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- DA12A
- Installation And Service Manual
Pacific DA12A Installation And Service Manual
Summary of DA12A
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Installation and service manual models da12a da12l da24a da24l da36a da36l.
Page 2: Warranty Policy
Warranty policy instruction and service manual pacific scientific redi-line generators warranty policy pacific scientific warrants its redi-line generator to the original purchaser and in the case of original equipment manufacturers or distributors, to their original consumer, to be free from defect...
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Instruction and service manual table of contents pacific scientific redi-line generators tables of contents about this manual .......................................................................................................................... 5 1. Description and operation .......................
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Table of contents instruction and service manual 4 pacific scientific redi-line generators 7. Field troubleshooting ......................................................................................................... 25 f ield s ervice ..............................................................
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Instruction and service manual about this manual pacific scientific redi-line generators 5 about this manual the purpose of this manual is twofold: first, to provide comprehensive installation instructions for pacific scientific redi-line generators; and second, to provide comprehensive maintenance,...
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Description and operation instruction and service manual 6 pacific scientific redi-line generators 1. Description and operation the redi-line generator is an electromechanical device that converts dc battery power to ac power. The dc supply consists of one or more deep cycle batteries typically adde...
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Instruction and service manual general specifications pacific scientific redi-line generators 7 2. General specifications nameplate data the generator nameplate provides the operational specifications of the generator. The beginning letter designations of the catalog listing describe the generator t...
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Unpacking instruction and service manual pacific scientific redi-line generators 3. Unpacking unpacking open the box and lift out the generator 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 genera...
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Instruction and service manual preparation for installation pacific scientific redi-line generators 9 4. Preparation for installation most redi-line service requests result from improperly installed units. Improper installation will affect generator performance and may damage the unit. Note: damage ...
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Preparation for installation instruction and service manual 10 pacific scientific redi-line generators caution: do not install the redi-line generator and it’s supply batteries in the same compartment. Caution: do not install the redi-line generator in a compartment that could contain explosive fume...
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Instruction and service manual preparation for installation pacific scientific redi-line generators 11 da12a series if the load requirement is not heavy (intermittent hand tool use or light loads for a long period of time) the vehicle battery and charging system should handle both vehicle and additi...
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Preparation for installation instruction and service manual 12 pacific scientific redi-line generators da12l series if the load requirement is not heavy (intermittent hand tool use or light loads for a long period of time) install one or more auxiliary deep cycle batteries. The auxiliary battery sho...
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Instruction and service manual preparation for installation pacific scientific redi-line generators 13 da24a series if the load requirement is not heavy (intermittent hand tool use or light loads for a long period of time) the vehicle battery and charging system should handle both the vehicle and ad...
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Preparation for installation instruction and service manual 14 pacific scientific redi-line generators da24l series if the load requirement is not heavy (intermittent hand tool use or light loads for a long period of time) the vehicle battery and charging system should handle both the vehicle and ad...
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Instruction and service manual preparation for installation pacific scientific redi-line generators 15 da36a series if the load requirement is not heavy (intermittent hand tool use or light loads for a long period of time) the vehicle battery and charging system should handle both the vehicle and ad...
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Preparation for installation instruction and service manual 16 pacific scientific redi-line generators da36l series if the load requirement is not heavy (intermittent hand tool use or light loads for a long period of time) the vehicle battery and charging system should handle both the vehicle and ad...
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Instruction and service manual preparation for installation pacific scientific redi-line generators 17 battery selection standard automotive batteries are designed to supply 300 to 500 amps of current for a relatively short period; therefore they are not the best power source for redi- line generato...
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Preparation for installation instruction and service manual 18 pacific scientific redi-line generators wiring considerations installation and wiring must conform to all applicable codes, including the national electric code, state and local, or other codes in effect at the time of installation. Paci...
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Instruction and service manual installation pacific scientific redi-line generators 19 5. Installation before beginning installation the redi-line generator is a quality product, designed to be rugged, reliable and safe when installed properly. Improper installation can cause damage to the unit and/...
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Installation instruction and service manual 20 pacific scientific redi-line generators installation interconnection install your redi-line generator according to the interconnection shown in the appropriate installation figure (figures 4-1 through 4-12). Use the correct cable size (table 4-1) betwee...
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Instruction and service manual installation pacific scientific redi-line generators 21 figure 5-1. Mounting template for small frame generators.
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Installation instruction and service manual 22 pacific scientific redi-line generators figure 5-2. Mounting template for large frame generators.
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Instruction and service manual installation pacific scientific redi-line generators 23 installation checkout after installation is complete, perform the following checkout to see that the redi- line generator has been properly installed. Where remedial action is indicated, respond as directed. If sp...
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Maintenance instruction and service manual pacific scientific redi-line generators 24 6. Maintenance because the redi-line generator contains long life bearings and brushes, it is virtually maintenance free. We recommend that the few maintenance procedures given below be performed on a periodic basi...
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Instruction and service manual field troubleshooting pacific scientific redi-line generators 25 7. Field troubleshooting field service pacific scientific recommends that field troubleshooting be performed whenever a problem is encountered with the redi-line generator, to correct or eliminate problem...
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Field troubleshooting instruction and service manual 26 pacific scientific redi-line generators appropriate equipment and skills, some of the tests and repairs suggested can be performed in the field. However, before repairs are attempted, you should check with your distributor to make sure that suc...
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Instruction and service manual field troubleshooting pacific scientific redi-line generators 27 field troubleshooting checklist form we have performed the following troubleshooting checks: and the results were: 1. 2. 3. 4. 5. 6. 7. 8. 9. Customer name:________________________________________________...
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Field troubleshooting instruction and service manual 28 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 sec...
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Instruction and service manual field troubleshooting pacific scientific redi-line generators 29 generator turning too fast or 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...
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Field troubleshooting instruction and service manual 30 pacific scientific redi-line generators using wrong meter output voltage or frequency too high or too low no recheck with correct meter *. Yes okay * use a true rms voltmeter fluke models 87, 8060, or 8062 are recommended. Return for repair che...
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Instruction and service manual field troubleshooting pacific scientific 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 no...
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Field troubleshooting instruction and service manual 32 pacific scientific redi-line generators generator will not start motor on equipment plugged into it or faulty equipment check with independent power source repair or replace equipment return to service see figure 7-6 this section okay okay star...
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Instruction and service manual field troubleshooting pacific scientific redi-line generators 33 generator does not start automatically incorrect load check with 100 watt light bulb okay yes no increase load on generator . Return to service incorrect installation return for repair check to see that b...
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Field troubleshooting instruction and service manual 34 pacific scientific redi-line generators generator starts when load is turned on, but stops after a few seconds. Okay yes no load too high, circuit breaker trips reduce load install larger generator reset circuit breaker and restart return to se...
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Instruction and service manual field troubleshooting pacific scientific 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 c...
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Field troubleshooting instruction and service manual 36 pacific scientific redi-line generators battery discharges too quickly determine run time capability. See battery selection, section 4, preparation for installation install additional batteries okay no yes check to see that deep cycle batteries...
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Instruction and service manual field troubleshooting pacific scientific redi-line generators 37 generator runs all the time installation problem check for continuous load. See note remove continuous load return to service tsfaruns note: power strips with on indicator lamps, equipment with power conn...
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Field troubleshooting instruction and service manual 38 pacific scientific redi-line generators other troubleshooting checks checking generator speed users familiar with redi-line operation may detect a change in sound if the generator is running off-speed. Such an occurrence is generally the result...
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Instruction and service manual bench troubleshooting pacific scientific redi-line generators 39 8. Bench troubleshooting units that have been returned for repair are usually accompanied by information identifying the problems encountered with the equipment. The troubleshooting flow charts contained ...
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Bench troubleshooting instruction and service manual 40 pacific scientific redi-line generators troubleshooting flowcharts field complaint generator is noisy replace armature see armature replacement, section 9, repair procedures replace bearings see bearing replacement section 9, repair procedures ...
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Instruction and service manual bench troubleshooting pacific scientific redi-line generators 41 field complaints generator turning too slow... Voltage or frequency too low yes test armature see inspection procedure, this section no okay replace shell see disassembly and assembly, section 9, repair p...
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Bench troubleshooting instruction and service manual 42 pacific scientific redi-line generators tsbanost inspect dc brushes see brush inspection procedure, this section inspect ac brushes see brush inspection procedure, this section inspect diode see diode inspection procedure, this section inspect ...
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Instruction and service manual bench troubleshooting pacific scientific redi-line generators 43 field complaint generator cycles on and off every few seconds or older version* newer version does not occur replace pc board. See pc board replacement, section 9 repair procedures tsbacycl return to serv...
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Bench troubleshooting instruction and service manual 44 pacific scientific redi-line generators field complaint generator runs all the time or large frame version small frame version or older versions* newer versions* replace solenoids see solenoid replacement, section 9, repair procedures return to...
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Instruction and service manual bench troubleshooting pacific scientific redi-line generators 45 procedure no. 1: dc brush inspection procedure: 1. Remove any electrical connections to the generator. 2. Remove the electrical assembly cover. 3. Disconnect the lead wires to the components inside the co...
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Bench troubleshooting instruction and service manual 46 pacific scientific redi-line generators procedure no. 2: ac brush inspection procedure: 1. Remove any electrical connections to the generator. 2. Remove the electrical assembly cover. 3. Disconnect the lead wires to the components inside the co...
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Instruction and service manual bench troubleshooting pacific scientific redi-line generators 47 procedure no. 3: bearing inspection procedure: 1. Remove any electrical connections to the generator. 2. Remove the end cap covering the cooling fan. 3. Manually spin the armature by turning the fan in bo...
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Bench troubleshooting instruction and service manual 48 pacific scientific redi-line generators procedure no. 5: armature test procedure: 1. Disassemble the generator. 2. Measure the resistance between adjacent ac slip rings. 3. Measure the resistance of the dc windings by testing adjacent bars all ...
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Instruction and service manual bench troubleshooting pacific scientific redi-line generators 49 procedure no. 6: solenoid test note: this test does to apply to a da12a-500a. This generator does not have a solenoid. Procedure: 1. Disconnect the battery from the generator. 2. Remove the electrical ass...
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Bench troubleshooting instruction and service manual 50 pacific scientific redi-line generators procedure no. 7: circuit breaker test procedure: 1. Remove any electrical connections to the generator. 2. Remove the electrical assembly cover from the generator but do not disconnect any electrical wire...
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Instruction and service manual bench troubleshooting pacific scientific redi-line generators 51 procedure no. 8: diode test note: this test does not apply to redi-line generator models da12l-1600a and da12a- 500a. Procedure: 1. Remove any electrical connections to the generator. 2. If checking a sma...
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Repair procedures instruction and service manual 52 pacific scientific redi-line generators 9. Repair procedures general repair of redi-line generators is confined to replacement of defective parts. The following procedures, therefore, consist of disassembly and assembly procedures only. Many of the...
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Instruction and service manual repair procedures pacific scientific redi-line generators 53 3. 100w light bulb assembly (for testing generator performance). This device consists of a 100-watt light bulb in a keyless fixture mounted on a utility box. Equip the utility box with a short power cord and ...
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Repair procedures instruction and service manual 54 pacific scientific redi-line generators re-assembly of small frame units note: steps 1 through 4 must be done in the order presented. 1. Assemble front end bell (31) and armature (39). Install bearing (35) on armature and retain with c ring (40) be...
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Instruction and service manual repair procedures pacific scientific redi-line generators 55 disassembly of large frame units note: steps 2, through 6 can be done independently of one another. 1. Remove any electrical connections to the generator. 2. Remove solenoid cover (1). Disconnect the electric...
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Repair procedures instruction and service manual 56 pacific scientific redi-line generators re-assembly of large frame units note: steps 1 through 7 must be done in the order presented. 1. Assemble front end bell (25 or 29) and armature (39, 43, 44, or 48). Install bearing (36, 40, 41, or 45)) on ar...
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Instruction and service manual repair procedures pacific scientific redi-line generators 57 dc brush removal and replacement refer to figure 9-1 . Removal 1. Move brush shunts out of the way from the spring. 2. Note the brush ramp position and spring location before removing brushes. Brushes must be...
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Repair procedures instruction and service manual 58 pacific scientific redi-line generators checkout after repair 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 mod...
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Instruction and service manual parts lists pacific scientific redi-line generators 59 10. Parts lists models covered the following parts lists cover small frame generator models da12a, da24a, and da36a; and large frame generator models da12l and da24l. Several versions of each of these models exist;...
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Parts lists instruction 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.
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Instruction and service manual parts lists pacific scientific redi-line generators 61 table 10-1: parts list - small frame generators part number item da12a da12a-500 da12a-500a description qty ref fgd1201 fgd1297 fgd1252 generator assembly 1 1 yp63444 yp63444 yp63444 . Ac brush assembly 2 2 yk11230...
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Parts lists instruction and service 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.
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Instruction and service manual parts lists pacific scientific redi-line generators 63 table 10-1: parts list - small frame generators, continued part number item da12a da12a-500 da12a-500a description qty ref fgd1201 fgd1297 fgd1252 generator assembly 1 24 not used not used yp05816 . Printed circuit...
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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.
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Instruction and service manual parts lists pacific scientific redi-line generators 65 table 10-2: parts list - end bell for earlier small frame generators item part no. Description qty ref no longer available end bell assembly 1 1 no longer available . End bell 1 ni no longer available brush holder ...
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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.
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Instruction and service manual parts lists pacific scientific redi-line generators 67 table 10-3: parts 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 . I...
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Parts lists instruction and service manual 68 pacific scientific 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 g...
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Instruction and service manual parts lists pacific scientific redi-line generators 69 table 10-4: parts list - 12-volt large frame generator, earliest version item part no. Description qty da12l-1600 generator assembly 1 1 no longer available . Solenoid cover 1 2 yk11230 . Screw, slotted, pan hd, 10...
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Parts lists instruction and service manual 70 pacific scientific 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 g...
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Instruction and service manual parts lists pacific scientific redi-line generators 71 table 10-4: parts list - 12-volt large frame generator, earliest version, continued item part no. Description qty ref da12l-1600 generator assembly 1 30 no longer available . Bell assembly, rear end (fan shroud end...
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Parts lists instruction and service manual 72 pacific scientific 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 g...
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Instruction and service manual parts lists pacific scientific redi-line generators 73 table 10-5: parts list - 12-volt large frame generator, interim version item part no. Description qty ref da12l-1600-1 generator assembly 1 1 no longer available . Solenoid cover 1 2 yk11230 . Screw, slotted, pan h...
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Parts lists instruction and service manual 74 pacific scientific 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 g...
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Instruction and service manual parts lists pacific scientific redi-line generators 75 table 10-5: parts list - 12-volt large frame generator, interim version, continued item part no. Description qty ref da12l-1600-1 generator assembly 1 31 yj11240 . Tie rod 4 32 yk11322 . Nut, acorn, 10-32 4 33 yk10...
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Parts lists instruction and service manual 76 pacific scientific 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 generato...
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Instruction and service manual parts lists pacific scientific redi-line generators 77 table 10-6: parts list - 12-volt large frame generator, current version item part no. Description qty da12l-1600a generator assembly 1 1 yc63238 . Solenoid cover 1 2 yk11230 . Screw, slotted, pan hd, 10-32 x 3/8 4 ...
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Parts lists instruction and service manual 78 pacific scientific 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 generato...
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Instruction and service manual parts lists pacific scientific redi-line generators 79 table 10-6: parts list - 12-volt large frame generator, current version, continued item part no. Description qty da12l-1600a generator assembly 1 30 yp03151 . Washer, wavy spring 1 31 yl35532 . Terminal, positive, ...
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Parts lists instruction and service manual 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.
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Instruction and service manual parts lists pacific scientific redi-line generators 81 table 10-7: parts list - 24-volt large frame generator, earlier version item part no. Description qty ref da24l-1600 generator assembly 1 1 no longer available . Solenoid cover 1 2 yk11230 . Screw, slotted, pan hd,...
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Parts lists instruction and service manual 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.
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Instruction and service manual parts lists pacific scientific redi-line generators 83 table 10-7: parts list - 24-volt large frame generator, earlier version, continued item part no. Description qty ref da24l-1600 generator assembly 1 31 yk11212 . Tie rod 2 32 yk11322 . Nut, acorn, 10-32 2 33 yk1091...
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Parts lists instruction and service 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.
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Instruction and service manual parts lists pacific scientific redi-line generators 85 table 10-8: parts list - 24-volt large frame generator, current version item part no. Description qty ref da24l-1600a generator assembly 1 1 yc63238 . Solenoid cover 1 2 yk11230 . Screw, slotted, pan hd, 10-32 x 3/...
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Parts lists instruction and service manual 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.
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Instruction and service manual parts lists pacific scientific redi-line generators 87 table 10-8: parts list - 24-volt large frame generator, current version, continued item part no. Description qty ref da24l-1600a generator assembly 1 31 yl35532 . Terminal, positive, with lead wire 1 32 yp02237 . I...
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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.
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Instruction and service manual parts lists pacific scientific redi-line generators 89 table 10-9: parts list - end bell for large frame generators, earlier version item part no. Description qty ref no longer available end bell assembly 1 1 no longer available . End bell 1 2 no part number . Right ha...
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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.
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Instruction and service manual parts lists pacific scientific redi-line generators 91 table 10-10: parts list - end bell for large frame generators, current version item part no. Description qty ref yr70215 end bell assembly 1 1 yr20226 . End bell 1 2 no part number . Right hand brush holder assembl...
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Technical data instruction and service manual 92 pacific scientific redi-line 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...
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Instruction and service manual technical data pacific scientific redi-line generators 93 figure 11-1: performance curves for da12a-500a redi-line generators 80 100 120 140 160 0 100 200 300 400 500 600 output power (watts) output voltage (vac) 13.6 vdc 12.6 vdc 11.6 vdc 55 60 65 70 75 80 0 100 200 3...
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Technical data instruction and service manual 94 pacific scientific redi-line generators figure 11-2: performance curves for da12l-1600a redi-line generators 80 100 120 140 160 0 200 400 600 800 1000 1200 1400 1600 1800 2000 output power (watts) output voltage (vac) 14.6 vdc 13.6 vdc 12.6 vdc 11.6 v...
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Instruction and service manual technical data pacific scientific redi-line generators 95 figure 11-3: performance curves for da24a-800a redi-line generators 80 100 120 140 160 0 100 200 300 400 500 600 700 800 900 1000 output power (watts) output voltage (vac) 27.2 vdc 25.2 vdc 23.2 vdc 50 55 60 65 ...
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Technical data instruction and service manual 96 pacific scientific redi-line generators figure 11-4: performance curves for da24l-1600a redi-line generators 80 100 120 140 160 0 200 400 600 800 1000 1200 1400 1600 1800 2000 output power (watts) output voltage (vac) 27.2 vdc 25.2 vdc 23.2 vdc 55 60 ...
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Instruction and service manual technical data pacific scientific redi-line generators 97 figure 11-5: performance curves for da36a-900a redi-line generators 80 100 120 140 160 0 100 200 300 400 500 600 700 800 900 1000 1100 output power (watts) output voltage (vac) 40.8 vdc 37.8 vdc 34.8 vdc 55 60 6...