Babson Bros. Co. SURGE 20004 Instruction Manual

PTO-POWEREDALTERNATORS
OPERATORS MANUAL
ANDPARTSCATALOG
15 KW
MODELNO. 20004
•y-:7
BABSON BROS. CO.2100s.YORKRD.OAKBROOK,ILLINOIS 60521
BABSON BROS. CO. (CANADA) LTD.PORTCREDIT, ONTARIO
943-0011
Printed inU.S.A. 1
1 -73

TABLE OFCONTENTS
GENERAL INFORMATION. 2
SPECIFICATIONS ' 2
INSTALLATION 3
OPERATION 7
SERVICE ANDMAINTENANCE8
WIRING DIAGRAM12
PARTS CATALOG . 13

GENERAL INFORMATION
INTRODUCTION
This manualcontainsinformationfortheproperinstal-
lation, operationandmaintenanceofyouralternator.We
suggest you keep thisbookhandysoitcanbereferred
to when necessary.
If youwishtocontactyour dealer regardingthisequip-
ment;be sure tosupplythecomplete MODEL NUMBER
andthe full SERIAL NUMBER ofyourequipment.This
information is necessary to identify yourequipmenta-
mongthemanyunitsmanufactured.
DESCRIPTION
These 15 KW models;arerevolvingarmature,3600RPM,
2polealternators with rectifierexcitation.This elimi-
nates the need fora commutatororcommutator brushes.
Outputvoltageisinherentlyregulatedtoproducea
non-fluctuating source ofelectricalpower.Thealterna-
tor iscompletely wired internallyandconnectedtothe
output receptacles. Nofurther wiring isrequirednor
recommended.Thealternatoris gear drivenbya stan-
dardtractorPTO.
( CAUTION
3
Theunitiscomplete with lifting eye,mountingfeet,
mounted gear box with splinedshaftandsafetyshield
anda mountedcontrolbox.
Thecontrolboxcontainsa voltmeter;two70 ampere
circuit breakers foralternatorprotection;one240 volt,
SOampere, 3blade range receptacle;one120/240volt,
60ampere full output receptacle (3blade with grounding
post);andoneduplex120 volt, 15 ampere (fused) recep-
tacle(seeFigure.1).Anauxiliary field timerswitchis
also provided which canbemanuallysetfortime
intervalsupto five minutestoprovideadded field
strengthwhenrequiredforstartinglargerelectric
motors.
OPTIONAL ACCESSORIES
PowerTake-OffShaft:Telescoping,shielded,heavy
duty powertake-offshafts,recommendedforuse with
PTOpowered, gear drivealternators,providemaximum
safetyfortheoperator.Thesplineduniversal joint
with snap ring typeshieldandquickdisconnectfeature,
fits a 1-3/8inchtractorPTOdrive.Telescopingpower
take-off shaftoperatinglengthsare:minimum45inch,
maximum 60 inch; weight35pounds.Sixsplineuniversal
for 520rpmPTO.
This alternator cannot be belt driven.
SPECIFICATIONS
Watts15,000(31.0PF
Volts '. '. '.'.'.'. '. '. '.[ '. '. '. '. '. '. '. '. '. '. '.. '. 120/240
Phase 1
Cycles60
Current(Amperes)63
Wire : 3
Alternator Speed (RPM)
3600
TractorPTO Speed (RPM)520
Minimum HorsepowerRequired, Driving Source 30
Weight (GeneratorSet)300
6ear Reduction Unit VonRuden Apex
Gear Ratio6.9to1 6.78to1
Gear BoxOilCapacity,Pints(SAE90)1-1/22
Gear BoxWeight7684
TractorPTO Speed (RPM)520530

INSTALLATION
LOCATION
Selecta siteforthealternator with the following points
in mind:
1. Ventilation: Thealternator creates considerable
heat whenoperatingunderloadconditions.Itis
important thatthis heat bedissipatedbyproper
ventilation. If installing thealternatorinsidea
small roomorcompartment,providea ventforentry
of fresh, cool air.Providea separate ventfor
exhaustingtheair heated bythealternator.Locate
the heated air exhaust vent above the inlet vent.
Heatedairisdischarged from thedriveshaftendof
thealternator.
EXHAUST GAS IS DEADLY! U operat-
ing alternator inside a building, provide
adequate ducting ior tractor exhaust iumes.
2. Convenienceto Driving Power:Locatethealterna-
tor for easy connectiontothetractor. Align the
power take-off tothealternator.Stay within the
limits ofthepower take-off shaft.
3.DustyorDamp Condition: Avoid excessivelydusty
or dampconditionsasmuchaspossible.Dustand
dirt are enemies ofanypieceofmachinery.The
alternatoris dripproof indesign,but unnecessary
exposure tomoistureshouldbeavoided.Thealter-
natorshouldbemountedundercoverorinsidea
building toprotectit from theweather.
4. ServicingConvenience: Allow at least 24inchesof
space onall sides ofthealternatorforconvenient
servicing.
5. Wiring Convenience:Donotlocatethealternator
in a location difficult toserviceor whichwould
have poor ventilation, to save a fewfeetof wiring.
Install thealternatorasclosetotheloadtransfer
switch aspossible.Donotmovetheloadtransfer
switch tothealternator.Referto INSTALLING THE
LOAD TRANSFER SWITCH.
LIFTING FYE
ALTERNATOR
VENTPLUG
120 VOLT
AMPFUSE
20/240VOLT 60AMP
CONTROL BOX
.GEARREDUCTION BOX
240VOLT.SOAMP_ VQLTMETER
CIRCUITBREAKERS _ / AUXILIARYFIELD
TIMERSWITCH
-PTOSHAFTGUARD
FIGURE I. ALTERNATORDESCRIPTION

POWER TAKE-OFF
SHAFT SHOULD
BE AS STRAIGHT AS
POSSIBLE
ALTERNATOR
PERMANENT
BASE-
TOLOAD
FIGURE 2. TRACTORCONNECTION
FIGURE 4. RECOMMENDED MOUNTING BASE
MOUNTING THE ALTERNATOR
Provide a substantialmounting baseof concrete, wood
or steel anduse largebolts. The surface ofthe mount-
ing base should be flat so that the alternatormounting
brackets will notbe sprungwhentightening into place.
It should be possible to turn the shaft by handafter
thealternator is bolteddown.
C
^J^JJ^ To develop 15 KW requires 30 to 35
^K^^^^^l horsepower at the power take-off. The
torque will flip the alternator over unless secured to a
strong substructure. A narrow (30 inch) trailer is not
suitable for operation. A 40 inch hub to hub minimum
measurement is required.
Be sure that the alternator is properlyaligned with the
driving mechanism and that it will stay in alignment.
INSTALLING THE LOAD TRANSFER SWITCH
Before using the alternator for standby purposes,
install a DOUBLE THROW LOAD TRANSFER
SWITCH. The switch must have an ampere rating
largeenough to carry the total loadwhen the main
source of power isinuse. Follow the local electrical
code. The loadtransfer switch shouldalways be
installed close tothe main line switch, and between
themain line switch andthe load.Whenproperly
installed, the loadtransfer switch inone position
will connect the electricalload tothe highline. When
theloadtransfer switch is thrown tothe otherposi-
tion, the load is first disconnected from the main
source of power, and thenconnected tothe tractor
alternator.Using the loadtransfer switch makes it
impossible to connect the alternator tothe main
source of power. The loadlinesmustconnect to
-34-
TATION
-IgDIA.SSPLINE
PER SAE J7I8
-|DIA
4MTG HOLES
g°@
a
.ol.
92
FIGURE 3. INSTALLATION OUTLINE
4

USETHISDIA-
GRAMIFNEUTRAL^
ISNOTSWITCHED
SWITCH
OR SAFETY
BREAKER
2-POLE DOUBLEi
THROW
LOAD
TRANSFER
SWITCH
It
SERVICE
HEAD
DRIP
LOOPS
USETHISDIA-
GRAMIFNEUTRAL^
ISSWITCHED.
SWITCH
OR SAFETY
BREAKER
3 POLE DOUBLE
THROW
LOAD
TRANSFER
SWITCH
GfOUNOING-
CONDUCTOR
PROTECTALTERNATOR
FROMWEATHER
GROUNDING
ELECTRODB
TOMAINSWITCHOR
BREAKERAT
MET5B.FUSE
if^POWERRETURNSIGNAL
*HOT r A LIGHTANDSWITCH
TO
ELECTRICAL
LOAD
TOCIRCUIT
BREAKERBOX
LOAD TRANSFER SWITCHCONNECTIONS
FIGURE5. TYPICALFARMSTANDBY

the center terminalsofthetransferswitch.The
alternator leads andthemainpower source leads
mustbeconnectedatOPPOSITE ends oftheswitch.
POWER RETURN SIGNAL
When the generator is used foremergencyapplications,
install a pilotlight oralarmsignaltoindicatewhen
thepowerisrestoredandwhenthealternatorcanbe
disconnected.Connecta signal light across the
regularpower line, just ahead oftheloadtransfer
switch. Installan on-off switchanda fuseforthe
signal light. Whena powerfailureoccurs, snap the
signal switchtotheONpositionbeforeputtingthe
alternatorintooperation.Whenthenonnalpower
returns,thesignal operates andthealternatorcan
thenbedisconnected.

OPERATION
STARTING
Before engagingpowertake-off,proceedas follows in
theordershown.
1. Alternator circuit breakers mustbeintheOFF
position.
2. Connectpower leads betweenthealternatorand
load transferswitch.
3.Throwtransferswitchtoconnectloadtoalternator.
4.Turn powerreturnsignalONifonehas been in-
stalled.
5.Enginepower take-off and bring PTOshaft speed
to 520rpm(530rpmforApex gear box).Thealter-
nator speed atthistime will be3600rpm(60cycle).
Thevoltmeteronthealternatorcontrolbox will
readapproximately250volts.A green segment on
thevoltmeter scale indicatesthecorrectoperating
range.
6. Snap bothalternator circuit breakers totheON
position. SeeNotesA andB.
OPERATING
Voltage will decrease ordrop,asthealternatorwarms
upevenwhenconstant speed ismaintained.Thisis
normal. However,ifthepowerdropsbelowtherecom-
mendedoperatingvoltage(230to240volts)it will be
necessary to increase thetractorPTO speed tocom-
pensate. Also, avoidover-voltagetoprevent damage to
electrical equipmentand/orthealternator. Reduce
voltagebydecreasingPTO speed.
NOTE A: Keep the alternator load within its nameplate
rating. If the alternator is seriously overloaded the cir-
cuit breakers will automatically trip, disconnecting the
entire electrical load. Reduce the load before throwing
the circuit breakers back to the ON position.
NOTE B: Motors require low to five times more current
for starting than running. If several motors start simul-
taneously, the total electrical load may overload the
alternator causing the circuit breakers to open and dis-
connect the circuit. To avoid this, always start larger
horsepower motors one at a time. Your alternator is
equipped with an auxiliary field timer switch, which,
when actuated, will connect an auxiliary winding for
supplying added field strength for starting motors rated
at 3 H.P. or larger. Set the timer at one minute or longer
for proper timer operation. At the end of the preset time,
the switch cuts out and the motor runs on normal current.
T^Cf^jJIQfit^\ H tractor engine horsepower is
t~-*^»^-*~^^*^^J> less than 2 H.P. per kilowatt load, care
should be exercised in disconnecting large loads. Gover-
nor speed changes can cause high voltage surges which
could damage electrical equipment of lesser current
draw than that which is removed from the line.
TIPS ON OPERATION
Total thewattagerequirementsofalltheequipmentthat
could beoperatingsimultaneouslyduringa power fail-
ure.Thiscanbedonebytakingthe information either
from the typical wattagerequirementguide,orbytaking
the informationfrom thenameplateontheequipment
itself.
Startmotorsoneata time,beginning with thelargest
one,ifpossible.Then,afterallmotorsarerunning,
there will beextrapowerforother less critical equip-
mentsuchasa television,airconditioner,etc.See
Note B.
Checkthemotor nameplates forthehorsepowerrating
of essentialequipment:furnaceblowermotor, circu-
lating heater, electric milking machine, milk pump,barn
cleaner,feedconveyor,silageunloader,chickbrooder,
sumppump, well pump,ventilatingfans,freezer, refrig-
erator,washingmachine,etc.
TYPICAL WATTAGE REQUIREMENTS
SINGLEPHASE
MOTORS*(CAPACITORTYPE)
WATTS REQUIRED
SINGLEPHASE
MOTORS*(CAPACITORTYPE)
START
RUN
1/2 horsepower 2800 550
3/4horsepower 4300 775
1horsepower 5500 1000
2horsepower 7130 I960
3horsepower 10350 2970
5horsepower 16660 3500
T/ihorsepower 23000 5250
* - Repulsion - inductionmotorsrequirelessstarting
wattage.Splitphasemotorsrequireslightlymore
startingwattage.

SERVICE AND MAINTENANCE
PERIODICSERVICE AND INSPECTION
Follow a definitescheduleofinspectionandservicing.
Make a goodvisualcheckbefore, while andafteralter-
natorisoperating; look forlooseorbroken leads and
badconnections.
SLIPRINGS
Slip rings must be clean and free of scratches and burrs
(do not remove the dark brown film). If necessary to use
an abrasive on the slip rings, use No. 00 sandpaper,
never use emery cloth or other conducting abrasives.
Internal alternatorpartsshouldbeexamined periodi-
cally. Removeend bell coverandinspectbrushes,
springs,bearings,etc.
GEAR BOX LUBRICATION
Use only SAE90multi-purpose gear lubricant. Drain the
gear boxafterthe first lOOhoursofoperationand refill
with freshlubricantoftherecommendedgrade. Repeat
this procedureeverysixmonthsthereafter,orevery
lOOhours.
Maintain theproperoil level between changes. Over-
fillingwill cause foaming, which canleadtoanoilleak
duetooverheating.Removethe filler plug ontopofthe
case andtheoil level plug from thefaceofthe gear
case. Fill the case until theoiljustbeginsto flow
from theoil level plug hole.SeeSpecificationsfor
gear boxcapacity.Replacebothplugs.
FILL AND
VENTPLUG
JOTATICX
OILLEVEL
PLUG
DRAIN
PLUG
FIGURE 6. GEAR BOX LUBRICATION
POWERTAKE-OFFSHAFT
Grease theuniversaljointsatleastevery25operating
hours.Under adverse conditions, grease thejointsas
required, possiblyevery4 to8 hours.Neveroperatethe
alternator with theshieldremoved from thepowertake-
off shaft.
BEARINGS
The ball bearingsaredoubledsealedandlubricatedfor
life.
BRUSHES
Replacethe brushes whentheyweartoabout5/8 inch
in length.Orderreplacement brushes bypartnumber,
neverbydescription: similar brushes mayhave differ-
entelectricalcharacteristics.
1
XXXXXX
REPLACEBEFORE
BRUSH WEARS
TOTHISPOINT
FIGURE 7. BRUSHREPLACEMENT
,^^J^JJV^?
// brushes are not replaced by the time
they wear past the stamped name and
number, severe damage to the slip rings will take place.
INSTALLBRUSHESWITHBEVELED
TOPSLANTINGDOWNTOWARD
SPRINGHOLDER
TOREMOVEBRUSH
SPRING.PRESS
SPRINGHOLDER
DOWN ANDOUTAS
SHOWN IN BROKEN
LINES.
FIGURE 8. BRUSH REMOVAL

ARMATURE GROUNDED
Seethatallbrushesare lifted high intheirholders.Use
a continuity typetestlampset.Placeonetest prod on
oneofthe slip ringsandoneother prod ona bareclean
part ofthealternatorframeorarmatureshaft.Theprods
mustmakegoodelectricalcontact.Thetestlampset
should not light. Ifit does light up,the slip ring is
grounded. Testallofthe slip ringsinthe same manner.
If thearmature tests grounded,replace with a newone.
ARMATURE
SHAFT
TESTING FOR GROUNDED ARMATURE-
IF GOOD SHOULD NOT LIGHT.
FIGURE 9. ARMATURE GROUNDED
ARMATURE OPEN
Usea continuity typetestlamp.
1. Testbetweenthetwo slip rings nearest the wind-
ings.
2. Testbetweenthetwo slip rings nearest the bear-
ing.
3.Testbetweenthetwoouter slip rings.
ARMATURE, SHORT CIRCUIT
To testfora short circuit, useanarmaturegrowler.
Placethearmatureinthegrowler which isconnected
to alternatingcurrent. Hold a steel knife blade(orold
hacksawblade)1/4 inch from thearmaturelaminations.
If thesteelbladeisattractedtoanymagnetizedarma-
ture laminations,eitherthearmaturewindingsor col-
lector ringsareshort circuited. A pieceof foreign
material betweenthecollectorrings could beresponsi-
ble. Donottestformagnetismatjustone point ofthe
armaturelaminations,buttestallofthelaminations
from onesideovertotheotherside(alongthedotted
line in illustration). After testinginone position, re-
volve thearmatureabout1/8 turn andtestformagnetism
in thenew position. Continueto turn andtest until the
armaturehasbeentestedcompletelyaround.
ARMATU F
GROWLER
FIGURE II. ARMATURE SHORTED
NOTE: In each ol the above combinations the test lamp
should glow. If the test lamp does not glow, an open
armature is indicated.
ARMATURE
SHAFT
TESTING FOR OPEN ARMATURE-
IF GOOD SHOULD LIGHT.
FIGURE 10. ARMATURE OPEN
FIELD WINDINGS, OPEN CIRCUIT
A testlampsetcanbeusedtotest field windingsfor
anopen circuit. Placeonetest prod ononeoftheter-
minal ends ofthe field windingsandtheothertest prod
on theother terminal endofthe winding. Thetestlamp
should light. Ifit does not,anopen circuit isindicated.
Check carefully toseethattheopen circuit isnotat
the terminal leadsora loose terminal. Anopen circuit
due toa brokenleadorloose terminal iseasilyrepair-
ed. Anopen circuit within a coil requiresreplacement
of thesetof coils.
INSPECTING AND CLEANING DIODES (RECTIFIERS)
When inspectingthediodes,makesuretheyarekept
free ofdust, dirt and grease. Excessive foreign matter
on these diodes causes overheatingandeventualdiode
failure. Blow outthediodeassembly periodically. Use
filtered, compressedair.
Also checktoseethatthediodesaresecurelymounted
and theleadwiresare tight andingood condition.

BRUSH RIG
GOOD DIODE WILL HAVE HISH RESISTANCE READING INONE DIRECTION
AND LOW READING WHEN OHMMETER LEADS ARE REVERSED.
FIGURE 12. TESTING DIODES
TESTING DIODES
Faulty diodes(eithershortedoropen) will cause abnor-
mal alternatoroperation.Check these individual diodes
as follows:
1. Remove sheet metalendcoverandband from end
of thealternator.
2. Isolate each ofthediodesbeforeprocedingbydis-
connectingoneend from itsconnectionpoint.
3.Tocheck,useanohmmeterto measure theresis-
tance inthe individual diode. Reverse theohmmeter
leads and repeat resistance measurement. A good
diodeshould have a high resistance valueforone
measurement anda low measurement when leads
arereversed.Ifdiodeisnotingoodcondition,
replace with oneknowntobeingoodcondition.
REPLACEMENT OF DIODES
When replacingdefectivediodes, follow these steps:
1. Useproper size wrenchesto hold thebodyofthe
diode while removingnutattachingthediodetothe
heat sink(bracket).
2. Push thediodefreeofitsmountingholeinthe heat
sink.
3.Be sure toinstallthenewdiodeinthe same posi-
tion (ordirection)asthedefectivediode. These
parts have directionalarrowsmarkedonthemfor
this reason.
4. Insertnewdiodeintoitsmountingholeinthe heat
sink orbracket,making sure heat sinksurfaceis
clean.Usingnutand washer provided, secure diode,
beingcarefulnottoallowittoturn while tighten-
ing nut.Tightenfinger-tightplus1/4turnor30 in-lb.
5.Connectleadwirestoappropriateterminals.
6. Replace access cover.
10

ALTERNATOR TROUBLESHOOTING GUIDE
We suggest that only a qualified mechanicorelectricianperformanyofthe following tests.
NATURE OF TROUBLE
PROBABLE CAUSE
REMEDY
Arcing orpoorcontactatalternator
brushes
1. Brushesnot seated properly
2. Alternatorheavilyoverloaded
3.Brushes binding inholder
4. Brushtension insufficient
5.Brushes worn tooshort
6.Brushtensionunequal
7. Wrong typebrush
1. Sandbrushtopropercontour
2. IfAC amperage ismorethanstated
on thenameplateremovepartof
load
3.Cleaneachbrushandholder
4. Replacebrushsprings
5.Replace brushes
6.Replaceweakbrushsprings
7.Replace with correcttypebrush
andspring
Alternator overheats
1. Windingsandpartscovered with
dirt andoil
2. Overloaded
3.Short circuit orgrounded circuit
in the field winding orarmature
winding
4. Airintakeisrestrictedorincoming
air istoohot.
1. Cleanalternator
2. Checkload
3.Replacedefectiveparts
4. Take necessary steps to allow
for proper cooling
Noisy alternator
1. Alternatorlooseon base
2. Defectivebearingsor gears
3. Field polerubbingarmature
4. Loosegearboxbolts
1. Tightenmountingbolts
2. Replace.Checkalignment
3.Tighten field polestoframe
4. Retorque
Alternator runsbut does not
producecurrent
1. Rectifier failed
2. Open,shortorgrounded circuit
in alternator
3.Alternator leads brokenorloose
1. Replace rectifier
2. Testwindingsandrepairorreplace
defective parts
3.Tightenconnectionsandreplace
broken leads
Low voltageoutputofalternator
1. Tractorgovernorsetatwrong
speed
2. Externalshort circuit on line
3.Open circuit ofshunt field winding
4. Short circuit of winding inthe
field orarmature
1. Reset governorforcorrect speed
(520 RPM)
2. Testalternator with line wires
disconnected
3.Makeproperconnections
4. Replacedefectivepart
Flashoverbetweenrings
1. Poormaintenance-dirt,oil,
cleaning solventresidues
2. Excessive humidity orwater
condensation
3.Poorshielding from environment
1. Damagecan'tberepaired,must
bereplaced
Slip ringsoutofround
1. Loose brushes orguides
1. Turn smoothonlatheorreplace
Raw coppershowsuponinter-
mittent pointson slip rings
1. Ringsoutofround
2. Notenough cooling air
3.Overloaded
4. Wrong brushgrade
1. Turn smoothonlatheorreplace
2. Correctsituation
3.Removepartofload
4. Replace with correcttype brushes
Raw coppershowsupcontinuously
around slip rings
1. Low humidity
2. High altitude
3.Dustand dirt
1. Turn smoothonlatheorreplace
11

WIRING DIAGRAM
INSIDEVIEW OFBOX
Jl
_J2
BF,
iSl
TDO
)
F|-
Ml
J3 CBI
CRI
Gl
-SHT' ' (ACVM2
SCHEMATIC
Fl J2
CB2
_r'_n_
MlCBI
m,| r--t
J3
Ml
Gl
AC
SI
TDO
—M-
CRIi
PARTSLIST
REF DESCRIPTION
CBI.2 CIRCUITBREAKER-TOAMP
Cfil RECTIFlER-1AMP400PIV
Fl FUSE- 15AMP
HOLDFR- FUSE
Gl GENERATOR
Jl RECEPTACLE- OUTPUT
12 RECEPTACLE- DUPLEX.120V
J3 RECEPTACLE.50AMP
Ml VOLTMETER- AC
0-300
Sl SWITCH- TIME.5 MIN
CONTROLBOX
COVER- CONTROLBOX
SILKSCREEN
SILKSCREEN
SILKSCREEN
WIRING DIAGRAM
12

PARTS CATALOG
REF.
PART QTY. PART
REF. PART QTY. PART
NO.
NO.
USED DESCRIPTION
NO.NO. USED DESCRIPTION
1 518-0014 1 Ring, Retaining 18 520-0498 2 Stud, GeneratorThrough
2 201-1444 1 Armature
1 9 232-0596 1
Clip, Bearing
3 205-0060 1 B1ower 22 234-0077 1 Scroll& Screen,Blower
4 204-0010 1 Ring, Collector 23 222-1674 1 CoilSet.Field
5 510-0047 1 Bearing 24 312-0058 2 Condenser,l-Mfd.
6 210-0437 1 Frame 25 358-0024 2 Rectifier
7 221-0154 2 Shoe, Pole 26
1 90-0323 1
Guard, PowerTake-Off
8 211-0097 1 Bell, End(BearingRigEnd) 27 190-0317 4 Spacer,PowerTake-OffGuard
9 212-0343 1 RigAssembly,Brush 28 403-0989 1 Bracket,GeneratorMounting
10 2
1 4-0056 6 Brush 29 403-0990 1 Brace,GeneratorMounting
11
212-1105 6
Spring, Brush Bracket
12 212-1214 4 Clamp,BrushRig 30 403-0988 1 Angle, Base-GeneratorMounting
13 21
1-0188
1 Bell, End(DriveEnd) (RightSide)
14 516-0103 1 RollPin,BrushRigEnd 31 403-0987 1
Angle, Base-GeneratorMounting
15 516-0176 2 DrivePin,DriveEnd (LeftSide)
16
51 5-0108 1 Key,ArmatureShaftDrive 32 332-0050 1 Clamp.Wire
17 403-0095 1 Bolt,Eye-Lifting
13

GEAR DRIVE GROUP
Mfg . byVon
Ruden Mfg.Co.
REF. PART QTY. PART
NO. NO.
USED
DESCRIPTION
1 90-0294 1 GearDriveBox(Complete
Shaft)
1 190-0358 1 Case
2
190-0359 1 Case
3
190-0280 1 Gasket
4 190-0360 1
Plate, End
5 190-0361 AsReq.
ShimSet
6 190-0362
2
BearingBall
7 190-0363 1
Plate, OpenEnd
8 190-0279
2
Seal, Oil
9 190-0365 1 Shaft,Gear
10 190-0366 1 Gear
11
190-0367 4 Bearing
12 190-0368 1 Gear& Shaft,Idler
13 190-0369 1 Shaft,Splined
14 190-0371 1 Seal, Oil
15 190-0372 1 Gear
16 190-0373 12 Nut
17 190-0374 12 Bolt
18 190-0375
2
Key, Woodruff
19
1 90-0376 4 Screw,Cap
20
1 90-0377 1
Plug, Drain
21 190-0378 1
Plug. Check
22
1 90-0379
2
Washer,Lock
23
1 90-0380 6 Screw,Cap
24 190-0381
2
Bushing, LineUp
*- NOTE:Checknameplateongearboxtoidentify
manufacture.
14

GEAR DRIVE GROUP
Mfg. byApexIndustries
27
=4=
0Ji-
iJ
28
7&
24
23
12
REF.
PART QTY. PART
REF. PART QTY. PART
NO. NO.
USED DESCRIPTION
NO. NO.
USED DESCRIPTION
190-0386 1 GearDriveBox(Complete
SplinedShaft) 15
16 10206
30072 1
1 Seal
Shaft,Input
1 50046 1 Flange.Mounting 17 10180 1 Key,Woodruff
2 10178 2 Screw,Cap 18 40038 1
Gear, LeftHand
3 10018 2 Washer,Lock 19 10207 2
Bearing, Ball
4 30073 1 Shaft&
Gear, Idler(LH) 20 30074 1
Gear, Pinion(RH)
5 20100 2 Washer,Spacer 21 10209 2 Seal
6 10035 1 Key,Woodruff 22 10177 4 Screw,Cap
7 20098 2 Cover,Dust 23 20108 AsReq .Shim
(.005)
8 10179 2
Ring, Retaining 24 10175 2 Screw,SocketHeadCap
9 10173 4
Bearing, Bell 25 10166 2
Plug, OilLevelCheckPipe
10 40037 1
Gear, RightHand 26 10176 1
Plug, Cap(3/8)
1 1 10181 8 Screw,Cap 27 20020 1
Plate, Name
12 50051 1 Gasket 28 10024 2 Screw,Drive
13 10094 8 Nut
14 50047 1
Case, SubAssembly gearboxtoidentifymanufacturer
14 50047 NOTE :Checknameplateon
gearboxtoidentifymanufacturer
15

CONTROLGROUP
REF
PART QTY. PART
NO. NO.
USED DESCRIPTION
1 301-3436 1 Box,Control
2 301-3441 1 Cover,ControlBox
3
301-3443
2
Bracket,Mounting
A 323-0207 4 Receptacle,50Amp
5
508-0001 1 Grommet,Rubber-
6 320-0148
2
Breaker,Circuit
7 302-0665 1 Voltmeter,AC(0-300)
8 308-0252 1
Switch, Time(5-Min)
9 321-0138 1 Fuse(I5-Ampere)
10 321-0104 1 Holder,Fuse
1 1 323-0635 1 Receptacle,Output
12 323-0)84 1 Receptacle,Duplex
13 305-0240 1 Rectifier
12 &
13
16

ForPARTS.SERVICE & WARRANTY:
AlwaysprovideMODEL and SERIAL NO.
foundonAlternatornameplatewhenreferring
to any SurgeAlternator.Contact the Author-
izedSurgeDealerfromwhom you purchased
thisequipment.
IMPORTANT
Pleasefill out thisinformation and returncard
within 10 days in order to establishyourwarranty.
RETURN TO:
BABSONBROS. CO.
2100 S. YORKROAD
OAKBROOK,ILLINOIS60521
CUT ALONGDOTTED LINE ANDDETACH
Purchasedfrom
WARRANTYVALIDATIONCERTIFICATE
for {SURGEI ALTERNATOR
Dealer.
Address.
Model.
Datepurchased
—Serial No.
Owner'sName
Address
Town .State/Province -Zip

{SURGE}ALTERNATOR WARRANTY
BABSONBROS. CO. warrants tothe originaluser of thisAlternator,that its
manufacture is freefromdefects in material and factoryworkmanship — if properly
installed, serviced and operatedundernormalconditionsaccording to BABSON
BROS. CO.'sinstructions.
BABSONBROS. CO.'s obligationunderthiswarranty is limited to correcting
withoutcharge fora period ofone year any part or partsthereofwhichshall bere-
turned toits factory or authorizedservicestations(transportationprepaid by cus-
tomer) — and whichuponexaminationshalldisclose to BABSONBROS. CO.'s
satisfaction to havebeenoriginallydefective.Correction of suchdefects by repair to
orsupplying of replacements for defectivepartsshallconstitutefulfillment ofall
obligations to originaluser.
Thiswarrantyshall not apply toany SurgeAlternatorwhichmust be replaced
because of normalwear,which has beensubjected to misuse,negligence or accident
orwhichhasbeenrepaired or alteredoutsidethefactory or ServiceCenterauthorized
byBABSONBROS. CO.
BABSONBROS.CO.shall notbe liable for loss,damage or expensedirectly orin-
directlyfrom the use of thisAlternator or from any othercause.
Theabovewarrantysupersedes andisin lieu ofall otherwarrantiesexpressed or
implied andofall otherliabilities or obligations onthe part of BABSONBROS. CO.
Noperson,agent or dealer is authorized to giveanywarranties on behalf of BABSON
BROS. CO.,norto assume any otherliabilities in connectionwith any SurgeAlter-
nators,unlessmade in writing and signed byan officer of BABSONBROS. CO.
BABSONBROS.CO., OAK BROOK,ILLINOIS
BABSONBROS.CO..(Canada)LTD.,PORTCREDIT,ONTARIO
CUT ALONG DOTTED LINE ANDDETACH
GUARANTEE
AND
WARRANTY
DEPARTMENT
BABSONBROS. CO.
^ 2100S. YORKROAD
OAKBROOK,ILLINOIS60521
IMPORTANT:
Pleasefill out information on
reverseside of thiscard andre-
turnwithin 10 days — in order
toestablishyourwarranty.
PRINTED INU.S>.