900 0181 Onan YB 200 350 KW Generators & Controls Service Manual (11 1981)
User Manual: 900-0181 Onan YB 200-350 KW Generators & Controls Service Manual (11-1981)
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Caution: This document contains mixed page sizes (8.5 x 11 or 11 x 17), which may affect printing. Please adjust your printer settings according to the size of each page you wish to print. Service Manual 200 to 350 kW VB Generators And Controls Troubleshooting and Test Procedures For Generators Regulator Controls 900-0181 11-81 Printed in U.S.A. Redistribution or publication of this document, by any means, is strictly prohibited. Safety Precautions The following symbols in this manual highlight conditions potentially dangerous to the operator, or equipment. Read this manual carefully. Know when these conditions can exist. Then, take necessary steps to protect personnel as well as equipment. This symbol warns of immediate hazards which will result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. k&&!%%l GUARD AGAINST ELECTRIC SHOCK PROTECT AGAINST MOVING PARTS Disconnect electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) o r allow skin surfaces to be damp when handling electrical equipment. Avoid moving parts of the unit. Loose jackets, shirts or sleeves should not be worn because of the danger of becoming caught in moving parts. Disconnect batteries to prevent accidental engine start. Jewelry is a good conductor of electricity and should be removed before working on electrical eq u ipment. Make sure all nuts and bolts are secure. Keep power shields and guards in position. If adjustments are madewhile the unit is running, use extreme caution around hot manifolds, moving parts, etc. Do not work on this equipment when mentally or physically fatigued. Use extreme caution when working on electrical components. High voltages cause injury or death. Follow all state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Redistribution or publication of this document, by any means, is strictly prohibited. 7 3- Contents . . TITLE . PAGE ...... ............................. .................. ............................................................................... ............................................................................. .................................................................................. .................................................................................... ..................................................... .................................................... SAFETY PRECAUTIONS ; Inside Front Cover INTRODUCTION 2 Forward ....................................................................................... 2 Test Equipment 2. Abbrevations 2 Generator .4 GENERATOR TROUBLESHOOTING i . . 6 Preparation.. i . . ............................ 6 7 Flow Chart A. No. AC Output Voltage at Rated Engine RPM .................................. Flow Chart B. Unstable Voltage, Eng'ine Speed Stable 1800 RPM .......................... /. .. 8 . . . 8 Flow Chart C. Output Voltage Too High or Low,. ............................................. 9 . Flow Chart. D. Exciter Field Breaker Trips.. .................................................. Flow Chart E. Unbalanced Generator Output Voltage. .:. ...................................... 10 . Adjustments and Tests ................................................................... . 1 11 [ A ] Testing AC Residual Voltage.. ......................... ............................ 11 [ B ] Testing L21 Reactor.. ................................................................. 11 [C] Testing Rectifier Bridge Asse-mbly (CR21) ....................... .'.:. :.... 11 [D] Flashing the Field ......................................... ............................. 12' [E ] Testing Reference Transformer T21 .................................................... 13 [F ] VR21 Replacement.. .(......:. ...i . . i . . ........... ..................13 . [GI Testing Rotating Rectifiers ........ .................................. i.. ......: 13 . [HI Testing Exciter Stator .;..... .................... :............................ i . 14 . [J ] Testing Exciter Rotor. .: .............:. ............:.............................14 [ K ] Testing Generator Stator .................... :.. :..........................14 [L ] Testing Generator Rotor.. ................................................................ .15 . [MI .Wiring Harness Check.. ................................................................. 16. [hJ] Sensitivity Reference Circuit. ..................................................i.. : 16 [ P I Voltage Regulator Adjustment. :. ...................17 . . .: .;.. .:. ....................... 17 . [Q] Reconnection Generator Disassembly ................................................................. :. .... 19 . .Generator Assembly :.................................................................... 19 .!. .............. .... .,:. ....... ;. ........ ..'. ;. :. .............:. ......... .......... . ..... ........................ ..............'. ............... ...... ................. .:. ..... CONTROL'SYSTEM ................................................................................. 820 . . . General ... .'. ................!..................................................... i.. ... ;....... 2b . . . Control .Operation .............................................................................. .';...: 22 . : Engine Control Relays ................... ..;................ ..: ......... :. ..... ...... :.. .I.. .. 22 . . Engine Control Modules. ...... ....................: .................... ;;............. :.'.. 24 .. Engine Control System CheGkout Procedure ........................... i ................i .... '29, Control Troubleshooting ........................................................... .:........ 31 General ................................................................... ;.................. 31 .:..... 32 .Flow Chart A. Engine Fails to Crank. Switch In "Run" Position ........................ Flow Chart B. Engine Fails to Crank. Switch In "Remote Position.. .......................... 33 . Flow Chart C. Engine Malfunction Shutdown, Fault .Light "ON" (Five Light System), ...........34 Flow.Char;t D.Engine Malfunction Shutdown, Fault Light "ON" (Single Light System) ........ 35 WIRING DIAGRAMS .......................... .'.............................................. 36 ~ . . ; ; I . 4 . . I . , . .:.I. ' . _. . . . . Redistribution or publication of this document, by any means, is strictly prohibited. . Introduction FOREWORD This :manual is .divided 'into fwo sectims a s follows: 1. GENERATOR .Co:ns!ists o f ;g!ene:r.a.l c a t i o n s .on e .YB g:en.erato:r, troubleshooting guides and :procedures 'for testing and repairin:g I h e systems. 2. C0NTR:OLS T!r:o.ubleslhoot:i-ng guides, procedures for testing :and repairing the system are contained 'in this section. Adescr'i,pY'iono i the cornpone.nts and an analysis .of the module !ci:rcaitryare ii-nc'luded- - This manual provides troubleshooting and repair information for O"AN series Y 8 generators. %Itis intended t o provide the maintenance technician,serviceman or Onan distributor with a logica'l .procedure to enable him to systematically locate and re,pa'ir malfunctions in the generator and control systems. This information is not applicable to the (engine; refer to the engine manufacturer's ,manual. - 'Re,pa'ir .i.nf.ormationon :printed circuit irnodules .is ,no1 extensive ;because t.he iplwg-in lrnodu'les 'lemild ?:hemselves m.oreto replacem.e:n$fhan :repair..ONRNdp.es not .reco.mmend.repair .of the :printed .c'i.rc.uit exce,pl at the factory and :has in'it'iated..a 're change service obtai,nab le t h rough .d:istrii.bufo rs. For rno.re .inforrnation, contact your :d.istr.i:butor 'or t,he .ONANservice department TEST iEQU'I.P.M,E"T :Most 01 fh:e tests o.utlined 'in this .manual can be iperf o.rmed *withS'i,m.pso-n'V.OM. .Model 260, 262 o'r :equivalent. .Kelvin .or W.heatsto-ne b.rid.g.e.ohrnme%e,r.. .A,pp'l:icationof meters .orihlgh 'heat soldering :i.ronsto printed c i rcui.t:boardsby other Pha ual if ied ipersom.neI can .result .in u nnecessary.and .expen.sive damage. An equivalent VOM io a Simpson 260 o r 262 should have a maximum battery voltage of 6VDC (preferably with size AA bat.teries), on ranges other than R x 1. Some VOM's have outputs of \9UDC or 22.5VDC, which are sufficiently high to damage solid state devices. High vdiage testing or high potential (or Megger) testing of generator windings can cause damage to solid state components. 'Isolate these components :before testing. WAR N:lNG ONAN RECOMMENDS THXT A L L SERVICE INCLUDING INSTALLATION OF REPLACEMENT .PARTS ONLY BE DONE BY PERSONS .QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE. FROM THESTANDPDINT~OF POSSIBLE 'INJURY AND/OREQUlPMENT T THE SERYICE PERSON BE QUALIFIED. CDAMAGE IT IS SIMPERA R-S-R wx3 * 'N0 VDC VAC LOP HET K *Q R C ;R.unDo not replace the printed circuit board untilexternal trouble has been corrected to avoid damage to new PC board. Replace voltage regulator PC board per procedure [F]. * Isengine running at correct RPM? Set RPM per instructions in appropriate engine manual. -nob. Does adjustment of control R l 8 on VR21 result in correctoutput voltage? Set per Voltage Calibration Adjustment [PI. no c .. 1 Are reference transformer (T21) tap connections correct and secure on TB22? See TEST [Q]. r( Do not replace the printed circuit board until external trouble has been corrected to avoid damage to new PC board. Are generator output leads properly connected? See Figure 19, page 18. Replace voltage regulator PC board VR21 per procedure [F]. 8 Redistribution or publication of this document, by any means, is strictly prohibited. FLOW CHART D. EXCITER FIELD BREAKER TRIPS Does AC output voltage build up to 150% or more of rated voltage before breaker trips? ' Check for any loose or broken wires or connections on VR21 assembly. . -yes- I nb I t t Check diodes CR1.2.3.4.5 and 6 in rotor assembly Replace if bad. per TEST [GI. ' . Check diodes and SCRs in bridge assembly CR21 per TEST IC]. 1 r I I Check reference transformer T21 and connections per TESTS [E] and [a].Replace if bad. Check generator stator leads for proper connection. See Figure 19. page 18. Check exciter rotor winding per TEST [J]. Replace i f bad. 7 Check generator rotor field winding per TEST [L]. Replace if bad. Check generator stator windings per TEST [K]. Replace i f bad. w L I Do not replace the printed circuit board untilexternal trouble has been corrected to avoid damage to new PC board. Replace voltage regulator PC board VR21 per procedure [F]. J 1 9 Redistribution or publication of this document, by any means, is strictly prohibited. FLOW CHART E. UNBALANCED GENERATOR OUTPUT VOLTAGE Remove load at generator terminals. Is output still unbalanced? Check for correct grounding of generator and load. -no c Are generator leads connected and grounded properly? See Figure 19. page 18. E. Isgenerator stator winding continuous per TEST [Kl. no d , - n o 4 Correct as necessary. Replace stator assembly. Check load for ground faults and correct as necessary. . . i 10 Redistribution or publication of this document, by any means, is strictly prohibited. ADJUSTMENTS AND TESTS All of the following Adjustments and Tests can be performed without disassembly of the generator. They should be used for testing generator and regulator components in conjunction with the troubleshooting flow charts. All ohmmeter tests must be made with the unit stopped to prevent meterdamage. . Testing AC Residual Voltage FIGURE 6. Generator residual A C voltage should be checked first if there is no AC power output. A good place to check is at TB21 across terminals 62 and 63 (see Figure 5). Residual voltage should be 5-10 VAC at normal operating rpm. If none, flash field per Test ID]. If residual voltage is present at TB21, then check continuity of circuit breaker CB21. If CB21 is OK, proceed to VR21 PC board and check for residual voltage between connector numbers 11 & 1 2 , l &2, and 9 & 10. If none, check continuity between these points with the gen set shut down. If voltage is low, test L21 reactor Test [B] and T21 transformer Test L21 REACTOR A C TERMINALS ARE GIVEN NUMERIC DESIGNATIONS FOR TEXT REFERENCE ONLY. DOES NOT APPEAR ON UNIT. ' [El- Testing L21 Reactor The L21 commutating reactor (Figure 6) mounts inside the control box. The coils 1-2 and 3-4 are wound on the same core. Resistance between 1-2 and 3-4 should be .031 to .037and .038 to .046 ohms respectively at 77" F (25O). Resistance between coils and from any terminal to frame of the reactor should be infinity. ~~ ~~ FIGURE 7. SCR BRIDGE ASSEMBLY Testing Rectifier Bridge Assembly (CR21) The rectifier bridge located within the control cabinet contains 3 diodes (CRl. CR2 and CR3) and two silicon controlled rectifiers (SCR.1 and' SCR2). The components are encapsulated within a hermetically sealed block. Therefore, failure of any diode or SCR means the entire unit has to be replaced. See Figure 7. Disconnect wires from rectifier unit prior to testing. Test unit in order shown in Table 2. Refer to Figure 8 for SCRl and SCR2 test circuit. When test is complete and satisfactory, reconnect unit observing correct wiring hook-up. 11 Redistribution or publication of this document, by any means, is strictly prohibited. { 1 oon_ I I 1-1 t 6 VOLT DRY CELL BATTERY v FIGURE 8. .TESTING SCR series respectively with the 12amp 300 V diode. Start the generator set and operate at normal rpm. Touch positive lead to + terminal on rectifier bridge, and negative lead to the -terminal. Hold leads on terminals just long enough for voltage to build up. TABLE 2. TESTING RECTIFIER BRIDGE ASSEMBLY CR21 OHMMETER LEAD + - X a X Do not keep excitation circuitry connected longer than 5 seconds, or damage may occur to the exciter regulator. CAUTION X X X I - tntlnlty RXlOK 6- 10 SO-Ohms RXl t CR1 AC1 I PLACE RESISTOR HERE FOR 12V OR 24V BATTERY RXlOK RXlOK 1"ll"ll" 6- lo SO-Ohms X R X l DIODE AC2 + - + 9' ACI + SCRl ACl + 3 VO11S Io" AC2 + SCRZ AC2 + 3 VO115 loss than RECTIFIER BRIDGE ASSEMBLY CDI 6 VOLT DRY CELL BATTERY Flashing The Field If output voltage does not build up it may be necessary to restore residual magnetism by flashing the field. Assemblea 6-volt batteryand diodeasshown in Figure 9. FIGURE 9. FIELD FLASHING CIRCUIT If a 6-volt lantern battery is not available, a 12-volt or 24-volt generator set battery can be used. However, a 20-ohm or a 40-ohm, 2 watt resistor must be used in 12 Redistribution or publication of this document, by any means, is strictly prohibited. , . Testing Reference Transformer T21 Testing Rotating Rectifiers Transformer T21 has eight leads; six are primary leads marked H I through H6 and two are secondary leads marked X1 and X2. Six diodes labeled CR1 thru CR6 are mounted on the rotating exciter assembly asshown in Figure 17. Test diodes as follows: 1. Remove one diode at a time from heat sink. Test that diode and reinstall on heat sink before proceeding to the next one. 2. Check the resistance of the diode with an ohmmeter. Connect one lead to the top of the diode and the other lead to the diode stud. Observe reading . 3. Now reverse leads and again observe reading. A good diode should have a higher reading in one direction than the other. If both readings are high, or if both readings are low, diode is defective and must be replaced with new, identical part. The winding schematic (Figure 10) shows the resistance values for the individual coils. Resistance between any primary and secondary leads and from any lead to transformer frame should be infinity. ' I . I 350-427.OHMS I -333-407 I OHMS -303-371 rn *282-344 OHMS Excessive dust or dirt on diodes and other components will cause overheating and eventual failure. Keep these assemblies clean! CAUT,ON -270-33 T21 k 1 2 8 - 1 5 6 6HMS x1 VR21-9 I x2 4 .VI321-10 OUNTED ON HEAT-SINK FIGURE 10. T21 WINDING SCHEMATIC Use 24-lbs-in. (2.7 Nom) torque,when replacing nuts of F1+ and F2-, CR1, CR2, CR3, CR4, CR5, and CR6. FIGURE 11. DIODE ASSEMBLY VR21 Replacement . Use the following procedure for replacing the voltage regulator PC board or VR chassis. 1. Stop engine. 2. Disconnect and if necessary, label wires; VR21-1 through VR21-12. Refer to AC control wiring d iagram. 3. Remove four screws at corners. 4. Remove old PC board. 5. Install new PC board and secure with fourscrews. 6. Reconnect wires removed in step 2 to proper terminals. 7. ConnectjumperW12to properterminalsfor your particular voltage code and voltage connection. See Test Procedure [Q]. 8. Perform voltage calibration and stability adjustment procedures to obtain the correct generator output voltage and stability with new PC board in set. Replace rectifiers using the following procedure: 1. Unsolder leadwires from terminals. 2. Use proper size wrenches to hold the body while removing the nut. 3. Push the rectifier free of mounting hole in the heat sink. 4. Insert new rectifier into mounting hole. Using nut and washer provided, secure rectifierto heat sink. 5. Torque diodes on rotating exciter assembly to 24-lb. in. (2.7 Nom). 6. Solder leadwires to new rectifiers. ' Use a 40 watt soldering iron. Hold a needlenose pliers between rectifier and soldering point io prevent destructive heating. Excessive heat on these components will destroy them. 13 Redistribution or publication of this document, by any means, is strictly prohibited. , C R I CR4 Testing Exciter Stator Testing for grounds: Using an ohmmeter (R x 100 scale), measure the insulation resistance between either lead F1 or F2 and the laminations. A reading of less than infinity indicates a grounded coil. See Figure 12. c FIGURE 14. TESTING EXCITER ARMATURE Testing Generator Stator Testing for grounds: Before testing stator, disconnect control wires 4,7,8,9 and 10 from TB21. Isolate from ground and each other. Connect all stator output leads (Tl-T12) together. Use an ohmmeter set on the R x 100scale to measure the insulation resistance between the windings and the statorframe. A reading of less than infinity indicates a grounded coil. FIGURE 12. TESTING FOR GROUNDS Testing winding resistance: Measure coil resistance between leads F1 and F2 with an ohmmeter (scale R x 1). Resistance.should be 15.55 to 17.79 ohms at 68" F (20°C). See Figure 13. Testing for shorts: Connect an ohmmeter (R x 100 scale) between each individual winding and the other windings connected together. Repeat until all six coils have been tested. A reading of less than infinity indicates a short. Measure resistance of windings using a Wheatstone or Kelvin bridge meter. See Figure 15. If anywindings are shorted, open, or grounded, replace the stator assembly. Before replacing the assembly, check the leads for broken wires or damaged insulation. Stator output leads T4, T7, T8, T9 and T10 are interconnected (within the stator) to five stranded (#lo aircraft) control wires. These wires are labeled 4,7,8,9 and 10 respectivelyand terminate at TB21 (terminals 61-65). FIGURE 13. MEASURING FIELD RESISTANCE OM KELVIN BRIDGE Testing Exciter Rotor Testing for grounds: Remove diodes CRl, CR2, CR3, CR4, CR5, and CR6from diode heat sink assemblies. Using an ohmmeter (R x 100 scale) measure insulation resistance between any of the leads and the laminations (exclude the diodes from the test circuit). A reading of less than infinity indicates a ground. Testing winding resistance: Using a Wheatstone or Kelvin bridge meter, measure resistance between leads pairs Tl-T2, T2-T3 and Tl-T3. Resistance should be 0.496-0.607 ohms. at 68" F (20" C). See Figure 14. FIGURE 15. TESTING STATOR WINDINGS 14 Redistribution or publication of this document, by any means, is strictly prohibited. TABLE 3. RESISTANCE VALUES FOR STATORS All resistances should be within the value shown at 68" F (20" C). Use a Wheatstone or Kelvin bridge for this test. Measure between the following leads: T I -T4 T9-112 . T7-T 10 T3-T6 T2-T5 T8-T11 KW RATING 50Hz I 60 Hz CONTACT ONE PROD TO ONE'FIELD LEAD AND THE SECOND PROD T O THE OTHER FIELD LEAD. ,RESISTANCE VALUES ARE GIVEN IN TABLE 4 , RESISTANCE , Ohms FIGURE 17. MEASURING ROTOR WINDING RESISTANCE 208 250 .0032 to .004 250 300 .0022 to ,0027 350 .0018 to .0022 290 . TABLE 4. ROTOR RESISTANCES I kW RATING AND'SERIES 60 Hz 50 Hz Testing Generator Rotor ' 165.0 DYH 165.0 DFP 192.0 DFP \. Testing for grounds: Remove F.+ and F- rotor leads from diode heat sink assemblies. Connect an ohmmeter (R x 100 Scale) between either rotor lead and the rotor shaft. A reading of less than'infinit.y indicates a grounded coil. See Figure 16. . 208.0 DYB 208.0 DFM 208.0 FT 250.0 DFS 250.0 DFT' 250.0 DHA 290.0 DFN 290.0.DFU 290.0 DHB 290.0 WF 200.0DYH 200.0 DFP 230.0 DFP 250.0 DYB 250.0 DYB 250.0 FT 300.0 DFS 300.0 DFT 300.0 DHA 350.0 DFN 350.0 DFU 350.0 DHB 350.0 WF RESISTANCE OHMS. 1.61 - 1.97 1.61 - 1.97 1.8G to 2.20 1.91 to 2.33 1.91 to 2;33 '1.91 to 2.33 2.17 to 2.35 2 3 7 to 2.35 2.17 to 2.35 2.38 to 2.90 2.38 to 2.90 2.38 to 2.90 2.38 to 2.90 CONTACT'ONE PROD TO EACH OF THE FIELD LEADS AND THE OTHER PROD T O THE ROTOR SHAFT. IF ROTOR IS GOOD THERE SHOULD B E N O READING O N OHMMETER FIGURE 16. TESTING ROTOR FOR GROUNDS Testing winding resistances: Use a Wheatstone or Kelvin bridge for this test. Remove F+ and F- rotor leads from diode heat sink assembly. Connect meter leads between F+ and F-. Resistances should be within the values specified in Table 4 at 68" F (20" C). See Figure 17. 15 Redistribution or publication of this document, by any means, is strictly prohibited. I 1. Frequency sensitive-voltage output reduces in direct proportion to the engine speed. 2. Non-frequency sensitive-voltage output does not decrease when engine speed decreases. Wiring Harness Check Carefully check wiring harnesses as follows: 1. Inspect all wires for breaks, loose connections, and reversed connections. Refer to applicable wiring diagram. 2. Remove wires from terminals at each end and using an ohmmeter, check each wire end to end for continuity or opens. 3. Using an ohmmeter, check each wire against each of the other wires for possible shorts or insulation breaks under areas covered by wrapping, material. 4. Reconnect or replace wires according to applicable wiring diagram. A temporary overload with non-frequency sensitive reference could cause the engine to reduce speed, and then require a 50- to 60-percent load reduction before it could return to rated speed. 3. Semi-frequency sensitive-voltage output decreases as engine speed decreases, but not as severely as in the “frequency sensitive” mode. Unless otherwise requested by the purchaser, Onan sets are connected at the factory for semifrequency sensitive voltage regulation because a decrease in voltage output reduces the effective load on the engine, permitting the set to return to its rated voltage and frequency when the overload is removed. Changing Sensitivity Reference: The sensitivity reference can be changed if necessary, by unsoldering W1 on VR21 at “S” (semi-frequency sensitive) and resoldering it to hole “F” (for frequency sensitive) or to hole “N” (for non-frequency sensitive) voltage regulation. See Figure 18. IN1 Sensitivity Reference Circuit Three types of sensitivity references are possible with voltage regulator VR21 R26 DAMPING \ R18 VOLTAGE 8 WlREW1 - 1 -2-3 4 5 6 7 8 9 IO VR2lBOARD ASSY-PC R ~ Y II 12 TBI 332-1956 FIGURE 18. VR21 PRINTED CIRCUIT BOARD 16 Redistribution or publication of this document, by any means, is strictly prohibited. . Voltage Regulator Adjustment Reconnection If VR21 voltage regulator printed circuit board has been replaced, it may b,e necessary to center the . voltage adjust rheostat (R21) on meter panel. 1. Center the voltage adjust knob so pointer is in a vertical position. . Figure 19 shows reconnection possibilitiesfor the YB series generators. When reconnecting bus-bars for a different voltage, be sure to reconne'ct lead from terminal 63 (inside control box) to either H3, H4 or H5. See Figure and 19. . . 2. Open meter panel doors and start unit. 3. Using a screwdriver, turn R18 potentiometer on printed circuit board VR21 in direction shown to increase or decrease the voltage (See Figure 18). Observe voltmeter on-meter panel while making adjustment. Set voltage with no load connected to generator. ' (Example: For a 120/240 volt connection, set no. load voltage at .approximately 246 volts). .. r ' , If voltage is unstable or tends to hunt, turn R26 potentiometer on VR.21 in the direction shown .on printed circuit,board to increase damping (Figure 18). . 17 . Redistribution or publication of this document, by any means, is strictly prohibited. GENERATOR CONNECTION SCHEMATIC DIAGRAM GENERATOR CONNECTION WIRING DIAGRAM IL3 3 if-s OJII L2 120/24C 240/48( 3 3 2 5fld HS 0110 LI HS O1I2 1201208 3 H3 127/220 3 H4 139/240 3 110/190 -5 - T6v92 HI H3 115/200 3 H4 120/20a 5 H4 127/220 5 H5 - - 220/38c 3 - H3 240/416 5 H3 254M4C 3 H4 T3 L3 L3 -- 277/480 5 H5 220/38( 5 H3 230/40 0 5 H I 240/416 5 H4 254/44( 5 HI - CT'P L2 LI P. LI 347/600 5 5/018 bP 411 -7 di LO L3 - 6 [ 0 ] 9 63 - H5 L 3 b 3 L 2 6 2 LId n 0 II o IO 0 12 l ' T - - i3 YB SERIES GENERATORS N O T E SINGLE PHASE NOT AVAILABLE 98-2579(C) FIGURE 19. OPTIONAL VOLTAGE CONNECTIONS 18 Redistribution or publication of this document, by any means, is strictly prohibited. GENERATOR DISASSEMBLY If generator testing determines that generator needs repair, remove and disassemble as follows: 1. Disconnect and remove load wires in outlet box. 2. Disconnect leadwires from control box. Check wire markings for legibility to ease assembly. Arrange leads so they can be easily withdrawn from the control box. 3. Remove generator air inlet grille and end bell cover. Disconnect and remove control box housing. Remove capscrew. washer and speed sensor wheel from rotor shaft. 4. Block the rear of the engine in place by supporting the flywheel housing. Remove capscrews securing the generator mounting bracket to the skid base. Remove thegenerator air outlet screen. Step 5 applies to models using disc with holes (Figure 20). 5. Attach an overhead hoist to the stator assembly lifting bar. Remove the capscrews securing the stator assembly to the engine flywheel housing and slide the stator back about three inches. Remove the capscrews attaching the flexible drive coupling to the engine flywheel and remove the stator assembly and rotor assembly (rotor inside the stator) from the engine. 8. Remove end bell from stator assembly; remove exciter field from end bell assembly if necessary. 9. Remove bearing and spacer from shaft. 10. Disconnect rotor field leads from rectifier assemblies F1 and F2 on exciter armature. Remove exciter armature. GENERATOR ASSEMBLY Generator assembly is the reverse of disassembly procedure: 1. Always replace bearing with a new one; apply a layer of Molykote grease Onan #524-0118 on endbell bearing bore before inserting bearing. 2. Torque bearing capscrew to 60-70 Ib. ft. (81.3 to 94.9 N.m). Step 3 applies to models DYH and DYB only. 3. Assemble rotor and stator to engine. Be sure to install theeight flat washers between the disc and blower (Figure 20). Use spray adhesive or heavy grease to hold washers in place during assembly. 4. Torque drive disc to rotor capscrews to 200-240 Ib. ft. (271 to 325 N.m). 5. Torque drivedisc to flywheel capscrews to 110 to 120 Ib. ft. (149 to 162 N m ) . 6. Torque end bell mounting stud nuts to 55to 65 Ib. ft. (75 to 88.0 N.m). 7. Torque stator mounting capscrews to 45 to 55 Ib. ft. (61 to 75 N m ) . 8. Adjust magnetic sensor air gap at .050- to .060inch (1.27 to 1.52 mm). 9. Refer to parts catalog for replaceable parts and assemblies. Refer to applicable wiring diagram for reassembly. Do not lei rotor hang unsupported by the flexible drive coupling. Rotor weight will damage the flexible drive coupling. Proceed to step 8. Attach an overhead hoist t o the stator assembly 6. lifting bar. Remove the capscrews securing the stator assembly t o the engine flywheel housing and slide t h e stator assembly off the rotor assembly. 7. Attach hoist and sling to the rotor assembly and apply a slight lift to support the rotor. Remove capscrews securing the flexible drive coupling to the engine flywheel and remove the rotor from the engine. ,FLAT WASHER (8) 1 STATOR I DISC (WITH HOLES) 6-1104 FIGURE 20. GENERATOR DISASSEMBLY 19 Redistribution or publication of this document, by any means, is strictly prohibited. Control System Governor Control: This single-pole double-throw, center-off, momentary contact switch is wired into a split-field series motor situated on top of the engine governor. Used only with a Woodward PSG Governor, the switch operates the motor which adjusts the governor and therefore the engine speed. GENERAL The shock-mounted control box has two doors that open from the middle. For identification purposes, left and right is determined by facing the control panel. The left hand door is designated the AC panel and contains the following standard equipment. See Figure 2.1. Standard .DC Panel Equipment: Dual RangeAC Voltmeter: Scales 50 to 300 volts and 100 to 600 vol.ts AC. Oil Pressure Gauge: Connected to a resistance type sender on the engine, this instrument indicates engine circulating oil pressure. Dual range AC. Ammeter: Range of meter depends upon size of generator. Water Temperature Gauge: Connected to a resistance type sender on the engine, this instrument indicates engine coolant tem perature. Voltmeter ammeter phase selector switch: Selects the phases of the generator output to be measured by the AC voltmeter and AC ammeter, ie., line-to-line, line-ta-neutral, single phase or three phase. Ammeter: Indicates the output current of the battery charging alternator. Range Indicator Lights: Identifies high or low scale to be read on the AC ammeter or AC voltmeter. Run-Stop-Remote Switch: Starts and stops the unit locally or from a remote location. Frequency Meter: Pointer type meter indicates generator output frequency in Hertz. Reset Switch: Manual reset for engine monitor after shut-down. Run-Stop-Remoteswitch in “STOP” position. Running Time Meter: Registers total number of hours, to one-tenth hour that unit has run. Recorded time is accumulative; the meter cannot be reset to zero time. Lamp Test: Depress to test warning lamp bulbs. Operate only while engine is running. Warning Light: Indicates “Fault in engine operation”. Voltage Regulator: Rheostat (R21) provides an adjustment of plus or minus 5 percent of generator output voltage. Optional DC Panel Equipment: Penn State Run-Stop/Reset-Remote Switch: Momentary contact in the depress during reset position. To reset engine monitor, hold switch in the DDR position, actuate reset switch, release and select run to start engine. Exciter Circuit Breaker (CB21): Provides generator exciter and regulator protection from overheating in the event of certain failure modes of the generator exciter and voltage regulator. Warning Lights: Eliminates the one “Fault” light and substitutes five indicator lights to give warning of: 1. Overc rank 2. Overspeed 3. Low Oil Pressure 4. High Engine Temperature 5. Low Engine Temperature Optional AC Panel Equipment: Kilowatt Meter: Connected to a transducer mounted on the back of the control cabinet, this instrument indicates generator output in kilowatts. The transducer is connected across the phases of the generator, and to the current transformers. 20 Redistribution or publication of this document, by any means, is strictly prohibited. INDICATOR LAMPS INDICATE UPPER AND LOWER SCALE ON VOI TMFTER AND AMMETER - 1/4 TURN FASTENERS TURN BOTH SCREWS TO OPEN HINGED CONTROL PANEL DOORS DUAL RANGE AMMETER R ' P A N E L LIGHT AND. SWITCH .t . D U A L RANGE AC VOLTMETEI 01L PRESSURE GAUGE ...,,...... VOLTAGE ADJUST ING RHEOSTAT .....:. .-.a .I.> I 11.1. . .: ..... -WATER TEMPERATURE GAUGE : FREQUENCY METER- ' EXCITER CIRCUIT BREAKER RUNNING TIME METER - . - - . .- DC AMMETER RESET SWITCH FOR ENGINE MONITOR n o u n s 1-3 \ PHAS2 SE,LECTOR SWITCH F A U L T LAMPS (I STANDARD 5 OPTIONAL) -I 'i-RUN-STOP-REM0T E LKILOWATT METER (OPTIONAL) FIGURE 21. CONTROL PANEL 21 Redistribution or publication of this document, by any means, is strictly prohibited. CONTROL OPERATION Ignition Relay, K12: Energized b y B+, through module A1 1when R-S-R switch is placed in run position. Relay A1 1-K1 N.C. contacts complete the circuit through module A l l - 2 0 terminal .to relay K12 coil. This relay remains energized for duration of engine run. In emergencies, service personnel may be required t o service afailed generatorset in minimum time. This is especially true if generator is the backup power source for life support equipment in hospitals. The information in this section will instruct personnel on operation of relays and printed circuit modules. Used with the Wiring Diagrams, it will providegreater understanding of control system function. When K12 energizes the following occurs: 1. Contacts 8 and 5 close and apply B+ to voltage regulator of battery charging alternator to provide excitation. 2. Contacts 4 and 7 close and apply B+ to: a. Oil pressure gauge. b. Water temperature gauge. c. Water solenoid valve. d. Fuel pump. e. Energize K15, stop relay (not diesel).. f. K11-7, input to module A14. g. K15(-6) to energize fuel solenoid valve (not diesel ) . Engine Control Relays The following are brief descriptions of operation and functions of the control relays. The term B+ is used t o designate battery voltage (+24 VDC). Start Disconnect Relay K11: Placing R-S-R (RunStop-Remote) switch in Run position applies B+ to coil terminal B of relay K11. Coil terminal A is connected to terminal 1 of Start Disconnect module A17. Coil ground is completed by transistor Q2 on A17. When K11 energizes, the following occurs: 1. Contacts7and 4closeand apply B+ through K14, (7-1) to Cranker module A14. Relay K13 energizes and applies B+ to the starter solenoid. 2. Contacts 3 and 9 open to start the Overcrank timing sequence. 3. Contacts 8 and 2 open and allow engine starting . without low oil pressure shutdown. 3. Contacts 3 and 9 open to initiate Cycle Cranker sequence. Deactivation of relay K12 will shut down the engine. Start Solenoid, K13: Relay K13 has only one set of contacts. It is energized by closure of K11 (7-4) through K14 (7-1) and Cranker module A14. When relay is energized, it applies B+ through circuit breaker CB1 (one engine) to starter shift solenoid K. When engine starts, relay contacts K11 (7-4), followed by K14 (7-1) open. to . de-energize K13. Relay K11 remains energized until engine begins to runandan inputof 150to 190hertzfrom themagnetic speed sensor is applied to A17 terminals 21 and 22. This causes transistor Al7-Q2 to stop conducting and opens the ground circuit to K11 coil causing the following: Starter Protection Relay, K14: Relay K14 is energized by generator output (190 to 240’VAC) and deenergizes when voltage falls to 135 V.AC. When energized the following occurs: 1. Contacts of K14 (9-6) close to apply B+ to TB1358 and to remote station “Generator on” lamp. 2. Contacts K14 (7-1) open to de-energize K13 and act as a backup for relay K11 (7-4). 1. Contacts 7 and 4 open to disconnect the B+ from the cranking starter circuit. 2. Contacts 3 and 9 close to terminate overcrank timer. 3. Contacts8and 2closeto enable Low Oil Pressure shut down circuit. 22 Redistribution or publication of this document, by any means, is strictly prohibited. ENGINE :ENGINE IRMT. TD. !nART/STOq iCRANKlNG / OVERSPEEG ' STARTER FIGURE Z.. ENGINE CONTROL MODULE LOCATION 23 Redistribution or publication of this document, by any means, is strictly prohibited. Stop Relay, K15 (Natural Gas: Relay K15 is energized by closure of K12 (4-7) contacts. Contact switching is as follows: 1. Contacts 7-1 and 8-2 open to disconnect ground from magneto (or magnetron) primary coils. 2 .Contacts 3-9 open to disconnect K1 fuel solenoid from AUX output of battery charging alternator. 3. Contacts 6-9 close and apply B+ to K1 fuel solenoid. Overspeed Relay K15 (DHA and DHB Only): Relay K15 is normally de-energized and used as a back-up to the standard Overspeed installation. If engine overspeed occurs transistor A16-Q2 conducts and a ground is supplied to terminal 13 of A l l Engine Shutdown module. This causes A l l - Q 1 to conduct and apply B+ to energize K15 relay. . Closure of K15 contacts 6 and 9 applies B+ t o K4 Air Inlet solenoid which actuates air shutters to starve the engine and induce shutdown. Engine shutdown caused by malfunction will leave A1 1-K1 relay latched. Reset relay as follows: Standard Installation: Place R-S-R switch in Stop position and press Reset button. Return R-S-R switch to operational position (Run or Remote). Penn State Installation: Place and hold R-S-R switch in Depress During Reset position. Press Reset button. Release switch and return to the required operational position. Engine Monitor Module, A12: The R-S-R switch in Run position applies B+ to A l l (pins 5 and 20), to terminal A12-20, to DS12 Overcrank, DS13 Overspeed and DS14 Low Oil Pressure lamps. Grounds for the fault lamps are provided within the Engine Monitor module. Shouldthis back-up systembe actuated, manually reset air shutter doors. The engine will not start until shutters are open. Engine Control Models The following are brief descriptions of operating functions of the engine control modules shown in Figure 22. The term B+ is used to designate battery voltage (+24 VDC). Engine Control Module, All: The R-S-R switch in Run position applies B+ to energize K12 ignition relay via A l l pins 5 and 20. The B+ at pin 14 goes through lamp test switch S13, then re-enters at pin 18 and applied to coils of A1 l - K 1 and -K2. A ground at A1 1-7 energizes A1 l - K 1 to perform the following functions: 1. The N.C. contacts open to remove B+ from K12 coil which shuts down the engine. 2. The N.O.contacts close to apply B+ (from the alarm reset switch) to the alarm terminal on TB12. A ground at A11-3 energizes A l l - K 2 which will function as follows: 1. N.O. contacts close to energize alarm and apply B+through All-19toA12-1 to keepfault lampon. 2. N.O.contacts close; if a ground is present on A l l - 1 , relay AII-K1 will energize and shut down engine .The ground on A1 1-1 will act as a hold-in circuit for A l l - K l coil. DHA and DHB only: During overspeed shutdown, a ground is applied to terminal 13. The current flow across resistor A1 l-R1 will turn on A1 l-Q1 transistor which applies B+ to terminal 9 t o energize relay K15. Start Disconnect relay K11, N.C. contacts 9-3 (open when K11 energized) are between A12-22 and ground. If after 75-seconds of cranking engine does not start, a potential built up in capacitor A12-C7 will discharge and cause unijunction Al2-Q7 to fire. Unijunction Al2-Q5firesand turns on A 12-CR9 to apply a ground to A1 1-K1 relay, which energizes and stops any further starting action. Al2-CR9 also provides a ground for the Overcrank lamp to indicate a fault. Engine start within 75-seconds will cause a signal from the overspeed sensor through module A16 to turn off transistor Al7-Q2and de-energize relay K l l . N.C. contacts 9-3 close and short out capacitor A12C7 to prevent engine shutdown through Overcrank function. With the engine running and relay K11 de-energized, low engine oil pressure will cause LOP switch to close applying a ground to pin 4. Transistor Al2-Q6 will turn off, Al2-CR6 will turn on and apply aground for Low Oil Pressure light to indicate a fault. A1 1-K1 will cause K12 relay to shut down the engine and energize the alarm system. If engine overspeeds (rpm in excess of 2010), the output of A16-IC2 turns on Al6-Q2 which conducts and applies ground to A12-2. This turns on A12-Q1; Al2-CR3 will conduct and make ground for the Overspeed light t o indicateafault. A1 l - K 1 will energize to shut off K12 relay to stop the engine. The alarm will ope rate. Redistribution or publication of this document, by any means, is strictly prohibited. . Standard Cranker Module, Al4A:This module allows B+ t o be applied to K13 Starter relay, and cranking to continue until the engine starts and relay K11 is deenergized as described above. The 75-second cranking period is established by module A12. Remote Indicator Module, A13: This module is used o n five Fault light systems only, to light fault indicators at remote stations. If a low oil pressure shutdown occursaground will be applied to A12-5 and A13-1. This turns on A13-Q1 and applies B+ to A l l - 2 to light the Low Oil Pressure fault indicator at the remote station. Two extra fault lightsareconnected into theA13module: DS15 High Engine Temperature and DS16 Low Engine Temperature. Closure of High Engine Temperature Sensing switch appliesa ground toAl3-20.ThisstartsAl3-Q6 conducting which turns on CR7 to ground pin 14, and light the High Engine Temperature lamp and apply a ground to A1 1-K2 for the alarm system. Al3-Q5 will conduct and apply B+ to A13-12 for the remote station light. Time Delay Start-Stop, A15: Used only with a remote control station, this module insertsa timed delay into the Start and Stop functions. Delay times are adjustable: Start, up to 15-seconds and Stop, from 30seconds t o 5 minutes. Adjustments can be made through access holes in the module plate. .When engine start signal is initiated from a remote station, the set control panel R-S-R switch is left in Remote position. Initiation of a start signal will apply B+ to terminals A15-17 and A15-9. Voltage at A15-17 allows capacitor A15-C3 to charge. Voltage at A15-9 prevents capacitor A15-C4 from charging. Charge time of A15-C3 is adjusted by rheostat A15-Rl4. When charged capacitor Al5-C3 will turn on A15-Q1 which will cause A15-CR1 to conduct and apply B+to the output terminals of the module, then to distribution points in the control panel. Once the gate of Al5-CR1 has been .triggered, it will continue to conduct. Closure of the Low Engine Temperature Sensing switch applies a ground to A13-8. Transistor A 1 3 4 4 will turn on the sets panel and remote Low Engine Temperature lights to indicate a fault. There is no alarm or engine shutdown with this fault. Cycle Cranker Module, A14: Available as an option, the Cycle Cranker allows three crank cycles and two rest cycles of the engine starter motor within the 75-second cranking period established by module A12. Initiation of a stop signal is really removal of the start signal, which removed B+ from terminals 17 and 9 to allow capacitor Al5-C4 to charge. Charge rate is adjusted by rheostat A15-Rl6. When Al5-C4 has charged, transistor A15-Q8 will turn on and cause the potential across capacitor Al5-C6 t o go more positive and bias the cathode of Al5-CR1 to turn it off. This will shut down the set. Cycle timesare adjustable. Crank cycle time isvaried by A14-R4 and rest time by A14-R6. Crank time is 13-to 17-seconds and rest time is 8- to 12-seconds. The rheostats are accessible through holes in the module plate. -. When the R-S-R switch is in Run position, K11 is energized. K11 (7-4) contacts closeand B+ isapplied to terminals 3,'A and 5 of A14. Transistor Al4-Q2 conducts and causes Q3, Q4 and A5 to conduct and apply B+ to K13 starter .relay. Capacitor A14-C2 charges and turns off Al4-Q2 which allows Q1 to turn on.Q3, Q4 and Q5 turn off and de-energize K13. Capacitor A14-C2 discharges, transistor Q2 turns on and the cranking cycle is repeated until capacitor A12-C7 is charged. At this point A12-CR9 turns on allowing relay A I 1-K1 to pull-in, t o de-activate igntion relay K12 and prevent any further cranking action. Time Delay Bypass Module, 15A: Use of this module allows Start/Stop control from a remote station without the time delay advantage. Engines fitted with turbo super chargers should be run for at least five minutes after load removal before shutdown. This allows engine temperature to stabilize and the turbo housing to cool off and prevent warping or cracking of the turbo assembly. If the engine starts within the cranking cycle time (75-seconds) relay K11 will de-energize, contacts K11 (3-9) will close and capacitor Al2-C7 will be discharged setting its voltage to zero. Control panels with the time delay will allow the set to run for five minutes before automatic shutdown. 25 Redistribution or publication of this document, by any means, is strictly prohibited. Overspeed Sensor Module, A16: The Overspeed sensor system has two sections: A 20-tooth disc mounted on the generator shaft and a magnetic pick up, and an Overspeed sensor printed circuit module. Start Disconnect Module, A17: This module is responsible for disconnecting the starter at an engine speed of 450- to 570- rpm to protect the starter and the engine flywheel. A 5V square wave is fed into pins 21 and 22from the Overspeed Sensor board and then into an integrated circuit A17-IC1. A difference in time constant circuitry divides A17-IC1 into two sections: one for disconnect and one for reconnect. A square wave output from A17-IC1 is fed into Al7-IC2 (essentially a flip-flop circuit) where it becomes +5VDC applied t o an amplifier in A17-IC3 and amplified to 13V. This voltage is connected through azener diode to the base of transistor A 1 7 4 2 t o turn it on and provide a ground to energize Start/Disconnect relay K11. The output of the disc pickup device is fed into the sensor module and is used for two purposes: 1. Engine shutdown when speed reaches 2010 rpm. 2. Disconnects starter when engine speed reaches 450 to 570 rpm and reconnects starter at 10 to 30-rpm if engine fails to start. The 20 tooth disc rotates at engine speed and is positioned so that the teeth are in the field of the magnetic pick-up. Rotation of the disc induces a voltage i n the pickup which is fed to a switching amplifier in A16-IC2, and then into a multivibrator (A16I C l ) , where a voltage is produced which is proportional to the inputfrequency. AttransistorAl6-Q1 the same amplifier output i s applied t o A17 Starter Disconnect module. Division of A17-IC1 also allows a second square wave output to be applied to another amplifier in Al7-IC3. Here it connects to a filter network and into a Nand gate of A17-IC2. At an engine speed of 450-to 570rpm (150- to 190- Hertz), the voltage output of A17IC2 is switched t o zero which causes A17-Q2to turn off and disconnect ground from K l l . De-energizing of K11 will open Starter solenoid K13and prevent the starter from operating. If engine overspeed occurs, the output of the frequency-to-voltage converter (A16-IC1) switches a zener diode into the base of Al6-Q2. Q2 turns on and provides a ground for the Overspeed fault light, alarm and engine shutdown if engine speed reaches 2010 rpm- A characteristic of the Starter Disconnect circuit is that Al7-1G2 will not reverse outputpolarity until the input is reduced to less than 10-Hertz. Therefore, the starter motorwill not be reconnected until the engine rpm drops below 30. DHA and DHB only: An additional function when Al6-Q2 turns on is application of a ground t o terminal 13 of All Engine Shutdown module for air shutter operation. 26 Redistribution or publication of this document, by any means, is strictly prohibited. Fault Lights: For a list of the fault light options, refer to Table 6. On a standard single light installation a fault indication will be accompanied by an engine shutdown and an alarm. Pennsylvania State installations will not shut down the engine for low oil pressure or high engine temperature, otherwise the installations are the same. With four faults lighting one lamp, troubleshooting without an Engine Tester board (Figure 23) is a process of elimination to find which fault caused the indication. TABLE 6. FAULT LAMP OPTIONS SYSTEM PENN-STATE SINGLE LIGHT SINGLE FAULT LAMP ‘FAULT STOP ENGINE EXTERNAL ALARM X X X X Overcrank Overspeed Low-Oil Pressure High Engine Temperature Overcrank Overspeed _. Low Oil Pressure High Engine Temperature Overcrank Overspeed - -_ Low Oil Pressure High Engine Temperature Low Engine Temperature Overcrank Overspeed Pre Low Oil Pressure Low Oil Pressure Pre High Engine Temperature High Engine Temperature Low Engine Temperature a_... 27 X X X X X X Redistribution or publication of this document, by any means, is strictly prohibited. Engine Malfunctions Low Oil Pressure and High Engine Temperature (+Fault Light System): These two switches, although performing dissimilar functions, have the same result. Closure of either switch will apply a ground to pin 4 of the A12 module. Transistor Al2-Q6 will turn on causing unijunction.A12-Q3 to fire and trigger A12-CR6. The fault light will illuminate. On a standard installation the alarm and engine shutdown will be initiated, but a Penn State installation will set off the alarm only. The following are common engine malfunctions and a brief description of control operation for alarm or shutdown. Overcrank: If after cranking for 75 seconds the engine will not start, capacitor Al2-C7 on the Engine Monitor module will charge to turn on Al2-CR9, illuminate the fault light and apply a ground to pin 7 on A-11 Engine Shutdown modu!e. This energizes A l l - K l and allows K12 to de-energize and stop cranking action. Five Light System: On a five fault light system, the High Engine Temperature switch connects to module A13-20 and the Low Oil Pressure switch to A12-4. If an engine has been running and shuts down for a malfunction, the starter will be energized (when engine rpm drops below 30) to restart the engine. After 75-seconds of cranking, the above shutdown sequence is initiated and the cranking. circuitry is disabled. Closure of High Engine Temperature switch will apply a ground to A13-20. This turns on A 1 3 4 6 which triggers Al3-CR7 into conduction. This provides a ground path for High Engine Temperature fault light and to relay A I 1-K2 for engine shutdown. Closure of the Low Oil Pressure switch has the same effect as that given for the single light system. An adjustable rheostat (A12-RlO) provides a timeddelay period up to 10 seconds to allow.the engine t o be started and oil pressure to build up. This prevents immediate shutdown due to low.oil pressure during starting. Overspeed: Engine speed in excess of 2010 rpm will cause transistor A16422 on the Overspeed Sensor moduletoconductandapplyaground topin2of A12 Engine Monitor module. A12-Ql will then turn on and trigger Al2-CR3 to illuminate the fault light and initiate shutdown and alarm from A l l . shutdown module. I XI00 I c #-~.223l FIGURE 23. ENGINE CONTROL TESTER 20 Redistribution or publication of this document, by any means, is strictly prohibited. . -: ENGINE CONTROL SYSTEM CHECKOUT PROCEDURE This checkout procedure of the Engine Control System is for use with the Engine Control Tester Part Number 420-0336 (Figure 23). Designed to enable the serviceman to check out the complete system, the Engine Control Tester module is an indispensable tool for-rapid location of faults, or final pre-start system test. Proceed with the checkout as follows: 1. Remove front cover of engine module rack. 2. Remove Cycle Cranker module A14. See Figure 22. 3. Insert Engine Control Tester module into A14 position. 4. Set rheostat on Tester module fully counterclockwise. Engine will not start with controls in this configuration. 5. P1ace.R-S-R switch i n run position. depress lamp test switch to test fault lamp. CHECKOUT Turn Tester rheostat lo 2300 rpm. Does Overspeed or Fault light illuminate on both Tester and panel? Does Tester cranking light Replace Start-Disconnect Module A17. Return to Does Overspeed or Fault light illuminate on Tester only? Yi' I yes . I 1 Place Run-Stop-Remote switch in Run position. Turn Tester rheostat to 650 rpm. Does Tester Cranking light go off? Turn Tester rheostat to 2300 rpm. Does Overspeed or Fault light come on? Replace generator Overspeed sensor module A16. Return 1 Yes In 10-20 seconds, does Low Oil Pressure or Fault Light come on? no Replace Engine Monitor Module A12. Return to test 0. Replace Starter Disconnect Module A17. Return to test I yes I cont. following page 29 Redistribution or publication of this document, by any means, is strictly prohibited. + yt's Rcsct Turn Tcstcr rheostat lo 2300 rlmi n o w ---.--------no -L. Turn Tester rheostat to 400 rpm. Reset. Turn - - - - - .- - - -- Replace Overspeed Circuit Module A16. Return to test GJ. Replace Engine Monitor Module A12. Return to test @, - Replace Starter Disconnect ModukA17. Return to test 0. . . light come on below 30 rpm? . I .... position. Turn Tester rheostat fully CCW. Jumper B+ to Remote on TB12. Does Tester Cranking light Time Delay Start/Stop.Module A15. _.._. . .. ~ Remove Module A12. Remove B+ to:Remote Jumper on TB12. Does Tester Cranking light go off after 30 seconds? Reinstall Module A12:. ... .. ,. Replace Time Delay StartlStop Module A1.5. Returnto test 0. , . . .. yks ~ ~ 1 r ~ ~ Remove Tester Module. plug in Cycle Cranker Board A14 Place Run-Stop-Remote switch in Run position Does engine crank? no- Replace Cycle Cranker Module A14 i ! 30 Redistribution or publication of this document, by any means, is strictly prohibited. .- CONTROL TROUBLESHOOTING Before troubleshooting, visually inspect all wiring and connections. Check relay plug-in receptaclesfor cold solder connections. Look at the engine control modules for signs of burned or damaged solid state devices, and again check for cold solder connections. This manual will help troubleshooting electrical control problems. The information in this section is divided into Flow Charts A, B, C and D as follows: A. Engine Fails to Crank. Switch in “Run” position. B. Engine Fails TO Crank, Switch i n “Remote” position. . C. Engine Malfunction Shutdown, Fault Light “On”. Five Light System. . D. Engine Malfunction Shutdown. Fault Light “ON”. Single Light System. This troubleshooting guide assumes the technicians knowledge of the generator set will allow.him to consider the nature of the fault before proceeding. For example, the set cranks without starting; he would check fuel, fuel lines, ignition, carburetion, etc. If it does not crank, he would check 0 0 0 Batteries Connected properly? Connections clean and secure? Fully charged? Starter connecjions secure? Remote station Start switch in correct position? A few minutes spent logically analyzing a malfunction can save time and expense. Consult the engine operator’s manual for engine troublesho.oting information. To troubleshoot a problem,, start at upper-left corner of the chart related to the problem, and answer all questions either YES or NO. Follow the chart until the problem is found, making voltage ‘measurements as referenced. , . Do. not make voltage measurement - on any module unless an extender card is used. Make measurement on the extender card. Doing so helps prevent damage to the module from accidental short circuit by the test probe. , 31 Redistribution or publication of this document, by any means, is strictly prohibited. FLOW CHART A. ENGINE FAILS TO CRANK. SWITCH IN “RUN” POSITION. NOTE: Place R-S-R. switch in Run position when making voltage measurements. t d I t Art? ballcries connected properly. is voltage normal? 1; c Chcck batlcry lcrrninal connections. Recharge or replace bnllcrias i f defective. 1: yes: P with R-S-R switch in Run, actuate (observe.visually.)? switch now? Gheckvoltage,at terminal 6 Does starter relay K 1 3 actuate (verify by sound orfeel)? Replace Start. Disconnect moduleA37. yes. c ? of R-S-R switch in.Run position ; i If not +24‘VDC. replace switch. Check wiring to K l l . L i no p Is voltage atJlarge. terminal of starter +ZrYY%D@? . ‘ no 1 ID KT3-2. Doearelay. actuate.? f no Ir 1. ! Replace. Starter. Is voltege at‘K-14-1 t24-VD C?’ i 1 ; starter solenoid 1: )’ DoerKf2actuate when R-S-R‘switch IS moved between. RunandStop? I Replace Cranker Is voltage atK14-7 +24-VDC? ; Replace ‘ module All. 1 i i ; no Ternporarilyjurnper TB11-24 to K12-B. Does-relay actuate? Replace relay K12. yks 1 Check wire from K11-4 to K14-7. Repair i f necessary, 32 Redistribution or publication of this document, by any means, is strictly prohibited. FLOW CHART B. ENGINE FAILS T O CRANK. SWITCH IN "REMOTE POSITION. NOTE: This chart is concerned with failure to crank in Remote only. Fault light "ON"should be solved after this malfunction is corrected. See section on Fault Lights (Charts C and D). Is remote station switch in Start position? Does set crank and start See Flow Chart A. yes 1 Automatic transfer switch? crank (R-S-R in Remote)? . . Replace T.D. Start/Stop module A 1 5 1 Is remote station other _ .than an Onan automatic transfer switch? I I i"' - yes set crank (R-S-R switch in Remote)? Check wiring between gen set and remote station. I yes I Replace T.D. StartIStop manual switch box?. TBlP-B+ to RMT. After 10 seconds does engine crank? Apply jumper across remote station Start switch. Does engine crank? Check wiring between set and remote station. Repair as needed. Replace remote station Start switch. 33 Redistribution or publication of this document, by any means, is strictly prohibited. FLOW CHART C. ENGINE MALFUNCTION SHUTDOWN, FAULT LIGHT “ON”. FIVE LIGHT SYSTEM OVERCRANK (Altrr 75 Seconds) Check fuel system. Are valves open and tanks full? Chcck ignilion syslcm. (Scc ciiginc?operators mantml. Is ignition OK? Rclcr to lirst half of OVERSPEED Check throttle. Is throttle and governor linkage free and clear? Remove air cleaner. Are filters clean and dry? No fuel saturation? Is injector rack movement Restart engine. Is governor set correctly?’ Replace Engine Monitor module A14. LOW OIL PRESSURE Is oil at correct level? Is oil pressure sensor workinq correctly? DISCONNECT WIRE FROM TB11-30. DOES LIGHT REMAIN ON? Replace Engine Monitor module A 1 4 HIGH f N G l N E TEMPERATURE Ifcity water cooled. is Are fan belts tight? Is temperature sensor OK? Is radiator cooling duct yes 1 Disconnect wire A l l - 1 from TEll-34. Does light remain Is thermostat operation OK? 1 I Replace Engine Monitor module A14. *Woodward governors have optionally installed externally-controlledmotors. Adjust governor with switch on control panel. 34 Redistribution or publication of this document, by any means, is strictly prohibited. FLOW CHART D. ENGINE MALFUNCTION SHUTDOWN. FAULT LIGHT ON SINGLE LIGHT SYSTEM - . AIP lui’l tanks lull and IllCl V i l l V C S oprll? t- Di!prt!ss Ri:si!l switch Placr? s w ~ l cto l ~RIIII. Dor!s r!iigini! r!nqinm. chcck ICJnltlCJn systcm and relay K15 I I ves I Does engine start and shirldown~ Check free movement of throttle and governor linkage. Do controls Is elapsed time from start to shutdown about 10 seconds (Penn State units ignore instruction)? . Is elapsed time from start to shutdown less than 5 no yes I Is injector rack movement free? Is elapsed time from start to shutdown about 75 seconds? Oil Pressure sensor working correctly? yes Are intake air filters clean and dry. no fuel saturation? Is water temperature gauge reading high (i.e.. full scale)? I yis Move R-S-R switch between Stop and Run. Does relay K11 actuate (observe visually)? I I Is governor speed control set correctly? See operators manual. I t fi0 I Replace Engine Monitor module A12. fl0 Radiator air ilow clear? Input valve open (city Replace Engine Monitor module A14. thermal switch operating Is coolant level correct? OBSERVE WARNING BELOW! I to ground terminal. Does K11 actuate now with R-S-R Unplug K11. Is voltage +24 VDC at socket pin B (R-S-R in Run position)? Replace Start Disconnect module A17. . . I Replace relay K l l . I switch terminal 6. If not. replace switch. Check wiring to relay KII. Bleed off block coolant pressure before attempting to remove filler cap. Severe liquid burns could result from erupting coolant. WARN,NG 35 Redistribution or publication of this document, by any means, is strictly prohibited. I Wiring Diagrams TITLE PAGE . . 300-0954 A l l Engine Shutdown Module ...................................... 300-0953 A12 Engine Monitor Module ........................................ 300-0955 A13 Remote Indicator Module ....................................... 300-0956 A14 Cycle Cranker Module ......................................... 300-0977 A14A Cranker. STandard Module .................................... 300-0973 A15 TD Start/Stop Module .......................................... 300-0987 A15A Bypass Module ............................................... 300-0957 A16 Overspeed Sensor Module ...................................... 300-0958 A17 Starter Disconnect Module ..................................... 612-4558 STD YB Generator .................................................. 612-4753 YB with Governor Control ........................................... 612-4795 YB with Wattmeter and Transducer .................................. 625-1440 Voltage Regulator (VR21) ........................................... 612-4546 WF with Single Light Control ........................................ 612-4547 WF with Five Light Control .......................................... 612-4548 FT with Single Light Control .......................................... 612-4549 FT with Five Light Control ........................................... 612-4645 DYH, DYB, DFT, DFU Single Light Control ........................... 612-4754,DYH, DYB, DFT, DFU Five Light Control ............................. 300-0964 A11 Engine Shutdown Module, DHA-DHB ............................ 612-5048 DHA, DHB, Single Light Control ...................................... 612-5049 DHA, DHB, Five Light Control ....................................... . . . . . . . 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Redistribution or publication of this document, by any means, is strictly prohibited. SCHEMATIC DIAGRAM 2 18 17 16 14 5 8 1'1' YR5 21 ' MECHANICAL ASSY lo I I :R 2 R4 1 7 3 19 22 20 I >18 >13, I4 I I ?ti 7" I CRI 2 21 4 5 3 6 S PEC IFI C AT I0 N S MECHANICAL ASSY N N 0 O K INPUT O/C OUTPUT LAMP TEST m SHUTDOWN c! N 2 5 B+ POWER .............................................. .24-6.VDC LOW OIL PRESSURE .12.5~2.5SEC TIME DELAY (TDC) ................................... OVERCRANK .75+5 SEC TIME DELAY (TDC) ...................................... 40'C to 100°C STORAGE TEMPERATURE.. ......................... OPERATING TEMPERATURE.. ....................... 40°C to 80°C DIAGRAM SYMBOL SHUTDOWN LOW OIL PRESSURE W QROUND W ois Ln P OVERCRANK OUTPUT OVERSPEED 0 N r Y r I I1 10. I Y d R 3 1 BN3 11.1 dR31 SN3 Mol ........................ 3 t l f l l V t l 3 d W 3 1 DNIlVtl3dO ......................... 3tlnlVkl3dW313E)VtlOlS ............................................. kl3MOd +9 01300p3oooL 01300p3a*9 -+ pe 3oo* SNOllV313133dS 02' . LI t l E l 2 1 0 1 8 . 6 9 E C € 2 m ASSV 1V31NVH33W IC IY3 WVUWKl 311VW3H3S . . . SCHEMATIC DIAGRAM IGN RELAY 9 '-#- T8 7 I I ICTORY ADJUST POTENTIOMETER R 6 FOR Dt2 SEC REST TIME ICTORY ADJUST POTENTIOMETER R 4 FOR 5r2 SEC CRANK TIME 0 MECHANICAL ASSY SPEC IFICAT IONS DIAGRAM SYMBOL 03 . . SCH EMATlC DIAGRAM -< I, 2, 3.4.5 MECHANICAL ASSY L d 0 0CONTROL-STD CRANKER 300 c 977 (12 a 24 v) CRI 7 TEST DIAGRAM rn CONTINUITY b +ILVOC I D.11 11-29-72 KNONE 4 ........ .~ ~ ................. , ...... I' . . . . . . . . . . . SCHEMATIC D IAG.RAM 1 1 1 R16 CR7 21,22 PWR / I CR3 9,lO INPUT MECHANICAL ASSY SPEC IFICA T I ON S 24 TO 30 VDC INPUT.. ........... .................................. LOAD CURRENT.. ......................................... 400 MA TIMING ACTION DELAY ON OPERATE PLUS DELAY ON RELEASE ADJ TIME RANGE: 0.5 TO 15 SECONDS START ...................................... STOP.. ....................................... 0.5 TO 5 MINUTES 5 20% TOLERANCE .............................................. SWITCH FUNCTIONS S S 1-4 T.D. START 5-8 T.D STOP LEK - DIVISION 01 OlUN m C Q A l l O N Ml-*ll.. YI.".#.rn -h $dn !D I T r . i 43 Redistribution or publication of this document, by any means, is strictly prohibited. S C H E M A T IC OUTPUT p"' P.W R MECHANICAL ASSY SPEC1 F ICATIONS INPUT INPUT PWR SYMBOL FOR SCHEMATIC DIAGRAM 'OUTPUT GND OUTPUT THE CONTACT SYMBOLIZES A SOLID STATE SWITCH THAT CLOSES AT AN INPUT FREQUENCY OF 700 HZ + 30 HZ SCHEMATIC . R3 R5 C RR32 , I + 2 ? 4 I C- 3 - - - - - -8- r IC2 r-----i - 7 i4 INPUT - I 131 L I I cn I I dl. 2 OUTPUT MECHANICAL ASSY SPEC1 F ICATIONS IUQUT PWR 6UD INPUT VOLTAGE..... .......... sv'p sa WAVE INPUT FRERUENCY.. .......... 0-400 HZ E+ POWER ................... 24 +E VOC . LOA0 CURRENT ............... I O O M A MAX LOAD VOLTAGE... ............ 24 26 THE CONTACT SYMBOLIZES A SOLID STATE SWITCH THAT OPENS AT AN INPUT, FREQUENCY OF 170 HZ 2 20 HZ AND CLOSES AT 10 i 10 HZ voc SYMBOL FOR SCHEMATIC DIAGRAM NOTE 4 DIVISION Or ONAN CORPORAlION Minn.apolls. Minnesota = 24 VOC T a8 D : . YB If €-STARTER DISC 300-0958 1'2 1 " 1 W22-NOTE: SEE VOLTAGE CONNECTION CHART I I I AC CONTROL PARTS LIST REF. DES. I I I- -I I ---t 1 -- -- HGSGG-CONTROL BOX OTY. 1 1 1 CB21 CR21 CT21-23 D321 DS22 G21 K21 L21 M21 M22 DESCRIPTION Circuit Breaker 3 Amp Rectifier Bridge Transformer Assy - Cur Light-Upper Scale Light-Lower Scale Generator Relay-Voltage Selector Reactor Assy Comm Ammeter AC Voltmeter - AC 0-30G 1 1 1 1 1 1 1 ~ 0-600 L3 L2 1 1 M23 M24 R21 1 R22 1 521 T21 TB21 VU21 1 1 1 Meter Frequency Meter - Running Time 3.5 k 25 w Ad1 Rheostal-Voltage - Resislor 47 000 1 2 Watt Switch-Volt 8 Ammeter Transformer - Volt Re1 Marker-Strip Board Assy - PC Voltage Regulator 1 LI LO EXCITER EXCITER @ F r CRIk F+ ..,-. CONNECT LEAD W22 FROM GENERATOR TERMINAL T821-63 TO T821-IH-I FOR THESE VOLTAGE CONNECTIONS - CR2T CR3 l 110/190V. W CR4 CR5 CR6 T2 T3 T4 T5 T6 T7 ALTERNATOR 021 -- - -- TB T9 TlO- a 517R [ill1 5 0 8 0 LI LO 4 0 7 0 0 2 010 0 I 0 12 M 220f380V 50HZ 'pH 230f400V' lH3) IH4) IH41 3PH SOHZ. lH5) 6 0 H q H3 60H2, IH41 3PH SOHI. IH51 SOHI) 240f416V.' 50Hz: "WL2 "W 17R L2 L3 50Hi. IH31 tH4) IH41 IH5) lH31 lH41 IHSI 11Sf2OOV. 50H1, 120f208V. 5 0 H q 127/220V. SOHI. 120/208V 6 0 H r l27f220V:60H~. 139f240V. 60Hz. ZS4M4OV. 3PH 24Of41E.V. 254f440V. 27714BOV. 17 CT21 T6 CT23 Lo L2 no TU TI2 CT22 LJI LL 6 1 0 9 a 3 1 I l 5 [ 0 8 12 0 10 4 [ 0 7 1I 0 12 LI CT23 Tv LL2 3 THIS CHART USE0 FOR MANUFACTURING ONLY 2~~-';;OKW-17R,, NOTE: KW 60Hz 50Hz 60Hz 200-350KW-517WWI UNLESSOTHERWISE NOTED 4LL COMPONENTS ARESHOWk ;1; IN THE DE-ENERGIZED POSITION 251-300 301-350 -03 -04 -- 7-30-73 VCIP - rasA l ~ ~ ! R U S H L E S S . ' -07 -08 --12 11 3PH,5D/60Hz 12W RECONNECTABLE. v'''~q CONTROL-BEN SET AC (WIRING DIAGRAM) -- 612-4558 - SCHEMATIC-DlAGR AM WIRING DIAGRAM - -REAR VIEW PANEL - - -- CONTROL BOX (INSIDE) -- 1 ----1 -P- I. . In I I . I L-1 67 AC CONTROL PARTS LIST REF. DES. W22-NOTE: SEE VOLTAGE f CONNECTION CHART 62 CR22 CB21 CR2l CT21-23 DS21 DS22 Gal K21 L21 M21 M22 1I OTY. 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION Diode ASS/ Circuit Breaker 3 Amp Reclilier Bridge Translormer Assy Light-Upper Scale Light-Lower Scale Generator Relay-Voltage Selector Reactor Assy Comm Ammeter AC Voltmeter-AC 0-300 - 0-600 I I -t - I i' I -I _ I I HOUSING-CONTROL B O X MOUNT O N BOT: L3 c9, k ; RAISE LOWER COM LO I I ALTERNATOR FIELD GENERATOR T7 T9 \6 \S R22 1 521 1 1 NOTE: CONNECT LE40 W22 F R O M TERMlN4L TB21.63 T O TEZI-IH-1 FOR THESE V O L T I G E CONNECTIONS n '"' CB2l 1 1 1 1 822 1 w22 T922 1 1 1 L2 JLI EXCITER 1 T2 1 TB21 VR21 OF CONTROL BOX ' M23 M24 R21 Meter-Frequency Meter-Running T m e Rheostat Voltage Ad! 35k2Sw Resistor 4 7 000 1 2 Watt Switch-Volt a Arnmeler Translormer Vol: Re' MarKer-SlrlD 9oard Assy PC Voltage SwllCh Regulator Governor - - - . - Control Wiring Harness Lead Assy Terminal-Block - REAR - VIEW PANEL - -WIRING DIAGRAM- -- SCHEMATIC DIAGRAM CONTROL 0OX-(4SlDEl REF. DES. -3W22-NOTE: SEE VOLTAGE CONNECTION CHART TO VR21 T21 M24 Y J --Y- HGSKG-CONTROE- P 00 'I*' K21 " c021 c/ my. DESCRIPTION A21 CB21 CR21 CT21-23 DS21 DS22 G21 K21 L2 1 M21 M22 1 1 Watt Transducer Circuit RectilierBreaker Bridge 3 Amp 1 1 Translormer Assy Cur Light UppeiScale Llghl Lower Scale 1 11 Generator Relay ReactorVollage Assy C Selector orm t M23 M24 M25 R21 1 1 1 Ammeter - AC Vollmeter AC 0-300. 0-600 Meter - Frequency Meter Running Time Wattmeter AC Rheostat - Voltage R22 s21 T21 TB21 VR2l 1 1 1 1 1 1 1 - - - - - 1 Resistor Ad1 3 5 K47 25000 W 1 2 VJ switch - volt a Ammeter Transformer - Volt - Ref Marker Strip PC Board ASSYVoltage Regulator I 1 I d VR21 WARD A5SY.K ’ 332-1956iD) .- ICLASSB ::-,- 1 SCHEMATK DIAG-VR SYSTEM 625-1440, ] z L L L L L z PL'ZLBJ. L LBJ. PLS ELS ZLS L 1s ZL'LLH L L L L &LW ZLW LLW L L L L L L Pin tin z sin 0 LD ztn tin ZLSQ ttsa L L L L L ZL'L L H 3 LLV 9LV SLV PLV ZLV 1 LLV 1113 I ..I "l"(1110 01111. ENGINE PARTS LIST (REF) REF. DES. W l l Y O 0IAOIA.Y ,. 114 l... I TI' OTY. 81 1 ET1 CB1 1 1 El E2 E3 'E4 E5 1 1 12 1 1 G1 1 G2.3 'K1 'KZ K3.4 s1 52 53 54 2 1 1 2 1 1 1 1 113 s5 1 T1 12 DESCRIPTION - Starler 8 Solenold Engine Baltery-24 V Circuit Breaker 12 5 Amp Sender-Oil Pressure Sander-Water Temp Spark Plug Fuel Pump Sensor-Speea i U a q ~ rReli Allernator 8 Regulator Magneto Solenoid-Fuel SOlenOld-Waler Swltch-Low 011 Valve-Gas PrCSs,.rr: SvillCh-Hlgh VJaler T r F i Swilch-Low Waler Tecc Switch-Low Oil Presst.*f IPre-Alarm I Switch-Hi Vlater Temo IPre-Alarm, Coil-lgnilion CONTROL BOX PARTS LIST (REF) A1 1 1 A12 A13 1 1 A14 A15 A16 A17 CR11.12 DS11 DS12 DS13 DS14 DS15 DS16 Kll K12 K13 K14 K15 M11 M12 M13 R11.12 SI1 512 513 s14 TB11 TB12.14 TB13 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 - Whcil UScd Uodule-Engine Shutdown Module-Englne hlorlicr Moatile-Remale Indicator Module-Cranher Module-TD Star!-Sic@ Module-Oserspeec Sen Module-Starter DISC Diode iReli Lamp-Panel Lamp-Overcranh Lamp-Overspeea Lamp-Low Oil Pres Lamp-Hi Eng Temp Lanip-Lo Eng Temp Relay-Start Dmonncc: Relay-Ignition Relay-Start Sclri~aic Relay-Slarlri Prs:?r:w Relay-Slop Gauge-Oil Prrssurr Gauge-Watei Tenit\ Aninlelcr-Charge 30-0-30 Resistor-Gauge Swltch-Pailel Llglll SwltCh-Selt~i.l~i SwItCh-LclIlI~TPSI Switch-Alariii R r ~ d l Tsrniiiial Blacb Tcitlriirnl Bloch Tt.rt1ilii.ll Bloc h ENGINE PARTS LIST (REF) REF. DES. IUS NI4 QTY. 61 1 ET1 CB1 1 1 El E2 E3 E5 1 1 12 1 G1 G2 1 1 'K1 'K2 s1 52 T1 1 1 1 1 12 DESCRIPTION - Starter 8 Solenoid Engine Battery-24 V Circuit Breaker, 12.5 Amp Sender-Oil Pressure Sender-Water Temp Spark Plug Sensor-Speed (Mag) (Ref) Alternator 8 Regulator Magneto 8 Ignition Isolator Solenoid Solenoid-Water Switch-Low Oil Pressul Switch-High Water Ten Coil-Ignition CONTROL BOX PARTS LIST (REF) m 1111 I + .,& . . I A1 1 1 A12 A14 A15 A16 A17 CR11.12 OS11 OS12 K11 K12 K13 K14 K15 M11 M12 M13 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 R11.12 s11 s12 S13 S14 TI311 2 1 1 1 1 1 Module-Engine Shutdown Module-Engine Monito Module-Cranker Module-TD Start-Stop Module-Overspeed Sen Module-Starter Disc Diode (Ref) Lamp-Panel Lamp-Fault Relay-Start Disconnect Relay-Ignition Relay-Start Solenoid Relay-Starter Protectioi Relay-Stop Gauge-Oil Pressure Gauge-Water Temp Ammeter-Charge 30-0-30 Resistor-Gauge Switch-Panel Light Switch-Selector Switch-Lamp Test Switch-Alarm Reset Terminal Block Terminal Block .- When Used I . ., . , . . . . . . Z W U L RLYDIE ~ARTIYG "-a- lam 1--612-4548 I W I I I Y O Dl.C"IYI E I. - L a L I .. ., .: *.. . 0 e; - I - * OI G c ! e- I I 53 Redistribution or publication of this document, by any means, is strictly prohibited. ENGINE PARTS LIST (REF) REF. DES. I Li i.; U QTY. B1 1 BT 1 CB1 1 1 El 1 E2 E4 E5 1 1 1 G1 K1 'K2 K3 K4 s1 1 1 1 1 1 1 1 s2 DESCRIPTION Starter 8 Solenoid Engine Ballery-24 V Circuit Breaker. 12.5 Amp Sender-Oil Pressure Sender-Waler Temp Fuel Pump Sensor-Speed (Mag) (Ref) Alternalor 8 Regulator Solenoid-Eng Sloping Solenoid-Water Sol-Eng Stopping Solenoid-Air Inlet Switch-Low Oil Pressuri Swilch-High Water Tern CONTROL BOX PARTS LIST (REF) All 1 A12 A14 A15 A16 A17 CR11.12 DSll DS12 K11 K12 K13 K14 M11 M12 M13 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 R11.12 s11 512 513 514 TB11 TB12.14 1 1 1 1 1 2 . - When Used i Module-Engine Shutdown Module-Engine Monitor Module-Cranker Module-TD Starl-Slop Module-Overspeed Sen Module-Starter Disc Diode (Ref) Lamp-Panel Lamp-Fault Relay-Slarl Oisconnecl Relay-lgnilion Relay-Start Solenoid Relay-Slarter Prolection Gauge-Oil Pressure Gauge-Waler Temp Ammeter-Charge 30-0-30 Resistor-Gauge Swilch-Panel Light Swilch-Seleclor Svrilch-Lamp Test Switch-Alarm Reset Terminal Block Terminal Block ENGINE PARTS LIST (REF) REF. DES. QTY. 61 1 ET1 CB1 1 DESCRIPTION 1 El E2 E4 1 E5 1 G1 K1 1 1 1 1 'K2 1 K3 1 s1 SJ 1 1 1 1 s5 1 s2 s3 CONTROL BOX PARTS LIST (REF) 1111 110-1.01 All 1 A12 A13 1 A14 A15 A16 Ali CRll.12 DS11 DSl2 DS13 1 DSlJ DSl5 DS16 K11 K12 K13 K1J M11 M12 M13 m11 I I 1311.12 s11 512 513 S1.l TBll TBl2.14 TB13 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 ? 1 II SCHEMATIC DIAGRAM 16 17 K2 14 KI CRl2 v 3 19 5 0" 5 0 1 1 1 51oevmg Wire No 20 Transistor .PNP # 6 5 3 ? , R e s w o r . 200 !! 10': 2V Resislor - 5600 !! 1 0 ' . 1 2Vl Resnslor - 10006 !!lCP: 1 2VI R2 1 1 K1 K2 CRl CR12 2 Relaj 12 Roclhc:,r - Dvzs 3 R2 w2 v W1 W2 W l W2 01 R3 R2 1 5 REF. DES.OTY. DESCRIPTION CR3 > P 15 13 9 ! MECHANICAL ASSY -. ,=rm...,4 I I Lh''dI ' '1' CONTROL- ENG SHUTDOWN KNONE I & 300-964 ]mcw "I I I r I I ! i Redistribution or publication of this document, by any means, is strictly prohibited. ENGINE PARTS LIST (REF) REF. DES. OTY. B1 1 BT1 CB1 1 1 El E2 E4 E5 1 1 1 1 G1 K1 K2 K3 K4 s1 1 1 1 1 1 1 s2 1 DESCRIPTION Starter 8 Solenoid Engine Battery-24 V Circuit Breaker 12 5 Amp Sender-Oil Pressure Sender-Water Temp Fuel Pump Sensor-Speed #Magi lRefi Alternator 8 Regulator Solenoid-Eng Sloping Solenoid-Water Sot-Eng Stopping Solenoid-Air Inlet Switch-Low Oil Pressure Switch-High Water Tern1 CONTROL BOX PARTS LIST (REF) TO 1n11 t A1 1 1 A12 A14 A15 A16 A17 CR11.12 DS11 DSl2 K11 Kl2 K13 K14 K15 Mll M12 M13 1 R11.12 s11 512 513 S14 TB11 TB12.14 2 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 . - When Used Module-Engine Shutdown Module-Engine Monitor Module-Cranker Module-TD Start-Stop Module-Overspeed Sen Module-Starter Disc Dlode iReli Lamp-Panel Lamp-Fault Relay-Start Disconnect Relay-lgnilion Relay-Start Solenoid Relay-Starter Protection Relay-Overspeed Gauge-Oil Pressure Gauge-Water Temp Ammeter-Charge 30-0-30 Resistor-Gauge Switch-Panel Light Switch-Selector Switch-Lamp Test Switch-Alarm Reset Terminal Block Terminal Block Redistribution or publication of this document, by any means, is strictly prohibited. F Onan Corporation 1400 73rd Avenue N.E. Minneapolis, MN 55432 1-800-888-ONAN 612-574-5000 International Use Telex: 275477 Fax: 612-574-8087 Onan is a registered trademark of Onan Corporation Redistribution or publication of this document, by any means, is strictly prohibited.
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