Pacific Scientific within two (2) years after the date of the product date code that is affixed to the product, and within thirty (30) days from the date any such defect is first discovered.
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, troubleshooting, and repair procedures. It is imperative that the installation instructions be followed closely. Successful installation depends upon a number of factors, and ignoring any one factor can lead to major problems with the unit.
Easily delivers peak output currents up to 1.5 times the continuous output rating for extra starting power. • Conveniently mounts in any position in a minimum of space. • True sine-wave output. • Optional GFI outlet. • Operates in ambient temperatures from -30°F to 104°F Pacific Scientific REDI-LINE Generators...
** Variance from output voltage and frequency is dependent on load size and the DC input voltage. Typical voltage tolerance is ±15%. Typical frequency tolerance is ±5%. Carefully monitor any equipment that is sensitive to fluctuations in either voltage or frequency. Pacific Scientific REDI-LINE Generators...
Inspect the unit for any damage that may have been sustained during shipment. If you find damage, contact the shipper immediately to file a claim. Pacific Scientific REDI-LINE Generators...
Allow at least 2 inches of free air space around the REDI-LINE generator. Do not obstruct the ventilation as it can cause the generator to overheat. Install the battery system in an area that is ventilated, so that battery fumes can be readily dissipated. Pacific Scientific REDI-LINE Generators...
Determine how frequently and at what loads you plan to use your generator. Find the Redi-Line generator series you purchased and choose the correct installation diagram based on your usage and loads. Use this diagram as a guide when it comes time to do the system installation. Pacific Scientific REDI-LINE Generators...
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This will ensure the vehicle battery is always charged and you will be able to start your vehicle. Figure 4-1. Infrequent Use with Varying Loads *Use fuse size recommended by isolator manufacturer Figure 4-2. Frequent Use with Varying Loads Pacific Scientific REDI-LINE Generators...
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This will ensure the vehicle battery is always charged and you will be able to start your vehicle. Figure 4-3. Infrequent Use with Varying Loads Figure 4-4. Frequent Use with Varying Loads Pacific Scientific REDI-LINE Generators...
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This will ensure the vehicle battery is always charged and you will be able to start your vehicle. Figure 4-5. Infrequent Use with Varying Loads Figure 4-6. Frequent Use with Varying Loads Pacific Scientific REDI-LINE Generators...
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This will ensure the vehicle battery is always charged and you will be able to start your Figure 4-7. Infrequent Use with Varying Loads Figure 4-8. Frequent Use with Varying Loads Pacific Scientific REDI-LINE Generators...
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This will ensure the vehicle battery is always charged and you will be able to start your vehicle. Figure 4-9: Infrequent Use with Varying Loads Figure 4-10. Frequent Use with Varying Loads Pacific Scientific REDI-LINE Generators...
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This will ensure the vehicle battery is always charged and you will be able to start your vehicle. Figure 4-11. Infrequent Use with Varying Loads Figure 4-12. Frequent Use with Varying Loads Pacific Scientific REDI-LINE Generators...
If the charging system is not powerful enough, the batteries may still ultimately become discharged after a long operating time. If that is the case, you may need to install a larger alternator in your vehicle. Consult your REDI-LINE distributor for more information Pacific Scientific REDI-LINE Generators...
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. Pacific Scientific recommends that the REDI-LINE Generator always be installed using proper fuses or circuit breakers. Refer to the appropriate Installation figure (Figures 4-1 through 4-12) for fuse sizes and locations.
If you have questions on installation or operation of the generator, contact your REDI-LINE distributor for assistance. If you do not have a distributor contact, call Pacific Scientific direct at (815) 226-3100.
Cable, connectors, fuses and isolators may be available from your authorized REDI-LINE distributor. Many also provide complete installation services. NOTE: When attaching power cables to the generator; a spark at the connection may occur. This is normal and does not mean the generator is defective. Pacific Scientific REDI-LINE Generators...
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Instruction and Service Manual Installation Figure 5-1. Mounting Template for Small Frame Generators Pacific Scientific REDI-LINE Generators...
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Installation Instruction and Service Manual Figure 5-2. Mounting Template for Large Frame Generators Pacific Scientific REDI-LINE Generators...
If it does not, refer to the field troubleshooting procedure in Section 7. 11. Remove the load. The generator should stop within 10 seconds. If it does not, refer to the field troubleshooting procedure in Section 7. Pacific Scientific REDI-LINE Generators...
Return your unit to the distributor or factory for service. . Usually three sets of brushes can be worn out before it is necessary to turn the commutators. Pacific Scientific REDI-LINE Generators...
Field Troubleshooting 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 problems caused by faulty installation or load changes, and thereby avoid unnecessary returns.
Should You Need to Return the Unit Before returning any products for repair, authorization must first be received from your dealer. Dealer requirements may vary, so contact your dealer for instructions before returning a unit to him. Pacific Scientific REDI-LINE Generators...
Instruction and Service Manual Field Troubleshooting Field Troubleshooting Checklist Form We have performed the following troubleshooting checks: And the results were: Customer Name:________________________________________________________________________ Street Address:__________________________________________________________________________ City:_______________________________________________State:___________________Zip:_________ By:____________________________________________ Position:________________________________________ Phone:_________________________________________ Fax:___________________________________________ e-mail:_________________________________________ Pacific Scientific REDI-LINE Generators...
See Figure 7-7 This Section See Figure 7-5 This Section This Section Battery Generator runs discharges all the time too quickly See Figure 7-9 See Figure 7-10 This Section This Section TSFSTART Figure 7-1. Identifying Symptoms Pacific Scientific REDI-LINE Generators...
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Okay Check cable size from battery to generator. See Cable Sizing, Section 4, Preparation for Installation. Install correctly Return for Return to Okay sized cables Repair Service TSFSPEED Figure 7-2: Generator Running at an Incorrect Speed Pacific Scientific REDI-LINE Generators...
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Check to see that both sets of DC input terminals are connected to batteries. See Installation Interconnection, Section 5, Installation Connect DC Input Return for Return to okay Cables Correctly Repair Service TSFAVFHL Figure 7-3: Generator Output Voltage or Frequency Incorrect Pacific Scientific REDI-LINE Generators...
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No Load Check with 100 watt light bulb Increase load Return Okay to service on generator Return for Repair TSFACON Figure 7-4. Generator Does not Start When Connected to Battery Pacific Scientific REDI-LINE Generators...
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Equipment Starting Load Requirements Return to Service Return to Service NOTE: The Redi-Line Generator can provide 1.5 TSFALOAD times its rated capacity for starting motors and loads. Figure 7-5: Generator Runs but does not Start Equipment Pacific Scientific REDI-LINE Generators...
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DA12A 80294 Connect load DA12L 81221 Connect DC Input ground directly DA24A 79632 Cables Correctly to battery DA24L 79203 DA36A 79632 DA36L Return Return to to service Service TSFPERF Figure 7-6. Generator Does Not Start Automatically Pacific Scientific REDI-LINE Generators...
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Okay Restart This Section Return to Okay Increase load Service on generator Return Install Larger to service Reduce Load Generator Return to Service TSFALOD2 Figure 7-7. Generator Starts With Load, But Stops After A Few Seconds Pacific Scientific REDI-LINE Generators...
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Load is too light Check with 100 watt light bulb Return for Okay Repair Increase load on generator Return to service TSFACYCL Figure 7-8. Generator Cycles On And Off Every Few Seconds Pacific Scientific REDI-LINE Generators...
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Check to see that deep cycle batteries are being used Replace batteries Okay with deep cycle type Return to Service Check battery condition Replace with Okay new batteries Upgrade vehicle charging system TSFAQDIS Figure 7-9. Battery Discharges Too Quickly Pacific Scientific REDI-LINE Generators...
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Note: Power strips with ON indicator lamps, equipment with POWER CONNECTED indicator lamps, or similar devices can place enough load on the generator to cause it to run, even though the intended load has been removed. Figure 7-10. Generator Runs All The Time Pacific Scientific REDI-LINE Generators...
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 Model, 87, Model 8060, Model 8062, or equivalent. Connect the voltmeter leads to the power output points on the generator to take a reading.
Be sure to follow individual disassembly and assembly procedures given in Section 9, Repair Procedures, when performing these steps. Pacific Scientific REDI-LINE Generators...
Replace Armature Replace Brushes See Armature See Brush Okay Replacement, Replacement, Section 9, Section 9, Repair Procedures Repair Procedures Replace Bearings See Bearing Replacement Section 9, Repair Procedures Return to Service TSBNOISE Figure 8-1. Generator Is Noisy Pacific Scientific REDI-LINE Generators...
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Repair Procedures Replace Armature Replace See Armature Bearings Replacement, See Bearing Section 9, Replacement Repair Procedures Section 9, Repair Procedures Return to Service TSBSPEED Figure 8-2. Generator Speed, Voltage, or Frequency Too High or Too Low Pacific Scientific REDI-LINE Generators...
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79632 DA24L 79203 Version* DA36A 79632 Replace PC Board. DA36L See PC Board Replacement, Okay Section 9. TSBANOST Repair Procedures Figure 8-3. Generator Does Not Start When Connected to the Battery or Does Not Start Automatically Pacific Scientific REDI-LINE Generators...
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See PC Board Model Serial Number Replacement, Break Section 9 DA12A 80294 Repair Procedures TSBACYCL DA12L 81221 DA24A 79632 DA24L 79203 DA36A 79632 DA36L Return to Service Figure 8-4. Generator Cycles On and Off Every Few Seconds Pacific Scientific REDI-LINE Generators...
When removing or assembling components and subassemblies to perform checkout procedures, refer to the detailed disassembly and assembly instructions contained in Section 9, Repair Procedures. Failure to do so may result in improper disassembly or assembly. Pacific Scientific REDI-LINE Generators...
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3. Burnishing of the brush faces is acceptable, but if pitting or damage is discovered, replace both brushes in the pair. Inspect the armature commutator for damage. 4. If either brush is too short, replace both brushes in the pair. Pacific Scientific REDI-LINE Generators...
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3. Burnishing of the brush faces is acceptable, but if pitting or damage is discovered, replace both brushes in the pair. Inspect the armature commutator for damage. 4. If either brush is too short, replace both brushes in the pair. Pacific Scientific REDI-LINE Generators...
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If any damage is found, replace the armature. NOTE: A damaged commutator may be resurfaced and undercut if facilities and skills are available to do so. However, it is recommended that any armature with commutator damage be replaced. Pacific Scientific REDI-LINE Generators...
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3. If there is measurable but inconsistent resistance between adjacent bars of the DC windings, remove any dirt or foreign metal pieces which may have created a bridge between the bars. Recheck the resistance. If it is still inconsistent, replace the armature. Pacific Scientific REDI-LINE Generators...
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Instruction and Service Manual Bench Troubleshooting 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 assembly cover from the generator but do not disconnect any electrical wires.
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Resistance between the circuit breaker terminals should be less than 1 ohm. Disposition: 1. If resistance is greater than 1 ohm, replace the circuit breaker. 2. If resistance is less than 1 ohm, the circuit breaker is good. Pacific Scientific REDI-LINE Generators...
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Instruction and Service Manual Bench Troubleshooting 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 small frame generator, separate but do not disconnect the electrical assembly cover from the generator…...
2. Battery cable, at least #4 gauge, preferably #2 gauge. The exact length of cable needed depends upon the set-up of the test bench. Terminals used on the battery cable should be copper. Pacific Scientific REDI-LINE Generators...
8. If armature (39) is to be replaced, separate bearing (35) from front end bell (30) end bell with a rubber hammer (the bearing is bonded to the end bell). Pacific Scientific REDI-LINE Generators...
This retains the brush in the holder during installation. Remove the retaining wire after the assembly is secured. Pacific Scientific REDI-LINE Generators...
13. If armature (39, 43, 44, or 48) is to be replaced, separate bearing (36, 40, 41 or 45) from front end bell (25 or 29) end bell with a rubber hammer (the bearing is bonded to the end bell). Pacific Scientific REDI-LINE Generators...
12. Install the electrical components inside solenoid cover (1). Make sure wire routing and electrical connections are properly made. Install solenoid cover on housing and secure with screws (2). Pacific Scientific REDI-LINE Generators...
2. Install the spring assembly so that the bottom of the brush ramp is closest to the spring assembly. 3. Press on the spring assembly to ensure the hook on the end of the spring engages with the brush holder. 4. Connect the brush shunts. Figure 9-1. Brush Removal and Installation Pacific Scientific REDI-LINE Generators...
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 Model, 87, Model 8060, Model 8062, or equivalent. Connect the voltmeter leads to the power output points on the generator to take a reading.
The part number column provides the Pacific Scientific part number; this part number is to be used when ordering the item from Pacific Scientific or your local dealer. The description column identifies assemblies and assembly parts through the use of dots preceding the item description.
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Parts Lists Instruction and Service Manual Figure 10-1: Small Frame Generators Pacific Scientific REDI-LINE Generators...
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NOT USED NOT USED . Printed Circuit Board AVAILABLE NO LONGER NOT USED NOT USED . Nut AVAILABLE NO LONGER NOT USED NOT USED . Nut AVAILABLE NO LONGER NOT USED NOT USED . Washer AVAILABLE continued….. Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-1: Small Frame Generators, continued Pacific Scientific REDI-LINE Generators...
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. Shell Assembly, 24 Volt AVAILABLE NO LONGER YH83053 YH83053 . Shell Assembly, 36 Volt AVAILABLE YP80007 YP80007 YP80007 . Foot Mount YK11231 YK11231 YK11231 . Screw, Hex Head, ¼-20 X 9/16 YP00987 YP00987 YP00987 . Plug Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-2. End Bell for Earlier Small Frame Generators Pacific Scientific REDI-LINE Generators...
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. Insulator YP02103 . Power Terminal YK10027 . Nut, Std. Hex, ¼-20 NO LONGER AVAILABLE . Diode, 25 Amp X 800 Volt, Black (negative) NO LONGER AVAILABLE . Diode, 25 Amp X 800 Volt, Red (positive) Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-3. End Bell for Current Small Frame Generators Pacific Scientific REDI-LINE Generators...
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End Bell Assembly YR20193 . End Bell YP00351 . Brush YP00872 . Brush Spring YP02246 . Insulator, Brush YP02103 . Power Terminal YK10027 . Nut, Std. Hex, ¼-20 YK10384 . Washer YK10027 . Nut, Std. Hex, ¼-20 Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-4: 12 Volt Large Frame Generator, Earliest Version Pacific Scientific REDI-LINE Generators...
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. Nut, 5/16 YK10960 . Nut, 5/16 YP80105 . End Cover (Shroud) YK11230 . Screw, Slotted, Pan Hd YP01581 . Fan Impeller YK11134 . C-Ring YR70150 . Bell Assembly, Front End, (opposite fan shroud end) Continued….. Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-4: 12-Volt Large Frame Generator, Earliest Version, continued Pacific Scientific REDI-LINE Generators...
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. Terminal, Positive, with lead wire YP02237 . Insulator YK11424 . Washer HB623SL . Bearing, 6203, double sealed HB623SL , Bearing, 6203, double sealed YK10199 . C-Ring NO LONGER AVAILABLE . Armature NO LONGER AVAILABLE . Housing Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-5: 12-Volt Large Frame Generator, Interim Version Pacific Scientific REDI-LINE Generators...
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. End Cover, (Shroud) YK11230 . Screw, Slotted, Pan Hd YP01581 . Fan Impeller YK11134 . C-Ring YR70150 . Bell Assembly, Front End, (Opposite Fan Shroud) YR70215 . Bell Assembly, Rear End, (Fan Shroud End) Continued….. Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-5: 12-Volt Large Frame Generator, Interim Version, continued Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-6: 12-Volt Large Frame Generator, Current Version Pacific Scientific REDI-LINE Generators...
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. C-Ring YR70150 . Bell Assembly, Front End (opposite fan shroud end) YR70215 . Bell Assembly, Rear End (fan shroud end) YJ11240 . Tie Rod YK11322 . Nut, Acorn, 10-32 YK10960 . Nut, Lock, 10-32 Continued….. Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-6: 12-Volt Large Frame Generator, Current Version, continued Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-7: 24-Volt Large Frame Generator, Earlier Version Pacific Scientific REDI-LINE Generators...
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. End Cover, (Shroud) YK11230 . Screw, Slotted, Pan Hd YP01581 . Fan Impeller YK11134 . C-Ring YR70226 . Bell Assembly, Front End (opposite fan shroud end) NO LONGER AVAILABLE . Bell Assembly, Rear End (fan shroud end) Continued….. Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-7: 24-Volt Large Frame Generator, Earlier Version, continued Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-8: 24-Volt Large Frame Generator, Current Version Pacific Scientific REDI-LINE Generators...
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. Bell Assembly, Front End (opposite fan shroud end) YR70226 . Bell Assembly, Rear End (fan shroud end) YJ11212 . Tie Rod YK11322 . Nut, Acorn, 10-32 YK10960 . Nut, Lock, 10-32 YP03151 . Washer, Wavy Spring Continued….. Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual 33 31 Figure 10-8: 24-Volt Large Frame Generator, Current Version, continued Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-9: End Bell for Large Frame Generators, Earlier Version Pacific Scientific REDI-LINE Generators...
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NO LONGER AVAILABLE . Diodes Bracket Assembly NO LONGER AVAILABLE . Screw, Socket Head, 10-32 X 2 YP00372 . Brush YP00886 . Brush Spring YK10398 . Screw, Std Hex Hd, 10-32 X 3/8 YK10343 . Washer, No. 10 Pacific Scientific REDI-LINE Generators...
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Parts Lists Instruction and Service Manual Figure 10-10: End Bell for Large Frame Generators, Current Version Pacific Scientific REDI-LINE Generators...
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. Left Hand Brush Holder Assembly YK11738 . Screw, Socket Head, 10-32 X 2 YP00372 . Brush YP00886 . Brush Spring YK10398 . Screw, Std Hex Hd, 10-32 X 3/8 YK10343 . Washer, No. 10 YP02985 . Standoff Pacific Scientific REDI-LINE Generators...
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 analysis and repair. It is not of use to the generator user. Pacific Scientific REDI-LINE Generators...
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11.6 Vdc Output Power (Watts) 13.6 Vdc 12.6 Vdc 11.6 Vdc Output Power (Watts) 12.6 Vdc Output Power (Watts) 12.6 Vdc Output Power (Watts) 12.6 Vdc Output Power (Watts) Figure 11-1: Performance Curves for DA12A-500A Redi-Line Generators Pacific Scientific REDI-LINE Generators...
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