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1 i - Keystone GSE

1. 0 2 007 e Remove filler cap on valve cover and refill crankcase with new clean oil of proper specification and viscosity see Para 2 E 2 and Figure 4 7 quarts are required when oil filter is changed f Start engine and allow it to idle 011 pressure should come up to normal quickly Check for oil leaks at filter and drain plug g Stop engine Allow several minutes for oil to drain to crankcase then check oil level It should be at FULL mark on dipstick h Check hourmeter and record time of oil change Change engine oil filter 100 hours Place a container under the oil filter to catch oil drippings b Loosen filter with a special oil filter removal wrench Several types are available Discard oil filter c Coat the gasket on the new filter with oil d Place the new filter in position on the cylinder block and spin on until the gasket contacts the adapter face then hand tighten another 1 2 turn Do not over tighten e Start engine and check filter gasket for leaks F Trailer 1 2 Dec gt 1 85 n KK Front axle assembly The front axle assembly drawbar and steering linkage are equipped with high pressure lubrication fittings Lubricate the trailer each 400 hours Use a good quality chassis lubricant See Figure 2 Clean lube fittings before applying grease Wheel bearings Lubricate and check wheel bearing adju
2. l i i attery Service General Two 12 volt batteries connected in parallel supply power for operation of the engine electrical system clearance and panel lights and for flashing the generator Battery Location and Accessibility The batteries are located in a tray directly beneath the cooling fan at the front of the unit These batteries are easily accessible for service by removing two 1 4 inch wing nuts and lifting out the battery access panel at the bottom front of the unit Battery Care 1 Never allow battery which has been removed from a unit to sit on concrete ground or metal unless proper insulation is provided wooden platform or board will parovide sufficient insulation 2 Maintain stored batteries in a charged condition avoid damage from vibration s s i i i 3 Be sure batteries are fastened securely in their compartment t 5 Keep battery terminal posts and lead cable connectors clean WARNING NEVER ALLOW SPARKS OR OPEN FLAME NEAR BATTERIES AVOID SPILLING ELECTROLYTE ON HANDS OR CLOTHING 4 Maintain battery fluid at proper level i 2 2 Dec 1 85 D Liquid Level prevent battery failure Check the level of the electrolyte every two weeks When electrolyte level is low add pure disti
3. NES BO42V1NOO SODA 39VL 10A83A0 POLA 035079 MOLOVINOO 211954 3078 300W Av HOIVOIONL 5 yagny OW WMOIVOIONI 60950 t 9839371 JU mh uj 7 POPP PODA M NOILdO LINON A bt N HISOd 3190904 P TD psa pred kvediwos 1044024 pogoj jo Ajjedoid 39H y pue Po e Gil 44 1 204 90431 ONY 1 03003230 WOR 4432X32 A144V 0138 32NVW33O0O1 FIVIE OQ SIHINI NI IVV NOVATO SP PE AA 03SN 3u3HM 10 0826 082008 JONVHI 02 lt 016 5030236 XOddW 38 01 FAIL did OIE 235 ESS 38 OLIWIA 4181 3034 ANANI 110A SE v SINOA 16 4181 OL LON 51 QuVO8 JHL 30 SNNIW ONY 50114 5 20 123 09 72 LH911 THA 81087184 HL
4. gana 2099 MOIVNJN3O HOIV1n93H ZObYA NA i NUNS N3HM VGI 15915 H3H1V3M 01027 3504 7094 N3HM HOSN3S 4931 3NION3 HOLIMS 455 MOLV 01938 39v130A 3803 2094 330 NO 3S079 YOLIVINO9 5 8075 Y 3NION3 3514 2054 39V11OA dn g1I08 01 HS nd NOLLASHSNd HOLIMS 4085 358 _ Opa NOILISOd NI NMOHS IONLNOD 033dS H2iiMS _ 905 an S1H9 1 9NILVNIWI II H2LIMS 2 5 oN 1 OV1NOO SQ 4015 18 15 3JNI9N3 HOLIMS vOvS HOLY OMNI 20950 38055384 WO HOLIMS 5 u 1 917 90950 20950 HOLIMS 2095 31IHM SNLLVNIW TTII LHOI1 20950 10950 184916 3NI9N3 NOL1n8HSfd HOLIMS 095 mS 22942 WHO Ol H31SISJM gt 6058 p 8 4300 gt 22 2 H3L3WWV LNAHS Ot 10 1 02 SitHO2 lbHO S WHO S2 H31SIS3H 9oru Gs 3ALLISOd zJOI 9 tH2 SZtH2 OO WHO 014831615234 3008 9lbH2 GOtHO 01 1 13 3 104 f 2098 9NINDO 19 3000 ObHO IOpHO ets Q OO HO1IDVdVO 069 MO1V1n93M 90719 SOtd APR 2092 i 624
5. gt di I e E 7 i i in i Ak A reas SUBJECT Antifreeze attery Service General Battery Care Liquid Level au Cleaning the Battery Testing the Battery Rp 1 Test with Battery Starter 2 Test with Hydrometer Maintenance General B Brush Service 1 Cleaning C Generator Revolving Field Brush Replacement Adjustment Test 1 2 4 3 General Testing the Generator Set A Preoperational Test Procedures Operational Tests Voltage Regulator Adjustment 28 5 Volt Adjustment Line Drop Compensation Wr ae Contents lt th t Page 6 Battery Location and Accessibility Tester TABLE OF CONTENTS CONTINUED 4 Loo Le 2007 CHAPTER SECTION PAGE i 2 2 8 x s JE l 10 10 10 10 10 E 4 Dec 1 85 i x Wu TABLE CONTENTS CONTINUED 1 X ud Bw P N E S t i 207 1 55500 E i pi 4 E e T inc pus el Soden ed Edo 204 2007 SUBJECT CHAPTER SECTION Troubleshooting 3 1 1 1 General 1 2 Troubleshooting C
6. o Revi ned Apr 15 88 Page 392 G ae 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 13 489593 LINES FUEL AND RETURN ASSY For NHA See Fig 12 REF 1 490036 LINE FUEL 3 2 W 10869 14 CLAMP HOSE 6 3 355325 4 HOSE RUBBER 36 1 4 355325 6 HOSE RUBBER 6 1 5 405091 1 ELBOW MALE BARBED 1 6 402927 1 CONNECTOR MALE 1 7 402265 VALVE SHUT OFF 70411 NO 130C J 1 8 491889 5 HOSE RUBBER 15 1 Apr 15 88 Revised 4 3 Page 33 TRUE d NR 2007 Cooling System IATA 7 17 AAA 4 3 Page Flo o A A E S A a co cc ANE 5780 0M 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 14 Number COOLING SYSTEM For NHA See Fig 5 REF 1 408441 1 RADIATOR V94177 No 1A13713D 1 2 W 10869 12 CLAMP V35708 6 3 406655 HOSE TOP RADIATOR 1 4 405977 1 HOSE BOTTOM RADIATOR 1 5 405743 CAP FILLER 78225 NO AAX 0418 1 6 489121 SHROUD ASSY 1 7 489122 SUPPORT RADIATOR 2 8 180710 1 HOSE BOTTOM RADIATOR 1 9 489765 CONNECTOR HOSE RADIATOR 1 10 351541 LABEL CAUTION FAN 1 11 401842 TAG ATTENTION ENGINE COOLING 1 12 400902 ANTI FREEZE 1 13 489533 SUPPORT RADIATOR NECK 1 14 10869 2 CL
7. WO ZIEL IOAZ MONIZ be INDUS 40 ANI 11032412 YO 1956337431 300107 114405 3204 MENT LINDT 19109 153171504 vt 693 7501 51538 X i OB JINIS WIS 831 39801289104 82 1 MHO Xi 0899 750151538 Rest ve Sco 15 82 7 WHO WANA LL OLNI O REAL 2 Wor ot WIL 34013104 Mesi 001 15183 CHORUNO WOLSIS N T HORS 151534 AJA 069920161538 WHO 372 1551417411 901183104 4971 00 HOSS HOISTS A AB715940 270451817432 340043102 TD 71 U 791 9701515 0 X806 ni 91 13104 ZR XS 3700157101703 3901193104 AZZI xt JINIS WHL WJ 301183104 Xt WNI LIO SIS de PHO OLG 741970151534 90 xt 70161534 Avs NOBUNI WOISIS3N 76 9 4 700947401515 WHO 1515 4 0 51538 MMT 922225 NODIS 7174557401515 1 41003 CPW ON WOL SISE 010919 VOT 1 505801 5114 WO 9 2 BO 19 0111504 989042903 0111504 81801234905 1003 0 5995 400 1004 1 OA 30010 703 WOCLONTTAL A279 33730010 41003 WO
8. SGA i 2 2E RIGHT SIDE VIEW 50 39 i i i 1 Radiator 14 Load contactor 2 Air cleaner 15 Batteries 3 Muffler 16 Alternator 4 Engine 17 Fuel filter i 5 Lifting yoke 18 Starter 6 Rectifier assembly 19 Starter relay 7 Fuel tank 20 Frame i 8 Control panel 21 Fuel tank support 9 22 Engine governor 10 Fuel filter 23 Water temperature 11 Throttle control assembly sender amp switch i 12 Oil filter 24 Oil pressure sender 13 Drain cock amp switch Generator Set Components 1 i 0M 2007 HOBART JeZe Fh OIL PRESSURE WATER TEMP STARTING CURRENT 20 19 15 13 2 18 14 1 011 Pressure Gauge ll Contactor Control Switch 2 Tachometer 12 Contactor Closed Light 3 Water Temperature Gauge 13 Speed Control Switch 4 Current Limit Control 14 Engine On Light 5 Ammeter Generator 15 Hourmeter 6 Voltmeter 16 Deleted 7 Panel Light l7 Engine Start Switch 8 Panel Lights Switch 18 Engine Circuit Fuse 9 Panel Lights Fuse 19 Engine Circuit Switch 10 Push To Build Up Voltage Switch 20 Ammeter Engine Control Panel Assembly W Shelf On Rear Figure 2 3 1 f Revised Apr 15 88 2007 5 2 VIEW 4 BOTTOM VIEW 2 l Voltage Regulator 2 Overvoltag
9. wec es 1 1 a L l I L L L i 1 1 1 Ol ED OP A E ae Ae 37 29 4 27 26 24 50 28 25 23 1 7 4 36 Control Panel Assembly W Enclosure On Rear rfr E n EP Red 8188 2 Page 5 18 9 om mi enm FIGURE HOBART ITEM NO PART NO i 489263 1 489237 2 11166 5 3 402658 4 406040 5 404856 6 78A 1120 1 7 78 1115 1 8 489219 9 76 1115 10 403127 11 78 1117 1 12 78 1116 1 13 408596 1 13A 798 1101 1 14 848 1003 15 389535 3 16 401937 8 17 11166 3 18 489658 5 19 180591 2 20 402662 21 20RT 353 1 22 25 5 156 23 180913 2 24 16 2162 25 401428 1 26 488598 27 180913 1 28 402682 29 30GH 1119 30 406815 31 180135 32 400642 3 33 400641 12 34 489218 35 405608 Aug 15 88 Revised NOME NCLATURE 1234567 EFF CONTROL PANEL ASSY For NHA See Fig 1 PANEL CONTROL ASSY FUSE AGC 20A V71400 HOLDER FUSE V71400 TYPE HKP HH BOOT TOGGLE SWITCH No H 1030A SWITCH TOGGLE V81640 NO 8860 5 GAUGE HOURMETER V16476 NO S6288 AMMETER V16476 NO 06354 SUPPORT MAGNET LEFT LATCH ADJUSTABLE GRIP CATCH MAGNETIC GAUGE OIL PRESSURE V16476 NO 06340 GAUGE WATER TEMP V16476 NO 06343 TACHOMETER V33955 NO 54314 B C TACHOMETER V33955 No 1136075 A LIGHT PANEL 12V V77977 NO
10. 0M 2007 1 FIGURE ITEM NO Column This column lists the figure number of the illustration applicable to a particular parts list and also identifies each part in the list by an item number These item numbers also appear on the illustration Each item number on an illustration is connected to the part to which it pertains by a leader line Thus the figure and item numbering system ties the parts list to the illustrations and vice versa The figure and index numbers are also used in the numerical index to assist the user in 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 part is a purchased item the vendor s identifying five digit code and his part number will appear in the NOMENCLATURE column Parts manufactured by Hobart reflect no vendor code or part number in the NOMENCLATURE column 3 NOMENCLATURE Column The item identifying name appears in this column The indenture method is used to indicate item relationship Thus components of an assembly are listed directly below the assembly and indented one space Vendor codes and part numbers for purchased parts are shown in this column Hobart modification to vendor items is also noted in this column 4 Effective Column This column is used to indicate the applicability of parts to different models of equipment Whe
11. IDOLO 7 1003 WO AREER vS UNO2I TS 30010 0703 WO 817 221715 010 30010 SOARS 044 T WIO 2303 WN WOLD OAR 852 084 99774714 515701129492 MAR 0 44 81 0100972313 yn 081 2303 HO LEON SOARS 034 WOT wav Ga 20505 51 II IO III 20492 034 04 ZZEE 21 8327 01129442 27405 04 ur 043537 METIENDO iW RES tar 3104 14 ter 7 3 HUE peg Te Stu riy s 5 su Cn Cu 929196979776 cu zr tu twa 2 2143 241 82410 UT ues teer ntt 4 PUE 92 5 2 H ss UNUSUAL SERVICE CONDITIONS U L i gt 1 i i D This information is a general guideline and cannot cover all possible conditions of equipment use The specific local environments may be dependent upon conditions beyond the manufacturer s control The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical cond
12. i x EXPECTED 1 85 i 1 2 EE CST a ee ee es RON 1 Engine lubricating oil The oil level dipstick is located on the right side of the engine Refer to Perkins User s Handbook for oil recommendations 7 Make sure air cleaner element is installed Recommended replacement element is Donaldson Duralite Element No P10 1222 Hobart Part No 408436 8 Check fluid level in 12 volt batteries Fluid should cover plates Output Cable Installation Units are normally supplied without a generator to aircraft cable 1 Cable requirements Cable length is determined by the customer s requirements It is recommended that the cable be no longer than 30 feet 9 m The cable should be two conductor with lug type terminals on one end and an AN 2551 plug connector on the other Ihe recommended single conductor sizes for 28 5 volt DC continuous rated amperage and 90 C 194 F rise is as follows for 285 amperes use 2 0 size for 385 amperes use 4 0 size for 530 amperes use 350 MCM size NOTE Some operators may wish to add a second cable assembly with MS 25019 plug connector for starting aircraft such as Jetstar and Sabre liner me VR 2 Cable connector a Connect 28 volt conductors to output terminals on output terminal panel Figure 1 Connect POSITIVE cables to ou pas lower terminals of load contactor Connect NEGATIVE cables to vertically mounted bus bar b Store ca
13. SP CAUTION UNDER NO CIRCUMSTANCES SHOULD THE CARTRIDGE BE POUNDED OR STRUCK IN THE CENTER TO AFFECT A SEAL 2 Lock the cartridge in place with the washer gasket 5 and the wing i nut 6 Then install the baffle 7 into the cup assembly 8 and fasten it to the end of body 1 with clamp 3 Tignten clamp 3 down in place 4 Servicing the Fuel Filter Refer to Perkins Diesel User s Handbook in Chapter 6 for instructions on emoval and replacement of fuel filter elements ce m lt lt den lt 5 Drive Belt Service Check all drive belts and adjust if necessary each 200 hours Refer to Perkins Diesel User s Manual in Chapter 6 for proper procedures x x x x x i i i 1 i i 1 22 23 1 85 1 m t M e cw ui a n br gt P 4 d k p fas E EUN eet iuf rupto fratri c La POP A ONE US EC pere icd 09 2007 DOO Wen ML aM 1 Body Assembly 6 Wing Nut 2 O Ring 7 Baffle 3 Clamp Assembly 8 Cup Assembly 4 Cartridge 9 Indicator with 5 Washer Gasket V
14. 1 r cautiona ab ls on the equ iene monthly Order and replace all tabels that cannot be easily read 2 i 2 is ad 5 T Before inspecting or servicing electrically powered equipment 7 BN the following preeauttons O Lowi i 1 P d T as Lteh or lin breaker power at the disconneeting before inspecting servicing the equipment 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 trained in turning off the equipment and providing or calling for first aid FIRE AND EXPLOSION PREVENTION Fire and explosion are caused by electrical short circuits combustible material near engine exhaust piping misuse of batteries and fuel or unsafe operating or fueling conditions 1 Electrical Short Circuits and Overloads Overloaded or shorted equipment can become hot enough to cause fires either by self destruction or causing nearby combustibles to ignite For electrically powered equipment in particular provide primary input protection to remove short circuited or heavily overloaded equipment from the line 2 Bat
15. 2 121115 34 JS 5 2 5 6 M En 1 1780 9 719 T a blo 9NI2Y3 bd 8 gt Q RT ET k g E E 45 A 4 145 0015 ANNONS yazer 9 uo qu 89 votum 06 2doozo Lord qt ELEM peterstep poenperdes 09 seu Y el Qm Wo TT sos I 932710 4 SAIL ONY D C T U T 235252 A E i DI I 143093 A Mant 078 nue E me E En re La AA fecr ENTE DM cur Luna o scorn o cu umane jp ier D II iE M 45 o N3HM 1391 H3H1V3 0109 3105 24091 9 01314 9091 1304 0 0 3105 _ 1304 00043305 gt GIONS 10S ri 9053 135 _ E A MOIOVINOO VOT 2064 222 39VI 10A 31291430234
16. ON Qn IN NO 0 ON Ui N e OM 2007 DATE Dec Dec Dec Dec Dec Dec Dec Dec Dec Jun Jun Jun Dec Dec Dec Dec Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr Apr 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 01 85 15 88 05 87 05 87 05 87 01 85 01 85 01 85 01 85 15 88 15 88 15 88 15 88 15 88 15 88 15 88 15 88 15 88 15 88 15 88 15 88 15 88 15 88 15 88 Pages Page 1 2007 LIST EFFECTIVE PAGES CHAPTER CHAPTER SECTION PAGE DATE SECTION PAGE DATE 4 1 1 Dec 01 85 4 3 37 15 88 4 1 2 15 88 4 3 38 15 88 4 1 3 15 88 4 3 39 15 88 4 1 4 15 88 4 3 40 15 88 4 3 41 15 88 4 2 1 01 85 4 3 42 15 88 4 2 2 Apr 01 87 4 3 43 15 88 4 2 3 Dec 01 85 4 3 44 Apr 15 88 4 2 4 01 85 4 3 45 15 88 4 2 5 Sept 22 86 4 3 46 Apr 15 88 4 2 6 01 86 4 3 47 Apr 15 88 4 3 48 Apr 15 88 4 3 1 Dec 01 85 4 3 49 15 88 4 3 2 Dec 01 85 4 3 50 Apr 15 88 4 3 3 Oct 16 86 4 3 51 15 88 4 3 4 01 85 4 3 52 15 88 4 3 5 Apr 15 88 4 3 6 Dec 01 85 4 4 1 15 88 4 3 7 15 88 4 4 2 14 88 4 3 8 Dec 01 85 4 4 3 Apr 15 88 4 3 9 15 88 4 4 4 15 88 4 3 10 Aug 04 87 4 4 5 15 88 4 3 11
17. excessive wear and check brush contact with slip rings Replace brushes if excessively worn and make sure that brush contact with slip rings is proper Connect a jumper lead between pins 1 and 3 on voltage sensing relay 5 Fig 3 voltage then builds up when switch S407 is pushed voltage sensing relay is defective and must be replaced voltage sensing relay is good proceed to Step C 0 2007 TROUBLE SYMPTOM AND CONDITION PROBABLE CAUSE TEST CHECK AND REMEDY GENERATOR AND CONTROLS Cont d 1 Generator will Generator revolving Locate yellow and red orange not build up field L406 defective wires on the right terminal voltage at all strip at lower rear of control when push to panel Disconnect the yellow build up volt and red orange wires which go age switch down to the generator Refer S407 is to connection diagram 489612 in operated Chapter 5 Measure resistance Engine running between these two wires normally Should be 6 to 8 ohms If Cont d reading indicates an open short or lower than normal resistance proceed to Step D D Defective generator D If check of the generator armature 0402 revolving field Step C above revealed no trouble the gen erator armature is defective Send unit to overhaul 2 Generator builds A Generator voltage Replace voltage regulator up to only a low regulator fuse F403 fuse 4 Fig 3 Resume voltage while blown operatio
18. 1795 11 2 Se RESIS OF CARBON 19 le F 6 584 E ARO TEA TRI SEGLE TURN 29K 1 7 100 Oros 0 RESIS gt Il 24 1485446 5 fe lt i a 553 22555252 22 o Ag 3 4 P 5 13 Yes x 4H is ihn i TIME jii 21295 2 95Y a 1329 s lt HITER 5 844464 E E ats A y 1 1 LOADED 10 wes T POWER TRANSI CUT CIRCUIT PRIN BETWEEN PINS 15 2 Mu ie po 5 c i T DAT A Wes tomy faros Seres m the peim and amf umani propery of bers of Trey us ouf u ast i be cepredesad ar a ia stern m whale or por ema pr tv p s T a a lt 9 fy 03804 PARTE LOST ad 24 Lee m E 000 IT NOMAD Vw T RINT 5306704 401129493 2 0443345 55310 701 TW 1
19. Metus ud E dos A Page 2007 fe a 1 Z N h l V a Jet Ex 4D Generator Set Figure 1 a e e am Dec 1 85 i e 2 Pag UNIT WITH CABLE HANGERS amp SPACERS UNDER FRAME Length 65 75 inches 1670 mm Width 34 25 inches 870 mm Height 53 inches 1346 mm Weight dry fuel tank 1900 pounds 862 kg UNIT WITH TRAILER AND CABLE HANGERS Without Fenders Length 78 75 inches 2000 mm Width 54 5 inches 1384 mm Height 57 5 inches 1461 mm Weight dry fuel tank 2125 pounds 964 kg Ground Clearance 3 625 inches 92 mm UNIT WITH TRAILER FENDERS AND CABLE TRAY M Y M r y M M A A aaaea Length 79 75 inches 2026 mm Width 56 inches 1422 mm i Height 57 5 inches 1461 mm Weight dry fuel tank 2280 pounds 1034 kg Ground Clearance 3 625 inches 92 mm gt GENERATOR i Output Power Rating 15 7 kW Voltage 28 5 volts DC Rated Load Capacity 550 amperes continuous at 28 5 volts DC Starting Current Capacity 2000 amperes maximum Current Limiting Capability 300 to 2000 amperes con tinuously adjustable Operating Speed 2600 RPM i l 1 Manufacturer Perkins Diesel i Model 4 236 4 cylinder 4 stroke direct injection Fuel AS
20. SCREW CAP HH 3 8 24 X 1 NYLOK WASHER LOCK STD 3 8 BUSHING SPLIT TAPER FLYWHEEL SUPPLIED W ENGINE BEARING BALL SINGLE ROW RADIAL V53035 NO 6207DDUC3E1BT3 COVER GENERATOR HOUSING GROMMET LEAD HOLE TUBE Z FLEX STATOR LEAD TUBE Z FLEX STATOR LEAD QOO 00 1 1 2 6 6 Page 51 Not Illustrated 0M 2007 This page intentionally left blank 4 3 Laie IA Revised Apr 15 88 1 2007 SECTION 4 NUMERICAL INDEX Explanation of Numerical Index The purpose of this index is to assist the user in finding the illustration and description of a part when the part number is known Part numbers are arranged in alpha numerical sequence Thus any part number beginning with the letter A would be located at or near the top of the index list Like wise a part number 9 would be listed near the end of the list and far below a part number 1000 The figure number and item number location of the part is directly opposite the part If the part is used in more than one place each location is listed commencing with the first location the part is listed NUMBERICAL INDEX Apr 15 88 Revised PART NUMBER FIGURE AND ITEM NUMBER A 25 15 8 626 15 9 BATTERY INSTALLATION 11 0 COOLING SYSTEM 14 0 DDW 495 8 5 41 DWP 982 1 8 3 4 FRAME LIFTING YOKE ASSY 5 1 19 0 FUEL SYSTEM 5 15 12 0 FW 1312 6 10 GENERATOR SET W
21. 0100 3JAVA QION310S YOLVY3N29 9NIA10A3H 01313 7383 010 3106 31110 1 TIN 0 0 3105 3313915 010 3105 9NISN3S 39V110A Av13H 39VL 10A43A0 3 19 1 9903 8O1V 0938 39V110A 310V143234 HOLVN3N39 AZI ANIONS HOLVNH3LTV _ NUMA N3HM VSI LuVIS H3H1V3M 0702 3613 HOLY 10938 39v130A 3514 3NI9N3 3503 vO SLH911 3603 N3339 835012 YOLOVLNOD NHOLVOIONI ONINNNY 3NION3 HOLVOIONI H34HVW 2 8 414 30010 TOS 831311238 11508 30010 3AI1V93N 534010 9NI320718 30010 ASN HOLIOVd VO AJA 0001 HOLIDUIVO Ad311v8 gt 831445 9INOH12313 31000 34056354 10 830N35 0 Sen LVHadW3L M31VM H30N3S 943937 5 O SERES 0 16 x3 uni 705 025 2095 1065 60vM 4078 SOVN or 9077 gorl lov 90 poor 2079 1099 149512 2003 809504 40954 90950 60950 20750 10950 22992 6 8159 2182 9tbHO0 S2bHO 91 52 0098 20 0982 2095 2018 108 vOvV covv tov V 3411231064 0
22. 408396 17 14 18 14 408397 17 12 18 12 408398 17 15 18 15 408399 17 21 18 21 408400 17 23 18 23 408401 17 22 18 22 408402 17 24 18 24 408403 17 27 18 27 408404 17 38 18 38 408405 17 35 18 35 408406 17 33 18 33 408407 17 32 18 32 408408 17 29 18 29 408409 5 3 408410 17 28 18 28 408411 17 36 18 36 Numerical Index 4 4 4 5 pr SNR RE TP Revised Apr 15 88 0M 2007 NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 408412 17 37 18 37 408413 17 30 18 30 408414 17 31 18 31 408417 17 41 18 41 408418 17 42 18 42 408432 3 5 17 6 18 6 408436 5 13 408441 1 14 1 408442 5 21 408458 5 8 408534 10 5 408507 18 0 408508 18 0 408556 4 9 408558 10 1 408559 10 8 408596 1 6 2 408999 1 16 3 41546 6 33 42543 15 10 483630 12 5 486567 3 12 4 488555 1 20 6 488577 2 20 3 488562 16 1 488564 15 8 488592 4 10 488598 6 37 488628 16 2 488633 4 25 488640 4 7 488784 16 0 20 8 488799 4 16 488880 3 2 1 18 0 488880 4 3 1 17 0 488904 1 9 488930 18 45 488931 18 10 488971 3 3 488972 3 6 489064 20 5 489077 1 20 2 489086 20 9 489114 5 19 Apr 45 98 Revised oou ss cent gt dun A quis 4 4 Page 5 0M 2007 NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 489121 14 6 489122 14 8 489123 20 10 489125 20 10 489126 20 13 489135 20 4 489151 5 1 19 1 489158 4 22 489156 4 23 489167 4 8 489168 4
23. NES PANE 4 9 18 17 6 RIGHT SIDE VIEW i i 1 Radiator 14 Load contactor 2 Air cleaner 15 Batteries 3 Muffler 16 Alternator 4 Engine 17 Fuel filter i 5 Lifting yoke 18 Starter i 6 Rectifier assembly 19 Starter relay 7 Fuel tank 20 Frame I 8 Control panel 21 Fuel tank support i 9 Generator 22 Engine governor 10 Fuel filter 23 Water temperature sender 11 Throttle control solenoid amp switch i 12 Oil filter 24 Oil pressure sender 13 Drain cock amp switch i i i e A 1 85 YA A A C Generator The generator 9 Figure 3 is a multi phase synchronous salient pole revolving field AC generator whose output is rectified The output is rectified by a rectifier assembly 6 made up of twelve rectifiers connected into a full wave configuration The generator is self excited and receives excitation from a three phase full wave rectified stator winding One positive and one negative brush in contact with slip rings supply controlled excitation current from the stator winding through the voltage regulator to the rotating field winding The voltage regulator controls the excitation current and maintains a const
24. gt i 0 18 C to 30 F 1 C 10W 30 F 1 C to 80 F 27 C 15W 40 Above 80 F 27 C 154 40 Temperature and Oil Viscosity Chart Figure 4 4 Change lubrication engine oil 100 hours Oil should be changed after each 100 hours of engine operation The generator set is equipped with an hourmeter which records actual engine operating time The ideal time to change oil is soon after a power delivery run when the engine is at operating temperature NOTE If lubricating oil is drained immediately after the unit has been run for some time most of the sediment will in suspension and oil will drain readily without clinging to internal surfaces CAUTION DO NOT USE SOLVENTS AS FLUSHING OILS IN RUNNING ENGINES Change the oil filter each time the oil is changed 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 time for oil to drain from valve train timing gear case etc before reinstalling plug c Change oil filter while oil is draining see Para 2 E 5 below d Clean drain plug and reinstall Do not over tighten Allow sufficient s er T mona Am cdm md I ET 20523713 emot mas 5 tm 1 y AE DRE MEM
25. inch kVA kilovolt ampere microfarad No number NHA next higher assembly 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 its assembled state or it is similar right hand left hand top etc to an item which is illustrated Dec 1 85 4 3 Page 2 Generator Set Stationary Mtg Assy Figure 1 50 1075 m c Oct 16 85 FIGURE ITEM NO l Y 10 11 12 13 Oct 16 86 6854 1 489203 76 1152 489263 84B 1078 81 1064 400435 402987 DWP 982 488904 78 1000 79 1110 489267 180298 180297 11242 12 W 11280 11 W 11100 3 W 11254 8 NOMENCLATURE 1234567 GENERATOR SET JET EX 4D YOKE LIFTING ASSY For Details See Fig 18 FUEL CAP V49234 NO 1275 Type B PANEL CONTROL ASSY For Details See Fig 6 amp Fig 7 LABEL OPERATING INSTRUCTIONS LABEL ENGINE DRIVE LABEL NAMEPLATE 28V NAMEPLATE HOBART BRACKET CABLE BRACKET SPACER FRAME AY NAMEPLATE ID NAMEPLATE OPTION CANOPY ASSY For Details See Fig 4 KIT TIE DOWN ASSY OPTION BRACKET TIE DOWN OPTION WASH
26. 5 Engine does not attain normal idle RPM or idles too fast Continued 6 Engine will not run at rated speed 2600 RPM 7 Engine lacks power 8 Engine overheats Apr 15 88 Revised C Defective full throt tle solenoid L403 A Speed control switch S406 defective A Insufficient air to engine B Restricted exhaust system C Low compression Dirt or sludge in coolant Debris and dirt in radiator core 2007 TEST CHECK AND Check for 12 V DC across two terminals of solenoid when S406 is in RATED RPM position If 12 V DC is measured but solenoid core does not pull in replace the solenoid If engine will not go from idle to rated speed when speed control switch 13 Fig 2 is in RATED RPM position turn off engine and take resistance measurements at speed control switch terminals with switch in the RATED SPEED position Zero resistance should be measured between terminals having red blue and orange yellow wires Replace speed control switch if measure ment is improper Check and service air cleaner Check exhaust pipe for re strictions Check muffler for clogged condition Replace as required Check compression in all cylinders according to Perkins Engine User s Manual E Y H FF y Tn V lt 3 Drain coolant flush radi ator put clean coolant Refer to Per
27. 8 4391 ION NOIL HOLIMS 055 gt 2 5301991402 OvO1 gt Sopy 1 vOv f f y 1 CANTO NET Waku uuu MO DNILIMIT 7831 1 300W ABZ HOlVO ONI 4345 18 153 18 l BOLVINDIY BOVLIOA 9070 Ded ONINDON 30010 ior 9 e mt UOLVH3N3D YT LIMA OPW 10 39079 Ave Badal vOv 4110410 4 ov CODA W313N ABILIVO u313AWY 2 N3HM IBYIS 9702 31AYA 05 4071 2092 01313 9097 1303 QION330S porn 371108 1 TNA 9103105 06 608 H318V1S QION3 OS 109 tL ONISN3S 35V110A AVTIH 90v YOLOVINOD Qvo r4 HOLVIND3Y 39v110A 3199193934 SOvr vopr osa 9 9 QE L4 6 N3HM L8YLS M3H1Y3M 0302 3504 EM orn Zorn 40080 3503 Ors 53504 2094 VO S1H911 354 1094 055 2004 Ys N3349 035012 HOLOY1NO2 HOLVDIONI 80 50 SNI
28. B 4 AUD D A KC 1 3 1 3 ce e 0M 2007 WARNING ENGINE S ENTIRE EXHAUST SYSTEM WILL GET VERY HOT AND CAUSE SEVERE BURNS IF TOUCHED 7 Allow engine to warm up before applying a load Generator Operation 1 Place speed control switch 13 in RATED RPM up position Engine speed will be 2600 RPM 2 Press BUILD UP VOLTAGE pushbutton 10 Generator will produce rated voltage 3 Adjust STARTING CURRENT rheostat 4 if necessary Deliver Power 1 Connect output cable to AIRCRAFT 2 Hold CONTACTOR switch 11 in CLOSE position Release to ON posi tion as soon as green CONTACTOR CLOSED light 12 comes on Stop Operation Shutdown 1 Place CONTACTOR switch 11 in OFF position Light 12 should go off to indicate load contactor has opened and power is no longer available at the aircraft 2 Place speed control switch 13 in IDLE down position Allow engine to run for 2 to 3 minutes 3 Disconnect output cable from aircraft receptacle and store cable in cable trays or on cable hangers as the case may be 4 Place START RUN STOP switch 19 in STOP position Adverse Weather Precautions 1 Cold weather operation Operation of engine driven units at sub zero temperatures requires special precautions and extra servicing from both operation and maintenance personnel if poor performance or total functional failure is to be avoided Consult Maintenance and Operator s Manual and re
29. i i Pd E m i _OM 2007 om APA m 255055 A Leads D Brush B Brushholder Caps E Slip Rings C Brushholder Generator Revolving Field Brushes Figure 6 1 5 1 i i a 4 i i i i 1 i 1 i i I AA ee 2 2 Dec 1 85 eet O Page 12 s ae Dur Pid 23 lt J 2207 NN PRE TS SECTION 3 ADJUSTMENT TEST 1 General The adjustments and test procedures presented below are required after major repairs parts replacement or long storage 2 Testing the Generator Set Test values listed below will result when the generator set is operating properly your test results are not within the limits shown perform the applicable troubleshooting procedures given in Chapter 3 i i If major repairs have been made or if critical components have been replaced make sure that the applicable adjustments have been made before testing the generator set Adjustment procedures are described in Para 3 of this Section Preoperational Test Procedures 13 mm slack 1 Open engine compartment
30. i i 4 60 g n i E 74 V A i 5 1 y 75 X Va DE Mre RET E kd 2 Xe lt t i ale L y 1 Dec 1 85 2 3 MEE Qe Lio CHAPTER 3 TROUBLESHOOTING SECTION 1 TROUBLESHOOTING PROCEDURES 1 General Troubleshooting is orderly process of checking and eliminating pos sible causes of trouble until the exact cause of a trouble is found As a rule the best place to start looking for the cause of a trouble in a circuit is at the source of power Continue testing and checking the circuit step by step in an orderly manner until the cause of trouble is located See connection and schen id 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 Engine will not start Starter vili NOT crank engine If the starter WILL crank the engine then obviously this is not your symptom and condition Go the next
31. j g ME ME i i 1 MEE USERS NC x ME E a 5 t o a necem RSS hu er T p sme sii a dust Reeve XT es rms A i A Mw 5 C P 1 7212 El 177 181 vp _ 12 21 1 _____ Gr J HOS 14 JOXI Alea ___ ___ ___ ____ ____5 _____ AE E 766661 UU wasa 1969 fowl 53 os NN HSINI4 3A119310td 3002 111111111 eise 4 BASE 220928 22212222659 3 9 59 aI Tie Rie YO1VYIN39 YO0LVANIIY 39V1310A NAHM HOSN3S 4031 3NION3 HOLIMS IPS 340 35012 HOLOVLINOO HOLIMS 8075 39 110 40 01108 01 504 1 HOLIMS 20 5 NOI LISOd NMOHS 1 1 02 Q33dS HOLIMS 9095 S1H9I 1 SNIAVNIWO13I HOLIAS 5095 dOLS NNY LYVLS 211 5 9095 3YNSSIYA 7 0 211 5 5 34n1VH3dW31 H31VM HOLIMS
32. 0151534 501515 1 96 209 S lO 1 42801 ALAVA NHO NI 8313M0 IN310d LIYA Y 1 OCC 80161638 LAVA 2 1 WHO AZ 1 40161538 1 629109 Ae 43432 30010 8 6 22 Y G1 00 021716 30010 4 12801 LLVM 2 1 WHO O42 80151538 8 21 12801 LAVA 2 1 750151539 98 TFS 3AO8V 91 5 OL 9 14 LNDON 8994 lt 0 35V110AH3 O0 Id OYVOB 9 ON 14142530 39V110A834A0 2 ON 34111 SNIT OL 419 MO LU Sartre Ptr anre dim APRI UH Para 10 Ur peto 26 Pardes 04 1 VENIO gt 2 3 3 305 Sees 2 4 5 alo ite 55 H 31 1825 34 1 E T v 125555 a a AA tN fje eje 58 Dir TP15 4 gt S 811 37 0 11 28 21 37 38 4862 9 2 H 58 41 42 2w S97 Leda TRIM SINGLE TURN TER TRIM SINGLE TURM Sk 1 20 Q 5 Ta Fl
33. 1 3 4 1 Maintenance Inspection Check General Maintenance Schedule A General B Maintenance Schedule Time Intervals Engine and Related Components Inspection and Cleaning Maintenance Procedures 2 2 1 t Oie A 1 9 eame s u u cel LL ae Pag rr MA V ud SUBJECT CHAP TER SECTION PAGE 1 RH Sree ieee mun 4 1 I i E 2 po Sos 27 a t ix a E E dd 0 2007 AI E o en era sar i SUBJECT A General B Lubrication Chart C Generator D Generator Controls E Engine 1 2 3 4 5 Lubrication schedule Oil specification Oil viscosity Change engine oil 100 hours Change engine oil filter 100 hours G Trailer 1 Front axle assembly 2 Wheel bearings 3 Servicing the Air Cleaner A Cartridge Removal B Cartridge Installation 4 Servicing the Fuel Filter 5 Drive Belt Service 6 Engine Cooling System A General B Rust Inhibitor TABLE OF CONTENTS CONTINUED CHAPTER SECTION 2 2 1 _ Dec 1 85 Contents ni 5 69 A ge ay any 1
34. 14 489169 12 1 489192 8 10 489195 9 1 489196 1 9 0 489199 9 3 489203 1 1 9 4 489208 15 7 489209 18 9 489213 18 46 489215 6 48 489216 18 44 489217 4 3 489218 6 45 489219 6 46 489220 4 19 489224 4 15 489227 4 2 489229 4 21 489230 4 18 489235 4 13 489237 6 43 489243A 4 1 489258 4 4 489259 4 5 489263 1 3 6 0 489267 1 12 4 0 489270 4 6 489272 17 10 18 47 489533 14 13 489554 5 20 8 0 489564 5 18 10 0 _ Revised 15 88 Numerical Index AMEN Page 6 0M 2007 NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 489567 10 3 489577 4 24 489579 8 7 489580 8 9 489593 12 6 13 1 489639 5 24 489641 5 5 489661 5 17 20 0 489702 15 5 489703 15 1 489704 7 1 15 0 489765 14 10 489810 4 17 490036 13 1 491668 1 11 6 491687 11 5 491713 1 11 2 491784 20 1 491799 19 5 491889 5 13 8 492098 5 0 492416 1 5 28 493384 9 20 15 493384 10 20 16 5CW 1932 0 5 42 5CW 2127 9 5 5CW 3420 1 12 3 5CW 975 9 4 5CW 976A 9 11 56529 14 9 60FC 405 15 1 6854 1 1 0 2 0 3 0 7J 422 0 4 33 76A 1152 1 2 1922 768 1149 4 32 784 1000 1 10 78 1001 5 22 78 1002 5 23 78A 1115 1 6 24 78A 1116 1 6 3 78A 1117 1 6 1 78A 1118 1 5 32 78A 1120 1 6 20 Apr 15 88 Revised s ______ Numerical Index 4 4 oo EE RES MEC Page 7 PART NUMBER 78B 1010 788 1118 1 798 1101 1 79 1110 798 1119 1 79 1127 2 80A 1117 818 1019 818 1062 818 1063 818 1064 84 1054 1 84A 1071 84A 1075
35. 2095 1391 HOLIMS 1095 2 WHO OI 83151538 60bY LNNHS 2098 41 83151538 90byY 01831561634 SObY LObY 9NLILINUT LIN34909 H31 3NOLLN310d 20vM MOLIVA1n93M 39Vi17OA 9n1ld SObd bObd HO1VH3N39 240991 HOLVH3N39 H313A110A 38055384 39 9 3H 1VH3dW3l H31VM 39Vno9 A H313WOHOVI A H313W 301 ONINNNY 013 AH311V8 H313NWV 940 73041 92041626 tionen 4496008 aus pue 84446920 0 PARAS m 743090 51N0312313 0 v Q300Yv D 091 2 LYVLS YIHLVIM 0100 QI ON310S 9NIA10A38 01314 13N4 010N370S 371110Y9H1 13n43 QI0N310S 83189165 0043105 9NISN3S 39V11OA AV 138 39V110 43A0 AV 13H YOLIVINO9 avol HO1V71193M 39V110A 37155133934 3Hn1VWHY HOLVH3N39 3NI2N3 NOLVNN311V N3HM VGI Lu VIS 0100 ISNI Y OI HO1V71n93H 39V110A 3Sn4 3504 S1H9I1 3504 435012 012 1 02 HOLVOIQONI N33H9 SNINNDH YISNV YIABVA LH901 30010 ONIONIM 1ONLNOO 3AILISOd 30010 30010 94
36. 30 408408 INNER OUTER BEARING CONE 4 COMPLETE BRAKE ASSY LH REAR WHEELS 1 31 408413 ELECTRICAL BRAKE LH 7 1 32 408417 SECONDARY SHOE 6 LINING ASSY REAR WHEELS 1 NOT ILLUSTRATED Apr 15 88 Revised 4 3 This page intentionally left blank 0M 2007 Revised Apr 15 88 FIGURE HOBART ITEM NO PART NO 18 33 408418 34 408414 35 408417 36 408418 37 408407 38 408764 39 DELETED 40 408411 41 408412 42 408392 43 489216 44 488930 45 489213 180310 46 489272 47 180130 48 180322 2 49 180322 1 Apr 15 88 Revised _____ NOMENCLATURE 1234567 PRIMARY SHOE amp LINING ASSY REAR WHEELS COMPLETE BRAKE ASSY RH REAR WHEELS ELECTRICAL BRAKE RH REAR WHEELS SECONDARY SHOE amp LINING ASSY REAR WHEELS PRIMARY SHOE amp LINING ASSY REAR WHEELS HUB amp DRUM W CUPS amp STUDS STUD SCREW IN 1 2 20 X 1 3 4 COVER DUST NUT WHEEL NUT SPINDLE RAIL CABLE BUMPER REAR FENDER SIDE RIGHT FENDER SIDE RIGHT WASHER FLAT 5 8 SPACER AXLE FRONT RECEPTACLE FORK LIFT FRONT ASSY RECEPTACLE FORK LIFT REAR ASSY Not Illustrated 0M 2007 UNITS per ASSY EFF N B A gt c gt e POR fn N UJ UJ 0M 2007 Lifting Yoke and Frame Assembly Figure 19 4 3 Revised Apr 15 88 Page 48 RD Re OM 2007 NOME
37. 31 406000 32 768 1149 33 71 422 0 34 400435 35 180015 36 181179 37 181161 Apr 15 88 Revised NOMENCLATURE 1234567 EFF CANOPY ASSY FOR NHA SEE FIG 1 PANEL ASSY PANEL ASSY C PANEL GEN INSULATION ASSY STOP CONTROL PANEL DOOR ENGINE DOOR ENGINE PANEL CENTER LEFT CANOPY BRACKET OUTPUT CABLE ASSY SUPPORT CONTROL PANEL LT ASSY LIGHTS CLEARANCE V75175 NO 514 0168 LIGHTS CLEARANCE V75175 NO 525 0101 C COVER CONTROLS ASSY COVER PLEXIGLASS PLATE MAGNETIC CATCH LABEL OPERATING INSTRUCTIONS PLUG HOLE PLASTIC PANEL LOWER REAR SUPPORT CONTROL PANEL RT ASSY PANEL GEN INSULATION RT ASSY COVER OUTPUT CABLES PANEL CENTER RIGHT CANOPY PANEL SIDE RT REAR ASSY SUPPORT CONTROL PANEL LATCH T HANDLE PANEL SIDE LT PANEL ACCESS BATTERY PANEL FRONT SPACER CONTROL PANEL HINGE SUPPORT FRONT PANEL LABEL CAUTION INSUFFICIENT COOLING LABEL HOT WATER amp STEAM LABEL ACCESS PANEL LABEL DANGER MOVING PART NAMEPLATE HOBART LABEL ENGINE FUEL LABEL GASOLINE CLAMP OUTPUT CABLE NAMEPLATE 28 V STRAP BACKUP COVER CONTROLS SHIELD RAIN MUFFLER C STRAP REINFORCING HINGE Not Illustrated 2007 UNITS per ASSY N N Im IN
38. 85 5 age 4 Mon mi the Se CODE 82445 83613 88136 91636 94177 94222 96152 No Number VENDOR S NAME AND ADDRESS Abex Corp Signal Stat Div 1200 Commerce Ave Union NJ 11211 Kirkhill Inc 12021 S Woodroof Ave Downey CA 90241 Trombetta Corp 1633 E North Ave Milwaukee 53202 Curtis 34999 Curtis Blvd Eastlake OH 44094 Modine Mfg Co 1500 Dekoven Ave Racine WI 53401 Southco Inc 210 N Brinton Lk Rd Concordville PA 19331 Borg Warner Corp 2195 S Elwin Rd Decatur IL 62525 Pipe amp Supplies Inc 329 E Poplar St Sidney 45365 2007 This page intentionally left blank 4 2 rM A Revised Apr 15 88 04 2007 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 parts list will appear on the opposite right hand page Unless the list is unusually long the user will be able to look 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 or 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
39. 88 Page 2 PARC EEE A 7 6 demone ahis 0 2007 B Operational Tests 1 Start the engine as described in 1 3 Para 3 a and let it warm at idle speed 2 Inspect for oil fuel and coolant leaks 3 Check the engine ammeter 20 Fig 1 for a slight charge Check oil pressure gauge 1 It should read 35 to 60 psi 241 to 414 kPa Check coolant temperature gauge It should read 180 to 200 deg F 82 to 93 deg C when engine is hot 4 Observe engine RPM on the tachometer and observe engine for excessive vibration Idle speed should be 1000 RPM 50 RPM there is excessive vibration within this range adjust engine idle speed gradually increasing or decreasing it whichever is necessary until vibration is reduced Refer to Figure 2 below To adjust idle speed loosen idle speed retaining nut and adjust idle speed screw on throttle assembly to raise idle speed while observing tachometer and observing engine vibration Turning idle speed screw INWARD increases idle speed and turning it OUTWARD decreases idle speed When vibration has been satisfactorily reduced tighten idle speed retaining nut IDLE SPEED ADJUSTMENT SCREW RETAINING NUT Idle Speed Adjustment Figure 2 5 Check engine RPM s at operating speed 2600 RPM 6 Depress the PUSH TO BUILD UP VOLTAGE Switch to build up output voltage of generator 7 Set current limit control 4 Figure 1 to maximum full clock wise
40. Fig 19 1 18 489564 FULL THROTTLE SOLENOID ASSEMBLY For Details See Fig 9 1 19 489114 SUPPORT ENGINE ASSY 2 406254 2 MOUNT SHOCK ENGINE GREEN 2 20 489554 SUPPORT RECTIFIER AND FUEL TANK ASSY 1 For Details See Fig 7 21 408442 KIT TACH DRIVE A 1 22 78A 1002 TIP DRIVE SENDER V33955 NO 5933572 1 23 78 1001 SENDER 33955 NO 9604276 A 1 24 489639 GUARD BELT RIGHT 1 25 405099 FAN ALTERNATOR 16764 NO 800612 1 26 405015 ALTERNATOR V16764 NO 1105070 1 405015 ALTERNATOR V31211 NO 70044220 09 1 181098 BRACKET ALTERNATOR 1 181099 SPACER ALT BRACKET 1 181100 5 SCREW ALTERNATOR 1 492098 BRACKET SUPPORT WIRE ALTERNATOR 1 27 407706 MOTOR STARTER 16764 NO 1998383 1 NOT ILLUSTRATED Apr 15 88 Revised 24 3 wage 12 7 0 2007 7 This page intentionally left blank Dec 1 85 FIGURE HOBART 15 88 Revised ITEM NO PART NO E 28 DELETED 29 403618 6 30 406149 31 403809 2 32 788 1118 1 33 798 1119 1 34 403782 0 35 788 1010 36 10910 0 37 10119 1 38 W 10750 2 39 W 7814 4 40 406768 1 41 180957 42 5CW 1932 0 43 80A 1117 44 404154 8 45 W 11095 2 NOMENCLATURE 1234567 BELT FAN V24161 No 9002 2050 FAN ENGINE V13446 No 31257017 SWITCH OIL PRESSURE V51377 No C 25900 10 SENDER OIL PRESSURE V16476 No 02504 SENDER
41. INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 25MS 156 6 15 280012 4 0 280297 5 44 280298 5 45 280686 7 58 30 1119 6 22 351541 14 11 351683 20 14 355325 4 13 3 355325 6 13 4 359985 5 16 361052 9 8 4 3895228 6 30 389535 3 6 47 400149 1 15 6 400434 9 9 400435 1 6 4 34 9 9 400480 2 6 34 400562 40 17 7 18 7 400613 3 6 17 400613 4 6 19 400641 12 6 6 400642 3 6 7 400741 13 6 31 400902 14 13 401428 1 6 5 401842 14 11 401937 8 6 25 402087 1 5 2 11 7 402265 13 7 402530 16 5 402531 16 4 402658 6 21 402682 6 18 402788 16 6 402908 9 2 402987 1 7 4 30 403055 2 6 39 403056 4 6 38 403091 4 6 49 403091 9 4 12 403127 6 44 403618 6 5 29 403782 0 5 34 403809 2 9 31 404065 2 6 26 404101 1 4 9 404172 3 2 PONE Do Pe on 22 15 88 Revised 000000000000 Numerical Index X O 4 4 Page 3 0M 2007 NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER 404856 6 16 405015 5 26 405091 1 13 5 405099 5 25 405278 6 8 3 405485 1 6 41 405743 14 5 405977 1 14 4 406000 4 31 406001 4 29 406040 6 9 406149 5 30 406254 1 19 3 406538 5 9 406651 5 7 406655 14 3 406768 1 5 40 406815 6 23 406974 5 11 407366 4 26 407706 5 27 408386 17 25 18 25 408387 17 13 18 13 408388 17 17 18 17 408389 17 18 18 18 408390 17 20 18 20 408391 17 19 18 19 408392 17 43 18 43 408393 17 16 18 16 408394 17 11 18 11 408395 17 26 18 26
42. OUT CANOPY 5 0 HF 2518 7 6 17 2518 8 6 19 W 4541 D 7 56 W 10072 63 20 12 W 10097 3 9 12 10097 31 9 10 W 10119 1 5 33 W 10750 2 5 38 W 10869 2 14 14 W 10869 5 5 12 W 10869 7 5 10 W 10869 12 14 2 W 10869 14 13 2 10910 0 5 36 W 10931 3 15 3 W 10933 3 15 2 W 11095 2 5 45 W 11100 3 1 13 W 11166 3 6 12 W 11166 5 6 36 W 11242 10 9 6 W 11242 12 1 13 W 11242 18 9 13 8 112546 20510 22222 Numerical Index 4 4 A NUN Page 1 200 7 NUMERICAL INDEX CONTINUED PART NUMBER FIGURE AND ITEM NUMBER W 11254 8 1 13 W 11280 11 1 13 11278 5 9 8 W 11280 3 10 3 W 11337 2 17 5 18 5 W 11434 6 27 W 11562 10 7 W 11563 17 4 18 4 W 2974 J 8 6 W 7814 4 5 39 W 799F 110 10 4 W 9218 254 6 42 W 9218 255 8 12 W 9360 2 29 11 8 Y 971 6 13 1CZ 93B 6 32 12CW 2146 17 3 18 3 10 6 16DA 3493 8 8 16DW 335 19 6 180130 17 44 18 48 180135 6 50 180286 5 44 180289 6 28 180297 1 13 180298 1 13 180310 18 46 180311 18 9 180322 1 18 49 180322 2 18 48 180427 1 11 1 180540 19 10 180542 19 9 180543 19 2 180544 19 6 180593 7 57 180945 8 14 181098 5 26 181099 5 26 181100 5 26 181152 4 11 181159 8 13 181160 1 8 15 181160 2 8 16 181161 4 37 181166 20 0 181179 4 36 181212 4 1 A WEE l4 INE rs tia aa Ray aed Apr 15 88 Page 2 I pr P S XC e T aswaa SAA 0 2007 NUMERICAL
43. Time Storage 1 Engine protection 2 Generator protection 11 11 11 11 11 2 201 E 3 3 P nic SSS C MI MU 28 TABLE OF CONTENTS continued SUBJECT CHAPTER SECTION PAGE A OP sm lt KVU 3 Preparation for Shipping 4 Stationary Unit Mounting Operation 1 3 1 1 1 a 2 Operating the Generator Set 21 A Prestart Inspection 1 Prestart Instructions 1 C Starting the Engine 2 3 D Generator Operation 4 E Deliver Power 4 Stop Operation Shutdown x 4 G Adverse Weather Precautions 1 Cold weather operations 4 2 Fuel system 4 3 Fuel 5 4 Cooling system 5 5 Lubrication 5 6 Electrical system 5 7 7 Battery 5 Operation in Hot and Humid Conditions 6 x 1 Cooling system 6 2 Battery x 6 TON v Dec 1 85 Contents 2 i i b i a ex 27 T P he A RN cu i i fABEE 0F CONTENTS CONTINUED I Operation in Extremely Dusty Conditions 1 3 1 Fuel system 2 Oil filter and air cleaner 3 Crankcase Operation Salt Water Areas 1 Canopy 2 Covering 3 Brushes 4 Field Coils 5 Battery Terminals K Miscellaneous Trailer Operation Towing Parking Servicing 2
44. VOLTMETER DC V60741 LIGHT PANEL 12V V77977 NO 431W BOOT TOGGLE SWITCH NO H 1030A SWITCH TOGGLE DPST V15605 NO 80600 BJ Deleted FUSE AGC 10A V71400 SWITCH PUSHBUTTON V15605 NO 810865NR DIODE CONTROLLED AVALANCHE V51589 NO ST 230ECAN BUS JUMPER SWITCH TOGGLE V81640 NO 8860 5 LIGHT PILOT GREEN 24V LENS GREEN BULB SWITCH TOGGLE 3PDT V74559 NO HLA 211 73 LIGHT PILOT ENGINE GREEN LENS GREEN BULB GAUGE HOURMETER V16476 NO 56288 HOLDER FUSE V71400 TYPE HKP HH SWITCH PUSHBUTTON BOOT PUSHBUTTON SWITCH 13445 NO 83280 AMMETER V16476 NO 06354 BLOCK TERMINAL 20A 91636 NO GBSY 14 TB29 RECTIFIER SILICON 704713 NO 5DA 10270 2 FUSEHOLDER V71400 NO 4407 BOARD PC REGULATOR MOUNT RUBBER BOARD PC OVERVOLTAGE ASSY RESISTOR SW 7 5 OHM 12V Not Illustrated EFF 0M 2007 UNITS per ASSY EN pa e y Mm Page 15 This page intentionally left blank Dec 1 85 s eamm 4 3 lt i i on st 0 00 FIGURE ITEM NO 6 32 33 34 35 36 37 38 39 40 41 42 43 44 1 85 PART NO 1CZ 93B 41546 400480 2 488944 W 11116 5 488598 403056 4 403055 2 16DA 4253 2 405
45. an overvoltage condition Connect a jumper lead between terminals 1 and 2 orange red and yellow red wires on the contactor close switch 11 Fig 2 If the load contactor now remains closed replace contactor close switch Using an ohmmeter check resistor R406 for proper resistance 7 5 ohms If an open circuit is indicated replace resistor This diode is also located on the right terminal strip at bottom rear of the control panel Using an ohmmeter check this diode for an open circuit If diode is defective replace it If no fault was found in steps 4A B and C above the load contactor 22 Fig 1 is defective Replace load contactor Resume operation and closely observe voltmeter 6 Fig 2 for evidence of overvoltage If contactor opens when no overvoltage condition exists proceed to Step B Revised Apr 15 88 TROUBLE SYMPTOM AND CONDITION PROBABLE CAUSE GENERATOR AND CONTROLS Cont d B Overvoltage relay K403 B defective 6 Load contactor opens during power delivery cont d C Load contactor 402 C defective Defective current limit A ing potentiometer R402 7 Output current cannot be limit ed by operating current limiting potentiometer B Defective voltage B regulator VR402 Apr 15 88 Revised OM 2007 TEST CHECK AND REMEDY Check overvoltage relay by operating the machine under load and gradually raising voltage a
46. control to 1000 Current displayed on ammeter will be 1000 100 amperes and voltage will not drop below 12 volts Restart the engine check the instruments as directed in step 3 and check the entire generator set for unusual vibration and noises 3 Voltage Regulator Adjustment 28 5 Volt Adjustment The regulating voltage in the 28 5 volt range is determined by the position of the wiper arm of the multi turn potentiometer R46 Clockwise CW rotation increases the voltage level at which the unit operates Conversely counterclockwise CCW rotation decreases the voltage level B Line Drop Compensation Line drop compensation allows the voltage at the load end of the output cable to remain constant despite the voltage drop associated with the output cable Clockwise rotation of the single turn potentiometer R24 increases the compensation This potentiometer should be set for flat regulation of voltage at the load end of the ded tc p ud m i 5 87 a w m 0M 2007 om rra Ol C cu a Ema cur 50 1662 1 28 5 Voltage Adjustment 2 Line Drop Compensation Voltage Adjustment Voltage Regulator Adjustment _Figure 3 _ Jun 5 87 _____ AC Pag e 5 KS 3 4 Y 7 IX E 9 m Y i i gt re i 4
47. details Apr 15 88 Revised 4 3 r I dee w s 50 107 Generator Set W Portable Mounting Option Figure 3 Dec 1 85 a j Page 6 0M 2007 NOMENCLATURE UNITS FIGURE HOBART 1234567 ASSY 3 6854 1 GENERATOR SET JET EX 4D WITH PORTABLE MTG OPTION Cod 6854 1 GENERATOR SET JET EX 4D WITH PORTABLE MTG OPTION B 1 6854 2 GENERATOR SET JET EX 40 STATIONARY C 1 1 488880 4 TRAILER ASSY OPTION For Details See Fig 16 1 2 848 1099 TIRE 4 80 X 8 WHEEL ASSY 4 3 488971 BRACKET CABLE REAR BRAKE RT SIDE 1 4 DWP 982 BRACKET CABLE 2 5 408432 CABLE BRAKE ASSY FOR DETAILS See Fig 16 6 488972 BRACKET CABLE REAR BRAKE LT SIDE 1 Not Iliustrated _Apr 15 88 Revised n a 4 3 Canopy Assembly Dec 1 85 Be cote we FIGURE HOBART ITEM NO PART NO 4 489267 1 489243A 181212 2 489227 3 489217 4 489258 5 489259 6 489270 7 488640 8 489167 9 404101 1 9A 408556 280012 10 488592 11 181152 408429 12 403091 9 13 489235 14 489168 15 489224 16 488799 17 489810 18 489230 19 489220 20 818 1019 21 489229 22 489156 23 489158 24 489577 25 488633 26 407366 27 818 1063 28 84A 1071 29 406001 30 402987
48. doors and inspect the interior for rags tools and other foreign materials i i 2 Check engine oil level i 3 Check coolant level 4 Check battery water level 1 l 5 Check for sufficient fuel 6 Check drive belts Each belt should have approximately 1 2 inch 7 Inspect all wiring for possible trouble spots such as loose wires or terminals frayed insulation obvious shorts etc 1 8 Check panel lights panel light switch and fuse i 9 Connect cables from generator output terminals to a load bank Use cables of the same size and length as those used in service preferably No 2 0 not more than 30 feet 9 m long c m i i 1 i i I i 1 0M 2007 HOBART JeP EX Fb OIL PRESSURE WATER TEMP STARTING CURRENT 24 1 Oil Pressure Gauge 11 Contactor Control Switch 2 Tachometer 12 Contactor Closed Light 3 Water Temperature Gauge 13 Speed Control Switch 4 Current Limit Control 14 Engine Light 5 Ammeter Generator 15 Hourmeter 6 Voltmeter 16 Deleted 7 Panel Light 17 Engine Start Switch 8 Panel Lights Switch 18 Engine Circuit Fuse 9 Panel Lights Fuse 19 Engine Circuit Switch 10 Push To Build Up Voltage Switch 20 Ammeter Engine Operating Controls and Indicators Rear Shelf amp Rear Enclosure Models Figure 253 Revised Apr 15
49. electrical system to make sure the connections are secure and properly connected Check the battery electrolyte level 7 Check air cleaner service indicator and replace air cleaner element if indicator window is red C Starting The Engine Make sure that all Prestarting Instructions have been carried out and reference to Initial Preparation For Use has been checked for operating details 1 Check engine oil fuel and coolant levels 2 Place speed control switch 13 in IDLE down position CAUTION 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 INTERVAL OF AT LEAST TWO MINUTES SHOULD BE ALLOWED BETWEEN CRANKING PERIODS PROTECT THE STARTER FROM OVERHEATING 3 Hold engine START RUN STOP switch 19 in START position 4 Press and hold ENGINE START pushbutton 17 Release as soon as engine starts 5 Release engine START RUN STOP switch 19 to RUN position when oil pressure builds up 6 Observe engine RPM on the tachometer and observe engine for excessive vibration Idle speed should be 1000 RPM 50 RPM there is excessive vibration adjust engine idle speed gradually increasing or decreasing it whichever is necessary until vibration is reduced For idle speed adjustment procedure refer to Section 2 3 Para 2
50. position 8 Adjust the load bank for a load of 550 amperes Jun 5 87 Page 3 9 10 11 12 13 14 15 m EA 0M 2007 Place the contactor control switch 11 in the CLOSE position CONTACTOR CLOSED light 12 will glow and the contactor will close Release the switch to the center ON position The tachometer 2 will indicate 2550 25 RPM Disconnect the load bank and check the overvoltage protection by adjusting voltage regulator potentiometer R46 1 Fig 3 to increase the voltage The overvoltage relay will trip and open the load contactor at 32 to 34 volts in 2 to 10 seconds Readjust the voltage to 28 5 volts connect the load bank set it at 550 amperes and close the contactor 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 and 660 amperes and check voltage at each setting Voltage will be 28 5 1 volts at each different load With current limit control 4 set to 2000 apply 600 to 700 amperes load to the generator and then set the current limit control 4 to 400 Current displayed on ammeter 6 will be 400 t 40 amperes NOTE Voltage will not drop below 12 volts Set current limit control to 2000 and apply 1200 amperes load Then set current limit
51. rules and take precautionary actions Safe practices have been developed from past experience in the use of power source equipment While certain practices below apply only to electrically powered equipment other practices apply to engine driven equipment and some practices to both B SHOCK PREVENTION Bare conductors or terminals in the output circuit or ungrounded electrically live equipment fatally shock a person Have a certified electrician verify that the equipment is adequately grounded and learn what 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 flow through it When inspecting or servicing equipment do not work in damp areas Stand on a dry rubber mat or dry wood use insulating gloves when dampness or sweat cannot be avoided Keep clothing dry and never work alone 1 Installation and Grounding of Electrically Powered Equipment Equipment driven by electric motors rather than by diesel or gasoline engines must be installed and maintained in accordance with the National Electrical Code ANSI NFPA 70 and other applicable codes power disconnect switch or circuit breaker must be located at the equipment Check the nameplate for voltage frequency and phase requirements I only 3 phase power is available connect any single phase rate
52. starting the unit Learn to use the manual ahd to locate information contained in it The Table of Contents which follows this Introduction lists all Chapters Sections and the paragraph titles within each Section The location of each listing is identified by Chapter Section and page number A complete list of illustrations with their locations follows the Table of Contents Each Chapter is divided into as many Sections as necessary Sections 1 1 ways referred to by combination Chapter Section number for example 2 8 refers to Chapter 2 Section 3 The material within each Section is divided into main subjects with applicable paragraph headings and subheadings as required For example a portion of the Description Section might logically follow this arrangement and paragraphing 4 1 Control Interior Panel 1 Protective devices Va T ISI a Overload relay i 1 i 2 Contactors 1 Page numbers do not run consecutively throughout the manual Each page 18 identifed by the Chapter Section number which it appears and by a page number within the Chapter Section Therefore the first page in each Section is page l These identifying numbers appear in the lower outside corner of each page Each page also bears a date located in the corner opposite the page number This date is either that of original issue or of the latest revilsion Any revision to the origina
53. the engine speed in RPM On Series 6854 units this instrument is operated by tachometer sender mounted on the engine governor 22 Figure 3 Series 6854A units there is no sender and the tachometer receives its operating signal from the alternator Revised Apr 1 87 aan ig ENS 2227556 125977 4 5 water temperature gauge 3 indicates the engine coolant temperature and is by temperature sender 23 Figute 3 mounted on the engine s water jacket oil pressure gauge 1 Figure 4 displays the pressure in the engine s lubrication system is operated by a sender 24 Figure 3 mounted on the engine block The ammeter 20 Figure 4 indicates the rate of charge or discharge in the engine s 12 volt DC electrical system scheduling maintenance hourmeter 15 records the total hours of engine operation for Potentiometer The current limiting potentiometer 4 is used to select the BEATE ing current recommended for various aircraft The current lihitin setting is continuously adjustable from 300 to 2000 amperes Switches i The contactor control switch 11 Figure 4 is three position toggle switch used to close and open the output load contactor The top CLOSE position is spring loaded and is hel
54. trouble and symptom directly below If the starter will NOT crank the engine look to the right under PROBABLE CAUSE and TEST CHECK AND REMEDY and find the various things which could cause the trouble and what to do to check and remedy hemen 3 Equipment for Troubleshooting A good quality multi scale voltohmmeter is the only instrument required u for troubleshooting At least two jumper leads with alligator or similar clips will be required 12 volt engine electrical QR be used for a 12 volt DC power source 4 Safety BY PERSONNEL NEAR THE FAN OR OTHER EXPOSED MOVING PARTS OF THIS EQUIPMENT WHILE IT IS RUNNING ALSO AVOID CONTACT WITH LIVE WARNING LOOSE GARMENTS NECKTIES AND OTHER HANGING ITEMS MUST NOT BE WORN ELECTRICAL PARTS DEATH OR SERIOUS INJURY COULD RESULT Pese TEES T Wu E Dec 1 85 3 1 Page 1 schematic diagram of the generator set is provided Chapter 6 This agram can be very helpfull in troubleshooting Components shown in the agram are identified by reference designators or item names in some x nstances legend appearing on the diagram identifies each reference designator by its full item name For example the symbol K403 identifies the overvoltage relay and M406 identifies the voltmeter connection diagram is also provided in Chapter 6 Tt also can be ve
55. xu oq cu 37 38 40 27 53 34 39 M 10 Lu 14 15 i2 5 W ea US 5 d as 4 I is E 3 LB WE 17 XC DS 27 E a 19 18 LEFT SIDE VIEW 3 32 36 38 12 24 25 20 35 2 3 16 28 RIGHT SIDE VIEM Generator Set Without Canopy Figure 5 4 3 Revised Aug 4 87 Page 10 ENERO 0 2007 11 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 EFF ASSY 5 No Number GENERATOR SET WITHOUT CANOPY For NHA See Fig 1 REF 1 489151 FRAME MOUNTING ASSY For Details See Fig 18 1 2 402087 1 BATTERY 12 V For Details See Fig 10 2 3 408409 ENGINE DIESEL V13446 TYPE 4 236 1 4 Number GOVERNOR ENGINE 1 5 489641 GUARD BELT LEFT 1 6 No Number COOLING SYSTEM For Details See Fig 13 1 7 406651 AIR CLEANER V18265 FWG 06 5295 1 8 408458 MUFFLER 76700 NO 0 49115 1 9 406538 BRACKET MOUNTING AIR CLEANER V18265 NO PPPOO 7192 2 10 W 10869 7 CLAMP HOSE V35708 NO 5 36 1 11 406974 HOSE CLEANER 1 12 W 10869 5 CLAMP HOSE V35708 NO 12 1 13 408436 FILTER AIR CLEANER l 14 489704 RECTIFIER ASSEMBLY For Details See Fig 14 1 15 No Number FUEL SYSTEM For Details See Fig 11 1 16 359985 BRACKET FUEL FILTER 1 17 489661 GENERATOR ASSEMBLY For Details See
56. 0 Excitation rectifiers Two diode bridge rectifiers 418 and 18 3 Fig 5 convert voltage from the generator armature to the DC voltage need ed for the generator revolving field 11 Voltage sensing relay Voltage sensing relay KA06 5 Fig 5 is a safety device which automatically opens the grounding circuit of the revolving field to prevent excessive voltage build up if the push to build up voltage switch is held in too long or if it is pushed in after voltage is built up Contactor The load contactor which is mounted behind the control panel on the fuel tank support provides a safe and convenient means of connecting and disconnecting the generator from the load Initial power for closing the load contactor is supplied by the generator through the spring loaded momentary contacts of the contactor control switch 11 Figure 4 Holding power to keep the contactor closed passes through the normally open auxiliary contacts in the load contactor F Output Terminals e control panel positive terminal is the A2 terminal of the 10 4 contactor and the negative terminal is to the right of the load tactor x The output terminal panel is mounted inside the unit just behind the x x G Rectifier Assembly The rectifier assembly 6 Figure 3 is located at the center of the machine on the fuel tank supp
57. 034 000 HOLIOVdVO YOLVUINIO 1069 5 YOLVYINI9 90tW n Lo 21 431199 20 18 0518 3055354 20 222000200002 3 318 15 1098 N31VM 39vn9 a ObY H313WN i 110 HW30N3S 20pv AH311V8 H313AWV J3univH3dW31 H31VM M30N3S 109 ng N3931 aac ort i pa LABEL AA lt hd ES A AUN T Y rm wak 4 6 0 D ae dg A E CLOSE CURE x 1 eS BO1VH3N39 uQ1V10534 39V1104 ZONA 02982 N3HM BOSNIS dl 3NION3 HO IMS SOvf SOvd 330 3 079 HOLIVINOD HOLIMS 6055 39Vi 0A NONB QL HSid NOLLNGHSNd HOLIMS 1055 INOLLISOd 3701 NANOHS 1081 93345 HOLIMS 905 9075 330 0 35072 BOJIVINO HOLIMS 0195 DIM pors 504 NMOHS AbI 82 300W HOLIMS 6095 3univU3dW3l H31VM HOLIMS 20 5 MS 4 HO1SIS3 80
58. 1 ous 0M 2007 TEST CHECK AND REMEDY Check battery connections and check voltage across battery Voltage should be approximately 13 5 VDC Be sure this voltage is reaching starter relay input terminal If battery and connections are good proceed to Step B Momentarily connect large capacity jumper cable between the hot side of the starter relay L401 and the start switch terminal on the starter relay yellow blue wire If the starter operates check pushbutton start switch 17 Fig 2 Replace faulty switch If starter doesn t crank proceed to Step C Momentarily connect a large capacity jumper cable between the hot side of the starter relay 19 Fig 1 and the starter input terminal If the starter attempts to crank the engine the starter solenoid is defective Replace it If engine still won t crank proceed to Step D If starter did not attempt to operate in Step C above the starter is defective Replace starter If starter did attempt to operate but couldn t turn engine proceed to Step E Revised Apr 15 88 TROUBLE SYMPTOM AND CONDITION ENGINE AND CONTROLS 1 Engine will not start Starter will not crank engine Cont d 2 Engine will not A start Starter DOES crank engine 15 88 Revised PROBABLE CAUSE Internal engine seizure Engine circuit fuse 402 blown or Fuel valve at tank closed or no fuel in tank engine has lost its pr
59. 1 85 vam mre Y oe CHAPTER 6 MANUFACTURER S LITERATURE e Perkins Users Handbook for Perkins Engines Inc 4 236 Series Diesel Engines 0 Box 697 32500 Van Born Rd Wayne Michigan 48184 Hobart Diagrams Hobart Brothers Company Power Systems Division i Troy Ohio 45373 489612 Connection Jet Ex 4D Series 6854 Units 180435 Connection Jet Ex 4D Series 6854A Units 489611 Schematic Jet Ex 4D Series 6854 Units _ 180436 Schematic Jet Ex 4D Series 6854A Units Printed Circuit Boards 180289 28 Volt Overvoltage Module 489708 1 Voltage Regulator 7 Apr 1 87 Revised 5 O 22 TIME a rpm a Page 1 A lvi zu EU rs es A eri A mie e Saa penne Aaa A MEL oco C t 1 lt gt REM Pd k a 120077 gt Dec 1 85 Sa M M A T P x lt i m nan w nM MA s EON i 4 4 1 g 1 t I 1 i t t 1 4 3 i i n 1 k k 1 Y E E 9 fond gt MN a
60. 35078 30010 20 10 YOLIDVAVI 8 00019 HOLIOVd VO 21 AM311V8 3NI9N3 Y3LYVLS 9INOY 19313 3 MOON Y3LINOHIVL 830835 JYNASSIYA 710 830N3S 3Hn1VH3dW31 H31V W3ON3S QN3931 00M a 9 0 PURA 20 putes 01 Caparo ues 1091410902 097 9091 votl 1091 9093 2097 SOvf 20 9 1099 vOvs 2094 1094 80550 10954 90950 60954 20954 10954 2 IZeH2 61 b H2 81983 21982 9 2 52982 91042 SOb HO 2092 1095 20918 10918 1078 tittpmied quum ipd so 29 perdon 24 9t AQ 4024 Moda oropan LARUM 99 MBA piunt Dro EMI 9 1000006 fupe oT weal 8244 4 NOD q Manon D 91 Gador VOI EVIL LOVE NO GA qadov Q3HSINHI3 SIMM NEEDLE 13 4 JOUiNOO 40 RIP SERERE SHE 010000000001 647 737 dea MAA 5 7 4 2 x Y 9 2 u Sas 8 8 8 apa 4 g 5 T g
61. 431W SUPPORT ROPE HINGED DOOR BLOCK TERMINAL 20A V91636 NO GBSY 14 TB29 FUSE AGC 10A V71400 DIODE ASSY RESISTOR 5W ASSY SWITCH TOGGLE DPST V74559 NO 20 71 73 DIODE CONTROLLED AVALANCHE V51589 NO ST 230ECAN BUS JUMPER LIGHT PILOT GREEN 28V KNOB RHEOSTAT V44655 NO 5150 POTENTIOMETER 10 OHM 2W 44655 NO CMU 1031 COVER 14V OPTION LIGHT PILOT ENGINE GREEN 12V SWITCH TOGGLE 3 PDT V74559 NO HLA 211 73 SWITCH PUSHBUTTON BOOT PUSHBUTTON SWITCH V13445 NO 83280 PLUG HARNESS VOLTMETER DC V60741 AMMETER V60741 SUPPORT MAGNET RIGHT CLIP WIRE NOT ILLUSTRATED 0M 2007 UNITS per ASSY o N E mM Ria m PN This page intentionally left blank os 0 2007 __ Revised Apr 15 88 FIGURE ITEM NO HOBART PART NO Y 971 403091 5 280529 406003 2 180289 84 1075 181022 1 11434 W 11166 3 404065 2 W 10051 14 181039 403056 1 403055 2 180591 1 280527 400828 2 489658 5 402461 5 402197 1 W 454 D 180593 1 280686 Aug 15 88 Revised NOMENCLATURE 1234567 SWITCH PUSHBUTTON V15605 NO 810865NR PLUG HOLE 5 8 BOX PC BOARD ASSY STRIP TERMINAL QUICK CONNECT BOARD PC OVERVOLTAGE ASSY MOUNT RUBBER BOARD REGULATOR HOLDER FUSE V71400 NO 4407
62. 485 1 9714 25 489237 403127 489218 489219 389535 3 489215 403091 4 180135 76 115 NOMENCLATURE 1234567 DIODE V05277 NO 4820 INS SLEEVING TERMINAL PLUG HARNESS FUSE AGC 20A V71400 COVER 14V OPTION RELAY ENCLOSED DPDT 24V DC V77343 NO KUP 110 15 24VDC SOCKET RELAY V77343 NO 24 067 SPRING RETAINING RELAY CAPACITOR 0 1 uF 400 VDC V14655 NO DPMS4P1 RESISTOR 10 OHM 2 WATT PANEL CONTROL CATCH MAGNETIC DOOR V94222 NO 02 10 201 10 SUPPORT MAGNET RIGHT SUPPORT MAGNET LEFT SUPPORT ROPE SUPPORT P C BOARD PLUG HOLE HARNESS PLUG LATCH ADJUSTABLE Not Illustrated 0 2007 UNITS per ASSY 4 gt 00 N N e 3 ue 2 eu fa bh ETA w pun uytu PO 0M 2007 isis 16 38 8 19 40 4 239 5 56 ELS a ae 17 le a ut gt 1 3 Pata 4 t 5 By it 1 38 i t e ay 1 1 e 4 4 810 2 NA E eren 5 IS MEE RAE 7 d e 3 4 y 4 C lt 23 X i UE
63. 84B 1003 84B 1078 84B 1099 84C 1003 84 1100 85 1004 2 Numerical Index 0 4 4 8 NUMERICAL INDEX CONTINUED 0M 2007 FIGURE AND ITEM NUMBER 5 35 5 24 6 2 1 11 5 33 12 7 5 43 4 20 17 8 18 8 4 27 1 5 2 2 4 28 6 29 6 8 1 4 4 11 3 2 17 2 18 2 9 2 18 1 20 10 Dec 1 85 __ 0M72007 CHAPTER 5 OPTIONAL EQUIPMENT Optional equipment available for use with the Jet Ex 4D Generator Set is listed below OPTION PART NUMBER MANUAL Henschen Trailer with Fenders 488880 3 0M 2007 Bumpers amp Cable Trays Henschen Trailer with 488880 4 0M 2007 Cable Hangers Prototype Trailer with Fenders 181000 1 0 181 amp Cable Trays Prototype Trailer with 181000 2 0 181 Cable Hangers Spacers Stationary Mounting 488952 0M 2007 Kit 14 V Output 489781 TO 168 120 V AC Generator Package 489100 TO 160 Trailer mounted units 120 V AC Generator Package 489104 TO 160 Stationary units and units without fenders Kit Tie Down Assy 180298 0 2007 See Fig 1 Trailer with Fenders Bumpers 4 488880 5 0M 2007 Cable Trays Fork Lift Mtg Kit Cold Weather Start Aid 489782 TO 167 Kit Water Heater 180630 TO 179 Jan 22 88 Revised F e 5 amp Ml t i 1 i 1 1 1 i i i i This page intentionally left blank L 5 D dum lt s m r
64. 88 0M 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 18 488880 3 KIT TRAILER JET EX 4D ASSY FOR NHA SEE FIG 2 2360 Lb Capacity A 1 488880 5 KIT TRAILER JET EX 4D ASSY FOR NHA SEE FIG 2 2360 Lb Capacity B C 1 1 84 1100 TRAILER JET EX 4 1 2 848 1099 TIRE 4 80 X 8 WHEEL ASSY 590 Lb Capacity 4 408507 AXLE FRONT ASSY 1 3 12CW 2146 YOKE THROTTLE ROD V03504 NO 4 J 4200 2 4 W 11563 PIN CLEVIS CLARK 03504 NO 4 04051 2 5 W 11337 2 PIN COTTER 2 6 408432 CABLE BRAKE ASSY 2 7 400562 40 SPRING TENSION CABLE 2 8 818 1062 LABEL WARNING DRAWBAR UNDERSIDE 1 9 489209 FENDER SIDE LEFT A 1 180311 FENDER SIDE LEFT 1 10 488931 BUMPER FRONT 1 11 408394 BOLT 3 4 16 2 12 408397 WASHER FL 3 4 8 13 408387 SPINDLE STEERING ARM ASSY LH 1 14 408396 BOLT 3 4 16 UNF X 400 1 15 408398 NUT SLOTTED 3 4 16 UNF 4 16 408393 PIN COTTER 4 L7 408388 DRAWBAR TUBE ASSY 1 18 408389 GREASE ZURK STRAIGHT 1 19 408391 LATCH TONGUE ASSY 1 20 408390 TONGUE ASSY 1 21 408399 TIE ROD ASSY LARGE 2 22 408401 TIE ROD COUPLER ASSY 2 23 408400 TIE ROD ASSY SMALL 2 24 408402 GREASE ZURK 90 4 25 408386 SPINDLE STEERING ARM ASSY RH 1 26 408395 BOLT 3 4 16 UNF X 6 00 1 408508 AXLE REAR ASSY 1 27 408403 HUBS 5 ON 4 1 4 2 28 408404 STUD PRESS IN 1 2 20 X 1 7 8 10 29 408410 SEAL GREASE 4
65. 9 HB Instrument Co American and Bristol St Philadelphia PA 19140 28478 Deltrol Controls 2745 S 19th St Milwaukee WI 53215 31211 Motorola Automotive and Electronics Group 1303 E Algonquin Road Schaumburg IL 60196 31510 Mainline Supply Co Inc lt 905 E Third St Dayton 45402 31695 Facet Ent Inc US No 1 Bypass South Henderson NC 27536 33955 Teleflex Inc 1816 57th St Sarasota FL 33580 35708 Tridon Limited P O Box 1600 Nashville TN 37202 w F a O M O CE ER RR me t M 4 2 c __ Revised Apr 1 87 _ s A AAN ES nme a CODE VENDOR S NAME AND ADDRESS 44655 Ohmite Mfg Co 3601 W Howard St Skokie IL 60076 46992 Phoenix Electric 3625 Halstead St Chicago IL 60613 49234 Protecto Seal Co 225 W Foster Avenue Bensenville IL 60106 51377 Kysor of Cadillac 1100 Wright St Cadillac MI 49601 51589 ST SEMICON INC 415 N College Ave Bloomington Indiana 47401 53035 Hoover NSK Bearing Co 3861 Research Park Drive P O Box 1507 Ann Arbor MI 48106 56289 Sprague Electric Co 87 Marshall St No Adams Mass 01247 57448 Allis Chalmers Corp 275 Ridgeway Avenue Box 1367 Aurora Illinois 60507 60741 Triplett Electrical Instrument 286 Harmon Road Bluffton Ohio 45817 61864 TRW I
66. AMP RADIATOR NECK 1 Not Illustrated Apr T5788 Revised c censu eo uu ou LE ONS NU eee page 35 NUR 0M 2007 FRONT VIEW 250 121 Rectifier Assembly CL c RE en a FIGURE ITEM NO 15 1 2 Qu 489704 60 405 W 10933 3 10931 3 489703 489702 400149 1 489208 25 626 42543 Apr 15 88 Revised NOMENCLATURE 1234567 RECTIFIER ASSY For NHA See Fig 8 SHUNT 2000 50 ASSY RECTIFIER SILICON CONTROLLED V05277 NO R6110328 NEGATIVE BASE RECTIFIER SILICON CONTROLLED V05277 NO R6110328 POSITIVE BASE HEAT SINK RECTIFIER NEGATIVE HEAT SINK RECTIFIER POSITIVE NUT SPRING DISHED 3 4 16 V78189 NO 534 750200 52 SUPPORT RECTIFIER WASHER INSULATING V CELCON NO M270 04 BUSHING INSULATING SLEEVING Not Illustrated 2007 UNITS per ASSY 16 108 2120 22 22 C EE Tr 2098 Brushholder Assembly Fig 16 IO RS NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 16 488784 BRUSHHOLDER ASSY For NHA See Fig 19 1 1 488562 BRACKET
67. Apr 15 88 4 4 6 15 88 4 3 12 Dec 01 85 4 4 7 Apr 15 88 4 3 13 Apr 15 88 4 4 8 Dec 01 85 4 3 14 Apr 15 88 4 3 15 Aug 15 88 5 0 1 Jan 12 88 4 3 16 Apr 15 88 5 0 2 Dec 01 85 4 3 17 Apr 15 88 4 3 18 15 88 6 0 1 01 87 4 3 19 Aug 15 88 6 0 2 Dec 01 85 4 3 20 Apr 15 88 4 3 21 Aug 15 88 Unusual Service Conditions 4 3 22 15 88 4 3 23 15 88 4 3 24 Apr 15 88 4 3 25 15 88 4 3 26 15 88 4 3 27 15 88 4 3 28 15 88 4 3 29 15 88 4 3 30 15 88 4 3 21 15 88 4 3 32 Apr 15 88 4 3 33 15 88 4 3 34 15 88 4 3 35 Apr 15 88 4 3 36 Apr 15 88 wa lt saksaq di e e Revised Aug 15 88 List of Effective Pages Page 2 Mar m Pa a MU EE E i D X P d 8 7 s H n 1 i p H _ A M M b tee gt 7 7 A lt w TABLE OF CONTENTS SUBJECT CHAPTER SECTION Description Operation 1 1 l 2 3 5 6 me ide e Description Special Features Standard Options Orientation Identification Canopy Engine Generator and Controls General Engine 1 2 3 4 5 6 General Cooling fan Fuel s
68. BRUSHHOLDER 1 2 488628 BRACKET DIODE 1 3 408999 1 DIODE SILICON 30A POS V08452 1 4 402531 BRUSHHOLDER V46992 NO DE 55 2 5 402530 GUIDE BRUSHHOLDER 46992 661 0 23 2 6 402788 BRUSH A C V78377 NO 443E 22 Apr 15 88 Revised 22 32 _____ _4 3 Au apes gea ies E SOME T E CPage 39 Kit Trailer Without Fenders Option _ Figure 17 2 1 53 ____________ ___________________________ _ _ Apr 15 88 0 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 17 488880 4 KIT TRAILER WITHOUT FENDERS FOR NHA SEE FIG 3 2360 Lb Capacity 1 1 84C 1100A TRAILER JET EX 4D 1 2 848 1099 TIRE 4 80 X 8 WHEEL 55 590 Lb Capacity 4 408507 AXLE FRONT ASSY 1 3 12CW 2146 YOKE THROTTLE ROD V03504 NO 4 1 4200 2 4 W 11563 PIN CLEVIS CLARK V03504 NO 4 04051 2 5 W 11337 2 PIN COTTER 2 6 408432 CABLE BRAKE ASSY 2 7 400562 40 SPRING TENSION CABLE 2 8 818 1062 LABEL WARNING DRAWBAR UNDERSIDE 1 9 DWP 982 BRACKET CABLE 2 10 489272 WASHER FLAT 5 8 8 11 408394 BOLT 3 4 16 2 12 408397 WASHER FL 3 4 8 13 408387 SPINDLE STEERING ARM ASSY LH 1 14 408396 BOLT 3 4 16 UNF X 400 1 15 408398 NUT SLOTTED 3 4 16 UNF 4 16 408393 PIN COTTER 4 17 408388 DRAWBAR TUBE ASSY 1 18 408389 GREASE ZURK STRAIGHT 1 19 408391 LATCH TONGUE A
69. CE OR OTHER when contactor COMPONENT IS JUMPERED close switch S408 is A Defective contactor Momentarily connect a jumper operated Engine close switch S408 lead between terminals 4 and 5 voltage normal the contactor close switch 11 no load applied Fig 2 the load contactor to output cable closes momentarily replace contactor close switch B Defective load B If load contactor 22 Fig 1 contactor K402 will not close when contactor close switch is jumpered it is likely that the contactor is defective Replace contactor C Overvoltage relay C Connect a jumper lead between K403 defective terminals T and P on the overvoltage relay 2 Fig 3 If contactor will now close replace overvoltage relay running normally red and yellow red wires on Apr 15 88 Revised 3 1 TROUBLE SYMPTOM AND CONDITION GENERATOR AND CONTROLS PROBABLE CAUSE Cont d 0 2 007 TEST CHECK AND REMEDY Load contactor opens as soon as contactor close switch is released from its top spring loaded position 6 Load contactor opens during power delivery Defective contactor close switch S408 Defective resistor R406 located in back of control panel on right terminal strip at bot tom of panel See con nection diagram 489612 Defective diode CR402 C Load contactor 402 defective Contactor opening could A have been normal because of
70. Call Area code 513 339 6000 Extension 4276 x TWX 810 456 2907 T TN MEN Introduction 185 xU CHAPTER SECTION PAGE List of Effective Pages 1 thru 2 Introduction Introduction Contents Contents Contents Contents Contents Contents Contents Contents Contents Contents pa FS RBS ps 1 1 d l LEE 1 rs S U Lo Lo Co Co CO Co Ly 1 1 1 1 1 1 1 1 O WO Qn DN VO Y ON Ui POCO ug 15 88 Revised DATE Aug Dec Dec Apr Dec Dec Dec Dec Dec Dec Apr Apr Dec Apr Dec Dec Aug Dec Apr Dec Apr Dec Dec Dec Apr Apr Dec Dec Dec Dec Dec Dec Dec Apr Jun Dec Dec Dec Dec 01 85 15 88 01 85 01 85 01 87 01 85 01 85 01 85 01 85 01 85 01 85 15 88 15 88 01 85 01 87 01 85 01 85 15 87 01 85 01 87 01 85 01 87 01 85 01 85 01 85 15 88 15 88 15 88 15 88 15 88 01 85 01 85 01 85 01 85 01 85 01 85 01 85 15 88 05 87 01 85 01 85 01 85 01 85 CHAPTER LIST OF EFFECTIVE PAGES SECTION 2 3 2 3 2 3 2 3 2 3 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 AUN NO COON ON Qn
71. ER FL ST 1 2 OPTION NUT 1 2 20 HEX JAM ST OPTION SCREW 1 2 13 X 1 1 4 HHC ST OPTION WASHER LK STD 1 2 OPTION Not Illustrated 2007 UNITS per ASSY 1 B CO OO j N CO O TER A at ar nel eee Ls A Laa lt yey 2 2 T E E 50 1076 25522222 SRA Generator Set W Portable Mounting and Fenders Option ee Dec 1 85 EA 2222 0M 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 EFF ASSY 2 6854 1 GENERATOR SET W PORTABLE MTG AND FENDERS OPTION 6854 1 GENERATOR SET W PORTABLE AND FENDERS OPTION B 1 6854 2 GENERATOR SET STATIONARY W LOW PROFILE CLEARANCE LIGHTS amp RAIN SHIELD C 1 1 488880 3 TRAILER ASSY OPTION For Details See Fig 17 E 2 84 1054 1 REFLECTOR RED V82445 NO SAE A 71 DOT 4 Series 6854A generator sets are identical in appearance construction and electrical operation to Series 6854 generator sets They differ from Series 6854 generator sets in that the tachometer sending device is eliminated a different tachometer is used and a different brand of alternator is used See Figures 5 and 6 for
72. FUSE 10A V71400 RECTIFIER SILICON V04713 NO 5DA 10270 2 CLAMP WIRE PLASTIC BRACKET RELAY SOCKET MTG RELAY ENCLOSED 24V DC V77343 NO KUP 110 15 24VDC SOCKET RELAY V77343 24 067 RESISTOR 2 WATT ASSY BOX PC BOARD ASSY TIE WIRE PLASTIC DIODE ASSY CAPACITOR 100MFD 350VDC TERMINAL QUICK DISCONNECT RESISTOR 1000HM 25 WATT CAPACITOR 0 1 MFD 400 V DC INSULATOR WALL BOX NOT ILLUSTRATED 0M 2007 UNITS per ASSY a fot NO mL N ya A Aa uem 7 M M e monet ee tS M X ENTM 0 2007 Z o 5 e N 2 ONO PREA Rectifier and Fuel Tank Support Assembly Figure 8 e we cd crc cl ro devised Apr 15 88 _ 0M 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 8 489554 SUPPORT RECTIFIER AND FUEL TANK ASSY REF 1 489704 RECTIFIER ASSY For Details See Fig 15 1 2 489196 1 PANEL TERMINAL OUTPUT ASSY For Details See Fig 9 H 3 405278 6 CAPACITOR V56289 NO 36DX413G075DF 2A 1 4 361052 9 CLAMP MOUNTING CAPACITOR 1756289 1 4586 2 5 350488 94 INSULATION CAPACITOR 1 6 W 2974 J RES
73. ISTOR 10 100W 44655 NO 0957 3 7 489579 BRACKET RESISTOR 1 8 160 3493 INSULATOR WASHER 6 9 489580 INSULATOR RESISTOR 1 10 489192 SUPPORT FUEL TANK 1 11 W 9218 254 CABLE SHUNT TO NEGATIVE OUTPUT TERMINAL 201 2 12 W 9218 255 CABLE POSITIVE HEAT SINK TO LOAD CONTACTOR 1 202 2 13 181159 CLAMP CABLE 2 14 180945 BRACKET CAPACITOR 1 15 181160 1 TUBING Z FLEX NEG CABLE 2 16 181160 2 TUBING Z FLEX POS CABLE 1 Not Illustrated Apr 15 88 Revised 240242 5 8 3 Output Terminal Panel Assembly MM ed AR 24 is SS 0 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 9 489196 1 PANEL TERMINAL OUTPUT ASSY For NHA See Fig 8 REF 1 489195 PANEL OUTPUT 1 2 84C 1092 CONTACTOR 28 V V26659 NO JGA6003A 1 3 489199 BUS TERMINAL 1 4 5CW 975 BUSHING INSULATOR 1 5 5CW 2127 BUSHING 1 6 W 11242 10 WASHER FLAT 3 8 ST 3 7 W 11254 6 WASHER LOCK 3 8 ST 4 8 W 11278 5 NUT 3 8 16 HEX ST 2 9 400435 NAMEPLATE 28 1 10 W 11097 31 SCREW 3 8 16 X 1 3 4 HHC ST 1 11 5CW 976A WASHER INSULATOR 2 12 W 11097 3 SCREW 3 8 16 X 1 1 4 HHC ST l 13 W 11242 18 WASHER FLAT 3 8 ST 1 Apr 15 88 Revised 4 3 usu sd Figure _ d gt S A Bag O A p br D R
74. L 46152 or See Perkins Engine Duty MIL L 2104C User s Handbook for recommended oil viscosity Grease Automotive Military Wheel bearings MIL G 10924B Lubricants Figure 2 1 2 SYMBOL TIME INTERVAL 10 hours or Daily 100 hours or Biweekly 200 hours or Monthly 400 hours or Bimonthly 800 hours or Semiannually Symbols and Time Intervals Figure 3 Lubrication schedule Time schedules indicated on the Lubrication Chart Figure 1 are approximate They are based on average operating conditions It may be necessary to lubricate more frequently under severe x operating conditions such as low engine temperature high oil temperature intermittent operation or dusty conditions However time intervals should not exceed those indicated in the chart without careful evaluation The use of quality lubricating oil combined with proper oil drain and filter change intervals are important factors in ng engine life Oil specification Lubricating oils must be equal to the U S Ordnance specification MIL L 46152 or MIL L 2104C Lubricating oils for use in Perkins diesel engines must have a minimum viscosity index of 80 2 i 3 Oil viscosity Always ensure that the correct viscosity grade of lubricating oil is used for the temperature range in which the engine will operate as shown below AMBIENT TEMPERATURE RANGE VISCOSITY f i eme x
75. M 531835 NI 8108 130A ZI V LO3NNOO 1 SNOILONYLSN 1531 ONY 4018 SI10A Ot 02 AddNS 20 03504 03831714 03033N 1631 110A 22 Y3N32 22 12 38 LLVA 2 1 WHO OSI 30451533 018 WHO YOLSISIN 6H L1VM2 WHO 042 HO1SIS3H 8u WHO MOI HOJSIS3N 44 271 322 1651638 LAVA 2 1 9 151538 tH 9 LlVA2 l HOLSIS3H u 1 NHO HOLSIS3H 28 gt 9 1 801651538 1209 2 318vWWvubOHd YOLSISNVYL 06 2 NOISISNVHI 6066 2 1516 10 9 LLYMA 2 1 WHO 5313901103109 td Si 30010 20 10 92103 06 HOLI2VdVO AOS 48 LIOVAVO 19 3931 262081 10 sen SLIVINOO tA 682081 90 ISSY eol zd m 36 110 83 6 0 922 STONY LHOIY NO1SV3 1 2 262081 NOI49nMISNI 71387 86 0 HOLINOW 3 19340 4 12801 LAYA 2 1 NHO 40161538 29720 MINN 515 1 22 12801 LIVA 2 0 4976 80161538 41 42801 LLIUMZ 1 WHO NO 80161638 SLA 06 01 06 2 516 2 1 X22 80161538 110A 2 Q4M OS YOLIIVAVI 41V 2 1 049
76. NCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 19 No Number FRAME LIFTING YOKE ASSY For NHA See Fig 1 1 1 489151 FRAME MOUNTING 1 2 180543 BAR GENERATOR 1 3 406254 3 MOUNT SHOCK GENERATOR RED 2 4 489203 YOKE LIFTING 1 5 491799 WASHER SHOCK MOUNT 4 180544 KIT GENERATOR SUPPORT 1 6 W 11102 1 SCREW 5 8 11 X 1 HHC ST 4 7 W 11254 10 WASHER LOCK 5 8 ST 4 8 W 11280 12 NUT HEX 5 8 11 ST 4 9 180542 SUPPORT LEFT 1 10 180540 SUPPORT RIGHT 1 11 406254 2 MOUNT SHOCK ENGINE GREEN REF NOT ILLUSTRATED Apr 15 88 Revised dab cde ME EE pens Page 49 2007 Generator Assembly Figure 20 4 3 Revised Apr 15 88 Page 50 FIGURE HOBART ITEM NO PART NO 489661 491784 489077 1 488557 2 489135 489064 488555 1 5 260 0 488784 489086 489123 489125 181166 W 11254 5 85C 1004 2 11 No Num er 12 W 10072 63 T Po O o 00 YD ui E Whe 13 489126 14 351683 15 493384 9 16 493384 10 Apr 15 88 Revised _ _________ 0M 2007 NOMENCLATURE UNITS per 1234567 ASSY GENERATOR ASSY RING ADAPTER HOUSING FLYWHEEL HOUSING amp STATOR ASSY KEY COUPLING ARMATURE ASSY HOUSING BEARING ASSY CAP BEARING BRUSHHOLDER ASSY FOR DETAILS SEE FIG 16 COVER FLYWHEEL HOUSING COUPLING amp FAN ASSY COUPLING GEN TO GEN ASSY
77. NING 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 the fuel 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 is applied and that the drawbar is raised and locked in the vertical position Raising the drawbar to the vertical position automatically applies the brakes and they will be released when the drawbar is lowered 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 of service Therefore the following steps should be taken to optimize maximum efficient operation 1 Check the supply of fuel crankcase oil and radiator coolant See Perkins Engine User s Manual for specifications 2 Inspect the unit thoroughly to be sure it is in proper working order Check all fuel lines and wire connections to be certain they are secure Tighten any loose screws nuts or bolts 3 Wipe off the entire unit and clean the air passages control panel and other hard to reach places with compressed air not o
78. NNAY YOLVAQNI 10954 U38NV YINSVA 90 50 lt 0950 20750 10950 XIVE ATI 3000 12942 ONIONIM 531311934 GIVA LO 11504 30000 9 H2 C2tu2 3A11V93N 30011 91 9 2018 3000 0982 0982 29 HOLIOVd YO 202 62 02 19 4 AH311V8 20918 10938 3 431995 lOve 20515313 INON 331 B30N3S cory 38155389 WO 830435 20bv 3HfllvH3dWil YIONIS 10 1 9 393171 I HO1VH3N39 HOLv 1n93H NUMA N3HM 305436 3NI9N3 HOLIMS 330 35010 19 1 HOLIMS 01 NOLLnaHsSnd H211MS NOLLISOd IN NMOHS 1031409 03345 HOLIMS S1H9I1 HOLIMS 9015 1 5715 3NION3 HOLIMS WO HILIMS 3Hn1VH3dW31 H31VM HOLIMS 1491 3NION3 NOLInGHShd 5 MGZ WHO OO 30151534 WHO Ol VOLSISAN U313AWV LNnHS WHO SL 40151538 MOO WHO 01 0151634 MO ONILIWIT H313NOLLN310d 39V1104 8O1V83N39 YILINAY 9 Ju313N110 384055384 710 9 34n1vB3JW31 M31VM s YILIN 11 8 H313AWY CONANA N3HAO 1891
79. OPERATION AND MAINTENANCE MANUAL for JET EX 4D GENERATOR SETS Series 6854 and Series 6854A Specification 6854 1 Specification 6854 1 Specification 6854A 2 HOBART BROTHERS COMPANY POWER SYSTEMS DIVISION TROY OHIO 45373 U S A Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised Revised 2007 120185 092286 100186 101686 102886 121086 012887 040187 041487 042487 051187 060587 061587 070687 080487 111887 011288 041588 081588 IT EONS i WARNINGS FOR ELECTRICAL POWER EQUIPMENT 777777 SAFETY INSTRUCTIONS AND 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 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 IMPORTANT Protect all operating personnel Read understand and follow A EC all instructions in the Operating Instruction Manual before installing operating or servicing the equipment Keep the manual available for future use by all operators GENERAL Equipment that supplies electrical power can cause serious injury or death or damage to other equipment or property operator must strictly observe all safety
80. PERATING THE UNIT Inspection Check Inspect the unit completely prior to operation 1 Remove crating blocking banding ties and other securing and gt gt protective material After shipping carton is removed remove the four carton supports from the bases of the clearance lights i Then install the attached clearance light lenses in their bases OS sheet metal etc 2 Inspect exterior for shipping damage such as broken glass damaged t x x 1 3 Open canopy door and inspect interior for foreign material such as rags tools shipping papers etc l 4 Check fuel coolant and oil hoses and connections for visible leaks leaks 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 21 5 gallons 81 4 liters Use b Engine coolant S kam i i l 1 i The radiator is located above the front canopy Coolant level should be approximately one inch below th filler neck Allow a sufficient capacity for coolant expansion i i CAUTION BE SURE THE COOLING SYSTEM ANTIFREEZE SOLUTION IS ADEQUATE TO PROTECT BELOW LOWEST TEMPERATURE P YYPAT U ane gene
81. S 800 HRS OR 1 MONTH 2 MONTHS 6 MONTHS i oil level X Check coolant level X Check fuel quantity X i i 1 Check gages and instruments for i proper operation X Change engine oil X Change engine oil filter X Check and tighten drive belts X X Clean and inspect exterior of radiator X ed exhaust system X i Check cooling system X Check and adjust idle speed X X Check and refill cooling system Twice yearly summer and winter 1 Replace fuel filter X X Clean engine X ELECTRICAL SYSTEM 12 V DC i j Check lights Check charging rate Check battery water level X Check battery state of charge X Charge wiring and connections X Check all instruments and gages X Check battery terminals and i connectors X x x x P Inspection Check Maintenance Schedule Figure l Sheet 1 of 2 lt 2 Y x 1 i 1 eed 200 HRS 400 HRS 800 HRS OR OR OR ct AAA A 5 1 MONTH 2 5 6 MONTHS ELECTRICAL SYSTEM 28 5 V DC i Check indicating light X Check operation of all instru ments meters etc X Check generator brushes for length cleanliness
82. SSY 1 20 408390 TONGUE ASSY 1 21 408399 TIE ROD ASSY LARGE 2 22 408401 TIE ROD COUPLER ASSY 2 23 408400 TIE ROD ASSY SMALL 2 24 408402 GREASE ZURK 90 4 25 408386 SPINDLE STEERING ARM ASSY RH 1 26 408395 BOLT 3 4 16 UNF X 6 00 1 408508 AXLE REAR ASSY 1 27 408403 HUBS 5 4 1 4 2 28 408404 STUD PRESS IN 1 2 20 X 1 7 8 10 29 408410 GREASE SEAL 4 30 408408 INNER OUTER BEARING CONE 4 COMPLETE BRAKE ASSY RH REAR WHEELS 1 31 408413 ELECTRICAL BRAKE RH 7 1 32 408417 SECONDARY SHOE amp LINING ASSY REAR WHEELS 1 33 408418 e PRIMARY SHOE LINING ASSY REAR WHEELS 1 Apr 15 88 Revised NOT ILLUSTRATED 4 3 Page 41 2007 This page intentionally left blank 4 3 2 m Revised 15 88 Page 42 A Aere 0M 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 17 COMPLETE BRAKE ASSY LH REAR WHEELS 1 34 408414 e ELECTRICAL BRAKE LH REAR WHEELS 1 35 408417 SECONDARY SHOE LINING ASSY REAR WHEELS 1 36 408418 e PRIMARY SHOE LINING ASSY REAR WHEELS 1 37 408407 HUB amp DRUM W CUPS amp STUDS 2 38 408764 e STUD SCREW IN 1 2 20 X 1 3 4 10 39 408411 COVER DUST 4 40 408412 NUT WHEEL 20 41 408392 NUT SPINDLE 4 42 180130 SPACER FRONT AXLE 4 Apr 15 88 Revised 4 3 43 OM 2007 Kit Trailer With Fenders Option Figure 18 Revised 15
83. T A OM 2007 Page 20 TT PSD 1 89 Full Throttle Solenoid Assembly EE OE Ape VIT mM p yO eso 0 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 10 489564 THROTTLE FULL SOLENOID ASSY REF 1 408557 SOLENOID V88136 ASSY NO 610 1 1 lA 408559 MODULE ELECTRONIC V88136 NO SS12 30A 1 2 180413 SUPPORT SOLENOID 1 3 W 11280 3 NUT 1 4 28 HEX FULL ST 2 4 DELETED 5 408534 FITTING SWIVEL SPRING V78388 NO 5 3157 1 6 12CW 2146 YOKE CLEVIS VO3504 NO 4 J 4200 1 7 W 11562 PIN CLEVIS 1 Not Illustrated Apr 15 88 Revised ss VALL lll 4 3 M 2 7 i 2 x H G Ha ru ANN NS AS Ok ee 2 007 Battery Installation p Figure lh P P A eth SUIT S Ape 15788 pasa ELLE te a ac e PE 0M 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 11 No Number BATTERY INSTALLATION For NHA See Fig 5 REF 1 180427 1 CABLE ASSEMBLY POS 1 2 491713 1 CABLE ASSEMBLY NEG 1 3 Numbe
84. TEMPERATURE V16476 No 02019 SWITCH WATER TEMPERATURE V51377 NO 1002 4880 33 DIODE ALTERNATOR V72582 NO 05100420 TEE STREET BRASS COUPLING PIPE STEEL NIPPLE PIPE 1 8 BUSHING PIPE STEEL INDICATOR RESTRICTION V18265 NO RBX00 2251 ELBOW EXHAUST DRAIN BLOCK CLAMP HOSE CLAMP ELBOW EXHAUST BOLTS STARTER NYLOK Not Illustrated 04 2007 UNITS ASSY N U m a HOBART 20 STARTING CURRENT 16 23 20 37 6 Control Panel Assembly W Shelf On Rear Figure 6 0M 2007 43 44 45 12 21 9 10 50 1083 Dec 1 85 FIGURE ITEM NO 6 14 15 16 17 18 26 27 28 29 30 31 HOBART PART NO 489263 78A 1117 1 798 1101 1 408596 1 78 1116 1 1604 2162 401428 1 400641 12 400642 3 848 1003 406040 FW 1312 W 11166 3 Y 971 20RT 353 1 25 5 156 404856 2518 7 404172 3 400613 3 402682 2518 8 404172 3 400613 4 78 1120 1 402658 30GH 1119 406815 78A 1115 1 401937 8 404065 2 W 11434 181022 1 84 1075 180289 400741 13 Aug 15 88 Revised NOMENCLATURE 1234567 CONTROL PANEL ASSY FOR NHA SEE FIG 1 GAUGE OIL PRESSURE V16476 NO 06340 TACHOMETER V33955 No 1136075 TACHOMETER V33955 No 54314 GAUGE WATER TEMP V16476 NO 06343 KNOB RHEOSTAT V44655 NO 5150 POTENTIOMETER 10K OHM 2W V44655 NO 1 031 AMMETER V60741
85. TM 0975 66T Numbers 10 or 2D I Displacement 236 cubic inches 3 86 liters Rated Power at 2400 RPM 77 Horsepower 011 Capacity with filter change 8 quarts 7 57 liters Coolant Capacity 3 5 U S gallons 13 25 liters B I Specifications and Capabilities Figure 2 Sheet 1 of 2 nae Dec 1 85 0 2007 Electrical System 12 volt DC negative ground Governed Speed at No Load 2600 50 RPM Speed 1000 50 Fuel Tank Capacity 21 5 U S gallons 81 4 liters PROTECTIVE DEVICES GENERATOR 28 5 volt overvoltage module trips at 32 to 34 volts 14 volt overvoltage module trips at 18 to 20 volts ENGINE Water Temperature Switch opens engine circuit at 225 F Low oil pressure switch opens at 20 PSI 138 kPa Specifications and Capabilities Figure 2 Sheet 2 of 2 B Options 1 A four wheel torsional spring trailer is available to add mobility to the generator set is equipped with pneumatic rubber tires a drawbar for towing and drawbar operated drum type parking brake It also includes fenders bumpers and cable trays This option is available from Hobart Brothers as Part No 488880 3 2 A four wheel torsional spring trailer is available to add mobility to the generator Set It is equipped with pneumatic rubber tires drawbar for towing and drawbar operated drum type parking brake It also includes cable hangers which are mounted on th
86. URE HOBART per ITEM NO PART NO 1234567 ASSY 3 68544 1 GENERATOR SET JET EX 4D WITH PORTABLE MTG OPTION 1 1 181000 2 TRAILER ASSY OPTION For Details See 0 181 1 2 85 1013 TIRE 5 30 X 12 WHEEL ASSY 4 3 DWP 982 BRACKET CABLE 2 Not Illustrated Page 6 Oe aes ee o TENERE uisa lp A aM Ud CHAPTER 1 DESCRIPTION OPERATION SECTION 1 DESCRIPTION 1 General The Jet Ex 4D unit covered in this manual Figure 1 is a diesel engine driven self contained generator set manufactured by Hobart Brothers Company Power Systems Division Troy Ohio U S A The basic unit is identified by a Series Number either 6854 or 6854A plus a dash number which defines a specific configuration Series number plus the dash number make up the Specification Number Specification No 6854 1 or Specification No 6854A 1 covers a stationary skid mounted unit rated at 28 5 Volts DC output It is equipped with a sheet metal canopy and hinged engine compartment door Various options are available for use with the basic unit These options are listed in paragraph 2 B below The generator sets in Series 6854A are identical in appearance constr c tion and electrical operation to Series 6854 generator sets They differ from Series 6854 generator sets in that in Series 6854A units the tachometer sending device is eliminated a different tachometer is use
87. URRENT 18 14 1 Oil Pressure Gauge 11 Contactor Control Switch 2 Tachometer 12 Contactor Closed Light 3 Water Temperature Gauge 13 Speed Control Switch 4 Current Limit Control 14 Engine On Light 5 Ammeter Generator 15 Hourmeter 6 Voltmeter 16 deleted 7 Panel Light 17 Engine Start Switch 8 Panel Lights Switch 18 Engine Circuit Fuse 9 Panel Lights Fuse 19 Engine Circuit Switch 10 Push To Build Up Voltage Switch 20 Ammeter Engine Control Panel Assembly W Enclosure On Rear Eo soo x ERN uu Boe Su ds Revised Apt 15 88 0M 2007 1 Excitation Rectifiers 2 Voltage Sensing Relay 3 Overvoltage Relay 4 Voltage Regulator 5 Voltage Regulator Fuse Voltage Regulator Support W Enclosure On Rear 2101 Figure 7 595224 Apr 15 88 Revised 1 1 This page intentionally left blank 0M 2007 Revised Apr 15 88 2 _ v DICE SECTION 2 PREPARATION FOR USE STORAGE OR SHIPPING l Preparation for Use A General The generator set is shipped with dry batteries and an empty fuel tank After the batteries are filled with electrolyte and charged the fuel tank filled and the generator set inspected the generator set is ready for use Ao 4 h CAUTION READ OPERATING INSTRUCTIONS IN SECTION 1 3 BEFORE O
88. al controls has two hinged doors on each side at the front to provide access for service and maintenance Panels at ithe rear provide access to the generator Plexiglas window is mounted above the control panel to allow observation of the instruments while protecting them from the weather The left rear panel has a round hole in it to permit viewing the fuel gage mounted in the fuel tank 6 Engine Generator and Controls A General Refer to Figure 3 The engine 4 and generator 9 are mounted on a welded steel frame 20 fuel tank support 21 located at the rear of the unit supports the fuel tank 7 and provides a mounting frame for the load contactor 14 and output terminals The radiator 1 is mounted to the front canopy heavy U bolt is attached to the cen trally located lifting yoke 5 for moving the generator set with a crane or hoist B Engine 1 General The engine used the Jet Ex 4D generator set is a Perkins four cylinder four stroke direct injection diesel engine It has a 236 cubic inch 3 86 liter cylinder displacement and a 16 1 compression ratio Engine firing order is 1 3 4 2 CM d D 2 2 1 i Bo i ES Ns 2 1 MUT 1 e 1 2 i Ps i ro mem ets tend mme nm eM gt 1272 u spring loa
89. an cloths and compressed air 4 Seal all engine openings Use a waterproof vaporproof material which is strong enough to resist puncture damage from air pressure C Long Time Storage 1 Engine Protection The Jet Ex 4D generator set may be stored for long periods if the engine is given proper protection from rust and corrosion Refer to the Perkins Diesel Users Handbook Series 4 236 for prop r procedures to be followed 2 Generator Protection To protect the generator and other electrical components the complete unit should be packaged using moisture proof packaging and sealing materials Place packages of moisture absorbing chemicals such as silica gel in the unit before packaging WARNING PLACE WARNING TAGS IN SEVERAL PLACES TO MAKE CERTAIN THAT THE INDIVIDUAL WHO TAKES THE UNIT OUT OF STORAGE IS WARNED THAT ENGINE OIL AND COOLANT HAVE BEEN DRAINED AS AA SS 1 85 1 2 yo E _ Page 3 3 Battery Care Remove batteries and store in a cool dry place Store the batteries on wood rather than directly on cement or metal 3 for Shipping Prepare the unit for shipping as follows 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 Disconnect bat
90. and Free peration X Check slip rings for smooth ness and cleanliness X 23 Check the entire unit X Check overvoltage protection X Check all wiring connections X TRAILER Lubricate Check tire inflation and adjust wheel bearings Lubricate wheel bearings X Check brake tension X P4 Inspection Check Maintenance Schedule Figure 1 Sheet 2 of 2 Every week wipe off accumulated dust dirt and oil from the engine and generator Check all parts for loose connections and wear If arcing has occurred at any electrical connections recondition them and securely refasten Check engine oil andi coolant levels Every month check generator for amperage and voltage output Blow out genetatot windings with compressed air not over 25 psi 172 kPa pressure or remove with suction type cleaner with a nozzle windings should become slightly damp use space heaters or electrical light bulbs to effectively dry out the wi dings d mpness is excessive apply external heat under a canvas cover well vented Heating should not exceed 194 F 90 C i Pound out any dents in the canopy Sand prime and repaint any dented or rusted Spots i mar m T en Ded 1 85 2 1 eet D MEM i s s A de r T
91. ant output voltage Access to the brushes is through holes in the anti drive end bracket The rotor is supported at the anti drive end slip ring end by a single row ball bearing The drive end is connected to the engine fly wheel by a flexible disc and hub coupling assembly and is supported by the engine main bearings A radial blade fan of formed and welded sheet metal construction is mounted on the coupling hub and draws cooling air over the generator windings Air enters through the anti drive end of the generator and is discharged through openings in the flywheel housing at the drive end to cool the rectifier assembly above it The generator housing assembly which contains the generator stator is bolted to the engine flywheel housing D Control Panel Assembly Figure 4 1 General The hinged control panel 8 Figure 3 houses and provides mounting facilities for controls monitoring instruments voltage regulator relays etc The panel is mounted at the rear of the canopy Its control are accessible behind a hinged Plexiglas cover 2 Lights panel lights 7 Figure 4 provide illumination for instruments and controls One green pilot light 12 glows when the output load contactor is closed and another one 14 glows green when the engine is running 3 Monitoring instruments The voltmeter 6 Figure 4 indicates generator output voltage and the ammeter 5 displays generator current A tachometer 2 displays
92. bles in cable tray provided on top of fender or on hangers on side of canopy if fenders are not used s s Preparation for Storage hen a generator set is to be stored or removed from operation special recautions should be taken to protect the internal and external parts from rust and corrosion i i i MC INEO e e 3 s eA i 1 mA 4 4 4 on A a J MN 0M 2007 General 1 The unit should be prepared for storage as soon as possible after being removed from service 2 Storage should be in a building which is dry and which may be heated during winter months 3 Moisture absorbing chemicals are available for use where excessive dampness is a problem however the unit must be completely packaged and sealed if moisture absorbing chemicals are to effective 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 This will include changing engine oil and filter elements 2 Make certain the cooling system antifreeze solution is adequate to protect below the lowest temperatures expected during the storage period 3 Clean the exterior of the engine with fuel oil and dry with cle
93. column of the parts list directly following the item name and description In case a manufacturer does not have ven dor code the name of the manufacturer will be listed in the nomenclature column CODE 02231 03504 04713 05277 07525 08452 13445 13446 14655 VENDOR S NAME AND ADDRESS Anchor Rubber Company 840 S Patterson Blvd Dayton Ohio 45402 Clark Equipment 324 E Dewey Buchanan MI 49107 Motorola Inc Semiconductor Products Div Phoenix Arizona 85008 Westinghouse Electric Corp Semi Conductor Div Hill Street Youngwood Pennsylvania 15697 Blackstone Corp 111 Allen St Jamestown NY 14701 Westinghouse 0 Box 300 Sykesville MD 21784 Cole Herse 20 Old Colony Ave Boston MA 02127 Perkins Engines Inc 32500 Van Born Road Wayne MI 48184 Cornell Dubilier 209 W Central St Natick MA 01760 4 2 CH BENE yan M Page CODE VENDOR S NAME AND ADDRESS 15605 Eaton Corporation 4201 27th St Milwaukee Wisconsin 53216 16476 Datcon Instrument Co i 0 Box 128 East Petersburg PA 17520 16764 General Motors Corp f Delco Remy Div 2401 Columbus Ave 0 Box 2439 Anderson IN 46018 18265 Donaldson Co P 0 Box 1299 Minneapolis Minn 55440 24161 Gates Rubber Co 5610 Crawfordsville Rd Suite 2002 Speedway IN 46224 2665
94. commendations below 2 Fuel system Keep system clean and free from water which may collect in a low spot in the fuel line and freeze plugging the line Fuel tanks should be kept FULL to prevent water condensation from the air above the fuel 9 J A nr A n ____ 1 85 A 1 3 4 5 6 7 Dec 1 85 qn Pl 1 Poe 04 2007 Fuel Keep fuel storage tanks or drums as full as possible to avoid condensation of moisture from the 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 any foreign matter When operating outdoors take steps to prevent the entry of snow water and ice into the fuel containers Cooling system Prior to cold weather drain and flush the cooling system to remove accumulations of rust and sediment 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 system cleaner and furnish lubrication for the water pump Lubrication Drain the crankcase preferably when warm after running and fill with a lighter grade of oil See Engine Oil Recommendations chart in the Perkins Engine User s Manual for recomme
95. d and a different brand of alternator is used The basic generator set is designed to generate and deliver 28 5 volts DC power to an aircraft when its on board generators are shut down In addition to poviding continuous regulated power to the aircraft the unit is designed for starting any fixed wing aircraft or helicopter which is equipped with an external 28 5 volt DC power receptacle Refer to Figure 2 for complete Specifications and Capabilities 22 Special Features A Standard The Soft Start current limiting feature recommended by most engine manufacturers provides the operator with a control which limits the inrush current to the aircraft engine s starter When the operator presets this control the generator will provide constant voltage to the preset currrent value more current is applied beyond the preset current value the voltage will decrease to a minimum of 14 volts DC after which the voltage will remain constant as more current may be delivered beyond the preset current value Limiting inrush current is recomienden by most engine manufacturers to protect the aircraft engine s starter shear section current limiting control is continuously adjustable from 300 amperes which is recommended for helicopter and small turbine starting to 2000 amperes required for starting larger aircraft engines when the control is turned fully clockwise Apr 1 87 Revised NE T T
96. d equipment to only two wires of the 3 phase line DO NOT CONNECT the equipment grounding conductor lead to the third live wire of the 3 phase line as this makes the equipment frame electrically HOT which can cause a fatal 3 Always connect the grounding lead if supplied in a power line cable to the grounded switch box or building ground not provided use separate grounding lead Ensure that the current amperage capacity of the grounding lead will be adequate for the worst fault current situation Refer to the National Electrical Code ANSI NFPA 70 for details Do not remove plug ground prongs Use correctly mating receptacles 2 Output Cables and Terminals Inspect cables frequently for damage to the insulation and the connectors Replace or repair cracked or worn cables immediately Do not overload cables not touch output terminal while equipment is energized 3 Service and Maintenance j E di his equiprent must be mainteined n good eiectricai end mechenicaii condition to avoid hazards stemming from disrepair Report i equipment defect or safety hazard to the supervisor and discontinue use of the equipment until its safety has been assured Repairs i Should be made by qualified personnel only Instruction 910082 1 Feb 25 86 Revised gt ee L Lom Sduad immediately s EQUIPMENT PRECAUTIONARY LABELS mese
97. d momentarily until the contactor closed light 12 glows then it is released to the center ON position In this position the switch provildes holding current to the load contactor to keep it closed Protective devices in the load contactor circuit provide protection against overvoltage by opening the load contactor if that condition occurs the bottom OFF position the contactor is opened The push to build up voltage switch 10 is a momentary contact pushbutton switch which flashes the generator fields wen 12 volt engine circuit when flashing the fields Y sN lt panel lights switch 8 Figure 4 turns the lights 7 on and off The engine start switch 17 is a momentary contact pushbutton which closes the starter relay 8 Figure 3 and the engine This switch is operable only when the engine switch 19 is held in its top spring loaded START position engine switch 19 when released from its top START positi n after the engine starts will return to center RUN position The engine ON light 14 will glow as long as the switch is in RUN position the bottom STOP position the switch will stop the engine and the light 14 will go out 1 i Refer to Figure 4 The speed control switch 13 is a two position toggle switch wired to idling device on the nginel In the IDLE position used for starting the engine speed is controlled approximatel
98. ded relief valve in the pump limits maximum pressure in the system full flow oil filter 12 Figure 3 cleans the entire output of the pump before it enters the oil distributing system valve the filter provides a bypass to oil gallery case the filter becomes clogged low oil pressure switch is mounted on the engine block as a protective device primary ignition circuit is wired through the contacts of this switch which closes at 20 PSI 138 kPa This prevents the engine from running if oil pressure will not build up and also shuts down the engine if oil pressure drops radically during operation See Figure 2 and the engine operator s manual for engine specifications The generator and engine are mounted on a welded steel skid and are enclosed by a sheet metal canopy that bolts to the skid i Access to engine serviceable components oil filter air cleaner and rectifier assembly etc is through two doors at the front on each side of the machine Two removeable panels to the right side and one to the left rear allow access to the other components such as the load contactor and output terminals The rear panel is removeable and permits access to the rectifier assembly x 2 Cooling fan The cooling fan on the engine is designed to blow air out through the radiator rather than to draw it This prevents hot air heated by the engine from entering the ge
99. e right side of the canopy This option is available from Hobart Brothers as Part No 488880 4 3 For mounting the generator set as a stationary unit a stationary mounting kit is available This kit identified as part number 489689 consists of four spacer brackets which support the unit and permit anchoring it to a floor or platform screws for fasten ing the spacer brackets to the unit and two cable hanger brackets 3 Orientation The radiator end of the Jet Ex 4D is the front Right and left are determined by standing at the rear of the unit facing it The control panel is located at the rear 1 1 Revised Aug 15 88 Page 4 24 Identification The Jet Ex 4D unit is identified by Specification numbers as described in paragraph 1 above There may be any number of generator sets with the same Specification number Individual machines are identified by Serial number assigned to one machine only Each generator set has an Identification plate attached inside the hinged control panel door This nameplate lists the machines s Model No Jet Ex 4D Specification No Serial No and electrical rating any of the options described paragraph 2 B included they will be listed by name and part number on a separate option nameplate next to the Identification plate 5 standard canopy is a sheet metal enclosure which protects the engine generator and electric
100. e Relay 3 Control Winding Rectifier 4 Voltage Regulator Fuse 5 Voltage Sensing Relay Voltage Regulator Support W Shelf On Rear Figure 3 15 88 Revised eU 200 3 1 0M 2007 HOBART JeteEX 20 OtL PRESSURE WATER TEMP SYARTING CURRENT 20 19 7 15 13 2 8 18 14 1 011 Pressure Gauge 11 Contactor Control Switch 2 Tachometer 12 Contactor Closed Light 3 Water Temperature Gauge 13 Speed Control Switch 4 Current Limit Control 14 Engine On Light 5 Ammeter Generator 15 Hourmeter 6 Voltmeter 16 Deleted 7 Panel Light 17 Engine Start Switch 8 Panel Lights Switch 18 Engine Circuit Fuse 9 Panel Lights Fuse 19 Engine Circuit Switch 10 Push To Build Up Voltage Switch 20 Ammeter Engine Control Panel Assembly W Enclosure On Rear Figure 4 2 200 7 4 3 1 Excitation Rectifiers 2 Voltage Sensing Relay 3 Overvoltage Relay 4 Voltage Regulator 5 Voltage Regulator Fuse Voltage Regulator Support W Enclosure On Rear m PN Sor ET 15 88 Revised TROUBLE SYMPTOM AND CONDITION PROBABLE CAUSE ENGINE AND CONTROLS 1 Engine will not A start Starter will not crank engine Batteries discharged A or loose battery or ground connection Engine pushbutton B start switch S401 defective Defective starter C relay L401 D Defective starter D 8401 Troubleshooting Chart Sheet a Figure B
101. e will applied when the drawbar is raised 1 on N gi 9 M ONCE ORA _ d E e co 1 51600 5 sE 4 14 1 1 an 7 i H i i a t 5 j 2 gt i amp 4 8 L 4 i H 5 1 2 E gt 22 22 i D Pi 1 1 bg i i i i ee NR _ ERR T _ me _ bMS d i cv bi 1 Ay zh CHAPTER 2 SERVICING 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 WARNING STOP OPERATIONS AT ONCE IF A SERIOUS OR POSSIBLY DANGEROUS FAULT IS DISCOVERED 2 Maintenance Schedule A General Figure provides a suggested schedule for periodic checks and services Refer to Section 2 2 for lubrication requirements B Maintenance Schedule Check Sheet It i
102. ed when all cells are gassing Dec 1 85 fma lt cma 0M 2007 3 Inspect slip rings whenever brushes are removed for servicing brushes or brushholders Note surface conditions of rings Surface should appear smooth and clean Scoring or roughness of slip rings may be caused by grit or abrasive substance in brushes or by oil on the rings Moderately rough slip rings be smoothed by holding grade 00 flint paper against their surface while the rings are revolving slowly If the rings are badly scored the unit must be sent to an overhaul facility for repair After cleaning slip rings blow dirt and grit out of the unit with compressed air Do not use over 25 psi 172 kPa air pressure to blow dirt out 4 Slip new brushes into brushholder guides and place caps on top and screw them into the guides to a bottomed position The spring attached to the brush will determine the pressure at which the brush contacts the slip rings 5 To fit new brushes to the slip rings lay a strip of No 00 sand paper smooth side down on slip ring surface and draw the sand paper in the direction of rotation of the slip ring lifting the brush on the return stroke Continue until the brushes have same curvature as the slip rings Blow all carbon dust out of the machine using not over 25 psi 172 kPa air pressure Apr 15 88 Re ised tn 272 1 AL
103. erator controls and instruments require periodic lubrication few drops of oil may be required on door hinges occasionally to insure free and quiet operation E Engine Although the engine and its accessories require more attention than any other similar installation they still inherently require a me Jot portion of the generator set lubrication and maintenance Recommendations regarding engine lubrication have been taken fromi the Perkins Diesel Users Manual for Series 4 236 engines Dec 1 85 m 2 2 Az ia a saw sasa EE LER RR Z DEAN ENE RL 2007 Draw Bar BM 1 Pivot Pin BM 1 Tie Rod BM 1 Tie Rod BM 1 Tie Rod BM 1 King Pin BM 1 King Pin BM 1 Wheel Bearing SA 3 Wheel Bearings SA 3 Lube Oil Filter M Fuel Filter SA 12 Fuel Filter SA Wheel Bearing 3 Wheel Bearings SA 3 Check crankcase oil daily change 200 hours Change oil filter after 200 hours Lubrication Chart U o ect Figure 1 2 2 nto ic o Revised May 11 87 2 1 ba Sara A 1 SYMBOL 1 Dec 1 85 04 2007 Be ENTENDU RUNE 2 1 Tete NAME SPECIFICATION NOTES Grease Automtive Federal Sinclair Litholene and Industrial 632 Industrial No 2 Mobil Mobilplex 47 equivalent Oil Engine Heavy MIL
104. fective engine switch S404 Choked fuel filter restriction in air cleaner or air in fuel system 5 Engine does not attain normal idle RPM or idles too fast Idie speed set either too high or too low Loose throttle link age 19 4 MN M RA Revised Apr 15 88 0 2007 TEST CHECK AND REMEDY Turn on fuel shutoff valve Connect a jumper wire across the C and No terminals of oil pressure switch Start engine and check oil pressure If it is below 10 PSI 69 kPa shut down the engine and check lubrication system for leaks Check also the oil pump Tf oil pressure comes up to normal and the engine continues to run the oil pressure switch is defective Replace oil pressure switch If oil pressure switch is good proceed to Step C Place a clip lead jumper wire on the water temperature switch terminals If engine then starts properly replace water temperature switch If not replace engine switch Check for these faults ac cording to instructions in Perkins Diesel User s Manual Adjust idle speed to approxi mately 1000 50 RPM If solenoid core is pulled into the full throttle sole noid L403 when S406 is in RATED RPM position check for loose control wire between solenoid and throttle Tighten if required solenoid core does not pull in proceed to step C TROUBLE SYMPTOM AND CONDITION PROBABLE CAUSE ENGINE AND CONTROLS Cont d
105. hart 1 3 Equipment for troubleshooting 1 4 Safety 1 5 Diagrams 2 6 Illustrations 3 1 2 7 Connections and Wiring 2 Illustrated Parts List 4 0 1 1 General 4 1 1 2 Purpose 1 3 Arrangement 1 4 Explanation of Parts List 1 Contents 1 B Parts List Form 1 1 Figure Item No Column 1 2 Hobart Part Number Column 2 3 Nomenclature Column 2 4 Effective Column 2 5 Units Per Assembly Column 2 Manufacturer s Codes 4 2 1 1 Explanation of Manufacturer s Vendor Code List 1 Parts List 4 3 1 1 Explanation of Parts List Arrangement 11 2 Symbols and Abbreviations pua NEN S ENT cx Dec 1 85 Contents ___ 7 Es 0M 2007 TABLE OF CONTENTS CONTINUED SUBJECT CHAPTER SECTION PAGE Numerical Index 4 4 1 1 Explanation of Numerical Index 1 Optional Equipment 5 0 1 Manufacturer s Literature 6 0 1 LIST OF ILLUSTRATIONS CHAPTER FIGURE PAGE SECTION NUMBER TITLE NUMBER 1 1 Jet Ex 4D Generator Set 2 1 1 2 Specifications and Capabilities Sheets 1 and 2 3 4 1 1 3 Generator Set Components 7 1 1 4 Control Panel Assembly W Shelf On Rear 12 1 1 5 Voltage Regulator Support Shelf Mod 13 1 1 6 Control Panel Assembly W Enclosure On Rear 14 1 1 7 Voltage Regulator Support Enclosure Model 15 1 2 1 28 Volt Output Terminal Panel 4 1 2 2 Stationary Unit Mounting Holes 5 1 3 1 Operating Controls and Indicators 2 2 1 1 Inspection Check Mainte
106. his page intentionally left blank Dec 1 85 Page 4 emu o 2 DM SECTION 2 MAINTENANCE PROCEDURES l General A suggested Maintenance Schedule is provided in Section 1 of this Chapter Each step of the schedule is also covered in general in Section 1 ius Section covers maintenance in more detail where necessary WARNING STOP OPERATION IMMEDIATELY IF SERIOUS OR POSSIBLY D NGEROUS FAULT IS DISCOVERED 2 Lubrication A General Proper lubrication is one of the most important steps in good x maintenance procedure Proper lubrication means the use of correct lubricants and adherence to a proper time schedule Lubrication points frequency of lubrication and recommended lubricants are indicated in Figure 1 B Lubrication Chart Lubrication points are illustrated and identified by name on Lubrication Chart Figure 1 Number symbols used to designate the kind of lubricant required and the specification recommended identified in Figure 2 Letter symbols used to designate the normal lubrication period are identified in Figure 3 C Generator The 28 5 volt DC generator requires NO lubrication The armature is supported at the rear by a single ball bearing which is lubricated and sealed at the factory for lifetime maintenance free operation The front end of the armature is supported by the engine main bearings i D Generator Controls Gen
107. iewing Chamber Air Cleaner Cartridge Replacement Figure 5 6 Engine Cooling System A General NOTE Refer to the Perkins Diesel User s Manual in Chapter 6 for detailed instructions on servicing the engine s cooling system During warm weather operation when plain water is used as coolant the cooling system MUST be protected against rust by a rust inhibitor additive During cold weather operation the system MUST be protected against freezing The system should NEVER be operated on plain water without a rust inhibitor or antifreeze i WARNING WHEN REMOVING THE CAP FROM A VERY HOT RADIATOR COVER THE CAP WITH THICK CLOTH AND TURN IT SLOWLY COUNTERCLOCKWISE TO THE FIRST STOP WHEN PRESSURE IS COMPLETELY RELEASED PRESS DOWNWARD AND FINISH REMOVING T rent et 1 85 yp re _ _ CAUTION DO NOT ADD COOLANT TO AN EXTREMELY HOT ENGINE THIS CAN RESULT IN A CRACKED BLOCK OR CYLINDER HEAD Use only a corrosion inhibitor that is compatible with aluminum not use inhibitors labeled as acid neutralizer Antifreeze A permanent type Ethylene Glycol antifreeze is recommended for use in the cooling system The coolant when mixed as equal parts of water and i l Rust Inhibitor 6 I 1 the recommended antifreeze will provide protection to 35 degrees
108. ilable to add mobility to the generator set It is equipped with a drawbar for towing and a hand lever actuated parking brake It also includes cable hangers which are mounted on the right side of the canopy This option is available from Hobart Brothers as Part No 181000 2 Jet Ex 4D Generator Set With Prototype Trailer Page 2 ne Y B n 1 ADDENDUM NO Generator Set W Portable Mounting and Fenders Option a 3 FIGURE ITEM NO 2 oO E GW Re MO HOBART PART NO 6854A 1 181000 1 408665 1 181006 181007 181010 181009 181013 181011 181008 181012 ADDENDUM NO 1 NOMENCLATURE 1234567 GENERATOR SET W PORTABLE MTG AND FENDERS OPTION TRAILER ASSY OPTION For Details See TO 181 REFLECTOR RED FENDER LEFT OPTION FENDER RIGHT OPTION BRACKET MTG FENDER RT FRONT amp LT REAR OPTION BRACKET FENDER LT FRONT amp RT REAR OPTION BRACKET MIG FENDER RT CENTER OPTION BRACKET MTG FENDER LT CENTER OPTION SUPPORT FENDER REAR OPTION SUPPORT FENDER FRONT OPTION UNITS per ASSY IN ADDENDUM NO 1 PSD 13 Generator Set W Portable Mounting Option Figure 3 s me ADDENDUM NO 1 NOMENCLATURE UNITS FIG
109. ime or Defective engine start switch S404 or Defective fuel valve solenoid L404 Defective fuel pump 0M 2007 TEST CHECK AND REMEDY CAUTION MAKE CERTAIN THAT ENGINE START SWITCH IS IN STOP POSITION SO THAT ENGINE DOES NOT START Use a socket wrench on the front crankshaft pulley to try to turn engine by hand If engine will not turn internal damage is indicated NOTE If engine is over charged with ether for cold weather starting it could seize up If So wait approximately 1 2 hour until it will be possible to turn engine Replace engine circuit fuse 18 Fig 2 Use type AGC 20 fuse Check and correct required Check for 12 V DC from ter minal 4 of S404 to ground with S404 in START position If 12 V DC is not measured replace defective switch Attempt to start engine while applying 12 V DC to the fuel valve solenoid the engine starts the solenoid is defec tive and should be replaced engine still doesn t start proceed to Step D Check fuel pump according to instructions in the Perkins Diesel User s Manual TROUBLE SYMPTOM AND CONDITION PROBABLE CAUSE ENGINE AND CONTROLS 3 Engine starts then stops A Fuel not turned on B Defective oil pres sure switch S403 located on engine block 4 Engine starts then stops when engine switch S404 is re leased to ON position Open overtemperature switch S402 or de
110. ise for three successive readings taken at hourly intervals b If the battery starter test indicated that battery voltage was below the acceptable voltage value test each cell with the hydrometer the difference in specific gravity readings between any two cells is 50 points 0 050 or more the battery isn t satisfactory for service and should be replaced Generator Maintenance A General The only maintenance service required for the generator will be brush replacement slip ring cleaning etc B Brush Service 1 Cleaning If inspection reveals that brushes are gummy or sticking in the brushholders they should be removed and cleaned Clean both the brushes and brushholders Use a good SAFE commercial cleaner DRY ALL PARTS THOROUGHLY sure brushes can move freely in brushholders WARNING DO NOT USE A FLAMMABLE SOLVENT NOT USE STEAM CLEANER OR SOAPS AND DETERGENTS UNDER PRESSURE C Generator Revolving Field Brush Replacement See Figure 6 1 Disconnect leads from connectors on brushholder caps CAUTION 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 2 Lift brush D from brushholder C for inspection brushes are worn unevenly or are shorter than 7 16 inch 11 mm replace them e E t ty H e NOTE The battery is fully charg
111. ition or operation of the equipment Among such conditions are 1 Exposure to A Combustible explosive abrasive or conducting dusts B Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation C Chemical fumes flammable or explosive gases D Nuclear radiation E Steam salt laden air or oil vapor or very dry locations radiant heat vermin infestation or atmospheres conducive to fungus growth B Mant nes Fr 4 i Abnormal shock vibration or mechanical loading from external sources during equipment operation x H Abnormal axial side thrust imposed on rotating equipment shafts 1 i i i I Low and or high ambient temperatures i i 1 High electromagnetic fields 2 Operation at i i Voltages above or below rated voltage i Speeds other than rated speed C Frequency other than rated frequency D Standstill with rotating equipment windings energized E Unbalanced voltages F Operation at loads greater than rated i 3 Operation where low acoustical noise levels are required i 4 Operation with 1 A Improper fuel lubricants or coolant Parts or elements unauthorized by the manufacturer i C Unauthorized modifications i 5 Operation in poorly ventilated area
112. kins Engine User s Manual in Chapter 5 for instructions Clean radiator core fully Refer to Perkins Engine User s Manual 0M 2007 TROUBLE SYMPTOM AND CONDITION PROBABLE CAUSE TEST CHECK AND REMEDY ENGINE AND CONTROLS Cont d 8 Engine overheats C Fan belt slips or is C Tighten belt or replace as continued broken required 3 1 eae wats Revised Apr 15 88 0M 2007 TROUBLE SYMPTOM AND CONDITION PROBABLE CAUSE TEST CHECK AND REMEDY GENERATOR AND CONTROLS 1 Generator will not build up voltage at all Flashing power not A reaching generator revolving field L406 Check as follows when push to build up volt 1 Defective push to 1 Momentarily connect two age switch build up voltage jumper leads across the S407 is switch S407 push to build up voltage operated contacts stuck in switch one lead across Engine running open position the terminals on the left normally side and the other lead across the terminals on the right side If the voltage builds up replace switch 2 Defective diode 2 Use ohmmeter to check CRA01 diode on back of push to build up voltage switch Replace diode if defec tive 3 Excessive brush 3 Check brushes closely for Apr 15 88 Revised wear or poor contact of brushes to slip rings Voltage sensing relay B 406 defective Relay contact 1 7 or 3 9 stuck in open position
113. l text is identified by a heavy black line in the left hand margin Illustrations follow a numbering system similar to page num bering The first Figure in each Section is Figure 1 lt s A AKEnAYK Hj gt ll tables charts and diagrams as well as illustrations are identified by igure numbers to avoid confusion ee 5 1 85 i NER ma 1 Reve 2 1 A V T The general location of any information can be found quickly by running through the Table of Contents For example locate 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 of the text referred to by identifying the paragraph in which the referenced material be found When referenced material is located in the same Chapter Section as the reference only the paragraph identification 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 and the paragraph identification are given for example Ref 1 2 Para 1 A
114. ler is parked When the 18 7 Optional Equipment x raised it applies the brakes on the rear wheels 0M 2007 HOBART 6 TACHOMETER OIL PRESSURE WATER TEMP STARTING CURRENT i 9 18 14 1 011 Pressure Gauge 11 Contactor Control Switch 2 Tachometer 12 Contactor Closed Light 3 Water Temperature Gauge 13 Speed Control Switch 4 Current Limit Control 14 Engine On Light 5 Ammeter Generator 15 Hourmeter 6 Voltmeter 16 deleted 7 Panel Light 17 Engine Start Switch 8 Panel Lights Switch 18 Engine Circuit Fuse 9 Panel Lights Fuse 19 Engine Circuit Switch 10 Push To Build Up Voltage Switch 20 Ammeter Engine Control Panel Assembly W Shelf On Rear Figure 4 nm 1 1 22 o o Revised Apr 15 88 2007 The rear axle is also a solid beam type rear wheels are mounted to the axle by means of torsional springs and they have drum type brakes 5 3 TOP VIEW 4 BOTTOM VIEW 2 1 Voltage Regulator 2 Overvoltage Relay 3 Excitation Rectifiers 4 Voltage Regulator Fuse 5 Voltage Sensing Relay Voltage Regulator Support W Shelf On Rear et L57889 Revised uu nodo e RM 0M 2007 HOBART 7 7 5 0 OIL PRESSURE WATER TEMP STARTING C
115. lled water Do not use hydrant water or any water which has been in contact with amp metal container Acid should never be added except by a skilled battery man NOTE It is especially important to keep the batteries at full charge for cold weather operation Add distilled water to the batteries in freezing temperatures only when the engine is to operate for several hours to thoroughly mix the water and the 2 i If the top of the batteries are dirty they 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 cleaning solution from entering cells Clean batteries as required and cleaning solution Flush off the batteries with clean water Brighten terminal and post surfaces with steel wool wire brush or special terminal cleaning tool certain that vent holes in filler caps are not clogged i i CAUTION NEVER ADD ANY SPECIAL BATTERY DOPES SOLUTIONS OR POWDERS I electrolyte in each cell should be above the plates at all times to x E Cleaning the Batteries Testing Battery Tests made on battery to determine the state of charge and also its condition The results of these tests show whether the battery is good needs recharging or must be replaced a batte
116. lustrates main assemblies sub assemblies and detail parts of the Jet Ex 4 Generator Sets manufactured by Hobart Brothers Company Power Systems Division Troy Ohio 45373 I 2 Purpose purpose of this list is to provide parts identification and descriptive information to maintenance and provisioning personnel for use in provilsion ing requisitioning purchasing storing and issuing of spare parts 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 Contents The parts list contains a breakdown of the equipment into groups assemblies subassemblies and detail parts All parts of the equip ment are listed except 1 Standard hardware items attaching parts such as nuts screws washers etc which are available commercially 2 Bulk items such as wire cable sleeving tubing etc which are also commercially available 3 Permanently attached parts which lose their identity by being welded soldered riveted etc to other parts weldments or assemblies B Parts List Form This form is divided into six columns Beginning at the left side of the form and proceeding to the right columns are identified as follows Dec 1 85 4 1 v RC A eRe Se vet ORTOS oes hk B H prend TTE IEICE
117. means that the referenced material is located in Chapter Section 1 2 and paragraph 1 A within that Chapter Section H 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 appears are given for 1 2 Fig 3 refer to item number 2 in illustration Figure 3 of the Chapter Section When a referenced figure appears in another Chapter Section the reference will include the Chapter Section number for example 2 3 1 Fig 4 tells the user that the information is in Chapter Section 2 3 ind refer to item 1 in Figure 4 Once a Figure number reference has been established the Figure number is not repeated and only the item numbers 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 Figure number mentioned in the text A of manufacturer s literature is supplied as part of the informa tion package If you have any questions concerning your Hobart Power Systems Division equip ment you are invited to contact our Service Department by mail telephone or TWX Write Hobart Brothers Company Power Systems Division Service Department Troy Ohio 45373 U S A
118. n more than one model of equipment is covered by a parts list there are some parts which are used on only one model This column is used for insertion of a code letter A B etc to indicate these parts and to identify the particular model they are used on This column is not used in this manual as this manual covers only one model Uncoded parts are usable on all models Parts coded A are usable on Specs 6854 1 Parts coded B are usable on Specs 6854 1 Parts coded C are usable on Specs 6854A 2 RA viens agn aqa pce ct eno 0M 2007 5 UNITS PER ASSEMBLY Column This column indicates the quantity of parts required for an j assembly or subassembly in which the part appears This column does not necessarily reflect the total used the complete end item E PRE U ee nee enact yg 42 Am aa mas AA A KA De Page 3 This page intentionally left blank o 04 2007 Revised Apr 15 88 A E 0M 2007 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 addres ses for suppliers of purchased parts listed in this publication The codes are in accordance with the Federal Supply Codes for Manufacturer s Catalog ing Handbook 4 1 and are arranged in numerical order Vendor codes are inserted in the nomenclature
119. n of generator set to push to build see if problem is corrected up voltage If not proceed to Step B switch is depressed B Defective control B Check control winding rec winding rectifier tifiers 3 Fig 3 with an ohmmeter to see if they are good either rectifier is defective replace it If both rectifiers are good proceed to Step C C Generator voltage C Replace voltage regulator regulator VR402 1 Fig 3 defective 3 1 2 21245012 Revised Apr 15 88 2007 TROUBLE SYMPTOM AND CONDITION PROBABLE CAUSE TEST CHECK AND REMEDY GENERATOR AND CONTROLS Cont d 3 Generator volt Voltage sensing relay Remove voltage sensing relay age builds too K406 defective 5 Fig 3 from its socket high a voltage Relay coil is open or and apply 24V DC to the coil contacts 1 7 and 3 9 terminals A and B Using stuck in closed an ohmmeter check to see that position contacts open and close properly If voltage sensing relay is defective replace it If not proceed to Step B Defective voltage Replace voltage regulator regulator VR402 2 Fig 3 with a voltage regulator known to be good and resume operation of generator set If new voltage regulator produces normal operating voltage send old voltage regulator to factory for service 4 Load contactor CAUTION DO NOT OPERATE THE GENERATOR SET TO DELIVER POWER will not close TO AN AIRCRAFT WHEN ANY PROTECTIVE DEVI
120. nance Schedule Sheets 1 and 2 2 3 2 2 1 Lubrication Points 2 2 2 2 Lubricants 3 2 2 3 Symbols and Time Intervals 3 2 2 4 Temperature and Oil Viscosity Chart 4 292 5 Air Cleaner Cartridge Replacement 7 2 2 6 Generator Revolving Field Brushes 12 2 3 1 Operating Controls and Indicators 2 2 3 2 Idle Speed Adjustment 3 2 3 2 Voltage Regulator Adjustment 5 3 1 1 Generator Set Components 3 3 1 2 Control Panel Assembly W Shelf On Rear 4 3 1 93 Regulator Support 1 5 1 Contents o __ 2 2 e Revised Apr 15 88 0 2007 LIST OF ILLUSTRATIONS CHAPTER FIGURE PAGE SECTION NUMBER TITLE NUMBER 3 1 4 Control Panel Assembly W Enclosure On Rear 6 3 1 5 Voltage Regulator Support 7 3 1 6 Troubleshooting Chart 8 18 4 3 1 Generator Set Stationary Assy 2 4 3 2 Generator Set with Portable Mounting and Fenders Option 4 4 3 3 Generator Set with Portable Mounting Option 6 4 3 4 Canopy Assembly 8 4 3 5 Generator Set Without Canopy 10 4 3 6 Control Panel Assembly W Rear Shelf 14 4 3 7 Control Panel Assembly W Enclosure on Rear 18 4 3 8 Support Rectifier and Fuel Tank Assy 22 4 3 9 Output Terminal Panel Assembly 24 4 3 10 Full Throttle Solenoid Assy 26 4 3 11 Battery Installation 28 4 3 12 Fuel System 30 4 3 13 Fuel and Return Lines Assy 32 4 3 14 Cooling System 34 4 3 15 Rectifier Assembly 36 4 3 16 Brushholder Assembly 38 4 3 17 Kit Trailer Without Fenders Option 40 4 3 18 Kit T
121. nc United Carr Div 31 Burlington Mall Rd Burlington MA 01803 70411 Anderson Brass Co 100 S Campbell Ave Detroit MI 48209 71400 Bussman Division of McGraw Edison Company 114 Old State Rd St Lou s Missouri 63178 EEIPEIPDMTcX EE A A P __ m m TROD RTE RE mM I QE lt VENDOR S AND ADDRESS 74465 Hoof Products 4051 W 5156 St Chicago IL 60632 74559 Carling Switch Co 505 New Park Ave West Hartford CT 06110 75175 K D Lamp Co 1910 Elm St Cincinnati OH 45210 76700 Nelson Muffler Corp Stoughton WI 53589 77343 Potter amp Brumfield Inc 200 Richland Creek Drive Princeton IN 47671 78189 Illinois Tool Works Inc St Charles Rd Elgin IL 60120 78225 Stant Manufacturing Co 1620 Columbia Ave Connersville IN 47331 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 78940 United Air Cleaners 9705 S Cottage Grove Ave Chicago IL 60628 79409 Woodhead Daniel Co 3411 Woodhead Dr Northbrook IL 60062 81640 Eaton Sarasota FL 33580 ERA T Yk 7 n r Irs j ZA 12 22222 1
122. nded viscosity for various atmospheric temperatures cold weather drain oil more frequently Water condenses and collects quickly mixes with the oil and increases deposits to form a sludge Check oil frequently for this condition Water in crankcase or oil lines may freeze and cause serious damage to the oil pump or shut off the oil supply Electrical system In cold weather the most efficient electrical system is needed to start the cold engine Check the entire system for loose connections or indication of bad wiring or shorted conditions Battery Battery efficiency decreases sharply with lower temperatures Maintain the specific gravity of the battery between 1 275 and 1 300 fully charged condition Make sure of full charge before attempting to start engine in sub zero conditions i x 2 i MEN Operation Hot and Humid Conditions e i t 1 E s 1 Cooling system Maintain a more frequent check of the coolant level in the radiator 2 Battery The specific gravity and proper level of the battery electrolyte should be maintained Observe recommendations in the Perkins Diesel User s Manual for proper care of the battery I Operation in Extremely Dusty Conditions If unit is to be operated under dusty out of door conditions place in a sheltered area Take advantage of any natural barriers which may offer protection from blowing du
123. nerator arre 3 Fuel system fuel system consists of 21 5 11 81 4 liters tank 7 Figure 3 with all the necessary fittings and hoses i 4 Alternator and regulator The battery charging alternator 16 Figure 3 is rated at 42 amperes on Series 6854 generator sets and at 62 amperes on Series 6854A generator sets voltage regulator is an integral part of each of these alternators 5 Starter relay The starter relay 19 Figure 3 is mounted on the starter motor 18 on the right side of the engine 6 Exhaust muffler 3 Figure 3 This muffler helps deaden audible noise from the engine s exhaust i 1 1 d RR cares EET EU te M 1 1 Revised Apr 1 87 O A 14 Load contactor Generator Set Components Figure 3 2 P i M iN br SARI S ET i i NE 22 i LEFT SIDE VIEW I 24 12 23 2 9 3 N 1 8 Q x EL x5 E 1 ee E d SER TUA Un e N 5 HS TL DEDE SI
124. ort It consists of two aluminum heat sinks with twelve diodes on each heat sink The negative heat 51 assembly is mounted nearest to the fuel tank and the positive heat sink assembly is mounted nearest to the engine rectifier assembly converts the AC output of the generator to 28 5 V DC H Ammeter Shunt The ammeter shunt is connected in the generator s negative output circuit It supplies a small voltage proportional to output current for operation of the generator ammeter 5 Fig 4 and for sensing output current for the current limit circuit of the voltage regulator 1 Fig 5 This shunt is mounted on the negative heat sink of the rectifier assembly 6 Fig 3 i Trailer The portable Jet Ex 4D is mounted an optional four wheel trailer see Figure 1 which consist of front and rear axle assemblies The axles are mounted directly to the main frame of the generator seti It is available with or without the fenders bumpers and cable trays The front axle is a solid beam type Front wheels are mounted on spindles which are operated by tie rods connected to the hitch and drawbar assembly The spindles are mounted to the axle by means of torsional springs em ms lt x x x Any side to side movement of the drawbar turns the wheels in the direction of travel The drawbar can be folded upward and locked in the vertical position when the trai
125. r NUT PLAIN HEX 5 16 18 2 4 No Number WASHER FLAT 5 16 IN 4 5 491687 BATTERY CLAMP 2 6 491688 1 CLAMP BATTERY 1 7 402087 1 BATTERY 12V 2 8 W 9360 229 CABLE BONDING 1 UST ca 4 3 Page 29 E e EV HAE 0M 2007 Fuel System uc M M LA LLL RPSL B A M Ee Se ERROR ENEMIES E I jaca con 0 2007 NOMENCLATURE UNITS FIGURE HOBART per ITEM NO PART NO 1234567 ASSY 12 No Number FUEL SYSTEM For NHA See Fig 5 REF 1 489169 TANK FUEL ASSY 1 2 76 1152 CAP FUEL TANK V49234 NO 1275 1 3 5CW 3420 1 GUAGE FUEL TANK l 4 486567 3 STRAP FUEL TANK ASSY 2 5 483630 INSULATION STRAP FUEL TANK 2 6 489593 LINES FUEL amp RETURN ASSY For Details See Fig 12 1 7 79 1127 2 GUARD FILLER NECK C 1 Not Illustrated Apr 15 88 Revised 20 TS 4 3 _ E SZ NR ERS aoe a m Pp bo Tur 22 St es HU musasasa asa s m t M 2 007 2 4 23 TO PRE FILTER 2 3 4 FILTER FUEL LINE cat RETURN LINE TO FUEL TANK TO FUEL TANK Fuel and Return Lines Assembly Cum Figure 13
126. railer With Fenders option 44 4 3 19 Lifting 8 Frame Assembly 48 4 3 20 Generator Assembly 50 Apr 19 00 Revised o oi iab as CONTENTS 9 em e Meis HM T ASA aem Haa A o x Dec 1 85 This page intentionally left blank ERA O Mi O t ccc M t m Ta 5 V y 4 H b Nos w m duds Ni I ak ais cet ADDENDEM NO 1 JET EX 4D OPTIONAL PROTOTYPE TRAILER ASSEMBLY KIT 181000 This Addendum along with TO 181 Chap 5 covers Kit Prototype Trailer with Fenders Jet Ex 4D is offered with a choice of two different trailers both of which are optional Henschen Trailer With or Without Fenders Part Number 488880 All References to the Trailer and Fenders OM 2007 Pertain to the Henschen Trailer Prototype Trailer With or Without Fenders Part Number 181000 reference this Addendum and 0 181 ADDENDUM NO 1 1 A four wheel trailer is available to add mobility to the generator set See TO 181 for Details It is equipped with a drawbar for towing and a hand lever actuated parking brake also includes fenders that can be used as cable trays This option is available from Hobart Brothers as Part No 181000 1 2 A four wheel trailer is ava
127. ry helpful in troubleshooting parts replacement etc P Ld I ins 223 Le gt a 7 7 d e E pm T s em ne cee 5 ENSE MN gt H E mum em gt cm M M S 2007 i CRAS SI ee A MEM C NS Bs 5 Diagrams Eod 6 Illustrations aid maintenance personnel with troubleshooting three illustrations are provided in this section showing the locations of various components of the generator set i Connections and Wiring MM Before condemning any electrical component check all connections and wiring which could affect its operation In many instances a component may be non functional simply because it is not receiving power because of a loose connection or a poor ground most cases throughout the troubleshooting chart it will be assumed that connections and wiring have been checked i i Mm rr ce T erp mA a 4 1 H B 48 eem BORN RET i i a ME 1 mmi 9 ml ETA m WL gt i i TE M E a a i i P L Q
128. ry has failed is low in charge or requires water frequently the reason for the condition must be found and corrected Visually inspect the batt ry 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 battery damage cracked case etc The battery may be tested by two methods A battery starter Tester may be used to determine the battery s ability to deliver current A battery hydrometer test determines the charge condition of the battery i i Connect battery to the tester according to instructions furnished with the instrument Test battery according to tester 1 umm i 1 Test with Battery Starter Tester instructions the test determines that the battery has acceptable voltage this indicates that the battery has output capacity and will accept a charge if required l with Hydrometer a Remove filler caps and check the specific gravity of the electrolyte in each cell If specific gravity is 1 230 or below add water if necessary and charge the battery until it is fully charged fully charged battery will give a specific gravity reading of 1 265 to 1 285 specific gravity of a fully discharged battery may range from 1 140 down to 1 120 freely and the specific gravity ceases to r
129. s Ed NI A gt em
130. s strongly recommended that the customer use a maintenance schedule check sheet The check sheet will provide a record of maintenance operations performed and may also serve to improve scheduling for a specific operation C Time Intervals The schedule is based on both hours of operation and calendar intervals These two intervals are not necessarily the same The calendar period is included to make certain services are performed regularly when equipment is being operated infrequently or at irregular intervals Hourly time intervals agree with the engine manufacturer s recommendations Perform all services on a whichever comes first basis NOTE Refer to the Perkins Diesel User s Manual for detailed engine maintenance information 23 Engine and Related Components See the Perkins Diesel User s Manual for Series 4 236 engines 4 Inspection and Cleaning Every day check for oil coolant or fuel leaks Also check for pose electrical connection Check pressure with engine running at rat d RPM 2600 Do not operate engine if oil pressure is less than 15 psi Wipe accumulated water off from all electrical connections and instruments Make sure that the alternator ammeter is not discharging which xd s that the battery is being charged MT MEE I P mq THES II E 2232 2223 3 eer 21 32 22 Dec 1 85 cad 22 4 200 400 HR
131. st the installation is more than temporary erect a protection shield 1 Fuel system Change the fuel filter at prescribed intervals and keep fuel containers covered and protected against dust entry 2 Oil filter and air cleaner These both need more frequent attention under dusty conditions Check air cleaner daily Replace oil filter cartridge as needed 3 Crankcase The crankcase oil level will bear close attention Dusty conditions tend to load crankcase oil with dirt Watch for dirty and gritty oil conditions and change oil more frequently as required J Operation in Salt Water Areas 1 Canopy Wash canopy regularly to remove salt film Repaint any damaged places and oil the side panel hinges regularly 2 Covering To protect the engine and generator as much as possible from salt water atmosphere keep the side panels on the canopy closed when not in use is advisable to keep the unit covered with a tarpaulin if available while in operation Salt water should be wiped from the engine and all terminals and connections in the electrical system wiped dry Keep all linkage oiled Dec 1 85 MAMMA mnt ee r een ne annem Rt a The brushes of the generator should be inspected regularly td make certain that they are free in the holders Lift the brushes in the brushholders about every two days to insure their freedom to slide within the holder Wipe dry all the parts
132. stment each 800 hours or semiannually Use a good quality bearing lubricant See Fig 2 Servicing the Air Cleaner efer to Figure 5 The air cleaner is a dry type with replaceable filter artridges A definite time schedule for changing the filter cartridge annot be determined because of varying operating conditions Change the ilter cartridge when the red indicator flag becomes fully visible in the iewing chamber 9 and locks in that position Change the cartridge as ollows Cartridge Removal 1 Open left front canopy door to gain access to the air cleaner 2 Remove clamp assembly 3 from air cleaner and remove cup assem bly 8 with the baffle 7 3 Remove wing nut 6 and washer gasket 5 4 Remove cartridge 4 and replace it with a new cartridge CAUTION DO NOT ATTEMPT TO CLEAN OR RE USE OLD CARTRIDGE 5 Inspect the interior of the cleaner housing 1 Make certain that it is free from all foreign material Cartridge Installation Jm sme mme ma mne EM 1 Carefully install the new cartridge into the housing Avoid bumping the cartridge tubes against the housing sealing flance Seat the cartridge properly within the housing Press all edges and corners of the cartridge firmly with fingers to make a x positive air seal against the sealing flange of the housing M m in a ame mt
133. t the voltage regulator 1 Fig 3 while observing voltmeter 6 Fig 2 Start with a low voltage 25 V DC and gradually increase voltage until relay functions to open load contactor If relay trips at less than 32 V DC replace relay 2 Fig 3 and return old relay to factory for service no fault was found in Step replace load contacts 22 Fig 1 Shut down engine and check current limiting potentiometer 4 Fig 2 with an ohmmeter To do this disconnect plug from generator voltage regulator l Fig 3 and take resistance measurements from pin 2 to pin 9 and then from pin 2 to p n 10 on the plug For each measurement slowly turn potentiometer through its entire range while observing ohmmeter readings Replace potentiometer if defective If it isn t defective proceed to Step B Replace voltage regulator with one known to be good and then operate the generator set under sufficient load to observe current limiting If current limiting potentiometer now controls current properly send old voltage regulator to factory for service 3 1 Page 17 0 2007 This page intentionally left blank 3 1 ET TT 9 Revised Apr 15 88 Page 18 N 4 E AAA A AA RAN P Mix aaa 0M 2007 CHAPTER 4 ILLUSTRATED PARTS LIST SECTION 1 INTRODUCTION 1 General 51 illustrated Parts List identifies describes and il
134. teries Batteries may explode and or give off flammable hydrogen gas The acid and arcing from a ruptured battery can cause fires and additional failures When servicing do not smoke cause sparking or use open flame near the battery 3 Engine Fuel Use only approved fuel container or fueling system Fires and explosions can occur if the fuel tank is not grounded prior to or during completely fill tank because heat from the equipment may cause fuel expansion overflow Remove all spilled fuel IMMEDIATELY including that penetrates the unit After clean up open equipment doors and blow fuel transfer Shut unit DOWN before removing fuel tank Do not fumes away with compressed air TOXIC FUME PREVENTION Carbon monoxide Engine exhaust fumes can kill and cause health problems Pipe or vent the exhaust fumes to a suitable exhaust duct or outdoors Never locate engine exhausts near intake ducts of air conditioners BODILY INJURY PREVENTION injury result from contact with fans inside some equipment Shut DOWN such equipment for inspection and routine maintenance When equipment is in operation use extreme care in doing necessary troubleshooting and adjustment o not remove guards while equipment is operating MEDICAL AND FIRST AID TREATMENT First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of all injury vic
135. tery cables c s s 1 Positive Output Connection 2 Negative Output Bus Bar I 3 Load Contactor i 28 Volt Output Terminal Panel x Figure 1 ba M i 1 2 Dec 1 85 M M 450 31 e 4 a P Em i3 AA R 3 p EE Pudens deed _ 0M 2007 4 Stationary Unit Mounting Figure 2 illustrates the mounting hole pattern in the base of the stationary Jet Ex 4D generator set Each of the eight holes is 11 16 17 5 mm diameter 305 1 13 1 13 pure 32 18 716 Gu p eri Stationary Unit Mounting Holes Figure 2 ee sees Dec 1 85 men I a d Lx EI This page intentionally left blank PR Dec 1 85 1 2007 SECTION 3 OPERATION l General This section contains information and instructions for the safe and efficient operation of the generator set Operating instructions are presented in a step by step sequence of procedures to be followed in supplying power to an aircraft NOTE Read ALL of the operating instructions before attempting to operate the equipment WAR
136. that can be reached and use compressed air if available to dry the parts of the generator that cannot otherwise be reached See MAINTENANCE for brush care i 4 Field coils fields should be dried as thoroughly as possible they have become damp proceed with recommended procedure in MAINTENANCE section l 5 Battery terminals Thoroughly clean the battery terminals and connections Co y terminals and connections with petroleum jelly to retard l corrosion K Miscellaneous O rt Once a month oil hinges on the engine compartment doors and the Hinged plexiglas cover 3 Trailer Operation A Towing i Observe the following rules when towing the trailer 1 Be sure all output cables are disconnected and properly stowed 2 Be sure parking brake is released by keeping the drawbar no higher than 30 degrees above horizontal i freely allow Avoid speeds greater that 15 MPH and sudden turns B Parking M o9 i i 1 1 Observe the following rules when parking the trailer 1 Always place drawbar an upright vertical position and lock it when trailer is parked i 2 Be sure parking brake is applied should be automatically x x 3 Avoid turns which are shorter than the steering linkag
137. tims Electric shock victims should be checked by a physician and taken to a hospital immediately if any abnormal signs are observed EMERGENCY FIRST AID 11 physician immediately Seek additional assistance and use First Aid t chniques recommended by American Red Cross until medical help arrives 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 1 rnal heart massage Call Emergency Rescue A emer vera a i i Instruction 910082 Revised Feb 25 86 This manual contains operation and service information for 28 5 V DC Generator sets identified as Jet Ex 4D 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 4D in general Information which applies to options and special equipment is identified as such 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 guide and assist operators and maintenance personnel in the proper use and care of the equipment Read the instructions before
138. ver 25 psi 172 kPa Dec 1 85 T 2 TEMP 1 3 Page 1 0 2007 20 OIL PRESSURE WATER TEMP STARTING CURRENT 4007466 uP AR ANCE 1 011 Pressure Gauge 11 Contactor Control Switch 2 Tachometer 12 Contactor Closed Light 3 Water Temperature Gauge 13 Speed Control Switch 4 Current Limit Control 14 Engine On Light 5 Ammeter Generator 15 Hourmeter 6 Voltmeter 16 deleted 7 Panel Light 17 Engine Start Switch 8 Panel Lights Switch 18 Engine Circuit Fuse 9 Panel Lights Fuse 19 Engine Circuit Switch 10 Push To Build Up Voltage Switch 20 Ammeter Engine Operating Controls and Indicators Rear Shelf amp Rear Enclosure Models Figure 1 1 3 i m mS 4 Revised Apr 15 88 Page 2 mae qm ee oo TOM DOT 4 Make sure that no loose bars tools parts are in or on part of the engine as they could cause 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 the engine exhaust system and discharged out of doors Avoid short bends or reduction in line sizes in exhaust pipes Locate the unit so as to necessitate the shortest possible exhaust line to insure the least amount of back pressure on the engine Back pressure can cause engine damage and loss of power 6 Check the
139. y In the Rated RPM position engine speed is controlled to approximately 2600 RPM gt Ur EON a i 6 Fuses 1 Three cartridge type fuses protect the engine ignition circuit the panel lights circuit and the voltage regulator The engine cir cuit fuse 13 Figure 4 is rated at 20 amperes the panel lights fuse 9 at 10 amperes and the voltage regulator fuse 4 Fig 5 at 10 amperes 7 Voltage regulator x Refer to Figure 5 The voltage regulator 1 is a solid state device which regulates the 28 5 volt DC generator output after the l voltage is built up 8 Overvoltage module i The overvoltage relay 2 is solid state protective device on printed circuit board normally closed relay in the circuit is i wired into the load contactor coil circuit overvoltage condi tion causes the relay contacts to open which turn prevents the contactor from closing or opens the load contactor and discon i tinues the power delivery overvoltage module is adjusted to to trip at 32 to 34 volts DC in 2 to 10 seconds x 9 Resistor and diode assembly This network which is mounted on a terminal strip behind the control panel protects the load contactor hold circuit against excessive current draw when the generator is delivering power 1
140. ystem Alternator and regulator Starter relay Spark arrester muffler Generator Control Panel Assembly 1 2 3 5 Apr 1 87 Revised General Lights Monitoring instruments Potentiometer Switches M 2007 9 91 Contents Mns a e dt Page 1 i lor di T 2007 gt _ i 5 7 2 DEN s BUB CHAPTER SECTION 6 Fuses id 7 Voltage regulator 10 8 Overvoltage module 10 9 Resistor and Diode Assembly 10 10 Excitation Rectifiers 10 11 Voltage Sensing Relay 10 E Output Terminals 11 F G Contactor Rectifier Assembly Ammeter Shunt 7 Optional Equipment Trailer Preparation for Use Storage or Shipping 1 2 1 Preparation for Use General Inspection Check Output Cable Inspection 1 Cable requirements 2 Cable connector 2 Preparation for Storage A B Cs 1 i kuspa Ae 5 22512225 oe oe E L Contents Dec 1 85 I KOATA ESEL ENE RF A PERRO IRR RR ERE L PHSG C A Lo s I General Temporary Storage 1 2 Long

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