Regal Marathon Lima Mac, Installation And Operation Manual

Page 1: ...REEFER Generator INSTALLATION AND OPERATION MANUAL 260 FRAME SELF REGULATED BRUSHLESS SYNCHRONOUS AC GENERATOR ...

Page 2: ...nce Service TABLE OF CONTENTS Page No 1 2 2 3 4 5 6 7 8 9 9 10 10 15 Trouble Shooting Procedures 16 18 Parts Lists Length Air Filtration Syatem Construction Bearing Features SB516 3 97 SPECIFICATIONS 17 length over all Side inlet air filtration baffel Optional exhaust baffel 19 21 Cast aluminum frame Cast iron bearing carrier Double sealed 6308 bearing Chevron SRI 2 grease 100 000 hours B 10 life ...

Page 3: ... moving your Lima MAC generator are pointed out in the installation and service sections Incorrect lifting or moving can result in personal injury or damage to the unit Prior to stan up ofthe unit insure that all generator leads are properly and securely connected to the terminal strip Always assume that there will be voltage present at the generator terminals whenever the generator s shaft is rot...

Page 4: ...ed synchronous AC generator and does not employ an automatic voltage regulator The main stator and exciter stators are housed in the generator frame All rotating electrical components exciter rotor main rotor and the rotating rectifier assembly are mounted on a common shaft Lima MAC Refrigeration Duty alternator main stators are two circuit wye connected 10 load lead designs Principles of Operatio...

Page 5: ... MAC REFRIGERATION DUTY ALTERNATOR For clarity only interconnections of one phase is diagramed Temperature Rise Lima MAC Refiigeration Duty alternators are constructed with Class F insulating materials on the stator windings and Class H materials on the rotating windings These machines are designed for continuous duty and are conservatively rated at 80 C temperature rise over a maximum ambient tem...

Page 6: ...e in an area where there is considerable vibration it is recommended that the bearing s be inspected and replaced ifnecessary prior to placing the unit into service Preparation for Use Although the generator has been carefully inspected and tested in operation prior to shipment from the factory it is recommended that the unit be thoroughly inspected all bolts checked for tightness and insulation o...

Page 7: ...DO NOT USE SPLIT TYPE LOCK WASHERS Split lock washers when biting into the drive discs will cause stress risers and may result in the discs fracturing Endplay Test Procedure After the generator has been assembled to the prime mover check for endplay Using a suitabl e lever force the engine flywheel forward so that the crankshaft is pressed against its thrust bearing When force is released the engi...

Page 8: ...s and or the system distribution wiring schematic diagram for the proper connection ofLO Figure 2 illustrates the terminal strip mounted in the connection box Figure 2 TERMINAL STRIP ASSEMBLY FRAME 260 Lima MAC ALTERNATORS Generator Load Lead Terminal Strip Mounting Plate 0 Ground Stud Assembly Lead Marker Note Neutral lead TO is connected at the factory to the frame grounding stud with a jumper w...

Page 9: ...77 Volts 7 L l 4so v Connections to be made on terminal strip Ll Tl T7 Jumpered L2 T2 T8 Jumpered L3 T3 T9 Jumpered LO T4 TS T6 TO Jumpered Connections to be made on terminal strip Ll Tl L2 T2 L3 T3 LO TO Series Connections Jumper together T4 T7 Jumper together TS T8 Jumper together T6 T9 ...

Page 10: ...NGINE GENERATOR SET USING THE GENERATOR S FAN AS A FULCRUM FAN MATERIAL IS LIGHT WEIGHT ALUMINUM AND NOT DESIGNED FOR TIDS PURPOSE BARRING OVER THE SET WITH THE FAN COULD DAMAGE THE FAN AND RESULT IN INJURY TO PERSONNEL OR DAMAGE TO THE EQUIPMENT 3 Check all wiring against the proper connection diagrams and insure that all connections on the terminal strip are securely tightened 4 Insure that all ...

Page 11: ...be as reliable and trouble free as is possible However costly repairs and down time can be minimized by operating the unit under conditions that are compatible with those at which the equipment was designed to operate See Operation Section The following maintenance procedures should be followed to insure long equipment life and satisfactory performance 1 Routinely check intake and exhaust air scre...

Page 12: ...eed below the generator s voltage build up speed For this procedure bring the engine speed as slowly as possible up to 1000 RPM Do not let the engine speed exceed 1000 RPM during start op or during the drying process Cleaning Methods When electrical components get dirty the insulation must be cleaned There are a number of acceptable methods for cleaning the generator each ofwhich will necessitate ...

Page 13: ... Restoring Residual Magnetism The current necessary to magnetize the alternator field during operation is obtained from the exciter Initially upon starting the unit voltage is induced into the main stator armature by the flux across the air gap supplied by the permanent magnets embedded in the poles ofthe main rotor Current then flows through interconnecting leads to the shunt portion of the excit...

Page 14: ...nally after swapping leads re number the leads that were swapped Re numbered leads should then be preminantly connected as shown in Figure I page 3 SWAP LEADS TRIAL CONNECTIONS Hi WYE EXCITER EXCITER MAIN EXCITER EXTERNAL TS T6 T13 T13 Tl LINE T8 T9 T14 TIS TI LINE TI4 TIS TIS T14 TI LINE T17 TIS T16 T16 T4 T7 T17 TIS TS TS TIS T17 T6 T9 TO Bearing and Exciter Rotor Removal and Replacement Procedu...

Page 15: ...g oil to the press fit area ofthe rotor shaft Using suitable heat resistant gloves install the bearing over the end ofthe shaft until it seats against the shaft shoulder The bearing should slide on the shaft and be seated without excessive force Should the bearing bind on the shaft prior to being seated against the shoulder a piece oftubing slightly larger than the press fit area can be used to dr...

Page 16: ...at the procedure Y m have now tested the three diodes on this sub assembly Repeat the test on the second sub assembiy These tests should indicate one ofthree conditions 1 Good diode Will have a much greater resistance in one direction than the other Typical reverse resistance will be 30 000 300 000 ohms or greater while typical forward resistance will be less than 10 ohms The battery light tester ...

Page 17: ...y in the same place as before Pay particular attention to assure that the white exciter rotor leads are installed on the sub assembly having white diode leads and that the assembly having black diode leads receive the black exciter rotor leads Replacing Diodes on the Rectifier Assembly Prior to installing a replacement diode on the heat sink sparingly apply a film ofconductive heat sink compound a...

Page 18: ...THE UNIT IS RUNNING TOOLS EQUIPMENT CLOTHING AND YOUR BODY MUST BE KEPT CLEAR OF ROTATING PARTS AND ELECTRICAL CONNECTIONS EXTRA PRE CAUTIONS MUST BE TAKEN DURING TROUBLESHOOTING SINCE PROTECTIVE COVERS AND SAFETY DEVICES MAY BE REMOVED OR DISABLED TO GAIN ACCESS AND MAKE TESTS BE CAREFUL SERIOUS PERSONAL INJURY OR DEATH CAN RESULT FROM THESE HAZARDS CONSULT QUALIFIED PERSONNEL WITH ANY QUESTIONS ...

Page 19: ...ections Check all tenninations Re make as necessary Faulty diodes Check rectifier assy Faulty main rotor Check main rotor pole windings Ifwinding appears to bulge mid way down body ofpole refer to service shop or return to factory for sefV ce SYMPTOM GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED CAUSE Driver speed droop Excessive load CHECK AND REMEDY Check engine For proper operation engine mu...

Page 20: ...AND REMEDY Reduce load Check with ammeter and compare with nameplate Clean air passages Improve ventilation or reduce load Provide cross ventilation The load on each leg should be as evenly balanced as possible and should not exceed rated current on any leg Replace bearing SYMPTOM GENERATOR PRODUCES MECHANICAL NOISE CAUSE Defective bearing Loose screens or guards CHECK AND REMEDY Replace bearing C...

Page 21: ... 9 780893 0A MAIN ROTOR WINDING 1 10 789412 0a EXCITER STATOR WINDING 1 11 791164 0A EXCITER ROTOR WINDING 1 12 778714 0A RECTIFIER 1 13 716407 01 FAN 1 14 702949 01 PILOT DISK 260FR RFR KUBOTA ENGINE 2 15 702948 01 DRIVE DISK 260FR RFR KUBOTA ENGINE 2 16 707112 01 DRIVE HUB 260FR RFR 1 17 809865 xx KEY 38 X 38 X 1 00 1 18 90005R xx BALL BRG 308 SGL ROW DBL SEALS N CONTACT 1 19 865876 01 O RING 1 ...

Page 22: ...9 0A 16 5 I Frame SAE 5 Base Model 3386A I 706228 01 16 4 I Frame SAE 4 Base Model 3384A I 706227 01 18 Kev main rotor 3 8 x 3 8 x I 5 8 I 809865 02 19 0 Rine I 865876 01 20 Hx hd cao screw 114 20 I 1 2 zn 8 801000 07 21 Washer snli t lock 114 20 801065 05 22 Hx hd cao screw 114 20 x 1 2 Gr 5 zn 4 801000 01 23 Hexhd screw 5 16 18 x 1Gr5 zn 4 801002 05 24 Washer lit lock 5 16 4 801065 06 25 Hex Hd ...

Page 23: ... 2 N R nS329 01 I D 195119 0A 7 S 0 400 N R 702512 01 2 725328 01 6 N R c 03 20 97ffiW Note Adaption Kit pin 795270 reqircs 2 pilot discs pin 702332 0A Installed outboard ofthe flex discs Disc Bolts A Soc Hd Cap Screw MIO x 1 5 x 55 pin 801129 10 6 required with 6 3 8 Belleville washers plnA 9682 9CC B Soc Hd Cap Screw f IO x 1 5 t 30 pin 801129 05 6 required With 6 3 8n Belleville washers pin A 9...