Download Miller Electric TRAILPOWER 7GA1 Specifications
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January 1983 FORM: OM-468 Effective With Serial No. JC654458 o~ MODEL TRAILPOWER 25DA1 TRAILPOWER 25DA3 OWN ERS MANUAL miliEu ~ff MILLER ELECTRIC MFG. Co. 718 S. BOUNDS ST, P.O. Box 1079 APPLETON, WI 54912 USA ADDITIONAL COPY PRICE 75 CENTS NWSA CODE NO. 4579 PRINTED IN U.S.A. LIMITED WARRANTY EFFECTIVE: JUNE 1, 1979 . This warranty supersedes all previous MILLER warranties and is ex clusive with no other guarantees or warranties expressed or implied. f LIMITED WARRANTY~Subject to the terms and conditions hereof, Miller Electric Mfg. Co. Appleton, Wisconsin warrants to its Distributor/Dealer that all new and unused Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade accessories or other items manufactured by others. Such engines, frade accessories and other items are sold subject to the warranties of their respective manufacturers, if any All engines are warranted by their manufacturer for one year from date of original purchase. As ~ warr~nty or any other duty of any goods, the exclusive remedies therefore shall be, at Millers option (1) repair or (2) replacement or, where authorized in writing by Miller in appropriate cases, (3) not workmanship or mant on the or replacement at an authorized or warranty claim procedures ? be followed. to ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND . ANY GUARANTY OR REPRESENTA- IMPLIED WARRANTY, ? PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING lION material. required to honor warranty claims on warEquipment in the event of failure resulting from a defect within the following periods from the date of delivery of Equipment to the original user: Miller shall be ranted ( repair (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at Customers risk and expense. Upon receipt of notice of apparent defect or failure, Miller shall instruct the claiMiller service station nozzles and nozzle insulators where failure does result from defect in breach of quality the reasonable cost of as including general policy only, Miller may honor claims original user within the foregoing periods. In the case of Millers specified below, Millers warranty does not apply to components having normal useful life of less than one (1) year, such as spot welder tips, relay and contactor points, MILLERMATIC parts that come in contact with the welding wire of matter with respect to the . Except a submitted by the ANY TO AS IMPLIED WARRANTY OF MERCHANTABILITY OR ~ OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX CLUDED AND DISCLAIMED BY MILLER. 1. Arc welders, power sources and components 2. Original main power rectifiers (labor . . 3 years 4. All other Millermatic Feeders 5. Replacement 6. Batteries or repair parts, exclusive of labor AS EXCEPT 1 year only) 3. All welding guns and feeder/guns - 1 year WRITING, 90 . days EXPRESSLY MILLER ULTIMATE PURCHASE BY that Miller is notified in EXPERIENCED 6months WELDING writing within thirty (301 days TO, of the date of such failure. AND MILLERS ~. .,~ ARE BY MILLER INTENDED IN FOR COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND 1 year 60 days IN USE THE EQUIPMENT AND CONSUMER USE. MILLER provided PROVIDED PRODUCTS ~,. ...~, ~ NO RESELLER AND NOT MAINTENANCE FOR CONSUMERS OF ( OR ~ WARRANTIES DO NOT EXTEND IS AUTHORIZED TO ~ EXTEND WARRANTIES TO, ANY CONSUMER. .~ ~ I July 8, 1983 ERRATA SHEET After this manual appearing was printed, refinements in equipment design occurred. This sheet lists exceptions FORM: OM-468 to data later in this manual. AMENDMENT TO SECTION 3 - INSTALLATION Amend Section 3-4. PHASE SENSING SWITCH Add the IMPORTANT block at the IMPORTANT beginning of The Phase SENSING switch the Section. on this unit is locked in the 1 PHASE position. ______________ AMENDMENT TO SECTION 6 Amend Figure 6-1. Circuit - TROUBLESHOOTING Diagram For Single Phase Units 0~ -, 2~ OC 5] 0 0 JOE 2 OLO 0 N 0 CAUTION ~E~ER TQ ~rrEMpT OR NSTRUC1~O~S RE~OR~ NO M~NTR~ TO IU5rALLO~EPaTE ~QP~.~ENT Circuit Diagram No. B-090 359 Figure 6-1. Circuit Diagram For Single Phase Units ~FLE COPY RETURN TO FOW,k E a) C U a, I. a, (0 0 C) 4 a Co 0, Co E U 0 I Cl) C 0) a, I -C a) a, a -c Co C/) C 4 U, 901 060-3 pu~ ON W~J6e!(] 9~IE69~ 0M 0Sl IS Of 1!fl3J! 0 N U45 6 00 1 01 N OIl If 0 te 1I~Sl 3 1OS .503 I0~d0 IN InVD SNOTJ)fl015 Nol 01 1 3fl0 ,e!JOS -I1!M IS C If N 1051 iIldfOJ OA!~3J 01. 0l4I1d7 1 101 FJ oVl S~!Ufl so OS~LJd 4\IAJ IA A A A ~A A A10N41N~ . O9J~1-lBU!S :d~1 ~ /1;*o~oo ///// JO~ WPI6rn~J ~ - 9Jfl6!j 6uiMoI ~ 9 Y TABLE OF CONTENTS Section No. SECTION 1 1 1 1 - - - 1. General Information And Safety 1 Receiving-HandUng 1 3. Description 1 2-1. - 2. 3. 2-4. 2 5. 2 - - 2 2 2 - - - 6. 7. 8. 2 9. 2-10. - SECTION 3 3 3 3 3 3 3 - - - - - - Generator Reconnection Auxiliary Power Connection - 5 5 6 6 6 6 OPERATOR CONTROLS Voltage Adjustment Control Phase Sensing Switch 8 5. Ammeters 8 6. Voltmeter 8 Frequency Meter Stop Control Battery Charge Indicator Lamp 9 HourMeter 9 EtherStartingAid Sensitivity Adjustment OvervoltageAdjustrnentControl 9 1. SECTiON 5 - Engine Ether Starting Aid Equipment Grounding Terminal Frequency Changeover 3. 4-2. 5 5 Pre-Start Checks 4 4. SECTION 4 - Fuel 4 7 3-12. 3-13. - 3 7 - 5 Location Spark Arrestor/Muffler Installation Preparing New Battery For Service Start Push Button - 5 INSTALLTION Safety Shutdown System 8. 3 3 9. 3-10. 3-11. - - 1. 2. 3 -7. 4 INTRODUCTION 2. SECTION 2 2 - Page 1. 2. 3. - 9 9 9 9 SEQUENCE OF OPERATION Starting The 9 Engine Engine Shutdown - 8 10 MAINTENANCE General Periodic Cleaning And Inspection 10 Fuel/Water 10 Separator And Sludge Drain Plug 10 5 -4. Air Cleaner Service 10 5 Electrical System Servicing The Spark Arrestor 10 5 - - 5. 6. 5-7. 5 -8. 5 -9. SECTION 6 BrushesAndSlipRings EtherStartingAid Engine Speed Adjustment - General 6 Troubleshooting Chart 2. 6-3. 12 12 12 TROUBLESHOOTING 6-1. - 11 Booster BatteryJump 13 13 Starting 13 No. I SECTION 1 INTRODUCTION - Single Phase Output 25 KVA @ KW Volts 60 Phase Single-Three Output .8 power factor 20 25 @ .8 power factor 20 120/240 120/240 3 Wire 4 Wire* 104 Amperes Duty Cycle 100% 60 100% Max RPM No Load 1850 1850 KVA 20 16 20 Volts 115/230 3 Wire 115/230 Amperes Duty Cycle 87 100% 100% Max RPM No Load 1550 1550 Hertz KW 50 Hertz Heigth 16 4 Wire* 50 . Width Dimensions Depth Net Weight Shipping *Single.Three phase units are reconnectable for other voltages listed in Figure 1-2. Figure 1 - 1. A. 1-1. Specifications carefully followed could result or damage to this equipment. GENERAL INFORMATION AND SAFETY in minor personal injury General signal word, iWil~];1V~h~Ij highlights instruc special emphasis to obtain the most efficient operation of this equipment. A third Information presented in this manual and on various labels, tags, and plates on the unit pertains to equip design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equip tions which need ment ment. B. The Safety installation, operation, maintenance, and troubleshooting power generating equipment re quires practices and procedures which ensure personal safety and the safety of others. Therefore, this equip ment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all applicable codes. of 1 - RECEIVING-HANDLING - Prior installing to material from around packing equipment, the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading will be furnished by the manufacturer on re clean all quest if occasion to file claim arises. requesting information concerning this equip ment, it is essential that Model Description and Serial (or Style) Numbers of the equipment be supplied. When 1 Safety instructions specifically pertaining to this unit ap pear throughout this manual highlighted by the signal words I!i 1;hll~ei and CAUTION which identify 2. this - 3. DESCRIPTION supply 25 kva, 60 Hz. primarily for use where this unit is used on a - This generator is designed to 20 kva, 50 Hz. ac power or utility standby no power is available. If or emergency basis, ___________ always consult the local electrical utility, local different levels of hazard. ~YL1 l ~ I I~ statements include and maintenance procedures or installation, operating, practices which if not carefully followed could result in serious personal injury or loss of life. I statements include and maintenance procedures or installation, operating, practices or state codes, and the latest issue of the National Electrical Code for proper installation procedures. which if not WARNING ELECTRIC SHOCK can kill. __________ Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding procedure are employed. OM.468 Page 1 All units are shipped set up to provide the type of power output specified by the customer. If no specific output request is made, single phase units are shipped set up to supply 60 Hz. single phase output and single-three phase units are shipped set up to supply 120/240 volts, 60 Hz., three phase output (Series Delta generator con nection). Both single phase and single-three phase generators driven are Deutz diesel by a three cylinder, air-cooled, Equipment that must be operated on an electrical supp ly that has precise frequency tolerance or a pure sinisoidal wave form should not be connected to the output of this generator. Equipment that is sensitive to frequency ow engine. Single-three phase generators are reconnectable in parallel or series wye, or parallel, series, or double delta connection with available voltages listed on Figure 1-2. /~/ / /1//GENERATOR ~ G f 89 120/206 3 50 86 27/220 3 60 60 I 3 60 110/190 3 50 58 15/200 3 50 56 20/208 3 50 39/240 33 27/220 Y2 110 ~ -J 50 35 240/416 3 80 33 254/440 3 60 30 277/480 3 80 30 220 380 3 50 15 1 ~ 112 LO ~ ~ 3 13 .~rai 1 ~.. 17 ~ 61 29 230/400 3 50 240/418 3 50 26 254/440 ~ ~ 80 20/240 3 40 3 ~, ~ 76 ~TI2 ~ ~ LO ~T6 1~ 50 L3~- ~ ~L0 ~T7 ~ 16 50 ~ T~ 12 ,J, 120/240 3 50 1 60 15 14 15 110 111 112 L2 LO LI 19 73 75 18 72 74 77 TI 110 III 112 LI 112 19,(4~~1T1 I 48 17 L3 III 3 II V J~ V I J ~ rg~ W 15/230 18 12 ~ 0 50 12 L2 15 17 4 110/220 19 L3 Ll 13 53 OIAGRAM L3 U1 26 WIRING VVV~. 19 13 TI / GENERATOR CONNECTION L2 LI 5 TO LOAO CONNECTION p~ ~ / 13 ~II 18 19 12 Tb 15 18 TI 112 14 17 yVyVyy L2 04 20/240 16 --~ ~L0 -J SI 110/220 I 50 ~ 15 12 19 ~ 0 La 87 15/230 I 50 ~ ~ ~ 33 120/240 206 120 I 50 I 50 ~ 174 115 I 50 ~ ~ < I ~ 1 50 fl~ 16 110 13 TI 75 12 14 TI 112 VVVV~ .2 LO LI a. 12 14 18 ItO 13 15 19 13 ~19 ~ ~1I1 33 ~T8 T4JTIO III II 16 17 112 ~K (L ~ ~T1,T? ~ 12 L2 Figure 1-2. Generator Connection Diagrams Output Specifications Page 2 15 LI ItO 20 19 L2 16 < 82 167 T7 18 ~ I ~ TI~O 50 I LI 13~ or voltage be disconnected from this generator when the generator is started or stopped. must And SECTION 2 Figure 2-1. - in open well ventilated can areas kill. or if vent engine exhaust outside the building. Keep engine exhaust vent outlet away from building air in takes. operated indoors ENGINE EXHAUST SPARKS can cause fire. Exhaust spark arrestor must be installed in accor dance with local, state, and federal regulations. The engine exhaust system on And Base Moun Exceeding damage. 1fj~ll~Ic~ ENGINE EXHAUST GASES Operate Drawing Layout Hole LOCATION (Figure 2-1) 1. INSTALLATION Dimensional ting 2 - this generator is equip these limits can cause severe engine RESTRICTED AIR FLOW causes overheating and possible damage to internal parts~ least 24 inches (610 mm) of at unrestricted space on all sides of unit and keep underside free of obstructions. Do not p/ace any filtering device over the intake air Maintain passages of this generator. Do not install this unit in a permanent indoor loca tion. Warranty is void if any type of filtering device is used. ped with a combination spark arrestor/muffler as stan dard equipment. This device carries U.S.D.A. Forest Service Approval. A spark arrestor, maintained in effec tive working order, is mandatory if this generator is to be operated in a National Forest or on California Grasslands, brush, or forest covered land (see Section 4442 of California Public Resources Code). For other areas, check your state and local laws. IMPROPER LIFTING OF EQUIPMENT can result in personal injury and equipment damage. equipment of adequate capacity Use to lift the unit. If using lift forks to handle this unit, be sure the lift are long enough to extend out of the op posite side of the base. Using lift forks too short will expose internal com ponents to damage should the tips of the lift forks forks penetrate the bottom of the unit. OPERATION ON LINLEVEL SURFACE improper lubrication and result damage. Operate unit in an in approximately level cause engine position. 2-2 for maximum allowable tilt for pro See Figure per operation. Check crankcase oil level with unit face. can severe TA.046 152 on a level sur Figure 2-2. Allowable Tilt Angles OM-468 Page 3 This genertor is provided with a lifting eye for moving the unit and mounting holes in the base rails for secur ing the unit in a permanent location, or to a trailer, or transport vehicle. Figure 2-1 gives overall dimensions and base mounting hole layout. running. However, power mounting location should allow sufficient room to open the side doors and remove the cover and for maintenance and repair functions. panels Wi~II~Ic~ CHARGING cause A FROZEN BATTERY the battery to explode and result in serious personal injury or damage to equipment. I Check the state of the e/ctro/yte solution and allow battery to warm up to 60F (16C) before charging The service life and operating efficiency of this unit are reduced when the unit is subjected to high levels of dust, dirt, moisture, corrosive vapors, and - 1. Raise the left side door and secure Remove for if electrolyte is frozen vent caps charging slushy. 2-3C, Steps 7-9 or and refer to Section instructions. extreme C. Dry Charged Battery INSTALLA 1. Obtain open. 2. heat. 2 2. SPARK ARRESTOR/MUFFLER TION battery fails to supply enough engine, the battery will require recharging. can The if the crank the to battery grade (1 .265 specific gravity) electrolyte solution. Remove battery from unit and place or other suitable surface. on a level worktable 2. Install the exhaust pipe in the exhaust the manifold. flange on 3. Remove vent caps. I~h1;I~Il~(e~ BATTERY ACID 3. Close the side door. 4. Install the spark arrestor/muffler onto the ex haust pipe and secure with the muffler clamp. can burns eyes and and destroy clothing and other materials; BATTERY GASES can explode and shatter the bat skin tery. Wear correct eye and body protection. spill or splash battery fluid. Do not apply pressure to walls of filled battery-use battery carrier or place hands on opposite corners when llfting battery. Keep sparks, flames, cigarettes, and other ignition Do not 5. Install weather cap onto spark arrestor/muffler that exhaust is discharged toward side of unit so as shown in Figure 2-1. 3. PREPARING NEW BATTERY FOR SER This unit may be equipped with a maintenanceVICE free battery, a conventional wet charged battery, or a dry charged battery. Maintenance-free batteries do not 2 - sources away from batteries. - have conventional vent caps since they do not require the addition of water during normal service. Once the battery type is determined, read the following WARN ING and proceed to the appropriate section: A. Maintenance-Free Battery; B. Wet Charged Battery; C. Dry Charged Battery. enough ventilation to keep battery building up during activation. Use gases from 4. Fill battery cells trolyte. to 5. Allow stand for 20 minutes. 6. battery Recheck to top of separators with elec electrolyte level and add if necessary to fill to top of separators. ~ BATTERY ACID can burn eyes and destroy clothing and other material. Wear correct eye and body protection when work ing with batteries. ABNORMAL VOLTAGE can cause damage to engine electrical components. Do not operate engine without the battery con skin and 7. center nected. Do not disconnect the battery while the engine electrolyte temperature in one of the For a battery thermometer. each 10F (6C) increment above 80F (27C), a correction factor of 0.004 specific gravity must be added to the specific gravity reading taken in Step 8. For each 10F (6C) increment below 80F (27C), 0.004 must be subtracted from the reading taken in Step 8. Check is cells with running. 8. Maintenance-Free Battery A. To place this battery in service connect the negative (-) battery cable to the negative battery terminal. No other preparation should be Check the specific gravity of each cell with a hydrometer. (Draw in and expel the electrolyte two or three times from the first cell to be tested to adjust the temperature of the that of the Wet Charged Battery Connect the negative (-) battery cable to the negative on the battery. If the battery has enough power Page 4 the engine, it will charge the below in addition to those WARNING statements. terminal to start to required. L~k1;li~Il~~c-r Follow B. hydrometer electrolyte.) up while the engine is Use enough ventilation building up during and tery charging. precautionary steps given in the previous to keep battery gases from for several hours after bat off before charger Turn battery tion making connec battery. to or move connections on battery charger is on. over battery when charging. Be sure battery charger connections to batter, are clean and tight. Keep vent caps in place and cover top of battery with damp cloth. Be sure battery charger output matches battery voltage. while batter, Do not lean If a corrected specific (27C) 80F caps and is not gravity reading of 1 .260 at obained, replace the vent battery following the bat the recharge tery charger manufacturers ~ engine at the factory and could rough engine running if not properly diluted with cause Do not touch 9. side of fuel tank and instructions. BATTERY GASES can a full tank of fresh fuel. Keep the fuel tank filled tO ensure that the injector system receives an adequate supply of fuel. If the fuel tank is allowed to empty, air will enter the system caus ing starting problems. The Engine Manufacturers Manual outlines procedures for air venting the fuel system. Figure 2-3 illustrates typical fuel consumption under specific load conditions. Fuel consumption will vary from one engine to another. Different brands of fuel, operating conditions, condition of the engine, etc., will affect the fuel consumption of this engine. explode and shatter the battery. Turn the battery charger off before disconnecting charger from the battery. Recheck electrolyte level and add if necessary. the 10. ACID BATTERY CAUTION is corrosive to metals. electrolyte into Do not pour Thoroughly 11. metal sink a drain. or rinse with water and mutilate empty electrolyte containers before discarding. 12. Reinstall battery in generator. 13. Replace battery holddown and tighten securely. Do not overtighten. Connect positive 1) (+1 battery terminal. 14. battery cable to positive Figure 2-3. Fuel Consumption Chart 2 - ENGINE PRE-START CHECKS 5. Oil Level A. Connect negative (-I battery cable to battery terminal. 1 5. 2 - 4. negative I-) engine is shipped with its crankcase filled with break-in oil. If the oil level is not up to the full mark on the dipstick, add oil according to the recommendations in the Engine Manufacturers Manual before starting the The FUEL (Figure 2-3) ENGINE FUEL L~h1lI~c~ can cause fire engine. or ex plosion. B. Do not Do not Do not spill fuel; if spilled, wipe up. fill fuel tank if engine is hot or running. refuel near sparks or open flame. Perform the before Do not smoke while refueling. Do not fill fuel tank to top; a//ow 3/4 inch (19 mm) Do not use gasoline to fuel a pump and diesel engine. damage the injector in Engine Manufacturers See the Engine open position. Manual for fuel recommendations. The the capacity of the fuel tank is 23 4. preventative was added to in- Manual). impeller for obstructions Ensure that all sheet metal and 2 time. Rust and corrosion Check the blower free movement. gallons (87 liters). II ~i I ~Ls] t f~1 ~ 1 ~ Fill fuel tank up to 3/4 in (19 mm) from top with fresh fuel before starting engine the first cooling system Check the blower belt for proper tension (see the 3. tank, the air 2. injectors. Manufacturers on Check the engine air intake and exhaust open ings to ensure no blockage exists. This generator is shipped with a small amount of fuel in the fuel tank, and fuel shut-off valve, located under the fuel following checks operating the engine: 1. from fuel to tank top for expansion. USE OF GASOLINE will damage engine. Lack of lubrication in the fuel will Cooling System panels are and cowlings, shrouds, properly in place and secure. 6. ETHER STARTING AID (Optional) This unit is shipped without the ether cylinder. Before this device is operational, an ether cylinder must be obtained and - - installed. OM-468 Page 5 HANDLING OR EX IMPROPER ETHER can seriously harm your 1. Open and 2. Reposition jumper links frequency. on 3. Readjust engine speed 2-11, Section 5-9. as that the nozzle on the ether cylinder and the fit ting into which the ether cylinder is inserted are both 4. Close right side door If dirt is present in either of these areas, system may be rendered inoperative. 5. Reconnect WARMNG: ____ POSURE TO health. Pa//ow the manufacturers safety instructions the cylinder when handling ether components. I 1Wi1 ~1 I f~ I ~ Prior to the ether installing on cylinder, right secure side door. 2T to match desired instructed in Steps ensure clean. To install ether cylinder, proceed as the follows: negative battery changing output frequency, it readjust the VOL TAGE ADJUST II~I~s1;~f~If After may be necessary to 1. Open right side panel and ether start components 2. secure on center open. Identify frame upright. Loosen 4. Place new cylinder onto valve Secure cylinder with clamp. 6. Using a fitting, and rotate liquid soap solution, check all ether system connections for leaks. If escaping gas will produce - 9. GENERATOR generators secure. 5. output voltage. a RECONNECTiON Three Phase Generators cylinder clamp. clockwise until MENT control (see Section 3-3) to obtain the desired 2 Remove protective cap from ether valve. 3. cable. start (Single Only) Single-Three Phase be operated in series or parallel wye or can - series, parallel, or double delta connections. The voltages available for each generator connection and output frequency (see Figure 6-2) and set by the VOLTAGE ADJUSTMENT control. To generator, proceed as follows: reconnect ~ ELECTRIC SHOCK kill. can the Do not touch live electrical parts. Shut down engine and disconnect negative 1-) battery cable from battery before attempting 1 leak exists, bubbles in the soap solution. generator reconnection. IMPORTANT After installing or replacing Ground in accordance with NEC, state, or local codes; connect grounding lead to appropriate generator leads depending on output load lead ether ______________ do not use or test ether start system for at/east 10 to 15 minutes to allow particles in fuel to settle to prevent atomizer plugging. cylinder, connection. Be nected to the sure that a proper ground is con terminal on leads in connection box on equipment grounding the generator frame. 2 - 7. EQUIPMENT MINAL GROUNDING TER This unit is equipped with a grounding ter minal, located on the left base rail, for frame and case grounding. For detailed grounding instructions consult your local or state codes or the latest issue of the Na tional Electrical Code. If additional information regar ding your particular operating circumstances and/or grounding requirements is needed, consult a qualified electrician or your dealer. After determining the extent to which any grounding requirements apply to your par tricular situation, follow them explicitly. 2 - 8. 1. - 2. Open and Locate T stator 3. and L door. barrel. Reconnect T and L leads to obtain the desired generator output. Refer to Figure 1 -2. If the generator reconnection results in a phase change, the position of the Phase SENSING switch may also have to be changed (see Section 3-4). FREQUENCY CHANGEOVER EXCESSIVELY HIGH EXCITATION CURRENT can damage generator. Be sure engine speed for 50 Hz. operation is 1550 4. Reinsulate all connections. 5. Close side door. 6. Reconnect rpm. This unit is equipped with a frequency changeover ter minal strip 2T, located in the connection box on the stator frame behind the right side door. If it becomes necessary to change the output frequency of the generator proceed as follows: IT~IT~II~(c~ ELECTRIC SHOCK can kill. Do not touch live electrical parts. Shut down engine and disconnect negative (-) battery cable from battery before attempting fre quency changeover. Page 6 right side secure negative battery cable. 2-10. AUXILIARY POWER CONNECTION LkYL1;1~ll~e~ ELECTRIC SHOCK can kill. Do not touch live electrical parts. Shut down engine and disconnect negative (-) battery cable from battery before attempting to connect the load circuit to the generator. Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding procedure are employed. 1. 2. 3. Select desired lead entry location, and knockout blank from junction box. remove Install proper connector (not supplied) into open ing and route load leads through connector into junction box. the 100 ampere circuit Connect the load leads to breaker in the box. junction On Single-Three phase units, the generator output located behind the left side door. Connect the load leads directly to the generator output leads or in leads SECTION 3 - are stall desired customer connecting supplied junction box or panel for the generator output leads and the load cir cuit. Reconnect negative battery cable. OPERATOR CONTROLS Ammeters Hour Meter Stop control / Oil Pressure Switch/Gauge / Frequency Meter Engine Temperature ~ Switch/Gauge I !Ba~e~ Overvoltage Safety Shutdown Condition Switch Warning Lamp Light Single Phase Model Shown Figure 3 1. - SAFETY SHUTDOWN SYSTEM 3-1. Front Panel Controls (Figure 3-1) B. Engine Temperature Switch/Gauge The ENGINE TEMPERATURE switch/gauge indicates crankcase oil temperature. If oil temperature rises to an unsafe level the The SAFETY SHUTDOWN switch must be depressed and held closed until the engine starts. If oil pressure or oil temperature reach unsafe levels, or if the overvoltage device is actuated, the Safety Shutdown System stops the engine. Do not attempt to C. to 1-1/2 minutes. The engine engine is will falter before 1 coming complete stop. to a This switch is protected by an in-line fuse. Should this engine would not start. fuse open, the A. Oil Pressure engine. Vfi operate the engine until The shut-off time for the down the Overvoltage Condition Light the trouble is remedied. ~ switch/gauge shuts The OVERVOLTAGE CONDITION light lites up in dicating an immediate interruption of generator output caused by an overvoltage condition. The light remains on until the SAFETY SHUTDOWN switch is depressed. 3 - 2. START PUSH BUTTON (Figure 3-1) Switch/Gauge push button is provided on the front panel for starting the engine. Pressing the START push button will engage the starter motor and start the engine. Once the engine has started, release the START button. A START The OIL PRESSURE switch/gauge indicates lubrication system pressure. If oil pressure drops to the an switch/gauge shuts down the engine. unsafe level OM-468 Page 7 CAUTION REENGAGING STARTER MOTOR _________ while flywheel is rotating can damage starting components. Do reengage starter motor until starter and flywheel have stopped rotating. I 3 3. - not VOLTAGE ADJUSTMENT pinion 120/240 volt load is connected the ammeter in dicating the lower current is reading the 240 volt cur rent. The ammeter indicating the high current is reading If a the combined 120 and 240 volt currents. The difference between the two ammeter readings is the 120 volt cur example: if ammeter Li reads 80 amperes and L2 reads 30 amperes, the 240 volt load is drawing 30 amperes, the combined 120 and 240 volt load is draw rent. For CONTROL (Figure 3-1) ing 80 amperes, and the difference between the two 50) is the 120 volt load cur readings (80-30 meter = rent. V B. The VOLTAGE ADJUSTMENT control fine adjusts out put voltage. Loosen the control brake and rotate the control shaft clockwise to increase output voltage/load voltage. reading Accurate the ac voltage adjustment voltmeter. Retighten can be made by brake. Single-Three Phase Units This unit is equipped with three ammeters, labeled Li, L2, and L3. Ammeters, Li and L2, enable the operator to read the separate 120 volts single phase loads; or either meter can be read for a 240 volts single phase load. through current two Overvoltage Adjustment If 120/240 volt load is connected the ammeter in dicating the lower current is reading the 240 volt cur rent. The ammeter indicating the higher current is a the combined 120 and 240 volt currents. The reading Phase difference between the two ammeter readings is the 120 volt current. For example: if ammeter Li reads 80 Sensin Switch amperes and L2 reads 30 amperes, the 240 volt load is drawing 30 amperes, the combined 120 and 240 volt Sensitivity Adjustment load is drawing 80 amperes, and readings (80-30 the two meter the difference between = 50) is the 120 volt load current. 240 volts the Figure 3-2. Voltage Regulator Panel 3 4. - 3-2) - voltage regulator panel behind the left side door. The Phase SENSING switch must be placed in the 1 PHASE position when single phase power is used and in the 3 PHASE position when three phase or a combination of three phase and switch positions CAUTION: PHASE 3 VOLTAGE - IMBALANCES equipment damage. one 3 - 6. VOLTMETER one the im (Figure 3-1) V regulated ac voltage output of the generator and the load voltage. If two separate 120 volts loads are connected to the generator, read half of the voltmeter indication for each load. ~ On connected (Figure 3-1) Single Phase Units This unit is equipped with two ammeters, labeled Li and L2, which enables the operator to read the current through two separate 1 20 volts loads; or either meter can be read for a 240 volts load. 8 value. If different from the balance. single phase units, the voltmeter is series-connected 120 volt power windings. If a load is connected across one of the 120 volt windings the voltmeter still reads the seriesconnected voltage (240 volts). To obtain the voltage across across voltage across two the dication. reads the Page any of phase A A same on three-phase reading phase is loaded differently causing PHA SE position. AMMETERS be read balanced a current power with the Phase SENSING switch in the 1 5. current can Under The voltmeter indicates the Do not attempt to draw unbalanced three I indicates single phase power is used. Changing may require readjustment of the VOLTAGE ADJUSTMENT control. could result in ammeter others, ammeters. all ammeters will read the loading, PHASE SENSING SWITCH (Figure The Phase SENSING switch is located on the three-phase ac three single load read one-half the voltmeter in single-three phase units, the voltmeter voltage across one phase (L 1 -L2). The voltage On the other two phases is –2% of the L 1-L2 if the Phase SENSING switch is in the 3 PHA SE position. 3 -7. FREQUENCY METER (Figure 3-1) IMPORTANT The measured quantity of ether is sprayed into the engine when this switch is re/eased. Depressing the switch does not spray the ether into the engine but rather fills the valve chamber. ___________ Hz The Frequency Meter indicates the output frequency from 45 to SENSITIVITY 3-12. 65 Hertz. (Figure ADJUSTMENT A SENSITIVITY ADJUSTMENT control is pro vided on the voltage regulator panel behind the left side 3-2) - door eliminate to voltmeter instability when the VOLTAGE ADJUSTMENT control is set at low voltage adjustment conditions. Loosen the control brake and 3 8. STOP CONTROL (Figure 3-1) The PULL OUT TO STOP ENGINE control, when pulled fully out, cuts off the flow of fuel at the fuel injection pump, - - thereby stopping the engine. This control is springloaded and must be held fully out until the engine is completely stopped. 3 - 9. BATTERY CHARGE INDICATOR LAMP (Figure 3-1) rotate the SENSITIVITY ADJUSTMENT control only enough to eliminate meter instability. Over adjustment can adversely affect voltage regulation. Retighten brake. 3-13. OVERVOLTAGE ADJUSTMENT CONTROL (Figure 3-2) II~I~.1;If~1 f The OVERVOLTAGE ADJUSTMENT control located i: ~i the left side on the voltage regulator panel behind door, is factory set and requires readjust only after component failure regulator board. rnent The AMPS warning lamp will be illuminated engine battery charge current is not flowing. 3-10. HOUR METER when the on the voltage The overvoltage circuitry actuates the Safety Shutdown system if the upper limit for load circuit voltage is ex (Figure 3-1) ceeded by the generator. To make overvoltage circuit adjustment proceed as follows: t 1. This unit is equipped with hour meter. The meter registers the total hours of engine operation. This infor mation is useful for routine maintenance on the engine. 2. 3-11. 3. Start the ETHER STARTiNG AID Loosen the brake and rotate the OVERVOLTAGE ADJUSTMENT control fully counterclockwise. (Optional) The cold starting components which are incorporated into this generator provide a means of supplying a premeasured portion of ether into the manifold. The amount of ether supplied should be sufficient to permit easy engine starting under cold weather conditions. - weather 4. Loosen the brake and rotate the VOLTAGE AD JUSTMENT control to a 15% value above desired operating voltage level upper limit for the load circuit. Rotate control Actuating the ETHER STARTING AID switch, located to the left of the START push button, for 1 second while cranking the engine will provide the proper amount tion of ether to the manifold. This control will func MOVING PARTS injury; IMPROPER AIR FLOW can can - 5. cause result in serious operating. Keep clear of moving parts. Warranty is void if the generator is operated with portion of the outer enclosure open or removed. to start as sure the and on the engine shuts down. brake. Start the engine and readjust Voltage Adjust ment control for desired output voltage. 4 1. - STARTING THE ENGINE 1. Press the START push button (see SECTION 3-1) and the SAFETY SHUTDOWN switch (see Section 3-2) and actuate the ETHER STARTING AID switch, if applicable, for 1 second and release (see Section 3-1 1). any the unit has been installed _____ prepared comes damage internal parts; EXPOSURE TO WEATHER can shorten the life of internal components. Keep all covers and panels in place while IMPORTANT: Be the OVERVOLTAGE ADJUSTMENT until the OVERVOLTAGE CONDITION SEQUENCE OF OPERATION to ting light Tighten only while cranking the engine. SECTION 4 and engine (see Section 4-1). an instructed in Section 2 before attemp 2. As soon the engine starts, release the as START push button and allow the engine to warm up for approximately three minutes with no power load applied. engine. OM-468 Page 9 3. Loosen the brake and rotate the VOLTAGE AD JUSTMENT control to obtain the desired voltage 2. Allow the engine to run for a few minutes to per mit the internal engine temperature to equalize. (see Section 3-5). Tighten brake. Increase the operating for 4 2. - 3. HOT WARNING severe engine period or has been at full load. fully Out and hold it in this position until the engine stops completely. ENGINE PARTS can - Do not allow fuel to drain onto the cause ing protective gloves and clothing when work on a Keep hot engine. can cause c/ear of serious injury. moving parts. engine and disconnect negative (-) Shut down the battery cable from battery before internally specting engine or other components. MOVING PARTS or in servicing. 1. GENERAL The service life of this generator operating efficiency maintained under normal conditions by following the routine ser vice and workshop maintenance procedures outlined in be MAINTENANCE burns. Wear - the Pull the STOP control Remove the power load from the unit. SECTION 5 can if extended ENGINE SHUTDOWN 1. 5 time an prolonged - and this section and in the Engine Manufacturers Manual (F3L912 Engine). Where operating conditions are severe, more frequent attention must be given to all routine service categories; however a special effort must be made to maintain clean Do not spill fuel; if spilled, wipe up. The fuel/water separator, located below the fuel tank on the right side of the generator, provided to drain off water from the fuel tank. Before the first time each starting day, open the petcock the on engine for the bottom of the separator and drain the water into a metal tainer. Close the petcock at the first signs of fuel. con The fuel/water separator should be changed every 125 hours of operation or 4 months, whichever occurs first. A sludge drain plug is provided on the bottom of the fuel tank to drain off sediment from the fuel tank. Once a week, drain the sludge into a metal container. If ex tremely dirty fuel is encountered, ing will be necessary. a more frequent drain internal and external engine surfaces. 5 -4. CLEANER SERVICE (Figure 5-1) The one of the most important parts of the engine from the standpoint of engine life. An engine consumes several thousand cubic feet of air per hour when operating. If dirty air gets into the engine, it can AIR - air cleaner is 5 -2. PERIODIC CLEANING AND IN SPECITON A schedule for cleaning and inspection should be set up, based on the type and conditions of - service, to include the following: a set of piston rings within a few operating Every 50 hours or less depending on conditions, empty the dust cup and inspect the element. wear out hours. Keep the inside of the unit clean by blowing the unit out with clean, dry compressed air. II ~A I ~s] I f..i ~ I ~ A Examine all intake and sure that free of they foreign are discharge air openings, and en not blocked in any manner and are Check for fluid leaks indicating loose oil or fuel loose connections and clean oil leaks oft of engine surfaces. or engine exhaust. When it becomes necessary to service the air cleaner in the field, follow the steps in Figure 5-1. It is recom mended that a spare element always be kept on hand for replacement. New elements distributor. or fuel IMPORTANT Periodically inspect the labels on this precautionary labels must be main c/early readable state and replaced when legibility. tained in a are available from your L~I1I.1~ DIRTY AIR can damage engine. Do not operate engine with dirty air cleaner ele ment in place. Do not operate _______________ unit for dirty air cleaner element is usually loss of power and black smoke in the connec Tighten spills a matter. Examine blower impeller to be sure that the blades do not have an obstruction of any kind lodged between them. The blower must be able to turn freely. tions. accompanied by All necessary. See the Parts List for part number of precau in 5 - 5. engine without air cleaner element p/ace. ELECTRICAL SYSTEM tionary labels. A. 5 3. FUEL/WATER SEPARATOR AND SLUDGE DRAIN PLUG - WARNING: ENGINE FUEL can cause fire or ex plosion. Do not drain fuel tank while Do not smoke while Page 10 engine handling fuel. is running. Cables And Wiring Check interconnecting wiring and connections for tightness and flaws. Check the insulation for breaks or other signs of damage. Repair or replace cables or wir ing as necessary. I B. 6. SERVICING THE AR SPARK RESTOR Internal combustion engines operating in a highly combustible environment are a common fire hazard. Glowing carbon particles blown Out with the ex 5 Battery - - WARNiNG BATTERY ACID burn eyes and and other material. ___________ skin and destroy clothing can haust Wear correct eye and body protection. Periodically inspect the battery for loose connections, cables, corrosion, cracked case or cover, holddowns, and loose or deformed terminal posts. Easy Steps: Important 1. Stop engine. 2. Wipe off arrestor should be spark hours or before opening before Remove 4. Remove element. 1. Dont cover, attempt cleaner with to service air leave open air cleaner blowing dust while Dont 3. engine running, exposed blow out the inside of the 8. Replace 5. For Donaclone air cleaners cover. installed If sir cleaner is Compressed Air or Washing. a sure positioned is Clean element by one of the following methods: better is recommended horizontally into the point when exhaust soot has lodged in fine pores of the filter media. Use Donaldson D-1400 detergent for removing a special additive soot you will blow dust engine. up. and must be used job or cover lit any) correctly cover that dust cup so arrows which contains Compressed air blow out Donaclone tube and inner mounted, be Re-Use Reinstall element. section without element, Replace cover, 4. Clean 7. dont to air cleaner with compressed air. Elements F or operating use. you clean element. How To every 1000 season. 6. 3. Dont materials. ignite Inspect new element and all gaskets for shipping damage air cleaner. 2. inspected three times per 5. Wipe out element chamber with clean, damp cloth. cover heat to no The carbon trap should be serviced weekly or every 50 operating hours, whichever occurs first. The entire On units with conventional batteries frequently check the electrolyte level. Add clean mineral-free or distilled water to bring the elctrolyte in each cell up to the level indicator Follow These sufficient retain practical spark arresting device will stop all sparks, this device will minimize fire hazards by remov ing and trapping most solid particles provided that it is properly maintained. defective loose can While and carbon. (When cleaning Cyclopac elements, do not remove plastic fin assembly back-flowing with - compressed remove fin air or washing will dust from beneath the assembly.) when element will be re-used immediately element re-use. because must a However, Replace element after 6 cleanings annually, whichever washed be dried before washing does or occurs first. compressed Air Washing through element in the direction opposite to normal air flow through the element. 1. water Move nozzle up and down while instructions, rotating element. Keep nozzle at least one inch from pleated 2. Direct air paper. Maximum air pressure - 100 P.5.1. Inspection Soak element 15 minutes more in Donaldson D-1400 and solution. See carton for full Rinse until IMaximum 40 PSI.) Place bright light inside element and rotate element slowly. If any rupture, holes or damaged gaskets are discovered replace. . water is clear water pressure 3. Air-dry or use warm Do not air. max. 160F. compressed Figure 5-1. or air or flowing use light bulbs. Air Cleaner Service OM-468 Page 11 A. as part of the emery will embed itself into the and in turn destroy the carbon brushes. Visually examine the outside of the device for holes, cracks, or metal corrosion. 1. Replace the brushes if they become chipped With the look inside the engine stopped, arrestor outlet tube with a flashlight Visually examine source. outlet tube for metal or the or spark other light and the vanes weld failure. The vanes be firmly attached to the inlet tube and the outlet tube must be completely intact (this is an important factor in maintaining spark arresting efficiency). must 3. Check the mounting clamp to ensure that the is securely mounted. Replace the arrestor if inspection reveals any signs of spark spark arrestor failure. B. The Carbon Servicing Trap EXHAUST SPARKS can cause fire. Clean spark arrestor/muffler in a non-combustible environment. LTk!~1~h~lIk1(C~ S left. 5 8. ETHER STARTING Stop the and allow the exhaust system to engine cool. AID The (Optional) starting aid system is contained in a replaceable cylinder located behind the right side access door on the center portion of the frame. No indicator is provided to show the amount of ether left in the cylinder; therefore it is recommended that a spare cylinder be kept on hand. Generally, the ether cylinder is empty when the engine fails to start in cold weather while utilizing the cold weather starting system. To check if the cylinder is empty, remove the cylinder and shake it. If a slushing sound is not heard, the ether cylinder is empty. The ether cylinder can also be weighed to check for contents, 33 ounces is the weight of the cylinder when empty. To replace the ether cylinder, loosen the clamp which secures the cylinder to the mounting bracket, and rotate the ether cylinder in a - - ether used in the cold weather counterclockwise direction. II ~ I ~s] ~I fe.! ~ I ~ Prior 1. broken or if less than 1/2 inch (12.7 mm) of brush material is or 2. rings cloth Inspection cylinder, and the ensure fitting to the installing that the nozzle into which the ether ether new the ether on cylinder cylinder is inserted both clean. If dirt is present in either of these areas the system may be rendered inoperative. Also check for are 2. Remove the cleanout spark ed arrestor over with the screwdriver or a hole, plug from the side of the wrench. If break a Crust it has form loose with a similar tool. HOT EXHAUST can cause severe burns; HOT CARBON PARTICLES DISCHARGED FROM CLEANOUT HOLE can burn eyes and skin. CAUTION: _____ Wear correct eye and S body protection. damage Start the the engine cleanout to blow hole. If discharge, momentarily collected particles Out particles are slow to cover the end of the ex 4. Stop the engine. cleanout plug. Replace and secure the which is located the in on IMPORTANT After installing or replacing ether _______________ cylinder, do 10 to ether start system for at/east allow particles in fuel to settle to not use or test 15 minutes to prevent atomizer plugging. the manufacturers maintenance and 5 9. instruction sheet for troublehsooting procedures. ENGINE SPEED ADJUSTMENT (Figure engine was shipped fully adjusted and ready for operation. If an engine speed adjustment becomes - 5-2) haust stack. gasket fitting into which the ether cylinder is in serted. Replace the valve gasket if worn or damaged. See 3. to the valve side of the - This necessary, proceed CAUTION Keep as follows: body limbs c/ear of belts and mov ___________ 5 7. BRUSHES AND SLIP RINGS Brush life is very good under normal operating conditions. The brushes and slip rings should be inspected every six - months - ing parts, and wear heat-protective gloves this adjustment. when Fuel making Injector Pump whenever excitation voltage is lost. Check for cleanliness of the slip rings and freedom of motion of the brushes. If the generator has been operating under or extremely dusty or dirty conditions, increase the fre quency of inspection. If the generator has not been used for an extended period of time, oxidation may form on the slip rings causing excitation voltage to be lost. This can usually be remedied by simply spraying the slip rings with an an tioxidant type contact cleaner and running the engine. Protective Pastic Under normal brown. If use the slip rings will discolor to a dark a build up of brush material is noted, it may be necessary to clean the slip rings. Use a 3/0 or finer sandpaper followed by a crocus cloth. Never use emery Page 12 (lock nut Cap underneath) Nigh Speed Stop Screw A045 768 Figure 5-2. Engine Speed Adjustment A. 1. Shut down the 2. Remove lead seal and protective plastic cap from engine. high speed stop 3. screw. Loosen high speed stop screw lock nut, and high speed stop screw Out (toward front of engine) several turns. 4. Tighten high speed stop 5. Loosen 6. Start engine. 7. Adjust engine speeds (no load) linkage lock screw B. - GENERAL 1. - - Operation nuts. as - lock nuts. 8. Tighten linkage 9. Be sure linkage lock nuts are completely tighten ed, and then recheck rpm. follows: 10. Stop 11. Completely tighten high speed stop screw lock nut, and reinstall protective plastic cap onto high speed stop screw. Reseal cap/stop screw. engine. the TROUBLESHOOTING It is assumed that proper installa made, according to Section 2 of this manual, and that the generator has been functioning properly until this trouble developed. 6 For 50 Hz. Adjust linkage until 51 .5 Hz. is indicated on Frequency Meter on front panel. If setting engine speed with a tachometer, adjust linkage for 1550 rpm. lock nut. SECTION 6 tion Operation Adjust linkage until 61 .5 Hz. is indicated on Frequency Meter on front panel. If setting engine speed with a tachometer, adjust linkage for 1850 rpm. back 6 For 60 Hz. has been BATTERY GASES OR A DAMAGED I~!~i;l~II~c-r BATTERY can explode thereby shattering the bat tery; BATTERY ACID can burn eyes, skin, destroy clothing, and damage other material; MOVING PARTS and IMPROPER CONNECTIONS can cause serious personal injury and damage equipment. 2. TROUBLESHOOTING CHART Keep sparks, flames, cigarettes, and other ignition ~ ELECTRIC SHOCK can kill. Do not touch live electrical parts. Shut down engine and disconnect Wear can cause severe protective gloves and clothing hot engine. ing Troubleshooting of internal parts by qualified persons. in Do not jump start a frozen or comletely discharg ed battery. Do not lump minals burns. when work start a or one having battery which has loose evidence of damage cracked case or cover. Be that vent caps are tight and level cover both batteries with sure batteries and on a to be away from batteries. Ensure that all personnel are a safe distance from batteries and c/ear of moving parts while starting. negative (-) battery cable from battery before internally specting or servicing. MOVING PARTS can cause serious injury. Keep c/ear of moving parts. HOT ENGINE PARTS sources performed only ter such both on a as damp cloth. Wear correct eye and body protection. clear of moving parts. Keep jumper cab/es The following chart and the chart provided in the Engine Manufacturers Manual are designed to diagnose and provide remedies for some of the troubles that may Ensure that both batteries S are the same voltage. Do not jump start a trailer mounted generator with the towing vehicle battery unless the trailer is develop in this welding generator. completely disconnected from the towing vehicle. jump start a vehicle mounted generator from the vehicle battery. If booster battery is installed in a vehicle, do not Do not conjunction with the circuit diagram performing troubleshooting procedures. If the trouble is not remedied after performing these pro cedures, the nearest Factory Authorized Service Sta tion should be contacted. In all cases of equipment Use these charts in while malfunction, the manufacturers recommendations allow vehicle to make or frame. 1. should be strictly followed. BOOSTER BATTERY JUMP STARTING If 2. 3. - 3. with generator case properly insulated jumper cables of ade quate size. jump starting is attempted, employ the safety precau tionsbelow and the following step by step procedures in order of appearance. 6 Use con tact - Connect end of one cable to positive H-) minals of each battery. Connect terminal one or end of other cable to booster ter negative I-) battery. OM-468 Page ~3 4. Connect remaining end of cable to generator engine block (do not connect to generator case, 7. Remove jumper cable from frame, 8. Remove other end of or damage 5. equipment grounding equipment can result). Wait at least before 6. to one minute after terminal as connecting cables engine unless thirty seconds some cable from booster 9. Remove other jumper cable from generator bat tery positive (+) terminal. Start engine following procedures outlined in Section 4 (Sequence of Operation) of this manual. If the unit does not start after cranking for thirty seconds, stop the jump starting pro the same block. battery negative (-) terminal. starting engine. cedure. More than engine 10. Remove remaining end of cable from booster battery positive (+) terminal. 11. Discard damp cloth. seldom starts mechanical adjustment is made. TROUBLE Engine fails PROBABLE CAUSE Inspect the electrical system (see Section 5-5B). Test the battery and recharge it if necessary (see Section 2-3B). If the battery does not recharge, Battery. to start. REMEDY replace the battery. Jump start the practices engine employing approved safety and booster battery jump starting structions provided in Section 6-3. No ac Main output. circuit breaker open units only). in Reset main circuit breaker. (single phase Poor contact between slip rings and brushes. Clean the slip rings (see Section 5-7). Replace the brushes. Engine suddenly shuts Out of fuel. Fill fuel tank and air vent fuel system (see Manual). down. Cooling belt broken. PRESSURE gauge actuated. OIL switch/ Engine Temperature switch/gauge actuated. Replace blower belt (see Engine Manual). Add oil up ing; Fuse Page 14 on safety shutdown full mark obstructed blower Make open. to on dipstick. Check for obstructed air intake panels, Overvoltage condition. Engine sure all etc., Defect in are sheet impeller; metal properly in or discharge worn cowlings, shrouds, place. voltage regulator circuit. Replace fuse. open blower belt. CR1 CAUTON REFER TO NSTRUCTIQNS BEFORE ATTEMPTING TO INSTALL.opEpArE OR MAINTAIN EQUIPMENT Circuit Diagram No. B-088 323 Figure 6-1. Circuit Diagram For Single Phase Units OM-468 Page 15 391 C-08 1 I ~0i~z No. - - Diagr m Circuit 94 4 9 5 I ,? 2? 2 II ICAUTION NS10CIOR STAL.OPE01E01P4N. 801 Single-Thr 10 MAIhTN REF R 01E4 G 10 OR Y ~MV~ For Diagr m Units. Jc,f vv V Circuit Phase JV Iv vvvv vvvY 6-2. lr <~ IF : I Figure ii~: January1983 FORM: OM-46: Effective With Seri& No. JC654458 MODEL TRAILPOWER 25DA1 TRAILPOWER 25DA3 PARTS LIST - 22 21~ 2O~...... 6 8 19 18~ 17 11 12 13 16 -~ 4 Figure OM-468 Page 1 A Front View Of Generator /. 6 4 2 1 Quantity Model Item Dia. No. Mkgs. Figure Part No. ,. 072 046 034 047 873 376 392 MUFFLER, exhaust-spark arrestor FITTING, pipe-black nipple L2NPT CLAMP, muffler 2-1 /2 clamp dia 159 CAP, weather-exhaust AIR CLEANER 0.21 114 .CLAMPASSEMBLY ELEMENT Phase 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 004 116 NUT, wing BAFFLE, dust CAP, dust 1 1 021 CAP, intake 1 1 113 049 525 010 863 023 313 +046 034 046 392 017 479 010 515 604 433 5 048 223 027 529 049 685 6 087 341 HM 032 936 604 784 601 829 8 9 SW/GA 10 SW/GA 11 PL1,2 12 MSI 13 P81 14 15 16 17 V 18 HZ 19 A1,2 19 20 A1-3 R8 8 BAND, mtg-air cleaner 049 965 21 Three Phase 1 004 115 4 x (consisting of) 019 994 *020 319 020 115 020 117 22 Single Front View Of Generator A 2 3 7 Description 019 603 010 546 088 634 010 320 086 478 085 766 085 765 082 789 *048 155 cap HOSE, air cleaner NUT, speed 5/16-18 mtg air cleaner CLAMP, hose2-1/16 clamp dia 1 1 4 CLAMP, hose 3-1 /4 clamp dia COVER LABEL, general precautionary SEAL, weather-lift eye BOLT,J 5/16-18 NUT, self locking-hex 5/16-18 DOOR, side-right hand PIN, cotter 1/4x3-1/2 CATCH, door BUMPER, door-rubber METER, hour 4-40 VDC SCREW, brass-md hd 6-32 x 1/2 NUT, brass-hex 6-32 KNOB, round BUSHING, nylon 3/8 ID 4 4 6 2 6 1 2 2 2 2 1 1 ROD, shutdown STOP, travel-throttle SWIVEL, cable-shutdown GAUGE/SWITCH, oil pressure 0-100 PSI.... GAUGE/SWITCH, temperature 0-240 degree 2 LENS, light-indicator red BULB, incandescent 12 volt 082 788 LIGHT, indicator holder 2 2 SWITCH, magnetic shutdown l2voltsdc 084 098 SWITCH, push button MC NO 36 volts dc 084 246 CAP, switch-dust/weatherproof black 048 212 PANEL, front-lower 085 768 086 462 048 221 086 806 086 807 086 086 073 072 087 805 805 933 590 926 BASE 1 DOOR, side-left hand METER, volt ac 0-300 METER, frequency 55-65 Hz 120 volts METER, amp ac 0-200 METER, amp ac 0-200 RHEOSTAT, NW 50 watt 50 ohm LOCK, shaft-rheostat PANEL, front-upper NAMEPLATE (order by model and serial number) 1 1 1 2 3 1 1 1 1 1 1 1 1 *Recommended Spare Parts When ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-468 Page 2 Quantity Model Item Dia. Part No. Mkgs. No. Figure B 2 Descriptions Right Z2 048 227 088037 087 831 087 087 087 604 088 071 071 010 049 018 035 3 4 5 858 857 918 435 072 868 389 434 169 858 968 010 314 UPRIGHT, base-front REACTOR, saturable PLUG, hardwood 2-3/8 x 1-1/2 x 2-1 /2 INSULATION, reactor-round fiber INSULATION, reactor-round paper BLOCK, support-reactor BOLT, carriage 5/16-18 x7 GUARD, reactor STRAP, mtg-fuel tank STRIP, rubber 1/8 x 1 x 34 (fuel tank strap) STRIP, rubber 1/2 x 2 x 2 (fuel tank) TANK, fuel (consisting of) CAP, fuel tank WASHER, neoprene 5-7/8 003 x 5/8 ID (filler fuel tank) VALVE, shut-off fuel 16 15 I \\ 14 Figure Page Three Phase Phase 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Side View Of Generator 17 3 Single B - 13 Right Side 12 View Of Generator 1 1 2 2 2 2 4 4 1 1 1 1 1 1 1 1 Quantity Model Item Dia. Part No. Mkgs. No. Figure B Descriptions Three Phase Phase 1 1 Right Side View Of Generator (Contd.) 605 288 020 185 073 432 010 089 010 678 049 164 FITTING, pipe-galv plug (fuel tank) FITTING, pipe-brass elbow st 1/8 NPT (fuel tank 2ft 2ft 1 1 089 019 088 087 086 088 087 089 TRANSFORMER ASSEMBLY, current 594 STRIP, support-transformer 1 1 916 ANGLE, mtg-transformer 27 inches Ig 1 1 467 ANGLE, mtg-transformer 27 inches Ig ANGLE, mtg-transformer 9 inches Ig FRAME, mtgfuel tank TRANSFORMER, 3 phase (consisting of) BLOCK, terminal 30 amp 6 pole BASE, filter w/adapter SEPARATOR, fuel-filter & water BRACKET, mtg-separator STATOR, generator STATOR, generator ROTOR, generator (consisting of) 1 1 1 1 1 1 1 1 595 923 020 038 639 083 553 062 342 083 088 089 083 859 481 023 751 083 748 FAN, rotor 035 776 .KEY,3/8x3/8x2 024 617 RING, retaining 053 390 BEARING, ball 039 207 BAFFLE, air-generator 071 890 RETAINER, mount-stator 083 476 TUBING, neoprene 2-1/2 OD x 7/8 ID x 2 (stator mount) 071 731 WASHER, flat2l/32 ID x2-1/4 00 x3/16 (statormount) 071 730 TUBING, steel 7/8 00 x 12 ga wall x 2-3/8 (stator mount) 601 945 SCREW, cap-hex hd 5/8-18 x 4 (stator mount) 601 851 NUT, self locking-hex 5/8-18 (stator mount) 049 235 ENDBELL, generator 049 650 BRACKET, mtg-brushholder 018 614 BRUSH SET (consisting of) 13 14 15 *044 755 600 270 018 665 035 080 088 380 088 524 16 17 088 523 088 522 044 426 010 467 2T 1 604 550 CT 1-3 12 12 1 071 126 CT1,2 11 2 1 7 3T 1 2 3 4ft 7 10 1 3 4ft R3 9 line) 1 6 8 return FITTING, brass-barbed M 3/16 TBG x 1/8 NPT (1 engine 1 fuel tank) FITTING, pipe-brass coupling 1/8 NPT (non return valve) FITTING, pipe-brass elbow St 1/4 NPT (fuel filter) FITTING, brass-barbed M 3/8 TBG xl /4 NPT (1 fuel tank 2 fuel filter) HOSE, fuel line 3/8 ID (order byft) HOSE, fuel line 3/16 ID (order by ft) 030 060 RESISTOR, WW adj 375 watt 20 ohm... 088 599 TRANSFORMER ASSEMBLY, current 18 Single BRUSH, contact HOLDER, brush CAP, holder SCREW, cap-socket hd 5/16-18 xl (adjusting brushes) STATOR, exciter ENCLOSURE, connection box COVER, connection box BRACKET, mtg-connection box cover 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 1 1 2 2 2 2 2 1 1 3 3 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 CONNECTOR, clamp-cable 1 inch CONNECTOR, clamp-cable 1-1/4 inch 010 907 NUT, locking 1 inch connection box 1 1 1 1 038 639 038 620 1 1 2 2 BLOCK, terminal 30 LINK, jumper2T amp 6 pole *Recommended Spare Parts. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-468 Page 4 1, Figure C Page 5 - Left Side View Of Generator Quantity Model Item Dia. Part No. Mkgs. No. Figure C 088 526 087 057 087 91 5 010 610 088 473 088 474 088 475 088 597 CB1 0 086 433 038 654 601 839 004 130 017420 010 266 032 453 082 672 010 640 082 673 012 724 032 452 089 366 4 5 6 7 8 9 10 Si 011 917 605 429 601 811 601 872 605 430 061 441 010 150 048 220 FS1 11 049 158 085 767 086016 048 216 065 005 065 006 070 661 604 393 070 023 044941 044 942 071 890 CIRCUIT BREAKER BOX COVER, enclosure-circuit breaker box STRIP, mtg-circuit breaker box CONNECTOR, clamp-cable 1/2 inch CONNECTOR, conduit-squeeze type BX Three Phase Phase 1 1 1 1 x 2 1/4 BUSHING, conduit-insulated 1-1/4 SLEEVE, conduit-insulating 1 -1/4 CONDUIT, metallic-flexable 1 -1/4 x 10 CIRCUIT BREAKER, man reset 2P 100 amp 240 volts STUD, brass 1/2-13 x 2-5/8 (ground NUT, brass-hex 1/2-13 (ground) BRACKET, support-door LATCH,door SPRING, door latch CABLE, battery-negative BOLT, L 5/16-18 x 6-3/8 (battery hoiddown) STUD, steel 5/16-18 x 10 (battery hoiddown) HOLDDOWN, battery BATTERY, l2volts95 amp hr CABLE, battery-positive 2 2 1 ac 048 208 048 213 048 206 087 371 087 370 088 687 048 209 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 SWITCH, pressure2P ALTERNATOR, 35 amp 12 volts BOLT, hex hd 3/8-16 x 6 mtg alternator .NUT, hex-full 3/8-16 PULLEY, single belt-alternator STRAP, mtg-alternator TUBING, steel 1/2 OD x 17 ga xl mtg alternator SPACER, alternator BELT, V VALVE, non return-fuel .LINE,oil BRACKET, mtg-breather 1 1 1 1 . . 1 1 5 5 . 1 . 1 1 1 1 1 1 . . . 1 1 1 1 1 1 1 1 CONCORDIA FUEL VALVE CONCORDIA SOCKET ADAPTER 1 1 1 1 ROD, speed control NUT, speed 3/16 inch WASHER, exhaust-manifold 1 1 1 1 . . . . . . . . .SCREW,cap-hexhdl/2-13x2-1/2 NUT, locking 1/2-13 1 1 3 3 6 6 2 2 2 2 2 . RETAINER, . mount-stator WASHER, fIat 21/32 ID x 2-1/4 OD x 3/16 (engine mount) TUBING, steel 7/8 OD x 12 ga wall x 2-3/8 (engine mount) SCREW, cap-hex hd 5/8-18 x 4 (engine mount) NUT, self locking-hex 5/8-18(engine mount) SUPPORT, engine BLOCK, mtg-oil line BAFFLE, air outlet NUT, speed 10-24 screw (air outlet baffle) BRACKET, support-outlet air baffle BAFFLE, air-intake PANEL, engine end ROD, shutdown BODY, oil filter GASKET, copper 1/8 FLANGE, exhaust 605 670 1 4 1 071 731 048 207 1 4 1 ,TUBING,neoprene2-1/2ODx7/8lDx2(enginemount) 601 945 601 851 083 746 086 026 1 ENGINE (consisting of) 072 848 071 730 12 Single Left Side View Of Generator 1 2 3 Description 2 . 2 2 2 2 2 2 . . . 1 . 1 1 1 1 4 4 1 1 1 1 1 1 . 1 . 1 1 . 1 1 . 1 1 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. . 1 OM-468Page6 Item Dia. Part No. Mkgs. No. Figure D 088 034 3 Ri 4 CR1 ,2 5 D7,8 D5,6,9,10 R12 037 577 087 919 026 202 088 023 R4-7 088 063 Dl -4 087 038 038 035 035 073 030 087 030 11 12 13 iT 14 SR1-4 15 SR5 16 19 20 R2 R9 21 22 S4 Ri 1 073 918 1 2 2 4 2 4 RESISTOR, carbon2watt 6.8K ohm RESISTOR, carbon 2 watt lOOK ohm 4 1 1 1 1 4 2 2 1 CHOKE, 2.3 HY 150 MA RESISTOR, WWadj50watt75 ohm 1 POTENTIOMETER, carbon 1 turn2watt2.5K ohm 1 072 590 LOCK, shaft-potentiometer 1 011 611 SWITCH,toggleDPoTl5ampl25volts 1 POTENTIOMETER, carbon 1 turn 2 watt 500 ohm CAPACITOR, metal film 10 uf 220 volts CLAMP, capacitor CAPACITOR, electrolytic 2200 uf 16 volts dc CLAMP, 5/8 dia 1 830 826 009 156 059 887 007 532 C2 1 DIODE, rectifier 1 amp 400 volts SP GROMMET, rubberl/21D5/8mtghole 752 RESiSTOR, WW adj 100 watt200 ohm Zi 1 HEATSINK 344 RiO + watt STRIP, mtg-diode LINK, jumper-terminal block 646 BLOCK, terminal 30 amp 10 pole 704 RECITFIER, integrated 30 amp 600 volts 704 RECTIFIER, integrated 30 amp 600 volts 18 Cl ,3 DIODE, zener47 volts 10 917 620 17 Quantity All Models PANEL, mtg-components PLATE, identification 076 390 RESISTOR, WW adj 50 watt 5000 ohm 059 267 RELAY, enclosed 12 volts dc DPDT w/flange 028 296 DIODE, zener20 volts 10 watt 7 8 9 10 Panel, Control 087 882 088 025 1 2 6 Description 085 694 010 146 1 4 8 1 1 2 Y 3 * TB-088 945 Figure D - Panel, Control + Cl consists of 3 of 059 887 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. 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