Hobart JET-EX 4 Operation And Maintenance Manual

OM-2049

052089
040593

OPERATION AND MAINTENANCE

MANUAL

for

JET-EX 4

GENERATOR SETS

SPECIFICATION SERIES NO.

7005-1
7005-2

HOBART BROTHERS COMPANY

POWER SYSTEMS GROUP

TROY,OHIO45373

GROUND POWER EQUIPMENT

U.S.A.

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SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER E QUIPMENT

WARNING

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

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

material. DO NOT use power cables to break load and prevent tools from causing short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached

equipment.

Important:- 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.

A. GENERAL

Equipment that supplies electrical power can cause serious injury or death, or damage to other 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 equipment. While certain practices be­low apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and some
practices to both.

B. SHOCK PREVENTION

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

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

1. Installation and Grounding of Electrically Powered Equipment

Equipment driven by electric motors
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 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 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.

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
grounding lead will be adequate for the worst fault current situation. Refer to the National Electrical Code
ANSI/NFPA 70 for details. Do not remove plug ground prongs. Use correctly mating receptacles.

2. Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked or
worn cables immediately. Do not overload cables. Do not touch output terminal while equipment is energized.

3. Service and Maintenance

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

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

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

(rather than by diesel or gasoline engines)

must be installed and

(amperage)

capacity of the

ment.

b. Lock switch OPEN
c. Disconnect power to equipment if it is out of service.
d. If troubleshooting must be done with the unit energized, have another person present who is trained in

turning off the equipment and providing or calling for first aid.

C . FIRE AND EXPLOSION PREVENTION

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust pip-

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

1. Electrical Short Circuits and Overloads

Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by causing

nearby combustibles to ignite. For electrically-powered equipment, provide primary input protection to remove
short circuited or heavily overloaded equipment from the line.

2. Batteries

Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured battery

can cause fires and additional failures. When servicing,do not smoke, cause sparking, or use open flame near
the battery.

3. Engine Fuel

Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is not

grounded prior to or during 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. Remove all spilled fuel IMME-
DIATELY, including any that penetrates the unit. After clean-up, open equipment doors and blow fumes away
with compressed air.

D. TOXIC FUME PREVENTION

Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust

fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air condition­ers.

(or remove line fuses)

so that power cannot be turned on accidentally.

E. BODILY INJURY PREVENTION

Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipment for

inspection and routine maintenance. When equipment is in operation, use extreme care in doing necessary
trouble-shooting and adjustment. Do not remove guards while equipment is operating.

F. MEDICAL AND FIRST AID TREATMENT

First aid facilities and a qualified first aid person should be available for each shift for immediate treatment

of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital immedi­ately if any abnormal signs are observed.

EMERGENCY FIRST AID

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

by American Red Cross until medical help arrives.

IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELECTRI-

CAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration, preferably
mouth-to-mouth. If no detectable pulse, begin external heart massage. CALL EMERGENCY RESCUE
SQUAD IMMEDIATELY.

G. EQUIPMENT PRECAUTIONARY LABELS

Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be eas-

ily read.

LIST OF EFFECTIVE PAGES

CHAPTER/ CHAPTER/

SECTION PAGE DATE SECTION PAGE DATE

List of 2-1 1 May 20/89

Effective 2-1 2 May 20/89

Pages 1 thru 2 May 20/89 2-1 3 May 20/89

2-1 4 May 20/89
Introduction 1 May 20/89
Introduction 2 May 20/89 2-2 1 May 20/89

2-2 2 May 20/89
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Table of Contents

SUBJECT CHAPTER/SECTION PAGE

WARNING
LIST OF EFFECTIVE PAGES
INTRODUCTION

CHAPTER 1. DESCRIPTION/OPERATION

SECTION 1. DESCRIPTION 1-1 1

1. General 1-1 1

2. Special Features 1-1 1

A. Standard 1-1 1
B. Options 1-1 4

3. Orientation 1-1 4

4. Identification 1-1 4

5. Canopy 1-1 5

6. Engine, Generator, and Controls 1-1 5

A. General 1-1 5
B. Engine 1-1 5

(1) General 1-1 5
(2) Cooling fan 1-1 6
(3) Engine speed governor 1-1 6
(4) Engine overspeed device 1-1 6
(5) Crankcase ventilation 1-1 6
(6) Fuel system 1-1 6
(7) Alternator and regulator 1-1 6
(8) Starter relay 1-1 6
(9) Carburetor 1-1 6

(10) Spark arrester muffler 1-1 8
C. Generator 1-1 8
D. Control Panel Assembly 1-1 8

(1) General 1-1 8

(2) Lights 1-1 8

(3) Monitoring instruments 1-1 8

(4) Potentiometer 1-1 9

(5) Switches 1-1 9

(6) Fuses 1-1 9

(7) Voltage regulator 1-1 9

(8) Overvoltage module 1-1 9

(9) Resistor and diode assembly 1-1 9

(10) Choke control 1-1 10

(11) Excitation Rectifiers 1-1 10

(12) Voltage Sensing Relay 1-1 10

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SUBJECT CHAPTER/SECTION PAGE

E. Output Terminals 1-1 10
F. Contactor 1-1 10
G. Rectifier Assembly 1-1 10
H. Ammeter Shunt 1-1 10

7. Optional Equipment 1-1 12

A. Trailer 1-1 12

SECTION 2. PREPARATION FOR USE,
STORAGE, OR SHIPPING 1-2 1

1. Preparation for Use 1-2 1

A. General 1-2 1
B. Inspection/Check 1-2 1
C. Output Cable Installation 1-2 2

2. Preparation for Storage 1-2 2

A. General 1-2 2
B. Temporary Storage 1-2 3
C. Long Time Storage 1-2 3

3. Preparation for Shipping 1-2 4

4. Stationary Unit Mounting 1-2 6

SECTION 3. OPERATION 1-3 1

1. General 1-3 1

2. Operating the Generator Set 1-3 1

A. Pre-start Inspection 1-3 1
B. Pre-start Instructions 1-3 1
C. Starting The Engine 1-3 3
D. Generator Operation 1-3 4
E. Deliver Power 1-3 4
F. Stop Operation Shutdown 1-3 4
G. Adverse Weather Precautions 1-3 4

(1) Cold weather operation 1-3 4
(2) Fuel system 1-3 4
(3) Fuel 1-3 4
(4) Cooling system 1-3 4
(5) Lubrication 1-3 5
(6) Electrical system 1-3 5
(7) Battery 1-3 5

H. Operation in Hot and Humid Conditions 1-3 5

(1) Cooling system 1-3 5
(2) Battery 1-3 5

I. Operation in Extremely Dusty Conditions 1-3 5

(1) Fuel system 1-3 5
(2) Oil filter and air cleaner 1-3 5
(3) Crankcase 1-3 5

J. Operation in Salt Water Areas 1-3 6

(1) Canopy 1-3 6

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SUBJECT CHAPTER/SECTION PAGE

(2) Covering 1-3 6

(3) Brushes 1-3 6

(4) Field coils 1-3 6

(5) Battery terminals 1-3 6
K.Miscellaneous 1-3 6

3. Trailer Operation 1-3 6

A. Towing 1-3 6
B. Parking 1-3 7

CHAPTER 2. SERVICING

SECTION 1. MAINTENANCE
INSPECTION/CHECK 2-1 1

1. General 2-1 1

2. Maintenance Schedule 2-1 1

A. General 2-1 1

B. Maintenance Schedule Check Sheet 2-1 1

C. Time Intervals 2-1 1

3. Engine and Related Components 2-1 1

4. Inspection and Cleaning 2-1 1

SECTION 2. MAINTENANCE
PROCEDURES 2-2 1

1. General 2-2 1

2. Lubrication 2-2 1

A. General 2-2 1
B. Lubrication Chart 2-2 1
C. Generator 2-2 1
D. Generator Controls 2-2 1
E. Engine 2-2 1

(1) Lubrication schedule 2-2 3

(2) Oil specification 2-2 4

(3) Oil viscosity 2-2 4

(4) Change engine oil (100 hours) 2-2 4

(5) Change engine oil filter (100 hours) 2-2 5
F. Engine Accessories 2-2 5

(1) Distributor 2-2 5

(2) Governor linkage 2-2 5

(3) Governor 2-2 5
G. Trailer 2-2 5

(1) Front axle assembly 2-2 5

(2) Wheel bearings 2-2 5

3. Servicing the Air Cleaner and Crankcase
Ventilation System 2-2 6

A. General 2-2 6

May 20/89 Table of Contents

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SUBJECT CHAPTER/SECTION PAGE

B. Clean and Service Air Cleaner 2-2 6
C. Clean Crankcase Ventilation System 2-2 6

4. Servicing the Fuel Filter 2-2 6

5. Drive Belt Service 2-2 6

6. Engine Cooling System 2-2 7

A. General 2-2 7
B. Rust Inhibitor 2-2 7
C. Antifreeze 2-2 7

7. Battery Service 2-2 7

8. Generator Maintenance 2-2 7

A. General 2-2 7
B. Brush Service 2-2 7

(1) Cleaning 2-2 8

C. Generator Revolving Field Brush Replacement 2-2 8

SECTION 3. ADJUSTMENT/TEST 2-3 1

1. General 2-3 1

2. Testing the Generator Set 2-3 1

A. Preoperational Test Procedures 2-3 1
B. Operational Tests 2-3 3

3. Governor Adjustment 2-3 4

A. General 2-3 4
B. Troubleshooting 2-3 4

4. Overspeed Relay Adjustment 2-3 6

A. General 2-3 6

5. Voltage Regulator Adjustment 2-3 7

A. 28.5 Volt Adjustment 2-3 7
B. Line Drop Compensation 2-3 7

CHAPTER 3. TROUBLESHOOTING

SECTION 1. TROUBLESHOOTING
PROCEDURES 3-1 1

1. General 3-1 1

2. Troubleshooting Chart 3-1 1

A. Description 3-1 1
B. Use of the Troubleshooting Chart 3-1 1

3. Equipment for Troubleshooting 3-1 1

4. Safety 3-1 1

5. Diagrams 3-1 2

6. Illustrations 3-1 2

7. Connections and Wiring 3-1 2

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CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION 4-1 1

1. General 4-1 1

2. Purpose 4-1 1

3. Arrangement 4-1 1

4. Explanation of Parts List 4-1 1

A. Contents 4-1 1
B. Parts List Form 4-1 1

(1) “FIGURE-ITEM NO.” Column 4-1 2

(2) “HOBART PART NUMBER” Column 4-1 2

(3) “NOMENCLATURE” Column 4-1 2

(4) “EFF” (Effective) Column 4-1 2

(5) “UNITS PER ASSEMBLY” Column 4-1 2

SECTION 2. MANUFACTURER’S CODES 4-2 1

1. Explanation of Manufacturer’s (Vendor)
Code List 4-2 1

SECTION 3. PARTS LIST 4-3 1

1. Explanation of Parts List Arrangement 4-3 1

2. Symbols and Abbreviations 4-3 1

SECTION 4. NUMERICAL INDEX 4-4 1

1. Explanation of Numerical Index 4-4 1

CHAPTER 5. OPTIONAL EQUIPMENT

CHAPTER 6. MANUFACTURER’S LITERATURE

UNUSUAL SERVICE CONDITIONS

May 20/89 Table of Contents

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Table of Contents May 20/89
Page 6

INTRODUCTION

This manual contains operation and service information for 28.5 V DC Generator sets identified as Jet Ex

4. These units are available as stationary, skidmounted units, or they may be trailer-mounted for portabil­ity. Both versions are available with 14 V DC output capability.

Most information in the manual applies to the 28.5 V Jet Ex in general. Information which applies to op­tions and special equipment is identified as such.

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

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

The Table of Contents, which follows this Introduction, lists all Chapters, Sections, and the paragraph ti­tles within each Section. The location of each listing is identified by Chapter, Section and page number. A
complete list of illustrations, with their locations, follows the Table of Contents.

OM-2049

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

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

1. Control
A. Interior Panel

(1) Protective devices

(a) Overload relay

(2) Contactors

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

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

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

May 20/89 Introduction

(shown as 2-3).

Page 1

OM-2049

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 identification is given, for example:
graph 1, A, of the same Section.

When referenced material is located in another Chapter/Section, both the Chapter and Section numbers
and the paragraph identification are given, for example:
material is located in Chapter/Section 1-2, and paragraph 1, A within that Chapter/Section.

Components shown in illustrations, and the illustrations themselves, are referenced in a similar manner.
When this type of reference is made, the item number of the part and the Figure number in which it ap­pears are given, for example:
ter/Section.

When a referenced figure appears in another Chapter/Section, the reference will include the Chapter/Sec­tion number, for example:
to refer to item 1 in Figure 4.

Once a Figure number reference has been established, the Figure number is not repeated and only the
item numbers of the parts involved are referenced, for example: “Loosen screw
nector

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

(4)

, and remove brush

(2, Fig.3)

(2-3, 1, Fig. 4)

(6).”

(Ref. Para. 1, A)

refer to item number 2 in illustration Figure 3 of the same Chap-

tells the user that the information is in Chapter/Section 2-3, and

means that the material is to be found in para-

(Ref. 1-2, Para. 1, A)

means that the referenced

(2, Fig.6),

slide out con-

A collection of manufacturer’s literature is supplied as part of the information package.
If you have any questions concerning your Hobart Power Systems Group equipment, you are invited to

contact our Service Department by mail, telephone, or FAX.

Write: Hobart Brothers Company

Power Systems Group

Service Department

Troy, Ohio 45373

U.S.A.

Call: Area code [phone]

FAX: [phone]

Introduction May 20/89
Page 2

OM-2049

CHAPTER 1. DESCRIPTION/OPERATION

SECTION 1. DESCRIPTION

1. General

The Jet-Ex 4 unit covered in this manual
set manufactured by Hobart Brothers Company, Power Systems Group, Troy, Ohio U.S.A. The basic
unit is identified by a Specification Number 7005, plus a dash number which defines a specific configura­tion. The Series number, plus the dash number, make up the Specification Number.

Specification No. 7005-1 covers a stationary, skid mounted unit rated at 28.5 Volts DC output. It is
equipped with a sheet metal canopy and hinged engine compartment door. The unit is also equipped with
a mechanical governor. Various options are available for use with the basic unit. These options are listed
in paragraph 2.B. below.

The basic generator set is designed to generate and deliver 28.5 volts DC power to an aircraft when its on­board generators are shut down. In addition to poviding continuous, regulated power to the aircraft, the
unit is designed for starting any fixed-wing aircraft or helicopter which is equipped with an external 28.5
volt DC power receptacle. Refer to Figure 2 for complete Specifications and Capabilities.

(Figure 1)

is a gasoline engine driven, self-contained generator

2. Special Features

A. Standard

The “Soft-Start” current limiting feature, recommended by most engine manufacturers, provides the
operator with a control which limits the inrush current to the aircraft engine’s starter. When the opera­tor presets this control, the generator will provide constant voltage to the preset currrent value. As
more current is applied beyond the preset current value, the voltage will decrease to a minimum of 14
volts DC, after which the voltage will remain constant as more current may be delivered beyond the
preset current value. Limiting inrush current is recommended by most engine manufacturers to pro­tect the aircraft engine’s starter shear section. The current limiting control is continuously adjustable
from 300 amperes, which is recommended for helicopter and small turbine starting, to 1600 amperes,
required for starting larger aircraft engines when the control is turned fully clockwise.

Additional features include a mechanical governor which maintains the engine speed at 2600 RPM at
no load, an all-electric engine overspeed protection device which shuts down the engine by opening
the ignition circuit if the engine speed reaches 3200 RPM.

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1-1 May 20/89
Page 2

Jet-Ex 4 Generator Set

Figure 1

OM-2049

UNIT WITHOUT TRAILER AND CABLE HANGERS

Length 65.5 inches (1664 mm)
Width 34.25 inches (870 mm)
Height 46.25 inches (1175 mm)
Weight (dry fuel tank) 1365 pounds (619 kg)

UNIT WITH TRAILER AND CABLE HANGERS (Without Fenders)

Length 72.5 inches (1841 mm)
Width 55 inches (1397 mm)
Height 51.75 inches (1314 mm)
Weight (dry fuel tank) 1590 pounds (721 kg)
Wheelbase 36 inches (914 mm)
Track 49 inches (1245 mm)

UNIT WITH TRAILER, FENDERS AND CABLE TRAY

Length 72.5 inches (1841 mm)
Width 58 inches (1473 mm)
Height 51.75 inches (1314 mm)
Weight (dry fuel tank) 1740 pounds (816 kg)
Wheelbase 36 inches (914 mm)
Track 49 inches (1245 mm)

GENERATOR

Output Power Rating 15.7kW
Voltage 28.5 volts DC
Rated Load Capacity 550 amperes continuous at 28.5 volts DC
Starting Current Capacity 1600 Maximum
Current Limiting Capability 300 to 1600 amperes

continuously adjustable

Operating Speed 2600 RPM

ENGINE

Manufacturer Ford Motor Company
Model LSG 423I-6005-A (with special options:

SO-2802A)
Type Overhead valve, in-line, 4 cylinder
Fuel Gasoline, no lead
Displacement 140 cubic inches (2.3 liters)
Rated Power at 2600 RPM 64 Horsepower
Oil Capacity (with filter change) 5 quarts (4.7 liters)
Coolant Capacity 2.5 U.S. gallons (9.5 liters)
Spark Plugs Type AWSF-52 (.042 - .046 gap)

May 20/89 1-1

Specifications and Capabilities

Figure 2 (Sheet 1 of 2)

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Ignition System (Distributor-coil type) 12 volt DC, negative ground
Governed Speed 2600
Idle Speed 900 to 1000 RPM
Fuel Tank Capacity 21 U.S. gallons (79.5 liters)

PROTECTIVE DEVICES

GENERATOR

28.5 volt overvoltage module trips at 32 to 34 volts.
14 volt overvoltage module trips at 18 to 20 volts.

ENGINE

Overspeed device trips at 3100 to 3200 RPM.
Low oil pressure switch opens at 10 PSI (69 kPa).

Specifications and Capabilities

Figure 2 (Sheet 2 of 2)

+25RPM

B. Options

(1) A four-wheel trailer is available to add mobility to the generator set. It is equipped with pneumatic

rubber tires, a drawbar for towing, and hand lever-operated, parking brake. It also includes fenders,
bumpers and cable trays. This option is available from Hobart Brothers as Part No. 181000-3.

(2) A four-wheel trailer is available to add mobility to the generator set. It is equipped with pneumatic
rubber tires, a drawbar for towing, and hand lever-operated, parking brake. It also includes cable
hangers which are mounted on the right side of the canopy. This option is available from Hobart Broth­ers as Part No. 181000-4.

(3) For mounting the generator set as a stationary unit, a stationary mounting kit is available. This kit,
identified as part number 488952, consists of four spacer brackets which support the unit and permit
anchoring it to a floor or platform, screws for fastening the spacer brackets to the unit, and two cable
hanger brackets.

3. Orientation

The radiator end of the Jet-Ex 4 is the front. Right and left are determined by standing at the rear of the
unit, facing it. The control panel is located at the rear.

4. Identification

The Jet-Ex 4 unit is identified by Specification numbers as described in paragraph 1, above. There may
be any number of generator sets with the same Specification number. Individual machines are identified
by a Serial number, assigned to one machine only.

Each generator set has an Identification plate attached inside the hinged door. This nameplate lists the
machines’s Model No.

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.

1-1 May 20/89
Page 4

(Jet-Ex 4),

Specification No., Serial No., and electrical rating.

OM-2049

5. Canopy

The standard canopy is a sheet metal enclosure which protects the engine, generator, and electrical con­trols. It has one large, hinged door at the left front to provide access for service and maintenance. Panels
at the rear provide access to the generator. A Plexiglas window is mounted above the control panel to al­low observation of the instruments while protecting them from the weather. The right rear panel has a
round hole in it to permit viewing the fuel gage mounted in the fuel tank.

6. Engine, Generator, and Controls

A. General

Refer to Figure 3. The engine
tank support
for the load contactor and output terminals
bolt is attached to the centrally located lifting yoke

B. Engine

(1) General

(7)

located at the rear of the unit supports the fuel tank

The in-line four cylinder engine is a Ford Model LSG 423I-6005-A. It has 140 cubic inch

cylinder displacement and uses no lead gasoline.

ters)

The ignition distributor is mounted on the left side of the engine and is driven by a gear on the
camshaft. The distributor, in turn, drives the oil pump through a short intermediate drive shaft.

Oil pressure is maintained in the lubrication system by a rotary oil pump located in the crankcase.
A spring-loaded relief valve in the pump limits maximum pressure in the system. A full-flow oil fil­ter

(16, Figure 3)

A valve in the filter provides a bypass to an oil gallery in case the filter becomes clogged. A low oil
pressure switch is mounted on the engine block as a protective device. The primary ignition circuit
is wired through the contacts of this switch, which closes at 10 PSI
gine from running if oil pressure will not build up, and also shuts down the engine if oil pressure
drops radically during operation. A vacuum switch mounted in the intake manifold prevents ener­gizing of the starter motor once the engine is running.

See Figure 2 and the engine operator’s manual for engine specifications.
The generator and engine are mounted on a welded steel skid, and are enclosed by a sheet met-

al canopy that bolts to the skid. Access to engine serviceable components

etc.)

is through a gull-wing door at the front left of the machine.

(3)

and generator

(2).

The radiator

cleans the entire output of the pump before it enters the oil distributing system.

(15)

are mounted on a welded steel frame

(13)

and provides a mounting frame

(5)

is mounted to the front canopy. A heavy U-

(12)

for moving the generator set with a crane or hoist.

(69 kPa).

This prevents the en-

(oil filter, air cleaner,

(10).

A fuel

(2.3 li-

Two removeable panels to the right side and one to the left rear allow access to the other compo­nents such as spark plugs, load contactor and output terminals. The rear panel is removeable and
permits access to the rectifier assembly.

May 20/89 1-1

Page 5

OM-2049

(2) Cooling fan

(3) Engine speed governor

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

The engine speed governor
arm is linked to the carburetor fuel control lever by a rod with ball joints threaded on both ends.
This governor maintains the engine speed at approximately 2600 RPM when the generator is in
operation.

(4) Engine overspeed device

The engine and generator are protected against the danger of overspeed by an overspeed relay

(21, Figure 3).

cuit. It senses the distributor pulses, and when they reach a frequency which indicates an engine
speed of approximately 3150 RPM, an internal relay shorts the ignition circuit to ground and shuts
down the engine.

(5) Crankcase ventilation

This engine is equipped with an open crankcase ventilation system. This open ventilation system
consists of a breather cap on the rocker arm cover.

(6) Fuel system

The fuel system consists of an 21-gallon
fuel pump

(14)

is mounted in the fuel line in front of the tank. It shuts off the supply of fuel to the engine

when the ENGINE

nition OFF).

when the engine is not running.

This unit is a sealed, solid-state device which is wired into the primary ignition cir-

(17)

with all the necessary fittings and hoses. A 12 volt, solenoid operated shutoff valve

(ignition)

This keeps the engine from flooding due to the gravity flow or siphoning from the tank

(4, Figure 3)

switch on the control panel is in the STOP/SHUTDOWN position

is a constant speed mechanical governor. Its actuator

(79.5 liters)

tank

(13, Figure 3)

and a diaphragm type

(ig-

Power to open the solenoid valve is supplied when the ENGINE switch is in the START and RUN
positions.

(7)Alternator and regulator

The battery charging alternator
mounted on the side of the left engine support.

(8)Starter relay

The starter relay

(9) Carburetor

The carburetor, specially designed for engine governor type applications, is mounted on the en­gine and adjusted at the Hobart factory. Replacement carburetor, spare parts, and repair kits are
availbable from Hobart Brothers only.

(8, Figure 3)

(20, Figure 3)

is mounted on the right side of the lifting yoke near the starter motor.

is rated at 40 amperes. Its voltage regulator

(18)

is

1-1 May 20/89
Page 6

OM-2049

1. Control Panel 11. Oil Pressure & Coolant Temp. Senders

2. Output Terminals 12. Lifting Yoke

3. Engine 13. Fuel Tank

4. Governor 14. Fuel Shut-off Solenoid Valve

5. Radiator 15. Generator

6. Drain Cock 16. Oil Filter

7. Fuel Tank Support 17. Fuel Pump and Fuel Filter

8. Starter Relay 18. Engine Voltage Regulator

9. Rectifier Assembly 19. Battery

10. Frame 20. Alternator

May 20/89 1-1

21. Engine Overspeed Relay

Generator Set Components

Figure 3

Page 7

OM-2049

(10) Spark arrester muffler

C. Generator

This muffler prevents the discharge of sparks from the engine’s exhaust.

The generator
whose output is rectified. The output is recitified by a rectifier assembly (9) made up of twelve rectifi­ers connected into a full wave configuration. The generator is self-excited and receives excitation from
a three phase full wave rec-tified stator winding. One positive and one negative brush in contact with
slip rings supply controlled excitation current from the stator winding through the voltage regulator to
the rotating field winding. The voltage regulator controls the excitation current and maintains a 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
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 sheet metal construction is mounted on the
coupling hub and draws cooling air over the rectifier assembly and generator windings.

Air enters through the anti-drive end of the generator and is discharged through openings in the fly­wheel housing at the drive end. The generator housing assembly, which contains the generator sta­tor, is bolted to the engine flywheel housing.

D. Control Panel Assembly

(1) General

The control panel
ties for controls and monitoring instruments. The panel is mounted at the rear of the canopy. Its
control are accessible behind a hinged Plexiglas cover. A small hinged panel
mounting for the starting current potentiometer, and also provides access to the voltage regulator
and overvoltage relay, etc.

(15, Figure 3)

(1, Figure 3)

is a multi-phase, synchronous salient pole, revolving field, AC generator

(slip ring end)

is a sheet metal panel which houses and provides mounting facili-

by a single-row ball bearing. The drive end

(Figure 4)

provides

(2) Lights

Two panel lights

(12)

light
the engine is running.

(3) Monitoring instruments

The voltmeter
erator current.

A tachometer
the distributor.

A w ater temperature gauge
perature sender

An oil pressure gauge
operated by a sender

The ammeter
electrical system.

The hourmeter

(4) Potentiometer

glows when the output load contactor is closed, and another one

(7, Figure 4)

(6, Figure 4)

(2)

displays the engine speed in RPM. This instrument is operated by pulses from

(11, Figure 3)

(1, Figure 4)

(11, Figure 3)

(20, Figure 4)

(15)

records the total hours of engine operation for scheduling maintenance.

provide illumination for instruments and controls. One green pilot

(14)

glows green when

indicates generator output voltage, and the ammeter

(3)

indicates the engine coolant temperature and is actuated by a tem-

mounted on the engine’s water jacket.

displays the pressure in the engine’s lubrication system. It is

mounted on the engine block.

indicates the rate of charge or discharge in the engine’s 12 volt DC

(5)

displays gen-

1-1 May 20/89
Page 8

OM-2049

The current limiting potentiometer (4) is used to select the starting current recommended for vari­ous aircraft. The current limiting setting is continuously adjustable from 300 to 1600 amperes.

(5) Switches

The contactor control switch (11, Figure 4) is a three-position toggle switch used to close and
open the output load contactor. The top CLOSE position is spring-loaded and is held momentarily
until the contactor closed light (12) glows, then it is released to the center ON position. In this posi­tion the switch provides holding current to the load contactor to keep it closed. Protective devices
in the load contactor circuit provide protection against overvoltage by opening the load contactor if
that condition occurs. In the bottom OFF position, the contactor is opened. The push-to-build-up­voltage switch (10) is a momentary contact pushbutton switch which flashes the generator fields
with 12 volt engine circuit when flashing the fields.

The panel lights switch (8, Figure 4) turns the lights (7) on and off. The engine start switch (17) is
a momentary contact pushbutton which closes the starter relay (8, Figure 3) and cranks the en­gine. This switch is operable only when the engine (ignition) switch (19) is held in its top spring­loaded START position.

The engine (ignition) switch (19), when released from its top START position after the engine
starts, will return to center RUN position. The engine ON light (14) will glow as long as the switch
is in RUN position. In the bottom STOP position, the switch will stop the engine and the light (14)
will go out.

Refer to Figure 4. The speed control switch, (13) is a two position toggle switch wired to an idling
device on the engine. In the IDLE position, used for starting, the engine speed is controlled ap­proximately 900-1000 RPM. In the Rated RPM position, engine speed is controlled to approxi­mately 2600 RPM.

(6) Fuses

Three cartridge-type fuses protect the engine ignition circuit, the panel lights circuit, and the volt­age regulator. The engine circuit fuse (16, Figure 4) is rated at 20 amperes, the panel lights fuse
(9) at 10 amperes, and the voltage regulator fuse (4, Fig. 5) at 10 amperes.

(7) Voltage regulator

Refer to Figure 5. The voltage regulator (1) is a solid-state device which regulates the 28.5 volt
DC generator output after the voltage is built up.

(8) Overvoltage module

The overvoltage relay (2) 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 overvoltage condition
causes the relay contacts to open, which in turn prevents the contactor from closing, or opens the
load contactor and discontinues the power delivery. The overvoltage module is adjusted to to trip
at 32 to 34 volts DC in 2 to 10 seconds.

(9) Resistor and diode assembly

This network which is mounted on a terminal strip behind the control panel, protects the overvol­tage module against reverse current when the generator is delivering power.

May 20/89 1-1

Page 9

OM-2049

(10) Choke control

(11) Excitation Rectifiers

The choke control is connected to the carburetor choke butterfly with a flexible control cable. Pull­ing it out closes and enriches the fuel mixture. Pushing it in opens the choke.

Two diode bridge rectifiers, CR418 and CR417,
ator armature to the DC voltage needed for the generator revolving field.

(12) Voltage Sensing Relay

Voltage sensing relay K404
circuit of the revolving field to prevent excessive voltage build-up if the push-to-build-upvoltage
switch is held in too long, or if it is pushed in after voltage is built up.

E. Output Terminals

The output terminal panel

F. Contactor

The load contactor which is mounted beside the output terminal panel, provides a safe and conven­ient means of connecting and disconnecting the generator from the load. Initial power for closing the
load contactor is supplied by the generator through the spring-loaded momentary contacts of the con­tactor control switch
normally open auxiliary contacts in the load contactor.

G. Rectifier Assembly

The rectifier assembly
consists of two aluminum heat sinks w ith six diodes on each heat sink. The negative rectifier assem­bly is mounted nearest to the rear frame and the positive rectifier assembly is mounted nearest to the
generator. The rectifier assembly converts the AC output of the generator to 28.5 V DC.

(11, Figure 4).

(9, Figure 3)

(5, Fig. 5)

(2, Figure 3)

Holding power, to keep the contactor closed, passes through the

is located at the rear of the machine below the control panel. It

is a safety device which automatically opens the grounding

is mounted on the side of the fuel tank support.

(3, Fig. 5)

convert an AC voltage from the gener-

H. Ammeter Shunt

The ammeter shunt is connected in the generator’s negative output circuit. It supplies a small voltage
proportional to output current for operation of the generator ammeter
current for the current limit circuit of the voltage regulator
connected to the negative heat sink of the rectifierassembly

1-1 May 20/89
Page 10

(1, Fig. 5).

(9, Fig. 3).

(5, Fig. 4)

This shunt is mounted on a bus

and for sensing output

OM-2049

1. Oil Pressure Gauge 11. Contactor Control Switch

2. Tachometer 12. Contactor Closed Light

3. Water Temperature Gauge 13. Speed Control Switch

4. Current Limit Control 14. Engine On Light

5. Ammeter (Generator) 15. Hourmeter

6. Voltmeter 16. Engine Circuit Fuse

7. Panel Light 17. Engine Start Switch

8. Panel Lights Switch 18. Choke

9. Panel Lights Fuse 19. Engine Ignition Switch

10. Push-To-Build-Up-Voltage Switch 20. Ammeter (Engine)

May 20/89 1-1

Control Panel Assembly

Figure 4

Page 11

OM-2049

7. Optional Equipment

A. Trailer

The portable Jet-Ex 4 is mounted on an optional four-wheel trailer
front and rear axle assemblies. The axles are mounted directly to the main frame of the generator set.
It is available with or without the fenders, bumpers and cable trays. The front axle is a solid beam
type. Front wheels are mounted on spindles which are operated by tie rods connected to the hitch
and drawbar assembly. The spindles are mounted to the axle by means of torsional springs.

Any side-to-side movement of the drawbar turns the wheels in the direction of travel. The drawbar can
be folded upward and locked in the vertical position when the trailer is parked. The parking brake is
operated by a hand operated brake lever.

(see Figure 1)

which consist of

1-1 May 20/89
Page 12

1. Voltage Regulator

2. Overvoltage Relay

3. Excitation Rectifiers

4. Voltage Regulator Fuse

5. Voltage Sensing Relay

Control Panel Wrapper

Figure 5

SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING

1. Preparation for Use

A. General

The generator set is shipped with a dry battery and an empty fuel tank. After the battery is filled with
electrolyte and charged, the fuel tank filled and the generator set inspected, the generator set is ready
for use.

CAUTION: READ OPERATING INSTRUCTIONS IN SECTION 1-3 BEFORE OPERATING THE
UNIT.

B. Inspection/Check

Inspect the unit completely prior to operation.

OM-2049

(1) Remove crating, blocking, banding, ties, and other securing and protective material. After shipping
carton is removed, remove the four carton supports from the bases of the clearance lights. Then in­stall the attached clearance light lenses in their bases.

(2) Inspect exterior for shipping damage such as broken glass, damaged sheet metal, etc.
(3) Open canopy door and inspect interior for foreign material such as rags, tools, shipping papers,

etc.
(4) Check fuel, coolant, and oil hoses and connections for visible leaks. If leaks are discovered, cor-

rect by tightening hose clamps, tube fittings, etc., as required.

(5) Check security of attaching and retaining hardware.
(6) Check the following for sufficient quantity.

(a) Fuel

Fuel tank capacity is 21 gallons

(b) Engine coolant

The radiator cap is located above the front canopy. Coolant level should be approximately
one inch below the filler neck. Allow a sufficient capacity for coolant expansion.

CAUTION: BE SURE THE COOLING SYSTEM ANTIFREEZE SOLUTION IS ADEQUATE TO PRO­TECT BELOW LOWEST TEMPERATURE EXPECTED.

(79.5 liters).

Use no lead gasoline.

(c) Engine lubricating oil

The oil level dipstick is located on the left side of the engine. Refer to Ford Maintenance and
Operator’s Manual for oil recommendations.

May 20/89 1-2

Page 1

OM-2049

(7) Air cleaner

Make sure air cleaner element is installed. Recommended replacement element is United Air
Cleaner No. 250A13.

(8) Battery

Check fluid level in 12 volt battery. Fluid should cover plates.

C. Output Cable Installation
Units are normally supplied without a generator-to-aircraft cable.

(1) Cable requirements

Cable length is determined by the customer’s requirements. It is recommended that the cable be
no longer than 30 feet
end and an AN-2551 plug connector on the other.

The recommended single conductor sizes for 28.5 volt DC, continuous rated amperage and 90C

(194F)

for 285 amperes use 2/0 size
for 385 amperes use 4/0 size

rise is as follows:

(9 m).

The cable should be two conductor with lug-type terminals on one

for 530 amperes use 350 MCM size

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

(2) Cable connector

(a) Connect 28 volt conductors to output terminals on output terminal panel
are identified POSITIVE and NEGATIVE. Tighten terminal nuts securely.

(b) Store cables in cable tray provided on top of fender, or on hangers on side of canopy if fend-

ers are not used.

(Figure 1).

2. Preparation for Storage

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.

A. General

(1) The unit should be prepared for storage as soon as possible after being removed from service.
(2) Storage should be in a building which is dry and which may be heated during winter months.
(3) Moisture absorbing chemicals are available for use where excessive dampness is a problem, how-

ever the unit must be completely packaged and sealed if moisture absorbing chemicals are to be ef­fective.

Terminals

1-2 May 20/89
Page 2

B. Temporary Storage

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

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

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

(3) Start the engine and operate at idle speed. With air cleaner removed, spray an engine preserv­ative oil into the carburetor air intake for about two minutes. This oil should be SAE No. 10, formulated
for anti-rust and anti-corrosion protection. It should also be a high detergent-type that meets require­ments for most severe

(M.S.)

service and Ford Specification M-4834-A.

OM-2049

(4) Throw the speed control switch to RATED RPM
the iginition switch off and allow the engine to come to a stop while continuing to spray oil into the car­buretor air intake.

(5) Clean the exterior of the engine with fuel oil and dry with clean cloths and compressed air.
(6) Seal all engine openings. Use a waterproof, vaporproof material which is strong enough to resist

puncture damage from air pressure.

C. Long Time Storage

(1) Engine operation method

The unit may be stored for long periods with no special preparation if it is possible to operate the
engineonceeachweek.

(a) Make certain that the cooling system is adequately protected.
(b) Start the engine once each week and operate at idle speed until coolant temperature has

reached at least 140 deg F
tery in a fully charged condition.

(60 deg C).

Operating time should be sufficiently long to keep the bat-

(up)

position for a short burst of speed, then turn

WARNING:MAKE CERTAIN OFADEQUATEVENTILATION BEFORE STARTING
ENGINE

(c) Operate normal operating controls.

(2) If weekly operation is not possible, nor convenient, prepare the unit for storage as follows:

(a) Lubricate the unit in accordance with instructions in Section 2-1. Drain the crankcase com-

pletely and refill with engine preservative oil Ford Specification M-4834-A
(b) Drain the fuel tank and run the engine until the carburetor is empty. Pour about a gallon of un-

leaded, undyed gasoline in the fuel tank and operate the engine for at least 10 minutes. With the
engine running at idle speed and the air cleaner removed, treat the upper cylinders,valves, etc.,
by spraying an engine preservative oil into the carburetor air intake for about two minutes. Throw
the IDLE/GENERATE switch to GENERATE position for a short burst of speed, turn the ignition
off, and continue to spray oil into the carburetor until the engine stops.

(c) Drain engine oil. Drain fuel tank, carburetor and fuel line. Drain cooling system at bottom of ra­diator and left side of engine block. Remove radiator cap so coolant will drain completely.

(d) Remove all grease and oil from exterior surfaces of engine.

May 20/89 1-2

Page 3

OM-2049

(e) Seal all engine openings and accessories with water resistant tape.
(f) Remove battery and store in a cool dry place. Store the battery on wood rather than directly on

cement or metal.
(g) To protect the generator and other electrical components, the complete unit should be pack-

aged, using moisture proof packaging and sealing materials. Place packages of moisture absorb­ing chemicals, such as silica-gel, in the unit before packaging.

WARNING: PLACE WARNING TAGS IN SEVERAL PLACES TO MAKE CERTAIN
THAT THE INDIVIDUAL WHOTAKES THE UNIT OUT OF STORAGE IS WARNED
THAT ENGINE OIL AND COOLANT HAVE BEEN DRAINED.

3. Preparation for Shipping

Prepare the unit for shipping as follows:

A. Seal all engine openings to prevent the entrance of water, dirt, and dust
B. Disconnect battery cables.
C. Drain all fuel from tank, carburetor, and fuel lines as required by carrier rules.
D. Crate the unit solidly to prevent damage to instruments, glass, and sheet metal.

1-2 May 20/89
Page 4

OM-2049

May 20/89 1-2

1. Positive Output Terminal

2. Negative Output Terminal

3. Load Contactor

28 Volt Output Terminal Panel

Figure 1

Page 5

OM-2049

4. Stationary Unit Mounting

Figure 2 illustrates the mounting hole pattern in the base of the stationary Jet-Ex 4 generator set. Each of
the eight holes is 9/16"

(14.3 mm)

in diameter.

1-2 May 20/89
Page 6

Stationary Unit Mounting Holes

Figure 2

SECTION 3. OPERATION

1. General

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

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

WARNING: EAR PROTECTION MAY BE NECESSARY WHEN WORKING
CLOSE TO THIS EQUIPMENT.

2. Operating the Generator Set

OM-2049

A. Pre-start Inspection

(1) Always be sure there is sufficient oil and coolant in the engine.
(2) Be sure the fuel shutoff valve is open. The valve is located at the fuel tank outlet. Observe the fuel

gage. Make certain of sufficient fuel to complete the job to be done.
(3) If the unit is trailer mounted and is not connected to a tow vehicle, be sure the parking brake is ap-

plied.

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

B. Pre-start Instructions

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

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

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

(3) Wipe off the entire unit and clean the air passages, control panel and other hard to reach places
with compressed air not over 25 psi

(172 kPa).

May 20/89 1-3

Page 1

OM-2049

1. Oil Pressure Gauge 11. Contactor Control Switch

2. Tachometer 12. Contactor Closed Light

3. Water Temperature Gauge 13. Speed Control Switch

4. Current Limit Control 14. Engine On Light

5. Ammeter (Generator) 15. Hourmeter

6. Voltmeter 16. Engine Circuit Fuse

7. Panel Light 17. Engine Start Switch

8. Panel Lights Switch 18. Choke Control

9. Panel Lights Fuse 19. Engine Ignition Switch

10. Push-To-Build-Up-Voltage Switch 20. Ammeter (Engine)

1-3 May 20/89
Page 2

Operating Controls and Indicators

Figure 1

OM-2049

(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.

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

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

C. Starting The Engine

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

(1) Check engine oil, fuel and coolant levels.
(2) Place speed control switch
(3) If engine is COLD pull out CHOKE
(4) Hold IGNITION switch
(5) Press and hold ENGINE START pushbutton

CAUTION: IF THE ENGINE STALLS OR FALTERS IN STARTING, WAIT THREE OR FOUR SEC­ONDS BEFORE RE-ENGAGING STARTER. THIS WILL PREVENT POSSIBLE DAMAGE TO
STARTER OR THE ENGINE. DO NOT OPERATE THE STARTER FOR PERIODS LONGER THAN
15 SECONDS AT A TIME. AN INTERVAL OF AT LEAST TWO MINUTES SHOULD BE ALLOWED
BETWEEN CRANKING PERIODS TO PROTECT THE STARTER FROM OVERHEATING.

(a) Push the CHOKE control in if the engine does not start after being cranked a few revolutions.
(b) If engine flooding is suspected, push the CHOKE control in and crank the engine again, ob-

serving the CAUTION above.
(6) Release IGNITION switch
(7) Adjust CHOKE
(8) As engine warms up, push CHOKE all the way in.
(9) Allow engine to warm up before applying a load.

(18).

(13)

in IDLE

(18).

(19)

in START position.

(19),

to RUN position when oil pressure builds up.

(down)

Do not choke HOT engine.

position.

(17).

Release as soon as engine starts.

WARNING: THE ENGINE’S ENTIRE EXHAUST SYSTEM WILL GET VERY HOT
AND CAUSE SEVERE BURNS IF TOUCHED.

NOTE: B e sure that the Choke control is pushed all the way in before operating the engine under load.

May 20/89 1-3

Page 3

OM-2049

D. Generator Operation

(1) Place speed control switch
(2) Press BUILD UP VOLTAGE pushbutton
(3) Adjust STARTING CURRENT rheostat

E. Deliver Power

(1) Connect output cable to AIRCRAFT.
(2) Hold CONTACTOR switch

CONTACTOR CLOSED light

F. Stop Operation Shutdown

(1) Place CONTACTOR switch

has opened and power is no longer available at the aircraft.

(2) Place speed control switch
(3) Disconnect output cable from aircraft receptacle and store cable in cable trays or on cable hang-

ers as the case may be.

(4) Place IGNITION switch

G. Adverse Weather Precautions

(1) Cold weather operation

(13)

in RATED RPM

(10).

(4)

(11)

in CLOSE position. Release to ON position as soon as green

(12)

comes on.

(11)

in OFF position. Light

(13)

in IDLE

(19)

in STOP/SHUTDOWN position.

(down)

(up)

Generator will produce rated voltage.

if necessary.

position. Allow engine to run for 2 to 3 minutes.

position. Engine speed will be 2600 RPM.

(12)

should go off to indicate load contactor

Operation of engine-driven units at sub-zero temperatures requires special precautions and extra
servicing from both operation and maintenance personnel if poor performance or total functional
failure is to be avoided. Consult Maintenance and Operator’s Manual and recommendations be­low.

(2) Fuel system

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

(3) Fuel

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

(4) Cooling system

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

1-3 May 20/89
Page 4

(5) Lubrication

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Drain the crankcase

Engine Oil Recommendations chart in the Maintenance and Operator’s Manual for recommended

viscosity for various atmospheric temperatures. In cold weather, drain oil more frequently. Water

condenses and collects quickly, mixes with the oil and increases deposits to form a sludge. Check

oil frequently for this condition. Water in crankcase or oil lines may freeze and cause serious dam-

age to the oil pump, or shut off the oil supply.

(6) Electrical system

In cold weather, the most efficient electrical system is needed to start the cold engine. Check the

entire system for loose connections or indication of bad wiring or shorted conditions. Check spark

gaps of the spark plugs, and distributor point gaps, consult the Maintenance and Operator’s Man-

ual for the engine.

(7) Battery

Battery efficiency decreases sharply with lower temperatures. Maintain the specific gravity of the

battery between 1.275 and 1.300

tempting to start engine in sub-zero conditions.

H. Operation in Hot and Humid Conditions

(1) Cooling system

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

(preferably when warm after running)

(fully charged condition).

and fill with a lighter grade of oil. See

Make sure of full charge before at-

(2) Battery

The specific gravity and proper level of the battery electrolyte should be maintained. Observe rec-

ommendations in the Maintenance and Operator’s Engine Manual for proper care of the battery.

I. Operation in Extremely Dusty Conditions

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

(1) Fuel system

Change the fuel pump filter regularly and keep all fuel containers covered and protected against

dust entry.

(2) Oil filter and air cleaner

These both need more frequent attention under dusty conditions. Check air cleaner daily. Re-

place oil filter cartridge as needed.

(3) Crankcase

The crankcase oil level will bear close attention. Dusty conditions tend to load crankcase oil with

dirt. Watch for d irty and gritty oil conditions, and change oil more frequently as required.

May 20/89 1-3

Page 5

OM-2049

J. Operation in Salt Water Areas

(1) Canopy

Wash canopy regularly to remove salt film. Repaint any damaged places and oil the side panel
hinges regularly.

(2) Covering

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

(3) Brushes

The brushes of the generator should be inspected regularly to make certain that they are free in
the holders. Lift the brushes in the brushholders about every two days to insure their freedom to
slide within the holder. Wipe dry all the parts that can be reached, and use compressed air, if
available, to dry the parts of the generator that cannot otherwise be reached. See MAINTE-

NANCE for brush care.

(4) Field coils

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

(5) Battery terminals

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

K.Miscellaneous

Once a month, oil hinge on the engine compartment door and the hinged plexiglas cover, and apply
several drops of oil to the choke cable wire at the carburetor
each drop to soak back into sheath.

3. Trailer Operation

A. Towing

Observe the following rules when towing the trailer.
(1) Be sure all output cables are disconnected and properly stowed.
(2) Be sure parking brake is released.
(3) Avoid turns which are shorter than the steering linkage will freely allow.
(4) Avoid speeds greater that 15 MPH and sudden turns.

(where wire exits from its sheath).

Allow

1-3 May 20/89
Page 6

B. Parking

Observe the following rules when parking the trailer.
(1) Always place drawbar in an upright, vertical position and lock it when trailer is parked.
(2) Be sure parking brake is applied.

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May 20/89 1-3

Page 7

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1-3 May 20/89
Page 8

CHAPTER 2. SERVICING

SECTION 1. MAINTENANCE INSPECTION/CHECK

1. General

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

WARNING: STOP OPERATIONS AT ONCE IF A SERIOUS OR POSSIBLY DAN­GEROUS FAULT IS DISCOVERED.

2. Maintenance Schedule

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A. General

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

lubrication requirements.

B. Maintenance Schedule Check Sheet

It is strongly recommended that the customer use a maintenance schedule check sheet. The

check sheet will provide a record of maintenance operations performed and may also serve to im-

prove scheduling for a specific operation.

C. Time Intervals

The schedule is based on both hours of operation and calendar intervals. These two intervals are

not necessarily the same. The calendar period is included to make certain services are performed

regularly when equipment is being operated infrequently, or at irregular intervals. Hourly time inter-

vals agree with the engine manufacturer’s recommendations. Perform all services on a “which-

ever comes first” basis.

NOTE: Refer to the Ford Maintenance and Operator’s Manual fordetailed engine maintenance informa­tion.

3. Engine and Related Components

See the Ford Maintenance and Operator’s Manual for LSG423, 140 cu. in. engine.

4. Inspection and Cleaning

Every day, check for oil, coolant, or fuel leaks. Also check for loose electrical connection. Check oil
pressure with engine running at rated RPM
15 psi. Wipe accumulated water off from all electrical connections and instruments. Make sure that
the alternator ammeter is not discharging, which indicates that the battery is being charged.

May 20/89 2-1

(2600).

Do not operate engine if oil pressure is less than

Page 1

OM-2049

A/R 10 HRS. 100 HRS. 200 HRS. 400 HRS. 800HRS.

OR OR OR OR OR
DAILY 2WKS 1MTH 2MTHS 6MTHS

ENGINE

Check oil level X
Check coolant level X
Check governor oil X
Check fuel quantity X
Check gages and instruments for
proper operation X
Clean or replace dry-type
carburetor air cleaner element X X
Lubricate distributor X
Clean crankcase ventilation system X X
Change engine oil X
Change engine oil filter X
Change governor oil X
Lubricate choke linkage X
Check and tighten drive belts X X
Clean and inspect exterior of
radiator X
Check exhaust system X
Check cooling system X
Check and adjust idle speed and
mixture X X
Check and refill cooling system (Twice yearly, summer and winter)
Replace fuel filter X X
Clean engine X

ELECTRICAL SYSTEM (12-V DC)

Check lights X
Check charging rate X
Check battery water level X
Check battery state of charge X
Charge wiring and connections X
Check all instruments and gages X
Check battery terminals and
connectors X

Inspection/Check/Maintenance Schedule

Figure 1 (Sheet 1 of 2)

2-1 May 20/89
Page 2

A/R 10 HRS. 100 HRS. 200 HRS. 400 HRS. 800HRS.

OR OR OR OR OR
DAILY 2WKS 1MTH 2MTHS 6MTHS

ELECTRICAL SYSTEM (28.5-V DC)

Check indicating light X
Check operation of all instru­ments, meters, etc. X
Check generator brushes for
length, cleanliness, and
free operation X
Check slip rings for smooth­ness and cleanliness X
Checktheentireunit X
Check overvoltage protection X
Check all wiring connections X

TRAILER
Lubricate X
Check tire inflation X
Check and adjust wheel bearings X
Lubricate wheel bearings X
Check brake tension X

OM-2049

Inspection/Check/Maintenance Schedule

Figure 1 (Sheet 2 of 2)

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

Every month, check generator for amperage and voltage output. Blow out generator windings with
compressed air, not over 25 psi
metalic 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 cover,
well vented. Heating should not exceed 194 F

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

(172 kPa)

pressure or remove with a suction-type cleaner with a non-

(90 C).

May 20/89 2-1

Page 3

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2-1 May 20/89
Page 4

SECTION 2. MAINTENANCE PROCEDURES

1. General

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

WARNING: STOP OPERATION IMMEDIATELY IF A SERIOUS OR POSSIBLY
DANGEROUS FAULT IS DISCOVERED.

2. Lubrication

A. General

Proper lubrication is one of the most important steps in good maintenance procedure. Proper lubrica­tion means the use of correct lubricants and adherence to a proper time schedule. Lubrication points,
frequency of lubrication, and recommended lubricants a re indicated in Figure 1.

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B. Lubrication Chart

Lubrication points are illustrated and identified by name on Lubrication Chart, Figure 1.
Number symbols used to designate the kind of lubricant required and the specification recommended

are identified in Figure 2.
Letter symbols used to designate the normal lubrication period are identified in Figure 3.

C. Generator

The 28.5 volt DC generator requires NO lubrication. The armature is supported at the rear by a single,
ball bearing which is lubricated and sealed at the factory for lifetime, maintenance free operation. The
front end of the armature is supported by the engine main bearings.

D. Generator Controls

Generator controls and instruments require no periodic lubrication. A few drops of oil may be required
on door hinges occasionally to insure free and quiet operation.

E. Engine

Although the engine and its accessories require no more attention than any other similar installation,
they still inherently require a major portion of the generator set lubrication and maintenance. Recom­mendations regarding engine lubrication have been taken from the engine manufacturer’s “Mainte­nance and Operator’s Manual”.

May 20/89 2-2

Page 1

OM-2049

* Check crankcase oil daily; change 200 hours.

2-2 May 20/89
Page 2

** Change oil filter after 200 hours.

Lubrication Chart

Figure 1

SYMBOL NAME SPECIFICATION NOTES

1 Grease, Automtive Federal Sinclair Litholene

and Industrial VV-G-632 Industrial No. 2;

Mobil-Mobilplex 47, or
equivalent

2 Oil, Engine, Heavy Ford spec. Ford Motorcraft, or

Duty ESE-M2C101-C equivalent. Refer to

Figure 4 for recom­ended oil viscosity.

3 Grease, Automotive Military Wheel bearings

MIL-G-10924B

4 Oil Military Mechanical governor.

MIL-L-21260

OM-2049

Lubricants

Figure 2

SYMBOL TIMEINTERVAL

D 10 hours or Daily
BW 100 hours or Biweekly
M200hoursorMonthly
BM 400 hours or Bimonthly
SA 800 hours or Semiannually

Symbols and Time Intervals

Figure 3

(1) Lubrication schedule

Time schedules indicated on the Lubrication Chart, Figure 1, are approximate. They are based on

average operating conditions. It may be necessary to lubricate more frequently under severe oper-

ating conditions such as: low engine temperature, high oil temperature, intermittent operation, or

dusty conditions. However, time intervals should not exceed those indicated in the chart without

careful evaluation.

The use of quality lubricating oil, combined with proper oil drain and filter change intervals are im-

portant factors in extending engine life.

May 20/89 2-2

Page 3

OM-2049

(2) Oil specification

Engine lubricating oil recommended by the engine manufacturer must meet Ford Specification
No. ESE-M2C101-C. Oil that meets this specification is normally marked so on the can and
meets API
recommends Ford or Motorcraft oils, which meet all specifications for Ford Industrial Engines.

(3) Oil viscosity

When you change or add oil, you should select oil with the proper specifications and with the vis­cosity, selected from the following table, which most closely matches temperature range you ex­pect to encounter for the next 100 hours of operation.

SINGLE VISCOSITY OILS MULTI-VISCOSITY OILS
When Outside Use SAE When Outside Use SAE
Temperature is Viscosity Temperature is Viscosity
Consistently Number Consistently Number

-10F to +32F (*) 10W Below +32F (*) 5W-30
+10F to +60F 20W-20 -10F to +90F 10W-30
+32F to +90F 30 -10F to +90F (or above ) 10W-40
Above 60F 40 Above +10F 20W-40

(American Petroleum Institute)

classification designation SF or SG. The manufacturer

(*) Where sustained high RPM operation is anticipated, use 20W20.

Temperature and Oil Viscosity Chart

Figure 4

(4) Change engine oil (100 hours)

Oil should be changed after each 100 hours of engine operation. The generator set is equipped
with an hourmeter which records actual engine operating time. The ideal time to change oil is
soon after a power delivery run when the engine is at operating temperature.

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

CAUTION: DO NOT USE SOLVENTS AS FLUSHING OILS IN RUNNING ENGINES.

Change the oil filter each time the oil is changed.

Change oil as follows:

(a) Provide a container for catching used oil. Capacity should be greater than 2 gallons.
(b) Remove drain plug located in oil pan. Allow sufficient time for oil to drain from valve train, tim-

ing gear case, etc., before reinstalling plug.

(c) Change oil filter while oil is draining
(d) Clean drain plug and reinstall. Do not over-tighten.

2-2 May 20/89
Page 4

[see Para. 2, E, (5) below].

OM-2049

(e) Remove filler cap on valve cover and refill crankcase with new, clean oil of proper specifica-

tion and viscosity

changed.

(f) Start engine and allow it to idle. Oil pressure should come up to normal quickly. Check for oil

leaks at filter and drain plug.

(g) Stop engine. Allow several minutes for oil to drain to crankcase, then check oil level. It should

be at FULL mark on dipstick.

(h) Check hourmeter and record time of oil change.

[see Para. 2, E, (2) and Figure 4].

7 quarts are required when oil filter is

(5) Change engine oil filter

(a) Place a container under the oil filter

(b) Loosen filter with a special oil filter removal wrench. Several types are available. Discard oil fil-

ter.

(c) It is recommended that a Motorcraft No. FL-1A or a Ford No. D9AZ-6731A replacement be

used.

(d) Coat the gasket on the new filter with oil.

(e) Place the new filter in position on the cylinder block and spin on until the gasket contacts the

adapter face; then hand tighten another 1/2 turn. Do not over-tighten.

(f) Start engine and check filter gasket for leaks.

F. Engine Accessories

(1) Distributor

Place a few drops of SAE 10W engine oil in the oil cap on the distributor housing each 100 hours

operation.

(2) Governor linkage

Lubricate all wear points with one or two drops of SAE 30 engine oil each 200 hours.

(100 hours)

(1-1; 23, Figure 3)

to catch oil

(3) Governor

Change governor oil each 800 hours. Add SAE 20-30 oil to governor.

G. Trailer

(1) Front axle assembly

The front axle assembly, drawbar, and steering linkage are equipped with high pressure lubrica-

tion fittings. Lubricate the trailer each 400 hours. Use a good quality chassis lubricant

2).

Clean lube fittings before applying grease.

(2) Wheel bearings

Lubricate and check wheel bearing adjustment each 800 hours or semiannually. Use a good qual-

ity bearing lubricant

May 20/89 2-2

(See Figure

(See Fig. 2).

Page 5

OM-2049

3. Servicing the Air Cleaner and Crankcase Ventilation System

A. General

It is important that the air cleaner be cleaned and serviced regularly each 100 hours of engine opera­tion. Service the air cleaner more often under severe dust conditions. Failure to service the cleaner
can cause damage to the cylinder walls and rings, excessive oil consumption, and excessive fuel con­sumption. The recommended filter element for replacement is United Air Cleaner No. 250A13.

B. Clean and Service Air Cleaner

(1) Remove thumb nut and remove air cleaner assembly.
(2) Disassemble air cleaner and discard dry filter element.
(3) Wash all components with solvent and blow dry with compressed air.
(4) Replace air cleaner body on carburetor.
(5) Install a new filter element.
(6) Replace air filter cover.
(7) Reinstall thumb nut and tighten securely.

C. Clean Crankcase Ventilation System

Clean breather cap at each oil change

(1) Remove breather cap from the rocker cover and clean it in a petroleum solvent.
(2) Replace breather cap.

(100 hours).

4. Servicing the Fuel Filter

The fuel filter is a disposable in-line type and is mounted on the intake manifold
left side of the engine. The recommended filter element for replacement is Ford No. C2RZ-9155-A, and
should be changed every 800 hours.

A. Remove inlet and outlet hose clamps.
B. Disconnect the hoses and discard the filter.
C. Install new filter by connecting the hose from the fuel pump to the inlet side and the hose from the

carburetor to the outlet side of the filter.

D. Position the hose clamps and tighten them.
E. Start the engine and check for leaks.

(1-1; 17, Figure 3)

5. Drive Belt Service

Check all drive belts and adjust if necessary each 200 hours. Refer to Ford Maintenance and Operator’s
Manual in Chapter 5 for proper procedures.

on the

2-2 May 20/89
Page 6

6. Engine Cooling System

A. General

NOTE: Refer to the Ford Maintenance and Operator’s Manual in Chapter 5 for detailed instructions on
servicing the engine’s cooling system.

During warm weather operation, when plain water is used as a coolant, the cooling system MUST be
protected against rust by a rust inhibitor additive. During cold weather operation the system MUST be
protected against freezing. The system should NEVER be operated on plain water, without a rust in­hibitor or antifreeze.

WARNING: WHEN REMOVING THE CAP FROM A VERY HOT RADIATOR,
COVER THE CAP WITH A THICK CLOTH AND TURN IT SLOWLY COUNTER­CLOCKWISE TO THE FIRST STOP. WHEN PRESSURE IS COMPLETELY RE­LEASED, PRESS DOWNWARD AND FINISH REMOVING CAP.

CAUTION: DO NOT ADD COOLANT TO AN EXTREMELY HOT ENGINE. THIS CAN RESULT IN A
CRACKED BLOCK OR CYLINDER HEAD.

OM-2049

B. Rust Inhibitor

The recommended rust inhibitor to use in this engine is Ford Rotunda 8A-19546-C.

C. Antifreeze

The recommended antifreeze for use in this engine is Ford Rotunda 8A19549-A. The coolant, when
mixed as equal parts of water and the recommended antifreeze, will provide protection to -35 degrees

(-37 degrees C).

F

If another coolant is used, it must meet Ford Specification ESE-M97B18-C.

7. Battery Service

Refer to the Ford Maintenance and Operator’s Manual in Chapter 5 for battery service instructions.

8. Generator Maintenance

A. General

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

B. Brush Service

May 20/89 2-2

Page 7

OM-2049

(1) Cleaning

If inspection reveals that brushes are gummy or sticking in the brushholders, they should be re­moved and cleaned. Clean both the brushes and brushholders.Use a good, SAFE, commercial
cleaner. DRY ALL PARTS THOROUGHLY. Be sure brushes can move freely in brushholders.

WARNING: DO NOT USE A FLAMMABLE SOLVENT. DO NOT USE STEAM
CLEANER, OR SOAPS AND DETERGENTS UNDER PRESSURE.

C. Generator Revolving Field Brush Replacement
SeeFigure5

(1) Disconnect leads

CAUTION: When removing the lead wires, do so one at a tim e and replace each brush accord­ingly, to insure that the lead wires are put back onto the proper brushes.

(2) Lift brush

7/16 inch
(3) Inspect slip rings whenever brushes are removed for servicing brushes or brushholders. Note sur-

face conditions of rings. Surface should appear smooth and clean. Scoring or roughness of slip rings
may be caused by grit or abrasive substance in brushes, or by oil on the rings. Moderately rough slip
rings 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 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

kPa)

air pressure to blow dirt out.

(4) Slip new brushes into brushholder guides, and place caps on top, and screw them into the guides
to a “bottomed” position. The spring attached to the brush will determine the pressure at which the
brush contacts the slip rings.

(5) To fit new brushes to the slip rings, lay a strip of No. 00 sandpaper, smooth side down, on slip 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 carbon dust out
of the machine using not over 25 psi

(D)

(11 mm),

(A)

from connectors on brushholder caps

from brushholder

replace them.

(B).

(C)

for inspection. If brushes are worn unevenly or are shorter than

(172 kPa)

air pressure.

(172

2-2 May 20/89
Page 8

OM-2049

May 20/89 2-2

A-Leads D-Brush
B-Brushholder Caps E-Slip Rings
C-Brushholder

Generator Revolving Field Brushes

Figure 5

Page 9

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2-2 May 20/89
Page 10

SECTION 3. ADJUSTMENT/TEST

1. General

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

2. Testing the Generator Set

Test values listed below will result when the generator set is operating properly. If your test results are not
within the limits shown, perform the applicable troubleshooting procedures given in Chapter 3.

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

A. Preoperational Test Procedures

(1) Open engine compartment door and inspect the interior for rags, tools, and other foreign materials.

OM-2049

(2) Check engine oil level.
(3) Check coolant level.
(4) Check battery water level.
(5) Check for sufficient fuel.
(6) Check drive belts. Each belt should have approximately 1/2 inch
(7) Inspect all wiring for possible trouble spots such as loose wires or terminals, frayed insulation, obvi-

ous shorts, etc.

(8) Check panel lights, panel light switch, and fuse.
(9) Check governor linkage for freedom of travel. Proper control rod length is approximately 7-1/8

inches

CAUTION: IF GOVERNOR WAS REPLACED OR LINKAGE WAS DISCONNECTED FOR ANY
REASON, REFER TO ADJUSTMENT PROCEDURES IN PARA. 3 BEFORE TESTING GENER­ATOR.

(10) Connect cables from generator output terminals to a load bank. Use cables of the same size and

length as those used in service, preferably No. 2/0, not more than 30 feet

(181 mm)

center-to-center of ball joints.

(13 mm)

(9 m)

slack.

long.

May 20/89 2-3

Page 1

OM-2049

1. Oil Pressure Gauge 11. Contactor Control Switch

2. Tachometer 12. Contactor Closed Light

3. Water Temperature Gauge 13. Speed Control Switch

4. Current Limit Control 14. Engine On Light

5. Ammeter (Generator) 15. Hourmeter

6. Voltmeter 16. Engine Circuit Fuse

7. Panel Light 17. Engine Start Switch

8. Panel Lights Switch 18. Choke Control

9. Panel Lights Fuse 19. Engine Ignition Switch

10. Push-To-Build-Up-Voltage Switch 20. Ammeter (Engine)

2-3 May 20/89
Page 2

Operating Controls and Indicators

Figure 1

B. Operational Tests

OM-2049

(1) Start the engine as described in 1-3; Para. 3
(2) Inspect for oil, fuel and coolant leaks.
(3) Check the engine ammeter

read 35 to 60 psi
F

(82to93deg.C.).

(4) Idle speed displayed on the tachometer
(5) Check engine rpm’s at operating speed:

(a) Governor

Place speed control switch
reading of 2600 rpm at no load speed.

(6) Depress the PUSH TO BUILD UP VOLTAGE Switch to build up output voltage of generator.
(7) Set current limit control
(8) Adjust the load bank for a load of 550 amperes.
(9) Place the contactor control switch

will glow and the contactor will close. Release the switch to the center ON position. The tachometer

(2)

will indicate 2550 + 25 RPM.

(10) Disconnect the load bank and check the overvoltage protection by adjusting voltage regulator po­tentiometer R46
contactorat32to34voltsin2to10seconds.

(240 to 414 kPa).

(1, Fig. 3)

(20, Fig. 1)

Check coolant temperature gauge. It should read 180 to 200 deg.

(13)

in RATED RPM

(4, Figure 1)

to maximum, full clockwise, position.

(11)

to increase the voltage. The overvoltage relay will trip and open the load

(a),

and let it warm at idle speed.

for a slight charge. Check oil pressure gauge

(2)

should be 900 to 1000 RPM.

(up)

position. Tachometer

in the CLOSE position. CONTACTOR CLOSED light

(1).

It should

(2)

should show a

(12)

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

(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 660 amperes
and check voltage at each setting. Voltage will be 28.5

(13) Apply 600 to 700 amperes load to the generator and set the current limit control

(6)

rent displayed on ammeter

will be 400 + 40 amperes.

+ 1 volts at each different load.

(4)

to 400. Cur-

NOTE: Voltage will not drop below 12 volts.

(14) Set current limit control to 1000. Apply 1200 amperes load. Current dispalyed on ammeter will be

+ 100 amperes and voltage will not drop below 12 volts.

1000
(15) To check the overspeed relay, manually override the governor linkage at the ignition circuit and

shutdowntheengineat3100to3200RPM.
(16) Restart the engine, check the instruments as directed in step

set for unusual vibration and noises.

(3),

and check the entire generator

May 20/89 2-3

Page 3

OM-2049

3. Governor Adjustment

A. General

(1) Put a slight tension on governor spring

(A, Fig. 2).

so that the throttle arm on the carburetor is 1/16 inch off the full throttle stop. Release spring tension
and operate throttle lever manually to check for any binding or lost motion in linkage. Make correc­tions as required.

(2) If governor is equipped with bumper screw
threads are engaged and secure with locknut.

(3) Start engine and operate at fast idle until warmed to operating temperature.
(4) Obtain desired no-load speed with adjusting screw
(5) Check regulation by applying and removing engine load. If drop in engine speed between no-load

and full-load is too much, adjust regulation screw
surges under load, adjust screw
tion is obtained.

(6) Check speed adjustment after making regulation adjustment.
(7) Bumper screw

screw

CAUTION: DO NOT TURN BUMPER SCREW IN FAR ENOUGH TO INCREASE NOLOAD SPEED
OF ENGINE.

Install linkage from governor throttle lever to carburetor lever, adjusting length of linkage

(B)

(C)

is used to remove a no-load surge only. If governor surges at no-load, turn

(C)

in slowly until surging stops. Secure adjustment with locknut.

(just enough to crank the coils apart)

(C),

back out bumper screw until only three or four

(A).

(B)

to draw spring closer to lever hub. If governor

to move spring away from lever hub. Repeat until desired regula-

with adjusting screw

B. Troubleshooting

When installing the governor, carefully follow the instructions for installation and adjustment. To fur­ther aid in checking installation and servicing of the governor after it has been in use, check the follow­ing troubleshooting hints.

(1) Engine speed lugs down when load is applied

(a) Governor improperly adjusted.

(b) Friction in throttle linkage.

(c) Load is too great for engine.

(d) Engine worn, compression too slow.

(e) Timing slow.

(f) Governor running too slow.

(g) Springs in carburetor or throttle mechanism opposing governor action.

(h) Governor worn internally.
(2) Engine over-speeds when load is applied

(a) Governor belt slipping.

2-3 May 20/89
Page 4

OM-2049

May 20/89 2-3

Governor Adjustment

Figure 2

Page 5

OM-2049

(b) Governor running too slow.

(c) Friction in throttle linkage.

(d) Governor improperly adjusted.

(e) Friction in carburetor.

(f) Springs in carburetor or throttle mechanism opposing governor action.

(g) Governor worn internally.
(3) Governor surges at no-load

(a) Friction in throttle linkage.

(b) Governor belt slipping.

(c) Carburetor mixture too lean or too rich.

(d) Timing set too fast.

(e) Faulty ignition.

(f) Governor worn internally.
(4) Governor surges under-load

(a) Governor improperly adjusted.

(b) Friction in throttle linkage.

(c) Governor belt slipping.

(d) Carburetor mixture too lean or too rich.

(e) Timing too fast.

(f) Faulty ignition.

(g) Governor running too fast.

(h) Governor worn internally.

NOTE: The governor has beenpre-lubricated at thefactory and doesnot requirefurther attention forthe
warranty period. If after the warranty period e xpires, the governor shows any oil leakage, the oil level
can be checked and maintained to the “OIL LEVEL HOLE” depth.

4. Overspeed Relay Adjustment

A. General

If the overspeed relay has been replaced, the new unit may require adjustment as described below.

(1) Make certain that the speed control switch
and let it run at idle speed until it reaches operating temperature of 180 to 200 deg. F

deg. C).

(13, Figure 1)

is in IDLE position. Start the engine

(82to93

(2) Manually override the control linkage at the carburetor to increase the engine speed. The over­speed relay should shut down the engine at 3100 to 3200 RPM. If the engine shuts down below
3100 RPM or if it does not shut down at 3200 RPM, adjustment is required.

2-3 May 20/89
Page 6

(3) Adjust the screwdriver adjustable pot at the point shown in the illustration. Turn it counter

clockwise to increase the speed at which the engine will shutdown. Turn it counterclockwise to de-

crease the shutdown RPM.

5. Voltage Regulator Adjustment

A. 28.5 Volt Adjustment

The regulating voltage, in the 28.5 volt range, is determined by the position of the wiper arm of the
multi-turn potentiometer R46 Clockwise
erates. Conversely, counterclockwise

B. Line Drop Compensation

Line drop compensation allows the voltage at the load end of the output cable to remain constant de­spite the voltage drop associated with the output cable. Clockwise
tentiometer
voltage at the load end of the output cable when delivering rated load current.

(R24)

increases the compensation. This potentiometer should be set for flat regulation of

(CCW)

(CW)

rotation increases the voltage level at which the unit op-

rotation decreases the voltage level.

(CW)

rotation of the single-turn po-

OM-2049

May 20/89 2-3

Page 7

OM-2049

2-3 May 20/89
Page 8

1. 28.5V VoltageAdjustment

2. Line Drop Compensation VoltageAdjustment

Voltage Regulator Adjustment

Figure 3

CHAPTER 3. TROUBLESHOOTING

SECTION 1. TROUBLESHOOTING PROCEDURES

1. General

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

2. Troubleshooting Chart

A. Description

The troubleshooting chart lists information under three headings:

OM-2049

(1) Trouble, symptom, and condition.
(2) Probable cause
(3) Test, check and remedy

B. Use of the Troubleshooting Chart

Read the trouble symptoms and conditions before proceeding to causes and remedies. For example,
at the beginning of the troubleshooting chart under ENGINE, the first trouble listed is: “Engine will not
start. Starter will NOT crank engine.” If the starter WILL crank the engine, then obviously this is not
your symptom and condition. Go the next trouble and symptom directly below.

If the starter will NOT crank the engine, look to the right under PROBABLE CAUSE and TEST,
CHECK, AND REMEDY and find the various things which could cause the trouble and what to do to
check and remedy them.

3. Equipment for Troubleshooting

A good quality, multi-scale voltohmmeter is the only instrument required for troubleshooting. At least two
jumper leads with “alligator”, or similar clips, will be required. The 12 volt engine electrical system may be
used for a 12 volt DC power source.

4. Safety

WARNING: LOOSE GARMENTS, NECKTIES, AND OTHER HANGING ITEMS
MUST NOT BE WORN BY PERSONNEL NEAR THE FAN OR OTHER EX­POSED MOVING PARTS OF THIS EQUIPMENT WHILE IT IS RUNNING. ALSO,
AVOID CONTACT WITH LIVE ELECTRICAL PARTS. DEATH OR SERIOUS IN­JURY COULD RESULT!

May 20/89 3-1

Page 1

OM-2049

5. Diagrams

A schematic diagram of the generator set is provided in Chapter 6. This diagram can be very helpfull in
troubleshooting. Components shown in the diagram are identified by reference designators

names in some instances).

full item name. For example, the symbol K403 identifies the overvoltage relay, and M406 identifies the
voltmeter.

A connection diagram is also provided in Chapter 6. It also can be very helpful in troubleshooting, parts re­placement, etc.

A legend appearing on the diagram identifies each reference designator by its

(or item

6. Illustrations

To aid maintenance personnel with troubleshooting, three illustrations are provided in this section, show­ing the locations of various components of the generator set.

7. Connections and Wiring

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

3-1 May 20/89
Page 2

OM-2049

1. Control Panel 11. Oil Pressure & Coolant Temp. Senders

2. Output Terminals 12. Lifting Yoke

3. Engine 13. Fuel Tank

4. Governor 14. Fuel Shut-off Solenoid Valve

5. Radiator 15. Generator

6. Drain Cock 16. Oil Filter

7. Fuel Tank Support 17. Fuel Pump and Fuel Filter

8. Starter Relay 18. Engine Voltage Regulator

9. Rectifier Assembly 19. Battery

10. Frame 20. Alternator

May 20/89 3-1

21. Engine Overspeed Relay

Generator Set Components

Figure 1

Page 3

OM-2049

1. Oil Pressure Gauge 11. Contactor Control Switch

2. Tachometer 12. Contactor Closed Light

3. Water Temperature Gauge 13. Speed Control Switch

4. Current Limit Control 14. Engine On Light

5. Ammeter (Generator) 15. Hourmeter

6. Voltmeter 16. Engine Circuit Fuse

7. Panel Light 17. Engine Start Switch

8. Panel Lights Switch 18. Choke

9. Panel Lights Fuse 19. Engine Ignition Switch

10. Push-To-Build-Up-Voltage Switch 20. Ammeter (Engine)

Control Panel Assembly

Figure 2

3-1 May 20/89
Page 4

OM-2049

May 20/89 3-1

1. Voltage Regulator

2. Overvoltage Relay

3. Control Winding Rectifier

4. Voltage Regulator Fuse

5. Voltage Sensing Relay

Control Panel Wrapper

Figure 3

Page 5

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

1. Engine will not A. Ignition switch (S404) A. Momentarily connect large
start. Starter or pushbutton start capacity jumper cable between
will not crank switch (S401) the hot side of the starter
engine. defective. relay (L401) and the start

switch terminal on the starter
relay (blue wire). If the
starter operates, check
ignition switch (19, Fig. 2)
and pushbutton start switch
(17, Fig. 2). Replace faulty
switch. If starter doesn’t
crank, proceed to Step B.

B. Batteries discharged, B. Check battery connections
or loose battery or and check voltage across
ground connection. battery. Voltage should be

approximately 13.5 VDC. Be
sure this voltage is reaching
starter relay input terminal.
If battery and connections are
good, proceed to Step C.

C. Defective starter C. Momentarily connect a large
relay (L401) capacity jumper cable between

D. Defective starter. D. If starter did not attempt
(B401) to operate in Step C above,

Troubleshooting Chart (Sheet 1 of 16)

Figure 4

the hot side of the starter
relay (8, Fig. 1) and the
starter input terminal.
If the starter attempts to
crank the engine, the starter
solenoid is defective.
Replace it. If engine still
won’t crank, proceed to Step D.

the starter is defective.
Replace starter. If starter
did attempt to operate, but
couldn’t turn engine, proceed
to Step E.

3-1 May 20/89
Page 6

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

1. Engine will not E. Internal engine E. CAUTION: MAKE CERTAIN
start. Starter seizure. THAT IGNITION IS OFF SO
will not crank THAT THE ENGINE DOES
engine. (Cont’d) NOT START.

Useasocketwrenchonthe
front crankshaft pulley to
try to turn engine by hand.
If engine will not turn,
internal damage is indicated.

2. Engine will not A. Engine circuit fuse A. Replace engine circuit fuse
start. Starter (F402) blown or- (16, Fig. 2). Use type
DOES crank AGC-20 fuse.
engine.

B. Fuel valve at tank B. Check and correct as required.
closed, or no fuel in
tank or-

C. Defective overspeed C. Disconnect the black wire from
relay (K401) or- terminal 4 on the overspeed

relay (21, Fig. 1). If engine
now starts, replace overspeed
relay.

D. Defective component in D. C heck these components in
ignition system: accordance with Ford Mainten­ignition coil (L402), ance and Operator’s Manual.
distributor (E405), or Replace faulty component
ignition module, or-

E. Defective anti-diesel E. The anti-diesel solenoid is
solenoid (L405). located at the base of the

carburetor in front of it.
Disconnect the red wire of the
solenoid from the engine
circuit. With a jumper lead
attached to the positive
terminal of the battery, check
the operation of the solenoid
by listening for its opening
and closing when the other end
of the jumper lead is touched
to the terminal of the red
solenoid wire. If no sound is
heard from the solenoid, it
must be replaced.

May 20/89 3-1

Page 7

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

2. Engine will not WARNING: EXERCISE CARE TO AVOID A FIRE WHEN
start. Starter WORKING WITH THE FUEL SYSTEM. DO NOT PERFORM
DOES crank STEPS F AND G WHEN ENGINE IS HOT
engine. (cont’d)

F. Defective fuel valve F. Disconnect hose at input side
solenoid (L404). of fuel pump (17, Fig. 1).

Momentarily apply 12-VDC to
the fuel valve solenoid (14,
Fig. 1). If fuel valve
solenoid is good, fuel should
flow from it when voltage is
applied. Replace fuel valve
solenoid if defective. If
solenoid is good, proceed to
Step G.

G. Defective fuel pump. G. Disconnect hose at output

side of fuel pump and crank
engine. If fuel does not
spurt from pump when engine is
cranked, replace pump.

3. Engine fires A. Spark plug cables A. Check high tension spark plug
and/or backfires incorrectly installed wires. Firing order is 1-3-4-2
but will not run on plugs or in Correct as required. If

distrubutor cap. firing order is correct,

proceedtoStepB.

B. Distributor not B. Time in accordance with
correctly timed to instructions in Ford Mainten­engine. ance and Operator’s Manual

in Chapter 5. If timing is
correct, proceed to Step C.

C. Water in gasoline. C. Check for water in fuel tank

and fuel lines. Drain tank
and refill if necessary.

3-1 May 20/89
Page 8

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

4. Engine starts A. Fuel not turned on. A. Turn on fuel shutoff valve.
then stops.

B. Defective oil pressure B. Connect a jumper wire across
switch (S403) located the “C” and “No” terminals
on engine block. of oil pressure switch. Start

engine and check oil pressure.
If it is below 10 PSI (69 kPa)
shut down the engine and check
lubrication system for leaks.
Check also the oil pump. If
oil pressure comes up to
normal, and the engine
continues to run, the oil
pressure switch is defective.
Replace oil pressure switch.
If oil pressure switch is
good, proceed to Step C.

C. Fuel valve solenoid C. Refer to 2.F. above and check
(L404) defective. accordingly.

D. Excessive engine speed. D. Check and correct as follows:

(1) Loose or defective (1) Check condition of
governor drive governor belt. If
belt. excessively worn, replace

it. If its condition is
good, tighten it in
accordance with Ford
Maintenance and Operators
Manual in Chapter 5.

(2) Improperly (2) Adjust governor. Refer
adjusted governor. to Section 2-3, Para. 3,

and Ford Maintenance
and Operator’s Manual
in Chapter 5.

May 20/89 3-1

Page 9

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

5. Engine runs A. Distributor timing A. Check timing. Set timing
roughly, then improperly set. according to Ford Maintenance
stalls. and Operator’s Manual.

B. Moisture or damaged B. Check distributor according
components in to Ford Maintenance and
distributor. Operator’s Manual. Service

or replace items as necessary.

6. Engine does not A. Idle speed set either A. Adjust idle speed to approx­attain normal too high or too low. imately 900-1000 RPM.
idle RPM, or
idles too fast.

7. Engine goes to A. Loose, slipping or A. Inspect belt. Adjust or
overspeed defective drive belt. replace as required.
immediately
when speed con- B. Improper setting of B. Set governor for proper engine
trol switch is engine RPM at governor. RPM.
placed in
RATED RPM C. Governor defective. C. Replace governor. Send old
position. governor to overhaul.

8. Engine will not A. Speed control switch A. If engine will not go from
run at rated (S406) defective. idle to rated speed when speed
speed (2600 RPM) control switch (13, Fig. 2) is

in RATED RPM position, turn
off engine and take resistance
measurements at speed control
switch terminals with switch
in the RATED SPEED position.
Measure for about 15 ohms
between terminals having
red-blue and orange-yellow
wires. Zero resistance should
be measured between terminals
having brown-red and red
wires. Replace speed control
switch if any of these
measurements are improper.

3-1 May 20/89
Page 10

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

8. Engine will not A. Speed control switch A. If engine will not go from
run at rated (S406) defective. idle to rated speed when speed
speed (2600 RPM) control switch (13, Fig. 2)
Cont’d. is in RATED RPM position, turn

off engine and take resistance
measurements at speed control
switch terminals with switch
in the RATED SPEED position.
Measure for about 15 ohms
between terminals having
red-blue and orange-yellow
wires. Zero resistance should
be measured between terminals
having brown-red and red
wires. Replace speed control
switch if any of these
measurements are improper.

B. Carburetor throttle B. Check throttle linkage and
linkage improperly make certain the governor can
adjusted. actuate the carburetor

throttlevalveto“wideopen”
position. Adjust and free
linkage as required. Refer to
Section 2-3, Para. 2, A, (9),
and Para. 3.

C. Governor improperly C. Adjust governor in accordance
adjusted. with Section 2-3, Para. 3.

9. Engine surges A. Governor improperly A. Adjust governor. See Sect
at no load. adjusted. 2-3, Para. 3.

B. Binding in governor-to- B. Free linkage.
carburetor linkage.

May 20/89 3-1

Page 11

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

10. Engine surges A. Governor improperly A. Adjust governor. See Sect.
under load. adjusted. 2-3, Para. 3.

B. Binding in governor-to- B. Free linkage.
carburetor linkage.

C. Governor belt slipping. C. Adjust or replace belt as

required.

D. Carburetor mixture D. Check carburetor. Adjust
either too lean or for proper mixture according
too rich. to Ford Maintenance and

Operator’s Manual. Replace
carburetor if defective.

E. Engine timing too fast. E. Adjust timing according

to instructions in Ford
Maintenance and Operator’s
Manual.

F. Faulty ignition. F. Check complete ignition

system and repair as required.

11. Engine lacks A. Insufficient air A. Check and service air
power. to carburetor. cleaner.

B. Restricted exhaust B. Check exhaust pipe for
system. restrictions. Check muffler

for clogged condition.
Replace as required.

C. Carburetor dirty or C. Clean and/or adjust or re­improperly adjusted. place carburetor as necessary

D. Low compression. D. Check compression in all

cylinders according to
Ford Maintenance and
Operator’s Manual. Engine
may need new rings or valves.

3-1 May 20/89
Page 12

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

12. Engine “misses” A. Fault in ignition A. Check and correct as follows:
at rated speed system.
and under load.

(1) Spark plugs (1) Clean spark plugs and
faulty. re-gap them. (.042" to

.046"). Replace any plugs
found to be defective.

(2) Distributor (2) Check distributor accord­(E405) faulty. ing to Ford Maintenance

and Operator’s Manual.
Service or replace items
as necessary.

(3) Defective igni- (3) Check ignition coil accord­tion coil. (L402) ing to Ford Maintenance

and Operator’s Manual.
Replace coil if defective.

B. Fault in fuel system. B. Check and correct as follows:

(1) Defective carbu- (1) Check carburetor. Replace
retor, float if necessary and send old
level too low, or carburetor to overhaul.
dirt in carburetor.

(2) Defective fuel (2) Check fuel pump pressure.
pump. If pressure is low,

replace pump.

C. Mechanical fault in C. Check engine compression to
engine such as burned determine fault. Send unit
valve, defective pis- to overhaul.
ton rings, “blown”
head gasket, etc.

May 20/89 3-1

Page 13

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

13. Excessive A. Ignition timing too far A. Check ignition timing and
“pinging” and advanced. adjust according to Ford
detonation Maintenance and Operator’s
under load. Manual in Chapter 5.

B. Poor grade of gasoline. B. Use good, clean gasoline of

92 to 94 octane rating.

C. Fuel mixture too lean. C. Check carburetor main metering

system, float level, etc.
Replace carburetor if defective.

D. Engine overheating. D. If engine is running exces-

sively hot, check entire
cooling system. Check for
dirt in system and for dirt
outside of core. Check
thermostat. Repair as
required.

14. Engine speed A. Governor improperly A. Adjust governor. Refer to
drops excess- adjusted. Section 2-3, Para. 3.
ively when load
is applied. B. Governor-to-carburetor B. Free the linkage where

linkage binding. binding.

C. Governor-to-carburetor C. Adjust linkage. Refer to
linkage improperly Section L-3, Para. 2, A, (9)
adjusted. and Para. 3.

D. Excessive load on D. See that load does not exceed
generator, or defective generator’s rating (550A).
governor. Re-check engine speed at

approximately rated load. If
engine speed still drops ex­cessively, replace governor
and send old governor to
overhaul.

E. Engine timing is slow. E. Adjust timing in accordance

with Ford Maintenance and
Operator’s Manual in Chap. 5.

F. Governor worn or F. Remove governor and inspect
defective. Replace if necessary.

3-1 May 20/89
Page 14

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

15. Engine A. Governor-to-carburetor A. Check linkage. Adjust and/or
response slow linkage either loose, tighten as necessary.
when going binding, or out of
from idle to adjustment.
rated speed or
from rated B. Ignition timing slow. B. Check ignition timing and
speed to idle. adjust in accordance with

Ford Maintenance and Operator’s
Manual in Chapter 5.

C. Engine needs tune-up. C. Tune up engine as required.

Refer to Ford Maintenance and
Operator’s Manual in Chapter 5.

16. Engine overheats A. Dirt or sludge in coolant. A. Drain coolant, flush radiator,
and put in clean coolant Refer to
Section 2-2, Para. 6 and to Ford
Maintenance & Operator’s Manual
Chapter 5.

B. Debris and dirt on B. Clean radiator core carefully.
radiator core. Refer to Ford Maintenance and

Operator’s Manual in Chap. 5.

17. Engine does A. Malfunction of governor A. Stop engine by placing ignition

not slow down to-carburetor throttle switch in STOP/SHUTDOWN
to idle with linkage, speed control position. Check and correct
speed control switch (S406), or idle as follows:
switch in IDLE solenoid (L403).
position.

(1) Governor-to- (1) Manually check linkage.
carburetor If binding, free up the
throttle linkage binding. linkage.
(2) Speed control (2) With speed control switch
switch (S406) in IDLE (DOWN) position,
defective. take resistance measure-

ments between switch ter­minals. Measure for ZERO
resistance between terminals
having red-blue and orange­yellow wires. Measure for
INFINITY (OPEN) between
terminals wired with brown-red
and red wires, & terminals wired
with black-yellow and
black wires. Replace
switch if any of these
readings are improper

May 20/89 3-1

Page 15

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

ENGINE AND CONTROLS

17. Engine does (3) Idle solenoid (3) Idle solenoid is located
not slow down (L403) defective. just behind carburetor.
to idle with Disconnect idle solenoid’s
speed control wire leads at the quick­switch in IDLE disconnect clips which
position. wire the solenoid to
(Cont’d) engine circuitry. With

clip leads, attempt to
operate the solenoid by
putting 12-V DC directly
into the solenoid from
the engine battery. The
white wire is positive
and the black wire is
negative.

18. Engine will A. Plunger of anti-diesel A. Remove engine circuit fuse to
not shut off. solenoid (L405, on stop engine. Replace idle
Speed control front of carburetor solenoid.
switch in IDLE just above its base)
position and becomes stuck while
ignition engine is running.
switch in OFF/
SHUTDOWN
position.

3-1 May 20/89
Page 16

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

GENERATOR AND CONTROLS

1. Generator will A. Flashing power not A. Check as follows:

not build up reaching generator
voltage at all revolving field (L406).
when push-to­build-up volt- (1) Defective push-to- (1) Momentarily connect two
age switch build-up-voltage jumper leads across the
(S407) is switch (S407) push-to-build-up-voltage
operated. (contacts stuck in switch; one lead across
Engine running open position) the terminals on the left
normally side and the other lead

across the terminals on
the right side. If the
voltage builds up, replace
switch.

(2) Defective diode (2) Use ohmmeter to check
(CR401) diode on back of push-to-

build-up-voltage switch.
Replace diode if defec­tive.

(3) Excessive brush (3) Check brushes closely for
wear, or poor excessive wear and check
contact of brushes brush contact with slip
to slip rings. rings. Replace brushes

if excessively worn, and
make sure that brush
contact with slip rings
is proper.

B. Voltage sensing relay B. Connect a jumper lead
(K404) defective. between pins 1 and 3 on
Relay contact 1-7 or voltage sensing relay
3-9 stuck in open (5, Fig. 3). If voltage
position. then builds up when

switch S407 is pushed,
voltage sensing relay is
defective and must be
replaced. If voltage
sensing relay is good,
proceedtoStepC.

May 20/89 3-1

Page 17

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

GENERATOR AND CONTROLS

1. Generator will C. Generator revolving C. Locate yellow and red-orange
not build up field (L406) defective. wires on terminal strip that is
voltage at all just beneath base of voltage
when push-to- sensing relay (at rear of
build-up volt- control panel). Disconnect the
age switch yellow and red-orange wires
(S407) is which go down to the generator.
operated. (Refer to connection diagram
Engine running 488860 in Chapter 5). Measure
normally. resistance between these two
(Cont’d) wires. Should be 6 to 8 ohms.

If reading indicates an open,
short or lower than normal
resistance, proceed to Step D.

D. Defective generator D. If check of the generator
armature (G402) revolving field (Step C above)

revealed no trouble, the gen­erator armature is defective.
Send unit to overhaul.

2. Generator builds A. Generator voltage A. Replace voltage regulator
up to only a low regulator fuse (F403) fuse (4, Fig. 3). Resume
voltage while blown. operation of generator set to
push-to-build- see if problem is corrected.
up voltage If not, proceed to Step B.
switch is
depressed. B. Defective control B. Check control winding rec-

winding rectifier tifiers (3, Fig. 3) with an

ohmmeter to see if they are
good. If either rectifier
is defective, replace it. If
both rectifiers are good,
proceedtoStepC.

C. Generator voltage C. Replace voltage regulator
regulator (VR402) (1, Fig. 3).
defective.

3-1 May 20/89
Page 18

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

GENERATOR AND CONTROLS

3. Generator volt- A. Voltage sensing relay A. Remove voltage sensing relay

age builds too (K404) defective. (5, Fig. 3) from its socket
high a voltage. Relay coil is open or and apply 24V DC to the coil

contacts 1-7 and 3-9 (terminals A and B). Using
stuck in closed an ohmmeter, check to see that
position. contacts open and close

properly. If voltage sensing
relay is defective, replace it
If not, proceed to Step B.

B. Defective voltage B. Replace voltage regulator
regulator (VR402). (2, Fig. 3) with a voltage

regulator known to be good, and
resume operation of generator
set. If new voltage regulator
produces normal operating
voltage, send old voltage
regulator to factory for
service.

4. Load contactor CAUTION: DO NOT OPERATE THE GENERATOR SET TO

will not close DELIVER POWER TO AN AIRCRAFT WHEN ANY PROTEC­when contactor TIVE DEVICE OR OTHER COMPONENT IS JUMPERED.
close switch
(S408) is A. Defective contactor A. Momentarily connect a jumper
operated. Engine close switch (S408). lead between terminals 4 and 5
running normally (red and yellow-red wires) on
voltage normal, the contactor close switch (11,
no load applied Fig. 2). If the load contactor
to output cable. closes momentarily, replace

contactor close switch.

May 20/89 3-1

B. Defective load B. If load contactor (22, Fig. 1)
contactor (K402). will not close when contactor

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

C. Overvoltage relay C. Connect a jumper lead between
(K403) defective. terminals T and P on the

overvoltage relay (2, Fig. 3).
If contactor will now close,
replace overvoltage relay.

Page 19

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

GENERATOR AND CONTROLS

5. Load contactor A. Defective contactor A. Connect a jumper lead between
opens as soon close switch (S408). terminals 1 and 2 (orange-red
as contactor and yellow-red wires) on the
close switch is contactor close switch (11,
released from Fig. 2). If the load contactor
its top (spring- now remains closed, replace
loaded) position contactor close switch.

B. Defective resistor R406 B. Using an ohmmeter, check
(located in back of resistor R406 for proper
control panel, on resistance (7.5 ohms). If
terminal strip beneath an open circuit is indicated,
base of voltage sensing replace resistor.
relay. See connection
diagram 488860)

C. Defective diode CR402. C. This diode is also located on

the terminal strip beneath the
voltage sensing relay. Using
an ohmmeter, check this diode
for an open circuit. If diode
is defective, replace it.

D. Load contactor (K402) D. If no fault was found in steps
defective. 4A, B, and C above, the load

contactor (22, Fig. 1) is
defective. Replace load
contactor.

6. Load contactor A. Contactor opening could A. Resume operation and closely
opens during have been normal because observe voltmeter (6, Fig. 2)
power delivery. of an overvoltage for evidence of overvoltage.

condition. If contactor opens when no

overvoltage condition exists,
proceedtoStepB.

3-1 May 20/89
Page 20

OM-2049

TROUBLESYMPTOM TEST, CHECK, AND/OR
AND CONDITION PROBABLE CAUSE REMEDY

GENERATOR AND CONTROLS

6. Load contactor B. Overvoltage relay (K403) B. Check overvoltage relay by

opens during defective. operating the machine under
power delivery. load and gradually raising
(cont’d) voltage at the voltage

regulator (1, Fig. 3) while
observing voltmeter (6, Fig. 2).
Start with a low voltage
(25-V DC) and gradually
increase voltage until relay
functions to open load
contactor. If relay trips at
less than 32-V DC, replace
relay (2, Fig. 3) and return
oldrelaytofactoryfor
service.

C. Load contactor (K402) C. If no fault was found in Step B
defective. replace load contacts (22, Fig. 1).

7. Output current A. Defective current limit- A. Shut down engine and check

cannot be limited ing potentiometer (R402) current limiting potentiometer
by operating (4, Fig. 2) with an ohmmeter.
current limiting To do this, disconnect plug
potentiometer. from generator voltage

regulator (1, Fig. 3) and take
resistance measurements from
pin2topin9andthenfrom
pin 2 to pin 10 on the plug.
For each measurement, slowly
turn potentiometer through its
entire range, while observing
ohmmeter readings. Replace
potentiometer if defective. If
it isn’t defective, proceed to
Step B.

B. Defective voltage B. Replace voltage regulator with
regulator (VR4020) one known to be good, and then

operate the generator set under
sufficient load to observe
current limiting. If current
limiting potentiometer now
controls current properly, send
old voltage regulator to
factory for service.

May 20/89 3-1

Page 21

OM-2049

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3-1 May 20/89
Page 22

OM-2049

CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION

1. General

The illustrated Parts List identifies, describes, and illustrates main assemblies, sub-assemblies, and detail
parts of the Jet-Ex 4 Generator Sets manufactured by Hobart Brothers Company, Power Systems Group,
Troy, Ohio 45373.

2. Purpose

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

3. Arrangement

Chapter 4 is arranged as follows:

Section 1 - Introduction
Section 2 - Manufacturer’s Codes
Section 3 - Parts List
Section 4 - Numerical Index

4. Explanation of Parts List

A. Contents

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

(1) Standard hardware items
available commercially.

(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.
(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc.,

to other parts, weldments, or assemblies.

B. Parts List Form

(attaching parts)

such as nuts, screws, washers, etc., which are

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:

May 20/89 4-1

Page 1

OM-2049

(1) “FIGURE-ITEM NO.” Column

(2) “HOBART PART NUMBER” Column

(3) “NOMENCLATURE” Column

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

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

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

(4) “EFF” (Effective) Column

This column is used to indicate the applicability of parts to different models of equipment. When
more than one model of equipment is covered by a parts list, there are some parts which are
used on only one model. This column is used for insertion of a code letter “A”, “B”, etc., to indicate
these parts and to identify the particular model they are used on. Parts in this manual are coded
as follows:

Uncoded parts are usable on all models.

Parts coded “A” are usable on Specification 7005-1 only.
Parts coded “B” are usable on Specification 7005-2 only.

(5) “UNITS PER ASSEMBLY” Column

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.

4-1 May 20/89
Page 2

SECTION 2. MANUFACTURER’S CODES

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

The following list is a compilation of vendor codes with names and addresses for suppliers of purchased
parts listed in this publication. The codes are in accordance with the Federal Supply Codes for Manufac­turer’s Cataloging Handbook H4-1, 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 case a
manufacturer does not have a vendor code, the name of the manufacturer will be listed in the nomencla­ture column.

CODE VENDOR’S NAME AND ADDRESS

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

03504 Clark Equipment, 324 E. Dewey, Buchanan, MI 49107

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

OM-2049

05277 Westinghouse Electric Corp., Semi Conductor Div., Hill Street,

Youngwood, Pennsylvania 15697

08452 Westinghouse, P.O. Box 300, Sykesville, MD 21784

11288 Dayco Corp., 333 W. First St., Dayton, OH 45401

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

14655 Cornell Dubilier, 209 W. Central St., Natick, MA 01760

15605 Eaton Corporation, 4201 N. 27th St., Milwaukee, Wisconsin 53216

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

26659 HB Instrument Co., American and Bristol St., Philadelphia, PA 19140

28478 Deltrol Controls, 2745 S. 19th St., Milwaukee, WI 53215

31510 Mainline Supply Co., Inc., 905 E. Third St., Dayton, OH 45402

31695 Facet Ent. Inc., US. No. 1 Bypass South, Henderson, NC 27536

35708 Tridon Limited, P.O. Box 1600, Nashville, TN 37202

44655 Ohmite Mfg. Co., 3601 W. Howard St., Skokie, IL 60076
46992 Phoenix Electric, 3625 N. Halstead St., Chicago, IL 60613
49234 Protecto Seal Co., 225 W. Foster Avenue, Bensenville, IL 60106
51589 ST - SEMICON, INC., 415 N. College Ave., Bloomington, Indiana 47401

May 20/89 4-2

Page 1

OM-2049

CODE VENDOR’S NAME AND ADDRESS

57448 Allis Chalmers Corp., 275 Ridgeway Avenue, P.O. Box 1367, Aurora,

Illinois 60507

60741 Triplett Electrical Instrument Company, 286 Harmon Road, Bluffton,

Ohio 45817

61864 TRW-Inc. United Carr Div., 31 Burlington Mall Rd., Burlington,

MA 01803

70411 Anderson Brass Co., 100 S. Campbell Ave., Detroit, MI 48209

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

St. Louis, Missouri 63178

74465 Hoof Products, 4051 W. 51st St., Chicago, IL 60632

74559 Carling Switch Co., 505 New Park Ave., West Hartford, CT 06110

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

77343 Potter & Brumfield, Inc., 200 Richland Creek Drive, Princeton, IN 47671

77977 Signal-Stat Corp., 1200 Commerce Ave., Union, NJ 11211

78189 Illinois Tool Works Inc., St. Charles Rd., Elgin, IL 60120

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

78940 United Air Cleaners, 9705 S. Cottage Grove Ave., Chicago, IL 60628

79409 Woodhead Daniel Co., 3411 Woodhead Dr., Northbrook, IL 60062

81640 Eaton Corp., 2074 Whitfield Ave. E., Sarasota, FL 33580

83613 Kirkhill Inc., 12021 S. Woodroof Ave., Downey, CA 90241

90927 Ford Motor Co., Ind. Engine Operations, 300 RenaissanceCtr., P.O.

Box 43338, Detroit, MI 48243

91636 Curtis, 34999 Curtis Blvd., Eastlake, OH 44094

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

96152 Borg Warner Corp., 2195 S. Elwin Rd., Decatur, IL 62525
No Number Pipe & Supplies Inc., 329 E. Poplar St., Sidney, OH 45365
No Number Modine Mfg. Co., 1500 Dekoven Ave., Racine, WI 53401

4-2 May 20/89
Page 2

SECTION 3. PARTS LIST

1. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a lefthand page and the applicable parts list
will appear on the opposite righthand page. Unless the list is unusually long, the user will be able to look
at the illustration and read the parts list without turning a page.

2. Symbols and Abbreviations

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

* - item not illustrated
A, or AMP - ampere
AC - alternating current
AR - as required
DC - direct current
Fig. - Figure
hd. - head
hex - hexagon
Hz - Hertz (cycles-per-second)
I.D. - inside diameter
IN - inch
kVA - kilovolt-ampere
u F - microfarad
No. - number
NHA - next higher assembly
OM - Owners Manual
PRV - peak reverse voltage
PSI - pounds per square inch
Ref - reference (the item has been listed previously)
TM - Technical Manual
V - volt (when used as a prefix to a five-digit number, indicates vendor code)

OM-2049

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

May 20/89 4-3

Page 1

OM-2049

4-3 May 20/89
Page 2

Generator Set Stationary Mtg. Assy.

Figure 1

OM-2049

NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

1- 7005-1 GENERATOR SET, STATIONARY A 1

7005-2 GENERATOR SET, STATIONARY W/KEY

START B 1

1 488580 . YOKE, LIFTING ASSY.,

(For Details See Fig. 19)

1
2 6FW-5027 . FUEL, CAP, V49234, NO. 1273 1
3 488934 . PANEL, CONTROL ASSY,

180335 . PANEL, CONTROL ASSY,

(For Details See Fig. 6)
(For Details See Fig. 6)

A1
B1

4 84B-1078 . LABEL, OPERATING INSTRUCTIONS 1
5 81B-1064 . LABEL, ENGINE DRIVE 1

6 400435 . LABEL, NAMEPLATE, 28V 1
7 402987 . NAMEPLATE, HOBART 1
8 DWP-982 . BRACKET, CABLE 2
9 488904 . BRACKET, SPACER FRAME AY. 4

*10 78A-1000 . NAMEPLATE, ID 1
*11 79A-1110 . NAMEPLATE, OPTION 1
* 180298 . KIT, TIE DOWN ASSY.
12 180297 . BRACKET, MTG. TIE DOWN

(OPTION)

(OPTION)

Ref

4
* W-11242-12 . WASHER,FL.ST. 1/2 (OPTION) 8

* W-11280-11 . NUT, 1/2-20 HEX, JAM, ST.

(OPTION)

* W-11100-3 . SCREW 1/2-13 X 1-1/4, HHC. ST.
* W-11254-8 . WASHER, LK, STD. 1/2

(OPTION)

(OPTION)

8

8

8

* Not Illustrated

May 20/89 4-3

Page 3

OM-2049

W/Portable Mounting and Fenders (Option)

4-3 May 20/89
Page 4

Generator Set

Figure 2

OM-2049

NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

2- 7005-1 GENERATOR SET, STATIONARY MOUNTING A 1

7005-2 GENERATOR SET, STATIONARY MOUNTING

W/ KEYSTART B 1

1 181000-3 . TRAILER, ASSY, W/FENDERS

(OPTION)

1

May 20/89 4-3

Page 5

OM-2049

Generator Set W/Portable Mounting (Option)

4-3 May 20/89
Page 6

Figure 3

OM-2049

NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

3- 7005-1 GENERATOR SET, W/PORTABLE MOUNTING A 1

7005-2 GENERATOR SET, KEYSTART, W/PORTABLE

MOUNTING B 1

1 181000-4 . TRAILER ASSY.,

(OPTION)

1

May 20/89 4-3

Page 7

OM-2049

4-3 May 20/89
Page 8

Canopy Assembly

Figure 4

OM-2049

NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

4- 181317 CANOPY ASSY (FOR NHA SEE FIG. 1) 1
1 280987 . PANEL, TOP, REAR ASSY. 1

2 181318 . PANEL, GEN. INSULATION, LT, ASSY. 1
3 488933 . PANEL, CANOPY, ENGINE ASSY. 1
4 488938 . PANEL, ENGINE, INSULATION ASSY. 1
5 488822 . PLATE, CATCH, DOOR 1

6 488820 . PANEL, CENTER RT. CANOPY 1
7 DELETED
8 280992 . SUPPORT, CONTROL PANEL, RT. ASSY. 1
9 408556 . LIGHT, MARKER, CLEARANCE 4
* 181316 . GUARD, CLEARANCE LIGHT 4

280011 . COVER, CONTROLS ASSY. 1
10 488592 . . COVER, CONTROLS 1
11 181152 . . PLATE, ADHESIVE, V94222, NO. 02-14-201-14 2
12 403127 . . CATCH, MAGNET DOOR, V94222, NO. 02-10-201-10 2

84B-1078 . . LABEL, OPERATING INSTRUCTIONS 1
13 488639 . PANEL, LOWER REAR 1

14 280994 . SUPPORT, CONTROL PANEL, LEFT ASSY. 1
15 488940 . PANEL, GEN. INSULATION RT., ASSY. 1
16 488799 . COVER, OUTPUT CABLES 1
17 488631 . PANEL, CENTER, CANOPY ASSY. 1

18 180197 . PANEL, SIDE, LT, REAR ASSY. 1
19 488580 . YOKE, LIFTING ASSY. 1
20 81B-1019 . LATCH, T-HANDLE 2
21 488942 . DOOR, ENGINE, INSULATION, LT ASSY 1
22 84A-1096 . LATCH, BOLT STEEL 1

23 488790 . SPACER, LATCH 4
24 488632 . PANEL, SIDE, RT. 1
25 488791 . ACTUATOR, RELEASE CATCH 1
26 489529 . PANEL, FRONT 1
27 489530 . COVER, TAIL PIPE 1

28 488633 . SUPPORT, FRONT PANEL 4
29 488635 . PANEL, ACCESS BATTERY 1
30 407366 . LABEL, CAUTION INSUFFICIENT COOLING 1
31 81B-1063 . LABEL, HOT WATER & STEAM 1
32 84A-1071 . LABEL, ACCESS PANEL 1

33 406001 . LABEL, DANGER, MOVING PART 1
34 402987 . NAMEPLATE, HOBART 1
35 406000 . LABEL, ENGINE FUEL 1
36 76B-1149 . LABEL, GASOLINE 1
37 403153-1 . FOOT, RUBBER STOP, V83613, NO. B-232A 2

38 7J-422-0 . CLAMP, OUTPUT CABLE 1
* 39 180015 . STRAP, BACKUP COVER CONTROLS 1
*40 488640 . BRACKET, MTG., CLAMP, OUTPUT CABLE 1

* NOT ILLUSTRATED

Revised April 5/93 4-3

Page 9

OM-2049

4-3 May 20/89
Page 10

Generator Set Without Canopy

Figure 5

OM-2049

NOMENCLATURE UNITS
FIGURE HOBART PER
ITEM NO. PART NO. 1234567 EFF ASSY

5- No Number GENERATOR SET WITHOUT CANOPY

(For NHA See Fig. 1) REF

1 280988 COOLING SYSTEM
2 489534 . GUARD
3 408419 . CARBURETOR, V31695, NO. 0-14024, MOD. 33AW81
3A 84A-1097 . VALVE, SOLENOID SHUT DOWN V31695, No. B75-22 1
* 3B 408435 . KIT, CARBURETOR OVERHAUL V31695, No. K-2220 REF

3C NO NUMBER . GASKET, CARBURETOR

(For Details See Fig. 13)

CARBURETOR)

3D NO NUMBER . ADAPTER, CARB.

# E4JL-9A589-BA)

4 404898 . IDLING DEVICE
5 402086-1 . BATTERY, 12 V

6 488571 . SUPPORT, ENGINE, LEFT ASSY. 1
7 488868 . RELAY, OVERSPEED,
8 487050-3 . RESISTOR ASSY., PRELOAD 1
9 405278-6 . CAPACITOR 1

10 361052-9 . CLAMP, MTG., CAPACITOR 1
11 488800 . SUPPORT, CAPACITOR 1
12 488947 . GENERATOR,
13 NO NUMBER . ENGINE EXHAUST
14 488613 . SHROUD, FAN ASSY.,

15 488576 . SUPPORT, ENGINE RIGHT ASSY. 1
16 No Number . FUEL SYSTEM
17 488870 . SUPPORT, FUEL TANK, CONTACTOR ASSY.

(For Details See Fig. 7)

18 488901 . GOVERNOR
19 407713 . CLEANER, AIR, V78940, NO. B-1B33 1

408434 . FILTER, AIR CLEANER 1
20 5CW-2163-2 . HOSE, BREATHER 1
21 W-10869-15 . CLAMP, HOSE, BREATHER, V35708, NO. HS12 1
22 488948 . RECTIFIER ASSY.

23 403809-1 . SWITCH, OIL PRESSURE 1
24 78B-1118-1 . SENDER, OIL PRESSURE, V16476, NO. 02504 1
25 488565 . FRAME, MTG. ASSY.
26 W-11294-1 . NUT, WING 1
27 492572 . ROD, AIR CLEANER 1

28 79B-1119-1 . TEMPERATURE, SENDER, V16476, NO. 02019 1
29 DELETE
30 400581 . SWITCH, VACUUM, V13445, NO. 9253 1
31 No Number . REGULATOR, VOLTAGE, V90927,

No. E2P2-10316-A 1

32 W-10909-1 . TEE, STREET, BRS. 1
33 W-10119-1 . COUPLING, PIPE STEEL

(For Details See Fig. 13)

(SUPPLIED W/

No. 0146-30 1

(SUPPLIED W/ENGINE, Ford

(For Details See Fig. 9)

(For Details See Fig. 10)

(For Details See Fig. 17)

(For Details See Fig. 19)

(For Details See Fig. 16)

(For Details See Fig. 13)

(For Details See Fig. 11)

(For Details See Fig. 8)

(For Details See Fig. 14)

(For Details See Fig. 17 )

(Supplied W/Engine)

(PIPE & SUPPLIES, INC.)

1
1

1
1

1

1

1
1
1

1

1

1

1

1

1

May 20/89 4-3

Page 11

OM-2049

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4-3 May 20/89
Page 12