Onan DKD Service Manual
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DKC, DKD
MDKC, MDKD
Printed in U.S.A.
981-0502
3-94
Redistribution or publication of this document
by any means, is strictly prohibited.
Before operating the generator set, read this manual
and become familiar with it and the equipment. Safe and
efficient operation can be achieved only if the unit is
properly operated and maintained. Many accidents
are caused by failure to follow fundamental rules and
precautions.
The following symbols, found throughout this manual,
alert you to potentiallydangerous conditions to the operator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal injury or
death.
IQWARP(ING1 Thissymbol refers to a hazard or unsafe
practice which can result in severe personal injury or
death.
1-b
Thissymbol refers to a hazard or unsafe
practice which can result in personal injury or
product or propetty damage.
Read and observe each of the following safety
precautions.
0
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
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FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury can result from improper practices.
0 Do not smoke or allow an open flame or spark-producing equipment near the generator set or fuel tank.
Inspect the fuel lines and connections daily for leaks
per the maintenance schedule.
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0
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Never sleep in the vehicle with the generator set
running unless vehicle is equipped with an operating
carbon monoxide detector.
Inspect exhaust system daily for leaks per the
maintenance schedule. Do not use engine cooling air
to heat a compartment.
Never operate the generator set inside a building or in
an area where exhaust gases could accumulate, such
as near a wall or snow bank, or in high grass. When
parking, make sure the exhaust outlet is not
obstructed. Make sure the generator set is well
ventilated.
ELECTRICALSHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
0
0
Disconnect the negative (-) cable at the starting
battery before removing protective shields or touching
electrical equipment. Use rubber insulative mats
placed on dry wood platforms on the ground or over
floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surfaces to be
damp when handling electrical equipment.
Use extreme caution when working on electrical components. High voltages can cause injury or death.
Tag remote or open switches to avoid accidental closure or starting.
Before starting work on the generator set, disconnect
negative (-) cable at the battery. This will prevent
accidental arcing or starting.
Keep your hands away from moving parts.
Make sure that fasteners on the generator set are secure. lighten supports and clamps, keep guards in position over fans, etc.
Do not wear loose clothing or jewelry while working on
generator sets, because they can become caught in
moving parts. Jewelry can short out electrical contacts
and cause shock or burning.
If adjustment must be made while the unit is running,
use extreme caution around hot manifolds, moving
parts, etc.
GENERAL SAFETY PRECAUTIONS
0
EXHAUST GASES ARE DEADLY
0
DO NOT CONNECT GENERATOR SET DIRECTLY
TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set
into the utility line. This creates a potential for
electrocution or property damage. Connect only
through an approved device and after building main
switch is open. Consult an electrician in regard to
emergency power use.
0
0
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Wear safety glasses and protective clothing when
servicing batteries. DO NOT SMOKE while servicing
batteries. Lead-acid batteries emit a highly explosive
hydrogen gas that can be ignited by electrical arcing or
by smoking.
Have a fire extinguisher rated ABC nearby. Maintain
extinguisher properly and become familiar with its use.
Benzene and lead, found in some gasoline, have been
identified by some state and federal agencies as
causing cancgr or reproductive toxicity. When
checking, draining or adding gasoline, take care not to
ingest, breathe the fumes, or contact gasoline.
Used engine oils have been identifiedby some state or
federal agencies as causing cancer or reproductive
toxicity. When checking or changing engine oil, take
care not to ingest, breathe the fumes, or contact used
oil.
Remove all unnecessary grease and oil from the unit.
Accumulated grease and oil can cause overheating
and engine damage, which presents a potential fire
hazard.
Do not store anything in the generator set compadment such as oil or gas cans, oily rags, chains, wooden
blocks, portable propane cylinders, etc. Afire could result or the generator set operation (cooling, noise and
vibration) may be adversely affected. Keep the compartment floor clean and dry.
Do not work on this equipment when mentally or
physically .fatigued, or after consuming any alcohol odrug that makes the operation of equipment unsafe.
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RGA-OP'
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Table of Contents
SECTION
TITLE
SAFETY PRECAUTIONS
1
2
3
4
5
...............................
PAGE
Inside Cover
............................................
INTRODUCTION
About this Manual
How to Obtain Assistance
Test Equipment
Safety Considerations
Set Removal
.........................................
....................................
...........................................
.......................................
..............................................
MARINE ENGINE CONTROL ...................................
General .................................................
Control Description ........................................
Control Operation ..........................................
Control Troubleshooting .....................................
STANDBY ENGINE CONTROL ..................................
General .................................................
Electric Start Control .......................................
Remote Start Control .......................................
ENGINE CONTROL SERVICE ..................................
General .................................................
(A) BatteryCheck ..........................................
(B) Battery Cable Check .....................................
(C) Battery Charging Check ..................................
(D) Solenoid Check .......................................
(E) Relay Check ...........................................
(F) Fuel Solenoid Check .....................................
(G) Switchcheck ..........................................
(H) Solenoid Check .......................................
GENERATOR AND VOLTAGE REGULATOR .......................
Generator Description ......................................
Generator Operation ........................................
Voltage Regulator ..........................................
Generator Service .........................................
i
1-1
1-1
1-1
1-1
1-1
1-2
2-1
2-1
2.1
2-3
2-5
3.1
3-1
3-1
3-7
4.1
4-1
4-1
4.1
4.1
-4-1
4.1
4.2
4-2
-4-2
5-1
5-1
5-2
5-3
5-5
Redistribution or publication of this document
by any means, is strictly prohibited.
Table Of COIltentS (Continued)
SECTION
TITLE
PAGE
..................6-1
................................................. 6-1
................................. 6-2
...................... 6.3
.................... 6-4
...................... 6-5
...................... 6-5
.................... 6-6
...................... 67.
GENERATOR/REGULATOR TROUBLESHOOTING
General
Troubleshooting Procedures
(A) NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM
(ELECTRONIC VOLTAGE REGULATOR)
(B) NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM
(TRANSFORMER VOLTAGE REGULATOR)
(C) UNSTABLE OUTPUT VOLTAGE. ENGINE SPEED STABLE
(ELECTRONIC VOLTAGE REGULATOR)
(D) OUTPUT VOLTAGE TOO HIGH OR TOO LOW
(ELECTRONIC VOLTAGE REGUMTOR)
(E) OUTPUT VOLTAGE TOO HIGH. TOO LOW. OR UNSTABLE
(TRANSFORMER VOLTAGE REGULATOR)
(F) FIELD BREAKER (CB21) TRIPS
(ELECTRONIC VOLTAGE REGULATOR)
(G) UNBALANCED GENERATOR OUTPUT VOLTAGE
(TRANSFORMER OR ELECTRONIC VOLTAGE REGULATOR)
7
8
......6-7
.............................. 7-1
................................................. 7-1
............................... 7-1
.............................. 71.
............. 7-1
....................................... 7-2
............................. 7-2
...................................... 7-2
................................ 7-3
.................................... 7-3
..................................... 7-4
.................................. 7-5
.................................. 7-6
................................... 7-7
......................... 7-7
...................................... 7-8
.......................................... 7-8
WIRING DIAGRAMS .........................................
8-1
GENERATOR/REGULATOR TESTS
General
(A) Testing AC Residual Voltage
(B) Testing Commutating Reactor
(C) Testing Rectifier Bridge CR21 and Suppressor RV21
(D) Flashing the Field
(E) Testing Reference Transformer
(F) VR21 Replacement
(G) Testing Rotating Rectifiers
(H) Testing Exciter Stator
(J) Testing Exciter Rotor
(K) Testing Generator Stator
(L) Testing Generator Rotor
(M) Wiring Harness Check
(N) Testing Regulating Transformer T21
(P) Voltage Adjustment
(a) Reconnection
ii
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Section 1 Introduction
ABOUT THIS MANUAL
For servicing purposes, the generator set can be
divided into three basic parts: the engine, the generator,
and the control. This manual contains troubleshooting
and repair information for the generator and the control.
Refer to the Engine Service Manual (981-0501) when
servicing the engine.
Study this manual carefully and observe all the warnings and cautions throughout the manual. Knowing the
generator set, using it properly, and following a regular
maintenance schedule can result in longer unit life,
better performance and safer operation.
Information for printed circuit board repair is limited
because it is more efficient to replace the boards in the
field and repair them at the factory. Application of meters
or hot soldering irons to printed circuit boards by other
than qualified service personnel can cause unnecessary and expensive damage.
Incorrect service or replacement of
Z
linjury,
CEdeath,
HE4
parts can result in severe personal
and /or equipment damage. Service personnel must be qualified to perform electrical and
mechanical service.
SAFETY CONSIDERATIONS
Always consider the safety aspects of any service
procedure. Generator sets present several safety
hazards that the service person must be aware of to
safely completethe job. Readthrough the safety precautions listed on the inside cover and familiarize yourself
with the hazards shown in Table 1-1. Once the hazards
are known, approach the job with a safety conscious
attitude. Being safety conscious is the most effective
way to avoid injury to yourself or others. Reduce the
chance that an accident will occur by adopting the
following safeguards.
Safeguards to Avoid Hazards
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Use personal protection Protect your body by
wearing the appropriate safety equipment. Protective clothing includes safety shoes, gloves, safety
glasses, and hard hats. Leave rings and jewelry off
and do not wear loose clothing that might get
caught on equipment.
This manual contains basic wiring diagrams and schematics that are included to help in troubleshooting. Service personnel should use the actual wiring diagram
and schematic shipped with each unit. The wiring diagrams and schematics that are maintained with the unit
should be updated when modifications are made to the
unit.
Work to Reduce the Hazard The workshop area
and all pieces of equipment used can contribute to
reducing the hazard potential. Keep guards and
shields in place on machinery and maintain equipment in good working order. Store flammable liquids in approved containers awayfrom open flame,
spark, pilot light, cigarette, or other ignition source.
Keep the workshop clean and well-lighted, and
provide adequate ventilation. Keep fire extinguisher
and safety equipment nearby and be prepared to
respond to an emergency.
0
Develop Safe Work Habits Unsafe actions are
identified as the source of most accidents involving
the use of tools and machines. Be familiar with the
equipment and know how to use it safely. Use the
correct tool for the job and check its condition
before starting. Observe the warnings and cautions
in this manual and take special precautions when
working around electrical equipment. Do not work
alone if possible and do not take risks.
HOW TO OBTAIN ASSISTANCE
Always give the complete model number and serial
number as shown on the Onan nameplate when seeking additional service information or replacement parts.
TEST EQUIPMENT
Most of the test procedures in this manual can be performed with a multimeter such as the Simpson Model
260 VOM or with a digital VOM. Additional instruments
used to service generator sets that should be available
are:
AC Voltmeter
DC Voltmeter
Frequency Meter
Jumper Leads
Load Test Panel
Megger or Insulation Resistance Meter
Frequency Meter or Strobotach
Variac
Wheatstone Bridge or Digital Ohmmeter
1-1
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by any means, is strictly prohibited.
TABLE 1-1. HAZARDS AND THEIR SOURCE
0
Fire and Explosions
-Leaking or spilled fuel
-Hydrogen gas from battery
-Oily rags improperly stored
-Flammable liquids improperly stored
0
Burns
-Hot exhaust pipes
-Hot engine and generator surfaces
-Electrical short in DC wiring system
Poisonous Gases
-Carbon monoxide from faulty exhaust
pipes, joints or hangers
-Operating generator set where
exhaust gases can accumulate
0
Electrical Shock (AC)
-Improper generator set load connections
-Faulty load circuit
-Faulty electrical appliance
-Faulty generator set wiring
-Working in damp conditions
-Jewelry touching electrical components
Rotating Machinery
-Jewelry or loose clothing catching in moving parts
0
Slippery Surfaces
-Leaking or spilled oil
0
Heavy Objects
-Removing generator set from RV
-Removing heavy components
Leakage of fuel in or around the
Be prepared if an accident does occur. Numerous
agencies such as the Red Cross and local police and
fire departments offer basic courses in first aid, CPR,
and fire control. Take advantage of these offerings so
you are ready to respond when an accident occurs.
Learn to be safety conscious and make safe practices a
part of your work routine. Do not work when tired or after
consuming any alcohol or drug that makes the operation of equipment unsafe.
[BWARNINGI generator set compartmentpresents
the hazard of fire or explosion that can cause severe
personalinjury or death. Do not disconnector connect
battery cables if fuel vapors are present. Ventilate the
compartment thoroughly, use bilge blowers or power
exhausters in boats, and park vehicles outdoors in a
well ventilated area.
1. Disconnect the generator set negative (-) battery
cable at the battery terminal.
SET REMOVAL
Some service procedures will require removing the
generator set from a vehicle or boat. Because of the
wide variety of generator set installations, it is not possible to specify the exact removal procedures for each
generator set. If, after examining the installation,a satisfactory method for removing the set cannot be determined, contact the vehicle or boat manufacturer or the
generator set installerto obtain their recommendations.
2. Disconnect the generator set positive (+) battery
cable from the wire harness.
Generator sets are heavy and they
lZEEEl
can cause severe personal injury or
death if dropped during removal. Use adequate lifting
5. Disconnect the exhaust system and support
brackets or hangers to allow set removal.
devices to provide sufficient support for the set. Keep
hands and feet clear while lifting the generator set.
6. Disconnect the fuel line at the generator set housing. Securely plug the end of the fuel line to prevent
fuel leakage or an accumulation of explosive gasoline vapor.
3. Disconnect the remote control plug wire from the
generator set, if applicable.
4. Disconnect the generator load wires and tag for
identificationwhen reconnecting.
Disconnecting Generator Set Systems
Some installationsmay require partial removal of the set
to gain access to the battery cable, fuel line, and other
connections. Read this entire section before starting set
removal. The following steps are a general guideline for
set removal.
7. Verify that the generator set is adequately supported before loosening any of the mounting bolts
or support members.
1-2
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Leakage of fuel presents fhe hazard
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ofIfire or explosion that can cause
severe personal injury or death. Make certain all fuel
When reinstallingthe generator set, be sure all mounting hardware, and electrical, exhaust, and fuel system
componentsareconnectedexactly as they were before
removal. Refer to the appropriate installation manual
during reinstallation for important safety precautions.
line openings are plugged to prevent gasoline vapor
from accumulating. Before disconnecting the fuel line,
be certain thereare no ignition sources such as flame,
spark, pilot light, cigareite, etc., near the generator set.
Keep an ABC type fire extinguisher nearby.
Check for oil and fuel leaks. Check exhaust system
audibly and visually with the generator set running.
Repair any leaks immediately. Replaceworn, damaged,
or corroded exhaust and fuel line components before
leaks occur.
1-3
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by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
Section 2. Marine Engine Control
GENERAL
The marine engine control system includesall thefunctions that relate to the operation of the engine. This
includes starting and stopping, instrumentation, monitoring for fault conditions, and battery charging. This
section covers a description of the controls and shows
where they are located, describes how the control
operates, and provides basic troubleshooting procedures.
CONTROL DESCRIPTION
Gauges/Meters and Switches
Oil Pressure Gauge (0ptional):Shows engine lubricating oil pressure. The gauge hasa range of 0 to 100 psi (0
to 700 kPa) and is connected to an engine sensor. See
Figure 2-1.
Coolant Temperafure Gauge (Optional): The water
temperature should be in the range of 165OF to 195°F
(74°C to 91 "C) depending on the load and the ambient
temperature.
DC Voltmeter (Optional): Normal battery B+ voltage during operation should be 13.5 to 15 volts on a 12-volt
system; 27 to 30 volts on a 24-volt system.
Starf/StopSwitch S77:Starts and stopsthe unit locally.
Unit may be operated from an optional remote switch
wired to the control panel. Preheat added to stop position on later production sets.
Preheat Switch S72: Activates heater relay K13 to connect battery B+ to the engine glow plugs prior to starting
the engine. S12 is not used on later production sets.
Fault Reset:A manual reset breakerthat shuts down the
engine for low oil pressure, high coolant temperature,
high exhaust temperature, and overspeed (option).
Emergency Stop DC Control Breaker: A 15-ampere
breaker providing protection to the control box wiring
and remote wiring from short circuits or overload. Also
serves as an emergency stop switch.
TRANSFORMER
ELECTR 0NI C
REGULATOR BOARD
REGULATOR
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Control Components
The following describes the basic engine control components and how they function.
K71 Start Solenoid: Located over the engine monitor
circuit board. It connects the battery B+ to the starter
solenoid B1 during cranking.
Engine Monitor Circuit Board; A printed circuit board
that monitors engine control system functions. This
includes starting, stopping, and fault system operation.
A terminal board is includedfor making remote connections. See Figure 2-1.
K73 HeaterRelay: Located On the relay mountingtray. It
C O m ~ ~ t s tbattery
he
B+to the engine glow Plugs Prior to
and during cranking. It is energized by the Preheat
Switch (S12 early production/Sll late production) and
the start switch S11 during start sequence.
Two relays are soldered to the circuit board that are not
serviceable. Power Relay K12 connects and maintains
battery B+ to the control meters and fuel solenoid during
operation. Starter Protection Relay K15 is an AC operated relay. When the start switch is actuated, B+ is
connected to the K11 start solenoid through K15 NC
contacts until the generator output reaches 90 volts AC.
K15 activates and disconnects the starter.
K74 Fuel Solenoid Relay: Located on the relay mounting tray. It is energized only during cranking and connects B+ to the fuel solenoid K1, fuel pump E5, and fault
breaker CB12 circuits.
F7 I n l i n e Fuse: A 30-amperefuse is located in afuseholder connected to the B+ terminal of the starter. This
fuse connects B+ to the control and it will open if ashort
or overload should occur.
K7 Fue/So/enoid:Opens the fuel control valve when the
start/stop switch is placed in the Start position.
OPTIONAL
OIL PRESSURE
K76 Start Disconnect Relay: Located on the relay
mounting tray. It is connected through C R l l to the 12volt battery charging alternator. The relay actuates at 5.5
to 7.5 volts DC. The K16 relay and C R l l diode are not
used on later production sets and were disconnected
on some sets (refer to Product Support Bulletin 450).
Engine Sensors
The following briefly describes the engine mounted
sensors and switches, and how they protect the engine
from adverse operating conditions.
CONTROL
OPTIONAL COOLANT
TEMPERATURE SENDER
E2
BREAKER
CB12
OPTIONAL
OVERSPEED
SWITCH
s4
ES-1445-2
FIGURE 2-2. MDKClMDKD FAULT SENSOR LOCATION
2-2
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by any means, is strictly prohibited.
All safety sensors (switches)close to ground if abnormal
operating conditions exist and trip the fault breaker
CB12 to stop the engine. See Figure 2-2.
High Coolant Temperature Switch S2: This switch
closes if the coolanttemperature risesto 222OF (1OSOC),
activating the fault breaker and stopping the engine.
Resistance units and switches in the monitoring and
shutdown systems are sealed units and are not repairable. When replacing a sensor, do not use a substitute
item since resistance units are matched to the gauge
they supply. Cutoff switches are close tolerance parts
made for a specific application.
High Exhaust Temperature Switch S5: This switch is
mounted on the exhaust elbow and it closes on temperature rise above 23OOF (llO°C), activating the fault
breaker and stopping the engine. It will open again
when the temperature reaches about 190°F (88°C).
Oil Pressure Monitors
Refer to Figure 2-2 for the location of the oil pressure
sensors.
High exhaust elbow temperature is caused by insufficient or lack of sea water flow. Sea water flow at the
exhaust outlet should be about 3 gal/min (11 litre/min).
Oil Pressure Sender E l (Optional): The sender resistance changes with oil pressure and results in a reading
on the oil pressure meter. The meter range is 0 to 100 psi
(0 to 700 kPa).
Low Oil Pressure Switch S1: This switch closes if oil
pressure drops to 9 psi (62 kPa), activating the fault
breaker and stopping the engine.
SWITCH CONT
ControlPowerLafch S6:This oil pressureswitch closes
at 5 psi (34 kPa) and provides a latch function for the
control circuits. When closed, the switch supplies a
ground path for relay K12 on the engine monitor board.
Overspeed Switch (Optional)
The mechanical overspeed switch is mounted on the
front of the engine crankshaft as shown in Figure 2-3. It
is factory adjusted to close and shut down 60 hertz units
at 2200 r/min +/- 90 rimin; 50 hertz unitsat 1900 rimin
t/- 90 r/min. An overspeed condition grounds the
shutdown circuit on the Engine Monitor Board and trips
the fault breaker. After the problem is corrected, starting
will not occur until the breaker is reset.
If necessary, the speed trip point can be corrected by
turning the adjusting screw, to adjust the magnetic air
gap (see Figure 2-3). An accurate tachometer or strobotach is needed to check the overspeed trip point after
adjustment is made. The air gap must not be less than
0.005 inch (0.13 mm).
Engine Temperature Monitors
Refer to Figure 2-2 for the location of the engine
temperature sensors.
Coolant TemperatureSender €2 (0ptional):The resistance of the sender unit changes with theengine coolant
temperature and causes a reading of the Water Temp
Meter. The meter range is 100OF to 25OOF (4OOC to
121OC).
ES-1514
FIGURE 2-3. OPTIONAL OVERSPEED SWITCH
CONTROL OPERATION
Trouble-free operation of the control system should be
the major concern of generator set service personnel.
Service personnel must thoroughly understandhow the
controls operate, know how to make the proper adjustments, replacements, or repairs in a reasonableamount
of time.
The following section covers the control operation. The
schematic diagram shown in Figure 2-4 can be used to
help follow the circuit description. Always refer to the
specific wiring diagram that corresponds to the model
and specification number of the generator set when
troubleshooting. Relay contact references normally
open (NO) and normally closed (NC) refer to the position
of the contacts with the unit at rest (not energized).
Priorto starting the generator set, Check the fuel supply,
engine oil level, and battery connections for loose or
broken wires. Check the entire exhaust system for worn
or corroded parts. Replace defective parts before leaks
occur.
2-3
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by any means, is strictly prohibited.
Figure 2-4 shows a typical schematic for the circuits
described in the following Starting, Start-Disconnect,
and Stopping sequences. Relay contact references
normally open (NO) and normally closed (NC) refer to
position of contacts with the unit at rest (not energized).
Starting Sequence: The engine Preheat switch is held
for 10 to 30 seconds (depending upon temperature).
This energizesthe HeaterSolenoid K13 and closes aset
of NO contactsto connect B+ to the glow plugs. After the
preheat time, the start sequence is initiated by pressing
the Start button S l l .
Switch S11 connects B+ to the coil of K14 and (through
the A1 1-K15 contacts and K16 [early production only]
NC contacts)to the Start Solenoid K11. The coil of K11 is
grounded through the pull coil of K1 after K1 is
completely pulled in and the pull coil is disconnected
from B+. K1 must pull in completely before the engine
will crank.
The closing of the K11 contacts connects B+ to the glow
plugs and to the starter solenoid B1. K14 connects B+ to
the fuel solenoid K1, fuel pump E5,CB21 fault breaker
and engine monitor circuits only during starting.
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Start-Disconnect Sequence:As the engine starts, latch
switch S6 closes and completes the ground circuit
through resistor A l l -R1 for the K12 power relay. The
closing of K12 dual contacts completes the B+ running
circuit to CB12 fault circuit breaker. This was accomplished by K14 during cranking.
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The start-disconnect circuit provides starter protection.
As the generator gains speed and output voltage, the
K15 starter protection relay energizes at about 90 volts
AC. The A1 1-K15 NC contacts open and de-energize
the K11 start solenoid; the A1 1-K15 NO contacts close
and provide another ground path for K12 through K11
coil similar to S6.
A backup start-disconnect circuit is initiatedby the battery charging alternator G1. When DC output at CR11
reaches approximately 6 volts, K16 energizes and
opens B+ to the K11 start solenoid. De-energizing K11
disconnects B+ from the starter solenoid to stop cranking and eliminate glow plug heating. The K16 relay and
CR11 diode are not used in later production generator
sets.
Stopping Sequence: Placing S11 in the Stop position
puts B+ on the ground side of K12 power relay. This
causes K12 to de-energize and disconnect B+ from
CB12, fuel pump E5, and the K1 fuel solenoid. Deenergizing K l shuts off the fuel flow and stops the
engine.
JND
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FIGURE 2-4.
MDKWMDKD CONTROL SCHEMATIC
Emergency Shutdown: Fault breaker CB12 opens to
stop the engine any time afault sensor closes the circuit
to ground. The fault sensors, shown in Figure 2-4, are:
0
0
0
0
S1 low oil pressure
S2 high coolant temperature
S4 overspeed (option)
S5 high exhaust temperature
CB21 should not be reset for starting until fault is located
and corrected.
Redistribution or publication of this document
by any means, is strictly prohibited.
CONTROL TROUBLESHOOTING
The information in this section is divided into three flow
charts. Determine the problem and then refer to the
appropriateflow chart (A, B, or C) for the troubleshooting
procedures.
A. Engine does not crank.
B. Engine cranks but does not start.
C. Engine starts but stops after running several
seconds.
Check all modifications, repairs, and replacements
that have been performedsince the last satisfactory
operation of the set. A loose wire connection could
cause problems. An incorrect connection, an
opened switch or circuit breaker, or a loose plug-in
are all potential problems that can be eliminated by
a visual check.
Unless absolutely sure that panel instruments are
accurate, use portable test meters for troubleshooting.
Before starting a troubleshooting procedure, make a
few simple checks that could expose the problem and
cut down on troubleshooting time.
Totroubleshoot a problem, Start at the upper left corner
of the chart and answer all questions either YES or NO.
Follow the chart until the problem is found, performing
referenced adjustment or test procedures. Refer to Figures 2-1 through 2-4 to locate control components.
FLOW CHART A. ENGINE DOES NOT CRANK
Many troubleshooting procedures present hazards that can result in severe personal injury or
b
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death.
lOnly qualified servicepersonnel with knowledge of fuels, electricity, and machineryhazards
should perform service procedures. Review safety precautions on inside cover page.
START
Check batteryper Checkout [ A ] and rechargeor
replace. Check battery charger operation per
Checkout [Cl.
Is battery dead?
no
1
Check C B l l control breaker and F1 fuse. If okay.
jumper battery cable B+ connection to E1 starter
silenoid terminal. Does engine crank?
Check battery cables for clean tight connections
(rel. Checkout [B]. Check B1 starter solenoid
and motor-if bad. repair or replace.
ves
1
With S11 in Start position, is battery voltage
present between K11 terminal S and ground?
no
W
Check B+ wiring toSl1. and betweenS11 and K11
Check NC contacts of A11-Kl5 and K16. Replace 11
bad.
1
It K11 does not energize, test per Checkout [HI
and replace if bad. Is battery voltage present at B1
solenoid terminal with S11 in Start position.
nn
2-5
Check Btlwiring between K11 and B1 solenoid
terminal. Replaceif bad. Check K1 plungertravel for
feedom to bottom in solenoid which is necessary to
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART B. ENGINE CRANKS BUT DOES NOT START
Many troubleshooting procedures present hazards that can result in severe personal injury or
k!should
@%@l
death. Only qualifiedservicepersonnel with knowledgeof fuels, electricity,andmachinery hazards
perform service procedures. Review safety precautions on inside cover page.
START
r
1
I
Is engine getting fuel? Exhaust smoke should be
blue-white and fuel flow steady from fuel
return line.
Check fuel system: fuel tank level, shut-off
valves, fuel lines and connections, fuel filters,
fuel pump and injection pump. Okay?
Does K1 fuel solenoid energize when S11 is in
Start position?
1
Is battery B+ applied to glow plug heaters when
Preheat Switch is closed?
3
I
I
1
Check B+ circuit through S11. Test S11 per
Checkout [GI.Test K1 per Checkout [F].
I
no
I
yes
1
Incorrect fuel? See Operator’s Manual
recommendations.
Check Preheat switch and heater relay K13 per
Check heater wiring.
Checkouts [GIand
[a.
FLOW CHART C. ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS
Many troubleshooting procedures present hazards that can result in severe personal injury or
death. Only qualified servicepersonnel with knowledge of fuels, electricity, and machinery hazards
should perform service procedures. Review safety precautions on inside cover page.
Is a fault condition indicated by fault breaker
CB12 on control panel.
Does latching relay K12 energize and contacts
close when generator set comes up to operating
speed?
Does DC control breaker trip when the
generator set is started?
Yes
*
Check for a possible fault condition. If none,
check fault monitors S1 through S5 and fault
breaker CB12 for improper wiring.
no
*
Check for closing of S6 power latch switch. If
okay, replace engine monitor PC board.
Yes
5
Check all B+ wiring for shorts to ground.
2-6
Redistribution or publication of this document
by any means, is strictly prohibited.
Section 3. Standby Engine Controls
GENERAL
b
This section contains control information for standby
generator sets. Two starting controls are available that
differ primarily in the methodof starting. An ElectricStart
Control is used for electric starting and stopping at the
generator set only. A Remote Start Control is used for
electric starting and stopping with provision for remote
operation with optional accessory equipment. Each of
the start controls will be covered in a separate section.
ELECTRIC START CONTROL
This control has a key switch for Preheat, Start and Stop
on the front panel and cannot be connected for remote
operation. Component references are found on separate wiringlschematic diagrams in the Wiring Diagrams
section of this manual.
Coolant Temperature Gauge (Optional):Shows engine
coolant temperature. The gauge is wired to a sensor on
the engine and has a range of 100°F to 250°F (40°C to
121"C).
Oil Pressure Gauge (Optional):Shows engine Iubricating oil pressure. The gauge has a range of 0 to 100 psi (0
to 700 kPa) and is connected to an engine sensor.
frelreat/Stop/Run/Start Switch S77: This is a key
switch that preheats, starts and stops the generator set
locally.
fault Reset Breaker C612:A manual reset breaker that
shuts down the engine for low oil pressure, high coolant
temperature, and overspeed.
K1 fuel Solenoid: It opens the fuel control valve when
the start/stop switch is placed in the Start position.
GaugesIMeters and Switches
DC Voltmeter(0ptional)~Normalbattery B+ voltage during operation should be 13.5 to 15 volts on a 12-volt
system; 27 to 30 volts on a 24-volt system. See Figure
3-1.
I
I
TRANSFORMER
REGULATOR
ES-1515
OIL PRESSURE
WATER
TEMPERATURE
GAUGE
ELECTRONIC
AC REGULATION
TRANSFORMER
AC REGULATION
DC
VOLTMETER
.
FIELD BREAKER CB21
(ELECTRONIC REGULATORS ONLY)
TIME
METER
PREHEATISTOPI
RUNISTART
SWITCH S11
/
FAULT
RESET
BREAKER C812
ES-1448
FIGURE 3-1. DKCIDKD ELECTRIC START AND LAND SET CONTROL BOX
3-1
Redistribution or publication of this document
by any means, is strictly prohibited.
F7 I n l i n e Fuse: A 30-ampere fuse is located in a fuse
holder connected to the B+ terminal of the starter. This
fuse connects B+ to the control and opens if a short or
overload should occur.
Resistance units and switches in the monitoring and
shutdown systems are sealed units and are not repairable. When replacing a sensor, do not use a substitute
item since resistance units are matched to the gauge
they supply. Cutoff switches are close tolerance parts
made for a specific application.
,
Oil Pressure Monitors
Engine Temperature Monitors
Refer to Figure 3-2 for the location of the engine
temperature sensors.
Coolant TemperatureSenderE2 (0ptional):The resistance of thesender unit changes with theengine coolant
temperature and causes a reading on the Water Temp
rneter.Themeterrangeis100" to25O0F(4O0to121"C).
I
High Coolant Temperature Switch S2: This switch
closes if the coolant temperature rises to250"F (121"C),
activating the fault breaker CB12 and stopping the
engine.
Refer to Figure 3-2 for the location of the oil pressure
sensors.
Oil Pressure Sender E7 (Optional): The sender resistance changes with oil pressure and results in a reading
on the oil pressuremeter. The meter range is 0 to 100 psi
(0 to 700 kPa).
Low Oil Pressure Switch S7: This switch closes if oil
pressure drops to 9 psi (62 kPa), activating the fault
breaker and stopping the engine.
OPTIONAL COOLANT
TEMPEFWTU,RE SENDER E2
LOW OIL
PRESSURE
OIL PRESSURE
SENDER E l
HIGH COOLANT
TEMP SWITCH-
52
F1 FUSEH
FIGURE 3-2. DKCIDKD ELECTRIC START FAULT SENSOR LOCATION
3-2
Redistribution or publication of this document
by any means, is strictly prohibited.
Overspeed Switch (Optional)
The mechanical overspeed switch is mounted on the
front of the engine crankshaft as shown in Figure 3-3. It
is factory adjusted to close and shut down 60 hertz units
at2200+/-90r/min;50hertzunitsat1900r/min+/-90
r/min. An overspeed condition grounds the shutdown
circuit on the Engine Monitor Board and trips the fault
breaker. After the problem is corrected, starting will not
occur until the fault breaker is reset.
Prior to starting the generator set, check the fuel supply,
engine oil level, and all battery connections for loose or
broken wires.
Figure 3-4 shows a schematic diagram for the circuits
described in the following Starting, Start-Disconnect
and Stopping sequences. Relay contact references
normally open (NO) and normally closed (NC) refer to
position of contacts with the unit at rest (not energized).
Starting Sequence: When the control key switch S11 is
in the Preheat position, contacts 1-2 connects B+ to the
glow plug heaters. See Figure 3-4.
In the Start position, S11 contacts 1-2, 3-4 and 5-6
close. Contacts 1-2 energize the glow plugs during
cranking; contacts 3-4 connect B+ to CB12 Fault
breaker, K1 fuel solenoid, S4 overspeed switch and
VR11 battery charging voltage regulator; contacts 5-6
connect B+ to the starter solenoid B1.
S
co
In the Run position, S11 contacts 3-4 and 7-8 close.
Contacts 3-4remain closed and maintain B+ to CB12,
K1, S4 and VR11. Contacts 7-8 connect B+ to the engine
fault sensors S1 and S2. Contacts 1-2 open the glow
plug heater circuit, and contacts 5-6 open the starter
solenoid circuit
Start-Disconnect Sequence:This function is completed
manually when keyswitch S11 is releasedfrom the Start
position opening S i 1 contacts 5-6 for the starter solenoid B1.
ES-1514
FIGURE 3-3. OPTIONAL OVERSPEEDSWITCH
If necessary,the speed range can be corrected by turning the adjusting screw, thereby changingthe magnetic
air gap. An accurate tachometer or strobotach is
needed to check the overspeed trip point after adjustment is made. The air gap must not be less than 0.005
inch (0.13 mm).
Control Operation
Trouble-free operation of the control system should be
the major concern of generator set service personnel.
Service personnel must thoroughly understandhow the
controls operate, know how to make the proper adjustments, replacements,or repairs in a reasonable amount
of time.
Stopping Sequence: This function is completed manually when key switch S i 1 is turned to the Stop position.
This opens all switch contacts and removes B+from the
fuel solenoid K1. De-energizing K1 shuts off the fuel
flow and stops the engine.
Emergency Shutdown: Fault breaker CB12 opens and
disconnects B+from the fuel solenoid K1 anytime a fault
sensor closes the circuit to ground. The fault sensors
are:
0
0
S1 low oil pressure
S2 high engine temperature
S4 overspeed
CB12 should not be resetfor starting until fault is located
and corrected.
.
3-3
Redistribution or publication of this document
by any means, is strictly prohibited.
Control Troubleshooting
_c
--.
!tl
The information in this section is divided into three flow
charts. Determine the problem and then refer to the
appropriate flow chart (A,B, or C) for the troubleshooting
procedures.
I
A. Engine does not crank.
B. Engine cranks but does not start.
C. Engine starts but stops after running several
seconds.
-+
HRI
Before starting a troubleshooting procedure, make a
few simple checks that may expose the problem and cut
down on troubleshooting time.
4 t i
Check all modifications, repairs, and replacements
performed since last satisfactory operation of set. A
loose wire connection overlooked when installinga
replacement part could cause problems. An incorrect connection, an opened switch or circuit
breaker, or a loose plug-in are all potential problems that can be eliminated by a visual check.
Unless absolutely sure that panel instruments are
accurate, use portable test meters for troubleshooting.
To troubleshoot a problem,start at the upper-left corner
of chart and answer all questions either YES or NO.
Follow the chart until the problem is found, performing
referenced adjustments or test procedures. Refer to
Figures 3-1 through 3-4 for locating control components, leads, terminals and other check points.
FIGURE 3-4. ELECTRIC START CONTROL
SCHEMATIC DIAGRAM
3-.4
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART A. ENGINE DOES NOT CRANK
lliEEEl only qualijiec,
Many tmubleshootingpmcedures present hazards that can resutf in severe personalinjury or death.
service personnel with knowidge of fuels, electricity, and machinery /manis should
perform service procedures. Review safefy precautions on inside cover page.
Check battery per Checkout [A] and recharge
or replace. Check battery charger operation per
Checkout IC].
Is battery dead?
no
w
Check battery cables for clean tight connections
(ref. Checkout [B]). Check 81 starter solenoid and
motor-if bad, repair or replace.
*
Check wiring and replace if bad,
engine crank?
Is B+ present at key switch S l l ?
no
I s engine getting fuel? Exhaust smoke should be
blue-white and fuel flow steady from fuel
return line.
Check fuel system: fuel tank level, shut-off
valves, fuel lines and connections, fuel filters,
fuel pump and injection pump. Okay?
yes
I
IS battery B+ applied to glow plug heaters when
switch S11 is in Preheat and Start positions?
Does K1 fuel solenoid energize when S11 is in
Start position?
I
Check B+ circuit through S11. Test S11 per
Checkout (GI.Test K1 per Checkout [F].
&
1
Incorrect fuel? See Operator's Manual
Check switch 3 1 1 per Checkout [GI.Check
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART C. ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS
1aWAR"Gl
Many troubleshooting procedures present hazards that can result in severe personal injury or
death. Only qualified service personnel with knowledge oi fuels, electricity, andmachinery hazards
should perform service procedures. Review safety precautions on inside cover page.
START
Check fora possible fault condition. If none,
check fault monitors S1,S2, S4 and fault breaker
CB12 for improper wiring.
Is a fault condition indicated by fault breaker CB12
on control panel?
no
I
Test key switch S11 per Checkout [GI.Check
wiring. Check fuel system.
3-6
Redistribution or publication of this document
by any means, is strictly prohibited.
REMOTE START CONTROL
In-Line Fuse F7 (Land Generator sets): A 30 ampere
fuse is located in a fuseholder connected to the B+
terminal of the starter. This fuse connects B+ to the
control and opens if a short or overload should occur.
This control can provide starting and stopping from
remote locations when connected to optional accessory equipment. The following text explains control
conponents function, control operation and troubleshooting.
Engine Monitor Circuit Board: A printed circuit board
that monitors engine control system functions. This
includes starting, stopping, and fault system operations.
A terminal board is included for making remote connections. See Figure 3-5.
OilPressure Gauge (0ptional):Shows engine lubricating oil pressure. The gauge has a range of 0 to 100 psi (0
to 700 kPa) and is connected to an engine sensor. See
Figures 3-5 and 3-6.
Two relays are soldered to the circuit board and are not
serviceable. Power relay K12 connects and maintains
battery B+ to the control meters and fuel solenoid during
operation. Starter protection relay, K15 energizes at
about 90 volts AC. The A1 1-K15 NC contacts open and
de-energize the K11 start solenoid; the A11-Kl5 NO
contacts closeand provideanother ground path for K12
through K11 coil similar to S6.
Coolant Temperature Gauge (Optional): The water
temperature should be in the range of 165OF to 195OF
(74°C to 91OC)depending on the load and ambient
temperature.
DC Voltmeter(0ptional): Normal battery B+ voltage during operation should be 13.5 to 15 volts on a 12-volt
system; 27 to 30 volts on a 24-volt system.
K1 fuelSolenoid:Opens the fuel control valve when the
start/stop switch is placed in the Start position.
Preheat Switch S72:Activates heater relay K13 to connect battery B+ to the engine glow plugs prior to starting
the engine.
K71 Start Solenoid: Located over the engine monitor
circuit board. It connects battery B+ to the starter solenoid B1 during cranking.
Start-Stop Switch: Starts and stops the unit locally.
When released, unit may be operated from a remote
switch wired to the control panel.
K13 Hoaror Relay:Located on the relay mounting tray. It
connects battery B+ to the engine glow plugs prior to
cranking. It is energized by S12 preheat switch.
DC ControlBreaker CB7 7:A 15 ampere breaker providing protection to the control box wiring and remote
wiring from short circuits or overload. Also serves as an
emergency stop switch.
K74 Fuel Solenoid Relay: Located on the relay mounting tray. It is energized only during cranking and connects B+ to the fuel solenoid K1, fuel pump E5 and fault
breaker CB12 circuits.
Fault Reset Breaker CB72:A manual reset breaker that
shuts down the engine for low oil pressure, high coolant
temperature, high exhaust temperature and overspeed.
K16 Start Disconnect Relay: Located on the relay
mounting tray. It is connected through C R l l to the 12volt battery charging alternator. The relay actuates at
about 6 volts DC. The K16 and C R l l diode are not used
on later production sets and were disconnected on
some sets (refer to Product Support Bulletin 450).
Battery Charge Breaker CB13 (RV Generator sets): A
15-ampere breaker protecting the DCvoltage regulator,
alternator and wiring from short circuits or overload.
3-7
Redistribution or publication of this document
by any means, is strictly prohibited.
TRANSFORMER
REGUIATOR
OPTIONAL
LINE CIRCUIT
/
\
ELECTRONIC
REGULATOR BOARD
FIELD BREAKER CB21
(ELECTRONIC REGULATORS ONLY)
-\
REMOTE CONTROL CONNECTION J3
(UNDER FLANGE OF CONTROL BOX)
(RV GENSETS ONLY)
TRANSFORMER
AC REGULATION
ES-1513-2
STANDBY
GENSET
II
K13 HEATER RELAY
\
I
ELECTRONIC
AC REGULATION
STARTISTOPI PREHEAT
SWITCH S11
RUNNING
TIME
METER
I
FAULT
RESET
BREAKER CB12
FAULT
RESET
BREAKER CB12
PREHEAT
SWITCH S12
(EARLY PROD1UCTION
ONLY)
~
DC CONTROL
BREAKER CB 11
DC CONTROL
BREAKER C B l l
RUNNING
TIME
METER
ES-1513
BAlTERY
CHARGE
BREAKER
CB13
ES-1404
STARTISTOPIPREHEAT
SWITCH S11
.
PREHEAT
SWITCH S12
(EARLY PRODUCTION
ONLY)
IC1525
FIGURE 3-5. DKD RV CONTROLBOX COMPONENTS
3-a
Redistribution or publication of this document
by any means, is strictly prohibited.
S11 START-STOP-
"
------B
CB13 DC CHARGING
BREAKER
I
1
J2CONNECTOR
(ENGINE MONITORS)
\
FRONT
J1 CONNECTOR
(AC CONTROL BOX)
REAR
K13 RELAY
K14 RELAY
K11 START
A l l ENGINE
MONITOR BOARD
SOLENOID
\-
CR2 RECTIFIER
FIGURE Ma. DKD DC CONTROL BOX
3-8a
Redistribution or publication of this document
by any means, is strictly prohibited.
GROUNDING
RV21 SUPPRESSOR
ASSEMBLY
TB3 TERMINAL
/
BLOCK \
AC HARNESS (TO DC
CONTROL BOX)
5
FIGURE 35b. DKD AC CONTROL ASSEMBLY
3-8b
Redistribution or publication of this document
by any means, is strictly prohibited.
Engine Sensors
The following briefly describes the engine mounted
sensors and switches, and how they protect the engine
from adverse operating conditions. All safety sensors
(switches)close to ground if abnormal operating conditions exist and trip the fault breaker CB12 to stop the
engine. See Figure 3-6.Resistance units and switches
in the monitoring and shutdown systems are sealed
units and are not repairable. When replacing a sensor,
do not use a substitute item since resistance units are
matched to the gauge they supply. Cutoff switches are
close tolerance parts made for a specific application.
Overspeed Switcl, (Optional’; The mechanical overspeed switch is mounted on the front of the engine
crankshaft as shown in Figure 3-7. It is factory adjusted
to close and shut down 60 hertz units at 2200 r/min +/90 r/min; 50 hertz units at 1900 r/min +/- 90 r/min. An
overspeed condition grounds the shutdown circuit on
the Engine Monitor Board and trips the fault breaker.
After the problem is corrected, starting will not occur
until the fault breaker is reset.
Oil Pressure Sender €7 (Optional): The sender resistance changes with oil pressure and results in a reading
on the oil pressure meter. The meter range is 0 to 100 psi
(0 to 700 kPa).
Low Oil Pressure Switch S7: This switch closes if oil
pressure drops to 9 psi (62 kPa). Some early generator
sets had switches closing at 14 psi (97 kPa). This activates the fault breaker and stops the engine.
S
co
Control Power Latch (S6): This oil pressure switch
closes at 5 psi (34 kPa) and provides a latch function for
the control circuits. When closed, the switch supplies a
ground path for relay K12 on the engine monitor board.
1
.
ES-1514
FIGURE 3-7. OPTIONAL OVERSPEED SWITCH
OPTIONAL
OIL PRESSURE
SENDER El
CONTROL
POWER LATCH S6
HIGH COOLANT
TEMP. SWITCH
FAULT
RESET
BREAKER
CB12
ES-1551-1
FIGURE 3-6.
ENGINE SENSOR LOCATIONS
Redistribution or publication of this document
by any means, is strictly prohibited.
If necessary, the speed trip point can be corrected by
turning the adjusting screw, thereby changing the magnetic air gap. An accurate tachometer or strobotach is
needed to check the overspeed trip point after adjustment is made. The air gap must not be less than 0.005
inch (0.13 rnm).
c
Coolant TemperatureSender E2 (0pfional):The resistance of the sender unit changes with the engine coolant
temperature and causes a reading on the Water Temp
meter. The meter range is 100" to 250°F (40" to 121 "C).
High Coolant Temperature Switch S2: This switch
closes if the coolant temperaturerisesto 222°F (106"C),
activating the fault breaker and stopping the engine.
i
Control Operation
Trouble free operation of the control system should be
the major concern of generator set service personnel.
Service personnel must thoroughly understandhow the
controls operate, know how to check for troubles, and
know how to make the proper adjustments, replacements, or repairs in a reasonable amount of time.
Figure 3-8 shows a typical schematic for the circuits
described in the following Starting, Start-Disconnect
and Stopping sequences. Relay contact references
normally open (NO) and normally closed (NC) refer to
position of contacts with the unit at rest (not energized).
I
CBII(
tc
I
Starling Sequence: The engine Preheat switch S12 is
held for 10 to 30 seconds (depending upon temperature). This energizes the K13 heater solenoid which
closes a NO set of contacts to connect B+ to the glow
plugs. After preheat time, the start sequence is initiated
by pressing the Start button S1 1.
i
t
Switch S11 contacts B+ to the coil of K14 and (through
the A1 1-K15 contacts and K16 NC contacts) to the Start
Solenoid K l l . The coil of K11 is grounded through the
pull coil of K1 after K1 is completely pulled in and the
pull coil is disconnected from B+. K1 must pull in
completely or the engine will not crank.
The closing of K11 contacts connects B+ to the glow
plugs and B1 starter solenoid. K14 connects Bt to K1
fuel solenoid, K5 fuel pump, CB12 fault breaker and
engine monitor circuits only during starting.
Start-Disconnect Sequence:As the engine starts, latch
relay S6 closes and completes the ground circuit
through resistor A11-R1 for the K12 power relay. The
closing of K12 dual contacts completes the B t running
circuit to CB12 fault circuit breaker.
FIGURE 3-8. TYPICAL CONTROL SCHEMATIC
The start-disconnectcircuit provides starter protection.
As the generator gains speed and output voltage, the
K15 starter protection relay energizes at about 90 volts
AC. The A1 1 -K15 NC contacts open and de-energize
the K11 start solenoid; the A1 1-K15 NO contacts close
and provide another ground path for K12 through K11
coil similar to S6.
3-10
Redistribution or publication of this document
by any means, is strictly prohibited.
A backup start-disconnect circuit is initiatedbythe battery charging alternator G1.When DC output at CR11
reaches approximately 6 volts, K16 energizes and
opens B+ to the K11 start solenoid. De-energizing K11
disconnects B+ from the starter solenoid to stop cranking and eliminate glow plug heating. The K16 relay and
CR11 diode are not used in later production generator
sets.
Stopping Sequence: Placing S i 1 in the Stop position
puts B+ on the ground side of K12 power relay. This
causes K12 to de-energize and disconnect B+ from
CB12, fuel pump E5 and the K1 fuel solenoid. Deenergizing K1 shuts off the fuel flow and stops the
engine.
Control Troubleshooting
The information in this section is divided into three flow
charts. Determine the problem and then refer to the
appropriate flow chart (A, B, or C) forthe troubleshooting
procedures.
A. Engine does not crank.
B. Engine cranks but does not start.
C. Enginestarts but stops after running several seconds.
Before starting a troubleshooting procedure, make a
few simple checks that may expose the problem and cut
down on troubleshooting time.
Emergency Shutdown: Fault breaker CB12 opens to
stop the engine anytime afault sensor closes the circuit
to ground. The fault sensors as shown in Figure3-8 are:
0
0
0
S1 low oil pressure
S2 high coolant temperature
S4 overspeed
CB12 should not be reset for starting until fault is located
and corrected.
Check all modifications, repairs, and replacements
performed since the last satisfactory operation of
set A loose wire connection could cause problems.
An incorrect connection, an opened switch or circuit breaker, or a loose plug-in are all potential
problems that can be eliminated by a visual check.
Unless absolutely sure that panel instruments are
accurate, use portable test meters for troubleshooting.
To troubleshoot a problem, start at the upper-lef!
corner of chart and answer all questions either YES
or NO. Follow the chart until the problem is found,
performing reference adjustment or test
procedures. Refer to Figures 3-5 through 3-8 for
locating control components, leads, terminals and
other check points.
FLOW CHART A. ENGINE DOES NOT CRANK
Many troubleshooting procedures present hazards fhat can resulr in severe personal injury or
death. Only qualifi~servicepersonnelwith knowledge of fuels, electricity,andmachinery hazards
should perform service procedures. Review safety precautions on inside cover page.
Check battery per Checkout [A)and rechargeor
replace Check battery charger operation per
Is battery dead?
1
Check battery cables for clean tight connections
(re1 Checkout [BI. Check B1 starter solenoid
and motor-if bad. repair or replace
jumper oattery cable B+ connection to B1 starter
salenoid terminal. Does engine crank?
Yes
With S11 in Start position. is battery voltage
present between K11 terminal S and ground?
I
I-"+
Check B+ wiring to S11.and between S11 and K11.
Check NC contacts of All-K15 and K16 Replace if
bad
I
I
1
1
It K11 does not energize, test per Checkout [HI
and replace i f bad. Is battery voltage present at I31
solenoid terminal with S11 in Start position.
Check B+/wiring between K11 and 81 solenoid
terminal. Replaceif bad. Check K1 plunger travel for
feedom to bottom in solenoid which i s necessary to
nc
3-11
I
I
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART B. ENGINE CRANKS BUT DOES NOT START
Many troubleshooting procedures present hazards that can result in severe personal injury or
death. Only qualifiedservicepersonnel withknowledgeof fuels, electricity, and machinery hazards
should perlorm service procedures. Review safety precautions on inside cover page.
START
Check fuel system: fuel tank level, shut-off
valves, fuel lines and connections, fuel filters,
fuel pump and injection pump. Okay?
blue-white, and fuel flow steady from fuel
return line.
I
Does K1 fuel solenoid and E5 fuel pump energize
when S11 is in Start position?
I
1
no
Is battery B+ applied to glow plug heaters when
Preheat Switch is closed?
I
I
I
Check B+ circuit to K14 coil. Test relay K14 per
Checkout [E]. Test K1 fuel solenoid per Checkout [F].
I
I
no
yes
t
1
I
i
I
Incorrect fuel? See Operator’s Manual
recommendations.
I
K13 per Checkouts [GIand [E].
Check heater wiring.
FLOW CHART C. ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS.
Many troubleshooting procedures present hazards that can result in severe personal injury or
death. On/yqualifiedservicepersonnel with knowledgeof fuels, electricity,and machinery hazards
should perform service procedures. Review safety precautions on inside cover page.
START
Check for a possible fault condition. If none, check
fault monitors S1 through S4 and fault breaker
CB12 for improper wiring.
Is a fault condition indicated by fault breaker
CB12 on control panel.
no
I
Does latching relay A1 1-K12 energize and contacts
close when generator set comes up
to operating speed?
Check for closing of S6 power latch switch. If
okay. replace engine monitor PC board.
yes
I
I
I
.
Does DC control breaker trip after generator
set is started?
I
1
Fyes-i
Check all B+ wiring for shorts to ground.
I
1
3-12
3
I
I
Redistribution or publication of this document
by any means, is strictly prohibited.
Section 4. Engine Control Service
GENERAL
[CI
The following component checks are referenced in the
Control Troubleshooting flow charts. They are an aid to
isolating circuit problems caused by faulty engine control components. Disconnect leads before testing
components.
BATTERY CHARGING CHECK
With the engine running, check the DC voltmeter (control option).A 12-voltsystem should be 13.5to 15volts;a
24-volt system should be 27 to 30 volts.
Many troubleshooting procedures
JQWAR"GJ
present hazards that can result in
severe personal injury or deafh. Only qualiiied service
The power source is a belt driven alternator.The charge
rateholtage is determined by voltage regulator VR11.
On marine sets VR11 is located on the bottom of the
control box saddle and it is located inside the control
box on land sets.
personnel with knowledge of fuels, electricity, and
machinery hazards should perform service
procedures. Review safety precautions on inside cover
page.
Improper output may be caused by a loose drive belt,
poor terminal connections, broken wires, bad regulator
or alternator. Checkout procedures for the regulator
and alternator are found in Section 5 of the engine
service manual. The charge circuit on RVseries generator sets is protected by a circuit breaker CB13.
[AI
BATTERY CHECK
Battery electrolyte can cause severe
JQWAR"G1 eye damage and burns to the skin.
If the output voltage is high (over 15 volts), check for
loose or corroded voltage regulator leads. If this does
not correct the problem, the regulator is probably
shorted and should be replaced. With remote start
Kubota powered sets, exhibiting overcharging symptoms, refer to Product Support Bulletin 450.
Wear goggles, rubber gloves and a protective apron
when working wifh batteries.
Check charge condition of the battery with a hydrometer. The electrolyte specific gravity should be about
1.260 for a fully charged battery at 80°F (27OC).If not,
add distilled waterto keep electrolyteat proper leveland
rechargethe battery. If battery will not recharge, replace
it.
SOLENOID CHECK
If battery loses excess water, the charge rate may be too
high. if battery state of charge is not maintained, the
charge rate may be too low.
1. Apply battery positive(B+)to the terminal marked S.
2. Connect a ground wire to the solenoid mounting
bracket. Solenoid should activate.
3. If the contacts are good, battery voltage should be
read between terminal 1 and ground. The voltage
drop measured across the contacts should never
exceed one volt in circuit application.
BATTERY CABLE CHECK
With the starter motor operating, check the voltage
drops (1) from the battery negative post (not the cable
clamp) to the cylinder block, (2)from the battery positive
post to the battery terminal stud on the solenoid. Normally, each of theseshould be lessthan 0.3 volts. If extra
long battery cables are used, slightly higher voltage
drops may result. Thoroughly clean all connections in
any part of the circuit showing excessive voltage drop.
RELAY CHECK
1. Connect relay coil voltage across relay coil terminals. Relay should activate if coil is okay.
2. Connect voltage source to one side of relay
contacts.
3. Connect a voltmeter to other side of relay contact
and voltage source. If voltage appears when relay
energizes, contact is okay. The voltage reading
appears in reverse order when checking normally
closed (NC) contacts.
4-1
Redistribution or publication of this document
by any means, is strictly prohibited.
FUEL SOLENOID CHECK
SOLENOID CHECK
If there is fuel to the injection pump, but no fuel at
injection nozzle, the fuel solenoid may be defective.
1. Apply battery positive(B+) to the terminal marked S.
To check solenoid operation, watch for solenoid actuation when B+ is applied (start switch in start or run
position). Ifthere is no actuation when B+ is applied, the
fuel solenoid must be replaced. When B+ is removed,
the solenoid must de-activate.
2. Connect a ground wire to the terminal marked 1.
Solenoid should activate.
3. Continuity should be read across the two large terminals while solenoid is activated.
SWITCH CHECK
1. Remove battery B+ cable.
2. Place ohmmeter leads across switch.
3. Open and close switch whileobservingtheohmmeter. A normally open (NO) switch should indicate
infinite resistance when open and continuity when
closed. A normally closed (NC) switch should indicate continuity when closed and infinite resistance
when open.
4. Replace switch if defective.
4-2
Redistribution or publication of this document
by any means, is strictly prohibited.
Section 5. Generator/Voltage
Regulator
GENERAL DESCRIPTION
A ball bearing in the end bell supports the outer end of
The YD generator (Figure 5-1) is a four-pole, revolving
field, brushless exciter design with drip-proof construction. Single and three phasegeneratorsare availablefor
both 50 and 60 hertz models.
the rotor shaft. The end bell is attached with four studs
that thread into the generator adapter casting. The
brushless exciter stator mounts in the end bell while the
exciter rotor and its rotating diode assemblies mount on
the generator rotor shaft. Leads F1 (+)and F2 (-)from the
exciter stator winding are connected to the output terminals of the voltage regulator.
The generator rotor is directly coupled to the engine
flywheel with a flexible drive disc (engine speed determines generator output voltage and frequency). A centrifugal blower on the drive disc circulates generator
cooling air which is drawn in through the end bell and
discharged through an outlet in the blower end.
The composite illustration in Figure 5-2 shows the
generator output and control/meter leads for the various voltage options. Voltage reconnection diagrams
appear in Section 7. Generator/Regu/ator Tests, and in
Section 8, Wiring Diagrams.
END BELL
DRIVE
DISC
1
BLOWER
/
BRUSHLESS
/EXCITER
ROTOR
END
BEARING
'
ROTATING
DIODE
ASSEMBLIES
(NOT SHOWN)
\
RUSHL LESS
EXCITER STATOR
ROTOR
XG-1201
FIGURE 5-1. TYPICAL YD SERIES GENERATOR
5-1
Redistribution or publication of this document
by any means, is strictly prohibited.
GENERATOR OPERATION
CONTROL LEADS
Power generation involves the generator components
shown in Figure 5-3. These componentsareitalicized in
the following text. A permanent magnetembeddedin an
exciterstatorfield pole begins the voltage build-up process as the generator set 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.
,
ROTOR
MAIN
FIELO
The exciterrotorproduces three-phase AC voltage that
is converted to DC by the full wave rotating rectifier
assemblies.The DC voltage excites the rotor main field
winding to produce main stator AC for the load.
18 8 518
THREE-PHASE
I I
Generator sets without control panel AC meters are
shipped from the factory with the AC output leads
separated in the control box. Generator sets with AC
meters have the AC output leads wired as specified on
the customer’s purchase order to deliver the voltage
specified.
ROTATING
EXCITER
STATOR
-#
TO VOLTAGE
REGULATOR
ES-1489.2
- NOT USED ON 1 0 GENSETS WITH ELECTRONIC REGULATION
5-
NOT USED ON 1 0 GENSETS WITH TRANSFORMER
REGULATION
FIGURE 5-2. SINGLE AND THREE PHASE GENERATOR
SCHEMATIC (COMPOSITE)
e3
EXCTIER
ROTOR
MAIN FIELD
-----
ROTOR
EXCITER
1
-
-J3- --0DC
I
I
I
I
I
MAIN
FIELD
-----__
VOLTAGE
REGULATOR
LOAD
ES-1322-2
FIGURE 5-3. EXCITATION BLOCK DIAGRAM
5-2
Redistribution or publication of this document
by any means, is strictly prohibited.
VOLTAGE REGULATOR
Thevoltage regulator controls the output of the generator so that a constant voltage is maintained under varying load conditions.There are two types of voltage regulators used on these sets: transformer and electronic
(solid state). The description and operation of each type
is covered separately.
Transformer Voltage Regulator
The transformer voltage regulator is standard equipment on all single-phase generator sets. It is located
inside the generator set control box. A typical transformer and a schematic showing circuit application is
shown in Figure 5-4. The transformer provides a feedback loop from the output of the generator to the exciter
stator.
The number of primary windings and secondary taps
will change for 50 hertz and different model applications. See individual model wiring diagrams in the back
of this manual.
The transformer primary is connected in series with the
generator output leads making it a current boost winding for the secondary. Separate coils in the primary
allows the generator to be reconnected for other voltages without causing an output voltage unbalance.
The transformersecondary is in the exciter circuit and is
connected through a diode bridge. The diode bridge
converts AC to DC for the exciter. Thus the exciter DC
boost current is dependent upon the primary/load current.
ES1491
FIGURE 5-4. TYPICAL TRANSFORMER AND CIRCUIT APPLICATION
5-3
Redistribution or publication of this document
by any means, is strictly prohibited.
Electronic Voltage Regulator
A rise or fall in the generator stator output voltage pro-
Electronic Voltage Regulator is standard equipment on
all three phase generator sets, and is optional for single
phase sets. Basic components consist of the following
items shown in Figure 5-5.
duces a corresponding change in the transformer
secondary.
0
0
,
Thegenerator stator isalso connected to thecommutating reactor CMR21. Reactor E 1 is a choke used to
producea uniformAC wave to the circuit board AC input
terminal TB1-1.
Regulator Board Assembly
Voltage Reference Transformer T21
Commutating Reactor CMR21
Terminal Board TB21
During operation, the regulator circuit board responds
to changes in the reference voltage supplied by transformer T21. These changes raise or lower the DC output
voltage produced for field excitation which results in a
stable output for the load.
The electronic regulator provides better voltage regulation than the transformer type. It is recommended when
powering non-linear SCR loads (usually associated
with solid-state equipment).
STATOR
ASSEMBLY
Only the basic functions of the regulator are described.
Current from one of the generator stator windings is
supplied to the primary side (H1 and H2) of voltage
reference transformer T21. See Figure 5-6 wiring diagram. AC in the secondary winding (X1 and X2) is supplied as a reference voltage to the regulator circuit
board.
EXCITER
STATOR
--1
I
i
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I
5621
@ VOLTAGE
ADJUST
I
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I
JUMPER TERMINALS 6 & 7 FOR 60 HZ
7 & 8 FOR 50 HZ
I
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!
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L - - - - - - - - - - - - - - - - _ _ _ _V R 2 1 j
ES1493
FIGURE 5-6. ELECTRONIC REGULATOR WIRING DIAGRAM
VOLTAGE REFERENCE
TRANSFORMER T21
COMMUTATING
REACTOR CMR2l
TERMINAL
BOARD TB21
ES1492
FIGURE 5-5. ELECTRONIC REGULATOR BASIC COMPONENTS
5-4
Redistribution or publication of this document
by any means, is strictly prohibited.
GENERATOR SERVICE
10. Use a hoist and safe lifting device (stator handling
tongs, nylon lifting strap or chain and lift hooks) to
The following sections describe the disassembly and
reassembly proceduresfor the generator.
support the stator assembly. A support must be
placed under the engine before removing stator
from the vibration mounts.
Generator components are heavy
@@@%I
and can cause severepersonalinjury
if dropped during service. Be careful, keep hands and
11. Remove stator assembly being careful not to touch
feet clear during service, and use the recommended
service procedures.
or drag it on the rotor. Place stator on its side in the
horizontal position.
Disassembly
12. Using a hoist and sling to supportthe rotor, carefully
remove the capscrews that attach the drive disc to
the engine flywheel (Figure 5-8).
1. Disconnect the negative (-) battery cable from the
battery to prevent accidental starting of the generator set while servicing.
-
13. Remove the rotor assembly and place upon wood
block in the horizontal position. The drive disc and
fan should not be resting on anything or distortion
may occur.
Accidenfal starting of the set
LiiESEl
can cause severe personal
injury or death. Disconnect the baffery cables,
negative (-)lead first, when repairs are made to the
engine, controls or generator.
14. Remove bolts that hold the drive disc and fan to the
rotor shaft. Remove bolts holding drive disc to the
fan.
2. Remove cover from the control box and disconnect
all stator leads. If control has load circuit breakers,
disconnect leads at breaker. If lead markings do not
clearly identify reconnection, mark leads with tape.
15. Use a gear puller to remove the end bearing from
the rotor shaft (Figure 5-7).
The end bearing will be damaged if pulled on the outer race.
If reused, the bearing musf be pulled on fhe inner
race.
3. Remove end bell cover and remove field leads F1
and F2.
4. Remove load wiresand flexible conduit from control
box.
16. Clamp the rotor in a fixed position and remove the
exciter rotor lock nut.
5. Remove leads from the plug of the DC voltage regulator mounted on the bottom of saddle.
17. Remove the generator field leads from the exciter
rotor and slide the exciter off the rotor shaft.
6. Remove capscrews securing the control box
mounting saddle to the stator. The control box and
saddle are removed as an assembly.
7. Pull stator leads through opening in bottom of control box and saddle as they are liftedfree from stator.
Do not disconnect any engine DC control wires in
the control box.
8. Set control box and saddle on top of engine.
.
9. Remove the end bell stud nuts and slide off the end
bell and exciter stator. It may be necessary to pry or
jar the assembly loose from the main stator
assembly.
ES1495
FIGURE 5-7. END BEARING REMOVAL
5-5
Redistribution or publication of this document
by any means, is strictly prohibited.
DRIVE
DISK
EXCITER
ROTOR
RECTIFIER
ASSEMBLIES
6-1158.2
FIGURE 5-8. GENERATOR ASSEMBLY
5-6
Redistribution or publication of this document
by any means, is strictly prohibited.
Reassembly
1. Slide the exciter rotor over the generator shaft and
woodruff key. Installthe exciter nut and apply torque
values shown in Figure 5-9.
12. Connect all applicable control leads (Fl, F2, battery
charging, etc.) and verify that all connections are
secure.
13. Connect leads to the plug of the DC voltage regulator mounted on the bottom of saddle. Figure 5-1 0.
2. Connect generator field leads to F1+ and F2- terminals on exciter assembly. Torque to values shown.
14. Install the end bell cover.
3. Press the end bearing onto the rotor shaft.
15. Connect the stator wires to the load wires.
4. Assemble rotor fan and drive disc to the engine
flywheel. Use a hoist and sling to support rotor. Be
sure the drive disc is assembled with the chamfer on
the flywheel side. Apply torque values shown in
Figure 5-9.
16. Connect the negative (-) battery cable and test
5. Install air baffle.
generator operation.
BLUE
6. Using a hoist and safe lifting device, carefully move
the stator into position over the rotor. The leads
should be in the top position. Apply a thin film of
Molykote grease to mating surfaces of end bearing
and hole in the end bell.
7. Install the end bell stud bolts through the stator and
into the generator adapter.
BLACK
BLUE
8, Install end bell assembly on the stator with the
generator lead opening at top position.
ES1497
9. Torque end bell stud nuts to 20 ft Ibs (27 Nom).
10. Using a lead hammer tap the end bell at the horizon-
FIGURE 5-10. DC REGULATOR PLUG CONNECTIONS
tal and vertical to relieve stress. Torque end bell
stud nuts.
11. Feed stator and control leads through opening in
control box and saddle and secure saddle to the
generator.
TORQUE TO
23-26INCH LES
(SEE DETAIL 8)
(2.6-2.9NDm)
ASSEMBLE DRIVE DISK
WITH CHAMFER THIS SIDE
WOODRUFF
“i
3
SEE DETAIL A
(
FLATWASHER
TORQUETO 130-150FT LBS
(176-203N*m)
DETAIL A
20-22FT LBS
(27-30Nom)
DETAIL B
ES-1496-3
FIGURE 5-9. ROTOR ASSEMBLY AND TORQUE VALUES
5-7
Redistribution or publication of this document
by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
Section 6. Generator/Regulator
Troubleshooting
I-
GENERAL
This section contains service information for single and
three phase generator sets with transformer or electronic voltage regulators. Make the following visual
checks prior to starting the troubleshooting procedures.
0
Check any modification or repair that has been performed since the last satisfactory operation of the
set to see that they are installed properly.
0
Check to see that generator leads are connected
correctly. Also check the circuit board connectors.
A loose, contaminated, or misplaced wire connection will cause problems that can be detected by
close inspection.
Check for an open circuit breaker. If the breaker is
open, check for an overloaded circuit and correct
load problems before resetting circuit breaker.
1
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i
.
I
.
L
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(-011
.
I
f
JUMPER TERMINALS6 & 7 FOR 60 HZ
6,7,&8 FOR 50 HZ
TRANSFORMER
REGULATION
ELECTRONIC
REGULATION
FIGURE 6-1. ELECTRONICAND TRANSFORMER REGULATIONWPlCAL SCHEMATICS)
6-1
Redistribution or publication of this document
by any means, is strictly prohibited.
F. FIELD BREAKER (CB21) TRIPS
(ELECTRONIC VOLTAGE REGULATOR)
G. U N B A L A N C E D O U T P U T V O L T A G E
(TRANSFORMER OR ELECTRONIC VOLTAGE
REGULATOR)
TROUBLESHOOTING PROCEDURES
Determine the type of problem and then refer to the
corresponding flow chart (A, B, C, D, E, F, or G) for
troubleshooting procedures.
To troubleshoot a problem, start at the upper-left corner
of the chart that corresponds to the problem, and
answer all questions either YES or NO. Follow the chart
until the problem is found. Performthe referencedtest or
adjustment procedures in the GeneratorIRegulator
Tests section.
A. NO AC OUTPUT VOLTAGE AT RATED ENGINE
RPM (ELECTRONIC VOLTAGE REGULATOR)
B. NO AC OUTPUT VOLTAGE AT RATED ENGINE
RPM (TRANSFORMER VOLTAGE REGULATOR)
C. UNSTABLE OUTPUT VOLTAGE, ENGINE SPEED
STABLE (ELECTRONIC VOLTAGE REGULATOR)
D. OUTPUT VOLTAGE TOO HIGH OR TOO LOW
(ELECTRONIC VOLTAGE REGUMTOR)
E. OUTPUT VOLTAGE TOO HIGH, TOO LOW, OR
UNSTABLE (TRANSFORMER VOLTAGE
REGULATOR)
Referencedcomponents in the flow charts and test and
adjustment procedures can be found on the electrical
schematics (Figure 6-1) and on the wiring diagrams.
6-2
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART A. NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM
(ELECTRONIC VOLTAGE REGULATOR)
Many troubleshootlng procedures present hazards that can result in severe personal [email protected]
laWAR"Gl
death. Onlyqualitliedsefflcepersonnel withknowledgeof tuels,electricity, and machinery hazards
should perform service procedures. Review safety precautions on inside cover page.
Are load circuit
breakers closed?
Close circuit breakers,
or replace if bad.
Yes
Remove one lead from breaker
and check continuity with
ohmmeter. Is breaker open?
Is control panel field
breaker CB21 on?
Replace defective
field breaker
I
no
If voltage is unstable, high or low. or
causes breaker to trip, see Flow Charts
6.C.D or E.
Push to reset breaker. Does generator
AC output voltage build up?
no
Is residual voltage across terminals 2 and
3 of VR21 5 to 10 VAC or more?
Flash exciter field per TEST [D]. Does
generator output voltage build up?
I
Disconnect stator leads 1 and 2 from AC
terminals of A l l . Is residual voltage across the
Check reactor CMR21 and transformer T21
per TESTS [B] and 14.
for shorts per TEST [MI.
across VR21 terminals
Replace bad wiring.
4 and 5,5VDC or more?
Check lead continuity
between AC terminals
on A1 1 and terminals
2 and 3 on VR21 per TEST
PI.
board per procedure [F]
if defective.
harness per TEST [MI.
Replace bad wiring.
I
I
Check diodes CR1 through CR6
on rotor per TEST [GI.Replace
if bad.
1
Check exciter rotor winding
per TEST [J]. Replace if bad.
Check exciter field winding
per TEST [HI. Replace if bad.
A new printed circuit board can be
/BcAuTIoNJ
damaged by malfunctioning components within the control. Do not Install a new PC board
until all other problems have been located and
corrected.
6-3
I
winding per TEST [L].
Replace if bad.
Check generator stator
windings per TEST [K]. Replace
if bad.
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART B. NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM
(TRANSFORMER VOLTAGE REGULATOR)
Many froubleshooting procedures present hazards fhaf can result in severe personal injury or
1 - should
1 perform service
deafh. Only quallfledservicepersonnel with knowledge ot fuels, electrlclfy, and machinery hazards
procedures. Review safefy precautions on inside cover page.
START
I
t
Are load circuit
breakers closed?
Close circuit breakers,
or replace if bad.
I
1
yes
I f voltage is unstable. high or low. or
causes breaker to trip See Flow Charts
B.C.D. or E
t
Flash exciter field per TEST [D]. Does
generator output voltage build up7
Is residual voltage across stator leads S1
and 52 2.5 to 5 VAC or more'?
yes
no
J
I
.c
1
1
Does suppressor assembly
RV21 test okay per TEST
Yes
4
"0
I
Check lead continuity between
TB2-2 and 8 (1) on generator,
and TB2-H1 and 7 (4) per TEST
Replace CR21.
1
1
Heplace HV21
TEST IN]. Replace i f bad.
1
Dwonnect stator leads S1 and S2. Is
residual voltage across the leads 2.5 to 5
VAC or more now?
Does bridge rectifier CR21 test okay per
test IC].
,
1
Check diodes CR1 through CR6
on rotor per TEST [GI. Replace
if bad
+
Test exciter stator per TEST
[HI Replace i f bad
I
Check exciter rotor winding
per TEST [J]. Replace if bad.
I
6-4
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART C. UNSTABLE VOLTAGE, ENGINE SPEED STABLE
(ELECTRONIC VOLTAGE REGULATOR)
Many troubleshooting procedures prerenf hazards that can result in severe personal injury or
jawnR"c(
death. Only qualifiedservicepersonnel with knowiedge of fuels, electricity, and machinery hazads
should perlorm service procedures. Review safety precautions on inside cover page.
Are there any broken wires or loose connections
on voltage regulator assembly?
Repair as required.
A
I
Check wiring harness from regulator assembly
to end bell per TEST [MI. Check okay?
Repair wiring or replace as required.
yes
I
A new printed circuit board can be
[email protected]%!
@
!
l
damaged by malfunctioning components within the control. Do not Install new PC board
Replace the regulator PC board per
procedure (F).
8
until ai/ other problems have been located and
corrected.
FLOW CHART D. OUTPUT VOLTAGE TOO HIGH OR TOO LOW
(ELECTRONIC VOLTAGE REGULATOR)
Many troubleshoofing procedures present hazards that can result in severe personal injury or
death. On/yqualifiedservicepersonnei wHh knowiedge of fuels, electricity,andmachineryhazards
should perform service procedures. Review safefy precautions on inside cover page.
START
I
Is engine running at correct RPM?
-t
i
I
1
Set RPM per instructions in appropriate
engine manual.
I
Does adjustment of Voltage Adjust control on
the regulator board result in correct
output voltage?
I
1
I
Are reference transformer T21 connections
correct and secure on TI317
1
I
Set control per Voltage
Adjustment [PI
I
I
-t
1
Are generator output leads properly
connected? See TEST [Q].
~
I
I
A new printed circuit board can be
@!%[email protected]
damaged by malfunctioning components within the conhi. Do not install a new PC board
Replace the regulator PC board per
procedure [F].
until all other problems have been located and
corrected.
6-5
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART E. OUTPUT VOLTAGE TOO HIGH, TOO LOW, OR UNSTABLE
(TRANSFORMER VOLTAGE REGULATOR)
Many iroubieshooting procedures present hazards that can resuit in severe personal injury or
b
%
!
l
death. Only qualified senice personnel
knowledge of fuels,eieciricity, and macbimry hazads
should perform service procedures. Review safety precautions on inside cover page.
witt,
START
Set r/min per instructions in
appropriate engine manual.
Is engine running stable and at
correct r/min?
Are there broken wires or loose connections
to any AC regulator components?
Apply load to generator and then remove.
Is voltage across generator leads S1 and S2
60 VAC 2 5 percent?
+
no
*
Repair as required.
Test stator assembly per TEST [K].
Replace if bad.
1I
Test transformer T21 per TEST
[N]. Replace if bad.
,
Test exciter stator per TEST [HI
Replace if bad,
1
Test rotor assembly per TEST [J]. Replace i f
bad.
6-6
Redistribution or publication of this document
by any means, is strictly prohibited.
FLOW CHART F. FIELD BREAKER TRIPS
(ELECTRONIC VOLTAGE REGULATOR)
troubleshootlng procedures present hazards that cen result in severe personel injury or
death. Only qua/i~i~servicepe~onne/
wmknowledge offue/s, electric&, andmachinery hasanis
should pertorm service procedures. Review safety precauHons on inside cover page.
li5EEEI Many
Check for any loose or broken wires or
connections on VR21 assembly.
Does AC output voltage build up to 150%or
more of rated voltage before breaker trips?
no
1
I
Check exciter stator winding per TEST [HI.
Replace if bad.
I
Check reference transformer T21
per TEST [E]. Replace if bad.
A new printed circuit board can be
damaged by malfunctioning components within the control. Do not installa new PC board
until all other problems have been located and
corrected.
Replace the regulator PC board per
procedure [F].
FLOW CHART G. UNBALANCED GENERATOR OUTPUT VOLTAGE
(TRANSFORMER OR ELECTRONIC VOLTAGE REGULATOR)
Many troubleshooting procedures present hazards that can result in severe pmonal injury or
deafh. Only quallfiadservice personnel w/fh knowledge of fuels, electrichy, andmachlnery hazards
should perform service procedures. Review safety precaufions on inside cover page.
Check lor correct grounding of generator
and load.
Remove load at generator terminals. lsoutput
still unbalanced?
Are generator leads connected and grounded
properly' See Test [a].
no
Is generator stator winding continuous per
TEST [ K ]
*
Correct as necessary.
Replace stator assembly.
1
Check load lor ground faults and correct
as necessary.
6-7
Redistribution or publication of this document
by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
Section 7. Generator/Regulator Tests
[CI
GENERAL
The following tests and adjustments can be performed
without disassembly of the generator. These procedures should be used for testing the generator components and the regulator in conjunction with theTroubleshooting Flow Charts in the Generator/RegulatorTroubleshooting section.
TESTING RECTIFIER BRIDGE CR21
AND SUPPRESSOR RV21
The rectifier bridge and suppressor are located within
the control box of transformer regulated sets. The
bridge contains four diodes as shown in Figure 7-2.
They are encapsulated within a hermetically sealed
block, and failure of any diode requires replacement of
the entire bridge.
Many troubleshooting procedures
1 - severe
1 personal injuq
present hazards that can result in
or death. Only qualified service
personnel with knowledge of fuels, electricity, and
machinery hazards should perform service procedures. Review safety precautions on inside cover
page.
Disconnectwires from the bridge prior to testing. Check
forward resistancewith an ohmmeter on the R x 1 scale;
reverse resistance on the R x 1OKscale. Forward resistance should be 6 to 50 ohms, and reverse resistance
infinity.
[AI
If CR21 is defective,the suppressor RV21 should also be
replaced. RV21 should have infinite ohmmeter readings
in both directions.
TESTING AC RESIDUAL VOLTAGE
Test for residual AC voltage if there is no AC power
output from the generator. Check between generator
leads 1 and 2 (electronic regulation controls); between
S1 and S2 (transformer regulation controls). See Figure
6-1. Residual voltage should be as follows:
Electronic Regulation 5 to 10 VAC minimum. Transformer Regulation 2.5 to 5 VAC minimum.
TESTING COMMUTATING REACTOR
The commutating reactor is shown in Figure 7-1. It is
referenced CMR21 on schematics. Only one winding of
the reactor (leads 1 and 2) is used. Remove reactor
leads from terminal board for testing.
Resistance across 1 and 2 should be 330 to 390 milliohms at 77°F (25'C). Resistance between winding and
the reactor frame should be infinity.
RV21
'
ELECTRICAL SCHEMATIC
'
ES1501
FIGURE 7-2. RECTIFIER BRIDGE, SUPPRESSOR ASSEMBLY
ES1500
FIGURE 7-1. COMMUTATING REACTOR
7-1
Redistribution or publication of this document
by any means, is strictly prohibited.
[El
FLASHING THE FIELD
TESTING REFERENCE TRANSFORMER
If output voltage does not build up it may be necessaryto
restore residual magnetism by flashing the field. This
requires a 12-volt storage battery, 10-amp fuse,
momentary-on switch, and diode assembled as shown
in Figure 7-3.
The reference transformer has four leads; two primary
marked H1 and H2 and two secondary leads markedX1
and X2. See Figure 7-4. Resistance readings are made
with leads disconnected. The resistance of either coil
should b e l lOohms+/-10%at77"F (25°C). Resistance
between leads and transformer frame should be infinity.
1-(
lncorrect flashing procedure can
damage the voltage regulator. Do not
keep excitation circuitry connected longer than 5
seconds.
1
Start the generator set and operate at normal speed.
Connect the positivelead to the F1(+) exciter stator lead,
and the negative lead to the F2 (-)exciter lead. Close the
switch just long enough for the generator output voltage
to build up, but not longer than 5 seconds.
Check the output voltage, then shut down the generator
set. Restart the generator set and operate at no load.
Output voltage must build-up without field flashing. If
not, shut down the generator set and perform continuity
check of all related wiring.
F2-
0
MOMENTARY-ON
SWITCH
F1+
w
(PRIMARY)
"'
HZ
0
12-AMP
300 V
DIODE
WINDING SCHEMATIC
ES1502
FIGURE 7.4. REFERENCE TRANSFORMER
10-AMP
FUSE
VOLTAGE REGULATOR VR21
REPLACEMENT
Use the following procedure for replacing the voltage
regulator PC board or VR chassis.
1. Stop the generator set and disconnect the starting
battery leads, negative (-) lead first.
2. Disconnect (and label if necessary) the wires from
voltage regulator. Refer to the AC control wiring
diagram.
3. Remove mounting screwsfrom the old voltage regulator, then install new regulator.
4. Reconnect wires removed in Step 2 to the proper
terminals.
5. Set voltage as outlined in test [PI Voltage
Adjustment.
ES-1658.2
FIGURE 7-3 FIELD FLASHING CIRCUIT
7-2
Redistribution or publication of this document
by any means, is strictly prohibited.
Testing for Grounds
Connect a megger or insulation resistance meter that
applies 500 VDC or more between either field lead and
the exciter stator lamination. Be sure both exciter leads
are disconnected from the terminal block. Reading
should be 1,000,000 ohms or greater. If not, the exciter
stator is questionableand may require removalfor oven
drying and retest. A shorted stator must be replaced.
TESTING ROTATING RECTIFIERS
Two different rectifier assemblies make up the rotating
rectifier bridge assembly (Figure7-5).Usingan ohmmeter, test each CR rectifier using negative (-) and positive
(t)polarities. Use the following procedure.
1. Disconnect all leads from assembly to be tested.
2. Connect one ohmmeter test lead to F1+ stud and
connect the other lead to CRl, CR2 and CR3 in turn;
record resistance value of each rectifier.
3. Connect one lead to F2- stud and connect other
lead to CR4, CR5, and CR6 in turn; record resistance
value of each rectifier.
4. Reverse ohmmeter leads from steps 2 and 3 and
record resistancevalue of each rectifier F1+to CR1,
CR2 and CR3 and F2- to CR4, CR5 and CR6.
5. All the resistance readings should be high in one
test and low in theother test If any reading is high or
low in both tests, rectifier assembly is defective.
6. Replace defectiverectifier assemblywith new identical part.
F1. F2
LEADS
Use 23 to 26 inch Ibs (2.6 to 2.9 Nom) torque when
replacing nuts of F1t and F2-, CR1, CR2, CR3, CR4,
CR5 and CR6.
WHEATSTONE
BRIDGE OR
DIGITAL OHMMETER
CA-1010-10
OHMMETER
TESTING FOR OPEN OR SHORTED WINDING
STATOR
LAMINATIONS
F1. F2
LEADS
J
CR5
CA-1010-9
FIGURE 7-5. TESTING ROTATING RECTIFIERS
[HI
'
MEGGER OR
INSULATION
RESISTANCE
METER
TESTING EXCITER STATOR
Test the exciter stator (Figure 7-6) for open or shorted
windings and grounds as follows:
CA-1010-11
TESTING FOR GROUND TO LAMINATION
Testing for Open or Shorted Windings
FIGURE 7-6. TESTING EXCITER STATOR
Use a Wheatstone Bridge or digital ohmmeter for this
test. Disconnect F1+ and F2- exciter field leads from
terminal block in generator end bell. The resistance
between field leads should be 11.16 to 13.64 ohms at
77°F (25°C).
7-3
Redistribution or publication of this document
by any means, is strictly prohibited.
[JI
Testing for Grounds
Test with an insulation resistance meter or Megger that
applies at least5OOvolts to the test leads. With all generator leads disconnected from rotating rectifiers CR1
through CR6, apply test leads between any CR lead and
the rotor laminations. Reading should be 1,000,000
ohms or higher. If not, the exciter rotor is questionable
and may require removal for oven drying and retest. A
shorted rotor must be replaced.
TESTING EXCITER ROTOR
Test the exciter rotor (Figure 7-7) for open or shorted
windings or grounds as follows:
Testing for Open or Shorted Windings
Use a Wheatstone Bridge or digital ohmmeter for this
test. Disconnect main rotor field leads that connect to
rotating rectifier assemblies at F1+ and F2-. Disconnect
lead wires from diodes CR1, CR2, CR3, CR4, CR5, and
CR6. Test between exciter lead pairs T1-T2, T2-T3 and
T1 -T3. Resistanceat 77OF (25OC) should be 486 to 594
milliohms.
Use 23 to 26 inch pounds (2.6 to 2.9 Nom) torque when
replacing nuts of F1+ and F2- leads, CR1, CR2, CR3,
CR4, CR5, and CR6.
EXCITER ROTOR
ASSEMBLY
R
.
.
MEGGER OR
INSULATION
RESISTANCE
METER
WHEATSTONE
BRIDGE OR
DIGITAL OHMMETER
TESTING WINDING FOR GROUNDS
TESTING WINDING RESISTANCE
CR3
CW
CONNECTION DIAGRAM
ES-1794
FIGURE 7-7. TESTING EXCITER ROTOR
7-4
Redistribution or publication of this document
by any means, is strictly prohibited.
TESTING GENERATOR STATOR
Testing for Open or Shorted Windings
Test for continuity between coil leads shown in Figure
7-8;all pairs should have equal resistance. Use an
accurate instrument for this test such as a Wheatstone
Bridge. Resistance values at 77OF (25OC) are given in
Using proper test equipment, check the stator for
grounds, opens, and shorts in the windings.
Testing for Grounds
Table 7-1.
Some generators have ground connections to the
frame. Check wiring diagram. All stator leads must be
isolated for testing.
If a winding is shorted, open or grounded, replace the
stator assembly. Before replacing the assembly, check
the leads for broken wires or insulation.
Use a megger or insulation resistance meter which applies 500 VDC or more to the test leads (Figure 7-9).Test
each stator winding for short to laminations. A reading
less than 1,000,000ohms indicates a questionable stator. Oven dry the stator and retest.
-
TESTING WINDING RESISTANCE
Ill
11
TESTING WINDING FOR GROUNDS
--
MEGGER OR
INSULATION
RESISTANCE
METER
111
-
/Ay
/
THREE PHASE MODELS
TEST BETWEEN WIRE PAIRS
Tl-T4
T7-Tl0
T3-T6
T9-Tl2
T2-TS
&@
-
i
TB-T11
J
WHEATSToNE
BRIDGE
SINGLE PHASE MODELS
TEST BETWEEN WIRE PAIRS
Tl-T2
T3-T4
ES-1795
FIGURE 7-8.
TESTING STATOR WINDINGS
TABLE 7-1. STATOR RESISTANCE VALUES IN MILLIOHMS*
I
kWRATlNGANDMODEL
50 Hertz
60 Hertz
3.5 DKC/MDKC 4.OMDKCiMDKC
I
60HZ
I
50Hz
1
60HZ
I
50HZ
1010
10
290
10
380
30
30
920
6.0DKD
7.5 DKD
460
498
190
260
6.5MDKD
8.0 MDKD
460
498
190
260
I
*Resistance in ohms @ 77OF (25OC) f10%
7-5
Redistribution or publication of this document
by any means, is strictly prohibited.
[LI
TESTING GENERATOR ROTOR
For these tests, use a megger or insulation resistance
meter which applies 500VDC or more to the test leads.
MEGGER OR
INSULATION
RESISTANCE
METER
Testing for Grounds
Check for grounds between each rotor lead and the
rotor shaft, Figure 7-9. Use a Megger or insulation
resistance meter which applies 500 VDC or more at the
test leads. Perform test as follows:
Remove rotor leads F1+ and F2- from the rotating
rectifier assemblies.
Connect test leads between F1t and rotor shaft,
then between F2- and rotor shaft. Meter should
register 1,000,000 ohms or greater.
If less than 1,000,000 ohms, rotor is questionable.
Oven dry the rotor and retest.
Replace a grounded rotor with a new identical part.
CA-1010-12
TESTING WINDING FOR GROUNDS
FIGURE 7-9. TESTING ROTOR FOR GROUNDS
Testing for Open or Shorted Windings
DIGITAL
OHMMETER
Performthis test with an accurate meter such as a digital
ohmmeter.
1
Ohms Resistance*
DKC/ MDKC
DKD/MDKD
2.50
2.82
--_
MAIN ROTOR
LEADS F1+, F2-
1. Remove rotor leads F1+ and F2- from rotating rectifier assemblies.
2. Using ohmmeter, check resistancebetween F1 and
F2 leads, Figure 7-10.
Model
fl
-
CA-1010-8
TESTING WINDING RESISTANCE
FIGURE 7-10. TESTING ROTOR FOR AN OPEN CIRCUIT
*Resistancein ohms @ 7 7 O F (25OC) f10%
7-6
Redistribution or publication of this document
by any means, is strictly prohibited.
[MI
a
H1 THROUGH H4
WIRING HARNESS CHECK
Carefully check wiring harness as follows:
TRANSFORMER
WINDING
SCHEMATIC
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 with
an ohmmeter, check each wire end to end for continuity or opens.
3. Using an ohmmeter, check each wire to other wires
and to ground for possible shorts or insulation
breaks under areas covered by wrapping material.
4. Reconnect or replace wires/ harness according to
applicable wiring diagram.
x2
H2
x3
H4
PRIMARY SECONDARY
ES-1510
FIGURE 7-11. TYPICAL REGULATING TRANSFORMER
TEST1NG REGULATING
TRANSFORMER T21
Regulating transformer 121 is used only on single
phase generators. It consists of a multi-coil primary and
a multi-tapped secondary. Figure 7-1 1 shows a typical
transformer. Some transformers may have up to three
coils in the primary and six taps on the secondary.
DC resistance of windings at 77OF (25OC) are shown in
Table 7-3. Resistance between primary and secondary
and the transformer frame should be over 100,000 ohms
when measured with a megger or insulation meter.
TABLE 7-3. TRANSFORMER RESISTANCE VALUES IN OHMS
Primary H1-H2
H3-H4
H5-H6
Secondary X1 -X6
x1 -x5
x1 -x4
x1 -x3
x1 -x2
315-0571
315-0572
315-0582
315-0583
.007 f.0005
.007f.OM5
.003 f .0005
.003 f.0005
N.A.
N.A.
N.A.
1.15 -f .01
1.11 .01
.019 .01
.007f.0005
-007 f.0005
.003 f.0005
.004 f.0005
.004 f.OM5
.002f.0005
1.37 f.1
1.35 -f .1
1.24 k .1
.04 f -01
.02 f .01
N.A.
N.A.
N.A.
1.29 f -01
1.24 f .01
.019 f .01
*
*
1.44 .1
1.33 f .1
1.21 f.1
.04 f.01
.02 .01
*
N.A. (Not applicable)
7-7
Redistribution or publication of this document
by any means, is strictly prohibited.
[PI
With the generator set running, set the Voltage Adjust
potentiometer on the regulator board assembly for correct voltage. See Figure 7-12.
VOLTAGE ADJUSTMENT
This section supplies informationfor adjusting the transformer and electronic regulators.When checking output
voltage, be sure the generator set has stabilized and is
running at the correct speed (frequency). Adjusting the
transformer regulator is done with the set stopped. The
electronic regulator is adjusted with the set running.
Do not adjust the other potentiometer
lsible
2iC
E
E
I
po/ts/Hz Adjust) as can be imposto reset for
operation. It is factory set using
-
it
proper
special calibration equipment.
Accidental starting of the set can
l3iEGEI
cause severe personal injury or
death. Disconnectbofh battery cables, negative (-1 cable
first, when repairs are made to the engine, controls, or
generator.
Transformer Voltage Regulator
The transformer regulator circuit supplies a feedback
voltage (dependent on load)to the exciter stator. Voltage
adjustment is made by changing tap connections on the
transformer. When replacement is necessary, install
leads to the same terminals on the new transformer. To
change voltage, refer to the model wiring diagram or the
generator reconnection diagrams in Test [Q].
ElectronicVoltage Regulator
ES-1388
FIGURE 7-12. ELECTRONIC REGULATOR BOARD
Contact with high voltage can cause
severe personal injury or death. Do
not touch any exposed wiring or components with any
pari of the body, clothing, tool or jewelry. Do nor use
non-insulated tools inside the control. Stand on an
insulating mat or dry wood platform when the control
doors are open.
[Ql
RECONNECTION
Generator reconnection is dependent upon the nameplate code. Figure 7-13 shows reconnectionpossibilities.
Information is also found on the individual model wiring
diagrams in Section 8 of this manual.
7-8
Redistribution or publication of this document
by any means, is strictly prohibited.
Transformer Regulation
60 Hz
120-240 VAC
LI
L'
-*-;---
*L2
H4
RECONNECTION
H4
H3
H3
T3Tl TZT4
LYE
RECONNECTION
DIAGRAM
SHOWN FOR
120 240 V 60 H Z
11Sf230 V 50 H2
----
J
t
LI
CWl
To Adjust OUtpLit Voltage. Move Taps on
T21 According to Following Charts
L2
DKD
,MOUE
5rC
uw:
1:&
,I 4
12
IO
I
I
I
14
I
NOTES
IIN ALL VOLTAGE CONNECTIONSl5OAflD60H~~
LEAVE TIPNOT4
CONNECTEDTOHI ANDH4 RESPECTIVELY
2FDRM)Hz USES2LEADlFROMCENIDN TAPSXI-2
I 4 l A P S I USE 1XLEADONTAPSX3-4
3 FDR50Hz USES2LEADlFROMGENIONTAPS XI.3
16TAPS1 USETXLEADONTAPS 14.6
D FOR IIOI2X)VANDllOVCONNECT H2 TO H6.
FOo9 l l O V COHNECTH5 T O T I l L I l A H D H 3 T D T Z l L 2 1
FOR 11012ZOV USE H I FORLIINOH3FORLZITZ ANOT3AREGHO
. . ..
.
, -:
-
. .. . .. . . .
. ... ... ... ... ... .
_ ..
I
.-.. ..
Electronic Regulation
.-. .
..
- -.
a .
....
. e.
..
.
. -..
.. --- . . - . . M W
..
I..
..
..
_.
.
...........
-.
..
.-:
e.
.. .._
.. .. . . 5--:
. ?;,.
.-
......
.
.....
:.
..
..-:
......-
..
e.
-Codes IC
mw
.. . ._-.
. .*
. 5Qnz
60 HI Code 53C SO HI
~
am
..
5QHL
. . .
a
.1 .
A
.
.
..
::
-
-
.- *
.,.
mw
....
a,.
**
mw
....
....
...
.....
FIGURE 7-13. GENERATOR RECONNECTIONDIAGRAMS
7-9
Redistribution or publication of this document
by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
.
Section 8 Wiring Diagrams
Notes
The electrical schematics and wiring diagrams that apply to the generator sets covered inthis manual are listed below:
.
WIRING DIAGRAM
..................................
..........................
..................................
..............
...............
......
....................
.................
...........
........
Single Phase AC Control
Single and Three Phase AC Control
MDKC/MDKD DC Control
DKC/DKD 3-Wire Start Control ("R" Remote Start)
RV and "AUX" Generator Set Control 3-wire Start
DKC/DKD Control ("E"Electric Start Standby Generator sets)
Electronic AC Voltage Regulator Assembly
65/73 DKD DC Control (Spec F RV Gensets)
Single-phase AC Genset Control (Spec F RV Gensets)
6 W . 5 DKD Control Schematic (Extended Oil Fill Version)
DRAWING NO
PAGE
612-6184
612-6185
612-6187
612-6262
612-6353
612-6186
305-0691
612-6624
612-6442
612-6631
8-2
8-3
8-4
8-5
8-6
8-7
8-8
8-9
8-10
8-11
8-1
Redistribution or publication of this document
by any means, is strictly prohibited.
AC SCHEMATIC
SINGLE PHASE TRANSFORMER REG
EXCITER
\G21
I
All
II
,-l-l-,
IAC AC I
I !
I
I
I
I
I
I
I
I
I
I
I
I
L---..J
1-
LO
I
CB
SOHI (-021
IM,110/220V
0
W
n
W
B
L
DKC
OKC
-I.
I I I 5 , I I m v 1120.120/240v
11
L2 LI
NOTED
TO ADJUST
OvlpvT
VOLTAGE. WVETLR MI TZI ACCOROlffi TO TABLES.
1 IN K L WLTAGE COHHECllOHS~5OOAHOWH).LEAVE TI ANDT4
CWNECTED TO HI AN0 H4 REWXTlVEJY.
Z F O R 6OtW USE SZ L E L D t W GENI Cn Tu19 X I 4
(.)TIPS)
USE ?X L U D O H T B X 3 - 4
(6 TAR?) USE Tx LEAD On T Y S X4-6
a FOR IlOlZZOV uy) llOV CCnNECT HZ TO tt6.
M llOV CONNECT H J TOTS(LI1 A W H 3 TOTZ(L-2).
FOR 110122OV USE H 5 FOR L I ANOH3 FOR LZ(TZAH)T3AILGRD)
LRR 115/230V*ND I I J V INSULATE H I AND H 6 (HOT USED)
c . M 120/240V &IO 12OV CDlHECT HZ TO HS.
RR 12OV CWHHECT H6 TO T3 t LI' H I T O R (LZJ
FOR126/24OV USE Hb FORLI AH) H3FCRLZ~Z'MDT3APFGRD)
4. UNLESS OTHER NOTED ALL COIPOHENTS
ARE sim m M
DE-EI(ERGISD
posnii.
l l CWNECTIOMIKnUm
ON-xR,.-S3CRMoDLLS
m a USED.
@ J.& ADASHED
INSUIATE L u D l On -%E. -5XE
llwEs
YODELS.
I
I
MILY.
FROM PANEL
VIEW)
(REAR
x4.
CONTROL BOX(DC SECTION)
I
SINGLE PHASEAC CONTROL
8-2
Redistribution or publication of this document
by any means, is strictly prohibited.
F-":
'
8
.m
6
612-6185
m
tfT
5
I
4
I
3
I
AC WIRING DIAERCIM
- ELECTRONlC R'S2ULATION
2
I
101
-
1
._.
-
AC SCHEMATiC ELECTRGXIC REG
VOLTAGE CODES (IBBS!3,3C&5X)
18, 518, 36,532
EXCITER
NOTES '
I.
CUT LEADS 3 8 4 mtm ~ 2 1 .n
W A R E NCrrwm.
i~9
2. UNLESS O M R W I S E NOTED.ALL COMPONENTS
ARE SHOWN m DE-ENERGIZED FWMIN.
FI
3. DASHED LINES HDICAlE CONNECTrONS
WHEN USED.
@4
2s
2s
2s
A l l CONNECTIONSON-3CR;J?ICR,-I8R;SI8R
HDELS
ONLY. FOR-3CE,-53CE;18E,-5l8E
MODELS CONNECT
LEADS 182 DIRECTLY TO VR21.
10GENERATOR r 3 c ANDBC) LEADS SIAN~SZ
WILL NOT BE USED. INSULATE ANDLEAVE IN
CONTROL BOX.
A 6. JUMPER TERMINALS 6a.7 FOR 60 Hr.(-OI).ADD JUMPER
-EN
TERMINALS 788 FOR 5 0 Hz.(-02)
5.
mR
I I
18 8 518
COMROL BOX (AC SECTION)
VR21
y--
I
W
r
RECONNECTION MAGRAM
..
SEE
E RECONNECTION
DIAGRAM
k
*I--I
FRONT PANEL
(REAR VIEW 1
Jr1
--
I
13
I
L2
I1 I
I
--
SINGLE AND THREE PHASEAC CONTROL
8-3
Redistribution or publication of this document
by any means, is strictly prohibited.
SCHE MAT IC
i
i
---
All K
I
:
-r
I
.
J
L
REMOTE
I
I
!-
-I
IA
-!
CB12
PANEL INSERT
-i
CC'NTROL
I
I
I
I
-'I
+-HRI
I
1-
E---
R E M VIEW
OF JS- FEMALECONNECTOR
I
VIEW OF WIRING FOR
VRI I PLUG
I
j
BTI
MDKCIMDKD DC CONTROL
8-4
Redistribution or publication of this document
by any means, is strictly prohibited.
SCHEMATIC
CB'?
I
I
I
I
r-----.
I
I
I
-.-1
Y! I
+
la
MI4
'-----I
r-
/
I
AI I
I REAR VIEW OF REMOTE PAREL
I----CBll(
t
HRI
aLuc
KLLW
~
I
I
VIEW OF WIRING FOR
V H l l PLUG
-
ND
L
W"
REAR VIEW OF FRONT PANEL
I" C u p l - . l . . r
I
DKC/DKD &WIRE START CONTROL (,,R' REMOTESTART)
8-5
Redistribution or publication of this document
by any means, is strictly prohibited.
612-6353
I
1.
WIRING DIAGRAM
-.-
L
u
W
,
-I
f
W
-J
REAR VIEW
I
I
---
$E*--
r-----1
PANEL INSERT
-___f
I
I
-,?
;I-&
,"
BLACK
&I
(ELLOW
GREEN
I
I
LUC
RED
VIEW OF WIRING FOR
VRll PLUG
I
BT t
'1III-
RV AND "AUX' GENERATOR SET CONTROL, 3-WIRE START
8-6
Redistribution or publication of this document
by any means, is strictly prohibited.
CB12
Llwl
SII
RI
VIEWOF WIRING FOR
VRll PLUG
I
I
t
REAR VIEW W-WT
PANEL
_____
.
DKClDKD CONTROL(“E” ELECTRIC START STANDBY GENERATOR SEIS)
8-7
Redistribution or publication of this document
by any means, is strictly prohibited.
I
WIRING TABULATION
0
0 VOLTAGE
FROM
STATION NO
ADJUST
VOLTWHr
ADJUST
@
I
T21-XI
TO
STATION NO
I TBI-9
FAD
NOTES:
FIND NO
I -
TZI-XZ
781-10
TLI-HI
TBI-2
-
TZI-HZ
TBI-3
-
CMR21-I
TB21-I
CMR21-2
TB21-3
-
TB 1-2
TB21- I
12
-
I
A CUT CMR21-3 a -4 OFF AT REACTOR.
2. EXTERNAL CONNECTIONS
CIRCUIT BREAKER
TB21-3, TBI-l
GENERATOR
TBI-2, TBI-3
FIELD
FI-TBI-4
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ELECTRONIC AC VOLTAGE REGULATORASSEMWY
8-8
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8-9
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AC WIRING DIAGRAM
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SINGLE-PHASEAC GENSET CONTROL (SPEC F RV GENSETS)
8-10
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SCHEMATIC
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MODIFIED
6.5!73 k W DKD CONTROL SCHEMATIC (EXTENDED OIL FILL VERSION)
8-1I
Redistribution or publication of this document
by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-574-8087
Cummins andOnanare registeredtrademark of Cummins Inc.
Redistribution or publication of this document
by any means, is strictly prohibited.
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