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Onan service manual - Police Interceptor.Com!!

1. Starter Electric Choke Fuel Pump T E Spark Plugs A 5 amp Fuse com Battery Charging Alternator ur Start Solenoid I C TTE Breaker Box Q Low Oil Pressure Switch Start Stop Switch 1 C M DT Voltage Regulator BIB Running Time Meter Opt ie Im Battery Condition Meter Opt E PET PE A Pee ee ERE Fuel Solenoid FIGURE 5 10 CONTROL SYSTEM SCHEMATIC 5 9 Power Generation Redistribution or publication of this document by any means is strictly prohibited EMERGENCY START STOP OPERATION In an emergency the control board can be bypassed to start or stop the genset Connect a jumper between terminals 9 and 11 to energize the ignition fuel solenoid and fuel pump Then temporarily jumper terminals 1 and 7 to energize starter Remove this jumper as soon as the engine starts and runs DO NOT jumper these terminals while the engine is running To stop the genset remove the jumper from terminals 9 and 11 START STOP 5 AMP REMOVE COVER TO REPLACE Oen ee This emergency operation DOES ACAUTION NOT provide fuse protection start disconnect or low pressure shutdown and should not be used without monitoring the generator set
2. 1 2 Reconnectible Single Phase 1 4 Three Phase Delta Wound Generator 1 4 Three Phase Wye Connected 1 6 2 GENERATOR rer ee 2 1 Generator Disassembly Ree EN 2 1 Generator 2 3 Generator Service Procedures and Tests 2 4 Generator Assembly 2 teen 2 11 3 CONTROL SYSTEM dat dead b ER PR ERE 3 1 Operation Description ____ ___ 3 1 HE gt 3 1 Spec D and NH Spec A through C 3 2 CCK Spec MCCK begin Spec NH Spec D through F Models 3 4 BF CCK begin Spec LK begin Spec M and NH begin Spec J Models 3 6 BFA Spec A BGA Spec and Spec 3 7 MOGK Spec H 3 8 4 TROUBLESHOOTING 4 1 NE NOO 4 1 MCCK Spec D and NH Spec through C 4 5 CCK Spec R MCCK begin Spec
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5. T _ OSk OZ2 2 OW dc Hag 002 081 v OM 2 02 nz 3009 39 170 9175 3v ey isti Iv cw b 2 s 118 gt IDO JUR Mea T 1518 T 11 Sym mal DI 2x 99 922 M OO lt x INC EVI ste WVH5ViIQ 9NIYMIA 116 2LLVIN3H2S 96019119 Redistribution or publication of this document by any means is strictly prohibited 6 12 T Power ofi Generation SPL 0002 9 8 38 siram 4D 01494 Redistribution or publication of this document by any means is strictly prohibited 1342 SLA LO NNODSIG 14715 Nil 301 84 51041502 310434 IHL 388 011104 IHL OMY O31YMINIT3 if amp 008E MI HN 078 2056 91 18 077 HG 03007 Si WALMOT 310832 340130 dG OL ZT 30 1 802 3414 TMORLIOOY Hy 31 0350 36 AWM 75 0 004 304 402 310638 130 i 153415 TT 6 13 131 5 i 413 3102 5 JIAVWS3HOS amp OMu 9 2 lt Wvuovig 9 Pare per aid 54 01
6. OX 18 3 x D 1 t dors gt 2 16 9 ter fE 0 DH LI ss e 6 eee ee d tY NOLViS IDHINOD 340 3H 33901513 HOJ 3015 SIHL 2108 x WvHOVIG Redistribution or publication of this document by any means is strictly prohibited 6 9 Gra Power _ of Generation 0 0601 19 RES n NIMIA Mi H BE HN 5 BSS 135 39 10 1 02 92065 ey almeti HNE OXDYH XOT 031YH 61 1090 iNOS PD 11 CAIRO t5 WS Tans ANG WA HILIMS 5 310N3H YINOLSNJI JOIS iHyIS HMOLIMS 1 ASSY avd 3 aiue l dMil WSIN H2114 BOF 10 730 0 0 55304 110 M91 H3LIAS A pese bH 3904 49 9v AAOH CAINS 01009105 130 01083105 1 15 7 045534 2 30040 21 1 0 80 10 50 0 NYNO 37082 lhe 13 N39 943 5462 13 7 l rm e un y umm jet VJILVANSHOS 15918 6 orn 2v 99 50 50 NOILO3NNU23H QN3 ONS ON JO WAOD
7. 4 RJ voposiAt2 HN a a Eo T 0210 20 3 2091 00 S 1 8 1791 006 11 14 BOIYW3N3 CAO 51 2 oem 10 1 02 LLORIA 1 ate 411 WYYOVIC Redistribution or publication of this document by any means is strictly prohibited 6 19 Generation ha 0 ee DY 13 N39 lOWLNGD i QUE EC 930 92 06 59 soda euujpy H 20 989 oe FT P a My lavi M M M MM Rats 61 29 VARII 9 SINGS IN d30 v a 5 _ 0862 6 95 03044 8062 8829 3 0198 SVA 3 699 952 9 1160 8506 IHD 3 9288 AHNT II BO INIL ONINHNY 34OH3H 1 9 94 9 626 98 v3 GL 9 184 SYA 059 Jal 431 10 i Inpssez NOD AMSIINQ SLONSY NO 8 03 SI a 9554 SLSi LO SYM T EN 10 put VN Mum et tt EE 4 2 4 4 m
8. Generator MP PP Start Solenoid Relay E5 E E E Crank ignition Relay E Run Ignition Relay Stop Relay IM CMM Resistor R3 R4 R5 z E E E IUE E Start Stop Switch Breaker and Cap Assy Switch n ee Low Oil Pressure Switch ory High Water Temperature Switch pP ignition Coil jp Terminal Block Mt pi Terminal Block wd FIGURE 3 5 TYPICAL SCHEMATIC FOR MCCK SPEC H GENERATOR SETS RESTORING RESIDUAL MAGNETISM 3 Connect the diode end of the jumper lead to the Residual magnetism in shunt field F1 may be lost if genset B terminal and the resistor end to the posi diode bridge CR1 fails or if the shunt field is replaced live terminal of the bridge rectifier Maintain the connection for 5 seconds maximum This renders the genset inoperative The set will not 9 4 Remove the jumper lead connections and test operate because start disconnect relay K3 is not energized genset operation Replace the end bell wrapper Residual magnetism is restored through the following procedure 1 Remove the generator end bell wrapper and locate the CR1 bridge rectifier on the brush holder SHUNT FIELD 2 Make a jumper lead containing a 12 ampere 300 volt diode and a 20 ohm 10 watt res
9. eet uuo DH Ld SNO 133307 1081505 m ASSV dv2 8 dOLS LYVLS HOLIMS 338 0 YOLSISSY 915 010 3105 HO1VYANAD 338 dW d 1374 434 13 1 010 3105 NT 34595 NUYNO 3H0H2 RE Reel E si e 23 SY ASSY YOLIOVdV3 AB3LIVH ______ _ __ ___ 4339 1081 02 SLOWS IxM 455 7041405 151 1074 E LE ale THOS Hdl 2 21 2009 2 4060F 0140 NOI LdO JILWASHOS eH am ZW IW 062 021 MZ AQZI NOILISNNGOSY f L EEO relin IW 25 e 1NVIS 5 24e 3815 D 5 9 on E um dl 2 i d 438 JOULNOD 310W3U v J3u 10HINO2 319 UT qu vONVLS EM d ex WVMHOVIQ 9NIYIM 9 119 Redistribution or publication of this document by any means is strictly prohibited 6 14 Power ori Generation 2 TROOJA INS 135 N39 10H1MO2 23175 4 an
10. 9 Replace resistor or wire leads as necessary Check wire connections from generator to start solenoid K1 terminal 1 OK per form generator tests see Generator Troubleshooting and Procedures EM ENGINE IS RUNNING THEN STOPS YES Check the unit for a high air temperature high water temperature or low oil pres sure condition if applicable which would shut down the engine If no safety shutdown occurred connect a DC voltmeter to the IGN terminal of control terminal block TB1 control cover open Crank the engine Does engine start 2 1B A WARNING Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is operating Do not touch meter or meter leads during testing Did engine keep running after start switch was released Recheck for high air temperature tow oil condition etc which may have occurred LOW BATTERY NO HIGH CHARGE RATE 1 Jumper two step voltage regulator relay terminals BAT and B Open contro cover Start generator set Does ammeter indicate higher charge rate A WARNING Batteries present the hazard of explosion which can resuit in severe personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area Replace two step voltage regulator relay Check resistor R1 and resis
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12. TAN GC M e gt gt GROWLER 5 1816 FIGURE 2 7 ARMATURE SHORT CIRCUIT TEST WITH GROWLER After testing in one position rotate the armature slightly in the growler and repeat the test Continue until the armature is completely rotated in the growler Replace a short circuited armature with a new one The continuity tester may be used to test for a short circuit between AC and DC circuits of the armature With one test prod contacting the commutator contact the second test prod to the slip rings Figure 2 8 lamp lights or buzzer sounds a short circuit exists Replace the armature Redistribution or publication of this document by any means is strictly prohibited To test the AC winding place one test prod on the armature shaft and the other prod to a slip ring Figure 2 10 If the tester lights or buzzer sounds a grounded winding or slip ring is indicated repeat for each slip ring Replace the armature ONE TEST PROD ON COMMUTATOR ONE TEST PROD ON SLIP RINGS LAMP SHOULD NOT LIGHT OR BUZZER SHOULD NOT SOUND ES 1817 ONE TEST PROD ON SLIP RING FIGURE 2 8 ARMATURE SHORT CIRCUIT TEST ONE TEST PROD ON ARMATURE SHAFT WITH CONTINUITY TESTER LAMP SHOULD NOT LIGHT OR BUZZER SHOULD NOT SOUND Armature Ground Test Use a continuity tester To test the DC winding place one test prod on the armature shaft and the other on a commutator bar Figure 2 9 If the tester lights or buzz
13. HAE 11009 325 20 Lit iw AE AG2Z Lzi 240 ooga yne HN AN 59 6 0351 NAHM X 61 127 9NO1 13330 iOH4NO3 310A3H 318v2 5S3NUVH 133401 CTOHINO2O AV 138 luvis 01003705 3439 338 SON Tiv ER 41 POR lt U ASSY 1 80 10 557 JOHINODI 1 NOU4425 X1 AAD 7230 15 1 Simve L JOT ZH j 3i1QN AWYLS 4055 15 JILYVASHOS 29 SV 3 VS DHL ONOM Sv ANS AHL 33nON SfwSY 2 ONOM I 2 any SNQLLDANNOD AW TAY 6 THLON 14 i334 10HLNO2 310m3H QHYONYAS Redistribution or publication of this document by any means is strictly prohibited 6 15 m M eel Fr 2 7 L 4334 TOH1NO2 31083 2v 3xnTag WVueo9 vEO 9S9NIHNHIM Generation ha o BIN HOH LIS N39 Taa ii mill pera pany HOLY uO4AIOO JO O 2 901 IBEYIS
14. AG OUTPUT VOLTAGE HIGH WITH NO LOAD CONNECTED GENERATOR RUNNING AT 1800 RPM 1 Compounding reactor 1 Remove test and replace Power 9 3 Redistribution or publication of this document Generation by any means is strictly prohibited d GENERATOR SERVICE PROCEDURES AND TESTS BRUSH REMOVAL AND REPLACEMENT To reach the brushes remove the plastic end bell screens See Figure 5 1 for location of generator com ponents Measure brush wear as shown in Figure 5 2 by inserting a small narrow scale into the top of the brush block If the brushes need replacing remove and tag the wires connected to the brush blocks Then remove the brush blocks and lift them out of the end bell Pull the brushes and springs out from the bottom of the brush block Clean the brush block at this time The brushes are easily damaged dur ACAUTION ing genset disassembly assembly Use extreme care while installing removing the genset brushes New brushes are shaped to fit and seldom need sand ing to seat properly Always replace brushes as a set and use only the correct brushes Never use a substitute brush which may appear to be the same but have different electrical characteristics TOP VIEW OF BRUSH BLOCK Note that brush blocks are stamped BRG END on one side Be sure that this stamped side faces the bearing end of the generator for correct brush alignment Tighten the brush block screws t
15. XL w ON 212 0 ADBE OZ2 4 ON Ovz O2 09 NON AgOz O OVe O2 nan 3003 39vI10 4175 IY 03650 10N SI OW Hd ASH 30v110A 66 310N 9 1919 8 6000 t s 9NISIM 0601 19 Redistribution or publication of this document by any means is strictly prohibited 6 10 Gra Power _ Generation 76012119 ONTHIM 135 N39 1041402 1 Z 2 d 2 2 2 nime 0 2 aparis THOI 30096 HI HNO S 39006 51 180 Redistribution or publication of this document by any means is strictly prohibited 549 L23NINO2SIO LYVLS ATA I 3 LON e z 4 te 21 25 n e 51101094 E 6 11 ___ SS NT 135 830 563 8 DM HIA JOWLIOA 1 31 1109 71304 HONAT 55344 ID 01 1145 ASS 49 34Y3UG 11083105 IYNH311Y 9034 X Yas 1303 Zi L I i 1 L l Er Ls 134 S104INDO2 1 118 OIL VW3HOS 9NISIM NO SIR 25 3d
16. Hd E WI DN ax T SEN 1 pr NC MEM s mie tes ta a 1 V v 1 LEST lt 15 u 01 3839 2 v3 cH ea AWA 392 o Rie RN aE 0N43HI73NDH o ty 13 Fi ma eee 4 i r1 us e i 14915 9 1815 8313 114 pa o 1318873510 tl aby BNnD49 di 0112 4 2 418 i d JAVA SM3HID 117 0731 IF OMCs ON3 y38 3822 owt 022 TATE S 0x CH tae Aoc P 3009 13 SONI 4175 27 1136 02516 18415 EOLVTTR 39Y 1 10A 10 JISHI VEINS SHIA 22 801 HOII9i1NHUJ3N 83402 10 301581 138253415 301714 4 Redistribution or publication of this document by any means is strictly prohibited Generation ha o 2501219 SHINE DL 011204 2 QJM 170 3AYH 135 N39 0009 KK HN SH3RLD TW 0 31 JY ONND8D ie T ON ery usu 9 331838 4221 MZ 09 AE DZI Bi
17. been disconnected ing ire dis ofore attempting load wire dis able divide the load equaily among them connection reconnection Reconnectible single phase generators can supply the following vol tages Figure 1 4 120 240 volts 3 wire 120 volts 2 wire 240 volts 2 wire 120 VOLT 2 WIRE 240 VOLT 2 WIRE th i UNGROUNDED LOAD WIRE 1 M3 UNGROUNDED LOAD WIRE JOIN d M3 BLACK l BLACK K K 120 V Full nameplate rating 240 V Full nameplate rating 1 M4 0 F lt JOIN 4 GROUNDED LOAD WIRE c GROUNDED LOAD WIRE 2 4 M2 7 WHITE JOIN AND Z WHITE 6 GROUND D D DO NOT USE FOR 120 240 VOLT 3 WIRE UNGROUNDED LOAD WIRE BLACK M1 NOTE Only half nameplate a dd rating be taken off each 940 V 120 volt connection GROUNDED LOAD WIRE WHITE M2 M3 JOIN 120 V UNGROUNDED LOAD WIRE BLACK T FIGURE 1 4 120 240 VOLT RECONNECTIBLE GENERATOR LOAD CONNECTIONS GENERATOR LEADS ES 1811 Power 1 4 Generation Redistribution or publication of this document by any means is strictly prohibited Three Phase Delta Wound Generator 120 240 Volt Code 5D Electrical shock can cause severe AWARNING personal injury or death Check volt age at ihe main junction box to be sure power has been disconnected before attempting load wire disconnec tion reconnection Three phase delta connected generator
18. e Description Troubleshooting Chart Testing Procedures Repairs Wiring Diagrams 900 0196 9 96 Power Generation Service Manual UIN Generator and Controls Redistribution or publication of this document by any means is strictly prohibited Safety Precautions Before operating the generator set read the Operator s Manual arid bacome familiar with it and the equipment Safe and efficiant oparation can be achieved only H the unit is properly operated and maintained Many accidents are caused by failure to follow fundamental rules and precautions The following symbols found throughout this manual alert you to potentially dangerous conditions to the operator service per sonnel or the equipment This symbol warns of immediate haz ards which will resuit in severe personal injury or death AWARNING This symbol refers to a hazard or unsafe practice which can resuit in severe personal injury er death la CAUTION This symbol refers to a hazard or unsafe practice which can result In personal injury or prod uct or property damage FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury can result from improper practices DONOT fillfueltanks with the engine running unless tanks are outside the engine compartment Fuel contact with hot angina or exhaust is a potential fire hazard DONOT SMOKE OR ALLOW AN OPEN FLAME near the generator set or fuel tank Interna
19. 2 MQ M1 THREE PHASE COMMUTATOR ES 1814 FIGURE 2 5 ARMATURE AC OPEN TEST Ga Power 2 7 Redistribution or publication of this document by any means is strictly prohibited Generation Testing DC Armature Windings Open Circuit Test Using a six volt continuity tester touch one prod to a commutator bar and hoid it there Touch the other prod to successive bars working completely around the commutator If the light does not glow and the buzzer does not buzz there is open DC winding Replace the armature The growler can also indicate an open circuit Place the armature in the growler and turn the current on Pass a smooth steel strip across the commutator bars Figure 2 6 Rotate the armature to check all bars and coils spark should occur between the commutator bars No spark indicates an open coil Replace the armature GROWLER ES 1815 FIGURE 2 6 ARMATURE DC OPEN TEST WITH GROWLER Power _ Generation 2 8 Armature Short Circuit Test Totestfor a short circuit place the armature in a growler Figure 2 7 With the growler current on hold a steel strip about gt inch 13 mm above the armature lamina tions Pass the strip back and forth over the lamination Cover as much of the lamination area as possible If the strip is magnetically attracted to the armature at any point this indicates a short circuit ARMATURE AS 2 AT NIA S SM S 57 1 Ema
20. 415530 ra Power Generation 20 209 3svtid ren WUYSWIC 9NISIA 136 29 109 2 m 210 d2 4220 8 20 a 39 ONNGHS 01 80112 4 2 04 0 Su3HiD 1314 0 31 ONMOHS s 570 209 Mimmo Re mage MOHYROSROD uO Redistribution or publication of this document by any means is strictly prohibited 97313 GISAN WAHM 19 ONIY WNINSSL ASSY ayan ASSX ASSY ASSY Ova 011 149 1103 404 TINYd 30 3938 41033 0720 2209 Generation gt o 2 O O nT 9 uis 9 020 909 4999 MY 22 61 65 L 9911 92 52 ome A9v2 021 C CN ED S 0 T 5 2 ju ud torre A UgE22 32 uN 6 6 707 lt gt 3 9 6 1511 s f ws 445 2z Zi w 39602 306 Qv i6 91 92915 IOS 1 pf 9 2 NOMIAIG unuQ ae 8 2 GL NOLI2Y4NO 5 SWHH1LO 31 03001045 0351 N3HM OT AS
21. Open control cover Is battery voltage present when start switch is pushed to START Jumper stop relay terminals 5 and 11 Crank the engine Does engine start and run Stop the engine Jumper battery positive to stop relay K2 terminal 9 Does stop relay operate A WARNING Batteries present the hazard of explosion which can result in seyere personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area Replace stop relay K2 Check resistor R1 and resistor connections Are they OK Repair wire leads or replace resistor as necessary Perform generator tests See Generator Troubleshooting and Procedures Power 4 3 Redistribution or publication of this document Generation by any means is strictly prohibited LOW BATTERY NO HIGH CHARGE RATE YES Jumper two step voltage regulator relay terminals BAT and Start generator set Open control cover Does ammeter indicate higher charge rate A WARNING Batteries present the hazard of explosion which can result in severe personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area Replace two step voltage regulator relay K3 Check resistor R2 resistor connections and replace if necessary Power 4 4 Redistribution or publication of this document Generation by any means is strictly prohibited MCCK
22. Remote Start Stop Switch Customer Remote SO Vacuum Switch When Used Ignition A181 Hand Crank Electric Start Switch 152 Start Stop Switch FIGURE 3 3 TYPICAL SCHEMATIC FOR CCK SPEC R AND NH SPEC D THROUGH F Power 3 4 Redistribution or publication of this document Generation by any means is strictly prohibited START DISCONNECT Controls With 300 1227 Start Disconnect Adapter When the engine starts generator DC voltage supplied to terminal 2 turns on transistor of the start disconnect adapter and turns off transistors and A3Q2 Start solenoid K1 is deenergized and breaks the starting circuit At the same time the generator output at terminal 8 supplies currentthrough diode A1CR2 through switch 151 to ignition coil 1 and either electric fuel pump E1 or fuel solenoid K2 gasoline or LPG fueled sets respectively Controls Without Start Disconnect Adapter When the engine starts generator DC voltage supplied to terminal 8 causes A1CR5 to stop conducting and turns off transistor A1Q2 This deenergizes start sole noid K1 and breaks the starting circuit Atthe same time the generator output at terminal 8 supplies current through A1CR2 diode to ignition coil 1 and electric fuel pump E1 or fuel solenoid K2 BATTERY CHARGING The two step battery charging circuits Figure 3 3 provide either a continuous low 1 5 ampere or a high 5 26 ampere charge rat
23. SPEC D MODELS AND NH SPEC A THROUGH C MODELS To correct a problem answer the question in the appropriate troubleshooting chart either YES or NO Refer to the number in that column and proceed to that step Use the wiring diagrams see Wiring Diagrams section to locate terminals relays etc Figure 4 2 shows some ofthe control components for NH generator sets Spec through C Many troubleshooting procedures A WARNING present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service pro cedures Review safety precautions on inside cover page RESISTOR R2 TERMINAL BLOCK TB1 START SOLENOID VOLTAGE REGULATOR START STOP START ECT SWITCH SC 1621 FIGURE 4 2 GENERATOR SET CONTROLS MCCK SPEC D NH SPEC A THROUGH A Engine does not crank B Engine cranks but does not start Engine starts but stops when start switch is released D Engine is running then stops Low battery no charge rate Le Teva noes ea Check battery Are battery cables tight AWARNING Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing Replace start stop switch S1 D WARNING B
24. h AUR MN od dh F2 TERMINAL TOP BRUSH BLOCK TERMINAL 83 5 1820 FIGURE 2 11 GENERATOR FRAME WOUND STATOR ASSEMBLY To connect the voltmeter first remove the wrapper from the end bell With the generator set stopped connect one voltmeter lead to the top commutator brush lead which goes to ground and connect the other voltmeter lead to the commutator brush lead on the left Start the generator set and note the DC field voltage Stop the generator set remove the voltmeter lead from the brush on the left side and connect it to the other commutator brush lead on the right side Restart the generator set and check the DC voltage again Stop the generator set when finished Power Generation 2 10 Electrical shock can cause severe AWARNING personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing Field Ground Tests With an ohmmeter or continuity tester touch one prod to each coil terminal and the other test prod to a clean paint free part of the generator frame If the lamp lights or the ohmmeter shows continuity replace the frame assembly Field Open Tests Checkthe shunt winding resistance between S1 and F2 Table 2 3 lists field winding resistances Measure the series winding resistances between 51 and S2 and 51 and
25. 0 AX ee el U 3W10BLNOD 3107 2H QuvaNvis IYNOILdO IE d db AND CERAM oa GbIL H9 i Redistribution or publication of this document by any means is strictly prohibited T Power oi Generation Redistribution or publication of this document by any means 15 strictly prohibited 4 Onon Corporation 1400 7378 Avenue MN 55332 Telex 275477 Fax 612 574 8087 ef Onan Corparat on Cunimins si a t gntered traderaek of Cummins ne Company Ga Power Redistribution or publication of this document d Generation by any means is strictly prohibited
26. 110 3 434 451 54 GA Power Generation 96019119 oma Hd nvH5vid DING IS v 4931 GAGNNOYS 135 _N39 ONLNDD 3I 82 amp 420N8 9 8 Ot E Zh 02 Qd 92 21 24 T TUM o aD OL uiuo 4d 9 o 6111096 061344 1109 H IWOLSADGOLS 189145 H2INMS ae 3 0351 N3HM dW 31 HALVA HOU 491185 55182 110 01 221 5 4 ea Ree we AS OEE 0983114 860151514 SLE EE A M ____ 0717 0m 00m om v6 13 01093705 18115 47138 Ul HN 0151538 T 2 ve 30030 _ 301983495 q 9vm OwsiHi 74 weeds 12 7220 erae nena 13 44 iN 10 01 1149 12 304 i 19i11v8 l 118 438 835 583 1511 51884 ana _ A J Fk Alc o po LIS IHBYH SHEBIR 1510 9103 01 r 314 2 1uY1S 10E KD2 ASSY 135 N35 10KLHO3 1 WEINO2 1 151 Slave AOk2 021 c oc TN 12 Pil2OOC 22000 AIIN 2 OWH3HI 20 QN3 20012006 21108 5NIuv39 ASSY 3091909 SSSNUYH
27. 12u tos M as th es ss an PEST ae ____ 081 pum emm PRSE 95 L 25 i at SH 0 29411 9NINNOH 3103 Y 51 9 181 UUW NOLLIONOO 310934 28304 5 SJAL I 340N WEE Eas 9YW OEVE 86 OL VA3HOS _ to ON Hdf A ls OrE XL 17 HAE 22 L AQUE OZ 05 Hdt gO2 021 2 021 3002 30V100A 8 n tA IW A T p 1 LN ZA ONY dis 27 QN3 4937 JY WHO AD Z Ivi MY Hdl 91234233 401 1 4 9 Redistribution or publication of this document by any means is strictly prohibited 6 16 Generation ra Power 119 En DHIMA Las H35 104 1N0D LISTE ASSY av 8339349 9015 1915 Katies NOILINSI 138 NOtLIMSI WA BD Av11U 1081403 1 0130 diy oF e ee ASSY 00H INOS Oc 1 20 20 2 ASSY 155 1091921 MOLLdIi253Q 530 43M 157 Sluvd M OOD9I WOt HN 5 8 000 1 JOE 06 27000 38 0
28. 611 1094 611 1109 611 1123 611 1127 611 1135 611 1146 611 1135 611 1146 606 0203 606 0203 602 0245 611 1090 611 1086 611 1127 610 0350 611 1096 611 1096 611 1143 611 1145 611 1185 601 0197 610 0326 611 1135 611 1094 611 1109 606 0203 611 1052 611 1019 611 1090 611 1086 611 1127 6 1 SEE PAGE 6 11 6 13 6 14 6 15 6 19 6 17 6 19 6 17 6 4 6 14 6 3 6 10 6 9 6 15 6 6 6 12 6 12 6 16 6 20 6 18 6 2 6 5 6 19 6 11 6 13 6 4 6 6 7 6 10 6 9 6 15 Redistribution or publication of this document by any means is strictly prohibited 8908 A90S 2 9109 13 N39 1051909 Hdl Abrz Dzl 2618109 9NIHIA VI W9E QNO C VI NQES BNE Z N39 NI QNIOJJ 04 80112 4 2 OIM 0 3AVH 0 33 8 11 50731 03040989 51 MOLVEMEOD 40 Redistribution or publication of this document by any means is strictly prohibited 13 3 LNORS M So ET add I 1 __ 5 FTV AIT IY n 312 143238 13 2 e ome 30 1 2 Cows T T 9338953118177 7 i TOT Vidi33H o A Mn e u01 v4 1N39 A 1619109
29. CCK SPEC R MCCK BEGIN SPEC E AND NH SPEC D THROUGH F MODELS This description refers to CCK and NH generator sets but applies for the most part to the MCCK generator set begin Spec as well See Figure 3 3 STARTING AND IGNITION Controls With 300 1227 Start Disconnect Adapter Switch 152 when moved to START Figure 3 3 closes a circuit through diode A1CR1 and switch 151 to termina 6 This energizes ignition coil T1 and either electric fuel pump E1 orfuel solenoid K2 for gasoline or gaseous fuel respectively When switch A1S2 closes it places B on terminal 16 of start disconnect adapter A3 Transistor A3Q1 is ener gized and connects B to start solenoid K1 K1 contacts close connecting B to the generator The generator actsas a motor and cranks the engine If ignition voltage and fuel are present the engine starts and accelerates to governed speed On some madels the start solenoid K1 also energizes a choke For generator sets with a three wire start adapter A2 moving the switch to START energizes relay 2 2 which closes contacts A2K2 This connects B to termi nal 16 and start disconnect adapter A3 which energizes start solenoid K1 A1F1 FUSE USED ON EARLIER MODELS Later models use a9 ampere in line fuse F1 for protecting board against reverse battery connections This fuse 15 located in wiring harness between terminal and battery Controls Without Start Disconnect Adapter Switch 152
30. E and NH Spec D through Models 4 9 CCK begin Spec LK begin Spec M and NH begin Spec J Models 4 16 BFA Spec BGA Spec and NH Spec 5 4 20 5 POWER DRAWER 5 5 1 Generator Disassembly 5 1 Generator Troubleshooting 5 2 Generator Service Procedures and Tests 5 4 6 WIRING 5 6 1 Redistribution or publication of this document i by any means is strictly prohibited Power Redistribution or publication of this document Generation by any means is strictly prohibited Introduction This manual provides troubleshooting and repair informa tion for Onan UN generators It includes procedures for repairing the generator and contro system This infor mation does not apply to the engine engine information is provided in the ENGINE portion of the Master Service Manual 922 0501 Many troubleshooting procedures pre A WARNING sent hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of electricity and machinery hazards should perform service procedures Review safety precaulions on inside cover page TEST EQUIPMENT Most of th
31. FUSE PROTECTION 5 ampere fuse installed on the control board protects the board from shorts in the remote wiring If the fuse is blown correct the situation that blew the fuse then remove the cover on the control and replace it with an identical fuse Figure 5 11 CONTROL ELECTRIC POWER B134 5 1779 FIGURE 5 11 FUEL LOCATION 5 10 Power _ Generation Redistribution or publication of this document by any means is strictly prohibited CONTROL SYSTEM TROUBLESHOOTING After removing the contro cover use a long nosed pli ers to remove the flag connectors from the terminals on the board Pull these connectors straight out to avoid breaking the control board terminals Do not attempt to adjust the contacts on relays K2 and K3 they are precision set at the factory Blow dirt out of the relay contacts with a low pressure compressed air source To correct a problem answer the question in the appropriate troubleshooting chart either YES or NO Refer to the number in that column and proceed to that Step Many troubleshooting procedures A WARNING present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service pro cedures Review safety precautions on inside cover page PROBLEM a A Engine does not crank Engine cranks but does not start C Engine runs for 3 or 4 seconds t
32. Generation by any means is strictly prohibited GENERAL CONTROL P C BOARD PROBLEMS AND SYMPTOMS Continued A1F2 On units not having a 9 ampere fuse protection on terminal 5 install insulated jumper wire from TB2 18 to TB1 5 Add in line fuse package 4321 0212 Refer to Product Support Bulletin 57 A1F3 Connect bypass fuse assembly 321 0210 between TB1 2 and TB2 10 Refer to Product Support Bulletin 40 SYMPTOM Engine won t stop on low oil pressure or may not stop with stop watch PROBLEM Customer wiring errors which place battery voltage on terminal 14 destroys diode A1CR8 and or copper path from terminal 4 through switch A182 and A1CR8 may also destroy copper path from terminal 1 to 14 SOLUTION Correct the problem wiring etc To prevent future failure of diode 1 8 or burnt copper paths install in line fuse package 321 0212 Older units having fuse link ATF1 on the printed circuit board may also have blown Replace A1F1 fuse link with jumper wire SYMPTOM Engine won t stop with stop switch pushed or from low oil pressure PROBLEM On units without 9 ampere fuse on terminal 5 accidental connection of battery positive voltage from terminal 15 or 16 to terminal 14 burns one of the following copper paths Path from terminal 1 to 14 Path from terminal 4 to switch 151 Path from terminal 12 to switch 151 Path from terminal 14 to diode AiCR8 SOLUTION To prevent future burning out of copper paths
33. S3 If resistance is high an open circuit is likely and the frame assembly should be replaced TABLE 2 3 FIELD WINDING RESISTANCES pem mm mu SET WINDING 009 NB 067 006 NH oa 000 Resistance values 5 at 77 F or 25 C See Generator section in Service Manual 900 0196 for procedure TABLE 2 4 ROTOR STATOR RESISTANCE VALUES RESISTANCE OHMS 77 25 C COMPONENT 4 0 MCCK 3CR 6 5 MCCK 3CR ROTOR 0 194 0 238 0 103 TO 0 127 STATOR Shunt Field Fi F2 F2 F3 15 33 to 16 27 3 8310 4 07 11 5040 12 20 15 23 to 16 17 3 81 to 4 04 F3 F1 11 42 to 12 13 by any means is strictly prohibited Redistribution or publication of this document GENERATOR ASSEMBLY Clean and inspectall mating surfaces The surfaces must be clean and smooth Coat the mating area between the generator shaft and the engine crankshaft with a thin film of lub ricating oil Assemble the armature through stud to the engine crankshaft with required torque Make certain that the key is in the crankshaft Slide the armature over the through stud and onto the crankshaft taking care not to let the weight of the armature rest on the through stud Misalignment can shorten the ACAUTION life of the rear main and outboard bearings it can also double cranking torque requirements resulting in damage to the commutator and DC brushes For this reason do not tighten t
34. assembly 3 Brushes not making contact with 3 Check brush springs for collector ring free movement or brushes which i may be excessively worn 4 Open grounded or 4 Test with tester or short circuit in field ohmmeter and replace if or armature winding defective 5 Defective bridge 5 Test with ohmmeter and rectifier assembly replace if defective 6 Bridge rectifier 6 Reinstall making sure assembly installed marks on case and rectifier wrong in its case match LIGHTS FLICKER 1 Loose or broken lead 1 Repair broken lead or INTERMITTENTLY leads in generator Teconnect loose lead LOW AC OUTPUT 1 External short circuit 1 Locate and eliminate short VOLTAGE on line circuit problem 2 Generator overloaded 2 Remove part of load 3 Shorted or grounded 3 Test with ohmmeter or circuit in field or tester and replace armature winding if defective 4 Refer to Engine Troubleshooting guide 4 Engine not running properly causing generator to slow down NO SY GENERATOR 1 Replace bearing end ball GENERATOR OVERHEATS 1 Generator overloaded 1 Remove part of load 2 Windings and parts 2 Clean generator covered with oil or dirt 3 Air intake restricted 3 Take necessary steps to or incoming air too hot allow for proper cooling 4 Test with ohmmeter or tester and replace if defective 4 Shorted or graunded circuit in armature or field windings
35. be replaced Is electric choke closed when engine is cranking 13 12 Voltage at choke terminal when engine is cranking should be 12 volts If choke does not move room temperature with 12 volts applied replace it Also check wire from choke to control for shorts to ground The fault is in the ignition system Check points plugs wires and coil Refer to Igni tion section of master service manual C ENGINERUNS3OR4SECONDS THENSTOPS ENGINE RUNS 3 OR 4 SECONDS THEN STOPS mU Check oil level Refill to FULL mark on dipstick Does engine now continue to run ACAUTION Operating the engine with inadequate and pressure damage or destroy it Make sure the engine has sufficient and oil pressure Otherwise engine damage will occur Check voltage from terminal 11 to 12 15 it 12 volts with engine stopped and does voltage drop to zero when engine runs Check oil pressure sensor wire for shorts to ground by visually tracing wire from 52 low oil pressure switch to control Is wire grounded Replace or repair wire making sure it isn t rubbing against anything that may again cause a ground problem Remote lead 1 may be shorted to remote lead 2 Lead 2 may be grounded With engine cranking measure voltage at terminal 8 to BAT terminal of K1 start sclenoid 15 6 volis present Check battery connections They must be clean and tight Check flywheel alternat
36. burning e If adjustment must be made while tha unit is running use axtreme caution around hot manifolds moving parts etc ELECTRICAL SHOCK WILL CAUSE SEVERE PERSONAL INJURY OR DEATH Removeslectricpowar before removing protective shields or touching electrical equipment Use rubber insulative mats placed dry wood platforms over floors that are metal or concrete when around elsctrical equipment not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling electrica equip ment Use extreme caution when working on electrical compo nents High voltages can cause injury ot death DO NOT tamper with interlocks Follow state and local electrical codes all electri cal installations performed by a qualified licensed alactr cian Tag open switches to avoid accidental closure e DONOTCONNECT THE GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL POWEH SYSTEM Hazardous voltages can flow from the generator set into the utility line This creates a potential for electrocution or property damage Connect only through an approved da and after building main switch is open Consult alectrician in regard to emergency power use GENERAL SAFETY PRECAUTIONS Provide appropriate fire extinguishers and install them convenient locations Consult your local fire dapartmant for the correct type of extinguishsrto use Donotusa foam on electrical fires Use extin
37. charging circuit provides a continuous low current charge from the generator through resistor R1 diode CR1 and ammeter M1 to battery BT1 If this charging rate is too low the circuit automatically switches to a higher rate as follows Voltage regulator relay receives too low a voltage to energize so its N C contacts remain closed allowing generator current to pass through resistor R2 K3 contacts diode CR1 and to the battery When the battery is fully charged enough voltage is present to energize K3 opening its contacts to remove the high charge rate from the circuit STOPPING Moving switch S1 to STOP grounds the positive side of stop relay K2 K2 deenergizes opening its contacts to remove B from the primary side ofthe ignition coil This prevents a make and break of the ignition primary to eliminate the spark at the plug stopping the engine Power _ 3 1 Generation Redistribution or publication of this document by any means is strictly prohibited NC zu PY Battery CRI sss Reverse Current Diode EL sian Electric Choke 2 Fuel Pump When Used uM Spark Plug Generator Q gt KT Start Solenoid Relay 1 ee TAL ETT Stop Relay Ini Two Step Voltage Regulator Relay T 4 Gas Solenoid When Used aa Charge Ammeter M ee R1 R2 R3 Resistor Start Stop Switch SE Breaker and Cap Ass
38. condition which would shut down the engine If no safety shutdown has occurred connect a DC voltmeter from control terminal 6 to ground Crank the engine Is there DC generator output voltage 1B 2 Is fuse F2 in circuit to control terminal 6 blown 3 4 Replace fuse Check resistor R1 and all resistor connections If OK perform generator tests See Generator Troubleshooting and Procedures LOW BATTERY NO CHARGE RATE YES NO Is reverse current diode CR1 shorted or open Replace diode Check wiring from diode CR1 to start solenoid and to battery RUNNING TIME METER INOPERATIVE YES NO Check wires between control terminal 6 and battery positive terminal for running time meter and ground wire and connection to meter Does this correct the problem Replace defective running time meter Power 4 18 Redistribution or publication of this document gt Generation by any means is strictly prohibited Is fuse F1 blown Replace fuse with equivalent type fuse Check wires between control terminal 5 and battery positive terminal for battery condition meter terminal and ground wire and connection to meter Does this correct problem Replace defective battery condition meter Power 4 19 Redistribution or publication of this document Generation by any means is strictly prohibited ri BFA BGA AND NH SPEC K MODELS AWARNING Many troubleshooting procedures present hazards whic
39. fumes Keep an type fire extinguisher near Power 4 2 Redistribution or publication of this document e Generation by any means is strictly prohibited B ENGINE CRANKS BUT DOES NOT START YES Check wire lead to fuel pump check fuel pump and replace if necessary See the gnition System section in the ENGINE portion of the Master Service Manual 922 0501 eee ENGINE STARTS BUT STOPS WHEN START SWITCH IS RELEADED YES NO Connect DC voltmeter to start solenoid relay K1 terminal 1 and to a good ground Crank the engine until it starts release start switch and note voltmeter Did voltme ter indicate a voltage after start switch was released AWARNING Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter feads only when generator set is not operating Do not touch meter or meter leads during testing Check wire connections from generator to start solenoid K1 terminal S1 If OK perform generator test Generator Troubleshooting and Procedures Check resistor R1 and resistor connections Are they OK Replace resistor or wire leads as necessary Check reverse current diode CR1 for short or open and diode connections Replace if necessary Press start switch S1 to ees tm sul SSR aI Did engine start but stop when switch S1 is released Connect a DC voitmeter between stop relay K2 terminal 5 and a good ground
40. lead from low oil pressure switch grounded Repair or replace wire lead Check low oil pressure switch and replace if necessary Does unit have a high air temperature switch Power 4 17 Redistribution or publication of this document Generation by any means is strictly prohibited ENGINE CRANKS BUT DOES NOT START YES Remove wire lead from high air temperature switch and push start switch 51 do not let wire lead ground while disconnected Does engine crank and run 17 Is wire lead from high air temperature switch grounded 16 Repair or replace wire lead Check high air temperature switch and replace if necessary See the ignition System section ENGINE STARTS BUT STOPS WHEN START SWITCH IS RELEASED rw Connect DC voltmeter from control terminal 6 to ground Crank engine is there DC voltage output from generator fuse F2 should be OK if unit started initially Electrical shock can cause severe personal injury or death AWARNING Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is nol operating Do not touch meter or meter leads during testing Check resistor R1 and resistor connections If OK perform generator tests see Generator Troubleshooting and Procedures ENGINE IS RUNNING THEN STOPS YES NO Check the unit for a high air temperature or high water temperature whichever applies or iow oil pressure
41. mp AP n n nnn n gn 5 1102 me de m 2199 139 108 0465 anager camp aa d gala inns m 9 Js xw E m keit 1 1 tii Wd 110 WOT iiS 5 Lb 6 a ou 52 2257 1 8 724 OOMSLAN YILS S39 Y t T iind NTN GTS 4015 AY13U vu 2 4 3 re lt lt N913 H3E NAT AY TI eee ee 2 2 13 01083105 1915 1139 eee 23 3519 53 19K OTE SG 191 14 MADRE 1 8 031215 83121153 P tee om uu eee m 21 390188 8 311230 f d 1 G90 S0E rere be OBKCO0T ASST 930301037 7E M M M Pen hn 44 i 51 1 1 1 hy ere a Pg 1 118 4 1991409 1511 SluY iia e BREED sita 7 m TOTEM Viel savy 331 4 LS YT s min
42. on units without 9 ampere fuse on terminal 5 add the in line fuse package 321 0212 Refer to Product Support Bulletin 57 SYMPTOMS Excessive current overheats and destroys diode A1CR10 and copper path from A1CR10 to terminal 2 PROBLEM There are three known causes of excessive currents which may cause this problem 1 Reverse battery connections on units not having the 9 ampere in line fuse F1 and diode 11 protection 2 Improper transfer switch that may connect AC utility power to the generator output while transferring from utility to generator power See Product Support Bulletin 58 3 Starting solenoid chatter or sticking solenoid at high cranking current causes current surges beyond the thermal capability of diode A1CR10 SOLUTION To prevent future failure of diode A1CR10 on units without a 9 ampere fuse on terminal 5 for symptoms 1 and 2 above add in line fuse package 321 0212 Refer to Product Support Bulletins 57 and 58 To prevent future failure of diode A1CR10 due to start solenoid chatter or sticking for symptom 3 units without a start disconnect adapter add a start disconnect package 300 1231 PROBLEM 151 push button and 151 spring can snap off if care is not used in removing cover SOLUTION Install cover and switch repair package part 300 1232 which contains all necessary hardware and parts to repair a missing switch push button or spring This means itis notnecessary to replace the complete p
43. open contacts to remove battery positive from fuel pump E4 and ignition coil 11 This prevents a make and break of the ignition primary to eliminate spark at the plugs and stop the en gine After the engine stops blocking diode CR1 pre vents battery discharge through the generator 2 Deluxe Remote Control BTI Battery zy P Electric Choke E2 Spark Plug 22 0 Fuel Pump G1 Generator K1 Start Solenoid Relay 2 Crank Ignition Relay Run Ignition Relay R1 R2 Resistor Start Stop Switch SS Breaker and Assembly Low Oil Pressure Switch e OTT Ignition Coil uus Circuit Breaker FIGURE 3 4 TYPICAL SCHEMATIC FOR BFA BGA AND NH SPEC K Power _ 3 7 Generation Redistribution or publication of this document by any means is strictly prohibited MCCK SPEC H MODELS STARTING When switch 51 is moved to the START position the ground circuit is completed for start solenoid coi K1 and crank ignition relay coil K2 Battery current flows through fuse F2 5A relay coil normally closed contacts of run ignition start disconnect relay and relay coil K1 to ground Solenoid contacts Ki close and connect B to starter motor B1 which cranks the engine The contacts of relay K2 close connecting B to the ignition circuit and fuel pump 4 IGNITION During cranking battery ignition curren
44. or publication of this document Generation by any means is strictly prohibited rae 2i Check battery Are battery cables tight AWARNING Batteries present the hazard of explosion which can result in severe personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area Is battery voltage present between control remote connector plug terminals 3 and 5 or between TB1 3 and TB1 5 where applicable when start stop switch S1 is pushed to START See drawing of connector plug in Figure D WARNING Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing Replace start stop switch 51 ls battery voltage present between start solenoid K1 terminal 51 and ground when start switch is pushed to ON Replace start solenoid Perform generator tests See Generator section 1 ts 5 ampere fuse F2 blown 2 Replace fuse 3 Is battery voltage present between control remote connector plug terminal 6 or terminal TB1 6 where applicable and ground when start stop switch S1 is pushed to START Figure D shows locations of connector plug terminals 4 Make sure Faston terminals are making good connections to crank ignition relay K2 If OK repl
45. sets can supply the following voltages Fig ure 1 5 120 volt single phase current 240 volt single phase current 240 volt three phase current Forthree phase operation connectthe three load wires to the three terminals M1 M2 and M3 one wire per terminal MO is neutral and is not used for three phase operation Connect the hot black load wire to either M1 or M2 for 120 volt single phase service Connect the neutral white wire to MO Two 120 volt circuits are available Do not use MO and M3 as a 120 volt circuit For single phase 240 volt service connect the load between M1 and M2 or between M2 and M3 or between M1 and M3 three circuits available MO is not used Any combination of single phase and three phase load ing can be used if no one terminal current exceeds the generator nameplate rating Single phase loads as large as two thirds of the three phase rating may be used if no other load exists on the generator DELTA GENERATOR CONNECTIONS FOR VOLTAGE CODE 5D UNGROUNDED LOAD WIRE BLACK anes NGROUNDED LOAD WIRE 240 V 240 V E M2 UNGROUNDED LOAD WIRE M3 BLACK 159 v 120 V GROUNDED LOAD WIRE MO WHITE FIGURE 1 5 THREE PHASE 120 240 VOLT DELTA ae GENERATOR LOAD CONNECTIONS Power 1 5 Redistribution or publication of this document Generation by any means is strictly prohibited Three Phase Wye Connected Generator 120 208 Volt Code 4 277 480 Volt Code 4X Electri
46. the carburetor IGNITION The generator acts as a motor to crank the engine If ignition voltage and fuel are present the engine starts and reaches rated speed At this time the operator can release the start switch because the generator through resistor Rt and fuse F2 supplies voltage to fuel solenoid E5 ignition coil T1 and breaker point assembly 52 It also supplies voltage through diode CR1 to recharge and maintain the battery Generator voltage also oper ates the Onan electric choke E1 which slowly opens as the engine runs STOPPING Moving switch 1 to STOP connects battery ground to terminal 2 to ground the point side of the ignition coil This prevents a make and break of the ignition primary to eliminate spark at the plugs As the engine stops blocking diode CR1 prevents battery discharge through the generator ES Se 2 Deluxe Remote Control 1 Battery 1 Electric Choke E2 E3 Spark Plug 4 Fuel Pump When Used ES Fuel Solenoid When Used 61 Generator access Start Solenoid Crank Ignition Relay Start Stop Switch S2 Breaker and Cap Assembly 83 Low Oil Pressure Switch When Used High Air Temperature Switch When Used ignition Coil FIGURE 3 4 TYPICAL SCHEMATIC FOR BF BEGIN SPEC B CCK BEGIN SPEC U LK BEGIN SPEC M AND NH BEGIN SPEC J Redistribution or publication of this do
47. which opens contacts that remove B from the ignition coil When the genset is used with an automatic transter switch or automatic demand control and one of the emergency stopping devices operates the engine stops then cranks until the control cranking limiter opens STOPPING Moving switch 1 to STOP grounds the positive side of stop relay K2 K2 deenergizes opening contacts that remove B from the primary side of the ignition coil This eliminates spark at the plugs stopping the engine The six volt stop relay is used in series with the 30 ohm voltage drop resistor Goil resistance of the stop relay is roughly 30 ohms a problem arises check the resistance inspect the contacts and check contact operation when voltage is applied to the coil NN wi X Blass Battery Electric Choke When Used Be gaan wee Fuel Pump or Gas Valve When Used 4 Spark Plug 15565 Generator Start Solenoid Retay 2 Stop Relay 3 Two Step Voltage Regulator Relay 4 Start Disconnect Relay Assembly Charge Ammeter HT R2 R3 Resistor Start Stop Switch Breaker and Cap Assembly a High Air Temperature Switch When Used 54 Low Pressure Switch When Used y rr Ignition Coil FIGURE 3 2 TYPICAL SCHEMATIC FOR NH 3 3 Power Generation Redistribution or publication of this document by any means is strictly prohibited
48. 4 4 GENERATOR SET CONTROLS BF CCK form service procedures Review safety precautions BEGIN SPEC U LK BEGIN SPEC M NH BEGIN SPEC J on inside cover page PROBLEM SEE PAGE A Engine does not crank Engine cranks but does not start C Engine starts but stops when start switch is released D Engine is running then stops E Low battery no charge rate F Running time meter inoperative G Battery condition meter inoperative ENGINE DOES NOT CRANK m Check battery Are battery cables tight Batteries present the hazard of explosion which can result in A WARNING severe personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the area Is battery voltage present between control terminal 3 and 5 when switch S1 is pushed to START A WARNING Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operaling Do not touch meter or meter leads during testing Sm Power 4 1 6 Redistribution or publication of this document Generation by any means is strictly prohibited Se 21 7 Replace start stop switch 1 Is battery voltage present between start solenoid K1 terminal 1 and ground when start switch is pushed to START Replace start solenoid Perform gen
49. ES NO Check resistor G1R11 and all resistor connections s voltage present from terminal 6 to ground after engine starts and start switch 152 is released Replace contro board ENGINE IS RUNNING THEN STOPS YES NO Check the unit for a high air temperature high water temperature or low oil condi tion if applicable which would shut down unit If no safety shutdown occurred connect a DC voltmeter from control terminal 8 to ground Crank the engine Is there generator DC output voltage 1B 2 Check resistor G1R11 and all resistor connections If OK perform generator tests Generator Troubleshooting and Procedures LOW BATTERY HIGH CHARGE RATE YES Remove wire lead from fuse F1 to control terminal 5 Connect DC ammeter between wire lead and terminal 5 Start generator set Is high battery charge rate present over 3 amperes Measure battery terminal voltage with voltmeter one percent accuracy or better Does voltage rise to 14 volts or more AWARNING Batteries present the hazard of explosion which can result in severe personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area AWARNING Electrical shock can cause severe personal injury or death Use exireme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter fead
50. IDGE RECTIFIER p Emm ow 4 GENERATOR 5 1822 FIGURE 5 9 AC GENERATOR SCHEMATIC APPROXIMATE GENERATOR VALUES TYPICAL TYPICAL N L VOLTS N L VOLTS RESISTANCE RESISTANCE CURRENT MODEL N L VOLTS F L VOLTS X1 to H1 F1 to F2 F1 to F2 H1 to X1 FULL LOAD No Load F L Full Load GENERATOR TORQUE VALUES DESCRIPTION TORQUE VALUE Generator Through SUIS 4 OR ANAS RR ECCO ORARE RR 15 to 18 ft Ib 20 to 24 Nem Armature Hold down Nut 12 45 to 50 ft lb 61 to 67 Compounding Reactor 4 to 6 fi b 5 to 8 prush Block ASSBIRDIY RE RC CR n 4 to 6 ft ib 5 to 8 Nem Power Redistribution or publication of this document Generation by any means is strictly prohibited CONTROL SYSTEM OPERATION DESCRIPTION When relay operation is described refers to normally open relays and N C refers to narmally closed relays STARTING When switch 53 Figure 5 10 is moved to the START position B current flows through Ki solenoid K2 con tacts and switch 53 to battery negative K1 solenoid closes contacts feding current ihe starter motor and to choke E1 and relay K3 Relay K3 contacts close the circuit to the ignition coil Ti and fuel pump E2 fuel solenoid K4 The engine cranks and the fuel pump fuel sol
51. LACK A A A GROUNDED LOAD WIRE MO WHITE Lower nameplate voltage phase circuit 7 B Higher nameplate voltage phase circuit ES 1813 FIGURE 1 6 THREE PHASE FOUR WIRE WYE GENERATOR LOAD CONNECTIONS Power 1 6 Redistribution or publication of this document Generation by any means is strictly prohibited Section 2 Generator Onan Power Drawer gensets and controls are described in a separ ate section of this manual GENERATOR DISASSEMBLY Before disassembling the generator mark all leads and note their connection points Figure 2 1 illustrates a typical generator parts breakdown Many service procedures present AWARNING hazards which can in severe personal injury death and or equipment damage Only qualified service personnel with knowledge of fuels electricity and machinery hazards should per form service procedures Review safely precautions on inside cover pago 1 Disconnect the battery cables from the generator set negative cable first COLLECTOR RINGS COMMUTATOR ARMATURE ASSEMBLY DRIVE HUB GENERATOR TO ENGINE ADAPTER WRAPPER ARMATURE BEARING DC CONDENSER Batteries presentthe hazard of explo AWARNING sion which can result in severe personal injury Because batteries produce sive gas do not smoke or allow any arc producing devices in the battery area To avoid excessive arcing always disconnect the negative cable first and co
52. SY dy 2 banya i RI3NOYVH 1 ___25 1342938 40 3415100 PIC 4141153 ELT 22222 _ 31411939 NOLLdIIJS 30 1511 am saa 8 020 909 Power Generation 310W34 ATI 01 90112409 0360101 3AYH VIF 0731 23 040089 at 403 NOLIT3NNU23H 3109 30 JISNE 83389053115 3 774 Redistribution or publication of this document by any means is strictly prohibited 3 ra san 8 7 Sv5 d oN3106 901013915 DYW 0 81 1 i 4 04K 170 71 t TN end 21015 cet 33925115 XE 3N90238 533835 1115 108 1041802 53502 i 10 1 09 33130 52 assy 3031 a ih aed _ TI M 31 89018 7 4015 TYIS HJIIAS n o 2 2 557 4 7 t mE aisis 57538 7 PS E TY UL 0151590 amp Sz UL 536 t Ae dit aa sH i a 9 uO atur ENP Q 30 MISH tO SHINEE ee el UL 0 01 315 8 1 i
53. ace crank ignition relay 5 Disconnect B wire from ignition coil Remove the fuel line from the carburetor connect a flexible hose long enough to run fuel in a suitable container Momentarily push start stop switch to START Does fuel pulsate into container Reconnect line and wire to ignition coil after test A WARNING Fuel presents the hazard of fire or explosion which can cause severe personal injury or death Do not permit any flame spark pilot light cigarette or other ignition source near the fuel system Use extreme care during this test Run fuel into a suitable container and make sure area is well ventilated to prevent accumulation of explosive gasoline fumes Keep an ABC type fire extinguisher nearby Lm Power 4 21 Redistribution or publication of this document Generation by any means is strictly prohibited B ENGINE CRANKS BUT DOES NOT START YES NO Check iead to fuel pump Check fuel element to see if it needs cleaning Replace fuel pump if necessary See the gnition System section ENGINE STARTS BUT STOPS WHEN START SWITCH IS RELEASED YES NO is engine oil level OK Add oil as needed Remove cover from contro assembly Are resistor Ri 120 ohm and resistor con nections OK located near bottom of control Remedy or replace as needed If oil level was OK in Step 1 pull apart feed through connector shown in Figure 4 5 in control from run ignition relay and conne
54. al injury or death Do not permit any flame spark pilot light cigarette or other ignition source near the fuel system Keep an ABC type fire extin guisher nearby Arcing or inadvertent starting of the AWARNING generator set can cause damage to the generator set severe personal injury or death For this reason disconnect the negative battery cable before beginning these procedures and do not recon nect the negative battery cable until these proce dures are complete Electrical shock can cause severe A WARNING personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not teuch meter or meter leads during testing The brushes are easily damaged dur ACAUTION ing genset disassembly assembly Use extreme care while insialling removing the genset brushes Continuous generator set overload A CAUTION ing can cause high operating temp eratures that could damage the generator windings Keep the load within the nameplate rating Power _ 5 2 Generation Redistribution or publication of this document by any means is strictly prohibited TROUBLE POSSIBLE CAUSE CORRECTIVE ACTION NO AC OUTPUT 1 Blown fuse or circuit breaker 1 Look for cause and repair Then VOLTAGE replace fuse or reset circuit breaker 2 Disconnected wire or lead on 2 Reconnect wire or wires brushes bridge rectifier or reactor
55. ar the set to following Insulate the bare ends of ungrounded wires absorb vibration Strip enough insulation from the wire Install a fused main switch or circuit breaker between ends for clean connections the generator set and the load r Electrical shock can cause severe AWARNING personal injury or death Check vol lage at the main junction box to be sure power has been disconnected before attempting load wire disconnec tion reconnection CONTRACTOR MODEL SHOWN 240 VOLT 20 AMPERE TWIST LOCK RECEPTACLES FIGURE 1 2 CONTRACTOR AND PORTABLE GENSETS DUPLEX RECEPTACLES 1773 OTHER RV MODELS POWER DRAWER MODELS Svid MODELS m BOX GROUND LUG GROUND GROUND CONNECTOR A GENERATOR SET TO KNOCKOUTS CLEAN BARE GROUND M Lu ES 1810 FIGURE 1 3 AC OUTPUT BOX LOCATION Power 1 3 Redistribution or publication of this document Generation by any means is strictly prohibited Reconnectible Single Phase Generator A WARNING Electrical shock can cause severe personal injury or death Check volt lage at the vehicle junction box to be sure power has Use the connection for two wire service when one load exceeds one half rated capacity Balance the load when connecting for three wire service Currentfor any one output lead must not exceed the nameplate rating Serious overloading can damage the generator wind ings When two or more single phase circuits are avail
56. atteries present the hazard of explosion which can result in severe personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area Connect a DC voltmeter between control terminal 3 and B terminal Open control cover Is battery voltage present when start switch is pushed to START Power 4 5 ti Redistribution or publication of this document Weneration by any means is strictly prohibited URL 3 Connect the DC voltmeter between terminal 7 of the start disconnect relay assembly and battery B terminal Is battery voltage present when start switch 1 is pushed to START Replace start disconnect relay from start disconnect assembly Connect the DC voltmeter to the start solenoid reiay terminal 51 and to a good ground Is battery voltage present when start switch is pushed to START Replace start solenoid relay K1 Perform generator tests See Generator section Lu eon a DC voltmeter between the contro B terminal and terminal 9 of the start disconnect relay assembly Open control cover is battery voltage present when start switch S1 is pushed to START A WARNING Elecirical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing Replace the start disconnect
57. ature AC Windings Continuity Single Phase Models Using a Continuity Tester 6 volt Buzzer or Test Lamp Continuity should exist between collector rings 1 2 and between rings On single phase BFA mod els continuity should exist only between 1 and 2 should be no continuity between M2 M3 Figure 2 5 Using an Accurate Ohmmeter Resistances between collector rings M1 M2 and between M3 M4 should match values in Table 2 1 On single phase BFA mod els measure resistance only between M1 and M2 TABLE 2 1 SINGLE PHASE ARMATURE RESISTANCES VOLTAGE kW RESISTANCE 120 248 65 Oi5ohms 120 240 55 l025ohms 120 120 240 0 141 ohms ____120 40 027 120 20 40 1039 0 120 270 30 10300hms 120 240 0 56 ohms TEST PRODS TWO SLIP RINGS Three Phase Models Using a Continuity Tester 6 volt Buzzer or Test Lamp Continuity should exist between collector rings 1 2 M2 M3 and M1 M3 Figure 2 5 Using an Accurate Ohmmeter Resistances between collector rings M1 M2 M2 M3 and M1 M3 should match values in Table 2 2 TABLE 2 2 THREE PHASE ARMATURE RESISTANCES VOLTAGE kW RESISTANCE 120 208 65 020ohms 12020 65 32 20 58 120 240 40 128 es 0760hms COLLECTOR RING BEARING M2 Mi SINGLE PHASE COMMUTATOR COLLECTOR RINGS M3 2 SINGLE PHASE M3
58. cal shock can cause severe A WARNING personal injury or death Check voit age atthe main junction box to be sure power has been disconnected before attempting load wire disconnection reconnection Three phase wye connected generator sets produce single phase voltage of the lower nameplate voltage e g 120 volts and three phase voltage of the higher nameplate voltage e g 208 volts The MO terminal is grounded For single phase current connectthe neutral white load wire to MO Connect the hot black load wire to either M1 M2 or M3 Three separate single phase circuits are available each having no more than one third the rated genset capacity from any one circuit Forthree phase current connectseparate load wires to generator terminals M1 M2 and M3 Single phase cur rent is found between any two three phase terminals lf using single phase and three phase current at the same time take care to balance the single phase load properly Continuous generator set overload A CAUTION ing can cause high operating temper atures that could damage the generator windings Use any combination of single phase and three phase loads as long as the current in each load line of generator does not exceed rated current WYE GENERATOR CONNECTIONS FOR VOLTAGE CODES 4 120 208 and 4X 277 480 UNGROUNDED LOAD WIRE MI BLACK 3 PHASE HIGHER 5 UNGROUNDED LOAD WIRE 2 NAMEPLATE BLACK VOLTAGE B UNGROUNDED LOAD WIRE B
59. charging at the high rate STOPPING The generator set stops when switch 152 is moved to the STOP position This switch grounds the point side of the coil preventing a make and break of the ignition primary cutting off spark to the plugs At the same time the battery is prevented from discharging through the generator by AiCR3 diode On generator sets with a three wire adapter A2 moving the switch to STOP energizes relay A2K1 and A2K1 contacts close which ground terminal 14 the point side of the coil etc Redistribution or publication of this document by any means is strictly prohibited Generation BF CCK BEGIN SPEC U LK BEGIN SPEC M AND NH BEGIN SPEC J MODELS This operation description applies to all the series listed above except the Spec A series BF The Spec A BF operates identically except that it does not have a separate crank ignition relay for the ignition circuit see Wiring Diagrams section STARTING When switch S1 is moved to START Figure 3 4 battery negative is connected through switch 1 to start solenoid K1 and crank ignition relay K2 Start solenoid relay K1 closes its K1 contacts to connect to the series field cranking windings of the generator Ignition relay K2 closes its N O K2 contacts to connect B to ignition coil 1 breaker points assembly S2 and electric fuel pump E4 or fuel solenoid E5 E5 opens the fuel line to permit gaseous fuel flow from the fuel pump to
60. ck wire leads to gaseous fuel solenoid check solenoid and replace if necessary 9 Does generator set have an electric fuel pump 10 Does generator set have a gasoline shutoff solenoid 11 Fuel solenoid must open during cranking and running Remove the fuel line from carburetor and push switch 151 Does fuel pulsate from fuel line Power 4 1 1 Redistribution or publication of this document Generation by any means is strictly prohibited B ENGINE CRANKS BUT DOES NOT START YES NO A WARNING Fuel presenis the hazard of fire or explosion which can cause severe personal injury or death Do not permit any flame spark pilot light cigarette or other ignition source near the fuel system Use extreme care during this test Run fuel into a suitable container and make sure area is well ventilated to prevent accumulation of explosive gasoline fumes Keep an AB type fire extinguisher nearby Remove the fuel solenoid from the fuel line Push switch 151 Does fuel pulsate from the line Check wire lead to fuel pump check fuel pump and replace if necessary Check wire leads to gasoline solenoid check solenoid and replace if necessary Check oil level okay remove wire lead for low oil pressure switch S1 from control terminal 4 and push start switch A182 Does engine crank and run A CAUTION Operating the engine with inadequate oil and oil pressure can damage or destroy it Make sure t
61. ct lead from to a good ground Push start switch Does engine crank and run ACAUTION Operating ihe engine with inadequate oil and oil pressure can damage or destroy il Make sure the engine has sufficient oil and oil pressure Otherwise engine damage will occur Stop engine and reconnect feed through connector Check low oil pressure switch check lead to low oil pressure switch and repair or replace as needed Reconnect feed through connector in control jumper remote connector plug ter minals 5 and 6 or terminals TB1 5 and TB1 6 if applicable and push start switch 81 to START fuse F1 must be OK for this test Does engine crank and run Figure 4 5 shows locations of connector plug terminals With engine running is there 12 VDC from remote connector plug terminal 2 or terminal block terminal TB1 2 to ground Replace run ignition relay K3 See Generator Troubleshooting and Procedures Is there fuel in the fuel tank Does engine have a low oil level pressure condition Refill oil to proper oil level See ENGINE STARTS BUT STOPS WHEN START SWITCH IS RELEASED in Troubleshooting 5 reverse current diode CR1 shorted or open Replace diode Is wiring from reverse current diode to battery OK Remedy as necessary gd Power 4 22 Redistribution or publication of this document Generation by any means is strictly prohibited LOW BATTERY NO CHARGE RATE connections OK Re
62. ct the ohmme ter leads to 1 and 2 At70 F 21 C resistance should 28 8 ohms 3 for the BF and 38 ohms 3 for the NH Power on 5 6 Redistribution or publication of this document Generation by any means is strictly prohibited LOAD WIRES COMPOUNDING REACTOR f L Ww TORQUE TO 40 70 INCH LBS 5 8 Nem 40 70 iN LB 5 TO 8 Nem y BRIDGE RECTIFIER X1 LEAD ASSEMBLY BRUSH BLOCK ASSEMBLY TORQUE 1776 FIGURE 5 6 END BELL ASSEMBLY terminals are marked on both the bridge rectifier and the nylon case Observe the proper polarity when reinstalling If installed incorrectly generator voltage will not build up to the proper level 4 Use an ohmmeter to test the bridge rectifier Set the ohmmeter dial to x 1 scale Place the meter leads on the points shown in Figure 5 7 and note the readings from the table below If any tests do not agree with the above readings install a new bridge rectifier NOTE RED MARK APPEARS NEAR LEAD AC VIEW SCHEMATIC 1777 FIGURE 5 7 TESTING BRIDGE RECTIFIER Power Ser em RED LEAD RESISTANCE 8 Ohms 8 Ohms 3 Ohms 8 Ohms Infinity infinity Infinity Infinity BLACK LEAD A 10 Readings taken at 70 F 21 COLLECTOR RINGS Collector rings acquire a glossy brown finish in normal operation Do not attempt
63. cument by any means is strictly prohibited Power 3 6 Generation BFA SPEC A BGA SPEC A AND NH SPEC K MODELS STARTING When start stop switch S1 is moved to START see schematic ground is connected from the battery through switch S1 to start solenoid K1 and crank ignition relay K2 Start solenoid relay K1 closes its normally open contacts to connect battery positive to the series field cranking windings of the generator and to the electric choke E1 Crank ignition relay K2 closes its normally open contacts to connect battery positive through ignition fuse F2 to electric fuel pump E4 and ignition coil T1 The fuel pump begins to pump fuel to the carburetor SCHEMATIC IGNITION The generator acis as a motor and cranks the engine If sufficient ignition voltage and fuel are present the engine starts and reaches rated speed Generator output ener gizes run ignition relay K3 which connects B to ignition coil T1 and fuel pump E4 This enables the operator to release start stop switch which causes start solenoid K1 and crank ignition relay K2 to de energize Generator output also supplies a voltage through diode CR1 to re charge and maintain the battery and to operate the Onan e E1 which slowly opens as the engine continues to run STOPPING Moving start stop switch S1 to STOP connects battery ground to run ignition relay K3 and resistor R1 Relay K3 is de energized and opens its normally
64. dapter enable the frame to be pried loose Be careful not to let the frame rest or drag on the armature during removal 12 While pulling outward on the armature with one hand strike a blow on the end of the armature through stud with the nut on the stud to loosen the armature Remove the armature and drive hub as a unit Do not lose the key from the drive hub on the engine shaft If the armature does not come loose place a heavy brass rod on the armature shaft near the ball bear ing and strike a sharp downward blow on the rod with a hammer Rotate the armature 180 before repeating inadvertently striking the com ACAUTION mutator collector rings bear ing can damage these parts severely Use extreme care when performing this procedure Remove the engine generator adapter by removing the mounting screws Redistribution or publication of this document by any means is strictly prohibited Generation Power 2 2 GENERATOR TROUBLESHOOTING AWARNING Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page TROUBLE POSSIBLE CAUSE CORRECTIVE ACTION NO NOACVOLTAGE VOLTAGE 4 Blown fuse or circuit 0 Blown fuse or circuit 1 1 Look for cause and repair for cause and repair breaker if
65. e The low charge circuit about 1 56 amperes from generator G1 passes through charge resistor G1R1 8 3 ohm side terminal 2 control terminal 8 through A1CR3 control terminal 5 through fuse A1F2 and fuse F1 tothe battery The high charge circuit about 3 7 amperes goes through charge resistor G1R1 3 8 ohm side terminal 4 control terminal 7 transistor A1Q1 diode A1CR3 fuse A1F2 control terminal 5 and fuse F1 to the battery Together the low and high charge circuits provide roughly 5 26 amperes during high charging periods The high charging circuit switches on each time the generator set is started and switches off when the battery is almost fully charged Blocking diode A1CR3 prevents the battery from discharging when the gen erator is stopped Power 3 5 High Charge Rate Control Circuit Battery voltage and switching transistors A1Q1 A1Q3 A1Q4 and A1Q5 control the high charge rate control circuit Figure 3 3 This circuit switches on when battery voltage drops to 13 volts automatically turning off transistor A1Q5 This action turns on A104 which then turns on A1Q3 This turns on A1Q1 which com pletes the high charge circuitto the battery for charging at the high rate The circuit switches off when battery voltage rises to 15 volts automatically turning on transistor A1Q5 This action turns off A1Q4 which then turns off A1Q3 This turns off A1Q1 which opens the high charge circuit to the battery to stop
66. e if necessary 27 Does unit have high air temperature switch 28 Remove wire lead from high air temperature switch and push start switch 1 Do not let wire lead ground while disconnected Does engine crank and run 29 ils wire lead from high air temperature switch grounded 30 Repair or replace wire lead 31 Check high air temperature switch and replace if necessary 32 Does generator set have an electric fuel pump Power 4 7 Redistribution or publication of this document Generation by any means is strictly prohibited ENGINE CRANKS BUT DOES NOT START yes Remove fuel line from carburetor and jumper momentarily B to fuel pump Does fuel pulsate from fuel line AWARNING Fuel presents the hazard of fire or explosion which can cause severe personal injury or death Do not permit any flame spark pilot light cigarette or other ignition source near the fuel system Use extreme care during this test Run fuel into a suitable container and make sure area is well ventilated to prevent accumulation of explosive gasoline fumes Keep an AB type fire extinguisher nearby Check wire lead to fuel pump check fue pump and replace if necessary See the ignition System section in the ENGINE portion of the Master Service Manual 922 0501 EM ENGINE STARTS BUT STOPS WHEN START SWITCH IS RELEASED Check resistor R2 and resistor connections in control open cover Are they OK
67. e leads supplying current to the ignition coil electric fuel pump or fuel solenoid when start switch closes To prevent future failure of diode A1CR1 on units without 9 ampere fuse on terminal 5 add in line fuse package 321 0212 Refer to Product Support Bulletin 57 Engine stops running as soon as start switch is released Diode A1CR2 is destroyed through accidental grounding of terminal 6 or the leads supplying current to the ignition coil electric fuel pump or fuel solenoid while engine is running To prevent future failure of diode A1CR2 on units without 9 ampere fuse on terminal 5 add inline fuse package 4321 0212 Refer to Product Support Bulletin 57 The fuse does not protect A1CR2 but will blow during cranking if terminal 6 is grounded Start solenoid will not energize check for faulty solenoid before checking following Diode AiCR4 may be burned out if battery connections are accidentally reversed on units not protected by 9 ampere fuse F1 on terminal 5 To prevent future failure of diode A1CR4 on units without 9 ampere fuse on terminal 5 add inline fuse package 4321 0212 Refer to Product Support Bulletin 57 Accidental reverse battery connection to units not protected by in line fuse package 321 0212 may damage diode A1CR5 To prevent future failure of diode A1CR5 on units without 9 ampere fuse on terminal 5 add in line fuse package 1321 0212 Refer to Product Support Bulletin 57 Controis Without Start Discon
68. e tests described in this manual can be made with an AC DC multimeter Other test equipment includes Onan Multi Tester 420 0303 e Wheatstone or Kelvin bridge tests resistance values below one ohm e Continuity tester 6 volt e Jumper wires e Onan load test panels 420 0413 420 0414 420 0501 Onan armature growler 420 0194 Electrical shock can cause severe AWARNING personal injury or death Do nottouch electrical wiring or components during testing Dis connect electrical power by removing the starting bat tery negative cable before handling electrical wiring or components Electrical shock can cause severe AWARNING personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing FIGURE 1 1 TEST EQUIPMENT Power 1 Generation 1 Redistribution or publication of this document by any means is strictly prohibited LOAD WIRE CONNECTIONS The genset nameplate displays its electrical output rating in watts volts and hertz Table 1 1 lists these A WARNING Flectr cal shock can cause severe figures for gensets using the UN generator Contractor personal injury or death Check vol and portable gensets are prewired and include a tage at the main junction box to be sure power has been receptacle box with two duplex 120 volt 15 ampere disconnected before disconnect
69. embly DEO Ignition Coil Ld FIGURE 3 1 TYPICAL SCHEMATIC FOR NB MCCK SPEC D AND NH IGNITION SPEC A THROUGH C MODELS This description refers to an NH generator set but applies for the most partto the Spec D MCCK generator set as well See Figure 3 2 STARTING When switch 1 is moved to START battery negative is connected through switch 51 closed K4 contacts and start disconnect relay assembly K4 terminals 6 and 7 to start solenoid relay K1 The contacts of K1 are closed to connect Bt to the choke and to connect B to the series field windings of the generator and stop relay K2 K2 closes its N O contacts to connect B to the two step voltage regulator relay K3 to the fuel pump or gas valve E2 if used and to ignition coil T1 and breaker points assembly S2 The generator acts as a motor and cranks the engine If ignition voltage and fuel are present the engine starts and reaches rated speed Generator DC output after reaching 10 to 11 volts energizes the transistor in start disconnect relay K4 assembly which connects ground to start disconnect relay K4 K4 remains energized during genset operation hoiding its N O contacts closed to keep stop relay K2 energized and providing voltage for the ignition circuit and battery charging through ammeter M1 The N C contacts of K4 are opened atthis time breaking the startsignal from switch 1 and siart solenoid K1 Optionally another se
70. enoid and ignition operate starting the engine IGNITION After the engine starts and its rpm increases the fly wheel alternator develops a voltage which is rectified to DC energizing relay K2 K2 N O contacts close to hold relay K3 energized and K2 N C contacts open to drop K1 start solenoid K3 contacts maintain current to the ignition coil the fuel pump and the fuel solenoid As the engine runs K2 remains energized STOPPING Relay K3 energized by K2 maintainsthe ignition Push ingthe stop switch shorts K3 which drops outto remove power from the fuel pump fuel solenoid and ignition coil Resistor R2 absorbs the power that was supplied to K3 while the stop switch is held closed as the engine stops LOW OIL PRESSURE SHUTDOWN pressure is low switch S2 closes to charge capaci tor C3 through resistor R3 This provides a time delay of 2 to 4 seconds When the voltage on capacitor C3 matches the voltage of the divider R5 R6 programma ble unijunction transistor Q1 fires to trigger turns on to deenergize relay K2 contacts open as the engine stops and CR8 turns off BATTERY VOLTAGE SENSING The battery voltage sensing portion ofthe voltage regu lator determines whether the voltage regulator should turn on or off To test battery charging connect a DC voltmeter from B of the regulator to ground A reading of 14 1 to 14 5 volts is acceptable
71. er Field Winding Tests sounds a grounded circuit is indicated Replace The following tests can be performed without dis armature assembling the generator Disconnect the field coil leads from their terminal points on brush blocks and disconnect the 51 terminal from the start solenoid Electrical shock can cause severe AWARNING personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is operating Do not touch meter or meter leads during FIGURE 2 10 ARMATURE AC GROUND TEST testing ONE TEST PROD COMMUTATOR ONE TEST PROD ON ARMATURE SHAFT LAMP SHOULD NOT LIGHT OR BUZZER SHOULD NOT SOUND ES 1818 FIGURE 2 9 ARMATURE DC GROUND TEST M Power 2 9 Redistribution publication of this document rr fy 4 Generation by any means is strictly prohibited ifthe frame assembly failure is an external lead between coils or the coil lead the connection may easily be repaired If the problem lies inside a coil replace the entire frame assembly wound stator Figure 2 11 shows the wound stator assembly separated from the other generator components to simplify the wire lead illustration DC field voltage during no load operation for the LK is 17 volts 27 to 33 volts for the CCK MCCK and NH 61 TERMINAL 9 CONNECTS START SOLENOID TERMINAL S2 ENGINE END e Tn
72. er it on a lathe Turn the commutator or collector ring just enough to provide a true concentric surface Use 240 sandpaper to remove tool marks incorrect use of lathe or other AWARNING power tools can cause severe per sonal injury death or equipment damage Service personnel must be fully qualified to operate a lathe before attempting this service procedure Wear eye and hand protection while performing this procedure After turning the slip rings cut a slight chamfer on them to remove burrs and sharp edges This reduces the possibility of a flash over between the rings After the commutator ts turned undercut the mica insulation between the commuiator bars as described in the para graph Undercutting the Mica Insulation Undercutting the Mica Insulation When the commutator wears down to the point that the mica insulation between bars contacts the brushes the brushes will jump spark operate noisily and wear rapidly This lowers the efficiency of the generator and burns the commutator Figure 2 4 When a high mica condition exists or after the commutator has been turned on a lathe the mica insulation must be undercut tool for this task is illustrated in Figure 2 4 The undercutting process can easily ACAUTION damage the slip rings Use extreme care nol to draw the undercutting tool into the slip rings To undercut the mica center the cutting tool over the mica and draw the tool the lengt
73. erator tests See Generator section Is battery voltage present at control terminal 6 and ground when start switch S1 is pushed to START Is fuse F2 in circuit to control terminal 6 blown Replace fuse Make sure Faston terminals are making good connections If OK replace defective start solenoid on 4 0 BF Spec A or crank ignition relay K2 on 2 5 LK Spec M 4 0 BF Spec B CCK Spec and NH Spec J Fuel solenoid must open during cranking and running Remove the fuel line from carburetor and momentarily jumper contro terminal 5 to 6 Does fuel pulsate from fuel line A WARNING Fuel presents the hazard of fire or explosion which can cause severe personal injury or death Do not permit any spark pilot light cigarette or other ignition source near ihe fuel system Use extreme care during this lest Run fuel into a suitable container and make sure area i5 well ventilaled to prevent accumulation of explosive gasoline fumes Keep ABC type fire extinguisher nearby Check wire lead to fuel pump Check fuel pump and replace if necessary Does engine have pump and full pressure lubrication Check oil level If okay remove wire lead from low oil pressure switch and push start swtich Does engine crank and run A CAUTION Operating the engine with inadequale oil and oil pressure can damage or destroy it Make sure the engine has sufficient oil and oil pressure Otherwise engine damage will occur Is wire
74. f relay K4 to ground K4 energizes and opens the circuitto K3 which breaks the ignition circuit With the ignition current cut off the generator set stops BATTERY CHARGING DIODE CR2 rectifies the AC power from the generator prevent ing battery discharge through the generator on shut down The diode replaces the reverse current relay used on some earlier models SHUNT FIELD BRIDGE RECTIFIER CR1 Diode bridge CR1 is located on the top brush holder of the generator It rectifies AC power from generator ter minals M1 and M2 and supplies DC currentfor energiz ing the generator shuntfield At normal operating condi tions field voltage measured between F1 and F2 is 100 to 110 volts DC If there is no generator output check CR1 as a possible fault The residual magnetism may need restoring as shown in Figure 3 6 Power 3 8 Generation Redistribution or publication of this document by any means is strictly prohibited Deluxe Remote Cantrol racc Standard Remote Control pce Starter Motor Condenser Assembly rl Bridge Rectifier E PS Silicon Rectifier Lem Spark Plug PE EREAAEERVATARERENE RA VE E Fuel Pump Electric Chake TES Fuse 5 amp 32 V Fuse 3 amp
75. genera tor set is not operating Do not touch the meter or meter feads during testing G 1221 FIGURE 5 3 ARMATURE GROUND TEST ARMATURE OPEN TEST Place one test prod on each collector ring Figure 5 4 The tester should buzz or light If it does not do so the armature has an open or a bad connection Electrical shock can cause severe AWARNING personal injury or death Use exireme caution when working on electrical circuitry Attach and remove meter leads oniy when generator set is not operating Do not touch meter or meter leads during testing FIGURE 5 4 ARMATURE OPEN TEST TESTING FIELD WINDINGS FOR GROUNDS Before testing disconnectall field leads Touch one test prod to F1 and the other prod to the frame Figure 5 5 The buzzer should not sound or the lamp should not light If the tester buzzes or lights the field is grounded and must be replaced Test lead F2 in the same manner Electrical shock can cause severe AWARNING personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads oniy when generator set is not operating Do not touch meter or meter leads during testing d Generation Redistribution or publication of this document by any means is strictly prohibited Electrical shock can cause severe AWARNING personal injury or death Use extreme caution when working on electrical circuitry Atiach and remove meter leads only
76. guisher rated ABC by NFPA Used engine ollshave been identified by some state or fed eral agencies as causing cancer or reproductive toxicity When checking or changing engine l take care notio in gest breathe the fumes or contact used oil e Benzene and lead found in some gasoline have been identified by some state and federal agencies as causing cancer or reproductive loxicity When checking draining or adding gasoline take cars not to ingast breathe the furnes cr contact gasoline Make sure that rags are not left on ar near the angina Remove all unnecessary grease and oil from the unit Ac cumulated grease and oil can cause over heating and en gine damages and present a potent al fire hazard Keep the generator set and the surrounding area claan and free from obstructions Remove any debris from the sat and keep the floor clean and dry Donotwork on this equipment when mentally or physically fatigued or consuming any alcohol or drug thal makes the operation of equipment unsafa _ Redistribution or publication of this document Generation by any means is strictly prohibited Table Of Contents SECTION TITLE SAFETY 6 Inside front cover 1 INTRODUCTION bet rd kr 1 1 Test oni 1 1 Load Wire CONN SCIONS
77. h can result in To correct a problem answer the question in the severe equipment damage Only qualified service per appropriate troubleshooting chart either YES or NO sonnel with knowledge of fuels electricity and Refer to the number in this column and proceed to that machinery hazards should perform service step procedures Review safety precautions on inside cover Use the wiring diagrams see Wiring Diagrams section page for location of terminals relays etc Figure 4 5 shows some of the control components for the generator sets CONTROL BOX TERMINAL BLOCK p TB1 WHEN USED CA REMOTE Wael Y CONNECTOR PLUG FEED THROUGH gt CONNECTOR TO Tes OIL PRESSURE SWITCH it NT Sb AN REVERSE CURRENT 7 650 DIODE CRI RESISTOR 1 START SOLENOID K1 Mi i t CRANK IGNITION RELAY K2 AUN IGNITION RELAY K3 C MEE a CONTROL PANEL START STOP SWITCH S1 FUSE Fi IGNITION NOTE CONTROL PANEL FUEL Fe SHOWN ROTATED 90 TO ENABLE ILLUSTRATION 5 OF CONTROL COMPONENTS FIGURE 4 5 GENERATOR SET CONTROLS BFA BGA NH SPEC K PROBLEM SEE PAGE A Engine dees not crank Engine cranks but does not start C Engine starts but stops when start switch is released D Engine is running then stops E Low battery no charge rate Running time meter inoperative G Battery condition meter inoperative Power m Redistribution
78. h of the commutator with a firm steady pull Repeat the cutting operation unti the mica is removed to approximately 1 32 inch 0 8 mm below the surface of the commutator When each section of mica is cut to the proper depth proceed to the next section until all are equally under cut Carefully remove any burrs by holding a piece of 240 sandpaper against the commutator with a flat piece of wood while the commutator turns rapidly Power _ 2 5 Generation Redistribution or publication of this document by any means is strictly prohibited AWARNING Contact with rotating machinery can Before returning the armature to service blow or brush severe personal injury Wear all mica dust metallic particles etc from the commuta eye protection and gloves and use extreme care when tor grooves and surface Bevel the edges of the bars on performing this burr removal procedure the larger commutators WOODEN HANDLE HACK SAW BLADE T lt WRONG TEETH POINT WAY TO WAY TO TOWARD HANDLE GRIND GRIND TEETH TEETH WIDTH OF MICA BRUSH COMMUT ATOR BARS COMMUTATOR BARS WORN BELOW LEVEL OF MICA SEPARATORS CAUSE SPARKING JUMPING NOISY BRUSHES a HIGH MICA 1775 FIGURE 2 4 UNDERCUTTING MICA INSULATION Power 2 6 Redistribution or publication of this document Generation by any means is strictly prohibited Testing Arm
79. he armature or rotor through stud before mounting the frame and end Install the frame and end bell with bearing Install the four generator through bolis washers lockwashers and nuts Tighten to the specified torque Install the generator fan cover Torque down the armature through stud nut 10 1t 12 13 Tap the end bell in the horizontal and vertical planes with a lead hammer to relieve stresses on the components then recheck the torque Install the generator fan cover Reconnect the wire leads to the engine Reinstall the battery cables Arcing or inadvertent starting of AWARNING ihe generator set can cause damage to the generator set severe personal injury or death For this reason do not reconnect the negative battery cable until instructed to do so in this procedure Power 2 11 Generation Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means 15 strictly prohibited Section 3 Control System OPERATION DESCRIPTION This manual section is divided into five parts correspond ing to the different types of controls used with the UN generators Table 3 1 indexes the operation descrip tions for the different types of controls Troubleshooting procedures are described in Section 4 of this manual NOTE Section 5 of this manual describes the generators and controls of the Onan P
80. he engine has sufficient oil and oil pressure Otherwise engine damage will occur Is wire lead from low oil pressure switch grounded Repair or replace wire lead Check low oil pressure switch S1 and replace if necessary Is unit water cooled and does it have a high water temperature switch Jumper across high water temperature switch and push start switch 152 Does engine crank and run Check high water temperature switch and replace if necessary Is unit air cooled and have a high air temperature switch Remove wire lead from high air temperature switch from control terminal 3 and push start switch 4152 Does engine crank and run Is wire lead from high air temperature switch grounded Repair or replace wire lead Check high air temperature switch and replace if necessary See the Ignition System section ENGINE STARTS BUT STOPS WHEN START SWITCH IS RELEASED YES NO Connect voltmeter from control terminal 8 to ground Crank engine s there DC vol tage output from generator AWARNING Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing y sU Power 4 12 Redistribution or publication of this document Generation by any means is strictly prohibited C ENGINE STARTS BUT STOPS WHEN START SWITCH IS RELEASED Y
81. hen stops D Low no charge rate A ENGINE DOES NOT CRANK Check battery Are battery terminals clean and are cables tight Check battery cables for polarity 1 12 volts present across battery terminals with engine stopped and is 8 volts or higher present with engine cranking For this reason disconnect the negative battery cable before beginning these procedures and do not reconnect the negative battery cable until these proce dures are complete Arcing or inadvertent starting of the generator set can cause damage to the generator set severe personal injury or death Remove cover on printed circuit board Jumper terminal 7 to 3 Press start switch Does engine crank Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove jumpers only when generator set is not operating Do not touch jumpers during testing Power _ Generation 5 11 Redistribution or publication of this document by any means is strictly prohibited CX ENGINE norca K2 contact is defective Replace printed circuit board Jumper terminal 7 to 1 Does engine crank Start switch S3 is defective Replace printed circuit board Jumper from S termina of B1 starter motor to positive Does engine crank Replace K1 start solenoid Starter is defective Remove and perform tests listed in Starter section of master ser
82. ing chart either YES or NO Refer to the number in that column and proceed to that step Use the wiring diagrams see Wiring Diagrams section to locate terminals relays etc Figure 4 1 shows some of the control components for the NB model generator sets Many troubleshooting procedures A WARNING present hazards which can result in severe personal injury death and or equipment damage Only qualified service personnel with know ledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page TERMINAL BLOCK TB1 e 2 STOP RELAY VOLTAGE REGULATOR i vw SC 1620 FIGURE 4 1 NB GENERATOR SET CONTROL Power 4 1 Generation Redistribution or publication of this document by any means is strictly prohibited PROBLEM SEE PAGE A Engine does not crank B Engine cranks but does not start C Engine starts but stops when start switch is released D Generator set is running then stops Low battery no high charge rate Check battery Are battery cables tight Is battery voltage present between control TB1 terminal and B terminal when start switch 1 is pushed to START A WARNING Batteries present the hazard of explosion which can result in severe personal injury Because produce explosive gas do not smoke or allow any arc producing devices in the battery area Re
83. ing load wires grounding receptacles and two 240 volt 20 ampere twist lock receptacles Figure 1 2 Figures 1 4 and 1 5 show the electrical circuits and connections for various voltages on all other UN based generator sets TABLE 1 1 ELECTRICAL DATA FOR UN GENERATORS 60 HERTZ 1800 r min 60HERIZ 1800r mn 1 10 O SERIES WATTS VOLTAGE Inches A i EIER EE ERR i el ERU 120 240 120 240 120 240 BF Power Drawer BFA RV BGA RV 120 240 120 240 120 240 120 240 120 240 120 240 120 208 120 208 120 240 277 480 120 208 120 240 277 480 120 120 240 1 120 240 1 30 15 120 240 1 30 15 120 240 1 35 17 5 120 240 1 46 23 120 240 1 46 23 120 240 3 10 220 380 3 6 4 120 240 3 13 2 220 380 3 8 4 Current rating for three phase voltage only higher nameplate rating Special generator set model for recreational vehicles ma Power 1 2 Redistribution or publication of this document Generation by any means is strictly prohibited Meet all applicable code requirements A qualified The AC output box has openings for load wires Figure serviceman or electrician must install the genset and 1 3 Connect each load wire to the proper generator the installation must be inspected and approved Use output lead inside the AC output box descriptions flexible conduit and stranded load wires ne
84. istor in series as shown Observe diode polarity The lead mustreach from the genset B terminal to the positive terminal of bridge rectifier CR1 Install clips at each end and insulate bare wires and connections 12 AMP 300 VOLT DIODE BRIDGE RECTIFIER TO BRUSH BLOCKS TO GENSET BATTERY 25 1065 POSITIVE TERMINAL FIGURE 3 6 RESTORING RESIDUAL MAGNETISM EP GA Power 3 9 Redistribution or publication of this document Generation by any means is strictly prohibited Redistribution or publication of this document by any means 15 strictly prohibited Section 4 Troubleshooting This section is divided into five parts corresponding to the types of control circuitry used with the UN generaior An index for this section is shown below 1 Many troubleshooting procedures pre AWARNING sent hazards which can result in severe personal injury death and or equipment damage Only qualitied service personnel with know ledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page MCCK Spec D NH Spec A through C CCK Spec MCCK Begin Spec NH Spec D through F BF CCK Begin Spec U LK Begin Spec NH Begin Spec J BFA Spec A BGA Spec A NH Spec K RESISTOR START STOP SWITCH NB MODELS To correct a problem answer the question in the appropriate troubleshoot
85. l combustion engine fu als ara highly flammable e Fual lines must be adequately secured and free of leaks connections at the engine should be made with an ap proved tlaxible line Do not use copper piping on flexible lines as copper will work harden and become brittle Be sure that all fuel supplies have a positive shutoff valve DONCOT SMOKE while servicing batteries Lead acid bat terias emit a highly explosive hydrogen gas that can be ig nited oy electrical arcing or by smoking EXHAUST GASES AHE DEADLY Provideanadequate exhaust system to properly expel dis charged gases Inspactthe exhaust system daily for faaks par the maintenance schedule See that exhaust mani folds are Secure and are not warped Do not use exhaust gases to heat a compartment e Be sure the unit is wall vantilated MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH 5 Kasp your hands away from moving parts alors performing any maintenance on the generator set disconnect the starting battery negative ground iead lirst This will prevent accidental starting Make sura that fasteners on tha generator set are secure Tightansupparts and clamps keap guards in position over fans drive belts etc Donot wear loose clothing or jewalry while servicing any part of the generator set Loose clothing and jewelry can become caught in moving parts Jewelry can short out alectrica contacts and cause shock or
86. medy replace as necessary l See Generator Troubleshooting and Procedures a Check wires between control remote connector plug termina 6 or TB1 6 where applicable and battery positive terminal for running time meter and ground wire and connection to meter Does this correct problem Figure 4 5 shows locations of connector plug terminals Replace defective running time meter i 0 BATTERY CONDITION METER INOPERATIVE s o Is fuse F1 blown Replace fuse with equivalent type fuse Check wires between control remote connector plug terminal 5 or TB1 5 where applicable and battery positive terminal for battery condition meter terminal and ground wire and connection to meter Does this correct problem Figure 4 5 shows locations of connector plug terminals Replace defective battery condition meter pi Power 4 23 Redistribution or publication of this document dim Generation by any means is strictly prohibited Redistribution or publication of this document by any means 15 strictly prohibited Section 5 Power Drawer Models GENERATOR DISASSEMBLY The generator used in the Power Drawer genset nor mally needs little care other than a periodic check of the brushes and collector rings If a major repair is neces sary have the genset checked and tested by an Onan service technician or a qualified electrician Many troubleshooting procedures AWARNING present hazards which can result in severe pers
87. nect Adapter SYMPTOM Siart solenoid won t energize PROBLEM On units without 9 ampere fuse on terminal 5 accidental grounding of terminal 9 or reverse battery connections may damage transistor 102 SOLUTION To prevent future failure of transistor A1Q2 on units without 9 ampere in line fuse on terminal 5 install in line fuse package 7321 0212 Refer to Product Support Bulletin 57 SYMPTOM Engine cranks but will not start no battery voltage at terminal 6 PROBLEM A short circuit or accidental ground on terminal 6 may burn the copper path from terminal 610 151 when start switch is pushed and or burn the copper path from terminal 5 to 151 if handcrank switch is pushed SOLUTION To prevent future burning of copper path on units not having 9 ampere fuse on terminal 5 add in line fuse package 321 0212 Refer to Product Support Bulletin 57 SYMPTOMS 1 Engine won t crank F1 or A1F2 open 2 Remote running time meter or generating lamp won t work fuse open PROBLEM On units not having a 9 ampere fuse protection on terminal 5 customer wiring errors including reverse battery connections causes 1 2 and 1 to SOLUTION F1 On units not having a 9 ampere in line F1 fuse protection solder a wire place of A1F1 fuse link on printed circuit board wire size not important Add in line fuse package 321 021 2 Refer to Product Support Bulletin 57 Power 4 14 Redistribution or publication of this document
88. nnect it last Inadvertent starting of the A WARNING generator set can cause damage to the generator set severe personal injury or death For this reason do not reconnect the nega tive battery cable until instructed to do so in this procedure Remove the control leads and other electrical leads to the engine Disconnect the load wires from the generator output wires in the AC output box Remove accessories attached to the generator Remove the generator fan cover and end bell wrapper Loosen and lift out the brush rigs or use wooden dowels or alligator clips to hold the brushes out of the way to remove the end bell AC CONDENSER COLLECTOR RING BRUSH BRUSH BLOCK COMMUTATOR BRUSH M 1774 FIGURE 2 1 TYPICAL GENERATOR DISASSEMBLY EARLY MODELS Power _ Generation Redistribution or publication of this document by any means is strictly prohibited The brushes may be damaged ACAUTION during removal if not held off the slip rings Make certain to hold the brushes out of the way before removing the generator end bell Remove the generator fan mounting nut and washer Remove all the generator wire leads from the end bell assembly Remove the four generator through boits Lift or pull the end bell from the frame assembly do not pry with a screwdriver Tap around the edges of the end beil with a plastic hammer Remove the frame assembly Screwdriver slots in the engine generator a
89. o 40 to 70 in b or 4 to 6 fi lb 5 to 8 Nem if sparking occurs after replacing the brushes run the generator with a light load until they seat properly Check the brush springs for freedom of movement ARMATURE GROUND TEST While the armature is removed for checking shorts using a growler additional checks can be made if the armature is still installed liftthe brushes before conduct ing these tests These tests use either the continuity tester buzzer or the test light Place onetest prod on one ofthe collector rings and the other test prod on the armature shaft Figure 5 3 The tester buzzer should not buzz lamp should not light If it buzzes or lights the AC winding or a collector ring 1 grounded to the shaft Test each collector ring in this manner r y 14 BRUSH BLOCK LOCATION MAXIMUM WEAR f LIMIT ONE INCH 7 7 al 5 oe WV REPLACE WHEN WORN d 5 8 1 16mm THIS DIMENSION OR CROSS SECTION OF BRUSH BLOCK NOTE IF MEASUREMENT A EXCEEDS ONE INCH 25 mm MEASURE FROM TOP FACE OF BRUSH BLOCK TO TOP OF BRUSH G 1220 FIGURE 5 2 BRUSH WEAR LIMITS Power 5 4 Generation Redistribution or publication of this document by any means is strictly prohibited Electrical shock can cause severe AWARNING personal injury or death Use extreme caution when working on electrical circuitry and remove meter leads only when the
90. oad until the brushes are properly seated Redistribution or publication of this document by any means is strictly prohibited Generation Power 2 4 Collector Rings and Commutator lf the collector rings are so grooved or pitted that good brush seating cannot be maintained remove the arma ture and refinish the collector rings in a lathe If the commutator appears rough or scored refinish it at the same time incorrect use of a fathe or other AWARNING power tools can cause severe per sonal injury death or equipment damage Service pers onnel must be fully qualified to operate a lathe before atiempting this service procedure Wear eye and hand protection while performing this procedure The fathe refinishing process can ACAUTION damage the ball bearing Shield the ball bearing during refinishing to prevent damage The commutator gradually wears with use If the proper brushes have been used and if they have been replaced at proper intervals the commutator will wear slowly and evenly dusty conditions or if the wrong brushes are used wear occurs faster Improper or excessive clean ing with sandpaper may cause the commutator to become grooved or out of round If this condition exists refinish the commuiator in a lathe Lathe Turning Collector Rings or Commutator When collector ring or commutator becomes grooved or pitted turn it true in a lathe as follows Remove the armature and cent
91. onal injury death and or equipment dam age Only qualified service personnel with knowledge of fuels electricity and machinery hazards should per form service procedures Review safety precautions on inside cover page Remove the unit from its slide rails Remove all accessories attached to the generator Tag and remove all leads Loosen and lift out both brush rigs Figure 5 1 The brushes will be damaged A CAUTION during disassembly if not held off the slip rings Use extreme care when removing the brush rigs gt 5 Remove four generator through stud nuts 6 Lift or pull the end bell from the frame assembly Do not pry it loose with a screwdriver rather tap around the edges of the end bell with a plastic hammer to loosen it Striking the end bell or other ACAUTION generator parts can damage or destroy them Use extreme care while tapping the edges of the end beil to loosen it Remove the frame field assembly being careful not to let it rest or drag on the armature The generator will overheat if it ACAUTION is reassembled incorrectly Four seals are used between the frame field assembly and engine lo generator adapter These seals must be used to reassemble the generator correcily Insert a square 3 8 inch drive into the 12 point internal wrenching armature holddown nut to remove it While pulling outward with one hand under the armature strike a sharp blow on
92. or G1 output Disconnect AC lead that connects to voltage regulator VR1 and connect voltmeter to this lead and BAT terminal of K1 start sole noid This checks AC open circuit voltage Start engine Is AC output voltage approximately 28 volts with unit running at 1800 rpm Replace alternator stator G1 Connect a voltmeter across battery terminals Start engine Does DC voltage increase to 13 to 14 1 2 volts after engine is running for a few minutes Remove and replace voltage regulator VR1 rua Power 5 13 Redistribution or publication of this document Generation by any means is strictly prohibited Power Redistribution or publication of this document ion by any means is strictly prohibited section 6 Wiring Diagrams All the wiring diagrams included in this section apply to generator sets equipped with the UN generator To find the correct wiring diagram proceed to the page corresponding to the generator set series WIRING DIAGRAM SERIES BF 1R 9000A 95004 BF 1R 9000B BF 3CR 16000A BF 3CR 16000B BFA 1R 16000A BFA 1H 16000B BGA 3CR 16000A 60008 CCK 3CE 2236R CCK 3CE 13276R CCK 3CPAR CCK R 1R CCK 3CR 12000R CCK 3CH 16000U LK 3CRAM MCCK 3CR 1F MCCK 3CR 1G MCCK H MCCK J NB 3CH 1A NH 3CR 16000A 1 9000 95004 1 9000 NH 3CE 2236D NH R 6000A NH R A NH RAR NH 3CR 12000D NH 3CH 16000J Power Generation
93. ower Drawer gensets TABLE 3 1 INDEX OF CONTROL SYSTEM DESCRIPTIONS UNIT PAGE NB MCCK Spec D NH Spec A through C 3 2 CCK Spec R MCCK Begin Spec E NOTE When relay operation is described refers to normally open relays and N C refers to normally closed relays NH Spec D through F BF CCK Begin Spec U LK Begin Spec M NH Begin Spec J BFA Spec A BGA Spec A NH Spec K MCCK Spec H NB MODELS STARTING When switch 51 is moved to START Figure 3 1 battery negative is connected to start solenoid relay Battery positive B is already present Relay K1 closes its contacts to connect B to the series field cranking windings of the generator K1 also connects Bt to stop relay K2 The contacts of K2 close to connect B to ignition coil 1 and breaker points 52 Solenoid K4 energizes to release gaseous fuel to the engine or electric fuel pump E2 operates to pump gasoline to the engine IGNITION The generator acts as a motor to crank the engine ff ignition voltage and fuel are present the engine starts and attains rated speed After starting the start switch can be released because generator voltage is con nected through resistor R1 to keep relay K2 energized connecting voltage through and diode to ignition coil 1 and breaker point assembly 52 to keep the engine running BATTERY CHARGING The two stage battery
94. place start stop switch 1 Is battery voltage present between start solenoid terminal S1 and ground when start switch 51 is pushed to START Replace start solenoid K1 which is defective Perform generator tests See Generator section battery voltage present between stop beeen K2 terminal 5 and good ground when start switch is pushed to START Open control cover A WARNING Batteries present the hazard of explosion which can resuit in severe personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area Check wiring to stop relay K2 and connections Replace stop relay if necessary Does unit have tuel solenoid Does fuel solenoid operate when start switch is pressed to START Check wires to fuel solenoid check solenoid and replace if necessary Does generator set have an electric fuel pump Remove fuel line from carburetor and momentarily jumper control positive terminal of ignition coil to battery positive post Does fuel pulsate from fuel line AWARNING Fuel presents the hazard of fire or explosion which can cause severe personal injury or death Do not permit any flame spark pilot light cigarette or other ignition source near the fuel system Use extreme care during this test Run fuel into a suitable container and make sure area is well ventilated to prevent accumulation of explosive gasoline
95. printed circuit board Connect a DC voltmeter between control terminal 2 and 1 s battery voltage present when the start switch is pushed to START Check resistor R3 and resistor connections Are they OK Repair wire lead connections or replace resistor as required Replace start disconnect relay K4 Is the unit an MCCK series generator set Is the red button on the low oil pressure relay K5 out Wait at least one minute then push in red button Check oil level okay remove wire lead from low oil pressure switch S4 and push start switch Does engine crank and run A WARNING Operating ihe engine with inadequate oil and oil pressure can damage or destroy it Make sure the engine has sufficient oil and oil pressure Otherwise engine damage will occur Check for a grounded wire lead to the low oil pressure switch S4 Check low oil pressure switch S4 and resistor R4 Replace as necessary Connect the DC voltmeter to stop relay K2 terminal 5 and to a good ground Is bat tery voltage present when start switch S1 is pushed to START d ad Power 4 6 Redistribution or publication of this document e Generation by any means is strictly prohibited ENGINE CRANKS BUT DOES NOT START 12 Check wiring to stop relay K2 and connections Replace stop relay if necessary 13 Jumper resistor RT1 terminal with wire lead which goes to low oil pressure relay K5 and push start switch 51 Does engine crank and r
96. rinted circuit board unless the entire switch itself becomes broken In order to prevent either problem exercise greater care when removing the printed circuit board cover Refer to Product Support Bulletin 57 Corroded or burned printed circuit parts can and should be repaired by soldering a piece of 20 gauge or larger insulated wire between soldered connections on the printed circuit board Soldering on the printed circuit paths themselves on the bottom of the board is difficult and should be avoided In some cases a jumper wire can be connected between terminals on the terminal strips ower 4 15 Redistribution or publication of this document Generation by any means is strictly prohibited CCK BEGIN SPEC FUSES F1 AND F2 LK BEGIN SPEC M AND gt __ PM NH BEGIN SPEC J MODELS E lt wire To correct a problem answer the question in the appropriate troubleshooting chart either YES or NO Refer to the number in that column and proceed to that step CRANK IGNITION RELAY START SOLENOID Use the wiring diagrams see Wiring Diagrams section to locate terminals relays etc Figure 4 4 shows some of the control components for these generator sets Many troubleshooting procedures AWARNING present hazards which can result in severe personal injury death and or equipment dam SC 1623 age Only qualified service personnel with knowledge of fuels electricity and machinery hazards should per FIGURE
97. rm generator tests See Generator section Is voltage present from terminal 15 17 or 18 to around With start switch A1S2 depressed jumper terminal 5 to terminal 15 17 or 18 Does engine crank and start Remove contro P C board Replace A1F2 fuse path with a one inch 25 mm length of number 22 wire Solder in place through holes provided Jumper control terminal 5 to 16 Does engine crank Replace start switch A1S2 With start switch A1S2 depressed jumper control terminals 9 to 16 Does engine crank Check transistor A1 Q2 lf defective replace control P C board 1 15 battery voltage present between control terminal 6 and ground when start switch 152 is depressed A WARNING Elecirical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing 2 Is battery voltage present between control terminal 6 and ground when switch 151 is depressed Faulty switch 151 or diode A1CR1 Replace control P C board Is operation with gasoline Does gaseous fuel solenoid operate when switch A1S1 is pressed o m a Jumper terminal VALVE of gaseous vacuum switch on intake manifold to control terminal 6 Does fuel solenoid operate when switch A1S1 is pressed N Check wire leads to vacuum switch check switch and replace if necessary 8 Che
98. s during testing Remove contro cover and jumper control terminals 7 and 8 Does charge rate increase Check battery and replace if necessary Stop generator set Check wire leads to charge resistor G1R1 Check resistor and replace if necessary Replace control P C board BWHERVIONSENESWETER Connect voltmeter one percent accuracy or better to battery terminals start and run generator set for 30 minutes Does battery terminal voltage exceed 14 volts at 100 F 38 C or above or b 15 volts at 50 to 100 F 10 to 3890 or 16 volts at 50 F 10 C or below A WARNING Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing Replace control P C board E p rd Powe r 4 13 Redistribution or publication of this document Generation by any means is strictly prohibited SYMPTOM PROBLEM SOLUTION SYMPTOM PROBLEM SOLUTION SYMPTOM 1 PROBLEM SOLUTION 2 PROBLEM SOLUTION GENERAL CONTROL P C BOARD PROBLEMS AND SYMPTOMS Engine won t start and electric fuel pump won t work unless hand crank switch 151 is pushed during cranking Engine runs okay after starting with hand crank switch Diode A1CR1 is destroyed through accidental grounding of terminal 6 or th
99. s not crank B Engine cranks but does not start C Engine starts but stops when start switch is released D Engine is running then stops E Low battery no high charge rate F Battery loses excess water Power _ Generation Redistribution or publication of this document by any means is strictly prohibited A ENGINEDOESNOTCRANK S NO For generator sets with a three wire start adapter printed circuit P C board below the control P C board and a remote start stop slation perform stari tests first from the generator set control If the generator set starts using the generator set control the problem lies in the three wire adapter board or ihe remote switch Check relay K2 of the adapter by jumping terminal 3 to ground II the relay does not operate or its contacts do nol close to energize the start circuit replace the board 1 Check battery Are battery cables tight A WARNING Batieries present the hazard of explosion which can result in severe personal injury Because batteries produce explosive gas do not smoke or allow any arc producing devices in the battery area 2 Does generator set have a start disconnect adapter P C board below the tor set control assembly P C board don t confuse this board with a three wire adapter P C board on some models which has a terminal block 5 AWARNING For marine applications be sure bilge blower has operated and time delay if applicable on s
100. t is conducted by the relay contacts of K2 As the engine starts and oil pressure switch 3 closes relay is energized by current build up in the generator field Relay contacts K3 open cranking solenoid K1 cranking stops and complete the run ignition circuit K2 contacts are open when start switch is released The ignition current flows through resistor R3 1 72 ohm high water temperature switch S5 feedthrough capacitor C1 ignition coil T1 and the breaker assembly to ground Run ignition start disconnect relay K3 gets its operating current from a tap on the generator shunt field The circuit is completed by resistor R1 100 ohm oil pressure switch S3 and the normally closed contact of stop relay K4 BATTERY CHARGING AND CHOKE HEATER CIRCUIT Choke heater E5 is connected in series with the battery charging c rcuit Power is taken from the generator 120 volt AC winding M1 M2 The AC current is rectified by diode CR2 and flows through resistors R4 and R5 7 5 ohm each fuse choke heater 5 40 ohm resistor H2 25 ohm and fuse F2 5A The circuit components limit the charging current to about one ampere Fuse F3 protects the battery charging circuit If blown the battery will not receive any charging current and the carburetor choke will notopen resulting in poor engine performance after warm up STOP CIRCUIT When switch 1 is held in the STOP position current flows from B through the coil o
101. t of K4 contacts are closed connecting B to the choke and its heating element when used Redistribution or publication of this document by any means is strictly prohibited Gd Power _ 3 2 Generation To test the start disconnect relay check the coil resistance 20 to 24 ohms and the contact operation when the unit starts BATTERY CHARGING CIRCUIT The generator DC windings supply battery charging current through adjustable charge rate resistor H2 start disconnect relay K4 contacts and ammeter M1 to battery BT1 The slider on R2 adjusts the charge rate between two and five amperes AUTOMATIC EMERGENCY STOPPING The emergency stopping system consists of two devices the high temperature cut off and the low oil pressure cut off The optional high air temperature switch S3 in Figure 3 2 for the NH generator set closes during high temperatures grounding the coil side of the ignition points to stop the engine A high water temperature shutdown on MCCK marine generator set also shuts downthe engine for high water coolanttemperature by opening to remove B from the ignition coil A low oil pressure circuit optional on the NH includes a non adjustable low oil pressure switch shown as S4 in Figure 3 2 This switch closes if low oil pressure occurs grounding the ignition breaker points On the MCCK this switch closes during low oil pressure conditions but connects ground to a low oil pressure relay
102. tart has completed Otherwise there is potential danger of explosion or fire from vapors 3 Jumper between control terminal 16 and start solenoid terminal K1 S Press start switch A181 Does engine crank 5 4 Replace start disconnect adapter P C board 5 Push Hand Crank ELECTRIC called ROPE START or on some models switch 151 Is battery voltage present between control terminal 6 and ground 6 6 Remove control cover and jumper terminal 5 to terminal 6 5 battery voltage present between terminal 6 and ground 8 AWARNING Electrical shock can cause severe personai injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing 7 Replace switch 151 8 Check battery cables for correct polarity Replace fuse F1 with 9 ampere in line fuse Push start switch A1S2 9 9 With start switch A152 depressed is at least 8 volts present from terminal 9 to ground 14 10 Jumper solenoid coil terminal 5 to battery Does start solenoid K1 operate 12 Powe r an 4 1 0 Redistribution or publication of this document Generation by any means is strictly prohibited ee Blane is battery voltage present from right hand terminal of start solenoid to ground when start solenoid is energized Start solenoid is defective and must be replaced Perfo
103. the end of the armature shaft to loosen the armature The armature has an internal taper which fits onto the external taper of the engine adapter Ifthe armature does not come loose place a heavy brass rod on the arma ture shaft near the ball bearing and strike a sharp downward blow on the rod with a hammer Rotate the armature 1 2 turn before repeating Striking the collector rings or A CAUTION bearing can severely damage or destroy them Use exireme care when performing the procedure described above Power _ 5 1 Generation Redistribution or publication of this document by any means is strictly prohibited GENERATOR TO THROUGH STUD ARMATURE FRAME AND STATOR ADAPTER ARMATURE ASSEMBLY v ARMATURE THROUGH STUD NUT BRIDGE RECTIFIER gt GROMMET FOR ASSEMBLY OUTPUT LEADS 4 GENERATOR GENERATOR COMPOUNDING AIR DUCTS MOUNTING CTO STUDS BRUSH BLOCK pulos mu ASSEMBLY END BELL BRUSH SPRING 1219 FIGURE 5 1 EXPLODED VIEW OF AC GENERATOR GENERATOR TROUBLESHOOTING GUIDE AWARNING Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualitied service personnel with knowledge of fuels electricity and machinery hazards should pertorm service procedures Review safety precautions on inside cover page Fuel presents the hazard of fire or AWARNING explosion which can cause severe person
104. tion of this document by any means is strictly prohibited a Z ro 4 1 420184 ft s31YA I 282 18155384 110 ASSY 4 2 guiXw3uG H12 Ou u 401 1 15 11181 C s ty 1 vu SEU v EHISTSiH T v3 zal 5 17 9 7 45 fu 301 138 HOILING NmP AY138 NNYH3 1Y13N Qi0Nil0S 1 15 139 _ _ e VIL Ln IH S o oa 1 5 45 eee i i RN Hank rf zr rini id a I a x s E E I nuu iE A6I 14311YH 1 118 f 134 1091909 1511 SLuYd Y 1081 0 5 NELEF zy 10H1NO2 FLOWS WIM 1044 NOO SLOWSH 1511 Si dva ME QuYONYIS 1YNO4LdO _ 1wNOILdO EA 3811 1159 Gra Power _ oi Generation Sal 2 E SEO te wu 225 HOU 13 E eee ree E eee EI i See m us eee 5A p Se ee eee UE UE m pocos dime sey OF lJ ASSY 11 d POE 9 1
105. to maintain a bright new looking surface on the rings Cleaning with a dry lint free cloth is usually sufficient Very fine sandpaper 240 or finer may be used to sand the collector rinas while the genset is running to remove slight roughness Use only light pressure on the sandpaper Do not use emery or carborundum paper or cloth Clean out all carbon dust from the generator Contact with rotating machinery can AWARNING result in death or severe personal injury Use extreme care and keep hands and fingers clear while sanding the collector rings Redistribution or publication of this document by any means is strictly prohibited Generation GENERATOR BEARING The generator is pre lubricated and double sealed Replace the bearing approximately every 5 years or each engine overhaul or whenever the generator is COMPOUNDING REACTOR With the generator running at 1800 rpm if the output voltage is high with no electrical load attached then the compounding reactor is probably defective Test as disassembled shown Figure 5 8 using a variac WITH ONE AMPERE INPUT THE VOLTAGE SHOULD READ VOLTAGE AKW 315 380 65 75 6KW 315 378 60 70 COMPOUNDING VARIAC AMMETER REACTOR H2 SECONDARY PRIMARY d x1 FIGURE 5 8 TESTING COMPOUNDING REACTOR END BELL REACTOR m 71 H3 ES 1821 Ht CIRCUIT PROTECTOR LI LOAD LEADS LOAD GRD L2 a GRD L BR
106. tor connection and replace if necessary 0 4 8 Redistribution or publication of this document gt Generation by any means is strictly prohibited CCK SPEC R MCCK BEGIN SPEC E AND NH SPEC D THROUGH F MODELS To correct a problem answer the question in the appropriate troubleshooting either YES or NO Refer to the number tn that colurnn and proceed to that step Use the wiring diagram see Wiring Diagrams section to locate terminals relays etc Fiqure 4 3 shows some of the control components for NH generator sets Spec D through F CCK generator sets Spec R and MCCK generator sets begin Spec E except automatic starting MCCK units described under CONTROL O MATIC in Part III Section 5 of the Onan Master Service Manual START SOLENOID Many troubleshootin rocedures Present hazards which result in severe personal injury death and or equipment dam age Only qualified service personnel with knowledge of fuels electricity and machinery hazards should per form service procedures Review safety precautions on inside cover page ROPE START SWITCH START STOP SWITCH GENERATOR SET CONTROL P C BOARD DISCONNECT ADAPTER START ADAPTER CONTROL FAS TERMINAL BLOCK WITH FOUR TERMINALS SC 1622 FIGURE 4 3 GENERATOR SET CONTROLS CCK SPEC MCCK BEGIN SPEC E NH SPEC D THROUGH F PROBLEM SEE PAGE A Engine doe
107. un AWARNING Electrical shock can cause severe personal injury or death Use exireme caution when working on electrical circuitry Attach and remove jumper leads only when generator set is not operating Do not touch jumper leads during testing 14 Check low oil pressure K5 and replace if necessary 15 Jumper high water temperature switch S3 and push start switch Does engine crank and run 16 Check high water temperature switch 3 and wiring Replace as necessary 17 Does generator set have a fuel solenoid K6 18 Does fuel solenoid operate when you push start switch S1 to START 19 Check wire to fuel solenoid check fuel pump and replace if necessary 20 Connect a DC voltmeter to the terminal of the ignition coil and to good ground Is battery voltage present when the start switch S1 is pushed to START 21 Check wiring to stop relay K2 and connections Replace stop relay if necessary 22 Does unit have a low pressure switch 23 Check oil level If okay remove wire lead from low pressure switch and push start switch Does engine crank and run A CAUTION Operating the engine with inadequate oil and oil pressure can damage or destroy it Make sure the engine has sufficient oil and oil pressure Otherwise engine damage will occur 24 s wire lead from low pressure switch grounded 25 Repair or replace wire lead 26 Check low oil pressure switch and replac
108. ure or continuity tester and replace field windings if defective i ad Power 2 3 Redistribution or publication of this document Generation by any means is strictly prohibited GENERATOR SERVICE PROCEDURES AND TESTS Brush Replacement Install new brushes when the old ones are worn to the dimensions shown in Figure 2 2 Replace the brush springs if they are damaged or if their correct tension is doubtful MEASURE FROM TOP FACE OF iid BRUSH BLOCK TO TOP OF BRUSH 5 8 15 8 mm 11 16 17 5 mm WEAR 13 16 20 6 mm 7 8 22 2 mm REPLACE 1 25 4mm 1 1 16 26 9 mm FIGURE 2 2 MEASURING BRUSH WEAR 1 Remove the generator end bell wrapper to expose the brushes 2 Measure the brush wear 3 Removethethree screws holding each brush block in place Figure 2 3 4 Remove the old brushes and clean the holders so the new brushes can move easily in their holders 5 Install the new brushes G 1218 FIGURE 2 3 GENERATOR BRUSH REMOVAL Using the wrong brush can ACAUTION damage or destroy the genera tor Never substitute a brush which appears to be the same because it may have different electrical characteristics Always use the correct Onan brush correct part number listed in parts catalog 6 instali the brush blocks and the generator end bell wrapper New brushes are shaped to fit and seldom need sand ing to fit properly If brush sparking occurs run the generator set with a light l
109. used Then replace fuse or reset breaker 2 wire or 2 wire or wires brushes 3 Brushes not making contact 3 Check brush for free with collector rings movement or brushes which may be excessively worn 4 Open grounded or short circuit 4 Test with ohmmeter or in field or armature winding continuity tester and repair or replace as necessary LOW AC OUTPUT 1 External short circuit on line 1 Locate and eliminate short circuit problem 2 Generator 2 Generator overloaded 00 2 Remove part of load Remove 2 Remove part of load of load EX I Shorted or grounded circuit in 3 Test with continuity tester or field or armature winding ohmmeter and replace if defective 4 Engine not running properly 4 Refer to Engine Section causing generator to slow Troubleshooting down NOISY GENERATOR 1 Defective bearing in end bell 1 Replace bearing 2 Brush rig loose 2 Retorque 3 Armature and field frame 3 Check generator alignment and rubbing together clean air gap between arm and a of varnish lumps GENERATOR 1 1 Generator overloaded overloaded 1 Remove 1 Remove part of load sd of load OVERHEATS 2 Windings and parts covered 2 Clean generator with oil or dirt 3 Air intake restricted or 3 Take necessary steps to allow incoming air too hot for proper cooling 4 Shorted open or grounded 4 Test with ohmmeter circuit in armat
110. vice manual and or replace starter Replace battery ENGINE CRANKS BUT DOES NOT START YES NO 2 Is Ft fuse on control board OK 3 Replace with an identical 5 ampere fuse Correct problem which caused fuse to burn Note Remote teads may be shorted or grounded While engine cranks check K1 I start solenoid voltage Is 12 volts present between terminals 10 and 1 5 4 Replace 1 start solenoid Jumper terminais 9 to 11 Does engine start when start switch is pushed 6 7 K3 contacts are defective Replace printed circuit board Fuel solenoid K4 must be open during starting and running Remove fuel line from carburetor Does fuel pulsate from line when start switch is pushed 11 8 AWARNING Fuel presents the hazard of fire or explosion which can cause severe personal injury or death Do not permit any flame spark pilot light cigarette or other ignition source near the fuel system Keep an ABC type fire extinguisher nearby Disconnect fuel solenoid from line and check fuel pump E2 Pump will click when operating properly Does fuel pulsate from pump solenoid disconnected when start switch is pushed 10 9 Fuel pump or wiring is defective and must be replaced pi Power 5 1 2 Redistribution or publication of this document Generation by any means is strictly prohibited ENGINE CRANKS BUT DOES NOT START YES Fuel solenoid is defective and must
111. when generator set is not operating Do not touch meter or meter leads during testing Using a Continuity Tester Disconnect the external leads and touch the test prods to F1 and 22 The lamp should light or the buzzer should sound If not the field winding is open and must be replaced Check the terminal ends closely for loose connections These can be tightened without replacing the assembly TESTING BRIDGE RECTIFIER To accurately test the bridge rectifier proceed as follows TESTING FOR GROUNDS 1 Loosen the screw to remove the bridge rectifier assembly see Figure 5 6 for location 2 Disconnect the nylon connector from the bridge rectifier assembly noting the polarity marking of the bridge rectifier assembly and connector 3 Pull the assembiy out from the end bell and remove n the bridge rectifier from its case The bridge rectifier and attached ts p f p A CAUTION components may be damaged or 5 destroyed by incorrect mounting Note that the connector can only be mounted in the end bell in one direction but the bridge rectifier can be mounted in four 4 directions of which only one will work Use extreme care to mount the bridge rectifier correctly G 1223 TESTING FOR OPENS FIGURE 5 5 TESTING FIELD WINDINGS TESTING FIELD WINDINGS FOR AN OPEN CIRCUIT Use either a continuity tester or an ohmmeter for this test Using an Ohmmeter Disconnect the external leads and conne
112. when moved to START closes a circuit through diode A1CR1 switch 151 and to terminal 6 This energizes ignition coil T1 electric fuel pump 1 when used and fuel solenoid K2 when used When switch A1S2 closes transistor A1Q2 turns on energizing terminal 9 and start solenoid K1 K contacts close connecting the battery to the generator which acts as a motor and cranks the engine If proper coil voltage and fuel are available the engine starts and accelerates to governed speed On some models start solenoid K1 also energizes a choke For generator sets with a three wire start adapter 2 moving the switch to START energizes relay A2K2 clos ing its contacts This places on terminal 16 connect ing through transistor A1Q2 to start solenoid K1 Ki gt aw m tz FI 77 1525 f an2 1 Ki 1 airg 5 2 Generator Set Assembly 3 rd AB oes Start Adapter Control 4 to 3 wire ars _ s A3 Disconnect Adapter Control T C BI fossas Battery AIRG AICRE Else Fuel Pump or Gas Valve When Used E2 E3 Spark Plug ES euis Electric Choke When Used 1 Generator Start Solenoid Retay Fuel Sotenoid When Used Low Pressure Switch When Used csi ees High Air Temperature Switch When Used 583 Breaker and Cap Assembly 94
113. z 4021 26 302 HO 123NN T 38 43 01 iQ 36ISNE NO 33495311 1014 1 uf 3 a a a aa 2510 4341 ASSY 139205 i 650 H rae 182171103 lr MESS COMI 001 1145 anil BAD RENS A 2859 909 9 a _ i 1 ieee 19 ES P MN Ti ni dM d 9YW 0 2390 9 22 2H L Q 61 1052 11111 ps e H 4045 1 4 15 334254 115 108 0U N03 33A05 X03 1491802 ASSY 7931 4554 31 ASSY 0731 455 4731 41815 9018 TYNIRYJL 4015 15 821145 9 A 5 Uo 801515389 lt Ova F 91151525 001 US 6025 1539 44415 4015 4734 JULVIA3H2S are l HE AMA eee d 251 Slave HdE ADPT 001 OS HdE AGOZ OZE Hal Appz OZI v5 25 e Wr 23 BRES SINIY 4135 27 m 9138 4015 201 1334492519 18915 XON 29 AGIA 28012119 WVs9vig Redistribution or publication of this document by any means is strictly prohibited 6 8 Power ori Generation 1H03

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