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