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1. i SNINA mt 2209 219 FIGURE 36 SINGLE PHASE AC CONTROL WITH OPTIONAL METERS 46 U313fOH2V1 21812313 NY 39019 38un19334N31 710 2919333 390 9 99 WNOMdOE SANIT Z 11 RI 031038802 5 BUY 01302 45 TEE HOULISOd Q221983N3 30 NI NMOHS 21 209 219 MVECTIQ ONINIM 2 135 N39 0H1N02 20 LI 8 gt 001 81 gt 5 71Y 0310N 3SIA2 3H10 55374 kO 310N 01 Iom pa O G ua 6 120 ae 2 200016 wz 2 ri ie mis 176 _ e ERE LEES m C RA gt gt QICGY 9H HOS utis 209 A08 242 SH 09 0 2 661 94030 22 4742 3 THOS 1409 ricos THOS IH O9 1903 9H 2H OS 022 0 09 0227221 09 0 2 021 US 3 xix Eie ma 39nw9 20 39099 3a saonyvo 30 3909 da M1407 3S5YHd in nos n mee ees He abet DEL 59 1 2 3ION HOS IH 067 7s 9H tH 09 02 1 ISEN 19 015
2. 6 V Battery DC Voltmeter DC Voltmeter with Resistor Lead Reading less than scm a avons sc Aca avons Apply temporary juniper from AC1 to G1 to test SCR1 Remove jumper and read voltmeter see Figure 15 Apply temporary jumper from AC2 to G2 to test SCR2 Remove jumper and read voltmeter See Figure 15 24 Redistribution or publication of this document by any means is strictly prohibited The winding schematic Figure 17 shows the resist G ance values for the individual coils in ohms Resist ance between any primary and secondary leads TESTING ROTATING RECTIFIERS from any lead to transformer frame should be infinity NAE Two different rectifier assemblies make up the rotat ing rectifier bridge assembly Figure 18 Using an accurate ohmmeter test each CR using negative and H1 H6 positive polarities Test rectifiers as follows 1 Disconnect all leads from assembly to be tested P 2 Connect one test lead to F1 stud and connect other lead to CR1 CR2 and CR3 in turn record 333 407 OHMS 303 371 OHMS NES resistance value of each rectifier H3 3 Connect one lead to F2 stud and connect other 282 344 OHMS lead to CR5 and CR6 in turn record resist H2 un ance value of each rectifier 270 330 4 Reverse ohmmeter leads from steps 2 and 3 and toe record resistance value of each rectifier 1 to e 1 CR2 and
3. 4 9 k w ES M7 gt N 5 5 4 DASHED LINES ARE WHEN USED TEA NOTHING OL 6 HEMATIC QUA 6 2 602 j 70 AC DIAGRAM 745 0 785 9 FIGURE 47 NINE LIGHT DC CONTROL SCHEMATIC 51 Redistribution or publication of 5 document by any means is strictly prohibited 1 300 250 y 9 TUM 9 0162 00E 53 10 39355 2 48 1 LINOW 3NI9N3 LON 1WwHS 50431 4 HO QNY LNIOF 420105 72 peser JHL df ONINDIM 30105 OL 03830106 JAWM 3UY 4935 9 3 005 40 431 830105 LY EO ti e _ 51920040102 3 10 TW 33124 43930105 ONVH 39 OL 3uY EF PIP 9 03430105 HS LINJN mum poa tnu 33 15310N 1102312 9021154 HOW 5H3 N33N25 115 53AY 38 1 31039 2 4015 I 56 12514 18154 401 spin TOT 422415 ase 3702 30112 Y2 5 YILIN 105 3303 28v1 0112 4 2 30010 10121H892 e ser wit a 9 ri e Et eit if E E TM o 6 Q9 060 11 13 205 HAQQ 010H 44134 9 1
4. p d USE 197 Lr E mean n ca Le OA U313WONIN3IOd 1 CZW se na ES NU j EOKA T 2 LS ie ee ro IN02 n3jixsxus Td 150275332253 es 140 771722587 9 43502 50 eee ee ee E 1 EE Tn lyziiH 2y sp3HYVH EEEE i eos Ho0r 9 2 WiRV a st ee ro0s 0 2v rrY sisa 7150 _ L Q8 ep fr ooro 2ov rwv 100900050197 110A U313m If zzn LL wlan __ 0 xix 1 al E D 2 iq t 125 ABIATWiISHAV smrl 2 12544 MENDES DL ASS 1 121 u31X3 RESUME E Jv 3SVHd JINIS ___ 27 z x L AY 9 Hi VIWYOsSHYME 4 221212 8 1 Y 11583 2077 SM 2 200212 137 D 958227 2 11112 333 20 01 iT yates 1 12151 9 8 281
5. 900 0336 8 83 Replaces 900 0336 7 82 Printed in U S A o Service Manual DILG DIL TT Generator and Controls Redistribution or publication of this document by any means is strictly prohibited Safety Precautions The following symbols in this manual highlight con ditions potentially dangerous to service personnel or equipment Read this manual carefully Know when these conditions can exist Then take necessary steps to protect personnel as well as equipment This symbol is used throughout the manual to warn of possible serious personal injury This symbol refers to possible equipment damage PROTECT AGAINST MOVING PARTS Avoid moving parts of the unit Avoid use of loose jackets shirts or sleeves due to danger of becoming caught in moving parts Make sure all nuts and bolts are secure Keep power Shields and guards in position If you must make adjustments while the unit is _ running use extreme caution around hot manifolds moving parts etc Do not work on this equipment when mentally or physically fatigued GUARD AGAINST ELECTRIC SHOCK Disconnect electric power before removing protec tive shields or touching electrical equipment Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp wh
6. Does adjustment of Voltage Adjust contro R23 on control panel result in correct output voltage Set control per Voltage Calibration Adjustment P yes no Does adjustment of control R36 on VR21 result in correct output voltage yes Set per Voltage Calibration Adjustment P no Are reference transformer T21 tap connections correct and secure on TB1 See TEST Q The new printed circuit board might be damaged by malfunctioning components within the control Do not install the new PC board until all other problems have been located and corrected Are generator output leads properly connected See Figure 26 Test voltage regulator assembly per procedure T Replace the regulator PC board per procedure F if defective 21 Redistribution or publication of 5 document by any means is strictly prohibited FLOW CHART D EXCITER FIELD BREAKER TRIPS SWITCHING VOLTAGE REGULATOR Does AC output voltage build up to 150 or Ch i eck for any loose or broken wires or connections more of rated voltage before breaker trips on VR21 assembly NOTE High voltage will usually damage the regulator board Complete all recommended checks before replacing the PC board Check reference transformer T21 and connections per TESTS E and Q Replace if bad Check diodes CR1 2 3 4 5 ana 6 in rotor per TEST G Replace if bad Check generator stator lead
7. 30010 9 21 13222222 ee ete tt HF 80151530 wo1sisau 60 600090 Po 9 9 9 9 6 a E 1 00151533 se 06060909009 PB WMOMLIN 14 17301 21 MAO NMOMISN 538 91 21 A31CYKYN9O34 21 NOML11N 53 1001 21 3969 21 313H32Z 30010 2 22 26010 4747 2 50151529 Rot 2 1 4 1 0161534 6 t Ni 6 6 6656 E Hi St OPOOOOOG 7 Se 4 E m ES d ES 4 1 e 4 1 11 4 6 eel 5 mm q ER ZEAL 9313139 ice 26 4 qz 1100 065 12 WILIS 10 f 9 D D 200 PED ERE _____ __ 9 40 32v3snS QNOA38 NVHL 330W 153 108 5 50 31 YO QANY 830105 72 215 9 JO AWIL 4 005 40 9432 830105 9 WILI 03430105 3H TAYHS 4 08 LINW 74 ISILON 5 x 212 FLOW 38 B25 eis i aes 253 AVIA 3318715 er
8. K1 START SOLENOID ES 1312 FIGURE 31 ENGINE CONTROL RELAYS AND SENSORS Oil Pressure Monitors Refer to Figure 31 for the location of the oil pressure sensors The oil pressure sender resistance changes with oil pressure and results in a reading on the oil pressure meter The meter range is O to 100 psi O to 700 kPa The low oil pressure switch closes if pressure drops to 14 psi 97 kPa stopping the engine and activating the optional low oil pressure fault lamp The optional pre low oil pressure switch closes at 20 psi 138 kPa and turns on the amber Pre Lo Oil Pres lamp The engine does not shut down but the warn ing lamp remains on until the Resetswitch is pressed Engine Temperature Monitors Refer to Figure 32 for the location of the engine temperature sensors 3 The resistance of the temperature 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 121 C The high engine temperature switch closes if the cool ant temperature rises to 222 F 106 C stopping the engine and activating the red Hi Eng Temp light The optional pre high engine temperature switch closes at a nominal 2169 F 102 C and turns on the amber Pre Hi Eng Temp lamp The engine does not shut down butthe warning lamp remains on until the Reset switch is pressed Theoptional low engine temperature switches closes if coolant temper
9. 5 SEEISEISSIPREISIS y 0 14 TBI 4 ame a 2 RESISTOR ASSY ol HARNESS WIRING REACTOR ASSY COMM TERMINAL BLOCK MARKER STRIP TRANSFORMER VOLT TII SCREW RHM 6 32 X 3 8 NUT HH ET 6 32 SCREW 6 32 5 6 WASHER LK 90 SCREW RHM L 32 X 1 4 BOARD ASSY PANEL VOLT REGLTR MTG DESCRIPTION OR MATERIAL ONON s A REGULATOR ASSY VOLTAGE ES seme 1 1 _ roterendedtooner f 305 0655 3 D w o 01 WITH 21 Y ______ aape 0209 2 2 272 6020 TINVS JO 14112 20 LAO 1 E 2 215 115 zm m 7 00721 92 pere e ae PE dd PTFE gt s 77 L4 ls 119 iii SUH IH 4 5 23 L 49 5 tris 401122402 OH Lo 20 I om po2 9 9 er Ue 1 im YOR VOSLO LO NOLA E 27411 var IV 9002287 LON 6700 SIIN IY OL 0 191 FAM
10. H OS 0 2 51 uoc 9H 7H OS AO22 011 0739 LYVHD 39V110A 838 H 2 1 01 2 2 L HOUT ZIM QY31 LOINNOD 310N e a M 23 ME E 83112 3 i i a a u01YH2N30 i 1 582 r i 4 ee Y Y Y 1 i t 1 i 9 B 5 1 1 1 BEEN E f H i TALES E n 4 Ege a 4 ____________________ 109100 2d L At Se E 1 11 1 82 92 1 l f p 4 9 1 ZIM 550080 68945 a T tz gt 20 OL 812209 219 WVHOVIQ FIGURE 41 SINGLE THREE PHASE AC CONTROL Redistribution or publication of this document 91 by any means is strictly prohibited W01YEO2NO NYKO dO NMOISIMQ Y 7 Pim zs oru mun a a 918 31138 LIGA 1344 34 ASSY 0308 122 0 25 9 t v 1 43895 7727 200 zo 32018 781 28 13 3 5 25 3 I R ANH 25 9 X 8 6 83495 83 40345 1 721 825 390148 72227 2 9 504 3025 R02 ASSY 4012 3
11. 7 gz s 00i20 0 0 TM Hime 7 i C721 2 LT TZ Orie SEM 7 22 322 A iB OCHO Warsaw 3 1289 27 2IIVW3SHOS 3SVHd 33891 z 19 11 x R7 TOI t ASY viuo 7 Ot CJ 1411972 428 M pan te ZETEC AD Es RO 300 H3WEOTER VEI 9 201 12 SEE EL ELM LAN ae 6 116530 2344 1511 INAANO BOLVH3N35 8 113 nvuovig 20 OL 209 cI9 FIGURE 37 THREE PHASE AC CONTROL WITH OPTIONAL METERS 4 PE EE ELT 2 9044 5526 tye ee 27476 cu 1 Oe TUO HT olo aros SHH 21010 lov N OL ane Cay VED 9 3 SYM On 1300 0105411 Ep x k EEEN HELIVIIAG YO 39773 710 MY OOI SI pom 203433 NV IONNS 75079 20 7 40 3 341 NI 0312300002 TV 50 02 0 HOMISO4 Q32iDH3N3 30 5 S IN3HO
12. 3 Test regulator according to the steps in Table 5 Terminal 8 may be used as the chassis ground connection 32 CR2 82 AS SWITQHING ue E op 0059 m CR4 FD ur Jn Rm L sii EROR 12 VDC 4 s ad mri R34 R35 R36 VOLT ff OSCILLOSCOPE TEST PATTERN ES 1422 FIGURE 28 SWITCHING VOLTAGE REGULATOR TEST SCHEMATIC Redistribution or publication of this document by any means is strictly prohibited TABLE 5 SWITCHING REGULATOR TEST V1 AC Input Voltage V2 V3 and V4 DC Output Voltages 01 and 02 Oscillation Bandwidth Step Procedure Requirements Set R5 at midpoint and turn H36 fully CCW Set V1 to 208 VAC V2 shall be 105 125 VDC V3 shall be 2 5 VDC 01 shall be 30 60 microseconds 02 shall be 330 390 microseconds Connect jumper wires W as shown Figure28 Adjust R36 fully V3 shall be 4 4 4 8 VDC Adjust R36 fully CW V3 shall be 7 0 7 8 VDC Adjust R36 until V2 falls to 10 VDC Max Wait 5 seconds then proceed to step 3 Adjust V1 to 200 VAC wait 5 seconds V2 shall be 105 125 VDC Adjust V1 to 210 VAC wait 5 seconds V2 shall lt 10 VDC Set V1 to 208 VAC V4 shall be 11 5 12 5 Must be steady with no drift 33 Redistribution or publication of this document by any means Is strictly pro
13. 5 THOG 0987022 ugig OS AO6I 01I OL OOW AE X 01012 HOS ASip Ov2 OS 02 021 EEG ESAE 220 2 210 07006 SH THOS AObb 952 tcni r 05 7022 121 E CHY Z9 01 2 2 74 291 GL 2 SNOILD3NNOD 35Y11304 MCA 310N OE xn Fe 9158 bisa 9 p 1 h 11 WYuovia 01 62 J 1 CATT UEM EA yao 1 1 pe a 5 EZY 4 4 3 Tt 2 2 2 WYNSYIO 20 OL ape A ix g oJ 71 _ 09 17 rmn n CLRI t TT E OF R IATER AECE G1 ee eee eras EE HERREN 0 4UvVATO QUVOS 34 iil 13894 30 902 C zu b T A JN EJ ETE 2549 1100 H13242931 5 7 T T UNI Quom 28 140 72y7502 11h Yd I 9150 5150 p ha ia WYHu5YK 20 Ol t SIT 0V17 Ti 27A mel em EE CY BOlSiS3H 1 224 11 23 0624 Ged ame d OtZd 64 624 22d 128 DLW Avida 13xovsd Te ay Sy S538VVH A 910 75 098 0 027 0 2y Wmv Il A OS CH OOE O O0I 0 OV WHY T OS1 O Gi O 2V FwY t
14. CONTROL BOX TO OC DIAGRAM GENERATOR OUTPUT BOX F2 FI IAGRAM VR I VRA2 Hi EXCITER CONNECT LEAD WI2 FROM TERMINAL 52 2 TO 762 H_ PER VOLTAGE CHART BELOW 3 58 1t0 220V 50 Hz H6 R 115 230 50 Hy H61 t20 240v 60 Hz H3 VOLTAGE CONNECTIONS 3 PHASE 127 220V 50 Ht H5 120 208V 50 Hr H4 110 190 50 Hz 15 200V 50 Hr 4 120 208 60 He H3 12722207 Hz H4 139 240 60 Hr H5 558 254 440V 50 H5 240 4165 V 50 Hz H4 220 380 50 H3 230 400v 50 Hr H4 240 416 V GOHz H3 2354 440v COH 14 27 1 480V 60 H5 XII A TO OC DIAGRAM SISREIS 250v 50 LH6 THREE PHASE SCHEMATIC DIAGRAM AC ExCtTER 1 PHASE uO 220V SO HG i RI O 240V GO Hr Ui5 PARYS IST oet GENERATOR __________ Fees C ERE 283 4 EJ H RAMS OEHUC CUERDUT d 4237 kw ___ henan r aeren e Te 1 TRANSFORMER VR2I PC BOARD VOLTAGE NOLTR a AuM AC 0 500 100 18 24 kw _ 4 um ii SPRING RELAY HOLODOW endete ALLEE LAMPHOLDENR ee UM PRXEL CONTROL OPTJOWAL fre ae
15. OUTPUT SS TERMINAL YELLOW by TO TERMINAL 26 TERM FIGURE 35 ALTERNATOR GROUND ES 1319 ALTERNATOR CHECKOUT With the engine running check the battery charge rate DC ammeter If the alternator is operating prop erly the ammeter should show a slight charge grad 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 shorted and should be replaced 43 Redistribution or publication of this document by any means is strictly prohibited If the output voltage is low equals battery voltage the problem could be worn or broken brushes an open regulator or an open field diode Refer to Motorola Service Manual 25 183 for more detailed test and service procedures D SOLENOID CHECKOUT 1 Apply battery positive B to the terminal marked S 2 Jumper a ground wire to the solenoid mounting bracket Solenoid should activate 3 If the contacts are good 12 volts should be read between terminal and ground The voltage drop measured across the contacts should never exceed one volt in circuit application RELAY CHECKOUT 1 Connect 12 volts across relay coil terminals Relay should activate if coil is okay 2 Connect a 12 volt source to one side of relay contacts 9 Connect a voltmeter to other side of relay contact and 12 volt source If 12 volts appear when relay e
16. yes no Does adjustment of control R18 on VR21 result in correct output voltage Set per Voltage Calibration Adjustment P no Are generator output leads properly connected See Figure 26 Are reference transformer T21 tap connections correct and secure on TB1 See TEST 0 The new printed circuit board might be damaged by malfunctioning components within the control Do not install the new PC board until ail other problems have been located Test voltage regulator assembly per and corrected procedure S Replace the regulator PC board per procedure F if defective 11 Redistribution or publication of this document by any means is strictly prohibited FLOW CHART D EXCITER FIELD BREAKER TRIPS STANDARD VOLTAGE REGULATOR START Does AC output voltage build up to 150 or more of rated voltage before breaker trips no Check diodes CR1 2 3 4 5 and rotor assembly per TEST Replace if bad Check exciter stator winding 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 The new printed circuit board might be damaged by malfunctioning components within the control Do not install the new PC board until all other problems have been located and corrected 18 Check for any loose or broken wires or connections on VR21 assembly Check diod
17. Check K1 start solenoid K2 on off relay K3 and K11 start disconnect relays S10 switch and all connections See Checkouts D E and G With 510 in Start position does start solenoid K1 energize 15 at least 7 volts DC present between K1 terminal S and ground yes Is at least 7 volts DC present between B1 starter solenoid terminal and ground Check wiring and connections between K1 terminal and the solenoid terminal B1 41 Redistribution or publication of this document by any means is strictly prohibited FLOW CHART B ENGINE CRANKS BUT DOES NOT START START Check fuel solenoid Test F and related wiring Does K3 fuel solenoid energize when 510 is in Start position yes Is engine getting fuel Exhaust smoke should blue white and fuel flow steady from fuel return line Check fuel supply system fuel tank shutoff vaives fuel lines and connections fuel filters and transfer pump yes Check heater solenoid K2 and switch S11 per Checkouts HS D and G Check wiring and heater elements 15 preheat system operating properiy yes Incorrect fuel See Operator s Manual recommendations FLOW CHART C ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS START Check for possible fault condition If OK check S1 engine temp switch 56 overspeed switch S3 oil pressure switch Check K1 fault
18. Silicon NPN Transistor Unijunction Resistor 1 2 Watt 47 Ohm Resistor 1 2 Watt 33 Ohm Resistor 2 Watt 4 7 Meg Ohm Resistor Fixed 10 Watt 270 Resistor Fixed 15 Watt 5 000 Resistor 1 2 Watt 3 000 Ohm Resistor 1 2 Watt 330 000 Ohm Resistor 1 2 Watt 51 100 Ohm Resistor Fixed 5 Watt 15 000 Ohm Resistor 1 2 Watt 90 900 Ohm Resistor 1 2 Watt 10 000 Ohm Resistor 1 2 Watt 220 000 Ohm Resistor 1 2 Watt 100 000 Ohm Resistor Metal Film 1 4 Watt 11 000 Ohm Potentiometer 5 000 Ohm 1 2 Watt Resistor 1 4 Watt 28 000 Ohm Resistor Metal Film 1 4 Watt 5 110 Ohm Resistor Metal Film 1 4 Watt 8 870 Ohm Resistor 2 Watt 10 000 Ohm Potentiometer 1 2 Watt 100 000 Ohm Resistor 1 2 Watt 47 Meg Ohm Terminal Block Diode Zener 24 Volt Fuse Relay Magnetic Reed Resistor 2 Watt 6 800 Ohm 56 1 tmm T TTT 7 Oates mw REIR t f C FIGURE 5 REGULATOR PC BOARD 332 2044 M M quam ee mt m an an aa Ur m m SD OS roe Hm rh n m n re Sey o m m m ES SS R D WE eub G D D NEN EG Qua YP 479 E pe
19. Push to reset breaker Does generator AC output voltage build up ED posta to trip see Flow Charts Flash exciter field per TEST D Does Is residual voltage across TB2 2 and H1 generator output voltage build up 5 to 10 VAC or more TESTS B and E Is exciter field voltage across TB1 5 amp 6 5 VDC or more Check exciter field wiring harness per TEST M Replace bad wiring Check exciter field winding per TEST H Replace if bad Check reactor L21 and transformer T21 per yes Check diodes and SCR s on bridge assembly CR21 per TEST C Check fuses F2 and F3 for continuity on VR21 regu lator PC board Check exciter field wiring for shorts per TEST M Heplace bad wiring Test voltage regulator assembly per procedure S Replace the regulator PC board per procedure F if defective new printed circuit board might be damaged by malfunctioning components within the control Do not install the new PC board until all other problems have been located and corrected 16 Disconnect stator leads 7 4 and 8 1 from TB2 2 and H1 Is residual voltage across leads 5 to 10 VAC or more now Check lead continuity between TB2 2 and 8 1 on generator and 2 1 and 7 4 per TEST M Check diodes CR1 through CR6 on rotor per TEST G Re place if bad Check exciter rotor winding per TEST J Repiace if bad Check gen
20. This manual has separate sections for the generator and voltage regulator engine control and associated wiring diagrams While the wiring diagrams the end of the manual are included to help trace or isolate problems it is suggested that service personnel use the wiring diagrams shipped with the unit for trouble shooting Repair information for printed circuit boards is not extensive because the solid state printed circuit boards lend themselves more to replacement than repair Application of meters or hot soldering irons to printed circuit boards by other than qualified person nel can cause unnecessary and expensive damage Repair of the printed circuit boards is not recom mended except by the factory A return and exchange service has been initiated whereby faulty printed cir cuit boards can be returned to the Distributor and exchanged for good units For more information contact your Onan Distributor High voltage testing or high poten tial or Megger testing of generator windings can cause damage to solid state compo nents Isolate these components before testing TEST EQUIPMENT Most of the test procedures in this manual can be performed with an AC DC multimeter such as a Simpson Model 260 VOM or a digital VOM Some other instruments to have available are Onan Multitester Wheatstone Bridge Kelvin Bridge Jumper Leads Onan Load Test Panel Variac AC Voltmeter DC Voltmeter See Tool Catalog 900 0019 IN
21. and F2 to CR4 CR5 and 84 5 All theresistance readings should be high in one test and low in the other test If any reading is high 531 649 OHMS or low in both tests rectifier assembly is defective 1 X2 6 Replace defective rectifier assembly with new vR21 9 vR21 10 identical part Use 24 Ibs in 2 7 Nem torque when replacing nuts of F1 and F2 FIGURE 17 T21 WINDING SCHEMATIC CR1 CR2 CR3 CR4 CR5 and CR6 OHMMETER fw F VR21 REPLACEMENT Use the following procedure for replacing the voltage MD regulator PC board or VR chassis y 1 Stop engine 2 Disconnect and if necessary label wires Refer to AC control wiring diagram 3 Remove four screws at corners CRS 4 Remove old PC board 5 Install new PC board secure with four screws FIGURE 18 TESTING ROTATING RECTIFIERS 6 Reconnect wires removed in step 2 at proper terminals RE TESTING EXCITER STATOR See Test Procedure Q Testing the exciter stator Figure 19 for open or 8 Adjustthe voltage and stability potentiometers as shorted windings and grounds as follows indicated Standard Regulator Turn R18 fully counter clockwise and R26 fully clockwise Testing for Open or Shorted Windings Disconnect F1 and F2 exciter field leads from ter minal block in generator end bell The resistance Switching Regulator Turn R5 and R36 fully between field leads should b
22. eee ect 92162 eee zer EEr Oana Quins Mw NOUIWO 19 IE 330 5 2491 334 131 m Ww sinn 310W Ws jd pes HMOOLOHS 18 Q3 O G uvas Iwy 2 2 FIGURE 50 NINE LIGHT ENGINE MONITOR BOARD SCHEMATIC Redistribution or publication of this document by any means is strictly prohibited K3 START DISCONNECT K2 ON OFF RELAY K1 FAULT RELAY RELAY K3 j 25 2 RII He 4 CE gt t uis Ul4 UIS Ule 83 84 5 16 87 a E C2 04 gt 5 pi U9 t o UIO o 08 J2 14 Jl Ul U2 2 V 58 x v Fu i 9 RI amp TBI z J2 PLUG J1 PLUG FIGURE 51 NINE LIGHT ENGINE MONITOR BOARD 61 Redistribution or publication of 5 document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited e Onon Onan Corporation 1400 73rd Avenue N E Minneapolis MN 55432 612 574 5000 Telex 275477 Fax 612 574 8087 Onan is a registered trademark of Onan Corporation Cummins is a registered trademark of Cummins Engine Company Redistribution or
23. tage stabilizes Switching Voltage Regulator Adjust the voltage by turning R36 potentiometer on printed circuit board VR21 counterclockwise to increase the voltage or clockwise to decrease the voltage Observe the voltmeter on control panel while making the adjustment Set voltage with no load con nected Example For a 120 240 volt connection set no load voltage for 246 volts Adjust the stability dampening by turning R5 poten tiometer on printed circuit board VR21 counter clockwise until the voltage becomes unstable or tends to hunt Then turn R5 clockwise until the volt age stabilizes Redistribution or publication of this document by any means Is strictly prohibited 0 RECONNECTION Figure 26 shows reconnection possibilities for the generator When reconnecting for a different voltage be sure to also reconnect lead W12 inside control box to the proper H terminal as shown in Figure 25 CONNECT LOOSE WIRE FROM TB2 2 TO TB2 H2 H3 H4 H5 OR H6 DEPENDING ON VOLTAGE SELECTED TB1 10 X2 240 V 1 9 W12 WIRE ES 1066 FIGURE 25 RECONNECTION LEAD W12 29 TESTING Q1 CAPACITORS Single phase generator sets with the switching regu lator have two capacitors Q1 mounted in the gener ator output box If the generator set does not build up an AC output voltage the Q1 capacitors should be tested with an ohmmeter for an open condition or a short Make sure the capacito
24. 0 e hn hn 41 aus dada qe tu edd dn dde EE 41 Flow Chart Engine Does Not 41 Flow Chart B Engine Cranks But Does Not Start 42 Flow Chart C Engine Starts But Stops After Running Several Seconds 42 ENGINE CONTROL ADJUSTMENTS TESTS 43 General ae 43 A Battery Checkout dee ee RR DARE Te ERE Pao RN sadi s 43 Bs Battery Cable ChecKOUL aee Rub MINCE RE HUE DEI 43 Os Altemalor Checkolb 43 D Solenoid CHECKOUT 54 ____ RR RR 44 Relay ChECKOUN oso vex km d uen em dH UE UU VS o RR V avi od je uicina 44 Fue Solenoid ChecKOUL adios vola er ER RP ECL HE DERE CES noQ 44 3 Switch __ S dE 44 WIRING DIAGRAMS S AE REIR 45 Redistribution or publication of 5 document by any means is strictly prohibited Introduction ABOUT THIS MANUAL For servicing purposes the generator set can be dividedinto three basic parts the engine the genera tor and the controls This manual covers trouble shooting and repair information for the generator and the controls Refer to the L Engine Service Manual 934 0750 when servicing the engine
25. 7022 221 zn A 9 9 h hk Jeera V E amp amp Y 1 1 Qt i i E 1 1 1 1 1 t 1 1 21 n m 09 A092 021 SHI H 09 A0 2 798 ESG 2 0139 30Y110A 834 1 281 Of 2 281 1YNIU31 ZIM 0 31 193NNO2 3108N ualioxa3 281 129 dix WES MBIA 13 4 40 401 23 U01YU3N35 _ __ 9 1 20 01 3031103 7209 219 FIGURE 38 SINGLE AND THREE PHASE AC CONTROL WITHOUT OPTIONAL METERS 48 SWualaW TVNOILdO 9NIHOLIAS OV 3SVHd 3 T9NIS 66 2 0075 CONTROL BOX WIRING DIAGRAM TB DC DIAGRAM KII A Kij B n 7 OUTPUT BOX a M am o GENERATOR EXCITER r2 Ft GEHERATOR CONNECTION Tl tl 1207240 V 60Hz H5 MO 220V 50Ha 115 230V 50 Hz 120 240V 50 15 521 POSITION CONTACTS CLOSED 11 18 21 25 31 32 11 32 21 25 1 31 35 3 11 12 21 27 31 34 1 10 3 731 14 21 27 31 35 OFF 11 14 21 28 31 36 Li L2 e 1 16 21 22 31 32 t fti f 21 22 31 35 SINGLE PHASE SCHEMATIC DIAGRAM EXCITER F2 EXITER
26. ARMATURE T3 T E GND 4 4 2 a _ P27 626 12 10 A TO 0 xi DIAGRAM j oM 223 du G 4 toot y y n cl 5 t 1 vy LINE MODEL 1270 0 GAUGESIOPT DC GAUGES 15 20 kw 1 By aLi TRANSFORMER ASSY 66 90 REGULATOR ASSY VOLTAGE PC BOARD VOLTAGE 800 REACTOR A55Y COM LAMPHOLOER LAMP __ __________ 1 FRIGUNCY 50 4 P 55 4 et E ISI 2 NOTES 1 UNLESS OTHERWISE NOTED ALL COMPONENTS SHOWH IN THE DE ENERGIZEO POSITION 2 CAPACITOR ASSY MOUNTED IH OUTPUT BOX 3 OPTIONAL DC GAUGE EITHER AN ELECTRIC OIL TEMP GAUGE OR AN ELECTRIC TACHOMETER 4 OPTIONS ARE SHOWN CONNECTED DASHED LINES i eee __ A e a _ __ _ _________ _ D pec mcd EE B REVISED PER ER Ge ES ELC IL 41 18552 FOR PAOD LI LL ER eum OM CORPORATION ope pb __7 15 15 90 KW GEN SET WIRING DIAGRAM bras 642 6075 1VNOI LdO ANY YOLVINDSAY ONIHOLIMS TOB LNOO OV ASVHd OF SYNDIA 12 6076
27. Reference Transformer T21 le 24 2 SCR ew daten Rd M pared T RI 25 G Testing Rotating Rectifiers io cae ca ege Od Roe 25 Tesling EXCES E Pope ds 25 J Testing RE E NM ARS 26 K Testing Generator Staton ess era ERRAT ua dre ins eee ware wae 26 L Testing Generator ca a sees E 27 MeWiring Harness 27 Sensitivity Reference 28 P Voltage Adjustment dee das me 28 Q Reconnection oui EAS edades EM Lee err 29 RH Testing QT Gabacitols 29 5 Testing Standard Regulator GE E RECEN 29 T Testing Switching 32 ENGINE CONTROL dud dee see a pip eta Rate 34 34 Pall sus Ee 34 Gontrol COMPONENTS 2 taro sew Vice nbi x SE Eum A EATER CR 35 Engine Senso Sever RA tinea ane 36 C 38 ENGINE CONTROL TROUBLESHOOTING 0
28. changes in the generator output voltage and adjust ing the voltage supplied to the exciter field is how regulation is achieved SWITCHING VOLTAGE REGULATOR Optional The switching voltage regulator is available as an option on DL series generator sets This regulator can provide frequency sensitive non frequency sen sitive or semi frequency sensitive regulation All sets are connected at the factory for frequency sensitive regulation A separate printed circuit board assembly is used for each method of regulation The switching voltage regulator is recommended when the generator set must power non linear SCR loads usually associated with solid state equipment The voltage sensing circuitry in the standard regulator tends to overreact to the switch ing transients created by SCR loads This can result in erratic voltage regulation The switching regulator is designed to overcome this limitation Voltage Regulator Description The voltage regulator controls the output voltage of the generator sothat a constant voltage is maintained under varying load conditions Basic components of the regulator are e Printed circuit board VR21 e Voltage reference transformer T21 e Commutating reactors L21 L22 e Capacitors C1 single phase only All components except the C1 capacitors are located within the control box When used the C1 capacitors are mounted within the generator output box The switching voltage regulator asse
29. publication of this document by any means is strictly prohibited
30. relay for short to ground Is a fault condition indicated panel light Ps no Check switch S10 and related wiring open circuit or short to ground Connect voltmeter between stop terminal of 510 and ground 1 battery voltage read as RPM increases yes Jump normally open contacts of K2 on off relay Does engine start and run Replace A 11 engine monitor circuit board yes Replace K2 on off relay 42 Redistribution or publication of this document by any means is strictly prohibited Engine Control Adjustments Tests GENERAL The following component checkouts are referenced in the Control Troubleshooting flow charts They are an aid to isolating circuit problems caused by faulty engine control components external engine control components such as leads switches relays indicator lights senders and gauges plug into the engine monitor board When testing external components disconnect the corres ponding jack J1 J2 or J3 from the board Refer to the appropriate wiring diagram to determine the jack number A BATTERY CHECKOUT Check charge condition of the battery with a hydro meter The electrolyte specific gravity should be about 1 260 for a fully charged battery at 80 F 27 C If not add approved water to keep electrolyte at proper level and recharge the battery If battery will not recharge replace it If the battery los
31. to the DL series generator sets are listed below FIGURE 36 FIGURE 37 FIGURE 38 FIGURE 39 FIGURE 40 FIGURE 41 FIGURE 42 FIGURE 43 FIGURE 44 FIGURE 45 FIGURE 46 FIGURE 47 FIGURE 48 FIGURE 49 FIGURE 50 FIGURE 51 Single Phase AC Control with Optional Meters 612 6022 Three Phase AC Control with Optional Meters 612 6023 Single and Three Phase AC Control 612 6024 Single Phase AC Control with Switching Regulator and Optional Meters 612 6075 Three Phase AC Control with Switching Regulator and Optional 612 6076 Single and Three Phase AC Control with Switching Regulator 612 6077 Standard Voltage Regulator Assembly 305 0693 Switching Voltage Regulator Assembly 305 0695 Two Light DC Control Wiring Diagram 612 6020 Two Light DC Control Schematic 612 6020 Nine Light DC Control Wiring Diagram 612 6021 Nine Light DC Control Schematic 300 2510 Two Light Engine Monitor Board Schematic 300 2510 Two Light Engine Monitor Board Nine Light Engine Monitor Board Schematic 300 2453 Nine Light Engine Monitor Board 45 Redistribution or publication of this document by any means is strictly prohibited PESCE an nos Ate 5n DNIUIMI hae 8H 2 011 gl 106 81 sn nd EPI ELI n 1 I ___ esnie 365
32. 1 ES 1322 FIGURE 3 EXCITATION BLOCK DIAGRAM 4 Redistribution or publication of this document by any means is strictly prohibited STANDARD VOLTAGE REGULATOR The voltage regulator shown in Figure 4 is standard on DL series generator sets with the YD generator This regulator can be connected for frequency sensi tive non frequency sensitive semi frequency sensitive regulation Unless requested all sets are connected at the factory for frequency sensitive regulation Voltage Regulator Description The voltage regulator controls the output voltage of the generator so that a constant voltage is maintained under varying load conditions Basic components of the regulator are e Printed circuit board VR21 e Voltage reference transformer T21 e Commutating reactor L21 e SCR bridge rectifier CR21 All components are located within the generator con trol box The voltage regulator printed circuit board VR21 schematic diagram is shown in Figure 5 Voltage Regulation Operation The regulator assembly functions as follows Current from one of the generator stator windings is supplied to the primary side of the voltage reference trans former 21 This produces 240 volts AC in the trans former secondary windings which is supplied as a reference voltage to the regulator circuit board VR21 A rise or fall in the generator stator output voltage will produce a corresponding change in the output voltage fr
33. 1 5526 020 22 amp 414153 5202 v VL 20 22 Wi 3202 935012 6 8716 SLE 3108 0101 Sy TE 5 1450 4 2 7 SIN 0105 SYN 93 0 012 214 N39 S 3300 147707 72 2977 07007 Pi ESA rp RENT em VM qasami st 959 TE ______ 1 iue ctn pa mn is Sanyo 96 539072 50 ss9nv9 94 PT 211 E T A 1694 140 ISOH 015 180 5 NOt23NNO9 BOLYH3N39 SINN Ni GALISNKOD MMONS MY VILTMONIVL 2012723 WF YO 29079 10 2 9423 HAV JO 79092 20 TFAOLIO E HOIAISOd 1321083N3 30 RMOHS P ed 0310 3SIMUZHLO 55314 i bog S3L10N 6154 bisa 43102X3 1 HO1vuiN39 Iil Ix m 1 20 OL 4 1 3 5 5 MESES 22 A i 5 i RE Wem 9 7 0X pl Y 7 It inex Og ant y f BEAD ea n REN Gb AS ASSP EEE I YAI 39vYil0A Guvog 341 1 9YDOA ASSY YOLVINGT 1
34. 445 SX x 20 90 5 1645 24 13 1045 24 13 ROl M ZA UNL y 40151529 15S 7A2 1 UX22 40151538 Xs M2A U002 10151514 35 VATA x01 BOLSICAY TEM EEEE 04 94 52019 1VHIWM31 Bist 6100 31 AVMWY 34010 31 2 INIT Ni 34919 9 721 MVE 2t VNOM L3H TIA V 01 21 WOML3N 3H 3001 21 NOWWIOD 218Y832 31 1 51 uI 32010 FEVER NONINOD a 5 e emu ism _ ay es LII EE BASE AR Ru t ms EPIS ee allo CMM A OD A CREE LIFE xx 75 ne presens EN 5 Sao 38 RUE 5200 EE Tii Lu 3214 0044 0152 00 lt by any means is strictly prohibited Redistribution or publication of this document FIGURE 48 TWO LIGHT ENGINE MONITOR BOARD SCHEMATIC 58 START DISCONNECT K2 ON OFF RELAY K1 FAULT RELAY GND FAULT SHUT ALARM DOWN OC RUN SHUTDOWN E 2 J3 PLUG J1 PLUG FIGURE 49 TWO LIGHT ENGINE MONITOR BOARD 99 Redistribution or pub
35. 7 579772 20 DYXMIY S IVA 021 204 82 ol 22777 12802 2599331 92 42 po n uec 3 PINOT IHA MITIS JAHVE FHL FO 222702 FAIS QIFAN LA AIHA gt 055 10 4 P I E 7 TUTINI IO MONE PIV FIV 597777 7287 XI WO SNOUIIANGI Y LEE BLES PNF NOP 70 1279 22529 FIGURE 44 TWO LIGHT DC CONTROL WIRING DIAGRAM m Redistribution or publication of this document 54 by any means is strictly prohibited 2 2 ut AUTEM EM SLT 570 Minnespals s H l S 5 aa a E SCHEMATIC oi CONTROL 272 6020 amp OASHED LINES ARE WHEN USED 2 2 6020 30 lt 5 gt 5 a S 9 E ly EE 3 PUE x MAS IN FIGURE 45 TWO LIGHT DC CONTROL SCHEMATIC 55 Redistribution or publication of this document by any means is strictly prohibited 96 TOHLNOO 79 AYNDIS 6 2 602 rr SACK OF CONTROL BOX START RUN ALARN FOR CUSTOMER USE 1 CONT
36. 8 27 SHIMLA SS3NHYH 3182 311 MSS YING 70 7 ASN 30151533 27 310 335 PIS Fer 9J Hy 27 Li AWL TVNIW3J3L 9 Q QU PUN HIM ILENI Z 1 6 244 01 1 Y LALL 0112383802 5 b 0 S Siuvd 43H10 ROJA 1834344 11 310 3507 311 0 1 r 813 6 9 Q t690 SO amp FIGURE 42 VOLTAGE REGULATOR ASSEMBLY by any means is strictly prohibited Redistribution or publication of this document 92 AT18N3SSV YOLVINDAY ADVLIOA ONIHOLIMS com ER Ont ex ENGL CHR BATE 305 0695 207041 RLSE FOR PROD m IER 20722 ITEM 2 WAS 300 2409 2 H 1 82 21165 ITEM 2 WAS 300 1930 JsP 5 10 H 33 52 ZEIT EET ne AO E QU H EAT Hir p loni A usc Ld n rd NOTE TRANSFORMER CONNECTION A X TO VRI 10 B X TO VRI 9 JE T d o amp 620 So E an LII
37. ACT RATING 1 40 AND 28 PC 120 VAC BOTTOM OF CONTROL BOY ee 1 i 5 TACHOMETER INSTALLATION 1 MS L cipia cuia es 07 AMI LII REAR VIEW OF CONTROL PANEL TOP 068 WIRING DIAGRAM 26 70 AC 9 DIAGRAM SHUT DOWN GROUND FAVT 0574 295 a 773 1209 2791 NOIES sro ZACH p p p I ld qoi juss o 2 e c3 vss i av 4 15591 j 0 e 04 e e 40765 1 DASHED CONNECTIONS INDICATE WHEN USED 2 WHEN 2 FLANGED SPADE CONNECTORS ARE USED ON THE SAME SCREW TERMINAL INSTALL THE LOWER COAWECTOR WITH FLANGES TOWARD TERMINAL BLOCK AND UPPER ren TO WITH FLANGES AWAY FROM TERMINAL LOCK 3 t SIl AND 3 2 50 THAT PROTRUSION OF ACTUATOR UP 4 UNLESS OTHERWISE SPECIFIED ALL COMPONENTS ARE SHOWNIN THE DE ENERGIZEO POSITION 5 OPTIORIL METERING 0C CAUEES 6 7 7 SOLDER LEAD TO ANODE OF ALT RECTIFYING DIODE LOLATED BETWEEN THE REGULATOR AND THE GROOND YERAUNAL FOR IET TESTROOM TACH CALIBRATION START SET AND FREQUENCY TURN CAULBRATION ON RIAR OF UNTIL READS 1420 RPM 11 LEADS SUPPLIED WITH TACH LAMP AFQUIRED THEN TERM
38. CORRECT SERVICE OR REPLACEMENT OF PARTS MIGHT RESULT IN SEVERE PERSONAL INJURY AND OR EQUIPMENT DAMAGE SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND OR MECHANICAL SERVICE Redistribution or publication of this document by any means is strictly prohibited Generator and Voltage Regulator GENERATOR DESCRIPTION The YD generator see Figure 1 is afour pole revolv ing field brushless exciter design with drip proof construction Several single and three phase models are available in both 50 and 60 hertz The generator rotor is directly coupledtothe engine flywheel with a flexible drive disc Engine speed determines genera tor output voltage and frequency A centrifugal blower on the drive disc circulates generator cool ing air which is drawn in through the end bell and discharged through an outlet in the blower end bearing in the end bell supports the outer end of the rotor shaft The end bell is attached with four studs that thread into the stator DL4 and DL6 or generator adapter casting DL6T BLOWER Iii wo 9 4 dei The brushless exciter stator mounts in the end bell while the exciter rotor and its rotating rectifier assemblies mount on the generator rotor shaft Within the end bell leads Fi and F2 from the exciter stator winding are connected to the output terminals of the voltage regulator In addition to the AC output leads single phase ge
39. DC OUTPUT VOLTAGE StpNo Tet Procedure Requirements Set V1 to 208 VAC A Set V1 to 211 VAC B Set V1 to 213 VAC A Set V1 to 203 VAC B Set V1 to 205 VAC Set Pot R18 to hold V2 Between 90 110 VDC V2 shall be lt 60 VDC V2 shall be lt 10 VDC V2 shall be gt 180 VDC V2 shall be gt 140 VDC Redistribution or publication of this document by any means is strictly prohibited 1 TESTING SWITCHING REGULATOR The voltage regulator assembly can be removed from the control and tested for proper operation if neces sary The following test equipment is required EQUIPMENT SCHEMATIC REFERENCE Switch S 5 Amp Fuse F Variable Transformer 4 Amp 0 280 VAC T1 AC Voltmeter or 2 10 VAC 1 250 VAC V1 3 Scale DC Voltmeter 0 10 0 50 and 0 300 or 296 of full scale V2 V4 Capacitors 2 400 MFD C1 Resistor 1 5 or 150 ohm R1 Resistor 50 80 ohm 1200 W R2 Resistor 4700K ohm 2 W R3 Oscilloscope 10 MHZ Bandwidth 01 02 Jumper Wires W Switching Voltage Regulator Test The regulator must be tested separately with all com ponent connections removed from terminal board TB1 The 50 80 ohm resistor R2 serves as the exci ter during testing Use the following procedure to check 1 Connectthetest equipment except jumper wires W to the regulator as shown in Figure 28 2 Open switch S and then connect the variable transformer T1 to the power supply
40. ETY PRECAUTIONS Inside Front Cover TABLE OF CONTENTS iu eco IAE NER ERR EE EA d s 1 INTRODUCTION UR S 2 About This ______ 2 Test EOulpmerit _ 2 GENERATOR AND VOLTAGE REGULATOR 3 Generator DescrtpllOh ___ SANE EN EMEN Id n e Ue 3 Generator OperatllOn iouis v ux ___________________ SORS a 4 Standard Voltage 5 Switching Voltage Regulator Rar RR eR rS wees 7 Generator ded EE _______ oe p d Ed 10 GENERATOR REGULATOR TROUBLESHOOING Sapete Ve uq 13 FreparallOli oae DR ED Ro urs 13 Troubleshooting 13 GENERATOR REGULATOR 6 6 23 _ 23 Testing AC Residual Voltage 23 B esting L21 HeactOE suse 23 C Testing Rectifier Bridge Assembly 23 D Flashing the Field TP ERE 23 Testing
41. INATE WITH A wa CONNECTOR ONAN 532 0147 NRI HA2 HR HRS KRE Ko E 6 2 6027 Ee 12 24 42 cow Ar PUN cOuTKOL amp M SET DE V METER TILI ______ 02 PART3 Ro Soo Er A Car SENDER ON 2 3 0 WATIA TCMPEXAYURE pus gaa Di ii OLEND O NEATER OLENDID FUEL WITCH NEE WITCH LO NiTCH LcE T EZAN 742 _ at BREAKER et vork OS AW EAD MEI 2454 URS LT gt WIRU PARTS LIST COUTIAVCS PAGE 2 RTT i 7 Hm KC CONT PR AD mn E al al CUSTOMER USE PRE PRE 10 HET SW 05 HET OFF LET O Q AN 10 00 amp 2 602 1 h LOSI OF Legere OF 0F 04 HARNESS DE P ETER ____ AE LLM 0104 0919 d TIT 3 O S 1580 N i 5 ox 5 X X C S O fH
42. L PRESS SENDER E1 RUNNING TIME METER BI NU QUIERAS PANEL GLOW PLUGS SOLENOID AND STARTER HRI HR HR4 _ BTt Hiji BATTERY FIGURE 34 TYPICAL WIRING DIAGRAM ES 1314 39 Redistribution or publication of 5 document by any means is strictly prohibited the NC set of K3 contacts disconnects fromthe K1 start solenoid De energizing the K1 start solenoid disconnects B from the starter solenoid to stop cranking and also disconnects B from the K2 heater solenoid to stop preheating A back up start disconnect relay is used to stop cranking When the generator set starts output volt age from the generator stator energizes the K11 start disconnect relay Energizing the K11 start disconnect relay opens a set of NC contacts Opening the NC set of K11 contacts disconnects B from the start solenoid De energizing the K1 start solenoid dis connects B from the starter solenoid to stop crank ing and also disconnects B from the K2 heater sole noid to stop preheating Stopping Sequence Placing the 510 Start Stop Remote switch in the Stop position disconnects B from the K2 on off relay De energizing K2 on off relay disconnects B from the K3 fuel solenoid and the electrical circuits on the engine monitor board De energizing the fuel solenoid shuts off the fuel flow which stops the engine Emergency Shutdown The K1 fault relay is energ
43. MFD 250 V FIGURE 7 REGULATOR PC BOAR CRIB TB 4 0 9 T8I 9 0 STUD OUTPUT M a TBI 5 B ae E TBI 7 Redistribution or publication of this document by any means is strictly prohibited The basic regulating circuit performs several func tions A voltage sensing circuit samples the generator terminal voltage by sensing changes in the output voltage from the reference transformer T21 The AC output from 21 is rectified to DC and fed to the sensing side of the error detector circuit U2 The error detector compares the sensed voltage with a constant DC zener diode regulated voltage The dif ference is amplified and fed to the control section of a voltage controlled variable frequency oscillator U1 Theoscillator responds to changes in the voltage fed to its control section by increasing or decreasing the oscillation frequency The current pulses produced by the oscillator are fed to the pulse transformer which triggers firing of the power transistor By modifying the rate of current pulses fed to the pulse transformer the DC field voltage can be con trolled This allows the generator terminal voltage to be maintained within specified limits Several additional circuits are used to improve the operation and efficiency of the regulating circuit However the basic regulating functions are per formed as described GENERATOR SERVICE The following se
44. NOdMO3 11 Q310N ISIMYIHLO 5537 0 1 T 5310 Por tid rot ee a 1 4 A 2 PH Ecl prec Te MM p a BEI 1 ee NU EES ME eS 11 _ Uva 1 11 1N09 B amr T T0077 Tava 4 EE 01 1 T m T T 21 ki E T m m L ES 221 ES e S 11 21 82 i d H H 592 120 1951 1511 StuYd Ei 2198 01055 21 SH 2 05 AorZ O 1 HOS ACES StI 9H 2HOS 4022 011 SH Aov2 0 21 SGIVYINID 4SVHd 319 15 N011238N0 39Y110A i e qe gtCgc 12 81313 MOLYNYILTY SH IHO9 2 021 6 Hog AOTZ S1I NSIS 9 22 1 SH 7809 AOR 2 2809 919 092 eH OG 009 062 S14 3H OS 00 022 CoH HOS 91 SH THOS PeZ o OIvM3HOS 3SVHd YO 319 15 SH 09 09 2 221 A902 02t 0027611 HOS AOGIZO 2 OS 502 021 2 OG 022 221 5 SH Rt09 A0b2 02
45. ON SCHEMATIC DIAGRAM DOUBLE DELTA T1 T2 T8 112 4 120 240 4 T8 14 T6 TI m 17 T2 T8 T3 T9 T5 110 112 12 22 SERIES WYE TIO 12 T7 T4 T2 T8 75 FIGURE 26 GENERATOR VOLTAGE CONNECTIONS TEETAN 30 Redistribution or publication of this document by any means is strictly prohibited Standard Voltage Regulator Test The regulator must be tested as a complete assembly with all components connected including the voltage reference transformer T21 PC board VR21 com mutating reactor L21 and SCR bridge rectifier CR21 The50 ohm resistor R2 serves as the exciter field during testing Use the following procedure to check VRZI BOARD ASSY PC CE QM O TBI 7 5 9 TBi GTB2 4 HI 5 82 5 Lens 220 3 we TBI IO TBI 4 782 8 1 Connect the test equipment to the regulator as shown in Figure 27 2 Open switch S and then connect the variable transformer T1 to the power supply 3 Test regulator according to the steps in Table 4 L2 t Ww a4 F2 URSUS CHASSIS ASSY RGLTR CR2i BRIDGE RECTIFIER FIGURE 27 STANDARD VOLTAGE REGULATOR TEST SCHEMATIC TABLE 4 STANDARD REGULATOR TEST AND CALIBRATION Calibration Range Range V1 AC INPUT VOLTAGE V2
46. T BOX AND CONTROL 10 Redistribution or publication of this document by any means is strictly prohibited 4 DL4 DL6 STATOR ASSEMBLY BRUSHLESS EXCITER STATOR gt END BELL STATOR OVERSPEED BRACKET AND SWITCH END BELL NUT A S S STATOR ASSEMBLY lt BRUSHLESS EXCITER gt STATOR 7 2 7 4 END BELL STATOR LIFT OVERSPEED 4 e BRACKET AND END BELL FIGURE 9 GENERATOR ASSEMBLY 11 Redistribution or publication of this document by any means is strictly prohibited 10 11 12 13 14 15 Remove the stator assembly being careful notto _ touch or drag on the rotor Place stator on its side in the horizontal position On DL6T sets remove the four end bell studs from the generator adapter Using hoist and sling to support the rotor care fully remove the capscrews that attach the drive disc to the engine flywheel Figure 9 Remove the rotor assembly and place it on wood blocks in the horizontal position The drive disc and fan should not be resting on anything to avoid possible distortion Remove the bolts that hold the drive disc to the rotor shaft and remove the drive disc and rotor fan Use a gear puller to remove the end bearing from the rotor shaft Figure 10 Clamp the rotor ina fixed position and remove the exciter rotor lock nut Remove the generaior field leads
47. alfunction areas to be eliminated by a visual check e Uniess absolutely sure that panel instruments accurate use portable test meters for trouble shooting e Visually inspect components on VR21 Look for dirt dust or moisture and cracks in the printed solder conductors Burned resistors arcing tracks are all identifiable Do not mark on printed circuit boards with a pencil Graphite lines are conductive and can cause leakage or short circuit between components 13 TROUBLESHOOTING PROCEDURES The information in this section is for both single and three phase YD generators using the standard UR type voltage regulator or the optional switching volt age regulator Determine the problem and then refer to the appropriate Flow Chart A B C D or E forthe troubleshooting procedures A NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM P B UNSTABLE OUTPUT VOLTAGE ENGINE SPEED STABLE 1800 RPM OUTPUT VOLTAGE TOO HIGH OR LOW EXCITER FIELD BREAKER TRIPS UNBALANCED GENERATOR OUTPUT VOLT AGE troubleshoot a problem start at upper left corner of the chart related to problem and answer all ques tions either YES or NO Follow the chart until the problem is found performing referenced Adjustment and Test procedures following the Flow Charts Referenced components in the Flow Charts and Adjustment and Test procedures can be found on the electrical schematics Figure 11 and 12 and on assembly dr
48. as engine speed decreases but not as severely as in the frequency sensitive mode Changing Sensitivity Reference The sensitivity reference can be changed if neces sary by unsoldering W1 on VR21 at hole F fre quency sensitive and resoldering it to hole S for semi frequency sensitive or to hole N for non frequency sensitive voltage regulation See Figure 24 SENSITIVITY REFERENCE R26 BOARD ASSY PC 232 1956 Rev R18 FIGURE 24 PC BOARD ASSEMBLY 332 2044 P VOLTAGE ADJUSTMENT After replacement of the regulator printed circuit board VR21 the regulator must be adjusted for sta bility and voltage Center the panel mounted voltage adjustment knob if equipped so the pointer is ina vertical position Start the set and allow it to stabilize at the correct frequency and speed Adjust as speci fied in the following sections Standard Voltage Regulator 28 Adjust the voltage by turning R18 potentiometer on printed circuit board VR21 counterclockwise to decrease the voltage or clockwise to increase the voltage Observe the voltmeter on control panel while making the adjustment Set voltage with no load con nected Example For a 120 240 volt connection set no load voltage for 246 volts Adjust the stability dampening by turning R26 potentiometer on printed circuit board VR21 coun terclockwise until the voltage becomes unstable or tends to hunt Then turn R26 clockwise until the volt
49. ature drops below 70 F 21 C to turn on the red Lo Eng Temp light Redistribution or publication of this document by any means is strictly prohibited PRE HI ENGINE TEMP LO ENGINE TEMP HI ENGINE TEMP nhe La Se Sa Oui te oan pcm e min ane ang ma SA a an rn Wat pi f 2 774 e gt a E AF AF 3 5 ae t 3 1 2 27 B E x J k ni r is A LA Adi Ae c WAT IG Lii mem 2 21 2 FL Z 11 LR oW I f A X4 wd 1 3 7 WT Gs fo 1 5 1313 FIGURE 32 ENGINE TEMPERATURE SENSORS Overspeed Switch The overspeed switch is a mechanical switch which groundsthe overspeed circuit on the Engine Monitor Circuit Board if an overspeed condition exists caus ing an engine shutdown and activating the optional overspeed fault lamp After the problem is corrected starting will not occur until the Reset switch is pressed ij ADJUST SCREW GENERATOR AIR GAP ES 1298 1 FIGURE 33 OVERSPEED SWITCH The overspeed switch is set so contacts close at 2200 to 2250 rpm necessary the speed range can be corrected by turning the adjusting screw thereby changing the ma
50. awings and wiring diagrams Redistribution or publication of this document by any means is strictly prohibited 1 21 Es a 24 21 ma DC OUTPUT VOLTAGE F2 BRUSHLESS EXCITER EXCITER ROTATING 2 GENERATOR ROTOR RECTIFIER 320 WYE ASSEMBLIES ES 1317 1 FIGURE 11 YD GENERATOR AND STANDARD VOLTAGE REGULATOR 14 Redistribution or publication of this document by any means is strictly prohibited C1 CAPACITORS 1300 MFD 1300 MFD SEE NOTE 1 7 4 OUTPUT VOLTAGE 1 1 22 1 BRUSHLESS EXCITER NOTE 1 CAPACITOR ASSEMBLY USED FOR SINGLE PHASE INSTALLATIONS ONLY EXCITER ROTATING F2 GENERATOR 9 ROTOR RECTIFIER NOTE 2 122 AND USED FOR THREE 30 WYE ASSEMBLIES PHASE INSTALLATIONS ONLY TEE ER SEE NOTE 2 ES 1421 FIGURE 12 YD GENERATOR AND SWITCHING VOLTAGE REGULATOR 15 Redistribution or publication of 5 document by any means is strictly prohibited FLOW CHART A NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM STANDARD VOLTAGE REGULATOR START Remove one lead from breaker and check continuity with ohmmeter Is breaker open Replace defective field breaker Is control panel field es breaker CB3 ON y yes If voltage is unstable high or low or
51. ctions describe the disassembly and reassembly procedures for the generator WARNING Accidental starting of the set might cause severe personal injury or death Disconnect the negative battery cable when repairs are made to the engine controls or generator Disassembly 1 Disconnect the negative battery cable to pre vent accidental starting of the generator set while servicing 2 Removethe generator output box cover see Fig ure 8 and disconnect the stator lead wires from the load wires 3 Unplug the control wiring harness from the underside of the control box 4 Remove the overspeed switch bracket and switch assembly from the end bell 5 Remove the upper and lower brackets that secure the output box to the end bell 6 Remove the end beli stud nuts and slide off the end bell and exciter stator assemby see Figure 9 It may be necessary to tap around the joint to separate the end bell from the stator assembly 7 Loosen the screws that fasten the output box to the generator and remove the output box and control box as an assembly 8 Use a hoist and safe lifting device stator handling tongs or chain and lift hooks to support the sta tor assembly as shown in Figure 9 On DL4 and DL6 sets carefully remove the capscrews from the stator attachment ring CONTROL WIRING HARNESS CONTROL BOX OVERSPEED SWITCH END BELL STATOR LEADS Nes E FIGURE 8 OUTPU
52. dMOD Wv Q310N 35 AH3HIO 55318074 S310N 1 ASSY NOI12Y BLOW e 390159 0313119 ISU TR 2104 338000 H34Y349 INT M x 47 1 20 29 45 1517 BEI o1 11 SH 2H05 2 021 1 SH THOS 09 222 wit ZHOS 2 us 09 917 092 HOGS 400 052 08 022 rH HOS 91 092 SH THOS AOD 1 05 ACES Stl 9 HOS AO Z GI SH A022 011 9H 4022700 20 10 4xoorsr 09 A0720 22277 390 9 01083839 20442 20 012 35 4 31915 gt 29VI10A 3SYH4 SNOIM23NNO9 39Y110 gt 5 Q 0 1 1 1 1 1 Ao es re ee ee re ee 1 iil 2univnsy 23 T 727 3SVHd 3384 319515 1 ee i25 9 M M aM SH 74 09 AOP2 6E1 pH ZH 09 140227221 2H 09 802 021 NH OS 002 6 OG 1 0 PH tH OS A802 021 SH 2 OS
53. des through CR6 on rotor per TEST G Re place if bad i Check exciter rotor winding per TEST J Replace if bad Check generator rotor field winding per TEST L Replace if bad Check generator stator wind ings per TEST Replace if bad Redistribution or publication of this document by any means is strictly prohibited FLOW CHART B UNSTABLE VOLTAGE ENGINE SPEED STABLE 1800 RPM SWITCHING VOLTAGE REGULATOR START Are there any broken wires or loose connections on voltage regulator assembly yes Repair as required no Check wiring harness from regulator assembly to end bell per TEST M Check OK Repair wiring or replace as required yes Does adjustment of Dampening Control R5 on 21 per adjustment P result in stable voltage is voltage stable within spec at no load to full load range of generator set S yes no no The new printed circuit board might be damaged by malfunctioning components within the control Do not install the new PC board until all other problems have been located and corrected Test voltage regulator assembly per procedure S Replace the regulator PC board per procedure F if defective FLOW CHART C OUTPUT VOLTAGE TOO HIGH OR LOW SWITCHING VOLTAGE REGULATOR START Set RPM per instructions in appropriate engine manual Is engine running at correct RPM
54. e 13 05 to 15 95 ohms at clockwise F 2570 9 Perform voltage calibration and stability adjust Testing for Grounds ment procedures to obtain the correct generator em Connect ohmmeter between either field lead and 4 E With new PC 1 exciter stator laminations Use ohmmeter set at the highest resistance range Resistance must be one megohm 1 000 000 ohms or greater 75 Redistribution or publication of this document by any means is strictly prohibited OHMMETER RESISTANCE BETWEEN F1 AND F2 SHOULD BE 13 05 TO 15 95 OHMS AT 77 F 25 C FIGURE 19 TESTING EXCITER FIELD FOR OPENS OR SHORTED WINDINGS J TESTING EXCITER ROTOR Test the exciter rotor Figure 20 for open or shorted windings or grounds as follows Testing for Open or Shorted Windings Use a Wheatstone Bridge for this test Disconnect main rotor field leads which connect to rotating recti fier assemblies at F1 and F2 Disconnect lead wires from diodes CR1 CR2 CR3 CR5 and CR6 Test between exciter lead pairs T1 T2 T2 T3 and T1 T3 Resistance should be 0 6 to 0 7 ohms at 68 F 209 C Testing for Grounds Connect leads of ohmmeter between each CH lead and exciter rotor laminations Use an ohmmeter set at the highest resistance range An ohmmeter reading less than one megohm 1 000 000 ohms indicates defective ground insulation K TESTING GENERATOR STATOR Using proper test equipment check t
55. en handling electrical equipment Disconnect batteries to prevent accidental engine start Jewelry is a good conductor of electricity and should be removed before working on electrical equipment Use extreme caution when working on electrical components High voltages cause injury or death Follow all state and local codes To avoid possible personal injury or equipment damage a qualified electrician or an authorized service representative must perform installation and all service WARNING EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide a poisonous gas that might cause unconsciousness and death It is an odorless and colorless gas formed during combustion of hydrocarbon fuels Symptoms of carbon monoxide poisoning e Dizziness e Headache e Weakness and Sleepiness e Vomiting e Muscular Twitching e Throbbing in Temples If you experience any of these symptoms get out into fresh air immediately shut down the unit and do not use until it has been inspected The best protection against carbon monoxide inhalation is proper installation and regular frequent inspections of the complete exhaust system If you notice a change in the sound or appearance of exhaust system shut the unit down immediately and have it inspected and repaired at once by a competent mechanic Redistribution or publication of this document by any means is strictly prohibited Table of Contents TITLE SAF
56. ent from the commutating reactors is rectified to DC and supplied to the exciter field The current flow stops when the power transistor is turned off The voltage of the DC output is directly proportional to the on off switching frequency of the power transis tor An increase or decrease in the switching fre quency causes a corresponding increase or decrease in the DC voltage produced The nominal switching frequency is approximately 125 Hz The pulse transformer T1 is used to trigger the firing of the power transistor Triggering is accomplished by reverse saturating the transformer and then releas ing it This initiates conduction in the power transis tor which remains on until the transformer saturates in the forward direction Using the pulse transformer totrigger the powertransistor helps isolate the power Circuit from the voltage regulating circuit Redistribution or publication of this document by any means is strictly prohibited VR2 VR1 US 02 U1 1 T2 T1 R36 R34 35 R33 R32 R30 H29 R28 R24 R22 R20 R19 R18 R17 R15 814 21 R13 R12 11 R10 R9 R8 R7 R16 H6 R5 R3 4 R2 R1 Q4 Q3 Q1 2 K1 CR28 15 22 27 CR3 5 14 16 21 amp 29 CR1 2 4 6 7 8 C15 C14 C13 C11 C10 C9 C7 12 C6 8 C5 C4 C3 C2 Wire Jumper 1 Diode Zener Diode Zener BW C 12 Volt Regulator Integrated Circuit 1C Timer Terminal Block Transforme
57. erator rotor field winding per TEST L Replace if bad Check generator stator wind ings per TEST K Replace if bad Redistribution or publication of this document by any means is strictly prohibited FLOW CHART B UNSTABLE VOLTAGE ENGINE SPEED STABLE 1800 RPM STANDARD VOLTAGE REGULATOR START Are there any broken wires or loose connections Repair as required on voltage regulator assembly P yes no Check wiring harness from regulator assembly to end bell per TEST M Check OK Repair wiring or replace as required yes Is voltage stable within spec at no load to full load range of generator set Does adjustment of Dampening Control R26 on VR21 per adjustment P result in stable voltage no The new printed circuit board might be damaged by malfunctioning components within the control Do not install the new PC board until all other problems have been located and corrected FLOW CHART C OUTPUT VOLTAGE TOO HIGH OR LOW STANDARD VOLTAGE REGULATOR Test voltage regulator assembly per procedure S Replace the regulator PC board per procedure F if defective START Set RPM per instructions in appropriate engine manual Is engine running at correct RPM yes Does adjustment of Voltage Adjust control R23 on control panel result in correct output voltage Set control per Voltage Calibration Adjustment P
58. es and SCR s in bridge assembly CR21 per TEST C Check reference transformer T21 and connections per TESTS E and Q Replace if bad Check generator stator leads for proper connection See Figure 26 Check generator stator windings per TEST K Replace if bad Test voltage regulator assembly per procedure S Replace the regulator PC board per procedure F if defective Redistribution or publication of this document by any means is strictly prohibited FLOW CHART E UNBALANCED GENERATOR OUTPUT VOLTAGE STANDARD AND SWITCHING VOLTAGE REGULATOR START Check for correct grounding of generator Remove load at generator terminals Is output and load still unbalanced no yes Are generator leads connected and grounded properly See Figure 26 Correct as necessary yes 5 generator stator winding continuous per TEST K Replace stator assembly yes Check load for ground faults and correct as necessary 19 Redistribution or publication of 5 document by any means is strictly prohibited FLOW CHART NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM SWITCHING VOLTAGE REGULATOR Are field circuit breakers es CB3 and CB4 32 ON y Push to reset breaker Does generator AC output voltage build up Is residual voltage across TB2 2 and H1 5 to 10 VAC or more yes Check reactors L21 L22 32 and transformer T21 pertest
59. es excess water the alternator charge rate may betoo high Likewise if battery state of charge is not maintained the charge rate may be too low Refer to ALTERNATOR CHECKOUT C B BATTERY CABLE CHECKOUT 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 bat tery positive post to the battery terminal stud on the solenoid Normally each of these should beless than 0 3 volt If extra long battery cables are used slightly higher voltage drops may result Thoroughly clean all connections in any part of the circuit showing exces sive voltage drop C ually tapering to zero as the battery becomes fully charged If the ammeter shows a constant discharge or a constant high rate of charge stop the generator set and check for a loose or slipping drive belt poor terminal connections or broken lead wires Repair or replace as required If everything checks out use a voltmeterto determine the alternator output voltage Connect the positive lead to the output terminal see Figure 35 and connect the negative lead to ground Start the generator set and run for a few minutes to allow the voltage to stabilize A properly operating system will have a nominal output voltage of between 13 8 14 8 volts MOTOROLA AUXILIARY TERMINAL MODEL 8RF2021 A SER NO XAXX 12 v e
60. f no voltage is present check continuity between these points with the generator shut down If voltage is low check reactor Test B and T21 transformer Test E B TESTING COMMUTATING REACTORS L21 and L22 commutating reactors Figure 13 mount inside the control box Remove reactor leads from terminal board for testing The coils 1 2 and 3 4 are wound on the same core Resistance between 1 2 and 3 4 should be 031 to 0 37 and 037 to 0 46 ohms respectively at 77 F 25 C Resistance between coils and from any ter minal to frame of the reactor should be infinity FIGURE 13 COMMUTATING REACTORS C TESTING RECTIFIER BRIDGE ASSEMBLY CR21 The rectifier bridge located within the control cabinet contains diodes CR1 CR2 and and two silicon controlled rectifiers SCR1 and SCR2 The components are encapsulated within a hermetically sealed block therefore failure of any diode or SCR means the entire unit has to be replaced See Figure 14 Disconnect wires from rectifier unit prior to testing Test unit in order shown in Table 1 Refer to Figure 15 for SCR1 and SCR2 test circuit When test is com plete and satisfactory reconnect unit observing cor rect wiring hook up AC TERMINALS ARE GIVEN NUMERIC DESIGNATIONS FOR TEXT REFERENCE ONLY DOES NOT APPEAR ON UNIT FIGURE 14 RECTIFIER BRIDGE ASSEMBLY D FLASHING THE FIELD If output voltage does not build up it may be neces
61. from the exciter rotor and slide the exciter off the rotor shaft FIGURE 10 END BEARING REMOVAL Reassembly T Slide the exciter rotor over the generator shaft and install the exciter lock nut Torque to 130 to 150 ft Ibs 176 to 203 Nem Connect generator leads to 1 and F2 terminals on exciter assembly Torque to 2310 26 inch Ibs 2 6 to 2 9 Nem Press the end bearing onto the rotor shaft Place the generator fan in position on the rotor shaft TO 5 Install the drive disc on the end of the rotor shaft with the chamfer on the flywheel side Torque the 8 placement bolts to 70 to 80 ft Ibs 95 to 108 Nem Using a hoist and sling to support the rotor align the holes in the drive disc and fan with the corres ponding holes in the flywheel 12 10 11 12 13 14 15 Install the 8 capscrews that hold the drive disc to the engine flywheel and torque to 39 ft Ibs 52 Nem Using a hoist and safe lifting device carefully move the stator into position over the rotor assembly The stator leads should be at the 4 o clock position when viewed from the end bell position DL4 and DL6 sets align the holes in the stator attachment ring with the holes in the flywheel housing and install the 12 capscrews Torque to 39 ft Ibs 52 Nem DL6T sets install the end bell studs in the generator adapter Install the control box assembly Apply a thi
62. generator set starts Energized when the K3 start dis milli amperes for each indicator lamp and 5 amperes connect relay connects battery positive B to the for the fault alarm green Run indicator lamp K21 Voltage Scale Relay Located inside the control box Used to operate the scale indicator lights caution Control components be dam aged if these current limits are ENGINE SENSORS exceeded for the optional equipment The following briefly describes the engine mounted sensors and switches and how they protect the Resistance units and switches in the monitoring and engine from unfavorable operating conditions shutdown systems are sealed units and not repair able When replacing a sensor do not use a substitute item since resistance units are matched to the gauge All cut off switches close to ground if abnormal oper they supply Cutoff switches are close tolerance ating conditions exist and energize the Fault Relay to parts made for a specific application stop the engine The respective contro panel lamps optional light to indicate cause of the shutdown An optional remote fault alarm can be connected to the 36 Redistribution or publication of 5 document by any means is strictly prohibited OIL GAUGE SENDER M S PRE LOW OIL PRESSURE AND LOW OIL PRESSURE M annum rum Aum am m n as 7 fi 4 a 2 1 1 1 k 1 X T f
63. gnetic air gap see Figure 33 The air gap must not be less than 0 005 inch 0 13 mm OPERATION Dependable 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 check for troubles and know how to make the proper adjustments replacements or repairs in a reasonable amount of time Prior to starting the generator set check the fuel supply engine oil level and all battery connections for loose or broken wires an automatic demand control is in use check for correct connections Figure 34 shows a typical wiring diagram for the cir cuits 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 For cold engine starting the Preheat switch S11 is held in the preheat position for 10 seconds This energizesthe K2 heater solenoid which closes a set of NO contacts that connect B to the glow plugs Atthe end of the preheat period the starting sequence is 38 initiated by placing the Start Stop Remote switch 510 in the Start position Placing switch S10 in the Start position energizes the K2 On Off relay which closes a set of NO contacts Closing K2 contacts connects to the electrical circuits on the e
64. he 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 an ohmmeter set at the highest resistance range to test each stator for shorts to laminations A reading less than one megohm 1 000 000 ohms indicates a ground Led E WHEATSTONE BRIDGE CR1 SCHEMATIC OF EXCITER WIRING CR2 5 ES 1316 FIGURE 20 TESTING EXCITER ROTOR Testing for Open or Shorted Windings Test for continuity between coil leads shown in Fig ure 21 all pairs should have equal resistance Use an accurate instrument for this test such as a Kelvin Bridge Resistance values at 77 F 25 C are given in Table 2 If any windings are shorted open or grounded replace the stator assembly Before replacing the assembly check the leads for broken wires or insulation i FROM THREE PHASE MODELS TEST BETWEEN WIRE PAIRS 11 74 77 110 1713 16 T9 T12 12 1 11 SINGLE PHASE MODELS TEST BETWEEN WIRE PAIRS T1 T2 T3 T4 G 1142 FIGURE 21 TESTING STATOR WINDINGS Redistribution or publication of this document by any means is strictly prohibited TABLE 2 RESISTANCE VALUES FOR STATORS Models Ohms Resistance 20 0 014 0 049 0 127 25 0 01 6 0 100 30 0 01 6 0 072 40 0 DL6T 0 045 Models Ohm
65. hibited Engine Control GENERAL The engine control system includes all functions that relate to the operation of the engine This includes starting and stopping instrumentation monitoring for fault conditions and battery charging This sec tion covers how the engine control operates and where the various components are located CONTROL PANEL The following is a brief description of the two nine light control panels with the optional AC meters Although the AC meters are not part of the engine control they are mentioned here in order to complete description of the control panel exterior Refer to Figure 29 for the location of each component Gauges Meters and Switches Oil Pressure Gauge Indicates engine lubricating oil pressure The gauge has a range of 0 to 100 psi 0 to 700 kPa Water Temperature Gauge Indicates engine coolant temperature The gauge is wired to a sensor unit on the engine and has a range of 100 to 2509 40 to 12190 Battery Charge Rate DC Ammeter Indicates battery charging current Meter range is 30 amperes Running Time Meter Registers the total number of hours that the unit has run Use itto keep record for periodic servicing Time is cumulative meter cannot be reset Frequency Meter Optional indicates generator output frequency in hertz It can be used to check engine speed Each hertz equals 30 r min AC Voltmeter Optional Dual range instr
66. ing Timer A solid state circuit on the engine monitor circuit board that limits cranking time from 45 to 75 seconds the engine does not start cranking will stop and an overcrank fault will be indi cated K1 Fault Relay Located on the engine monitor circuit Energized when a fault condition occurs Turns off the engine and prevents restarting until the fault condition is corrected and the Reset switch is pressed This relay can also be used to operate a remote DC alarm 5 amp maximum connected to the faultterminal of the engine monitor circuit board See Figure 30 K2 On Off Relay Located on the engine monitor board Connects battery positive B to the electrical circuits on the engine monitor circuit board whenthe 33 Start Stop Remote switch is placed the Start posi tion See Figure 30 K3 Start Disconnect Relay Located on the engine monitor circuit board Energized by voltage output from the battery charging alternator Disconnects the cranking circuit and turns on the green Run indicator lamp when the engine starts See Figure 30 K1 Start Solenoid Located on the generator set skid base Connects battery positive B to the starter solenoid and K2 heater solenoid when the Start Stop Remote switch is placed in the Start position See Figure 31 K2 Heater Solenoid Located on the generator set skid base Connects battery positive B to the glow plugs when the Pre heat switch is placed in the On posi
67. ized when fault sensors respond to one of the following fault conditions overcrank low oil pressure high engine temperature and overspeed Energizing the K1 fault relay opens one set of NC contacts and closes two sets of NO contacts Open ing the NC set of K1 contacts disconnects B from the K1 start solenoid and the K3 fuel solenoid This stops cranking if the engine is being cranked and shuts off the fuel flow Closing one of the NO sets of K1 con tacts grounds the K1 fault relay so that the K1 relay cannot be de energized until the 512 reset switch is momentarily opened Closing the other NO set of K1 40 contacts connects the remote alarm terminal The Low Oil Pressure Delay circuit is not actuated until the Start Disconnect Relay is energized The circuit allows a delay of 7 5 to 12 5 seconds before LOP shutdown and pre alarm are functional Follow ing this initial delay both the LOP shutdown and pre alarm functions are immediate Redistribution or publication of this document by any means is strictly prohibited Engine Control Troubleshooting GENERAL performed since last satisfactory operation of set The information in this section is divided into three A loose wire connection overlooked when install flow charts Determine the problem and then refer to ing a replacement part could cause problems An the appropriate flow chart A B or C forthetrouble incorrect connection an opened switch or circ
68. lication of this document by any means is strictly prohibited 1 300 2453 0 t 5 1 9 3 HH SESS EE 4 4 18 HSYO 335 sis 653 HL dA 9NINJIM 830105 OL 03810105 3AYM 24V WAHLO 114 8311 03930105 38 Ol IWW EC Y 2f If m zo i0 bO E0 SYIJWAN 0312812 uuum men EOP ery 24 73000 20 t0 03 SHISWAN Nl O312H12NA 40 90 NO Tiina us Esp E rasa ES rnit GQuvCS 1102312 AIAN HOW 3N3 N33925 15 HOW 9 3 2 925 115 1 533x348 T 7091602 fin 1521 59 13521 283 N32u25 1t5 HOW 1 334254115 10125 ARYL 0112 4 2 mrs Y M0123HW22 AQd1 AV11M AN114 133205 AY 134 ORIYAT VE 2t 90 25 38 11 w3HSY 2 9 SrH 1nN 1545 24 13 FEJED 1045 2d AY712u ful dt 8 24 6 Qi euylo2 f Tn NEN OND 414 8 0151575 281192 tale2 O7 erg enlez 8 lp ru Xs A2 i 025153 s sn ot 900006 HO sine MON 9 If SUF 94 24 2018 1YNIMW31 Qd 2d4 32019 TWNIMM3L AYWEY MISK GYNG II ANAMYV 34010 31 51 1 22010 9 71
69. mbly is shown in Figure 6 The voltage regulator printed circuit board VR21 schematic diagram is shown in Figure 7 Voltage Regulator Operation The regulator assembly functions as follows Current from one of the generator stator windings is supplied to the primary side of the voltage reference transformer 721 This produces 240 volts AC in the transformer secondary windings which is supplied as a reference voltage to the regulator circuit board VR21 A rise or fall in the generator stator output will produce a corresponding change in the output volt age from the reference transformer secondary windings Redistribution or publication of this document by any means is strictly prohibited PC BOARD 21 2 3 4 5 e 7 amp 9 il 12 2 en p TRANSFORMER T21 iEn tes uu TB2 COMMUTATING REACTORS L21 amp L22 FIGURE 6 VOLTAGE REGULATOR ASSEMBLY 305 0695 02 Generator stator current is also supplied to the com mutating reactors L21 and L22 three phase only These reactors are used to produce a uniform AC wave The outputterminals of the reactors supply AC current to the power circuit on the regulator circuit board VR21 The power circuit primarily consists of a power tran sistor Q4 pulse transformer T1 and rectifying diodes When the power transistor is turned on AC curr
70. n erators have three control wires and three phase gen erators have five control wires that extend from the stator housing see Figure 2 On single phase sets leads 1 and 4 lead 2is not used are used for control inputand metering On three phase sets leads 4 7 8 9 and 10 are used for control input and metering END BELL BRUSHLESS EXCITER ROTOR OVERSPEED SWITCH 57 o ELI HERE BEARING LRS ROTATING 2 RECTIFIER ASSEMBLIES BRUSHLESS EXCITER STATOR XG 1141 FIGURE 1 TYPICAL YD SERIES GENERATOR DL4 and DL6 Redistribution or publication of this document by any means is strictly prohibited Figure 2 is a composite illustration showing four output leads for GENERATOR OPERATION single phase units 12 output leads for 3 phase broad range units RAT and four output leads for code 7 and 9X 3 phase generators Operation of the generator involves the stator volt age regulator exciter field and armature full wave bridge rectifier and the generator rotor Figure 3 Residual magnetism in the generator rotor and a permanent magnet embedded in one exciter field pole begin the voltage build up process as the gener ator set starts Single phase AC voltage taken from one of the stator windings is fed to the voltage regu CONTROL AND 7 4 METER LEADS 7 3 amp 53 lator as reference for maintaining the generator F2 7 SINGLE output voltage AC voltage is conve
71. n film of Molykote grease or equivalent to the mating surfaces of the end bearing and the end bell bearing hole Install end bell assembly on the stator with the opening for the generator leads in the 4 o clock position Torque end bell stud nuts to 20 ft Ibs 27 Nem Using a lead hammer tap the end bell at the horizontal and vertical plane to relieve stress Retorque end bell stud nuts Install the upper and lower output box brackets Plug in the control wiring harness and connect the stator lead wires to the load wires Refer to Figure 26 for the generator voltage connections Install the overspeed switch assembly and switch bracket Verify that all connections are secure and then install the output box cover Connect the negative battery cable and test generator for operation Redistribution or publication of this document by any means is strictly prohibited Generator Regulator Troubleshooting PREPARATION few simple checks and a proper troubleshooting procedure can locate the probable source of trouble and reduce down time e Check all modifications repairs replacements performed since last satisfactory operation of set to ensure that connection of generator leads are correct A loose wire connection overlooked when installing a replacement part could cause problems An incorrect connection an opened circuit breaker or a loose connection on printed circuit board are all potential m
72. nc URN w p purses uen ae ene Rite IS PSI 5 D SSS Ss y Di Se 1 i gS 7 7 7 Quam uum ama AUR WD Dei mum um mum rere qum dub Gus duum nnus uum dum nuam ends suus 7 7 7 7 7 7 __ __ E E E RE em p m Redistribution or publication of this document by any means is strictly prohibited Generator stator 15 also supplied to com mutating reactor L21 Reactor L21 is a chokethat is used to produce a uniform AC wave The output ter minals of the reactor supply AC current to the AC input terminals on the rectifier bridge assembly CR21 Rectifier bridge assembly CR21 is made up of two silicon controlled rectifiers SCR s and three recti fier diodes The generator exciter field is connected to the DC output terminals and on CR21 The regulator circuit board VR21 is connected to the SCR gate terminals G1 and G2 When a voltage impulse from the regulator circuit board is applied to SCR gate terminals G1 and G2 input AC current from L21 is rectified to DC curre
73. nce Code Code 3R amp 53R 15R amp 515R 20 0 DL4 25 0 DL6 32 0 DL6T 40 0 DL6T M WIRING HARNESS CHECK Carefully check wiring harnesses 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 using an ohmmeter check each wire end to end for continuity or opens 3 Using an ohmmeter check each wire against each of the other wires for possible shorts or insulation breaks under areas covered by wrap ping material 4 Reconnect or replace wires according to appli cable wiring diagram Redistribution or publication of this document by any means Is strictly prohibited SENSITIVITY REFERENCE CIRCUIT Standard Voltage Regulator u Three types of frequency sensitivity reference voltage are possible with voltage regulator VR21 1 Frequency sensitive voltage output reduces in proportion to the engine speed Unless otherwise requested by the purchaser the factory equips the set with frequency sensitive regulation 2 Non frequency sensitive voltage output does not decrease when engine speed decreases A temporary overload with a non frequency sen sitive reference could cause the engine to reduce speed and then require a 50 to 60 percent load reduction before it could return to rated speed 3 Semi frequency sensitive voltage output de creases
74. nergized contact is okay The 12 volt reading appears in reverse order when checking normally closed NC contacts F FUEL SOLENOID CHECKOUT If there is fuel to the injection pump but no fuel at injection nozzle the fuel solenoid may be defective To check energized to run fuel solenoid operation listen fora click in injection pump when start switch is placed in the run position no click is heard and there is power to solenoid with the start switch in the run position the fuel solenoid must be replaced To check energized to stop fuel solenoid operation listen fora click in injection pump when start switch 15 placed in the stop position If no click is heard and there is no power to solenoid with the start switch in the stop position the fuel solenoid must be replaced Refer to the L Engine Service Manual 934 0750 for fuel solenoid replacement procedures G SWITCH CHECKOUT 1 Remove battery B cable 2 Place ohmmeter leads across switch 3 Open and close switch while observing the ohm meter A normally open NO switch should indi cate infinite resistance when open and continuity when closed A normally closed NC switch should indicate continuity when closed and infi nite resistance when open 4 Replace switch if defective Redistribution or publication of this document by any means is strictly prohibited Wiring Diagrams The electrical schematics and wiring diagrams that apply
75. ngine monitor board the K1 start solenoid and the K3 fuel solenoid Energizing the K1 start solenoid closes two sets of NO contacts that connect B to the starter solenoid and K2 heater solenoid Energizing the starter sole noid initiates cranking Energizing the K2 heater solenoid continues initiates operation of the glow plugs The K3 fuel solenoid opens the fuel control when energized This solenoid is an integral part of the fuel injection pump Start Disconnect Sequence When the generator set starts output voltage from the auxiliary terminal of the DC alternator energizes the start disconnect relay Energizing start disconnect relay closes one set of NO contacts and opens another set of NC contacts Closing the NO set of contacts connects to the run lamp Opening Redistribution or publication of this document by any means Is strictly prohibited 052 FAULT LAMP CUSTOMER USE 12 12 12 gik TERMINALS 12 START RUN RELAY SHUT ENGINE MONITOR RUN D eH em CIRCUIT BOARD A11 REMOTE 9 510 5 C S12 PRE 11 HEAT START DISCONNECT RELAY DC HIGH ENG TEMP SWITCH OVERSPEED SWITCH LOW OIL PRESS SWITCH FUEL SOLENOID K3 AC 5 10 1 1 11 2 17 CIRCUIT BREAKERS j TO GENERATOR TB5 9 WATER TEMP SENDER OI
76. nt which is then supplied to the exciter field Rectification of AC current to DC current proceeds until the input AC voltage wave falls to zero At this point rectification of AC to DC stops As the AC voltage wave begins to build again a voltage impulse is again applied to the SCR gate terminals G1 and G2 by the regulator circuit board This initiates a new rectification cycle The voltage ofthe DC current produced atthe output terminals of CR21 and is dependent on when the rectification process begins If a voltage impulse is applied to the SCR gate terminals early in the AC wave cycle the DC voltage is higher the voltage impulse is applied later in the AC wave cycle the DC voltage is lower During operation the regulator circuit board re sponds to changes in the reference voltage supplied by the voltage transformer If the reference voltage is low the circuit board supplies a voltage impulse to the SCR gate terminals early in the AC wave cycle This raises the voltage of the DC current produced for field excitation which results in an increase in the generator output voltage 1 the reference voltage supplied to the regulator circuit board is high the circuit board supplies a voltage impulse to the SCR gate terminals later in the AC wave cycle This lowers the voltage of the DC current produced for field exci tation which results in a decrease in the generator output voltage The process of continuously sensing
77. om the reference transformer secondary windings PC BOARD VR 1 NIS L SIS A fixed resistor R21 is used on generator sets WITHOUT optional meters A panel mounted potentiometer R23 is used on generator sets WITH optional meters SISISISIS VOLTAGE REFERENCE TIL TRANSFORMER T21 HENGI SCR BRIDGE CR21 LJ am I e TERMINAL BOARD GNT D E 1 REACTOR 121 WIRING HARNESS ES 1318 FIGURE 4 VOLTAGE REGULATOR ASSEMBLY 305 0693 Redistribution or publication of this document by any means is strictly prohibited REF NO C1 14 C2 C7 C4 C12 C5 C8 C6 C11 C13 CR3 Thru 11 CR12 CR13 CR14 F2 1C1 Q2 Q3 R1 R2 R3 R5 R6 R7 R8 R16 R10 R11 R9 R12 R13 R14 R15 R27 R17 R18 R20 22 29 amp 30 R21 R24 R25 R31 R26 R28 CR15 K1 R19 PART DESCRIPTION Board Assembly Printed Complete Capacitor 47 Mfd 250 Volt Capacitor 22 Mfd 250 Voit Capacitor 47 Mfd 400 Volt Capacitor 47 Mfd 250 Volt Capacitor 1 Mfd 100 Voit Capacitor 33 Mfd 250 Volt Capacitor 1 Mfd 400 Volt Capacitor Electrolytic 100 10 Volt Rectifier Silicon Diode Zener 5 6 Volt Diode Zener 20 Voit Diode Zener 18 Volt Fuse 1 4 Amp Integrated Circuit Transistor
78. omes on as soon as the starter circuit is opened after unit starting The red light indicates an emergency shutdown of the generator set The optional control panel has nine monitor system indicator lights e Run green e Pre Hi Eng Temp amber Pre Low Oil Pres amber Lo Eng Temp red Hi Eng Temp red Overcrank red e Overspeed red e Lo Cil Pres red e Switch Off flashing red High and Low Indicator Lights indicate which scale to use on the AC voltmeter and ammeter Redistribution or publication of this document by any means is strictly prohibited FREQUENCY METER DUAL RANGE AC AMMETER DUAL RANGE AC VOLTMETER VOLTAGE ADJUST VOLTAGE ADJUST RHEOSTAT LO PHASE Lf cw SELECTOR PV SWITCH K SCALE N AMMETER VOLTMETER SCALE INDICATING _ LIGHTS RUNNING TIME METER SC 1302 1 WATER TEMPERATURE GAUGE FIGURE 29 NINE LIGHT CONTROL PANEL WITH OPTIONAL AC METERS INDICATOR LAMPS PRE RESET START HEAT LAMP TEST SWITCHES REMOTE CONTROL FIELD CIRCUIT BREAKERS DC AMMETER CONTROL COMPONENTS The following describes the basic engine control components and how they function Engine Monitor Circuit Board A solid state printed circuit board that monitors all engine control system functions This includes starting stopping and fault system operation terminal board is included for making remote connections See Figure 30 Overcrank
79. r 115 230 V 50 60 Hz Transformer Pulse Potentiometer 10 K 1 2W Resistor 61 9 K 1 2W 1 Resistor 28 1 4W 1 Resistor 51 1K 1 4W 196 Resistor 2 2M 1 2W 595 Resistor 15K 5W 5 Resistor 5 1 2W 5 Resistor 220 1 2W 5 Resistor 330K 1 2W 5 Resistor 1000 1 2W 5 Resistor 10K 5W 5 Resistor 1M 1 2W 596 Resistor 4 7K 1 2W 5 Resistor 220K 1 2W 5 Resistor 100 K 1 2W 596 Resistor 5 1 K 1 2W 5 Resistor 1 2 K 1 2W 596 Resistor 2 7K 1 2W 5 Resistor 62K 1 2W 596 Resistor 27K 1 2W 5 Resistor 68K 1 2W 596 Resistor 47K 1 2W 5 Resistor 150 Q 2W 5 Potentiometer 100K 1 2W Resistor 10K 1 2W 596 Resistor 2 2 K 1 2W 5 Resistor 270 10W 5 Power Transistor Silicon NPN Transistor Silicon NPN High Volt Transistor Silicon PNP Relay Rectifier Fast Recover Rectifier Silicon 6A 800V Diode Fast Switching Rectifier Silicon 1A 800V Capacitor 4000 MFD 30V Capacitor Metalized 33 400 V Capacitor Metalized 001 1000V Capacitor Metalized 47 250V Capacitor Metalized 1 MFD 100V Capacitor Metalized 1 MFD 100V Capacitor Metalized 22 MFD 630 V Capacitor Metalized 1 MFD 250 V Capacitor Metalized 1 MFD 400V Capacitor Metalized 47 MFD 400V Capacitor 10 MFD 20V Capacitor Monolytic 22 MFD 50V Capacitor Metalized 047
80. rs are discharged before testing Contact with high voltage might cause serious personal injury or death Avoid contact with capacitor terminals Dan gerous voltage might be present up to a minute after set shutdown Place the ohmmeter on the R x 1 scale and touch the test prods to the capacitor terminals The meter poin ter should rise and then quickly drop back as the capacitor becomes charged If the pointer does not move the capacitor is open If the pointer rises but does not drop back the capacitor is shorted Replace the capacitor if either condition exists 5 TESTING VOLTAGE REGULATOR The voltage regulator assembly can be removed from the control and tested for proper operation if neces sary The following test equipment is required SCHEMATIC EQUIPMENT REFERENCE Switch S 5 Amp Fuse F Variable Transformer 4 Amp 0 280 VAC T1 AC Voltmeter or 2 10 1 250 V1 3 Scale DC Voltmeter 0 10 0 50 and 0 300 or 296 of full scale V2 Resistor 1 65 or 150 Ohm R1 Resistor 50 ohm 1200 W R2 Redistribution or publication of this document by any means is strictly prohibited GENERATOR CONNECTION GENERATOR SCHEMATIC CONNECTION DIAGRAM SCHEMATIC DIAGRAM 120 240 220 380 347 600 T GENERATOR CONNECTION WIRING DIAGRAM WITH CURRENT TRANSFORMERS WHEN USED 110 220 115 230 120 240 GENERATOR CONNECTI
81. rted to DC by a 12 silicon controlled rectifier bridge and fed into the exciter field windings The exciter armature produces three phase AC voltagethat is converted to DC by the rotating rectifier assembly The resultant DC voltage excites the generator rotor winding to produce the T3 15 amp 515 stator output voltage for the AC load 7 AND 9X a THREE PHASE 55 TO VOLTAGE REGULATOR EXCITER CIRCUIT 2 rs Generator sets without a control panel or switch ES 1315 board containing AC instruments such as voltmeters ONLY ammeters running time meter frequency meters FIGURE 2 SINGLE AND THREE PHASE GENERATOR and line circuit breakers are shipped from the factory SCHEMATIC COMPOSITE with the AC output leads separated in the output box On generator sets with switchboards containing AC instruments the AC output leads are wired as speci fied on the customer s purchase order to deliver only the voltage specified BRUSHLESS ROTATING GENERATOR EXCITER DIODE ROTOR URE ROTOR ARMAT ASSEMBLIES MAIN FIELD SHAFT FULL WAVE BRIDGE RECTIFIERS EXCITER A MAIN a RESIDUAL MAGNETISM FIELD FIELD IN ROTOR STARTS MAGNETISM BESIBOAE MAGNETISM PROCESS MAGNETISM cer INPERMANENT tetro diem MAGNET STARTS PROCESS YD ONLY STATOR ASSY GENERATOR ___ STATOR BRUSHLESS EXCITER FIELD VOLTAGE REGULATOR VR 2
82. s B and E 15 exciter field voltage 5 volts DC or more between TB1 5 and TB1 11 yes no Check exciter field wiring harness per TEST M Replace bad wiring Replace if bad Check exciter field winding per TEST H Replace if bad Test voltage regulator assembly per procedure Replace the regulator PC board per procedure F if defective Th new printed circuit board might be damaged by malfunctioning components within the control Do not install the new PC board until all other problems have been located and corrected 20 Remove one lead from breaker and check continuity with ohmmeter Is breaker open Check C1 capacitors for opens or shorts per Test R WARNING Contact with high voltage might cause serious personal injury or death Avoid contact with capacitor terminals Dangerous voltage might be present up to a minute after set shutdown Replace defective field breaker yes If voltage is unstable high or low or causes breaker to trip see Flow Charts B C D or E Flash exciter field per TEST D Does generator output voltage build up Disconnect stator leads 7 4 and 8 1 from TB2 2 and H1 15 residual voltage across leads 5 to 10 VAC or more now Check lead continuity between the following terminal points and the generator per Test M TB2 2 and T8 16 lead 1 TB2 Hi and T7 12 lead 4 TB2 1 and T9 Check dio
83. s Resistance 50 Hertz Code 53R Code 515R 16 0 DL4 20 0 DL6 25 0 DL6 32 0 DL6T L TESTING GENERATOR ROTOR For these tests use an ohmmeter on the highest res istance range R x 10 k Q Testing for Grounds On brushless type generators check for grounds between each rotor lead and the rotor shaft Figure 19 Perform tests as follows 1 Remove rotor leads 1 and F2 from rotating rectifier assemblies 2 Connect ohmmeter leads between F1 and rotor shaft and between F2 and rotor shaft Meter should register one megohm or greater If less than one megohm rotor is grounded 4 Replace grounded rotor with new identical part Testing for Open or Shorted Windings Perform tests as follows 1 Remove rotor leads F1 and F2 from rotating rectifier assemblies SASS SES M B215 CONTACT ONE PROD TO EACH OF THE FIELD LEADS AND OTHER PROD TO ROTOR SHAFT IF ROTOR IS GOOD THERE WILL BE ONE MEGOHM OR GREATER RESISTANCE FIGURE 22 TESTING ROTOR FOR GROUNDS 60 Hertz Code 3R Code 15R 2 2 Using ohmmeter check resistance between F1 and F2 leads Figure 23 The resistance values at77 F 25 C should beas shown in Table 3 lf not replace defective rotor with new identical part Zn P CONTACT ONE PROD TO EACH FIELD LEAD 8213 FIGURE 23 TESTING ROTOR FOR AN OPEN CIRCUIT TABLE 3 RESISTANCE VALUES FOR ROTORS ______ OhmsResista
84. s eee ISILKSCREEN CONT SILKSCREEN CONT 35 ee ie ees ee 771 Ly TT r 4 ee 5 5 se eel 9 4 II t it l 1 1 nares I 1 1 1 UNLESS OTHERWISE NOTED ALL COMPONENTS SHOWN THE DE ENEAGIZED POSITION LINE 2 OPTIONAL DC GAUGE CAN BE EITHER ELECTRIC OIL TEMP GAUGE OR AN ELECTRIC TACHOMETER 3 OPTIONS ARE SHOWN CONNECTED N DASHED LINES JJ 1 258 REVISTO PER EA SEE ER te1 4 TegpopRLSE 7 OF OMAN CORPORATION Minneopelts Mina renta _______ 4 65 DEA 15 100 38 SET AC mj WIRING DIAGRAM 8 ez e 6015 GEYOW MY 001 91 nz Eus a 21709 2191 9MIBIA 1 9v 135 0u1802 tz L0 2870372 U313NO0H2YL 21812313 YO 39nv9 10 20112313 38 390 9 20 YNO ldO 104100 ASSY WoLl2Ydvo Qausva O3IO93HHOO9 HAOHS 3uY 5 01140 NOILISOd 032 043N3 30 NI HMOHS 419 S1N3
85. s for proper connection See Figure 26 Check generator rotor field winding per TEST L Replace if bad Check exciter stator winding per TEST Replace if bad Check exciter rotor winding per TEST J Replace if bad Check generator stator windings per TEST K Replace if bad Test voltage regulator assembly per procedure T Replace the regulator PC board per procedure F if defective The new printed circuit board might be damaged by malfunctioning components within the control Do not install the new PC board until all other problems have been located and corrected 22 Redistribution or publication of this document by any means is strictly prohibited Generator Regulator Tests GENERAL of the following Adjustments and Tests can be performed without disassembly of the generator They should be used for testing generator regulator components in conjunction with the troubleshooting flow charts TESTING AC RESIDUAL VOLTAGE Test for residual AC voltage if there is no AC power output from the generator Check between terminals 2 and H1 on TB2 Figures 11 and 12 Residual volt age should be 5 to 10 VAC If none flash the field per Test D If residual voltage is present at TB2 proceed to PC board VR1 On sets with the standard regulator check between terminals 1 and 2 on TB1 Figure 11 On sets with the switching regulator check between terminals 2 and 3 on 1 Figure 12 I
86. sary to restore residual magnetism by flashing the field Assemble a 6 volt battery 10 ohm resistor and diode as shown in Figure 16 Redistribution or publication of this document by any means is strictly prohibited DC VOLTMETER 6 VOLT DRY CELL BATTERY FIGURE 15 TESTING 21 If a 6 volt lantern battery is not available a 12 volt 24 volt generator set battery can be used However 20 ohm or a 40 ohm 2 watt resistor must be used in series respectively with the 12 amp 300 V diode Start 2 5 the generator set and operate at normal rpm Touch the positive lead to terminal TB2 4 and the nega tive lead to terminal TB2 5 Hold leads on termi nals just long enough for voltage to build up Incorrect flashing procedure can damage the voltage regulator Do not keep excitation circuitry connected longer than 5 TB2 4 4 PLACE RESISTOR HERE seconds 6V Use 100 2V Use 2092 ES 1420 45 TESTING REFERENCE BATTERY TRANSFORMER 21 Transformer T21 has eight leads six are primary FIGURE 16 FIELD FLASHING CIRCUIT leads marked H1 through H6 two are secondary leads marked X1 and X2 TABLE 1 TESTING RECTIFIER BRIDGE ASSEMBLY CR21 RECTIFIER TESTING TERMINALS CR SCR METERSCALE 24 6 to 50 Ohms 4 M Te MN AC2 Ae 2 x
87. tion See Figure 31 K3 Fuel Solenoid An integral part of the fuel injection pump Opens the fuel control valve when the Start Stop Remote switch is placed in the Start position K11 Start Disconnect Relay Located inside the con trol box Energized by a voltage output from the gen erator Disconnects the cranking circuit when the engine starts See Figure 30 Redistribution or publication of this document by any means is strictly prohibited K11 START DISCONNECT RELAY START DISCONNECT RELAY K2 ON OFF RELAY K12 START RUN RELAY K1 FAULT RELAY ENGINE MONITOR CIRCUIT BOARD REMOTE NINE LIGHT TERMINAL BOARD REMOTE FAULT ALARM SWITCH baa REMOTE LIGHTS RMT 3 RUN LOP OC OS HET LET PLOP SW OFF GND AMT 4 FAULT START SHUTDOWN PR LO ALARM RUN SC 1313 DOWN OIL SWITCH ER HIENG RANK TEMP PRESS OFF GROUND PRE HI LO OIL LO ENG FAULT SHUT START PRESS SPEED TEMP temp ALARM DOWN 5 1293 PREHEAT REMOTE FIGURE 30 CONTROL BOX INTERIOR K12 Run Relay Optional Located inside the control terminal shown in Figure 30 Current limitations for box Used with warning alarm to indicate when the optional equipment not supplied by ONAN are 100
88. uit shooting procedures breaker or a loose plug in are all potential prob lems that can be eliminated by a visual check A Engine does not crank e Unless absolutely surethat panel instruments are B Engine cranks but does not start accurate use portable test meters for trouble shooting C Engine starts but stops after running several seconds To troubleshoot 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 per forming referenced adjustment or test procedures Refer to typical wiring diagram in Figure 29 for locat ing control component leads terminals and other check points Before starting a troubleshooting procedure make a few simple checks that may expose the problem and cut down on troubleshooting time e Check all modifications repairs replacements FLOW CHART A ENGINE DOES NOT CRANK START Check battery per Checkout A and recharge or replace Check alternator operation per t checkout C is battery dead no Check for possible fault conditions Is the K1 fault relay energized If ok check K1 fault relay per Checkout E no Check battery cables for clean and tight connections ref Checkout B Check B1 starter solenoid motor if bad repair or replace Jumper battery cable B connection to B1 starter solenoid terminal Does engine crank yes
89. ument indicating AC generator voltage AC Ammeter Optional Dual range instrument indi cating AC generator line current Tachometer Optional indicates engine speed in r min The gauge has a range of 0 to 3500 r min Oil Temperature Gauge Optional Indicates engine oil temperature The gauge has a range of 150 to 300 F 66 to 149 C Start Stop Remote Switch Starts and stops the unit locally or from a remote location wired to the control panel Pre Heater Switch Provides control for glow plugs for cold diesel engine starting 34 Reset Switch Resets engine monitor circuits after an emergency shutdown On the optional contro panel the switch is also utilized to verify that the ninelamps are functioning properly Phase Selector Switch Optional Selects phase of generator to be measured by AC voltmeter and ammeter Voltage Adjustment Optional Provides approx imately plus or minus 5 percent adjustment of the rated voltage Circuit Breakers Field Breaker 5 ampere breaker provides generator protection in case of a malfunction Control Breaker A 7 ampere breaker provides pro tection to the control box wiring from a short circuit or overload Remote Breaker A 7 ampere breaker protects acces sory remote controls and wiring from a short circuit or overload Indicator Lights The standard control panel has two monitor system indicator lights e Run green Fault red The green Run light c

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