Onan JB, JCA, JCB Generator Set Service Manual

Onon Service Manual
JB
JCA
JCB
GENERATOR SET
|
Printed U.S.A. 967-0507 8-94
Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS ..........ciiiiiiiitiieiterereciaencnnnas ii, fii
1 INTRODUCTION .............2.00 0.000 eu ma ane nee 0000 aa a 0000» 1-1
About This Manual ..............—.e—eemeec0sossorecrorcoreccosvene. 1-1
How To Obtain Assistance ..........._.ecoooerreossocorsrorcorcoreno 1-1
| Test Equipment..............._—eee0eoszarersonesvecuecareecenace, 1-1
2 AC CONTROL .............oeoe_rerenococacacsonecensareonocrennecaa 2-1
General ........ enoroorrrccaanoreanccccanasmecaanancaraneanvece 2-1
AC Control Box Controls ..........—..e—.enreresríesrererorercercecane, 2-1
Optional AC Control! Components (Housed Units Only) ............... 2-2
Automatic Voltage Regulator (AVR) Adjustments ..................... 2-3
Principle Of Generator Operation ...........000000000000000 000000000 2-8
3 ENGINE CONTROL ..................00000e su umeu sono 0 ass a 0000000 3-1
General ..........ecoeweneronsrvnesoecosarcororencanocacarorecarano 3-1
Standard Control Panel Components ..............e.eoosouesceoreao 3-1
Deluxe Control Panel Components .........ecemerecoverocacencoon. 3-2
Sequence Of Operation ................e.eee2oscsnoconccacocccereoa 3-3
4 TROUBLESHOOTING ............._.._er_eononccoroccoreaccancecaacane E
Start - Cranking Mode ............e.__eeeecooseneacorco. PA 4-2
Run Mode ...................-20000e ca 0ae maman aa nues acces 0 00000 4-4
Battery Charge Mode ............eeeeoenecccrcorocorreemerecacere, 4-6
Stop Made .......e..._e.eerencecrsrrcsrscecocerosnereecacacenvona 4-7
Generator Troubleshooting .............._eeoorersocrocsocccverecen. 4-8
5 GENERATOR TESTS AND ADJUSTMENTS ......................... 5-1
General .........ee.ceorenenrsccnscconcconorareantcarococonromeo 5-1
Flashing The Exciter Field ......0000000000000000 0000000000000 00 5-2
Testing Reactor CMR21 20ER EEE ao ne se sa ce 0 5-3
Testing Reference Transformer T21 ........._eccovcsacrerorocacure 5-3
Testing Exciter Rotating Rectifiers ...............eñeeoeendonecoooo. 5-4
Testing Exciter Stator .............—.—.eeeeereseorescccrosarreacenao 5-5
Testing Exciter Rotor .............._e2eeéresnseoornvrearoccxorerconeoo 5-6
Testing Main Rotor Winding ...........eeeeocsenrrosocorecrcconzeon 5-7
Testing Main Stator Windings ...........eeeorenoccccarosconeoccomoo 5-8
Removing And Disassembling the Generator ........................ 5-9
Reassembling The Generator ............2.2.0 220000 a asus aan an 00 5-11
6 ADJUSTMENTS ...............recwewccorenevecoo e nacerocecarecronne. 6-1
Battery Charge Rate Adjustment .............e...eme.eeeroccomonco 6-1
Centrifugal Switch .........._.eereeeescsaccrcacrrocrosnecececeameo 6-1
Automatic Choke (Gasoline SetS) ...........00000000000000 0000000 kn 6-2
Vacuum Pulloff Diaphragm Adjustment ........................._.. 6-4
7 WIRING DIAGRAMS ............e—oer—eexooonocsncococacocoaorecraceeo 7-1
General .........oeorreconverccorecoccarorecanconeanorenroeacaramo 7-1
Safety Precautions
Before operating the generator set, read the Op-
erator's Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment 15 properly oper-
ated and maintained. Many accidents are caused
by failure to follow fundamental rules and precau-
tions.
The following symbols, found throughout this man-
ual, alert you to potentially dangerous conditions to
the operator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal in-
jury or death:
[AWARNING]7his symbol refers to a hazard or un-
safe practice which can result in severe per-
sonal injury or death.
This symbol refers to a hazard orun-
safe practice which can result in personal injury
or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can re-
sult from improper practices.
e DO NOT fill fuel tanks while engine is running,
unless tanks are outside the engine compart-
ment. Fuel contact with hot engine or exhaust
is a potential fire hazard.
e DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition
source near the generator set or fuel tank.
e Fuel lines must be adequately secured and
free of leaks. Fuel connection at the engine
should be made with an approved flexible line.
Do not use copper piping on flexible lines as
copper will become brittle if continuously vi-
brated or repeatedly bent.
e Be sure all fuel supplies have a positive shutoff
valve.
¢ Do not smoke while servicing lead acid batter-
ies. Lead acid batteries emit a highly explosive
hydrogen gas that can be ignited by electrical
arcing or by smoking.
EXHAUST GASES ARE DEADLY
e Provide an adequate exhaust system to prop-
erly expel discharged gases away from en-
closed or sheltered areas and areas where in-
dividuals are likely to congregate. Visually and
audibly inspect the exhaust daily for leaks per
the maintenance schedule. Ensure that ex-
haust manifolds are secured and not warped.
Do not use exhaust gases to heat a compart-
ment.
e Be sure the unit is well ventilated.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
e Keep your hands, clothing, and jewelry away
from moving parts.
‚ ® Before starting work on the generator set, dis-
connect starting batteries, negative (-) cable
first. This will prevent accidental starting.
e Make sure that fasteners on the generator set
are secure. Tighten supports and clamps,
keep guards in position over fans, drive belts,
etc.
e Do not wear loose clothing or jewelry i in the vi-
cinity of moving parts, or while working on elec-
trical equipment. Loose clothing and jewelry
can become caught in moving parts. Jewelry
can short out electrical contacts and cause
shock or burning.
e If adjustment must be made while the unit is
running, use extreme caution around hot mani-
folds, moving parts, etc.
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
e Remove electric power before removing pro-
tective shields or touching electrical equip-
ment. Use rubber insulative mats placed on
dry wood platforms over floors that are metal or
concrete when around electrical equipment.
Do not wear damp clothing (particularly wet
shoes) or allow skin surface to be damp when
handling electrical equipment.
Use extreme caution when working on electri-
cal components. High voltages can cause in-
jury or death. DO NOT tamper with interlocks.
Follow all applicable state and local electrical
codes. Have all electrical installations per-
formed by a qualified licensed electrician. Tag
open switches to avoid accidental closure.
DO NOT CONNECT GENERATOR SET DI-
RECTLY TO ANY BUILDING ELECTRICAL
SYSTEM. Hazardous voltages can flow from
the generator set into the utility line. This cre-
ates a potential for electrocution or property
damage. Connect only through an approved
isolation switch or an approved paralleling de-
vice.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling
point than water. DO NOT open a radiator or
heat exchanger pressure cap while the engine
is running. Allow the generator set to cool and
bleed the system pressure first.
Benzene and lead, found in some gasoline,
have been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. When checking, draining or adding
gasoline, take care not to ingest, breathe the
fumes, or contact gasoline.
Used engine oils have been identified by some
state or federal agencies as causing cancer or
reproductive toxicity. When checking or
changing engine oil, take care not to ingest,
breathe the fumes, or contact used oil.
Provide appropriate fire extinguishers and in-
stall them in convenient locations. Consult the
local fire department for the correct type of ex-
tinguisherto use. Do not use foam on electrical
fires. Use extinguishers rated ABC by NFPA.
Make sure that rags are not left on or near the
engine.
Remove all unnecessary grease and oil from
the unit. Accumulated grease and oil can
cause overheating and engine damage which
present a potential fire hazard.
Keep the generator set and the surrounding
area clean and free from obstructions. Re-
move any debris from the set and keep the floo
clean and dry. |
Do not work on this equipment when mentally
or physically fatigued, or after consuming any
alcohol or drug that makes the operation of
equipment unsafe.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
LS-10
1. Introduction
— ABOUT THIS MANUAL.————.
This service manual includes a guide for engine and
generator troubleshooting. Engine service instruc-
tions are in the applicable engine service manual.
Operating and maintenance instructions are in the
applicable Operator's Manual.
This manual does not have instructions for servic-
ing printed circuit board assemblies. After determin-
ing that a printed circuit board assembly is faulty, re-
place it. Do not repair it. Attempts to repair a printed
circuit board can lead to costly damage to the equip-
ment.
This manual contains basic (generic) wiring dia-
grams and schematics that are included to help in
troubleshooting. Service personnel should use the
actual wiring diagram and schematic shipped with
each unit. The wiring diagrams and schematics that
are maintained with the unit should be updated
when modifications are made to the unit.
Read Safety Precautions and carefully observe all
instructions and precautions in this manual.
ame
HOW TO OBTAIN ASSISTANCE
When seeking additional service information or re-
placement parts, always give the complete model
and serial number as shown on the genset data tag
“or nameplate. The genset data tag or nameplate is
on the A.C. output box.
TEST EQUIPMENT
Most of the test procedures in this manual can be
performed with a multimeter like the Simpson
Model 260 VOM, or a digital VOM. Other instru-
ments that should be available are:
AC Voltmeter
DC Voltmeter
Frequency Meter
Jumper Leads
Load Test Panel
Variac
Tachometer or Strobotach
Megger or Insulation Resistance Meter
Wheatstone Bridge or Digital Ohmmeter
Improper service can lead to equip-
ment damage, severe personal injury or death.
Service must be performed by qualified per-
sons who know about fuel, electrical and me-
chanical hazards. Read the safely precautions
page and carefully observe all instructions and
precautions in this manual. |
— 2. AC Control
GENERAL Output Voltage Trimmer (R21) (Optional) The
output voltage trimmer can be used to adjust output
This section describes the AC control components
voltage plus or minus five percent of nominal voit-
of the genset. The AC contro! box, which contains
the AC controls and components, is mounted ontop age.
of the control panel assembly (Figure 2-1).
AC CONTROL BOX CONTROLS
Field Circuit Breaker (CB21) The field circuit
breaker protects the generator from prolonged
over-excitation.
OUTPUT VOLTAGE FIELD CIRCUIT
TRIMMER BREAKER (CB21)
O 1 N. LO \ AC CONTROL BOX
©
-- © a
CONTROL PANEL
ASSEMBLY
|
300-4279
FIGURE 2-1. AC CONTROLS
TUN
2-1
OPTIONAL AC CONTROL COMPONENTS
(HOUSED UNITS ONLY)
The optional control panel (Figure 2-2) used on
housed units only , has the following components.
AC Voltmeter (M1). The voltmeter indicates output
voltage for the phase selected.
Voltmeter Phase Selector Switch (S1). Selects
the phase of the generator output voltage to be
measured.
Running Time Meter (M5). This meter indicates
the accumulated number of hours the set has run.
Frequency Meter (M6). Indicates the frequency of
the output voltage in hertz. It can be used to check
engine speed (30 rpm-produces one hertz).
AC Ammeter (M2, M3, M4). The ammeter indi-
cates output amperage for each phase. The third
ammeter is used on three phase units only.
Line Circuit Breaker (CB1). Protects generator
from line overloads.
AC AMMETER (M2)
AC AMMETER (M3)
AC AMMETER (M4)
FREQUENCY METER (M6)
AC VOLTMETER (M1)
BREAKER (CB1) —
RUNNING TIME METER (M5)
VOLTMETER PHASE
SELECTOR SWITCH (S1)
LINE CIRCUIT
FIGURE 2-2. AC METER PANEL
2-2
AUTOMATIC VOLTAGE REGULATOR
(AVR) ADJUSTMENTS
The voltage regulator controls the output ofthe gen-
erator so that a constant voltage is maintained un-
der varying load conditions. There are two types of
automatic voltage regulators used on these sets,
which are shown in Figures 2-3 and 2-4. For refer-
ence purposes only, they are identified as AVR-A
. and AVR-B.
The automatic voltage regulator is mounted inside
of the AC control box. It can be adjusted by means
of the potentiometer (pot) shown in Figure 2-3 and
2-4. Figures 2-5 and 2-6 show typical voltage regu-
lating circuits.
These measurements and adjustments are done
while the set is running and require access to unin-
sulated high voltage parts in the control and power
output boxes.
HAZARDOUS VOLTAGE. Touching
uninsulated high voltage parts inside the con-
trol and power output boxes can result in severe
personal Injury or death. Measurements and ad-
justments must be done with care to avoid
touching high voltage parts.
For your protection, stand on a dry wooden plat-
form or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry and
wear elbow length insulating gloves.
2-3
Voltage Adjustments (AVR-A and B)
Use the control panel mounted output voltage trim-
mer (see Figure 2-1), if provided, for small voltage
adjustments. Measure generator output voltage
while the set is running without load at the nominal
frequency. If the trimmer does not provide enough
adjustment, set it at its midpoint. Then turn the
VOLTS ADJUST pot (Figure 2-3 or 2-4) until rated
voltage is obtained. Turn clockwise to increase out-
put voltage; counterclockwise to decrease output
voltage.
Voltage Stability Adjustment (AVR-A Only)
Voltage stability is set atthe factory, but if printed cir-
cuit board AVR-A has been replaced or if damping
potentiometer R27 has been unnecessarily ad-
justed it may be necessary to reset stability. Set sta-
bility as follows.
1. With generator set running at no load, turn po-
tentiometer R27 (Figure 2-3) to a position
where voltage tends to be unstable or hunt.
2. Turn R27 clockwise slowly until voltage first
stabilizes. This setting will result in stable volt-
age under ali conditions in maximum voltage
regulator response time.
AC CONTROL BOX
AUTOMATIC VOLTAGE
REGULATOR (VR21)
—
FACTORY ONLY
ADJUSTMENT
CMR 21
T21
2
VOLTAGE
ADJUST
FIGURE 2-4. AVR-B VOLTAGE REGULATOR
2-5
К с Ва i
su = ml
Y ue
N Ё К КЛ far as
AC CONTROL BOX
AUTOMATIC VOLTAGE
REGULATOR (VR21)
V3
—
Vi —— m}
уг
масом
DAMPING
ADJUST (R27)
CMR2!
| то == = = = 4
re —_— — аа —_»
VOLTAGE
ADJUST
FIGURE 2-3. AVR-A VOLTAGE REGULATOR
2-4
EXCITER ROTATING
ROTOR RECTIFIERS MAIN
ed | + TA ROTOR
Y YY
EXCITER
STATOR MAIN STATOR
(T1 THROUGH
T4 OR T42)
9) (9
X2 X1
T21
H2 Hi |
VOLTAGE
REGULATOR
TB21 (VR21) (305-0688)
GEN1
1 — - >)
F1+ O, @
o 300 сое
a ta
NU E
À , 2,
FIELD CIRCUIT] + "VOLTAGE “1
BREAKER CR21] * TRIMMER Ras |
. NOTES 1 & 2 +
— NOTES —
1. For 50 Hz operation, jumper is required be- 2. Without voltage adjust option: connect jumper
tween TB1-7 & TB1-8. Not required for 60 Hz. from TB1-6 to TB1-7. With voltage adjust op-
Generators are not 50/60 Hz reconnectable. tion: connect R23 to TB1-6 & TB1-7. Remove
jumper.
FIGURE 2-6. VOLTAGE REGULATING CIRCUIT USING AVR-B (P/N 305-0688)
2-7
EXCITER ROTATING
ROTOR RECTIFIERS MAIN
a A + + + | ROTOR
A x A i
(YY YL | EE EE
EXCITER |
STATOR | MAIN STATOR
- (T1 THROUGH
T4 OR T12)
@ © © МОТЕ 2
50 60 V4 COM @-
x T21 * HZ HZ v2e |
H1 H2 NOTE 3 Vi e-
| v3e
VOLTAGE
TB21 REGULATOR
GEN-1 Fa] © (VR21) (800-1540)
GEN-2 5 o
F2-
©} 200 OO
AE
| - - - À :
m} 2 CMR dE
1! 2:
— IFIELDCIRCUIT] + VOLTAGE >
BREAKER CR21| * TRIMMER R21 |
, NOTE 1 :
— NOTES —
1. Without voltage adjust option: connect jumper 2. Connect jumper from V4-COM to V1, 20r3ac-
from VR21-1 to VR21-2. With Voltage adjust cording to voltage reconnecting diagram. Ap-
option: connect R21 to VR21-1 & VR21-3. Re- plies to 300-1540 only.
move jumper. 3. 60 Hz operation: connect T21-X1 to VR21-6.
50 Hz operation: connect T21-X1 to VR21-5.
Generators are not 50/60 Hz reconnectable.
FIGURE 2-5. VOLTAGE REGULATING CIRCUIT USING AVR-A (P/N 300-1540)
2-6
PRINCIPLE OF GENERATOR OPERATION
1.
The generator field (main rotor) is rotated by
the engine to induce output current (AC) in the
main stator windings.
Generator output current is proportional to field
strength, which is varied to match the load.
Output voltage and frequency are held con-
stant by the voltage regulator and engine gov-
emor, respectively.
Generator field strength is proportional to field
current, which is supplied by the exciter.
The exciter field (stator) induces current in the
exciter rotor windings. A full wave rectifier
bridge (rotating rectifiers) mounted on the
exciter rotor converts exciter output (3-phase
AC) to DC. The exciter rotor is mounted on the
main rotor shatt.
5.
6.
Exciter output current is proportional to exciter
field current.
The automatic voltage regulator (AVR) regu-
lates exciter field current by comparing genera-
tor output voltage and frequency with refer-
ence values.
The exciter field current is supplied by the gen-
erator stator through the voltage regulator. Re-
sidual field magnetism in the exciter rotorand a
permanent magnet embedded in one exciter
stator field pole, initiate “self-excitation” during
startups.
MAIN STATOR
AVR
oh
EXCITER So
ROTOR a
— AND - < Б -
STATOR Qu
MAIN ROTOR 2 = =
FIGURE 2-7. SCHEMATIC OF GENERATOR OPERATION
2-8
Safety Precautions
Before operating the generator set, read the Op-
erator's Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly oper-
ated and maintained. Many accidents are caused
by failure to follow fundamental rules and precau-
tions.
The following symbols, found throughout this man-
ual, alert you to potentially dangerous conditions to
the operator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal in-
jury or death.
This symbol refers to a hazard or un-
safe practice which can result in severe per-
sonal injury or death.
This symbol refers to a hazard or un-
safe practice which can result In personal injury
or product or properly damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can re-
sult from improper practices.
e DO NOT fill fuel tanks while engine is running,
unless tanks are outside the engine compart-
ment. Fuel contact with hot engine or exhaust
is a potential fire hazard. |
e DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition
source near the generator set or fuel tank.
e Fuel lines must be adequately secured and
free of leaks. Fuel connection at the engine
should be made with an approved fiexible line.
Do not use copper piping on flexible lines as
copper will become brittle if continuously vi-
brated or repeatedly bent.
e Be sure all fuel supplies have a positive shutoff
valve.
+ Do not smoke while servicing lead acid batter-
ies. Lead acid batteries emit a highly explosive
hydrogen gas that can be ignited by electrical
arcing or by smoking.
EXHAUST GASES ARE DEADLY
e Provide an adequate exhaust system to prop-
erly expel discharged gases away from en-
closed or sheltered areas and areas where in-
dividuals are likely to congregate. Visually and
audibly inspect the exhaust daily for leaks per
the maintenance schedule. Ensure that ex-
haust manifolds are secured and not warped.
Do not use exhaust gases to heat a compart-
ment.
e Be sure the unit is well ventilated.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
e Keep your hands, clothing, and jewelry away
from moving parts.
e Before starting work on the generator set, dis-
connect starting batteries, negative (-) cable
first. This will prevent accidental starting.
eo Make sure that fasteners on the generator set
are secure. Tighten supports and clamps,
keep guards in position over fans, drive belts,
etc.
e Do not wear loose clothing or jewelry in the vi-
cinity of moving parts, or while working on elec-
trical equipment. Loose clothing and jewelry
can become caught in moving parts. Jewelry
can short out electrical contacts and cause
shock or buming.
e If adjustment must be made while the unit is
running, use extreme caution around hot mani-
folds, moving parts, etc.
ZN
3. Engine Control
GENERAL
This section describes the engine control system.
The control system includes all the functions that re-
late to the operation of the engine. This includes
starting and stopping, instrumentation, monitoring
for fault conditions, and battery charging. Note that
the genset can be configured with either the stan-
dard control panel (Figure 3-1) or the optional de-
luxe control panel (Figure 3-2).
STANDARD CONTROL PANEL
COMPONENTS
Start / Stop Switch (S11): This switch is a single-
pole, double-throw (SPDT) rocker type switch used
for starting and stopping the generator set.
Holding the switch in the Start position will initiate
engine cranking. When the engine reaches ap-
proximately 900 rpm, the starter motor will auto-
matically disengage, preventing starter motor dam-
age. The switch will automatically return to the cen-
ter (Run) position when released.
Pushing the switch to the Stop position will initiate
the stop function.
DC Ammeter (M21): The DC ammeter indicates
the rate in amperes at which the battery is being
charged.
Running Time Meter (M12): This meter indicates
the accumulated number of hours the set has run.
Common Fault Circuit Breaker (CB4): This fault
circuit breaker shuts down the engine by de-ener-
gizing the ignition, when any fauit shutdown switch
functions (contacts close). A fault shutdown is indi-
cated when the breaker reset button extends out
past normal. Push the button to restore operation
(after the engine has been properly serviced).
Fuse (F1): A 10-ampere fuse that provides protec-
tion to the control box wiring and remote wiring from
short circuits or overload.
DC AMMETER — |
COMMON FAULT __—
CIRCUIT BREAKER
RUNNING TIME
METER
Ee FE
START / STOP SWITCH
LL
FIGURE 3-1. STANDARD CONTROL PANEL
DELUXE CONTROL PANEL
COMPONENTS
The deluxe control panel (Figure 3-2) has the fol-
lowing fault indicators and circuit breakers in addi-
tion to the standard control panel controls.
Start / Stop / Test Switch (S11): In addition to the
Start / Stop function provided on the standard con-
trol panel, a test position is provided on the deluxe
control panel. in the Stop / Test position, this switch
will light all fault indicator lamps on the deluxe con-
trol panel and the corresponding lamps on the re-
mote annunciator panel. (Replace lamps that do not
light.) The remote signals that are tested via the
Test switch are LOP, HET, OS and Common Alarm.
The LET and generating signals are not tested.
Individual Fault Circuit Breakers (CB4, CB5,
CB6). An individual fault circuit breaker is provided
in connection with each fault shutdown switch to
shut down the engine (de-energize ignition) when
the contacts of a fault switch close. Each breaker is
identified according to fault by the fault indicator
next to it on the panel. Fault shutdown is indicated
when the fault indicator lights and the breaker reset
button extends out past normal. Push the button to
restore operation (after the engine has been prop-
erly serviced).
Fault Indicator Lamps. An individual fault lamp is
provided in connection with each fault shutdown
switch to indicate the following fault conditions.
¢ Low Oll Pressure. This lamp indicates thatthe
engine has shut down due to low oil pressure
(less than 14 psi +2 psi).
e High Engine Temperature. This lamp indi-
cates that the engine has shut down due to high
engine temperature (greater than 375% F
[190.5* CJ).
e Overspeed. This lamp indicates that the en-
gine has shut down due to an overspeed condi-
tion (2100-2200 RPM, 60 Hz and 1800-1900
RPM, 50 Hz).
LOW OIL PRESSURE
INDICATOR/ <<
CIRCUIT BREAKER
HIGH ENGINE
TEMPERATURE —
INDICATOR/ —
CIRCUIT BREAKER
OVERSPEED
INDICATOR/ -<
CIRCUIT BREAKER
RUNNING TIME
METER
=== LL
ı Of DC AMMETER
START / STOP / TEST
SWITCH
FIGURE 3-2. DELUXE CONTROL PANEL
SEQUENCE OF OPERATION
The sequence of operation is as follows. Refer to
the schematic on Page 7-4 or 7-6, as appropriate.
ZN
1.
2
3
4
STN
5
6
The start circuit is completed by the panel Start
switch contacts 2-3, or automatically by a re-
mote controller connected between terminals
TB11-1 and TB11-3.
This action energizes K11 (Start Solenoid) via
NC contacts of relay K15 (Start Disconnect).
. Relay K11 has two sets of NO contacts that
perform the following functions when ener-
gized.
a. One set connects battery B+ to the starter
motor shift solenoid B1. Engine cranking
begins.
b. The other set energizes relay K12 (Run).
Relay K12 connects B+ to the ignition sys-
tem, M12 (run time meter) and optional
equipment.
. The engine starts and runs up to governed
speed in a matter of seconds.
. When the engine speed reaches approxi-
mately 900 RPM, the centrifugal switch S1
closes and energizes relay K15.
. Relay K11 is de-energized (by relay K15)
which disconnects the battery B+ to the starter
motor.
. Deluxe Control Panel only: Relay K17 is pow-
ered by the generator output voltage (120
3-3
10.
VAC) through TB21-1 and TB21-2. The remote
AC AVAILABLE indicator lamp should light
(connected through terminal TB13-58).
. Relay K12 (Run) remains energized via cen-
trifugal switch S1 and through all the fault cir-
cuit breakers, which are connected in series.
When any fault switch closes, the individual cir-
cuit breaker de-energizes relay K12 which
opens B+ circuit to the ignition system. On the
deluxe contro! panel, the appropriate fault indi-
cator lamp lights and common alarm terminal
TB13-12 is powered.
. To restore operation after a shutdown fault has
been serviced, reset the appropriate fault cir-
cuit breaker. The set is ready to start when the
panel switch is pushed to Start position.
. The stop circuitis completed by the panel Stop
switch contacts 1-2, or automatically by a re-
mote controller connected between terminals
TB11-1 and TB11-2. This action energizes
K14.
Relay K12 is de-energized (by relay K14)
which disconnects the battery B+ to the ignition
system. |
Genset with optional fault indicators - Holding
S11 in the Stop / Test position closes momen-
tary contacts 4-5, which applies battery B+ via
CR7 to the fault indicators. All fault indicators
should light.
Ee TN
4. Troubleshooting
The following charts are a guide to help you think
through problems with the generator set. You can
save time if you read through the manual ahead of
time and understand the system.
Try to think through the problem. Go over what was
done during the last service call. The problem could
be as simple as a loose wire or a tripped circuit
breaker.
Figure 4-1 shows the location of the components
within the control panel that are referenced in the
following troubleshooting procedures. Pages 7-3
through 7-6 show the control wiring connections.
OUTPUT VOLTAGE _.
TRIMMER (R21 / R23)
70, EXCITER FIELD CIRCUIT
м, ВВЕАКЕВ (СВ21)
DC AMMETER (M21)
START / STOP / TEST
— — SWITCH (S11)
RUNNING TIME
—.— METER (M12)
—— FUSE (F1)
(K11)
LOW OIL PRESSURE
INDICATOR / CIRCUIT
BREAKER (СВ)
HIGH ENGINE
TEMPERATURE
INDICATOR / CIRCUIT <<
BREAKER (CBS)
OVERSPEED
INDICATOR / CIRCUIT——
BREAKER (CBS)
TB13 STOP RELAY
(K14)
RUN RELAY (K12)
START SOLENOID __
START FAULT ISOLATION
DISCONNECT BRIDGE (CR7)
RELAY (K15)
a LOW ENGINE
TEMPERATURE
THERMOSTAT (S8)
GENERATING
RELAY (K17)
FIGURE 4-1. CONTROL PANEL COMPONENT LOCATIONS
START - CRANKING MODE
Holding the Start / Stop / Test switch in the Start position activates the start/ignition circuitry.
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safety Precautions on pages il and iil.
TABLE 4-1. CONTROL TROUBLESHOOTING - CRANKING MODE
2. Insufficient battery voltage due to:
a. Batteries not charged.
b. Battery connections loose or
dirty.
¢. Insufficient battery charging volt-
age.
3. Start solenoid (K11) not energized due
to:
a. Defective Start / Stop / Test
switch (S11).
b. Defective solenoid (K11).
4. Starter (B1) not energized due to:
a. Open circuit between battery
(B+) and the start solenoid con-
tact (BAT).
b. Defective starter (B1).
2b.
2c.
3b.
4a.
Ab.
Trouble Possible Cause Corrective Action
Engine Does 1. Fuse F1 on the control panel is blown. 1. Replace the fuse with one of the same type and
Not Crank. amp rating. If fuse F1 blows again, refer to wir-
ing diagram in Section 7 to locate short or de-
fective component.
Recharge or replace the battery. Specific grav-
ity for a fully charged battery is approximately
1.260 at 80° F (27° C).
Clean and tighten or replace the battery cable
connectors and cables at the battery and the
set.
Adjust charge rate of battery charging circuit.
Refer to Battery Charge Rate Adjustment in
Section 6.
Test Start / Stop / Test switch and wiring.
Test solenoid K11 and wiring.
Check wiring continuity between battery (B+)
and start solenoid (BAT).
Test starter, see engine service manual.
4-2
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safety Precautions on pages ii and ii.
TABLE 4-1. CONTROL TROUBLESHOOTING - CRANKING MODE (CONT.)
clogged or the choke needs adjust-
ment (gasoline-fueled sets).
Trouble Possible Cause Corrective Action
Engine Cranks | 1. Restricted fuel supply due to: 1a. Open any closed shutoff valve in the fuel line
But Does Not a. Closed shutoff valve in supply supplying the engine.
Start line. 1b. Fill the main fuel supply tank if the set is gaso-
b. Engine is not getting fuel. line or propane fueled. for natural gas fueled
sets, check with the gas utility.
2. The engine ignition system is malfunc- | 2. Service according to the engine service man-
tioning (ignition coil, distributor, spark ual.
plugs, high tension spark plug and coil
cables and timing.
3. Run relay (K12) not energized due to: | За. Test solenoid K11 and wiring.
a. Defective start solenoid (K11). 3b. Test run relay K12 and wiring.
b. Defective run relay (K12).
4. Optional fuel solenoid (K1) not ener-| 4a. Check wiring continuity of fuel solencid circuit.
gized due to: 4b. Test fuel solenoid.
a. Open in fuel solenoid circuit.
b. Defective fuel solenoid.
5. Optional fuel tank solenoid (K2) not | 5a. Checkwiring continuity of fuel tank solenoid cir-
energized due to: cuit. |
a. Open in fuel tank solenoid circuit. | 5b. Test fuel tank solenoid.
b. Defective fuel tank solenoid.
> 6. Lowenginetemperature is causingtoo | 6. Plug in, repair or install engine oil heaters.
low a cranking speed for starting. Replace the engine oil if it is not of the recom-
| mended viscosity for the ambient temperature.
7. Cranking voltageis toolowtoreachre-| 7. While cranking the engine, measure voltage di-
quired cranking speed. rectly across the battery terminals and then im-
mediately across the starter motor terminal and
the grounding bolt on the block. Cable, terminal
or relay contact resistance is too high if the dif-
ference is more than 1 volt. Service as neces-
sary.
Recharge or replace the battery. Specific grav-
ity for a fully charged battery is approximately
1.260 at 80° F (27° C).
8. The fuel pump (gasoline-fueled sets) | 8. Replace or service the fuel pump according to
is malfunctioning. the engine service manual.
9. The carburetor fuel passages are| 9. Cleanand rebuild gasoline carburetors with the
appropriate carburetor kit according tothe kitin-
structions. Adjust fuel mixture according to the
engine service manual. Refer to Section 6, Ad-
justments, to service the automatic choke.
4-3
RUN MODE
When the engine starts, release the Start / Stop / Test switch and it will return to the center run position. The
control assembly begins the run. mode when the switch is released or the engine speed exceeds 900 pm.
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safety Precautions on pages ii and lii.
TABLE 4-2. CONTROL TROUBLESHOOTING - RUN MODE
Trouble Possible Cause Corrective Action
Engine Starts 1. Low oil level. Check oil level and add oil if low.
But Stops
When Start | 2. Centrifugal switch (S1) faulty oroutof | 2. Referto Section 6, Adjustments.
Switch is adjustment.
Released 3. Defective fault sensor switch (low oil | 3. Refer to engine service manual.
pressure, high air temp., or overspeed |
switch).
4. Open or defective fault circuit breaker | 4. Check breakers. If open, locate and correct
(CB4, CB5, or CB6). cause of fauit.
5. Diode CR12 defective. 5. A good diode has a higher reading in one direc-
tion than the other. If both readings are high, or
low, diode is defective.
Engine Starts, | 1. Fuel delivery to the set is inadequate. 1a. Check for and replace clogged fuel lines and fil-
but Lacks ters.
Power or 1b. Measure the vertical distance between the fuel
Stops lift pump on the engine and the bottom of the dip
2. Fuel is contaminated.
3. Dirty air filter.
4. The govemor and carburetor fuel mix-
ture adjustments are incorrect.
5. Gaseous fuel delivery (vapor with-
drawal) to the set is inadequate.
6. Gaseous fuel delivery (vapor with-
drawal) to the set is inadequate.
tube in the supply tank. Make necessary provi-
sions so that lift does not exceed 6 feet (1.8
metres).
2. Connect the set to a container of fuel of known
quality and run the set under various loads. Re-
place the contents of the fuel supply tank if there
is a noticeable improvement in performance.
Check air filter and clean if dirty.
Adjust the carburetor fuel mixture according to
the engine service manual. Refer to Section 6,
Adjustments, to service the automatic choke.
5. Check the gas supply pressure at the fuel inlet
fitting on the skid. Make necessary provisions
so that gas supply pressure is at least 10 inches
(254 mm) Water Column (WC) when the set is
under full load, and not more than 20 inches
(508 mm) WC. (The gas supply system must be
able to supply this pressure when supplying all
other concurrent building loads.)
6. Check with the propane supplier or the gas util-
ity to confirm the energy content of the gaseous
fuel being used. Propane must have approxi-
mately 2500 BTU’s per cubic foot and natural
gas 1000 BTU's per cubic foot.
4-4
AN
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safety Precautions on pages ii and iil.
TABLE 4-2. CONTROL TROUBLESHOOTING - RUN MODE (CONT.)
Trouble Possible Cause Corrective Action
Engine Starts, | 7. The carburetor fuel passages (gaso- | 7. Clean and rebuild gasoline carburetors with the
but Lacks line-fueled sets) are clogged. appropriate carburetor kit according to the kitin-
Power or structions. Adjust fuel mixture according to the
Stops (Cont.) engine service manual.
8. Fault shutdown occurs, but no fault | 8. Perform lamp test by engaging Alarm Test
lamp indication. switch. All lamps should light. Replace defec-
tive lamp.
9. Fault lamp illuminated: 9a. Refer to Section 6, Adjustments, to verify op-
a. Overspeed eration of overspeed switch (S5).
b. Low Oil Pressure 8b. Check oil level and add oil if low. Monitor oil
pressure gauge. If gauge reading is within nor-
mal range, switch S4 is defective. If oil pressure
is low, stop engine immediately. Refer to engine
service manual.
9c. Checkairinletto make sure itis open and free of
debris. Refer to engine service manual to verify
operation of high engine temp switch (S6).
c. High Engine Temperature.
10. No fault condition. 10. Check condition of all control wiring to ensure
correct and secure terminal connections.
4-5
BATTERY CHARGE MODE
_ With the genset running, AC voltage is produced in the B1-B2 windings for the battery charge circuit. The AC
output voltage from the B1-B2 winding is converted to DC voltage when it passes through the half-wave recti-
fier diode (CR21). The voltage is then supplied through battery charge resistor (R21). The 12-volt DC output
(two-ampere maximum) is used to prevent discharge of the generator set starting battery during genset opera-
tion. This output is not sufficient to charge a low or dead battery.
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safety Precautions on pages il and iii.
TABLE 4-3. BATTERY CHARGE MODE
b. Low electrolyte level in battery.
c. Long periods of non-use.
d. Improperly wired battery.
2. Generator set charging circuit not
functioning due to: |
a. Open in circuit between genera-
tor B1-B2 winding and battery
(B+).
b. Open charging resistor (R21).
¢. Diode CR21 defective.
d. Generator B1-B2 defective.
1b.
ic.
1d.
2b.
2c.
2C.
Trouble Possible Cause Corrective Action
Low Battery 1. Weak or discharged battery due to: la. Adjust slide tap on adjustable resistor R21 for
Voitage a. Low charge rate. proper charge rate. Refer to Battery Charge -
Rate Adjusiment in Section 6.
Replenish electrolyte and recharge battery.
Connect a separate battery charger to bring
battery up to full charge.
Reconnect and check battery connection.
Check all wiring connections between the gen-
erator B1-B2 windings and the battery B+ con-
nections, including all connections to the diode
CR21 and battery charge resistor (R1).
Remove wires from the charge resistor (R21)
and measure its resistance. A normal reading is
2 ohms.
A good diode has a higher reading in one direc-
tion than the other. If both readings are high, or
low, diode is defective.
Refer to servicing the generator section.
4-6
STOP MODE
Momentarily pushing the Start / Stop / Test switch (S11) to the Stop / Test position begins the stop mode.
[AWARNING| Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safety Precautions on pages ii and iil.
TABLE 4-4. CONTROL TROUBLESHOOTING - STOP MODE
Trouble Possible Cause Corrective Action
Generator Set | 1. Stop relay (K14) not energized due to: | 1a. Test Start / Stop / Test switch and wiring.
Does Not Stop a. Defective Start / Stop / Test | 1b. Testrelay K14 and wiring.
When Switch switch (S11).
Is Pushed To b. Defective relay (K14).
Stop
4-7
GENERATOR TROUBLESHOOTING
Use the following troubleshooting guide to help locate problems related to the generator. Refer to the wiring
diagram in Section 7 for wiring connections.
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safety Precautions on pages Ii and iil.
TABLE 4-5. GENERATOR TROUBLESHOOTING
2. The line circuit breaker has TRIPPED.
3. The line circuit breaker is faulty.
4. Field circuit breaker CB21 has
TRIPPED.
5. Field circuit breaker CB21 is faulty.
6. The field has lost its residual magnet-
ism.
7. The generator is faulty.
8. Defective commutating reactor
CMR21.
9. Defective voltage reference trans-
former (T21)
Trouble Possible Cause Corrective Action
No AC Output | 1. The line circuit breaker is OFF. 1. Find out why the circuit breaker was turned
voltage OFF, make sure it is safe to reconnect power,
and then throw the circuit breaker ON.
2. Shut down the set and service as necessary to 1
clear the short circuit or ground fault that
caused tripping, and then RESET the circuit
breaker and start the set.
3. Shut down the set, make sure the power output
lines from the set have been disconnected from
all other sources of power, attempt to RESET
the circuit breaker and throw it ON and check for
electrical continuity across each line contact.
Replace the circuit breaker if there is measur-
able resistance across any contact.
4. RESET the circuit breaker. If it keeps tripping,
troubleshoot according to Trouble heading,
Field Circuit Breaker Keeps Tripping.
5. Shutdown the set, attemptto RESET the circuit
breaker and disconnect either lead. Replace
the circuit breaker if there is measurable resis-
tance across the terminals.
6. If reference voltage across TB21-1 & 2 is not
20VAC or more, flash the field according to
Servicing the Generator in Section 5.
7. Disconnect stator leads 1 & 2 from TB21-1 & 2.
Reference voltage across leads must be 20
VAC or more. If not, troubleshoot according to
Trouble heading, Field Circuit Breaker Keeps
Tripping.
8. Shut down the set and check CMR21 winding
resistances according to Servicing the Genera-
tor in Section 5.
9. Shutdown the set and check T21 winding resis-
tances according to Servicing the Generator in
Section 5.
4-8
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safely Precautions on pages il and ill.
TABLE 4-5. GENERATOR TROUBLESHOOTING (CONT.)
Trouble Possible Cause Corrective Action
No AC Output | 10. Voltage Regulator VR21 is faulty. 10. Check voltage across TB21-3 & 4. Voltage
voltage (Cont.) across leads must be 7.0VDC or more. If not,
check all connections against the wiring dia-
grams on page 7-7 and rewire as necessary.
Replace the voltage regulator if the wiring is
correct and there is no output voltage.
[A.cauTioN] Rep acing the voltage regulator
pefore servicing other faults can lead to
damage to the new voltage regulator.
Output Voltage | 1. Engine speed is too high or too low. 1a. Adjust engine speed according to engine serv-
Is Too High Or ice manual.
Too Low 1b. If engine speed is unstable, troubleshoot ac-
cording to Table 4-2, Control Troubleshooting -
Run Mode
2. The voltage has been adjusted im- | 2. Adjust output voltage according to AC Control
properly. . in Section 2.
3. Improper connections have been | 3. Shut down the set and reconnect according to
made at the generator output termi- the appropriate reconnection diagram (Page
nals.
4. The rotating rectifier assembly (diodes | 4. Shut down the set and check each diode ac-
CR1 through CR6) is faulty. cording to Servicing the Generator in Section 5.
Service as necessary.
5. Defective reference transformer T21. 5. Shutdown the set and check T21 winding resis-
| tances according to Servicing the Generator in
Section 5.
6. Voltage Regulator VR21 is faulty. 6. Replace the voltage regulator.
Replacing the voltage regulator
before servicing other faults can lead to
damage to the new voltage regulator.
4-9
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery A
hazards should perform service procedures. Review Safety Precautions on pages ii and iii. |
TABLE 4-5. GENERATOR TROUBLESHOOTING (CONT.)
Trouble Possible Cause Corrective Action
Output Voltage | 1. The voltage has been adjusted im- | 1. Adjust output voltage according to AC Control
Is Unstable properly. in Section 2.
2. The voltage adjusting rheostaton the | 2. Unlock the voltage adjusting screw on the front
control panel is faulty (if provided). of the control panel and disconnect either lead
| from the rheostat. Measure resistance between
terminals 1 and 2 while turning the adjusting
screw fully one way and thenthe other. Replace
the rheostat if it is open at any point, or if resis-
tance does not vary smoothly from zero to ap-
proximately 100,000 ohms.
3. Voltage Regulator VR21 is faulty. 3. Replace the voltage regulator.
A CAUTION | Replacing the voltage regulator
before servicing other faults can lead to
damage to the new voltage regulator.
4-10
Many troubleshooting procedures present hazards that can result in severe personal In-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review Safety Precautions on pages ii and lil.
TABLE 4-5. GENERATOR TROUBLESHOOTING (CONT)
Trouble Possible Cause Corrective Action
Field Circuit 1. The rotating rectifier assembly (diodes | 1. Shut down the set and check each diode ac-
Breaker Keeps CR1 through CR6) is faulty. cording to Servicing the Generator in Section 5.
Tripping Service as necessary.
2. The exciter field winding is shorted. 2. Shut down the set and check exciter field wind-
ing resistance according to Servicing the Gen-
erator in Section 5. Replace the exciter field as-
sembly if winding resistance does not meet
specifications.
3. The exciter rotor windings areshorted. | 3. Shutdown the setand check exciter winding re-
sistances according to Servicing the Generator
in Section 5. Replace the generator rotor as-
sembly if exciter rotor winding resistances do
not meet specifications.
4. The main rotor winding is shorted. 4. Shutdown the set and check main rotor winding
resistance according to Servicing the Genera-
tor in Section 5. Replace the generator rotor as-
sembly if main rotor winding resistance does
not meet specifications.
5. The stator windings are shorted. 5. Shut down the set and check stator winding re-
~ sistances according to Servicing the Generator
in Section 5. Replace the generator stator as-
sembly if stator winding resistances do not
meet specifications.
6. Voltage Regulator VR21 is faulty. 6. Replace the voltage regulator.
Replacing the voltage regulator
before servicing other faults can lead to
damage to the new voltage regulator.
4-11
Many troubleshooting procedures present hazards that can result in severe personal in-
jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery 2 —
hazards should perform service procedures. Review Safety Precautions on pages li and ili.
TABLE 4-5. GENERATOR TROUBLESHOOTING (CONT.)
Trouble Possible Cause Corrective Action
Phase 1. The connected loads are distributed | 1. Shutdown the set and redistribute the loads so
Currents Are unevenly among the phases. that there is a difference of less than 10 percent
Unbalanced | | between phases.
2. Improper connections have been | 2. Shut down the set and reconnect according to
made at the generator output termi- the appropriate reconnection diagram (Page
nals. 7-7).
3. The stator windings are faulty {openor | 3. Shut down the set and check stator winding re-
shorted). sistances according to Servicing the Generator
in Section 5. Replace the generator stator as- |
sembly if stator winding resistances do not
meet specifications. |
4. A load has a ground fault or short cir- | 4. Service the faulty equipment as necessary
cuit.
4-12
5. Generator Tests and Adjustments
GENERAL
The following tests and adjustments can be per-
formed without disassembly of the generator. Be-
fore starting resistance measurements, disconnect
the starting battery cables (negative [-] first) to
make sure the engine will not start while performing
these tests.
Always disconnect a battery
charger from its AC source before disconnect-
ing the battery cables. Otherwise, disconnect-
ing the cables can result in voltage spikes high
enough to damage the DC control circuits of the
set.
Accidental starting of the generator
set while working on it can cause severe per-
sonal Injury or death. Prevent accidental start-
ing by disconnecting the starting battery cables
(negative [-] first).
Arcing can Ignite the explosive hydrogen gas
given off by batlerles, causing severe personal
injury. Arcing can occur if the negative (—) bat-
tery cable Is connected and a tool being used to
connect or disconnect the positive (+) battery
cable accidentally touches the frame or other
grounded metal part of the set. To prevent arc-
ing, always remove the negative (-) cable first,
and reconnect it last.
BLOWER
ENGINE-GENERATOR
ADAPTER
AIR BAFFLE
STATOR-
THROUGH-STUD
STATOR
ROTOR
BRUSHLESS
EXCITER ROTOR
TORQUE TO
130-150 FT. LBS
(176-203 Nem)
TORQUE TO
55-60 FT. LBS
(75-81 Nem)
ROTOR-
THROUGH-STUD
O-RING
SEAL
ROTATING
RECTIFIER
ASSEMBLIES
COVER
(HOUSED)
BRUSHLESS
EXCITER STATOR
END BELL TORQUE TO 19-21
FT. LBS (26-28 Nem)
FIGURE 5-1. GENERATOR
5-1
FLASHING THE EXCITER FIELD
The following procedure is used for momentarily
flashing the exciter field with a low voltage to restore
the residual magnetism in the alternator rotor.
Flashing the field is usually necessary when install-
ing a new brushless exciter stator wound assembly,
but seldom is necessary under other circum-
stances. If the residual voltage is missing, it might
be necessary to restore magnetism by flashing the
exciter field as follows.
HAZARDOUS VOLTAGE. Touching
uninsulated high voltage parts inside the con-
trol box can result in severe personal injury or
death. Measurements and adjustments must be
done with care to avoid touching high voltage
parts.
For your protection, stand on a dry wooden plat-
form or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry from
your hands and wear elbow length insulating
gloves.
1. There are two types of voltage regulators
(VR21) that are available for this genset. Refer
to Figure 5-2 to locate the appropriate termi-
nals for battery lead connection.
. Use a six volt dry cell battery with two clip leads
and a 12 amp., 300 volt diode as shown in Fig-
ure 5-2. If a six volt battery is not available, a 12
volt automotive battery can be used by adding
a 20-ohmresistorin series; or a 24 volt automo-
tive battery can be used by increasing the re-
sistance to 40-ohms.
Incorrect flashing procedure
can damage the voltage regulator. Do not
keep excitation circuitry connected longer
than five seconds.
. After starting engine, touch positive (+) battery
lead to TB1-4 or PIN 8, and negative (-) lead to
TB1-5 or PIN 7 terminais just long enough until
voltage starts to build up or damage may occur
to exciter-regulator system.
AA Aled ©
TT
e
|
!
| 4
Q [|
3 =
= LE
(AVR P/N 300-1540))
12 AMP
300 VOLT DIODE
(AVR P/N 305-0688)
FIGURE 5-2. FLASHING THE EXCITER STATOR
TESTING REACTOR CMR21
The reactor assembly CMR21 leads are marked 1,
2, 3 and 4. Wires 1-2 and 3-4 are wound on the
same iron core.
Resistance between 1-2 and 3-4 should be 0.38 to
0.39 ohms and 0.38 to 0.46 ohms respectively at
77° F (25° C). Resistance between coils (e.g. 1-3)
and from any terminal to reactor frame should be in-
finity.
TESTING REFERENCE TRANSFORMER
T21
The reference transformer T21 has four leads
marked H1, H2, X1 and X2. H1-H2 are the primary
leads. X1-X2 are the secondary leads.
Resistance between H1-H2 should be 133 to 139
ohms, between X1-X2, 133 to 163 ohms at 77° F
(25° C). Resistance between coils and from any ter-
minal to transformer frame should be infinity.
5-3
FIGURE 5-3. REACTOR CMR21
1 TO 1 RATIO
HT H2
AANA /
T21
Y Y YY
X1 X2
FIGURE 5-4. TRANSFORMER T21
TESTING EXCITER ROTATING
RECTIFIERS
Two different rectifier assemblies make up the rotat-
ing rectifier bridge assembly (Figure 5-5). Using an
accurate ohmmeter, test each CR using negative
and positive polarities.
Layers of dust can cause diodes to
overheat and fall. Brush dust off regularly.
1.
2.
Disconnect all leads from assembly to be
tested.
Connect one test lead to F1+ stud and connect
other lead to CR1, CR2, and CRS3 in tum; re-
cord resistance value of each rectifier.
. Connect one lead to F2- stud and connect
other lead to CR4, CR5 and CR6 in turn; record
resistance value of each rectifier.
. Reverse ohmmeter leads and repeat steps 2
and 3. Record resistance value of each rectifier
F1+ to CR1, CR2, and CR3 and F2- to CRA,
CRS5 and CRE.
. All three resistance readings should be high in
one test and low in the other test. If any reading
is high or low in both tests, rectifier assembly is
defective.
. Replace defective rectifier assembly with new,
identical part.
Use 24 Ibs-In. (2.7 Nem) torque when tightening
nuts on F1+ and F2- and CR1 through CR6.
5-4
DIGITAL
OHMMETER
=]
|
FIGURE 5-5. TESTING ROTATING RECTIFIERS
TESTING EXCITER STATOR
Test the exciter stator {Figures 5-6 and 5-7) for open
or shorted windings and grounds as follows.
Testing For Open or Shorted Winding
Measure winding resistance with a Wheatstone
bridge or digital ohmmeter.
Disconnect F1+ and F2— exciter field leads from ter-
minal block in generator end bell. The resistance
between field leads should be 10.98 to 13.42 ohms
at 68° F (20° C). Replace the stator if winding resis-
tance is not as specified.
Testing For Grounds
Use a Megger. or insulation resistance meter that
applies 500 VDC or more for this test.
Disconnect F1+ and F2—exciter field leads from ter-
minal block in generator end bell. Measure resis-
tance between either lead and the stator lamina-
tions. Reading should be 1 megohm (1,000,000
ohms) or greater. If not, the exciter stator is ques-
tionable and might require removal for oven drying
and retest. A shorted stator must be replaced.
WHEATSTONE
BRIDGE
FIGURE 5-6. TESTING WINDING RESISTANCE
= PVRS Ne
7 = 7
7
MEGGER OR INSULATION
RESISTANCE METER
FIGURE 5-7. TESTING WINDING FOR GROUNDS
9-5
TESTING EXCITER ROTOR
Disconnect the main rotor field leads that connect to
the rotating rectifier assemblies at F1+ and F2-.
Testing For Open or Shorted Winding
Use a Wheatstone Bridge or a digital ohmmeter for
this test.
Disconnect main rotor field leads which connect to
rotating rectifier assemblies at F1+ and F2-. Discon-
nect lead wires from diodes CR1 through CRE. Test
between exciter lead pairs T1-T2, T2-T3 and T1-T3.
Resistance should be 0.5 to 0.6 ohms at 68° F (20°
C).
Testing For Grounds
Use a Megger or insulation resistance meter that
applies 500 VDC or more for this test.
With all generator leads disconnected from rotating
rectifiers CR1 through CR6, apply test leads be-
tween any CR lead and the rotor laminations. Read-
ing should be 1 megohm (1,000,000 ohms) or
greater. If not, the exciter rotor is questionable and
might require removal for oven drying and retest. A
shorted rotor must be replaced.
Use 24 Ibs-in. (2.7 Nem) torque when tightening nuts
on F1+ and F2- and CR1 through CR6.
EXCITER ROTOR
ASSEMBLY
WHEATSTONE
BRIDGE
TESTING WINDING
CONNECTION DIAGRAM
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5
EXCITER ROTOR || ZE
LAMINATION |
MEGGER OR INSULATION
RESISTANCE METER
TESTING WINDING FOR GROUNDS
. ES-17945
FIGURE 5-8. TESTING THE EXCITER ROTOR
5-6
TESTING MAIN ROTOR WINDING
Test the main rotor winding (Figures 5-9 and 5-10)
for grounds, opens, and shorts as follows.
Testing For Open or Shorted Winding
Use a digital ohmmeter for this test.
1. Disconnect main rotor field leads which con-
nect to rotating rectifier assemblies at F1+ and
F2-.
2. Check resistance across F1+ and F2- leads.
Resistance should be within + 10% of the fol-
lowing values at 77° F (25° C). If resistance is
low, there are shorted turns. If resistance is
high, rotor winding is open. In either case, rotor
must be replaced.
e JB: 2.76 to 2.82 ohms
e JCA 8 JCB: 2.50 to 2.55 ohms
Testing For Grounds
Check for grounds between the rotor winding and
the rotor shaft as shown. Use a Megger or insulation
resistance meter which applies 500 VDC or more
for this test.
Be sure to remove both rotor leads
so the rotating rectifiers are isolated. Fallure to
do this will damage the rectifiers.
1. Disconnect main rotor field leads which con-
nect to rotating rectifier assemblies at F1+ and
F2-.
2. Connect test leads between one of the two
leads and the rotor shaft. Meter should read 1
megohm (1,000,000 ohms) or greater. If not,
the rotor is questionable and might require re-
moval for oven drying and retest. A shorted ro-
tor must be replaced. |
5-7
MAIN ROTOR
LEADS Fi+, F2—
FIGURE 5-9. TESTING WINDING RESISTANCE
MEGGER OR
INSULATION
RESISTANCE
METER
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FIGURE 5-10. TESTING MAIN ROTOR WINDING
TESTING MAIN STATOR WINDINGS
Testthe main stator (Figure 5-11) for opens, shorted
windings, and grounds as follows.
Testing For Open or Shorted Windings
Use a Wheatstone bridge or ohmmeter having at
least 0.001 ohm precision for this test.
Measure electrical resistance across each pair of
stator leads as shown in Figure 5-11. The proper re-
sistance values are shown in Table 5-1. All resis-
tances should be +10% of value shown at 68° F (20°
C).
If a winding is shorted, open or grounded, replace
the stator assembly. Before replacing the assembly,
check leads for broken wires or insulation.
TABLE 5-1. RESISTANCE VALUES FOR STATORS
GENERATOR JB JCA/JCB
12 Lead 60HZ ..460 .220
12 Lead 50Hz ..498 .198
4 Lead 60HZ 224 .087
4 Lead 50Hz ..294 .110
Testing For Grounds
Use a Megger or insulation resistance meter that
applies 500 VDC or more for this test.
Some generators have ground connections to the
frame. Check wiring diagram.
Disconnect all stator leads and winding taps from
their respective terminals and make sure the ends
do not touch the generator frame. Measure electri-
cal resistance between any stator lead and the sta-
tor laminations. Replace the stator if insulation re-
sistance is less than 1 megohm.
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FIGURE 5-11. TESTING THE GENERATOR STATOR
5-8
REMOVING AND DISASSEMBLING THE
GENERATOR
The generator is heavy. You will need an assistant
and a hoist of sufficient capacity to remove and
service the generator.
Accidentally dropping the genera-
tor can damage It and cause severe personal in-
jury and death. The hoist, straps and chains
must have sufficient capacity and be attached
properly so that the load cannot shift.
Before starting, disconnect the starting battery ca-
bles (negative [-] first) to make sure the set will not
start while working on it.
Always disconnect a battery
charger from its AC source before disconnect-
ing the battery cables. Otherwise, disconnect-
ing the cables can result in voltage spikes high
enough to damage the DC control circuits of the
sel.
Accidental starting of the generator
set while working on it can cause severe per-
sonal injury or death. Prevent accidental start-
ing by disconnecting the starting battery cables
(negative [-] first).
Arcing can Ignite the explosive hydrogen gas
given off by batteries, causing severe personal
injury. Arcing can occur if the negative (-) bat-
tery cable is connected and a tool being used to
connect or disconnect the positive (+) battery
cable accidentally touches the frame or other
grounded metal part of the set. To prevent arc-
ing, always remove the negative (~) cable first,
and reconnect It last.
Disconnecting Generator Leads
1. Disconnect the line cables and conduit. For
reconnections later, make sure each cable is
clearly marked to indicate the correct terminal.
5-9
. Disconnect the remote control wiring and con-
duit. For reconnections later, make sure each
wire is clearly marked to indicate the correct
terminal.
. Disconnect all engine wiring harness connec-
tions in the generator control and output boxes.
For reconnections later, make sure each wire is
clearly marked to indicate the correct terminal.
. Disconnect all generator control leads (winding
taps) from connections in the output box. For
reconnections later, make sure each wire is
clearly marked to indicate the correct terminal.
. Ifthe set has a mounted line circuit breaker, dis-
connect the cables to the circuit breaker. For
reconnections later, make sure each cable is
clearly marked to indicate the correct terminal.
. Remove B1 lead from tapped adjustable resis-
tor in generator air outlet opening (Figure
5-12).
CHARGING
RESISTOR
COOLING AIR
OUTLET
CHARGING
DIODE
LE
!
=
B1 LEAD
FIGURE 5-12. B1 LEAD LOCATION
Removing The Generator From The Set
7. Remove stator-through-stud nuts, end bell,
and stator assembly (Figure 5-13). Screw-
driver slots in adapter provide a means for pry-
ing stator loose from the adapter. Be careful not
to let stator touch or drag on rotor.
8. Remove air baffle from adapter.
9. Support rotor with hoist and sling to avoid
bending rotor through-stud (Figure 5-14).
Loosen rotor-through-stud nut and turn out un-
til nut is at the end of the shaft.
While pulling rotor outward with one hand,
strike nut a sharp blow. Use a heavy, soft faced
hammer to loosen the rotor from its tapered
shaft fit. If rotor does not come loose, strike it a
sharp downward blow in the center of the lami-
nation stack. Rotate rotor and repeat until it
comes loose. Be careful not to hit bearing or
windings.
Raise the generator end approximately one
inch (12 mm) and securely block the engine un-
der the flywheel housing. Lower the generator
slightly so that the blocks carry most of the
weight.
After disassembly, all parts should be wiped
clean and visually inspected.
10.
11.
12.
13.
SUPPORT ROTOR WITH
HOIST AND SLING TO AVOID
BENDING THROUGH-STUD
INSERT PRY BEHIND
Bt OWER WHEEL THROUGH
AIR OUTLET OPENING
TURN NUT OUT TO END OF
GENERATOR THROUGH-STUD. STRIKE
WITH SOFT HAMMER WHILE PRYING
FIGURE 5-14. ROTOR REMOVAL
ROTOR-
THROUGH-STUD
ROTOR
ADAPTER
BLOWER
STATOR-
THROUGH-STUD
END BELL COVER
BRUSHLESS [/
EXCITER ROTOR-THROUGH #6
STATOR
-STUD NUT
BEARING
AIR BAFFLE
BRUSHLESS
EXCITER
STATOR
FIGURE 5-13. GENERATOR ASSEMBLY
5-10
REASSEMBLING THE GENERATOR
Reassembling is the reverse of disassembling.
Note the following.
1.
2.
La
~
Clean and inspect all mating surfaces.
Coat mating area between generator bearing
and end bell bearing hole with a thin film of
Molykote or equal.
. Install rotor-through-stud in engine crankshaft.
. Install key in the crankshaft.
. Slide rotor over through-stud and onto crank-
shaft. Be careful not to let weight of rotor rest on
or bend the through-stud.
. Install air baffle.
. Install stator through-studs in adapter.
. Install stator and end bell. Torque nuts on
through-studs to 19-21 ft-lbs (26-28 Nem).
9-11
10.
11.
12.
Make certain the B1 lead is placed through the
grommet in the baffle ring and out the air dis-
charge opening In the adapter.
. Torque the rotor-through-stud nut to 55-60 ft-
Ibs (75-81 Nem). The rotor and stator are auto-
matically aligned because the stator and bear-
ing support were tightened in Step 8.
Tap end bell to align at horizontal and vertical
plane; use a lead hammer to relieve stresses
on components (recheck torque).
Reconnect all generator leads.
Reconnect lead B1 on adjustable resistor, R21.
Check B1 lead to see that is is
short and is kept away from the blower. If
necessary when installing a new stator or
leads, cut B1 lead shorter and reinstall the
connector.
13. Install end bell cover.
6. Adjustments
BATTERY CHARGE RATE ADJUSTMENT
One generator winding (leads B1 and B2) supplies
current for the battery charging circuit. The current
flows through diode CR21, resistor R21 and amme-
ter M21 to the battery.
1. The slide tap on adjustable resistor R21 (see
Figure 6-1), should be set to give about 2 am-
peres charging rate. For applications requiring
frequent starts, check battery charge condition
(specific gravity) periodically, and if necessary,
increase charging rate slightly (slide tap nearer
ungrounded lead) until it keeps battery
charged. Having engine stopped when read-
justing avoids accidental shorts. Avoid over-
charging.
2. If charge winding AC output is below:
a. 19 volts on 12 volt battery charge models,
b. 38 volts on 24 volt battery charge models,
test the charging circuit for opens or grounds in
the leads and charging winding. If leads are de-
fective, replace them. If winding is defective,
replace generator stator.
3. If a separate automatic demand control for
starting and stopping is used, adjust charge
rate for maximum 4.5 amperes. This normally
keeps battery charged even if starts occur as
often as 15 minutes apart.
CENTRIFUGAL SWITCH
The start-disconnect centrifugal switch (Figure 6-2)
is located on the side of the engine, above the oil fil-
ter. The switch opens when the engine stops, and
closes when engine speed reaches 900 mm. If nec-
essary, loosen the stationary contact and adjustthe
point gap to 0.020 inch (51 mm). Replace burned or
faulty points.
High voltage, which can cause se-
vere personal injury or death, Is present at the
breaker point gap. For this reason, disconnect
the battery cable, negative (—) terminal first, be-
fore setting the breaker point gap.
COOLING AIR
OUTLET
CHARGING
RESISTOR
SLIDE TAP ES1971C
FIGURE 6-1. CHARGING RESISTOR
CENTRIFUGAL SWITCH
BREAKER POINTS
SET GAP AT 0.020 INCH (51 mm)
FIGURE 6-2. CENTRIFUGAL SWITCH
ADJUSTMENT
AUTOMATIC CHOKE (GASOLINE SETS)
Fuel is highly flammable and may
cause severe personal injury and property dam-
age. Do not allow cigarettes, flame, pilot lights,
arcing switches or equipment in area or areas
sharing ventilation.
The automatic choke is operated by a bi-metal/
heater assembly (Figure 6-3) and a vacuum pulloff
diaphragm assembly (Figure 6-4). The pulloff dia-
phragm assembly is used to partially open the
choke when the engine first starts.
An electric element controls the automatic choke.
Before the engine starts, the electric choke will keep
the choke partially closed. When the engine starts,
current is applied to the heating element, which
heats the bi-metal coil, opening the choke. The bi-
metalis calibrated to position the choke to the prop-
‘er opening under any ambient condition.
If the choke will not close, check for binding orincor-
rect assembly of the heating coil. If it will not open
after the engine starts, check for heating. The back
of bi-metal cover assembly should be warm to the
touch within a minute or two of engine starting.
If the automatic choke will not heat properly, check
for 12 volts DC at the heating element terminals dur-
ing engine starting. If not present, troubleshoot de-
fective wiring. If present, check the heater resis-
tance with an ohmmeter. With the element at room
temperature, resistance should be about 2.5 to 3
ohms. If the heating element is defective, replace
the bi-metal cover assembly (Figure 6-3) as follows.
6-2
10.
. Remove the two wire leads from the bi-metal
cover assembly.
. Remove insulating boot from the bi-metal cov-
er assembly.
. Remove the three screws that secure the bi-
metal cover assembly to the carburetor and re-
move assembly.
. Install new bi-metal cover assembly. When
installing the cover assembly onto the choke
bracket, be sure that the slot in the bi-metalarm
assembly straddles and holds the outer end of
the coil spring.
. Install, but do not tighten the three screws re-
moved in Step 2, to attach the bi-metal cover
assembly to the carburetor.
. Turn the body of the bi-metal cover in both
directions to verify that the choke plate opens
and closes. This ensures that the coil spring/bi-
metal arm assembly is correctly assembled
and that there is no binding.
. Turn the body of the bi-metal coverto select the
appropriate model (JB or JC) ofthe genset (see
Figure 6-3) and tighten the three screws to se-
cure the cover assembly to the carburetor.
. Install insulating boot over the bi-metal cover
assembly.
. Connect the two wire leads to the bi-metal cov-
er assembly.
Check operation of the vacuum pulloff dia-
phragm assembly and adjust as required. Re-
fer to the Vacuum Pulloff Diaphragm Assembly
Adjustment procedure in this section.
MODEL JC
SELECTION
MODEL JB
SELECTION
BI-METAL HEATER
ASSEMBLY
WIRE LEAD
a SLOT IN
BI-METAL ARM
ASSEMBLY
OUTER END OF
Ó COIL SPRING
BI-METAL COVER
ASSEMBLY
INSULATING
BOOT
FIGURE 6-3. CHOKE ASSEMBLY
6-3
VACUUM PULLOFF DIAPHRAGM
ADJUSTMENT
Adjust the pulloff diaphragm assembly each time it
is assembled to the carburetor as follows.
1. Apply a vacuumofat least 152.4 mm (6 inches)
of mercury to fully pull in the choke piston rod.
2. Insert a 8.5 mm (0.335 inch) drill rod between
the choke plate and the carburetor throat.
3. If necessary, bend the choke piston rod at the
point shown in Figure 6-4 until the lip of the
choke plate just touches the drill rod. Use two
pliers to bend the link.
VIEW A-A
GAUGE THE DISTANCE
BETWEEN THE CHOKE PLATE
AND THE CARBURETOR THROAT
WITH A 0.335 INCH (8.5 mm)
DRILL ROD WHEN ADJUSTING
THE CHOKE VACUUM PULLOFF
DIAPHRAGM ASSEMBLY
CHOKE PLATE
IF NECESSARY, BEND
CHOKE PISTON ROD AT THIS
POINT WHEN ADJUSTING
CHOKE VACUUM PULLOFF
DIAPHRAGM ASSEMBLY
APPLY VACUUM
FIGURE 6-4. VACUUM PULLOFF DIAPHRAGM ASSEMBLY ADJUSTMENT
7. Wiring Diagrams
GENERAL
This section consists of the schematic and connec-
tion wiring diagrams referenced in the text. The foi-
lowing drawings are included.
7-1
e Page 7-3 and 7-4 — Standard Genset DC Con-
trol Diagrams
e Page 7-5 and 7-6 — Deluxe Genset DC Control
Diagrams
e Page 7-7 — Generator Reconnection/AC Con-
trol Diagram
7-2
Onan Corporation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
Telex: 275477
Fax: 612-574-8087
Onan is a registered trademark of Onan Corporation
Cummins is a registered trademark of Cummins Engine Company
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THIS IS A REPRESENTATIVE (GENERIC)
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ENGINE DIAGRAM (2 CYL)
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NOTE:
1. ALL COMPONENTS SHOWN IN DE-ENERGIZED POSITION.
NO. 612-6642 sh3
REV.C
MODIFIED 8/3/94
GENSET DC CONTROL DIAGRAMS (STANDARD CONTROL)
7-4
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THIS IS A REPRESENTATIVE (GENERIC)
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1. ALL COMPONENTS SHOWN iN DE-ENERGIZED POSITION.
NO. 612-6640 sh3 .
REV. C
MODIFIED 8/3/94
GENSET DC CONTROL DIAGRAMS (DELUXE CONTROL)
G2 | (GENERATOR)
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110/190V, V4-VI
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120/208V, V4-V3
127/220V, V4-V4
120/240V, v4-VI
110/220V, V4-Vi
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120/240Ÿ, V4-V3
GENERATOR RECONNECTION/AC CONTROL DIAGRAM
!20V, V4-Vi
254/440V, V4-V2
277/7480V, V4-V3
120/240V, VA-VI
110 V4-VI
115 V4-V2
120 V4-V3
7-7
230/380V, V4-VI
230/400V, V4-V2
240/416V, V4-V3
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| ol Iz 4
. SA A AJ
CMR2 | r Hy а
REACT-COMM | 2 \(3)(4 | TB21}
ArT я
7 e Y 1
Fo | Iba
| | y y | ¡VOLTAGE REG ASSY
— AT —— = —————
Y I Pod
KI7-7 K17-8 |
|} } 1 1
(WHEN USED) | | | |
| 1
o A ss 7 = = = = po Ag l
| PHASE RECONNECTABLE
240V V4-vi
220V V4-V!
230V V4-V2
240V V4-V3
120V V4-Vi
Li
T4 T2
HOY Y4-VviI
НБУ V4-V2
120V V4-V3
120/240 V4-VI es HZ
Ll
Tt
110/220Y, V4-Vi
|15/230V, VA-V2
120/240V, V4-Y3
50 HZ
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
NOTES
. WITHOUT VOLTAGE ADJUST OPTION:
CONNECT JUMPER FROM VR21-!
TO VR21-2. WITH VOLTAGE
ADJUST OPTION CONNECT R23 TO
VR2!1-1 AND VR21-3. REMOVE JUMPER.
. CONNECT JUMPER FROM VR21-V4-COM
T0 Vi,2,3 OR 4 ACCORDING TO VOLTAGE
RECONNECT ING DIAGRAM,
APPLIES TO 300-1540 VOLTAGE REG ONLY.
60Hz OPERATION: CONNECT T2I-XI
TO VR21-6.
S0Hz OPERATION: CONNECT T21-X!
TO VR21-5
GENERATORS ARE NOT 50/60 Hz
RECONNECTABLE.
LEADS 3 & 4 OF CMR21 NOT USED.
. FOR 50Hz OPERATION JUMPER IS
REQUIRED BETWEEN TB1-7 & TBI-B8.
NOT REQUIRED FOR 60Hz. GENERATORS
ARE NOT 50/60Hz RECONNECTABLE.
. WITHOUT VOLTAGE ADJUST OPTION:
CONNECT JUMPER FROM TB!-6 TO
TB1-7. WITH VOLTAGE ADJUST OPTION:
CONNECT R23 TO TBi-6 & TBI-7.
REMOVE JUMPER.
OPTIONAL VOLTAGE REGULATORS (VR21)
NOT AVAIABLE ON ALL MODELS.
NO. 612—6650
REV.
MODIFIED 6/93
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