Kohler Fast-Response generator Service manual

7 STRESPONSE
SERVICE MANUAL
~~ KOHLER
~ GENERATORS
Table of Contents
Page
Safety Precautions .............e.eeeconevrccccorecenes
Introduction ..............2.2.0000 00000000 a 00 0000000 ii
Service Assistance ...............0.0000000 0000000000 iii
Section 1.
Fast-Response Concepts ........................ 1-1
General...........e_eeeeccoreoros FT neue eee 1-1
System ......eeeonccscorrccresrrcacencecorecaro 1-1
Capabilities ............recesrececorcereroreres 1-1
Section 2.
Operation ............—.—_e_ee-rereovccecororceceees 2-1
Controls .........._.eeeeeccrsororecreroceroacen. 2-1
Indicators........eceQ_ecorecorercsrvereroecreore. 2-1
Prestart Checks ......e..ceoorerrecscroccooaceres 2-3
Starting ..........oee.. PP 2-3
Stopping.............. ecocerosverresconerarer: 2-3
Emergency Stopping ..........- RS 2-4
Resetting ............000000000 000000000000 000 2-4
Section 3.
Controller and Engine Troubleshooting ........... 3-1
Fast Check.........eeoreeorocercoercecocrares 3-1
Fast Check Features .........rrweeocrecorecerres 3-1
Fast Check Operations ...........eereoeeecsenoo 3-1
Engine and ElectricS.............00.000000 00000 3-9
Page
Section 4.
Generator Troubleshooting ...................... 4-1
Power Scanner..........08.+0000 0000000 0000000 4-1
Generator FunctioNS.........000000000000 0000004 4-3
Section 5.
Generator Disassembly-Reassembly .............. 5-1
Disassembly .......r_ereceeeeeroncocororereecores 5-1
Reassembly ........e_.—r_eeeesresvecoecocererees 5-4
Section 6. |
Wiring Diagrams ............e-eeeeseserrrareeeo> 6-1
— Appendix A.
Main Generator Field Resistance ................ A-1
Appendix B.
Uniboard for Controller Lower Tray .............. B-1
Appendix C.
Uniboard to Decision Maker Il (Dec-II)
Tray Conversion. ..........0.0.00.0.00000000 0000 HEHE C-1
Safety Precautions
A Generator Set, like any other electro-mechanical device
can pose potential dangers to life and limb if improperly
maintained orimprudently operated. The best safeguards
against accident are to be ever mindful of the potential
dangers and to always use good common sense. In the
interest of safety, some general precautions relating to
operating of a Generator Set are presented below. Keep
these in mind.
À WARNING
LETHAL EXHAUST GAS! The engine power-
ing your generator discharges deadly carbon
monoxide as part of the exhaust gas when
operating. Carbon monoxide is particularly
dangerous in that it is odorless and colorless.
Keep in mind that it can cause death if inhaled
for even a short period of time. Never operate
the generator set inside a building unless the
exhaust gas is piped safely outside. Never
operate in any area where exhaust gas could
accumulate and seep back inside an occupied
building. Avoid breathing exhaust fumes when
working on or near the generator set.
À WARNING
EXPLOSIVE BATTERY GASES! The gases
generated by a battery being charged are
highly expiosive. Do not smoke or permit
flame or spark to occur near a battery at any
time, particularly when it is being charged.
Avoid contacting terminals with tools, etc, to
prevent burns and to prevent sparks that could
cause an explosion. Remove wristwatch, rings,
and any other jewelry before handling battery.
Any compartment containing batteries should
be well ventilated to prevent accumulation of
explosive gases. To avoid sparks, do not dis-
turb battery charger connections while battery
is being charged and always turn charger off
before disconnecting.
AN WARNING
UNIT STARTS WITHOUT NOTICE! Units with
Automatic Transfer Switches start automati-
cally. Potential injury or electrocution can
result. Turn Generator Master Switch on con-
troller to OFF position, and remove battery
cables (remove negative lead first and recon-
nect it last) to disable generator set before
working on any equipment connected to gen-
erator.
AN WARNING
EXCESSIVE NOISE! Never operate without
adequate muffler or with faulty exhaust sys-
tem—exposure to excessive noise is not only
tiring but can lead to impairment of hearing.
À WARNING
HIGH VOLTAGE! Remember that the function
of a generator set is to produce electricity and
whenever electrical energy is present, there is
the potential danger of electrocution. Keep
everyone, especially children, away from the
set while it is running and take precautions to
prevent unqualified personnel from tampering
with or attempting to operate your generator
set. Have the setand electrical circuits serviced
only by qualified specialists. Wiring should be
inspected frequentiy—replace leads that are
frayed or in poor condition. Be sure that
generator is properly grounded. Do not oper-
ate electrical equipment when standing in
water, on wet ground, or when your hands are
wet.
À WARNING
DANGEROUS ACID! Avoid contact with bat-
tery electrolyte. It contains acid which can eat
holes in clothing, burn skin, and cause per-
manent damage to eyes. Always wear splash-
proof safety goggles when working around the
battery. If battery electrolyte is splashed in the
eyes or on skin, immediately flush the affected
area for 15 minutes with large quantities of
clean water. in the case of eye contact, seek
inmediate medical aid. Never add acid to a
battery once the battery has been placed in
service. Doing so may result in dangerous
spattering of electrolyte.
À WARNING
DANGEROUS FUELS! Use extreme caution
when handling, storing, and using fuels—all
fuels are highly explosive in a vapor state.
Store fuel in a well-ventilated area away from
spark producing equipment and out of the
reach of children. Never add fuel to the tank
while the engine is running to prevent spilled
fuel from igniting on contact with hot parts or
from ignition spark. Keep fuel lines and con-
nections tight and in good condition—don't
replace flexible fuel lines with rigid lines.
Flexible sections are used to avoid breakage
due to vibration. Should any fuel leakage, fuel
accumulation, or electrical sparks be noted,
DO NOT OPERATE GENERATOR SET. Have
systems repaired by qualified specialists be-
fore resuming generator operation. Additional
precautions should be taken when using the
following fuels:
Gasoline - Store gasoline only in approved red
containers clearly marked GASOLINE. Don't
store gasoline in any occupied building.
Propane (LP) - Adequate ventilation is man-
datory. Propane is heavier than air; install gas
detectors low in room. Inspect detectors often.
Natural Gas - Adequate ventilation is man-
datory. Natural gas rises; install gas detectors
high in room. Inspect detectors often.
A WARNING
ELECTRICAL SHOCK! Battery can cause elec-
trical burns and shocks. Exercise reasonable
care when working near the battery to avoid
electrical connections through tools. Remove
wristwatch, rings, and any other jewelry.
— AN WARNING
HOT COOLANT! Engine coolant is pressur-
ized and hot enough to cause severe burns. If
generator set is equipped with a coolant re-
covery tank, check coolant level at tank. If
necessary to check coolant level at radiator or
surge tank (on city-water or remote radiator-
cooled sets), place a rag over the cap and turn
slowly to release pressure, before removing
cap.
À WARNING
MOVING PARTS! Keep hands, hair, necktie,
loose clothing, and test leads well away from
moving parts, as serious injury could result
from entanglement. Never run generator set
with guards, covers, or screens removed.
À WARNING
FLASH FIRE! To avoid the possibility of a flash
fire, do not smoke or permit flame or spark to
occur near carburetor, fuel line, fuel filter, fuel
pump, or other potential sources of spilled fuel
or fuel vapors.
À WARNING
BACKFIRE! A sudden backfire can cause ser-
ious burns. Keep hands and face away from
the carburetor when the air cleaner is removed.
À WARNING
EXPLOSIVE GASES! Remove AC power plug
from outlet or turn off AC supply before
connecting or disconnecting charger clips to
battery terminais to avoid sparks igniting ex-
plosive battery gases.
À WARNING
FIRE OR EXPLOSION! Do not clean air cleaner
bowl with gasoline or equivalent inflammable
liquids because of danger of fire or explosion.
A WARNING
DANGER OF ELECTROCUTION! The follow-
ing procedure requires that the generator set
be running while adjustments are made. Avoid
contacting electrical connections with adjust-
ment tool. Remove wristwatch, rings, and
jewelry that can cause short circuits. Do not
touch electrical equipment when standing in
water, on wet ground, or when your hands are
wet.
AN WARNING
HIGH VOLTAGE! Disconnect set from load by
opening line circuit breaker, or by disconnect-
ing generator output leads from transfer switch
and heavily taping ends of leads. The GEN-
ERATOR SAFEGUARD BREAKER MUST NOT
BE USED IN PLACE OF LINE CIRCUIT BREAK-
ER! If high voltage is transferred to load during
test, personal injury and equipment damage
may result.
A WARNING
UNINTENTIONAL STARTING! To prevent
remote starting, unplug P3 connector at rear
of controller. Place Generator Master Switch
on controller to OFF position, and remove
battery cables (negative lead first and recon-
nect it last) to disable generator set before
working on any equipment connected to gen-
erator.
AN WARNING
HIGH VOLTAGE! Before starting generator set
with generator end cover removed, place black
electrical tape over LED of circuit board mount-
ed on end of generator end bracket. Ceiling
voltage will result if photo transistor is ex-
posed to outside light.
A WARNING
HIGH VOLTAGE! When testing photo transis-
tor board, keep all other light sources away.
Otherwise, dangerous ceiling voltage may re-
sult.
A WARNING
HIGH VOLTAGE! Be sure that foil side of
photo transistor board, end of shaft, and
threaded holes are clean and free of metal
particles and chips. Dangerous HIGH VOL-
TAGE may result. AC voltmeter must show
proper output before generator may be recon-
nected to load.
A WARNING
HIGH VOLTAGE! Use high voltage test only as
directed. High voltage may cause personal
injury, damage equipment, or lead to future
failures. Follow manufacturer's instructions
when operating tester.
AN WARNING
HOT PARTS! Exciter armature will get hot if
armature is shorted. Avoid touching armature!
AN WARNING
FIRE HAZARD! Spilled fuel may ignite on
contact with hot engine parts. Wipe up all
spilled fuel after bleeding system.
AQ WARNING
HOT PIPING! An engine gets hot while run-
ning and exhaust system components get
extremely hot. Do not work on generator set
until unit is allowed to cool.
À WARNING
DANGER OF ELECTROCUTION! When the
generator is used for standby power, use ofan
automatic transfer switch is required to pre-
vent inadvertent interconnection of standby
and other sources of power. In some states
and/or localities it is illegal to operate a
standby generator without an automatic trans-
fer switch. Failure to install an automatic
transfer switch will cause “backfeed” into
utility transmission lines and can cause seri-
ous injury or death.
introduction
This manual covers concept, operation, troubleshooting,
and repair of Kohler Fast-Response generators and con-
trols. Engine service and parts information is available
separately for particular models and specs.
Service Assistance
Contact your Kohler Generator Distributor to obtain
additional service information for particular models. See
Yellow Page listing under Generators-Electric. Supply
Model, Specification, Serial, and Engine Serial numbers
from generator nameplate for complete engine service
manual and generator set parts list.
Section 1
FAST-RESPONSE CONCEPTS
General
A Kohler Fast-Response set is easily understood as a ro-
tating-field generator, and a smaller rotating armature
generator turned by a common shaft. The main, rotating
field generator supplies AC power to load circuits, while
the rotating armature (exciter) generator supplies DC to
excite the main generator’s field. See Figure 1-1.
System
Fast-Response begins with the smaller, exciter generator.
Permanent magnet fields allow exciter current to be pro-
duced without dependence upon the main generator's AG
output. Exciter current is rectified and controlled by the
FR Activator and passed to the main generator field. See
Figure 1-2. AC is then available to load circuits.
Changes in AC load demand are sensed by the voltage
regulator. Signals from the regulator pass through a light
emitting diode (LED)/photo transistor optical coupling
(at end of generator shaft) to the FR Activator. Excitation
current is controlled by the voltage regulator and FR
Activator to maintain proper field strength and main gen-
erator output voltage. See Figure 1-2.
Capabilities
Response Time
Fast-Response systems deliver proper exciter current to
the main field within 0.05 seconds of a change in load de-
mand.
Short Circuit Performance
When a short occurs in the load circuit(s) being served,
output voltage drops to a low level until short is removed,
and amperage momentarily rises to 600-1000% of the gen-
erator’s rated current. The FR activator sends full exciter
power to the main field. The generator then sustains up to
Exciter
; Field
: Magnets
Exciter EX
Armature A,
Generator
Field
Figure 1-1. Generator Cutaway
FAST-RESPONSE CONCEPTS
1-1
Capabilities (Continued)
300% of its rated amperage. Sustained high current will
cause properly rated load circuit fuses/breakers to open,
or generator safeguard breaker to trip. The Safeguard
breaker serves to collapse the generator's main field in the
event of a sustained heavy overload or short circuit.
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FAST RESPONSE CONCEPTS
1-2.
Figure 1-2. Fast Response Schematic
Section 2
OPERATION
Controls — Figures 2-1, 2-2 e Emergency Stop — will shut down generator set im-
mediately.
e Selector Switch (Voltmeter-Ammeter) — selects e Generator Switch — AUTO position, allows start-up by
generator output circuits to be measured. If switched to automatic transfer or remote start-stop switch. TEST
a point with three circuit lead pes, vonage IS mea- position, used for exercise runs or for normal start-up
sured between the upper two leads and amperage on without automatic transfer switch. CENTER OFF posi-
the lower lead. If switched to a point with two circuit la- tion, used to prevent automatic start-up while servicing
bels, voltage only IS measured. With switch in OFF po- set, making non-emergency manual stops, or resetting
sition, AC voltmeter and ammeter will not register. system
NOTE
| ds | | NOTE
Indicated switch positions will vary among Sin- _ |
gle and three phase models with different voit- Switch in CENTER OFF position will prevent
ages. start-up by automatic transfer or remote start-
stop switch. |
e Regulator Rheostat — used to fine-adjust generator
output voltage. | .
o Indicators
e Lamp Test — used to test indicator lamps.
e Reset — must be pressed to allow engine restart after e Frequency Meter — measures frequency (HERTZ) of
fault shut-down or emergency stop. generator output voltage.
Frequency AC Voltmeter Selector AC Ammeter
Meter Switch
Generator
Switch
Figure 2-1. Decision Maker
OPERATION
2-1
IFT
Figure 2-2. Decision Monitor (remote annuciator) Option
Indicators (Continued)
AC Voltmeter — measures voltage across output leads
indicated by selector switch.
Scale Lamps (upper lower) — indicate voltmeter and/or
ammeter scales to be read.
AC Ammeter — measures amperage from output leads
indicated by selector switch.
Oil Pressure — measures engine oil pressure.
Water Temperature — measures engine coolant tem-
perature.
DC Ammeter — measures charge/discharge rates of
engine alternator and starting battery(ies).
Hourmeter — records total generator set operating
hours for reference in maintenance scheduling.
Switch Off — lamp flashes when generator switch isin
CENTER OFF position. Lamp will not light when LAMP
TEST button is pushed and generator switch isin AUTO
or TEST position.
Overcrank — lamp lights if engine fails to start within
preset cranking period.
Emerg. Stop — lamp lights if EMERG. STOP button has
been pushed.
High Water Temp. — lamp lights if set has shut down
due to high engine coolant temperature.
OPERATION
2-2
Overspeed — lamp lights if set shuts down due to over-
speed.
Low Oil Press. — lamp lights if set shuts down due to
loss of engine oil pressure.
Antic. Low Oil Press.* — lamp lights if engine oil pres-
sure approaches shut-down level.
Antic. High Water Temp.* — lamp lights if engine cool-
ant temperature approaches shut-down level.
Low Water Temp.* — lamp lights if optional engine
block heater is not working and/or water temperature
may be too iow (below 70°F, 21°C) for 10-second start-
up.
Bat. High Volts* — lamp lights if battery or charging
voltage exceeds normal (will also light if over voltage
occurs due to battery charger malfunction while set is
not operating).
Bat. Low Volts* — lamp lights if battery or charging volt-
age drops below normal (will also light if under voitage
occurs due to battery or charger malfunction while set
is not operating).
Low Fuel* — lamp lights if fuel tank level approaches
empty.
System Ready* — lamp lights when GENERATOR
SWITCH is in AUTO or TEST positions and system
senses no faults.
* Optional
Decision Monitor (remote
annunciator) Option Indicators
Decision Monitors have the same lamp indicators as the
Decision Maker Controller, plus the following (See Figure
2-2).
e Line Power — indicates commercial utility power in use.
e Generator Power — indicates generator power in use.
e Alarm Switch Off — indicates ALARM switch in OFF
position.
e Alarm Switch — controls alarm horn on Decision Moni-
tor.
e Alarm Horn — sounds if any fault or anticipatory con-
dition occurs.
An alarm horn and alarm horn switch may be installed on
the generator set.
Prestart Checks
The following items should be checked before each start-
up of manually controlled generator sets or at regular in-
tervals on sets equipped with Automatic Transfer Panels
which automatically start and stop the generator set.
dA WARNING
UNIT STARTS WITHOUT NOTICE! Units with
Automatic Transfer Switches start automati-
cally. Potential injury or electrocution can
result. Turn Generator Master Switch on con-
troller to OFF position, and remove battery
cables (remove negative lead first and recon-
nect it last) to disable generator set before
working on any equipment connected to gen-
erator.
OILLEVEL: Check and add oil as necessary to
bring the level up to the full mark on
the dipstick.
COOLANTLEVEL: (radiator, and heat exchanger cool-
ed sets): Allow engine to cool. Re-
move the filler cap and add coolant
as needed to bring the level up to the
full point. CAUTION: Remove filler
cap slowly.
DRIVEBELTS: Make visual check of radiator fan,
water pump, and battery charging
alternator belts to make sure they
are tight and in good condition. See
engine operation manual for ad-
justments.
AIR CLEANER: Inspect components to make sure
they are tight and in proper posi-
tion.
FUEL LEVEL: Make sure there is an adequate
supply — keep tanks full to allow op-
eration for extended periods.
Check connections and level of
electrolyte inside battery — add dis-
tilled water as needed.
BATTERY:
NOTE
Battery negative (-) connection must be made to
a good ground.
EXHAUST SYSTEM: Check to make sure components
are tight and in good condition.
OPERATING AREA: Check to make sure no obstruc-
tions block the flow of cooling air.
Also make sure that the area is
clean, and that rags, tools, etc., are
not left on or near the generator set.
Clean the intake and outlet screens.
LAMP TEST: Press the lamp test button and
check to make sure all lamps on
your controller and annunciator are
working.
Starting (See Figure 2-3)
Test
Use generator switch TEST position to test run generator
set, or for normal start-up if set is not connected to an
automatic transfer or remote start-stop switch.
Moving switch into TEST position will initiate cyclic crank-
ing (2 to 20 second periods) for up to 75 seconds to start
engine.
Automatic
Use generator switch AUTO position to allow start-up
from an automatic transfer switch or remote start-stop
switch.
Stopping (See Figure 2-3)
Use generator switch CENTER OFF position to make non-
emergency manual stops.
1. Disconnect load from generator set.
2. Move generator switch to CENTER OFF position. Set
will stop after 5-minute (approx.) cool-down period.
OPERATION
2-3
Reset
Switch
Generator
Switch
Emergency
Stop Switch
Figure 2-3. Emergency Stop Switch and Generator Switch Positions
Emergency Stopping
Press EMERG. STOP switch for immediate shut-down.
Resetting
The generator set will shut down automatically under the
following fault conditions:
e Overcrank
e High water temperature
e Overspeed
eLow oil pressure
OPERATION
2-4
CAUTION
Failure to place generator switch in CENTER OFF
position may allow accidental start-up by push-
ing RESET button!
To Restart:
1. Move generator switch to CENTER OFF position.
2. Correct cause of fault shut-down.
=
3. Press RESET switch (fault indicator light will go off).
4.
Move generator switch to necessary position (AUTO or
TEST) for start-up.
Section 3
CONTROLLER AND ENGINE TROUBLESHOOTING
Fast Check
The Fast Check is an engine simulator for testing and
troubleshooting Fast-Response controller lower trays.
Fast Check Features (See Figure 3-1)
Engine conditions are simulated by the following engine
switch positions:
e OFF - engine not running
e CRANK - battery voltage switched to starter
* RUN - engine running
* OVERSPEED button - engine overspeed
Toggle
Switches
ET
Indicator OVERSE
Lamps oF Е
Indicator
Lamps
— Ня я
LCL Pend
Engine
Switch
Overspeed
Button
Figure 3-1. Fast Check
Lamps:
¢ IGN. - (ignition) lamp shows
- battery voltage suppled to ignition, fuel valves, water
valve (city water-cooled sets)
- lights during cranking and running
CRK. - (crank) lamp shows
- battery voltage switched to starter (engine not nec-
essarily turning)
- lights only during “on-crank” cycles
REG. - (regulator) lamp shows
- battery voltage supplied to generator's AC voltage
regulator
- lights during cranking and running
A.D. (anti-diesel, fuel shut-off solenoid) lamp - lights
during normal or fault shut-down or any non-run con-
dition.
ALARM lamp - lights when engine fault is simulated by
one of three upper toggle switches or OVERSPEED but-
ton
BATT. (battery) lamp - lights when test battery (ies) or
DC power supply is live and properly connected.
Upper toggle switch positions:
e L.F. - low fuel
* L.W.T. - low engine water temperature
e A.O.P. - anticipatory (low) oil pressure
e AW.T. - anticipatory (high) water temperature
L.O.P. - low oil pressure
H.W.T. - high water temperature
Fast Check Operation
The Fast Check may be used to:
- test controller lower tray on generator set when trouble-
shooting start-up problems
- test, troubleshoot, and adjust lower tray when removed
from controller
CONTROLLER AND ENGINE TROUBLESHOOTING
3-1
Fast Check (Continued)
Equipment required:
- Fast Check and harness (B-291930 and 287870)
- Variable low-voltage DC power supply; 0-50 volt, 3 amp
minimum current, 0.5% maximum output voltage ripple
at 30 volts DC
- Stopwatch
NOTE
When troubleshooting lower tray, remove from
controller to inspect parts and wiring for dam-
age, corrosion and moisture. Make any needed
repairs before testing.
NOTE
To prevent water from collecting in lower cab-
inet, remove 4 screws holding top cabinet to
lower, and lift away upper cabinet. Apply sealer
around bases of 4 nylon posts, and reinstall upper
cabinet.
NOTE
Trays with B-version circuit boards have nylon
daughter board securing pegs. When replacing
board, compress peg detent barbs and carefully
lift board to remove.
See Figure 3-11 for lower tray connections.
NOTE
If fower tray uses uni-board, check wiring and
connections. Replace complete board if faulty.
See Appendix B to install uni-board.
To Connect Fast Check:
1. Unplug harness connectors from P1, P2 and P3 plugsat
rear of controller.
2. Connect P1 and P2 connectors of Fast Check harness
to P1 and P2 connectors at rear of controller. Connectors
are keyed to prevent misconnection. See Figure 3-2.
3. Push plastic harness connector onto plug at top of Fast
Check.
4. Move controller's generator switch to CENTER OFF.
See Figure 3-3.
5. Move Fast Check engine switch to OFF.
6. Clip red (+) and black (-) harness leads to battery(ies)
or DC power supply of proper voltage for generator set (12
or 24 volt). See BATT rating on nameplate. Generator set's
batteries may be used if accessible and fully charged.
BATT and A.D. lamps of Fast Check should light if red (+)
and black (-) harness leads are properly connected.
> SWITCH OFF lamp on controller should flash,
- if not, push LAMP TEST button on controller.
- if other lamps do not light, check/replace 3 amp fuse
at rear of controller, and/or replace bulbs as needed.
See Figure 3-4.
- if fuse is good and other lamps light when LAMP TEST
button is pushed, but SWITCH OFF lamp does not
flash,
e check or fix regulator board pin connections
OR
e replace regulator board
o REPEAT TEST
DC Supply
Figure 3-2. Fast Check Connection
CONTROLLER AND ENGINE TROUBLESHOOTING
3-2 |
-
SD AT AT
CWOLTMETER-AMMETER -
aed Kap
Generator
Reset Lamp Test
Switch
Switch Switch
Figure 3-3. Controller
Main Control Cyclic Cranking
Board Board Timer Board
aE
Mother
Board
1CR Relay
Regulator Lamp Driver Hospital
Board Board Board
Figure 3-4. Controller Tray
CONTROLLER AND ENGINE TROUBLESHOOTING
3-3
Fast Check (Continued)
To check controller's ability to stop a start-up attempt if
starter locks or does not engage (to prevent starter burn-
out and battery drain):
1. Be sure Fast Check engine switch is OFF
2. Move controller's generator switch to TEST
> IGN., CRK., and REG. lamps of Fast Check should light
(CRK should light for around 10 seconds)
- If not,
e fix regulator board pin connections or replace
board
e fix mother board connections or replace board
oe REPEAT TEST
- If CRK, lamp alone does not light (voltage not con-
ducted to starter circuit):
e fix main control board pin connections or replace
board
® fix cyclic cranking board pin connections or re-
place board
e fix mother board connections or replace board
e fix 1 CR relay wiring or replace relay
e REPEAT TEST
- If IGN. or REG. lamps do not light,
e fix main contro! board pin connections or replace
board
e fix mother board connections or replace board
e fix CR relay wiring or replace relay
eo REPEAT TEST
> CRK. lamp should go out (for around 15 seconds), then
light again for a second cranking cycle.
> After second cranking cycle, IGN., CRK. and REG.
lamps should go out (after around 35 seconds of “cyclic
cranking”). OVERCRANK lamp on controlier plus A.D.
and ALARM lamps on Fast Check should light.
- If not,
e fix main control board pin connections or replace
board
e fix regulator board pin connections or replace
board
e fix mother board connections or replace board
e REPEAT TEST
3. Reset System
- Move controller's generator switch to CENTER OFF
- Press RESET button
CONTROLLER AND ENGINE TROUBLESHOOTING
34
To test main control board's ability to stop a start-up at-
tempt if starter works but engine will not run:
1. Be sure Fast Check's engine switch is OFF.
2. Move controller's generator switch to TEST. See NOTE
following. |
3. Move Fast Check's engine switch to CRANK and start
stopwatch.
NOTE
Main control boards numbered A-284931 give a re-
start cranking delay of about 20 seconds after gen-
erator switch is moved from CENTER OFF (CRK.
lamp on Fast Check may not light immediately when
engine switch is moved to CRANK). If this delay is
too long, replace board with B-284931. New board
will give delay of 1-2 seconds.
> IGN., CRK., and REG. lamps on Fast Check should light
to show “on-crank” cycle. CRK. lamp will go out during
“off-crank” cycles.
> After 40-75 seconds of cyclic cranking, IGN., CRK. and
REG. lamps on Fast Check should go out; ALARM and
A.D. lamps on Fast Check, plus OVERCRANK lamp on
controller should light, stop stopwatch.
- If cyclic cranking does not stop after 40-75 seconds,
e replace main control board
e REPEAT TEST
4. Reset System
- Move Fast Check engine switch to OFF.
- Move controlier's generator switch to CENTER OFF.
- Press RESET button.
To test normal start-up ability:
1. Move controller's generator switch to TEST.
2. Move Fast Check engine switch to CRANK. IGN., CRK.,
and REG. lamps should light after restart time delay.
.3. Move Fast Check engine switch to RUN.
> CRK. lamp should go out
- If CRK. lamp does not go out,
e replace main control board
e REPEAT TEST
To test safety features:
1. Low fuel (hospital option) — hold first toggle switch up
to L.F.
> LOW FUEL lamp on controller and ALARM lamp on Fast
Check should light as long as switch is held.
- If LOW FUEL lamp does not light
e check bulb with LAMP TEST or replace bulb
e fix hospital board pin connections or replace board
e REPEAT TEST
9. Lower water temperature (hospital and prealarm op-
tions) — hold first toggle switch down to L.W.T.
> LOW WATER TEMP. lamp on controller and ALARM
lamp on Fast Check should light as long as switch is
held.
- If LOW WATER TEMP lamp does not light,
e check bulb with LAMP TEST or replace bulb
e fix lamp driver board pin connections or replace
board
e fix mother board connections or replace board
e REPEAT TEST
3. Anticipatory low oil pressure (hospital and prealarm
options) — hold second toggle switch up to A.O.P.
> ANTIC. LOW OIL PRESS. lamp on controller and
ALARM lamp on Fast Check should light as long as
switch is held.
- IF ANTIC. LOW OIL PRESS. lamp does not light,
e Check bulb with LAMP TEST or replace bulb
e fix lamp driver board pin connections or replace
board
e fix mother board connections or replace board
e REPEAT TEST
4. Anticipatory high water temperature (hospital and pre-
alarm options) — hold second toggle switch down to
A.W.T.
> ANTIC. HIGH WATER TEMP. lamp on controller and
ALARM lamp on Fast Check should light as long as
switch is held.
- 1 ANTIC. HIGH WATER TEMP. lamp does not light,
e check bulb with LAMP TEST or repiace bulb
e fix lamp driver board pin connections or replace
board
e fix mother board connections or replace board
e REPEAT TEST
5. Low oil pressure — hold third toggle switchupto L.O.P.
and start stopwatch.
> In 20-60 seconds, LOW OIL PRESS. lamp on controller
should light, stop stopwatch.
> ALARM and A.D. lamps on Fast Check should light to
show engine shut-down (IGN. and REG. should be out).
- 1f low oil pressure shut-down does not show,
check LOW OIL PRESS. lamp with LAMP TEST or
replace bulb
fix lamp driver board pin connections or replace
board
fix main control board pin connections or replace
board
fix mother board connections or replace board
REPEAT TEST
Reset system
Move Fast Check engine switch to OFF.
Move controlier's generator switch to CENTER OFF.
Push RESET button on controller.
Move Fast check engine switch to RUN.
6. High water temperature — hold third toggle switch
down to H.W.T. and start stopwatch.
> In 3-6 seconds HIGH WATER TEMP. lamp on controller
should light; stop stopwatch. |
> ALARM and A.D. lamps on Fast Check should light to
show engine shut-down (IGN. and REG. should be out).
- If high water temperature shut-down does not show
within 6 seconds,
e check HIGH WATER TEMP. lamp with LAMP TEST
or replace bulb
e fix lamp driver board pin connections or replace
board
e fix mother board connections or replace board.
e Reset System and REPEAT TEST
Reset System:
Move Fast Check engine switch to OFF.
Move controller's generator switch to CENTER OFF.
Push RESET button on controlier.
Move controller's generator switch to TEST.
Move Fast Check engine switch to RUN.
7. Overspeed — push and hold OVERSPEED button on
Fast Check
> OVERSPEED lamp on controller should light; ALARM
and A.D. lamps on Fast Check should light (IGN. and
REG. should be out).
- If not, turn OVERSPEED pot on lamp driver board
clockwise until OVERSPEED lamp on controller lights
along with ALARM and A.D. on Fast Check (showing
shut-down). See Figure 3-5.
- If lamps do not show shut-down after adjusting pot,
e check OVERSPEED lamp with LAMP TEST or re-.
piace bulb
CONTROLLER AND ENGINE TROUBLESHOOTING
3-5
Fast Check (Continued)
Overspeed
Figure 3-5. Adjusting Overspeed Pot
e fix lamp driver board pin connections or replace
board
e fix main contro! board pin connections or replace
board
e fix mother board connections or replace board
e Reset System and REPEAT TEST
NOTE
Make final adjustment to OVERSPEED Pot by
manually overspeeding engine to 70 Hz for 60 Hz
sets, and 60 Hz for 50 Hz sets. Adjust potto cause
shut-down at proper frequency.
Reset System:
- Move Fast Check engine switch to OFF.
- Move controller's generator switch to CENTER OFF.
- Push RESET button on controller.
CONTROLLER AND ENGINE TROUBLESHOOTING
3-6
To test normal shut-down delay:
1. Move controller's generator switch to TEST.
2. Move Fast Check engine switch to RUN. Wait until IGN.
and REG. lights of Fast Check are on.
3. Move generator switch to CENTER OFF and start stop-
watch.
> In 4-6 minutes IGN. and REG. lamps on Fast Check
should go out to show shut-down.
- If not,
e carefully turn TIME ADJ. pot on timer board coun-
terclockwise to adjust delay and retest. See Figure
3-6.
To adjust “on-crank” time as needed for engine starting
under usual conditions:
1. Move Fast Check engine switch to CRANK.
2. Move controlier's generator switch to TEST and start
stopwatch. |
Time Adi.
3. Stop stopwatch when CRK. lamp on Fast Check goes
out.
4. Adjust ON TIME pot on cyclic cranking board as
needed. See Figure 3-7.
5. Move Fast Check engine switch to OFF.
6. REPEAT TEST to recheck “on-crank” time.
To adjust “off-crank” time to allow “engine” to stop turn-
ing between “on-crank” cycles (if engine would not start in
preceding “on-crank” cycle):
1. Move Fast Check engine switch to CRANK.
2. Move controller's generator switch to TEST.
3. Start stopwatch when CRK. lamp on Fast Check goes
out.
4. Stop stopwatch when CRK. lamp relights.
5. Adjust OFF TIME pot on cycle cranking board as nec-
essary. See Figure 3-7.
6. REPEAT test to recheck “off-crank” time.
To test and adjust high/low battery voitage and system
ready indicators (hospital option):
1. Connect red (+) and black (-) Fast Check harness leads
to positive (+) and negative (-) terminals of variable-volt-
age DC power supply. Place controller's generator switch
in AUTO position and Fast Check engine switch in OFF
position.
2. Slowly turn DC supply voltage up until BAT. HIGH
VOLTS lamp on controller lights. DC supply voltmeter
should read about 15 volts for 12 volt systems and about 30
volts for 24 volt systems.
3. Slowly turn DC supply voltage down until BAT. LOW
VOLTS lamp on controller lights. DC supply voltmeter
should read about 11 volts for 12 volt systems and 22 volts
for 24 volt systems.
If adjustments are needed, continue as follows:
4. Turn HIGH VOLT ADJ. pot on hospital board fully
counterclockwise (turn from outside of board).
5. Set DC power supply to 14 volts for 12 volt systems or
28 volts for 24 volt systems.
BAT. HIGH VOLTS on controller should be “on”; SYS-
TEM READY “off”
6. Slowly turn HIGH VOLT ADJ. pot clockwise until BAT.
HIGH VOLTS goes out, and SYSTEM READY lights. See
Figure 3-8.
CONTROLLER AND ENGINE TROUBLESHOOTING
3-7
Fast Check (Continued)
“Off” Pot
i,
JN Voltage]
“12 Pots
Figure 3-8. Battery Volt Indicator Adjustment
(Hospital Option)
CONTROLLER AND ENGINE TROUBLESHOOTING
3-8
7. Slowly turn HIGH VOLT ADJ. pot counterclockwise
until BAT. HIGH VOLTS lights,and SYSTEM READY goes
out.
8. Turn LOW VOLT ADJ. pot counterclockwise to stop.
9. Set DC power supply to 10 volts for 12 volt systems, or
20 volts for 24 volt systems. |
BAT. LOW VOLTS should be “out”; SYSTEM READY,
7”
on .
LL
10. Slowly turn LOW VOLT ADJ. pot clockwise until BAT.
LOW VOLTS lights and SYSTEM READY goes out.
- If any indicator lamps do not work check with LAMP
TEST and replace bulbs as necessary.
- If any indicator lamps do not work, or adjustments
cannot be made,
e fix hospital board pin connections or replace board
e fix mother board connections or replace board
11. Vary DC voltage below and above described leveis
and observe indicators. Repeat tests. Make final adjust-
ments if needed.
Engine & Electrics
À WARNING
UNINTENTIONAL STARTING! To prevent
remote starting, unplug P3 connector at rear
of controller. Place Generator Master Switch
on controller to OFF position, and remove
battery cables (negative lead first and recon-
nect it last) to disable generator set before
working on any equipment connected to gen-
erator.
y Output *
Leads 7
Figure 3-9. Insulate Output Leads
NOTE
Remote announciator will not work with P3 un-
plugged.
AX WARNING
HIGH VOLTAGE! Disconnect set from load by
opening line circuit breaker, or by discon nect-
ing generator output leads from transfer switch
and heavily taping ends of leads. The GEN-
ERATOR SAFEGUARD BREAKER MUST NOT
BE USED IN PLACE OF LINE CIRCUIT
BREAKER! If high voltage is transferred to
‘load during test, personal injury and equip-
ment damage may result.
A WARNING
HIGH VOLTAGE! Before starting generator set
with generator end cover removed, place black
electrical tape over LED of circuit board mount-
ed on end of generator end bracket. Ceiling
voltage will result if photo transistor is exposed
to outside light.
Figure 3-10. Tape LED Board
If Engine Will Not Start
AN WARNING
ELECTRICAL SHOCK! Battery can cause elec-
trical burns and shocks. Exercise reasonable
care when working near the battery to avoid
electrical connections through tools. Remove
wristwatch, rings, and any other jewelry.
CONTROLLER AND ENGINE TROUBLESHOCTING
| | 3-9
Engine & Electrics (Continued)
Check battery(ies)
1. Test with hydrometer and/or voltmeter.
2. Check battery connections.
3. Check BAT. HIGH/LOW VOLTS indicators on controi-
ler (hospital option).
4. Check battery charger adjustment:
- Set charger to supply 1MA for each Amp Hour (Ah) of
one battery. With multimeter set on DCMA 500 scale,
and generator set stopped, check for any additional
current draws by controller, governor or options. Ad-
just charger as needed for battery(ies) and additional
current draws. |
NOTE
SYSTEM READY indicator (hospital) option will
draw up to 275MA. Remote annunciator (Deci-
sion Monitor option) will draw up to 75 MA addi-
tional.
Check engine start and run functions
See Figure 3-11. For interconnections on specific models,
see Section 6. Check 15 amp fuse at rear of controller.
Fuse may be blown due to: |
- shorted choke or circuit
- shorted anti-diesel solenoid, fuel valve, gas valve, or
circuit
- shorted injector pump, fuel pump, or circuit
- shorted oil pressure gauge, sender or circuit
- shorted water temperature gauge, sender or circuit
- shorted water valve or circuit (city-water cooled sets)
- shorted ignition coil or circuit
- shorted automatic change over relay or circuit
(LP/natural gas sets)
- shorted starter solenoid or circuit
Make repairs as needed.
Check continuity from disconnected P1 harness connec-
tor to engine functions (see Figure 3-11):
CONTROLLER AND ENGINE TROUBLESHOOTING
3-10
- Circuit 70: ignition and running including
e choke
e anti-diesel solenoid
e injector pump |
® ignition coil
- Circuit 71: cranking, C relay
- Circuit N: ground at starter
|! ОМЕВСВАМК is indicated, correct starter problem.
If Engine Starts But Shuts Down
Check fuel supply
If OVERSPEED ls indicated,
- Adjust engine governor to run set at rated HERTZ
- Adjust OVERSPEED pot on controller's lamp driver
board (Figure 3-12) slowly turn pot clockwise until en-
gine shuts down (at 70 Hz for 60 Hz sets, or 60 Hz for
50 Hz sets).
If OVERCRANK is indicated and engine shuts down 30-45
seconds after start, |
(Safeguard breaker “on”)
- set speed sensor air gap at 0.020 in. (0.508 mm) be-
tween shaft's surface and sensor, or actuator projec-
tion and sensor, depending on model. See Figure 3-
13.
- repair speed sensor wiring, including shield — leads
2, 16 and 24 to P2 connector at rear of controlier.
- manually overspeed engine to check speed sensor
- if set will not shut down, replace speed sensor.
If engine starts and runs, but starter re-engages with no
fault indicated on controller,
(Safeguard breaker “off”)
- set speed sensor air gap at 0.020 in. (0.508 mm). See
Figure 3-13.
~ repair speed sensor wiring, including shield — leads
2, 16 and 24 to P2 connector at rear of controller.
- manually overspeed set to check speed sensor.
- if set will not shut-down, replace speed sensor.
If HIGH WATER TEMP. or LOW OIL PRESS. is indicated,
— correct engine problem.
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Figure 3-11. Interconnection
o EMERG. STOP SW. AUTO. OFF TEST
RESET SW. CONTROLLER AND ENGINE TROUBLESHOOTING
3-11
Engine & Electrics (Continued)
Overspeed
Rd Black
(24)
(2)
White-Clear
(16)
+ -
Shaft
Surface
\ —— =
-—
/ N
< N
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NJ Actuator
Projection
0.020 in.
(0.508 mm)
\
Figure 3-13. Speed Sensor
CONTROLLER AND ENGINE TROUBLESHOOTING
3-12
Section 4
GENERATOR TROUBLESHOOTING
Power Scanner | МОТЕ
If FR Activator does not have Power Scanner, use
The Power Scanner function of the FR Activator (power AC meters on controlier when troubleshooting.
module) gives a visual troubleshooting aid showing gen-
erator exciter and output performance. See Figure 4-1.
Figure 4-1. FR Activator
A WARNING
HIGH VOLTAGE! Disconnect set from load by
opening line circuit breaker, or by disconnect-
ing generator output leads from transfer switch
and heavily taping ends of leads. The GEN-
ERATOR SAFEGUARD BREAKER MUST NOT
BE USED IN PLACE OF LINE CIRCUIT
BREAKER! If high voltage is transferred to
load during test, personal injury and equip-
ment damage may result.
A WARNING
UNINTENTIONAL STARTING! To prevent
remote starting, unplug P3 connector at rear
of controller. Place Generator Master Switch
on controller to OFF position, and remove
battery cables (negative lead first and recon-
nect it last) to disable generator set before
working on any equipment connected to gen-
erator.
NOTE
Remote annuciator will not work with P3 un-
plugged. Figure 4-2. Insulate Output Leads
GENERATOR TROUBLESHOOTING
4-1
- Full green ring with segments evenly spaced.
A WARNING - Red ring of four groups of evenly spaced segments —
heavier loads will show more red segments.
HIGH VOLTAGE! Before starting generator set
with generator end cover removed, place black
electrical tape over LED of circuit board mount-
ed on end of generator end bracket. Ceiling
voltage will result if photo transistor is exposed
to outside light.
To View Power Scanner:
1. STOP ENGINE. Move controller's generator switch to
CENTER OFF and wait for engine shutdown.
2. Remove left-hand louvered panel from the generator
end cover. Loosen 3 upper and 3 lower capscrews hold-
ing end cover to generator housing.
3. Lift end cover to remove.
4. Tape LED on circuit board.
Power Scanner Patterns Figure 4-4. Normal Pattern (Low Load)
During generator operation, the FR Activator travels with
the rotor shaft to have the Power Scanner show red and
green circular light segment patterns. View scanner pat-
terns looking into each of four openings of end bracket
casting. No generator output (See Figure 4-5)
- Full green shows voltage from exciter armature to FR
Activator.
- Nored shows exciter voltage not passing to main gen-
erator field.
Figure 4-5. Full Green Only
Figure 4-3. Tape LED Board
GENERATOR TROUBLESHOOTING
4-2 |
No generator output (See Figure 4-6)
- No green shows no voltage from exciter armature to
FR Activator.
Figure 4-6. No Green
No generator output (See Figure 4-7)
- Partial green shows low voltage from exciter arma-
ture to FR Activator.
- Partial red may also show.
Figure 4-7. Partial Green
Overload or high output voltage (See Figure 4-8)
- Fuli green shows voltage from exciter armature.
- Full red shows exciter voitage sent to main field.
Figure 4-8. Fuil Green/Full Red
Low generator output (See Figure 4-9)
- Fuil green (shows voltage from exciter armature).
- Partial red with missing segments (segments unequal
in 4 groups).
Figure 4-9. Full Green/Partial Red
Generator Functions
AN WARNING
HIGH VOLTAGE! Disconnect set from load by
opening line circuit breaker, or by disconnect-
ing generator output leads from transfer switch
and heavily taping ends of leads. The GEN-
ERATOR SAFEGUARD BREAKER MUST NOT
BE USED IN PLACE OF LINE CIRCUIT
BREAKER! If high voltage is transferred to
load during test, personal injury and equip-
ment damage may result.
NOTE
See Figure 4-10 when using the following proce-
dures.
GENERATOR TROUBLESHOOTING
4-3
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GENERATOR TROUBLESHOOTING
4-4
À WARNING
HIGH VOLTAGE! Be sure that foil side of
photo transistor board, end of shaft, and
threaded holes are clean and free of metal
particles and chips. Dangerous HIGH VOL-
TAGE may result. AC voltmeter must show
proper output before generator may be recon-
nected to load.
No AC output — full green/no red
> Safeguard breaker open. Close it, and with set running,
check AC voltmeter for proper output voltage.
A WARNING
HIGH VOLTAGE! When testing photo tran-
sistor board, keep all other light sources away.
Otherwise, dangerous ceiling voltage may re-
sult.
- Reconnect red and black photo transistor board leads
to C and E terminals of FR Activator. Start set, shine
bright flashlight on photo transistor. AC voltmeter
should show ceiling voltage, and return to normal
when flashlight is removed.
> If proper voltage does not show,
> If AC voltage does not show, stop set. Replace FR
Activator and REPEAT TEST.
> If tests show photo transistor board and FR Activator to
be good, but proper voltage does not show when LED
board is installed and connected,
- Check for 2-6 DC volts across 3B (+) and 5B (-) of LED
board with set running and safeguard breaker closed.
See Figure 4-12.
- remove LED board and shine bright flashiight on ex-
posed photo transistor. AC voltmeter should show
ceiling voltage.
> If red scanner pattern does not show,
- Stop set. Disconnect red and black photo transistor
board leads from C and E terminals of FR Activator.
- Clip red and black leads to ohmmeter (+) and (-).
Meter should read 300 K Ohms or higher.
- Shine bright flashlight on photo transistor; meter
* If voltage shows, stop set and replace LED board.
should read 5K Ohms or lower.
- Mohmmeter does not respond, replace photo transis-
tor board/harness assembly. REPEAT TEST.
NOTE
Remove plastic sleeve from LED on back of new
board before mounting new board.
(LED Board)
Photo
Transistor
Figure 4-11. Photo Transistor Board
GENERATOR TROUBLESHOOTING
4-5
Generator Functions (Continued)
Figure 4-12. LED Board Voitage Check
e Start set and look for proper AC voltage.
If DC voltage does not show at LED board,
- Check voltages at voltage regulator board (in con-
troller upper cabinet) with set running and safeguard
breaker closed. See Figure 4-13.
- Set's battery voltage (12 or 24 DC volts) should show
across R-16 and R-19 resistors. Voltage across R20
should be 4.3 for 12 volt sets and 9.1 for 24 volt sets.
If proper voltages show at voltage reguiator board,
Stop set and remove harness plugs from LED board
and voltage regulator board. Check wiring between
sockets 3B and 6, 5B and 9 (includes P5 connector at
rear of upper cabinet) for short, grounded oropen cir-
cuit. See Figure 4-14.
- Repair or replace wiring as necessary. Start set and
look for proper AC voltage.
> If proper voltages do not show at voltage regulator
board,
Disconnect harness piug from voltage regulator
board and run set with safeguard breaker closed.
GENERATOR TROUBLESHOOTING
4-6 |
-
Check for battery voltage (12 or 24 DC volts) across
sockets 2(-) and 11(+) of harness plug.
If battery voltage shows at harness plug, but proper
voltages at board resistors and/or proper AC voltage
does not show when harness is connected to voltage
regulator board, replace board. REPEAT TESTS and
look for proper AC voltage.
If battery voltage does not show at voltage regulator
board harness plug, stop set.
- Check continuity from harness plug socket 2 to
ground (circuit includes P5 connector atrear of upper
cabinet).
- Check continuity from harness plug socket 11 to
terminal 4 of CR relay with Safeguard breaker closed
(circuit includes P5 and P2 connectors at rear of con-
troller).
- Repair or replace wiring or safeguard breaker as nec-
essary.
- Restart set and look for proper AC voltage.
Figure 4-13. Voltage Regulator Board DC Voltage Check
Varying AC output voltage — varying green and red
>
Intermittent exciter voltage
Stop set
Check A1 and A2, F3 and F4 connections to FR Activa-
tor for tightness.
Restart set. Check for proper AC output voltage and
scanner patterns.
- H output voltage varies, stop set, disconnect A1 and
A2 leads from FR Activator, leaving leads tied to shaft
or heat sink.
AN WARNING
HIGH VOLTAGE! Use high voltage test only as
directed. High voltage may cause personal
injury, damage equipment, or lead to future
failures. Follow manufacturer's instructions
when operating tester.
- Apply 1,500 AC volts to either A1 or A2 lead and shaft
for not-more-than one second.
- Repair A1 or A2 leads if test shows leads shorted to
ground.
GENERATOR TROUBLESHOOTING
4-7
Generator Functions (Continued)
Figure 4-14. Harness Plugs
- Solder and insulate splices. Use new sleeving when
tying leads to shaft or heat sink.
- Replace exciter armature if test shows armature
shorted to ground.
- Repair leads or replace exciter armature if continuity
check shows open condition across A1 and A2 leads.
No AC output — no green
> Open exciter armature or A1, A2 leads
- Stopset. Disconnect A1 and A2 leads from FR Activa-
tor.
- Check continuity across A1 and A2 leads.
- Repair A1 and A2 leads if damaged or open. Solder
and insulate splices. Use new sleeving when tying
leads to shaft or heat sink.
- Replace exciter armature if test shows open wind-
ings. |
- Restart set. Check for proper AC voltage and scanner
patterns. |
GENERATOR TROUBLESHOOTING
4-8
> Shorted or grounded exciter armature
- Stop set.
A WARNING
HOT PARTS! Exciter armature will get hot if
armature is shorted. Avoid touching armature!
- Disconnect A1 and A2 leads from FR Activator, leav-
ing leads tied to shaft or heat sink.
A WARNING
HIGH VOLTAGE! Use high voltage test only as
directed. High voltage may cause personal
injury, damage equipment, or lead to future
failures. Follow manufacturers instructions
when operating tester.
- Apply 1,500 AC volts to either A1 or A2 lead and shaft
for not-more-than one second.
- Repair A1 or A2 leads if test shows leads shorted to
ground. Solder and insulate splices. Use new sieev-
ing when tying leads to shaft or heat sink.
- Replace exciter armature if test shows armature
shorted or grounded.
> FR Activator Shorted
- Stop set. Replace FR Activator.
- Restart set; look for proper AC voltage.
NOTE
Shorted generator field will cause FR Activator
failure.
> Generator Field Shorted
- Stop set. Check field resistance as described in Ap-
pendix A.
- Replace FR Activator and generator field if shorted.
- Restart set; look for proper AC voltage.
No AC output — full green and full red
> Check for open field
- Stop set. Disconnect F3 and F4 leads from FR Activa-
tor and check continuity across leads.
- Repair F3 and F4 leads. Solder splices and use new in-
sulation as necessary or replace field.
High AC output voltage — full green and full red with safe-
guard breaker open OR closed
> Photo transistor board or harness shorted
- Stop set. Disconnect C (red) and E (black) leads from
FR Activator.
- Restart set and check AC voltage.
e If AC voltage does not show, stop set and replace
photo transistor board/harness assembly.
AN WARNING
HIGH VOLTAGE! Be sure that foil side of
photo transistor board, end of shaft, and
threaded holes are clean and free of metal
particles and chips. Dangerous HIGH VOL-
TAGE may result. AC voltmeter must show
proper output before generator may be recon-
nected to load.
e Restart set and check AC voltmeter for proper
output.
High or erratic AC output — full green, erratic-to-full red
with safeguard breaker closed only.
> Open or poor voltage-sensing circuit
- Start set. Check AC voltage across red wires near har-
ness connector on voltage regulator board. See Fig-
ure 4-15.
Figure 4-15. Voltage Regulator Board AC Voltage Check
Voltmeter should read 150 volts on 600-volt sets; 208 or
240 volts on others.
— If very low or erratic voltage shows, stop set,
e Check wiring from sockets 4 and 10 of discon-
nected voltage regulator board harness plug to
stator terminals 3B and 2B on 600-voltsets orstator
leads 9 and 2 on others. Circuit includes P4 con-
nector at rear of upper cabinet.
e Repair or replace wiring or connections as neces-
sary. |
e Reconnect voltage regulator board.
GENERATOR TROUBLESHOOTING
— 4-9
Generator Functions (Continued) NOTE
Wiggle photo transistor board harness near
- Restart set. Recheck AC voltage at voltage regulator splice to board when checking for shorts or
board as shown in Figure 4-15. AC voltmeter must | “opens”.
show proper output. ; - Replace photo transistor board/harness assembly as
necessary.
> Shorted or faulty photo transistor board/harness as- À WARNING
sembly. HIGH VOLTAGE! Be sure that foil side of
photo transistor board, end of shaft, and
threaded holes are clean and free of metal
particles and chips. Dangerous HIGH VOL-
- Stop set. Disconnect C (red) and E (black) leads from
FR Activator.
e Use onmmeter to check for intermittent shorts be- TAGE may result. AC voltmeter must show
tween C and E loads. proper output before generator may be recon-
e Use ohmmeter to check for intermittent “opens” be- nected to load. |
tween end of bare ground/shield wire and shaft. |
- Restart set. Look for proper AC voltage.
GENERATOR TROUBLESHOOTING
4-10
Section 5
GENERATOR DISASSEMBLY-REASSEMBLY
CAUTION
Any cranes, hoists, or other devices used in dis-
assembly or reassembly must be rated for weight
of generator set. See table following for approxi-
mate dry weights of various models. Check gen-
erator set name plate for weight of any model not
listed.
MODEL WEIGHT
KW Engine-Fuel Lbs. (Kg)
30 Gas-Gasoline 1470 ( 668)
Diesel 1495 ( 679)
45 Gas-Gasoline 1900 ( 863)
Diesel 1960 ( 890)
55 Gas-Gasoline 2035 ( 924)
60 Diesel 2140 ( 972)
70 Gas-Gasoline (Chrysler) | 2095 ( 952)
(Ford) 2009 ( 913)
75 Diesel (D4800) 2734 (1242)
(D3400T) 2100 ( 954)
85 Gas-Gasoline 2650 (1203)
100 Diesel | 2895 (1315)
125 Diesel 4000 (1816)
130 Diesel 4010 (1821)
150 Diesel 4465 (2028)
230 Diesel 5874 (2668)
250 Diesel 6425 (2917)
260 Diesel 5990 (2720)
A WARNING
UNIT STARTS WITHOUT NOTICE! Units with
Automatic Transfer Switches start automati-
cally. Potential injury or electrocution can
result. Turn Generator Master Switch on con-
troller to OFF position, and remove battery
cables (remove negative lead first and recon-
nect it last) to disable generator set before
working on any equipment connected to gen-
erator.
AN WARNING
ELECTRICAL SHOCK! Battery can cause elec-
trical burns and shocks. Exercise reasonable
care when working near the battery to avoid
electrical connections through tools. Remove
wristwatch, rings, and any other jewelry.
A WARNING
HOT PIPING! An engine gets hot while run-
ning and exhaust system components get
extremely hot. Do not work on generator set
until unit is aliowed to cool. |
‘Disassembly
1. Disconnect and remove starting batteries from work
area to prevent fire hazard. Disconnect any AC ac-
cessories such as battery charger, block heater, and
fuel transfer pump.
2. Shut off fuel supply. Drain fuel system as necessary,
emptying fuel into proper containers. Remove any fuel
containers from work area to prevent fire hazard. Ven-
tilate work area to ciear fumes.
3. Disconnect fuel, cooling, and exhaust systems as nec-
essary to tilt generator set. Disconnect output leads or
load circuit cables at generator.
4. Disconnect ali controller-to-engine and engine-to-
generator harnesses and wiring, including alarm horn
circuit board connector, LED board and connector,
and speed sensor. Enclosure and controller may be
removed as unit.
5. Unplug C (red) and E (black) leads from FR Activator.
Remove photo transistor board and harness.
6. Loosen generator end bearing retainers, if so
equipped. See Figure 5-1.
Figure 5-1. Loosening Bearing Retainers
7. Remove bolts from generator vibro-mounts.
8. Suspend generator at both ends and raise with hoist,
as shown in Figure 5-2, to lift generator off of vibro-
mounts.
9. Place wood blocks under flywheel housing to sup-
port engine; lower, allowing flywheel housing to rest
on blocks.
10. Remove bolts holding adapter to flywheel housing.
See Figure 5-3. Remove nuts or bolts holding fan and
drive discs to flywheel.
GENERATOR DISASSEMBLY-REASSEMBLY
5-1
Disassembly (Continued)
‘Mounts .
с
“Adapter 4
Figure 5-4. Hoisting Generator Assembly
14. Lower generator assembly to rest in suitable cradle as
shown in Figure 5-5.
15. Remove adapter, if separate, drive discs and fan.
Figure 5-3. Removing Adapter Bolts
11. If studs hold drive discs to flywheel, work drive discs
over studs to separate generator from engine.
12. Set generator horizontally on floor. Remove slings or
chains.
13. Hook hoist to adapter and suspend generator assem-
bly. See Figure 5-4.
GENERATOR DISASSEMBLY-REASSEMBLY
5-2 |
Figure 5-5. Cradied Generator Assembly
16. Fasten chains and hoist to stator. Remove bolts hold-
ing stator to end bracket. See Figure 5-6.
17. Raise stator to remove, taking care not todamage sta-
tor laminations or rotor.
: Magnets
(In Case)
es
. Figure 5-6. Preparing to Remove Stator
18. Fasten lifting eye and hoist hook to rotor flange. If so
equipped, remove nuts and bolts holding bearing re-
tainers to end bracket. Hoist rotor to remove. Take
care not to damage exciter armature or exciter field
magnets. See Figure 5-7.
19. Lower rotor allowing bearing end to rest on wood
block as shown in Figure 5-8. Slowly lower rotor to
horizontal position taking care not to damage field
cage or laminations.
Figure 5-8. Rotor Handling
GENERATOR DISASSEMBLY-REASSEMBLY
5-3
eassembly 3. Suspend rotor over end bracket. Lower rotor into end
bracket taking care not to damage exciter armature or
field magnets. Position end bracket to guide rotor end
bearing into end bracket. See Figure 5-11. Fasten both
bearing retainers to end bracket, if equipped, but do
not final tighten.
1. Place end bracket in suitable cradle as shown in Fig-
ure 5-9. Be sure outer bearing retainer or snap ring is
in position. Outer bearing retainer, if so equipped,
should be in position with bolts in place.
Outer Bearing
Retainer
Figure 5-9. Cradled End Bracket
JER
— soul | =. hs Field Magnets
2. Raise rotor allowing bearing end to rest on wood block 5 ss. ‘ (In Case)
as shown in Figure 5-10. | S E и: A
и
End
Bearing
Figure 5-11. Lowering Rotor
4. Suspend stator and lower over rotor taking care notto
damage stator windings and laminations or rotor.
5. Lower stator to within 1/2 to 1/4 in. (12.7-6.4 mm) of
end bracket. Turn stator to position, and start bolts to
hold end bracket to stator. Lower stator onto end
bracket and tighten bolts. See Figure 5-12.
NOTE
For models with speed sensor mounting holes in
end bracket, mount stator to end bracket as
shown in Figure 5-13.
6. Place fan over end of rotor. Fasten drive discs to rotor
flange. Torque drive disc bolts to 80 ft. Ibs. (11.06
Kg-m).
Figure 5-10. Rotor Handling
7. Fasten adapter to stator, if separate, and final tighten.
GENERATOR DISASSEMBLY-REASSEMBLY
5-4
Figure 5-12. Positioning Stator
Speed Sensor
Mounting Holes
End
Bracket
Stator
Figure 5-13. End Bracket Position
8. Hoist assembled generator by adapter and set on side
taking care not to damage end bracket or stator. See
Figure 5-14.
If bolts are used to fasten drive discs to flywheel, guide
pins should be used to align flywheel with drive discs.
Make guide pins by removing heads from two proper-
ly sized and threaded bolts, leaving approximately 1
in. (25.4 mm) of unthreaded shank to protrude from
flywheel face. Thread guide pins into flywheel as
shown in Figure 5-15.
©
Figure 5-15. Guide Pin Placement (If Used)
If studs are used to fasten drive discs to flywheel, be
sure ali studs are threaded into flywheel. ©
10. Suspend assembled generator in level position as
shown in Figure 5-16. Turn flywheel to align studs or
guide pins with drive discs.
GENERATOR DISASSEMBLY-REASSEMBLY
— 55
eassembly (Continued)
Figure 5-16. Positioning Generator
11. Move generator as necessary to work drive discs and
fan over guide pins or studs. See Figure 5-17. Fasten
drive discs and fan to flywheel with two bolts or nuts at
opposite holes or studs.
12. Move generator as necessary to align adapter and fly-
wheel housing. Fasten and final tighten adapter to fiy-
wheel housing. See Figure 5-18.
13. Hoist generator and engine slightly and remove
blocks from under flywheel housing. Lower genera-
tor to align and rest on vibro-mounts. Tighten gener-
ator to mounting. See Figure 5-19.
14. Remove chains or slings used to suspend generator.
Final tighten end bracket to stator.
15
Final tighten fan and drive discs to flywheel. Insert bar
through fan blades to turn and hold engine and rotor.
CAUTION |
Be sure to remove guide pins if used, and replace
with proper bolts and lockwashers.
NOTE
On 125-260 KW models, end bearing must be
packed if rotor or end bearing has been replaced.
Remove outer bearing retainer to expose bear-
ing and pack with #2 EP bearing grease.
Speed sensor mounting boss on inner bearing re-
tainer must be positioned at top.
16. Final tighten bearing retainers to end bracket.
17. Complete reassembly reversing steps 1 through 5 of
Disassembly.
GENERATOR DISASSEMBLY-REASSEMBLY
5-6 |
Figure 5-18. Coupling Fiywheel Housing to Adapter
White-Clear
Figure 5-19. Mounting Generator
dA WARNING
HIGH VOLTAGE! Be sure that foil side of
photo transistor board, end .of shaft, and
threaded holes are clean and free of metal
particles and chips. Dangerous HIGH VOL-
TAGE may result. AC voltmeter must show
proper output before generator may be recon-
nected to load.
NOTE
Set speed sensor air gap 0.020 in. (0.508 mm)
when remounting. See Figure 5-20.
Red
(24) N lack
(2)
(16)
8 8
N— 0.020 in.
(0.508 mm)
Shaft
IAN
Actuator
Projection
Figure 5-20. Speed Sensor Air Gap
GENERATOR DISASSEMBLY-REASSEMBLY
5-7
Section 6
WIRING DIAGRAMS
Model Voltage Code Diagrams
(As shown by second-to-last numeral of model number.) UPPER CABINET
Voltage Code Page
Code Voltage Phase Wires 0.57.89 6-2
0 "120/240 3 4 8 63
5 240 3 3 10 64
6 120/240 1 3 CONTROLLER TO ENGINE-GENERATOR
7 277/480 3 4 voltage
Model Code Page
8 120/208 3 À KW Engine
9 347/600 3 4 30-60 White-Hercules 0 6-5
10 Triple: | (60Kw w/D3000T 57,8 6-6
120/240 1 3 engine) 6 6-7
277/480 3 4 9 6-8
120/208 3 4 70 Ford/Chrysler 0 6-9
85 I-H 5, 7,8 6-10
6 6-11
9 6-12
60-125 | White-Hercules О 6-13
w/battery charging 5, 7,8 6-14
regulator in alternator 6 6-15
(60Kw w/D3300T 9 6-16
engine)
100 White-Hercules 0 6-17
w/separate battery 5, 7, 8 6-18
charging regulator 6 6-19
9 6-20
125-175 | John Deere 0 (12-V) 6-21
(125 & 175 24-V) 0 (24-V) 6-22
(130 & 150 12-V) 5, 7, 8 6-23
6 6-24
| 9 6-25
250 Allis-Chalmers 0 6-26
5, 7, 8 6-27
6 6-28
9 6-29
190-260 | Cummins 0 6-30
5, 7, 8 6-31
6 6-32
9 6-33
30-100 10 6-34
WIRING DIAGRAMS
6-1
LEAD COLORS
(5)- BLUE/ WHITE (O YELLOW / GREEN | | Upper Cabinet
(8) BLACK N- WHITE / BLACK 39, 4-wire, 600-volt
(> RED/ BLUE E)- RED | 30, 4-wire, 120/240-volt
67 WHITE / PURPLE (E) GRAY 39, 4-wire, 120/208-volt
MRE a /BLACK 30, 4-wire, 277-480-volt
Ti ORANGE / GREEN | ()- BLUE /RED | 39, 3-wire, 240-volt FOR COMPLETE DIAGRAM OF CONTROLLER
D- BROWN / {2 ORANGE /BLACK TO ENGINE WIRING, SEE INDIVIDUAL ENGINE
(B-BLUE /ORANCE FomRED /ORANGE NOTE- | MODEL INTERCONNECTION DIAGRAMS.
USE ON 600V
@B- GREEN /YELLOW VO-PURPLE /WHITE ONLY
5B— BROWN / ORANGE VD-YELLOW / BLUE
ED- WHITE /PINK Y2-ORANGE/RED
IOB— BROWN / WHITE V3-YELLOW /PINK
AC VOLTAGE
REGULATOR
CIRCUIT
BOARD
———— —]]]]——]] —]———]———> Jj
NOTE ADAPTORS
SHOWN DOTTED.
USED ON 24 VOLT
SYSTEMS ONLY
VOLT ADJ.
PROTECTION
CIRCUIT
BOARD
о!
FREQ
AC VOLTS
L AMP
CENTER TERMINAL
NOTE-THESE LAMPS NOT
USED ON 600 VOLT, /
CENTER TERMINAL
МотЕ--
RECEPTACLES VIEWED FROM
- TERMINAL INSERTION END.
NOTE-
USE ON 600V
ONLY
NOTE-
DISCONNECT THIS LEAD FROM HR.
METER AND TAPE OR SEAL LOOSE END
WHEN 34-4 WIRE 40 VOLT CONNECTION
WIRING DIAGRAMS
6-2
LEAD COLORS
&- BLUE / WHITE
BLACK |
(UD RED/BLUE
6) WHITE / PURPLE
&>- BLACK /GREEN
Z0- WHITE /GREEN
7) ORANGE / GREEN
79- BROWN / YELLOW
(B-— BLUE / ORANGE
SB- GREEN / YELLOW
EB— BROWN / ORANGE
ÉD- WHITE / PINK
©D- BROWN /WHITE
NOTE -ADAPTORS
SHOWN DOTTED,
USED ON Za VOLT
SYSTEMS ONLY
CO- YELLOW / GREEN
IN-WH-HTE/ BLACK
69- RED
E) GRAY
(N-WHITE /BLACK
(P)> RED
(TD BLUE/RED
T2-ORANCE /BLACK
T3- RED/ORANGE
VO PURPLE / WHITE
VD YELLOW / BLUE
{2 ORANGE /RED
(> YELLOW / PINK
FOR COMPLETE DIAGRAM OF CONTROLLER
TO ENGINE WIRING, SEE INDIVIDUAL ENGINE
MODEL INTERCONNECTION DIAGRAMS.
PROTECTION
CIRCUIT
BOARD
AC VOLTAGE
RECULATOK
CIRCUIT
BOARD
AC VOITS
CENTER TERMINAL
Upper Cabinet
18, 3-wire, 120/240 volt
RECEPTACLES VIEWED FROM
TERMINAL INSERTION END.
LEADS V3 AND T3 ARE NOT
CONNECTED OR USED, TAPE OR
SEAL ENDS TO AVOID ACCIDENTAL
MISCONNECTIONS AND SHORT
CENTER TERMINAL
WIRING DIAGRAMS -
6-3
NOTE ADAPTORS
SHOWN DOTTED,
USED ON 24 VOLT
SYSTEMS ONLY
GIRLUF/WHITF
(BLACK
C-PEn/3L.1F
E)-WII TE /PURPLE
E3-3LACK/6OFFN
GD-WHITE/GREEN
G2-IPA"IGE/GPFEN
C9-BROWN/YFLLAN
(3-BL1E/0PANGF
É3-CPEFN/YFILOW
GB-BRAWY/ORANGF
GO-WUITF/PINK
OP-2RAW/WEITE
€3 -WHITE/PINK
CD-YELLAN/GREE"!
GY-WHITF/RLACK
(ВРЕТ
GRAY
CWAITE/BLACK
CRE
C)-BLIF/PEN
CI-IRMIGE/BILACK
E3-PEN/APA" IRF
(PURPLE /MHITF
C-YFLLAW/ALUF
OY-1RaNGE/OFT
C3-YELLAW/PINK
NOTE.
NOTE :
Triple-Voltage
19, 3-wire, 120/240-volt
30, 4-wire, 120/208-volt
30, 4-wire, 277/480-volt
RECEPTACLES VIEWED FROM
TERMINAL
INSERTION END
FUT 82 (WHITE/PINK) LEAD, THE ENT
FROM P4 IS CALLED SC AND GOES TO THE — TOP
INSULINK, THE END FROM THE VOLTAGE Ш
REGULATOR GOES TO THE HONR METEP,
A.C. VOLTAGE
REGUL ATOR
CIRCUIT
BOARD
VOLT ADJ.
RHEO.
SIGNAL 78 |
PROTECTION |
CIRCUIT ©
BOARD 177
| |
| ||
FREQ.
LAMP
O O
AC VOLTS
=)
^^
N
O
5
ит И
>
15
JO дме
>
CENTER oS
[oa
AC
AMPS
+
CENTER TERMINAL
FOR COMPLETE DIAGRAM OF CONTROLLER
TO ENGINE WIRING, SEE INTERCONNECTION
DIAGRAM.
WIRING DIAGRAM
6-4
OUTSIDE REAR VIEW OF INSTRUMENT BOX & CONTROLLER DRAWER 30-60Kw White-Hercules
39, 4-wire, 120/240-volt
Code — 0
NOTE-
THE AC. AND DC. HARNESSES ARE UNIVERSAL,
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS. DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS,
FUSES
ENGINE
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MAGNETIC PICK-UP
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WIRING DIAGRAMS
6-5
OUTSIDE REAR VIEW OF INSTRUMENT BOX & CONTROLLER DRAWER
30-60Kw White-Hercules
39, 4-wire, 120/208-volt
39, 4-wire, 277/480-volt
39, 3-wire, 240-volt
Code — 5, 7, 8
EXCIT
ARMATURE R RELAY AND CITY
CHANGEOVE
WATER VALVE.
NOTE -
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE . OPTIONS, DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
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USES
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dos ® e ©! © BRKH.CSEE NOTES ) 70 15 CONNECTED TO FUEL VALVE.
10
ji 1
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a
à
3
$
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MAIN FIELD 277 487. 2811, (CUSTOMER OPTION)
3$-4 WIRE © Дао |502 | | 8 3 649
-
39-4 WIRE 12950814548 |, 47 [208 |3á9
30-3WIRE- 240 [10,812
IF IT 15 NOT DESIRED TO READ THE NEUTRAL ON STRAIGHT
240 VOLT DISCONNECT LEAD VO FROM 12.
290419
WIRING DIAGRAMS
6-6
OUTSIDE REAR VIEW OF INSTRUMENT BOX & CONTROLLER DRAWER
30-60Kw White-Hercules
19, 3-wire, 120/240-volt
Code — 6
NOTE -
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAFE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS,
FUSES
ENGINE
© és HIGHWATER LOWWATER ANTIC. WATER TEMP
TEMP SW. TEMP SW. HWT. SW. SENDER :
oT FUN
\
- GREEN-TO 3 -
mL 71 o
35-YELLOW- TO 35 in Pi
N-WHT./BLK - TO STARTER GROUND
- PURPLE - TO 40 IN PI
Dese IN PS IGNITION
= [Tf CAMES ARRE) Tao On DEL
5 o
AMILABLE FOR REMOTE START SW yy IE
CONTROL CONTACT ON TRANSFER PANEL - Me JUNCTION BOX
SEE 267804 FOR THIS CONNECTION WHEN o RO — ==
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on Sn ii [
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255 e LT} HORN f—— ——
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30-CREEN YELLON=TO 3 IN PS < opta y ihe | M-\WHT/FLK-TO STARTER GROUND —< TI-YELLOW (GA JTO N IN Pi
38-GREEN YELLOW-TO 38 IN PS5——— 285 - = - — 7 /CAN -
STATIONARY | 7 SEUNINSULATED" WIKE- TO 52 TR PI 23553 € (4 Ga) с " A EE Inuecton vue
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| H-RED/BLUE-TO 11 IN A4 — SEES (JUMPER -DIESEL. SOL.
| г 3553 | __ANTCLOP USED ON NE N-WHT/ELK.
A aa _ PLANTS ONLY. (JUMPERYTO
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pe a | meo |
то 12 MPa La Fro NA — AN NOTE
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= = DIODE SUPPLIED ~_ 7 USED ON CITY
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VO-PURPLE/ WHITE—TO VO IN P4 - © S © ol ay ri NOTES) T=" ON LP OR NATURAL GAS PLANTS
e 70 15 CONNECTED TO FUEL VALYE.
| | |
| у No ON LP AND NATURAL GAS PLANTS
LO Ты L2 Do | — ITH AUTOMATIC CHA » 70
HEN | — SET LA Ane cy
1 —
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Y | —
USTOMER OPTION
|
REE то Бо | BATTER
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MAGNETIC PICK-UP ES Sator IN FUEL TANK
MAIN FIELD
WIRING DIAGRAMS
67
OUTSIDE REAR VIEW OF INSTRUMENT BOX 8 CONTROLLER DRAWER
30-60Kw White-Hercules
39, 4-wire, 600-volt
Code — 9
NOTE -
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS :
ON
FUSES
Ca se О USE ENGINE
O Da @ e HIGHWATER LOWWATER ANTIC. WATER TEMP
№ © “С
e 9 TEMP SW. TEMP SW. + HWISW SENDER
x ` ‘
Be: - GREEN-T0 34 IN mL a y 7 A
35-YELLOW-TO 35 IN Pi
N-wHT/EUL-TO STARTER GROUND
\ -PURPLE- TT 40 IN F1
\ -~ ) sir T-105 INPS IGNITION
L .
TE D.C. HARNESS (290373 SENET) WIR ON CASUINE PLANTS
< day
a 2 zz a .
AMAILABLE FOR REMOTE START SWITCH OR ze JUNC
CONTROL CONTACT ÓN TRANSFER PANEL. "от —çef TION BOX
SEE 287804 FOR THIS CONNECTION WHEN $ | o
REMOTE DECISION MONITOR 15 USED. = 3 is
= 5 ЧЕ 2
nN > q
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— GENERATOR $ sot = | Se Е 3 0 wT CA INJECTOR PUMP TO ALTERNATOR ——
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| L—i6-WHITE 22 TO 16 IN P2-———— 121 5 ] 20 WHT/GRN. TO ¡ PUMP |
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| = HI x2 [| En (Jaume) TMP
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= о ; Ol
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119 PURPLE/WHT.— € 5e “RED(AGAITO C RELAY P— hp +
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! иен = === == z E w % REO (IN GATO PIN РЪ ==
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— 1 LH QL 70 15 CONNECTED TO FUEL VALVE.
top td
3 | [1
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|| AMAILABLE SUPPLY A :
[FOR ALARM HORN WT. - У +
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EXCITER FIELD BATTERY
HEAT SINK & FR TO LOAD y
ACTNATOR AMNLABLE SUFRLY FOR LOW
SWITCH :
MAGNETIC PICK-UP Е IN FUEL TARK
MAIN FIELD
WIRING DIAGRAMS
6-8
OUTSIDE REAR VIEW OF INSTRUMENT BOX & CONTROLLER DRAWER 70Kw Ford/Chrysler
85Kw -100Kw International
Harvester
39, 4-wire, 120/240-volt
Code — 0
NOTE-
THE AC AND DC HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
ARE NOT REQUI AND TAPE OR SEAL ENDS TO — CHOKE
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS,
FEEDBACK CIRCUIT
p Ts
AN
ее E a ENGINE
< or EN ANTIC. OL PRESS, LOP _ ANTI- O FEEDBACK €
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и A - WHT ®
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=; < 7 T .
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an es og 2 7C- YEL/GAN-TO 7C IN PO——
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TT D.C. HARNESS(290735 SEED) IES 4 : P-RED(MGA) TO SOL. P
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AVAILABLE FOR REMOTE START SWITCH 5 EZ wy E CS CONNECTED TO
OR CONTROL CONTACT ON TRANSFER PANEL. 2 or : CITY WATER VALVE
SEE 287804 FOR THIS CONNECTION WHEN & Eva $ 5
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A ехРВ £ 2x y RESISTOR
2 IZ
>
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= V HYELLOW/BLUE-TO VI IN_P4 63 64 42a P| STARTER ON LP OR NATURAL GAS PLANTS,
STATIONARY PURPLEIWHETO 3-9 © © E LP AND NATIMALCAS PLAN
LED BOARD | | | WITH AUTOMATIC CHANGE OVER, o
| CTED TO AUTOMA
ROTATING PHOTO LO < di Yo E | | | | CHANGEOVER RELAY,
— | | =
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+ + |
EXCITER U AVAILABLE SUPPLY A
Ÿ | (CUSTOMER OPTION) - +
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PICK-UP TO LOAD ‘ BATTERY
EXCITER FIELD FASO N FOL EN |
(CUSTOMER OPTION)
HEAT SINK &
FR ACTNATOR
_ MAIN FIELD
WIRING DIAGRAMS
6-9
TP-1122
END
BRKT.
STATIONARY
LED BOARD
ROTATING PHOTO
EXCITER
ARMATURE
MAGNETIC
PICK-UP
EXCITER FIELD
HEAT SINK &
FR ACTIVATOR
MAIN FIELD
OUTSIDE
REAR VIEW OF INSTRUMENT BOX & CONTROLLER DRAWER
Р
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S069 E © 380
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SEE 287804 FOR THIS CONNECTION WHEN & EOD £
REMOTE DECISION MONITOR 15 USED. © ED e SS5
Ly ZR > xX
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SB-BROWN /ORANGF-TO SB IN P5—— < ode rm
3B- GREEN /YELLOW-TO 3B IN PS—— 12335
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| WT to GA)-T0 16 IN P2—— 408 EZ
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da
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70Kw Ford/Chrysler
85Kw - 100Kw International Harvester
38, 4-wire, 277/480-volt
30, 4-wire, 120/208-volt
39, 3-wire, 240-volt
Code — 5, 7, 8
FEEDBACK CIRCUIT
A-RED(46A)-TO SOL. —
(-71-YEL. (4 GATO 71 IN PI
+
—_—_— óoy....
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Ts
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; 13- ORANGE- TO 13 IN PI-—H—M————
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b MA-BLUE- TO SIA IN PI
L
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ALSO
LO Li L2 L3 |CONNECT
TOGETHER
277 487, 241l,
480 [1012 | в 3 649
4,5,6. | 187 | 248 |369
Po 101 1 2
IF IT IS NOT DESIRED TO READ THE NEUTRAL ON
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240 VOLT, DISCONNECT
LEAD
VO FROM 12.
LO- MAY
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= Ba À L3
TO LOAD
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N- WT/BLK.-TO STARTER GROUND ————— ——
~— TN-WHT/BLX.~ TON WN PS
ANR .] BLK.— TO N IN P
j——N- WHT/BLK.- TO N IN PS
L—N-WHT/ELK-TO LW.T.
LABLE SUPPLY FOR LOW
SWITCH IN FUEL TANK
(CUSTOMER OPTION)
—N-WHT/BLK~ TO C RELAY (A GA) —
|
R-BRNJRED (6A TR SAAT
PRED (MGAXTO P IN Pt
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66- PINK/WHT.
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ph 70 -WHT/GRN.- TO SAFE G. BRKR (SEE NOTE)
pe 70-WHT /GRN. - TO 70 IN PI (M GA)
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\ J0-WHT/GRN-FROM SAFE G.BRKR (SEE NOTES)
4 - BROWN {146A TO 74 IN PR A
be Al -YEL./ GRAY (M4 GA) TD FEEDBACK CIR. TERM. Al
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RELAY
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|
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ONLY.
BALLAST
Em
70
y
TO
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_
NOTE-
ON LP OR NATURAL GAS PLANTS,
70 IS CONNECTED TO FUEL VALVE. ‘
ON LP AND NATURAL GAS PLANTS,
WITH AUTOMATIC CHANGEOVER, 70
IS CONNECTED TO NIC
CHANGEOVER RELAY.
| A ]
BATTERY
NOTE-
THE AC AND DC HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS. DETERMINE WHICH WIRES
ANO e REQUIRED AND TAPE OR SEAL ENDS TO
A ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS,
WIRING DIAGRAMS
6-10
TP-1124
OUTSIDE REAR VIEW OF INSTRUMENT BOX 8 CONTROLLER DRAWER 70Kw Ford /Chrysler
85Kw -100Kw International
Harvester
19, 3-wire, 120/240-volt
~~ Code — 6
NOTE-
THE AC AND DC HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
В
El
AND ENGINE OPTIONS. DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO HOKE
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS. €)
FEEDBACK CIRCUIT
P TL
FUSES è 7
- É 3 ENGINE
©) © ar o ATC OLPRES oF ANT E
$ 55 3 $ LOR SW. SENDER Sw. DIESEL Sw. TE TO CAMPER)
7 .
3 ek ur e SFA ь Ree
= + en ¥ - T - _
РН ЕЛЕ TO or —
Te o I3-ORANGE- TO 13 IN PI
g Ei g 2 7C-YEL /GRN.-TO 7C IN PS
a! à don. a MA-BLUE-TO MA IN' PI
IT D.C. HARNESS(230735 SEENOTE) TEL = P-RED (MGA) TO SOL. P
A | | 3 hÁ ————— 66- PINKIWHT. TO ANT-DIESEL SW—
$3 x | ie вам (A SANTO HA IN
Bl Ne sy he Al -YEL./ GRAY (4 GA) 10 FEEDBACK CIR
La RZ zz 38 | ———m—— P-RED(MGA)-TO SOL. P=-—— — ——
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xx a
Ss 52 | ISES | peop JUNCTION BOX —— P-WMT/GAN.- TO SAFE G. BRKR (SEE NOTE) ON CITY WATER
~ Г ET wd COOLED PLANTS,
AVAILABLE FOR REMOTE START SWITCH ea 5>2| З$ Е ¡[CONNECTED
OR CONTROL CONTACT ON TRANSFER PANEL. 2 258 | 33% AM “с
SEE 287804 FOR THIS CONNECTION WHEN к Eva £ _ TT
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SE-BROWN /ORANGF - TO SB IN PS5—— < c oF 23 $ a AN +
38- GREEN /YELLOW-TO 38 IN PS—— 220227 A + ол = A GREER-TO 34 IN PI
583268 PURPLE-TO 40 IN PI———
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VI-YELLOW/BLUE-TO VI IN P4 — lez 64 424 P! ON LF OR NATURAL GAS PLANTS,
VO-PURPLE/WHT-TO VOIN M4 | о ©! 70 1S CONNECTED TO FUEL VALVE.
STATIONARY 9-9 22 ON LP AND NATURAL GAS PLANTS,
LED BOARD | WITH AUTOMATIC CHANGEOVER, 70
ED. | 1S CONNECTED TO AUTOMATIC
ANS = |
| TO LOAD
dd — —= —— — — == —
EXCITER
ARMATURE
MAGNETIC
PICK-UP BAT TERY
EXCITER FIELD ANT!
HEAT SINK 8 (CUSTOMER OPTION)
FR ACTIVATOR
MAIN FIELD
WIRING DIAGRAMS
6-11
TP-1121
OUTSIDE REAR VIEW OF INSTRUMENT BOX & CONTROLLER DRAWER
70Kw Ford/Chrysler
85Kw -100Kw International Harvester
30, 4-wire, 600-volt
re. Code — 9
THE AC AND DC HARNESSES ARE UNIVERSAL.
CERTAIN WIRES INTHESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS. DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO CHOKE
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS. €)
FEEDBACK CIRCUIT Г
Р ©, Ts
§ \ J
Se E SE 3 ENGINE
© ® = © (aa) e ANTIC. OIL PRESS, LOR ANTI- TO FEE CRACK CIR.
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Ree e $ or h L TO HEUAY
: (-ORANGE" TO ES PI
| EE
MIT De GEO — rete и
£3 5 x Row (GATO 24 NN |
\ ' 8838 h ——Al-YEL./ GRAY (14 GA) TO FEEDBACK CIF. A
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SEE 26008 FOR THIS CONNECTION WHEN E || UE р - вацдет
3 e < $ wm P13 ye vy I RESISTOR
$ est 3 Ч наем | Е 5 LN 70-WHT [GRN. = TO 70 INPI (14 GA) |
z ! WA WATER TEMP ANTIC- WATER — и )
GENERATOR — 9 CM q ULEAD Hz xi $ 3 TEMP_SW. SENDER HW Sw TEMP SW. - Y R-BRN/RED(14 GA)-TO SOL. R——
SB-BROWN /ORANGE - TO 5B IN PS—— < o Ar $ 1 $ > Do
38- GREEN /YELLOW-TO 3B IN PS KE PRE: wm P12 fe vi |
E 335 x TR 2 | 34-GREEN-TO 34 IN Pi
ох > PURPLE-TO 40 IN Pi-=-———
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8 НУ £ —— se
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ETS
| : E ES /
$ = 7 E
ina |
d 8-8 + | FO-WHT/GRN-FROM SAFE G.BRKR (SEE NOTES) ——e NOTE-
Ви On LF TURAL GAS PLANTS,
ST —e I | = 1 | Wr Te AUTOMATIC CHANGEOVER. 70
.D. BOARD |
J ING PHOTO Lo Yu Y.z YL3 | | | CHANGEOVER RELAY.
_ a | й
EXCITER PA pp 1
{{FOR ALARM HORN KIT = +
CUSTOMER OPTION)
Ta TO 1 | BATTERY
TO LOAD AVAILABLE SUPPLY FOR LOW
EXCITER FIELD | CUSTOMER one)
HEAT SINK &
MAIN FIELD
WIRING DIAGRAMS
6-12
TP-1123
OUTSIDE REAR VIEW OF INSTRUMENT BOX & DRAWER
FUSES
МОТЕ--
USED ON VARIOUS GENERATOR
THE AC. AND D.C. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES
ARE NOT
APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO -
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS,
60-125Kw White-Hercules
(w/battery charging
regulator in alternator)
39, 4-wire, 120/240-volt
Code — 0
N——
| ENGINE
| DC. HARNESS 7 =~
7 (291094 SEE NOTE ABOVE) — Y | | 7 \
Fa. 4
8 JUNCTION BOX T
AVAILABLE POR REMOTE START SWITCH N e 5 2 TO-WHT /GRN- TO FUEL PUMP LOW OtL Y +
OR CONTROL ACT OB TRANSFER PANEL. e N-WHT - — | PRESSURE SW
cz Wx /BLK-TO STARTER GRD
SEE 287004 POR THIS CONNECTION WHEN $ = 70- WHT, /GRN. (14GA)- TO 70 IN Pt INJECTOR
REMOTE DECISION MONITOR IS USED. À y 8 ; A
of e 13 - ORANGE - TO 13 IN PI
5 ® |8 + Bp 41A- BLUE - TO 414 IN PI :
79 zu y z : J C-YEL/GRN-TO XC IN PS——) oy PRESSURE ANTIC |
К, R © <S —+— th
GENERATOR & © 3 : / E
- e 5 e e > Ta
—— 58- BROWN /ORANGE - TO 5B IN P5 —o L ë AS A y 33 3 T их
| — 38-GREEN/YELLOW- TO 38 IN PS5—— " N Rg 3 ме
(= SEUNINSOLATED WIRE -TO $2 N PE psf 3 7 | TENDER Y
¡Y —e-BLACK (226A)-TO 2 IN P2 1 25 Li HORN SW
, ‚ 1S-WHITE (22GA)-TO I6 IN P2———— $ € E (CUSTOMER OPTION) FUEL
END BRK T | Y=--24-RED (2264)-T0 24 IN PE—— IES 3 SAFE PUMP =
= : - o = +
= Е? : : | BREAKER Бы sds TEME ow.
REP e 7 ] & ,
2
LL LL = +; =
—— TI- BLUE/RED-TO TI IN P4 > a ANTIC
es { “TO T2 IN Ré — Zz 3 8 N-WHT /BLK -TO INJECTOR PUMP ———————, HWI SW
Ne T3- RED/ORNG-TO T3 IN M4M—0 3 = $ Y N- WHT./BLK-TO C RELAY PEA
§ Ё ze” 2 —7N-WHT/BLK-7N IN PS | A >
24593 || ERTTACENTZ RESTE
z< ea CS BLUÉ/WHT.-T0 5 IN PS EN
e 3 = — 34 CREEN TO 34 IN PI Æ
| $ y 20 - PURPLE TO 40 IN PI cto ,
a — 35-YELLOW- TO 35 IN PI EN
2 2 3; — 8+ -RED (I0GA)-TO B+ IN P5
Y — Dow AN (uc 3-0 SAFE © BRK'R,
0D | 5255 1 == ss re ‘
À —— P-RED (MGAJ-TO P IN PI P-RED (14GA.)
| CTI C12] C13 + 29 ol +—P-RED (GA) TO ALARM
RM, BLOCK P-RED (UGA:
Ne H- GRAY (4GAY-TO H IN Ps | | | (Usa)
h —— 108-BAOWN/WHT- TO 108 IN PA | |
Nr VI-YEL/PINK-TO V3 IN M4 |1 S-BLK/PINK (4 GA)
| | SOL.
N — 28-WHT/PINK-TO 88 IN Fa ' | | |
| V2-OANG/ RED — TO VZ IN AA | |! ALT.
Vi-YELLOW/ BLUE-TO Vi IN P4 | | | 8
IN FIELD Na VO -PURPLE/ WHT.- TO VO IN P4 || | | 2 XX STARTER J
| | = 7 |
НЕАТ ane e TR ACTIVATOR + Li M2 M3 | 3 = я. —
| Y O] L —
E PORN KIT a МОТЕ-
EXCITER FIELD Il MER OPTION 12-V owiY DA MATER VALVE USED ON
EXCITER ARMATURE Y NE PLANTS ONLY.
LOAD AVAILABLE SUPPLY FOR LOW
ROTATING PHOTO TRANSISTOR BOARD SWITCH IN FUEL TANK
(CUSTOMER OPTION) A}
STATIONARY L.ED. BOARD
+
BATTERY
WIRING DIAGRAMS
6-13
TP-1118
OUTSIDE
REAR VIEW OF INSTRUMENT BOX & DRAWER
FUSES
NOTE -
CIRCUITS.
60-125Kw White-Hercules
(w/battery charing
regulator in alternator)
30, 4-wire, 277/480-volt
30, 4-wire, 120/208-voit
30, 3-wire, 240-volt
Code — 5, 7, 8
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
, ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
L DC HARNESS
(291091 SEE NOTE ABOVE) |] | | a |
Y JUNCTION_BOX
AVAILABLE POR REMOTE START SWITCH z Na <:
e 3
OR CONTROL CONTACT ON TRANSFER PANEL. Aw = 38
SEE 287804 POR THIS CONNECTION WHEN 45 zz
REMOTE DECISION MONITOR IS USED. Es a Ne a
“a e e
vie & 3 $ © ; a у
GENERATOR > cfg e $ Е
f SB-BROWN ORANGE-TO SB IN P5——! zP.p P 22 *
-—38-GREEN YELLOW-TO 38 IN P5 — RÍO Y Da $
[e eses A]
pr * - | L'or À =
[—16-WHITE - (22GA) TO 16 IN Р2——+-+- Loo LY == .. O HORN SW
24RD (226A)- 10 24 N P2— 5556 $ (CUSTOMER OPTIONS)
AER setef ME
vo- “TD VO IN PAU ELIT e GUARD
VI- YEL/ BLUE - TO VI IN Pa —" ET Sop BREAKER
V2-ORNG. /RED- TO V2 IN Pa) RER -
уз. УЕСУРИЧК ТО va IN Pa — | | | | | ] ]
BB WITZ PINK. TO 8B IN P4—
12 LEAD
STATOR
FOR GENERATOR
CONNECTIONS
SEE CHART
BELOW
Mm
-
U
H-GREY-(14 GA) —
TI-BLUE/RED-TC TI IN Pa
T2-ORNG./BLK-TO T2 IN PA
T3-RED/ORNG.-TO Ta IN Pa
m
; A
er
LL
EXCITER ARMATURE
MAIN FIELD
HEAT SINK 4 FR ACTIVATOR
MAGNETIC PICK-UP
EXCITER FIELD
“o CONNECTION (on on 3 "
"YT!
LOAD
&
ed
$
+
5
63- BROWN —63 IN PI
«фа —t- ———————
FUEL
| 70-WHTAGRN = MP
MJECT PUMP =
pa Ne WHT./BLK-TO REL AY
70-WHT./GRN-TO FUEL PUMP
N-WHT /BLK-TO STARTER GRO.
то - WHT./GAN. (4GA) - TO 70 IN PI
13 - ORANGE - TO 13 IN PI
41A-BLUE -TO 4IA IN PL
7C-YEL/GRN-TO X IN PS
— 7 WET. /BER TO INJECTOR
ENGINE
=
PUMP oe
}—-7N-WHT/BLK.- 7N IN PS5
ra N-WHT/BLK-TO N IN PS
be N-WHT/BLK -TO N IN FI
OIL PRESSURE
SEN
LOW OIL
PRESSURE SW
id
| INJECTOR
PUMP
hb £-BLUE/WHT.-TO 5 IN PS
h— 34 -GREEN- TO 34 IN PI
AZA-WHITE- TO 42A(14GA)-IN P2
64-WHT/YEL.- TO HORN SW.
p-rED (14GA)- TO SOL P
hme P-RED
LA GA
TERM
AVAIL
ALARM HORN KIT
CUSTOMER OPTION
li —— — еек = === сев = —
= — === == == — — —
«щ- — — — — — ——
53
Ё
5
«
BLOCK
| S-'BLK/PINK (4 GA)
P-RED (14GA)
|
STARTER
ROTATING PHOTO TRANSISTOR BOARD LO Li (2 | 3 CONNECT |
STATIONARY L.E.D. BOARD TOGETHER
- 277, 487, 2811,
9-4 WIRE “Zeo|s.0.2| 1 | ea | 3 [eS
- |
30 4 WIRE 708 14,56, 1 1,7 | 2,8 |3,9
30-3 WIRE-240 V| 91h12
IF IT S NOT DESIRED TD READ THE NEUTRAL ON
STRAIGHT 240 VOLT, DISCONNECT LEAD VO FROM 12
AVAILABLE SUPPLY FOR LOW
FUEL SWITCH IN FUEL TANK
(CUSTOMER OPTION
BAT TERY
P-RED (14GA)
NOTE~
WATER VALVE USED ON
CITY WATER COOLED AND
MARINE PLANTS ONLY.
Le
WIRING DIAGRAMS
6-14 |
TP-1120
OUTSIDE REAR VIEW OF INSTRUMENT BOX 8 DRAWER
FUSES
AVAILABLE FOR REMOTE START TCH
OR CONTROL CONT
SEE 297804 FOR THIS CONNECTION
ACT ON
8
fp
REMOTE DECISION MONITOR IS USED. 5 2
és |
<8 ZE E Е
Sg 2
GENERATOR & JRE" ©
SB-BROWN ORANGE- TO 56 IN P5— 2e Pp
138 GREEN YELLOW- TO 38 IN PS EE
IS ONS ATED WIRE-TO SZ IN P27 REVS
| f—2-8LACK (22GA) -TO 2 IN P2 ——+—+— pres
| P-— 16-WHITE (22GA) - TO 16 № Рен y
!|-—24-RED (22GA)-TO 24 IN P2——iy— 8 z 53 =
£55: °
RR RR ||,
ul D.C. HARNESS
NOTE -
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS,
60-125Kw White-Hercules
(w/battery charging
regulator in alternator)
19, 3-wire, 120/240-volt
Code — 6
1 (291091 SEE NOTE ABOVE) 117)
SWI
TRANSFER PANEL.
WHEN
LL
3g
?
>
zZ
y
P
>
>
A
z
3
e
2
5
y
LE
(
|
— a
Nee T1- BUJE /RED=TO TI IN P4
N T2-ORNG/BLK-TO T2 IN P4—
B- BLACK-TO 8 IN P4
CUSTOMER OPTION)
Na — H- GRAY (L4GA) - TO H IN P4—
Ne 10B~ BROWN/WHT= TO 108 IN PA
MN V2-ORNG/RED-TD V2 IN P4
Mae BB-WHT./PINK- TO 8B IN P4
\ ‘ N-— Vi< YELLOW/BUVE-TO МОМ РА
IN FIELD VO- PURPLE/WHT.- TO VO IN P4
HEAT SINK & FR ACTIVATOR io Ll
MAGNETIC PICK-UP
EXCITER FIELD
EXCITER ARMATURE
ROTATING PHOTO TRANSISTOR BOARD
STATIONARY L.E.D. BOARD
ENGINE
1 / \
JUNCTION BOX ]
70-WHT./GRN-TO FUEL me | LOW OIL
N-WHT /BLK-TO STARTER GRD. | PRESSURE SW INJECTOR
70 -WHT /GAN. (14GA)- TO 70 IN PI р
13-ORANGE- TO (3 IN Pi PUM
41A- BLUE - TO 414 IN PI
IC -YEL/GRN - TO 7C IN PS — OIL PRESSURE
SENDER
WATER TEMP
HORN SW.
FUEL
PO-WHT/GAN — MP F
INJECT. SC HIGH WATER
7 TEMP_ SW.
N
a
z =
= i =
> e ANTIC.
z 3 8 N-WHT /BLK = TO INJECTOR PUMP — HWT Sw.
= $ = — N- WHT./BLK-TO C RELAY Za
< —— A
zp ? e b—7N -WHT/BLK-?N IN PS NAF
m N PA e N-WHT/BLK-TO NIN PS LOW WATER
таз CS NWHT/EUK-T0 N IN PI TEME. SW.
2 о тол — S-BLUE/WHT.-TO 5 IN PS5 AT
5 TI - }— 34 -GREEN- TO 34 IN PI tof
is — 36 VEL Low-T0 38 IN Pi FL
1 1 from = Pf —
2 2 84 h— B+ - REDCIOGAJ-TO B IN PS
SEEN is Eten >
m 70 WW - 3 "А.
| 1 || ЕВЕ ENS _
P —P- -
63 64 42A a INT P- RED (MGA)
|9 ФФ h —P-RED (4 GA) TO ALARM
По TERM BLOCK P-RED (MGA)
bp
boy | N
BEE S-BLK/PINK (MGA) SOL.
| | | | x ALT.
| — ©
Ly || E - STARTER
| pol] $ 7 —
3 —
L2 | | 1] z 5 Р и
spades sen NOTE”
CUSTOMER OPTION t2-VonLr и WATER VALVE ON
ug CITY WATER COOLED AND
FUEL SWITCH IN FUEL TANK
AVAILABLE SUPPLY FOR LOW
{CUSTOMER OPTION
BATTERY
MARINE PLANTS ONLY.
WIRING DIAGRAMS
6-15
TP-1117
OUTSIDE REAR VIEW OF INSTRUMENT BOX & DRAWER
60-125Kw White-Hercules
(w/battery charging
regulator in alternator)
39, 4-wire, 600-volt
Code — 9
NOTE-
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
FUSES ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS
MAIN FIELD
HEAT SINK & FR ACTIVATOR
——MAGNETIC PICK-UP —
NOTE-
WATER VALVE USED ON
| AVAILABLE SUPPLY
FOR ALARM HORN KIT
CUSTOMER OPTION
{ La CITY WATER COOLED AND
Es SUPPLY FOR LOW MARINE PLANTS ONLY.
—
|. \
y
| | ENGINE
_ DC HARNESS \ /
(291091 SEE NOTE ABOVE) ] | h
~~
3 JUNCTION BOX | | [ |
e 87808 TOR THIS CONNECTION MEN | DE 25s e 2 N-WHT/BLK-TO STARTER GRD PRESSURE SN INJECTOR
REMOTE DECISION MONITOR IS. USED 2 3 8 w e | 70 -WHT./GRN (14GA)- TO 70 IN PI
" EA 2 e 3 13- ORANGE- TO 13 IN PI PUMP
Ra ok § a >. AlA- BLUE - TO 41A IN PI =
a r zz 8 X-YEL/GRN -TO X IN PS OIL PRESSURE
2 E yA © 2 SENDER
GENERATOR Pue 8 © ee E =
38-GREEN/ YELLOW-TO 38 IN PS—— 9 a Sh 3
— 2 UNINSOLATED” WIRE-10 52 IN P22 Eliza! ES OA WATER TEMP
{ f—2-BLACK(22GA)-TO 2 IN P2 3 zz | НН R
| fmm 46-WHITE (22GA) -TO 16 IN P2-—-— tr 0 Fée ALARM 5 a
END BRK'T | —24-RED (2264) -TO 24 IN P2— + PzPrp HORN | aa FUEL
ин * | CL ОЛО ОЛЕОЛЕ 1 LZ A ER SW. 4 1) | 70-WHTAGAN — PUMP =
e TRY CUSTOMER JECT PUMP = HIGH WATER
Ses? OPTION : TEMP_SW.
$ 1 E EEN &
& z SAFE- z
> ht GUARD x $ ANTIC =
D BREAKER a .
Е e 2 £ rf = 3 8 | N-WHT /BLK =ТО INJECTOR PUMP HWT SW.
8 i, RRR = $ y — N- WHT./BLK-TO C RELAY 7 №
. a 1
$ ze” 2 H—7N-WHT/BLK-7N IN PS Ve =
T1-BLUE/RED-TI IN Pd — o
Z = , O TN a 2 `` Bo ha NN VAT /BLK-TO NN PS LOW WATER
T3- RED/ORNG-FO T3 № РА ! J u $ hr N-VHT/BLK-TO N IN PI - ТЕМЕ. SW.
zl EZ >— S-BLUE/WHT.-TO $ IN ES ZN
$ 5 tI = h— 34-GREEN- TO 34 IN PI +
> Y h—40- PURPLE -TO 40 IN FI #14
| Por of b— 35-YELLOW=TO 35 IN PI FN
2 3 Ñ a — B+ -RED (I0GA)-TO Ben PS
ha 70-WHT/GRN (14GAYTO SAFE G. ВЕКЕ. Mad
h— 70-WHT/GRN.- TO SAFE G. BRKR. (14GA) TT
ESS Eee
63 64 42A —P- -
—enotoo. TO PIN Pi P-RED (14GA)
_ Le ++ -—P-RED (14 GA }— TO ALARM
Roto da TERM BLOCK P-RED (4GA) e
| 1 | | | | 12
+
| | S-BLK/PINK (14 GA) SOL
“ | 1 | ALT.
Й | | ,
1 —]
pH =
bop bad 7
JL 10
1
|
STARTER (С) |
/ и
——
EXCITER FIELD
\——— EXCITER ARMATURE
—— ROTATING PHOTO TRANSISTOR BOARD
STATIONARY L.E.D. BOARD
FUEL SWITCH IN FUEL TANK
(CUSTOMER OPTION) 4
BATTERY
WIRING DIAGRAMS |
6-16 TP-1119
OUTSIDE REAR VIEW OF INSTRUMENT BOX 8 DRAWER
100Kw White-Hercules
(w/separate battery
charging regulator)
39, 4-wire, 120/240-volt
Code — 0
NOTE-
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
FUSES ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
DE me
ENGINE
L TC HARNESS Va > N
Y | (291054 SEE NOTE ABOVE) | | | @ | | 7 \
—
3 JUNCTION BOX
‘ 3 En | с
AVAILABLE FOR REMOTE START SWITCH - - LOW OIL
CONTACT ON TRANSFER PANEL. Bw zo E. = feo. START ca CRD PRESSURE SW
SEE 287804 FOR THIS CONNECTION WHEN 9 = 70-WHT /GAN. (4GA)- TO 70 IN PI INJECTOR
REMOTE DECISION MONITOR 15 USED. és 9 y $ 13- ORANGE - TO 13 161 Pl PUMP
> & $ © Рр of MA BETO 41A IN e | =
Vin Zup Z ! ! 7C-YEL /GRN TO 7C IN OIL PRESSURE ANTIC
< e 3 = : g SENDER | Lop
GENERATOR у” © oo o | < \
58-BROWN /ORANGE - TO 58 IN P5 L = As y 2 z 7 ия
38-GREEN/YELLOW- TO ЭВ М Р5— N es 3 y
(SEURINSOLATER WIRE E TN E seis | TENDER
| 2 BLACK (22GA)-TO 2 IN P2 “СВЕ LI __ 8 HOËN SW
END BRKT 16 wh TE (22GA)-TO 16 IN P2 § ES E yu (cs OPTION) FUEL
24-RED (22GA)-TO 24 IN P2
— HEE {2264):T0 24 N PE —— Spee 3 SAFE- owen f YU =
= $ = $ $ © pe INJECT PUMP = HIGH WATER
— ; 4 я A T "
MD 7
ke Ti- BLUE/RED-TO TI IN P4 и a АМТ,
— TORN BL TO T2 IN P4 Z 3 8 | N-WHT /BLR = TO INJECTOR PUMP HWI SW.
Me T3-RED/ORNG-TO T3 М 4 — 6 ё $ < HN- WHT /BLK-TO C RELAY ‚ \
Ë ze” я hee TN- WHT /BLR = TN IN PS | d / +
ь "na T
. : e Ро — N- VAT /BLA-TO N IN PS — N-WHI /BLM-TO STARTER GRD LOW WATER
g u 3 h— MAT /BLa -TO N INP TEME, SW.
2X = 3 h— S-BLUE/WHT -TO 5 IN PS их
$ £ 5 — 34-GREEN=TO 34 IN Pi
| E >—-40- PURPLE -TO 40 IN PI мо
is: Ea a Nr —
y h.—. 70-WHT /GRN (4GAY- TO SAFE G. BRK'R.
—70-WHT/GRIN -TO SAFE G BRK'R. (14GA)
[ 1 h—71- YELLOW {IGA )Y-TO лом РЕ) |
» С D d ) ( D 63 64 42A P [5 2eoçoce D PIN Ps
tp QED (MGA PIN PI
ст pep Le 9 2-9 .— P-RED (AGA) TD ALARM | P-RED (MGA)
10 TERM BLOCK P-RED (MGA)
| NN H- GRAY (MGA)-TO H IN PA LI 4 à
; Na 10B- BROWN/WHT- TO 108 IN P4 ,
| \ Ne v3-vE1/PNK-TO V3 IN P4 | ll, 5-BLK/PINK (14 GA) SOL.
4 \ Nm B6- WHTL/PANK-TO 88 IN Pa | Na | N VODAGE
Na Ne V2-ORNG/RED — TO VE IN E | | x - REG ALT.
a N__— VI-YELLOW/ BLUE -TO VI IN P4 l 1 4 1 —— €
MAN FIELO Ne VO - PURPLE / WHT.— TO VO IN E | | E = STARTER
HEAT SINK & FR AGTIVATOR Fr U 12 li | | | $ = = ! — __/
MAGNETIC PICK-UP 1 Ti 1 0
|| AVILABLE SUPPLY ya NOTE-
FOR ALARM HORN KIT ————— |]——
EXCITER FIELD jee OPTION A WATER VALVE USED ON
Lege CITY WATER COOLED AND
EXCITER ARMATURE 7
LOAD AMAILABLE SUPPLY FOR LOW | MARINE PLANTS ONLY.
ROTATING PHOTO TRANSISTOR BOARD FUEL SWITCH IN FUEL TANK
(CUSTOMER OPTION) A
STATIONARY L.E.D. BOARD + -
BATTERY
WIRING DIAGRAMS
6-17
a 100Kw White-Hercules
(w/separate battery
charging regulator)
30, 4-wire, 277/480-volt
39, 4-wire, 120/208-volt
39, 3-wire, 240-volt
Code — 5, 7, 8
NOTE -
FUSES THE AC. AND D.C. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
| ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS
ENGINE
DC HARNESS /
(201054 SEE NOTE ABOVE) = | | | N || f | Y
3 JUNCTION BOX
=
AVAILABLE POR REMOTE SYART SWITCH E Sy 5 20-WHT ASAN-TO FUEL PUMP | | LOW OIL.
See TATRO4 FOR THIS CONNECTION WHEN Ge =z 3px N-WHT/BLK-TC STARTER GPD PRESSURE SW T
REMOTE DECISION MONTTOR IS USED $ nN 3 70 WHT /GRN (14GA) - TO 75 IN PI INJECTOR
- En Ч a 13-ORANGE- TO [3 IN PI PUMP
= 2 Р e Р 41A- BLUE - TO 414 IN PI =
45 NO $ © E 7C-VEL/GRN-TO X In PS OIL PRESSURE LT ANTIC
3 z S Sz : < SENDER 1. LOP
GENERATOR S pR32e BE € e
S8-BROWN ORANGE-TO SB IN PS —— == P Y = + or >
= +
38-GREEN YELLOW-TO 38 IN PS5 — ROA q + 3 = -
7 UNINSULATED. WIRE TO SZ NA $53 ae
CES EN Se ma SEE bom |
r—24:RED (226A)-TO 24 IN P-——47- LEE 8 (CUSTOMER OPTIONS) FUEL
: B-BLACIC-TO В № Рен LENS _ tan PUMP
1 RELY BUIE-TO 11 IN 64 ——— = CEE ; SAFE ECT PUMP =
BATE Y eh FREE Ym vom 55
- 11 va
_/RED-TO V2 IN Pa— ge RR \ м
V3-YEL /PINK- TO V3 IN P4 т
N - TO 108 IN P4-— > 7
7 PINK-TO 8B IN Pa— | A $ о
~~ Tor ORNG [BLK TO T2 № м —— ES 8 -—N- WHT /BLK ~T0 INJECTOR PUMP
- $ T3-RED/ORNG.-TO T3 IN Ра — à $ < H— N- WHAT /BLK-TO C RELAY
12 L > ze? TN WHT/BLK - TN IN PS
STATOR $ = y e ha NWT /B1 4- TO NON PS — N-wHT BLK -TO STARTER GRD
FOR GENERATOR $ dd —— N-WT /ELK-TO N IN Pi
CONNECTIONS À = DES a BLUE /WHT 10 5 In PS
po * - 4 IN
SEE CHART $ ï $ e —40- PURPLE -TO 40 IN PI
m Ta [— 35-YELLOW- TO 35 IN OF
- à : 8 à — B+ -REDCIOGA TO E: IN PS
1111 | ERC Ce ия
h. 70 - WH К
[ ] I 7r- YELLOW (14 GA} 70 MIN Pi (AGA)
9 4 YU 63 64 42A P немое, -10P WPS
Lo | — (ac AAA (
+ - LARM P-REO (KMGA
ЮВ), 2 | 1 41a M BLOCK RE )
I Li
1 Y Lo : I | | | | S-BLK/PINK (14 GA) +— — ; ve "
\ , || |! ! . VOLTAGE ALT
LO CONNECTION (CUSTOMER OPTION boy | a REG
| S
MAIN FIELD u A In I | E F| STARTER
HEAT SINK & FR ACTIVATOR | | | | : | = —
MAGNETIC PICK-UP | y 1 { € —
; Y Y Y Y | ARILABLE SUPPLY yan | NOTE-
ALARM HORN —_— —— |
EXCITER FIELD USTOMER OPTION и WATER VALVE USED ON
LOAD й Lae CITY WATER COOLED AND
EXCITER ARMATURE TE Tron on MARINE PLANTS ONLY.
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6-18
AVAILABLE FOR REMOTE START SWITCH
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SEE 287804 FOR THIS CONNECTION WHEN
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NOTE-
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ARE NOT
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(291054 SEE NOTE ABOVE) a
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6-19
OUTSIDE REAR VIEW OF INSTRUMENT BOX & DRAWER
100Kw White-Hercules
(w/separate battery
charging regulator)
39, 4-wire, 600-volt
Code — 9
NOTE -
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
FUSES ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
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REAR VIEW OF METER BOX 8 CONTROLLER DRAWER
NOTE-
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130 &
150Kw John Deere
38, 4-wire, 120/240-volt
Code — 0 (12-Volt)
THE AC. AND D.C. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
OPTIONS. DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
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6-21
TP-1134
REAR VIEW OF METER BOX 8 CONTROLLER DRAWER 1 25 & 1 75 Kw J ohn Dee re
39, 4-wire, 120/240-volt
Code — 0 (24-Volt)
NOTE-
THE AC AND DIC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNEC TIONS AND SHORT
IRCUITS,
FUSES
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6-22
REAR VIEW OF METER BOX 8 CONTROLLER DRAWER
125-175Kw John Deere
39, 4-wire, 277/480-volt
39, 4-wire, 120/208-volt
30, 3-wire, 240-volt
NOTE- | Code — 5,7, 8
THE AC. AND D.C. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS. DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNEC TIONS AND SHORT
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6-23
TP-1136
REAR VIEW OF METER BOX 8 CONTROLLER DRAWER
125-175Kw John D
19, 3-wire, 120/240-volt
Code — 6
NOTE-
THE AC AND D.C. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS. DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
eere
|
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MAGNETIC PICK-UP i YF i
EXCITER FIELD
EXCITER ARMATURE
ROTATING PHOTO TRANSISTOR BOARD
STATIONARY L.ED. BOARD
WIRING DIAGRAMS
6-24
TP-1133
REAR VIEW OF METER BOX 8 CONTROLLER DRAWER
NOTE -
THE AC. AND D.C. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS. DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNEC TIONS AND SHORT
125-175Kw John Deere
30, 4-wire, 600-voit
Code — 9
EXCITER FIELD
EXCITER ARMATURE
ROTATING PHOTO TRANSISTOR BOARD
STATIONARY LED BOARD
CIRCUITS,
FUSES
e ENGINE
HIGH WATER LOW WATER ANTIC WATER TEMP N
TEMP SW. TEMP SW HWISW SENDER
soma yy
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TP-1135
OUTSIDE REAR VIEW OF INSTRUMENT BOX & DRAWER
FUSES
AVAILABLE FOR REMOTE START SWITCH OR
CONTROL. CONTACT
Dwe. 287804 FOR TH
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WIRING DIAGRAMS
6-26
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PA
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END BRKT.
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WIRING DIAGRAMS
6-27
OUTSIDE REAR VIEW OF INSTRUMENT BOX & DRAWER
РА
AC PLUG
FUSES
DAD
NOTE -
A
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WIRING DIAGRAMS
6-28
OUTSIDE REAR VIEW OF INSTRUMENT BOX & DRAWER | 250Kw Allis-Chalmers
39, 4-wire, 600-volt
Code — 9
NOTE-
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6-29
OUTSIDE REAR VIEW OF INSTRUMENT BOX € DRAWER
P4
AC PLUG
FUSES
190-260Kw Cummins
38, 4-wire, 120/240-volt
Code — 0
NOTE—
THE AC. AND DC. HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
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BATTERY
WIRING DIAGRAMS
6-30
TP-1138
OUTSIDE REAR VIEW OF INSTRUMENT BOX & DRAWER
190-260Kw Cummins
39, 3-wire, 240-volt
39, 4-wire, 277/480-volt
39, 4-wire, 120/208-volt
— Code — 5, 7, 8
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|| -RED/BLUE-TO IN Pa STI 8 SAFE
у IN Pa— = $ == GUARD ANTIC
=== LC VI—-YEL/BLUE—TO WI IN Pa— LL be | BREAKER HW.I. SW.
p V2-ORNG/RED-TO V2 IN P4— Р.Р Е = NOTE— A TP
) V3-YEL/PINK-TO V3 IN P. WATER VALVE USED OM
- ¡08-BRN/WHT.-TO 108 IN Pa—h >, < WATER CITY WATER COOLED AND Г < —
--8B-WHT/PINK-TO 88 IN Pa— in 4 VALVE. MARINE PLANTS ONLY 7 dr
TI-BUJE/RED— TO TI IN P4 — кот © © 7 WATER TEMP.
$ T2-ORG/ELK. T5 T2 IN РА — > $ z 2 70=-WHT./CRN (4 CA)TO SAFE G. BRK'R. o Ta DER
< T3I- RED/ORS.— Ti T3 IN РА о 2 « ©
\ 12 LEAD 3 | ero
STATOR 8 2 ol — m-WWT/8Lx-70 7m ¡NS N , | +=
FOR GENERATOR =! IO un _ WHT/BLK LOW WATER
CONNECTIONS oT Zu q NT TT N Ne PI = TEME: SW.
SE | $ T I = hÁ—3a-GREEN — TO 34 IN PI
Y] = $ © -— 40-PURPLE-TO 40 IN PI
Ll «= h— 5 -BLUE/WHT.-T0 $ IN PS ~~
© Ÿ% à h 35-YELLOW-TO 35 IN PI
SON * h— B+—RED (10 CA)TO 3+ INP
0 —T70-WHT/CRN TO SALE ©. BAIR. - (la GA)
121 ios 6 3Г 2] › | ] N YELLOW (14 GR) 10 71 1 Pi
Ó 63 64 42A P RED de cm EIN PS — RED (MGA)
Iva ve RED (14 GA) - TO P 114 PI RED (14 GA
Tie e TT RS (AN ie AE
. | | =
1.1 o Lo q RELAY °F
| Е
\_ PIE LO CONNECTION (CUSTOMER OPTION) | | | T
MAIN FIELD to [ui №2 |L3 | |
HEAT SINK & FR ACTIVATOR ol | |, | 7
MAGNETIC PICK-UP | i { i и
| | Г AVAILABLE SUPPLY
EXCITER FIELD LOAD USTCUER м OPTION
EXCITER ARMATURE _
GENERATOR CONNECTIONS AVAILABLE SUPPLY FOR LOW
ROTATING PHOTO TRANSISTOR BOARD о Li Lo L3 cone FUEL SZ/1TCM IN SUEL TANK
NNE CUSTOMER OPTION
STATIONARY LED BOARD L TOGETHER { ) + -
277 447,649
3ф-4 WIRE ““Zeo 151012 | 1 ae |a >” BATTERY
- 20
30-4 WIRE 7208 14,5,6. 1,7 | 2.8 13,9
30-3 WIRE—240 10.1112
FITIS NOT D:SIRED TO READ THE NEUTRAL ON
STRAIGHT 240 VOLT, DISCONNECT LEAD VO FROM 12
WIRING DIAGRAMS
6-31
TP-1140
OUTSIDE REAR VIEW. OF INSTRUMENT BOX 8 ORAWER
NOTE—
190-260Kw Cummins
19, 3-wire, 120/240-volt
Code — 6
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
AND TAPE OR SEAL ENCS TO
ENGINE
MAIN FIELD
HEAT SINK 4 FR ACTIVATOR
MAGNETIC PICK-UP
EXCITER FIELD
| EXCITER ARMATURE
ROTATING PHOTO TRANSISTOR BOARD
STATIONARY LE.D BOARD
Me SO -WH T/PINK- TO 8B IN P4
Na H-GRAY (4 GA) —TO H IN TA
N— J0B-BROWN/WHT.—TO 108 IN Pa
Nu V2-ORNG/RED-TO V2 IN P4
Ne VI—YELLOW/BLUE-TO VI IN PA ——
NN VO-—PURPLE/WHT.-TO VO IN P4
—
| OIL PRESSURE
TO-WHT /GAN. (14 GAJ-TO 70 IN Pi—-—-
IC-YEL/GRN.—10 TC IN PS
4 14-BLUE- TO 414 EN PI
SUPPLY |
HORN KIT
ION
р Mi
[rot aa
| USTOMER OPT
AVAILABLE SUPPLY FOR LOW
FUEL SWITCH IN FUEL TANK
| (CUSTOMER OPTION)
Pa] JO-WWL/GRN. (m4 CAYO SAFE
1I-ORANGE —TC 13 1N Pi
po IN=WHTYBLK-TO TN IN PS
N WHT/BLK.
hee N=WHT/BLK=TO N IN PS
—N-WHT/BLK-TO N IN PI
INJECTOR
ANTIC.
LES.
NY, >
HIGH WATER
TEMP SW
ANTIC.
HIT. SW.
USED ON
CITY WATER COOLED AND
WATER MARINE
PLANTS ONLY.
G. BRCR
Co
(7%
je 34 =GREEN—TO 34 IN PI
— 5 - BL —T0 5 IN P5
UE/WHT,
br 35-TELLOW-TO 35 IN PI
hee B 4 =RED (10 GAI-TO B+ IN PS
be TO~ WH T/ =10 SAFE
G, BRKR. - (14 GA)
70- ,
ve LOW E GAJ—10 71 IN PI
PA й
GA)=TO P IN PS
RED (14 GA)
ED
“RED (14 GA) -TO P tN PI
FUSES ARE NOT REQUIRED
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS.
D.C. HARNESS
(290734 SEE NOTE ABOVE) y ? Y
AVAILABLE FOR REMOTE START SWITCH A
OR CONTROL CONTACT ON TRANSFER PANEL. $ JUNCTION BOX
SEE 237804 FOR THIS CONNECTION WHEN me 8 1
REMOTE DECISION MONITOR IS USED. Ve & 33
ui т т Te y
zg No SES
& > A y o
2 e ee 2%
us м т - "
«© = $ $ =
= z5 d 2 << $
GENERATOR © ve 2 => zz >
@ SB- BROWN / ORANGE -TO 58 IN P5—— ze ge ST :
38-GREEN/ YELLOW -TO 38 IN PS—— | 2335 3 aa q
= = == == == == == == — == оч di —— ——— —— Pe = | ‘
S2-UNINSULATED WIRE -TO S52 IN F2 Na
— ¿NAC (G2GA) TO 2 IN cm eR & oe
— 16- WHITE (22GA) -TO 186 INN P2———— > zzz S Ld HORN SW.
END BRICT —]—] — Зое ее бе се неон = == = == — — = yo 5 5 < 5 3 (CUSTOMER OPTION)
Ем ева. Ea
= SII b SAFE
' SIZES T GUARD
zz | |8
2 = z :
о © Г. бе
о, aa? | BLUE /RED-TO TI IN PA cg Z J
T uw No———TI2-ORANGE/BLK-TO T2 IN PA 2 lI «< $
x J n 2 so
ЗЕ SES
* o i
De tits
© = = > E =
т Е
E z 5
+ ' < ©
= Na
o O | EZ)
CTI
RED (14 GA) =TO ALARM
TERM. BLOCK
BATTERY
RED (14 GA)
FIELD 3D
RELAY
‘ 2
WIRING DIAGRAMS
6-32
TP-1137
ENC BRKT.
Mo
OUTSIDE
REAR VIEW OF INSTRUMENT BOX & DRAWER
AC PLUG
NOTE—
"AVAILABLE FOR REMOTE START SWITCH
OR CONTROL CONTACT ON TRANSFER PANEL
SEE 287804 FOR THIS CONNECTION WHEN
REMOTE DECISION MONITOR IS USED. —
CERTAIN WIRES
“
mina
FUSE E NOT REQU
(SA) (5) CIRCUITS,
L
\
DC. HARNESS
97— YY ( | (290734 SEE NOTE ABOVE)
8 $ JUNCTION BOX
“< +
E 3% E
28 pg" of
a 5 zz
= at +
GENERATOR = | $ ap ‚+
58-BROWN /ORANGE-TO 58 IN PS ——] g $ 45 бло
3B-GREEN /YELLOW-TO 38 IN PS — adil : E —
(ES RNSULATED WiRELTO SN PR alza ç = )
"o > - — + о >=
Y— I6-WHITE 22 СА. ~-TD u No
| —2a“RED 2264 -10 24 N EU ezpE ALARM | ae
tfezz----------------- > > Age? HORN mm
‘| $ nez! SW. 4 Л)
‹ Р <e 359 CUSTOMER
= - 1 == OPTION
$ SELEO
S 55538 GUARD 5
= Е a +331 BRÉAKER z
. = . я, RERR |
À A = ARM. Е
© > N—Ti=BLUE/RED--TI IN РА
5 x pr “TO 12 IN P4-
o “T NG-TO Ta IN Pads
200000
A
NETO Ae
THE AC. AND D.C. HARNESSES ARE UNIVERSAL.
IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
AR {RED AND TAPE OR SE
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
AL ENDS TO
if
ENGINE
190-260Kw Cummins
39, 4-wire, 600-volt
| OIL_ PRESSURE
70-WHT./GRN. (4 GA)-TO 70 IN PI
TC-YEL/GRN.—TO 7C IN PS
4 IA-BLUE-TO 41A IN PI
8-BLACK-TO P4
13-QRANGE—TO I3 IN PI
42A-WHITE-TO 42A IN P2(ia
—TO SOL. P
64-WH T/YEL.-TO HOR
P-RED (14 GA)
83-BROWN-TO 83 IN PI
RED TOR
VI-YEL - TO P4-—
VO-PURREE A E10 Phe
Opti-cREY (la GAI-TO Pa —
\ \ main FIELD
SINK & FR ACTIVATOR
0.0.0
—
6
$
$
TU
hee TN~-WHT/BLK=TO TN INP5
h—N=-WHT/BLK—TO MN IN PS
he N=WHT/BLK—TO N IN PI
e 34-GREEN— TO 34 IN PI
po JO-WHT/GRN. (4 GAJTO SAFE G. BRXR
e AO-PURPLE-TO 40 IN Pi
pus 5 —BLUE/WHT-TO 5 IN PS5
he A5—-YELLOW=TO 35 IN PI
he 54+ =RED (10 GA)=TC B+ IN PS
har 70=-WHT/ GRN =
TO, Sa
Í TIYELLOW (14 GA)=TO 71 IN PI
ED
pr —
MAGNETIC PICK-UP
EXCITER FIELD
EXCITER ARMATURE
ROTATING PHOTO TRANSISTOR BOARD
STATIONARY L.E.D BOARD
BATTERY
LOW OIL
PRESS. SW. =
\_ FT
Jae
WATER CITY WS
ON
N WHT/BLK:
FE_G. BRKR. (14 GA)
RED (14 м
RED (14 GA) (нем
FIELD
PELAY]
Code — 9
WIRING DIAGRAMS
| 6-33
OUTSIDE REAR VIEW OF INSTRUMENT BOX CONTROLLER DRAWER 30-1 O0Kw
Triple-Voltage
30, 277/480-volt
39, 120/208-volt
19, 120/240-volt
Code — 10 NOTE-
THE AC. AND DC, HARNESSES ARE UNIVERSAL.
CERTAIN WIRES IN THESE HARNESSES ARE NOT
USED ON VARIOUS GENERATOR APPLICATIONS
AND ENGINE OPTIONS, DETERMINE WHICH WIRES
ARE NOT REQUIRED AND TAPE OR SEAL ENDS TO
AVOID ACCIDENTAL MISCONNECTIONS AND SHORT
CIRCUITS,
16H
TEMP SW HWT SW SENDER
-GREEN-TO 34 IN =e Da 7 ; a y,
" Nr +
35-YELLOW-TO 35 IN PI
N- WHT/BLK: TO STARTER GROUND
40-PURPLE- TO 40 IN AI
5- BLUE/ WHT-TO $ IN PS IGNITION
| | ENGINE |
& HIGH WATER LOW WATER ANTIC WATER TEMP x
| TEMP SW.
| SEE NOTE) | JO-WHTASAN -TO 70 IN EL TO DIST. ON GAS-
> DC. HARNESS(290257 E) , (laca) OLINE PLANTS
AVAILABLE FOR REMOTE START SWITCH
R
и
à
OR CONTROL CONTACT ON TRANSFER "
E
Le
<
———
м
32 IN P2-—1
JUNCTION BOX
eo
|
J
PANEL. SEE 287804 FOR THIS CONNECTION
WHEN REMOTE DECISION. MONITOR IS USED.
E.
1
aD
1
NG A FUEL SYSTEMS — —
1
he N- WHT/BLK.- TO STARTER GROUND
“BLK /ORANGE - TO 32 IN P2—
BLA ORANGE - TO
1 GA-MHT/YEL
—
PE
PZ —
2 4 7O- WHT/GAN- TO
MAGNETIC Ze £ Ya ON ——70-WHT/GRIN- INJECTOR PUMP TO ATERNATOR——
\ > © CUSTOM | ` | CHOKE
REVOLVING GENERATOR — | gue 5 as _N-WHT/BLK-TO STARTER 7H YELLOW (UGAXO 71 IN PI" NOTE -
SCR ASSEM. SB- BROWN / ORANGE-TO 5B IN PS——H ze E (14 GA) | sare О” EE NUECTOR PUNP-
28- GREEN / YELLOW-TO 38 IN PS5-—— 0 y 5 P P-RED(4GA)TO SOL P BRA. ANTI! ESEL ne (БЕ ON DIESEL
STATIONARY SE UNT SOL AED WIRE SO S2UN Per axFPà 5 = 7O-WHT/GAN TO: "ee a
-BLACK (22 ‘ IN — = . 1
OPTIC BOARD EEE En) TO 6 'N P2- EEE 3 SAFEGUARD S-BLK/PINK (14GA) TO SOL. S —————Y Mower BO NTE pese SOL | = -
24 RED_(226A)-TO_24 IN_P2-——+4— ORO 2 BREAKER _ANTIC LOP JUMPER USED ON GASOLINE N-WHT
(—t-BLACK-TO 8 IN IIIf © FD THIS POLE & WIRING USED ONLY “TA PLANTS ONLY.
[—11- RED/BLUE TO Il IN Pl $37 | Го | c Sp 414- BUUE- TO 41A IN PY ——]
--VO-PURPLE /WHT:- pa— RERRR | oc] WHEN LINE CIR. BRKR. IS USED. NN»
МОНО ВЕНЕТО vi IN Pa ГА | Low SL SW
ANGE 7 к Е N мо ‚ i
\ I TELLOW/RNK TO va iN PAL To'ORG /BLK TO T2 IN Pa | о . ОВ 13-ORANGE -TO 3 IN PI——
ns [— SCWHT/PINK-TO 5C IN pa —]T? RED/ORG:T0 T3 Ш } | o 7
160 | © .
BSP AN Й 2 — ; | x I 5 IC-YEL/GAN:TO7C IN PS—1
- 9 t2 LEAD | а zz OIL PRESSURE
STATOR 3 © ZZ DER | 7O-WHT/GAN.-TO INJECTOR PUMP
STATOR 2 | # Ÿ << SENDER po. nen (4 GATTO ALARM HORN
LCE x 8 9 “xP -P-RED (IAGA)TO C RELAY P— в -
+ $ | е eZ НУ WHT/BLKTO INJECTOR PUMP — [RED САТО PIN ——8+-RED(IOGA)- TO B+ IN PS
Litas 2 ó | z £ w § || {venus TO Lit SW mms RED (IOGA)-TO PIN P5 —
| i 5 : z hd kN-WHT/BLK-TO 7N IN Р5 — —
' | Е a EN-WHT/BL.K-TO NIN PS —— S-BLK/PINK/I4GAJ
1 — зол 5 & AN-WHT/BLK- TO N IN Pl ———— FTO C RELAY S
Г 2 3d UN WHT/BLk-TOC RELAY
| Edo e NOTE -
' 163 64 424 P| _70-WHT/GRN- FROM SAFE: gu. _ ON LP OR NATURAL GAS PLANTS,
(Г al | {5c | 19.0 Q ol G. BRK'R, {SEE NOTES) 70 1S CONNECTED TO FUEL VALVE
ROTATING a \ | Po 7 ON LP AND NATURAL GAS PLANTS
LP AN L
OPTIC BOARD + 1 ! 1 4 WITH AUTOMATIC CHANGEOVER, 70
| ПЕ IS CONNECTED TO AUTOMATIC
| | $ y = | CHAGEOVER RELAY
EXCITER | hy SUPPLY - Cl 1
ARMATURE — | | FOR ALARM HORN KT] — +
¡[CUSTOMER OPTION)
Q @ | + BATTERY
{ 3)
—, г” m3 AVAILABLE SUPPLY FOR LOW
EXCITER \ sf } I EL SWITCH IN FUEL TANK
FIELD 9 OC * CUSTOMER OPTION)
|
120/208 | . 277/420 120/240 | o
MAIN FIELD / NL NA ® ® O - FT 3
4 m
= aH |e as
INTERLOCK НР +
SWITCH. Jee _$ MF ео y Ts
1 ++ 4 N=
LINE CIRCUIT BREAKER N ©
4
N— RECONNECTION BOARD
WIRING DIAGRAMS
6-34
NOTES
Appendix A
MAIN GENERATOR FIELD RESISTANCE
Fast-Response field resistance should measure 2-3 ©. Resistances given above were obtained using a Kelvin
Measurements should be made using a high-quality me- double bridge at room temperature — 68°F (20°C). Varia-
ter, with good connections to F3 and F4 leads, for proper tions in wire temperature will cause variations in resis-
readings. F3 and F4 leads must be disconnected from the tance. |
FR Activator. Field resistances may also vary up to + 5% due to wire tol-
erances and variations in field coil windings.
NOTES
MAIN GENERATOR FIELD RESISTANCE
A-1
NOTES
Appendix B
UNIBOARD FOR CONTROLLER LOWER TRAY
Complete mother-daughter circuit board assemblies may
be replaced with uniboard as shown below.
Lamp Test Switch
Connector
Overspeed
Pot
Relocated
Standoff
mE
“С п”
Ро!
“Off”
Pot
_ —-Pin 30
Time
Adj.
Pot
To Install Uniboard
1. Unplug LAMP TEST switch connector (blue and green
wires) from mother board.
2. Unplug 3 harness connectors'at back edge of mother
board.
3. Remove 7 screws holding mother board to tray and lift
mother-daugher board assembly from tray.
4. Remove right front nylon board-mounting standoff
from tray. Drill a 5/16 in. (8mm) hole in tray to align with
corresponding hole in new circuit board. Push standoff in-
to new hole.
5. Transfer lamp bulbs to sockets on uniboard as neces-
sary. Mount board assembly to tray with 7 screws.
6. Connect LAMP TEST switch connector to board (See
Figure) - blue wire to pin 43; green to pin 54.
7. Connect two long harness connector to rows of pins at
back edge of board. Connect small harness connector
leaving end pin 30 exposed.
8. Test with Fast Check before reinstalling tray in con-
troller.
UNIBOARD INSTALLATION
B-1
NOTES
Appendix C
“ Uniboard to Decision Maker II (Dec-11) Tray Conversion
for Fast-Response | Generator Sets
Installation and Operation
Uniboard Decision Maker Il
Tray No. Board No. Controller Assy. No. Kit No.
12V | A-291779 (NFPA) C-291492 A-292315 PA-292780
A-291850 (Basic) C-291849 :
24V | A-291780 (NFPA) C-291492 A-292335 PA-292781
A-291870 (Basic) C-291849
The conversion kit eliminates the uniboard tray and a. Connect Fast Check on Decision Maker |! tray
provides a complete Decision Maker |! tray assembly to connectors and variable DC voltage power supply.
make interchange a simple procedure. See Figure 1 and b. Move generator master switch to AUTO position.
use the following procedure. Keep this instruction for SYSTEM READY lamp should go on.
future reference. |
c. Slowly turn DC supply volt tit BAT. HIGH
INSTALLATION PROCEDURE wly turn DC supply voltage up unt
VOLTS lamp goes on. DC supply voltmeter should
read about 15 Volts for 12 Volt systems and about 30
À WARNING Volts for 24 Volt systems. If adjustment is needed,
| init wi turn DC supply to desired HI voltage and turn Pot.
UNIT STARTS WITHOUT NOTICE! Units with R42 just to the point where the BAT. HIGH VOLTS
Automatic Transfer Switches start automati-
E lamp goes on.
caliy. Potential injury or electrocution can
result. Turn Generator Master Switch on con- d. Siowly turn DC supply voltage down until BAT. LOW
troller to OFF position, and remove battery VOLTS lamp goes on. DC supply voltmeter should
cables (remove negative lead first and recon- | — readabout 11 Volts for 12 Volt systems and 22 Volts
nect it last) to disable generator set before for 24 Volt systems. Ifadjustmentis needed, turn DC
working on any equipment connected to gen- supply to desired LO voltage and turn Pot. R25 just
erator. to the point where the BAT. LOW VOLTS lamp goes
on. |
1. Place controller master switch to OFF Position. Dis- e. Seal Pots. R25 and R42 with insulating varnish or
connect battery of generator set, negative lead first. equivalent.
2. Remove four screws, lock washers, and washers on f. Disconnect Fast Check from Decision Maker Il tray
lower controller enclosure and slide out uniboard tray
connectors and DC power supply.
by grasping P1, P2, and P3 connectors. Once the tray
back panel clears enclosure, remove P1, P2, and P3 5. Slide in Decision Maker Il tray. Tilt tray slightly to clear
connectors. While sliding out tray, it may be neces- mounting hardware of upper controller. |
sary to tilt tray in order to clear mounting hardware of 6. Install four screws, lock washers, and washers to
upper controller. secure Decision Maker Il tray to enclosure.
3. JUMPER OPTIONS: Cut J1 on main circuit board for 7. Connect P1, P2, and P3 connectors to Decision Maker
60-second continuous cranking. Cut J2 on main cir- Ii tray.
cuit board for 50 Hz operation.
8. Check that the controller master switch is in the OFF
NOTE position. Reconnect battery, negative lead last.
On kits ordered for 24 Volt operation, jumper
J4 is sent from the factory already cut.
4. If the factory HI/LO battery voltage adjustments are
not to be used or are suspected to be incorrect, pro-
ceed as follows: otherwise omit Step 4.
DECISION MAKER || CONVERSION
C-1
J1
(Remove for
60-Sec.
Cranking)
Battery Hi
Volts Pot.
(R42)
Battery LO
Volts Pot.
(R25)
J2 (Remove for
50 Hz Operation)
Generator
| Switch
Figure 1. Fast-Response | Controller with Decision Maker Il Microprocessor Tray
OPERATION AND FEATURES
For identification of components, see Figure 2; for an
explanation of their function refer to the following para-
graphs.
LAMPS:
1. Switch Off — lamp flashes when generator master
switch is in the OFF/RESET position. Lamp will not
light when generator master switch is in the AUTO or
TEST position.
Overcrank
— cranking stops and overcrank lamp will light if
engine does not start after 60 seconds.
— lamp will light after 25 seconds of attempted cran k-
ing if starter or engine will not turn.
— lamp will light and engine will stop after starting
and 25 seconds running without speed sensor signal.
Overcrank Flashing — lamp will flash if speed sensor
fails during a normal run. Engine will keep running.
1 2 3 4
5 6 7 8
12 13 15
9 10 11
10.
Figure 2. Decision Maker 11 Microprocessor Base Tray
Emergency Stop — lamp lights if emergency stop has
been made or if overvoltage device (if equipped) has
shut down. See “Emergency Stopping” following.
High Water Temperature — lamp lights if set has shut
down due to high engine coolant temperature.
Overspeed — lamp lights if set shuts down due to
overspeed.
Low Oil Pressure — lamp lights if set shuts down due
to loss of engine oil pressure.
Anticipated Low Oil Pressure (if equipped) — lamp
lights if engine oil pressure approaches shutdown
level.
Anticipated High Water Temperature (if equipped) —
lamp lights if engine coolanttemperature approaches
shutdown level.
Low Water Temperature (if equipped) — lamp lights if
optional engine block heater is not working and/or
temperature may be too low (below 70°F, 21°C) for
10-second start-up.
Battery High Volts—lamp lights if battery or charging
voltage exceeds 15 Volts for 12-Volt systems; 30 Volts
for 24-Volt systems (will also light if overvoltage
occurs due to battery charger malfunction whilesetis
not operating).
11. Battery Low Volts—lamp lights if battery or charging
voltage drops below 11 Volts for 12-Volt systems, 22
Volts for 24-Volt systems (will also light if undervoltage
occurs due to battery or charger malfunction while set
is not operating).
12. Low Fuel (if equipped)—lamp lights if fuel tank level
approaches empty.
13. System Ready—lamp lights when Generator Master
Switch is in the AUTO or TEST position and system
senses NO faults.
SWITCHES:
14. Lamp Test — used to test indicator lamps.
15. Generator Master Switch—3-position AUTO, CENTER
OFF/RESET, and TEST switch. AUTO position allows
start-up by automatic transfer switch or remote start-
stop switch connected to controller terminals 3and 4.
CENTER OFF/RESET position will stop the generator
set regardless of the cool-down time delay. The
master switch must be in the AUTO position for the
cool-down time delay to function.
C-3
C-4
NOTE
If engine stop is signaled by a remote switch or
Automatic Transfer Switch, the generator set
will keep running for a cool-down cycle of 5
minues.
TEST position will start the generator set
locally.
FUSES:
16. 4-Amp—protects remote annunciator circuit, lamp
circuit board, and alarm horn circuit (if equipped).
17. 1-Amp—protects the main circuit board and the CR
and 1CR relay coils.
18. 15-Amp—protects engine DC and primary starting
circuits.
NOTE
Earlier models utilize a 3 Amp. fuse to protect
remote annunciator and alarm horn circuits (if
equipped). A 4 Amp. fuse protects controland
lamp circuit boards, and control relay coils.
EMERGENCY STOPPING
Turn generator master switch to OFF/RESET, or operate
remote emergency stop switch (if equipped), for imme-
diate shutdown.
FAULT SHUT-DOWNS
The generator set will shut down automatically under the
following fault conditions:
Overcrank: See “Overcrank™ preceding.
High Temperature: Shutdown occurs 4 seconds after
fault.
CAUTION
High temperature shutdown will not function if
proper coolant level is not maintained.
NOTE
High temperature and low oil pressure shut-
downs are overridden during the first 30
seconds after start-up.
Low Oil Pressure: Shutdown occurs 4 seconds after fault.
CAUTION
Low oil pressure shutdown is not intended to
provide protection againstiow oil level. Check
for proper oil level at engine dipstick.
Overspeed: Unit shuts down immediately, if governed fre-
quency exceeds 70 Hz on 60 Hz sets, or 60 Hz on 50 Hz
sets.
Overvoltage (if equipped): Unit will shut down after
approximately one second of 15% or more over nominal
voltage. EMERG. STOP lamp will light.
CAUTION
Sensitive equipment may suffer damage in
less than one second of an overvoltage condi-
tion. On-line equipment requiring faster shut-
downs should have its own overvoltage protec-
tion.
RESETTING
Use the following procedure to restart set after a fault
shutdown.
1. Move generator master switch to OFF/RESET posi-
tion.
2. Disconnect generator set from load with line circuit
breaker or automatic transfer switch.
3. Correct cause of fault shutdown.
4. Move Generator Master Switch to TEST position for
start-up.
5. Verify that cause of shutdown has been corrected.
6. Reconnect to load.
7. Move Generator Master Switch to proper position
(AUTO or TEST) for start-up.
120 Vv. A.C. SUPPLY
A-287742
AC INTERLACK CIR. B
Di
D,
LOCATED IN INSTRUMENT
BOX. -
10
SAFEGUARC—7 Que — нью,
BREAKER
32
1
ALARM MORN SW.
та Fi
a
— i
AYAILABLE SUPPL
IN JUNCTION BOX
FROM STARTER SOL.P
Y
2
de
nN
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AVAILABLE SUPPLY 63 IN.
JUNCTION BOX CONNECTED
TO THIS TERM, WHEN HORN
KIT IS FURNISHED.
53
10%
MEA py oe
4 2704
i Dl
HH
ALARM MORN
CIRCUIT BO.
A-287924
ое р SRE NO STARTER SOL.
40:
uz
—— Je AVATLABLE SUPPLY IN
JUNCTION BOX FOR LOH
; ze FUEL SK. IN FUEL TANK
Эа Pal TON
LOW WATER
TEMP, SH.
NICK MATER
"EMP,SW
Dz gl
| elz
» — | TO COIL OF ANTIC «28
| © RELAY ,=xL.0.P. 53
: й ut —— —Y Ses
r——?Q0e= TO 1EN.COIL» ANTIC ZY
"nx HHT SH, 5 =
vio
3—= AYAILABLE SUPPLY
FOR Ri
IS NOT REQUESTED.
<< RECEPTACLES AS VIEWED
FROM TERMIMAL INSERTION
END.
424
DIS 1403 LED3 аз
3
ne
LOK WATER TE ma 203, a LéO1 a1
‘ ANTIC HIGH WATER TEW 30 1g J Sens —
3 “ещо L as
2 HIGH MATER TEMP ES SE LEDS jas
= LOW DIL PRESS] 28
12 > 1624 Me EDO J Ril
OVERCRANE > N—€ “EDS
51 ‚DRM Da | RY
Lo HIGH BATT, mim 510 LEDIO
CONNECTION BOX - —— сон ватт |_52 а НРК 800
A- ' 7
emErc stop | 46 ‚ реа” = R7
HH —— 3 —— AYAILABLE SUPPLY ANTIC LOW O1L PRESS 41 ла R2
FOR REMOTE START * 1208 ze
© = SW. WHEN DECISION OVERSPEED 2 4 Re
MONITOR 15 REQUESTED, Da LED4 #4
LOW FUEL
SHITCH OFF
14015 gt 4 R12
Dao) 421% ЕО)
019 Т yw
GEN. POWER
LINE POKER
013 Neos
la La le (a [a |
"o
A
COMMON FAULT LINE
SYSTEM READY
|
о
RECEPTACLES IN DECISION MAKER
VTEWEL FROM TERMINAL INSERTICN
MICROCOMPUTER BOARD
SPEED PICK-UP (O)
„ее HN.T. LaMP
7.) |+ 1..0.Р. LanP
fon} EMERG. STOP LAMP
Вен OVER-CRANK LAMP
— OVER SPEED LAMP
Pp E) —— | ALARM HORN
| —— fest LON BATTERY VOLTS LAMP
{rl ANTIC. L.C.P. LAMP
и {za LAMP ТЕБТ GHITCH
{===} HIGH BATT. VOLTS LAMP
ba) +— LON WATER TEMP. LAMP
foes} LOW FUEL LAMP
pa) ANTIC. H.W.T. LAMP
Gre) SPEED PICK-UP { o )
= lee
4 AMP, FUSE
LOW OIL PRESSURE SWITCH.
ANTIC. LOH OIL PRESSURE SWITCH — | fr (io) A
3
HIGH WATER TEMP. SMITCH —t——fo) EG 3)
T
су
A.C. INTERLOCK SOARD — {5 }---(-79
A.C. INTERLOCK BOARD {=} >
EMERG. STOP SMITCH ——
REMOTE START SWITCH ——
AUTO, —————— [WT asma
TEST
FE
SYSTEM READY Lame ——Tee:i]-—
SHITCH OFF САМР ——ф [тета
mo
(>
"CR" COTL 1 Eto
"AER" COLL. —4— (+
r
“
TEST SH.
DECISION MONITOR
A-207900
J
NOTES:
JUMPER FUNCTIONS:
(REMOVE TO ACTIVATE)
#14 .
J-1 = CONTINUOUS CRANKING
(60 SECONDS)
a 1 J-2 = FOR SOMZ OPERATION
1-67
rq rr
NS
LOW WATER TEMP. SWITCH
LOW FUEL SWITCH
vs
ANTIC. HIGH WATER TEMP. SWITCH ——— Fr HT
y
—
ZA UNREGULATED BATTERY
VOL TAGE
ÁN REE'LATED +SV SUPPLY
1 GROUND
ALL RESISTORS 1/4 HATT
UNLESS OTHERWISE SPECIFIED.
ICIO & 1C13 - 10K SIP
RESISTORS.
U pc BoARD CONNECTIONS
CO EXTERNAL CONNECTIONS
С) INTERNAL CONNECTIONS
GENERATOR SWITCH
292340
Wiring Schematic — Decision Maker II Tray
C-5
KOHLER
GENERATORS
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