Hobart Jet-Ex 4D Operation And Maintenance Manual
OM-2063
011091
123192
031993
Operation and Maintenance Manual
Jet-Ex 4D
Generator Sets
Series 7003A-3 and
Series 7003B-3
Hobart Brothers Company
Airport Systems Group
Ground Power Equipment
Troy, Ohio
U.S.A.
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OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 / Generator Set
Section 1. Safety Instructions and Warnings
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 breakload 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.
1. 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.
2. 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
a. Installation and Grounding of Electrically Powered Equipment
Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed
and maintained in accordance with the N ational 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
(amperage) capacity of the grounding lead will be adequate for the worst fault current situation.
Refer to the National Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs.
Use correctly mating receptacles.
Revised Safety Warnings
August 01/95 Page 1
Om-2063 Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 / Generator Set
b. 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.
c. Service and Maintenance
(1)
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.
(2)
Before inspecting or servicing electrically-powered equipment, take the following precautions:
(3)
Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the
equipment.
(4)
Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally.
(5)
Disconnect power to equipment if it is out of service.
(6)
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.
3. Fire and Explosion Prevention
Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust
piping, misuse of batteries and fuel, or unsafe operating or fueling conditions.
a. 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.
b. 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.
c. 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 IMMEDIATELY, including any that penetrates the unit. After clean-up, open
equipment doors and blow fumes away with compressed air.
4. 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.
5. 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.
6. 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.
Safety Warnings Revised
Page 2 August 01/95
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 / Generator Set
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 ELECTRICAL SHOCK, turn off power. Remove victim; if not
breathing, begin artificial respiration, preferably mouth-to-mouth. If no detectable
pulse, begin external heart massage. CALL EMERGENCY RESCUE SQUAD
IMMEDIATELY
7. Equipment Precautionary Labels
Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be
easily read.
Revised Safety Warnings
August 01/95 Page 3
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Jet-Ex 4D / Spec. 7003A-3 / Generator Set
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Safety Warnings Revised
Page 4 August 01/95
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B-3 / Generator Sets
Introduction
This manual contains operation and service information for 28.5 V DC Generator sets identified as
Jet-Ex 4D . These units are available as stationary, skid- mounted units, or they may be trailer-mounted for
portability. Both versions are available with 14 V DC output capability.
The primary purpose of the manual is t o 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.
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
sub-headings as required. For example, a portion of the Description Section might logically follow this
arrangement and paragraphing:
Section 1. Description
1. Engine, Generator and Controls
a. Interior Panel
(1)
Protective devices
a. Overload relay
(2)
Contactors
Page numbers do not run consecutively throughout the manual. Each page is identified by the ChapterSection 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
SectionisFigure1.
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,
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:
of the same Section.
(Ref. Para. 1, A)
(shown as 2-3)
means that the material is to be found in paragraph 1, A,
.
Dec 31/92 Introduction
Page i
OM-2063 / Operation and Manitenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B-3 / Generator Sets
When referenced material is located in another Chapter/Section, both the Chapter and Section numbers and
the paragraph identification are given, for example:
(Ref. 1-2, Para. 1, A)
means that the referenced material
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:
(2, Fig.3)
refer to item number 2 in illustration Figure 3 of the same Chapter/Section.
When a referenced figure appears in another Chapter/Section, the reference will include the Chapter/Section
number, for example:
(2-3, 1, Fig. 4)
tells the user that the information is in Chapter/Section 2-3, and to refer
toitem1inFigure4.
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
(6)
and remove brush
.
(2, Fig.6)
slide out connector
(4)
,
When an item number is referenced without a Figure number, it always applies to the last preceding Figure
number mentioned in the text.
A collection of manufacturer’s literature is supplied as part of the information package.
If you have any questions concerning your Hobart Power Systems Group equipment, you are invited to
contact our Service Department by mail, telephone, or FAX.
Write: Hobart Brothers Company
Airport Systems Group
Ground Power Division
Service Department
Troy, Ohio 45373
U.S.A.
Call: (937) 332-5060 (Service Assistance)
(937) 332-5050 (Replacement Parts)
FAX: (937) 332-5121
Introduction Dec 31/92
Page ii
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B / Generator Sets
Table of Contents
Chapter 1. Description/Operation
Section 1. Safety Instructions and Warnings 1-1 1
Section 2. Description 1-2 1
General 1-2 1
Special Features 1-2 1
Orientation 1-2 1
Identification 1-2 1
Canopy 1-2 4
Engine, Generator, and Controls 1-2 4
General.................................................... 1-2 4
Engine..................................................... 1-2 4
Generator 1-2 6
Control Panel Assembly 1-2 6
General.................................................... 1-2 6
Lights...................................................... 1-2 6
Monitoringinstruments....................................... 1-2 6
Potentiometer............................................... 1-2 6
Switches................................................... 1-2 6
Fuses...................................................... 1-2 8
Voltageregulator............................................ 1-2 8
Overvoltage module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 9
Resistoranddiodeassembly.................................. 1-2 9
Excitationrectifiers.......................................... 1-2 9
Voltagesensingrelay ........................................ 1-2 9
Contactor 1-2 9
Output Terminals 1-2 9
Rectifier Assembly 1-2 9
Ammeter Shunt 1-2 9
Section 3. Preparation for Use, Storage or Shipping 1-3 1
Preparation for Use 1-3 1
General.................................................... 1-3 1
Inspection/Check............................................ 1-3 1
Dec 31/92 Table of Contents
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OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B / Generator Sets
Preparation for Storage 1-3 3
General....................................................1-3 3
TemporaryStorage...........................................1-3 3
LongTimeStorage...........................................1-3 3
Preparation for Shipping 1-3 4
Section 4. Operation 1-4 1
General 1-4 1
Operating the Generator Set 1-4 1
Pre-startInspection..........................................1-4 1
Pre-startInstructions.........................................1-4 1
StartingTheEngine ..........................................1-4 2
GeneratorOperation..........................................1-4 3
AdverseWeatherPrecautions.................................. 1-4 3
OperationinHotandHumidConditions.......................... 1-4 4
OperationinExtremelyDustyConditions........................ 1-4 5
OperationinSaltWaterAreas.................................. 1-4 5
Miscellaneous...............................................1-4 5
Chapter 2. Servicing/Troubleshooting
Section 1. Maintenance Inspection/Check 2-1 1
General 2-1 1
Maintenance Schedule 2-1 1
General..................................................... 2-1 1
MaintenanceScheduleCheckSheet.............................2-1 1
TimeIntervals...............................................2-1 1
Engine and Related Components 2-1 1
Inspection and Cleaning 2-1 1
Section 2. Troubleshooting Procedures 2-2 1
General 2-2 1
Troubleshooting Chart 2-2 1
Description ................................................. 2-2 1
Use of the Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1
Equipment for Troubleshooting 2-2 1
Diagrams 2-2 1
Illustrations 2-2 1
Connections and Wiring 2-2 1
Engine and Controls 2-2 5
Generator and Controls 2-2 9
Section 3. Maintenance Procedures 2-3 1
General 2-3 1
Table of Contents Dec 31/92
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OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B / Generator Sets
Lubrication 2-3 1
General.................................................... 2-3 1
LubricationChart............................................ 2-3 1
Generator .................................................. 2-3 1
GeneratorControls .......................................... 2-3 1
Engine..................................................... 2-3 1
Servicing the Air Cleaner 2-3 4
CartridgeRemoval........................................... 2-3 4
CartridgeInstallation......................................... 2-3 5
Servicing the Fuel Filter 2-3 5
DrainingtheFuel/WaterSeparatorBowl......................... 2-3 5
ReplacingtheFilterElement................................... 2-3 5
Drive Belt Service 2-3 6
Engine Cooling System 2-3 6
RustInhibitor............................................... 2-3 6
Antifreeze.................................................. 2-3 6
Battery Service 2-3 6
General.................................................... 2-3 6
BatteryLocationandAccessibility.............................. 2-3 6
BatteryCare................................................ 2-3 6
LiquidLevel ................................................ 2-3 7
CleaningtheBattery ......................................... 2-3 7
TestingaBattery............................................ 2-3 7
Generator Maintenance 2-3 8
General.................................................... 2-3 8
BrushService............................................... 2-3 8
GeneratorRevolvingFieldBrushReplacement................... 2-3 8
Section 4. Adjustment/Test 2-4 1
General 2-4 1
Testing the Generator Set 2-4 1
Pre-operationalTestProcedures............................... 2-4 1
OperationalTests............................................ 2-4 3
Voltage Regulator Adjustment 2-4 4
28.5VoltAdjustment......................................... 2-4 4
LineDropCompensation...................................... 2-4 4
Chapter 3. Overhaul/Major Repair
Dec 31/92 Table of Contents
Page v
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B / Generator Sets
Chapter 4. Illustrated Parts List
Table of Contents 4-1 1
Section 1. Introduction 4-1 3
General 4-1 3
Purpose 4-1 3
Arrangement 4-1 3
Explanation of Parts List 4-1 3
Contents ...................................................4-1 3
PartsListForm..............................................4-1 3
Section 2. Vendor Codes 4-2 1
Explanation of Vendor Code List 4-2 1
Section 3. Parts List 4-3 1
Explanation of Parts List Arrangement 4-3 1
Symbols and Abbreviations 4-3 1
Section 4. Numerical Index 4-4 1
Explanation of Numerical Index 4-4 1
Chapter 5. Manufacturer’s Literature
Unusual Service Conditions
Table of Contents Dec 31/92
Page vi
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B / Generator Sets
List of Illustrations
Chapter 1. Description/Operation
Section 1. Safety Instructions and Warnings
Section 2. Description
Jet-Ex4DPGeneratorSet..................................... 1-2 2
Generator Set Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 5
ControlPanelAssembly...................................... 1-2 7
VoltageRegulatorSupport.................................... 1-2 8
Section 3. Preparation for Use, Storage or Shipping
28VoltOutputTerminalPanel:Specification7003A-3.............. 1-3 2
Output Cable Connections: Specification 7003A-3 . . . . . . . . . . . . . . . . 1-3 3
Section 4. Operation
ControlPanelAssembly...................................... 1-4 2
Chapter 2. Servicing/Troubleshooting
Section 1. Maintenance Inspection/Check
Inspection/Check/MaintenanceSchedule........................ 2-1 2
Section 2. Troubleshooting Procedures
Generator Set Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2
ControlPanelAssembly...................................... 2-2 3
VoltageRegulatorSupport.................................... 2-2 4
ElectricalConnectionDiagram-281329......................... 2-2 5
Electrical Schematic - 180436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 9
Section 3. Maintenance Procedures
LubricationChart............................................ 2-3 2
Lubricants.................................................. 2-3 3
TemperatureandOilViscosityChart............................ 2-3 3
SymbolsandTimeIntervals................................... 2-3 3
Air Cleaner Cartridge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 4
Fuel/WaterSeparator......................................... 2-3 5
Dec 31/92 Table of Contents
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Jet-Ex 4D / Spec. 7003A-3 and 7003B / Generator Sets
GeneratorRevolvingFieldBrushes............................. 2-3 8
Section 4. Adjustment/Test
OperatingControlsandIndicators..............................2-4 2
IdleSpeedAdjustment....................................... 2-4 3
VoltageRegulatorAdjustment ................................ 2-4 4
Chapter 3. Overhaul/Major Repair
Chapter 4. Illustrated Parts List
Section 1. Introduction
Section 2. Vendor Codes
Section 3. Parts List
Generator Set w/Portable Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 2
Trailerw/FendersandCableTrays.............................. 4-3 4
Trailer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 6
Canopy Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 10
GeneratorSetwithoutcanopy.................................. 4-3 12
ControlPanel................................................ 4-3 16
P.C. Board Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 18
Fuel Tank Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 20
FullThrottleSolenoid......................................... 4-3 22
BatteryInstallation........................................... 4-3 24
FuelSystem................................................. 4-3 26
Filter,Fuel/WaterSeparator.................................... 4-3 28
CoolingSystem.............................................. 4-3 30
WaterHeaterInstallationKit ................................... 4-3 32
RectifierAssembly........................................... 4-3 34
RectifierAssembly........................................... 4-3 36
Brushholder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 40
Lifting Yoke & Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 42
GeneratorAssembly.......................................... 4-3 44
Section 4. Numerical Index
Chapter 5. Manufacturer’s Literature
Unusual Service Conditions
Table of Contents Dec 31/92
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OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
Section 2. Description
1. General
The two Jet-Ex 4D units covered in this manual
trailer-mounted generator sets manufactured by Hobart Brothers Company, Ground Power Division,
Troy, Ohio U.S.A. They are identified by specification numbers 7003A-3 and 7003B-3.
The basic generator set is designed to generate and deliver 28.5 volts DC power to an aircraft when its
on-board generators are shut down. In addition to providing continuous, regulated power to the aircraft,
the unit is designed for starting any fixed-wing aircraft or helicopter which is equipped with an external
28.5 volt DC power receptacle (see page 3 for complete Specifications and Capabilities).
The Specification 7003B-3 generator set is virtually identical to the Specification 7003A-3 generator set,
except that it has a Furnas contactor and a different air cleaner.
2. Special Features
The “Soft-Start” current limiting feature, recommended by most aircraft engine manufacturers, provide
the operator with controls to limit the inrush current to the aircraft engine’s starter. When the operator
presets this control, the generator will provide constant voltage to the preset current 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 2000 amperes, required for
starting larger aircraft engines when the control is turned fully clockwise.
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.181000-1.
A water heater kit is installed inside the enclosure and is connected to the cooling system of the diesel
engine. Its purpose is to keep the coolant warm when the engine is shut down for extended periods of
time in cold weather and permit the engine to start quickly.
A fuel/water separator, attached to the side of the engine, replaces the standard prefilter. This special
filter removes water/condensation along with any solid contaminants from the fuel.
(Figure 1)
are diesel engine driven, self-contained,
3. Orientation
The radiator end of the Jet-Ex 4D is the front. Right and left are determined by standing at the rear of
the unit, facing it. The control panel is located at the rear.
4. Identification
Each generator set has an Identification plate attached inside the hinged control panel door. This
nameplate lists the machines Model No. (Jet-Ex 4D), Specification No., Serial No., and electrical rating.
If any of the options described in paragraph 2.b. are included, they will be listed by name and part
number on a separate option nameplate located next to the Identification plate.
Dec 31/92 Chapter 1-2
Page 1
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
Chapter 1-2 Dec 31/92
Page 2
Jet-Ex 4DP Generator Set
Figure 1
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
Unit with Trailer, Fenders & Cable Tray
Length 75.5 inches (1918 mm)
Width 58 inches (1473 mm)
Height 63.75 inches (1632 mm)
Weight (dry fuel tank) 2410 pounds (1093 kg)
Ground Clearance 7.5 inches (191 mm)
Generator
Output Power Rating 15.7 kW
Voltage 28.5 volts DC
Rated Load Capacity 550amperes continuous at 28.5
volts DC
Starting Current Capacity 200 amperes maximum
Current Limiting Capability 300 to 2000 amperes, continuously
adjustable
Operating Speed 2000 RPM
Engine
Manufacturer Perkins Diesel
Model 4.236
Type 4-cylinder, 4-stroke, direct injection
Fuel ASTM D975 66T Numbers 1D or 2D
Displacement 236 cubic inches (3.68 liters)
Rated Power at 2000 RPM 70 Horsepower
Oil Capacity (without filter change) 8 quarts (7.57 liters)
Coolant Capacity 3.5 U.S. gallons
Electrical System 12 volt DC, negative ground
Governed Speed at No Load 2000 +/- 50 RPM
Idle Speed 1000 +/- 50 RPM
Fuel Tank Capacity 21.5 U.S. gallons (81.4 liters)
Protective Devices
Generator Engine
28.5 volt overvoltage module trips at
32 to 34 volts.
14 volt overvoltage module trips at
18 to 20 volts.
Water Temperature Switch opens
engine circuit at 225 F.
Low Oil Pressure Swiych opens at
20 PSI (138 kPa).
Dec 31/92 Chapter 1-2
Page 3
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
5. Canopy
The standard canopy is a sheet metal enclosure which protects the engine, generator, and electrical
controls. It has two hinged doors on each side at the front to provide access for service and
maintenance. Panels at the rear provide access to the generator. The left rear panel has a round hole
in it to permit viewing the fuel gage mounted in the fuel tank.
6. Engine, Generator, and Controls
a. General
(4)
Refer to Figure 2. The engine
(21)
fuel tank support
mounting frame for the load contactor (14) and output terminals. The radiator
front canopy. A heavy U-bolt is attached to the centrally located lifting yoke
generator set with a crane or hoist.
b. Engine
(1)
General
The engine used in the Jet-Ex 4D generator set is a Perkins four-cylinder, four-stroke, direct
injection diesel engine. It has a 236 cubic inch
compression ratio. Engine firing order is 1-3-4-2.
A spring-loaded relief valve in the pump limits maximum pressure in the system. A full-flow oil
filter
(12, Figure 2)
system. 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 20 PSI
. This prevents the engine from running if oil pressure will not build up, and also shuts down
kPa)
the engine if oil pressure drops radically during operation. (See Figure 2 and the engine
operator’s manual for engine specifications).
The generator and engine are mounted on a welded steel skid, and are enclosed by a sheet
metal canopy that bolts to the skid. Access to engine serviceable components
located at the rear of the unit supports the fuel tank
cleans the entire output of the pump before it enters the oil distributing
cleaner, and rectifier assembly, etc.)
machine.
Two removable panels to the right side and one to the left rear allow access to the other
components such as the load contactor and output terminals. The rear panel is removable and
permits access to the rectifier assembly.
and generator
is through two doors at the front on each side of the
(9)
are mounted on a welded steel frame
(7)
and provides a
(1)
is mounted to the
(5)
for moving the
(3.86 liter)
cylinder displacement and a 16:1
(oil filter, air
(20)
.A
(138
(2)
Cooling fan
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.
(3)
Fuel system
The fuel system consists of an 2l.5-gallon
fittings and hoses.
(4)
Alternator and regulator
The battery charging alternator
sets. The voltage regulator is an integral part of each of the alternator.
(5)
Starter relay
The starter relay
engine.
(6)
Exhaust muffler
This muffler helps deaden audible noise from the engine’s exhaust.
Chapter 1-2 Dec 31/92
Page 4
(19, Figure 2)
(3, Figure 2)
(81.4 liters)
(16, Figure 2)
is mounted on the starter motor
is rated at 62 amperes on Series 7003 generator
tank
(7, Figure 2)
with all the necessary
(18)
, on the right side of the
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
1. Radiator
2. Air cleaner
3. Muffler
4. Engine
5. Lifting yoke
6. Rectifier assembly
7. Fuel tank
8. Control panel
9. Generator
Dec 31/92 Chapter 1-2
10. Fuel filter
11. Throttle control solenoid
12. Oil filter
13. Drain cock & switch
14. Load contactor
15. Batteries
16. Alternator
17. Fuel filter
18. Starter
Generator Set Components
Figure 2
19. Starter relay
20. Frame
21. Fuel tank support
22. Engine governor
23. Water temperature
sender
24. Oil pressure sender
Page 5
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
7. Generator
The generator
whose output is rectified. The output is rectified by a rectifier assembly
connected into a full wave configuration. The generator is self-excited and receives excitation from a
three phase full wave rectified stator winding. One positive and one negative brush in contact with slip
rings supply controlled excitation current from the stator winding through the voltage regulator to the
rotating field winding. The voltage regulator controls the excitation current and maintains a 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
the engine fly-wheel by a flexible disc and hub coupling assembly and is supported by the engine main
bearings. A radial-blade fan of formed and welded sheet metal construction is mounted on the coupling
hub and draws cooling air over the generator windings.
Air enters through the anti-drive end of the generator and is discharged through openings in the flywheel
housing at the drive end, to cool the rectifier assembly above it. The g enerator housing assembly, which
contains the generator stator, is bolted to the engine flywheel housing.
(9, Figure 2)
is a multi-phase, synchronous salient pole, revolving field, AC generator
(6)
made up of twelve rectifiers
(slip ring end)
by a single-row ball bearing. The drive end is connected to
8. Control Panel Assembly
a. General
The hinged control panel
monitoring instruments, voltage regulator, relays, etc. The panel is mounted at the rear of the
canopy. The controls are accessible behind a hinged Lexan cover.
(8, Figure 2)
houses and provides mounting facilities for controls,
b. Lights
Two panel lights
(12) glows when the output load contactor is closed, and another one
engine is running.
c. Monitoring instruments
The voltmeter
generator current.
A tachometer
from the alternator.
A water temperature gauge
temperature sender
An oil pressure gauge
operated by a sender
The ammeter
electrical system.
The hourmeter
d. Potentiometer
The current limiting potentiometer
aircraft. The current limiting setting is continuously adjustable from 300 to 2000 amperes.
e. Switches
The contactor control switch
the output load contactor. The top CLOSE position is spring-loaded and is held momentarily until the
contactor closed light
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-up-voltage switch
generator fields with 12 volt engine circuit when flashing the fields.
(7, Figure 3)
(6, Figure 3)
(2)
displays the engine speed in RPM. This instrument receives its operating signal
(23, Figure 2)
(1, Figure 3)
(24, Figure 2)
(19, Figure 3)
(15)
records the total hours of engine operation for scheduling maintenance.
(12)
provide illumination for instruments and controls. One green pilot light
(14)
glows green when the
indicates generator output voltage, and the ammeter
(3)
indicates the engine coolant temperature and is actuated by a
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
(4)
is used to select the starting current recommended for various
(11, Figure 3)
glows, then it is released to the center ON
(10)
is a three-position toggle switch used to close and open
is a momentary contact pushbutton switch which flashes the
(5)
displays
Chapter 1-2 Dec 31/92
Page 6
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
1. Oil Pressure Guage
2. Tachometer
3. Water Temperature Guage
4. Current Limit Control
5. Ammeter
(Generator)
6. Voltmeter
7. Panel Light
8. Panel Lights Switch
9. Panel Lights Fuse
10. Push-To-Build-Up-Voltage Switch
Dec 31/92 Chapter 1-2
Control Panel Assembly
Figure 3
11. Contactor Closed Switch
12. Contactor Closed Light
13. Speed Control Switch
14. Engine On Light
15. Hourmeter
16. Engine Control Switch
17. Engine Circuit Fuse
18. Engine Circuit
19. Ammeter
(Engine)
Page 7
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
The panel lights switch
momentary contact pushbutton which closes the starter relay
This switch is operable only when the engine switch
position.
The engine switch
to center RUN position. The engine ON light
In the bottom STOP position, the switch will stop the engine and the light
Refer to Figure 3. The speed control switch,
device on the engine. In the IDLE position, used for starting, the engine speed is controlled
approximately. In the Rated RPM position, engine speed is controlled to approximately
2000 RPM.
f. Fuses
Three cartridge-type fuses protect the engine ignition circuit, the panel lights circuit, and the voltage
regulator. The engine circuit fuse
amperes, and the voltage regulator fuse
g. Voltage regulator
Refer to Figure 4. The voltage regulator
generator output after the voltage is built up.
(8, Figure 3)
(18)
, when released from its top START position after the engine starts, will return
turns the lights
(14)
(13)
(13, Figure 3)
(4, Fig. 4)
(1)
is a solid-state device which regulates the 28.5 volt DC
(7)
on and off. The engine start switch
(8, Figure 2)
(18)
is held in its top spring-loaded START
will glow as long as the switch is in RUN position.
is a two-position toggle switch wired to an idling
is rated at 20 amperes, the panel lights fuse
at 10 amperes.
and cranks the engine.
(14)
will go out.
(16)
(9)
is a
at 10
Chapter 1-2 Dec 31/92
Page 8
1. Excitation Rectifiers
2. Voltage Sensing Relay
3. Overvoltage Relay
4. Voltage Regulator
5. Voltage Regulator Fuse
Voltage Regulator Support
Figure 4
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
h. Overvoltage module
(2)
The overvoltage relay
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 trip at 32 to 34
voltsDCin2to10seconds.
i. Resistor and diode assembly
This network, which is mounted on a terminal strip behind the control panel, protects the load
contactor hold circuit against excessive current draw when the generator is delivering power.
j. Excitation rectifiers
Two diode bridge rectifiers, CR418 and CR418,
armature to the DC voltage needed for the generator revolving field.
k. Voltage sensing relay
Voltage sensing relay K406
circuit of the revolving field to prevent excessive voltage build-up if the push-to-build-up-voltage
switch is held in too long, or if it is pushed in after voltage is built up.
is a solid-state protective device on a printed circuit board. A normally
(5, Fig. 4)
(3, Fig. 4)
is a safety device which automatically opens the grounding
convert an AC voltage from the generator
9. Contactor
The load contactor, which is mounted behind the control panel on the fuel tank support, provides a safe
and convenient means of connecting and disconnecting the generator from the load. Initial power for
closing the load contactor is supplied by the generator through the spring-loaded momentary contacts of
the contactor control switch
the normally open auxiliary contacts in the load contactor.
(11, Figure 3)
. Holding power, to keep the contactor closed, passes through
10. Output Terminals
The output terminal panel is mounted inside the unit just behind the control panel. The positive terminal
is the A2 terminal of the load contactor, and the negative terminal is to the right of the load contactor.
11. Rectifier Assembly
This assembly consists of two aluminum heat sinks with twelve diodes on each heat sink. The rectifier
assembly converts the AC output of the generator to 28.5 VDC.
12. 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
negative heat sink of the rectifier assembly
(6,Fig.2)
(1, Fig. 4)
.
(5, Fig. 3)
. This shunt is mounted on the
and for sensing output
Dec 31/92 Chapter 1-2
Page 9
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
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Chapter 1-2 Dec 31/92
Page 10
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B-3 / Generator Sets
Section 3. Preparation for Use, Storage or Shipping
1. Preparation for Use
a. General
The generator set is shipped with an empty fuel tank. After the fuel tank filled and the generator set
inspected, the generator set is ready for use.
CAUTION
Read operating instructions in Section 1-4 before operating the unit.
b. Inspection/Check
Inspect the unit completely prior to operation.
(1)
Remove crating, blocking, banding, ties, and other securing and protective material. 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 or shipping papers.
(4)
Check fuel, coolant, and oil hoses and connections for visible leaks. If leaks are discovered,
correct by tightening hose clamps, tube fittings, etc., as required.
(5)
Check security of attaching and retaining hardware.
(6)
Check the following for sufficient quantity.
a. Fuel
Fuel tank capacity is 21.5 gallons (81.4 liters).
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
c. Engine lubricating oil
The oil level dipstick is located on the right side of the engine. Refer to Perkins User’s
andbook for oil recommendations.
(7)
Output Cable Installation
Units are normally supplied without a generator-to-aircraft cable.
a. Cable requirements
• Cable length is determined by the customer’s requirements. It is recommended that the
• The recommended single conductor sizes for 28.5 volt DC, continuous rated amperage
Be sure the cooling system antifreeze solution is adequate to protect below
lowest temperature expected.
cable be no longer than 30 feet (9 m). The cable should be two conductor with lug-type
terminals on one end and an AN-2551 plug connector on the other.
o
C
and 90
4/0 size for 530 amperes use 350 MCM size
(194oF)
rise is as follows: for 285 amperes use 2/0 size for 385 amperes use
Dec 31/92 Chapter 1-3
Page 1
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
NOTE:Some operators may wish to add a second cable assembly with M5-25019 plug connector for
starting aircraft such as Jetstar and Sabre liner.
b. Cable connection
• Remove the screws that secure the lower panel (below control panel). Set the panel aside.
• Loosen the output cable clamp and thread the lugged end of the output cable through the
opening in the side of the unit.
• Connect the POSITIVE cable lead to the output terminal on the contactor. Connect the
NEGATIVE cable lead to the shunt. ALWAYS place the lead under the flat washer shown.
• Tighten the cable clamp and install the lower panel.
• Store cables in cable tray provided on top of fender, or on hangers on side of canopy if
fenders are not used.
28-Volt Output Terminal Panel: Specification 7003A-3
Chapter 1-3 Dec 31/92
Page 2
1. Positive Output Connection
2. Negative Output Connectioon
3. Load Contactor
Figure 1
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B-3 / Generator Sets
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
The unit should be prepared for storage as soon as possible after being removed from service.
Storage should be in a building which is dry and which may be heated during winter months.
Moisture absorbing chemicals are available for use where excessive packaged and sealed if
moisture absorbing chemicals are to be effective.
Dec 31/92 Chapter 1-3
Output Cable Connections: Specification 7003B-3
Figure 2
Page 3
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
b. Temporary Storage
When storing the unit for one month, prepare as follows:
(1)
Lubricate the unit completely in a ccordance with instructions in Section 2-2. This will include
changing engine oil, and filter elements.
(2)
Make certain the cooling system antifreeze solution is adequate to protect below the lowest
temperatures expected during the storage period.
(3)
Clean the exterior of the engine with fuel oil and dry with clean cloths and compressed air.
(4)
Seal all engine openings. Use a waterproof, vaporproof material that is strong enough to resist
puncture damage from air pressure.
c. Long Time Storage
(1)
Engine Protection
The Jet-Ex 4D generator set may be stored for long periods if the engine is given proper
protection from rust and corrosion. Refer to the Perkins Diesel Users Handbook (Series 4.236)
for proper procedures to be followed.
(2)
Generator Protection
To protect the generator and other electrical components, the complete unit should be packaged,
using moisture proof packaging and sealing materials. Place packages of moisture absorbing
chemicals, such as silica-gel, in the unit before packaging.
WARNING
Place warning tags in several places to make certain that the individual who
takes the unit out of storage is warned that engine oil and coolant have been
drained.
(3)
Battery Care
Remove battery and store in a cool dry place. Store the battery on wood rather than directly on
cement or metal.
3. Preparation for Shipping
Prepare the unit for shipping as follows:
• Seal all engine openings to prevent the entrance of water, dirt, and dust.
• Disconnect battery cables.
• Drain all fuel from tank and fuel lines as required by carrier rules.
• Crate the unit solidly to prevent damage to instruments, glass, and sheet metal.
Chapter 1-3 Dec 31/92
Page 4
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Spec. 7003A-3 and 7003B-3 / Generator Sets
Section 4. 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
a. Pre-start Inspection
(1)
Always be sure there is sufficient oil and coolant in the engine.
(2)
Be sure the fuel shutoff valve is open. The valve is located at the fuel tank outlet. Observe the
fuel gage. Make certain of sufficient fuel to complete the job to be done.
(3)
If the unit is trailer mounted and is not connected to a tow vehicle, be sure the parking brake is
applied and that the drawbar is raised and locked in the vertical position. Raising the drawbar to
the vertical position automatically applies the brakes, and they will be released when the drawbar
is lowered.
(4)
Open the engine compartment doors and inspect interior for rags, tools, and foreign material.
b. Pre-start Instructions
In all probability, the unit will be moved from one location to another many times during its lifetime of
service. Therefore, the following steps should be taken to optimize maximum efficient operation.
(1)
Check the supply of fuel, crankcase oil and radiator coolant. See Perkins Engine User’s Manual
for specifications.
(2)
Inspect the unit thoroughly to be sure it is in proper working order. Check all fuel lines and wire
connections to be certain they are secure. Tighten any loose screws, nuts or bolts.
(3)
Wipe off the entire unit and clean the air passages, control panel and other hard to reach places
with compressed air not over 25 psi
(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 t he electrical system to make sure the connections are secure and properly connected.
Check t he battery electrolyte level.
(7)
Check air cleaner service indicator, and replace air cleaner element if indicator window is red.
(8)
Check the fuel/water separator and drain any water and/or solid contaminants if necessary.
(See Section 2-3, Servicing the Fuel Filter).
(172 kPa)
.
Dec 31/92 Chapter 1-4
Page 1
OM-2063 / Operation and Maintenance Manual
Jet-Ex 4D / Specs 7003A-3 and 7003B-3 / Generator Sets
1. Oil Pressure Guage
2. Tachometer
3. Water Temperature Guage
4. Current Limit Control
5. Ammeter
(Generator)
6. Voltmeter
7. Panel Light
8. Panel Lights Switch
9. Panel Lights Fuse
11. Contactor Closed Switch
12. Contactor Closed Light
13. Speed Control Switch
14. Engine On Light
15. Hourmeter
16. Engine Control Switch
17. Engine Circuit Fuse
18. Engine Circuit
19. Ammeter
(Engine)
10. Push-To-Build-Up-Voltage Switch
Control Panel Assembly
Figure 1
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.
NOTE:When operating in cold weather environments, read Adverse Weather Precautions before
starting the generator set.
(1)
Check engine oil, fuel and coolant levels.
(2)
Place speed control switch
(13)
in IDLE
(down)
position.
Chapter 1-4 Dec 31/92
Page 2
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