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3. Ammeter Shunt Preparation for Use Storage or Shipping Preparation for Use c nprppec 1 Output Cable Preparation for Storage General e IE ees Temporary Storage Long Time Preparation for Shipping Stationary Unit Mounting Section 3 Operation General Operating the Generator Set Pre start lt Pre start 51 5 Starting The Engine Generator Operation gt A A EUER 10 unu eda Ra iade 11 rm 11 Acc Dec 31 96 Table of Contents Page xi OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Deliver owen eae d ae om an 3 Stop Operation 3 Adverse Weather 5 3 Operation in Hot and Humid 5 4 Operation in Ex
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7. 283752 287049 1 W 11112 3 W 11245 3 W 11254 3 COVER CONTROLS ASSY FASTENER RETRACTABLE SCREW V94222 47 11 606 10 SCREW 10 24 X 3 4 WASHER FLAT 10 WASHER LOCK 10 P W 11287 4 403091 9 489235 489168 NUT HEX 10 24 PLUG HOLE PLASTIC PANEL LOWER REAR SUPPORT CONTROL PANEL RT ASSY O10101T9 488799 402119 2 50MS 732 0 489810 COVER OUTPUT CABLES SCREW 1 4 20 X 1 2 NUT 1 4 20 KEPS PANEL CENTER RIGHT CANOPY 286872 489220 30GHP 391 286871 PANEL SIDE RIGHT LOWER SUPPORT CONTROL PANEL LATCH CANOPY V94222 K5 2812 07 PANEL SIDE LEFT LOWER 282005 DELETED 7J 422 0 180015 181161 286847 DWP 982 PANEL FRONT CLAMP OUTPUT CABLE STRAP BACKUP COVER CONTROLS STRAP REINFORCING HINGE GUARD CLEARANCE LIGHT CABLE HANGER 283621 HANDLE GRIP Dec 31 96 Chapter 4 3 Page 5 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER Generator Set Interior Components Right Side Figure 3A Generator Set Interior Components Left Side Figure 3B Chapter 4 3 Page 6 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Not Illustrated NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM NO PARTNO PART NO 1234567 No Number
8. 7 Allow engine to warm up before applying a load WARNING M The engine s entire exhaust system will get very hot and cause severe burns if touched d Generator Operation Figure 1 1 Place speed control switch 77 in RATED RPM up position Engine speed will be 2000 RPM and the generator will automatically build up to produce rated voltage 2 Adjust STARTING CURRENT potentiometer 10 if necessary e Deliver Power 1 Connect output cable to AIRCRAFT 2 Hold CONTACTOR switch 8 in CLOSE position Release to ON position as soon as green CONTACTOR CLOSED light 9 comes on f Stop Operation Shutdown 1 When power delivery is completed aircraft discontinues drawing current place CONTACTOR switch 8 in OFF position Light 9 should go off to indicate load contactor has opened and power is no longer available at the aircraft 2 Place speed control switch 77 in IDLE down position Allow engine to run for 2 to 3 minutes 3 Disconnect output cable from aircraft receptacle and store cable in cable trays or on cable hangers as the case may be 4 Place START RUN STOP switch 74 in STOP position CAUTION THE BATTERY WILL DRAIN if the START RUN STOP switch 74 is not placed in STOP position after shutdown g Adverse Weather Precautions 1 Cold weather operation Operation of engine driven units at sub zero temperatures requires special precautions and extra servicing from both op
9. Chapter 1 1 Page 5 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Muffler Alternator Fuel filter Starter Starter solenoid Water temp switch and sender Generator Set Components Sheet 2 of 3 Figure 2 Chapter 1 1 Dec 31 96 Page 6 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 24 23 22 Radiator Air cleaner Throttle control assembly Fuel filter Oil pressure sender Oil pressure switch Oil filter Engine fuel pump governor Generator Set Components Sheet 3 of 3 Figure 2 Dec 31 96 Chapter 1 1 Page 7 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 4 Alternator and regulator The battery charging alternator 13 Figure 2 is rated at 62 amperes The voltage regulator is an integral part of each of the alternator 5 Starter solenoid The starter solenoid 16 Figure 2 is mounted on the starter motor 15 on the right side of the engine 6 Exhaust muffler 12 Figure 2 This muffler helps deaden audible noise from the engine s exhaust c Generator The generator 5 Figure 2 is a multi phase synchronous salient pole revolving field AC generator whose output is rectified The output is rectified by a rectifier assembly 4 made up of twelve rectifiers connected into a full wave configuratio
10. Load contactor K402 defective Test Check and Remedy Connect a jumper lead between terminals with red and blue orange wires on the contactor close switch 8 Fig 2 If the load contactor now remains closed replace contactor close switch If no fault was found in steps 4 a b and c above the load contactor 10 Fig 1 is defective Replace load contactor Resume operation and closely observe voltmeter 4 Fig 2 for evidence of overvoltage If contactor opens when no overvoltage condition exists proceed to Step b Check overvoltage relay by operating the machine under load and gradually raising voltage at the voltage regulator 2 Fig 3 while observing voltmeter 4 Fig 2 Start with a low voltage 25V DC and gradually increase voltage until relay functions to open load contactor If relay trips at less than 32 V DC adjust potentiometer P1 on the overvoltage board 1 Fig 3 If this does not correct problem return old board to factory for service If no fault was found in Step b c replace load contactor 10 Fig 1 October 28 96 Chapter 2 5 Page 7 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Generator and Controls continued Trouble Symptom and Condition Probable Cause Test Check and Remedy Output current cannot be a Defective current limiting Shut down engine and check limited by operating current poten
11. 6 Testing a Battery erre giana de che She aedes 6 Generator Maintenance 7 General eon eae ee A cee ee oe 7 Brush Servic edens 7 Generator Revolving Field Brush Replacement 7 Table of Contents Dec 31 96 Page xii OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Section 3 Adjustment Test 1 General 1 Testing the Generator Set 1 Pre operational Test Procedures 1 Operational 15 en nnn nnn 3 Voltage Regulator Adjustment 4 28 5 Volt 4 Line Drop 2 2 4 Section 4 Troubleshooting Procedures 1 General 1 Troubleshooting Chart 1 Description Mem 1 Use of the Troubleshooting Chart 1 Equipment for Troubleshooting 1 Safety Precautions 1 Diagrams 1 Illustrations 1 Connections and Wiring 2 Section 5 Troubleshooting Charts 1 Chapter 3 Major Overhaul Section 1 Flexable Coupling 1 General 1 Coupling Screws Routine Coupling Maintenance 2 Disassembly 3 Separate Engine and Generator 3 Remove Coupling 3 Coupling Service 4 Coupling Installation and Reasse
12. 284575 GENERATOR ASSY 491784 489077 1 488557 5 489135 180776 RING ADAPTER FLYWHEEL HOUSING HOUSING amp STATOR ASSY KEY COUPLING ARMATURE ASSY 488555 1 5J 260 0 488784 489086 489125 HOUSING BEARING ASSY CAP BEARING BRUSHHOLDER ASSY For Details See Fig 14 COVER FLYWHEEL HOUSING COUPLING GEN TO GEN ASSY 181166 W 11254 5 85C 1004 2 No Number 354592 SCREW CAP HH 3 8 24 X 1 NYLOK WASHER LOCK STD 3 8 BUSHING SPLIT TAPER FLYWHEEL Supplied w Engine RING SLIP 281688 402037 34 284507 W 10072 063 COVER GENERATOR HOUSING GROMMET PANEL GROMMET BEARING ho T Not Illustrated Dec 31 96 Chapier 4 3 Page 31 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set ZEON POWER Brush Holder Assembly Figure 14 Chapter 4 3 Page 32 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM NO PARTNO PART NO 1234567 EFF QTY 488784 BRUSHHOLDER ASSEMBLY 488562 BRACKET MTG BRUSHHOLDER 488628 BRACKET MTG DIODE 489658 010 DIODE SILICON 30A POS ASSEMBLY 402531 CAP BRUSHHOLDER V46992 DE 55 402530 GUIDE BRUSHHOLDER V46992 661 D 23 402788 BRUSH A C V78377 443E Not Illustrated
13. 3 Loosen and remove the clamp and air cleaner from the intake hose b Cartridge Installation 1 Attach the new air cleaner to the intake hose and tighten the clamp 2 Secure the air cleaner to the bracket with the two large clamps DO NOT overtighten 4 Servicing the Fuel Filter Refer to Perkins Diesel User s Handbook for instructions on removal and replacement of fuel filter elements 5 Drive Belt Service Check all drive belts and adjust if necessary each 200 hours Refer to Perkins Diesel User s Manual for proper procedures 6 Engine Cooling System NOTE Refer to the Perkins Diesel User s Manual for detailed instructions on servicing the engine s cooling system During warm weather operation if plain water is used as a coolant the cooling system MUST be protected against rust by a rust inhibitor additive During cold weather operation the system MUST be protected against freezing The system should NEVER be operated on plain water without a rust inhibitor or antifreeze WARNING When removing the cap from a very hot radiator cover the cap with a thick cloth and turn it slowly counterclockwise to the first stop When pressure is completely released press downward and finish removing cap Chapter 2 2 Dec 31 96 Page 4 2077 Operation and Maintenance Manual a Jet Ex 4D Spec 7003C Generator Set GROUND POWER _ CAUTION _ DO NOT add coolant to an extremely hot engine This can result in a crack
14. Change the fuel filter at prescribed intervals and keep fuel containers covered and protected against dust entry 2 Oil filter and air cleaner These both need more frequent attention under dusty conditions Check air cleaner daily Replace oil filter cartridge as needed 3 Crankcase The crankcase oil level will bear close attention Dusty conditions tend to load crankcase oil with dirt Watch for dirty and gritty oil conditions and change oil more frequently as required Chapter 1 3 Dec 31 96 Page 4 2077 Operation and Maintenance Manual P Jet Ex 4D Spec 7003C Generator Set GROUND POWER j Operation in Salt Water Areas 1 Canopy Wash canopy regularly to remove salt film Repaint any damaged places and oil the side panel hinges regularly 2 Covering To protect the engine and generator as much as possible from salt water atmosphere keep the side panels on the canopy closed when not in use It is advisable to keep the unit covered with a tarpaulin if available while in operation Salt water should be wiped from the engine and all terminals and connections in the electrical system wiped dry Keep all linkage oiled 3 Brushes The brushes of the generator should be inspected regularly to make certain that they are free in the holders Lift the brushes in the brusholders about every two days to insure their freedom to slide within the holder Wipe dry all the parts that can be reached and use compressed
15. GROUND POWER 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 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 equipment Lock switch OPEN or remove line fuses so that power cannot be turned on accidentally c Disconnect power to equipment if it is out of service If troubleshooting must be done with the unit energized have another person present who
16. Chapter 4 3 Page 11 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set POWER Battery Components Figure 5 Chapter 4 3 Page 12 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM NO PARTNO PART NO 1234567 EFF QTY No Number BATTERY COMPONENTS 281881 1 BATTERY 12 V 388827 19 BATTERY CABLE POSITIVE ASSY 388828 9 BATTERY CABLE NEGATIVE ASSY 282784 TRAY BATTERY V92489 9091 1 Dec 31 96 Chapter 4 3 Page 13 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set ROUNO POWER Muffler and Air Cleaner Components Figure 6 Chapter 4 3 Page 14 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM PARTNO PART NO 1234567 EFF QTY No Number MUFFLER AND AIR CLEANER COMPONENTS 282388 MUFFLER ASSEMBLY 402433 CLAMP AIR CLEANER 282569 AIR CLEANER 282571 HOSE AIR CLEANER W 10869 5 CLAMP HOSE AIR CLEANER W 10750 3 NIPPLE PIPE 1 8 X2 406768 1 INDICATOR AIR RESTRICTION 282570 BRACKET AIR CLEANER Pp 1 2 3 4 5 6 7 8 Dec 31 96 Chapter 4 3 Page 15 OM 2077 Operation and Maintenance Manual HOBART Jet EX 4D Spec 7003C Generator Set
17. L406 defective Defective generator armature G402 Voltage regulator fuse 2403 is blown Defective rectifier CR401 GROUND POWER Test Check and Remedy Replace voltage build up fuse 5 Fig 3 Proceed to Step b to determine cause of blown fuse Check excitation rectifiers 3 Fig 3 with an ohmmeter to see if they are good If either rectifier is defective replace it If both rectifiers are good proceed to Step c Check capacitor 8 Fig 3 with an ohmmeter to see if it is good If defective replace it otherwise proceed to Step d Check diode on brushholder mounting bracket with an ohmmeter to see if it is good If defective replace it otherwise proceed to Step e Locate yellow and red orange wires on the right terminal strip at lower rear of control panel Disconnect the yellow and red orange wires which go down to the generator Refer to connection diagram 282654 Chapter 5 Measure resistance between these two wires It should be 10 to 11 ohms If reading indicates an open short or lower than normal resistance proceed to Step f If check of the generator revolving field Step f above revealed no trouble the generator stator is defective Send unit to overhaul Replace voltage regulator fuse 6 Fig 3 Proceed to Step d to determine reason for blown fuse Use ohmmeter to check rectifier CR401 beside ENGINE RUNNING pilot light on rear of control panel
18. Operation and Maintenance Manual e Jet Ex 4D Spec 7003C Generator Set GROUND POWER Safety Warnings and Cautions WARNING CALIFORNIA PROPOSITION 65 DIESEL ENGINES Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 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 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 i
19. GROUND POWER Rectifier Assembly Figure 7 Chapter 4 3 Page 16 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set FIGURE amp HOBART ITEM NO PART NO AIRLINE PART NO 7 286848 GROUND POWER NOMENCLATURE 1234567 RECTIFIER ASSY Cs 287184 3 7 405278 6 7 286887 7 W 11254 6 fs W 11278 5 INSULATOR CAPACITOR CAPACITOR 41000MFD 75 VDC V22751 75 95 SHROUD AIR TOP RECTIFIER WASHER LOCK 3 8 NUT HEX 3 8 16 AR S B W 10869 6 7 402037 4 7 405154 6 W 11254 4 W 11114 12 NN 1 1 CLAMP CAPACITOR GROMMET RUBBER V02231 ACW 5001 RESISTOR 100 100 WATT V44655 61917 WASHER LOCK 1 4 SCREW 1 4 20 X 7 1 4 N 1 400589 8 405117 2 494681 1 W 11280 15 402119 4 N 1 BLOCK TERMINAL 3 STATION SCREW 8 18 X 3 4 WASHER SPRING NUT JAM HEX 3 4 16 SCREW HHC 1 4 20 x 3 4 W 11242 5 50MS 732 0 283063 W 11242 18 A 25 WASHER FLAT 1 4 NUT KEPS 1 4 SPACER RECTIFIER WASHER FLAT 3 8 WASHER INSULATING 286813 AW 626 W 11097 22 W 11097 7 286884 HEAT SINK RECTIFIER POSITIVE BUSHING INSULATING SCREW HHC 3 8 16 x 2 1 2 SCREW HHC 3 8 16 x 2 BRACKET MTG HEAT SINK W 11263 6 282239 180600 285647 W 11254 6 WAS
20. Key Setscrew Tapped setscrew hole WD Split Taper Bushing SIDE VIEW Figure 3 FRONT VIEW 4 Coupling Service 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 When ordering coupling kits or other parts from your Hobart Brothers Company Distributor be sure to include all pertinent information from the unit s identification plate Specification No Model No and unit rating Write Hobart Brothers Company Airport Systems Group Service Department 1177 Trade Square East Troy Ohio 45373 U S A In U S A Call 800 422 4166 Parts 800 422 4177 Service From Foreign Countries Call 937 332 5050 Parts 937 332 5060 Service Fax 937 332 5121 Chapter 3 1 Dec 31 96 Page 4 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set Skane ro weak 5 Coupling Installation and Reassembly of Engine and Generator CAUTION Improper installation of the coupling assembly can result in serious damage to the equipment Follow these installation instructions exactly a Cleaning Figure 4 It is VERY IMPORTANT that the shaft the bore and the outside of the split bushing and the tapered inside of the hub be thoroughly CLEANED FREE OF DIRT AND GRIT CAUTION Do not lubricate any of the surfaces listed above Lubrication of these surfaces can cause t
21. Line drop compensation allows the voltage at the load end of the output cable to remain constant despite the voltage drop associated with the output cable Clockwise CW rotation of the single turn potentiometer 124 increases the compensation This potentiometer should be set for flat regulation of voltage at the load end of the output cable when delivering rated load current Voltage Regulator PC Board Figure 3 Chapter 2 3 Dec 31 96 Page 4 OM 2077 Operation and Maintenance Manual E Jet Ex 4D Spec 7003C Generator Set GROUND POWER Section 4 Troubleshooting Procedures 1 General Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the exact cause of a trouble is found As a rule the best place to start looking for the cause of a trouble in a circuit is at the source of power Continue testing and checking the circuit step by step in an orderly manner until the cause of trouble is located See connection and schematic diagrams 2 Troubleshooting Chart a Description The troubleshooting chart lists information under three headings 1 Trouble symptom and condition 2 Probable cause 3 Test check and remedy b Use of the Troubleshooting Chart Read the trouble symptoms and conditions before proceeding to causes and remedies For example at the beginning of the troubleshooting chart under ENGINE the first trouble listed is Engine will not st
22. Replace rectifier if defective October 28 96 Chapter 2 5 Page 5 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Generator and Controls continued Trouble Symptom and Condition Probable Cause Test Check and Remedy i Generator voltage regulator Replace voltage regulator 2 VR402 defective Fig 3 Generator builds up to only a a Defective excitation rectifier Check excitation rectifiers 3 low voltage when speed CR417 and or CR418 Fig 3 with an ohmmeter to see control switch S406 2 4 11 if they are good If either Fig 2 is placed in RATED rectifier is defective replace it RPM position If both rectifiers are good proceed to Step b b Generator voltage regulator Replace voltage regulator 2 VR402 defective Fig 3 Generator builds too high a a Defective speed control Use ohmmeter to check speed voltage switch S406 control switch 11 Fig 2 Replace switch if defective b Defective rectifier CR401 Use ohmmeter to check rectifier CR401 beside ENGINE RUNNING pilot light on rear of control panel Replace rectifier if defective c Generator voltage regulator Replace voltage regulator 2 VR402 defective Fig 3 with a voltage regulator known to be good and resume operation of generator set If new voltage regulator produces normal operating voltage send old voltage regulator to factory for service Load contact
23. SENDER WATER TEMP BUSHING PIPE 3 8 X 1 2 DRAIN BLOCK Not Illustrated SH AH ASH ASB HS SOS Dec 31 96 Chapter 4 3 Page 25 OM 2077 Operation and Maintenance Manual HOBART Jet EX 4D Spec 7003C Generator Set GROUND POWER Fuel System Components Figure 11A 36 TO ENGINE t FUEL RETURN CONNECTION RETURN LINE pum TANK TO ENGINE FUEL TANK RETURN CONNECTION ON TOP OF TANK TO FUEL TANK SUPPLY CONNECTION 1 1 ON BOTTOM OF TANK TO PRIMER PUMP ON RIGHT SIDE TO PREFILTER OF ENGINE OUTLET SUPPLY LINE FUEL PUMP TO PREFILTER Er TO PREFILTER A 707 OUTLET SUPPLY LINE PREFILTER TO TANK Fuel Lines Figure 11B Chapter 4 3 Page 26 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM NO PART NO PART NO 1234567 2 FUEL SYSTEM COMPONENTS 282299 TANK FUEL ASSEMBLY 282257 TANK FUEL 486719 010 SENDER FUEL 286938 TANK FUEL ASSEMBLY 486719 10 SENDER FUEL 284203 PLATE MTG FUEL TANK 282562 282699 FUEL CAP GREEN SUPPORT FUEL TANK Q 282717 FUEL LINES 2 m A W 7814 1 282734 BUSHING PIPE 1 8 X 3 8 ELBOW MALE 90DEG W 10869 14 CLAMP HOSE 4
24. 10 Amp Voltage regulator fuse 10 Amp Spare fuse 10 Amp Control Panel Assembly Rear View Figure 4 g Rectifier Assembly This assembly consists of two aluminum heat sinks with six diodes on each heat sink The rectifier assembly converts the AC output of the generator to 28 5 VDC h Ammeter Shunt The ammeter shunt is connected in the generator s negative output circuit It supplies a small voltage proportional to output current for operation of the generator ammeter 5 Fig 3 and for sensing output current for the current limit circuit of the voltage regulator 2 Fig 4 This shunt is mounted on the negative heat sink of the rectifier assembly 4 Fig 2 Dec 31 96 Chapter 1 1 Page 11 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Chapter 1 1 Dec 31 96 Page 12 2077 Operation and Maintenance Manual P Jet Ex 4D Spec 7003C Generator Set GROUND POWER Section 2 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 NEZ Read operating instructions in Section 1 3 before operating the unit b Inspection Check Inspect the unit completely prior to operation 1 Remove crating blocking banding ties and other securing and
25. Ave Racine WI 53401 94222 Southco Inc 210 N Brinton Lk Rd Concordville PA 19331 Dec 31 96 Chapter 4 2 Page 1 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Chapter 4 2 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Section 3 Parts List 1 Explanation of Parts List Arrangement The parts list is arranged so that the illustration will appear on a left hand page and the applicable parts list will appear on the opposite right hand page Unless the list is unusually long the user will be able to look at the illustration and read the parts list without turning a page 2 Symbols and Abbreviations The following is a list of symbols and abbreviations used in the parts list item not illustrated A or AMP ampere AC AR asrequired alternating current DC direct current Fig Figure hd head hex hexagon Hz Hertz cycles per second 1 0 inside diameter IN inch kVA kilovolt ampere uF microfarad No number OM Owners Manual PRV peak reverse voltage PSI pounds per square inch Ref reference the item has been listed previously TM Technical Manual lt volt when used as prefix to a five digit number indicates vendor code NOTE An item which does not reflect an index number is an assembly which is not illustrated in
26. Dec 31 96 Chapter 4 3 Page 33 5 OM 2077 Operation and Maintenance Manual GROUND POWER Jet EX 4D Spec 7003C Generator Set Frame Assembly Figure 15 Dec 31 96 Chapter 4 3 Page 34 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM NO PARTNO PART NO 1234567 EFF QTY No Number FRAME LIFTING YOKE ASSEMBLY 282006 FRAME MOUNTING ASSEMBLY 180543 BAR MTG GENERATOR 406254 3 MOUNT SHOCK GENERATOR RED 489203 YOKE LIFTING 491799 WASHER SHOCK MOUNT 282008 PLATE REAR Not Illustrated Dec 31 96 Chapier 4 3 Page 35 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set ROUNO POWER This page intentionally left blank Chapter 4 3 Page 36 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set Section 4 Numerical Index 1 Explanation of Numerical Index GROUND POWER The purpose of this index is to assist the user in finding the illustration and description of a part when the part number is known Part numbers are arranged in numeric alpha sequence Thus any part number beginning with the number 9 would be located at or near the top of the index list Like wise a part beginning with the letter A would be listed near the end of the list and far below a part number 1000 The figure number an
27. Figure 4 Once a Figure number reference has been established the Figure number is not repeated and only the item numbers of the parts involved are referenced for example Loosen screw 2 Fig 6 slide out connector 4 and remove brush 6 When an item number is referenced without a Figure number it always applies to the last preceding Figure number mentioned in the text A 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 Ground Power Division Service Department 1177 Trade Road East Troy Ohio 45373 U S A Call 937 332 5060 Service Assistance 937 332 5050 Replacement Parts FAX 937 332 5121 Introduction Dec 31 96 Page x OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Table of Contents Chapter 1 Description Operation Section 1 Section 2 Description General Special Features Standard ass vias wisn waa a as aw ODHOnS oes onus unm Sees cae ted Ce Sees Orientation Identification Canopy Engine Generator and Controls ENUO Cnr Control Panel Assembly CONTAGION Sr REC T Rectifier
28. GENERATOR SET INTERIOR COMPONENTS No Number BATTERY COMPONENTS See Fig 5 No Number MUFFLER amp AIR CLEANER COMPONENTS See Fig 6 286848 RECTIFIER ASSEMBLY See Fig 7 286810 1 CONTACTOR DC 800 AMP See Fig 8 No Number ENGINE COMPONENTS See Fig 9A amp 9B No Number COOLING SYSTEM See Fig 10 No Number FUEL SYSTEM COMPONENTS See Fig 11A amp 11B 282220 SOLENOID FULL THROTTLE ASSY See Fig 12 281333 GENERATOR ASSEMBLY See Fig 13 Dec 31 96 Chapter 4 3 Page 7 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set entre Tania 22 26 FRONT VIEW 23 Control Panel Assembly Figure 4 Chapter 4 3 Page 8 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set FIGURE amp HOBART ITEM NO 1 AIRLINE PART NO 282633 PART NO GROUND POWER NOMENCLATURE 1234567 CONTROL PANEL ASSY For NHA See Fig 1 EFF QTY 282632 W 11166 5 402658 494134 1 403189 PANEL CONTROL ASSY FUSE AGC 20A V71400 HOLDER FUSE V71400 TYPE HKP HH GAUGE FUEL ELECTRIC 12V SWITCH TOGGLE 1 78 1120 1 286699 1 282639 286812 50
29. NUT KEPS 6 32 wow Not Illustrated Dec 31 96 Chapier 4 3 Page 9 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set ROUNO POWER This page intentionally left blank Chapter 4 3 Page 10 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set FIGURE amp HOBART ITEM NO PART NO 282633 AIRLINE PART NO GROUND POWER NOMENCLATURE 1234567 CONTROL PANEL ASSY Continued EFF QTY 2 400641 12 11110 3 50 5 732 4 180289 W 11245 15 AMMETER V74542 SCREW 6 32 X 3 8 NUT KEPS 6 32 BOARD PC OVERVOLTAGE ASSY WASHER FLAT 8 BRASS 50MS 732 1 844 1075 181022A 1 W 11245 15 50MS 732 1 NUT KEPS 448 32 MOUNT RUBBER V5P059 51083 BOARD PC REGULATOR WASHER FLAT 8 BRASS NUT KEPS 8 32 404065 2 W 11111 8 W 11245 15 W 11254 2 W 10051 13 RECTIFIER SILICON V04713 5DA 10270 2 SCREW 8 32 X 3 4 WASHER FLAT 8 BRASS WASHER LOCK 8 CLAMP WIRE PLASTIC W 11245 3 50MS 732 5 400828 1 180593 3 WASHER FLAT 10 NUT KEPS 10 24 TIE WIRE PLASTIC CAPACITOR 100MFD 350VDC 283754 286815 286811 SUPPORT COVER CONTROLS BRACKET ROD SUPPORT RETAINER DOOR Not Illustrated NIA AR NOJO WW Dec 31 96
30. Page 1 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Wet Stacking Dec 31 96 Page 2
31. a quick look at the Table of Contents shows that Adjustment Test is located in Chapter 2 Section 3 shown as 2 3 Dec 31 96 Introduction Page ix 2077 Operation and Manitenance Manual P Jet Ex 4D Spec 7003C Generator Set GROUND POWER 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 Hef Para 1 A means that the material is to be found in paragraph 1 A of the same Section When referenced material is located in another Chapter Section both the Chapter and Section numbers and the paragraph identification are given for example Ref 1 2 Para 1 A 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 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 to item 1 in
32. air if available to dry the parts of the generator that cannot otherwise be reached See MAINTENANCE for brush care 4 Field coils The fields should be dried as thoroughly as possible If they have become damp proceed with recommended procedure in MAINTENANCE section 5 Battery terminals Thoroughly clean the battery terminals and connections Coat terminals and connections with petroleum jelly to retard corrosion k Miscellaneous Once a month oil hinges on the engine compartment doors and the hinged plexiglas cover Dec 31 96 Chapter 1 3 Page 5 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set E RIEN POWER This page intentionally left blank Chapter 1 3 Dec 31 96 Page 6 OM 2077 Operation and Maintenance Manual a Jet Ex 4d Spec 7003C Generator Set GROUND POWER Chapter 2 Servicing Troubleshooting Section 1 Maintenance Inspection Check 1 General To make certain that generator set is always in good operating condition it must be inspected maintained and lubricated regularly and systematically WARNING Stop operations at once if a serious or possibly dangerous fault is discovered 2 Maintenance Schedule a General Figure 1 provides a suggested schedule for periodic checks and services Refer to Section 2 2 for lubrication requirements b Maintenance Schedule Check Sheet It is strongly recommended that the customer use a maintenance
33. are shorter than 7 16 inch 11 mm replace them 3 Inspect slip rings whenever brushes are removed for servicing brushes or brusholders Note surface conditions of rings Surface should appear smooth and clean Scoring or roughness of slip rings may be caused by grit or abrasive substance in brushes or by oil on the rings Moderately rough slip rings can be smoothed by holding grade 00 flint paper against their surface while the rings are revolving slowly If the rings are badly scored the unit must be sent to an overhaul facility for repair After cleaning slip rings blow dirt and grit out of the unit with compressed air Do not use over 25 psi 172 kPa air pressure to blow dirt out 4 Slip new brushes into brush holder guides and place caps on top and screw them into the guides to a bottomed position The spring attached to the brush will determine the pressure at which the brush contacts the slip rings 5 To fit new brushes to the slip rings lay a strip of No 00 sand paper smooth side down on slip ring surface and draw the sandpaper in the direction of rotation of the slip ring lifting the brush on the return stroke Continue until the brushes have same curvature as the slip rings Blow all carbon dust out of the machine using not over 25 psi 172 kPa air pressure B Brusholder Caps C Brusholder E Slip Rings Generator Revolving Field Brushes Figure 5 Dec 31 96 Chapter 2 2 Page
34. diesel engine The flexible coupling assembly compensates for slight misaligment between the engine and the generator due to manufacturing tolerances A split taper bushing secures the coupling to the generator s armature shaft See Fig 3 8 4 REAR VIEW SIDE VIEW Coupling Assembly Figure 1 Dec 31 96 Chapter 3 1 Page 1 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set ONE 2 Coupling Screws Routine Coupling Maintenance CAUTION CAUTION Failure to verify proper coupling screw installation may result in coupling failure and damage to the equipment If the generator set is functioning properly servicing the coupling assembly will be essentially limited to checking the screws which attach the flexible coupling to the engine flywheel of the generator set These 8 screws should be checked periodically to make certain that 1 screws of proper type length and hardness are installed 2 that the threads of the screws are not stripped and 3 that they are torqued properly Proceed as follows to check coupling screws a Remove the sheet metal covers from around the generator housing and the flywheel housing b Refer to Figure 2 Hold a short iron bar through the flywheel housing against the fan blades of the fan and coupling assembly to block the armature against clockwise rotation Do this carefully to avoid damaging the fan blades Use long handled rever
35. is trained in turning off the equipment and providing or calling for first aid 4 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 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 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 5 Toxic Fume Prevention Carbon monoxide Engine exhaust fumes can kill and cause health problems Pipe or vent the exhaust fumes to a suita
36. of this switch which closes at 20 PSI 138 kPa This prevents the engine from running if oil pressure will not build up and also shuts down the engine if oil pressure drops radically during operation See the engine operator s manual for additional engine specifications The generator and engine are mounted on a welded steel skid and are enclosed by a sheet metal canopy that bolts to the skid Access to engine serviceable components oil filter air cleaner etc is through two doors at the front on each side of the machine Two removable panels one on each side at the 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 2 Cooling fan The cooling fan on the engine is designed to blow air out through the radiator rather than to draw itin This prevents hot air heated by the engine from entering the generator 3 Fuel system The fuel system consists of an 20 5 gallon 77 6 liters plastic fuel tank 2 Figure 2 with all the necessary fittings and hoses Chapter 1 1 Dec 31 96 Page 4 2077 Operation and Maintenance Manual E Jet Ex 4D Spec 7003C Generator Set GROUND POWER 11 1 Lifting yoke 5 Generator 9 Battery 2 Fuel tank 6 Frame 10 Contactor 3 Control panel 7 Engine 11 Fuel tank support 4 Rectifier assembly 8 Air cleaner Generator Set Components Sheet 1 of 3 Figure 2 Dec 31 96
37. operable only when the engine switch 14 is held in its top spring loaded START position The engine switch 14 when released from its top START position after the engine starts will return to center RUN position The engine ON light 72 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 12 will go out The speed control switch 11 is a two position toggle switch wired to a throttle solenoid on the engine In the IDLE position used for starting the engine speed is controlled to approximately 1000 RPM In the Rated RPM position engine speed is controlled to approximately 2000 RPM 6 Fuses Two cartridge type fuses protect the engine ignition circuit and the panel lights circuit The engine circuit fuse 15 is rated at 20 amperes and the panel lights fuse 6 at 10 amperes e Control Panel Assembly Rear Figure 4 1 Voltage regulator The voltage regulator 2 is a solid state device which regulates the 28 5 volt DC generator output after the voltage is built up 2 Overvoltage module The overvoltage relay 1 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 m
38. 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 20 5 gallons 77 6 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 Be sure the cooling system antifreeze solution is adequate to protect below lowest temperature expected c Engine lubricating oil The oil level dipstick is located on the right side of the engine Refer to Perkins User s handbook for oil recommendations 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 9 m The cable should be two c
39. schedule check sheet The check sheet will provide a record of maintenance specific operation c Time Intervals The schedule is based on both hours of operation and calendar intervals These two intervals are not necessarily the same The calendar period is included to make certain services are performed regularly when equipment is being operated infrequently or at manufacturer s recommendations Perform all services on a whichever comes first basis NOTE Refer to the Perkins Diesel User s Manual for detailed engine maintenance information 3 Engine and Related Components See the Perkins Diesel User s Manual for Series 4 236 engines 4 Inspection and Cleaning Every day check for oil coolant or fuel leaks Also check for loose electrical connection Check oil pressure with engine running at rated RPM 2000 Do not operate engine if oil pressure is less than 15 psi Wipe accumulated water off from all electrical connections and instruments Make sure that the battery voltmeter reads proper voltage Dec 31 96 Chapter 2 1 Page 1 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set Recommended Service Intervals GROUND POWER 100 hrs A R 2 Weeks 1 Month 2 Months Engine Check oil level Check coolant level Check fuel quantity Check gages and instruments for prpoer operation Change engine oil Change oil filter Check and tighten drive be
40. the locations of various components of the generator set Dec 31 96 Chapter 2 4 Page 1 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 7 Connections and Wiring Before condemning any electrical component check all connections and wiring which could affect its operation In many instances a component may be non functional simply because it is not receiving power because of a loose connection or a poor ground In most cases throughout the troubleshooting chart it will be assumed that connections and wiring have been checked Chapter 2 4 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 1 Lifting yoke 5 Generator 9 Battery 2 Fuel Tank 6 Frame 10 Contactor 3 Control Panel 7 Engine 11 Fuel tank support 4 Rectifier assembly 8 Air Cleaner Generator Set Components Sheet 1 of 3 Figure 1 Dec 31 96 Chapter 2 4 Page 3 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER TT bs i sa PX T t a t Ll 15 12 Muffler 13 Alternator 14 Fuel filter 15 Starter 16 Starter solenoid 17 Water temp switch and sender Generator Set Components Sheet 2 of 3 Figure 1 Chapter 2 4 Dec 31 96 Page 4 OM 2077 Operation and Maintenance Manual T Jet Ex 4D Spec 7003C
41. 02119 4 4 9 286812 2 2 402119 9 7 21 286813 11 8 402265 4 64 286815 6 2 402433 2 2 286816 14 5 402530 2 29 286847 14 4 402531 3 286848 4 2 402658 7 286848 4 19 402662 8 7 286849 4 26 402663 9A 1 286850 4 38 402682 2 21 286871 14 6 402788 2 18 286872 2 12 403091 9 7 25 286884 4 4 403189 7 3 286887 10 12 403618 6 4 23 286923 10 13 403782 0 1 1 286924 98 5 403809 2 2 286924 4 54 404065 2 9A 11 286925 9A 5 405015 11A 1 286938 11B 9 405091 1 2 11 287049 1 9A 6 405099 7 1 287184 3 7 12 405117 2 4 39 30GH 1119 4 35 405129 1 2 20 30GHP 391 7 8 405154 6 1 15 351541 7 2 405278 6 13 12 354592 1 17 405309 11B 10 355325 4 10 8 405743 11B 11 355325 6 1 21 406000 9A 3 359985 1 16 406001 5 2 388827 19 10 3 406149 5 3 388828 9 9B 2 406254 2 8 4 400435 15 3 406254 3 1 9 400435 10 10 406655 7 11 400589 8 6 7 406768 1 4 44 400641 12 4 40 406815 Chapter 4 4 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER FIG ITEM PART NUMBER FIG ITEM PART NUMBER 1 18 407366 7 17 50MS 732 0 4 27 407948 4 49 50MS 732 1 9A 2 407948 4 53 50MS 732 1 9A 4 408409 4 17 50MS 732 4 4 13 408596 1 4 43 50MS 732 4 12 1 482496 1 4 46 50MS 732 4 11A 1 486719 010 4 25 50MS 732 5 11A 1 486719 10 4 60 50MS 732 5 13 6 488555 1 4 10 50MS 732 7 13 3 488557 5 7 32 5CW 1308 0 14 1 488562 10 16 5CW 1932 0 14 2 488628 4 24 5CW 3884 2 2 7 488640 13 7 5J 260 0 13 8 488784 2 9 6F
42. 5 732 7 GAUGE HOURMETER V16476 56288 VOLTMETER BATTERY V16476 06351 001 LABEL CONTROL PANEL BRACKET MOUNTING CONTROLS NUT KEPS 6 32 78A 1117 1 78A 1116 1 408596 1 82B 1047 401937 4 GAUGE OIL PRESSURE V16476 06340 GAUGE WATER TEMP V16476 06343 TACHOMETER V16476 71076 00 LIGHT PANEL 12V BLOCK TERMINAL 20A W 11245 2 50MS 732 4 W 11166 3 402662 180913 2 WASHER FLAT 6 NUT KEPS 6 32 FUSE AGC 10A SWITCH TOGGLE DPST V74559 2GK71 73 LIGHT PILOT GREEN 28V 16DA 2162 401428 1 286923 5CW 3884 2 KNOB RHEOSTAT V44655 5150 POTENTIOMETER 10K OHM 2W V44655 SCMU 1031 COVER 14V OPTION SCREW 10 24 X 1 2 50MS 732 5 402663 407948 W 11245 2 W 11254 1 NUT KEPS 10 32 NUT POTENTIOMETER LOCK RECIFIER ISOLATED BASE WASHER FLAT 6 BRASS WASHER LOCK 6 W 11287 2 W 10051 14 W 11112 1 W 11245 3 W 11254 3 NUT 6 32 CLAMP WIRE PLASTIC SCREW 10 24 X 1 2 WASHER FLAT 10 BRASS WASHER LOCK 10 405129 1 W 11221 1 180913 1 402682 BLOCK FUSE SCREW 6 20 X 3 8 LIGHT PILOT ENGINE GREEN 12V SWITCH TOGGLE 3 PDT V74559 HLA 211 73 30GH 1119 406815 400642 3 W 11110 3 50MS 732 4 SWITCH PUSHBUTTON BOOT PUSHBUTTON SWITCH V13445 83280 VOLTMETER DC V74542 SCREW 6 32 X 3 8
43. 7 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Chapter 2 2 Dec 31 96 Page 8 2077 operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Section 3 Adjustment Test 1 General The adjustments and test procedures presented below are required after major repairs parts replacement or long storage 2 Testing the Generator Set Test values listed below will result when the generator set is operating properly If your test results are not within the limits shown perform the applicable troubleshooting procedures given in Chapter 3 If major repairs have been made or if critical components have been replaced make sure that the applicable adjustments have been made before testing the generator set Adjustment procedures are described in Para 3 of this Section a Pre operational Test Procedures 1 Open engine compartment doors and inspect the interior for rags tools and other foreign materials 2 Check engine oil level 3 Check coolant level 4 Check battery water level if required 5 Check for sufficient fuel 6 Check drive belts Each belt should have approximately 1 2 inch 13 mm slack 7 Inspect all wiring for possible trouble spots such as loose wires or terminals frayed insulation obvious shorts etc 8 Check panel lights panel light switch and fuse 9 Connect cable
44. 758 gt Q fd 0 voz M 20 4 gory LU 9071 r ZirS bs pere Y CNN 119 Ll 2075 2075 TT NOIL cora G0t4 apa 2188 1 VSL 12532 4 Lora qu 6071 20740 nm 101 m m 5 3055 10 5 19518 A Au 05r a ISS SE t L Z v 5 9 L 8 59282 0 os se gown c 30 z 13305 xs AIEO potens sions voee djO NO 3SO10 YOLIVINOD HOLIMS 0 75 9691 6 Par Durpnioui siu NOILISOd Avl NI 5 1 85 JOON HOLIMS 6075 Tihs a 490 he z noe 043931 XAN MOIOVINOO QVO NOLOJNNOO 29 sw Tasas vor aod saa N3349 035010 YOLOVINOD HOIVOIONI 150 sio Woo Wn AuNvnb on wean 031310395 3SIMe3HIO SS3INO 3nd8 3090N APL NOLVOIONI OLvsd nae SOON ABC HOLYOIONI 60950 F ava ON 23
45. 91889 5 HOSE RUBBER 3 16 I D 402265 VALVE SHUT OFF 1 4 TURN 405091 1 ELBOW MALE BARBED 90DEG 355325 4 HOSE RUBBER 5 16 I D 355325 6 HOSE RUBBER 5 16 I D lt aja Dec 31 96 Chapter 4 3 Page 27 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set ROUNO POWER rj WM Wn Full Throttle Solenoid Assembly Figure 12 Chapter 4 3 Page 28 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM NO PARTNO PART NO 1234567 EFF QTY 282220 FULL THROTTLE SOLENOID ASSY 12CW 2146 282218 W 11280 3 282217 282219 YOKE CLEVIS FITTING SWIVEL V78388 SA 4049 1 4 28 HEX SOLENOID V88136 D610 A1V12 SUPPORT SOLENOID 482496 1 W 11563 W 11337 1 CLAMP WIRE PIN CLEVIS PIN COTTER Not Illustrated cl cl Dec 31 96 Chapter 4 3 Page 29 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set co Generator Assembly Figure 13 Chapter 4 3 Page 30 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE AIRLINE PART NO FIGURE amp HOBART NO PART NO EFF QTY 1234567
46. AMP 286849 INSULATOR CONTACT Dec 31 96 Chapter 4 3 Page 19 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set POWER Engine Components Right Side Figure 9A Chapter 4 3 Page 20 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM PARTNO PART NO 1234567 EFF QTY No Number ENGINE COMPONENTS RIGHT SIDE 286850 SOLENOID STARTER CUT OUT 407948 RECTIFIER SOLENOID STARTER CUT OUT 359985 BRACKET FUEL FILTER MOUNTING 408409 ENGINE V13446 LD70195 405015 ALTERNATOR 405099 FAN ALTERNATOR 181098 BRACKET ALTERNATOR MOUNTING 181099 SPACER BRACKET ALTERNATOR 181100 SPACER SCREW ALTERNATOR 492098 BRACKET SUPPORT WIRE ALTERNATOR 286925 HARNESS WIRE ENGINE ASSY 285795 FILTER FUEL WATER RACOR 78B 1010 WIRE ALTERNATOR W DIODE Not Illustrated Dec 31 96 Chapter 4 3 Page 21 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER Engine Components Left Side Figure 9B Chapter 4 3 Page 22 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE NO PART NO PARTNO 1234567 EFF QTY 2 ENGINE COMPONENTS L
47. C Generator Set GROUND POWER 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 b Temporary Storage When storing the unit for one month prepare as follows 1 Lubricate the unit completely in accordance with instructions in Section 2 2 This will include changing engine oil and filter elements 2 Make certain the cooling system antifreeze solution is adequate to protect below the lowest temperatures expected during the storage period 3 Clean the exterior of the engine with fuel oil and dry with 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 Pl
48. EFT SIDE 489114 SUPPORT MOUNTING ENGINE 406254 2 MOUNT SHOCK ENGINE 491799 WASHER MOUNT SHOCK W 9360 229 CABLE ENGINE TO GROUND 403809 2 SWITCH OIL PRESSURE 78B 1118 1 SENDER OIL PRESSURE W 10750 3 NIPPLE PIPE 1 8 X 2 W 10910 0 TEE PIPE BRASS 1 8 Not Illustrated Dec 31 96 Chapter 4 3 Page 23 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER Cooling System Components Figure 10 Chapter 4 3 Page 24 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set FIGURE amp HOBART ITEM NO 10 AIRLINE PART NO No Number PART NO GROUND POWER NOMENCLATURE 1234567 COOLING SYSTEM COMPONENTS EFF QTY 2 ET 10 1 281874 80A 1117 489641 489639 406149 HOSE RADIATOR BOTTOM CLAMP HOSE BOTTOM GUARD FAN LEFT GUARD FAN RIGHT FAN ENGINE 15 489122 489547 281423 1 489121 489533 SUPPORT RADIATOR BAFFLE RADIATOR RADIATOR PRESSURIZED V94177 1A15628D SHROUD RADIATOR SUPPORT RADIATOR NECK W 10869 2 405743 W 10869 12 406655 W 10869 3 CLAMP RADIATOR NECK CAP RADIATOR 7LB CLAMP HOSE RADIATOR HOSE RADIATOR TOP CLAMP HOSE ENGINE OUTLET 403618 6 403782 0 78B 1119 1 W 7814 4 5CW 1932 0 BELT FAN SWITCH WATER TEMP
49. GROUND POWER OM 2077 123196 Operation and Maintenance Manual Jet Ex 4D Generator Sets Series 7003C Hobart Brothers Company Airport Systems Group Ground Power Equipment Troy Ohio 45373 WARRANTY HOBART BROTHERS COMPANY TROY OHIO U S A GROUND POWER DIVISION Hobart Brothers Company hereinafter called HOBART warrants that each new and unused Hobart Ground Power Equipment hereinafter called the PRODUCT is of good workmanship and is free from mechanical defects provided that 1 the PRODUCT is installed and operated in accordance with the printed instructions of HOBART 2 the PRODUCT is used under the normal operating conditions for which it is designed 3 the PRODUCT is not subjected to misuse negligence or accident and 4 the PRODUCT receives proper care lubrication protection and maintenance under the supervision of trained personnel This warranty expires 15 months after shipment by HOBART to the first user or 12 months after installation whichever first occurs This warranty does not apply to primary and secondary switch contacts cable connectors carbon brushes fuses bulbs and filters unless found to be defective prior to use Hobart DOES NOT WARRANT THE FOLLOWING COMPONENTS Engines gasoline or diesel storage batteries engine starters generators alternators regulators governors tires axles transmissions and cable retrieving devices Many of the foregoing components are warranted direc
50. Generator Set GROUND POWER 18 19 20 21 22 23 24 Radiator Air cleaner Throttle control assembly Fuel filter Oil pressure sender Oil pressure switch Oil filter Generator Set Components Sheet 3 of 3 Figure 1 Dec 31 96 Chapter 2 4 Page 5 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER TAY __ B aN JET EX 4D 3 gt C YS eC 4 HOBART Vw ENGINE CIRCUIT 20 28 5 V OUTPUT ENGINE CONTACTOR A OO N Panel light 10 Tachometer 11 Hourmeter 12 Voltmeter Generator 13 Ammeter 14 Panel lights fuse 10 Amp 15 Panel lights switch 16 Contactor control switch 17 Contactor closed light 18 Current limit control Speed control switch Engine on light Engine start switch Engine circuit switch Engine circut fuse 20 Amp Water temperature gauge Oil pressure gauge Fuel gauge Control Panel Assembly front Figure 2 Chapter 2 4 Page 6 Dec 31 96 OM 2077 Operation and Maintenance Manual T Jet Ex 4D Spec 7003C Generator Set GROUND POWER 1 Overvoltage relay 2 Voltage regulator 3 Excitation rectifiers 4 Control windings fuses 10 Amp 5 Voltage build up fuse 10 Amp 6 Voltage regulator fuse 10 Amp 7 Spare fuse 10 Amp 8 Capacitor 100MFD 350 VDC C
51. HER LOCK IET 3 8 HEAT SINK RECTIFIER NEGATIVE SPACER SHROUD SHROUD AIR BOTTOM RECTIFIER WASHER LOCK 3 8 W 11278 5 5CW 1308 0 W 11242 6 W 11254 5 W 11278 6 NUT HEX 3 8 16 SCREW 5 16 18 X 1 1 4 WASHER FLAT 5 16 WASHER LOCK 5 16 NUT HEX 5 16 18 2 4 2 4 8 8 1 4 4 5 2 5 1 3 1 5 5 6 W 10931 3 W 11097 7 W 11242 10 W 11254 6 W 11278 5 RECTIFIER POS BASE V12293 134049 SCREW HHC 3 8 16 x 2 WASHER FLAT 3 8 WASHER LOCK 3 8 NUT 3 8 16 180065 W 11245 3 W 11254 2 W 11111 9 16DA 3493 SHUNT 2000 AMP WASHER FLAT 10 WASHER LOCK 8 SCREW RHM 8 32 x 1 4 WASHER INSULATING W 10933 3 RECTIFIER SILICON NEG BASE ND OD 31 96 Chapier 4 3 Page 17 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER H 5 gt E gt fe Contactor Componenis Figure 8 Chapter 4 3 Page 18 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE FIGURE amp HOBART AIRLINE ITEM NO PARTNO PART NO 1234567 EFF QTY No Number CONTACTOR COMPONENTS A 25 WASHER INSULATING 626 BUSHING INSULATING W 9218 227 CABLE OUTPUT NEGATIVE 400435 LABEL 28 VOLTS W 9218 251 CABLE OUTPUT POSITIVE 286810 1 CONTACTOR DC 800
52. Insufficient air to engine Check and service air cleaner for clogged condition Replace as required b Restricted exhaust system Check exhaust pipe for restrictions Check muffler for clogged condition Replace as required c Low compression Check compression in all cylinders according to Perkins Engine User s Manual October 28 96 Chapter 2 5 Page 3 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Engine and Controls continued Trouble Symptom and Condition Probable Cause Test Check and Remedy 8 Engine Overheats a Dirt or sludge in Coolant Drain coolant flush radiator put in clean coolant Refer to Perkins Engine User s Manual in Chapter 5 for instructions b Debris and dirt in radiator Clean radiator core carefully core Refer to Perkins Engine User s Manual c Fan belt slips or is broken Tighten belt or replace as required Chapter 2 5 October 28 96 Page 4 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set Generator and Controls Trouble Symptom and Condition Probable Cause 1 Generator will not build up a Voltage build up fuse voltage when speed control 2405 is blown switch 5406 2 4 11 Fig 2 is placed in RATED RPM position Defective excitation rectifier CR417 and or CR418 Defective capacitor C403 Defective flyback diode CR419 Generator revolving field
53. R This page intentionally left blank Unusual Service Conditions Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Wet Stacking in Generator Set 1 Diesel Engines All diesel engines operated for extended periods under light load may develop a condition commonly referred to as wet stacking This condition results from the accumulation of unburned fuel in the exhaust system It is recognizable by fuel oil wetness around the exhaust manifold pipes and muffler Liquid fuel in the form of droplets may be spewed from the exhaust outlet Wet stacking is common and may be expected in diesel engines operated under light load Light loads do not allow the engine to reach most efficient operating temperature for complete combustion of fuel The unburned fuel collects in the exhaust system to create the wet condition known as wet stacking To alleviate wet stacking in lightly loaded engines it is recommended that the machine be connected to a load bank after each 200 hours of use and operated under full rated load for one hour This will burn away and evaporate the accumulation of fuel in the exhaust system This clean out procedure should be considered as a regular maintenance operation for machines operated under light load The time schedule of 200 hours may be changed as required to suit each user s particular needs and operating conditions Dec 31 96 Wet Stacking
54. T COOLING LABEL HOT WATER amp STEAM D N H AH WO AH AS 76B 1148 406000 81B 1061 282658 401842 LABEL DIESEL FUEL LABEL ENGINE FUEL LABEL ELECTRIC SHOCK LABEL CLEARANCE TAG ATTENTION ENGINE COOLANT 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 O PO PD PO PO AH AH 40201 281991 SEALANT NEOPRENE RETAINER FUEL DRIP AY Not Illustrated a gi ui ui e Revised March 18 93 Chapter 4 3 Page 3 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER Canopy Assembly Figure 2 Chapter 4 3 Page 4 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER NOMENCLATURE AIRLINE PART NO FIGURE amp ITEM NO HOBART PART NO 1234567 286924 CANOPY ASSY 283734 282641 286816 402119 9 W 11254 4 PANEL TOP SSY PANEL TOP ASSY PANEL SIDE UPPER REAR SCREW 1 4 20 X 1 3 4 WASHER LOCK 1 4 W 11242 5 W 11280 2 282226 282225 WASHER FLAT 1 4 NUT HEX 1 4 20 DOOR CANOPY ASSY DOOR CANOPY ASSY o A a ADA A a 489270 488640 489167 282732 1 6FW 3430A 5 PANEL CENTER LEFT CANOPY BRACKET OUTPUT CABLE ASSY SUPPORT CONTROL PANEL LT ASSY LIGHTS CLEARANCE A C LIGHTS CLEARANCE B
55. TE If engine is overcharged with ether for cold weather starting it could seize up If so wait approx 1 2 hour until it will be possible to turn engine Replace engine circuit 15 Fig 2 Use type AGC 20 fuse Check and correct as required Check for 12 V DC from terminal 4 of S404 in START position If 12 V DC is not measured replace defective switch Attempt to start engine while applying 12 V DC to the fuel valve solenoid If the engine starts the solenoid is defective and should be replaced If engine still doesn t start proceed to Step e Check fuel pump according to instructions in the Perkins Diesel User s Manual Turn on fuel shutoff valve Connect a jumper wire across the C and No terminals of oil pressure switch Start engine and check oil pressure If it is below 10 PSI 69 kPa shut down the engine and check lubrication system for leaks Check also the oil pump If oil pressure comes up to normal and the engine continues to run the oil pressure switch is defective Replace oil pressure switch Place a clip lead jumper wire on the water temperature switch terminals and check for normal operating temperature If engine then starts properly replace water temperature switch If not replace engine switch Chapter 2 5 Page 2 October 28 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Engine and Controls continu
56. W 11254 6 4 45 W 11110 3 7 4 W 11254 6 4 55 W 11111 8 7 26 W 11263 6 7 44 W 11111 9 7 31 W 11278 5 4 32 W 11112 1 7 40 W 11278 5 2 11 W 11112 3 7 5 W 11278 5 7 10 W 11114 12 7 35 W 11278 6 4 18 W 11166 3 7 14 W 11280 15 4 W 11166 5 2 2 W 11280 2 4 36 W 11221 1 12 1 W 11280 3 7 38 W 11242 10 4 30 W 11287 2 7 19 W 11242 18 2 11 W 11287 4 2 2 W 11242 5 12 1 W 11337 1 7 16 W 11242 5 12 1 W 11563 7 33 W 11242 6 11B 4 W 7814 1 4 48 W 11245 15 10 15 W 7814 4 4 52 W 11245 15 8 3 W 9218 227 4 56 W 11245 15 8 5 W 9218 251 4 16 W 11245 2 98 4 W 9360 229 Chapter 4 4 Dec 31 96 Page 4 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Chapter 5 Manufacturer s Literature Section 1 Manufacturer s Listing Perkins Users Handbook for 4 236 Series Diesel Engines Perkins Engines Inc P O Box 697 32500 Van Born Wayne Michigan 48184 Hobart Diagrams Hobart Brothers Company Power Systems Division Troy Ohio 45373 282654 Connection and Schematic Diagram Jet Ex 4D Series 7003C Chapter 5 1 Dec 31 96 Page 1 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Dec 31 96 Chapter 5 1 Page 2 z y 5 9 n 2 8 6 0L L
57. W 3430A 5 14 488784 1 7003C 1 2 16 488799 1 7003C 2 13 2 489077 1 1 7003C 3 13 9 489086 1 20 76B 1148 9B 1 489114 1 11 78A 1000 10 6 489121 4 12 78A 1116 1 10 4 489122 4 11 78A 1117 1 13 10 489125 4 5 78A 1120 1 13 4 489135 9A 13 78B 1010 2 8 489167 9B 6 78B 1118 1 2 14 489168 10 14 78B 1119 1 15 4 489203 1 12 79A 1110 2 19 489220 1 5 79A 1127 2 2 13 489235 2 26 7J 422 0 2 6 489270 10 1 80A 1117 10 7 489533 1 22 81B 1061 10 5 489547 1 19 81B 1063 10 2 489639 1 8 81B 1064 10 2 489641 1 14 81B 1084 14 3 489658 010 4 14 82B 1047 2 17 489810 4 50 844 1075 13 1 491784 13 10 85C 1004 2 15 5 491799 7 20 A 25 9B 3 491799 8 1 A 25 11B 7 491889 5 7 22 AW 626 9A 10 492098 8 2 AW 626 4 3 4941 34 1 2 30 DWP 982 7 13 494681 1 4 58 W 10051 13 2 16 50MS 732 0 4 31 W 10051 14 Dec 31 96 Chapter 4 4 Page 3 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER FIG ITEM PART NUMBER FIG ITEM PART NUMBER 13 16 W 10072 063 4 28 W 11245 2 6 6 W 10750 3 2 11 W 11245 3 9B 7 W 10750 3 4 33 W 11245 3 10 9 W 10869 12 4 59 W 11245 3 11B 6 W 10869 14 7 42 W 11245 3 10 7 W 10869 2 4 29 W 11254 1 10 11 W 10869 3 4 57 W 11254 2 6 5 W 10869 5 7 43 W 11254 2 7 6 W 10869 6 2 11 W 11254 3 9B 8 W 10910 0 4 34 W 11254 3 7 36 W 10931 3 2 2 W 11254 4 7 46 W 10933 3 7 9 W 11254 4 7 23 W 11097 22 7 34 W 11254 5 7 24 W 11097 7 13 10 W 11254 5 7 37 W 11097 7 7 30 W 11254 6 4 42 W 11110 3 7 39
58. WYSHL 079 ONIGNIM 710541405 33141935 81759 51515975 3nd 39nvo9 430N3S 80v 3ALISOd QLPYO LLbYO 1 INnHS L0 3ALVO3N OLFYD SOPYD MOOL WHO OL 30151534 30019 0559 OL 133515 8313NOLLN310d SNIM2018 53144935 0739 1059 YOLVINDAY JOVIIOA SObd bOrd OSE OJW OOL HOlIOvdvO 0v2 A GL UJN 000 YOLIOVd YO LOTO 91519975 39nv9 80t MOLIVH3N39 W313WIAV LO ZL AMSLLVE LOTH MOLVH3N39 M313AL10A 90 531918 LOTH 34nss3Md 110 3ovno SO 34nivM3dW3l s31vM 39vn9 70 3313AOHOVL YILIN JAIL 34 SS3Hd WO M3ON3S H31I3AL10A Lov 3anlvs3dW3l YSLVM s30N3S QN3941 L Y S 9 L 8
59. ace packages of moisture absorbing chemicals such as silica gel in the unit before packaging CAUTION 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 e Disconnect battery cables e Drain all fuel from tank and fuel lines as required by carrier rules e Crate the unit solidly to prevent damage to instruments glass and sheet metal Dec 31 96 Chapter 1 2 Page 3 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Stationary Unit Mounting Holes Figure 2 4 Stationary Unit Mounting Figure 2 illustrates the mounting hole pattern in the base of the stationary Jet Ex 4D generator set Each of the eight holes is 11 16 17 5 mm in diameter Chapter 1 2 Dec 31 96 Page 4 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Section 3 Operation 1 General This section contains information and instructions for the safe and efficient operation of the generator set Operating instructions are presented in a step by step sequ
60. anufacturer s Cataloging Handbook H4 l and are arranged in numerical order Vendor codes are inserted in the nomenclature column of the parts list directly following the item name and description In case a manufacturer does not have a vendor code the name of the manufacturer will be listed in the nomenclature column Code Vendor s Name and Address 02231 Anchor Rubber Company 840 S Patterson Blvd Dayton Ohio 45402 04713 Motorola Inc Semiconductor Products Div Phoenix Arizona 85008 12293 Leubbe Sales Co 3832 Kettering Blvd Dayton OH 45439 13445 Cole Herse 20 Old Colony Ave Boston MA 02127 13446 Perkins Engines Inc 32500 Van Born Road Wayne MI 48184 16476 Datcon Instrument Co P O Box 128 East Petersburg PA 17520 44655 Ohmite Mfg Co 3601 W Howard St Skokie IL 60076 46992 Phoenix Electric 3625 N Halstead St Chicago IL 60613 5P059 Tech Products Corp 2348 Sandridge Dr Dayton OH 45439 71400 Bussman Division of McGraw Edison Company 114 Old State Rd St Louis Missouri 63178 74542 Hoyt Electrical Instruments P O BOX 8798 Penacook NH 03303 74559 Carling Switch Co 505 New Park Ave West Hartford CT 06110 78377 SCP Inc 9115 George Ave Cleveland OH 44105 78388 Synchro Start Products Inc 8109 N Lawndale Ave P O Box 147 Skokie IL 60076 9990 88136 Trombetta Corp 1633 E North Ave Milwaukee WI 53202 92489 Attwood Corp 1016 Monroe Ave Lowell MI 49331 94177 Modine Mfg Co 1500 Dekoven
61. art Starter will NOT crank engine If the starter WILL crank the engine then obviously this is not your symptom and condition Go the next trouble and symptom directly below If the starter will NOT crank the engine look to the right under PROBABLE CAUSE and TEST CHECK AND REMEDY and find the various things which could cause the trouble and what to do to check and remedy them 3 Equipment for Troubleshooting A good quality multi scale voltmeter is the only instrument required similar clips will be required The 12 volt engine electrical system may be used for a 12 volt DC power source 4 Safety Precautions WARNING Loose garments neckties and other hanging items must not be worn by personnel near the fan or other exposed moving parts of this equipment while it is running Also avoid contact with live electrical parts death or serious injury could result 5 Diagrams A schematic connection diagram of the generator set is provided in Chapter 5 This diagram can be very helpful in troubleshooting Components shown in the diagram are identified by reference designators or item names in some instances A legend appearing on the diagram identifies each reference designator by its full item name For example the symbol K403 identifies the overvoltage relay and M406 identifies the voltmeter 6 Illustrations To aid maintenance personnel with troubleshooting three illustrations are provided in this section showing
62. at as these screws are tightened the armature will be pulled back into the bearing hub b Repeat step a above until 3 8 16 screws can no longer be tightened 14 Make certain that the armature is pulled slightly into the bearing hub so that it does not interfere with the bearing cap 15 Using a 3 16 inch Allen wrench tighten the set screw in the bushing to apply pressure on the key 16 Re install the bearing cap that was removed in step 8 17 Re install the generator housing cover and the flywheel housing cover 18 Re install the fuel tank and canopy components Fan amp Coupling Assembly Flexible Coupling Disks Pa Su Coupling P d 3 8 24X1 Split Taper 8 required 4 Split Bushing Mounting Bolt 3 8 18 X 3 4 3required Armature Shaft Assembly Procedure Illustration Figure 4 Chapter 3 1 Dec 31 96 Page 6 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set 6 Run in and Periodic Check a Mount the engine generator assembly in a suitable test area and operate it for a 2 hour run in b Shut down the engine after 2 hours and re torque all coupling screws to 40 45 foot pounds 54 67 Nm to compensate for normal torque relaxation c Return the unit to normal service d After 200 hours of operation check all coupling screws and taper lock bolts with a torque wrench set at 40 45 foot pounds 54 61 Nm e Return the unit to nor
63. at this time 8 Remove the bearing cap from the back of the generator assembly 9 Slide the armature rearward so that it extends approximately 1 8 inch out the back of the bearing housing It may be necessary to use a bearing puller to break the bearing loose from the hub 10 Slide the coupling bushing forward until it is snug in the coupling hub CAUTION Make certain that only the screws are lubricated and that no lubricant is permitted to get inside the bushing where the armature shaft will enter the bushing 11 Lubricate the three 3 8 16 X 3 4 screws SPARINGLY and start them into the three unthreaded holes finger tight See Figure 4 Dec 31 96 Chapter 3 1 Page 5 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set 12 Refer to Figure 2 Insert and hold a short iron bar through the flywheel housing against the fan blades of the fan and coupling assembly to block the armature against clockwise rotation Do this carefully to avoid damaging the fan blades 13 Tighten the 3 8 16 X 3 4 screws alternately and evenly as follows a Set a torque wrench to 30 foot pounds 41 N m and tighten all three 3 8 16 screws to that value As illustrated in Figure 2 insert and hold a short iron bar through the fan housing against the fan blades of the fan and coupling assembly to block the coupling against clockwise rotation Do this carefully to avoid damaging the fan blades Note th
64. ble exhaust duct or outdoors Never locate engine exhausts near intake ducts of air conditioners Safety Warnings Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual e Jet Ex 4D Spec 7003C Generator Set GROUND POWER 6 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 7 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 ELECTRICAL SHOCK turn off power Remove victim if not breathing begin artificial respiration preferably mouth to mouth If detectable pulse begin external heart massage CALL EMERGENCY RESCUE SQUAD IMMEDIATELY 8 Equipment Precautionary Labels Inspect all precautionary labels on the equipment monthly Order and inspect all labe
65. compressed air not over 25 psi 172 kPa 4 Make sure that no loose bars tools parts etc are in or on any part of the engine as they could cause serious damage to the engine generator or personal injury to anyone standing nearby 5 If the unit is operated indoors make sure that an exhaust line is properly connected to the engine exhaust system and discharged out of doors Avoid short bends or reduction in line sizes in exhaust pipes Locate the unit so as to necessitate the shortest possible exhaust line to insure the least amount of back pressure on the engine Back pressure can cause engine damage and loss of power 6 Check the electrical system to make sure the connections are secure and properly connected Check the battery electrolyte level 7 Check air cleaner service indicator and replace air cleaner element if indicator window is red Dec 31 96 Chapter 1 3 Page 1 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set E RON POWER GENERATOR G Panel Light 11 Speed Control Switch Tachometer 12 Engine On Light Hour meter 13 Engine Start Switch Voltmeter Generator 14 Engine Circuit Switch Ammeter 15 Engine Circuit Fuse Panel Lights Fuse 16 Water Temperature Gauge Panel Lights Switch 17 Oil Pressure Gauge Contactor Control Switch 18 Fuel Gauge Contactor Closed Light 19 Voltmeter Engi
66. d item number location of the part is directly opposite the part If the part is used in more than one place each location is listed commencing with the first location the part is listed FIG ITEM PART NUMBER FIG ITEM PART NUMBER 12 1 12CW 2146 12 282220 4 21 16DA 2162 3B 8 282220 7 45 16DA 3493 2 5 282225 2 27 180015 2 4 282226 7 41 180065 7 27 282239 4 47 180289 11 1 282257 15 2 180543 11 1 282299 4 62 180593 3 6 1 282388 7 28 180600 1 6 282554 1 13 5 180776 11 2 282562 4 37 180913 1 6 3 282569 4 20 180913 2 6 8 282570 4 51 181022 1 6 4 282571 9A 7 181098 4 1 282632 9A 8 181099 4 282633 9A 9 181100 4 282633 2 28 181161 1 3 282633 13 10 181166 4 8 282639 1 7 181263 2 1 282641 3B 9 281333 1 23 282658 10 6 281423 1 11A 3 282699 13 13 281688 11B 282717 10 1 281874 2 9 282732 1 5 1 281881 1 11B 5 282734 1 26 281991 5 4 282784 2 23 282005 7 18 283063 15 1 282006 1 13 283533 15 6 282008 2 31 283621 12 1 282217 2 1 283734 12 1 282218 2 10 283752 12 1 282219 4 63 283754 Dec 31 96 Chapter 4 4 Page 1 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER FIG ITEM PART NUMBER FIG ITEM PART NUMBER 1 10 283887 4 41 400642 3 11A 1 284203 4 61 400828 1 13 15 284507 4 22 401428 1 13 284575 1 24 401842 7 29 285647 4 15 401937 4 9A 12 285795 1 25 40201 4 7 286699 1 13 14 402037 34 3A 4 286810 1 7 7 402037 4 8 6 286810 1 2 16 402119 2 4 65 286811 7 15 4
67. e User s Manual for recommended viscosity for various atmospheric temperatures In cold weather drain oil more frequently Water condenses and collects quickly mixes with the oil and increases deposits to form a sludge Check oil frequently for this condition Water in crankcase or oil lines may freeze and cause serious damage to the oil pump or shut off the oil supply 6 Electrical system In cold weather the most efficient electrical system is needed to start the cold engine Check the entire system for loose connections or indication of bad wiring or shorted conditions 7 Battery Battery efficiency decreases sharply with lower temperatures Maintain the specific gravity of the battery between 1 275 and 1 300 fully charged condition Make sure of full charge before attempting to start engine in sub zero conditions h Operation in Hot and Humid Conditions 1 Cooling system Maintain a more frequent check of the coolant level in the radiator 2 Battery The specific gravity and proper level of the battery electrolyte should be maintained Observe recommendations in the Perkins Diesel User s Manual for proper care of the battery i Operation in Extremely Dusty Conditions If unit is to be operated under dusty out of door conditions place in a sheltered area Take advantage of any natural barriers which may offer protection from blowing dust If the installation is more than temporary erect a protection shield 1 Fuel system
68. ease Automotive Military MIL G 10924B Wheel bearings Lubricants Figure 2 Time Interval 10 hours or Daily 100 hours or Biweekly 200 hours or Monthly 400 hours or Bimonthly 800 hours or Semiannually Symbols and Time Intervals Figure 4 3 Change lubrication engine oil 200 hours Oil should be changed after each 200 hours of engine operation The generator set is equipped with an hourmeter which records actual engine operating time The ideal time to change oil is soon after a power delivery run when the engine is at operating temperature NOTE If lubricating oil is drained immediately after the unit has been run for some time most of the sediment will be in suspension and oil will drain readily without clinging to internal surfaces CAUTION _ DO NOT use solvents as flushing oils in running engines NOTE Change the oil filter each time the oil is changed 4 Change oil as follows a Provide a container for catching used oil Capacity should be greater than 2 gallons b Remove drain plug located in oil pan Allow sufficient time for oil to drain from valve train timing gear case etc before reinstalling plug c Change oil filter while oil is draining 5 Change oil filter as follows a Place a container under the oil filter to catch oil drippings b Loosen filter with a special oil filter removal wrench Several types are available Discard oil filter C Coat the gasket on t
69. eatures The following is a list of options available for Spec 7003C This chart contains the description part number and document number of the option There is also a column to identify which option is contained in this Appendix OPTIONS FEATURES AVAILABLE DESCRIPTION PART NUMBER DOCUMEN IN THIS NUMBER SECTION Trailer with Fenders amp Cable Trays 181000 1 TO 181 Trailer with Cable Hangers 181000 2 TO 181 Spacers Stationary Mounting 489689 Kit 14 V Output with Fenders amp Cable Trays 286990 1 Kit 14 V Output with Cable Hangers 286990 2 120 V AC Generator Package Trailer mounted units 181735 TO 194 with Fenders Kit Water Heater 180630 TO 179 Kit Glow Plug 181259 TO 188 Kit Fork Lift 181391 TO 243 Shield Rain Muffler 181179 TO 244 Kit Fuel Water Separator Racor 285795 TO 245 Kit Insulation Noise 282427 Kit Start Ether 489782A TO 211 Crate Shipping Export 489848 Dec 31 96 Appendix A Page 1 OM 2077 Operation and Maintenance Manual 9 Jet Ex 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Appendix A Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual 5 Jet Ex 4D Spec 7003C Generator Set GROUND POWER Unusual Service Conditions This information is a general guideline and cannot cover all possible conditions of equipment use The specific local environments ma
70. ed Trouble Symptom and Condition Probable Cause Test Check and Remedy Engine starts then stops when b Choked fuel filter restriction Check for these faults according engine switch S404 is in air cleaner or air in fuel to instructions in Perkins Diesel released to ON position System User s Manual continued Engine does not attain normal Idle speed set either too Adjust idle speed to idle RPM or idles too fast high or too low approximately 1000 50 RPM Loose throttle linkage If solenoid core is pulled into the full throttle solenoid L403 when S406 is in RATED RPM position check for loose control rod between solenoid and throttle Tighten if required If solenoid core does not pull in proceed to Step c Defective full throttle Check for I2 V DC across two solenoid L403 terminals of solenoid when 5406 is in RATED RPM position If I2 V DC is measured but solenoid core does not pull in replace the solenoid Engine will not run at rated Speed control switch If engine will not go from idle to speed 2000 RPM S406 defective rated speed when speed control switch 17 Fig 2 is in RATED RPM position turn off engine and take resistance measurements at speed control switch terminals with switch in the RATED RPM position Zero resistance should be measured between terminals having red blue and orange yellow wires Replace speed control switch if measurement is improper Engine lacks power a
71. ed block or cylinder head a Rust Inhibitor Use only a corrosion inhibitor that is compatible with aluminum Do not use inhibitors labeled as acid neutralizer b Antifreeze A permanent type Ethylene Glycol antifreeze is recommended for use in the cooling system The coolant when mixed as equal parts of water and the recommended antifreeze will provide protection to 35 degrees F 7 Battery Service a General A 12 volt battery supplies power for operation of the engine electrical system clearance and panel lights and for flashing the generator The battery supplied with a new unit is a maintenance free type Some of the following topics apply to non maintenance free type battery which requires additional maintenance such as checking liquid levels b Battery Location and Accessibility The battery is located on the fuel tank support on the right side of the unit The battery is easily accessible for service by removing two 1 4 inch screws and removing the right rear side panel c Battery Care 1 Never allow a battery which has been removed from a unit to sit on concrete ground or metal unless proper insulation is provided A wooden platform or board will provide sufficient insulation 2 Maintain stored batteries in a charged condition 3 Be sure battery is fastened securely in their compartment to avoid damage from vibration 4 Maintain battery fluid at proper level 5 Keep battery terminal post
72. ence 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 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
73. ent operation or dusty conditions However time intervals should not exceed those indicated in the chart without careful evaluation The use of quality lubricating oil combined with proper oil drain and filter change intervals are important factors in extending engine life 2 Oil Specification Lubricating oils must be equal to the U S Ordnance specification MIL L 46152 or MIL L 2104C See Perkins engine user s handbook for recommended oil viscosity Dec 31 96 Chapter 2 2 Page 1 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER Draw Bar BM 1 Pivot Pin BM 1 Tie Rod BM 1 Tie Rod BM 1 poe Tie Rod BM 1 King Pin BM 1 aM dx p Pin BM 1 Wheel Bearing SA 3 c li Wheel Bearings SA 3 Lube Oil Filter M Fuel Filter SA Crankcase D2 Fuel Filter SA Wheel Bearing SA 3 Whee Bearings SA 3 PSD 1140 Check crankcase oil daily change 200 hours Change oil filter after 200 hours Lubrication Chart Figure 1 Chapter 2 2 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual a Jet Ex 4D Spec 7003C Generator Set GROUND POWER Name Specification Notes Grease Automotive and Federal VV G 632 Sinclair LItholene Industrial Industrial No 2 Mobile Mobilplex 47 or equivalent Oil Engine Heavy Duty MIL L 46152 or See Perkins Engine User s MIL L 2104C Handbook for recommended oil viscosity Gr
74. eration and maintenance personnel if poor performance or total functional failure is to be avoided Consult Maintenance and Operator s Manual and recommendations below Dec 31 96 Chapter 1 3 Page 3 OM 2077 Operation and Maintenance Manual E Jet Ex 4D Spec 7003C Generator Set EINEN POWER 2 Fuel system Keep system clean and free from water which may collect in a low spot in the fuel line and freeze plugging the line Fuel tanks should be kept FULL to prevent water condensation from the air above the fuel 3 Fuel Keep fuel storage tanks or drums as full as possible to avoid condensation of moisture from the air above the fuel After filling or moving fuel containers allow fuel to settle before using Never draw fuel from the extreme bottom of the container Strain all fuel to remove any foreign matter When operating outdoors take steps to prevent the entry of snow water and ice into the fuel containers 4 Cooling system Prior to cold weather drain and flush the cooling system to remove accumulations of rust and sediment Mix and add antifreeze solution check the cooling system connections for leaks Add a can of rust inhibitor to the radiator when system is winterized This will keep system cleaner and furnish lubrication for the water pump 5 Lubrication Drain the crankcase preferably when warm after running and fill with a lighter grade of oil See Engine Oil Recommendations chart in the Perkins Engin
75. he NOMENCLATURE column 3 NOMENCLATURE Column The item identifying name appears in this column The indenture method is used to indicate item relationship Thus components of an assembly are listed directly below the assembly and indented one space Vendor codes and part numbers for purchased parts are shown in this column Hobart modification to vendor items is also noted in this column 4 EFF Effective Column This column is used to indicate the applicability of parts to different models of equipment men more than one model of equipment is covered by a parts list there are some parts which are used on only one model This column is used for insertion of a code letter A B etc to indicate these parts and to identify the particular model they are used on 5 UNITS PER ASSEMBLY Column This column indicates the quantity of parts required for an assembly or subassembly in which the part appears This column does not necessarily reflect the total used in the complete end item Chapter 4 1 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual a Jet Ex 4D Spec 7003C Generator Set GROUND POWER Section 2 Manufacturer s Codes 1 Explanation of Manufacturer s Vendor Code List The following list is a compilation of vendor codes with names and addres ses for suppliers of purchased parts listed in this publication The codes are in accordance with the Federal Supply Codes for M
76. he bushing 1 is loose in the hub use a mallet to GENTLY tap the bushing out of the hub 5 Slide the coupling assembly off the shaft and remove the key 5 6 Using a 9 16 inch socket wrench remove the screws which attach the flexible disks to the hub 7 Inspect the coupling assembly components carefully as follows a Check for deformed fan blades and damage to the disk b Check hub and split bushing for cracks evidence of galling and rust pits Light rust is permissible on the split bushing and the tapered bore of the hub c Check the flexible coupling disks for warping cracks or worn mounting holes d Check the screws which attach the flexible disks to the hub The screws are Hobart Part No 181153 which are hex head self locking 3 8 16 X 3 4 inch long If they are cracked stretched have stripped threads or the nylon pellet imbedded in the threads is worn or damaged replace them NOTE Use of the proper coupling screws and washers for replacement is very important Replacement screws and washers MUST be those specified above torqued to 40 45 foot pounds 54 61 Nm There is NO ACCEPTABLE SUBSTITUTE for these screws or washers e Check the shaft for any damage or deformation where the coupling was mounted on it Dec 31 96 Chapter 3 1 Page 3 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set Bushing Split Mounting Holes 3 Tapped holes 2
77. he coupling to fail and damage the generator set Slight traces of rust are permissible only on the bushing but nothing else b Assembly Figure 4 CAUTION Use of the proper coupling screws is very important Failure to use the proper screws as outlined below can result in coupling failure and damage to the generator set Proceed as follows to reassemble engine and generator 1 Using a 9 16 inch socket wrench attach the four flexible disks to the coupling hub with the six hex head 3 8 16 X 3 4 inch screws Hobart Part No 181153 The screws must be torqued to 40 45 foot pounds 54 67 Nm 2 Attach the coupling assembly to the flywheel using the socket head 3 8 24 X 1 inch screws Hobart Part No 181166 DO NOT tighten with a wrench See Figure 4 3 Torque all of the coupling screws to 40 50 foot pounds 54 68 Nm Be sure the flexible disks are all seated evenly into the seat of the flywheel 4 Install the key in the keyway of the armature shaft 5 Place the coupling bushing on the shaft of the armature aligning the keyway of the bushing with the keyway of the shaft 6 Using a hoist align the bushing to the coupling keyway and also the generator housing flange to the engine flywheel housing and insert the attaching screws for the housing Start the screws into the tapped holes just enough to ensure thread engagement DO NOT TIGHTEN 7 Tighten the generator housing attaching screws
78. he new filter with oil Dec 31 96 Chapter 2 2 Page 3 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER d Place the new filter in position on the cylinder block and spin on until the gasket contacts the adapter face then hand tighten another 1 2 turn Do not over tighten e Clean drain plug and reinstall DO NOT over tighten f Remove filler cap on valve cover and refill crankcase with new clean oil of proper specification and viscosity see Para 2 E 2 and Figure 2 Seven quarts are required when oil filter is changed g Start engine and allow it to idle Oil pressure should come up to normal quickly Check for oil leaks at filter and drain plug h Stop engine Allow several minutes for oil to drain to crankcase then check oil level It should be at FULL mark on dipstick i Check hourmeter and record time of oil change 3 Servicing the Air Cleaner The air cleaner is a dry type with flow cartridge A definite time schedule for changing the filter cartridge cannot be determined because of varying operating conditions therefore an air restriction indicator is mounted on the intake manifold Change the filter when the red indicator flag becomes fully visible in the viewing chamber and locks in that position a Cartridge Removal 1 Open left front canopy door to gain access to the air cleaner 2 Loosen the clamps which secure the air cleaner to the bracket
79. igure 3 provide illumination for instruments and controls One green pilot light 9 glows when the output load contactor is closed and another one 12 glows green when the engine is running 3 Monitoring instruments The voltmeter 4 Figure 3 indicates generator output voltage and the ammeter 5 displays generator current A tachometer 2 displays the engine speed in RPM This instrument receives its operating signal from the alternator A water temperature gauge 16 indicates the engine coolant temperature and is actuated by a temperature sender 17 Figure 2 mounted on the engine s water jacket An oil pressure gauge 17 Figure 3 displays the pressure in the engine s lubrication system It is operated by a sender 22 Figure 2 mounted on the engine block The battery voltmeter 19 Figure 3 indicates the battery voltage of the engine s 12 volt DC electrical system The hourmeter 13 records the total hours of engine operation for scheduling maintenance The fuel gauge 18 indicates the amount of fuel remaining in the fuel tank Chapter 1 1 Revised Page 8 Mar 18 93 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER HOBART JET EX 4D Panel light Tachometer Hourmeter Voltmeter Generator Ammeter Panel lights fuse 10 Amp Panel lights switch Contactor control switch Con
80. iod of ninety 90 days whichever is greater UNDER NO CIRCUMSTANCES whatsoever shall HOBART and its authorized distributors be liable for any special or consequential damages whether based on lost goodwill lost resale profits work stoppage impairment of other goods or otherwise and whether arising out of breach of any express or implied warranty breach of contract negligence or otherwise except only in the case of personal injury as may be required by applicable law Continued use of the PRODUCT S after discovery of a defect VOIDS ALL WARRANTIES Except as authorized in writing this warranty does not cover any equipment that has been altered by any party other than HOBART THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE OF HOBART MAKES NO WARRANTIES EXPRESSED OR IMPLIED OF ERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE HOBART neither assumes nor authorizes any person to assume for HOBART any liability in connection with the PRODUCTS sold and there are no oral agreements or warranties collateral to or affecting this written Warranty This warranty and all undertakings of HOBART thereunder shall be governed by the laws of the State of Ohio United States of America WARNING AT ALL TIMES SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE INSTALLATION SERVICING AND OPERATION OF THE PRODUCT AND SKILLED TECHNICALLY QUALIFIED PERSONNEL SHOULD ALWAYS BE EMPLOYED FOR SUCH TASKS OM 2077
81. ion them and securely refasten Check engine oil and coolant levels Every month check generator for amperage and voltage output Blow out generator windings with compressed air not over 25 psi 172 kPa pressure or remove with a suction type cleaner with non metalic nozzle If windings should become slightly damp use space heaters or electrical light bulbs to effectively dry out the windings If dampness is excessive apply external heat under a canvas cover well vented Heating should not exceed 194 F 90 C Pound out any dents in the canopy Sand prime and repaint any dented or rusted spots Dec 31 96 Chapter 2 1 Page 3 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Chapter 2 1 Dec 31 96 Page 4 OM 2077 Operation and Maintenance Manual a Jet Ex 4D Spec 7003C Generator Set GROUND POWER Section 2 Maintenance Procedures 1 General A suggested Maintenance Schedule is provided in Section 1 of this Chapter Each step of the schedule is also covered in general in Section 1 This Section covers maintenance in more detail where necessary WARNING Stop operation immediately if a serious or possibly dangerous fault is discovered 2 Lubrication a General Proper lubrication is one of the most important steps in good maintenance procedure Proper lubrication means the use of correct lubricants and adherence to a p
82. its assembled state or it is similar right hand left hand top etc to an item which is illustrated Dec 31 96 Chapter 4 3 Page 1 OM 2077 Operation and Maintenance Manual Jet EX 4D Spec 7003C Generator Set GROUND POWER Generator Set Assembly Figure 1 Chapter 4 3 Page 2 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set FIGURE amp HOBART ITEM NO AIRLINE PART NO 7003C 1 PART NO GROUND POWER NOMENCLATURE 1234567 GENERATOR SET ASSEMBLY 7003C 2 GENERATOR SET ASSEMBLY WITH SPECIAL MODS FOR ISRAEL 7003C 3 GENERATOR SET ASSEMBLY WITH SPECIAL MODS FOR FED EXPRESS mk 1 286924 No Number 282633 No Number CANOPY ASSY See Fig 2 GENERATOR SET INTERIOR COMPONENTS ENGINE MODULE AY See Fig 3 PANEL CONTROL ASSY See Fig 4 YOKE AND FRAME ASSY See Fig 15 co 0 GK 79A 1127 2 282554 1 181263 81B 1064 400435 GUARD FILLER NECK KIT REFLECTOR LABEL OPERATING INSTRUCTIONS LABEL ENGINE DRIVE LABEL NAMEPLATE 28V 283887 78A 1000 79A 1110 283533 81B 1084 NAMEPLATE HOBART NAMEPLATE ID NAMEPLATE OPTION LABEL SUPPORT CENTERS LABEL 28 VOLTS 351541 406001 405309 407366 81B 1063 LABEL CAUTION FAN LABEL DANGER MOVING PARTS LABEL LUBE OIL FILTER LABEL CAUTION INSUFFICIEN
83. ls that cannot be easily read Dec 31 96 Safety Warnings Page 3 OM 2077 Operation and Maintenance Manual e Jet Ex 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Safety Warnings Dec 31 96 Page 4 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 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 Most information in the manual applies to the 28 5 V Jet Ex 4D in general Information which applies to options and special equipment is identified as such 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 Each Chapter is divided into a
84. lts Clean and inspect exterior of radiator Check exhuast system Check cooling system X Check and adjust idle speed X Check and refill cooling system Twice yearly summer and winter Replace fuel filter Drain Daily Clean engine Electircal System 12V DC Check lights Check charging rate Check battery water level Check battery state of charge Check wiring and connections Check all instruments and gages Check battery terminals and connectors Electrical system 28 5V DC Check indicating light Check operation of all instruments meters etc Check generator brushes for length cleanliness and free operation Check slip rings for smoothness and clealiness Check the entire unit Check overvoltage protection Check all wiring connections Trailer Option Lubricate See Lubrication Chart Check tire inflation Check and adjust wheel bearings Lubricate wheel bearings Check brake tension Inspection Check Maintenance Schedule Figure 1 Chapter 2 1 Page 2 Dec 31 96 OM 2077 Operation and Maintenance Manual Jet Ex 4d Spec 7003C Generator Set GROUND POWER Every week wipe off accumulated dust dirt and oil from the engine and generator Check all parts for loose connections and wear If arcing has occurred at any electrical connections recondit
85. mal service f After each additional 2 000 hours of operation or every year recheck all coupling screws to maintain the same torque value Dec 31 96 Chapter 3 1 Page 7 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set ee eee This page intentionally left blank Chapter 3 1 Dec 31 96 Page 8 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Chapter 4 Illustrated Parts List Section 1 Introduction 1 General The illustrated Parts List identifies describes and illustrates main assemblies sub assemblies and detail parts of the Jet Ex 4D Generator Sets manufactured by Hobart Brothers Company Power Systems Division Troy Ohio 45373 2 Purpose The purpose of this list is to provide parts identification and descriptive information to maintenance and provisioning personnel for use in provisioning requisitioning purchasing storing and issuing of spare parts 3 Arrangement CHAPTER 4 is arranged as follows Section 1 Introduction Section 2 Manufacturer s Codes Section 3 Parts List Section 4 Numerical Index 4 Explanation of Parts List a Contents The parts list contains a breakdown of the equipment into groups assemblies subassemblies and detail parts All parts of the equipment are listed except 1 Standard hardware items attaching parts such as nuts screws washers etc which are available co
86. mbly of Engine Generator 5 Cleaning cee 5 Assembly sein dele de eee ee e Ere el et 5 Run In and Periodic Check 7 Chapter 4 Illustrated Parts List Section 1 Introduction 1 General 1 Purpose 1 Arrangement 1 Dec 31 96 Table of Contents Page xiii OM 2077 Operation and Maintenance Manual 40 Spec 7003 Generator Set GROUND POWER Explanation of Parts List 1 Contents Parts List Form Section 2 Manufacturer s Codes Explanation of Manufacturer s Vendor Code List ok Section 3 Parts List Explanation of Parts List Arrangement Symbols and Abbreviations m Section 4 Numerical Parts List Explanation of Numerical Parts List Chapter 5 Manufacturer s Literature gt Appendix A Options Features Table of Contents Dec 31 96 Page xiv OM 2077 Operation and Maintenance Manual ia Jet Ex 4D Spec 7003C Generator Set GROUND POWER Chapter 1 Description Operation Section 1 Description 1 General The Jet Ex 4D units covered in this manual Figure 1 are diesel engine driven self contained generator sets manufactured by Hobart Brothers Company Ground Power Division Troy Ohio U S A A basic unit is identified by a Series Number 7003C plus a dash number which defines a specific configuration The Series number plus the dash number make up the Specification Number Specification No 7003C 1 covers a sta
87. mmercially 2 Bulk items such as wire cable sleeving tubing etc which are also commercially available 3 Permanently attached parts which lose their identity by being welded soldered riveted etc to other parts weldments or assemblies b Parts List Form This form is divided into six columns Beginning at the left side of the form and proceeding to the right columns are identified as follows 1 FIGURE ITEM NO Column This column lists the figure number of the illustration applicable to a particular parts list and also identifies each part in the list by an item number These item numbers also appear on the illustration Each item number on an illustration is connected to the part to which it pertains by a leader line Thus the figure and item numbering system ties the parts list to the illustrations and vice versa The figure and index numbers are also used in the numerical index to assist the user in finding the illustration of a part when the part number is known Dec 31 96 Chapter 4 1 Page 1 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set BOONE POWER 2 HOBART PART NUMBER Column ALL part numbers appearing in this column are Hobart numbers In all instances where the part is a purchased item the vendor s identifying five digit code and his part number will appear in the Nomenclature column Parts manufactured by Hobart reflect no vendor code or part number in t
88. n 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 slip ring end by a single row ball bearing The drive end is connected to the engine fly wheel by a flexible disc and hub coupling assembly and is supported by the engine main bearings A radial blade fan of formed and welded sheet metal construction is mounted on the coupling hub and draws cooling air over the generator windings Air flows over the rectifier assembly 4 and then 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 Front Figure 3 1 General The hinged control panel 8 Figure 2 houses and provides mounting facilities for controls monitoring instruments voltage regulator relays etc The panel is mounted at the rear of the canopy Its control are accessible behind a hinged Lexan cover 2 Lights Two panel lights 1 F
89. n 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 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 Dec 31 96 Safety Warnings Page 1 OM 2077 Operation and Maintenance Manual e Jet Ex 4D Spec 7003C Generator Set
90. nal If the starter attempts to crank the engine the starter solenoid is defective Replace it If engine still won t crank proceed to Step d If starter did not attempt to operate in Step C above the starter is defective Replace starter If starter did attempt to operate but couldn t turn engine proceed to Step e CAUTION Make certain that engine start switch is in stop position so that engine does not start Use a socket wrench on the front crankshaft pulley to try to turn engine by hand If engine will not turn internal damage is indicated October 28 96 Chapter 2 5 Page 1 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set Engine and Controls continued Trouble Symptom and Condition Probable Cause Engine will not start Starter will not crank engine continued Engine will not start Starter Engine circuit fuse F402 DOES crank engine blown or Fuel valve at tank closed or no fuel in tank engine has lost its prime or Defective engine start switch S404 or Defective fuel valve solenoid L404 Defective fuel pump Engine starts then stops Fuel not turned on Defective oil pressure switch S403 located on engine block Engine starts then stops when a Open overtemperature engine switch S404 is Switch S402 or defective released to ON position engine switch S404 GROUND POWER Test Check and Remedy NO
91. nd power unit is VERY DIFFICULT because of the limited working space During removal DO NOT cut any cables or wires Disconnect cables or wires if as necessary and tag them for reassembly a Separate Engine and Generator 1 Remove fuel tank and canopy components 2 Remove the sheet metal cover from around the generator housing and the flywheel housing 3 Attach a hoist to the generator housing 4 Use long handled reversible ratchet drive fitted with a 5 16 inch Allen wrench to remove the screws which attach the flexible coupling disk to the engine flywheel 5 Support the rear of the engine with a jack stand 6 Remove the bolts and shock mounts attaching the generator housing to the frame 7 Remove the bolts attaching the generator housing to the engine flywheel housing 8 Separate the generator from the engine with the hoist and move it to a clear working area b Remove Coupling Assembly Figure 3 1 Using a socket wrench remove all three of the 3 8 16 X 3 4 inch screws 3 that secure the bushing 1 to the hub of the fan and coupling assembly 2 To separate the bushing from the hub lubricate two of the 3 8 16 X 3 4 inch screws and insert them into the threaded holes 4 in the bushing With socket wrench screw these screws into the bushing such that the bushing pops loose from the hub 3 Using a 3 16 inch Allen wrench loosen the set screw 6 in the bushing to release pressure on the key 5 4 When t
92. ne 0 Current Limit Control Operating Controls and Indicators Figure 1 c Starting The Engine Figure 1 Make sure that all Prestarting Instructions have been carried out and reference to Initial Preparation For Use has been checked for operating details 1 Check engine oil fuel and coolant levels 2 Place speed control switch 77 in IDLE down position Chapter 1 3 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER CAUTION If the engine stalls or falters in starting wait three or four seconds before re engaging starter This will prevent possible damage to starter or the engine DO NOT Operate the starter for periods longer than 15 seconds at a time An interval of at least two minutes should be allowed between cranking periods to protect the starter from overheating 3 Hold engine START RUN STOP switch 14 in START position 4 Press and hold ENGINE START push button 13 Release as soon as engine starts 5 Release engine START RUN STOP switch 14 to RUN position when oil pressure builds up 6 Observe engine RPM on the tachometer and observe engine for excessive vibration Idle speed should be 1000 RPM 50 RPM If there is excessive vibration adjust engine idle speed gradually increasing or decreasing it whichever is necessary until vibration is reduced For idle speed adjustment procedure refer to Section 2 3 Para 2 b 4
93. o 1 285 The specific gravity of a fully discharged battery may range from 1 140 down to 1 120 NOTE The battery is fully charged when all cells are gassing freely and the specific gravity ceases to rise for three successive readings taken at hourly intervals b If the battery starter test indicated that battery voltage was below the acceptable voltage value test each cell with the hydrometer If the difference in specific gravity readings between any two cells is 50 points 0 050 or more the battery isn t satisfactory for service and should be replaced Chapter 2 2 Dec 31 96 Page 6 OM 2077 Operation and Maintenance Manual a Jet Ex 4D Spec 7003C Generator Set 8 Generator Maintenance a General GROUND POWER The only maintenance service required for the generator will be brush replacement slip ring cleaning etc b Brush Service If inspection reveals that brushes are gummy or sticking in the brusholders they should be removed and cleaned Clean both the brushes and brusholders Use a good SAFE commercial cleaner DRY ALL PARTS THOROUGHLY Be sure brushes can move freely in brusholders WARNING DO NOT use a flammable solvent DO NOT use steam cleaner or soaps and detergents under pressure c Generator Revolving Field Brush Replacement 1 Disconnect leads A Fig 5 from connectors on brusholder caps B 2 Lift brush D from brushholder C for inspection If brushes are worn unevenly or
94. odule is adjusted to trip at 32 to 34 volts DC in 5 seconds or less 3 Excitation rectifiers Two diode bridge rectifiers CR417 and CR418 3 Fig 4 convert an AC voltage from the generator armature to the DC voltage needed for the generator revolving field 4 Fuses Six cartridge type fuses are located below the voltage regulator All of them are rated at 10 amperes They include the control windings fuses 4 the voltage build up fuse 5 the voltage regulator fuse 6 and a spare fuse 7 f Contactor The load contactor which is mounted on the right side of the unit below the fuel tank provides a safe and convenient means of connecting and disconnecting the generator from the load Initial power for closing the load contactor is supplied by the generator through the spring loaded momentary contacts of the contactor control switch 8 Figure 3 Holding power to keep the contactor closed passes through the normally open auxiliary contacts in the load contactor Output power connection is made by attaching the positive lead to the top terminal of the load contactor and the negative lead to the negative output terminal located above the load contactor Chapter 1 1 Dec 31 96 Page 10 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Overvoltage relay Voltage regulator Excitation rectifiers Control windings fuses 10 Amp Voltage build up fuse
95. onductor with lug type terminals on one end and an AN 2551 plug connector on the other e The recommended single conductor sizes for 28 5 volt DC continuous rated amperage and 90 C 194 F rise is as follows for 285 amperes use 2 0 size for 385 amperes use 4 0 size for 530 amperes use 350 size Dec 31 96 Chapter 1 2 Page 1 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 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 connection e Remove the screws that secure the right rear side panel Set the panel aside e 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 negative output terminal located above the load contactor ALWAYS place the lead under the flat washer shown e Tighten the cable clamp and install the lower panel e Store cables in cable tray provided on top of fender or on hangers on side of canopy if fenders are not used EGITIVE CABLE CONNECTION v 5 5 E 2 POSITIVE CABLE CONNECTION Output Cable Connections Figure 1 Chapter 1 2 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual P Jet Ex 4D Spec 7003
96. ontrol Panel Assembly Rear Figure 3 Dec 31 96 Chapter 2 4 Page 7 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER This page intentionally left blank Chapter 2 4 Dec 31 96 Page 8 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set Section 5 Troubleshooting Charts See section 2 4 for all figures referenced in this section Engine and Controls Trouble Symptom and Condition Probable Cause 1 Engine will not start Starter a Batteries discharged sure will not crank engine this voltage is reaching or loose battery or ground connection Engine push button start switch 5401 defective Defective starter relay 1401 Defective starter 8401 Internal engine seizure GROUND POWER Test Check and Remedy Check battery connections and check voltage across battery Voltage should be approximately 12 8 VDC starter relay input terminal If battery and connections are good proceed to Step b Momentarily connect a jumper between the hot side of the starter relay L401 and the start switch terminal on the starter relay yellow blue wire If the starter operates check push button start switch 13 Fig 2 Replace faulty switch If starter doesn t crank proceed to Step c Momentarily connect a large capacity jumper cable between the hot side of the starter relay 16 Fig 1 and the starter input termi
97. or will not close a Defective contactor close Momentarily connect a jumper when contactor close switch S408 lead between terminals with red switch S408 is operated and yellow red wires on the Engine running normally contactor close switch 8 Fig voltage normal no load 2 If the load contactor closes applied to output cable momentarily replace contactor close switch b Defective load contactor If load contactor 70 Fig 1 will K402 not close when contactor close switch is jumpered it is likely that the contactor is defective Replace contactor c Overvoltage relay K403 Connect a jumper lead between defective terminals T and P on the overvoltage relay 1 Fig 3 If contactor will now close replace overvoltage relay Chapter 2 5 October 28 96 Page 6 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Generator and Controls continued Trouble Symptom and Condition 5 Load contactor opens as soon as contactor close switch is released from its top spring loaded position Load contactor opens during power delivery Load contactor opens during power delivery continued Probable Cause a Defective contactor close switch S408 b Load contactor K402 defective a Contactor opening could have been normal because of an overvoltage condition b Overvoltage relay K403 defective c Overvoltage board out of adjustment
98. r amp Fender Option Shown Figure 1 Chapter 1 1 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Unit with Cable Hangers amp Spacers Under Frame Length 65 75 inches 1670 mm Width 34 25 inches 870 mm Height 53 inches 1346 mm Weight dry fuel tank 1970 pounds 894 kg Unit with Trailer amp Cable Hangers without fenders Length 75 5 inches 1918 mm Width 55 inches 1397 mm Height 63 75 inches 1632 mm Weight dry fuel tank 2280 pounds 1043 kg Ground Clearance 7 5 inches 191 mm Unit with Trailer Fenders amp 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 550 amperes continuous at 28 5 volts DC Starting Current Capacity 2000 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 Go
99. re is excessive vibration within this range adjust engine idle speed gradually increasing or decreasing it whichever is necessary until vibration is reduced Refer to Figure 2 below To adjust idle speed loosen idle speed retaining nut and adjust idle speed screw on throttle assembly to raise idle speed while observing tachometer and observing engine vibration turning idle speed screw INWARD increases idle speed and turning it OUTWARD decreases idle speed When vibration has been satisfactorily reduced tighten idle speed retaining nut 5 Place the speed control switch 77 in the RATED RPM position Check engine RPM s at operating speed 2000 RPM 6 Check for 28 5 output voltage on generator voltmeter 4 to assure automatic voltage buildup 7 Set current limit control 10 to maximum full clockwise position 8 Adjust the load bank for a load of 550 amperes 9 Place the contactor control switch 8 in the CLOSE position CONTACTOR CLOSED light 9 will glow and the contactor will close Release the switch to the center ON position The tachometer 2 will indicate 1950 25 RPM Idle Speed Adjustment Screw Idle Speed Adjustment Dec 31 96 Chapter 2 3 Page 3 2077 operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 10 Disconnect the load bank and check the overvoltage protection by adjusting voltage regulator potentiometer R46 7 Fig 3 to increase the voltage The o
100. roper time schedule Lubrication points frequency of lubrication and recommended lubricants b Lubrication Chart Lubrication points are illustrated and identified by name on Lubrication Chart Figure 1 Number symbols used to designate the kind of lubricant required and the specification recommended are identified in Figure 2 Letter symbols used to designate the normal lubrication period are identified in Figure 3 c Generator The 28 5 volt DC generator requires NO lubrication The armature is sealed at the factory for lifetime maintenance free operation The front end of the armature is supported by the engine main bearings d Generator Controls Generator controls and instruments require no periodic lubrication A few drops of oil may be required on door hinges occasionally to insure free and quiet operation e Engine Although the engine and its accessories require no more attention than any other similar installation they still inherently require a major portion of the generator set lubrication and maintenance Recommendations regarding engine lubrication have been taken from the Perkins Diesel Users Manual for Series 4 236 engines 1 Lubrication Schedule Time schedules indicated on the Lubrication Chart Figure 1 are approximate They are based on average operating conditions It may be necessary to lubricate more frequently under severe operating conditions such as low engine temperature high oil temperature intermitt
101. s and lead cable connectors clean WARNING Never allow sparks or open flame near battery Avoid spilling electrolyte on hands or clothing d Liquid Level If battery is not a maintance free type The electrolyte in each cell should be above the plates at all times to prevent battery failure Check the level of the electrolyte every two weeks When electrolyte level is low add pure distilled water Do not use hydrant water or any water which has been in contact with a metal container Acid should never be added except by a skilled battery man _ CAUTION Never any special battery dopes solutions powders NOTE It is especially important to keep the battery at full charge for cold weather operation Add distilled water to the battery in freezing temperatures only when the engine is to operate for several hours to thoroughly mix the water and the electrolyte or damage to the battery will result from the water freezing Dec 31 96 Chapter 2 2 Page 5 OM 2077 Operation and Maintenance Manual 40 Spec 7003C Generator Set GROUND POWER Cleaning the Battery If the top of the battery are dirty they may be cleaned with a brush dipped in ammonia or soda solution Disconnect lead connectors from battery posts Vent plugs should be tightened to prevent cleaning solution from entering cells Clean battery as required using brush and cleaning solution Flush off the battery with clean wa
102. s from generator output terminals to a load bank Use cables of the same size and length as those used in service preferably No 2 0 not more than 30 feet 9 m long Dec 31 96 Chapter 2 3 Page 1 2077 operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set C ROUND POWER lol 1 Panel light 11 Speed control switch 2 Tachometer 12 Engine on light 3 Hourmeter 13 Engine start switch 4 Voltmeter Generator 14 Engine circuit switch 5 Ammeter 15 Engine circuit fuse 20 Amp 6 Panel lights fuse 10 Amp 16 Water temperature gauge 7 Panel lights switch 17 Oil pressure gauge 8 Contactor control switch 18 Fuel gauge 9 Contactor closed light 19 Voltmeter Engine 10 Current limit control Chapter 2 3 Dec 31 96 Page 2 2077 operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER b Operational Tests Figure 1 1 Start the engine as described in 1 3 Para 3 a and let it warm at idle speed 2 Inspect for oil fuel and coolant leaks 3 Check the engine voltmeter 19 for proper voltage Check oil pressure gauge 17 It should read 35 to 60 psi 241 to 414 kPa Check coolant temperature gauge 16 It should read 180 to 200 deg F 82 to 93 deg C when engine is hot 4 Observe engine RPM on the tachometer 2 and observe engine for excessive vibration Idle speed should be 1000 RPM 50 RPM If the
103. s 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 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
104. s when the control is turned fully clockwise b Options Chapters 1 5 of this manual describes Specification No 7003C 1 a stationary skid mounted unit Appendix A lists all options available for this unit The following is a brief description of mounting configurations 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 See TO 181 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 2 See TO 181 For mounting the generator set as a stationary unit a stationary mounting kit is available This kit identified as part number 489689 consists of four spacer brackets which support the unit and permit anchoring it to a floor or platform screws for fastening the spacer brackets to the unit and two cable hanger brackets See Appendix A for a Complete List of Options Dec 31 96 Chapter 1 1 Page 1 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER Jet Ex 4D Generator Set Traile
105. sible ratchet drive fitted with a 5 16 inch Allen wrench to remove one coupling screw Examine the screw Screws specified for this coupling are Hobart Part No 181166 which are socket head self locking 3 8 24 X 1 inch long NOTE Use of the proper coupling screws for replacement is very important Replacement screws MUST be those specified above torqued to 40 45 foot pounds 54 61 Nm There is NO ACCEPTABLE SUBSTITUTE for these screws d Check the threads of the screw for stripping and replace it if the threads are stripped If the screw is not stripped reinstall it and torque it to 40 45 foot pounds 54 61 Nm e Repeat the steps b c and d above for the remaining seven screws f Reinstall covers around housings Access to Coupling Screws for removal and installation Figure 2 Ce Chapter 3 1 Dec 31 96 Page 2 OM 2077 Operation and Maintenance Manual WER Jet Ex 4D Spec 7003C Generator Set 3 Disassembly Removal of the flexible coupling is required for servicing the generator armature generator bearings or the coupling itself To remove the coupling for any reason it is necessary to separate the engine and generator Many mechanics prefer to remove the engine and generator as an assembly and then separate them Others may prefer to remove the engine or the generator separately to reach the coupling However separating the engine and generator while they are installed in the grou
106. tactor closed light Current limit control Control Panel Assembly Front View Figure 3 Speed control switch Engine on light Engine start switch Engine circuit switch Engine circuit fuse 20 Amp Water temperature gauge Air Cleaner Indicator Oil pressure gauge Fuel gauge Voltmeter Engine Dec 31 96 Chapter 1 1 Page 9 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 4 Potentiometer The current limiting potentiometer 10 is used to select the starting current recommended for various aircraft The current limiting setting is continuously adjustable from 300 to 2000 amperes 5 Switches The contactor control switch 8 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 9 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 panel lights switch 7 turns the lights 1 on and off The engine start switch 13 isa momentary contact push button which closes the starter solenoid 16 Figure 2 and cranks the engine This switch is
107. ter Special terminal cleaning tool Make certain that vent holes in filler caps are not clogged Testing a Battery Tests are made on a battery to determine the state of charge and also its condition The results of these tests show whether the battery is good needs recharging or must be replaced If a battery has failed is low in charge or requires water frequently the reason for the condition must be found and corrected Visually inspect the battery before testing to determine if it has been damaged Moisture on the outside of the case or low fluid level in one or more cells indicates possible battery damage cracked case etc The battery may be tested by two methods A battery starter tester may be used to determine the battery s ability to deliver current A battery hydrometer test determines the charge condition of the battery e Test with Battery Starter Tester Connect battery to the tester according to instructions furnished with the instrument Test battery according to tester instructions If the test determines that the battery has acceptable voltage this indicates that the battery has output capacity and will accept a charge if required e Test with Hydrometer a Remove filler caps and check the specific gravity of the electrolyte in each cell If specific gravity is 1 230 or below add water if necessary and charge the battery until it is fully charged A fully charged battery will give a specific gravity reading of 1 265 t
108. tiometer R402 current limiting potentiometer limiting potentiometer 10 Fig 2 with an ohmmeter To do this disconnect the plug P404 from the regulator board 2 Fig 3 and take resistance measurements from pin 2 to pin 9 and then from pin 2 to pin 10 on the plug For each measure ment slowly turn potentiometer through its entire range while observing the ohmmeter readings Resistance should be from 0 10kO Replace if necessary If it isn t defective proceed to Step b b Defective voltage regulator Replace voltage regulator with VRAO2 one known to be good and then operate the generator set under sufficient load to observe current limiting If current limiting potentiometer now controls current properly send old voltage regulator to factory for service Chapter 2 5 October 28 96 Page 8 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set Ska ro weak Chapter 3 Overhaul Major Repair Section 1 Flexible Coupling 1 General This chapter provides basic instructions for removal service and installation of a flexible coupling kit with fan attached manufactured by Hobart Brothers Company and identified as Part Number 489123 This flexible coupling kit is designed for use with Series 7003C single bearing generator sets Figure 1 shows a rear view and side view of the flexible coupling assembly The primary function of this assembly is to couple a Hobart generator set to a
109. tionary skid mounted unit rated at 28 5 Volts DC output It is equipped with a sheet metal canopy and hinged engine compartment door Various options are available for use with the basic unit These options are listed in paragraph 2 B below The 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 2 Special Features a Standard 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 engine
110. tly by the manufacturer to the first user and serviced by a worldwide network of distributors and others authorized to handle claims for component manufacturers A first user s claim should be presented directly to such an authorized component service outlet In the event any component manufacturer has warranted its component to HOBART and will not deal directly with a first user then HOBART will cooperate with the first user in the presentation of a claim to such manufacturer Under NO circumstances does HOBART assume any liability for any warranty claim against or warranty work done by in behalf of any manufacturer of the foregoing components This warranty is extended by HOBART only to the purchaser of new PRODUCTS from HOBART or one of its authorized distributors The PRODUCTS purchased under this warranty are intended for use exclusively by the buyer and his employees and by no other persons and therefore there shall be no third party beneficiary to this warranty claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and judgment HOBART S liability is limited to repair of any defects found by HOBART to exist or at HOBART S option the replacement of the defective product F O B factory after the defective product has been returned by the purchaser at its expense to HOBART S shipping place Replacement and exchange parts will be warranted for the remainder of the original Warranty or for a per
111. tor 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 A Lexan window is mounted above the control panel to allow observation of the instruments while protecting them from the weather 6 Engine Generator and Controls a General Fig 2 The engine 7 and generator 5 are mounted on a welded steel frame 6 A fuel tank support 1 1 located at the rear of the unit supports the fuel tank 2 and provides a mounting frame for the load contactor 10 and output terminals The radiator 18 is mounted to the front canopy A heavy U bolt is attached to the centrally located lifting yoke 1 for moving the 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 3 86 liter cylinder displacement and a 16 1 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 24 Figure 2 cleans the entire output of the pump before it enters the oil distributing 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
112. tremely Dusty Conditions 4 Operation in Salt Water 4 Miscellaneols sn eee NUR ne RA TR NS 5 Chapter 2 Servicing Troubleshooting Section 1 Maintenance Inspection Check 1 General 1 Maintenance Schedule 1 emus a erate 1 Maintenance Schedule Check 5 1 Time Intervals acie ume toe ue x 1 Engine and Related Components 1 Inspection and Cleaning 1 Section 2 Maintenance Procedures 1 General 1 Lubrication 1 mc ep 1 Lubrication Charl usos oie rn Rob rn Rim Rm RI ewe Vita 1 Generator 5 22 2 2 4 EARNS EENS Shedd le ine Ron 1 Generator 2 1 ENJING EE 1 Servicing the Air Cleaner 4 Servicing the Fuel Filter 4 Drive Belt Service 4 Engine Cooling System 4 iliud nm 5 Antifreeze oie loculos ex b EX EEG GRE Ue ee SA REA UE EUR MUR ee oe 5 Battery Service 5 elles dev xa Rx qe Ee dex us 5 Battery Location and 515 5 Battery te L 5 Liquid LeVel ees eee eee RE IRR Ems 5 Cleaning the
113. verned Speed at No Load 2000 50 RPM Idle Speed 1000 50 RPM Fuel Tank Capacity 20 5 U S gallons 77 6 liters Protective Devices Generator Engine 28 5 volt overvoltage module trips at Water Temperature Switch opens engine circuit at 225 F 32 to 34 volts 14 volt overvoltage module trips at Low Oil Pressure Switch opens at 20 PSI 138 kPa 18 to 20 volts Dec 31 96 Chapter 1 1 Page 3 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWER 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 The Jet Ex 4D unit is identified by Specification numbers as described in paragraph 1 above There may be any number of Generator sets with the same Specification number Individual machines are identified by a Serial number assigned to one machine only Each generator set has an Identification plate attached inside the hinged control panel door This nameplate lists the machines 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 5 Canopy The standard canopy is a sheet metal enclosure which protects the engine genera
114. vervoltage relay will trip and open the load contactor at 32 to 34 volts 11 Readjust the voltage to 28 5 volts connect the load bank set it at 550 amperes and close the contactor 12 Remove load bank and check voltage regulation at no load Voltage will be 28 5 volts Reconnect load bank and check voltage regulation with load bank set at 137 275 413 550 and 660 amperes and check voltage at each setting Voltage will be 28 5 1 volts at each different load 13 With current limit control 70 set to 2000 apply 600 to 700 amperes load to the generator and then set the current limit control 10 to 400 Current displayed on ammeter 5 will be 400 40 amperes NOTE Voltage will not drop below 12 volts 14 Set current limit control to 2000 and apply 1200 amperes load Then set current limit control to 1000 Current displayed on ammeter will be 1000 100 amperes and voltage will not drop 15 Stop and restart the engine check the instruments as directed in step 3 and check the entire generator set for unusual vibration and noises 3 Voltage Regulator Adjustment Figure 3 a 28 5 Volt Adjustment 1 The regulating voltage in the 28 5 volt range is determined by the position of the wiper arm of the multi turn potentiometer R46 clockwise CW rotation increases the voltage level at which the unit operates Conversely counterclockwise CCW rotation decreases the voltage level b Line Drop Compensation 1
115. y be dependent upon conditions beyond the manufacturer s control The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical condition or operation of the equipment Among such conditions are 1 Exposure to Combustible explosive abrasive or conducting dusts Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation Chemical fumes flammable or explosive gases Nuclear radiation Steam salt laden air or oil vapor Damp or very dry locations radiant heat vermin infestation or atmospheres conducive to fungus growth Abnormal shock vibration or mechanical loading from external sources during equipment operation Abnormal axial or side thrust imposed on rotating equipment shafts Low and or high ambient temperatures 2 Operation at Voltages above or below rated voltage Speeds other than rated speed Frequency other than rated frequency Standstill with rotating equipment windings energized Unbalanced voltages Operation at loads greater than rated 3 Operation where low acoustical noise levels are required 4 Operation with Improper fuel lubricants or coolant Parts or elements unauthorized by the manufacturer Unauthorized modifications 5 Operation in poorly ventilated areas Dec 31 96 Unusual Service Conditions Page 1 OM 2077 Operation and Maintenance Manual Jet Ex 4D Spec 7003C Generator Set GROUND POWE

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