SB-619 3/02

SERVICE BULLETIN
Original Issue Date: Model: Market: Subject: 3/02 20-300 kW Industrial and Marine Generator Sets Troubleshooting Flowchart for No/High Output Voltage

Substitute the attached flowcharts for the flowcharts found on pages 7-2 and 7-3 of TP-5353 8/94c, 20--300 kW Industrial Generator Set Service Manual and pages 58 and 59 of TP-5737 5/01, 40--150 kW Marine Generator Set Service Manual.

Use this service bulletin in conjunction with the Service Manual. Read and follow the Safety Precautions and Instructions found in the Service Manual.

Routing Initial Here

Service Manager

Sales Manager

Parts Manager

Technician No. 1

Technician No. 2

Technician No. 3

Return This to

No output voltage is detected

Is the safeguard breaker in the ON position? Yes

No

Place the safeguard breaker in the ON position

Check the voltage adjust pot. Does it function? Yes Perform the flashlight test on the photo transistor circuit board

No

Repair the voltage adjust pot. and/or wiring connections

Is ceiling voltage being measured?

No

Remove G and F+ (small red) leads from the SCR assembly. Jumper G and AC terminals.

Yes Is battery voltage present at the regulator? Yes Unplug the connector from the LED circuit board. Measure the DC voltage across 3B and 5B of the connector. Is DC voltage present at 3B and 5B of LED circuit board? Yes 6--12 VDC

Check and repair the wiring to the regulator

No

Is ceiling voltage being measured?

No

Test the exciter armature and main field windings

Yes

No

Replace the photo transistor circuit board

No

Do the windings meet specs?

Yes

Replace the regulator and/or verify the wiring connections

No

Is DC voltage present at the plug of LED circuit board? Yes 6--12 VDC Replace LED PCB (shorted LED)

Replace the LED circuit board (shorted LED)

Replace the SCR assembly Replace the rotor assembly

Figure 1

Troubleshooting Flowchart for No Output Voltage

SB-619

3/02

High output voltage is detected

Place the safeguard breaker in the OFF position

Does the output voltage remain high?

No

Check for sensing voltage on V7 and V8 at the AC fuse terminal and regulator plug pins 4 and 10

Yes

Remove and tape off G and F+ (small red) leads from the SCR assembly

Is sensing voltage present?

(190--277 VAC)

No

Check and repair open wiring to the AC fuse terminal block and to regulator plug pins 4 and 10

Yes

Replace the photo transistor circuit board

No

Does the output voltage remain high?

Is the sensing voltage higher than

190--277 VAC?

No

Check voltage on all the phases. Are all phases balanced?

Yes

Yes

Yes

No

Replace the SCR assembly

Replace the voltage regulator

Replace the voltage regulator

Test the main stator windings

Figure 2

Troubleshooting Flowchart for High Output Voltage

SB-619

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SB-619

3/02