Генераторы leroy somer руководство по эксплуатации

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Summary of Contents for Leroy-Somer TAL A44

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Generator ManualInstallation • Operation • Maintenance

Publication 62047801, 06/28/09

Single or double-bearing

Drive-end air discharge

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Table of ContentsIntroduction………………………………………………… 4Foreword…………………………………………………………………. 4Safety instructions……………………………………………………..4

Ratings/description…………………………………………………… 4

Application……………………………………………………………….. 4

Construction and Operating Princip les………… 7

 Stator……………………………………………………………………… 7Rotor………………………………………………………………………. 7Bearings…………………………………………………………………. 7Connection boxes…………………………………………………….. 8Excitation system……………………………………………………… 8Optional PMG system……………………………………………….. 9

Other options…………………………………………………………… 9

Instal lat ion………………………………………………….10

 Receiving inspection……………………………………………….. 10Unpacking and moving……………………………………………..10Location………………………………………………………………… .10Base design…………………………………………………………… 10Assemble to prime mover, alignment…………………………. 11

Two-bearing alignment…………………………………….11Two-bearing close-coupled alignment………………. 13Single-bearing alignment………………………………… 19

Foot deflection……………………………………………………….. 26

Doweling……………………………………………………………….. 26Electrical connections……………………………………………… 26Space heaters……………………………………………………….. 26Inspection before startup…………………………………………. 27

Operation………………………………………………….. 28Initial startup: generators w/auto & manual control………. 28Initial startup: generators w/auto control only………………. 28Restoring residual magnetism/fieldflashing………………… 29Continuous operation………………………………………………. 30Idling……………………………………………………………………… 31

Parallel operation……………………………………………………..31

Note: Because of rapid changes in designs

and processes and the available variability

of our products, information in this manual

is not contractually binding and is subject to

change without notice.

The image on the front cover is representa-

tive only and may include optional features.

Several variations are available within the

range of generators covered within this

manual.

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Maintenance………………………………………………. 33

 Schedules……………………………………………………………… 33Maintenance procedures…………………………………………. 34

Visual inspection methods of windings……………… 34Cleaning………………………………………………………. 36Insulation resistance tests at low voltage………….. 36Dry out procedures……………………………………….. 38Bearing lubrication………………………………………… 39Rectifier tests……………………………………………….. 39

Disassembly…………………………………………………………… 42Overall disassembly……………………………………….. 42Exciter armature removal…………………………………43PMG removal………………………………………………… 45

Bearing removal……………………………………………. 45Assembly……………………………………………………………….. 46

Bearing installation………………………………………… 46Overall assembly…………………………………………… 47Exciter installation…………………………………………. 47PMG installation……………………………………………. 48

Storage…………………………………………………………………. 49

Troubleshooting Guide………………………………. 50

 Appendices………………………………………………. 511: List of equipment for installation/maintenance…………. 51

2: Standard SAE engineflywheel……………………………… 543: Standard SAE engine flange…………………………………. 55

4: Six-lead generator marking…………………………………… 565: 12-lead generator marking……………………………………. 566: Optional component marking………………………………….577: Six lead generator connections……………………………… 588: 12-lead generator connections………………………………. 599: Single bearing 40 Frame key parts ……………………….. 6010: Single bearing 50/500 Frame key parts………………….6111: Single bearing 60/600 frame key parts………………….. 6212: Single bearing 80/800 frame key parts…………………..63

13: Two bearing 60/600 frame key parts…………………….. 6414: Two bearing 80/800 frame key parts…………………….. 65

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Introduction 

ForewordThis manual contains instructions for installing, operating and

maintaining AC brushless revolving field generators. These generators

are manufactured in many sizes and ratings and with various options.

Please read this manual in its entirety before unpacking, installing, and

operating your generator.

Safety instructionsIn order to prevent injury or equipment damage, everyone involved in

installation, operating and maintenance of the generator described in this

manual must be qualified and trained in the current safety standards that

govern his or her work.

The following paragraphs define warnings, cautions, and notes as theyare used in this manual:

Warning: Warnings identify an installation, operating or maintenance

 procedure, practice, condition, or statement that, if not strictly followed,

could result in serious injury to personnel.

Caution: Cautions identify an installation, operating or maintenance

 procedure, practice, condition, or statement that, if not strictly followed,

could result in destruction of or damage to equipment or serious

impairment of system operation.

Note: Notes highlight an installation, operating or maintenance

 procedure, condition, or statement and are essential or helpful but are not

of known hazardous nature as indicated by warnings and cautions.

Ratings/description Nameplates, which are located on the side of the generator, include serial

and model number as well as rating information.

Application:The generators have been designed for use in a maximum ambient

temperature of 40° C, and altitude less than 3300 ft (1000 meters)

above sea level in accordance with NEMA MG1. Ambient temperaturesin excess of 40° C, and altitudes above 3300 ft (1000 meters) can be

tolerated with reduced ratings. Refer to the generator nameplate for 

rating and ambient temperature and to the factory for appropriate

derating factors. Refer to NEMA MG1 for additional information on

usual/unusual operating conditions.

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The generators are self ventilated screen protected designs and are

not suitable for mounting outdoors unless adequately protected by

enclosures. The enclosure must provide suf ficient cooling air so the

generator does not overheat. The enclosure air intake must also be

designed to prohibit the ingress of moisture. The air intake/outlet must

 be sized for the air flow required. Consult the factory for air flow and

additional pressure drops.

Dynamic balancing of the generator rotor assembly has been carried out

during manufacture to ISO 1940 Class G2.5. The vibration produced by

the generator is caused by residual unbalance at operating speed. The

fundamental vibration frequencies are shown in Table 1.

Caution: Reduction in cooling air flow or 

inadequate protection to the generator can

result in damage and/or failure.

Vibrations generated by the engine are complex and contain harmonics

of the fundamental frequency. The generator will be subjected to these

vibrations, which will result in the generator being subjected to vibration

levels higher than those produced by the generator itself. Our generators

are designed to withstand the vibration levels encountered on generating

sets built to meet the requirements of ISO 8528-9. Table 2 lists the

vibration limits by kVA range and speed for acceptable generator set

operation.

 Table 1: Fundamental vibration frequencies

Pole RPMFundamental

vibration frequency

41500 25 Hz

1800 30 Hz

61000 16.7 Hz

1200 20 Hz

Engine RPM kVA Vibration

displacement

mm (rms)

Vibration

velocity

mm/s (rms)

Vibration

acceleration

m/s2 (rms)

Four pole1500 RPM, 50 Hz1800 RPM, 60 Hz

10<kVA≤50 0.64 40 25

50<kVA≤125 0.4 25 16

125<kVA≤250 0.4 25 16

250<kVA 0.32 20 13

Six pole1000 RPM, 50 Hz

1200 RPM, 60 Hz

250<kVA≤1250 0.32 20 13

1250<kVA 0.29 18 11

 Table 2: Vibration levels measured on the generator

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It is the responsibility of the generating set designer/manufacturer to

ensure the alignment of the genset, stiffness of the skid and mountings

are such that the vibration limits as defined above are met.

If the vibration levels of the generating set are not within what is

specified in Table 2, then 1) Consult the genset builder. The genset

 builder should address the genset design to reduce the vibration levelsas much as possible. 2) Consult the factory if the above levels cannot be

met.

Torsional vibrations occur in all engine-driven shaft systems and may be

of a magnitude to cause damage at certain critical speeds. It is therefore

necessary to consider the torsional vibration effect on the generator shaft

and couplings.

It is the responsibility of the generator set manufacturer to ensure

compatibility. Rotor torsional data is available upon request for torsional

analysis.

Grounding terminals are provided on the feet of the generator and inside

the main terminal box. The neutral terminal is NOT connected to the

frame.

Damage and decrement curves along with reactance and time constants

are available upon request to assist the system designer with the

coordination of the protection devices. It is the responsibility of the

user, system designer and/or generator set manufacturer to coordinate

 protections on breakers installed or supplied with a generator.

Warning: Exceeding ISO 8528-9 vibration

levels will have a detrimental effect on

the generating set and also the life of 

the bearings. This will void the generator 

warranty. Refer to the product service group

at the factory if you are in doubt.

Warning: Torsional incompatibility and/or 

excessive vibration levels can cause

damage or failure of the generator and/or 

genset components.

Warning: Ground the neutral in accordance

to local, national and international codes.

Incorrect grounding and/or protection can

result in personal injury and equipment

damage.

Warning: Protection devices must be

coordinated in order to prevent personalinjury and equipment damage.

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Construction and Operating Principles

StatorThe stator consists of the supporting frame, core, and armature windings.

The stator core is made from laminations, thin sheets of electrical steel,

which are stacked and held in place by steel end rings and support bars.

The rings and bars are welded to or are part of the steel frame. Feet are

welded to the bottom of the frame and allow the assembly to be mounted

on the genset base.

The windings (coils) are constructed of layered and insulated copper 

wire. The coils are inserted in the core slots, connected together, and the

entire assembly is dipped or vacuum-pressure impregnated with resin.

Stator leads terminate in standard connection lug for ease of connection

to the load.

RotorThe main rotor assembly is the revolving field. It consists of windings

in a core, which is in turn mounted on a steel shaft. The exciter armature

assembly and optional permanent magnet generator (PMG) rotor are also

mounted on the shaft as are the fan(s) and other optional accessories. The

core consists of thin sheets of electrical steel, which are stacked together.

The core makes the salient poles (four or six).

The rotor windings consists of insulated magnet wire wound around

each pole. V-blocks between each pole keep the rotor windings in place.

Damper windings consist of aluminum or copper rods that are inserted

through each pole surface and are attached to copper or aluminum

damper end plates at each end of the lamination stack. The end plates

are attached to adjacent poles to form a continuous damper winding. The

ends of the windings are supported with bars or pole shoes. The rotor 

either has epoxy applied during the winding process or is impregnated

with resin or epoxy.

The shaft is made from rolled or forged steel and machined to

accommodate all the rotating generator components. Keyways in the

shaft ensure precise positioning of the revolving field, exciter armature,

and optional PMG rotor. On the exciter side, the shaft has a slot or hole

in its center line for running the revolving field leads to the rectifier.

BearingsThe generator will contain either one or two bearings. Bearings are

typically ball or roller type and are either 1) heavy duty double shielded

 bearings, greased for life or 2) regreaseable bearings, which contain fill

and drain ports for easy lubrication.

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Connection boxesThe main lead connection box houses the load lead terminals. In

addition, the generator may have auxiliary terminal strips for temperature

detectors, space heaters, sensing leads, and other accessories.

Excitation systemThe excitation system consists of the exciter stator assembly and the

exciter armature assembly:

The exciter stator assembly consists of windings in a core. The core is

made from steel laminations that are stacked and welded together. The

main exciter stator coils are placed in slots in the core and form alternate

 North and South poles. The entire assembly is mounted to the end

 bracket. The stator is a stationary field, which is powered by the voltage

regulator.

The exciter armature assembly is keyed onto the generator shaft. A three-

 phase winding is inserted into slots in the laminations. The coils are heldin place by insulating wedges. The coil extensions are braced with tape.

Output leads from the winding are connected to the rotating rectifier 

assembly.

The rotating rectifier is a three-phase full wave bridge rectifier,

converting the AC from the exciter armature to DC, which is transferred

to the revolving field windings. Two designs are used. The standard

design uses positive and negative diode cubes fitted on an aluminum

 back plate along with the surge suppressor. The other design, used on

special applications, has two stainless steel plates, each containing three

rotating rectifier diodes, which are mounted on each side of an insulating

hub to form the negative and positive terminals. The plates also act as

heat sinks for the diodes.

Excitation system functional overview: Exciter field control is

established by the strength of the exciter field current developed by

the voltage regulator system. The DC voltage and current levels of the

exciter field signal from the voltage regulator varies depending upon

the generator output voltage and the loading of the output lines (see

Figure 1). The voltage regulator system can be energized by the main

stator (SHUNT excitation system) or by the optional PMG stator (PMG

excitation system).

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Optional PMG systemThe permanent magnet generator (PMG) system consists of the PMG

stator and PMG rotor:

The PMG stator is a stationary armature and is mounted next to the

exciter stator. The PMG stator consists of steel laminations. The PMG

windings are placed in slots in the laminations. Insulating wedges are

inserted at the top of each slot to hold the coils in position.

The PMG rotor consists of a magnetized disk and cast pole tips or 

 permanent magnets assembled into a rotor using round insulating plates

and steel magnet separators. The PMG rotor is secured to an aluminumhub. The PMG rotor hub is keyed to the shaft and secured with a

hardened retaining washer and bolts.

PMG system overview: The PMG system functions as a pilot exciter,

 providing power to the automatic voltage regulator power supply. The

PMG is an AC generator that uses permanent magnets in the rotor instead

of electromagnets to provide the magnetic field (see Figure 1).

Other optionsOther options include, but are not limited to, space heaters, filters, and

temperature sensing devices.

Figure 1: Overview of excitation system(with an optional PMG)

Output leads

Voltageregulator

Exciter stator(field)

Main stator

(armature)

Shaft

Main rotor (DC)

RectifierExciter

armature (AC)

PMG stator(armature)

PMG rotor(field)

Prime mover

Power input

Optional

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Installation

Receiving inspectionBefore accepting a shipment, examine the packaging for any sign of 

damage that might have occurred during transit. Report any damage to

the transportation company and the factory.

Unpacking and movingIf the generator is received during cold weather, reduce condensation on

cold surfaces and failure due to wet windings by allowing the generator 

to reach room temperature before removing the protective packing.

Unpack the generator carefully to avoid scratching painted surfaces. Do

not remove the protecting lubricant from the shaft end, drive plates, and

flange machined surfaces. Inspect for loosely mounted components and

the presence of moisture. Inspect to make certain foreign material, such

as crating nails, loose bolts or packing material, which may have falleninto the machine during unpacking, is removed. If damage is noted,

determine the extent of damage and immediately notify the transportation

company claims of fice and the factory. Be sure to give complete and

accurate details when reporting damage.

Move the generator by attaching an overhead hoist to the lifting

eyes installed on the generator frame or by lifting the generator from

underneath the skid with a forklift.

Single-bearing generators are shipped with plastic strips between the

main rotor and stator to maintain air gap and a shipping bar across the

drive discs.

LocationInstall the generator in an area so it complies with all local and industrial

regulations. Locate it in a clean, dry, well-vented area or area that is

suitable for the generator enclosure. Make sure it is easily accessible for 

inspection and maintenance.

Protect generators operating intermittently in very damp locations with

space heaters. Slowly warm generators placed in operation after being

subjected to very low temperatures to prevent excessive condensation.

Check winding and insulation resistance before placing the generator inoperation (see instructions later in this manual).

Base designThe type of base to be used will depend upon the nature of the

installation site. However, the generator base must be rigid, level, and

free from vibration. Mounting holes must be larger than the fasteners to

allow for alignment.

Warning: Be alert at all times when

installing, operating and maintaining the

generator. Avoid contact with the uninsulated

metal parts of the generator. Most injuries

occur from faulty ground connections on

portable electrical equipment and failure to

ground stationary equipment.

Test all portable devices frequently to

prove that a solid electrical circuit exits

from the metal frame though the grounding

conductor, in the electrical cord, to the

grounding contact in the attachment plug.

Do not use electrical equipment with frayed,

burned or damaged cords. Always take

extreme care when moving the generator.Be careful to not strike objects or personnel.

 Apply lifting force to structural points

specifically provided for lifting. Do not use

the enclosure lifting holes to lift the whole

unit. Use lifting means adequate for the

weight. Observe lifting notices attached

to the generator. Failure to observe these

instructions can result in personnel injury

and damage to the generator.

Caution: Do not attempt to transport a

single-bearing generator without maintainingproper rotor support. Failure to observe this

warning can result in equipment damage.

Caution: Blocking or restriction of normal air 

flow into or out of the generator may cause

damage to the electrical windings.

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Assemble to prime mover, alignmentFollow either the two-bearing alignment (if your generator model has

two bearings but no adapter to bolt to an engine flywheel housing),

two-bearing close-coupled alignment (if your generator model has two

 bearings and an adapter for bolting to a flywheel housing), or single-

 bearing alignment (if your generator has one bearing and drive plates).

Two-bearing alignment

Follow the tolerances specified by the coupling manufacturer when they

are tighter than described in this manual.

Use shims, if necessary, between the mounting pad and the base to

 properly level and align the generator to the prime mover.

Install the coupling(s) on the generator and engine drive shafts in

accordance with the coupling manufacturer installation procedures. Use

a straight edge and a thickness gauge for rough alignment as shown in

Figure 2. Check for angular and parallel alignment as follows:

Figure 2: Rough alignment

Straight edge

 Thickness gauge

Notes: Mounting of the indicators must

allow complete rotation of the prime mover.

Use dial indicators that are rigid so indicator

sag won’t be a factor. Using the shortest

offset distance of the indicator bracket will

reduce the effects of indicator droop or sag.

During alignment, you may also need to

compensate for engine expansion due to

heating. Generator expansion is generallynot considered a factor.

If the genset is moved to a different

location, check alignment before startup.

Caution: Do not pry on the generator fan.

Angular alignment: Fasten a dial indicator to one of the coupling halves,

and scribe the position of the dial button on the face of the opposite

coupling half as shown in Figure 3. Rotate both shafts simultaneously,

keeping the finger or button on the indicator at the reference mark on the

coupling hub. Note the reading on the indicator dial at each one quarter revolution.

A variation of readings at different positions will indicate how the

machine needs to be adjusted to obtain a maximum misalignment of 

0.001 inch (0.0254 mm) for each inch (25.4 mm) of the coupling hub’s

radius, total indicator runout. Place or remove slotted shims from under 

the front or rear engine or generator mounting pads and/or shift the front

or back half of one component from side to side until the components are

 properly aligned. Tighten the mounting bolts, and recheck alignment.

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Parallel alignment: Fasten a dial indicator to one of the coupling halves,

and scribe the position of the dial button on the top of the oppositecoupling half as shown in Figure 4. Rotate both shafts simultaneously,

keeping the finger or button on the indicator at the reference mark on the

coupling hub. Note the reading on the indicator dial at each one quarter 

revolution. A variation of readings at different positions will indicate how

the machine needs to be adjusted to obtain a maximum misalignment of 

0.002 inch (0.0508 mm). Place or remove slotted shims from under all

of the engine or generator mounting pads and/or shift one component

from side to side until the components are properly aligned. Tighten the

mounting bolts, and recheck alignment.

Dial indicator

Figure 3: Angular alignment

Dial indicator

Figure 4: Parallel alignment

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Two-bearing close-coupled alignment

Check the engine flywheel housing pilot’s radial and face runout by

mounting a dial indicator and measuring the flywheel to the flywheel

housing as shown in Figure 5. See Table 3 for maximum allowable

runout.

SAE housingnumber

654321

0.5000

0.002 (0.051)0.003 (0.076)0.003 (0.076)0.004 (0.102)0.004 (0.102)0.005 (0.127)0.005 (0.127)0.006 (0.152)0.007 (0.178)

Allowable runout(TIR) inch (mm)

10.500 (266.70)12.375 (314.33)14.250 (361.95)16.125 (409.58)17.625 (447.68)20.125 (511.18)23.000 (584.20)25.500 (647.70)31.000 (787.40)

Housing insidedia., inch (mm)

 Table 3: Maximum allowableflywheel housing runout

Figure 5: Flywheel housing check

Shaft

Flywheel

Flywheel housingDial indicator

pointer for radialrunout

Dial indicator pointer forface runout

Notes: Mounting of the indicators must

allow complete rotation of the prime mover.

Use dial indicators that are rigid so indicator

sag won’t be a factor. Using the shortest

offset distance of the indicator bracket will

reduce the effects of indicator droop or sag.

During alignment, you may also need to

compensate for engine expansion due to

heating. Generator expansion is generally

not considered a factor.

If the genset is moved to a different

location, check alignment before startup.

Caution: Do not pry on the fan.

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Check the engine flywheel’s radial and face runout by mounting a dial

indicator and measuring the flywheel housing to the flywheel as shown

in Figure 6. See Table 4 for maximum allowable runout.

 Table 4: Maximum allowableflywheel runout

Figure 6: Flywheel check

Shaft

Flywheel

Flywheel housing

Dial indicator pointerfor radial runout

Dial indicatorpointer for face

runout

6.57.5810

11.514161821

24

0.002 (0.051)0.002 (0.051)0.002 (0.051)0.003 (0.076)0.003 (0.076)0.004 (0.102)0.005 (0.127)0.005 (0.127)0.006 (0.152)

0.007 (0.178)

Pilotdiameter

Allowable runout(TIR) inch (mm)

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Figure 7: Generator adapter check

Shaft

AdapterDial indicator pointerfor radial runout

Dial indicatorpointer for face

runout

Figure 8: Generator coupling check

Shaft

Adapter

Dial indicatorpointer for radial

runout

Dial indicatorpointer for face

runout

Check the generator adapter’s radial and face runout by mounting a

dial indicator on the generator shaft or coupling as shown in Figure 7.

The maximum radial and face runout on the generator adaptor must not

exceed 0.010 inch (0.254 mm).

Check the generator coupling’s radial and face runout by mounting

a dial indicator to the generator adapter as shown in Figure 8. The

maximum radial and face runout on the coupling must not exceed 0.003

inch (0.076 mm).

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Measure and record the engine crank shaft end play and generator end play. Set the engine end play to the manufacturer’s recommended

 position for alignment. Verify the generator end play is set at a position

of one half of the measured distance or at a position that will allow

full thermal growth of the generator shaft when operated at rated

temperatures.

Mount the generator on the skid, and move the generator to within

0.010 inch (0.254 mm) of the engine. Place two 0.010-inch (0.254 mm)

shims in the horizontal (9 o’clock and 3 o’clock) positions between the

generator adapter and the engine flywheel housing. Raising the rear,

exciter end of the generator as necessary, place two 0.010-inch (0.254

mm) shims in the vertical (6 o’clock and 12 o’clock) positions between

the generator adapter and the engine flywheel housing. This will give

a good starting point for alignment. Remove the vertical shims at this

time. (If necessary, mark holes to be drilled on the base, and remove the

generator at this time.)

Shaft

Flywheel

Flywheel housing

Dial indicator pointerfor radial runout

Dial indicatorpointer for face

runout

Figure 9: Engine coupling check

Install the portion of the coupling that fits into the engine flywheel

following the manufacturer’s recommended procedures and in

accor dance with engine manufacturer’s specifications. Check the

coupling’s radial and face runout by mounting a dial indicator to the

engine flywheel housing as shown in Figure 9. The maximum radial and

face runout on the coupling must not exceed 0.004 inch (0.102 mm).

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Mount a dial indicator on the generator shaft or half coupling to the

flywheel radial surface for parallel alignment as shown in Figure 10.

Mount a dial indicator on the flywheel coupling to the face of the

generator half coupling for angular alignment as shown in Figure 10.

Align the engine by rotating the prime mover in 90-degree increments

and measuring total indicator runout. Tighten the generator to the base

 before taking each set of readings. Raise or lower the generator byadding or removing shims under the feet.

Shaft

Flywheel housing

Dial indicator pointerfor angular alignment

Dial indicator pointerfor parallel alignment

Flywheel

Figure 10: Alignment checkFollowing the final generator adjustment and runout check, remove

the horizontal shims from the adaptor flywheel housing, and move the

generator all the way to the adaptor. Then tighten the fasteners. Recheck 

alignment. Make sure angularity (face) total indicated runout does not

exceed 0.001 inch (0.0254 mm) per inch (25.4 mm) of generator shaft

diameter and parallel (radial) total indicated runout does not exceed

0.003 inch (0.076 mm).

Torque the fasteners to the value shown in Table 5.

Note: Clearances between the adaptor 

pilot and the flywheel housing recess are

designed to meet the tolerance of 0.001 to

0.015 inches (0.0254 to 0.381 mm).

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 Table 5: Recommended lubricated torque values. (If no lubricant is used, increase values by 25%.)

Grade 2

Sizein-lbs. ft-lbs N-M

Min. Max. Min. Max. Min. Max.

4-40 3.3 4.7 0.4 0.5

6-32 6.1 8.7 0.7 1.0

8-32 12.5 17.8 1.0 1.5 1.4 2.0

10-32 20.8 29.7 1.7 2.5 2.3 3.4

1/4-20 50.4 72.0 4.2 6.0 5.7 8.1

5/16-18 92.4 132.0 7.7 11.0 10.4 14.9

3/8-16 159.6 228.0 13.3 19.0 18.0 25.8

7/16-14 252.0 360.0 21.3 30.0 28.5 40.7

1/2-13 378.0 540.0 31.5 45.0 42.7 61.0

9/16-12 46.2 66.0 62.6 89.5

5/8-11 65.1 93.0 88.3 126.1

3/4-10 105.0 150.0 142.4 203.4

7/8-9 141.4 202.0 191.7 273.9

Grade 8

Size in-lbs. ft-lbs N-MMin. Max. Min. Max. Min. Max.

10-32 36 49 4.1 5.5

1/4-20 72 144 6 12 8.1 16.3

5/16-18 156 276 13 23 17.6 31.2

3/8-16 324 444 27 37 36.6 50.2

7/16-14 480 720 40 60 54.2 81.3

1/2-13 780 1020 65 85 88.1 115.2

9/16-12 1140 1500 95 125 128.3 169.5

5/8-11 1560 2040 130 170 176.8 230.5

3/4-10 2760 3600 230 300 311.8 406.77/8-9 4320 5760 660 480 488.1 650.8

1-8 6720 8640 560 720 759.3 976.2

Grade 5

Size in-lbs. ft-lbs N-MMin. Max. Min. Max. Min. Max.

1/4-20 60 84 5 7 6.8 9.5

5/16-18 120 192 10 16 13.5 21.7

3/8-16 228 336 19 28 25.8 38

7/16-14 360 528 30 44 40.7 59.7

1/2-13 540 804 45 67 61 90.8

9/16-12 792 1152 66 96 89.5 130.2

5/8-11 1104 1608 92 134 124.7 181.7

3/4-10 2052 2724 171 227 231.8 307.8

7/8-9 3372 4368 281 364 381 493.51-8 5160 6432 430 536 583 726.7

Class 8.8

Sizein-lbs. ft-lbs N-M

Min. Max. Min. Max. Min. Max.

M4 20 32 1.7 2.7 2.3 3.6

M5 40 64 3.3 5.4 4.5 7.3

M6 65 113 5.4 9.4 7.3 12.8

M8 168 264 14 22 20 30

M10 324 516 27 43 38 58

M12 612 900 51 75 69 101

M14 960 1428 80 119 109 161

M16 126 184 170 250

M18 183 243 248 330

M20 263 341 357 463

M22 367 457 497 619

M24 465 580 631 787

Class 10.9

Sizein-lbs. ft-lbs N-M

Min. Max. Min. Max. Min. Max.

M4 22 36 1.8 3 2.5 4.1

M5 46 74 3.8 6.2 5.2 8.4

M6 77 122 6.4 10.2 8.7 13.8

M8 192 288 16 24 22 32

M10 384 576 32 48 43 66

M12 672 996 56 83 77 112

M14 1080 1554 90 132 122 179

M16 140 206 190 279

M18 205 271 277 368

M20 294 381 398 517

M22 409 510 554 691

M24 531 662 720 898

1-NM =0.737 ft-lbs. =8.85 in-lbs.

 ASTM & SAE grade markings

Metric grade markings

Grade 2 Grade 5 Grade 8

Class 8.8 Class 10.9

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Single-bearing alignment

Before assembling the generator to the prime mover, remove the exciter 

cover and adapter cover. Remove the blocking holding the drive discs to

the adapter and the air gap spacers. Also make sure the generator bearing

end clearance is not less than the total engine crankshaft axial movement

 plus 1/16 inch (1.59 mm). The generator is shipped from the factory with

approximately 1/4-inch (6.36 mm) bearing endplay. (This dimension isspecified on the generator’s corresponding outline drawing.)

Check the engine flywheel housing pilots’s radial and face runout by

mounting a dial indicator and measuring the flywheel to the flywheel

housing as shown in Figure 5. See Table 3 for maximum allowable

runout.

Check the engine flywheel’s radial and face runout by mounting a dial

indicator and measuring the flywheel housing to the flywheel as shown

in Figure 6. See Table 4 for maximum allowable runout.

Measure the generator drive plate diameter (dimension S of Figure 11)and flywheel bore diameter (dimension B of Figure 12). Drive plate

diameter must not be greater than the flywheel bore diameter. Also check 

to make sure the hole centers match (dimension W of Figure 11 and

dimension C of Figure 12).

Notes: Mounting of the indicators must

allow complete rotation of the prime mover.

Use dial indicators that are rigid so indicator

sag won’t be a factor. Using the shortest

offset distance of the indicator bracket will

reduce the effects of indicator droop or sag.

During alignment, you may also need to

compensate for engine expansion due to

heating. Generator expansion is generally

not considered a factor.

If the genset is moved to a different

location, check alignment before startup.

Caution: Do not pry on the generator fan.

Figure 11: Single bearing generator drive plateand adaptor

S

Y

W A

Adaptor

Bolt holes

Driveplates

Fan

Shaft

Caution: Never grind the OD of drivediscs or attempt to drill out the holes. If the

dive discs do not fit properly, use different

discs or a different flywheel.

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Figure 12: SAE flywheel and adapter

Caution: The number and thickness

of drive discs are specified for torque

requirements. Do not remove drive discs

to compensate for spacing.

BC

G

 Tappedbolt holes

Flywheel

Measure the axial distance from the surface on the generator adapter to

the outside surface on the drive disc coupling plates (dimension Y inFigure 11). This dimension is specified on the generator’s corresponding

outline drawing. If the dimensions do not match, move the rotor axially

relative to the stator until the dimensions are equal, ensuring the bearing

is not contacting either face. Approximately 0.060 inch (1.52 mm) gap is

needed to avoid axial or thrust loading.

Measure the axial distance from the machined surface on the engine

flywheel housing the bottom of the flywheel drive disc recess

(dimension G in Figure 12). Make sure the difference between

dimensions Y (of Figure 11) and G are less than 1/32 inch (0.79 mm).

If G is more than Y, install additional spacers between the drive discsand the generator hub. If Y is more than G, remove spacers (if supplied)

 between the drive discs and generator hub. If not spacers were

 provided, move the rotor, ensuring the bearing is not contacting either 

face. Approximately 0.060 inch (1.52 mm) gap is needed to avoid axial

or thrust loading.

Support the generator shaft to ease the mating process, and install the

generator to the engine. Make sure the drive discs seat in the recess of 

the flywheel housing. Secure the generator to the engine (drive discs to

flywheel, adapter to flywheel housing), and the base. Use lock washers

on all bolts. Torque the adapter and drive discs in a criss-cross pattern

to the values in Table 5.

Ensure that the bolts in the flywheel do not bottom out. If they are too

long or cannot be tightened with a socket or box wrench, use a shorter 

 bolt or spacers inserted in the bolts as shown in Figure 13 to increase

the clearance between the bolt head and the flywheel.

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Figure 13: Disc-to-flywheel installation

Flywheel

Drive plates

Drive hub

Spacer

Bolt

Lock washer

After installing the drive disc-to-flywheel bolts, check the alignment

of the generator. This involves two steps: 1) making sure the generator shaft is centered in the flywheel and 2) making sure the crankshaft and

generator shaft form a straight line horizontally and vertically.

Centering pilot (parallel alignment):

To measure how well the shaft is centered in the flywheel pilot, clamp

a dial indicator to the flywheel housing or generator body. The dial

indicator will read the total runnout of the generator shaft, drive hub, or 

fan, which must be machined (see Figure 14).

Drive hub

Shaft

Fan

Adapter

Figure 14: Centering pilot setup

Drive plates

Dial indicator pointer

Note: Indicating from a cast surface will

result in false readings.

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1. Clean the machined surface of any dirt, grease, rust, or paint. Use

Emery cloth, if necessary, to ensure a smooth surface to measure

from.

2. Mount a dial indicator to the flywheel housing or generator 

stator, to take the readings from the machined surface. Check for 

clearance before rotating the shaft.

3. Bar the engine over counterclockwise (facing the flywheel), and

take a reading every 90º. A maximum of 0.005 inch (0.127 mm)

total indicator runnout (TIR) is acceptable.

If the runnout exceeds this amount, roll the highest point to the

top. Loosen the coupling bolts at this point to allow the shaft and

coupling to drop in the flywheel counterbore. Once all the bolts are

loose, re-torque the bolts.

4. Repeat steps 2 and 3, and, if TIR is still unacceptable, remove thecoupling bolts, and rotate the generator shaft 90º with respect to the

engine flywheel. Further adjustments can be made by rotating in

additional 90º increments until the specifications are achieved.

 Angular alignment 

To measure angular alignment, mount a dial indicator on the shaft of 

one machine to read against the shaft face of the other machine (see

Figure 15. The dial indicator can be clamped to the generator fan and

measured from the flexplate-to-flywheel mounting bolt.

Figure 15: Angular alignment

Generator fanFlywheel

Drive plates

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Before taking readings, roll the shaft in reverse 45º and then back 45º,

and zero the dial indicator. This sets the axial position of the crankshaft

and the generator shaft.

Take readings at the 12:00, 9:00, 6:00 and 3:00 o’clock positions.

Readings in the 12:00 and 6:00 o’clock positions determine the

vertical alignment, and readings in the 9:00 and 3:00 o’clock positionsdetermine horizontal alignment.

A total indicator reading (TIR) is the difference between the two

readings on opposites sides of the shafts. For example, in Figure 16,

the horizontal TIR is (-0.009) and (+0.004), which is a difference of 

0.013 in. (0.330 mm) or 13 thousandths of an inch TIR. Vertical TIR 

is (0) and (+0.005), which is a difference of 0.005 in. (0.127mm) or 5

thousandths of an inch TIR.

+0.004-0.009

-0.005

0

Figure 16: Example of runnout readings

The shaft shown in Figure 17 is angularly misaligned from that of the

engine. This could either be vertical or horizontal misalignment.

The distance “S” divided by the distance to the bearing (or rear mount)

“L” is equal to 1/2 TIR divided by the radius from the dial indicator tothe center of the shaft “R.”

S 1/2 (TIR)L R

Thus, the amount of shimming or horizontal sliding required is

S = L x (1/2 TIR)/R

Figure 16: Exaggerated example of shaftmisalignment

R 

S

L

=

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This relationship is used with the outboard mount or any inboard

mount (closer to the flywheel) as long as the distance to the required

mount is used for “L”.

Make vertical adjustments by adding or removing shims from the

mounts on each end of the generator. Adjust the left-hand and right-

hand inboard mounts the same, and adjust the left-hand and right-handoutboard mounts the same (see Figure 17).

Figure 17: Mount locations

Outboard mount Inboard mount

Engine

Generator

I-beam common skid

Make horizontal adjustments by loosening all the mounting bolts

and moving the generator to the desired side. This can be done with

a jacking screw or a pry bar in the bolt hole. Set up dial indicators to

monitor how far the machine is moved, or, as a alternative method,

rotate the shaft to the 3:00 or 9:00 o’clock position (see Figure 18),

and make adjustments until 1/2 TIR is indicated by the angular dial

indicator.

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Figure 18: Setup for horizontal adjustment

Angular alignment is acceptable when the TIR in all directions is less

than 0.005 in (0.127 mm) measured at the flexplate-to-flywheel bolt,

which is 14 in. (355.6 mm) from the shaft center.

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Foot deflectionAfter alignment, check for foot deflection or “soft foot” condition on

each shim location to eliminate distortion of the generator frame. Do

this by loosing one mounting bolt at a time and checking deflection

after retightening. Deflection at the shim location from shims under 

compression to a loosened condition must not exceed 0.003 inch (0.076

mm).

DowelingIn case the mounting bolts loosen during operation, doweling will

 prevent movement of the generator. Dowel as follows:

Check the alignment after the generator has been in operation for at least

48 hours. If alignment is not satisfactory, realign.

Drill holes through the footpads and into the base in two mounting pads

opposite each other. Drill the holes slightly smaller than the dowel pin.

Ream the holes to the proper diameter for the pin. Clean out chips, and

install the pins.

Electrical connectionsIf the generator was subjected to a rapid change in temperature, freezing

or wet conditions during shipment or storage, measure the insulation

resistance of each winding and dry the generator, if necessary, as

described in the maintenance section.

Make all electrical connections (main load, temperature monitoring

device, space heater, AVR) in accordance with local regulations andnational/international electrical code requirements. Check the electrical

diagrams provided with the generator or manual. The main terminals

need to be properly spaced for the load connections. Refer to Table 5 for 

the proper torque values for the connections.

Grounding points are provided for properly grounding the system to

the generator frame. The grounding wire must be sized per national/

international codes.

Space heatersWhen the generator has optional space heaters to prevent water 

condensation during long periods of downtime, connect the space heatersso they start when the generator is turned off and stop when the generator 

is switched on. Refer to the electrical diagrams for the space heater 

characteristics.

Warning: The space heaters are designed

to be energized when the generator is

shut down. They are hot enough to cause

skin burns. Terminals for power at the

space heaters are live during operation.

Disconnect power to the space heaters

before removing the generator covers.

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Inspection before startupAfter electrical connections have been made, perform the following

checks:

• Check all the connections to the electrical diagrams provided.

• Secure all covers and guards.

• Turn the rotor slowly with the appropriate starting mechanism (bar 

the engine or flywheel) through one revolution to see if the rotor 

turns freely.

• Determine the direction of the engine rotation, and make sure that it

matches the rotation of the generator.

• Make sure the power requirements comply with the data on the

generator nameplate.

• Make sure that the engine-generator set is protected with an adequate

engine governor and against overspeed above 125% of rated speed.

• Make sure the output of the generator is protected with an overload

 protection device, such as circuit breakers or fuses, sized in

accordance with national/international electrical code and local

electrical code standards.

• Remove tools and other items from the vicinity of the generator.

Caution: Do not pry on the fan.

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Operation

Initial startup: generators with both automatic and

manual voltage control

1. Disconnect the generator output from the load by opening the maincircuit breaker.

2. Turn the manual voltage adjust rheostat fully counterclockwise, and

actuate the auto-manual switch to the manual position.

3. Start the prime mover, and bring the set to rated speed. Turn the

manual voltage adjust rheostat to reach rated voltage. Close the

output circuit breaker, and apply load in steps until the rated load is

reached. Adjust the manual adjust rheostat as necessary to obtain the

desired output voltage.

4. Gradually reduce load, and adjust the rheostat accordingly until noload is reached. Open the circuit breaker, and stop the prime mover.

5. Turn the voltage adjust rheostat on the voltage regulator fully

counterclockwise.

6. Put the auto-manual switch in auto. Then start the genset, and bring it

to rated speed. Adjust the voltage to the desired value.

7. Close the output circuit breaker. Then check the generator voltage

and voltage regulation. Apply load in steps until the rated load is

reached.

8. Check for vibration levels at no load and rated load. A slight increase

is normal. As the load is maintained for 2-3 hours, the vibration

levels will gradually increase and reach a final level. See Table 2 for 

acceptable vibration levels .

Initial startup: Generators with automatic voltage control

only (generator has an automatic voltage regulator (AVR)

with no auto-manual switch)1. Disconnect the generator output from the load by opening the main

circuit breaker.

2. Turn the voltage adjust rheostat fully counterclockwise. Start the

 prime mover, and bring the set to rated speed. Turn the voltage adjust

rheostat to obtain the desired voltage.

3. Close the output circuit breaker, and apply load in gradual steps until

the rated load is reach. Note the voltage regulation with the changes

in load steps.

Caution: Do not actuate the auto-manual

switch with the full load applied to the

generator. Whenever possible, stop the

generator before switching.

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4. Check for vibration levels at no load and rated load. A slight increase

is normal. As the load is maintained for 2-3 hours, the vibration

levels will gradually increase and reach a final level. See Table 2 for 

acceptable vibration levels .

Restoring residual magnetism/ field flashingThe direct current necessary to magnetize the revolving field is obtained

from the exciter. Upon starting the generator, current and voltage is

induced into the exciter by the magnetic lines of force set up by residual

magnetism of the exciter field poles. Residual magnetism of the exciter 

field poles may be lost or weakened by a momentary reversal of the field

connection, a strong neutralizing magnetic field from any source, or non-

operation for a long time. If the generator fails to generate voltage after 

it has come up to rated speed, it may be necessary to restore residual

magnetism.

To restore the small amount of residual magnetism necessary to begin

the voltage build up, connect a 12 or 24V battery to the exciter field coilcircuit and flash as follows:

1. Open the output circuit breaker, and stop the engine.

2. Disconnect the exciter field coil wires F1 and F2, and connect the

 battery positive lead to the field coil lead F1.

3. Flash the field by touching the battery lead to the field coil circuit

terminal F2.

4. Disconnect the battery leads, and reconnect the field coil lead F1, and

reconnect the field coil lead F2.

5. Start the generator, and check for voltage build up. Reflash if 

the generator output voltage does not build up, or flash with the

generator running, the field coil wires connected to the regulator, and

a 10-amp or larger diode off the positive terminal of a maximum 12

V battery per Figure 19.

Figure 19: Field flashing setup with the field wires con-nected to the regulator

12 V battery

+

—

10 amp orlarger diode Voltage

regulatorF-

F+

F1(+)F2 (-)

Note: If the polarity of the exciter is reversed

by flashing the field, it may be corrected by

interchanging the battery leads.

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Continuous operationOperate the generator within the nameplate values. If the generator is

operated below the rated power factor and voltage, decrease the kVA to

 prevent overheating of the field and stator windings. Consult the factory

for derating factors if the application requires the unit to be run beyond

nameplate values.

Rotor overheating may occur when the generator is carrying excessive

unbalanced loads. Negative sequence currents flowing in the field pole

face cause the rotor heating. For a general guide to the allowable phase

unbalance, see Figure 20, Guide to allowable phase unbalance (which is

 based on a 10% equivalent negative sequence current).

Figure 20: Guide to allowable phase unbalance

0 20 40 60 80 100

20

40

60

80

100

Max. current in any phase (% of rated)

Min.currentinanyphase(%

ofrated)

Excessiveunbalance

Allowable

unbalance

Caution: Operating the unit beyond name-

plate values may cause equipment damage

or failure.

The guide is used in the following manner: Find the point where the

vertical line (determined by the minimum current in any of the phases

and expressed in percent of rated current) crosses the horizontal line

(determined by the maximum current in any of the phases and expressed

in percent of rated current). Ensure the point where these two lines

intersect is within the permissible allowable unbalance region for safe

operation of the generator.

Loss of fi

eld excitation can result in the unit operating out of synchronization with the system when operating is parallel. This has the

effect of producing high currents in the rotor, which will cause damage

very quickly. Protective relays should be considered to open the circuit

 breaker.

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IdlingUnless the voltage regulator has V/Hz protection built in, having the

generator set in operating mode while idling the engine can cause

 permanent equipment damage. If engine adjustments require that

the engine be run at idle speed and the regulator does not have V/Hz

 protection, make the generator regulating system inoperative during

idling by one of the following methods:

When the generator is provided with a voltage shutdown switch, be sure

the switch is set to the idle position while the engine is running at idle

speed.

Where the generator set is provided with field circuit breakers, set the

circuit breaker to the off position while the generator is running at idle

speed.

Where the generator set is provided with an automatic/manual control

switch that has an off position, switch it to off while the engine isrunning at idle speed.

Where the generator set does not have any of the above options, remove

the wires from the voltage regulator input power terminals when the

engine is running at less than rated speed.

Parallel operationFor the generator to operate in parallel with a system in operation, the

 phase sequences of the generator must be the same as that of the system.

Use transformers to reduce the voltage to an acceptable level, and then

use a phase rotation meter or incandescent lamp method, described in

electrical machinery handbooks, for a phase sequence check.

The output voltage at the paralleling point must be the same as each

instant, which requires that the two voltages be of the same frequency,

same magnitude, same rotation, and in coincidence with each other.

Voltmeters indicate whether the voltage magnitude is the same, and

frequency meters indicate whether the frequencies are the same. Whether 

the voltages are in phase and exactly at the same frequency is indicated

 by a synchroscope or by synchronizing lamps.

A synchroscope can be used to indicate the difference in phase angle between the incoming machine and the system. The generator can be

 paralleled by using incandescent lamps connected as shown in Figure 21.

The voltage rating of the series lamps must equal the voltage rating of the

transformer-low voltage winding.

Each prime mover in the system must have the same speed regulating

characteristics, and the governors must be adjusted to give the same

speed regulation as determined by applying load that is proportional to

the full load rating of the generator.

Caution: Refer to the voltage regulator 

manual for complete details and possible

additional instructions. Damage to the rotat-

ing diodes, generator, and voltage regulator 

can be caused if the regulator is operated

improperly.

Caution: Do not make connections or other-

wise make contact with the generator leads

or other devices connected to them unless

the genset is stopped and the phase leads

are grounded.

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The voltage regulator must include paralleling circuitry. In addition, the

voltage, droop settings and the V/Hz regulation characteristics must bethe same for all the voltage regulators. This will allow the generators to

 properly share reactive loads.

If cross-current compensation is used, paralleling current transformers

must give the same secondary current.

Current transformer secondary windings provide reactive kVA droop

signal to the voltage regulator. Accidental reversal of this electrical

wiring will cause the voltage to attempt to rise with load rather than

droop. If this occurs during paralleling, stop the unit and reverse the

wires at the voltage regulator terminals.

If the set is provided with a unit/parallel switch, set the switch to the

 parallel position on the unit being synchronized.

Synchronize the generator by adjusting the speed (frequency) slightly

higher than the system. Observe the synchroscope or the lamps. The

lamps should fluctuate from bright to dark at the rate of one cycle every

2 to 3 seconds. When the generator is in phase (the lights will be dark),

close the circuit breaker. Immediately after closing the breaker, measure

the line current of the generator. The readings must be within the rating

of the unit. A high ammeter reading accompanied by a large kW reading

indicates faulty governor control. A high ammeter reading accompanied

 by a large kVAR unbalance indicates problems with the voltage regulator.

Adjusting the cross current or voltage droop rheostat should improve the

sharing of kVAR.

To shut down the generator operating in parallel, gradually reduce the

kW load using the governor to reduce fuel or power. When kW load

and line current approach 0, open the generator circuit breaker. Operate

the generator unloaded for several minutes to dissipate the heat in the

windings. Refer to the prime mover manual for shutdown and cool-down

 procedures.

Figure 21: Synchronizing paralleled generators with testlamps

Load lines from the incoming generator

Loadswitch

Synchronizinglamps

System bus

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Maintenance

SchedulesA regular preventive maintenance schedule will ensure peak 

 performance, minimize breakdowns and maximize generator life. The

schedule listed below is a guide for operating under standard conditions.

Specific operating conditions may require reduced or increased

maintenance intervals. Also, if there is a different or more specific

schedule for your generator than the schedule provided below, it will be

included as a supplement to the manual package.

Every day

Visually check generator bearing housings for any sign of grease/oil

seepage.

Check the operating temperatures of the generator stator windings.

Check the control panel voltmeter for proper stability and voltage output.

Monitor the power factor and generator loading during operation.

Every week

Visually inspect the bearing exterior for dirt, and clean if necessary.

Inspect any generator air filters for build up of contaminants, and clean or 

replace as required

Every 2000 Hours or 6 months of operation

Remove generator outlet box cover. Visually inspect the stator outputleads and insulation for cracking or damage. Check all exposed electrical

connections for tightness. Check transformers, fuses, capacitors, and

lightning arrestors for loose mounting or physical damage. Check all lead

wires and electrical connections for proper clearance and spacing.

Clean the inside of the outlet box, air screens, and air baf fles with

compressed air or electrical solvent if needed.

Check machine vibrations and bearing condition with a spectrum

analyzer or shock pulse.

Regrease the optional regreaseable-type bearings.

Every 8000 hours or 1 year of operation

Check insulation resistance to ground on all generator windings,

including the main rotating assembly, the main stator assembly, the

exciter field and armature assemblies, and the optional PMG assembly.

Check the space heaters for proper operation.

Check the rotating rectifier connection tightness.

Warning: Do not service the generator 

or other electrical machinery without de-

energizing and tagging the circuits as out of 

service. Dangerous voltages are present,

which could cause serious or fatal shock.

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Every 20,000 hours or 3 years of operation

Remove the endbrackets, and visually inspect the generator end windings

for oil or dirt contamination. Excessive contamination may necessitate

surface cleaning with compressed air and electrical solvent.

Replace the bearing(s) if dictated by operating conditions, otherwise

inspect them for any indiction of wear or damage, and replace as needed.

Inspect the fan and fan hub for damage.

Every 30,000 hours or 5 years of operation

Disassemble the generator (this includes rotor removal).

Clean the generator windings using either (depending upon the severity

of contamination) 1) compressed air and electrical solvent or 2) de-

greaser and high pressure hot water wash. Dry the windings to acceptable

resistance levels (see the dry out procedure).

Inspect the rotor shaft bearing journals and bracket bearing cavity for 

wear or scoring.

Replace the bearings.

Maintenance procedures

Visual inspection of windings

Electric machines and their insulation systems are subjected to

mechanical, electrical, thermal and environmental stresses that give rise

to many deteriorating influences. The most significant of these are the

following:

Thermal aging: This is the normal service temperature deteriorating

influence on insulation.

Over temperature: This is the unusually high temperature of operation

caused by conditions such as overload, high ambient temperature,

restricted ventilation, foreign materials deposited on windings, and

winding faults.

Overvoltage: This is an abnormal voltage higher than the normal service

voltage, such as caused by switching or lightning surges or non-linear loads. Operating above rated nameplate voltage will reduce insulation

life.

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Contamination: This deteriorates electrical insulation by 1) conducting

current over insulated surfaces 2) by attacking the material to reduce

electrical insulation quality or physical strength, or by 3) thermally

insulating the material so the generator operates at higher than normal

temperatures. Such contaminants include water or extreme humidity, oil

or grease including unstable anti-wear and extreme pressure lubricants,

conducting and non-conducting dusts and particles, industrial chemicalssuch as acids, solvents, and cleaning solutions.

Physical damage: This contributes to electrical insulation failure by

opening leakage paths through the insulation. Physical damages can be

caused by physical shock, vibration, over-speed, short-circuit forces or 

line starting, out-of-phase paralleling, erosion by foreign matter, damage

 by foreign objects and thermal cycling.

Ionization effects: Ionization (corona), which may occur at higher 

operating voltages, is accompanied by several undesirable effects such as

chemical action, heating, and erosion.

To achieve maximum effectiveness, set up a direct visual inspection

 program initially to those areas that are prone to damage or degradation

caused by the influences listed above. The most suspect areas for 

deterioration or damage are 1) ground insulation, which is insulation

intended to isolate the current carrying components from the non-current

 bearing components, and 2) support insulation, which includes blocks

and slot wedges and are usually made from compressed laminates of 

fi brous materials, polyester, or similar felt pads impregnated with various

types of bonding agents. Look for the following:

Deterioration or degradation of insulation from thermal aging: Coils witha general puf finess, swelling into ventilation ducts, or a lack of firmness

of the insulation, suggesting a loss of bond with consequent separation of 

the insulation layers from themselves or from the winding conductors or 

turns.

Abrasion: Abrasion or contamination from other sources, such as

chemicals and abrasive or conducting substances, which damages coil(s)

and connection surfaces.

Cracking: Cracking or abrasion of insulation resulting from prolonged or 

abnormal mechanical stress. In stator windings, looseness of the bracing

structure is a certain sign of such phenomena and can itself cause further 

mechanical or electrical damage if allowed to go unchecked.

Erosion: Foreign substances impinging against coil insulation surfaces,

which may cause erosion.

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Cleaning

Remove dust, preferably using a vacuum cleaner to prevent the

redistribution of the contaminant. A small non-conducting nozzle or tube

connected to the vacuum cleaner may be required to reach dusty surfaces

or to enter into narrow openings. After most of the dust has been

removed, a small brush can be af fixed to the vacuum nozzle to loosen

and allow removal of dirt that is more firmly attached.

If compressed air must be used, exercise care in the application of 

 pressure to prevent damage to the insulation. If available, (30 PSI (2

Bars) or less) instrument air should be used. In any case, the air must be

clean, oil-free and dry.

Wipe all exposed surfaces with clean cloths to remove any remaining

oil or dirt. It may be necessary to use a cleaning solution made of mild

soap and water in order to effectively remove the dirt. Use clean water to

remove any soap residues.

Any cleaning fluid is more or less a solvent for insulating compounds,

hence avoid the application of these fluids in large quantities. They

should not be allowed to remain in contact with the winding any longer 

than necessary to remove the oil and dirt. Also avoid excessive wetting

 because it washes impurities into inaccessible crevices.

Dry the machine according to the procedure in this manual until normal

insulation resistance values are obtained at room temperature.

Inspect the generator for any signs of deterioration.

Clean electrical contacts, switch contacts and terminals with an approvedcontact cleaner. Do not file contacts.

Insulation resistance tests at low voltage

Insulation tests are conducted for two reasons: to discern existing

weakness or faults or to give some indication of expected service

reliability.

Insulation resistance tests are based on determining the current through

the insulation and across the surface when DC voltage is applied. The

leakage current is dependent upon the voltage and time of application,

the area and thickness of the insulation, and the temperature and

humidity conditions during the test.

The insulation resistance test is used to determine the insulation

condition prior to application of more extensive testing measures. Refer 

to the following electrical measurement procedures for testing detail.

Contact the factory or refer to IEEE Standard. 432-1992 when more

extensive insulation tests are required.

Warning: When using cleaning solvents,

ensure adequate ventilation and user 

protection.

Warning: Exercise safety precautions when

using compressed air.

Caution: Use only manufacturer-approved

cleaning fluids.

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Exciter field (stator) and PMG armature (stator)

1. Disconnect the exciter leads from the terminals in the ter minal box or 

from the voltage regulator.

2. Connect exciter leads to one clamp of 500-volt megger, and connect

the other clamp to the generator frame.

3. Apply 500 V from the megger, and measure the resistance reading

after 1 minute. The reading must be a minimum of 1 megohm. If it is

not, refer to the cleaning or dry out procedures.

4. Ground the exciter field leads to the generator frame for several

minutes after the megger has been disconnected. This will allow the

voltage build up to be properly discharged.

Exciter armature

1. Disconnect the exciter armature leads from the rotating rectifiers.

2. Connect the leads of the exciter armature to one clamp of a 500-volt

megger, and connect the other clamp to a suitable connection on the

shaft.

3. Apply 500 V from the megger, and measure the resistance reading

after 1 minute. The reading must be a minimum of 1 megohm. If it is

not, refer to the cleaning or dry out procedures.

4. Ground the exciter leads to the shaft after disconnecting the megger.

This will allow the voltage build up to be properly discharged.

Main rotor 

1. Disconnect the generator field leads from the positive and negative

terminals of the rotating rectifier assembly.

2. Connect the positive and negative leads to one clamp of the 500-volt

megger, and connect the other clamp to the shaft.

3. Apply 500 V from the megger, and measure the resistance reading

after 1 minute. The reading must be a minimum of 1 megohm. If it is

not, refer to the cleaning or dry out procedures.

4. Ground the field leads to the shaft after disconnecting the megger.

This will allow the voltage build up to be properly discharged.

Caution: The insulation resistance tests are

usually made on all or parts of an armature

or field circuit to ground. They primarily

indicate the degree of contamination of the

insulating surfaces or solid insulation by

moisture and other conducting influences

and will not usually reveal complete or uncontaminated ruptures.

Note: The insulation resistance value

increases with decreasing winding

temperatures. All readings must be

corrected to winding temperatures. Use

Table 6 for converting megger readings to

other temperatures (e.g., 100 megohms at

50º C is converted to 170 megohms at 40°

C: 1.7 x 100).

 Table 6: Temperature conversionfactor for resistance readings

Winding Temp(º C)

0.230.370.61

1.72.74.57.5142338

61

Conversionfactor

102030405060708090100110

120

Warning: Never apply the megger to the

rotating rectifier, the voltage regulator or 

generator accessories (eg., temperature

detection devices, space heaters).

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Main stator 

1. Disconnect power connections and all control apparatus from the

generator terminals.

2. Measure insulation resistance of each phase separately with the two

other phases shorted to the frame.

3. Use a 500-volt megger connected between the leads of the phase to

 be measured and generator frame. The minimum 1-minute insulation

resistance must not be less than that given by the following formula:

Resistancein megohms =Rated generator voltage +1000

1000

If it is less than above, refer to cleaning or dry out procedures.

4.  Ground the leads to the frame after the 1-minute megger test. This

will allow the voltage build up to be properly discharged.

5. Repeat with the other phases.

Dry out procedures

If the insulation resistance readings are below the recommended

minimum values specified previously, use one of the dry out procedures

described below. Select the procedure based on the size and location

of the unit, available equipment, and experience of personnel. Before

drying, remove the voltage regulator.

Drying with external heat: Place heat lamps or space heaters (in addition

to the ones already supplied). Monitor winding temperatures. Raise

winding temperature gradually at a rate of 50° F (28° C) per hour up

to 200° F (93° C). Measure insulation resistance at 1-hour intervals.

Typically the insulation resistance will slowly drop while the temperature

is coming up, and then gradually increase and level out.

Drying with AC current in the armature: Short circuit the generator 

terminals. Provide DC excitation to the brushless exciter field winding.

Insert a current transformer and an ammeter to read full load current.

Run the generator at rated speed. Apply excitation to the exciter field

until rated current is developed. Monitor winding temperatures until they

stabilize. Continue running until insulation resistance values level off.

Monitor winding temperatures. Raise winding temperature gradually at

a rate of 50° F (28° C) per hour up to 200° F (93° C). Measure insulation

resistance at 1-hour intervals. Typically, the insulation resistance will

slowly drop while the temperature is coming up and then gradually

increase and level out.

Caution: Do not apply heat too rapidly. It

could damage the windings.

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Bearing lubrication

Shielded or sealed ball bearings: Shielded or sealed ball bearings are

factory packed with lubricants and generally can be operated several

years without requiring replenishment or change of the grease.

Regreaseable ball or roller bearings: In applications where regreaseable

 bearings are used, grease fill fittings and relief valves are incorporatedinto the bearing housing. Lubricate the bearings in accordance with the

lubricating instructions attached to the generator.

Rectifier tests

If a failure of a rotating rectifier is suspected, remove the exciter cover.

Test the entire rectifier assembly with an ohmmeter or test lamp as

follows.

Different designs of rotating rectifier assemblies can be used.

Diode cubes: They consist of three or six diodes depending on thegenerator frame. The figures below show how the rotating rectifier 

assemblies are assembled and wired for each frame. Locate and

disconnect all terminals on the rectifier/heat sink assemblies to test

the rectifiers inside the diode cubes. See Figures 22, 23, and 24 for an

overview.

Six discrete diodes: Remove the nut and washer holding the rectifier in

the heat sink, and remove the diode lead wire. Lift the rectifier from the

heat sink. See Figures 25 and 26 for an overview.

Figure 22: 40 Frame rotating rectifier assembly

!#!#

!#

!#

!#

!#

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Figure 23: 50/500 Frame rotating rectifier assembly

!# !#

!#

!  #   

     !      #

!#

!#

!#

!#!#

!#

!# !#

!#

     !      #

!  #   

   !   #

   !   #

   !   # !   

#    

!   #    

!   #    

!# !#

!#

!# !#

!#!#

!#

     !      #

!  #   

!#

!#!#

Figure 24: 60/600-80/800 Frame rotating rectifier assembly

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Ohmmeter method:

Diode cubes: Using an ohmmeter, measure the resistance between one of the AC terminals and the (-) terminal on the negative (-) rectifier / heat

sink assembly. Note the resistance reading and reverse the ohmmeter 

 probes. Note the second resistance reading. One of these resistance

readings should be high and one should be low. A low resistance in both

directions indicates a short. A high resistance in both directions indicates

an open rectifier. Repeat this procedure with the other two AC terminals

and the (-) terminal on the negative (-) rectifier / heat sink assembly.

Replace the rectifier / heat sink assembly if defective. Repeat the above

 procedure with each of the three AC terminals and the (+) terminal on the

 positive (+) rectifier/heat sink assembly.

Discrete components: Connect the ohmmeter leads across the rectifier inone direction (see Figure 26). Note the meter reading. Reverse the leads,

and note the meter reading. The meter should indicate a low resistance

when the leads are across the rectifier in one direction and a high

resistance when the leads are across the rectifier in the opposite direction.

A low resistance in both directions indicates a short. A high resistance in

 both directions indicates an open rectifier. Replace the rectifier / heat sink 

assembly if defective.

Figure 25: Rotating rectifier assembly, special designs

Negative

Positive

Positive

Caution: Failure to properly secure the

leads can cause equipment damage or 

failure.

Reversediode

Standarddiode

Anode

Cathode

Ohmmeter

Figure 26: Testing the rotating rectifier with anohmmeter

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Test lamp:

Connect the leads of a test lamp built as shown in Figure 27, consisting

of standard flashlight batteries and a flashlight. Test the rotating rectifiers

as described above but using the two test probes of this makeshift tester 

instead of the ohmmeter probes. The light should light in one direction

 but not in the other. If the light lights in both directions, the rectifier isshorted. If the light does not light in either direction, the rectifier is open.

Replace the rectifier/heat sink assembly if defective.

Replace defective rectifiers with rectifiers of the same operating

characteristics as rectifiers installed in the generator at the factory.

Order rectifiers by part number, including the model, serial number and

generator part number.

Surge protectors may be included on the rotating rectifier assembly.

Disconnect one lead of the surge protector, and connect the probes of an

ohmmeter or makeshift test lamp as shown in Figure 23, across the surge

 protector in either direction. If the light comes on, the surge protector is

defective. Order surge protectors by part number, including the model,

serial number and generator part number. Following replacement, make

sure that the revolving field, exciter armature, and rotating diode leads

are properly secured.

Disassembly

Overall disassembly

1. Remove the terminal box cover, and disconnect the load leads and

all other generator leads. Tag the leads to ensure they are correctly

connected when the generator is reassembled.

2. Remove the bolts securing the generator to the base and the engine,

and move the generator to an area that allows suf ficient room for 

disassembly.

3. Remove the coupling or drive plates.

4. Remove the exciter cover, rotating diode assembly, optional PMG if 

necessary, and the exciter assembly as explained later.

5. Support the shaft. Remove the exciter-end bracket bolts, and remove

the bracket. Tap lightly with a rubber or fi ber mallet to loosen

the bracket if necessary. Repeat with the drive-end bracket (if 

applicable).

Figure 27: Test lamp

Caution: Failure to properly secure the

leads can cause equipment damage or failure.

Note: The following procedures are meant

to be a general guide. Procedures for your 

unit may vary.

Warning: Ensure the generator has stopped

and is de-energized before disassembly.

Warning: Use a hoist and slings or chainsto support components during removal. Use

lifting devices that are selected for generator 

component weights, which can be found on

the mechanical data sheet. Be extremely

careful not to damage components.

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6. Remove the fan from the hub where applicable. If necessary, make

sure to mark the location of the fan for reinstallation.

7. Float out the rotor (see Figure 28). First attach a thick-wall pipe over 

the shaft on the drive end. Attach slings around the pipe on one end

and around the shaft on the opposite end. Lift up the rotor, and move

it out, resting the rotor as the slings are moved down the pipe for thenext lifting stage. Finally attach slings to each side of the core for 

moving the rotor to the final work space.

Figure 28 Floating the rotor

Drive end Exciter end

Warning: Make sure the pipe is strong

enough to support the weight of the rotor 

and that it does not have rough edges on

the inside, which could damage the shaft.

Caution: To prevent tension on the shaft,

put the slings around the largest shaft steppossible.

Caution: Make sure the rotor does not

rest on the stator during the stages of 

movement. Make sure the rotor does not hit

the stator.

Caution: Ensure the generator field wires

are flat in the wireway so they don’t tear 

during pulling. Do not pull on the edges of 

the heat sinks or on the exciter armature

windings.

Warning: Pull the PMG and exciter rotor 

straightly off. The assembly may pull toward

other steel components. Be careful that your

fingers or hands do not get pinched.

Exciter removal (see Figures 29 and 30)

1. Remove the exciter cover.

2. Remove the rotating diode assembly and/or PMG, if needed, as

explained separately. Disconnect the exciter stator leads.

3. Locate and remove the four bolts in the end of the shaft that hold the

retaining washer. Remove the retaining washer.

4. Remove the aluminum sleeve, and slide the exciter rotor off the shaft.

5. Remove the four bolts that hold the exciter stator to the bearing

 bracket.

6. Mark the location of the exciter for reassembly, and remove the

exciter stator.

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Retainingbolts

PMG stator

Exciter stator

Retainingwasher

ShaftExciterarmature

PMG rotor

spacer

Bearing

Rotating diodeassembly

Figure 29 Exciter armature assembly, PMG, 40, 50/500 Frames

Figure 30: Exciter armature assembly, 60/600 and 80/800 Frames

Retainingwasher

PMG rotor

Exciterarmature

PMG rotor

Aluminum

sleeve

PMG rotorspacer

Rotating diodeassembly

Shaft

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Optional PMG removal

1. Remove the exciter cover.

2. Remove the rotating diode assembly and/or the exciter, if needed, as

explained separately.

3. Disconnect the PMG stator leads.

4. Remove the four bolts that hold the PMG stator to the bearing

 bracket. Mark the location for reassembly, and remove the PMG

stator.

4. Remove the PMG rotor spacer if supplied, and slide the PMG rotor 

assembly off the shaft.

5. Wrap the PMG rotor in plastic to avoid contamination as it will

attract metal particles.

Bearing removal

1. Remove the endbracket(s) to expose the bearing(s).

2. Use a puller to remove the bearing from the shaft end with a cap (see

Figure 31). Replace it with a new bearing.

Figure 31: Pulling the bearing

Puller againstbearing

Cap to protect shaft end

Outer ring Inner ring

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.Assembly

Bearing installation (done prior to installing the rotor)

1. Heat the bearing to 220º to 250º F (104º to 121º C) in a clean oven or 

with an induction heater.

2. Start the heated bearing on the shaft. Then use a fi ber or soft metal

tube to tap the bearing into place.

3. Ensuring that pressure is applied only to the bearing inner ring,

 press the bearing onto the shaft until the inner ring seats against the

 bearing shoulder on the shaft.

4. Grease the generator bearing and/or bearing bracket cavity after the

 bearing has cooled according to bearing type as follows:

Shielded bearings are factory packed with grease. Fill the bearing

 bracket cavity to 40% with high quality ball bearing grease of NLGI#2 grade, which must be capable of lubricating satisfactorily over a

temperature range of the lowest ambient temperature to 250° F (121° 

C). Standard grease is Chevron SRI or Polyrex EM with mineral oil

 base.

With optional regreaseable ball or roller bearings, fill the bearing

to 30% with grease. Fill the bearing bracket cavity to 60%, and

add 3 shots or 3 oz. (85 gr.) to the bearing cap with high quality

 ball bearing grease of NLGI #2 grade, which must be capable of 

lubricating satisfactorily over a temperature range of the lowest

ambient temperature to 250°F (121° C). Standard grease is Chevron

SRI or Polyrex EM with mineral oil base. Table 7 provides anindication of the amount of grease to add to the bearing.

Caution: Make sure all components are

clean before assembly.

Note: Torque fasteners to the values speci-

fied in Table 5 unless otherwise specified.

Frame Bearing type Grams

40 6016 C3 9 ±2

50/500 6217 C3 26 ±3

60 6322 C3 146 ±7

600 6321 C3 123 ±6

80/800 6326 C3 219 ±11

 Table 7: Optional regreaseable ball or roller bearingfi

ll of 30%

Warning: Grease migrates between the

shields and into the bearing. The sametype of grease must be used. Grease

incompatibly can cause bearing and

generator failure.

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Overall assembly

1. Float in the rotor until the rotor and stator laminations line up.

Position the rotor such that a full pole face is at the bottom.

2. Install the endbrackets. Support the rotor during installation. Put anti-

corrosion agent on the bare mating surfaces.

3. Install the exciter, rotating diodes and optional PMG as described

 below.

4. Install the covers.

5. Install the coupling or drive plates.

6. Reconnect the load leads, exciter leads and accessories, if applicable.

Exciter installation (see Figures 29 and 30)

1. Assemble the exciter stator to the bearing bracket with four retaining bolts and washers.

2. Connect the exciter stator leads.

3. Clean the shaft and inside of the exciter laminations.

4. Place the key in the slot in the shaft, if applicable.

5. Lay the generator field wires flat in the wire slot with the wire ends

 protruding past the end of the shaft if applicable.

6. Position the exciter armature assembly in line with the shaft, andturn the assembly to the position where the keyway in the exciter 

laminations is in line with the key in the generator shaft.

7. With hand force, push the exciter armature assembly over the shaft,

so the edge of the armature is against the shoulder on the shaft or 

sleeve.

8. Route the main rotor leads through the retaining washer.

9. Secure the exciter rotor assembly using the retaining washer and four 

retaining bolts at the end of the shaft.

10. Connect the exciter armature and evolving field wires to the rectifier 

terminals.

11. Measure the air gap between the exciter armature and exciter field.

 Nominal values are shown in Table 8. If the air gap is less than 0.02

inch (0.058 mm), 1) check generator-engine alignment, 2) check for 

 bearing wear, 3) check for misalignment of the exciter armature or 

stator.

Caution: Ensure the generator field wiresare flat in the wire slot so they don’t tear 

during assembly. Do not pull on the edges

of the heat sinks or on the exciter armature

windings.

Caution: Do not pound on the rectifier or 

armature windings.

Note: To measure air gap, measure com-

pletely around the gap between the exciter 

armature and exciter field with a feeler 

gauge. Keep the gauge at the tightest point,

and turn the generator over to measure the

air gap as the rotor turns.

Caution: Do not pry on the fan.

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Optional PMG installation (See Figures 25 and 26)

1. Attach the PMG stator to the bearing bracket.

2. Place the main rotor leads in the shaft slot.

3. Carefully slide the PMG onto the shaft. Avoid contact between the

rotor and stator that could damage the windings or the permanentmagnets.

4. Connect the PMG stator leads.

5. Measure the air gap between the PMG rotor and PMG stator.

 Nominal values are shown in Table 8. If the air gap of the PMG

is less than 0.020 inch (0.508 mm), 1) check generator-engine

alignment, 2) check for bearing wear, 3) check for misalignment of 

the armature, PMG or stator.

Caution: Ensure the generator field wires

are flat in the wire slot so they don’t tear 

during assembly. Do not pull on the edges

of the heat sinks or on the exciter armature

windings.

40 Frame 50/500 Frame 60/600 Frame 80/800 FrameInch mm Inch mm Inch mm Inch mm

Exciter stator ID 6.446 163.7 6.446 163.7 10.125 257.2 10.125 257.2

Exciter rotor OD 6.318 160.5 6.318 160.5 9.98 253.5 9.98 253.5

Exciter air gap* 0.0624 1.63 0.064 1.63 0.0725 1.84 0.0725 1.84

PMG stator ID 7.187 182.5 9.9925 253.8 9.9925 253.8 9.9925 253.8

PMG rotor OD 7.116 180.7 9.893 251.3 9.893 251.3 9.893 251.3

PMG air gap* 0.0355 0.90 0.04975 1.26 0.4975 1.26 0.04975 1.26

 Table 8: Exciter and PMG air gap

*Nominal values do not include varnish and red sealer buildup.

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StorageIf the generator is not installed in its operating location as soon as

received, store it in a clean, dry area, not subject to vibrations or sudden

temperature or humidity changes. Make sure the storage area temperature

is between 10º F (-12º C) and 120º F (49º C) and the relative humidity is

less than 60%. If possible, storage should be in an ambient temperature

of approximately normal room temperature. Protect the shaft from

corrosion by applying an anti-corrosion agent. Cover the unit with a

durable cover.

Prepare units that cannot be stored in a temperature and humidity

controlled area as follows:

Install desiccant bags in the exciter cover and inside the end bells.

Vacuum seal the unit in a covering of plastic or other material designed

for that purpose.

Adequately tag the generator to ensure that preservative greases and

desiccant bags are removed before the unit is placed in operation.

If space heaters are supplied, energize them to keep condensation from

the windings.

For storage longer than 2 months, rotate the shaft a minimum of 10

revolutions every 60 days.Warning: If necessary, remove the covers

around the space heaters to reduce the risk

of fire.

Caution: Grease used in ball and roller 

bearing generators is subject to timedeterioration. Before placing the unit into

service after long-term storage, check the

bearings for corrosion, and replace the

grease or bearing(s).

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Troubleshooting Guide

(corrective maintenance)

Between regular preventive maintenance inspections, be alert for any

signs of trouble. Correct any trouble immediately. See Table 9 for symptoms, causes and remedies.

Warning: Problems left uncorrected can

result in injury or serious damage, which canresult in costly repairs and downtime.

Symptom Cause Remedy

No Voltage Defective voltage regulator, opened circuitbreaker, or fuse(s)

Check the voltage regulator. Reset the circuitbreaker or replace fuses if open.

Overvoltage, undervoltage, or overloaddevices tripped (when protective devicesare incorporated into the circuit)

Check for the cause of the abnormal condition.Correct any deficiencies. Reset devices.Check the generator nameplate for nominaloperating values.

Open circuit in exciter field Check continuity of shuntfield and leads

to voltage control. (Use ohmmeter orwheatstone bridge) If open infield coils,remove exciterfield assembly and returnassembly to factory for repair.

Loss of residual magnetism Restore residual magnetism orflashfield. Whenthe voltage regulator is a model that requiresflashing, install an automatic field flashingsystem.

Open circuit in stator windings Check for continuity in the windings. Return thegenerator to the factory for repair if open.

Malfunction of automatic voltageregulator

See troubleshooting of voltage regulator.Correct deficiencies.

Short-circuited generator output leads Clear lead to restore voltage buildup.

Open in rotating rectifiers Check rotating rectifiers, and replace if open.

Open in generatorfield Check for continuity and return rotor tofactory for repair if field coils are open.

Shorted or grounded surge protector Check for shorts or grounds. Replace .

Shorted or grounded rotating rectifier Check for shorts grounds. Replace or repair.

Shorted or grounded exciter armature Check for shorts or grounds. Replace or repair.

Low voltage Shorted leads between the exciter armatureand generatorfield

 Test and repair.

Incorrect stator connections Check connections and reconnect

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Page 51

Troubleshoot ing Guide (cont.)

Symptom Cause Remedy

Low voltage(cont.)

Improper adjustment of voltage adjustrheostat

Adjust rheostat.

Excessive load Reduce load. With three-wire, single-phase andfour-wire, three-phase generators, the load oneach leg must be as evenly balanced as possibleand must not exceed the rated current on any leg.

Line loss Increase the size of the line wire.

High resistance connections (hot) Make better connections.

Shorted main or exciter field Test the field coils for possible short bychecking resistance with an ohmmeter orresistance bridge. Return the rotor assemblyto the factory for repair if field coils are shorted.

Low power factor Reduce inductive (motor) load. Some ac

motors draw approximately the samecurrent regardless of load. Do not usemotors of larger horsepower rating thanis necessary to carry the mechanicalload.

Weak field due to operating in a warmtemperature

Improve the ventilation of the generator.Field current can be increased providingthe generator temperature ratingstamped on the nameplate is notexceeded.

Defective rectifiers in rectifier assembly(stationary)

Check rectifier assembly. Replacedefective fuses or rectifiers.

Excessive load Reduce load to rated value.Defective bearing Replace the bearing.

Improper speed of engine drivengenerator set due to defective governor,ignition system, or carburetor

Check and correct deficiencies.

Voltage regulator not operating properly Check the regulator. Adjust, repair or replace.

Fluctuatingvoltage

Prime mover speed fluctuating Check frequency and voltage of incomingpower when the generator set is motordriven. Check engine governor onengine-driven generator sets.

Loose internal or load connections Tighten all connections.

Generator overloaded Reduce load to rated value.dc excitation voltagefluctuating Trace dc excitation circuit. Correct any

defects.

Overspeed Correct speed of prime mover.

Voltage regulator not operating properly Check the regulator. Adjust, repair or replace.

High voltage Improper adjustment of voltage adjustrheostat or voltage regulator

Adjust rheostat and/or voltage regulator.

Voltage regulator not operating properly Check the regulator. Adjust, repair or replace.

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Page 52

Troubleshooting Guide (cont.)

Symptom Cause Remedy

Overheating Clogged ventilating screens and airpassages

Clean all screens and air passages.

Dry or defective bearings Replace defective bearings.

Coupling misaligned Align the generator set.

Generatorfield coils shorted orgrounded

 Testfield coils for shorts. Replaceshorted rotor or return it to the factory forrepair.

Unbalanced load or overload, low PF Adjust load to nameplate rating.

Vibrations Defective or dry bearings Replace defective bearings.

Misalignment of generator and primemover

Align the generator set.

Generator not properly mounted Check mounting. Correct defectivemounting.

 Transfer of vibration from anothersource

Isolate the generator set from the source of vibration by installing vibration dampenersbetween generator set base and foundation.

 Table 9: Troubleshooting

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Page 53

 Appendices

Appendix 1: List of equipment required for installation and maintenance:

Test equipment Notes

Ammeter Clamp-on rated, 0 to the generator rated amperage for measuringelectrical current.

Multimeter Digital, for measuring voltage, current, frequency and resistance. Thermometer For measuring temperature in Celsius or FahrenheitMegger To measure insulation resistance.Resistive Bridge To measure resistance of windings.

Special tools

Bearing puller For changing bearing.Exciter puller For pulling exciter armature

Standard too ls

Cable tool Crimping

Flashlight As requiredGrease gun For lubricating bearingsHammer Soft-facedLamp (incandescent) Safety lightScrewdrivers Standard, sized as requiredScrewdrivers Phillips, sized as requiredWrench Adjustable, 12-inchWrench Torque 0 to 800 ft-lb (1085 N-M)Wrench set Allen, 1/8 to 1/2 inchWrench set Socket, 1/4 to 1 Inch (6-25 mm) with 3/8 and 1/2 inch driveWrench set Standard, open-end/box-end combination sized 1/4 to 1 inch (6-25 mVacuum Electric with nonmetallic nozzle

Materials

Air Compressed, dry.Anti-corrosion agent Nox-Rust VC #10 Oil or equivalentCovering material Waterproof desiccant bags for protection from

moisture during long-term equipment storageDetergent As required for cleaningGloves Chemical-protectiveGloves Electrical-protectiveHeaters Space Heater, for eliminating excess moisture in damp areas and dry

out of motor or generator windingsPlastic Protection for long-term storageRags As required for cleaning

Water Warm and clean, for cleaning Tags Warning and cautions

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Page 54

Appendix 2: Standard SAE engine flywheel per SAE J 620

SAE A B C G Holes Size

6-1/27.25

(184.15)8.5

(215.9)7.875(200)

1.188(30.16)

6 5/16-18

7-1/28.125

(206.37)9.5

(241.13)8.75

(222.25)1.188

(30.16)8 5/16-18

88.875

(220.42)10.375

(263.52)9.625

(244.47)2.438

(61.91)6 3/8-18

10 10.875(276.22) 12.375(314.32) 11.625(295.27) 2.125(53.97) 8 3/8-18

11-1/212.375

(314.32)13.875

(352.42)13.125

(333.37)1.563

(39.68)8 3/8-18

1416.125

(409.75)18.375

(466.72)17.25

(438.15)1

(25.4)8 1/2-13

1618.125

(460.37)20.375

(517.52)19.25

(488.95)0.625

(15.875)8 1/2-13

1819.625

(494.78)22.5

(571.52)21.375

(543.92)0.625

(15.875)6 5/8-11

21 23(584.2)

26.5(673.1)

25.25(641.35)

0(0)

12 5/8-11

2425.375

(644.52)28.875

(733.42)27.25

(692.15)0

(0)12 3/4-10

GM-7113.5

(342.9)17.75

(450.0)15.5

(393.7)0.703

(17.85)4X2 5/8-11

GM-5312.375

(314.32)15.5

(393.7)13.875

(352.42)0.734

(18.65)4X2 5/8-11

Inches (mm)

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Page 55

Appendix 3: Standard SAE engine flange per SAE J 617

SAE A B C Holes Size

0031.00

(787.37)34.750

(862.62)33.500

(850.87)16 1/2-13

025.500

(647.67)28.00

(711.17)26.750

(679.42)16 1/2-13

1/223.00

(584.18)25.500

(647.67)24.375

(619.10)12 1/2-13

1 20.125(511.25) 21.750(552.43) 20.875(530.20) 12 7/16-14

217.625

(447.66)19.250

(488.93)18.375

(466.70)12 3/8-16

316.125

(409.56)17.750

(450.83)16.875

(428.61)12 3/8-16

414.25

(361.94)15.875

(403.21)15.00

(380.99)12 3/8-16

512.375

(314.31)14.00

(355.59)13.125

(333.36)18 3/8-16

610.500

(266.69)12.125

(307.96)11.250

(285.74)18 3/8-16

Inches (mm)

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Page 56

Appendix 4: Six-lead generator marking

Appendix 5: 12-lead generator marking

HIGH VOLTAGE SERIES STAR LOW VOLTAGE PARALLEL STAR

U (LI)

U1(T1)

U2(T4)

U5(T7)

U6(T10)

V5(T8)

W (L3)

W1(T3)

V2(T5)W2(T6)

N(L0)

V6(T11)

 V1( T2)

V (L2)

W5(T 9)

W6(T 12)

7,

74

774

74

5,)

54

54

54

54

.,

6,

64

64

64

6

4

621517-01

U(L1)

U1(T1)

U2(T4)

W1(T3)

W2(T6)V2(T5)

V1(T2)

W(L3) V(L2)

N(L0)

621518-01

STAR CONNECTION

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Page 57

Appendix 6: Optional component marking

   R   T   D   ‘   S

   T   H   E   R   M   O   C   O   U   P   L   E   S

   S   E   R   I   E   S

   P   A   R   A   L   L   E   L

   1   2   0   V   A   C

   2   4   0   V   A   C

   S   P   A   C   E

   H   E   A   T   E   R   S

   S   H   1

   S   H   2

   S   H   3

   S

   H   4

   S   H   1

   S   H   2

   S   H   3

   S   H   4

   S   T   A   T   O   R

   S   T   A   T   O   R

   B   E   A   R   I   N   G

   B   E   A   R   I   N   G

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Page 58

   S   Y   M   B   O   L   S

   C   R   1 —   C   R   6   R   O   T   A   T   I   N   G    R

   E   C   T   I   F   I   E   R   S

   C   R   7 —   C   R   8   S   U   R   G   E   S   U   P   P   R   E   S   S

   I   O   N

   D   I   O   D   E   S

   E   1

   P   O   S   I   T   I   V   E   H   E   A   T   S   I   N   K

   E   2

   N   E   G   A   T   I   V   E   H   E   A   T   S   I   N   K

   L   1

   E   X   C   I   T   E   R

   S   T   A   T   O   R

   L   2

   E   X   C   I   T   E   R

   A   R   M   A   T   U   R   E

   L   3

   R   E   V   O   L   V   I   N   G    F

   I   E   L   D

   L   4

   S   T   A   T   O   R

   R   5

   S   U   P   P   R   E   S   S   I   O   N

   R   E   S   I   S   T   O   R

   R   F   A

   R   E   V   O   L   V   I   N   G    F

   I   E   L   D   A

   S   S   E   M   B   L   Y

   P   O   L   A   R   T   Y   M   A   R   K

   O   P   T   I   O   N   A   L

   P   M   G

   F   U   S   E

   F   U   S   E

   L   1

   O   P   T   I   O   N   A   L   P   A   R   A   L   L   E   L   I   N   G    C

   U   R   R   E   N   T   T   R   A   N   S   F   O   R

   M   E   R

   O   P   T   I   O   N   A   L

   S   E   N   S   I   N   G    T

   R   A   N   S   F   O   R   M   E   R   S

   T   3

   2   6

   2   4

   2   2

   2   0

   2   8

   3   0

   F   1

   F   2

   6   5

       C       R       7

       R       F       A

      E      1

R   5

   L   2

       C       R       3

       C       R       2

   C   R   1

   E   2

       C       R       6

       C       R       5

       C       R       4

   —      +

      +

   L   3

       C       R       8

   —

      T      1

   L   4   T

   2

   T   4

   T   5

   T   6

Appendix 7: Six-lead generator connections

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Page 59

Appendix 8: 12-lead generator connections

   S   Y   M   B   O   L   S

   C   R   1  —   C   R   6   R   O   T   A   T   I   N   G    R

   E   C   T   I   F   I

   E   R   S

   C   R   7  —   C   R   8   S   U   R   G   E

   S   U   P   P   R   E   S   S

   I   O   N

   D   I   O   D   E   S

   E   1

   P   O   S   I   T   I   V   E

   H   E   A   T   S   I   N   K

   E   2

   N   E   G   A   T   I   V   E

   H   E   A   T   S   I   N   K

   L   1

   E   X   C   I   T   E   R

   S   T   A   T   O   R

   L   2

   E   X   C   I   T   E   R

   A   R   M   A   T   U   R   E

   L   3

   R   E   V   O   L   V   I   N   G    F

   I   E   L   D

   L   4

   S   T   A   T   O   R

   R   5

   S   U   P   P   R   E   S   S   I   O   N

   R   E   S   I   S

   T   O   R

   R   F   A

   R   E   V   O   L   V   I   N   G    F

   I   E   L   D

   A   S

   S   E   M   B   L   Y

   P   O   L   A   R   T   Y

   M   A   R   K

   O   P   T   I   O   N   A   L

   P   M   G

   F   U   S   E

   F   U   S   E

   L   1

   O   P   T   I   O   N   A   L

   S   E   N   S   I   N   G    T

   R   A   N   S   F   O   R

   M   E   R   S

   O   P

   T   I   O   N   A   L   P   A   R   A   L   L   E   L   I   N   G    C

   U   R   R   E   N   T   T   R   A   N   S   F   O   R   M   E   R

   2   6

   2   4

   2   2

   2   0

   2   8

   3   0

   F   1

   F   2

   L   4

   T   6

   T   3

   T   4

   T   1   2

   T   9

   T   1

   T   7   T

   1   0

   T   5

   T   8

   T   1   1

   T   2

   6   5

       C       R       7

       R       F       A

       E       1

R       5

   L   2

       C       R       3

       C       R       2

   C   R   1

   E   2

       C       R       6

       C       R       5

       C       R       4

   —      +

      +

   L   3

       C       R       8

   —

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Page 60

Appendix 9: Single bearing 40 frame key parts (Shunt and PMG models)

Item Description

1 Air outlet screen

2 Bearing (Exciter end)

3 Bracket (Exciter end)

4 Drip proof cover

5 Drive discs

6 Exciter armature

7 Exciter cover

8 Exciter stator

9 Fan

11 PMG rotor

12 PMG stator

13 Revolvingfield and shaft

14 Rotating rectifier assembly

15 Stand-off / Buss bar assembly

16 Stator assembly (wound)

17 Terminal box assembly

18 Terminal box top cover

19 Voltage regulator

ShuntOptional PMG

2/4!4)/.

4

19

18

5

9

38

6

7

2

1

13

16

15

17

14

38

6 12

11

7

14

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Page 61

Appendix 10: Single bearing 50/500 Frame key parts (Shunt and PMG models)

Item Description

1 Air outlet screen

2 Bearing (Exciter end)

3 Bracket (Exciter end)

4 Drip proof cover

5 Drive discs

6 Exciter armature

7 Exciter cover

8 Exciter stator

9 Fan

11 PMG rotor

12 PMG stator

13 Revolvingfield and shaft

14 Rotating rectifier assembly

15 Stand-off / Buss bar assembly

16 Stator assembly (wound)

17 Terminal box assembly

18 Terminal box top cover

18

ShuntOptional PMG

8

3

7

6

14

1112 9

5

1

2

7

6

8 3

1316

15

17

14

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Page 62

Appendix 11: Single bearing 60/600 Frame key parts (Shunt and PMG models)

Item Description

1 Air outlet screen

2 Bearing (Exciter end)3 Bracket (Exciter end)

4 Drip proof cover

5 Drive discs

6 Exciter armature

7 Exciter cover

8 Exciter stator

9 Fan

11 PMG rotor

12 PMG stator

13 Revolvingfield and shaft

14 Rotating rectifier assembly

15 Stand-off / Buss bar assembly

16 Stator assembly (wound)

17 Terminal box assembly

18 Terminal box top cover

19 Voltage regulator

Optional PMG

Shunt

N

T0

U

T1W

T3

V

T2

3

2

8

7 1

5

9

6

15

16

13

17

12

11

14

4

ROTATION

C

C

FF

F

T

T

F

T

T

2

2

2

2

2

2

B

B

B

B

B

T

T

T

T

T

T

T

T

T

T

T

C

T

C

T

T

T

T

T

T

T

T

T

T

T

S

S

S

S

S

S

S

S

18

19

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Page 63

Appendix 12: Single bearing 80/800 Frame key parts (Shunt and PMG models)

Item Description

1 Air outlet screen

2 Bearing (Exciter end)3 Bracket (Exciter end)

4 Drip proof cover

5 Drive discs

6 Exciter armature

7 Exciter cover

8 Exciter stator

9 Fan

10 PMG mounting ring

11 PMG rotor

12 PMG stator13 Revolvingfield and shaft

14 Rotating rectifier assembly

15 Stand-off / Buss bar assembly

16 Stator assembly (wound)

17 Terminal box assembly

18 Terminal box top cover

19 Voltage regulator

ROTATION

C

B

C

B

B

C

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

BS

B

BS

S

S

S

S

S

S

18

4

19

Optional PMG

Shunt

17 15

16

1310

12

11

14

3

2

9

5

1

8

6

7

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Page 64

Appendix 13: Double bearing 60/600 Frame key parts (Shunt and PMG models)

N

 T00

U

 T11W 

 T33

V 

 T22

83

17

12Optional PMG

Shunt

14

7

9

15

16

13

1

220

21

6

11

Item Description

1 Air outlet screen

2 Bearing (Exciter end)

3 Bracket (Exciter end)

4 Drip proof cover5 Drive discs

6 Exciter armature

7 Exciter cover

8 Exciter stator

9 Fan

11 PMG rotor

12 PMG stator

13 Revolvingfield and shaft

14 Rotating rectifier assembly

15 Stand-off / Buss bar assembly16 Stator assembly (wound)

17 Terminal box assembly

18 Terminal box top cover

19 Voltage regulator

20 Bearing (drive end)

21 Bracket (drive end)

4

18

19

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Page 65

Appendix 14: Double bearing 80/800 Frame key parts (Shunt and PMG models)

4

18

19

ENCLOSUREOVERSPEED

RATING

PHASE

RPM

Hz

ROTATION

ARRANGEMENT

STATOR CONN

WEIGHT

INSULATION

AMPS

VOLTS

P.F.

KW

kVA

EMI

MODEL

EXC VOLTS

AMB

DATE

SERIALNO

ALT

EXC AMPS

 TEMP RISE

Shunt

17

7

3

8

1012

Optional PMG

11

14

6

9

1316

15

21

20

1

2

Item Description

1 Air outlet screen

2 Bearing (Exciter end)

3 Bracket (Exciter end)

4 Drip proof cover5 Drive discs

6 Exciter armature

7 Exciter cover

8 Exciter stator

9 Fan

10 PMG mounting ring

11 PMG rotor

12 PMG stator

13 Revolvingfield and shaft

14 Rotating rectifi

er assembly15 Stand-off / Buss bar assembly

16 Stator assembly (wound)

17 Terminal box assembly

18 Terminal box top cover

19 Voltage regulator

20 Bearing (drive end)

21 Bracket (drive end)

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Leroy Some North America669 Natchez Trace Drive