Winpower G1536B Owner's manual

ENGINE
DIFFICULTIES
"In order to eliminate a needless waste of time to you, our customer, it is best in case
of engine trouble to contact the local dealer or distributor of that particular engine
within your area. He can often diagnose
a problem and correct the trouble without
any difficulty. He also will have a stock of spare parts in case something has to be
replaced. All of our engines have National and International distributors or dealers.
There should be no trouble with getting our engine serviced within your area.
We are always glad to assist you in obtaining full satisfaction from any engine as-
sembled to a Generator of our manufacture but we know that by contacting the
local engine distributor or dealer, a more prompt correction of the engine malady
can be achieved."

SMALL ENGINE MAINTENANCE CHART
WISCONSIN
& BRIGGS & STRATTON ENGINES & CLINTON ENGINES
(FAVORABLE WEATHER CONDITIONS WERE USED IN THE ESTABLISHMENT OF THIS CHART.)
(THIS CHART IS TO BE USED FOR PROPER CARE OF THE ENGINE ON A WINPOWER GENERATOR SET.)
HOURS OF OPERATION
* CHECK AIR CLEANER OFTEN.
NEW OIL EVERY
25 HOURS. CHECK FOR LOOSE CONNECTIONS IF GASKETS ARE EVER TO BE REMOVED FUEL SHOULD NEVER BE BELOW
68
OR FITTINGS. AND THEY ARE CRACKED OR BROKEN, OCTANE. HIGH LEAD CONTENT
NEW ONES SHOULD BE REPLACED. FUEL SHOULD NOT BE USED.

Each Generator is carefully inspected at the Factory and run until the brushes are
satisfactorily seated. Then
it is checked for correct output under average operating
conditions.
When unpacking the machine, be sure to inspsct it carefully to see that no damage
occurred in transit. If damage
is noted, notify the transportation company ime-
diately and have them write the nature of the damage on the freight bill, so that
a claim can be filed
if necessary.
If upon installation a new Generator does not work properly, check all of the elec-
trical connections and the Generator speed before assuming that the Generator
is not
performing satisfactorily,
LOCATION
For best service from a ~ermanentlyinstalled unit, it should be installed in a
reasonably clean and dry location. Excessive moisture has a tendency to deterio-
rate the electric insulation and damp surfaces always greatly increase the possi-
bility of shorts and grounds, The surroundings should be relatively free from dirt
and dust because these or other foreign articles have a tendency to clog the venti-
lation slots, and thus cause excessive heating, This dust and dirt
is also another
cause of rapid brush wear,
During the operation of the Generator Set, considerable heat is given off by the
engine, this thus
merits a good and adequate ventilation system to prevent temper-
ature from becoming excessive. Without proper ventilation both the Engine and Gen-
erator can suffer severe damage. Under no circumstances should the temperature in
the room
be allowed to reach 1200F.
Rxha~istgases from Gasaline Engines are extremely poisonous! Whenever an engine
is
installed indoors, exhaust fumes must be vented to the outside. The engine should
be installed about two feet from the outside wall so the exhaust pipe
will be kept
short and yet the engine
will be a safe distance from the wall. Using an exhaust
pipe that is too small or too long will cause excessive back-pressure which will
cause the engine to heat up excessively and eventlially cause serious damage to the
engine.
Pine the same size as the exhaust hole in the engine
is satisfactory for distances
not exceeding five feet. For each additional ten feet use pipe
one size larger.
Keep the number of elbows to a minimum and make sure that the outward end of the
pipe is tilted slightly downward, so rain and snow do not run into the exhaust
pipe and down into the cylinders of the engine.
Where exhaust noises are to be kept to a minimum in urban areas, an underground
tank made from an old oil drum can be used successfully
if installed above the
ground water level.
A fifty gallon oil drum, vented above the ground and with
the bottom knocked out or pierced with holes
is satisfactory for this purpose.
If the exhaust pipe slants downward towards the engine,
a condensation trap should
be installed near the cylinder head to prevent the
water which condenses from the
exhaust from flowing back into the cylinders
after the engine has stopped. This
condensation trap consists of a T connection, a short piece of pipe and a pipe
cap. A petcock 3hould also be provided at the end of the cap so the water can
be drained
if necessary.

The exhaust pipe should be supported so the weight is not applied to the engine.
In order to keep vibration of the exhaust pipe to a minimum,
a 24 inch piece of
flexible exhaust tubing should
be installed between the engine and exhaust pipe.
Generators, which are installed to operate automatically, should preferably be
located where the temperature does not fall much below freezing. Engines atart
and perform better if not subjected to excessively cold temperatures. Batteries,
if not fully charged "my also be damaged by low temperatures.
BASE
-
For best results from a permanently installed Generating Plant, a concrete base
should be used. Although being mounted on concrete the Generator Set should
be
rubber shock mounted to absorb some of the vibration from the set as it is run-
ning. Many owners, who have
small Generator Sets use a rubber pad instead of
individual shock mounts. This
is a very good application but for every day use
your rubber shock mounts are much better d-ue to the fact that dirt collects
underneath the Generator around the pad.
BA TTE RY
1 or 512 Volt batteries rated at 72 ampere-hours or more is recommended for
starting Remote Start or Elect,ric Start Plants of over 1500Watts capacity. Two
6-Volt car batteries connected inseries can do the same job. This can be done
by connecting the positjive terminal of one batteqr to the negative terminal of
the other. The remaining positive battery terminal
is joined to the positive
terminal on the side of the Generator panel and the remaining negative battery
terminal to the negative terminal on the side of the Generator also. Speaking
of the Generator as we have above, we are referring directly to the- ene era tor
panel. All connections must be clean and tight. Check the electrolyte (fluid)
in the battery periodially to be sure it is above the plates. Never allow the
battery to remain in a discharged condition.
The charge rate on battery charging for the Generator remains constant. There
is no worry to switch from high to low as on several other type Generators.
To
check the battery charger to find out if it is functioning,
start the unit and
after it is running smoothky, comsct, an ammeter in series to one of the battery
leads.
It should read between 3 and 5 amps. CAUTION: Do not hook ammeter to
battery while cranking engine.
If this is done most generally you will burn out
the ammeter. This is caused by the surge load in cranking.
ENGINE FUELS
The Remote-Start Generators are equipped with fuel pumps and are designed for
use with small portable tanks or underground tanks. Manual and Electric Start
Plants are equipped with engine mounted tanks.
The installation included in this manual shows a typical installation of an Auto-
matic Stand-by Generator. Many states and cities codes require an underground
tank i.f gasoline is to be used as fuel. In Stand-by service, the Generator may
remain idle for
a considerable period of time. If the gasoline has evaporated
fromthe carburetor, it becomes necessary to crank the engine until fuel has been
pumped up from the storage tank.
In some locations a one quart reserve tank or
day tank may be located close to the plant to feed gasoline to the carburetor
by gravity so that much of the prolonged cranking
is eliminated.

GASEOUS FDEL
Gaseous fuels can be used as a fuel for ensnes equipped with special gas-gasoline carbu-
retion kits which are installed at the Factory. These gaseous fuels may
be natural or
manufactured gas, or a mixture of the two, supplied to the customer through regular
gas
mains or liquified petroluem gas (LP or LPG) such as butane or propane - these are also
referred to as bottle gas since they are delivered in steel tanks under considerable
pressure. Gaseous fuels are often preferred for permanent installations because of
convenience, safety, cost and cleaner operation.
Engines adapted for burning gaseous fuels are equipped with Model F Ensign Gas Fuel Regu-
lators, This regulator
is designed to regulate the proper flow of gas over the entire
load range, from no load to full load on the Generator, and to stop the flow of gas when
the engine
is stopped,
This regulator is often referred to as the Secondary regulator
because the pressure of the gas from a storage tank or from the high pressure gas mains
has already been reduced by a primary regulator.
Gas reaching the secondary regulator is usually at a pressure of four to six ounces per
square inch, (seven to ten inches of water), When the engine is not running, that is
when the pressure at the inlet to the regulator is highest, the pressure should not ex-
ceed six ounces, (with greater pressure the regulator may be unable to stop the flow of
gas ) ,
When the enane Generator is running at
full load,
that is when the pressure is
lowest, it should not fall below four ounces -
less pressure may cause the engine to be
starved for fuel. The engine will then lack power and be damaged internally.
Bottled gas, such as propane is usually stored in a liquid state in steel tanks under a
pressure in excess of 70 pounds per square inch, Normally, from one-tenth to fifteen-
hundreths gallons of propane fuel is required per hour of operation for each horsepower
rating of the engine,
A primary regulator must be used to reduce the pressure to about
six ounces per square inch, Natural gas, manufactured gas or a mixture of the two
is
usually delivered at a pressure not exceeding six ounces per square inch, so that no
primary regulator
is required.
When burning
LP gas or natural gas having a BTU content of 1100 or over, the Engine
Generator Plant will deliver its full rated output, When burning mixed
gas (natural
and manufactured) with the rating of
825 BTU, it will deliver up to 80% of its rated
capacity. When burning manufactured gas of approximately
550 BTU, it will produce up
to of its rated capacity.
Natural gas, manufactured gas and bottle gas do not usually ignite as readily as gaso-
line. However, since the Generators on remote starting Electric Start Generators crank
the engines at a high rate of speed, no difficulty in starting is usually experienced
at normal temperatures. The use of
LP bottle gas, however is not recommended in freezing
temperatures,
OPERATING ENGINES ON GAS FUEL
Engines equipped with combination gas-gasoline carburetors are properly adjusted before
they leave the Factory,
A tag attached to the unit specifies whether the adjustments
were made for gasoline, propane gas (LPG) or natural gas. On
this tag also will be the
correct pressures for proper operation of this unit with the new type gaseous fuels.
To operate on gasoline: If the engine
is equipped with a gasoline tank it can be used
in the regular manner, If the engine does not have a gasolilre
tank but is equipped with

a fuel pump, connect the fuel supply line to the fuel inlet.
When operating on gasoline,
it will be necessary to shut off the gas supply (propane gas or natural gas) by plugging
the inlet or closing the supply valve,
To operate on propane or natural gas: To
start,
open the supply valve to permit the
flow of fuel. Remote Type Units are equipped with automatic choke.
This automatic choke
eliminates the need for hand choking after the installation has been completed and the
proper adjustments made, On Manual Start and Electric Start generators, depress the
primer button on the outlet side of the regulator until gas can be smelled at the air
cleaner, Then crank the engine manually or electrically.
After the engine is running, apply a sufficient electrical load so the Generator is load-
ed to
its capacity or to the maximum amount to which it will be used, Check the opera-
tion of the engine carefully to see that it runs smoothly, If it does not, a slight
adjustment may be necessary to compensate for the different fuel or operating conditions,
Loosen the locknut and turn the adjusting valve open.or closed slightly so the engine
runs
smoothly at full load. Then tighten the locking nut in its position, NOTICE: !his
adjusting valve is the only adjustment to give the engine a richer or Leaner fuel mixture.
Do not adjust the idle valve or needle valve on the engine carburetor since these only
effect the engine operation when burning gasoline or other liquid fuel. If difficulty
in starting the engine
is experienced, start it on gasoline and while it is running,
dtchover to gas fuel and make the proper setting of the adjusting valve,
TRANSFER SWITCH
Any Generator which is installed for standby or emergency power, must be equipped with a
suitable double-throw switch for use when the power line fails. The switch transfers
the load from the power line to the Generator.
It may be an automatic type or may be
manually operated.
When the switch is thrown to the power line the stand-by Generator is not connected to
either the load or the power line, When the switch
is thrown to the stand-by side, the
generator is connected to the load but the load is disconnected from the power line,
Consequently, no electricity produced by the generator can feed back to the power line
where
it would be hazardous to line repairmen.
There are two general classifications of transfer switch installations: those which
switch the entire electrical load frm the power line to the standby generator
as in
the circuit shown in Figure
1 and those which switch only one or a few circuits as shown
in Figure
2.
If the system is connected as in the figures below and the generator does
not have sufficient capacity to carry the entire electrical load, you will usually find
it necessary to turn off all electric motors and disconnect some appliances, Since the
transfer switch carries
all the current when the system is connected to the power line,
the switch must have the same ampere ratina
as the main service entrance,
LOAD
Figure 1 FUSE BOX

When a double-throw switch is connected into the circuit as shown in the Figure below,
the load on only one branch
is transferred. The capacity of the switch need be only as
large as the total of the rating of the circuits to which it is connected. For example,
if the transfer switch is to switch only two 15 ampere circuits, a 30 ampere switch is
large enough. Such installations have the disadvantage that only part of the electrical
circuits can be used with the standby plant. With small generators, however, they have
the advantage that the generator less likely
will be overloaded.
METER I beL IOAO
I
SIANO 81
Figure 2 PLAN?
The circuits mentioned so far have been for 115 Volts only. The third figure below which
we speak of shows how a 115/230 Volt circuit may be connected.
I ITAND BY PLANT
I
LOAD
Mlllt
Figure 3
ALL WIRING MUST BE DONE IN CONFORMANCE WITH THE NATIONAL CODE AND STATE AND LOCAL
FGGULATIONS .
REQUIRED OPERATING SPEED
When a load is applied to a generator the engine has a tendency to slow down. The gover-
nor on the engine is designed to hold the speed as nearly constant as possible. As the
engine increases its electrical load, its speed dimenishes. Due to this fact, the volt-
age
will usually drop minutely and as the load increases to an overload situation, the
voltage
will drop off rapidly.
As the load increases over the generator and engine ca-
pacity, you not only have voltage trouble but also frequency drop. This frequency
variation has no appreciable effect on the operation of motors, lights or most appli-
ances. However, timing devices and clocks, will not keep perfect time when used on
these generators.
Most generator sets purchased in the United States operate on a 60 cycle frequency. In
some foreign countries frequency is often 50 cycles. Below are two charts showing
50
and 60 cycle Generators being operated on no load, half load and full load. These are
not extreme cases.
It is always a good idea when checking your Generator to look at
your volt meter and find out if the voltage is below its rated voltage.
If so, the
voltage will decrease until it is so low no equipment can be operated satisfactorily.

50 AND 60 CYCLE FREQUENCY AND VOLTAGE VARIATIONS AT DIFFERENT LOADS
For 50 cycle generators the corresponding speeds,
frequencies and voltages would
be approximately as follows:
Load
Applied
None
Half
Full
The speed of the engine is carefully adjusted at the factory so the Generator produces
the proper voltage and frequency, For all normal usage the speed setting should not
be
changed, If the generator
is being run continuously on a very small load, it may be
well to lower the speed slightly, if it is being used continously at a full load, it
may be well to raise the speed slightly. Whenever making any speed adjustments, check
the
unit Kith a voltmeter or tachometer to be sure the speed is neither too high nor
too low.
-
Load
Applied
None
Half
Full
Unless the engine is equipped with a special idlini speed control, the engine must be
run at the specified speed at all times. Lower voltage may damage both the generator
and any appliances connected to it.
Running the engine at excessively high speeds
results in too high voltage which may materially shorten the life of appliances being
used and decrease the life of the engine and generator.
Generator Speed
The output voltage should be checked periodically to insure proper operation of the
generating plant andappliances. If the generator
is not equipped with a voltmeter,
it can be checked with a portable meter. A convenient voltage tester, which can be
plugged into any ordinary outlet can be purchased under our Part No. VJ4-32. This is a
0-150 Volt A.Co voltage tester. Our W4-33 is 150 to 300 Volt AoC. for testing higher
voltages.
Frequency
6 1
60
58%
2 Pole
3660
3600
3510
STOPPING AND STARTING
4 Pole
1830
1800
1755
Generator Speed
Manual type units must be cranked by hand using a rope, recoil starter or crank. To
stop the engine depress the stop button or toggle switch on the control box. Electric
and Remote units can be started electrically by moving the switch to the start position
and stopped by moving
it to the stop position.
Generator Voltage
Frequency
5 1
50
481/2
2 Pole
3050
3000
2925
To start and stop the engine on a Remote Start Plant at a distance, a single pole-double
throw switch such as our part No,
G-1789 may be installed by connecting to the terminal
block in the upper left side of the control box.
115v.
Plants
129
120
115
4 Pole
1525
1500
1462
230v.
Plants
258
240
230
Generator Voltage
1 15v.
Plants
129
120
115
230v.
Plants
258
240
230
-

THERE IS NO OIL IN TIE ENGINE WJBN THE UNIT IS SHIPPED. See the Engine Instruction
Book regarding the amount and type of oil and fuel to be used,
Engines supplied as part of this generating plant are manufactured by highly reputable
manufacturers who have established an excellent world-wide engine Service Organization.
See the Engine Instruction book for information pertaining to engine service in your
area, for regular maintenance and for special overhaul information.
Each Generator plant
is checked at the Factory at full rated capacity before it is re-
leased for shipment. For high altitude operation deduct
3% from the rating for each
1000 feet of altitude over 3000 feet above sea level.
USE OF ELECTRIC MOTORS
A split phase motor takes a great deal more current to start than a single phase motor.
For example:
An electric motor connected to an air compressor,
will take and require
more than a motor to which no load is connected.
Because the heavy surge of current required for starting motors is required for only an
instant, the generator
will not be damaged if it can bring the motor up to a speed in
a few seconds of time. If difficulty
is experienced in starting motors, turn off all
other electrical loads and if possible reduce the load on the electric motor.
GENERATOR MAINTENANCE
Neglect of simple maintenance necessary to maintain peak performance of the Generator
can cause failure at
a time when the Plant is most urgently needed. Inspect the brushes
every 30 hours of service. Always replace them when they have worn to a length of 5/8".
Never use any other than the same grade, size and make of brushes
as supplied with the
original generator.
A spare set of brushes should be on hand at all times.
It is very important to keep the generator clean and free from accumulations of dirt
and grease. It is not necessary to take the generator apart to clean it, as in most
cases the dust can be readily blown out with
an air hose. The slip rings and commutator
can be wiped with a clean cloth.
Never use gasoline or any petroleum based product on the commutator or rings 0%
the generator. The grooves between the canmutator bars should be occasionally cleaned
out and kept free from accumulations of carbon dust, or other foreign matter.
Examine the ccaunutator and rings at regular intervals for any sign of wear on these
parts,
At the first sign of any wear, machine commutator and rings as the wear will
increase rapidly after the commutator or ring has once become rough. Undue wear on the
rings is usually caused by brushes that are sticking in the brush holders. Improper
grade of carbon in the brushes or the use of motor type brushes may cause rapid deterio-
ration of the rinas. When smoothing down
a commutator after machiking use a-fine made
of sandpaper.
NEk USE EMERY PAPEE AS THIS HAS MEfALLIC PARTICLES WHICH WILL WORK INTO
THE GEBERATOR AND CAUSE SHOqT CIRCUITING.

If trouble occurs and the operator is unable to determine the cause after a thorough
study of
this book, or if he is unable to determine what repair parts are required,
needed information will be furnished upon request. When asking for information, be
sure to state the Model and Serial Numbers of the unit. This information
is absolutely
necessary and may be obtained from the name plates. Give all other details available.
The process of building up voltage in all types of generators requires that there be
a mall amount of residual magnetism in the iron parts of the field exciter structure
when the machine
is standing still. This residual magnetism produces the initial volt-
ages in the armature coils as soon as the armature
is rotated, which are built up until
the full magnetic field is developed, and the machine delivers full voltage.
All gen-
erators leave the factory with sufficient residual magnetism to build up when started.
However, through long periods of storage, and sometimes due to rough handling in transit,
an occasional generator
will lose all or part of its residual magnetism, and so fail to
build up voltage. The following procedures
will usually correct the trouble:
1.
Carefully check that all brushes are free in the brush holders, are seated
on the commutator, and that no objectionable film has collected on the
commutator. See that brush shunts
are not binding on adjacent parts or
shorted to ground.
2.
With the generator running, apply light pressure to the top of one or two
D. C. brushes with a wooden stick, to polish the commutator and break
through commutator film. Often
this will permit the generator to build
up when the residual field is weak.
3.
If the machine still refuses to build up, the residual magnetism can
be
restored by applying direct current to the fields. Lift all the brushes
clear of the commutator. With the generator at standstill, connect the
positive terminal of a 6-volt storage battery or "Hot Shotwdry battery to
a positive brush holder. In generators where one brush holder is grounded
this will be the grounded commutator brush. Touch the negative connection
fran the battery to the adjacent commutator brush holder. This will be a
negative brush. Hold the connection
a few seconds. Remove battery connect-
ions, lower brushes and start generator.
4.
Should the generator build up with reversed polarity, that is, should the
positive connection became negative, or in a
A.C. machine still fail to
produce current,
this can be
overcome by reversing the connections between
the battery used to build up the residual magnetism and repeating the
process described above.
In electrically cranked,plants, where the generator serves as the starting
motor, residual magnetism
is automatically restored when the starting winding
is energized.
Examples of Receptacles Used in Generator Panels:
1 15 VOL~ GROUNDING T
Part No.
EE-322
A 3 - prong grounding
type cap (Hubbell No.
5265 or 5274) should be
used in this receptacle. The
round prong is intended for
grounding the appliance
frame to the generator
frame. Any ordinary paral-
lel bladed cap as shown in
the lower illustration can
also be used.
3 WIRE (20 AMPERE) TWIST-LOCK RECEPTACLE
This receptacle requires a 20 ampere, 3-prong cap such as a
Hubbell No. 731 1. This receptacle is used in different applications:
. .
ur Part No. EE-369

Trouble
Generator fails to
build up rated
voltage
Low output voltage
SERVICE DIAGNOSIS
Cause I Remedy
Brushes sticking IClean brush and brushholders
in brushholder s
I and adjust brushes.
Overload ICheck ammeter readinas with
Grounded, open, or nameplate rating.
r educe load.
Replace or repair defective
shorted field coil
windings.
Open Armature
Loose brushholder
( paired or rewound.
Field coils shorted l~isconnectfield leads (F, and
coil. (See diagram for method
of checking.
)
Hepair or replace armature.
Re-alim and ti~hten holder.
~ ~
Armature shorted or
grounded.
or grounded
I F2) from brushes and armkture
.a -
Remove armature and test, on
growler or as shown on diagram.
If test shows short, or open,
armature
will have to be re-
I leads and check for continuity
I and resistance to ground with
I connecting generator to line.
Grounded condensers ICheck for shorted filter con-
Short circuit on line
I densers on output of generator
ohm meter or lamp and batteries.
Locate short in system before
reversed. Loss of I positive and negative terminals
Polarity of generator
residual magnetism.
I with 6 to 12 volts to produce
with lamp and batteries.
Raise DC brushes and contact
I correct polarity.
Open armature winding lCommutator must be resoldered,
due to commutator
throwing solder from
riser. Due to ex-
cessive heat and load
Voltmeter inoperative
Excessive load
Too much field
resistance
High resistance
connections
High line losses
Low Speed
1. Defective
Governor
2. Defective bearing
3. Excessive Load
Brushes not seated
properly or dirty
Dirty commutator
turned, and undercut.
Replace voltmeter.
Reduce load.
Reduce resistance of field
resistor.
Connections will be warm or
hot to the touch. Make better
electrical and mechanical joints
and connections.
Increase size of line wires
1. Adjust, repair or replace
governor.
2. Replace bearings.
3. Reduce load. . .
Clean or replace brushes and
reseat.
Sand commutator lightly with
sanqpaper or crocus-cloth. DO
NOT USE EMERY PAPER. If commu-
tator
is greasy, wipe with non-
inflammable liquid.

Trouble
Low output voltage
(cont'd)
High output voltage
Excessive Heating.
Most generators are
designed to with-
stand
a temperature
rise of 50°C.(500C.
is equivalent to
122OF.) Thus if a
room is 2S°C a genera.-
tor could be approxiaigh
mately 7S°C or 1670~-
without being over-
heated.
Excessive sparking
at the brushes
Cause
Shorted field coil.
Excessive speed.
Improper governor
adjustment.
Overload.
Clogged ventilating
screens.
Room bmperature
Insufficient air
circulation.
Operating with ex-
cessive voltage.
Armature or field
coils shorted or
grounded.
Faulty brush pressure
or worn out brushes.
Brushes dirty or not
seated properly
Improper brush grade
High Mica
High commutator bar
or rough commutator
Remedy
Test field coils for possible
shorts, replace bad coil.
Reduce engine speed to rated
value.
Re set governor.
Reduce load. (Check ammeter
reading again
st nameplate
rating.) Allow proper correc-
tion value for power-factors
less than unity.
Remove and clean air passages
in screens. Make sure passages
within machine are open.
Improve ventilation to operating
area.
Provide cross ventilation,
additional openings to room
housing plant
.
Check voltage drop in distribu-
tion lines and connections.
Provide service lines large
enough to overcome excessive
line drops.
Repair or replace.
Ad just pressure or replace
brushes and springs.
Clean or replace and reseat.
Use only brushes recommended,
or duplicate of originalbrushes
Commutator should be turned
on lathe and undercut.
All
micas should be carefully
undercut below commutator
surface.
1. It may be necessary to
machine the commutator on a
lathe; however, when doing so
a competent machinist must be
employed. The maximum out of
roundness of the commutator and
rings should not exceed .002
inches. Make absolutely sure
that the armature shaft
is
centered concentric with the
bearing surface. Don
' t machine
commutator until you have
checked to see that shaft

Remedy
center is concentric with bear-
ing. The surface of the commu-
tator should be machined
as little
as possible and polished with fine
grit, high grade sandpaper after
undercutting.
2. A very effective polisher may
be constructed by folding
several layers of canvas or
duck over the end of
a strong
piece of wood and tacking
it
in place. The canvas pad may
be held on the commutator or
collector rings. This
will
give a high polish without cut-
ting the surface. However, if
the commutator
is pitted, it
will be necessary to first polish
with
a fine grade of sandpaper,
(001, following with the canvas
polisher. NEVER USE EMERY CLOTH
TO POLISH, since it contains
metallic particles which
will
short out the commutator.
Adjust or replace tension springs.
Trouble
Excessive sparking
at the brushes
(cont'd)
Cause
Lack of brush
pressure

INSTRIJCTIONS FOR ORDERING REPAIR PARTS
OR SERVICE OR PARTS, CONTACT THE DEAIER FROM WHOM YOU PURCHASED THIS EQIJIPMENT, OR
!E FER TO THE COMPANY LISTED ON THE NAMEPLATE.
Be sure tostate on your order the Generator Model Number and the Generator Serial
Number of the plant for which the parts are required. Obtain these numbers directly
from the generator nameplates on the plant. Do not use engine
serial numbers when
ordering generator parts.
Order parts by part numbers and complete description as listed herein. State
the
quantity of each part desired. Do not order parts as uriLess they are listed
as "setswin the parts list.
If unable to identify the part required, return the;old
part to the address shown on the nameplate.
Be sure to print your name and address
plainly on the package. Regardless of any previous correspondence,
write a letter to
the same address describing the part and stating the reason for returning it.

PARTS LIST
(G-B536B)
PART NO,
G-2500-2 Armature Assembly
Commuta%or
Collector Wing
Brush Gear Assembly
Commutator End Bell
A,C, BrushhoHders
DOC, Brushholders
AoCo Brushes
D,C. Brushes
Brushbolder Caps
Field
Coils
Field Poles
Drive End Bell
Blower Fan
Beaff ns
Outlet Box Assembly
Receptacle
(Duplex)
Condensers
Field Resistor
Outlet Box
Shockmount Bushings
QUANTITY --.-
B
1
3.
1
1
2
2
2
WIRING DIAGRAM
2-1257-1 & -db03 -/