Operation and Maintenance Manual With Illustrated Parts List For Jetex6D Generator Set

Operation and Maintenance Manual with
Illustrated Parts List for

JetEx6D Generator Set
Series 500074A
OM-2241-A
Rev A August 17, 2016
Maintenance
OM – 2241-A
Operation
Manual
OM – 2241-A
And Jet-Ex®6 Generator Set Series 500074A
OM-2241-A / Operation and Maintenance Manual
JetEx6D / Series 500074A / 400 Hz. Generator Set
Introduction
This manual contains operation and maintenance information for a diesel engine-generator manufactured by
ITW GSE, Palmetto, Florida 34221.
This manual, including all information contained thereon, is exclusive and confidential property of
ITW GSE. This manual is not to be copied, reproduced, or delivered or disclosed to others, in whole
or in part, except with express written permission of ITW GSE.
This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics that have never operated
this equipment. It is the intent of this manual to guide and assist operators and maintenance personnel in the
proper use and care of the equipment.
Use of the manual should not be put off until trouble or a need for help develops. Read the instructions
before starting the unit. Learn to use the manual and to locate information contained in it. Its style and
arrangement are very similar to commercial aircraft manuals.
The manual is divided into five chapters plus an appendix. Each chapter is divided into as many sections as
required. Each new section starts with page 1. Each page is identified by chapter, section and page number,
which are located in the lower, outside corner.
When information located in another portion of the manual is referred to, a chapter, section, and paragraph or
figure number identify its location. For example: “(see Section 2-3, Paragraph 1.a.)” refers to information
located in Chapter 2, Section 3, Paragraph 1.a. If a chapter and section are not indicated in a reference, the
referenced material is located in the same section as the reference, for example: “(see Paragraph 1.a.).”
The appendix is the last section. It contains a list of available options that may be purchased or have been
purchased with that unit. Items on the list with check marks next to them have been added to the standard
unit per the customer’s order. Literature for each option follows. The appendix will help control the
information in the manual making it unique to the unit purchased.
In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chapter
4 and a collection of manufacturer’s literature and supplemental information in Chapter 5.
Contents of the manual are arranged as follows:
Chapter 1 Description/Operation
Chapter 2 Servicing/Troubleshooting
Chapter 3 Overhaul/Major Repair
Chapter 4 Illustrated Parts List
Chapter 5 Manufacturer’s Literature
Appendix A Options
OM2241-A Rev A August 17, 2016 Introduction

Page 1
JetEx6D / Series 500074A / 400 Hz. Generator Set
If you have any questions concerning your Hobart Ground Systems equipment, immediately contact our
Service Department by mail, telephone, FAX, or E-Mail.
Write: ITW GSE Americas

Service Department
11001 US Highway 41, North
Palmetto, FL 34221
U.S.A.
Call Inside U.S.A./Canada: (866)-845-0441 (Parts)

(877) 874-5322 (Service)
Call From Foreign Countries: (941) 721-1092 (Technical Support)

(941) 721-1000 (Spare Parts)
FAX inside U.S.A. (800) 367-4945
FAX From Foreign Countries: (941) 721-1091
E-Mail: [email protected]
[email protected]
Web Page: www.itwgse.com
OM2241-A Rev A August 17, 2016 Introduction

Page 2
JetEx6D / Series 500074A / 28.5 VDC. Generator Set
Safety Warnings and Cautions
WARNING
ELECTRIC SHOCK can KILL. Do not touch live electrical parts.
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and
ignite combustible material. DO NOT use power cables to break load. Prevent tools
from causing short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and

attached equipment.
IMPORTANT
Protect all operating personnel. Read, understand, and follow all instructions in the
Operating/Instruction Manual before installing, operating, or servicing the equipment.
Keep the manual available for future use by all operators.
WARNING
CALIFORNIA PROPOSITION 65 - DIESEL ENGINES. Diesel engine exhaust and
some of its constituents are known to the State of California to cause cancer, birth
defects and other reproductive harm.
1) General
Equipment that supplies electrical power can cause serious injury or death, damage to other equipment or
property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices
have been developed from experience in the use of power source equipment. While certain practices below
apply only to electrically powered equipment, other practices apply to engine-driven equipment, and some
practices to both.
2) Shock Prevention
Bare conductors, terminals in the output circuit, or ungrounded, electrically live equipment can fatally shock a
person. Have a certified electrician verify that the equipment is adequately grounded and learn what
terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,
procedures, and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow through it.
When inspecting or servicing the equipment, do not work in damp areas. Stand on a dry rubber mat or dry
wood, and 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
This equipment must be installed and maintained in accordance with the National Electrical Code,
ANSI/NFPA 70, or other applicable codes. A power disconnect switch or circuit breaker must be
located at the equipment. Check the nameplate for voltage, frequency, and phase requirements. If
only 3-phase power is available, connect any single-phase rated equipment to only two wires of the 3-
phase line. DO NOT CONNECT the equipment grounding conductor (lead) to the third live wire of
the 3-phase line, as this makes the equipment frame electrically HOT, which can cause a fatal shock.
OM-2241-A Rev A August 17, 2016 Safety Warnings

Page 1
Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or
building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)
capacity of the grounding lead will be adequate for the worst fault current situation. Refer to the
National Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs and 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 condition to avoid hazards stemming from
disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the
equipment until its safety has been assured. Repairs should be made by qualified personnel only.
Before inspecting or servicing this equipment, take the following precautions:
a) Shut off all power at the disconnecting switch, or line breaker, or by disconnecting battery, 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 pipes,
misuse of batteries and fuel, or unsafe operating or fueling conditions.
a) Electrical Short Circuits and Overloads
Overloaded or shorted equipment can become hot enough to cause fires by self-destruction or by
causing nearby combustibles to ignite. For electrically powered equipment, provide primary input
protection to remove short circuited or heavily overloaded equipment from the line.
b) Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or use
open flame near the battery.
c) Engine Fuel
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is
not grounded prior to or during fuel transfer. Shut unit DOWN before opening fuel tank cap. DO NOT
completely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove
all spilled fuel IMMEDIATELY including any that penetrates the unit. After clean-up, open equipment
doors and blow fumes away with compressed air.

Page 2
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 or hot spots inside some equipment. Shut DOWN such
equipment for inspection and routine maintenance. When equipment is in operation, use extreme care in
doing necessary troubleshooting and adjustment. Do not remove guards while equipment is operating.
7) Medical and First Aid Treatment

First aid facilities and a qualified first aid person should be available for each shift for immediate treatment
of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital
immediately if any abnormal signs are observed.
EMERGENCY
FIRST AID CALL EMERGENCY RESCUE SQUAD 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.
8) Equipment Precautionary Labels
Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be
easily read.

Page 3
This page intentionally left blank.

Page 4
JetEx6D / Series 500074A / 28.5 VDC Generator Set
Preventive Maintenance
Here are the replacement filters for Jet-Ex 6 (500074A) ground power unit (GPU). This list is provided as a
quick reference chart for the maintenance technician or diesel mechanic in charge of routine preventative
maintenance to the ground power unit.
Generator Set Model Number
Make sure your generator set is the

model listed above. Identify the model
number by looking on the data plate,
which is located next to the control
panel.
Data Plate
Filter Part Numbers

The table below lists the filter part numbers for your generator set.
Hobart
Filter
Part Number
Oil Filter Element 286897-029
Engine Primary Fuel Filter Element 286897-036
Lubricity/Fuel Water Separator Element 286897-031
Air Filter Replacement Element 290941
The oil and fuel filters are available as a kit for maintenance every 500 hours. The kit does not include the air
filter element.
Hobart
Kit
Part Number
Preventative Maintenance Kit 290300-013
This kit includes:
• Engine Oil Filter (286897-029)
• Fuel Filter Element Elements (286897-036)
• Lubricity / Fuel Water Separator Element (286897-031)
OM2241-A Rev A August 17, 2016 Preventive Maintenance

Page 1
ITW GSE - Supply Contact Information
ITW GSE has a supply staff that is able to help with the quote and sale of parts. Our helpful supply staff is
also able to provide delivery information for the customer.
Contact the ITW GSE supply department staff for all the preventative maintenance parts:
e-mail: [email protected]
call (inside USA) (877) 874-5322
call (other countries) (941) 721-1092
For more information about maintenance procedures, refer to Chapter 2 of the manual.
Filter Pictures
Air Cleaner Oil Filter
Fuel Filter Lubricity Fuel/Water Separator
OM2241-A Rev A August 17, 2016 Preventive Maintenance

Page 2
Table of Contents
Chapter 1 Description/Operation Chapter-Section/Page#
Section 1 Description 1-1/1

General 1-1/1
Optional Equipment - Appendix A 1-1/1
Orientation 1-1/1
Special Features 1-1/3
Canopy 1-1/3
Specifications and Capabilities 1-1/4
Engine and Generator 1-1/5
Control Box Panel Assembly 1-1/10
Control Box Interior Assembly 1-1/14
Rectifier Assembly 1-1/15
Section 2 Preparation for Use, Storage or Shipping 1-2/1

Preparation For Use 1-2/1
Preparation for Storage 1-2/4
Preparation for Shipment 1-2/5
Section 3 Operation 1-3/1

General 1-3/1
Operation Procedure 1-3/1
Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#
Section 1 Maintenance Inspection/Check 2-1/1

General 2-1/1
Maintenance Schedule 2-1/1
Inspection / Check 2-1/3
Lamps, Circuit Breakers, and Fuses 2-1/12
OM2241-A Rev A August 17, 2016 Table of Contents

Page 1
Section 2 Maintenance Procedures 2-2/1

General 2-2/1
Preventative Maintenance 2-2/1
Lubrication 2-2/2
Servicing the Air Cleaner 2-2/6
Engine Fuel 2-2/7
Engine Fuel System 2-2/7
Engine Cooling System 2-2/10
Generator Maintenance 2-2/13
Drive Belt 2-2/13
Section 3 Adjustments / Tests 2-3/1

General 2-3/1
Testing the Generator Set 2-3/1
Section 4 Troubleshooting Procedures

General 2-4/1
Equipment for Troubleshooting 2-4/1
Check Connections and Leads 2-4/1
Illustrations 2-4/1
Connection and Schematic Diagrams 2-4/1
Troubleshooting Charts 2-4/4
…Engine Controls 2-4/4
…Generator and Controls 2-4/9
Chapter 3 Overhaul / Major Repair Chapter-Section/Page#
Section 1 Flexible Coupling 3-1/1

General 3-1/1
Coupling Screws 3-1/1
Disassembly 3-1/2
Coupling Installation and Re-assembly of Engine and Generator 3-1/5
Run-in and Periodic Check 3-1/7
Coupling Service 3-1/8

Page 2
Chapter 4 Illustrated Parts List Chapter-Section/Page#
Section 1 Introduction/Numerical Index 4-1/1

General 4-1/1
Purpose 4-1/1
Arrangement 4-1/1
Explanation of Parts List 4-1/1
Numerical Index 4-1/3

Explanation of Numerical Index 4-1/3
Section 2 Manufacture's Codes 4-2/1

Explanation of Manufacture's (Vendor) Code List 4-2/1
Section 3 Illustrated Parts List 4-3/1

Explanation of Parts List Arrangement 4-3/1
Symbols and Abbreviations 4-3/1
Figure 1: General Assembly 4-3/2
Figure 2: Trailer and Frame Assembly 4-3/4
Figure 3: Canopy Assembly 4-3/6
Figure 4: Canopy Assembly 4-3/8
Figure 5: Internal Components (Right Side) 4-3/10
Figure 6: Internal Components (Left Side) 4-3/12
Figure 7: Control Box Exterior Assembly 4-3/14
Figure 8: Control Box Interior Assembly 4-3/16
Figure 9: 12 VDC Battery Components 4-3/18
Figure 10: Exhaust System Assembly 4-3/20
Figure 11: Air Cleaner Components 4-3/22
Figure 12: Engine Cooling System Assembly 4-3/24
Figure 13: Fuel System Components 4-3/26
Figure 14: Engine Components 4-3/28
Figure 15: Rectifier Components 4-3/30
Figure 16: Contactor Components 4-3/32
Figure 17: Generator Components and Brush Holder Assembly 4-3/34

Page 3
Chapter 5 Manufacture's Literature
Appendix A Options/Features
Wet Stacking
Unusual Service Conditions

Page 4
Jet Ex® 6D / Series 500074A / 28.5 VDC Generator Set
Chapter 1 Description/Operation
Section 1 Description
1) General
The basic generator set (GPU) covered in this manual is manufactured by ITW GSE in Palmetto, Florida.
The generator set is designed to produce and deliver 28.5 V DC, 600 A, power to a parked aircraft or
other load. This unit is also designed for starting any fixed-wing aircraft or helicopter that is equipped with
an external 28.5 V DC power receptacle.
The number 500074A identifies the “model or series” of the generator set. Figure 1 uses the part number
to identify the variations possible covered in this manual.
Fuel Exhaust AC 28.5V DC

Part Number Mounting
Tank Outputs Output
DCE600CU2000T3-A Composite Horizontal Trailer None Yes
DCE600CU2000ST3-A Composite Vertical Fixed None Yes
Figure 1 500074A Series Generator Set Part Number Descriptions
The CE certified units have an additional fuse in the control box and a CE Kit option listed in the
Appendix. CE is "Conformité Européene" or "European Conformity."
2) Optional Equipment - Appendix A

Chapters 1 through 5, of this Operation and Maintenance Manual, identify only the basic version of the
Jet-Ex6D generator set. Appendix A contains a list of optional equipment to customize the unit to your
requirements.
3) Orientation
For purpose of orientation, the radiator end of the Jet-Ex 6D is the front. Right and left are determined by
standing at the rear of the unit, facing it. The control panel is located at the rear.
OM2241-A Rev A August 17, 2016 Chapter 1-1

Page 1
10 11
9 1
5
7
4 2
1. Fuel Filler Neck

8. Engine Air Intake
2. Operator’s Control Panel
9. Lift Off Access Doors
3. Output Cable Trays
th 10. CAC/Radiator End
4. 5 Wheel Assembly
11. Generator End
5. Rear Axle Assembly
12. Cable Rollers (optional)
6. Emergency Stop (not shown,)
13. Forklift Pockets (optional)
7. Exhaust Stack Outlet
Figure 2 General Assembly of Generator Set

Page 2
4) Special Features
The generator set has special features that are described more fully under the assemblies in which they
appear.
a) Current Limit
The “Soft-Start” current limiting feature provides controls to limit the inrush current to the aircraft’s
engine starter. When the operator presets to the desired value, the generator will provide constant
voltage to the preset current value. The more current is increased beyond the preset current value,
the voltage will decrease to a minimum of 14 volts DC, after which the voltage will remain constant as
more current may be delivered beyond the preset current value. Limiting inrush current is
recommended by most aircraft engine manufacturers to protect the engine’s starter. The current
limiting control is continuously adjustable from 300 amperes, recommended for helicopter and small
turbine starting, to 2000 amperes required for starting larger engines.
b) Engine Electronic Control Module (ECM)
The engine is equipped with an electronic control module (ECM) that monitors, records, and controls
engine performance. The ECM is specially calibrated in the factory to ensure the generator set
performance meets industry standards.
c) Battery System Disconnect Switch
The generator set is equipped with a battery disconnect switch inside the unit on the LEFT side. The
disconnect switch can be placed in the off position during long periods of shutdown.
5) Canopy
The standard canopy is a sheet metal enclosure that protects the engine, generator, and electrical
controls. It has four hinged doors to provide access for service and maintenance. A bolted on panel at
the rear (below the control box) provides access to the rectifier assembly. A Plexiglas window is mounted
in front of the control panel to allow observation of the instruments while protecting them from the
weather. The canopy is also designed to reduce the operational noise level in the immediate area of the
machine.

Page 3
6) Specifications and Capabilities

a) Physical Size
Quantity Basic Unit (Fixed Mount) With Trailer (w/ tow bar up)
Length 74 in. (1880 mm) 101 in. (2570 mm)
Width 37 in. (940 mm) (no cable trays) 67 in. (1702 mm)
Height 60 in. (1524 mm) 67 in. (1702 mm)
Weight 3700 lb. (1678 kg.) 4000 lb. (1814 kg.)
b) Generator
Output power rating 22.8 kW

Output voltage 28.5 volts DC
Rated load capacity 800 amperes continuous at 28.5 volts DC
Starting Current Capacity 2000 amperes maximum
Current Limiting Capability 300 to 2000 amperes, continuously adjustable
Operating Speed 1800 +/-50 RPM
c) Engine
Manufacturer Cummins Engine Company
Model No. QSB4.5
Type In-Line 4 cylinder, 4 cycle diesel, electronic controlled
Bore and Stroke 4.21 in. x 4.88 in. (107 mm x 124 mm)
Displacement 275 in3 (4.5 L)
Horsepower 110 hp (82 kW)
Idle speed 1000 ± 50 rpm
Maximum over-speed capability 3700 ± 50 rpm
Normal governed speed 1800 rpm
Firing Order 1-3-4-2
Electrical system 12 VDC
Ground Negative
Lubricating oil capacity (w/ filter) 11.6 quarts (11 liters)
Coolant capacity system 20 quarts (18.9 liters)
d) Cable
Output Cable 600 AMP Continuous, 2000 AMP starting
e) Protective Devices
Generator 28.5 volt over voltage module trips at 32 to 34 volts.
Water Temperature Switch opens engine circuit at 210º F
Engine (98.8º C).
Low Oil Pressure Switch opens at 20 PSI (138 kPa).
OM2241-A Rev A August 2017 Chapter 1-1

Page 4
6) Engine and Generator

The engine and generator comprise the principal components of the generator set. They are mounted on
the welded steel frame and trailer. Figures 3 and 4 show the locations of all major components and sub-
assemblies.
a) Basic Engine
The engine used in the Jet-Ex6D is a Cummins Model QSB4.5, four-cylinder, four-stroke diesel
engine. See the previous page for specifications and capabilities.
b) Engine Manufacturer’s Equipment
As received from the engine manufacturer, the engine includes the following equipment, which is
more fully described in the Engine Manufacture’s Operation and Maintenance Manual.
(1) Alternator (G401)
The alternator is rated at 100 amperes. Its 12 VDC output charges the batteries and powers the
internal electrical system.
(2) Fuel Filters
The fuel filters are remote-mounted, spin-on, disposable types. One of the fuel filters is the
lubricity additive fuel filter, which also serves as the fuel/water separator. The other filter is the
primary engine fuel filter.
(3) Oil Filter
The engine oil filter is a spin-on, full-flow type. It is mounted on the right side of the engine.
(4) Starter (B401) and Starter Solenoid (L401)
The starter solenoid is mounted on the starter motor, on the right side of the engine.
(5) Pre-programmed Electronic Control Module (ECM)
The ECM is a pre-programmed engine control module, mounted directly to the engine block.
(6) Engine low coolant sensor
The engine is equipped with a low coolant sensor that is located in the top tank of the radiator.
The sensor will send a signal to the engine’s ECM to shut the engine down in case of low coolant.

Page 5
c) Hobart Installed Equipment
This generator set is assembled at Hobart Ground Systems by the addition of some of the following
equipment:
(1) Radiator and Charge-Air-Cooler
The radiator and charge-air-cooler are combined into one complete module assembly in a side to
side fashion.
(2) Engine-cooling fan
The engine fan is designed to blow air outward through the radiator, rather than pulling the air
inward as a conventional fan does.
(3) Shut Down/Reset devices
In addition to the other devices provided by the engine manufacturer, the factory also added
engine shutdown/reset features and protections.
a EMERGENCY STOP and SHUTDOWN/RESET SWITCH (S28)
The emergency shutdown switch has two purposes. One is to reset the starting circuit
following a failed starting sequence. The other is to provide instant manual shut off of the
generator set by disconnecting power to the ECM through the control box. The switch is
located below the control box.
To operate the EMERGENCY STOP and SHUTDOWN/RESET SWITCH:
• Push the button in until the engine stops or until button travel stops
• After the engine stops, pull the button back out to reset it.
b Coolant high temperature shutdown system
The coolant temperature shutdown system consists of a factory supplied temperature switch,
which will stop the engine if the temperature reaches 210º F (99º C).
c Oil pressure shutdown system
The oil pressure shutdown system consists of a factory supplied oil pressures switch, which
will stop the engine if the oil pressure is under 20 PSI (138 kPA).
(4) Fuel Tank
The composite fuel tank holds approximately 50-gallons (189 liters) with all the necessary fittings
and hoses. The large fuel tank gives the user over 10 hours of use at the 600 A rated output.

Page 6
(5) Air cleaner
The diesel engine air cleaner is so constructed that air enters through a rain hood to its cylindrical
body and then is filtered in the process before being passed onto the engine turbo-charger
assembly. An air cleaner service indicator device is mounted on the air cleaner assembly to
monitor the airflow of the air cleaner. As the air cleaner becomes filled with dust, dirt, and carbon,
the intake system airflow becomes increasingly restricted. This restriction causes a diaphragm
inside the indicator to move toward an electrical contact. When the maximum allowable
restriction level is reached, the circuit closes and the air cleaner indicator fault appears on the
control panel to warn the operator that the air cleaner must be changed soon. The electrical
indicator automatically resets when the restriction level drops sufficiently.
(6) Exhaust Muffler
The exhaust system is designed to safely route the engine exhaust out of the generator set and
reduce the engine exhaust noise level. The exhaust exit can be configured to either exit vertically
(standard) above the radiator or horizontally under the cable tray (optional).
(7) Master [Battery] Disconnect Switch (S417)
The master disconnect switch is designed to isolate the batteries from the entire electrical system
to eliminate the possibility of battery voltage draw by the engine ECM or any other components
between long periods of no operation. The switch can also be used to prevent starting of the
equipment for maintenance conditions.
d) Generator (G402)
The generator is a multi-phase, synchronous salient pole, revolving field, AC generator whose output
is rectified. The output is rectified by a rectifier assembly made up of twelve rectifiers connected into
a full-wave configuration. The generator is self-excited, receiving excitation from a three phase full
wave rectified stator winding. One positive and one negative brush in contact with slip rings supplies
a controlled excitation current from the stator winding through the voltage regulator to the rotating
field winding. The voltage regulator controls the excitation current and maintains a constant output
voltage. Access to the brushes is through holes in the anti-drive end bracket. The rotor is supported
at the anti-drive end (slip ring end) by a single-row ball bearing. The drive end is connected to the
engine flywheel by a flexible disc and hub coupling assembly and is supported by the engine’s main
bearings. A generator fan is mounted on the coupling hub and draws cooling air over the generator
windings.
Air flows over the rectifier assembly and then enters through the anti-drive end of the generator and is
discharged through openings in the flywheel housing at the drive end. The generator housing
assembly, which contains the generator stator, is bolted to the engine flywheel housing.
e) Rectifier Assembly
The Rectifier Assembly consists of two aluminum heat sinks with six diodes on each heat sink. The
rectifier assembly converts the AC output of the generator to 28.5 V DC.
f) Ammeter Shunt (R407)
The ammeter shunt is connected in the generator’s negative output circuit. It supplies a small voltage
proportional to output current for operation of the ammeter, and to the current limit circuit of the
voltage regulator. This shunt is mounted on the negative heat sink of the rectifier assembly.

Page 7
3
4
9
1
8 11 12 5 2 10
1. 28.5 VDC Contactor (optional) 7. 12 VDC Batteries (not shown)

2. Cummins QSB4.5 Engine 8. Generator
3. Air Filter Assembly 9. Turbo Exhaust Pipe / Exhaust Outlet
4. Operator’s Control Panel (back side) 10. Engine Alternator
5. Engine Fuel Filter 11. Battery Disconnect Switch
6. Engine Oil Filter (not shown) 12. Engine ECM Connector
Figure 3: Main Components of Generator Set (Right Side)

Page 8
6 5 4 1 3 2
1. Generator (G402) 5. Cummins QSB4.5 Engine

2. Rectifier Assembly 6. Exhaust System
3. Fuel Tank Fuel Tank w/ Protectoseal Cap 7. Engine ECM (ECM1)
4. Lubricity Fuel Filter with Hand Pump 8. Engine Electrical Panel
Figure 4 Interior Components (Left Side)

Page 9
g) Contactor (K402)
The load contactor, which is mounted on the right side of the generator set, provides a safe and
convenient means of connecting and disconnecting the generator from the load. Initial power for
closing the load contactor is supplied by the generator through the spring-loaded momentary contacts
of the contactor control toggle switch. Holding power, to keep the contactor closed, passes through
the normally open auxiliary contacts in the load contactor. The output power connection is made by
attaching the positive lead to the top terminal of the load contactor, and the negative lead to the
negative output terminal located above the load contactor.
7) Control Box Panel Assembly

The control box assembly houses and provides mounting facilities for controls, monitoring instruments,
voltage regulator, relays, PCB’s, etc. The box is mounted in the rear of the generator set.
a) Tachometer (M403)
This instrument receives its operating signal from the alternator to display the engine speed in RPM.
b) Hour Meter (M402)
The hour meter records the total hours of engine operation for scheduling maintenance.
c) Generator Voltmeter (M406)
The voltmeter indicates generator output voltage.
d) Generator Ammeter (M407)
The ammeter displays generator current output.
e) Panel/Clearance Lights Toggle Switch (S405)
The panel/clearance lights toggle switch turns the panel lights and clearance lamps (if supplied) on
and off.
f) Contactor Control Toggle Switch (S408)
The contactor control toggle switch 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 lamp glows, then released to the center “ON” position. In this position the switch
provides holding current to the load contactor to keep it closed. Protective devices in the load
contactor circuit provide protection against over voltage by opening the load contactor if that condition
occurs. In the bottom “OFF” position, the contactor is opened.
g) Contactor Closed Lamp (DS408)
The contactor closed lamp glows green when the output load contactor is closed.
h) Current Limiting Control Potentiometer (R402)
The current limiting control potentiometer is used to select the starting current recommended for
various aircraft. The current limiting setting is continuously adjustable from 300 to 2000 amperes.

Page 10
16 18 17 1 14 2 8 3 4
12 11 13 15 9 10 7 6 5
1. Tachometer (M403) 10. Engine On Lamp (DS407)

2. Hour Meter (M402) 11. Engine Start Pushbutton Switch (S401)
3. Voltmeter [Generator] (M406) 12. Engine Toggle Switch (S404)
4. Ammeter [Generator] (M407) 13. Engine Heater Lamp (DS426)
5. Panel Lights Toggle Switch (S405) 14. Water Temperature Gauge (M404)
6. Contactor Control Toggle Switch (S408) 15. Air Filter Restriction Indicator Lamp (DS412)
7. Contactor Closed Lamp (DS408) 16. Oil Pressure Gauge (M405)
8. Current Limiting Control Potentiometer (R402) 17. Fuel Gauge (M408)
9. Speed Control Toggle Switch (S406) 18. Voltmeter [Battery] (M401)
Figure 5 Control Box Panel Assembly

Page 11
i) Speed Control Toggle Switch (S406)
The speed control toggle switch is a two-position switch. In the “IDLE” position, the engine speed is
controlled to approximately 1000 RPM. In the “RATED RPM” position, the engine speed is controlled
to approximately 1800 RPM.
j) Engine On Lamp (DS407)
The engine on lamp glows green when the engine is running.
k) Engine Start Push Button Switch (S401)
The engine start push button switch is a momentary contact switch that closes the starter solenoid
circuit and cranks the engine. This switch is operable only when the engine toggle switch (S404) is
held in its top spring-loaded “START” position.
l) Engine Toggle Switch (S404)
The engine toggle switch must be held in the top “START” position and the engine start push button
must be pressed to start the generator set. When released from its top “START” position, after the
engine starts and the oil pressure comes up, this toggle switch will return to center “RUN/FUEL
CHECK” position. The “ENGINE RUNNING” lamp will glow as long as the switch is in “RUN/FUEL
CHECK” position. In the bottom “OFF/SHUTDOWN” position, this switch will trigger the delayed
shutdown mode and the engine will stop in about 4 minutes and the “ENGINE RUNNING” lamp will
go out.
In cold operating conditions, the engine heater may need to warm the engine up before starting.
When the engine toggle switch is placed in the “RUN/FUEL CHECK” position, the engine’s ECM
powers up and checks the engine’s manifold temperature. If the engine heater is required, the ECM
turns on the grid heater in the intake manifold for about 30 seconds.
m) Engine Heater Lamp (DS426)
The engine heater lamp is on when the engine heater is running.
n) Water Temperature Gauge (M404)
The water temperature gauge indicates the engine coolant temperature and is actuated by a
temperature sender mounted in the engine’s water jacket.
o) Air Filter Restriction Lamp (DS412)
The air filter restriction red lamp glows when the air filter needs changed.
p) Oil Pressure Gauge (M405)
The oil pressure gauge displays the pressure in the engine’s lubrication system. It is operated by a
sender mounted on the engine block next the engine ECM.
q) Fuel Gauge (M408)
The fuel gauge indicates the amount of fuel remaining in the fuel tank.

Page 12
3 11 23 24 4 5 6 2
8
9
7
12
13 10 1
14
15
16
17
22 21 20
18
19
1. Over Voltage Relay (K403)
13. Check Engine Indicator (DS68)
2. Voltage Regulator (VR402)
14. Check Stop Indicator (DS67)
3. Excitation Rectifiers (CR417 and CR418)
15. Engine Fault Code Switch (S82)
4. Control Windings Fuses (10 A) (F406 - F408)
16. Engine Diagnostic Switch (S80)
5. Voltage Build-up Fuse (10 A) (F405)
17. Light Circuit Breaker, 10 A (CB11)
6. Voltage Regulator Fuse (10 A) (F403)
18. Control Circuit Breaker, 5 A (CB7)
7. Rectifier Harness Connector (J43)
19. Engine Circuit Breaker, 10 A (CB4)
8. Engine Harness Connectors (J46–Power)
20. Shutdown Rectifier (CR426)
9. Engine Harness Connectors (J47 – Engine)
21. Shutdown Relay(K407)
10. Blocking Rectifier (CR401)
22. Shutdown Timer Relay (K406)
11. 100 MFD, 350 VDC Capacitor (C403)
23. Interlock CE Fuse (0.5 A) (F411)
12. Terminal Block (TB1)
24. Switch Interlock Fuse (5 A) (F413)
Figure 6 Control Box Interior Assembly

Page 13
r) Battery Voltmeter (M401)
The battery voltmeter indicates the voltage of the engine’s 12-volt DC electrical system.
8) Control Box Interior Assembly

a) Over Voltage Relay (K403)
The over-voltage relay is a solid-state protective device on a printed circuit board. A normally closed
relay in the circuit is wired into the load contactor coil circuit. An over-voltage 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 over-voltage module is adjusted to trip at 32 to 34 volts DC
in .5 seconds ±.2 seconds.
b) Voltage Regulator (VR402)
The voltage regulator is a solid-state device, which regulates the 28.5 V DC generator output voltage.
c) Excitation Rectifiers (CR417 and CR418)
Two diode bridge rectifiers convert an AC voltage from the generator armature to the DC voltage
needed for the generator’s revolving field.
d) Control Windings Fuses – cartridge type – 10 amp each (F406 – F408)
e) Voltage Build-up Fuse – cartridge type – 10 amp (F405)
f) Voltage Regulator Fuse – cartridge type – 10 amp (F403)
g) Panel Lights Circuit Breaker – 10 amp (CB4)
h) Engine Circuit Breaker – 10 amp (CB11)
i) Control Circuit Breaker – 5 amp (CB7)
j) Check / Stop Engine Indicator Light (DS68 and DS67)
The indicator lights display the condition of the engine (i.e. fault code present).
k) Engine Fault Code Switch (S82)
The switch is used to scroll through the fault codes of the engine, as read from the check/stop engine
indicator light.
l) Engine Diagnostic Switch (S80)
The switch is used to disable the engine starter, thus still allowing the user to turn on the control
circuitry for diagnostics and troubleshooting.
m) Rectifier Harness Connector (J43)
The connector provides connections between the control box and the rectifier assembly.

Page 14
n) Engine Harness Connectors (J46 & J47)
The connectors provide connections between the control box and engine components.
o) Blocking Rectifier (CR401)
This rectifier provides generator automatic voltage build-up.
p) Capacitor (C403)
A 100mfd, 350V DC Capacitor that filters the DC excitation volts produced by rectifiers CR417 and
CR418.
q) Shutdown Timer Relay (K406)
r) Interlock CE Fuse (F411)
s) Switch Interlock Fuse (5 A) (F413)
When the engine switch is placed in the “OFF/SHUTDOWN” position, this timer relay is activated and
will shut the engine down after a proper turbo cooling period of approximately 4 minutes.
9) Rectifier Assembly
a) Filter Capacitor (C401) and Preload Resistors (R403 – R405)
The DC output voltage is smoothed (filtered) by an R-C filter made up of the capacitor and preload
resistors. The resistors also provide a safety discharge circuit for quickly discharging the filter
capacitor whenever the power supply is turned off.
b) Shunt (R407)
The shunt provides current feedback to the regulator for purpose of line drop comp and current
limiting and also provides a signal to the output ammeter
c) Positive/Negative Heat Sinks and Diodes (CR405 – R410 and CR411 – R416)
Forms a 6-phase full wave rectifier
d) Terminal Block (TB3)
The terminal block provides a connection point for the field leads and exciter leads.

Page 15
3,4 1 2 8
5,6 9 10 7
1. Filter Capacitor (C401) 6. Negative Diodes (CR405 – R410)

2. Preload Resistors (R403 – R405) 7. Shunt (R407)
3. Positive Heat Sink Panel 8. Terminal Block (TB3)
4. Positive Diodes (CR411 – R416) 9. Generator Leads
5. Negative Heat Sink Panel 10. Exciter and Field leads
Figure 7 Rectifier Assembly

Page 16
JetEx6D/ Series 500074A / 28.5 VDC Generator Set
Section 2 Preparation for Use, Storage, or Shipping

1) Preparation for Use
a) General
The generator set is shipped with an empty fuel tank. After the fuel tank is filled and the generator set
is inspected, the generator set is ready for use.
b) Inspection/Check
Inspect the unit thoroughly prior to operation.
(1) Remove blocking, banding, ties, and other securing material.
(2) Inspect exterior for shipping damage such as broken lights, 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, oil hoses and connections for visible leaks. Visually inspect the compartment
floor and ground surface under the unit for signs of leakage. If leaks are found, correct by
tightening hose clamps, tube fitting, etc., as required.
(5) Check to be sure all retaining hardware is tight and secure (i.e. engine mounting bolts)
(6) Check the following:
a Fuel
Place the engine toggle in the “RUN/FUEL CHECK” position to energize the fuel gauge when
engine is stopped. Fuel is supplied from a customer-furnished source. Fuel tank capacity is
approximately 50 gallons (189 liters).
NOTE: For recommended fuel specifications refer to the Engine Manufacturer’s Operation
and Maintenance Manual provided with this manual.
b Engine coolant
Remove radiator cap to check coolant level. Coolant level should be at the bottom of the filler
neck. See Figure 1 for capacity.
CAUTION
BE SURE the cooling system antifreeze solution is adequate to protect below the
lowest temperature expected.
NOTE: Typical antifreeze mixture, as received from the factory, is a solution of 50%
permanent antifreeze (Ethylene glycol) and 50% clean water.

Page 1
ENGINE OIL AND COOLANT CAPACITIES
Lubricating oil capacity (w/ filter) 11.6 quarts (11 liters)

Coolant capacity system 20 quarts (18.9 liters)
Figure 1
c Engine lubricating oil level
The oil check gage has “H” high level mark and “L” low level mark to indicate the operating
lubrication oil supply. Oil level should be kept as near the high mark as possible, without
going over it.
CAUTION
NEVER operate the engine with oil level below the “L” level mark or above the
”H” level mark.
NOTE: See Engine Manufacture’s Operation and Maintenance Manual for oil
recommendations.
Engine ECM
Oil Check Gauge
Figure 2 Oil Level Check Locations

Page 2
Check Batteries
Inspect the batteries for proper connection of the terminals and also check the electrolyte
level (if required). Service or replace as necessary.
c) Output Cable Requirements and Installation
Jet-Ex 6D units are normally supplied with a 30 foot generator-to-aircraft output cable. This output
cable consists of two single conductor 4/0 cables (positive and negative).
(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). It should be two conductor type with lug-type terminals on one end
and an MS-90347 plug connector on the other.
The recommended cable size for 28.5 volt DC is determined by the maximum starting load
amperage expectations. A maximum starting load of 1500 amps requires two single conductor
4/0 cables. A maximum starting load of 600 amps requires two single conductor 2/0 cables.
(2) Cable Connection (See Figure 3)
Open and remove the right rear door and the panel below the door (if necessary). Carefully set
panels aside.
Loosen the output cable clamp and push the lugged end of the output cable through the opening
in the right side of the unit.
Connect the positive cable lead to the positive output terminal on the contactor. Connect the
negative cable lead to the negative output terminal located above the load contactor on the
support bracket. Always place the lead (terminal lug) behind a flat washer.
Negative Cable Connection
Figure 3 Output Cable

Connections
Positive Cable Connection

Page 3
Tighten the cable clamp and re-install the lower panel and the access door, if removed.
Store cables in cable tray or on hangers on side of canopy if cable trays are not used.
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, corrosion, and gumming in the engine fuel system.
a) General
Pull all circuit breakers and/or disconnect battery negative terminal.
(1) The unit should be prepared for storage as soon as possible after being removed from service.
(2) The unit should be stored in a building which is dry and which may be heated during winter
months.
(3) Moisture absorbing chemicals (Hobart Brothers Part No. 76A1354-001) 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 30 days or less, prepare as follows:
(1) Lubricate the unit completely in accordance with instructions in Section 2-2. This will include
changing engine oil, and all filter elements.
(2) Start the engine and operate for about two minutes so that all internal engine components will be
coated with new oil.
NOTE: Do not drain the fuel system or crankcase after this run.
(3) Make certain the cooling system antifreeze solution is adequate to protect below the lowest
temperatures expected during the storage period. Be sure the solution is thoroughly mixed.
(4) Clean the exterior of the engine. Dry with clean rags and compressed air.
(5) Seal all engine openings. Use a waterproof, vapor proof material that is strong enough to resist
puncture damage from air pressures.
c) Long Time Storage (Over 30 Days)
To protect the generator and other electrical components, the complete unit should be packaged
using moisture proof packaging material and sealing material. Place containers of moisture
absorbing chemicals (Hobart Brothers Part No. 76A-1354-001) in the unit before packaging. The unit
may be stored for long periods with no special preparations, if it is possible to operate the engine
once each week. When starting once a week, proceed as follows:
(1) Make certain the cooling system is adequately protected.

Page 4
WARNING
ENSURE adequate ventilation before starting the engine.
(2) Start the engine and operate under full load until coolant temperature has reached at least 176ºF
(80ºC) or the thermostat opens.
(3) While the engine is running, ensure that normal operating controls are in good working condition
before shutdown and storage.
3) Preparation for Shipment

a) Disconnect battery negative terminal before shipping.
b) During long shipments, vibration, jolting, etc may loosen the generator set retaining hardware.
CAUTION
When shipping the unit, provide sufficient retaining materials to ensure the
GENERATOR SET cannot roll out or off the vehicle in which it is being transported.

Page 5

Page 6
Chapter 1
Section 3 Operation
1) General
This section contains information and instructions for the safe and efficient operation of the equipment.
Operating instructions are presented in the sequence of procedures to be followed in supplying power to
aircraft.
NOTE: Read all of the operating instructions below before attempting to operate the equipment. A simple
step-by-step operating procedure can also be found on the control panel.
WARNING
Ear protection equipment may be necessary when working close to this equipment.
2) Operating Procedure
a) Pre-start Inspection
(1) Check the supply of fuel, crankcase oil and radiator coolant.
(2) Be sure the fuel shutoff valve (located at the fuel tank outlet) is open. Checking the fuel gauge
make certain there is sufficient fuel to complete the job to be done.
(3) If the unit is trailer mounted and is not connected to a tow vehicle, be sure the parking brake is
applied and that the drawbar is raised and locked in the vertical position.
(4) Open the engine compartment doors and inspect interior for rags, tools, and foreign material as
they could cause serious damage to the engine, generator, or personal injury to anyone standing
nearby.
(5) Inspect the unit thoroughly to be sure it is in proper working order. Check all fuel lines and wire
connections to be certain they are secure. Tighten any loose screws, nuts or bolts.
(6) Be sure all air passages are not blocked (i.e. nothing in front of the radiator).
(7) If the unit is operated indoors, make sure that an exhaust line is properly connected to the engine
exhaust system, and discharged outside. Avoid short bends or reduction in line sizes in exhaust
pipes. Locate the unit so as to necessitate the shortest possible exhaust line to insure the least
amount of back pressure on the engine. Back-pressure can cause engine damage and loss of
power.
(8) Check the electrical system to make sure the connections are secure and properly connected.
(9) If applicable, check the battery electrolyte level. The factory installed battery is maintenance free.

Page 1
16 18 17 1 14 2 8 3 4
12 11 13 9 10 15 7 6 5

2. Hour Meter (M402) 11. Engine Start Push Button Switch (S401)
3. Voltmeter [Generator] (M406) 12. Engine Circuit Toggle Switch (S404)
4. Ammeter [Generator] (M407) 13. Engine Heater (DS426)

Page 2
b) Starting the Engine
Make sure that all pre-starting instructions have been carried out and be sure the unit was prepared
for use per Section 2 of this chapter.
(1) Place “SPEED CONTROL” toggle switch in the “IDLE” position.
(2) Switch the ‘ENGINE” toggle switch into the “RUN/FUEL CHECK” position. If the “ENGINE
HEATER” light comes on, then wait until the light goes out before starting the engine.
(3) After the engine heater check, hold ‘ENGINE” toggle switch in “START” position.
(4) Press and hold “ENGINE START” push-button switch. Release as soon as engine starts and oil
pressure comes up (1-2 seconds), as seen on oil pressure gauge.
CAUTION
If the engine stalls or falters in starting, wait three or four seconds before re-engaging
starter. This will prevent possible damage to starter or the engine. DO NOT operate
the starter for periods longer than 15 seconds at a time. An interval of at least two
minutes should be allowed between cranking periods to protect the starter from
overheating.
(5) Release ‘ENGINE” toggle switch to “RUN/FUEL CHECK” position when oil pressure builds up.
(6) Observe engine RPM on the tachometer, idle speed should be 1000 RPM +/- 50 RPM.
(7) Check air cleaner service indicator lamp. If lamp is glowing, replace air filter element and/or
remove other objects that obstruct air flow.
(8) Allow engine to warm up before applying a load.
CAUTION
To eliminate the possibility of wet stacking and excessive oil consumption (See
Appendix A), DO NOT allow the engine to idle for long periods of time.
WARNING
The engine’s entire exhaust system will get very hot and cause severe burns if
touched.
c) Generator Operation
(1) Place “SPEED CONTROL” toggle switch into “RATED RPM” position (1800 RPM) and the
generator will automatically build up to produce rated voltage.
(2) Adjust current limiting control potentiometer, if necessary. Refer to aircraft documentation for
proper setting.

Page 3
d) Power Delivery
(3) Connect output cable to aircraft.
(4) Hold “28.5 VDC OUTPUT CONTACTOR” toggle switch in “CLOSED” position. Release to “ON”
position as soon as green “28.5 VDC OUTPUT CONTACTOR CLOSED” lamp comes on.
WARNING
NEVER disconnect the output cable while power is being delivered. The output
contactor must be opened prior to removal of the cable from the aircraft.
e) Shutdown/Stop Operation
(1) Normal Shutdown Condition
a When power delivery is completed, place “28.5 VDC OUTPUT CONTACTOR” toggle switch
in the “OFF” position. The “28.5 VDC OUTPUT CONTACTOR CLOSED” lamp should go off
to indicate load contactor has opened and power is no longer available at the aircraft.
b Place “SPEED CONTROL” toggle switch in “IDLE” position.
c Disconnect output cable from aircraft receptacle and store cable in cable trays or on cable
hangers, whichever is available.
d Place ‘ENGINE” toggle switch in “STOP” position. This will engage the delayed shutdown
timer. The engine will shut down in approximately 4 minutes.
CAUTION
The battery will drain if the ‘ENGINE” toggle switch is not placed in “STOP” position
after shutdown.
(2) Emergency Shutdown Condition
To prevent personal injury or damage to the generator set an emergency stop push-button switch
is provided for immediate shutdown of the engine. Once pushed in, the emergency stop button
must be pulled back out to restart the engine.
f) Adverse Weather Precautions
(3) Cold weather operation
Operation of this generator set at sub-zero temperatures requires special precautions and extra
servicing from both operation and maintenance personnel, if poor performance or total functional
failure is to be avoided. Consult the Engine Manufacture’s Operation and Maintenance Manual
and recommendations below.
a Fuel system
Keep system clean and free from water that may collect in a low spot in the fuel line and
freeze. Fuel tanks should be kept FULL to prevent water condensation from the air above
the fuel.

Page 4
b Cooling system
Prior to cold weather, drain and flush the cooling system to remove accumulations of rust and
sediment. Add antifreeze solution and check the cooling system connections for leaks. Add
a can of rust inhibitor to the radiator when system is winterized. This will keep system
cleaner and furnish lubrication for the water pump.
c Lubrication
Drain the crankcase (preferably when warm after running) and fill with a lighter grade of oil.
See engine oil recommendation chart in the Engine Manufacture’s Operation and
Maintenance Manual for recommended viscosity for various atmospheric temperatures. In
cold weather, drain oil more frequently. Water condenses and collects quickly, mixes with the
oil and increases deposits to form sludge. Check oil frequently for this condition. Water in
crankcase may freeze and cause serious damage to the oil pump or shut off the oil supply.
d Electrical system
Cold weather requires an efficient electrical system to start the cold engine. Check the entire
system for loose connections or indication of bad wiring or shorted conditions.
e Battery
Battery efficiency decreases sharply with lower temperatures. Make sure the battery is fully
charged before attempting to start engine in sub-zero conditions.
(2) Operation in Hot and Humid Conditions
Maintain a more frequent check of the coolant level in the radiator.
(3) Operation in Extremely Dusty Conditions
If unit is to be operated under dusty outdoor conditions, place it in a sheltered area. Take
advantage of any natural barriers which may offer protection from blowing dust. If the installation
is more than temporary, erect a protection shield.
a Fuel system
Change the fuel filter at prescribed intervals and keep fuel containers covered and protected
against dust entry.
b Air Cleaner
This filter needs more frequent attention under dusty conditions. Check air filter restriction
lamp located on control panel daily.
c Crankcase Oil
The crankcase oil level will require close attention. Dusty conditions tend to load crankcase
oil with dirt. Watch for dirty and gritty oil conditions, and change oil more frequently as
required.

Page 5
(4) Operation in Salt Water Areas
a Canopy
Wash canopy regularly to remove salt film. Repaint any damaged places and oil the hinges
regularly.
b Covering and Cleaning
To protect the engine and generator as much as possible from salt water atmosphere, keep
the side doors on the canopy closed, when not in use. It is advisable to keep the unit
covered with a tarpaulin when not in use. Salt water should be wiped from the engine and all
terminals and connections in the electrical system wiped dry. Keep all linkage oiled.
c Brushes
The brushes of the generator should be inspected regularly to make certain that they are free
in the holders. Lift the brushes in the brush holders about every two days to insure their
freedom to slide within the holder. Wipe dry all the parts that can be reached, and use
compressed air, if available, to dry the parts of the generator that cannot otherwise be
reached.
d Field coils
The fields should be dried as thoroughly as possible.
e Battery terminals
Thoroughly clean the battery terminals and connections. Coat the terminals and connections
with petroleum jelly (or equivalent) to prevent corrosion.

Page 6
Chapter 2 Service and Troubleshooting

Section 1 Maintenance Inspection/Check
1) General
To make certain the ground power unit is always ready for operation, it must be inspected and maintained
regularly and systematically so that defects may be discovered and corrected before they result in serious
damage to components or failure of the equipment.
WARNING
STOP operations immediately if a serious or possibly dangerous fault is discovered.
2) Maintenance Schedule
a) General
A periodic maintenance schedule should be established and maintained. A suggested schedule is

provided in Figure 1 on the following pages. It may be modified as required to meet varying operating
and environmental conditions. It is suggested that ground power units and vehicle inspections be
coordinated as much as possible.
b) Maintenance Schedule Check Sheet
It is strongly recommended that the customer use a maintenance schedule check sheet such as the
one in engine manufacture’s operation manual. The check sheet will provide a record and serve as a
guide for establishment of a schedule to meet the customer’s maintenance requirements for his
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. For example, in normal operation the oil change period, based on hours of
operation, will be reached long before the three month calendar period. The calendar period is
included to make certain services are performed regularly when the equipment is stored or being
operated infrequently. Lubricating oil standing in engines that are stored, or used very little, may tend
to oxidize and may require changing although it is not dirty. Perform all services on a whichever-
comes-first basis.
d) Identification of Interval Periods
Each interval period is identified by a letter A, B, C, etc. For example, services under B schedule
should be performed at the end of each 250 hours of operation, or every three months, BR service is
performed during the BREAK IN period (first 50-150 hours) and AR service is performed as required.

Page 1
Hourly Interval AR 10 250 500 1000 1500 2000

Calendar Interval Daily 3 Mo. 6 Mo. 1 Yr. 1.5 Yr. 2 Yr.
Symbol AR A B C D E F
Change Air Cleaner Cartridge X
Check Coolant Hose and Clamps X
Check Air Cleaner X X
Check Crankcase Oil Level X
Check Crankcase Breather Tube X
Drain Fuel/Water Separator Element X
Check Coolant Level X X
Check for Leaks and Correct X
Check Exhaust System X
Air Intake Piping and Hoses X
Check Charge-Air-Cooler and Hoses X
Check Radiator Core and Hoses X
Check Belts Conditions X
Check and Record Oil Pressure X
Check Engine Coolant X X
Change Lubricity Fuel Filter Element X
Change Primary Fuel Filter Element X
Change Oil and Filter Element X
Check Oil Pressure and Record X
Engine Cylinder Carbon Build-Up X
Check Cooling Fan Belt Tensioner X
Check Fan Hub and Drive Pulley X
Drain and Flush Cooling System X
Check Vibration Damper X
Check Engine and Generator Mounts X
Steam Clean Engine X
Check and/or Adjust Valve Clearance X
Check Alternator X
Check Starter Motor X
Clean Cooling System Cores Spring & Fall
Figure 1 Maintenance Schedule
(Sheet 1 of 2)

Page 2
Hourly Interval AR 10 250 500 1000 1500 2000

Calendar Interval Daily 3 Mo. 6 Mo. 1 Yr. 1.5 Yr. 2 Yr.
Symbol AR A B C D E F
Engine (continued)
Clean Electrical Connections Spring & Fall
Check Thermostats and Seals Fall
Electrical (12 VDC System)
Check all Lights X
Check Alternator Charging Rate X
Check Battery X
Clean Battery Terminals X X
Check Wiring and Connections X
Check All Engine Meters X
Electrical (28.5 VDC System)
Check Interlock Operation (if supplied) X
Check Output Cable and Connectors X
Check Volt and Amp Meters X
Check and/or Adjust Output Voltage X X
Inspect Wiring and Connectors X
Clean and Inspect all Components X
Figure 1 Maintenance Schedule

(Sheet 2 of 2)

Page 3
3) Inspection/Check
a) General
Inspections, checks, and maintenance are described in general with more specific and detailed
information that can be found in Chapter 2, Section 2 and 3.
Always refer to the engine manufacturer’s operations and maintenance manual for assistance and the
most update to date information on inspection, repair and replacement procedures for the engine.
b) “AR” Checks and Operations (As Required)
(1) Engine
a Change Air Cleaner Cartridge
A definite time schedule for changing the air cleaner cannot be established. This filter should
not be washed or retained for more than one year of service.
b Check Coolant Hose and Clamps
Check and tighten all coolant hose clamps, air intake hose clamps and exhaust clamps as
required. Check all coolant hoses, air intake hoses and exhaust pipes for leaks.
(2) Electrical System (12 VDC)
a Check Battery Terminals
Visually check battery cable connectors and battery posts. If corrosion is observed,
disconnect cables and clean battery posts and connectors with a wire brush or special battery
post-cleaning tool. Coat the posts and connectors with a light film of petroleum lubricant
before reconnecting cables.
(3) Electrical (28.5 VDC System)
a Check and/or Adjust Output Voltage
Check the output voltage and be sure it is set for 28.5 VDC ± 1 V. Adjustments can be made
using the multi-turn potentiometer (R46) on the voltage regulator PCB (VR402). Clockwise
rotation increases the voltage level and counterclockwise rotation decreases the voltage
level.

Page 4
c) “A” Checks and Operations (10 Hours or Daily)
(1) Engine
a Check Air Cleaner
Check for excessive dirt build-up and/or air blockages. Change or clean the filter as
necessary to allow the proper amount of air flow to the engine.
At each daily start-up, observe the air cleaner indicator light. If this light comes on, it
indicates that the air cleaner should be cleaned, changed or it is obstructed.
b Check Crankcase Oil Level
CAUTION
DO NOT overfill. DO NOT operate the engine with oil level below the lower bar or
above the upper bar on the dipstick.
Check oil level daily with oil gauge dipstick.
Oil level should not be checked until 3 to 5 minutes after engine shutdown. Keep oil level as
near the upper bar as possible.
c Check Crankcase Breather Tube
Inspect the breather tube for sludge, debris or ice in the tube. Inspect the tube more
frequently in icy conditions. Be sure the tube is routed in such a way to prevent a water/fluid
trap. Blockage of the breather tube could reduce the power of the engine or cause internal
damage.
d Drain Fuel/Water Separator Element
The life of the fuel pump and injectors can be extended if the operator drains water from the
fuel/water separator on a daily basis.
1. Provide a container for catching drained fuel and water.
2. Open the drain valve on the fuel/water separator.
3. Drain the filter until clear fuel is visible.
4. Tighten the drain valve.
5. Safely dispose of drained fuel.
6. Purge air from fuel system if necessary.

Page 5
Figure 2 Fuel/Water Separator Drain
e Check Coolant Level
Check coolant level daily or at each fuel fill interval. Investigate for cause of any coolant loss
and fill as necessary.
WARNING
Cooling system is pressurized. To avoid personal injury, DO NOT remove radiator
cap when engine is hot. Wait until the engine is cooled down before removing the
radiator cap.
f Check for Leaks and Correct
At each daily start-up, check for coolant, fuel, and oil leaks. Observe pumps, hoses, fittings,
gasket connections, etc., for signs of leakage. Correct as required.
g Check Exhaust System
Visually inspect muffler and exhaust pipes for rust, leaks and signs of approaching failure.
WARNING
A leaking and defective exhaust system could be a fire hazard.

Page 6
(2) Electrical System (12 VDC)
a Check All Lights
Check all indicating lights to be sure they will operate when they should. If any light fails to
operate, check both the lamp and its protective circuit breaker. Reference tables listed in this
section for all lamps and circuit breakers information.
b Check Alternator Charging Rate
Observe the 12 VDC voltmeter each time the engine is started to be sure the battery is
charging.
c Check All Engine Meters
Check the operation of all the engine meters.
a Check Output Cables and Connector
Check the output cable plug connection for damaged insulation and contacts each time the
connector is detached from the aircraft. If the cable head sockets are exposed, even just a
little, the cable head or cable should be changed immediately.
b Check Volt and Amp Meters
Check operation of voltmeter and ammeter meter each time the unit is started.
d) “B” Check and Operations (250 Hours or 3 Months)
(1) Engine
a Check Air Intake Piping and Hoses
Visually inspect piping and hoses for wear points and damage. Inspect clamps for proper
tightening to prevent air from leaking. Check for corrosion under the clamps and hoses to
prevent corrosive products and dirt from entering the air intake system.
b Check Charge-Air-Cooler and Hoses
Inspect the charge-air-cooler for dirt and debris blocking the fins. Clean as necessary.
Check for cracks, holes, or other damage.
Inspect the pipes and hoses for leaks, holes, cracks, or loose connections. Tighten the hose
clamps if necessary.
c Check Radiator Core and Hoses
Inspect the radiator core for dirt and debris blocking the fins. Clean as necessary. Check for
cracks, holes, or other damage.
Inspect the pipes and hoses for leaks, holes, cracks, collapsing or loose connections.
Tighten the hose clamps if necessary.
Page 7
d Check Belts Conditions
Inspect the belt for cracks and proper tension. Refer to the engine operation and
maintenance manual for details on belt repair and tightening.
e Check Air Cleaner
Check for excessive dirt build-up and/or air blockages. Change or clean the filter as
necessary to allow the proper amount of air flow to the engine.
At each daily start-up, observe the air cleaner indicator light. If this light comes on, it
indicates that the air cleaner should be changed or it is obstructed.
f Check Coolant Level
Check coolant level daily or at each fuel fill interval. Investigate for cause of any coolant loss
and fill as necessary.
WARNING
Cooling system is pressurized. To avoid personal injury, DO NOT remove radiator
cap when engine is hot. Wait until the engine is cooled down before removing the
radiator cap.
g Check and record oil pressure
After each oil change, check and record oil pressure at idle speed after the engine has
reached operating temperature. Record the oil pressure under identical conditions after each
oil change. A comparison of pressure at idle speed with previous readings will give an
indication of progressive wear of oil pump, bearings and shafts. Investigate any abnormal
change in pressure readings.
(2) Electrical (12 VDC system)
NOTE: The battery furnished with this generator set is MAINTENANCE FREE.
Check Battery Terminals
Visually check battery cable connectors and battery posts. If corrosion is observed,
disconnect cables and clean battery posts and connectors with a wire brush or special battery
post-cleaning tool. Coat the posts and connectors with a light film of petroleum lubricant
before reconnecting cables.
Check Optional Interlock Operation (if supplied)

Page 8
f) “C” Checks and Operations (500 Hours or 6 Months)
(1) Engine
a Check Engine Coolant
Check the coolant level and fill as necessary.
Check the anti-freeze concentration. Use a 50/50 mixture of water and ethylene glycol as the
preferred mixture.
b Change Lubricity Fuel Filter and Primary Fuel Filter Element
Change all fuel filter elements. The lubricity fuel filter can only be changed with a lubricity
fuel filter replacement.
c Change Oil Filter Element.
The oil filter must be changed with the every oil change.
d Check and record oil pressure
After each oil change, check and record oil pressure at idle speed after the engine has
reached operating temperature. Record the oil pressure under identical conditions after each
oil change. A comparison of pressure at idle speed with previous readings will give an
indication of progressive wear of oil pump, bearings and shafts. Investigate any abnormal
change in pressure readings.
e Engine Cylinder Carbon Build-Up
To prevent the build-up of oil and sludge in the cylinders, and prevent “wet stacking” of the
engine, a full operating load should be placed on the unit for 30 minutes during each
preventative maintenance cycle.
(2) Electrical (12 VDC system)
a Check Wiring and Connections
Check all cables, leads, and wiring for broken, worn, damaged insulation or corrosion. Check
all connections for tightness.

Page 9
a Check and/or Adjust Output Voltage
Check the output voltage and be sure it is set for 28.5 VDC ± 1 V. Adjustments can be made
using the multi-turn potentiometer (R46) on the voltage regulator PCB (VR402). Clockwise
rotation increases the voltage level and counterclockwise rotation decreases the voltage
level.
b Inspect Wiring and Connections
Check all cables, leads, and wiring for broken, worn, damaged insulation or corrosion. Check
all connections for tightness.
c Clean and Inspect all Components
A periodic cleaning of all control PCB’s, terminal blocks, terminal studs, relays, fuse holders,
etc. will help eliminate hot spots and possible premature failure.
g) “D” Checks and Operations (1000 Hours or 1 Year)
(1) Engine
a Check Cooling Fan Belt Tensioner
Check the tensioner arm, pulley and stops for cracks. Tensioner must be replaced if cracks
or found.
Check for belt location on pulley. The belt should be centered or in the middle of the pulley.
Incorrect belt location can cause premature belt wear, belt roll-off, or tensioner bushing wear.
b Check Fan Hub and Drive Pulley
Inspect for loose bolts or worn features. Tighten bolts and replace parts if necessary. Refer
to the engine manufacturer’s operations and maintenance manual for assistance and the
most update to date information.
c Drain and Flush Cooling System
Periodic flushing of the coolant system is essential for efficient engine heat transfer and
preventing engine cooling jacket damage. Refer to the engine manufacturer’s operations and
maintenance manual for assistance and the most update to date information.
d Check Vibration Damper.
Check vibration damper for looseness, wobble, chunking and streaking. Also, verify the hub
bolts are tightened to the engine manufacturer’s specifications.
Refer to the engine manufacturer’s operations and maintenance manual for assistance and
the most update to date information.
e Check Engine and Generator Mounts

Page 10
CAUTION
An unstable or loosely mounted engine can create hazardous environment and may
also damage equipment.
(i) Engine mount bolts must have an applied torque of 135 N-m (100 ft-lb).
(ii) Generator mount bolt must have an applied torque of 80 N-m (60 ft-lb).
7
6
4
1 3
8
2
5
1. Fan Pulley 5. 12 VDC Starter

2. Vibration Damper 6. 12 VDC Alternator
3. ECM (Electronic Control Module) 7. Belt Tensioner
4. Primary Fuel Filter (Remote Mounted) 8. Oil Filter
Figure 3 Engine Accessories

Page 11
h) “E” Checks and Operations (1500 Hours or 1.5 Year)
(1) Engine
a Steam Clean Engine
There are several reasons why the engine exterior should be kept clean. Dirt on the outside
will enter fuel and oil filter cases and rocker housings when covers are removed. Also, a
clean engine will run cooler and develop fewer hot-spots. Steam cleaning is one of the most
satisfactory methods of cleaning an engine; however, there are some CAUTIONS to be
observed:
WARNING
Exercise care to avoid injury and damage to eyes and skin.
CAUTION
• If a cleaning compound is used, select one that is free from acid and will not remove paint.
• Protect (or remove) all electrical accessories such as the voltage regulator, alternator, and
electrical wiring.
• Seal all openings.
• DO NOT use a flammable solvent.
• DO NOT use mineral spirits or solvents on a hot engine.
• Remove or protect bottom panel of unit (belly pan) to protect insulation.

Page 12
i) “F” Checks and Operations (2000 Hours or 2 Years)
(1) Engine
a Check and/or Adjust Valve Clearance
b Check Alternator
Check the drive belt and alternator pulley to be sure the alternator is rotating properly.
Check all wiring connections for cleanliness, tightness and defects.
c Check Starter Motor
Check all wiring connections for cleanliness, tightness and defects.
j) Seasonal Maintenance Checks Spring/Fall (Engine)
(1) Clean Cooling System Cores
Cleaning the radiator core and the charge-air-cooler core will keep the cooling system running
efficiently and keep the engine operating temperatures within limits to meet the emissions
standards (EPA/CARB/EURO).
(2) Check All Electrical Connections
Check all wiring connection. Check for damages wires and connections. Clean and remove all
dirt and debris.
(3) Check Thermostats and Seals
Check thermostat operation and all engine seals. Refer to the engine manufacturer’s operations
and maintenance manual for assistance and the most update to date information.

Page 13
4) Lamps, Circuit breakers, and Fuses

a) Check all lamps daily
The lamp table lists all lamps with their location and identifying trade number.
b) Check circuit breakers and fuses as required.
The circuit breaker tale lists all circuit breakers with their location, size, and type.
c) Check all fuses
The fuse table lists all fuses with their location, size, and type.
Item Protected Location Quantity Size

Voltage Regulator Inside Control Box (F403) 1 10 A
Voltage Build-up Inside Control Box (F405) 1 10 A
Control Windings Inside Control Box (F406-F408) 3 10 A
Interlock CE Inside Control Box (F411) 1 0.5 A
Switch Interlock Inside Control Box (F413) 1 5A
Engine Pre-Heater Electronic Panel 1 125 A
Figure 4 Fuse Identification Chart
Lamp (Bulb) as per

Light Identification Illustration or Location Lamp Industry Trade
Number
Engine On Lamp Switch Panel (DS407) 1815
Engine Pre-Heater Lamp Switch Panel (DS426) 757
Contactor Closed Lamp Switch Panel (DS408) 757
Air Filter Restriction Lamp Switch Panel (DS412) 1815
Engine Check Lamp Inside Control Box (DS68) 1815
Engine Stop Lamp Inside Control Box (DS67) 1815
Figure 5 Lamp Identification Chart
Item Protected Location Quantity Size
Engine Circuit Inside Control Box (CB4) 1 10 A

Controls Circuit Inside Control Box (CB7) 1 5A
Light Circuit Inside Control Box (CB11) 1 10 A
Figure 6 Circuit Breaker Identification Chart

Page 14
Section 2 Maintenance Procedures

1) General
This section provides maintenance procedure details for the maintenance schedule items that were
described in the previous section.
WARNING
STOP operations immediately if a serious or possibly dangerous fault is discovered.
2) Preventive Maintenance
The table below lists the filter part numbers for your generator set.
ITW GSE Part

Filter
Number
Oil Filter Element 286897-029
Engine Primary Fuel Filter Element 286897-036
Lubricity/Fuel Water Separator Element 286897-031
Air Filter Replacement Element 290941
For more information, refer to the Preventive Maintenance page in the front of this manual.
3) Lubrication
a) General
Proper lubrication is one of the most important steps in a 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 following figures and
tables.
b) DC Generator
The 28.5-volt DC generator requires NO lubrication. The armature is sealed at the factory for lifetime,
maintenance free operation. The front end of the armature is supported by the engine main bearings.
c) Generator Controls
Generator controls and instruments require no periodic lubrication.
d) 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
operation and maintenance manual and incorporated here to make them more readily available to
operators and maintenance personnel.
OM2241-A Rev A August 17,2016 Chapter 2-2
Page 1
(1) Lubrication schedule
Lubrication schedules are based on average operating conditions. It may be necessary to

lubricate more frequently under severe operating conditions such as low engine temperatures,
high oil temperatures, or intermittent operation. However, time intervals should not exceed those
indicated in the chart without careful evaluation.
(2) Oil specification
Engine lubricating oil, recommended by the engine manufacturer, is identified by an API

(American Petroleum Institute) classification designation. The manufacturer does not
recommend any specific brand of lubricating oil.
The use of quality lubricating oil, combined with appropriate lubricating oil drain and filter change
intervals, are important factors in extending engine life.
Oil recommended for the diesel engines in this application is API Class CCMC.
(3) Oil viscosity
A sample temperature and oil viscosity index chart is shown in Figure 2. Refer to the engine
manufacturer’s operation manual for the most recent updates. For operation at temperatures
consistently below 5º F (-15º C) refer to the engine manufacturer’s operation manual.
(4) Changing engine oil
Oil Filter
Figure 1 Oil Filter Location

Page 2
Change the oil once after the first 50 to 150 hours of use and then every 500 hours of engine
operation thereafter. The generator set is equipped with an hour meter to record actual engine
operating time. The ideal time to change engine oil is soon after a power delivery run, when the
engine is at operating temperature.
Change the oil filter element each time the oil is changed.
Change oil as follows:
1. Provide an open container for catching the old oil below the oil drain plug. Container capacity
must be greater than 20 quarts (19 liters).
2. Remove drain plug in the oil pan.
3. While oil is draining, change the oil filter element. See instructions below.
a. Provide a container for catching spilled oil from the filter.
b. Remove the oil filter by twisting counter-clockwise and inspect it.
NOTE: The gasket can stick to the filter head. Make sure it is removed before installing a
new filter.
CAUTION
If bearing metal particles are found in the filter element or in the
shell, the source should be determined before a failure.
c. Fill the new filter with clean lubricating oil before installation.
d. Apply a light coating of lubricating oil to the gasket’s sealing surface and install the filter.
DO NOT over tighten the filter.
4. Clean the drain plug and install when engine oil has completely drained.
5. Refill the crankcase with new clean oil that meets engine manufacturer’s recommendations.
CAUTION
• Always use clean containers, funnels, etc.
• Remember to close the drain plug valve and install the new
oil before starting the engine.
6. Start engine and check oil pressure at once. Allow engine to idle for 5 minutes, check for
leaks, than stop the engine.
7. After the engine has been stopped for about 5 minutes, recheck the oil level. Add oil, if
required, to bring the level up to the high bar on the oil dipstick.

Page 3
Item Maintenance Required

Check oil level daily or after every 10 hours of use. Change oil and the oil filter
after the first 50 to 150 hours of use, then at 500 hours or 6 month intervals
Lube Oil
thereafter. Use oil SAE 15W40 heavy duty oil which meets API CH-4/SJ or CI-
4/SK.
Capacity 11.6 quarts (11 liters)
ITW GSE Part No. - 286897-029

Oil Filter Replacement
Cummins Part No. - LF3970
VISCOSITY AMBIENT TEMPERATURE CONDITIONS
Lube Oil Viscosity SAE 15W40 (Preferred) 5ºF (-15ºC) and above for most climates
Required as per CI-4 and SAE 10W30 -10ºF to +70ºF (-23ºC to +21ºC) Winter conditions
Ambient Temperatures
SAE 5W30 -15ºF to +70ºF (-26ºC to +21ºC) Arctic Conditions
SAE 0W30 -30ºF and below to 32ºF (-34ºC and below to 0ºC)
See the engine manufacturer’s operations manual for usable synthetic oils and
Synthetic Oils
instructions.
Fuel Water Separator and Drain filters daily. Change the filter elements every 500 hours or after 3 months
Lubricity Additive Filter of use, whichever comes first.
Check coolant level daily. Engine coolant capacity (system): 20 quarts (18.9
Coolant
liters)
Coolant hoses and
Check coolant hoses and connections daily for leaks.
connections
Change air cleaner filter as required when air cleaner indicator (on engine control
Air Cleaner
panel) shows that it should be changed.
Fan Belt Check fan belt condition and tension every 500 hours or 6 months of use.
AC Generator AC generator bearings are sealed and require no periodic lubrication.
Alternator Alternator bearings are sealed and require no periodic lubrication.
Starter Starter motor bearings are sealed and require no periodic lubrication.
Water Pump The water pump is packed at assembly and requires no periodic lubrication.
Fan Hub The fan hub is lubricated at assembly and requires no periodic lubrication.
Figure 2 Lubrication and Maintenance Chart

Page 4
e) Engine Accessories Lubrication
(1) Alternator
Most alternators contain sealed bearings and require no periodic lubrication, however, check to
make certain there are no lubrication points on your particular alternator.
(2) Starter
Most starting motors are lubricated at assembly and should be re-lubricated only when the starter
is removed and disassembled, however, inspect the starter to make certain it has no lubrication
points.
(3) Water Pump
The water pump is packed at assembly and requires no periodic lubrication. Replace pump if
signs of lubricant leakage are found.
(4) Fan Pulley
The fan hub is also lubricated at assembly and requires no periodic lubrication. Replace hub if
lubricant is leaking.

Page 5
3) Servicing the Air Cleaner

This air cleaner filter element is a disposable type that may be discarded when dirty. A definite time
schedule for cleaning or changing the air cleaner cannot be determined because of varying operating
conditions. This air cleaner filter element can be removed and replaced by rotating the rear housing cap
counter-clockwise and removing it to gain access to the elements. The filter elements can be inspected
either at prescribed service intervals or at any time deemed necessary.
Figure 3 Air Cleaner

Assembly
a) Inspecting the Air Cleaner
Make periodic checks of air cleaner filter element for obstructions. If any obstructions are present,
remove them.
Check all connections for proper sealing.
b) Changing the Air Filter
1. Rotate the rear housing cap counter-clockwise and remove the cap.
2. Remove the filter element and replace.
3. Replace the rear cap housing back on the air filter housing.
c) Disposal
Dispose of the filter properly per local guidelines.

Page 6
4) Engine Fuel
a) How to select fuel quality
The quality of fuel oil used in the diesel engine is a major factor in engine performance and life. Fuel
oil must be clean, completely distilled, stable and non-corrosive.
CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely important that
the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause
severe damage to both the injection pump and the injection nozzles.
CAUTION
The use of low lubricity fuels (i.e. Jet-A or JP8) can shorten life and/or damage the
engine’s fuel pump. The engine manufacturer recommends only diesel fuel.
For recommended fuel specifications that meet the EPA/CARB/EURO emissions, refer to the engine
manufacturers operation and maintenance manual provided with this manual. In general, fuels
meeting the properties of ASTM number 2D will result in optimum engine performance.
b) Cold Weather Operation
In cold weather, diesel fuel will form wax crystals, which can restrict flow and clog filters. Fuel oil
suppliers approach this problem several ways. Some provide a specially refined product, while
others may use flow-improving additives or winter blends. Winter blended fuel can contain a blend of
number 2D and 1D fuel providing good cloud point temperatures. These blended fuels may be used,
but they may result in reduced engine power and/or fuel consumption.
In most cases, adequate resistance to cold can be obtained by adding an additive. For further
assistance contact the nearest engine manufacturer’s service representative.
5) Engine Fuel System

The fuel system consists of a fuel tank, fuel supply line, fuel/water separator (lubricity additive fuel filter),
fuel lift pump, engine primary fuel filter, and the fuel return line. The following are maintenance
procedures for each of these items.
a) Fuel Tank
Be sure that no foreign objects are permitted into the fuel tank. The fuel tank must be removed and
flushed out if objects are found in the fuel filters.
b) Fuel Supply Line
The fuel supply line takes fuel from the tank and delivers it to the fuel/water separator. No
maintenance, repair, or replacement is required unless fuel leaks or cracks or noticed.

Page 7
c) Fuel/Water Separator (Lubricity Additive Fuel Filter)
The fuel/water separator is mounted on the engine flywheel housing near the fuel fill location. Its
function is to remove foreign material, extract water from the fuel before it enters the fuel lift pump
and automatically add lubricity additives to the fuel. Daily draining of the filter/water separator is
required.
• Draining the fuel/water separator:
1. Open drain valve
2. Drain accumulated water and contaminants.
3. Close drain valve.
• Priming fuel/water separator:
1. Loosen the vent plug.
2. Pump until fuel purges at the vent plug.
3. Close the vent plug and start the engine. Check for leaks,
4. Correct or repair leaks as necessary with the engine off.
• Changing the fuel water/separator element:
The filter element replacement part number:
• ITW GSE Part No. 286897-031

• Cummins Part No. FS20022
1. Drain off some fuel by loosening the vent plug and opening the drain valve.
2. Shut off fuel valve.
3. Remove the element and clean the O-ring gland in the filter head.
4. Apply a coating of clean fuel or motor oil to the new O-ring and element seal.
5. Screw in the new fuel filter “snug”. Check that the cartridge is seated correctly against the
gasket and tighten with a final half turn. DO NOT OVER TIGHTEN!
6. Open fuel valve
7. With the vent plug still loosened pump knob until fuel purges at the vent plug. Close the vent
plug and start the engine. Check for leaks and correct as necessary with the engine off.
c) Fuel Pump
The fuel pump supplies pressure to the fuel system so the diesel fuel can circulate freely. A
consistent check of the fuel pressure maybe necessary at times, because a loss in fuel pressure in
the fuel line may indicate a faulty fuel pump.

Page 8
Fuel/Water Separator Engine Primary Fuel Filter
Engine Fuel Filter Locations

Figure 4
d) Engine Primary Fuel Filter
The primary engine filter removes the smaller particles not removed in the pre-filter stage before the
fuel enters the engine’s fuel pump.
• Replacement fuel filter part number:
• ITW GSE Part No. 286897-036

• Cummins Part No. FF5612
• Change the fuel filter after every 500 hours.
• Changing the primary fuel filter:
1. Shut off fuel valve.
2. Place a pan underneath the fuel filter to catch spilled fuel.
3. Remove the fuel filter.
4. Catch any fuel.
5. Clean any dirt from the filter head.
6. Apply a light film of oil or diesel on the rubber seal on the new filter.

Page 9
CAUTION
When installing new element, do not over tighten it; mechanical tools may distort or
crack filter head.
7. Fill new filter with diesel fuel
8. Screw in the new fuel filter “snug”. Check that the cartridge is seated correctly against the
gasket and tighten with a final half turn. DO NOT OVER TIGHTEN!
9. Open fuel valve.
10. With the vent plug still loosened pump knob until fuel purges at the vent plug. Close the vent
plug and start the engine. Check for leaks and correct as necessary with the engine off.
e) Fuel Lift Pump
Observe for leaks. Refer to a local engine manufacturer’s agent for maintenance or repair.
f) Fuel Return Line
The fuel return line takes unused fuel from the engine and returns the fuel to the fuel tank. No
maintenance, repair, or replacement is required unless fuel leaks or cracks or noticed.
6) Engine Cooling System

a) General
Cooling system service requires more than maintaining the proper coolant level in the radiator and
protecting the system against freezing. Water should by clean and free of any corrosive chemicals
such as chloride, sulfate, and acids. Any water, which is suitable for drinking, can be used in the
engine when properly treated as described in engine manufacturer’s operation manual. The engine
manufacturer’s representative should be consulted regarding the selection of satisfactory brand,
permanent-type antifreeze for use in the cooling system.
b) Radiator Cap
(1) General
A pressure relief valve is built into the radiator cap. It is designed to open at a pressure of
approximately 15 psi (103 kPa).
WARNING
When removing cap from a very hot radiator, do not turn cap past safety stop until the
coolant has cooled to an acceptable temperature.
(2) Removal
To remove, turn the cap to the left (counter-clockwise) to the safety stop. When all pressure is
released, press down on the cap and continue to turn until the cap is free to be removed.

Page 10
CAUTION
Allow engine to cool before adding coolant.
CAUTION
Do not attempt to repair the valve in a radiator cap in case of failure. Replace with a
new cap.
(3) Installation
When installing the cap, be sure it is turned clockwise as far as it will go so that the pressure
retaining valve will be functional.
c) Coolant
The preparation and maintenance of the coolant solution is important to engine life and is completely
covered in the engine manufacturer’s operation manual. For information regarding coolant
specifications, testing equipment, antifreeze, etc., refer to engine manufacturer’s operation manual or
consult the local engine manufacturer’s representative.
(1) Filling Radiator
A fully formulated type antifreeze meeting the requirements specified in the engine manual should
only be used in the cooling system.
CAUTION
DO NOT mix brands or type of antifreeze. A solution containing two or more types of
antifreeze is impossible to test accurately.
(2) Checking antifreeze solution
Check the solution with a reliable tester when in doubt about antifreeze protection.
d) Draining the Cooling System
To completely empty the cooling system requires draining the engine block and the radiator
assembly.
To drain the cooling system, proceed as follows:
1. Remove radiator cap after coolant is at a proper temperature level.
2. Place a drain pan with at least a 40 quarts (28.4 liters) capacity under radiator to catch coolant.
3. Place the radiator drain hose over the drain pans.
4. Open the radiator drain valves.
5. Allow the system to drain completely.

Page 11
NOTE: Be sure the drain valves do not clog during draining.
6. When the system is completely drained, close the drain valves.
e) Flushing the Cooling System
Flushing the cooling system should be a yearly maintenance procedure. By flushing the system,
clean water is forced through the engine block to remove expired coolant and other contaminants.
f) Cleaning the Radiator Core
Blow out accumulated dirt from the radiator core air passages, using air or water. Bent or clogged
radiator fins often cause engine overheating. When straightening bent fins, be careful not to damage
the tubes or to break the bond between fins and tubes.
NOTE: Direct the air or water in a reverse direction to normal air flow. Normal flow on this
installation is from the engine compartment outward.
g) Filling the Cooling System
The preparation and monitoring of coolant in liquid-cooled engines is especially important because
corrosion, cavitations, and freezing can lead to engine damage. For coolant system protection details
see the engine manufacturer’s operations manual.
• Install coolant:
1. Remove radiator cap. Be sure the radiator drain valve is closed.
2. Pour coolant into radiator very slowly until it reaches the bottom of fill neck. Allow time for
trapped air to escape from the system then continue filling until the coolant level remains at
the bottom of the fill neck.
3. Start the engine and bring up to rated speed and allow the thermostat to open. Add coolant
as trapped air escapes from the system and the coolant level falls.
4. Continue to check coolant level until all trapped air escapes. Add coolant if needed to fill to
the bottom of fill neck. Install radiator cap.
• Inspection/Check
1. Check system for evidence of leaks.
2. Inspect all hoses. Install new hoses as necessary. Tighten hose clamps as required.
3. Check the condition of fan and water pump belts. Replace belts if necessary.
h) Thermostat
Check the thermostat each fall or as required. Refer to engine manufacturer’s operations manual for
recommended instructions.

Page 12
7) Generator Maintenance
The only maintenance service required for the generator will be brush replacement, slip ring cleaning, etc.
Figure 5 Generator Revolving Field

Brushes
a) Brush Service
If inspection reveals that brushes are gummy or sticking in the brush holders, they should be removed
and cleaned. Clean both the brushes and brush holders. Use a good, safe, commercial cleaner. Dry
all parts thoroughly. Be sure brushes can move freely in brush holders.
CAUTION
Do not use a flammable solvent. Be sure the unit is completely dry before
operating.
b) Generator Revolving Field Brush Replacement (See Figure 5)
1. Disconnect leads (A) from connectors on brush holder caps (B).
2. Remove brush holder caps (B) from brush holder.
`WARNING
When removing the lead wires, do so one at a time and replace each brush
accordingly, to insure that the lead wires are put pack onto the proper
brushes.
3. Lift brush (D) from brush holder (C) for inspection. If brushes are worn unevenly or are shorter
than 7/16 inch (11 mm), replace them.

Page 13
4. Inspect slip rings whenever brushes or brush holders are removed for servicing. Note surface
conditions of rings. Surface should appear smooth and clean. Scoring or roughness of slip rings
may be caused by grit or abrasive substance in brushes, or by oil on the rings. Moderately rough
slip rings can be smoothed by holding grade 00 sand paper against their surface while the rings
are revolving slowly. If the rings are badly scored, the unit must be sent to an overhaul facility for
repair. After cleaning slip rings, blow dirt and grit out of the unit with compressed air. Do not use
over 25 psi (172 kPa) air pressure to blow dirt out.
5. Slip new brushes into brush-holder guides, and place caps on top, and screw them into the
guides to a “bottomed” position. The spring attached to the brush will determine the pressure at
which the brush contacts the slip rings.
6. To fit new brushes to the slip rings, lay a strip of No. 00 sand paper, smooth side down, on slip
ring surface, and draw the sand paper in the direction of rotation of the slip ring, lifting the brush
on the return stroke. Continue until the brushes have same curvature as the slip rings. Blow all
carbon dust out of the machine using no more than 25 psi (172 kPa) air pressure.
7) Drive Belt
a) General
The engine cooling fan, alternator, and water pumps are driven by one serpentine belt, which must be
replaced if worn or damaged.
b) Preparation for Belt Check and Adjustment
All driven assemblies must be securely mounted in operating position before checking belt tension.
c) Checking Belt Tension
Check belt tension every 1000 hours or once year, whichever comes first. A belt that is too tight is
destructive to bearings of the driven part. A loose belt will slip and cause inefficient operation of the
part being driven as well as wear to the belt.
CAUTION
Inspect and replace the belt if it has unacceptable cracks, is frayed, or has pieces of
material missing.
Belt tension may be checked by hand. To do so, manually depress the belt with an index finger to
determine the amount of belt deflection obtained. When a force is applied at a point halfway between
pulleys on the longest span of a belt, there should be no more than one belt thickness per foot of
deflection.
Refer to the engine manufacturer’s operation manual for checking belt tension and changing worn
belts.

Page 14
Section 3 Adjustment/Test
1) General
These adjustments and test procedures are applicable to testing and adjusting the generator set after
major repair, major parts replacements, or overhaul.
2) Testing the Generator Set

a) Pre-operational Test Procedures
1. Check engine oil level. Oil should be at high bar on the dipstick.
2. Check radiator coolant level.
3. Check tension of drive belt.
4. Inspect for oil, fuel and coolant leaks.
5. Check control panel lights and fuse by toggling panel light switch. If panel lights operate, the
fuse, switch, and lamps are good.
6. Make a general inspection of all wiring and terminals. Inspect the equipment to be certain no
damage will result from starting the engine.
7. Connect the output cable to a load bank. The output cable consists of two single conductor
cables not more than 30 feet (9 m) long. The diameter size of each of these two cables is
determined by the maximum rating current expectations:
- Use No. 2/0 cable for < 600 amperes of current.

- Use No. 4/0 cable for > 600 amperes of current.
Be sure the generator output “N” cable is grounded.
b) Operational Test Procedures
1. Start the engine and let it warm up at idle speed.
2. Inspect for oil, fuel, and coolant leaks.
3. Check the engine voltmeter for proper voltage.
4. Check oil pressure gauge. It should read 35 to 60 psi (241 to 414 kPa).
5. Check water temperature gauge. It should read 180 to 200º F (82 to 93º C) when engine
thermostat is fully open.
6. Observe engine RPM on the tachometer, idle speed should be 1000 RPM ± 50 RPM.
7. Place the “SPEED CONTROL” toggle switch into the “RATED RPM” position. The engine’s
operating speed should be 1800 ± 50 RPM.

Page 1
16 18 17 1 14 2 8 3 4
12 11 13 9 10 15 7 6 5


Page 2
8. Check for 28.5 output voltage on generator voltmeter to assure automatic voltage buildup.
9. Set “STARTING CURRENT” limiting control potentiometer to the maximum full clockwise
position.
10. Adjust the load bank for a load of 600 amperes.
11. Place the “28.5 VDC OUTPUT CONTACTOR” toggle switch in the “CLOSED” position. The
“28.5 VDC OUTPUT CONTACTOR CLOSED” lamp will glow as the contactor closes. Release
the contactor control toggle switch to the center “ON” position. The tachometer will indicate an
engine speed of 1800 ± 50 RPM.
12. Remove the load from the load bank and check the over-voltage protection by adjusting voltage
regulator potentiometer (R66) to increase the voltage. The over-voltage relay will trip and open
the load contactor between 32 to 34 V DC.
13. Re-adjust the voltage to 28.5 VDC and re-apply the 600 amperes to the load bank and close the
contactor.
14. Remove the load from the load bank and check voltage regulation at no load. Voltage will be
28.5 VDC. Re-apply loads to the load bank and check voltage regulation with load bank settings
of 137, 275, 413, 550, and 600 amperes and check voltage at each setting. Voltage will be 28.5
± 1 VDC at each different load.
15. With the “STARTING CURRENT” limiting control potentiometer set to 2000 apply 600 to 700
amperes load to the generator and then set the current limiting control potentiometer to 400.
Current displayed on ammeter will be 400 ± 40 amperes.
NOTE: Voltage will not drop below 14 VDC.
16. Set “STARTING CURRENT” limiting control potentiometer to 2000 and apply a 1200 amperes
load. Then set the “STARTING CURRENT” limiting control potentiometer to1000 amperes.
Current displayed on ammeter will then be 1000 ± 100 amperes.
17. Remove load. Set engine to idle and stop the engine which will engage the delayed shutdown.
a) Voltage regulator adjustment
(1) 28.5 Volt Adjustment
The operating voltage is determined by the position of the regulator potentiometer (R66) setting.
Clockwise (CW) rotation increases the voltage level at which the unit operates. Conversely,
counter-clockwise (CCW) rotation decreases the voltage level.
(2) Line-Drop Compensation
Line-drop compensation allows the voltage at the load end of the output cable to remain constant
despite the voltage drop associated with the output cable. Clockwise (CW) rotation of the single-
turn potentiometer (R12) increases the compensation. This potentiometer should be set for flat
regulation of voltage at the load end of the output cable when delivering rated load current.

Page 3
1. 28.5 VDC Output Voltage Adjustment (R66)
2. Line Drop Compensation Adjustment (R12)
Figure 2 Voltage Regulator PC Board

Page 4
Section 4 Troubleshooting Procedures

1) General
The Troubleshooting Chart, located in the section, covers the common malfunctions that you may find
during operation or maintenance of this equipment. It cannot list all the malfunctions that may occur. If a
malfunction is not listed in the chart, start looking for the cause at the source of power in the affected
circuit. Refer to the schematic and connection diagrams in Chapter 5 and test the circuit step by step
until the source of the malfunction is isolated.
The Troubleshooting Chart is arranged under 3 headings: Trouble Symptom and Condition, Probable
Cause, and Test Check and/or Remedy. Trouble, Symptom, and Condition are described and numbered.
Probable Cause is indented to the right and listed in numbered steps. Test Check and/or Remedy
provide instructions for correcting the malfunction.
2) Equipment for Troubleshooting
WARNING
Exercise extreme care to avoid contact with high voltage leads and components.
High voltage can kill!
CAUTION
Maintenance personnel must be very careful when performing terminal-to-terminal
checks to be certain the proper terminals are being used, especially when using
jumper leads. Damage to electrical components may result from the application of
improper voltage and current.
A good quality multi-scale voltmeter is the only instrument required for troubleshooting. At least two
jumper leads with alligator, or similar clips, will be required. The engine electrical system may be
used as a 12 VDC power source.
3) Check Connections and Leads

ALWAYS make a check of connections and leads of a component suspected of being faulty. With the
exception of a few instances, we will assume that all connections and wiring have been checked first and
that power has not been lost as a result of defective wiring or connections.
4) Illustrations
Items in figures 1 and 2 are referred to throughout the Troubleshooting Chart
5) Connection and Schematic Diagrams

All connection and schematic diagrams for generator, engine, lights, and all controls are located in
Chapter 5.

Page 1
16 18 17 1 14 2 8 3 4
12 11 13 9 10 15 7 6 5


Page 2
3 11 5 23 24 4 6 2
8
9
7
12
13 10 1
14
15
16
17
22 21 20
18
19
1. Over Voltage Relay (K403)
13. Check Engine Indicator (DS68)
2. Voltage Regulator (VR402)
14. Check Stop Indicator (DS67)
3. Excitation Rectifiers (CR417 and CR418)
15. Engine Fault Code Switch (S82)
4. Control Windings Fuses (10 A) (F406 - F408)
16. Engine Diagnostic Switch (S80)
5. Voltage Build-up Fuse (10 A) (F405)
17. Light Circuit Breaker, 10 A (CB11)
6. Voltage Regulator Fuse (10 A) (F403)
18. Control Circuit Breaker, 5 A (CB7)
7. Rectifier Harness Connector (J43)
19. Engine Circuit Breaker, 10 A (CB4)
8. Engine Harness Connectors (J46–Power)
20. Shutdown Rectifier (CR426)
9. Engine Harness Connectors (J47 – Engine)
21. Shutdown Relay(K407)
10. Blocking Rectifier (CR401)
22. Shutdown Timer Relay (K406)
11. 100 MFD, 350 VDC Capacitor (C403)
23. Interlock CE Fuse (0.5 A) (F411)
12. Terminal Block (TB1)
24. Switch Interlock Fuse (5 A) (F413)

Page 3
Engine Controls
Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy
1. Engine will not start and the a. Emergency Stop switch has Check to be sure the Emergency
starter will NOT crank engine. been pressed or is defective Stop is pulled out or replace if
defective.
b. Battery disconnect switch is in Open the canopy doors on and be
the “OFF” position sure the battery disconnect switch
is in the “ON” position.
c. Battery discharged or loose Check voltage across batteries
battery or ground cable terminals. Voltage should be
connection approximately 12.8 volts DC.
Check all battery terminals
connections.
d. Circuit breaker (CB4) is open Check to be sure circuit breaker is
or a defective engine start closed. Place engine start switch
switch (S404). in “Run/Fuel Check” position.
Does fuel gauge operate, if no
replace switch.
e. The oil pressure switch (S403) Replace with a known good oil
is defective. pressure switch and place the
engine start switch in “Run/Fuel
Check” position and press the
engine start pushbutton. If engine
starts, replace oil pressure switch.
f. Blocking rectifier (CR402) Place the engine start switch in
defective. “Run/Fuel Check” position. Check
for battery voltage between the two
small terminals on auxiliary starter
solenoid (L402). If no voltage,
replace rectifier.
g. Defective starter push-button Place engine start switch in
(S401) or auxiliary starter “Run/Fuel Check” position and the
solenoid (L402). auxiliary starter solenoid should
energize. If not, replace solenoid.
If the solenoid energizes and
pressing the “Engine/Start” push
button does not start the engine,
replace push button.
h. Defective starter solenoid L401 Contact engine manufacturer or
refer the engine manuals for
troubleshooting procedures.

Page 4
Engine Controls (Continued)

(continued) i. Defective starter B401 Contact engine manufacturer or
Engine will not start and the refer the engine manuals for
starter will NOT crank engine. troubleshooting procedures.
j. If none of the above, possible CAUTION:
internal engine seizure. Make certain that engine start
switch is in “Off/Shutdown” position
so that engine does not start.
Use a socket wrench on the front

crankshaft pulley to try to turn
engine by hand. If engine will not
turn, internal damage is indicated.
2. Engine will not start. Starter a. Fuel valve at tank closed, or no Check fuel valve and fuel tank level
does crank engine. fuel in tank and engine has lost and correct as required.
its prime.
b. Defective engine fuel lift pump Check fuel filters, fuel lines, and
of plugged up fuel filter or fuel fuel fittings for plugged areas.
lines. If needed, contact the engine
manufacture to inspect or replace
the engine fuel lift pump.
c. Blown ECM engine power Check fuses and replace if
fuses F101 and F102. necessary.
d. Defective engine start switch When the engine start switch is
S404 placed in “Start” position the
engine running light DS407 should
be on and battery voltmeter M401
reporting voltage. If neither,
replace engine start switch.

Page 5
Engine Controls
e. Defective engine control When engine start switch is placed
module (ECM) in the “Start” position check the
engine check lamp DS68 and
engine stop lamp DS67 inside the
control box. The lamps should
briefly come on and then turn off. If
they do not come on contact
engine manufacture about a
possible defective engine ECM.
3. Engine starts then stops when a. Fuel valve at tank closed, or no Check fuel valve and fuel tank level
the engine start toggle switch fuel in tank and engine has lost and correct as required.
S404 is released to “Run/Fuel its prime.
Check” position. b. Plugged up fuel filter or fuel Check fuel filters, fuel lines, and
lines. fuel fittings for plugged areas.
c. Performed improper engine Reset the engine circuit by cycling
start sequence. the E-stop button. Hold the engine
start switch in the “Start” position
while pressing the engine start
push button. Once the engine
starts, do not release the engine
start switch until the oil pressure
comes up on oil pressure gauge
M405.
d. Defective oil pressure switch Connect a jumper wire across the
S403 or low oil level. “C” and “NO” terminals of oil
pressure switch. Start the engine
and check the oil pressure. If the
oil pressure is below 20 PSI shut
down the engine and check the oil
level and check for oil leaks. If oil
pressure comes up to normal and
the engine continues to run, the oil
pressure switch is defective and
needs replaced.

Page 6
Engine Controls
(continued) e. Engine in over-temperature Place a clip-lead jumper wire
Engine starts then stops when condition or a defective water across the “C” and “NC” terminals
ENGINE CIRCUIT toggle switch temperature switch S402. of the water temperature switch.
S404 is released to “Run/Fuel Start engine and check water
Check” position. temperature. If above 210° F (99°
C) shut down the engine and let the
engine cool down. If water
temperature is normal and the
engine continues to run, the water
temperature switch is defective and
needs replaced.
f. Defective low coolant level Check engine coolant level. If
switch S416 engine coolant level is good, then
the low coolant switch may be
defective and needs replaced.
Contact engine manufacture.
g. Clogged or blocked air cleaner Check the air cleaner.
4. Engine does not go to the a. Speed control toggle switch If engine will not go from idle to
normal rated RPM. S406 defective. rated speed when speed control
toggle switch is in “Rated RPM”
position, turn off engine and take
resistance measurements at speed
control toggle switch terminals
when switching into the “Rated
RPM” position.
Zero resistance should be

measured between terminals.
Replace if measurement is other
than zero.
b. The engine’s ECM may be Contact engine manufacturer or
defective or corrupt engine refer the engine manuals for
calibration.. troubleshooting procedures.

Page 7
Engine Controls
5. Engine lacks power a. Engine control module is de- Check ECM for fault codes and
rating the output. contact engine manufacturer.
b. Insufficient air to engine. Check air filter for blockage and
replace or clean as required.
c. Improper fuel being used. Check to be sure ASTM number 2D
diesel fuel is being used.
d. Plugged up fuel filter or fuel Check fuel filters, fuel lines, and
lines. fuel fittings for plugged areas.
e. Restricted exhaust system. Check exhaust pipe for restrictions.
Check muffler for plugged up
condition. Replace and/or clean as
required.
6. Engine Overheats a. Debris and dirt in radiator and Clean radiator core carefully and
CAC cores. remove any restrictions, dirt and
debris.
b. Dirt or sludge in coolant. Drain coolant, flush radiator, put in
clean coolant. Refer to the Engine
Manufacture’s Operation and
Maintenance Manual.
c. Fan belt slips or is broken. Tighten belt or replace as required

Page 8
Generator and Controls

1. Generator will not build up a. Voltage build-up fuse F405 is Check and replace the fuse as
voltage when speed control blown. required.
toggle switch S406 is placed in b. Voltage regulator fuse F403 is Check and replace the fuse as
rated “RPM” position. blown required.
c. Defective excitation rectifier Check excitation rectifiers with an
CR417 and/or CR418. ohmmeter to see if they are good. If
either of the rectifiers is defective,
replace them.
d. Defective fly-back diode Check fly-back diode on brush
CR419. holder mounting bracket with an
ohmmeter to see if it is good. If
diode is defective, replace it.
e. Defective rectifier CR401 Use ohmmeter to check rectifier
CR401. Replace the rectifier if
defective.
f. Defective voltage regulator Replace voltage regulator with one
board VR402. known to be good, and then
operate the generator set under
sufficient load to observe current
limiting. If current limiting control
potentiometer now controls current
properly, replace the PCB..
g. Generator revolving field L406 Measure resistance between these
defective. two wires coming from CR419.
The reading should be 10 to 11
ohms. If reading indicates an
open, short or lower than normal
resistance, proceed to next step.
h. Shorted power diodes CR405- Disconnect and check diodes with
CR416. an ohmmeter to see if they are
good. If any diodes are defective
replace.

Page 9

i. Defective generator armature If check of the generator revolving
G402. field (in the previous step) reveals
no trouble, the generator stator is
defective. Contact Hobart factory
for details.
2. Generator builds up to only low a. Defective excitation rectifier Check excitation rectifiers with an
voltage when the speed control CR417 and/or CR418. ohmmeter to see if they are good. If
toggle switch S406 is place in either of the rectifiers is defective,
rated “Rated RPM” position. replace them.
b. Blown fuse or fuses F406-F408 Check and replace the fuse(s) as
required.
c. Defective generator armature If check of the generator revolving
G402. field (in the previous step) reveals
no trouble, the generator stator is
defective. Contact Hobart factory
for details.
3. Generator builds up to a high a. Defective rectifier CR401 Use ohmmeter to check rectifier
voltage when the speed control CR401. Replace the rectifier if
toggle switch S406 is place in defective.
rated “Rated RPM” position. b. Defective excitation rectifier Check excitation rectifiers with an
CR417 and/or CR418. ohmmeter to see if they are good. If
either of the rectifiers is defective,
replace them.
c. Defective voltage regulator Replace voltage regulator with one
4. Load contactor will not close a. Circuit breaker CB7 open Check to see if circuit breaker CB7
when contactor control toggle is closed.
switch S408 is placed in b. Defective contactor control Replace switch.
“Closed” position. Engine toggle switch S408.
running normally, voltage
normal, no load applied to c. Defective speed control toggle Use ohmmeter to check speed
output cable. switch S406. control toggle switch. Replace
switch if defective.

Page 10

(Continued) d. The over-voltage PCB relay Connect a jumper lead between
Load contactor will not close defective K403. terminals T and P on the over-
when contactor control toggle voltage relay. If contactor closes,
switch S408 is placed in replace over-voltage PCB relay.
“Closed” position. Engine e. Defective load contactor K402. With engine at rated speed and the
running normally, voltage S408 held in the “Closed” position,
normal, no load applied to check for 28 VDC between K402
output cable. auxiliary coil terminals. If voltage is
present, contactor is defective and
needs replaced.
f. Interlock voltage is not being Place digital multi-meter on fuse
sensed. F413 checking voltage to ground is
24 to 30 VDC. If voltage to ground
is below min. replace fuse and
check again. If issue still exist
verify aircraft is looping power
back to interlock.
5. Load contactor opens as soon a. Defective contactor control Replace switch.
as contactor control toggle toggle switch S408.
switch S408 is released from b. Defective load contactor K402. With engine at rated speed and the
its “Closed” position to the S408 held in the “Closed” position,
“On” position. check for 28 VDC between K402
auxiliary coil terminals. If voltage is
present, contactor is defective and
needs replaced.
6. Load contactor K402 opens a. Contactor opening could have Resume operation and closely
during power delivery. been normal because of an observe voltmeter for evidence of
over-voltage condition. over-voltage. If contactor opens
when no over-voltage condition
exists, proceed to next step.
b. The over-voltage PCB relay Check over-voltage relay by
defective K403. operating the machine under load
and gradually raising voltage at the
voltage regulator while observing
voltmeter. Start with a low voltage
(25VDC) and gradually increase
voltage until relay functions to open
load contactor (32 to 34V).
c. The over-voltage PCB relay If relay trips at less than 32 VDC,
K403 out of adjustment. adjust potentiometer (R12) on the
over-voltage board. If this does not
correct problem, replace the PCB.
d. Output load contactor K402 If no fault was found in above
defective. steps, replace load contactor

Page 11

7. Output current cannot be a. Defective current limiting Shut down engine and check
limited by current limiting control potentiometer. potentiometer with an ohmmeter.
potentiometer R402. Disconnect the plug (P404) from
the regulator board and take
resistance measurements from pin
2 to pin 9 and then from pin 2 to pin
10 on the plug. For each
measurement, slowly turn current
limiting control potentiometer
through its entire range, while
observing the ohmmeter readings.
Resistance should be from 0 to 10k
ohms. Replace if necessary.
b. Defective voltage regulator Replace voltage regulator with one

Page 12
Chapter 3 Overhaul/Major Repair

Section 1 Flexible Coupling
1) General
This section provides basic instructions for removal, service and installation of a flexible coupling kit, with
a fan attached. This flexible coupling kit is designed for use with single-bearing generator sets. Figure 1
shows a rear view and side view of the flexible coupling assembly. The primary function of this assembly
is to couple a Hobart generator set to a diesel engine. The flexible coupling assembly compensates for
slight misalignment between the engine and the generator, due to manufacturing tolerances. A split taper
bushing secures the coupling to the generator’s armature shaft (See Figures 3 & 4).
Figure 1 Flexible Coupling

Page 1
2) Coupling Screws (Routine Coupling Maintenance)
CAUTION
Failure to verify proper coupling screw installation may result in coupling
failure and damage to the equipment.
If the generator set is functioning properly, servicing the coupling assembly will be essentially limited to
checking the screws that attach the flexible coupling to the engine flywheel of the generator set. These
eight [8] screws should be checked periodically to make certain that: (1) screws of proper type, length,
and hardness are installed, (2) that the threads of the screws are not stripped, and (3) that they are
torqued properly. Follow the procedure below to check the coupling screws:
1. Remove the sheet metal covers from around the generator housing and the flywheel housing.
2. Refer to Figure 2. Hold a short iron bar through the flywheel housing against the blades of the fan
and coupling assembly to prevent rotation of the generator. Do this carefully to avoid damaging the
fan blades.
3. Use a long-handled, reversible ratchet drive fitted with a 5/16-inch Allen wrench to remove one
coupling screw. Examine the screw. Screws specified for this coupling are Hobart Part No. 402789-
004, which are socket-head, 3/8-16 X 3/4 inch long. NOTE: Use of the proper coupling screws for
replacement is very important. Replacement screws must be those specified above, torqued to 40 -
45 foot-pounds (54 - 61 Nm). There is no acceptable substitute for these screws.
4. Check the threads of the screw for stripping and replace it if the threads are stripped. If the screw is
not stripped, reinstall it and torque it to 40 - 45 foot-pounds (54 - 61 Nm).
5. Repeat the steps 2, 3, and 4 above for the remaining seven screws.
6. Reinstall covers around housings.
Figure 2 Access to Coupling

Bolts
(for removal or installation)

Page 2
3) Disassembly
Removal of the flexible coupling is required for servicing the generator armature, generator bearings, or
the coupling itself. To remove the coupling, for any reason, it is necessary to separate the engine and
generator. During removal, DO NOT cut any cables or wires. Disconnect cables or wires as necessary
and tag them for reassembly.
a) Separate Engine and Generator
1. Remove canopy components and any other components to allow for complete access to the
coupling assembly area.
2. Remove the sheet metal cover from around the generator housing and the flywheel housing.
3. Attach a hoist to the generator housing.
4. Use a long-handled, reversible ratchet drive fitted with a 5/16-inch Allen wrench to remove the
screws that attach the flexible coupling disk to the engine flywheel. Reference Figure 2 for locking
the coupling into place.
5. Support the rear of the engine with another separate hoist or other suitable supporting
mechanism.
6. Remove the bolt in the shock mount attaching the generator housing to the frame.
7. Remove the bolts attaching the generator housing to the engine flywheel housing.
8. Separate the generator from the engine with the hoist and move it to a clear working area.
b) Remove Coupling Assembly (Figure 3)

1. Remove all three of the screws that secure the bushing to the hub of the fan and coupling
assembly.
2. To separate the bushing from the hub, lubricate two screws and insert them into the additional
threaded holes in the bushing. Tighten these screws into the bushing until that the bushing pops
loose from the hub.
3. Using a 3/16-inch Allen wrench, loosen the set screw in the bushing to release pressure on the
key.
4. When the bushing is loose in the hub, use a mallet to GENTLY tap the bushing out of the hub.
5. Slide the coupling assembly off the shaft and remove the key.
6. Inspect the coupling assembly components carefully as follows:
a Check for deformed or damaged fan blades and damage to the disk.
b Check hub and split bushing for cracks, evidence of galling, and rust pits. Light rust is
permissible on the split bushing and the tapered bore of the hub.
c Check the flexible coupling disks for warping, cracks, or worn mounting holes.
d Check the screws that attach the flexible disks to the hub (if required). The socket head
screws are Hobart Part No. 287935-001 [3/8 - 16 X 2-1/4 inch long]. If they are loose,
cracked, stretched, or have stripped threads, replace them.
NOTE: Use of the proper coupling screws and washers for replacement is very important.
Replacement screws and washers must be those specified above. There is no acceptable
substitute for these screws or washers.
e Check the shaft for any damage or deformation where the coupling was mounted on it.

Page 3
5 2 6 4 3
1. Taper Bushing
2. Taper Bushing Split
3. (3) Mounting Holes for fastening bushing into place
4. (2) Tapped holes for breaking bushing loose
5. Key
6. Set Screw Location
Figure 3 Split Taper Bushing

Page 4
4) Coupling Installation and Re-assembly of Engine and Generator
CAUTION
Improper installation of the coupling assembly can result in serious damage to
the equipment. Follow these installation instructions exactly.
a) Cleaning
It is very important that the shaft, the bore, the outside of the split bushing, and the taper inside of the
hub be thoroughly cleaned free of dirt and grit.
CAUTION
Do not lubricate any of the surfaces. Lubrication of these surfaces can
cause the coupling to fail and damage the generator set. Slight traces of
rust are permissible only on the bushing, but nothing else.
b) Assembly (Reference Figure 4)

Proceed as follows to reassemble engine and generator.
1. If required, attach the four flexible disks to the coupling hub with the six [6] socket head 3/8-16 X
2-1/4 inch screws (Hobart Part No. 287935-001). The screws must be torqued to 40 - 45 foot-
pounds (54 - 61 N-m) and have had Loctite 262, or equivalent, applied to the threads.
2. Attach the coupling assembly to the flywheel, using the socket-head 3/8-16 X 3/4 inch screws and
vibration proof washers (install small teeth side facing the flex disk and bolt head). Apply Loctite
262, or equivalent, to the threads and do not tighten until all screws are installed.
3. Torque all of the coupling screws to 40 - 50 foot-pounds (54 - 68 N-m). Be sure the flexible disks
are all seated evenly into the seat of the flywheel.
4. Install the key in the keyway of the armature shaft.
5. Place the coupling bushing on the shaft of the armature, aligning the keyway of the bushing with
the keyway of the shaft.
6. Using a hoist, align the bushing to the fan coupling keyway and also the generator housing flange
to the engine flywheel housing, and insert the attaching screws for the housing. Start the screws
into the tapped holes just enough to ensure thread engagement. Do not tighten until all screws
are installed.
7. Tighten the generator housing attaching screws 30 foot-pounds (41 N-m).
8. Remove the bearing cap from the back of the generator assembly.
9. Inspect the rear bearing. If it has moved in the rear bearing support hub it will need to be reset.
Correct placement of the rear bearing should be within 1/8” from the rear surface of the bearing
hub.
10. Slide the split taper bushing forward until it is snug in the fan coupling hub.
CAUTION
Make certain that only the screws are lubricated, and that no lubricant
is permitted to get inside the bushing where the armature shaft will
enter the bushing.

Page 5
11. Lubricate the three bushing screws SPARINGLY and start them into the three (unthreaded) holes
finger-tight (See Figure 4).
12. Refer to Figure 2. Insert and hold a short iron bar through the flywheel housing against the fan
blades of the fan and coupling assembly to block the armature against clockwise rotation. Do this
carefully to avoid damaging the fan blades.
13. Tighten the bushing screws alternately and evenly as follows:
a Set a torque wrench to 30 foot-pounds (41 N-m) and tighten all three screws to that value.
Note that when these screws are tightened, the armature will be pulled back into the bearing
hub and a gap of .313 inches (8 mm) should still exist between the hub and bushing flange.
b Repeat step (a) above until screws can no longer be tightened. This step may need to be
repeated as many as 5 times to assure proper torque on bolts.
14. Once again, make certain that the armature is pulled slightly into the rear bearing hub (so that it
does not interfere with the bearing cap).
15. Using a 3/16-inch Allen wrench, tighten the setscrew in the bushing to apply pressure on the key.
16. Re-install the generator housing cover and the flywheel housing cover.
17. Re-install all other components.
c) Checking the Rear Bearing Hub Assembly
The next steps are performed to assure that the rear bearing outer race does not spin in the bearing
support hub.
1. Carefully remove brush holder from the bearing support.
2. Remove the bearing cap.
3. Remove the 6 bolts attaching the bearing support to the housing.
4. Carefully attempt to slide bearing support hub off the bearing.
5. Note: If the bearing support hub will not slide off the bearing or bearing begins to slide on the
shaft, “STOP” the bearing outer race is secure. Re-attach the bearing support hub to the
generator housing and proceed to step 7.
6. If successful in removing the bearing support, apply a thin bead of Loctite RC-680 Retaining
Compound to the inside of the bearing support hub.
7. Re-install bearing support hub on bearing and reattach the bearing support hub to the generator
housing.
8. Re-install brush holder.
9. Re-install the bearing cap.
10. Re-install the generator housing cover and the flywheel housing cover (if removed).
11. Re-install all other components.

Page 6
Figure 4 Assembly Procedure Illustration

Page 7
5) Run-in after Assembly and Periodic Check

1. Mount the engine-generator assembly in a suitable test area and operate it for a 2-hour run-in.
2. Shut down the engine after 2 hours and re-torque all coupling screws to 40 to 45 foot-pounds (54
to 61 Nm) to compensate for normal torque relaxation.
3. Return the unit to normal service.
4. After 200 hours of operation, check all coupling screws and taper-lock bolts with a torque wrench
set at 40 to 45 foot-pounds (54 to 61 Nm).
5. Return the unit to normal service.
6. After each additional 2,000 hours of operation (or every year), recheck all coupling screws to
maintain the same torque value.
6) Coupling Service
When ordering coupling kits, or other parts, from your Hobart Ground Systems or Company Distributor,
be sure to include all pertinent information from the unit’s identification plate like the Specification No.,
Model No., and unit rating.
If you have any questions concerning your Hobart Ground Systems equipment, immediately contact our
Service Department by mail, telephone, e-mail, or FAX.
Write: ITW GSE Americas

Service Department
Palmetto, FL 34221
U.S.A.

(877) 874-5322 (Service)

(941) 721-1000 (Spare Parts)
FAX inside U.S.A. (877) 874-5321
[email protected]

Page 8
Chapter 4 Illustrated Parts List

Section 1 Introduction
1) General
The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail
parts of a Diesel Engine-Generator Set manufactured by ITW GSE, Palmetto, Florida.
2) Purpose
The purpose of this list is to provide parts identification and descriptive information to maintenance and
provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare
parts.
3) Arrangement
Chapter 4 is arranged as follows:
Section 1 – Introduction/ Numerical Index

Section 2 - Manufacturer’s Codes
Section 3 - Parts List
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:
• Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are
available commercially
• Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available
• Permanently attached parts, which lose their identity by being welded, soldered, riveted, etc., to
other parts, weldments, or assemblies
b) Parts List Form
This form is divided into six columns. Beginning at the left side of the form and proceeding to the
right, columns are identified as follows:
(1) FIGURE- ITEM NO. Column
This column lists the figure number of the illustration applicable to a particular parts list and also
identifies each part in the list by an item number. These item numbers also appear on the
illustration. Each item number on an illustration is connected to the part to which it pertains by a
leader line. Thus the figure and item numbering system ties the parts 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.
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 and his part number will appear in the
“NOMENCLATURE” column. Vendor parts, which are modified by Hobart, will be identified as
such in the “NOMENCLATURE” column. In case Hobart does not have an identifying part number
for a purchased part, the “HOBART PART NUMBER” column will reflect “No Number” and the
vendor’s number will be shown in the “NOMENCLATURE” column. Parts manufactured by Hobart
will reflect no vendor 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, components of an assembly are listed directly below the assembly and
indented one space. Vendor codes and part numbers for purchased parts are also listed in this
column when applicable. Hobart modification to vendor items is also noted in this column.
(4) EFF (Effective) Column
Not Applicable
(5) QTY. 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.

Page 2
Numerical Index
6)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 alphanumerical sequence.
FIGURE – ITEM NO. HOBART PART NO. FIGURE – ITEM NO. HOBART PART NO.
7- 040201 6- 284372-002
7- 040213 1- 285125
10- 042471 15-18 285647
4- 050984 7-25 286388-001
7-10 16DA2162 7- 286477-002
15-6 16DA3493 4-13 286485-001
15-16 180065 7-24 286485-001
8-6 180289A 7- 286607-001
8-3 180593-003 8-11 286611
15-19 180600 7-6 286699-001
17-6 180776 16-1 286810-001
8-5 181022C-005 15-24 286813
17-13 281688 16- 286849
9-1 281881-001 5-13 286850
15-20 282239 15-13 286884
2-13 282562 15-3 286887
13-10 282562 13-1 286897-031
1-25 282658 13-7 286897-036
11- 282918 14- 286903
11- 282919 14- 287144-002
15-26 283063 14- 287145-001
14-11 283154-001 15-1 287184-003
4-10 283597 17-8 287401
4-9 283824 1-14 287459
12- 283873 1-26 287460
8-17 283978-001 13-11 287461
8-16 283978-002 1-15 287462
17-2 284371-002 1-16 287463
5-10 284372-002 6-13 287464
Page 3
1-18 287465 5- 24656

1- 287466 6-8 24656
1-13 287467 1- 288120
4- 287526-002 12- 288123-001
4- 287542-001 11-5 288197-001
4- 287542-002 17-1 288210
5-7 287564 1- 288300
6- 287564 8- 288303
17-3 287564 15- 288306
1-19 287571 14-12 288331
8-8 287621 8-14 288339
1-17 287696 15-7 288380-001
1- 287698-001 7- 288836-001
14-2 287735 7- 288836-002
4- 287785 1-22 288862
9-4 287795 1-12 288866
9- 287796 1-10 288917-002
7-9 287908 1-32 288918-002
12-11 287909 5-14 288973-001
14-8 287909 17-4 288984-001
2-5 292016 5-6 288985
5-15 292016 6-4 288985
3-5 287986 17- 288985
2-3 287998 1-28 288987-006
3- 287998 7-13 288999-001
5- 288003 13-8 289037
6- 288003 7- 289078
17-9 288003 7-2 289092
15-28 288015 7- 289104-001
1- 288020 12-7 289200-001
7-23 288020 12-9 289200-002
1- 288023 1- 289278
10- 288052-002 12-14 289827

Page 4
12-13 289828 7-18 290957

12- 290145 8-1 290958
1-23 290216 8-15 290959
13- 290388 7-19 290981
11- 290597-001 2-4 292012
12- 290597-001 1-1 292042
11- 290597-006 2-1 292042
11- 290597-007 5- 292011
17-10 290646 6-7 291054
13-2 290685 3-4 291056
13-6 290686 4-14 291057
5- 290831 3-3 291066
14- 290831 5-5 291066
5- 290847 9-6 291067
14- 290847 3-1 291069
8-21 290871 12-3 291070
9-2 290902 12-4 291071
6-9 290918 12-6 291072
14-3 290918 12-8 291073
8-7 290925-A 12-17 291074
7-3 290931 12-16 291075
7- 290932 13-5 291076
11-3 290936 10-2 291077
12-15 290936 11-10 291078
11-1 290938 4-1 291080
11-9 290939 4-3 291081
11-2 290940 4-5 291084
8-18 290947 4-17 291085
8-22 290948 4-16 291087
8- 290949 2-6 291088
11-8 290951 2-7 291089
11-7 290952 2-8 291092
11-6 290953 9-8 291092

Page 5
2-9 291093 14-4 291334

9-7 291093 4- 291335
12- 291097 15-29 291358
3-2 291152 10-4 291379
5-4 291152 10-5 291380
9-5 291160 10-7 291382
10-1 291168 10-6 291383
10-3 291169 4- 291386
12-1 291223 1- 291393
12-2 291224 6-10 291393
12-5 291225 10-8 291394
4-4 291237-001 5-11 292502
4-2 291237-002 6-6 292502
4-8 291237-003 1-27 291402
4-7 291237-004 2-11 291407
4-19 291237-005 13- 291407
4-18 291237-006 2-12 291408
14-9 291248 13- 291408
1-2 291252 2- 291409
1-30 291253-001 13- 291409
1-31 291253-002 2-10 291420
5-9 292917 13-9 291420
6- 292917 7-1 291431
5-8 291262 8-10 291431
6- 291262 6-2 291432-003
17-15 291262 6- 291432-004
4-6 291297 15-27 291433
4-15 291302 11-4 291453
7-21 291307 9-3 291481
1- 291329 5- 291482
1- 291330 14- 291482
5- 291334 8-24 291864
14- 291334 8-23 291865-001

Page 6
7-15 30GH1119 15-2 405278-006

17-12 354592 14- 405548
16-5 400435 7- 406815
15-8 400589-001 1-24 407366
7- 400613-003 8-4 407948
7- 400613-004 8-19 407948
7- 400613-004 8- 408352
8- 400613-004 7-5 408596-001
7-12 400641-012 1-20 408665-001
7-11 400642-003 1-21 408665-002
8-9 401937-004 17-18 408999-001
1- 402025-003 2- 486719-005
16-6 402025-003 13- 486719-005
15-5 402037-004 17-7 488555-001
17-20 402530 17-16 488562
17-19 402531 17-17 488628
7- 402663 17- 488784
17-21 402788 17-5 489135
1-9 402987 17-22 489426
1-8 403091-008 14- 489658-007
7-14 403189 16- 489658-010
12-10 403782-002 7-4 494134-001
14-7 403782-002 9- 494295
14-6 403809-002 15-11 494681-001
8-2 404065-002 13-12 76B1148
10- 404154-013 1- 77A1157
7- 404172-001 7-8 78A1117-002
8- 404172-001 7-7 78A1120-001
7- 404172-002 14-5 78B1118-002
8- 404172-002 8- 79B1138
7- 404172-003 8-20 79B1140
7- 404173 1- 7J422-000
8- 404173 1-11 81B1084

Page 7
8- 84A1075 15-14 W10933-003

17- 85C1004-002 15-15 W11097-007
15-22 A25 15-17 W11097-007
16- A25 15-21 W11097-022
15-23 AW626 15-9 W11114-012
16- AW626 8- W11166-003
7-22 HF2518-002 8- W11166-011
8-13 HF2518-002 15-25 W11242-018
7-16 HF2518-005 7- W11254-003
8-12 HF2518-005 15-10 W11280-015
7-20 HF2518-007 14- W7814-000
7-17 HF2518-008 12- W7814-004
8- W10051-014 14- W7814-004
17-14 W10072-063 16-2 W9218-251
14- W10750-001 16-3 W9218-251
10- W10869-006 5- W9360-289
15-4 W10869-006 14- W9360-289
14- W10910-000 14-1 W9407-446
15-12 W10931-003

Page 8
Section 2 Manufacturer's Codes
1) Explanation of Manufacturer’s (Vendor) Code List

The following list is a compilation of vendor codes with names and addresses for suppliers of purchased
parts listed in this publication. The codes are in accordance with the Federal Supply Codes for
Manufacturer’s Cataloging Handbook H4-1, (CAGE CODES) and are arranged in numerical order.
Vendor codes are inserted in the nomenclature column of the parts list directly following the item name
and description. If a manufacturer does not have a code, the manufacturer’s full name is listed in the
nomenclature column.
Code Vendor’s Name and Address Code Vendor’s Name and Address
D0024 SEMIKRON ELEKTRONIK GMBH 01XD4 Contact Industries Inc

Sigmundstrasse 200 25 Lex-Industrial Dr
P.O. Box 82 02 51 Mansfield OH 44903 - 8699
Nuernberg, Germany 90431
01428 Tuthill Corporation
E0615 Kraus and Naimer DBA Tuthill Controls Group
42 Miramar Avenue 2110 Summit St.
P.O. Box 15-009 New Haven, IN 46774-9524
Wellington, New Zealand
02660 Amphenol Corp.
S7023 Bossard LTD Fasteners Spectra-Strip/Itd
Steinhauserstrasse 70 40-60 Delaware Ave
Zug, Switzerland, CH-6300 SIDNEY, NY 13838 - 1395
0CYC7 Western Rubber & Supply 02768 Illinois Tool Works Inc.
7888 Marathon Dr Ste Fastex Division
Livermore, CA 94550 - 9314 195 S. Algonguin Rd.
Des Plaines, IL 60016-6197
0E8J0 Emka Inc.
1961 Fulling Mill Rd. 02929 Newark Electronics Div
Middletown, PA 17057-3125 4801 N Ravenswood Ave
Chicago, IL 60640 - 4457
0HZP9 Diesel Radiator Co.
1985 Janice Ave. 05HB5 Magnecomp Inc.
Melrose Park, IL 60160-1008 161 Eagles Nest Dr
Pickens, SC 29671-7808
0MR72 Henkel Corp
26941 Cablot Rd, Suite 124 05YB3 Acon Inc.
Laguna Hills, CA 92653-7007 22 Bristol Dr.
South Easton, MA 02375-1108
0TSE6 Infineon Technologies Industrial Power
Inc. 1AA44 Collmer Semiconductor Inc.
1050 US HWY 22 2542 Highlander Way
Lebanon, NJ 08833-4208 Carrollton, TX 75006
00779 Tyco Electronics (Amp) 1DG36 Phillips And Temro Industries Inc
2800 Fulling Mill Rd Bldg-38 E. M. Products Inc.
Middletown, PA 17057 - 3142 5380 Cottonwood Ln
Prior Lake, MN 55372

Page 1
1DL99 Fleetguard Inc. 2N562 Power Transmission Sales Inc.

Div. of Cummins Engine Company 531 Washington
311 N. Park Street P.O. Box 229
Lake Mills, IA 50450 - 1299 Chagrin Falls, OH 44022-0229
1E045 Austin Hardware and Supply Co. 23803 N T N Bearing Corp of America
950 Northwest Technology Dr 191 Sheree Blvd Ste 101
Lees Summit, MO 64086 - 5692 Exton PA 19341-1265
1SPJ9 ITW GSE 24161 Gates Corporation
11001 U.S. Hwy. 41, N 900 S Broadway
Palmetto, FL 34221 Denver CO 80217-5887
1W134 Eaton Corp. 24446 General Electric Co.
TH
4201 N. 27 St 3135 Easton Tpke.
Milwaukee, WI 53216-1897 Fairfield, CT 06431
12662 Peterson Mfg Co. 25710 Deka Plastics Inc.
4200 E 135th St 914 Westfield Ave.
Grandview MO 64030-2896 Elizabeth, NJ 07208-1222
13445 Cole-Herse 27410 Harris Corp.
20 Old Colony Ave. 1025 W NASA Blvd.
Boston, MA 02127-2405 Melbourne, FL 32901
14552 Microsemi Corporation 28520 Heyco Inc.
2381 Morse Ave 1800 Industrial Way N.
Irvine, CA 92614-6233 Toms River, NJ 08755-4809
14799 Square D Company, Inc 3A054 McMaster Carr Supply Co.
Dba Schneider Electric USA, Inc. 9630 Norwalk Blvd.
9522 Winona Ave Santa Fe Springs, CA 90670-2932
Schiller Park, IL 60176-1084
3Y208 Taylor And Summerville Battery Co
16476 Maxima Technologies & Systems Llc 3485 Successful Way
1811 Rohrerstown Rd Dayton Oh 45414-4319
Lancaster, PA 17601-2321
30104 Automotive Controls Corp.
18265 Donaldson Company Inc. 1300 W. Oak St.
DBA Torit Products P.O. Box 788
1400 W. 94th St. Independence, KS 67301-0788
Minneapolis, MN 55431-2370
30430 Marathon Electric Mfg. Corp.
2B428 MJO Industries Inc. 398 Beach Rd.
DBA Hughes-Peters Burlingame, CA 94010-2004
8000 Technology Blvd.
Huber Heights, OH 45424 - 1573 311K7 Kissling Electrotec Incorporated
320 Business Pkwy, Ste A
2B664 All-Phase Electric Supply Co Greer, SC 29651
1620 W Main St
P.O. Box 149 38151 Marathon Electric Mfg. Co.
Springfield OH 45501-0149 100 E. Randolph St.
Wausau, WI 54401-2568

Page 2
39TH9 Motion Industries Inc. 57347 Wall Industries Inc.

8580 Industry Park Dr. 5 Watson Brook Rd.
Piqua, OH 45356-8535 Exeter, NH 03833-4589
40121 Peterson Mfg. Co. Inc. 57733 Stewart-Warner Corporation
700 W. 143rd St. 333 Ludlow St
Plainfield, IL 60544-9733 Stamford, CT 06902-6987
44655 Heico Ohmite LLC 59656 Dean Technology Inc.
1600 GOLF RD 850 DBA CKE
ROLLING MEADOWS, IL 60008-4204 1000 Lucerne Road
Lucernemines, PA 15754-0211
46922 Crawford Electric Co
445 E 32 Mile Rd 6S553 Wes-Garde Components Group Inc
Romeo MI 48065-5270 300 Enterprise Dr
Westerville, OH 43081-8840
49234 Protectoseal Company
225 W Foster Ave 6Y440 Micron Technologies Inc.
Bensenville, IL 60106-1631 8000 S. Federal Way
Boise, ID 83716-7128
5N8K3 Alpha Devices
11963 Abbey Rd. 60038 Timken Corporation
Cleveland, OH 44133 1835 Dueber Ave Sw
Canton, OH 44706-2728
5P059 Tech Products Corp.
2215 Lyons Rd 61706 EAO Switch Corporation
Miamisburg, OH 45342-4465 98 Washington St.
Milford, CT 06460-3133
50508 Magnetic Components Inc.
9520 Ainslie St. 62292 EBM Industries Inc.
Schiller Park, IL 60176-1191 110 Hyde Rd.
P.O. Box 4009
52793 Saginaw Products Corp. Farmington, CT 06034-4009
DBA CIGNYS
68 Williamson St. 62445 Deutz Corporation
Saginaw, MI 48601-3246 3883 Steve Reynolds Blvd
Norcross Ga 30093
54646 Clampco Products Inc.
1743 Wall Road 66180 Automatic Timing and Controls
Wadsworth, OH 44281-9558 3312 Bloomingdale
Melrose Park, IL 60160-1030
55752 Parker Hannifin Corp.
DBA Racor Div. 66844 Powerex Inc.
3400 Finch Rd. 173 PAVILION LN
Modesto, CA 95354-4125 Youngwood, PA 15697-1800
56289 Sprague Electric Company 7M613 Wright F.B. Co. of Cincinnati
678 Main St 4689 Ashley Dr.
Sanford, MA, 04073-7003 Hamilton, OH 45011-9706
57330 Remke Industries Inc. 71382 Seal Master Bearings
310 Chadick Drive Sub Of Emerson Electric Co.
Wheeling, IL 60090-6039 1901 Bilter Rd.
Aurora, IL 60502-9704

Page 3
71400 Cooper Bussmann Inc. 81703 Mulberry Metal Products Inc.

114 Old State Road 2199 Stanley Terrace
Ellisville, MO 63021-5942 Union , NJ 07083-4399
72619 Dialight Corporation 82866 Research Products Corp.
1501 State Rte 34 S P.O. Box 1467
Farmingdale, NJ 07727-3932 1015 E. Washington Ave.
Madison, WI 53701
74400 Hobbs Corporation
1034 East Ash Street 86797 Rogan Corp
PO Box 19424 3455 Woodhead Dr.
Springfield, IL 62794-9424 Northbrook, IL 60062-1812
74542 Hoyt Electrical Instruments 9Y826 Marsh Electronics Inc.
23 Meter ST. 1563 S. 101st St.
Concord, NH 03303-1894 Milwaukee, WI 53214-4032
74545 Hubbell Inc 91637 Vishay Dale Electronics Inc.
Wiring Device Div 1122 23RD St.
185 Plains Road Columbus, NE 68601-3647
Milford, CT 06460
91929 Honeywell International Inc.
74829 Ilsco Corp. DBA Honeywell
4730 Madison Rd. 11 W. Spring St.
Cincinnati, OH 45227-1426 Freeport, IL 61032-4316
75418 Kysor Industrial Corporation 94222 Southco Inc.
1 Madison Ave 210 N. Brinton Lake Rd.
Cadillac, Michigan 49601-9784 Concordville, PA 19331
75915 Littelfuse, Inc. 97520 Basler Electric Company
8755 W Higgins Road Ste 500 Route 143
Chicago, IL 60631 - 2701 Highland, IL 62249-1074
77342 TYCO Electronics Corporation
8010 Piedmont Triad Pkwy
Greensboro, NC 27409
78388 Woodward Controls Inc.
6250 W Howard St
Niles, Il 60714-3433
8A334 Cummins Bridgeway LLC
2297 SW Blvd Ste K
Grove City, OH 43123-1822
8T246 Whitesell RO & Associates, Inc.
7009 CORPORATE WAY
Dayton, OH 45459-4238
81483 International Rectifier Corp
233 Kansas St.
El Segundo, CA 90245

Page 4
OM 2241-A / Operation and Maintenance Manual
Section 3 Illustrated Parts List

1) Explanation of Parts List Arrangement
The parts list is arranged so that the illustration will appear on a left-hand page and the applicable parts
list will appear on the opposite right-hand page. Unless the list is unusually long, the user will be able to
look at the illustration and read the parts list without turning a page.
2) Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list:
* - Item not illustrated

# - Number or Part Number
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
uF - Microfarad
No. - Number
NHA - Next higher assembly
PRV - Peak reverse voltage
PSI - Pounds per square inch
Ref - Reference (the item has been listed previously)
RH - Right Hand
LH - Left Hand
TM - Technical Manual
T-R - Transformer-rectifier
V - Volt or used as a prefix indicating vendor code
NOTE: An item that does not reflect an index number is an assembly that is not illustrated in its
assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item that is illustrated.
OM2241-A Rev A Change 1 March 29, 2017 Chapter 4-3

Page 1
21 5
20
7
16
19 1
Figure 1 General Assembly

Page 2
FIGURE - HOBART
NOMENCLATURE EFF QTY.
ITEM NO. PART NO.
1- 1 292042 Trailer and Frame Assembly (See Figure 2) A, 1
3 Canopy Assembly (See Figure 3 and 4) Ref.
4 Control Box Panel Assembly (See Figure 7 and 8) Ref.
5 Emergency Stop Switch (below control panel)
77A1157 …Switch, Maintained, Push-Pull (V14799 #KR-9R-H6) 1
291393 …E-Stop Extension Harness
285125 …Guard, Mushroom Button (V14799 # K564M) 1
288300 …Label, Emergency Stop 1
287466 …Label, Emergency Stop 1
* 6 Control Panel Cover
291329 …Controls Cover 1
291330 …Controls Cover Hinge 1
288023 …Wing Knob Latch 2
288020 …Cover Support Bracket 2
289278 …Slotted Latch (optional for CE kits) 2
7 Output Cable and Clamp Assembly
288120 …Output Cable Bracket 1
7J422-000 …Output Cable Clamp 1
287698-001 …Output Cable Cover (unused output cable hole) 1
402025-003 …Cable, DC Output 30 ft. 1
* 8 403091-008 Plastic Hole Plug (if block heater not used) 1
9 402987 Hobart Nameplate (on doors) 2
* 10 288917-002 Label, I.D. (on control panel) 1
* 11 81B1084 Nameplate, Output Cable, 28 Volts 1
* 12 288866 Support Center Label (on back panel) 1
* 13 287467 Label, Glow Plug 2
* 14 287459 General Information (on back panel) 1
* 15 287462 Engine Coolant Label (at radiator cap access) 1
16 287463 Hot Muffler Label (at muffler outlet) 2
* 17 287696 Hearing Protection Label 1
* 18 287465 Falling Objects Label 2
19 287571 Tire Pressure Label (mounted above tires) 4
20 408665-001 Red Reflector (on the ends) 8
Red Reflector 4
21 408665-002 Amber Reflector (on the sides) 24
Amber Reflector 12
* 22 288862 Engine Speed Caution Label 1
* 23 290216 Low Emissions Label (near fill neck) 1
* 24 407366 Label, Caution 1
* 25 282658 Label, Warning, Clearance 1
* 26 287460 Label, Warning, High Voltage 3
Optional Components
* 27 291402 Forklift Pockets (optional accessory, call factory) 1
* 28 288987-006 Cable Tray Rollers (optional accessory, call factory) 1
* 29 Call Factory Spare Tire 1
* 32 288918-002 Option Label (only if options are added) 1

Page 3
2 9
3
15
4 8
1
9 7
6
5
14
12
6
10
8 7
11
Figure 2 Trailer and Frame Assembly

Page 4
FIGURE - HOBART
ITEM NO. PART NO.
2- 1 292042 Trailer Assembly 1
2 12 VDC Battery Components (See Figure 9) 1
3 287998 Front Panel Bracket 2
4 292012 Engine Support (included with frame) Ref.
5 292016 Generator Support (included with frame) Ref.
6 291088 Cable Tray Fender 3
7 291089 Cable Tray Fender 3
8 291092 Cable Tray 2
9 291093 Battery Tray Cover 2
10 291420 50 Gallon Fuel Tank Assembly 1
* 486719-005 …Fuel Gauge Sender 1
11 291407 Fuel Tank Belly Pan 1
12 291408 Fuel Tank Strap 2
291409 …Fuel Tank Strap Gasket 2
* 13 282562 Cap, Fuel Fill, Diesel Green 1
14 Call Factory Spare Tire 1
15 Call Factory Spare Tow bar 1

Page 5
7 4 5
Figure 3 Canopy Assembly

Page 6
FIGURE - HOBART
ITEM NO. PART NO.
3- 1 291069 Front Panel 1
* 287998 …Front Panel Bracket (See Figure 2) 1
2 291152 TR Panel Support Leg 2
3 291066 TR Support Panel 1
4 291056 Control Box Support 1
5 287986 Control Panel Support 1
6 Trailer/Frame Assembly (See Figure 2) Ref.
7 Fuel Tank Assembly (See Figure 2) Ref.

Page 7
6
14 5
8
5 7
15
9
17
7
3
6
11 8 4
12 19
14
2 1 10
18 16
Figure 4 Canopy Assembly

Page 8
FIGURE - HOBART
ITEM NO. PART NO.
4- 1 291080 Fuel Side Lower Door Panel 1
* 292118-003 …Insulation, Lower Panel RH 1
287785 Access Panel Fastener 2
2 291237-002 Fuel Side Lower Door Panel Insulation 1
3 291081 Lower Door Panel 1
* 292118-004 …Insulation, Lower Panel LH 1
287785 Access Panel Fastener 2
4 291237-001 Lower Door Panel Insulation 1
5 291084 Access Door 2
6 291297 Access Door 2
7 292118-001 …Access Door Insulation 2
8 292118-001 …Access Door Insulation 2
9 283824 …Access Door Hinge Assembly (To Door PN 291084) 6
10 283597 …Access Door Hinge Assembly (To Door PN 291297) 6
11 …Access Door Top Latch Assembly 4
291335 ……Access Door Latch Pawl 4
287542-001 ……Access Door Latch, Hex 4
287542-002 ……Access Door Latch, T-Handle 4
287526-002 ……Access Door Latch Pull Tab 4
12 …Access Door Bottom Latch Assembly 4
291386 ……Access Door Latch Pawl 4
287542-001 ……Access Door Latch, Hex 4
287542-002 ……Access Door Latch, T-Handle 4
287526-002 ……Access Door Latch Pull Tab 4
* 13 286485-001 …Access Door Gasket (cut in four 31-inch strips) 124 in.
* 050984 …Access Door Gasket (cut in two 62-inch strips) 124 in.
14 291057 Access Door Stop 2
15 291302 Radiator Cap Access Door 1
16 291087 Lower Rear Panel 1
17 291085 Top Canopy Assembly 1
18 291237-006 …Top Canopy Insulation 1
19 291237-005 …Top Canopy Insulation 2

Page 9
12 5 1 11
6
3
13
2 4
10 9
7
15
Figure 5 Internal Components (Right Side)

Page 10
FIGURE - HOBART
ITEM NO. PART NO.
5- 1 Engine Air Intake System (See Figure 11) Ref.
2 Engine Dongle and Battery Disconnect Panel Ref.
291334 … Engine Dongle/Battery Disconnect Panel 1
290831 … Battery Disconnect Switch 1
290847 …… Battery Disconnect Plate 1
291482 … Disconnect Switch to Starter Cable 1
W9360-289 … Disconnect Switch to Electronics Panel Cable 1
3 Engine Exhaust System (See Figure 10) Ref.
4 291152 TR Panel Support Leg 2
5 291066 TR Support Panel 1
6 288985 Generator Assembly (See Figure 17) 1
7 287564 Fan Housing 1
288003 …Fan Housing Cover 1
8 291262 Generator Support Bracket (mounted on generator) 1
9 292017 Generator Rear Bracket Support 1
10 24656 Mount, Shock 1
11 292052 Cummins QSB4.5 Electronic Engine (V8A334) 1
* 292011 …Bracket, Engine Support 2
* 24656 …Mount, Shock 2
12 Control Box Assembly (See Figures 7 and 8) 1
13 286850 Solenoid, Aux. Starter, 12 VDC 1
* 14 288973-001 Diode, Starter Solenoid 1
15 292016 Generator Support (included with frame) Ref.

Page 11
12 5 6 1 2
16 15
14
9 11
7
8
7
8
Figure 6 Internal Components (Left Side)

Page 12
FIGURE - HOBART
ITEM NO. PART NO.
6- 1 Engine Electronic Panel (See Figure 14) 1
2 291432-003-A Control Box Assembly (See Figures 7 and 8) Ref.
291432-004 Control Box Assembly, CE (See Figures 7 and 8) Ref.
3 Rectifier Assembly (See Figure 15) 1
4 288985 Generator Assembly (See Figures 5 and 17) 1
* 287564 …Fan Housing 1
* 288003 …Fan Housing Cover 1
* 291262 … Generator Support Bracket (mounted on generator) 1
* 292017 …Generator Support Column
* 24656 …Shock Mount 1
5 Engine Cooling System Assembly (See Figure 12) 1
6 292052 Cummins QSB4.5 Electronic Engine 1
7 292011 … Engine Support Bracket 2
8 24656 …Shock Mount 2
9 290918 …Engine Wire Harness 1
* 10 291393 …E-Stop Extension Harness 1
11 Engine Fuel System (See Figure 13) Ref.
12 Exhaust System Assembly (See Figure 10) Ref.
13 287464 Label, Fan and Moving Parts 2
14 3999798 Cummins Parts Elbow 1
15 3903652 Cummins Parts Elbow 1
16 4898590 Clamp 1

Page 13
21 22 2 6 5 4 7 9 10 11 12 13
8 3 14 15 16 17 18 14 19 20 23
24
25
21
1
25
Figure 7 `Control Box Exterior Assembly

Page 14
FIGURE - HOBART
ITEM NO. PART NO.
7- 1 291431 Control Box Mounting Panel 1
2 289092 Control Box Door 1
290932 …Control Box Label 1
288836-001 …Type A Miniature Offset Hinge 1
288836-002 …Type B Miniature Offset Hinge 1
* 289078 …Hinge Spacer (located behind hinge) 2
* 040213 …Neoprene Door Gasket AR ft.
3 290931 Switch Panel 1
040201 …Neoprene Switch Panel Gasket 12.5 ft.
4 494134-001 12 V Electric Fuel Gauge (V16476 #06339-01) 1
5 408596-001 Tachometer (V16476 #71076-00) 1
6 286699-001 Battery Voltmeter (V16476 #06351-001) 1
7 78A1120-001 Hour Meter Gauge (V16476 #56288) 1
8 78A1117-002 Oil Pressure Gauge (V16476 #06340) 1
9 287908 Water Temperature Gauge (V16476 #06343) 1
10 16DA2162 Rheostat Knob (V44655 #5150) 1
286607-001 …Potentiometer 1
402663 … Potentiometer Lock Nut 1
11 400642-003 DC Voltmeter (V74542 #D-1007819T81) 1
12 400641-012 DC Ammeter (V74542 #D-1218619379) 1
13 288999-001 Latch, Control Box 1
14 403189 Toggle Switch (V1W134 #8946K613) 2
15 30GH1119 Pushbutton Switch (V13445 #9095-09) 1
406815 … Pushbutton Switch Boot (V13445 #83280) 1
16 HF2518-005 12 V Amber Pilot Light Assembly 1
* 404173 …Light Base (V72619 #26-1310-11-301) 1
* 404172-002 …Amber Lens (V72619 #26-1133-300) 1
* IL11562 …Bulb (V02929 Type 1815) 1
17 HF2518-008 12 V Green Pilot Light Assembly 1
* 404173 …Light Base (V72619 #26-1310-11-301) 1
* 404172-003 …Green Lens (V72619 #26-1192-300) 1
* 400613-004 …Bulb (V02929 Type 1815) 1
18 290957 Toggle Switch (V91929 #312TS1-59) 2
19 290981 Toggle Switch (V1W134 #8946K613) 1
20 HF2518-007 28 V Green Pilot Light Assembly 1
* 404173 …Light Base (V72619 #26-1310-11-301) 1
* 404172-003 …Green Lens (V72619 #26-1192-300) 1
* 400613-003 …Bulb (V02929 Type 757) 1
* 21 291307 Control Box Housing 1
22 HF2518-002 12 V Red Pilot Light Assembly 1
* 404173 …Light Base (V72619 #26-1310-11-301) 1
* 404172-001 …Red Lens (V72619 #26-1192-300) 1
* 400613-004 …Bulb (V02929 Type 1815) 1
23 288020 Cover Support Bracket 2
24 286485-001 Sealing Gasket 124 in.
25 286388-001 Ring and Bushing Mount 4
289104-001 …#10-24 Shoulder Screw 4
286477-002 …Snubber Washer 4
W11254-003 …#10 Brass Flat Washer 4

Page 15
10 2 3 23 25 1 5 11
7
9
8 4 6
12
13
14 22
15
16 17 21 20 19

Page 16
FIGURE - HOBART
ITEM NO. PART NO.
8- 1 290958 6-Position Fuse Block (V71400 #S8301-6) 1
W11166-003 …10 A Fuse (V71400) 5
2 404065-002 Silicon Rectifier 2
3 180593-003 100 MFD, 350VDC Capacitor Assembly 1
W10051-014 …Plastic Wire Clamp 1
4 407948 Isolated Base Rectifier (V14552 #CT 106) 1
5 181022C-005 Regulator PC Board 1
* 84A1075 …Rubber Mount (V5P059 #51083) 4
6 180289A Overvoltage PC Board 1
* 84A1075 …Rubber Mount (V5P059 #51083) 3
* 7 290925-A Control Box Wire Harness 1
8 287621 …Resistor And Diode Assembly 1
9 401937-004 Terminal Block 1
10 291431 Control Box Mounting Panel 1
11 286611 …Blank Label (when low fuel option is not used) 1
12 HF2518-005 12 V Amber Pilot Light Assembly 1
* 404173 …Light Base (V72619 #26-1310-11-301) 1
* 404172-002 …Green Lens (V72619 #26-1133-300) 1
* 400613-004 …Bulb (V02929 Type 1815) 1
13 HF2518-002 12 V Red Pilot Light Assembly 1
* 404173 …Light Base (V72619 #26-1310-11-301) 1
* 404172-001 …Red Lens (V72619 #26-1192-300) 1
* 400613-004 …Bulb (V02929 Type 1815) 1
14 288339 Momentary Toggle Switch 1
15 290959 Toggle Switch 1
16 283978-002 10 A Circuit Breaker 2
17 283978-001 5 A Circuit Breaker 1
18 290947 Panel, Switches 1
290949 …Bracket Label 1
19 407948 Isolated Base Rectifier 1
20 79B1140 12 VDC Relay 1
408352 …Relay Socket 1
21 290927 12 VDC Timer Relay-Settings: Mode”D”,Range:”M” & 1
Set to 4 minutes
79B1138 …Relay Socket 1
22 290948 Relay Support Bracket 1
23 291865-001 Kit, Fuse, CE 1
288303 …Fuse holder Ref.
W-11166-11 …Fuse, AGC 0.5 A 250 V Ref.
24 291864 Labels, Component, CE 1
25 W11166-002 …Fuse, Fast Blow, AGC, 5 AMP 1

Page 17
7
4 6
1
Figure 9 12VDC Battery Components

Page 18
FIGURE - HOBART
ITEM NO. PART NO.
9- 1 281881-001 12 VDC Battery (V25710 #1231-PMF) 2
287796 …Battery Hold Down (V3Y208) 2
494295 …Battery Hold Down Bolt (V3Y208) 4
* 2 290902 Negative Battery Cable (V3Y208) 1
* 3 291481 Positive Battery Cable (V3Y208) 1
4 287795 Battery Tray 1
5 291160 Battery Tray Support Bracket 1
6 291067 Battery Tray Housing 1
7 291093 Battery Cover 1
8 291092 Cable Tray 2

Page 19
1
6
Figure 10 Exhaust System Assembly

Page 20
FIGURE - HOBART
ITEM NO. PART NO.
10 - 1 291168 Muffler and Exhaust Ay. 1
IN5016 …Muffler Wrap Insulation 3.5 ft2
288052-002 …Accuseal Clamp (3.0”) 2
2 291077 Exhaust Flex Pipe Assembly 1
EB5224 …Muffler Wrap Insulation 1.7 ft2
404154-013 …Full Circle Clamp (3.0”) 1
W10869-006 …Stainless Steel Hose Clamp 7
3 291169 Exhaust Outlet Pipe (optional exhaust routing) 1
288052-002 …Accuseal Clamp (3.0”) 1
4 291379 Exhaust Outlet Elbow 1
288052-002 …Accuseal Clamp (3.0”) 1
5 291380 Exhaust Pipe 1
288052-002 …Accuseal Clamp (3.0”) 2
6 291383 Stainless Steel Exhaust Clamp 2
7 291382 Stainless Steel Exhaust Guard 1
* 8 291394 Exhaust Hole Cover (used to cover optional opening) 1

Page 21
3 4 5 2
9
7
8
10 6
Figure 11 Engine Air Intake Assembly

Page 22
FIGURE - HOBART
ITEM NO. PART NO.
11 - 1 290938 Air Cleaner (V1DL99 # AH19261) 1
282918 …Air Restriction Indicator (V18265 #REX77-0062) 1
282919 …Indicator Adapter Fitting 1
2 290940 Air Cleaner Bracket (V1DL99 # 3918197S) 1
3 290936 3 in. I.D. Straight Hose 1
4 291453 Air Cleaner Tube 1
5 288197-001 3 in to 4 in. Hump Hose Fitting (V1DL99 # 3316617S) 1
* 290597-001 …3 in Floating Bridge Clamp (V54646 # 94143-0325) 2
* 290597-006 …4.5 in Floating Bridge Clamp 1
(V54646 # 94143-0450) 1
* 290597-007 …3.5 in Floating Bridge Clamp 1
(V54646 # 94143-0350)
6 290953 4 in. Hump Hose Fitting 1
7 290952 Hump Hose Sleeve 1
8 290951 Intake Air Extension 1
9 290939 Weather Hood (V1DL99 # 3946458S) 1
10 291078 Air Filter Mounting Bracket 1

Page 23
Figure 12 Engine Cooling System Assembly

Page 24
FIGURE - HOBART
ITEM NO. PART NO.
12 - 1 291223 Radiator/CAC Assembly 1
* 290145 …Coolant Level Sensor 1
* 283873 …Radiator Drain Valve 1
2 291224 Radiator Fan, 22” Diameter 1
3 291070 Top Fan Shroud 1
291097 …Access Panel 1
4 291071 Bottom Fan Shroud 1
5 291225 Fan Guard 1
6 291072 Top Radiator Hose 1
7 289200-001 …1.75” ID Hose (each piece is 3” long) 2
8 291073 Bottom Radiator Hose 1
9 289200-002 …2.25” ID Hose (each piece is 3” long) 2
10 403782-002 210° F Shutdown Switch (V75418 #1002-04880-36) 1
11 287909 Water Temperature Sender 1
* W7814-004 …Bushing, Pipe, Steel 3/8 x 1/2 1
12 Deaeration Line 1
288123-001 …Male Connector 2
13 289828 3.00” ID 90° Elbow 1
14 289827 3.00” ID 90° Elbow 1
15 290936 3.00” ID Connection Hose 2
16 291075 CAC Intake Manifold Hose 1
* 290597-001 …CAC Cooler Hose Clamps 4
17 291074 CAC Turbo Outlet Hose 1
* 290597-001 …CAC Cooler Hose Clamps 4

Page 25
8 9,10
Figure 13 Fuel System Components

Page 26
FIGURE - HOBART
ITEM NO. PART NO.
13 - 1 286897-031 Lubricity Fuel Filter 1
2 290685 Tank to Filter Fuel Line 1
* 290388 …12 mm x 3/8 MJIC Adapter 1
* 4 Call Factory Filter to Pump Fuel Line (supplied with engine) 1
5 291076 Lubricity Fuel Filter Bracket 1
* 6 290686 Fuel Return Line 1
7 286897-036 Filter, Primary Fuel 1
8 289037 Primary Fuel Filter Bracket 1
9 291420 50 Gallon Composite Fuel Tank (See Figure 2) 1
* 486719-005 …12 V Fuel Gauge Sender 1
* 291407 … Fuel Tank Bellypan 1
* 291408 … Fuel Tank Strap 2
* 291409 …Fuel Tank Rubber Strap 2
10 282562 Cap, Fuel Fill, Diesel Green 1
11 287461 Label, Fuel Warning 1
12 76B1148 Diesel Fuel Label (near filler neck) 1

Page 27
7 8
13 1, 2
9 10
12
11
Engine Control Module 5, 6
Figure 14 Engine Components

Page 28
FIGURE - HOBART
ITEM NO. PART NO.
14 - 1 W9407-446 Ground Cable 2
2 287735 Ground Plate 1
405548 …Label, Frame Ground 3
3 290918 Engine Wire Harness (shown throughout) 1
4 291334 Engine Dongle Panel 1
5 78B1118-002 Oil Pressure Sender (V16476 # 109600) 1
6 403809-002 Oil Pressure Switch 1
W7814-000 … Bushing, Pipe, Steel, 1/4 x 1/8 1
286903 … M14-1.5 x ¼ NPT Adapter 1
W10910-000 …Tee Fitting 1
W10750-001 …1/8 Pipe Nipple 1
7 403782-002 Water Temperature Switch 1
W7814-004 …Bushing, Pipe, Steel 3/8 x 1/2 1
8 287909 Water Temperature Sender 1
9 291248 “E” Engine Parts Panel 1
10 Engine Preheater Fuse Circuit
287145-001 …Fuse Holder 1
287144-002 …125 A Fast Acting Fuse 1
11 283154-001 Standoff Insulator 1
12 288331 Relay, Grid Heater 1
489658-007 …Diode Assembly 1
13 Engine Dongle and Battery Disconnect Panel Ref.
291334 … Engine Dongle/Battery Disconnect Panel 1
290831 … Battery Disconnect Switch 1
290847 …… Battery Disconnect Plate 1
291482 … Cable, Disconnect Switch to Starter 1
W9360-289 … Cable, Disconnect Switch to Electronics Panel 1

Page 29
4 5
3 6
1 7
2 8
22, 25, 26 9
27 22, 23 10, 11
12, 14
17, 21 13
13 15, 16
20 27
19
18 17
Figure 15 Rectifier Components

Page 30
FIGURE - HOBART
ITEM NO. PART NO.
15 - 288306 Rectifier Assembly Ref.
1 287184-003 Capacitor Insulator 1
2 405278-006 Capacitor, 90,000 MFD, 75 VDC 1
3 286887 Shroud, Air, Top, Rectifier 1
4 W10869-006 Capacitor Clamp 1
5 402037-004 Rubber Grommet 1
6 16DA3493 Insulating Washer 6
7 288380-001 10 OHM, 100 W Resistor (V44655 #61917) 3
8 400589-001 5 Station Terminal Block (V6S553) 1
Preload Resistor Hardware
9 W11114-012 …Screw, 1/4-20 X 7-1/4 inches Lg. 3
Diode Hardware
10 W11280-015 …Nut, Jam, Hex, 3/4-16 12
11 494681-001 …Spring Washer 12
12 DR11171 Positive Rectifier (V81483 #300U30A) 6
13 286884 Heat Sink Bracket 2
14 DR11170 Negative Rectifier (V81483 #300UR30A) 6
Shunt Hardware
15 W11097-007 …Screw, HHC, 3/8-16 x 2 inches Lg. 1
16 180065 2000 A Shunt 1
Top and Bottom Connection Hardware
17 W11097-007 …Screw , 3/8-16 x 2 inches Lg. 5
18 285647 Bottom Rectifier Air Shroud 1
19 180600 Rectifier Spacer 3
20 282239 Negative Rectifier Heat Sink 1
21 W11097-022 …Screw , 3/8-16 x 2-1/2 inches Lg. 4
22 A25 Insulating Washer 8
23 AW626 Bushing, Insulating 4
24 286813 Positive Rectifier Heat Sink 1
25 W11242-018 …Washer, Flat, 3/8” 8
26 283063 …Rectifier Spacer 8
27 291433 Rectifier Mounting Bracket 2
* 28 288015 Wire Harness 1
* 29 291358 Splice, Solder 3

Page 31
3 5 4,5
6 1 2
Figure 16 Contactor Components

Page 32
FIGURE - HOBART
ITEM NO. PART NO.
16 - 1 286810-001 800 AMP DC Contactor (V01XD4 #CT800A-24C2) 1
286849 …Contactor Insulator 1
* 489658-010 … Fly-back Diode 1
2 W9218-251 Positive Output Cable 1
3 W9218-251 Negative Output Cable 1
4 Negative Cable Connection
A25 …Insulating Washer 2
AW626 … Insulating Bushing 1
5 400435 28 V Label 1
6 402025-003 …30 ft DC Output Cable 1

Page 33
9
13
3
11
Brushholder
Assembly
12
10
7
4 8
5
6
18 16
19
17
20
21
Figure 17 Generator Components and Brush Holder Assembly

Page 34
FIGURE - HOBART
ITEM NO. PART NO.
17 - 1 288210 Spare Generator (Replacement Only) 1
* 2 284371-002 Shock Mount (V5P059 # 51508-2) 1
288985 Generator Assembly Ref.
3 287564 Fan Housing 1
4 288984-001 Housing & Stator Assembly 1
5 489135 Coupling Key 1
6 180776 Armature 1
7 488555-001 Housing, Bearing Assembly 1
8 287401 Bearing Cap 1
9 288003 Fan Housing Cover 1
10 290646 Fan and Coupling Assembly 1
* 85C1004-002 …Split Taper Bushing 1
11 Flywheel - (Supplied with Engine) Ref.
12 354592 Slip Ring 2
13 281688 Generator Housing Cover 1
* 14 W10072-063 Bearing, Rear (V23803 #6207LLUC3) 1
* 15 291262 Rear Generator Support Bracket 1
488784 Brush Holder Assembly Ref.
16 488562 Brush Holder Bracket 1
17 488628 Diode Bracket 1
18 408999-001 Diode, Silicon, 30 A, Positive Assembly 1
19 402531 Cap 2
20 402530 Guide 2
21 402788 Brush, AC 2
22 489426 Chart, Wire, Brush Holder 1

Page 35

Page 36
Chapter 5 Manufacturer’s Literature
Vendor Literature
Type Diagram Description
Engine Operation and Maintenance Manual

(Included)
Parts Catalog: Cummins Bulletin #4056563

(Not included. Purchased separately from Cummins)
Diagram Number Diagram Description
291870-A Rev. A Diagram, Schematic & Connection
Contact ITW GSE if copies of these drawings or manuals are not with this manual (unless otherwise noted
above). Refer to Appendix A for specific information on optional equipment for the JetEx6D, 28 VDC
Generator Set.

Page 1

Page 2
Appendix A Features
The following is a list of features available on the Standard and Deluxe JetEx6, 28.5 VDC Generator Set.
This chart contains the description, part number, and document number (if applicable) of the feature.
Option/Features Available
Document
Description Part Number In This Section
Number
Kit, Block Heater, 120V 292215-001
Kit, Block Heater, 240V 292215-002
Battery Blanket, 120V 287917
Battery Blanket, 240V 287917-001
Support, Fork Lift Assembly 291374
Kit, Tie-Down 284706
Kit, CE Certification, Trailer 287589-020
Kit, Clearance Lights 288234
Package, 120 VAC Generator (Factory Inst.) 181735
Package, 120 VAC Generator (Field Inst.) 181735-001
Reel, Grounding 83A1103
Kit, Unit Operating Light, Specify Color(Amber or Blue) 288482-XXX
Kit, Cable Interlock 289942
Kit, Wheel Chocks 287609
Kit, Low Fuel Beacon 291365-XXX
Cable, Output, 28 VDC [different lengths available] 402025-XXX
Kit, Cable Tray Rollers 288987-006
Kit, Non Split C Cable 292230
Write: ITW GSE

Technical Support
Palmetto, FL 34221 U.S.A.

(877) 874-5322 (Technical Support)

(941) 721-1000 (Spare Parts)
FAX inside U.S.A. (877) 874-5321
[email protected]
OM2241-A Rev A Change 1 March 29, 2017 Appendix A

Page 1

Page 2
Wet-Stacking in Generator Set

1) Diesel Engines
All diesel engines operated for extended periods under light load may develop a
condition commonly referred to as wet-stacking. This condition results from the
accumulation of unburned fuel in the exhaust system. It is recognizable by fuel oil
wetness around the exhaust manifold, pipes, and muffler. Liquid fuel, in the form of
droplets, may be spewed from the exhaust outlet.
Wet-stacking is common, and may be expected in diesel engines operated under light
load. Light loads do not allow the engine to reach the most efficient operating
temperature for complete combustion of fuel. The unburned fuel collects in the exhaust
system to create the wet condition known as wet-stacking.
To alleviate wet-stacking in lightly loaded engines, it is recommended that the machine

be connected to a load bank after each 200 hours of use and operated under full rated
load for one hour. This will burn away and evaporate the accumulation of fuel in the
exhaust system. This clean-out procedure should be considered as a regular
maintenance operation for machines operated under light loads. The time schedule of
200 hours may be changed as required to suit each user’s particular needs and
operating conditions.

Page 3

Page 4
Unusual Service Conditions

This information is a general guideline and cannot cover all possible conditions of equipment use. The
specific local environments may be dependent upon conditions beyond the manufacturer’s control. The
manufacturer should be consulted if any unusual conditions of use exist which may affect the physical
condition or operation of the equipment.
Among such conditions are:
1) Exposure to:
a) Combustible, explosive, abrasive or conducting dusts
b) Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation
c) Chemical fumes, flammable, or explosive gases
d) Nuclear radiation
e) Steam, salt-laden air, or oil vapor
f) Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus
growth
g) Abnormal shock, vibration or mechanical loading from external sources during equipment operation
h) Abnormal axial or side thrust imposed on rotating equipment shafts
i) Low and/or high ambient temperatures
j) High electromagnetic fields
2) Operation at:
a) Voltages above or below rated voltage
b) Speeds other than rated speed
c) Frequency other than rated frequency
d) Standstill with rotating equipment windings energized
e) Unbalanced voltages
f) Operation at loads greater than rated
3) Operation where low acoustical noise levels are required

Page 5
4) Operation with:
a) Improper fuel, lubricants or coolant


b) Parts or elements unauthorized by the manufacturer

c) Unauthorized modifications
5) Operation in poorly ventilated areas

Page 6

Operation and Maintenance Manual With Illustrated Parts List For Jetex6D Generator Set

Uploaded by

Copyright:

Available Formats

Operation and Maintenance Manual With Illustrated Parts List For Jetex6D Generator Set

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation and Maintenance Manual With Illustrated Parts List For Jetex6D Generator Set

Uploaded by

Copyright:

Available Formats

Operation and Maintenance Manual with

Illustrated Parts List for

Contents of the manual are arranged as follows:

Chapter 3 Overhaul/Major Repair

Chapter 4 Illustrated Parts List

Chapter 5 Manufacturer’s Literature

OM2241-A Rev A August 17, 2016 Introduction

Write: ITW GSE Americas

Call Inside U.S.A./Canada: (866)-845-0441 (Parts)

Call From Foreign Countries: (941) 721-1092 (Technical Support)

FAX inside U.S.A. (800) 367-4945

FAX From Foreign Countries: (941) 721-1091

Web Page: www.itwgse.com

OM2241-A Rev A August 17, 2016 Introduction

Safety Warnings and Cautions

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and

a) Installation and Grounding of Electrically Powered Equipment

OM-2241-A Rev A August 17, 2016 Safety Warnings

b) Output Cables and Terminals

3) Service and Maintenance

c) Disconnect power to equipment if it is out of service.

4) Fire And Explosion Prevention

a) Electrical Short Circuits and Overloads

OM-2241-A Rev A August 17, 2016 Safety Warnings

5) Toxic Fume Prevention

6) Bodily Injury Prevention

7) Medical and First Aid Treatment

8) Equipment Precautionary Labels

OM-2241-A Rev A August 17, 2016 Safety Warnings

This page intentionally left blank.

OM-2241-A Rev A August 17, 2016 Safety Warnings

Generator Set Model Number

Make sure your generator set is the

Filter Part Numbers

OM2241-A Rev A August 17, 2016 Preventive Maintenance

ITW GSE - Supply Contact Information

Air Cleaner Oil Filter

Fuel Filter Lubricity Fuel/Water Separator

OM2241-A Rev A August 17, 2016 Preventive Maintenance

Chapter 1 Description/Operation Chapter-Section/Page#

Section 1 Description 1-1/1

Section 2 Preparation for Use, Storage or Shipping 1-2/1

Section 3 Operation 1-3/1

Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#

Section 1 Maintenance Inspection/Check 2-1/1

OM2241-A Rev A August 17, 2016 Table of Contents

Section 2 Maintenance Procedures 2-2/1

Section 3 Adjustments / Tests 2-3/1

Section 4 Troubleshooting Procedures

Chapter 3 Overhaul / Major Repair Chapter-Section/Page#

Section 1 Flexible Coupling 3-1/1

OM2241-A Rev A August 17, 2016 Table of Contents

Chapter 4 Illustrated Parts List Chapter-Section/Page#

Section 1 Introduction/Numerical Index 4-1/1

Numerical Index 4-1/3

Section 2 Manufacture's Codes 4-2/1

Section 3 Illustrated Parts List 4-3/1

OM2241-A Rev A August 17, 2016 Table of Contents

Chapter 5 Manufacture's Literature