Manual Detector DL4

onon Manual
$- MODEL SERIES
DGAB DL4 4A2.3-GS QSA3
DGAC DL6 6A3.4-GS QSA4
DGAD DL6T 6AT3.4-GS QSA6
DGAE
GENERATOR AND DETECTOR CONTROL
Printed in USA. 934-0502 3-91

Safety Precautions
Before operatlng the generator set, read the Operator's Do not wear loose clothing or jewelry in the vicinity of mov-
Manual and become familiar with it and the equipment. Safe ing parts, or while working on electrical equipment. Loose
and efficient operation can be achieved only If the e q u i p clothing and jewelry can become caught in moving parts.
ment Is properly operated and maintained. Many accidents Jewelry can short out electricalcontacts and cause shock
are caused by failure to follow fundamental rules and precau- or burning.
tions.
If adjustment must be made while the unit is running, use
The following symbols, found throughout this manual, alert you extreme caution around hot manifolds, moving parts, etc.
to potentiallydangerous conditions to the operator, service per-
sonnel, or the equipment. ELECTRICAL SHOCK CAN CAUSE SEVERE PER-
SONAL INJURY OR DEATH
. B. Thls symbol warns of Immediate haz- Remove electric power before removing protective shields
ards whlch will result In severe personal Injury or or touching electrical equipment. Use rubber insulative
death. mats placed on dry wood platforms over floors that are
metal or concrete when around electrical equipment. Do
~ W A R N ~Thls
G ~symbol refers to a hazard or unsafe not wear damp clothing (particularly wet shoes) or allow
practlce whlch can result In severe personal Injury skin surface to be damp when handling electrical equip-
or death. ment.
Use extreme caution when working on electrical compo-
jirc~UTlON/Thissymbol refers to a hazard or unsafe nents. High voltages can cause injury or death. DO NOT
practlce whlch can result In personal Injury or prod- tamper with interlocks.
uct or property damage. Follow all applicable state and local electricalcodes. Have
all electrical installations performed by aqualified licensed
FUEL AND FUMES ARE FLAMMABLE. Fire and explosion electrician. Tag open switchesto avoid accidental closure.
can result from improper practices.
DO NOT CONNECT GENERATOR SET DIRECTLY TO
DO NOTfill fuel tankswhile engine is running, unlesstanks ANY BUILDINGELECTRICALSYSTEM. Hazardousvolt-
are outside the engine compartment. Fuel contact with hot ages can flow from the generator set into the utility line.
engine or exhaust is a potential fire hazard. This creates a potential for electrocution or property dam-
age. Connectonly through an approved isolation switch or
DO NOT permit any flame, cigarette, pilot light, spark, or an approved paralleling device.
other ignition source near the generator set or fuel tank.
GENERAL SAFETY PRECAUTIONS
Fuel lines must be adequately secured and free of leaks.
Fuel connection at the engine should be made with an ap- Coolants under pressure have a higher boiling point than
proved flexible line. Do not use copper piping on flexible water. DO NOT open a radiator or heat exchanger pres-
lines as copper will become brittle if continuously vibrated sure cap while the engine is running. Allow the generator
or repeatedly bent. set to cool and bleed the system pressure first.
Be sure all fuel supplies have a positive shutoff valve. Benzene and lead, found in some gasoline, have been
identified by some state and federal agencies as causing
Do not smoke while servicing lead acid batteries. Lead
acid batteries emit a highly explosive hydrogen gas that cancer or reproductive toxicity. When checking, draining
or adding gasoline, take care not to ingest, breathe the
can be ignited by electrical arcing or by smoking.
fumes, or contact gasoline.
EXHAUST GASES ARE DEADLY Used engine oils have been identifiedby some state orfed-
Providean adequate exhaust system to properly expel dis- era1 agencies as causing cancer or reproductive toxicity.
charged gases. Visually and audibly inspect the exhaust When checking or changing engine oil, take care not to in-
daily for leaks per the maintenance schedule. Ensure that gest, breathe the fumes, or contact used oil.
exhaust manifolds are secured and not warped. Do not
Provide appropriate fire extinguishers and install them in
use exhaust gases to heat a compartment.
convenient locations. Consult the local fire department for
Be sure the unit is well ventilated. the correct type of extinguisher to use. Do not use foam on
electrical fires. Use extinguishers rated ABC by NFPA.
MOVING PARTS CAN CAUSE SEVERE PERSONAL
Make sure that rags are not left on or near the engine.
INJURY OR DEATH
Remove all unnecessary grease and oil from the unit. Ac-
Keep your hands, clothing, and jewelry away from moving cumulated grease and oil can cause overheating and en-
parts. gine damage which present a potential fire hazard.
Beforestarting work on the generator set,disconnect start- Keep the generator set and the surrounding area clean
ing batteries, negative (-) cable first. This will prevent acci- and free from obstructions. Remove any debris from the
dental starting. set and keep the floor clean and dry.
Make sure that fasteners on the generator set are secure. Do not work on thisequipmentwhen mentally or physically
Tighten supports and clamps, keep guards in position over fatigued, or after consuming any alcohol or drug that
fans, drive belts, etc. makes the operation of equipment unsafe.
LS-9
Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Front Cover
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How To Obtain Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
ACCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
DCCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
ControlOperation ................................................. 3-9
ENGINE CONTROL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
TroubleshootingTables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Engine Cranks But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Engine Starts But Stops After Running Several.Seconds . . . . . . . . . . . . . . . . . 4-5
Engine Generator is in Operation, Then a Fault Shutdown Occurs . . . . . . . . . . 4-7
Tests ........................................................... 4 8
GENERATOR AND VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1
Generator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1
Generatoroperation .............................................. 5-2
VoltageRegulator ................................................. 5 3
CircuitBreaker ................................................... 5-5
GENERATORIREGULATOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6-1
ComponentLocation .............................................. 6-1
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TrouMeshootingCharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
No AC Output Voltage at Rated Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Unstable AC Output Voltage, Engine Stable at Rated Speed . . . . . . . . . . . . . . 6-4
AC Output Voltage Too High or Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Exciter Field Breaker Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Unbalanced AC Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
No AC Output Through Set Mounted Circuit Breaker . . . . . . . . . . . . . . . . . . . . 6-7
GENERATORIREGULATORTESTSIADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . 7-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
{A] Testing AC Residual Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
[B] Flashing The Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
[C] AC Voltage Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
[Dl Testing Rotating Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
[El Testing Exciter Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
[FJ Testing Exciter Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
[GI Testing Main Rotor Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
SECTION TITLE PAGE
[HI Testing Main Stator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
[J1 Wiring Harness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
[Kj Voltage Regulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
[L] Voltage Adjust Potentiometer R21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
[MI Testing AC Load Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
GENERATOR DISASSEMBLYIASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
Trailer Option (QSA-Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Diesel Fuel Tank Control System (QSA Gensets) . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Voltage Reconnection Panel (QSA Gensets) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Fan Belt Replacement Procedure (QSA Gensets) . . . . . . . . . . . . . . . . . . . . . . .9-21
WIRING DIAGRAMS, CONTROUGENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Section 1. Introduction
ABOUT THIS MANUAL Information for printed circuit board repair is limited.
For servicing purposes, the genset can be divided into The solid state boards lend themselves more to field
three basic parts: engine, generator, and controi. This replacement than repair. Application of meters or hot
manual containstroubleshooting and repair information soldering irons to printed circuit boards by other than
for the generator and control. Refer to the applicable qualified personnei can cause unnecessary and expen-
Engine Service Manual for servicing the engine. sive damage. Repair of the printed circuit boards is not
recommended.
Study this manual carefully and observe all warnings
and cautions. It is extremely important that the genset HOW TO OBTAIN ASSISTANCE
installation maintain compliance with the applicable When seeking additional service information or
codes and standards.The most critical areas of concern replacement parts, always give the complete model and
include the exhaust system, fuel system, electrical wir- serial number as shown on the genset data tag or
ing, and ventilation system. Improper servicing can nameplate. The genset data tag or nameplate is on the
create an unsafe installationthat can result in damage to A.C. output box.
the equipment or can cause severe personal injury or
death to the users.
TEST EQUIPMENT
Refer to the genset Operators's Manual as an additional Most of the test procedures in this manual can be per-
source of information. This Service Manual covers formed with a multimeter like the Simpson Model 260
many models, and the components and options listed VOM, or a digital VOM. Other instrumentsthat should be
might not apply to all models. available are:
Always use genuine Onan replacement parts obtained AC Voltmeter

from an authorized Onan Dealer or Distributor. Univer- DC Voltmeter
sal replacement parts may look similar but might not Frequency Meter
perform to Onan specifications. Only genuine Onan Jumper Leads
replacement parts are designed and tested for the Load Test Panel
application to provide reliable service and dependable Variac
operation. Tachometer or Strobotach
Megger or Insulation Resistance Meter
Wheatstone Bridge or Digital Ohmmeter
See Onan Tool Catalog 900-0019.
INCORRECTSERVICE OR REPLACEMENT OF PARTS CAN RESULTIN SEVERE

PERSONAL INJURY. DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PER-
SONNEL MUST BE QUALIFIED TO PERFORM ELECTRICALAND MECHANICAL
SERVICE.
Section 2. AC Control
CONTROL DESCRIPTIONS Phase Selector Switch: Selects phases of generator
The control cabinet has an AC panel for generator- output measured by AC voltmeter and AC ammeter.
related components on the left side, Figure 2-1. A DC
panel for engine-related components is on the right side Upper and Lower Scale Indicator Lamps: Indicates
(see Section 3, DC Control). which scale to use on the AC voltmeter and ammeter.
UPPER AND CONTROL PANEL INTERIOR

LOWER SCALE
INDICATOR LAMPS
The following describes the internal components and
VOLTAGE I their function.
Voltage Regulator
The voltage regulator circuit is connected directly to the
AC generator. Because it regulates excitation in
DUAL RANGE responseto generator output, the regulator is covered in
AC VOLTMETER detail in Section 6, Generator and Voltage Regulator.
Control Heater
DUAL RANGE The optional control heater providesa means of humidity/
AC AMMETER temperature control for the control box interior. The
heater protects the components from varying environ-
mental conditions during extended periods of nonuse.
The heater element is controlled by an adjustable ther-
mostat. See Figure 2-2. The resistance of the element is
192 ohms, and dissipates 75 watts at 120 VAC.
PHASE SELECTOR WATTMETER

SWITCH
sim
HEATER
ELEMENT
FIGURE 2-1. AC CONTROL PANEL
The components shown in Figure 2-1 are optional,

except for the field breaker. They are as follows:
AC VoltmetecDual range instrument indicating genera-

tor AC voltage. Measurement range in use shown by the ....
indicator lamp.
,
TO 120 VAC
ACAmmetecDual range instrument indicating genera- '.......
tor AC current. Measurement range in use shown by the
indicator lamp.
ES-1563-4
Frequency Meteclndicates generator output frequency
in hertz. It can be used to check engine speed (each FIGURE 2-2. TYPICAL CONTROL HEATER
hertz equals 30 r/min).
Wattmeter (optional): lndicates generator output in

kilowatts.
Voltage Adjust: Rheostat providing about plus or minus

five percent adjustment of the rated output voltage.
Field Breaker Provides generator exciter and regulator

protection from overheating in the event of a failure
mode of the generator, exciter, and voltage regulator.
Section 3. DC Control
CONTROL DESCRIPTIONS Speed Adjust Potentiometer (Optional): Operator co-: -
trol for adjusting engine speed (available only with
A typical DC control panel with options is shown in
optional electronic governor).
Figure 3-1. The right side DC panel is for engine-related
components, and the left side AC panel is for generator-
related components (see Section 2, AC Control). Run/Stop/Remote Switch: Starts and stops the genset
locally, or from a remote location wired to the control
OIL PRESSURE engine monitor board.
GAUGE
PANEL
I LAMP
RESETILAMP TESTIPREHEATI
PANEL LAMP SWITCH Preheat, Lamp Test, Reset/Panel Lamp Switch: Multi-
( RUNISTOPI
REMOTE SWITCH / ple function switch used to provide momentary warm-
up of glow plugs, test the fault lamps, and reset the fault
circuits when the Run/Stop/Remote switch is in the
stop (reset) position. This switch is also used to turn on
the control panel lamp. Some models might not have the
preheat function.
Emergency Stop Switch (Optional): Round, red, push1-

pull switch used for stopping the genset when pushed
in. Pull out to reset.
Running Time Metec Registers the total number of

hours that the genset has run. Use it to keep a record for
TACHOMETER
(OPTIONAL)
periodic servicing. Time is cumulative and cannot be
reset.
RUNNING TIME Control Panel Lamp: Convenience lamp that illumi-

nates control panel for the operator.
Indicator Lamps
Depending on the genset model and the options
ordered, the control might have a 4-, 7-, lo-, or 12-lamp
EMERGENCYSTOP BUTTON monitoring system. Refer to the applicable lamp des-
(OPTIONAL)
criptions that follow. Red lamps when lit indicate genset
shutdown.
FIGURE 3-1. DC CONTROL PANEL
RUN (green) This lamp comes on when both starter-
The components shown in Figure 3-1 are standard disconnect circuits are opened after genset start.
unless identified as optional in the following descrip-
tions. The panel has 4, 7, 10 or 12 indicator lamps. PRE LO OIL PRES (yellow) lndicates engine oil
pressure is marginally low.
Oil Pressure Gauge: lndicates lubricating oil pressure
in the engine (wired to a sensor unit on the engine). PRE HIGH ENG TEMP (yellow) lndicates engine
temperature is marginally high.
Water Temperature Gauge: lndicates temperature of
circulating coolant in the engine (wired to a sensor unit LOW OIL PRES (red) lndicates engine has shut
on the engine). down because of critically low oil pressure.
Battery Charge Rate DC Voltmetec Indicatesthe battery HI ENG TEMP (red) lndicates engine has shut down
charging voltage. because of critically high engine temperature, or a
low coolant level.
Oil Temperature Gauge (Optional): lndicates tempera-
ture of lubricating oil in the engine (wired to a sensor unit OVERSPEED (red) lndicates engine has shut down
on the engine). because of excessive speed.
Tachsmeter(0ptional):Providesconstant monitor of engine OVERCRANK (red) lndicates the starter has been
r/min. locked out because of excessive cranking time.
LOW ENG TEMP (yellow) lndicates the engine CONTROL PANEL INTERIOR
temperature is marginally low for starting. lndicates
The following describes the engine control components
inoperative coolant heater on gensets with this
option. and how they function (Figures 3-1, 3-2). Some of the
following descriptions may not apply depending on
LO FUEL (yellow) lndicates fuel supply is marginally options included on each individual control system.
low. Engine Control Monitor (ECM-All)
This solid state printed circuit board monitors basic
SWITCH OFF (flashing red) lndicates genset is not engine control system functions (Figure 3-3). This
in automatic start operation mode.
includes starting, stopping, and fault system operation.
Terminal blocks are included for making remote con-
FAULT 1 (red) A customer installed auxiliary equip- nections and adding further control options.
ment fault switch. The lamp is part of the timed
factory-set (10 second) shutdown circuit.
The ECM provides the following functions for genset
FAULT 2 (red) A customer installed auxiliary equip- protection:
ment fault switch. The lamp is part of the factory set,
non-timed delayed shutdown circuit. Overcrank: Limits engine cranking to 75 seconds. If
engine fails to start, the module lights a fault lamp and
opens the cranking circuit. The cycle cranking option
allows three 15-second cranking cycles with two 15-
second rest periods on 10- and 12-light controls.
OVERIUNDER VOLTAGE SENSOR

A1 7
TERMINAL INTERFACE TIME DELAYED STARTISTOP

BOARD TB21 RELAY MODULE AND PREHEAT A15
A1 4
FIGURE 3-2. CONTROL INTERIOR (WITH OPTIONS)
3-2
0verspeed:Shuts down the engine immediately if over- Pre-Low Oil Pressure: Sensor and lamp option pro-
speed occurs and turns on the fault lamp. The sensor vides an alarm indicating that oil pressure is marginally
switch is mounted in the end bell on the generator shaft. low, 20 psi (138 kPa) or less. The cause should be found
It is factory adjusted to shut down 1800 r/min gensets at and corrected as soon as possible. This fault is delayed
2200 f100 r/min, and 1500 r/min gensets at 1900 +I00 with low oil pressure functio:,.
rlmin.
High Engine Temperature: Shuts down the engine
Low Oil Pressure:Shuts down the engine immediately if immediately if coolant temperature rises above 222°F
oil pressure drops below 14 psi (97kPa) and turas on a (106°C)and turns on a fault lamp. The fault is time
fault lamp. The fault is time delayed about 10 seconds delayed about 10 seconds following starter disconnect
following starter disconnect and is inhibited during and is inhibited during cranking. This delay allows cool-
cranking. The delay allows oil pressure to rise to normal ant in a hot engine time to circulate and return the water
before the electronic control module monitors the jacket temperature to normal before the electronic con-
pressure. trol module monitors the system.
BLOCk D I A G R A M
LO F U E L
I SW O F F
I
LET -4 TB1-6 IS SIGNAL MODE SELECTABLE AS FOLLOWS:
P R L LOP
W3 8 W4 POSITION REMOTE START SIGNAL

A GND TO START
B B+ TO START
PRE LOP
P2-283 ARE FUNCTION MODE SELECTABLE AS FOLLOWS

SHUTDOWN
SW OF1 B e
srop
LAMP TEST ' R E S E T
44 :\, F 4
>!I
SW OFF
LO F U F L
P2-2:W7 P2-3:W6 POSITION
A
FUNCTION MODE
NON-SHUTDOWN
B SHUTDOWN
p : : ; : : ; :
RMT
ALT S l A R T DISC F' I

O I L PRESS
0 5 IN
OC DISC I N
S T A R T SOL
PI 6
-7
nRnuun
FIGURE 3-3. ENGINE CONTROL MONITOR
3-4
Pre-High Engine Temperature:Sensor and lamp option
provides an alarm that engine temperature is marginally
high, 202°F (94°C). The cause should be found and
corrected as soon as possible. This fault is delayed with
the high engine temperature function.
The high engine temperature shut-

]=[ down system will not operate i f cool-
ant level is low, and the engine does not have the low
coolant sensor option. The high engine temperature
sensor monitors coolant temperature. Loss of coolant
will prevent sensor operation and allow the engine to
overheat andcause severe engine damage. Therefore,
maintain adequate coolant levelfor proper operation of
the high engine temperature shutdown system.
-
Low Coolant Level an optional solid-state sensor/
K l t RELAY
switch that provides engine shutdown if coolant level
falls too low. It also turns on the high enginetemperature
fault lamp.
Low Engine Temperature: Lamp comes on when water

jacket temperature is 70°F (21"C) or lower. Lamp turn- K11 BLOCK DIAGRAM
on should be no cause for alarm, even during initial
genset operation, since the lamp should go out after the
coolant warms up. It indicates an inoperative coolant
heater on gensets with this option.
Run Relay (K11)

This relay option, Figure 3-4, provides wiring connec-
tions for external functions of the site installation. The
relay operates functions that are controlled by the start-
ing and/or stopping of the genset such as ventilation air
louvres, blowers, etc. The terminals on the relay base
provide for either closing or opening a circuit upon
energizing or de-energizing. The run relay is energized
when the genset starts by connecting it to the ECM
switched B+ terminal TB1-10. Up to three run relays can
be used to operate external functions.
FIGURE 3-4. RUN RELAY

Interface Relay Modules (A13, A14)
These optional relay modules are used to provide exter-
nal monitoring of the genset at the customers control
panel (Figure 3-5). As add-on circuit boards, they inter-
face with the remote annunciator signals from the
engine control monitor and allow the use of either AC or
DC for alarm drives. The relays are configured for low
side switching by the control and supply sets of contacts
for external alarm connections.
A13
TBZ
-5 All-TB1J
0-
mEm
LOP 8
@
nm g
FAULTIl
FAULT%?
LET
LOW FUEL
SWITCH OFF
- 2 " - - -
PCB ASSY -ALARM R E L A Y 112VI
FIGURE 3-5. INTERFACE RELAY MODULES
3-6
Time Delayed Start/Stop, and Preheat Module
(A15)
BLOCK DIAGRAM This optional module includes the preheat feature with
B.
the time delayed start/stop option. See Figure 3-6. The
functions are as follows.
Preheat: The preheat circuit provides a signal during

time delayed start and during cranking to activate the
SECONDARY I T A R T D l i L
4
2 engine glow plugs.
Delayed Starting: The time delay start function pre-

cludes automatic start-up of the genset for a determined
amount of time (adjustable from 1 to 15 seconds). It is
used for installationsthat might experience power inter-
ruptions of short duration, and not want the genset to
T E R M I N A L t5 IS I I L N A L M O D E S t L E C T A B L E AS FOLLOWS
start.
R U N SIGNAL I N MODE
De1ayedStopping:The time delay stop function (adjust-
-- - - -- able from 1 to 15 minutes) provides for automatic cool-
down running of the genset for a preset amount of time
(approximately 3 to 5 minutes is recommended).
PCB A S S Y - T D S T 8 S P P H T ( 1B 2 V I
R E V C WI
R I c.w.
- -
T O INCREASE R2
A
W2 B A
CRI a START DELAY STOP D E L A Y I
FIGURE 3-6. PREHEAT MODULE WITH OPTIONAL TIME DELAYED STARTISTOP

Magnetic Pickup Interface Module (A16)
The optional magnetic pickup module, Figure 3-7,
senses engine speed and provides a starter disconnect BLOCK D I A G R A M
signal and an engine overspeed signal. Engine speed is B +
sensed using a magnetic pickup mounted on the end-

bell and a toothed wheel mounted on the rotor shaft. A
signal LED (DS1) provides an indication that a usable
START
input signal is received from the magnetic pickup. DISCONNECT
MAGNET
PICKUP
The magnetic pick-up module is designed to operate at
the following preset output values: OVERSPEED
Start Disconnect: 510 f60 r lmin

Overspeed Trip Point: 2200 rlmin f8 percent for t GND
50 or 60 Hz.
The starter reconnect value is from 0 to 30 rlmin, and

the overspeed reconnect is 50 percent of the trip point.
FIGURE 3-7. MAGNETIC PICKUP INTERFACE MODULE

CONTROL OPERATION During genset operation, all safety systems function to
Because of the many different control options and com- protect and monitor the genset. At the end of the genset
binations, the following operating descriptions will duty cycle, the generator output is disconnected from
cover all options. Read the sections that apply to gain a the load and the remote run signal is discontinued. The
full understanding of the options and how they interact time delayed stop function of module A1 5 will continue
with the ECM (engine control monitor). the genset run time for the prescribed engine cool-
down period of 5 minutes before deactivating the run
If you are reviewing this operation information for trou- circuits of the ECM.
bleshooting purposes, be sure to eliminate all other
malfunction checks external to the control prior to trou- Starter-Disconnect Operation
bleshooting the control. This control requires two means of starter disconnect to
protect the starter in case one means should fail. The
Regardless of the type of control on the set, the ECM first uses a DC relay (K14). A B+ signal taken from the
includes the shutdown fault commands. Controls with battery charging alternator energizes this relay to dis-
options provide prealarm of the shutdown faults, time connect the starter. The second method uses an AC
delayed starting and stopping, and additional monitor- relay (K1O).Voltage from the generator energizes K10 to
ing and control features that are all controlled through provide a back-up to the DC relay.
the ECM.
The control uses this method to provide uninterrupted
Starting Sequence genset operation even if only one means of start discon-
Manual: For cold weather starting of the genset, the nect is operational. However, the local Run lamp does
preheat switch S11 (if used) is held in the preheat posi- not turn on unless both start disconnect relays operate.
tion for the necessary period of time (30 seconds maxi- If the genset is equipped with a remote Run lamp, the
mum). This energizes the glow plug solenoid and the operator can then determine which means of start dis-
plugs. The starting sequence begins by placing the connect has failed for such an occurrence. If the remote
RunIStoplRemote Switch (S12) in the Run position. Run lamp turns on and the local Run lamp does not, the
DC relay is not functioning.
Placing S12 in the Run position energizes the ECM Run
Relay (K7).By energizing K7, B+ is supplied through the All power paths leaving the ECM are protected by fuses
electrical circuits of the ECM to energize the engine run so that the circuit board paths are protectedfrom exces-
circuits (i.e. fuel solenoid), front panel gauges, and the sive current. These fuses are described below.
starter solenoid (through K3).
F1 - Starter circuit fuse (20-ampere) protects circuit
The engine cranking period is determined by the Over- board, K3 and associated wiring.
crank Timer and Cycle Crank Relay (K12). They control
energizing and deenergizing of power relays K2 and K3 F2 - Switched B+ fuse (20-ampere) protects circuit
that supply current to the starter and fuel solenoids. board, K2 and associated wiring.
Automatic: With S12 in the Remote position, a start F3 - B+ out fuse (15-ampere) to protect circuit board.
command to the control activates the Time Delayed
StartIStop and Preheat Module (A15), which initializes F4 - Main ECM circuit fuse (5-ampere)to protect circuit
its time delay start and preheat period. board paths and components on the ECM.
Upon completion of the time delay startlpreheat period, F5 - Gauge fuse (5-ampere) to protect circuit board,
the ECM begins the cranking and startup by energizing gauges on the front panel, and all associated wiring.
Run Relay (K7) as described in Manual starting.
High Engine Temperature (HET) and Low Oil Pressure
After the engine successfully cranks and the starter (LOP) faults are time delayed about 10 seconds follow-
disconnects, input signals from either start disconnect ing starter disconnect and are inhibited during crank-
system of the ECM will activate the Start Disconnect ing. This allows the coolant in a hot engine some time to
Relay of Module A1 5 (K1).This deactivates the preheat circulate and return the water jacket to normal tempera-
output and programs the module for Time Delayed Stop ture before the ECM begins monitoring it. It also allows
mode. the oil pressure to build to normal before monitoring this
system. Following this delay, these faults become
immediate shutdowns for engine protection.
If conditions are correct, the engine will start and the Continuous operation of the genset also dependson the
starter will disconnect. If not, the overcrank fault circuit proper oil pressure and engine temperature being main-
times out to energize Fault Relay (K6). This opens the tained, and also any customer required fault conditions
start circuit of the ECM. The reset switch (S11) must be connected to the ECM.
pushed to clear any fault before attempting to restart.
Stopping Sequence
Start-Disconnect Sequence Placing the Run/Stop/Remote switch at Stop position
When the genset starts, output voltage from the DC de-energizes Run Relay K7. This opens the circuit
alternator, or from the Magnetic Pickup Module, ener- through the ECM (K2) and de-energizes the genset fuel
gizes Start-Disconnect relay K14. Relay K14 then solenoid (stops fuel flow which stops the engine).
closes its normally-open contacts to illuminate the con-
trol panel RUN lamp. Also, when the genset starts, out- Emergency Shutdown
put voltage from the generator stator energizes Starter- The K6 fault relay energizes when fault sensors respond
Disconnect relay K10. Energizing K10 closes its to any one of several fault conditions such as overcrank,
normally-open contacts and illuminates a Remote Run low oil pressure, low coolant, high engine temperature,
lamp (if equipped). overspeed, overlunder voltage output. Energizing the
K6 fault relay opens its normally-closed (N.C.) contacts
After the starter disconnects, the LOP and HET fault and closes its normally-open (N.O.) contacts.
shutdowns will remain inhibited for another 10 seconds
to allow oil pressure and engine temperature to stabilize Opening K6 N.C. contacts disconnects B+ from the
within the operating range. Power Relays K3 and K2. This stops cranking (if the
engine is being cranked) and shuts off the fuel flow.
Normal Operating Parameters Closing one of the K6 contacts activates the K8 relay.
After a successful engine start-up, with all conditions This relay breaks power to the fault interface relays so
satisfied, the engine will gain rlmin to the governor that only the indicator associated with the fault will acti-
setting. Should the engine go into an overspeed condi- vate. Closing the other N.O. contacts of K6 connects B+
tion, the Magnetic Pickup Module (A16) will reach the to the remote alarm terminal.
trip point and ground the ECM overspeed circuit to
cause shutdown. Emergency Stop Switch
Pushing in the Emergency Stop button energizes the
If the genset does not use Magnetic P i c k u p fault shutdown circuit and stops the genset. Pull out the
Module/toothed-wheel speed sensing, a mechanical Emergency Stop button to reset the fault circuit.
overspeed switch is used. Either means of controlling
overspeed activates the overspeed fault lamp. After the
problem is corrected, starting will not occur until the
Reset switch is pressed.
Section 4. Engine Control Service
TROUBLESHOOTING PROCEDURES 8 Review troubleshooting information as outlined in
Regardless of the controller model the genset is the Operator's manual.
equipped with, basic troubleshooting is fundarrientally
the same. The basic fault conditions are as follows: 8 Check all modifications, repairs, or parts replace-
ments performed since the last satisfactory opera-
A. Engine does not crank. tion of the genset. A poor wire connection, an open
switch or circuit breaker, or a loose plug-in device
B. Engine cranks, but does not start. are all potential problems that can be eliminated by
a visual check.
C. Engine starts, but stops after running several
8 Unless absolutely sure that panel instruments are
seconds.
accurate, use portable test meters for trouble-
shooting.
D. Genset is in operation,then a fault condition occurs.
Because the troubleshooting tables in this section Remember to keep the problem solving process factual
include informationabout various control options, read and methodical, and always use safe troubleshooting
through this section to identify which options relate to practices.
the specific genset. This will save time when an actual
fault condition occurs. Before starting the troubleshoot-
ing procedures, make the following simple checks.
Many troubleshooting procedures present hazards that can result in severe personal injury or
death. Only qualified service personnel with knowledge of fuels, electricity, andmachinery hazards
should perform service procedures. Review safety precautions on page ii.
TABLE 4-1. ENGINE DOES NOT CRANK
SYMPTOM CAUSE CORRECTIVE ACTION

p~ -
- p~ - -
1. SWITCH OFF Run/Stop/ Remote Press to desired, Run

indicator switch in Stop or Remote position.
lamp flashing. position.
2. Other fault Lamp Reset switch Press Lamp Reset switch

indicator lamps not actuated after to de-energize fault
illuminated, but a previous fault lamp relays of ECM, after
no fault exists. was remedied. Run/Stop/Remote switch
is pressed to Stop position.
3. No indication. Fuses blown on ECM Check fuses F1 and F4.

board A1 1. Replace if necessary with
proper fuse:
F1 - 20 Ampere
F4 - 5 Ampere
Starter solenoid Inspect starter solenoid

will not energize. per proper test procedure.
Possible defective Check A1 1 board TB1-9

ECM board A1 1. for B+ voltage in.
With S12 switch in Run

position, check for voltage
out to starter solenoid
at TB1-8 of board A1 1.
Broken wiring or poor Check and repair as

connections between necessary.
board A1 1 TB1-8 and
starter solenoid.
4. Time delay start Possible defective Check A15 board TB1-4

is initiated, but Time Delayed Start/ for constant B+ voltage in.
starter solenoid does Stop Module A15.
not energize after Check A15 board TB1-5 for
desired time delay Run Signal In voltage.
period. Voltage at A15 board
TB1-6 should be at B+
at end of start delay period.
Check wiring and

connections
from A15 TI31-6 to ECM TB1-6.
troubleshooting procedures present hazards that can result in severe personal injury or
Only qualified service personnel with &nowledge of fuels, electricity, and machinery hazards
TABLE 4-2. ENGINE CRANKS BUT DOES NOT START I

I
SYMPTOM CAUSE
I CORRECTIVE ACTION
1. Overcrank Fault
shutdown lamp
illuminated.
A. Low Fuel lamp Insufficient fuel Fill with correct fuel.

also illuminated. supply in tank.
B. Fuel solenoid Fuse blown on ECM Check fuse F2. Replace

does not energize. board A1 1. if necessary with proper
fuse: F2-20 Ampere.
Possible defective Check for voltage out at

ECM board A1 1. A1 1 TBl-10 when engine
is cranking.
Broken wiring or poor Check and rectify as

connections between necessary.
board A1 1 TB1-10 and
fuel solenoid.
C. Fuel solenoid Blockage of fuel Check fuel supply system,

energizes, but supply system. fuel tank shutoff valves,
no fuel flows. fuel lines and connections,
fuel filters and transfer
pump.
D. Engine hard to Heater system not Check heater system

start due to cold keeping engine warm. power supply, controls,
ambient air etc., and correct as
temperature. necessary.
Engine glow plugs not Improper start-up

being energized. procedures used. Depress
Preheat switch S11 to
energize glow plugs.
Time delayed Start/ Initiate a restart and

Stop and Preheat module check for voltage at
A15 not energizing A1 5 TB1-7 to Preheat
Preheat solenoid for solenoid.
glow plugs.
Depress Preheat switch

S11 to bypass A15. Check
if Preheat solenoid
energized.
Check Preheat solenoid per

proper test procedure.
death. Only qualified servicepersonnel with kno~ I e d g of
e fuels, electricity, and machinery hazards
TABLE 4-2. ENGINE CRANKS BUT DOES NOT START (Continued)
D. (Continued) Check wiring and

Engine hard to connections from switch
start due to S11 and module
cold ambient A15 to Preheat solenoid.
air temperature
Fuel supply line freeze Refer to Symptom 1.C of

to engine. this table.
2. Fault shutdown occurs, Lamp burned out. Depress Lamp Test switch
but no fault lamp S11 to check fault lamps.
indication.
Possible defective Refer to Symptom 3.
ECM board A1 1.
3. Short cranking period.
A. Controller ECM (A11 Defective ECM board A1 1. Replace ECM (A11).

is equipped to perform
cycle cranking, but
stops cranking before
15 f 3 seconds.
B. Controller ECM (A11) Defective ECM board A1 1. Replace ECM (A11).

is equipped to provide
constant cranking to
fault limit, but stops
cranking before 75
f 15 seconds.
IBWPIRNING] death. Only clualifiedsenicepersonnel with knowledgeof fuels, electricity, and machinery hazards
1 TABLE 4-3. ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS. I
1. Fault lamp illuminated: Mechanical Switch overspeed Refer to Generator Disassembly/

A. Overspeed sensing faulty or out of Assembly section for adjustment
adjustment. specifications.
Magnetic Pickup Module Refer to Magnetic Pickup Module

(A16) overspeed sensing description in the DC
faulty or out of adjustment. Control section.
Perform start-up and monitor
engine speed to overspeed
shutdown.
Fixed Setpoint
If shutdown occurs before
limit, replace A16 module.
Adjustable Setpoint
If shutdown occurs before
desired, setpoint, readjust
module A16. If adjustment does
not correct fault conditions,
replace module A16.
Engine governor faulty or If shutdown occurs within

out of adjustment. module A16 limits, refer to
Governor Adjustments section
B. Low Oil Pressure Low oil level in engine. Replenish as necessary.
LOP switch S1 faulty. Check oil level, perform

restart, and monitor oil
pressure gauge M11. If
gauge reading is within
normal range, switch S1
is faulty. Replace.
1- death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards
I TABLE 4-3. ENGINE STARTS BUT STOPS RUNNING AFTER SEVERAL SECONDS. (Continued) I
I SYMPTOM
C. High Engine
Temperature.
CAUSE
Low coolant level
in engine.
CORRECTIVE ACTION
Replenish as necessary.
HET switch S2 faulty. Check coolant level, perform

restart, and monitor engine
temperature gauge M I 2. If
gauge reading is within
normal range, switch S2 is
faulty. Replace.
Thermostat defective. Replace thermostat.
Fan belt slipping. Tighten fan belt.
Radiator core or Clean radiator.

fins clogged.
2. No fault condition. Intermittent control Check condition of all

wiring connections. control wiring to ensure
correct and secure
terminal connections.
Low fuel level. Replenish fuel supply.

Many troubleshooting procedures present hazads that can result in severe personal injury or
death. Only qualitied service personnel with knowledge of fuels, electricity, and machinery hazards
TABLE 4-4. ENGINE GENERATOR IS IN OPERATION, THEN A FAULT SHUTDOWN OCCURS
1. Fault indicator
lamp illuminated.
A. LOP,HET. As indicated. Refer to Table 4-3.

Overspeed, etc.
2. No fault lamp indication. Possible defective Check fuses F4 and F2 of

ECM board A11. ECM board A1 1.
F4-(Main) - 5 Ampere
F2- (Fuel solenoid or
ignition) - 20 ampere
Perform restart and check for

B+ voltage in at TB1-9 and
voltage out at TB1-10 to fuel
solenoid.
If there is voltage out at

TI31-10, check fuel supply
solenoid, shutoff valves.
etc.
If there is no voltage out
at TB1-10, ECM board A11
is defective. Replace.
Other customer Refer to installation

required shutdown reference material.
command.
Defective lamp. Replace lamp.

TESTS If the output voltage is high (over 15 volts), check for
Refer to the following tests when isolating circuit prob- loose or corroded voltage regulator leads. If this does
lems caused by faulty engine control components. Fol- not correct the problem, the regulator is probably
low instructions closely to protect test instruments and shorted and should be replaced.
components from damage.
If the output voltage is low (equals battery voltage), the
All external engine control components such as leads, problem could be worn or defective brushes, an open
switches, indicator lamps, senders, and gauges plug regulator, or an open field diode. Refer to the engine
into the engine control monitor board. When testing service manual for additional service information.
external components, disconnect the corresponding
jack (Jl, J2, J3, or J4) from the board. Refer to the Solenoid Check
appropriate wiring diagram to determine the jack 1. Apply battery positive (B+) to the terminal marked S.
number. Engine sender locations are shown in Figure
4-1. 2. Jumper a ground wire to the solenoid ground
bracket. Solenoid should activate.
Contact with rotating machinery can
result in severe personal injury or 3. If the contacts are good, 12 volts DC should be read
death. Keep hands clear while performing tests on between terminal 1 and ground. The voltage drop
operating equipment. measure across the contact should never exceed
one volt in circuit application.
Battery Check
Check battery charge condition with a hydrometer Relay Check
(non-maintenance free battery).The electrolyte specific The run and interface relays can be checked as follows:
gravity should be about 1.260 for a fully charged battery
at 80" F (27" C). If not, add distilled water to keep 1. Connect 12 volts DC across the relay coil terminals.
Relay should activate if coil is okay.
electrolyte at proper level and recharge the battery. If
battery will not recharge, it should be replaced.
2. Connect 12 volts DC to one side of the relay
contacts.
Ignition of explosive battery gasses
Inot smoke whileI servicing
can cause severe personalinjury.
batteries.
DO
3. Connect a voltmeter between the other side of the
contacts and the 12-volt source. If 12 volts appear
when relay is energized, contact is okay. The 12-
If the battery loses water, the alternator charge rate may
be too high. If the battery state of charge is not main- volt reading appears in reverse order when check-
ing normally closed contacts.
tained, the charge rate may be too low. Refer to the
alternator check below.
Fuel Solenoid Check
Battery Cable Check If there is fuel to the injection pump, but no fuel at the
With the starter motor operating, check the voltage injection nozzle, the fuel solenoid might be defective.
drops from the battery negative (-) post (not the cable
clamp) to the cylinder block, and from the battery posi- To check fuel solenoid operation, remove the harness
tive (+) post to the battery terminal stud on the starter B+ lead connection from the solenoid and jumper a
solenoid. Normally each of these should be less than 0.3 separate B+ connection to this terminal. The injection
volts DC. If extra long cables are used, slightly higher pump should click. If no click is heard, the fuel solenoid
voltage drops may result. Thoroughly clean all connec- must be replaced.
tions in any part of the circuit showing excessive voltage
drop. Control Switch Check
1. Remove battery B+ cable.
Alternator Check
With the genset running, check the reading on the DC 2. Place ohmmeter across switch contacts.
voltmeter. (If the control panel is not equipped with a DC
voltmeter, attach a voltmeter, positive (+) lead to the 3. Open and close the switch while observing the
output terminal and negative (-) lead to ground.) Start the ohmmeter. A normally open switch should indicate
genset and run for a few minutes to allow the voltage to infinite resistance when open and continuity when
stabilize. If the alternator is operating properly, the volt- closed. A normally closed switch should indicate
meter should show a reading of approximately 13.8 to continuity when closed and infinite resistance when
14.8 volts. open.
MODELS: OSA3 OlL PRESSURE
094 SEN,MR
0-6 SWITCH
VlEW A-A ld WENGIN€

TEMPERATURE
SWlTCH
WATER
SENDER +' A
I / :<
LQ
PRE-HIGH
ENGINE
TEMPERATURE
SWITCH
PRE-LOW OIL
PRESSURE
SWITCH
-- WATW
sB(DER
,
PRE-HIGH
ENGINE
TEMPERATURE
!WITCH
HIGH ENGINE
VlEW A-A
VIEW B-B
FIGURE 4-1. ENGINE SENSOR LOCATIONS
4-9
Section 5. Generator and Voltage
Regulator
GENERATOR DESCRIPTION A ball bearing in the end bell supports the rotor shaft.
The generator is a four-pole, revolving field, brushless The end bell is attached with four studs that thread into
exciter design. Single and three phase generators are the generator adapter casting. The exciter stator mounts
available in both 50 and 60 hertz. in the end bell; the exciter rotor and its rotating rectifier
assemblies mount on the rotor shaft. Within the end bell,
The generator rotor is directly coupled to the engine leads F1(+) and F2(-), from the exciter stator winding,
flywheel with a flexible drive disc (Figure 5-1). The connect to the output terminals of the voltage regulator.
engine speed determines output frequency. A centrifu-
gal blower on the drive disc pulls cooling air through the
end bell and discharges it through an outlet near the
blower.
DRIVE END BELL

DISC BLOWER \
FIGURE 5-1. TYPICAL GENERATOR

The composite illustration in Figure 5-2 shows the Voltage reconnection diagrams appear in Section 7.
generator output and controllmeter leads for the var- GeneratorlRegulator TestslAdjustment, and in Section
ious voltage options. 10, Wiring Diagrams. Gensets ordered with the optional
circuit breaker have the leads connected for the name-
plate voltage.
CONTROL AND METER LEADS-
TAPS OFF MAIN STATOR WINDING
SINGLE PHASE ONLY: 1 , 4
GENERATOR OPERATION
THREE PHASE: 12-LEAD: 4.7.8,9,10
4-LEAD: 7.8,9,10 Power generation involves the generator components
shown in Figure 5-3. These componentsare italicized in
the following text. A permanent magnet embedded in an
exciter stator field pole begins the voltage build-up pro-
cess as the genset starts. Single phase AC voltage,
taken from a main stator winding, is connected to the
voltage regulator as a reference for regulating the
generator output voltage. The regulator DC output is
coupled to the exciter stator.
The exciter rotor produces three phase AC voltage that

is converted to DC by the full wave rotating rectifier
THREE PHASE
assemblies. The DC voltage excites the rotor main field
winding to produce main stator AC for the load.
FIGURE 5-2. SINGLE AND THREE PHASE

GENERATOR SCHEMATIC (COMPOSITE)
ROTOR
-*m-
MAIN FIELD
---
a
ROTOR
-- -
- -0-DC --
I
1
EXCITER I 1 1
1
MAIN
FIELD
I
-------
VOLTAGE LOAD
REGULATOR
FIGURE 5-3. GENERATOR EXCITATION BLOCK DIAGRAM

VOLTAGE REGULATOR Operating Modes
Description Torque-Matching: Matching the torque characteristics
of the engine and generator is required to properly
The voltage regulator (Figure 5-4) provides switch
manage momentary application of overloads such as
selections that alter its sensing and command signals
motor starting. Because of variance in engine character-
for maximum performance in a variety of generator sizes
istics, different torque matching may be applied.
and applications. Review the sections titled Operation
Switches on the reguiator provide flexibility to test and
Modes and Operating Stability, then the Adjustments
set the torque-matching function for different engine/
section for switch locations and settings specific for the
generator combinations.
genset kilowatt rating.
When properly set, the regulator is able to maintain
output voltage within reasonable limits under transient
conditions. It allows use of the engine's full power to
GENERATOR SET CONTROL
(TOP VIEW)
prevent an unstable response.
VOLTAGE
REGULATOR
Non-Torque-Matching:Even though thevoltage regula-

tor can also be switch-selected to a non-torque-
matching constant voltage mode, independent of
engine speed, this mode will not prevent the gensetfrom
stalling during momentary overload conditions. This
setting is not recommended. Consult a service repre-
sentative before selecting this mode to be sure that load
demands specific to the installation would not cause
unstable operation of the genset.
Operating Stability
Different regulator gain compensation is required for
different generator sizes and exciter/main field time
constants. The voltage regulator is switch-selectable to
FRONT METER a kilowatt range that best suits the genset application.
PANELS
FIGURE 5-4. LOCATION OF VOLTAGE REGULATOR

(CONTROL TOP VIEW)
Voltage Regulator Adjustments Potentiometer R32: Provides adjustment to
The Voltage Regulator board is shown in Figure 5-5. increase or decrease generator voltage to proper
Three switches and two potentiometers provide the fol- setting.
lowing functions:
Potentiometer R34: Is adjusted at the factory to set
a Switch S1:Selects the overall range of operation for the frequency breakpoint, and does not require
the regulator. Refer to Table 5-1. further adjustment.
a Switches S2 andS3: Determinethe mode of regula- See Section 7 of this manual for replacement and
tion (Torque-Matched or Non-Torque-Matched). adjustment procedures.
Refer to Table 5-1.
TABLE 5-1. VOLTAGE REGULATOR SWITCH SETTINGS
771 REGULATION MODE

GENSET STABILITY 60 Hz 50 HZ NON-
RANGE TORQUE-MATCHING TORQUE-MATCHING TORQUE-MATCHING
S1-1 I S1-2 S2 I S3-1 I S3-2 S2 [ S3-1 I S3-2 S2 I S3-1 1 53-2
16-35 OFF OFF POS 2 OFF ON POS 2 ON ON POS2 OFF OFF

40 OFF ON POS2 OFF ON POS2 ON ON POS2 OFF OFF
R32
VOLTAGE ADJUST '
TB1-2.-3 AC INPUT VOLTS

TB1-3. -4 CROSS-CURRENT COMPENSATION
TB1-7. - 8 VOLTAGE ADJUSTING RHEOSTAT
\
S3 DO NOT ADJUST
(SEE TEXT)
FIGURE 5-5. VOLTAGE REGULATOR ADJUSTMENTS
5-4
LINE CIRCUIT BREAKER
Depending on site specifications and code require-
ments, an optional line circuit breaker may be mounted ,u
CONTROL
in the generator AC output box. 1 PANEL
i
Description
All factory supplied line circuit breakers are thermal and
magnetic trip type. Depending on customer require-
ments, the breaker may also include shunt trip and
remote alarm connections. Review the following func-
tions/requirements and Figure 5-6.
Genset output is connected to the load through the

circuit breaker.
When an overload or short circuit occurs on any

one conductor, a common trip bar will disconnect
all three conductors.
The thermal trip action of the breaker is accom-

plished by bimetal strips. A sustained overcurrent
condition will cause a thermal reaction of the bime-
tal and trip the breaker. Response of the bimetal is
proportional to current; high current-fast response,
low current-slow response. This action provides a
time delay for normal inrush current and temporary
overload conditions such as motor starting.
The magnetic trip action of the breaker is caused by

an electromagnet which partially surrounds the
internal bimetal strips. If a short circuit occurs, the
high current through the electromagnet will attract
the bimetal armature and trip the breaker. Some
breaker models provide front adjustment of the . . ;FO
F
magnetic trip action. These adjustments are nor- RESET
mally set at the factory at the high position, but
provide for individual conductor settings to suit cus-
tomer needs.
-
SIDE VIEW HANDLE POSmONS
The shunt trip mechanism (if equipped) consists of a ---7
- - TRIP SHUNT
solenoid tripping device mounted in the breaker
with external lead connectionsfor remote signaling.
A momentary signal to the solenoid coil will cause
- +COMMON ALARM
-GROUND
AUX~JARY
the breaker to trip. COMMON
B
This feature is available in AC or DC voltages, and is
normally installed at the factory to meet customer
needs. The shunt trip mechanism is most often con-
nected to a common fault shutdown circuit of the
Es-lSs4-4
genset. This quickly disconnects the set from the
load on shutdown and avoids a reverse power FIGURE 5-6. GENERATOR-MOUNTEDCIRCUIT BREAKER
condition.
i",.lxiliary c;c):-I:~(.?-,( i f t ~ q ~;!:?dj t~ art3 ijse:! tor lo(.:&!:.: @ C?p;:;at , . : of the circuit Lroakcr , s dett.r:r!ir:i-c! !,)
~i'a:c,?' :rnili~r-ic.l;-:tii;: of 'I:( breaker status They s i t c ,-.,:r:b!ishecf p r r i c e d l l r t : s ' f - el-::r-.;il;f?(>~~
.*:.t;a!!,,; k , ~ v c :r:r.:<:;
! r , , , ,!,,<3:'; ! '7, > i ,.>i- ; ,3f,' ! ) ~ r ~ ~ a l l y - standtjy installat~or:~, the breaker is often piac,ed to
.,!(,!,\$(j L(,;,:;yf A
. , '
,
. " t , . ! : . . ,:,,3pii; .ti:!: t l ~ t dOr-i pi;siliori. % f i r ? ;:; ,:-itended for safety trip actua
?I,P
i?n~itjr.:i~t~ ~: t?ei~,:>t,!
,:.<!i +;,.* I!: it>:.. . v ( \ . , + . ' . : fatiit corid!tio:, If the breaker
, , k . ~ s .
t:lps opc!l. !i~urstig,:itnt ! ~ ec;::lse and perforn-I reme

' 4 1 6 I*: , itf) I t
'1' 2k1 t' $ 5f ? t ~ e ~ i ~ d i ~ e x t i
~;!bl !:I? r . ' /.3 ~ per :ti.- ! f . : , 1 i 2 r . ~ ~ ! ! ~ : , i - ~ t r ! ~ ( : ;:,n.-edu;es. To
1 i?i2 b f c j A t ~tri :;I<- -.I lid ,;\a r t a i r its prope,

qf t l i close t i i t breaker, tlic haiidia i r ~ u sbe t p i a ~ c to
d the
operatlor3 Rotati~lgtbrs ~rctuatoimechanically slrn- Reset positlor, a r ~ dther; to On Refer to m a n ~ i a l
clates over-current t r ~ p p ~ nthrough g actuation of Sections 6 arid 7 for troubleshootirlg and safety
l~nkagesnot operated by the On/Off handle See procedures.
S e c t ~ o n7 Generator/ Regulator Tests/Adjust-
ments for further ~nformation.
Section 6. Generator1Regulator
Troubleshooting
COMPONENT LOCATIONS Visually inspect the components of the voltage reg-
The following listing of components and their locations ulator. Look for dust, dirt, or moisture and cracks ~n
are referenced in the troubleshooting charts of the the printed conductors or solder connections.
Troubleshooting Procedures section.. The charts will Burned resistors and arcing tracks are easily seen.
only reference components by name, so become famil- Do not mark on the board with a graphite pencil as
iar with their locations before proceeding. Other com- this can cause leakage or short circuit between
~onentsare located on the control an el and are not components.
iisted here, or are covered in section 9. Options.
Visually inspect the exciter rotor assembly for
AC Output CircuitBreaker: Mounted in the genera- burned components, broken wires, loose connec-
tor AC output box. tions, and carbon tracks caused by arcing between
parts or between parts and ground. Also check for
Voltage Regulatoc lnside the control panel. shorted paths between terminals caused by dust,
dirt, and moisture.
Terminal Board TB21: lnside the control panel.
Unless absolutely sure that the panel instruments are
Current Transformers CT21,22, and 23: lnside the accurate, use portable test meters for troubleshooting.
generator AC output box.
To prevent meter damage, ohmmeter
Rotating Rectifiers: Within the generator end bell checks must be made with the
on the exciter rotor. generator set stopped and the starting battery
disconnected.
PREPARATION
TROUBLESHOOTING PROCEDURES
Before starting any troubleshooting procedure, be sure
to disable the genset by disconnecting the battery The information in this section is divided into Trouble-
cables, the negative (-) cable first. The negative (-) cable shooting Flow Charts as follows:
is disconnected first to prevent arcing if a tool acciden-
tally touches the frame or other grounded metal parts of 6.1 No AC Output Voltage at Rated Engine Speed.
the genset while disconnecting the positive (+) cable
from the battery. Severe injury can result if arcing ignites 6.2 Unstable AC Output Voltage, Engine Stable at
the explosive hydrogen gas given off by the battery. Rated Speed.
Accidental starting of the generator 6.3 AC Output Voltage Too High or Low.
IBEECI set can cause severe personal injury
or death during service procedures. Be sure to disable 6.4 Exciter Field Breaker Trips.
the generator set by disconnecting the starting battery
cables (negative [-I cable first). 6.5 Unbalanced AC Output Voltage.
Ignition of explosive battery gases 6.6 No AC Output Through Set-Mounted Circuit

PG!EESI can cause severe personal injury. Do
not smoke. Wear goggles and protective, rubber
Breaker.
gloves and apron when servicing battery. After determining the problem, refer to the applicable
troubleshooting flow chart. Start at the chart upper left-
A few simple checksand a valid troubleshooting proce- hand corner and answer all the questions either YES or
dure can quickly locate the trouble source and cut ser- NO. Follow the chart until the problem is found, perform-
vice time. The following are inspection areas often over- ing the referenced Adjustment and Test Procedure(s)
looked when troubleshooting. following the flow charts.
Check all modifications, repairs, and replacements The referenced components in the flow charts and in
performed since the last satisfactory operation of the Adjustment and Test Procedures can be found on
the set to be sure that all generator leads are cor- the electrical schematic in Figure 6-1, and on assembly
rectly connected. A loose or incorrect wire terminal and wiring diagrams in Section 10 of this manual.
connection, or an open circuit breaker overlooked
when replacing a part could cause problems. A
thorough visual check can quickly eliminate these
potential problems.
6- 1
COMPONENT DESCRIPTION
REF. DESCRIPTION
CB21 Field Circuit Breaker

CT21-23 Current Transformer Assembly
DS21-22 Lamp Assembly (Upper / Lower Scale)
G21 Generator
M21 AC Voltmeter
M22 AC Ammeter
M23 Frequency Meter
R21 'Jolts Adjust Potentiometer
S21 Rotary Switch. Volt 8 Ammeter
TB21 Terminal Block
VR21 Voltage Regulator
S21 PHASE SELECTOR SWITCH
-
LNO
LCi23jT
=
, 1;
NOTES
1. See generator connection diagram 625-2108 in Section 10 for
input connections.
2. Dashed components and leads indicate when used.
3. This figure is for reference only. Use the d.ctrical schematic
specific to the application when troubleshooting.
FIGURE 6-1. TYPICAL AC ELECTRICAL SCHEMATIC

(INCLUDES METER OPTIONS)
CHART 6-1. NO AC OUPUT VOLTAGE AT RATED ENGINE SPEED
r --
Many troubleshooting procedures present hazards which can result in severe personal injury or
Ii- AWARNINF]
death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards
C
Is control panel field breaker CB21 on
(fully-in pos~tion)?
Replace defectcve field b r w k u
4
I
Remove one lead from breaker and
NO check cont~nu~ty
wlth ohmmeter Is
I breaker open?
I Push to reset breaker Does generator

AC output voltage build up7
-yes
El0
If voltage is unstable, high or low, or
causes
7-2.3.4breaker
or 5 to trip, see Flow Charts
4
Yes
I
Flash the exc~terstator per TEST
I [B] Does AC output voltage build up?
Is res~dualvoltage across TB21-22

and 23 equal to 5 to 10 VAC or
Disconnect maln stator leads 7
and 8 from TB21-22 and 23. Is
:
res~dualvoltage across the leads 5 to
10 VAC or more now?
I No
i
Check lead continuity between
voltage regulatorITB1-2 and maln
Is exciter stator voltage across
voltage regulator/TB-9 and 10 equal -NO stator lead 7, and between voltage
regulatorITB1-3 and stator lead 8
7 to 5 to 10 VDC or more? per test [J].
I
Yes
I I Check exclter stator wlrlng for
shorts per TEST [J] Replace bad
wlrlng I
Check exclter stator wlrlng for
Check rectlf~ersCR1 - CR6 on
opens per TEST [J] Replace bad
exc~terrotor per TEST [Dl Replace
per procedure [C]
Check exc~terrotor wlndlng per

Check exciter stator wlndlng per TEST [F] Replace 11bad
TEST [El Replace 11bad
t
Check maln rotor windlng per TEST
[GI Replace ~f bad
IaCAUTION
] TOavoidpossible damage to the new
voltage regulator board, do not
--
b
Check maln stator wlndlngs per
replace until all external problems have been Test [HI Replace i f bad
corrected.
CHART 6-2. UNSTABLE AC OUTPUT VOLTAGE, ENGINE STABLE AT RATED SPEED
1 -should perform service
death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards
procedures. Review safety precautions on page ii.
Are there any broken wires or loose

Repair as required. Check control
connections on voltage regulator - panel voltage adjust rheostat and replace
assembly? Does voltage cycle from zero
if defective (open).
to rated output?
1
No
I
Check wirlng harness from
regulator assembly to the end bell
per TEST [J]. Check okay?
FN0 Repair wiring or replace as required.
I
Check voltage regulator
adjustment/switch settings per
- Is voltage stable within specifications
at no load to full load range of
generator set?
I
No
w I
m
r
Replace voltage regulator To avoid possible damage to the new
per TEST [C]. voltage regulator board, do not
replace until a l l external problems have been
corrected.
CHART 6-3. AC OUTPUT VOLTAGE TOO HIGH OR LOW
~ w A R N ~Many
N Gtroubleshooting
eath.
procedures present hazards which can result in severe personal injury or
~ qualifiedservice
Only personnel with knowledge of fue/s, electricity, and machinery hazards
Is englne runnlng at correct rlmln?
Yes
I No I,
i
Set r / m ~ nper instructions in the
appropr~ateengine manual
Refer to Generator Descript~on

Are generator output connect~ons NO
correct and secure?
. i
Opt~onalVoltage Connections, and
appropr~ateelectrical schematic
Yes
II Does adjustment of Voltage Adjust

control R21 ( ~equipped)
f
~ncorrect output voltage?
result
I
Set control per TEST [K] Check
voltage adjust rheostat and
replace 11defectlve
I I
Yes
Is voltage w ~ t h ~spectt~cat~ons
n at
swltch sett~ngsper TEST [K]
-- no load to full load range of generator set?
Check okay? I
No
A
Check cond~tionof rotatlng

rectlt~ersVlsually Inspect for No Test rotatlng rect~f~ers
per TEST
loose connect~ons,faulty rect~f~ers [Dl Replace 11defectlve
etc Check okay?
To avoid possible damage to the new
b c A e i voltage regulator board, do not
replace until all external problems have been
per procedure [Cl corrected.
CHART 6-4. EXCITER FIELD BREAKER TRIPS
-
pNING1 death. Only qualified service personnel with knowledgeof fuels, electricity, andmachinery hazards
Does AC output voltage build up

to 150% or more of rated voltage or connections on voltage regulator
before breaker trips? assembly.
I Check rotat~ngrectifiers in
excuter rotor per TEST [Dl.
Replace if bad.
adjustments and connections
per TEST [K].
I
Check exciter stator winding
Check exciter rotor winding

per TEST [F]. Replace if bad. I
I Check generator stator leads for
proper, and secure connection. Refer
to Generator Description. Optional
Voltage Connections. and appropriate
electrical schematic.
I Check main rotor w~nding

per TEST [GI.Replace if bad.
I
Check maln stator windings
per TEST [HI. Replace 11bad
Replace voltage regulator

I
Toavoid possible damage to the new

voltage regulator board, do not
replace until all external problems have been
corrected.
CHART 6-5. UNBALANCED AC OUTPUT VOLTAGE
AWARNING death. Only qualifiedservicepersonnel with knowledge of fuels, electricity, andmachinary hazards
D~sconnectload from generator (tr~p Reconnect load and check each phase
AC breaker if used). Is output NO for balanced current. If not within
stdl unbalanced? 10% of each other, redistribute the load.
Yes and load
Are generator leads connected and NO

grounded properly?
I Are maln stator w~nd~ngs

per TEST [HI?
cont~nuous
Replace maln stator assembly.
I
Yes
1
Check load lor ground faults and correct as
necessary I
CHART 6-6. NO AC OUTPUT THROUGH SET MOUNTED CIRCUIT BREAKER
death. Only qualifiedservicepersonnel with knowledge of fuels, electricity, andnuchinery hazards
Is set-mounted output breaker at NO Is set-mounted output breaker to

Tripped position? OFF position?
I I
Ygs
- - -- -
-
I
not immediately known, stop
generator set and investigate cause
Circuit overload (per site-
established procedures).
Short circu~t(per site-

established procedures).
Confirm that no maintenance IS
being performed, or other
purpose for breaker at OFF
pos~t~on,
1
and that set IS available for use
Shunt trlp (check for If set is operating and available

generator set fault shutdown. for use, reset circuit breaker to ON
or other signal source). position.
I Rev~ewTEST [MI. TESTING AC LOAD

CIRCUIT BREAKER I
clrcu~tbreaker to ON pos~t~on
Section 7. Generator1Regulator
Tests1Adjustments
death. Only qualified sewice personnel with knowledge of fuels, electricity, and machinery hazards
GENERAL
The following tests and adjustments can be performed FLASHING THE EXCITER FIELD
without disassembly of the generator. They should be
used for testing the generator components and regula- If the residual voltage is missing, it might be necessary to
tor together with the troubleshooting flow charts in Sec- restore magnetism by flashing the exciter field. This
tion 6. All resistance measurements must be made with requires a 12-volt battery, 10-ampere fuse, momentary-
the genset stopped and battery disconnected (negative on switch, and 12-ampere diode assembled as shown
[-I cable first) to prevent instrument damage. in Figure 7-2.
Field flashing can be done during genset operation or

[A1 when stopped. Either method should be sufficient to
restore magnetism.
TESTING AC RESIDUAL VOLTAGE
Incorrect flashing procedure can
Test for generator residual AC voltage if there is no
power output. Agood check point is across terminals 22 @ % damage !? %
the voltage I Do not
regulator.
keep excitation circuitry connected longer than five
and 23 at terminal blockTB21. See Figure 7-1. Residual
voltage should be 5 to 10 VAC minimum at normal oper- seconds.
ating r/min and no load. The voltage can be as high as
35 to 50 VAC.
If residual voltage is present at TB21, check voltage at

the voltage regulator terminals 2 and 3. If zero, check
continuity of field circuit breaker CB21, wiring, and con-
nections with the genset shut down.
R21 R21 (USED WHEN VOLT
VOLTAGE ADJUST ADJUST POT IS NOT
,(WHENUSED) ON CONTROL PANEL) VOLTAGE REGULATOR
F: TO EXCITER FIELD
\ U
CB21
FIELD
CIRCUIT TB21
BREAKER TERMINAL BOARD
FIGURE 7-1. CONTROL COMPONENT LOCATION
7-1
During Genset Operation
1. Connect the positive (+) lead to terminal 9, and the AC VOLTAGE REGULATOR REPLACEMENT
negative (-) lead to terminal 10 on the voltage regu- Use the following procedureto replace the voltage regu-
lator (Figure 7-1). lator assembly shown in Figure 7-1.
1. Stop the genset and disconnect the starting battery

TO VOLTAGE REGULATOR
leads, negative (-) lead first.
TERM. TB1-10
(F2-)
2. Disconnect (and label if necessary) the wires from
MOMENTARY-ON
voltage regulatorTB1.Refer to the AC control wiring
TO VOLTAGE REGULATOR SWITCH diagram.
lA
TERM. TB1-9 3. Remove mountingscrewsfrom the old voltage regu-
12-AMP
(Fl+)
300v
lator, then install new regulator.
DIODE
4. Reconnect wires removed in Step 2 to the proper
terminals.
5. Perform the voltage regulator adjustment/switch

settings for specific voltage and method of regula-
tion desired per procedure [J].
ROTATING RECTIFIERS
Two different rectifier assemblies make up the rotating
rectifier bridge assembly, Figure 7-3. Using an ohmme-
ter, test each CR rectifier using negative (-)and positive
-
(+) polarities. Use the following procedure.
FIGURE 7-2. FIELD-FLASHING CIRCUIT
2. Start the genset and operate at normal speed. Close OHMMETER

the switch long enough for the generator output
voltage to build up, but not longer than five seconds.
3. Check the output voltage, then shut down the

genset. Restart the genset and operate at no load.
Output voltage must build up without field flashing. If
not, shut down the genset and perform continuity
check of all related wiring.
CA-1010-9
FIGURE 7-3. TESTING ROTATING RECTIFIERS

1. Disconnect all leads from the assembly to be tested. F1. F2
LEADS
2. Connect one ohmmeter test lead to F1+ stud and
connect the other test lead to CR1, CR2, and CR3 in
turn. Record resistance value of each rectifier.
3. Connect one lead to F2- stud and connect other test

lead in turn to CR4, CR5, and CR6. Record resist-
ance value of each rectifier.
4. Reverse ohmmeter test leads in Steps 2 and 3 and

record resistance value of each rectifier.
5. All resistance readings should be high in one test

and low in the other test. If any reading is high or low
WHEATSTONE
in both tests, rectifier assembly is defective. BRIDGE OR
DIGITAL OHMMETER
Use 23 to 26 inch pounds (2.6 to 2.9 Nam) torque
when replacing nuts of F1+, F2- leads, and on
diodes CR1, CR2, CR3, CR4, CR5, and CR6.
TESTING EXCITER STATOR

Test the exciter stator (Figure 7-4) for open or shorted
windings and grounds as follows. F1,F2
STATOR LEADS
LAMINATIONS
Testing For Open or Shorted Winding \ I
- Use a Wheatstone Bridge or digital ohmmeter for this
test. Disconnect F1+ and F2- exciter field leads from the
terminal block in the generator end bell. Resistance per
model at 77°F (25OC) should be as follows:
20.0 DL4 14.5 ohms f10%

25.0 DL6
40.0 DL6T
4A2.3
6A3.4
6AT3.4
DGAB
DGAC
DGAD
MEGGER OR
DGAE INSULATION
RESISTANCE
12.4 ohms f10% METER
TESTING FOR GROUND TO LAMINATION
Use 23 to 26 inch pounds (2.6 to 2.9 Nom) torque when replacing nuts CA-1010-11
of F1+ and F2- leads, CR1, CR2, CR3, CR4, CR5, and CR6.
FIGURE 7-4. TESTING EXCITER STATOR
Testing for Grounds 20.0 DL4 0.645 ohms f10%
Connect a Megger or insulation resistance meter that 25.0 DL6
applies 500 VDC or more between the field and the 40.0 DL6T
exciter stator lamination. See Figure 7-4. Be sure both DGAB
exciter leads are disconnected from the terminal block. DGAC
Reading should be 100,000 ohms or greater. If not, the DGAD
exciter stator is questionable and might require removal DGAE
for oven drying and retest. A shorted stator must be 4A2.3
replaced. 6A3.4
6AT3.4
0.54 ohms f10%
TESTING EXCITER ROTOR

Test the exciter rotor winding (Figure 7-5) for open or
shorted winding, or grounds as follows: Testing For Grounds
Test with an insulation resistance meter or Megger that
Testing For Open or Shorted Windings applies at least 500volts to the test leads. With all gener-
Use a Wheatstone Bridge or digital ohmmeter for this ator leads disconnected from rotating rectifiers CR1
test. Disconnect the main rotor leads that connect to through CR6, apply test leads between any CR lead and
rotating rectifier assemblies at terminals F1+ and F2-. the rotor laminations. Reading should be 100,000 ohms
Disconnect exciter rotor leads from diodes CR1, CR2, or higher. If not, the exciter rotor is questionable and
CR3, CR4, CR5 and CR6. Test between exciter lead might require removal for oven drying and retest. A
pairs T I -T2, T2-T3, and T I -T3. See connection diagram shorted rotor must be replaced.
in Figure 4-5. Resistance per model at 77OF (25OC) Use 23 to 26 inch pounds (2.6 to 2.9 Nom) torque when replacing nuts
should be as follows: of F1+ and F2- leads, CR1, CR2, CR3, CR4, CR5, and CR6.
EXCITER ROTOR
ASSEMBLY
WHEATSTONE RESISTANCE
BRIDGE OR METER
DIGITAL OHMMETER
TESTING WINDING FOR GROUNDS
TESTING WINDING RESISTANCE
CONNECTION DIAGRAM
FIGURE 7-5. TESTING EXCITER ROTOR

DK;ITM
OHMMETER
TESTING MAlN ROTOR WINDING
Test the main rotor winding (Figure 7-6) for grounds,
MAlN ROTOR
opens, and shorts as follows. LEADS F1+. F2-
Testing For Open or Shorted Winding

Perform this test with a known, accurate instrument
such as a digital ohmmeter.
1. Remove rotor leads F1+ and F2- from the rotating

rectifier assemblies.
2. Check resistance across F1+ and F2- leads. The

resistance values at 77OF (25°C) should be as
shown in Table 7-1. See Figure 7-7 for determining
the stack length. If resistance is not as shown,
replace the defective rotor with a new, identical part.
TABLE 7-1. MAlN ROTOR RESISTANCE
'STACK LENGTH *OHMS RESISTANCE

5.88 (149) 2.75
7.12 (181) 1.80
8.75 (222) 2.04
10.50 (267) 2.55
*5.12 (130) 2.55
*5.88 (149) 2.75
*7.12 (181) 1.98
*8.75 (222) 2.24 RESISTANCE
METER
*10.50 (267) 2.91
L
'Lamination Stack Length in Inches (mm).

2Resistance in Ohms @ 77°F (25°C) f10%.
*QSA-Series Generators (Rental Construction)
TESTING WINDING FOR GROUNDS
a-101012
FIGURE 7-6. TESTING MAlN ROTOR WINDING

Testing For Grounds
Check for grounds between the rotor winding and the
rotor shaft as shown. Use a Megger or insulation resist-
TESTING MAlN STATOR WINDINGS
ance meter which applies 500 VDC or more at the test Test the main stator (Figure 7-7) for opens, shorted
leads. Perform test as follows. windings, and grounds as follows.
1. Remove rotor leads F1+ and F2- from the rotating Testing For Open or Shorted Windings
rectifier assemblies. Test for continuity across stator coil leads. Each coil
should have equal resistance. Use an accurate instru-
Be sure to remove both rotor
/nCAUTION\ leads so the rotating rectifiers
are isolated. Failure to do this will damage the
ment for this test such as a Wheatstone Bridge. Resist-
ance readings should be as shown in Table 7-2 at 77OF
(25°C) +10 percent. See Figure 7-7 for determining the
rectifiers. stator stack length.
2. Connect test leads between one of the two leads If a winding is shorted, open or grounded, replace the
and the rotor shaft. Meter should read 100,000 ohms stator assembly. Before replacing the assembly, check
or greater. leads for broken wires or insulation.
3. If less than 100,000 ohms, the rotor is questionable
and might require removal for oven drying and Testing For Grounds
retest. Use a Megger or insulation resistance meter which app-
lies 500 VDC or more at the test leads. Test each stator
4. Replace a grounded rotor with a new identical part. winding for short to laminations. If less than 100,000
ohms, the stator is questionable and might require re-
moval for oven drying and retest.
GENERATOR
CROSS-SECTION
VIEW
STACK
LENGTH
(LAMINATION)
MEGGER OR
INSULATION
RESISTANCE
THREE PHASE MODELS

TEST BETWEEN WIRE PAIRS
SINGLE PHASE MODELS T I - T 4 T7-TI0 T3-T6 WHEATSTONE
TEST BETWEEN PAIRS BRIDGE
T I - T 2 T3-14 T9-T12 T2-T5 T8-TI1
ES-1795
FIGURE 7-7. TESTING MAIN STATOR WINDINGS
TABLE 7-2. MAIN STATOR RESISTANCE 2. Control with AC meter option: Refer also to adjust-
ment (L).
'STACK ZRESISTANCE
LENGTH Control without AC meter option: Connect an accu
1, GENERATORS 3 0 GENERATORS
50 Hz 60 Hz 50 Hz
rate voltmeter to voltage regulatorl.TB1-2 and -3
60 Hz
terminals.
5.75 (146) 0.1 27 0.186 3. Start the genset and operate to bring temperature
7.00 (178) 0.049 0.071 0.100 up to normal.
8.62 (219) 0.039 0.072 0.084
10.38 (264) 0.029 0.036 0.045 0.059
*5.00 (127) 0.224 0.256 0.224 0.256 4. As a precaution against electrical shock, place an
*5.75 (146) 0.128 0.150 0.128 0.1 50 insulating mat or a dry wood platform on the floor in
*7.00 (178) 0.105 0.120 0.105 0.1 20 front of the control panel.
*8.62 (219) 0.071 0.079 0.071 0.079
* 10.38 (264) 0.046 0.063 0.046 0.063
Contact with high voltage can
cause severe personal injury or
'Lamination Stack Length in Inches (mm). death. Do not touch any exposed wiring or compo-
2Resistance in Ohms @ 77°F (25OC) f10%. nents with any part of the body, clothing, tool or
*QSA-Series Generators (Rental Construction).
jewelry. Do not use non-insulated tools inside the
control. Stand on an insulating mat or dry wood
platform when the control doors are open.
5. Using an insulated screwdriver, turn R32 potenti-
WIRING HARNESS CHECK ometer on the voltage regulator to increase or
Carefully check the wiring harnesses as follows. decrease the voltage for proper setting with no load.
1. Inspect all wires for breaks, loose connections, and Example: For a 1201240 volt generator connection,
reversed connections. Refer to applicable wiring set no-load voltage for approximately 246 volts. If
diagram. voltage is unstable or tends to hunt, refer to the
applicable troubleshooting flow chart.
2. Remove wires from terminals at each end and using
an ohmmeter, check each wire end to end for conti- Potentiometer R34 is for factory adjustment only.
nuity or opens. Setting requires special calibration equipment. Do
not adjust.
3. Using an ohmmeter, check each wire to other wires
and to ground for possible shorts or insulation 6. Stop the genset and close the control panel doors.
breaks under areas covered by wrapping material. Set control for operation readiness.
4. Reconnect or replace wireslharness per the appli-

cable wiring diagram.
VOLTAGE ADJUST
POTENTIOMETER R21
The following procedure is for gensets equipped with
VOLTAGE REGULATOR ADJUSTMENT the AC meter option only. Perform adjustment as
After replacement, the voltage regulator adjustment is follows:
performed as follows. Also refer to the Regulator Speci- 1. Loosen the locking nut of R21 Voltage Adjust poten-
fications in Figure 7-8. tiometer on the control front panel. Adjust R21 to
mid-range.
1. Open the control panel doors. Refer to Figure 7-8
for the proper setting of S1 (Stability Range) and S2, 2. Start the genset and operate to bring temperature
S3 (Mode Selection) switches. up to normal.
3. As a precaution against electrical shock, place an

insulating mat or a dry wood platform on the floor in
front of the control panel.
REGULATION MODE
GENSET STABILITY 60 Hz 50 Hz NON-
kW RANGE TORQUE-MATCHING TORQUE-MATCHING TORQUE-MATCHING
S1-1 S1-2 S2 S3-1 S3-2 S2 S3-1 S3-2 S2 S3-1 S3-2
16-35 OFF OFF POS2 OFF ON POS2 ON ON POS2 OFF OFF
40 OFF ON POS2 OFF ON POS2 ON ON POS2 OFF OFF
GENERATOR SET CONTROL

(TOP VIEW)
PANELS
R32
'AGE P
\
TB1-2 -3 AC INPUT VOLTS R34
TB1-3 -4 CROSS-CURRENT COMPENSP.TIGN DO NOT ADJUST
TBl-7 -8 VOLTAGE ADJUSTING RHEOSTAT (SEE TEXT)
TB1-9 -10 EXCITER FIELD
FIGURE 7-8. VOLTAGE REGULATOR LOCATIONIADJUSTMENTS
7-8
EEEEGI Contact with high vonage can
cause severe personal injury or
death. Do not touch any exposed wiring or compo-
nents with any part of the body, clothing, tool or
jewelry. Do not use non-insulated tools inside the
control. Stand on an insulating mat or dry wood TRIP
platform when the control doors are open.
OFF
4. With no load on the generator, turn the Phase Selec- RESET
tor switch to read output voltage/current while per-
forming the following adjustments.
A. Open the control panel doors and adjust R32 on

the voltage regulator for the approximate SIDE VIEW - HANDLE POSITIONS
desired voltage .
B. Fine-adjust the voltage with R21 on the control

-7 SHUNT TRIP
panel. When set at correct voltage, carefully + COMMON ALARM

- GROUND
tighten the locking nut using care not to change
AUXILIARY CONTACTS
the setting.
A
COMMON
C. If correct voltage cannot be obtained by R21 at B
mid-range, refer to voltage adjustment proce- I
--
dure [K].
5. Move the Phase Selector switch to the Off ES-1564-4

position.
FIGURE 7-9. OPTIONAL CIRCUIT BREAKER DIAGRAM
6. Stop the genset and set the control for unit standby
readiness.
Checking Insulation Resistance: Disconnect the load
and line conductors from the breaker, and place the
breaker in the On position. Use an insulation resistance
TESTING AC LOAD CIRCUIT BREAKER meter that will apply at least 500 volts to the test leads.
General Measure the insulation resistance between each pole,
and to ground. Also test between the line and load
The AC circuit breaker does not require any special
terminals with the breaker in the Off position.
maintenance other than periodic exercise and a check
of conductor mounting. Circuit breaker options vary by
A resistance reading less than 100,000ohms indicates a
customer requirements.
ground. Investigate for possible contamination on the
breaker case surfaces, clean if necessary and retest.
Review the Optional Circuit Breaker description in Sec-
tion 6. Generator/Voltage Regulator and perform
Checking Contact Resistance: Extensive operation of
checks and adjustment applicable to the breaker. A
the breaker under load may eventually cause contacts
typical breaker diagram is shown in Figure 7-9 for
to deteriorate. Test by a Resistance Check, or by a
reference. Voltage Drop Check across the breaker poles.
When performingtests and adjustments, avoid acciden-
Except when genset operation is required for testing,
tal start-up by placing the Run/Stop/Remote switch in
avoid accidental start-up by placing the Run/Stop/
Stop position and disconnecting the battery negative (-)
Remote switch in Stop position and disconnecting the
cable. battery negative (-) cable.
TawAR~ii-iAccidental starting of the generator --

Accidental starting of the generator
set during service procedures can
result in severe personal injury or death. Place the
k w A R N
set IN
during G!procedures can
service
result in severe personal injury or death. Place the
Run/Stop/Remote switch in Stop position, am? dis-
Run/Stop/Remote switch in Stop position, and dis-
car rlec t the battery negative (-1 cable.
connect the battery negative (-) cable.
Exe, ~isingBreaker: Actuate the breaker handle to the
On and Off positions several times. If the breaker is
equipped with a Trip Test button, the breaker should be
tripped, reset and actuated to On several times. This will
remove any dust from the mechanism and latch
surfaces.
Resistance Check: Checking Shunt-Trip Operation: The shunt- trip feature
is available in varying AC or DC voltages. The circuit
1. Disconnect the line and load wires from the circuit breaker model is selected and installed at the factory to
breaker. meet customer requirements. Check the shunt-trip
function as follows:
2. Move the breaker handle to the On position and
check the resistance across each pole (line to load). 1. Refer to the original equipment order, installation
wiring diagrams, and unit wire routing to identify
3. Resistance should be very low (near zero) and rela- and confirm proper AC or DC signal source
tively equal across all poles. connections.
Voltage Drop Check:This test is done with the conduc- 2. Check security of the wire connections.
tors connected, genset operating, and load applied. As a
precaution against electrical shock, place an insulating 3. Apply the appropriate signal voltage (12-VDC; 240-,
mat or a dry wood platform on the floor to stand on when 480-VAC). The shunt-trip solenoid should energize
taking measurements. and trip the breaker open.
Contact with high voltage can cause 4. If the breaker did not trip open, remove the signal
severe personal injury or death. Do source. Perform continuity check of interconnect
not touch any exposed wiring or components with any wiring and shunt-trip solenoid lead wires. Replace
body part, clothing, tool orjewelry. Stand on an insulat- interconnect wiring if defective.
ing mat or dry wood platform when taking
measurements. Checking Auxiliary Contacts: If equipped, the breaker
will have three leads for wiring to an internal single-
1. Operate the genset with the breaker in the On posi- pole, double throw switch. The switch allows connec-
tion and load applied. tion of a remote annunciator (see installation wiring
diagrams).
2. Take voltage readings at the line connections, then
the load connections. Perform continuity checks of the switch with the breaker
in On and Off positions to confirm operation.
3. There should only be slight variation in the voltage
dropped across each pole of the breaker. Unequal Adjusting Magnetic Trip Operation: If equipped with
-
or excessive millivolt drops across the complete front-adjustable magnetic trip controls, the short circuit
breaker, or one pole, indicates contaminated con- protection feature for each pole of the breaker can be
tacts or loose connections. adjusted equally or individually as required. Surge cur-
rent above the trip settings will actuate the trip mecha-
4. Stop the genset by placing the Run/Stop/Remote nism. These adjustors are set equally to the high posi-
switch in Stop position and disconnecting the bat- tion at the factory. Consult on-site requirements and
tery negative (-) cable. adjust to proper position.
Accidental starting of the

lprocedures
nWRNlNcan Gl result
generator set during service
in severe personal injury or
death. Place the Run/Stop/Remote switch in Stop
position, and disconnect the battery negative (-)
cable.
Section 8. Generator Disassembly1
Assembly
GENERAL 9. Slide the engine harness/grommet free as the out-
If testing determines that the generator needs ser- put box is removed from the generator.
vice, use the following disassembly and assembly
procedures. The procedures cover major compo- 10. Remove lead from the overspeed switch (if used),
nents of the generator as shown in Figure 8-1. and control leads F1+ and F2- from the end bell
terminal board.
DISASSEMBLY 11. Remove the overspeed switch and bracket (if used)
Access to the generator requires removal of the from the end bell and rotor shaft.
control box and the generator output box.
12. Remove the end bell and exciter stator assembly. It
1. Disconnect the genset starting battery (negative [-I might be necessary to pry or jar the assembly loose
cable first) before performing service procedure. from the main stator assembly.
Accidental starting of the 13. Use a hoist and safe lifting device (stator handling
generator set can cause severe tongs, nylon lifting strap or chain and lifting hooks)
personal injury or death during service proce- to support the main stator assembly.
dures. Be sure to disable the generator set by dis-
connecting the starting battery cables (negative[-] Generator components are
cable first). heavy and can result in severe
personal injury during removal. Use the recom-
2. Remove screws securing the back grille to the rear mended removal techniques and keep hands and
of the generator. feet clear while removing mounting bolts.
3. Remove screws securing the output box cover. 14. Remove screws and lock washers securing the
main stator assembly to the engine adapter.
4. Open control box doors and disconnect the genera-
tor control wires. Check wire stamping legibility to 15. Remove the main stator being careful not to touch or
ease reassembly (if necessary, attach identification drag it on the rotor. Place the stator on its side and
with tape). Arrange leads so they can be withdrawn block to prevent rolling, especially if placed on a
easily through the control box grommet opening. workbench.
5. Remove four screws (5/16-18) and lock washers Falling, heavy objects can cause
securing the control box to the generator output severe personal injury or death.
box. Carefully lift the control box free of leads and Be sure to block or support heavy objects to pre-
set aside. vent falling. Wearprotective shoes and keep hands
and feet clear.
6. Remove all leads from the circuit breaker and free
the output box of all electric conduit. 16. Using a hoist and sling to support the rotor, carefully
remove the capscrews that attach the drive disk to
7. Remove four 3/8-inch nuts securing the upper and the engine flywheel (Figure 8-1).
lower output box brackets at the rear of the end bell.
17. Remove the rotor assembly and place upon wood
8. Remove three capscrews at the front of the output block in the horizontal position. The drive disk and
box. Two capscrews are on the outside (5116-18 x fan should not be resting on anything or distortion
1.25 and flat washers), and one inside the output might occur.
box beside the breaker (5/16-18 x 0.62).
18. Remove bolts that hold the drive disk and fan to the
rotor shaft.
/
OVERSPEED
SWITCH
ASSEMBLY
END BELL NUT STATOR LIFT
FIGURE 8-1. TYPICAL GENERATOR DISASSEMBLYIASSEMBLY
8-2
19. Use a gear puller to remove the end bearing from 7. Apply a thin film of grease to the mating surfaces of
the rotor shaft (Figure 8-2). If reusing the bearing, be the end bearing and the end bell. Install the end bell
sure to apply puller to the inner race. over the stator stud bolts. Do not install nuts and
lock washers until later.
8. Install theoverspeed switch and bracket to the rotor

shaft and end bell. Apply torque values from Figure
8-3.
FIGURE 8-2. END BEARING REMOVAL
Improper removal of the end

bearing r i l l damage it. If
intended for reuse, the bearing must be pulled off
by the inner race.
20. Clamp the rotor in a fixed position and remove the

exciter rotor lock nut.
FLAT WASHER
:i
21. Remove the generator field leads from the exciter
rotor and slide the exciter off the rotor shaft.
REASSEMBLY
Reassembly procedures are basically the reverse of
disassembly. Use the following steps as a guide. Apply DETAIL B
torque as specified in Figure 8-3.
1. Slide the exciter rotor over the generator shaft and

woodruff key. Install the exciter nut and torque as
specified.
2. Connect the main rotor leads to terminals F1+ and

F2- on the exciter rotor and torque as specified. SPACER WASHER (2)
DJUST SCREW
3. Press the end bearing onto the rotor shaft. Spacing
between the shaft end and bearing side surface
20 FT LBS (27 Nm
.)
must be as specified in Figure 8-3.
4. Assemble rotor fan and drive disk to the engine

f!ywheel. Use a hoist and sling to support the rotor.
Be sure the drive disk is assembled with the chamfer
on the flywheel side. Apply torque values as shown RSPEED SWITCH
in Figure 8-3.
5. With a hoist and safe lifting device, carefully move

the main stator into position over the rotor. The H ASSFMBLY BRACKET
stator leads should exit in the 4 o'clock position.
6. Secure the main stator to the engine adapter with

screws and lock washers removed in disassembly.
Torque bolts to 39 ft-lb (52 Nom). FIGURE 8-3. ROTOR COMPONENT ASSEMBLY /
TORQUE VALUES
9. Connect control leads to the F1+, F2- terminals, 16. Close and secure the control box doors. Do not in-
and to the overspeed switch. stall the output box back grille until the overspeed
switch setting has been checked.
10. Place the AC output box into position. Slide the en- 17. Connect the genset starting battery leads (positive
gine harnesslgrommet into the slot opening. [+] lead first) and test generator operation.
1 1. Installfour (318-16) nuts and lockwashers to the end 18.The rlmin at which the overspeed switch shuts
bell studs; then three capscrews and flat washers at down the genset can be changed by the adjust
the front of the AC box. Torque the end bell nuts to screw. Turning this screw in or out changes the
20 ft-lb (27Nom). magnetic air gap. When set correctly, the switch
closes and shuts down 60 hertz gensets at 2100
f90 rlmin; 50 hertz gensets at 1900*I00 rlmin. On
12. Tighten the output box capscrews. Using a lead QSA model gensets the overspeed switch is set to
hammer, tap the end bell at the horizontal and verti- shut down 60 hertz gensets at 2400 i150 rlmin; 50
cal plane to relieve stress. Retorque the four end hertz gensets at 21 00 f150 rlmin.
bell nuts.
An accurate frequency meter or strobotach is
13. Assemble wire conduit to the generator output box. needed to check the overspeed trip point when the
Connect the generator, load, and auxiliary wires to engine speed is increased (see the engine service
the AC circuit breaker (if used). manual). The air gap must not be less than 0.005
inch (0.13 mm).
14. Set the control box on the output box. Route all con- W N Contact~wlth high voltage wlres
trol leads through grommet in control box bottom. can cause severe personal Injury or death.
Secure control box with four screws and lock- Some model generator sets can have exposed
washers. wlre termlnals when making this adjustment.
Be sure the generator set battery is dlscon-
15. Carefully connect all control leads to their marked nected (negailve 1-1 lead flrst) to prevent start-
terminations. ing before making an adjustment -4
Section 9. Miscellaneous
GENERAL TRAILER OPTION (QSA-SERIES)
This section contains basic service and maintenance
Trailer Brakes
informationfor miscellaneous components that might not The trailer uses a system called surge braking. When
be referencedelsewhere in this manual, or in other Onan the tow vehicle brakes are applied, the push of the trailer
literature. The components are mostly "model specific." toward the tow vehicle automatically synchronizes its
braking with the tow vehicle. The actuator telescopes
together and applies force to the master cylinder that
supplies hydraulic pressure to the brakes. See Figure
9-1. A breakaway system applies the trailer brakes
should both the coupling and safety chains fail.
1 outer Case Assembly

2 Bearing
3 Front Roller
4 Front Roller Pin
5 CotterF5n
6 Front Roller Cover
7 Cable
8 S-Hook
9 Breakaway Lever
10 Breakaway Spnng
11 Hex Ban. Sen-Tap
12 washer
13 Cylinder Mounting Plate
14 Hex Bdt
15 Push Rod Block
16 Push Rod
17 Master Cylinder
18 Master Cylinder Cap
19 Connector
20 Nut Hex 318
21 Washer. 318
22 Spring
23 Damper
24 Rear Roller
25 Master Pin
26 Coner Pin
27 Damper Pln
28 Inner Slide Assembly
29 Washer
30 Cover
31 Latch Bolt
32 Lock Plate
33 Ball Latch
34 Latch Spring
35 Lock. Hand Wheel
36 Hand Wheel
FIGURE 9-1. TRAILER SURGE BREAKING SYSTEM
9-1
Brake Maintenance tions, the actuator should be flushed periodically with
a high pressure water hose. Grease bearings and oil all
1. Before towing, check the brake fluid level in the
moving parts after the unit has dried. At the end of
reservoir. It should be at least half full. If not, add
season when unit is stored, remove the brake drums
DOT 3 brake fluid. Check for leaks and repair as and clean inside the brakes. Pack the wheel bearings
required.
before installing drum.
2. Examine the actuator for bent parts or wear.
Replace parts as necessary and make sure mount- Trailer WiringILighting
ing bolts are tight and welds not cracked. There are Check the trailer wiring and operation as follows. Table
no adjustments on the brake actuator. 9-1 lists the wire color codes and their purpose.
Readjust the brake shoes to reduce actuator stroke TABLE 9-1. WIRING COLOR CODES
length if it exceeds 1 inch (25 mm). The length of the
roller path on top of the actuator, when it is fully COLOR PURPOSE
extended, is the same as stroke length. Brake shoe I
adjustment isaccessible through slots in the backof White Ground

each drum assembly. Turn the wheel forward while Brown Tail and Side Marker Lights
making shoe adjustment. Back off each shoe 10 Yellow Left Turn and Stop
clicks from the point where wheel cannot be turned Green Right Turn and Stop
by hand.
Braking power can dimish when 1. Check that the white (ground) wire of the trailer
LAWARNING actuator stroke length exceeds harness is connected to the trailer frame; and that
1 inch (25 mm), leading to a serious road accident. the white (ground) wire of the tow vehicle is con-
Check actuator stroke length regularly, and ser- nected to its frame or body. Be sure the tie points are
vice the brakes if necessary. free of corrosion and are a good electrical bond.
This is very important.
3. Before each towing, wipe the coupler and ball clean
and add a film of grease. Doing so will extend their 2. If turn signals do not work properly, check the tow
life while eliminating squeaking. vehicle flasher. Many flashers used in automobile
applications will not carry the additional load of the
4. Bleeding the Brakes: Use the following procedure trailer turn signals. Install only a heavy duty flasher.
to bleed the brake system. Also make sure that the light bulbs are good and
have the correct replacement.
A. Fill the system with DOT-3 heavy duty hydraulic
fluid using a pressure type brake bleeder. This 3. The trailer tail lights should come on with the head-
type bleeder is available at your local automo- lights; the trailer turn signals should flash simul-
tive jobber. Follow the manufacturer's direc- taneously with the tow vehicle turn signals; the
tions. trailer brake lights should come on and go off with
each application and release of the brake pedal.
B. Install bleeder hose on first wheel to be bled.
Submerge loose end of hose in a glass con- 4. If the trailer turn signal lights flash opposite to the
tainer of brake fluid to observe bubbling. towing vehicle, the yellow and green wire connec-
tions from the tow vehicle connector have been
C. Loosen bleeder screw one turn. Bleeding is reversed. Correct problem by reversing the wire
complete for the wheel when bubbling stops. Be connections.
sure to close the bleeder screw securely.
D. Repeat bleeding operation at other wheel. Dur-

ing the process, replenish brake fluid so the
level does not fall below half in the master
cylinder reservoir.
E. After brakes are bled, make sure master cylinder

reservoir is filled and the filler cap securely in
place.
1-1 Saltwater, granular fertilizer, and

other corrosive materials are des-
tructive to metal in the braking system. To prolong the
life of the braking system used under corrosive condi-
DIESEL FUEL TANK CONTROL SYSTEM Diesel fuel is highly flammable and
can cause severe personal injury or
(QSA GENSETS) death and loss of property if ignited. Faulty component
General replacement or service can lead to spillage of large
The fuel tank control system consists of a skid-mounted quantities of fuel. Installation and service must be per-
tank, fuel pump, float switches, and the automatic con- formed by qualified persons and in compliance with
trol. The control operates the fuel pump to maintain a applicable codes.
reservoir of fuel in the tank, and provides a seven light
monitor of the system operation. Figure 9-2 shows an Do not smoke near fuel. Keep flames, sparks and other
~nstallationon the QSA genset. sources of ignition well away from fuel tanks and
piping.
The DC control power source can be wired to use either
the 24-volt genset battery, or a transformer connected to p R F N G IAccidental starting of the generator
120 or 240 VAC. The pump motor can be wired to oper- set, or working on equipment with
ate from either 120 or 240 VAC. power connected can cause severe personal injury or
death. Be sure all sources of power are disconnected.
Disconnect the starting battery cables (negative [-I
cable first) from the battery to prevent accidental
starting.
Always disconnect the negative (-) cable first, and

reconnect it last to prevent arcing if a tool accidentally
touches the frame or other grounded metal parts of the
equipment while disconnecting or connecting the posi-
tive (+) cable. Arcing can ignite the explosive hydrogen
gas given off by the battery and cause severe injury.
FLOAT
.
SKID-BASE
SWITCHES FUEL TANK
FIGURE 9-2. FUEL TANK CONTROL SYSTEM COMPONENTS, OSA GENSET

Continued operation with a LO
Operation
This section explains functions of the control panel /BCAUTION FUEL fault can lead to a low fuel
shutdown if the low fuel float switch fails.
lamps, components and operation of the fuel control
system. All red color lamps indicate a fault condition.
The control front panel is shown in Figure 9-3. LO SHUTDOWN: Red lamp comes on if fuel level
has dropped to near tank bottom. It indicates a pos-
Lamps: sibleempty main fuel tank,fuel line restriction, pump
READY: Green lamp comes on if all the following failure, or failure of both the "pump-off" and "low
conditions are met: fuel" float switches.
Control switch is in ON position. The control should be wired to shut down the
If AC power is available for pumping. genset (optional) as continued operation will allow
IfDC power is available for internal logic circuits air to enter the engine injection pump necessitating
(connections to the engine starting battery bleeding to restart the engine. (See Operator's
might be required). Manual). After restoring the tank fuel level, reset
circuit with the RESET switch. This switch also res-
HI FUEL: Red lamp comes on if fuel has reached an tores engine operation if the tank control has been
abnormally high level. It indicates a possible failure connected to shut down the engine.
of the "pump-off" float switch (Figure 9-4). The lamp
can be turned off with the RESET switch after the BASIN: Red lamp comes on if fuel has flooded the
fuel level drops to normal. The lamp will come back optional safety basin surrounding the fuel tank. It
on again during the next pumping cycle if the fault indicates possible failure of both the "pump-off
remains. and "high fuel" float switches. The basin float switch
turns off the fuel pump. The pump cannot function
Diesel fuel is highly flammable again until the basin is drained of fuel and the circuit
and can cause severe personal reset with the RESET switch.
injury or death and loss of property if ignited. Con-
tinued operation with a HI FUEL fault can lead to -
BLANK For customer use.
spillage of large quantities of fuel if the high fuel
float switch fails. PUMP: Green lamp is on when the pump is running.
It will come on and go off as fuel is pumped to
-
LO FUEL: Red lamp comes on if fuel level has maintain tank level. The lamp does not come on
dropped abnormally low. It indicates possible fail- when the EMERGENCY RUN switch is used.
ure of the "pump-on" float switch, a fuel restriction,
low fuel supply, or a defective fuel pump. The lamp
can be turned off with the RESET switch after the
fuel level rises to normal. The lamp will come back
on again during the next pumping cycle if the fault
remains.
SYSTEM READ
LO SHUTDOWN RESET EMERGENCY
BLANK PUMPON
RED GREEN
FIGURE 9-3. CONTROL FRONT PANEL
9-4
Switches and Circuit Breakers:
Circuit continuity through these control panel compo-
nents can be checked with an ohmmeter after all power
is removed. The following text describes their function.
Do not test circuits with an ohmmeter I i

when power is applied. Doing so can
damage the instrument.
I i
, ,
1 25" NPT BRASS PLUG
1
I
ONIOFFIEMERGENCY RUN: Switches both AC Ce
and DC power supplies. The momentary EMER-

GENCY RUN position allows pump operation if the
control fails to operate the pump automatically.
TESTIRESET: Hold the TEST position to test the

indicator lamps and pump operating circuits.
Replace any lamps that fail to come on. Pressing the
RESET position after correcting a fault condition
will restore control operation and turn off the indica-
tor fault lamp. The RESET position also restores
engine operation if the fuel control has been con-
nected to shut down the engine.
AC and DC CIRCUIT BREAKERS: Press the breaker

reset button to restore control operation if either has
tripped.
Float Switch Assembly

This assembly containsfive switches, each with a pair of
color coded leads coming out the top as identified in
Figure 9-4.
Testing: The switches on the float assembly can be

tested with an ohmmeter without removing from the fuel
tank. However, the tank must be empty of fuel.
Remove the J5 connector from the PC board assembly.

Each float switch must show continuity when measured
across its corresponding pair of contacts shown in Fig-
ure 9-4. If a switch is defective, the entire assembly must
be replaced.
Further testing can be done with the float assembly

removed from the tank. Connect an ohmmeter across a
switch as done in the previous paragraph. Place a 0.1 25
inch (3 mm) feeler gauge between the float and the
C-clip stop above the float. Lifting the float to lightly
pinch the feeler gauge should open the switch. Switch
should close again when float is moved down. Repeat
test on the other float switches.
Control Drawing and Schematic

The following control assembly drawing and overall
schematic will be helpfull when troubleshooting. Be
sure to read all notes on the schematic. An abbreviated
schematic is silkscreened inside the control box cover.
FIGURE 9-4. FLOAT SWITCH ASSEMBLY

COMPONENT IDENTIFICATION
1 CIRCUIT BOARD ASSEMBLY

2 SPACER, PCB
3 RELAY.2PST
4 SCREW, RELAY MOUNTING
5 CONNECTOR. KNOCKOUT
6 CIRCUIT BREAKER. DC 1-POLE
7 FRONT PANEL, REAR VIEW
8 SWITCH, ON/OFF/EMERGENCY RUN
9 SWITCH, TEST/RESET
10 CIRCUIT BREAKER. AC 2-POLE
11 LAMP ASSY, 7-LIGHT
12 CONTROL BOX
13 CONNECTOR, ROMEX
14 TRANSFORMER. WHEN USED
15 HARNESS. CONTROL
16 JUMPER, TERMINAL
FIGURE 9-5. CONTROL ASSEMBLY DRAWING
9-6
C B I O I - 2 POLE AC C I R C U I T
COLUMN I BREAKER. 1 5 AMP. 7 . 5 AMP
LLPTH
5 1 0 2 - 2 POLE SWITCH
P I 0 3 - 120/24OV PUMP MOTOR
TB1-5 K l 0 4 - SYSTEM READY INTERLOCK 7

EMERGENCY
TI05 - 120/240V TRANSFORMER
CR106- R E C T I F I E R BRIDGE
CB107 - 2 AMP C I R C U I T BREAKFR
DSI 15-OPTIONAL FAULT LAMP
D S I 17-SYSTEM READY 1 AMP

K I 18 -SYSTEM READY RE1 AY 4 7
@ DS I 2 1 B A S I N F AUI T LAMP
US 123-LOW FUEL FAUL T LAMP
0 s 1 2 5 - L O SHUTDOWN F ACJI T LAMP
0 5 1 2 7 - H I G H F U t L FAlJLT LAMP
K I 0 8 - H I G H 6UEL S t 1 @. 2i. 38
K 3 0 PUMP RCLAY 0 3 . 30
DS 1 3 2 PUMP RUN LAMP
K 109-L OW FULL SET @. 23.39
K 1 0 - L O SHUTDOWN SET @. 25.40
K 1 2 - B A S I N FAULT SET @ 21 .41 .30

K 13-OPTIONAL FAULT SET @ 15.43.44
NOTES:
I . SCHEMATIC KEY:
EACH COMPONENT I S LOCATED BY PART
NUMBER. ON THE RIGHT HAND S I D E . A
DESCRIPTION I S G I V E N OF THE PART AND I T S
K108 FUNCTIONAL LOCATIONS.
1 s -lo-++ TBI-l l H I G H FUEI. FAULT CONTACTS
K109
TBI-I~--++ TBI-13 LOW FUEL FAULT CONTACTS
Kl I0
181. 14 -++ THI 15 LOW SHUTDOWN FAlJL CONTACTS
N/O CCUTAClS
K I2 ON L I N E S 21 A K ) 41
TBI - lb-+l- TBI 17 B A S I N FALJLT CCJNIACTS
K I 18
Tap-26 18:'-2/ S Y ' J T E M K t A U Y CflNTAC!'; 2 S I L K S C R E E N ONAN "98 5 4 5 Of C I R C U I T S C H M A T I C LOCATED ON
THE l N S l L i E TOP OF THE COVER
1 , 1 ,4 I N A L rAOL1 ~ O b J l A
1'~
S T W C I TFRMINAL JUMPERS ARC S L P P L I E U BETWEEN T E R N I N A L S b h 7
WITH THF FACTORY S U P P L I E D 240 A i CONVECTION FUF. 120 VAC FIELd
, ,;, 3'
OPCRATION PLACE ONE JCIMPER BETWEEN TERMINALS 5 b b A N 1 T K
Sf CONLI JIINPLR B k l W t F Y 7 A N 0 8 CHANGk J L M ' f PS ON
IPANSIORMFR I F F DUII'PED Si k S I L K S C R E E N ONAN (98-5954
8 111 1HL IP1S101 OF - H E COVER FOG F a L 1?0/240 C W V E R S I O N
Ih?STRlJL !ON5
L I .Lr,yRATI TLUM.I.AL; s i .'. i )2 . AND S I G Z d SHOLILD

!li A:SIWRI FP wi 18- 1 4 I V i l l l A T C n FASTON TC, T H C rU I T C l n T
I lbll ',Wlii- TL1 P U u / l U t l i i L MAXIMUH AMOVNT OF
L L f C I R I C A L PWO'FC'ION
FIGURE 9-6. OVERALL SCHEMATIC DIAGRAM
9-7
PUMP
MOTOR
PUMP
OUTLET BROWN RED
BLACK BLACK
TERMINAL NO
I
P103-GND
WHITE
4 8
WHITE
PUMP
INLET
CONNECTIONS
VIEW FROM BEFORE RECONNECTIONS AFTER RECONNECTIONS

ABOVE
FIGURE 9-7. FUEL PUMP MOTOR RECONNECTIONS
Fuel Pump Motor Wiring Connections Control Wiring Connections

Connect a replacement fuel pump motor as follows to Remove the control cover for access to the wiring ter-
the wiring harness. See Figure 9-7. minals. See Figure 9-8.
1. Remove the end bell cover for access to the motor 1. Connect the float switch wiring harness plug to
wiring terminals. receptacle J5 on the PCB (Printed Circuit Board).
2. Reconnect the brown motor lead from terminal 3 to 2. Connect the 5 leads of the pump wiring harness to
terminal 6, and the red lead from terminal 2 to termi- the appropriate terminals on the control PCB.
nal 3. 3. Connect a 120 VAC or 240 VAC power supply to the
3. Cut the ring terminal connector from the white lead appropriate control terminals. The control is set up
and strip the insulation 1/ 2 inch (12 mm) for splicing at the factory for connection to 240 VAC. Make sure
to the wire harness lead marked PLUS-WHITE. selector switch S103 on the control PCB is in the
4. Connect the 5 leads of the wiring harness to the down position for 240V. If the power supply is to be
appropriate motor terminals or splice. Replace the 120 VAC, make the following reconnections:
end bell cover.
A. Remove the two jumpers between terminals
TB1-6 and TBl-7. Connect one jumper between
terminals TB1-5 and TB1-6, and the other
between terminals T B l - 7 and TB1-8.
B. Move selector switch S103 on the PCB to the up
position for 120V.
4. Use the two-lead wire harness to connect term~nal

TB1-19 to the positive (+) terminal of the starter
motor solenoid, and terminal TB-20 to the negative
(-) terminal.
5. Connect terminals TB1-14 and TB1-15 to shut 7. Terminal TB2-22 is available for connection of a
down the engine under low fuel conditions. grounding signal to activate the blank red light.
6. Terminals TB1-10 through TB1-17 and TB2-23 8. Terminals TB1-8 and TBl -5 are available for con-
through TB2-27 are available for connections to nection of a 120 or 240 VAC electric fuel shutoff
remote annunciators. valve rated not more than 5 amperes. The voltage
rating of the valve must correspond with the voltage
used for the pump. See proceeding Step 3.
POWER CONNECTIONS 1 7N/C VALVE

P103-4
M 1240Vl P103-WHITE
24 V BAlTERY
EARTH M ~ 1 0 3 - 3 CONNECTlONS
LEUTRAL 1120Vl P103-I (+)
AC 1 120/210V I
i 2
Y
3
1
1 5 6 7 8 9 10
N/C VALVE
I I t2 ,J Id $5 ,a r7 18
II
19 20 21
(4
rl
TB I 22 U W &o i. 27 ZB
3 =v
0000000000 TBZ a.
J6
0 0 0 0 0 0 0 0 0 0 0 0 0
J3
O(ooj
1 0
FIGURE 9-8. CONTROL TERMINAL CONNECTIONS

VOLTAGE RECONNECTION PANEL Accidental starting of the generator
(QSA GENSETS) leWARNlNGI set can cause severe personal injury
or death due to electrocution. Disconnect the starting
This option includes a heavy duty, multi-pole rotary battery cables (negative (-) cable first) when repairs
switch, hard-wired output terminals for single- and are made to the voltage reconnection panel.
three-phase voltages, and four convenience recepta-
cles supplying 120 and 240 VAC. The voltage select Batteries give off explosive gas that
positions of the switch are shown in Figure 9-9. The
switch eliminates rewiring of the generator leads to
b@%%l can result in severe personal injury
ignited. Do not smoke or allow any arc-producing
if
obtain the required voltage. devices in the battery area.

A lockable switch cover prevents inadvertent voltage Disconnect the genset starting battery cables (negative
changes. All hard-wired single- and three-phase out- (-) cable first) and do not reconnect until repair is com-
puts, and all convenience receptacles are circuit pleted. The negative (-) cable is disconnected first (and
breaker protected. reconnected last) to prevent arcing if a tool accidentally
touches the frame or other grounded metal parts of the
A step-by-step procedure for removal of the voltage re- genset while disconnecting/connecting the positive (+)
connection panel is found on page 9-14. Use the follow- cable to the battery. Severe injury can result if arcing
ing wiring diagrams and drawings when troubleshooting ignites the explosive hydrogen gas given off by the
or replacing components on the panel. If terminations battery.
stamped on wires are obliterated for any reason, use
tape to identify wire termination before removing. Hazardous voltage will cause severe
injury or death. Disconnect all elec-
trical supply sources before testing or repairing the
voltage reconnection panel.
TRANSFORMER CIRCUIT BREAKER CIRCUIT BREAKER

TX1, VOLT REF 2-POLE 6-POLE (CB1-3. CB7-9)
(FARSIDE) I
\
-
VOLTAGE \
RECONNECTlON
SWITCH (Sf) mWAmR WAIN ClRIlIT mENm
n w m u r
CLOSED
?. .-&€-Ell.- - ."."---. --
M U E l I R 7"
MER - M Y E R
YI PVSI 10 R Y '
1 CIRCUIT BREAKER
i
@ @
CIRCUIT BREAKER
(CBl4)
2
.
0 "3i 1 1 1 "LC 2 Vd, \
V i) 0 CIRCUIT BREAKER
OUTPUT TERMINALS
(HARD-WIRE) GROUND
T".
8
0 ce
1 lib &Mi 10 I* iC L*
- --
0 I C
TERMINAL BLOCK,
--- -
R
--- -
-
- e
-1 -
RECEPTACLES
GENERATOR LEAD
(TB-2) I
I
-- -2
I
e R
ACCESS
COVER
FIGURE 9-9. VOLTAGE RECONNECTION PANEL

" A SET CONNECTION SCHEDULE
TXl-XI TO VR21-2
TX1-X2 TO VR21-4
S1-35 TO TB21-23
TB1-LO TO GROUND
FIGURE 0-1 1. RECEPTACLE WIRING DIAQRAM. OW-SERIES

MODEL (IS GENERATOR CONNECTIONS WITH GENERATOR SWITCH OPTION
FIGURE 9-12. GENERATOR RECONNECTION DIAGRAM, QSA-SERIES SWITCH OPTION

Removing Reconnection Panel Assembly ( ) = WIRE TERMINATIONS
(S1-36,T8, (Sl-34lT8.
240 VAC)
Use the following procedure to gain access to compo- (GEN T7) 208 VAC)
-
H5
nents for troubleshooting, or to remove the panel HI H3
assembly from the genset.
-
370 OHMS b
1. Disconnect the genset starting battery cables, the

negative (-) cable first. 313 OHMS
2. Remove the 6 self-lock capscrews securing the
control door and hinge at the rear housing panel.
3. Remove the access cover over the TB-2 terminal
block (Figure 9-9).
4. Remove 17 hex-head capscrews from the perime-
ter of the reconnection panel. The panel can now be
oriented for troubleshooting; or proceed to Step 5
for complete removal and further service.
5. Remove all generator leads from the bottom con-
nectors of TB-2 terminal block. Make sure all leads
are marked for correct re-assembly.
6. Disconnect lead TB1-LO at the chassis GROUND
stud directly below the panel assembly.
7. Disconnect the following 3 leads inside the control
box as follows:
TX1-XI to VR21-2 (TX1 is transformer on panel.)
TX1-X2 to VR21-4.
S1-35 to TB21-23 (S1 is the main rotary switch). FIGURE 9-13. TRANSFORMER TX1 SCHEMATIC
8. Re-assemble in the reverse order of disassembly.
Connect all leads before installing the reconnect
panel. Connect the generator leads to terminal
block TB-2 per the terminal identification sticker on
the back of the reconnect panel.
Transformer TX1
This transformer eliminates the need for changing leads
at the voltage regulator when different voltages are
selected by the voltage reconnection switch (S1). The
five transformer lead connections are shown on the
voltage reconnection panel schematic Figure 9-10.
Input voltage to the primary winding of TX1 (HI and H3

or H5) are taken from taps of the stator winding (T7 and
T8). The voltage across the stator taps changes from S1
position 1 (208 VAC) and positions 2 and 3 (240 VAC).
The primary tap of TXl is switched by S1 so the voltage
regulator input remains unchanged.
The transformer schematic in Figure 9-13 shows lead

connection points and resistance readings of the coils.
Resistance readings should be within +lo%, and taken
at 77°F (25°C). There should be no resistance between
windings, and between windings and ground (lamina-
tion). Use an insulation resistance meter that applies
500 VDC or more at the test leads for this test.
ELECTRONIC GOVERNOR If the genset has the optional electronic governor shown
General in Figure 9-14, refer to the following sections for trou-
bleshooting and adjustment/calibration procedures.
The governor is used to maintain a constant engine
speed during varying generator loads. The mechanical
governor (standard) is set at the factory and does not
require further adjustment for normal standby service.
Refer to the engine service manual for service in-
formation.
CONTROL
BOX
GENERATOR END VIEW GENSET SIDE VIEW
n ,
ACTUATOR
MOUNTING
BRACKET
I1 ACTUATOR
1 ARM
\ LINKAGE
STOP ASSEMBLY
FUEL INJECTION LINKAGE DETAIL

PUMP (SHOWN AT MINIMUM FUEL POSITION)
FIGURE 9-14. ELECTRONIC GOVERNOR COMPONENT LOCATION

Troubleshooting
The electronic governor system consists of three major
components. These are the MPU (MagneticPickup),Con-
troller, and Actuator. The DC power source shown on the
drawing is the genset starting battery. The following
information providesfunctionaldescription and checkout MAGNETIC PICKUP
information for these components, and is useful to isolate
a governor system malfunction. A troubleshooting chart is
s
also included at the end of this section. LOCKNUT
The DC voltage readings referenced when troubleshoot- -1 FLYWHEEL HOUSING

ing are sourced from the starting battery. It is recom-
mended that the cranking motor be disabled when mak-
ing these tests by disconnecting the starter solenoid B+
lead. This permits application of battery voltage to the
governor system (by depressing the Start button) without GAP (1/ 2
engine cranking and starting.
Taking ohmmeter resistance

readings with battery voltage con
nected can cause severe meter damage. Be sure to GEAR TOOTH
disengagebattery voltagebefore taking resistance read-
ings of governor components. E f 1012
MPU (Magnetic Pickup):The pickup is threaded into the FIGURE 9-15. MAGNETIC PICKUP ADJUSTMENT
top of the generator flywheel housing and secured with a
lock nut. The flywheel teeth moving past the magnetic
face of the MPU generates an AC voltage that is coupled
to the Controller. Refer to the wiring diagram in Figure
9-18 for component wire terminations. The following
checks will establish a functioning unit
The DC resistance measured across the MPU leads

Controller) (disconnected from terminals 5 and 6 on
should be 175 ohms f 15% at 77OF (25OC). Resist-
ance from the leads to the case (ground) should be
infinity.
At cranking speed the MPU output voltage measured

between terminals 5 and 6 on the Controller should
be 1.5 VAC RMS or more (the meter AC input impe-
dance must be 5000 ohms/volt or greater). If not,
remove the MPU and clean the magnetic pole face. It
is important that all magnetic particles be removed.
MPU Adjustment: Incorrect adjustment of the MPU

can also affect the voltage output. Rotate the engine
so a tooth of the ring gear is centered in the MPU
mounting hole. Clean the mounting hole with com-
pressed air, then turn the MPU into the threaded hole
until it contacts the flywheel tooth positioned directly
below. See Figure 9-15. Then turn out from the tooth
1I 2 turn and lock in place with the jam nut. Be sure
the pickup does not rotate when tightening the jam
nut.
Control1er:This unit (Figure9-16) contains the electron- Measure resistance of the Actuator coil with the
ics for driving the Actuator. It has two controls (Gain and leads disconnected. Resistance should be 1 ohm
Speed) that provide governor adjustment. Voltage flO%at 77°F (25OC). Resistanceto the case should
checks that can be made to the Controller during crank- be infinity.
ing are as follows:
Disconnect the Actuator leads and apply battery
Battery voltage should appear between terminals 3 voltage to the Actuator terminals. Be sure to observe
(+) and 4 (-). If not present, check for wiring correct polarity as shown in Figure 9-18. The Actua-
problems. tor should go full fuel. If not, replace.
Voltage measured between terminals 8 (+) and 4 (-)

should be 3.75 +/2 I VDC (this is the Controller's
internal power supply). Replace Controller if not
present, or incorrect.
Battery voltage should appear between terminals 2

and 4 (-). Replace Controller if not present.
FIGURE 9-17. ELECTRONIC GOVERNOR ACTUATOR
Governor AdjustmentICalibration
This section contains information on adjusting the
optional electronic governor. The adjustments
covered are to the stop screws on the injection pump
FIGURE 9-16. ELECTRONIC GOVERNOR CONTROLLER mechanical governor (Figure 9-14), and to the GAIN and
SPEED screws on the Controller (Figure 9-18).
Actuator:The Actuator (Figure 9-17) controls the injec-
tion pump throttle lever. It receives input from the Con-
Contact with rotating machinery can
troller, which in turn receives input from the MPU. Afew result in severe personal injury or
operational checks can establish a functioning unit as
death. Keep hands and fingers clear while performing
follows:
tests on operating equipment.
Wipe the Actuator shaft and linkage if dirty with a
1. Check the governor Actuator linkage to see that it
clean, dry rag.
does not bind through its full travel. The linkage
should be as shown in Figure 9-14.
Check the end bearings on the linkage assembly. If
worn, replace. Prior to adjusting the governor controller, be sure that terminals
7 and 8 are jumpered.
The Actuator must be securely mounted.
2. Attach a tachometer to the engine or a frequency
Check wiring for corroded or loose connections. meter to the generator if the control panel does not
have one of these meters.
n
MAGNmC
PICKUP
CONTROLLER ' a IOC

II
FIGURE 9-18. GOVERNOR COMPONENT WIRING DIAGRAM
When using a frequency meter to determine engine speed, 9. Connect full rated load to the genset and observe
multiplyfrequency by 30 tocalculateengine speed. Example: 30 the frequency meter. If the genset cannot manage
X 60 = 1800 rlmin. the load, stop the genset and shorten the governor
rod by one-half turn. Repeat the procedure until the
3. Set the Controller GAlN adjustment (Figure 9-18) to
genset is able to manage the load, then tighten the
the second mark from zero.
locknuts.
4. Disconnect the governor rod from the throttle lever.
10. Connect 1 /4 rated load. Turn the GAlN screw on the
Controller clockwise until the Actuator becomes
5. Place Run/Stop/Remote switch in Run position to
unstable (hunts). It might be necessary to nudge the
start the genset.
Actuator lever by hand to cause it to begin hunting.
Back off the adjustment until operation is again
6. Adjust the right stop screw on the mechanical gov-
stable.
ernor to obtain a frequency of 72 Hz (2,160r/min) for
60 Hz gensets (62 Hz [I860 rlmin] for 50 Hz
11. Stop the genset and wait for 30 seconds to allow the
gensets). It might be necessary to loosen the left
turbo to coast down (if equipped). Restartthe genset
stop screw depending on direction of adjustment.
and check for speed overshoot. If the genset has an
overspeed shutdown, check the linkage for binding
7. Adjust the left stop screw to just take up the slack,
and make necessary repairs.
then tighten the locknut. Be careful not to bind the
shaft by setting the screw too tightly.
12. Restart the genset and check for frequency and
stability under various loads. Correct as necessary.
8. Stop the genset and attach the governor rod to the
throttle lever. Start the genset and operate without
13. Stop the genset and remove tachometer or fre-
load. Adjust the SPEED screw on the Controller to
quency meter if previously attached. The electronic
obtain 60 Hz or 50 Hz as appropriate.
governor is now calibrated.
1 - 1should perform service
death. Only qualified service personnel with knowledge of fuels, electricity, andmachinery hazards
procedures. Review safety precautions on page ii.
ELECTRONIC GOVERNOR TROUBLESHOOTING CHART
PROBLEM DETECTION I CORRECTIVE ACTION /

System appears dead. Battery voltage must appear between terminals Check wiring/connections
Actuator fails to move to full 3 (+) and 4 (-) during cranking (system between Controller and battery.
fuel. activation).
Manually operate the linkage. It must not stick Free linkage.
or bind.
Weak or no signal from the MPU (magnetic Check MPU (magnetic pickup)
pickup). Measure AC voltage between terminals adjustment; clean pole face of
5 and 6 of Controller during cranking. Voltage any metallic particles; or
should be 1.5 volts RMS or greater. Meter AC replace MPU.
impedance must be 5000 ohms/volt or greater.
Check Controller's internal power supply Replace Controller if voltage
between terminals 8 (+) and 4 (-) with system reading is incorrect.
activated. Reading should be 3.75 +0.5 VDC.
Check Actuator with power to Controller. Replace Controller if battery
Battery (B+) voltage should be read at voltage is not present. I
Controller terminals 1 and 2 with respect to
terminal 4 (B-).
Continue with testing only if battery voltage
was not present above. The following Actuator
checks are measured from terminal 4 (B-) on
the Controller.
1. No battery (B+) voltage at either Actuator Broken Actuator lead.

terminal.
2. Battery (B+) voltage at both Actuator Broken Actuator lead.

terminals.
3. Battery (B+) voltage at only one Actuator Replace Actuator.

terminal.
Actuator lever goes to full fuel Remove Actuator lead from Controller
whenever system power is terminal 1. Then apply power to the
applied and engine is not Controller.
running.
/
1. Actuator goes full fuel. Check for shorted Actuator
lead.
1 2. Actuator does not go full fuel. Replace Controller because it
should not cause Actuator level
NOTE: Remove power from Controller before to go to full fuel with engine
reconnecting the Actuator lead. not running.
- - -- - -- - -- -
/
1
r ~ c t u a t o hunts
operation.
r during r ~ i n k a bearings
I
~e sticking or binding.
I
Lubricate or replace.
I
i-- Improper governor adjustment
- -
See Calibration section for
adjustment.
@@&%I death. Only qualifiedservice personnel with knowledge of fuels, electricity, andmachinery hazards
ELECTRONIC GOVERNOR TROUBLESHOOTING CHART (Continued)
PROBLEM DETECTION CORRECTIVE ACTION
Inadequate power supply 1. Remove Actuator lead at terminal 1 on the

voltage to the Controller. Controller. Connect a DC voltmeter between
terminals 3 (+) and 4 (-) on the Controller.
2. Apply power to the Controller and If Actuator does not get to full
momentarily connect the Actuator lead to fuel, check Actuator leads. If
Terminal 4 (-). Actuator should go to full fuel voltage is less than specified,
position, and DC voltage (between terminals check for loose or poor
3 (+) and 4 (-) should be greater connections to battery.
than 80% of supply.
24 volts X 80% = 19.2 VDC

12 volts X 80% = 9.6 VDC
Reconnect Actuator lead to terminal 1

after test.
Placing The Genset In Service

Place the genset in service (where applicable) by mak-
ing sure the RUNISTOPIREMOTE switch is in
REMOTE position for automatic-standby mode of
operation.
FAN BELT REPLACEMENT PROCEDURE 4. Remove the four blower hub bolts and lockwashers.
QSA-SERIES GENSETS Then withdraw the blower, fan spacer, and asso-
ciated hardware (cap, two rubber isolators, and fan
Series QSA gensets use a centrifugal blower for radiator spacer.)
cooling and ventilation. See Figure 9-19. The blower
and fan spacer are mounted by four bolts to the top 5. At the engine compartment, slip the new belt over
engine belt pulley. The fan spacer extends through a the pulley. Make beltadjustments per instructions in
hole in the blower compartment bulkhead. The blower the engine service manual.
and spacer have to be removed to slip a new belt over
the pulley. Use the following procedure. 6. Reassemble the fan spacer, blower and associated
hardware as shown in the drawing. Note that there
Accidental starting of the generator
lornWARNl N G set can cause severe personal injury
death. Disconnect the starting battery cables (nega-
are eight holes drilled in the blower, cap, rubber
isolators, and the backing isolator. Align these
components so the blower hub bolts go through the
tive [-I cable first) from the battery to prevent acciden- four outer circumference holes of each component.
tal starting. See hole locations (typical) on the backing isolator
in drawing below.
Always disconnect the negative (-) cable first, and
reconnect it last to prevent arcing if a tool accidentally 7. Snug the four hub bolts. Then in opposite progres-
touches the frame or other grounded metal parts of the sion, torque each bolt o x to 9-1 1 foot pounds
genset while disconnecting or connecting the positive (12-15 Nem). The rubber isolators do not permit
(+) cable. Arcing can ignite the explosive hydrogen gas repeat torque application to the bolts.
given off by the battery and cause severe injury.
8. Reassemble the cone, air inlet guard and air box.
1. Disable the genset by removing the battery starting
cables, the negative (-) cable first. 9. Reconnect the starting battery cables, the positive
(+) cable first.
2. Remove the screws securing the air inlet guard and
box from the front of genset. 10. Start the genset and check operation.
3. Remove the cone.
FAN SPACER
BLOWER
AIR INLET
GUARD
LOCKWASHER
BLOWER \
fi BACKING
ISOLATOR
RUBBER
ISOUTORS v
CONE RETAINERS
OUTER
CIRCUMFERENCE
HOLES
FIGURE 9-19. QSA-SERIES COOLING BLOWER ASSEMBLY
9-21
This section consists of the wiring diagrams referenced 10-Light DC Control-Pages 10-6 and 10-7
in the text. It should be noted that they are typical, and
that wiring and component specifications are subject to 7-Light DC ControCPages 10-8 and 10-9
change. Contact your Distributor if you do not have the 12-Light DC ControCPages 10-10 and 10-1 1
applicable wiring diagrams.
Voltage Regulator Installation and Generator
The following drawings are included: Reconnections-Page 10-12
AC Control without Meters-Page 10-2 Generator Reconnections (Model QS)-Page
AC Control with Meters-Page 10-3 10-13
4-Light DC Control-Pages 10-4 and 10-5 Engine Monitor PC Boards-Page 10-14.
LEFT SIDE DOOR (REAR I N S
3. LOCATE ONE ( I 1 DANGER LABEL ON EXTERIOR AN0 ONE ( 1 )

0 ON INTERIOR OF LEFT SIDE DOOR I N ANY READILY V I S I B L E
n AREA AVAILABLE.
.
5 . SEE VOLTAGE REGULATOR INSTALLATION FOR CONNECTIONS
.
TO VR2 1 CB2 1 AND TB2 1
WITHOUT METERS
AC CONTROL WIRING DIAGRAM, BASIC WITHOUT METERS
10-2
WIRING DIAGRAM
( 3 & C ENGINES) ( A ENGINES)
LEFT SIDE DOOR BACK WALL O F CABINET RIGHT SIDE DOOR NOTES:
(REAR I N S I D E VIEW) ( I N S I D E VIEW) (REAR I N S I D E VIEW) I . A L L CCMPCNENTS SHOMN I N GE-ENERGIZED POSITICN.
DC CONTROL WIRING DIAGRAM. DETECTOR 10, SHEET 1
10-6
STARTER
CONFIGURATION
DC CONTROL WIRING DIAGRAM, DETECTOR 4, SHEET 2
18-5
c n ~ a t m~ ; b - ~ .ab-
=
y7yzyo ;,~zr mow

ww
2 J W L 0 L Z Z
a a
u u L L T+ O
2 C & y
2
C 5 2 E+
I
P C P
a + a b - m
C f
+
P P f
L C
P C P C 4 P f 4
o w o w o w m o w
2 1 2 1
, ,
W W
a a
n n I
+ 3
YD & UC GENERATORS FOR QS MODELS
18 -
- 518 -
18 -
518
L z L z
3 PHASE RECONNECTABLE I PHASE RECONNECTABLE
SECONDARY CURRENT TRANSFORMER CONN. 1-3
110/220V. 50HZ 1 10/190V. 5 0 ~

1 2 0~/ 2 0 a ~ . 6 0 ~ ~ 220/380V. 50HZ 240/416V. 60HZ 110/220V. 50HZ
1 15/230V. 50HZ 115/220V. 50HZ 127/220V. 60HZ 230/400V. 50HZ 254/440V. 60HZ
120/240V. 60HZ 120/208V. 50HZ 139/230V. 60HZ 240/416V. 50HZ 277/480V. 60HZ 120/24OV. 60HZ
127/220V. 50HZ tT21 254/440d. 50HZ CT2 1
LI
TI
LO
LO
LO
-8
-9 19 I1 I
12
CT13 CT23 CT22
L3 L2
NOTES :
I . CURRENT TRANSFOZMER SECONOARY MUST BE MANUALLY SELECTED.

HIGH VOL rAGE (AEOVE 300 VOLTS1 TERMINALS I&2.LO$_VOLTAGE
BELOW 3 0 0 VOLTS USE TERMINALS 1&3. TERMINAL # I 12 COMMON
2. GENERATORS 7 / F AND 9 X ARE NOT RECONNECTABLE AND ARE

I SECONOARY CURRENT TRANSFORMER CONN. 1-2 WOUND FOR A S P E C I F I C VOLTAGE
3. CONTROL
THESE CONNECTIONS ARE FOR SPEC E " L " WITH THE STANDARDIZED
4. T I E OFF UNUSED WIRES ( X I IF APPLICABLE)
1- VOLTAGE CODE
GENERATOR RECONNECTION DIAGRAM, (WITHOUT SWITCH OPTION)
10-13
-
18 -
518 18 518
- -
L z L z
3 PHASE RECONNECTABLE I PHASE RECONNECTABLE
l T I
VOLTAGE CODE
CONT
INPUT
TR9, 1 1 1
SECONDARY NRRENT TRANYCX1VER CCNV 1 ~ 2
NOTES:
I. CURRENT TRANSFORMER SECONDARY MUST BE.MANUALLY SELECTED.

HIGH VOLTAGE [ABOVE 300 VOLTS1 TERMINALS I&2.LOW VOLTAGE
BELOW 3 0 0 VOLTS USE TERMINALS 1&3. TERMINAL # I I S COMMON
2 . GENERATORS 7/F AND 9 X ARE NOT RECONNECTABLE AND ARE

WOUND FOR A SPECIFIC VOLTAGE
3 . THESE CONNECTIONS ARE FOR SPEC E " L " WITH THE STANDARDIZED
CONTROL
12-LIGHT DC CONTROL WIRING DIAGRAM, SHEET 1
10-10
d
cr3
WC3
I-H
cr LL
az
I-0
(/I 0
I G N I T I O N SYSTEM
STARTER
CONFIGURATION
i2VDCI24VDC
A1 I-TB1-3
ALTERNATOR C O N F I G U R A T I O N S
12 V O L T / 2 4 V O L T
MOTOROLA
10-7
WIRING D I A G R A M
( B & C ENGINES) ( A ENGINES)
LEFT S I D E DOOR BACK WALL O F CABINET RIGHT S I D E DOOR NOTES:

(REAR I N S I D E VIEW) ( I N S I D E VIEW) (REAR I N S I D E VIEW)
I . ALL COMPONENTS SHOWN I N DE-ENERGIZED POSITION.
2. I L L U S T R A T I O N NUMBERS REFER TO ONAN DWG. NO. 5 3 9 - 0 9 5 7

B & C ( D l I L L U S - S T D CONTROL AND 5 3 9 - 0 9 7 7 A ENG.
3. GAUGE RESISTORS R 1 2 . 1 3 ( I L L U S # 8 8 ) ARE USED ON 2 4 V

( - 0 2 . ~ 0 4 1 VERSION ONLY. MOUNT BEFORE ATTACHING HARNESS
4 . T I E A L L UNUSED LEADS I N T O HARNESS
5 . GROUND BETWEEN M l l & M I 2 ( I L L U S # 7 7 . 7 8 ) I S THROUGH

THE FRONT PANEL.
8* OUT L 5 AMPS HAXI
6. DASHED LEADS I N D I C A T E WHEN USED.
7. WHEN USING PRE-HEAT USE SILKSCREEN 9 8 - 5 9 0 1 - 0 2
OC STR DISC INPUT
. . .
10-4
ZONE 5 - B , C , D
I A L L COMPONENTS SHOWN I N DE-ENERGIZED P O S I T I O N
2 I L L U S T R A T I O N NUMBERS REFER TO DWG NO 5 3 9 - 0 7 4 1

( VERT ( D l I L L U S - S T 0 CONTROL AND 539-0997 ( D l H O R I Z
3 LOCATE ONE ( I ) DANGER L A B E L ON ;EXTERIOR AND ONE I I )

ON I N T E R I O R OF L E F T S I D E o O O R ' I N ANY R E A D I L Y V I S I B L E
AREA A V A I L A B L E
4 SEE GENERATOR CONNECTION DIAGRAM FOR I N P U T CONNECTIONS
5 SEE VOLTAGE REGULATOR I N S T A L L A T I O N FOR CONNECTIONS

TO V R 2 I . C B 2 1 . R 2 1 AN0 T B 2 l
==-
AC CONTROL WIRING DIAGRAM, WITH METERS
10-3
Onan Corporation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
612-574-5000
Telex: 275477
Fax: 612-574-8087
Onan is a registered trademark of Onan Corporation

Cummins is a registered trademark of Cummins Engine Company

Manual Detector DL4

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onon Manual

Printed in USA. 934-0502 3-91

Always use genuine Onan replacement parts obtained AC Voltmeter

See Onan Tool Catalog 900-0019.

INCORRECTSERVICE OR REPLACEMENT OF PARTS CAN RESULTIN SEVERE

UPPER AND CONTROL PANEL INTERIOR

PHASE SELECTOR WATTMETER

The components shown in Figure 2-1 are optional,

AC VoltmetecDual range instrument indicating genera-

Wattmeter (optional): lndicates generator output in

Voltage Adjust: Rheostat providing about plus or minus

Field Breaker Provides generator exciter and regulator

Emergency Stop Switch (Optional): Round, red, push1-

Running Time Metec Registers the total number of

RUNNING TIME Control Panel Lamp: Convenience lamp that illumi-

OVERIUNDER VOLTAGE SENSOR

TERMINAL INTERFACE TIME DELAYED STARTISTOP

FIGURE 3-2. CONTROL INTERIOR (WITH OPTIONS)

W3 8 W4 POSITION REMOTE START SIGNAL

P2-283 ARE FUNCTION MODE SELECTABLE AS FOLLOWS

ALT S l A R T DISC F' I

FIGURE 3-3. ENGINE CONTROL MONITOR

The high engine temperature shut-

Low Engine Temperature: Lamp comes on when water

Run Relay (K11)

FIGURE 3-4. RUN RELAY

FIGURE 3-5. INTERFACE RELAY MODULES

Preheat: The preheat circuit provides a signal during

Delayed Starting: The time delay start function pre-

CRI a START DELAY STOP D E L A Y I

FIGURE 3-6. PREHEAT MODULE WITH OPTIONAL TIME DELAYED STARTISTOP

sensed using a magnetic pickup mounted on the end-

Start Disconnect: 510 f60 r lmin

The starter reconnect value is from 0 to 30 rlmin, and

FIGURE 3-7. MAGNETIC PICKUP INTERFACE MODULE

TABLE 4-1. ENGINE DOES NOT CRANK

SYMPTOM CAUSE CORRECTIVE ACTION

1. SWITCH OFF Run/Stop/ Remote Press to desired, Run

2. Other fault Lamp Reset switch Press Lamp Reset switch

3. No indication. Fuses blown on ECM Check fuses F1 and F4.

Starter solenoid Inspect starter solenoid

Possible defective Check A1 1 board TB1-9

With S12 switch in Run

Broken wiring or poor Check and repair as

4. Time delay start Possible defective Check A15 board TB1-4

Check wiring and

TABLE 4-2. ENGINE CRANKS BUT DOES NOT START I

A. Low Fuel lamp Insufficient fuel Fill with correct fuel.

B. Fuel solenoid Fuse blown on ECM Check fuse F2. Replace

Possible defective Check for voltage out at

Broken wiring or poor Check and rectify as

C. Fuel solenoid Blockage of fuel Check fuel supply system,

D. Engine hard to Heater system not Check heater system

Engine glow plugs not Improper start-up

Time delayed Start/ Initiate a restart and

Depress Preheat switch

Check Preheat solenoid per

TABLE 4-2. ENGINE CRANKS BUT DOES NOT START (Continued)

SYMPTOM CAUSE CORRECTIVE ACTION