Procedures

1. General

A suggested Maintenance Schedule is provided in Section 1 of this Chapter. Each step of the scheduleis also covered in general in Section 1. This Section covers maintenance in more detail wherenecessary.

Stop operation immediately if a serious or possibly dangerous fault is

discovered.

2. Lubrication

a. General

Proper lubrication is one of the most important steps in good maintenance procedure. Properlubrication means the use of correct lubricants and adherence to a maintenance time schedule.Lubrication points, frequency of lubrication, and recommended lubricants are part of the timeschedule.

b. Lubrication Chart

Lubrication points are illustrated and identified by name on Lubrication Chart, Figure 1. Numbersymbols used to designate the kind of lubricant required and the specification recommended areidentified in Figure 2. Letter symbols used to designate the normal lubrication period are identified inFigure 3.

c. Generator

The 28.5 volt DC generator requires NO lubrication. The armature is sealed at the factory forlifetime, maintenance free operation. The front end of the armature is supported by the engine mainbearings.

d. Generator Controls

Generator controls and instruments require no periodic lubrication. A few drops of oil may berequired on the clear plexiglass cover hinge occasionally to insure free and quiet operation.

e. Engine

Although the engine and its accessories require no more attention than any other similar installation,they still inherently require a major portion of the generator set lubrication and maintenance.Recommendations regarding engine lubrication have been taken from the Engine ManufacturersUsers Manual.

(1) Lubrication Schedule

Time schedules indicated on the Lubrication Chart, Figure 1, are approximate. They are basedon average operating conditions. It may be necessary to lubricate more frequently under severeoperating conditions such as: low engine temperature, high oil temperature, intermittentoperation, or dusty conditions. However, time intervals should not exceed those indicated in thechart without careful evaluation.

The use of quality lubricating oil, combined with proper oil drain and filter change intervals areimportant factors in extending engine life.

(2) Oil Specification

Lubricating oils must be equal to the U.S. Ordnance specification MIL-L-46152 or MIL-L-2104C.See Engine Manufactures user’s handbook for recommended oil viscosity.



Jet-Ex 5D / Series 500285A/ Generator Set

WARNING




Check oil dailyCheck crankcase oil daily; change 200 hours.Change oil filter after 200 hours.

Lubrication Chart

Figure 1

Symbol Name Specification Notes

1 Grease, Automotive andIndustrial

Federal VV-G-632 Sinclair LItholene IndustrialNo.2; Mobile-Mobilplex 47 orequivalent.

2 Oil, Engine, Heavy Duty MIL-L-46152 orMIL-L-2104C

See Cummins EngineUser’s Handbook forrecommended oil viscosity

3 Grease, Automotive Military MIL-G-10924B Wheel bearings

LubricantsFigure 2

Symbol Time Interval

D 10 hours or Daily

BW 100 hours or Biweekly

M 200 hours or Monthly

BM 400 hours or Bimonthly

SA 800 hours or Semiannually

Symbols and Time IntervalsFigure 3

(3) Change lubrication engine oil

Oil should be changed once after the first 20/40 hours of operation and then once every 250hours of operation thereafter. The generator set is equipped with an hourmeter which recordsactual engine operating time. The ideal time to change oil is soon after a power delivery runwhen the engine is at operating temperature.

NOTE: If lubricating oil is drained immediately after the unit has been run for some time, most of thesediment will be in suspension and oil will drain readily without clinging to internal surfaces.

DO NOT use solvents as flushing oils in running engines.

NOTE: Change the oil filter each time the oil is changed (250 hours).

(4) Change oil as follows:

a. Provide a container for catching used oil. Capacity should be greater than 2 gallons.

b. Remove drain plug located in oil pan. Allow sufficient time for oil to drain from valve train,timing gear case, etc., before reinstalling plug.

NOTE: Change oil filter while oil is draining.

Change oil filter as follows:

c. Place a container under the oil filter to catch oil drippings.

d. Loosen filter with a special oil filter removal wrench. Several types are available. Discard oilfilter.

e. Coat the gasket on the new filter with oil.

f. Place the new filter in position on the cylinder block and spin on until the gasket contacts theadapter face; then hand tighten another 1/2 turn. Do not over-tighten.

g. Clean drain plug and reinstall. DO NOT over-tighten.




CAUTION

h. Remove filler cap on valve cover and refill crankcase with fresh clean oil, of properspecification and viscosity (see Para. 2, E, (2) and Figure 2). Seven quarts are required whenoil filter is changed.

i. Replace oil filler cap.

j. Start engine and allow it to idle. Oil pressure should come up to normal quickly. Check for oilleaks at filter and drain plug.

k. Stop engine. Allow several minutes for oil to drain to crankcase, then check oil level. It shouldbe at FULL mark on dipstick.

l. Check hourmeter and record time and date of oil change for maintenance reasons..

3. Servicing the Air Cleaner

The air cleaner is a dry type with a “C” flow cartridge. A definite time schedule for changing the filtercartridge cannot be determined because of varying operating conditions, therefore an air restrictionindicator lamp (Sect. 1-3; 16, Figure 1) is mounted on the control panel. Change the filter when the redindicator lamp glows.

a. Cartridge Removal

(1) Open right rear canopy door to gain access to the air cleaner.

(2) Using a 5/16 socket, loosen the clamps which surround the air cleaner and secure it to the airfilter bracket.

(3) Loosen and remove the clamp and air cleaner from the intake hose.

DO NOT attempt to clean or re-use old cartridge.

b. Cartridge Installation

(1) Attach the new air filter cartridge to the intake hose and tighten the clamp.

(2) Secure the air filter cartridge to the air filter bracket with the same two large clamps. DO NOTover-tighten.

4. Servicing the Engine Fuel Filter

Refer to the Engine Manufacturers User’s Handbook for instructions on removal and replacement offuel filter element.

5. Drive Belt Service

Check all drive belts and adjust if necessary each 250 hours. Refer to Engine Manufacturers User’sManual for proper procedures.

6. Engine Cooling System

NOTE:Refer to the Engine Manufacturers User’s Manual for detailed instructions on servicing the engine’scooling system.

In all weather situations, the engine coolant should always contain a solution of 50% water and 50%antifreeze (ethylene glycol). Rust inhibitors are recommended in the coolant as rust corrosion can stilloccur.

Never remove the cap from a hot radiator. The radiator cap should not be

removed unless the engine temperature is 122º F (50º C) or below.




WARNING

CAUTION

a. Radiator Cap Removal

Cover the cap with a thick cloth and turn it slowly counterclockwise to the first stop. When pressureis completely released, press downward and finish removing cap.

DO NOT add coolant to an extremely hot engine. This can result in a cracked

block or cylinder head.

b. Rust Inhibitor

Use only a corrosion inhibitor that is compatible with aluminum. Do not use inhibitors labeled as“acid neutralizer.”

c. Antifreeze

A permanent type (Ethylene Glycol) antifreeze is recommended for use in the cooling system. Thecoolant, when mixed as equal parts of water and the recommended antifreeze, will provideprotection to -35º F.

7. Battery Service

a. General

A 12-volt battery supplies power for operation of the engine electrical system, clearance and panellights, and for building up generator voltage. The battery supplied with a new unit is a maintenancefree type. Some of the following topics apply to non-maintenance free type battery, which requiresadditional maintenance such as checking liquid levels.

b. Battery Location and Accessibility

The battery is located on a tray mounted to the left front frame. The battery is easily accessible forservice by opening the left front door and removing the lower panel below the door.

c. Battery Care

(1) Never allow a battery which has been removed from a unit to sit on concrete, ground, or metal,unless proper insulation is provided. A wooden platform or board will provide sufficient insulation.

(2) Maintain stored batteries in a charged condition,

(3) Be sure battery is fastened securely in their compartment to avoid damage from vibration.

(4) If applicable, maintain battery fluid at proper level (see below).

(5) Keep battery terminal posts and lead cable connectors clean.

Never allow sparks or open flame near battery. Avoid spilling electrolyte on

hands or clothing.

d. Liquid Level (If battery is not a maintenance free type)

The electrolyte in each cell should be above the plates at all times to prevent battery failure.Check the level of the electrolyte every two weeks. When electrolyte level is low, add puredistilled water. Do not use hydrant water or any water which has been in contact with a metalcontainer. Acid should never be added except by skilled battery personal.

Never add any special battery dopes, solutions, or powders.

NOTE: It is especially important to keep the battery at full charge for cold weather operation. Add distilled waterto the battery in freezing temperatures only when the engine is to operate for several hours. Thoroughly




WARNING

CAUTION

CAUTION

mix the water and the electrolyte, or damage to the battery will result from the water freezing.

e. Cleaning the Battery

If the top of the battery is dirty, it may be cleaned with a brush dipped in ammonia or soda solution.Disconnect lead connectors from battery posts. Vent plugs should be tightened to prevent cleaningsolution from entering cells. Clean battery as required, using brush and cleaning solution. Flush offthe battery with clean water. Special terminal cleaning tool. Make certain that vent holes in fillercaps are not clogged.

f. Testing a Battery

Tests are made on a battery to determine the state of charge and also its condition. The results ofthese tests show whether the battery is good, needs recharging, or must be replaced. If a batteryhas failed, is low in charge, or requires water frequently, the reason for the condition must be foundand corrected. Visually inspect the battery before testing, to determine if it has been damaged.Moisture on the outside of the case, or low fluid level in one or more cells indicates possible batterydamage (cracked case, etc.). The battery may be tested by two methods. A battery-starter testermay be used to determine the battery’s ability to deliver current. A battery hydrometer testdetermines the charge condition of the battery.

(1) Battery-Starter Tester

Connect battery to the tester according to instructions furnished with the instrument. Testbattery according to tester instructions. If the test determines that the battery has acceptablevoltage, this indicates that the battery has output capacity and will accept a charge if required.

(2) Hydrometer

Remove filler caps and check the specific gravity of the electrolyte in each cell. If specific gravityis 1.230 or below, add water if necessary and charge the battery until it is fully charged. A fullycharged battery will give a specific gravity reading of 1.265 to 1.285. The specific gravity of afully discharged battery may range from 1.140 down to 1.120.

NOTE: The battery is fully charged when all cells are gassing freely, and the specific gravity ceases torise for three successive readings taken at hourly intervals.

a. If the battery starter test indicated that battery voltage was below the acceptable voltagevalue, test each cell with the hydrometer. If the difference in specific gravity readings betweenany two cells is 50 points (0.050) or more, the battery isn’t satisfactory for service and shouldbe replaced.




A-Leads

B-Brusholder Caps

C-Brusholder

D-Brush

E-Slip Rings

Generator Revolving Field BrushesFigure 4

8. Generator Maintenance

a. General

The only maintenance service required for the generator will be brush replacement, slip ringcleaning, etc.

b. Brush Service

If inspection reveals that brushes are gummy or sticking in the brush holders, they should beremoved and cleaned. Clean both the brushes and brush holders. Use a good, SAFE, commercialcleaner.DRY ALL PARTS THOROUGHLY. Be sure brushes can move freely in brush holders.

DO NOT use a flammable solvent. DO NOT use steam cleaner, or soaps and

detergents under pressure.

c. Generator Revolving Field Brush Replacement (See Figure 4)

(1) Disconnect leads (A, Fig. 4) from connectors on brush holder caps (B).

(2) Remvoe brush holder caps (B) from brusholder.

When removing the lead wires, do so one at a time and replace each brush

accordingly, to insure that the lead wires are put pack onto the proper brushes.

(3) Lift brush (D) from brush holder (C) for inspection. If brushes are worn unevenly or are shorterthan 7/16 inch (11 mm), replace them.

(4) Inspect slip rings whenever brushes are removed for servicing brushes or brush holders. Notesurface conditions of rings. Surface should appear smooth and clean. Scoring or roughness ofslip rings may be caused by grit or abrasive substance in brushes, or by oil on the rings.Moderately rough slip rings can be smoothed by holding grade 00 flint paper against theirsurface while the rings are revolving slowly. If the rings are badly scored, the unit must be sentto an overhaul facility for repair. After cleaning slip rings, blow dirt and grit out of the unit withcompressed air. Do not use over 25 psi (172 kPa) air pressure to blow dirt out.

(5) Slip new brushes into brush-holder guides, and place caps on top, and screw them into theguides to a “bottomed” position. The spring attached to the brush will determine the pressure atwhich the brush contacts the slip rings.

(6) To fit new brushes to the slip rings, lay a strip of No. 00 sandpaper, smooth side down, on slipring surface, and draw the sandpaper in the direction of rotation of the slip ring, lifting the brushon the return stroke. Continue until the brushes have same curvature as the slip rings. Blow allcarbon dust out of the machine using not over 25 psi (172 kPa) air pressure.




CAUTION

WARNING

Section 3. Adjustment/Test

1. General

The adjustments and test procedures presented below are required after major repairs, partsreplacement, or long storage.

2. Testing the Generator Set

Test values listed below will result when the generator set is operating properly. If your test results arenot within the limits shown, perform the applicable troubleshooting procedures given in Chapter 3.

If major repairs have been made or if critical components have been replaced, make sure that theapplicable adjustments have been made before testing the generator set. Adjustment procedures aredescribed in Para. 3 of this Section.

a. Pre-operational Test Procedures

(1) Open engine compartment doors and inspect the interior for rags, tools, and other foreignmaterials.

(2) Check engine oil level.

(3) Check coolant level.

(4) Check battery water level (if required)

(5) Check for sufficient fuel.

(6) Check drive belts. Each belt should have approximately 1/2 inch (13 mm) slack.

(7) Inspect all wiring for possible trouble spots such as loose wires or terminals, frayed insulation,obvious shorts, etc.

(8) Check panel lights, panel light switch, and fuse.

(9) Connect cables from generator output terminals to a load bank. The output cable consists of twosingle conductor cables not more than 30 feet (9 m) long. The diameter size of each of thesetwo cables is determined by the maximum starting current expectations:

� Use No. 2/0 cable for 600 amp. maximum starting current

� Use No. 4/0 cable for 1500 amp. maximum starting current.







1. TACHOMETER M403

2. HOUR METER M402

3. VOLTMETER (generator) M406

4. AMMETER M407

5. PANEL LIGHTS FUSE (10 amp) F401

6. PANEL LIGHTS toggle switch S405

7. CONTACTOR CONTROL toggle switch S408

8. CONTACTOR CLOSED lamp DS408

9. CURRENT LIMITING CONTROLpotentiometer R402

10. SPEED CONTROL toggle switch S406

11. ENGINE ON lamp DS407

12. ENGINE START push button switch S401

13. ENGINE CIRCUIT toggle switch S404

14. ENGINE CIRCUIT FUSE (20 Amp.) F402

15. WATER TEMPERATURE gauge M404

16. AIR FILTER RESTRICTIONINDICATOR lamp DS412

17. OIL PRESSURE gauge M405

18. FUEL gauge M408

19. VOLTMETER (battery) M401


(Front View)Figure 1

b. Operational Tests (Figure 1)

(1) Start the engine as described in 1-3; Para. 2, and let it warm at idle speed.

(2) Inspect for oil, fuel, and coolant leaks.

(3) Check the engine VOLTMETER (19) for proper voltage. Check OIL PRESSURE gauge (17). Itshould read 35 to 60 psi (241 to 414 kPa). Check WATER TEMPERATURE gauge (15). Itshould read 180 to 200º F (82 to 93º C.) when engine is hot.

(4) Observe engine RPM on the TACHOMETER (1), idle speed should be 1000 RPM ± 50 RPM.

(5) Place the SPEED CONTROL switch (10) in the RATED RPM position. Check engine RPM’s atoperating speed: 2500 RPM ±50

(6) Check for 28.5 output voltage on generator VOLTMETER (3) to assure automatic voltagebuildup.

(7) Set CURRENT LIMITING CONTROL potentiometer (9) to maximum, full clockwise, position.

(8) Adjust the load bank for a load of 550 amperes.

(9) Place the CONTACTOR CONTROL toggle switch (7) in the CLOSE position. The CONTACTORCLOSED lamp (8) will glow as the contactor will close. Release the CONTACTOR CONTROLtoggle switch to the center ON position. The TACHOMETER (1) will indicate 2200 ± 25 RPM.

(10) Disconnect the load bank and check the overvoltage protection by adjusting voltage regulatorpotentiometer R46 (1, Fig. 2) to increase the voltage. The overvoltage relay will trip and open theload contactor between 32 to 34 volts.

(11) Readjust the voltage to 28.5 volts, connect the load bank, set it at 550 amperes, and close thecontactor.

(12) Remove load bank and check voltage regulation at no load. Voltage will be 28.5 volts.Reconnect load bank and check voltage regulation with load bank set at 137, 275, 413, 550, and660 amperes and check voltage at each setting. Voltage will be 28.5 ± 1 volts at each differentload.

(13) With CURRENT LIMITING CONTROL potentiometer (9) set to 2000, apply 600 to 700 amperesload to the generator and then set the CURRENT LIMITING CONTROL potentiometer to 400.Current displayed on AMMETER (4) will be 400 ± 40 amperes.

NOTE: Voltage will not drop below 14 volts.

(14) Set CURRENT LIMITING CONTROL potentiometer (9) to 2000 and apply 1200 amperes load.Then set the CURRENT LIMITING CONTROL potentiometer to1000. Current displayed onAMMETER (4) will then be 1000 ± 100 amperes and voltage will not drop

(15) Remove load. Set engine to idle. Run for 3 minuets at idle

(16) Stop and restart the engine, check the instruments as directed in step (3), and check the entiregenerator set for unusual vibration and noises.




3. Voltage Regulator Adjustment

a. 28.5 Volt Adjustment

(1) The regulating voltage, in the 28.5 volt range, is determined by the position of the wiper arm ofthe multi-turn potentiometer (1,Figure 2) R46. Clockwise (CW) rotation increases the voltagelevel at which the unit operates. Conversely, counterclockwise (CCW) rotation decreases thevoltage level.

b. Line Drop Compensation

(1) Line drop compensation allows the voltage at the load end of the output cable to remain constantdespite the voltage drop associated with the output cable. Clockwise (CW) rotation of thesingle-turn potentiometer (2,Figure 2) R24 increases the compensation. This potentiometershould be set for flat regulation of voltage at the load end of the output cable when deliveringrated load current.




Voltage and Line Drop Adjustments

Figure 2

Section 4. Troubleshooting Procedures

1. General

Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until theexact cause of a trouble is found. As a rule, the best place to start looking for the cause of a trouble in acircuit is at the source of power. Continue testing and checking the circuit, step-by-step, in an orderlymanner, until the cause of trouble is located. Referance connection and schematic diagrams.

2. Troubleshooting Chart

a. Description

The troubleshooting chart lists information under three headings:

(1) Trouble, Symptom, and Condition,

(2) Probable Cause

(3) Test, Check, and Remedy

b. Use of the Troubleshooting Chart

Read the trouble symptoms and conditions before proceeding to causes and remedies.

For example:

At the beginning of the troubleshooting chart under ENGINE, the first trouble listed is: “Enginewill not start. Starter will NOT crank engine.”

If the starter WILL crank the engine, then obviously this is not your symptom and condition. Go tothe next “Trouble, Symptom, and Condition” directly below. If the starter will NOT crank the engine,look to the right under “Probable Cause” and “Test, Check, and Remedy” to find the various thingswhich could cause the trouble and what to do to check and remedy them.

3. Equipment for Troubleshooting

A good quality, multi-scale voltmeter is the only instrument required similar clips, will be required. The12 volt engine electrical system may be used for a 12 volt DC power source.

4. Safety Precautions

Loose garments, neckties, and other hanging items must not be worn by

personnel near the fan or other exposed moving parts of this equipment while it

is running. Also, avoid contact with live electrical parts. death or serious injury

could result!

5. Diagrams

A schematic/connection diagram of the generator set is provided in Chapter 5. This diagram can bevery helpful in troubleshooting. Components shown in the diagram are identified by referencedesignators (or item names in some instances). A legend appearing on the diagram identifies eachreference designator by its full item name. For example, the symbol K403 identifies the overvoltagerelay, and M406 identifies the voltmeter.

6. Connections and Wiring

Before condemning any electrical component, check all connections and wiring which could affect itsoperation. In many instances a component may be non-functional simply because it is not receivingpower because of a loose connection or a poor ground. In most cases throughout the troubleshootingchart, it will be assumed that connections and wiring have been checked.




WARNING




7 2 1

3

4

569

8

10

1. Fuel Tank Support

2. Fuel Tank

3. Control Panel

4. Rectifier Assembly

5. Generator

6. Frame

7. Engine

8. Air Cleaner

9. Battery

10. Contactor

Generator Set ComponentsFigure 1




4

5

2

1

3

1. Muffler

2. Alternator

3. Oil filter

4. Starter

5. Starter solenoid

Engine Comp[onents(Right Side of Unit)

Figure 2




4

5

1

267

3

1. Fuel filter2. Air cleaner3. Throttle control assembly4. Oil pressure sender5. Oil pressure switch 20 psi (138 kPA)6. Water Temp. Sender7. Radiator

Engine Components(Left Side of Unit)

Figure 3




1. TACHOMETER (M403)

2. HOUR METER (M402)

3. VOLTMETER (generator) (M406)

4. AMMETER (generator) (M407)

5. PANEL LIGHTS FUSE (10 amp) (F401)

6. PANEL LIGHTS toggle switch (S405)

7. CONTACTOR CONTROL toggleswitch (S408)

8. CONTACTOR CLOSED lamp (DS408)

9. CURRENT LIMITING CONTROLpotentiometer (R402)

10. SPEED CONTROL toggle switch(S406)

11. ENGINE ON lamp (DS407)

12. ENGINE START push button switch (S401)

13. ENGINE CIRCUIT toggle switch (S404)

14. ENGINE CIRCUIT FUSE (20 Amp.) (F402)

15. WATER TEMPERATURE gauge (M404)

16. AIR FILTER RESTRICTIONINDICATOR lamp (DS412)

17. OIL PRESSURE gauge (M405)

18. FUEL gauge (M408)

19. VOLTMETER (battery) (M401)

Control Box Assembly(Front View)

Figure 4




1. Over voltage relay (K403)

2. Voltage regulator (VR402)

3. Excitation rectifiers (CR417 & CR418)

4. Control windings fuses (10 Amp.) (F406 - F408)

5. Voltage build-up fuse (10 Amp.) (F405)

6. Voltage regulator fuse (10 Amp.) (F403)

7. Throttle solenoid fuse (20 Amp. Slo-Blo) (F409)

8. Control Panel Lights (DS401, DS402 & DS420)

9. Rectifier Harness Connector (J43)

10. Engine Harness Connectors (J46 & J47)

11. Rectifier (CR401)

12. Capacitor (C403)Control Box Assembly

(Interior View)Figure 5

Section 5. Troubleshooting Charts

See section 2-4 for all figures referenced in this section.

Engine and Controls

Trouble, Symptom and Condition Probable Cause Test, Check, and Remedy

1. Engine will not start. Starterwill not crank engine.

a. Batteries discharged, surethis voltage is reaching orloose battery or groundconnection.

Check battery connections andcheck voltage across battery.Voltage should be approximately12.8 VDC. If battery andconnections are good, proceedto the next step.

b. ENGINE START pushbutton switch S401(12, Figure 4) defective.

Momentarily connect a jumperbetween the hot side of thestarter solenoid L401 and thestart switch terminal on thestarter relay wire. If the starteroperates, replace faulty switch.If starter doesn’t crank, proceedto the next step.

c. Defective starter solenoidL401 (5, Figure 2)

Momentarily connect a largecapacity jumper cable betweenthe hot side of the starter relay(Figure 2) and the starter inputterminal. If the starter attemptsto crank the engine, the startersolenoid is defective. Replaceit. If engine still won’t crank,proceed to the next step.

d. Defective starter B401(4, Figure 2)

If the engine will not crank afterthe previous steps, the starter isdefective. Replace starter. Ifstarter did attempt to operate,but couldn’t turn engine,proceed to the next step.

e. Internal engine seizure. CAUTION:Make certain that engine startswitch is in “stop” position sothat engine does not start.

Use a socket wrench on the frontcrankshaft pulley to try to turnengine by hand. If engine willnot turn, internal damage isindicated.




Engine and Controls (continued)



Engine will not start. Starterwill not crank engine(continued).

f. Engine seized up NOTE:If engine is overchargedwith ether for cold weatherstarting, it could seize up. If so,wait approx. 1/2 hour until it willbe possible to turn engine.

2. Engine will not start. StarterDOES crank engine.

a. ENGINE CIRCUIT FUSEF402 (14, Figure 4) blown

Replace ENGINE CIRCUITFUSE. Use type AGC-2O fuse.

b. Fuel valve at tank closed, orno fuel in tank, engine haslost its prime

Check and correct as required.

c. Defective ENGINECIRCUIT toggle switchS404 (13, Figure 4)

Check for 12-V DC fromterminal 4 of S404 in “START”position. If 12-V DC is notmeasured, replace defectiveswitch.

d. Defective fuel valvesolenoid (L404).

Attempt to start engine whileapplying 12-V DC to the fuelvalve solenoid. If the enginestarts, the solenoid is defective,and should be replaced. Ifengine still doesn’t start,proceed to next step.

e. Defective fuel pump. Check fuel pump according toinstructions in the EngineManufactures User’s Manual.

3. Engine starts then stops. a. Fuel not turned on. Turn on fuel shutoff valve.

b. Defective oil pressureswitch S403 (5, Figure 3)

Connect a jumper wire acrossthe “C” and “N.O.” terminals ofoil pressure switch. Start engineand check oil pressure. If it isbelow 10 PSI (69 kPa) shutdown the engine and checklubrication system for leaks.Also check the oil pump forleaks. If oil pressure comes upto normal and the enginecontinues to run, the oilpressure switch is defective.Replace oil pressure switch.







4. Engine starts then stops whenENGINE CIRCUIT toggleswitch S404 is released to“ON” position.

a. Open over temperatureswitch S402 or defectiveENGINE CIRCUIT toggleswitch.

Place a clip-lead jumper wire onthe water temperature switchterminals and check for normaloperating temperature. If enginethen starts properly, replacewater temperature switch. If not,replace engine switch.

b. Choked fuel filter, restrictionin air cleaner, or air in fuelsystem.

Check for these faults accordingto instructions in the EngineManufactures User’s Manual.

5. Engine does not attain normalidle RPM, or idles too fast.

a. Loose throttle linkage If solenoid core is pulled into thefull throttle solenoid L403 whenSPEED CONTROL toggleswitch S406 is in RATED RPMposition, check for loose controlrod between solenoid andthrottle. Tighten if required. Ifsolenoid core does not pull in,proceed to the next step.

b. Defective full throttlesolenoid L403.

Check for l2-V-DC across twoterminals of solenoid whenS406 is in RATED RPMposition. If l2-V DC is measured,but solenoid core does not pullin, replace the solenoid.

6. Engine will not run at ratedspeed (2450-2550 RPM)

a. SPEED CONTROL toggleswitch S406 (10, Figure 4)defective.

If engine will not go from idle torated speed when SPEEDCONTROL toggle switch is inRATED RPM position, turn offengine and take resistancemeasurements at SPEEDCONTROL toggle switchterminals with switch in theRATED RPM position.

Zero resistance should bemeasured between terminalshaving red-blue and orangeyellow wires. Replace speedcontrol switch if measurement isimproper.







7. Engine lacks power. a. Insufficient air to engine. Check AIR FILTERRESTRICTION INDICATORlamp (16, Figure 4) forillumination. Replace or clean asrequired.

b. Restricted exhaust system. Check exhaust pipe forrestrictions. Check muffler forclogged condition. Replace asrequired.

c. Low compression. Check compression in allcylinders according to theEngine Manufactures User’sManual.

8. Engine Overheats. a. Dirt or sludge in Coolant Drain coolant, flush radiator, putin clean coolant. Refer to theEngine Manufactures User’sManual in for instructions.

b. Debris and dirt in radiatorcore.

Clean radiator core carefully.Refer to the EngineManufactures User’s Manual.

c. Fan belt slips or is broken. Tighten belt or replace asrequired




Generator and Controls



1. Generator will not build upvoltage when SPEEDCONTROL toggle switch S406(10, Figure 4) is placed inRATED RPM position.

a. Voltage build-up fuse F405is blown.

Replace voltage build-up fuse(5, Figure 5). Proceed to Step bto determine cause of blownfuse.

b. Defective excitation rectifierCR417 and/or CR418.

Check excitation rectifiers ( 3,Figure 5) with an ohmmeter tosee if they are good. If eitherrectifier is defective, replace it.If both rectifiers are good,proceed to Step c.

c. Defective capacitor C403. Check capacitor (12, Figure 5)with an ohmmeter to see if it isgood. If defective, replace it;otherwise proceed to Step d.

d. Defective flyback diodeCR419.

Check diode, on brushholdermounting bracket, with anohmmeter to see if it is good. Ifdefective, replace it; otherwiseproceed to Step e.

e. Generator revolving fieldL406 defective.

Locate yellow and red-orangewires on the right terminal stripat lower rear of control panel.Disconnect the yellow andred-orange wires which go downto the generator. Refer toconnection diagrams in Chapter5.

Measure resistance betweenthese two wires. It should be 10to 11 ohms. If reading indicatesan open, short or lower thannormal resistance, proceed toStep f.

f. Defective generatorarmature G402.

If check of the generatorrevolving field (Step e. above)revealed no trouble, thegenerator stator is defective.Send unit to overhaul.

g. Voltage regulator fuse F403is blown.

Replace voltage regulator fuse(6, Figure 5). Proceed to Steph. to determine reason for blownfuse.




Generator and Controls (continued)



Generator will not build upvoltage when SPEEDCONTROL toggle switch S406(10, Figure 4) is placed inRATED RPM position(continued)

h. Defective rectifier CR401. Use ohmmeter to check rectifierCR401 (11, Figure 5). Replacerectifier if defective.

i. Generator voltage regulatorVR402 defective.

Replace voltage regulator (2,Figure 5).

2. Generator builds up to only alow voltage when SPEEDCONTROL toggle switch S406(10, Figure 4) is place inRATED RPM position

a. Defective excitation rectifierCR417 and/or CR418.

Check excitation rectifiers (3,Figure 5) with an ohmmeter tosee if they are good. If eitherrectifier is defective, replace it.If both rectifiers are good,proceed to Step b.

b. Generator voltage regulatorVR402 defective.

Replace voltage regulator (2,Figure 5).

3. Generator builds too high avoltage.

a. Defective SPEEDCONTROL toggle switchS406 (10, Figure 4).

Use ohmmeter to check SPEEDCONTROL toggle switch.Replace switch if defective.

b. Defective blocking rectifierCR401.

Use ohmmeter to checkblocking rectifier (11, Figure 5)Replace rectifier if defective.

c. Generator voltage regulatorVR402 defective.

Replace voltage regulator (2,Figure 5) with a voltageregulator known to be good, andresume operation of generatorset. If new voltage regulatorproduces normal operatingvoltage, send old voltageregulator to factory for service.

4. Load contactor will not closewhen CONTACTORCONTROL toggle switch S408(7, Figure 4) is placed in closedposition. Engine runningnormally, voltage normal, noload applied to output cable.

a. Defective CONTACTORCONTROL toggle switch.

Momentarily connect a jumperlead between terminals with redand yellow wires on theCONTACTOR CONTROLtoggle switch. If the loadcontactor closes momentarily,replace switch.

b. Defective load contactorK402.

If load contactor (10, Figure 1)will not close when contactorclose switch is jumpered, it islikely that the contactor isdefective. Replace contactor.







Load contactor will not closewhen CONTACTORCONTROL toggle switch S408(7, Figure 4) is placed in closedposition. Engine runningnormally, voltage normal, noload applied to output cable(continued)

c. Overvoltage relay K403defective.

Connect a jumper lead betweenterminals T and P on theovervoltage relay (1, Figure 5). Ifcontactor will now close, replaceovervoltage relay.

5. Load contactor opens as soonas CONTACTOR CONTROLtoggle switch S408 (7, Figure4) is released from its top(spring-loaded) position, to Runposition.

a. Defective CONTACTORCONTROL toggle switch.

Connect a jumper lead betweenterminals with red and bluewires on the CONTACTORCONTROL toggle switch. If theload contactor now remainsclosed, replace contactor closeswitch.

b.c. Load contactor K402defective.

If no fault was found in steps 4-aand b, the load contactor (10,Figure 1) is probably defective.Replace load contactor.

6. Load contactor K402 opensduring power delivery.

a. Contactor opening couldhave been normal becauseof an overvoltage condition.

Resume operation and closelyobserve VOLTMETER (3,Figure 4) for evidence ofovervoltage. If contactor openswhen no overvoltage conditionexists, proceed to Step b.

b. Overvoltage relay K403defective.

Check overvoltage relay byoperating the machine underload and gradually raisingvoltage at the voltage regulator(2, Figure 5) while observingVOLTMETER (3, Figure 4).Start with a low voltage (25VDC) and gradually increasevoltage until relay functions toopen load contactor. (32 to 34V)

c. Overvoltage board out ofadjustment.

If relay trips at less than 32-VDC, adjust potentiometer (P1)on the overvoltage board(1, Figure 5). If this does notcorrect problem, return oldboard to factory for service.

d. Load contactor K402defective.

If no fault was found in abovesteps, replace load contactor(10, Figure 1)







7. Output current cannot belimited by CURRENT LIMITINGCONTROL potentiometer R402(9, Figure 4)

a. Defective CURRENTLIMITING CONTROLpotentiometer

Shut down engine and checkpotentiometer with anohmmeter. To do this,disconnect the plug (P404) fromthe regulator board (2, Figure 5)and take resistancemeasurements from pin 2 to pin9 and then from pin 2 to pin 10on the plug. For eachmeasurement, slowly turnCURRENT LIMITING CONTROLpotentiometer through its entirerange, while observing theohmmeter readings. Resistanceshould be from 0-10 k ohms.Replace if necessary.

b. Defective voltage regulatorVR402.

Replace voltage regulator withone known to be good, and thenoperate the generator set undersufficient load to observecurrent limiting. If CURRENTLIMITING CONTROLpotentiometer now controlscurrent properly, send oldvoltage regulator to factory forservice.




Chapter 3. Overhaul/Major Repair

Section 1. Flexible Coupling

1. General

This chapter provides basic instructions for removal, service and installation of a flexible coupling kit,with a fan attached. This flexible coupling kit is designed for use with single-bearing generator sets.

Figure 1 shows a rear view and side view of the flexible coupling assembly. The primary function of thisassembly is to couple a Hobart generator set to a diesel engine. The flexible coupling assemblycompensates for slight misalignment between the engine and the generator, due to manufacturingtolerances. A split taper bushing secures the coupling to the generator’s armature shaft. (See Fig. 3 &4).




Coupling Assembly

Figure 1

2. Coupling Screws (Routine Coupling Maintenance)

Failure to verify proper coupling screw installation may result in coupling failure

and damage to the equipment.

If the generator set is functioning properly, servicing the coupling assembly will be essentially limited tochecking the screws which attach the flexible coupling to the engine flywheel of the generator set.These 8 screws should be checked periodically to make certain that: (1) screws of proper type, length,and hardness are installed, (2) that the threads of the screws are not stripped, and (3) that they aretorqued properly. Proceed as follows to check coupling screws.

a. Remove the sheet metal covers from around the generator housing and the flywheel housing.

b. Refer to Figure 2. Hold a short iron bar through the flywheel housing against the fan blades of thefan and coupling assembly to block the armature against clockwise rotation. Do this carefully toavoid damaging the fan blades.

c. Use a long-handled, reversible ratchet drive fitted with a 5/16-inch Allen wrench to remove onecoupling screw. Examine the screw. Screws specified for this coupling are Hobart Part No.402789-004, which are socket-head, 3/8 - 16 X 3/4 inch long.

NOTE: Use of the proper coupling screws for replacement is very important. Replacement screwsMUST be those specified above, torqued to 40 - 45 foot-pounds (54 - 61 Nm). There is NOACCEPTABLE SUBSTITUTE for these screws.

d. Check the threads of the screw for stripping and replace it if the threads are stripped. If the screw isnot stripped, reinstall it and torque it to 40 - 45 foot-pounds (54 - 61 Nm).

e. Repeat the steps b, c, and d above for the remaining seven screws.

f. Reinstall covers around housings.




Access to Coupling Screws

(for removal and

installation)

Figure 2

CAUTION

3. Disassembly

Removal of the flexible coupling is required for servicing the generator armature, generator bearings, orthe coupling itself. To remove the coupling, for any reason, it is necessary to separate the engine andgenerator. Many mechanics prefer to remove the engine and generator as an assembly, and thenseparate them. Others may prefer to remove the engine or the generator separately to reach thecoupling. However, separating the engine and generator while they are installed in the ground powerunit is VERY DIFFICULT because of the limited working space.

During removal DO NOT cut any cables or wires. Disconnect cables or wires if/as necessary and tagthem for reassembly.

a. Separate Engine and Generator

(1) Remove fuel tank and canopy components.

(2) Remove the sheet metal cover from around the generator housing and the flywheel housing.

(3) Attach a hoist to the generator housing.

(4) Use a long-handled, reversible ratchet drive fitted with a 5/16-inch Allen wrench to remove thescrews which attach the flexible coupling disk to the engine flywheel.

(5) Support the rear of the engine with a jack stand.

(6) Remove the bolt and shock mount attaching the generator housing to the frame.

(7) Remove the bolts attaching the generator housing to the engine flywheel housing.

(8) Separate the generator from the engine with the hoist and move it to a clear working area.

b. Remove Coupling Assembly (Figure 3)

(1) Using a socket wrench, remove all three of the 3/8-16 X 3/4 inch screws (3) that secure thebushing (1) to the hub of the fan and coupling assembly.

(2) To separate the bushing from the hub, lubricate two of the 3/8-16 X 3/4 inch screws and insertthem into the threaded holes (4) in the bushing. With socket wrench, screw these screws into thebushing such that the bushing pops loose from the hub.

(3) Using a 3/16-inch Allen wrench, loosen the set screw (6) in the bushing to release pressure onthe key (5).

(4) When the bushing (1) is loose in the hub, use a mallet to GENTLY tap the bushing out of thehub.

(5) Slide the coupling assembly off the shaft and remove the key (5).

(6) Using a 9/16-inch socket wrench, remove the screws which attach the flexible disks to the hub.

(7) Inspect the coupling assembly components carefully as follows:

a. Check for deformed fan blades and damage to the disk.

b. Check hub and split bushing for cracks, evidence of galling, and rust pits. Light rust ispermissible on the split bushing and the tapered bore of the hub.

c. Check the flexible coupling disks for warping, cracks, or worn mounting holes.

d. Check the screws which attach the flexible disks to the hub. The screws are Hobart Part No.287935-001, which are socket head, 3/8 - 16 X 2-1/4 inch long. If they are cracked,stretched, or have stripped threads, replace them.

NOTE: Use of the proper coupling screws and washers for replacement is very important.Replacement screws and washers MUST be those specified above, torqued to 40 - 45foot-pounds (54 - 61 Nm). There is NO ACCEPTABLE SUBSTITUTE for these screws orwashers.

e. Check the shaft for any damage or deformation where the coupling was mounted on it.




4. Coupling Service

If you have any questions concerning your Hobart Ground Power equipment, immediately contact ourService Department by mail, telephone or FAX. When calling about service or parts from your HobartBrothers Company Distributor, be sure to include all pertinent information from the unit’s identificationplate: Specification No., Model No., and unit rating.

Write: Hobart Brothers CompanyGround Power DivisionService Department1177 Trade Road EastTroy, Ohio 45373U.S.A

In U.S.A. Call Toll Free (800) 422-4166 (Parts)(800) 422-4177 (Service)

From Foreign Countries, Call: (937) 332-5050 (Parts)(937) 332-5060 (Service)

Fax: (937) 332-5121800-367-4549 Toll Free in U.S.A.




Split Taper Bushing

Figure 3

1. Bushing

2. Split

3. Mounting Holes (3)

4. Tapped holes (2)

5. Key

5. Coupling Installation and Reassembly of Engine and Generator

Improper installation of the coupling assembly can result in serious damage to

the equipment. Follow these installation instructions exactly.

a. Cleaning (Figure 4)

It is VERY IMPORTANT that the shaft, the bore and the outside of the split bushing, and thetapered inside of the hub be thoroughly CLEANED FREE OF DIRT AND GRIT.

Do not lubricate any of the surfaces listed above. Lubrication of these surfaces

can cause the coupling to fail and damage the generator set. Slight traces of

rust are permissible only on the bushing, but nothing else.

b. Assembly (Figure 4)

Use of the proper coupling screws is very important. Failure to use the proper

screws, as outlined below, can result in coupling failure and damage to the

generator set.

Proceed as follows to reassemble engine and generator.

(1) Attach the four flexible disks to the coupling hub with the six socket head 3/8 - 16 X 2-1/4 inchscrews (Hobart Part No. 287935-001). The screws must be torqued to 40 - 45 foot-pounds (54 -61 Nm).

(2) Attach the coupling assembly to the flywheel, using the socket-head 3/8 - 16 X 3/4 inch screws(Hobart Part No. 402789-004). DO NOT tighten with a wrench. See Figure 4.

(3) Torque all of the coupling screws to 40 - 50 foot-pounds (54 - 68 Nm). Be sure the flexible disksare all seated evenly into the seat of the flywheel.

(4) Install the key in the key way of the armature shaft.

(5) Place the coupling bushing on the shaft of the armature, aligning the key way of the bushing withthe key way of the shaft.

(6) Using a hoist, align the bushing to the coupling key way and also the generator housing flange tothe engine flywheel housing, and insert the attaching screws for the housing. Start the screwsinto the tapped holes just enough to ensure thread engagement. DO NOT TIGHTEN.

(7) Tighten the generator housing attaching screws at this time.

(8) Remove the bearing cap from the back of the generator assembly.

(9) Inspect the rear bearing. If it has moved out of the rear bearing support hub, it will need to bereset. Correct placement of the rear bearing, should be within 1/8” from the rear surface of thebearing hub.

(10) Slide the coupling bushing forward until it is snug in the coupling hub.

Make certain that only the screws are lubricated, and that no lubricant is

permitted to get inside the bushing where the armature shaft will enter the

bushing.

(11) Lubricate the three 3/8-16 X 3/4 screws SPARINGLY and start them into the three (unthreaded)holes finger-tight. See Figure 4.




CAUTION

CAUTION

CAUTION

CAUTION

(12) Refer to Figure 2. Insert and hold a short iron bar through the flywheel housing against the fanblades of the fan and coupling assembly to block the armature against clockwise rotation. Dothis carefully to avoid damaging the fan blades.

(13) Tighten the 3/8-16 X 3/4 screws alternately and evenly as follows:

a. Set a torque wrench to 30 foot-pounds (41 N-m) and tighten all three 3/8-16 screws to thatvalue. As illustrated in Figure 2, insert and hold a short iron bar through the fan housingagainst the fan blades of the fan and coupling assembly to block the coupling againstclockwise rotation. Do this carefully to avoid damaging the fan blades. Note that as thesescrews are tightened, the armature will be pulled back into the bearing hub.

b. Repeat step (a) above until 3/8-16 screws can no longer be tightened.

(14) Make certain that the armature is pulled slightly into the bearing hub (so that it does not interferewith the bearing cap).

(15) Using a 3/16-inch Allen wrench, tighten the set screw in the bushing to apply pressure on thekey.

(16) Re-install the bearing cap that was removed in step (8).

(17) Re-install the generator housing cover and the flywheel housing cover.

(18) Re-install the fuel tank and canopy components.




Assembly Procedure Illustration

Figure 4

6. Run-in and Periodic Check

a. Mount the engine-generator assembly in a suitable test area and operate it for a 2-hour run-in.

b. Shut down the engine after 2 hours and re-torque all coupling screws to 40 - 45 foot-pounds (54 -61 Nm) to compensate for normal torque relaxation.

c. Return the unit to normal service.

d. After 200 hours of operation, check all coupling screws and taper-lock bolts with a torque wrenchset at 40 - 45 foot-pounds (54 - 61 Nm) .

e. Return the unit to normal service.

f. After each additional 2,000 hours of operation (or every year) recheck all coupling screws tomaintain the same torque value.




Chapter 4. Illustrated Parts List

Section 1. Introduction

1. General

The illustrated Parts List identifies, describes, and illustrates main assemblies, sub-assemblies, anddetail parts of the Jet-Ex 5D Generator Sets manufactured by Hobart Brothers Company, GroundPower Division, Troy, Ohio 45373.

2. Purpose

The purpose of this list is to provide parts identification and descriptive information to maintenance andprovisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spareparts.

3. Arrangement

CHAPTER 4 is arranged as follows:

Section 1 - Introduction

Section 2 - Manufacturer’s Codes

Section 3 - Parts List Section 4 - Numerical Index

4. Explanation of Parts List

a. Contents

The parts list contains a breakdown of the equipment into groups, assemblies, subassemblies, anddetail parts. All parts of the equipment are listed except:

(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which areavailable 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., toother parts, weldments, or assemblies.

b. Parts List Form

This form is divided into six columns. Beginning at the left side of the form and proceeding to theright, columns are identified as follows:

(1) “FIGURE-ITEM NO.” Column

This column lists the figure number of the illustration applicable to a particular parts list and alsoidentifies each part in the list by an item number. These item numbers also appear on theillustration. Each item number on an illustration is connected to the part to which it pertains by aleader line. Thus the figure and item numbering system ties the parts list to the illustrations andvice versa. The figure and index numbers are also used in the numerical index to assist the userin finding the illustration of a part when the part number is known.




(2) “HOBART PART NUMBER” Column

ALL part numbers appearing in this column are Hobart numbers. In all instances where the partis a purchased item, the vendor’s identifying five-digit code and his part number will appear inthe “Nomenclature” column. Parts manufactured by Hobart reflect no vendor code or partnumber in the “NOMENCLATURE” column.

(3) “NOMENCLATURE” Column

The item identifying name appears in this column. The indenture method is used to indicate itemrelationship. Thus, components, of an assembly are listed directly below the assembly andindented one space. Vendor codes and part numbers for purchased parts are shown in thiscolumn. Hobart modification to vendor items is also noted in this column.

(4) “EFF” (Effective) Column

This column is used to indicate the different models that use the part on that line. There aresome parts may be used on only one, or a variety of models. A code letter “A”, “B”, etc., isplaced in EFF column to indicate these parts. It can be cross referenced to the particular model itis used on. If a letter is not placed in that column, then all models use that part.

Parts coded “A” are useable on part number 500285A-001 only.

Parts coded “B” are useable on part number 500285A-002 only.

(5) “UNITS PER ASSEMBLY” Column

This column indicates the quantity of parts required for an assembly or subassembly in which thepart appears. This column does not necessarily reflect the total used in the complete end item.




Section 2. Manufacturer’s Codes

1. Explanation of Manufacturer’s (Vendor) Code List

The following list is a compilation of vendor codes with names and addresses for suppliers ofpurchased parts listed in this publication. The codes are in accordance with the Federal Supply Codesfor Manufacturer’s Cataloging Handbook H4-l, and are arranged in numerical order. Vendor codes areinserted in the nomenclature column of the parts list directly following the item name and description. Incase a manufacturer does not have a vendor code, the name of the manufacturer will be listed in thenomenclature column.

Code Vendor’s Name and Address

01XD4 Contact Industries Inc., 25 Lex-Industrial Dr.,

P.O. Box 3086, Mansfield, OH 44904-3086

02231 Anchor Rubber Company, 840 S. Patterson Blvd. Dayton, Ohio 45402

04055 East Penn Mfg., Co., Inc., Deka Rd., Lyon Station, PA 19536

04713 Motorola Inc., Semiconductor Products Div. Phoenix, Arizona 85008

13445 Cole-Herse, 20 Old Colony Ave. Boston, MA 02127

14552 Microsemi Corp., 2830 S. Fairview St., Santa Ana, CA 92704-5948

14799 Square D Co., Chicago Assembly Plant,

9522 W. Winona, Schiller Park, IL 60176-1025

16476 Datcon Instrument Co., P.O. Box 128, East Petersburg, PA 17520

18265 Donaldson Co., 1400 W. 94th St., P.O. Box 1299, Minneaplis, MN 55420

21585 Farr Co., 2221 Park Pl., EL Segundo, CA 90245

23803 NTN Bearing Corp., 650 Pennsylvania Dr., Exton PA 19341

28520 Heyco Molded Products, 750 Boulevard,

P.O. Box 160, Kenilworth, NJ 07208-1222

30104 Automotive Controls Corp., 1300 W. Oak St.,

P.O. Box 788 Independence, KS 67301-2347

33457 Fleetguard Inc., 402 BNA Dr., Nashville, TN 37217

40121 Peterson Mfg. Co. Inc, 700 W. 143rd St., P.O. Box 8 Plainfield, IL

60544-9733

44655 Ohmite Mfg. Co., 3601 W. Howard St., Skokie, IL 60076

46992 Phoenix Electric, 3625 N. Halstead St., Chicago, IL 60613

49234 Protectoseal Company, 1920 S. Western, Chicago IL 60608

5P059 Tech Products Corp, 2348 Sandridge Dr., Dayton, OH 45439




Code Vendor’s Name and Address

5E599 NVF Co., Primary Products Div., Yorklyn Rd, Yorklyn DE 19736

57733 Stewart-Warner Corp., 1826 Diversey Parkway, Chicago, IL 60614

59993 International Rectifier, 233 Kansas St., EL Segundo CA 90245

71400 Bussman Division of McGraw-Edison Company, 114 Old State Rd.,

St. Louis, Missouri 63178

74542 Hoyt Electrical Instruments, P.O. BOX 8798, Penacook, NH 03303

74559 Carling Switch Co., 505 New Park Ave.,

West Hartford, CT 06110

75175 K-D Lamp Co., 1910 Elm St., Cincinnati, OH 45210-2451

78377 SCP Inc., 9115 George Ave., Cleveland, OH 44105

78388 Synchro-Start Products, Inc., 8109 N. Lawndale Ave.,

P.O. Box 147 Skokie, IL 60076-9990

79470 Dana Corp., Weatherhead Div., 5278 US 24, Antwerp, OH 45813

7L306 Clarke GM Diesel, 1340 Terminal Rd., Indianapolis, IN 46217-9342

83330 Dialight Corp., 1913 Atlantic Ave., Manasquan, NJ 08736-1005

88136 Trombetta Corp., 1633 E. North Ave., Milwaukee, WI. 53202

91929 Honeywell Inc., Micro Switch Div., 11 W. Spring St., Freeport IL 61032

92489 Attwood Corp., 1016 Monroe Ave., Lowell MI, 49331

94177 Modine Mfg. Co., 1500 Dekoven Ave., Racine, WI 53401

94222 Southco Inc., 210 N. Brinton Lk. Rd., Concordville, PA 19331

9X737 Buyers Products Co., 7700 Tyler Blvd., Mentor, OH 44060-4802




Section 3. Parts List

1. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a left-hand page and the applicable partslist will appear on the opposite right-hand page. Unless the list is unusually long, the user will be able tolook at the illustration and read the parts list without turning a page.

2. Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list.

* - item not illustrated

A, or AMP - ampere

AC - alternating current

AR - as required

DC - direct current

Fig. - Figure

hd. - head

hex - hexagon

Hz - Hertz (cycles-per-second)

I.D. - inside diameter

IN - inch

kVA - kilovolt-ampere

uF - microfarad

No. - number

OM - Owners Manual

PRV - peak reverse voltage

PSI - pounds per square inch

Ref - reference (the item has been listed previously)

TM - Technical Manual

v - volt (when used as a prefix to a five-digit number, indicates vendor code)

NOTE: An item which does not reflect an index number is an assembly which is not illustrated in itsassembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated.







Generator Set Assembly(Stationary Mounted Unit Shown)

Figure 1

NOMENCLATUREFIGURE & HOBART AIRLINEITEM NO. PART NO. PART NO. 1 2 3 4 5 6 7 EFF QTY

1- 500285A-001 GENERATOR SET ASSEMBLYWITH TRAILER AND CABLE TRAYS A REF

500285A-002 GENERATOR SET ASSEMBLYSTATIONARY MOUNT WITH CABLE HANGERS B REF

1-1 77A1157 . SWITCH, EMERGENCY STOP (V14799 #KR-9R-H6) 1

1-2 288300 . EMERGENCY STOP LABEL 1

1-3 285125 . EMERGENCY STOP GUARD (V14799 #K56YM) 1

1-4 No Number . CANOPY COMPONENTS (See Fig. 3) REF

1-5 No Number . GENERATOR SET INTERIOR COMPONENTS

(See Fig. 4) REF

1-6 No Number . MOUNTING FRAME COMPONENTS (See Fig. 2) REF

1-7 288021 . CONTROLS COVER 1

1-8 288022 . CONTROLS COVER HINGE 1

1-9 288023 . WING KNOB LATCH 2

* 288020 . LATCH BRACKET 2

1-10 288007-001 . CONTROL BOX ASSEMBLY (See Fig. 5) 1

1-11 282562 . CAP, FUEL (V49234 #1275G/12T) 1

1-12 79A1127-002 . FILLER NECK GUARD 1

1-13 288060-001 . EXHAUST RAIN CAP 1

1-14 488640 . OUTPUT CABLE BRACKET 1

1-15 7J422-000 . OUTPUT CABLE CLAMP 1

1-16 403091-008 . PLASTIC HOLE PLUG 1

* 1-17 287698-001 . OUTPUT CABLE COVER 1

* 1-18 402987 . NAMEPLATE, HOBART 3

* 1-19 78A1000 . NAMEPLATE, ID 1

* 1-20 79A1110 . NAMEPLATE, OPTION 1

* 1-21 283533 . LABEL, SUPPORT CENTERS 1

* 1-22 81B1084 . LABEL, 28 VOLTS 1

* 1-23 405309 . LABEL, LUBE OIL FILTER 1

* 1-24 407366 . LABEL, CAUTION - INSUFFICIENT COOLING 1

* 1-25 76B1148 . LABEL, DIESEL FUEL 1

* 1-26 282658 . LABEL, CLEARANCE 1

* 1-27 401842 . TAG, ATTENTION - ENGINE COOLANT 1

* 1-28 40201 . TAPE, SEALANT, NEOPRENE 612"

* 1-29 287459 . LABEL, GENERAL INFORMATION 1

* 1-30 287460 . LABEL, DANGER HIGH VOLTAGE 2

* 1-31 287461 . LABEL, FUEL WARNING 1

* 1-32 287462 . LABEL, ENGINE COOLANT 1

* 1-33 287463 . LABEL, HOT MUFFLER 1

* 1-34 287464 . LABEL, FAN AND MOVING PARTS 2

* 1-35 287466 . LABEL, EMERGENCY STOP 1

* 1-36 282554-003 . REFLECTOR KIT 1

* 1-37 282554-004 . REFLECTOR KIT A 1




* Not Illustrated




Mounting Frame Components(Trailer Mounted Frame Shown)

Figure 2


2- No Number MOUNTING FRAME COMPONENTS REF

2- 1 287971 . CONTROL PANEL SUPPORT, LEFT 1

2- 2 287980 . FUEL TANK SUPPORT 1

2- 3 287972 . DOOR SUPPORT PANEL 2

* 288064-004 . DOOR SUPPORT INSULATION 2

2- 4 288350 . ENGINE SUPPORT 1

2- 5 287984 . BATTERY TRAY 1

2- 6 287998 . FRONT PANEL BRACKET 2

2- 7 288340 . FRAME/TRAILER ASSY. (SEE FIG. 16) A 1

* 287950 . STATIONARY MOUNTING FRAME B 1

* 489689 . STATIONARY MOUNTING KIT B 1

2- 8 287970 . CONTROL PANEL SUPPORT, RIGHT 1

2- 9 287955 . GENERATOR SUPPORT 1

2-10 287986 . CONTROL PANEL SUPPORT 1

* Not Illustrated







Canopy Components(Trailer Mounted Frame Shown)

Figure 3


3- No Number CANOPY COMPONENTS REF

3- 1 287981 . TOP CANOPY 1

* 288064-003 . TOP CANOPY INSULATION 1

* 288064-005 . TOP CANOPY INSULATION 1

3- 2 287999 . RADIATOR CAP ACCESS DOOR 1

3- 3 288352 . FRONT PANEL 1

3- 4 287542-001 . DOOR LATCH 4

3- 5 287526-002 . DOOR LATCH PULL 4

3- 6 287978 . ACCESS DOOR 4

* 288064-001 . DOOR INSULATION 4

3- 7 283824 . RIGHT HAND HINGE 4

3- 8 283597 . LEFT HAND HINGE 4

3- 9 287977 . SIDE PANEL 4

* 288064-002 . SIDE PANEL INSULATION 4

* 287785 . PANEL FASTENER 16

3-10 287987 . LOWER REAR PANEL 1

* Not Illustrated







Generator Interior ComponentsFigure 4

2 5 7

3981

610

4


4- No Number GENERATOR SET INTERIOR COMPONENTS REF

4- 1 No Number . BATTERY COMPONENTS (See Fig. 6) REF

4- 2 No Number . MUFFLER COMPONENTS (See Fig. 7) REF

4- 3 288306 . RECTIFIER ASSEMBLY (See Fig. 8) 1

4- 4 No Number . CONTACTOR COMPONENTS (See Fig. 9) REF

4- 5 No Number . ENGINE COMPONENTS (See Fig. 10) REF

4- 6 No Number . COOLING SYSTEM (See Fig. 11) REF

4- 7 No Number . FUEL SYSTEM COMPONENTS (See Fig. 12) REF

4- 8 No Number . THROTTLE CONTROL COMPONENTS (See Fig 10) REF

4- 9 287556 . GENERATOR ASSEMBLY (See Fig. 13) 1

4- 10 No Number . AIR CLEANER COMPONENTS (See Fig. 15) REF

* NOT ILLUSTRATED







Control Box AssemblyFigure 5


5- 288007A-001 CONTROL PANEL ASSY 1

5- 1 288369 . PANEL, CONTROL, . 1

5- 2 W11166-005 . FUSE, , 20A, V71400 1

5- 3 402658 . HOLDER, FUSE (V714OO #TYPE) 2

5- 4 494134-001 . GAUGE, FUEL, ELECTRIC, 12V(V16476 #06339-01) 1

5- 5 403189 . SWITCH, TOGGLE (V91929 #312TS1-59) 2

5- 6 78A1120-001 . GAUGE, HOUR METER (V16476 #56288) 1

5- 7 286699-001 . VOLTMETER, BATTERY (V16476 #06351-001) 1

5- 8 286864 . LABEL, CONTROL PANEL 1

5- 9 288368 . COMPRESSION LATCH 2

5-10 78A1117-002 . GAUGE, OIL PRESSURE (V16476 #06340) 1

5-11 287908 . GAUGE, WATER TEMP., (V16476 #06343) 1

5-12 408596-001 . TACHOMETER (V16476 #71076-00) 1

5-13 30GH1262 . LIGHT, PANEL, SOCKET 3

* 50GHP206 . PANEL LIGHT LAMP 3

* 288018 . PANEL LIGHT BRACKET 3

5-14 401937-004 . BLOCK, TERMINAL, 20A. (V83330 #699-18KT50) 2

5-15 W11166-003 . FUSE, 10A. 6

5-16 402662 . SWITCH, TOGGLE, DPST, (V74559 #2GK71-73) 1

5-17 180913-002 . LIGHT, PILOT, GREEN, 28V. ASSEMBLY 1

* 180914 . . BASE, LIGHT (V83330 #26-5710-11-301) 1

* 404172-003 . . LENS, GREEN (V83330 #26-1192-300) 1

* 400613-003 . . BULB 1

5-18 16DA2162 . KNOB, RHEOSTAT, (V44655 #5150) 1

5-19 401428-001 . POTENTIOMETER, 10K OHM, 2W.(V44655 #CMU-1031) 1

5-20 286923 . COVER, 14V OPTION 1

5-21 402663 . NUT, POTENTIOMETER, LOCK 1

5-22 407948 . RECTIFIER, ISOLATED BASE (V14552 #CT 106) 1

5-23 W10051-014 . CLAMP, WIRE, PLASTIC 1

5-24 405129-001 . BLOCK, FUSE (V71400 #S8202-6) 1

5-25 180913-001 . LIGHT, PILOT, ENGINE, GREEN, 12V. ASSY. 1

* 180914 . . BASE, LIGHT (V83330 #26-5710-11-301) 1

* 404172-003 . . LENS, GREEN (V83330 #26-1192-300) 1

* 400613-004 . . BULB 1

5-26 402682 . SWITCH, TOGGLE, 3 PDT (V74559, HLA-211-73) 1

5-27 30GH1119 . SWITCH, PUSHBUTTON (V13445 #9095-09) 1

5-28 406815 . BOOT, PUSHBUTTON SWITCH (V13445 #83280) 1

5-29 400642-003 . VOLTMETER, DC (V74542 1

5-30 400641-012 . AMMETER (V74542 1

5-31 180289 . BOARD, PC, OVERVOLTAGE, ASSY. 1

5-32 84A1075 . MOUNT, RUBBER (V5P059 #51083) 7

5-33 181022A-005 . BOARD, PC, REGULATOR 1

287683 . BOARD, PC, REGULATOR

(FOR REPLACEMENT/SUPPLY ONLY) 1




* NOT ILLUSTRATED


5- 288007A-001 CONTROL BOX ASSY (continued) REF

5-34 404065-002 . RECTIFIER, SILICON (V04713 #5DA-10270-2) 2

* 5-35 W10051-010 . CLAMP, WIRE, PLASTIC (V28520 #3334) 1

* 5-36 288012 . WIRE HARNESS 1

5-37 180593-003 . CAPACITOR ASSEMBLY, 100MFD, 350VDC 1

5-38 288016 . HINGE, PANEL MOUNTING 3

5-39 287988 . CONTROL BOX ENCLOSURE 1

5-40 180913-004 . RED PILOT LIGHT 1

5-41 288017 . ARM, TELESCOPIC STAY 1

5-42 287621 . RESISTOR AND DIODE ASSEMBLY 1

* 5-43 286611 . LABEL, BLANK 2

5-44 288019-004 . FUSE, , 20A 1

* 5-45 W10051-012 . PLASTIC CLAMP 1

* Not Illustrated







5 32

1 4

Battery ComponentsFigure 6


6- No Number BATTERY COMPONENTS REF

6- 1 281881-001 . BATTERY, 12 V. (V04055 #724 DT) 1

6- 2 288046 . BATTERY CABLE, POSITIVE, ASSY. 1

6- 3 288047 . BATTERY CABLE, NEGATIVE, ASSY. 1

6- 4 287796 . BATTERY HOLD DOWN 1

6- 5 494295 . BATTERY HOLD DOWN BOLT 1







Muffler ComponentsFigure 7


7- No Number MUFFLER AND EXHAUST COMPONENTS REF

7- 1 288374 . EXHAUST ELBOW 1

* 042471 . INSULATION 3 SF.

* 404154-013 . 3” FULL CIRCLE CLAMP 1

* W10869-006 . HOSE CLAMP 2

7- 2 288375 . FLEXIBLE EXHAUST CONNECTOR 1

* 042471 . INSULATION 3.5 SF.

* 404154-013 . 3” FULL CIRCLE CLAMP 2

* W10869-006 . HOSE CLAMP 2

7- 3 288376 . MUFFLER ASSEMBLY 1

* 042471 . INSULATION 1.4 SF.

* 288059-001 . HOSE CLAMP 2

* NOT ILLUSTRATED







Rectifier AssemblyFigure 8


8 - 288306 RECTIFIER ASSEMBLY 1

8 - 1 287184-003 . INSULATOR, CAPACITOR 1

8 - 2 405278-006 . CAPACITOR, 90000MFD, 75 1

8 - 3 286887 . SHROUD, AIR, TOP, RECTIFIER 1

8 - 4 W10869-006 . CLAMP, CAPACITOR 1

8 - 5 402037-004 . GROMMET, RUBBER (V02231 #) 1

8 - 6 16DA3493 . WASHER, INSULATING 6

8 - 7 288380-001 . RESISTOR, 10OHM, 100 WATT (V44655 #61917) 3

8 - 8 401911-005 . BLOCK, TERMINAL, 5 STATION 1

8 - 9 W11114-012 . SCREW, 1/4-20 X 7-1/4 3

8 -10 W11280-015 . NUT, JAM, HEX, 3/4-16 12

8 -11 494681-001 . WASHER, SPRING 12

8 -12 W10931-003 . RECTIFIER, POS., BASE (V59993 #300U30A) 6

8 -13 286884 . BRACKET, ., HEAT SINK 2

8 -14 W10933-003 . RECTIFIER, NEG. BASE (V59993 #300UR30A) 6

8 -15 W11097-007 . SCREW, HHC, 3/8-16 x 2" 1

8 -16 180065 . SHUNT, 2000 AMP 1

8 -17 W11097-007 . SCREW, , 3/8-16 x 2" 5

8 -18 285647 . SHROUD, AIR, BOTTOM, RECTIFIER 1

8 -19 180600 . SPACER, SHROUD 3

8 -20 282239 . HEAT SINK, RECTIFIER, NEGATIVE 1

8 -21 W11097-022 . SCREW, , 3/8-16 x 2-1/2" 4

8 -22 A25 . WASHER, INSULATING 8

8 -23 AW626 . BUSHING, INSULATING (V5E599 # #E48013(M)) 4

8 -24 286813 . HEAT SINK, RECTIFIER, POSITIVE 1

8 -25 W11242-018 . WASHER, FLAT, 3/8 8

8 -26 283063 . SPACER, RECTIFIER 4

8 -27 288008 . RECTIFIER MOUNTING BRACKET 2

* 8 -28 DELETED

* 8 -29 288015 . RECTIFIER WIRE HARNESS 1

* Not Illustrated







Contactor Components

Figure 9

4

12 3

7

6 58


9 - No Number CONTACTOR COMPONENTS REF

9 - 1 A25 . WASHER, INSULATING 2

9 - 2 AW626 . BUSHING, INSULATING (V5E599 #UL#E48013(M)) 1

9 - 3 W9218-227 . CABLE, OUTPUT, NEGATIVE 1

9 - 4 400435 . LABEL, 28 VOLTS 1

9 - 5 W9218-251 . CABLE, OUTPUT, POSITIVE 1

9 - 6 286810-001 . CONTACTOR, DC, 800 AMP (V01XD4 #CT800A-24C2) 1

9 - 7 286849 . INSULATOR, CONTACT 1

9 - 8 489658-010 . DIODE ASSEMBLY 1







Engine ComponentsFigure 10

16

17

3 21

4

5

18

6

2

1

9

8

8

197

13

14

15

18

20

11

12


10- No Number ENGINE COMPONENTS REF

10- 1 W9360-229 . GROUND CABLE 1

10- 2 287735 . GROUNDING PLATE 1

10- 3 288014 . ENGINE HARNESS 1

10- 4 286850 . STARTER CUT-OUT SOLENOID 2

10- 5 407948 . RECTIFIER, STARTER SOLENOID 1

10- 6 489658-007 . FLYBACK DIODE 2

10- 7 288065 . THROTTLE SOLENOID LINKAGE 1

10- 8 288215-001 . BEARING END ROD 3

10- 9 288221-001 . THREADED ROD 1

10-10 NOT USED

10-11 288045-001 . THROTTLE SOLENOID 1

10-12 286558 . THROTTLE SOLENOID BRACKET 1

10-13 78B1118-002 . OIL PRESSURE SENDER 1

10-14 W10910-000 . TEE FITTING 1

* 287419 . ADAPTER, M10 TO 1/8 NPT 1

* W10750-001 . 1/8” PIPE NIPPLE 1

10-15 403809-002 . OIL PRESSURE SWITCH 1

10-16 403782-002 . WATER TEMPERATURE SWITCH 1

* 287909 . WATER TEMPERATURE SENDER` 1

10-17 W7814-004 . PIPE BUSHING 1

10-18 288347-001 . ENGINE SUPPORT BRACKET, LEFT 1

288347-002 . ENGINE SUPPORT BRACKET, RIGHT 1

10-19 288341 . ENGINE, CUMMINS, 4BT3.9 1

10-20 284372-002 . ENGINE SHOCK MOUNT 2

10-21 286897-016 . OIL FILTER (V33457 #LF3345) 1

* NOT ILLUSTRATED







Cooling System ComponentsFigure 11

1 2 34 5

7

8

9

10


11- No Number COOLING SYSTEM COMPONENTS REF

11-1 056534 . DEAERATION HOSE 21.5”

* W7814-000 . 1/8 X 1/ 4 PIPE BUSHING 1

* 402927-003 . MALE CONNECTOR 2

* W10869-014 . HOSE CLAMP 2

11-2 287333-001 . 10LB. RADIATOR CAP 1

11-3 288343 . PRESSURIZED RADIATOR 1

* 283873 . DRAIN VALVE 1

* 056535 . 3/8” ID HOSE 12”

* W10869-014 . HOSE CLAMP 1

* W10051-007 . PLASTIC WIRE CLAMP 2

11-4 288063 . TOP RADIATOR HOSE 1

* W10869-003 . HOSE CLAMP 2

11-5 288002 . FAN GUARD 1

11-6 288001 . 20" ENGINE FAN 1

11-7 287982 . TOP FAN SHROUD 1

11-8 287373 . BELT AND PULLEY GUARD 1

11-9 288000 . BOTTOM FAN SHROUD 1

11-10 288062 . BOTTOM RADIATOR HOSE 1

* W10869-005 . HOSE CLAMP 2

* Not Illustrated







Fuel System ComponentsFigure 12

69

5

2

8

7

1

9

3


12- No Number FUEL SYSTEM COMPONENTS REF

12-1 056535 . HOSE, 3/8” I.D (TANK TO FILTER) 1

12-2 288358 . FITTING, STRAIGHT, 3/8 BARB TO 3/8 NPT 1

* W10869-014 . HOSE CLAMP 2

12-3 056544 . HOSE, 5/16 ID (FUEL RETURN LINE) 1

* 12-4 288224 . STRAIGHT FITTING 1

* W10869-014 . HOSE CLAMP 2

12-5 282299 . FUEL TANK ASSEMBLY 1

* 284203 . FUEL TANK MOUNTING PLATE 5

* 12-6 288382 . FUEL STRAINER 1

12-7 288384 . NIPPLE, ADAPTER 1

12-8 288383 . SHUT-OFF VALVE 1

12-9 288254-001 . CLAMP 1

* Not Illustrated







Generator AssemblyFigure 13


13- 287556 GENERATOR, ASSY. 1

288210 SPARE GENERATOR ASSEMBLYFOR REPLACEMENT ONLY REF

* 13- 1 284371-002 . SHOCK MOUNT 1

13- 2 287564 . FAN HOUSING 1

13- 3 488557-008 . HOUSING & STATOR ASSY. 1

13- 4 489135 . KEY, COUPLING 1

13- 5 180776 . ARMATURE, . 1

13- 6 488555-001 . HOUSING, BEARING ASSY. 1

13- 7 287401 . CAP, BEARING 1

13- 8 488784 . BRUSHHOLDER ASSY. (For Details See Fig. 14) 1

13- 9 288003 . COVER, FLYWHEEL HOUSING 1

13-10 489125 . FAN AND COUPLING ASSEMBLY 1

* 402789-004 . . SCREW, CAP, , 3/8-24 X 3/4, NYLOK 6

* W11254-005 . . WASHER, LOCK, STD., 3/8 6

* 85C1004-002 . . BUSHING, SPLIT TAPER 1

13-11 No Number . FLYWHEEL - (Supplied w/Engine) REF

13-12 354592 . RING, SLIP 2

13-13 281688 . COVER, GENERATOR HOUSING 1

* 13-16 W10072-063 . BEARING (V23803 #6207LLUC3) 1

* 13-17 287956 . GENERATOR SUPPORT BRACKET (REAR) 1

* Not Illustrated







Brushholder AssemblyFigure 14


14 - 488784 BRUSH HOLDER ASSEMBLY REF

14- 1 488562 . BRACKET, ., BRUSH HOLDER 1

14- 2 488628 . BRACKET, , DIODE 1

14- 3 408999-001 . DIODE, SILICON, 30A, POS. ASSEMBLY 1

14- 4 402531 . CAP, , (V46992 #DE-55) 2

14- 5 402530 . GUIDE, , (V46992 #661-D-23) 2

14- 6 402788 . BRUSH, A.C., (V78377 #443E) 2

* Not Illustrated







67

542 3

1

Air Cleaner ComponentsFigure 15


15 - No Number AIR CLEANER COMPONENTS REF

15- 1 288059-001 . CLAMP, STAINLESS STEEL 1

15- 2 288049 . AIR CLEANER SUPPORT BRACKET 1

15- 3 288048-001 . AIR CLEANER 1

15- 4 282918 . AIR RESTRICTION INDICATOR 1

* 282919 . INDICATOR ADAPTER 1

15- 5 280732-004 . AIR CLEANER CLAMP 3

15- 6 288056-001 . RUBBER PIPE, TURBO INLET 1

15- 7 288057-001 . STRAIGHT PIPE 1

* Not Illustrated







Trailer ComponentsFigure 16

NOMENCLATURE UNITSFIGURE HOBART PERITEM NO. PART NO. 1234567 EFF ASSY

16- 288340 FRAME/TRAILER ASSEMBLY A 1

-1 288389 . REAR AXLE WELDMENT (V52793 #05-053285) A 1

-2 287587 . HUB AND BRAKE ASSY. (V52793 #05-046894) A 2

* 285917 . . LUG NUT (V52793 #05-007805) A 5

-3 285911 . . DUST SHIELD (V52793 #317968) A 1

-4 286205 . . HUB BOLT (V52793 #05-006440) A 5

-5 287627 . . BRAKE DRUM (V52793 #05-006712-21) A 1

-6 287626 . . HUB ASSEMBLY (V52793 #05-046879-1AL) A 1

-7 287626-001 . . . GREASE SEAL (V52793 #16743 CR) A 1

-8 287626-002 . . . INNER BEARING CONE (V60038) #67048) A 1

-9 287626-003 . . . INNER BEARING CUP (V60038) #67010) A 1

-10 287628 . . . HUB (V52793 #03-044880-AL) A 1

-11 287626-004 . . . OUTER BEARING CUP (V60038) #11910) A 1

-12 287626-005 . . . OUTER BEARING CONE (V60038) #11949) A 1

-13 287626-006 . . . WHEEL HUB CAP (V52793 #1517) A 1

-14 288390 . FRONT AXLE WELDMENT (V52793 #05-053308) A 1

-15 288392 . HUB ASSEMBLY (V52793 #2-1206-01-01) A 1

-16 285851 . LATCH PEDAL (V52793 #05-051009) A 1

-17 285850 . COMPRESSION SPRING (V52793 #LC-063F-7) A 1

-18 286735 . HUB ASSEMBLY (V52793 #03-044876-1AL) A 2

* 285917 . . LUG NUT (V52793 #05-007805) A 5

-19 286735-001 . . GREASE SEAL (V52793 #16743 CR) A 1

-20 286735-002 . . INNER BEARING CONE (V60038 #67048) A 1

-21 286735-003 . . INNER BEARING CUP (V60038) #67010) A 1

-22 286205 . . HUB BOLT (V52793 #03-006440) A 5

-23 286734 . . WHEEL HUB (V52793 #03-044875-AL) A 1

-24 286735-004 . . OUTER BEARING CUP (V60038) #11910) A 1

-25 286735-005 . . OUTER BEARING CONE (V60038) #11949) A 1

-26 286735-006 . . WHEEL HUB CAP (V52793 #1517) A 1

-27 285844 . . DRAWBAR PIN ASSY. (V52793 #05-046787-A) A 1

-28 288393 . . DRAWBAR WELDMENT (V52793 #05-053590)A 1

-29 286978 . BRAKE LEVER ASSEMBLY (V52793 #05-031110) A 1

-30 286982 . CLEVIS (V52793 #2708-4A) A 6

-31 288394 . BRAKE HANDLE ROD (V52793 #05-053305) A 1

-32 288395 . BRAKE LEVER ROD (V52793 #05-053304) A 2

-33 288398 . SHAFT LEVER A 3

* 286985 . COLLAR, SET SCREW (V52793 #SC-075) A 2

* 286984 . ROLL PIN (V52793 #LL 5/16 X 1-1/4RP) A 3

-34 286981 . SHAFT BEARING (V52793 #05-046646) A 2

-35 288396 . BRAKE CROSS BAR (V52793 #05-053306) A 1

-36 288397 . SPACER BLOCK (V52793 #05-053414) A 1

-37 288391 . REAR FRAME PLATE (V52793 #05-053276) A 1

-38 287996 FENDER A 2

-39 287994 FENDER MOUNTING BRACKET A 4

-40 287993 FENDER MOUNTING BRACKET A 2

-41 282720 . WHEEL AND TIRE ASSEMBLY A 4





16- 288340 FRAME/TRAILER ASSEMBLY (CONT) A 1

-42 286201 . BRAKE ASSEMBLY (SEE FIGURE 17) A 2

* Not Illustrated







Brake AssemblyFigure 17


17- 286201 BRAKE ASSEMBLY REF

-1 285911 . DUST SHIELD (V52793 #317968) REF

-2 285915-006 . CAM ASM. (V14892) #317687) 1

-3 285915-001 . HOLD DOWN SPRING (V14892) #4152194) 2

-4 285915-005 . CAM SHAFT (V14892) #313061) 1

-5 285915-003 . SHOE RETURN SPRING (V14892) #4152195) 1

-6 285915-004 . SUPPORT PLATE (V14892) #310949) 1

-7 285915-002 . SHOE ASM. (V14892) #320647) 1




7- 1 042471

7- 2 042471

7- 3 042471

11-1 056534

11-3 056535

12-1 056535

12-3 056544

5-18 16DA2162

8 - 6 16DA3493

8 -16 180065

5-31 180289

5-37 180593-003

8 -19 180600

13- 5 180776

5-25 180913-001

5-17 180913-002

5-40 180913-004

5-17 180914

5-25 180914

5-33 181022A-005

15- 5 280732-004

13-13 281688

6- 1 281881-001

8 -20 282239

12-5 282299

1-36 282554-003

1-37 282554-004

1-11 282562

1-26 282658

16-41 282720

15- 4 282918

15- 4 282919

8 -26 283063

1-21 283533

3- 8 283597

3- 7 283824

11-3 283873

12-5 284203

13- 1 284371-002

10-20 284372-002

1-3 285125

8 -18 285647

16-27 285844

16-17 285850

16-16 285851

16-3 285911

17-1 285911

17-3 285915-001

17-7 285915-002

17-5 285915-003

17-6 285915-004

17-4 285915-005

17-2 285915-006

16-18 285917

16-2 285917

16-42 286201

17- 286201

16-22 286205

16-4 286205

10-12 286558

5-43 286611

5- 7 286699-001

16-23 286734

16-18 286735

16-19 286735-001

16-20 286735-002

16-21 286735-003

16-24 286735-004

16-25 286735-005

16-26 286735-006

9 - 6 286810-001

8 -24 286813

9 - 7 286849

10- 4 286850




Section 4. Numerical Index

1. Explanation of Numerical Index

The purpose of this index is to assist the user in finding the illustration and description of a part whenthe part number is known. Part numbers are arranged in numeric-alpha sequence. Thus, any partnumber beginning with the number 9 would be located at or near the top of the index list. Like-wise, apart beginning with the letter A would be listed near the end of the list and far below a part number1000. The figure number and item number location of the part is directly opposite the part. If the part isused in more than one place, each location is listed commencing with the first location the part is listed.

FIG-ITEM PART

NUMBER

FIG-ITEM PART

NUMBER

5- 8 286864

8 -13 286884

8 - 3 286887

10-21 286897-016

5-20 286923

16-29 286978

16-34 286981

16-30 286982

16-33 286984

16-33 286985

8 - 1 287184-003

11-2 287333-001

11-8 287373

13- 7 287401

10-14 287419

1-29 287459

1-30 287460

1-31 287461

1-32 287462

1-33 287463

1-34 287464

1-35 287466

3- 5 287526-002

3- 4 287542-001

13- 287556

4- 9 287556

13- 2 287564

16-2 287587

5-42 287621

16-6 287626

16-7 287626-001

16-8 287626-002

16-9 287626-003

16-11 287626-004

16-12 287626-005

16-13 287626-006

16-5 287627

16-10 287628

5-33 287683

1-17 287698-001

10- 2 287735

3- 9 287785

6- 4 287796

5-11 287908

10-16 287909

2- 7 287950

2- 9 287955

13-17 287956

2- 8 287970

2- 1 287971

2- 3 287972

3- 9 287977

3- 6 287978

2- 2 287980

3- 1 287981

11-7 287982

2- 5 287984

2-10 287986

3-10 287987

5-39 287988

16-40 287993

16-39 287994

16-38 287996

2- 6 287998

3- 2 287999

11-9 288000

11-6 288001

11-5 288002

13- 9 288003

1-10 288007-001

5- 288007A-001

8 -27 288008

5-36 288012

10- 3 288014

8 -29 288015

5-38 288016

5-41 288017

5-13 288018

5-44 288019-004

1-9 288020

1-7 288021

1-8 288022

1-9 288023

10-11 288045-001

6- 2 288046

6- 3 288047

15- 3 288048-001

15- 2 288049

15- 6 288056-001

15- 7 288057-001

15- 1 288059-001

7- 3 288059-001

1-13 288060-001

11-10 288062

11-4 288063

3- 6 288064-001

3- 9 288064-002

3- 1 288064-003

2- 3 288064-004

3- 1 288064-005

10- 7 288065

13- 288210

10- 8 288215-001

10- 9 288221-001




FIG-ITEM PART

NUMBER

FIG-ITEM PART

NUMBER

12-4 288224

12-9 288254-001

1-2 288300

4- 3 288306

8 - 288306

16- 288340

2- 7 288340

10-19 288341

11-3 288343

10-18 288347-001

10-18 288347-002

2- 4 288350

3- 3 288352

12-2 288358

5- 9 288368

5- 1 288369

7- 1 288374

7- 2 288375

7- 3 288376

8-7 288380-001

12-6 288382

12-8 288383

12-7 288384

16-1 288389

16-14 288390

16-37 288391

16-15 288392

16-28 288393

16-31 288394

16-32 288395

16-35 288396

16-36 288397

16-33 288398

5-27 30GH1119

5-13 30GH1262

13-12 354592

9 - 4 400435

5-17 400613-003

5-25 400613-004

5-30 400641-012

5-29 400642-003

5-19 401428-001

1-27 401842

8 - 8 401911-005

5-14 401937-004

1-28 40201

8 - 5 402037-004

14- 5 402530

14- 4 402531

5- 3 402658

5-16 402662

5-21 402663

5-26 402682

14- 6 402788

13-10 402789-004

11-1 402927-003

1-18 402987

1-16 403091-008

5- 5 403189

10-16 403782-002

10-15 403809-002

5-34 404065-002

7- 1 404154-013

7- 2 404154-013

5-17 404172-003

5-25 404172-003

5-24 405129-001

8 - 2 405278-006

1-23 405309

5-28 406815

1-24 407366

10- 5 407948

5-22 407948

5-12 408596-001

14- 3 408999-001

13- 6 488555-001

13- 3 488557-008

14- 1 488562

14- 2 488628

1-14 488640

13- 8 488784

14 - 488784

13-10 489125

13- 4 489135

10- 6 489658-007

9 - 8 489658-010

2- 7 489689

5- 4 494134-001

6- 5 494295

8 -11 494681-001

1- 500285A-001

1- 500285A-002

5-13 50GHP206

1-25 76B1148

1-1 77A1157

1-19 78A1000

5-10 78A1117-001

5- 6 78A1120-001

10-13 78B1118-001

1-20 79A1110

1-12 79A1127-002

1-15 7J422-000

1-22 81B1084

5-32 84A1075




FIG-ITEM PART

NUMBER

FIG-ITEM PART

NUMBER

13-10 85C1004-002

8 -22 A25

9 - 1 A25

8 -23 AW626

9 - 2 AW626

11-3 W10051-007

5-35 W10051-010

5-45 W10051-012

5-23 W10051-014

13-16 W10072-063

10-14 W10750-001

11-4 W10869-003

11-10 W10869-005

7- 1 W10869-006

7- 2 W10869-006

8 - 4 W10869-006

11-1 W10869-014

11-3 W10869-014

12-2 W10869-014

12-4 W10869-014

10-14 W10910-000

8 -12 W10931-003

8 -14 W10933-003

8 -15 W11097-007

8 -17 W11097-007

8 -21 W11097-022

8 - 9 W11114-012

5-15 W11166-003

5- 2 W11166-005

8 -25 W11242-018

13-10 W11254-005

8 -10 W11280-015

11-1 W7814-000

10-17 W7814-004

9 - 3 W9218-227

9 - 5 W9218-251

10- 1 W9360-229




FIG-ITEM PART

NUMBER

FIG-ITEM PART

NUMBER

Chapter 5. Manufacturer’s Literature

Section 1. Manufacturer’s Listing

VENDOR LITERATURE

Engine Cummins Engine Operation ManualCummins Engine Parts Catalog

Hobart Brothers Diagrams:

288005 - Connection and Schematic Diagram, Jet-Ex 5D, Series 500285A



Jet-Ex 5D / Series 500285 A/ Generator Set

Appendix A. Options/Features

The following is a list of options available for Series 500285A. This chart contains the description, partnumber, and document number of the option. There is also a column to identify which option is contained inthis Appendix.

OPTIONS / FEATURES AVAILABLE

DESCRIPTION PART NUMBERDOCUMENT

NUMBERIN THIS

SECTION

Kit, 14-V Output with Fenders & Cable Trays 288296-001 TO-275

Kit, 14-V Output with Cable Hangers 288296-002 TO-275

120-V AC Generator Package (Trailer-mounted unitswith Fenders)

181735 TO-194

Kit, Water Heater 120V 288139-001 TO-271

Kit, Water Heater 240V 288139-002 TO-271

Grounding Reel 83A-1103

Kit, Start, Ether 489782A TO-211

Crate, Shipping, Export 489848

Kit, Ring Tie Down 284706

Kit, CE, Trailer Mount 287589-003

Kit, CE, Stationary Mount 287589-004

Kit, Forklift Pockets 288257

Kit, Clearance Lights 288234

Kit, Fuel/Water Separator 288372

August 01, 2001 Appendix APage 1




Appendix A August 01, 2001Page 2



Unusual Service Conditions

This information is a general guideline and cannot cover all possible conditions of equipment use. Thespecific local environments may be dependent upon conditions beyond the manufacturer’s control. Themanufacturer should be consulted if any unusual conditions of use exist which may affect the physicalcondition or operation of the equipment.

Among such conditions are :1. Exposure to:

Combustible, explosive, abrasive or conducting dusts.Environments where the accumulation of lint or excessive dirt will interfere with normalventilation.Chemical fumes, flammable or explosive gases.Nuclear radiation.Steam, salt-laden air, or oil vapor.Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive tofungus growth.Abnormal shock, vibration or mechanical loading from external sources during equipmentoperation.Abnormal axial or side thrust imposed on rotating equipment shafts.Low and/or high ambient temperatures.

2. Operation at:

Voltages above or below rated voltage.Speeds other than rated speed.Frequency other than rated frequency.Standstill with rotating equipment windings energized.Unbalanced voltages.Operation at loads greater than rated.

3. Operation where low acoustical noise levels are required.

4. Operation with:

Improper fuel, lubricants or coolant.Parts or elements unauthorized by the manufacturer.Unauthorized modifications.

5. Operation in poorly ventilated areas.

August 01, 2001 Unusual Service ConditionsPage 1




Unusual Service Conditions August 01, 2001Page 2



Wet-Stacking in Generator Set

1. Diesel Engines

All diesel engines operated for extended periods under light load may develop acondition commonly referred to as wet-stacking. This condition results from theaccumulation of unburned fuel in the exhaust system. It is recognizable by fuel oilwetness around the exhaust manifold, pipes, and muffler. Liquid fuel, in the form ofdroplets, may be spewed from the exhaust outlet.

Wet-stacking is common, and may be expected in diesel engines operated under lightload. Light loads do not allow the engine to reach most efficient operatingtemperature for complete combustion of fuel. The unburned fuel collects in theexhaust system to create the wet condition known as wet-stacking.

To alleviate wet-stacking in lightly loaded engines, it is recommended that themachine be connected to a load bank after each 200 hours of use and operated underfull rated load for one hour. This will burn away and evaporate the accumulation offuel in the exhaust system. This clean-out procedure should be considered as aregular maintenance operation for machines operated under light load. The timeschedule of 200 hours may be changed as required to suit each user’s particularneeds and operating conditions.

August 01, 2001 Wet StackingPage 1




Wet Stacking August 01, 2001Page 2



Operation and Maintenance ManualIntroduction This manual contains operation and service information...

Documents

Transcript of Operation and Maintenance ManualIntroduction This manual contains operation and service information...