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Service Manual
PowerCommand Control
3200 Series
Generator Sets
Models
DQKH
LS-14M
Redistribution or publication of this document,
iii by any means, is strictly prohibited.
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH • Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
• Remove electric power before removing protective changer pressure cap while the engine is running.
shields or touching electrical equipment. Use rub- Allow the generator set to cool and bleed the system
ber insulative mats placed on dry wood platforms pressure first.
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing • Used engine oils have been identified by some state
(particularly wet shoes) or allow skin surface to be or federal agencies as causing cancer or reproduc-
damp when handling electrical equipment. Do not tive toxicity. When checking or changing engine oil,
wear jewelry. Jewelry can short out electrical con- take care not to ingest, breathe the fumes, or con-
tacts and cause shock or burning. tact used oil.
• Use extreme caution when working on electrical • Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
components. High voltages can cause injury or
such as wood and cloth; Class B fires, combustible
death. DO NOT tamper with interlocks.
and flammable liquid fuels and gaseous fuels; Class
• Follow all applicable state and local electrical C fires, live electrical equipment. (ref. NFPA No. 10).
codes. Have all electrical installations performed by • Make sure that rags are not left on or near the en-
a qualified licensed electrician. Tag and lock open gine.
switches to avoid accidental closure.
• Make sure generator set is mounted in a manner to
• DO NOT CONNECT GENERATOR SET DIRECT- prevent combustible materials from accumulating
LY TO ANY BUILDING ELECTRICAL SYSTEM. under the unit.
Hazardous voltages can flow from the generator set • Remove all unnecessary grease and oil from the
into the utility line. This creates a potential for elec- unit. Accumulated grease and oil can cause over-
trocution or property damage. Connect only heating and engine damage which present a poten-
through an approved isolation switch or an ap- tial fire hazard.
proved paralleling device.
• Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
MEDIUM VOLTAGE GENERATOR SETS
bris from the set and keep the floor clean and dry.
(601V to 15kV) • Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
• Medium voltage acts differently than low voltage. or drug that makes the operation of equipment un-
Special equipment and training is required to work safe.
on or around medium voltage equipment. Operation • Substances in exhaust gases have been identified
and maintenance must be done only by persons by some state or federal agencies as causing can-
trained and qualified to work on such devices. Im- cer or reproductive toxicity. Take care not to breath
proper use or procedures will result in severe per- or ingest or come into contact with exhaust gases.
sonal injury or death.
• Do not store any flammable liquids, such as fuel,
• Do not work on energized equipment. Unauthorized cleaners, oil, etc., near the generator set. A fire or
personnel must not be permitted near energized explosion could result.
equipment. Due to the nature of medium voltage
electrical equipment, induced voltage remains even
• Wear hearing protection when going near an oper-
after the equipment is disconnected from the power ating generator set.
source. Plan the time for maintenance with autho- • To prevent serious burns, avoid contact with hot
rized personnel so that the equipment can be de-en- metal parts such as radiator, turbo charger and ex-
ergized and safely grounded. haust system.
When all conditions are met (i.e., no unacknowl- InPower service tool is required to selected desired
edged faults, Screen Saver Mode is active, and O/ mode.
REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
ANALOG AC PANEL LAMP/ FAULT EMERGENCY
METERING LAMP TEST ACKNOWLEDGE STOP PUSH
PANEL BUTTON BUTTON BUTTON
GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH
STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
GRAPHICAL
DISPLAY
MENU MENU
BUTTONS BUTTONS
ENGINE MORE>>
PAGE ALTERNATOR POWER TRAN or _\_ Page
2-12 CONTROL HISTORY/ABOUT 2-9
PAGE PAGE
2-13 2-14
MENU B
Section
3
ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 2-16
GRAPHICAL
Section DISPLAY MENU
3 A
MANF TEMP 75 °F
MANF PRESS ABS 180 INHG
RAIL PRESS ABS 180 PSI
PUMP PRESS ABS 291 PSI
FUEL INLET TEMP 172 °F
COOLANT PRESSURE 59 PSI
MODEL 1750DQKB
VOLTAGE 416 WYE
FREQUENCY 60
RATING STANDBY
CONTROLLER VERSION
RTOP DN30008.DFA
BATS APR 23 1999
OP PANEL VERSION
RTOP 1.09 AUG 17 1999
BATS 1.02 MAY 6 1999
If you press the “POWER TRANS” button in Menu The symbol displayed in the middle of the Pow-
A, the Power Transfer main menu will appear (Fig- er Transfer main menu indicates which breaker
ure 2-10). The Power Transfer Control (PTC) fea- (utility or genset) is closed/opened to the load. The
ture must be installed to display this menu. symbol presently shown indicates that the utility
breaker is closed and supplying power to the load.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and
The Power Transfer main menu also indicates if the
control the opening and closing of the contacts (cir-
utility and the generator set are available to accept
cuit breakers) for the utility (S1) and the genset
load. When the control detects that either source is
(S2).
ready to accept load, UTILITY and/or GENSET will
If utility fails, the control will initiate the genset start- be displayed in inverse video.
ing sequence, open S1 and close S2 to the load.
When utility returns, the load is retransferred to the The Power Transfer main menu has four submenu
utility (S1 closes/S2 opens) and the control initiates groups. Refer to the page numbers shown in Figure
the genset shutdown sequence. 2-10 for the Power Transfer submenu descriptions.
MENU MENU
BUTTONS PAGE PTC STATUS LINE PAGE BUTTONS
2-19 2-22
UTILITY GENSET
PAGE STATUS
2-20 TRANSFER CONTROL
DEG −123 SYNCHRONIZING
PAGE MENU
2-21 A
Pressing the OPEN UTIL button will display the CLOSE UTIL CB ENABLE
fourth submenu, indicating that the utility circuit << BACK
breaker is now opened.
Note that the fourth submenu displays CLOSE
UTIL. Pressing this button will close the utility circuit
breaker and redisplay the third submenu. FIGURE 2-13. TRANSFER CONTROL SUBMENUS
+ OR − BUTTON + OR − BUTTON
MENU A MENU B
MENU
ENGINE MORE>> B ADJUST
ALTERNATOR POWER TRAN or _\_ PARALLEL DATA
MENU
CONTROL HISTORY/ABOUT SETUP BACK<<
A
SETUP MENU 1
PAGE MENU
3-4 B
GOVERNING/VOLT REG
PAGE CUSTOMER FAULTS NEXT
3-5 MENU
CALIBRATION
PAGE MENU
3-6 A
SETUP MENU 2
PAGE ABOVE
3-12 MENU
PAGE MENU
3-11 A
UTILITY SENSORS
PAGE GENSET SENSORS NEXT
3-15 MENU
TIMERS
PAGE
3-17
PTC MAIN
MENU 2
PAGE
TEST/EXERCISE
3-18
If you press the “UTILITY SENSORS” button in the U CT RATIO: Enter the CT Ratio of the Utility L2 CT.
PTC Main Menu 1, the Utility Sensors submenus This is the Ratio to 1 Amp. Range: 1−18000 (1A).
will appear (Figure 3-9).
The following field descriptions show the valid field CAUTION This CT must be rated for 1 Amp
entries and default value (shown in parenthesis) for output (e.g. NOT 5 Amp). Be sure CT secondary
each field. circuit has burden resistor or a shorting jumper
in place before putting power through the CT.
Use the + and − buttons to increase or decrease the Example: CT Ratio = 2650:1. Thus enter 2650.
values in the following fields. Use the arrow (→) but-
ton to move the cursor within a field or to the next
field. Exit menu to save changes.
U SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
U PT VOLT LL: Enter the value of the utility line-to- (L-L) for 3 phase line-line voltage sensing. This ap-
line voltage which yields 100% voltage at the termi- plies to both the utility undervoltage and overvol-
nals of the utility (bus) PT module. tage sensors. Range: L−L, L−N (L−N).
Range: 1−15000V, adjustable by standard nominal U <wye> <delta>: Enter utility connection type.
voltage values, 100V, 10V and 1V increments (1V). Range: Delta, Wye (Wye).
The 100% voltages for each of the four possible util-
ity (bus) PT modules are as follows, based on mod- U UNLOADED KW: Enter the kW on utility Line 2 at
ule dash number: which the utility is considered as unloaded. This is
−01 = 208 volts LL the L2 kW level at which a closed transition soft
−02 = 416 volts LL transfer will disconnect from the utility.
−03 = 600 volts LL
−04 = 120 volts LL UTILITY UNDERVOLTAGE: Non-adjustable field,
always enabled.
Example 1: Nominal Utility voltage is 480V. This
means that utility (bus) PT module number −02 UTILITY OVERVOLTAGE, FREQUENCY: Used to
should be used. The voltage which will yield 100% enable or disable menu function. Choose Enabled
volts at this PT module is 416 per the above table. or Disabled (Enabled).
Thus enter 416V.
Example 2: Nominal Utility voltage is 4160V. A pri- UV PICKUP: Enter a number between 85 and
mary stage transformer with a ratio of 4200/240 is 100% of the nominal voltage (90%).
used. This means that utility (bus) PT module num-
ber −01 should be used. The voltage which will yield UV DROP OUT: Enter a number between 75 and
the 100% volts (208V from above table) is calcu- 98% of the under-voltage pick-up percentage
lated as follows: (90%).
208 x (4200/240) = 3640. Thus enter 3640V.
UV DELAY: Enter a time between 0.1 and 5.0 sec-
U NOM VOLT LL: Enter the nominal utility line-to- onds (0.5 seconds).
line voltage. For example, 480, 4160, etc.. Range:
1−15000 V, adjustable by standard nominal voltage UV MIN PHASE: Displays the lowest line voltage of
values, 100V, 10V and 1V increments (1V). the three utility phases.
If you press the “GENSET SENSORS” button in the G RAMP UNLOAD: Enter the ramp time for the
PTC Main Menu 1, the Genset Sensors submenus genset ramp unload rate during a closed transtion
will appear (Figure 3-10). soft load retransfer. Ramp rate is −100%kW divided
by this time setting. Range: 0−900 seconds (20
The following field descriptions show the valid field sec).
entries and default value (shown in parenthesis) for
each field. G UNLOADED KW: Enter the %kW (based on
standby rating) that the genset is considered un-
Use the + and − buttons to increase or decrease the
loaded. This is the %kW level at which a closed tran-
values in the following fields. Use the arrow (→) but-
ton to move the cursor within a field or to the next sition soft retransfer will disconnect from the gen-
field. Exit menu to save changes. set. Range: 0−100% (5%).
G NOM VOLT LL: Non-adjustable field, displays GEN UNDERVOLTAGE: Non-adjustable field, al-
current setting of genset nominal voltage. (See Ad- ways enabled.
just submenu to adjust the output voltage ±5%.) GEN OVERVOLTAGE, FREQUENCY: Used to en-
G SENSOR TYPE: Enter the line-to-line (L-N) for 3 able or disable menu function. Choose Enabled or
phase line-neutral voltage sensing or line-to-line Disabled (Enabled).
(L-L) for 3 phase line-line voltage sensing. This ap- UV PICKUP: Enter a number between 85 and
plies to both the genset undervoltage and overvol- 100% of the nominal voltage (90%).
tage sensors. Range: L−L, L−N (L−N).
UV DROP OUT: Enter a number between 75 and
G BASE LOAD: Enter the maximum load the gen- 98% of the under-voltage pick-up percentage
set will carry during a closed transition. Range: (90%).
0−100% (80%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
G RAMP LOAD: Enter the ramp time for the genset onds (4 seconds).
ramp load rate during a closed transition soft load
transfer. Ramp rate is +100%kW divided by this UV MIN PHASE: Displays the lowest line voltage of
time setting. Range: 0−900 seconds (20 sec). the three genset phases.
Changes are automatically saved when you exit FREQUENCY: Used to adjust the frequency ±3 Hz.
this menu.
VOLTAGE/SPEED DROOP: These two submenus
If the generator set is operating in parallel with a apply to a genset that has the paralleling option and
system bus, the voltage and frequency adjustments is configured to operate in droop mode.
MENU A
ADJUST:
MENU START DELAY 5 SEC
ENGINE MORE>> +
B STOP DELAY 11 SEC
ALTERNATOR _\_ − VOLTAGE 208 1.2 %
CONTROL HISTORY/ABOUT → FREQ 60.0 HZ -0.0 HZ
MENU B
ADJUST:
+ STANDBY
VOLTAGE DROOP OFF
ADJUST − BUS L1 480 V
BUS DATA → POWER FACTOR 0.80
MENU VOLT 4.99 %
SETUP BACK<<
A
ADJUST:
+ STANDBY
SPEED DROOP OFF
− BUS FREQ 60.0 HZ
→ TOTAL KW 300 KW
FREQ 60.0 0.40 HZ
CONTROL
BOX DOOR
TB8
CARD
CAGE
CUSTOMER
K11, K12, K13
CONNECTIONS
NO NO NO
NC NC NC
COIL TB3-7
TB3-5
(SWITCHED B+) COM (GND)
K16
CUSTOMER
K16
CONNECTIONS
K16
K16
SHUTDOWN ALARM
NO
NC
COIL TB3-18
TB3-17
(COM ALARM) COM (GND)
ENGINE
FLYWHEEL
RING GEAR
EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET
PMG
STATOR
END
STATOR BEARING
BLOWER PMG
ROTOR
COUPLING
EXCITER
ROTOR
ROTATING
RECTIFIER
ASSEMBLY
DRIVE ROTOR
DISCS
FRAME
END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT
SURGE SUPPRESSER
REMOVE TO TEST
WINDING SCHEMATIC
WHEATSTONE
BRIDGE
New grease is a whitish-beige color but some mild 2. Install bearing onto rotor shaft. Refer to bearing
discoloration will occur with use. If the grease kit instruction sheet.
shows signs of gross discoloration, the bearing
should be replaced. 3. Install two threaded studs into end bearing car-
tridge to aid subsequent procedures. Position
Bearing Removal: The bearing is press fitted onto
the end bearing cartridge assembly close to
the shaft and can be removed with standard work-
proper position for hole alignment with end-
shop tools (i.e., two or three legged manual or hy-
bracket.
draulic bearing pullers). The bearing should only be
removed for replacement (bearing is destroyed dur- 4. Install endbracket to the stator frame using the
ing removal and must be replaced). proper screws and lock washers, but do not
The end bearing is enclosed in a pre-packed car- tighten securely as yet.
tridge housing and must only be dismantled as nec-
essary for relubrication, replacement, or when a 5. Insert and start the threads of the bearing car-
major overhaul is carried out on the generator set. tridge fasteners, and remove threaded align-
Removal of the bearing can only be accomplished ment studs, through the endbracket into the
after removal of the endbracket, as follows: cartridge housing.
1. Remove the endbracket (complete steps 1 6. Lift slightly on endbracket and remove wooden
through 21 of the Main Stator and Rotor Re- shims holding rotor on center with stator.
moval (P7) procedure.
7. Securely tighten the endbracket fasteners.
2. Remove the four screws holding bearing cap.
Medium-voltage, 601 to 15,000 5. Tap the stator housing out of its spigot, and
volts, present special hazards of severe person- carefully remove from generator endbracket.
al injury or death. Even after genset shutdown,
an electrical shock hazard may still exist, The highly magnetic rotor will attract the stator
caused by induced voltage within the genera- core; care must be taken to avoid any contact
tor. Service personnel must be well-trained/ which may damage the windings.
qualified to work with distribution voltages.
6. Remove the hex head through-bolt from the ro-
Permanent Magnet (PMG) Removal tor shaft and firmly pull the complete rotor as-
(P7) sembly from its location. Keep the rotor clean
by avoiding contact with metal dust or particles.
1. Disconnect the negative (-) battery cable to
prevent accidental starting of the generator set Place in a plastic bag as soon as is practicable.
while servicing. CAUTION The rotor assembly must not be
dismantled, or the magnetic properties will
WARNING Arcing at battery terminals, arc-
be destroyed.
ing in light switch or other equipment,
flame, pilot lights and sparks can ignite bat- Permanent Magnet (PMG) Installation (P7)
tery gas causing severe personal injury.
1. Install the complete rotor assembly to the end
Ventilate battery area before working on or of the main rotor shaft using the hex head
near battery—Wear safety glasses—Do not through-bolt. Keep the rotor clean by avoiding
smoke—Switch trouble light ON or OFF contact with metal dust or particles.
away from battery—Stop genset and dis-
connect charger before disconnecting bat- 2. Carefully locate the stator housing to position
tery cables—Disconnect negative (−) cable on the generator endbracket. (The leads must
first and reconnect last. be located at the top and facing out, Figure
4-2.) Fasten in place using the 4 bolts and
CAUTION Disconnect battery charger clamps, and tighten securely.
from AC source before disconnecting bat-
tery cables. Otherwise, disconnecting The highly magnetic rotor will attract the stator
cables can result in voltage spikes damag- core, care must be taken to avoid any contact
ing to DC control circuits of the set. which may damage the windings.
WARNING Accidental starting of the gen- 3. Connect the PMG wiring harness connector.
erator set while working on it can cause se-
vere personal injury or death. Prevent acci- 4. Install the PMG assembly cover using the three
dental starting by disconnecting the nega- M5x12mm capscrews and lockwashers, and
tive (−) cable from the battery terminal. tighten securely.
8. Remove the eight bolts holding the endbracket FIGURE 4-7. P7 LIFTING POSITION
to the generator housing.
14. Remove the fasteners from the four generator 17. Using a forklift, position a lifting bar of the forklift
mounting feet brackets. (inside and inline with the generator) under the
rotor shaft. Lift the rotor shaft slightly so that ro-
15. Using an adequate lifting device, lift the gener- tor is not resting on inside of stator assembly.
ator (at lifting eyes, and main stator housing) See Figure 4-8.
STATOR ROTOR
ASSEMBLY ASSEMBLY
19. Being careful not to drag the windings on the WARNING To prevent personal injury, use
rotor, move the stator assembly sufficiently adequate lifting devices to support heavy
away from engine to sling and support the rotor components. Keep hands and feet clear
assembly. Do not allow rotor assembly to hang while lifting.
on engine flywheel.
CAUTION Drive disc damage can be 23. Remove the rotor assembly and place it on
caused by allowing the rotor assembly to wood blocks in the horizontal position. To avoid
hang on flywheel. Use adequate hoist and possible distortion, do not allow the drive discs
sling to support the rotor assembly. and fan to rest on anything.
STATOR LIFT
(EXAMPLE)
ROTOR LIFT
(EXAMPLE)
26. Disconnect the grounding strap from the fly- adequate lifting devices to support heavy
wheel housing. components. Keep hands and feet clear
while lifting.
27. Carefully remove the capscrews and flat wash-
CAUTION Improper generator assembly
ers that secure the drive discs to the engine fly-
wheel. rigging and handling can result in damage
to stator and rotor assemblies. Lifting eyes
28. Verify that the generator assembly is ade- may not be at center-of-gravity position of
quately supported. Carefully remove the caps- stator assembly. Therefore, lifting and mov-
crews securing the engine adaptor endbracket ing the generator by hoisting at lifting eyes
to the engine flywheel housing. only, presents the hazard of load imbal-
ance; allowing one end to drop and other
WARNING To prevent personal injury, use end to rise. Make sure the generator is ade-
adequate lifting devices to support heavy quately hooked/strapped to maintain level
components. Keep hands and feet clear control of assembly while lifting and mov-
while lifting. ing.
CAUTION Improper generator assembly 2. Align the holes of the engine adaptor endbrack-
rigging and handling can result in damage et with the holes in the flywheel housing and
to stator and rotor assemblies. Lifting eyes install the capscrews and lock washers. Tight-
may not be at center-of-gravity position of en fasteners to 85-100 ft-lbs. (116-136 N•m).
stator assembly. Therefore, lifting and mov-
ing the generator by hoisting at lifting eyes 3. Secure the rotor assembly to the flywheel.
only, presents the hazard of load imbal- Tighten fasteners to 150-180 ft-lbs. (204-245
ance; allowing one end to drop and other N•m).
end to rise. Make sure the generator is ade-
quately hooked/strapped to maintain level 4. Connect the grounding strap to the flywheel
control of assembly while lifting and mov- housing using a capscrew and EIT locking
ing. washer; and tighten securely.
29. Remove the generator assembly away from
5. Install the mounting feet bracket fasteners; and
engine. Place generator assembly on floor with
tighten securely.
a piece of wood beneath the stator housing (to-
ward PMG end) to allow for endbracket remov-
If endbracket has been removed, continue with
al, if desired. step 6, otherwise skip to step 14.
Generator Reassembly (P7)
6. Lift slightly on end of rotor shaft and install
Generator reassembly is the reverse of disassem- wooden shims to hold rotor on center with sta-
bly procedure. tor.
To assemble the stator and rotor at the same time,
continue with step 1. To assemble the stator and ro- 7. Install two threaded studs into end bearing car-
tor individually, skip to step 15. tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to
1. Using an adequate lifting device, locate the proper position for hole alignment with end-
generator assembly into position near the en- bracket
2. Install bearing onto rotor shaft. Refer to bearing 7. Securely tighten the endbracket fasteners.
kit instruction sheet.
3. Install two threaded studs into end bearing car- 8. Tighten the bearing cartridge fasteners to 4.5
tridge to aid subsequent procedures. Position ft-lbs. (6 N•m) torque.
the end bearing cartridge assembly close to
proper position for hole alignment with end- 9. Install the PMG assembly. Refer to Permanent
bracket. Magnet (PMG) P80.
The following procedures provide information for maintain air gap between rotor and stator
removal and reassembly of the generator PMG ex- during generator removal or permanent
citer and generator assembly from the engine and damage to exciter and PMG assembly will
removal of end bearing. Be sure to read through this occur.
section first, before performing procedures listed, to 3. Place shims (non-compressible material such
determine the steps most appropriate for the ser-
as plastic) between all four poles. Minimum air
vice attention required.
gap must be maintained in all radial directions
Medium-voltage, 601 to 15,000 from the center of the bore to prevent damage
volts, present special hazards of severe person- to the exciter and PMG assembly. Minimum air
al injury or death. Even after genset shutdown, gap is 0.2 inch (5 mm). Normal air gap is
an electrical shock hazard may still exist, approximately 0.3 inch (7.5 mm).
caused by induced voltage within the genera-
tor. Service personnel must be well-trained/ 4. Disconnect all load wires from the reconnec-
qualified to work with distribution voltages. tion terminal block assembly. If equipped with
the circuit breaker option, disconnect load
Generator Assembly Removal wires from circuit breaker. Check that all leads
are labeled to ease reassembly.
1. Remove the generator air discharge covers.
5. Disconnect remote control wiring between
generator and control box. For reconnections
CAUTION Do not use fan blade to bar over
later, make sure each wire/plug is clearly
engine. That can damage blades and cause marked to indicate the correct terminal.
property damage and personal injury
6. Remove as necessary, air intake components
2. Crank or bar the engine/generator to position to engine that may interfere with removal of the
the rotor such that a full pole face is at the bot- generator assembly.
tom of the main stator core. Proper positioning
can be viewed through the generator access 7. Attach cables of lifting device to generator lift-
openings. Refer to engine service manual for ing points as shown on the label attached to the
proper cranking or barring procedure. generator lifting eye.
WOOD
BLOCKS
1. Disconnect the negative (-) battery cable to The highly magnetic rotor will attract the stator
prevent accidental starting of the generator set core; care must be taken to avoid any contact
while servicing. which may damage the windings.
WARNING Arcing at battery terminals, arc- 6. Remove the hex head through-bolt from the ro-
ing in light switch or other equipment, tor shaft and firmly pull the complete rotor as-
flame, pilot lights and sparks can ignite bat- sembly from its location. Keep the rotor clean
tery gas causing severe personal injury. by avoiding contact with metal dust or particles.
Ventilate battery area before working on or Place in a plastic bag as soon as is practicable.
near battery—Wear safety glasses—Do not
CAUTION The rotor assembly must not be
smoke—Switch trouble light ON or OFF
dismantled, or the magnetic properties will
away from battery—Stop genset and dis-
be destroyed.
connect charger before disconnecting bat-
tery cables—Disconnect negative (−) cable Permanent Magnet (PMG) Installation
first and reconnect last. (P80)
CAUTION Disconnect battery charger
1. Install the complete rotor assembly to the end
from AC source before disconnecting bat-
of the main rotor shaft using the hex head
tery cables. Otherwise, disconnecting
through-bolt. Keep the rotor clean by avoiding
cables can result in voltage spikes damag-
contact with metal dust or particles.
ing to DC control circuits of the set.
WARNING Accidental starting of the gen- 2. Carefully locate the stator housing to position
erator set while working on it can cause se- on the generator endbracket. Fasten in place
vere personal injury or death. Prevent acci- using the 4 bolts and clamps, and tighten se-
dental starting by disconnecting the nega- curely.
tive (−) cable from the battery terminal.
The highly magnetic rotor will attract the stator
2. Remove the four screws and lockwashers from core, care must be taken to avoid any contact
the PMG cover, and remove cover. which may damage the windings.
3. Disconnect the PMG wiring harness connector. 3. Connect the PMG wiring harness connector.
4. Remove the four bolts and clamps retaining the 4. Install the PMG assembly cover using the four
exciter stator housing to the endbracket. screws and lockwashers, and tighten securely.
DIAL
CLAMP INDICATOR
GENERATOR AND
ENGINE AXIAL
CRANKSHAFT ALIGNMENT, SEE
CENTERLINE FIGURE 4-13
SHIMS FLEX
DISCS
+.010
+.010
MEASURED AT
BOLT CIRCLE
DIAMETER
-.002
-.004
10.7 IN.
-.010
-.010
-.015
-.015
No. 630-2572 sh 1 of 7
Rev. B
Modified 9-03
No. 630-2572 sh 2 of 7
Rev. B
Modified 9-03
No. 630-2572 sh 3 of 7
Rev. B
Modified 9-03
No. 630-2572 sh 4 of 7
Rev. B
Modified 9-03
CUSTOMER CONNECTIONS
No. 630-2572 sh 5 of 7
Rev. B
Modified 9-03
CUSTOMER CONNECTIONS
No. 630-2572 sh 6 of 7
Rev. C
Modified 9-03
No. 630-2572 sh 7 of 7
Rev. B
Modified 9-03