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Onan DKD Service Manual

1. i ee RUM ae PM p LE SHOWN FOR uf 53 4 ae LI 120 240 60 Hz x T pl ac fari IZ 2 CB22 ij lec 27221 L FAN 5 Li 1 L2 LO TO ADJUST OUTPUT VOLTAGE MOVE TAPS ON T21 ACCORDING TO i L2 LI TABLES CB 22 ALL VOLTAGE CONNECTIONS LEAVE Ti AND T4 CONNECTED TO HI AND H4 RESPECTIVELY 2 FOR 60Hz USE 52 LEAD FROM GEN ON TAPS X1 2 m 4 TAPS USE TX LEAD ON TAPS X3 4 1 3 UNLESS OTHERWISE NOTED ALL COMPONENTS ARE SHOWN IN THE DE ENERGIZED POSITION bee 4 DASHED LINES INDICATE WHEN USED 5 IF CB22 15 NOT USED CONNECT LEADS DIRECTLY TO THE LOAD 1 M EPUM CONTROL BOX AC __ RECONNECTION DIAGRAM T TIT2TA FOR 20 6OHs EM 120 240 OUTPUT OUTPUT VOLTAGE TAP Poemon VOLTAGE TAF POSITION TL mb PORTION MN X AH EN ine mal iol al 612 6442 REV MODIFIED SINGLE PHASE AC GENSET CONTROL SPEC F RV GENSETS 8 10 Power Redistribution or publication of this document Generation by any means is strictly prohibited B Power DC WIRING DIAGRAM 8 11 rr
2. 612 6187 8 4 DKC DKD 3 Wire Start Control Remote Start 612 6262 8 5 RV and AUX Generator Set Control 3 Wire Start 612 6353 8 6 DKC DKD Control E Electric Start Standby Generator sets 612 6186 8 7 Electronic AC Voltage Regulator Assembly 305 0691 8 8 6 5 7 5 DC Control Spec RV Gensets 612 6624 8 9 Single phase AC Genset Control Spec RV Gensets 612 6442 8 10 6 5 7 5 DKD Control Schematic Extended Oil Fill Version 612 6631 8 11 8 1 Power M Generation Redistribution or publication of this document by any means is strictly prohibited 612 6184 0 SCHEMATIC WIRING DIAGRAM SINGLE PHASE TRANSFORMER REG 2 N T j Bhd 621 m EXCITER EXCITER 5 s 2 2 x3 1x4 1 bun SHOWN 120 240 60 Hz x ANO 4 15 230 VAC 50 Hz 45 CONNECTION SEE NOTES 2 amp 3 CONTROL BOX SECTION gt 7 DI o We b m omo ADJUST OUTPUT VOLTAGE MOVE TAPS ON 721 ACCORDING TO TABLES L IN ALL VOLTAGE CONNECTIONS 50 AND 60 Hz LEAVE AND 74 CONNECTED TO HI AND H4 RESPECTIVELY LO 2 FOR 60Hz USE 52 LEAD FROM GEN TAPS XI 2 L2 LI 4TAPS USE TX LEAD TAPS X3 4 3 FOR 504 USE 52 LEAD FROM GEN TAPS Xi 5
3. FIGURE 2 4 MDKC MDKD CONTROL SCHEMATIC Starting Sequence The engine Preheat switch is held for 10 to 30 seconds depending upon temperature This energizes the Heater Solenoid K13 and closes aset of NO contacts to connect B to the glow plugs After the preheat time the start sequence is initiated by pressing the Start button 11 Switch S11 connects to the coil of K14 and through the A11 K15 contacts and K16 early production only NC contacts to the Start Solenoid K11 The coil of K11 is grounded through the pull coil of K1 after K1 is completely pulled in and the pull coil is disconnected from K1 must pull in completely before the engine will crank The closing of the K11 contacts connects B to the glow plugs and to the starter solenoid B1 K14 connects B to the fuel solenoid K1 fuel pump E5 CB21 fault breaker and engine monitor circuits only during starting Start Disconnect Sequence As the engine starts latch switch S6 closes and completes the ground circuit through resistor A11 R1 for the K12 power relay The closing of K12 dual contacts completes the B running circuit to CB12 fault circuit breaker This was accomp lished by K14 during cranking The start disconnect circuit provides starter protection As the generator gains speed and output voltage the K15 starter protection relay energizes at about 90 volts AC The A11 K15 NC contacts open and de energize the K1
4. dC 1 2 2 MARINE ENGINE 2 1 General snes 2 1 Control 2 1 Control OBSPAUOR 6 65 0 5454 CR 2 3 Control TroublesnoDllng a 4a RR RR OC a REIR ER 2 5 3 STANDBY ENGINE 3 1 3 1 Electric Stan 3 1 Remote Start Control eR 9 9C 3 7 4 ENGINE CONTROL SERVICE 4 1 Genelia thee eee eases 4 1 A Battery Chok 4 1 B Battery Cable 4 1 Battery Charging 4 1 D 2 s seer ewes 4 1 E Relay DOCK iios sek ER EA 4 1 F Fuel Solenoid Check ws ER ERROR 4 2 6 SWIC CHECK E E 4 2 HY Solenoid 4 2 5 GENERATOR AND VOLTAGE REGULATOR 5 1 Generator Description 2 2235 5 1 Generator DBIBIOIT S Roe RERO aS 5 2 5 3 Generator Ser
5. 6OHZ sonz 12 12 3 5 4 0 920 290 380 6 0 7 5 DKD 460 190 260 8 0 MDKD 460 190 260 6 5 MDKD Resistance in ohms 77 F 25 10 Power _ 7 5 Generation Redistribution or publication of this document by any means is strictly prohibited L TESTING GENERATOR ROTOR For these tests use a megger or insulation resistance meter which applies 500 VDC or more to the test leads Testing for Grounds Check for grounds between each rotor lead and the rotor shaft Figure 7 9 Use a Megger or insulation resistance meter which applies 500 VDC or more at the test leads Perform test as follows 1 Remove rotor leads 1 and F2 from the rotating rectifier assemblies 2 Connect test leads between F1 and rotor shaft then between F2 and rotor shaft Meter should register 1 000 000 ohms or greater 3 If less than 1 000 000 ohms rotor is questionable Oven dry the rotor and retest 4 Replace a grounded rotor with a new identical part Testing for Open or Shorted Windings Perform this test with an accurate meter such as a digital ohmmeter 1 Remove rotor leads 1 and F2 from rotating recti fier assemblies 2 Using ohmmeter check resistance between F1 and F2 leads Figure 7 10 The resistance values at 77 F 25 C should be as shown in Table 7 2 If not replace defective rotor with new identical part
6. load at generator terminals s output still unbalanced yes Are generator leads connected and grounded properly See Test Q Correct as necessary Power 6 7 Redistribution or publication of this document Generation by any means is strictly prohibited Redistribution or publication of this document by any means Is strictly prohibited Section 7 Generator Regulator Tests GENERAL The following tests and adjustments can be performed without disassembly of the generator These proce dures should be used for testing the generator compo nents and the regulator in conjunction with the Trouble shooting Flow Charts in the Generator Regulator Trouble shooting section Many troubleshooting procedures AWARNING present hazards that 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 TESTING AC RESIDUAL VOLTAGE Test for residual AC voltage if there is no AC power output from the generator Check between generator leads 1 and 2 electronic regulation controls between 1 and 2 transformer regulation controls See Figure 6 1 Residual voltage should be as follows Electronic Regulation 5 to 10 VAC minimum Trans former Regulation 2 5 to 5 VAC minimum B TESTING COMMUTATING REACTOR The commut
7. L ALI KEOI GTART SCHEMATIC em B 5 8 4 0 ARTS LIST FOR REF ONLY d pm x 02 4320 1140 2 CIRCUIT BREAKER CONTROL ________ 2 20 141 1 CIRCUIT FAULT 1 ________________ 07 1617 1 B 1 RELAY START_SOLENOID STARTER 124 7 KIS 1107 1986 P 1 129 14 507 1896 1 IRELAY FUEL SOLENDID IREF IRELAY STARTER PROTECTION 0 0 0 ee RESISTOR 1 REF RESISTOR LOP TIMING Sil 508 0759 11 IENITCH BTART P NO 812 6631 HEV MODIFIED 6 5 7 5 kW DKD CONTROL SCHEMATIC EXTENDED OIL FILL VERSION Redistribution or publication of this document by any means is strictly prohibited Redistribution publication of this document by any means 15 strictly prohibited Redistribution publication of this document by any means 15 strictly prohibited Onon Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 763 574 5000 Fax 763 574 8087 ins and Onan are registered trademarks af Cummins Inc Power Redistribution or publication of this document Generation by any means is strictly prohibited
8. 11 START STOP PREHEAT SWITCH 0 CB11 DC CONTROL Conte BREAKER 21 086 pie CB13 DC CHARGING E I BREAKER p i FAULT BREAKER FRONT J3 CONNECTOR GENSET REMOTE CONTROL J2 CONNECTOR ENGINE MONITORS AC CONTROL BOX REAR K13 RELAY K11 START SOLENOID A11 ENGINE MONITOR BOARD CR2 RECTIFIER FIGURE 3 5 DC CONTROL BOX Power _ Generation Redistribution or publication of this document by any means is strictly prohibited GROUNDING RV21 SUPPRESSOR TB3 TERMINAL ASSEMBLY CR21 RECTIFIER BRIDGE S AC HARNESS TO DC CONTROL OUTPUT NN HARNES FIGURE 3 5b DKD AC CONTROL ASSEMBLY Powe r 3 86 Redistribution or publication of this document Generation by any means is strictly prohibited Engine Sensors The following briefly describes the engine mounted sensors and switches and how they protect the engine from adverse operating conditions safety sensors switches close to ground if abnormal operating condi tions exist and trip the fault breaker CB12 to stop the engine See Figure 3 6 Resistance units and switches in the monitoring and shutdown systems are sealed units and are not repairable When replacing a sensor do not use a substitute item since resistance units are matched to the gauge they supply Cutoff switches are close tolerance parts made for a specif c applicat
9. 5 T WIR REAR VIEW OF FRONT PANEL RV AND AUX GENERATOR SET CONTROL 3 WIRE START Power Redistribution or publication of this document Generation by any means is strictly prohibited 612 6186 WIRING DIAGRAM SCHEMATIC 811 2 HRI HRZ 1 Ap 1 prama LL 3E 2 REVISION ee a LDR ENG CKR DATE REAR VIEW OF FRONT PANEL i CONTROL GEN SET DC WIRING DIAGRAM DKC DKD CONTROL E ELECTRIC START STANDBY GENERATOR SETS Power 24 8 7 Redistribution or publication of this document Generation by any means is strictly prohibited 305 069 4 E Oe 2 WIRING TABULATION FROM TO LEAD STATION NO STATION NO FIND NO 9 2 T21 X2 T21 HI T21 H2 _ ______5 _ 50 Hz ONLY NOTES CUT CMR21 3 4 OFF AT REACTOR 2 EXTERNAL CONNECTIONS CIRCUIT BREAKER 821 3 1 GENERATOR TBI 2 TBI 3 FIELD FI TBI 4 F2 TBI 5 3 TO PREVENT SHORTING AGAINST REGULATOR ASSEMBLY COVER VERIFY THAT TERMINAL TABS ITEM 17 ARE NOT BENT UP 2 I690 S0 TOLERANCES OTHERWISE SPECIFIEM Ray PANT _ 552 QTY DESCRIPTION OR ni Hi P Eel S ME ee LP BU 0 092 owned by Onan
10. Control Troubleshooting The information in this section is divided into three flow charts Determine the probiem and then refer to the appropriate flow chart A B or C forthe troubleshooting procedures A Engine does not crank B Engine cranks but does not start C Engine starts but stops after running several seconds Before starting a troubleshooting procedure make a few simple checks that may expose the problem and cut down on troubleshooting time Check all modifications repairs and replacements performed since the last satisfactory operation of set Aloose wire connection couid cause problems incorrect connection an opened switch or cir cuit breaker or a loose plug in are ail potential problems that can be eliminated by a visual check Unless absolutely sure that panel instruments are accurate use portable test meters for trouble shooting To troubieshoot a problem start at the upper left corner of chart and answer all questions either YES or NO Follow the chart until the problem is found performing reference adjustment or test procedures Refer to Figures 3 5 through 3 8 for locating control components leads terminals and other check points FLOW CHART A ENGINE DOES NOT CRANK A WARNING Many troubleshooting procedures present hazards thal can resull in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity machinery hazards should per
11. Power 3 7 In Line Fuse F1 Land Generator sats 30 ampere fuse is located in a fuseholder connected to the B terminal of the starter This fuse connects to the control and opens if a short or overload should occur Engine Monitor Circuit Board printed circuit board that monitors engine control system functions This includes starting stopping and fault system operations Aterminal board is included for making remote connec tions See Figure 3 5 Two relays are soldered to the circuit board and are not serviceable Power relay K12 connects and maintains battery B to the control meters and fuel solenoid during operation Starter protection relay 15 energizes at about 90 volts AC The A11 K15 NC contacts open and de energize the K11 start solenoid the A11 K15 NO contacts close and provide another ground path for K12 through K11 coil similar to S6 Fuel Solenoid Opens the fuel control valve when start stop switch is placed in the Start position K11 Start Solenoid Located over the engine monitor circuit board connects battery to the starter sole noid B1 during cranking K13 Heater Relay Located on the relay mounting tray It connects battery to the engine glow plugs prior to cranking It is energized by S12 preheat switch K14 Fuel Solenoid Relay Located on the relay mount ing tray It is energized only during cranking and con nects B to the fuel solenoid K1 fuel pump E5 and faul
12. fuel pump and injection pump Okay yes yes Does K1 fuel solenoid energize when S11 is in Start position Check circuit through 11 Test S11 per is battery B applied to glow plug heaters when Checkout G Test K1 per Checkout F Preheat Switch is closed no yes Incorrect fuel See Operator s Manual Check Preheat switch and heater refay K13 par recommendations Checkouts G and E Check heater wiring FLOW CHART C ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS A WARNING Many troubleshooting procedures present hazards that 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 START Check for possible fault condition none Is a fault condition indicated by fault breaker yes check fault monitors 51 through S5 and fault CB12 on contro panel breaker CB12 for improper wiring Does latching relay 12 energize and contacts close when generator set comes up to operating Speed Check for closing of S6 power latch switch okay replace engine monitor PC board yes Does DC control breaker trip when the generator set is started yes Check all B wiring for shorts to ground Power 2 6 Redistribution or publication of this document Generation by any means
13. 7 2 E Testing Reference 7 2 F VR21 7 2 Testing Rotating Rectifiers 7 3 Hi Testing Exclior S 7 9 Testing EXCHer ROl 7 4 Testing Generator 7 5 L Testing Generator Rotor 7 6 Wiring Harness 7 7 Testing Regulating Transformer 721 7 7 P Voltage Adjustment coa ces 40490666808 HONS Se eee EV Y OM 7 8 i Heconne tof 7 8 8 WIRING DIAGRAMS 8 1 um Power ii Redistribution or publication of this document Generation by any means is strictly prohibited Section 1 Introduction ABOUT THIS MANUAL For servicing purposes the generator set can be divided into three basic parts the engine the generator and the control This manual contains troubleshooting and repair information for the generator and the control Refer to the Engine Service Manual 981 0501 when servicing the engine Study this manual carefully and observe all the warn ings and cautions throughout the manual Knowing the generator set using it properly and following a regular maintenance schedule ca
14. and safety equipment nearby and be prepared to respond to an emergency Develop Safe Work Habits Unsafe actions are identified as the source of most accidents involving the use of tools and machines Be familiar with the equipment and know how to use it safely Use the correct tool for the job and check its condition before starting Observe the warnings and cautions in this manual and take special precautions when working around electrical equipment Do not work alone if possible and do not take risks Redistribution or publication of this document by any means is strictly prohibited TABLE 1 1 HAZARDS AND THEIR SOURCE Fire and Explosions Leaking or spilled fuel Hydrogen gas from battery Oily rags improperly stored Flammable liquids improperly stored Burns Hot exhaust pipes Hot engine and generator surfaces Electrical short in DC wiring system Poisonous Gases Carbon monoxide from faulty exhaust pipes joints or hangers Operating generator set where exhaust gases can accumulate Be prepared if an accident does occur Numerous agencies such as the Red Cross and local police and fire departments offer basic courses in first aid CPH and fire control Take advantage of these offerings so you are ready to respond when an accident occurs Learn to be safety conscious and make safe practices a part of your work routine Do not work when tired or after consuming any alcohol or drug that makes
15. be certain there are no ignition sources such as spark pilot light cigaretle etc near the generator set Keep an ABC type fire extinguisher nearby When reinstalling the generator set be sure all mount ing hardware and electrical exhaust and fuel system components are connected exactly as they were before removal Refer to the appropriate installation manual during reinstaliation for important safety precautions Check for oil and fuel leaks Check exhaust system audibly and visually with the generator set running Repair any leaks immediately Replace worn damaged or corroded exhaust and fuel line components before leaks occur Redistribution or publication of this document by any means is strictly prohibited Redistribution publication of this document by any means 15 strictly prohibited Section 2 Marine Engine Control GENERAL The marine engine control system includes all the func tions that relate to the operation of the engine This includes starting and stopping instrumentation moni toring for fault conditions and battery charging This section covers a description of the controls and shows where they are located describes how the control operates and provides basic troubleshooting pro cedures CONTROL DESCRIPTION Gauges Meters and Switches Oil Pressure Gauge Optional Shows engine lubricat ing oil pressure The gauge has a range of 0 to 100 psi 0 to 700 kPa and is co
16. corrected Are generator ouipult leads properly connected See TEST Q yes Replace the regulator PC board per procedure F Power 6 5 Redistribution or publication of this document Generation by any means is strictly prohibited FLOW CHART OUTPUT VOLTAGE TOO HIGH TOO LOW OR UNSTABLE TRANSFORMER VOLTAGE REGULATOR AWARNING Many troubleshooting procedures present hazards that can result in severe personal injury death Only qualified service personnel with knowledge of tuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page START 15 engine running stable and at Set r min per instructions in appropriate engine manual correct r min yes Are there broken wires or joase connections to any AC regulator components yes Repair as required Does changing the tap connect ons on transformer T21 correct high or low yes Adjust for voltage rat ng on nameplate voltage condition Apply load to generator and then remove Is voltage across generator leads S1 and S2 60 VAC 5 percent Test stator assembly per TEST K Repiace bad yes Test bridge rectifier CR21 and suppressor 1 per TEST C Replace if bad Test transformer T21 per TEST Replace if bad Test exciter stator per TEST H Replace if bad Test rotor assembly per TEST Repl
17. is strictly prohibited section 3 Standby Engine Controls GENERAL This section contains control information for standby generator sets Two starting controls are available that differ primarily in the method of starting An Electric Start Control is used for electric starting and stopping at the generator set only A Remote Start Control is used for electric starting and stopping with provision for remote operation with optional accessory equipment Each of the start controls will be covered in a separate section ELECTRIC START CONTROL This control has a key switch for Preheat Start and Stop on the front panel and cannot be connected for remote operation Component references are found on separ ate wiring schematic diagrams in the Wiring Diagrams section of this manual Gauges Meters and Switches DC Voltmeter Optional Normal battery B voltage dur ing operation should be 13 5 to 15 volts on a 12 volt system 27 to 30 volts on a 24 volt system See Figure 3 1 TRANSFORMER REGULATOR TRANSFORMER AC REGULATION OPTIONAL LINE CIRCUIT wee BREAKER FIELD BREAKER C821 ELECTRONIC REGULATORS ONLY RUNNING TIME METER PREHEAT STOP Coolant Temperature Gauge Optional Shows engine coolant temperature The gauge is wired to a sensor on the engine and has a range of 100 F to 250 F 40 C to 12190 Oil Pressure Gauge Optional Shows engine lubricat ing oil pressu
18. lon PROD 20 y gt vi ENVIR PROT 305 0691 Power _ Generation ELECTRONIC AC VOLTAGE REGULATOR ASSEMBLY Redistribution or publication of this document by any means is strictly prohibited WIRING DIAGRAM SCHEMaTI wt GNO E f gt Em 969 B p HOLD 16 lt 1 E GND 4 END Lef N S st a 296 E t SWITCH OW PRESSURE 52 SWITCH HIGH COGLANT TEMP GNO a 2 GNO gt 1 m E GNO VRII BLUE 8 ALTER SATOR van _ _ r SWITCH CONTROL FOWER LATCH CONTROL BOX PARTS LiST 300 2004 e LL PER ASSY ENGINE ASST ENGINE MONITOR n CIRCUIT BREAKER EGG 320 1141 CIRCUIT BREAKER FAULT 39 RECTIFIER RECTIFIER ASSY TR STOP Bae 307 1617 IH IIECYRTGSLERSEDEURTTEREV SOLENOID STARTER I2V REF An k2 RELAY POWER 307 1086 LP fI RELAY HEATER ey REF 4 307 1886 P I RELAY FUEL SOLENOID REF RELAY STARTER PROTECTION S ger REF An R2 RES
19. 12 volt storage battery 10 amp fuse momentary on switch and diode assembled as shown in Figure 7 3 Incorrect flashing procedure can damage the voltage regulator Do keep excitation circuitry connected longer than 5 seconds Start the generator set and operate at normal speed Connectthe positive lead to the F1 exciter stator lead and the negative lead to the F2 exciter lead Close the switch justlong enough for the generator output voltage to build up but not longer than 5 seconds Check the output voltage then shut down the generator set Restart the generator set and operate at no load Output voltage must build up without field flashing If not shut down the generator set and perform continuity check of all related wiring MOMENTARY ON SWITCH 5 1858 2 FIGURE 7 3 FIELD FLASHING CIRCUIT Power _ Generation TESTING REFERENCE TRANSFORMER The reference transformer has four leads two primary marked H1 and H2 and two secondary leads marked X1 and X2 See Figure 7 4 Resistance readings are made with leads disconnected The resistance of either coil should be 110 ohms 10 at 77 F 25 C Resistance between leads and transformer frame should be infinity Ht le PRIMARY PA n S e x1 SECONDARY X2 WINDING SCHEMATIC 51502 FIGURE 7 4 REFERENCE TRANSFORMER VOLTAGE REGULATOR 21 REPLACEMENT Use the following procedure for
20. 6 TAPS USE TX LEAD TAPS X4 6 FOR 110 220V AND LIOV CONNECT H2 TO FOR CONNECT TO T3 LI AND L2 FOR 110 220V USE H5 FOR 1 1 FOR L2 T2 ANO 73 ARE GRD 115 230V AND 115 INSULATE HS AND NOT USED 120 240 AND I20V CONNECT H2 TO H5 FOR 20 CONNECT TO LI Hz TO T2 L2 FOR 120 240 USE FOR L1 FOR L2 T2 AND 75 APF GRD 4 UNLESS OTHER NOTED ALL COMPONENTS ARE SHOWN IN THE DE ENERGISED POSITIOM 5 DASHED NES INDICATE WHEN USED EL 6 All CONNECTION ON 3CR S3CR MODELS ONLY INSULATE LEADS ON 53CE MODELS 7 HS AND H6 LEADS ARE USED ONLY ON SOHz 1 0 110 220 50 120 2072 40 V CONNECTIONS 6 1 822 15 USED CONNECT LEADS DIRECTLY TO THE Luay Q5OHz 02 77 120 120 240 1 0 220 15 120 120 240 TAP POSITION POSITION POSITION TAP POSITION ADJUSTMENT 52 TX 52 Tx 52 52 TX INCREASE LLL STD Xt X6 X4 LX 5 Pe ye ye TOP EDGE F A 4 1 1 1 um CB22 MN 44 l 1 1 FRONT PANEL REAR VIEW RECONNECTION DIAGRAM 13117274 FOR ey 2097 AND 115 OUTPUT 20 120 240V 15 15 250 I20 20 240V SEE NOTES VOLTAGE TAP POSITION TAP POSITION TA
21. PREHEAT SWITCH 12 5 1513 EARLY PRODUCTION ONLY FAULT DC CONTROL RESET BREAKER CB11 BREAKER CBi2 5 1404 FIGURE 2 1 MDKC MDKC CONTROL BOX Power 2 1 Redistribution or publication of this document Generation by any means is strictly prohibited Control Componenis The following describes the basic engine control com ponents and how they function Engine Monitor Circuit Board A printed circuit board that monitors engine control system functions This includes starting stopping and fault system operation A terminal board is included for making remote connec tions See Figure 2 1 Two relays are soldered to the circuit board that are not serviceable Power Relay K12 connects and maintains battery B to the control meters and fuel solenoid during operation Starter Protection Relay K15 is an AC oper ated relay When the start switch is actuated B is connected to the K11 start solenoid through K15 NC contacts until the generator output reaches 90 volts AC K15 activates and disconnects the starter F1 In Line Fuse A 30 ampere fuse is located in a fuse holder connected to the B terminal of the starter This fuse connects B to the control and it will open if a short or overload should occur K1 Fuel Solenoid Opens the fuel contro valve when the start stop switch is placed in the Start position OPTIONAL OIL PRESSURE CONTROL SENDER E1 POWER LATCH 56 K11 Start Sofenoid Located over the engin
22. Pressure Monitors Refer to Figure 3 2 for the location of the oil pressure sensors Oil Pressure Sender E1 Optional The sender resist ance changes with oil pressure and results in a reading on the oil pressure meter The meter range is 0 to 100 psi 0 to 700 kPa Low Oil Pressure Switch 51 This switch closes if oil pressure drops to 9 psi 62 kPa activating the fault breaker and stopping the engine LOW OIL PRESSURE SWITCH 51 OIL PRESSURE SENDER E1 e EP a gt A 2 N S pa Engine Temperature Monitors Refer to Figure 3 2 for the location of the engine temperature sensors Coolant Temperature Sender E2 Optional The resist ance of the sender unit changes with the engine coolant temperature and causes a reading on the Water Temp meter The meter range is 100 to 250 F 40 to 12190 High Coolant Temperature Switch 2 This switch closes if the coolant temperature rises to 250 F 121 C activating the fault breaker CB12 and stopping the engine OPTIONAL COOLANT TEMPERATURE SENDER E2 FAULT RESET Mo BREAKER CB12 Wa OVERSPEED SWITCH 54 5 1449 FIGURE 3 2 DKC DKD ELECTRIC START FAULT SENSOR LOCATION 3 2 Redistribution or publication of this document by any means is strictly prohibited d ad Power Generation Overspeed Switch Optional The mechanical overspeed switch is mounted on the front of the engi
23. TABLE 7 2 ROTOR RESISTANCE VALUES Ohms Resistance DKC MDKC DKD MDKD Resistance in ohms 77 F 25 C 10 Power _ Generation 7 6 METER _ __ gt 1010 12 TESTING WINDING FOR GROUNDS FIGURE 7 9 TESTING ROTOR FOR GROUNDS DIGITAL OHMMETER MAIN ROTOR LEADS F2 2 1010 8 TESTING WINDING RESISTANCE FIGURE 7 10 TESTING ROTOR FOR AN OPEN CIRCUIT Redistribution or publication of this document by any means is strictly prohibited d c Mtm cm MT 11 WIRING HARNESS CHECK Carefully check wiring harness as follows 1 Inspect all wires for breaks loose connections and reversed connections Refer to applicable wiring diagram 2 Remove wires from terminals at each end and with an ohmmeter check each wire end to end for conti nuity or opens 3 Using an ohmmeter check each wire to other wires and to ground for possible shorts or insulation breaks under areas covered by wrapping material 4 Reconnect or replace wires harness according to applicable wiring diagram N TESTING REGULATING TRANSFORMER T21 Regulating transformer T21 is used only on single phase generators It consists of a multi coil primary and a multi tapped secondary Figure 7 11 shows a typical transformer Some transformers may have up to three coils in the primary and six taps on the secondary DC resistance of windings at 7
24. The diode bridge converts AC to DC for the exciter Thus the exciter DC boost current is dependent upon the primary cur rent H1 THROUGH H4 51491 FIGURE 5 4 TYPICAL TRANSFORMER AND CIRCUIT APPLICATION Power Generation 5 3 Redistribution or publication of this document by any means is strictly prohibited Electronic Voltage Regulator Electronic Voltage Regulator is standard equipment on all three phase generator sets and is optional for single phase sets Basic components consist of the following items shown in Figure 5 5 Regulator Board Assembly Voltage Reference Transformer T21 e Commutating Reactor CMR21 e Terminal Board TB21 The electronic regulator provides better voltage regula tion than the transformer type Itis recommended when powering non linear SCR loads usually associated with solid state equipment Only the basic functions of the regulator are described Current from one of the generator stator windings is supplied to the primary side H1 and H2 of voltage reference transformer T21 See Figure 5 6 wiring dia gram AC in the secondary winding X1 and X2 is sup plied as a reference voltage to the regulator circuit board 9 10 ADJUST VOLTS 2 ADJUST REGULATOR BOARD ASSEMBLY TERMINAL VOLTAGE REFERENCE COMMUTATING BOARD 7821 TRANSFORMER 21 REACTOR 21 51492 FIGURE 5 5 ELECTRONIC REGUL
25. and 3 on VR21 per TEST M Check exciter field wiring for shorts per TEST M Replace bad wiring Is exciter field voltage across VR21 terminals 4 and 5 5 VOC or more Check diodes CR1 through CH6 on rotor per TEST Replace if bad Check exciter field wiring harness per TEST Replace bad wiring Replace the regulator PC board per procedure F if defective Check exciter rotor winding per TEST J Replace if bad Check exciter field winding per TEST H Replace if bad Check generator rotor winding per TEST L new printed circuit board can be epa ACAUTION damaged by malfunctioning compo nenis within the control Do not Install a new PC board until all other problems have been located and Check generator stator corrected windings per TEST Replace if bad Powe r E 6 3 Redistribution or publication or this document Generation by any means is strictly prohibited FLOW CHART NO OUTPUT VOLTAGE RATED ENGINE RPM TRANSFORMER VOLTAGE REGULATOR AWARNING Many troubleshooting procedures present hazards that 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 START Are load circuit Close circuit breakers n replace bad breakers closed yes If vol
26. as 51498 ane ee m aaa gt 9 JUMPER TERMINALS 6 amp 7 FOR 60 HZ 6 7 amp 8 FOR 50 HZ T ELECTRONIC ES 1499 1 REGULATION FIGURE 6 1 ELECTRONIC AND TRANSFORMER REGULATION TYPICAL SCHEMATICS Power 6 1 Redistribution or publication of this document Generation by any means is strictly prohibited TROUBLESHOOTING PROCEDURES FIELD BREAKER CB21 TRIPS Determine the type of problem and then refer to the ELECTRONIC VOLTAGE REGULATOR orresponding flow chart A B C D E F or G for UNBALANCED OUTPUT VOLTAGE TRANSFORMER ELECTRONIC VOLTAGE REGULATOR To troubleshoot a problem start at the upper left corner A NO AC OUTPUT VOLTAGE AT RATED ENGINE of the chart that corresponds to the problem and RPM ELECTRONIC VOLTAGE REGULATOR answer all questions either YES or NO Follow the chart B NO AC OUTPUT VOLTAGE AT RATED ENGINE until the problem is found Perform the referenced test or RPM TRANSFORMER VOLTAGE REGULATOR adjustment procedures in the Generator Regulator C UNSTABLE OUTPUT VOLTAGE ENGINE SPEED Tests section T Referenced components in the flow charts and test and o D ELECTRONIC VOLT Cc EG LOW adjustment procedures can be found on the electrical schematics Figure 6 1 and on the wiring diagrams OUTPUT VOLTAGE TOO HIGH TOO LOW O
27. from the generator set into the utility line This creates a potential for electrocution or property damage Connect only through an approved device and after building main switch is open Consult an electrician in regard to emergency power use MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Before starting work on the generator set disconnect negative cable at the battery This will prevent accidental arcing or starting Keep your hands away from moving parts Make sure that fasteners on the generator set Se cure Tighten supports and clamps keep guards in po sition over fans etc Do not wear loose clothing or jewelry while working on generator sets because they can become caught in moving parts Jewelry can short out electrical contacts and cause shock or burning If adjustment must be made while the unit is running use extreme caution around hot manifolds moving parts etc GENERAL SAFETY PRECAUTIONS Wear safety glasses and protective clothing when servicing batteries DO NOT SMOKE while servicing batteries Lead acid batteries emit a highly explosive hydrogen gas that can be ignited by electrical arcing or by smoking Have a fire extinguisher rated ABC nearby Maintain extinguisher properly and become familiar with its use Benzene and lead found in some gasoline have been identified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or add
28. i 4715 8 PANEL INSERT __ REAR VIEW OF J3 FEMALE CONNECTOR VIEW OF WIRING FOR VRII PLUG UM BTI CAD 612 6624 REAR VIEW OF FRONT PANEL MODIFIED 6 5 7 5 DKD DC CONTROL SPEC F RV GENSETS m 8 9 Power Redistribution or publication of this document by any means is strictly prohibited Generation SCHEMATIC DESTPAF DESGRIF EET SINGLE PHASE TRANSFORMER REG Ses are AREAK ER REF CIRCUIT 4040 2 __ 505 0695 B REF BRIDGE RECTIFIER __ REF GENERATOR 2 RV21 205 0703 A X Ye SENI T nS C REFIRAREFORMEN ASET COT ___ FC REF TRANSFORMER ASSY _____ 50555 ITPANSFORMpE 12 2 332 2370 P REFISTANGOFF INSULATOR CREF TERMINAL BLOCK _________ EON NS PARTS o L 5300 3135 AC WIRING DIAGRAM EXCITER EXCITER i 621 TE C1 CONTROL ASSY A FI ean Roe Re RE m 300 4237 1 ASSY AC 7061 rx x pet m x ee p ee a EI
29. if battery state of charge is not maintained the charge rate may be too low B BATTERY CABLE CHECK With the starter motor operating check the voltage drops 1 from the battery negative post not the cable clamp to the cylinder block 2 from the battery positive post to the battery terminal stud on the solenoid Nor mally each of these should less than 0 3 volts ff extra long battery cables are used slightly higher voltage drops may result Thoroughly clean all connections in any part of the circuit showing excessive voltage drop C BATTERY CHARGING CHECK With the engine running check the DC voltmeter con trol option A 12 volt system should be 13 5 to 15 volts a 24 valt system should be 27 to 30 voits The power source is belt driven alternator The charge rate voltage is determined by voltage regulator VR11 On marine sets VR11 is located on the bottom of the controi box saddle and it is located inside the control box on land sets improper output may be caused by a loose drive belt poor terminal connections broken wires bad regulator or alternator Checkout procedures for the regulator and alternator are found in Section 5 of the engine service manual The charge circuit on RV series genera tor sets is protected by a circuit breaker CB13 If the output voltage is high over 15 volts check for loose or corroded voltage regulator leads If this does not correct the problem the regulator is probably
30. located and corrected Redistribution or publication of this document by any means is strictly prohibited 5 ee ee FIGURE 3 4 ELECTRIC START CONTROL SCHEMATIC DIAGRAM Control Troubleshooting The information in this section is divided into three flow charts Determine the problem and then refer to the appropriate flow chart A B or C for the troubleshooting procedures A Engine does not crank B Engine cranks but does not start C Engine starts but stops after running several seconds Before starting a troubleshooting procedure make a few simple checks that may expose the problem and cut down on troubleshooting time Check all modifications repairs and replacements performed since last satisfactory operation of set loose wire connection overlooked when installing a replacement part could cause problems incor rect connection an opened switch or circuit breaker or a loose plug in are all potential prob lems that can be eliminated by a visual check Uniess absolutely sure that panel instruments are accurate use portable test meters for trouble shooting To troubleshoota problem start at the upper left corner of chart and answer all questions either YES or NO Follow the chart until the problem is found performing referenced adjustments or test procedures Refer to Figures 3 1 through 3 4 for locating control compo nents leads terminals
31. not energized Starting Sequence When the control key switch 511 is in the Preheat position contacts 1 2 connects B to the glow plug heaters See Figure 3 4 In the Start position S11 contacts 1 2 3 4 and 5 6 close Contacts 1 2 energize the glow plugs during cranking contacts 3 4 connect B to CB12 Fault breaker K1 fuel solenoid S4 overspeed switch and VR11 battery charging voltage regulator contacts 5 6 connect B to the starter solenoid B1 in the Run position S11 contacts 3 4 and 7 8 close Contacts 3 4 remain closed and maintain B to CB12 1 54 and VR11 Contacts 7 8 connect B to the engine fault sensors 1 and S2 Contacts 1 2 open the glow plug heater circuit and contacts 5 6 open the starter solenoid circuit Start Disconnect Sequence This function is completed manually when key switch 11 is released from the Start position opening S11 contacts 5 6 for the starter sole noid B1 Stopping Sequence This function is completed manu ally when key switch S11 is turned to the Stop position This opens all switch contacts and removes B from the fuel solenoid K1 De energizing K1 shuts off the fuel flow and stops the engine Emergency Shutdown Fault breaker CB12 opens and disconnects B from the fuel solenoid K1 anytime a fault sensor closes the circuit to ground The fault sensors are 51 low oil pressure 52 high engine temperature 54 overspeed CB12 should not be reset for starting until fault is
32. operation of the set loose wire connection could appropriate flow chart A B or C for the troubleshooting cause problems An incorrect connection an procedures opened switch or circuit breaker or a loose plug in are all potential problems that can be eliminated by A Engine does not crank a visual check B Engine cranks but does not start Engine starts but stops after running several Unless absolutely sure that panel instruments are seconds accurate use portable test meters for trouble shooting Before starting a troubleshooting procedure make a tew simple checks that could expose the problem and To troubleshoot a probiem start at the upper left corner cut down on troubleshooting time of the chart and answer all questions either YES or NO Follow the chart until the problem is found performing referenced adjustment or test procedures Refer to Fig ures 2 1 through 2 4 to locate control components FLOW CHART A ENGINE DOES NOT CRANK A WARNING Many troubleshooting procedures present hazards that 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 START Check battery per Checkout A and recharge or replace Check battery charger operation per Checkout C 5 battery dead yes no Check CB11 control breaker and F1 fus
33. publication of this document by any means is strictly prohibited If necessary the speed trip point be corrected turning the adjusting screw thereby changing the mag netic air An accurate tachometer or strobotach is needed to check the overspeed trip point after adjust ment is made The air gap must not be less than 0 005 inch 0 13 mm Coolant Temperature Sender E2 Optional The resist ance ofthe sender unit changes with the engine coolant temperature and causes a reading on the Water Temp meter The meter range is 100 to 250 40 to 121 C High Coolant Temperature Switch S2 This switch closes if the coolant temperature rises to 222 106 C activating the fault breaker and stopping the engine Controi Operation Trouble free operation of the control system should be the maior concern of generator set service personnel Service personnel mustthoroughly understand how the controls operate know how to check for troubles and know how to make the proper adjustments replace ments or repairs in a reasonable amount of time Figure 3 8 shows a typical schematic for the circuits described in the following Starting Start Disconnect and Stopping sequences Relay contact references normally open NO and normally closed NC refer to position of contacts with the unit at rest not energized Starting Sequence The engine Preheat switch 812 is held for 10 to 30 seconds depending upon temper
34. replacing the voltage regulator PC board or VR chassis 1 Stop the generator set and disconnect the starting battery leads negative lead first 2 Disconnect and label if necessary the wires from voltage regulator Refer to the AC control wiring diagram 3 Remove mounting screws from the old voltage regu lator then install new regulator 4 Reconnect wires removed in Step 2 to the proper terminals 5 Set voltage as outlined in test P Voltage Adjustment 7 2 Redistribution or publication of this document by any means is strictly prohibited TESTING ROTATING RECTIFIERS Two different rectifier assemblies make up the rotating rectifier bridge assembly Figure 7 5 Using an ohmme ter test each CR rectifier using negative and positive polarities Use the following procedure 1 Disconnect all leads from assembly to be tested 2 Connect one ohmmeter test lead to 1 stud and connectthe other lead to CR1 CR2 and CRG in turn record resistance value of each rectifier Connect one lead to F2 stud and connect other lead to CR4 CR5 and CR6 in turn record resistance value of each rectifier Reverse ohmmeter leads from steps 2 and 3 and record resistance value of each rectifier F1 to and and F2 to CR5 and All the resistance readings should be high in one test and low in the other test If any reading is high or low in both tests rectifier assemb
35. shorted and should be replaced With remote start Kubota powered sets exhibiting overcharging symp toms refer to Product Support Bulletin 450 D SOLENOID CHECK 1 Apply battery positive B to the terminal marked S 2 Connect a ground wire to the solenoid mounting bracket Solenoid should activate 3 If the contacts are good battery voltage should be read between terminal 1 and ground The voltage drop measured across the contacts should never exceed one volt in circuit application E RELAY CHECK 1 Connect relay coil voltage across relay coil termi nals Relay should activate if coil is okay 2 Connect voltage source to one side of relay contacts 3 Connect a voltmeter to other side of relay contact and voltage source voltage appears when relay energizes contact is okay The voltage reading appears in reverse order when checking normally closed NC contacts Power _ 4 1 Generation Redistribution or publication of this document by any means is strictly prohibited Fl TH 7 FUEL SOLENOID CHECK SOLENOID CHECK If there is fuel to the injection pump but no fuel at injection nozzie the fuel solenoid may be defective 1 Apply battery positive B to the terminal marked S To check solenoid operation watch for solenoid actua 2 Connect a ground wire to the terminal marked tion when B is applied start switch in start or run Solenoid should activate position Ifthere is no actuation
36. the opera tion of equipment unsafe SET REMOVAL Some service procedures will require removing the generator set from a vehicle or boat Because of the wide variety of generator installations it is not possi ble to specify the exact removal procedures for each generator set If after examining the installation a satis factory method for removing the set cannot be deter mined contact the vehicle or boat manufacturer or the generator set installer to obtain their recommendations Generator sets are heavy and they A WARNING can cause severe personal injury or death if dropped during removal Use adequate lifting devices to provide sufficient support for the set Keep hands and feet clear while lifting the generator set Disconnecting Generator Set Systems Some installations may require partial removal ofthe set to gain access to the battery cable fuel line and other connections Read this entire section before starting set removal The following steps are a general guideline for set removal Power Electrical Shock AC Improper generator set load connections Faulity load circuit Faulty electrical appliance kFaulty generator set wiring Working in damp conditions Jewelry touching electrical components e Rotating Machinery Jewelry or loose clothing catching in moving parts Slippery Surfaces Leaking or spilled oil Heavy Objects hRemoving generator set from RV Removing he
37. this document Generation by any means is strictly prohibited TESTING GENERATOR STATOR Using proper test equipment check the stator for grounds opens and shorts in the windings Testing for Grounds Some generators have ground connections to the frame Check wiring diagram All stator leads must be isolated for testing Use a megger or insulation resistance meter which app ties 500 VDC or more to the test leads Figure 7 9 Test each stator winding for short to laminations A reading less than 1 000 000 ohms indicates a questionable sta tor Oven dry the stator and retest TESTING WINDING FOR GROUNDS MEGGER OR INSULATION RESISTANCE 77 METER Testing for Open or Shorted Windings Test for continuity between coil leads shown in Figure 7 8 all pairs should have equal resistance Use an accurate instrument for this test such as a Wheatstone Bridge Resistance values at 77 F 25 C are given in Table 7 1 winding is shorted open or grounded replace the stator assembly Before replacing the assembly check the leads for broken wires or insulation TESTING WINDING RESISTANCE THREE PHASE MODELS TEST BETWEEN WIRE PAIRS e a e 11 74 17 10 T3 T6 19 12 1712 15 178 111 SINGLE PHASE MODELS TEST BETWEEN WIRE PAIRS 11 72 T3 T4 5 1795 FIGURE 7 8 TESTING STATOR WINDINGS TABLE 7 1 STATOR RESISTANCE VALUES IN MILLIOHMS RW RATING AND MODEL 60AZ
38. 1 start solenoid the A11 K15 NO contacts close and provide another ground path for K12 through K11 coil similar to S6 backup start disconnect circuit is initiated by the bat tery charging alternator G1 When DC output at CR11 reaches approximately 6 volts K16 energizes and opens to the K11 start solenoid De energizing K11 disconnects from the starter solenoid to stop crank ing and eliminate glow plug heating The 16 relay and CR11 diode are not used in later production generator sets Stopping Sequence Placing S11 in the Stop position puts on the ground side of K12 power relay This causes K12 to de energize and disconnect from CB12 fuel pump 5 and the K1 fuel solenoid De energizing K1 shuts off the fuel flow and stops the engine Emergency Shutdown Fault breaker CB12 opens to stop the engine any time a fauit sensor closes the circuit to around The fault sensors shown in Figure 2 4 are 51 low oil pressure e 52 high coolant temperature S4 overspeed option e S5 high exhaust temperature CB21 should not be reset for starting until fault is located and corrected Redistribution or publication of this document by any means is strictly prohibited CONTROL TROUBLESHOOTING Check all modifications repairs and replacements The information in this section is divided into three flow that have been performed since the last satisfactory charts Determine the problem and then refer to the
39. 127 5 i t gt All CR r 1 1 1 6 ET 29 i E29 5 1 Da 2077 on a 7 C1 El L i All 5 Ail mE 5 d num Kil Ul c 2 pg u e 41 m Ae umma vum P Eu EMT ON PANEL INSERT __ ___ 224 4 CONTROL BOX qeu me O r REAP VIEW OF J3 FEMALE CONNECTOR VIEW OF WIRING FOR YRIE PLUG BTI ENO ae patio Peano I REVISION IDR EN cR M uaaa Bieb mi OQ ed re ROL GEN SET DC The prowewiany age DIA 08 MDKC MDKD 612 687 REAR VIEW OF FRONT PANEL MDKC MDKD DC CONTROL 8 4 rua Power Redistribution or publication of this document gt Generation by any means is strictly prohibited 5 5262 0 WIRING DIAGRAM SCHEMATIC feo 1 4 1 CB 7 __ oc AM KIZ iN 953528 BRC 55 3 al r vars 9 1 All 01 5 t 5 dx 3 1 K
40. 7 F 25 C are shown in Table 7 3 Resistance between primary and secondary and the transformer frame should be over 100 000 ohms when measured with a megger or insulation meter H1 THROUGH H4 Mf 1 X3 X4 TRANSFORMER WINDING SCHEMATIC Ht oy E x2 H2 e 3 PRIMARY SECONDARY ES 1510 FIGURE 7 11 TYPICAL REGULATING TRANSFORMER TABLE 7 3 TRANSFORMER RESISTANCE VALUES IN OHMS Primary 1 2 H3 H4 H5 H6 Secondary X1 X6 X1 X5 X1 X4 X1 X3 X1 X2 007 0005 007 0005 019 01 N A Not applicable Power Generation 003 0005 003 0005 1 15 01 1116 01 019 01 TRANSFORMER PART NUMBER 315 0582 007 0005 007 0005 003 0005 1 44 1 1 33 1 1 21 1 04 01 02 01 004 0005 004 0005 002 0005 1 37 1 1 35 1 1241 04 01 02 01 Redistribution or publication of this document by any means is strictly prohibited VOLTAGE ADJUSTMENT This section supplies information for adjusting the trans former and electronic regulators When checking output voltage be sure the generator set has stabilized and is running at the correct speed frequency Adjusting the transformer requiator is done with the set stopped The electronic regulator is adjusted with the set running Accidental starting of the set can AWARN
41. ATOR BASIC COMPONENTS A rise or fall in the generator stator output voltage pro duces a corresponding change in the transformer secondary The generator stator is also connected to the commutat ing reactor CMR21 Reactor 121 15 a choke used to produce a uniform AC wave to the circuit board AC input terminal TB1 1 During operation the regulator circuit board responds to changes in the reference voltage supplied by trans former T21 These changes raise or lower the DC output voltage produced for field excitation which results in stable output for the load STATOR ASSEMBLY EXCITER STATOR 0 35 1 _ _ 2 1 X1 11 Eus Y je IT 1 oes 821 E T Hu 1 i JUMPER TERMINALS 6 amp 7 FOR 60 HZ 7 amp 8 50 _ _ c2 _ ____________ _ __ MM 51493 FIGURE 5 6 ELECTRONIC REGULATOR WIRING DIAGRAM Power Generation 5 4 Redistribution or publication of this document by any means is strictly prohibited GENERATOR SERVICE The following sections describe the disassembly and reassembly procedures for the generator Generator components are heavy AWARNING and can cause severe personal injury if dropped during service Be careful keep hands and 10 Use a hoist and safe lifting device stator handling tongs nylon lifting strap or chain and lift hooks to support the stator assembly A su
42. Caution This document contains mixed page sizes 8 5 x 11 or 11 x 17 which may affect printing Please adjust your printer settings to the 5176 page you wish to print of this document by any means is strictly prohibited MDKC E tie Printed U S A 981 0502 3 94 Redistribution or publication of this document by any means is strictly prohibited Safety Precautions Before operating the generator set read this manual and become familiar with it and the equipment Safe and efficient operation can be achieved only if 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 opera tor service personnel or the equipment This symbol warns of immediate hazards which will result in severe personal injury or death This symbol refers to a hazard orunsafe practice which can result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage Head and observe each of the following safety precautions FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury can result from im proper practices Donot smo
43. E REGULATOR The voltage regulator controls the output of the genera tor so that a constant voltage is maintained under vary ing load conditions There are two types of voltage lators used on these sets transformer and electronic solid state The description and operation of each type is covered separately Transformer Voitage Regulator The transformer voltage regulator is standard equip ment all single phase generator sets It is located inside the generator set control box A typical trans former and a schematic showing circuit application is shown in Figure 5 4 The transformer provides a feed back loop from the output of the generator to the exciter stator ROTOR DIODE ASSEMBLIES EXCITER DIODE EXCITER STATOR BRIDGE ROTOR STATOR ASSEMBLY 6 law masa E wai tae X1 X2 X3 X5 CIRCUIT BREAKERS SUPPRESSOR The number of primary windings and secondary taps will change for 50 hertz and different model applica tions See individual model wiring diagrams in the back of this manual The transformer primary is connected in series with the generator output leads making it a current boost wind ing for the secondary Separate coils in the primary allows the generator to be reconnected for other tages without causing an output voltage unbalance The transformer secondary is in the exciter circuit and is connected through a diode bridge
44. ING cause severe personal injury or death Disconnect both battery cables negative cable first when repairs are made to the engine controls or generator Transformer Voltage Regulator The transformer regulator circuit supplies a feedback voltage dependent on load to the exciter stator Voltage adjustment is made by changing tap connections on the transformer When replacement is necessary install leads to the same terminals on the new transformer To change voltage refer to the model wiring diagram or the generator reconnection diagrams in Test Q Electronic Voltage Regulator Contact with high voltage can cause A WARNING severe personal injury or death Do not touch any exposed wiring or components with any part of the body clothing tool or jewelry Do not use non insulated tools inside the control Stand on an insulating mat or dry wood platform when the control doors are open Power Generation With the generator set running set the Voltage Adjust potentiometer on the regulator board assembly for cor rect voltage See Figure 7 12 ii Do not adjust the other potentiometer ACAUTION Voits Hz Adjust as it can impos sible to reset for proper operation It is factory set using special calibration equipment VOLTAGE ADJUST VOLTS HZ ADJUST 5 1388 FIGURE 7 12 ELECTRONIC REGULATOR BOARD Q RECONNECTION Generator reconnection is dependent upon the name plate code Fiqure 7 13 show
45. ISTOM LOT TIMING L4 2 METER TIME TOTALIZING 4 40 0 SWITCH START STUP ISOLATOR VIBRATION 50 47 3 QR NEF Miz t GAUGE IL PRESSURE 3 1 dm pe LN ko am as 508 015 1 GROMMET 21 8 1 5 GROMMET 1 1 8 10 1 REF 4 58 0457 1 CLIP HOLDDOWN TINNEAMAA S il p Iz x t T REF VOLTMETER INSTALL SEHIND CONTROL TRAY ON BOTTOM O 970 0598 A 4 NUT RETAINING 0 52 TINNERMAN INSTALL ON HOLES OF CONTROL BOX 017131 418A e 1319 1680 amp i BOX ASSY CONTROL 1 391 8454 D TRAY CONTROL 319 0203 a Ae __ 9 0934 A KIS Al HU d qM 5 Bun 2 9 sez pr 870 0131 2 NUT HEX WET 10 32 senes tx j9z 0i5 amp 1 SCREW LK 4 2 1 50 KGND _ amp 001 NUT HMBS g56 0006 WASHER EIT LK 1 4 20 GNO ____ 62 0008 2 SCREW LK HO 1 4 20X 57S SEREN R WAIT SERT ____ 2 NUT W ET amp SZHMI UM MENT 511
46. ITH CHAMFER THIS SIDE WOODRUFF KEY N TORQUE SEE DETAILA FLATWASHER TORQUE 130 150 LBS DETAIL 176 203 20 22 LBS 27 30 Nem ES 1495 3 FIGURE 5 9 ROTOR ASSEMBLY AND TORQUE VALUES 5 7 Redistribution or publication of this document by any means is strictly prohibited Redistribution publication of this document by any means 15 strictly prohibited Section 6 Generator Regulator Troubleshooting GENERAL This section contains service information for single and Check to see that generator leads are connected three phase generator sets with transformer or elec correctly Also check the circuit board connectors tronic voltage regulators Make the following visual loose contaminated or misplaced wire connec checks prior to starting the troubleshooting procedures tion will cause problems that can be detected by close inspection Check any modification or repair that has been per formed since the last satisfactory operation of the Check for an open circuit breaker If the breaker is set to see that they are installed properly open check for an overloaded circuit and correct load problems before resetting circuit breaker 13 9 TB lt 4 IE T3 Te Ne 5 3C Fx Tel yi B 53C All mat 2 L EXCITER 1 mmm lt TRANSFORMER ti REGULATION
47. MODELS ONLY FOR 3CE 53CE 18 518 MODELS CONNECT LEADS 182 DIRECTLY 21 5 FOR I GENERATOR 3 ANDS3C LEADS SIAN2S2 WiLL NOT BE USED INSULATE ANDLEAVE IN CONTROL BOX JUMPER TERMINALS 687 FOR 60 Hz OI ADD JUMPER BETWEEN TERMINALS 7 amp 6 FOR 50 Hz 02 CONTROL EXCITER BOX i 1 RECONNECTION DIAGRAM i 229 254 440N t v m Jua rer a x CONTROL GEN SETAC t 3PH 5022 t Wu h DEKC EXD MOKC MDKD r og 612 6185 LU Qi 5819 89 Redistribution or publication of this document by any means is strictly prohibited 612 6187 D WIRING DIAGRAM SCHEMATIC 8 2 5o 350 401 9 MS GN5 18915 4915 55 y oA g 4 74 E END P puto 4 o mv 4 d NS lt RAT be ee AM 51 KIG 51 GND Alt SHUT The m 0 x 52 E5 Km v t ti OND wie 9 B m a y KI GND A BLUE VRrI BLuE RE at 85 REAR VIEW OF PANEL INSERT 4
48. P POSITION POSITION E dinis ADJUSTMENT 52 52 tx se tx 52 TX 7 6 1 M 7 1 INCREASE 10 ___ 2 xa xe x X5 DECREASE X5 DOAN CONTROL BOX DC SECTION 46 e NOTET A _ Q Au 6 OKO MDKD 03 m SINGLE PHASE AC CONTROL _ 8 2 Power Redistribution or publication of this document Generation by any means is strictly prohibited k 1 76 5 _ 62 6185 AC WIRING DIAGRAM ELECTRON C REGULATION 13 5 8 2 53 EXCITER 999 24 tor o2 SEE NOTE 6 TOP EDGE SEE T4 12 73 74 T5 T6 T7 T8 T9 TH 2 I LOAD 13 8 58 t i CONTROL SECTION _ _ CB22 I d 21 7 2 TBI _ 090966 2 1 RECONNECTION DIAGRAM _ dn 21 FRONT PANEL REAR VIEW All NOTE 4 SINGLE AND THREE PHASE AC CONTROL 8 3 Power 1 Generation tm 4 3 e 1 SCHEMATIC ELECTRONIC REG VOLTAGE CODES 38513 35 amp 53C NOTES 1 CUTLEADS 384 FROM 1 21 THESE LEADS ARE NOT USED G 2 UNLESS OTHERWISE NOTED ALL COMPONENTS 4 D ARE SHOWN IN DE ENERGIZED POSITION lt gt 3 DASHEO LINES INDICATE CONNECTIONS E WHEN USED AW CONNECTIONS ON 3CR 53CR IBR SIBR
49. R UNSTABLE TRANSFORMER VOLTAGE REGULATOR Power 6 2 Generation Redistribution or publication of this document by any means is strictly prohibited FLOW CHART OUTPUT VOLTAGE RATED ENGINE RPM ELECTRONIC VOLTAGE REGULATOR A WARNING Many troubleshooting procedures present hazards that 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 START Are load circuit breakers closed Close circuit breakers or replace if bad yes Remove one lead from breaker and check continuity with ohmmeter s breaker open 8 control panel field breaker CB21 on Replace defective field breaker yes yes H voltage is unstable high or low or Push to reset causes breaker to trip see Flow Charts AC output voltage build B C D or E Is residual voltage across terminals 2 and Flash exciter field per TEST D Does 3 of VR21 5 to 10 VAC or more generator output voltage build up yes no Disconnect stator leads 1 and 2 AC terminals of A11 is residual voltage across the leads 5 to 10 VAC or more now Check reactor CMR21 and transformer T21 per TESTS and JE yes Check lead continuity between AC terminals on A11 and terminals 2
50. SCHEMATIC The start disconnect circuit provides starter protection As the generator gains speed and output voltage the K15 starter protection relay energizes at about 90 volts AC The A11 K15 NC contacts open and de energize the K11 start solenoid the A11 K15 NO contacts close and provide another ground path for K12 through 11 coil similar to S6 Power Generation 3 10 Redistribution or publication of this document by any means is strictly prohibited ci gt E A backup start disconnect circuit initiated by the bat tery charging alternator G1 When DC output at CR11 reaches approximately 6 volts K16 energizes and opens to the K11 start solenoid De energizing K11 disconnects from the starter solenoid to stop crank ing and eliminate glow plug heating The K16 relay and CR11 diode are not used in later production generator sets Stopping Sequence Placing S11 in the Stop position puts B on the ground side of K12 power relay This causes K12 to de energize and disconnect from CB12 fuel pump E5 and the K1 fuel solenoid De energizing K1 shuts off the fuel flow and stops the engine Emergency Shutdown Fault breaker CB12 opens to stop the engine anytime a fault sensor closes the circuit to ground The fault sensors as shown in Figure 3 8 are 51 low oil pressure 52 high coolant temperature 54 overspeed CB12 should not be reset for starting until fauitis located and corrected
51. Single phase AC volt age taken from a main stator winding is connected to the voltage regulator as a reference for regulating the generator output voltage The regulator DC output is coupled to the exciter stator 2 AD SINGLE The exciter rotorproduces three phase AC voltage that is converted to DC by the full wave rotating rectifier assemblies The DC voltage excites the rotor main field winding to produce main stator AC for the load CODE 18 amp 51B THREE PHASE Generator sets without control panel AC meters are shipped from the factory with the AC output leads separated in the control box Generator sets with AC meters have the AC output leads wired as specified on the customer s purchase order to deliver the voltage specified EXCITER EXCITER STATOR ARMATURE TO VOLTAGE REGULATOA E ES 1483 2 NOT USED ON 1 2 GENSETS WITH ELECTRONIC REGULATION 8 NOT USED ON 1 2 GENSETS WITH TRANSFORMER REGULATION FIGURE 5 2 SINGLE AND THREE PHASE GENERATOR SCHEMATIC COMPOSITE EXCTIER ROTOR ROTOR ROTOR MAIN FIELD ME nn tm S RECTIFIER 4 ASSEMBLIE E EXCITER FIELO MAGNETISM 1 MAIN PERMANENT FIELD 1 MAGNET STARTS PROCESS a STATOR 21212 2 EXCITER STATOR REGULATOR 5 1322 2 FIGURE 5 3 EXCITATION BLOCK DIAGRAM Power 5 2 Redistribution or publication of this document Generation by any means is strictly prohibited VOLTAG
52. V INSULATE H5 ANO WG INOT 120 240 V AND IZ0 CONNECT H2 TOMS NOTES GE CONNEC TIONS LEAVE TI ANO ated chia LIR ALL VOLTA f 1 F CONNECTED TO HI AND RESPECTIVELY OR 1255240 H6 LIANDH3FORLZIT2 AND T3 ARE GND 2FORGOHE USE 52 LEAD FROM ON TAPS 2 DASHED LINES INDICATE WHEN USED 14 TAPS USE TX ON TAPS 5 4 HS AND LEADS ARE USED ONLY ON 509 220 AND 3 50H USE 2 LEADI FROM TAPS 1 3 12 7207240 CONNECTIONS GTAP5 USE TX LEAD ON TAPS x4 6 FOR 220 AND CONNECT H2 H6 FOR CONNECT H5 TOTS 15 AND HS T2 t 2 FOR 0 220 USE H5 FOR LIANDH3FORL 2 2 GNO Electronic Regulation Codes 3C 60 Hz Code 53 50 to nz FIGURE 7 13 GENERATOR RECONNECTION DIAGRAMS Gra Power 7 9 Redistribution or publication of this document Generation by any means is strictly prohibited Redistribution publication of this document by any means 15 strictly prohibited Section 8 Wiring Diagrams Notes The electrical schematics and wiring diagrams that apply to the generator sets covered in this manual are listed below WIRING DIAGRAM DRAWING NO PAGE Single Phase AC Control 612 6184 8 2 Single and Three Phase AC 1 612 6185 8 3 MDKC MDKD DC
53. a ture This energizes the K13 heater solenoid which closes NO set of contacts to connect to the glow plugs After preheat time the start sequence is initiated by pressing the Start button S11 Switch S11 contacts B to the coil of K14 and through the A11 K15 contacts and K16 NC contacts to the Start Solenoid K11 The coil of K11 is grounded through the pull coil of K1 after K1 is completely pulied in and the pull coil is disconnected from B K1 must pull in completely or the engine wili not crank The closing of K11 contacts connects to the glow plugs and B1 starter solenoid K14 connects B to K1 fuel solenoid K5 fuel pump CB12 fault breaker and engine monitor circuits only during starting Start Disconnect Sequence As the engine starts latch relay S6 closes and completes the ground circuit through resistor A11 R1 for the K12 power relay closing of K12 dual contacts completes the B running circuit to CB12 fault circuit breaker E e G KI5 alt au 2 SI 511 52 ESTART 59 I KI KI2 models p 7 LINE 1 ma 1 1 m scm A MI Sa Ho PA F3 Lar Lewes J Zi o LU T A E ud a 0 NEN 8 Ril FIGURE 3 8 TYPICAL CONTROL
54. ace if bad Power 6 6 Redistribution or publication of this document Generation by any means is strictly prohibited FLOW CHART FIELD BREAKER TRIPS ELECTRONIC VOLTAGE REGULATOR AWARNING Many troubleshooting procedures present hazards that can result in severe personal injury or death Only qualified service personnel with knowledge of fuels eleciricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Check for any loose or broken wires or connections on VR21 assembly Check reference transformer T21 per TEST Replace if bad new printed circuit board can be A CAUTION damaged by malfunctioning compo nents within the control Do not install a new PC board uniil all other problems have been located and corrected START Does AC output voltage build up to 150 or yes more of rated voltage before breaker trips Check exciter stator winding per TEST Replace if bad Replace the regulator PC board per procedure F FLOW CHART G UNBALANCED GENERATOR OUTPUT VOLTAGE TRANSFORMER OR ELECTRONIC VOLTAGE REGULATOR A WARNING Many troubleshooting procedures present hazards that 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 START
55. and other check points Power Generation Redistribution or publication of this document by any means is strictly prohibited FLOW CHART ENGINE DOES CRANK AWARNING Many troubleshooting procedures present hazards that 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 START Check battery per Checkout A and recharge or replace Check battery charger operation per Checkout 15 battery dead yes Check battery cables for clean tight connections ref Checkout B Check B1 starter solenoid and motor if bad repair or replace Check F1 fuse If okay jumper battery cable connection to B1 starter solenoid terminal Does no engine crank yes 15 present at key switch S11 no Check wiring and replace if bad yes Test switch S11 per Checkout G Replace if bad FLOW CHART B ENGINE CRANKS BUT DOES NOT START A WARNING Many troubleshooting procedures present hazards that 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 START Check fuel system fuel tank level shut oft valves fuel lines and connectio
56. any means is strictly prohibited TESTING EXCITER ROTOR Test the exciter rotor Figure 7 7 for open or shorted windings or grounds as follows Testing tor Open or Shorted Windings Use a Wheatstone Bridge or digital ohmmeter for this test Disconnect main rotor field leads that connect to rotating rectifier assemblies at F1 and F2 Disconnect lead wires from diodes CR1 CR2 CR4 and 6 Test between exciter lead pairs T1 T2 T2 T3 and T1 T3 Resistance at 77 F 25 C should be 486 to 594 milliohms EXCITER ROTOR ASSEMBLY EXCITER ROTOR Testing for Grounds Test with an insulation resistance meter or Megger that applies at least 500 volts to the test leads With all gener ator leads disconnected from rotating rectifiers CR1 through CR6 apply test leads between any CR lead and the rotor laminations Reading should be 1 000 000 ohms or higher not the exciter rotor is questionable and may require removal for oven drying and retest A shorted rotor must be replaced Use 23 to 26 inch pounds 2 6 to 2 9 Nem torque when replacing nuts of F1 and F2 leads CR1 CR2 and CR6 _ LAMINATION INSULATION WHEATSTONE RESISTANCE BRIDGE OR METER DIGITAL OHMMETER TESTING WINDING FOR GROUNDS TESTING WINDING RESISTANCE CONNECTION DIAGRAM ES 1794 FIGURE 7 7 TESTING EXCITER ROTOR Power 7 4 Redistribution or publication of
57. ating reactor is shown in Figure 7 1 It is referenced CMR21 on schematics Only one winding of the reactor leads 1 and 2 is used Remove reactor leads from termina board for testing Resistance across 1 and 2 should be 330 to 390 milli ohms at 77 F 25 C Resistance between winding and the reactor frame should be infinity 51500 FIGURE 7 1 COMMUTATING REACTOR C TESTING RECTIFIER BRIDGE CR21 AND SUPPRESSOR RV21 The rectifier bridge and suppressor are located within the control box of transformer regulated sets The bridge contains four diodes as shown in Figure 7 2 They are encapsulated within a hermetically sealed block and failure of any diode requires replacement of the entire bridge Disconnect wires from the bridge prior to testing Check forward resistance with an ohmmeter on the Rx 1 scale reverse resistance on the R x 10K scale Forward resist ance should be 6 to 50 ohms and reverse resistance infinity If CR21 is defective the suppressor RV21 should also be replaced RV21 should have infinite ohmmeter readings in both directions ELECTRICAL SCHEMATIC ES1501 FIGURE 7 2 RECTIFIER BRIDGE SUPPRESSOR ASSEMBLY Power Generation Redistribution or publication of this document by any means is strictly prohibited D FLASHING THE FIELD If output voltage does not build up it may be necessary to restore residual magnetism by flashing the field This requires a
58. avy components Leakage of fuel in or around the AWARNING generator set compariment presents the hazard of fire or explosion that can cause sovere personal injury or death Do not disconnect or connect battery cables if fuel vapors are present Ventilate the compariment thoroughly use bilge blowers or power exhausters in boats and park vehicles outdoors in a well ventilated area 1 Disconnect the generator set negative battery cable at the battery terminal Disconnect the generator set positive battery cable from the wire harness Disconnect the remote control plug wire from the generator set if applicable Disconnect the generator load wires and tag for identification when reconnecting Disconnect the exhaust system and support brackets or hangers to allow set removal Disconnect the fuel line at the generator set hous ing Securely plug the end of the fuel line to prevent fuel ieakage or an accumulation of explosive gaso line vapor Verify that the generator set is adequately sup ported before loosening any of the mounting bolts or support members 1 2 Redistribution or publication of this document by any means is strictly prohibited Generation Leakage of presents the hazard AWARNING of fire or explosion that can cause severe personal injury or death Make certain all fuel line openings are plugged to prevent gasoline vapor from accumulating Before disconnecting the fuel line
59. concern of generator set service personnel Service personnel must thoroughly understand how the controls operate know how to make the proper adjust ments replacements or repairs in a reasonable amount of time The following section covers the control operation The schematic diagram shown in Figure 2 4 can be used to help follow the circuit description Always refer to the specific wiring diagram that corresponds to the model and specification number of the generator set when troubleshooting Relay contact references normally open NO and normaily closed NC refer to the position of the contacts with the unit at rest not energized Priorto starting the generator set Checkthe fuel supply engine oil level and battery connections for loose or broken wires Check the entire exhaust system for worn or corroded parts Replace defective parts before leaks occur Power Generation 2 3 Redistribution or publication of this document by any means is strictly prohibited Figure 2 4 shows a typical schematic for the circuits described in the following Starting Start Disconnect and Stopping sequences Relay contact references normally open and normally closed NC refer to position of contacts with the unit at rest not energized B Cri en E su 7 1702 21 24 Ail early models cae KI2 CR
60. dle Figure 5 10 2 Connect generator field leads to 1 and F2 termi on exciter assembly Torque to values shown 14 Install the end bell cover 3 Press the end bearing onto the rotor shaft 15 Connect the stator wires to the load wires 4 Assemble rotor fan and drive disc to the engine 16 Connect the negative battery cable and test flywheel Use a hoist and sling to support rotor Be generator operation surethe drive disc is assembled with the chamfer on the flywheel side Apply torque values shown in Figure 5 9 5 Install air baffle BLUE RED 6 Using a hoist and safe lifting device carefully move the stator into position over the rotor The leads should be in the top position Apply a thin film of Molykote grease to surfaces of end bearing and hole in the end bell 7 Install the end bell stud bolts through the stator and into the generator adapter oe GREEN 8 Install end bell assembly on the stator with the generator lead opening top position ES1497 9 Torque end bel stud nuts to 20 ft ibs 27 Nem 10 Using a lead hammer tap the end bell atthe horizon tal and vertical to relieve stress Torque end bell FIGURE 5 10 DC REGULATOR PLUG CONNECTIONS stud nuts 11 Feed stator and control leads through opening in control box and saddle and secure saddle to the generator TORQUE TO 23 26 INCH LBS SEE DETAIL B 2 6 2 9 Nem ASSEMBLE DRIVE DISK W
61. e If okay jumper battery cable B connection to B1 starter solenoid terminal Does engine crank Check battery cables for clean tight connections no ret Checkout B Check B1 starter solenoid and motor if bad repair or replace yes Check wiring to 511 and between 511 and 11 Check NC contacts of A11 K15 and K16 Replace if bad With S11 in Start position is battery voltage present between K11 terminal S and ground It K11 does not energize test per Checkout and replace if bad 5 battery voltage present at B1 solenoid terminal with 511 in Start position Check B wiring between K11 and B1 solenoid terminal Replace if bad Check K1 plungertravel for ieedom to bottom in solenoid which is necessary 10 open pull coil circuit Power 2 5 Redistribution or publication of this document Generation by any means is strictly prohibited FLOW CHART ENGINE CRANKS BUT DOES NOT START AWARNING Many troubleshooting procedures present hazards that 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 START Check fuel system fuel tank level shut off 15 engine getting fuel Exhaust smoke should be blue white and fuel flow steady from fuel return line no valves fuel lines and connections fuel filters
62. e monitor circuit board It connects the battery 8 to the starter solenoid B1 during cranking 13 Heater Relay Located on the relay mounting tray It connects the battery B to the engine glow plugs prior to and during cranking it is energized by the Preheat Switch 812 early production 11 late production and the start switch 511 during start sequence K14 Fuel Solenoid Relay Located on the relay mount ing tray It is energized only during cranking and con nects to the fuel solenoid K1 fuel pump E5 and fault breaker CB12 circuits K16 Start Disconnect Relay Located on the relay mounting tray It is connected through CR11 to the 12 volt battery charging alternator The relay actuates at 5 5 to 7 5 volts DC The K16 relay and CR11 diode are not used on later production sets and were disconnected on some sets refer to Product Support Bulletin 450 Engine Sensors The following briefly describes the engine mounted sensors and switches and how they protect the engine from adverse operating conditions LOW OIL PRESSURE SWITCH 51 HIGH EXHAUST TEMP SWITCH 55 HIGH COOLANT TEMP SWITCH S2 OPTIONAL COOLANT FAULT TEMPERATURE SENDER RESET E2 BREAKER CB12 OPTIONAL OVERSPEED SWITCH 4 5 1445 2 FIGURE 2 2 MDKC MDKD FAULT SENSOR LOCATION 4 Power 2 2 Generation Redistribution or publication of this document by any means is strictly prohibited All safety sensors switches close t
63. ecautions on inside cover page Repair as required no Repair wiring or replace as required START Are there any broken wires or loose connections on voltage regulator assembly gen no Check wiring harness from regulator assembly to end bell per TEST M Check okay yes Replace the regulator PC board per procedure FLOW CHART D OUTPUT VOLTAGE TOO HIGH OR TOO LOW ELECTRONIC VOLTAGE REGULATOR A WARNING Many troubleshooting procedures present hazards that 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 A new printed circuit board can be A CAUTION damaged by malfunctioning compo nents within the control Do not install a new PC board until all other problems have been located and corrected START Is engine running at correct RPM Set RPM per instructions in appropriate engine manual Set control per Voltage Adjustment yes Does adjustment of Voltage Adjust controlan the regulator board result in correct output voltage Are reference transformer 121 connections correct and secure on TB1 A new printed circuit board can be damaged by malfunctioning compo nents within the control Do not install a new PC board until all other problems have been located and
64. form service procedures Review safety precautions on inside cover page START Check battery per Checkout A and recharge or replace Check battery charger operation per Checkout C yes Is battery dead no Check CB11 control breaker and F1 fuse okay jumper pattery cable B connection to B1 starter solenoid terminal Does engine crank Check battery cables for clean tight connections rel Checkout B Check B1 starter solenoid and motor if bad repair or replace Check B wiring to 511 and between S11 and K11 Check NC contacts of A11 K15 and K16 Replace if bad With S11 in Start position is battery voltage present between K11 terminal S and ground yes It K11 does not energize test per Checkout and replace if bad 15 battery voltage present at B1 solenoid terminal with 11 in Start position Check B wiring between K11 and B1 solenoid terminal Replace bad Check plunger travel for feedom to bottom in solenoid which is necessary to open pull coil circuit Power _ 3 11 Generation Redistribution or publication of this document by any means is strictly prohibited FLOW CHART ENGINE CRANKS BUT DOES NOT START AWARNING Many troubleshooting procedures present hazards that can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should
65. il 3 54 mud _ PANEL INSERT Zee 4 m o 5 A LiNE V sia VIEW OF WIRING FOR VRII PLUG Si 7 GN 5 NOS Low Haan 8 lt MODEL 570 GAUGES Meroe poles ECCO REAR VIEW OF FRONT PANEL DKC DKD 3 START CONTROL REMOTE START Generation by any means is strictly prohibited rua Power Redistribution or publication of this document 612 6353 0 WIRING DIAGRAM SCHEMATIC eNO HRE 7 GND 6 amp 8 GND e A E HAS Sit 52 52 3102 1 1000 _ 7 j KI 25 2 4 KIZ 5 4 2d 5 4 5 A 5 af APIS gt 4 D o a o n z E m 559 f 3 St 06 4 SI 2 5 8 s 2 wi gt PANEL INSERT __ ees epi s e we t ISW _ VIEW OF WIRING FOR VRII PLUG as MU ume 20 GND pe enson ex ex 1 1 1 ONON CONTROL GEN SET DC
66. ing gasoline take care not to ingest breathe the fumes or contact gasoline Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity When checking or changing engine oil take care not to ingest breathe the fumes or contact used Remove unnecessary grease and from the unit Accumulated grease and oil can cause overheating and engine damage which presents a potential fire hazard Do not store anything in the generator set ment such as oil or gas cans oily rags chains wooden blocks portable propane cylinders etc A fire could re sult or the generator set operation cooling noise and vibration may be adversely affected Keep the com partment floor clean and dry Do not work on this equipment when mentally or physically fatigued or after consuming any alcohol 0 drug that makes the operation of equipment unsafe Power _ Generation Redistribution or publication of this document by any means is strictly prohibited Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS Inside Cover 1 INTRODUCTION ee 1 1 About tis MANUAL ER 1 1 How to Obtain 1 1 Test EGGIDIBGEIE 1 1 Safety 1 1
67. ion Oil Pressure Sender E1 Optional The sender resist ance changes with oil pressure and results in a reading on the oil pressure meter The meter range is 0 to 100 psi 0 to 700 kPa Low Oil Pressure Switch 51 This switch closes if oil pressure drops to 9 psi 62 kPa Some early generator sets had switches closing at 14 psi 97 kPa This acti vates the fault breaker and stops the engine Contro Power Latch S6 This oil pressure switch closes at 5 psi 34 kPa and provides a latch function for the control circuits When closed the switch supplies a ground path for relay K12 on the engine monitor board Overspeed Switch Optional The mechanical over speed switch is mounted on the front of the engine crankshaft as shown in Figure 3 7 It is factory adjusted to close and shut down 60 hertz units at 2200 r min 90 r min 50 hertz units at 1900 r min 90 r min overspeed condition grounds the shutdown circuit on the Engine Monitor Board and trips the fault breaker After the problem is corrected starting will not occur until the fault breaker is reset ADJUST SCREW AIR GAP SWITCH CONTACTS 5 1514 FIGURE 3 7 OPTIONAL OVERSPEED SWITCH OPTIONAL PRESSURE CONTROL SENDER 1 POWER LATCH S6 LOW OIL PRESSURE SWITCH 1 HIGH COOLANT TEMP SWITCH 2 OPTIONAL OVERSPEED SWITCH 4 5 1551 1 FIGURE 3 6 ENGINE SENSOR LOCATIONS Generation 4 Power Redistribution or
68. ith four studs that thread into the generator adapter casting The brushless exciter stator mounts in the end bell while the exciter rotor andits rotating diode assemblies mounton the generator rotor shaft Leads F1 and fromthe exciter stator winding are connected to the output ter minals of the voltage regulator The composite illustration in Figure 5 2 shows the generator output and control meter leads for the var ious voltage options Voltage reconnection diagrams appear in Section 7 Generator Regulator Tests and in Section 8 Wiring Diagrams END BELL 4 BRUSHLESS EXCITER ROTOR END BEARING Es i li i ee ee re ew gt t ee i ee ROTATING DIODE ASSEMBLIES NOT SHOWN a ee Du fte POE BRUSHLESS EXCITER STATOR ROTOR XG 1201 FIGURE 5 1 TYPICAL YD SERIES GENERATOR Gd Power _ 5 1 di Generation Redistribution or publication of this document by any means is strictly prohibited CONTAOL LEADS 451852 87 HOTOR MAIN FIELD ROTATING DIODE ASSEMBLIES T2 T4 BRUSHLESS GENERATOR OPERATION Power generation involves the generator components shown in Figure 5 3 These components are italicized in the following text A permanent magnet embedded in exciter statorfield pole begins the voltage build up pro cess as the generator set starts
69. ke or allow an open flame or spark produc ing equipment near the generator set or fuel tank Inspect the fuel lines and connections daily for leaks per the maintenance schedule EXHAUST GASES ARE DEADLY Never sleep in the vehicle with the generator set running uniess vehicle is equipped with an operating carbon monoxide detector Inspect exhaust system daily for leaks per the maintenance schedule Do not use engine cooling air to heat a compartment Never operate the generator set inside a building or in an area where exhaust gases could accumulate such as near a wall or snow bank or in high grass When parking make sure the exhaust outlet is obstructed Make sure the generator set is well ventilated ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disconnect the negative cable at the starting battery before removing protective shields or touching electrical equipment Use rubber insulative mats placed on dry wood platforms on the ground or over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling electrical equipment Use extreme caution when working on electrical com ponents High voltages can cause injury or death Tag remote or open switches to avoid accidental clo Sure or starting DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous voltages can flow
70. ly is defective Replace defective rectifier assembly with new iden tical part Use 23 to 26 inch Ibs 2 6 to 2 9 Nem torque when replacing nuts of Fi and F2 CR2 CR4 CR5 and CR6 OHMMETER 1010 9 FIGURE 7 5 TESTING ROTATING RECTIFIERS H TESTING EXCITER STATOR Test the exciter stator Figure 7 6 for open or shorted windings and grounds as follows Testing for Open or Shorted Windings Use a Wheatstone Bridge or digital ohmmeter for this test Disconnect 1 and F2 exciter field leads from terminal block in generator end bell The resistance between field leads should be 11 16 to 13 64 ohms at 77 F 25 Power _ Generation Testing for Grounds Connect a megger or insulation resistance meter that applies 500 VDC or more between either field lead and the exciter stator lamination Be sure both exciter leads are disconnected from the terminal block Reading should be 1 000 000 ohms or greater f not the exciter stator is questionable and may require removal for oven drying and retest A shorted stator must be replaced WHEATSTONE 1010 10 BRIDGE OR DIGITAL TESTING FOR OPEN OR SHORTED WINDING F1 22 STATOR LEADS LAMINATIONS xi MEGGER OR INSULATION RESISTANCE METER 1010 11 TESTING FOR GROUND TO LAMINATION FIGURE 7 6 TESTING EXCITER STATOR Redistribution or publication of this document by
71. n result in longer unit life better performance and safer operation Information for printed circuit board repair is limited because it is more efficient to replace the boards in the field and repair them atthe factory Application of meters or hot soldering irons to printed circuit boards by other than qualified service personnel can cause unneces sary and expensive damage This manual contains basic wiring diagrams and sche matics that are included to help in troubleshooting Ser vice personnel should use the actual wiring diagram and schematic shipped with each unit The wiring dia grams and schematics that are maintained with the unit should be updated when modifications are made to the unit HOW TO OBTAIN ASSISTANCE Always give the complete model number and serial number as shown on the Onan nameplate when seek ing additional service information or replacement parts TEST EQUIPMENT Most of the test procedures in this manual can be per formed with a multimeter such as the Simpson Model 260 VOM or with a digital VOM Additional instruments used to service generator sets that should be available are AC Voltmeter DC Voltmeter Frequency Meter e Jumper Leads Load Test Panel Megger or Insulation Resistance Meter Frequency Meter or Strobotach Wheatstone Bridge or Digital Ohmmeter Power _ Generation 1 1 Incorrect service or replacement of A WARNING parts can result in Jar
72. ne crankshaft as shown in Figure 3 3 It is factory adjusted to close and shut down 60 heriz units at 2200 90 r min 50 hertz units at 900 r min 90 r min An overspeed condition grounds the shutdown circuit on the Engine Monitor Board and trips the fault breaker After the problem is corrected starting will not occur until the fauit breaker is reset ADJUST SCREW AIR GAP SWITCH CONTACTS 5 1514 FIGURE 3 3 OPTIONAL OVERSPEED SWITCH If necessary the speed range can be corrected by turn ing the adjusting screw thereby changing the magnetic air gap An accurate tachometer or strobotach is needed to check the overspeed trip point after adjust ment is made The air gap must not be less than 0 005 inch 0 13 mm Control Operation Trouble free operation of the control system should be the major concern of generator set service personnel Service personnel must thoroughly understand how the controls operate know how to make the proper adjust ments replacements or repairs ina reasonable amount of time ower 3 3 p Generation Prior to starting the generator set check the fuel supply engine oil level and all battery connections for loose or broken wires Figure 3 4 shows a schematic diagram for the circuits described in the following Starting Start Disconnect and Stopping sequences Relay contact references normally open NO and normally closed NC refer to position of contacts with the unit at rest
73. nnected to an engine sensor See Figure 2 1 Coolant Temperature Gauge Optional The water temperature should be in the range of 165 F to 195 F 74 C to 91 depending on the load and the ambient temperature TRANSFORMER REGULATOR GAUGE K13 Heater Relay A K11 START SOLENOID Ki4 FUEL SOLENOID 16 START DISCONNECT RELAY ENGINE MONITOR OPTIONAL GAUGES WATER OIL PRESSURE TEMPERATURE DC GAUGE VOLTMETER DC Voltmeter Optional Normal battery B voltage dur ing operation should be 13 5 to 15 volts on a 12 volt system 27 to 30 volts on a 24 volt system Start Stop Switch 11 Starts and stops the unitlocally Unit may be operated from an optional remote switch wired to the contro panel Preheat added to stop posi tion on later production sets Preheat Switch 12 Activates heater relay K13 to con nect battery B to the engine glow plugs prior to starting the engine 12 is not used on later production sets Fault Reset A manual reset breaker that shuts down the engine for low oil pressure high coolant temperature high exhaust temperature and overspeed option Emergency Stop DC Control Breaker A 15 ampere breaker providing protection to the control box wiring and remote wiring from short circuits or overload Also serves as an emergency stop switch ELECTRONIC REGULATOR BOARD RMER TRANSFO START STOP PREHEAT ELECTRONIC AC REGULATION SWITCH 11 AC REGULATION
74. ns fuel filters fuel pump and injection pump Okay 15 engine getting fuel Exhaust smoke should be blue white and fuel flaw steady from fuel return fine yes yes Does K1 fuel solenoid energize when S11 is in Start position Check circuit through S11 Test S11 per Is battery B applied to glow plug heaters when Checkout G Test K1 per Checkout F switch S11 is in Preheat and Start positions yes Incorrect fuel See Operator s Manual Check switch 311 per Checkout Check recommendations heater wiring eneration by any means is strictly prohibited FLOW CHART ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS AWARNING Many troubleshooting procedures present hazards that 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 START Check for a possible fault condition none check fault monitors S1 S2 S4 and fault breaker CB12 for improper wiring Is a fault condition indicated by fault breaker CB12 on control panel yes Test key switch S11 per Checkout G Check wiring Check fuel system Power 3 6 Generation Redistribution or publication of this document by any means is strictly prohibited REMOTE START CONTROL This control can provide starting and stopping from
75. o ground if abnormal operating conditions exist and trip the fault breaker 12 to stop the engine See Figure 2 2 Resistance units and switches in the monitoring and shutdown systems are sealed units and are not repair able When replacing a sensor do not use a substitute item since resistance units are matched to the gauge they supply Cutoff switches are close tolerance parts made for a specific application Oil Pressure Monitors Refer to Figure 2 2 for the location of the oil pressure sensors Oil Pressure Sender E1 Optional The sender resist ance changes with oil pressure and results in a reading onthe oil pressure meter The meter range is Oto 100 psi 0 to 700 kPa Low Oil Pressure Switch S1 This switch closes if oil pressure drops to 9 psi 62 kPa activating the fault breaker and stopping the engine Control Power Latch S6 This oil pressure switch closes at 5 psi 34 kPa and provides a latch function for the control circuits When closed the switch supplies a ground path for relay K12 on the engine monitor board Overspeed Switch Optional The mechanical overspeed switch is mounted on the front of the engine crankshaft as shown in Figure 2 3 It is factory adjusted to close and shut down 60 hertz units at 2200 r min 90 r 50 hertz units at 1900 r min 90 r min overspeed condition grounds the shutdown circuit on the Engine Monitor Board andtrips the fault breaker After the problem is co
76. on the bottom of saddle 17 Remove the generator field leads from the exciter 6 Remove capscrews securing the control box mounting saddle to the stator The contro box and saddle are removed as an assembly 7 stator leads through opening in bottom of con trol box and saddle as they are lifted free from stator Do not disconnect any engine DC control wires in the control box 8 Set control box and saddle on top of engine 9 Remove the end bell stud nuts and slide off the end bell and exciter stator It may be necessary to pry or jar the assembly loose from the main stator assembly rotor and slide the exciter off the rotor shaft 51495 FIGURE 5 7 END BEARING REMOVAL Power Redistribution or publication of this document Generation by any means is strictly prohibited EXCITER RECTIFIER ASSEMBLIES LOCK NUT AIR BAFFLE STATOR ASSEMBLY EXCITER STATOR G 1158 2 FIGURE 5 8 GENERATOR ASSEMBLY Power un 9 6 Redistribution or publication of this document Generation by any means is strictly prohibited 12 Gonnectall applicable control leads F1 F2 battery charging etc and verify that all connections are 1 Slide the exciter rotor over the generator shaft and secure woodruff key Install the exciter nutand apply torque values shown in Figure 5 9 13 Connect leads to the plug of the DC voltage regula tor mounted on the bottom of sad
77. pertorm service procedures Review safety precautions on inside cover page Is engine getting fuet Exhaust smoke should be blue white and fuel flow steady from fuel return line Check fuel system fuel tank level shut off valves fuel lines and connections fuel filters fuel pump and injection pump Okay yes yes Does K1 fuel so enoid and E5 fuel pump energize when 11 is in Start position 5 battery B applied to glow plug heaters when Check B circuit to K14 coil Test relay K14 per Preheat Switch is closed Checkout Test K1 fuel solenoid per Checkout A Check Preheat switch and heater relay Incorrect tuel See Operator s Manual K13 per Checkouts G and E recommendations Check heater wiring FLOW CHART C ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS AWARNING Many troubleshooting procedures present hazards that 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 START Check for a possible fault condition none check fault monitors 1 through 54 and fault breaker 12 for improper wiring Is a fault condition indicated by fault breaker on control panel yes no Does latching relay A11 K12 energize and contacts close when generator set comes up to operating
78. pport must be placed under the engine before removing stator from the vibration mounts feet clear during service and use the recommended 11 Remove stator assembly being careful notto touch service procedures or drag it on the rotor Place stator on its side in the horizontal position Disassembly 12 Usinga hoistand sling to supportthe rotor carefully remove the capscrews that attach the drive disc to battery to prevent accidental starting ofthe genera tor set while servicing 13 Remove the rotor assembly and place upon wood Accidental starting of the set block in the horizontal position The drive disc and fan should not be resting on anything or distortion AWARNING can cause severe personal may occur 9 eng injury or death Disconnect the battery cables negati ve lead first when repairs are made to the 14 Remove bolts that hold the drive disc and fan to the engine controls or generator rotor shaft Remove bolts holding drive disc to the fan 2 Remove cover from the control box and disconnect clearly identify reconnection mark leads with tape The end bearing will be dam 3 Remove end bell cover and remove field leads F1 A CAUTION aged if pulled and F2 If reused the bearing must be pulled on the inner race 4 Remove load wires and flexible conduit from control box 16 Clamp the rotor in a fixed position and remove the exciter rotor lock nut 5 Remove leads from the plug of the DC voltage regu lator mounted
79. ra personal injury death and or equipment damage Service per sonnel must be qualified to perform electrical and mechanical service SAFETY CONSIDERATIONS Always consider the safety aspects of any service procedure Generator sets present several safety hazards that the service person must be aware of to safely complete the job Read through the safety precau tions listed on the inside cover and familiarize yourself with the hazards shown in Table 1 1 Once the hazards are known approach the job with a safety conscious attitude Being safety conscious is the most effective way to avoid injury to yourself or others Reduce the chance that an accident will occur by adopting the following safeguards Safequards to Avoid Hazards Use personal protection Protect your body by wearing the appropriate safety equipment Protec tive clothing includes safety shoes gloves safety glasses and hard hats Leave rings and jewelry off and do not wear loose clothing that might get caught on equipment Work to Reduce the Hazard The workshop area and all pieces of equipment used can contribute to reducing the hazard potential Keep guards and shields in place on machinery and maintain equip ment in good working order Store flammable tiq uids in approved containers away from open flame spark pilot light cigarette or other ignition source Keep the workshop clean and well lighted and provide adequate ventilation Keep fire extinguisher
80. re The gauge has a range of Oto 100 psi 0 to 700 kPa and is connected to an engine sensor Preheat Stop Run Start Switch 511 This is a key switch that preheats starts and stops the generator set locally Fault Reset Breaker CB12 A manual reset breaker that shuts down the enginefor low oil pressure high coolant temperature and overspeed K1 Fuel Solenoid It opens the fuel control valve when the start stop switch is placed in the Start position RUN START SWITCH 11 ELECTRONIC 5 1515 1 REGULATOR BOARD OPTIONAL GAUGES WATER TEMPERATURE ELECTRONIC OIL PRESSURE GAUGE AC REGULATION PREHEAT STOP RUN START SWITCH 511 FAULT 01 12 5 1448 FIGURE 3 1 ELECTRIC START AND LAND SET CONTROL BOX Power _ Generation 3 1 Redistribution or publication of this document by any means is strictly prohibited HIGH COOLANT TEMP SWITCH 52 Gus F1 LEN JW Ae CM In Line Fuse 30 ampere fuse is located in a fuse holder connected to the B terminal of the starter This fuse connects to the contro and opens if a short or overload should occur Resistance units and switches in the monitoring and shutdown systems are sealed units and are not repaira ble When replacing a sensor do not use a substitute item since resistance units are matched to the gauge they supply Cutoff switches are close tolerance parts made for a specific application Oil
81. remote locations when connected to optional acces sory equipment The following text explains control conponents function control operation and trouble shooting Oil Pressure Gauge Optional Shows engine lubricat ing oil pressure The gauge has a range of Oto 100 psi 0 to 700 kPa and is connected to an engine sensor See Figures 3 5 and 3 6 Coolant Temperature Gauge Optional The water temperature should be in the range of 165 F to 195 F 74 to 91 depending on the load and ambient temperature DC Voltmeter Optional Normal battery B voltage dur ing operation shouid be 13 5 to 15 volts on a 12 volt system 27 to 30 volts on a 24 volt system Preheat Switch S12 Activates heater relay K13 to con nect battery B to the engine glow plugs prior to starting the engine Start Stop Switch Starts and stops the unit locally When released unit may be operated from a remote switch wired to the control panel DC Control Breaker CB11 15 ampere breaker provid ing protection to the control box wiring and remote wiring from short circuits or overload Also serves as an emergency stop switch Fault Reset Breaker CB12 A manual reset breaker that shuts down the engine for low oil pressure high coolant temperature high exhaust temperature and overspeed Battery Charge Breaker CB13 RV Generator sets A 15 ampere breaker protecting the DC voltage regulator alternator and wiring from short circuits or overload
82. rrected starting will not occur until the breaker is reset necessary the speed trip point can be corrected by turning the adjusting screw to adjust the magnetic air gap see Figure 2 3 An accurate tachometer or strob otach is needed to check the overspeed trip point after adjustment is made The air gap must not be less than 0 005 inch 0 13 mm Engine Temperature Monitors Refer to Figure 2 2 for the location of the engine temperature sensors Coolant Temperature Sender E2 Optional The resist ance of the sender unit changes with the engine coolant temperature and causes a reading of the Water Temp Meter The meter range is 100 F to 250 F 40 to 121 C High Coolant Temperature Switch S2 This switch closes if the coolant temperature rises to 222 F 106 C activating the fault breaker and stopping the engine High Exhaust Temperature Switch S5 This switch is mounted on the exhaust elbow and it closes on temper ature rise above 230 F 110 C activating the fault breaker and stopping the engine It will open again when the temperature reaches about 190 F 88 High exhaust elbow temperature is caused by insuffi cient or lack of sea water flow Sea water flow at the exhaust outlet should be about 3 gal min 11 litre min ADJUST SCREW AIR GAP SWITCH CONTACTS ES 1514 FIGURE 2 3 OPTIONAL OVERSPEED SWITCH CONTROL OPERATION Trouble free operation of the control system should be the major
83. s reconnection possibilities Information is also found on the individual model wiring diagrams in Section 8 of this manual Redistribution or publication of this document by any means is strictly prohibited Transformer Regulation 50 Hz 120 240 VAC 110 220V 115 2301 RECONNECTION LJ J LJ SHOWN FOR RECONNECTION T3T1T2 120 V 60 Hz DIAGRAM 115 V 50 Hz SHOWN FOR o 120 240 V 60 Hz 2 115 230 V 50 Hz ww sf LO Ic 2 n H3 SEE C22 4 NOTES 72 i 2 WIRE 47 41 OUTPUT 1 12 15 OUTPUT 2 15 Adjust Output Voltage Move Taps T21 According to Following Charts 03 04 120 20 240 2207 OTP YT 1 0 1207240 102207 5 572530 1 120120 240 POSITION POSITION TAP POSITION POSITION 52 VOLTAGE TAP POSITION TAP POSITION TAP POSITION POSITION VOLTAGE tx 52 ADJJSTMEST pew OxD 7 NOKO OX 1 N REASE X2 X3 x3 X3 J NCRESSE 2 X8 3 x8 gre xt x2 2 c BR NM 227 1 I ECREASE x2 Ta XI Xi X4 DECRE ASE x 4 2 X4 _ ______ b FOR 15 230 115
84. speed Check for ciosing of S6 power latch switch lf Okay replace engine monitor PC board yes Does DC contro breaker trip after generator 5 set is Started Check wiring for shorts fo ground Power 3 1 2 Redistribution or publication of this document Generation by any means is strictly prohibited Section 4 Engine Control Service GENERAL The following component checks are referenced in the Control Troubleshooting fiow charts They are an aid to isolating circuit problems caused by faulty engine trol components Disconnect leads before testing componenis Many troubleshooting procedures AWARNING present hazards that can result in seyere 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 A BATTERY CHECK Battery electrolyte can cause severe AWARNING eye damage and burns to ihe skin Wear goggles rubber gloves and a protective apron when working with batteries Check charge condition of the battery with a hydrome ter The electrolyte specific gravity should be about 1 260 for a fully charged battery at 80 F 27 C If not add distilled waterto keep electrolyte at proper level and recharge the battery If battery will not recharge replace it If battery loses excess water the charge rate may betoo high
85. t breaker CB12 circuits K16 Start Disconnect Relay Located on the relay mounting tray It is connected through CR11 to the 12 voit battery charging alternator The relay actuates at about 6 volts DC The K16 and CR11 diode are not used on later production sets and were disconnected on some sets refer to Product Support Bulletin 450 Redistribution or publication of this document by any means is strictly prohibited Generation TRANSFORMER REGULATOR OPTIONAL REGULATO R BOARD FIELD BREAKER C821 ELECTRONIC REGULATORS ONLY K13 HEATER RELAY a K11 START 2 SOLENOID K14 FUEL SOLENOID K16 START DISCONNECT RELAY ENGINE MONITOR BOARD OPTIONAL GAUGES OIL PRESSURE DC TEMPERATURE GAUGE GAUGE VOLTMETER REMOTE CONTROL CONNECTION J3 UNDER FLANGE OF CONTROL BOX RV GENSETS ONLY ELECTRONIC AC REGULATION TRANSFORMER AC REGULATION RUNNING START STOP PREHEAT ES 1513 TIME SWITCH 811 ES 1513 2 STANDEN METER GENSET PREHEAT SWITCH 512 RESET CB 11 BREAKER 12 START STOP PREHEAT DC CONTROL SWITCH S11 BREAKER CB11 RV GENSET TRUCK GENSET AUX RUNNING FAULT BATTERY PREHEAT TIME RESET CHARGE SWITCH 512 METER BREAKER CB12 BREAKER EARLY PRODUCTION CB13 ONLY FIGURE 3 5 DKD RV CONTROL BOX COMPONENTS Pow 3 8 Redistribution or publication of this document Generation by any means is strictly prohibited
86. tage ts unstable high or Jow or causes breaker to trip See Flow Charts B C D or yes s residual voltage across stator leads 51 Flash exciter field per TEST D Does and S2 2 5 to 5 VAC or more generator output voltage build up yes no stator leads S1 and 52 Is residual voltage across the leads 2 5 to 5 VAC or more now Does bridge rectifier CR21 test okay per test C no Does suppressor assembly RV21 test okay per TEST Check lead continuity between TB2 2 and 8 1 on generator and TB2 H1 and 7 4 per TEST Mi Replace CR21 Test transformer 21 per Check diodes CR1 through CR6 TEST N Replace if bad Replace RV21 on rotor per TEST G Replace if bad Test exciter stator per TEST H Replace if bad Check exciter rotor winding per TEST J Replace if bad Check generator rotor field winding per TEST L Replace if bad Check generator stator windings per TEST Replace if bad Power 22 6 4 Redistribution or publication of this document Generation by any means is strictly prohibited FLOW CHART UNSTABLE VOLTAGE ENGINE SPEED STABLE ELECTRONIC VOLTAGE REGULATOR AWARNING Many troubleshooting procedures present hazards that 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 pr
87. vi GB 5 5 Power Redistribution or publication of this document Generation by any means is strictly prohibited Table of Contents Continued SECTION TITLE PAGE GENERATOR REGULATOR TROUBLESHOOTING i seen ee yee sees 6 1 cc inveavies 6 1 Troubleshooting Procedures 6 2 A NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM ELECTRONIC VOLTAGE REGULATOR 6 3 AC OUTPUT VOLTAGE AT RATED ENGINE RPM TRANSFORMER VOLTAGE 6 4 UNSTABLE OUTPUT VOLTAGE ENGINE SPEED STABLE ELECTRONIC VOLTAGE 6 5 D OUTPUT VOLTAGE TOO HIGH OR TOO LOW ELECTRONIC VOLTAGE 6 5 OUTPUT VOLTAGE TOO HIGH TOO LOW OR UNSTABLE TRANSFORMER VOLTAGE 6 6 FIELD BREAKER CB21 TRIPS ELECTRONIC VOLTAGE REGULATOR 6 7 G UNBALANCED GENERATOR OUTPUT VOLTAGE TRANSFORMER OR ELECTRONIC VOLTAGE REGULATOR 6 7 7 GENERATOR REGULATOR 8 5 7 1 Ch 7 1 A Testing AC Residual 7 1 B Testing Commutating 7 1 C Testing Rectifier Bridge CR21 and Suppressor RV21 7 1 Di Flashing Rea
88. when B is applied the fuel solenoid must be replaced When is removed 3 Continuity should be read across the two large ter the solenoid must de activate minals while solenoid is activated SWITCH CHECK 1 Remove battery cable 2 Place ohmmeter leads across switch 3 close switch while observing the ohmme ter A normally open NO switch should indicate infinite resistance when open and continuity when closed A normally closed NC switch should indi cate continuity when closed and infinite resistance when open 4 Replace switch if defective pd Power 4 2 Redistribution or publication of this document Generation by any means is strictly prohibited section 5 Generator Voltage Regulator GENERAL DESCRIPTION The YD generator Figure 5 1 is a four pole revalving field brushless exciter design with drip proof construc tion Single and three phase generators are available for both 50 and 60 hertz models The generator rotor is directly coupled to the engine flywheel with a flexible drive disc engine speed deter mines generator output voltage and frequency cen trifugal blower on the drive disc circulates generator cooling air which is drawn in through the end bell and discharged through an outlet in the blower end DRIVE BLOWER DISC m YOTA O a nie STATOR ball bearing in the end beli supports the outer end of the rotor shaft The end bell is attached w

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