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Hobart JET-EX 4 Operation And Maintenance Manual

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OPERATION AND MAINTENANCE

MANUAL
for
JET-EX 4
SPECIFICATION SERIES NO.
7005-1
7005-2
HOBART BROTHERS COMPANY
POWER SYSTEMS GROUP
TROY, OHIO 45373
GROUND POWER EQUIPMENT
U.S.A.
OM-2049
052089
040593

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Summary of Contents for Hobart JET-EX 4

  • Page 1: Operation And Maintenance

    OM-2049 052089 040593 OPERATION AND MAINTENANCE MANUAL JET-EX 4 GENERATOR SETS SPECIFICATION SERIES NO. 7005-1 7005-2 HOBART BROTHERS COMPANY POWER SYSTEMS GROUP TROY, OHIO 45373 GROUND POWER EQUIPMENT U.S.A.
  • Page 2 This page intentionally left blank...
  • Page 3 SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT 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.
  • Page 4 ment. b. 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. d. If troubleshooting must be done with the unit energized, have another person present who is trained in turning off the equipment and providing or calling for first aid.
  • Page 5 OM-2049 LIST OF EFFECTIVE PAGES CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE List of May 20/89 Effective May 20/89 Pages 1 thru 2 May 20/89 May 20/89 May 20/89 Introduction May 20/89 Introduction May 20/89 May 20/89 May 20/89 Contents May 20/89 May 20/89...
  • Page 6 OM-2049 May 20/89 CHAPTER/ CHAPTER/ SECTION PAGE DATE SECTION PAGE DATE May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89 May 20/89...
  • Page 7 OM-2049 Table of Contents SUBJECT CHAPTER/SECTION PAGE WARNING LIST OF EFFECTIVE PAGES INTRODUCTION CHAPTER 1. DESCRIPTION/OPERATION SECTION 1. DESCRIPTION 1. General 2. Special Features A. Standard B. Options 3. Orientation 4. Identification 5. Canopy 6. Engine, Generator, and Controls A. General B.
  • Page 8 OM-2049 SUBJECT CHAPTER/SECTION PAGE E. Output Terminals F. Contactor G. Rectifier Assembly H. Ammeter Shunt 7. Optional Equipment A. Trailer SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING 1. Preparation for Use A. General B. Inspection/Check C. Output Cable Installation 2.
  • Page 9 OM-2049 SUBJECT CHAPTER/SECTION PAGE (2) Covering (3) Brushes (4) Field coils (5) Battery terminals K.Miscellaneous 3. Trailer Operation A. Towing B. Parking CHAPTER 2. SERVICING SECTION 1. MAINTENANCE INSPECTION/CHECK 1. General 2. Maintenance Schedule A. General B. Maintenance Schedule Check Sheet C.

  • Page 10: Table Of Contents

    OM-2049 SUBJECT CHAPTER/SECTION PAGE B. Clean and Service Air Cleaner C. Clean Crankcase Ventilation System 4. Servicing the Fuel Filter 5. Drive Belt Service 6. Engine Cooling System A. General B. Rust Inhibitor C. Antifreeze 7. Battery Service 8. Generator Maintenance A.

  • Page 11: Table Of Contents

    3. Arrangement 4. Explanation of Parts List A. Contents B. Parts List Form (1) “FIGURE-ITEM NO.” Column (2) “HOBART PART NUMBER” Column (3) “NOMENCLATURE” Column (4) “EFF” (Effective) Column (5) “UNITS PER ASSEMBLY” Column SECTION 2. MANUFACTURER’S CODES 1. Explanation of Manufacturer’s (Vendor) Code List SECTION 3.
  • Page 12 OM-2049 This page intentionally left blank Table of Contents May 20/89 Page 6...
  • Page 13 OM-2049 INTRODUCTION This manual contains operation and service information for 28.5 V DC Generator sets identified as Jet Ex 4. These units are available as stationary, skidmounted units, or they may be trailer-mounted for portabil- ity. Both versions are available with 14 V DC output capability. Most information in the manual applies to the 28.5 V Jet Ex in general.
  • Page 14 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.
  • Page 15 SECTION 1. DESCRIPTION 1. General The Jet-Ex 4 unit covered in this manual (Figure 1) is a gasoline engine driven, self-contained generator set manufactured by Hobart Brothers Company, Power Systems Group, Troy, Ohio U.S.A. The basic unit is identified by a Specification Number 7005, plus a dash number which defines a specific configura- tion.
  • Page 16 OM-2049 Jet-Ex 4 Generator Set Figure 1 May 20/89 Page 2...
  • Page 17 OM-2049 UNIT WITHOUT TRAILER AND CABLE HANGERS Length 65.5 inches (1664 mm) Width 34.25 inches (870 mm) Height 46.25 inches (1175 mm) Weight (dry fuel tank) 1365 pounds (619 kg) UNIT WITH TRAILER AND CABLE HANGERS (Without Fenders) Length 72.5 inches (1841 mm) Width 55 inches (1397 mm) Height...
  • Page 18 3. Orientation The radiator end of the Jet-Ex 4 is the front. Right and left are determined by standing at the rear of the unit, facing it. The control panel is located at the rear. 4. Identification The Jet-Ex 4 unit is identified by Specification numbers as described in paragraph 1, above.
  • Page 19 OM-2049 5. Canopy The standard canopy is a sheet metal enclosure which protects the engine, generator, and electrical con- trols. It has one large, hinged door at the left front to provide access for service and maintenance. Panels at the rear provide access to the generator. A Plexiglas window is mounted above the control panel to al- low observation of the instruments while protecting them from the weather.
  • Page 20 The starter relay (8, Figure 3) is mounted on the right side of the lifting yoke near the starter motor. (9) Carburetor The carburetor, specially designed for engine governor type applications, is mounted on the en- gine and adjusted at the Hobart factory. Replacement carburetor, spare parts, and repair kits are availbable from Hobart Brothers only. May 20/89...
  • Page 21 OM-2049 1. Control Panel 11. Oil Pressure & Coolant Temp. Senders 2. Output Terminals 12. Lifting Yoke 3. Engine 13. Fuel Tank 4. Governor 14. Fuel Shut-off Solenoid Valve 5. Radiator 15. Generator 6. Drain Cock 16. Oil Filter 7. Fuel Tank Support 17.
  • Page 22 OM-2049 (10) Spark arrester muffler This muffler prevents the discharge of sparks from the engine’s exhaust. C. Generator The generator (15, Figure 3) is a multi-phase, synchronous salient pole, revolving field, AC generator whose output is rectified. The output is recitified by a rectifier assembly (9) made up of twelve rectifi- ers connected into a full wave configuration.
  • Page 23 OM-2049 The current limiting potentiometer (4) is used to select the starting current recommended for vari- ous aircraft. The current limiting setting is continuously adjustable from 300 to 1600 amperes. (5) Switches The contactor control switch (11, Figure 4) is a three-position toggle switch used to close and open the output load contactor.
  • Page 24 OM-2049 (10) Choke control The choke control is connected to the carburetor choke butterfly with a flexible control cable. Pull- ing it out closes and enriches the fuel mixture. Pushing it in opens the choke. (11) Excitation Rectifiers Two diode bridge rectifiers, CR418 and CR417, (3, Fig. 5) convert an AC voltage from the gener- ator armature to the DC voltage needed for the generator revolving field.
  • Page 25 OM-2049 1. Oil Pressure Gauge 11. Contactor Control Switch 2. Tachometer 12. Contactor Closed Light 3. Water Temperature Gauge 13. Speed Control Switch 4. Current Limit Control 14. Engine On Light 5. Ammeter (Generator) 15. Hourmeter 6. Voltmeter 16. Engine Circuit Fuse 7.

  • Page 26: Optional Equipment

    7. Optional Equipment A. Trailer The portable Jet-Ex 4 is mounted on an optional four-wheel trailer (see Figure 1) which consist of front and rear axle assemblies. The axles are mounted directly to the main frame of the generator set.

  • Page 27: Preparation For Use

    OM-2049 SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING 1. Preparation for Use A. General The generator set is shipped with a dry battery and an empty fuel tank. After the battery is filled with electrolyte and charged, the fuel tank filled and the generator set inspected, the generator set is ready for use.

  • Page 28: Preparation For Storage

    OM-2049 (7) Air cleaner Make sure air cleaner element is installed. Recommended replacement element is United Air Cleaner No. 250A13. (8) Battery Check fluid level in 12 volt battery. Fluid should cover plates. C. Output Cable Installation Units are normally supplied without a generator-to-aircraft cable. (1) Cable requirements Cable length is determined by the customer’s requirements.
  • Page 29 OM-2049 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 tem- peratures expected during the storage period.
  • Page 30 OM-2049 (e) Seal all engine openings and accessories with water resistant tape. (f) Remove battery and store in a cool dry place. Store the battery on wood rather than directly on cement or metal. (g) To protect the generator and other electrical components, the complete unit should be pack- aged, using moisture proof packaging and sealing materials.
  • Page 31 OM-2049 1. Positive Output Terminal 2. Negative Output Terminal 3. Load Contactor 28 Volt Output Terminal Panel Figure 1 May 20/89 Page 5...
  • Page 32 OM-2049 4. Stationary Unit Mounting Figure 2 illustrates the mounting hole pattern in the base of the stationary Jet-Ex 4 generator set. Each of the eight holes is 9/16" (14.3 mm) in diameter. Stationary Unit Mounting Holes Figure 2 May 20/89...
  • Page 33 OM-2049 SECTION 3. OPERATION 1. General This section contains information and instructions for the safe and efficient operation of the generator set. Operating instructions are presented in a step-by-step sequence of procedures to be followed in supply- ing power to an aircraft. NOTE: Read ALL of the operating instructions before attempting to operate the equipment.
  • Page 34 OM-2049 1. Oil Pressure Gauge 11. Contactor Control Switch 2. Tachometer 12. Contactor Closed Light 3. Water Temperature Gauge 13. Speed Control Switch 4. Current Limit Control 14. Engine On Light 5. Ammeter (Generator) 15. Hourmeter 6. Voltmeter 16. Engine Circuit Fuse 7.
  • Page 35 OM-2049 (4) Make sure that no loose bars, tools, parts, etc., are in or on any part of the engine as they could cause serious damage to the engine, generator, or personal injury to anyone standing nearby. (5) If the unit is operated indoors, make sure that an exhaust line is properly connected to the engine exhaust system, and discharged out of doors.
  • Page 36 OM-2049 D. Generator Operation (1) Place speed control switch (13) in RATED RPM (up) position. Engine speed will be 2600 RPM. (2) Press BUILD UP VOLTAGE pushbutton (10). Generator will produce rated voltage. (3) Adjust STARTING CURRENT rheostat (4) if necessary. E.
  • Page 37 OM-2049 (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 Maintenance and Operator’s Manual for recommended viscosity for various atmospheric temperatures. In cold weather, drain oil more frequently. Water condenses and collects quickly, mixes with the oil and increases deposits to form a sludge.
  • Page 38 OM-2049 J. Operation in Salt Water Areas (1) Canopy Wash canopy regularly to remove salt film. Repaint any damaged places and oil the side panel hinges regularly. (2) Covering To protect the engine and generator as much as possible from salt water atmosphere, keep the side panels on the canopy closed, when not in use.
  • Page 39 OM-2049 B. Parking Observe the following rules when parking the trailer. (1) Always place drawbar in an upright, vertical position and lock it when trailer is parked. (2) Be sure parking brake is applied. May 20/89 Page 7...
  • Page 40 OM-2049 This page intentionally left blank May 20/89 Page 8...
  • Page 41 OM-2049 CHAPTER 2. SERVICING SECTION 1. MAINTENANCE INSPECTION/CHECK 1. General To make certain that generator set is always in good operating condition, it must be inspected, main- tained, and lubricated regularly and systematically. WARNING: STOP OPERATIONS AT ONCE IF A SERIOUS OR POSSIBLY DAN- GEROUS FAULT IS DISCOVERED.
  • Page 42 OM-2049 10 HRS. 100 HRS. 200 HRS. 400 HRS. 800 HRS. DAILY 2 WKS 1 MTH 2 MTHS 6 MTHS ENGINE Check oil level Check coolant level Check governor oil Check fuel quantity Check gages and instruments for proper operation Clean or replace dry-type carburetor air cleaner element Lubricate distributor...
  • Page 43 OM-2049 10 HRS. 100 HRS. 200 HRS. 400 HRS. 800 HRS. DAILY 2 WKS 1 MTH 2 MTHS 6 MTHS ELECTRICAL SYSTEM (28.5-V DC) Check indicating light Check operation of all instru- ments, meters, etc. Check generator brushes for length, cleanliness, and free operation Check slip rings for smooth- ness and cleanliness...
  • Page 44 OM-2049 This page intentionally left blank. May 20/89 Page 4...
  • Page 45 OM-2049 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.
  • Page 46 OM-2049 * Check crankcase oil daily; change 200 hours. ** Change oil filter after 200 hours. Lubrication Chart Figure 1 May 20/89 Page 2...
  • Page 47 OM-2049 SYMBOL NAME SPECIFICATION NOTES Grease, Automtive Federal Sinclair Litholene and Industrial VV-G-632 Industrial No. 2; Mobil-Mobilplex 47, or equivalent Oil, Engine, Heavy Ford spec. Ford Motorcraft, or Duty ESE-M2C101-C equivalent. Refer to Figure 4 for recom- ended oil viscosity. Grease, Automotive Military Wheel bearings MIL-G-10924B...
  • Page 48 OM-2049 (2) Oil specification Engine lubricating oil recommended by the engine manufacturer must meet Ford Specification No. ESE-M2C101-C. Oil that meets this specification is normally marked so on the can and meets API (American Petroleum Institute) classification designation SF or SG. The manufacturer recommends Ford or Motorcraft oils, which meet all specifications for Ford Industrial Engines.
  • Page 49 OM-2049 (e) Remove filler cap on valve cover and refill crankcase with new, clean oil of proper specifica- tion and viscosity [see Para. 2, E, (2) and Figure 4]. 7 quarts are required when oil filter is changed. (f) Start engine and allow it to idle. Oil pressure should come up to normal quickly. Check for oil leaks at filter and drain plug.

  • Page 50: Servicing The Fuel Filter

    OM-2049 3. Servicing the Air Cleaner and Crankcase Ventilation System A. General It is important that the air cleaner be cleaned and serviced regularly each 100 hours of engine opera- tion. Service the air cleaner more often under severe dust conditions. Failure to service the cleaner can cause damage to the cylinder walls and rings, excessive oil consumption, and excessive fuel con- sumption.

  • Page 51: Battery Service

    OM-2049 6. Engine Cooling System A. General NOTE: Refer to the Ford Maintenance and Operator’s Manual in Chapter 5 for detailed instructions on servicing the engine’s cooling system. During warm weather operation, when plain water is used as a coolant, the cooling system MUST be protected against rust by a rust inhibitor additive.
  • Page 52 OM-2049 (1) Cleaning If inspection reveals that brushes are gummy or sticking in the brushholders, they should be re- moved and cleaned. Clean both the brushes and brushholders. Use a good, SAFE, commercial cleaner. DRY ALL PARTS THOROUGHLY. Be sure brushes can move freely in brushholders. WARNING: DO NOT USE A FLAMMABLE SOLVENT.
  • Page 53 OM-2049 A-Leads D-Brush B-Brushholder Caps E-Slip Rings C-Brushholder Generator Revolving Field Brushes Figure 5 May 20/89 Page 9...
  • Page 54 OM-2049 This page intentionally left blank. May 20/89 Page 10...

  • Page 55: Testing The Generator Set

    OM-2049 SECTION 3. ADJUSTMENT/TEST 1. General The adjustments and test procedures presented below are required after major repairs, parts replace- ment, 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.
  • Page 56 OM-2049 1. Oil Pressure Gauge 11. Contactor Control Switch 2. Tachometer 12. Contactor Closed Light 3. Water Temperature Gauge 13. Speed Control Switch 4. Current Limit Control 14. Engine On Light 5. Ammeter (Generator) 15. Hourmeter 6. Voltmeter 16. Engine Circuit Fuse 7.
  • Page 57 OM-2049 B. Operational Tests (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 ammeter (20, Fig. 1) for a slight charge. Check oil pressure gauge (1). It should read 35 to 60 psi (240 to 414 kPa).

  • Page 58: Governor Adjustment

    OM-2049 3. Governor Adjustment A. General (1) Put a slight tension on governor spring (just enough to crank the coils apart) with adjusting screw (A, Fig. 2). Install linkage from governor throttle lever to carburetor lever, adjusting length of linkage so that the throttle arm on the carburetor is 1/16 inch off the full throttle stop.
  • Page 59 OM-2049 Governor Adjustment Figure 2 May 20/89 Page 5...

  • Page 60: Overspeed Relay Adjustment

    OM-2049 (b) Governor running too slow. (c) Friction in throttle linkage. (d) Governor improperly adjusted. (e) Friction in carburetor. (f) Springs in carburetor or throttle mechanism opposing governor action. (g) Governor worn internally. (3) Governor surges at no-load (a) Friction in throttle linkage. (b) Governor belt slipping.

  • Page 61: Voltage Regulator Adjustment

    OM-2049 (3) Adjust the screwdriver adjustable pot at the point shown in the illustration. Turn it counter clockwise to increase the speed at which the engine will shutdown. Turn it counterclockwise to de- crease the shutdown RPM. 5. Voltage Regulator Adjustment A.
  • Page 62 OM-2049 1. 28.5V Voltage Adjustment 2. Line Drop Compensation Voltage Adjustment Voltage Regulator Adjustment Figure 3 May 20/89 Page 8...

  • Page 63: Troubleshooting Chart

    OM-2049 CHAPTER 3. TROUBLESHOOTING SECTION 1. TROUBLESHOOTING PROCEDURES 1. General Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the ex- act cause of a trouble is found. As a rule, the best place to start looking for the cause of a trouble in a cir- cuit is at the source of power.

  • Page 64: Connections And Wiring

    OM-2049 5. Diagrams A schematic diagram of the generator set is provided in Chapter 6. This diagram can be very helpfull in troubleshooting. Components shown in the diagram are identified by reference designators (or item names in some instances). A legend appearing on the diagram identifies each reference designator by its full item name.
  • Page 65 OM-2049 1. Control Panel 11. Oil Pressure & Coolant Temp. Senders 2. Output Terminals 12. Lifting Yoke 3. Engine 13. Fuel Tank 4. Governor 14. Fuel Shut-off Solenoid Valve 5. Radiator 15. Generator 6. Drain Cock 16. Oil Filter 7. Fuel Tank Support 17.
  • Page 66 OM-2049 1. Oil Pressure Gauge 11. Contactor Control Switch 2. Tachometer 12. Contactor Closed Light 3. Water Temperature Gauge 13. Speed Control Switch 4. Current Limit Control 14. Engine On Light 5. Ammeter (Generator) 15. Hourmeter 6. Voltmeter 16. Engine Circuit Fuse 7.
  • Page 67 OM-2049 1. Voltage Regulator 2. Overvoltage Relay 3. Control Winding Rectifier 4. Voltage Regulator Fuse 5. Voltage Sensing Relay Control Panel Wrapper Figure 3 May 20/89 Page 5...
  • Page 68 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 1. Engine will not A. Ignition switch (S404) A. Momentarily connect large start. Starter or pushbutton start capacity jumper cable between will not crank switch (S401) the hot side of the starter engine.
  • Page 69 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 1. Engine will not E. Internal engine E. CAUTION: MAKE CERTAIN start. Starter seizure. THAT IGNITION IS OFF SO will not crank THAT THE ENGINE DOES engine. (Cont’d) NOT START.
  • Page 70 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 2. Engine will not WARNING: EXERCISE CARE TO AVOID A FIRE WHEN start. Starter WORKING WITH THE FUEL SYSTEM. DO NOT PERFORM DOES crank STEPS F AND G WHEN ENGINE IS HOT engine.
  • Page 71 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 4. Engine starts A. Fuel not turned on. A. Turn on fuel shutoff valve. then stops. B. Defective oil pressure B. Connect a jumper wire across switch (S403) located the “C”...
  • Page 72 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 5. Engine runs A. Distributor timing A. Check timing. Set timing roughly, then improperly set. according to Ford Maintenance stalls. and Operator’s Manual. B. Moisture or damaged B.
  • Page 73 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 8. Engine will not A. Speed control switch A. If engine will not go from run at rated (S406) defective. idle to rated speed when speed speed (2600 RPM) control switch (13, Fig.
  • Page 74 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 10. Engine surges A. Governor improperly A. Adjust governor. See Sect. under load. adjusted. 2-3, Para. 3. B. Binding in governor-to- B. Free linkage. carburetor linkage. C. Governor belt slipping. C.
  • Page 75 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 12. Engine “misses” A. Fault in ignition A. Check and correct as follows: at rated speed system. and under load. (1) Spark plugs (1) Clean spark plugs and faulty.
  • Page 76 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 13. Excessive A. Ignition timing too far A. Check ignition timing and “pinging” and advanced. adjust according to Ford detonation Maintenance and Operator’s under load. Manual in Chapter 5. B.
  • Page 77 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 15. Engine A. Governor-to-carburetor A. Check linkage. Adjust and/or response slow linkage either loose, tighten as necessary. when going binding, or out of from idle to adjustment. rated speed or from rated B.
  • Page 78 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY ENGINE AND CONTROLS 17. Engine does (3) Idle solenoid (3) Idle solenoid is located not slow down (L403) defective. just behind carburetor. to idle with Disconnect idle solenoid’s speed control wire leads at the quick- switch in IDLE disconnect clips which...
  • Page 79 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR AND CONTROLS 1. Generator will A. Flashing power not A. Check as follows: not build up reaching generator voltage at all revolving field (L406). when push-to- build-up volt- (1) Defective push-to- (1) Momentarily connect two age switch build-up-voltage...
  • Page 80 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR AND CONTROLS 1. Generator will C. Generator revolving C. Locate yellow and red-orange not build up field (L406) defective. wires on terminal strip that is voltage at all just beneath base of voltage when push-to- sensing relay (at rear of build-up volt-...
  • Page 81 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR AND CONTROLS 3. Generator volt- A. Voltage sensing relay A. Remove voltage sensing relay age builds too (K404) defective. (5, Fig. 3) from its socket high a voltage. Relay coil is open or and apply 24V DC to the coil contacts 1-7 and 3-9 (terminals A and B).
  • Page 82 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR AND CONTROLS 5. Load contactor A. Defective contactor A. Connect a jumper lead between opens as soon close switch (S408). terminals 1 and 2 (orange-red as contactor and yellow-red wires) on the close switch is contactor close switch (11, released from...
  • Page 83 OM-2049 TROUBLESYMPTOM TEST, CHECK, AND/OR AND CONDITION PROBABLE CAUSE REMEDY GENERATOR AND CONTROLS 6. Load contactor B. Overvoltage relay (K403) B. Check overvoltage relay by opens during defective. operating the machine under power delivery. load and gradually raising (cont’d) voltage at the voltage regulator (1, Fig.
  • Page 84 OM-2049 This page intentionally left blank. May 20/89 Page 22...

  • Page 85: Chapter 4. Illustrated Parts List

    SECTION 1. INTRODUCTION 1. General The illustrated Parts List identifies, describes, and illustrates main assemblies, sub-assemblies, and detail parts of the Jet-Ex 4 Generator Sets manufactured by Hobart Brothers Company, Power Systems Group, Troy, Ohio 45373. 2. Purpose The purpose of this list is to provide parts identification and descriptive information to maintenance and provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts.
  • Page 86 (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”...

  • Page 87: Section 2. Manufacturer's Codes

    OM-2049 SECTION 2. MANUFACTURER’S CODES 1. Explanation of Manufacturer’s (Vendor) Code List The following list is a compilation of vendor codes with names and addresses for suppliers of purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes for Manufac- turer’s Cataloging Handbook H4-1, and are arranged in numerical order.
  • Page 88 OM-2049 CODE VENDOR’S NAME AND ADDRESS 57448 Allis Chalmers Corp., 275 Ridgeway Avenue, P.O. Box 1367, Aurora, Illinois 60507 60741 Triplett Electrical Instrument Company, 286 Harmon Road, Bluffton, Ohio 45817 61864 TRW-Inc. United Carr Div., 31 Burlington Mall Rd., Burlington, MA 01803 70411 Anderson Brass Co., 100 S.

  • Page 89: Section 3. Parts List

    OM-2049 SECTION 3. PARTS LIST 1. Explanation of Parts List Arrangement The parts list is arranged so that the illustration will appear on a lefthand page and the applicable parts list will appear on the opposite righthand page. Unless the list is unusually long, the user will be able to look at the illustration and read the parts list without turning a page.
  • Page 90 OM-2049 Generator Set Stationary Mtg. Assy. Figure 1 May 20/89 Page 2...
  • Page 91 . PANEL, CONTROL ASSY, (For Details See Fig. 6) B 1 84B-1078 . LABEL, OPERATING INSTRUCTIONS 81B-1064 . LABEL, ENGINE DRIVE 400435 . LABEL, NAMEPLATE, 28V 402987 . NAMEPLATE, HOBART DWP-982 . BRACKET, CABLE 488904 . BRACKET, SPACER FRAME AY. 78A-1000 . NAMEPLATE, ID 79A-1110 .
  • Page 92 OM-2049 Generator Set W/Portable Mounting and Fenders (Option) Figure 2 May 20/89 Page 4...
  • Page 93 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 7005-1 GENERATOR SET, STATIONARY MOUNTING 7005-2 GENERATOR SET, STATIONARY MOUNTING W/ KEYSTART 181000-3 . TRAILER, ASSY, W/FENDERS (OPTION) May 20/89 Page 5...
  • Page 94 OM-2049 Generator Set W/Portable Mounting (Option) Figure 3 May 20/89 Page 6...
  • Page 95 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 7005-1 GENERATOR SET, W/PORTABLE MOUNTING 7005-2 GENERATOR SET, KEYSTART, W/PORTABLE MOUNTING 181000-4 . TRAILER ASSY., (OPTION) May 20/89 Page 7...
  • Page 96 OM-2049 Canopy Assembly Figure 4 May 20/89 Page 8...
  • Page 97 81B-1063 . LABEL, HOT WATER & STEAM 84A-1071 . LABEL, ACCESS PANEL 406001 . LABEL, DANGER, MOVING PART 402987 . NAMEPLATE, HOBART 406000 . LABEL, ENGINE FUEL 76B-1149 . LABEL, GASOLINE 403153-1 . FOOT, RUBBER STOP, V83613, NO. B-232A 7J-422-0 .
  • Page 98 OM-2049 Generator Set Without Canopy Figure 5 May 20/89 Page 10...
  • Page 99 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number GENERATOR SET WITHOUT CANOPY (For NHA See Fig. 1) 280988 COOLING SYSTEM (For Details See Fig. 13) 489534 . GUARD (For Details See Fig. 13) 408419 . CARBURETOR, V31695, NO. 0-14024, MOD. 33AW8 1 84A-1097 .
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  • Page 101 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY GENERATOR SET WITHOUT CANOPY (CONTINUED) W-10750-1 . NIPPLE, PIPE, 1/8, V31510 W-7814-0 . BUSHING, PIPE, STEEL W-7814-1 . BUSHING, PIPE, STEEL No Number . STARTER, V90927 (SUPPLIED W/ENGINE) NO. E4DF-11001-AA No Number .
  • Page 102 OM-2049 Control Panel Assembly (7005-1 SHOWN) Figure 6 May 20/89 Page 14...
  • Page 103 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488934 CONTROL PANEL ASSY (FOR NHA SEE FIG. 1) 180334 CONTROL PANEL ASSY (FOR NHA SEE FIG. 1) 78A-1117-1 . GAUGE, OIL PRESSURE, V16476, NO. 06340 78B-1121-1 . TACHOMETER, V16476, NO. 71000 78A-1116-1 .
  • Page 104 OM-2049 This page intentionally left blank May 20/89 Page 16...
  • Page 105 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY (CONTINUED) 1CZ-93B . DIODE, V05277, NO. IN4820 * 33 41546 . INS. SLEEVING 8 “ * 34 400480-2 . TERMINAL 488944 . PLUG HARNESS 385765 . CONTROL, CHOKE 488598 .
  • Page 106 OM-2049 Support, Fuel Tank, Contactor Assembly Figure 7 May 20/89 Page 18...
  • Page 107 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488870 SUPPORT, FUEL TANK, CONTACTOR ASSY. (For NHA See Fig. 5) 488601 . SUPPORT, FUEL TANK ASSY. 84C-1092 . CONTACTOR, V26659, NO. JGA6003A 488990 . BUS, STUD, CABLE 5CW-975 .
  • Page 108 OM-2049 Governor Figure 8 May 20/89 Page 20...
  • Page 109 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number GOVERNOR ASSY. (For NHA See Fig. 5) 85C-1001 . GOVERNOR, V74465, NO. BD875C 402908 . JOINT, BALL, V57448, NO. TF-4Y 488842 . SPACER, GOVERNOR, ROD W-9476-39 . ROD, GOVERNOR THROTTLE 180959 .
  • Page 110 OM-2049 Idling Device Assembly Figure 9 May 20/89 Page 22...
  • Page 111 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 489946 IDLING DEVICE ASSY. (FOR NHA SEE FIG. 5.) 404898 . DEVICE, IDLING, V28478, NO. 54699-63 489947 . ROD, IDLING DEVICE 493114 . BRACKET MTG, IDLING DEVICE No Number .
  • Page 112 OM-2049 Battery Installation Figure 10 May 20/89 Page 24...
  • Page 113 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number BATTERY INSTALLATION (For NHA See Fig. 5) . CABLE ASSEMBLY (NEG.) 12CW-1915-2 12CW-1914-20 . CABLE ASSEMBLY (POS.) No Number . NUT, PLAIN, HEX, 5/16-18 No Number . WASHER, FLAT, 5/16 IN.
  • Page 114 OM-2049 Fuel System Figure 11 May 20/89 Page 26...
  • Page 115 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number FUEL SYSTEM (For NHA See Fig. 5) 181322 . TANK, FUEL ASSY. 6FW-5072 . CAP, FUEL TANK, V49234, NO. 1273 281131-1 . GUAGE, FUEL TANK 486567-2 . STRAP, FUEL TANK ASSY.
  • Page 116 OM-2049 Fuel Line Assembly Figure 12 May 20/89 Page 28...
  • Page 117 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488946 FUEL LINE ASSY. (For NHA See Fig. 11) 402265 . VALVE, SHUT-OFF, V70411, NO. 130C-J W-10750-1 . NIPPLE, PIPE, 1/8, V31510 403615 . VALVE, SOLENOID, FUEL SHUT-OFF V96152, NO.
  • Page 118 OM-2049 Cooling System Figure 13 May 20/89 Page 30...
  • Page 119 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 280988 COOLING SYSTEM (For NHA See Fig. 5) 408441-2 . RADIATOR, MODINE MFG. CO., NO. 1A13714D W-10869-3 . CLAMP, V35708 407170 . HOSE, TOP, RADIATOR 408445 . HOSE, BOTTOM, RADIATOR, V11288, NO. 81171 1 406989 .
  • Page 120 OM-2049 Rectifier Assembly Figure 14 May 20/89 Page 32...
  • Page 121 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488948 RECTIFIER ASSY. (For NHA See Fig. 5) 489602 . SHROUD, RECTIFIER ASSY 488558 . SHROUD, RECTIFIER AAW-3909-15 . INSULATOR, SHOCK 488840 . BRACKET, MTG., HEATSINK 488841 . BRACKET, MTG., HEATSINK 488621 .
  • Page 122 OM-2049 Brushholder Assembly Figure 15 May 20/89 Page 34...
  • Page 123 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488784 BRUSHHOLDER, ASSY. (For NHA See Fig. 21) 488562 . BRACKET, MTG., BRUSHHOLDER 488628 . BRACKET, MTG, DIODE 408999-1 . DIODE, SILICON, 30A, POS. V08452 402531 . CAP, BRUSHHOLDER, V46992, NO. DE-55 402530 .
  • Page 124 OM-2049 Engine, Exhaust System Figure 16 May 20/89 Page 36...
  • Page 125 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number ENGINE EXHAUST SYSTEM (For NHA See Fig. 5) REF 84C-1095 . MUFFLER 404154-8 . CLAMP, EXHAUST PIPE 488616 . PIPE, MANIFOLD ASSY. 488581 . GASKET, MANIFOLD 489545 .
  • Page 126 OM-2049 Lifting Yoke and Frame Assembly Figure 17 May 20/89 Page 38...
  • Page 127 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number FRAME, LIFTING YOKE ASSY. (For NHA See Fig. 1) 488565 . FRAME, MOUNTING 488570 . BAR, MTG., GENERATOR 12CW-2234 . MOUNT, SHOCK 488580 . YOKE, LIFTING No Number .
  • Page 128 OM-2049 Ignition Module Assy. Figure 18 May 20/89 Page 40...
  • Page 129 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY No Number IGNITION MODULE ASSY. 488813 . SUPPORT, IGNITION MODULE No Number . IGNITION, MODULE, V90927, (Supplied W/Engine), No. D9VZ-12A199-A May 20/89 Page 41...
  • Page 130 OM-2049 Generator Assembly Figure 19 May 20/89 Page 42...
  • Page 131 OM-2049 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 488947 GENERATOR SPARE ASSY. 491758-1 . COVER - HOLE, FLYWHEEL HOUSING 488843-1 . HOUSING, FLYWHEEL 488557-1 . HOUSING & STATOR ASSY. C-31 . KEY - COUPLING 488552 . ARMATURE, ASSY.
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  • Page 133: Section 4. Numerical Index

    OM-2049 SECTION 4. NUMERICAL INDEX 1. Explanation of Numerical Index 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 alpha-numerical sequence. Thus, any part number beginning with the letter A would be located at or near the top of the index list.
  • Page 134 OM-2049 PART NUMBER FIGURE AND ITEM NUMBER W-11166-5 6-11 W-11242-10 W-11242-12 1-13 W-11254-6 W-11254-8 1-13 W-11278-5 W-11280-11 1-13 W-11294-1 5-26 W-11337-2 17-5, 18-11 W-11434 6-27 W-11563 17-4, 18-10 W-7814-0 5-35 W-7814-1 5-36 W-9476-39 W-9714-25 6-42 Y-971 6-13 1CZ-93B 6-32 12CW-908 12CW-1914-20 10-2 12CW-1915-2...
  • Page 135 OM-2049 PART NUMBER FIGURE AND ITEM NUMBER 400613-4 6-19 400641-12 400642-3 400741-13 6-31 400902 13-17 401428-1 401842 13-16 401937-1 19-6 401937-8 6-24 402086-1 5-5, 10-7 402265 12-1 402530 15-5 402531 15-4 402658 6-21 402682 6-18 402788 15-6 402908 402987 1-7, 4-34 403055-2 6-39 403056-4...
  • Page 136 OM-2049 PART NUMBER FIGURE AND ITEM NUMBER 408389 17-18 408390 17-20 408391 17-19 408392 17-43 408393 17-16 408394 17-11 408395 17-26 408396 17-14 408397 17-12 408398 17-15 408399 17-21 408400 17-23 408401 17-22 408402 17-24 408403 17-27 408404 17-38 408405 17-35 408406 17-33...
  • Page 137 OM-2049 PART NUMBER FIGURE AND ITEM NUMBER 488576 5-15 488580 1-1, 4-19, 19-4 488581 16-4 488584 13-12 488588 10-9 488592 4-10 488598 6-37 488601 488611 11-1 488613 5-14, 13-6 488614 10-8 488615 16-6 488616 16-3 488621 14-4 488628 15-2 488631 4-17 488632 4-24...
  • Page 138 OM-2049 PART NUMBER FIGURE AND ITEM NUMBER 488928 18-7 488929 18-2 488930 18-3 488931 18-4 488932 13-11 488933 488934 1-3, 6-0 488938 488939 488940 4-15 488941A 488942 4-21 488944 6-35 488946 11-7, 12-0 488947 5-12, 21-0 488948 5-22, 14-0 488949 10-10 488990 489420...
  • Page 139 OM-2049 PART NUMBER FIGURE AND ITEM NUMBER 78A-1115-1 6-24 78A-1116-1 78A-1117-1 78A-1120-1 6-20 78B-1118-1 5-24 78B-1121-1 79A-1110 1-11 79B-1119-1 5-28 81B-1061 11-9 81B-1062 4-32, 17-8, 18-4 81B-1063 4-31 81B-1064 84A-1053 4-11 84A-1054-1 84A-1068-1 12-4 84A-1071 4-32, 18-15 84A-1075 6-29 84A-1096 4-22 84A-1097 5-3A...
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  • Page 141: Chapter 5. Optional Equipment

    OM-2049 CHAPTER 5. OPTIONAL EQUIPMENT Optional equipment available for use with the Jet-Ex 4 Generator Set is listed below. OPTION PARTNUMBER MANUAL Trailer with Fenders, Bumpers & 181000-3 TO-181 Cable Trays Trailer with Cable Hangers 181000-4 TO-181 Spacers, Stationary Mounting...
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  • Page 143: Chapter 6. Manufacturer's Literature

    P.O. Box 43338 Detroit, Michigan 48243 HOBART DIAGRAMS Hobart Brothers Company Power Systems Division Troy, Ohio 45373 S7005-1 180137 - Connection, Jet-Ex 4 S7005-1 180136 - Schematic, Jet-Ex 4 S7005-2 180339 - Connection, Jet-Ex 4 S7005-2 180338 - Schematic, Jet-Ex 4...
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  • Page 145 OM-2049 UNUSUAL SERVICE CONDITIONS This information is a general guideline and cannot cover all possible conditions of equipment use. The specific local environments may be dependent upon conditions beyond the manufacturer’s control. The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical con- dition or operation of the equipment.
  • Page 146 OM-2049 This page intentionally left blank Unusual Service Conditions May 20/89 Page 2...

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