JCB GENERATORS
SERVICE MANUAL
SELF-REGULATING ALTERNATORS
Publication No.
9813/2800
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
, Section 0 - Alternator Service Manual
Notes:
0-0 9813/2800 0-0
, Section 0 - 1
Contents Page No.
Care and Safety
Safety Check List ....................................................................................... 1-1
Safety - Yours and Others .....................................................................1-1
Safety Warnings ....................................................................................1-1
Safety Check List ..................................................................................1-2
Principle of Operation
Self-Excited AVR Controlled ...................................................................... 1-5
AVR Accessories ....................................................................................... 1-6
Identification .............................................................................................. 1-7
Key Component .....................................................................................1-8
Maintenance
JCB HM Range Alternators ....................................................................... 1-9
Assessment of windings conditions after long periods of storage or inactiv-
ity. ..........................................................................................................1-9
Assessment of current functioning (absence of anomalous noises or vibra-
tions). .....................................................................................................1-9
Mechanical checks of fastening bolts and, in particular, of electric connec-
tions. ....................................................................................................1-10
Internal and external cleaning of the generator. ..................................1-10
Maintenance and replacement (if necessary) of bearings. .................. 1-11
Generator versions HM160-200-250 ...................................................1-12
Generator versions HM230-HM355 ....................................................1-13
Cleaning of Air Filters (if available) ......................................................1-14
Cleaning of Windings ..........................................................................1-15
Replacement of Diode Bridge .............................................................1-18
Generator versions: HM160-200. Procedure to check the diodes of the ex-
citer rotor. ............................................................................................1-19
Replacement of exciter. Generator versions: HM160-250 ..................1-21
Generator versions: HM280-355. ........................................................1-22
Replacement of voltage .......................................................................1-23
Check of Residual Voltage ..................................................................1-25
DSR AVR .............................................................................................1-26
Cummins Range Alternators ................................................................... 1-29
Guidance of Typical Insulation Resistance [IR] Values .......................1-29
New Machines .....................................................................................1-29
At Generating Set Manufacturers Works .............................................1-29
Generators in Service ..........................................................................1-29
Winding Condition Assessment ...........................................................1-29
Procedure for Insulation Testing ..........................................................1-30
Methods of Drying Out Generators .....................................................1-30
Typical Drying Out Curve ....................................................................1-31
Air Filters .............................................................................................1-32
Fault Finding ........................................................................................1-32
SX460 AVR - Fault Finding .................................................................1-32
SX440 AVR - Fault Finding .................................................................1-33
SX421 AVR - Fault Finding .................................................................1-33
Transformer Control - Fault Finding ....................................................1-33
MX341 AVR - Fault Finding .................................................................1-34
MX321 AVR - Fault Finding .................................................................1-34
Residual Voltage Check ......................................................................1-35
Separate Excitation Test Procedure ....................................................1-36
0-1 0-1
, Section 0 - 1
Contents
Contents Page No.
AVR Maintenance
HM Range Regulators ............................................................................. 1-40
Electrical Connection ...........................................................................1-40
DSR Digital Regulator .........................................................................1-45
Cummins Range ...................................................................................... 1-49
Direction of Rotation ............................................................................1-49
Generator Set Testing .........................................................................1-52
Connections Electrical
HM Range Alternators ............................................................................. 1-57
Winding Resistance at 20°C Ambient. ................................................1-57
4 Poles 50Hz 3 Phase .........................................................................1-79
4 Poles 50Hz 3 Phase .........................................................................1-80
4 Poles 50Hz 3 Phase .........................................................................1-81
4 Poles 50Hz 3 Phase .........................................................................1-82
4 Poles 50Hz 3 Phase .........................................................................1-83
4 Poles 50Hz 3 Phase .........................................................................1-84
4 Poles 60Hz 3 Phase .........................................................................1-85
4 Poles 60Hz 3 Phase .........................................................................1-87
Ratings Book Glossary ............................................................................ 1-89
Winding Configurations and Winding Numbers ...................................1-89
Specification
Rating Definitions .................................................................................... 1-91
Base Continuous Ratings ....................................................................1-91
Peak Standby Rating (40ºc ambient temperature) ..............................1-91
Peak Standby Rating (27ºC ambient temperature) .............................1-91
Winding Numbers Used On Cummins/Stamford Alternators ................... 1-92
AVR Controlled 40°C Ambient Temperature Class H Temp Rise 125°C
(Base Continuous Rating) ...................................................................1-93
0-2 0-2
SERVICE MANUAL
SELF-REGULATING ALTERNATORS
Publication No.
9813/2800
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
, Section 0 - Alternator Service Manual
Notes:
0-0 9813/2800 0-0
, Section 0 - 1
Contents Page No.
Care and Safety
Safety Check List ....................................................................................... 1-1
Safety - Yours and Others .....................................................................1-1
Safety Warnings ....................................................................................1-1
Safety Check List ..................................................................................1-2
Principle of Operation
Self-Excited AVR Controlled ...................................................................... 1-5
AVR Accessories ....................................................................................... 1-6
Identification .............................................................................................. 1-7
Key Component .....................................................................................1-8
Maintenance
JCB HM Range Alternators ....................................................................... 1-9
Assessment of windings conditions after long periods of storage or inactiv-
ity. ..........................................................................................................1-9
Assessment of current functioning (absence of anomalous noises or vibra-
tions). .....................................................................................................1-9
Mechanical checks of fastening bolts and, in particular, of electric connec-
tions. ....................................................................................................1-10
Internal and external cleaning of the generator. ..................................1-10
Maintenance and replacement (if necessary) of bearings. .................. 1-11
Generator versions HM160-200-250 ...................................................1-12
Generator versions HM230-HM355 ....................................................1-13
Cleaning of Air Filters (if available) ......................................................1-14
Cleaning of Windings ..........................................................................1-15
Replacement of Diode Bridge .............................................................1-18
Generator versions: HM160-200. Procedure to check the diodes of the ex-
citer rotor. ............................................................................................1-19
Replacement of exciter. Generator versions: HM160-250 ..................1-21
Generator versions: HM280-355. ........................................................1-22
Replacement of voltage .......................................................................1-23
Check of Residual Voltage ..................................................................1-25
DSR AVR .............................................................................................1-26
Cummins Range Alternators ................................................................... 1-29
Guidance of Typical Insulation Resistance [IR] Values .......................1-29
New Machines .....................................................................................1-29
At Generating Set Manufacturers Works .............................................1-29
Generators in Service ..........................................................................1-29
Winding Condition Assessment ...........................................................1-29
Procedure for Insulation Testing ..........................................................1-30
Methods of Drying Out Generators .....................................................1-30
Typical Drying Out Curve ....................................................................1-31
Air Filters .............................................................................................1-32
Fault Finding ........................................................................................1-32
SX460 AVR - Fault Finding .................................................................1-32
SX440 AVR - Fault Finding .................................................................1-33
SX421 AVR - Fault Finding .................................................................1-33
Transformer Control - Fault Finding ....................................................1-33
MX341 AVR - Fault Finding .................................................................1-34
MX321 AVR - Fault Finding .................................................................1-34
Residual Voltage Check ......................................................................1-35
Separate Excitation Test Procedure ....................................................1-36
0-1 0-1
, Section 0 - 1
Contents
Contents Page No.
AVR Maintenance
HM Range Regulators ............................................................................. 1-40
Electrical Connection ...........................................................................1-40
DSR Digital Regulator .........................................................................1-45
Cummins Range ...................................................................................... 1-49
Direction of Rotation ............................................................................1-49
Generator Set Testing .........................................................................1-52
Connections Electrical
HM Range Alternators ............................................................................. 1-57
Winding Resistance at 20°C Ambient. ................................................1-57
4 Poles 50Hz 3 Phase .........................................................................1-79
4 Poles 50Hz 3 Phase .........................................................................1-80
4 Poles 50Hz 3 Phase .........................................................................1-81
4 Poles 50Hz 3 Phase .........................................................................1-82
4 Poles 50Hz 3 Phase .........................................................................1-83
4 Poles 50Hz 3 Phase .........................................................................1-84
4 Poles 60Hz 3 Phase .........................................................................1-85
4 Poles 60Hz 3 Phase .........................................................................1-87
Ratings Book Glossary ............................................................................ 1-89
Winding Configurations and Winding Numbers ...................................1-89
Specification
Rating Definitions .................................................................................... 1-91
Base Continuous Ratings ....................................................................1-91
Peak Standby Rating (40ºc ambient temperature) ..............................1-91
Peak Standby Rating (27ºC ambient temperature) .............................1-91
Winding Numbers Used On Cummins/Stamford Alternators ................... 1-92
AVR Controlled 40°C Ambient Temperature Class H Temp Rise 125°C
(Base Continuous Rating) ...................................................................1-93
0-2 0-2
