OM-168

080681
Revised 111782
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Revised 021084
i4 Revised 031284
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OPERATION AND MAINTENANCE MANUAL

with

ILLUSTRATED PARTS LIST

for

JET-EX 3

GENERATOR SETS

SPECIFICATION bERIES NO. 6272-l thru 4

HOBART BROTHERS COMPANY

POWER SYSTEMS DIVISION
... ._,
,--._.__-._-----..-.
.-_.-
,__._.
_.__ TROY, OHIO 45373
U.S.A.

.- ,._ _” ----- ---- ,. .._-_- __...

 HoBARr
GROUND POWER

Safety Warnings and Cautions

CALIFORNIA PROPOSITION 65 - GASOLINE ENGINES. The

engine exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects or other
reproductive harm.

CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine

exhaust and some of its constituents are known to the State of
I California to cause cancer, birth defects and other reproductive harm.
I

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.

I 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.

Revised Safety Warnings

August 01195 Page 1
 GROUND POWER

2. Shock Prevention
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally
shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn
what terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,
procedures, and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow
through it. When inspecting or servicirfig 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, ANSVNFPA 70, or other applicable
codes. A power disconnect switch or circuit breaker must be located at the equipment. Check the
nameplate for voltage, frequency, and phase requirements. If only 3-phase power is available,
connect any single-phase rated equipment to only two wires of the 3-phase line. DO NOT
CONNECT the equipment grounding conductor (lead) to the third live wire of the 3-phase line, as this
makes the equipment frame electrically HOT, which can cause a fatal shock.
Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or
building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)
capacity of the grounding lead will be adequate for the worst fault current situation. Refer to the
National Electrical Code ANSVNFPA 70 for details. Do not remove plug ground prongs. Use
correctly mating receptacles.
b. Output Cables and Terminals

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

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 I
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.

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.

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.

Safety Warnings Revised

Page 2 August 01195
 GROUND POWER

b. Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or use
open flame near the battery.
c. Engine Fuel
Use only approved fuel cont$iner or fueling system. Fires and explosions can occur if the fuel tank is
notgrounded prior to or during fuel transfer. Shut unit DOWNbefore 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 1
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 suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air
conditioners.

6. Bodily Injury Prevention

Serious injury can result from contact with fans inside some equipment. Shut DOWNsuch 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.

Call physician immediately. Seek additional assistance. Use

First Aid techniques recommended by American Red Cross
until medical help arrives.

IF BREATHING IS DIFFICULT, give oxygen, if available, and

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

8. Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be
easily read.

Revised Safety Warnings

August 01195 Page 3
 GROUND POWER

This page in ten tionally left blank.

Safety Warnings Revised

Page 4 August 01195
 OM-I 68

INTRODUCTION

This manual contains operation and service information for 28.5 V DC Generator sets identified as Jet Ex 3. 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,
I f
! ‘I
Most information in the manual applies to the 28.5 V Jet Ex in general. Information which applies to options and spec-
ial equipment is identified as such.

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

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

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

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

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

1. Control

A. Interior Panel

(1) Protective devices

(a) Overload relay

(2) Contactors

Page numbers do not run consecutively throughout the manual. Each page is 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, a quick look at the Table of Contents shows that “Adjustment/
Test” is located in Chapter 2, Section 3 (shown as 2-3).

Portions of the text are referred to by identifying the paragraph in which the referenced material may be found.
When referenced material is located in the same Chapter/Section as the reference, only the paragraph identification
is given, for example: (Ref. Para. 1, A) means that the material is to be found in paragraph 1, A, of the same Section.

Aug 6181 Introduction

Page 1
 I
m
I 1 OM-168
I I

When referenced material is located in another Chapter/Section, both the Chapter and Section numbers and the para-
graph identification are given, for example: (Ref. 1-2, Para. 1, A) means that the referenced material is located in
Chapter/Section I-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 thelpart and the Figure number in which it appears are given, for ex-
ample: (2, Fig. 3) refer ito item number 2 in illustration Figure 3 of the same Chapter/Section.

When a referenced figure appears in another Chapter/Section, the reference will include the Chapter/Section number,
for example: (2-3; 1, Fig. 4) tells the user that the information is in Chapter/Section 2-3, and to refer to item 1 in
Figure 4.

Once a Figure number reference has been established, the Figure number is not repeated and only the item numbers
of the parts involved are referenced, for example: “Loosen screw (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 Division equipment, you are invited to contact
our Service Department by mail, telephone, or TWX.

Write: Hobart Brothers Company

Power Systems Division
Service Department
Troy, Ohio 45373
U.S.A.

Call: Area Code (513) 339-6000

Extension 4276

TWX : 81 o-456-2907

Introduction Revised Ott 28/83

Page 2
 OM-168

CHAPTER/ CHAPTER/
: SECTION PAGE DATE SECTION PAGE DATE

I List of l-3 5 Feb lo/84

Effective l-3 6 Feb lo/84
Pages 1 thru 21 'I Feb lo/84 l-3 7 Aug 6/81
l-3 8 Feb lo/84
Introduction 1 Aug 6/81 l-3 9 Feb lo/84
Introduction 2 Ott 28/83 l-3 10 Feb 10/84'

Contents 1 Nov 17/82 2-l 1 Feb lo/84

Contents 2 Feb lo/84 2-l 2 Feb lo/84
Contents 3 Aug 6/81 2-l 314 Feb lo/84
Contents 4 Feb lo/84
Contents 5 Aug 6/81 2-2 1 Aug 6/81
Contents 6 Feb lo/84 2-2 2 Feb lo/84
Contents 7 Aug 6/81 2-2 3 Aug 6/81
Contents 8 Feb lo/84 2-2 4 Aug 6/81
Contents 9 Aug 6/81 2-2 5 Feb lo/84
Contents 10 Feb lo/84 2-2 6 Aug 6/81
Contents 11/12 Feb lo/84 2-2 7 Aug 6181
2-2 8 Aug 6/81
l-l 1 Feb lo/84 2-2 9 Aug 6/81
l-l 2 Aug 6/81 2-2 10 Aug 6/81
l-l 3 Aug 6/81 2-2 11 Aug 6/81
l-l 4 Aug 6/81 2-2 12 Aug 6/81
l-l 5 Aug 6181
l-l 6 Nov 17/82 2-3 1 Aug 6181
l-l 7 Nov 17/82 2-3 2 Feb lo/84
l-l 8 Aug 6/81 2-3 3 Feb lo/84
, l-l 9 Aug 6/81 2-3 4 Aug (i/81
l-l 10 Aug 6181 2-3 5 Aug 6/81
l-l 11 Aug 6/81 2-3 6 Aug 6181
l-l 12 Aug 6/81 2-3 7 Feb lo/84
l-l 13 May 30184 2-3 8 Nov 17/82
l-l 14 Aug 6/81 2-3 9 Nov 17/82
l-l 15 Aug 6/81 2-3 10 Nov 17/82
l-l 16 Feb lo/84 2-3 11 Feb lo/84
l-l 17/18 Aug 6/81 2-3 12 Feb lo/84
2-3 13 Feb lo/84
l-2 1 Aug 6/81 2-3 14 Feb lo/84
l-2 2 Aug 6/81
l-2 3 Aug 6/81 2-4 1 Ott 28183
; l-2 4 Aug 6/81 2-4 2 Ott 28183
l-2 5/6 Aug 6/81 2-4 3 Ott 28/83
2-4 4 Aug 6/81
l-3 Feb lo/84 2-4 516 Aug 6181
; l-3 Feb lo/84
/ l-3 May 30/84
i l-3 May 30/84

May 30184 Revised List of Effective Pages

Page 1
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 OM-168

LIST OF EFFECTIVE PAGES

CHAPTER/ CHAPTER/
SECTION
-- PAGE DATE SECTION PAGE DATE

3-1 1 Aug 6181 . 4-3 24. Nov 17182

3-l 2 Feb 10/84j i, 4-3 25 Nov 17182
3-1 : 3 , Aug 6181 4-3 26 Aug 6/81
3-1 4 Aug 6/81 4-3 27 Aug 6/81
3-1 ! 5 Feb lo/84 4-3 28 Aug 6181
3-l 6 Feb lo/84 4-3 29 Aug 6181
3-l 7 Aug 6181 4-3 30 Aug 6181
3-l 8 Aug 6181 4-3 31 Aug 6181
3-l 9 Aug 6181 4-3 32 Aug 6/81
3-l 10 Aug 6/81 4-3 33 Aug 6/81
4-3 34 Aug 6181
4-l 1 Aug 6181 4-3 35 Aug 6181 I
'4-l 2 Aug 6181 4-3 36 Feb lo/84
4-l 3/4 Nov 17182 4-3 37 Aug 6181
4-3 38 Aug 6/81
4-2 Feb lo/84 4-3 39 Aug 6/81
4-2 Feb lo/84 4-3 40 Aug 6181
4-2 Feb lo/84 4-3 41 Nov 17182
4-2 Feb lo/84 4-3 42 Nov 17182
4-3 43144 Nov 17182
4-3 1 hug 6/81
I 4-3 2 Aug 6/81 4-4 1 Jun 28/85
4-3 3 Feb lo/84 4-4 2 Aug 6181
4-3 4 Aug 6/81 4-4 3 Jun 28185
4-3 5 Aug 6/81 4-4 4 Jun 28185
4-3 6 Aug 6181 4-4 5 Jun 28/85
4-3 7 Aug 6/81 4-4 6 July 15/ti5
4-3 8 Feb lo/84 4-4 7 Feb lo/84
I 4-3 9 Aug 22185 4-4 8 July 15185
4-3 10 Aug 6/81 4-4 9/10 Jun 28/85
4-3 11 Feb lo/84
4-3 12 Aug 6/81 5-o l/2 Aug 6/81
I 4-3 13 Jun 28185
4-3 14 Aug 6/81 6-O l/2 Aug 6/81
4-3 15 Aug 6181
,4-3 16 Aug 6/81
4-3 17 Aug 6/81
4-3 18 Feb lo/84
4-3 19 Feb lo/84
4-3 19A Feb lo/84
,4-3 ; 19B Feb lo/84
4-3 20 Aug 6181
4-3 21 Aug 6/81
4-3 22 Aug 6181
.4-3 23 Aug 6181

List of Effective Pages Revised Aug 22/85

Page 2 .._
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 OM-168

TABLE OF CONTENTS

SUBJECT CHAPTER/SECTION PAGE

Description/Operation 1-o 1

Description l-l 1

1. General 1 '

2. Special Features

A. Standard

B. Options 1

3 Orientation 4

4. Identification 4

5. Canopy 5

6. Engine, Generator, and Controls 5

A. General 5

B. Engine 5

(I) General 5

(2) Cooling fan 5

(3) Engine speed governor 5

(4) Engine overspeed device 7

(5) Crankcase ventilation 7

(6) Fuel system 7

(7) Alternator and regulator -- .‘7

(8) Starter relay 7

(9) Special carburetor .7

C. Generator 7

D. Control Box Assembly 8

(I) General 8

(2) Lights 8

Nov 17182 Revised Contents

Page 1

..
 _’

TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

(3) Monitoring instruments l-l 8

(4) Potentiometer i i, 8
,
(5) Switches 8

(6) Fuses 10

E. Rear Panel Assembly (Control Box) 10

(1) Voltage regulator 10

(2) Overvoltage module 10

(3) Overload module 10

(4) Load contactor 12

(5) Ammeter shunt 12

(6) Automatic/manual switch 12

(7) Overspeed governor 12

(8) Resistor and diode assembly 12

'F. Engine Control Panel '12

(1) Generate/idle switch 12

(2) Choke control 13

(3) Throttle control .13

G. Output Terminals 13

7. Optional Equipment 13

A. Trailer 13

B. 14 Volt DC Output 14

(1) 14 volt contactor panel 14

(a> Overload relay 14

(b) Control relays 14

- --. (c) Load contactor .--____-- ----.---.---

-.-_ 14,

Contents .._.~__.._._._~ - ----__ ~.-------~- -Revised

--._-.._- - _. Feb 10184
..-.=
age .2.- .--.
- -._-
_-
 OM-168

TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

(d) Overvoltage module , I-1 14

i 4
, (e) Resistors 14

(2) 14 volt control panel 16 ’

(a) Mode indicating light 16

(b) Contactor closed light 17118

(c) Control switch 17118

(3) 14 volt output terminal panel 17/18

Preparation for Use, Storage, or Shipping 1-2

1. Preparation for Use

A. General

B. Inspection/Check

C. Output Cable Installation

(I) Cable requirements

(2) Cable connector 2

2. Preparation for Storage 2

A. General

B. Temporary Storage

C. Long Time Storage

(1) Engine operation method

3. Preparation for Shipping

4. Stationary Unit Mounting 516

1-3 1
Operation

1. General 1

2. Operating the Generator Set 1

Aug 6181 Contents

Page 3
 c- ..
,-.L - - 1.’ ___TARLE._OF_CONTF_N_TS(CO_NT_INVFD_)-~___._.~~~__
L"-~--~~~

SUBJECT CHAPTER/SECTION PAGE

A. Pre-start Inspection l-3 1

8. Operating Generator with Electronic Governor 1

i iI
(1) Start up procedure 1

(2) 28.5 volt power delivery with automatic 3

voltage control

(3) 28.5 volt power delivery with manual

voltage control

C. Operating Generator with Mechanical Governor

D. Discontinue Power Delivery: Electronic Governor

E. Discontinue Power Delivery: Mechanical Governor

3. Qperation of 14 Volt DC Output Circuit

A. Preparation for Power Delivery

B. Power Delivery

(1) Normal 14 volt power delivery with

automatic voltage control

(2) 14 volt power delivery with

manual voltage control

c. Discontinue 14 Volt Power Delivery 8

D. Switching Power from Mode-to-Mode 8

(1) Switch from 14 volt to 28.5 volt delivery 9/10

(2) Switch from 28.5 volt to 14 volt delivery 9/10

4. Trailer Operation 9/10

A. Towing 9/10

B. Parking 9/10

Servicing 2-o 1

Maintenance Inspection/Check 2-l 1

1. General 1

2
_L -_Maintenance
.-- Schedule 1,

Page 4
 w
I OM-168

TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

B. Maintenance Schedule Check Sheet 2-l 1

C. Time Intervals i 4 1

3. Inspection/Check 1

A. 10 Hours or Daily Checks and Operations 1

(I) Engine 1

(2) Electrical system (12 volt DC) 3

(3) Electrical system (28.5 volt DC) 3

B. 100 Hours or Biweekly Checks and Operations 3

(I) Engine 3

(2) Electrical system (28.5 volt DC) 3

C. 200 Hours or Monthly Checks and Operations

(I) Engine

(2) Electrical system (12 volt DC)

D. 400 Hours or Bimonthly Checks and Operations

(1) Engine

(2) Electrical system (12 volt DC)

(3) Electrical system (28.5 volt DC)

E. 800 Hours or 6-Month Checks and Operations

(I) Engine

(2) Electrical system (12 volt DC)

(3) Electrical system (28.5 volt DC) 516

Maintenance Procedures 2-2

1. General

2. Lubrication

Aug 6181 Contents

Page 5
 TABLE OF CONTENTS(CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

A. General 2-2 1
i 4 1
j3. Lubrication Chart

c. Generator

b. Generator Controls

E. Engine

(1) Lubrication schedule 1

(2) Oil specification 3

(3) Oil viscosity 3

(4) Change engine oil (100 hours) 4

(5) Change engine oil filter (100 hours) 5

F. Engine Accessories 5

(1) Distributor 5

(2) Governor linkage 5

(3) Mechanical governor '5

G. Trailer 5

(1) Front axle assembly 5

(2) Wheel bearings .5

3. Servicing the Air Cleaner and Crankcase Ventilation System 5

A. General 5

B. Clean and Service Air Cleaner 6

C. Clean Crankcase Ventilation System 6

4. Servicing the Fuel Filter 6

5. Drive Belt Service 6

6. Engine Cooling System 7

,...= age 6 . - -..

 OM-168

TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

A. General 2-2 7

B. Rust Inhibitor 7

C. Antifreeze 7 t

7. Battery Service 7

8. Generator Maintenance 7

A. General 7

B. Brush Service 7

(1) Cleaning 7

(2) Replacement 8

(3) Brush seating 9

(4) Brush springs 9

(5) Commutator cleaning 9

9. Generator Controls Maintenance (14 Volt Output Option Only) 9

A. General 9

B. Overload Relay 9

(I) Disassemble 10

(2) Inspection 10

(3) Assemble 11

Adjustment/Test 2-3 1

1. General 1

2. Testing the Generator Set 1

A. Preoperational Test Procedures 1

B. Operational Tests 3

C. 14 Volt Output Option Test 4

Aug 6181 Contents

Page 7
 TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

3. Adjusting the Generator Set , 2-3 4

i i, 4
A. Brushholder Adjustment

B. Initial Adjustment of Brushholder 6

k. Brush Spring Adjustment 6

D. Engine Electronic Governor Adjustments 7

E. Engine Mechanical Governor Adjustments 13

F. Overspeed Governor Adjustment 13

6. Voltage Regulator Adjustment (14 volt and 28.5 volt) 14

A. 14 Volt Option Circuit Adjustments 14

(1) Adjust overvoltage relay trip point 14

(2) Adjust 14 volt output voltage 14

Repair 2-4 1

1. General 1

2. Disassembly '1

A. Separate Engine and Generator 1

B. Remove Coupling Assembly 2

3. Cleaning .2

4. Assembly 2

A. Check 2

B. Assembly Procedures 2

Troubleshooting 3-o 1

Introduction 3-l 1

1. General 1

Illustrated Parts List 4-o 1

_ Introdwtio-n.
~-._---~-______________~. .JPJ 1,
 1 I OM-I 68

TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

1. General 4-I

2. Purpose
i 4

3. Arraigement

4. Explanation of Parts List 1

A. Contents 1

B. Parts List Form 1

(I) Figure-Item No. Column 1

(2) Hobart Part Number Column 2

(3) Nomenclature Column 2

(4) Rec. Spares Column 2

(5) Eff (Effective) Column 2

(6) Units Per Assembly Column 2

5. Reference Designator Index 2

Manufacturer’s Codes 4-2 1

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

Parts List 4-3 1

1. Explanation of Parts List Arrangement 1

2. Symbols and Abbreviations 1

Numerical Index 4-4 1

1. Explanation of Numerical Index 1

Optional Equipment 5-o II2

Manufacturer’s Literature 6-O II2

Aug 6181 Contents

Page 9
 LIST OF ILLUSTRATIONS

CHAPTER/ FIGURE PAGE

SECTION NUMBER TITLE NUMBER

l-l 1 J f-E& Generator Set 2

l-l 2 Sbe&fications and Capabilities
(Sheets 1 and 2) 314
i-i 3 Generator Set Components 6
l-l 4 Control Box Front Panel 9
l-l 5 Rear Panel Assembly (Control Box) 11
l-l 6 Engine Control Panel 13
l-l 7 14 Volt Contactor Panel 15
f-1 8 14 Volt Control Panel 16
l-l 9 14 Volt Output Terminal Panel 17/18

i-2 1 28 Volt Output Terminal Panel 4

l-2 2 Stationary Unit Mounting Holes 516

l-3 1 Operating Controls and Indicators 2

2-l 1 Inspection/Check/MaintenanceSchedule
(Sheets 1 and 2) 2-3

i-2 1 Lubrication Chart

2-2 2 Lubricants
2-2 3 Symbols and Time Intervals
T-2 4 Temperature and Oil Viscosity Chart
2-2 5 Not Used
2-2 6 Generator Brush Installation 8
2-2 7 Overload Relay Installation 10 (
i-2 8 Overload Relay Dashpot Assembly 11

2-3 1 Operating Controls and Indicators 2

2-3 2 Brushholder Assembly 5
2-3 3 Measuring Spring pressure 7
2-3 4 Generator Brushes 8
2-3 5 Governor Linkage 9
2-3 6 Internal Governor Adjustments 10
2-3 7 Mechanical Governor Adjustments 11
2-3 8 Overspeed Governor 12

2-4 Coupling and Fan Assembly 3

2-4 Coupling Attached to Flywheel 4
2-4 Armature Position 516

3-l Operating Controls and Indicators 2

3-l Troublshooting Chart (8 Sheets) 3 thru 10

Contents
.--.--
- --__ -.--.-Revised
Feb lo/84 - _.___
__-.--.~ -i
-Page-10. _- .~_
 LIST OF ILLUSTRATIONS (CONTINUED)

CHAPTER/ FIGURE PAGE

SECTION NUMBER TITLE NO.

4-l 1 Reference Designator Index 3/4

I 'I
4-3 1 Generator Set 2
4-3 2 Canopy Assembly 4
4-3 3 Canopy Assembly 6
4-3 4 Generator Set Without Canopy 8
4-3 5 Control Box Assembly 110
4-3 6 Rear Panel Assembly 14
4-3 7 28.5 Volt Output Terminal Assembly 16
4-3 8 Engine Control Panel Assembly 18
4-3 9A Mechanical Governor '19A
4-3 9 Speed Control Group 20
4-3 10 Battery Installation 22
4-3 11 Fuel System 24
4-3 12 Cooling System 26
4-3 13 Generator and Drive Group 28
4-3 14 Brushholder Assembly 30
4-3 15 Trailer Assembly (Option) 32
4-3 16 14 Volt Control Panel Assembly (Option) 36
4-3 17 14 Volt Contactor Panel Assembly (Option) 38
4-3 18 14 Volt Output Terminal Assembly 40
4-3 19 Zenith Carburetor Kit 42
 CHAPTER 1. DESCRIPTION/OPERATION

SECTION 1. DESCRIPTION

: 1. General

The Jet-Ex 3 units coyeiredin this manual (Figure 1) are gasoline engine-
i driven, self-contained generator sets manufactured by Hobart Brothers
Company, Power Systems Division, Troy, Ohio U.S.A. The basic units are
identified by a Specification Number 6272, plus a dash number which defines,
a specific configuration. The Series number, plus the dash number, make up
the Specification Number.

Specification No. 6272-l covers a stationary, skid mounted unit rated at

28.5 Volts DC output. It is equipped with a sheet metal canopy and hinged
doors. The 6272-2 unit is the same as the 6272-l unit, but it is equipped
with lift-off doors. This allows it to be mounted in confined areas. The
6272-3 unit is the same as the 6272-l unit, but it is equipped with a
mechanical governor instead of an electronic governor. The 6272-4 unit is
the same as a 6272-2 unit but it is equipped with a mechanical governor.
Various options are available for use with the two basic units. 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 de-
signed for starting any fixed-wing aircraft or helicopter which is equipped with an external 28.5-volt DC power
receptacle. Refer to Figure 2 for complete Specifications and Capabilities.

Special Features

A. Standard

The “Soft-Start” current limiting feature, recommended by most engine manufacturers, provides the operator
with a control which limits the inrush current to the aircraft engine’s starter. When the operator presets this
control, the generator will provide constant voltage up to the preset current value, at which point the voltage
drops, but the preset current limit is maintained. Limiting inrush current is recommended by most engine
manufacturers to protect the aircraft engine’s starter shear section. The current limiting control is contin-
uously adjustable from 300 amperes, which is recommended for helicopter and small turbine starting, to
1500 amperes, required for starting larger aircraft engines. With the control turned fully.clockwise, 1600
amperes can be achieved.

Additional features include an all-electronic governor which maintains the engine speed at 2400 RPM, and
an all-electronic engine overspeed protection device which shuts down the engine by opening the ignition
circuit if the engine speed reaches 2900 RPM.

Units with serial numbers 82PSO1305 and higher are equipped at the factory with a Zenith carburetor, special-
ly designed for engine governor type applications. This improved carburetor also eliminates dieseling when the
engine is shut down.

B. Options

(I) 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 a hand-operated parking brake. This option is available from
/
Hobart Brothers as Part No. 484331. , /’
,’
_ (2) A kit is available which provides 14.25 volt DC output capability in addition to the 28.5 volt DC _,
standard output. This option is available from
~-___ Hobart Brothers as Part No. 485910. /..,'
-- .-.
_- ---Feb.-lQ.,&4
.-~~~-~_------~_..--.---.-. - .--
---
- - .___.
~_---_..__
~..
.~~ -1-1
 OM-168

! ‘I
-
--

Jet-Ex 3 Generator Set

Figure 1
1-I
Aug 6181
Page 2
 STATIONARY UNIT

Length 74 inches (1880 mm)

Width 43 inches (1092 mm)
Height 43- inches (1992 mm)
i 4
Weight (dry fuel tank) 1860 pounds (844 kg)

TRAILER-MOUNTED UNIT

Length 91 inches (2311 mm)

Width 66 inches (1676 mm)
Height 55 inches (1397 mm)
Weight (dry fuel tank) 2240 pounds (1016 kg)

TRAILER

Tread 58 inches (1473 mm)

Wheelbase 50.5 inches (1283 mm)
Ground Clearance 7 inches (178 mm)
Tires 6.9016.00 X 9 (6 ply)
Tire Pressure 60 PSI (414 kPa)

GENERATOR

Output Power Rating 21.4 kW

Voltage 28.5 volts DC
Rated Load Capacity 750 amperes at 50% duty cycle (5 minutes on, 5 minutes off)
530 amperes continuous at 28.5 volts DC
1600 amperes maximum
Current Limiting Capability 300 to 1500 amperes continuously adjustable
Operating Speed 2400 RPM

ENGINE

Manufacturer Ford Motor Company

Model CSG-6491-6005-A (with Special Options: SO-2800C)
Type Overhead valve, in-line, 6 cylinder
Fuel Gasoline, leaded, regular
Displacement 300 cubic inches (4.92 liters)
Rated Power at 2400 RPM 92 Horsepower
Oil Capacity (with filter change) 7 quarts (7 liters)
Coolant Capacity 5.5 U.S. gallons (21 liters)
Ignition System (Distributor-coil type) 12 volt DC, negative ground
Governed Speed 2400 f 25 RPM
Idle Speed 609 to 650 RPM
Fuel Tank Capacity 30 U.S. gallons (114 liters)

Specifications and Capabilities

Figure 2 (Sheet 1 of 2)

Aug 6181 I-l

Page 3
 OM-I 68

PROTECTIVE DEVICES

GENERATOR

.d i
28.5 volt overvoltage module trr s ai 32 to 34 volts in 2 to IO seconds.
Overload relays trip at 1000 amperes in 1 minute.
14 volt overvoltage module trips at 18 to 20 volts in 2 to IO seconds.

ENGINE

Overspeed device trips at 2850 to 2900 RPM.

Low oil pressure switch opens at IO PSI (69 kPa).

Specifications and Capabilities

Figure 2 (Sheet 2 of 2)

(3) An air heater kit is available which helps prevent carburetor icing when the engine is operated in a low
ambient temperature. Heated air passing over the exhaust manifold is collected and conducted to the
carburetor’s air cleaner intake. A thermostatically controlled valve in the duct regulates the temperature
of the air delivered. This option is available from Hobart Brothers as Part No. 486113.

(4) A spark arrester muffler kit is available which prevents the discharge of sparks from the engine’s, ex-
haust. The manufacturer recommends this muffler for use on engines which operate in areas where this
type of exhaust protection is required by local codes or company restrictions. The muffler exceeds the
performance standards set by DOD Specification MIL-A-27302Aand U.S. Forest Service Standard
5100-I. This option is available from Hobart Brothers as Part No. 486114.

3. Orientation

The radiator end of the Jet-Ex 3 is the front. Right and left are determined by standing at the rear of the unit,
facing it. The control box and engine control panel are located on the right side.

4. Identification

The Jet-Ex 3 units are identified by Specification numbers as described in paragraph 1, above. There may be any
number of generator sets with the same Specification number. Individual machihes are identified by a Serial
number, assigned to one machine only.

Each generator set has an Identification plate attached inside the front panel of the control box. This nameplate
lists the machine’s Model No. (Jet-Ex 3). 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.

l-l Aug 6181

Page 4
 OM-I 68

5. Canopy

The standard canopy, used on Specification No. 6272-1, is a sheet metal enclosure which protects the engine,
generator, and electrical controls. It has two large, hinged doors on each side to provide access for service and
maintenance. A large panel at the rear provides access to the generator. A Plexiglass window is mounted in the
right rear door to allow observation of the instruments without opening the door. The window is mounted at an
angle and is open at the bottom to !allow
’ access to the controls without opening the door. The left rear door has
a round hole in it to permit viewing the fuel gage mounted in the fuel tank.

The canopy used on Specification 6272-2 is identical to the one above, except for the doors, which, are not
hinged. Each door may be lifted off after unlatching its fasteners.

6. Engine, Generator, and Controls

A. General

Refer to Figure 3. The engine (3) and generator (16) are mounted on a welded steel frame (11). A sub-frame
(18) located at the rear of the unit supports the control box (1) and fuel tank (15) and provides a mounting
frame for the engine control panel (10). The radiator (13) is mounted on the main frame at the front of the
unit. A heavy U-bolt is attached to the centrally located lifting yoke (14) for moving the generator set with
a crane or hoist.

B. Engine

(1) General

The in-line six cylinder engine is a modified Ford Model CSG-6491-6005-A. It has 300 cubic inch (4.92
liters) cylinder displacement and uses leaded, regular gasoline.

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

Oil pressure is maintained in the lubrication system by a rotary oil pump located in the crankcase. A
spring-loaded relief valve in the pump limits maximum pressure in the system. A full-flow oil filter
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 (21, Figure
3) is mounted on the engine block as a protective device. The primary ignition circuit is wired through
the contacts of this switch, which close at IO PSI (69 kPa). This prevents the engine from’starting if oil
pressure will not build up, and also shuts down the engine if oil pressure drops radically during operation.

See Figure 2 and the engine operator’s manual for engine specifications.

(2) Cooling fan

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

(3) Engine speed governor

The engine speed governor (4, Figure 3) is a sealed, solid-state unit which is controlled by pulses from the
engine’s distributor circuit. Its actuator arm is linked to the carburetor fuel control lever by a rod with
ball joints threaded on both ends. This governor maintains the engine speed at approximately 2400
RPM when the generator is in operation.

Aug 6181 I-l

Page 5
 OM-168

RIGHT
SIDE

12

13 14 I5

16

LEFT
SIDE

18

24 23 22 21 20 19
‘.
‘.-.,... I IpsD-04891
1. Control Box 9. Battery 17. 14 Volt Output Panel (When Used)
2. Alternator Regulator 10. Engine Control Panel 18. Sub-frame Support
3. Engine 11. Frame 19. 14 Volt Contactor Panel (When Used)
4. Governor 12. 28 Volt Output Terminal Panel 20. Fuel Shutoff Solenoid Valve
5. Alternator 13. Radiator 21. Low Oil Pressure Switch
6. Drain Cock 14. Lifting Yoke 22. Oil Pressure Sender
7. Coolant Temperature Sender 15. Fuel Tank 23. Oil Filter
8. Starter Relay 16. Generator 24. Fuel Pump and Fuel Filter

Generator Set Components

I-l Figure 3
Revised Nov 17182
Page 6
 (4) Engine overspeed device OM-168

The engine and generator are protected against the danger of overspeed by an overspeed governor (9,
Figure 5). This unit is a sealed, solid-state device which is wired into the primary ignition circuit. It
senses the distributor pulses, and when they reach a frequency which indicates an engine speed of
approximately 2900 RPM, an internal relay opens the primary ignition circuit and shuts down the
engine.

(5) Crankcase ventilation i 4

This engine is equipped with an open crankcase ventilation system. This open ventilation system con-
sists of two breather caps on the rocker arm cover.

(6) Fuel system

The fuel system consists of a 30 gallon (114 liters) tank (15, Figure 3) and a diaphragm type fuel pump
(24) with all necessary fittings and hoses. A 12 volt, solenoid operated shutoff valve (20) is mounted in
the fuel line under the tank. It shuts off the fuel supply to the engine when the ENGIN,E (ignition)
switch on the control box is in the STOP position (ignition OFF). This keeps the engine from flooding
due to gravity flow or siphoning from the tank when the engine is not running.

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

(7) Alternator and regulator

The battery charging alternator (5, Figure 3) is rated at 40 amperes. Its voltage regulator (2) is mounted
on the side of the control box.

(8) Starter relay

The starter relay (8, Figure 3) is mounted on the control box support below the alternator regulator.

(9) Special carburetor

The carburetor, specially designed for engine governor type applications, is mounted on the engine and
adjusted at the Hobart factory. Replacement carburetor, spare parts, and repair kits are available from
Hobart Brothers only. Refer to the Illustrated Parts List in Section 4-3 for part numbers.

C. Generator

The 28.5-V DC generator (16, Fig. 3) is a,self-excited, shunt-wound type with interpoles to imyj‘rovecomt .,I _-
mutation. Excitation voltage is taken from the main generator output at the brushes and is controlled at the
option of the operator either by a manual voltage control rheostat (7, Figure 5) or by an automatic voltage
regulator (1). Sixteen brushes, mounted in four stacks of four brushes each, conduct the 28.5 volt DC gen-
erator output from the armature commutator to the two output cables (one positive, one negative). A
two-piece cover protects the brushholder assembly and allows access for brush service.

The armature is supported at the rear, commutator end by a single-row ball bearing. The front (drive) end is
connected to the engine flywheel by a flexible disc and hub coupling assembly and is supported by the engine
main bearings. A radial-blade fan of spot-welded construction is mounted on the coupling hub and draws
cooling air over all of the generator windings.

Air enters through louvers in the rear (brushholder) cover and is discharged through openings in the fly-
wheel housing. An expanded-metal cover surrounds the flywheel housing. The generator housing assembly
contains a set of main shunt coils, and a set of interpole coils which are mounted alternately between the
shunt coils. The generator housing is bolted directly to the engine flywheel housing.

Nov 17182 Revised I-l

Page 7
 ‘4
1 I
I 1 OM-168

D. Control Box Assembly

(1) General

The control box (1, Figure 3) is a sheet metal enclosure which houses and provides mounting facilities
for controls and monitoring instrurhehts. The box is mounted on the support frame over the generator.
Its controls are accessible through the opening provided in the right rear canopy door. The hinged front
panel (Figure 4) provides mounting for monitoring instruments and controls, and also provides access
to the rear panel assembly (Figure 5) which is inside the control box. A quick-release latch (5, Figure 4)
secures the front panel in the closed position.

(2) Lights

Two lights (2, Figure 4) provide illumination for instruments and controls. One green pilot light (8)
glows when the output load contactor is closed, and another one (19) glows green when the engine is
running.

(3) Monitoring instruments

The voltmeter (3, Figure 4) indicates generator output voltage, and the ammeter (6) displays generator
current.

A tachometer (4) displays the engine speed in RPM. This instrument is operated by pulses from the
distributor.

A water temperature gauge (1) indicates the engine coolant temperature and is actuated by a temperature
sender (7, Figure 3) mounted in the engine’s water jacket.

An oil pressure gauge (16, Figure 4) displays the pressure in the engine’s lubrication system. It is operated
by a sender (22, Figure 3) mounted on the engine block.

The ammeter (14, Figure 4) indicates the rate of charge or discharge in the engine’s 12 volt; DC electrical
system.

The hourmeter (11) records the total hours of engine operation for scheduling maintenance.

(4) Potentiometer

The current limiting potentiometer (7) is used to select the starting current recommended for various
aircraft. The current limit setting is continuously adjustable from 300 to 1600 amperes.

(5) Switches

The contactor control switch (9, Figure 4) is a three-position toggle switch used to close and open the
output load contactor. The top CLOSE position is spring-loaded and is held momentarily until the
contactor closed light (8) glows, then 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 holding cir-
cuit provide protection against overload and overvoltage by opening the load contactor if either fault
occurs. In the bottom OFF position, the contactor is opened.

I-l Aug 6181

Page 8
 OM-I 68

I 2 3 4 5 6 2 7

19 18 17 16 15 14 I3 I2 II IO 9 8

1. Water Temperature Gauge 11. Hourmeter

2. Panel Light 12. Panel Lights Switch
3. Voltmeter 13. Panel Lights Fuse
4. Tachometer 14. Ammeter (Engine)
5. Latch 15. Engine Circuit Fuse
6. Ammeter (Generator) 16. Oil Pressure Gauge
7. Current Limit Control 17. Engine Start Switch
8. Contactor Closed Light 18. Engine Ignition Switch
9. Contactor Control Switch 19. Engine On Light
10. Push-To-Build-Up-Voltage Switch

Control Box Front Panel

Figure 4

Aug 6/8l I-l

Page 9
 The push-to-build-up-voltage switch (10) is a momentary contact pushbutton switch which flashes the
generator fields with 12 volts DC at initial startup. Use this switch at startup only if the generator fails
to build up voltage by itself. A diode is wired into this switch to prevent 28.5 volts DC generator output
from entering the 12 volt engine circuit when flashing the fields.

The panel lights switch (12, Figurei4\ {turns the lights (2) on and off. The engine start switch (17) is a
momentary contact pushbutton which closes the starter relay (8, Figure 3) and cranks the engine. This
switch is operable only when the engine (ignition) switch (18) is held in its top spring-loaded START
position.

The engine (ignition) switch (18), when released from its top START position after the engine starts,
will return to its center RUN position. The engine on light (19) 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 (19) will go
out.

(6) Fuses

Two cartridge-type fuses protect the engine ignition circuit and the panel lights circuit. The engine cir-
cuit fuse (15, Figure 4) is rated at 20 amperes and the panel lights fuse (13) is rated at 10 amperes.

E. Rear Panel Assembly (Control Box)

The rear panel assembly provides a mounting place for various control and protection components of the
generator set. It also serves as the back enclosure panel for the control box. Components mounted on this
panel are accessible when the front panel on the control box is opened.

(I) Voltage regulator

Refer to Figure 5. The voltage regulator (I) is a solid-state device which regulates the 28.5 volt DC
generator output when the switch (8) is in the AUTOMATIC position.

(2) Overvoltage module

The overvoltage module (2) is a solid-state protective device on a printed circuit board. A normally closed
relay in the circuit is wired into the load contactor closing and holding circuit. An overvoltage condition
causes the relay contacts to open, which in turn prevents the contactor from closing or opens the load
contactor and discontinues the power delivery. The overvoltage module is adjusted to trip at 32 to,34
volts DC in 2 to 10 seconds.

(3) Overload module

The overload module (3) is a solid-state protective device on a printed circuit board which protects the
generator and output circuit against overload. Its circuitry includes a relay with normally closed contacts
which are wired into the load contactor holding circuit. An overload condition at the generator’s output
terminals will open the relay contacts, which in turn opens the load contactor holding circuit and dis-
continues power delivery. The module is adjusted to trip at 1000 amperes in 1 minute. A larger load will
trip it in a much shorter time.

I-l Aug 6181

Page 10
 OM-168

.I -1

+I II

r
I
f I ’

Id, I2 ii IO 9

1. Voltage Regulator 9. Overspeed Governor

2. Overvoltage Module 10. Ammeter Shunt
3. Overload Module 11. Diode
4. Load Contactor 12. Rubber Grommet
5. Resistor 13. Terminal Block (18 T)
6. Contactor-To-Shunt Bus 14. Terminal Block (12 T)
7. Field Rheostat Control 15. Resistor and Diode Assembly
8. Automatic/Manual Switch 16. Terminal Block (12 T)

Rear Panel Assembly (Control Box)

Figure 5
Aug 6181 I-l
Page 11
 (4) Load contactor

The load contactor (4) provides a safe and convenient means of connecting and disconnecting the gen-
erator 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 (9, Figure 4). Holding power to keep
the contactor closed passes throu h )the ‘contacts of the control switch in the ON position and also
through the normally closed relays31in \he overvoltage and overload modules. If an overvoltage or over-
load fault’occurs, the holding circuit is broken, the load contactor opens, and power delivery is discon-
tinued.

A resistor (5, Figure 5) provides a light load across the generator’s output terminals which is required
to close the differential relay contacts in the load contactor.

(5) Ammeter shunt

The ammeter shunt (10) is connected in the generator’s positive output circuit. It supplies a voltage pro-
portional to current for operation of the generator ammeter (6, Figure 4). A diode (11, Figure 5) is
mounted in the bus bar (6) to prevent 12 volt field-flashing power from entering any part of the generator
circuit and building up reverse polarity.

(6) Automatic/manual switch

The automatic/manual switch (8, Figure 5) is a two-position toggle switch which selects the mode of ex-
citation to the generator fields. In AUTOMATIC position, controlled excitation to the fields is provided
by the voltage regulator (1). In the MANUAL position, excitation is controlled manually with the field
rheostat (7). Manual operation is to be used temporarily, for emergency operation, if a voltage regulator
malfunction should occur. Manual operation is also used in troubleshooting.

(7) Overspeed governor

The overspeed governor (9, Figure 5) is a sealed, solid-state protection device which receives pulses from
the engine’s distributor. When the pulses reach a frequency which indicates an engine speed of 2900 RPM,
a relay in this unit opens the primary ignition circuit and shuts down the engine.

(8) Resistor and diode assembly

This network (15, Figure 5) protects the overload and overvoltage modules against reverse current when
the generator is delivering power.

F. Engine Control Panel

The engine control panel (IO, Figure 3) is mounted on the support frame below the control box. It provides
mounting for the GENERATE/IDLE (engine speed) switch and the engine CHOKE control knob.

(1) Generate/idle switch

Refer to Figure 6. The generate/idle switch is a two-position toggle switch wired directly into the engine’s
speed control governor (4, Figure 3). In the IDLE position, used for starting, the engine speed is con-
trolled to approximately 600-650 PRM. In the GENERATE position, engine speed is controlled to
approximately 2400 RPM.

l-l Aug 6181

Page 12
, , ‘I..
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. .’ OH-168
4 l

O&TIE 0

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Engine Control Panel
Figure 6

(2) Choke control

The choke control is connected to the carburetor choke butterfly

with a flexible control cable. Pulling it out closes and enriches
the fuel mixture. Pushing it in closes the choke. ,

(3) Throttle control (6272-3 & 4)

The throttle control is connected to the carburetor throttle lever

with a flexible control cable. Pulling it out decreases the fuel
flow to the carburetor. Pushing it in increases the fuel flow.
.
G. Output Terminals

The output terminal panel (12, Figure 3) is mounted at the rear of the control box support. Two capacitors
on this panel help suppress radio frequency interference at the output.

7. Optional Equipment

The two options most frequently used with the basic Jet-Ex 3 generator set are the trailer and the 14 volt output.
These two options are included in the Illustrated Parts List, Chapter 4 of this manual and are described here in
detail because of their frequent use.

Other available options are covered in separate manuals which are included in Chapter 5 of this manual when they
are ordered with the generator set.

A. Trailer

The portable Jet-Ex 3 is mounted on an optional four-wheel trailer (see Figure 1) which consists of front and
rear axle assemblies. The axles are mounted directly to the main frame of the generator set.

The front axle is a solid beam type. Front wheels are mounted on spindles which are operated by tie rods
connected to the hitch and drawbar assembly. Any side-to-side movement of the drawbar turns the wheels
in the direction of travel. The drawbar can be folded upward and locked in the vertical position when the
trailer is parked.

The rear axle is also a solid beam type. The parking brake consists of a bar mounted across the underside of
the frame ahead of the rear wheels. Metal pads are located on each end of the bar just ahead of each tire.
When the bar is actuated by a hand lever and brake operating rods, the pads are pulled against the tire tread
with sufficient pressure to prevent wheel rotation. The actuating mechanism works on an over-center locking
principle which will not unlock until the hand lever is pushed to release position.

May 30184 Revised

-_-_-__ _ . -.-----.- ..--__.---~.~~--.-. .--.. Page 13

~..~~~
 OM-168

6. 14 Volt DC Output

All Jet-Ex 3 units are available with optional 14 volt DC output capability. The 14 volt DC output kit consists
of a contactor panel (Figure 7), a control panel (Figure 8), an output terminal panel (Figure 9), and mis-
cellaneous cables, wiring, and hardware ’
I ‘I

(I) 14 volt cdntactor panel

The 14 volt contactor panel (Figure 7) is located on the left side of the machine below the fuel tank
(19, Figure 3). Its function in the 14 volt DC output circuit is similar to that of the rear panel assembly
(Figure 5) in the 28.5 volt DC output circuit.

(a) Overload relay

This solenoid-operated, dashpot-type relay (8, Figure 7) opens the load contactor (4) if a load of
1000 amperes continues for 1 minute. A larger load will trip the relay in a shorter time.

(b) Control relays

The two control relays (1 and 3, Figure 7) are identical. They are identified as 14 volt and 28.5 volt
relays because of the voltage values of their coil circuits. Their function is to prevent operation of
both output circuits (14 volt and 28.5 volt) at the same time. They also prevent closing of the 14
volt circuit while the 28.5 volt circuit is in operation. When the 14 volt system is in operation,
they allow the 28.5 volt system to be closed by the operator and at the same time automatically
open the 14 volt circuit. The 14 volt relay (1) energizes the 14 volt control circuit when the 14
volt load contactor is closed.

(c) Load contactor

The 14 volt load contactor (4, Figure 7) performs the same function as the one in the 28.5 volt
output circuit. See para. 6. E. (4) for description.

(d) Overvoltage module

The 14 volt, overvoltage module (6, Figure 7) is similar to the module used on the rear panel assem-
bly of the control box. See Para. 6, E, (2) for description. The 14 volt module is adjusted by a, resistor
(9) to trip at 18 to 20 volts DC in 2 to IO seconds. The relay resets at 14.5 to 15.5 volts DC.

(e) Resistors

The 300 ohm, 25 watt variable resistor (9, Figure 7) is used to adjust the trip point of the over-
voltage module (6). Adjust the resistor to give 20 volts at the overvoltage module input.

The 100 ohm, 25 watt resistor (7) is not adjustable. It is connected across the 14 volt output leads
to provide a small load required to close the differential relay contacts in the load contactor to make
the contactor closing circuit functional and allow the main contacts to be closed when desired.

The 120 ohm, 2 watt resistor (2) is connected in series with the 28.5 volt control relay coil to reduce
power to the coil and protect it when-the 28.5 volt output circuit is in operation.

I-l Aug 6181

Page 14
 OM-168

1. Control Relay, 14 Volt 6. Overvoltage Module

2. Resistor 7. Resistor
3. Control Relay, 28 Volt 8. Overload Relay
4. Load Contactor 9. Resistor
5. Positive Output Terminal IO. Negative Output Terminal

14 Volt Contactor Panel

Figure 7

Aug 6181 I-1

Page 15
 (2) 14 volt control panel

NOTE: When the 14 volt output kit is ordered with the generator set, it is completely
installed, wired, and tested at the factory. Installation instructions for the con-
trol panel below apply ONLY to. kits furnished separately, for installation
on existing generator sets $r$ady in use.

When the optional 14 volt output kit is installed, the engine control panel illustrated in Figure 6 must be
replaced with the panel shown in Figure 8. When the new panel is installed, use the existing hardware
from the old panel, and reinstall the GENERATE/IDLE switch and the CHOKE control in the same
positions that they occupied before. The replacement panel has 14 volt output controls grouped to-
gether at the right side over the label: 14 V. CONTROL PANEL.

A wire harness is connected to the switch and lights at the rear of the panel to provide proper connec-
tions for the added 14 volt controls. Refer to the schematic and connection diagrams in Chapter 6 to
make the proper connections.

(a) Mode indicating light

This light (1, Figure 8) glows AMBER if and when the 14 volt output circuit is functional. If
the light does not come on when the switch (2) is placed in ON position, it indicates to the operator
that the 14 volt circuit is not functional and the 14 volt contactor cannot be closed.
,,’

i. L : 1 :-.-i , .._ _,

1. Circuit On Light
2. Circuit Control Switch
3. Contactor Closed Light

14 Volt Control Panel

Figure 8

:_
-L?J-~--__---.~.---._-____~__~~~____--_~ --Revised Feb-LQ/@
 I I

m
I I OM-168

(b) Contactor closed light

This GREEN light (3 glows when the 14 volt contactor is closed and power is available at the 14
volt output terminal barIel.
!

(c) Control switch

In the ON position, this three-position toggle switch (2) connects power to the 14 volt control relay
and to the amber mode indicating light. In the CLOSE CONTACTOR position, it connects power to
the load contactor coil for initial closing of the contactor. When released from the CLOSE CON-
TACTOR position, it returns automatically to ON and maintains power to the 14 volt control relay.
Power to the load contactor coil is maintained through contacts in the 14 volt control relay, the 28
volt control relay, the overload relay, and the overvoltage module. Placing the control ,switch in OFF
position opens the load contactor by disconnecting power to the 14 volt control relay, which opens
the contactor coil holding circuit.

(3) 14 volt output terminal panel

The output terminal panel is located at the rear of the unit on the left side (17, Figure 3). Refer to Figure
9. Two capacitors, and one on the back of the panel, are wired into the output terminals to help suppress
radio frequency interference at the output.

I b 14 VOLTS @j I

1. Positive Output Terminal

2. Negative Output Terminal
3. RFI Suppression Capacitor

14 Volt Output Terminal Panel

Figure 9

Aug 6181 l-l

Page 17/I 8
 OM-168

SECTION 2. PREPARATION FOR USE, STORAGE, OR SHIPPING

1. Preparation for Use

A. General i 4

The generator set is shipped in operating condition and is ready for use after inspection and check.

CAUTION: READ OPERATING INSTRUCTIONS IN SECTION l-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 protective material.

(2) Inspect exterior for shipping damage such as broken glass, damaged sheet metal, etc.

(3) Open all canopy doors and inspect interior for foreign material such as rags, tools, shipping papers, etc.

(4) Check fuel, coolant, and oil hoses and connections for visible leaks. Check the ground surface under the
unit for evidence of 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 30 gallons. Use leaded, regular gasoline.

(b) Engine coolant

The radiator cap is accessible by opening the hinged access cover on the front canopy housing. Twist
the cover fastener one-half turn to unlock. 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 left side of the engine. Refer to Ford Maintenance and
Operator’s Manual for oil recommendations.

Aug 6181 1-2

Page 1
 OM-168

(7) Air cleaner

Make sure air cleaner element is installed. Recommended replacement element is Motorcraft No.
FA-52 or Ford part number CBTF-9601-A.

(8) Battery

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

C. Output Cable Installation

Units are normally supplied without a generator-to-aircraft cable.

(1) Cable requirements

Cable length is determined by the customer’s requirements. It is recommended that the cable be no
longer than 30 feet (9 m). The cable should be two conductor with lug-type terminals on one end and
an AN-2551 plug connector on the other.

The recommended single conductor sizes for 28.5 volt DC, continuous rated amperage and 90°C (194OF)
rise is as follows: for 285 amperes use 2/O size
for 385 amperes use 4/O size
for 530 amperes use 350 MCM size

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

(2) Cable connector

(a) Connect 28 volt conductors to output terminals on output terminal panel (Figure 1). Connect 14
volt conductors to output terminals on the 14 volt contactor panel (see l-l, Figure 9). Terminals
are identified POSITIVE and NEGATIVE. Tighten terminal nuts securely.

(b) Store cables on hangers provided at the rear of canopy.

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

(I) The unit should be prepared for storage as soon as possible after being removed from service.

(2) Storage should be in a building which is dry and which may be heated during winter months.

(3) Moisture absorbing chemicals are available for use where excessive dampness is a problem, however the
unit must be completely packaged and sealed if moisture absorbing chemicals are to be effective.

B. Temporary Storage

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

l-2 Aug 6181

Page 2
 (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 stora+)e;yeriod.

(3) Start the engine and operate at idle speed. With air cleaner removed, spray an engine preservative oil into
the carburetor air intake for about two minutes. This oil should be SAE No. 10, formulated for anti-rust 1
and anti-corrosion protection. It should also be a high detergent-type that meets requirements for most
severe (M.S.) service and Ford Specification M-4834-A.

(4) Manually override the governor control linkage at the carburetor for a short burst of speed, then turn the
ignition switch off and allow the engine to come to a stop while continuing to spray oil into the car-
buretor air intake.

(5) Clean the exterior of the engine with fuel oil and dry with clean cloths and compressed air.

(6) Seal all engine openings. Use a waterproof, vaporproof material which is strong enough to resist puncture
damage from air pressure.

C. Long Time Storage

(1) Engine operation method

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

(a)Make certain that the cooling system is adequately protected.

(b)Start the engine once each week and operate at idle speed until coolant temperature has reached at
least 140 deg F (60 deg C). Operating time should be sufficiently long to keep the battery in a fully
charged condition.

WARNING: MAKE CERTAIN OF ADEQUATE VENTILATION BEFORE STARTING

ENGINE.

(clOperate normal operating controls.

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

(a) Lubricate the unit in accordance with instructions in Section 2-l. Drain the crankcase completely
and refill with engine preservative oil Ford Specification M-4834-A.

(b) Drain the fuel tank and run the engine until the carburetor is empty. Pour about a gallon of unleaded,
undyed gasoline in the fuel tank and operate the engine for at least 10 minutes. With the engine
running at idle speed and the air cleaner removed, treat the upper cylinders, valves, etc., by spraying
an engine preservative oil into the carburetor air intake for about two minutes. Manually override the
governor control linkage at the carburetor for a short burst of speed, turn the ignition off, and con-
tinue to spray oil into the carburetor until the engine stops.

Aug 6181 1-2

Page 3
 w
OM-168
I I
(cl Drain engine oil. Drain fuel tank, carbure=l lines. Drain cooling system at bottom of
radiator and left side of engine block. Remove radiator cap so coolant will drain completely.

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

(e) Seal all engine openings and accessories with water resistant adhesive tape.

(f) Remove battery and store in a 1’odl 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 packaged,
using moisture proof packaging and sealing materials. Place packages of moisture absorbing chemi-
cals, such as silica-gel, in the unit before packaging.

WARNING: PLACE WARNING TAGS IN SEVERAL PLACES TO MAKE CERTAIN THAT

THE INDIVIDUAL WHO TAKES THE UNIT OUT OF STORAGE IS WARNED
THAT ENGINE OIL AND COOLANT HAVE BEEN DRAINED.

3. Preparation for Shipping

Prepare the unit for shipping as follows:

A. Seal all engine openings to prevent the entrance of water, dirt, and dust.

B. Disconnect battery cables.

C. Drain all fuel from tank, carburetor, and fuel lines as required by carrier rules.

D. Crate the unit solidly to prevent damage to instruments, glass, and sheet metal.

\I I 2 3
piiGz-\
:
1. RFI Capacitor
2. Positive Output Terminal
3. Negative Output Terminal

28 Voft Output Terminal Panel

Figure 1
1-2 Aug 6181
Page 4
 OM-168

4. Stationary Unit Mounting

Figure 2 illustrates the mounting hole pattern in the base of the stationary Jet-Ex 3 generator set. Each of the
eight holes is 5/B inch (16 mm) in diameter.

Stationary Unit Mounting Holes

Figure 2

Aug 6181 1-2

Page 516
c

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 i
supplying power to an aircraft.
i;
NOTE: Read ALL of the oberating instructions before attempting to operate
-!
the equipment.

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

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 locate4 at
the fuel tank outlet. Observe 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 I,

is raised and locked in the vertical position. The brake lever

operates on an over-center locking principle. Pull the lever
backward until it snaps into locked position. To unlock, push the
lever forward to full off position.

(4) Open doors and inspect interior for rags, tools, and fqreign
material.

B. Operating Generator with Electronic Governor

(1) Start-up Procedure

(a) Connect the output cable between the generator and the
aircraft receptacle connector.

(b) If the engine is cold, pull the CHOKE control (Ref Fig.'l,
Item 2) out to choke position. The amount of choking
required for a particular engine will become apparent to the:
operator after a few starts.

NOTE: Do not choke a hot engine.

(c) Make sure GENERATE/IDLE switch (20) is in IDLE Position'. ~

(d) Place the ENGINE (ignition) switch (18) in START position,

hold until the engine starts and the ENGINE ON light (19)
glows, then release to RUN position.

~~(e)_...Press
andholddthe EWI-NESTART pushbutton (17) to crank the
___~__
engine. Release the switch as soon as the engine starts.
Feb~_.
L0/_84_~_Revised__.._.._~...
-~~..~___..
.~-.--..~.-~__--~.---~.~__I__
_ ______1-q
- - -.
- -__
--___-----page-l
I 2 3 4 5 6 2 7 25 26

19 18 17 16 I5 14 I3 I2 II IO 9 8

20 21 27 22 23 24

NOTE: Items marked * are

used with 14 Volt
option only.
jpsDo2661 **
: Used with mechanical
governor only.'

*** : Used with electronic

governor only.

1. Water Temperature Gauge 14. Ammeter (Engine)

Panel Light
2. 15. Engine Circuit Fuse
Voltmeter
3. 16. Oil Pressure Gauge
Tachometer
4. 17. Engine Start Switch
5. Latch 18. Engine Ignition Switch
6. Ammeter (Generator) 19. Engine On Light
7. Current Limit Control *** 20. Generate/Idle Switch
8. Contactor Closed Light 21. Choke Control
9. Contactor Control Switch * 22. .14Volt Mode Light
10. Push-To-Build-Up-Voltage Switch * 23. 14 Volt Contactor Control Switch
11. Hourmeter * 24. 14 Volt Contactor Closed Light
12. Panel Lights Switch 25. Field Rheostat Control
13. Panel Lights Fuse 26. Automatic/Manual Switch
** 27 Throttle Control
 ! ./-
.I

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
ENGINE.

, ,DO'NOT
-m OPERATE THE STARTER FOR PERIODS LONGER THAN
1 '115SECONDS AT A TIME. AN INTERVAL OF AT LEAST TWO
MINUTES SHOULD BE ALLOWED BETWEEN SUCH CRANKING
PERIODS TO PROTECT THE STARTER FROM OVERHEATING. ,

(f) Push the CHOKE control in if the engine does not start after
being cranked a few revolutions.

(g) If engine flooding is suspected, push the CHOKE control in and

crank the engine again, observing the CAUTION above.

(h) When the engine starts, it should be allowed to idle and warm
before applying a load.

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

NOTE: Be sure that the CHOKE control is pushed all the way
in before operating the engine under load.

(2) 28.5 volt power delivery with automatic voltage control

(a) If lighting is required, position PANEL LIGHTS switch (12,

Figure 1) to ON.

(b) AUTOMATIC/MANUAL switch (26) should be in AUTOMATIC position.

(c) Push throttle control (27) in to generate speed and twist to

lock in place. Tachometer (4) should read 2400 RPM when engine
reaches operating speed.

(d) Check engine gages.

Ammeter should indicate a slight charge. It may be near zero

if the battery is fully charged.

Normal oil pressure is 35 to 60 PSI (240 to 414 kPa) hot.

Normal coolant temperature is 180 to 200 deg F (82 to 93 deg

C) depending on ambient temperature, load, etc.

(e) Press the push-to-build-up-voltage switch (10) to flash the

generator field coils.

NOTE: It is necessary to press this switch only when the

generator will not build up voltage by itself.

May 30/84 Revised

Page '3
 A voltage value of approximately 28.5 volt DC should be
observed on the voltmeter (3). If value is other than 28.5
volt DC, adjust voltage regulator according to instructions
in the voltage regulator manual in Chapter 6.

(f) Check to be &tain that the aircraft is in condition to

, receive power.

(g) If current limiting is required, adjust current limiting

rheostat (7) to maximum current desired.

(h) To apply power to the aircraft, close the load contactor by

holding the contactor control switch (9) in top CLOSE
position momentarily until indicating light (8) glows green.
Release switch and allow it to position to center ON ,
position. Light (8) should continue to glow, indicating that
the load contactor is closed and power is available at the
aircraft.

Voltage will be automatically regulated at approximately 28.5

volts DC by the voltage regulator (l-l; 1, Figure 4).

(3) 28.5 volt power delivery with manual voltage control

This mode of operation is recommended for generator testing, or

for emergency use in case of voltage regulator trouble only. For
manual control of generator output voltage, use normal operating
procedures except:

(a) Place AUTOMATIC/MANUAL switch (26) in MANUAL position. '

(b) Use the rheostat (25) to manually regulate voltage at 28.5

volts DC. Turn knob clockwise to SNCREASE voltage.

Operating Generator with Mechanical Governor

(1) Start-up procedure

(a) Connect the output cable between the generator and the
aircraft receptacle connector.

(b) If the engine is cold, pull the CHOKE control (21) out to
choke position. The amount of choking required for a
particular engine will become apparent to the operator after
a few starts.

NOTE: Do not choke a hot engine.

(c) Pull throttle control (27) out to idle position and twist to
lock into place.

Revised May 30/84

 , ‘.
\

(d) Place the ENGINE (ignition) switch (18) in START position,

hold until the engine starts and the ENGINE ON light (19)
glows, then release to RUN position.

(e) Press and hold the ENGINE START pushbutton (17) to crank the
engine. me' ease the switch as soon as the engine starts.
94
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
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 SUCH CRANKING
PERIODS TO PROTECT THE STARTER FROM OVERHEATING.

(f) Push the CHOKE control in if the engine does not start after
being cranked a few revolutions.

(g) If engine flooding is suspected, push the CHOKE control in'and

crank the engine again, observing the CAUTION above.

(h) When the engine starts, it should be allowed to idle and warm
before applying a load.

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

NOTE: Be sure that the CHOKE control is pushed all the way
in before operating the engine under load.'

D. Discontinue Power Delivery: Electronic Governor

(1) Place load contactor control switch (9) in OFF position.

Light (8) should go off to indicate load contactor has .openedand

power is no longer available at the aircraft.

(2) Position GENERATE/IDLE switch (20) to IDLE position.

(3) Disconnect cable plug from aircraft receptacle and store cable on
hangers at the rear of canopy.

(4) Stop engine by placing ignition switch to OFF position.

NOTE: If the engine has been under heavy load for a long period,
allow it to idle and cool for a few minutes before stopping.
 ,’
\ _,
(% /
\
_I
__.~_--..-oMY168

Discontinue Power Delivery: Mechanical Governor

(1) Place load contactor control switch (9) in OFF position.

Light (8) should gq ;Sffto indicate load contactor has opened and
payer is no longer available at the aircraft.

(2) Pull throttle control (27) out to IDLE position.

(3) Disconnect cable plug from aircraft receptacle and store cable on
hangers at the rear of canopy.

(4) Stop engine by placing ignition switch to OFF position.

NOTE: If the engine has been under heavy load for a long period,
allow it to idle and cool for a few minutes before stopping.
3. Operation of 14 Volt DC Output Circuit

Instructions above apply to 28.5 volt DC operation. The following instructions are for 14 volt DC power delivery.

A. Preparation for Power Deliver ,

Y ‘I
(1) Prepare the unit for 14 volt DC operation the same as for 28.5 volt DC. See Para. 2, A and B.

(2) Remove 14 volt DC output cable from its stored position.

(3) Connect cable plug to aircraft (or other) receptacle connector.

NOTE: Both 14 volt DC and 28.5 volt DC cables may be connected to aircraft (or loads) at the
same time, but 14 volt and 28.5 volt DC power CANNOT BE DELIVERED AT THE
SAME TIME.

B. Power Delivery

All of the 28.5 volt power delivery methods including normal automatic voltage control, manual voltage
control, and limited current engine starting, apply to the 14 volt system. Each method is covered below.
For each method it is assumed that the engine has been started and warmed, and is running at IDLE
speed.

(1) Normal 14 volt power delivery with automatic voltage control

(a) If lighting is required, place light switch (12, Figure 1) in ON position.

(b) Place AUTOMATIC/MANUAL switch (26) in AUTOMATIC position.

(c) Place GENERATE/IDLE switch (20) in GENERATE position. Tachometer (4) should indicate
approximately 2400 RPM.

(d) Check engine gages

Ammeter should indicate a slight charge. It may be near zero if the battery is fully charged.

Normal oil pressure is 35 to 60 PSI (240 to 414 kPa) hot.

Normal coolant temperature is 180 to 200 deg F (82 to 93 deg C) depending on ambient tempera-
ture, load, etc.

(e) Press the push-to-build-up-voltage switch (IO, Figure 1) to flash the generator field coils.

NOTE: 1. It is necessary to press this switch only when the generator will not build up voltage
by itself.

2. The voltmeter will indicate 28.5 volts until the unit is switched to 14 volt mode.

(f) Check to be certain that the aircraft is in condition to receive power.

 , k. _
‘\ _, ”
-..
‘, i’
, , ,, ” ‘\-,
.i / -A.. _,,,*’
’ .’ ,/- ’
/‘- I
/ ..
_,’ ._;-~-.----;-- -.--.- ~- .. . -.7,m-.A,”--. - - -~ ~ ~.
,/“: \ .> / **’
_,’ 1’ ,I -. O&168 :..-1-m

(g) Adjust current limiting rheostat (7) to maximum current desired.

(h) Make certain that the 28.5 volt control switch (9) is OFF. (The 14 volt circuit will not operate if
the 28.5 volt load contactor is,c(osed.)
I ‘I
(j) To switch to 14 volt power mode, place the control switch (23) in center ON position. Amber light
(22) should glow immediately and voltage indicated on voltmeter should decrease from 28.5 volts
to 14 volts within 1 second.

If indicated voltage is not exactly 14 volts, adjust voltage regulator (1-I ; 1, Fig. 5) according to in-
structions in the voltage regulator manual in Chapter 6.

(k) To deliver 14 volt power, hold control switch (23, Figure 1) in top CLOSE CONTACTOR position.
Green contactor closed light (24) should glow at once to indicate that the load contactor is closed,
and power is being delivered to the 14 volt output cable. Release control switch. It will return to
center ON position. Voltage regulator will regulate output voltage at 14 volts automatically.

(2) 14 volt power delivery with manual voltage control

This mode of operation is recommended for generator testing, or for emergency use in case of voltage
regulator trouble only. For manual control of generator output voltage, use normal 14 volt operating pro-
cedures (see Para. 3, B, [II ) except:

(a) Place AUTOMATIC/MANUAL switch (26, Fig. 1) in MANUAL position.

(b) Use the rheostat (25) to manually regulate voltage at 14 volts DC. Turn knob clockwise to IN-
CREASE voltage.

C. Discontinue 14 Volt Power Delivery

(1) Place 14 volt control switch (23, Figure 1) in OFF position.

Green light (24) will go off to indicate the load contactor is open.

Amber light (22) will go off to indicate that the 14 volt DC circuit is not operational.

(2) Position GENERATE/IDLE switch (20) to IDLE position.

(3) Disconnect cable plug from aircraft receptacle and store cable on hangers at the rear of canopy.

(4) Stop engine by placing ignition switch in OFF position.

NOTE: If the engine has been under heavy load for a long period, allow it to idle and cool for a
few minutes before stopping.

D. Switching Power from Mode-to-Mode

Power delivery can be switched from one mode to the other without stopping the machine and without
making major control changes.

gepised Feb 1@[8$.._

 (1) Switch from 14 volt to 28.5 volt delivery

For this change, place 28.5 volt DC load contactor control switch (9, Figure 1) in top CLOSE position
momentarily, then release t,o center ON position. The 28.5 volt DC load contactor will close and the
14 volt DC load contactok hill be automatically opened.

(2) Switch from 28.5 volt to 14 volt delivery

(a) Place 28.5 volt DC load contactor control switch (9, Figure 1) in OFF position.

(b) Hold 14 volt DC control switch (23) in top CLOSE CONTACTOR position until both indicating
lights (22 and 24) are on. Release switch to center ON position.

NOTE: Switching from 14 volt DC to 28.5 volt DC can be made simply by operating the 28.5 volt
DC contactor switch (9); however, the 28.5 volt DC switch must be turned off first to
change from 28.5 volt to 14 volt power.

4. Trailer Operation

A. Towing

Observe the following rules when towing the trailer.

(I) Be sure all output cables are disconnected and properly stowed.

(2) Be sure parking brake is released.

(3) Avoid turns which are shorter than the steering linkage will freely allow.

(4) Avoid dangerous speed and sudden turns.

8. Parking

Observe the following rules when parking the trailer.

(1) Apply parking brake before disconnecting tow vehicle.

(2) Always place drawbar in an upright, vertical position and lock it when trailer is parked.
 ,’
‘\ (_ ,‘”
..

___-----
--..i
_I_-_----..-- --_-
?--
OMI-148

CHAPTER 2. SERVICING

SECTION 1. MAINTENANCE INSPECTION/CHECK

General
i;
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.

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 schedule,

check sheet. The check sheet will provide a record of maintenance
operations performed and may also serve to improve scheduling for a
specific operation.

c. Time Intervals

The schedule is based on both hours of operation and calendar

intervals. These two intervals are not necessarily the same. The
calendar period is included to make certain services are performed
regularly when equipment is being operated infrequently, or at
irregular intervals. Hourly time intervals agree with the engine
manufacturer's recommendations. Perform all services on a "whichever
comes first" basis.

NOTE: Refer to the Ford Maintenance and Operator's Manual for detailed
engine maintenance information.
 -$5-T
-l-

A/R LO HRS. LOO HRS. 200 HRS, ioo HRS.

OR OR OR OR OR
)AILY 2 WEEKS 1 MONTH ! MONTHS '6 MO1 'HS
ENGINE
i ;I
Check oil level X
Check coolant level X
Check governor oil X
Check fuel quantity X
Check gages and instruments for
proper operation X
Clean or replace dry-type
c'arburetorair cleaner element
Lubricate distributor
Cle'ancrankcase ventilation system
Change engine oil
Change engine oil filter
Change governor oil
Lubricate choke linkage
Cheickand tighten drive belts
Clean and inspect exterior of
radiator
Check exhaust system
Check cooling system X
Check and adjust idle speed and
mixture X
Check and refill cooling system (Twite yearly, ,summer an winter)
Replace fuel filter
Clean engine

ELECTRICAL SYSTEM (12-V DC)

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

Inspection/Check/MaintenanceSchedule
Figure 1 (Sheet 1 of 2)
 -F

A/R LO HRS. 100 HRS. 200 HRS. iO0 HRS. 800 MS.
OR OR OR OR OR
>AILY 2 WEEKS 1 MONTH ! MONTHS 6 MONTHS

ELECTRICAL SYSTEM (28.5-V DC) , B

1 'I
Check indicating light x
Cheek operation of all instru-
ments, meters, etc. X
Check generator brushes for
length, cleanliness, and
free operation
Check commutator for smooth-
ness and cleanliness
Che{k the entire unit
Check overload protection
Che&k overvoltage protection X
Check all wiring connections

TRAILER

Lubricate
Check tire inflation
Check and adjust wheel bearings
Lubricate wheel bearings

Inspection/Check/MaintenanceSchedule
Figure 1 (Sheet 2 of 2)

Feb lo/84 Revised

_...
_-.
-._-_.
_-,.--
---.- -
 m
I I
OM-168

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.
1
WARNING: STOP OPERATION IIv’MEDIATELY IF A SERIOUS OR POSSIBLY DANGEROUS FAULT
IS DISCOVERED.

2. Lubrication

A. General

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

B. Lubrication Chart

Lubrication points are illustrated and identified by name on Lubrication Chart, Figure 1.

Number symbols used to designate the kind of lubricant required and the specification recommended are
identified in Figure 2.

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

C. Generator

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

D. Generator Controls

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

E. Engine

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

(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, intermittent operation, or dusty conditions.
However, time intervals should not exceed those indicated in the chart without careful evaluation.

Aug 6181 2-2

Page 1
 1 ‘I
BM 1 Draw bar
’ Steering pinion BM 1

4 BM 1 Tie rods ’
Axle pin BM

Tie rod BM , BM 1 iie rods

King pin BM BM 1 King pins

Wheel bearing SA SA 3 Wheel bearings

.-

Fuel Filter $A _ -B W2 Governor

* Crankcase D2

** Oil Filter M,

Whee 81bearing SA 3 Wheel beatings

* Check crankcase oil daily; change 200 hours.

** Change oil filter 200 hours.

Lubrication Chart
Figure 1 .
j- - - - .-,_..
-2z2----_-. .- --.~ - _-__- ______ ~_______~ Revised Feb 10184
-- - - __ ._. pact .-2-.’ .-.
 I 1
&gggjg
I
L
I , OM-I 68

SYMBOL NAME SPECIFICATION NOTES

1 Grease, Automoti?e’&rd Federal Sinclair Litholene Industrial No. 2;

I
Industrial VV-G-632 Mobil-Mobilplex 47, or equivalent.

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

ESE-M2ClOl-C Refer to Figure 4 for recommended
oil viscosity.

3 Grease, Automotive Military Wheel bearings

Ml L-G-10924B

Lubricants
Figure 2

SYMBOL TIME INTERVAL

D 10 hours or Daily
BW 100 hours or Biweekly
M 200 hours or Monthly
BM 400 hours or Bimonthly
SA 800 hours or Semiannually ’

Symbols and Time Intervals

Figure 3

(2) Oil specification

Engine lubricating oil recommended by the engine manufacturer must meet Ford Specification No.
ESE-M2ClOl-C. Oil that meets this specification is normally marked so on the can and meets API
(American Petroleum Institute) classification designation SD/SE. The manufacturer recommends Ford
or Motorcraft oils, which meet all specifications for Ford Industrial Engines.

The use of quality lubricating oil, combined with proper oil drain and filter change intervals are im-
portant factors in extending engine life.

(3) Oil viscosity

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

Aug 6181 2-2

Page 3
 w
I I OM-168

SINGLE VISCOSITY OILS MULTI-VISCOSITY OILS

When Outside Use SAE When Outside Use SAE

Temperature is Viscosity Temperature is Viscosity
Consistently /$-r,mber Consistently Number

-1 OoF to +32oF (“1 row Below +32oF (“1 5w-30

+I OoF to +6OoF 2ow-20 -1 OoF to +9OoF 1ow-30
+32oF to +9OoF 30 -1 OoF to +9OoF (or above) 1ow-40
Above 600F 40 Above +I OoF 2OW-40

(“1 Where sustained high RPM operation is anticipated, use 2OW20.

Temperature and Oil Viscosity Chart

Figure 4

(4) Change engine oil (100 hours)

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

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

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

Change the oil filter each time the oil is changed.

Change oil as follows:

(a) Provide a container for catching used oil. Capacity should be greater than 2 gallons.

(b) Remove drain plug located in oil pan. Allow sufficient time for oil to drain from valve train,
timing gear case, etc., before reinstalling plug.

(c) Change oil filter while oil is draining [see Para. 2, E, (5) below].

(d) Clean drain plug and reinstall. Do not over-tighten.

(e) 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 41 .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.

2-2 Aug 6181

Page4 -.
 ;’ /- : . -.__ .-
-._
/’
, ’ ,” ‘--I
. . -.. ,,‘- ,-
,
-<
_, ” . . ,-._
,. .-.
_-/ .. -. -. +:‘L. -. .-. - -~ .DM-168
\ , / ..I
~-~.~
--Cg‘)-~--~~~~~~e----Atlwr-~v~-ral---~~~t~s-~for.'~~---t-o-.drain~~
to
then check oil level. It should be at FJJLL
mark on dipstick.

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

(5) Change engine oil filter (100 hours)

(a) Place aidgntainer under the oil filter (l-l; 23, Figure 3) to
catch oil

(b) Loosen filter with a special oil filter removal wrench.

Several types are available. Discard oil filter.

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

D9AZ-6731A replacement be used.

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

(e) Place the new filter in position on the cylinder block and
spin on until the gasket contacts the adapter face; then hand
tighten another l/2 turn. Do not over-tighten.
(f) Start engine and check filter gasket for leaks.

F. Engine Accessories

(1) Distributor
Place a few drops of SAE 1OW engine oil in the oil cap on the
distributor housing each 100 hours operation.

(2) Governor linkage

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

(3) Mechanical Governor

Change governor oil each 800 hours. Add SAE 40 oil to governor.

G. Trailer
(1) Front axle assembly
The front axle assembly, drawbar, and steering linkage are
equipped with high pressure lubrication fittings. Lubricate the
trailer each 400 hours. Use a good quality chassis lubricant (See
Figure 2). Clean lube fittings before applying grease.
(2) Wheel Rearings

Lubricate and check wheel bearing adjustment each 800 hours or

semiannually. Use a good quality bearing lubricant (See Fig. 2).
3. Servicing the Air Cleaner and Crankcase Ventilation System
A. General
It is important that the air cleaner be cleaned and serviced regularly
after each 100 hours of engine operation. Service the air cleaner more
often under severe dust conditions. Failure to service the cleaner can
- -------.----cause
-~am~~~o--th~~cy~~n-~~al-ls-~-d-rfngs-,-exc~--con~umption,
and excessive fuel consumption.

-
Feb"lO/'84 Revised
Page 5
 OM-I 68

B. Clean and Service Air Cleaner

(I) Remove thumb nut and remove air cleaner assembly.

(2) Disassemble air cleaner and discard,dry filter element.

1 ‘I
(3) Wash all components with solvent and blow dry with compressed air.

(4) Replace air cleaner body on carburetor.

(5) Install a new filter element Motorcraft No. FA-52 or Ford Part No. C8TF-9601-A.

(6) Replace air filter cover.

(7) Reinstall thumb nut and tighten securely.

C. Clean Crankcase Ventilation System

Clean both breather caps at each oil change (100 hours).

(I) Remove both breather caps from the rocker cover and clean them in a petroleum solvent.

(2) Replace both breather caps.

4. Servicing the Fuel Filter

The fuel filter is a replaceable cartridge type and is mounted on the fuel pump (I-l ; 24, Figure 3) on the left side
of the engine. The recommended filter element for replacement is Motorcraft No. FG-1 or Ford No. C4AZ-9365A,
and should be changed every 800 hours.

A. Unscrew the filter housing from the pump body, and remove the filter element and gasket. Discard the ele-
ment and gasket.

B. Clean the filter housing in a petroleum cleaning solvent.

C. Place a new filter element over the spout in the pump body.

D. Coat the new gasket with light engine oil and position it on the pump body. (New gasket is packaged with the
replacement element.)

E. Screw the filter housing on to the body and hand tighten it until it contacts the gasket. Then tighten it an
additional II8 turn.

F. Start the engine and check for leaks.

5. Drive Belt Service

Check all drive belts and adjust if necessary each 200 hours. Refer to Ford Maintenance and Operator’s Manual in
Chapter 6 for proper procedures.

2-2 Aug 6181

.Page 6
 &gJ
1 1 OM-I 68

6. Engine Cooling System

A. General

NOTE: Refer to the Ford Maintenance and Operator’s Manual in Chapter 6 for detailed instructions
on servicing the engi e’? cooling system.
? I

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

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

CAUTION: DO NOT ADD COOLANT TO AN EXTREMELY

-- HOT ENGINE. THIS CAN RESULT IN
A CRACKED BLOCK OR CYLINDER HEAD.

B. Rust Inhibitor

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

C. Antifreeze

The recommended antifreeze for use in this engine is Ford Rotunda 8A19549-A. The coolant, when mixed
as equal parts of water and the recommended antifreeze, will provide protection to -35 degrees F (-37
degrees C). If another coolant is used, it must meet Ford Specification M-97Bl8-C.

7. Battery Service

Refer to the Ford Maintenance and Operator’s Manual in Chapter 6 for battery service instructions.

8. Generator Maintenance

A. General

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

B. Brush Service

(I) Cleaning

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

WARNING: DO NOT USE A FLAMMABLE SOLVENT. DO NOT USE STEAM CLEANER, OR

SOAPS AND DETERGENTS UNDER PRESSURE.

Aug 6181 2-2

Page 7
 m
I I OM-I 68

(2) Replacement

Brushes for this application are l-3/4 inches long when new. They should be replaced when worn
to one-half their original length, or 7/8 inch. Replacement brushes are available from Hobart Brothers
as Part No. AW-1470. Replace all 16 brushes at the same time.

(a) Remove pigtail attaching screw.

i4
(b) Move brush spring (1, Figure 6) aside and remove old brush (3).

(c) Check new brushes before installation. Size must be 3/4 x 1 x l-3/4 inch long.

(d) Move brush spring aside and install new brush.

NOTE: Check position of brush pigtail and install so that pigtail is on the forward side of
the brush.

(e) Check the clearance between brush and brushholder. The brush should move up and down freely
in the holder, yet without excessive side-to-side or fore-and-aft movement.

(f) Connect the pigtail. A single screw attaches two brush pigtails.

(9) Repeat steps (a) through (f) for other brushes.

1. Spring
2. Pigtail
3. Brush
4. Nut
5. Spring mounting adapter
6. Wrench

Generator Brush Installation

Figure 6

2-2 Aug 6181

Page 8
 m
I I OM-I 68

(3) Brush seating

When replacing brushes, it is important that they be carefully fitted to the commutator ring. The seating
stone method of brush seating is recommended for this installation. Brush seating stones are available
from Hobart Brothers as Part No. 410117.

i.4
Seating stones are fine-gram, abrasive blocks made especially for brush seating. When applied to the
commutator, fine particles from the stone drift under the brush and shape its face to the same curve
as the commutator.

(a) Start the engine and operate the generator with no power output.

(b) Hold the stone against the commutator immediately behind the brushholder so that stone particles
will be carried directly under the brush. Steady the stone by holding it against the brushholder.

(c) Seating may be speeded up by applying extra pressure on the brush.

WARNING: EXERCISE CARE TO AVOID INJURY BY THE ROTATING EQUIPMENT

OR ELECTRICAL SHOCK.

(d) Use dry compressed air to blow out any grit or foreign material.

CAUTION: DO NOT APPLY A FULL LOAD UNTIL BRUSHES HAVE RUN-IN FOR
APPROXIMATELY ONE HOUR AT 300 TO 400 A LOAD.

(4) Brush springs

Refer to Section 2-3, Para. 3, A, (3) for brush spring adjustment instructions.

(5) Commutator cleaning

The most effective method of cleaning and smoothing the commutator is the use of a flexible abrasive
block especially manufactured for commutator cleaning. When held against the revolving commutator,
the block will quickly remove deposits of dirt and grease. Commutator cleaning blocks are available
from Hobart Brothers as Part No, AW-817.

Operate the generator at 300 to 400 A load for approximately one hour to allow a film to form on the
commutator after cleaning.

9. Generator Controls Maintenance (14 Volt Output Option Only)

A. General

The overload relay dashpot (Figure 7) is the only component of the control system which requires periodic
inspection and maintenance.

B. Overload Relay

The entrance of water into the dashpot or the use of improper fluid may cause operating troubles requiring
disassembly and repair of the dashpot assembly. The following instructions include repair procedures in the
recommended sequence of steps.

Aug 6181 2-2

Page 9
 OM-168

_ Contacts

/ Bus bar (28.5 V output)

Plunger

Dashpot

Overload Relay Installation

Figure 7

(1) Disassemble

(a) Hold the dashpot and unlatch the spring clamp (4, Figure 8) by prying with a screwdriver to swing
the clamp forward. Lower and remove the complete dashpot assembly.

(b) Lift the core (I), cover (2), and valve plate (6) out of the dashpot (3) as an assembly.

(c) Pour the dashpot fluid into a clean glass container and inspect for signs of water.

NOTE: Moisture may condense in the dashpot to form water which will cause corrosion of the
valve plate and dashpot.

(2) Inspection

Inspect the valve plate (6, Figure 8) and the dashpot (3) for evidence of corrosion. Discard, if corroded,
and replace with new parts. Observe the position of the two valve plate covers. One is diamond shaped
and retains two steel balls (5). This cover should not be disturbed. The other plate serves to cover the
valve plate bypass holes, and MUST be positioned to completely COVER and CLOSE the holes.

2-2 Aug 6181

Page 10
 OM-168

(3) Assemble

(a) Pour a sufficient quantity of new fluid into the dashpot to cover the circular ridges in the bottom.
Use a silicon fluid with a viscosity rating of 100 centistokes at 25OC.

Approved fluids are: i 4

Dow-Corning No. 200 (100 centistokes)

Allen-Bradley No. 810-N98, Series A
Allen-Bradley No. X-106518

NOTE: Allen-Bradley numbers indicate different container sizes.

(b) Install the valve plate (6) and core (1) as an assembly. Make certain that the valve plate bottoms
in the dashpot.

(c) Add fluid until the surface of the fluid is level with the tops of the three cylindrical projections on
top of the valve plate. Actuate the piston a short distance up and down to expel any air trapped
below the plate. Recheck the fluid level and add fluid if required.

1. Core (plunger)
2. Cover
3. Dashpot
4. Spring clamp
5. Steel balls OIL LEVEL
6. Valve plate
7. Lock spring

Overload Relay Dashpot Assembly

Figure 8

Aug 6181 2-2

Page 11
 OM-168

(d) Install the dashpot cover (2).

(e) Make certain the valve plate (6) is bottomed in the dashpot and measure the height that the core
extends above the rim of the dashpot. Adjust core (1) so that it extends l-1/8 inch above the dashpot
rim. This adjustment should cause the overload relay to trip at 1000 ampere load in 1 minute. In-
crease the height by turning the core in a counterclockwise direction. Decrease the height by turning
the cure in a clockwise direction. Turn the core a full turn at a time and be sure the lock spring (7)
is seated in the valve plate stud groove when the adjustment is completed.

(f) Position the dashpot assembly in the overload relay and lock in place with the spring clamp (4).

2-2 Aug 6181

Page 12
 r I

OM-168

SECTION 3. ADJUSTMENT/TEST

1. ~General

The adjustments and test procedures presented below are required after major repairs, parts replacement, or
long storage. i 4

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 descirbed in Para. 3
of this Section.

A. Preoperational Test Procedures

(I) Open all access 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.

(5) Check for sufficient fuel.

(6) Check drive belts. Each belt should have approximately l/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) Check governor linkage for freedom of travel. Proper control rod length is approximately 1 l-1/2 inches
(292 mm) center-to-center of ball joints.

CAUTION: IF GOVERNOR WAS REPLACED OR LINKAGE WAS DISCONNECTED

FOR ANY REASON, REFER TO ADJUSTMENT PROCEDURES IN PARA.
3 BEFORE TESTING GENERATOR.

(IO) Connect cables from generator output terminals to a load bank. Use cables of the same size and length
as those used in service, preferably No. 2/O, not more than 30 feet (9 m) long.

(11) Set AUTOMATIC/MANUAL switch (26, Figure 1) to MANUAL.

(12) Turn field rheostat (25) to minimum.

(13) Set GENERATE/IDLE switch (20) to IDLE.

Aug 6181 2-3

Page 1
 2 3 4 5 6 2

NOTE: Items marked * are

used with 14 Volt
Option only.
**: Used with mechanical
governor only. '

ps5Eiq ***: Used with electronic

governor only.

1. Water Temperature Gauge 14. Ammeter (Engine)

2. Panel Light 15. Engine Circuit Fuse
3. Voltmeter 16. Oil Pressure Gauge
4. Tachometer 17. Engine Start Switch
5. Latch 18. Engine Ignition Switch
6. Ammeter (Generator) 19. Engine On Light
7. Current Limit Control *** 20. Generate/Idle Switch
8. Contactor Closed Light 21. Choke Control
9. Contactor Control Switch * 22. 14 Volt Mode Light
10. Push-To-Build-Up-Voltage Switch * 23. 14 Volt Contactor Control Switch
11. Hourmeter * 24. 14 Volt Contactor Closed Light
12. Panel Lights Switch 25. Field Rheostat Control
13. Panel Lights Fuse 26. Automatic/Manual Switch
** 27 Throttle Control

.~-p~~s ‘.2..‘ - _ ..- -. -

 B. Operational Tests

(1) Start the engine as described in l-3; Para. 2, B, and let it warm at
idle speed.
(2) Inspect for oil, fuel, and coolant leaks.
(3) Check the engki& ammeter (14 Figure 1) for a slight char e
oil pressure gau e (16). It'should dis lay 35 to 60 PSI f220 FE?4
kPa). Check coo!? 1 . It should show 180 to
ant temperature gauge ?>
200 deg. F (82 to 93 deg. C).
(4) Idle speed displayed on the tachometer (4) should be 600 to 650 RPM.
(5) Check engine rpm's at operating speed:
(a) ;igz;;i.c governor. Switch GENERATE/IDLE switch (20) to
. Tachometer (4) should show a 2400 rpm no load speed.
(b) Mechanical governor. Push throttle control (27) all the way
in. Tachometer (4) should show a 2400 rpm no load Speed.
(6) Check voltage range of manual voltage control rheostat (25). Voltage range should be approximately 2 to
49 volts DC displayed on the voltmeter (3).

(7) Manually set voltage at 28.5 volts.

63) Adjust the load bank for a load of 750 amperes.

(9) Place the contactor control switch (9) in the CLOSE position. CONTACTOR CLOSED light (8) will
glow and the contactor will close. Release the switch to the center ON position. The tachometer (4)
will indicate 2400? 25 RPM.

(IO)Disconnect the load bank and check the overvoltage protection by increasing voltage manually. The
overvoltage relay will trip and open the load contactor at 32 to 34 volts in 2 to 10 seconds.

(11)Reset voltage to 28.5 volts, connect the load bank set at 750 amperes, and close the contactor.

(12) Check overload protection by increasing the load to 1000 amperes. The overload relay will trip and open
the load contactor in approximately 1 minute.

(13) Set AUTOMATIC/MANUAL switch (26) to AUTOMATIC. Voltmeter (3) will display 28.5 k 1 volts.

NOTE: It may be necessary to adjust potentiometer R33 on Voltage Regulator (l-l ;

1, Figure 5) to get voltage within tolerance.

(14) Set current limit control (7, Figure 1) to maximum, full clockwise, position.

(l-5) Remove load bank andcheck voltage regulation at no load. Voltage will be 28.5 volts. Reconnect load
bank and check voltage regulation with load bank set at 187,375,562,750, and 900 amperes and check
voltage at each setting. Voltage will be 28.5 * 1 volts at each different load.

(16) Apply 800 to 900 amperes load to the generator and set the current limit control (7) to 400. Current
displayed on ammeter (6) will be 400 k 25 amperes.

NOTE: Voltage will not drop below 12 volts.

Setcurrent limit control to 1000. Apply 1200 amperes load. Current displayed on ammeter will be
1000+25 amperes and voltage will not drop below 12 volts.

?---.- __ - - - -.. _ _
-Page.-
3
 OM-168

(18) To check the overspeed governor, manually override the governor linkage at the carburetor to increase
engine speed. The overspeed governor will open the ignition circuit and shut down the engine at 2850
to 2900 RPM.

(19) Restart the engine, check the instruments as directed in step (3), and check the entire generator set for
unusual vibration and noises.
i 4
C. 14 Volt Output Option Test

(1) With generator operating normally at 28.5 volts DC, place both 28.5 volt and 14 volt contactor control
switches (9 and 22, Figure 1) in OFF position.

(2) Place 14 volt contactor control switch (22) in ON position. 14 volt MODE light (22) will glow amber.

(3) Check voltage on voltmeter (3). It should be 14 volts DC. If not, adjust voltage regulator for 14 volt
output as directed in the Voltage Regulator Manual in Chapter 6.

(4) Close the 14 volt load contactor. The CONTACTOR CLOSED light (24) will glow green.

(5) Close the 28.5 volt load contactor. The 14 volt contactor will open at once and the green light (24)
will go out. Open the 28.5 volt contactor.

(6) Close the 14 volt contactor. Place the AUTOMATIC/MANUAL switch (26) in MANUAL position.
With the manual control rheostat (25) lower the voltage below 14 volts, then gradually increase the
voltage one volt at a time, pausing at least 10 seconds between settings. The overvoltage relay will
trip and open the load contactor at 18 to 20 volts, in 2 to 10 seconds. Lower the voltage gradually.
The overvoltage relay will reset at 15.5 to 14.5 volts. Return the switch (26) to AUTOMATIC position.

(7) Close the 28.5 volt contactor. Attempt to close the 14 volt contactor. It should not close and the 28.5
volt contactor should remain closed.

(8) Operate the generator at 28.5 volts with both contactors open. Hold the 14 volt contactor control
switch (23) in the top CLOSE CONTACTOR position. Voltage indicated on voltmeter (3) will drop
from 28.5 to 14 volts in 1 second. Contactor should not close until 14 volts is indicated.

(9) Use a load bank to test the overload relay adjustment. The 14 volt overload relay (l-l ; 8, Figure 7)
should trip in 1 minute at 1000 amperes load. If adjustment is required, refer to 2-2; Para. 9, B, (3),
(ei.

3. Adjusting the Generator Set

If brushes have been replaced, follow the brush seating instructions given in 2-2; Para. 8, B, (3).

WARNING: DO NOT MAKE ADJUSTMENTS WHEN THE GENERATOR IS RUNNING. LETHAL

ELECTRICAL SHOCK HAZARD EXISTS.

A. Brushholder Adjustment,

The brushholder assembly is mounted in a machined, circular seat in the rear of the generator housing.
The brushholder mounting ring is held in the seat by clamps and the entire brushholder assembly may be
rotated when the clamps are loosened. To adjust, proceed as follows:

2-3 Aug 6181

Page 4”1-
-_
 m
I I OM-168

(1) With generator running at no load and AUTOMATIC/MANUAL switch (26, Figure 1) in MANUAL
position, use manual control rheostat (25) to adjust voltage to 28.5 volts.

(2) Apply a load of 750 amperes and check output voltage. If voltage is 27.5 to 28.5 volts, the brushholder
is properly adjusted. If voltage is below 27.5, or above 28.5 volts, adjustment is required.

i1
(3) Stop generator and scribe a mark on the brushholder mounting ring, and on one of the seat bars to
determine a starting point for adjustment.

(4) Loosen brushholder clamping screws (2, Figure 2) and rotate the brushholder (I) in the direction of
armature rotation to REDUCE voltage, or opposite the direction of rotation to INCREASE voltage.
Do not rotate the brushholder more than l/8 inch (3 mm) without rechecking voltage. Tighten clamp-
ing screws (2) before starting generator.

(5) Start generator and repeat steps (I), (2). (3), and (4) as required until a satisfactory adjustment has been
made.

(6) Be sure clamping screws (2) are securely tightened at conclusion of adjustment.

1. Brushholder mounting ring

2. Clamp screw
3. Clamp
4. Seat bar
5. Commutator segment

Brushholder Assembly
Figure 2

Aug 6181 2-3

Page 5
 OM-I 68

B. Initial Adjustment of Brushholder

In the event that the generator is disassembled and the brushholder assembly is removed, locate the brush-
holder as follows:

(1) Rotate armature so that an armatur#e b}ot is directly under an interpole piece. Carefully observe and
trace the wires which lead from the winding in the slot to a commutator segment (5, Figure 2). Rotate
the brushholder ring (I) so that a row of 4 brushes is directly over this segment. Tighten brushholder
clamping screws (2).

NOTE*
A Exercise care in tracing the armature to commutator wire because the wires run at an
angle and not directly to a commutator segment. It may be possible to detect yellow
paint marks on the armature slot and the commutator riser which were used to position
the brushholder originally. If these marks can be found, it will make brushholder ad-
justment easier.

(2) Make final adjustment in accordance with Para. 3, A, above

C. Brush Spring Adjustment

Recommended spring pressure is 18 to 30 ounces (510 to 850 grams) measured along an imaginary line
which passesthrough the center of the brush and the center of the commutator.

Spring pressure is critical to long brush life and generator performance in that it must be sufficiently strong
to maintain stable brush-commutator contact, yet not strong enough to cause mechanical wear. Insufficient
spring pressure can cause excessive surface film buildup on the commutator, arcing, heat, and more rapid
brush wear than excessive brush pressure. For these and other reasons it is best to use the higher recommended
brush pressures.

It is difficult to measure brush pressure accurately. Take the following precautions to reduce chances of,
error.

1. Be sure brush can move freely in brush box.

2. Be sure brush finger and spring are not corroded or sticking.

3. Make certain the scale to be used is accurate.

The following is a suggested method of measuring brush pressure.

(1) A leather loop and an ordinary tension scale which is graduated in ounces or grams are required. The
leather loop gives firmer contact with the brush spring or finger than the scale hook (see Figure 3).

(2) Place a strip of paper between the brush and commutator.

(3) Place a leather loop over the brush spring (or finger) and position it under the point where the spring
(or finger) touches the brush. Attach scale to leather loop.

(4) Pull lightly outward on scale ring. The direction of pull must be parallel to the brush length. At the same
time, pull gently on the paper strip.

2-3 Aug 6181

Page 6
 i? 1 - Leather loop

Measuring Speed Pressure

Fi’gure 3

~. .?..-
(5) Increase pull on the scale until paper strip slips free. Read scale to the nearest ounce. . ’

(6) Pressure should be within recommended range, preferably at, or near, the high limit.

(7) Adjust pressure as required.

To adjust spring pressure, loosen nut (4, Figure 4) and turn spring adapter (5) toward the brush
(arrow direction) to increase pressure. Turn the opposite direction to decrease pressure. Tighten
nut (4).

NOTE: The adapter must be held in its new adjusted position while tightening nut.
.~
D. Engine Electronic Governor Adjustments

If the governor has been replaced, the new governor will have to be adjusted according to the procedures listed
below.

(I) Set the GENERATE/IDLE switch (20, Figure I) to IDLE, start the engine, and check the idle speed. It
should be 600 to 650 RPM. If it is not, adjust the idle speed as described below.

(2) Push choke control knob in as far as it will go.

(3) Refer to Figure 5. Turn idle speed adjusting screw until the engine speed is 600 to 650 RPM.

.. - _ - _. - ~~ --P-age
-7
 OM-I 68

1. Spring
2. Pigtail
3. Brush
4. Nut
5. Spring mounting adapter
6. Wrench

Generator Brushes
Figure 4

(4) Turn the idle fuel adjusting screw in (clockwise) until the engine RPM begins to drop from the lean mix-
ture, then turn it out (counterclockwise) until the RPM increases and just begins to drop from the rich
mixture. Then turn it in (clockwise) for maximum engine RPM and smoothness.

NOTE: Always favor a rich mixture rather than a lean mixture for final adjustment. A lean mixture
puts an unnecessary heat load on the valves and may cause premature valve failure.

(5) After verifying the idle speed, shut down the engine.

(6) Make sure that the electrical connections to the governor have been made as shown on the connection
and schematic diagrams in Chapter 6.

(7) Refer to Figure 5. Check the length of the governor control rod. It should be 1 l-1/2 inches (292 mm)
from center to center of the ball joints. Loosen the locknuts and adjust if necessary.

(8) Attach the ball joint on one end of the rod to the throttle control lever on the carburetor and secure it
with the nuts provided.

(9) Remove one nut from the threaded stud on the other ball joint and thread the remaining nut approxi-
mately halfway up the stud.

(IO) Loosen the cap screw which secures the control arm to the governor shaft and rotate the control arm to a
position where the ball joint stud will pass through the hole in the arm. Make sure that the governor shaft
does not rotate with the arm. Thread the second nut on the stud just far enough to insure thread engage-
ment.

2-3 Revised Nov 17182

Page 8
 ‘4
I I OM-168

&~~~c~:“~~~

I I
i- II- 1/2inches (292 mm)
Control Rod
4

Screw

Nuts
Control Arm

Threoded Stud

Control Arm -/

Governor Linkage
‘Figure 5

Nov 17182 Revised 2-3

Page 9
 w
i OM-I 68

(11) Rotate the control arm slightly to the right and tighten the cap screw to secure the control arm to the
governor shaft. Refer to the detail in Figure 5. When the bottom nut is tightened against the control arm,
the control arm should be preloaded toward the carburetor approximately l/16 inch (1.6 mm). Repeat
this step if necessary to get the proper preload.

(12) Refer to Figure 6. Turn speed CO Srol i counterclockwise 4 or 5 turns to insure control of the engine
when it is started. r I

(13) Make sure that switch (20, Figure 1) is in IDLE position. Start the engine and let it run at idle speed until
it reaches operating temperature of 180 to 200 deg F (82 to 93 deg C).

(14) Set the switch (20) to GENERATE position and turn the speed control pot N (Figure 6) slowly clockwise
until 2400 f 25 RPM is indicated on the tachometer. If the engine surges, adjust the gain control G
counterclockwise until the surging stops. This setting is approximately at IO o’clock position.

NOTE: Adjust the gain control G in very small increments, no more than IO degrees at a time.

I I:00 O’clock Y IO:00 O’clock L 2400 RPM

piGGiq

Internal Governor Adjustments

Figure 6
2-3 Revised Nov 17162
Page IO
(15) Attach a load bank to the generator output terminals, set it ~
for 750 amperes load, and close the load contactor.

If the engine will not pick up the load, adjust the gain
control G clockwise until the engine recovers quickly when the
load is a,pp,likd.

NOTE: Optimum setting for this control is at approximately 10

to 11 o'clock position.

FULL SPEEO - IDLE

Mechanical Governor Adjustments

Fis.cKe1_----.~
_ .._
~~ _-...

--- -- Page--J&
 OM-168

Trip Point
Adjust Pot

Overspeed Governor
Figure 8
E. Engine Mechanical Governor Adjustment

(1) Connect the generator output to a load bank capable of applying

750 amperes load,
1
p Refer to Fig!& 7. Back out the bumper screw (7) until only 3 or
4 threads are engaged and secure it with the locknut (6).

(3) Pull the throttle control T handle all the way out and start the
engine. Let it run at fast idle until warmed to operating
temperature, then push the throttle control all the way in.

(4) Adjust the screw (3) to obtain a no load speed of 2450 RPM, then
lock the screw with the lockout (4).

(5) Apply a load of 750 amperes with the load bank. Check speed
regulation by alternately closing and opening the load contactor.
Droop should be no more than 100 RPM (governed speed should not
drop lower than 2350 RPM).

(6) If droop is more than 100 RPM, loosen nuts (10) and adjust screw
(9) to draw the spring (5) CLOSER to the lever hub (11). If the
engine surges under load, adjust the screw (9) to move the spring
(5) AWAY from hub (11).

NOTE: Recheck engine speed after each adjustment of screw (9).

Readjust speed with screw (3) if necessary.

Tighten 2 locknuts (10) on regulation screw (9) after a

satisfactory droop, without surging, has been achieved:

(7) If surging occurs at no load, loosen locknut (6) and turn bumper
screw (7) IN (clockwise) a turn at a time until surging stops,
then tighten locknut (6).

CAUTION: DO NOT TURN BUMPER SCREW IN FAR ENOUGH TO INCREASE NO

LOAD SPEED.

F. Overspeed Governor Adjustment

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

(1) Make sure that the electrical connections to the new overspeed
governor have been made as shown in the connection and schematic
diagrams in Chapter 6.

(2) Make sure that switch (20, Figure 1) is in IDLE position. Start
the engine and let it run at idle speed until it reaches operating
temperature of 180 to 200 deg F (82 to 93 deg C).
 (3) Manually override the control linkage at the carburetor to
increase the engine speed. The overspeed governor should shut
down the engine at 2850 to 2900 RPM. If the engine shuts down
below 2850 RPM or if it does not shut down at 2900 RPM, adjustment
is required.
i4
(4) Refer to Figure 8. The overspeed governor is located inside the
control box on the rear panel.
I

Adjust the screwdriver adjustable pot at the point shown in the :

illustration. Turn it clockwise to increase the speed at which
the engine will shutdown. Turn it counterclockwise to decrease
the shutdown RPM.

G. Voltage Regulator Adjustment (14 volt and 28.5 volt)

Refer to Voltage Regulator Manual in Chapter 6 for adjustment

procedures.

T$ 14 Volt Option Circuit Adjustments

(1) Adjust overvoltage relay trip point

The trip point of the overvoltage relay is adjusted by a variable

resistor (l-l; 9, Figure 7) on the 14 volt contactor panel.

(a) Operate generator at normal 28.5 volts with both load

contactor switches in OFF position.

(b) Adjust variable resistor (9) to give 20 volt input at '

overvoltage module (6).

(c) Relay should trip at 18 to 20 volts in 2 to 10 seconds.

(2) Adjust 14 volt output voltage

Refer to Voltage Regulator Manual in Chapter 6 for voltage

regulator adjustment.

Revised Feb lo/84

.----F-! /
!
 I I

OM-I 68

SECTION 4. REPAIR

1. General

Repairs to this generator set are Ii iSed to the replacement of parts. In general, removal and installation proce-
7
dures for parts replacement is obvrous(and is not covered in this manual. However, separating the engine and gen-
erator to replace internal generator parts, or to repair the engine, requires some special precautions and disassem-
bly/assembly procedures which are outlined below.

2. Disassembly

Most mechanics prefer to remove the engine and generator as an assembly, and then separate them. Some prefer
to remove the engine or generator separately to gain accessto internal parts. However, separating the engine and
generator while they are installed in the unit is very difficult because of the limited working space.

DO NOT CUT any cables or wires during disassembly. Disconnect and tag them for reassembly.

A. Separate Engine and Generator

(I) Install a lifting eye with 1/2-l 3 threads in the tapped hole on top of the generator frame and attach a
hoist to it.

Suitable lifting eyes are available from Hobart Brothers as Part No. CTW-116A.

(2) Install wooden blocks under the rear (flywheel) end of the engine to support it when the generator is
removed.

(3) Remove the expanded metal screen from the flywheel housing.

(4) Remove 2 setscrews which secure the coupling hub to the generator shaft.

(5) Inspect the fan for the location of balance weights. When used, one or more balance weights are secured
to the fan by the screws which secure the fan to the coupling hub.

CAUTION: MARK THE LOCATION OF BALANCE WEIGHTS WITH CHALK OR PENCIL

BEFORE REMOVING SCREWS WHICH SECURE THEM. FAN BALANCE,AT
REASSEMBLY IS VERY CRITICAL.

(6) Remove 8 screws and lockwashers which secure the fan to the coupling hub. Retain any balance weights
released by these screws for use at reassembly.

(7) Slide the fan away from the coupling to provide access to coupling-to-flywheel screws.

(8) Remove 6 screws which secure the flexible coupling disk to the flywheel.

(9) Remove 4 screws and lockwashers which secure the generator housing to the flywheel housing.

(10) Use the hoist to separate the generator from the engine and move it to a clear working area.

Ott 28/83 Revised 2-4

Page 1
 OM-168

B. Remove Coupling Assembly

(1) Refer to Figure 1. Apply penetrating oil to the generator shaft and coupling hub.

(2) Use chalk or a felt-tip pen and make a mark across the coupling hub and disk. Make another mark across
the outside edge of the 3 coupling This will insure that the assembly is reassembled in balance.
This balance is VERY CRITICAL. emove the 8 screws which attach the disks to the hub and discard
the screws.

NOTE: Replacement screws for reassembly are: Grade 5, self-locking, hex-head, steel,
5/16-18,5/8 inch long. These screws are available from Hobart Brothers as
Part No. DW-3146A.

(3) Attach a puller to the coupling hub and pull the coupling hub off the shaft. If driving is required, use a
brass driving rod. Reassemble the disks to the hub immediately, lining up the marks made in step (2)
above, and using ONLY the Grade 5 screws as specified in the NOTE.

3. Cleaning

Clean the generator shaft and the bore of the coupling hub with a nonflammable solvent to remove all dirt and
gum. Use fine emery cloth to remove any rust or compacted dirt from the governor shaft, coupling hub bore,
and the machine key. Then remove all grit from the mating surfaces of the shaft, keyway, key, and hub.

4. Assembly

A. Check

Before starting assembly, make sure that the coupling hub will slip onto the generator shaft easily by trying
it as follows:

(1) Apply anti-seize iubricantsuch as LPS-2 to the shaft and the coupling hub bore.

(2) Slide the coupling hub onto the shaft to make sure that it slides on and off, and turns easily. If it does
not, repeat the cleaning procedures in Para. 3 above until it does. Then remove the coupling from the
shaft.

B. Assembly Procedures

(1) Refer to Figure 2. Attach the coupling to the engine flywheel with the 6 screws yemoved
at disassembly, and tighten the screws securely.

(2) Slide the fan onto the coupling hub. Setscrews in hub must be removed. Replace any balance weights
removed at disassembly. The EXACT location of EACH WEIGHT, marked at disassembly, is VERY
CRITICAL. Then secure the fan to the coupling hub with the 8 screws and lockwashers removed at
disassembly. Install 2 setscrews in the coupling hub just far enough to insure thread engagement.

(3) Install the machine key in the shaft keyway, apply more anti-seize lubricant to the shaft and key, and
move the generator to the engine with the hoist.

(4) Align the generator with the engine and carefully start the generator shaft into the bore of the coupling
hub. Use careful alignment rather than force to work the shaft into the hub.
 OM-I 68

Setscrews (2)

Grade 5
Self-Locking
Screws (8) 1 =~ ,~ ( / ,,- Machine Key

Generator Shaft
L
Screw, Fan
to coupling
hub (8)

Coupling Hub

\-Screw, Coupling
to flywheel (6)

Coupling and Fan Assembly

Figure 1
Ott 28183 Revised 2-4
Page 3
 OM-I 68

COUPLING’
]]

Coupling Attached to Flywheel

Figure 2

(5) Install 4 screws and lockwashers through the flywheel housing and into the generator frame. Install
all 4 screws finger tight, then tighten securely with a wrench.

(6) Refer to Figure 3. Carefully slide the generator armature axially until the back edge of the commutator
is aligned visually with the front face of the brushholder ring. Then tighten the 2 setscrews in the hub
securely. This adjustment insures the proper location of the generator brushes on the commutator.

(7) Replace the expanded metal screen around the flywheel housing.

2-4 Aug 6181

Page 4
 OM-I 68

CHAPTER 3. TROUBLESHOOTING

SECTION 1. INTRODUCTION

1. General
i 4

The Troubleshooting Chart, Figure 2, covers the common malfunctions which you may find during operation or
maintenance of this equipment. It cannot list all malfunctions that may occur. If a malfunction is not listed in the 1
chart, start looking for the cause at the source of power in the affected circuit. Refer to the schematic and con-
nection diagrams in Chapter 6 and test the circuit, step by step, until the source of the malfunction is isolated.

The Troubleshooting Chart is arranged under 3 headings: Malfunction, Test or Inspection, and Corrective Action.

Malfunctions are described and numbered. Tests and Inspections are indented to the right and listed in numbered
steps below Malfunctions. Corrective Action provides instructions for correcting the malfunction, and is listed
below each Test or Inspection procedure.

Tests and inspections called for in the Troubleshooting Chart are to be performed as described in Section 2-3 of
this manual.

Aug 6181 3-l

Page 1
 7 25 26

NOTE: Items marked * are

used with 14 Volt
Option only.
1 I
- **:
0 1 0 Used with mechanical
0 0 ccl governor only.'
n
***: Used with electronic
[psD-o266I governor only.

1,’ /! Water Temperature Gauge Ammeter (Engine)

14.
2. Panel Light Engine Circuit Fuse
15.
3. / Voltmeter Oil Pressure Gauge
16.
4. Tachometer Engine Start Switch
17.
5. Latch 18.
Engine Ignition Switch
6. j Ammeter (Generator) 19. Engine On Light
I
7. I Current Limit Control *** 20. Generate/Idle Switch
8. Contactor Closed Light 21. Choke Control
9. Contactor Control Switch * 22. 14 Volt Mode Light
10. Push-To-Build-Up-Voltage Switch * 23. 14 Volt Contactor Control Switch
11. Hourmeter * 24. 14 Volt Contactor Closed Light
12. Panel Lights Switch 25. Field Rheostat Control
13. Panel Lights Fuse 26. Automatic/Manual Switch
** 27 Throttle Control

-.A,- --- ___-__.-- Operating Controls and Indicattts

Figure 1
 w
I OM-168

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

ENGINE AND CONTROLS

1. STARTER WILL NOT CRANK EN&E.

Step 1. Momentarily connect a jumper lead between the hot side of starter solenoid (L402) and ,
start switch terminal on the solenoid (yellow-red wire). If the starter operates, check ig-
nition switch (S401) and pushbutton start switch (S402).

Replace faulty switch.

Step 2. Check voltage across battery for 13.5 volts DC.

Recharge or replace battery if defective.

Step 3. Momentarily connect a large capacity jumper cable between hot side of starter solenoid
(L402) and starter input terminal.

If starter operates, replace starter solenoid. If starter does not operate, replace
starter.

Step 4. Turn engine by hand, using a socket wrench on the front crankshaft pulley nut.

If the engine will not turn, replace or repair engine.

2. STARTER CRANKS ENGINE. ENGINE WILL NOT START.

Step 1. Check engine circuit fuse (15, Figure I)

Replace fuse (F402) if blown.

Step 2. Connect a jumper between terminals 3 and 4 on the overspeed governor (inside control box).

If engine will start, replace overspeed governor (E404).

Step 3. Connect a jumper between the positive battery terminal and the positive terminal on the
ignition coil.

If engine will start, check the ignition resistor (R401) mounted on the engine
block for continuity. Also check wiring from ignition coil (L405) to starter
solenoid (L402).

Step 4. Connect a jumper between terminals 3 and 4 on the overspeed governor and check the
ignition coil (L405) and distributor contacts (E402).

Replace defective parts.

Troubleshooting Chart
Figure 2
(Sheet 1 of 8)

Aug 6181 3-l

Page 3
 w
I I OM-168

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

ENGINE AND CONTROLS

2. STARTER CRANKS ENGINE. ENGINE WI ,L;NOT START (CONTINUED)

4

Step 5. Hold ignition switch in START position and check voltage at fuel solenoid valve (in fuel
line below fuel tank).

If voltage is not approximately 12 volts DC, check wiring and battery.

Step 6. Place a jumper across terminals 3 and 4 on the overspeed governor (inside control box).

If solenoid valve (L401) operates, replace overspeed governor (E404).

Step 7. Disconnect fuel line from output end of fuel solenoid valve. Connect 12 volts DC to sole-
noid. Fuel will flow if valve is good.

Replace defective fuel solenoid valve (L401).

Step 8. Disconnect fuel line from fuel pump output and crank the engine. Fuel will flow from a
good pump when engine is cranked.

Replace faulty fuel pump.

3. ENGINE STARTS, THEN STOPS WHEN IGNITION SWITCH RETURNS TO RUN POSITION.

Step 1. Check ignition switch contacts in RUN position.

Replace defective switch (S401).

Step 2. Connect a jumper across low oil pressure switch terminals (on engine block). Start engine
and check oil pressure. If it is below 10 PSI (69 kPa), shut down the engine and check
lubrication system for leaks and check oil pump. If oil pressure comes up to normal, the
oil pressure switch is defective.

Replace faulty oil pressure switch (S404).

Step 3. Connect a jumper between the positive battery terminal and the positive terminal on the
ignition coil.

If engine will run, check the ignition resistor (R401) for continuity.

4. ENGINE RUNS ROUGHLY, THEN STALLS.

Step 1. Check cables from distributor to spark plugs. Firing order is l-5-3-6-2-4.

Correct connections or replace damaged cables.

Troubleshooting Chart
Figure 2
(Sheet 2 of 8)

3-l Aug 6181

Page 4
 I
, ‘\
’ ! +
-.
I \ ,’ ’ -, .
, I
I
\ ‘.
//’
x.
-..., __
;< ’
/ .-
.,.
" OM-168
4'
,’ \
. I _.
I .,
I I “-
/’
-i mmN::--I --.-____ _---- ___ I’

TEST OR INSPECTION
CORRECTIVE ACTION
--i-e ----=- -__I .- ------.
ENGINE AND CONTROLS

4. ENGINE RUNS ROUGHLY, irr;rFN

STALLS. (CONTINUED)
' Step 2. Remove distributor cap and check for moisture or damaged
components.

Remove moisture or replace damaged components.

Step 3. Check distributor timing (Ford Manual)

Set timing as outlined in Ford Manual.

5. ENGINE WILL NOT RUN AT RATED SPEED (2400 RPM).

NOTE: Steps 1 thru 3 only apply to an electronic governor.

Step 1. Check GENERATE/IDLE switch (20, Figure 1).

Set switch (S409) to GENERATE position.
Step 2. Place GENERATE/IDLE switch (20, Figure 1) in GENERATE
position. Check voltage at terminals (+) and (-) on governor
(mounted on engine block).
Voltage should be 12 volts DC. If voltage is zero,
check switch (S409) and wiring, and repair or
replace as necessary.
Step 3. Apply 12 volts DC to terminals (+) and (-> on governor
(mounted on engine block).
If governor does not actuate, replace governor (E403).

Step 4. Check governor control linkage for freedom of movement.

Readjust linkage or lubricate.

Step 5. Check governor adjustment.

Adjust governor as outlined in Section 2-3, Para. 3, D

and 3, E.

6. ENGINE WILL NOT PICK UP LOAD WHEN CONTACTOR IS CLOSED.

Step 1. Check governor adjustment.

Adjust governor as outlined in Section 2-3, Para. 3, D

and 3, E.
Step 2. Check engine timing.
Set engine timing as outlined in Ford Manual.

Troubleshooting Chart (Sheet 3 of 8)

-- .-___--__ ---_---.-----____
Feb lo/84 Revised Figure 2 3-l
I-----
---__ -- -....
-.-
_.__
Page 5
 TEST OR INSPECTION
CORRECTIVE ACTION
-.- .- .L--~ ..-_=_
ENGINE AND CONTROLS
i4
,

7. FNGINE GOVERNED SPEED TOO LOW OR TOO HIGH.

Step 1. Check governor adjustment.

Adjust governor as outlined in Section 2-3,

Para. 3, D and 3 E.

8. ENGINE SURGES UNDER LOAD

Step 1. Check governor adjustment.

Adjust governor as outlined in Section 2-3,

Para. 3, D and 3 E.

Step 2. Check fuel mixture at carburetor.

Adjust carburetor fuel mixture (see Ford Manual).

Step 3. Check engine timing.

Set timing as outlined in Ford Manual.

Step 4. Check complete ignition system.

Repair and adjust as required.

9. ENGINE SURGES AS NO LOAD.

Step 1. Check governor adjustment.

Adjust governor as outlined in Section 2-3,

Para. 3, D and 3 E.

10. ENGINE RF,SPONDSSLOWLY.

Step 1. Check ignition timing.

Set ignition timing per Ford Manual.

Step 2. Check governor adjustment.

Adjust governor as outlined in Section 2-3,

Para. 3, D and 3 E.

Troubleshooting Chart (Sheet 4 of S)

Figure 2

3-1 Revised Feb lo/84

Page 6
- -- -
 OM-168

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

ENGINE AND CONTROLS

11. ENGINE OVERHEATS. i iI

Step 1. Check coolant for dirt and sludge.

Drain coolant, flush, and replace. Refer to Section 2-2, Para. 6.

Step 2. Check radiator core for debris and dirt.

Clean radiator core carefully.

GENERATOR AND CONTROLS

1. GENERATOR WILL NOT BUILD UP VOLTAGE WHEN BUILD-UP-VOLTAGE SWITCH IS PUSHED.

Step 1. Momentarily connect a jumper across terminals of switch (IO, Figure 1).

Replace switch (S406) if voltage builds up.

Step 2. Check diode on back of switch (10, Figure 1).

Replace defective diode (CR403).

Step 3. Check AUTOMATIC/MANUAL switch (inside control box).

Replace faulty switch (S408).

Step 4. Check Voltage Regulator (inside control box). Refer to Voltage Regulator Manual
in Chapter 6.

Replace defective Voltage Regulator.

2. GENERATOR WILL NOT BUILD UP VOLTAGE IN MANUAL MODE.

Step 1. Connect a jumper across the manual control FIELD RHEOSTAT (inside control box),
and flash the fields using the PUSH-TO-BUILD-UP-VOLTAGE switch (IO, Figure 1).

If voltage builds up, replace defective rheostat (R450).

Step 2. Check generator shunt fields for open circuit.

Replace shunt fields as required.

Troubleshooting Chart
Figure 2
(Sheet 5 of 8)

Aug 6181 3-1

Page 7
 OM-I 68

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

GENERATOR AND CONTROLS

3. LOAD CONTACTOR WILL NOT CLOSE Ak’NO LOAD.

Step 1. Check contactor switch (9, Figure 1).

Replace defective switch (S407).

Step 2. Apply 28 volts DC to terminals marked SW (+) and GD (--) on load contactor (I-1 ; 4,
Figure 5).

If contactor does not close, replace faulty contactor (K404).

4. LOAD CONTACTOR WILL CLOSE, BUT OPENS WHEN CONTROL SWITCH RETURNS TO ON POSITION.

Step 1. Check control switch (9, Figure 1).

Replace defective switch (S407).

Step 2. Check overload module (l-l ; 3, Figure 5).

Replace faulty module (K403). (Contacts normally closed.)

Step 3. Check overvoltage module (l-l; 2, Figure 5).

Replace faulty module (K402). (Contacts normally closed.)

Step 4. Check the load contactor (l-l ; 4, Figure 5).

Replace defective load contactor (K404).

Step 5. Check 100 ohm, 25 watt resistor (l-l ; 5, Figure 5).

Replace faulty resistor (R402).

5. LOAD CONTACTOR OPENS DURING POWER DELIVERY.

Step 1. Check overload module (I-1 ; 3, Figure 5).

Replace faulty module (K403).

Step 2. Check overvoltage module (I-l ; 2, Figure 5).

Replace faulty module (K402).

Step 3. Check load contactor (l-l ; 4, Figure 5).

Replace faulty load contactor (K404).

Troubleshooting Chart
3-1 Figure 2 Aug 6181
Page 8 (Sheet 6 of 8)
 w
1 OM-168

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

GENERATOR AND CONTROLS

6. GENERATOR WILL NOT BUlLDjUlQVOLTAGE PROPERLY IN AUTOMATIC MODE.

Step 1. If 14 volt output option is used, make sure that switch (23, Figure 1) is in OFF position.
Set AUTOMATIC/MANUAL switch (inside control box) to MANUAL position and control ’
voltage to 28.5 volts with FIELD RHEOSTAT.

If voltage can be controlled to 28.5 volts manually, readjust Voltage Regula-

tor (I-1 ; 1, Figure 5) (VR401). Refer to the Voltage Regulator Manual in
Chapter 6. If unable to obtain proper output voltage, replace the Voltage
Regulator.

7. OUTPUT CURRENT CANNOT BE CONTROLLED PROPERLY.

Step 1. Check current limit control (7, Figure 1).

Replace faulty rheostat (R451).

Step 2. Check Voltage Regulator (l-l; 1, Figure 5).

Adjust or replace the Voltage Regulator (VR401). Refer to the Voltage

Regulator Manual in Chapter 6.

14 VOLT OUTPUT (OPTION)

1. 14 VOLT LOAD CONTACTOR WILL NOT CLOSE.

Step 1. Check resistor (l-l; 7, Figure 7).

Replace defective resistor (R406).

Step 2. Check position of 28.5 volt load contactor control (9, Figure 1).

Place control switch to OFF position.

Step 3. Check 28.5 volt control relay (I-l ; 3, Figure 7).

Replace defective relay (K405).

Step 4. Check 14 volt control relay (I-l ; 1, Figure 7).

Replace defective relay (K406).

Step 5. Check overvoltage module (l-l; 6, Figure 7).

Replace defective module (K409).

Troubleshooting Chart
Figure 2
Aug 6/l 8 (Sheet 7 of 8) 3-I
Page 9
 ,:a -
bEEd

OM-168

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

14 VOLT OUTPUT (OPTION)

I. 14 VOLT LOAD CONTACTOR WILL NOT&OSE. (CONTINUED)

Step 6. Check overload relay (l-l ; 8, Figure 7).

Replace faulty relay (K408).

Step 7. Check contactor control switch (23, Figure 1).

Replace faulty switch (S410).

Step 8. Check load contactor (I-l ; 4, Figure 7).

Replace defective load contactor (K407).

2. LOAD CONTACTOR CLOSES, BUT OPENS WHEN CONTROL SWITCH RETURNS TO ON POSITION.

Step 1. Check 14 volt control relay (I-l ; 1, Figure 7).

Replace faulty relay (K406).

3. LOAD CONTACTOR OPENS DURING POWER DELIVERY.

Step 1. Check overload relay (I-l; 8, Figure 7).

Replace defective relay (K408).

Step 2. Check overvoltage module (I-l ; 6, Figure 7).

Replace faulty module (K409).

Step 3. Check adjustment of resistor (1-I; 9, Figure 7).

Adjust or replace resistor (R407).

Step 4. Check control relays (l-l; 1 and 3, Figure 7).

Replace defective relay (K405 or K406).

Step 5. Check load contactor (l-l ; 4, Figure 7).

Replace defective load contactor (K407).

Troubleshooting Chart
Figure 2
(Sheet 8 of 8)

3-l Aug 6181

Page IO
 OM-I 68

CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION

1. General

The Illustrated Parts List identifies1 de+scribes,and illustrates main assemblies, subassemblies, and detail parts of
the Jet-Ex 3 Generator Sets manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio.

2. Purpose

The purpose of this list is to provide parts identification and descriptive information to maintenance and pro-
visioning 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 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 com-
mercially.

(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 identi-
fies 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 lists 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.

Aug 6181 4-l

Page 1
 (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 an ;his part number will appear in the NOMENCLATURE
column. Parts man ! fhctured by Hobart reflect no vendor code or part
number in the NOMENCLATURE column.

(3) NOMENCLATURE Column

The item identifying name appears in this column. The indenture method
is used to indicate item relationship. Thus, componenents 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.

(4) REC. SPARES Column

When there is an entry in this column, it shows the quantity of that item
recommended for spares to support ONE end item.

(5) EFF (Effective) Column

This column is used to indicate the applicability of parts to different

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

Uncoded parts are used on all units.

Parts coded A are used on 6272-l only.

Parts coded B are used on 6272-2 only.
Parts coded C are used on 6272-3 only.
Parts coded D are used on 6272-4 only.

(6) "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.

5. Reference Designator Index

The reference designators listed in Figure 1 are the same as those used on the
connection and schematic diagrams furnished in Chapter 6. Each reference
designator is cross-referenced to the Figure and Item number of that item in the
Illustrated Parts List, Section 4-3.

- Revised
_..~.Mar
- .~~ ~. 13/85

Pag-e 2
 OM-168

REF. l- LOCl ION lr REF. LOU ION lr REF. LOU ION

DES. ITEM :IG. DES. ITEM -IG. DES. ITEM -IG.

A404 18 13 ’ K407 14 17
K408 17 17
8401 IO 4 K409 14 17

BT401 7 IO L401 5 11
L403 14 13
c401 19 5 L404 12 13
c402 6 7 L406 19
c403 19 5 M401 11 5
c404 lot Showr 13 M402 7 5
c405 9 4 M403 6 5
C406 3 13 M404 3 5
c407 3 13 M405 10 5
C408 3 13 M406 9 5
c409 3 13 M407 5 5
c410 6 18
c411 6 18 R402 7 6
R405 7 16
CR401 18 5 R406 15 16
CR402 18 5 R407 19 -17
CR403 18 6 R409 21 6
CR404 21 6 R450 IO 6
R451 13 5
DS401 4 5 R490 17 6
DS402 4 5
DS420 19,17 2,3 s401 17 5
DS421 19,17 2,3 S402 18 5
DS422 19,17 2,3 S403 21 5
DS423 19,17 2,3 s404 17 4
DS440 25,26 5 S406 18 5
DS441 15 5 S407 17 5
DS442 6,7,8 6 S408 12 6
DS460 2,3,4 16 s409 2 8
s410 5 16
E403 2 9
E404 19 6 VR401 2 6

F401 22,23 5
F402 22,24 5

K402 4 6
K403 5 5
K404 6 5
K405 5 17
K406 5 17

Reference Designator Index

Nov 17182 Revised Figure 1
4-I
Page 314
“-
 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 purc/-t+sedparts listed in this publication. The codes are
in accordance with the bedera Supply Codes or Manufacturer's Cataloging
Handbook H4-1, and are arranged in numerical order. Vendor codes are inser-
ted 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 full name of the manufacturer will be listed in the nomenclature column.

CODE VENDOR'S NAME AND ADDRESS

No Number Precision Governors Inc.

10524 Product Drive
Rockford, Illinois 61111

0112 1 Allen-Bradley Company

1201 South 2nd Street
Milwaukee, Wisconsin 53204

08108 Lamp Industry Designations

and Abbreviations for Lamps

14655 Cornell & Dubilier Electric Corporation

50 Paris Street
Newark, New Jersey 07101

16476 Datcon Instrument Company ,

P.O. Box 128
East Petersburg, Pennsylvania 17520

20796 Dayco Corp.

Rubber Products Division
P.O. Box 3258
Springfield, MO 65808

22938 Prototype Development Inc.

7750 Hub Parkway
Cleveland, Ohio 44125

24248 South Chester Corporation

South Company Division
3rd Street SrGovernor Printz Boulevard
Lester, Pennsylvania 19113

28520 Heyco Molded Products

Kenilworth, NJ 07033

30327 Imperial-Eastman Corporation

6300 W. Howard St.
Chicago,_T~~~~~~.s---.60~~~_._.
_._~~_

----
~--Page-1
 -..- --.--j_-. .-- -. -. .‘L - - - ~. --
,,./-
,.-- -.
OM-168-

CODE VENDOR'S NAME AND ADDRESS

34383 General Radiator Company

410 S. 12th Street
P.O. Box 948
'Mount Vernon, Illinois 62864
i4
Ohmite Manufacturing Company
3601 W. Howard Street
Skokie, Illinois 60076

Protectoseal Company
1920 S. Western
Chicago, Illinois 60608

$7448 Stephens & Adamson Manufacturing Company

275 Ridgeway Avenue
Aurora, Illinois 60507

58849 Syntron Company

1938 Black Street
Homer City, Pennsylvania 15748

60741 Triplett Electrical Instrument Company

Harmon Road
Bluffton, Ohio 45817

66295 Wittek Manufacturing Company

4309 W. 24th
Chicago, Illinois 60623

72619 Amperex Electronics Corp.

Dialight Division
203 Harrison Place
Brooklyn, NY 11237

Carling Electric Inc.

505 New Park Avenue
West Hartford, Connecticut 06110

74063 Hartman Electrical Manufacturing Company

P.O. Box a
Mansfield, Ohio 44901

751 75 The Duplan Corporation

KD Lamp Division
1910 Elm Street
Cincinnati, Ohio 45210

75418 Kysor Industrial Corporation

1100 W. Wright Street
Cadillac, Michigan 49601

j 4-2
2 - - - --.. - -.--. - -_.-.-. -.--____
__...---
Revised Feb lo/84
CODE VENDOR'S NAME AND ADDRESS

76700 Nelson Muffler Corporation

P.O. Box la9
Stoughton, Wisconsin 53589

77342
i ;I American Machine & Foundry Company
Potter & Brumfield Division
1200 E. Broadway
P.O. Box 522
Princeton, Indiana 47570

77574 Richland Auto Parts Company, Inc.

151 Distl. Avenue
Mansfield, Ohio 44903

79260 Walker Manufacturing Company

1201 Michigan Blvd.
Racine, Wisconsin 53402

79470 The Weatherhead Company

300 East 131st Street
Cleveland, Ohio 44108

79497 Western Rubber Company

620 East Douglas
Goshen, Indiana 46526

a9373 United States Rubber Company

Detroit, Michigan

89616 Uniroyal Inc.

Consumer Industrial and Plastic Products
312 N. Hill Street
Mishawaka, Indiana 46544

90201 Mallory Capacitor Company

3029 E. Washington Street
P.O. Box 372
Indianapolis, Indiana 46206

90927 Ford Motor Company

Industrial Engine Operations
300 Renaissance Center
P.O. Box 43338
Detroit, Michigan 48243

91929 Honeywell Inc.

Building Controls and Components Group
Micro Switch Division
Freeport, Illinois 61032

-...,.----p-age
&I
 CODE VENDOR'S NAME AND ADDRESS

92701 Harry Davies Company

700 N. 27th
1 Camden, New Jersey
1 ‘I

98293 Pierle Co. Inc.

P.O. Box 2000
Upland, IN 46989

98410 E.T.C. Inc.

990 E. 67th Street
Cleveland, Ohio 44103

., ^ -. -- --- .--.-.-.--- ~---.--__------- _..

:.-4--2_
.__-.--_.~.--..--..-.-.-.-__ Revised Feb lo/84
- - I_---____..--- .- ..._~
..-. ..__
'-p.a-g-~
..&..---- - - -
 w
I 1 OM-I 68

SECTION 3. PARTS LIST

1. Explanation of Parts List Arrangement

The parts list is arranged so that the jllustration will appear on a left-hand page and the applicable parts list will
appear on the opposite right-hand pa%. Unless the list is unusually long, the user will be able to look at the illustra-
tion and read the parts list without turning a page.

2. Symbols and Abbreviations

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

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

Aug 6181 4-3

Page 1
 w
I I OM-168

l---H
0

1 PSD-0285 i

Generator Set
Figure 1
4-3 Aug k/81
Page 2
 ,, ,’

.-

NOMENCLATURE UNITS
REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

l- 6272-l GE FRAkOR SET, JET-EX, STATIONARY

N'LT, ELECTRONIC GOVERNOR
f: 1
’ 6272-2 GENERATOR SET, JET-EX, STATIONARY
UNIT WITH LIFT OFF DOORS,
ELECTRONIC GOVERNOR 1
6272-3 GENERATOR SET, JET-EX, STATIONARY
UNIT, MECHANICAL GOVERNOR 1
6272-4 GENERATOR SET, JET-EX, STATIONARY
UNIT WITH LIFT OFF DOORS,
MECHANICAL GOVERNOR 1
1 30GH-872 . U-BOLT, LIFTING 1
2 79A-1127-1 . GUARD, FILLER NECK 1
3 DW'P-1804-1 . REFLECTOR, RED, V75175, NO. m-333 4 4
4 4857 14-1 . CANOPY ASSEMBLY (For Details See
Fig. 2) A 1
5 4857 14-2 . CANOPY ASSEMBLY (For Details See
Fig. 3) B 1
6 No Number . GENERATOR SET WITHOUT CANOPY
(For Details See Figure 4) 1
7 483331 . TRAILER ASSEMBLY (OPTION)
(For Details See Figure 15) 1
 cn’

n- \ \ n

\ ”
) ., .~.
 w
I 1 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

2- 485714-1 CANOPY ASSEMBLY (For NHA See Figure 1) A REF

387438 . PAfl$t, COVER, RADIATOR OPENING,
ASSEMBLY A 1
2 603127 . CATCH, MAGNETIC V24248, No. 02-10-201-10 A
3 485719 . TOP, CANOPY, ASSEMBLY A 1 1
4 485741 . PANEL, END, FRONT CANOPY ASSEMBLY A
5 485747 . PANEL, END, REAR CANOPY ASSEMBLY A
6 485772 . PANEL, ACCESS, REAR CANOPY A
7 48576 1 . PANEL, SIDE, CANOPY A
8 485732 . PANEL, CENTER, CANOPY A
9 485810 . DOOR, RIGHT, REAR CANOPY, ASSEMBLY A
IO 485795 . DOOR, RIGHT, FRONT CANOPY, ASSEMBLY A$ 1
11 485796 . DOOR, LEFT, REAR CANOPY, ASSEMBLY A
12 485777 . DOOR, LEFT, FRONT CANOPY, ASSEMBLY A
13 387859 ROD, HOOK, DOOR A 4
14 HJ-129A : JOINT, BALL, DOOR ROD V01428,
No. SPS1002CP 2 A
15 485908 . COVER, PLEXIGLASS, RIGHT DOOR A
16 DWP-982 . BRACKET, CABLE A
*
50N H-622 . PLATE, REINFORCING CABLE BRACKET A
17 402987 . NAMEPLATE, HOBART A
18 81B-1019 . LATCH, T-HANDLE V24248,
No. 68-10-101-10 2 A 4
*
40201 . STRIP, NEOPRENE, RUBBER A 112”
*
400435 . NAMEPLATE, 28 VOLT A 1
19 404101-1 LIGHTS, CLEARANCE V75175, No. 514-0168 2 A 4
*
400613-10 . LAMP, CLEARANCE LIGHT, 12 V 4 A’
*
W-l 0051-3 CLAMP, WIRING, LIGHT A 4
I * 486207-7 . LABEL, WARNING, COMP A 5

Mar 12184 Revised 4-3

Page 5
 OM-I 68

‘\I
14-

s
Canopy Assembly
Figure 3
4-3 Aug 6181
Page 6
 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

3- 485714-2 CANOPY ASSEMBLY (For NHASee Figure 1) 6 REF

1 387438 PANCL, COVER, RADIATOR OPENING,
’ AS&MBLY
2 403127 . CATCH, MAGNETIC V24248, No. 02-10-201-10
3 4857 19 . TOP, CANOPY, ASSEMBLY 1
4 48574 1 . PANEL, END, FRONT CANOPY ASSEMBLY
5 485747 . PANEL, END, REAR CANOPY ASSEMBLY
6 485772 . PANEL, ACCESS, REAR CANOPY
7 48576 1 . PANEL, SIDE, CANOPY
8 485897 . PANEL, CENTER, CANOPY
9 485905 . DOOR, RIGHT, REAR CANOPY, ASSEMBLY
10 485904 . DOOR, RIGHT, FRONT CANOPY, ASSEMBLY
11 485907 . DOOR, LEFT, REAR CANOPY, ASSEMBLY
12 485904 . DOOR, LEFT, FRONT CANOPY, ASSEMBLY 1
13 485908 . COVER, PLEXIGLASS, RIGHT DOOR
14 DWP-982 . BRACKET, CABLE 2
50NH-622 . PLATE, REINFORCING CABLE BRACKET 2
15 402987 . NAMEPLATE, HOBART 2
16 81 B-1019 . LATCH, T-HANDLE V24248,
No. 68-10-101-10 2 8
*
40201 . STRIP, NEOPRENE, RUBBER 225”
*
400435 . NAMEPLATE, 28 VOLT
17 404101-1 LIGHTS, CLEARANCE V75175, No. 514-0168 2
400613-10 . LAMP, CLEARANCE LIGHT, 12 V 4
*
W-l 0051-3 CLAMP, WIRING, LIGHT
I * 486270- 7 . LABEL, WARNING, COMP.

Mar 12/84 Revised 4-3

Page 7
 25
26

i I
24 5

I2

Generator Set Without Canopy

Figure 4

4-3

.Page-8
 c ’

.,
OM-168
.
NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

4- NO NUMBER GENERATOR SET WITHOUT CANOPY (For

NHA see Fig. 1) REF
1 485678-l BOX ASSEMBLY, CONTROL (For
i '[Details See Figure 5) 1
'485678-2 . BOX ASSEMBLY, CONTROL (For
Details See Figure 5) 1
2 485831-1 . PANEL, ENGINE CONTROL ASSEMBLY
(For Details See Figure 8) 1
485831-2 . PANEL, ENGINE CONTROL ASSEMBLY
(For Details See Figure 8) 1
3 NO NUMBER . GENERATOR AND DRIVE GROUP
(For Details See Figure 13) 1
4 485660 . SUPPORT, ENGINE, LEFT
5 485657 . SUPPORT, ENGINE, RIGHT 1
6 NO NUMBER . COOLING SYSTEM (For Details See
Figure 12) 1
7 485818 . FRAME, MOUNTING, ASSEMBLY 1
8 485664 . YOKE, LIFTING, ASSEMBLY 1
9 W-10853-4 . CAPACITOR, 0.5 $, 100 V. DC
V90201, No. B-206020 1 1
10 402461-l . CAPACITOR, IGNITION COIL, V14655,
NO. BR-250-50 1 1
11 NO NUMBER . BATTERY INSTALLATION (For Details
See Figure 10) 1
* 485829 . TERMINAL, OUTPUT, ASSEMBLY (For
Details See Figure 7) 1
12 489300 . SUPPORT, FUEL TANK 2
13 NO NUMBER . SPEED CONTROL GROUP (For Details
See Figure 9) 1
14 NO NUMBER . FUEL SYSTEM (For Details See
Figure 11) 1
15 78B-1119-1 . SENDER, TEMP., V16476, NO. 02019 1 1
16 78B-1118-1 . SENDER, OIL PRESS, V16476, NO. 02500 1 1
17 403809 . SWITCH, OIL PRESS, V75418,
NO. C-25900-10 1 1
18 W-7814-O . FITTING, PIPE, BSHG 1
19 w-10750-1 . FITTING, PIPE, NIPPLE 1
20 w-10910-0 . FITTING, PIPE, TEE 1
21 8111-1044 . ENGINE, FORD 300, V90927,
NO. CSG-6491-6005-A 1
22 81A-1045 . KIT, ENGINE, PARTS, FORD SPECIAL
OPTIONS, V90927, NO. SO-2800C 1
A 485819 . HARNESS, ENGINE 1
* 6OGHP-424 . CLAMP, OUTPUT CABLE
23 81C-1013 . MUFFLER, ASSY, V76700, NO. 18546-N 1 1
24 487933 . PIPE, MAN. TO MUFF. 1
25 486028 . PIPE, EXHAUST 1
26 486003 . BRACKET, SUPPORT, TAILPIPE 1
27 486004 . SHIELD, MUFFLER 1

4-3

Page 9
 OM-168

4-3
Aug 6181
Page 10
 NOMENCLATURE UNiTS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF AS$Y

* 4- 486001 . CLAMP,MUFFLER i
* 486002 . STRIP, MTG. MUFFLER i
* 404154-8 . @+MP, MUFFLER, 2", V79260, NO. 35408 3
,486Oll . COVER, EXH. OUTLET ASSEMBLY i
79A-1110 . NAMEPLATE, OPTION i
78A-1000 . NAMEPLATE, RATING 1
75-422-o . CLAMP, CABLE, OUTPUT 1
W-9218-123 . CABLE 8134
T
486115 . KIT, SPACERS, STATIONARY MTG.
(OPTION) 1
* 485910 KIT, 14 VOLT OUTPUT ASSEMBLY
l (OPTION) I
28 828-1056 . PULLEY, 3 GROOVE i
29 828-1057 . BELT, GOVERNOR DRIVE, (V20796), L324 1
30 487092 l BRACKET, CONTROL, THROTTLE MOUNTING
6272-3 AND 4 ONLY
ATTACHING PARTS i
31 NO NUMBER . SCREW, CAP, HEX HD, 5/16-18 X 3/4 i
32 NO NUMBER . WASHER, LOCK 5/16 2
***
* 33 487532 . HARNESS, WIRE, ENGINE,
6272-l sr2 ONLY i
* 34 487533 . HARNESS, WIRE, ENGINE,
6272-3 h 4 ONLY i
* 35 485915 . . PANEL, CONTACTOR, 14 V. ASSY.
(For Details See Figure 17) ;
* 36 485909 . . BRACKET, MOUNTING CONTACTOR i
* 37 485921 . . SHIELD, CONTACTOR, PLEXIGLASS i
38 485925 . . PANEL, CONTROL, ENGINE ASSY.
(For Details See Figure 16) ;1
* 485830 . . TERMINAL, OUTPUT, 14 V. ASSY.
(For Details See Figure 18) '1
75-422-o . . CLAMP, OUTPUT, CABLE i
400434 . . NAMEPLATE, 14 VOLT F
485927 . . BAR, BUS, SHUNT il
485928 . . BAR, BUS, OUTPUT (28 V.) 11
W-9218-36 . . CABLE, POS. 4/o (CONTACTOR
TO OUTPUT PANEL) 11
* W-9218-41 . . CABLE, NEG. 4/O (28.5 V.
PANEL TO 14 V. PANEL) !l
* W-9218-128 . . CABLE, POS. 4/O (SHUNT !
TO 14 V. PANEL) il
39 487084 . KIT, ZENITH CARBURETOR
(For Details See Figure 19) jl
/
i
I
I
I

,_-- -s* f
I-
1
\ Ott l/86 Revised ;4-3
-----?-- ----_

Page 11
iI.----_----__ __-----
 x
- -.

Voltmeter Tach Ammeter

5B
-

.. . .
Water Temp Oil Pres. Eng. Amp Hour Meter

,.L
-

Eng. Start Push Fuse Fuse Panel Build Contactor Contactor

Lamp Run Start 20A 10A Light Volt. Light
IH
 I 1 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

5- 485678 - 1 BOX, CONTROL ASSEMBLY REF

43.%7&2 BC ‘, FONTRbL ASSEMHzY PEF
485710 . WRz PbER, CONTROL BOX, ASSEMBLY
4b5679 PANEL, FRONT, ASSEMBLY 1
.!@7-J
15 :PANEL- FRc.I’I T ASSEMBLY i
2 485684 . . PANEL, FRONT 1
3 78A-1116-l . . GAUGE, WATER, TEMP V16476,
No. 06343 1 1
4 84B- 1903 . . LIGHT, PANEL V74400, No. Ml-3216 1 2
*
50GHP-206 . . . BULB 2
400642-3 . . VOLTMETER, 0 TO 50 V DC V60741 1
78A-1117-l . . GAUGE, OIL PRESSURE V16476, No. 06340 1 1
78A-1115-l . . GAUGE, AMMETER Vl6476, No. 06354 1 1
80A-1134 . . LATCH, ADJUSTABLE GRIP V24248,
No. 16-10-311-14
9 786-l 121-1 . . TACHOMETER V16476, No. 71000 1
10 78A-1120-l GAUGE, HOURMETER V16476, No. S6288
11 400641- 12 : : AMMETER2000 V60741 1 1
12 81 B-1030 . . NAMEPLATE, STARTING CURRENT 1
13 401428-l . . POTENTIOMETER 10,000 OHM 2 WATT
V44655, No. CMU-1031
14 16DA-2 162 . . KNOB, CURRENT, RHEOSTAT
15 HF-2518-7 . . LIGHT, PILOT, ASSEMBLY 1
16 400613-3 . . . LAMP 2
17 403 189 . . SWITCH, TOGGLE V91929, No. 312TSl-59 1
18 DW-1777% . . SWITCH, PUSHBUTTON 1
19 20RT-353-l . . DIODE
20 25MS-156 . . BUS
21 402662 . . SWITCH, TOGGLE V73559,
No. 2GK71-73-DPST 1 1
22 402658 . . HOLDER, FUSE V71400, TYPE HKP-HH 2
23 W-l 1166-3 . . FUSE, AGC, 10 AMP 5
24 W-l 1166-5 . . FUSE, AGC, 20 AMP 5 1
25 HF-2518-8 . . LIGHT, PILOT, ENGINE, GREEN 1
26 4006134 . . . LAMP 2 1
485681 . PANEL, REAR, ASSEMBLY (For Details
See Figure 6)
*
485682 . HARNESS, CONTROL, PANEL ASSEMBLY 1
*
485683 . HARNESS, INTERIOR PANEL, ASSEMBLY 1
389535-2 . SUPPORT, HINGED PANEL 2

!June 28185 Revised 4-3

Page 13
 w 1 OM-168

2 3 4 56 7

b 0 9
\
0 0

0 0

Rear Panel Assembly

Figure 6
4-3 Aug 6181
Page 14
 I I OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPAR ES EFF ASSY

6- 485681 PANEL, REAR, ASSEMBLY (For NHA See

Figur?e51)
1 485728 . PANEL, REAR, CONTROL BOX
2 485972 . BOARD, PC, VOLTAGE REGULATOR,
ASSEMBLY 1 1
3 401556 . MOUNT, RUBBER, SHOCK, P.C. BOARD
V89373. No. B-323 7
4 3895228 . BOARD, PC OVERVOLTAGE, ASSEMBLY 1 1
5 484567 . BOARD, PC OVERLOAD, ASSEMBLY 1 1
6 6FW-2087A . CONTACTOR V74063, No. A-791 M 1 1
7 W-4541 D . RESISTOR, VARIABLE, 100 OHM, 25 W
8 48597 1 . BUS, CONTACTOR TO SHUNT
9 485970 BRACKET, MOUNTING, RHEOSTAT,
’ SWITCH 1
10 402159 . RHEOSTAT, 150 WATT, 32 OHM
V44655, MODEL L 1
11 AAW-835A . KNOB, CURRENT, RHEOSTAT V92701,
No. 4103AX
12 400400 . SWITCH, TOGGLE V73559, No. 26L61 1 1
13 401937-3 . BLOCK, TERMINAL, 20 AMP, 12
V98410, No. 35012-3526 2
14 401937-4 . BLOCK, TERMINAL, 20 AMP, 18
V98410, No. 35018-3526 1
15 402037-29 . GROMMET, RUBBER, l/2 IN. I.D., l-1/16
O.D. V79497
16 484294 . INSULATOR, SHUNT
17 6OFC405 . SHUNT, 2000 AMP, 50 NIV., ASSEMBLY
18 20RT-353-1 . DIODE, NEGATIVE, BASE V58849,
No. R2025lH 1
@ 19 81 B-1026 . GOVERNOR, OVERSPEED, ASSEMBLY
Precision Governors Inc. No. S-207A
20 48588 1 . BRACKET, MOUNTING, OVERSPEED 1
21 484987 . RESISTOR AND DIODE ASSEMBLY 1

@ Mfg’s No. S-207 used before SN 83-PSO-1001 shipped 13 JAN 1983 requires kit 487467
to replace S-207 governor.

April ‘T2/83 Revised 4-3

Page 15
 w
I I OM-168

28.5 Volt Output Terminal Assembly

Figure 7
4-3 Aug 6181
Page 16
 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

7- 485829 TERMINAL, OUTPUT, 28.5 V. ASSEMBLY

(For rJhA See Figure 4) REF.
1 4,85864 . PANEL, TERMINAL, OUTPUT 1
2 W-l 1097-8 SCREW, 318-16 X 2 2
3 W-l 1254-6 : WASHER, LOCK, 318 4 I
4 W-l 1242-10 . WASHER, FLAT, 318 4
5 W-l 1278-5 . NUT, 3/8-16, HEX 2
6 W-l 0853-4 . CAPACITOR, 0.5 pF, 100 V. DC
V90201, No. B-206020
7 A-897-l . NAMEPLATE, NEGATIVE
8 400435 . NAMEPLATE, 28 VOLT
9 A-896-l . NAMEPLATE, POSITIVE
10 5CW-2127 . BUSHING
11 5CW-976A . WASHER, INSULATOR
12 IOOGH-112 . TERMINAL, OUTPUT
13 5cw-975 . BUSHING, INSULATOR
* 485878 . STRAP, MOUNTING, CAPACITOR

Aug 6181 4-3

Page 17
,’

i ‘I

[ PSD-02821

Engine Control Panel Assembly

 OM&&

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

8- 1 485831-1 PANEL,, ENGINE, CONTROL

'(For NHA See Fig. 4) A REF
2 , 485831-2 PAhEfL, ENGINE CONTROL B REF
(For NHA See Fig. 4)
3 485865 . PANEL, CONTROL AB 1
4 402662 . SWITCH, TOGGLE, 2GK71-73,
(v73559) 1 Al3 1
5 385765 CONTROL, CHOKE, AN-0940-00,
l (v77574) 1 AB 1
6 404603-3 . CONTROL, THROTTLE, 43141-002-
0042.0 1 B 2
7 5AW-989 . NAMEPLATE, THROTTLE CONTROL
ATTACHING PARTS 1 B 2
8 NO NUMBER . SCREW, PAN HD, SELF-TAPPING,
# 4-40 x l/4 B 2
***
9 403091-2 . PLUG, HOLE, DP-437, (V28520) A 1

4-3
 359754 Throttle Bracket

Mechanical Governor
Figure 9A
__473-.
.~.___
-.~~
_._._ Revised Feb lo/84
 /
‘\ -’ !
-. / ’
,
,
-. ,_,’
._
;-/’ 1
I , .

NOMENCLATURE UNITS
FIGURE HOBART REC per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

9A- 1 NO NUMBER SPEED CONTROL GROUP REF

FfEF FIG. 4 FOR NHA)
2 ( 83C-1003 6Ot'ERNOR MECHANICAL‘ 1
l (V98293): GC-10965
ATTACHING PARTS
3 NO NUMBER . SCREW, CAP, HEX HD, 3/8-24 X 1 l/4
4 NO NUMBER . WASHER, LOCK, 3/8
5 NO NUMBER . WASHER, 318
6 NO NUMBER NUT, HEX, 3/8-24
;**

7 487741 . BRACKET, MOUNTING, GOVERNOR 1

ATTACHING PARTS
8 NO NUMBER . SCREW, CAP, HEX HD, 3/8-16 X 1 l/4 1
9 NO NUMBER WASHER, LOCK 3/8 1
;**

10 402908 . JOINT, BALL 2

ATTACHING PARTS
11 NO NUMBER . NUT, HEX, l/4-28 2
12 NO NUMBER WASHER, LOCK 2
i**

13 W-9476-6 . ROD, CONTROL, GOVERNOR 1

14 NO NUMBER . NUT, HEX, V4-28 2
15 487093 . LEVER, ARM, CARBURETOR
16 487094 . SPACER, LEVER, CARBURETOR
17 430506-10 . CHAIN, SAFETY
18 356354-l . CHAIN, JACK
19 HJ-200 . CLAMP, WIRE, THROTTLE LINKAGE
20 NO NUMBER . SCREW, HEX HD, f8-32 X 7/8

.-Feb--la/&-*ised---
-._- -. - . . __ . .-. - -. __ _.
-.--..T~age- 19-B
 m

I
I
I
I
OM-168

Precision Governor
Control Box 9016
Actuator 9025

Speed Control Group

Figure 9

4-3
Page 20
 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPAR ES EFF ASSY

.g- No Number SPEED CONTROL GROUP (For NHASee

Figure 4) . REF
1 485838 BR+GrET, MOUNTING GOVERNOR 1
2 tjlC-1025 : GOVERNOR Precision Governors Inc. No. SKA 1 1
3 402908 . BALL, JOINT V57448, No. TF4Y 2 2
4 W-9476-4 . ROD, THROTTLE CONTROL 1 ’

Aug 6181 4-3

Page 21
 OM-I 68

Battery Installation
Figure IO
4-3
Aug 6181
Page 22
 w
I, II OM-I 68

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPAR ES EFF ASSY

IO- No Number BATTERY. INSTALLATION (For NHASee

Figu e;4) REF
1 12cw-1914-4 . CA H Lk ASSEMBLY, BATTERY TO STARTER
SWITCH 1
2 12cw-1915-14 . CABLE ASSEMBLY, BATTERY TO GROUND 1 ,
3 No Number . NUT, PLAIN, HEX, 5/16-18 2
4 No Number . WASHER, FLAT, 5116 IN. 4
5 5CW-2048 . ROD, BATTERY CLAMP 2
6 485793 . CLAMP, BATTERY HOLD-DOWN 1
7 402086-I . BATTERY, 12 V. 1
8 485790 . SUPPORT, BATTERY 1
Y
W-9648-22 . CABLE ASSEMBLY, STARTER SWITCH TO
SOLENOID 1

Aug 6181 4-3

Page 23
 OM-168

./I
F

Fuel System
Figure 11
Revised Nov 17lSi
4-3

Page 24
 I I

OM-I 68

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPAR ES EFF ASSY

ll- No Number FUEL SYSTEM, ENGINE (For NHASee

Figure 4) REF
1 6FW-5072 . CAP, FUEL TANK V49234, No. 1273 1

I 2
3

4
486562
5CW-3420-I
485817
. TANK, FUEL, ASSEMBLY
. . GAUGE, FUEL
. LINE, FUEL, ASSEMBLY
1
1
1
’

81 A-1017-1 . . VALVE, SHUT-OFF 1

5 403615 . . VALVE, FUEL, SOLENOID V96152,
No. 4-2314 1
6 W-10891-7 . . FITTING, ELBOW, MALE V79470,
No.49 x4 1
7 W-l 0893-o . . FITTING, HOSE, SWIVEL, FEMALE
V30327, No. KA06-06NS 1
8 W-10869-14 . . CLAMP, HOSE 7132 TO 51% 1
9 56544 . . HOSE, LOW PRESSURE 5/16 I.D. 34”
*
482496-l . CLAMP, FUEL LINE 2
10 486577 . PAN, FUEL TANK 1
11 486567-l . STRAP, FUEL TANKASSEMBLY’ 2
12 483630 . INSULATION STRAP, FUEL TANK 2

Nov 17/82 Revised 4-3

Page 25
E

P
 I 1 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

12- No Number COOLING SYSTEM (For NHA See Figure 4) REF

1 FW-3449 . CAP, RADIATOR 1 1
2 W-l 0869-3 . CL@l’p, HOSE V66295, No. C32P 2 4
3 485827-I . HOSE, RADIATOR, TOP 1 1
4 56581 . HOSE, RADIATOR, BOTTOM 1 18”
5 389897 . GUARD, FAN ASSEMBLY 2 ’
6 351541 . LABEL, CAUTION FAN 2
485762 . RADIATOR ASSEMBLY 1
7 w-10051-5 . . CLAMP, PLASTIC 2
8 56555 . . HOSE, OVERFLOW 45”
9 485335 . . SHROUD, FAN 1
IO 485334 . . HEAD, RADIATOR 1
11 485336 . . BASE, RADIATOR 1
12 DW-3641 . . STRIP, WASHER 4
13 DW-3590 . . GASKET, TOP AND BASE 2
14 DW-3587 . . SIDE, RADIATOR 2
15 487305
81 D-1007 . . CORE, RADIATOR V34383, No. 122-4004 1
16 5cw-1932-o . . COCK, DRAIN RADIATOR
V79470, No. 145 1

Aug 6181 4-3

Page 27
 -_
--

_. _, ,_ .- .-
 w
I I OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPAR ES EFF ASSY

13- No Number GENERATOR AND DRIVE GROUP (For NHA

See Figure.4) REF
1 484506 . COp$R, END 1
2 485113 . COVER, FLYWHEEL HOUSING 1
3 W-l 0855-4 . CAPACITOR, 0.25 pF, 100 V DC
V90201, No. B-20601 1 4 (
4 483798 . LEAD, CAPACITOR 4
5 DW-882A . CAP, BEARING 1
6 DW-883 . GASKET, BEARING CAP 2 1
7 FW-446 . NUT, BEARING 1
8 W- 10072-8 . BEARING, BALL V21335, No. 310NP 1 1
9 16DW-967 . CLAMP, BRUSHHOLDER 2
10 35822 1-32 . BRUSHHOLDER (For Details See Figure 14) 1
11 358830- 14 . POLEPIECE, INTERPOLE 4
No Number . COIL SET, INTERPOLE 1 SET
12 380706 . . COIL, INTERPOLE 2
380707 . . COIL, INTERPOLE 2
13 DW-1045 . POLEPIECE, PLUG HAT 4
14 1361 . COIL SET, SHUNT FIELD 1 SET
15 430278 . GROMMET, GENERATOR HOUSING
V89616, NO TPR-1812 8
16 484810-I . HOUSING, GENERATOR 1
17 c-30 . KEY, MACHINE 1
18 389839 . ARMATURE 1
485887 . COUPLING, HUB AND DISK ASSY 1
19 HJ-6 . . DISC, COUPLING 1
20 355897 . . HUB, COUPLING 1
21 485809-I . FLYWHEEL 1
22 485893 . FAN, GENERATOR 1
23 357170 . COVER, FRONT FLYWHEEL HOUSING 1
24 356800-4 . HOUSING, FLYWHEEL 1
*
W-9234-l 42 . LEAD, BRUSHHOLDER 1
1 * W-9234-60 . LEAD, BRUSHHOLDER 1
* 16DW-246 . BUS, INTERPOLE 1

1 : W-9234-8 1
W-9234-l 67
. LEAD, INTERPOLE
. LEAD, INTERPOLE
1
1
*
350330-I 82 . INSULATION 4

*
FW-339-O . INSULATION, TOE 8
*
350330-I 31 . FLUX, RING, INSULATION 32
*
W-l 0853-4 . CAPACITOR, RFI V90201, No. B-206020 1 1

4-3
Mar 12/84 Revised Page 29
 OM-168

Brushholder Assembly
Figure 14

4-3
Aug 6181
Page 30
 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

14- 358221-32 BRUSHHOLDER IN BRUSHES, ASSEMBLY

(For N,HA See Figure 13) REF
1 AW-1470 . BRbShi 32 16
116DW-148A . BRUSHHOLDER (LESS BRUSHES) ASSY
2 W-l 1236-7 . . SCREW, TAPPING, THREAD FORMING,
l/4-20 x 718 IN. TYPE F 8 '
3 16DW-200 . . BUS 4
4 8BW-12-3 . . BOLT, CARRIAGE, 1/4-20x 4-I/2 IN. IO
5 8BW-12-8 . . BOLT, CARRIAGE, 1/4-20x 4-3/4 IN. 4
6 W-l 1280-2 . . NUT, HEX, l/4-20 14
7 W- 11242-5 . . WASHER, FLAT l/4 IN. 8
8 W-l 1254-4 . . WASHER, LOCK l/4 IN. 14
9 352413 . . SPACER, BRUSH BOX 4
10 AW-1156B . . PLATE ASSEMBLY, BRUSH GUIDE 16
11 W-799H-173 . . . SPRING, BRUSH 16 1
12 AW-1719 . . . ADAPTER, SPRING
13 W-l 1280-2 . . . NUT, HEX 1
14 AW-734 . . . GUIDE 1
15 AW-740 . . SPACER 20
16 AW-1683 . . SPACER 8
17 12CW-962 . . RING, MOUNTING 1

Aug 6/81 4-3

Page 3 1
 OM-168

‘”
.. .

24

36

Trailer Assembly (Option)

Figure 15

Page 32
 OM-I 68

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

15- 48433 1 TdPitLER, WITH STANDARD 6.00 x 9

! Tl RES ASSY (For NHA See Figure I) REF.
1 400238 . TIRE, 6.00 x 9 6-PLY 4
484259 . BRAKE, ASSEMBLY 1
2 484255 . . LEVER, BRAKE MOUNT ASSEMBLY 1
3 484256 . . BRAKE, SHOE ASSEMBLY 1
4 HF-1882 . . SHOE, BRAKE ASSEMBLY 4
5 484250 . . ROD, ADJUSTING, BRAKE 2
6 484254 BRACKET, MTG., BRAKE SHOE ANGLE 2
7 W-l 1242-12 : : WASHER, FLAT, l/2“, STEEL 2
8 400954 . . CLEVIS, ADJUSTING, BRAKE ’ 2
9 W-l 1338-5 . . PIN, COTTER, 1/8x 1, STEEL 4
IO 401468 . . PIN, CLEVIS 2
78B-1123 . TRAILER ASSEMBLY 1
11 79A-1075 . . DRAWBAR ASSEMBLY V22938
No. 63502 1 1
12 79A-1057 . . . HINGE PIN V22938, No. 5416 1 1
: 13 76A-1171 . . . COTTER PIN V22938, No. 4800-6 2
79A-1045 . . CENTER ARM ASSEMBLY V22938,
No. l-3854 1
14 79A-1046 . . . CENTER ARM V22938, No. 3854 1 .$
1. 15 404529 . . . LATCH PEDAL V22938, No. 3855 1 1
: 16 404530 . . . ROLL PIN V22938, No. 5000-I 1
17 404528 . . . SPRING V22938, No. 4006 1
j’ 18 79A-1047 . . FLAT WASHER V22938, No. 4701-3 3 1
: 19 79A-1048 CENTER PIN V22938, No. 5400-5 1 1
79A- 1074 : : AXLE, REAR, ASSEMBLY V22938,
No. 363-2006 1
20 79A-1078 . . . AXLE, REAR, BEAM WELDMENT
V22938, No. 363-2006-3 1
76A-1184 . . . HUB ASSEMBLY, REAR AXLE
V22938, No. 13612 2
21 404539 . . . . CAP, GREASE V22938, NO. 6312 1 1
22 404540 . . . . BEARING, CONE, OUTER V22938,
No. 6058 2 1
I 23 404541 . . . . BEARING, CONE, INNER V22938,
No. 6057 2 1
‘( 24 404543 . . . . SEAL, GREASE V22938, No. 6311 2 1
25 404544 . . . . NUT, STUD V22938, No. 4601-6 5
26 404545 . . . . LOCKWASHER V22938, No. 4700-5 5
76A-1185 . . . . HUB, STUD AND CUP ASSEMBLY
V22938, No. 3603-I I
27 404551 . . . . . HUB V22938, No. 3603 4 1
28 404552 . . . . . STUD, WHEEL V22938, No. 6251-10 5
29 404553 . . . . . CUP, BEARING, INNER V22938,
No. 6152 2 1

Ayg 6181 4-3

Page 33
 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

15-30 404554 CUPj $ ARING, OUTER V22938,

. . . . .
No.61 5:1 2 1
31 404537 ’ . . . WASHER, SPINDLE V22938, No. 4702-2 2
32 404538 . . . NUT, SPINDLE V22938, No. 4600-2 2
33 76A-1182 . . . PIN, COTTER V22938, No. 4800-5 2
404546 . . WHEEL ASSEMBLY (For 6.00 x 9 in. IO
Ply Tire) V22938, No. 3712 1 4
34 76A-1219 . . . DISC, WHEEL (Without valve hole)
V22938, No. 3712-2 1

35 76A-1220 . . . DISC, WHEEL (With valve hole) V22938,

No. 3712-I 1 6
36 76A-1221 . . . BOLT, 318 in. 24NF, 3/4 in. Lg. Hex Hd.
V22938. No. 4901-8 8
37 76A-1223 . . . LOCKWASHER, 318 in. V22938,
No. 47004 8
38 76A-1222 . . . NUT, 318 in. 24 UNFV22938, No. 4601-5 8
39 400599 . . TUBE, INNER V22938, No. 3600-200 4
79A-1073 . . AXLE, FRONT ASSEMBLY V22938,
No. 363-2056 1
40 79A-1076 . . . AXLE, FRONT BEAM ASSEMBLY V22938,
No. 363-205X-l 1
41 404533 . . . SPINDLE & KNUCKLE ASSEMBLY (Left)
V22938. No. 3-3806 1 1
42 404534 . . . SPINDLE & KNUCKLE ASSEMBLY (Right)
V22938, No. 43806 1 1
43 404535 . . . PIN, KING V22938, No. 5401 2 1 ’
44 404536 . . . PIN, ROLL 3/16x l-3/4 in. V22938,
No. 5000-6 1
76A-1184 . . . HUB ASSEMBLY FRONT AXLE,
V22938, No. 1-3612 2
45 404539 . . . . CAP, GREASE V22938. No. 6312 1
46 404540 . . . . BEARING, CONE, OUTER V22938,
No. 6058 1
47 404541 . . . . BEARING, CONE, INNER V22938.
No. 6057
48 404543 . . . . SEAL, GREASE V22938, No. 6311
49 404544 . . . . NUT, STUD V22938, No. 4601-6
50 404545 . . . . LOCKWASHER V22938, No. 4700-5
76A-1185 . . . . HUB, STUD & CUP ASSEMBLY
V22938, NO. 3603-I 1
5: 404551 . . . . . HUB V22938, No. 3603 1
52 404552 . . . . . STUD, WHEEL V22938. No. 6251-10 5
53 404553 . . . . . CUP, BEARING, INNER V22938,
No. 6152 1

4-3 Aug 6181

Page 34
 w
I I OM-I 68

NOMENCLATURE UNITS‘..
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

15-54 404554 dUP BEARING, OUTER V22938,

‘Iii’ No. 6151 1
55 ho4537 . . . WASHER, SPINDLE V22938, No. 4702-2 2
56 404538 . . . NUT, SPiNDLE V22938, No. 4600-2 2 .: ,
57 76A-1182 PIN, COTTER V22938, No. 4800-5 2
79A-1049 : : TIE, ROD ASSEMBLY V22938,
No. 3906-235 1
58 79A-1077 . . . TUBE v22938, N0.35100-200 2 2
59 7914-1051 . . . JAM NUT, R.H. V22938, No. 4602-l 1 2
60 79A- 1052 . . . JAM NUT, L.H. V22938, No. 4602-2 1 2 ‘*
61 79A-1053 . . . BALL JOINT, R.H. W/NUT V22938,
No. 3950-I 1 2 j
62 79A- 1054 . . . BALL JOINT, L.H. W/NUT V22938,
No. 3950-2 1 2 :
79A-1035 . . LUBE FITTING V22938, No. 5801 4
79A-11 a3 . . LUBE FITTING V22938, No. 5800 5 ;
e.. ..~. .._. ..~. ~. ._ . 1

Aug 6181 4-3

Page 35
 ‘.

. - p.a-~~ .‘36 -- -- ._- -

 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

16- 485925 PANEL, CONTROL, 14 VOLT ASSEMBLY

(For NHA See Figure 4) REF
1 485919 . PAId&, CONTROL, 14 V. 1
Ii F-251 8-4 . LIGHT, PILOT, AMBER, 14 V., ASSEMBLY 1 1
2 404173 . .. BASE
3 404172-2 . . LENS (AMBER) 2
4 400613-3 . . BULB 6
5 403189 . SWITCH, TOGGLE, 3 POS., 2 POLE 1
HF-2518-8 . LIGHT, PILOT, GREEN, 14 VOLT, ASSY 1
6 404173 . . BASE
7 404 172-3 . . LENS (GREEN) 2
8 400613-4 . . BULB 6
9 w-10051-5 . CLAMP, WIRE, PLASTIC
*
485918 . HARNESS, WIRE, ASSEMBLY

Aug 6181 4-3

Page 37
 OM-168

i 4

i 6

14 Volt Contactor Panel Assembly (Option)

Figure 17
4-3 Aug 6181
Page 38
 m
I
I
I
I OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

17- 485915 PANEL, CONTACTOR, 14 VOLT ASSEMBLY

(For jNk/A See Figure 4) REF
485916 . PANEL, CONTACTOR, 14 VOLT
2 485932 . BUS, INPUT 1
3 387725 . BRACKET, MTG., SOCKET, RELAY 3 ’
4 16DA-4253-1 . RETAINER, SPRING, RELAY V77342,
No. 2OC206 2
5 16 DA-4004A-IO . RELAY, PLUG-IN, 12 VOLT V77342.
No. KAP-14DG 2
16DA-4052-0 . SOCKET, RELAY VO2660, No.77-MIP-11 2
W-97 14-22 . RESISTOR, 120 OHM, 2 WATT
400785-7 . RIVET, BLIND, STEEL, DOMED HEAD 3
6FW-6423A . LOAD CONTACTOR, 14 VOLT V74063,
No. A-791 N
IO A-896-l . NAMEPLATE, POSITIVE
11 401937-2 . STRIP, TERMINAL V98410, No. 35008-3526
12 401556 . MOUNT, SHOCK, RUBBER
13 400434 . NAMEPLATE, 14 VOLTS
14 481231 . BOARD, P.C., OVERVOLTAGE, ASSY
15 W-9746-3 . RESISTOR, 100 OHM, 25 WATT
16 400701 . CONNECTOR, RIGHT ANGLE
17 FW-2131 . RELAY, OVERLOAD V01121,
No. X-10,000
18 w-10051-7 . CLAMP, WIRE, PLASTIC
19 w-4541 L . RESISTOR, 300 OHM, 25 WATT
20 1cz-74 . INSULATOR, TOP, RESISTOR
21 484265-3 . SPACER
22 481227 . BRACKET, MOUNTING, UPPER, ASSY 2
*
400828-I . TIE, WIRE, PLASTIC 22
* 12
484689-l . SLEEVING, PLASTIC, l/8 I.D.
*
484690-2 . SLEEVING, PLASTIC, 3/16 I.D. 2

Aug 6181 4-3

Page 39
 OM-168

L PSD-0281 1

14 Volt Output Terminal Assembly

Figure 18
4-3 Aug 6181
Page 40
 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPAR ES EFF ASSY

18- 485830 TERMINAL, OUTPUT, 14 V. ASSEMBLY

(ForayHA See Figure 4) REF
485864 . PA lbEL, TERMINAL, OUTPUT 1
h-1 1097-8 SCREW, 318-16 x 2 2
W-l 1254-6 : WASHER, LOCK 3/8 4 ,
W-l 1242-10 . WASHER, FLAT 318 4
W-l 1278-5 . NUT, 3/8-16, HEX 2
W- 10853-4 . CAPACITOR, 0.5 pF, 100 V. DC
V90201, No. B-206020
7 A-897-l . NAMEPLATE, NEGATIVE
8 400434 . NAMEPLATE, 14 VOLT
9 A-896-l . NAMEPLATE, POSITIVE
IO 5CW-2127 . BUSHING
11 5CW-976A . WASHER, INSULATOR
12 IOOGH-112 . TERMINAL, OUTPUT
13 5cw-975 . BUSHING, INSULATOR
*
485878 . STRAP, MOUNTING, CAPACITOR

I Nov 17182 Revised

Page 41
4-3
 OM-I 68

.6

[PSD-04911

Zenith Carburetor Kit

Figure 19
4-3
Revised Nov 17182
Page 42
 OM-168

NOMENCLATURE UNITS
FIGURE HOBART REC. per
ITEM NO. PART NO. 1234567 SPARES EFF ASSY

19- 487084 KIT,,ZENITH, CARBURETOR (For NHA

Seej Pigure 4) REF.
486666 . ADAPTER, AIR CLEANER 1
486667 . ROD, l/4-20 AIR CLEANER MOUNTING 1
82A-1027 . ZENITH CARBURETOR 1 t
No Number . GASKET, CARB. MTG. V90927,
No. C5J2-9447A 1
5 No Number . SOLENOID, ANTIDIESEL, VALVE
V90927, No. B-75-16A
6 W-l 0887-5 . FITTING, FUEL LINE
7 48677 1 . WIRE ASSEMBLY ANTIDIESEL SOLENOID
8 No Number . ADAPTER, NYLON V90927,
No. D3JL-9B663A
9 No Number . GASKET, AIR CLEANER V90927,
No. C8DF-9654A 2
*
82A-1061 GASKET KIT REF.
*
82A-1060 CARBURETOR, OVERHAUL, KIT REF.

Nov 17182Revised 4-3

Page 43144
i4
 OM-I 68

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’& near the top of the index list. Likewise a part number 9 would be listed
near the end of the list and far below a part number 1000. The figure number and 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.

FIGURE AND
PART NUMBER ITEM NUMBER

A-896- 1 7-9
17-10
18-9
A-897-l 7-7
18-7
AAW-835A 6-11
AW-1156B 14-10
AW-1470 14-1
AW-1683 14-16
AW-1719 14-12
AW-734 14-14
AW-740 14-15
BATTERY INSTALLATION 4-I 1

COOLING SYSTEM 4-6

c-30 13-17
DW-1045 13-13

DW-1777B 5-18
DW-3587 12-14
DW-3590 12-13
DW-364 1 12-12
DW-882A 13-5
DW-883 13-6
DWP-1804-I 1-3
DWP-982 2-16
3-14
FUEL SYSTEM 4-14
FW-2131 17-17
FW-339-O 13-o
FW-3449 12-I
FW-446 13-7

GENERATOR AND DRIVE GROUP 4-3

GENERATOR SET WITHOUT CANOPY 1-6
HF-1882 15-4

Numerical Index
4-4
I Page 1
~-.,---June
I 28185 Revised
/
I
1-1
-I.I._
I-_--- -.-_ _
 OM-168

NUMERICAL INDEX (CONTINUED)

FIGURE AND
PART NUMBER ITEM NUMBER

H F-251 84 16-O
HF-2518-7
HF-2518-8 ,
i iI 5-15
5-25
16-O
HJ-129A 2-14
HJ-6 13-19
SPEED CONTROL GROUP 4-13
w-10051-3 2-o
3-o
W-l 005 1-5 12-7
16-9
w-10051-7 17-18
W-l 0072-8 13-8
W-l 0750-I 4-19
W-l 0853-4 4-9
7-6
13-o
18-6
W-l 0855-4 13-3
W-l 0869-3 12-2
W-10869-14 1 l-8
W-10891-7 1 l-6
W-l 0893-O 11-7
w-10910-0 4-20
W-l 1097-8 7-2
18-2
W-l 1166-3 5-23
W-l 1166-5 5-24
W-l 1236-7 14-2
W-l 1242-5 14-7
W-l 1242-10 74
18-4
W-l 1242-12 15-7
W-l 1254-4 14-8
W-l 1254-6 7-3
18-3
W-l 1278-5 7-5
18-5
W-l 1280-2 14-6
14-13
W-l 1338-5 15-9
W-454 1 D 6-7
w-4541 L 17-19
W-7814-O 4-18
W-799H-173 14-11
W-92 18-36 4-o
W-9218-41 4-o
W-9218-123 4-o
Numerical Index Aug 6181
4-4
Page 2
 ,’
.. ,.’ ’ “. i I --=. _ -._
~ -. / ,.’ “’ .‘\\,
/\ I , ”
..
\ I -y i
\ ,, /’ ” i k. ..“^..’
__./.-- .., I
/ x,
/’ > T-.,r-“-+-.- .I_-- -._---.--- ._--- ---. I- _-__ _- LLl?:.;
,,.-
,/ +
.. 8 i ,, .’
_.. -.. ,I
.--_ .__-.- -... ~_.-_~.~~~~~~_~_~.~.-_-~_-..~~.-~~_-~..-~--~._~_~...~~~ 1,,*a
._-..- _-.--.- .-.----- OM&"....
.

NUMERICAL INDEX (CONTINUED)

FIGURE AND
PART NUMBER ITEM NUMBER

W-10887-5 19-6
W-9218-128 4-o
W-9234-60 i4 13-o
w-9234-142 13-o
W-9234-167 13-o
W-9234-81 13-o
W-9476-4 9-4
W-9648-22 10-O
w-9714-22 17-7
W-9746-3 17-15
lCZ-74 17-20
lOOGH-112 7-12
18-12
12cw-1914-4 10-l
12cw-1915-14 10-2
12CW-962 14-17
1361 13-14
16DA-2162 5-14
16DA-4004A-10 17-5
16DA-4052-0 17-6
16DA-4253-1 17-4
16DW-148A 14-o
16DW-200 14-3
16DW-246 13-o
16DW-967 13-9
2ORT-353-1 5-19
6-18
25MS-156 5-20
3OGH-872 l-l
350330-131 13-o
350330-182 13-o
351541 12-6
352413 14-9
355897 13-20
356354-l 9A-18
356800-4 13-24
357170 13-23
358221-32 13-10
358830-14 13-11
380706 13-12
380707 13-o
385765 8-5
387438 2-l
3-l
387725 17-3
387859 2-13
389522B 6-4
389535-2 5-o I
389839 13-18 E
I_.
._
_ I’.-
‘-;if--38g8g7 -- ----- ~-. \- -----.I

12-5 1
I j
3_._.
-- .AhmG&&5 Revised _-_ -.---_-- II_~-Numerical I$ex 1
1 4147
's--,-
._._
___..,-
_-_____ I
---------..---_----J?age-3 __.-
 NUMERICAL INDEX (CONTINUED)
FIGURE AND
P$RT NUMBER ITEM NUMBER

4'00238 15-l
400400 6-12
4bo434 4-o
17-13
18-8
400435 2-o
3-o
7-8
460599 15-39
400613-3 5-16
16-4
400613-4 5-26
16-8
4b0613-10 2-o
3-o
400641-12 5-11
4pO642-3 5-5
400701 17-16
400785-7 17-8
4b0828-1 17-o
460954 15-8
401428-l 5-13
4b1468 15-10
461556 6-3
17-12
401937-2 17-11
401937-3 6-13
401937-4 6-14
40201 2-o
3-o
402037-29 6-15
492086-l 10-7
402159 6-10
402461-l 4-10
492658 5-22
402662 5-21
8-4
402908 9-3
9A-10
402987 2-17
3-15
4b3091-2 8-9
4b3127 2-2
3-2
413189 5-17
I 16-5
4'3615 11-5
413809 4-17
4 4101-l 2-19
P

-.--.-- .- ---- Revised

---..-----.-d~-----_~~ June -I-
28/85 i
LpQE”-& .,. .- ..-. ..I -, ._ “_
-__--- ,- _I-- --.. -_.-- -_-_. -- ..-._ ______
 NUMERICAL INDEX (CONTINUED)

FIGURE AND
PART NUMBER ITEM NUMBER

404154-a 4-o
404172-2 16-3
404172-3 i4 16-7
404173 16-2
16-6
404528 15-17
404529 15-15
404530 15-16
404533 15-41
404534 15-42
404535 15-43
404536 15-44
404537 15-31
15-55
404538 15-32
15-56
404539 15-21
15-45
404540 15-22
15-46
404541 15-23
15-47
404543 15-24
15-48
404544 15-25
15-49
404545 15-26
15-50
404546 15-o
404551 15-27
15-51
404552 15-28
15-52
404553 15-29
15-53
404554 15-30
15-54
404603-3 8-6
430278 13-15
430506-10 9A-17
481227 17-22
481231 17-14
482496-l 11-O
483331 l-7
483630 11-12
483798 13-4
484250 15-5

.....-.-.
I 1June 28185 Revised -.--_-.-_ Numerical In/lex i
I -----4z4-j
._..-
._. .. --".,
-I-.I.._
--1
_- -----.
- --1---------
____._.
Page_S..--1
 NUMERICAL INDEX (CONTINUED)

FIGURE AND
PART NUMBER ITEM NUMBER

484254 15-6
484255 15-2
484256
i4 15-3
484259 15-o
484265-3 17-21

484294 6-16
484506 13-1
484567 6-5
484689-l 17-o
484690-2 17-o
484810-I 13-16
484987 6-21
485113 13-2
485334 12-10
485335 12-9
485336 12-11
485657 4-5
485660 4-4 -
4-8 *, -.:.
485664 .:1
485678-l -“_1: .- 4- 1‘1’~‘~.$0
.I
485678-2. 4-J. 5-o
5-o ” ., :
485679
485681 5-o
485682 5-o
485683 5-o
485684 5-2

485710 5-l
485714-1 l-4
485714-2 1-5
485719 2-3
3-3
485728 6-1
485732 2-8
485741 2-4
3-4
485747 2-5
3-5
485761 2-7
3-7
485762 12-o
485772 2-6
3-6
485777 2-12
485790 1O-8
485793 1O-6
I--

i
Revised July 15185 i
L i
t
--__I--_
I
___----_____ --_- ___-..E
 mimIcAL INDEX (CONTINUED)
FIGURE AND
PART NUMBER ITEM NUMBER

485795 2-10
485796 2-11
i4
485899-l 13-21
485810 2-9
485817 11-O
485818 4-7
485819 4-o
485827-l 12-3
485829 4-o
485830 4-o
485831-1 4-2
485831-2 4-2
485838 9-l
485864 7-l
18-1
485865 8-3
485878 7-o
18-O
485881 6-20
485887 13-o
485893 13-22
485897 3-8
485904 3-10
3-12
485905 2-15
( 3-9
3-13
485907 3-11
485908 2-15
3-13
4-31
485909 4-o
485910 4-30
485915 17-1
485916 16-O
485918 16-1
485919 4-32
485921 4-34
485925 4-o
485927 4-o
485928 17-2
485932 6-9
485970 6-8
485971 6-2
485972 4-o
486001 4-o
486002 4-26
486003 4-27
 P@T NUMBER /
ITEM NUMBER
I
4b6011 4-o /
!
4:6028 4-25
4ii
6115 4-o I
/
416270-7 2-o ,
3-o /
/
416562 ' 11-2 {
486567-l 11-11 1
486577 11-10 ,
i
416666 19-l I
4Ii6667 19-2
4b6771 19-7
467084 4-34
4'7092 9A-22
4.7093
t 9A-15
487094 9A-16
4fS7741 9A-7 !
487933 4-24 !
4h9300 4-12
5AW-989 8-7 !
5+-1932-o 12-16
5tiW-2048 10-5
5$W-2127 7-10 /
18-10
5bW-3420-l 11-3
5bw-975 7-13
18-13
5b-976A 7-11
18-11 /
5hGHP-206 5-o
5@?H-622 2-o ,,
3-o
56544 11-9
5Q555 12-8
56581 12-4 I
6hW-2087A 6-6
6h-5072 11-l /
6iW-6423A 17-9 I
Q;FC-405 6-17 I
6jGHP-424
8 4-o /
7.f-422-O 4-o
7$A-1171 15-13
7$A-1182 15-33
I 15-57 I
7&A-1184 15-o
7hA-1185 15-o I
7&A-1219 15-34 1
7gA-1220 15-35
15-36 i
15-38 I
15-37 i
I
4-o I
/
i
5-i
5-3 I
----_ I
'NumericalIndex Revised'July 157X?-
;4-4-.-----.---- -----_-
Page 8
 NUMERICAL INDEX (CONTINUED)
\
PART NUMBER FIGURE AND
ITEM NUMBER

i4
78A-1117-l 5-6
78A-1120-l 5-10
78B'1118-1 4-16
78B-1119-l 4-15
78B-1121-l 5-9
78B-1123 15-o
79A-1035 15-o
79A-1045 15-o
79A-1046 15-14
79A-1047 15-18
79A-1048 15-19
79A-1049 15-o /
79A-1051 15-59
79A-1052 15-60
79A-1053 15-61
79A-1054 15-62
79A-1057 15-12
79A-1073 15-o
79A-1074 15-o
79A-1075 15-11
79A-1076 15-40
79A-1077 15-58
79A-1078 15-20
79A-1110 4-o
79A-1127-l l-2
79A-1183 15-o
~BW-12-3 14-4
8BW-12-8 14-5
8OA-1134 5-8
SlA-1017-l 11-4
81A-1044 4-21
8111-1045 4-22
81B-1019 2-18
3-16 1
81B-1026 6-19
81B-1030 5-12
81C-1013 4-23
81C-1025 9-2
81D-1007 .12-15 2
/
82A-1027 19-3
82A-1028 19-4
82A-1029 19-5
82A-1056 4-29
82A-1057 4-30 I
82A-1060 19-o !
!
82A-1061 19-o
83C-1003 9A-2 I
-. 5-4 ----~ ----j-J
-.___--- IC.---_.-- Numerical In$ex 1
--.-,-
-- -F._____
 OM-168

CHAPTER 5.
-- OPTIONAL EQUIPMENT

Optional equipment available for use with the Jet-Ex 3 Generator Set is listed
below.

OPTION
-- i4 PART NUMBER
--- MANUAL
--

Trailer 484331 TO-139

14 Volt output 485910 None
Spark Arrester Muffler Kit 486114 OM-203
Air Heater Kit 486113 OM-204
Mechanical Governor Kit 487091 I-127 + Assy Dwg
115 Volt Power Generator Assy. 489090 TO-154
~ Generator Replacement Kit 281308 TO-195

5-o

Page l/2
-
 OM-168

CHAPTER 6. MANUFACTURER’S LITERATURE

Engine Maintenance and Operator’s Manual No. IEO-194-127 Ford Motor Company
Industrial Engine Operations
360 Renaissance Center
i 4 P. 0. Box 43338
, Detroit, Michigan 48243

Voltage Regulator Manual No. OM-200 Hobart Brothers Company

Power Systems Division
Troy, Ohio 45373

Hobart Diagrams

485839 - Connection, Jet-Ex 3

485840 - Schematic, Jet-Ex 3

485920 - 14 Volt Unit Connection

Printed Circuit Boards

389522B - 28 Volt Overvoltage Module

484567 - 28 Volt Overload Module

481231 - 14 Volt Overvoltage Module

Aug 6181 6-O

Page l/2
 .- _ ___~
FACING FRONT OF REAR PANEL FACING REAR OF FRONT PANEL
I

15 BLACK-WHT
I

r-

TO WS. CONN ,TO BUS BAR

ON CONTACTOR.
(SEE CQNN. DIA. $35920) GREEN

71-J

R490
1‘
:

I I LEGEND

A401 ALTERNATOR, BATTERY L401 SOLENOID, FUELVAlVE s401 SWITCH, ENG..START-RUN-STOP

A402 SENSOR, OIL PRESSURE i-402 SOLENOID,STARTER 5402 SWITCH, PB. ENGlNE START
A403 SENSW , WATER TEMPERATURE L4D3 FIELD.SHUNT 5403 SWITCH, PANEL LIGHTS
L404 FIELD, INTERPOLE s40-4 SWITCH. OIL PRESSURE
0401 STARTERsENGINE L405 COIL, IGNITION 5406 SWITCH, PUSHBUTTON:PUSH To
L406 ANTI-DIESEL SOLENOID BUILD UP VOLTAGE’:
ET401 BATTERY, 12 V M401 AMMETER.GENERATOR SWITCH ,CDNTACTOR
M402 AMMETER. BATTERY :4”z SWITCH,AUTDMATlC-MANUAL
C40, CAPACITOR, 250 MFD , 50” b.4403 GAUGE.OIL PRESSURE 5409 SWITCH, IDLE- GENERATOR
C402-C405 CAPACITOR.0.5 MFD,IOO” M404 GAUGE ,WATER TEMPERATURE
C406- C409 CAPACITOR. D 25 MFD, 100” M405 HOUR METER. RUNNING TIME “R401 VOLTAGE,REWLATOR.GENERATOR
M4D6 TACHOMETER “R402 VOLTAGE.REGULATOR.ENGlNE
CR401 .CR402 WDE,SH”NT FIELDS.EXCITATION M407 VOLTMETER .GENERATOR
CR403.CR4O-l DKK)E,REVERSE CURRENT BZCK,iiG
WOI PLUG,VOLTAGE REGULATDR
DS401.DS402 LAMP, PANEL, WHITE P402 PLUG.OVERLOAD
D9420-Ds423 LAMP, CLEARANCE, AMBER
DS440 LAMP,ENGINE.RUNNING.GREEN R401 RESISTOR,, 5 OHM
DS441 LAMP.CONTACTOR.CLOSED,GREEN (FURNISHED WITH ENGINE) NOTE
R402 RESISTOR, 100 OHM, 2SW ALL WIRES ARE IE HT UNLESS
E401 SPARK PLUG R409 RESISTOR.Z5OHM, 6W OTHERWISE SPECIFIED.
E402 DISTRIBUTOR R450 RHEOSTAT, MANUAL
E403 GOVERNOR, ELECTRIC R451 RHEOSTAT, CURRENT LIMIT . WIRES FURNISHED
E404 OVERSPEED, RELAY R490 SHUNT, AMMETER
F401 FUSE, IOA
F402 FUSE, 208.

J401 RECEPTACLE .v~LTAGE REG

J402 RECEPTACLE.OVERLOAD

K402 RELAY.OVER”OLTAGE,,?C. BOARD

HOBART BROTHERSCO.
K403 RELAY.O”ERLOAD. F!C BOARD TROY,OHIO 43373 USA
FACING GENERATOR HOUSING FROM MOTOR END K404 CONTACTOR, LOAD

TlTLEDIAGRAb! ,CONN.
JET-EX3

($frFIDENTIAL - This drawing, in$uding all information contained thereon, is the exclusive andconfidential property of Hobart Brothers Company REV. DWO.
ND.
oy I Ohio, and is not to be copped, reproduced or delivered or disclosed to others, in whole or in part, except with express written permission. 1 485839
i4
 LEGEND --. - - -----_.
A401 ALTERNATOR. BATTERY L4Dl SOLENOID, FUEL WLVE ---
A402 SENSOR, OIL PRESSURE L402 SOLENOID,STARTER
A403 SENSOR, WATER TEMPERATURE L403 FlELD.StiUNT
GENERATCB ARMATURE FIELD. INTERPOLE
ii% STARTER, EhGlNE EZ COIL, IGNITION
L406 ANTI-DIESEL SOLENOID
BT401 BATTERY, 12” M401 AMMETER. GENERATOR A403
MO2 AMMETER. 6ATTERY
c401 CAPACITOR. 25OuF. 50”. M4D3 GJiUGE.OIL PRESSURE
C402-C405 CAPACITOR. 0.5uF. IDO” GAUGE. WATER TEMPERATURE
c4D6-c409 CAPACITOR. 0.25uF. IOO”. c% HOlM METER, RUNNING TIME
M406 TACHOMETER
CR401, CR402 DIODE.SHUNT FlfLDS EXCITATION Ma7 VOLTMETER, GENERATOR
CR403.CR404 DIODE, REVERSE CEMENT BLOCKING
IV01 PLUG, VOCTAGE REGULATOR
05401, DS402 LAMP, PAML,WHITE P402 ma ,.n ^I.r... ^.^ I
DS420-DS423 LAMP, CLEARANCE, A”-
DS440 LAMP, ENGINE RUNNING. GREEN R401 5403
RESISTOR, I.SOHM,iFURNISHED WITH ENG)
OS441 LAMP, CDNTACTOR CLOSED, GREEN R402 RESISTOR, 100 OHM, 25 W
R409 RESISTOR, 7.5 OHM. 5 W. F4Ol
E40l SPARK FLUG R450 RHEOSTAT, MANUAL IO A.
E402 DISTRIBUTOR R451 -&DS40/
RHEOSTAT, CURRENT LlMlT
E403 GOVERNOR. ELECTRIC R490 SHUNT, AMMETER
E404 OVERSFEED. RELAY
s401 SWITCH, ENGINE,START-RUN~,,,r
F‘IOI FUSE. IOA S402 SWITCH, PUSHBUTTON, ENGINE START r
F402 FUSE, 201. s403 SWITCH, PANEL LIGHTS OS440
5404 SWITCH. OIL PRESSURE
J401 RECEPTACLE, VOLTAGE REGULATOR S406 SWITCH. PUSHBUTTON,“PUS,, TO
J402 RECEPTACLE. OVERLOAD BUILD UP VOLTAGE”
s407 SWITCH, CONTACTOR.“CLOSE-ON-OFF”
K402 RELAY, OVERVOLTAGE PC. BOARD S406 SWITCH, AUTOMATIC-MANUAL
RELAY, OMRLOAO. CC. BOARD 5409 SWITCH, IDLE. GENERATE
t:ii CONTACTOR. WAD
VR401 VOLTAGE REGULATOR, GENERATOR -+
VR402 VOLTAGE REGULATOR. ENGlNE
=z,- ,
OS
E4O3
LEGENO 14 V. CIRCUIT
c410-C4ll CAPACITOR, O.hF, KID v c--3
K409 RELAY, OVERVOLTAGE 14V.
PC. BOARD
DS442 LAW? 14v. CGNTACTOR CLOSED , GREEN ns
DS46D IJAW l4V. MC%. AMBER I I

K405 RELAY, l4v. CONTROL

RELAY. l4v. CONTROL
R405
R406
R407
RESISTOR.
RESISTOR’
RESISTOR:
120 OHM 1w
I% i$i %i+,.
300 OHd, 25W
3 I
L

X404
I

E3 ------------------------- _---_--___
CONTACTOR LOAD 14~ S41D SWITCH, CONTACTOR. l4V -l
K406 RELAY, OVE~~AD 14~. “CLOSE-ON-OFF” : -I
I CYfZ- I I

HOBART BROTHERSCO.
TROY,OHlO 45373 USA
(.‘,
I4 VOCT CIRCUIT (WHEN FURN.,
TITLEDI& .Sc,WjATIC
i:
JET-EX3
,’

tf?NrFIDENTIAL - Thir drawing, including all information contained thereon, is the exclusive andconfidential property of Hobart Brothers Company REX DW0.ND.
W, OctiOLti IS not to be co~ied~reproduced or delivered or disclosed to others, in whole or in part, except with express written permission. 1 485840
--
 --.._- A..._ -.---_-..-_ .._-- i-J__. .._ .___...__^.....^__ ..__ __- _._.. .._..__,-...- )I_ . ..__...._ _. ._.

,Ir-- t -- --

1’
E

c
2
I
 @ DIP TO THIS LINE

MOUNT ITEM I I (RI) 3116

r TO 5/16 ABOVE BOARD.

TEST EPWPMENT NEEDED

FILTERED AND FUSED DC POWER SVPPY 20 TO 40 VOLTS, STOP WATCH,AND
VOLT AND OHMMETER
TEST lNSTR”CTlONS

__ I. CONNECT A 12 VOLT BULB IN SERIES WITH P 8 T. BULB WILL LIGHT.

2. CONNECT DC POWER SUPPLY TO PLUS AND M,N”S OF THE PC. BOARD.
3. ADJUST PI TO TRIP{ LIGHT WILL GO OUT). AT 32 VOLTS IN 2-10 SECONDS
c2 RELAY IS NOT TO TRIP AT 31 VOLTS.
:I. 50 MFD 4 WITH 35 VOLT INPUT, CHECK FOR TRIP TIME TO BE APPROXIMATELY I SECOIg
25V

R3

fj:KWoHM 02 T
RIO
I50 OHM
l/2W

HOBART BROTHERSCO.
TROY,OHtO 433’73 USA
rmr Board, P. C.

CONFIDENTIAL - htis drewlng, Including all information cont~lrwl thereon, Is the exclusive andconfkJentlal properly of Hobart Brothers Company
of TI oy, Ohlo, and IS not to be copied, reproduced or delivered or disclosed to others, In wllole or In part, except wftll exprers written pennlsslon,
 I-
, TITLE: NO.
BOA%, PC, OVERLOAD : ! 484567
‘k----- 4” --
ITEM 1 T.Pw-RIPTIC)N ,2 wn T-T

-.,-“,-”
43MlO-29 2
430410-18
-2
RESISTOR, 330 OHM, l/4 W 430410-34 1
POTENTIOMLTER, 500 OHM, 20 TURN --’ 4034.104 I
KCSISTOR, 75 K OHM, l/4 W

RESISTOR. 2.7 M OHM, T/2 W

RESISTOR, 47 K OHM, l/4 W

I I”’ I n II-J-J I 1 22 1 TRANSISTOR, NPN, 2N4921 1 402455-l I 1

i 23 1 GUAD OP-AMP I 4ns’,l4-l I 1

HOUSING, PIN, CONNECTOR 1;

1567 &ERLOAD PROTECTION’ * IJJ Rw~ ” *“““” - 1 w, MTG., CONNECTOR -
RIVET. BLIND. DOMED HEAD c
CAPACITOR, i5 MF, 25 VDC I
--- 0612 -- CHART, WIRE (NOT SHOWN )
2N492; = INSTRUCTIONS, TEST (NOT SHOWN )
- -_.- CAPACITOR. TANT, F: MF, 15 VDC
t

LEGEND
A602 GUAD, OP-AhIP (324)

C611 CAPACITOR, 3.3 MF, 35 VDC, TAN1

C620 CAPACITOR, 10 MF, 20 VDC, TANT
C621 CAPACITOR, 25 MF, 25 VDC
9319 CAPAC17OR. 22 MF, ISVDC, TAN1
CR636-CR638 DIODE, SILICON,(IN4148)
CR639 DIODE, SILICON, (11‘14820)

K614 RELAY, REEO, 12 VOC

Q610 TRANSISTOR, 2N3905, PNP
Cd611 TRANSISTOR, 21‘13903, NPN
Q612 TRANSISTOR,2N4921, NPN

R648 RESISTOR, 1 K OHM, 1 W

R649 RESISTOR, 1CiI OHM, l/4 W
R650 P:::::OR, 470 OHM, l/4 W
R662 POTENTIOMETER, 500 OHM, 20 TURN
R670 RESISTOR, 100 OHM, l/4 W
R671 RESISTOR. 330 OHM, l/4 W
R672 RESISTOR, 75 K OHM, l/4 W
R673 RESISTOR, 270 K OHM, l/4 W
R674-R6?V RESISTOR, 1 K OHM, t/4 W
R678 RESISTOR, 120 K OHM, l/4 W
R679 RESISTOR, 2.2 M OIiM, l/2 W
 TYPICAL TIME-
VOLTAGE CURVE. -

- .ITT D.
3 MTG

1.;
NOTE -ii--
MOUNT ITEM ll IRI BRIOI
r;t8;0 5118 AEOVE

.\ --
,-UP IN “ARNlG”
--
(9036381 TO HERE:

L.&E&

ZN-6027

TEST EG”lPElENT NEEDEQ

__ 3. AO.I”SfPI FORA TRIPAT 18 VOLTS

IN 2-10 SECONOS.
NOTRlPAT 16 Y LTS.
@MUST RESET AT 14.5 TO 15.5 YOLTS. L,G”T WILL GO OUT WI,” A Till 8 .

A3
2.2 Kn