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Service Manual, 20-300 kW FR II (TP-5353)

1. AC F AC F 7 x N Y O O O A N A 2 lt 233999 292902 3 SCR Assembly 180 300 kW Figure 7 6 Component Locations To test the SCR assembly and photo transistor board the following components are needed e One 120 volt 110 watt light bulb with socket Switch DPST double pole single throw 120 volt 10 amp minimum e Fuse 1 amp in holder 120 volt AC plug with cord e One good SCR assembly and photo transistor board TP 5353 8 94 This test simulates the normal operation of the components when the generator is running In the test a known good component example photo transistor board is matched with a component of unknown quality example SCR assembly If the components do not function normally during the test it is reasonable to assume that the component of unknown quality is defective Test either component in this manner Generator Troubleshooting 7 9 Hazardous voltage can cause severe injury or death Carefully follow instructions in the equipment manual when testing or servicing generator set in the presence of voltage Hazardous voltage can cause severe injury or death Whenever electricity is present there is the hazard of electrocution Open main circuit breaker on all power sources before servicing equipment Electrically ground the generator set and electrical circuit
2. t LOG GL 2515 eva Q 2 VY Lr E Java Coo E a EY 338 ted Lz ASSEMBLY NO 6 292806 Safeguard Circuit Breaker Voltage Bac Reg Q Alternator Flash Aux Delay Shutdown BATTERY nor Ha Auxiliary Immediate Overvoltage Shutdown Switch 0 er 56 9 1 Engine Air P Damper Switch 57 AUX AUX PRE AWT ture BCF Anticipatory Low Oil Pressure Auxiliary Auxiliary Prealarm Anticipatory High Water Tempera Battery Charger Fault EAD Engine Air Damper E STOP Emergency Stop FS Fuel Solenoid HWT High Water Temperature LBV Low Battery Volts LF Low Fuel LOP Low Oil Pressure IWT Low Water Temperature NIA Not In Auto Overcrank OS Overspeed SG Safeguard Circuit Breaker SYS RDY System Ready WLS Water vil iiteh Output G 292806 S Figure 5 4 Microprocessor Controller Connections P1 and P2 TP 5353 8 94 Controller Troubleshooting 5 5 Anticipatory Low Oil Pressure AUX Auxiliary 26 12 39 38 36 68 80 40 41 32 63 61 62 35 AUXPRE Auxiliary Prealarm D 2 2 AWT Anticipatory High Water Temperature Z Z 2 BCF Battery Charger Fault EAD Engine Air Damper E STOP Emergency Stop FS Fuel Solenoid HWT High Water Temperature LBV Low Battery Volts LF Low Fuel LOP Low Oil Pressure
3. 1 Drive Discs Figure 8 4 Separating Generator and Engine 8 Set the generator assembly on the floor in a horizontal position Remove support slings or chains To remove the rotor assembly hook hoist to adapter and place generator assembly on floor ina vertical position See Figure 8 5 Before lowering assembly place boards along the edge of end bracket to prevent damage to photo transistor board Generator Disassembly Reassembly 8 5 1 Drive Disc Removal 2 End Bracket Support Figure 8 5 Generator Support Drive Disc and Fan Removal 10 11 12 13 Remove drive discs and fan from generator assembly See Figure 8 5 NOTE Some 50 100 kW Ford powered models use a special drive disc flywheel mounted to the rotor shaft The special drive disc flywheel had a lip on the outer circumference and was not a flat surface drive disc Later models use a flat surface drive disc Fasten lifting eye and hoist hook to rotor flange Hoist rotor carefully to avoid damaging exciter armature or exciter field magnets See Figure 8 6 While rotor is suspended remove photo transistor board and actuator cup Remove F3 G and AC leads from SCR assembly Cut off photo transistor board terminals to remove circuit board If photo transistor board is reused leave leads as long as possible Slowly lower rotor to horizontal position Set the rotor on a wooden surface Take care not
4. generator master switch in RUN position Is emergency stop switch controller or remote activated See emergency stopping in Section 2 Operation Do controller LED2 and LED3 light with A Was there a fault shutdown No Yes o Yes Reset emergency stop switch controller or remote Reset air damper on 200 1600 kW Detroit Diesel models only Is LED4 lit No Y Replace circuit Correct fault board Check engine start circuit P1 harness starter solenoid battery connections etc Is start circuit okay Yes Repair defective Replace component circuit board Place test jumper between TB1 1 test jumper before proceeding and TB1 1A Is LED4 lit Remove emergency stop switch Repair replace defective controller or remote Y Check for DC voltage at Fuse F2 3 amp See Figure 6 4 Voltage at fuse indicates fuse is good Is voltage present Check fuse Is Replace circuit board fuse okay Y Replace fuse If fuse blows again refer to Fuses earlier in this section 6 4 Generator Controller Troubleshooting Check P1 connector harness Check if battery connections are loose or reversed TP 5353 8 94 Engine Cranks
5. X X 273000 Droop Pot Gain Pot Idle Spd Speed Pot Run Spd Speed Pot Power Cable Relay Connect to Ground Stud in Controller Connect to Cranking Solenoid Battery Connect to 70 of Safeguard Breaker Terminal Block 10 Actuator 11 Magnetic Pickup 12 Twist Magnetic Pickup Leads Before Connecting to Controller 1 turn per inch 25 mm Figure 7 32 Governor Control Unit Paralleling Generator Set Generator Troubleshooting 7 31 Low Idle Adjustment Screw High Idle Adjustment Screw Injector Pump Actuator Shutoff Shaft Assembly Droop Adjusting Screw Figure 7 33 Governor Adjustments Typical Actuator Calibration The following procedure is used to setup the mechanical governor for operation with the electronic integrated actuator Perform calibration of both the mechanical and electronic governor in order for the system to operate correctly Lack of maximum power or poor steady state speed control results from incorrect calibration See Figure 7 33 NOTE The actuator calibration procedure was performed at the factory and no additional adjustment is necessary The actuator calibration procedure is done only if removal of fuel injection pump has occurred or the adjustment is questionable Do not perform this procedure unless it is deemed necessary 1 Position the shutoff s
6. and gain adjustments Slowly turn the gain adjustment potentiometer clockwise until the output shaft and linkage oscillates Slowly turn gain adjustment potentiometer counterclockwise until the actuator lever is stable Jog the actuator lever by hand If the actuator lever oscillates three to five times and then stabilizes the gain setting is correct Turn the gain potentiometer division counterclockwise Turn the D adjustment fully clockwise while observing the actuator shaft If the lever does not become unstable jog it by hand When the lever oscillates turn the D adjustment counterclockwise slowly until the actuator shaft is stable Jog the lever again it should oscillate 3 5 times and then become stable If the system response to load changes is satisfactory at this point omit Step 8 Turn potentiometer fully clockwise and watch the actuator shaft If the actuator lever does not become unstable jog it by hand When the actuator lever slowly oscillates slowly turn the I potentiometer counterclockwise until the lever is stable Jog the actuator lever by hand It should oscillate 3 5 times before stabilizing The governor is now calibrated Stop the generator set TP 5353 8 94 Electronic Governor Barber Colman Dyna 70025 using Stanadyne D Series Injection Pump 20 100 kW John Deere Powered and 20 100 kW Detroit Diesel Powered Models Some sets are equipped with Barber Colman Dyna
7. e The auxiliary lamp lights and engine shuts down if activated by customer supplied sensing devices connected to auxiliary immediate shutdown ports P1 17 and P1 18 Battery Charger Fault if battery charger equipped and connected Lamp lights if battery charger malfunctions Operation 2 3 11 12 13 14 15 2 4 Low Battery Volts if Battery Charger equipped and connected Lamp lights if battery voltage drops below preset level Overcrank Lamp lights and cranking stops if engine does not start after 45 seconds of continuous cranking or 75 seconds of cyclic cranking See Auto Starting e Cranking stops and overcrank lamp lights after 15 seconds if starter or engine will not turn locked rotor e Overcrank lamp flashes if speed sensor signal is absent longer than one second NOTE The controller is equipped with an automatic restart function The generator set will attempt to restart if the engine speed drops below 13 Hz Decreased engine speed causes an overcrank condition Auxiliary Prealarm is activated by customer provided sensing devices Air Damper Lamp lights after emergency stop or overspeed fault or overvoltage fault Lamp indicates that engine air damper is closed lamp remains lit until air damper is manually reset See Resetting Emergency Stop Switches later in this section Used on 200 1600 kW models with Detroit Diesel engines only System Ready Lamp lights when g
8. TENE wv L1 WETER SCALE Tm elo Lave Jovee REGULATOR 58 Ep AE As 60HZ 277 480V 3 PH 4 WIRE HGH WYE 60HZ 120 208V OR 139 240V NE 50H2 220 380N 3 PH 4 WRE HIGH WYE 3 PH 4 WIRE LOW 50HZ 7120 208V OR I0 SOV 3PH 4 WIRE LOW WYE 250v 250V TSA TSA 6 24 7 SPEED SENSOR d PHOTO COUPLING i 2 va Te2 Lave 12 LEAD STATOR SEE GENERATOR CONNECTONS 9 METER SCALE JNPER MAIN FIELD LOW WATER TEMPERATURE WATER LEVEL SWITCH SAFEGUARD BREAKER LOW OL PRESSURE PREALARM LOW OL PRESSURE HIGH ENGINE TEMPERATURE PREALARM HIGH ENGINE TEMPERATURE OL PRESSURE CURRENT TRANSFORMER HERTZ ENGINE IGNITION SYSTEM VOLTMETER AMMETER BATTERY CHARGING ALTERNATOR ADV 5618 D CONTROLLER BOARD TERMINAL STRIP CT METER SCALE TERMINAL BLOCK AC FUSE TERMNAL BLOCK SAFEGUARD BREAKER TERMINAL BLOCK STARTER MOTOR STARTER SWITCH AR DAMPER RELAY GOVERNOR CONTROL RELAY FUEL SOLENOID HOUR METER BATTERY VOLTS WATER TEMPERATURE SENSOR ACTUATOR ROTATING PHOTO TRANSISTOR BOARD STATIONARY LED BOARD EXCITER ARMATURE RED BLACK HELD BLACK WHITE
9. replace circuit board Y Check starter solenoid on starter motor if so equipped Check starter motor Check battery ies Load test battery ies TP 5353 8 94 Generator Controller Troubleshooting 6 15 Does engine start _ Troubleshooting Manual Controller Continued No Is DC voltage present at the following components if so equipped Ignition module gas gasoline Fuel pump gasoline Fuel valve gas Fuel solenoid diesel 20 180 kW Governor controller diesel 200 300 kW Is K4 relay ad LED lit B Check harness connections from control board to component Engine fault check the following components if so equipped Fuel supply Ignition module gas gasoline Fuel pump gasoline Fuel valve gas Fuel solenoid diesel 20 180 kW Governor controller diesel 200 300 kW Y Did an engine safety shutdown for overspeed occur 6 16 Generator Controller Troubleshooting No Replace main circuit board defective K4 relay e Check for overspeed overfrequency e Check test electronic gov ernor and or voltage regu lator TP 5353 8 94 Troubleshooting Manual Controller Continued Does engine continue B to run after start switch is released Yes Does engine stop when engine fault shutdown lead
10. AUXILIARY T27 2 OVERVOLTAGE PREALARM oro SHUTDOWN BATT CHG ALTERNATOR VOLTAGE Avo METER SCALE REGULATOR TB2 O 9 URALO MAME JUMPER UPViLO LAMP JUMPER 6 LEAD STATOR 12 LEAD STATOR MOLT 60HZ 277 480V 3 PH 4 WIRE HIGH WYE SOHZ 220 380V 3 PH 4 WIRE HIGH WYE uo en 44 VOLTAGI ADJUST SPEED SENSOR Ly Ej Y re D 9 PHOTO COUPLING aaa aan AA METERLSGALE 2 METER SCALE ae f aan ae LAMP JUMPER Te LAMP JUMPER 0 4 E js ee MAIN FIELD 12 LEAD STATOR SEE GENERATOR CONTROLLER BOARD TERMINAL STRIP CONNECTONS CT METER SCALE TERMINAL BLOCK f 45 AS AC FUSE TERMINAL BLOCK SPEED SENSOR SAFEGUARD BREAKER TERMINAL BLOCK STATIONARY ACTUATOR L EXCITER SM STARTER MOTOR A gt SRR L E D ARMATURE Ki STARTER SWITCH BOARD K6 AIR DAMPER RELAY ABD GOVERNOR CONTROL RELAY FS FUEL SOLENOID HR HOUR METER RED BLACK SHIELD NOTE BV BATTERY VOLTS BLACK WHITE CURRENT TRANSFORMER WT WATER TEMPERATURE DOT OR TOWARD LWT LOW WATER TEMPERATURE SHIELD WIRE ON GENERATOR WLS WATER LEVEL SWITCH 4 amp 6 CYL ONLY SFG SAFEGUARD BREAKER LOP LOW OIL PRESSURE R PLOP PREALARM LOW OIL PRESSURE Y HET HIGH ENGI
11. IWT Low Water Temperature NIA Not In Auto Overcrank OS Overspeed SG Safeguard Circuit Breaker SYS RDY System Ready WLS Water Level Switch S Ica 5 y ERE 5 sureerco eere 5 s OS 2515 Input te Output Q Lj N x RSSEMBLY NO 6 292806 EAD Switch Controller Circuit Board Off Reset 00000000000000005008 ET Generator TA Control Run Switch Horn 4 Switch Logic On Silence C Mil LL LLLI js O IBI Je ita eq Alarm Horn PRE O00 00000 EAD Controller 16 Light LED Indicators G 292806 S Figure 5 5 Microprocessor Controller to 16 Light LED Indicator Connections P3 5 6 Controller Troubleshooting TP 5353 8 94 BATTERY s TBI P3 P4 T56 amp T27 LE DESCRIPTION TERMNAL 0 70 RED Le BLACK RB WHITE WHITE BATTERY VOLTAGE FUSE 1 PROTECTED GROUND REMOTE START GROUND REMOTE START ACTIVE LOW CRANK MODE
12. Preliminary Adjustments 1 Place generator master switch to OFF position Generator set must not be running 2 Set the gain adjustment three divisions from zero 1 Control Unit Final Adjustments 2 Magnetic Pickup 3 Actuator 1 Place generator master switch to RUN to start 4 12 Volt Battery generator set Figure 7 25 Governor Control Unit 2 Adjust the control unit speed pot until the engine is operating at the desired rpm 50 or 60 Hz on the frequency meter 3 If governing is unstable turn gain pot slightly counterclockwise Gain pot has internal stops a 0 and 100 4 With the engine running at no load finalize gain adjustment Turn the gain adjustment clockwise until the output shaft and linkage is stable Upset the linkage by hand If the linkage oscillates 3 5 times then stops the setting is correct Stop the generator set 1 Actuator 2 Linkage Figure 7 26 Throttle Actuator Typical 7 26 Generator Troubleshooting TP 5353 8 94 Electronic Governor Barber Colman Dyna 8000 125 300 kW Detroit Diesel Powered Models Early 20 100 kW John Deere Powered and Early 20 100 kW Detroit Diesel Powered Models Some sets are equipped with Barber Colman Dyna 8000 electronic governors Since this is an electronic device no mechanical drive or hydraulic connection is required The system consists of a magnetic pickup a
13. ethylene glycol and 50 clean softened water is recommended to inhibit rust corrosion A coolant solution of 50 ethylene glycol will provide freezing protection to 34 F 37 C and overheating protection to 265 F 129 C A coolant solution with less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause damage to engine and components Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for specific engine coolant specifications Do not add coolant to an engine that has overheated until engine has cooled Adding coolant to an extremely hot engine can cause a cracked block or cylinder head NOTE Do not turn on block heater before filling cooling system Before energizing block heater run engine until warm and refill radiator to purge air from the system Block heater failure will result if heater element is not immersed in water Exhaust System Keep the exhaust outlet clear silencer and piping must be tight and in good condition Lamp Test Press the lamp test button if equipped to verify all controller lamps are operational Exercising the Generator Set If the generator set is not equipped with an automatic transfer switch or the transfer switch does not have the automatic exercise option run the generator set under load once a week for o
14. 18 55 65 F 13 18 55 65 F 13 18 C C C 55 65 F 13 18 C High Engine Temperature Shutdown Switch Powered 20 kW before serial no 329000 Ford 20 100 kW Ford Powered 20 180 kW John Deere Powered 20 60 kW Detroit Diesel Powered 80 100 kW Detroit Diesel Powered 125 180 kW Detroit Diesel Powered 200 300 kW Detroit Diesel Powered 211 225 F 99 107 C 218 238 F 103 111 C 211 225 F 99 107 C 211 225 F 99 107 C 218 232 103 111 C 211 225 F 99 107 C 211 225 F 99 107 C Low Oil Pressure Shutdown Switch 20 70 kW Ford Powered 80 100 kW Ford Powered 20 180 kW John Deere Powered 20 60 kW Detroit Diesel Powered 80 100 kW Detroit Diesel Powered 125 180 kW Detroit Diesel Powered 200 300 kW Detroit Diesel Powered 11 5 18 5 psi 79 128 kPa 32 36 psi 211 248 kPa 11 5 18 5 psi 79 128 kPa 11 5 18 5 psi 79 128 kPa 5 5 10 5 psi 38 72 kPa 11 5 18 5 psi 79 128 kPa 11 5 18 5 psi 79 128 kPa Specifications 1 5 Controller Gauge Senders Specification Oil Pressure Sender 0 psi 0 kPa 25 psi 172 kPa 50 psi 345 kPa 75 psi 517 kPa 100 psi 690 kPa in ohms 227 257 138 162 92 114 50 80 21 50 Water Temperature Sender 100 F 38 C 160 F 71 220 F 104 C 1 6 Specifications in ohms 10 450 130 47 TP 5353 8 94 Accessories Several accessories are avail
15. 2 Studs NOTE 3 Spacers Figure 8 18 Installing Spacers Some models mount drive discs to flywheel using bolts Some applications use hardened washers 18 Move generator as necessary to align generator adapter and flywheel housing Fasten and final tighten adapter to flywheel housing using bolts and hardened lock washers See Figure 8 19 Torque bolts to value given in Section 1 Specifications 20 Hoist generator and engine slightly to remove wood block s from under flywheel housing Align generator assembly and skid Lower generator and tighten vibromount mounting bolts Generator 21 Remove chains or slings used for suspending generator Final tighten drive discs to flywheel Torque hardware to values given in Section 1 Specifications Generator 22 Install fan guard 8 12 Generator Disassembly Reassembly TP 5353 8 94 23 Install and set speed sensor air gap at 0 014 0 028 in 0 36 0 71 mm See Figure 8 20 Replace LED board housing assembly to end bracket 24 Reinstall junction box and controller Reconnect all controller to engine and engine to generator harnesses and wiring Refer to wiring diagrams as required 25 Reconnect fuel cooling and exhaust systems that were disconnected during disassembly Reconnect output leads or load circuit cables at generator Open fuel supply valve 26 Reconnect starting batteries negative lead last Connect any AC powered accessories such as 0 014 0 028 in battery
16. 70025 electronic governor used in conjunction with a Stanadyne D Series injection pump This particular set up uses different governor controllers for a nonparalleling generator set or a paralleling generator set The system consists of a magnetic pickup an electronic control unit and an actuator The magnetic pickup monitors engine speed and transmits this information to the electronic control unit LEAD COLORS BLACK WHITE WHITE PURPLE mmoou 6 N GO 273000 Twist Magnetic Pickup Leads Before Connecting to Controller 1 turn per inch 25 mm Power Cable Relay Connect to Ground Stud in Controller Connect to Cranking Solenoid Battery 4 Connect to 70 of Safeguard Breaker Terminal Block Actuator Magnetic Pickup Figure 7 31 Governor Control Unit Nonparalleling Generator Set ONDARON TP 5353 8 94 See Figure 7 31 for nonparalleling generator sets or Figure 7 32 for paralleling generator sets The electronic control unit interprets the signal from the magnetic pickup to control current input to the throttle actuator The integrated throttle actuator adjusts the throttle position internally in the fuel injection pump See Figure 7 33 The magnetic pickup air gap is 0 014 0 028 in 0 36 0 71 mm ZNZ LEAD COLORS ANA NA ets gt 6 Pi d N d A BLACK B WHITE X
17. Figure 7 30 Throttle Actuator Typical Generator Troubleshooting 7 29 Preliminary Adjustments 1 Place generator master switch to OFF Generator set must not be running Set the control unit I adjustment one division from zero the D adjustment four divisions from zero and the gain adjustment at the third division from zero For isochronous operation set the droop adjustment potentiometer counterclockwise to the minimum position For droop operation set droop potentiometer to desired droop Droop adjustment may be necessary with parallel generator operation NOTE If the full stroke of the actuator shaft is used and the linkage is adjusted to use only the active fuel range the maximum obtainable droop would be approximately 12 at full load Position actuator lever to hold fuel pump lever in STOP position when power is off Adjust the actuator linkage for smooth non binding operation Final Adjustments Place generator master switch to RUN or TEST position to start generator set Adjust the control unit speed potentiometer until the engine is operating at the desired rpm 50 or 60 Hz on the frequency meter governing is unstable turn and gain potentiometers slightly counterclockwise 7 30 Generator Troubleshooting NOTE Except for the speed potentiometer control unit pots have internal stops at 0 and 100 With the engine running at no load finalize the I D
18. Ibs in Ibs in Ibs in Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs 5 2222227777727 333333333333 o Onn O ON AOR W 2 gt A o 2 2 2 333 on z 3 Dv a rer o o o o 222 z 3 Dv LC C D Assembled in Size mm Measurement i Aluminum 6 x 1 00 8x 1 25 8 x 1 00 10x 1 50 10x 1 25 12x 1 75 12x1 50 14 x 2 00 14x 1 50 16 x 2 00 16 x 1 50 18 x 2 50 18 1 50 5353 8 94 Appendices D 1 5353 8 94 1993 1994 2000 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Web site www kohlergenerators com Fax 920 459 1646 U S A Sales Fax 920 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
19. See Figure 3 1 For Ambient Temperatures Consistently Above Use Viscosity 32 F 0 10 F 23 C 20W 50 or 40W 10W 40 or 10W50 Figure 3 1 Oil Recommendation for 30 80 100 kW Ford Powered Models Oil Change Procedure 30 80 and 100 kW Ford Powered The 30 with LSG 423 engine 80 and 100 kW Ford powered models are equipped with turbochargers See the following service schedule turbocharger maintenance After changing the engine lube oil use the following procedure prior to restarting the generator set to prevent premature turbocharger bearing wear 1 Place generator master switch to OFF RESET position microprocessor controller or STOP position manual controller 2 Remove ignition coil to distributor wire at distributor Connect jumper wire to ignition coil lead and engine block NOTE ELECTRONIC IGNITION DAMAGE Damage to the electronic ignition system may occur if the coil is not grounded during turbocharger priming procedure 3 Remove turbocharger oil drain line at engine connection Place suitable container under oil drain hose 4 Place generator master switch to RUN position microprocessor controller or START position 3 2 Scheduled Maintenance manual controller to crank engine until fresh oil flows from turbocharger oil drain line NOTE STARTER DAMAGE Do not crank engine continuously for more than 10 seconds at a time Allow a 60 second cooldown period between
20. The switchgear provides the logic to start and stop the generator set Use the service literature supplied with the switchgear for troubleshooting See the appropriate wiring diagram for available paralleling engine gauge box controller wiring diagrams The paralleling engine gauge box controller contains a speed switch which controls crank and overspeed adjustments See Figure 5 8 OVERSPEED TEST RESET OVERSPEED pi E2 CRANK TACH CAL OVERSPEED 4 5 6 7 8 9 10 11 12 3 Sisisislsisisisis TP 5353 7 Overspeed Test Switch Overspeed Reset Switch Overspeed Adjustment Pot Crank Adjustment Pot Red Overspeed LED Green Crank LED Figure 5 8 Speed Switch Adjustments Speed Switch Adjustments The speed switch is powered by the generator set battery and the input speed signal is supplied by a magnetic pickup sensor monitoring the engine camshaft gear As the speed of the rotating gear increases the frequency of the AC signal from the magnetic pickup increases until each set point is surpassed An LED lights after the speed surpasses the set point and triggers an internal relay The set point for the speed settings are independent and are adjusted precisely with a 25 turn potentiometer The crank adjustment feature latches when the set point has been exceeded The overspeed adjustment feature latches and remains on until power is removed or the overspeed reset
21. and F red leads from SCR assembly Repeat flashlight test on photo transistor board If high voltage is detected voltage regulator Is battery voltage present check for battery voltage at _ Check wiring to voltage regulator Yes Check DC voltage at LED circuit board If high voltage is detected replace photo transistor board If no voltage is de tected test rotor Do exciter armature and main field windings check out okay No Yes Replace rotor Replace SCR assembly If no DC voltage is present unplug connector at LED circuit board and check voltage If DC voltage of 6 12 volts is pres ent replace LED circuit board LED is open If no DC voltage is present check wiring between voltage regu lator and LED circuit board Does wiring check out okay No Yes If DC voltage of 6 12 volts is present re place LED circuit board LED orflyback diode is shorted and or grounded Repair replace wiring regulator Replace voltage 7 2 Generator Troubleshooting 5353 8 94 Troubleshooting Generator High Output Voltage Remove and F red leads from SCR assem bly Does output voltage remain high Turn safeguard circuit breaker to OFF position Does output voltage remain h
22. approximately 500K ohms 1 2 megohm and higher indicates the field winding is good A reading of less than 500K ohms approximately indicates deterioration of winding insulation and possible current flow to ground Repair or replacement of the rotor assembly is necessary TP 5353 8 94 Repair F and F if test should show leads shorted to ground Solder and insulate splices Use new sleeving when tying leads to shaft or heat sink Replace generator rotor assembly if test shows a shorted or grounded winding Hazardous voltage can cause severe injury or death Carefully follow instructions in the equipment manual when testing or servicing generator set in the presence of voltage Hot parts can cause severe injury or death Avoid touching generator set field or exciter armature Generator set field and exciter armature will become hot if shorted Hazardous voltage can cause severe injury or death Follow instructions of test equipment manufacturer when performing high voltage test on rotor or stator An improper test procedure can damage equipment or lead to future generator set failures 1 Megohmmeter connections across F and F leads and rotor shaft Figure 7 13 High Voltage Test Generator Troubleshooting 7 15 Exciter Armature Hot parts can cause severe injury or death Avoid touching generator set field or exciter armature Generator set field and exciter armature
23. or fuel solenoid diesel fuel valves water valve city water cooled sets e lights during cranking and running CRK crank lamp e shows battery voltage switched to starter engine not necessarily turning e lights only during on crank cycles REG regulator lamp e shows battery voltage supplied to generator set s AC voltage regulator e lights only during cranking and running BATT battery lamp shows lights when test battery ies DC power supply is live and properly connected NOTE LO PB and OVERSPEED simulate malfunctions causing engine to shut down L O P and H W T circuits will start timing after engine has been running for 30 seconds Engine shutdown should occur 5 seconds after pushing fault switch TP 5353 8 94 1 Toggle Switches 2 Indicator Lamps 3 Overspeed Button 4 Engine Switch Figure 6 8 FASTCHECK Simulator Switches L O P low oil pressure H W T high water engine temperature OVERSPEED simulates a 70 Hz overspeed condition L F low fuel not used for testing L W T low engine water temperature A O P anticipatory low oil pressure A W T anticipatory high water temperature Generator Controller Troubleshooting 6 9 Operation Use the FASTCH
24. range Selector Switch Selects generator output circuits measure When switched to a position with three circuit lead labels amperage is measured on the upper lead and voltage is measured between the lower two leads AC ammeter and voltmeter will not register with switch in the OFF position Lamp Test Switch tests the controller indicator lamps Generator Master Switch Switch functions as controller reset and generator operation switch Refer to Starting Stopping and Controller Resetting Procedure following Alarm Horn Sounds if any fault or anticipatory condition exists except emergency stop battery charger fault or low battery volts Place generator master switch in the AUTO position before silencing alarm horn See Controller Resetting Procedure following Alarm Silence Switch disconnects alarm during servicing place generator master switch in the AUTO position before silencing alarm horn Restore alarm horn switches at all locations controller remote annunciator or audio visual alarm to normal position after fault shutdown is corrected to avoid reactivating alarm horn See Controller Resetting Procedure following Voltage Adjustment generator output voltage Fine adjustment for 2 12 Operation 13 14 15 16 17 18 19 20 21 22 Emergency Stop If equipped Switch is used to instantly shut down the generator set in emergency situations Reset switch after
25. stud green lead to G stud and black lead to remaining AC stud Secure leads with stop nuts Torque connections to 8 in Ibs 0 9 Nm maximum photo transistor board and cause hazardous voltage in generator set AC voltmeter must show correct output before generator set may be reconnected to load 3 089 R12758 29 R12758 29 1 Magnetic Actuator 2 Photo Transistor Board Figure 8 15 Mounting Photo Transistor Board and Figure 8 14 Installing Photo Transistor Board Magnetic Actuator 8 10 Generator Disassembly Reassembly TP 5353 8 94 12 13 14 Loctite is a registered trademark of Loctite Corporation Suspend the rotor over the generator assembly Lower the rotor field into stator Be extremely careful while lowering the rotor to avoid damaging the exciter armature field magnets stator windings or rotor laminations See Figure 8 16 Carefully align rotor bearing into end bracket Check for an outer race measurement of 1 4 in 0 6 mm from bracket to bearing Make sure the photo transistor board and actuator cup have clearance below the end bracket Figure 8 16 Installing Rotor Place fan over rotor flange and torque bolts to 260 in Ibs 29 Nm Attach drive disc s to end of rotor shaft Torque drive disc s mounting bolts to 50 ft Ibs 68 Nm NOTE Some 50 100 kW Ford powered models use a special drive disc flywheel moun
26. they should seek medical attention Carbon monoxide can cause severe nausea fainting or death Do not use copper tubing in diesel exhaust systems Diesel fumes can rapidly destroy copper tubing in diesel exhaust systems Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust leakage Fuel System WARNING f b Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels TP 5353 8 94 Explosive fuel vapors can cause severe injury or death All fuels are highly explosive in a vapor state Use extreme care when handling and storing fuels Store fuel in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running since spilled fuel may ignite on contact with hot parts or from ignition spark Do not smoke or permit flame or spark to occur near potential sources of spilled fuel or fuel vapors Keep fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Flexible sections are used to avoid breakage due to vibration If any fuel leakage fuel accumulation or electrical sparks are noted DO NOT OPERATE GENERATOR SET Repair systems before resuming generator set operation atety Precautions and Instructions III Explosive fuel vapors can cause severe injury or death Take additional precautions when usi
27. 258782 3 PUE WA V eee ls IV AV AVIA DIG DA IG DAGS Js ll ow 212A 237 2A 227 4 lex o ES 42B SI 2 1 10AMP Figure 1 2 Remote Annunciator with 14 Relay Dry Contact Kit TP 5353 8 94 Specifications 1 7 Surface Mount Flush Mount ORE Os OSEN LOW WATER SYSTEM TEMPERATURE READY GENERATOR O LON FUEL O NTN AUTO 7 S SILENCE C NORMAL LAMP Test 258782 256452 Dry Contact Kit T RATINGS 28 P t Mean A 256472 Figure 1 3 Remote Annunciator with 10 Relay Dry Contact Kit 1 8 Specifications TP 5353 8 94 Audio Visual A V Alarm with microprocessor controller only An ANN alarm warns the operator of fault shutdowns and prealarm conditions except battery charger fault and low battery voltage from a location remote from the generator A V alarms include alarm horn alarm silence switch and common fault lamp See Figure 1 4 NOTE Use the audio visual alarm with a dry contact kit Front View Side View Figure 1 4 Audio Visual Alarm Ten Relay Dry Contact Kit with microprocessor controller onl
28. 50 and 60 Hz operation at no load if the generator set is equipped with an isochronous governor Connect a frequency meter across VO and V7 on the control board terminal strip generator set must not be running while making connections if the controller is not equipped with a frequency meter Refer to Figure 9 5 To adjust governor speed refer to Section 7 Component Testing and Adjustment Governors UP CO 2 C3 TP 5353 6 a Frequency Meter Connection Points Figure 9 5 Frequency Meter Connections TP 5353 8 94 AD 9 A ossary Abbreviations Abbreviations are used throughout this manual Normally they will appear in the text in complete form with the abbreviation following in parentheses the first time they are used After that they will appear in the Abbreviation Description ABDC after bottom dead center AC alternating current AISI American Iron and Steel Institute AHWT anticipatory high water temp ALOP anticipatory low oil pressure AM amplitude modulation amp ampere amps amperes ANSI American National Standard Institute API American Petroleum Institute approx approximate approximately A R as required as requested A S as supplied as stated as suggested ASA American Standards Associat
29. A defective voltage 3 101 adjust rheostat usually results in a nonadjustable R8371 3 voltage 3 Check for battery voltage at the voltage regulator harness plug pins 2 and 11 with the generator set running If there is nota voltage reading check the safeguard circuit breaker If battery voltage is not present there should be a very low voltage at the main output leads 4 While the generator set is running check for approximately 1 2 volts DC output at terminals 3B and 5B on the LED board or separate 3B 5B connector and check for 8 volts approximately at the connector If voltage is not measured at connector check for open or short circuit in wiring back to voltage regulator If a fault exists in voltage regulator wiring repair or replace as necessary If 1 AVR Board in Junction Box voltage regulator wiring tests good replace the voltage regulator Low voltage at the LED circuit Figure 7 9 AVR and Connections board may cause a low output voltage fault TP 5353 8 94 Generator Troubleshooting 7 13 Stator NOTE Generator sets use a skewed slanted rotor with a straight stator When replacing either rotor or stator be sure replacement is the same as the original 1 Check the generator output leads for proper connections Refer to Wiring Diagrams 2 Check the stator windings for e Shorted windings Inspect for burnt or hot windings Replace stator i
30. DISCONNECT RELAY K2 ENGINE RUN RELAY ENGINE CRANK RELAY K4 FAULT SHUTDOWN RELAY K5 FAULT SHUTDOWN TIME DELAY RELAY GOVENOR CONTROL RELAY K20 STARTER RELAY SOLENOID FS FUEL SOLENOID WT WATER TEMPERATURE GAUGE a wees N 12 LEAD STATOR 6 SEE GENERATOR Figure 5 9 Manual Controller BLANK DENOTES CONTACT OPEN C DENOTES CONTACT CLOSED M DENOTES MAKE BEFORE BREAK CONTACT HR HOUR METER BV BATTERY VOLTMETER SFG SAFEGUARD BREAKER OP OIL PRESSURE GAUGE CURRENT TRANSFORMER HZ HERTZ FREQUENCY METER 15 IGNITION SYSTEM VOLTMETER A AMMETER OPS OIL PRESSURE SENDER WTS WATER TEMP SENDER S ADV 5664 C Controller Troubleshooting 5 13 Section 6 Generator Controller Troubleshooting Microprocessor Controller Relay Descriptions A description of the controller and generator relays is given below Use this information in troubleshooting the generator set conjunction with the Troubleshooting Microprocessor Controller flow charts on the following pages Use the troubleshooting section following and the appropriate wiring diagram for additional information K1 Relay Starter Solenoid e Energizes starter K1 relay is located on engine See Figure 6 1 TP 5353 6 Figure 6 1 Starter Solenoid K2 Relay Crank Relay on Main Circuit Board e Energizes K1 Relay LED2 lights when energized during crank
31. OPEN CYCLIC GROUND CONTNUDUS OVERCRANK INDICATOR 2 REGULATED AUXILIARY INDCATOR COMMON FAULT LINE HIGH ENGINE TEMPERATURE INDICATOR DAR LOW OL PRESSURE INOICATOR OVERSPEED NOCATOR OFF RESET COMMAND LOW AUTO COMMAND ACTIVE LOW RUN COMMAND ACTIVE LOW AR DAMPER INDICATOR SYSTEM READY NOCATOR NOT N AUTO INDICATOR AUXILIARY PREALARM CUSTOMER DEFINED LOW WATER TEMPERATURE REQUFES PREALARM HIGH ENGINE TEMP NOCATOR PREALARM LOW OIL PRESSURE NDICATOR OPERATE EMERGENCY STOP RELAY K4 GROUND EMERGENCY STOP RELAY K4 COL NEGATIVE EMERGENCY STCP INDICATOR BATTERY CHARGER FAULT ACTIVE LOW LOW BATTERY VOLTS ACTIVE LOW LOW FUEL ACTIVE LOW MUST HAVE JUMPER IF THERE 6 NO EMERGENCY STOP KIT CONNECTED ELECTRONIC 19 SELECTOR SWITCH GOVERNOR CONTE CONTROLLER BOARD FUSE 1 FUSE 2 3 GROUND P1 5 1 12 FUSE BATTERY PET FUSE B BATTERY VOLTAGE FUSE 3 CONTACTS SHOWN WITH SWITCH IN OFF POSITION ACTUATOR AUXLIARY DELAY SHUTDOWN WLS FOR J 30 SEC AFTER START THEN 5 SECONDS BATTERY Lx acl FUSE P2 3 SHUTDOWN AC CRANK DISCONNECT 2 5 AUXILIARY DELAY 31 SHUTDOWN OVERVOLTAGE MNEDIATE P2 2 SHUT
32. P2 Connections Fuses The chart following lists the possible causes of blown replace it and resume operation If the fuse blows again controller fuses F1 F2 and If a fuse is blown use the chart to identify the faulty component s Blown F1 fuse remote annunciator 3 amp Defective dry contact kit Defective audio visual alarm Remaining accessories connected to TB1 42A Blown F2 fuse controller 3 amp Battery connections reversed Shorted DC supply to indicator panel Shorted controller circuit board Blown F3 fuse engine and accessories 15 amp Defective engine electrical components Defective overvoltage board Defective panel lamps engine gauges TP 5353 8 94 Generator Controller Troubleshooting 6 3 Engine will not crank with generator master switch in RUN position Engine Will Not Crank Y Is battery fully charged troubleshooting sequence Y Charge battery and attempt restart If engine will not crank continue Do lamps light Press lamp test button No Are connections okay Check P3 P4 harness and connections Yes Replace P3 P4 harness Replace defective indicator panel circuit board Is controller LEDA lit Y
33. after 75 seconds of cyclic cranking crank 15 seconds reset 15 seconds crank 15 seconds etc for a total of 75 seconds Shutdown occurs after 15 seconds if engine or starter will not turn locked rotor Low Oil Pressure Shutdown occurs 5 seconds after fault Low oil pressure shutdown will not function during the first 30 seconds after start up NOTE Low oil pressure shutdown will not protect against low oil level Check for oil level at engine High Engine Temperature Shutdown occurs 5 seconds after fault High engine temperature shutdown will not function during first 30 seconds after start up NOTE High temperature shutdown will not function if coolant level is not maintained Low Coolant Level Shutdown occurs 5 seconds after fault Low coolant level shutdown will not function during the first 30 seconds after start up NOTE Low oil pressure high engine temperature and low coolant level shutdowns will not function during the first 30 seconds after start up Overvoltage if equipped Unit will shut down after approximately two seconds of voltage 1596 or more over nominal voltage Low water temperature auxiliary lamp will light NOTE Sensitive equipment may suffer damage in less than one second of an overvoltage condition Install separate overvoltage protection to on line equipment requiring faster shutdowns TP 5353 8 94 Controller Resetting Procedure Following Fault Shutdown Use the following
34. alarm horn circuit board connector if equipped LED board and housing and speed sensor Remove junction box and controller as a unit 2 Remove bolts from generator vibromounts 3 Suspend the generator at both ends with hooks in lifting eyes Use a hoist to raise generator end off vibromounts See Figure 8 3 H Figure 8 3 Hoisting Generator 3 083 R8371 17 Hook Generator Adapter Wood Block s Support the engine by placing wood blocks under flywheel housing Lower generator end until generator flywheel housing rests on blocks See Figure 8 3 Remove fan guard Remove bolts holding adapter to flywheel housing NOTE Later 20 100 kW Ford powered models use a generator adapter that serves as the flywheel housing The stator attaches to the generator adapter flywheel housing Do not remove generator adapter flywheel housing from stator assembly unless replacing the stator assembly TP 5353 8 94 6 Remove nuts and spacers holding drive discs to flywheel NOTE The 200 300 kW Detroit Diesel powered models use screws and hardened washers to mount drive discs to flywheel The 33 45 kW 6 cylinder Ford powered models use screws and spacers to mount drive discs to flywheel 7 Work drive discs over studs if equipped to separate generator from engine See Figure 8 4
35. available at time of printing Kohler Co reserves the right to change this literature and the products represented without incurring obligation Read through this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Precautions and Instructions section at the beginning of this manual Keep this manual with equipment for future reference Equipment service requirements are minimal but are very important to safe and efficient operation therefore inspect parts often and perform required service at the prescribed intervals An authorized service distributor dealer should perform required service to keep equipment in top condition ervice Assistance For sales and service in the U S A and Canada check the yellow pages of the telephone directory under the heading GENERATORS ELECTRIC for an authorized service distributor dealer or call 1 800 544 2444 For sales and service outside the U S A and Canada contact your local distributor For further information or questions contact the company directly at KOHLER CO Kohler Wisconsin 53044 U S A Phone 920 565 3381 Fax 920 459 1646 U S A Sales 920 459 1614 International Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455 To ensure supply of correct parts or information make note of the following
36. block Replace the fuse TB3 See Figure 6 5 No Instrumentation is defective Replace or repair component TP 5353 6 1 AC Fuse Terminal Block Figure 6 5 AC Fuse Terminal Block 6 6 Generator Controller Troubleshooting TP 5353 8 94 Lamp Circuit Board Lamp circuit board not functioning or not functioning properly fault lamps and alarm horn only Y Press lamp test button Improper input signal Main Yes Do lamps light circuit board is defective No Y Is lamp circuit board receiving power Check for input voltage at P4 8 and P4 20 soldered Yes connections on lamp circuit board See Figure 6 6 No Panel circuit board defective Replace it Is P3 P4 ribbon connector undamaged and properly connected On 200 1600 kW models with Detroit Diesel engines Replace main For these lamps to function requires Circuit board connection of air damper and auxiliary prealarm leads between circuit boards No Replace ribbon connector 1 P4 8 Connection 2 P4 20 Connection Figure 6 6 Checking Input to Lamp Circuit Board TP 5353 8 94 Generator Controller Troubleshooting 6 7 Overcrank Lamp Engine starts and runs but overcrank lamp flashes NOTE The overcrank lamp will flash if speed sensor signal is absent lon
37. charger block heater fuel transfer pump 0 36 0 71 mm etc 1 Speed Sensor 2 Wire 16 White Clear 3 Wire 24 Red 4 Wire 2 Black 5 Air Gap 0 014 0 028 in 0 36 0 71 mm 6 Actuator Cup Figure 8 20 Speed Sensor Air Gap TP 5353 8 94 Generator Disassembly Reassembly 8 13 Section 9 Generator Reconnection Voltage Reconnection Procedure WARNING This reconnection procedure details voltage reconnections only If frequency changes are required the governor and voltage regulator will need adjustment See Generator Frequency Change and Adjustment for information regarding frequency adjustment To illustrate the proper reconnection of 12 lead generator sets the following information is provided In all cases follow the National Electrical Code NEC guidelines Reconnect the stator leads of the generator set if a different output phase or voltage is desired Refer to the following procedure and the connection schematics following Follow all safety precautions at the front of this manual and in the text during this procedure NOTE Affix notice to generator set after reconnecting to a voltage different than the nameplate Order voltage reconnection decal 246242 from authorized service distributors dealers A WARNING Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental
38. charger if equipped 3 Select desired voltage connection from Figure 9 1 Route leads through current transformers and connect according to the diagram for desired phase and voltage NOTE Position current transformers CT1 CT2 and CT3 with dot or HI side toward generator set NOTE Current transformers CTs are only used on generator sets equipped with controllers with meters and or safeguard circuit breakers Generator Reconnection 9 1 60HZ 120 240V 1 5 WIRE 60HZ 120 240V 35 PH 4 WIRE DELTA 50HZ 110 220V 1 3 WIRE 50HZ 110 220V 5 4 WIRE DELTA USED ON GENERATORS 20KW 100KW ONLY NOT USED 1 METER SCALE 1 METER SCALE TB2 LAMP JUMPER TB2 LAMP JUMPER 60HZ 1207 208V OR 139 240V 60HZ 277 480V 3 PH 4 WIRE HIGH WYE 3 PH 4 WIRE LOW WYE 50 7 220 380 3 PH 4 WIRE HIGH WYE 50HZ 120 308 OR 110 190V 4 WIRE LOW WYE CT2 8 OPTIONAL DROOP C T DROOP C T pROOP 1 METER SCALE 1 METER SCALE TB2 LAMP JUMPER TB2 LAMP JUMPER 6 LEAD STATOR 600 VOLT NOTE All 12 lead generator sets reconnectable The 6 600 volt generator set is not reconnectable Some special wound stators are made for a OPTIONAL specific voltage configuration and are also DROOP C T not reconnectable NOTE __ METER SCALE TWO TURNS THRU TP 5750 5 TB2 LAMP JUMPER CURRENT TRANS Figure 9 1 Generator Reconnections 9 2 Generator Reconnection TP 535
39. death Battery gases can cause an explosion Do not smoke or permit flame or spark to occur near a battery at any time particularly when it is being charged Avoid contacting terminals with tools etc to prevent burns and sparks that could cause an explosion Remove wristwatch rings and any other jewelry before handling battery Never connect negative battery cable to positive connection terminal of starter solenoid Do not test battery condition by shorting terminals together Sparks could ignite battery gases or fuel vapors Ventilate any compartment containing batteries to prevent accumulation of explosive gases To avoid sparks do not disturb battery charger connections while battery is being changed Always turn battery charger off before disconnecting battery connections Remove negative lead first and reconnect it last when disconnecting battery Safety Precautions and Instructions Engine Backfire Flash Fire A WARNING Gh 4 Fire Can cause severe injury or death Do not smoke or permit flame or spark to occur near fuel or fuel system sudden backfire can cause severe injury or death Do not operate with air cleaner removed A flash fire can cause severe injury or death Do not smoke or permit flame or spark to occur near carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing fuel line or car
40. engine speed is too high turn fast idle adjusting screw in until correct speed is obtained Tighten lock nut securely Stop generator set 7 24 Generator Troubleshooting NOTE If the fast idle is 50 rpm above or below the minimum maximum settings have an authorized service dealer remove and adjust the pump on a test stand 1 Injection Pump Lever 2 Fast Idle Adjusting Screw Figure 7 23 Governor Adjustments TP 5353 8 94 Mechanical Governor Bosch P 125 180 kW Detroit Diesel Powered Models NOTE Before checking and adjusting engine speed make sure engine has reached its normal operating temperature All speeds indicated apply to an engine hot under load The maximum permissible speed variation is 50 rpm for fast idle speed 1 Verify that injector pump lever is held in fast idle position See Figure 7 24 2 Check fast idle engine speed Engine speed should be 1800 rpm 60 Hz or 1500 rpm 50 Hz at full load 3 If fast idle speed is incorrect but not more than 50 rpm above or below the minimum maximum specified settings loosen fast idle adjusting lock nut 4 If engine speed is too low back out fast idle 1 Fast Idle Adjusting Screw adjusting screw until speed i
41. kW Ford Powered models These models are turbocharged and must use oil recommendations given in this manual Storage Procedure Perform the following steps if the generator set is out of service for three months or longer 1 Drain the lubrication oil while still warm from the crankcase and then refill with proper viscosity oil Run the generator set for a few minutes to distribute the clean oil Stop generator set 2 Gasoline fueled engines Add stabilizer to fuel or drain the fuel from fuel tank to prevent accumulated moisture with the fuel Drain the carburetor bowl or run unit until empty This step is done to prevent the gasoline from becoming stale which causes formation of gum Use of a gas stabilizer for 4 gasoline fueled generator sets is permitted in lieu of draining the carburetor bowl Add the correct amount of gas stabilizer to the fuel and follow all TP 5353 8 94 recommendations given by the gas stabilizer manufacturer Gaseous fueled engines With the generator set running shut off gas supply Run generator set until set stops from lack of fuel Gasoline and gaseous fueled engines Remove the spark plugs Pour approximately 1 tablespoon of engine oil into each spark plug hole Crank the engine two or three revolutions to lubricate the cylinders Reinstall spark plugs Clean exterior surface of the generator set and then spread a light film of oil over unpainted metallic surfaces to prevent rust o
42. least 30 seconds before pushing toggle switches Toggle generator master switch to OFF RESET position Move the FASTCHECK engine switch to OFF position Move generator master switch to RUN position Observe IGN CRK and REG lamps light Within 5 seconds move the FASTCHECK engine switch to RUN Generator Controller Troubleshooting 6 11 non EE LOT NO ASSEMBLY NO 12 24 VOLT 1 TB1 42A 2 TB1 See chart titled Generator Condition Indicator Terminals Figure 6 10 Indicator Lamp Test Connections Generator Condition Indicator Terminals Switch Position Remarks Check For Voltage Between System Ready Master switch in AUTO position engine TB1 42A and TB1 60 Switch in OFF position High Engine Water Temperature Master switch in RUN position engine TB1 42A and TB1 36 H W T Switch in RUN position hold toggle switch to H W T for at least 5 seconds Low Oil Pressure L O P Master switch in RUN position engine TB1 42A and TB1 38 Switch in RUN position hold toggle Switch to L O P for at least 5 seconds Auxiliary Fault 16 light controller or Master switch in RUN position engine TB1 42A and TB1 26 Low Water Temperature Auxiliary switch in RUN position wait 10 6 light controller seconds Flashing AUX lamp indicates proper operation of all Auxiliary functions Emergency Stop local remote if Master switch in RUN positio
43. literature Common Hardware Entries When hardware size diameter and threads per inch is given but no indication of type of additional hardware is shown use the illustration in Figure B 2 as a guide Preferred Nut Bolt Clearance NA IN Unacceptable Nut Bolt Clearance T E EA E 1 1 2 in bolt diameter 2 Min 1 full thread beyond top of nut 3 Below top of nut Figure B 1 Acceptable Bolt Lengths TP 5353 8 94 Steps for common hardware application k Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter uses a properly torqued whiz nut See Figure B 2 3 Follow these SAE washer rules after determining exit hole type Always use a washer between hardware and a slot b Always use a washer under a nut see Step 2 above for exception c Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to the diagram below which depicts the preceding hardware configuration possibilities Cap screw Entry hole types Standard nut and SAE washer greaterthan 1 2in dia hardware Whiz nut u
44. power to the speed switch and readjust the engine speed to the normal operating speed using the governor adjustment procedure The overspeed set point is tested by pressing the overspeed test button Troubleshooting Apply DC power and an input speed signal to the speed switch Connect a voltmeter to terminal 5 4 and engine ground As the speed input frequency is increased an increase in voltage is noted if functioning correctly If the voltage is proportional to frequency check the wiring atthe terminal strip If the voltage is not proportional to frequency check the output of the magnetic speed sensor Ifthe speed sensor is operating and the terminal strip is wired correctly the speed switch is defective TP 5353 8 94 Manual Controller The following text covers the manual controller sequence of operation during generator start run stop and fault shutdown modes Use this as a starting point for controller fault identification The LEDs on the controller circuit board are intended to assist in the troubleshooting process An illuminated LED indicates the respective relay is receiving power the LED does not indicate whether that relay is energized See Figure 5 9 Starting Close the start stop switch between and 47 e K2 relay is energized LED2 lights A set of normally open K2 contacts provide power for the oil pressure and water temperature gauges water level sensor panel lamps hourmeter voltmeter fuel
45. refer to Figure 2 4 and the following descriptions The 6 light microprocessor controller level 2 is available in the standard model and the oversize meterbox version for installation of additional meters and gauges For identification of controller components Standard Controller Low Water Temperature Aux Lamp Overspeed Lamp High Engine Temperature Lamp Air Damper Lamp Overcrank Lamp Low Oil Pressure Lamp Selector Switch Lamp Test Generator Master Switch Alarm Horn Alarm Silence Switch Voltage Adjustment Pot Zi ADV 5849 P2 Emergency Stop Switch Hourmeter Frequency Meter AC Voltmeter Scale Lamps upper lower AC Ammeter Oil Pressure Gauge Water Temperature Gauge DC Voltmeter Fuses Inside Controller Controller TB1 Terminal Strip on Circuit Board Figure 2 4 6 Light Microprocessor Controller Standard and Oversize Meterbox Models 2 10 Operation TP 5353 8 94 Features The numbered paragraphs following refer to Figure 2 4 1 Low Water Temperature LWT Auxiliary Flashing or continuously on lamp indicates a fault has occurred Flashing Lamp Conditions e The LWT auxiliary lamp will flash immediately if the controller senses no AC output while the unit is running except during first 10 seconds after start up When AC output is sensed the flashing will stop and the lamp will be off No manua
46. restart the generator set after shutdown by emergency stop switch local or remote Refer to Controller Resetting Procedure later in this section to restart the generator set following a fault shutdown 1 Investigate cause of emergency stop and correct problem s 2 If remote emergency stop switch was activated reset switch by replacing glass piece If controller mounted emergency stop switch was activated if equipped reset controller emergency stop switch by rotating switch clockwise until switch springs back to original position NOTE The controller auxiliary lamp will light if the generator master switch is in the RUN or AUTO position during the resetting procedure 3 If controller air damper light is on reset air damper on engine by rotating air damper lever as shown in Figure 2 6 and the air damper light will go out Used on 200 1600 kW models with Detroit Diesel engines only 4 Toggle generator master switch to OFF RESET and then to RUN or AUTO to resume operation The generator set will not crank until the resetting procedure is completed Figure 2 6 Air Damper Lever Detroit Diesel Powered TP 5353 8 94 Fault Shutdowns The generator set will shut down automatically under the following fault conditions Overspeed Unit shuts down immediately if governed frequency exceeds 70 Hz 2100 RPM on 50 and 60 Hz models Overcrank Shutdown occurs after 45 seconds of continuous cranking Shutdown occurs
47. starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and reconnectit last to disable generator set before working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed TP 5353 8 94 Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Hazardous voltage can cause severe injury or death Whenever electricity is present there is the hazard of electrocution Open main circuit breaker on all power sources before servicing equipment Electrically ground the generator set and electrical circuits when in use Never come into contact with electrical leads or appliances when standing in water or on wet ground as the chance of electrocution is increased under such conditions Hazardous voltage can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while adjustments are made Remove wristwatch rings and jewelry that can cause short circuits 1 Move generator set master switch to OFF RESET position 2 Disconnect engine starting battery negative lead first Disconnect power to battery
48. step 3 NOTE If generator set does not shut down stop generator set using generator master switch Recheck TP 5353 8 94 connections of overvoltage kit Retest shutdown function If shutdown still does not occur stop generator set using generator master switch Use the following voltage check procedure to determine fault a With generator set stopped disconnect lead 30 at overvoltage shutdown board Connect DC voltmeter 10 volt scale or higher positive test lead to terminal 30 on overvoltage shutdown board and negative test lead to controller ground lug b Start generator set Turn voltage adjustment rheostat to an overvoltage condition and observe voltmeter reading A reading of less than 5 volts indicates the overvoltage board is defective A reading of 5 volts or higher indicates the controller board is defective c Stop generator set Disconnect DC voltmeter Replace defective component Reconnect lead 30 to overvoltage shutdown board Repeat testing procedure Turn voltage adjustment rheostat on controller slightly counterclockwise Place generator switch to OFF RESET position Place generator master switch to RUN position to start generator set Turn voltage adjustment rheostat as necessary for AC voltmeter to read correct voltage for phase indicated by selector switch Disconnect battery negative lead first Reconnect generator to load Reconnect battery negative lead last
49. to e Detect a locked engine e Stop a start up attempt if the starter locks or will not engage 1 Move FASTCHECK engine switch to OFF 2 Move generator master switch to OFF position and then move switch to RUN position 3 IGN CRK and REG lamps on FASTCHECK should light for approximately 5 seconds and then go out 5 seconds later the IGN CRK and REG lamps should relight for 5 seconds before going out again 15 seconds total elapsed time Controller OVERCRANK lamp lights Check for operating voltage between TB1 42A and TB1 12 4 This test verifies the proper operation of the engine overcrank circuit If the OVERCRANK shutdown fails to function check the speed sensor and related circuitry See Controller Speed Sensor Circuitry followng and Speed Sensor Test in Section 7 Component Testing and Adjustment Controller Speed Sensor Circuitry To check the controller s ability to respond to signals from the speed sensor perform the following test 1 Move generator master switch to OFF RESET position 2 Move FASTCHECK engine switch to OFF position 3 Move generator master switch to RUN position Observe IGN CRK and REG lamps light 4 Within 5 seconds move FASTCHECK engine switch to RUN 5 If CRK lamp goes out on FASTCHECK the controller speed sensor circuitry is functioning correctly TP 5353 8 94 Generator Condition Indicator Terminal TB1 Terminal Strip Remote accessorie
50. to damage windings laminations or bearing See Figure 8 7 8 6 Generator Disassembly Reassembly 1 Hoist Hook Locations Figure 8 6 Rotor Removal 3 088 R8348 15 1 Rotor Assembly Figure 8 7 Lowering Rotor TP 5353 8 94 14 Place the generator assembly on the generator NOTE adapter end in order to remove the generator Some 50 100 kW Ford powered models use a adapter and end bracket from the stator Fasten special drive disc flywheel mounted to the rotor naina 9 An ONAN doc shaft The special drive disc flywheel had a lip on horizontal position Fasten hook to end bracket eye th terc d ta flat sur and hoist to a vertical position See Figure 8 8 E Qu Co eee ee ana WaS HO C ESSI drive disc Later models use a flat surface drive NOTE disc Some 50 100 kW Ford powered models use a special drive disc flywheel mounted to the rotor shaft The special drive disc flywheel had a lip on the outer circumference and was not a flat surface drive disc Later models use a flat surface drive 17 Remove exciter magnets from end bracket See dise Figure 8 9 16 Lower stator assembly Remove end bracket mounting bolts Separate end bracket from stator by bumping loose with a rubber mallet NOTE Some early models are equipped with a tolerance ring inside the end brac
51. will become hot if shorted Hazardous voltage can cause severe injury or death Follow instructions of test equipment manufacturer when performing high voltage test on rotor or stator An improper test procedure can damage equipment or lead to future generator set failures 1 Disconnect battery negative lead first See End Bracket Removal and Replacement and Section 8 Disassembly Reassembly for end bracket removal Remove end bracket Disconnect AC leads from SCR assembly 2 With an ohmmeter check for continuity across AC leads See Figure 7 14 3 Repair AC leads if damaged or open Solder and insulate splices Use new sleeving when tying leads to shaft or heat sink 1 Ohmmeter connections across AC leads Figure 7 14 Exciter Armature Continuity Check 7 16 Generator Troubleshooting 4 Visually check exciter armature for shorted winding s with ohmmeter check for low resistance readings See Section 1 Specifications Generator for resistance readings See Figure 7 14 Lowresistance readings indicate a faulty exciter armature requiring replacement of rotor assembly 5 Using a megohmmeter apply 500 volts DC to rotor shaft and either AC lead See Figure 7 15 Follow the instructions ofthe megohmmeter manufacturer when performing this test A reading of approximately 500K ohms 1 2 megohm and higher indicates the field winding is good A reading of less than 500K ohms app
52. 1 4 gt 1 1 gt 2 1 K5 Governor Control gt pra e Logic e Logic TB1 42A Low Battery Volts 62 TB1 62 Input _ Output Battery Charging Fault 61 1 61 C P3 14 Output Low Fuel 63 TB1 63 15 32 meus TB1 32 Output a P3 16 Input PHET 40A TB1 40 Output P1 16 Input P3 10 Output Common Fault Indicator Activated By HWT AWT LOP AOP AUX Connect AV Alarm or Common Fault Relay Kit Low Water Temperature 35A P1 24 Input TB1 35 P3 12 Emergency Stop K4 P3 1 Logic Engine Air Damper Switch E 1 18 TTA TB1 56 G 292806 S Figure 5 3 Microprocessor Controller Connections TB1 Terminal Strip 5 4 Controller Troubleshooting 5353 8 94 Overvoltage Shutdown 26 12 39 38 36 60 80 4 41 32 63 61 62 35 2 2 DOD S 120 VAC for Crank Disconnect T56 Engine Air Damper Indicator Panel Lamps LIL i N jn c n 000000 Oo 00000 za 5 EER sureerco eere 5 non 5
53. 3 8 94 4 If controller is equipped with meters remove controller cover and reposition meter scale lamp jumper see Figure 9 2 if necessary to match proper position for desired voltage shown in Figure 9 1 Replace cover k 5 If the generator set is equipped with the overvoltage kit verify correct use of the J1 jumper E aw Gu EDS tee co S on the overvoltage circuit board Install the J1 E jumper if the generator set is connected for 139 240 low wye or 277 480 volts high wye 3 phase 4 wire 60 Hz Remove the J1 jumper for all other voltages Replace controller cover 6 Turn the phase selector switch to the L1 L2 position 1 phase or 3 phase depending on generator connection if the controller is equipped with meters Connect a voltmeter across leads L1 and L2 if the controller is not equipped with meters NOTE High voltage may damage equipment Be sure that line circuit breakers transfer switch es and any other accessories using line voltage are sized for TP 5353 6 the voltage selected 1 Lamp Jumper 7 Reconnect starting battery negative lead last Figure 9 2 Meter Scale Lamp Jumper Move generator master switch to the RUN position to start the generato
54. 4 With the generator set running approximately 1 2 volts DC should be observed at 3B and 5B at the LED board See Figure 7 5 Shine flashlight on photo transistor DC voltage reading should drop showing the AVR is functioning properly If voltages are not observed refer to the AVR test Stop generator set R8936 10 Figure 7 5 Checking LED Board 7 8 Generator Troubleshooting TP 5353 8 94 SCR Assembly and Photo Transistor Board The SCR assembly is located behind the exciter armature and controls current flow to the generator field The command and sensing circuitry is located on the shaft mounted photo transistor board See Figure 7 6 The generator set will only function if both components are functional The following test will determine which component is faulty Since it is necessary to remove the end bracket from the set to correctly test these components do not begin this procedure unless there is reasonable certainty that these components are defective See Generator Troubleshooting earlier in this section Examine the photo transistor board for visible signs of damage open foil patterns and heat discoloration before removing entire SCR assembly for testing Refer to End Bracket Removal and Replacement later in this section and Section 8 Disassembly Reassembly for end bracket removal B 258545 A 3 100 R12758 8 1 Photo Transistor Board 2 SCR Assembly 20 150 kW
55. 44 will cause the SDR normally open contact to close and energize K4 relay LEDA lights Normally closed K4 contacts open to de energize the ignition system gas gasoline or fuel solenoid diesel Normally open K4 contacts close to maintain a ground connection to the K4 relay until the unit comes to a complete stop Fault lamp is energized until the generator speed and voltage decreases enough to de energize K1 relay K1 normally open contacts open and the fault lamp turns off 5 12 Controller Troubleshooting Low Oil Pressure High Engine Temperature or Low Water Level Shutdown Safety shutdown switch contacts close and energize the K4 relay LED4 lights Note During cranking Time Delay Relay TDR relay will cause a five second time delay before shutdown occurs This is allows the engine to reach normal operating engine oil pressure Normally closed K4 contacts open to de energize the ignition system gas gasoline or fuel solenoid diesel Normally open K4 contacts close to maintain a ground connection to the K4 relay until the unit comes to a complete stop Fault lamp is energized until the generator speed and voltage decreases enough to de energize K1 relay K1 normally open contacts open and the fault lamp turns off TP 5353 8 94 12 VOLT Dii RO LED2 y NNN fax oy WATER LEVEL R10 LEDS 4 p ka oS 70A mae e e P3 14 HIGH ENGINE T
56. 50 FOR 24V Th Figure 7 20 Overvoltage Circuit Board Generator Troubleshooting 7 21 Governor Adjustment Mechanical Governor Hoof 20 100 kW Ford Powered Models With the constant speed type governor the throttle linkage is fixed at a definite length to establish a specific load speed of 1800 rpm 60 Hz or 1500 rpm 50 Hz models Do not make any adjustment to the throttle linkage as any variation in speed causes frequency changes in output of the generator for this reason only slight readjustment of speed is possible If governor setting is too sensitive hunting or speed surging will occur with changing load If a considerable drop in speed is experienced when normal load is applied adjust the governor for greater sensitivity If one of the governor settings is readjusted the other settings should be readjusted since each has an effect on the other The governor components and adjustments are shown in Figure 7 21 With the generator set running at full or rated load make speed and sensitivity adjustments Speed Check speed with hand tachometer or frequency meter Loosen locking nut on speed adjusting screw Turn screw in clockwise direction to increase speed and frequency or in counter clockwise direction to decrease speed Lock nut at new setting Follow this adjustment with sensitivity droop adjustment Sensitivity Test under normal load conditions If readjustment is needed proceed as follows To make
57. A total of three dry contact kits may be connected to a specific output on the controller Figure 1 6 shows the single relay dry contact kit 2 o i o 2 lt 2 o D 1 N T o gt A ON 101 ps OUT K1 Zi A 273945 Figure 1 6 Single Relay Dry Contact Kit Common Fault Relay Kit with microprocessor controller only The common fault relay kit uses one set of relay contacts to trigger customer provided warning devices if a fault condition occurs A wiring harness included with the kit links the relay kit with the controller terminal strip or controller connection kit Refer to the accessory wiring diagram for proper connection of relay kit wiring harness Although the common fault alarm can be connected to any controller fault output on TB1 terminal strip the kit is typically used to signal the following fault conditions Emergency Stop Auxiliary Overspeed Low Oil Pressure High Engine Temperature 1 10 Specifications Safeguard Breaker The safeguard breaker senses output current on each generator phase and will shut off the AC voltage regulator in the event of a sustained overload or short circuit It is not a line circuit breaker and will NOT disconnect the generator from the load See Figure 1 7 4 Figure 1 7 Safeguard Breaker Line Circuit Breaker The line circuit breaker interrupts generator output in the event of an overload or short c
58. But Will Not Start Engine cranks but will not start Y Is fuel low Yes Add fuel No Y Is LEDS lit Yes Y Are controller panel lights lit Replace circuit board No Y Check bulbs Are bulbs burned out No Y Check circuit board P2 harness and connector pins Is harness defective No Yes replace Replace circuit board 1 Fuse Terminal Replace Does engine starting circuit checkout okay Check for battery voltage at ignition coil on gas gasoline units or fuel solenoid injector pump electronic governor on diesel units bulbs Repair or harness Figure 6 4 Checking Condition of Fuse F2 TP 5353 8 94 Yes Check P1 harness and connector pins Is harness defective r Repair or replace harness and or components Repair or replace harness Replace circuit board Generator Controller Troubleshooting 6 5 Controller Instrumentation Controller instrumentation not functioning properly Loose input or component lead connection at AC fuse terminal Secure the connection block TB3 or at component No Blown 1 5 amp fuse at AC fuse terminal
59. C Ammeter Oil Pressure Gauge Water Temperature Gauge DC Voltmeter Fuses Inside Controller Controller TB1 Terminal Strip on Circuit Board Figure 2 1 16 Light Microprocessor Controller Standard and Oversize Meterbox Models 2 2 Operation TP 5353 8 94 Some installations use the 16 light microprocessor controller with switchgear applications These are nonstandard controllers with remote start and no time delay for engine cooldown circuitry Consult switchgear literature for configuration and function Features The numbered paragraphs following refer to Figure 2 1 1 Anticipatory High Engine Temperature if equipped Lamp lights if engine coolant temperature approaches shutdown range Anticipatory Low Oil Pressure if equipped Lamp lights if engine oil pressure approaches shutdown range Low Water Temperature if equipped Lamp lights if water temperature approaches critical range Low Fuel if equipped Lamp lights if fuel level in tank approaches empty High Engine Temperature Lamp lights if engine has shut down due to high engine coolant temperature Shutdown occurs 5 seconds after engine reaches temperature shutdown range Low Oil Pressure Lamp lights if set shuts down due to insufficient oil pressure Shutdown occurs 5 seconds after engine reaches pressure shutdown range Emergency Stop if equipped Lamp lights and engine stops if emergency stop
60. Controller Instrumentation Lamp Circuit Board Overcrank Lamp FASTCHECK Features and Operation Features Operation Manual Controller Troubleshooting Manual Controller Component Testing and Generator Troubleshooting Troubleshooting Generator No Output Voltage Troubleshooting Generator High Output Voltage Generator Testing No Output On Any Phase Fluctuating Voltage LED Circuit Board SCR Assembly and Photo Transistor Board Automatic Voltage Regulator AVR Operation and To Test AVR PAGE 5 1 5 1 5 3 5 9 5 11 5 11 5 12 5 12 5 12 5 12 5 13 6 1 6 1 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 9 6 10 6 14 6 15 7 1 7 1 7 3 7 4 7 4 7 6 7 6 7 7 7 9 able ot Contents SUBJECT Stator od cocaine derbi De TEE Generator Field Exciter Armature End Bracket Removal and Replacement Speed Sensor Test Air Damper Switch Adjustment Overspeed Time Delay Circuit Board Overvoltage Circuit Board Governor Adjustment Mechanical Governor Hoof 20 100 kW Ford Powered Models Mechanical Governor Stanadyne 20 100 kW John Deere Powered and 20 100 kW Detroit Diesel Powered Models Mechanical Governor Nippondenso 125 180 kW John Deere Powered Models Mechanic
61. DOWN USED FOR ACCESSORES BATTERY pet FUSE 3 GROUND P2 6 AUXLIARY IMMEDIATE SHUTDOWN PLOP coe PREALARM 1 24 J CRANK DISCONNECT OVERCRANK LOCK ROTOR OVERSPEED P1 8 LAUTOMATIC RESTART 1 8 12VDC REGULATED FUSE 2 P1 2 GROUND 1 6 SHIELD GROUND AR DAMPER INDICATOR 2 4 NOTE BLANK DENOTES CONTACT OPEN DENOTES CONTACT CLOSED M DENOTES MAKE BEFORE BREAK CONTACT NOTE CURRENT TRANSFORMER DOT OR HIGH TOWARD INDICATOR PANEL ASSEMBLY GENERATOR CONNECTIONS GENERATOR GOHZ 120 240V 1 3 WIRE 5 220 1 PH 3 WI GOHZ 120 240V 3 PH 4 WIRE DELTA SOHZ T0 220V 3 PH 4 WRE DELTA RE USED ON GENERATORS 20KW IDOKW ONLY T56 AUXLIARY PREALARM CTS NOT USED O2 OVERVOLTAGE SHUTDOWN l BATT CHG ALTERNATOR
62. ECK to test the microprocessor controller on the generator set when troubleshooting start up problems or to test and troubleshoot the controller when removed from the generator set To operate the FASTCHECK the following equipment is required e FASTCHECK simulator B 291930 and harness 255915 e Variable low voltage DC power supply 0 30 volt 3 amp minimum current 0 5 maximum output voltage ripple at 30 volts DC 12 or 24 volt battery depending on system voltage can also be used to operate the FASTCHECK NOTE The 200 300 kW diesel powered models use a 24 volt battery system To Connect Operate the FASTCHECK Tester 1 Unplug DC engine harness from DC harness connector P1 See Figure 6 9 2 Connect FASTCHECK harness to DC harness connector P1 and top of FASTCHECK 3 Move generator master switch to OFF RESET position 4 Move FASTCHECK engine switch to OFF 5 Clip red and black harness leads to battery ies or DC power supply of proper voltage for generator set 12 or 24 volt Adjust output voltage to 1 2 volts above battery voltage when using a DC power supply See BATT rating on generator nameplate Use generator set battery ies if accessible and fully charged NOTE Circuit board damage will occur if correct polarity is not observed when connecting FASTCHECK NOTE Due to the absence of AC output the auxiliary lamp will flash during controller testing on 16 light micr
63. EMP R7 LEDS P3 21 P3 22 LOW OIL PRES L A O FAULT LAMP Ls ae e P2 8 STOP START Dar P24 wrs A Paner tawe Paner tawe OVER SPEED TIME DELAY CIRCUIT BOARD CONTACTS SHOWN WITH SWITCH IN OFF POSITION 1 129 3 129 SELECTOR SWITCH 1 5 74 9o 1b 13 gt 15 gt 17 19 gt Ct 21 3 2305 NOTE VOLTAGE REGULATOR BATT CHG ALTERNATOR YYYYY 3B 5B 67 68 V8 V7 5V8 V9 2 5 250v 5 15 PHOTO COUPLING d 7 VETE AA aoe Lr F30 STATIONARY LED BOARD TP 5353 8 94 EXCITER ARMATURE ROTATING PHOTO TRANSISTOR BOARD MAIN FIELD NND NP NP NDS Conn m HEAT SINK ASS Y ve e 1 OVERSPEED TIME DELAY TERMINAL STRIP TB2 CT METER SCALE TERMINAL BLOCK TB3 AC FUSE TERMINAL BLOCK TB4 SAFEGUARD BREAKER TERMINAL BLOCK M STARTER MOTOR K1 AC CRANK
64. Input from Overvoltage Board Wire 30 3 Input for AC Crank Disconnect and Instrumentation Wire V7F 4 Air Damper Output 200 1600 kW models with Detroit Diesel engines only wire 56 5 Input for AC Crank Disconnect and instrumentation Wire VO 6 Engine Ground Wire 2 Active low circuits may be checked for proper operation by placing ground on terminals so designated kk Common alarm triggered by High Engine Temperature High Engine Temperature Prealarm Low Oil Pressure Low Oil Pressure Prealarm Low Water Temperature Overcrank Overspeed Low Fuel and Auxiliary Faults TP 5353 8 94 Controller Troubleshooting 5 3 Air Damper Emergency Stop Sacs m STOP LI I LI 0 9 48 26 12 39 38 36 60 80 40 41 32 63 62 35 2 E 5 errio n 5 stone OS to 2575 az eva Q zy t E TE soa Ted 21 VY P L ASSEMBLY NO 6 292806 Battery hii gt
65. M frequency modulation ft foot feet ft Ibs foot pound s fs full scale ga gauge meters wire size gal gals gallon gallons gph gallons per hour gpm gallons per minute gr grade grd ground HCHT high cylinder head temperature HET high exhaust temperature Hg mercury element H20 water HP horsepower hr hrs hour hours HWT high water temperature Hz hertz cycles per second ID inside diameter IEEE Institute of Electrical and Electronic Engineers in inch inches inc incorporated in Ibs inch pounds int internal int ext internal external Appendices A 1 Abbreviation ISO J JIS kg kg cm kgm kJ km kPa kph kV kVA kW kWH L LxWxH LED s Ib lbs L hr L min LOP LP LWT m m max MCM meggar MHz mi mil min misc mJ MJ mm m3 min MPa mpg mph MS mW MW N A NBS N C NEC NEMA NFPA Nm N O A 2 Appendices Description International Standards Organization joule joules Japanese Industry Standard kilogram kilograms kilograms per square centimeter kilogram meter s kilojoules btu cal kilometer kilometers kiloPascal kiloPascals kilometers per hour kilovolt kilovolt amperes kilowatt kilowatts kilowatt hour liter liters length x width x height light emitting diode s pound pounds liter per hour liters per hour liter s per minute low oil pressure liquified petroleum low water temperature meter meters cubi
66. NCY STOP INDICATOR USED FOR NEPA SHUTDOWN SHUTDOWN BATTERY CHARGER FAULT ACTIVE LOW ACCESSORIES BATTERY LOW BATTERY VOLTS ACTIVE LOW VOLTAGEP2 1 s LOW FUEL ACTIVE LOW FUSE 3 MUST HAVE JUMPER IF THERE IS NO 2 EMERGENCY STOP CONNECTED GROUND 2 6 TB AUXILIARY IMMEDIATE 3071 SHUTDOWN PLOP 5 M j 10443 Lot2 10 11 12 8 1 2 s g O mi 4 15 EMERGENCY STOP SW PREALARM 17 he CRANK DISCONNECT 19 OVERCRANK 20 LOCK ROTOR OVERSPEED 21 P1 9 AUTOMATIC RESTART 22 P1 8 12VDC REGULATED FUSE 2 P1 2 GROUND e P1 6 SHIELD GROUND P1 24 AIR DAMPER INDICATOR 2 4 SHIELD NOTE BLANK DENOTES CONTACT OPEN C DENOTES CONTACT CLOSED M DENOTES MAKE BEFORE BREAK CONTACT GENERATOR CONNECTIONS 12 LEAD STATOR 12 LEAD STATOR 1 OR 139 240V GOHZ 120240V 3 PH 4 WIRE DELTA WIRE LOW WYE zi 50HZ 120 208V OR 110 190V SEEE A CH ANNIE 4 WIRE LOW WYE INDICATOR PANEL ASSEMBLY T56
67. NE TEMPERATURE LN _ PREALARM HIGH ENGINE TEMPERATURE MAIN SEE GENERATOR OP OIL PRESSURE RR RI CONNECTIONS CT CURRENT TRANSFORMER HZ HERTZ ENGINE 6LEAD STATOR 15 IGNITION SYSTEM VOLTMETER A AMMETER BATTERY CHARGING ALTERNATOR AD AIR DAMPER ADS AIR DAMPER SWITCH GC GOVERNOR COLTROL ADV 561 9 H Figure 5 7 Logic Schematic 3 Phase 600 Volt Models L HEAT SINK ASS Y v7 Ve 5 8 Controller Troubleshooting TP 5353 8 94 Fault Shutdowns Microprocessor Controller If the generator set will not start or stops running due to a Manual for detailed information on correcting engine fault shutdown fault lamp lit refer to the following chart related faults To resetthe set after a fault shutdown see to identify fault conditions Consult the Engine Service Section 2 Operation Fault Shutdown Troubleshooting Chart High Engine Temperature Lamp Lights Engine coolant temperature is above shutdown range See Section 1 Specifications for specific model Cooling system malfunction Low Oil Pressure Lamp Lights Engine oil pressure is below shutdown range See Section 1 Specifications for specific model Overspeed Lamp Lights Governed frequency is in excess of 70 Hz all models Overcrank Lamp Lights Continuous cranking is more than 45 seconds Cyclic cranking is more than 75 seconds Locked rotor Overcrank Lamp Flashe
68. No is grounded to engine block Did K4 relay LED Yes es light et Can engine be Replace circuit stopped by GENERATOR No board defective using stop SET CHECKS K4 relay switch OUT OKAY Does wiring harness No No checkout okay Did K4 Does start stop Replace relay LED switch function defective light correctly and wiring start stop checkout okay itch Replace circuit y switch board defective K4 relay Repair replace wiring harness Yes Replace circuit board defective K4 relay TP 5353 8 94 Generator Controller Troubleshooting 6 17 Troubleshooting Manual Controller Continued Does K1 Is there AC output when Go to generator relay LED start button is held and troubleshooting light unit is running flowchart in Section 7 A Yes Does start stop switch function correctly Y Did K4 relay LED light Is AC output at correct voltage Stator leads 7 and 10 at approximately 120 volts AC No Yes Replace Replace circuit K1 relay faulty defective board K4 relay replace circuit board start stop defective switch Y Is voltage adjusting rheostat set correctly Y Does lo
69. SS American Standard Metric ve O Grade2 Grade5 5 8 8 8 10 9 12 9 SAMPLE DIMENSIONS American Standard Major Thread Diameter In Fractional 1 4 20 Threads Per Inch Inches Or Screw Number Size Metric Major Thread Diameter In Millimeters M8 125 Distance Between Threads In Millimeters Washers a Plain Split Lock Spring Washer External Internal Internal External Washer Washer or or Wave Washer Tooth Lock Tooth Lock Tooth Lock Washer Spring Washer Washer Washer GRADE HARDNESS There is no marking to identify hardness Usually hardened washers have a black oxide or black phosphate finish rather than a zinc silver colored finish SAMPLE DIMENSIONS Plain Washers Internal Dimension ___ 9 32 x i 116 Thickness External Dimension Lock Washers 58 Internal Dimension Figure C 2 Nuts Washers 2 Appendices TP 5353 8 94 Appenc D General Torque Specifications Use the following specifications for American Standard non plated threads are used Screws threaded into fasteners when no torque values are given elsewhere in aluminum must have two diameters of threads engaged this manual for a specified bolt The values are based and may require 3096 or more reduction in the torque on new plated threads Increase values by 20 if American Standard Assembled in Assembled in Cast Iron or Steel Aluminum Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5 in Ibs Nm in Ibs in
70. Service Industrial Generator Sets Models 20 300 kW KOHLER POWER SYSTEMS sas ane able of Contents SUBJECT PAGE afety Precautions and Instructions DIERUM i oe Specifications 1 1 1 1 Fast Response Concepts 1 1 Short Circuit Performance 1 1 Specifications 1 3 Generator 1 3 ENQING i lisa d dedos 1 5 ACCeSSOTI S socks tein ea ik d Rr RR 1 6 Operation 2 1 Prestart Checklist 2 1 Exercising the Generator Set 2 1 16 Light Controller Level 1 Operation 2 2 Features eevee dee RR ae cane 2 3 Starting oiai IP ER Redes 2 6 Stopping eae seas swa aaa nsaan E EE 2 6 Resetting Emergency Stop Switches 2 7 Fault Shutdowns 2 8 Controller Resetting Procedure Following Fault Shutdown 2 9 6 Light Controller Level 2 Operation 2 10 Features 2 11 Starting soie tina ti 2 13 Stoppillg Taree es 2 14 Resetting Emergency Stop Switches 2 14 Fault Shutdowns 2 15 Controller Resetting Procedure Following Fault Shutdown 2 15 Paralleling Engine Gau
71. Shutdown Use the following procedure to restart the generator set after a fault shutdown Refer to Resetting Emergency Stop Switches earlier in this section to reset the generator set after an emergency stop 1 Move controller alarm horn switch to the SILENCE position If equipped A V annunciator alarm horn and lamp are activated Move A V annunciator alarm switch to SILENCE to stop alarm horn A V annunciator lamp stays lit 2 Disconnect generator set from load with line circuit breaker or automatic transfer switch 3 Correct cause of fault shutdown See Safety Precautions section of this manual before proceeding TP 5353 8 94 4 Start generator set by moving the generator master switch to OFF RESET and then to the RUN position If equipped A V annunciator alarm horn sounds and lamp goes out Verify that the cause of the shutdown has been corrected by test operating generator set Reconnect generator to load via line circuit breaker or automatic transfer switch Move generator master switch to AUTO position for start up by remote transfer switch or remote start stop switch If equipped move A V annunciator alarm switch to NORMAL Move controller alarm horn switch to the NORMAL position Place generator master switch in the AUTO position before silencing alarm horn Operation 2 9 6 Light Controller Level 2 Operation standard and oversize meterbox and an explanation of their functions
72. Wwe BE Sm WIRE ON 4 amp 6 CYL ONLY Figure 5 6 Logic Schematic 1 Phase 3 Phase Models TP 5353 8 94 Controller Troubleshooting 5 7 3 129 SELECTOR SWITCH TB1 4 T56 amp 27 BATTERY TERMINAL ID DESCRIPTION ELECTRONIC GOVERNOR 42A BATTERY VOLTAGE FUSE 1 PROTECTED CONTROL gt GROUND 8 REMOTE START GROUND EMOTE START ACTIVE LOW y V a CRANK MODE OPEN CYCLIC GROUND CONTINUOUS is QUEE 10 13 OVERCRANK INDICATOR CONTACTS SHOWN WITH 1006 REGULATED SWITCH IN OFF POSITION NDIGSTORT COMMON FAULT LINE VOLTAGIP1 7 oe OVERSPEED INDICATOR FUSE 3 c OFF RESET COMMAND ACTIVE LOW BATTERY RUN COMMAND ACTIVE LOW USE ADIPE 5 AR DAMPER INDICATOR INHIBIT FOR N SYSTEM READY INDICATOR Rr ot SHUTDOWN VOLTAGEP1 1 WLS FUSE 3 gt Z LOW WATER TEMPERATURE REQUIRES mO p23 PREALARM HIGH ENGINE TEMP INDICATOR KIT TO AC CRANK 1 PREALARM LOW OIL PRESSURE INDICATOR OPERATE DISCONNECT p 5 EMERGENCY STOP RELAY K4 GROUND CONTROLLER BOARD P1 12 TO FUSE 1 GROUND P1 5 FUSE 2 FUSE 3 STANDARD CONTROLLER 55 mnauna H ACTUATOR AUXILIARY OVERVOLTAGE EMERGENCY STOP RELAY K4 COIL NEGATIVE DELAY SHUTDOWN IMMEDIATEP2 2 EMERGE
73. able to finalize the installation add convenience to operation and service and to comply with state and local codes Accessories vary with each generator set model and controller Accessories are offered factory installed and or shipped loose Some accessories are available only with microprocessors controllers Obtain all the most current information by contacting your local authorized service distributor dealer Several accessories available at the time of print of this publication are as follows Remote Annunciator Kit with microprocessor controller only A remote annunciator allows convenient monitoring of the set s condition from a location remote from the generator See Figure 1 2 and Figure 1 3 Remote annunciator includes alarm horn alarm silence switch lamp test and the same lamp indicators except air damper and auxiliary prealarm as the microprocessor controller plus the following Line Power Lamp lights when using commercial utility power Generator Power Lamp lights when using generator power Remote Annunciator PREALARM O ENGINE TEMPERATURE HIGH ENGINE TEMPERATURE PREALARM O tow on PRESSURE LOW WATER TEMPERATURE LOW OIL PRESSURE O EMERGENCY STOP overspeep overcrank BATTERY LINE CHARGER FAULT POWER O GENERATOR POWER SYSTEM READY GENERATOR NOT IN AUTO LOW BATTERY VOLTAGE AUXILARY FAULT SILENCE C NORMAL ALARM LAMP TEST A
74. ace check charger operation Check connections Replace fuse See Resetting Emergency Stop Switches Correct fault and reset controller Move generator master switch to AUTO position Replace fuel Add fuel check fuel control circuit Bleed air from system Check ignition system Clean or replace filter element Return to the ON position Test and or replace Not applicable to generator sets equipped with manual controller TP 5353 8 94 Engine Operation Manual Wiring Diagrams Section 5 Controller Troubleshooting Wiring Diagrams Section 2 Operation Section 2 Operation Section 2 Operation Engine Operation Manual Engine Service Manual Engine Operation Manual Engine Service Manual Engine Operation Manual Section 6 Generator Controller Troubleshooting Section 7 Component Testing and Adjustment General Troubleshooting 4 1 General Troubleshooting Chart Sheet 2 of 2 Low output or Unit overloaded Reduce load excessive drop in it Engine speed too low Check governor Section 7 Component Testing and voltage Adjustment Faulty voltage rheostat or Test and or replace Section 6 Generator Controller voltage regulator Troubleshooting Section 7 Component Testing and Adjustment Unit stops Low oil pressure shutdown Check oil level if low check for Engine Operation Manual suddenly leaks High temperature shutdown Check for cooling air restrictions Engine Operation Manu
75. al or poor belt tension Low coolant level shutdown if Check coolant level if low Engine Operation Manual equipped check for leaks see Safety Section Out of fuel Add fuel Overcrank shutdown Reset if overcrank fault Section 5 Controller reoccurs check controller circuit Troubleshooting Fuse blown in controller Replace fuse if fuse blows Section 5 Controller again check controller circuit Troubleshooting Wiring Diagrams Engine malfunction Troubleshoot engine Engine Service Manual Overspeed shutdown Reset if unit overspeeds again Section 5 Controller check controller circuit and or Troubleshooting governor Section 7 Component Testing and Adjustment High oil temperature shutdown Check oil level and type If Engine Service Manual shutdown reoccurs troubleshoot engine lubrication system Overvoltage shutdown if Check controller circuit and or Section 5 Controller equipped voltage regulator Troubleshooting Section 6 Generator Controller Troubleshooting Section 7 Component Testing and Adjustment Generator master switch in Move switch to proper position Section 2 Operation OFF RESET position RUN or AUTO Emergency stop switch Check reason for emergency Section 2 Operation activated local or remote shutdown reset switch Not applicable to generator sets equipped with manual controller 4 2 General Troubleshooting TP 5353 8 94 Section 5 Controller Troubleshooting Micropro
76. al Governor Bosch P 125 180 kW Detroit Diesel Powered Models Electronic Governor Barber Colman Dyna 2500 20 100 kW Ford Powered Models Electronic Governor Barber Colman Dyna 8000 125 300 kW Detroit Diesel Powered Models Early 20 100 kW John Deere Powered and Early 20 100 kW Detroit Diesel Powered Models 5 pex tee Bench erred s able ot Contents PAGE 7 14 7 15 7 16 7 17 7 18 7 19 7 20 7 21 7 22 7 22 7 23 7 24 SUBJECT PAGE Electronic Governor Barber Colman Dyna 2500 125 180 kW John Deere Powered Models 7 29 Electronic Governor Barber Colman Dyna 70025 using Stanadyne D Series Injection Pump 20 100 kW John Deere Powered and 20 100 kW Detroit Diesel Powered Models 7 31 Generator Disassembly Heassembly 8 1 Disassembly Ex Ex b RR ERR nx 8 4 Reassembly 8 7 Generator Reconnection 9 1 Voltage Reconnection Procedure 9 1 Generator Frequency Change and Adjustment 9 4 Frequency Change 9 4 Frequency Adjustment 9 4 A 1 B 1 C 1 D 1 TP 5353 8 94 afet A generator set like any other electromechanical device can pose potential dangers to life and limb if improperly maintained or imprudently operated The best way to prevent accidents is to be aware of the potential dangers and to always use good common sense n the interest of safety some general p
77. ant alignment steps and provides critical torque specs WARNING als Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and reconnect it last to disable generator set before working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed TP 5353 8 94 Hot engine and exhaust system Can cause severe injury or death Do not work on generator set until it is allowed to cool Hot parts can cause severe injury or death Do not touch hotengine parts An engine gets hot while running and exhaust system components get extremely hot WARNING LI b W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Generator Disassembly Reassembly 8 1 Explosive fuel vapors can cause severe injury or death All fuels are highly explosive in a vapor state Use extreme care when handling and storing fuels Store fuel in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel t
78. assembly full on resulting in hazardous output voltage Hazardous voltage can cause severe injury or death Electrical shock may occur if battery charger is not electrically grounded Connect battery charger enclosure to ground of a permanent wiring system As an alternative run an equipment grounding conductor with circuit conductors and connect to equipment grounding terminal or lead on battery charger Perform battery charger installation as prescribed in equipment manual Install battery charger in compliance with all local codes and ordinances Hazardous voltage can cause severe injury or death Reconnect battery correctly to avoid electrical shock and damage to battery charger and battery ies Have a qualified electrician perform installation Hazardous voltage can cause severe injury or death Service day tank Electrical Control Module ECM as prescribed in equipment manual Disconnect power to day tank before servicing The power is disconnected when the day tank ECM OFF pushbutton is engaged However 120 volts AC is still present within the ECM when the POWER ON light is on Be sure that generator set and day tank are electrically grounded Do not operate when standing in water or on wet ground as the chance of electrocution is increased under such conditions Hazardous voltage can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or
79. ator Wire 26 5 42A Battery Voltage Fuse 1 Protected 3 Output to Overcrank Indicator Wire 12 6 2 Ground 4 Output to Overspeed Indicator Wire 39 7 9 Crank Mode open cyclic crank 5 Output to Low Oil Pressure Indicator Wire 38 ground continuous crank 6 8 48 Emergency Stop Indicator 7 Output to System Ready Indicator Wire 60 9 3 Remote Start Ground 8 Voltage to Front Panel Wire 24 10 4 Remote Start Active Low 9 Output to Not In Auto Indicator Wire 80 11 26 Auxiliary Indicator 10 12 12 Overcrank Indicator 11 13 39 Overspeed Indicator 12 14 38 Low Oil Pressure Indicator 13 Output to Low Battery Volts Indicator Wire 62 15 36 High Engine Temperature Indicator 14 16 60 System Ready Indicator 15 Output to Low Fuel Indicator Wire 63 17 80 Not In Auto Indicator 16 Output to Common Alarm Wire 32 18 40 Prealarm High Engine Temperature Indicator 17 19 41 Prealarm Low Oil Pressure Indicator 18 20 32 Common Fault Prealarm Wire 43 21 63 Low Fuel Active Low 19 22 61 Battery Charger Fault Active Low 20 Ground Front Panel Wire 2 23 62 Low Battery Volts Active Low 24 35 Low Water Temperature P1 Connector Pins Terminal T 1 Input to Emergency Stop Lamp Wire 48 Terminal Description 2 Input to Auxiliary Indicator Wire 26 1 Output to K1 Relay Crank Relay Wire 71 3 Input to Overcrank Indicator Wire 12 2 Ground for Speed Sensor Wire 2 4 Output to Overspeed Indicator Wire 39 3 Output to Sa
80. ator for shorted or open windings refer to stator testing later in this section Verify AVR adjustment See AVR Voltage Regulator Operation and Adjustment later in this section TP 5353 8 94 LED Circuit Board Test The following procedure provides information on testing the LED circuit board Certain steps require that the generator set be running When the generator set is not running disable the generator set See the safety precautions listed below Disconnect all load from the generator set during this test A WARNING 69 Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and reconnectit last to disable generator set before working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Hazardous voltage can cause severe injury or death Disconnect generator set from load by opening line circuit breaker or by disconnecting gen
81. attach end bracket to stator Torque bolts to 35 ft Ibs 47 Nm maximum 5 Attach hoist hooks to end bracket and suspend stator Place the generator adaptor on the floor and lower stator to within 1 2 1 4 in 12 7 6 4 mm of the adapter lip See Figure 8 11 Figure 8 11 Aligning Adapter and Stator Align adapter with stator and start bolts with washers Lower stator onto adapter and finish tightening bolts NOTE Position adapter hoisting eye so that it is opposite of the stator mounting bracket and directly below end bracket hoisting eye 5353 8 94 7 Place the generator assembly on the end bracket end when installing the rotor Fasten hoisting hook to end bracket eye and lower generator assembly to a horizontal position 8 Attach hoisting hooks to the adapter as shown in Figure 8 12 Suspend generator assembly Before lowering the generator place boards along the edge of the end bracket Maintain a 1 in 25 mm clearance underneath the center of the end bracket to prevent damage to the photo transistor board and actuator cup when the rotor in installed 1 Hoist Hook Figure 8 13 Hoisting Rotor 10 While the rotor is suspended install the photo transistor board insulator board and actuator cup Place photo transistor board lead through actuator cup as shown in Figure 8 14 Push lead through hole in rotor shaft and then through exciter laminations end
82. ay also provide separate accessory power source 2 Ground Terminal 9 Crank Mode Selection open cyclic crank ground continuous crank Connect TB1 2 to TB1 9 for continuous cranking Leave TB1 9 open for cyclic cranking see Starting 48 Emergency Stop Signal 3 Remote Start Ground Connect remote start switch to TB1 3 and TB1 4 4 Remote Start Connect remote start switch to TB1 3 and TB1 4 26 Auxiliary Signal 12 Overcrank Signal 39 Overspeed Signal 38 Low Oil Pressure Signal 36 High Engine Temperature Signal 60 System Ready Signal 80 Not In Auto Signal 40 Anticipatory High Engine Temperature Signal 41 Anticipatory Low Oil Pressure Signal 32 Common Fault Prealarm Line A V alarm or common fault relay activated by HET LOP LWT OC OS and AUX Faults 63 Low Fuel Connect fuel level sensor to TB1 63 to activate fault lamp if used 61 Battery Charger Fault Connect battery charger to TB1 61 to activate fault lamp if used 62 Low Battery Volts Connect battery charger to TB1 62 to activate fault lamp if used 35 Low Water Temperature Signal NOTE Not all terminals are used for all generator sets see appropriate wiring diagrams for specific generator set model T Normally closed contacts Use a remote annunciator and or A V alarm kit as an indicator with a dry contact kit connected to controller terminal strip TB1 TP 5352 1 Figure 1 13 Controller TB1 Terminal Strip Connec
83. buretor Exhaust System A WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected Carbon monoxide can cause severe nausea fainting or death Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate in any area where exhaust gas could accumulate and seep back inside an occupied building Avoid breathing exhaust fumes when working on or near the generator set Carbon monoxide is particularly dangerous because it is an odorless colorless tasteless nonirritating gas Be aware that it can cause death if inhaled for even a short time TP 5353 8 94 Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas which is present in exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If any of these symptoms is experienced and carbon monoxide poisoning is possible affected persons should seek fresh air immediately They should remain active They should not be permitted to sit lie down or fall asleep Alert others to the situation If the condition of affected persons does not improve within minutes of breathing fresh air
84. button is pushed The test button lowers the overspeed setting 5 10 Controller Troubleshooting by 3096 which initiates a shutdown Periodic testing during routine engine maintenance is recommended to ensure positive protection Crank Adjustment Crank adjustment is made by cranking the engine and simultaneously turning crank adjustment pot slowly counterclockwise until the desired crank termination speed is reached When the cranking termination set point is reached the green crank LED illuminates The unit is factory set for manual reset To reinitiate engine cranking remove battery power and then reapply Automatic reset when the engine speed falls below the cranking termination set point is done by removing the 82k ohm resistor located between terminals E1 and E2 on the circuit board near the overspeed pot Overspeed Adjustment Overspeed adjustment is made with the unit running Increase the engine speed to 1096 below the desired overspeed set point For example on a 60 Hz unit the desired overspeed set point might be 70 Hz and 1096 below this point is 63 Hz See Section 7 Governors for specific engine speed adjustment information Turn the overspeed adjustment counterclockwise until the overspeed internal relay energizes and the red overspeed LED illuminates Reset the overspeed relay by pressing the overspeed reset button After the engine comes to a complete stop remove battery power from the speed switch Reconnect
85. c meter cubic meters maximum one thousand circular mils megohmmeter megahertz mile miles one one thousandth of an inch minimum miscellaneous milli joule s mega joule s millimeter cubic meters per minute megaPascal miles per gallon miles per hour military standard milliwatt s megawatt s not available National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association Newton meter s normally open Abbreviation no nos NPT N R OC OD OEM OS O S OSHA OV OZ PF PMG pot psi pt pts PVC qt qts qty ref RFI r h m rms RPM RTV SAE SCR sec spec specs Sq Sq cm Sq in tach TDC tech pub temp TIF TP TPs turbo UHF UNC UNF UL U S U S A V vac vdc VHF W Description number numbers National Standard taper pipe thread per general use not required overcrank outside diameter original equipment manufacturer overspeed oversize Occupational Safety and Health Act overvoltage ounce ounces power factor permanent magnet generator potentiometer parts per million pounds per square inch pint pints polyvinyl chloride quart quarts quantity reference radio frequency interference round head machine screw root means square revolutions per minute room temperature vulcanization Society of Automotive Engineers silicon controlled recti
86. cessor Controller Description For external features see Section 2 Operation schematics showing input output circuits for reference Microprocessor Controller Figure 5 1 through Figure in troubleshooting This information deals directly with 5 5 show locations of controller components and the 16 light microprocessor Information applies to the connections Figure 5 6 and Figure 5 7 are the logic 6 light microprocessor where applicable gog Boe Hog BO 5353 5 1 Panel Lamps 7 Accessory Wire Guide Loops 2 Lamp Circuit Board 8 Lamp Selection Jumper 3 Selector Switch 9 Controller Fuses 4 Controller DC Ground Terminal 10 Control Panel Harness Connector P2 5 AC Fuse Terminal Block TB3 11 Controller Main Circuit Board 6 CT Meter Scale Terminal Block TB2 12 PS P4 Harness Figure 5 1 Microprocessor Controller TP 5353 8 94 Controller Troubleshooting 5 1 s 2 ML QJ eeszoan 1 Fuse 3 Amp F2 Controller 9 2 Fuse 15 Amp Engine and Accessories 10 3 LED4 K4 Relay 4 K4 Relay Emergency Stop 11 5 K2 Relay Control Relay Crank 12 6 K3 Relay Control Relay Run 13 7 LED2 K2 Relay 14 8 LED3 Relay SM A pn A m E pn gale olof LOT NO Controller TB1 Terminal Strip P3 Connector Control Panel Harness to P4 LED Indicator Panel Assembly Microproc
87. cranking intervals to prevent starter motor and or starter solenoid failure due to overheating 5 Place generator master switch to OFF RESET position microprocessor controller or STOP position manual controller 6 Reconnect turbocharger oil drain line at engine connection 7 Remove jumper wire and reconnect ignition coil wire to distributor 8 Test run the generator set for a few minutes and check for oil leaks at turbocharger drain line connection STOP generator set 9 Check oil level and add oil as necessary to bring oil up to proper level Refer to Engine Operation Manual for oil specifications 10 Wipe up any spilled oil and dispose of rags in a fireproof container Properly dispose of oil container 5353 8 94 Turbocharger Service Schedule 30 80 and 100 kW Ford Powered 500 Hours or 6 Months Check for abnormal turbo rotor noise during operation e g high frequency pitch and check for oil leakage at turbocharger 1000 Hours or 12 Months 2000 Hours Check turbo rotor shaft for wear end play and radial tolerances See Section 1 Specifications Engine Overhaul Turbocharger Change lube oil Refer to Engine Operation Manual Change lube oil filter Refer to Engine Operation Manual Change air filter Refer to Engine Operation Manual See Oil Requirements in this section Do not use oil recommendations given in engine operation manual for 30 80 and 100
88. ction pump lever and start engine 2 Verify that injector pump lever is held in fast idle position against fast idle adjusting screw See Figure 7 22 Using a tachometer check engine speed Adjust engine speed to obtain a full load engine speed of 1800 rpm 60 Hz or 1500 rpm 50 1 Injection Pump Lever Hz To increase engine speed rotate fast idle 2 Fast Idle Adjusting Screw adjusting screw counterclockwise rotate fast idle Figure 7 22 Governor Adjustments Typical adjusting screw clockwise to decrease engine speed Reconnect speed control to fuel injection pump lever Stop generator set TP 5353 8 94 Generator Troubleshooting 7 23 Mechanical Governor Nippondenso 125 180 kW John Deere Powered Models NOTE Before checking and adjusting engine speed make sure engine has reached its normal operating temperature All speeds indicated apply to an engine hot under load The maximum permissible speed variation is 50 rpm for fast idle speed 1 Verify that injector pump lever is held in fast idle position against fast idle adjusting screw See Figure 7 23 2 Check fast idle engine speed Engine speed should be 1800 rpm 60 Hz or 1500 rpm 50 Hz at full load 3 If fast idle speed is incorrect but not more than 50 rpm above or below the minimum maximum specified settings loosen fast idle adjusting screw lock nut 4 If engine speed is too low back out fast idle adjusting screw until speed is correct If the
89. d connected OFF RESET engine switch in RUN position Ground controller terminal TB1 62 to test If Low Battery Volts lamp lights circuit is functioning correctly Overspeed See Controller Speed Sensor Circuitry Not Applicable earlier in this section See Overcrank earlier in this section Not Applicable Auxiliary Prealarm Common Fault Master switch in RUN position engine TB1 42 and TB1 32 switch in RUN position hold toggle switch to L W T H W T or L O P TP 5353 8 94 Generator Controller Troubleshooting 6 13 Manual Controller Use the following charts as a reference in troubleshooting individual problems Before beginning any troubleshooting procedure read all safety precautions at the beginning of this manual and those included in the text Do not neglect these precautions WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place 6 14 Generator Controller Troubleshooting Hazardous voltage can cause severe injury or death Whenever electricity is present there is the hazard of electrocution Open main circuit breaker on all power sources before servicing equipment Electrically ground the generator set and electrical circuits when in use Never come into contact with electrical leads or appliances when standing in water or on wet ground as the chance of electrocution is increased under such co
90. dels 0 13 ohms Exciter armature resistance 180 300 kW 16 pole 0 26 ohms Exiter armature resistance 180 300 kW 24 pole early models 0 11 ohms SCR assembly terminal nut torque 20 150 kW 8 in Ibs 0 9 Nm SCR assembly mounting bolt torque 8 in Ibs 0 9 Nm End bracket to stator bolt torque 35 ft Ibs 47 Nm End bracket to bearing outer race clearance 0 25 in 6 35 mm Fan to rotor flange torque 260 in Ibs 29 Nm Drive disks to rotor shaft torque 50 ft Ibs 68 Nm Speed sensor air gap 20 300 kW 0 014 0 028 in 0 36 0 71 mm Speed sensor voltage 20 300 kW 2 black amp 16 white 3 6 volts DC 2 black amp 24 red 8 10 volts DC Electronic governor magnetic pickup air gap 20 180 kW 0 014 0 028 in 0 36 0 71 mm Magnetic pickup output voltage during cranking 2 5 volts AC minimum Electronic governor magnetic pickup air gap 200 300 kW 1 4 turn out cold Magnetic pickup output voltage during cranking 2 5 volts AC minimum Generator adapter to flywheel housing bolt see chart following torque Drive disks to flywheel torque see chart following TP 5353 8 94 Specifications 1 3 1 4 Specifications Generator Adapter to Flywheel Housing Bolt Torque Models Hardware Type Torque ft Ibs Nm 20 30 kW Ford Powered 33 45 kW Ford Powered 50 100 kW Ford Powered 20 60 kW John Deere Powered 80 150 kW John Deere Powered 150 kW Oversize Gen
91. dependent upon specific generator application Clip and remove resistor R2 from the overvoltage shutdown board if installing on generator set with 24 volt cranking Determine voltage of generator set output If voltage is 139 240 volts 3 phase 4 wire 60 Hz low wye or 277 480 volt 3 phase 4 wire 60 Hz high wye leave jumper wire J1 installed For all voltages except 139 240 volt or 277 480 volt remove jumper wire J1 from the overvoltage shutdown board If the function of the circuit board is questionable perform the following test See Figure 7 20 WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Hazardous voltage can cause severe injury or death Disconnect generator set from load by opening line circuit breaker or by disconnecting generator set output leads from transfer switch and heavily taping ends of leads If high voltage is transferred to load during test personal injury and equipment damage may result Do notuse the safeguard circuit breaker in place of the line circuit breaker 1 Disconnect generator from load if not already done Place generator master switch to RUN position to start generator set 2 Loosen locknut if equipped and turn voltage adjustment rheostat on controller slowly clockwise until generator set shuts down and auxiliary shutdown lamp lights If generator set shuts down go to
92. ding to engine speed and output voltage The LED is mounted on the end bracket opposite a photo transistor board which rotates on the shaft The photo transistor picks up the signal from the LED and tells the SCR assembly to turn on or off depending upon the need as dictated by the voltage regulator See Figure 1 1 The voltage recovery period of this type of generator is several times faster than the conventionally wound field brushless generator because it does not have to content with the inductance of the exciter field It also has better recovery characteristics than the static excited machine because it is not dependent upon the generator set output voltage for excitation power Possibly the greatest advantage of this type machine is its inherent ability to support short circuit current and allow system coordination for tripping downstream branch circuit breakers The generator set systems deliver exciter current to the main field within 0 05 seconds of a change in load demand Short Circuit Performance When a short circuit occurs in the load circuit s being served output voltage drops and amperage momentarily rises to 600 1000 of the generator set s rated current until the short is removed The SCR assembly sends full exciter power to the main field The generator then sustains up to 300 of its rated current TP 5353 8 94 Sustained high current will cause correspondingly rated load circuit fuses breakers to trip The sa
93. e If voltage is not present K2 relay on main circuit board is defective 2 Check for 110 190 volts across terminals 33 and 44 These are sensing leads for frequency If voltage is not present test stator 3 Connect a frequency meter to terminals 33 and 44 No continuity is measured using an ohmmeter between terminals 30 and N when frequency is below 68 70 Hz 4 Momentarily increase frequency at engine governor to a value of 70 Hz or greater When frequency reaches 68 70 Hz or greater continuity is measured using an ohmmeter between terminals 30 and N 5 If the circuit board fails steps 3 and or 4 it is defective Time Delay Circuit Board The following conditions indicate that the time delay circuitry and relay are functional 1 Check for 110 190 volts across terminals 33 and 44 after generator set comes up to speed These are sensing leads for frequency If voltage is not present test stator 2 Initially no continuity is measured using an ohmmeter between terminals 13 and 13A 3 After approximately 5 seconds continuity is measured using an ohmmeter between terminals 13 and 13A 4 the circuit board fails steps 2 and or 3 it is defective TP 5353 8 94 Overvoltage Circuit Board The overvoltage circuit board provides overvoltage protection when output voltage is 15 above nominal voltage for more than one second This option is available only on microprocessor controllers Initial setup is necessary
94. ective in this example the SCR Replace the SCR assembly NOTE When replacing SCR assembly do not exceed a torque value of 8 Ibs 0 9 Nm when tightening SCR mounting bolts TP 5353 8 94 1 SCR Assembly 20 150 kW T 2 SCR Assembly 180 300 kW 8 3 White Wire 9 4 Red Wire 10 5 Green Wire 11 6 Black Wire 12 Photo Transistor Board Light Source Flashlight 120 Volt 100 Watt Lamp Fuse 1 Amp Switch DPST S1 120 Volts AC Figure 7 7 SCR Assembly and Photo Transistor Board TP 5353 8 94 Generator Troubleshooting 7 11 Automatic Voltage Regulator AVR Operation and Adjustment The AVR monitors output voltage magnitude and frequency to supply current to the stationary LED board The AVR circuit board includes volts Hz and stability adjustment pots The volts Hz adjustment is factory set and normally requires no further adjustment If replacement of the controller circuit board or operation of the generator under extreme loads results in voltage instability adjust the pots according to the procedure following See Figure 7 8 a Sza 029997 9 ASSY 89d 8 ou R7 49 it MN a E m E 5 J N H lol SAA 9 SL Je eL 1 60 Hz Voltage Adjustment 2 50 Hz Voltage Adjustment 3 Stabili
95. enerator master switch is in AUTO position and the system senses no faults Operation 16 18 19 20 21 22 2 Scale Lamps Upper Lower Generator Switch Not in Auto Lamp lights when generator master switch is in RUN or OFF RESET position Lamps indicate which AC voltmeter and or ammeter scales to read Selector Switch Switch selects generator output circuits to measure When switched to a position with three circuit lead labels amperage is measured on the upper lead and voltage is measured between the lower two leads AC ammeter and voltmeter will not register with switch in the OFF position Lamp Test Switch tests the controller indicator lamps Generator Master Switch Switch functions as controller reset and generator operation switch Refer to Starting Stopping and Controller Resetting Procedure following Alarm Horn Horn sounds if any fault or anticipatory condition exists except emergency stop battery charger fault or low battery volts Place generator master switch in the AUTO position before silencing alarm horn See Controller Resetting Procedure following Alarm Silence Switch disconnects alarm during servicing place generator master switch in the AUTO position before silencing alarm horn Restore alarm horn switches at all locations controller remote annunciator or audio visual alarm to normal position after fault shutdown is corrected to avoid reactivating alarm ho
96. er after drive disc hardened washer nut 2 Hardened washer bolt 3 Stud spacer before drive disc hardened washer nut Engine Turbocharger Specifications 30 80 and 100 kW Ford Powered Specification Turbocharger Axial End Play Turbocharger Radial Play 0 0043 in 0 11 mm 0 0075 in 0 19 mm 1 TP 5353 8 94 5353 8 94 Engine Prealarm and Shutdown Switches Specification Anticipatory High Engine Temperature Switch Powered Powered 20 30 kW before serial no 329000 Ford 20 45 kW after serial no 329000 Ford 50 100 kW Ford Powered 20 180 kW John Deere Powered 20 180 kW Detroit Diesel Powered 200 300 kW Detroit Diesel Powered 198 212 F 92 100 C 211 225 F 99 107 C 211 225 F 99 107 C 198 212 F 92 100 C 198 212 F 92 100 C 198 212 F 92 100 C Anticipatory Low Oil Pressure Switch 20 70 kW Ford Powered 80 100 kW Ford Powered 20 180 kW John Deere Powered 20 60 kW Detroit Diesel Powered 80 100 kW Detroit Diesel Powered 125 180 kW Detroit Diesel Powered 200 300 kW Detroit Diesel Powered 18 22 psi 124 152 kPa 36 40 psi 248 276 kPa 18 22 psi 124 152 kPa 18 22 psi 124 152 kPa 18 22 psi 124 152 kPa 18 22 psi 124 152 kPa 23 27 psi 159 186 kPa Low Water Temperature Switch 20 100 kW Ford Powered 20 180 kW John Deere Powered 20 180 kW Detroit Diesel Powered 200 300 kW Detroit Diesel Powered 55 65 F 13
97. erator John Deere Powered 180 kW John Deere Powered 20 60 kW Detroit Diesel Powered 80 100 kW Detroit Diesel Powered 125 180 kW Detroit Diesel Powered 200 300 kW Detroit Diesel Powered 3 8 16 grade 5 3 8 16 grade 8 7 16 14 grade 5 3 8 16 grade 8 3 8 16 grade 8 28 38 35 47 44 60 35 47 39 53 7 16 14 grade 5 7 16 14 grade 5 3 8 16 grade 8 M10 1 5 class 8 8 9 8 3 8 16 grade 8 7 16 14 grade 5 44 60 Generator adapter mounts to engine flywheel housing mounting boss Drive Discs to Flywheel Torque Models Torque ft Hardware Type Ibs Nm Hardware Sequence 20 30 kW Ford Powered 33 45 kW Ford Powered 50 100 kW Ford Powered 20 60 kW John Deere Powered 80 100 kW John Deere Powered 150 kW Oversize Generator John Deere Powered above serial no 285000 150 kW Oversize Generator John Deere Powered below serial no 285000 180 kW John Deere Powered 20 60 kW Detroit Diesel Powered 80 100 kW Detroit Diesel Powered 125 180 kW Detroit Diesel Powered 200 300 kW Detroit Diesel Powered 200 300 kW Detroit Diesel Powered Hardware Sequence 3 8 16 grade 8 stud 3 8 16 grade 8 bolt 3 8 16 grade 8 stud 39 3 3 8 16 grade 8 stud 39 53 3 8 16 grade 5 stud 53 39 53 39 53 1 2 13 grade 8 stud 1 2 13 grade 5 stud 1 2 13 grade 8 bolt 3 8 24 grade 8 stud 3 8 24 grade 8 stud 3 8 16 grade 5 stud 1 2 13 grade 8 bolt 1 2 13 grade 8 stud 1 Stud spac
98. erator set output leads from transfer switch and heavily taping ends of leads If high voltage is transferred to load during test personal injury and equipment damage may result Do not use the safeguard circuit breaker in place of the line circuit breaker TP 5353 8 94 Hazardous voltage can cause severe injury or death Do not expose the photo transistor board to any external light source as exposure to light causes high voltage Keep foreign sources of light away from photo transistor board during testing Place black electrical tape over LED of circuit board mounted on generator set end bracket before starting generator set with end cover removed 1 Remove junction box panels from generator end of unit and remove photo transistor board LED board cover See Figure 7 3 1 Photo Transistor LED Board Cover Figure 7 3 Panels Removed 2 With the generator set running at no load shine a flashlight on the exposed photo transistor board See Figure 7 4 Figure 7 4 LED Flashlight Test Generator Troubleshooting 7 7 3 Observe the AC output voltmeter High AC output voltage indicates the SCR assembly and photo transistor board are functioning properly The fault is likely in the wiring AVR or LED circuit board as output voltage should drop to low level when flashlight is removed If no output is observed check the SCR assembly and photo transistor board
99. erminal strip Location of the TB1 terminal strip on the controller circuit board is shown in Figure 2 5 Refer to appropriate wiring diagrams for additional information on connecting accessories to the TB1 terminal strip 1 TB1 Terminal Strip 2 Fuses Figure 2 5 TB1 Terminal Strip on Controller Circuit Board TP 5353 8 94 Starting Local Starting Move the generator master switch to the RUN position to start the generator set at the controller NOTE The 6 light controller is equipped with a transient start stop function to avoid accidental cranking of the rotating engine If the generator master switch is momentarily placed in the OFF RESET position then quickly returned to RUN the generator set will slow to 249 RPM and recrank before returning to rated speed Auto Starting Move the generator master switch to the AUTO position to allow start up by automatic transfer switch or remote start stop switch connected to controller terminals 3 and 4 NOTE The 6 light microprocessor controller provides up to 45 seconds of continuous cranking or 75 seconds of cyclic cranking crank 15 seconds rest 15 seconds crank 15 seconds etc before overcrank shutdown Cranking mode cyclic or continuous select
100. es LEDs on the FASTCHECK indicate the energizing of the following circuits Engine Ignition gas gasoline or Fuel Solenoid diesel Engine Crank AC Voltage Regulator Engine Antidieseling Battery Connection correct polarity Engine Malfunction Alarm and or Alarm Shutdown Switches on the FASTCHECK simulate Engine Cranking Engine Running Engine Overspeed Low Fuel Low Engine Coolant Temperature Anticipatory Low Engine Oil Pressure Anticipatory High Engine Coolant Temperature Low Engine Oil Pressure High Engine Coolant Temperature 1 12 Specifications Figure 1 12 FASTCHECK Diagnostic Tester Accessory Connection with microprocessor controller only The microprocessor controller circuit board is equipped with a terminal strip TB1 for easy connection of generator set accessories Do not direct connect accessories to the controller terminal strip Connect all accessories to either a single relay dry contact kit or ten relay dry contact kit Connect the dry contact kit s to the controller terminal strip Connect alarms battery chargers remote switches and other accessories to the dry contact kit relay s using 18 or 20 gauge stranded wire Lower the controller circuit board panel until it is lying flat when connecting the d
101. essor Chip P1 Connector DC Harness P2 Connector AC Harness Fuse 3 Amp F1 Remote Annunciator Figure 5 2 Microprocessor Controller Circuit Board Components 5 2 Controller Troubleshooting TP 5353 8 94 Circuit Board Terminal Identification TB1 P3 Connector Pins Description Output to High Engine Temperature Indicator Wire 36 Output to Pre High Engine Temperature Indicator Wire 40 Output to Pre Low Oil Pressure Indicator Wire 41 Output to Low Water Temperature Indicator Wire 35 Output to Battery Charger Fault Indicator Wire 61 Input from Generator Master Switch RUN position Wire 47 Input from Generator Master Switch OFF RESET position Input from Generator Master Switch AUTO position Wire 46 P4 Connector Pins Description Input to High Engine Temperature Indicator Wire 36 Input to Pre High Engine Temperature Indicator Wire 40 Input to Pre Low Oil Pressure Indicator Wire 41 Input to Low Water Temperature Indicator Wire 35 Input to Battery Charger Fault Indicator Wire 61 Output from Generator Master Switch RUN position Output from Generator Master Switch OFF RESET position Output from Generator Master Switch AUTO position Wire 46 Terminal Wire Description 1 1 Ground Emergency Stop Relay K4 2 1 Emergency Stop Relay K4 Coil Terminal 3 56 Air Damper Indicator 1 Output to Emergency Stop Lamp Wire 48 4 Open 2 Output to Auxiliary Indic
102. f these conditions exist See Figure 7 10 NOTE Disconnect V7 V8 V9 VO at AC from controller terminal blocks before doing this test e Open windings With ohmmeter check each pair of leads for low resistance readings 1 Windings continuity High resistance across A or low 2v Leads resistance continuity across B and ground indicates a faulty stator replace stator See Figure 7 11 10 101 01 101 101 101 Figure 7 10 Stator t1 A CONTINUITY RESISTANCE B NO CONTINUITY C NO CONTINUITY Figure 7 11 Stator Winding Test 7 14 Generator Troubleshooting TP 5353 8 94 Generator Field 1 Disconnect battery negative lead first Remove end bracket See End Bracket Removal and Replacement later in this section and Section 8 Disassembly Reassembly Disconnect F and F from SCR assembly 2 With an ohmmeter check for continuity across F and F leads see Figure 7 12 Resistance readings are shown in Section 1 Specifications Generator 3 100 R12758 8 TP 5353 7 1 Ohmmeter connections across F and F leads Figure 7 12 Field Continuity Check Check for a grounded generator field continuity should exist between field leads and rotor assembly 4 Using a megohmmeter apply 500 volts DC to or F lead and rotor shaft See Figure 7 13 Follow the instructions ofthe megohmmeter manufacturer when performing this test A reading of
103. feguard breaker kit serves to collapse the generator set s main field in the event of a sustained heavy overload or short circuit Specifications 1 1 1 2 Field Main Generator SCR Assembly Exciter Generator Exciter Field Magnets Exciter Armature Optical Coupling Specifications 8 Starting Battery 9 Safegaurd Breaker Optional 10 AC Voltage Regulator 11 LED Board 12 Photo Transistor Board 13 Stator Figure 1 1 Alternator Schematic TP 5353 1 TP 5353 8 94 Specifications The generator set is a rotating field generator with a supplies current to load circuits while the smaller rotating armature generator turned by a rotating armature exciter generator supplies DC to common shaft The main rotating field generator excite the main generator s field Generator Component Specification Model Value Controller and battery electrical system 20 180 kW 12 volts DC Controller and battery electrical system 200 300 kW 24 volts DC Generator field resistance F 20 60 kW 2 0 2 9 ohms Generator field resistance F 80 150 kW 1 8 2 2 ohms Generator field resistance F 180 300 kW 1 0 1 5 ohms Exciter armature resistance 20 30 kW 24 pole 0 19 ohms Exciter armature resistance 40 60 kW 24 pole 0 13 ohms Exciter armature resistance 80 150 kW 16 pole 0 27 ohms Exiter armature resistance 80 150 kW 24 pole early mo
104. feguard Breaker Terminal and Water Level Switch 5 Input to Low Oil Pressure Indicator Wire 38 Wire 70 and K5 Relay if equipped with Electronic Governor 6 4 Not Used 7 Input to System Ready Indicator Wire 60 5 Ground Wire N 8 Voltage to Front Panel Wire 24 6 Speed Sensor Shield Ground Wire S2 9 Input to Not In Auto Indicator Wire 80 7 Output to Fuel Solenoid FS Wire 70 10 8 Battery Positive to Speed Sensor Wire 24 11 9 Input from Speed Sensor Wire 16 12 10 Not Used 13 Input to Low Battery Volts Indicator Wire 62 11 Not Used 14 12 Input from Battery Positive 14P 15 Input to Low Fuel Indicator Wire 63 13 Input from Auxiliary Delay Shutdown 16 Input to Common Alarm Wire 32 14 Input from Water Level Switch Wire 31 17 15 Input from Auxiliary Delay Shutdown Wire 47 16 Input from Pre High Engine Temperature Switch Wire 40A 18 17 Inputfrom Auxiliary Immediate Overvoltage Shutdown Wire 30 Wire 43 18 Input from Air Damper Wire 56 200 1600 kW models with 19 Detroit Diesel engines only 20 Ground Front Panel 19 Output to K6 relay Wire 57 200 1600 kW models with Detroit Diesel engines only 20 Not Used 21 Input from High Engine Temperature Switch Wire 34 22 Input from Low Oil Pressure Switch Wire 13 23 Input from Pre Low Oil Pressure Switch Wire 41A 24 Input from Low Water Temperature Switch Wire 35A P2 Connector Pins Terminal Description 1 Output to Oil Pressure Sender Wire 70 2
105. fier second seconds specification square square centimeters square inch es tachometer top dead center technical publications temperature telephone influence factor technical publications turbocharger ultrahigh frequency Unified coarse thread was NC Unified fine thread was NF Underwriter s Laboratories Inc undersize United States of America volt volts volts alternating current volts direct current very high frequency watt watts TP 5353 8 94 Appendix B Common Hardware Application Guidelines Many parts catalogs and service manuals will contain common hardware entries and hardware references instead of part numbers for common hardware This information gives common hardware application Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure B 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred size Split Lock Washers Split lock washers are no longer used as locking devices For hardware up to 1 2 in diameter a whiz nut serrated flange is used The locking method used for hardware above 1 2 in diameter will be SAE flat washers with preloading torque of the bolt screw See and other torque specifications in the service
106. ge Box Controller Operation Switchgear 2 16 Features iiv yer ew ea ae eee 2 17 Manual Controller Operation 2 18 Features 2 19 Starting xir RE pk 2 19 SIODDInQ e ek ERES 2 20 Fault Shutdowns 2 20 Scheduled Maintenance 3 1 Oil Requirements 30 80 and100 kW Ford Powered 3 2 Oil Change Procedure 30 80 and100 kW Ford PPOWeIGO esas e aloes 3 2 Turbocharger Service Schedule 30 80 and 100 kW Ford 3 3 Storage Procedure 3 3 General Troubleshooting 4 1 General Troubleshooting Chart 4 1 TP 5353 8 94 SUBJECT Controller Troubleshooting Microprocessor Controller Description Circuit Board Terminal Identification TB1 Fault Shutdowns Microprocessor Controller Paralleling Engine Gauge Box Controller Switchgear Speed Switch Adjustments Manual Controller Starting Running Stopping Engine Safety Shutdown Switches 5 Generator Controller Troubleshooting Microprocessor Controller Relay Descriptions Troubleshooting Microprocessor Controller FUSES esser EIN Engine Will Not Engine Cranks But Will Not Start
107. ger than one second Adjust speed sensor air gap to Excessive speed sensor air gap gap 0 014 0 028 in 0 36 0 71 mm See Figure 6 7 No Open speed sensor circuit Check continuity of wire 2 black wire 16 white and wire 24 red between P1 connector and speed sensor Check for 8 10 volts DC across speed sensor positive terminal and negative terminals Check wire 16 for 3 6 volts DC and wire 24 for 8 10 volts DC Does test check out okay No Repair circuit Defective speed sensor See Speed Sensor Test in this section 0 014 0 028 in 0 36 0 71 mm 3 100 R12758 3 1 Speed Sensor 4 Wire 2 Black 2 Wire 16 White Clear 5 Air Gap 0 014 0 028 in 0 36 0 71 mm 3 Wire 24 Red 6 Actuator Cup Figure 6 7 Speed Sensor Air Gap 6 8 Generator Controller Troubleshooting TP 5353 8 94 FASTCHECK Features and Operation The FASTCHECK is an engine simulator for testing and troubleshooting the microprocessor controller Features Features are shown in the following paragraphs see Figure 6 8 for illustration Engine conditions are simulated by the following engine switch position e OFF locked engine starter energized but not turning e CRANK engine cranking but not started e RUN engine running Indicator Lamps IGN ignition lamp shows battery voltage supplied to ignition gas gasoline
108. governor control more sensitive loosen the nut at bottom of adjusting eyebolt and tighten the top thereby drawing the head of the eyebolt closer to the governor arm pivot point To make governor control less sensitive loosen the top nut and tighten the bottom nut to move the head of the eyebolt away from the pivot point After sensitivity is correct tighten the nut that was previously loosened to 7 22 Generator Troubleshooting lock the eyebolt at the the new setting Recheck speed after sensitivity adjustment since changing this will also affect speed Stop generator set NOTE A speed droop of 3 Hz or 90 rpm between no load and full load is normal AN n D Governor Belt Governor Arm Throttle Linkage Pivot Point Eyebolt Head Sensitivity Adjustment Speed Adjustment Governor Mounting Figure 7 21 Governor Components and Adjustments 5353 8 94 Mechanical Governor Stanadyne 20 100 kW John Deere Powered and 20 100 kW Detroit Diesel Powered Models NOTE Before checking and adjusting engine speed make sure engine has reached its normal operating temperature All speeds indicated apply to an engine hot under load The maximum permissible speed variation is 50 rpm for fast idle speed 1 Disconnect speed control from fuel inje
109. haft assembly in the fuel on position by moving it in the clockwise position The shutoff shaft assembly is the lever located on the backside of the fuel injection pump Secure using existing mechanical linkage 2 Place the throttle shaft assembly in the high idle position Back out the low idle adjustment screw a maximum of three turns Excessive backing out of the low idle screw results in the disengagement of the pump s internal components 7 32 Generator Troubleshooting Follow this procedure carefully in order to not overspeed the engine and cause damage to the generator or other load Adjust the droop by turning the droop adjusting screw in a counterclockwise CCW direction until it stops Droop adjustment used only on paralleling generator sets Turn the droop adjusting screw clockwise CW two full turns The mechanical governor is now set in a position that will permit starting the engine to calibrate the electronic integrated actuator governor Do not operate the engine without the electronic governor connected and the system calibrated correctly as described in the following procedure Once this droop adjustment is made do not readjust Governor Calibration for Nonparalleling Generator Sets Preliminary Adjustments Place generator master switch to OFF position Generator set must not be running Set the gain adjustment three divisions from zero Final Adjustments Place ge
110. he switch Connect an ohmmeter to the harness of the switch 6 If the switch is correctly adjusted no continuity will be measured If continuity is measured loosen the two attaching switch screws and move the switch toward the air damper lever until no continuity is measured When the switch is correctly positioned tighten the switch screws 7 Reconnect the switch wiring harness 8 Reconnect the generator set battery The air damper LED on microprocessor controllers must not be on If the LED is on readjust the switch as described in step 2 TP 5353 8 94 9 Start the generator set and run for a few minutes Stop the generator set using the emergency stop switch The air damper LED on microprocessor controllers will turn on if correctly adjusted 10 Disconnect the switch wiring harness and reconnect an ohmmeter Continuity is measured when correctly adjusted 11 No continuity is measured when the air damper is reset Reconnect the switch wiring harness TP 5633 2 NC NO 272790 4 Air Damper Lever 5 Air Damper Switch 6 Wiring Harness Connector Figure 7 18 Air Damper Lever Detroit Diesel Powered Generator Troubleshooting 7 19 Overspeed Time Delay Circuit Board The overspeed circuitry protects the generator set and equipment connected to it from overfrequency The feature is standard on ma
111. hing oscillation Stop the generator set TP 5353 8 94 Droop Adjustment Place generator master switch to RUN or TEST position to start generator set Use the run speed pot to set the engine rpm to the desired no load speed frequency on the frequency meter 3 Apply full load to the generator set While watching the frequency meter slowly turn the droop pot clockwise CW until the desired droop percentage is obtained 5 Remove full load from generator set Using the run speed pot readjust the engine rpm to the desired no load speed frequency on the frequency meter Stop the generator set Generator Troubleshooting 7 33 Section 8 Generator Disassembly Reassembly WARNING Before beginning generator disassembly procedure carefully read all safety precautions at the beginning of this manual Please observe these precautions and those included in text during the disassembly reassembly procedure The following procedures cover many models and some steps may not apply to a particular engine Use Figure 8 1 and Figure 8 2 to help understand component descriptions and general configuration of the generator Use the disassembly procedure as a step by step means to help take apart the generator The disassembly procedure provides important information to minimize disassembly time and indicates where special configurations exist which may require taking notes The reassembly procedure includes import
112. ibutors dealers NOTE Charge only lead acid or nickel cadmium batteries with battery charger NOTE Wipe up all spilled diesel fuel after bleeding system Wash hands after any contact with fuel oil NOTE Pay special attention to the coolant level After the coolant has been drained some time is required before complete refill of the engine water jacket takes place NOTE Engine Damage Failure to bleed air from cooling system may cause overheating and subsequent damage to engine NOTE Do notturn on block heater before filling cooling system Run engine until warm and refill radiator to purge air from the system before energizing block heater Block heater failure occurs if heater element is not immersed in water NOTE Hardware Damage Engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of bolt heads and nuts NOTE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings American Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness Check markings on bolt head and nuts for identification TP 5353 8 94 This manual covers the concept operation troubleshooting repair of 20 300 kW Fast Response 11 generator sets Wiring diagram manuals are available separately All information in this publication represents data
113. identification numbers in the spaces provided GENERATOR SET MODEL SPEC and SERIAL numbers are found on the nameplate attached to the generator set Model No Specification No Serial No TP 5353 8 94 GENERATOR SET ACCESSORIES An alternate nameplate inside the junction box identifies factory installed generator set accessories Accessory Nos ENGINE The engine serial number is found on the engine nameplate Engine Serial No PART NUMBER AND SERIAL NUMBER Part and serial numbers are provided on the nameplate attached to the transfer switch Part No Serial No ntroduction i Section 1 Specifications The spec sheets for each generator set provide specific generator and engine information Refer to the respective spec sheet for data not supplied in this manual Consult the generator set operation manual installation manual engine operation manual and engine service manual for additional specifications Fast Response I Concepts The generator excitation system uses a permanent magnet exciter with a silicon controlled rectifier SCR Assembly which controls the amount of DC current fed to the generator field This type of system uses a voltage regulator which signals the SCR assembly through an optical coupling The voltage regulator monitors engine speed and generator output voltage to turn a stationary light emitting diode LED on or off accor
114. igh No No Yes High output voltage is detected Turn safeguard circuit breaker to OFF position Is sensing voltage 190 277 volts at leads V7 and V8 available Check for open wir ing between stator and safeguard circuit breaker If no voltage is de Replace tected replace pho SCR assembly to transistor board If sensing voltage If sensing voltage is is high replace low check voltage Replace voltage regulator on all phases Is voltage voltage balanced regulator on all windings No Test stator windings TP 5353 8 94 Generator Troubleshooting 7 3 Generator Testing This section covers generator testing for the following generator conditions e No output on any phase e Overvoltage e Fluctuating voltage Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and reconnectit last to disable generator set before working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclos
115. ing near SCR assembly NOTE Early model generators use insulator washers to insulate the photo transistor board from the Figure 8 12 Supporting Generator Assembly 9 Fasten the lifting eye and hoist hook to rotor flange actuator cup Ifthe unitis disassembled substitute See Figure 8 13 Hoist the rotor to a vertical the insulator washers with the insulated board position taking care not to damage windings available as service part no 257850 laminations or bearing WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place TP 5353 8 94 Generator Disassembly Reassembly 8 9 Hazardous voltage can cause severe injury or 11 Attach photo transistor board and magnetic death Be sure that foil side of photo transistor board actuator to end of rotor shaft with two mounting end of shaft and threaded holes are clean and free of screws See Figure 8 15 Cut off excess lead wire metal particles and chips Metal debris may short circuit leaving enough wire to reach SCR assembly Strip 2 3 in 50 75 mm of gray insulator jacket from lead Cut off all exposed uninsulated wire Strip about 1 4 in 0 6 mm of insulation on red and black leads and crimp on 8 electrical terminals part no X 283 7 Before connecting to SCR studs secure leads with tie wraps Reconnect photo board white lead to SCR AC stud red lead to F
116. ion former name of ANSI ASME American Society of Mechanical Engineers assy assembly ASTM American Society for Testing Materials ATDC after dead top center aux auxiliary AN audio visual AWG American Wire Gage AWM appliance wiring material BBDC before bottom dead center BDC before dead center BHP brake horsepower bmep brake mean effective power BTDC before top dead center Btu British thermal unit Celsius degree cc cubic centimeter CCA cold cranking amps CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute CID cubic inch displacement cm centimeter centimeters cmm cubic meters per minute continued CPVC chloropoly vinyl chloride CRT cathode ray tube CSA Canadian Standards Association CT current transformer cu in cubic inch es TP 5353 8 94 abbreviated form The commonly used abbreviations are shown below Some items may not apply to this application Abbreviation Description CWC city water cooled cyl cylinder dB decibel dBA decibels A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DIN Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss e g example given EIA Electronic Industries Association EMI electromagnetic interference EPA Environmental Protection Agency etc etcetera and so forth ext external F Fahrenheit degree fl oz fluid ounce s F
117. ion is made on the controller circuit board terminal strip For cyclic cranking leave circuit board terminal TB1 9 open Continuous cranking is achieved by running a jumper between circuit board terminal TB1 2 ground and terminal TB1 9 Operation 2 13 Stopping Normal Stopping 1 Disconnect load from generator set and allow it to run without load for 5 minutes NOTE Run the generator at no load for 5 minutes prior to stopping to ensure adequate cooling of the set 2 Move generator master switch to the OFF RESET position Engine will stop NOTE If engine stop is signaled by a remote switch or automatic transfer switch the generator set will continue running during a 5 minute cooldown cycle Emergency Stopping Turn generator master switch to the OFF RESET position or activate controller emergency stop switch if equipped or optional remote emergency stop for immediate shutdown If either emergency stop switch is activated the controller low water temperature auxiliary lamp will light and the unit will shut down On 200 1600 kW models with Detroit Diesel engines both the air damper and low water temperature auxiliary lamps will light if the emergency stop switch is activated NOTE Use the emergency stop switch es for emergency shutdowns only Use the generator master switch to stop the generator set under normal circumstances 2 14 Operation Resetting Emergency Stop Switches Use the following procedure to
118. ion when the power is off The magnetic pickup air gap is 0 014 0 028 in 0 36 0 71 mm 09 S1 OFF DIESEL S2 OFF 2000 2 2500 ACT REMOTE SPEED POT 4V ILS Aa 8 4 5 78 S AX 273000 L Control Unit Terminal 1 Positive Terminal 2 Negative Magnetic Pickup Optional Remote Speed Pot Actuator Connect to Ground Stud in Controller Connect to Cranking Solenoid Battery Rela Connect to 70 of Safeguard Breaker Terminal Block Figure 7 29 Governor Control Unit gt 5353 8 94 The Barber Colman control unit is equipped with switches S1 and S2 Prior to making governor adjustments verify that S1 and S2 are in the correct positions for your application Switch S1 selects the controller response range based upon engine type Place switch S1 to the OFF position for diesel models and to the ON position for gas gasoline models Place switch S2 to match the control unit of the governor actuator In all cases place switch S2 in the ON position These generators use the Dyna 2500 actuator LOU CO UI A YS 1 Actuator 2 Linkage
119. ircuit The kit will manually disconnect the generator set from the load when servicing the generator set See Figure 1 8 TP 5352 1 Figure 1 8 Line Circuit Breaker 5353 8 94 Overvoltage Kit with microprocessor controller only The microprocessor controller will cause immediate engine shutdown when it is triggered by a DC signal from an overvoltage shutdown option The generator set will automatically shut down if output voltage is 1596 above nominal voltage longer than two seconds The overvoltage option connects to wire 30 in the controller See Figure 1 9 SEE jal le TE MT c eO o ft Figure 1 9 Overvoltage Circuit Board Run Relay Kit The run relay kit is energized only when the generator set is running The three sets of contacts in the kit are typically used to control air intake and or radiator louvers However alarms and other signalling devices can also be connected to the contacts See Figure 1 10 L L 273705 Figure 1 10 Run Relay Kit TP 5353 8 94 Remote Emergency Stop Kit with microprocessor controller only The emergency stop kit allows immediate shutdown of the generator set from a station remote from the generator set See Figure 1 11 If the emergency stop switch is activated the emergency stop lamp lights and the unit shuts down Before attempting to restart the generator set reset the emerge
120. is made local or remote Overspeed Lamp lights if set shuts down due to overspeed condition exceeding 70 Hz governed frequency TP 5353 8 94 9 Auxiliary Lamp flashes lights under the following conditions Flashing Lamp Conditions e Auxiliary lamp will flash immediately if the controller senses no AC output while the unit is running except during first 10 seconds after start up When AC output is sensed the flashing will stop and the lamp will be off No manual reset is required e Theauxiliary lamp will flash if the battery power was reconnected or was low and then came back up again while the generator master switch was in the RUN or AUTO position A temporarily low battery condition where the battery is weak or undersized for the application may cause this condition Continuous On Lamp Conditions e The auxiliary lamp lights if the optional emergency stop switch is reset while the generator master switch is in the AUTO or RUN position To clear this condition place master switch in the OFF RESET position e The auxiliary lamp lights and engine shuts down 5 seconds after high oil temperature P1 13 low coolant level P1 14 or aux delay shutdown P1 15 faults if so equipped occur These conditions are inhibited during first 30 seconds after crank disconnect e The auxiliary lamp lights and engine shuts down immediately if overvoltage condition arises if equipped with overvoltage shutdown kit
121. jewelry while adjustments are made Remove wristwatch rings and jewelry that can cause short circuits Hazardous voltage can cause severe injury or death Engine block heater can cause electrical shock Remove engine block heater plug from electrical outlet before working on block heater electrical connections Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause serious injury or death to utility personnel working on transmission lines Heavy Equipment VI Safety Precautions and Instructions A WARNING Unbalanced weight Improper lift can cause severe injury or death or equipment damage Do not use lifting eyes Use lifting bars through holes in skid to lift generator set TP 5353 8 94 Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing pressure cap stop generator set and allow it to cool Then loosen pressure cap to relieve pressure WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on generator set until it is allowed to cool TP 5353 8 94 Hot parts can cause severe injury or death Avoid touching generator set field or exciter armature Generator set field and exciter armature will become hot if shorted Hot coolant can ca
122. ket bore 1 Hoist Hook 2 Hoist Hook 3 End Bracket 1 Exciter Magnets adapter Figure 8 9 End Bracket View Figure 8 8 Removing Generator Adapter 15 Remove generator adapter mounting bolts Fasten hoist hooks to end bracket and raise assembly slightly Bump generator adapter loose by using a rubber mallet TP 5353 8 94 Generator Disassembly Reassembly 8 7 Reassembly 1 Attach exciter field to end bracket with four mounting screws See Figure 8 9 NOTE Some early models are equipped with a tolerance ring inside the end bracket bore Install a new tolerance ring when reinstalling end bracket 2 Place stator in a vertical position with end bracket side up NOTE End bracket side of stator has four mounting bosses 3 Place end bracket on stator and use bolts to align holes Use a rubber mallet to mount end bracket flush with stator See Figure 8 10 Figure 8 10 Mounting End Bracket on Stator NOTE Position end bracket housing eye opposite the stator mounting bracket during reassembly 8 8 Generator Disassembly Reassembly NOTE Early models use a skewed slanted stator with a straight rotor When replacing either rotor or stator be sure replacement is the same as the original Use dissimilar rotor and stator styles skewed rotor with straight stator or straight rotor with skewed stator when reassembling the generator set 4 Install bolts and washers to
123. ket to stator 5 Use a puller tool to remove end bracket See Figure 7 16 NOTE To avoid loosening exciter field magnets do not attempt to remove end bracket by pounding with a hammer Figure 7 16 Removing End Bracket TP 5353 8 94 Generator Troubleshooting 7 17 Speed Sensor Test Follow the procedure outlined below to determine if the 1 Connect speed sensor voltmeter and DC voltage speed sensor overspeed fault is emitting a signal source as shown in Figure 7 17 1 With generator master switch in OFF RESET 2 Touch sensing surface with a flat piece of iron or position connect a DC voltmeter between positive lead wire 24 at speed sensor and ground wire 2 Voltmeter should read approximately 8 10 volts steel at least 1 4 cubic inch 4 1 cm in size Voltmeter test reading should equal source voltage DC 2 With generator set running connect DC voltmeter negative probe to 0 terminal wire 16 white on speed sensor Place voltmeter positive probe on positive terminal wire 24 red Voltmeter should indicate approximately 12 volts DC NOTE During the test the controller leads must remain connected to the speed sensor terminals Slide leads from speed sensor terminals only enough to expose connection for test leads Do not disconnect leads 4 Remove iron or steel from sensing surface and Observe no test voltmeter reading If speed sensor is emitting a signal check con
124. l reset is required e The LWT auxiliary lamp will flash if the battery power was reconnected or was low and then came back up again while the generator master switch was in the RUN or AUTO position A temporarily low battery condition where the battery is weak or undersized for the application may cause this condition Place the master switch in the OFF RESET position to clear this condition Continuous On Lamp Conditions e The LWT auxiliary lamp lights and unit shuts down immediately if the optional emergency stop switch is activated if equipped with optional emergency stop switch e The LWT auxiliary lamp lights if the optional emergency stop switch is reset while the generator master switch is in the AUTO or RUN position Place the generator master switch in the OFF RESET position to clear this condition e The LWT auxiliary lamp lights and engine shuts down 5 seconds after high oil temperature P1 13 low coolant level P1 14 or aux delay shutdown P1 15 faults if so equipped occur These conditions are inhibited during first 30 seconds after crank disconnect TP 5353 8 94 e The LWT auxiliary lamp lights and engine shuts down immediately if overvoltage condition arises if equipped with overvoltage shutdown kit e The LWT auxiliary lamp lights and engine shuts down if activated by customer supplied sensing devices connected to auxiliary immediate shutdown ports P1 17 and P1 18 e The LWT auxiliary lamp ligh
125. llowing charts as a quick reference in troubleshooting individual problems Consult the first chart for aid in locating the cause of blown fuses In the successive charts generator faults are listed by specific groups and correlated with possible causes and corrective action Before beginning any troubleshooting procedure read all safety precautions at the beginning of this manual and those included in the text Do not neglect these precautions WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Hazardous voltage can cause severe injury or death Whenever electricity is present there is the hazard of electrocution Open main circuit breaker on all power sources before servicing equipment Electrically ground the generator set and electrical circuits when in use Never come into contact with electrical leads or appliances when standing in water or on wet ground as the chance of electrocution is increased under such conditions 6 2 Generator Controller Troubleshooting WARNING 69 D 05 Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables
126. ltage is transferred to load during test personal injury and equipment damage may result Do notuse the safeguard circuit breaker in place of the line circuit breaker Hazardous voltage can cause severe injury or death Follow instructions of test equipment manufacturer when performing high voltage test on rotor or stator An improper test procedure can damage equipment or lead to future generator set failures Hazardous voltage can cause severe injury or death Do not expose the photo transistor board to any external light source as exposure to light causes high voltage Keep foreign sources of light away from photo transistor board during testing Place black electrical tape over LED of circuit board mounted on generator set end bracket before starting generator set with end cover removed Hazardous voltage can cause severe injury or death Be sure that foil side of photo transistor board end of shaft and threaded holes are clean and free of metal particles and chips Metal debris may short circuit photo transistor board and cause hazardous voltage in generator set AC voltmeter must show correct output before generator set may be reconnected to load afety Precautions and Instructions V Hazardous voltage can cause severe injury or death Make sure leads C and E leading to SCR assembly one piece are connected to the corresponding terminals Reverse connection of these leads or grounding of the C red lead will turn the SCR
127. m 60 Hz or 1500 rpm 50 Hz 10 Use controller voltage adjustment pot or remote voltage adjustment pot to make final adjustments to generator while running under normal load 11 Readjust stability pot if necessary To determine whether the AVR is functioning properly reduce engine speed Hz and watch for a corresponding drop in AC voltage At 60 Hz operation the voltage will remain constant until engine speed drops below 58 Hz approximately If AC frequency drops below 58 Hz AC voltage will decline At 50 Hz operation AC voltage remains constant until engine speed is reduced to 48 Hz approximately If the AVR is not functioning properly refer to the following test to determine cause of malfunction TP 5353 8 94 To Test AVR With the safeguard breaker closed if equipped 1 Disconnect the wiring harness connector from the voltage regulator and check for continuity between the voltage sensing leads V7 and V8 pins 4 and 10 See Figure 7 9 Ifthis circuit is open repair or replace An open circuit will normally result in a high voltage or overvoltage condition Check the 15 amp fuse if equipped 2 If there is continuity between V7 and V8 check for continuity in the voltage adjustment circuit leads 67 and 68 With the harness disconnected check the resistance between pins 1 and 3 This resistance should change as the voltage adjust rheostat is turned Repair or replace defective components as necessary
128. minal Strip on Circuit Board Terminal strip allows connection of generator accessories such as emergency stop switch remote start stop switch audio visual alarms etc Crank mode selection cyclic or continuous is also made on the TB1 terminal strip Location of the TB1 terminal strip on the controller circuit board is shown in Figure 2 2 Refer to appropriate wiring diagrams for additional information on connecting accessories to the TB1 terminal strip G 292806 1 TB1 Terminal Strip 2 Fuses Figure 2 2 TB1 Terminal Strip on Controller Circuit Board Operation 2 5 Starting Local Starting Move the generator master switch to the RUN position to start the generator set at the controller NOTE The alarm horn will sound and the Not In Auto lamp will light whenever the generator master switch is not in the AUTO position NOTE The 16 light controller is equipped with a transient start stop function to avoid accidental cranking of the rotating engine If the generator master switch is momentarily placed in the OFF RESET position then quickly returned to RUN the generator set will slow to 249 RPM and recrank before returning to rated speed Auto Starting Move the generator master switch to the AUTO position to allow start up by automatic transfer switch or remote start stop switch connected to controller terminals 3 and 4 NOTE The 16 light microprocessor controller provides up to 45 seconds of continuous c
129. mode K2 relay is located on controller circuit board See Figure 6 2 K3 Relay Run Relay on Main Circuit Board e Energizes ignition fuel solenoid fuel pump choke and instrumentation e Energizes generator voltage regulator LED3 lights when energized during crank and run TP 5353 8 94 modes K3 relay is located on controller circuit board K4 Relay Emergency Stop Relay on Main Circuit Board e The K4 relay is energized continuously except during emergency stop conditions LED4 is lit at all times except during emergency stop K4 relay is located on controller circuit board If emergency stop kit is connected local or remote remove jumper from circuit board TB1 1 and 1A If no emergency stop kit is connected a jumper must connect terminals TB1 1 and 1A See Figure 6 2 K5 Relay Governor Control Relay e Energizes engine governor control circuit Relay is located in generator junction box K6 Relay Air Damper Relay e Energizes air damper solenoid for emergency stop on 200 1600 kW models with Detroit Diesel engines only K6 relay is located in generator junction box 88 8 41 32 63 61 62 35 f a 26 12 38 96 60 piee i nd UE s f p LOT NO d G 292806 K4 Relay LED4 K2 Relay LED2 LEDS Relay Figure 6 2 Main Circuit Board Relays Generator Controller Troubleshooting 6 1 Troubleshooting Microprocessor Controller Use the fo
130. n electronic control unit and an actuator The magnetic pickup monitors engine speed and transmits this information to the electronic control unit see Figure 7 27 The electronic control unit interprets the signal from the magnetic pickup to control current input to the throttle actuator The throttle actuator adjusts the throttle position on the engine See Figure 7 28 Adjust the actuator shaft linkage to hold the fuel injection pump lever in the stop position when the power is off The magnetic pickup air gap is 0 014 0 028 in 0 36 0 71 mm Control Unit Terminal 1 Positive Terminal 2 Negative Magnetic Pickup Optional Remote Speed Pot Actuator Relay White Lead Black Lead NOOROM Figure 7 27 Governor Control Unit TP 5353 8 94 The Barber Colman control unit is equipped with switches S1 and S2 Prior to making governor adjustments verify that S1 and S2 are in the correct positions for your application Switch S1 selects the controller response range based upon engine type Set 1 to the OFF position for diesel models and to the ON position for gas gasoline models Place switch S2 to match the control unit of the governor actuator In all cases place switch S2 in the OFF position These generators use the Dyna 8000 actuat
131. n engine Not Applicable equipped switch in RUN position remove switch lead connected to controller terminals TB1 1 or 1A 6 12 Generator Controller Troubleshooting TP 5353 8 94 Generator Condition Indicator Terminals Continued Mmdiatr Switch Position Remarks Check For Voltage Between Generator Switch Not in Auto Master switch in RUN OFF RESET TB1 42A and TB1 80 engine switch in any position Anticipatory High Engine Water Master switch in RUN position engine TB1 42A and TB1 40 Temperature A W T switch in RUN hold toggle switch to A W T Anticipatory Low Engine Oil Pressure Master switch in RUN position engine TB1 42A and TB1 41 A O P switch in RUN hold toggle switch to A O P Low Water Temperature L W T Master switch in RUN position engine TB1 42A and TB1 35 switch in RUN hold toggle switch to L W T Low Fuel Generator master switch in Not Applicable OFF RESET engine switch in RUN position Ground controller terminal TB1 63 to test If Low Fuel lamp lights circuit is functioning correctly Battery Charger Fault if battery charger Generator master switch in Not Applicable equipped and connected OFF RESET engine switch in RUN position Ground controller terminal TB1 61 to test If Battery Charger lamp lights circuit is functioning correctly Low Battery Volts if battery charger Generator master switch in Not Applicable equipped an
132. n occurs after 75 seconds of cyclic cranking crank 15 seconds rest 15 seconds crank 15 seconds etc for a total of 75 seconds Shutdown occurs after 15 seconds if engine or starter will not turn locked rotor Low Oil Pressure Shutdown occurs 5 seconds after fault Low oil pressure shutdown will not function during the first 30 seconds after start up NOTE Low oil pressure shutdown will not protect against low oil level Check for oil level at engine High Engine Temperature Shutdown occurs 5 seconds after fault High engine temperature shutdown will not function during first 30 seconds after start up 2 8 Operation NOTE High temperature shutdown will not function if proper coolant level is not maintained Low Coolant Level Shutdown occurs 5 seconds after fault Low coolant level shutdown will not function during the first 30 seconds after start up NOTE Low oil pressure high engine temperature and low coolant level shutdowns will not function during the first 30 seconds after start up Overvoltage if equipped Unit will shut down after approximately two seconds of voltage 1596 or more over nominal voltage Low water temperature auxiliary lamp will light NOTE Sensitive equipment may suffer damage in less than one second of an overvoltage condition Install separate overvoltage protection to on line equipment requiring faster shutdowns TP 5353 8 94 Controller Resetting Procedure Following Fault
133. ncy stop switch by replacing glass piece and reset the generator set by placing the master switch in the OFF RESET position A single replacement glass piece is located inside the switch Additional glass pieces are available as a service part Reset the engine air damper switch on 200 1600 kW models using Detroit Diesel engines See Resetting Emergency Stop Switches A 222654 TP 5352 1 Figure 1 11 Emergency Stop Kit Specifications 1 11 Controller Connection Kit with microprocessor controller only The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip The kit uses a 65 in 165 cm wiring harness to link the controller TB1 terminal strip with a remote terminal strip With the exception of terminals TB1 1 1 and 56 the remote terminal strip is identical to that of the controller Connect all accessories except the emergency stop kit to the connection kit terminal strip FASTCHECK Diagnostic Tester with microprocessor controller only The FASTCHECK diagnostic tester simulates engine operation to identify faults in the controller and engine circuitry Use the FASTCHECK when troubleshooting start up problems or to test and troubleshoot the controller when removed from the generator Tests are performed without starting the generator set Functions performed by the FASTCHECK are listed below refer to Figure 1 12 to identify LEDs and switch
134. nditions Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and reconnectit last to disable generator set before working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed TP 5353 8 94 Troubleshooting Manual Controller Does engine crank No Press start switch I Verify that relay is energized by checking for DC voltage at K20 relay Is K3 rela due ta coil when START switch is actuated Is voltage present at relay No Is K2 relay LED lit Is 10 amp fuse okay Is DC voltage available No Yes Is K2 relay functioning properly See Section 7 following relay faulty replace circuit at K20 relay contacts starter motor side when START switch is board actuated Replace fuse Replace circuit board Replace K20 relay starter motor solenoid Y Check condition connections of start stop switch N 43 and 47 See Section 7 fol lowing Check battery condition and connections Y relay or K1 relay faulty
135. ne hour with an operator present Make all prestart checks before starting the exercise TP 5353 8 94 procedure Start the generator set according to the procedure given for the generator controller See the appropriate controller section for specific starting instructions Operation 2 1 16 Light Controller Level 1 Operation components standard and oversize meterbox and an explanation of their functions refer to Figure 2 1 and the following descriptions The 16 light microprocessor controller level 1 is available in the standard model and the oversize meterbox version for installation of additional meters and gauges For identification of 16 light controller Standard Model Anticipatory High Engine Temperature Lamp Anticipatory Low Oil Pressure Lamp Low Water Temperature Lamp Low Fuel Lamp High Engine Temperature Lamp Low Oil Pressure Lamp Emergency Stop Lamp Overspeed Lamp Auxiliary Lamp Battery Charger Fault Lamp Low Battery Volts Lamp Overcrank Lamp Auxiliary Prealarm Lamp Air Damper Lamp System Ready Lamp Generator Switch Not in Auto Lamp Scale Lamps Upper Lower E LOW WATER TEMPERATURE GENERATOR NOT IN AUTO L ADV 5849 P2 Selector Switch Lamp Test Generator Master Switch Alarm Horn Alarm Silence Switch Voltage Adjustment Pot Emergency Stop Switch Hourmeter Frequency Meter AC Voltmeter A
136. nerator master switch to RUN to start generator set Adjust the control unit speed pot until the engine is operating at the desired rom 50 or 60 Hz on the frequency meter If governing is unstable turn gain pot slightly counterclockwise NOTE Gain pot has internal stops a 0 and 100 With the engine running at no load finalize gain adjustment Turn the gain adjustment clockwise until the output shaft and linkage is stable Upset the linkage by hand If the linkage oscillates 3 5 times then stops the setting is correct Stop the generator set TP 5353 8 94 Governor Calibration for Paralleling Generator Sets Calibration Procedure Place generator master switch to OFF Generator set must not be running Set the gain pot at 3096 and the droop pot completely counterclockwise CCW Adjust the idle speed by turning the 20 turn pot clockwise CW to increase speed and counterclockwise CCW to decrease speed Adjust the run speed by turning the 20 turn pot clockwise CW to increase speed and counterclockwise CCW to decrease speed Place generator master switch to RUN or TEST position to start generator set Slowly turn the gain pot clockwise CW until the engine becomes unstable After the engine becomes unstable slowly turn the gain pot counterclockwise CCW until stable Interrupt the governor by momentarily removing power from the governor The engine should recover in 3 5 diminis
137. nerator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and reconnect it last to disable generator set before working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed TP 5353 8 94 Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Hazardous voltage can cause severe injury or death Disconnect generator set from load by opening line circuit breaker or by disconnecting generator set output leads from transfer switch and heavily taping ends of leads If high voltage is transferred to load during test personal injury and equipment damage may result Do notuse the safeguard circuit breaker in place of the line circuit breaker Generator Troubleshooting 7 1 Troubleshooting Generator No Output Voltage No output voltage is detected Is safeguard circuit breaker in ON position Yes Do flashlight test on photo transistor board See LED Circuit Board Place safeguard circuit breaker to ON position Test If no voltage is detected remove
138. ng the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is mandatory Propane is heavier than air install gas detectors low in room Inspect detectors often Natural Gas Adequate ventilation is mandatory Natural gas rises install gas detectors high in room Inspect detectors often Explosive fuel vapors can cause severe injury or death Fuelleakage can cause an explosion Check LP vapor gas or natural gas fuel system for leakage using a soap water solution with fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use test solutions that contain ammonia or chlorine since the soap will not bubble for an accurate leakage test IV Safety Precautions and Instructions Explosive fuel vapors can cause severe injury or death Storing gasoline and other volatile fuels in day or subbase fuel tanks can cause an explosion Store only diesel fuel in these tanks Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining fuel system Wipe up all spilled fuel after draining system Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check LP liquid withdrawal gas fuel system for leakage using a soap water solution with fuel system test pressurized not less than 90 psi 621 kPa Do notuse test s
139. ntenance Oil Pressure Gauge Gauge measures engine oil pressure Water Temperature Gauge Gauge measures engine coolant temperature DC Voltmeter Meter measures voltage of starting battery ies Emergency Stop If equipped Switch is used to instantly shut down the generator set in emergency situations Reset switch after shutdown by rotating switch clockwise Use the emergency stop switch for emergency shutdowns only Use the TP 5353 8 94 switchgear mounted operating controls to stop the set under normal circumstances Local emergency stop switch is standard on 200 1600 kW models with Detroit Diesel Engine Gauge Box Terminal Strips Use terminal strips to connect switchgear control wiring to generator set governor control crank relays safety switches gauge senders etc Connection Plug Use plug to connect wiring harness from generator set governor control crank relays safety switches gauge sender etc to gauge box terminal strips Electronic Speed Switch Switch signals engine control logic in switchgear to disconnect starter motor after start up or shuts down the system if an overspeed fault occurs Speed switch settings are adjustable for crank and overspeed Operation 2 17 Manual Controller Operation The manual controller is designed for prime power an explanation of their functions refer to Figure 2 8 and applications using manual nonautomatic operation the following de
140. nual controllers Overfrequency will occur if the governor was misadjusted or defective Shutdown will occur immediately should frequency reach 68 70 Hz or greater This setting applies to 50 and 60 Hz models The time delay circuitry provides approximately a 5 second delay before generator set is subject to fault shutdown from low oil pressure LOW high engine temperature HWT or low water level LWL NOTE Overspeed is not subject to the 5 second shutdown delay This 5 second delay is necessary during starting to allow engine to build up oil pressure This time delay is present only at cranking After the generator set comes up to correct AC voltage the time delay circuitry times out After approximately 5 seconds engine fault shutdowns are operative Test both relays and circuit board for function See Figure 7 19 and use the following procedure Tests are made with circuit board in place and connected to generator set Do not connect load to generator set Ground 12 Volts DC P1 1 12 Volts DC Not Used P1 13 K4 Relay Stator Lead VO Stator Lead V7 P1 15 K4 Relay Engine Shutdown Switches TP 5414 7 Figure 7 19 Overspeed Time Delay Circuit Board 7 20 Generator Troubleshooting Overspeed Circuitry and Relay The following conditions indicate that the overspeed circuitry and relay are functional 1 Check for 12 volts DC across terminals 70 4 and N This is the battery supply voltag
141. o the tank while the engine is running since spilled fuel may ignite on contact with hot parts or from ignition spark Do not smoke or permit flame or spark to occur near potential sources of spilled fuel or fuel vapors Keep fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Flexible sections are used to avoid breakage due to vibration If any fuel leakage fuel accumulation or electrical sparks are noted DO NOT OPERATE GENERATOR SET Repair systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is mandatory Propane is heavier than air install gas detectors low in room Inspect detectors often 8 2 Generator Disassembly Reassembly Perform the following steps prior to disassembling the generator set 1 Disconnect negative lead first and remove starting batteries from work area to prevent fire hazard Disconnect AC powered accessories such as battery charger block heater and fuel transfer pump 2 Shut off fuel supply Drain fuel system as necessary by emptying fuel into proper containers Remove any fuel containers from work area to prevent fire hazard Ventilate work area to clear fumes 3 Disconnect fuel cooling and exhaust systems a
142. olutions that contain ammonia or chlorine since the soap will not bubble for an accurate leakage test TP 5353 8 94 Hazardous Noise CAUTION Hazardous noise Can cause loss of hearing Never operate generator set without a muffler or with a faulty exhaust system Hazardous Voltage Electrical Shock WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place WARNING ha Hazardous voltage Backfeed to utility system can cause property damage severe injury or death When generator set is used for standby power use an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply TP 5353 8 94 Hazardous voltage can cause severe injury or death Whenever electricity is present there is the hazard of electrocution Open main circuit breaker on all power sources before servicing equipment Electrically ground the generator set and electrical circuits when in use Never come into contact with electrical leads or appliances when standing in water or on wet ground as the chance of electrocution is increased under such conditions Hazardous voltage can cause severe injury or death Disconnect generator set from load by opening line circuit breaker or by disconnecting generator set output leads from transfer switch and heavily taping ends of leads If high vo
143. ometer counterclockwise until the actuator lever is stable Jog the actuator lever by hand If the actuator lever oscillates three to five times and then stabilizes the gain setting is correct If the actuator lever does not perform as described proceed to Step 6 Turn the gain potentiometer one division j counterclockwise Turn potentiometer fully clockwise and watch the actuator lever If the actuator lever does not become unstable jog it by hand potentiometer counterclockwise until the lever is stable Jog the actuator lever by hand It should waver from three to five times before stabilizing The governor is now calibrated Stop the generator set TP 5353 8 94 Electronic Governor Barber Colman Dyna 2500 125 180 kW John Deere Powered Models Some sets are equipped with Barber Colman Dyna 2500 electronic governors Since this is an electronic device no mechanical drive or hydraulic connection is required The system consists of a magnetic pickup an electronic control unit and an actuator The magnetic pickup monitors engine speed and transmits this information to the electronic control unit see Figure 7 29 The electronic control unit interprets the signal from the magnetic pickup to control current input to the throttle actuator The throttle actuator adjusts the throttle position on the engine See Figure 7 30 Adjust the actuator shaft linkage to hold the fuel injection pump lever in the stop posit
144. oprocessor controllers On 6 light controllers the low water temperature auxiliary lamp will flash The NOT IN AUTO lamp is illuminated whenever the generator master switch is not in the AUTO position on 16 light microprocessor controllers 6 10 Generator Controller Troubleshooting 6 Move generator master switch to RUN position Move FASTCHECK engine switch to CRANK FASTCHECK IGN CRK and REG lamps should light The generator controller will cause the engine to crank until the FASTCHECK switch is moved to RUN or OVERCRANK shutdown appears on generator controller 7 Move the FASTCHECK engine switch to RUN CRK lamp should go out and REG and IGN lamps should stay on 8 Simulate engine malfunctions by pressing FASTCHECK fault switches Corresponding fault lamp on controller should light during each simulated engine malfunction NOTE Leave FASTCHECK engine switch in RUN position for at least 30 seconds before pushing toggle switches Toggle generator master switch to OFF RESET and FASTCHECK engine switch to OFF then back to RUN after simulated fault shutdowns 9 Procedures to test overcrank circuitry speed sensor circuitry and generator condition indicators are described later in this section R11118 2 3 187 1 FASTCHECK 2 Wiring Harness 3 DC Harness Connector 4 DC Power Supply Figure 6 9 FASTCHECK Connections TP 5353 8 94 Overcrank To test the controller s ability
145. or 1 Actuator 2 Linkage Figure 7 28 Throttle Actuator Typical Generator Troubleshooting 7 27 Preliminary Adjustments Place generator master switch to OFF Generator set must not be running amp Set the control unit I adjustment one division from zero and the gain adjustment at the third division from zero For isochronous operation set the droop adjustment potentiometer counterclockwise to the minimum position For droop operation set droop potentiometer to desired droop Droop adjustment may be necessary with parallel generator operation Position actuator lever to hold fuel pump lever in STOP position when power is off Adjust the actuator linkage for smooth nonbinding operation Final Adjustments Place generator master switch to RUN or TEST position to start generator set Adjust the control unit speed potentiometer until the engine is operating at the desired rpm 50 or 60 Hz on the frequency meter governing is unstable turn and gain potentiometers slightly counterclockwise 7 28 Generator Troubleshooting When the actuator lever wavers slowly turn the NOTE Except for the speed potentiometer control unit pots have internal stops at 0 and 10096 Slowly turn the gain adjustment potentiometer clockwise until the actuator level oscillates The actuator lever will waver faster than when the potentiometer was adjusted Slowly turn gain adjustment potenti
146. p to and including 1 2 in dia hardware Weld nuts Exit hole types OahWONM Figure B 2 Acceptable Hardware Combinations Appendices B 1 Appendix C Common Hardware Common hardware has many different head drive and guide for identification purposes Not all generator grade hardness styles Some of the more common hardware used is shown types are shown in Figure C 1 and Figure C 2 Thisisa Screws Bolts Studs HEAD STYLES yY qus gu gas om Hex Head or Hex Head or Hex Head or Flat Head Round Machine Head Machine Head Machine Head Head with Washer Pan Socket Socket Head or Sheet Metal Stud Head Head Cap Allen Head Screw or Allen Shoulder Bolt Head Cap DRIVE STYLES Hex Hex and Phillips Slotted Hex Socket Slotted GRADE HARDNESS American Standard re Grade 2 Grade5 Grade8 Grade 8 9 SAMPLE DIMENSIONS American Standard Major Thread Diameter In Fractional 1 4 20 1 t Length In Inches Inches Or Screw Number Size Threads ES Inch Metric M8 1 25 x 20 Major Thread Diameter In Millimeters r Length In Millimeters Distance Between Threads In Millimeters Allen is a trademark of Holo Krome Co Phillips amp is a registered trademark of the Phillips Screw Company Figure C 1 Screws Bolts Studs TP 5353 8 94 Appendices C 1 Nuts STYLES Os G C Hex Head Lock Nut or Square Nut Cap Nut or Wing Nut Nylock Nut Acorn Nut GRADE HARDNE
147. procedure to restart the generator set after a fault shutdown Refer to Resetting Emergency Stop Switches earlier in this section to reset the generator after an emergency stop 1 Move controller alarm horn switch to the SILENCE position If equipped A V annunciator alarm horn and lamp are activated Move A V annunciator alarm switch to SILENCE to stop alarm horn A V annunciator lamp stays lit 2 Disconnect generator set from load with line circuit breaker or automatic transfer switch 3 Correct cause of fault shutdown See Safety Precautions section of this manual before proceeding 4 Start generator set by moving the generator master switch to OFF RESET and then to the RUN position If equipped A V annunciator alarm horn sounds and lamp goes out 5 Verify that the cause of the shutdown has been corrected by test operating generator set 6 Reconnect generator to load via line circuit breaker or automatic transfer switch 7 Move generator master switch to AUTO position for start up by remote transfer switch or remote start stop switch If equipped move A V annunciator alarm switch to NORMAL 8 Move controller alarm horn switch to the NORMAL position Place generator master switch in the AUTO position before silencing alarm horn Operation 2 15 Paralleling Engine Gauge Box Controller Operation Switchgear STO EMERGENCY 89 1 Hourmete
148. r 2 Oil Pressure Gauge 3 Water Temperature Gauge 4 DC Voltmeter 5 Emergency Stop Switch if equipped 6 Gauge Box Terminal Strips inside controller 7 Connection Plug inside controller 8 Electronic Speed Switch inside controller Figure 2 7 Paralleling Engine Gauge Box Controller Operation Switchgear The paralleling engine gauge box is designed for interconnecting the generator set with switchgear mounted control logic An engine gauge box is required for each generator set in the paralleling system Other than the emergency stop switch if equipped no operating controls are included in the engine gauge box generator set operating controls are included in the switchgear A connection plug is used to connect the generator set governor crank relays safety switches high 2 16 Operation water temperature low oil pressure low coolant level and gauge senders to gauge box terminal strips The appropriate terminals on the terminal strips are then hard wired to the switchgear controls Also included in the gauge box is an electronic speed switch with overspeed and crank outputs For identification of paralleling meter box components and an explanation of their functions refer to Figure 2 7 and the following descriptions TP 5353 8 94 Features The numbered paragraphs following refer to Figure 2 7 1 Hourmeter Hourmeter records generator set total operating hours for reference in scheduling mai
149. r corrosion Scheduled Maintenance 3 3 Section 4 General Troubleshooting Use the following tables as a quick reference in troubleshooting individual problems Generator set faults are listed by specific groups and include likely causes and remedies The source of more detailed information needed to correct a problem is indicated These sources include various sections of this manual the generator operation manual engine operation manual and engine service manual Corrective action and testing in many cases requires knowledge of electrical and electronic circuits It is recommended that service be done only by authorized service distributors dealers Improper repair by unqualified personnel can lead to additional failures General Troubleshooting Chart Sheet 1 of 2 Unit will not crank Unit cranks but will not start No AC output Weak or dead battery Reversed or poor battery connections Fuse blown in controller Emergency stop switch activated local or remote Fault shutdown Generator master switch in OFF position attempting start up from remote switch microprocessor controllers only Improper fuel No fuel Air in fuel system diesel models Defective ignition system gas gasoline models Air cleaner clogged Line circuit breaker or safeguard breaker in the OFF position if equipped Generator problem such as defective voltage regulator or other internal fault Recharge or repl
150. r set Check voltmeter for proper voltage Adjust voltage if necessary with the voltage adjustment potentiometer on the generator controller front panel or switchgear See Figure 9 3 STOP generator set when adjustment is complete ADV 5849 P1 1 Voltage Adjustment Figure 9 3 Voltage Adjustment TP 5353 8 94 Generator Reconnection 9 3 Generator Frequency Change and Adjustment Frequency Change Set the voltage regulator circuit board for either 50 or 60 Hz application See Figure 9 4 Connect a jumper between terminals T1 and T2 for 60 Hz operation Connect a jumper between terminals T1 and T3 to convert voltage regulator circuit board to 50 Hz application This procedure changes the voltage regulator circuit board for the desired frequency See Frequency Adjustment for changing generator set frequency and speed 02999 0 ASSV 89d za per up per NI NEN Julio amaaa amomo RiR Ne INI E w fol Jo Js je HL Jo 50 255670 1 T1 Terminal 2 T2 Terminal 3 T3 Terminal Figure 9 4 Jumper Location for 50 or 60 Hz Operation 9 4 Generator Reconnection Frequency Adjustment Check the frequency meter for a no load reading of 63 Hz for 60 Hz operation and 53 Hz for 50 Hz operation to determine correct frequency operation Check for
151. ranking or 75 seconds of cyclic cranking crank 15 seconds rest 15 seconds crank 15 seconds etc before overcrank shutdown Cranking mode cyclic or continuous selection is made on the controller circuit board terminal strip For cyclic cranking leave circuit board terminal TB1 9 open Continuous cranking is achieved by running a jumper between circuit board terminal TB1 2 ground and terminal TB1 9 2 6 Operation Stopping Normal Stopping 1 Disconnect load from generator set and allow it to run without load for 5 minutes NOTE Run the generator at no load for 5 minutes prior to stopping to ensure adequate cooling of the set 2 Move generator master switch to the OFF RESET position Engine will stop NOTE If engine stop is signaled by a remote switch or automatic transfer switch the generator set will continue running during a 5 minute cooldown cycle Emergency Stopping Turn generator master switch to the OFF RESET position or activate controller emergency stop switch if equipped or optional remote emergency stop for immediate shutdown If either emergency stop switch is activated the controller emergency stop lamp will light and the unit will shut down NOTE Use the emergency stop switch es for emergency shutdowns only Use the generator master switch to stop the generator set under normal circumstances TP 5353 8 94 Resetti ng Emergency Stop Used on 200 1600 kW models with Detroit Diesel engine
152. recautions relating to the operation of a generator set follow Below are some general precautions relating to the operation of a generator set SAVE THESE INSTRUCTIONS DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage if the danger is ignored WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note communicates installation operation maintenance information that is important but not hazard related Safety decals are affixed to the generator set in prominent places to advise the operator or service technician of potential hazards The decals are reproduced here to improve operator recognition For a further explanation of decal information refer to the safety precautions throughout this manual Before operating or servicing the generator set be sure you understand the messages of these decals Replace decals if missing or damaged TP 5353 8 94 Precautions anc nstructions Accidental Starting A WARNING aC Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it las
153. red When switched to a position with three circuit lead labels amperage is measured on the upper lead and voltage is measured between the lower two leads ammeter and voltmeter will not register with switch in the OFF position TP 5353 8 94 10 Start Stop Switch Use switch to start and stop generator set Refer to Starting and Stopping following 11 Voltage Adjustment Fine adjust for generator output voltage 12 10 Amp Fuse Fuse protects controller circuitry from short circuits and overloads 13 Scale Lamps upper lower Lamps indicate AC voltmeter and or ammeter scales to be read Starting Hold controller or remote start stop switch in START position until the engine starts If the engine fails to start after cranking for 5 10 seconds release the switch Wait for the engine to come to a complete stop before attempting restart NOTE Do not crank engine continuously for more than 10 seconds at a time Allow a 60 second cooldown period between cranking attempts if the engine does not start If the engine does not start after three attempts contact an authorized service distributor dealer for repair Operation 2 19 Stopping 1 Disconnect load from generator set and allow it to run without load for 5 minutes NOTE Run the generator at no load for 5 minutes prior to stopping to ensure adequate cooling of the set 2 Press controller or remote start stop switch to the STOP position The generator set
154. remove negative lead first and reconnectit last to disable generator set before working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed NOTE If starting unit by remote switch verify proper operation of remote switch before troubleshooting controller Test remote switch operation by placing generator master switch in the AUTO position and running a jumper between terminals 3 and 4 on controller circuit board If the generator does not start proceed with the controller troubleshooting procedure outlined in the following pages TP 5353 8 94 To quickly check the condition of the components mentioned to in the following flowcharts use an ohmmeter to read resistance between the designated terminal and ground See Figure 6 3 With ohmmeter on the R x 1 scale a reading of less than one ohm continuity indicates that component may be defective Isolate the defective component and repair or replace Checking P1 and P2 Connections Connect between Component ground and terminal Engine Gauges Connector P2 pin 1 Overvoltage Circuit Board Connector P2 pin 2 Crank K1 Relay Circuit Connector P1 pin 1 Diesel Fuel Solenoid Clrcuit Connector P1 pin 7 1 Ground Connection 2 P2 Connection Figure 6 3 Checking P1 and
155. rn See Controller Resetting Procedure following Voltage Adjustment generator output voltage Fine adjustment for TP 5353 8 94 24 25 26 27 28 29 30 31 32 Emergency Stop If equipped Switch is used to instantly shut down the generator set in emergency situations Reset switch after shutdown by rotating switch clockwise Use the emergency stop switch for emergency shutdowns only Use the generator master switch to stop the set under normal circumstances Hourmeter Hourmeter records generator set total operating hours for reference in scheduling maintenance Frequency Meter Meter measures frequency Hz of generator output voltage AC Voltmeter Meter measures voltage across output leads indicated by selector switch AC Ammeter Meter measures amperage from output leads indicated by selector switch Oil Pressure Gauge Gauge measures engine oil pressure Water Temperature Gauge Gauge measures engine coolant temperature DC Voltmeter Meter measures voltage of starting battery ies Fuses Fuses are located on controller circuit board See Figure 2 2 e 3 Amp Remote Annunciator F1 Fuse protects dry contact kit if equipped e 3 Amp Controller F2 Fuse protects controller circuit board speed sensor and lamp circuit board TP 5353 8 94 e 15 Amp Engine and Accessories F3 Fuse protects _ engine starting circuitry accessories 33 Controller TB1 Ter
156. roximately indicates deterioration of winding insulation and possible current flow to ground Repair or replacement of the rotor is necessary 6 Repair AC leads if test indicates leads shorted to ground Solder and insulate splices Use new sleeving when tying leads to shaft or heat sink 7 Replace rotor assembly if test shows armature is shorted to ground 3 100 R12758 8 TP 5353 7 1 Megohmmeter connections across either AC lead and rotor shaft Figure 7 15 High Voltage Test TP 5353 8 94 End Bracket Removal and Replacement This procedure is a condensed version of the one found 6 Pull the end bracket and exciter field assembly in Section 8 Disassembly Reassembly over the exciter armature Be extremely careful to avoid damaging exciter field magnets or photo NOTE transistor board On some models it is necessary to loosen the 7 Reverse order of disassembly to reinstall end generator junction box to remove the end bracket bracket exciter field assembly Remove the six junction box mounting screws and pull the junction box away from the engine to remove end bracket 1 Remove LED board and cover Disconnect leads from speed sensor 2 Remove screws holding actuator cup and photo transistor board 3 Reach in and remove leads photo transistor board leads from SCR assembly This will allow slack when removing the end bracket 4 Remove four bolts holding end brac
157. ry contact kits to the controller TB1 terminal strip Route dry contact relay leads through the controller grommet and guide loops to the circuit board terminal strip Place the controller circuit board panel flat to ensure adequate slack in the dry contact relay leads For specific information on accessory connections refer to Figure 1 13 the accessory wiring diagram and the instruction sheet accompanying each kit 5353 8 94 32 Common Fault Indicator Activated by HET Fault LOP Fault LWT Fault OC Fault OS Fault Remove Jumper if AUX Fault Emergency Stop is Used Connect A V Alarm or Common Fault Relay Kit Emergency Stopt 56 42 2 9 48 3 4 26 12 39 38 36 60 80 40 41 32 63 61 62 35 Terminal Strip See NOTE below EL P1 CIRCUIT BOARD TERMINAL IDENTIFICATION TB1 1 Ground Emergency Stop Relay K4 Connect emergency stop across terminals TB1 1 and 1A 1A Emergency Stop Relay K4 Coil Negative Connect emergency stop across terminals TB1 1 and 1A 56 Not Used Not Used 42A Battery Voltage Fuse 1 Protected Accessory Power Supply Customer m
158. s A V alarm remote annunciator dry contact kits etc may be connected to the controller TB1 terminal strip to signal the condition of the generator set Some generator sets may not be equipped with the optional sending devices necessary to operate all generator condition indicators If remote accessories will not operate test for output voltage at the TB1 terminal strip To test the operation of each indicator move the generator master switch and FASTCHECK toggle in the position prescribed Test point voltage is slightly less than the voltage being supplied to the controller 12 or 24 volts If correct voltage is not detected at the test point remote accessories A V alarm remote annunciator dry contact kits etc will not function Test point connections are shown in Figure 6 10 and the chart titled Generator Condition Indicator Terminals NOTE When checking controller test point voltage place negative lead of voltmeter on terminal designated in the chart and and voltmeter positive lead on TB1 42A NOTE Due to the absence of AC output the auxiliary lamp will flash during controller testing on 16 light microprocessor controllers On 6 light controllers the low water temperature auxiliary lamp will flash The NOT IN AUTO lamp is illuminated whenever the generator master switch is not in the AUTO position on 16 light microprocessor controllers NOTE Leave FASTCHECK engine switch in the RUN position for at
159. s necessary to tilt generator set Disconnect output leads or load circuit cables at generator set 4 Any cranes hoists or other lifting devices used in the disassembly or reassembly procedure must be rated for the weight of the generator set Check generator set nameplate or spec sheet for weight TP 5353 8 94 1 Voltage Regulator Terminal Strip 8 2 Voltage Regulator 9 3 Voltage Regulator Wiring Harness 10 4 Junction Box 11 5 Generator Guard 12 6 Junction Box Rear Cover 13 7 Skid 14 273000 Junction Box Side Cover Alternator Assembly Drive Discs Engine Side of Flywheel Flywheel Stud Spacer Figure 8 1 Generator Components Typical TP 5353 8 94 Generator Disassembly Reassembly 8 3 o o2 occ oc EUG Lo ocu o0 0x00 ngagogog lt 2 lt 6 Soles Scr 20509 gt oooctSoo 0 00000 lt o gt gt 8 a ou mee 6 5 9 8 3 amos a X 22323 999 555 TXT amp 5 2065 5 5 uuu coosSscsx z uiui QN C iM Figure 8 2 Generator Components Typical TP 5353 8 94 8 4 Generator Disassembly Reassembly Disassembly 1 Disconnect all controller to engine and engine to generator harnesses and wiring Disconnect
160. s Speed sensor signal is absent longer than one second Auxiliary Lamp Flashes No AC output is present Battery power was reconnected or was low and then came back up again while generator master switch was in the RUN or AUTO position Optional emergency stop switch is reset while the generator master switch is in the RUN or AUTO position High oil temperature P1 13 low coolant level P1 14 or auxiliary delay shutdown P1 15 faults occur if sensor equipped Auxiliary Lamp Lights Overvoltage if equipped has occurred voltage 15 greater than nominal voltage for period longer than two seconds Activated by customer supplied sensing device connected to auxiliary immediate shutdown ports P1 17 and P1 18 Optional emergency stop switch is activated 6 light microprocessor controller only Engine low water temperature P1 24 condition occurs if sensor equipped 6 light microprocessor controller only Emergency Stop if equipped Emergency stop switch is activated local or remote Emergency stop switch es are disconnected from controller terminals TB1 1 or 1A Multiple Lamps Light where illumination may only appear Main circuit board F1 3 amp fuse blown F1 fuse supplies battery dim voltage to a remote annunciator and or dry contact kit TP 5353 8 94 Controller Troubleshooting 5 9 Paralleling Engine Gauge Box Controller Switchgear No logic circuitry is supplied with the paralleling engine gauge box controller
161. s correct Ifthe engine Pump Lever speed is too high turn fast idle adjusting screw in Fiqure 7 24 Adjustments until correct speed is obtained Tighten lock nut gure Aaust securely Stop generator set NOTE If the fast idle is 50 rpm above or below the minimum maximum settings have an authorized service dealer remove and adjust the pump on a test stand TP 5353 8 94 Generator Troubleshooting 7 25 Electronic Governor Barber Colman Dyna 2500 20 100 kW Ford Powered Models Some generator sets are equipped with Barber Colman electronic governors This is an electronic device requiring no mechanical drive or hydraulic connection I RED The system consists of a magnetic pickup an electronic control unit and an actuator The magnetic pickup Bact monitors engine speed and transmits this information to Mp the electronic control unit See Figure 7 25 The BLKWHT GAIN electronic control unit interprets the signal from the magnetic pickup to control current input to the throttle e actuator The throttle actuator adjusts the throttle position on the engine See Figure 7 26 Adjust the actuator shaft linkage for smooth nonbinding operation and to hold the carburetor throttle lever in the closed position when the power is off The magnetic pickup air gap is 0 014 0 028 in 0 36 0 71 mm
162. s only Switches 4 Toggle generator master switch to OFF RESET Use the following procedure to restart the generator set and then to RUN or AUTO to resume operation after shutdown by emergency stop switch local or The generator set will not crank until the resetting remote Refer to Controller Resetting Procedure later procedure is completed in this section to restart the generator set following a fault shutdown 1 Investigate cause of emergency stop and correct problem s 2 If remote emergency stop switch was activated reset switch by replacing glass piece If controller mounted emergency stop switch was activated if equipped reset controller emergency stop switch by rotating switch clockwise until switch springs back to original position NOTE The controller auxiliary lamp will light if the generator master switch is in the RUN or AUTO position during the resetting procedure TP 5633 2 3 If controller air damper light is on reset air damper Figure 2 3 Air Damper Lever Detroit Diesel on engine by rotating air damper lever as shown in Powered Figure 2 3 and the air damper light will go out TP 5353 8 94 Operation 2 7 Fault Shutdowns The generator set will shut down automatically under the following fault conditions Overspeed Unit shuts down immediately if governed frequency exceeds 70 Hz 2100 RPM on 50 and 60 Hz models Overcrank Shutdown occurs after 45 seconds of continuous cranking Shutdow
163. s when in use Never come into contact with electrical leads or appliances when standing in water or on wet ground as the chance of electrocution is increased under such conditions 1 Connect components as illustrated in Figure 7 7 If testing the photo transistor board the SCR assembly must be good If testing the SCR assembly the photo transistor board must be good NOTE When testing the SCR assembly used on 20 150 kW models connections must make good contact with the SCR foil pattern Secure all SCR connections with terminal nuts to ensure good contact with foil pattern during testing The SCR 7 10 Generator Troubleshooting threaded terminals are insulated from the SCR foil pattern and are not in contact except when bridged by terminal nut electrical lead terminal etc Do not exceed 8 in lbs 0 9 Nm when tightening SCR terminal nuts With cord switch in the OFF position plug in electrical cord 3 Turn cord switch to the ON position Apply light source directly to photo transistor board Shield the photo transistor board from all sources of light during this test If both components are good the test fixture light bulb will light when the external light source is applied to the photo transistor board Remove the light source the fixture light bulb should go out Ifthe test fixture light bulb does not light or is lit prior to receiving external light source the component being tested is def
164. scriptions For identification of manual controller components and ADV 5849 A 1 Fault Lamp 8 DC Voltmeter 2 Hourmeter 9 Selector Switch 3 Frequency Meter 10 Start Stop Switch 4 AC Voltmeter 11 Voltage Adjustment Pot 5 AC Ammeter 12 10 Amp Fuse 6 Oil Pressure Gauge 13 Scale Lamps upper lower 7 Water Temperature Gauge Figure 2 8 Manual Controller 2 18 Operation TP 5353 8 94 Features The numbered paragraphs following refer to Figure 2 8 1 Fault Lamp Lamp lights during engine shutdown if engine has shut down due to high engine temperature low oil pressure low water level or overspeed faults See Fault Shutdowns following for additional shutdown information NOTE The fault lamp will not stay lit after the unit shuts down on a fault condition Hourmeter Hourmeter records generator set total operating hours for reference in scheduling maintenance Frequency Meter Meter measures frequency Hz of generator output voltage AC Voltmeter Meter measures voltage across output leads indicated by selector switch AC Ammeter Meter measures amperage from output leads indicated by selector switch Oil Pressure Gauge Gauge measures engine oil pressure Water Temperature Gauge Gauge measures engine coolant temperature DC Voltmeter Meter measures voltage of starting battery ies Selector Switch Switch selects generator output circuits to be measu
165. shutdown by rotating switch clockwise Use the emergency stop switch for emergency shutdowns only Use the generator master switch to stop the set under normal circumstances Hourmeter Hourmeter records generator set total operating hours for reference in scheduling maintenance Frequency Meter Meter measures frequency Hz of generator output voltage AC Voltmeter Meter measures voltage across output leads indicated by selector switch Scale Lamps Upper Lower Lamps indicate which AC voltmeter and or ammeter scales to read AC Ammeter Meter measures amperage from output leads indicated by selector switch Oil Pressure pressure Gauge measures engine oil Water Temperature Gauge measures engine coolant temperature DC Voltmeter Meter measures voltage of starting battery ies Fuses Fuses are located on controller circuit board See Figure 2 5 e 3 Amp Remote Annunciator F1 Fuse protects dry contact kit if equipped e 3 Amp Controller F2 Fuse protects controller circuit board speed sensor and lamp circuit board e 15 Amp Engine and Accessories Fuse protects _ engine starting circuitry accessories 5353 8 94 23 Controller TB1 Terminal Strip on Circuit Board Terminal strip allows connection of generator accessories such as emergency stop switch remote start stop switch audio visual alarms etc Crank mode selection cyclic or continuous is also made on the TB1 t
166. shuts down Fault Shutdowns The generator set will shut down automatically under the following fault conditions and cannot be restarted until the fault condition has been corrected The shutdown switches will automatically reset when the problem is corrected or the generator set cools if overheating was the problem NOTE The fault lamp will not stay lit after the unit shuts down on a fault condition Overspeed Unit shuts down immediately if governed frequency exceeds 70 Hz 2100 RPM on 50 and 60 Hz models 2 20 Operation Low Oil Pressure Shutdown occurs after fault Low oil pressure shutdown will not function during the first 5 seconds after start up NOTE Low oil pressure shutdown will not protect against low oil level Check for oil level at engine High Engine Temperature Shutdown occurs after fault High engine temperature will not function during first 5 seconds after start up NOTE High temperature shutdown will not function if proper coolant level is not maintained Low Coolant Level Shutdown occurs after coolant level sensor detects no coolant Low coolant level shutdown will not function during first 5 seconds after start up NOTE Low oil pressure high engine temperature and low coolant level shutdowns will not function during the first 5 seconds after start up TP 5353 8 94 Section 3 Scheduled Maintenance Under normal operating conditions generator alternator service will not be req
167. solenoid for diesel ignition system for gas or gasoline relay and overspeed time delay circuit board e relay normally open contacts close to energize K20 starter solenoid e K20 relay normally open contacts close to engage starter motor and provide initial battery voltage to ignition system gas gasoline Running e Stator leads VO and V7 connected to terminals 33 and 44 provide speed sensing for overspeed shutdown e Once the generator is running and B1 B2 obtains the correct output voltage K1 relay is energized LED1 lights After a 5 10 second time delay K5 relay is energized LED5 lights Note Voltage to the K1 and K5 relays is supplied by stator leads VO and V7 t is reduced from 120 vac to 12 vac by a stepdown transformer Then it is rectified and regulated to 12 volts DC by the BH1 rectifier and VR1 voltage regulator TP 5353 8 94 One set of normally open K1 contacts close to maintain voltage to K2 LED2 remains lit Normally open K2 contacts remain closed to maintain voltage to engine controls Another set of K4 contacts close permitting the fault lamp to function A set of normally open K5 contacts close to permit low water level engine low oil pressure and high engine temperature shutdown switches to function Note All safety shutdown switches except overspeed are subject to a 5 second time delay during starting TDR normally open contacts close after a 5 second delay Overspeed sh
168. t Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and reconnectit last to disable generator set before working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Use protective goggles and clothes Battery acid can cause permanent damage to eyes burn skin and eat holes in clothing atety Precautions and Instructions WARNING Explosion Can cause severe injury or death Relays in battery charger cause arcs or sparks Locate in a well ventilated area Keep explosive fumes away Sulfuric acid in batteries can cause severe injury or death Sulfuric acid in battery can cause permanent damage to eyes burn skin and eat holes in clothing Always wear splash proof safety goggles when working around the battery If battery electrolyte is splashed in the eyes or on skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery once the battery has been placed in service This may result in hazardous spattering of electrolyte Explosion can cause severe injury or
169. ted to the rotor shaft The special drive disc flywheel had a lip on the outer circumference and was not a flat surface drive disc Later models use a flat surface drive disc TP 5353 8 94 15 Attach hoist to adapter eye and place generator assembly in a horizontal position Take care not to damage rotor or stator Place hoisting eyes of generator to the top Thread studs if so equipped into flywheel as shown in Figure 8 17 Install studs completely into flywheel Apply Loctite No 271 red to stud threads and install into flywheel Apply Loctite No 242 blue to stud threads on nut side NOTE Some 50 100 kw Ford powered models use a short spacer between flywheel and drive disc 1 Flywheel Studs Figure 8 17 Flywheel Studs 17 Place hoist hooks into end bracket and adapter eye Raise generator assembly and align studs with drive discs by turning the flywheel Move generator as necessary to work drive discs over studs When drive discs are about 1 in 25 mm over studs install spacers if so equipped See Figure 8 18 NOTE Some models mount drive discs to flywheel using bolts Some applications use hardened washers Generator Disassembly Reassembly 8 11 Figure 8 19 Aligning Adapter and Flywheel Housing 19 Install nuts on studs Do not final tighten at this time 1 Drive Discs
170. tinuity of speed sensor leads wires 2 16 and 24 between controller P1 connector and lead terminals at speed sensor TP 5353 7 1 DC Voltmeter 2 12 Volt Battery or DC Power Supply 3 Sensing Surface Figure 7 17 Speed Sensor Test If the speed sensor is not emitting a signal test the speed sensor through the following procedure 7 18 Generator Troubleshooting TP 5353 8 94 Air Damper Switch Adjustment The air damper switch is found on 200 1600 kW models using Detroit Diesel engines with microprocessor controllers paralleling engine gauge box switchgear controllers This switch uses the normally closed contacts to signal the microprocessor controller Models with paralleling engine gauge box switchgear controllers have both normally open and normally closed contacts available to signal the switchgear logic When the emergency stop button is energized the air damper is activated The generator set resetting procedure includes resetting the air damper lever An LED on the microprocessor controllers indicates a tripped air damper Resetting the air damper lever will turn off the microprocessor controller LED If the air damper lever is reset and the switch needs adjustment use the following procedure and see Figure 7 18 The generator set must not be running during this adjustment 5 Reset the air damper switch if not already done Disconnect the air damper switch wiring harness at the 2 pin connector near t
171. tion TP 5353 8 94 Specifications 1 13 Section 2 Operation Prestart Checklist Check the following items before each startup of manually controlled generator sets and at regular intervals on sets equipped with automatic transfer switches See your engine operation maintenance manual for specific service procedures Oil Level Keep the oil level at or near the full mark on dipstick but not over Keep the oil level in the governor if applicable is at or near the full level Fuel Level Make sure there is adequate fuel supply keep tanks full to allow operation for extended periods Battery Check battery connections and level of battery electrolyte Air Cleaner Keep air cleaner element clean and correctly installed to prevent unfiltered air from entering engine Drive Belts Check belt condition and tension of radiator fan water pump and battery charging alternator belt s Operating Area Check for obstructions that could block the flow of cooling air Keep the area clean Do not leave rags tools or debris on or near the generator set Coolant Level Maintain coolant level at just below the overflow tube on the radiator filler neck when the engine is cold Open air bleed petcocks if equipped when filling radiator Close air bleed petcock when coolant begins to flow from petcock Keep level in tank between 1 3 full cold and 2 3 full hot if the unit is equipped with a coolant recovery tank A coolant solution of 50
172. to the exciter armature test as described later in this section 6 Ifthe exciter armature test indicates the armature is functioning correctly proceed to the generator field test as described later in this section 7 If the generator field test indicates the field is functioning correctly replace the SCR assembly or the photo transistor board as described later in this section TP 5353 8 94 Components and Circuits to Test Under Certain Generator Output Conditions Automatic pres Pu Voltage SCR Safeguard Exciter Generator Generator Regulator Assembly Breaker Armature Stator Condition No output voltage if voltage adjustment pot circuit is open or shorted to ground Overvoltage will occur if an outside light source is present when the LED board is removed Figure 7 1 Troubleshooting Guide VOLTAGE ADJUSTMENT RHEOSTAT SELECTOR SWITCH AC AMPS SAFEGUARD BREAKER CONTROL RELAY CONTACTS SOLENOID 3 STARTER 8 BATTERY GENERATOR FIELD PHOTO SCR ASSEMBLY TRANSISTOR MAGNETS LED BOARD BOARD TP 5353 7 Figure 7 2 AC Voltage Control Typical TP 5353 8 94 Generator Troubleshooting 7 5 Overvoltage NOTE If overvoltage occurs disconnect harness plug at AVR voltage regulator If overvoltage continues the problem lies in the photo transistor circuit and or SCR assembly proceed through the following checks If output voltage disappears the problem is in the AVR voltage reg
173. ts if engine low water temperature P1 24 condition occurs if sensor equipped Overspeed Lamp lights if set shuts down due to overspeed condition governed frequency exceeding 70 Hz High Engine Temperature Lamp lights if engine has shut down due to high engine coolant temperature Shutdown occurs 5 seconds after engine reaches temperature of shutdown range Air Damper Lamp lights after emergency stop or overspeed fault or overvoltage fault Lamp indicates that engine air damper is closed lamp remains lit until air damper is manually reset See Resetting Emergency Stop Switches later in this section Used on 200 1600 kW models with Detroit Diesel engines only Overcrank Lamp lights and cranking stops if engine does not start after 45 seconds of continuous cranking or 75 seconds of cyclic cranking See Auto Starting e Cranking stops and overcrank lamp lights after 15 seconds if starter or engine will not turn locked rotor e Overcrank lamp flashes if speed sensor signal is absent longer than one second NOTE The 6 light controller is equipped with an automatic restart function The generator set will attempt to restart if the engine speed drops below 13 Hz Decreased engine speed causes an overcrank condition Operation 2 11 10 11 12 Low Oil Pressure Lamp lights if set shuts down due to insufficient oil pressure Shutdown occurs 5 seconds after engine reaches pressure shutdown
174. ty Adjustment Figure 7 8 AVR Adjustment Stability Pot Fine tunes voltage regulator to reduce light flicker Volt Hz Pot This adjustment determines engine speed Hz at which generator output voltage will begin to drop 1 Turn generator master switch to OFF RESET 2 Set stability pot to far counterclockwise position 3 Connect a 100 watt light bulb across terminals VO and V7 on controller terminal strip or across terminals on controller frequency meter 7 12 Generator Troubleshooting 4 Start generator set With generator running at no load observe light bulb flicker Excessive light bulb flicker indicates poor stability 5 Adjust stability pot until minimum flicker is obtained 6 Use controller voltage adjustment pot or remote voltage adjustment pot to make adjustments to generator while running under normal load if required 7 Adjust engine speed to desired cut in frequency factory setting is 57 5 58 0 Hz for 60 Hz models or 47 5 48 0 Hz for 50 Hz models as measured on frequency meter See Section 7 Governor for more information on engine adjustment 8 Rotate Volts Hz adjustment pot clockwise until voltage level begins to drop as measured on voltmeter When set to these specifications the generator will attempt to maintain normal output until engine speed drops below the frequency setin the previous step as load is applied 9 Adjust engine speed to obtain a full load engine speed of 1800 rp
175. uired on a regular basis The main areas of attention are listed in the prestart checklist If operating under extremely dusty and dirty conditions use DRY compressed air to blow dust out of the generator Do this with the generator running and direct the stream of air through openings in the generator end bracket The end bracket bearing should be replaced every 10 000 hours of operation in standby and prime power applications Service more frequently if bearing inspection indicates excessive rotor end play or bearing damage from corrosion or heat build up Replace the tolerance ring if equipped if the end bracket is removed The end bracket bearing is sealed and requires no additional lubrication Have all generator service performed by authorized service distributor dealer Perform generator engine service at the intervals specified by the engine manufacturer in the engine service literature Contact your authorized service distributor dealer to obtain service literature for specific models A WARNING 09 J KS 5 Accidental starting Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative lead first and reconnectit last to disable generator set before
176. ulator including connections and or wiring 1 Examine photo transistor board for visible signs of damage open foil pattern or heat discoloration Replace photo transistor board if visibly damaged If overvoltage continues after replacement of photo transistor board proceed to Step 2 2 Remove green center lead from G terminal and red lead from terminal of SCR assembly Tape each terminal end of leads to prevent contact with adjacent metal components 3 With safeguard breaker open start generator set The lack of AC output indicates the SCR assembly is functioning properly If overvoltage continues replace the SCR assembly NOTE When replacing SCR assembly do not exceed torque value of 8 in Ibs 0 9 Nm when tightening SCR mounting bolts 7 6 Generator Troubleshooting If overvoltage is read with the safeguard breaker closed check for an open circuit in leads V7 and V8 to the AVR voltage regulator If these circuits are open or shorted repair or replace Check the voltage rheostat circuit leads 67 and 68 Repair or replace as necessary Ifall the circuits described in step 4 are okay check the voltage regulator AVR as described later in this section Fluctuating Voltage Check the generator output leads for proper connections Refer to Wiring Diagrams Check for loose connections to the AVR voltage regulator LED board photo transistor board or SCR assembly Checkthe st
177. ures in place Hazardous voltage can cause severe injury or death Disconnect generator set from load by opening line circuit breaker or by disconnecting generator set output leads from transfer switch and heavily taping ends of leads If high voltage is transferred to load during test personal injury and equipment damage may result Do not use the safeguard circuit breaker in place of the line circuit breaker 7 4 Generator Troubleshooting Follow all safety precautions in front of this manual and the additional precautions within the text Figure 7 1 lists the various generator output conditions and component tests Refer to Figure 7 2 AC Voltage Control for assistance in troubleshooting No Output On Any Phase 1 Check the safeguard breaker if equipped If safeguard breaker is open close breaker and with set running check AC voltmeter for proper output voltage 2 If proper output does not show then a Check wire 1B from safeguard breaker and wire 7N ground to voltage regulator b Check for voltage to safeguard breaker if equipped 3 If all items in step 2 are okay proceed to the LED circuit board flashlight test and Automatic Voltage Regulator AVR test as described later in this section 4 If tests indicate LED and AVR are functioning correctly visually inspect photo transistor board for damage open foil pattern or heat discoloration 5 If the photo transistor board test appears good proceed
178. use severe injury or death Allow engine to cool and release pressure from cooling system before opening pressure cap To release pressure cover the pressure cap with a thick cloth then slowly turn it counterclockwise to the first stop Remove cap after pressure has been completely released and the engine has cooled Check coolant level at tank if generator set is equipped with a coolant recovery tank Hot parts can cause severe injury or death Do not touch hotengine parts An engine gets hot while running and exhaust system components get extremely hot atety Precautions and Instructions VII Moving Parts WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place WARNING Rotating parts Can cause severe injury or death Do not operate generator set without all guards screens and covers in place Exposed moving parts can cause severe injury or death Keep hands feet hair and clothing away from belts and pulleys when unit is running Replace guards covers and screens before operating generator set VIII Safety Precautions and Instructions Notes NOTICE This generator set has been rewired from its nameplate voltage to 246242 NOTE Affix notice to generator set after reconnecting to a voltage different than the nameplate Order voltage reconnection decal 246242 from authorized service distr
179. utdown is immediate and closing of K5 contacts is not required A set of normally closed K1 contacts in series with the start switch open to de energize K3 LEDS goes out normally open contacts open to de energize the starter motor and initial battery voltage to the ignition system gas gasoline When K1 normally open contacts open it provides protection against accidental reenergizing the starter motor When the unit is running the start switch contacts between N and 47 are opened by releasing the start stop rocker switch Stopping Close the stop switch between N and 43 K4 relay is energized LED4 lights Normally closed K4 contacts open and de energize the ignition system gas gasoline or fuel solenoid diesel Normally open K4 contacts close to maintain a ground connection to the K4 relay until the unit comes to a complete stop Fault lamp is energized until the generator speed and voltage decrease enough to de energize the K1 relay K1 normally open contacts open and the fault lamp turns off Controller Troubleshooting 5 11 Engine Safety Shutdown Switches Engine Overspeed Overspeed Time Delay Circuit Board The overspeed relay SDR receives its power when K2 normally open contact closes during starting and running The overspeed relay receives its sensing source frequency from stator leads VO and V7 at terminals 33 and 44 An overspeed overfrequency of 70 Hz or greater at terminals 33 and
180. w oil pressure Replace LOP safety shutdown defective switch e okay switch N Yes Y Readjust voltage adjusting rheostat Does engine have correct oil pressure Usea mechanical gauge to verify _ pressure Yes Check oil level Repair replace oil pump Do temperature safety shutdown switch and water Replace level switch checkout defective okay switch es Yes Do the following engine components function correctly if so equipped Check replace defective engine components e Ignition module gas gasoline Fuel pump gasoline Fuel valve gas Fuel solenoid diesel 20 180 kW Replace circuit board K4 relay Governor controller diesel 200 300 kW defective 6 18 Generator Controller Troubleshooting TP 5353 8 94 Component Testing and Adjustment Generator Troubleshooting WARNING Use the following flowchart to troubleshoot the generator set when no voltage or high voltage is detected The remaining parts of this section give additional and more detailed information about the individual checks tests mentioned in the flowchart Use the flowchart to initially isolate the possible problem See the flowcharts following WARNING e Ob Accidental starting Can cause severe injury or death Disconnect battery cables before working on ge
181. working on any equipment connected to generator set The generator set can be started by automatic transfer switch or remote start stop switch unless these precautions are followed TP 5353 8 94 Hot engine and exhaust system Can cause severe injury or death Do not work on generator set until it is allowed to cool Hot parts can cause severe injury or death Do not touch hot engine parts An engine gets hot while running and exhaust system components get extremely hot WARNING Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Exposed moving parts can cause severe injury or death Keep hands feet hair and clothing away from belts and pulleys when unit is running Replace guards covers and screens before operating generator set Scheduled Maintenance 3 1 Oil Requirements 30 80 and 100 kW Ford Powered To assure long life and minimal engine wear Ford Motor Company and the generator manufacturer have amended the engine viscosity recommendations for different temperature ranges Do not use oil recommendations given in the engine operation manual for 30 80 and 100 kW Ford Powered models These models turbocharged and must use oil recommendations that follow Oil used in these generator sets must be American Petroleum Institute API class SG CD API class SF CD or SF CC are acceptable substitutes
182. y The ten relay dry contact kit allows monitoring of the standby system and or the ability to activate accessories such as derangement panels The kit includes ten sets of relay contacts for connection of customer provided devices to desired generator functions Warning devices lamp and or audible alarms and other accessories are typically connected to controller outputs listed A total of three dry contact kits may be connected to a specific output on the controller An internal view of the contact kit is shown in Figure 1 5 Typical contact kit output connections include Overspeed Overcrank High Engine Temperature Low Oil Pressure Low Water Temperature Auxiliary Fault Air Damper if equipped Anticipatory High Engine Temperature Anticipatory Low Oil Pressure Emergency Stop ASSEMBLY NO R 29 3203 Jal In CONTACT RATINGS 28 voc MAX POVER ane LOT 273936 Figure 1 5 Ten Relay Dry Contact Kit TP 5353 8 94 Specifications 1 9 Single Relay Dry Contact Kit with microprocessor controller only The single relay dry contact kit uses one set of contacts to trigger customer provided warning devices if a fault condition occurs While any controller fault output from TB1 terminal strip can be connected to the single relay kit this accessory is typically used to signal an overspeed condition

Service Manual, 20-300 kW FR II (TP-5353)

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