Manual Hobart Jet Ex - 5d

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OM-2094
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110100
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Revised 01/01
Revised 02/01
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Revised 03/01
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Revised 06/01
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Revised 07/01
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Revised 08/01
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Operation and Maintenance Manual
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Jet-Ex 5D Generator Sets

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Series 500285
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Hobart
1. Hobart Brothers Company (hereinafter Brotherswarrants
called HOBART) Company that each new and unused Hobart Ground
To
Ground
Power Equipment, (hereinafter called the Power
PRODUCT) is of Division
good workmanship and is free from mechanical defects,
Troy, Ohio 45373
U.S.A.
Downloaded from www.Manualslib.com manuals search engine

WARRANTY
HOBART BROTHERS COMPANY, TROY, OHIO, U.S.A.
GROUND POWER DIVISION
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1. Hobart Brothers Company (hereinafter called HOBART) warrants that each new and unused Hobart Ground
Power Equipment, (hereinafter called the PRODUCT) is of good workmanship and is free from mechanical defects,
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provided that (1) the PRODUCT is installed and operated in accordance with the printed instructions of HOBART,
(2) the PRODUCT is used under the normal operating conditions for which it is designed, (3) the PRODUCT is not
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subjected to misuse, negligence or accident, and (4) the PRODUCT receives proper care, lubrication, protection,
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and maintenance under the supervision of trained personnel.
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2. This warranty expires 15 months after shipment by HOBART to the first user, or 12 months after installation,
whichever first occurs.
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3. This warranty does not apply to: primary and secondary switch contacts, cable connectors, carbon brushes, fuses,
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bulbs, and filters unless found to be defective prior to use.
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4. Hobart DOES NOT WARRANT THE FOLLOWING COMPONENTS: Engines (gasoline or diesel),storage
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batteries, engine starters generators, alternators, regulators, governors, tires, axles,transmissions, and cable
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retrieving devices. Many of the foregoing components are warranted directly by the manufacturer to the first user
and serviced by a worldwide network of distributors and others authorized to handle claims for component
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manufacturers. A first user’s claim should be presented directly to such an authorized component service outlet.
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In the event any component manufacturer has warranted its component to HOBART and will not deal directly with
a first user then HOBART will cooperate with the first user in the presentation of a claim to such manufacturer.
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Under NO circumstances does HOBART assume any liability for any warranty claim against or warranty work
done by or in behalf of any manufacturer of the foregoing components.
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5. This warranty is extended by HOBART only to the purchaser of new PRODUCTS from HOBART or one of its
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authorized distributors. The PRODUCTS purchased under this warranty are intended for use exclusively by the
buyer and his employees and by no other persons and, therefore, there shall be no third party beneficiary to this
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warranty.
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6. A claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and
judgment. HOBART’S liability is limited to repair of any defects found by HOBART to exist, or at HOBART’S
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option the replacement of the defective product, F.O.B. factory, after the defective product has been returned by
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the purchaser at its expense to HOBART’S shipping place. Replacement and exchange parts will be warranted for
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the remainder of the original Warranty, or for a period of ninety (90) days, whichever is greater.
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7. UNDER NO CIRCUMSTANCES whatsoever shall HOBART and its authorized distributors be liable for any special
or consequential damages, whether based on lost goodwill, lost resale profits, work stoppage impairment of other
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goods or otherwise, and whether arising out of breach of any express or implied warranty, breach of contract,
88
negligence or otherwise, except only in the case of personal injury as may be required by applicable law.
8. Continued use of the PRODUCT(S) after discovery of a defect VOIDS ALL WARRANTIES.
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9. Except as authorized in writing, this warranty does not cover any equipment that has been altered by any party
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other than HOBART.

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10. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE OF.
HOBART MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR FITNESS FOR
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A PARTICULAR PURPOSE.
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11. HOBART neither assumes nor authorizes any person to assume for HOBART any liability in connection with the
PRODUCTS sold, and there are no oral agreements or warranties collateral to or affecting this written Warranty.
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This warranty and all undertakings of HOBART thereunder shall be governed by the laws of the State of Ohio,
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United States of America.

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WARNING
AT ALL TIMES, SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE INSTALLATION,
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SERVICING AND OPERATION OF THE PRODUCT, AND SKILLED, TECHNICALLY QUALIFIED PERSONNEL
SHOULD ALWAYS BE EMPLOYED FOR SUCH TASKS.

OM-2094 / Operation and Maintenance Manual
Jet-Ex 5D / Series 500285 / Generator Set
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Safety Warnings and Cautions
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WARNING
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CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine exhaust
and some of its constituents are known to the State of California to cause
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cancer, birth defects and other reproductive harm.
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WARNING
ELECTRIC SHOCK can KILL. Do not touch live electrical parts.
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ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage,
and ignite combustible material. DO NOT use power cables to break load and
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prevent tools from causing short circuits.
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IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage
this and attached equipment.
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IMPORTANT
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Protect all operating personnel. Read, understand, and follow all instructions in
the Operating/Instruction Manual before installing, operating, or servicing the
equipment. Keep the manual available for future use by all operators.
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1. General
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Equipment that supplies electrical power can cause serious injury or death, or damage to other
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equipment or property. The operator must strictly observe all safety rules and take precautionary
actions. Safe practices have been developed from past experience in the use of power source
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equipment. While certain practices below apply only to electrically-powered equipment, other practices
apply to engine-driven equipment, and some practices to both.
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2. Shock Prevention
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Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally
shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn
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what terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,
procedures, and test equipment.
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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
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mat or dry wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry,
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and never work alone

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a. Installation and Grounding of Electrically Powered Equipment

Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed
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and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or other applicable
codes. A power disconnect switch or circuit breaker must be located at the equipment. Check the
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nameplate for voltage, frequency, and phase requirements. If only 3-phase power is available,
connect any single-phase rated equipment to only two wires of the 3-phase line. DO NOT
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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 shock.
November 1, 2000 Safety Warnings

Revised 03/01 Page 1
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Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or
building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)
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capacity of the grounding lead will be adequate for the worst fault current situation. Refer to the
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National Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs. Use
correctly mating receptacles.
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b. Output Cables and Terminals
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Inspect cables frequently for damage to the insulation and the connectors. Replace or repair
cracked or worn cables immediately. Do not overload cables. Do not touch output terminal while
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equipment is energized.
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3. Service and Maintenance
This equipment must be maintained in good electrical and mechanical condition to avoid hazards
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stemming from disrepair. Report any equipment defect or safety hazard to the supervisor and
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discontinue use of the equipment until its safety has been assured. Repairs should be made by
qualified personnel only.
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Before inspecting or servicing electrically-powered equipment, take the following precautions:
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a. Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the
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equipment.
b. Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally.
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c. Disconnect power to equipment if it is out of service.
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d. If troubleshooting must be done with the unit energized, have another person present who is trained
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in turning off the equipment and providing or calling for first aid.
4. Fire And Explosion Prevention
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Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust
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piping, misuse of batteries and fuel, or unsafe operating or fueling conditions.

a. Electrical Short Circuits and Overloads
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Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by
causing nearby combustibles to ignite. For electrically-powered equipment, provide primary input
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protection to remove short circuited or heavily overloaded equipment from the line.
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b. Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured
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battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or
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use open flame near the battery.

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

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Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust
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fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air
conditioners.
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6. Bodily Injury Prevention

Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipment
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for inspection and routine maintenance. When equipment is in operation, use extreme care in doing
necessary trouble-shooting and adjustment. Do not remove guards while equipment is operating.
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Safety Warnings November 1, 2000

Page 2 Revised 03/01
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7. Medical and First Aid Treatment
First aid facilities and a qualified first aid person should be available for each shift for immediate
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treatment of all injury victims. Electric shock victims should be checked by a physician and taken to a
hospital immediately if any abnormal signs are observed.
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EMERGENCY
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FIRST AID Call physician immediately. Seek additional assistance. Use First Aid techniques
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recommended by American Red Cross until medical help arrives.
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IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie
down. FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not
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breathing, begin artificial respiration, preferably mouth-to-mouth. If no detectable
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pulse, begin external heart massage. CALL EMERGENCY RESCUE SQUAD
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IMMEDIATELY.
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8. Equipment Precautionary Labels
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Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be
easily read.
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November 1, 2000 Safety Warnings

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Safety Warnings November 1, 2000

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Introduction
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This manual contains operation and service information for 28.5 V DC Generator sets identified as Jet-Ex 5D.
These units are available as stationary, skid- mounted units, or they may be trailer-mounted for portability.
Both versions are available with 14 V DC output capability.
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Most information in the manual applies to the 28.5 V Jet-Ex 5D in general. Information which applies to
options and special equipment are listed in Appendix A.
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The primary purpose of the manual is to provide information and instructions to experienced operators,
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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.
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Read the instructions before starting the unit. Learn to use the manual and to locate information contained in
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it.
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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.
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Each Chapter is divided into as many Sections as necessary. Sections are always referred to by a
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combination Chapter-Section number, for example: 2-3 refers to Chapter 2, Section 3.

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The material within each Section is divided into main subjects with applicable paragraph headings and
sub-headings as required. For example, a portion of the Description Section might logically follow this
arrangement and paragraphing:
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Section 1. Description
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1. Engine, Generator and Controls

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a. Interior Panel
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(1) Protective devices

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a. Overload relay
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(2) Contactors
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Page numbers do not run consecutively throughout the manual. Each page is identified by the
Chapter-Section number in which it appears, and by a page number within the Chapter-Section. Therefore,
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the first page in each Section is page 1. These identifying numbers appear in the lower, outside corner of
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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 revision. Any revision to the original text is identified by a heavy black line
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in the left-hand margin. Illustrations follow a numbering system similar to page numbering. The first Figure in
each Section is Figure 1.
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All tables, charts, as well as illustrations, are identified by Figure numbers to avoid confusion.
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The general location of any particular information can be found quickly by running through the Table of
Contents. For example: to locate any adjustment information, a quick look at the Table of Contents shows that
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“Adjustment / Test” is located in Chapter 2, Section 3, (shown as 2-3).
November 1, 2000 Introduction


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Portions of the text are referred to by identifying the paragraph in which the referenced material may be
found. When referenced material is located in the same Chapter/Section as the reference, only the paragraph
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identification is given, for example: (Ref. Para. 1, A) means that the material is to be found in paragraph 1, A,
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of the same Section.
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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) means that the referenced material
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is located in Chapter-Section 1-2, and paragraph 1,a. within that Chapter-Section.
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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
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are given, for example: (2, Fig.3) refer to item number 2 in illustration Figure 3 of the same Chapter/Section.
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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, and to refer
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to item 1 in Figure 4.
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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).
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When an item number is referenced without a Figure number, it always applies to the last preceding Figure
number mentioned in the text.
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A collection of manufacturer’s literature is supplied as part of the information package.
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If you have any questions concerning your Hobart Ground Power equipment, immediately contact our
Service Department by mail, telephone or FAX.
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Write: Hobart Brother Company
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Ground Power Division

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Service Department
1177 Trade Road East
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Troy, Ohio 45373

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

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(800) 422-4177 (Service)

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

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(937) 332-5060 (Service)

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FAX: (937) 332-5121

(800) 367-4945 Toll Free in U.S.A.
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Introduction November 1, 2000


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Table of Contents
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Chapter 1. Description/Operation
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Section 1. Description 1
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General 1
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Special Features 1
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Standard 1
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Options 1
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Orientation 4
Identification 4
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Canopy 4
Engine, Generator, and Controls /m 4
General 4
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Engine 4
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Generator 9
Rectifier Assembly 9
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Ammeter Shunt 9
Contactor 9
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Control Box Assembly (Front) 11

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Control Box Assembly (Inside) 15

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Emergency Sutdown Device 15

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Section 2. Preparation for Use, Storage or Shipping 1

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Preparation for Use 1

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General 1
Inspection/Check 1
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Output Cable Requirements and Installation 1

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Preparation for Storage 3

General 3
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Temporary Storage 3
Long Time Storage 3
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Preparation for Shipping 3

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Section 3. Operation 1
General 1
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Operating the Generator Set 1

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Pre-start Inspection 1
Pre-start Instructions 1
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Starting The Engine 3
November 1, 2000 Table of Contents

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Generator Operation 3
Deliver Power 3
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Stop Operation (Shutdown) 3
Adverse Weather Precautions 4
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Chapter 2. Servicing / Troubleshooting
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Section 1. Maintenance Inspection/Check 1
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General 1
Maintenance Schedule 1
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General 1
Maintenance Schedule Check Sheet 1
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Time Intervals 1
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Engine and Related Components 1
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Inspection and Cleaning 3
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Section 2. Maintenance Procedures 1
General /m 1
Lubrication 1
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General 1
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Lubrication Chart 1
Generator 1
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Generator Controls 1
Engine 1
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Servicing the Air Cleaner 4

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Air Filter Cartridge Removal 4

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Air Filter Cartridge Installation 4

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Servicing the Fuel Filter 4

Drive Belt Service 4
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Engine Cooling System 4

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Radiator Cap Removal 5

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Rust Inhibitor 5
Antifreeze 5
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Battery Service 5
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General 5
Battery Location and Accessibility 5
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Battery Care 5
Liquid Level (If Battery is not Maintenance Free) 5
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Cleaning the Battery 6

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Testing a Battery 6
Generator Maintenance 7
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General 7
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Brush Service 7
Generator Revolving Field Brush Replacement 7
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Table of Contents November 1, 2000

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Section 3. Adjustment/Test 1
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General 1
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Testing the Generator Set 1
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Pre-operational Test Procedures 1
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Operational Tests 3
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Voltage Regulator Adjustment 4
28.5 Volt Adjustment 4
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Line Drop Compensation 4
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Section 4. Troubleshooting Procedures 1
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General 1
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Troubleshooting Chart 1
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Description 1
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Use of the Troubleshooting Chart 1
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Equipment for Troubleshooting 1
Safety Precautions 1
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Diagrams 1
Connections and Wiring /m 1
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Section 5. Troubleshooting Charts 1-8
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Chapter 3. Major Overhaul

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Section 1. Flexible Coupling 1

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General 1
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Coupling Screws (Routine Coupling Maintenance) 2

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Disassembly 3
Separate Engine and Generator 3
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Remove Coupling Assembly 3

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Coupling Service 4
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Coupling Installation and Reassembly of Engine Generator 5

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Cleaning 5
Assembly 5
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Run-In and Periodic Check 7
Chapter 4. Illustrated Parts List

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Section 1. Introduction 1
General 1
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Purpose 1
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Arrangement 1
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November 1, 2000 Table of Contents

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Explanation of Parts List 1
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Contents 1
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Parts List Form 1
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Section 2. Manufacturer’s Codes 1
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Explanation of Manufacturer’s (Vendor) Code List 1
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Section 3. Parts List 1
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Explanation of Parts List Arrangement 1
Symbols and Abbreviations 1
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Section 4. Numerical Parts List 1
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Explanation of Numerical Parts List 1
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Chapter 5. Manufacturer’s Literature
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Appendix A. Options / Features
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Table of Contents November 1, 2000

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Chapter 1. Description/Operation
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Section 1. Description
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1. General
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The Jet-Ex 5D units (Figure 1) covered in this manual are diesel engine driven, self-contained
generator sets manufactured by Hobart Brothers Company, Ground Power Division, Troy, Ohio U.S.A.
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A basic unit is identified by a Series Number - 500285 - plus a dash number which defines a specific
configuration. The Series Number, plus the dash number, make up the Specification Number.
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Part Number Mounting Configuration
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500285-001 Trailer Mounted with Cable
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500285-002 Stationary Mounted with
Cable Hangers
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Specification No. 500285-001 covers a trailer mounted unit rated at 28.5 Volts DC output. It is equipped
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with a sheet metal canopy and four hinged engine compartment doors. Various options are available
for use with the basic unit. A few of these options are listed in paragraph 2.B below, but the complete
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list of options are located in Appendix A.

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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 providing continuous, regulated power to the aircraft,
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the unit is also designed for starting any fixed-wing aircraft or helicopter which is equipped with an
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external 28.5 Volts DC power receptacle.

2. Special Features
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a. Standard
The “Soft-Start” current limiting feature, recommended by most aircraft engine manufacturers,
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provides the operator with controls to limit the inrush current to the aircraft engine’s starter. When
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the operator presets this control, the generator will provide constant voltage to the preset current
value. The more current is increased 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
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delivered beyond the preset current value. Limiting inrush current is recommended by most engine
manufacturers to protect the aircraft engine’s starter shear section. The current limiting control is
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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
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fully clockwise.
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b. Options (See Appendix A for complete list)

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Chapters 1-5 of this manual describes a basic “no options” generator set. Appendix A lists the
options available for this unit. Below are the mounting configurations.
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November 1, 2000 Chapter 1-1

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Jet-Ex 5D Generator Set

Figure 1
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Chapter 1-1 November 1, 2000

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Unit with Stationary Mount (500285-002)
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Length 68” (172.7 cm)
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Width 37” (94 cm)
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Height 46” (116.8 cm)
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Weight (dry fuel tank) 2400 lbs (1088.6 kg) Approx.
Unit with Trailer and Cable Trays (500285-001)
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Length 76.3” (193.8 cm)
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Width 67” (170.1 cm)
Height 62” (157.5 cm)
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Weight (dry fuel tank) 2670 lbs (1211 kg) Approx.
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Ground Clearance 14” (35.6 cm)
Generator
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Output Power Rating 17.1 kW
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Voltage 28.5 volts DC
Rated Load Capacity 800 amperes continuous at 28.5 volts DC
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Starting Current Capacity 2000 amperes maximum
Current Limiting Capability
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300 to 2000 amperes, continuously adjustable
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Operating Speed 2500 +/-50 RPM
Engine
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Manufacturer Cummins Diesel

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Model 4BT3.9
Type 4-cylinder, 4-stroke, direct injection
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Fuel-Diesel recommended ASTM D975 66T Numbers 1D or 2D

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Displacement 238 cubic inches (3.9 liters)

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Rated Power at 2200 RPM 100 Horsepower (75 kW)

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

Coolant Capacity - engine only 7.4 U.S. Quarts (7 liters)
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Coolant Capacity - system 4.5 U.S Gallons (17 liters)

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Electrical System 12 volt DC, negative ground

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Governed Speed at No Load 2500 +/- 50 RPM

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Idle Speed 1000 +/- 50 RPM

Fuel Tank Capacity 20.5 U.S. gallons (77.6 liters)
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Protective Devices
Generator 28.5 volt over voltage module trips at 32 to 34 volts.
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Water Temp. Switch opens engine circuit at 210º F (98.8º

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

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3. Orientation
The radiator end of the Jet-Ex 5D is the front. Right and left are determined by standing at the rear of
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the unit, facing it. The control panel is located at the rear.
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4. Identification
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The Jet-Ex 5D unit is identified by Specification numbers as described in paragraph 1. There may be
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any number of Generator sets with the same Specification number. Individual machines are identified
by a Serial number, assigned to one machine only.
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Each generator set has an Identification plate attached inside the control box. This nameplate lists the
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machines Model No. (Jet-Ex 5D), Specification No., Serial No., and electrical rating.
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If any of the options described in paragraph 2.b. are included, they will be listed by name and part
number on a separate option nameplate located next to the Identification plate.
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5. Canopy
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The standard canopy is a sheet metal enclosure which protects the engine, generator, and electrical
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controls. It has four hinged doors to provide access for service and maintenance. A bolted on panel at
the rear (below the control box) provide access to the rectifier assembly. A Lexan window is mounted in
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front of the control panel to allow observation of the instruments while protecting them from the
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weather.
6. Engine, Generator, and Controls
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a. General
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The engine (7, Figure 2) and generator (5) are mounted on a welded steel frame (6). A fuel tank
support (1) located at the rear of the unit supports the fuel tank (2) and provides a mounting frame
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for the load contactor (10) and output terminals. The radiator (7, Figure 4) is mounted to the front
canopy and frame.
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b. Engine
-h
(1) General
The engine used in the Jet-Ex 5D generator set is a Cummins Model 4BT3.9 four-cylinder,
6
four-stroke, direct injection diesel engine. It has a 238 cubic inch (3.9 liter) cylinder displacement
32
and a 17.5:1 compression ratio. Engine firing order is 1-3-4-2.

-5
A spring-loaded relief valve in the oil pump limits maximum pressure in the system. A full-flow oil
filter (3, Figure 3) cleans the oil before it enters the oil distributing system. A low oil pressure
02
switch is mounted on the engine block as a protective device. The fuel valve solenoid circuit is
wired through the contacts of this switch, which closes at 20 PSI (138 kPa). This prevents the
-7
engine from continuing operation if oil pressure will not build up, and also shuts down the engine
88
if oil pressure drops radically during operation.

-8
See the engine operator’s manual for additional engine specifications.

The generator and engine are mounted on a welded steel skid, and are enclosed by a sheet
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metal canopy that bolts to the skid. Access to engine serviceable components (oil filter, air
cleaner, etc.) is through the doors on each side of the machine.
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The rear panel is removable and permits access to the rectifier assembly.
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1. Fuel Tank Support 5. Generator 9. Battery

2. Fuel Tank 6. Frame 10. Contactor
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3. Control Panel 7. Engine

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4. Rectifier Assembly 8. Air Cleaner
Generator Set Components

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Figure 2

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1. Muffler
2. Alternator
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3. Oil filter
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4. Starter
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5. Starter solenoid
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(Left Side)
Figure 3
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1. Fuel filter
2. Air cleaner
3. Throttle control assembly
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4. Oil pressure sender

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5. Oil pressure switch 20 psi (138 kPA)

6. Water Temp. Switch
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7. Radiator
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(Right Side)
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Figure 4

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(2) Cooling fan
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The cooling fan on the engine is designed to blow air out through the radiator rather than to draw
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it in. This prevents hot air, heated by the engine, from entering the generator.
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(3) Fuel system
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The fuel system consists of a 20.5-gallon (77.6 liters) plastic fuel tank (2, Figure 2) with all the
necessary fittings and hoses.
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(4) Alternator
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The battery charging alternator (2, Figure 3) is rated at 65 amperes. The alternators
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responsibility is to produce/regulate 12V DC for the generator sets internal electrical system.
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(5) Starter solenoid
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The starter solenoid (5, Figure 3) is mounted on the starter motor (4), on the right side of the
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engine.
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(6) Exhaust muffler (1, Figure 3)
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This muffler helps deaden audible noise from the engine’s exhaust.
(7) Engine faults
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The following is a table listing faults which may occasionally occur. Column two of the table
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explains what happens in the engine’s circuitry when the fault occurs, and column three tells how
to return the generator set to service.
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ENGINE FAULTS
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To Put the Generator Set Back

Engine Fault Condition What This Fault Condition Does
into Service:
6
Over Temperature Automatically removes power a) Let the engine cool down
32
from the fuel valve solenoid and enough to check for low coolant
shuts down the engine level and or faulty over
-5
temperature switch. Restart

02
engine.
Low Oil Pressure Automatically removes power a) Let the engine cool down
-7
from the fuel valve solenoid and enough to check for low oil level
88
shuts down the engine and or faulty oil pressure switch.

Restart engine.
-8
Clogged air cleaner or Turns on the air cleaner a) Replace clogged air filter if
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other restriction in the restriction indicating light needed; clean out the air intake
combustion air inlet. (16, Figure 5) chamber. Restart engine.
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c. Generator
The generator (5, Figure 2) is a multi-phase, synchronous salient pole, revolving field, AC generator
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whose output is rectified. The output is rectified by a rectifier assembly (4) made up of twelve
rectifiers connected into a full wave configuration. The generator is self-excited, receiving excitation
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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
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regulator to the rotating field winding. The voltage regulator, controls the excitation current and
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maintains a constant 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
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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
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construction is mounted on the coupling hub and draws cooling air over the generator windings.
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Air flows over the rectifier assembly (4, Figure 2) and then enters through the anti-drive end of the
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generator and is discharged through openings in the flywheel housing at the drive end. The
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generator housing assembly, which contains the generator stator, is bolted to the engine flywheel
housing.
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d. Rectifier Assembly
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The Rectifier Assembly (4, Figure 2) consists of two aluminum heat sinks with six diodes on each
heat sink. The rectifier assembly converts the AC output of the generator to 28.5 Volts DC.
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e. Ammeter Shunt
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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 AMMETER (4, Figure 5), and to the
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current limit circuit of the voltage regulator (2, Figure 6). This shunt is mounted on the negative heat
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sink of the rectifier assembly (4, Figure 2).

f. Contactor K402 (10, Figure 2)
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The load contactor, which is mounted on the right side of the unit below the fuel tank, provides a
safe and convenient means of connecting and disconnecting the generator from the load. Initial
6
power for closing the load contactor is supplied by the generator through the spring-loaded
32
momentary contacts of the CONTACTOR CONTROL toggle switch (7, Figure 5). Holding power, to
keep the contactor closed, passes through the normally open auxiliary contacts in the load
-5
contactor. Output power connection is made by attaching the positive lead to the top terminal of the
02
load contactor, and the negative lead to the negative output terminal located above the load
contactor.
-7
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02
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-8
1. TACHOMETER (M403) 11. ENGINE ON lamp (DS407)

2. HOUR METER (M402) 12. ENGINE START push button switch
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3. VOLTMETER (generator) (M406) (S401)

13. ENGINE CIRCUIT toggle switch (S404)
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4. AMMETER M407
5. PANEL LIGHTS FUSE (10 amp) (F401) 14. ENGINE CIRCUIT FUSE (20 Amp) (F402)
6. PANEL LIGHTS toggle switch (S405) 15. WATER TEMPERATURE gauge (M404)
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7. CONTACTOR CONTROL toggle switch (S408) 16. AIR FILTER RESTRICTION

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8. CONTACTOR CLOSED lamp (DS408) INDICATOR lamp (DS412)

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9. CURRENT LIMITING CONTROL 17. OIL PRESSURE gauge (M405)

potentiometer (R402) 18. FUEL gauge (M408)
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10. SPEED CONTROL toggle switch (S406) 19. VOLTMETER (battery) (M401)
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Control Box Assembly

(Front View)
To
Figure 5

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g. Control Box Assembly (Front) (Figure 5)
The Control Box Assembly (Figure 5) houses and provides mounting facilities for controls,
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monitoring instruments, voltage regulator, relays, etc. The box is mounted at the rear of the
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canopy. Its control are accessible behind a hinged plastic cover.
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(1) TACHOMETER (M403)
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This instrument receives its operating signal from the alternator to display the engine speed in
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RPM.
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(2) HOUR METER (M402)
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The HOUR METER records the total hours of engine operation for scheduling maintenance.
(3) VOLT METER, generator (M406)
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The VOLT METER indicates generator output voltage.
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(4) AMMETER (M407)
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The AMMETER displays generator current output.
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(5) PANEL LIGHTS FUSE (F401)
This protects the panel lights circuit.
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(6) PANEL/CLEARANCE LIGHTS toggle switch (S405)/m
The PANEL/CLEARANCE LIGHTS toggle switch turns the panel and clearance lamps on and
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off.
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(7) CONTACTOR CONTROL toggle switch (S408)

The CONTACTOR CONTROL toggle switch is a three-position toggle switch used to close and
-h
open the output load contactor. The top CLOSE position is spring-loaded and is held
momentarily until the CONTACTOR CLOSED lamp (8) glows, then it is released to the center
6
ON position. In this position the switch provides holding current to the load contactor to keep it
32
closed. Protective devices in the load contactor circuit provide protection against over voltage by
opening the load contactor if that condition occurs. In the bottom OFF position, the contactor is
-5
opened.
02
(8) CONTACTOR CLOSED lamp (DS408)

-7
The CONTACTOR CLOSED lamp glows green when the output load contactor is closed.
88
(9) CURRENT LIMITING CONTROL POTENTIOMETER (R402)

-8
The CURRENT LIMITING CONTROL POTENTIOMETER is used to select the starting current
recommended for various aircraft. The current limiting setting is continuously adjustable from
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300 to 2000 amperes.

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(10) SPEED CONTROL toggle switch (S406)

The SPEED CONTROL toggle switch is a two position switch wired to a throttle solenoid on the
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engine. In the IDLE position, used for starting, the engine speed is controlled to approximately
1000 RPM. In the Rated RPM position, engine speed is controlled to approximately 2500 RPM.
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(11) ENGINE ON lamp (DS407)

The ENGINE ON lamp glows green when the engine is running.
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(12) ENGINE START push button switch (S401)
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The ENGINE START push button switch is a momentary contact switch which closes the starter
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solenoid (5, Figure 3) circuit and cranks the engine. This switch is operable only when the
ENGINE CIRCUIT toggle switch (13, Figure 5) is held in its top spring-loaded START position.
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(13) ENGINE CIRCUIT toggle switch (S404)
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The ENGINE CIRCUIT toggle switch must be held in the top START position and the ENGINE
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START push button (12) must be depressed TO START THE GENERATOR SET. When
released from its top START position after the engine starts, this toggle switch will return to
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center RUN position. The ENGINE ON lamp (11) will glow as long as the switch is in RUN
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position. In the bottom STOP position, this switch will stop the engine and the lamp (11) will go
out.
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(14) ENGINE CIRCUIT fuse (F402)
The ENGINE CIRCUIT fuse (20 amp.) protects the engine circuitry.
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(15) WATER TEMPERATURE gauge (M404)
The WATER TEMPERATURE gauge indicates the engine coolant temperature and is actuated
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by a temperature sender (6, Figure 4) mounted on the engine’s water jacket.
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(16) AIR FILTER RESTRICTION lamp (DS412)
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The AIR FILTER RESTRICTION lamp glows red when the air filter needs changed.
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(17) OIL PRESSURE gauge (M405)
The OIL PRESSURE gauge displays the pressure in the engine’s lubrication system. It is
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operated by a sender (4, Figure 4) mounted on the engine block.

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(18) FUEL gauge (M408)

The FUEL gauge indicates the amount of fuel remaining in the fuel tank.
6
32
(19) VOLTMETER (battery) (M401)

The battery VOLTMETER indicates the voltage of the engine’s 12 volt DC electrical system.
-5
02
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6
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1. Over voltage relay (K403)

02
2. Voltage regulator (VR402)

-7
3. Excitation rectifiers (CR417 & CR418)

4. Control windings fuses (10 Amp.) (F406 - F408)
88
5. Voltage build-up fuse (10 Amp.) (F405)

-8
6. Voltage regulator fuse (10 Amp.) (F403)

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

8. Control Panel Lights (DS401, DS402 & DS420)
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9. Rectifier Harness Connector (J43)

10. Engine Harness Connectors (J46 & J47)
11. Rectifier (CR401)
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12. Capacitor (C403)

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(Interior View)
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Figure 6
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h. Control Box Assembly (Interior)
Numbers in parentheses below can be crossed referenced in Figure 6
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(1) Over voltage relay (K403)
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The over voltage relay is a solid-state protective device on a printed circuit board. A normally
closed relay in the circuit is wired into the load contactor coil circuit. An over voltage condition
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causes the relay contacts to open, which in turn prevents the contactor from closing, or opens
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the load contactor and discontinues the power delivery. The over voltage module is adjusted to
trip at 32 to 34 volts DC in .5 seconds ±.2 seconds.
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(2) Voltage regulator (VR402)
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The voltage regulator is a solid-state device which regulates the 28.5 Volts DC generator output
after the voltage is built up.
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(3) Excitation rectifiers (CR417 and CR418)
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Two diode bridge rectifiers, convert an AC voltage from the generator armature to the DC
voltage needed for the generator revolving field.
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(4) 3 Control Windings Fuses—cartridge-type—10 amp each (F406 - F408)
(5) Voltage Build-up Fuse—cartridge-type—10 amp (F405)
on
(6) Voltage Regulator Fuse—cartridge-type—10 amp (F403)
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(7) Throttle Solenoid Fuse—cartridge-type—20 amp (F409)
(8) Control Panel Lights (DS401, DS402, & DS420)
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Three control panel lights provide illumination for instruments and controls.
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(9) Rectifier Harness Connector (J43)

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Provides connections between the control box and the Rectifier assembly.
6
(10) Engine Harness Connectors (J46 & J47)

32
Provides connections between the control box and engine compartment components.
-5
(11) Rectifier (CR401)

02
Automatic Voltage Build-Up.

-7
(12) Capacitor (C403)

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A 100mfd, 350V DC Capacitor, that filters the DC excitation volts produced by rectifiers CR417
and CR418.
-8
i. EMERGENCY SHUT DOWN DEVICE

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In addition to the other devices provided by the engine manufacturer, an engine shutdown feature is
added by Hobart Brothers. Since diesel engines typically require several minutes of running at idle
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speed before shutdown, this push button switch is intended for use in emergencies only.
(1) EMERGENCY SHUTDOWN push button switch S413
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This push button switch has one purpose: To provide immediate shut off of the generator set by
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disconnecting power to the fuel solenoid through the control box. Once pushed, it must be
pulled back out to restart the generator set. It is located on the rear panel, below the control box.
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To operate the EMERGENCY SHUTDOWN push button switch:

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

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· Pull the button back out to reset.

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Section 2. Preparation for Use, Storage or Shipping
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1. Preparation for Use
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a. General
The generator set is shipped with an empty fuel tank. After the fuel tank is filled and the generator
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set is inspected, the generator set is ready for use.
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CAUTION
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Read operating instructions in Section 1-3 before operating the unit.
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b. Inspection/Check
Inspect the unit completely prior to operation.
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(1) Remove crating, blocking, banding, ties, and other securing and protective material.
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(2) Inspect exterior for shipping damage such as broken glass, damaged sheet metal, etc.
on
(3) Open canopy doors and inspect interior for foreign material such as rags, tools or shipping
papers.
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(4) Check the fuel and coolant systems, also the oil hoses and their connections for visible leaks. If
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leaks are discovered, correct by tightening hose clamps, tube fittings, etc., as required.
(5) Check security of attaching and retaining hardware.
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(6) Check the following for sufficient quantity.

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a. Fuel
6
Fuel tank capacity is 20.5 gallons (77.6 liters).

32
b. Engine coolant
-5
The radiator cap is located under the hinged door, at the front of the unit, on the top canopy.
The coolant level should be approximately one inch below the filler neck to allow for sufficient
02
capacity for coolant expansion.

-7
CAUTION
88
Be sure the cooling system antifreeze solution is adequate to protect below

lowest temperature expected.
-8
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c. Engine lubricating oil

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

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

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(1) Cable requirements

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· Cable length is determined by the customer’s requirements. It is recommended that the

cable be no longer than 30 feet (9 m). It should be two conductor with lug-type terminals
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on one end and an AN-2551 plug connector on the other.

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Page 1
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· The recommended cable size for 28.5 volt DC is determined by the maximum starting load
amperage expectations. A maximum starting load of 1500 amps. requires two single
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conductor 4/0 cables. A maximum starting load of 600 amps. requires two single
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conductor 2/0 cables.
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NOTE: Some operators may wish to add a second cable assembly with MS-25019 plug connector for
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starting aircraft such as Jetstar and Sabre liner.
(2) Cable connection (See Figure 1)
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· Open and remove the right rear door and the panel below the door. Set aside.
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· Loosen the output cable clamp and thread the lugged end of the output cable through the
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opening in the right side of the unit.
· Connect the POSITIVE cable lead to the output terminal on the contactor. Connect the
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NEGATIVE cable lead to the negative output terminal located above the load contactor.
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ALWAYS place the lead under the flat washer shown.
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Negative Cable Connection
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02
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Positive Cable Connection

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Output Cable Connections

(Right Side of Unit)
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Figure 1

Page 2
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· Tighten the cable clamp and install the lower panel, and the door.
·
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Store cables in cable tray or on hangers on side of canopy if fenders are not used.
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2. Preparation for Storage
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When a generator set is to be stored or removed from operation, special precautions should be taken
to protect the internal and external parts from rust and corrosion.
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a. General
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The unit should be prepared for storage as soon as possible after being removed from service.
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Storage should be in a building which is dry and which may be heated during winter months.
b. Temporary Storage
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When storing the unit for one month, prepare as follows:
(1) Lubricate the unit completely in accordance with instructions in Section 2-2; Para. 2. This will
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include changing engine oil, and filter elements.
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(2) Make certain the cooling system antifreeze solution is adequate to protect below the lowest
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temperatures expected during the storage period.
(3) Clean the exterior of the engine with fuel oil and dry with clean cloths and compressed air.
on
(4) Seal all engine openings. Use a vapor and waterproof proof material that is strong enough to
resist puncture damage from air pressure.
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c. Long Time Storage
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(1) Engine Protection
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The Jet-Ex 5D generator set may be stored for long periods if the engine is given proper
protection from rust and corrosion. Refer to the Engine Manufactures Users Handbook for proper
-h
procedures to be followed.
(2) Generator Protection

6
32
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
-5
absorbing chemicals, such as silica-gel, in the unit before packaging.

02
(3) Battery Care

-7
Remove battery and store in a cool dry place. Store the battery on wood rather than directly on
cement or metal.
88
3. Preparation for Shipping

-8
Prepare the unit for shipping as follows:

ll 1
· Disconnect battery cables.

· Seal all engine openings to prevent the entrance of water, dirt, and dust.
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· Drain all fuel from tank and fuel lines as required by carrier rules.
·
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Crate the unit solidly to prevent damage to instruments, glass, and sheet metal.
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Section 3. Operation
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1. General
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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
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supplying power to an aircraft.
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NOTE: Read ALL of the operating instructions before attempting to operate the equipment.
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WARNING
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Ear protection may be necessary when working close to this equipment.
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2. Operating the Generator Set
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a. Pre-start Inspection
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(1) Always be sure there is sufficient oil and coolant in the engine.
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(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.
/m
(3) If the unit is trailer mounted and is not connected to a tow vehicle, be sure the parking brake is
s:/
applied and that the drawbar is raised and locked in the vertical position.
(4) Open the engine compartment doors and inspect interior for rags, tools, and foreign material.
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b. Pre-start Instructions
-h
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.
6
(1) Check the supply of fuel, crankcase oil and radiator coolant. See the Engine Manufactures
32
User’s Manual for specifications.

-5
(2) Inspect the unit thoroughly to be sure it is in proper working order. Check all fuel lines and wire
02
connections to be certain they are secure. Tighten any loose screws, nuts or bolts.
(3) Wipe off the entire unit and blowout air passages, control box, and other hard to reach places
-7
with compressed air not over 25 psi (172 kPa).

88
(4) Make sure that no loose bars, tools, parts, etc., are in or on any part of the engine, as they could
cause serious damage to the engine, generator, or personal injury to anyone standing nearby.
-8
(5) If the unit is operated indoors, make sure that an exhaust line is properly connected to the
ll 1
engine exhaust system, and discharged outside. 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
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the least amount of back-pressure on the engine. Back-pressure can cause engine damage and
loss of power.
(6) Check the electrical system to make sure the connections are secure and properly connected.
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(7) If applicabled, check the battery electrolyte level. The factory installed battery is maintenance
free.
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-5
02
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1. TACHOMETER M403 11. ENGINE ON lamp DS407

-8
2. HOUR METER M402 12. ENGINE START push button switch S401
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3. VOLTMETER (generator) M406 13. ENGINE CIRCUIT toggle switch S404

4. AMMETER M407 14. ENGINE CIRCUIT FUSE (20 Amp.) F402
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5. PANEL LIGHTS FUSE (10 amp) F401 15. WATER TEMPERATURE gauge M404
6. PANEL LIGHTS toggle switch S405 16. AIR FILTER RESTRICTION
INDICATOR lamp DS412
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7. CONTACTOR CONTROL toggle switch S408

8. CONTACTOR CLOSED lamp DS408 17. OIL PRESSURE gauge M405
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9. CURRENT LIMITING CONTROL 18. FUEL gauge M408

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potentiometer R402 19. VOLTMETER (battery) M401

10. SPEED CONTROL toggle switch S406
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(Front View)
Figure 1
To

Page 2

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c. Starting The Engine (Figure 1)
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Make sure that all Prestarting Instructions have been carried out, and reference to Initial Preparation
ts.
for Use has been checked for operating details.
(1) Check engine oil, fuel and coolant levels.
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(2) Check AIR CLEANER SERVICE INDICATOR lamp (16, Figure 1). If lamp is glowing, replace air
tp
filter element and/or remove other objects that obstruct air flow.
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(3) Place SPEED CONTROL toggle switch (10) in the IDLE (down) position.
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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.
q
DO NOT Operate the starter for periods longer than 15 seconds at a time. An
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interval of at least two minutes should be allowed between cranking periods to
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protect the starter from overheating.
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(4) Hold engine ENGINE CIRCUIT toggle switch (13) in START position.
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(5) Press and hold ENGINE START push-button switch (12). Release as soon as engine starts.
(6) Release engine ENGINE CIRCUIT toggle switch (13) to RUN position when oil pressure builds
on
up.
/m
(7) Observe engine RPM on the TACHOMETER (1), idle speed should be 1000 RPM +/- 50 RPM.
s:/
(8) Allow engine to warm up before applying a load.
ttp
WARNING
The engine’s entire exhaust system will get very hot and cause severe burns if
-h
touched.
6
d. Generator Operation (Figure 1)

32
(1) Place speed control switch (10) in RATED RPM (up) position. Engine speed will be 2500 RPM,
-5
and the generator will automatically build up to produce rated voltage.

02
(2) Adjust CURRENT LIMITING CONTROL potentiometer (9) if necessary. Refer to Proper Aircraft
documentation for proper setting.
-7
e. Deliver Power
88
(1) Connect output cable to AIRCRAFT.

-8
(2) Hold CONTACTOR CONTROL toggle switch (7) in CLOSE position. Release to ON position as
ll 1
soon as green CONTACTOR CLOSED lamp (8) comes on.

f. Stop Operation (Shutdown)
Ca
(1) Normal Conditions

a. When power delivery is completed (aircraft discontinues drawing current), place
ts
CONTACTOR CONTROL toggle switch (7) in OFF position. The CONTACTOR CLOSED
ar
lamp (8) should go off to indicate load contactor has opened and power is no longer available
at the aircraft.
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b. Place SPEED CONTROL toggle switch (10) in IDLE (down) position. Allow engine to run for
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2 to 3 minutes.
c. Disconnect output cable from aircraft receptacle and store cable in cable trays or on cable
Or
hangers as the case may be.

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

Page 3

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CAUTION
ts.
THE BATTERY WILL DRAIN if the ENGINE CIRCUIT toggle switch (13), is not
placed in STOP position after shutdown,
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(2) Emergency Conditions
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To prevent personal damage or damage to generator set, use of the EMERGENCY SHUT
DOWN (E-STOP) push button switch will provide immediate shut down of the engine. Once
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pushed in, the E-STOP button must be pulled back out to restart the generator set.
·
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Depress E-STOP button; engine will shut down
· Pull E-STOP button back out to restart.
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g. Adverse Weather Precautions
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(1) Cold weather operation
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Operation of this engine-driven unit at sub-zero temperatures requires special precautions and
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extra servicing from both operation and maintenance personnel, if poor performance or total
functional failure is to be avoided. Consult the Engine Manufactures Maintenance and Operator’s
ste
Manual and recommendations below.
a. Fuel system
on
Keep system clean and free from water which may collect in a low spot in the fuel line and
/m
freeze, plugging the line. Fuel tanks should be kept FULL to prevent water condensation from
the air above the fuel.
s:/
b. Fuel Storage
ttp
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.
-h
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
6
ice into the fuel containers.

32
c. Cooling system
-5
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.
02
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.
-7
d. Lubrication
88
Drain the crankcase (preferably when warm after running) and fill with a lighter grade of oil.
-8
See Engine Oil Recommendations chart in the Engine Manufactures User’s Manual for
recommended viscosity for various atmospheric temperatures. In cold weather, drain oil more
ll 1
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 may freeze and
Ca
cause serious damage to the oil pump, or shut off the oil supply.
e. Electrical system
ts
In cold weather, the most efficient electrical system is needed to start the cold engine. Check
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the entire system for loose connections or indication of bad wiring or shorted conditions.
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f. Battery
Battery efficiency decreases sharply with lower temperatures. Make sure of full charge before
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attempting to start engine in sub-zero conditions.

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Page 4

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(2) Operation in Hot and Humid Conditions
c
a. Cooling system
ts.
Maintain a more frequent check of the coolant level in the radiator.
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(3) Operation in Extremely Dusty Conditions
en
If unit is to be operated under dusty, out-of-door conditions, place it in a sheltered area. Take
advantage of any natural barriers which may offer protection from blowing dust. If the installation
m
is more than temporary, erect a protection shield.
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a. Fuel system
Change the fuel filter at prescribed intervals and keep fuel containers covered and protected
q
against dust entry.
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b. Air Cleaner
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This filter needs more frequent attention under dusty conditions. Check Air Filter Restriction
Lamp located on control panel daily.
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c. Crankcase Oil
ste
The crankcase oil level will require close attention. Dusty conditions tend to load crankcase
on
oil with dirt. Watch for dirty and gritty oil conditions, and change oil more frequently as
required.
(4) Operation in Salt Water Areas /m
s:/
a. Canopy
Wash canopy regularly to remove salt film. Repaint any damaged places and oil the hinges
ttp
regularly.
-h
b. Covering
To protect the engine and generator as much as possible from salt water atmosphere, keep
6
the side doors on the canopy closed, when not in use. It is advisable to keep the unit covered
32
with a tarpaulin, if available, when not in use. Salt water should be wiped from the engine,
and all terminals and connections in the electrical system wiped dry. Keep all linkage oiled.
-5
c. Brushes
02
The brushes of the generator should be inspected regularly to make certain that they are free
-7
in the holders. Lift the brushes in the brush holders about every two days to insure their
freedom to slide within the holder. Wipe dry all the parts that can be reached, and use
88
compressed air, if available, to dry the parts of the generator that cannot otherwise be
reached. See MAINTENANCE for brush care.
-8
d. Field coils
ll 1
The fields should be dried as thoroughly as possible. If they have become damp, proceed
with recommended procedure in MAINTENANCE section.
Ca
e. Battery terminals
ts
Thoroughly clean the battery terminals and connections. Coat terminals and connections with
petroleum jelly to retard corrosion.
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(5) Miscellaneous
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Once a month, oil the hinged plexiglass cover.

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Page 5

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Page 6

c om
ts.
Chapter 2. Servicing / Troubleshooting
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Section 1. Maintenance Inspection/Check
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1. General
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To make certain that generator set is always in good operating condition, it must be inspected,
maintained, and lubricated regularly and systematically.
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WARNING
Stop operations at once if a serious or possibly dangerous fault is discovered.
on
2. Maintenance Schedule
a. General
/m
s:/
Figure 1 provides a suggested schedule for periodic checks and services. Refer to Section 2-2 for
lubrication requirements.
ttp
b. Maintenance Schedule Check Sheet

-h
It is strongly recommended that the customer use a maintenance schedule check sheet. The check
sheet will provide a record of maintenance specific operation.
6
32
c. Time Intervals
The schedule is based on both hours of operation and calendar intervals. These two intervals are
-5
not necessarily the same. The calendar period is included to make certain services are performed
02
regularly when equipment is being operated infrequently, or at manufacturer’s recommendations.

Perform all services on a “whichever comes first” basis.
-7
88
3. Engine and Related Components

Refer to the Engine Manufactures User’s Handbook for detailed engine maintenance information.
-8
ll 1
Ca
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8 hrs.
First or
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500 hrs.
Service Daily 250 hrs.
ts.
or 2000
Recommended Service Intervals at or
12 Hours
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20/40 6 Months
Months
Hrs
tp
en
Engine
Check oil level X
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Check coolant level X X
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Check fuel quantity X
Check gages and instruments for proper operation X
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Drain Fuel Pre-Filter Element X X
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Change engine oil X X
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Change oil filter X X
Check and tighten drive belts X X
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Clean and inspect exterior of radiator X
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Check exhaust system X
Check cooling system concentration X
on
Atomizer Maintenance X
Replace fuel filter
Clean engine
/m X
X
s:/
Check valve tip clearance, adjust if necessary X X
ttp
Electrical System (12V DC)

Check lights X
-h
Check charging rate X

Check battery state of charge (alternator) X
6
Check wiring and connections X

32
Check starter motor X

-5
Check battery terminals and connectors X

Electrical system (28.5V DC)
02
Check indicating light X

-7
Check operation of all instruments, meters, etc. X

88
Check generator brushes for length, cleanliness

X
and free operation
-8
Check slip rings for smoothness and cleanliness X

ll 1
Check the entire unit X

Check overvoltage protection X
Ca
Check all wiring connections X

Trailer (500285-001 only)
ts
Lubricate X
Check tire inflation X
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Check and adjust wheel bearings X

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Lubricate wheel bearings X

Check brake tension X
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Inspection/Check/Maintenance Schedule
Figure 1
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4. Inspection and Cleaning
Every day, check for oil, coolant, or fuel leaks. Also check for loose electrical connection. Check oil
c
ts.
pressure with engine running at rated RPM (2500). Do not operate engine if oil pressure is less than
20 psi (138 kPA). Wipe accumulated water off from all electrical connections and instruments. Make
ar
sure that the battery voltmeter reads proper voltage.
tp
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
en
securely refasten. Check engine oil and coolant levels.
m
Every month, check generator for amperage and voltage output. Blow out generator windings with
compressed air, not over 25 psi (172 kPa) pressure or remove with a suction-type cleaner with a
uip
non-metallic nozzle. If windings should become slightly damp, use space heaters or electrical light
bulbs to effectively dry out the windings. If dampness is excessive, apply external heat under a canvas
q
cover, well vented. Heating should not exceed 194º F (90º C).
re
Pound out any dents in the canopy. Sand, prime, and repaint any dented or rusted spots.
oo
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on
/m
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32
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Jet-Ex 5D / Series 500285/ Generator Set
c om
Section 2. Maintenance Procedures
ts.
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1. General
tp
A suggested Maintenance Schedule is provided in Section 1 of this Chapter. Each step of the schedule
en
is also covered in general in Section 1. This Section covers maintenance in more detail where
necessary.
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WARNING
Stop operation immediately if a serious or possibly dangerous fault is
q
discovered.
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2. Lubrication
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a. General
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Proper lubrication is one of the most important steps in good maintenance procedure. Proper
lubrication means the use of correct lubricants and adherence to a maintenance time schedule.
Lubrication points, frequency of lubrication, and recommended lubricants are part of the time
on
schedule.
b. Lubrication Chart
/m
s:/
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 are
ttp
identified in Figure 2. Letter symbols used to designate the normal lubrication period are identified in
Figure 3.
-h
c. Generator
6
The 28.5 volt DC generator requires NO lubrication. The armature is sealed at the factory for
32
lifetime, maintenance free operation. The front end of the armature is supported by the engine main
bearings.
-5
d. Generator Controls
02
Generator controls and instruments require no periodic lubrication. A few drops of oil may be
required on the clear plexiglass cover hinge occasionally to insure free and quiet operation.
-7
88
e. Engine
Although the engine and its accessories require no more attention than any other similar installation,
-8
they still inherently require a major portion of the generator set lubrication and maintenance.
ll 1
Recommendations regarding engine lubrication have been taken from the Engine Manufacturers
Users Manual.
Ca
(1) Lubrication Schedule

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

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

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(2) Oil Specification

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


Jet-Ex 5D / Spec. 7500285/ Generator Set
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32
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02
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88
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Check oil daily

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

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Lubrication Chart
To
Figure 1


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Symbol Name Specification Notes
1
c
Grease, Automotive and Federal VV-G-632 Sinclair LItholene Industrial
ts.
Industrial No.2; Mobile-Mobilplex 47 or
equivalent.
ar
2 Oil, Engine, Heavy Duty MIL-L-46152 or See Cummins Engine
tp
MIL-L-2104C User’s Handbook for
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recommended oil viscosity
3 Grease, Automotive Military MIL-G-10924B Wheel bearings
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Lubricants
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Figure 2
Symbol Time Interval
q
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D 10 hours or Daily
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BW 100 hours or Biweekly
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M 200 hours or Monthly
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BM 400 hours or Bimonthly
SA 800 hours or Semiannually
on
Symbols and Time Intervals
/m
Figure 3
s:/
(3) Change lubrication engine oil
Oil should be changed once after the first 20/40 hours of operation and then once every 250
ttp
hours of operation thereafter. 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
-h
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
6
sediment will be in suspension and oil will drain readily without clinging to internal surfaces.
32
CAUTION
-5
DO NOT use solvents as flushing oils in running engines.

02
-7
NOTE: Change the oil filter each time the oil is changed (250 hours).
88
(4) Change oil as follows:

a. Provide a container for catching used oil. Capacity should be greater than 2 gallons.
-8
b. Remove drain plug located in oil pan. Allow sufficient time for oil to drain from valve train,
ll 1
timing gear case, etc., before reinstalling plug.

NOTE: Change oil filter while oil is draining.
Ca
Change oil filter as follows:

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

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d. Loosen filter with a special oil filter removal wrench. Several types are available. Discard oil
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filter.
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e. Coat the gasket on the new filter with oil.

f. Place the new filter in position on the cylinder block and spin on until the gasket contacts the
Or
adapter face; then hand tighten another 1/2 turn. Do not over-tighten.
To
g. Clean drain plug and reinstall. DO NOT over-tighten.


om
h. Remove filler cap on valve cover and refill crankcase with fresh clean oil, of proper
specification and viscosity (see Para. 2, E, (2) and Figure 2). Seven quarts are required when
c
oil filter is changed.
ts.
i. Replace oil filler cap.
ar
j. Start engine and allow it to idle. Oil pressure should come up to normal quickly. Check for oil
tp
leaks at filter and drain plug.
en
k. Stop engine. Allow several minutes for oil to drain to crankcase, then check oil level. It should
m
be at FULL mark on dipstick.
uip
l. Check hourmeter and record time and date of oil change for maintenance reasons..
3. Servicing the Air Cleaner
q
The air cleaner is a dry type with a “C” flow cartridge. A definite time schedule for changing the filter
re
cartridge cannot be determined because of varying operating conditions, therefore an air restriction
oo
indicator lamp (Sect. 1-3; 16, Figure 1) is mounted on the control panel. Change the filter when the red
indicator lamp glows.
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a. Cartridge Removal
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(1) Open right rear canopy door to gain access to the air cleaner.
on
(2) Using a 5/16 socket, loosen the clamps which surround the air cleaner and secure it to the air
filter bracket.
/m
(3) Loosen and remove the clamp and air cleaner from the intake hose.
s:/
CAUTION
ttp
DO NOT attempt to clean or re-use old cartridge.

-h
b. Cartridge Installation
(1) Attach the new air filter cartridge to the intake hose and tighten the clamp.
6
32
(2) Secure the air filter cartridge to the air filter bracket with the same two large clamps. DO NOT
over-tighten.
-5
4. Servicing the Fuel Filter

02
Refer to the Engine Manufacturers User’s Handbook for instructions on removal and replacement of
fuel filter elements.
-7
5. Drive Belt Service

88
Check all drive belts and adjust if necessary each 250 hours. Refer to Engine Manufacturers User’s
-8
Manual for proper procedures.

6. Engine Cooling System
ll 1
NOTE: Refer to the Engine Manufacturers User’s Manual for detailed instructions on servicing the engine’s
Ca
cooling system.
In all weather situations, the engine coolant should always contain a solution of 50% water and 50%
ts
antifreeze (ethylene glycol). Rust inhibitors are recommended in the coolant as rust corrosion can still
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occur.
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WARNING
Never remove the cap from a hot radiator. The radiator cap should not be
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removed unless the engine temperature is 140º F (60º C) or below.

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To


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a. Radiator Cap Removal
Cover the cap with a thick cloth and turn it slowly counterclockwise to the first stop. When pressure
c
ts.
is completely released, press downward and finish removing cap.
ar
CAUTION
tp
DO NOT add coolant to an extremely hot engine. This can result in a cracked
block or cylinder head.
en
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b. Rust Inhibitor
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Use only a corrosion inhibitor that is compatible with aluminum. Do not use inhibitors labeled as
“acid neutralizer.”
q
c. Antifreeze
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A permanent type (Ethylene Glycol) antifreeze is recommended for use in the cooling system. The
oo
coolant, when mixed as equal parts of water and the recommended antifreeze, will provide
protection to -35º F.
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7. Battery Service
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a. General
on
A 12-volt battery supplies power for operation of the engine electrical system, clearance and panel
lights, and for building up generator voltage. The battery supplied with a new unit is a maintenance
/m
free type. Some of the following topics apply to non-maintenance free type battery, which requires
additional maintenance such as checking liquid levels.
s:/
b. Battery Location and Accessibility

ttp
The battery is located on a tray mounted to the left front frame. The battery is easily accessible for
-h
service by opening the left front door and removing the lower panel below the door.
c. Battery Care
6
(1) Never allow a battery which has been removed from a unit to sit on concrete, ground, or metal,
32
unless proper insulation is provided. A wooden platform or board will provide sufficient insulation.
-5
(2) Maintain stored batteries in a charged condition,

02
(3) Be sure battery is fastened securely in their compartment to avoid damage from vibration.
(4) If applicable, maintain battery fluid at proper level (see below).
-7
(5) Keep battery terminal posts and lead cable connectors clean.
88
-8
WARNING
Never allow sparks or open flame near battery. Avoid spilling electrolyte on
ll 1
hands or clothing.
Ca
d. Liquid Level (If battery is not a maintenance free type)

The electrolyte in each cell should be above the plates at all times to prevent battery failure.
ts
Check the level of the electrolyte every two weeks. When electrolyte level is low, add pure
ar
distilled water. Do not use hydrant water or any water which has been in contact with a metal
container. Acid should never be added except by skilled battery personal.
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CAUTION
Never add any special battery dopes, solutions, or powders.
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NOTE: It is especially important to keep the battery at full charge for cold weather operation. Add distilled water
To
to the battery in freezing temperatures only when the engine is to operate for several hours. Thoroughly


om
mix the water and the electrolyte, or damage to the battery will result from the water freezing.
c
e. Cleaning the Battery
ts.
If the top of the battery is dirty, it may be cleaned with a brush dipped in ammonia or soda solution.
Disconnect lead connectors from battery posts. Vent plugs should be tightened to prevent cleaning
ar
solution from entering cells. Clean battery as required, using brush and cleaning solution. Flush off
tp
the battery with clean water. Special terminal cleaning tool. Make certain that vent holes in filler
caps are not clogged.
en
f. Testing a Battery
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Tests are made on a battery to determine the state of charge and also its condition. The results of
uip
these tests show whether the battery is good, needs recharging, or must be replaced. If a battery
has failed, is low in charge, or requires water frequently, the reason for the condition must be found
q
and corrected. Visually inspect the battery before testing, to determine if it has been damaged.
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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
oo
may be used to determine the battery’s ability to deliver current. A battery hydrometer test
determines the charge condition of the battery.
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(1) Battery-Starter Tester
ste
Connect battery to the tester according to instructions furnished with the instrument. Test
battery according to tester instructions. If the test determines that the battery has acceptable
on
voltage, this indicates that the battery has output capacity and will accept a charge if required.
(2) Hydrometer
/m
s:/
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. A fully
ttp
charged battery will give a specific gravity reading of 1.265 to 1.285. The specific gravity of a
fully discharged battery may range from 1.140 down to 1.120.
-h
NOTE: The battery is fully charged when all cells are gassing freely, and the specific gravity ceases to
rise for three successive readings taken at hourly intervals.
6
32
a. If the battery starter test indicated that battery voltage was below the acceptable voltage
value, test each cell with the hydrometer. If the difference in specific gravity readings between
-5
any two cells is 50 points (0.050) or more, the battery isn’t satisfactory for service and should
be replaced.
02
-7
88
-8
A-Leads
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B-Brusholder Caps
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Generator Revolving Field Brushes C-Brusholder

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Figure 4
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D-Brush
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E-Slip Rings
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8. Generator Maintenance
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a. General
ts.
The only maintenance service required for the generator will be brush replacement, slip ring
cleaning, etc.
ar
b. Brush Service
tp
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If inspection reveals that brushes are gummy or sticking in the brush holders, they should be
removed and cleaned. Clean both the brushes and brush holders. Use a good, SAFE, commercial
m
cleaner.
DRY ALL PARTS THOROUGHLY. Be sure brushes can move freely in brush holders.
uip
CAUTION
q
DO NOT use a flammable solvent. DO NOT use steam cleaner, or soaps and
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detergents under pressure.
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c. Generator Revolving Field Brush Replacement (See Figure 4)
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(1) Disconnect leads (A, Fig. 4) from connectors on brush holder caps (B).
ste
(2) Remvoe brush holder caps (B) from brusholder.
on
WARNING /m
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.
s:/
ttp
(3) Lift brush (D) from brush holder (C) for inspection. If brushes are worn unevenly or are shorter
than 7/16 inch (11 mm), replace them.
-h
(4) Inspect slip rings whenever brushes are removed for servicing brushes or brush holders. Note
surface conditions of rings. Surface should appear smooth and clean. Scoring or roughness of
6
slip rings may be caused by grit or abrasive substance in brushes, or by oil on the rings.
32
Moderately rough slip rings can 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
-5
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.
02
(5) Slip new brushes into brush-holder guides, and place caps on top, and screw them into the
-7
guides to a “bottomed” position. The spring attached to the brush will determine the pressure at
which the brush contacts the slip rings.
88
(6) To fit new brushes to the slip rings, lay a strip of No. 00 sandpaper, smooth side down, on slip
-8
ring surface, and draw the sandpaper 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
ll 1
carbon dust out of the machine using not over 25 psi (172 kPa) air pressure.
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Section 3. Adjustment/Test
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1. General
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The adjustments and test procedures presented below are required after major repairs, parts
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replacement, or long storage.
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2. Testing the Generator Set
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Test values listed below will result when the generator set is operating properly. If your test results are
not within the limits shown, perform the applicable troubleshooting procedures given in Chapter 3.
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If major repairs have been made or if critical components have been replaced, make sure that the
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applicable adjustments have been made before testing the generator set. Adjustment procedures are
described in Para. 3 of this Section.
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a. Pre-operational Test Procedures
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(1) Open engine compartment doors and inspect the interior for rags, tools, and other foreign
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materials.
(2) Check engine oil level.
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(3) Check coolant level.
(4) Check battery water level (if required)
/m
s:/
(5) Check for sufficient fuel.
ttp
(6) Check drive belts. Each belt should have approximately 1/2 inch (13 mm) slack.
(7) Inspect all wiring for possible trouble spots such as loose wires or terminals, frayed insulation,
-h
obvious shorts, etc.

(8) Check panel lights, panel light switch, and fuse.
6
32
(9) Connect cables from generator output terminals to a load bank. The output cable consists of two
single conductor cables not more than 30 feet (9 m) long. The diameter size of each of these
-5
two cables is determined by the maximum starting current expectations:

02
· Use No. 2/0 cable for 600 amp. maximum starting current
· Use No. 4/0 cable for 1500 amp. maximum starting current.
-7
88
-8
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32
-5
02
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88
1. TACHOMETER M403 11. ENGINE ON lamp DS407

-8
2. HOUR METER M402 12. ENGINE START push button switch S401
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3. VOLTMETER (generator) M406 13. ENGINE CIRCUIT toggle switch S404

4. AMMETER M407 14. ENGINE CIRCUIT FUSE (20 Amp.) F402
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5. PANEL LIGHTS FUSE (10 amp) F401 15. WATER TEMPERATURE gauge M404
6. PANEL LIGHTS toggle switch S405 16. AIR FILTER RESTRICTION
INDICATOR lamp DS412
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7. CONTACTOR CONTROL toggle switch S408

17. OIL PRESSURE gauge M405
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8. CONTACTOR CLOSED lamp DS408

9. CURRENT LIMITING CONTROL 18. FUEL gauge M408
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potentiometer R402 19. VOLTMETER (battery) M401

10. SPEED CONTROL toggle switch S406
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(Front View)
Figure 1
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b. Operational Tests (Figure 1)
(1) Start the engine as described in 1-3; Para. 2, and let it warm at idle speed.
c
ts.
(2) Inspect for oil, fuel, and coolant leaks.
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(3) Check the engine VOLTMETER (19) for proper voltage. Check OIL PRESSURE gauge (17). It
should read 35 to 60 psi (241 to 414 kPa). Check WATER TEMPERATURE gauge (15). It
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should read 180 to 200º F (82 to 93º C.) when engine is hot.
en
(4) Observe engine RPM on the TACHOMETER (1), idle speed should be 1000 RPM ± 50 RPM.
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(5) Place the SPEED CONTROL switch (10) in the RATED RPM position. Check engine RPM’s at
operating speed: 2500 RPM ±50
uip
(6) Check for 28.5 output voltage on generator VOLTMETER (3) to assure automatic voltage
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buildup.
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(7) Set CURRENT LIMITING CONTROL potentiometer (9) to maximum, full clockwise, position.
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(8) Adjust the load bank for a load of 550 amperes.
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(9) Place the CONTACTOR CONTROL toggle switch (7) in the CLOSE position. The CONTACTOR
CLOSED lamp (8) will glow as the contactor will close. Release the CONTACTOR CONTROL
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toggle switch to the center ON position. The TACHOMETER (1) will indicate 2200 ± 25 RPM.
(10) Disconnect the load bank and check the overvoltage protection by adjusting voltage regulator
on
potentiometer R46 (1, Fig. 2) to increase the voltage. The overvoltage relay will trip and open the
load contactor between 32 to 34 volts. /m
(11) Readjust the voltage to 28.5 volts, connect the load bank, set it at 550 amperes, and close the
s:/
contactor.
ttp
(12) Remove load bank and check voltage regulation at no load. Voltage will be 28.5 volts.
Reconnect load bank and check voltage regulation with load bank set at 137, 275, 413, 550, and
-h
660 amperes and check voltage at each setting. Voltage will be 28.5 ± 1 volts at each different
load.
6
(13) With CURRENT LIMITING CONTROL potentiometer (9) set to 2000, apply 600 to 700 amperes
32
load to the generator and then set the CURRENT LIMITING CONTROL potentiometer to 400.
Current displayed on AMMETER (4) will be 400 ± 40 amperes.
-5
NOTE: Voltage will not drop below 14 volts.

02
(14) Set CURRENT LIMITING CONTROL potentiometer (9) to 2000 and apply 1200 amperes load.
-7
Then set the CURRENT LIMITING CONTROL potentiometer to1000. Current displayed on
AMMETER (4) will then be 1000 ± 100 amperes and voltage will not drop
88
(15) Remove load. Set engine to idle. Run for 3 minuets at idle
-8
(16) Stop and restart the engine, check the instruments as directed in step (3), and check the entire
ll 1
generator set for unusual vibration and noises.

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3. Voltage Regulator Adjustment
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a. 28.5 Volt Adjustment
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(1) The regulating voltage, in the 28.5 volt range, is determined by the position of the wiper arm of
the multi-turn potentiometer (1,Figure 2) R46. Clockwise (CW) rotation increases the voltage
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level at which the unit operates. Conversely, counterclockwise (CCW) rotation decreases the
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voltage level.
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b. Line Drop Compensation
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(1) 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 (CW) rotation of the
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single-turn potentiometer (2,Figure 2) R24 increases the compensation. This potentiometer
should be set for flat regulation of voltage at the load end of the output cable when delivering
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rated load current.
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32
-5
02
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Voltage and Line Drop Adjustments

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Figure 2
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Section 4. Troubleshooting Procedures
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1. General
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Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the
en
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
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manner, until the cause of trouble is located. Reference connection and schematic diagrams.
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2. Troubleshooting Chart
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a. Description
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The troubleshooting chart lists information under three headings:
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(1) Trouble, Symptom, and Condition,
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(2) Probable Cause
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(3) Test, Check, and Remedy
b. Use of the Troubleshooting Chart
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Read the trouble symptoms and conditions before proceeding to causes and remedies.
/m
For example:
s:/
At the beginning of the troubleshooting chart under ENGINE, the first trouble listed is: “Engine
will not start. Starter will NOT crank engine.”
ttp
If the starter WILL crank the engine, then obviously this is not your symptom and condition. Go to
-h
the next “Trouble, Symptom, and Condition” directly below. If the starter will NOT crank the engine,
look to the right under “Probable Cause” and “Test, Check, and Remedy” to find the various things
6
which could cause the trouble and what to do to check and remedy them.
32
3. Equipment for Troubleshooting

-5
A good quality, multi-scale voltmeter is the only instrument required similar clips, will be required. The
12 volt engine electrical system may be used for a 12 volt DC power source.
02
4. Safety Precautions
-7
88
WARNING
Loose garments, neckties, and other hanging items must not be worn by
-8
personnel near the fan or other exposed moving parts of this equipment while it
is running. Also, avoid contact with live electrical parts. death or serious injury
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could result!
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5. Diagrams
A schematic/connection diagram of the generator set is provided in Chapter 5. This diagram can be
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very helpful in troubleshooting. Components shown in the diagram are identified by reference
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designators (or item names in some instances). A legend appearing on the diagram identifies each
reference designator by its full item name. For example, the symbol K403 identifies the overvoltage
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relay, and M406 identifies the voltmeter.

6. Connections and Wiring
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Before condemning any electrical component, check all connections and wiring which could affect its
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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. In most cases throughout the troubleshooting
chart, it will be assumed that connections and wiring have been checked.
To

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7 2 1
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32
-5
02
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-8
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10
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1. Fuel Tank Support 6. Frame

2. Fuel Tank 7. Engine
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3. Control Panel 8. Air Cleaner

4. Rectifier Assembly 9. Battery
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5. Generator 10. Contactor

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Figure 1
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02
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3 2
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1. Muffler
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2. Alternator
3. Oil filter
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4. Starter
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5. Starter solenoid
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Engine Comp[onents
(Right Side of Unit)
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Figure 2
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5
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3
6
32
-5
02
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88
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1. Fuel filter
2. Air cleaner
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3. Throttle control assembly

4. Oil pressure sender
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5. Oil pressure switch 20 psi (138 kPA)

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6. Water Temp. Sender

7. Radiator
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Engine Components
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(Left Side of Unit)

Figure 3
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6
32
-5
02
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88
1. TACHOMETER (M403) 11. ENGINE ON lamp (DS407)

2. HOUR METER (M402) 12. ENGINE START push button switch (S401)
-8
3. VOLTMETER (generator) (M406) 13. ENGINE CIRCUIT toggle switch (S404)

ll 1
4. AMMETER (generator) (M407) 14. ENGINE CIRCUIT FUSE (20 Amp.) (F402)
5. PANEL LIGHTS FUSE (10 amp) (F401) 15. WATER TEMPERATURE gauge (M404)
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6. PANEL LIGHTS toggle switch (S405) 16. AIR FILTER RESTRICTION

7. CONTACTOR CONTROL toggle INDICATOR lamp (DS412)
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switch (S408) 17. OIL PRESSURE gauge (M405)

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8. CONTACTOR CLOSED lamp (DS408) 18. FUEL gauge (M408)

9. CURRENT LIMITING CONTROL 19. VOLTMETER (battery) (M401)
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potentiometer (R402)
10. SPEED CONTROL toggle switch
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(S406)
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(Front View)
To
Figure 4

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32
-5
02
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88
-8
1. Over voltage relay (K403)

2. Voltage regulator (VR402)
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3. Excitation rectifiers (CR417 & CR418)

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

5. Voltage build-up fuse (10 Amp.) (F405)
6. Voltage regulator fuse (10 Amp.) (F403)
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7. Throttle solenoid fuse (20 Amp. Slo-Blo) (F409)

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

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9. Rectifier Harness Connector (J43)

10. Engine Harness Connectors (J46 & J47)
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11. Rectifier (CR401)

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12. Capacitor (C403)

(Interior View)
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Figure 5

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Section 5. Troubleshooting Charts
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See section 2-4 for all figures referenced in this section.
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Engine and Controls
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Trouble, Symptom and Condition Probable Cause Test, Check, and Remedy
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1. Engine will not start. Starter a. Batteries discharged, sure Check battery connections and
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will not crank engine. this voltage is reaching or check voltage across battery.
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loose battery or ground Voltage should be approximately
connection. 12.8 VDC. If battery and
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connections are good, proceed
to the next step.
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b. ENGINE START push Momentarily connect a jumper
on
button switch S401 between the hot side of the
(12, Figure 4) defective. starter solenoid L401 and the
/m start switch terminal on the
starter relay wire. If the starter
s:/
operates, replace faulty switch.
If starter doesn’t crank, proceed
ttp
to the next step.

-h
c. Defective starter solenoid Momentarily connect a large

L401 (5, Figure 2) capacity jumper cable between
the hot side of the starter relay
6
(Figure 2) and the starter input

32
terminal. If the starter attempts

to crank the engine, the starter
-5
solenoid is defective. Replace

02
it. If engine still won’t crank,

proceed to the next step.
-7
d. Defective starter B401 If the engine will not crank after

88
(4, Figure 2) the previous steps, the starter is

defective. Replace starter. If
-8
starter did attempt to operate,

but couldn’t turn engine,
ll 1

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e. Internal engine seizure. CAUTION:

Make certain that engine start
switch is in “stop” position so
ts
that engine does not start.

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Use a socket wrench on the front

crankshaft pulley to try to turn
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engine by hand. If engine will

not turn, internal damage is
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indicated.
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Engine and Controls (continued)
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Engine will not start. Starter f. Engine seized up NOTE:
will not crank engine If engine is overcharged
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(continued). with ether for cold weather
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starting, it could seize up. If so,
wait approx. 1/2 hour until it will
be possible to turn engine.
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2. Engine will not start. Starter a. ENGINE CIRCUIT FUSE Replace ENGINE CIRCUIT
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DOES crank engine. F402 (14, Figure 4) blown FUSE. Use type AGC-2O fuse.
b. Fuel valve at tank closed, or Check and correct as required.
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no fuel in tank, engine has
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lost its prime
c. Defective ENGINE Check for 12-V DC from
on
CIRCUIT toggle switch terminal 4 of S404 in “START”
S404 (13, Figure 4) position. If 12-V DC is not
/m measured, replace defective
switch.
s:/
d. Defective fuel valve Attempt to start engine while
ttp
solenoid (L404). applying 12-V DC to the fuel

valve solenoid. If the engine
-h
starts, the solenoid is defective,

and should be replaced. If
6
engine still doesn’t start,

32
proceed to next step.

e. Defective fuel pump. Check fuel pump according to
-5
instructions in the Engine

02
Manufactures User’s Manual.

3. Engine starts then stops. a. Fuel not turned on. Turn on fuel shutoff valve.
-7
88
b. Defective oil pressure Connect a jumper wire across

switch S403 (5, Figure 3) the “C” and “N.O.” terminals of
-8
oil pressure switch. Start engine

and check oil pressure. If it is
ll 1
below 10 PSI (69 kPa) shut

down the engine and check
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lubrication system for leaks.

Also check the oil pump for
leaks. If oil pressure comes up
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to normal and the engine

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continues to run, the oil

pressure switch is defective.
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Replace oil pressure switch.

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4. Engine starts then stops when a. Open over temperature Place a clip-lead jumper wire on
ENGINE CIRCUIT toggle switch S402 or defective the water temperature switch
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switch S404 is released to ENGINE CIRCUIT toggle terminals and check for normal
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“ON” position. switch. operating temperature. If engine
then starts properly, replace
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water temperature switch. If not,
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replace engine switch.
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b. Choked fuel filter, restriction Check for these faults according
in air cleaner, or air in fuel to instructions in the Engine
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system. Manufactures User’s Manual.
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5. Engine does not attain normal a. Loose throttle linkage If solenoid core is pulled into the
idle RPM, or idles too fast. full throttle solenoid L403 when
on
SPEED CONTROL toggle
/m switch S406 is in RATED RPM
position, check for loose control
s:/
rod between solenoid and
throttle. Tighten if required. If
ttp
solenoid core does not pull in,

-h
b. Defective full throttle Check for l2-V-DC across two

solenoid L403. terminals of solenoid when
6
S406 is in RATED RPM

32
position. If l2-V DC is measured,

but solenoid core does not pull
-5
in, replace the solenoid.

02
6. Engine will not run at rated a. SPEED CONTROL toggle If engine will not go from idle to
speed (2450-2550 RPM) switch S406 (10, Figure 4) rated speed when SPEED
-7
defective. CONTROL toggle switch is in

RATED RPM position, turn off
88
engine and take resistance

-8
measurements at SPEED
CONTROL toggle switch
ll 1
terminals with switch in the

RATED RPM position.
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Zero resistance should be

measured between terminals
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having red-blue and orange

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yellow wires. Replace speed

control switch if measurement is
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improper.
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7. Engine lacks power. a. Insufficient air to engine. Check AIR FILTER
RESTRICTION INDICATOR
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lamp (16, Figure 4) for
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illumination. Replace or clean as
required.
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b. Restricted exhaust system. Check exhaust pipe for
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restrictions. Check muffler for
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clogged condition. Replace as
required.
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c. Low compression. Check compression in all
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cylinders according to the
Engine Manufactures User’s
Manual.
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8. Engine Overheats. a. Dirt or sludge in Coolant Drain coolant, flush radiator, put
/m in clean coolant. Refer to the
Engine Manufactures User’s
s:/
Manual in for instructions.
ttp
b. Debris and dirt in radiator Clean radiator core carefully.

core. Refer to the Engine
-h
Manufactures User’s Manual.

c. Fan belt slips or is broken. Tighten belt or replace as
6
required
32
-5
02
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88
-8
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Generator and Controls
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1. Generator will not build up a. Voltage build-up fuse F405 Replace voltage build-up fuse
voltage when SPEED is blown. (5, Figure 5). Proceed to Step b
m
CONTROL toggle switch S406 to determine cause of blown
uip
(10, Figure 4) is placed in fuse.
RATED RPM position.
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b. Defective excitation rectifier Check excitation rectifiers ( 3,
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CR417 and/or CR418. Figure 5) with an ohmmeter to
oo
see if they are good. If either
rectifier is defective, replace it.
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If both rectifiers are good,
proceed to Step c.
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c. Defective capacitor C403. Check capacitor (12, Figure 5)
with an ohmmeter to see if it is
on
good. If defective, replace it;
/m otherwise proceed to Step d.
d. Defective flyback diode Check diode, on brushholder
s:/
CR419. mounting bracket, with an
ohmmeter to see if it is good. If
ttp
defective, replace it; otherwise

proceed to Step e.
-h
e. Generator revolving field Locate yellow and red-orange

L406 defective. wires on the right terminal strip
6
at lower rear of control panel.

32
Disconnect the yellow and

-5
red-orange wires which go down

to the generator. Refer to
02
connection diagrams in Chapter

5.
-7
Measure resistance between

88
these two wires. It should be 10

to 11 ohms. If reading indicates
-8
an open, short or lower than

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normal resistance, proceed to

Step f.
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f. Defective generator If check of the generator

armature G402. revolving field (Step e. above)
revealed no trouble, the
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generator stator is defective.

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Send unit to overhaul.

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g. Voltage regulator fuse F403 Replace voltage regulator fuse

is blown. (6, Figure 5). Proceed to Step
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h. to determine reason for blown

fuse.
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Generator and Controls (continued)
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Generator will not build up h. Defective rectifier CR401. Use ohmmeter to check rectifier
voltage when SPEED CR401 (11, Figure 5). Replace
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CONTROL toggle switch S406 rectifier if defective.
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(10, Figure 4) is placed in
RATED RPM position
(continued)
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i. Generator voltage regulator Replace voltage regulator (2,
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VR402 defective. Figure 5).
2. Generator builds up to only a a. Defective excitation rectifier Check excitation rectifiers (3,
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low voltage when SPEED CR417 and/or CR418. Figure 5) with an ohmmeter to
ste
CONTROL toggle switch S406 see if they are good. If either
(10, Figure 4) is place in rectifier is defective, replace it.
RATED RPM position If both rectifiers are good,
on
proceed to Step b.
VR402 defective.
/m
b. Generator voltage regulator Replace voltage regulator (2,
Figure 5).
s:/
3. Generator builds too high a a. Defective SPEED Use ohmmeter to check SPEED
ttp
voltage. CONTROL toggle switch CONTROL toggle switch.

S406 (10, Figure 4). Replace switch if defective.
-h
b. Defective blocking rectifier Use ohmmeter to check

CR401. blocking rectifier (11, Figure 5)
6
Replace rectifier if defective.

32
c. Generator voltage regulator Replace voltage regulator (2,

-5
VR402 defective. Figure 5) with a voltage

regulator known to be good, and
02
resume operation of generator

set. If new voltage regulator
-7
produces normal operating

88
voltage, send old voltage

regulator to factory for service.
-8
4. Load contactor will not close a. Defective CONTACTOR Momentarily connect a jumper
ll 1
when CONTACTOR CONTROL toggle switch. lead between terminals with red
CONTROL toggle switch S408 and yellow wires on the
Ca
(7, Figure 4) is placed in closed CONTACTOR CONTROL

position. Engine running toggle switch. If the load
normally, voltage normal, no contactor closes momentarily,
ts
load applied to output cable. replace switch.

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b. Defective load contactor If load contactor (10, Figure 1)

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K402. will not close when contactor

close switch is jumpered, it is
likely that the contactor is
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defective. Replace contactor.

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c
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Load contactor will not close c. Overvoltage relay K403 Connect a jumper lead between
when CONTACTOR defective. terminals T and P on the
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CONTROL toggle switch S408 overvoltage relay (1, Figure 5). If
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(7, Figure 4) is placed in closed contactor will now close, replace
position. Engine running overvoltage relay.
normally, voltage normal, no
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load applied to output cable
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(continued)
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5. Load contactor opens as soon a. Defective CONTACTOR Connect a jumper lead between
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as CONTACTOR CONTROL CONTROL toggle switch. terminals with red and blue
toggle switch S408 (7, Figure wires on the CONTACTOR
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4) is released from its top CONTROL toggle switch. If the
(spring-loaded) position, to Run load contactor now remains
on
position. closed, replace contactor close
switch.
b.
/m
c. Load contactor K402 If no fault was found in steps 4-a
s:/
defective. and b, the load contactor (10,
Figure 1) is probably defective.
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Replace load contactor.

-h
6. Load contactor K402 opens a. Contactor opening could Resume operation and closely
during power delivery. have been normal because observe VOLTMETER (3,
of an overvoltage condition. Figure 4) for evidence of
6
overvoltage. If contactor opens

32
when no overvoltage condition

exists, proceed to Step b.
-5
b. Overvoltage relay K403 Check overvoltage relay by

02
defective. operating the machine under

load and gradually raising
-7
voltage at the voltage regulator

88
(2, Figure 5) while observing

VOLTMETER (3, Figure 4).
-8
Start with a low voltage (25V

DC) and gradually increase
ll 1
voltage until relay functions to

open load contactor. (32 to 34V)
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c. Overvoltage board out of If relay trips at less than 32-V

adjustment. DC, adjust potentiometer (P1)
ts
on the overvoltage board

(1, Figure 5). If this does not
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correct problem, return old

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board to factory for service.

d. Load contactor K402 If no fault was found in above
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defective. steps, replace load contactor

(10, Figure 1)
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7. Output current cannot be a. Defective CURRENT Shut down engine and check
limited by CURRENT LIMITING LIMITING CONTROL potentiometer with an
m
CONTROL potentiometer R402 potentiometer ohmmeter. To do this,
uip
(9, Figure 4) disconnect the plug (P404) from
the regulator board (2, Figure 5)
q
and take resistance
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measurements from pin 2 to pin
9 and then from pin 2 to pin 10
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on the plug. For each
measurement, slowly turn
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CURRENT LIMITING CONTROL
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potentiometer through its entire
range, while observing the
ohmmeter readings. Resistance
on
should be from 0-10 k ohms.
Replace if necessary.
/m
b. Defective voltage regulator Replace voltage regulator with
s:/
VR402. one known to be good, and then
operate the generator set under
ttp
sufficient load to observe

current limiting. If CURRENT
-h
LIMITING CONTROL
potentiometer now controls
6
current properly, send old

32
voltage regulator to factory for

service.
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02
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Chapter 3. Overhaul/Major Repair
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Section 1. Flexible Coupling
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1. General
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This chapter provides basic instructions for removal, service and installation of a flexible coupling kit,
with a fan attached. This flexible coupling kit is designed for use with single-bearing generator sets.
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Figure 1 shows a rear view and side view of the flexible coupling assembly. The primary function of this
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assembly is to couple a Hobart generator set to a diesel engine. The flexible coupling assembly
compensates for slight misalignment between the engine and the generator, due to manufacturing
on
tolerances. A split taper bushing secures the coupling to the generator’s armature shaft. (See Fig. 3 &
4).
/m
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Coupling Assembly
Figure 1
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2. Coupling Screws (Routine Coupling Maintenance)
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CAUTION
Failure to verify proper coupling screw installation may result in coupling failure
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and damage to the equipment.
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If the generator set is functioning properly, servicing the coupling assembly will be essentially limited to
en
checking the screws which attach the flexible coupling to the engine flywheel of the generator set.
These 8 screws should be checked periodically to make certain that: (1) screws of proper type, length,
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and hardness are installed, (2) that the threads of the screws are not stripped, and (3) that they are
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torqued properly. Proceed as follows to check coupling screws.
a. Remove the sheet metal covers from around the generator housing and the flywheel housing.
q
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b. Refer to Figure 2. Hold a short iron bar through the flywheel housing against the fan blades of the
fan and coupling assembly to block the armature against clockwise rotation. Do this carefully to
oo
avoid damaging the fan blades.
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c. Use a long-handled, reversible ratchet drive fitted with a 5/16-inch Allen wrench to remove one
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coupling screw. Examine the screw. Screws specified for this coupling are Hobart Part No.
402789-004, which are socket-head, 3/8 - 16 X 3/4 inch long.
on
NOTE: Use of the proper coupling screws for replacement is very important. Replacement screws
MUST be those specified above, torqued to 40 - 45 foot-pounds (54 - 61 Nm). There is NO
ACCEPTABLE SUBSTITUTE for these screws. /m
s:/
d. Check the threads of the screw for stripping and replace it if the threads are stripped. If the screw is
not stripped, reinstall it and torque it to 40 - 45 foot-pounds (54 - 61 Nm).
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e. Repeat the steps b, c, and d above for the remaining seven screws.
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f. Reinstall covers around housings.

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Access to Coupling Screws

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(for removal and

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installation)
Figure 2
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3. Disassembly
Removal of the flexible coupling is required for servicing the generator armature, generator bearings, or
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the coupling itself. To remove the coupling, for any reason, it is necessary to separate the engine and
generator. Many mechanics prefer to remove the engine and generator as an assembly, and then
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separate them. Others may prefer to remove the engine or the generator separately to reach the
coupling. However, separating the engine and generator while they are installed in the ground power
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unit is VERY DIFFICULT because of the limited working space.
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During removal DO NOT cut any cables or wires. Disconnect cables or wires if/as necessary and tag
them for reassembly.
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a. Separate Engine and Generator
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(1) Remove fuel tank and canopy components.
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(2) Remove the sheet metal cover from around the generator housing and the flywheel housing.
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(3) Attach a hoist to the generator housing.
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(4) Use a long-handled, reversible ratchet drive fitted with a 5/16-inch Allen wrench to remove the
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screws which attach the flexible coupling disk to the engine flywheel.
(5) Support the rear of the engine with a jack stand.
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(6) Remove the bolt and shock mount attaching the generator housing to the frame.
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(7) Remove the bolts attaching the generator housing to the engine flywheel housing.
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(8) Separate the generator from the engine with the hoist and move it to a clear working area.
s:/
b. Remove Coupling Assembly (Figure 3)
(1) Using a socket wrench, remove all three of the 3/8-16 X 3/4 inch screws (3) that secure the
ttp
bushing (1) to the hub of the fan and coupling assembly.

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(2) To separate the bushing from the hub, lubricate two of the 3/8-16 X 3/4 inch screws and insert
them into the threaded holes (4) in the bushing. With socket wrench, screw these screws into the
bushing such that the bushing pops loose from the hub.
6
32
(3) Using a 3/16-inch Allen wrench, loosen the set screw (6) in the bushing to release pressure on
the key (5).
-5
(4) When the bushing (1) is loose in the hub, use a mallet to GENTLY tap the bushing out of the
02
hub.
(5) Slide the coupling assembly off the shaft and remove the key (5).
-7
(6) Using a 9/16-inch socket wrench, remove the screws which attach the flexible disks to the hub.
88
(7) Inspect the coupling assembly components carefully as follows:

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

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b. Check hub and split bushing for cracks, evidence of galling, and rust pits. Light rust is
Ca
permissible on the split bushing and the tapered bore of the hub.
c. Check the flexible coupling disks for warping, cracks, or worn mounting holes.
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d. Check the screws which attach the flexible disks to the hub. The screws are Hobart Part No.
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287935-001, which are socket head, 3/8 - 16 X 2-1/4 inch long. If they are cracked,
stretched, or have stripped threads, replace them.
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NOTE: Use of the proper coupling screws and washers for replacement is very important.
Replacement screws and washers MUST be those specified above, torqued to 40 - 45
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foot-pounds (54 - 61 Nm). There is NO ACCEPTABLE SUBSTITUTE for these screws or

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

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1. Bushing
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2. Split
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3. Mounting Holes (3)
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4. Tapped holes (2)
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5. Key
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Split Taper Bushing
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Figure 3
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6
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4. Coupling Service
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If you have any questions concerning your Hobart Ground Power equipment, immediately contact our
Service Department by mail, telephone or FAX. When calling about service or parts from your Hobart
02
Brothers Company Distributor, be sure to include all pertinent information from the unit’s identification
plate: Specification No., Model No., and unit rating.
-7
88
Write: Hobart Brothers Company

Ground Power Division
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Service Department
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1177 Trade Road East

Troy, Ohio 45373
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U.S.A
In U.S.A. Call Toll Free (800) 422-4166 (Parts)
(800) 422-4177 (Service)
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From Foreign Countries, Call: (937) 332-5050 (Parts)

(937) 332-5060 (Service)
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Fax: (937) 332-5121

800-367-4549 Toll Free in U.S.A.
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5. Coupling Installation and Reassembly of Engine and Generator
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CAUTION Improper installation of the coupling assembly can result in serious damage to
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the equipment. Follow these installation instructions exactly.
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a. Cleaning (Figure 4)
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It is VERY IMPORTANT that the shaft, the bore and the outside of the split bushing, and the
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tapered inside of the hub be thoroughly CLEANED FREE OF DIRT AND GRIT.
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CAUTION
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Do not lubricate any of the surfaces listed above. Lubrication of these surfaces
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can cause the coupling to fail and damage the generator set. Slight traces of
rust are permissible only on the bushing, but nothing else.
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b. Assembly (Figure 4)
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CAUTION
Use of the proper coupling screws is very important. Failure to use the proper
on
screws, as outlined below, can result in coupling failure and damage to the
generator set. /m
s:/
Proceed as follows to reassemble engine and generator.
(1) Attach the four flexible disks to the coupling hub with the six socket head 3/8 - 16 X 2-1/4 inch
ttp
screws (Hobart Part No. 287935-001). The screws must be torqued to 40 - 45 foot-pounds (54 -
-h
61 Nm).
(2) Attach the coupling assembly to the flywheel, using the socket-head 3/8 - 16 X 3/4 inch screws
6
(Hobart Part No. 402789-004). DO NOT tighten with a wrench. See Figure 4.
32
(3) Torque all of the coupling screws to 40 - 50 foot-pounds (54 - 68 Nm). Be sure the flexible disks
are all seated evenly into the seat of the flywheel.
-5
(4) Install the key in the key way of the armature shaft.
02
(5) Place the coupling bushing on the shaft of the armature, aligning the key way of the bushing with
-7
the key way of the shaft.

(6) Using a hoist, align the bushing to the coupling key way and also the generator housing flange to
88
the engine flywheel housing, and insert the attaching screws for the housing. Start the screws
-8
into the tapped holes just enough to ensure thread engagement. DO NOT TIGHTEN.
(7) Tighten the generator housing attaching screws at this time.
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(8) Remove the bearing cap from the back of the generator assembly.
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(9) Inspect the rear bearing. If it has moved out of the rear bearing support hub, it will need to be
reset. Correct placement of the rear bearing, should be within 1/8” from the rear surface of the
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bearing hub.
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(10) Slide the coupling bushing forward until it is snug in the coupling hub.
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CAUTION
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Make certain that only the screws are lubricated, and that no lubricant is
permitted to get inside the bushing where the armature shaft will enter the
Or
bushing.
To
(11) Lubricate the three 3/8-16 X 3/4 screws SPARINGLY and start them into the three (unthreaded)
holes finger-tight. See Figure 4.

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(12) Refer to Figure 2. Insert and hold a short iron bar through the flywheel housing against the fan
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blades of the fan and coupling assembly to block the armature against clockwise rotation. Do
ts.
this carefully to avoid damaging the fan blades.
(13) Tighten the 3/8-16 X 3/4 screws alternately and evenly as follows:
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a. Set a torque wrench to 30 foot-pounds (41 N-m) and tighten all three 3/8-16 screws to that
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value. As illustrated in Figure 2, insert and hold a short iron bar through the fan housing
en
against the fan blades of the fan and coupling assembly to block the coupling against
clockwise rotation. Do this carefully to avoid damaging the fan blades. Note that as these
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screws are tightened, the armature will be pulled back into the bearing hub.
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b. Repeat step (a) above until 3/8-16 screws can no longer be tightened.
(14) Make certain that the armature is pulled slightly into the bearing hub (so that it does not interfere
q
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with the bearing cap).
(15) Using a 3/16-inch Allen wrench, tighten the set screw in the bushing to apply pressure on the
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key.
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(16) Re-install the bearing cap that was removed in step (8).
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(17) Re-install the generator housing cover and the flywheel housing cover.
(18) Re-install the fuel tank and canopy components.
on
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Assembly Procedure Illustration

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Figure 4
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6. Run-in and Periodic Check
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a. Mount the engine-generator assembly in a suitable test area and operate it for a 2-hour run-in.
ts.
b. Shut down the engine after 2 hours and re-torque all coupling screws to 40 - 45 foot-pounds (54 -
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61 Nm) to compensate for normal torque relaxation.
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c. Return the unit to normal service.
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d. After 200 hours of operation, check all coupling screws and taper-lock bolts with a torque wrench
set at 40 - 45 foot-pounds (54 - 61 Nm) .
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e. Return the unit to normal service.
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f. After each additional 2,000 hours of operation (or every year) recheck all coupling screws to
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maintain the same torque value.
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Chapter 4. Illustrated Parts List
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Section 1. Introduction
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1. General
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The illustrated Parts List identifies, describes, and illustrates main assemblies, sub-assemblies, and
detail parts of the Jet-Ex 5D Generator Sets manufactured by Hobart Brothers Company, Ground
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Power Division, Troy, Ohio 45373.
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2. Purpose
The purpose of this list is to provide parts identification and descriptive information to maintenance and
on
provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare
parts.
3. Arrangement
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CHAPTER 4 is arranged as follows:
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Section 1 - Introduction
Section 2 - Manufacturer’s Codes
-h
Section 3 - Parts List Section 4 - Numerical Index

4. Explanation of Parts List
6
32
a. Contents
-5
The parts list contains a breakdown of the equipment into groups, assemblies, subassemblies, and
detail parts. All parts of the equipment are listed except:
02
(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are
-7
available commercially.
88
(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
-8
other parts, weldments, or assemblies.

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b. Parts List Form

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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:
(1) “FIGURE-ITEM NO.” Column
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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
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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
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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.
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(2) “HOBART PART NUMBER” Column
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ALL part numbers appearing in this column are Hobart numbers. In all instances where the part
ts.
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
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number in the “NOMENCLATURE” column.
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(3) “NOMENCLATURE” Column
en
The item identifying name appears in this column. The indenture method is used to indicate item
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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
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column. Hobart modification to vendor items is also noted in this column.
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(4) “EFF” (Effective) Column
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This column is used to indicate the different models that use the part on that line. There are
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some parts may be used on only one, or a variety of models. A code letter “A”, “B”, etc., is
placed in EFF column to indicate these parts. It can be cross referenced to the particular model it
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is used on. If a letter is not placed in that column, then all models use that part.
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Parts coded “A” are useable on part number 500285-001 only.
Parts coded “B” are useable on part number 500285-002 only.
on
(5) “UNITS PER ASSEMBLY” Column
/m
This column indicates the quantity of parts required for an assembly or subassembly in which the
part appears. This column does not necessarily reflect the total used in the complete end item.
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Section 2. Manufacturer’s Codes
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1. Explanation of Manufacturer’s (Vendor) Code List
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The following list is a compilation of vendor codes with names and addresses for suppliers of
purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes
m
for Manufacturer’s Cataloging Handbook H4-l, and are arranged in numerical order. Vendor codes are
inserted in the nomenclature column of the parts list directly following the item name and description. In
uip
case a manufacturer does not have a vendor code, the name of the manufacturer will be listed in the
nomenclature column.
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Code Vendor’s Name and Address
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01XD4 Contact Industries Inc., 25 Lex-Industrial Dr.,
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P.O. Box 3086, Mansfield, OH 44904-3086
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02231 Anchor Rubber Company, 840 S. Patterson Blvd. Dayton, Ohio 45402
on
04055 East Penn Mfg., Co., Inc., Deka Rd., Lyon Station, PA 19536
04713
/m
Motorola Inc., Semiconductor Products Div. Phoenix, Arizona 85008
s:/
13445 Cole-Herse, 20 Old Colony Ave. Boston, MA 02127
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14552 Microsemi Corp., 2830 S. Fairview St., Santa Ana, CA 92704-5948

-h
14799 Square D Co., Chicago Assembly Plant,

9522 W. Winona, Schiller Park, IL 60176-1025
6
32
16476 Datcon Instrument Co., P.O. Box 128, East Petersburg, PA 17520
-5
18265 Donaldson Co., 1400 W. 94th St., P.O. Box 1299, Minneaplis, MN 55420
02
21585 Farr Co., 2221 Park Pl., EL Segundo, CA 90245

-7
23803 NTN Bearing Corp., 650 Pennsylvania Dr., Exton PA 19341

88
28520 Heyco Molded Products, 750 Boulevard,

-8
P.O. Box 160, Kenilworth, NJ 07208-1222

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

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P.O. Box 788 Independence, KS 67301-2347
33457 Fleetguard Inc., 402 BNA Dr., Nashville, TN 37217

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40121 Peterson Mfg. Co. Inc, 700 W. 143rd St., P.O. Box 8 Plainfield, IL
60544-9733
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44655 Ohmite Mfg. Co., 3601 W. Howard St., Skokie, IL 60076

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

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

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


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Code Vendor’s Name and Address
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5E599 NVF Co., Primary Products Div., Yorklyn Rd, Yorklyn DE 19736
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57733 Stewart-Warner Corp., 1826 Diversey Parkway, Chicago, IL 60614
en
59993 International Rectifier, 233 Kansas St., EL Segundo CA 90245
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71400 Bussman Division of McGraw-Edison Company, 114 Old State Rd.,
uip
St. Louis, Missouri 63178
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74542 Hoyt Electrical Instruments, P.O. BOX 8798, Penacook, NH 03303
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74559 Carling Switch Co., 505 New Park Ave.,
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West Hartford, CT 06110
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75175 K-D Lamp Co., 1910 Elm St., Cincinnati, OH 45210-2451
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78377 SCP Inc., 9115 George Ave., Cleveland, OH 44105
on
78388 Synchro-Start Products, Inc., 8109 N. Lawndale Ave.,
/m
P.O. Box 147 Skokie, IL 60076-9990
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79470 Dana Corp., Weatherhead Div., 5278 US 24, Antwerp, OH 45813
ttp
7L306 Clarke GM Diesel, 1340 Terminal Rd., Indianapolis, IN 46217-9342

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

6
88136 Trombetta Corp., 1633 E. North Ave., Milwaukee, WI. 53202

32
91929 Honeywell Inc., Micro Switch Div., 11 W. Spring St., Freeport IL 61032
-5
92489 Attwood Corp., 1016 Monroe Ave., Lowell MI, 49331

02
94177 Modine Mfg. Co., 1500 Dekoven Ave., Racine, WI 53401

-7
88
94222 Southco Inc., 210 N. Brinton Lk. Rd., Concordville, PA 19331

-8
9X737 Buyers Products Co., 7700 Tyler Blvd., Mentor, OH 44060-4802

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Section 3. Parts List
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1. Explanation of Parts List Arrangement
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The parts list is arranged so that the illustration will appear on a left-hand page and the applicable parts
en
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.
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2. Symbols and Abbreviations
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The following is a list of symbols and abbreviations used in the parts list.
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* - item not illustrated
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A, or AMP - ampere
AC - alternating current
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AR - as required
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DC - direct current
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Fig. - Figure
hd. - head /m
hex - hexagon
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Hz - Hertz (cycles-per-second)
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I.D. - inside diameter

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IN - inch
kVA - kilovolt-ampere
6
uF - microfarad
32
No. - number
-5
OM - Owners Manual
02
PRV - peak reverse voltage

-7
PSI - pounds per square inch

88
Ref - reference (the item has been listed previously)

TM - Technical Manual
-8
v - volt (when used as a prefix to a five-digit number, indicates vendor code)

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

Figure 1
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NOMENCLATURE
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FIGURE & HOBART AIRLINE
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ITEM NO. PART NO. PART NO. 1234567 EFF QTY
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1- 500285-001 GENERATOR SET ASSEMBLY
WITH TRAILER AND CABLE TRAYS A REF
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500285-002 GENERATOR SET ASSEMBLY
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STATIONARY MOUNT WITH CABLE HANGERS B REF
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1-1 77A1157 . SWITCH, EMERGENCY STOP (V14799 #KR-9R-H6) 1
uip
1-2 285681 . EMERGENCY STOP LEGEND PLATE 1
1-3 285125 . EMERGENCY STOP GUARD (V14799 #K56YM) 1
1-4 No Number . CANOPY COMPONENTS (See Fig. 3) REF
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1-5 No Number . GENERATOR SET INTERIOR COMPONENTS
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(See Fig. 4) REF
1-6 No Number . MOUNTING FRAME ASSEMBLY (See Fig. 2) REF
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1-7 288021 . CONTROLS COVER 1
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1-8 288022 . CONTROLS COVER HINGE 1
1-9 288023 . WING KNOB LATCH 2
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* 288020 . LATCH BRACKET 2
1-10 288007-001 . CONTROL BOX ASSEMBLY (See Fig. 5) 1
1-11 282562 . /m
CAP, FUEL (V49234 #1275G/12T) 1
1-12 79A1127-002 . FILLER NECK GUARD 1
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1-13 288060-001 . EXHAUST 1

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1-14 282732-001 . CLEARANCE MARKER LIGHT 4

1-15 286847 . GUARD, CLEARANCE LIGHT 4
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1-16 488640 . OUTPUT CABLE BRACKET 1

1-17 7J422-000 . OUTPUT CABLE CLAMP 1
6
32
1-18 403091-008 . PLASTIC HOLE PLUG 1

1-19 NOT USED
-5
* 1-20 287698-001 . OUTPUT CABLE COVER 1

* 1-21 402987 . NAMEPLATE, HOBART 3
02
* 1-22 78A1000 . NAMEPLATE, ID 1

-7
* 1-23 79A1110 . NAMEPLATE, OPTION 1

88
* 1-24 283533 . LABEL, SUPPORT CENTERS 1

* 1-25 81B1084 . LABEL, 28 VOLTS 1
-8
* 1-26 405309 . LABEL, LUBE OIL FILTER 1

* 1-27 407366 . LABEL, CAUTION - INSUFFICIENT COOLING 1
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* 1-28 76B1148 . LABEL, DIESEL FUEL 1

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* 1-29 282658 . LABEL, CLEARANCE 1

* 1-30 401842 . TAG, ATTENTION - ENGINE COOLANT 1
* 1-31 40201 . TAPE, SEALANT, NEOPRENE 612"
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* 1-32 287459 . LABEL, GENERAL INFORMATION 1

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* 1-33 287460 . LABEL, DANGER HIGH VOLTAGE 2

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* 1-34 287461 . LABEL, FUEL WARNING 1

* 1-35 287462 . LABEL, ENGINE COOLANT 1
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* 1-36 287463 . LABEL, HOT MUFFLER 1

* 1-37 287464 . LABEL, FAN AND MOVING PARTS 2
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* 1-38 287466 . LABEL, EMERGENCY STOP 1

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* 1-39 282554-003 . REFLECTOR KIT 1

* 1-40 282554-004 . REFLECTOR KIT A 1
November 1, 2000 * Not Illustrated Chapter 4-3

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Mounting Frame Assembly

Figure 2
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NOMENCLATURE
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2- No Number MOUNTING FRAME ASSEMBLY REF
tp
2- 1 287971 . CONTROL PANEL SUPPORT, LEFT 1
2- 2 287980 . FUEL TANK SUPPORT 1
en
2- 3 287972 . DOOR SUPPORT PANEL 2
m
* 288064-004 . DOOR SUPPORT INSULATION 2
2- 4 287953 . ENGINE SUPPORT 1
uip
2- 5 287984 . BATTERY TRAY 1
q
2- 6 287998 . FRONT PANEL BRACKET 2
re
2- 7 287950 . MOUNTING FRAME 1
2- 8 287970 . CONTROL PANEL SUPPORT, RIGHT 1
oo
2- 9 287955 . GENERATOR SUPPORT 1
rfl
2-10 287986 . CONTROL PANEL SUPPORT 1
ste
on
* Not Illustrated
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6
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Or
Canopy Components
Figure 3
To

om
NOMENCLATURE
c
ts.
ar
3- No Number CANOPY COMPONENTS REF
tp
3- 1 287981 . TOP CANOPY 1
* 288064-003 . TOP CANOPY INSULATION 1
en
* 288064-005 . TOP CANOPY INSULATION 1
m
3- 2 287999 . RADIATOR CAP ACCESS DOOR 1
3- 3 287979 . FRONT PANEL 1
uip
3- 4 287542-001 . DOOR LATCH 4
q
3- 5 287526-002 . DOOR LATCH PULL 4
re
3- 6 287978 . ACCESS DOOR 4
* 288064-001 . DOOR INSULATION 4
oo
3- 7 283824 . RIGHT HAND HINGE 4
rfl
3- 8 283597 . LEFT HAND HINGE 4
ste
3- 9 287977 . SIDE PANEL 4
* 288064-002 . SIDE PANEL INSULATION 4
on
* 287785 . PANEL FASTENER 16
3-10 287987 . LOWER REAR PANEL 1
/m
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ttp
* Not Illustrated
-h
6
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To

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/m
1 8 9 3
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10 6
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4
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Generator Interior Components

Or
Figure 4
To

om
NOMENCLATURE
c
ts.
ar
4- No Number GENERATOR SET INTERIOR COMPONENTS REF
tp
4- 1 No Number . BATTERY COMPONENTS (See Fig. 6) REF
4- 2 No Number . MUFFLER COMPONENTS (See Fig. 7) REF
en
4- 3 288306 . RECTIFIER ASSEMBLY (See Fig. 8) 1
m
4- 4 No Number . CONTACTOR COMPONENTS (See Fig. 9) REF
4- 5 No Number . ENGINE COMPONENTS (See Fig. 10) REF
uip
4- 6 No Number . COOLING SYSTEM (See Fig. 11) REF
q
4- 7 No Number . FUEL SYSTEM COMPONENTS (See Fig. 12) REF
re
4- 8 No Number . THROTTLE CONTROL COMPONENTS (See Fig 10) REF
4- 9 287556 . GENERATOR ASSEMBLY (See Fig. 13) 1
oo
4- 10 No Number . AIR CLEANER COMPONENTS (See Fig. 15) REF
rfl
* 4- 11 No Number . TRAILER COMPONENTS (See Fig. 16) A REF
ste
* 4-12 489689 . STATIONARY MOUNTING KIT B 1
on
* NOT ILLUSTRATED
/m
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6
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Or

Figure 5
To

om
NOMENCLATURE
c
ts.
ar
5- 288007-001 CONTROL PANEL ASSY 1
tp
5- 1 286865 . PANEL, CONTROL, . 1
5- 2 W11166-005 . FUSE, , 20A, V71400 1
en
5- 3 402658 . HOLDER, FUSE (V714OO #TYPE) 2
m
5- 4 494134-001 . GAUGE, FUEL, ELECTRIC, 12V
(V16476 #06339-01) 1
uip
5- 5 403189 . SWITCH, TOGGLE (V91929 #312TS1-59) 2
q
5- 6 78A1120-001 . GAUGE, HOUR METER (V16476 #56288) 1
re
5- 7 286699-001 . VOLTMETER, BATTERY (V16476 #06351-001) 1
5- 8 286864 . LABEL, CONTROL PANEL 1
oo
5- 9 288165 . ADJUSTABLE GRIP LATCH 2
rfl
5-10 78A1117-001 . GAUGE, OIL PRESSURE (V16476 #06340) 1
ste
5-11 287908 . GAUGE, WATER TEMP., (V16476 #06343) 1
5-12 408596-001 . TACHOMETER (V16476 #71076-00) 1
on
5-13 30GH1262 . LIGHT, PANEL, SOCKET 3
* 50GHP206 . PANEL LIGHT LAMP 3
* 288018 .
/m
PANEL LIGHT BRACKET 3
5-14 401937-004 . BLOCK, TERMINAL, 20A. (V83330 #699-18KT50) 2
s:/
5-15 W11166-003 . FUSE, 10A. 6
ttp
5-16 402662 . SWITCH, TOGGLE, DPST, (V74559 #2GK71-73) 1

5-17 180913-002 . LIGHT, PILOT, GREEN, 28V. ASSEMBLY 1
-h
* 180914 . . BASE, LIGHT (V83330 #26-5710-11-301) 1

* 404172-003 . . LENS, GREEN (V83330 #26-1192-300) 1
6
* 400613-003 . . BULB 1
32
5-18 16DA2162 . KNOB, RHEOSTAT, (V44655 #5150) 1

5-19 401428-001 . POTENTIOMETER, 10K OHM, 2W.
-5
(V44655 #CMU-1031) 1
02
5-20 286923 . COVER, 14V OPTION 1

-7
5-21 402663 . NUT, POTENTIOMETER, LOCK 1

5-22 407948 . RECTIFIER, ISOLATED BASE (V14552 #CT 106) 1
88
5-23 W10051-014 . CLAMP, WIRE, PLASTIC 1

5-24 405129-001 . BLOCK, FUSE (V71400 #S8202-6) 1
-8
5-25 180913-001 . LIGHT, PILOT, ENGINE, GREEN, 12V. ASSY. 1

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

* 404172-003 . . LENS, GREEN (V83330 #26-1192-300) 1
Ca
* 400613-004 . . BULB 1
5-26 402682 . SWITCH, TOGGLE, 3 PDT (V74559, HLA-211-73) 1
ts
5-27 30GH1119 . SWITCH, PUSHBUTTON (V13445 #9095-09) 1

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

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

5-30 400641-012 . AMMETER (V74542 1
de
5-31 180289 . BOARD, PC, OVERVOLTAGE, ASSY. 1

5-32 84A1075 . MOUNT, RUBBER (V5P059 #51083) 7
Or
5-33 181022A-005 . BOARD, PC, REGULATOR 1

287683 . BOARD, PC, REGULATOR
To
(FOR REPLACEMENT/SUPPLY ONLY) 1
* NOT ILLUSTRATED
om
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6
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Or
To

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NOMENCLATURE
c
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ar
5- 288007-001 CONTROL BOX ASSY (continued) REF
tp
5-34 404065-002 . RECTIFIER, SILICON (V04713 #5DA-10270-2) 2
* 5-35 W10051-010 . CLAMP, WIRE, PLASTIC (V28520 #3334) 2
en
* 5-36 288012 . WIRE HARNESS 1
m
5-37 180593-003 . CAPACITOR ASSEMBLY, 100MFD, 350VDC 1
5-38 288016 . HINGE, PANEL MOUNTING 3
uip
5-39 287988 . CONTROL BOX ENCLOSURE 1
q
5-40 180913-004 . RED PILOT LIGHT 1
re
5-41 288017 . ARM, TELESCOPIC STAY 1
5-42 287621 . RESISTOR AND DIODE ASSEMBLY 1
oo
* 5-43 286611 . LABEL, BLANK 2
rfl
5-44 288019-004 . FUSE, SLO-BLO, 20A 1
ste
* Not Illustrated
on
/m
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2 5 3
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6
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Battery Components
Figure 6
de
Or
To

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NOMENCLATURE
c
ts.
ar
6- No Number BATTERY COMPONENTS REF
tp
6- 1 281881-001 . BATTERY, 12 V. (V04055 #724 DT) 1
6- 2 288046 . BATTERY CABLE, POSITIVE, ASSY. 1
en
6- 3 288047 . BATTERY CABLE, NEGATIVE, ASSY. 1
m
6- 4 287796 . BATTERY HOLD DOWN 1
6- 5 494295 . BATTERY HOLD DOWN BOLT 1
quip
re
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6
32
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88
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de
Or
Muffler Components
To
Figure 7

om
NOMENCLATURE
c
ts.
ar
7- No Number MUFFLER AND AIR CLEANER COMPONENTS REF
tp
7- 1 288053-001 . 45 DEG. EXHAUST ELBOW 1
7- 2 288051-001 . FLEXIBLE EXHAUST CONNECTOR 1
en
7- 3 288050-001 . 2-1/2” TO 3” REDUCER FITTING 2
m
7- 4 288054-002 . 90 DEG. EXHAUST ELBOW, 2-1/2” 1
7- 5 288044-001 . MUFFLER 1
uip
7- 6 288055-001 . 2-1/2” EXHAUST TUBING 3.5”
q
7- 7 288059-001 . STAINLESS STEEL HOSE CLAMP 2
re
7- 8 288055-002 . 3” EXHAUST TUBING 34”
7- 9 288052-001 . CLAMP, 2-1/2” 4
oo
7- 10 288052-002 . CLAMP, 3” 2
rfl
7- 11 403483 . FITTING CLAMP 2
ste
* 7- 12 404154-013 . 3” FULL CIRCLE CLAMP 1
on
* NOT ILLUSTRATED
/m
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-8
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6
32
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88
-8
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de
Or
Rectifier Assembly
Figure 8
To

om
NOMENCLATURE
c
ts.
ar
8- 288306 RECTIFIER ASSEMBLY 1
tp
8- 1 287184-003 . INSULATOR, CAPACITOR 1
8- 2 405278-006 . CAPACITOR, 90000MFD, 75 1
en
8- 3 286887 . SHROUD, AIR, TOP, RECTIFIER 1
m
8- 4 W10869-006 . CLAMP, CAPACITOR 1
8- 5 402037-004 . GROMMET, RUBBER (V02231 #) 1
uip
8- 6 16DA3493 . WASHER, INSULATING 6
q
8- 7 405154-006 . RESISTOR, 10OHM, 100 WATT (V44655 #61917) 3
re
8- 8 401911-005 . BLOCK, TERMINAL, 5 STATION 1
8- 9 W11114-012 . SCREW, 1/4-20 X 7-1/4 3
oo
8 -10 W11280-015 . NUT, JAM, HEX, 3/4-16 12
rfl
8 -11 494681-001 . WASHER, SPRING 12
ste
8 -12 W10931-003 . RECTIFIER, POS., BASE (V59993 #300U30A) 6
8 -13 286884 . BRACKET, ., HEAT SINK 2
on
8 -14 W10933-003 . RECTIFIER, NEG. BASE (V59993 #300UR30A) 6
8 -15 W11097-007 . SCREW, HHC, 3/8-16 x 2" 1
8 -16 180065 .
/m
SHUNT, 2000 AMP 1
8 -17 W11097-007 . SCREW, , 3/8-16 x 2" 5
s:/
8 -18 285647 . SHROUD, AIR, BOTTOM, RECTIFIER 1
ttp
8 -19 180600 . SPACER, SHROUD 3

8 -20 282239 . HEAT SINK, RECTIFIER, NEGATIVE 1
-h
8 -21 W11097-022 . SCREW, , 3/8-16 x 2-1/2" 4

8 -22 A25 . WASHER, INSULATING 8
6
8 -23 AW626 . BUSHING, INSULATING (V5E599 # #E48013(M)) 4

32
8 -24 286813 . HEAT SINK, RECTIFIER, POSITIVE 1

-5
8 -25 W11242-018 . WASHER, FLAT, 3/8 8

02
8 -26 283063 . SPACER, RECTIFIER 4

8 -27 288008 . RECTIFIER MOUNTING BRACKET 2
-7
* 8 -28 DELETED
* 8 -29 288015 . RECTIFIER WIRE HARNESS 1
88
-8
ll 1
* Not Illustrated
Ca
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ar
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4 2 3
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8 6 5
-8
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Ca
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de
Or
Contactor Components
To
Figure 9

om
NOMENCLATURE
c
ts.
ar
9- No Number CONTACTOR COMPONENTS REF
tp
9- 1 A25 . WASHER, INSULATING 2
9- 2 AW626 . BUSHING, INSULATING (V5E599 #UL#E48013(M)) 1
en
9- 3 W9218-227 . CABLE, OUTPUT, NEGATIVE 1
m
9- 4 400435 . LABEL, 28 VOLTS 1
9- 5 W9218-251 . CABLE, OUTPUT, POSITIVE 1
uip
9- 6 286810-001 . CONTACTOR, DC, 800 AMP (V01XD4 #CT800A-24C2) 1
q
9- 7 286849 . INSULATOR, CONTACT 1
re
9- 8 489658-010 . DIODE ASSEMBLY 1
oo
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-8
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de
Or
To

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3
c
ts.
21
ar
tp
en
4
m
16
q uip
re
2 5
oo
17
rfl
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1
on
6 /m
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18
ttp
7 19
-h
8
6
32
9
-5
13
02
14
-7
8
88
15
-8
ll 1
18
Ca
11
ts
ar
20
12
rP
de
Or
Engine Components
Figure 10
To

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NOMENCLATURE
c
ts.
ar
10- No Number ENGINE COMPONENTS REF
tp
10- 1 W9360-229 . GROUND CABLE 1
10- 2 287735 . GROUNDING PLATE 1
en
10- 3 288014 . ENGINE HARNESS 1
m
10- 4 286850 . STARTER CUT-OUT SOLENOID 2
10- 5 407948 . RECTIFIER, STARTER SOLENOID 1
uip
10- 6 489658-007 . FLYBACK DIODE 2
q
10- 7 288065 . THROTTLE SOLENOID LINKAGE 1
re
10- 8 288215 . BEARING END ROD 3
10- 9 288221-001 . THREADED ROD 1
oo
10-10 DELETED
rfl
10-11 288045-001 . THROTTLE SOLENOID 1
ste
10-12 286558 . THROTTLE SOLENOID BRACKET 1
10-13 78B1118 . OIL PRESSURE SENDER 1
on
10-14 W10910-000 . TEE FITTING 1
* 287419 . ADAPTER, M10 TO 1/8 NPT 1
* W10750-001 .
/m
1/8” PIPE NIPPLE 1
10-15 403809-002 . OIL PRESSURE SWITCH 1
s:/
10-16 403782-002 . WATER TEMPERATURE SWITCH 1
ttp
* 287909 . WATER TEMPERATURE SENDER` 1

10-17 W7814-004 . PIPE BUSHING 1
-h
10-18 287954 . ENGINE SUPPORT BRACKET 2

10-19 287931 . ENGINE, CUMMINS, 4BT3.9 1
6
10-20 284372-002 . ENGINE SHOCK MOUNT 2

32
10-21 286897-016 . OIL FILTER (V33457 #LF3345) 1

-5
02
* NOT ILLUSTRATED
-7
88
-8
ll 1
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ar
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To

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1 4 5 2 3
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en
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7
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9
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6
32
10
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ar
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de
Cooling System Components

Or
Figure 11
To

om
NOMENCLATURE
c
ts.
ar
11- No Number COOLING SYSTEM COMPONENTS REF
tp
11-1 056534 . DEAERATION HOSE 20”
* W7814-000 . 1/8 X 1/ 4 PIPE BUSHING 1
en
* 402927-003 . MALE CONNECTOR 2
m
* W10869-014 . HOSE CLAMP 2
11-2 405743 . 7LB. RADIATOR CAP 1
uip
11-3 287888 . PRESSURIZED RADIATOR 1
q
* 283873 . DRAIN VALVE 1
re
* 287333-001 . RADIATOR CAP, 10 LB. 1
11-4 288063 . TOP RADIATOR HOSE 1
oo
* W10869-003 . HOSE CLAMP 2
rfl
11-5 288002 . FAN GUARD 1
ste
11-6 288001 . 20" ENGINE FAN 1
11-7 287982 . TOP FAN SHROUD 1
on
11-8 287373 . BELT AND PULLEY GUARD 1
11-9 288000 . BOTTOM FAN SHROUD 1
11-10 288062
/m
. BOTTOM RADIATOR HOSE 1
* W10869-005 . HOSE CLAMP 2
s:/
ttp
-h
* Not Illustrated
6
32
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02
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88
-8
ll 1
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de
Or
To

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en
7 4
m
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q
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5
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3
on
/m
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2
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6
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88
1
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ar
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de
Or
Fuel System Components

Figure 12
To

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NOMENCLATURE
c
ts.
ar
12- No Number FUEL SYSTEM COMPONENTS REF
tp
12-1 288009 . FUEL LINE, TANK TO FILTER W/SHUTOFF 1
12-2 287639 . FUEL WATER SEPARATOR 1
en
12-3 288010 . FUEL LINE, TANK TO ENGINE 1
m
12-4 288061 . FUEL FILTER BRACKET 1
12-5 282299 . FUEL TANK ASSEMBLY 1
uip
* 284203 . FUEL TANK MOUNTING PLATE 5
q
* 12-6 288011 . FUEL RETURN LINE 1
re
12-7 286897-017 . FUEL FILTER (V33457 #FS1251) 1
oo
* Not Illustrated
rfl
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on
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32
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88
-8
ll 1
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6
32
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88
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Ca
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de
Generator Assembly
Figure 13
Or
To

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NOMENCLATURE
c
ts.
ar
13- 287556 GENERATOR, ASSY. 1
tp
288210 SPARE GENERATOR ASSEMBLY
FOR REPLACEMENT ONLY REF
en
* 13- 1 284371-002 . SHOCK MOUNT 1
m
13- 2 287564 . FAN HOUSING 1
uip
13- 3 488557-008 . HOUSING & STATOR ASSY. 1
13- 4 489135 . KEY, COUPLING 1
q
13- 5 180776 . ARMATURE, . 1
re
13- 6 488555-001 . HOUSING, BEARING ASSY. 1
oo
13- 7 287401 . CAP, BEARING 1
13- 8 488784 . BRUSHHOLDER ASSY. (For Details See Fig. 14) 1
rfl
13- 9 288003 . COVER, FLYWHEEL HOUSING 1
ste
13-10 489125 . FAN AND COUPLING ASSEMBLY 1
* 402789-004 . . SCREW, CAP, , 3/8-24 X 3/4, NYLOK 6
on
* W11254-005 . . WASHER, LOCK, STD., 3/8 6
* 85C1004-002 . . BUSHING, SPLIT TAPER 1
13-11 No Number .
/m
FLYWHEEL - (Supplied w/Engine) REF
13-12 354592 . RING, SLIP 2
s:/
13-13 281688 . COVER, GENERATOR HOUSING 1

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

* 13-17 287956 . GENERATOR SUPPORT BRACKET (REAR) 1
-h
6
* Not Illustrated
32
-5
02
-7
88
-8
ll 1
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6
32
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Ca
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Brushholder Assembly
de
Figure 14
Or
To

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NOMENCLATURE
c
ts.
ar
14 - 488784 BRUSH HOLDER ASSEMBLY REF
tp
14- 1 488562 . BRACKET, ., BRUSH HOLDER 1
14- 2 488628 . BRACKET, , DIODE 1
en
14- 3 408999-001 . DIODE, SILICON, 30A, POS. ASSEMBLY 1
m
14- 4 402531 . CAP, , (V46992 #DE-55) 2
14- 5 402530 . GUIDE, , (V46992 #661-D-23) 2
uip
14- 6 402788 . BRUSH, A.C., (V78377 #443E) 2
q
re
* Not Illustrated
oo
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88
-8
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7 6
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6
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02
4
-7
2 3 5
88
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Air Cleaner Components

Or
Figure 15
To

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NOMENCLATURE
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15 - No Number AIR CLEANER COMPONENTS REF
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15- 1 288059-001 . CLAMP, STAINLESS STEEL 1
15- 2 288049 . AIR CLEANER SUPPORT BRACKET 1
en
15- 3 288048-001 . AIR CLEANER 1
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15- 4 282918 . AIR RESTRICTION INDICATOR 1
* 282919 . INDICATOR ADAPTER 1
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15- 5 280732-004 . AIR CLEANER CLAMP 3
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15- 6 288056-001 . RUBBER PIPE, TURBO INLET 1
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15- 7 288057-001 . STRAIGHT PIPE 1
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* Not Illustrated
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Trailer Components
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Figure 16
Or
To

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NOMENCLATURE UNITS
c
FIGURE HOBART PER
ts.
ITEM NO. PART NO. 1234567 EFF ASSY
ar
16- No Number TRAILER W/FENDERS & CABLE TRAYS A REF
tp
16-1 181256 . KNOB, BRAKE LEVER A 1
* 16-2 287565 . LABEL, TIRE PRESSURE A 1
en
16-3 282554-4 . KIT, REFLECTOR A 1
m
16-4 287995 . FENDER, LEFT A 1
16-5 287996 . FENDER, RIGHT A 1
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16-6 287994 . BRACKET, MTG. FENDER, A 4
q
16-7 287993 . BRACKET, MTG. FENDER A 2
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16-8 287465 . LABEL, FALLING OBJECT A 1
16-9 NOT USED
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16-10 NOT USED
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NOT USED
ste
16-11 NOT USED
16-12 NOT USED
on
16-13 NOT USED
16-14 282720 . TIRE & WHEEL ASSY., 5.30 X 12, 4-PLY,
/m
V05404, NO. 2036416130 A 4
16-15 85A-1040 . . RIM, 4", V05404, NO. 2036415251 A 4
s:/
16-16 No Number . BRAKE, ASSEMBLY A 1
ttp
16-17 287961 . LEVER, BRAKE MOUNT ASSY. A 1

16-18 287962 . SUPPORT, BRAKE, SHOE ASSY. A 1
-h
16-19 HF-1882A . SHOE, BRAKE ASSY. A 2

16-20 484250 . ROD, ADJUSTING, BRAKE A 2
6
16-21 484254 . BRACKET, MTG., BRAKE SHOE ANGLE A 2

32
16-22 W-11242-12 . . WASHER, FLAT, 1/2", STEEL A 2

-5
16-23 400954 . . CLEVIS, ADJUSTING, BRAKE A 2

16-24 W-11338-5 . . PIN, COTTER, 1/8 X 1, STEEL A 4
02
16-25 401468 . . PIN, CLEVIS A 2

-7
16-26 NOT USED

16-27 No Number . . DRAWBAR COMPONENTS A 1
88
16-28 79A-1057 . . . HINGE PIN, V22938, NO. 5416 A 1

-8
16-29 284399-36 . . . COTTER PIN, V22938, NO. 4800-6 A 2

ll 1
16-30 79A-1045 . . CENTER ARM ASSY., V22938, NO. 15-3854 A 1

16-31 404529 . . . LATCH PEDAL, V22938, NO. 3855 A 1
Ca
16-32 404530 . . . ROLL PIN, V22938, NO. 5000-1 A 1

16-33 181840 . . . SPRING, V22938, NO. 4006 A 1
16-34 79A-1047 . . . FLAT WASHER, V22938, NO. 4701-3 A 1
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16-35 79A-1048 . . . CENTER PIN, V22938, NO. 5400-5 A 1

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16-36 No Number AXLE, REAR COMPONENTS A 1

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16-37 85A-1019 . . . HUB ASSY., REAR AXLE, V22938, NO. 7-3601 A 2

16-38 DELETED
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16-39 85A-1020 . . . . CAP, GREASE, V22938, NO. 6301 A 1

Or
16-40 85A-1021 . . . . BEARING, CONE, OUTER, V22938,

NO. 6050 A 1
16-41 85A-1022 . . . . BEARING, CONE, INNER, V22938,
To
NO. 6051 A 1

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NOMENCLATURE UNITS
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FIGURE HOBART PER
ts.
ITEM NO. PART NO. 1234567 EFF ASSY
ar
16- No Number TRAILER W/FENDERS & CABLE TRAYS (cont) A REF
tp
16-42 85A-1023 . . . . SEAL, GREASE, V22938, NO. 6300 A 1
en
16-43 85A-1024 . . . . NUT, STUD, V22938, NO. 4603-1 A 5
16-44 85A-1027 . . . . STUD, WHEEL, V22938, NO. 6251-10 A 5
m
16-45 85A-1028 . . . . CUP, BEARING, INNER, V22938, NO. 6155 A 1
uip
16-46 85A-1029 . . . . CUP, BEARING, OUTER, V22938, NO. 6156 A 1
16-47 85A-1030 . . . . WASHER, SPINDLE, V22938, NO. 4701-10 A 2
q
16-48 85A-1031 . . . . NUT, SPINDLE, V22938, NO. 4600-1 A 2
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16-49 76A-1189 . . . . PIN, COTTER, V22938, NO. 4800-5 A 2
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16-50 No Number AXLE, FRONT COMPONENTS A REF
16-51 85A-1034 . . . SPINDLE & KNUCKLE ASSY. (LEFT),
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V22938, NO. 27-3800 A 1
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16-52 85A-1035 . . . SPINDLE & KNUCKLE ASSY. (RIGHT),
V22938, NO. 28-3800 A 1
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16-53 84A-1081 . . . . PIN, KING, V22938, NO. 5401 A 1
16-54 84A-1082 . . . . PIN, ROLL, 3/8 X 2", V22938, NO. 5000-6 A 1
16-55 85A-1019
/m
. . . HUB ASSY., FRONT AXLE, V22938, NO. 7-3601 A 2
s:/
16-56 DELETED
16-57 85A-1020 . . . . CAP, GREASE, V22938, NO. 6301 A 1
ttp
16-58 85A-1021 . . . . BEARING, CONE, OUTER, V22938, NO. 6051 A 1

16-59 85A-1022 . . . . BEARING, CONE, INNER, V22938, NO. 6050A 1
-h
16-60 85A-1023 . . . . SEAL, GREASE, V22938, NO. 6300 A 1

16-61 85A-1024 . . . . NUT, STUD, V22938, NO. 4603-1 A 5
6
32
16-62 85A-1027 . . . . STUD, WHEEL, V22938, NO. 6251-1-1 5

16-63 85A-1028 . . . . CUP, BEARING, INNER, V22938, NO.6155 1
-5
16-64 85A-1029 . . . . CUP, BEARING, OUTER, V22938., NO. 6156 1

02
16-65 85A-1030 . . . . WASHER, SPINDLE, V22938, NO 4701-10 2

16-66 85A-1031 . . . . NUT, SPINDLE, V22938, NO. 4600-1 2
-7
16-67 85A-1052 . . . . PIN, COTTER, V22938, NO. 4800-5 2

88
16-68 284399-13 . . . . TIE ROD ASSY., V22938, NO. 3906-187 2

16-69 284399-38 . . . . TUBE, TIE-ROD, V22938, NO. 3900-152 1
-8
16-70 79A-1051 . . . . NUT, JAM, R.H., V22938, NO. 4602-1 1

ll 1
16-71 79A-1052 . . . . NUT, JAM, L.H., V22938, NO.4602-2 1

Ca
16-72 79A-1053 . . . . BALL JOINT, R.H. W/NUT, V22938, NO.3950-1 1

16-73 79A-1054 . . . . BALL JOINT, L.H. W/NUT, V22938, NO.3950-2 1
ts
16-*74 79A-1035 . . . . LUBE FITTING, V22938, NO.5801 8

16-*75 DWP-982 . . . . CABLE HANGER B 1
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Section 4. Numerical Index
c
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ar
1. Explanation of Numerical Index
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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 numeric-alpha sequence. Thus, any part
en
number beginning with the number 9 would be located at or near the top of the index list. Like-wise, a
part beginning with the letter A would be listed near the end of the list and far below a part number
m
1000. The figure number and item number location of the part is directly opposite the part. If the part is
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used in more than one place, each location is listed commencing with the first location the part is listed.
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FIG-ITEM PART FIG-ITEM PART
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NUMBER NUMBER
11-1 056534
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13- 1 284371-002
5-18 16DA2162
10-20 284372-002
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8- 6 16DA3493
16-29 284399-36
8 -16 180065
1-3 285125
on
5-31 180289
8 -18 285647
5-37 180593-003
8 -19 180600 /m
1-2
10-12
285681
286558
13- 5 180776
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5-43 286611
5-25 180913-001
5- 7 286699-001
ttp
5-17 180913-002
9-6 286810-001
5-40 180913-004
8 -24 286813
-h
5-17 180914
1-15 286847
5-25 180914
9-7 286849
6
5-33 181022A-005
10- 4 286850
32
16-1 181256
5- 8 286864
16-33 181840
5- 1 286865
-5
15- 5 280732-004
8 -13 286884
13-13 281688
02
8-3 286887
6- 1 281881-001
10-21 286897-016
-7
8 -20 282239
12-7 286897-017
12-5 282299
88
5-20 286923
1-39 282554-003
8-1 287184-003
-8
1-40 282554-004
11-3 287333-001
16-3 282554-4
ll 1
11-8 287373
1-11 282562
13- 7 287401
1-29 282658
Ca
10-14 287419
16-14 282720
1-32 287459
1-14 282732-001
1-33 287460
ts
15- 4 282918
1-34 287461
15- 4 282919
ar
1-35 287462
8 -26 283063
rP
1-36 287463
13-10 283495
1-37 287464
1-24 283533
de
16-8 287465
3- 8 283597
1-38 287466
3- 7 283824
Or
3- 5 287526-002
11-3 283873
3- 4 287542-001
12-5 284203
To
13- 287556


om
NUMBER NUMBER
4-8 287556 10- 3 288014
c
13- 2 287564 8 -29 288015
ts.
16-2 287565 5-38 288016
5-42 287621 5-41 288017
ar
12-2 287639 5-13 288018
tp
5-33 287683 5-44 288019-004
en
10- 2 287735 1-9 288020
3- 9 287785 1-7 288021
m
6- 4 287796 1-8 288022
uip
11-3 287888 1-9 288023
5-11 287908 7- 5 288044-001
q
10-16 287909 10-11 288045-001
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10-19 287931 6- 2 288046
2- 7 287950 6- 3 288047
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2- 4 287953 15- 3 288048-001
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10-18 287954 15- 2 288049
2- 9 287955 7- 3 288050-001
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13-15 287956 7- 2 288051-001
16-17 287961 7- 9 288052-001
on
16-18 287962 7- 10 288052-002
1-20 287968-001 7- 1 /m 288053-001
2- 8 287970 7- 4 288054-002
s:/
2- 1 287971 7- 6 288055-001
2- 3 287972 7- 8 288055-002
ttp
3- 9 287977 15- 6 288056-001

3- 6 287978 15- 7 288057-001
-h
3- 3 287979 15- 1 288059-001

2- 2 287980 7- 7 288059-001
6
3- 1 287981 1-13 288060-001

32
11-7 287982 12-4 288061

2- 5 287984 11-10 288062
-5
2-10 287986 11-4 288063

02
3-10 287987 3- 6 288064-001

5-39 287988 3- 9 288064-002
-7
16-7 287993 3- 1 288064-003

88
16-6 287994 2- 3 288064-004

16-4 287995 3- 1 288064-005
-8
16-5 287996 10- 7 288065

2- 6 287998 13- 3 288151-001
ll 1
3- 2 287999 5- 9 288165
11-9 288000 13- 288210
Ca
11-6 288001 10-8 288215

11-5 288002 10-9 288221-001
ts
13- 9 288003 4-3 288306

ar
1-10 288007-001 8- 288306

5- 288007-001 5-27 30GH1119
rP
5- 288007-001 5-13 30GH1262

8 -27 288008 13-12 354592
de
12-1 288009 9-4 400435

Or
12-3 288010 5-17 400613-003

12-6 288011 5-25 400613-004
5-36 288012 5-30 400641-012
To


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NUMBER NUMBER
5-29 400642-003 9-8 489658-010
c
16-23 400954 4-11 489689
ts.
5-19 401428-001 5- 4 494134-001
16-25 401468 6- 5 494295
ar
1-30 401842 8 -11 494681-001
tp
8- 8 401911-005 1- 500285-001
en
5-14 401937-004 1- 500285-002
1-31 40201 5-13 50GHP206
m
8-5 402037-004 16-49 76A-1189
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14- 5 402530 1-28 76B1148
14- 4 402531 1-1 77A1157
q
5- 3 402658 1-22 78A1000
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5-16 402662 5-10 78A1117-001
5-21 402663 5- 6 78A1120-001
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5-26 402682 10-13 78B1118
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14- 6 402788 16-30 79A-1045
13-10 402789-004 16-34 79A-1047
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11-1 402927-003 16-35 79A-1048
1-21 402987 16-28 79A-1057
on
1-19 403091-008 1-23 79A1110
5- 5 403189 1-12
/m 79A1127-002
7- 11 403483 1-17 7J422-000
s:/
10-16 403782-002 1-25 81B1084
10-15 403809-002 5-32 84A1075
ttp
5-34 404065-002 16-53 84A-1081

7- 12 404154-013 16-54 84A-1082
-h
5-17 404172-003 16-37 85A-1019

5-25 404172-003 16-55 85A-1019
6
16-31 404529 16-39 85A-1020

32
16-32 404530 16-57 85A-1020

5-24 405129-001 16-40 85A-1021
-5
8-7 405154-006 16-58 85A-1021

02
8-2 405278-006 16-41 85A-1022

1-26 405309 16-59 85A-1022
-7
11-2 405743 16-42 85A-1023

88
5-28 406815 16-60 85A-1023

1-27 407366 16-43 85A-1024
-8
10- 5 407948 16-61 85A-1024

5-22 407948 16-44 85A-1027
ll 1
5-12 408596-001 16-45 85A-1028

14- 3 408999-001 16-46 85A-1029
Ca
16-20 484250 16-47 85A-1030

16-21 484254 16-48 85A-1031
ts
13- 6 488555-001 16-51 85A-1034

ar
14- 1 488562 16-52 85A-1035

14- 2 488628 16-15 85A-1040
rP
1-16 488640 13-10 85C1004-002

13- 8 488784 8 -22 A25
de
14 - 488784 9-1 A25

Or
13-10 489125 8 -23 AW626

13- 4 489135 9-2 AW626
10- 6 489658-007 16-19 HF-1882A
To


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NUMBER NUMBER
8 -17 W11097-007
c
5-35 W10051-010
ts.
8 -21 W11097-022
5-23 W10051-014 8- 9 W11114-012
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13-14 W10072-063 5- 2 W11166-001
10-14 W10750-001
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5-15 W11166-003
11-4 W10869-003 8 -25 W11242-018
en
11-10 W10869-005 16-22 W-11242-12
8-4 W10869-006 8 -10 W11280-015
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11-1 W10869-014 16-24 W-11338-5
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10-14 W10910-000 11-1 W7814-000
8 -12 W10931-003 10-17 W7814-004
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8 -14 W10933-003 9-3 W9218-227
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8 -15 W11097-007 9-5 W9218-251
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10- 1 W9360-229
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Chapter 5. Manufacturer’s Literature
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Section 1. Manufacturer’s Listing
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VENDOR LITERATURE
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Engine Cummins Engine Operation Manual
Cummins Engine Parts Catalog
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Hobart Brothers Diagrams:
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/m
288005 - Connection and Schematic Diagram, Jet-Ex 5D, Series 500285
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Page 2
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88
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Appendix A. Options/Features
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The following is a list of options available for Series 500285. This chart contains the description, part number,
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and document number of the option. There is also a column to identify which option is contained in this
Appendix.
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OPTIONS / FEATURES AVAILABLE
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DOCUMENT IN THIS
DESCRIPTION PART NUMBER
NUMBER SECTION
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Kit, 14-V Output with Fenders & Cable Trays 288296-001 TO-275
on
Kit, 14-V Output with Cable Hangers 288296-002 TO-275
120-V AC Generator Package (Trailer-mounted units /m 181735 TO-194
with Fenders)
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Kit, Water Heater 120V 288139-001 TO-271
ttp
Kit, Water Heater 240V 288139-002 TO-271

Grounding Reel 83A-1103
-h
Kit, Start, Ether 489782A TO-211

6
Crate, Shipping, Export 489848

32
Kit, Ring Tie Down 284706

-5
Kit, CE, Trailer Mount 287589-003

02
Kit, CE, Stationary Mount 287589-004

-7
88
-8
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November 1, 2000 Appendix A

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Appendix A November 1, 2000

Page 2
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ts.
Unusual Service Conditions
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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
q
condition or operation of the equipment.
re
Among such conditions are :
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1. Exposure to:
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Combustible, explosive, abrasive or conducting dusts.
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Environments where the accumulation of lint or excessive dirt will interfere with normal
ventilation.
on
Chemical fumes, flammable or explosive gases.
Nuclear radiation.
Steam, salt-laden air, or oil vapor. /m
Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to
s:/
fungus growth.
Abnormal shock, vibration or mechanical loading from external sources during equipment
ttp
operation.
Abnormal axial or side thrust imposed on rotating equipment shafts.
-h
Low and/or high ambient temperatures.

2. Operation at:
6
32
Voltages above or below rated voltage.

Speeds other than rated speed.
-5
Frequency other than rated frequency.

Standstill with rotating equipment windings energized.
02
Unbalanced voltages.
Operation at loads greater than rated.
-7
3. Operation where low acoustical noise levels are required.

88
4. Operation with:
-8
Improper fuel, lubricants or coolant.

ll 1
Parts or elements unauthorized by the manufacturer.

Unauthorized modifications.
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5. Operation in poorly ventilated areas.

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November 1, 2000 Unusual Service Conditions

Page 1

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Unusual Service Conditions November 1, 2000

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Wet-Stacking in Generator Set
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1. Diesel Engines
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All diesel engines operated for extended periods under light load may develop a
condition commonly referred to as wet-stacking. This condition results from the
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accumulation of unburned fuel in the exhaust system. It is recognizable by fuel oil
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wetness around the exhaust manifold, pipes, and muffler. Liquid fuel, in the form of
droplets, may be spewed from the exhaust outlet.
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Wet-stacking is common, and may be expected in diesel engines operated under light
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load. Light loads do not allow the engine to reach most efficient operating
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temperature for complete combustion of fuel. The unburned fuel collects in the
exhaust system to create the wet condition known as wet-stacking.
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To alleviate wet-stacking in lightly loaded engines, it is recommended that the
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machine be connected to a load bank after each 200 hours of use and operated under
full rated load for one hour. This will burn away and evaporate the accumulation of
on
fuel in the exhaust system. This clean-out procedure should be considered as a
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regular maintenance operation for machines operated under light load. The time
schedule of 200 hours may be changed as required to suit each user’s particular
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needs and operating conditions.
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November 1, 2000 Wet Stacking

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Wet Stacking November 1, 2000

Page 2

Manual Hobart Jet Ex - 5d

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Jet-Ex 5D Generator Sets

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other than HOBART.

United States of America.

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and never work alone

a. Installation and Grounding of Electrically Powered Equipment

November 1, 2000 Safety Warnings

piping, misuse of batteries and fuel, or unsafe operating or fueling conditions.

use open flame near the battery.

5. Toxic Fume Prevention

6. Bodily Injury Prevention

Safety Warnings November 1, 2000

November 1, 2000 Safety Warnings

This page intentionally left blank.

Safety Warnings November 1, 2000

combination Chapter-Section number, for example: 2-3 refers to Chapter 2, Section 3.

1. Engine, Generator and Controls

(1) Protective devices

“Adjustment / Test” is located in Chapter 2, Section 3, (shown as 2-3).

November 1, 2000 Introduction

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Ground Power Division

Troy, Ohio 45373

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

(800) 422-4177 (Service)

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

(937) 332-5060 (Service)

FAX: (937) 332-5121

Introduction November 1, 2000

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Control Box Assembly (Front) 11

Control Box Assembly (Inside) 15

Emergency Sutdown Device 15

Section 2. Preparation for Use, Storage or Shipping 1

Preparation for Use 1

Output Cable Requirements and Installation 1

Preparation for Storage 3

Preparation for Shipping 3

Operating the Generator Set 1

Starting The Engine 3

November 1, 2000 Table of Contents

Servicing the Air Cleaner 4

Air Filter Cartridge Removal 4

Air Filter Cartridge Installation 4

Servicing the Fuel Filter 4

Engine Cooling System 4

Radiator Cap Removal 5

Cleaning the Battery 6

Table of Contents November 1, 2000

Chapter 3. Major Overhaul

Section 1. Flexible Coupling 1

Coupling Screws (Routine Coupling Maintenance) 2

Remove Coupling Assembly 3

Coupling Installation and Reassembly of Engine Generator 5

Run-In and Periodic Check 7

Chapter 4. Illustrated Parts List

November 1, 2000 Table of Contents

Table of Contents November 1, 2000

list of options are located in Appendix A.

external 28.5 Volts DC power receptacle.