Pacific Scientific Redi-Line DA12A Installation And Service Manual Download Page 28

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Field Troubleshooting

Instruction and Service Manual

Pacific Scientific REDI-LINE Generators

Troubleshooting Flow Charts

Generator

Is Noisy

Return for

Repair

Generator

Iturning too fast

or too slow

See Figure 7-2

This Section

Output voltage

or frequency

too high or

too low

See Figure 7-3

This Section

TSFSTART

Generator does

not start

automatically

See Figure 7-6

This Section

Generator does

not start when

connected

to battery

See Figure 7-4

This Section

Generator will not

start motor on

equipment

plugged into it

See Figure 7-5

This Section

Generator Starts
automatically but

will not start

equipment

plugged into it.

See Figure 7-5

This Section

Generator starts

when load is

turned on, but

stops after a

few seconds.

See Figure 7-7

This Section

Generator Cycles

on and off every

few seconds

See Figure 7-8

This Section

Battery

discharges

too quickly

See Figure 7-9

This Section

See Figure 7-10

This Section

Generator runs

all the time

Locate

Symptoms

Figure 7-1. Identifying Symptoms

Summary of Contents for Redi-Line DA12A

Page 1: ...INSTALLATION AND SERVICE MANUAL Models DA12A DA12L DA24A DA24L DA36A DA36L ...

Page 2: ...ther than Pacific Scientific The foregoing warranties are in lieu of all other warranties except as to title whether expressed or implied including without limitation any warranty of merchantability or of fitness for any particular purpose and are in lieu of all other obligations or liabilities on the part of Pacific Scientific Pacific Scientific s maximum liability with respect to these warrantie...

Page 3: ...ATE DATA 7 3 UNPACKING 8 UNPACKING 8 4 PREPARATION FOR INSTALLATION 9 CHOOSING AN ACCEPTABLE LOCATION 9 DETERMINING INSTALLATION REQUIREMENTS 10 BATTERY SELECTION 17 WIRING CONSIDERATIONS 18 5 INSTALLATION 19 BEFORE BEGINNING INSTALLATION 19 MOUNTING 19 INSTALLATION INTERCONNECTION 20 INSTALLATION CHECKOUT 23 6 MAINTENANCE 24 CLEANING 24 MOUNTING AND ELECTRICAL CONNECTIONS 24 BRUSHES 24 COMMUTATOR...

Page 4: ...ECKS 38 8 BENCH TROUBLESHOOTING 39 USE OF FLOW CHARTS 39 CONDITIONAL BRANCHES 39 ASSEMBLY AND DISASSEMBLY 39 TROUBLESHOOTING FLOWCHARTS 40 TROUBLESHOOTING CHECKOUT PROCEDURES 44 9 REPAIR PROCEDURES 52 GENERAL 52 RECOMMENDED TOOLS AND EQUIPMENT 52 DISASSEMBLY OF SMALL FRAME UNITS 53 RE ASSEMBLY OF SMALL FRAME UNITS 54 DISASSEMBLY OF LARGE FRAME UNITS 55 RE ASSEMBLY OF LARGE FRAME UNITS 56 DC BRUSH ...

Page 5: ...ber of factors and ignoring any one factor can lead to major problems with the unit Troubleshooting has been divided into three sections the first for isolating installation problems the second for identifying problems with the unit itself while in the field and the third for isolating problems requiring bench repair The owner or installer should initially undertake troubleshooting Careful trouble...

Page 6: ... and an AC generator on a common armature assembly Speed of the DC motor and therefore frequency of the AC generator varies within limits as the load and battery power levels vary The unit starts automatically when an electrical load is applied Figure 1 The Two Basic Versions of REDI LINE Generators Features The following features recommend the REDI LINE DC to AC generator to users who have need o...

Page 7: ...nput Voltage DC 12 6 12 6 25 2 25 2 37 8 37 8 Continuous Output Watts 500 1600 800 1600 900 1600 Surge Output Watts 750 2400 1200 2400 1350 2400 Output Voltage AC 120 120 120 120 120 120 Output Frequency Hz 65 65 60 60 60 60 Continuous Output Current Amps 4 5 14 5 7 3 12 8 8 2 14 5 Surge Output Current Amps 7 22 11 20 12 22 Wave Shape Sine Sine Sine Sine Sine Sine Length inches 16 25 16 75 16 25 1...

Page 8: ...nerator and the insert CAUTION The generator is a piece of heavy equipment Removing it from the box may require more than one person to avoid dropping the generator and prevent personal injury Inspect the unit for any damage that may have been sustained during shipment If you find damage contact the shipper immediately to file a claim ...

Page 9: ...ll reduce the amount of voltage to the generator and decrease performance Carefully plan the power supply cable route Do not allow the cables to rub against sharp surfaces which could cut the cable insulation and cause a short against the vehicle frame Accessibility Be sure both the REDI LINE generator and the battery system are located so that they are easily accessible for servicing Protection f...

Page 10: ...ON Do not install the REDI LINE generator in a compartment that could contain explosive fumes Determining Installation Requirements Determine how frequently and at what loads you plan to use your generator Find the Redi Line generator series you purchased and choose the correct installation diagram based on your usage and loads Use this diagram as a guide when it comes time to do the system instal...

Page 11: ...e heavy constant use of hand tools or large loads install one or more auxiliary deep cycle batteries The auxiliary battery should be isolated from the vehicle battery using a battery isolator The battery isolator is a one way path so the vehicle charges both batteries but one battery cannot discharge the other This will ensure the vehicle battery is always charged and you will be able to start you...

Page 12: ...ry cannot discharge the other This will ensure the vehicle battery is always charged and you will be able to start your vehicle If the load requirements are heavy constant use of hand tools or large loads install two or more auxiliary deep cycle batteries The auxiliary batteries should be isolated from the vehicle battery using a battery isolator The battery isolator is a one way path so the vehic...

Page 13: ... If the load requirements are heavy constant use of hand tools or large loads install two or move deep cycle auxiliary batteries The auxiliary battery should be isolated from the vehicle battery using a battery isolator The battery isolator is a one way path so the vehicle charges both batteries but one battery cannot discharge the other This will ensure the vehicle battery is always charged and y...

Page 14: ...mand If the load requirements are heavy constant use of hand tools or large loads install two or move deep cycle auxiliary batteries The auxiliary battery should be isolated from the vehicle battery using a battery isolator The battery isolator is a one way path so the vehicle charges both batteries but one battery cannot discharge the other This will ensure the vehicle battery is always charged a...

Page 15: ...f the load requirements are heavy constant use of hand tools or large loads install two or more auxiliary deep cycle batteries The auxiliary batteries should be isolated from the vehicle battery using a battery isolator The battery isolator is a one way path so the vehicle charges both batteries but one battery cannot discharge the other This will ensure the vehicle battery is always charged and y...

Page 16: ...f the load requirements are heavy constant use of hand tools or large loads install two or more auxiliary deep cycle batteries The auxiliary batteries should be isolated from the vehicle battery using a battery isolator The battery isolator is a one way path so the vehicle charges both batteries but one battery cannot discharge the other This will ensure the vehicle battery is always charged and y...

Page 17: ...ow long a fully charged deep cycle battery will keep the REDI LINE operating continuously before the battery needs recharging Hours Cold Cranking Amps CCA 180 X AC Load Amps Where Cold Cranking Amps is equal to the sum of all the battery CCAs AC Load Amps is the AC current rating listed on the nameplate of the largest tool or appliance to be powered by the REDI LINE generator For Example Two batte...

Page 18: ...locations Place fuses no farther than 18 from the battery The connection between the supply battery and the REDI LINE Generator is one of the most critical installation steps Using the wrong supply cable size could damage the generator Choose the correct supply cable size from the Table 4 1 below Table 4 1 Supply Cable Size Between Battery and REDI LINE Generator Cable Length in Feet Generator up ...

Page 19: ...ication Excessive AC current draw above the rating stated on the nameplate may cause overheating of the generator Be sure that all the preparation for installation provisions described in Section 4 have been carried out CAUTION Automotive and marine type batteries produce dangerous current levels Protect yourself when working around batteries and associated electrical systems This includes the use...

Page 20: ...d be correctly connected to the generator Note polarity indications on the installation figure Figures 4 1 through 4 12 you are using Do not ground the negative REDI LINE supply terminal to the vehicle chassis The negative REDI LINE terminal must be connected directly to the supply battery using the proper size supply cable NOTE Cable connectors fuses and isolators may be available from your autho...

Page 21: ...Instruction and Service Manual Installation Pacific Scientific REDI LINE Generators 21 Figure 5 1 Mounting Template for Small Frame Generators ...

Page 22: ...Installation Instruction and Service Manual 22 Pacific Scientific REDI LINE Generators Figure 5 2 Mounting Template for Large Frame Generators ...

Page 23: ...ck all connection points to see that they are properly and securely made Correct any poorly or improperly made connections 5 Check to see that the REDI LINE generator is grounded directly to the battery and not to the vehicle ground Reconnect if necessary 6 Apply a load equivalent to a 100 Watt light bulb to the generator The generator should start If it does not see that there is no intervening o...

Page 24: ...ry Inspect electrical cables for damage and replace any that show signs of wear Brushes Inspect brushes periodically to insure uninterrupted service Brush life expectations vary based upon the type of tools or appliances you use with the generator To avoid damage to the generator a preventive maintenance inspection interval should be determined for your application We recommend initially that you ...

Page 25: ...e generator This will reduce the bench time required by your dealer to diagnose a problem and thereby reduce your repair costs Use of Flow Charts Locate your specific symptom or symptoms in the troubleshooting flow chart in Figure 7 1 Each symptom will advise you to return the unit for repair or refer you to an additional flow chart which will provide a series of inspections checks or actions whic...

Page 26: ...rmed in the field However before repairs are attempted you should check with your distributor to make sure that such repairs will not void your warranty Should You Need to Return the Unit Before returning any products for repair authorization must first be received from your dealer Dealer requirements may vary so contact your dealer for instructions before returning a unit to him ...

Page 27: ..._____________________________________________ Street Address __________________________________________________________________________ City _______________________________________________State ___________________Zip _________ By ____________________________________________ Position ________________________________________ Phone _________________________________________ Fax _______________________...

Page 28: ...es not start when connected to battery See Figure 7 4 This Section Generator will not start motor on equipment plugged into it See Figure 7 5 This Section Generator Starts automatically but will not start equipment plugged into it See Figure 7 5 This Section Generator starts when load is turned on but stops after a few seconds See Figure 7 7 This Section Generator Cycles on and off every few secon...

Page 29: ...too slow Check speed Correct speed is 3600 RPM at full load Okay Yes No Return to Service Check cable size from battery to generator See Cable Sizing Section 4 Preparation for Installation Yes No Okay Install correctly sized cables Return to Service Return for Repair TSFSPEED Figure 7 2 Generator Running at an Incorrect Speed ...

Page 30: ...able size from battery to generator See Cable Sizing Section 4 Preparation for Installation Yes No okay Install correctly sized cables Return to Service Return for Repair Return to Service Or Small Framve Version Large Frame Version Check to see that both sets of DC input terminals are connected to batteries See Installation Interconnection Section 5 Installation Yes No okay Connect DC Input Cable...

Page 31: ...entific REDI LINE Generators 31 Generator does not start when connected to battery No Load Check with 100 watt light bulb Okay Yes Increase load on generator Return to service No Return for Repair TSFACON Figure 7 4 Generator Does not Start When Connected to Battery ...

Page 32: ...rce Repair or Replace Equipment Return to Service See Figure 7 6 This Section Okay Okay Starting Load Too High Check Starting Load Requirements See Note Reduce Starting Load Requirements See Figure 7 6 This Section Return to Service NOTE The Redi Line Generator can provide 1 5 times its rated capacity for starting motors and loads TSFALOAD Yes Yes No No Figure 7 5 Generator Runs but does not Start...

Page 33: ...n Section 4 Installation Yes No okay Connect DC Input Cables Correctly Return to Service Check to see that load ground is not connected to the vehicle body Okay Return to service Connect load ground directly to battery Yes No Or Large Frame Version Older Version Neither Or Defective or Tripped Circuit Breaker Reset or Replace Circuit Breaker Return to Service Okay Yes Model Serial Number Break Old...

Page 34: ...econds Okay Yes No Load too high Circuit Breaker Trips Reduce Load Install Larger Generator Reset Circuit Breaker and Restart Return to Service Or Return to Service Or Check with 100 watt light bulb Increase load on generator Return to service Okay Yes No See Figure 7 5 This Section TSFALOD2 Figure 7 7 Generator Starts With Load But Stops After A Few Seconds ...

Page 35: ...ntific REDI LINE Generators 35 Generator Cycles on and off every few seconds Check with 100 watt light bulb Increase load on generator Return to service Okay Yes No Return for Repair Load is too light TSFACYCL Figure 7 8 Generator Cycles On And Off Every Few Seconds ...

Page 36: ...ttery Selection Section 4 Preparation for Installation Install additional batteries Okay No Yes Check to see that deep cycle batteries are being used Check battery condition Okay Replace with new batteries No Yes Upgrade vehicle charging system Okay Replace batteries with deep cycle type No Yes Return to Service TSFAQDIS Figure 7 9 Battery Discharges Too Quickly ...

Page 37: ...blem Check for Continuous Load See Note Remove Continuous Load Return to Service TSFARUNS Note Power strips with ON indicator lamps equipment with POWER CONNECTED indicator lamps or similar devices can place enough load on the generator to cause it to run even though the intended load has been removed Figure 7 10 Generator Runs All The Time ...

Page 38: ...ncy is within the proper range monitor the unit closely and check frequency frequently If the frequency degrades return the unit for service Checking Voltage or Frequency Use a true RMS voltmeter to check voltage or frequency Many voltmeters will not give accurate readings and Pacific Scientific recommends using a Fluke Model 87 Model 8060 Model 8062 or equivalent Connect the voltmeter leads to th...

Page 39: ...tions checks or actions that will enable you to isolate the problem and repair it so the unit can be returned to service Checkout procedures are found in the subsection titled Troubleshooting Checkout Procedures following the troubleshooting flow charts Repair procedures are found in Section 9 Repair Procedures Conditional Branches Where there are conditional branches diamonds labeled either Okay ...

Page 40: ...ure Replacement Section 9 Repair Procedures Replace Bearings See Bearing Replacement Section 9 Repair Procedures Return to Service TSBNOISE Okay Okay Inspect Bearings See Inspection Procedure This Section Inspect Brushes See Brush Inspection Inspection Procedure This Section Replace Brushes See Brush Replacement Section 9 Repair Procedures Yes No Yes No Figure 8 1 Generator Is Noisy ...

Page 41: ...ay Replace Shell See Disassembly and Assembly Section 9 Repair Procedures TSBSPEED Generator turning too fast Voltage or Frequency too high Return to Service Inspect Bearings See Inspection Procedure This Section Replace Bearings See Bearing Replacement Section 9 Repair Procedures Okay Yes No Replace Armature See Armature Replacement Section 9 Repair Procedures Figure 8 2 Generator Speed Voltage o...

Page 42: ...Repair Procedures Replace Circuit Breaker See Circuit Breaker Replacement Section 9 Repair Procedures Replace AC Brushes See AC Brush Replacement Section 9 Repair Procedures Replace DC Brushes See DC Brush Replacement Section 9 Repair Procedures Replace Solenoid s See Solenoid Replacement Section 9 Repair Procedures Return to Service FIELD COMPLAINTS Generator does not start when connected to batt...

Page 43: ...s Or Older Version Newer Version Does Not Occur Replace PC Board See PC Board Replacement Section 9 Repair Procedures TSBACYCL Return to Service Model Serial Number Break Older versions have serial numbers at or below those shown below DA12A 80294 DA12L 81221 DA24A 79632 DA24L 79203 DA36A 79632 DA36L Figure 8 4 Generator Cycles On and Off Every Few Seconds ...

Page 44: ... below those shown below DA12A 80294 DA12L 81221 DA24A 79632 DA24L 79203 DA36A 79632 DA36L Figure 8 5 Generator Runs all the Time Troubleshooting Checkout Procedures The following checkout procedures provide step by step procedures for performing the checkout of various components and subassemblies These procedures often involve some disassembly and re assembly of the unit To avoid repetition of d...

Page 45: ...e overall length of the brushes 10 Reassemble the entire unit 11 Reconnect the battery and test the unit with a load 100 watt light bulb Desired Results 1 The brushes should move freely within their holders with no binding when they are depressed and return to their original positions when released 2 A small amount of spring distortion is acceptable 3 Brush faces should be smooth and the entire br...

Page 46: ... brushes for damage 9 Inspect the overall length of the brushes 10 Reassemble the entire unit Desired Results 1 The brushes should move freely within their holders with no binding when they are depressed and return to their original positions when released 2 A small amount of spring distortion is acceptable 3 Brush faces should be smooth and the entire brush should be free from defects 4 Brushes s...

Page 47: ...binding is found replace the bearings Procedure No 4 Commutator Inspection Procedure 1 Remove any electrical connections to the generator 2 Remove one AC brush assembly from each commutator 3 Remove one brush access cover from each DC commutator 4 Visually inspect each commutator for scoring pitting or other signs of damage Desired Results There should be no evidence of damage Burnishing of the co...

Page 48: ... 0 5 and 1 5 ohms 2 Resistance between adjacent bars of the DC windings should be consistently similar Disposition 1 If there is no resistance or excessive infinite resistance between adjacent slip rings replace the armature 2 If there is no resistance or excessive infinite resistance between adjacent bars of the DC windings replace the armature 3 If there is measurable but inconsistent resistance...

Page 49: ... disconnect any electrical wires 3 Remove the PC board from the starting circuit by bypassing it with a jumper as shown in Figure 8 6 or 8 7 4 Reconnect the battery to the generator and apply a load 100 watt light bulb Figure 8 6 Jumper Connection Small Frame Unit Figure 8 7 Jumper Connection Large Frame Unit Desired Results There should be an audible click from the solenoid Disposition 1 If there...

Page 50: ...lectrical wires 3 Disconnect the black wires from the circuit breaker inside the electrical assembly cover Make note of the connection locations so re assembly can be performed correctly 4 Measure the resistance between the circuit breaker terminals Desired Results Resistance between the circuit breaker terminals should be less than 1 ohm Disposition 1 If resistance is greater than 1 ohm replace t...

Page 51: ...onnected properly to the terminals during re assembly 4 Set the ohmmeter to either the R X 1 or the R X 10 resistance range 5 Measure resistance between the orange lead and ground and between the white lead and ground as follows A Red probe to ground black probe to orange lead B Black probe to ground red probe to orange lead C Red probe to ground black probe to white lead D Black probe to ground r...

Page 52: ...opriate exploded view in Section 10 Parts Lists Disassembly and re assembly instructions do not include a step by step procedure to account for every component Disassembly and re assembly of many components especially those which will seldom require replacement is self evident and instructions should not be necessary Keep such components together with their attaching parts so re assembly after som...

Page 53: ...ter re assembly 3 Remove solenoid cover 3 by removing acorn nuts 9 Disconnect the electrical connections carefully noting their relationships If necessary remove solenoid 14 or printed circuit board 24 from solenoid cover 4 Remove fan shroud 10 by removing screws 11 If necessary remove fan impeller 12 from armature shaft by removing C ring 13 NOTE Steps 5 through 8 must be done in the order presen...

Page 54: ...ure commutator or bearing to strike a magnet 4 Install rear end bell 30 Retain with nuts 37 See the paragraph below titled Brush Replacement for end bell assembly instructions NOTE Steps 5 through 8 can be done independently of one another Steps 1 through 4 must be complete beforehand 5 Install the electrical components inside solenoid cover 3 Make sure wire routing and electrical connections are ...

Page 55: ...or removal instructions 6 Remove fan shroud 21 or 25 by removing screws 22 or 26 If necessary remove fan impeller 23 or 27 from armature shaft by removing C ring 24 or 28 NOTE Steps 7 through 13 must be done in the order presented 7 Disconnect terminals protruding through terminal insulator s 16 or 20 Note wire connections for later re assembly 8 If necessary remove the terminal nut 39 or 43 from ...

Page 56: ...re removed 7 Re install terminals through terminal insulator s 16 or 20 Be sure wire connection components are installed in the reverse order from which they were removed NOTE Steps 8 through 12 can be done independently of one another Steps 1 through 7 must be complete beforehand 8 If necessary install fan impeller 23 or 27 on armature shaft and retain with C ring 24 or 28 Install fan shroud 21 o...

Page 57: ...ndicates that the spring is disengaged from the brush holder 4 Carefully remove the spring Do not pull on the coiled spring Disconnect the brush shunt from the brush holder and remove brush Re assembly 1 Insert the brushes in the brush holder Position the ramp in exactly the same as it was when removed 2 Install the spring assembly so that the bottom of the brush ramp is closest to the spring asse...

Page 58: ... Model 8062 or equivalent Connect the voltmeter leads to the power output points on the generator to take a reading Checking Load Generator load can be checked using a simple 100 watt light bulb CAUTION The REDI LINE generator produces enough current to injure or kill a human Use extreme care when checking the load carrying capabilities of the generator To check load simply plug the device into th...

Page 59: ...uplicate part number columns each column pertaining to a specific Redi Line model The item column contains the callout found on the illustration on the facing page Items in the illustration are numbered generally in disassembly order were the unit to be disassembled completely Attaching parts screws nuts washers etc and similar parts are usually listed after the parts they attach The part number c...

Page 60: ...and Service Manual 60 Pacific Scientific REDI LINE Generators 34 33 17 16 24 26 25 27 20 23 22 21 14 6 4 9 8 7 5 42 41 38 37 28 29 39 40 18 19 31 32 35 44 45 36 46 43 10 11 13 12 1 2 15 3 30 Figure 10 1 Small Frame Generators ...

Page 61: ...PART NUMBER AVAILABLE NO PART NUMBER AVAILABLE Washer 1 9 YK10069 YK10069 YK10069 Nut Acorn 20 2 10 YC63229 YC63229 YC63229 Fan Shroud 1 11 YK11230 YK11230 YK11230 Screw Hex Hd 10 32 X 3 8 1 12 NO LONGER AVAILABLE YP01630 YP01630 Fan Impeller 1 13 NOT USED VM31079 VM31079 C Ring 1 NI NO PART NUMBER AVAILABLE NO PART NUMBER AVAILABLE NOT USED Solenoid Assembly 1 14 NO LONGER AVAILABLE NO LONGER AVA...

Page 62: ...ervice Manual 62 Pacific Scientific REDI LINE Generators 34 33 17 16 24 26 25 27 20 23 22 21 14 6 4 9 8 7 5 42 41 38 37 28 29 39 40 18 19 31 32 35 44 45 36 46 43 10 11 13 12 1 2 15 3 30 Figure 10 1 Small Frame Generators continued ...

Page 63: ...3SL HB623SL Bearing 6203 double sealed 1 36 YJ10106 YJ10106 YJ10106 Tie Rod 2 37 YK10027 YK10027 YK10027 Nut 20 2 38 YK10384 YK10384 YK10384 Washer Flat 2 NI NO LONGER AVAILABLE YAA3053 YAA3053 Armature Assembly 12 Volt Armature Assembly w bearings 1 NO LONGER AVAILABLE YAA3309 YAA3309 Armature Assembly 24 Volt Armature Assembly w bearings NO LONGER AVAILABLE YAA5575 YAA5575 Armature Assembly 36 V...

Page 64: ...Parts Lists Instruction and Service Manual 64 Pacific Scientific REDI LINE Generators 14 13 9 7 2 3 12 6 12 3 9 7 2 6 4 5 1 10 7 8 11 7 10 8 Figure 10 2 End Bell for Earlier Small Frame Generators ...

Page 65: ...sh Holder Assembly 2 2 NO LONGER AVAILABLE Brush Holder Plate 2 3 YP00351 Brush 2 4 YP02213 Insulator Brush 2 5 YP02211 Brush Holder Insulator 2 6 YP02224 Diode Plate Spacer 2 7 YP02220 Diode Plate Insulator 4 8 YK10021 Bolt Slotted Head 8 32 X 1 1 2 2 9 YK10314 Nut Std Hex 8 32 2 10 YP02218 Insulator 2 11 YP02103 Power Terminal 2 12 YK10027 Nut Std Hex 20 2 13 NO LONGER AVAILABLE Diode 25 Amp X 8...

Page 66: ...Parts Lists Instruction and Service Manual 66 Pacific Scientific REDI LINE Generators 1 2 3 4 6 4 3 2 7 5 8 5 7 Figure 10 3 End Bell for Current Small Frame Generators ...

Page 67: ...s List End Bell for Current Small Frame Generators Item Part No Description Qty Ref YR33072 End Bell Assembly 1 1 YR20193 End Bell 1 2 YP00351 Brush 2 3 YP00872 Brush Spring 2 4 YP02246 Insulator Brush 2 5 YP02103 Power Terminal 2 6 YK10027 Nut Std Hex 20 2 7 YK10384 Washer 2 8 YK10027 Nut Std Hex 20 2 ...

Page 68: ...fic REDI LINE Generators 46 47 32 30 26 25 40 41 19 18 16 17 19 18 31 48 45 28 27 35 37 36 33 29 34 39 38 18 19 22 21 20 24 23 18 19 15 12 13 14 9 7 8 4 11 10 15 17 16 23 24 21 22 20 49 43 42 44 3 5 6 2 1 Figure 10 4 12 Volt Large Frame Generator Earliest Version ...

Page 69: ... Hd 2 9 NO LONGER AVAILABLE Circuit Board Bracket 1 10 YP05251 Terminal End 1 11 YK11230 Screw Slotted Pan Head 10 32 X 3 8 2 12 YP05251 Terminal End 1 13 YP05251 Terminal End 1 14 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 2 15 NO LONGER AVAILABLE Solenoid 2 16 YP63445 Brush Assembly 2 17 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 4 18 YP00315 Access Cover 4 19 YK11230 Screw Slotted Pan Hd 10 32 X 3 ...

Page 70: ...EDI LINE Generators 46 47 32 30 26 25 40 41 19 18 16 17 19 18 31 48 45 28 27 35 37 36 33 29 34 39 38 18 19 22 21 20 24 23 18 19 15 12 13 14 9 7 8 4 11 10 15 17 16 23 24 21 22 20 49 43 42 44 3 5 6 2 1 Figure 10 4 12 Volt Large Frame Generator Earliest Version continued ...

Page 71: ... YK11322 Nut Acorn 10 32 4 33 YK10960 Nut Lock 10 32 2 34 YP03151 Washer Wavy Spring 1 35 YL35532 Terminal Positive with lead wire 1 36 YP02237 Insulator 1 37 YK11424 Washer 1 38 YP02237 Insulator 1 39 YK11424 Washer 1 40 YK11424 Insulator 1 41 YK11424 Washer 1 42 YL35532 Terminal Positive with lead wire 1 43 YP02237 Insulator 1 44 YK11424 Washer 1 45 HB623SL Bearing 6203 double sealed 1 46 HB623S...

Page 72: ...fic REDI LINE Generators 46 47 32 30 26 25 40 41 19 18 16 17 19 18 31 48 45 28 27 35 37 36 33 29 34 39 38 18 19 22 21 20 24 23 18 19 15 12 13 14 9 7 8 4 11 10 15 17 16 23 24 21 22 20 49 43 42 44 3 5 6 2 1 Figure 10 5 12 Volt Large Frame Generator Interim Version ...

Page 73: ...VAILABLE Circuit Board Bracket 1 10 YP05251 Terminal End 1 11 YK11230 Screw Slotted Pan Head 10 32 X 3 8 2 12 YP05251 Terminal End 1 13 YP05251 Terminal End 1 14 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 2 15 NO LONGER AVAILABLE Solenoid 2 16 YP63445 Brush Assembly 2 17 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 4 18 YP00315 Access Cover 4 19 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 8 20 YN00096 Term...

Page 74: ...EDI LINE Generators 46 47 32 30 26 25 40 41 19 18 16 17 19 18 31 48 45 28 27 35 37 36 33 29 34 39 38 18 19 22 21 20 24 23 18 19 15 12 13 14 9 7 8 4 11 10 15 17 16 23 24 21 22 20 49 43 42 44 3 5 6 2 1 Figure 10 5 12 Volt Large Frame Generator Interim Version continued ...

Page 75: ...10 32 4 33 YK10960 Nut Lock 10 32 4 34 YP03151 Washer Wavy Spring 1 35 YL35532 Terminal Positive with lead wire 1 36 YP02237 Insulator 2 37 YK11424 Washer 2 38 YP02237 Insulator 1 39 YK11424 Washer 1 40 YP02237 Insulator 1 41 YK11424 Washer 1 42 YL35532 Terminal Positive with lead wire 1 43 YP02237 Insulator 1 44 YK11424 Washer 1 45 HB623SL Bearing 6203 double sealed 1 46 HB623SL Bearing 6203 doub...

Page 76: ...entific REDI LINE Generators 8 1 6 5 2 3 4 7 11 10 9 13 12 19 20 17 18 9 11 10 19 20 17 18 15 14 16 16 39 40 38 45 15 14 36 37 26 28 22 21 42 43 12 13 15 14 24 23 27 44 41 31 33 32 30 29 25 35 34 14 15 Figure 10 6 12 Volt Large Frame Generator Current Version ...

Page 77: ...3 8 2 9 YP06171 Solenoid 2 10 YP05251 Tab Printed Circuit Board copper 2 11 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 4 12 YP63445 Brush Holder Assembly AC 2 13 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 4 14 YP00315 Access Cover 4 15 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 8 16 YN00096 Terminal Insulator 2 17 YK11656 Washer Lock 4 18 YK11658 Washer Flat 4 19 YK11656 Nut 5 16 4 20 YK10915 Nut 5 16 4...

Page 78: ...ic REDI LINE Generators 8 1 6 5 2 3 4 7 11 10 9 13 12 19 20 17 18 9 11 10 19 20 17 18 15 14 16 16 39 40 38 45 15 14 36 37 26 28 22 21 42 43 12 13 15 14 24 23 27 44 41 31 33 32 30 29 25 35 34 14 15 Figure 10 6 12 Volt Large Frame Generator Current Version continued ...

Page 79: ...03151 Washer Wavy Spring 1 31 YL35532 Terminal Positive with lead wire 1 32 YP02237 Insulator 1 33 YK11424 Washer 1 34 YP02237 Insulator 1 35 YK11424 Washer 1 36 YP02237 Insulator 1 37 YK11424 Washer 1 38 YP02237 Terminal Positive with lead wire 1 39 YP02237 Insulator 1 40 YK11424 Washer 1 41 HB623SL Bearing 6203 double sealed 1 42 HB623SL Bearing 6203 double sealed 1 43 YK11722 C Ring 1 44 YAA517...

Page 80: ...nual 80 Pacific Scientific REDI LINE Generators 9 16 17 19 18 1 2 6 5 3 4 8 7 11 10 14 13 12 15 17 16 23 24 21 22 20 38 19 18 39 34 35 37 36 33 29 40 43 31 42 41 30 32 26 25 28 27 44 Figure 10 7 24 Volt Large Frame Generator Earlier Version ...

Page 81: ...ONGER AVAILABLE Circuit Board Bracket 1 10 YP05251 Terminal End 1 11 YK11230 Screw Slotted Pan Head 1 12 YP05251 Terminal End 1 13 YP05251 Terminal End 1 14 YK11230 Screw Slotted Pan Hd 1 15 NO LONGER AVAILABLE Solenoid 1 16 YP63445 Brush Assembly 2 17 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 4 18 YP00315 Access Cover 2 19 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 4 20 YN00096 Terminal Insulator 1 ...

Page 82: ...82 Pacific Scientific REDI LINE Generators 9 16 17 19 18 1 2 6 5 3 4 8 7 11 10 14 13 12 15 17 16 23 24 21 22 20 38 19 18 39 34 35 37 36 33 29 40 43 31 42 41 30 32 26 25 28 27 44 Figure 10 7 24 Volt Large Frame Generator Earlier Version continued ...

Page 83: ...nerator Assembly 1 31 YK11212 Tie Rod 2 32 YK11322 Nut Acorn 10 32 2 33 YK10915 Nut Lock 10 32 2 34 YP03151 Washer Wavy Spring 1 35 YL35532 Terminal Positive with lead wire 1 36 YP02237 Insulator 1 37 YK11424 Washer 1 38 YP02237 Insulator 1 39 YK11424 Washer 1 40 HB623SL Bearing 6203 double sealed 1 41 HB623SL Bearing 6203 double sealed 1 42 YK11722 C Ring 1 43 YAA5168 Armature Assembly 1 44 YH842...

Page 84: ...ice Manual 84 Pacific Scientific REDI LINE Generators 8 1 6 5 2 3 4 7 11 10 9 12 13 19 20 17 18 16 40 34 15 14 35 30 12 25 29 32 33 31 14 15 13 37 38 27 39 36 22 21 24 23 26 28 Figure 10 8 24 Volt Large Frame Generator Current Version ...

Page 85: ...enoid 1 10 YP05251 Tab Printed Circuit Board copper 1 11 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 2 12 YP63445 Brush Holder Assembly AC 2 13 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 4 14 YP00315 Access Cover 2 15 YK11230 Screw Slotted Pan Hd 10 32 X 3 8 4 16 YN00096 Terminal Insulator 1 17 YK11656 Washer Lock 2 18 YK11658 Washer flat 2 19 YK11656 Nut 5 16 2 20 YK10915 Nut 5 16 2 21 YP80105 End Cov...

Page 86: ...anual 86 Pacific Scientific REDI LINE Generators 8 1 6 5 2 3 4 7 11 10 9 12 13 19 20 17 18 16 40 34 15 14 35 30 12 25 29 32 33 31 14 15 13 37 38 27 39 36 22 21 24 23 26 28 Figure 10 8 24 Volt Large Frame Generator Current Version continued ...

Page 87: ...on Continued Item Part No Description Qty Ref DA24L 1600A Generator Assembly 1 31 YL35532 Terminal Positive with lead wire 1 32 YP02237 Insulator 1 33 YK11424 Washer 1 34 YP02237 Insulator 1 35 YK11424 Washer 1 36 HB623SL Bearing 6203 double sealed 1 37 HB623SL Bearing 6203 double sealed 1 38 YK11722 C Ring 1 39 YAA5168 Armature 1 40 YH84279 Housing 1 ...

Page 88: ...Parts Lists Instruction and Service Manual 88 Pacific Scientific REDI LINE Generators 6 7 8 5 2 4 11 13 14 15 12 9 10 1 3 Figure 10 9 End Bell for Large Frame Generators Earlier Version ...

Page 89: ...rush Holder Assembly 1 3 NO LONGER AVAILABLE Diodes Bracket Assembly 1 4 NO LONGER AVAILABLE Screw Socket Head 10 32 X 2 2 5 YP00372 Brush 1 6 YP00886 Brush Spring 1 7 YK10398 Screw Std Hex Hd 10 32 X 3 8 1 8 YK10343 Washer No 10 1 9 NO PART NUMBER Left Hand Brush Holder Assembly 1 10 NO LONGER AVAILABLE Diodes Bracket Assembly 1 11 NO LONGER AVAILABLE Screw Socket Head 10 32 X 2 2 12 YP00372 Brus...

Page 90: ...Parts Lists Instruction and Service Manual 90 Pacific Scientific REDI LINE Generators 5 6 7 4 2 14 3 9 11 12 13 10 8 14 1 Figure 10 10 End Bell for Large Frame Generators Current Version ...

Page 91: ...d Bell 1 2 NO PART NUMBER Right Hand Brush Holder Assembly 1 3 YK11738 Screw Socket Head 10 32 X 2 2 4 YP00372 Brush 1 5 YP00886 Brush Spring 1 6 YK10398 Screw Std Hex Hd 10 32 X 3 8 1 7 YK10343 Washer No 10 1 8 NO PART NUMBER Left Hand Brush Holder Assembly 1 9 YK11738 Screw Socket Head 10 32 X 2 2 10 YP00372 Brush 1 11 YP00886 Brush Spring 1 12 YK10398 Screw Std Hex Hd 10 32 X 3 8 1 13 YK10343 W...

Page 92: ...Generators 11 TECHNICAL DATA Performance Curves Figures 11 1 through 11 5 are performance curves and should be used only by repair technicians who can apply it properly to generator performance during the course of bench analysis and repair It is not of use to the generator user ...

Page 93: ... Watts Output Voltage VAC 13 6 Vdc 12 6 Vdc 11 6 Vdc 55 60 65 70 75 80 0 100 200 300 400 500 600 Output Power Watts Output Frequency Hz 13 6 Vdc 12 6 Vdc 11 6 Vdc 0 1 2 3 4 5 0 100 200 300 400 500 600 Output Power Watts Output Current Amps 12 6 Vdc 0 20 40 60 80 0 100 200 300 400 500 600 Output Power Watts Efficiency 12 6 Vdc 0 20 40 60 80 0 100 200 300 400 500 600 Output Power Watts Input Current...

Page 94: ...2 6 Vdc 11 6 Vdc 55 60 65 70 75 80 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Output Power Watts Output Frequency Hz 14 6 Vdc 13 6 Vdc 12 6 Vdc 11 6 Vdc 0 5 10 15 20 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Output Power Watts Output Current Amps 13 6 Vdc 0 20 40 60 80 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Output Power Watts Efficiency 13 6 Vdc 0 50 100 150 200 250 0 200 400 6...

Page 95: ...7 2 Vdc 25 2 Vdc 23 2 Vdc 50 55 60 65 70 75 80 0 100 200 300 400 500 600 700 800 900 1000 Output Power Watts Output Frequency Hz 27 2 Vdc 25 2 Vdc 23 2 Vdc 0 2 4 6 8 0 100 200 300 400 500 600 700 800 900 1000 Output Power Watts Output Current Amps 25 2 Vdc 0 20 40 60 80 0 100 200 300 400 500 600 700 800 900 1000 Output Power Watts Efficiency 25 2 Vdc 0 10 20 30 40 50 0 100 200 300 400 500 600 700 ...

Page 96: ... 25 2 Vdc 23 2 Vdc 55 60 65 70 75 80 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Output Power Watts Output Frequency Hz 27 2 Vdc 25 2 Vdc 23 2 Vdc 0 2 4 6 8 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Output Power Watts Output Current Amps 25 2 Vdc 0 20 40 60 80 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Output Power Watts Efficiency 25 2 Vdc 0 25 50 75 100 125 0 200 400 600 800 1000 ...

Page 97: ...c 37 8 Vdc 34 8 Vdc 55 60 65 70 75 80 0 100 200 300 400 500 600 700 800 900 1000 1100 Output Power Watts Output Frequency Hz 40 8 Vdc 37 8 Vdc 34 8 Vdc 0 2 4 6 8 10 0 100 200 300 400 500 600 700 800 900 1000 1100 Output Power Watts Output Current Amps 37 8 Vdc 0 20 40 60 80 0 100 200 300 400 500 600 700 800 900 1000 1100 Output Power Watts Efficiency 37 8 Vdc 0 10 20 30 40 0 100 200 300 400 500 60...

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