Service Manual, 20-300 kW FR II (TP-5353) - ImageEvent

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Safety Precautions and Instructions A generator set, like any other electromechanical device, can pose potential dangers to life and limb if improperly maintained or imprudently operated. The best way to prevent accidents is to be aware of the potential dangers and to always use good common sense. In the interest of safety, some general precautions relating to the operation of a generator set follow. Below are some general precautions relating to the operation of a generator set. SAVE THESE INSTRUCTIONS. DANGER Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage if the danger is ignored. WARNING Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored. CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored. Note communicates NOTE installation, operation, or maintenance information that is important but not hazard related. Safety decals are affixed to the generator set in prominent places to advise the operator or service technician of potential hazards. The decals are reproduced here to improve operator recognition. For a further explanation of decal information, refer to the safety precautions throughout this manual. Before operating or servicing the generator set, be sure you understand the messages of these decals. Replace decals if missing or damaged. Accidental Starting WARNING Accidental starting. Can cause severe injury or death. Disconnect battery cables before working on generator set (negative lead first and reconnect it last). Accidental starting can cause severe injury or death. Turn generator set master switch to OFF position, disconnect power to battery charger, and remove battery cables (remove negative lead first and reconnect it last) to disable generator set before working on any equipment connected to generator set. The generator set can be started by automatic transfer switch or remote start/stop switch unless these precautions are followed. Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Use protective goggles and clothes. Battery acid can cause permanent damage to eyes, burn skin, and eat holes in clothing. TP-5353 8/94 Safety Precautions and Instructions I
WARNING Explosion. Can cause severe injury or death. Relays in battery charger cause arcs or sparks. Locate in a well-ventilated area. Keep explosive fumes away. Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can cause permanent damage to eyes, burn skin, and eat holes in clothing. Always wear splash-proof safety goggles when working around the battery. If battery electrolyte is splashed in the eyes or on skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery once the battery has been placed in service. This may result in hazardous spattering of electrolyte. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flame or spark to occur near a battery at any time, particularly when it is being charged. Avoid contacting terminals with tools, etc., to prevent burns and sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling battery. Never connect negative (--) battery cable to positive (+) connection terminal of starter solenoid. Do not test battery condition by shorting terminals together. Sparks could ignite battery gases or fuel vapors. Ventilate any compartment containing batteries to prevent accumulation of explosive gases. To avoid sparks, do not disturb battery charger connections while battery is being changed. Always turn battery charger off before disconnecting battery connections. Remove negative lead first and reconnect it last when disconnecting battery. Engine Backfire/Flash Fire WARNING Fire. Can cause severe injury or death. Do not smoke or permit flame or spark to occur near fuel or fuel system. A sudden backfire can cause severe injury or death. Do not operate with air cleaner removed. A flash fire can cause severe injury or death. Do not smoke or permit flame or spark to occur near carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuel or fuel vapors. Use a suitable container to catch all fuel when removing fuel line or carburetor. Exhaust System WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Carbon monoxide can cause severe nausea, fainting, or death. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate in any area where exhaust gas could accumulate and seep back inside an occupied building. Avoid breathing exhaust fumes when working on or near the generator set. Carbon monoxide is particularly dangerous because it is an odorless, colorless, tasteless, nonirritating gas. Be aware that it can cause death if inhaled for even a short time. II Safety Precautions and Instructions TP-5353 8/94
Page 1 and 2: Service Industrial Generator Sets M
Page 3: SUBJECT PAGE SUBJECT PAGE Stator ..
Page 7 and 8: Explosive fuel vapors can cause sev
Page 9 and 10: Hazardous voltage can cause severe
Page 11 and 12: Moving Parts WARNING Hazardous volt
Page 14 and 15: Section 1. Specifications The spec
Page 16 and 17: The generator set is a rotating-fie
Page 18 and 19: Engine Prealarm and Shutdown Switch
Page 20 and 21: Several accessories are available t
Page 22 and 23: Audio/Visual (A/V) Alarm (with micr
Page 24 and 25: Overvoltage Kit (with microprocesso
Page 26: Remove Jumper if Emergency Stop is
Page 29 and 30: 16-Light Controller (Level 1) Opera
Page 31 and 32: 11. Low Battery Volts (if Battery C
Page 33 and 34: Starting Local Starting Move the ge
Page 35 and 36: Fault Shutdowns The generator set w
Page 37 and 38: 6-Light Controller (Level 2) Operat
Page 39 and 40: 6. Low Oil Pressure. Lamp lights if
Page 41 and 42: Stopping Normal Stopping 1. Disconn
Page 43 and 44: Paralleling Engine Gauge Box Contro
Page 45 and 46: The manual controller is designed f
Page 47 and 48: Stopping 1. Disconnect load from ge
Page 49 and 50: Oil Requirements (30, 80, and 100 k
Page 52 and 53: Section 4. General Troubleshooting
Page 54 and 55:
Section 5. Controller Troubleshooti
Page 56 and 57:
Circuit Board Terminal Identificati
Page 58 and 59:
Overvoltage Shutdown 120 VAC for Cr
Page 60 and 61:
Figure 5-6. Logic Schematic, 1-Phas
Page 62 and 63:
Fault Shutdowns—Microprocessor Co
Page 64 and 65:
The following text covers the manua
Page 66:
Figure 5-9. Manual Controller S-ADV
Page 69 and 70:
Troubleshooting Microprocessor Cont
Page 71 and 72:
Engine will not crank with generato
Page 73 and 74:
Controller instrumentation not func
Page 75 and 76:
Engine starts and runs, but overcra
Page 77 and 78:
Operation Use the FASTCHECK to tes
Page 79 and 80:
1 G-292806 1. TB1-42A 2. TB1—(See
Page 81 and 82:
Use the following charts as a refer
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A Troubleshooting Manual Controller
Page 85 and 86:
Troubleshooting Manual Controller (
Page 87 and 88:
No output voltage is detected. 7-2
Page 89 and 90:
This section covers generator testi
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7-6 Generator Troubleshooting Overv
Page 93 and 94:
3. Observe the AC output voltmeter.
Page 95 and 96:
Hazardous voltage can cause severe
Page 97 and 98:
7-12 Generator Troubleshooting Auto
Page 99 and 100:
NOTE Generator sets use a skewed (s
Page 101 and 102:
Hot parts can cause severe injury o
Page 103 and 104:
Follow the procedure outlined below
Page 105 and 106:
7-20 Generator Troubleshooting Over
Page 107 and 108:
With the constant speed type govern
Page 109 and 110:
7-24 Generator Troubleshooting Mech
Page 111 and 112:
7-26 Generator Troubleshooting Elec
Page 113 and 114:
Preliminary Adjustments 1. Place ge
Page 115 and 116:
Preliminary Adjustments 1. Place ge
Page 117 and 118:
1 2 7-32 Generator Troubleshooting
Page 120 and 121:
Section 8. Generator Disassembly/Re
Page 122 and 123:
11 8 12 10 1. Voltage Regulator Ter
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1. Disconnect all controller-to-eng
Page 126 and 127:
14. Place the generator assembly on
Page 128 and 129:
7. Place the generator assembly on
Page 130 and 131:
12. Suspend the rotor over the gene
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23. Install and set speed sensor ai
Page 135 and 136:
NOTE All 12-lead generator sets are
Page 137 and 138:
Generator Frequency Change and Adju
Page 139 and 140:
Abbreviation Description Abbreviati
Page 142 and 143:
TP-5353 8/94 Appendix C. Common Har
Page 144:
Appendix D. General Torque Specific
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Service Manual, 20-300 kW FR II (TP-5353) - ImageEvent

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