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928-0500 Onan ENA ENB ENC ENAD ENBA Genset Generator

1. 2 CBI LN gt 4 0813 PAN di pass T 1 ga 18453 5 B 0514 26 RED f 4 7 57 12 BTI os FIERE 5 S2 C uer NE S ALIBI RED GRN STRIPE BI SOL BAT s2 J3 HET Q 0 16 6 i Bi i TEN 57 5 Q os 25 58 ES 9 SEN Be I 05 Us i Ls 9655 6 93 OVERSPEED TI E an j 2 J2 ILLUS E 8 oc 0518 3 y l 93 po CB2 A O EUN 55 PRE LOP P2 CHRYSLER APPLICATIONS SPARK IGNITION 56 PRE HET BRN WHT STRIPE J2 5 MODL GRAY 2VDC TBI D almsa FORD NON SOLENOID 2 182 11 1 9 AR
2. 2 TB2 BOORSREARS VIEW Pad DEBS er ote EEN fw BACK WALL OF CABINET 3 B CU e VR2 Loe BACK WALL OF CABINET SR S 2221 2 O 8 E TSO Y X X 821 2 X 82 NI uM X 21 1 VR2 5 B21 22 O S 2 5 aM S 5 22 5 Nc Q 8 os TE BI m 7 p2 O BI Mes B 9 M23 N 3 B21 22N 1821 2 E 5 b 21 23 Ree gt 1821 23 Ere Thes HERE E zi ani nin a ctr ASA ELECTRONIC 218 be l WHEN USED EN PMG J PMG EXCITER FIELD TO DC CONT 41 1 91 2 XI x2 TO DC CONT JI 2 5 2 2000 2 9 3 OA WITH PNL W OUT PNL QTY QTY QTY QTY QTY QTY QTY QTY QTY QTY QTY QTY QTY QTY QTY DASH VOLTAGE VOLTAGE ITEM ITEM ITEM ITEM ITEM ITEM ITEM ITEM ITEM ITEM ITEM ITEM NO ADJUS
3. DSII All NOTE AI INTERNAL CONN FOR REF ONLY WIRING DIAGRAM PACKAGE THAT WAS 7 INCLUDED WITH YOUR GENSET PE ASST ENGTNE WONTTORI Test DIESEL APPLICATIONS GAS GASOLINE APPLICATION E 4 6 OFF B y r EE LAMP PREHEAT 26 26 FUEL SOLENOID dele RUN 3 94 4 _ 5 8 s Jm 1 MEN E TBI Kl KI oie iH LK n a 64 5 7 STOP 2 d Lm 5 Q STARTER eor xad c mi CONFIGURATIONS 0087 dow 523 FORD APPLICATIONS SPARK IGNITION Al2 mio x CBI 0512 faa i 23 em 4 KA je W d 0513 34 51 T WHITE 5 3 23 LOP 26 gos f T T 0514 4 RED prex MOT 5 J amp 12 Bs FE SRN 11 1 8 ALITBI 9 me 0515 52 HET RED GRN STRIPE c E Bro BAT 82 oce pj wt P er Lp Len m NES E T B2 BI OS IN E T UG Y TBI W K4 s QNI quem E J3 P2 N ILLUS TI AIITBI 8 52 96 8 S4 LET CB2
4. 1 1 ae m4 2 3 Xxx P3P2KIKA De a 2 2 2 Q S XCITEI N 2 Aam TIR 1 i Vian Lr ad g 2 223 ala E eue cu cu lala c m m QUO c Q gt qu zy gt gt gt ele _ TO DC CONTROL gc 8 TERMINAL TAB ADAPTOR 7 TAB RESISTOR ASSY 6 2 TB21 22 5 TAB LEAD VR21 P2 TB21 23 4 TAB LEAD VR21 1 TB21 22 3 JUMPER 2 PLUG HOLE VR21 2 TB21 22 O TAB LEAD TB21 25 VR21 3 18 9 4 SCREW LKH 8 32X 8 RESISTOR ASSY E 7 TAB LEAD TB21 21 M23 TABULATION 6 TAB LEA VR21 3 VR21l P3 5 TAB LEAD VR21 I R21 1 NOTES DASH WITH PANEL WITHOUT PANEL QTY QTY QTY QTY QTY QTY QTY GT Ys QTY QTY ons oM QTY 4 ITAB LEAD TB21 22 R21 2 VOLTAGE ADJUST VOLTAGE ADJUST ITEM I ITEM 3 4 5 ITEM 6 7 ITEM 14 IS ITEM IGITEM I7 ITEM 18 x 2 5 TAB LEAD VR21 2 VR21 P2 DASHED LEADS INDICATE WHEN USED 01 x E _ 2 2 3 2 de REGULATOR 38 TUS ITEM QTY DESCRIPTION OR MATERIAL
5. PANEL LAMP WIRING DIAGRAM PACKAGE THAT WAS 7 INCLUDED WITH YOUR GENSET gt ASSY ENGINE MONITOR LAMP TEST DIESEL APPLICATIONS GAS GASOLINE APPLICATION 2 4 6 SW OFF B u Hy ws A 4 26 26 FUEL SOLENOID 10 nu 5 e 3 6 s p A 2 1 1 Jd sje I AI5 TBI 7 KI KI 7 STOP 2 X7 La 2 25 Q STARTER eere CONF IGURATIONS 1 0057 WP E GNE TO GUAGES FORD APPLICATIONS SPARK IGNITION E CUST GND CONN 10A OD 24NDC DF i 12 0 FORD 12 o SOLENOID SHIFT p a BI run 0512 PET 259 fes gm m ass uu PRE LOP D K GI OUT J3 LOP 26 GI OUT 7 M 0514 oa RED E P 2 MOT ex TK FER J2 A 7 LoP y 0515 1 52 RED GRN STRIPE s ATITBI 8 0516 B 2 22 ns DS 57 dns 5250 10 TB 75 OS IN 2 23 ER os 0517 2 93 9 2 J2 M ILLUS 7 TI 3 8 Gs i S4 ET 2 A EO Q DSI9 i P2 J2 M cx i i ee I Jt she ntur eta 1 23 0520 9 ES 55 CHRYS
6. 0 02 8 16 3 130 001 6 VR21 6 SO TAB LEAD 30 001 7 21 7 THIS IS A REPRESENTATIVE GENERIC 59 TAB LEAD T30 00T 6 VR21 8 SCHEMATIC WIRING DIAGRAM FOR 28 TAB LEAD 130 7 21 23 27 LEAD 30 8 TB21 22 TB21 TROUBLESHOOTING REFER THE SOS RP DOOR REAR VIEW ti Y WIRING DIAGRAM PACKAGE THAT WAS 25 LOCKWASHER 10 r 4 4 gt 6 BACK WALL OF INCLUDED WITH YOUR GENSET SX TABISGREW RHSM 10 32 X TETZ25 4 2 22 TERMINAL TAB ADAPTOR S 2 21 RESISTOR ASSY KI S St TRANSFORMER PCB ISLN X 821 224 I8 TAB LEAD 21 VR21 2 S 21 23 ASR 6 17 1 JUMPER 4 zx B21 29 4 SCREW RHM 8 32X1 X LEAD K VR21 EO TB21 23 i Y LJ 14 1 LEAD VR2I ET TB21 22 be j S LEAD 21 7 21 23 2 S po Q Bl 12 LEAD VR21 8 TB21 22 M23 LEAD VR2I 6 TB21 25 rue lt 5 E 2 EO 1821 22 9 PLUG HOLE TB21 23 8 RESISTOR ASSY Tw 7 TAB LEAD TB21 21 M23 sinibus j 6 TAB LEAD R21 2 VR21 2 IA oi 2
7. PIR a TRANSEORMESSSECDNDAR CURRENT TRANSFORMER SECONDARY CONN 1 2 SECONDARY CONN 3 SECONDARY CONN 1 3 QD 100 200V 50HZ R79 10 190V 50HZ 8004 133 230 50 60HZ 8057 220 380V 50 60HZ 8099 200 346 50 2 8068 100 200V 50HZ R054 100 200V 50HZ 8054 110 220V 50HZ R028 115 200V 50HZ 8050 139 240V 60HZ R067 260 450V 50 60HZ RIO9 230 400V 50HZ RO29 110 220V 50HZ R046 110 220V 50HZ R046 115 230V 071 120 208 50 60HZ R098 240 416V 50 60 7 ROO3 277 480 60 HZ R002 115 230V 60HZ RO41 115 230V 50HZ 8041 120 240V 60HZ RIO6 127 220 50 60HZ R020 255 440V 50HZ R023 266 460V 60HZ RO27 120 240V 60HZ RIO4 120 240V 60HZ R104 RANGE RANGE RANGE RANGE RANGE 100 150 200 240 VOLTS 10 139 190 240 VOLTS 220 277 380 480 VOLTS 100 120 200 240 VOLTS 100 120 200 240 VOLTS LI U nz LI U 100 U 22 ue 5 LO N 55 22 ve L2 V 55 cf 7 1 os x ge L2 V 5 we 22 Q 5 y li L5 LO W V 05 6 MOM ME Ul V5 LO CN 2 9 43 Mu LO N LO N en L2 V JI v2 v Z 6 1 ye LJ L4 N L3 W L3 W WOE 2 SERIES DELTA PARALLEL STAR SERIES STAR DOUBLE DELTA 5 PHASE 4 WIRE 5 PHASE 4 WIRE PHASE 4 WIRE PHASE WIRE PHASE
8. 6 5 Carburetors coo rei iE 6 8 WIRING DIAGRAMS 7 1 Safety Precautions Before operating the generator set read the Op erator s Manual and become familiar with it and the equipment Safe and efficient operation can be achieved only if the equipment is properly oper ated and maintained Many accidents are caused by failure to follow fundamental rules and precau tions The following symbols found throughout this manual alert you to potentially dangerous condi tions to the operator service personnel or the equipment This symbol warns of immediate hazards which will result in severe personal in jury or death This symbol refers to a hazard or un safe practice which can result in severe person al injury or death This symbol refers to a hazard or un safe practice which can result in personal injury or product or property damage FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury or death can re sult from improper practices DO NOT fill fuel tanks while engine is running unless tanks are outside the engine compart ment Fuel contact with hot engine or exhaust is a potential fire hazard DO NOT permit any flame cigarette pilot light spark arcing equipment or other ignition source near the generator set or fuel tank Fuel lines must be adequately secured and free of leaks Fuel connection at
9. 5 lt T 503 DLE 2 i 1 E lt U daaroor 1 5 e 1 T 5 lt gt gt 5 20 2 i 1 1 a 8 5296 TEE 1 Sji etl tao le Fugo 1 lt lt URS XE M g T Bo 22 S torzz gt 1 1 DA aN o m l e ER 5 1 n 1 1 2 1 1 1 2 No e 15 e 1 gt a 1 1 ecco Jd 5 1 1 of e o liv P 1 2 E AE 1 i g 2 zi lt i 1 i i 2 2 2 ach m i E E ALIN R i 15 5 CE S 2 1 1 1 E TEE E O9 bem M i aN O t 1 e 2 2 _ 1 gt un p o o E 1 1 m ME 9 2 E 8 5 1 4 1 NX 1 j 211 420 1 6j M E 1 8 NEC RENT 5 uen at 64 5 o 5 1 2
10. E o ho zm 2 Hag LE 1 a zu du XI lt 1 1 ar Ri ER 4 i 4 5 NES Vs sj R He 1 1 1 1 1 1 gt T TN 152 1 l 1 1 l n 5 1 t 1 8 1 1 1 m aN o 1 1 ae 1 1 gt le 1 1 FPE E 1 2 13 1 1 1 ME 1 El 5 Et aene 1 1 2 ME 1 l 1 zx lt g 1 lt ey a E D E CO 1 aps ee eer eae DE r r r r r r r r r F r F F ra ES m a Peet e e of af e of 1 EIOS clc e See ee ee Mtm ERES 4 ban SS eee ee 4 i 5 mon hy 50g Er amp amp 5 lt ee 85475 5 ze 5 98 6 2 a du moa w 2 m o o NL 1 f WU SN a m amp amp S 1 EA lt CUSTOMER CONNECTIONS THE AUXILIARY RELAY BOARD
11. EFER TO ILLUSTRATION DRAWING 539 0741 02 x i 5 z EXTRA WIRE INTO HARNESS 03 S X E 2 z 300 3607 JR a REV D 4 ON 03 04 USE ITEM 18 TO CONNECT 04 5 440 MODIFIED EAD TO VR21 2 VOLTAGE REGULATOR INSTALLATION SELF EXCITED GENERATORS 7 6 RIGHT SIDE DOOR SIDE WALL HORIZONTAI INSIDE VIEW THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR EN TROUBLESHOOTING REFER TO THE ERA LLLA 12 WIRING DIAGRAM PACKAGE THAT WAS All 0511 ASSY ENGINE MONITOR gt 2 INCLUDED WITH YOUR GENSET FBA 4 511 6 5 15 1 7
12. 5 5 VR21 I R21 1 EE 4 SCREW LKH 6 32 172 DASHED LEADS INDICATE WHEN USED 3 PLATE VOLT RGLTR MTG PMG 2 VOLTAGE REGULATOR 2 REFER TO ILLUSTRATION DRAWING 539 0741 TAB POTENTIOMETER EXCITER FIELD ITEM QTY DESCRIPTION OR MATERIAL 3 TIE EXTRA WIRE INTO HARNESS 486 T 04 6 epo 6 2 05 amp 06 TH alt 5
13. 12 m U6tTIO 02 14 6 3 W V 4 W 5 9 _ 2 347 600 VOLTS IF VOLTAGE REGULATOR SX440 e 5 89 WI T3 6 WO T6 9 ER ehe ONAN P N 300 3607 IS SPECIFIED CONNECT T V 8 V T V T V GENERATOR TAP STATOR LEADS 7 amp 8 TO VR2l P2 5 18 U6 710 2 7 Vo e VICT2 5 5 T8 W6 T 12 jo 5 amp VR2 P3 REPECTIVELY INSULATE AND V2 T5 I VI T2 7 V2 T5 W2 T6 VICT2 TIE 6 LEAD BACK Odd TU 8 9507 UI TI E UI CTI s _le el ve ID E ES U2 TA W6e TI2 QAM 4 02014 6 A HI y 3 347 600 VOLTS F VOLTAGE REGULATOR ONAN P N 300 3606 INSULATE AND TIE BACK GENERATOR TAP STATOR LEADS 6 7 amp 8 4 240 480 VOLTS IF VOLTAGE REGULATOR SX440 ONAN P N 300 3607 IS SPECIFIED CONNECT LEAD FROM W6 U AND W5 TO VR21 P2 AND VR2 P3 RESPECTIVELY pee OPTIONAL EXC FIELD VOLTAGE K2 KI P2PSPAS2SIABALXX XXX 8 7 6 8 2 AUXILIARY TERMINAL BLOCK QN DETECTOR CONTROL CONTROL INPUT J CONERO SERIES PARALLEL SERIES DOUBLE VOLTAGE REG DELTA STAR STAR DELTA m VOLTAGE REG OPTIONAL 5 8 8 8 8 amp OVERSPEED 3 7 7 7 7 24 4 4 4 4 25 6 6 6 6 26 5 5 5 5 JUMPER No 625 3061 sh 1 of2 Rev Sys CADAM Modified 8 3 95 GENERATOR RECONNECTION DIAGRAM SHEET 1 BEGIN
14. 20 20 CD R4 Wes R CONTROL Ul Ge CRS CR8 CRed C7 C8 03 U5 a 5A GAUGES Ue U4 A K18 20 a gt 15 K17 19 TB 1 C 11 6 7 8 TB2 1 FAULT 2 GROUND INPUT FROM SENDER 2 2 FAULT 2 GROUND OUTPUT LIGHT RELAY TB2 3 FAULT 1 GROUND INPUT FROM SENDER TB2 4 FAULT 1 GROUND OUTPUT TO LIGHT RELAY TB2 5 REMOTE RESET MOMENTARY CONTACT TO GROUND TB2 6 OVERCRANK FAULT GROUND OUTPUT TO LIGHT RELAY TB2 7 OVERSPEED FAULT GROUND OUTPUT TO LIGHT RELAY TB2 8 HIGH ENGINE TEMPERATURE FAULT GROUND OUTPUT TO LIGHT RELAY TB2 9 LOW OIL PRESSURE FAULT GROUND
15. VOLTAGE REG VOLTAGE REG KH OVERSPEED OPTIONAL No 625 2164 sh 1of2 Rev Sys CADAM Modified 8 3 95 GENERATOR RECONNECTION DIAGRAM SHEET 1 PRIOR TO SPEC E 7 15 THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS U L 2 N 5 U lt INCLUDED WITH YOUR GENSET 3 PHASE RECONNECTABLE 5 PHASE NON RECONNECTABLE CURRENT TRANSF ORME SECONDARY CONN 2 CURRENT TRANSFORMER SECONDARY CONN 2 347 600V 60HZ R114 i 220 440 50 HZ ROI9 240 480V 60 HZ RII9 21 U6 SEE SEE NOTE SERIES STAR SERIES DELTA NOTES FONG ROLL aR 3 PHASE 4 WIRE 3 PHASE 4 WIRE i DUTPUT TERMINALS OUTPUT TERMINALS 347 600 VOLTS F VOLTAGE REGULATOR 5 440 6 OR 12 LEAD U V W U V W N ONAN P N 300 3607 IS SPECIFIED CONNECT CONTROL AUX DAS GENERATOR TAP STATOR LEADS 7 amp 8 TO VR2I P2 INPUT TERM SERIES PERES amp VR21 P3 REPECTIVELY INSULATE AND EON 347 600 240
16. A load has a ground fault or short circuit Service the faulty equipment as necessary 4 19 5 Servicing Generator TESTING THE GENERATOR These tests can be performed without removing the generator Before starting tests disconnect the starting battery cables negative first to make sure the engine will not start while performing these tests Always disconnect a battery char ger from its AC source before disconnecting the battery cables Otherwise disconnecting the cables can result in voltage spikes high enough to damage the DC control circuits of the set Accidental starting of the generator set while working on it can cause severe per sonal injury or death Prevent accidental start ing by disconnecting the starting battery cables negative first STATOR LEADS OUTPUT TERMINALS MAIN STATOR GENERATOR ADAPTOR CASTING COOLING BLOWER MAIN ROTOR GENERATOR FIELD Make certain battery area has been well venti lated before servicing battery Arcing can ignite explosive hydrogen gas given off by batteries causing severe personal injury Arcing can oc cur when cable is removed or re attached or when negative battery cable is connected and a tool used to connect or disconnect posi tive battery cable touches frame or other grounded metal part of the set Always remove negative cable first and reconnect it last Make certain hydrogen from battery engine fuel and ot
17. 23 1 0 o 1 4 Q 0519 2 4 4 l 93 us 9 23 7 5 59 PRESLOP CHRYSLER APPLICATIONS SPARK IGNITION J3 SPS EE LET Q 0521 5 S6 BRE HET BRN WHT STRIPE 23 3 2vDC Lo FueL y Ds22 6 GRAY SOLENOID SHIFT J 5 L 3 com ALM AA 2 FORD NON SOLENOID SHIFT I2VDC 24VDC SW OFF 0523 id T AlI TBI 9 P3 182 5 5 a Sel dm SM T RST jem ETE B TATE B o eeu UI rie ET ga fes vm Q PNE GI OUT BAT 1 AITTBI 8 Sw FLT IN 120 JI PI F4 I PERLE cdi J GI BAT ZONE vel 2 ZO 5A TB2 FLT 2 IN PA RED 1 Rf 7 GI 3 TBI KIA 9 8 BTI 1 05 TBI 3 RUN 5A BLACK YELLOW STRIPE TI B ALT START DISC 4 JI TB2 z STARTER SPLENDID 8 A 10 5 24V 75 ay LOP 5 z n 9 NUES FIGURATIONS PREHEAT SOLENOID GLOW PLUGS HI OUTPUT MOTOROLA SW B ire Ke c o T i qe 5A 12 VOLT 24 VOLI AII TBI 2 GND SW TO GAUGES E mes aE TEN OC 5A BTI BT 813 me 16 SHUT DOWN 5 5 MIA Fs Tel T 15 O mee NOTE RECTIFIER BRIDGE MOUNTED HOUR METER ON INSIDE BACKWALL OF CONTROL MII TB2 FLT 2
18. Field circuit breaker CB21 is faulty Continued on next page There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Read the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual Continued from previous page THERE IS NO OUTPUT VOLTAGE CONT Determine as follows whether the fault is in the VOLTAGE REGULATING or GENERATOR circuits 1 Continued on next page Throw the line circuit breaker OFF and shut down the set This test involves unregulated excitation of the generator To prevent damage to the genera tor due to overcurrent make sure that all loads have been disconnected and that all faults have been cleared from the power output terminals of the generator Openthe control panel and disconnect the X and the XX leads from the voltage regulator See Figure 2 3 or 2 4 as appropriate Connect the XX lead to the ground stud on the floor of the control box battery negative Be prepared to connect the X lead to 12 VDC battery positive and to read output voltage across the generator terminals while the set is running Check polarity again Polarity must be correct or this test will be inconclusive because the induced and residual magnetic polarities in the exciter stator will
19. first to make sure the set will not start while working on it Accidental starting of the generator set while working on it can cause severe injury or death Prevent accidental starting by discon necting the starting battery cables negative first Always remove the negative cable first and reconnect it last to prevent arcing if a tool acci dentally touches the frame or other grounded metal part while removing the positive bat tery cable Arcing can ignite the explosive hy drogen gas given off by the batteries causing severe injury Removing The Generator Output Box 8 Disconnect the line cables and conduit For re connections later make sure each cable is clearly marked to indicate the correct terminal 9 Disconnect the remote control wiring and con duit For reconnections later make sure each wire is clearly marked to indicate the correct terminal Disconnect all engine wiring harness connec tions in the generator control and output boxes For reconnections later make sure each wire is clearly marked to indicate the correct terminal Disconnect all generator control leads winding taps from connections in the output box For 10 11 5 8 reconnections later make sure each wire is clearly marked to indicate the correct terminal If the set has a mounted line circuit breaker dis connect the cables to the circuit breaker For reconnections later make sure each cable is clearly mark
20. 3 6 Auxiliary Control Components 3 7 Sequence Of Operation 3 14 TROUBLESHOOTING x nt rdv i tee TR rete pd eters Pire 4 1 The Engine Does Not Crank 4 1 The Engine Cranks But Does Not Start 4 4 The Engine Runs Until Fault Shutdown 4 7 The Engine Lacks Power Or Stable Speed 4 9 Engine Condition Rd ps ed 4 11 There Is No Output Voltage Engine Speed Is Stable 4 12 Output Voltage Is Too High Or Too Low 4 16 Output Voltage Is Unstable 4 17 The Field Circuit Breaker Keeps Tripping 4 18 The Phase Currents Are Unbalanced 4 19 TITLE PAGE SERVICING THE GENERATOR 5 1 Testing The Generator 5 1 Removing And Disassembling The Generator 5 8 Reassembling The Generator 5 10 Servicing The PMG resin are De odi 5 10 GOVERNORS AND CARBURETORS 6 1 Mechanical Governor Prior To Spec 6 1 Electronic Governor Prior To Spec 6 2 Electronic Governor Begin Spec
21. 4 26 S RESISTOR AND o rs DIODE BI BAT OUTPUT 1 Lu 27 55 BI BAT 1 ALTERNATOR AUX P3 CONFIGURATION AUX P2 SEE C AIITBI BATTERY ALITBI 10 CONFIGURATION SALT BTS 1 CONFIGURATION 612 6686 sh2of2 Sys CADAM E Modified 8 7 95 7T LIGHT DC WIRING SHEET 2 BEGIN SPEC F 7 12 THIS IS A REPRESENTATIVE GENERIC RIGHT SIDE WALL HORIZONTAL RIGHT SIDE DOOR SCHEMATIC WIRING DIAGRAM FOR BACK WALL VERTICAL REAR INSIDE VIEW TROUBLESHOOTING REFER TO THE ES INCLUDED WITH YOUR GENSET AI2 0511 ASSY ENGINE MONITOR 1193 5 T TBI 5 8 iS 272 3 TDS I
22. MOUNTED ON A BRACKET IN FRONT OF A11 OVERSPEED MODULE ALARM RELAY MODULES A13 AND A14 ES1561s 1 FIGURE 3 4 ARRANGEMENT OF COMPONENTS INSIDE THE CONTROL BOX CONTROL BOX INTERIOR Figure 3 4 shows the arrangement of components inside the control box including the engine control monitor and some of the auxiliary components un der following headings ENGINE CONTROL MONITOR A11 The heart of the engine control system is the engine control monitor ECM It is a printed circuit board assembly mounted on the back wall of the control box It starts and stops the engine in response to the control panel switches engine sensors and remote control signals Figure 3 5 shows the newer ECM board used in current production and as a direct re placement for older boards The boards are distin quishable from each other in that the newer boards have automotive type fuses and the older boards have cartridge type fuses Terminals and Connectors See Pages 7 7 through 7 14 for the appropriate connection and schematic drawings for the DC con trol system See Page 7 19 for typical customer connections at terminal boards TB1 and TB2 on the ECM and page 7 20 if the set is also equipped with the auxiliary relay board 3 4 Fuses The ECM has five replaceable fuses to protect it from overloads and groundfaults They are F1 Starter solenoid circuit 20 amps F2 Fuel solenoid switched B circuits 20 amps F3 Continuous B
23. 0 400 1 3 0 500 1 3 0 750 1 3 0 800 1 3 m aud lt TABULATION Tio UL 500V VERTICAL 10 11 12 13 14 15 16 17 18 Aen E E TII 7 V1 341 5 E s E 5 BRIDGE RECTIFIER 600V VERTICAL 35 36 37 38 39 40 41 42 43 CE 4160 VERTICAL 90 91 92 93 94 95 96 97 98 500v HORIZONTAL 60 61 62 63 64 65 66 67 68 A 600V HORIZONTAL ITEM 32 M22 302 1727 302 1728 302 1729 302 1798 302 1799 302 1800 302 1908 0 500 0 1000 0 600 0 1200 0 750 0 1500 0 1000 0 2000 0 1500 0 3000 0 2000 0 4000 0 3000 0 6000 WITH METERS NO 612 6490 CURRENT TRANSFORMER 0 500 1 2 0 600 1 2 0 750 1 2 0 1000 1 2 0 1500 1 2 0 2000 1 2 0 3000 1 2 REV J SECONDARY CONNECTION O 1000 1 3 0 1200 1 3 0 1500 1 3 0 2000 1 3 0 3000 1 3 0 4000 1 3 0 6000 1 3 MODIFIED AC CONTROL WIRING DIAGRAM WITH METERS 7 4
24. There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THERE IS NO OUTPUT VOLTAGE ENGINE SPEED IS STABLE Find out why the circuit breaker was turned OFF make sure it is safe to reconnect power and then throw the circuit breaker ON The line circuit breaker is OFF Shut down the set and service as necessary to clear the short circuit or ground fault that caused tripping and then RESET the circuit breaker and start the set The line circuit breaker has TRIPPED Shut down the set make sure the power output lines from the set have been disconnected from all other sources of power attempt to RESET the circuit break er and throw it ON and check for electrical continuity across each line contact Replace the circuit breaker if there is measurable resistance across any contact The line circuit breaker is faulty RESET the circuit breaker If it keeps tripping trouble shoot according to the chart Field Circuit Breaker Keeps Tripping Field circuit breaker CB21 has TRIPPED Shut down the set attempt to RESET the circuit break er and disconnect either lead Replace the circuit breaker if there is measurable resistance across the terminals
25. o ape NOTES 6 6 REMOTE START zr als 1143 19 ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION 2 1 2 A O oy al 5 3 2 ILLUSTRATION NUMBERS REFER TO DWG NO 539 0741 82 4 COMMON ALARM 4 AMPS OST OT 89 e so VERT D ILLUS STD CONTROL AND 539 0997 HORIZ o 2 x lt A RUN 0511 0 3 GAUGE RESISTORS 12 13 ILLUS 88 ARE USED ON 24V DC START DISCONNECT INPUT 1103 8 das 02 04 VERSION ONLY MOUNT BEFORE ATTACHING HARNESS IBS 1 2 2 cs OVERSPEED meu g E 8 asc 511 812 4 TIE ALL UNUSED LEADS INTO HARNESS 9 2 ER DE 5 GROUND BETWEEN MI amp MI2 ILLUS 477 78 IS THROUGH 120522 2 THE FRONT PANEL E 05200 3 16 Al 13 6 2 Ae 6 DASHED LEADS INDICATE WHEN USED 25258 ug tdguuyh sg 120512 2 005218 i2 al O og Fd 2 7E i 2 D ERE UK UE o Uh 2052 e z 8 ITEMS CRI CR2 RI AND LEAD GI 3 TO AII TBI 2 lt 2061922 DSe21 lt xl ARE USED ONLY ON THE CUMMINS B amp C BLOCK ENGINES USING KH 2 sol 2 gt H 222222385 a
26. 55 9 SWITCHED B 2 109 IN 99 12 3 usd STARTER SOLENOID BS 2 OUT 15 AMPS eet d NN F 7 B OUT 15 AMPS i 1 55 6 REMOTE START e ara MN a 55 5 GROUND ol 1 ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION E O 22 4 COMMON ALARM 4 AMPS 2 ILLUSTRATION NUMBERS REFER TO DWG NO 539 0741 8 RUN w 2 Il VERT D ILLUS STD CONTROL AND 539 0997 HORIZ uu 1 _ 5 START DISCONNECT INPUT 5 UM 0 05181 3 GAUGE RESISTORS RI2 13 ILLUS 88 ARE USED ON 24V 2 5 IAT25808 1 02 04 VERSION ONLY MOUNT BEFORE ATTACHING HARNESS LU T OVERSPEED INPUT Poy 12 zt 61 3 5 afa ATTORE 4 TIE ALL UNUSED LEADS INTO HARNESS s 5 GROUND BETWEEN MI amp MI2 ILLUS 77 78 IS THROUGH 5 2 2 THE FRONT PANEL gt amp pum olo mi A 5 6 DASHED LEADS INDICATE WHEN USED lt 120512 2 EE D n EIS 2 MI2 C dE RUE Rn x VE 8 ITEMS CRI CR2 AND LEAD 61 3 AII TBI 2 lt z lt lt l ARE USED ONLY ON THE CUMMINS B amp C BLOCK ENGINES USING 100 c 120618 2 THE DELCO MOTOROLA ALTERNATOR QOO 120817 2 9 ON SOME SETS YOU MAY HAVE THIS INTERIM SILK
27. 55 GLOW PLUGS DUEB ds Al 2 z FOR BATTERY AND S6 STARTER CONNECTION t Al J2 3 9 x SEE SHEET 2 NO CONTROL Ts 01 vert 12 22 FOR ALTERNATOR 02 VERT 24V CONNECTIO SY 612 6488 sh 1of2 ENG 4 59 SEE SHEET 2 4 HORIZ 24V Rev Sys CADAM Modified 8 3 95 12 LIGHT DC WIRING SHEET 1 PRIOR TO SPEC F 7 9 THIS IS REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR SCHEMA AGRAM C D ON ASY ST EMS TROUBLESHOOTING REFER TO THE
28. Servicing the Genera open or shorted tor Replace the generator rotor assembly if exciter ro tor winding resistances do not meet specifications Shut down the set and check main rotor winding resist The main rotor winding is faulty open or ance according to Section 5 Servicing the Generator shorted Replace the generator rotor assembly if main rotor winding resistance does not meet specifications Shut down the set and check stator winding resistanc The stator windings are faulty open or es according to Section 5 Servicing the Generator shorted Replace the generator stator assembly if stator wind ing resistances do not meet specifications There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual OUTPUT VOLTAGE IS TOO HIGH OR TOO LOW Adjust engine speed according to Section 6 Gover Engine speed is too high or too low nors and Carburetors If engine speed is unstable troubleshoot according to the chart The Engine Lacks Power or Stable Speed Adjust output voltage according to Section 2 AC Con trol The voltage has been adjusted improper ly Improper connections have been made at Shut down the set and reconnect according
29. aL rod r 4 ED Ind bi E TII a le a e lt A 99 69 Al Jl 2 LE 2 lt xoxo Tle ob ats 521 44 V7 NP ps L l x u 2929 5 20 521 45 22 Fa 2l 3 H gt gt al 28 08 2 521 42 21 E 2 TB2 14 18 22 27 2 a ET 9 9 2 e eT SEND 2 9 DC WIRING DIAGRAM 53 64 5 b ZONE 5 B C D VR2 yy z 50 9 gt SO 521 14 9 9 GENERATOR VOLTAGE x LINE 1 _ ER 5 REGULATOR A 53 44 9 4 521 12 9 GENERATOR 1 21 el 24 24 VR2 82 9521 2 GENERATOR L 1 stots 0522 2 65 63 M21 S M23 GENERATOR L J NOTES a ala 59 65 a DE D ce ERATOR EM ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION 5 ei VOLTMETER A All JI 2 ILLUSTRATION NUMBERS REFER TO DWG NO 539 0741 521 VERT D ILLUS STD CONTROL AND 539 0997 D HORIZ 3 LOCATE ONE 1 DANGER LABEL ON EXTERIOR AND ONE 1 ON INTERIOR OF LEFT SIDE DOOR IN ANY READILY VISIBLE M22 AREA AVAILABLE n e TO DC WD P 20VAC STARTER 4 SEE GENERATOR CONNECTION DIAGRAM FOR INPUT CONNECTIONS AMMETER M23 DISCONNECT 5 SEE VOLTAGE REGULATOR INSTALLATION FOR CONNECTIONS TO VR21 CB21 R21 AND 2 4 BOTTOM OF CABINET 69 695 INSIDE VIEW 4 tad 521 22 XJ POSITION
30. out to remote circuits 15 amps F4 ECM circuits 5 amps F5 Engine gauge circuits 5 amps Function Selection Jumpers Newer ECM boards have six selection jumpers that can be repositioned to provide the following timed or non timed warnings or timed or non timed shut downs with warnings W1 Jumper Position jumper W8 must be in the B position A Non timed warning under FLT 2 condi tions B Non timed shutdown and warning under FLT 2 conditions C Timed warning under FLT 2 conditions Timed shutdown and warning under FLT 2 conditions W2 Jumper Position jumper W9 must be in the B position A Non timed warning under FLT 1 condi tions B Non timed shutdown and warning under FLT 1 conditions C Timed warning under FLT 1 conditions D Timed shutdown and warning under FLT 1 conditions W6 Jumper Position A Warning under Pre High Engine Tem perature conditions B Shutdown and warning under Pre High Engine Temperature conditions W7 Jumper Position STARTER 20A WITCHED B SHIT START SOL 1 e 5 000 Wi 2 E CR13 1 3 4 5 e gt e aw lt lt 2 ae Q e gt LAMP TEST A Warning under Pre Low Oil Pressure conditions B Shutdown and warning under Pre Low Cil Pressure conditions W8 Jumper Position A Warning while running
31. 24 j VOLTAGE REG OPTIONAL IN THE CONTROL IN THE CONTROL amp OVERSPEED JUMPER H 2 4 AUX 7 H D TB2 6 AUX 8 2 TRANSFORMER CONNECTIONS ASSEMBL Y 625 2164 sh 2of2 Rev Sys CADAM Modified 8 3 95 GENERATOR RECONNECTION DIAGRAM SHEET 2 PROIR TO SPEC E 7 16 THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR UC GENERATORS TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS 3 PHASE RECONNECTABLE 12 LEAD PHASE RECONNECTABLE 2 LEAD PHASE NON RECONNECTABLE 4 LEAD INCLUDED WITH YOUR GENSET E CURRENT TRANSFORMER CURRENT TRANSFORMER CURRENT TRANSFORMER SECONDARY CONN 1 3 CURRENT TRANSFORMER SECONDARY CONN 1 2 SECONDARY CONN 1 3 SECONDARY CONN 100 200V 50HZ R79 110 190 2 8004 133 230 50 60HZ 8057 220 380V 50 60 7 R099 200 346V 50HZ RO68 100 200V 50HZ RO54 100 200V 50HZ 8054 110 220V 50HZ R028 115 200V 50HZ R050 139 24
32. 3 8 ELECTRONIC OVERSPEED MODULE Run Relays K11 The set can be equipped with one to three 3 pole double throw relays to control auxiliary equipment such as fans pumps and motorized air dampers The relays are mounted on a standoff bracket in front of the ECM The contacts are rated 10 amps at 28 VDC or 120 80 PF 6 amps at 240 80 PF e 3 amps at 480 80 PF The set might instead be equipped with an auxiliary relay board If so see Auxiliary Relay Board ARB Alarm Relay Modules A13 and A14 The set can be equipped with relay modules to in terface with a remote annunciator that is powered independently of the control circuit of the set Sets with Detector 7 need module A13 and sets with De tector 12 modules A13 and A14 These are all normally open contacts and they are rated e 15 amps at 250 VAC e 15 amps at 30 VDC The set might instead be equipped with an auxiliary relay board If so see Auxiliary Relay Board ARB 3 8 CUSTOMER CONNECTIONS FAULT 1 FAULT 2 LOW FUEL SWITCH OFF 1 11 1 3 A11 TB2 11 12 LIGHT FIGURE 3 10 ALARM RELAY MODULES Auxiliary Relay Board The following describes the design functional crite ria for the auxiliary relay board ARB with a Detec tor 7 or 12 Genset control The board is mounted directly on top of the ECM using standoffs and has access holes for the fuses located on the ECM There ar
33. APPLICATIONS SPARK IGNITION rd START PA GND TO GUAGES D MN BI 5 CUST GND CONN 10A 5 OD 24VDC DF 2VDC FORD AI2 ES SOLENOID SHIFT 5 5 0512 BI j de 4 mmy BI 5 __ 0513 PI WEE K4 d SW GI OUT 7 23 l3 S53 SI LOP 26 er 2 GI OUT BAT j J PRE HET S RED pp i P2 ri oS E TBI 8 TO LOP Q 1 5 HET RED GRN STRIPE E8 1 AIITBI 8 0 0516 S Uy iy 7 HN i 0817 TK 19 Gs 78 1 05 IN T En PNE Be 06 I TBI Q psi Ix fps P2 TUS TI BAT 91 5 211 8 54 LET CB2 12 7 d 7 Fees oe eres J3 T T 0520 Ex T 2x 55 PRE LOP CHRYSLER APPLICATIONS SPARK IGNITION 25 fps MEE EET i 2321 PRE Ges BRN WHT STRIPE Lo DS22 Jg 2VDC 2 E EE 5 COM amesa FORD NON SOLENOID SHIFT avc SW OFF 2 4 AII TBI 9 93 173 E 5 LAMP T RST PINK E A 57 STARTER 1 TB2 LO FUEL IN ers Loa ee Spar JS PS 9 _ 29 lt OUT ipa AILITBI 8 E TO WD 120VAC SE SIS FA TB2 3 FLT I IN LL E n T D ZONE 6 2 PO SA 1 FLT 2 IN 26 5 T GI OUT BAT gig
34. CONTACTS CLOSED HOLS ING CONTROE BOX LI L2 30 11 18 C 22 32 44 N 33 R 060 CT23 L2 L3 30 12 22 44 42 41 43 P Eis mz GND T3 w6 13 11 3 11 18 B J 4 31 42 41 33 R T4 vee LI LO 30 11 18 21 14 44 N 42 41 33 R 5 5 i Zee UPPER OFE fe TRANSFORMER A M her cec 117 Li L2 14 11 18 C 22 32 44 53 8 T8 2 6522 LOWER LI L2 I 11 18 C 22 44 N 42 41 43 P T9 N2 01 N 52 2 LINE T12 wW TABULATION lt 500V VERTICAL 01 02 03 04 05 06 07 08 09 600V VERTICAL 26 27 28 29 30 31 32 33 34 FIG Go MV4160 VERTICAL 81 82 83 84 85 86 87 88 89 CENE TUS 500V HORIZONTAL 51 52 53 54 55 56 57 58 59 d ud T4 U5 4 600 HORIZONTAL 76 77 78 79 80 ITEM 22 M22 302 1975 302 1473 302 1147 302 1683 302 1684 302 1685 302 1724 302 1725 302 1726 m 2d T7 02 AME EB soon ce 0 25 0 50 0 50 0 100 0 75 0 150 0 100 0 200 0 150 0 300 0 200 0 400 0 250 0 500 0 375 0 750 0 400 0 800 A e 5 v2 L CURRENT TRANSFORMER 0 25 1 2 0 50 1 2 0 75 1 2 0 100 1 2 0 150 1 2 0 200 1 2 0 250 1 2 0 375 1 2 0 400 1 2 2 SECONDARY CONNECTION 0 50 1 3 0 100 1 3 0 150 1 3 0 200 1 3 0 300 1 3
35. DETECTOR CONTROL 7 20 5 T26 T26 THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR T26 IGN TROUBLESHOOTING REFER TO THE re WIRING DIAGRAM PACKAGE THAT WAS SUE Ma Em INCLUDED WITH YOUR 26 SSS S O GND 21 32 126 OGro DIST aoe JI 2 GND GOV BLK IGN BLK GOV RED GND S6 COIL CR2 2 Jl TB21 21 O T26 42 3 21 1 so GI D CUP DETAIL B C GI OND GI GND S GND P WH N PI WHITE B SW ENP GND Ye noue Al ITBI 8 01 6 SW 1 BI SW J2 lt 2 1 0682 1 11 1 2 CRI 2 BI BAT No Al ITBI 9 DETAIL uao gat E2 S4 GI B O sz J2 6 GND CONT GRIS CRI CRI 2 CR2 CR2 CR2 2 PI WHT PI WHITE ALI TB BI S PA BROWN FORD BIBAT 3 2 pens AII TBI 9 11 1 10 Pl 726 TEAD TABULATION DETAIL A DET
36. FIELD TIO UI 1 TII V TI2 WI 0 WITHOUT METERS TABULATION VERT Ol HORIZ 02 NO 612 6489 REV D MODIFIED SCHEMATIC DIAGRAM WIRING DIAGRAM THIS IS A REPRESENTATIVE GENERIC GENERATOR pe um A LEFT SIDE DOOR REAR INSIDE VIEW INSIDE VIEW SCHEMATIC WIRING DIAGRAM FOR 2 2 0 2 ub ae 0522 rors A Me uM orb T EABINE WIRING DINGHAINEACIAGE THAT WAS 2 2 C FI qi A IPEA ERI LEFT WALL OF TRAY HORIZONTAL TOTO J BOTTOM OF TRAY HORIZONTAL INCLUDED WITH YOUR GENSET a ES E n
37. J4 from the ECM board and check for electrical continuity zero ohms between The Run Stop Remote switch S12 or switch terminals 2 and 3 when the switch is in the Run wiring is faulty position and between terminals 1 and 2 when it is in the Remote position Replace the switch if either set of contacts is faulty If the switch works check for electrical continuity zero ohms between J4 6 and J4 7 on the wire harness when the switch is in the Run position and between J4 5 and J4 6 when the switch is in the Remote posi tion Replace the wire harness if there is no electrical continuity in either position of the switch Continued on next page There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE DOES NOT CRANK CONT Continued from previous page Push the Run Stop Remote switch to Run If the en The remote control circuit is faulty gine cranks find and repair the fault in the remote con trol circuit Push the Run Stop Remote switch to Run and check for battery voltage 12 VDC between ECM terminal The ECM is faulty Check fuse F1 again TB1 8 and the grounding stud on the floor of the con trol box If there is no volta
38. LIFT POINTS EXCITER STRAP STATOR AROUND THE MIDDLE OF THE ROTOR G1190s 1 FIGURE 5 7 GENERATOR ASSEMBLY 5 9 Withdrawing the Rotor From Generator 1 Remove the generator adaptor casting on the drive disc end and the end plate on the bearing end Using a hoist of sufficient capacity cinch a lift ing strap on the drive end of the rotor Lift the bearing end of the rotor by hand and push it to wards the drive end of the generator until half the width of the rotor core protrudes from the stator Release the weight of the rotor and re cinch the lifting strap around the middle of the rotor core Withdraw the rotor until it is free of the stator guiding it by hand on both ends to prevent contact with the stator windings Rest the rotor in a cradle solidly supporting it on two pole faces not on the drive discs blower or exciter Remove the retaining clip if the rotor shaft bearing is to be removed REASSEMBLING THE GENERATOR Reassembling is the reverse of disassembling Note the following 1 Apply force to the inner race of the rotor bearing when pressing it onto the shaft otherwise it will be damaged Be sure to secure the retaining clip The drive disc to rotor bolts should be torqued to 190 ft lbs 257 Nm The drive disc to flywheel bolts should be torqued to 50 ft lbs 67 Nm The exciter stator mounting screws should be torqued to 7 ft Ibs 10 Nm The generator end
39. OFF 5 OVERSPEED CONFIGURATION ALTERNATOR CONFIGURATIONS 1 2 EI ELECTRONIC MECHANICAL RI Push 5 5 g OLE PRESS I cr I2VOLT 24 VOLT 12 VOLT 24 VOLT 12 VOLT 24 VOLT 3 Fly 2 DELCO MOTOROL A MZ M 2 6 BOSCH MOTOROLA G 8 2 WATER TEMP GAUGE n CND See ey al X TO ENG HARNESS All JI 3 4 11 1 10 ENGINE TIE POINT 26 RESISTOR AND 2G 3 o DIODE BI BAT EE ds oW 111111 S TR san Mi ALTERNATOR AUX PS CONFIGURATION AUX P2 1781 10 CONF IGURATION 4118155 1 CONFIGURATION BE No 612 6687 sh20f2 Rev Sys CADAM Modified 8 7 95 12 LIGHT DC WIRING SHEET 2 BEGIN SPEC F 7 14 THIS IS REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE UC GENERATORS WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET 4 PHASE RECONNECTABLE 2 LEAD PHASE RECONNECTABLE 12 LEAD PHASE NON RECONNECTABLE 4 LEAD CURRENT TRANSFORMER CURRENT TRANSFORMER
40. POWER FACTOR METER FIGURE 2 1 AC CONTROL PANEL AUTOMATIC VOLTAGE REGULATOR AVR ADJUSTMENTS The automatic voltage regulator is mounted on the back wall of the control cabinet It can be adjusted by means of the potentiometers pots shown in Fig ure 2 2 Figures 2 3 and 2 4 show typical voltage regulating circuits These measurements and adjustments are done while the set is running and require access to unin sulated high voltage parts in the control and power output boxes HIGH VOLTAGE Touching uninsu lated high voltage parts inside the control and power output boxes can result in severe per sonal injury or death Measurements and ad justments must be done with care to avoid touching high voltage parts For your protection stand on a dry wooden platform or rubber insulating mat make sure your clothing and shoes are dry remove jewelry and wear elbow length insulating gloves in tended for hazardous voltages Jumper Reconnections Jumpers provide for reconnections to adapt the voltage regulator to the application See Figure 2 2 Reconnect the response jumper if necessary so that terminal A connects to terminal C if generator output is 90 kW or less B to C if generator output is greater than 90 kW but less than 550 kW and A to B if output is greater than 550kW Reconnect the fre quency jumper if necessary to correspond to the application frequency Voltage and Voltage Stability Adjustments Use the contro
41. Page 7 8 7 light DC Wiring Sheet 2 Prior to Spec F 7 1 Page 7 9 12 light DC Wiring Sheet 1 Prior to Spec F Page 7 10 12 light DC Wiring Sheet 2 Prior to Spec F Page 7 11 7 light DC Wiring Sheet 1 Begin Spec F Page 7 12 7 light DC Wiring Sheet 2 Begin Spec F Page 7 13 12 light DC Wiring Sheet 1 Begin Spec F Page 7 14 12 light DC Wiring Sheet 2 Begin Spec F Pages 7 15 and 7 16 Reconnection Diagram Prior to Spec E Pages 7 17 and 7 18 Reconnection Diagram Begin Spec E Page 7 19 Typical Connections to the Page 7 20 Customer Connections at the Aux iliary Relay Board Page 7 21 Engine Harness Begin Spec F 7 2 SCHEMATIC DIAGRAM WIRING DIAGRAM G2 GENERATOR LEFT SIDE DOOR REAR INSIDE VIEW INSIDE VIEW INSIDE VIEW BRIDGE RECTIFIER T3 DGE T2 EA TI LEFT SIDE WALL VERTICAL BACK WALL OF CABINET VERTICAI BOTTOM OF TRAY HORIZONTAL LEFT WALL OF TRAY HORIZONTAL 2 m T6 m TB2 ti TII 69 3 5 E 69 69 F2 99 69 CB2 68 69 zi A e 69 5 69 69 GENERATOR LINE 68 69 GENERATOR FI 21 CO 9 69 ENERATOR 2 ps G3 G3 GENERATOR i E 2 2 GENERATOR FI gt 69 6 N L 4 TO DC 120 STA
42. Re install the magnetic speed pick up unit to make sure the clearance with the fly wheel gear teeth is correct Section 6 Replace the speed pickup unit if output voltage at cranking speed is less than 2 5 VDC as measured at terminals 10 and 11 on the governor controller Disconnect the actuator lead connected at governor controller terminal 5 and connect it to the negative terminal of the cranking battery Then disconnect the lead connected at terminal 4 and touch it to the battery positive terminal Replace the actuator unit if it does not drive the throttle open when power is con nected or return it when power is disconnected Replace the governor controller if it still cannot be ad justed for full power or stable speed Continued on next page There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE LACKS POWER OR THE SPEED IS UNSTABLE Continued from previous page Check for and replace clogged gasoline fuel lines and filters Gasoline delivery to the set is inade quate Measure the vertical distance between the gasoline fuel pump on the engine and the bottom of the dip tube in the supply tank Ma
43. STOP BUTTON FIGURE 3 1 ENGINE CONTROL PANEL DC Voltmeter M13 The DC voltmeter indicates voltage across the battery terminals during opera tion Hour Meter M14 The hour meter indicates the ac cumulated number of hours the set has run It can not be reset Panel Lamp DS11 The panel lamp illuminates the control panel Detector 7 Fault and Status Indicator Lamps A12 Run Green This lamp indicates that the gen erator set is running and that the starter has been disconnected Pre Low Pressure Yellow This lamp indi cates that engine oil pressure is abnormally low less than 30 psi Low Oil Pressure Red This lamp indicates that the engine shut down because of exces sively low engine oil pressure less than 25 psi e Pre High Engine Temperature Yellow This lamp indicates that engine coolant tempera ture is abnormally high greater than 205 97 e High Engine Temperature Red This lamp indicates that the engine shut down because of excessively high engine coolant temperature greater than 215 F 102 C Overcrank Red This lamp indicates that the engine shut down because it did not start dur ing the timed cranking period approximately 75 seconds including two rest periods Overspeed Red This lamp indicates that the engine shut down because of overspeed OPTIONAL CONTROL PANEL COMPONENTS Oil Temperature Gauge M15 The oil temperature gauge indicates engine o
44. be opposed 35 HIGH VOLTAGE Touching uninsulated high voltage parts inside the control box can result in severe personal injury or death Measurements and adjustments must be done with care to avoid touch ing high voltage parts For your protection stand on a dry wooden platform or rubber insulating mat make sure your clothing and shoes are dry remove jewelry and wear elbow length insulating gloves intended for hazardous volt ages Start the set and connect the X lead to battery positive The generator is probably okay if rated output voltage or higher is obtained and the voltages for all phases are balanced when the exciter is powered by the 12 volt cranking battery Use the appropriate VOLTAGE REGULAT ING FAULT chart to troubleshoot Normal excitation voltage ranges from approximately 10 VDC at no load to approximately 40 VDC at full load Use the GENERATOR FAULT chart to troubleshoot if the output voltages are not balanced or are less than ninety percent of rated output voltage when the exciter is powered by the 12 volt cranking battery If the voltages are unbalanced troubleshoot the main stator first If the voltages are uniformly low troubleshoot the exciter and field circuits first There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head th
45. leads and connec tions between the voltage regulator and the PMG and repair as necessary before disas sembling the PMG Note the connections at the auxiliary terminal board in the power output box See Figure 2 3 Stop the set and measure electrical resistance across lead pairs P2 P3 P3 P4 and P4 P2 with Wheatstone bridge or digital onmmeter Each winding should have a resistance of approxi mately 4 4 ohms Disassembling the 1 Disconnect the starting battery cables nega tive first to make sure the set will not start while working on it Always disconnect a battery charger from its AC source before discon necting the battery cables Otherwise dis connecting the cables can result in voltage spikes high enough to damage the DC con trol circuits of the set Accidental starting of the gen erator set while working on it can cause se vere personal injury or death Prevent dental starting by disconnecting the start ing battery cables negative first Make certain battery area has been well ventilated before servicing battery Arcing can ignite explosive hydrogen gas given off by batteries causing severe personal inju ry Arcing can occur when cable is removed or re attached or when negative battery cable is connected and a tool used to con nect or disconnect positive battery cable touches frame or other grounded metal part of the set 5 11 Always remove negative ca
46. or a fuel pressure switch for automatic fuel changeover While the en gine is running the gas pressure switch causes the natural gas solenoid valve to close and the propane solenoid valve to open when natural gas pressure is lost without stopping the engine When natural gas pressure is restored the natural gas solenoid valve opens and the propane solenoid valve closes 6 9 GASOLINE AND GASEOUS FS 1251s NATURAL GAS AND PROPANE 5 12505 FIGURE 6 9 COMBINATION FUEL SYSTEMS Gaseous Fuel Adjustments Gas mixers have power and idle adjustment screws Engines equipped for natural gas and propane also have a propane flow adjustment valve If necessary make the following adjustments 1 Start the engine and let the set warm up under a partial load at least 1 4 rated load If the en gine is equipped for natural gas and propane start with natural gas 2 Disconnect all loads shut down the set con nect a tachometer and disconnect the gover nor linkage at the carburetor Start the engine and close the throttle by hand so that the en gine does not overspeed While holding the throttle closed adjust the throttle idle position screw the one next to the throttle lever to ob tain an engine speed of 900 RPM Then turn the idle adjusting screw counterclockwise until engine speed becomes unstable Turn the screw clockwise just enough to regain stability and reconnect the governor linkage 3 Next connect full rated
47. plate mounting bolts should be torqued to 25 ft lbs 34 Nm Make sure the rubber O ring is in place in the bearing bore in the generator endplate The generator mounting bracket bolts should be torqued to 65 ft lbs 88 Nm if M12 or 35 ft lbs 47 Nm if M10 The generator to adaptor bolts should be torqued to 40 ft lbs 55 Nm 5 10 10 The adaptor to engine bolts should be torqued to 35 ft lbs 48 Nm Reconnect the generator as required See Pages 7 15 through 7 18 SERVICING THE PMG The following is applicable if the generator is equipped with a PMG permanent magnet exciter Testing 1 Disconnect leads P2 P3 and P4 from the volt age regulator Start the engine at the set and let the speed sta bilize HIGH VOLTAGE Touching uninsulated high voltage parts inside the control and power output boxes can result in severe personal injury or death Mea surements and adjustments must be done with care to avoid touching high voltage parts For your protection stand on a dry wooden platform or rubber insulating mat make sure your clothing and shoes are dry re move jewelry and wear elbow length insu lating gloves intended for hazardous volt ages Measure voltage across lead pairs P2 P3 P3 P4 and P4 P2 Voltage should be at least 150 VAC for 50 Hz sets and at least 180 VAC for 60 Hz sets and should be approximately the same for each set of leads If the voltages are low or uneven check all the
48. required to restore full cooling capacity See Figure 3 6 Engine Sensor Locations to locate the switch Service as required The customer has supplied the The FAULT 1 or FAULT 2 lamp comes on system fault indicating switches By means of selec when the engine shuts down tion jumpers either fault may be chosen to display the warning only See Section 3 Engine Control There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE LACKS POWER OR STABLE SPEED The governor and carburetor fuel mixture Adjust the carburetor fuel mixture and the governor ac adjustments are incorrect cording to Section 6 Governors and Carburetors If the governor cannot be adjusted for full power or stable speed shut down the set and open and close the throttle by hand to check for binding Repair and adjust the linkage as necessary A spring inside the actuator of an electronic governor will resist opening the throttle which is normal and the governor spring of a mechanical governor will resist closing the throttle Mechanical Governor Replace the mechanical gov ernor unit if it cannot be adjusted for full power or stable speed Electronic Governor
49. set might be equipped with one or more of the following components Mechanical Overspeed Switch Standard The mechanical overspeed switch is bolted to the end of the generator rotor shaft 1 Check overspeed cutout RPM and turn the ad justment screw if necessary so that shutdown occurs within the following RPM ranges 60 Hz Sets 2000 to 2200 RPM 50 Hz Sets 1800 to 2100 RPM 2 Replace the switch if the cutout speed adjust ment results in an air gap between the magnet and the fly arm of less than 0 005 inches 0 13 mm 3 Torque the center rotor bolt to 40 ft lbs 54 Nm when replacing the switch Electronic Overspeed Module Optional PMG excited generators are equipped with an elec tronic overspeed module in the control box The module senses PMG output frequency to determine generator speed frequency Adjust the overspeed HIGH pot to cut out at 1800 to 1900 RPM for 50 Hz sets and 2100 to 2200 RPM for 60 Hz sets MODE switch must be set to zero 3 7 CUTOUT SWITCH ASSEMBLY SWITCH CONTACT BRACKET SWITCH COVER CUTOUT RPM ADJUSTMENT SCREW Es1860s SCHEMATIC J2 6 55 FIGURE 3 7 MECHANICAL OVERSPEED SWITCH A11 TB1 5 A11 TB1 10 VR P3 VR P2 OVERSPEED NOT ADJUSTMENT USED POT 51 HIGH Y f 24 2 22 E l4 Il I2 11 1 1 FIGURE
50. to restore operation First pull the emergency stop switch button and then push the panel Stop and Reset switches The set is stopped manually by pressing the panel Stop switch or automatically by a remote controller The panel switch must be in the Re mote position for remote automatic opera tion If the starter disconnects normally but the panel Run indicator lamp does not light the DC K14 starter disconnect circuit is not working Ifthe starter disconnects normally but neither the panel nor the remote Run indicator lamps light the AC K10 starter dis connect circuit is not working On newer ECM boards those having automotive type fuses Ifthe starter disconnects normally but neither the panel nor the remote Run indicator lamps light the AC K10 starter dis connect circuit is not working Both the remote and the panel Run indicator lamps will light even if the DC K14 starter disconnect circuit is not working Check the DC voltmeter to determine whether or not the battery charging alternator is working 4 Troubleshooting These troubleshooting charts are designed to help you think through generator set problems To save time troubleshooting read the entire manual ahead of time to understand the generator set Try to think through problems Go over what was done during the last service call The problem could be as simple as an empty fuel tank closed fuel shutoff valve loose wire blown fuse or
51. tripped circuit breaker There are hazards present in trou bleshooting that can cause equipment damage severe personal injury or death Troubleshoot ing must be performed by qualified persons who know about fuel electrical and machinery hazards Read the safety precautions inside the front cover and carefully observe all instruc tions and precautions in this manual THE ENGINE DOES NOT CRANK The Run Stop Remote switch is at Stop The Switch Off light will be flashing if provided The Emergency Stop switch has been used No fault lamp is on A Fault Shutdown is being indicated by one of the red lights on the control panel Cranking voltage is too low to crank the engine Continued on next page Push the Run Stop Remote switch to Run or Re mote Pull the Emergency Switch button To reset the con trol push the Run Stop Remote switch to Stop and the Reset switch to Reset Then push the Run Stop Remote switch to Run or Remote Service the set as necessary To reset the control push the Run Stop Remote switch to Stop and the Reset switch to Reset Then push the Run Stop Re mote switch to Run or Remote Clean and tighten or replace the battery cable connec tors and cables at the battery and the set Recharge or replace the battery Specific gravity for a fully charged battery is approximately 1 260 at 80 F 27 C If the set is in standby service install a battery charger There are haz
52. 0 VOLTS IF VOLTAGE REGULATOR U Uetrio ONAN P N 300 3606 INSULATE AND TIE BACK 5 7 gt u2 T4 7O 4 8 PTU H3 02 4 T9 8 PTU H2 BEMERATOIS TAB STATOR LEADS eo fU R S is 3 240 480 VOLTS IF VOLTAGE REGULATOR SX440 ONAN P N 300 3607 IS SPECIFIED CONNECT TRANSFORMER EXHSEDOMER e UE W5 N TO VR21 P2 AND PTU PTU 600V H3 X2 AUX 8 H2 x2 AUX 8 JPMG OPTIONAL 240 TBI 8 U EXC FIELD XI DN TBI I 5 PTV VOLTAGE 600V AUX 7 JUMPER W5 T9 TBI 2 6 600V H3 AUX 7 7 V 480V H2 240V H 7 v 480V H2 K2 KI P2 P4 52 1 A2 AI XXXX X 8 7 6 3 2 JUMPER _ o o o o o o AUXILIARY TERMINAL xi Bec LI S ee 2 C7 BLOCK PTW gt K2 KI P4 52 51 2 XX XX X 8 7 6 3 2 600V H3 x2 H2 x2 AUX 6 AUX 6 7 TBI 6 8 6 we YN Ho 240V m 6 W VOLTAGE REG HI XI i TB2 1 TB21 26 iiis VOLTAGE REG COMMON amp OVERSPEED OPTIONAL 5 1821 26 COMMON JUMPER TB2 2 AUX 6 5 21 26 3 REFERENCE ONLY H REFERENCE ONLY id JUMPER O 2 4 AUX 7 CONTROL INPUT REF NOTE JUMPER 21 21 TO 21 24 NOTE JUMPER 21 21 TO 21 24 6 OR 12 LEAD IN THE CONTROL IN THE CONTROL CONTROL AUX E TB2 6 AUX 8 INPUT TERM STAR DELTA D OR CONTROL 347 600 240 480V TBO 22 8
53. 0V 60HZ R067 260 450V 50 60HZ 8109 230 400V 50HZ 8029 110 220V R046 110 220V R046 115 230V 50HZ 71 120 208V 50 60HZ RO98 240 416V 50 60HZ R003 277 480V 60 HZ R002 115 230V 60HZ RO41 115 230V 50HZ RO41 120 240 60HZ 106 127 220 50 60HZ 8020 255 440V 50 2 R023 266 460V 60HZ RO27 120 240 60HZ RIO4 120 240 60HZ 8104 RANGE RANGE RANGE RANGE RANGE 100 120 200 240 VOLTS 110 139 190 240 VOLTS 220 277 380 480 VOLTS 100 120 200 240 VOLTS 100 120 200 240 VOLTS 49 LI U End 1 00 Ld LI U 2 CT2 CT22 xL 4 L2 V UICTI 5 UA u2 T4 02 4 3 WI T3 1 LO W V T10 LO NJ U L2 v 5 7 U6 T10 astro vi T2 Wl 3 5 9 2 76 6 712 U6 TIO N 23 22 HELZ W L3 W was ILL 2 Ww EO SERIES DELTA PARALLEL STAR SERIES STAR DOUBLE DELTA 3 PHASE 4 WIRE 3 PHASE 4 WIRE 3 PHASE 4 WIRE PHASE 3 WIRE PHASE WIRE OUTPUT TERMINALS OUTPUT TERMINALS OUTPUT TERMINALS OUTPUT TERMINALS OUTPUT TERMINALS U V W N U V W N U V W N U W CENTER TAP N NOTES 5 7 T UVW PHASE SEQUENCE WITH C W ROTATION 2 76 5 Ve denm 5 e 3 dM 5244 13 FACING DRIVE END W5 T9 L v6 T 1 2
54. 2 21 24 18 15 16 26 25 28 TB21 26 TB21 22 CONNECTED TO TB11 45 WHEN GENERA TOR IS PARALLELED CONNECTED TO GENERATOR LEAD LO WHEN THE GENERATOR IS CONNECTED FOR SINGLE PHASE FIGURE 3 12 OVER UNDER VOLTAGE MODULE Over Under Frequency Module A19 The set can be equipped with an adjustable fre quency sensitive relay to shut down the set when the output frequency Hz is over or under nominal frequency by the preselected amount It is usually connected into the Fault 2 circuit Detector 12 con trols only if the over under voltage module is also provided Set points are typically 5 Hertz over and under nominal frequency 50 or 60 Hertz and reset points 3 Hertz over and under 3 12 14 12 22 21 24 18 15 16 L 26 25 28 o TB2 1 26 TB21 22 300 3141 FIGURE 3 13 OVER UNDER FREQUENCY MODULE Time Delay Start Stop Module A15 The set can be equipped with a module to delay starting and stopping when the start and stop sig nals are received from the remote controller It is ad TIME DELAY START POTENTIOMETER 11 1 2 PRIMARY START DISCONNECT A11 TB1 3 SECONDARY START DISCONNECT 11 1 5 B justable to delay starts from 1 to 15 seconds to pre vent nuisance starts in installations where momen tary power interruptions are frequent It is adjust able to delay stops 1 to 30 minutes to allow the prime source of power time to stabilize TIME DELAY STO
55. 3 WIRE NOTES OUTPUT TERMINALS OUTPUT TERMINALS OUTPUT TERMINALS OUTPUT TERMINALS OUTPUT TERMINALS U V W N U V W N U V W N U W CENTER TAP N U N UVW PHASE SEQUENCE WITH C W ROTATION FACING DRIVE END W5 N 5 U5 N Ul N U2 N N 2 347 600 VOLTS IF VOLTAGE REGULATOR 5 440 5 oo 5 V5 V 5 Vi 5 W6 P N 300 3607 IS SPECIFIED CONNECT W2 Woe VI 4 WO W W u Jo put W GENERATOR TAP STATOR LEADS 7 amp 8 TO VR21I P2 M 2 VR21 P3 REPECTIVELY INSULATE AND 6 2 99 46 6 5 79 W6 7 2 e o UI L3 TIE se TEND BACK ve V va V v2 Y WI V Ne E 76 gt 2 V6 7 9 V6 WS V6 L2 3 347 600 VOLTS IF VOLTAGE REGULATOR U2 06 U U2 U U U ONAN P N 300 3606 INSULATE AND TIE BACK 8 U2 U6 8 E U6 8 LI 9 GENERATOR TAP STATOR LEADS 6 7 amp 8 U5 WI amp JG 4 240 480 VOLTS VOLTAGE REGULATOR SX440 ONAN P N 300 3607 IS SPECIFIED CONNECT LEAD FROM WI U AND W2 VR21 P2 AND VR21 P3 RESPECTIVELY peu OPTIONAL EXC FIELD CONTROL INPUT CONTROL 8 ETE INPUT SERIES PARALLEL SERIES DOUBLE VOLTAGE DELTA STAR STAR DELTA KI P2PSPAS2SIABAIXX XX X 8 7 6 3 2 AUXILIARY 24 4 4 4 4 TERMINAL 25 6 6 6 6 BLOCK 26 5 5 5 5 JUMPER 3 Mss e a
56. 480V W T N TIE 6 LEAD BACK as s E 5 5 23 7 2 7 6 W iM W6 2 347 600 VOLTS IF VOLTAGE REGULATOR E 5 0 6 6 PTW H3 e TA ONAN P N 300 3606 INSULATE AND TIE BACK 26 55 ue od Ls eu eh GENERATOR TAP STATOR LEADS 6 7 amp 8 JUMPER 21 24 21 24 7 PTV H3 v5 6 PTV H2 U 3 240 480 VOLTS IF VOLTAGE REGULATOR SX440 05 Bi Us S TUM ONAN P N 300 3607 IS SPECIFIED CONNECT LEAD FROM WI U AND W2 TO VR2I P2 AND VR21 P3 RESPECTIVELY TRANSFORMER TRANSFORMER PTU PTU 600V AUX 8 480V H2 2 AUX 8 58 Em Md 8 U L 240V HI XI HI XI PTV TBI PTV 600V H3 2 AUX 7 END 600V H3 AUX 7 _ PMG OPTIONAL T 54 BBO Be 8 7 V 480V H2 240V JUMPER P 2 TBI 2 6 oe EXC FIELD PTW n PTH eov H2 VOLTAGE AUXG JUMPER v2 TBI 4 7 AUX 6 6 W 480V H2 240V ih 6 W 240V K2 P4 2 1 A2 AI XX XX X 8 7 6 3 HI HI Xi D U2 TBI 6 8 O o o o o o AUXILIARY TERMINAL JUMPER n BLOCK 5 TB21 26 MN _ LAC 5 21 26 COMMON 2 KI 4 2 SI 2 AI XX XX X 8 7 6 3 2 TY REFERENCE ONLY REFERENCE ONLY P N 519 1246 P N 519 1246 JUMPER 2 2 AUX 6 VOLTAGE REG REF NOTE JUMPER 21 2 TO TB21 24 1 NOTE JUMPER 21 2 TO 21
57. 5A BOX BELOW AC VOLTAGE REGULATOR ilm TB2 3 LET 5 na T82 9 LO FUEL 5A OIL PRESS GAUGE a OVERSPEED CONFIGURATION 6 ALTERNATOR CONFIGURATIONS 2 H2 MI2 EI ELECTRONIC T 24 VOLT RIS OIL PRESS MECHANICAL I2VOLT 24 VOLT 12 VOLT 24 VOLT 12 VOL 4 L Lea 54 E2 a MOTOROLA DELCO MOTOROLA 44 1 Bi 8 ET A J2 6 WATER TEMP GAUGE WATER TEM l OUTPUT P E E All l TACH HARNESS All JI 3 gt 11 1 10 26 9 09 4 RESTS s TS 1 L BI BAT lt _ ALTERNATOR AUX P3 SS SEE CERE A CONFIGURATION gt ALI TBI 5 AITTBI I a i 612 6688 sh 2042 Rev Sys CADAM Modified 8 3 95 12 LIGHT DC WIRING SHEET 2 PRIOR TO SPEC F 7 10 THIS IS A REPRESENTATIVE GENERIC ira ET ERES ded 1 SCHEMATIC WIRING DIAGRAM FOR a TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS IN
58. 8 8 25 7 24 TRANSFORMER CONNECTIONS 25 6 6 6 ASSEMBL Y 26 km 5 5 JUMPER ia 2 24 21 24 No 625 3016 sh2of2 Rev Sys CADAM Modified 8 3 95 GENERATOR RECONNECTION DIAGRAM SHEET 2 BEGIN SPEC E 7 18 TB1 10 SWITCHED OUTPUT OUTPUT TO RELAY K12 FUSED 20 5 ENERGIZED WHEN THE START SIGNAL IS APPLIED AND DE ENERGIZED AT SHUTDOWN NORMAL AND FAULT TB1 9 B INPUT BATTERY POSITIVE CONNECTION TB1 8 START SOLENOID OUTPUT TO RELAY K11 FUSED AT 20 AMPS TB1 7 B OUTPUT OUTPUT TO TIME DELAY START STOP MODULE 15 FUSED AT 15 AMPS AVAILABLE WHEN THE STARTING BATTERIES ARE CONNECTED TB1 6 REMOTE START CONNECTED TO TIME DELAY START STOP MODULE A15 CONNECT REMOTE START CONTACT OF THE AUTOMATIC TRANSFER SWITCH TO TERMINAL TB1 5 OF MODULE 15 TB1 5 GROUND TB1 4 COMMON ALARM B OUTPUT 4 AMP RATED DEVICE MAXIMUM TB1 3 RUN CONNECTED TO TIME DELAY START STOP MODULE A15 TB1 2 DC DISCONNECT CONNECTED TO TIME DELAY START STOP MODULE 15 THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET STARTER 711 no SW K12 e F4 K7 K8 K11
59. AIL B DETAIL C STATION STATION SI NC Du 52 2 5 53 12 6 54 12 1 55 56 2 5 AlI TBI 2 CRI 2 CI Al TBI 8 T26 AII TBI IO GND GI GND 9 BI BAT GND GND CONT P5 4 Jis ES JI 8 GI D ess GI B BI BAT BI BAT PI WHITE BI SW CR2 BI SW 1 8 Jie TB21 21 SUE TB2I 32 NI GND CONT T26 T26 26 GOV RED GND BLK GND 1 No 338 3308 sh 1of 1 Rev Sys Modified 7 24 95 ENGINE HARNESS BEGIN SPEC F 7 21 Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 6626 763 574 5000 International Use Power Fax 763 528 7229 Generation Cummins is a registered trademark of Cummins Inc
60. CLUDED WITH YOUR GENSET Al rhe OX ae ASSY ENGINE MONITOR 2 2 G 511 7 Dosen Al 13 5 MI2 S 7 MIS NN 811 6 FMs 5 AIS TBI 7 is SWITCHED o a ae B IN 0514 512 3 1143 12 c al See STARTER SOLENOID E F AN S5 7 OUT 15 AMPS MAX i 5 Al lJ3 11 x 55 6 REMOTE START 5 B 5 GROUND BEI i 4 0 ra 82 2 COMMON ALARM 4 AMPS EDS MT 265 3 2 az A E 0811 04 105180 7 x M IRE 2 START DISCONNECT INPUT 143 8 OVERSPEED INPUT In 20505 1 52 En scs 5 4 512 S Bg 1 5 m o iS Sa SS m 1 lt amp 568 al 55 gt Ce 5 eye H 5 3 MI2 5 X amp auo is 4 el Ext 0 or lt lt A S x uu x lt E 433 2551822 0 3 8906990 gt AI2DSI6 2 1 m fepe 20815 2 Lx m CUSTOMER CONNECTIONS aas 21513 Pils 7 6 5 4 3 2 PRa e 5 4 3 2 120 14 2 JI 8 7 6 5 4 3 2 J2 6 5 4 3 1126612 5 m aj o mme wj wj 5 lt oO wo n 2 1 ZONE ge N 120V T Iz MIA GND STUD na
61. Caution This document contains mixed page sizes 8 5 x 11 or 11 x 17 which may affect printing Please adjust your printer settings according to the size of each page you wish to print Service Onon Manual GENERATOR SETS Printed in U S A 928 0500 3 92 Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS bes Beek PARE beaded ii INTRODUCTION tede ete vnb p b ED CV Rh 1 1 About This Manual 1 1 Test Equipment 25s re 1 1 How To Obtain Service 1 1 CONTROL 4t Paa S EE tad 2 1 G nefal ova pedis mire udo en e 2 1 Standard Control Panel 2 1 Optional Control Panel Components 2 1 Automatic Voltage Regulator AVR Adjustments 2 2 Principle Of Generator Operation 2 6 ENGINE CONTROL DEFENSOR DEPO prd 3 1 Control Panel ix pet edhe heed 3 1 Standard Control Components 3 1 Optional Control Components 3 2 Control Box rot tuse seda aiu mace 3 4 Engine Control Monitor e e Rena 3 4 Engine Sensor iners orm pe doe CE a o
62. ENG GND TT MIS nali 1 Al TBI 2 RI AII TBI 8 ENGINE HARNESS 5 amp Al 12 4 AllJI 7 a NOTES i ENG GND E2 Pac TE dh lu ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION GND 2 ITEM NUMBERS REFER TO DWG NO 539 0741 VERT D ILLUS STD CONTROL AND 539 0997 HORIZ 3 GAUGE RESISTORS 812 13 ILLUS 488 ARE USED ON 24V SEE SHEET 2 02 04 VERSION ONLY MOUNT BEFORE ATTACHING HARNESS FOR OVERSPEED 4 TIE ALL UNUSED LEADS INTO HARNESS CONF IGURAT ION AVEIBESEQ 26 5 GROUND BETWEEN MI amp MI2 ILLUS 477 78 IS THROUGH 20A THE FRONT PANEL BUE m DASHED LEADS INDICATE WHEN USED FE SPREE he 8 ITEMS CRI CR2 RI AND LEAD GI 3 TO AII TBI 2 PREHEAT SOLENOID ARE USED ONLY ON THE CUMMINS B amp C BLOCK ENGINES USING B 12 2 GLOW PLUGS THE DELCO MOTOROLA ALTERNATOR 0511 2 DSII I All J4 5 E wd m 9 ON SOME SETS YOU MAY HAVE THIS INTERIM SILKSCREEN E FOR BATTERY AND AND WIRING CONFIGURATION 1174 1314 8 7 56 STARTER CONNEC T ION 12 3 na af MII G 2 op All ua 7 12 3 SEE SHEET 2 2 5 3 53 6 31453 16 AI5 TBI 7 All JA4 11I 11 44 10 Al J4 6 GND STUD T FOR ALTERNATOR DETAIL A Em CONNECTIO A SEE SHEET 2 SEE NOTE 9 x ENG GND No 612 6686 sh 1of2 7T LIGHT DC WIRING SHEET 1 BEGIN SPEC F 7 11 Rev Sys CADAM Modified 8 7 95 THIS IS A REPR
63. ESENTATIVE GENERIC SCHEMAIIC DIAGRAM SCHEMATIC WIRING DIAGRAM FOR gt Bt Dsi All INTERNAL CONN FOR REF ONLY GNITION SYSTEMS TROUBLESHOOTING REFER TO THE PANEL LAMP WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET ASSY ENGINE MONITOR 251 LAMP TEST DIESEL APPLICATIONS GAS GASOLINE APPLICATION EE 44771 RESET PANEL FUEL SOLENOID 4 6 LAMP PREHEAT 26 26 amp 10 lt RM eH 5 e C e RUN 3 iB 4 Iz 12 4 4 64 AI5 TBI 7 K KI STOP 2 2764 1 5 Q SIA gn 1 JA 7 8 te REMOTE Br ene CONF IGURA ONS m Nu FORD
64. GURATION X AE SS A ITBI 10 CONF IGURATIONS 1 5 AITTBI I STARTER CONF IGURATIONS GND No 612 6487 sh 20f2 Rev Sys CADAM Modified 8 3 95 7T LIGHT DC WIRING SHEET 2 PRIOR TO SPEC F 7 8 RIGHT SIDE WALL HORIZONTAL RIGHT SIDE DOOR BACK WALL VERTICAL REAR INSIDE VIEW THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE NS WIRING DIAGRAM PACKAGE THAT WAS ALI 0511 INCLUDED WITH YOUR GENSET PCB ASSY ENGINE MONITOR NOST C mme 1123 5 A TB EM MI2 S 2 d MII S 005130 Kd Al 13 13 MEAIB IS 4 Norse SWITCHED B 05140 BI BAT 09 IN o 2 3 0312 NS STARTER SOLENOID 2 PS RI I B OUT 15 AMPS MAX ITA 95191 11 3 11 LU 77
65. HE DIODE PIGTAIL FROM THE TERMINAL AND MEASURE ELECTRICAL RESISTANCE BETWEEN THE PIGTAIL AND THE METAL PLATE UNDER THE DIODE DIODE PLATES TWO sistance is high or low in both directions replace the diode Replacing Diodes Make sure the replacement diode is of the correct polarity Disconnect the pigtail from the terminal post and unscrew the old diode Apply heat sink compound under the head of the diode Make sure the compound does not get on the threads Torque the diodes to 36 to 42 in lbs 4 to 4 8 Nm and the pigtail terminals to 24 in Ibs 2 7 Nm when reassembling Surge Suppresser Testing and Replacement Remove the suppresser Replace the suppresser if it appears to have overheated or if ohmmeter read ings indicate less than infinite resistance end of scale in both directions Torque the terminals to 24 in lbs 2 7 Nm when reassembling Layers of dust can cause diodes to overheat and fail Brush dust off regularly TERMINAL ONE OF SIX SURGE SUPPRESSER REMOVE TO TEST 201 3434 FIGURE 5 3 TESTING THE ROTATING RECTIFIER ASSEMBLY Exciter Rotor Testing Winding Resistance Disconnect the six rotor winding leads from the terminal posts on the rectifier assembly With a Wheatstone bridge mea sure electrical resistance across each pair of rotor windings U CR1 or CR4 and V CR2 or CR5 V CR2 or CR5 and W or CR6 W or CR6 and U CR1 or CR4 See the winding sche MEASURE WIND
66. I SWITCH OIL PRESS LOP 2 CUSTOMER CONNECTIONS aa STARTER PILOT SOLENOID 7 6 5 4 3 2 P2 6 5 4 3 2 1104 2 PREHEAT SOLENOID GLOW PLUGS JI 8 7 5 4 3 4046 5 4 3 2 725622 A KI FUEL SOLENOID x P G ALTERNATOR O u 9 2 al d al a 8 c2 E2 SENDER WATER TEMP lt D SENDER OIL PRESSURE 8T BATTERY STORAGE 5 BI STARTER amp SOLENOID REF DES DESCRIPTION NS TO AC i ENGINE PARTS LIST ABOVE SHOWN FOR REFERENCE ONLY ZONE 2 zi D 120V MIA GND STUD O GO MIS H 142 T 4 Al TBI 2 CRI L AII TBI 8 ENGINE HARNESS SI E NOTE 2 12 4 ALL COMPONENTS SHOWN IN DE ENERGIZED POSITIO ENG GND 2 2 ITEM NUMBERS REFER TO DWG NO 539 0741 CR2 S PM EE VERT D ILLUS STD CONTROL AND 539 0997 HORIZ d he a 3 GAUGE RESISTORS 12 13 ILLUS 88 ARE USED ON 24V 02 04 VERSION ONLY MOUNT BEFORE ATTACHING HARNESS ave 4 TIE ALL UNUSED LEADS INTO HARNESS SEE SHEET 2 ALITBI 10 5 GROUND BETWEEN MII amp MI2 ILLUS 77 78 IS THROUGH OVERSPEED aes 26 FRONT PANEL BONG LOIRE T LON 20A 6 DASHED LEADS INDICATE WHEN USED a 8 ITEMS CRI CR2 RI AND LEAD 61 5 AII TBI 2 SEE SHER SS ARE USED ONLY ON THE CUMMINS B amp C BLOCK ENGINES USING PREHEAT SOLENOID THE DELCO MOTOROLA ALTERNATOR Dsil 2 ALL J4 S S5 GLOW PLUCS 9 ON SOME SETS YOU MAY HAVE THIS INTERIM SIL
67. INDING RESISTANCE BETWEEN THE TWO STATOR LEADS X AND XX FLASHING THE FIELD SELF EXCITED GENERATORS ONLY APPLY 110 TO 220 VAC TO THE EXCITER STATOR FOR 1 TO 2 SECONDS WITH THE AVR DISCONNECTED AND THE SET NOT RUNNING 3 DIODE FUSE 110 to 220 EXCITER VAC STATOR ee ALTERNATIVELY APPLY 12 VDC FROM BATTERY TO THE EXCITER STATOR FOR 1 TO 2 SECONDS WITH THE AVR CONNECTED AND THE SET RUNNING WITHOUT LOAD DIODE 12 VDC EXCITER BATTERY STATOR 220 4293 FIGURE 5 2 TESTING AND FLASHING THE EXCITER STATOR Exciter Rectifier Bridge Rotating Rectifier Assembly The exciter rectifier bridge is mounted on the exciter rotor inboard facing the main rotor It consists of a positive plate and a negative plate split diametrical ly Each carries three diodes three terminal posts for connecting exciter rotor leads to the diode pig tails and a terminal for the main rotor generator field lead A surge suppresser is connected across the two plates to prevent transient voltages that could damage the diodes Testing Diodes Disconnect the diode pigtails from the terminal posts Using an ohmmeter measure electrical resistance between each diode pigtail and the plate on which the diode is mounted Reverse the meter test probes and repeat the tests The electrical resistance across each diode should be high in one direction and low in the other If the re DIODE ONE OF SIX DISCONNECT T
68. ING INSULATION RESISTANCE BETWEEN ANY LEAD OR THE TERMINAL TO WHICH IT IS CONNECTED AND THE ROTOR LAMINATIONS matic Replace the exciter rotor assembly if the re sistance of any winding is not as specified in Table 5 1 Testing Winding Insulation Resistance Using a megger voltage set at 600 VAC or less measure the resistance between any rotor winding lead or the terminal to which it is connected and the rotor laminations Replace the whole rotor shaft assem bly if insulation resistance is less than 1 megohm MAIN ROTOR LEADS DISCONNECT THE SIX ROTOR WINDING LEADS FROM THEIR TERMINALS AND MEASURE ELECTRICAL RESISTANCE ACROSS EACH PAIR OF WINDINGS U V V W W U FIGURE 5 4 TESTING THE EXCITER ROTOR 5 4 Main Rotor Generator Field Testing Winding Resistance Disconnect the two leads of the main rotor from the terminals on the ro tating rectifier assembly See Figure 5 4 Measure electrical resistance between the two leads with a Wheatstone bridge or digital ohmmeter Replace the rotor if the resistance is not as specified in Table 5 1 Connect the rotor leads and torque the termi nals to 24 in lbs 2 7 Nm when reassembling Testing Winding Insulation Resistance Using a megger voltage set at 600 VAC or less measure the resistance between either lead of the main rotor windings or the terminal to which it is connected and the main rotor laminations Replace the rotor if insulation resistance is less t
69. IPs 8 5 11 1 9 fon LTBI KI4 E ae 2 TBI 5 RUN 5 BLACK YELLOW STRIPE TI E L i 4 Br t ALT START DISC c L 1 l 1 PRE LoP 5 9 d 2 STARTER we 8 54 8 7 a TBI M A TB2 5A 5 24V 75 Hs wo Geo 8 IGURATIONS PREHEAT SOLENOID GLOW PLUGS HI OUTPUT MOTOROLA L F2 SB 19 20s 5 SW TO GAUGES 122 24 VOLT BE TB2 OC 5A BTI BTS SHUT DOWN MIA Ter A Q 15 15 ey 4 FLT 5A NOTE RECTIFIER BRIDGE MOUNTED os METER ON INSIDE BACKWALL OF CONTROL MI 2 FLT 2 5 BOX BELOW AC VOLTAGE REGULATOR RI2 4 3 LET 5 44 4 OIL PRESS GAUGE 15 LO FUEL 54 A 9 sw OFF OVERSPEED CONFIGURATION ALTERNATOR CONFIGURATIONS 2 EI ELECTRONIC MECHANICAL I NS 7 2L PRESS 77 I2VOLT 24 VOLT 2 VOLT 24 VOLT 2 VOLT 24 VOLT 1 E2 22 6 BOSCH MOTOROLA DELCO MOTOROLA xm il 874 2 WATERS GAUGE WATER TEMP All d QUTPUT _ sno 7 TO ENG HARNESS
70. KSCREEN 81 7 11 4 AND WIRING CONFIGURATIO 25 45 42 2 512 3 MII G All J4 7 di 514 2 LL FOR BATTERY AND 3135 Sele 3153216 S6 STARTER CONNECTION 15 1 7 11 4 11 All J4 10 11 04 6 ad Al 12 3 SEE SHEET 2 T FOR ALTERNATOR SEE NOTE 9 2 Eon 2 E No 612 6687 sh 1 of2 Rev Sys CADAM Modified 8 7 95 12 LIGHT DC WIRING SHEET 1 BEGIN SPEC F 7 13 THIS IS REPRESENTATIVE GENERIC SCHEMATIC DIAGRAM SCHEMATIC WIRING DIAGRAM FOR gt we 0511 All NOTE AII INTERNAL CONN FOR REF ONLY GNA T TON SYSTEMS TROUBLESHOOTING REFER TO THE
71. LER APPLICATIONS SPARK IGNITION J3 P3 Q 0 21 CA C RERET BRN WHT STRIPE Lo FUEL 0822 ue MODL GRAY 2VDC iss TS 2 FORD NON SOLENOID SHIFT SW OFF 4 Al TBI 9 23 P3 LAMP T RST PINK C Bis MES a B xl 5 14 LO FUEL IN SOR 1 Bi ON Aha TAS FLT IN 51 027 M 8 Sw TO WD 120VAC JI IP F4 3 mE E va AT ZONE 6 TB2 1 FLT 2 IN GI OUT Mel AIITBI 8 8 7 RUN 5A EXE L V TO CR ALT START DISC eil B BLACK YELLOW STRIPE TI 5 gr STARTER Sio TB2 PRE HET 5 d TEE 9 Lop cso 5 24V 75 CR am 8 HET GURATIONS PREHEAT SOLENOID GLOW PI HI OUTPUT MOTOROLA 2 Ke 9 H 2 5 END SW_B TO GAUGES 12 VOLT 24 VOLT I E PED EB 6 5A BT GND TB2 SHUT DOWN 5 M 15 1 7 MIA Ted 7 B CI5A V FLT 5A NOTE RECTIFIER BRIDGE MOUNTED ON INSIDE BACKWALL OF CONTROL 2 FLT 2 5 BOX BELOW AC VOLTAGE REGULATOR RI2 5 546 TB2 LET 5A m 15 LO FUEL 5A A sw
72. NTROL PANEL The control box is mounted on top of the generator facing the rear Figure 3 1 shows the components on the engine control panel STANDARD CONTROL PANEL COMPONENTS Run Stop Remote Switch 12 The switch is pushed to the Run position to start and run the gen erator set and the Stop position to stop the set The Remote position allows a remote controller to auto matically run the set The switch must be in the Stop position when the reset switch described next is used to restore generator set operation following a fault shutdown OIL PRESSURE COOLANT TEMPERATURE GAUGE DC VOLTMETER OIL TEMPERATURE GAUGE RUN STOP REMOTE PANEL SWITCH LIGHT Reset Lamp Test Panel Lamp Switch S11 The switch is pushed to the Reset position momentary contact to reset the engine control to restore opera tion following a fault shutdown The Run Stop Re mote switch must be in the Stop position for reset to occur The Lamp Test position momentary con tact lights all the fault indicator lamps Replace lamps that do not light The Panel Lamp position lights the panel illumination lamp Pressure Gauge M11 The oil pressure gauge indicates engine oil pressure Coolant Temperature Gauge M12 The coolant temperature gauge indicates engine coolant tem perature RESET LAMP TEST PANEL LIGHT SWITCH INDICATOR LAMPS Remote Panel Lamp SPEED ADJUSTING RHEOSTAT Frequency TACHOMETER EMERGENCY
73. OUTPUT TO LIGHT RELAY eese s Deci dass Sue theres TB2 10 PRE HIGH ENGINE TEMPERATURE WARNING GROUND OUTPUT TO LIGHT RELAY TB2 11 PRE LOW PRESSURE WARNING GROUND OUTPUT LIGHT RELAY CUSTOMER SUPPLIED WIRING 5 420 TB2 12 SWITCH OFF WARNING GROUND OUTPUT TO LIGHT RELAY i FACTORY WIRING TB2 13 LOW ENGINE TEMPERATURE WARNING GROUND OUTPUT TO LIGHT RELAY S 0 5 RATED DEVICE MAXIMUM TB2 14 LOW FUEL WARNING GROUND INPUT FROM SENDER M d EE TB2 15 LOW FUEL WARNING GROUND OUTPUT TO LIGHT RELAY TB2 16 EMERGENCY SHUT DOWN MOMENTARY CONTACT TO GROUND p r 300 2811 FACTORY AND CUSTOMER CONNECTIONS AT THE ENGINE MONITOR BOARD TERMINALS 7 19 0 0 ISOLATED 0 0 0 COMMON ALARM N C 0 N C 0 0 RUN 0 N C TBe
74. P POTENTIOMETER A11 TB1 6 REMOTE START A11 TB1 7 CONTROL A11 TB1 7 1855 FIGURE 3 14 TIME DELAY START STOP MODULE 3 13 SEQUENCE OF OPERATION The sequence of operation is as follows Refer to the schematic on Page 7 8 7 10 7 12 or 7 14 as appropriate 1 is powered battery age 24 VDC Terminal TB1 9 is connected to battery positive and connector P1 6 to bat tery negative The starting cycle begins when relay 7 is powered either manually by pushing the panel Run switch or automatically by a remote con troller connected at terminal TB1 6 The panel switch must be in the Remote position for re mote automatic operation Relay K7 powers relays K2 and K3 Relay K2 powers the engine gauges and termi nal TB1 10 to which the fuel solenoid and igni tion module are connected Relay K3 powers terminal TB1 8 to which start er relay K4 is connected Engine cranking be gins The engine starts and runs up to governed speed in a matter of seconds The starter is disconnected when engine speed gets to about 500 RPM This is done by relay K10 or K14 whichever acts first to open the circuit powering relay K3 Relay K10 is powered by the generator output voltage 120 VAC through plug in connectors P1 1 and P1 2 The remote Run indicator lamp should light connected through terminal TB1 3 Relay K14 is powe
75. PONSE JUMPER A TO C UNDER 90 KW TO C 90 550 KW A TO B OVER 550 KW OVER V o SELF EXCITED GENERATORS 0 I UFRO LED STABILITY RESPONSE JUMPER A TO C UNDER 90 KW B TO C 90 550 KW A TO B OVER 550 KW VOLTS FREQUENCY JUMPER 50 HZ C 50 60 HZ C 60 DROOP Q V TRIM THESE JUMPERS 2 3 4 5 AND 6 7 mNO FIGURE 2 2 VOLTAGE REGULATOR ADJUSTMENT POTS AND SELECTION JUMPERS 2 3 EXCITER ROTATING ROTOR RECTIFIERS EXCITER STATOR MAIN STATOR OUTPUT VOLTAGE SENSING LEADS NOTE 2 ISOLATION TRANSFORMER NOTE 3 INPUT OUTPUT 876 876 mr rere t WHEN PARALLELING WITH 1 A GENERATOR SET OR UTILITY TERMINALS 1 2 CONNECTING DROOP COMPENSATING CT 3 A REGULATOR VR21 ees res ne WHEN PARALLELING WITH 1 AUTILITY TERMINALS A1 FIELD CIRCUIT CONNECTING A VAR POWER FACTOR CONTROLLER NOTES 1 Connect like numbered terminals on auxiliary not connected to the isolation transformer but terminal board and voltage regulator is jumpered to voltage regulator terminal 8 2 See the appropriate reconnection diagram for 4 There must be a jumper between voltage regu connecting sensing leads 6 7 and 8 lator terminals 1 and 2 when voltage trimmer 3 When the generator is connected for single R21 is not used phase output voltage
76. RTER DISCONNECT 21 INE CONTROL WIRING DIAGRAM WITHOUT METERS 7 3 BOTTOM OF CABINET INSIDE VIEW 5 D SEE DC WIRING DIAGRAM ZONE THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET NOTES ALL COMPONE 2 ILLUSTRATIO VERT D IL 3 LOCATE ONE ON INTERIOR TS SHOWN IN DE ENERGIZE NUMBERS REFER TO DWG DANGER LABEL ON EXTE OF LEFT SIDE DOOR IN AN AREA AVAILABLE LUS STD CONTROL AND 539 D POSITION 0 559 0741 0997 D HORIZ RIOR AND ONE 1 Y READILY VISIBLE 4 SEE GENERATOR CONNECTION DIAGRAM FOR INPUT CONNECTIONS 5 SEE VOLTAGE TO VR21 CB2 HOUSING CONTROL BOX TI U6 1 T2 V6 4 T3 96 T4 06 T5 V5 7 T6 W5 4 A 7 U2 T8 V2 4 9 92 34 TIO Ul 4 TI2 TI I VI wl 4 REGULATOR INSTALLATION AND 21 FOR CONNECTIONS FIOQ0 G2 GENERATOR EXCITER FIELD 2 ARMATURE FULL WAVE BRIDGE RECTIFIER TI U6 2 6 W6 F 4 05 4 T5 V5 F 6 W5 4 TIe E T8 V2 T9 W2 73 ALTERNATOR
77. S TTS AIS TBI 7 cic ENG ag SWITCHED B 2 9 B IN 06140 512 3 Al 143 12 EN Bi SW 2 STARTER SOLENOID d RR Py RI I B OUT 15 AMPS MAX seas 13 11 g 6 REMOTE START 55 5 sROUND RN i mL T 32 4 COMMON ALARM 4 AMPS 1565 08178 3 7 O gt ful 2 run 051 00 106180 Lu 5 50 DC START DISCONNECT INPUT 13 8 8579 iX ul 120523 1 2 54 512 aes OVERSPEED INPUT Ir a H EE 120521 5 1103 7 45 7 TABULATIO NI 5 IN 2 S DASH BAT NN 1120622 2 Tu 8 6 CONTROL voi gt e2528 126 23 2 i ap ese ml eme dl as n lt 2 zy c ll E e d p esee 2 5 5 e BE 02 VERT 24V C5 120520 2 2 12 lt SEP 9 6 ps22 3 is lt 5 KH 535355326 x 2 47205782 5232 56 THERMOSTAT PRE HET A 55 SWITCH PRESS PRE LOP 009000000000900090 lolo 54 SWITCH LOW ENGINE TEMP SIS ENZDSISIS E S3 SWITCH OVERSPEED Al 13 1 E S2 THERMOSTAT HET n AI2DSI5 2 S
78. SCREEN TB2 9000 SoS SS AND WIRING CONFIGURATION C AI2DSI6 2 1 22 CARE riui 120515 2 m CUSTOMER CONNECTIONS afa L4 7 6 5 4 3 ero 4 3 m 1 ee JI 8 7 6 5 4 3 2 J2 6 5 4 3 2 1112051322 S6 THERMOSTAT PRE HET aj o 5 129 A 55 SWITCH PRESS PRE LOP 63 9 55 SWITCH OVERSPEED 5 52 THERMOSTAT 51 SWITCH OIL PRESS LOP 5 K4 STARTER PILOT SOLENOID i ii K2 PREHEAT SOLENOID GLOW PLUGS CO x ZONE 2 6 KI FUEL SOLENOID 120V J GI ALTERNATOR S e E2 SENDER WATER TEMP EI SENDER OIL PRESSURE MIA BTI BATTERY STORAGE STARTER amp SOLENOID GND STUD REF DES DESCRIPTION ENG GND M 5 ENGINE PARTS LIST ABOVE SHOWN FOR REFERENCE ONLY 19 lt ce 1 Al TBI 2 ALI TBI 8 ENGINE HARNESS SI E 2 L Al 12 4 AllJI 7 S 52 2 1141 8 EC ENG Al 12 5 bees GND an n 0511 2 0511 1 All J4 5 8 y 1174 1 4 2 512 3 MII G ALI J4 7 FOR OVERSPEED Motu aM ahs 2 2 CONFIGURATION Jeg 353 6 20 26 AI5 TBI 7 AlI J4 1 AlI J4 10 All J4 6 Al 12 1 A SEE SHEET 2 DETA 1 PREHEAT SOLENOID 55 GLOW PLUGS S NOTE 9 2 2 ae FOR BATTERY AND S6 STARTER NECTION TABULATIO AIIJ2 3 SEE SHEET 2 DASH contro NO VOLTS GND STUD FOR A ERNATOR 01 VERT 12V S
79. SPEC E 7 17 THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE C 5 N R WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET 3 PHASE RECONNECTABLE 3 PHASE NON RECONNECTABLE CURRENT TRANSFORMER SECONDARY CONN 2 CURRENT TRANSFORMER SECONDARY CONN 2 SO GO GONER 220 440V 50 HZ ROI9 240 480V 60 HZ RII9 ET ET LOU L I U W6 T12 7 UlCTI SEE NOTE 8 U6 TIO U2 T4 22 05 17 L2 V Ue TI VICT2 WELT 2 T5 SEE NOTE amp 2 5 9 W2 T6 CT23 73 Lois LO N SERIES STAR SERIES DELTA 5 PHASE 4 WIRE 5 PHASE 4 WIRE OUTPUT TERMINALS QUTPUT TERMINALS NOTE U V W N U V W N OTES 347 600 VOLTS IF VOLTAGE REGULATOR SX440 N We T12 P N 300 3607 IS SPECIFIED CONNECT 5 MC W2 T6 re 5 GENERATOR TAP STATOR LEADS 7 amp 8 TO VR21I P2 Wins wi amp VR21 P3 REPECTIVELY INSULATE AND W2 T6 0 6 PTW Hz TIE 6 LEAD BACK V E Uu 2 347 60
80. ST RED PINK 57 os L4 STARTER 03 fes 5 GI OUT Sr 1 pI o Ji TO AC WD 120 yis 1 ei 9 4 26 n T 11 1 8 ZONE 6 2 gt RED S abr RR 3 LTBI KI4 2 qT AlITBI 8 KY All TBI 9 ALT START DISC d 2 an TB2 PRE LOP 5A B BLACK YELLOW STRIPE TI aa 4 rer ar 3 5A 2 STARTER SOLENOID 5 RI I 208 1 9 LOP 5 2 B 5 5 24V 75 AMP E BATT GURATIONS EAT SOLENOID GLOW PLUGS HI OUTPUT MOTOROLA Tels Ke 7 OS 5 3 SW B 19 SacBee BAUER 8445 NEM 12 VOLT 24 VOLT 13 J4 5A F5 i BTI BTI AI5 TBI 7 MIA F3 TBI GND Paw OMA 7 B 15A NOTE RECTIFIER BRIDGE MOUNTED HOUR METER ON INSIDE BACKWALL OF CONTROL A BOX BELOW AC VOLTAGE REGULATOR RIZ 4 OIL PRESS GAUGE A OVERSPEED CONFIGURATION ED ALTERNATOR CONFIGURATIONS i press E 2VOLT 24 VOLT 12 VOLT 24 VOLT I s 7 Ed MECHANICAL 12 VOLT 24 VOLT L ANN mir PIC UI Eo BOSCH MOTOROLA DELCO MOTOROLA WATER E cauce 89 2 2 92 6 WATER TEMP TACH GND All JI 3 4d Al TBI 10 ENGINE TIE POINT 26 xc call 1 STI DIODE BI BAT output CONFI
81. T ADJUST 5 6 7 18 20 21 23 24 25 26 27 28 29 30 31 01 x eqs e 02 x x mp EX CH aa 2 ee NO 300 3606 05 x 2 4 4 4 REV G SX 03 amp 04 ARE QUIET SITE I amp II WITH RECONNECT PANEL MODIFIED REGULATOR IS CONNECTED FOR 2 PHASE SENSING VOLTAGE REGULATOR INSTALLATION PMG EXCITED GENERATORS 7 5 T gt SEE NOTE THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR 8 3 2 8 TROUBLESHOOTING REFER THE WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET 2 LEFT DOOR REAR VIEW fl BACK WALL OF CABINET 7 4 21 N x GN e 2 VRP be El a IT LL pes Br 4 N d LII ES LA E
82. The choke housing cover can be rotated to adjust the choke The perimeter of the cover is graduated with evenly spaced lines cast in it One of the lines has an asterisk For normal adjustments the as terisk should line up with the line cast in the edge of the housing 1 For better starting in cold weather loosen the three cover screws and rotate the cover clock wise richer so that the asterisk is one or two lines past the line on the housing and re tighten the cover screws For better starting in warm weather loosen the three cover screws and rotate the cover coun terclockwise leaner so that the asterisk is one or two lines past the line on the housing and re tighten the cover screws FUEL FILTER FUEL SHUTOFF SOLENOID IDLE ADJUSTMENT SCREW ON OTHER SIDE FIGURE 6 8 GASOLINE CARBURETOR 6 8 Gaseous and Combination Fuel Systems An engine equipped for gasoline and natural gas or propane has a regular gasoline carburetor with a gas mixer mounted on the horn of the carburetor The carburetor throttle serves both fuels Each fuel has a separate shutoff solenoid valve The position of the fuel selector switch mounted at the base of the carburetor determines which solenoid valve will open for operation An engine equipped for natural gas and propane has a gas mixer that serves both fuels Each fuel has a separate shutoff solenoid valve and either and a manual fuel selector switch
83. ards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE DOES NOT CRANK CONT Continued from previous page Fuse F1 on the ECM A11 board has Replace the fuse with one of the same type and amp blown rating If fuse F1 blows again the wire between ECM terminal TB1 8 and starter relay K4 terminal S may be loose or damaged causing a short to ground Repair as neces sary If fuse F1 still blows replace starter relay K4 Check for battery voltage 12 VDC between ter minal TB1 9 and the grounding stud on the floor of the control cabinet Check clean and tighten the connectors at both ends and replace the wire if it is damaged The wire between ECM terminal TB1 9 and starter relay K4 terminal BAT is loose damaged or missing Check for electrical continuity zero ohms between the the grounding stud on the floor of the control box and the battery negative terminal If there is no electrical continuity check for loose damaged or missing grounding straps and repair as necessary A grounding strap between the control box and the battery negative terminal is loose damaged or missing Disconnect pin connector
84. aulty Replacing the voltage regulator be fore servicing other faults can lead to damage to the new voltage regulator There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE FIELD CIRCUIT BREAKER KEEPS TRIPPING Shut down the set and check each diode according to Section 5 Servicing the Generator Service as neces sary The rotating rectifier assembly diodes CR1 through CR6 is faulty Shut down the set and check exciter field winding re The exciter field winding is faulty open or sistance according to Section 5 Servicing the Genera shorted tor Replace the exciter field assembly if winding re sistance does not meet specifications Shut down the set and check exciter winding resist The exciter rotor windings are faulty ances according to Section 5 Servicing the Genera open or shorted tor Replace the generator rotor assembly if exciter ro tor winding resistances do not meet specifications Shut down the set and check main rotor winding resist The main rotor winding is faulty open or ance according to Section 5 Servicing the Generator shorted Replace the generator rotor assembly if main rotor winding resistance does not m
85. ble first and reconnect it last Make certain hydrogen from battery engine fuel and other explo sive fumes are fully dissipated This is es pecially important if battery has been con nected to battery charger 2 Remove the PMG cover Figure 5 8 and dis connect the leads at the connector 3 Remove the bolts and clamps that secure the PMGi stator to the generator frame and careful ly pull away the stator The rotor is magnetic and will attract the stator Hold the stator firmly so that the windings are not damaged by striking the stator support lugs 4 Remove the rotor center bolt and pull away the rotor The rotor is magnetic and will attract iron filings Put it clean plastic bag until it is re mounted Do not take it apart or it will lose its magnetism Also if the dowel pin in the end of the shaft is loose stow it in a safe place until it is time to reassemble the PMG Reassembling the PMG The rotor is magnetic and will at tract the stator When installing the stator hold the stator firmly and keep fingers out of the way to prevent pinching of fingers between stator and generator assembly Reassembling is the reverse of disassembling Torque the rotor center bolt to 40 ft lbs 54 Nm The stator leads must be at 12 o clock STATOR PMG STATOR CLAMP PMG ROTOR THROUGH BOLT FIGURE 5 8 PMG ASSEMBLY 6 Governors and Carburetors MECHANICAL GOVERNOR Figure 6 1 Make the frequency adjustment un
86. carburetors with the ap propriate carburetor kit according to the kit instruc tions Adjust fuel mixture and choke according to Sec tion 6 Governors and Carburetors The carburetor fuel passages are clogged or the choke needs adjustment gasoline fueled sets The engine ignition system is malfunc distributor spark plugs high tension Service according to the engine service manual spark plug and coil cables and timing Th ngine is malfunctioning mechani cal matunctoning mecha Service according to the engine service manual There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE RUNS UNTIL FAULT SHUTDOWN Reset the ECM by pushing the Run Stop Remote switch to Stop and the Reset switch to Reset and re comes start the set monitoring engine speed Readjust the 9 cutout speed if it is lower than specified See Section 3 Engine Control If the set still shuts down due to overspeed open and close the throttle by hand to check for binding Repair and adjust the linkage as necessary according to Sec tion 6 Governors and Carburetors A spring inside the actuator of an electronic governor will r
87. cates that the fuel level in the supply tank has dropped to less than the reserve necessary to run the set at full load for the prescribed number of hours The customer has to make connections to use this lamp Fault 1 Red This lamp indicates that the en gine shut down because of a system fault The customer has to make connections to use this lamp The lamp is a part of a 10 second time delay shutdown circuit The customer can make reconnections for non timed shutdown See Engine Control Monitor ECM e Fault 2 Red This lamp indicates that the en gine shut down because of a system fault The customer has to make connections to use this lamp The lamp is part of a non time delay shut down circuit The customer can make recon nections for 10 second time delay shutdown See Engine Control Monitor ECM Switch off Flashing Red This lamp indi cates that the Run Stop Remote switch is in the Stop position which prevents remote au tomatic operation LOW RADIATOR COOLANT LEVEL SWITCH S7 SWITCH TERMINALS S2 OR S6 CHOUND SIG POS SWITCH SWITCHED LAN S2 OR S6 B T26 na SWITCHED B 126 T TEST 515 USED ENGINE GROUND SCHEMATICS WARNING ONLY PRE HET S6 FIGURE 3 3 LOW COOLANT LEVEL SWITCH ENGINE CONTROL MONITOR A11 TIME DELAY VOLTAGE REGULATOR VR21 TERMINAL BOARD START STOP MODULE A15 21 RUN RELAYS K11 NOT SHOWN
88. ch is in the Run position the control will attempt to crank the engine for approxi mately 75 seconds including two rest periods and then the red OVERCRANK lamp will light if the engine does not start If the OVERCRANK lamp comes on reset the control by pushing the Run Stop Remote switch to Stop and the Reset switch to Reset Then push the Run Stop Remote switch to Run or Remote The engine is not getting fuel If the set is SdHIpped vith tHe apre nan Ow TegHe oy Open any closed shutoff valve in the fuel line supplying the engine shutdown feature and the red FAULT 1 or FAULT 2 lamp is on the set probably ran out of fuel Fill the main fuel supply tank if the set is gasoline or propane fueled For natural gas fueled sets check with the gas utility Fuse F2 on the ECM board A11 has Replace the fuse with one of the same type and amp blown rating If fuse F2 blows again the wire between ECM terminal TB1 10 and engine block terminal T26 may be loose or damaged causing a short to ground Repair as nec essary See Figure 3 3 to locate terminal T26 If fuse F2 still blows a wire between the ignition coil fuel solenoid or ignition module and terminal T26 may be loose or damaged causing a short to ground Re pair as necessary Connect the terminal on fuel solenoid K1 to the BAT Fuel solenoid K1 is faulty does not terminal on starter relay K4 with a jumper wire Re open place the fuel solenoid if it does
89. cket To adjust the link 3 The governor actuator shaft has 60 degrees of 1 With the genset stopped check the angle of the rotation from stop to stop Check mounting of throttle lever and governor actuator Adjust gov governor arm and linkage to assure the 60 de ernor lever if required Throttle is shown in the gree actuator shaft rotation operates the throttle closed position from closed to fully open positions GOVERNOR ARM OUTSIDE END GOVERNOR THROTTLE LEVER BALL JOINT E BALL JOINT SCREW SCREW FIGURE 6 6 GOVERNOR LINKAGE 6 6 Magnetic Speed Pickup Unit Adjustment Begin Spec F With the magnetic speed pickup removed from the genset manually rotate the ring gear until a tooth MAGNETIC SPEED PICKUP UNIT x FIGURE 6 7 MAGNETIC SPEED PICKUP UNIT lines up in the center of the mounting hole Thread the sensor in gently by hand until it just touches the ring gear tooth Back it out 5 8 turn and set the lock nut TO GOVERNOR GENERATOR ADAPTER 6 7 The engine is equipped with carburetor to run regular gasoline and or a gas mixer to run on natu ral gas or propane or both Fuel is highly flammable and may cause severe personal injury and property dam age Do not allow cigaret
90. ctrical resistance between any stator lead and the stator laminations Replace the stator if insulation resistance is less than 1 megohm Testing For Shorts Using a megger voltage set at 600 VAC or less measure electrical resistance be tween each winding for example U1 U2 to U5 U6 U1 U2 to V1 V2 etc Replace the stator if insulation resistance is less than 1 megohm WHEATSTONE BRIDGE FIGURE 5 6 TESTING THE GENERATOR STATOR 5 6 TABLE 5 1 GENERATOR WINDING RESISTANCES MAIN STATOR EXCITER EXCITER PART STATOR ROTOR NUMBER OHMS 220 4289 31 220 4289 32 220 4289 33 220 4289 34 220 4289 35 220 4298 31 220 4298 32 220 4298 33 220 4298 34 220 4298 35 220 4298 36 220 4289 31 220 4289 32 220 4289 33 220 4289 34 220 4289 35 220 4298 31 220 4298 32 220 4298 33 220 4298 34 220 4298 35 220 4298 36 These values are approximate plus or minus 10 percent at 68 F 20 C See Figure 5 6 for the location of the stator part number 5 7 REMOVING AND DISASSEMBLING THE GENERATOR The generator is heavy You will need an assistant and a hoist of sufficient capacity to remove and ser vice the generator Accidentally dropping the genera tor can damage it and cause severe personal in jury and death The hoist straps and chains must have sufficient capacity and be attached properly so that the load cannot shift Before starting disconnect the starting battery cables negative
91. der Prior to Spec F full load after the engine has been warmed up un der at least 1 4 load If the governor hunts or if Governor Adjustment Prior to Spec F droop is excessive more than 3 Hz for 60 Hz sets or 2 5 Hz for 50 Hz sets adjust the length of the droop Output frequency 50 Hz or 60Hz can be adjusted adjusting screw accordingly by turning the governor speed adjustment screw ADJUSTING ADJUSTING VIEW A A GOVERNOR SPRING GOVERNOR GOVERNOR ASSEMBLY ROD CARBURETOR THROTTLE LEVER MOUNTING BRACKET GOVERNOR DRIVE BELT AND PULLEY ARRANGEMENT 539 1271 FIGURE 6 1 MECHANICAL GOVERNOR 6 1 ELECTRONIC GOVERNOR Prior to Spec F Electric Governor Adjustment Prior to Spec F If necessary adjust the linkage wire the controller and install the magnetic speed pickup unit as instructed in this section before adjusting the gover nor controller Also make sure that the governor linkage does not bind or have excessive play in it 1 Warm up the set under at least 1 4 load until the engine is up to its normal operating tempera ture Disconnect the load and turn the Droop Fig ure 6 2 potentiometer to zero Turn the Speed potentiometer to obtain the specified output frequency 50 Hz or 60 Hz Turn the Gain potentiometer clockwise until the governor begins to hunt Turn it back until there is no audible hunting Adjust the D potentiometer if provided the same way as the Gain potentiome
92. e THE DELCO MOTOROLA ALTERNATOR a olo oe 9 ON SOME SETS YOU MAY HAVE THIS INTERIM SILKSCREEN 2 5 6 9 9 090 09090209809 2097 9 AND WIRING CONFIGURATION LE 7 120616 2 Al 13 1 Fal 120515 2 5 CUSTOMER CONNECTIONS lix x Pils 7 6 5 4 3 2 pole 5 4 3 2 20514 2 lt 56 THERMOSTAT PRE HET 118 7 6 5 4 3 2 Jefe 5 4 3 2 5 SWITCH PRESS PRE LOP x 1525 54 SWITCH LOW ENGINE TEMP O 8 2 al ol a 9 6 53 SWITCH OVERSPEED 5 S2 THERMOSTAT HET 2 5 SI SWITCH OIL PRESS LOP Lu 2 STARTER PILOT SOLENOID Lil K2 PREHEAT SOLENOID GLOW PLUGS sd TO AC Wb KI FUEL SOLENOID WX ZONE 2 ALTERNATOR S 120 2 SENDER WATER TEMP EI SENDER OIL PRESSURE BTI BATTERY STORAGE MI4 BI STARTER amp SOLENOID O GND STUD REF DES QTY DESCRIPTION ux ENGINE PARTS LIST ABOVE SHOWN FOR REFERENCE ONLY MIS HO _ 4 1 2 CRI AII TBI 8 ENGINE HARNESS SI EI 2 1192 4 d 1o 10 2 S2 ENG GND E CR2 1192 5 AUB P a DSI1 2 0911 1 All J4 5 M ENG NEL 1 4 GND 512 3 MII G All J4 7 42 2 2 SHEETS E 21 H H OVERSPEED _ 26 als Sle 31453 16 CONF IGURATIO 20A 15 1 7 All J4 11 All J4 10 All J4 6 54 SEE SHEET 2 DETAIL A ex PREHEAT SOLENOID SEE NOTE 9
93. e safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THERE IS NO OUTPUT VOLTAGE CONT Continued from previous page Disconnect leads P2 P3 and P4 from the voltage reg ulator While the set is running check voltage across lead pairs P2 P3 P3 P4 and P4 P2 Service the PMG according to Section 5 Servicing the Generator if there is less than 150 VAC for 50 Hertz generators or less than 180 VAC for 60 Hertz generators across any pair of leads HIGH VOLTAGE Touching uninsu lated high voltage components and wiring in this compartment can result in severe personal injury or death Testing must be done with care to avoid touching high voltage parts VOLTAGE REGULATING FAULTS PMG EXCITED GENERATORS The PMG is faulty For your protection stand on a dry wooden plat form or rubber insulating mat make sure your clothing and shoes are dry remove jewelry and wear elbow length insulating gloves intended for hazardous voltages Check all connections using the appropriate wiring diagrams in Section 7 and rewire as necessary Re place the voltage regulator if the wiring is correct and there is no output voltage ACAUTION Replacing the voltage regulator be fore servicing other faults can lead to damage to the new voltage regulator Voltage Regulator VR21 is faulty VOLTAGE REGULATING FAULTS SELF EXCITED GENERATORS The field has lost its residual magne
94. e two versions of the ARB with and without the set of 12 Fault relays Figure 3 11 Page 7 20 is a detailed connection diagram for the ARB The set might instead be equipped with separate run and alarm relay modules If so see Run Relay K11 and Alarm Relay Modules A13 and A14 Terminal Blocks TB1 ARB TB1 and ECM TB1 are identically num bered and provide the same remote control connec tion points Note that additional terminals are pro vided for terminals 5 7 and 10 of ARB TB1 TB2 through TB5 Connection points for relays K1 through K3 TB2 provides the N O and N C con nections three form C contacts for each relay TB3 through TB5 provide the common connection points for K1 4 for K2 and TB5 for TB6 and TB7 Connection points for fault relays K4 through K15 Three terminals are provided for each relay which are labeled COM N C N O Plug In Relays K2 The ARB can be equipped with one to three 3 pole double throw relays These relays K1 K2 K3 are field changeable plug in relays for easy field addi tion and replacement The relay contact ratings are e 10 amps at 28 VDC or 120 VAC 8096 PF e 6 amps at 240 VAC 8096 PF e 3 amps at 480 VAC 8096 PF Each relay can be operated as a RUN COMMON ALARM or ISOLATED COIL with the changing of a jumper Jumper Positions for Plug In Relays Jumpers W1 W2 and W3 perform the same func tions for their respective relay
95. ed oil Provide appropriate fire extinguishers and install them in convenient locations Consult the local fire department for the correct type of extinguisher to use Do not use foam on electri cal fires Use extinguishers rated ABC by NFPA Make sure that rags are not left on or near the engine Remove all unnecessary grease and oil from the unit Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard Keep the generator set and the surrounding area clean and free from obstructions move any debris from the set and keep the floor clean and dry Do not work on this equipment when mentally or physically fatigued or after consuming any alcohol or drug that makes the operation of equipment unsafe Substances in exhaust gases have been iden tified by some state or federal agencies as causing cancer or reproductive toxicity Take care not to breath or ingest or come into contact with exhaust gases 1 Introduction ABOUT THIS MANUAL This service manual is for the EN series gasoline and gaseous fuel generator sets It includes engine and generator troubleshooting guides Engine ser vice instructions are in the applicable engine ser vice manual Operating and maintenance instruc tions are in the applicable Operator s Manual This manual does not have instructions for servic ing printed circuit board assemblies Always re place a faulty printed circuit board assemb
96. ed to indicate the correct terminal Attach a hoist to the generator output box loosen the mounting bolts on the sides of the generator and remove the box 12 13 Withdrawing The Generator From The Set 1 The rotor will be carried inside the stator when the generator is withdrawn from the engine Bar the engine until one of the four poles of the rotor points straight down so that the rotor will rest on the face of the pole when the generator is withdrawn The rotor can be damaged if it rests on the edges of the winding slot be tween two poles 2 Attach lifting eyes and a hoist of sufficient ca pacity Figure 5 7 3 Take up hoist slack and remove the two through bolts securing the generator to the rub ber isolation mounts 4 Raise the generator end approximately one inch 12 mm and securely block the engine un der the flywheel housing Lower the generator slightly so that the blocks carry most of the weight 5 Remove the bolts securing the generator drive discs to the flywheel 6 Loosen all the bolts securing the generator adapter casting to the flywheel housing Adjust the hoist to carry the full weight of the genera tor remove the bolts and pull the generator away Never withdraw the generator leaving the rotor to hang by the drive discs The weight of the rotor will damage the drive discs ROTATING DIODE ASSEMBLY EXCITER ROTOR STATOR COOLING BLOWER STATOR ROTOR BEARING GENERATOR
97. eet specifications Shut down the set and check stator winding resistanc The stator windings are faulty open or es according to Section 5 Servicing the Generator shorted Replace the generator stator assembly if stator wind ing resistances do not meet specifications Replace the voltage regulator A CAUTION Replacing the voltage regulator be fore servicing other faults can lead to damage to the new voltage regulator Voltage Regulator VR21 is faulty There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE PHASE CURRENTS ARE UNBALANCED The connected loads are distributed un Shut down the set and redistribute the loads so that evenly among the phases there is a difference of less than 10 percent between phases Improper connections have been made at the generator output terminals Shut down the set and reconnect according to the ap propriate reconnection diagram in Section 7 Shut down the set and check stator winding resistanc The stator windings are faulty open or es according to Section 5 Servicing the Generator shorted Replace the generator stator assembly if stator wind ing resistances do not meet specifications
98. esist open ing the throttle which is normal and the governor spring of a mechanical governor will resist closing the throttle Mechanical Governor Readjust the governor ac cording to Section 6 Governors and Carburetors Re place the mechanical governor unit if the set still shuts down due to overspeed Electronic Governor Readjust the governor accord ing to Section 6 Governors and Carburetors If the set still shuts down due to overspeed re install the mag netic speed pick up unit to make sure the clearance with the flywheel gear teeth is correct Section 6 Re place the speed pickup unit if output voltage at crank ing speed is less than 2 5 VDC as measured at termi nals 10 and 11 on the governor controller Disconnect the actuator lead connected at governor controller terminal 5 and connect it to the negative terminal of the cranking battery Then disconnect the lead connected at terminal 4 and touch it to the battery positive terminal Replace the actuator unit if it does not drive the throttle open when power is con nected or return it when power is disconnected Replace the governor controller if the set still shuts down due to overspeed Continued on next page There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the sa
99. fety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE RUNS UNTIL FAULT SHUTDOWN CONT Continued from previous page Reset the ECM by pushing the Run Stop Remote The LOW OIL PRESSURE lamp comes switch to Stop and the Reset switch to Reset and fill on when the engine shuts down up with as much engine oil as necessary and repair all oil leaks If the set still shuts down due to low oil pressure dis connect the wire to fuel solenoid K1 to keep the en gine from starting and observe oil pressure while cranking the engine Service the lubricating oil system in accordance with the engine service manual if oil pressure is less than 10 psi Replace the low oil pres sure cutout switch if oil pressure is greater than 10 psi See Figure 3 3 Section 3 Engine Control to locate the switch Reset the ECM by pushing the Run Stop Remote switch to Stop and the Reset switch to Reset and fill up with as much engine coolant as necessary and re pair all leaks The HIGH ENGINE TEMPERATURE lamp comes on when the engine shuts down If the set still shuts down due to high engine tempera ture start the engine and observe coolant tempera ture as the system heats up If shutdown occurs before the coolant reaches 200 F 93 C replace the high engine temperature cutout switch If coolant tempera ture exceeds 200 F 93 C clean and service the en tire cooling system as
100. ge when the switch is in the Run position replace the ECM If the ECM works push the Run Stop Remote switch to Run and check for battery voltage at starter relay K4 terminal S If there is no voltage repair the wiring as necessary The wire between ECM terminal TB1 8 and starter relay K4 terminal S is loose damaged or missing If there is voltage at starter relay K4 terminal S but not Starter relay K4 is malfunctioning at terminal SI when the Run Stop Remote switch is in the Run position replace relay K4 If there is voltage at relay K4 terminal SI but not at the starter motor terminal when the Run Stop Remote switch is in the Run position repair the cable as nec essary The cable between relay K4 and the starter motor is loose damaged or miss ing If there is voltage at the starter motor terminal but the motor does not function when the Run Stop Remote switch is in the Run position repair or replace the starter motor according to the engine service manual The starter motor is malfunctioning There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Read the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE CRANKS BUT DOES NOT START When the Run Stop Remote swit
101. han 1 megohm MEASURE WINDING INSULATION RESISTANCE BETWEEN EITHER ROTOR LEAD AND THE ROTOR LAMMINATIONS DISCONNECT THE MAIN ROTOR LEADS FROM THE ROTATING RECTIFIER ASSEMBLY AND MEASURE THE WINDING RESISTANCE BETWEEN THEM FIGURE 5 5 TESTING THE MAIN ROTOR 5 5 Main Stator Testing Winding Resistance Measure electrical resistance across each pair of stator leads U1 U2 U5 U6 VI V2 V5 V6 W1 W2 and W5 W6 with a Wheatstone bridge or ohmmeter having at least 0 001 ohm precision Replace the stator if the re sistance of any winding is not as specified in Table 5 1 Alternatively winding resistance can be measured line to line at the generator terminals U V V W W U on star connected generators On a 600 volt generator line to line resistance should be twice the table value two winding elements in series On a series star connected generator line to line re sistance should be four times the table value four winding elements in series On a parallel star connected generator line to line resistance should THE LAST SIX DIGITS OF THE STATOR PART NUMBER ARE STAMPED HERE be the same as the table value two sets of two winding elements in series Testing Winding Insulation Resistance Discon nect all stator leads and winding taps from their re spective terminals and make sure the ends do not touch the generator frame Testing For Grounds Using a megger voltage set at 600 VAC or less measure ele
102. her explosive fumes are fully dissi pated This is especially important if battery has been connected to battery charger EXCITER STATOR PMG ASSEMBLY ROTOR SHAFT BEARING EXCITER ROTOR ROTATING RECTIFIER ASSEMBLY FIGURE 5 1 GENERATOR 5 1 Exciter Stator Testing Winding Resistance Measure winding resistance with a Wheatstone bridge or digital ohm meter Replace the stator if winding resistance is not as specified by Table 5 1 Testing Winding Insulation Resistance Discon nect the exciter stator leads from terminals X and XX on the auxiliary terminal board in the generator output box Using an ohmmeter measure resist ance between either lead and the stator lamina tions Replace the stator if insulation resistance is less than 1 megohm 1 000 000 ohms MEASURE WINDING INSULATION RESISTANCE BETWEEN EITHER LEAD AND THE STATOR LAMINATIONS Flashing the Field Self Excited Generators Only If necessary flash the exciter field before or after installation Apply 110 to 220 VAC for one to two seconds to the X and XX leads of the exciter sta tor The generator must be shut down the AVR disconnected a diode used to establish correct polarity and a 3 amp fuse to prevent over excita tion See the diagram Alternatively while the set is running and discon nected from all loads apply a 12 VDC battery for one to two seconds as shown in the diagram Polar ity must be correct to X to XX MEASURE W
103. hese optional relay modules are used to operate a remote alarm annunciator that has an independent power source This allows the use of either AC or DC for alarm drives The relays are energized through the latching relays on the ECM and pro vided N O and N C contacts for each external alarm connection The 12 relays with form C contacts are rated e 10 Amp 120 VAC e 10 Amp 30 VDC JUMPERS RUN RELAY JUMPERS MODULE S COMMON J1 J2 WIRE ALARM N O N C N O N C N C N O 6 7 RUN HARNESS PLUG con A cin A A RELAYS 4 THROUGH 15 ARE OPTIONAL COM N O N O N C N O 0 N O COM 0 p Po Prener wr os COM N C N C COM N C N O COM N O FIGURE 3 11 AUXILIARY RELAY BOARD 300 4111 3 10 Over Under Voltage Module A17 The set can be equipped with an adjustable volt age sensitive relay usually connected into the Fault 1 circuit Detector 12 controls only to shut down the set when the output voltage is over or under nominal voltage by the preselected percentage typically 10 percent over and under With the module is an adjustable time delay relay K17 to preven
104. i 2 CONNECTIO 02 VERT 24V SEE SHEET o3 lev 612 6487 sh 1of2 04 HORIZ 24V Rev Sys CADAM ENG GND Modified 8 3 95 7 LIGHT DC WIRING SHEET 1 PRIOR TO SPEC F 7 7 SCHEMATIC DIAGRAM THIS IS A REPRESENTATIVE GENERIC HEMATIC WIRING DIAGRAM FOR Be ORT 7 GNITION SYSTEMS SC INTERNAL CONN FOR REF ONLY TROUBLESHOOTING REFER TO THE E WIRING DIAGRAM PACKAGE THAT WAS gt 28 96 MONITOR eesti ee DIESEL APPLICATIONS GAS GASOLINE APPLICATION INCLUDED WITH YOUR GENSET x 22 522 E pn A RESET PANEL 26 26 gu RUN 3 Roc B cas 4 12 Ee M as EIE AI5 TBI 7 ONES Kl m STOP 2 vi Di 2 SIAR 1 PI TID CONF IGURA T IONS conn 6 B bes GND TO GUAGES FORD APPLICATIONS SPARK IGNITION REMOTE START MEET O cust GND CONN 10A 4 OD 2AVDC DF I2VDC FORD 12 NS 8 SOLENOID SHIFT Bi RUN Q DS et t E LOP WHITE 5
105. il temperature Tachometer M16 The tachometer indicates en gine speed in RPM Speed Adjusting Rheostat The speed adjusting rheostat is used to adjust engine speed from the control panel an option with the optional electric governor 3 2 PRE LO OIL PRE RE HI ENG TEM 77 LO OIL PRES HI ENG TEMP OVERSPEED OVERCRANK FAULT 1 FAULT 2 LOW ENG TEMP LO FUEL SWITCH OFF Eos 539 0741 2 FIGURE 3 2 DETECTOR 12 INDICATOR LAMPS Emergency Stop Button S14 The emergency stop button is a red push in switch used to stop the engine The button lights up when it is pushed in The button has to be pulled out and the engine con trol reset to restore operation Low Coolant Level Cutout Switch When coolant level in the radiator top tank falls below the switch sensor the switch closes the circuit to ground This switch may be connected in parallel with the high engine temperature cutout switch to shut down the engine and light the High Engine Temperature lamp or in parallel with the pre high engine temper ature switch to light the Pre High Engine Tempera ture light only Detector 12 Fault and Status Indicator Lamps A12 The Detector 12 control panel has the five fol lowing indicator lamps in addition to the standard seven Low Engine Temperature Yellow This lamp indicates that engine temperature is less than 70 and the possibility that the engine might not start Low Fuel Yellow This lamp indi
106. ke necessary provisions so that lift does not exceed 6 feet 1 8 metres Connect the set to a container of regular gasoline of known quality and run the set under various loads Re place the contents of the fuel supply tank if there is a noticeable improvement in performance The Gasoline fuel is contaminated Check the gas supply pressure at the fuel inlet fitting on the skid Make necessary provisions so that gas supply pressure is at least 10 inches 254 mm Water Column WC when the set is under full load and not more than 20 inches 508 mm WC The gas supply System must be able to supply this pressure when sup plying all other concurrent building loads Gaseous fuel delivery vapor withdraw al to the set is inadequate Check with the propane supplier or the gas utility to confirm the energy content of the gaseous fuel being used Propane must have approximately 2500 BTU s per cubic foot and natural gas 1000 BTU s per cubic foot The Gaseous fuel is of insufficient ener content The engine air filter element is dirty Replace the air filter element Clean and rebuild gasoline carburetors with the ap The carburetor fuel passages gasoline propriate carburetor kit according to the kit instruc fueled sets are clogged tions Adjust fuel mixture according to Section 6 Service the engine or ignition system according to the engine service manual The engine is worn or is misfiring There are ha
107. l panel mounted voltage trimmer if provided for small voltage adjustments Measure generator output voltage while the set is running without load at the nominal frequency If the trimmer does not provide enough adjustment lock it at its midpoint Then turn the VOLTS pot fully counter clockwise and the STABILITY pot to its midpoint If the red LED light emitting diode on the board lights refer to Jumper Reconnections and to UFRO Adjustments Then turn the VOLTS pot clockwise until rated voltage is obtained If voltage becomes unstable when a large load is connected turn the STABILITY pot clockwise until voltage is stable Check and readjust the VOLTS pot if necessary each time the STABILITY pot is readjusted 2 2 UFRO Adjustments The voltage regulator has an under frequency pro tection circuit having a threshold frequency that can be preset typically at 59 Hz for 60 Hz applications and 49 Hz for 50 Hz applications The red LED on the board lights when frequency dips below the threshold The threshold frequency is preset by turning the UFRO under frequency roll off pot clockwise to raise it and counterclockwise to lower it Determine threshold frequency by lowering gen erator frequency until the LED lights Note that Dip and Dwell adjustments below are related Dip Adjustments The DIP pot adjusts the voltage vs frequency slope of the generator for frequencies below the threshold preset by the UFRO pot Turning the DIP
108. lator and engine gov ernor respectively Generator field strength is proportional to field current which is supplied by the exciter The exciter field stator induces current in the exciter rotor windings A full wave rectifier bridge rotating rectifiers mounted on the exciter rotor converts exciter output 3 phase AC to DC The exciter rotor is mounted on the main rotor shaft Exciter output current is proportional to exciter field current The automatic voltage regulator AVR regu lates exciter field current by comparing genera tor output voltage and frequency with refer ence values PMG Excited Generators Exciter field cur rent is supplied by a PMG permanent magnet exciter through the voltage regulator The PMG consists of a stator and a permanent magnet rotor mounted on the end of the main rotor shaft Self Excited Generators Exciter field current is supplied by the generator stator through the voltage regulator Residual field magnetism in itiates self excitation during startups PMG EXCITED GENERATORS EXCITER ROTOR AND STATOR ROTATING RECTIFIERS ELECTRICAL POWER OUTPUT MAIN STATOR ROTATING MECHANICAL POWER INPUT MAIN ROTOR SELF EXCITED GENERATORS ELECTRICAL POWER OUTPUT MAIN STATOR EXCITER ROTOR AND STATOR ROTATING RECTIFIERS MAIN ROTOR ROTATING MECHANICAL POWER INPUT FIGURE 2 5 SCHEMATIC OF GENERATOR OPERATION 3 Engine Control CO
109. load and turn the power adjusting screw clockwise until the engine be gins to lose speed and then slowly back out the screw counterclockwise until the engine car ries the full load smoothly 4 the set is equipped for natural gas and pro pane switch to propane by means of the con trol panel switch if provided or by closing the manual shutoff valve in the natural gas supply line 5 Reconnect full rated load and turn the propane flow adjustment valve clockwise until the en gine begins to lose speed and then slowly turn it back counterclockwise until the engine car ries full load smoothly 6 10 GAS MIXER IDLE ADJUSTING SCREW ADJUSTING SCREW THROTTLE STOP SCREW PROPANE FLOW ADJUSTMENT VALVE FIGURE 6 10 GASEOUS FUEL ADJUSTMENTS FS 1176s 7 Wiring Diagrams This section consists of the schematic and connec tion wiring diagrams referenced in the text The following diagrams are typical Your genset may differ Wiring and component specifications are sub ject to change Contact your Distributor if you do not have the wiring diagrams applicable to your equip ment The following drawings are included Page 7 3 AC Wiring without meters Page 7 4 AC Wiring with meters Page 7 5 Voltage Regulator Connections MX321 PMG excited generators Page 7 6 Voltage Regulator Connections SX440 self excited generators Page 7 7 7 light DC Wiring Sheet 1 Prior to Spec F
110. ly At tempts to repair a printed circuit board can lead to costly damage to the equipment This manual contains basic generic wiring dia grams and schematics that are included to help in troubleshooting Service personnel must use the actual wiring diagram and schematic shipped with each unit The wiring diagrams and schematics that are maintained with the unit should be updated when modifications are made to the unit Read Safety Precautions and carefully observe all instructions and precautions in this manual 1 1 TEST EQUIPMENT Most of the tests in this manual can be done with an AC DC multimeter frequency meter Wheatstone bridge 0 001 ohm precision is necessary for mea suring stator winding resistance and load test pan el HOW TO OBTAIN SERVICE Always give the complete Model and Serial number of the generator set as shown on the nameplate when seeking additional service information or re placement parts The nameplate is located on the side of the generator output box Incorrect service or replacement of parts can result in severe personal injury or death and or equipment damage Service per sonnel must be qualified to perform electrical and mechanical service Read and follow Safety Precautions on pages ii and iii FIGURE 1 1 TYPICAL GENERATOR SET 2 AC Control GENERAL The control box is mounted on top of the generator facing the rear Figure 2 1 points out the compo nents on the AC control
111. n repair or install engine coolant and engine oil low a cranking speed for starting heaters Replace the engine oil if it is not of the recommended viscosity for the ambient temperature Continued on next page There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE CRANKS BUT DOES NOT START CONT Continued from previous page While cranking the engine measure voltage directly across the battery terminals and then immediately across the starter motor terminal and the grounding Cranking voltage is too low to reach re quired cranking speed bolt on the block Cable terminal or relay contact re sistance is too high if the difference is more than 1 volt Service as necessary Recharge or replace the battery Specific gravity for a fully charged battery is approximately 1 260 at 80 F 27 C While cranking check for battery voltage at the termi The ECM is faulty Check fuse F2 again nal TB1 10 on the ECM Replace the ECM if there is no voltage at the terminal The fuel pump gasoline fueled sets is Replace or service the fuel pump according to the en malfunctioning gine service manual Clean and rebuild gasoline
112. not click each time power is connected Continued on next page There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THE ENGINE CRANKS BUT DOES NOT START CONT Continued from previous page Connect wires tighten terminal screws and adjust the governor linkage as necessary according to Section 6 Governors and Carburetors Open and close the throttle by hand to check for binding and repair as nec essary Opening the throttle will be resisted by a spring inside the actuator which is normal The throttle is not opening This applies only to sets with electronic governors There should be visible movement in the throttle linkage when cranking starts Disconnect the actuator lead connected at governor controller terminal 5 and connect it to the negative terminal of the cranking battery Then disconnect the lead connected at terminal 4 and touch it to the battery positive terminal Replace the actuator unit if it does not drive the throttle open when power is con nected or return it when power is disconnected Replace the governor controller if the actuator func tions properly Low engine temperature is causing too Plug i
113. or during standby under FLT 2 conditions B Allows selection of functions with W1 jumper W9 Jumper Position 7 8 Warning while running or during standby under FLT 1 conditions B Allows selection of functions with W2 jumper aii PREHET L 3 V 2 OP SW OFF LET 14 LN 1 GAUGES FIGURE 3 5 ENGINE CONTROL MONITOR FUSES AND FUNCTION SELECTION JUMPERS 3 5 won 79 A ENGINE SENSORS sensing switches to which the ECM responds The switches function by closing the fault or warning cir Figure 3 6 shows the locations of the gauge send cuit to the engine chassis ground battery nega ers and the coolant temperature and oil pressure tive PRE LOW OIL PRESSURE LOW OIL PRESSURE ENSOR SENSOR S1 T26 OF ENGINE HARNESS ay OIL PRESSURE c SENDER E1 s VIEW A A BEGIN SPEC F PRE HIGH HIGH ENGINE LOW OIL OIL PRE LOW OIL TEMPERATURE PRESSURE PRESSURE PRESSURE ENGINE SENSOR 1 SENDER E1 SENSOR S5 TEMPERATURE SENSOR 2 7 SENSOR S6 COOLANT TEMPERATURE SENDER E2 LOW ENGINE TEMPERATURE SENSOR S4 SWITCHED BAT TERMINAL T26 AND GND OTHER END FIGURE 3 6 ENGINE SENSOR LOCATIONS 3 6 AUXILIARY CONTROL COMPONENTS The
114. panel Pages 7 3 through 7 6 show the wiring connections STANDARD CONTROL PANEL COMPONENTS Field Circuit Breaker CB21 The field circuit breaker protects the generator from over excita tion OPTIONAL CONTROL PANEL COMPONENTS AC Voltmeter M21 The voltmeter indicates output voltage for the phase selected AC Ammeter M22 The ammeter indicates output amperage for the phase selected Input to the am OUTPUT VOLTAGE TRIMMER VERLA None Breaker AC AMPERES AMMETER MT METER WATTMETER meter is from current transformers CT21 CT22 and CT23 Phase Selector Switch S21 The selector switch is used to select the phase for voltage and amper age readings Scale Indicator Lamps DS21 and DS22 The scale indicator lamps indicate whether to read the upper or lower scales of the voltmeter and ammeter Frequency Meter M23 The frequency meter indi cates output frequency in Hertz Hz and engine speed in RPM Wattmeter M24 The wattmeter indicates output power in kilowatts kW Powerfactor Meter M25 The powerfactor meter indicates output powerfactor as a percentage of unity powerfactor Output Voltage Trimmer R21 The output voltage trimmer can be used to adjust output voltage plus or minus five percent of nominal voltage SCALE INDICATOR LAMPS gt af ys ey FIELD CIRCUIT BREAKER atm 2 PEN 6 PHASE SELECTOR SWITCH
115. pot clock wise increases the slope for greater voltage roll off as frequency drops making it easier for the engine to pick up a large load but also increasing the volt age dip The generator voltage vs frequency slope is the same above and below the threshold fre quency when the pot is turned fully counterclock wise Dwell Adjustments The DWELL pot times voltage recovery when fre quency dips below the preset threshold Clockwise adjustment increases dwell time Full counterclock wise adjustment eliminates dwell in which case voltage recovery follows engine speed recovery Droop Adjustments The DROOP pot is for adjusting the input signal from the droop compensating CT in paralleling ap plications DROOP is preset at the factory for five percent droop at full load and zero power factor V Trim Adjustments The Trim pot is for adjusting the input signal from a VAR PF controller in utility paralleling applica tions Full clockwise adjustment is normal resulting in maximum sensitivity The auxiliary controller has no effect when the pot is turned fully counterclock wise EXC OVER V I LIMIT STAB 1and RMS These pots are factory preset and do not require ad justment PMG EXCITED GENERATORS o o VOLTAGE REGULATOR v TRIM e VR21 LIMIT MX321 e FREQUENCY JUMPER 50 HZ 3 2 STABILITY 60 2 3 1 LEpe e 2 pip UFRO DWELL EXC o RES
116. re that the governor assem bly is securely mounted Also make sure that the governor linkage does not bind or have excessive play in it 4 Apply full load to the genset and adjust the sta bility 1 pot to minimize overshoot Adjust the stability 1 pot clockwise to increase stability Check stability under a range of loads from no 1 Check the dip switch settings Figure 6 5 to load to full load make sure they are set properly as follows 5 Attach a tachometer or frequency meter to the sw SW2 SW3 SWA4 generator output leads if control panel does not 50 Hz ON OFF OFF OFF come equipped with one of these meters Ad 60 Hz ON OFF OFF ON just the Speed Trim pot until the desired speed is obtained 2 Start the set let the engine warm up under a partial load at least 1 4 rated load and then dis 6 Shut down and restart the genset to check for connect all loads If the governor has been re overspeed shutdown on startup GAIN 1 OCT Qe STABILITY 1 DIP SWITCHES FIGURE 6 5 GOVERNOR CONTROLLER 6 5 Linkage Adjustment Begin Spec 2 Verify that the ball joint screw is mounted in the third hole from the outside end of the governor Figure 6 6 illustrates the governor linkage Make arm sure that the governor controller is securely mounted to the engine bra
117. red by the engine driven battery charging alternator 24 VDC through plug in connector P1 3 The panel Run indica tor lamp should light Relays K10 and K14 are redundant On older ECM boards those having cartridge type fuses 10 11 12 13 Relays K2 and K3 are deenergized by latching relay K6 causing shutdown to occur if the en gine does not start within 75 seconds The Overcrank indicator lamp lights and common alarm terminal TB1 4 is powered The ECM has a cycle crank feature whereby the engine is cranked for three 15 second periods alternated with two 15 second rest periods Relay K3 is deenergized by latching relay K6 causing shutdown to occur during operation when a low oil pressure high engine tempera ture or engine overspeed condition is sensed or the optional emergency stop button is pressed The appropriate fault indicator lamp lights and common alarm terminal TB1 4 is powered There is no fault lamp for emergency stop The low oil pressure and high engine tempera ture shutdowns have 10 second time delays to allow oil pressure and engine temperature to stabilize during startup To restore operation after a shutdown fault has been serviced reset latching relay K6 by push ing the panel Stop switch and then the Reset switch The set should run or be ready to run when the panel switch is pushed to Run or to Remote If the emergency stop switch has been used the control will have to be reset
118. regulator terminal 6 is FIGURE 2 3 TYPICAL VOLTAGE REGULATING CIRCUITS FOR PMG EXCITED GENERATORS 2 4 EXCITER ROTATING ROTOR RECTIFIERS EXCITER STATOR MAIN STATOR OUTPUT VOLTAGE SENSING LEADS NOTE 2 xi HH M t 1 K2 P2 P3 P4 S2 S1 A2A1XXXX X 8 7 6 3 5 440 AUXILIARY TERMINAL BOARD VOLTAGE REGULATOR VR21 le eo am WHEN PARALLELING WITH 1 A GENERATOR SET OR UTILITY TERMINALS 1 82 CONNECTING A DROOP COMPENSATING CT A UTILITY TERMINALS AND A2 ARE FOR FIELD CIRCUIT CONNECTING TRIMMER R21 BREAKER POWER FACTOR NOTE3 CONTROLLER m ey E NOTES 1 Connect like numbered terminals on auxiliary 3 There must be a jumper between voltage regu terminal board and voltage regulator lator terminals 1 and 2 when voltage trimmer 2 See the appropriate reconnection diagram for R21 is not used connecting sensing leads 6 7 and 8 FIGURE 2 4 TYPICAL VOLTAGE REGULATING CIRCUITS FOR SELF EXCITED GENERATORS 2 5 PRINCIPLE OF GENERATOR OPERATION 1 The generator field main rotor is rotated by the engine to induce output current AC in the main stator windings Generator output current is proportional to field strength which is varied to match the load Output voltage and frequency are held con stant by the voltage regu
119. s W1 for relay K1 W2 3 9 for relay K2 and W3 for relay They can be lo cated in any of 3 positions A B C independently of each other Jumper Position A Run The relay operates as a Run relay energizing when SW is plied from the ECM Jumper Position B Common Alarm The relay operates as a Common Alarm relay The relay energizes any time there is an engine shutdown This signal is provided from the ECM Jumper Position C Isolated The relay op erates as an Isolated relay The relay coil is en ergized by a customer applied signal through the terminal block TB3 1 for relay K1 TB4 1 for relay K2 and TB5 1 for relay Jumpers W11 W12 and W13 perform the same functions for their respective relays W11 for relay K1 W12 for relay K2 and W13 for relay K3 They can be located in two different positions A B inde pendently of one another Jumper Position A The relay operates iso lated from the board The customer provides the circuit completion through terminal block TB3 for relay K1 TB4 5 for relay K2 and TB5 5 for relay K3 The customer can operate the relay with switched ground logic or use this relay in the middle of more complex logic cir cuits if needed Jumper Position B The relays operate with the coils connected to ground through the board connections The coil will require a signal to energize with the jumper in this posi tion Fault Relays K4 through K15 T
120. t nuisance tripping An adjustment of 25 percent is equivalent to about 2 5 seconds delay Recalibrate the module as follows before installing it on 139 240 or 277 480 sets HIGH VOLTAGE Touching uninsu lated high voltage parts inside the control panel box can result in severe personal injury or death Measurements and adjustments must be done with care to avoid touching high voltage parts For your protection stand on a dry wooden plat form or rubber insulating mat make sure your clothing and shoes are dry remove jewelry and wear elbow length insulating gloves intended for hazardous voltages 1 Remove the two screws that secure the top to the case of the module and withdraw the top assembly 2 Adjust the SET pot for the UNDER setpoint on the face of the top assembly to 75 percent 3 Apply single phase 60 Hertz 104 25 VAC across terminals L and N 4 Adjust pot R25 on the PC board until the relay trips de energizes 5 Adjust the SET pot for the OVER setpoint on the face of the top assembly to 125 percent 6 Apply single phase 60 Hertz 173 75 VAC across terminals L and N 7 Adjust pot R26 on the PC board until the relay trips energizes 8 Repeat the above steps until no adjustments are necessary 9 Reassemble the module 10 On the module nameplate mark out the factory calibration value for monitored voltage 120 V and write in 139 V 3 11 GND AIITB2 3 AIITBI IO 14 11 12 2
121. ter Step 4 Manually push the throttle to the minimum speed position and hold it there until the engine 10 11 REMOTE SPEED POT reaches minimum speed Release the throttle and observe the overshoot on a frequency me ter Adjust the potentiometer counterclock wise slightly to decrease overshoot Some overshoot is acceptable Connect 1 4 load and readjust the Gain poten tiometer Step 4 Connect rated load in one step while the set is running Shut down the set if it cannot pick up the load Lengthen the governor rod by half turns and repeat the test until the set is able to pick up rated load in one step For B Series en gines shorten the governor rod by half turns and repeat the test until the set is able to pick up rated load in one step Back off the governor full speed stop screw if necessary Check for stability no audible hunting under a range of loads from no load to full load Stop the set and wait for 30 seconds for the tur bo to coast down Restart the set and check for speed overshoot If overspeed shutdown oc curs check for linkage binding and repair as necessary Set the governor rod locknuts if necessary and check again for binding in the linkage FIGURE 6 2 GOVERNOR CONTROLLER TERMINALS AND ADJUSTING POTENTIOMETERS 6 2 151 0715 Wiring Prior to Spec Wire the governor according to Figure 6 3 Be sure to twist together the power supply leads from and B Magne
122. tes flame pilot lights arching switches or equipment in area or areas sharing ventilation Gasoline Fuel System A gasoline carburetor is provided for gasoline fuel systems The idle mixture and choke are adjustable on the gasoline carburetor Idle Mixture Adjustment If the adjustment has been disturbed or the engine performs poorly under light load make the following adjustments 1 Shut off the engine and turn the idle adjustment screw in gently until it bottoms and then turn it out 2 1 2 turns so that the engine will run The adjustment screw and seat are easily damaged Do not force the adjust ment screw Start the engine and let the set warm up under a partial load at least 1 4 rated load and then disconnect all loads Turn the idle adjustment screw out counter clockwise approximately one half turn and jounce the throttle If the engine begins to hunt turn the adjustment screw in slowly until engine speed becomes stable If one half turn does not cause instability turn the adjustment screw out one half turn more and repeat the procedure Choke Adjustment The gasoline carburetor is equipped with an automatic choke for easier cold weather starting The choke has a bi metal coil that progressively closes the choke plate as ambient temperature drops in preparation for the next start It also has an electric heating element that heats the bi metal coil to fully open the choke soon after the engine starts
123. the engine should be made with an approved flexible line Do not use copper piping on flexible lines as copper will become brittle if continuously vi brated or repeatedly bent e Be sure all fuel supplies have a positive shutoff valve Be sure battery area has been well ventilated prior to servicing near it Lead acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing sparking smoking etc EXHAUST GASES ARE DEADLY e Provide an adequate exhaust system to prop erly expel discharged gases away from en closed or sheltered areas and areas where in dividuals are likely to congregate Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule Ensure that ex haust manifolds are secured and not warped Do not use exhaust gases to heat a compart ment e Be sure the unit is well ventilated e Engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Keep your hands clothing and jewelry away from moving parts e Before starting work on the generator set dis connect battery charger from its AC source then disconnect starting batteries negative cable first This will prevent accidental starting e Make sure that fasteners on the generator set are secure Tighten supports and clamps keep guards in position over fans dri
124. tic Speed Pickup Unit Prior to Spec F To install the magnetic speed pickup unit bar the engine until a gear tooth on the flywheel lines up in the center of the mounting hole in the flywheel hous ing Thread the unit in gently by hand until it just touches the gear tooth Back it out one quarter turn and set the lock nut 6 3 ACTUATOR REMOTE SPEED OPTIONAL B T26 GND MAG PICK UP TWIST THESE TWO WIRES TOGETHER FIGURE 6 3 WIRING THE GOVERNOR Linkage Adjustment Prior to Spec Assemble the linkage as shown in Figure 6 4 and adjust the length of the governor rod as necessary MAGNETIC SPEED PICKUP LINKAGE DETAIL SHOWN IN DE ENERGIZED POSITION ACTUATOR ELECTRONIC GOVERNOR CARBURETOR THROTTLE LEVER MOUNTING BRACKET FIGURE 6 4 ELECTRONIC GOVERNOR COMPONENTS ELECTRIC GOVERNOR Begin Spec F placed adjust the gain 1 and stability 1 pots to their center settings Electric Governor Adjustment CN Begin Spec F 3 Adjust the gain 1 pot until the engine 15 stable and responsive to governor control Adjust the gain 1 pot counterclockwise to eliminate hunt ing Bump the throttle lever a couple of times to check for hunting The unit should respond quickly but should not hunt If necessary adjust the gas mixture the governor linkage and the magnetic speed pickup unit as instructed in this section before adjusting the gover nor controller Make su
125. tism Flash the field according to Section 5 Servicing the Generator Check all connections against the wiring diagrams on pages 7 3 through 7 6 7 15 and 7 16 and rewire as necessary Replace the voltage regulator if the wiring is correct and there is no output voltage Replacing the voltage regulator be fore servicing other faults can lead to damage to the new voltage regulator Voltage Regulator VR21 is faulty Continued on next page There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Read the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual THERE IS NO OUTPUT VOLTAGE CONT Continued from previous page GENERATOR FAULTS Shut down the set and check exciter field winding re The exciter field winding is faulty open or sistance according to Section 5 Servicing the Genera shorted tor Replace the exciter field assembly if winding re sistance does not meet specifications Shut down the set and check each diode according to Section 5 Servicing the Generator Service as neces sary The rotating rectifier assembly diodes CR1 through CR6 is faulty Shut down the set and check exciter winding resist The exciter rotor windings are faulty ances according to Section 5
126. to the ap the generator output terminals propriate reconnection diagram Page 7 15 or 7 16 Shut down the set and check each diode according to Section 5 Servicing the Generator Service as neces sary The rotating rectifier assembly diodes through CR6 is faulty Replace the voltage regulator A CAUTION Replacing the voltage regulator be fore servicing other faults can lead to damage to the new voltage regulator Voltage Regulator VR21 is faulty There are hazards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual OUTPUT VOLTAGE IS UNSTABLE The voltage has been adjusted improper Adjust output voltage according to Section 2 AC Con ly trol Unlock the voltage adjusting screw on the front of the control panel and disconnect either lead from the rheo stat Measure resistance between terminals 1 and 2 The voltage adjusting rheostat on the control panel is faulty if provided while turning the adjusting screw fully one way and then the other Replace the rheostat if it is open at any point or if resistance does not vary smoothly from zero to approximately 100 000 ohms Replace the voltage regulator Voltage Regulator VR21 is f
127. ve belts etc e Do not wear loose clothing or jewelry in the vi cinity of moving parts or while working on elec trical equipment Loose clothing and jewelry can become caught in moving parts Jewelry can short out electrical contacts and cause shock or burning f adjustment must be made while the unit is running use extreme caution around hot man ifolds moving parts etc LS 11a ELECTRICAL SHOCK CAUSE SEVERE PERSONAL INJURY OR DEATH e Remove electric power before removing pro tective shields or touching electrical equip ment Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surface to be damp when handling electrical equipment Use extreme caution when working on electri cal components High voltages can cause inju ry or death DO NOT tamper with interlocks Follow all applicable state and local electrical codes Have all electrical installations per formed by a qualified licensed electrician Tag and lock open switches to avoid accidental clo sure DO NOT CONNECT GENERATOR SET DI RECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous voltages can flow from This creates a potential for electrocution or property damage Connect only through an approved isolation switch or an approved paralleling de the generator set into the utility line
128. vice HIGH VOLTAGE GENERATOR SETS 1 9kV to 15kV e High voltage acts differently than low voltage Special equipment and training is required to work on or around high voltage equipment Op eration and maintenance must be done only by persons trained and qualified to work on such devices Improper use or procedures will result in severe personal injury or death Do not work on energized equipment Unau thorized personnel must not be permitted near energized equipment Due to the nature of high voltage electrical equipment induced voltage remains even after the equipment is discon nected from the power source Plan the time for maintenance with authorized personnel so that the equipment can be de energized and safely grounded GENERAL SAFETY PRECAUTIONS Coolants under pressure have a higher boiling point than water DO NOT open a radiator or heat exchanger pressure cap while the engine is running Allow the generator set to cool and bleed the system pressure first Benzene and lead found in some gasoline have been identified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care not to ingest breathe the fumes or contact gasoline Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity When checking or changing engine oil take care not to ingest breathe the fumes or contact us
129. zards present troubleshooting that can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel electrical and machinery hazards Head the safety precautions inside the front cover and careful ly observe all instructions and precautions in this manual ENGINE CONDITION WARNINGS Shut down the set if possible or disconnect non critical The PRE LOW OIL PRESSURE lamp loads Cil pressure will be less than 30 psi but greater comes on while the engine is running than 25 psi Service the engine lubricating system ac cording to the engine service manual Shut down the set if possible or disconnect non critical loads Engine temperature will be greater than 205 F EAE AMpP COmES 97 C but less than 215 102 Service the en 9 gine cooling system to restore full cooling capacity The LOW ENGINE TEMPERATURE Plug in repair or install engine coolant and engine oil lamp comes on while the set is in standby heaters Fill the main fuel supply tank with the appropriate The LOW FUEL lamp comes on grade of fuel The customer must supply the fuel level switch to make use of this warning Service as required The customer has supplied the System fault indicating switches By means of selec FAULT 1 or FAULT 2 tion jumpers either fault may be chosen to shut down the engine See See Section 3 Engine Control

928-0500 Onan ENA ENB ENC ENAD ENBA Genset Generator

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