Home

(begin spec D) EM (begin spec W)

1. INCLUDED WITH YOUR GENSET gt Bt we 051 All INTERNAL CONN FOR REF ONLY GNIIION SYSTEMS PANEL LAMP r IPCB ASSY ENGINE MONITOR LAMP TEST DIESEL APPLICATIONS GAS GASOLINE APPLICATION J4 RESET PANEL 4 6 OFF B Bal LAMP PREHEAT 26 26 FUEL SOLENOID RUN 3 uy P 7 t SI2 6A AI5 TBI 7 Kl KI STOP 7 Q TE eod eo 5 Pl ec re TT FORD APPLICATIONS SPARK IGNITION Hia T iE START GND TO GUAGES 44 CUST GND CONN 10 OD 24VDC DF FORD 12 n 7 SOLENOID SHIFT 5 in BI 0512 5 BI BTI pup nan en w R 4 ax 13
2. FIGURE 1 1 TYPICAL GENERATOR SET Power 1 2 Redistribution or publication of this document Qua Generation by any means is strictly prohibited 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 panel Refer to Section 7 for 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 VOLTMETER 2 gM a ield WS Breaker 5 T gt 1 ingle Phase a 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 Powerfa
3. SCHEMATIC DIAGRAM WIRING DIAGRAM SCHEMATIC WIRING DIAGRAM FOR G2 GENERATOR XX LEFT SIDE DOOR REAR INSIDE VIEW INSIDE VIEW INSIDE VIEW TROUBLESHOOTING REFER TO THE EN WIRING DIAGRAM PACKAGE THAT WAS TI LEFT SIDE WALL VERTICAL BACK WALL OF CABINET VERTICAL FI BOTTOM OF TRAY HORIZONTAL LEFT WALL OF TRAY HORIZONTAL E CUBED WITH YOUR GENSET 16 5 n TB2 en TII E LO 5 6 F2 Fe CB2 2i A 5 2 9 6 9 ee ERROR LINE I Oe e NOTES GENERATOR 1 ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION FI F2 G2 62 ERATOR VR2 2 63 63 eg RN 6 E B xem F2 5 ee ca E L 4 5 SEE VOLTAGE REGULATOR INSTALLATION FOR CONNECTIONS TO AND 21 TO WD 20 VAC STARTER 23 DISCONNECT 4 SEE GENERATOR CONNECTION DIAGRAM FOR INPUT CONNECTIONS 2 KDE P 4 BOTTOM OF INSIDE VIEW j HOUSING CONTROL BOX M A Hi G2 GENERATOR 5 EXCITER ARMATURE FULL WAVE BRIDGE RECTIFIER F2 XX No 612 6489 sh 1 of 1 Rev Sys CADAM Modified 10 3 95 AC WIRIN
4. 5 1 Testing The Generator 5 1 Insulation Resistance Megger amp Polarization Index Testing 5 2 Drying ihe Windings 5 2 Exciter Stator RARE RAS 5 3 Exciter Rectifier Bridge Rotating Rectifier Assembly 5 5 Exciter ROTOT MER TP 5 6 Main Rotor Generator Field 5 7 Mal SIMON 5 8 Removing And Disassembling The Generator 5 9 Reassembling The Generator 5 10 6 GOVERNORS AND CARBURETORS 6 1 Electric Governor Adjustment 6 1 Linkage Adjustment 6 2 Magnetic Speed Pickup Unit 6 3 Carburetors pb ele iL 6 4 7 WIRING DIAGRAMS 7 1 ii Redistribution or publication of this document o Generation by any means is strictly prohibited o s Y lt 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 b
5. 3 1 Optional Control Control Components 3 3 Control Box Interior 3 4 Engine Control Monitor 11 3 4 Engine Gauge Senders and Shutdown 3 6 Auxiliary Control Components 3 9 Sequence Of Operation 3 15 4 TROUBLESHOOTING 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 Amber Warning Lamp On 4 11 The Green Run Lamps Stay Off But The Set Runs Normally 4 12 There Is No Output Voltage Engine Speed Is Stable 4 13 Output Voltage Is Too High Or Too Low 4 17 Output Voltage Is Unstable 4 18 The Field Circuit Breaker Keeps Tripping 4 19 The Phase Currents Are Unbalanced 4 20 Gra Powe r i Redistribution or publication of this document Generation by any means is strictly prohibited SECTION TITLE PAGE 5 SERVICING THE GENERATOR
6. 7 EE PEN 10 lt xi m 1 a 1 Eo Ec E ES E j Mee a c NIS 1 15 CI S 2 1 1 0 EI I 4 1 H M f D O I8 1 i mE 1 un pe HH sU MEE c MEET 1 T rs eN po o Tm E EO 1 08 4 1 8 x rud T 571 1 y SEG lt i 1 i Ms 2 4 ETE EZ l c i 1 e T 1 1 zi lt e ul BI lt 4 9 eux EE TERES z Ls le DIS d 1 2 1 x EE 2 S IA 1 ae 1 1 gt aN o co Io x uS 1 gu _ 1 lt io SE d H 1 MEE 9 T oN i O 15 E j lt 25 la dp 1 Z 2 5 I S MT 1 ee o o amp amp tm 2 5 566 o xoc wi iu ue Me Re i GA E
7. Rev Sys CADAM Modified 9 27 95 12 LIGHT DC WIRING SHEET 2 OF 2 Power 7 8 Redistribution or publication of this document 4 Generation by any means is strictly prohibited THIS IS A REPRESENTATIVE GENERIC UR GENERATORS SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS 15 L5 15 Ql 7 E 7 INCLUDED WITH YOUR GENSET 5 PHASE RECONNECTABLE PHASE RECONNECTABLE SECONDARY CURRENT TRANSFORMER CONN 1 3 SECONDARY CURRENT TRANSFORMER CONN 2 CURRENT 110 220V 50HZ 110 190V 50HZ 120 208V 60HZ 2 50HZ 240 416V 60HZ 110 220V 50HZ 115 230V 50HZ 115 220V 50HZ 127 220V 60HZ 250 400V 50HZ 254 440 60HZ 115 230V 60HZ 120 240V 60HZ 120 208V 50HZ 139 240 60HZ 240 416V 50HZ 277 480V 60HZ 120 240V 60HZ erai 127 220V 50HZ 254 440 50HZ 9 240 480V
8. SWITCHED ix IN 2 3 2 x 875725 STARTER SOLENOID N 2 B OUT 15 AMPS Al 1J3 11 START eo oH C ZH olo MITT 1 lt Sa 5 COMMON ALARM 4 AMPS MAX 705778 e z 5 89 V 9 u 2 amp psri 6n 105180 NU CHE 2 DC START DISCONNECT INPUT 13 8 A D OVERSPEED INPUT E EE Al 193 1 1 O amp 2 m 5 2549 T Es gt 2 HO Ra a ale Soe eos lla aps 12 2 i arm 65 BI i op M O X d lt is x ES B a 120618 2 m oS 80000 9 peer 120516 2 2 5 L CUSTOMER CONNECTIONS RI Pijs 7 6 5 4 3 2 paje 5 4 3 2 1209142 12 01 87665432 426 5 4 3 2 112051322 GND 2 0 8 o 8 amp O lt M gel a 2 oe Q 5 x FONE 2c 2 N 20V A J9 Jio MIA GND STUD P9 PIO PE T ENG GND mm MI2 JI 3 pe a 2 i 2 gt 1 2 RI AII TBI 8 ENGINE HARNESS S EI NOTES 2 1112 4 AllJi 7 f 4 m p a ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION NM SNETE
9. SI Lop 26 p 7 GI OUT PRE HET 0814 i 1 RED MOT lt 12 ES 2479 BRN AII TBI 8 EO Lop 0515 i 52 RED GRN STRIPE ALITBI 8 Sps 9 UB 7 x E8 31 ur 0516 S7 NT B2 i 03 05 0517 6 SS VERSPERD OL J3 P2 J2 ILLus 55 PRE LOP CB2 J3 gt 2 gt bera Ja 38 i m ASSY Lr m B Q 5520 d CHRYSLER APPLICATIONS SPARK IGNITION d _ Jg P2 PIO JI PI LE Q os KX 2 5509 Lu BRN WHT STRIPE Lo rue 9 0522 J2 P9 JI PI MODL GRAY 2VDC boum P T8 2 ALM 4A FORD NON SOLENOID SHIFT T Xx 5 d AII TBI 9 LAMP T RST RED 7 B 5 5 5 BTI STARTER 14 LO FUEL IN 60 7 T 665 GI OUT T YY fe 1 8 SE TO 0 120 JI 4 3 FLT 26 aes M E8 H 20 6 lt 2 TO 5A TB2 6 FLT 2 IN RED 1 4 rd ce 2 GI OUT scat lt SPI 8 7 11 1 9 qe aa KIA g AUMTE IRE BTI CRI ALT START DISC 2 1 RUN 5 BLACK YELLOW STRIPE TI 1 L ea
10. Power Generation 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 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 Non timed shutdown and warning under FLT 2 conditions C Timed warning under FLT 2 conditions D Timed shutdown and warning under FLT 2 conditions Redistribution or publication of this document by any means is strictly prohibited es 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 2 START g jy SWITCHED 501 B REHOTE START 1 RU Oo Wi 2 B ae CR13
11. 4 ar 3 m us PRE LOP 5A 4 5 A TB2 PRE HET 5A 8 RI I 20 9 LOP 5 5 24 75 S 2 f cn js 8 8 IGURATIONS PREHEAT SOLENOID GLOW PLUGS HI OUTPUT MOTOROLA SW DEN 7 5 ups AII TBI 2 SW TO GAUGES 9 bes pikes J4 F5 BT EC 16 SHUT DOWN M 15 1 7 e HR2 HR4 HR5 HR6 MIA TBI G ae 15 2 4 FLT 5A NOTE RECTIFIER BRIDGE MOUNTED HOUR METER ON INSIDE BACKWALL OF CONTROL MI I TB2 2 FLT 2 5A BOX BELOW AC VOLTAGE REGULATOR RI2 1 7 4 TB2 LET 5A M OIL PRESS GAUGE Lo FUEL 5 A 12 SW 5 OVERSPEED CONFIGURATION ALTERNATOR CONFIGURATIONS MI ELECTRONIC MECHANICAL zx 27 I2VOLT 24 VOLT 12 VOLT 24 VOLT 2 VOLT 24 VOLT ua fa E2 J2 6 BOSCH MOTOROLA DELCO MOTOROLA WATER GAUGE Ph e 2 WATER TEMP All d cl EL m lt lt ENG HARNESS All JI 3 4 11 1 10 26 3B 6 OO n RESISTOR AND 2053 2 2 DIODE BI BAT oUTPur se l 55 1 M cONETOURATION 1 AlITBI 10 CONFIGURATION gt ALITBI 5 N LCURATION GND No 612 6685 sh2of2
12. If there is generator output voltage check for 120 VAC across pin connectors P1 1 and P1 2 onthe ECM If there is no voltage check for loose or missing leads between the connectors and TB21 21 and TB21 32 inside the control box and service as necessary Replace the ECM if there is 120 VAC across pin con nectors P1 1 and P1 2 but neither RUN lamp lights during normal operation r 4 12 Redistribution or publication of this document 0 Generation by any means is strictly prohibited N Hazards present in troubleshooting 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 page and carefully 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 The line circuit breaker is OFF sure it is safe to reconnect power and then throw the circuit breaker ON Shut down the set and service as necessary to clear The line circuit breaker has TRIPPED the short circuit or ground fault that caused tripping and then RESET the circuit breaker and start the set 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 The line circuit breaker is faulty er and throw
13. 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 A11 TB1 2 PRIMARY START DISCONNECT A11 TB1 3 SECONDARY START DISCONNECT 11 1 5 GND 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 STOP POTENTIOMETER A11 TB1 6 REMOTE START A11 TB1 7 CONTROL A11 TB1 7 B ES1855s FIGURE 3 12 TIME DELAY START STOP MODULE Power Generation Redistribution or publication of this document by any means is strictly prohibited SEQUENCE OF OPERATION 10 Relays K2 are de energized by latch ing relay K6 causing shutdown to occur if the engine does not start within 75 seconds The Overcrank indicator lamp lights and common The sequence of operation is as follows Refer to the schematic on Page 7 6 or 7 8 1 The is powered by cranking battery volt age 12 VDC Terminal TB1 9 is connected to battery positive and connector P1 6 to bat tery negative alarm terminal TB1 4 is powered The ECM has a cycle crank feature where the en gine is cranked for three 15 second periods al ternated with two 15 se
14. i Generation by any means is strictly prohibited 0 N C N 0 ISOLATED N C N70 N C ALARM N C RUN N 0 N C TB2 t o E dp lt as cows 5 2 corr 5 5 Sz ug muc 2g gt Ou Ll 2 AA ee 1 SEPIO 5 55 1 xb ue 49940 zz gt gt 0 ul LE QE ae ies cor gt 1 azos Y 5 Wey Lo NE Ls Paris 1 L A s PE ozmo T tO Bo uo2zo 1 1 ol 1 CN la e i 1 gt gt 1 1 RAE E es e po lt lt 2 2 1 9 oN m 1 1
15. but greater than 14 psi 97 kPa Service the engine The PRE LOW OIL PRESSURE lamp comes on while the engine is running lubricating system according to the engine service manual Normal operating range is 35 to 60 psi 241 to 414 kPa Shut down the set if possible or disconnect non critical Li dia E UE loads Engine temperature will be greater than 220 F E lamp comes on while the engine is 104 C but less than 230 110 C Service the en running 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 grade of fuel The customer has supplied the fuel level The LOW FUEL lamp comes on switch to make use of this warning Service as required The customer has supplied the System fault indicating switches By means of selec tion jumpers either fault may be chosen to shut down the engine See See Section 3 Engine Control FAULT 1 or FAULT 2 RED P xd Pow r 4 11 Redistribution or publication of this document Generation by any means is strictly prohibited N SI Hazards present in troubleshooting 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 page and
16. Reconnection Diagram e Page 7 10 Typical Connections to the 7 11 Customer Connections at the Aux Page 7 2 Voltage Regulator VRAS 2 Instal iliary Relay Board lation Page 7 12 Engine Harness Page 7 3 AC Wiring without meters e Page 7 13 DC Harness FA Power 7 1 Redistribution or publication of this document 4 Generation by any means is strictly prohibited LEFT DOOR REAR VIEW 102 BACK WALL OF CABINET R2 y QUEE 9 L9 or a M ry 5 2 gt gt Ny 7 gt lt LINE ed p 1234 5 617 8 9 10 M23 LB 2 2 wos d Ao n N E ziel 9 lu sg aaga CX CALI diis 957 9 55 E TO EXCITER FIELD DC CONTROL JI l Jl 2 VOLTAGE REGULATOR VRAS 2 INSTALLATION 7 2 Redistribution or publication of this document Generation by any means is strictly prohibited ta THIS IS A REPRESENTATIVE GENERIC
17. THIS IS REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE RIGHT SIDE WALL HORIZONTAL RIGHT SIDE DOOR BACK WALL VERTICAL REAR INSIDE VIEW e WAS amp 3 NN niuis DSII All PCB ASSY ENGINE MONITOR TA 2 nn Al 193 8 MI2 S 2 a 105130 n ALJ3 13 oh AIS T81 7 5 H enea 19 SWITCHED B ojo E sraa JO 8 IN TDS I4 VENERE 2 S aS STARTER SOLENOID mam TAT RI I 7 B OUT 15 AMPS MAX bd ed Or 1103 11 2 g 6 REMOTE START ojok T ESTE 55 5 GROUND olo 2 O ay S 98 COMMON ALARM 4 5 10317 1112329 ejs 3 Cy RUN ul 1 2 z z amp Ll RE 2 DC START DISCONNECT INPUT 2 fosis t z CES 1 ovERsPEED INPUT ri ele Aenses gt E 120521 2 7 z I N _ 8 9 n 522 2 See 5 E
18. engine 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 Replace the engine driven battery charging alternator if normal battery charging voltage is not between 12 and 15 volts If the set is in standby service install a battery charger Fuse F1 on the ECM A11 board has Replace the fuse with one of the same type and amp blown If fuse F1 blows again the wire between ECM terminal TB1 8 and starter solenoid terminal S may be loose or damaged causing a short to ground Repair as neces sary If fuse F1 still blows service or replace the starter or the solenoid according to the engine service manual Check for battery voltage 12 VDC between EOM ter The wire between ECM terminal TB1 9 minal TB1 9 and the grounding stud on the and starter solenoid terminal BAT is floor of the control cabinet Check clean and tighten loose damaged or missing the connectors at both ends and replace the wire if it is damaged Continued on next page FA Po w 4 2 Redistribution or publication of this document Generation by any means is strictly prohibited N Hazards present in troubleshooting can cause equipment damage severe personal injury or death Troubleshooting must be performed by qualified persons who know about fuel elec
19. is faulty Replace the voltage regulator Voltage Regulator VR21 is faulty Replacing VRAS 2 before servicing other faults can lead to damage to the new VRAS 2 P xd Pow r 4 17 Redistribution or publication of this document Generation by any means is strictly prohibited N SI Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual OUTPUT VOLTAGE IS UNSTABLE Adjust output voltage according to Section 2 AC Con trol The voltage has been adjusted improper ly 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 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 1 500 ohms The voltage adjusting rheostat on the control panel is faulty if provided Replace the voltage regulator Voltage Regulator VR21 is faulty Replacing VRAS 2 before servicing other faults can lead to damage to the new VRAS 2 2 2 er GA Powe 4 18 Redistribution or publication of this document e Generation by any means is stri
20. 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 Provide an adequate exhaust system to 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 Make sure 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 Keep your hands clothing and jewelry away from moving parts 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 drive belts etc 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 e f adj
21. 4 33 zo UPPER OFF 44 N 42 41 33 R CURRENT 4 0521 ra LI L2 IB 11 18 22 32 M 44 N 33 R INSTALLATION FREQUENCY METER DS22 ie LOWER 1 12 14 11 18 c 22 44 N 42 41 43 Nod 2 C82 Line FICO GENERATOR B n n lt 5 X C EXCITER ARMATURE FULL WAVE _ Fa BRIDGE RECTIFIER 612 6490 sh 1 of 1 Rev 5 Sys CADAM Modified 10 3 95 AC WIRING WITH METERS GA Power 7 4 Redistribution or publication of this document 4 Generation by any means is strictly prohibited iz THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR BACK CABINET VERTICAL RIGHT SIDE DOOR TROUBLESHOOTING REFER TO THE SIDE WALL HORIZONTAL INSIDE VIEW WIRING DIAGRAM PACKAGE THAT WAS 5 12 ic cm 0511 ASSY ENGINE MONITOR TAR 2 7 1103 5 2 2 a 511 6 RIS MII S 0513 ARIES xu 15 1 7
22. AITU3 6 5252 egget PM 1 2 p t 25258 we 3 120612 2 105211 7 o E wal Pee ee SSeS RRS E MEC 5 E 5 555552885 9995 J a OO AllJ3 4 Sy Ga 2 0000090000 90000090 2572 1 516 2 WIE CUSTOMER CONNECTIONS 2281852 6 5 4 3 2 pole 5 4 3 2 MI2 JI Jile 7 6 5 4 3 2 1 42 6 5 4 3 2 L jAI DS13 2 1356 x NUS GND Bu 8 2 8 3 sl lel lt 5 l 5 1 2 gt gt 1 5 054 2 N ONE 2 my 120V MIA GND STUD J9 zs P9 PIO 2 P zv MI2 JI 6 545 2 MI2 JI 3 m 6 Js 19 xix m E 67 AII TBI 2 CRI 4 RI eim 11 1 8 ENGINE HARNESS _ SI EI NOTES 2f 1 2 4 1101 7 amp p ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION 7 ENG GND N E2 2 ITEM NUMBERS REFER TO DWG NO 539 0741 VERT D ILLUS STD CONTROL AND 539 0997 HORIZ 5 AN d c r1 p nes R3 3 GAUGE RESISTORS R12 13 ILLUS 88 ARE USED ON 24V zl 02 04 VERSION ONLY MOUNT BEFORE ATTACHING HARNESS ENG 4 TIE ALL UNUSED LEADS INTO HARNESS SEE SHEET 2 N ALITBI 10 5 GROUND BETWEEN MII amp MI2 ILLUS 477 78 I
23. AND LPG LIQUID FIGURE 6 6 COMBINATION FUEL SYSTEMS Power Generation 6 7 Redistribution or publication of this document by any means is strictly prohibited 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 load and turn the power adjusting screw clockwise until the engine be gins to lose speed and then sl
24. GROUND OUTPUT TO LIGHT RELAY TB2 3 FAULT 1 GROUND INPUT FROM SENDER a 3 4 33333559 TB2 4 FAULT 1 GROUND OUTPUT TO LIGHT RELAY gt TB2 5 REMOTE RESET MOMENTARY CONTACT TO GROUND TB2 6 OVERCRANK FAULT GROUND OUTPUT TO LIGHT RELAY po AARAU TB2 7 OVERSPEED FAULT GROUND OUTPUT TO LIGHT RELAY TB2 8 HIGH ENGINE TEMPERATURE FAULT GROUND OUTPUT TO LIGHT RELAY 742 TB2 9 LOW PRESSURE FAULT GROUND OUTPUT TO LIGHT RELAY E o lA TB2 10 PRE HIGH ENGINE TEMPERATURE WARNING GROUND OUTPUT TO LIGHT RELAY TB2 11 PRE LOW OIL PRESSURE WARNING GROUND OUTPUT TO LIGHT RELAY CUSTOMER SUPPLIED WIRING gt gt TB2 12 SWITCH OFF WARNING GROUND OUTPUT TO LIGHT RELAY FACTORY WIRING TB2 13 LOW ENGINE TEMPERATURE WARNING GROUND OUTPUT TO LIGHT RELAY A 0 5 RATED DEVICE MAXIMUM TB2 14 LOW FUEL WARNING GROUND INPUT FROM SENDER n poetae deed TB2 15 LOW FUEL WARNING GROUND OUTPUT TO LIGHT RELAY TB2 16 EMERGENCY SHUT DOWN MOMENTARY CONTACT GROUND p 300 284 FACTORY AND CUSTOMER CONNECTIONS AT THE ENGINE MONITOR BOARD TERMINALS GA Power 7 10 Redistribution or publication of this document o
25. Powe 6 1 Redistribution or publication of this document e Generation by any means is strictly prohibited Y lt LINKAGE ADJUSTMENT 2 Verify that the ball joint screw is mounted in the third hole from the outside end of the governor Figure 6 2 illustrates the governor linkage Make arm sure that the governor controller is securely mounted to the engine bracket To adjust the link age 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 BALL JOINT SCREW BALL JOINT SCREW P2 GASEOUS CARB 2 558 GOVERNOR ROD DETAILS SHOWN IN THROTTLE CLOSED POSITION GASOLINE n THROTTLE LEVER GOVERNOR ARM GOVERNOR OUTSIDE END x ROD FIGURE 6 2 GOVERNOR LINKAGE GA Powe r 6 2 Redistribution or publication of this document 24 Generation by any means is strictly prohibited MAGNETIC SPEED PICKUP UNIT lines up in the center of the mounting hol
26. REF ONLY GN ON SYS 5 TROUBLESHOOTING REFER THE WIRING DIAGRAM PACKAGE THAT WAS PANEL LAMP INCLUDED WITH YOUR GENSET ng gt Poe ASSY ENGINE MONITOR 2511 LAMB REED DIESEL APPLICATIONS GAS GASOLINE APPLICATION J4 4 46 Sw OFF B ui TA Po 26 26 FUEL SOLENOID RUN 3 EL 18 gg 4 4 94 P4 A 6 A WA AIS TBI 7 Sey 512 K7 S n 0 il
27. SW GND CONT BAT DETA B GND GI B AlI TBI 8 AII TBI 9 AII TBI IO LP CRI CR CRI 2 CR2 2 2 CRI 1 T26 12 5 11 1 8 AII TBI 2 BI SW P4 BROWN FORD LEAD TABULATION FROM TO STATION STATION DETAIL SI N J2 4 52 J2 5 S3 J2 6 55 12 2 All CRI 2 CRI 1 1 8 T26 Al1 TBI 10 GND GI GND SW All BI BAT GND GND CONT 2 5 4 1 7 W E2 JI 8 Al I TBI 8 GI D JI 3 BAT GI B BI BAT P WHITE BI B PI WHITE BI S 2 BI S 1 8 21 21 1 2 TB21 32 41 6 GND CONT T26 GOV RED GND GOV BLK 91 GND J2 MI2 UI 6 22 3 MI2 JI 3 s JI 3 T GND No 336 3322 sh 1 of 1 BI B9 Rev Sys CADAM Modified 9 26 95 ENGINE HARNESS Power 7 12 Redistribution or publication of this document 2 Generation by means is strictly prohibited THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET gt p J2 3 gt diee A GND C88 5 Ne A MIA LEAD TABULATION FROM TO STATION STATION MI2 JI 3 42 5 MI2 JI 6 J2 1 AllJA4 35 2 8 AllJ4 4 Al 1 4 5 5
28. Section 3 Engine Control The OVERSPEED lamp comes on when the engine shuts down Adjust the governor according to Section 6 Gover nors Mechanical Governor Service or replace the injec tion pump unit if the set still shuts down due to over speed Electronic Governor If the governor cannot be ad justed to prevent shutdown due to overspeed check for binding in the linkage Repair and adjust the linkage as necessary A spring inside the actuator will resist movement which is normal If the set still shuts down due to overspeed re install the magnetic speed pick up unit to make sure the clearance with the flywheel gear teeth is correct 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 linkage through its full travel when power is connected or return it when power is discon nected Replace the governor controller if the set still shuts down due to overspeed Continued on next page P xd Pow r 4 7 Redistribution or publication of this document Generation by any means is strictly prohibite
29. 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 Also this switch has a light which lights following a fault or emergency shut down The light remains lit until the engine control has been reset The Panel Lamp position lights the panel illumination lamp Coolant Temperature Gauge M12 The coolant temperature gauge indicates engine coolant tem perature Oil Pressure Gauge M11 The oil pressure gauge indicates engine oil pressure RESET LAMP TEST PANEL LIGHT SWITCH INDICATOR LAMPS EMERGENCY STOP BUTTON TACHOMETER FIGURE 3 1 ENGINE CONTROL PANEL P xd Pow r 3 1 Redistribution or publication of this document Generation by any means is strictly prohibited NX 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 Q A12 n t PRE LO OI
30. ad justment lock it at its midpoint Then turn voltage adjusting pot R32 on the regulator board until rated voltage is obtained TABLE 2 1 VRAS 2 SWITCH SETTINGS bo STABILITY RANGE RATING S1 1 4 51 2 3 2 3 20 35 40 50 OFF ON TORQUE MATCHING MODE VOLTAGE SENSING TMB VOLTS HZ 60HZ TMB TMC VOLTS HZ 50HZ NON FREQ FREQUENCY SENSING TMA SEMI FREQ seas s2 seve seaa s2 sra F Power Generation 2 3 Redistribution or publication of this document by any means is strictly prohibited VOLTAGE REGULATOR VRAS 2 STABILITY ON OFF Ces 530 VOL Re4 CIE 2
31. carefully observe all instructions and precautions in this manual THE GREEN RUN LAMPS STAY OFF BUT THE SET RUNS NORMALLY The set mounted RUN lamp does not light Press the panel Lamp Test switch and replace the run although the starter has disconnected lamp bulb if it does not light normally and the engine is running If the lamp is good this indicates that the DC discon nect circuit K14 relay circuit on the ECM is not work ing Check the DC voltmeter and if there is not at least 12 volts check for loose or missing wiring between the battery charging alternator and terminal TB1 2 and pin connector P1 3 on the ECM See Page 7 6 or 7 8 re garding the applicable alternator configuration If the connections are good replace the battery charging al ternator If the RUN lamp wiring connections and battery charging alternator are all good and the RUN lamp does not light during normal operation replace the ECM Press the panel Lamp Test switch and replace the run PAN ee d ananghie lamp bulb if it does not light Test the remote RUN lamp ae anche engineris by suitable means and replace it if it does not light If both lamps are good this indicates that the AC dis connect circuit K10 relay circuit on the ECM is not working Check the AC voltmeter to determine wheth er or not there is generator output voltage and service as necessary See There Is No Output Voltage
32. it ON and check for electrical continuity across each line contact Replace the circuit breaker if there is measurable resistance across any contact RESET the circuit breaker If it keeps tripping trouble Field circuit breaker CB21 has TRIPPED shoot according to the chart Field Circuit Breaker Keeps Tripping Shut down the set attempt to RESET the circuit break m and disconnect either lead Replace the circuit Field circuit breaker CB21 is faulty breaker if there is measurable resistance across the terminals Continued on next page P xd Pow r 4 13 Redistribution or publication of this document Generation by any means is strictly prohibited N SI Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THERE IS NO OUTPUT VOLTAGE CONT Continued from previous page Determine as follows whether the fault is the VOLTAGE REGULATING or GENERATOR circuits 1 Throw the line circuit breaker OFF and shut down the set CAUTION 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 fro
33. lock washers Torque to 4 5 ft Ib 6 Nem Refer to Figure 5 9 and set to proper gap Connect overspeed switch lead wire to termi nal on overspeed switch bracket Install the control sheet metal back on the gen erator Reconnect the generator as required Redistribution or publication of this document by any means is strictly prohibited DISK TO ROTOR BOLT GENERATOR DISK TO FLYWHEEL BOLT EXCITER ROTOR MODIFIED HEX HEAD BOLT OVERSPEED STATOR TO FLYWHEEL Tm c im SPACER Se BALL BEARING EXCITER TO END BELL BOLT GENERATOR STATOR OVERSPEED GENERATOR AIR SCREEN EXCITER STATOR O RING OIL SEAL FIGURE 5 9 GENERATOR ASSEMBLY Po wer Generation m 5 11 CONTACT ASSEMBLY Redistribution or publication of this document by any means is strictly prohibited 6 Governors Carburetors ELECTRIC GOVERNOR ADJUSTMENT 2 Start the set let the engine warm up under a partial load at least 1 4 rated load and then dis If necessary adjust the gas mixture the governor connect all loads If the governor has been re linkage and the magnetic speed pickup unit as placed adjust the Gain 1 and Stability 1 pots to instructed in this section before adjusting the gover their center settings nor controller Make sure that the governor assem E bly is securely mounted Also make sure that the 3 Adjustthe Gain 1 pot until the engine is stable governor
34. next page P xd Pow r 4 15 Redistribution or publication of this document Generation by any means is strictly prohibited N SI Hazards present in troubleshooting 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 page and carefully 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 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 assem
35. ohmmeter Resistance should be approximately 20 ohms at 68 F 20 C Before performing the following insulation resist ance test refer to the Insulation Resistance and Po larization Index Test procedure at the beginning of this section MEASURE WINDING INSULATION RESISTANCE BETWEEN EITHER LEAD AND THE STATOR LAMINATIONS Testing Winding Insulation Resistance Disconnect the F1 and F2 exciter stator leads at the voltage regulator and isolate them from ground Connect the megger between one of the leads and ground and conduct the test Replace the stator if insulation resistance is less than 1 megohm 1 000 000 ohms MEASURE WINDING RESISTANCE BETWEEN THE TWO STATOR LEADS F1 AND F2 FIGURE 5 2 TESTING AND FLASHING THE EXCITER STATOR Redistribution or publication of this document by any means is strictly prohibited Fa Power 5 3 osi Generation Y lt Y lt Flashing the Field If output voltage does not build up it may be neces sary to restore residual magnetism by flashing the field This requires a 12 volt battery a 12 ampere 300 volt diode and a 12 volt light bulb or a 2 watt 20 ohm resistor wired as shown in Figure 5 3 Flashing the field can be accomplished with gener ator set operating or not Either of the following pro cedures should be sufficient to restore residual magnetism Incorrect field flashing procedures can damage regulator or exciter stator wind ings Do not maintain
36. output voltage remain after the flash circuit is removed YES The generator assembly and VRAS 2 OK e VRAS 2 is defective Use the VOLTAGE REGULATING FAULTS chart to troubleshoot VRAS 2 Puta full load on the generator set Does the generator set output stay up after the generator set has responded to the load YES The generator assembly and VRAS 2 are OK NO Check each diode according to Section 5 Servicing the Generator Continued on next page Lan Pm Powe 4 14 Redistribution or publication of this document Generation by any means is strictly prohibited x I Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THERE IS NO OUTPUT VOLTAGE CONT Continued from previous page VRAS 2 FAULTS The field has lost its residual magnetism Flash the field according to Section 5 Servicing the Generator Check all connections against the wiring diagrams on pages 7 2 and 7 9 and rewire as necessary Replace VRAS 2 if the wiring is correct and there is no output Voltage Regulator VRAS 2 is faulty voltage Replacing VRAS 2 before servicing other faults can lead to damage to the new VRAS 2 Continued on
37. personal injury or death e 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 e 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 remains even after the equipment is discon e Substances in exhaust gases have been iden nected from the power source Plan the time for tified by some state or federal agencies as maintenance with authorized personnel so that causing cancer or reproductive toxicity Take the equipment can be de energized and safely care not to breath or ingest or come into contact grounded with exhaust gases GA Powe r iv Redistribution or publication of this document 24 Generation by any means is strictly prohibited 1 Introduction ABOUT THIS MANUAL This service manual is for the EK begin Spec D and EM begin Spec W series gasoline and gas eous fuel generator sets It includes engine and generator troubleshooting guides Engine service instructions are in the applicable engine service manual Operating and maintenance instructions 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 assembly At tempts to repair a printed circuit board can lead to cos
38. 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 This module has an adjustable time delay relay K17 to prevent 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 VAC or 277 480 VAC sets HAZARDOUS VOLTAGE Touching uninsulated high voltage parts inside the con trol panel box can result in severe personal inju ry 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
39. 12 1 4 6 512 3 4 7 512 2 Al 1 4 8 1 6 Al 1 4 9 T 1144 10 512 6 1194 1 511 3 11 4 2 2 0511 1 511 2 3 DSII 2 14 GND 4 3 0511 1 512 4 MII I GND 5 MI I G MI2 G 517 AllI J4 2 511 8 11 6 GND GND No 338 3326 sh 1 of 1 MI2 JI Rev A Sys CADAM MIg JI 9 Modified 9 27 95 DC HARNESS Power 7 13 Redistribution or publication of this document Generation by means is strictly prohibited Fd Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 6626 763 574 5000 International Use Fax 763 528 7229 Cummins is a registered trademark of Cummins Inc Power Generation Power Generation Redistribution or publication of this document by any means is strictly prohibited
40. 4224224222 5 87881g THIS JUMPER MUST 3 TO 4 FIGURE 2 2 VOLTAGE REGULATOR ADJUSTMENT POTS AND SELECTION JUMPERS GA Powe r 2 4 Redistribution or publication of this document lt Y Generation by any means is strictly prohibited 7 A OUTPUT VOLTAGE SENSING LEADS Power ROTATING RECTIFIERS EXCITER STATOR VRAS 2 300 2880 VOLTAGE REGULATOR VR21 Co CO de m 466 CO CO CO BRE FIELD CIRCUIT BREAKER CB21 VOLTAGE TRIMMER R21 optional FIGURE 2 3 TYPICAL VOLTAGE REGULATING CIRCUIT Generation 2 5 Redistribution or publication of this document by any means is strictly prohibited PRINCIPLE GENERATOR OPERATION 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 constant by the voltage regulator and engine governor 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 ex citer rotor converts exciter output 3 phase AC to DC The exciter rotor is m
41. 60HZ 1 L TI2 L 8 120 240 60HZ 19 SECONDARY CURRENT TRANSFORMER CONN 1 2 Lo PHASE 9 SECONDARY CURRENT TA TRANSFORMER CONN 1 5 TA 6D TRANSFORMER ASSY E LO L T8 T2 4 Wr Be ie 17 Hiel O TB21 22 i m T9 T5 2 xe TIO 2 75 LS LS L3 T7 L2 1821 23 g T7 240V2 t 120V TS 127 220V 60HZ 254 440V 60HZ T9 1 120 208 60HZ 240 416V 60HZ He xe 110 220V 60HZ 110 190V 60HZ 220 380V 60HZ 110 220V 60HZ ail ui i 115 230 60HZ 115 200V 60HZ 230 400V 60HZ 115 230 60HZ T5 19 0 O 25 3 24 EN SECONDARY CURRENT TRANSFORMER CONN 1 3 SECONDARY CURRENT TRANSFORMER CONN 1 2 TSRANSEOEUER CONE Ies LS H2 xe 3 PHASE RECONNECTABLE PHASE RECONNECTABLE 2 R R NOTES CURRENT TRANSFORMER SECONDARY MUST BE MANUALLY SELECTED HIGH VOLTAGE ABOVE 300 VOLTS TERMINALS 162 VOLTAGE 7 9X BELOW 300 VOLTS USE TERMINALS 143 TERMINAL 1 IS COMMO T 920 580V 60HZ 547 600 60HZ 2 GENERATORS 6D E 7 F AND 9X H ARE RECONNECTABLE SECONDARY CURRENT TRANSFORMER CONN 2 SECONDARY CURRENT TRANSFORMER CONN 2 AND ARE WOUND FOR A SPECIFIC VOLTAGE cT22 L2 2 Wo L2 TI 7 8 VOLTAGE CODE LO LO CONT 10 INPUT I5 515 6D 7 SR 52 9X Tao 1 Z B
42. 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 Power Generation 3 12 GND AIITB2 3 AIITBI IO 14 11 12 22 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 10 OVER UNDER VOLTAGE MODULE Redistribution or publication of this document by any means is strictly prohibited 20 2 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 Power Generation 3 13 14 12 22 21 24 18 15 16 L 26 25 28 21 26 21 22 300 3141 FIGURE 3 11 OVER UNDER FREQUENCY MODULE Redistribution or publication of this document by any means is strictly prohibited d Time Delay Start Stop Module 15
43. B with a Detector 7 or 12 Genset con trol The board is mounted directly on top of the using standoffs and has access holes for the fuses located on the ECM There are two versions of the ARB with and without the set of 12 Fault re lays Figure 3 9 Page 7 11 is a detailed connec tion diagram for the ARB 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 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 and N O Plug In Relays 1 2 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 W3 perform the
44. Caution This document contains mixed page sizes 8 5 or 11 x 17 which may affect printing Please adjust your printer settings c Poweraccording to the size of each page you wish to print on Or publication of this document Generation by any means is strictly prohibited e Onon Service Manual EK EM GENERATOR SET EK Begin Spec D EM Begin Spec W Printed U S A 928 0505 12 95 GA Redistribution or publication of this document d by any means is strictly prohibited kE Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS ii 1 INTRODUCTION 1 1 About This Manual css e eg RR RR ERR ERROR EROR RE eee ad 1 1 Test EguipMeEN TTL 1 1 How to Obtain Service 1 1 2 3522055 2 1 General 2 1 Standard Control Panel 2 1 Optional Control Panel Components 2 1 Voltage Regulator Description 2 2 Voltage Regulator Adjustments 2 3 Principle Of Generator Operation 2 6 3 ENGINE CONTROL PITE EINER ss 3 1 Control Panel ELTE 3 1 Standard Control Panel Components
45. E SENSOR S1 PRE LOW OIL PRESSURE LOW ENGINE TEMPERATURE SENSOR 55 PRE HIGH ENGINE TEMPERATURE amp WATER TEMPERATURE SENDER OIL PRESSURE SENDER 1 FIGURE 3 5 ENGINE SENSOR LOCATIONS P ud Pow r 3 6 Redistribution or publication of this document 1 Generation by any means is strictly prohibited Low Coolant Level Cutout Switch with the high engine temperature cutout switch to shut down the engine and light the High Engine When coolant level in the radiator top tank falls be Temperature lamp or in parallel with the pre high low the switch sensor the switch closes the circuit to engine temperature switch to light the Pre High En ground This switch may be connected in parallel gine Temperature light only See Figure 3 6 RADIATOR TOP TANK LOW COOLANT LEVEL SWITCH TO ECM TB2 8 HIGH ENGINE TEMP OR ECM TB2 10 PRE HIGH ENGINE TEMP FIGURE 3 6 LOW COOLANT LEVEL SWITCH gt GA Pow r 3 7 Redistribution or publication of this document di Generation by any means is strictly prohibited Coolant Temperature Gauge and Warning Light Circuits An electronic PCB assembly is mounted on the PCB MOUNTING ON BACK OF GAUGE back of the coolant temperature gauge M12 with three terminal nuts The PCB assembly carries two relays that provide signals
46. Ee uu SENE FEL rel al els al el abe Y LAAAAAAAAA 4 5 gt E m z EE be EM ee ee 22 2926 5 os u de 2 Ey y Top om mo ip T T T be 3 EE EB o gt be 22 o 2 gt aoe 2 sc THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET GND GND 55 GND CONT J2 2 TB21 32 JI 2 ak Jl 7821 21 SI NC JI 1 42 4 2 CR2 2 GND P4 BROWN JI 6 FORD P3 IGN COIL P4 GOV BLK SW GND jx 2j T26 Al TBI v 11 10 ane T26 7 MI2 JI 6 GOV RED 22 1 CR2 BI SW DETAIL A SEE DETAIL C PI WHITE PI WHITE SEE DE TAUG BI BAT FORD S3 J2 6 AII TBI 8 BI
47. F H 22 T7 T7 TI TZ 7 9 23 T8 T2 XI T8 T2 T8 8 24 T4 E ec pua 25 9 3 T9 T9 9 LS E ssa LS 26 TiO 11 2 3 2 Tio 0 10 JUMPER 22 24 23 24 22 24 625 2068 sh 1of1 Rev Sys CADAM Modified 10 2 95 RECONNECTION DIAGRAM Power 7 9 Redistribution or publication of this document Generation by any means is strictly prohibited NR CONTROL Ul C8 U3 05 5 711 T no SW Bt 7 ro GAUGES TB1 10 SWITCHED OUTPUT OUTPUT RELAY 12 FUSED 20 5 ENERGIZED WHEN THE START SIGNAL IS APPLIED AND DE ENERGIZED SHUTDOWN NORMAL AND FAULT Q K7 K8 eu CRI 00 4 A O TB1 9 B INPUT BATTERY POSITIVE CONNECTION D CO Ol CO TO CR4 10 C5 11 R4 we TB1 8 START SOLENOID OUTPUT TO RELAY K11 FUSED AT 20 AMPS 2 K11 15A 1 7 4 RB W7 R7 Cl R6 crig e 8 1 7 OUTPUT OUTPUT TIME DELAY START STOP MODULE A15 Lo FUSED AT 15 AMPS AVAILABLE WHEN
48. G WITHOUT METERS 7 3 Redistribution or publication of this document 4 Generation by any means is strictly prohibited iz THIS IS REPRESENTATIVE GENERIC SCHEMATIC DIAGRAM WIRING DIAGRAM SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE E LEFT SIDE DOOR PEAR INSIDE INSIDE VIEW INSIDE VIEW WIRING DIAGRAM PACKAGE THAT WAS EXCITER ARMATURE BRIDGE T2 T3 aly 0521 T5 neas Sine au BACK WALL OF CABINET VERTICAL INCLUDED WITH YOUR GENSET LEFT WALL OF TRAY HORIZONTAL a S BOTTOM OF TRAY HORIZONTAL a m 6 ox u VOY a ri a la bis M b
49. L 1 3 4 5 gt a aw lt lt 2 a DC DISC IN 0S IN 2 OUT LIN QUT LAMP 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 or during standby under FLT 2 conditions B Allows selection of functions with W1 jumper W9 Jumper Position A Warning while running or during standby under FLT 1 conditions B Allows selection of functions with W2 jumper GAUGES oon 79 A 7 8 g 11 13 15 1 LOP PREHET PRELOP SW OFF LET IN DUT SHUT 00 FIGURE 3 4 ENGINE CONTROL MONITOR FUSES AND FUNCTION SELECTION JUMPERS Power Generation 3 5 Redistribution or publication of this document by any means is strictly prohibited ENGINE GAUGE SENDERS AND Always use pipe thread sealant on gauge senders SHUTDOWN SWITCHES and warning and shutdown switches Figure 3 5 shows the locations of the gauge send Teflon tape is not recommended for ers and the coolant temperature and oil pressure switches and senders that are grounded to the sensing switches to which the ECM responds The engine by thread contact as it may interfere with switches function by closing the fault or warning cir the ground path cuit to the engine chassis ground battery nega tive T26 OF ENGINE HARNESS LOW OIL PRESSUR
50. L PRES Run Green This lamp indicates that the gen oom oss erator set is running and that the starter has REHLENG TEM been disconnected LO OIL PRES Pre Low Oil Pressure Yellow This lamp indi cates that engine oil pressure is abnormally low less than 20 psi 138 Normal operating OVERSPEED range is 35 to 60 psi 241 to 414 kPa Low Oil Pressure Red This lamp indicates that the engine shut down because of exces ENG TEMP OVERCRANK FAULT 1 ins sively low engine oil pressure less than 14 psi FAULT 2 LOW ENG TEMP e Pre High Engine Temperature Yellow This lamp indicates that engine coolant tempera LO FUEL ture is abnormally high greater than 220 F 104 Frequency High Engine Temperature Red This lamp indicates that the engine shut down because of excessively high engine coolant temperature greater than 230 110 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 539 0741 2 e Overspeed Red This lamp indicates that the engine shut down because of overspeed FIGURE 3 2 DETECTOR 12 INDICATOR LAMPS wer 3 2 Redistribution or publication of this document gt Generation by any means is strictly prohibited 2 gt OPTIONAL CONTROL PANEL COMPONENTS Oil Temperature Gauge M15 The oil temperature gaug
51. 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 6 TESTING THE MAIN ROTOR neration 5 7 Redistribution or publication of this document by any means is strictly prohibited MAIN STATOR Testing Winding Resistance Disconnect all stator leads from the terminals to which they are connected Using a Wheatstone bridge or ohmmeter having at least 0 001 ohm pre cision measure electrical resistance across each pair of stator leads T1 T4 T7 T10 T2 T5 T8 T11 T3 T6 T9 T12 Replace the stator if the resistance of any winding is not as specified in Table 5 1 TABLE 5 1 STATOR RESISTANCE VALUES VOLTAGE CODE MODEL L R 15 amp 32 H amp 9X 0 116 0 141 0 425 0 520 0 432 0 528 0 047 0 058 0 193 0 236 0 202 0 248 These values are approximate plus or minus 10 percent at 68 F 20 C Alternatively winding resistance can be measured line to line at the generator terminals L1 L2 L2 L3 L3 L1 on star connected generators On a 600 volt generator line to line resistance should be twice the table value two winding elements in se MEGGER OR INSULATION RESISTANCE METER ries On a series star connected generator line to line resistance should be four times the table val ue four winding elemen
52. ND ED 2 ITEM NUMBERS REFER TO DWG NO 539 0741 S2 Alldl 8 VERT D ILLUS STD CONTROL AND 539 0997 HORIZ AITJ2 5 Ale ENG rq gu pes 3 GAUGE RESISTORS 12 13 ILLUS 88 ARE USED ON 24V GND n 02 04 VERSION ONLY MOUNT BEFORE ATTACHING HARNESS 7 4 TIE ALL UNUSED LEADS INTO HARNESS 5 GROUND BETWEEN MII amp MI2 ILLUS 277 78 IS THROUGH SEE SHEET 2 s FOR OVERSPEED mou THE FRONT PANEL CONF IGURATION e 26 6 DASHED LEADS INDICATE WHEN USED 20A 8 ITEMS CRI CR2 RI AND LEAD GI 3 TO AII TBI 2 ARE USED ONLY ON THE CUMMINS B amp C BLOCK ENGINES USING SEE SHEET 2 THE DELCO MOTOROLA ALTERNATOR 1 PREHEAT SOLENOID 9 ON SOME SETS YOU MAY HAVE THIS INTERIM SILKSCREEN 55 GLOW PLUGS AND WIRING CONFIGURATION Al 1J2 2 0511 2 0511 Al J4 5 m gt FOR BAT ERY AND 8 19154 STARTER CONNECTION 512 3 Haag 2 ALL J4 7 SEE SHEET 2 2 5 352 56 3145 3216 15 1 7 All J4 11 All J4 10 NAL J4 6 STUD FOR ALTERNATOR DETATI A CONNECTION Lm A SEE SHEET 2 SEE NOTE 9 x ENG GND No 612 6684 sh 1 of2 Rev Sys CADAM Modified 9 26 95 7T LIGHT DC WIRING SHEET 1 OF 2 Power 7 5 Redistribution or publication of this document Generation by any means is strictly prohibited THIS IS REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR SCHEMATIC DIAGRAM mu gt Bt 0811 All NOTE AII INTERNAL CONN FOR
53. NNECTED AND THE ROTOR LAMINATIONS REMOVE DIODES CR1 THROUGH CR6 FROM DIODE HEAT SINK ASSEMBLIES AND MEASURE ELECTRICAL RESISTANCE ACROSS EACH PAIR OF WINDINGS T1 T2 T2 T3 T3 T1 FIGURE 5 5 TESTING THE EXCITER ROTOR Power Generation 5 6 Redistribution or publication of this document by any means is strictly prohibited Testing Winding Resistance Disconnect the two leads of the main rotor from the terminals on the rotating rectifier assembly See Figure 5 6 Measure electrical resistance between the two leads with a Wheatstone bridge or digital ohmmeter Replace the rotor if the resistance is not as shown in the following list Connect the rotor leads and torque the terminals to 24 in lbs 2 7 Nem when reassembling e EK 3 32 to 4 06 ohms at 68 F 20 C e 2 49 to 3 05 ohms at 68 F 20 C Before performing the following insulation resist ance test refer to the Insulation Resistance and Po larization Index Test procedure at the beginning of this section Insulation Resistance and PI Test Disconnect the two leads of the main rotor from the terminals on the rotating rectifier assembly Using a megger voltage set at 500 VDC measure the re sistance between either lead of the main rotor wind ings or the terminal to which it is connected and the main rotor laminations Replace the rotor if insula tion resistance is less than 1 megohm
54. R HE circuit powering relay K3 when the panel switch is pushed to Run or to Remote 8 Relay K10 is powered by the generator output voltage 120 VAC through plug in connectors If the emergency stop switch has been used the P1 1 and P1 2 The remote Run indicator lamp control will have to be reset to restore operation should light connected through terminal First pull the emergency stop switch button and TB1 3 then push the panel Stop and Reset switches 9 Relay K14 is powered by the engine driven The set is stopped manually by pressing the battery charging alternator 12 VDC through panel Stop switch or automatically by a remote plug in connector P1 3 The panel Run indica controller The panel switch must be in the Re tor lamp should light Relays K10 and K14 are mote position for remote automatic opera redundant tion Onolder ECM boards those having cartridge type fuses e If the starter disconnects normally but the panel Run indicator lamp does not light the DC K14 starter disconnect circuit is not working e Ifthe Minis disconnects normally but neither the panel nor the remote Run indicator lamps light the AC K10 starter dis connect circuit is not working 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 indica
55. S THROUGH OVERSPEED cag S 26 THE FRONT PANEL CONFIGURATION 20A 6 DASHED LEADS INDICATE WHEN USED 8 ITEMS CRI CR2 RI AND LEAD 61 3 2 SEE SHEET 2 ARE USED ONLY ON THE CUMMINS B amp C BLOCK ENGINES USING PREHEAT SOLENOID THE DELCO MOTOROLA ALTERNATOR oe 55 GLOW PLUGS 9 ON SOME SETS YOU MAY HAVE THIS INTERIM SILKSCREEN 8 7 AllJ2 2 AND WIRING CONFIGURATION fg 812 5 MIS Al J4 7 N 211 25 2 2 FOR BATTERY AND 3159 316 3155 316 STARTER CONNECTION AI5 TBI 7 11 04 11 ALI J4 10 Al J4 6 W SEE SHEET 2 DETATI stud FOR ALTERNATOR SEE NOTE 9 Si 2 J CONNECTION Ne C L SEE SHEET 2 612 6685 sh 1 of2 Rev Sys CADAM Modified 9 27 95 12 LIGHT DC WIRING SHEET 1 OF 2 Power 7 7 Redistribution or publication of this document Generation by any means is strictly prohibited THIS IS REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE SCHEMATIC DIAGRAM WIRING DIAGRAM PACKAGE THAT WAS
56. SC es L TB2 PRE LOP E BLACK YELLOW STRIPE JI fm 5 E TBI Q PRE HET 5A 2 E RI r 204 9 LOP 54 ni ITBI B d TB2 5 24V 75 E PREHEAT SOLENOID GLOW PLUGS HI QUTPUT MOTOROLA K2 7 OS 5A 8 2 SW Fe DEA IH 6 54 SW TO GAUGES ENG J SPa SA F5 ED GND 5 7 MIA TBI GND LA 15 O NOTE RECTIFIER BRIDGE MOUNTED HOUR METER ON INSIDE BACKWALL OF CONTROL S Mil BOX BELOW AC VOLTAGE REGULATOR ierra N 4 P4 G OIL PRESS GAUGE OVERSPEED CONFIGURATION ALTERNATOR CONFIGURATIONS MI2 ELECTRONIC MECHANICAL RI s 5 gt 7 2 PRESS I2VOLT 24 VOLT 2 VOLT 24 VOLT 12 VOLT 24 VOLT Mi 4 E2 J2 6 Bm BOSCH MOTOROLA DELCO MOTOROLA LE ocu 2 2 WATER TEMP GAUGE WATER TEMP ATI ze zi _ END a TO ENG HARNE All JI 3 4 AII TBI IO ENGINE TIE POINT 26 S EGG HARNESS DIODE BI BAT output 1 SS BI BAT CONFIGURATION AUKX PS uem L AUX P2 BATTERY CONF IGURATIONS e 1 5 SEE STARTER N CONFIGURATIONS 612 6684 sh20of2 Rev A Sys CADAM Modified 9 26 95 7 LIGHT WIRING SHEET 2 OF 2 d Power 7 6 Redistribution or publication of this document Generation by any means is strictly prohibited
57. STARTE ie lt p 1 p ie m CONF IONS CONN 9 Pat GND TO GUAGES FORD APPLICATIONS SPA REMOTE START m S CUST GND CONN 10 2AVDC DF I2VDC FORD 12 5 SOLENOID SHIFT 0512 BI i 5 5 e 24 BTI PRE LOP Q 0513 ui P5 i S LOP Jae 11781 9 T 5 Ji 13 Bs 4 WHITE BI BAT r K4 GI OUT BAT 0614 nde he a H BTI pg MOT T 2 93 52 BRN 8 LOP 1 f E 53 P2 J2 ut RED GRN STRIPE 710i ALETBITR Het 0516 ig T8 os IN DOSE osi 25 955 S3 N 2 05 i 6 OVERSPEED AII TBI 9 OA 9 P2 J2 1 r 2 JS oc 0518 55 m E wor 2 93 255 CB2 A la JIO ET Has ga gt mas CHRYSLER APPLICATIONS SPARK IGNITION 3 9 PRE HET BRN WHT STRIPE i ant i J2 P9 JI GRAY 4 ALM 4A FORD NON SOLENOID SHIFT SOLENOID SHIFT 2VDC 24VDC TB2 6 LAMB TARET 9 B BTI SIARTER 43 51 y IN a TO AC WD I20VAC a i 8 kH Dal goVAC Dau L EP al GI OUT 5 o RUN 5A v AITTBI 8 7 All 5 x ALT START DI
58. THE STARTING BATTERIES ARE CONNECTED CONTACT OF THE AUTOMATIC TRANSFER SWITCH TO TERMINAL TB1 5 OF MODULE A15 1 1 6 START CONNECTED TIME DELAY START STOP MODULE 15 CONNECT START L TB1 5 GROUND TB1 4 COMMON ALARM B OUTPUT 4 AMP RATED DEVICE MAXIMUM 7 lt gt 7 lt Kg K11 K13 K15 K17 K18 TB1 3 RUN CONNECTED TO TIME DELAY START STOP MODULE A15 t3 a CRI4 CRI5 CR16 20 1 TB1 2 DC DISCONNECT CONNECTED TIME DELAY START STOP MODULE A15 L 3 r 1 THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS i Plo INCLUDED WITH YOUR GENSET TB2 1 FAULT 2 GROUND INPUT FROM SENDER TB2 2 FAULT 2
59. 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 If fuse F2 still blows the wire between fuel solenoid K1 and terminal T26 may be loose or damaged causing a short to ground Repair as necessary Connect the terminal on fuel solenoid K1 to the BAT Fuel solenoid K1 is faulty does not terminal on starter relay with a jumper wire Re open place the fuel solenoid if it does not click each time power is connected Plug in repair or install engine coolant and engine oil heaters Low engine temperature is causing too low a cranking speed for starting Replace the engine oil if it is not of the recommended viscosity for the ambient temperature Continued on next page FA Po wW r 4 5 Redistribution or publication of this document Generation by any means is strictly prohibited SI Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THE ENGINE CRANKS BUT DOES NOT START Continued from previous page While cranking the engine measure voltage directly across the battery terminals and then immediately across the starter motor terminal an
60. ation of this document e Generation by any means is strictly prohibited 5 Servicing Generator TESTING THE GENERATOR These tests can be performed without removing the generator Before starting tests turn off or remove AC power from the battery charger and then discon nect 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 MAIN BLOWER STATOR EZ 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 other explosive fumes are fully dissi pated This
61. bly 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 Gr Pow r 4 16 Redistribution or publication of this document Generation by any means is strictly prohibited N SI Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual OUTPUT VOLTAGE IS TOO HIGH OR TOO LOW Engine speed is too high or too low Adjust engine speed according to Section 6 Gover 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 Shut down the set and reconnect according to the re connection diagram on page 7 9 Improper connections have been made at the generator output terminals 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
62. cond rest periods 2 The starting cycle begins when relay K7 is Relay K3 is de energized by latching relay K6 powered either manually by pushing the panel causing shutdown to occur during operation Run switch or automatically by a remote con when a low oil pressure high engine tempera troller connected at terminal TB1 6 The panel ture or engine overspeed condition is sensed switch must be in the Remote position for re or the optional emergency stop button is mote automatic operation pressed The appropriate fault indicator lamp 3 Relay K7 powers relays K2 and K3 lights and common alarm terminal TB1 4 is powered There is no fault lamp for emergency 4 Relay K2 powers the engine gauges and termi stop The switch button will light however and nal TB1 10 to which the fuel solenoid and igni the light in switch S11 tion module are connected 5 Relay K3 powers terminal TB1 8 to which start The low oil pressure and high engine tempera er relay K4 is connected Engine cranking be ture shutdowns have 10 second time delays to allow oil pressure and engine temperature to gins stabilize during startup 6 The engine starts and runs up to governed speed in a matter of seconds To restore operation after a shutdown fault has been serviced reset latching relay K6 by push f 4 4 donei ing the panel Stop switch and then the Reset relay K10 or K14 whichever acts first to open araug Be anya TU
63. ctly prohibited Hazards present in troubleshooting 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 page and carefully 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 EE sistance according to Section 5 Servicing the Genera The exciter feld winaing 16 shared tor Replace the exciter field assembly if winding re sistance does not meet specifications Shut down the set and check exciter winding resist rotor windinasare shorted ances according to Section 5 Servicing the Genera 9 i 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 mainrotor Indien shorted ance according to Section 5 Servicing the Generator g Replace the generator rotor assembly if main rotor winding resistance does not meet specifications Shut down the set and check stator winding resistanc es according to Section 5 Servicing the Generato
64. ctor 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 m ume ae FIELD CIRCUIT BREAKER atm ir te ER SELECTOR SWITCH POWER FACTOR METER FIGURE 2 1 AC CONTROL PANEL F Power Generation 2 1 Redistribution or publication of this document by any means is strictly prohibited VOLTAGE REGULATOR DESCRIPTION The design of the Torque Match 2 Voltage Regula tor VRAS 2 provides switch selections that alter its sensing and command signals in order to achieve maximum operating performance in a vari ety of generator sizes and applications Review the following then refer to Voltage Regulator Adjust ments for switch locations and settings specific to your generator set model 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 insulat
65. d N SI Hazards present in troubleshooting 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 page and carefully 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 switch to Stop and the Reset switch to Reset and fill up with as much engine oil as necessary and repair all oil leaks The LOW OIL PRESSURE lamp comes on when the engine shuts down 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 according to the engine service manual if oil pressure is less than 10 psi Replace the low oil pressure cutout switch if oil pressure is greater than 10 psi See Figure 3 5 Engine Control to locate the switch Reset the ECM by pushing the Run Stop Remote 2 switch to Stop and the Reset switch to Reset and fill d p 9 with as much engine coolant necessary and re SU pair all leaks 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 reac
66. d the grounding bolt on the block Cable terminal or relay contact re sistance is too high if the difference is more than 2 volts Service as necessary Cranking voltage is too low to reach re quired cranking speed Recharge or replace the battery Specific gravity for a fully charged battery is approximately 1 260 at 80 F 27 C Replace the engine driven battery charging alternator if normal battery charging voltage is not between 12 and 15 volts 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 engine is worn or malfunctioning me chanically Service according to the engine service manual P xd Pow r 4 6 Redistribution or publication of this document Generation by any means is strictly prohibited NX Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THE ENGINE RUNS UNTIL FAULT SHUTDOWN RED SHUTDOWN LAMP ON Reset the ECM by pushing the Run Stop Remote switch to Stop and the Reset switch to Reset and re start the set monitoring engine speed Readjust the cutout speed if it is lower than specified See
67. d the stud will destroy them Use a 40 watt soldering of the diode iron Hold a needlenose pliers between B Reverse the meter test probes and repeat diode and soldering point to prevent de the tests The electrical resistance across structive heating REMOVE DIODE 1 OF 6 FROM HEATSINK AND MEASURE ELECTRICAL RESISTANCE BETWEEN THE PIGTAIL AND THE METAL PLATE UNDER THE DIODE DIODE HEATSINKS FIGURE 5 4 TESTING THE ROTATING RECTIFIER ASSEMBLY P ud Pow r 5 5 Redistribution or publication of this document 1 Generation by any means is strictly prohibited gt N lt EXCITER ROTOR Testing Winding Resistance Remove diodes CR1 through CR6 from diode heat sink assemblies With a Wheatstone bridge mea sure electrical resistance across each pair of rotor windings T1 CR1 or CR4 and T2 CR2 or CR5 T2 CR2 or CR5 and T3 CR3 or CR6 T3 CR3 or CR6 and T1 CR1 or CR4 See the winding sche matic Resistance should be 0 464 to 0 567 ohms at 68 F 20 Testing Winding Insulation Resistance Remove diodes CR1 through CR6 from diode heat sink assemblies Using a megger voltage set at 500 VDC measure the resistance between any ro tor winding lead or the terminal to which it is con nected and the rotor laminations Replace the excit er rotor if insulation resistance is less than 1 meg ohm MEASURE WINDING INSULATION RESISTANCE BETWEEN ANY LEAD OR THE TERMINAL TO WHICH IT IS CO
68. ded Continued on next page Push the Run Stop Remote switch to Run or Re mote Pull the Emergency Switch button To reset the en gine control 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 Push the Run Stop Remote switch to Run If the en gine cranks find and repair the fault in the remote con trol circuit Service the set as necessary To reset the engine 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 Determine the cause and service as necessary To re set the engine control push the Run Stop Remote switch to Stop and the Reset switch to Reset Then push the Run Stop Remote switch to Run or Re mote Note that the engine control will shut down un less the day tank control has been reset first Gul Power 4 4 Redistribution or publication of this document eneration by means is strictly prohibited N ML Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THE ENGINE DOES NOT CRANK CONT Continued from previous page Cranking voltage is too low to crank the
69. e Thread ADJUSTMENT the pickup in gently by hand until it just touches the ring gear tooth Back it out 5 8 turn and set the lock With the magnetic speed pickup removed from the nut genset manually rotate the ring gear until a tooth TO GOVERNOR CONTROLLER MAGNETIC SPEED PICKUP UNIT GENERATOR ADAPTER TO GOVERNOR CONTROLLER FIGURE 6 3 MAGNETIC SPEED PICKUP UNIT GOVERNOR CONTROLLER CONNECTIONS Ed Power 6 3 Redistribution or publication of this document o Generation by any means is strictly prohibited 2 gt CARBURETORS The engine is equipped with a carburetor to run on 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 cigarettes flame pilot lights arcing switches or equipment in area or areas sharing ventilation Gasoline Fuel System A gasoline carburetor Figure 6 4 is provided for gasoline fuel systems The main and idle mixture and choke are adjustable on the gasoline carbure tor The main adjusting needle at the bottom of the carburetor affects operation at heavier load condi tions the idle adjusting needle at the side of the carburetor affects operation at light and no load conditions Under normal circumstances factory carburetor adjustments should not be disturbed If adjustments have b
70. e 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 e Fuel lines must be adequately secured free of leaks Fuel connection at 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 Be sure all fuel supplies have a positive shutoff valve Power Generation Be sure battery area has been well ventilated
71. e indicates engine oil temperature Tachometer M16 The tachometer indicates en gine speed in RPM 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 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 F and the possibility that the engine might not start Low Fuel Yellow This lamp indicates that the fuel level in the supply tank has dropped to less Power Generation 3 3 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 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 nect
72. e removed if you want to do so Do not allow the rotor to hang unsupported for any extended period Otherwise drive disk damage can occur Attach the hoist and sling to the rotor assembly and apply a slight lift to support the rotor Re move the bolts securing the drive disk to the en gine flywheel and remove the rotor from the en gine Set on wood blocks so fan is not support ing any of the rotor weight Remove bearing bolt flat washer and lock washer Then remove bearing If required re move fan from the rotor Disconnect rotor field leads from heat sinks 1 and F2 on the exciter rotor Remove exciter ro tor REASSEMBLING THE GENERATOR If any diodes are replaced in the exciter rotor secure the new diode using a lock washer and nut and torque to 12 to 15 in lbs 1 4 to 1 7 Nem Slide exciter rotor sleeve spacer and press ball bearing over the generator shaft Install the modified hex head bolt lock washer and flat washer and torque to 60 to 70 ft Ibs 81 to 95 Nem Place the generator fan in position on the rotor shaft Install the drive disk on the end of the rotor shaft with the chamfer on the flywheel side Torque Power Generation 5 10 10 11 12 13 14 15 16 the placement bolts to 200 to 240 ft Ibs 271 to 325 Nem Using a hoist and sling to support the rotor align the holes in the drive disk and fan with the corresponding holes in the flywheel Install the bolts
73. e 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 linkage through its full travel when power is connected or return it when power is discon nected Replace the governor controller if it still cannot be ad justed for full power or stable speed Service the fuel system according to the engine ser vice manual The engine fuel system lift pump injec tion pump injectors timing is faulty Er Service the engine according to the engine service The engine is worn manual GA Po Ww r 4 1 0 Redistribution or publication of this document Generation by any means is strictly prohibited SI Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual AMBER WARNING LAMP ON Shut down the set if possible or disconnect non critical loads Oil pressure will be less than 20 psi 138kPa
74. east 1 4 rated load and then apply a full load 3 Slowly turn needle out until speed no longer rises Try various electrical loads If engine speed fluctuates at any load turn main adjust ing needle out slightly Do not turn out more than 1 2 turn beyond original full load setting 4 If stable speed cannot be obtained by adjusting main adjusting needle a change in governor sensitivity adjustment will probably be neces sary Redistribution or publication of this document by any means is strictly prohibited IDLE ADJUSTMENT SCREW MAIN ADJUSTMENT FIGURE 6 4 GASOLINE CARBURETOR d od Power 6 5 Redistribution or publication of this document Generation by any means is strictly prohibited Choke Adjustment for Gasoline carburetor 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 prep ASTERISK aration for the next start It also has an electric heat ing element that heats the bi metal coil to fully open the choke soon after the engine starts 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 loos
75. ed to service Power Generation 5 2 If moisture is determined to be the cause of low test readings a winding drying process will be required DRYING THE WINDINGS If low readings are obtained and moisture is deter mined to be the problem the windings should be dried out and the test repeated Use the generator heaters or blow warm air through the generator with a fan A more effective way is to use a bolted 2 3 phase short across the generator terminals This procedure must be done as described or equipment damage can result To do this 1 Bolt the two or the three phases of the genera tor together at the terminals See the reconnec tion diagram in Section 7 2 Disconnect the F1 and F2 leads Figure 5 2 at the voltage regulator and connect them to a variable 12 VDC source Positive lead to F1 negative lead to F2 3 Attach a clamp on ammeter to the generator leads to measure generator current adjust the 12 VDC source for zero volts start the set and slowly increase the excitation voltage Obtain the highest current possible without exceeding generator rating 4 Run the set for approximately one hour and re peat the insulation resistance tests If further drying time is indicated continue the drying process Redistribution or publication of this document by any means is strictly prohibited STATOR Testing Winding Resistance Measure winding resistance with a Wheatstone bridge or digital
76. een changed an approximate setting of 1 1 2 turn open for idle needle and one turn open for main needle will permit starting Adjust temporarily for smoothest running Allow engine to thoroughly warm up before making final adjustment 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 1 1 2 turns so that the engine will run Power Generation 6 4 The adjustment screw and seat are easily damaged Do not force the adjust ment screw 2 Start the engine and let the set warm up under a partial load at least 1 4 rated load and then disconnect all loads 3 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 Main Mixture Adjustment If the adjustment has been disturbed or the engine performs poorly under heavy load make the following adjustments 1 Shut off the engine and turn the main adjust ment screw in gently until it bottoms and then turn it out 1 turn so that the engine will run 2 Start the engine and let the set warm up under a partial load at l
77. el e TII BE Ce ai E 60 60 2 8 521 44 9 99 2 2 lt 63 63 A 52 x m 521 45 2 oq us TB2 21 4 4 D 521 42 21 LL 6 65 6 025 nd Til 7 9 cerca 4 SEE DC WIRING DIAGRAM 23 26 04 5 2 3 DIAG LA 6666 ON SB3D VR2 Y 040 M2 521 14 89 GENERATOR angen VOLTAGE LINE ca 05 65 REGULATOR A 9 9 521 12 22 1 ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION G2 G2 12 2 D c 7 GENERATOR 4 2 63 2 vOLTMETER 23 7 99 GENERATOR L 1 3 at gg CAC GENERATOR e dex 65 6 5 1 ES C21 AA 521 DDR 4 SEE GENERATOR CONNECTION DIAGRAM FOR INPUT CONNECTIONS SEE NOTE 5 5 SEE VOLTAGE REGULATOR INSTALLATION FOR CONNECTIONS NOTE 5 TO VR21 CB21 R21 AND 2 zy TO DC wD d I20VAC STARTER f A 015 4 i 0 6 59 r82 INSIDE VIEW 4 tad 521 CT22 POSITION CONTACTS CLOSED FIOUSING CONTROL BOX LI L2 3 11 18 C 22 32 M 44 N 33 R JETER 2 13 12 22 44 42 4 43 P GND 3 11 32 8 B J 34 31 42 4 33 R M23 LI LO 30 11 18 21 14 44 N 42
78. en the three cover screws Figure 6 5 and rotate the cover clockwise richer so that the asterisk is one or two lines past the line on the housing and re tighten the cover screws LOCKING 2 For better starting in warm weather loosen the SCREWS 3 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 FIGURE 6 5 ELECTRIC CHOKE and re tighten the cover screws e Powe r 6 6 Redistribution or publication of this document Generation by any means is strictly prohibited 2 2 20 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 a manual fuel selector switch 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 W
79. fied licensed electrician Tag reproductive toxicity When checking or and lock open switches to avoid accidental clo changing engine oil take care not to ingest sure breathe the fumes or contact used oil DO NOT CONNECT GENERATOR SET DI e Provide appropriate fire extinguishers and RECTLY TO ANY BUILDING ELECTRICAL install them in convenient locations Consult SYSTEM Hazardous voltages can flow from the local fire department for the correct type of the generator set into the utility line This extinguisher to use Do not use foam on electri creates a potential for electrocution or property cal fires Use extinguishers rated ABC by damage Connect only through an approved NFPA isolation switch or an approved paralleling de View sure that rags are not left on or near the HIGH VOLTAGE GENERATOR SETS e Remove all unnecessary grease and oil from 1 9kV to 15kV the unit Accumulated grease and oil can High voltage acts differently than low voltage cause overheating and engine damage which Special equipment and training is required to present a potential fire hazard work on or around high voltage equipment Op e Keep the generator set and the surrounding eration and maintenance must be done only by area clean and free from obstructions persons trained and qualified to work on such move any debris from the set and keep the floor devices Improper use or procedures will result clean and dry in severe
80. field flash connection to exciter circuit longer than 5 seconds Make sure a diode is used in the field flash appa ratus to prevent the regulator from overcharg ing the battery Batteries can explode when overcharged EXCITER STATOR 12 AMPERE 300 VOLT DIODE N 12 VOLT LIGHT BULB OR 2 WATT 20 OHM RESISTOR 12 VOLT BATTERY With Generator Set in Operation This test involves unregulated ex citation of the generator To prevent damage to the generator due to overcurrent make sure that all loads have been disconnected and that all faults have been cleared from the power out put terminals of the generator 1 Start the generator set 2 Touch the positive battery lead to TB1 9 and the negative lead to TB1 10 of VRAS 2 Hold the leads in place just long enough for the volt age to build up to the normal operating level then remove the leads 3 Check generator voltage and shut down gen erator set Restart generator set and run at no load Unit must build up voltage without field flashing If not shut down generator set and perform continuity check of all related wiring With Generator Set Shut Down 1 Touch the positive battery lead to TB1 9 and the negative lead to TB1 10 of VRAS 2 2 Hold the leads in place for no longer than 5 sec ondas 3 Start generator and run at no load Unit must build up voltage without field flashing If it does not shut down generator set and perform con tinuity check of all
81. for the low coolant and pre high temperature warning lamps on the basis of the gauge sender output See Figure 3 7 GAUGE AND PCB CONNECTIONS Al J4 3 Al J2 3 FIGURE 3 7 COOLANT TEMPERATURE GAUGE GA Power 3 8 Redistribution or publication of this document Generation by any means is strictly prohibited AUXILIARY CONTROL COMPONENTS occurs within 2100 to 2300 RPM 50 or 60 Hz sets ne Turn adjustment screw clockwise to increase 9 i trip speed Mechanical Overspeed Switch Standard 2 Replace the switch if the cutout speed adjust ment results in an air gap between the magnet The mechanical overspeed switch is bolted to the and the fly arm of less than 0 005 inches 0 13 end of the generator rotor shaft mm 1 Check overspeed cutout RPM and turn the ad 3 Torque the center rotor bolt to 40 ft lbs 54 justment screw if necessary so that shutdown Nem when replacing the switch ADJUST SCREW GENERATOR SHAFT AIR GAP NOT LESS THAN 0 005 IN 13 MM FIGURE 3 8 OVERSPEED SWITCH ASSEMBLY P x T GA Powe J 3 9 Redistribution or publication of this document Generation by any means is strictly prohibited Y lt e E Auxiliary Relay Board ARB The following describes the design functional crite ria for the AR
82. h the jumper in this position Fault Relays K4 through K15 These 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 amps at 120 VAC e 10 amps at 30 VDC Redistribution or publication of this document by any means is strictly prohibited RUN RELAY JUMPERS MODULE S COMMON J1 AND J2 WIRE ALARM N O N C N C N C 6 7 RUN HARNESS PLUG con con A cin A A RELAYS CONNECTIONS THROUGH K15 FROM ECM ARE OPTIONAL COM N O COM N O COM N C N O N O N O COM 0 bo COM N C N C COM N C N O N C 787 pL nre loru FIGURE 3 9 AUXILIARY RELAY BOARD 300 4111 ad Po Ww v r 3 11 Redistribution or publication of this document O Generation by any means is strictly prohibited Q Y lt Over Under Voltage Module A17 The set can be equipped
83. hains must have sufficient capacity and be attached properly so that the load cannot shift Before starting disconnect the starting battery cables negative 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 4 bat tery cable Arcing can ignite the explosive hy drogen gas given off by the batteries causing severe injury GENERATOR SHAFT EN 8 10 11 12 13 14 Disconnect the line cables and conduit For re connections later make sure each cable is clearly marked to indicate the correct terminal 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 reconnections later make sure each wire is clearly marked to indicate the correct te
84. hen natural gas pressure is restored the natural gas solenoid valve opens and the propane solenoid valve closes Gas Pressure The fuel regulators in each line pro vide constant gas pressure at the gas mixer under GASOLINE AND NATURAL GAS Q varying load conditions approximately 5 inches for natural gas and 1 5 inches WC for LPG There is a pressure test port on the supply side if the gas mixer for measuring fuel inlet pressure The maximum permissible fuel supply pressure is 20 inches WC and the minimum is 7 inches WC This applies to LPG as well as to natural gas The minimum pressure refers to supply pressure under rated load maximum gas flow There is a pressure test port on the supply side of each fuel regulator for measuring fuel supply pressure Choke Adjustment for Combination Carbure tor If the engine is equipped with a combination carburetor see that the gasoline shut off valve is closed The electric choke Figure 6 5 must be ad justed so the adjustable cover is turned 10 to 12 notches counterclockwise from the asterisk mark When properly adjusted the electric choke will be completely open even at very low tempera tures Gas fuel main adjustment should be made only when full electrical load is applied to the genset NATURAL GAS
85. hes 230 F 110 C replace the high engine temperature cutout switch If coolant tempera ture exceeds 230 F 110 C clean and service the entire cooling system as required to restore full cooling capacity See Figure 3 5 in Section 3 Engine Control to locate the switch Service as required The customer has supplied the system fault indicating switches By means of selec tion jumpers either fault may be chosen to display the warning only See Section 3 Engine Control The FAULT 1 or FAULT 2 lamp comes on when the engine shuts down If the set is equipped with the optional low frequency shutdown feature and the red FAULT 1 or FAULT 2 lamp is on the set probably ran out of fuel Service as required FA Po wW r 4 8 Redistribution or publication of this document Generation by any means is strictly prohibited N Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THE ENGINE LACKS POWER OR STABLE SPEED Check for and replace clogged fuel lines and filters Fuel delivery to the set is inadequate Check for air in the fuel lines and repair all air leaks Measure the vertical distance between the fuel lift pump on the engine and the b
86. ing mat make sure your clothing and shoes are dry remove jewelry from your hands and wear elbow length insulat ing gloves Operating Modes Torque Matching Grequency Sensing most applications in order for the generator set to accept the application of a large momentary overload such as motor starting matching the torque characteris tics of the engine and generator is required Power Generation Because of the differences in engine characteris tics different torque matching may be used for vari ous engine generator combinations The switch selectable design of the VRAS 2 provides Onan the flexibility to test and set the torque matching func tion to best suit each engine generator configura tion When set to the proper torque matching switch set tings the VRAS 2 voltage regulator is able to main tain output voltage within reasonable limits by re ducing the voltage just enough to take full advan tage of the engine s full available power under tran sient conditions and prevent an unstable response Non Torque Matching Voltage Sensing Even though the voltage regulator can also be switch se lected to a non torque matching constant voltage mode independent of engine speed this mode will not prevent the generator set from stalling during momentary overload conditions and is not recom mended for use Consult an Onan service repre sentative before selecting this voltage regulation mode to make sure
87. ions 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 Redistribution or publication of this document by any means is strictly prohibited CONTROL MONITOR A11 TIME DELAY VOLTAGE REGULATOR VRAS 2 TERMINAL BOARD TB21 RUN RELAYS K11 START STOP MODULE A15 OVERSPEED MODULE NOT SHOWN MOUNTED A BRACKET IN FRONT OF A11 515615 1 FIGURE 3 3 ARRANGEMENT OF COMPONENTS INSIDE THE CONTROL BOX CONTROL BOX INTERIOR Figure 3 3 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 Figure 3 4 It is a printed circuit board assembly mounted on the back wall of the control box It starts and stops the engine in re sponse to the control panel switches engine sen sors and remote control signals Terminals and Connectors See Pages 7 5 through 7 8 for the appropriate con nection and schematic drawings for the DC control system See Page 7 10 for typical customer con nections at terminal boards TB1 and TB2 on the and page 7 11 if the set is also equipped with the auxiliary relay board
88. is especially important if battery has been connected to battery charger PMG ASSEMBLY EXCITER STATOR ROTATING RECTIFIER ASSEMBLY OVERSPEED SWITCH BEARING EXCITER ROTOR MAIN ROTOR SCREEN GENERATOR FIELD FIGURE 5 1 GENERATOR Power Generation 5 1 Redistribution or publication of this document by any means is strictly prohibited a INSULATION RESISTANCE MEGGER amp POLARIZATION INDEX PI TESTING These tests are used for insulation testing and to verify that the windings are dry before the generator set is operated and develop a base line for future test comparison Megger Testing 500 VDC megger is recommended for insulation testing A test consists of applying the voltage be tween the winding and ground for one minute Resistance value of at least 5 megohms should be obtained for a new generator with dry windings For a set that has been in service the resistance read ing should not be less than 1 megohm PI Testing The PI test consists of applying a voltage between the winding and ground for ten minutes and record ing resistance values at one minute and at ten min utes The Pl is the ratio of a ten minute reading in megohms divided by a one minute reading in meg ohms A ratio of two or greater is considered good for new and in service sets If low readings are obtained the cause should be in vestigated and corrected before the generator set is return
89. linkage does not bind or have excessive and responsive to governor control Adjust the play in it Gain 1 pot counterclockwise to eliminate hunt ing Bump the throttle lever a couple of times to check for hunting The unit should respond 1 Check the dip switch settings Figure 6 1 to quickly but should not hunt make sure they are set properly as follows 4 Apply full load to the genset and adjust the Sta IGNITION TRIGGER GOV MOD A378 bility 1 pot to minimize overshoot Adjust the SW2 SW3 sw4 Stability 1 pot clockwise to increase stability 8CYL 6CYL 4CYL 50 60HZ Check stability under a range of loads from no load to full load 50Hz OFF ON OFF OFF 60 2 OFF ON OFF ON 5 Attach a tachometer or frequency meter to the generator output leads if control panel does not come equipped with one of these meters Ad MPU TRIGGER GOV MOD A377 just the Speed Trim pot until the desired speed swi 5 2 543 5 4 is obtained 50 Hz ON OFF OFF OFF 6 Shut down and restart the genset to check for 60Hz OFF OFF ON overspeed shutdown on startup 1 GOVERNOR CONTROLLER CONNECTIONS SEE FIGURE 6 3 STABILITY 1 D 41 SPEED TRIM ON POSITION SWITCHES FIGURE 6 1 GOVERNOR CONTROLLER P x T
90. m the power output terminals of the generator Open the control panel and disconnect the F1 and the F2 leads from the voltage regulator See Figure 2 2 PNY Weiss 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 from your hands and wear elbow length insulating gloves Start the set and check for output voltage at the main stator terminals a Is there 5 20 VAC residual voltage at the output of the main stator windings when the exciter leads are dis connected YES The main stator windings are good continue with step 4 NO Use the GENERATOR FAULT chart to troubleshoot generator If the residual voltage is good stop the set and reconnect the exciter leads to the exciter stator Start the set Has the output voltage increased YES Adjust the Coarse Voltage Adjust pot on VRAS 2 e NO Check if CB21 is closed If CB21 is OK flash the field using the procedure in Section 5 When field is flashed does the output voltage from the main stator increase e YES The generator assembly is OK NO Use the GENERATOR FAULT chart to troubleshoot generator If the output voltage increased when the field was flashed does the
91. mote switch to Run and check for battery voltage 12 VDC between ECM terminal TB1 8 and the grounding stud on the floor of the con trol box If there is no voltage when the switch is in the Run position replace the ECM Push the Run Stop Remote switch to Run and check for battery voltage at starter solenoid terminal SW If there is no voltage repair the wiring as necessary If there is voltage at starter solenoid terminal SW but the motor does not function repair or replace the start er motor or solenoid according to the engine service manual Redistribution or publication of this document by any means is strictly prohibited g Power 4 3 osi Generation lt Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THE ENGINE CRANKS BUT DOES NOT START When the Run Stop Remote switch is in the Run position the control will attempt to crank the engine for approximate ly 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 Open any closed
92. ottom of the dip tube in the supply tank Make necessary provisions so that lift does not exceed 6 feet 1 8 metres Connect the set to a container of fuel of known quality and run the set under various loads Replace the con tents of the fuel supply tank if there is a noticeable im provement in performance The fuel is contaminated Replace the air filter element The engine air filter element is dirty Continued on next page P xd Pow r 4 9 Redistribution or publication of this document Generation by any means is strictly prohibited NX Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THE ENGINE LACKS POWER OR STABLE SPEED CONT Continued from previous page Adjust the governor according to Section 6 Gover The governor adjustment is incorrect nors Electronic Governor If the governor cannot be ad justed for full power or stable speed shut down the set and check for binding in the linkage Repair and adjust the linkage as necessary A spring inside the actuator will resist opening the movement which is normal Re install the magnetic speed pick up unit to make sure the clearance with the flywheel gear teeth is cor rect Replac
93. ounted on the main rotor shaft Exciter output current is proportional to exciter field current The automatic voltage regulator VRAS 2 reg ulates exciter field current by comparing gener ator output voltage and frequency with refer ence values Exciter field current is supplied by the genera tor stator through the voltage regulator Resid ual field magnetism initiates self excitation during startups SELF EXCITED GENERATORS ELECTRICAL POWER OUTPUT MAIN STATOR EXCITER ROTOR AND STATOR o o 25 MAIN ROTOR ROTATING MECHANICAL POWER INPUT FIGURE 2 4 SCHEMATIC OF GENERATOR OPERATION P x T GA Powe J 2 6 Redistribution or publication of this document Generation by any means is strictly prohibited Y lt 3 Engine Control CONTROL 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 812 The switch is pushed to the Run position to start and run the gen erator set and to the Stop position to stop the set The Remote position allows a remote controller to automatically run the set The switch must be in the Stop position when the reset switch described next is used to restore generator set operation fol lowing a fault shutdown OIL PRESSURE COOLANT TEMPERATURE GAUGE DC VOLTMETER OIL
94. owly back out the screw counterclockwise until the engine car ries the full load smoothly 4 f 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 Power Generation 2 6 8 GAS MIXER IDLE ADJUSTING POWER SCREW ADJUSTING SCREW THROTTLE LEVER PROPANE FLOW ADJUSTMENT VALVE FIGURE 6 7 GASEOUS FUEL ADJUSTMENTS Redistribution or publication of this document by any means is strictly prohibited 7 Wiring Diagrams This section consists of the schematic and connec e Page 7 4 AC Wiring with meters tion wiring diagrams referenced in the text Page 7 5 7 light DC Wiring Sheet 1 of 2 The following diagrams are typical Your genset may Page 7 6 7 light DC Wiring Sheet 2 of 2 differ Wiring and component specifications are sub Page 7 7 12 light DC Wiring Sheet 1 of 2 E to change Contact your Distributor if you do not Page 7 8 12 light DC Wiring Sheet 2 of 2 ave the wiring diagrams applicable to your equip ment Pages 7 9
95. r The stator winainga are snaned Replace the generator stator assembly if stator wind ing resistances do not meet specifications Replace the voltage regulator Voltage Regulator VR21 is faulty Replacing VRAS 2 before servicing other faults can lead to damage to the new VRAS 2 Gr Pow r 4 19 Redistribution or publication of this document Generation by any means is strictly prohibited N SI Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THE PHASE CURRENTS ARE UNBALANCED The connected loads are distributed un there is a difference of less than 10 percent between evenly among the phases phases P Shut down the set and reconnect according to the re connection diagram on page 7 9 Improper connections have been made at the generator output terminals 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 A load has a ground fault or short circuit Service the faulty equipment as necessary 2 er GA Powe 4 20 Redistribution or public
96. related wiring MAIN STATOR REFERENCE VOLTAGE FIGURE 5 3 FIELD FLASHING CIRCUIT Power Generation 5 4 Redistribution or publication of this document by any means is strictly prohibited EXCITER RECTIFIER BRIDGE ROTATING each diode should be high in one direction RECTIFIER ASSEMBLY and low in the other If the resistance is high or low in both directions replace the The exciter rectifier bridge is mounted on the exciter diode rotor outboard facing the rear It consists of a posi 3 To replace diodes use the following tive plate and a negative plate each carrying three g P i dure diodes A Unsolder lead wires of defective diodes Layers of dust can cause diodes to from flag terminals overheat and fail Brush dust off regularly B Insert new diode into heatsink mounting 1 Disconnect one diode at a time by removing hole Using nut and washer provided se diode from heatsink cure diode to heatsink A Use proper size wrenches to hold the C Use proper size wrenches to hold the diode body while removing the nut diode body while tightening the nut B Push the diode free of the heatsink mount Torque diodes on rotating exciter assem ing hole bly to 24 in Ibs 2 7 Nem 2 Test that diode before proceeding to the next D Solder lead wires to new diode flag termi one nals A Using an ohmmeter measure electrical Excessive heat on these diodes resistance between the flag an
97. rminal 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 marked to indicate the correct terminal Remove the sheet metal from around the gen erator Remove the overspeed switch and bracket from the end bell and rotor shaft See Figure 5 8 ADJUST SCREW AIR GAP NOT LESS THAN 0 005 IN 13 MM FIGURE 5 8 OVERSPEED SWITCH ASSEMBLY Power Generation 5 9 Redistribution or publication of this document by any means is strictly prohibited 15 16 17 18 19 20 21 22 23 24 25 gt 2 Block the rear of the engine in place by support ing the flywheel housing Remove the four nuts and washers from the studs that secure the end bell Remove end bell with oil seal from stator as sembly It might be necessary to tap around end bell joint to separate end bell from stator Remove the four 1 4 inch bolts and lock wash ers securing the exciter stator to the end bell Remove the narrow generator air screen Remove the large capscrews securing the generator to the skid base Remove the bolts securing the stator to engine flywheel housing Using an overhead hoist and sling slide the stator assembly off the long through studs note position of hose pieces on the studs and proper orientation of the stator being careful not to touch or drag on the rotor The studs can b
98. same func tions for their respective relays W1 for relay K1 W2 for relay K2 W3 for relay They be lo Power Generation 3 10 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 Switched is applied 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 relay operates with the coil connected to ground through the board connections The coil will require a signal to energize wit
99. shutoff valve in the fuel line supplying The engine is not getting fuel the engine Check fuel solenoid and related wiring Repair or re place as needed Fill the main fuel supply tank if the set is gasoline or propane fueled For natural gas fueled sets check with the gas utility The air cleaner is blocked Service as necessary The engine ignition system is malfunc tioning ignition coil distributor spark Service as necessary Refer to wiring diagrams in Sec lion 7 plugs high tension spark plug and coil cables and timing Clean and rebuild gasoline carburetors with the ap The carburetor fuel passages are propriate carburetor kit according to the kit instruc clogged or the choke needs adjustment e Adjust fuel mixture and choke refer to Section Continued on next page FA Po w 4 4 Redistribution or publication of this document Generation by any means is strictly prohibited SI Hazards present in troubleshooting 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 page and carefully observe all instructions and precautions in this manual THE ENGINE CRANKS BUT DOES NOT START Continued from previous page 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
100. that hold the drive disk to the engine flywheel and torque to 55 to 60 ft lbs 75 to 81 Nem Do not allow the rotor to hang unsupported for any extended period Otherwise drive disk damage can occur Using a hoist and safe lifting device carefully move the stator into position over the rotor as sembly The stator leads should be at the 12 o clock position when viewed from the end bell position Make sure the short hose pieces are in place next to the flywheel housing before installing stator Align the holes of the stator with the engine fly wheel housing and install the bolts Torque to 35 ft lbs 47 Nem Install the exciter stator in the end bell using the 1 4 inch bolts and lock washers Torque to 7 ft Ib 9 Nem Apply a thin film of Molykote grease or equiva lent to the mating surfaces of the end bearing and end bell bearing hole Install the end bell assembly lock washers and nuts on the studs Torque nuts to 35 ft lbs 47 Nem Using a lead hammer tap the end bell at the horizontal and vertical plane to relieve stress Retorque end bell stud nuts Install the generator air screen Refer to Figure 5 8 Mount and adjust Mechan ical Overspeed Switch When installing the overspeed switch assem bly capscrew lock washer switch small flat washers large flat washer and spacer on the rotor shaft torque to 53 ft lbs 72 Nem Install the overspeed switch assembly bracket and secure using two capscrews and
101. that load demands specific to your installation would not cause an unstable op eration of the generator set Operating Stability Because of the differences in exciter and main field time constants different gain compensation is re quired for the various generator sizes and applica tion The VRAS 2 voltage regulator is switch select able to a kW range of operation that best suits the generator set application Redistribution or publication of this document by any means is strictly prohibited VOLTAGE REGULATOR ADJUSTMENTS The VRAS 2 is shown in Figure 2 2 There are three switch modules and two potentiometers VRAS 2 Switch 51 Selects the overall range of opera tion for the regulator Refer to Table 2 1 Switches 52 and S3 Determine the mode of regulation Torque Matched or Non Torque Matched Refer to Table 2 1 e Potentiometer R32 Provides adjustability to increase or decrease generator voltage to achieve proper setting e Potentiometer R34 Used to set the frequency breakpoint The potentiometer is adjusted at the factoryand does not require further adjust ment Adjusting Voltage Use the control 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 See Section 6 Governor for instructions on how to adjust the fre quency If the trimmer does not provide enough
102. tly 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 Power Generation Read Safety Precautions and carefully observe all instructions and precautions in this manual 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 Specification and Serial number of the generator set as shown on the nameplate when seeking additional service infor mation or replacement parts The nameplate is lo cated 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 Redistribution or publication of this document by any means is strictly prohibited
103. tor 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 GA Power 3 15 Redistribution or publication of this document Generation by any means is strictly prohibited 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 tripped circuit breaker Hazards present in troubleshooting can cause equipment damage severe personal injury or death Troubleshooting must be per formed by qualified persons who know about fuel electrical and machinery hazards Read the Safety Precautions page and carefully ob serve all instructions and precautions in this manual THE ENGINE DOES NOT CRANK The Run Stop Remote switch is atStop The Switch Off light will be flashing if provided The Emergency Stop switch has been used The switch button and switch S11 will light The remote control circuit is faulty A Fault Shutdown is being indicated by one of the red lights on the control panel A Lo Shutdown is being indicated on the day tank pump control panel if provi
104. trical and machinery hazards Read the Safety Precautions page and carefully observe all instructions and precautions in this manual THE ENGINE DOES NOT CRANK CONT Continued from previous page A grounding strap between the control box and the battery negative terminal is loose damaged or missing The Run Stop Remote switch S12 or wiring is faulty The ECM is faulty Check fuse F1 again The wire between ECM terminal TB1 8 and starter solenoid terminal SW is loose damaged or missing The starter motor or solenoid is mal functioning Check for electrical continuity zero ohms between the grounding stud on the floor of the control box and the battery negative terminal If there is no electri cal continuity check for loose damaged or missing grounding straps and repair as necessary Disconnect pin connector J4 from the ECM board and check for electrical continuity zero ohms between switch terminals 2 and 3 when the switch is in the Run 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 4 5 and J4 7 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 Push the Run Stop Re
105. ts in series On a parallel star connected generator line to line resistance should be the same as the table value two sets of two winding elements in series Before performing the following insulation resist ance test refer to the nsulation Resistance and Po larization Index Test procedure at the beginning of this section Insulation Resistance and PI Test Disconnect all stator leads and winding taps from their respective terminals and make sure the ends do not touch the generator frame Testing For Grounds Using a megger voltage set at 500 VDC measure electrical resistance be tween 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 500 VDC measure electrical resistance between each winding for example T1 T4 to T7 T10 T1 T4 to T2 T5 etc Replace the stator if insulation resist ance is less than 1 megohm WHEATSTONE BRIDGE FIGURE 5 7 TESTING THE GENERATOR STATOR Power 5 8 Redistribution or publication of this document by any means is strictly prohibited E Generation o s Y lt 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 c
106. ustment must be made while the unit is running use extreme caution around hot man ifolds moving parts etc LS 11b Redistribution or publication of this document by any means is strictly prohibited ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS SEVERE PERSONAL INJURY OR DEATH e Coolants under pressure have a higher boiling Hemove electric power before removing pro point than water DO NOT open a radiator or shields or touching electrical equip heat exchanger pressure cap while the engine ment Use rubber insulative mats placed on is running Allow the generator set to cool and dry wood platforms over floors that are metal Or bleed the system pressure first concrete when around electrical equipment Do not wear damp clothing particularly wet e Benzene and lead found in some gasoline shoes or allow skin surface to be damp when have been identified by some state and federal handling electrical equipment agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care not to ingest breathe the fumes or contact gasoline Use extreme caution when working on electri cal components High voltages can cause inju ry or death DO NOT tamper with interlocks e Follow all applicable state and local electrical e Used engine oils have been identified by some codes Have all electrical installations per state or federal agencies as causing cancer or formed by a quali

(begin spec D) EM (begin spec W)

Contents

Download Pdf Manuals

Related Search

Related Contents