Onan Ek Service 928-0505

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EK Begin Spec D, EM Begin Spec W
Printed U.S.A. 9280505 1295
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Table of Contents
SECTION TITLE PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 AC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Standard Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Optional Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Voltage Regulator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Voltage Regulator Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Principle Of Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3 ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Standard Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Optional Control Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Control Box Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine Control Monitor (A11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine Gauge Senders and Shutdown Switches . . . . . . . . . . . . . . . . . . . . . 3-6
Auxiliary Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
The Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
The Engine Cranks But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
The Engine Runs Until Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
The Engine Lacks Power Or Stable Speed . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Amber Warning Lamp On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
The Green Run Lamps Stay Off But The Set Runs Normally . . . . . . . . . 4-12
There Is No Output Voltage (Engine Speed Is Stable) . . . . . . . . . . . . . . 4-13
Output Voltage Is Too High Or Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Output Voltage Is Unstable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
The Field Circuit Breaker Keeps Tripping . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
The Phase Currents Are Unbalanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
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SECTION TITLE PAGE
5 SERVICING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Testing The Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Insulation Resistance (Megger) & Polarization Index (PI) Testing . . . . . . . 5-2
Drying the Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Exciter Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Exciter Rectifier Bridge (Rotating Rectifier Assembly) . . . . . . . . . . . . . . . . 5-5
Exciter Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Main Rotor (Generator Field) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Main Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Removing And Disassembling The Generator . . . . . . . . . . . . . . . . . . . . . . . 5-9
Reassembling The Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
6 GOVERNORS AND CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Electric Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Magnetic Speed Pickup Unit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Carburetors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
7 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
ii Redistribution or publication of this document

Safety Precautions
Before operating the generator set, read the Op- Be sure battery area has been well-ventilated
erators Manual and become familiar with it and the prior to servicing near it. Lead-acid batteries
equipment. Safe and efficient operation can be emit a highly explosive hydrogen gas that can
achieved only if the equipment is properly oper- be ignited by arcing, sparking, smoking, etc..
ated and maintained. Many accidents are caused
by failure to follow fundamental rules and precau- EXHAUST GASES ARE DEADLY
tions. Provide an adequate exhaust system to prop-
erly expel discharged gases away from en-
The following symbols, found throughout this
closed or sheltered areas and areas where in-
manual, alert you to potentially dangerous condi-
dividuals are likely to congregate. Visually and
tions to the operator, service personnel, or the
audibly inspect the exhaust daily for leaks per
equipment.
the maintenance schedule. Make sure that ex-
This symbol warns of immediate haust manifolds are secured and not warped.
hazards which will result in severe personal in- Do not use exhaust gases to heat a compart-
jury or death. ment.
Be sure the unit is well ventilated.
WARNING This symbol refers to a hazard or un-
safe practice which can result in severe person-
Engine exhaust and some of its constituents
al injury or death. are known to the state of California to cause
cancer, birth defects, and other reproductive
CAUTION This symbol refers to a hazard or un- harm.
safe practice which can result in personal injury MOVING PARTS CAN CAUSE SEVERE
or product or property damage.
PERSONAL INJURY OR DEATH
FUEL AND FUMES ARE FLAMMABLE Keep your hands, clothing, and jewelry away
from moving parts.
Fire, explosion, and personal injury or death can re-
sult from improper practices. Before starting work on the generator set, dis-
connect battery charger from its AC source,
DO NOT fill fuel tanks while engine is running, then disconnect starting batteries, negative (-)
unless tanks are outside the engine compart- cable first. This will prevent accidental starting.
ment. Fuel contact with hot engine or exhaust Make sure that fasteners on the generator set
is a potential fire hazard.
are secure. Tighten supports and clamps,
DO NOT permit any flame, cigarette, pilot light, keep guards in position over fans, drive belts,
spark, arcing equipment, or other ignition etc.
source near the generator set or fuel tank. Do not wear loose clothing or jewelry in the vi-
Fuel lines must be adequately secured and cinity of moving parts, or while working on elec-
free of leaks. Fuel connection at the engine trical equipment. Loose clothing and jewelry
should be made with an approved flexible line. can become caught in moving parts. Jewelry
Do not use copper piping on flexible lines as can short out electrical contacts and cause
copper will become brittle if continuously vi- shock or burning.
brated or repeatedly bent. If adjustment must be made while the unit is
Be sure all fuel supplies have a positive shutoff running, use extreme caution around hot man-
valve. ifolds, moving parts, etc.
LS-11b
iii Redistribution or publication of this document
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH
Coolants under pressure have a higher boiling
Remove electric power before removing pro- point than water. DO NOT open a radiator or
tective shields or touching electrical equip- heat exchanger pressure cap while the engine
ment. Use rubber insulative mats placed on is running. Allow the generator set to cool and
dry wood platforms over floors that are metal or bleed the system pressure first.
concrete when around electrical equipment.
Do not wear damp clothing (particularly wet Benzene and lead, found in some gasoline,
shoes) or allow skin surface to be damp when have been identified by some state and federal
handling electrical equipment. agencies as causing cancer or reproductive
Use extreme caution when working on electri- toxicity. When checking, draining or adding
gasoline, take care not to ingest, breathe the
cal components. High voltages can cause inju-
fumes, or contact gasoline.
ry or death. DO NOT tamper with interlocks.
Follow all applicable state and local electrical Used engine oils have been identified by some
codes. Have all electrical installations per- state or federal agencies as causing cancer or
formed by a qualified licensed electrician. Tag reproductive toxicity. When checking or
and lock open switches to avoid accidental clo- changing engine oil, take care not to ingest,
sure. breathe the fumes, or contact used oil.
DO NOT CONNECT GENERATOR SET DI- Provide appropriate fire extinguishers and
RECTLY TO ANY BUILDING ELECTRICAL install them in convenient locations. Consult
SYSTEM. Hazardous voltages can flow from the local fire department for the correct type of
the generator set into the utility line. This extinguisher to use. Do not use foam on electri-
creates a potential for electrocution or property cal fires. Use extinguishers rated ABC by
damage. Connect only through an approved NFPA.
isolation switch or an approved paralleling de-
vice.
Make sure that rags are not left on or near the
engine.
HIGH VOLTAGE GENERATOR SETS
Remove all unnecessary grease and oil from
(1.9kV to 15kV) the unit. Accumulated grease and oil can
High voltage acts differently than low voltage. cause overheating and engine damage which
Special equipment and training is required to present a potential fire hazard.
work on or around high voltage equipment. Op- Keep the generator set and the surrounding
eration and maintenance must be done only by area clean and free from obstructions. Re-
persons trained and qualified to work on such move any debris from the set and keep the floor
devices. Improper use or procedures will result clean and dry.
in severe personal injury or death.
Do not work on this equipment when mentally
Do not work on energized equipment. Unau- or physically fatigued, or after consuming any
thorized personnel must not be permitted near
alcohol or drug that makes the operation of
energized equipment. Due to the nature of high
equipment unsafe.
voltage electrical equipment, induced voltage
remains even after the equipment is discon- Substances in exhaust gases have been iden-
nected from the power source. Plan the time for tified by some state or federal agencies as
maintenance with authorized personnel so that causing cancer or reproductive toxicity. Take
the equipment can be de-energized and safely care not to breath or ingest or come into contact
grounded. with exhaust gases.
iv Redistribution or publication of this document

1. Introduction
ABOUT THIS MANUAL Read Safety Precautions and carefully observe all
instructions and precautions in this manual.
This service manual is for the EK (begin Spec D)
and EM (begin Spec W) series gasoline and gas- TEST EQUIPMENT
eous-fuel generator sets. It includes engine and Most of the tests in this manual can be done with an
generator troubleshooting guides. Engine service AC-DC multimeter, frequency meter, Wheatstone
instructions are in the applicable engine service bridge (0.001 ohm precision is necessary for mea-
manual. Operating and maintenance instructions suring stator winding resistance) and load test pan-
are in the applicable Operators Manual. el.
This manual does not have instructions for servic- HOW TO OBTAIN SERVICE
ing printed circuit board assemblies. Always re-
Always give the complete Model, Specification and
place a faulty printed circuit board assembly. At-
Serial number of the generator set as shown on the
tempts to repair a printed circuit board can lead to
nameplate when seeking additional service infor-
costly damage to the equipment.
mation or replacement parts. The nameplate is lo-
cated on the side of the generator output box.
This manual contains basic (generic) wiring dia-
grams and schematics that are included to help in WARNING Incorrect service or replacement of
troubleshooting. Service personnel must use the parts can result in severe personal injury or
actual wiring diagram and schematic shipped with death, and/or equipment damage. Service per-
each unit. The wiring diagrams and schematics that sonnel must be qualified to perform electrical
are maintained with the unit should be updated and mechanical service. Read and follow Safety
when modifications are made to the unit. Precautions, on pages ii and iii.
1-1 Redistribution or publication of this document

FIGURE 1-1. TYPICAL GENERATOR SET

2. AC Control
GENERAL meter is from current transformers CT21, CT22 and

CT23.
The control box is mounted on top of the generator,
facing the rear. Figure 2-1 points out the compo- Phase Selector Switch (S21) The selector switch
nents on the AC control panel. Refer to Section 7 for is used to select the phase for voltage and amper-
wiring connections. age readings.
Scale Indicator Lamps (DS21 and DS22) The
STANDARD CONTROL PANEL scale indicator lamps indicate whether to read the
COMPONENTS upper or lower scales of the voltmeter and ammeter.
Frequency Meter (M23) The frequency meter indi-
Field Circuit Breaker (CB21) The field circuit
cates output frequency in Hertz (Hz) and engine
breaker protects the generator from over-excita-
speed in RPM.
tion.
Wattmeter (M24) The wattmeter indicates output
OPTIONAL CONTROL PANEL power in kilowatts (kW).
COMPONENTS Powerfactor Meter (M25) The powerfactor meter
indicates output powerfactor as a percentage of
AC Voltmeter (M21) The voltmeter indicates output unity powerfactor.
voltage for the phase selected.
Output Voltage Trimmer (R21) The output voltage
AC Ammeter (M22) The ammeter indicates output trimmer can be used to adjust output voltage plus or
amperage for the phase selected. Input to the am- minus five percent of nominal voltage.
OUTPUT SCALE
VOLTAGE INDICATOR
TRIMMER LAMPS
AC
VOLTMETER
FIELD
CIRCUIT
BREAKER
AC
AMMETER
PHASE
SELECTOR
SWITCH
FREQUENCY
METER
POWER
FACTOR
WATTMETER METER
FIGURE 2-1. AC CONTROL PANEL

VOLTAGE REGULATOR DESCRIPTION Because of the differences in engine characteris-
tics, different torque matching may be used for vari-
The design of the Torque Match-2 Voltage Regula- ous engine/generator combinations. The switch-
tor (VRAS-2) provides switch selections that alter selectable design of the VRAS-2 provides Onan the
its sensing and command signals in order to flexibility to test and set the torque-matching func-
achieve maximum operating performance in a vari- tion to best suit each engine/generator configura-
ety of generator sizes and applications. Review the tion.
following, then refer to Voltage Regulator Adjust-
ments for switch locations and settings specific to When set to the proper torque-matching switch set-
your generator set model. tings, the VRAS-2 voltage regulator is able to main-
tain output voltage, within reasonable limits, by re-
These measurements and adjustments are done ducing the voltage just enough to take full advan-
while the set is running and require access to unin- tage of the engines full available power under tran-
sulated high voltage parts in the control and power sient conditions and prevent an unstable response.
output boxes.
Non-Torque-Matching (Voltage Sensing): Even
WARNING HIGH VOLTAGE. Touching uninsu- though the voltage regulator can also be switch-se-
lated high voltage parts inside the control and lected to a non-torque-matching constant voltage
power output boxes can result in severe per- mode, independent of engine speed, this mode will
sonal injury or death. Measurements and ad- not prevent the generator set from stalling during
justments must be done with care to avoid momentary overload conditions, and is not recom-
touching high voltage parts. mended for use. Consult an Onan service repre-
For your protection, stand on a dry wooden sentative before selecting this voltage regulation
platform or rubber insulating mat, make sure mode to make sure that load demands specific to
your clothing and shoes are dry, remove jewelry your installation would not cause an unstable op-
from your hands and wear elbow length insulat- eration of the generator set.
ing gloves.
Operating Stability
Operating Modes
Because of the differences in exciter and main field
Torque-Matching (Grequency Sensing): In most time constants, different gain compensation is re-
applications, in order for the generator set to accept quired for the various generator sizes and applica-
the application of a large momentary overload, such tion. The VRAS-2 voltage regulator is switch-select-
as motor starting, matching the torque characteris- able to a kW range of operation that best suits the
tics of the engine and generator is required. generator set application.

VOLTAGE REGULATOR ADJUSTMENTS Potentiometer R34 Used to set the frequency
breakpoint. The potentiometer is adjusted at
The VRAS-2 is shown in Figure 2-2. There are three the factoryand does not require further adjust-
switch modules and two potentiometers on ment.
VRAS-2. Adjusting Voltage
Switch S1 Selects the overall range of opera- Use the control panel mounted voltage trimmer, if
tion for the regulator. Refer to Table 2-1. provided, for small voltage adjustments. Measure
generator output voltage while the set is running
Switches S2 and S3 Determine the mode of without load at the nominal frequency. (See Section
regulation (Torque-Matched, or Non-Torque- 6. Governor for instructions on how to adjust the fre-
Matched). Refer to Table 2-1. quency.) If the trimmer does not provide enough ad-
justment, lock it at its midpoint. Then turn voltage
Potentiometer R32 Provides adjustability to adjusting pot R32 on the regulator board until rated
increase or decrease generator voltage to voltage is obtained.
achieve proper setting.
TABLE 2-1. VRAS-2 SWITCH SETTINGS
STABILITY
GENSET RANGE
kW
RATING S1-1/4 S1-2/3
20-35 OFF OFF

40-50 OFF ON
TORQUE MATCHING MODE

VOLTAGE SENSING FREQUENCY SENSING
TMB TMB TMC TMA
VOLTS / HZ 60HZ VOLTS / HZ 50HZ NON-FREQ SEMI-FREQ
S2 S3-1/4 S3-2/3 S2 S3-1/4 S3-2/3 S2 S3-1/4 S3-2/3 S2 S3-1/4 S3-2/3
POS 2 OFF ON POS 2 ON ON POS 2 OFF OFF POS 1 OFF OFF

VOLTAGE REGULATOR
(VRAS-2)
S2
S1
R32
R34
THIS JUMPER S3
MUST BE 3 TO 4
FIGURE 2-2. VOLTAGE REGULATOR ADJUSTMENT POTS AND SELECTION JUMPERS

ROTATING
EXCITER
RECTIFIERS
ROTOR
MAIN
ROTOR
EXCITER
STATOR
MAIN
STATOR
T10 F1 (+)
T9 F2 ()
T8
T7
T4
OUTPUT
VOLTAGE
SENSING TB21
LEADS
32
31 VRAS-2
(3002880)
VOLTAGE
T10 REGULATOR
26
T9 (VR21)
25
T4
24
T8
23
T7 1 2 3 4 5 6 7 8 9 10
22
21
FIELD
CIRCUIT
BREAKER
CB21
VOLTAGE
TRIMMER
R21
(optional)
FIGURE 2-3. TYPICAL VOLTAGE REGULATING CIRCUIT

PRINCIPLE OF GENERATOR OPERATION bridge (rotating rectifiers) mounted on the ex-
citer rotor converts exciter output (3-phase AC)
1. The generator field (main rotor) is rotated by to DC. The exciter rotor is mounted on the main
the engine to induce output current (AC) in the rotor shaft.
main stator windings.
5. Exciter output current is proportional to exciter
2. Generator output current is proportional to field field current.
strength, which is varied to match the load.
6. The automatic voltage regulator (VRAS-2) reg-
Output voltage and frequency are held
ulates exciter field current by comparing gener-
constant by the voltage regulator and engine
ator output voltage and frequency with refer-
governor, respectively.
ence values.
3. Generator field strength is proportional to field 7. Exciter field current is supplied by the genera-
current, which is supplied by the exciter. tor stator through the voltage regulator. Resid-
4. The exciter field (stator) induces current in the ual field magnetism initiates self-excitation
exciter rotor windings. A full wave rectifier during startups.
SELF-EXCITED GENERATORS
VRAS-2 ELECTRICAL POWER OUTPUT
MAIN STATOR
EXCITER ROTATING
ROTOR MECHANICAL
MAIN ROTOR
AND POWER
STATOR INPUT
FIGURE 2-4. SCHEMATIC OF GENERATOR OPERATION

3. Engine Control
CONTROL PANEL Reset / Lamp Test / Panel Lamp Switch (S11) The
switch is pushed to the Reset position (momentary
The control box is mounted on top of the generator, contact) to reset the engine control to restore opera-
facing the rear. Figure 3-1 shows the components tion following a fault shutdown. The Run / Stop / Re-
on the engine control panel. mote switch must be in the Stop position for reset to
occur. The Lamp Test position (momentary con-
tact) lights all the fault indicator lamps. Replace
STANDARD CONTROL PANEL lamps that do not light. Also, this switch has a light
COMPONENTS which lights following a fault or emergency shut-
down. The light remains lit until the engine control
Run/Stop/Remote Switch (S12) The switch is has been reset. The Panel Lamp position lights the
pushed to the Run position to start and run the gen- panel illumination lamp.
erator set and to the Stop position to stop the set. Coolant Temperature Gauge (M12) The coolant
The Remote position allows a remote controller to temperature gauge indicates engine coolant tem-
automatically run the set. The switch must be in the perature.
Stop position when the reset switch (described
next) is used to restore generator set operation fol- Oil Pressure Gauge (M11) The oil pressure gauge
lowing a fault shutdown. indicates engine oil pressure.
OIL PRESSURE RUN/STOP/REMOTE PANEL RESET/LAMP TEST/

GAUGE SWITCH LIGHT PANEL LIGHT SWITCH
COOLANT INDICATOR
TEMPERATURE LAMPS
GAUGE
HOUR
METER
DC
VOLTMETER
OIL TEMPERATURE TACHOMETER EMERGENCY STOP

GAUGE BUTTON
FIGURE 3-1. ENGINE CONTROL PANEL

DC Voltmeter (M13) The DC voltmeter indicates
voltage across the battery terminals during opera-
tion.
Hour Meter (M14) The hour meter indicates the ac-
cumulated number of hours the set has run. It can-
not be reset.
Panel Lamp (DS11) The panel lamp illuminates the
control panel.
Detector-7 Fault and Status Indicator Lamps
(A12)
Run (Green) This lamp indicates that the gen-
erator set is running and that the starter has
been disconnected.
Pre Low Oil Pressure (Yellow) This lamp indi-
cates that engine oil pressure is abnormally low
(less than 20 psi [138 kPa]). Normal operating
range is 35 to 60 psi (241 to 414 kPa).
Low Oil Pressure (Red) This lamp indicates
that the engine shut down because of exces-
sively low engine oil pressure (less than 14 psi
[97 kPa]).
Pre High Engine Temperature (Yellow) This
lamp indicates that engine coolant tempera-
ture is abnormally high (greater than 220 F
[104 C]).
High Engine Temperature (Red) This lamp
indicates that the engine shut down because of
excessively high engine coolant temperature
(greater than 230 F [110 C]).
Overcrank (Red) This lamp indicates that the
engine shut down because it did not start dur-
ing the timed cranking period (approximately
75 seconds, including two rest periods). 539-0741c2
Overspeed (Red) This lamp indicates that the

engine shut down because of overspeed.
FIGURE 3-2. DETECTOR-12 INDICATOR LAMPS

OPTIONAL CONTROL PANEL than the reserve necessary to run the set at full
COMPONENTS load for the prescribed number of hours. The
customer has to make connections to use this
Oil Temperature Gauge (M15) The oil temperature lamp.
gauge indicates engine oil temperature.
Fault 1 (Red) This lamp indicates that the en-
Tachometer (M16) The tachometer indicates engine shut down because of a system fault. The
gine speed in RPM. customer has to make connections to use this
Emergency Stop Button (S14) The emergency lamp. The lamp is a part of a 10 second time
stop button is a red, push-in switch used to stop the delay shutdown circuit. The customer can
engine. The button lights up when it is pushed in. make reconnections for non-timed shutdown.
The button has to be pulled out and the engine con- See Engine Control Monitor (ECM).
trol reset to restore operation.
Fault 2 (Red) This lamp indicates that the en-
Detector-12 Fault and Status Indicator Lamps gine shut down because of a system fault. The
(A12) The Detector-12 control panel has the five fol- customer has to make connections to use this
lowing indicator lamps in addition to the standard lamp. The lamp is part of a non-time delay shut-
seven. down circuit. The customer can make recon-
Low Engine Temperature (Yellow) This lamp nections for 10 second time delay shutdown.
indicates that engine temperature is less than See Engine Control Monitor (ECM).
70 F, and the possibility that the engine might Switch-off (Flashing Red) This lamp indi-
not start. cates that the Run / Stop / Remote switch is in
Low Fuel (Yellow) This lamp indicates that the the Stop position, which prevents remote, au-
fuel level in the supply tank has dropped to less tomatic operation.

ENGINE
CONTROL
MONITOR A11
TIME DELAY
START/STOP
VOLTAGE MODULE A15
REGULATOR
(VRAS-2)
TERMINAL BOARD
TB21 OVERSPEED
MODULE
RUN RELAYS K11

(NOT SHOWN MOUNTED ON
A BRACKET IN FRONT OF A11)
ES1561s-
1
FIGURE 3-3. ARRANGEMENT OF COMPONENTS INSIDE THE CONTROL BOX
CONTROL BOX INTERIOR Fuses

The ECM has five replaceable fuses to protect it
Figure 3-3 shows the arrangement of components from overloads and groundfaults. They are:
inside the control box, including the engine control
monitor and some of the auxiliary components un- F1 Starter solenoid circuit, 20 amps
der following headings. F2 Fuel solenoid (switched B+) circuits, 20 amps
F3 Continuous B+ out to remote circuits, 15 amps
F4 ECM circuits, 5 amps
ENGINE CONTROL MONITOR (A11)
F5 Engine gauge circuits, 5 amps.
The heart of the engine control system is the engine Function Selection Jumpers
control monitor (ECM) (Figure 3-4). It is a printed
circuit board assembly mounted on the back wall of Newer ECM boards have six selection jumpers that
the control box. It starts and stops the engine in re- can be repositioned to provide the following timed
sponse to the control panel switches, engine sen- or non-timed warnings or timed or non-timed shut-
sors and remote control signals. downs with warnings:
W1 Jumper Position (jumper W8 must be in the B
position):
Terminals and Connectors
A Non-timed warning under FLT 2 condi-
tions.
See Pages 7-5 through 7-8 for the appropriate con-
B Non-timed shutdown and warning under
nection and schematic drawings for the DC control
FLT 2 conditions.
system. See Page 7-10 for typical customer con-
nections at terminal boards TB1 and TB2 on the C Timed warning under FLT 2 conditions.
ECM and page 7-11 if the set is also equipped with D Timed shutdown and warning under FLT 2
the auxiliary relay board. conditions.

W2 Jumper Position (jumper W9 must be in the B A Warning under Pre-Low Oil Pressure
position): conditions.
A Non-timed warning under FLT 1 condi- B Shutdown and warning under Pre-Low
tions. Oil Pressure conditions.
B Non-timed shutdown and warning under W8 Jumper Position:
FLT 1 conditions.
A Warning while running or during standby
C Timed warning under FLT 1 conditions.
under FLT 2 conditions.
D Timed shutdown and warning under FLT 1
conditions. B Allows selection of functions with W1
jumper.
W6 Jumper Position:
A Warning under Pre-High Engine Tem- W9 Jumper Position:
perature conditions. A Warning while running or during standby
B Shutdown and warning under Pre-High under FLT 1 conditions.
Engine Temperature conditions. B Allows selection of functions with W2
W7 Jumper Position: jumper.
8 7 6 5 4 3 2 1 6 5 4 3 2 1
FIGURE 3-4. ENGINE CONTROL MONITOR FUSES AND FUNCTION SELECTION JUMPERS

ENGINE GAUGE SENDERS AND Always use pipe thread sealant on gauge senders
SHUTDOWN SWITCHES and warning and shutdown switches.
Figure 3-5 shows the locations of the gauge send- CAUTION Teflon tape is not recommended for
ers and the coolant temperature and oil pressure switches and senders that are grounded to the
sensing switches to which the ECM responds. The engine by thread contact as it may interfere with
switches function by closing the fault or warning cir- the ground path.
cuit to the engine chassis ground (battery nega-
tive [-]).
T26 OF ENGINE
HARNESS
LOW OIL PRESSURE
SENSOR (S1)
PRE-LOW OIL PRESSURE

LOW ENGINE TEMPERATURE, SENSOR (S5)
PRE-HIGH ENGINE TEMPERATURE, &
WATER TEMPERATURE SENDER
OIL PRESSURE
SENDER (E1)
FIGURE 3-5. ENGINE SENSOR LOCATIONS

Low Coolant Level Cutout Switch with the high engine temperature cutout switch to
shut down the engine and light the High Engine
When coolant level in the radiator top tank falls be- Temperature lamp or in parallel with the pre-high
low the switch sensor, the switch closes the circuit to engine temperature switch to light the Pre High En-
ground. This switch may be connected in parallel gine Temperature light only. See Figure 3-6.
RADIATOR
TOP TANK
LOW COOLANT
LEVEL SWITCH
TO ECM TB2-8 (HIGH ENGINE TEMP), OR

ECM TB2-10 (PRE HIGH ENGINE TEMP)
FIGURE 3-6. LOW COOLANT LEVEL SWITCH

Coolant Temperature Gauge and Warning
Light Circuits
An electronic PCB assembly is mounted on the PCB MOUNTING ON BACK OF GAUGE
back of the coolant temperature gauge (M12) with
three terminal nuts. The PCB assembly carries two
relays that provide signals for the low coolant and
pre-high temperature warning lamps on the basis of
the gauge sender output. See Figure 3-7.
GAUGE AND PCB CONNECTIONS
FIGURE 3-7. COOLANT TEMPERATURE GAUGE

AUXILIARY CONTROL COMPONENTS occurs within 2100 to 2300 RPM (50 or 60 Hz
sets).
The set might be equipped with one or more of the
Turn adjustment screw clockwise to increase
following components.
trip speed.
Mechanical Overspeed Switch (Standard) 2. Replace the switch if the cutout speed adjust-
ment results in an air gap between the magnet
The mechanical overspeed switch is bolted to the and the fly arm of less than 0.005 inches (0.13
end of the generator rotor shaft. mm).
1. Check overspeed cutout RPM and turn the ad- 3. Torque the center rotor bolt to 40 ft-lbs (54
justment screw, if necessary, so that shutdown Nm) when replacing the switch.
ADJUST
SCREW
GENERATOR
SHAFT AIR GAP (NOT LESS
THAN 0.005 IN. (13 MM)
SWITCH
CONTACTS
END
BELL
FIGURE 3-8. OVERSPEED SWITCH ASSEMBLY

Auxiliary Relay Board (ARB) cated in any of 3 positions (A, B, C) independently of
each other.
The following describes the design/functional crite-
ria for the ARB with a Detector-7 or -12 Genset con- Jumper Position A (Run): The relay operates
trol. The board is mounted directly on top of the as a Run relay, energizing when Switched B+ is
ECM using standoffs and has access holes for the applied from the ECM.
fuses located on the ECM. There are two versions Jumper Position B (Common Alarm): The
of the ARB; with and without the set of 12 Fault re- relay operates as a Common Alarm relay. The
lays (Figure 3-9). Page 7-11 is a detailed connec- relay energizes any time there is an engine
tion diagram for the ARB. shutdown. This signal is provided from the
ECM.
Terminal Blocks: Jumper Position C (Isolated): The relay op-
erates as an Isolated relay. The relay coil is en-
TB1 ARB TB1 and ECM TB1 are identically num-
ergized by a customer applied B+ signal
bered and provide the same remote control connec-
through the terminal block; TB3-1 for relay K1,
tion points. Note that additional terminals are pro-
TB4-1 for relay K2, and TB5-1 for relay K3.
vided for terminals 5, 7, and 10 of ARB TB1.
Jumpers W11, W12, and W13 perform the same
TB2 through TB5 Connection points for relays functions for their respective relays; W11 for relay
K1 through K3. TB2 provides the N/O and N/C con- K1, W12 for relay K2, and W13 for relay K3. They
nections (three form C contacts for each relay). can be located in two different positions (A, B) inde-
TB3 through TB5 provide the common connection pendently of one another.
points (TB3 for K1, TB4 for K2, and TB5 for K3).
Jumper Position A: The relay operates iso-
TB6 and TB7 Connection points for fault relays lated from the board. The customer provides
K4 through K15. Three terminals are provided for the circuit completion through terminal block;
each relay, which are labeled COM, N/C, and N/O. TB3 for relay K1, TB4-5 for relay K2, and TB5-5
for relay K3. The customer can operate the
Plug-In Relays (K1, K2, K3): relay with switched ground logic or use this
relay in the middle of more complex logic cir-
The ARB can be equipped with one to three 3-pole, cuits if needed.
double-throw relays. These relays (K1, K2, K3) are
Jumper Position B: The relay operates with
field changeable plug-in relays for easy field addi-
the coil connected to ground through the board
tion and replacement.
connections. The coil will require a B+ signal to
The relay contact ratings are: energize with the jumper in this position.
10 amps at 28 VDC or 120 VAC, 80% PF Fault Relays (K4 through K15):
6 amps at 240 VAC, 80% PF These optional relay modules are used to operate a
3 amps at 480 VAC, 80% PF remote alarm annunciator that has an independent
power source. This allows the use of either AC or
Each relay can be operated as a RUN, COMMON DC for alarm drives. The relays are energized
ALARM, or ISOLATED COIL with the changing of a through the latching relays on the ECM and pro-
jumper. vided N/O and N/C contacts for each external alarm
connection.
Jumper Positions for Plug-In Relays:
The 12 relays with form C contacts are rated:
Jumpers W1, W2. and W3 perform the same func-
tions for their respective relays, W1 for relay K1, W2 10 amps at 120 VAC
for relay K2, and W3 for relay K3. They can be lo- 10 amps at 30 VDC

JUMPERS RUN RELAY JUMPERS
MODULE(S)
K1 K2 K3
J1 AND J2 WIRE TB6, TB7 AND

HARNESS PLUG RELAYS K4
CONNECTIONS THROUGH K15
FROM ECM ARE OPTIONAL
300-4111c
FIGURE 3-9. AUXILIARY RELAY BOARD (ARB)

Over/Under Voltage Module (A17)
The set can be equipped with an adjustable volt-
age-sensitive relay usually connected into the Fault
1 circuit (Detector-12 controls only) to shut down
*
the set when the output voltage is over or under *
nominal voltage by the preselected percentage
(typically 10 percent over and under).
This module has an adjustable time delay relay
(K17) to prevent nuisance tripping. An adjustment
of 25 percent is equivalent to about 2.5 seconds
delay.
Recalibrate the module as follows before installing
it on 139/240 VAC or 277/480 VAC sets.
WARNING HAZARDOUS VOLTAGE. Touching
uninsulated high voltage parts inside the con-
trol panel box can result in severe personal inju-
ry or death. Measurements and adjustments
must be done with care to avoid touching high
voltage parts.
**
For your protection, stand on a dry wooden plat-
form or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry and
wear elbow length insulating gloves intended * CONNECTED TO TB11-45 WHEN GENERA-
TOR IS PARALLELED.
for hazardous voltages.
** CONNECTED TO GENERATOR LEAD LO
1. Remove the two screws that secure the top to WHEN THE GENERATOR IS CONNECTED
the case of the module and withdraw the top FOR SINGLE PHASE.
assembly.
2. Adjust the SET pot for the UNDER setpoint on FIGURE 3-10. OVER/UNDER VOLTAGE
the face of the top assembly to 75 percent. MODULE
3. Apply single-phase, 60 Hertz, 104.25 VAC
across terminals L and N.
4. Adjust pot R25 on the PC board until the relay
trips (de-energizes).
5. Adjust the SET pot for the OVER setpoint on
the face of the top assembly to 125 percent.
6. Apply single-phase, 60 Hertz, 173.75 VAC
across terminals L and N.
7. Adjust pot R26 on the PC board until the relay
trips (energizes).
8. Repeat the above steps until no adjustments
are necessary.
9. Reassemble the module.
10. On the module nameplate mark out the factory
calibration value for monitored voltage (120 V)
and write in 139 V.

Over/Under Frequency Module (A19)
The set can be equipped with an adjustable fre-
quency-sensitive relay to shut down the set when
the output frequency (Hz) is over or under nominal
frequency by the preselected amount. It is usually
connected into the Fault 2 circuit (Detector-12 con-
trols only) if the over/under voltage module is also
provided. Set points are typically 5 Hertz over and
under nominal frequency (50 or 60 Hertz) and reset
points 3 Hertz over and under.
3003141
FIGURE 3-11. OVER/UNDER FREQUENCY

MODULE

Time Delay Start/Stop Module (A15) justable to delay starts from 1 to 15 seconds to pre-
vent nuisance starts in installations where momen-
The set can be equipped with a module to delay tary power interruptions are frequent. It is adjust-
starting and stopping when the start and stop sig- able to delay stops 1 to 30 minutes to allow the
nals are received from the remote controller. It is ad- prime source of power time to stabilize.
TIME DELAY START TIME DELAY STOP POTENTIOMETER

POTENTIOMETER
TB1
A11-TB1-2 A11-TB1-6
(PRIMARY START DISCONNECT) (REMOTE START)
A11-TB1-3 A11-TB1-7
(SECONDARY START DISCONNECT) (B+)
REMOTE
CONTROL
A11-TB1-5 A11-TB1-7
(GND) (B+)
ES1855s
FIGURE 3-12. TIME DELAY START/STOP MODULE

SEQUENCE OF OPERATION 10. Relays K2 and K3 are de-energized (by latch-
ing relay K6) causing shutdown to occur if the
The sequence of operation is as follows. Refer to engine does not start within 75 seconds. The
the schematic on Page 7-6 or 7-8. Overcrank indicator lamp lights and common
alarm terminal TB1-4 is powered.
1. The ECM is powered by cranking battery volt-
age (12 VDC). Terminal TB1-9 is connected to The ECM has a cycle crank feature where the en-
battery positive (+) and connector P1-6 to bat- gine is cranked for three 15 second periods al-
tery negative (-). ternated with two 15 second rest periods.
2. The starting cycle begins when relay K7 is 11. Relay K3 is de-energized (by latching relay K6)
powered, either manually by pushing the panel causing shutdown to occur during operation
Run switch, or automatically by a remote con- when a low oil pressure, high engine tempera-
troller connected at terminal TB1-6. (The panel ture or engine overspeed condition is sensed
switch must be in the Remote position for re- or the optional emergency stop button is
mote, automatic operation.) pressed. The appropriate fault indicator lamp
3. Relay K7 powers relays K2 and K3. lights and common alarm terminal TB1-4 is
powered. (There is no fault lamp for emergency
4. Relay K2 powers the engine gauges and termi- stop. The switch button will light, however, and
nal TB1-10, to which the fuel solenoid and igni- the light in switch S11.)
tion module are connected.
5. Relay K3 powers terminal TB1-8 to which start- The low oil pressure and high engine tempera-
er relay K4 is connected. Engine cranking be- ture shutdowns have 10 second time delays to
allow oil pressure and engine temperature to
gins.
stabilize during startup.
6. The engine starts and runs up to governed
speed in a matter of seconds. 12. To restore operation after a shutdown fault has
been serviced, reset latching relay K6 by push-
7. The starter is disconnected when engine
ing the panel Stop switch and then the Reset
speed gets to about 500 RPM. This is done by
switch. The set should run or be ready to run
relay K10 or K14, whichever acts first to open
when the panel switch is pushed to Run or to
the circuit powering relay K3.
Remote.
8. Relay K10 is powered by the generator output
voltage (120 VAC) through plug-in connectors If the emergency stop switch has been used, the
P1-1 and P1-2. The remote Run indicator lamp control will have to be reset to restore operation.
should light (connected through terminal First pull the emergency stop switch button and
then push the panel Stop and Reset switches.
TB1-3).
9. Relay K14 is powered by the engine-driven 13. The set is stopped manually by pressing the
battery charging alternator (12 VDC) through panel Stop switch or automatically by a remote
plug-in connector P1-3. The panel Run indica- controller. (The panel switch must be in the Re-
tor lamp should light. Relays K10 and K14 are mote position for remote, automatic opera-
redundant.* tion.)
* On older ECM boards (those having cartridge-type fuses):

If the starter disconnects normally but the panel Run indicator lamp does not light, the DC (K14) starter disconnect circuit is
not working.
If the starter disconnects normally but neither the panel nor the remote Run indicator lamps light, the AC (K10) starter dis-
connect circuit is not working.
* On newer ECM boards (those having automotive-type fuses):
If the starter disconnects normally but neither the panel nor the remote Run indicator lamps light, the AC (K10) starter dis-
connect circuit is not working.
Both the remote and the panel Run indicator lamps will light even if the DC (K14) starter disconnect circuit is not working.
Check the DC voltmeter to determine whether or not the battery charging alternator is working.

4. Troubleshooting
These troubleshooting charts are designed to help WARNING Hazards present in troubleshooting
you think through generator set problems. To save can cause equipment damage, severe personal
time troubleshooting, read the entire manual ahead injury or death. Troubleshooting must be per-
of time to understand the generator set. Try to think formed by qualified persons who know about
through problems. Go over what was done during fuel, electrical and machinery hazards. Read
the last service call. The problem could be as simple the Safety Precautions page and carefully ob-
as an empty fuel tank, closed fuel shutoff valve, serve all instructions and precautions in this
loose wire, blown fuse or tripped circuit breaker. manual.
THE ENGINE DOES NOT CRANK
The Run-Stop-Remote switch is at Stop.

Push the Run-Stop-Remote switch to Run or Re-
(The Switch-Off light will be flashing, if
mote.
provided.)
Pull the Emergency Switch button. To reset the en-

The Emergency Stop switch has been gine control, push the Run-Stop-Remote switch to
used. (The switch button and switch S11 Stop and the Reset switch to Reset. Then push the
will light.) Run-Stop-Remote switch to Run or Remote.
Push the Run-Stop-Remote switch to Run. If the en-

The remote control circuit is faulty. gine cranks, find and repair the fault in the remote con-
trol circuit.
Service the set as necessary. To reset the engine con-

A Fault Shutdown is being indicated by trol, push the Run-Stop-Remote switch to Stop and
one of the red lights on the control panel. the Reset switch to Reset. Then push the Run-Stop-
Remote switch to Run or Remote.
Determine the cause and service as necessary. To re-

set the engine control, push the Run-Stop-Remote
A Lo Shutdown is being indicated on the switch to Stop and the Reset switch to Reset. Then
day tank pump control panel (if provided). push the Run-Stop-Remote switch to Run or Re-
mote. Note that the engine control will shut down un-
less the day tank control has been reset first.
Continued on next page.

WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Troubleshooting must be performed by qualified persons who know about fuel, electrical
and machinery hazards. Read the Safety Precautions page and carefully observe all instructions and
precautions in this manual.
THE ENGINE DOES NOT CRANK (CONT.)
Continued from previous page.
Cranking voltage is too low to crank the Clean and tighten or replace the battery cable connec-
engine. tors and cables at the battery and the set.
Recharge or replace the battery. Specific gravity for a

fully charged battery is approximately 1.260 at 80 F
(27 C).
If the set is in standby service, install a battery charger.
Replace the engine-driven battery charging alternator

if normal battery charging voltage is not between 12
and 15 volts.
Fuse F1 on the ECM (A11) board has Replace the fuse with one of the same type and amp
blown. rating.
If fuse F1 blows again, the wire between ECM terminal

TB1-8 and starter solenoid terminal S may be loose or
damaged, causing a short to ground. Repair as neces-
sary.
If fuse F1 still blows, service or replace the starter or

the solenoid according to the engine service manual.
Check for battery voltage (12 VDC) between ECM ter-

The wire between ECM terminal TB1-9 minal TB1-9 (B+) and the grounding stud () on the
and starter solenoid terminal BAT is floor of the control cabinet. Check, clean and tighten
loose, damaged or missing. the connectors at both ends and replace the wire if it is
damaged.

THE ENGINE DOES NOT CRANK (CONT.)
Check for electrical continuity (zero ohms) between

A grounding strap between the control the grounding stud on the floor of the control box and
box and the battery negative () terminal the battery negative () terminal. If there is no electri-
is loose, damaged or missing. cal continuity, check for loose, damaged or missing
grounding straps and repair as necessary.
Disconnect pin connector J4 from the ECM board and

check for electrical continuity (zero ohms) between
The Run-Stop-Remote switch (S12) or switch terminals 2 and 3 when the switch is in the Run
wiring is faulty. position and between terminals 1 and 2 when it is in the
Remote position. Replace the switch if either set of
contacts is faulty.
If the switch works, check for electrical continuity (zero

ohms) between J4-6 and J4-7 on the wire harness
when the switch is in the Run position and between
J4-5 and J4-7 when the switch is in the Remote posi-
tion. Replace the wire harness if there is no electrical
continuity in either position of the switch.
Push the Run-Stop-Remote switch to Run and check

for battery voltage (12 VDC) between ECM terminal
The ECM is faulty. (Check fuse F1 again.) TB1-8 and the grounding stud on the floor of the con-
trol box. If there is no voltage when the switch is in the
Run position, replace the ECM.
The wire between ECM terminal TB1-8 Push the Run-Stop-Remote switch to Run and check
and starter solenoid terminal SW is loose, for battery voltage at starter solenoid terminal SW. If
damaged or missing. there is no voltage repair the wiring as necessary.
If there is voltage at starter solenoid terminal SW but

The starter motor or solenoid is mal- the motor does not function, repair or replace the start-
functioning. er motor or solenoid according to the engine service
manual.

THE ENGINE CRANKS BUT DOES NOT START
When the Run-Stop-Remote switch is in the Run position, the control will attempt to crank the engine for approximate-
ly 75 seconds (including two rest periods) and then the red OVERCRANK lamp will light if the engine does not start. If
the OVERCRANK lamp comes on, reset the control by pushing the Run-Stop-Remote switch to Stop and the Reset
switch to Reset. Then push the Run-Stop-Remote switch to Run or Remote.
Open any closed shutoff valve in the fuel line supplying

The engine is not getting fuel.
the engine.
Check fuel solenoid and related wiring. Repair or re-

place as needed.
Fill the main fuel supply tank if the set is gasoline or

propane fueled. For natural gas fueled sets, check
with the gas utility.
The air cleaner is blocked. Service as necessary.
The engine ignition system is malfunc-

tioning (ignition coil, distributor, spark Service as necessary. Refer to wiring diagrams in Sec-
plugs, high tension spark plug and coil tion 7.
cables and timing.
Clean and rebuild gasoline carburetors with the ap-

propriate carburetor kit according to the kit instruc-
The carburetor fuel passages are
tions. Adjust fuel mixture and choke (refer to Section
clogged or the choke needs adjustment.
6).

THE ENGINE CRANKS BUT DOES NOT START (CONT.)
Fuse F2 on the ECM board (A11) has Replace the fuse with one of the same type and amp
blown. rating.
If fuse F2 blows again, the wire between ECM terminal

TB1-10 and engine block terminal T26 may be loose
or damaged, causing a short to ground. Repair as nec-
essary.
If fuse F2 still blows, the wire between fuel solenoid K1

and terminal T26 may be loose or damaged, causing a
short to ground. Repair as necessary.
Connect the terminal on fuel solenoid K1 to the BAT

Fuel solenoid K1 is faulty (does not terminal on starter relay K4 with a jumper wire. Re-
open). place the fuel solenoid if it does not click each time
power is connected.
Low engine temperature is causing too Plug in, repair or install engine coolant and engine oil
low a cranking speed for starting. heaters.
Replace the engine oil if it is not of the recommended

viscosity for the ambient temperature.

THE ENGINE CRANKS BUT DOES NOT START (CONT.)
While cranking the engine, measure voltage directly

across the battery terminals and then immediately
Cranking voltage is too low to reach re- across the starter motor terminal and the grounding
quired cranking speed. bolt on the block. Cable, terminal or relay contact re-
sistance is too high if the difference is more than 2
volts. Service as necessary.
Recharge or replace the battery. Specific gravity for a

fully charged battery is approximately 1.260 at 80 F
(27 C).
Replace the engine-driven battery charging alternator

if normal battery charging voltage is not between 12
and 15 volts.
While cranking, check for battery voltage at the termi-

The ECM is faulty. (Check fuse F2 again.) nal TB1-10 on the ECM. Replace the ECM if there is
no voltage at the terminal.
The engine is worn or malfunctioning me-

Service according to the engine service manual.
chanically.

THE ENGINE RUNS UNTIL FAULT SHUTDOWN (RED SHUTDOWN LAMP ON)
Reset the ECM by pushing the Run-Stop-Remote

switch to Stop and the Reset switch to Reset and re-
The OVERSPEED lamp comes on when
start the set, monitoring engine speed. Readjust the
the engine shuts down.
cutout speed if it is lower than specified. See Section 3,
Engine Control.
Adjust the governor according to Section 6, Gover-

nors.
Mechanical Governor: Service or replace the injec-

tion pump unit if the set still shuts down due to over-
speed.
Electronic Governor: If the governor cannot be ad-

justed to prevent shutdown due to overspeed, check
for binding in the linkage. Repair and adjust the linkage
as necessary. (A spring inside the actuator will resist
movement, which is normal.)
If the set still shuts down due to overspeed, re-install

the magnetic speed pick-up unit to make sure the
clearance with the flywheel gear teeth is correct. Re-
place the speed-pickup unit if output voltage at crank-
ing speed is less than 2.5 VDC as measured at termi-
nals 10 () and 11 (+) on the governor controller.
Disconnect the actuator lead connected at governor

controller terminal 5 and connect it to the negative ()
terminal of the cranking battery. Then disconnect the
lead connected at terminal 4 and touch it to the battery
positive (+) terminal. Replace the actuator unit if it
does not drive the linkage through its full travel when
power is connected or return it when power is discon-
nected.
Replace the governor controller if the set still shuts

Continued on next page. down due to overspeed.

THE ENGINE RUNS UNTIL FAULT SHUTDOWN (CONT)

The LOW OIL PRESSURE lamp comes switch to Stop and the Reset switch to Reset and fill
on when the engine shuts down. up with as much engine oil as necessary and repair all
oil leaks.
If the set still shuts down due to low oil pressure, dis-
connect the wire to fuel solenoid K1 (to keep the en-
gine from starting) and observe oil pressure while
cranking the engine. Service the lubricating oil system
according to the engine service manual if oil pressure
is less than 10 psi. Replace the low oil pressure cutout
switch if oil pressure is greater than 10 psi. See Figure
3-5, Engine Control to locate the switch.

The HIGH ENGINE TEMPERATURE
switch to Stop and the Reset switch to Reset and fill
lamp comes on when the engine shuts
up with as much engine coolant as necessary and re-
down.
pair all leaks.
If the set still shuts down due to high engine tempera-

ture, start the engine and observe coolant tempera-
ture as the system heats up. If shutdown occurs before
the coolant reaches 230 F (110 C), replace the high
engine temperature cutout switch. If coolant tempera-
ture exceeds 230 F (110 C), clean and service the
entire cooling system as required to restore full cooling
capacity. See Figure 3-5 in Section 3, Engine Control,
to locate the switch.
Service as required. (The customer has supplied the

The FAULT 1 or FAULT 2 lamp comes on system fault indicating switches. By means of selec-
when the engine shuts down. tion jumpers, either fault may be chosen to display the
warning only. See Section 3, Engine Control.)
If the set is equipped with the optional low frequency

shutdown feature and the red FAULT 1 or FAULT 2
lamp is on, the set probably ran out of fuel. Service as
required.

THE ENGINE LACKS POWER OR STABLE SPEED
Fuel delivery to the set is inadequate. Check for and replace clogged fuel lines and filters.
Check for air in the fuel lines and repair all air leaks.
Measure the vertical distance between the fuel lift

pump on the engine and the bottom of the dip tube in
the supply tank. Make necessary provisions so that lift
does not exceed 6 feet (1.8 metres).
Connect the set to a container of fuel of known quality

and run the set under various loads. Replace the con-
The fuel is contaminated. tents of the fuel supply tank if there is a noticeable im-
provement in performance.
The engine air filter element is dirty. Replace the air filter element.

THE ENGINE LACKS POWER OR STABLE SPEED (CONT.)
Adjust the governor according to Section 6, Gover-

The governor adjustment is incorrect.
nors.
Electronic Governor: If the governor cannot be ad-

justed for full power or stable speed, shut down the set
and check for binding in the linkage. Repair and adjust
the linkage as necessary. (A spring inside the actuator
will resist opening the movement, which is normal.)
Re-install the magnetic speed pick-up unit to make

sure the clearance with the flywheel gear teeth is cor-
rect. Replace the speed-pickup unit if output voltage at
cranking speed is less than 2.5 VDC as measured at
terminals 10 () and 11 (+) on the governor controller.
Disconnect the actuator lead connected at governor

controller terminal 5 and connect it to the negative ()
terminal of the cranking battery. Then disconnect the
lead connected at terminal 4 and touch it to the battery
positive (+) terminal. Replace the actuator unit if it
does not drive the linkage through its full travel when
power is connected or return it when power is discon-
nected.
Replace the governor controller if it still cannot be ad-

justed for full power or stable speed.
The engine fuel system (lift pump, injec- Service the fuel system according to the engine ser-
tion pump, injectors, timing) is faulty. vice manual.
Service the engine according to the engine service

The engine is worn.
manual.

AMBER WARNING LAMP ON

Shut down the set if possible or disconnect non-critical
loads.(Oil pressure will be less than 20 psi [138kPa]
The PRE-LOW OIL PRESSURE lamp but greater than 14 psi [97 kPa].) Service the engine
comes on while the engine is running. lubricating system according to the engine service
manual. Normal operating range is 35 to 60 psi (241 to
414 kPa).
Shut down the set if possible or disconnect non-critical

The PRE-HIGH ENGINE TEMPERA- loads. Engine temperature will be greater than 220 F
TURE lamp comes on while the engine is (104 C) but less than 230 F (110 C). Service the en-
running. gine cooling system to restore full cooling capacity.
The LOW ENGINE TEMPERATURE Plug in, repair or install engine coolant and engine oil
lamp comes on while the set is in standby. heaters.
Fill the main fuel supply tank with the appropriate

The LOW FUEL lamp comes on. grade of fuel. (The customer has supplied the fuel level
switch to make use of this warning.)
Service as required. (The customer has supplied the

system fault indicating switches. By means of selec-
FAULT 1 or FAULT 2 (RED)
tion jumpers, either fault may be chosen to shut down
the engine. See See Section 3, Engine Control.

THE GREEN RUN LAMPS STAY OFF BUT THE SET RUNS NORMALLY
The set mounted RUN lamp does not light
Press the panel Lamp Test switch and replace the run
although the starter has disconnected
lamp bulb if it does not light.
normally and the engine is running
If the lamp is good, this indicates that the DC discon-

nect circuit (K14 relay circuit on the ECM) is not work-
ing. Check the DC voltmeter and if there is not at least
12 volts, check for loose or missing wiring between the
battery charging alternator and terminal TB1-2 and pin
connector P1-3 on the ECM. See Page 7-6 or 7-8 re-
garding the applicable alternator configuration. If the
connections are good, replace the battery charging al-
ternator.
If the RUN lamp, wiring connections and battery

charging alternator are all good and the RUN lamp
does not light during normal operation, replace the
ECM.
Neither the remote nor the set mounted

Press the panel Lamp Test switch and replace the run
RUN lamp light although the starter has
lamp bulb if it does not light. Test the remote RUN lamp
disconnected normally and the engine is
by suitable means and replace it if it does not light.
running.
If both lamps are good, this indicates that the AC dis-

connect circuit (K10 relay circuit on the ECM) is not
working. Check the AC voltmeter to determine wheth-
er or not there is generator output voltage and service
as necessary. See There Is No Output Voltage.
If there is generator output voltage, check for 120 VAC

across pin connectors P1-1 and P1-2 on the ECM. If
there is no voltage, check for loose or missing leads
between the connectors and TB21-21 and TB21-32
inside the control box and service as necessary.
Replace the ECM if there is 120 VAC across pin con-

nectors P1-1 and P1-2 but neither RUN lamp lights
during normal operation.

THERE IS NO OUTPUT VOLTAGE (ENGINE SPEED IS STABLE)
Find out why the circuit breaker was turned OFF, make
The line circuit breaker is OFF. sure it is safe to reconnect power, and then throw the
circuit breaker ON.
Shut down the set and service as necessary to clear

The line circuit breaker has TRIPPED. the short circuit or ground fault that caused tripping,
and then RESET the circuit breaker and start the set.
Shut down the set, make sure the power output lines
from the set have been disconnected from all other
sources of power, attempt to RESET the circuit break-
The line circuit breaker is faulty. er and throw it ON and check for electrical continuity
across each line contact. Replace the circuit breaker if
there is measurable resistance across any contact.
RESET the circuit breaker. If it keeps tripping, trouble-

Field circuit breaker CB21 has TRIPPED. shoot according to the chart, Field Circuit Breaker
Keeps Tripping.
Shut down the set, attempt to RESET the circuit break-

er and disconnect either lead. Replace the circuit
Field circuit breaker CB21 is faulty.
breaker if there is measurable resistance across the
terminals.

THERE IS NO OUTPUT VOLTAGE (CONT. )
Determine, as follows, whether the fault is in the VOLTAGE REGULATING or GENERATOR circuits:
1. Throw the line circuit breaker OFF and shut down the set.
CAUTION This test involves unregulated excitation of the generator. To prevent damage to the genera-
tor due to overcurrent, make sure that all loads have been disconnected and that all faults have been
cleared from the power output terminals of the generator.
2. Open the control panel and disconnect the F1 (+) and the F2 () leads from the voltage regulator. See Figure 2-2.
HIGH VOLTAGE. Touching uninsulated high voltage parts inside the control box can result in
severe personal injury or death. Measurements and adjustments must be done with care to avoid touch-
ing high voltage parts.
For your protection, stand on a dry wooden platform or rubber insulating mat, make sure your clothing
and shoes are dry, remove jewelry from your hands and wear elbow length insulating gloves.
3. Start the set and check for output voltage at the main stator terminals.
a. Is there 520 VAC residual voltage at the output of the main stator windings when the exciter leads are dis-
connected?
YES: The main stator windings are good, continue with step 4.
NO: Use the GENERATOR FAULT chart to troubleshoot generator.
4. If the residual voltage is good, stop the set and reconnect the exciter leads to the exciter stator. Start the set. Has
the output voltage increased?
YES: Adjust the Coarse Voltage Adjust pot on VRAS-2.
NO: Check if CB21 is closed. If CB21 is OK, flash the field using the procedure in Section 5.
5. When field is flashed, does the output voltage from the main stator increase?
YES: The generator assembly is OK.
NO: Use the GENERATOR FAULT chart to troubleshoot generator.
6. If the output voltage increased when the field was flashed, does the output voltage remain after the flash circuit is
removed?
YES: The generator assembly and VRAS-2 are OK.
NO: VRAS-2 is defective. Use the VOLTAGE REGULATING FAULTS chart to troubleshoot VRAS-2.
7. Put a full load on the generator set. Does the generator set output stay up after the generator set has responded to
the load?
YES: The generator assembly and VRAS-2 are OK.
NO: Check each diode according to Section 5, Servicing the Generator.

VRAS-2 FAULTS
Flash the field according to Section 5, Servicing the

The field has lost its residual magnetism.
Generator.
Check all connections against the wiring diagrams on

pages 7-2 and 7-9 and rewire as necessary. Replace
VRAS-2 if the wiring is correct and there is no output
Voltage Regulator VRAS-2 is faulty. voltage.
CAUTION Replacing VRAS-2 before servicing
other faults can lead to damage to the new VRAS-2.

GENERATOR FAULTS
Shut down the set and check exciter field winding re-
The exciter field winding is faulty (open or sistance according to Section 5, Servicing the Genera-
shorted). tor. Replace the exciter field assembly if winding re-
sistance does not meet specifications.
Shut down the set and check each diode according to

The rotating rectifier assembly (diodes
Section 5, Servicing the Generator. Service as neces-
CR1 through CR6) is faulty.
sary.
Shut down the set and check exciter winding resist-

The exciter rotor windings are faulty ances according to Section 5, Servicing the Genera-
(open or shorted). tor. Replace the generator rotor assembly if exciter ro-
tor winding resistances do not meet specifications.
Shut down the set and check main rotor winding resist-
The main rotor winding is faulty (open or ance according to Section 5, Servicing the Generator.
shorted). Replace the generator rotor assembly if main rotor
winding resistance does not meet specifications.
Shut down the set and check stator winding resistanc-

The stator windings are faulty (open or es according to Section 5, Servicing the Generator.
shorted). Replace the generator stator assembly if stator wind-
ing resistances do not meet specifications.

OUTPUT VOLTAGE IS TOO HIGH OR TOO LOW
Adjust engine speed according to Section 6, Gover-

Engine speed is too high or too low. nors.
If engine speed is unstable, troubleshoot according to

the chart, The Engine Lacks Power or Stable Speed.
The voltage has been adjusted improper- Adjust output voltage according to Section 2, AC Con-
ly. trol.
Shut down the set and reconnect according to the re-

Improper connections have been made at
connection diagram on page 7-9.
the generator output terminals.

sary.
Replace the voltage regulator.
Voltage Regulator VR21 is faulty. CAUTION Replacing VRAS-2 before servicing


OUTPUT VOLTAGE IS UNSTABLE
The voltage has been adjusted improper- Adjust output voltage according to Section 2, AC Con-
ly. trol.
Unlock the voltage adjusting screw on the front of the

control panel and disconnect either lead from the rheo-
stat. Measure resistance between terminals 1 and 2
The voltage adjusting rheostat on the
while turning the adjusting screw fully one way and
control panel is faulty (if provided).
then the other. Replace the rheostat if it is open at any
point, or if resistance does not vary smoothly from zero
to approximately 1,500 ohms.


THE FIELD CIRCUIT BREAKER KEEPS TRIPPING

sary.
Shut down the set and check exciter field winding re-
sistance according to Section 5, Servicing the Genera-
The exciter field winding is shorted. tor. Replace the exciter field assembly if winding re-
sistance does not meet specifications.
Shut down the set and check exciter winding resist-

ances according to Section 5, Servicing the Genera-
The exciter rotor windings are shorted.
tor. Replace the generator rotor assembly if exciter ro-
tor winding resistances do not meet specifications.
Shut down the set and check main rotor winding resist-
ance according to Section 5, Servicing the Generator.
The main rotor winding is shorted.
Replace the generator rotor assembly if main rotor
winding resistance does not meet specifications.

es according to Section 5, Servicing the Generator.
The stator windings are shorted.
Replace the generator stator assembly if stator wind-


THE PHASE CURRENTS ARE UNBALANCED
Shut down the set and redistribute the loads so that

The connected loads are distributed un-
there is a difference of less than 10 percent between
evenly among the phases.
phases.
Improper connections have been made at Shut down the set and reconnect according to the re-
the generator output terminals. connection diagram on page 7-9.

The stator windings are faulty (open or es according to Section 5, Servicing the Generator.
shorted). Replace the generator stator assembly if stator wind-
A load has a ground fault or short circuit. Service the faulty equipment as necessary.

5. Servicing the Generator
TESTING THE GENERATOR Make certain battery area has been well-venti-
These tests can be performed without removing the lated before servicing battery. Arcing can ignite
generator. Before starting tests, turn off or remove explosive hydrogen gas given off by batteries,
AC power from the battery charger and then discon- causing severe personal injury. Arcing can oc-
nect the starting battery cables (negative [-] first) to cur when cable is removed or re-attached, or
make sure the engine will not start while performing when negative () battery cable is connected
these tests. and a tool used to connect or disconnect posi-
tive (+) battery cable touches frame or other
CAUTION Always disconnect a battery char- grounded metal part of the set. Always remove
ger from its AC source before disconnecting the negative () cable first, and reconnect it last.
battery cables. Otherwise, disconnecting the Make certain hydrogen from battery, engine
cables can result in voltage spikes high enough fuel, and other explosive fumes are fully dissi-
to damage the DC control circuits of the set. pated. This is especially important if battery has
WARNING Accidental starting of the generator been connected to battery charger.
set while working on it can cause severe per-
sonal injury or death. Prevent accidental start-
ing by disconnecting the starting battery cables
(negative [] first).
MAIN PMG
BLOWER STATOR ASSEMBLY EXCITER
STATOR
ROTATING
RECTIFIER
ASSEMBLY
OVERSPEED
SWITCH
END
BEARING
EXCITER
ROTOR
DRIVE
DISCS
MAIN ROTOR
SCREEN (GENERATOR FIELD)
FIGURE 5-1. GENERATOR

INSULATION RESISTANCE (MEGGER) & If moisture is determined to be the cause of low test
POLARIZATION INDEX (PI) TESTING readings, a winding drying process will be required.
These tests are used for insulation testing and to DRYING THE WINDINGS
verify that the windings are dry before the generator
set is operated and develop a base line for future If low readings are obtained and moisture is deter-
test comparison. mined to be the problem, the windings should be
dried out and the test repeated. Use the generator
Megger Testing heaters or blow warm air through the generator with
a fan. A more effective way is to use a bolted 2 /
A 500 VDC megger is recommended for insulation 3-phase short across the generator terminals. This
testing. A test consists of applying the voltage be- procedure must be done as described or equipment
tween the winding and ground for one minute. damage can result. To do this:
Resistance value of at least 5 megohms should be 1. Bolt the two or the three phases of the genera-
obtained for a new generator with dry windings. For tor together at the terminals. See the reconnec-
a set that has been in service, the resistance read- tion diagram in Section 7.
ing should not be less than 1 megohm. 2. Disconnect the F1 and F2 leads (Figure 5-2) at
the voltage regulator and connect them to a
PI Testing variable 12 VDC source. Positive lead to F1,
negative lead to F2.
The PI test consists of applying a voltage between
the winding and ground for ten minutes and record- 3. Attach a clamp-on ammeter to the generator
ing resistance values at one minute and at ten min- leads to measure generator current, adjust the
utes. The PI is the ratio of a ten minute reading in 12 VDC source for zero volts, start the set and
megohms divided by a one minute reading in meg- slowly increase the excitation voltage. Obtain
ohms. A ratio of two or greater is considered good the highest current possible without exceeding
for new and in service sets. generator rating.
4. Run the set for approximately one hour and re-
If low readings are obtained, the cause should be in- peat the insulation resistance tests. If further
vestigated and corrected before the generator set is drying time is indicated, continue the drying
returned to service. process.

EXCITER STATOR Testing Winding Insulation Resistance
Testing Winding Resistance
Disconnect the F1 and F2 exciter stator leads at the
Measure winding resistance with a Wheatstone voltage regulator and isolate them from ground.
bridge or digital ohmmeter. Resistance should be
approximately 20 ohms at 68 F (20 C).
Before performing the following insulation resist- Connect the megger between one of the leads and
ance test, refer to the Insulation Resistance and Po- ground and conduct the test. Replace the stator if
larization Index Test procedure at the beginning of insulation resistance is less than 1 megohm
this section. (1,000,000 ohms).
MEASURE WINDING MEASURE WINDING

INSULATION RESISTANCE RESISTANCE BETWEEN
BETWEEN EITHER LEAD THE TWO STATOR
AND THE STATOR LEADS, F1 AND F2
LAMINATIONS
FIGURE 5-2. TESTING AND FLASHING THE EXCITER STATOR

Flashing the Field With Generator Set in Operation:
CAUTION This test involves unregulated ex-
If output voltage does not build up, it may be neces-
sary to restore residual magnetism by flashing the citation of the generator. To prevent damage to
field. This requires a 12-volt battery, a 12-ampere the generator due to overcurrent, make sure
300-volt diode, and a 12-volt light bulb or a 2-watt that all loads have been disconnected and that
20-ohm resistor wired as shown in Figure 5-3. all faults have been cleared from the power out-
put terminals of the generator.
Flashing the field can be accomplished with gener- 1. Start the generator set.
ator set operating or not. Either of the following pro- 2. Touch the positive battery lead to TB1-9 and
cedures should be sufficient to restore residual the negative lead to TB1-10 of VRAS-2. Hold
magnetism. the leads in place just long enough for the volt-
age to build up to the normal operating level,
CAUTION Incorrect field flashing procedures
then remove the leads.
can damage regulator or exciter stator wind-
3. Check generator voltage, and shut down gen-
ings. Do not maintain field flash connection to
erator set. Restart generator set and run at no
exciter circuit longer than 5 seconds.
load. Unit must build up voltage without field
Make sure a diode is used in the field flash appa- flashing. If not, shut down generator set and
ratus to prevent the regulator from overcharg- perform continuity check of all related wiring.
ing the battery. Batteries can explode when With Generator Set Shut Down:
overcharged.
1. Touch the positive battery lead to TB1-9 and
the negative lead to TB1-10 of VRAS-2.
2. Hold the leads in place for no longer than 5 sec-
onds.
3. Start generator and run at no load. Unit must
build up voltage without field flashing. If it does
not, shut down generator set and perform con-
tinuity check of all related wiring.
EXCITER
STATOR
L1
MAIN STATOR
12-AMPERE, L3
300-VOLT DIODE ()
10
AVR REFERENCE
VOLTAGE
9
(+) L0
L2
() (+)
12-VOLT LIGHT BULB OR 12-VOLT

2-WATT 20-OHM RESISTOR BATTERY
FIGURE 5-3. FIELD FLASHING CIRCUIT

EXCITER RECTIFIER BRIDGE (ROTATING each diode should be high in one direction
RECTIFIER ASSEMBLY) and low in the other. If the resistance is
high or low in both directions, replace the
The exciter rectifier bridge is mounted on the exciter diode.
rotor, outboard, facing the rear. It consists of a posi- 3. To replace diodes, use the following proce-
tive plate and a negative plate, each carrying three dure.
diodes.
A. Unsolder lead wires of defective diodes
CAUTION Layers of dust can cause diodes to from flag terminals.
overheat and fail. Brush dust off regularly. B. Insert new diode into heatsink mounting
1. Disconnect one diode at a time by removing hole. Using nut and washer provided, se-
diode from heatsink. cure diode to heatsink.
A. Use proper size wrenches to hold the C. Use proper size wrenches to hold the
diode body while removing the nut. diode body while tightening the nut.
B. Push the diode free of the heatsink mount- Torque diodes on rotating exciter assem-
ing hole. bly to 24 in-lbs (2.7 Nm).
2. Test that diode before proceeding to the next D. Solder lead wires to new diode flag termi-
one. nals.
A. Using an ohmmeter, measure electrical CAUTION Excessive heat on these diodes
resistance between the flag and the stud will destroy them. Use a 40 watt soldering
of the diode. iron. Hold a needlenose pliers between
B. Reverse the meter test probes and repeat diode and soldering point to prevent de-
the tests. The electrical resistance across structive heating.
REMOVE DIODE (1 OF
6) FROM HEATSINK AND
MEASURE ELECTRICAL
RESISTANCE BETWEEN
THE PIGTAIL AND THE
METAL PLATE UNDER
THE DIODE
DIODE
HEATSINKS
FIGURE 5-4. TESTING THE ROTATING RECTIFIER ASSEMBLY

EXCITER ROTOR Testing Winding Insulation Resistance:
Testing Winding Resistance: Remove diodes CR1 through CR6 from diode heat
Remove diodes CR1 through CR6 from diode heat sink assemblies. Using a megger (voltage set at
sink assemblies. With a Wheatstone bridge, mea- 500 VDC), measure the resistance between any ro-
sure electrical resistance across each pair of rotor tor winding lead or the terminal to which it is con-
windings: T1 (CR1 or CR4) and T2 (CR2 or CR5), nected and the rotor laminations. Replace the excit-
T2 (CR2 or CR5) and T3 (CR3 or CR6), T3 (CR3 or er rotor if insulation resistance is less than 1 meg-
CR6) and T1 (CR1 or CR4). See the winding sche- ohm.
matic. Resistance should be 0.464 to 0.567 ohms at
68 F (20 C).
MEASURE WINDING
INSULATION RESISTANCE
BETWEEN ANY LEAD OR
THE TERMINAL TO WHICH
IT IS CONNECTED AND
THE ROTOR LAMINATIONS
WINDING SCHEMATIC
REMOVE DIODES CR1 THROUGH
CR6 FROM DIODE HEAT SINK
ASSEMBLIES AND MEASURE
T11 T21 ELECTRICAL RESISTANCE
ACROSS EACH PAIR OF
T1 WINDINGS: T1-T2, T2-T3, T3-T1
T2
T23 T3 T12
T13 T22
FIGURE 5-5. TESTING THE EXCITER ROTOR

MAIN ROTOR (GENERATOR FIELD) Before performing the following insulation resist-
ance test, refer to the Insulation Resistance and Po-
Testing Winding Resistance larization Index Test procedure at the beginning of
this section.
Disconnect the two leads of the main rotor from the
terminals on the rotating rectifier assembly. See
Figure 5-6. Measure electrical resistance between Insulation Resistance and PI Test
the two leads with a Wheatstone bridge or digital
ohmmeter. Replace the rotor if the resistance is not Disconnect the two leads of the main rotor from the
as shown in the following list. Connect the rotor terminals on the rotating rectifier assembly. Using a
leads and torque the terminals to 24 in-lbs (2.7 megger (voltage set at 500 VDC), measure the re-
Nm) when reassembling. sistance between either lead of the main rotor wind-
ings, or the terminal to which it is connected, and the
EK 3.32 to 4.06 ohms at 68 F (20 C) main rotor laminations. Replace the rotor if insula-
EM 2.49 to 3.05 ohms at 68 F (20 C) tion resistance is less than 1 megohm.
MEASURE WINDING INSULATION

RESISTANCE BETWEEN EITHER
ROTOR LEAD AND THE ROTOR
LAMMINATIONS
DISCONNECT THE MAIN ROTOR LEADS

FROM THE ROTATING RECTIFIER
ASSEMBLY AND MEASURE THE
WINDING RESISTANCE BETWEEN THEM
FIGURE 5-6. TESTING THE MAIN ROTOR

MAIN STATOR ries). On a series star connected generator, line-
to-line resistance should be four times the table val-
Testing Winding Resistance ue (four winding elements in series). On a parallel
star connected generator, line-to-line resistance
Disconnect all stator leads from the terminals to should be the same as the table value (two sets of
which they are connected. Using a Wheatstone two winding elements in series).
bridge or ohmmeter having at least 0.001 ohm pre-
cision, measure electrical resistance across each Before performing the following insulation resist-
pair of stator leads (T1-T4, T7-T10, T2-T5, T8-T11, ance test, refer to the Insulation Resistance and Po-
T3-T6, T9-T12). Replace the stator if the resistance larization Index Test procedure at the beginning of
of any winding is not as specified in Table 5-1. this section.
TABLE 5-1. STATOR RESISTANCE VALUES* Insulation Resistance and PI Test
VOLTAGE CODE Disconnect all stator leads and winding taps from
MODEL their respective terminals and make sure the ends
L, R, 15, & 32 H & 9X E & 6D do not touch the generator frame.
EK 0.116-0.141 0.425-0.520 0.432-0.528 Testing For Grounds: Using a megger (voltage set
EM 0.047-0.058 0.193-0.236 0.202-0.248 at 500 VDC), measure electrical resistance be-
tween any stator lead and the stator laminations.
* These values are approximate, plus or minus
Replace the stator if insulation resistance is less
10 percent at 68 F (20 C).
than 1 megohm.
Alternatively, winding resistance can be measured Testing for Shorts: Using a megger (voltage set at
line-to-line at the generator terminals (L1-L2, 500 VDC) measure electrical resistance between
L2-L3, L3-L1) on star connected generators. On a each winding, for example T1/T4 to T7/T10, T1/T4
600 volt generator, line-to-line resistance should be to T2/T5, etc. Replace the stator if insulation resist-
twice the table value (two winding elements in se- ance is less than 1 megohm.
MEGGER OR WHEATSTONE
INSULATION BRIDGE
RESISTANCE
METER
FIGURE 5-7. TESTING THE GENERATOR STATOR

REMOVING AND DISASSEMBLING THE 8. Disconnect the line cables and conduit. For re-
GENERATOR connections later, make sure each cable is
clearly marked to indicate the correct terminal.
The generator is heavy. You will need an assistant
and a hoist of sufficient capacity to remove and ser- 9. Disconnect the remote control wiring and con-
vice the generator. duit. For reconnections later, make sure each
wire is clearly marked to indicate the correct
WARNING Accidentally dropping the genera- terminal.
tor can damage it and cause severe personal in-
jury and death. The hoist, straps and chains 10. Disconnect all engine wiring harness connec-
must have sufficient capacity and be attached tions in the generator control and output boxes.
properly so that the load cannot shift. For reconnections later, make sure each wire is
Before starting, disconnect the starting battery
cables (negative (-) first) to make sure the set will 11. Disconnect all generator control leads (winding
not start while working on it. taps) from connections in the output box. For
reconnections later, make sure each wire is
WARNING Accidental starting of the generator
set while working on it can cause severe injury
or death. Prevent accidental starting by discon- 12. If the set has a mounted line circuit breaker, dis-
necting the starting battery cables (negative (-) connect the cables to the circuit breaker. For
first). reconnections later, make sure each cable is
Always remove the negative (-) cable first, and clearly marked to indicate the correct terminal.
reconnect it last, to prevent arcing if a tool acci- 13. Remove the sheet metal from around the gen-
dentally touches the frame or other grounded erator.
metal part while removing the positive (+) bat-
tery cable. Arcing can ignite the explosive hy- 14. Remove the overspeed switch and bracket
drogen gas given off by the batteries, causing from the end bell and rotor shaft. See Figure
severe injury. 5-8.
ADJUST
SCREW
GENERATOR
SHAFT AIR GAP (NOT LESS
THAN 0.005 IN. [13 MM]
SWITCH
CONTACTS
END
BELL
FIGURE 5-8. OVERSPEED SWITCH ASSEMBLY

15. Block the rear of the engine in place by support- the placement bolts to 200 to 240 ft-lbs (271 to
ing the flywheel housing. 325 Nm).
16. Remove the four nuts and washers from the 5. Using a hoist and sling to support the rotor,
studs that secure the end bell. align the holes in the drive disk and fan with the
17. Remove end bell with oil seal from stator as- corresponding holes in the flywheel.
sembly. It might be necessary to tap around 6. Install the bolts that hold the drive disk to the
end bell joint to separate end bell from stator. engine flywheel and torque to 55 to 60 ft-lbs (75
18. Remove the four 1/4-inch bolts and lock wash- to 81 Nm).
ers securing the exciter stator to the end bell. CAUTION Do not allow the rotor to hang
19. Remove the narrow generator air screen. unsupported for any extended period.
20. Remove the large capscrews securing the Otherwise, drive disk damage can occur.
generator to the skid base.
7. Using a hoist and safe lifting device, carefully
21. Remove the bolts securing the stator to engine move the stator into position over the rotor as-
flywheel housing. sembly. The stator leads should be at the 12
22. Using an overhead hoist and sling, slide the oclock position when viewed from the end bell
stator assembly off the long through-studs position. Make sure the short hose pieces are
(note position of hose pieces on the studs, and in place next to the flywheel housing before
proper orientation of the stator) being careful installing stator.
not to touch or drag on the rotor. 8. Align the holes of the stator with the engine fly-
The studs can be removed if you want to do so. wheel housing and install the bolts. Torque to
CAUTION Do not allow the rotor to hang
35 ft-lbs (47 Nm).
unsupported for any extended period. 9. Install the exciter stator in the end bell using the
Otherwise, drive disk damage can occur. 1/4-inch bolts and lock washers. Torque to 7 ft-
lb (9 Nm).
23. Attach the hoist and sling to the rotor assembly
and apply a slight lift to support the rotor. Re- 10. Apply a thin film of Molykote grease or equiva-
move the bolts securing the drive disk to the en- lent to the mating surfaces of the end bearing
gine flywheel and remove the rotor from the en- and end bell bearing hole.
gine. Set on wood blocks so fan is not support- 11. Install the end bell assembly, lock washers,
ing any of the rotor weight. and nuts on the studs. Torque nuts to 35 ft-lbs
24. Remove bearing bolt, flat washer, and lock (47 Nm).
washer. Then remove bearing. If required, re- 12. Using a lead hammer, tap the end bell at the
move fan from the rotor. horizontal and vertical plane to relieve stress.
25. Disconnect rotor field leads from heat sinks F1 Retorque end bell stud nuts.
and F2 on the exciter rotor. Remove exciter ro- 13. Install the generator air screen.
tor.
14. Refer to Figure 5-8. Mount and adjust Mechan-
REASSEMBLING THE GENERATOR ical Overspeed Switch.
When installing the overspeed switch assem-
1. If any diodes are replaced in the exciter rotor,
bly (capscrew, lock washer, switch, small flat
secure the new diode using a lock washer and
washers, large flat washer, and spacer) on the
nut, and torque to 12 to 15 in-lbs (1.4 to 1.7
rotor shaft, torque to 53 ft-lbs (72 Nm).
Nm).
2. Slide exciter rotor, sleeve spacer, and press Install the overspeed switch assembly bracket
ball bearing over the generator shaft. Install the and secure using two capscrews and lock
modified hex head bolt, lock washer, and flat washers. Torque to 4.5 ft-lb (6 Nm). Refer to
washer and torque to 60 to 70 ft-lbs (81 to 95 Figure 5-9, and set to proper gap
Nm). Connect overspeed switch lead wire to termi-
3. Place the generator fan in position on the rotor nal on overspeed switch bracket.
shaft. 15. Install the control sheet metal back on the gen-
4. Install the drive disk on the end of the rotor shaft erator.
with the chamfer on the flywheel side. Torque 16. Reconnect the generator as required.

DISK
DISK-TO-ROTOR
BOLT GENERATOR
FAN
DISK-TO-FLYWHEEL
BOLT
ROTOR
EXCITER
ROTOR
MODIFIED HEX
HEAD BOLT
OVERSPEED
SWITCH
STATOR-TO-FLYWHEEL
HOUSING BOLT SLEEVE
SPACER
BALL
BEARING
EXCITER-TO-END
BELL BOLT
GENERATOR
STATOR
OVERSPEED
CONTACT
GENERATOR
ASSEMBLY
AIR SCREEN
EXCITER
STATOR
O-RING
OIL SEAL
END
BELL STUD
FIGURE 5-9. GENERATOR ASSEMBLY

6. Governors and Carburetors
ELECTRIC GOVERNOR ADJUSTMENT 2. Start the set, let the engine warm up under a
partial load (at least 1/4 rated load) and then dis-
If necessary, adjust the gas mixture, the governor connect all loads. (If the governor has been re-
linkage and the magnetic speed pickup unit as placed, adjust the Gain 1 and Stability 1 pots to
instructed in this section before adjusting the gover- their center settings.)
nor controller. Make sure that the governor assem-
bly is securely mounted. Also make sure that the 3. Adjust the Gain 1 pot until the engine is stable
governor linkage does not bind or have excessive and responsive to governor control. (Adjust the
play in it. Gain 1 pot counterclockwise to eliminate hunt-
ing.) Bump the throttle lever a couple of times to
1. Check the dip switch settings (Figure 6-1) to check for hunting. The unit should respond
make sure they are set properly, as follows: quickly but should not hunt.
4. Apply full load to the genset and adjust the Sta-

IGNITION TRIGGER (GOV MOD A378) bility 1 pot to minimize overshoot. (Adjust the
SW1 SW2 SW3 SW4 Stability 1 pot clockwise to increase stability.)
(8CYL) (6CYL) (4CYL) (50/60HZ) Check stability under a range of loads; from no-
load to full-load.
50 Hz OFF ON OFF OFF
60 Hz OFF ON OFF ON 5. Attach a tachometer or frequency meter to the
generator output leads if control panel does not
come equipped with one of these meters. Ad-
MPU TRIGGER (GOV MOD A377)
just the Speed Trim pot until the desired speed
SW1 SW2 SW3 SW4 is obtained.
50 Hz ON OFF OFF OFF 6. Shut down and restart the genset to check for
60 Hz ON OFF OFF ON overspeed shutdown on startup.
GAIN 1
GOVERNOR CONTROLLER
CONNECTIONS SEE STABILITY 1
FIGURE 6-3
SPEED TRIM
SW1
SW2
SW3
SW4 ON POSITION
DIP
SWITCHES
FIGURE 6-1. GOVERNOR CONTROLLER

LINKAGE ADJUSTMENT 2. Verify that the ball joint screw is mounted in the
third hole from the outside end of the governor
Figure 6-2 illustrates the governor linkage. Make arm.
sure that the governor controller is securely
mounted to the engine bracket. To adjust the link-
age:
3. The governor actuator shaft has 60 degrees of
1. With the genset stopped, check the angle of the rotation from stop to stop. Check mounting of
throttle lever and governor actuator. Adjust gov- governor arm and linkage to assure the 60 de-
ernor lever if required. (Throttle is shown in the gree actuator shaft rotation operates the throttle
closed position.) from closed to fully open positions.
BALL JOINT
SCREW
BALL JOINT
SCREW
GASEOUS
CARB
GOVERNOR ROD DETAILS

(SHOWN IN THROTTLE
CLOSED POSITION)
GASOLINE
CARB
THROTTLE
LEVER
GOVERNOR ARM GOVERNOR

OUTSIDE END ROD
FIGURE 6-2. GOVERNOR LINKAGE

MAGNETIC SPEED PICKUP UNIT lines up in the center of the mounting hole. Thread
ADJUSTMENT the pickup in gently by hand until it just touches the
ring gear tooth. Back it out 5/8 turn and set the lock-
With the magnetic speed pickup removed from the
nut.
genset, manually rotate the ring gear until a tooth
TO GOVERNOR
CONTROLLER
MAGNETIC SPEED
PICKUP UNIT
MPU TYPE
GENERATOR
ADAPTER
TO GOVERNOR
CONTROLLER
IGNITION
TYPE
FIGURE 6-3. MAGNETIC SPEED PICKUP UNIT / GOVERNOR CONTROLLER CONNECTIONS

CARBURETORS CAUTION The adjustment screw and seat
are easily damaged. Do not force the adjust-
The engine is equipped with a carburetor to run on ment screw.
regular gasoline and/or a gas mixer to run on natu-
ral gas or propane or both. 2. Start the engine and let the set warm up under
WARNING Fuel is highly flammable and may
a partial load (at least 1/4 rated load) and then
disconnect all loads.
cause severe personal injury and property dam-
age. Do not allow cigarettes, flame, pilot lights, 3. Turn the idle adjustment screw out (counter-
arcing switches or equipment in area or areas clockwise) approximately one half turn and
sharing ventilation. jounce the throttle. If the engine begins to hunt,
turn the adjustment screw in slowly until engine
Gasoline Fuel System speed becomes stable. If one half turn does not
A gasoline carburetor (Figure 6-4) is provided for cause instability, turn the adjustment screw out
gasoline fuel systems. The main and idle mixture, one half turn more and repeat the procedure.
and choke are adjustable on the gasoline carbure- Main Mixture Adjustment: If the adjustment has
tor. The main adjusting needle, at the bottom of the been disturbed or the engine performs poorly under
carburetor, affects operation at heavier load condi- heavy load, make the following adjustments.
tions. the idle adjusting needle, at the side of the
carburetor, affects operation at light and no load 1. Shut off the engine and turn the main adjust-
conditions. ment screw in gently until it bottoms, and then
Under normal circumstances, factory carburetor turn it out 1 turn so that the engine will run.
adjustments should not be disturbed. If adjustments 2. Start the engine and let the set warm up under
have been changed, an approximate setting of a partial load (at least 1/4 rated load) and then
1-1/2 turn open for idle needle and one turn open for apply a full load.
main needle will permit starting. Adjust temporarily
3. Slowly turn needle out until speed no longer
for smoothest running. Allow engine to thoroughly
rises. Try various electrical loads. If engine
warm up before making final adjustment.
speed fluctuates at any load, turn main adjust-
Idle Mixture Adjustment: If the adjustment has ing needle out slightly. Do not turn out more
been disturbed or the engine performs poorly under than 1/2 turn beyond original full load setting.
light load, make the following adjustments. 4. If stable speed cannot be obtained by adjusting
1. Shut off the engine and turn the idle adjustment main adjusting needle, a change in governor
screw in gently until it bottoms, and then turn it sensitivity adjustment will probably be neces-
out 1-1/2 turns so that the engine will run. sary.

IDLE ADJUSTMENT
SCREW
BOWL
DRAIN
PLUG
MAIN
ADJUSTMENT
FIGURE 6-4. GASOLINE CARBURETOR

Choke Adjustment for Gasoline carburetor: The
gasoline carburetor is equipped with an automatic LONG
choke for easier cold weather starting. The choke RAISED
has a bi-metal coil that progressively closes the LINE
choke plate as ambient temperature drops, in prep- ASTERISK
aration for the next start. It also has an electric heat- MARK
ing element that heats the bi-metal coil to fully open
the choke soon after the engine starts.
The choke housing cover can be rotated to adjust
the choke. The perimeter of the cover is graduated
with evenly spaced lines cast in it. One of the lines
has an asterisk (*). For normal adjustments, the as-
terisk (*) should line up with the line cast in the edge
of the housing.
1. For better starting in cold weather, loosen the
three cover screws (Figure 6-5) and rotate the
cover clockwise (richer) so that the asterisk (*)
is one or two lines past the line on the housing
and re-tighten the cover screws.
LOCKING
2. For better starting in warm weather, loosen the SCREWS (3)
three cover screws and rotate the cover coun-
terclockwise (leaner) so that the asterisk (*) is
one or two lines past the line on the housing FIGURE 6-5. ELECTRIC CHOKE
and re-tighten the cover screws.

Gaseous and Combination Fuel Systems varying load conditions (approximately 5 inches
WC for natural gas and 1.5 inches WC for LPG).
An engine equipped for gasoline and natural gas or There is a pressure test port on the supply side if the
propane has a regular gasoline carburetor with a gas mixer for measuring fuel inlet pressure.
gas mixer mounted on the horn of the carburetor.
The carburetor throttle serves both fuels. Each fuel The maximum permissible fuel supply pressure
has a separate shutoff solenoid valve. The position is 20 inches WC and the minimum is 7 inches
of the fuel selector switch (mounted at the base of WC. This applies to LPG as well as to natural gas.
the carburetor) determines which solenoid valve The minimum pressure refers to supply pressure
will open for operation. under rated load (maximum gas flow). There is a
pressure test port on the supply side of each fuel
An engine equipped for natural gas and propane regulator for measuring fuel supply pressure.
has a gas mixer that serves both fuels. Each fuel
has a separate shutoff solenoid valve and either a Choke Adjustment for Combination Carbure-
manual fuel selector switch or a fuel pressure tor: If the engine is equipped with a combination
switch for automatic fuel changeover. (While the en- carburetor, see that the gasoline shut-off valve is
gine is running, the gas pressure switch causes the closed. The electric choke (Figure 6-5) must be ad-
natural gas solenoid valve to close and the propane justed so the adjustable cover is turned 10 to 12
solenoid valve to open when natural gas pressure is notches counterclockwise from the asterisk (*)
lost, without stopping the engine. When natural gas mark. When properly adjusted, the electric choke
pressure is restored, the natural gas solenoid valve will be completely open even at very low tempera-
opens and the propane solenoid valve closes.) tures.
Gas Pressure: The fuel regulators in each line pro- Gas fuel main adjustment should be made only
vide constant gas pressure at the gas mixer under when a full electrical load is applied to the genset.
GASOLINE AND NATURAL GAS
NATURAL GAS AND LPG LIQUID
FIGURE 6-6. COMBINATION FUEL SYSTEMS

Gaseous Fuel Adjustments: Gas mixers have
GAS MIXER
power and idle adjustment screws. Engines
equipped for natural gas and propane also have a
propane flow adjustment valve. If necessary, make
the following adjustments.
1. Start the engine and let the set warm up under
a partial load (at least 1/4 rated load). If the en-
gine is equipped for natural gas and propane,
start with natural gas.
2. Disconnect all loads, shut down the set, con-
nect a tachometer and disconnect the gover- IDLE
nor linkage at the carburetor. Start the engine ADJUSTING
and close the throttle by hand so that the en- POWER SCREW
gine does not overspeed. While holding the ADJUSTING
SCREW
throttle closed, adjust the throttle idle position
screw (the one next to the throttle lever) to ob-
tain an engine speed of 900 RPM. Then turn
the idle adjusting screw counterclockwise until THROTTLE
LEVER
engine speed becomes unstable. Turn the
screw clockwise just enough to regain stability
and reconnect the governor linkage.
PROPANE FLOW ADJUSTMENT VALVE
3. Next, connect full rated load and turn the power
adjusting screw clockwise until the engine be-
gins to lose speed and then slowly back out the
screw (counterclockwise) until the engine car-
ries the full load smoothly.
4. If the set is equipped for natural gas and pro-
pane, switch to propane by means of the con-
trol panel switch (if provided) or by closing the
manual shutoff valve in the natural gas supply
line. FIGURE 6-7. GASEOUS FUEL ADJUSTMENTS
5. Reconnect full rated load and turn the propane
flow adjustment valve clockwise until the en-
gine begins to lose speed and then slowly turn
it back counterclockwise until the engine car-
ries full load smoothly.

7. Wiring Diagrams
This section consists of the schematic and connec- Page 7-4 AC Wiring (with meters)
tion wiring diagrams referenced in the text. Page 7-5 7-light DC Wiring (Sheet 1 of 2)
The following diagrams are typical. Your genset may Page 7-6 7-light DC Wiring (Sheet 2 of 2)
differ. Wiring and component specifications are sub- Page 7-7 12-light DC Wiring (Sheet 1 of 2)
ject to change. Contact your Distributor if you do not
have the wiring diagrams applicable to your equip-
Page 7-8 12-light DC Wiring (Sheet 2 of 2)
ment. Pages 7-9 Reconnection Diagram
Page 7-10 Typical Connections to the ECM
The following drawings are included:
Page 7-11 Customer Connections at the Aux-
Page 7-2 Voltage Regulator (VRAS-2) Instal- iliary Relay Board
lation Page 7-12 Engine Harness
Page 7-3 AC Wiring (without meters) Page 7-13 DC Harness

VOLTAGE REGULATOR (VRAS-2) INSTALLATION

THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6489 sh 1 of 1
Rev. H Sys: CADAM
Modified 10/3/95
AC WIRING (WITHOUT METERS)
No. 612-6490 sh 1 of 1
Rev. S Sys: CADAM
Modified 10/3/95
AC WIRING (WITH METERS)
No. 612-6684 sh 1 of 2
Rev. A Sys: CADAM
Modified 9-26-95
7-LIGHT DC WIRING (SHEET 1 OF 2)

No. 612-6684 sh 2 of 2
Rev. A Sys: CADAM
Modified 9-26-95
7-LIGHT WIRING (SHEET 2 OF 2)

No. 612-6685 sh 1 of 2
Rev. A Sys: CADAM
Modified 9-27-95

No. 612-6685 sh 2 of 2
Rev. A Sys: CADAM
Modified 9-27-95

No. 625-2068 sh 1of 1

Rev. B Sys: CADAM
Modified 10/2/95
RECONNECTION DIAGRAM
TB1-10 (SWITCHED B+ OUTPUT) OUTPUT TO RELAY K12, FUSED AT 20 AMPS, ENERGIZED WHEN THE
START SIGNAL IS APPLIED AND DE-ENERGIZED AT SHUTDOWN (NORMAL AND FAULT)
+ K12
TB1-9 (B+ INPUT) BATTERY POSITIVE (+) CONNECTION
TB1-8 (START SOLENOID) OUTPUT TO RELAY K11, FUSED AT 20 AMPS

K11
A15
TB1-7 (B+ OUTPUT) OUTPUT TO TIME DELAY START/STOP MODULE A15,
FUSED AT 15 AMPS, AVAILABLE WHEN THE STARTING BATTERIES ARE CONNECTED
TB1-6 (REMOTE START) CONNECTED TO TIME DELAY START/STOP MODULE A15. CONNECT REMOTE START
CONTACT OF THE AUTOMATIC TRANSFER SWITCH TO TERMINAL TB1-5 OF MODULE A15.
TB1-5 (GROUND)
TB1-4 (COMMON ALARM B+ OUTPUT) 4 AMP RATED DEVICE MAXIMUM
TB1-3 (RUN) CONNECTED TO TIME DELAY START/STOP MODULE A15
TB1-2 (DC DISCONNECT) CONNECTED TO TIME DELAY START/STOP MODULE A15

TB2-1 (FAULT 2) GROUND INPUT FROM SENDER

TB2-2 (FAULT 2) GROUND OUTPUT TO LIGHT/RELAY*
TB2-3 (FAULT 1) GROUND INPUT FROM SENDER
TB2-4 (FAULT 1) GROUND OUTPUT TO LIGHT/RELAY*
TB2-5 (REMOTE RESET) MOMENTARY CONTACT TO GROUND
TB2-6 (OVERCRANK FAULT) GROUND OUTPUT TO LIGHT/RELAY*
TB2-7 (OVERSPEED FAULT) GROUND OUTPUT TO LIGHT/RELAY*
TB2-8 (HIGH ENGINE TEMPERATURE FAULT) GROUND OUTPUT TO LIGHT/RELAY*
TB2-9 (LOW OIL PRESSURE FAULT) GROUND OUTPUT TO LIGHT/RELAY*
TB2-10 (PRE-HIGH ENGINE TEMPERATURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*
TB2-11 (PRE-LOW OIL PRESSURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*

CUSTOMER SUPPLIED WIRING
TB2-12 (SWITCH OFF WARNING) GROUND OUTPUT TO LIGHT/RELAY*
FACTORY WIRING
TB2-13 (LOW ENGINE TEMPERATURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*
* 0.5 AMP RATED DEVICE MAXIMUM
TB2-14 (LOW FUEL WARNING) GROUND INPUT FROM SENDER
TB2-15 (LOW FUEL WARNING) GROUND OUTPUT TO LIGHT/RELAY*

TB2-16 (EMERGENCY SHUT DOWN) MOMENTARY CONTACT TO GROUND
FACTORY AND CUSTOMER CONNECTIONS AT THE ENGINE MONITOR BOARD TERMINALS

710 Redistribution or publication of this document
THE TERMINALS IN THE SHADED BOXES ARE FOR CUSTOMER CONNECTIONS THIS IS A REPRESENTATIVE (GENERIC)
WIRING DIAGRAM PACKAGENO.THAT WAS
3004111
REV. B
MODIFIED
625-2712
CUSTOMER CONNECTIONS AT THE AUXILIARY RELAY BOARD

711 Redistribution or publication of this document
LEAD TABULATION
FROM TO
STATION STATION
No. 336-3322 sh 1 of 1
Rev. A Sys: CADAM
Modified 9-26-95
ENGINE HARNESS
No. 338-3326 sh 1 of 1
Rev. A Sys: CADAM
Modified 9-27-95
DC HARNESS
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.
Redistribution or publication of this document


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SECTION TITLE PAGE

i Redistribution or publication of this document

5 SERVICING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

ii Redistribution or publication of this document

iv Redistribution or publication of this document

1-1 Redistribution or publication of this document

1-2 Redistribution or publication of this document

GENERAL meter is from current transformers CT21, CT22 and

FIGURE 2-1. AC CONTROL PANEL

2-1 Redistribution or publication of this document

2-2 Redistribution or publication of this document

TABLE 2-1. VRAS-2 SWITCH SETTINGS

20-35 OFF OFF

TORQUE MATCHING MODE

POS 2 OFF ON POS 2 ON ON POS 2 OFF OFF POS 1 OFF OFF

2-3 Redistribution or publication of this document

FIGURE 2-2. VOLTAGE REGULATOR ADJUSTMENT POTS AND SELECTION JUMPERS

2-4 Redistribution or publication of this document

FIGURE 2-3. TYPICAL VOLTAGE REGULATING CIRCUIT

2-5 Redistribution or publication of this document

VRAS-2 ELECTRICAL POWER OUTPUT

FIGURE 2-4. SCHEMATIC OF GENERATOR OPERATION

2-6 Redistribution or publication of this document

OIL PRESSURE RUN/STOP/REMOTE PANEL RESET/LAMP TEST/

OIL TEMPERATURE TACHOMETER EMERGENCY STOP

FIGURE 3-1. ENGINE CONTROL PANEL

3-1 Redistribution or publication of this document

Overspeed (Red) This lamp indicates that the

3-2 Redistribution or publication of this document

3-3 Redistribution or publication of this document

RUN RELAYS K11

FIGURE 3-3. ARRANGEMENT OF COMPONENTS INSIDE THE CONTROL BOX

CONTROL BOX INTERIOR Fuses

3-4 Redistribution or publication of this document

3-5 Redistribution or publication of this document

PRE-LOW OIL PRESSURE

FIGURE 3-5. ENGINE SENSOR LOCATIONS

3-6 Redistribution or publication of this document

TO ECM TB2-8 (HIGH ENGINE TEMP), OR

FIGURE 3-6. LOW COOLANT LEVEL SWITCH

3-7 Redistribution or publication of this document

GAUGE AND PCB CONNECTIONS

FIGURE 3-7. COOLANT TEMPERATURE GAUGE

3-8 Redistribution or publication of this document

FIGURE 3-8. OVERSPEED SWITCH ASSEMBLY

3-9 Redistribution or publication of this document

3-10 Redistribution or publication of this document

J1 AND J2 WIRE TB6, TB7 AND

FIGURE 3-9. AUXILIARY RELAY BOARD (ARB)

3-11 Redistribution or publication of this document

3-12 Redistribution or publication of this document

FIGURE 3-11. OVER/UNDER FREQUENCY

3-13 Redistribution or publication of this document

TIME DELAY START TIME DELAY STOP POTENTIOMETER

FIGURE 3-12. TIME DELAY START/STOP MODULE

3-14 Redistribution or publication of this document

* On older ECM boards (those having cartridge-type fuses):