Onan ENA, ENB, ENC, ENAD, ENBA generator set Service manual

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Service
Manual
ENA
ENB
ENC
ENAD
ENBA
GENERATOR SETS
Printed in U.S.A.
928-0500
3-92
Table of Contents
SECTION
TITLE
PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How To Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2
AC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Voltage Regulator (AVR) Adjustments . . . . . . . . . . . . . . . . . . . . .
Principle Of Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-1
2-1
2-1
2-2
2-6
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Standard Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Optional Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Control Box Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine Control Monitor (A11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Auxiliary Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
The Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
The Engine Cranks But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
The Engine Runs Until Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
The Engine Lacks Power Or Stable Speed . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Engine Condition Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
There Is No Output Voltage (Engine Speed Is Stable) . . . . . . . . . . . . . . . 4-12
Output Voltage Is Too High Or Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Output Voltage Is Unstable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
The Field Circuit Breaker Keeps Tripping . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
The Phase Currents Are Unbalanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
i
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by any means, is strictly prohibited.
SECTION
5
TITLE
PAGE
SERVICING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Testing The Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Removing And Disassembling The Generator . . . . . . . . . . . . . . . . . . . . . . . 5-8
Reassembling The Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Servicing The PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
6
GOVERNORS AND CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Mechanical Governor (Prior To Spec F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governor (Prior To Spec F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governor (Begin Spec F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
6-1
6-2
6-5
6-8
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
ii
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by any means, is strictly prohibited.
Safety Precautions
• Be sure battery area has been well-ventilated
Before operating the generator set, read the Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated and maintained. Many accidents are caused
by failure to follow fundamental rules and precautions.
prior to servicing near it. Lead-acid batteries
emit a highly explosive hydrogen gas that can
be ignited by arcing, sparking, smoking, etc..
EXHAUST GASES ARE DEADLY
• Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and
audibly inspect the exhaust daily for leaks per
the maintenance schedule. Ensure that exhaust manifolds are secured and not warped.
Do not use exhaust gases to heat a compartment.
• Be sure the unit is well ventilated.
The following symbols, found throughout this
manual, 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 injury or death.
WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.
• Engine exhaust and some of its constituents
are known to the state of California to cause
cancer, birth defects, and other reproductive
harm.
CAUTION
This symbol refers to a hazard or unsafe practice which can result in personal injury
or product or property damage.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result from improper practices.
•
• DO NOT fill fuel tanks while engine is running,
unless tanks are outside the engine compartment. Fuel contact with hot engine or exhaust
is a potential fire hazard.
•
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition
source near the generator set or fuel tank.
•
• 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 vibrated or repeatedly bent.
•
• Be sure all fuel supplies have a positive shutoff
valve.
from moving parts.
Before starting work on the generator set, disconnect battery charger from its AC source,
then disconnect starting batteries, negative (-)
cable first. This will prevent accidental starting.
Make sure that fasteners on the generator set
are secure. Tighten supports and clamps,
keep guards in position over fans, drive belts,
etc.
Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry
can become caught in moving parts. Jewelry
can short out electrical contacts and cause
shock or burning.
If adjustment must be made while the unit is
running, use extreme caution around hot manifolds, moving parts, etc.
LS-11a
iii
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by any means, is strictly prohibited.
GENERAL SAFETY PRECAUTIONS
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
• Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on
dry wood platforms over floors that are metal or
concrete when around electrical equipment.
Do not wear damp clothing (particularly wet
shoes) or allow skin surface to be damp when
handling electrical equipment.
• Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks.
• Follow all applicable state and local electrical
codes. Have all electrical installations performed by a qualified licensed electrician. Tag
and lock open switches to avoid accidental closure.
• DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL
SYSTEM. Hazardous voltages can flow from
the generator set into the utility line. This
creates a potential for electrocution or property
damage. Connect only through an approved
isolation switch or an approved paralleling device.
HIGH VOLTAGE GENERATOR SETS
(1.9kV to 15kV)
•
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
install them in convenient locations. Consult
the local fire department for the correct type of
extinguisher to 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. Remove any debris from the set and keep the floor
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.
•
Substances in exhaust gases have been identified by some state or federal agencies as
causing cancer or reproductive toxicity. Take
care not to breath or ingest or come into contact
with exhaust gases.
• High voltage acts differently than low voltage.
Special equipment and training is required to
work on or around high voltage equipment. Operation and maintenance must be done only by
persons trained and qualified to work on such
devices. Improper use or procedures will result
in severe personal injury or death.
• Do not work on energized equipment. Unauthorized personnel must not be permitted near
energized equipment. Due to the nature of high
voltage electrical equipment, induced voltage
remains even after the equipment is disconnected from the power source. Plan the time for
maintenance with authorized personnel so that
the equipment can be de-energized and safely
grounded.
iv
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by any means, is strictly prohibited.
1. Introduction
ABOUT THIS MANUAL
TEST EQUIPMENT
This service manual is for the EN series gasolineand gaseous-fuel generator sets. It includes engine
and generator troubleshooting guides. Engine service instructions are in the applicable engine service manual. Operating and maintenance instructions are in the applicable Operator’s Manual.
Most of the tests in this manual can be done with an
AC-DC multimeter, frequency meter, Wheatstone
bridge (0.001 ohm precision is necessary for measuring stator winding resistance) and load test panel.
This manual does not have instructions for servicing printed circuit board assemblies. Always replace a faulty printed circuit board assembly. Attempts to repair a printed circuit board can lead to
costly damage to the equipment.
HOW TO OBTAIN SERVICE
Always give the complete Model and Serial number
of the generator set as shown on the nameplate
when seeking additional service information or replacement parts. The nameplate is located on the
side of the generator output box.
This manual contains basic (generic) wiring diagrams and schematics that are included to help in
troubleshooting. Service personnel must 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.
WARNING Incorrect service or replacement of
parts can result in severe personal injury or
death, and/or equipment damage. Service personnel must be qualified to perform electrical
and mechanical service. Read and follow Safety
Precautions, on pages ii and iii.
Read Safety Precautions and carefully observe all
instructions and precautions in this manual.
1-1
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by any means, is strictly prohibited.
5002800
FIGURE 1-1. TYPICAL GENERATOR SET
1-2
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by any means, is strictly prohibited.
2. AC Control
meter is from current transformers CT21, CT22 and
CT23.
GENERAL
The control box is mounted on top of the generator,
facing the rear. Figure 2-1 points out the components on the AC control panel. Pages 7-3 through
7-6 show the wiring connections.
Phase Selector Switch (S21) The selector switch
is used to select the phase for voltage and amperage readings.
STANDARD CONTROL PANEL
COMPONENTS
Scale Indicator Lamps (DS21 and DS22) The
scale indicator lamps indicate whether to read the
upper or lower scales of the voltmeter and ammeter.
Frequency Meter (M23) The frequency meter indicates output frequency in Hertz (Hz) and engine
speed in RPM.
Field Circuit Breaker (CB21) The field circuit
breaker protects the generator from over-excitation.
Wattmeter (M24) The wattmeter indicates output
power in kilowatts (kW).
OPTIONAL CONTROL PANEL
COMPONENTS
Powerfactor Meter (M25) The powerfactor meter
indicates output powerfactor as a percentage of
unity powerfactor.
AC Voltmeter (M21) The voltmeter indicates output
voltage for the phase selected.
Output Voltage Trimmer (R21) The output voltage
trimmer can be used to adjust output voltage plus or
minus five percent of nominal voltage.
AC Ammeter (M22) The ammeter indicates output
amperage for the phase selected. Input to the amOUTPUT
VOLTAGE
TRIMMER
SCALE
INDICATOR
LAMPS
AC
VOLTMETER
FIELD
CIRCUIT
BREAKER
AC
AMMETER
PHASE
SELECTOR
SWITCH
FREQUENCY
METER
POWER
FACTOR
METER
WATTMETER
FIGURE 2-1. AC CONTROL PANEL
2-1
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AUTOMATIC VOLTAGE REGULATOR
(AVR) ADJUSTMENTS
UFRO Adjustments
The voltage regulator has an under-frequency protection circuit having a threshold frequency that can
be preset (typically at 59 Hz for 60 Hz applications
and 49 Hz for 50 Hz applications). The red LED on
the board lights when frequency dips below the
threshold. The threshold frequency is preset by
turning the UFRO (under frequency roll off) pot
clockwise to raise it and counterclockwise to lower
it. Determine threshold frequency by lowering generator frequency until the LED lights. Note that Dip
and Dwell adjustments, below, are related.
The automatic voltage regulator is mounted on the
back wall of the control cabinet. It can be adjusted
by means of the potentiometers (pots) shown in Figure 2-2. Figures 2-3 and 2-4 show typical voltage
regulating circuits.
These measurements and adjustments are done
while the set is running and require access to uninsulated high voltage parts in the control and power
output boxes.
HIGH VOLTAGE. Touching uninsulated high voltage parts inside the control and
power output boxes can result in severe personal injury or death. Measurements and adjustments must be done with care to avoid
touching high voltage parts.
Dip Adjustments
The DIP pot adjusts the voltage vs. frequency slope
of the generator for frequencies below the threshold
preset by the UFRO pot. Turning the DIP pot clockwise increases the slope (for greater voltage roll off
as frequency drops), making it easier for the engine
to pick up a large load, but also increasing the voltage dip. The generator voltage vs. frequency slope
is the same above and below the threshold frequency when the pot is turned fully counterclockwise.
For your protection, stand on a dry wooden
platform or rubber insulating mat, make sure
your clothing and shoes are dry, remove jewelry
and wear elbow length insulating gloves intended for hazardous voltages.
Jumper Reconnections
Dwell Adjustments
Jumpers provide for reconnections to adapt the
voltage regulator to the application. See Figure 2-2.
Reconnect the response jumper, if necessary, so
that terminal A connects to terminal C if generator
output is 90 kW or less, B to C if generator output is
greater than 90 kW but less than 550 kW and A to B
if output is greater than 550kW. Reconnect the frequency jumper, if necessary, to correspond to the
application frequency.
The DWELL pot times voltage recovery when frequency dips below the preset threshold. Clockwise
adjustment increases dwell time. Full counterclockwise adjustment eliminates dwell, in which case,
voltage recovery follows engine speed recovery.
Droop Adjustments
The DROOP pot is for adjusting the input signal
from the droop compensating CT in paralleling applications. DROOP is preset at the factory for five
percent droop at full load and zero power factor.
Voltage and Voltage Stability Adjustments
Use the control panel mounted voltage trimmer, 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, lock it at its
midpoint. Then turn the VOLTS pot fully counterclockwise and the STABILITY pot to its midpoint. If
the red LED (light emitting diode) on the board
lights, refer to Jumper Reconnections and to UFRO
Adjustments. Then turn the VOLTS pot clockwise
until rated voltage is obtained. If voltage becomes
unstable when a large load is connected, turn the
STABILITY pot clockwise until voltage is stable.
Check and readjust the VOLTS pot, if necessary,
each time the STABILITY pot is readjusted.
V / Trim Adjustments
The V / Trim pot is for adjusting the input signal from
a VAR / PF controller in utility paralleling applications. Full clockwise adjustment is normal, resulting
in maximum sensitivity. The auxiliary controller has
no effect when the pot is turned fully counterclockwise.
EXC, OVER V, I / LIMIT, STAB/1and RMS
These pots are factory preset and do not require adjustment.
2-2
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by any means, is strictly prohibited.
PMG-EXCITED GENERATORS
VOLTAGE REGULATOR
(VR21)
V/TRIM
I/LIMIT
DROOP
MX321
VOLTS
FREQUENCY JUMPER:
50 HZ—3-2
60 HZ—3-1
1
2
STABILITY
3
A
B
DIP
LED
UFRO
C
DWELL
EXC
RESPONSE JUMPER:
A TO C—UNDER 90 KW
B TO C—90-550 KW
A TO B—OVER 550 KW
OVER V
SELF-EXCITED GENERATORS
A B C
60 C 50
UFRO
LED
STABILITY
SX440
RESPONSE JUMPER:
A TO C—UNDER 90 KW
B TO C—90-550 KW
A TO B—OVER 550 KW
8
7
6
5
4
3
2
1
FREQUENCY JUMPER:
50 HZ—C-50
60 HZ—C-60
VOLTS
DROOP
V/TRIM
THESE JUMPERS
MUST BE:
2-3, 4-5 AND 6-7
FIGURE 2-2. VOLTAGE REGULATOR ADJUSTMENT POTS AND SELECTION JUMPERS)
2-3
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EXCITER
ROTOR
ROTATING
RECTIFIERS
MAIN
ROTOR
PMG
ROTOR
N
S
EXCITER
STATOR
MAIN
STATOR
OUTPUT
8 VOLTAGE
7 SENSING
6 LEADS
PMG
STATOR
(NOTE 2)
ISOLATION TRANSFORMER
(NOTE 3)
INPUT
OUTPUT
8 7 6 –
8 7 6 –
K1 K2 P2 P3 P4 S2 S1 A2 A1 XXXX X 8 7 6 3 2 1
TB21
AUXILIARY TERMINAL BOARD
32
6
25
24
7
23
8
22
21
VOLTAGE
TRIMMER R21
(NOTE 4)
2
1
8
7
6
X
XX
P4
A2
A1
S2
MX321
VOLTAGE
REGULATOR
(VR21)
S1
P3
FIELD CIRCUIT
BREAKER
CB21
P2
K1
K2
WHEN PARALLELING WITH
A GENERATOR SET OR
UTILITY, TERMINALS S1
AND S2 ARE FOR
CONNECTING A DROOP
COMPENSATING CT
E1
E0
WHEN PARALLELING WITH
A UTILITY, TERMINALS A1
AND A2 ARE FOR
CONNECTING A
VAR / POWER FACTOR
CONTROLLER
— NOTES —
1. Connect like numbered terminals on auxiliary
not connected to the isolation transformer but
terminal board and voltage regulator.
is jumpered to voltage regulator terminal 8.
2. See the appropriate reconnection diagram for
4. There must be a jumper between voltage reguconnecting sensing leads 6, 7 and 8.
lator terminals 1 and 2 when voltage trimmer
3. When the generator is connected for singleR21 is not used.
phase output, voltage regulator terminal 6 is
FIGURE 2-3. TYPICAL VOLTAGE REGULATING CIRCUITS FOR PMG-EXCITED GENERATORS
2-4
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by any means, is strictly prohibited.
EXCITER
ROTOR
ROTATING
RECTIFIERS
MAIN
ROTOR
EXCITER
STATOR
MAIN
STATOR
OUTPUT
8 VOLTAGE
7 SENSING
6 LEADS
(NOTE 2)
K1 K2 P2 P3 P4 S2 S1 A2 A1 XXXX X 8 7 6 3 2 1
TB21
SX440
VOLTAGE
REGULATOR
(VR21)
32
6
25
24
S2
AUXILIARY TERMINAL BOARD
S1
21
WHEN PARALLELING WITH
A GENERATOR SET OR
UTILITY, TERMINALS S1
AND S2 ARE FOR
CONNECTING A DROOP
COMPENSATING CT
VOLTAGE
TRIMMER R21
(NOTE 3)
WHEN PARALLELING WITH
A UTILITY, TERMINALS A1
AND A2 ARE FOR
CONNECTING A
VAR / POWER FACTOR
CONTROLLER
7
23
8
A2
A1
22
1
2
3
X XX P4 P3 P2 K1K2
FIELD CIRCUIT
BREAKER
CB21
— NOTES —
1. Connect like numbered terminals on auxiliary
3. There must be a jumper between voltage reguterminal board and voltage regulator.
lator terminals 1 and 2 when voltage trimmer
R21 is not used.
2. See the appropriate reconnection diagram for
connecting sensing leads 6, 7 and 8.
FIGURE 2-4. TYPICAL VOLTAGE REGULATING CIRCUITS FOR SELF-EXCITED GENERATORS
2-5
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5. Exciter output current is proportional to exciter
field current.
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.
2. Generator output current is proportional to field
strength, which is varied to match the load.
Output voltage and frequency are held constant by the voltage regulator and engine governor, respectively.
3. Generator field strength is proportional to field
current, which is supplied by the exciter.
4. 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 shaft.
6. The automatic voltage regulator (AVR) regulates exciter field current by comparing generator output voltage and frequency with reference values.
7. PMG-Excited Generators. Exciter field current is supplied by a PMG (permanent magnet)
exciter through the voltage regulator. The PMG
consists of a stator and a permanent magnet
rotor mounted on the end of the main rotor
shaft.
8. Self-Excited Generators. Exciter field current
is supplied by the generator stator through the
voltage regulator. Residual field magnetism initiates “self-excitation” during startups.
PMG-EXCITED GENERATORS
ELECTRICAL POWER OUTPUT
AVR
MAIN STATOR
PMG
ROTOR
AND
STATOR
EXCITER
ROTOR
AND
STATOR
ROTATING
MECHANICAL
POWER
INPUT
MAIN ROTOR
SELF-EXCITED GENERATORS
ELECTRICAL POWER OUTPUT
AVR
MAIN STATOR
EXCITER
ROTOR
AND
STATOR
ROTATING
MECHANICAL
POWER
INPUT
MAIN ROTOR
FIGURE 2-5. SCHEMATIC OF GENERATOR OPERATION
2-6
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3. Engine Control
Reset / Lamp Test / Panel Lamp Switch (S11) The
switch is pushed to the Reset position (momentary
contact) to reset the engine control to restore operation following a fault shutdown. The Run / Stop / Remote switch must be in the Stop position for reset to
occur. The Lamp Test position (momentary contact) lights all the fault indicator lamps. Replace
lamps that do not light. The Panel Lamp position
lights the panel illumination lamp.
CONTROL PANEL
The control box is mounted on top of the generator,
facing the rear. Figure 3-1 shows the components
on the engine control panel.
STANDARD CONTROL PANEL
COMPONENTS
Run / Stop / Remote Switch (S12) The switch is
pushed to the Run position to start and run the generator set and the Stop position to stop the set. The
Remote position allows a remote controller to automatically run the set. The switch must be in the Stop
position when the reset switch (described next) is
used to restore generator set operation following a
fault shutdown.
OIL PRESSURE
GAUGE
Oil Pressure Gauge (M11) The oil pressure gauge
indicates engine oil pressure.
Coolant Temperature Gauge (M12) The coolant
temperature gauge indicates engine coolant temperature.
RUN/STOP/REMOTE
SWITCH
PANEL
LIGHT
COOLANT
TEMPERATURE
GAUGE
RESET/LAMP TEST/
PANEL LIGHT SWITCH
INDICATOR
LAMPS
SPEED
ADJUSTING
RHEOSTAT
DC
VOLTMETER
HOUR
METER
OIL TEMPERATURE
GAUGE
TACHOMETER
EMERGENCY STOP
BUTTON
FIGURE 3-1. ENGINE CONTROL PANEL
3-1
Redistribution or publication of this document,
by any means, is strictly prohibited.
DC Voltmeter (M13) The DC voltmeter indicates
voltage across the battery terminals during operation.
Hour Meter (M14) The hour meter indicates the accumulated number of hours the set has run. It cannot be reset.
Panel Lamp (DS11) The panel lamp illuminates the
control panel.
Detector-7 Fault and Status Indicator Lamps
(A12)
• Run (Green) This lamp indicates that the generator set is running and that the starter has
been disconnected.
• Pre Low Oil Pressure (Yellow) This lamp indicates that engine oil pressure is abnormally low
(less than 30 psi).
• Low Oil Pressure (Red) This lamp indicates
that the engine shut down because of excessively low engine oil pressure (less than
25 psi).
• Pre High Engine Temperature (Yellow) This
lamp indicates that engine coolant temperature is abnormally high (greater than 205° F
[97° C]).
• High Engine Temperature (Red) This lamp
indicates that the engine shut down because of
excessively high engine coolant temperature
(greater than 215° F [102° C]).
• Overcrank (Red) This lamp indicates that the
engine shut down because it did not start during the timed cranking period (approximately
75 seconds, including two rest periods).
• Overspeed (Red) This lamp indicates that the
engine shut down because of overspeed.
539-0741c2
FIGURE 3-2. DETECTOR-12 INDICATOR LAMPS
OPTIONAL CONTROL PANEL
COMPONENTS
Oil Temperature Gauge (M15) The oil temperature
gauge indicates engine oil temperature.
Tachometer (M16) The tachometer indicates engine speed in RPM.
Speed Adjusting Rheostat The speed adjusting
rheostat is used to adjust engine speed from the
control panel (an option with the optional electric
governor).
3-2
Redistribution or publication of this document,
by any means, is strictly prohibited.
Emergency Stop Button (S14) The emergency
stop button is a red, push-in switch used to stop the
engine. The button lights up when it is pushed in.
The button has to be pulled out and the engine control reset to restore operation.
Low Coolant Level Cutout Switch When coolant
level in the radiator top tank falls below the switch
sensor, the switch closes the circuit to ground. This
switch may be connected in parallel with the high
engine temperature cutout switch to shut down the
engine and light the High Engine Temperature
lamp or in parallel with the pre-high engine temperature switch to light the Pre High Engine Temperature light only.
LOW
COOLANT
LEVEL
SWITCH (S7)
RADIATOR
TANK TOP
SWITCH TERMINALS
SWITCH
S2 OR S6
Detector-12 Fault and Status Indicator Lamps
(A12) The Detector-12 control panel has the five following indicator lamps in addition to the standard
seven.
SWITCHED
B+ (T26)
• Low Engine Temperature (Yellow) This lamp
ENGINE
GROUND
OR
SWITCH
S2 OR S6
SWITCHED
B+ (T26)
indicates that engine temperature is less than
70° F, and the possibility that the engine might
not start.
• Low Fuel (Yellow) This lamp indicates that the
NOT
USED
fuel level in the supply tank has dropped to less
than the reserve necessary to run the set at full
load for the prescribed number of hours. The
customer has to make connections to use this
lamp.
–
ENGINE
GROUND
SCHEMATICS
WARNING
ONLY
• Fault 1 (Red) This lamp indicates that the engine shut down because of a system fault. The
customer has to make connections to use this
lamp. The lamp is a part of a 10 second time
delay shutdown circuit. The customer can
make reconnections for non-timed shutdown.
See Engine Control Monitor (ECM).
• Fault 2 (Red) This lamp indicates that the engine shut down because of a system fault. The
customer has to make connections to use this
lamp. The lamp is part of a non-time delay shutdown circuit. The customer can make reconnections for 10 second time delay shutdown.
See Engine Control Monitor (ECM).
SHUTDOWN
• Switch-off (Flashing Red) This lamp indicates that the Run / Stop / Remote switch is in
the Stop position, which prevents remote, automatic operation.
FIGURE 3-3. LOW COOLANT LEVEL SWITCH
3-3
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by any means, is strictly prohibited.
ENGINE
CONTROL
MONITOR A11
TIME DELAY
START/STOP
MODULE A15
VOLTAGE
REGULATOR
VR21
TERMINAL BOARD
TB21
OVERSPEED
MODULE
RUN RELAYS K11
(NOT SHOWN – MOUNTED ON
A BRACKET IN FRONT OF A11)
ALARM RELAY MODULES
A13 AND A14
ES1561s1
FIGURE 3-4. ARRANGEMENT OF COMPONENTS INSIDE THE CONTROL BOX
CONTROL BOX INTERIOR
Fuses
Figure 3-4 shows the arrangement of components
inside the control box, including the engine control
monitor and some of the auxiliary components under following headings.
The ECM has five replaceable fuses to protect it
from overloads and groundfaults. They are:
F1
F2
F3
F4
F5
ENGINE CONTROL MONITOR (A11)
The heart of the engine control system is the engine
control monitor (ECM). It is a printed circuit board
assembly mounted on the back wall of the control
box. It starts and stops the engine in response to the
control panel switches, engine sensors and remote
control signals. Figure 3-5 shows the newer ECM
board used in current production and as a direct replacement for older boards. The boards are distinquishable from each other in that the newer boards
have automotive-type fuses and the older boards
have cartridge-type fuses.
Starter solenoid circuit, 20 amps
Fuel solenoid (switched B+) circuits, 20 amps
Continuous B+ out to remote circuits, 15 amps
ECM circuits, 5 amps
Engine gauge circuits, 5 amps.
Function Selection Jumpers
Newer ECM boards have six selection jumpers that
can be repositioned to provide the following timed
or non-timed warnings or timed or non-timed shutdowns with warnings:
W1 Jumper Position (jumper W8 must be in the B
position):
A Non-timed warning under FLT 2 conditions.
B Non-timed shutdown and warning under
FLT 2 conditions.
C Timed warning under FLT 2 conditions.
D Timed shutdown and warning under FLT 2
conditions.
Terminals and Connectors
See Pages 7-7 through 7-14 for the appropriate
connection and schematic drawings for the DC control system. See Page 7-19 for typical customer
connections at terminal boards TB1 and TB2 on the
ECM and page 7-20 if the set is also equipped with
the auxiliary relay board.
3-4
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by any means, is strictly prohibited.
A Warning under Pre-Low Oil Pressure
conditions.
W2 Jumper Position (jumper W9 must be in the B
position):
A Non-timed warning under FLT 1 conditions.
B Non-timed shutdown and warning under
FLT 1 conditions.
C Timed warning under FLT 1 conditions.
D Timed shutdown and warning under FLT 1
conditions.
W6 Jumper Position:
A Warning under Pre-High Engine Temperature conditions.
B Shutdown and warning under Pre-High
Engine Temperature conditions.
W7 Jumper Position:
8
7
6
5
4
3
2
B Shutdown and warning under Pre-Low
Oil Pressure conditions.
W8 Jumper Position:
A Warning while running or during standby
under FLT 2 conditions.
B Allows selection of functions with W1
jumper.
W9 Jumper Position:
A Warning while running or during standby
under FLT 1 conditions.
B Allows selection of functions with W2
jumper.
1
6
5
4
3
2
1
FIGURE 3-5. ENGINE CONTROL MONITOR FUSES AND FUNCTION SELECTION JUMPERS
3-5
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by any means, is strictly prohibited.
sensing switches to which the ECM responds. The
switches function by closing the fault or warning circuit to the engine chassis ground (battery negative [-]).
ENGINE SENSORS
Figure 3-6 shows the locations of the gauge senders and the coolant temperature and oil pressure
LOW OIL PRESSURE
SENSOR (S1)
PRE-LOW OIL PRESSURE
SENSOR (S5)
T26 OF ENGINE
HARNESS
OIL PRESSURE
SENDER (E1)
VIEW A-A (BEGIN SPEC F)
LOW OIL
PRESSURE
SENSOR (S1)
OIL
PRESSURE
SENDER (E1)
PRE-HIGH
ENGINE
TEMPERATURE
SENSOR (S6)
PRE-LOW OIL
PRESSURE
SENSOR (S5)
VIEW A-A (SPEC A THRU E)
HIGH ENGINE
TEMPERATURE
SENSOR (S2)
VIEW B-B
COOLANT
TEMPERATURE
SENDER (E2)
LOW ENGINE
TEMPERATURE
SENSOR (S4)
SWITCHED BAT+
TERMINAL T26
AND GND
(OTHER END)
FIGURE 3-6. ENGINE SENSOR LOCATIONS
3-6
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by any means, is strictly prohibited.
AUXILIARY CONTROL COMPONENTS
The set might be equipped with one or more of the
following components.
CUTOUT
SWITCH
ASSEMBLY
MAIN
ROTOR
SHAFT
Mechanical Overspeed Switch (Standard)
The mechanical overspeed switch is bolted to the
end of the generator rotor shaft.
SWITCH
CONTACT
BRACKET
1. Check overspeed cutout RPM and turn the adjustment screw, if necessary, so that shutdown
occurs within the following RPM ranges:
60 Hz Sets . . . . . . . . 2000 to 2200 RPM
50 Hz Sets . . . . . . . . 1800 to 2100 RPM
2. Replace the switch if the cutout speed adjustment results in an air gap between the magnet
and the fly arm of less than 0.005 inches (0.13
mm).
3. Torque the center rotor bolt to 40 ft-lbs (54 Nm)
when replacing the switch.
SWITCH
COVER
ROTOR
CENTER
BOLT
CUTOUT RPM
ADJUSTMENT
SCREW
Es1860s
—SCHEMATIC—
FIGURE 3-7. MECHANICAL OVERSPEED SWITCH
A11-TB1-5
Electronic Overspeed Module (Optional)
A11-TB1-10
PMG-excited generators are equipped with an electronic overspeed module in the control box. The
module senses PMG output frequency to determine
generator speed (frequency). Adjust the overspeed
(HIGH) pot to cut out at 1800 to 1900 RPM for 50 Hz
sets and 2100 to 2200 RPM for 60 Hz sets. MODE
switch must be set to zero.
OVERSPEED
ADJUSTMENT
POT
NOT
USED
VR-P3
VR-P2
A11-TB1-1
FIGURE 3-8. ELECTRONIC OVERSPEED MODULE
3-7
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by any means, is strictly prohibited.
Run Relays (K11)
A11
K11
The set can be equipped with one to three 3-pole,
double-throw relays to control auxiliary equipment
such as fans, pumps, and motorized air dampers.
The relays are mounted on a standoff bracket in
front of the ECM.
TB1 10
B
TB1
A
5
The contacts are rated:
1
• 10 amps at 28 VDC or 120 VAC, 80% PF
K11
7
• 6 amps at 240 VAC, 80% PF
4
• 3 amps at 480 VAC, 80% PF
2
The set might instead be equipped with an auxiliary
relay board. If so, see Auxiliary Relay Board (ARB).
K11
8
CUSTOMER
CONNECTIONS
5
3
K11
9
6
FIGURE 3-9. RUN RELAYS
Alarm Relay Modules (A13 and A14)
A14
The set can be equipped with relay modules to interface with a remote annunciator that is powered
independently of the control circuit of the set. Sets
with Detector-7 need module A13 and sets with Detector-12, modules A13 and A14.
TB2
TB1
A11-TB2-4
FAULT#1
A11-TB2-2
FAULT#2
These are all normally open contacts and they are
rated:
• 15 amps at 250 VAC
LET
A11-TB2-13
LOW FUEL
A11-TB2-15
SWITCH
OFF
A11-TB2-12
A13-TB2-8
• 15 amps at 30 VDC
The set might instead be equipped with an auxiliary
relay board. If so, see Auxiliary Relay Board (ARB).
A13
TB1
RUN
TB2
A11-TB1-3
PRE -LOP
A11-TB2-11
PRE-HET
A11-TB2-10
LOP
A11-TB2-9
HET
A11-TB2-8
OS
OC
A11-TB2-7
A11-TB2-6
A11-TB1-7
A14-TB2-6
(12 LIGHT)
FIGURE 3-10. ALARM RELAY MODULES
3-8
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by any means, is strictly prohibited.
for relay K2, and W3 for relay K3. They can be located in any of 3 positions (A, B, C) independently of
each other.
Auxiliary Relay Board (ARB)
The following describes the design/functional criteria for the auxiliary relay board (ARB) with a Detector-7 or -12 Genset control. The board is mounted
directly on top of the ECM using standoffs and has
access holes for the fuses located on the ECM.
There are two versions of the ARB; with and without
the set of 12 Fault relays (Figure 3-11). Page 7-20 is
a detailed connection diagram for the ARB.
Jumper Position A (Run): The relay operates
as a Run relay, energizing when SW B+ is applied from the ECM.
Jumper Position B (Common Alarm): The
relay operates as a Common Alarm relay. The
relay energizes any time there is an engine
shutdown. This signal is provided from the
ECM.
The set might instead be equipped with separate
run and alarm relay modules. If so, see Run Relay
(K11) and Alarm Relay Modules (A13 and A14).
Jumper Position C (Isolated): The relay operates as an Isolated relay. The relay coil is energized by a customer applied B+ signal
through the terminal block; TB3-1 for relay K1,
TB4-1 for relay K2, and TB5-1 for relay K3.
Terminal Blocks:
TB1 – ARB TB1 and ECM TB1 are identically numbered and provide the same remote control connection points. Note that additional terminals are provided for terminals 5, 7, and 10 of ARB TB1.
Jumpers W11, W12, and W13 perform the same
functions for their respective relays; W11 for relay
K1, W12 for relay K2, and W13 for relay K3. They
can be located in two different positions (A, B) independently of one another.
TB2 through TB5 – Connection points for relays
K1 through K3. TB2 provides the N/O and N/C connections (three form ‘C’ contacts for each relay).
TB3 through TB5 provide the common connection
points (TB3 for K1, TB4 for K2 and TB5 for K3).
Jumper Position A: The relay operates isolated from the board. The customer provides
the circuit completion through terminal block;
TB3 for relay K1, TB4--5 for relay K2, and
TB5-5 for relay K3. The customer can operate
the relay with switched ground logic or use this
relay in the middle of more complex logic circuits if needed.
TB6 and TB7 – Connection points for fault relays
K4 through K15. Three terminals are provided for
each relay, which are labeled COM, N/C, N/O.
Plug-In Relays (K1, K2, K3):
Jumper Position B: The relays operate with
the coils connected to ground through the
board connections. The coil will require a B+
signal to energize with the jumper in this position.
The ARB can be equipped with one to three 3-pole,
double-throw relays. These relays (K1, K2, K3) are
field changeable plug-in relays for easy field addition and replacement.
Fault Relays (K4 through K15):
The relay contact ratings are:
• 10 amps at 28 VDC or 120 VAC, 80% PF
These optional relay modules are used to operate a
remote alarm annunciator that has an independent
power source. This allows the use of either AC or
DC for alarm drives. The relays are energized
through the latching relays on the ECM and provided N/O and N/C contacts for each external alarm
connection.
• 6 amps at 240 VAC, 80% PF
• 3 amps at 480 VAC, 80% PF
Each relay can be operated as a RUN, COMMON
ALARM, or ISOLATED COIL with the changing of a
jumper.
The 12 relays with form ‘C’ contacts are rated:
Jumper Positions for Plug-In Relays:
• 10 Amp, 120 VAC
Jumpers W1, W2 and W3 perform the same functions for their respective relays, W1 for relay K1, W2
• 10 Amp. 30 VDC
3-9
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by any means, is strictly prohibited.
JUMPERS
RUN RELAY
MODULE(S)
K1
K2
JUMPERS
K3
J1, J2 WIRE
HARNESS PLUG
CONNECTIONS
FROM ECM
TB6, TB7 AND
RELAYS K4
THROUGH K15
ARE OPTIONAL
300-4111c
FIGURE 3-11. AUXILIARY RELAY BOARD (ARB)
3-10
Redistribution or publication of this document,
by any means, is strictly prohibited.
Over / Under Voltage Module (A17)
The set can be equipped with an adjustable voltage-sensitive relay usually connected into the Fault
1 circuit (Detector-12 controls only) to shut down
the set when the output voltage is over or under
nominal voltage by the preselected percentage
(typically 10 percent over and under).
With the module is an adjustable time delay relay
(K17) to prevent nuisance tripping. An adjustment
of 25 percent is equivalent to about 2.5 seconds
delay.
Recalibrate the module as follows before installing
it on 139/240 VAC or 277/480 VAC sets.
*
*
WARNING HIGH VOLTAGE. Touching uninsulated high voltage parts inside the control panel
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 platform or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry and
wear elbow length insulating gloves intended
for hazardous voltages.
1. Remove the two screws that secure the top to
the case of the module and withdraw the top
assembly.
2. Adjust the SET pot for the UNDER setpoint on
the face of the top assembly to 75 percent.
3. Apply single-phase, 60 Hertz, 104.25 VAC
across terminals L and N.
4. Adjust pot R25 on the PC board until the relay
trips (de-energizes).
5. Adjust the SET pot for the OVER setpoint on
the face of the top assembly to 125 percent.
6. Apply single-phase, 60 Hertz, 173.75 VAC
across terminals L and N.
7. Adjust pot R26 on the PC board until the relay
trips (energizes).
8. Repeat the above steps until no adjustments
are necessary.
9. Reassemble the module.
10. On the module nameplate mark out the factory
calibration value for monitored voltage (120 V)
and write in 139 V.
**
* CONNECTED TO TB11-45 WHEN GENERATOR IS PARALLELED.
** CONNECTED TO GENERATOR LEAD LO
WHEN THE GENERATOR IS CONNECTED
FOR SINGLE PHASE.
FIGURE 3-12. OVER / UNDER VOLTAGE
MODULE
3-11
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Over / Under Frequency Module (A19)
The set can be equipped with an adjustable frequency-sensitive relay to shut down the set when
the output frequency (Hz) is over or under nominal
frequency by the preselected amount. It is usually
connected into the Fault 2 circuit (Detector-12 controls only) if the over / under voltage module is also
provided. Set points are typically 5 Hertz over and
under nominal frequency (50 or 60 Hertz) and reset
points 3 Hertz over and under.
3003141
FIGURE 3-13. OVER / UNDER FREQUENCY
MODULE
3-12
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by any means, is strictly prohibited.
justable to delay starts from 1 to 15 seconds to prevent nuisance starts in installations where momentary power interruptions are frequent. It is adjustable to delay stops 1 to 30 minutes to allow the
prime source of power time to stabilize.
Time Delay Start / Stop Module (A15)
The set can be equipped with a module to delay
starting and stopping when the start and stop signals are received from the remote controller. It is ad-
TIME DELAY STOP POTENTIOMETER
TIME DELAY START
POTENTIOMETER
TB1
A11-TB1-2
(PRIMARY START DISCONNECT)
A11-TB1-6
(REMOTE START)
A11-TB1-3
(SECONDARY START DISCONNECT)
REMOTE
CONTROL
A11-TB1-5
(B–)
A11-TB1-7
(B+)
A11-TB1-7
(B+)
ES1855s
FIGURE 3-14. TIME DELAY START / STOP MODULE
3-13
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by any means, is strictly prohibited.
10. Relays K2 and K3 are deenergized (by latching
relay K6) causing shutdown to occur if the engine does not start within 75 seconds. The
Overcrank indicator lamp lights and common
alarm terminal TB1-4 is powered.
SEQUENCE OF OPERATION
The sequence of operation is as follows. Refer to
the schematic on Page 7-8, 7-10, 7-12, or 7-14, as
appropriate.
1. The ECM is powered by cranking battery voltage (24 VDC). Terminal TB1-9 is connected to
battery positive (+) and connector P1-6 to battery negative (-).
The ECM has a cycle crank feature whereby the
engine is cranked for three 15 second periods
alternated with two 15 second rest periods.
11. Relay K3 is deenergized (by latching relay K6)
causing shutdown to occur during operation
when a low oil pressure, high engine temperature or engine overspeed condition is sensed
or the optional emergency stop button is
pressed. The appropriate fault indicator lamp
lights and common alarm terminal TB1-4 is
powered. (There is no fault lamp for emergency
stop.)
2. The starting cycle begins when relay K7 is
powered, either manually by pushing the panel
Run switch, or automatically by a remote controller connected at terminal TB1-6. (The panel
switch must be in the Remote position for remote, automatic operation.)
3. Relay K7 powers relays K2 and K3.
4. Relay K2 powers the engine gauges and terminal TB1-10, to which the fuel solenoid and ignition module are connected.
The low oil pressure and high engine temperature shutdowns have 10 second time delays to
allow oil pressure and engine temperature to
stabilize during startup.
5. Relay K3 powers terminal TB1-8 to which starter relay K4 is connected. Engine cranking begins.
6. The engine starts and runs up to governed
speed in a matter of seconds.
12. To restore operation after a shutdown fault has
been serviced, reset latching relay K6 by pushing the panel Stop switch and then the Reset
switch. The set should run or be ready to run
when the panel switch is pushed to Run or to
Remote.
7. The starter is disconnected when engine
speed gets to about 500 RPM. This is done by
relay K10 or K14, whichever acts first to open
the circuit powering relay K3.
8. Relay K10 is powered by the generator output
voltage (120 VAC) through plug-in connectors
P1-1 and P1-2. The remote Run indicator lamp
should light (connected through terminal
TB1-3).
If the emergency stop switch has been used, the
control will have to be reset to restore operation.
First pull the emergency stop switch button and
then push the panel Stop and Reset switches.
9. Relay K14 is powered by the engine-driven
battery charging alternator (24 VDC) through
plug-in connector P1-3. The panel Run indicator lamp should light. Relays K10 and K14 are
redundant.*
13. The set is stopped manually by pressing the
panel Stop switch or automatically by a remote
controller. (The panel switch must be in the Remote position for remote, automatic operation.)
* On older ECM boards (those having cartridge-type fuses):
• If the starter disconnects normally but the panel Run indicator lamp does not light, the DC (K14) starter disconnect circuit is
not working.
• If the starter disconnects normally but neither the panel nor the remote Run indicator lamps light, the AC (K10) starter disconnect circuit is not working.
* On newer ECM boards (those having automotive-type fuses):
• If the starter disconnects normally but neither the panel nor the remote Run indicator lamps light, the AC (K10) starter disconnect circuit is not working.
• Both the remote and the panel Run indicator lamps will light even if the DC (K14) starter disconnect circuit is not working.
Check the DC voltmeter to determine whether or not the battery charging alternator is working.
3-14
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4. Troubleshooting
WARNING There are hazards present in troubleshooting that can cause equipment damage,
severe personal injury or death. Troubleshooting must be performed by qualified persons
who know about fuel, electrical and machinery
hazards. Read the safety precautions inside the
front cover and carefully observe all instructions and precautions in this manual.
These troubleshooting charts are designed to help
you think through generator set problems. To save
time troubleshooting, read the entire manual ahead
of time to understand the generator set. Try to think
through problems. Go over what was done during
the last service call. The problem could be as simple
as an empty fuel tank, closed fuel shutoff valve,
loose wire, blown fuse or tripped circuit breaker.
THE ENGINE DOES NOT CRANK
The Run-Stop-Remote switch is at Stop.
(The Switch-Off light will be flashing, if
provided.)
Push the Run-Stop-Remote switch to Run or Remote.
The Emergency Stop switch has been
used. (No fault lamp is on.)
Pull the Emergency Switch button. To reset the control, push the Run-Stop-Remote switch to Stop and
the Reset switch to Reset. Then push the Run-StopRemote switch to Run or Remote.
A Fault Shutdown is being indicated by
one of the red lights on the control panel.
Service the set as necessary. To reset the control,
push the Run-Stop-Remote switch to Stop and the
Reset switch to Reset. Then push the Run-Stop-Remote switch to Run or Remote.
Cranking voltage is too low to crank the
engine.
Clean and tighten or replace the battery cable connectors and cables at the battery and the set.
Recharge or replace the battery. Specific gravity for a
fully charged battery is approximately 1.260 at 80° F
(27° C).
If the set is in standby service, install a battery charger.
Continued on next page.
4-1
Redistribution or publication of this document,
by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE DOES NOT CRANK (CONT.)
Continued from previous page.
Fuse F1 on the ECM (A11) board has
blown.
Replace the fuse with one of the same type and amp
rating.
If fuse F1 blows again, the wire between ECM terminal
TB1-8 and starter relay K4 terminal S may be loose or
damaged, causing a short to ground. Repair as necessary.
If fuse F1 still blows, replace starter relay K4.
The wire between ECM terminal TB1-9
and starter relay K4 terminal BAT is
loose, damaged or missing.
Check for battery voltage (12 VDC) between ECM terminal TB1-9 (B+) and the grounding stud (–) on the
floor of the control cabinet. Check, clean and tighten
the connectors at both ends and replace the wire if it is
damaged.
A grounding strap between the control
box and the battery negative (–) terminal
is loose, damaged or missing.
Check for electrical continuity (zero ohms) between
the the grounding stud on the floor of the control box
and the battery negative (–) terminal. If there is no
electrical continuity, check for loose, damaged or
missing grounding straps and repair as necessary.
The Run-Stop-Remote switch (S12) or
wiring is faulty.
Disconnect pin connector J4 from the ECM board and
check for electrical continuity (zero ohms) between
switch terminals 2 and 3 when the switch is in the Run
position and between terminals 1 and 2 when it is in the
Remote position. Replace the switch if either set of
contacts is faulty.
If the switch works, check for electrical continuity (zero
ohms) between J4-6 and J4-7 on the wire harness
when the switch is in the Run position and between
J4-5 and J4-6 when the switch is in the Remote position. Replace the wire harness if there is no electrical
continuity in either position of the switch.
Continued on next page.
4-2
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE DOES NOT CRANK (CONT.)
Continued from previous page.
The remote control circuit is faulty.
Push the Run-Stop-Remote switch to Run. If the engine cranks, find and repair the fault in the remote control circuit.
The ECM is faulty. (Check fuse F1 again.)
Push the Run-Stop-Remote switch to Run and check
for battery voltage (12 VDC) between ECM terminal
TB1-8 and the grounding stud on the floor of the control box. If there is no voltage when the switch is in the
Run position, replace the ECM.
The wire between ECM terminal TB1-8
and starter relay K4 terminal S is loose,
damaged or missing.
If the ECM works, push the Run-Stop-Remote switch
to Run and check for battery voltage at starter relay K4
terminal S. If there is no voltage repair the wiring as
necessary.
Starter relay K4 is malfunctioning.
If there is voltage at starter relay K4 terminal S, but not
at terminal SI ,when the Run-Stop-Remote switch is
in the Run position, replace relay K4.
The cable between relay K4 and the
starter motor is loose, damaged or missing.
If there is voltage at relay K4 terminal SI, but not at the
starter motor terminal, when the Run-Stop-Remote
switch is in the Run position, repair the cable as necessary.
If there is voltage at the starter motor terminal, but the
motor does not function, when the Run-Stop-Remote
switch is in the Run position, repair or replace the
starter motor according to the engine service manual.
The starter motor is malfunctioning.
4-3
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE CRANKS BUT DOES NOT START
When the Run-Stop-Remote switch is in the Run position, the control will attempt to crank the engine for approximately 75 seconds (including two rest periods) and then the red OVERCRANK lamp will light if the engine does not
start. If the OVERCRANK lamp comes on, reset the control by pushing the Run-Stop-Remote switch to Stop and the
Reset switch to Reset. Then push the Run-Stop-Remote switch to Run or Remote.
The engine is not getting fuel. (If the set is
equipped with the optional low frequency
shutdown feature and the red FAULT 1 or
FAULT 2 lamp is on, the set probably ran
out of fuel.)
Open any closed shutoff valve in the fuel line supplying
the engine.
Fill the main fuel supply tank if the set is gasoline or
propane fueled. For natural gas fueled sets, check
with the gas utility.
Fuse F2 on the ECM board (A11) has
blown.
Replace the fuse with one of the same type and amp
rating.
If fuse F2 blows again, the wire between ECM terminal
TB1-10 and engine block terminal T26 may be loose
or damaged, causing a short to ground. Repair as necessary. (See Figure 3-3 to locate terminal T26)
If fuse F2 still blows, a wire between the ignition coil,
fuel solenoid or ignition module and terminal T26 may
be loose or damaged, causing a short to ground. Repair as necessary.
Connect the terminal on fuel solenoid K1 to the BAT
terminal on starter relay K4 with a jumper wire. Replace the fuel solenoid if it does not “click” each time
power is connected.
Fuel solenoid K1 is faulty (does not
open).
Continued on next page.
4-4
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE CRANKS BUT DOES NOT START (CONT.)
Continued from previous page.
Connect wires, tighten terminal screws and adjust the
governor linkage as necessary according to Section 6,
Governors and Carburetors. Open and close the
throttle by hand to check for binding and repair as necessary. (Opening the throttle will be resisted by a
spring inside the actuator, which is normal.)
The throttle is not opening. (This applies
only to sets with electronic governors.
There should be visible movement in the
throttle linkage when cranking starts.)
Disconnect the actuator lead connected at governor
controller terminal 5 and connect it to the negative (–)
terminal of the cranking battery. Then disconnect the
lead connected at terminal 4 and touch it to the battery
positive (+) terminal. Replace the actuator unit if it
does not drive the throttle open when power is connected or return it when power is disconnected.
Replace the governor controller if the actuator functions properly.
Low engine temperature is causing too
low a cranking speed for starting.
Plug in, repair or install engine coolant and engine oil
heaters.
Replace the engine oil if it is not of the recommended
viscosity for the ambient temperature.
Continued on next page.
4-5
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE CRANKS BUT DOES NOT START (CONT.)
Continued from previous page.
While cranking the engine, measure voltage directly
across the battery terminals and then immediately
across the starter motor terminal and the grounding
bolt on the block. Cable, terminal or relay contact resistance is too high if the difference is more than 1 volt.
Service as necessary.
Cranking voltage is too low to reach required cranking speed.
Recharge or replace the battery. Specific gravity for a
fully charged battery is approximately 1.260 at 80° F
(27° C).
The ECM is faulty. (Check fuse F2 again.)
While cranking, check for battery voltage at the terminal TB1-10 on the ECM. Replace the ECM if there is
no voltage at the terminal.
The fuel pump (gasoline-fueled sets) is
malfunctioning.
Replace or service the fuel pump according to the engine service manual.
The carburetor fuel passages are
clogged or the choke needs adjustment
(gasoline-fueled sets).
Clean and rebuild gasoline carburetors with the appropriate carburetor kit according to the kit instructions. Adjust fuel mixture and choke according to Section 6, Governors and Carburetors.
The engine ignition system is malfunctioning (electronic module, ignition coil,
distributor, spark plugs, high tension
spark plug and coil cables and timing).
Service according to the engine service manual.
The engine is malfunctioning mechanically.
Service according to the engine service manual.
4-6
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WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE RUNS UNTIL FAULT SHUTDOWN
Reset the ECM by pushing the Run-Stop-Remote
switch to Stop and the Reset switch to Reset and restart the set, monitoring engine speed. Readjust the
cutout speed if it is lower than specified. See Section 3,
Engine Control.
The OVERSPEED lamp comes on when
the engine shuts down.
If the set still shuts down due to overspeed, open and
close the throttle by hand to check for binding. Repair
and adjust the linkage as necessary according to Section 6, Governors and Carburetors. (A spring inside
the actuator of an electronic governor will resist opening the throttle, which is normal, and the governor
spring of a mechanical governor will resist closing the
throttle.)
Mechanical Governor: Readjust the governor according to Section 6, Governors and Carburetors. Replace the mechanical governor unit if the set still shuts
down due to overspeed.
Electronic Governor: Readjust the governor according to Section 6, Governors and Carburetors. If the set
still shuts down due to overspeed, re-install the magnetic speed pick-up unit to make sure the clearance
with the flywheel gear teeth is correct (Section 6). Replace the speed-pickup unit if output voltage at cranking speed is less than 2.5 VDC as measured at terminals 10 (–) and 11 (+) on the governor controller.
Disconnect the actuator lead connected at governor
controller terminal 5 and connect it to the negative (–)
terminal of the cranking battery. Then disconnect the
lead connected at terminal 4 and touch it to the battery
positive (+) terminal. Replace the actuator unit if it
does not drive the throttle open when power is connected or return it when power is disconnected.
Replace the governor controller if the set still shuts
down due to overspeed.
Continued on next page.
4-7
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE RUNS UNTIL FAULT SHUTDOWN (CONT)
Continued from previous page.
Reset the ECM by pushing the Run-Stop-Remote
switch to Stop and the Reset switch to Reset and fill
up with as much engine oil as necessary and repair all
oil leaks.
The LOW OIL PRESSURE lamp comes
on when the engine shuts down.
If the set still shuts down due to low oil pressure, disconnect the wire to fuel solenoid K1 (to keep the engine from starting) and observe oil pressure while
cranking the engine. Service the lubricating oil system
in accordance with the engine service manual if oil
pressure is less than 10 psi. Replace the low oil pressure cutout switch if oil pressure is greater than 10 psi.
See Figure 3-3, Section 3, Engine Control to locate
the switch.
Reset the ECM by pushing the Run-Stop-Remote
switch to Stop and the Reset switch to Reset and fill
up with as much engine coolant as necessary and repair all leaks.
The HIGH ENGINE TEMPERATURE
lamp comes on when the engine shuts
down.
If the set still shuts down due to high engine temperature, start the engine and observe coolant temperature as the system heats up. If shutdown occurs before
the coolant reaches 200° F (93° C), replace the high
engine temperature cutout switch. If coolant temperature exceeds 200° F (93° C), clean and service the entire cooling system as required to restore full cooling
capacity. See Figure 3-6, Engine Sensor Locations, to
locate the switch.
Service as required. (The customer has supplied the
system fault indicating switches. By means of selection jumpers, either fault may be chosen to display the
warning only. See Section 3, Engine Control.)
The FAULT 1 or FAULT 2 lamp comes on
when the engine shuts down.
4-8
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE LACKS POWER OR STABLE SPEED
The governor and carburetor fuel mixture
adjustments are incorrect.
Adjust the carburetor fuel mixture and the governor according to Section 6, Governors and Carburetors.
If the governor cannot be adjusted for full power or
stable speed, shut down the set and open and close
the throttle by hand to check for binding. Repair and
adjust the linkage as necessary. (A spring inside the
actuator of an electronic governor will resist opening
the throttle, which is normal, and the governor spring
of a mechanical governor will resist closing the
throttle.)
Mechanical Governor: Replace the mechanical governor unit if it cannot be adjusted for full power or
stable speed.
Electronic Governor: Re-install the magnetic speed
pick-up unit to make sure the clearance with the flywheel gear teeth is correct (Section 6). Replace the
speed-pickup unit if output voltage at cranking speed
is less than 2.5 VDC as measured at terminals 10 (–)
and 11 (+) on the governor controller.
Disconnect the actuator lead connected at governor
controller terminal 5 and connect it to the negative (–)
terminal of the cranking battery. Then disconnect the
lead connected at terminal 4 and touch it to the battery
positive (+) terminal. Replace the actuator unit if it
does not drive the throttle open when power is connected or return it when power is disconnected.
Replace the governor controller if it still cannot be adjusted for full power or stable speed.
Continued on next page.
4-9
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE ENGINE LACKS POWER OR THE SPEED IS UNSTABLE (CONT.)
Continued from previous page.
Gasoline delivery to the set is inadequate.
Check for and replace clogged gasoline fuel lines and
filters.
Measure the vertical distance between the gasoline
fuel pump on the engine and the bottom of the dip tube
in the supply tank. Make necessary provisions so that
lift does not exceed 6 feet (1.8 metres).
The Gasoline fuel is contaminated.
Connect the set to a container of regular gasoline of
known quality and run the set under various loads. Replace the contents of the fuel supply tank if there is a
noticeable improvement in performance.
Gaseous fuel delivery (vapor withdrawal) to the set is inadequate.
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.)
The Gaseous fuel is of insufficient energy content.
Check with the propane supplier or the gas utility to
confirm the energy content of the gaseous fuel being
used. Propane must have approximately 2500 BTU’s
per cubic foot and natural gas 1000 BTU’s per cubic
foot.
The engine air filter element is dirty.
Replace the air filter element.
The carburetor fuel passages (gasolinefueled sets) are clogged.
Clean and rebuild gasoline carburetors with the appropriate carburetor kit according to the kit instructions. Adjust fuel mixture according to Section 6.
Service the engine or ignition system according to the
engine service manual.
The engine is worn or is misfiring.
4-10
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
ENGINE CONDITION WARNINGS
The PRE-LOW OIL PRESSURE lamp
comes on while the engine is running.
Shut down the set if possible or disconnect non-critical
loads.(Oil pressure will be less than 30 psi but greater
than 25 psi.) Service the engine lubricating system according to the engine service manual.
The PRE-HIGH ENGINE TEMPERATURE lamp comes on while the engine is
running.
Shut down the set if possible or disconnect non-critical
loads. (Engine temperature will be greater than 205° F
[97° C] but less than 215° F [102° C]). Service the engine cooling system to restore full cooling capacity.
The LOW ENGINE TEMPERATURE
lamp comes on while the set is in standby.
Plug in, repair or install engine coolant and engine oil
heaters.
The LOW FUEL lamp comes on.
Fill the main fuel supply tank with the appropriate
grade of fuel. (The customer must supply the fuel level
switch to make use of this warning.)
FAULT 1 or FAULT 2
Service as required. (The customer has supplied the
system fault indicating switches. By means of selection jumpers, either fault may be chosen to shut down
the engine. See See Section 3, Engine Control.
4-11
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THERE IS NO OUTPUT VOLTAGE ( ENGINE SPEED IS STABLE)
The line circuit breaker is OFF.
Find out why the circuit breaker was turned OFF, make
sure it is safe to reconnect power, and then throw the
circuit breaker ON.
The line circuit breaker has TRIPPED.
Shut down the set and service as necessary to clear
the short circuit or ground fault that caused tripping,
and then RESET the circuit breaker and start the set.
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 measurable resistance across any contact.
The line circuit breaker is faulty.
Field circuit breaker CB21 has TRIPPED.
RESET the circuit breaker. If it keeps tripping, troubleshoot according to the chart, Field Circuit Breaker
Keeps Tripping.
Field circuit breaker CB21 is faulty.
Shut down the set, attempt to RESET the circuit breaker and disconnect either lead. Replace the circuit
breaker if there is measurable resistance across the
terminals.
Continued on next page.
4-12
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THERE IS NO OUTPUT VOLTAGE (CONT. )
Continued from previous page.
Determine, as follows, whether the fault is in the VOLTAGE REGULATING or GENERATOR circuits:
1. Throw the line circuit breaker OFF and shut down the set.
CAUTION This test involves unregulated excitation of the generator. To prevent damage to the generator due to overcurrent, make sure that all loads have been disconnected and that all faults have been
cleared from the power output terminals of the generator.
2. Open the control panel and disconnect the X and the XX leads from the voltage regulator. See Figure 2-3 or 2-4, as
appropriate.
3. Connect the XX lead to the ground stud on the floor of the control box ( battery negative [–]).
4. Be prepared to connect the X lead to 12 VDC battery positive (+) and to read output voltage across the generator
terminals while the set is running. Check polarity again. Polarity must be correct or this test will be inconclusive
because the induced and residual magnetic polarities in the exciter stator will be opposed.
HIGH VOLTAGE. Touching uninsulated high voltage parts inside the control 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 platform or rubber insulating mat, make sure your clothing
and shoes are dry, remove jewelry and wear elbow length insulating gloves intended for hazardous voltages.
5. Start the set and connect the X lead to battery positive (+).
6. The generator is probably okay if rated output voltage or higher is obtained and the voltages for all phases are
balanced when the exciter is powered by the 12 volt cranking battery. Use the appropriate VOLTAGE REGULATING FAULT chart to troubleshoot. (Normal excitation voltage ranges from approximately 10 VDC at no-load to
approximately 40 VDC at full-load.)
7. Use the GENERATOR FAULT chart to troubleshoot if the output voltages are not balanced or are less than ninety
percent of rated output voltage when the exciter is powered by the 12 volt cranking battery. If the voltages are
unbalanced, troubleshoot the main stator first. If the voltages are uniformly low, troubleshoot the exciter and field
circuits first.
Continued on next page.
4-13
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THERE IS NO OUTPUT VOLTAGE (CONT. )
Continued from previous page.
Disconnect leads P2, P3 and P4 from the voltage regulator. While the set is running, check voltage across
lead pairs P2-P3, P3-P4 and P4-P2. Service the PMG
according to Section 5, Servicing the Generator if
there is less than 150 VAC for 50 Hertz generators or
less than 180 VAC for 60 Hertz generators across any
pair of leads.
VOLTAGE REGULATING FAULTS
(PMG-EXCITED GENERATORS)
HIGH VOLTAGE. Touching uninsulated high voltage components and wiring in this
compartment can result in severe personal injury
or death. Testing must be done with care to avoid
touching high voltage parts.
The PMG is faulty.
For your protection, stand on a dry wooden platform or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry and
wear elbow length insulating gloves intended for
hazardous voltages.
Check all connections using the appropriate wiring
diagrams in Section 7 and rewire as necessary. Replace the voltage regulator if the wiring is correct and
there is no output voltage.
Voltage Regulator VR21 is faulty.
CAUTION Replacing the voltage regulator before servicing other faults can lead to damage to
the new voltage regulator.
VOLTAGE REGULATING FAULTS
(SELF-EXCITED GENERATORS)
Flash the field according to Section 5, Servicing the
Generator.
The field has lost its residual magnetism.
Check all connections against the wiring diagrams on
pages 7-3 through 7-6, 7-15 and 7-16 and rewire as
necessary. Replace the voltage regulator if the wiring
is correct and there is no output voltage.
Voltage Regulator VR21 is faulty.
CAUTION Replacing the voltage regulator before servicing other faults can lead to damage to
the new voltage regulator.
Continued on next page.
4-14
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THERE IS NO OUTPUT VOLTAGE (CONT. )
Continued from previous page.
GENERATOR FAULTS
The exciter field winding is faulty (open or
shorted).
Shut down the set and check exciter field winding resistance according to Section 5, Servicing the Generator. Replace the exciter field assembly if winding resistance does not meet specifications.
The rotating rectifier assembly (diodes
CR1 through CR6) is faulty.
Shut down the set and check each diode according to
Section 5, Servicing the Generator. Service as necessary.
The exciter rotor windings are faulty
(open or shorted).
Shut down the set and check exciter winding resistances according to Section 5, Servicing the Generator. Replace the generator rotor assembly if exciter rotor winding resistances do not meet specifications.
The main rotor winding is faulty (open or
shorted).
Shut down the set and check main rotor winding resistance according to Section 5, Servicing the Generator.
Replace the generator rotor assembly if main rotor
winding resistance does not meet specifications.
The stator windings are faulty (open or
shorted).
Shut down the set and check stator winding resistances according to Section 5, Servicing the Generator.
Replace the generator stator assembly if stator winding resistances do not meet specifications.
4-15
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
OUTPUT VOLTAGE IS TOO HIGH OR TOO LOW
Adjust engine speed according to Section 6, Governors and Carburetors.
Engine speed is too high or too low.
If engine speed is unstable, troubleshoot according to
the chart, The Engine Lacks Power or Stable Speed.
The voltage has been adjusted improperly.
Adjust output voltage according to Section 2, AC Control.
Improper connections have been made at
the generator output terminals.
Shut down the set and reconnect according to the appropriate reconnection diagram (Page 7-15 or 7-16).
The rotating rectifier assembly (diodes
CR1 through CR6) is faulty.
Shut down the set and check each diode according to
Section 5, Servicing the Generator. Service as necessary.
Replace the voltage regulator.
CAUTION Replacing the voltage regulator before servicing other faults can lead to damage to
the new voltage regulator.
Voltage Regulator VR21 is faulty.
4-16
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
OUTPUT VOLTAGE IS UNSTABLE
The voltage has been adjusted improperly.
Adjust output voltage according to Section 2, AC Control.
The voltage adjusting rheostat on the
control panel is faulty (if provided).
Unlock the voltage adjusting screw on the front 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
then the other. Replace the rheostat if it is open at any
point, or if resistance does not vary smoothly from zero
to approximately 100,000 ohms.
Replace the voltage regulator.
CAUTION Replacing the voltage regulator before servicing other faults can lead to damage to
the new voltage regulator.
Voltage Regulator VR21 is faulty.
4-17
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE FIELD CIRCUIT BREAKER KEEPS TRIPPING
The rotating rectifier assembly (diodes
CR1 through CR6) is faulty.
Shut down the set and check each diode according to
Section 5, Servicing the Generator. Service as necessary.
The exciter field winding is faulty (open or
shorted).
Shut down the set and check exciter field winding resistance according to Section 5, Servicing the Generator. Replace the exciter field assembly if winding resistance does not meet specifications.
The exciter rotor windings are faulty
(open or shorted).
Shut down the set and check exciter winding resistances according to Section 5, Servicing the Generator. Replace the generator rotor assembly if exciter rotor winding resistances do not meet specifications.
The main rotor winding is faulty (open or
shorted).
Shut down the set and check main rotor winding resistance according to Section 5, Servicing the Generator.
Replace the generator rotor assembly if main rotor
winding resistance does not meet specifications.
The stator windings are faulty (open or
shorted).
Shut down the set and check stator winding resistances according to Section 5, Servicing the Generator.
Replace the generator stator assembly if stator winding resistances do not meet specifications.
Replace the voltage regulator.
CAUTION Replacing the voltage regulator before servicing other faults can lead to damage to
the new voltage regulator.
Voltage Regulator VR21 is faulty.
4-18
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by any means, is strictly prohibited.
WARNING There are hazards present in troubleshooting that can cause equipment damage, severe
personal injury or death. Troubleshooting must be performed by qualified persons who know about
fuel, electrical and machinery hazards. Read the safety precautions inside the front cover and carefully observe all instructions and precautions in this manual.
THE PHASE CURRENTS ARE UNBALANCED
The connected loads are distributed unevenly among the phases.
Shut down the set and redistribute the loads so that
there is a difference of less than 10 percent between
phases.
Improper connections have been made at
the generator output terminals.
Shut down the set and reconnect according to the appropriate reconnection diagram in Section 7.
The stator windings are faulty (open or
shorted).
Shut down the set and check stator winding resistances according to Section 5, Servicing the Generator.
Replace the generator stator assembly if stator winding resistances do not meet specifications.
A load has a ground fault or short circuit.
Service the faulty equipment as necessary.
4-19
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5. Servicing the Generator
Make certain battery area has been well-ventilated before servicing battery. Arcing can ignite
explosive hydrogen gas given off by batteries,
causing severe personal injury. Arcing can occur when cable is removed or re-attached, or
when negative (–) battery cable is connected
and a tool used to connect or disconnect positive (+) battery cable touches frame or other
grounded metal part of the set. Always remove
negative (–) cable first, and reconnect it last.
Make certain hydrogen from battery, engine
fuel, and other explosive fumes are fully dissipated. This is especially important if battery has
been connected to battery charger.
TESTING THE GENERATOR
These tests can be performed without removing the
generator. Before starting tests, disconnect the
starting battery cables (negative [-] first) to make
sure the engine will not start while performing these
tests.
CAUTION Always disconnect a battery charger from its AC source before disconnecting the
battery cables. Otherwise, disconnecting the
cables can result in voltage spikes high enough
to damage the DC control circuits of the set.
WARNING Accidental starting of the generator
set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnecting the starting battery cables
(negative [–] first).
STATOR
LEADS
OUTPUT
TERMINALS
END
PLATE
MAIN
STATOR
PMG
ASSEMBLY
ROTOR
SHAFT
BEARING
GENERATOR
ADAPTOR
CASTING
EXCITER
ROTOR
DRIVE
DISCS
COOLING
BLOWER
EXCITER
STATOR
MAIN ROTOR
(GENERATOR FIELD)
ROTATING
RECTIFIER
ASSEMBLY
FIGURE 5-1. GENERATOR
5-1
Redistribution or publication of this document,
by any means, is strictly prohibited.
Flashing the Field (Self-Excited Generators
Only): If necessary, flash the exciter field before or
after installation. Apply 110 to 220 VAC for one to
two seconds to the X and XX leads of the exciter stator. The generator must be shut down, the AVR
disconnected, a diode used to establish correct
polarity and a 3 amp fuse to prevent over-excitation. See the diagram.
Exciter Stator
Testing Winding Resistance: Measure winding
resistance with a Wheatstone bridge or digital ohmmeter. Replace the stator if winding resistance is
not as specified by Table 5-1.
Testing Winding Insulation Resistance: Disconnect the exciter stator leads from terminals X and
XX on the auxiliary terminal board in the generator
output box. Using an ohmmeter, measure resistance between either lead and the stator laminations. Replace the stator if insulation resistance is
less than 1 megohm (1,000,000 ohms)
Alternatively, while the set is running and disconnected from all loads, apply a 12 VDC battery for
one to two seconds as shown in the diagram. Polarity must be correct: + to X, – to XX.
MEASURE WINDING
INSULATION RESISTANCE
BETWEEN EITHER LEAD
AND THE STATOR
LAMINATIONS
MEASURE WINDING
RESISTANCE BETWEEN
THE TWO STATOR
LEADS, X AND XX
— FLASHING THE FIELD (SELF-EXCITED GENERATORS ONLY) —
APPLY 110 TO 220 VAC TO THE EXCITER
STATOR FOR 1 TO 2 SECONDS WITH THE
AVR DISCONNECTED AND THE SET NOT
RUNNING
ALTERNATIVELY, APPLY 12 VDC FROM A
BATTERY TO THE EXCITER STATOR FOR 1
TO 2 SECONDS WITH THE AVR CONNECTED
AND THE SET RUNNING WITHOUT LOAD
+
X
110 to 220
VAC
3 AMP
FUSE
X
DIODE
DIODE
EXCITER
STATOR
12 VDC
BATTERY
XX
EXCITER
STATOR
AVR
XX
–
220-4293
FIGURE 5-2. TESTING AND FLASHING THE EXCITER STATOR
5-2
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Exciter Rectifier Bridge (Rotating Rectifier
Assembly)
sistance is high or low in both directions, replace the
diode.
The exciter rectifier bridge is mounted on the exciter
rotor, inboard, facing the main rotor. It consists of a
positive plate and a negative plate, split diametrically. Each carries three diodes, three terminal posts
for connecting exciter rotor leads to the diode pigtails and a terminal for the main rotor (generator
field) lead. A surge suppresser is connected across
the two plates to prevent transient voltages that
could damage the diodes.
Replacing Diodes: Make sure the replacement
diode is of the correct polarity. Disconnect the pigtail
from the terminal post and unscrew the old diode.
Apply heat-sink compound under the head of the
diode. Make sure the compound does not get on the
threads. Torque the diodes to 36 to 42 in-lbs (4 to
4.8 Nm) and the pigtail terminals to 24 in-lbs (2.7
Nm) when reassembling.
Surge Suppresser Testing and Replacement:
Remove the suppresser. Replace the suppresser if
it appears to have overheated or if ohmmeter readings indicate less than infinite resistance (end of
scale) in both directions. Torque the terminals to 24
in-lbs (2.7 Nm) when reassembling.
Testing Diodes: Disconnect the diode pigtails from
the terminal posts. Using an ohmmeter, measure
electrical resistance between each diode pigtail and
the plate on which the diode is mounted. Reverse
the meter test probes and repeat the tests. The
electrical resistance across each diode should be
high in one direction and low in the other. If the re-
CAUTION Layers of dust can cause diodes to
overheat and fail. Brush dust off regularly.
DIODE (ONE OF SIX)
DISCONNECT THE
DIODE PIGTAIL FROM
THE TERMINAL AND
MEASURE ELECTRICAL
RESISTANCE BETWEEN
THE PIGTAIL AND THE
METAL PLATE UNDER
THE DIODE
TERMINAL
(ONE OF SIX)
DIODE PLATES
(TWO)
SURGE SUPPRESSER
REMOVE TO TEST
201-3434
FIGURE 5-3. TESTING THE ROTATING RECTIFIER ASSEMBLY
5-3
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by any means, is strictly prohibited.
matic. Replace the exciter rotor assembly if the resistance of any winding is not as specified in Table
5-1.
Exciter Rotor
Testing Winding Resistance: Disconnect the six
rotor winding leads from the terminal posts on the
rectifier assembly. With a Wheatstone bridge, measure electrical resistance across each pair of rotor
windings: U (CR1 or CR4) and V (CR2 or CR5), V
(CR2 or CR5) and W (CR3 or CR6), W (CR3 or
CR6) and U (CR1 or CR4). See the winding sche-
Testing Winding Insulation Resistance: Using a
megger (voltage set at 600 VAC or less), measure
the resistance between any rotor winding lead or
the terminal to which it is connected and the rotor
laminations. Replace the whole rotor shaft assembly if insulation resistance is less than 1 megohm.
MEASURE WINDING
INSULATION RESISTANCE
BETWEEN ANY LEAD OR
THE TERMINAL TO WHICH
IT IS CONNECTED AND
THE ROTOR LAMINATIONS
MAIN ROTOR
LEADS
DISCONNECT THE SIX
ROTOR WINDING LEADS
FROM THEIR TERMINALS
AND MEASURE
ELECTRICAL RESISTANCE
ACROSS EACH PAIR OF
WINDINGS: U-V, V-W, W-U
WINDING SCHEMATIC
FIGURE 5-4. TESTING THE EXCITER ROTOR
5-4
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by any means, is strictly prohibited.
Main Rotor (Generator Field)
5-1. Connect the rotor leads and torque the terminals to 24 in-lbs (2.7 Nm) when reassembling.
Testing Winding Resistance: Disconnect the two
leads of the main rotor from the terminals on the rotating rectifier assembly. See Figure 5-4. Measure
electrical resistance between the two leads with a
Wheatstone bridge or digital ohmmeter. Replace
the rotor if the resistance is not as specified in Table
Testing Winding Insulation Resistance: Using a
megger (voltage set at 600 VAC or less), measure
the resistance between either lead of the main rotor
windings, or the terminal to which it is connected,
and the main rotor laminations. Replace the rotor if
insulation resistance is less than 1 megohm.
MEASURE WINDING INSULATION
RESISTANCE BETWEEN EITHER
ROTOR LEAD AND THE ROTOR
LAMMINATIONS
DISCONNECT THE MAIN ROTOR LEADS
FROM THE ROTATING RECTIFIER
ASSEMBLY AND MEASURE THE
WINDING RESISTANCE BETWEEN THEM
FIGURE 5-5. TESTING THE MAIN ROTOR
5-5
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be the same as the table value (two sets of two
winding elements in series).
Main Stator
Testing Winding Resistance: Measure electrical
resistance across each pair of stator leads (U1-U2,
U5-U6, VI-V2, V5-V6, W1-W2 and W5-W6) with a
Wheatstone bridge or ohmmeter having at least
0.001 ohm precision. Replace the stator if the resistance of any winding is not as specified in Table
5-1.
Testing Winding Insulation Resistance: Disconnect all stator leads and winding taps from their respective terminals and make sure the ends do not
touch the generator frame.
Testing For Grounds: Using a megger (voltage set
at 600 VAC or less) measure electrical resistance
between any stator lead and the stator laminations.
Replace the stator if insulation resistance is less
than 1 megohm.
Alternatively, winding resistance can be measured
line-to-line at the generator terminals (U-V, V-W,
W-U) on “star” connected generators. On a 600 volt
generator, line-to-line resistance should be twice
the table value (two winding elements in series). On
a “series star” connected generator, line-to-line resistance should be four times the table value (four
winding elements in series). On a “parallel star”
connected generator, line-to-line resistance should
Testing For Shorts: Using a megger (voltage set at
600 VAC or less) measure electrical resistance between each winding, for example U1/U2 to U5/U6,
U1/U2 to V1/V2, etc. Replace the stator if insulation
resistance is less than 1 megohm.
THE LAST SIX DIGITS OF THE STATOR
PART NUMBER ARE STAMPED HERE
WHEATSTONE
BRIDGE
FIGURE 5-6. TESTING THE GENERATOR STATOR
5-6
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by any means, is strictly prohibited.
TABLE 5-1. GENERATOR WINDING RESISTANCES*
MAIN STATOR
PART
NUMBER**
MAIN
STATOR
(OHMS)
MAIN
ROTOR
(OHMS)
EXCITER
STATOR
(OHMS)
EXCITER
ROTOR
(OHMS)
220-4289–31
220-4289-32
220-4289-33
220-4289-34
220-4289–35
0.170
0.129
0.110
0.069
0.055
0.57
0.64
0.67
0.80
0.93
20.3
20.3
19.5
19.5
19.5
0.167
0.167
0.180
0.180
0.180
220-4298-31
220-4298-32
220-4298-33
220-4298-34
220-4298-35
22O-4298-36
0.062
0.047
0.033
0.025
0.022
0.016
1.11
1.20
1.31
1.50
1.66
1.80
19.5
19.5
19.5
19.5
19.5
19.5
0.180
0.180
0.210
0.210
0.210
0.210
220-4289–31
220-4289-32
220-4289-33
220-4289-34
220-4289–35
0.170
0.129
0.110
0.069
0.055
0.57
0.64
0.67
0.80
0.93
20.3
20.3
19.5
19.5
19.5
0.167
0.167
0.180
0.180
0.180
220-4298-31
220-4298-32
220-4298-33
220-4298-34
220-4298-35
22O-4298-36
0.062
0.047
0.033
0.025
0.022
0.016
1.11
1.20
1.31
1.50
1.66
1.80
19.5
19.5
19.5
19.5
19.5
19.5
0.180
0.180
0.210
0.210
0.210
0.210
* - These values are approximate, plus or minus 10 percent at 68° F (20° C).
** - See Figure 5-6 for the location of the stator part number.
5-7
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reconnections later, make sure each wire is
clearly marked to indicate the correct terminal.
12. If the set has a mounted line circuit breaker, disconnect the cables to the circuit breaker. For
reconnections later, make sure each cable is
clearly marked to indicate the correct terminal.
13. Attach a hoist to the generator output box,
loosen the mounting bolts on the sides of the
generator and remove the box.
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.
WARNING Accidentally dropping the generator can damage it and cause severe personal injury and death. The hoist, straps and chains
must have sufficient capacity and be attached
properly so that the load cannot shift.
Withdrawing The Generator From The Set
1. The rotor will be carried inside the stator when
the generator is withdrawn from the engine.
Bar the engine until one of the four poles of the
rotor points straight down so that the rotor will
rest on the face of the pole when the generator
is withdrawn.
Before starting, disconnect the starting battery
cables (negative (-) first) to make sure the set will
not start while working on it.
WARNING Accidental starting of the generator
set while working on it can cause severe injury
or death. Prevent accidental starting by disconnecting the starting battery cables (negative (-)
first).
CAUTION The rotor can be damaged if it
rests on the edges of the winding slot between two poles.
Always remove the negative (-) cable first, and
reconnect it last, to prevent arcing if a tool accidentally touches the frame or other grounded
metal part while removing the positive (+) battery cable. Arcing can ignite the explosive hydrogen gas given off by the batteries, causing
severe injury.
2. Attach lifting eyes and a hoist of sufficient capacity (Figure 5-7).
3. Take up hoist slack and remove the two
through bolts securing the generator to the rubber isolation mounts.
4. Raise the generator end approximately one
inch (12 mm) and securely block the engine under the flywheel housing. Lower the generator
slightly so that the blocks carry most of the
weight.
5. Remove the bolts securing the generator drive
discs to the flywheel.
6. Loosen all the bolts securing the generator
adapter casting to the flywheel housing. Adjust
the hoist to carry the full weight of the generator, remove the bolts and pull the generator
away.
Removing The Generator Output Box
8. Disconnect the line cables and conduit. For reconnections later, make sure each cable is
clearly marked to indicate the correct terminal.
9. Disconnect the remote control wiring and conduit. For reconnections later, make sure each
wire is clearly marked to indicate the correct
terminal.
10. Disconnect all engine wiring harness connections in the generator control and output boxes.
For reconnections later, make sure each wire is
clearly marked to indicate the correct terminal.
11. Disconnect all generator control leads (winding
taps) from connections in the output box. For
CAUTION Never withdraw the generator
leaving the rotor to hang by the drive discs.
The weight of the rotor will damage the
drive discs.
5-8
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MAIN
ROTOR
ROTATING
DIODE
ASSEMBLY
EXCITER
ROTOR
DRIVE
DISCS
STATOR
COOLING
BLOWER
STATOR
LEADS
MAIN
ROTOR
BEARING
GENERATOR
LIFT POINTS
CINCH
STRAP
AROUND
THE MIDDLE
OF THE
ROTOR
CORE TO
LIFT
EXCITER
STATOR
END
PLATE
G1190s-1
FIGURE 5-7. GENERATOR ASSEMBLY
5-9
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by any means, is strictly prohibited.
9. The adaptor-to-engine bolts should be torqued
to 35 ft-lbs (48 Nm).
10. Reconnect the generator as required. See
Pages 7-15 through 7-18.
Withdrawing the Rotor From the
Generator
1. Remove the generator adaptor casting on the
drive disc end and the end plate on the bearing
end.
2. Using a hoist of sufficient capacity, cinch a lifting strap on the drive end of the rotor. Lift the
bearing end of the rotor by hand and push it towards the drive end of the generator until half
the width of the rotor core protrudes from the
stator. Release the weight of the rotor and recinch the lifting strap around the middle of the
rotor core. Withdraw the rotor until it is free of
the stator, guiding it by hand on both ends to
prevent contact with the stator windings
3. Rest the rotor in a cradle, solidly supporting it
on two pole faces—not on the drive discs,
blower or exciter.
4. Remove the retaining clip if the rotor shaft
bearing is to be removed.
SERVICING THE PMG
The following is applicable if the generator is
equipped with a PMG (permanent magnet) exciter.
Testing
1. Disconnect leads P2, P3 and P4 from the voltage regulator.
2. Start the engine at the set and let the speed stabilize.
HIGH VOLTAGE. Touching
uninsulated high voltage parts inside the
control and power output boxes can result
in severe personal injury or death. Measurements and adjustments must be done
with care to avoid touching high voltage
parts.
REASSEMBLING THE GENERATOR
Reassembling is the reverse of disassembling.
Note the following.
For your protection, stand on a dry wooden
platform or rubber insulating mat, make
sure your clothing and shoes are dry, remove jewelry and wear elbow length insulating gloves intended for hazardous voltages..
1. Apply force to the inner race of the rotor bearing
when pressing it onto the shaft, otherwise, it will
be damaged. Be sure to secure the retaining
clip.
2. The drive disc-to-rotor bolts should be torqued
to 190 ft-lbs (257 Nm).
3. The drive disc-to-flywheel bolts should be
torqued to 50 ft-lbs (67 Nm).
4. The exciter stator mounting screws should be
torqued to 7 ft-lbs (10 Nm).
5. The generator end plate mounting bolts should
be torqued to 25 ft-lbs (34 Nm).
6. Make sure the rubber O-ring is in place in the
bearing bore in the generator endplate.
7. The generator mounting bracket bolts should
be torqued to 65 ft-lbs (88 Nm) if M12 or 35 ftlbs (47 Nm) if M10.
8. The generator-to-adaptor bolts should be
torqued to 40 ft-lbs (55 Nm).
3. Measure voltage across lead pairs P2-P3,
P3-P4 and P4-P2. Voltage should be at least
150 VAC for 50 Hz sets and at least 180 VAC for
60 Hz sets, and should be approximately the
same for each set of leads. If the voltages are
low or uneven, check all the leads and connections between the voltage regulator and the
PMG and repair as necessary before disassembling the PMG. Note the connections at the
auxiliary terminal board in the power output
box. See Figure 2-3.
4. Stop the set and measure electrical resistance
across lead pairs P2-P3, P3-P4 and P4-P2 with
a Wheatstone bridge or digital ohmmeter. Each
winding should have a resistance of approximately 4.4 ohms.
5-10
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Always remove negative (–) cable first, and
reconnect it last. Make certain hydrogen
from battery, engine fuel, and other explosive fumes are fully dissipated. This is especially important if battery has been connected to battery charger.
2. Remove the PMG cover (Figure 5-8) and disconnect the leads at the connector.
3. Remove the bolts and clamps that secure the
PMG stator to the generator frame and carefully pull away the stator.
Disassembling the PMG
1. Disconnect the starting battery cables (negative (-) first) to make sure the set will not start
while working on it.
CAUTION Always disconnect a battery
charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage
spikes high enough to damage the DC control circuits of the set.
The rotor is magnetic and will attract the stator.
Hold the stator firmly so that the windings are
not damaged by striking the stator support lugs.
WARNING
Accidental starting of the generator set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnecting the starting battery cables (negative [–] first).
4. Remove the rotor center bolt and pull away the
rotor. The rotor is magnetic and will attract iron
filings. Put it in a clean plastic bag until it is remounted. Do not take it apart or it will lose its
magnetism. Also, if the dowel pin in the end of
the shaft is loose, stow it in a safe place until it is
time to reassemble the PMG.
Make certain battery area has been wellventilated before servicing battery. Arcing
can ignite explosive hydrogen gas given off
by batteries, causing severe personal injury. Arcing can occur when cable is removed
or re-attached, or when negative (–) battery
cable is connected and a tool used to connect or disconnect positive (+) battery
cable touches frame or other grounded
metal part of the set.
Reassembling the PMG
CAUTION
The rotor is magnetic and will attract the stator. When installing the stator, hold
the stator firmly and keep fingers out of the way
to prevent pinching of fingers between stator
and generator assembly.
Reassembling is the reverse of disassembling.
Torque the rotor center bolt to 40 ft-lbs (54 Nm). The
stator leads must be at 12 o’clock.
5-11
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DOWEL
PIN
PMG
ROTOR
PMG STATOR
CLAMP
SPACER
BOLT
COVER
PMG
STATOR
PMG
ROTOR
THROUGH
BOLT
FIGURE 5-8. PMG ASSEMBLY
5-12
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6. Governors and Carburetors
(Figure 6-1). Make the frequency adjustment under
full-load after the engine has been warmed up under at least 1/4 load. If the governor hunts, or if
droop is excessive (more than 3 Hz for 60 Hz sets or
2.5 Hz for 50 Hz sets), adjust the length of the droop
adjusting screw accordingly.
MECHANICAL GOVERNOR
(Prior to Spec F)
Governor Adjustment (Prior to Spec F)
Output frequency (50 Hz or 60Hz) can be adjusted
by turning the governor speed adjustment screw
SPEED
ADJUSTING
SCREW
DROOP
ADJUSTING
SCREW
VIEW A–A
GOVERNOR
SPRING
GOVERNOR
ROD
GOVERNOR
ASSEMBLY
CARBURETOR
THROTTLE
LEVER
MOUNTING
BRACKET
GOVERNOR DRIVE BELT AND
PULLEY ARRANGEMENT
539-1271
FIGURE 6-1. MECHANICAL GOVERNOR
6-1
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reaches minimum speed. Release the throttle
and observe the overshoot on a frequency meter. Adjust the I potentiometer counterclockwise slightly to decrease overshoot. Some
overshoot is acceptable.
ELECTRONIC GOVERNOR
(Prior to Spec F)
Electric Governor Adjustment (Prior to
Spec F)
If necessary, adjust the linkage, wire the controller
and install the magnetic speed pickup unit as
instructed in this section before adjusting the governor controller. Also make sure that the governor
linkage does not bind or have excessive play in it.
7. Connect 1/4 load and readjust the Gain potentiometer (Step 4).
8. Connect rated-load in one step while the set is
running. Shut down the set if it cannot pick up
the load. Lengthen the governor rod by half
turns and repeat the test until the set is able to
pick up rated-load in one step. For B-Series engines, shorten the governor rod by half turns
and repeat the test until the set is able to pick up
rated-load in one step. Back off the governor
full speed stop screw if necessary.
1. Warm up the set under at least 1/4 load until the
engine is up to its normal operating temperature.
2. Disconnect the load and turn the Droop (Figure 6-2) potentiometer to zero.
3. Turn the Speed potentiometer to obtain the
specified output frequency (50 Hz or 60 Hz).
9. Check for stability (no audible hunting) under a
range of loads from no-load to full-load.
4. Turn the Gain potentiometer clockwise until
the governor begins to hunt. Turn it back until
there is no audible hunting.
5. Adjust the D potentiometer (if provided) the
same way as the Gain potentiometer (Step 4).
10. Stop the set and wait for 30 seconds for the turbo to coast down. Restart the set and check for
speed overshoot. If overspeed shutdown occurs, check for linkage binding and repair as
necessary.
6. Manually push the throttle to the minimum
speed position and hold it there until the engine
11. Set the governor rod locknuts, if necessary,
and check again for binding in the linkage.
FIGURE 6-2. GOVERNOR CONTROLLER TERMINALS AND ADJUSTING POTENTIOMETERS
1510715
6-2
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Wiring (Prior to Spec F)
Wire the governor according to Figure 6-3. Be sure
to twist together the power supply leads from B+
and B–.
TWIST THESE
TWO WIRES
TOGETHER
FIGURE 6-3. WIRING THE GOVERNOR
Magnetic Speed-Pickup Unit (Prior to
Spec F)
To install the magnetic speed-pickup unit, bar the
engine until a gear tooth on the flywheel lines up in
the center of the mounting hole in the flywheel housing. Thread the unit in gently by hand until it just
touches the gear tooth. Back it out one quarter turn
and set the lock nut.
6-3
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Linkage Adjustment (Prior to Spec F)
Assemble the linkage as shown in Figure 6-4 and
adjust the length of the governor rod as necessary.
MAGNETIC
SPEED-PICKUP
UNIT
ACTUATOR
ELECTRONIC
GOVERNOR
CARBURETOR
THROTTLE
LEVER
MOUNTING
BRACKET
53908
57
FIGURE 6-4. ELECTRONIC GOVERNOR COMPONENTS
6-4
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placed, adjust the gain 1 and stability 1 pots to
their center settings.)
ELECTRIC GOVERNOR (Begin Spec F)
Electric Governor Adjustment
(Begin Spec F)
3. Adjust the gain 1 pot until the engine is stable
and responsive to governor control. (Adjust the
gain 1 pot counterclockwise to eliminate hunting.) Bump the throttle lever a couple of times to
check for hunting. The unit should respond
quickly but should not hunt.
If necessary, adjust the gas mixture, the governor
linkage and the magnetic speed pickup unit as
instructed in this section before adjusting the governor controller. Make sure that the governor assembly is securely mounted. Also make sure that the
governor linkage does not bind or have excessive
play in it.
4. Apply full load to the genset and adjust the stability 1 pot to minimize overshoot. (Adjust the
stability 1 pot clockwise to increase stability.)
Check stability under a range of loads; from noload to full-load.
1. Check the dip switch settings (Figure 6-5) to
make sure they are set properly, as follows:
50 Hz
60 Hz
SW1
ON
ON
SW2
OFF
OFF
SW3
OFF
OFF
5. Attach a tachometer or frequency meter to the
generator output leads if control panel does not
come equipped with one of these meters. Adjust the Speed Trim pot until the desired speed
is obtained.
SW4
OFF
ON
2. Start the set, let the engine warm up under a
partial load (at least 1/4 rated load) and then disconnect all loads. (If the governor has been re-
6. Shut down and restart the genset to check for
overspeed shutdown on startup.
GAIN 1
STABILITY 1
SPEED
TRIM
SW1
SW2
SW3
SW4
DIP
SWITCHES
FIGURE 6-5. GOVERNOR CONTROLLER
6-5
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2. Verify that the ball joint screw is mounted in the
third hole from the outside end of the governor
arm.
Linkage Adjustment (Begin Spec F)
Figure 6-6 illustrates the governor linkage. Make
sure that the governor controller is securely
mounted to the engine bracket. To adjust the linkage:
3. The governor actuator shaft has 60 degrees of
rotation from stop to stop. Check mounting of
governor arm and linkage to assure the 60 degree actuator shaft rotation operates the throttle
from closed to fully open positions.
1. With the genset stopped, check the angle of the
throttle lever and governor actuator. Adjust governor lever if required. (Throttle is shown in the
closed position.)
GOVERNOR ARM
OUTSIDE END
GOVERNOR
ROD
THROTTLE
LEVER
BALL JOINT
SCREW
BALL JOINT
SCREW
FIGURE 6-6. GOVERNOR LINKAGE
6-6
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lines up in the center of the mounting hole. Thread
the sensor in gently by hand until it just touches the
ring gear tooth. Back it out 5/8 turn and set the locknut.
Magnetic Speed Pickup Unit Adjustment
(Begin Spec F)
With the magnetic speed pickup removed from the
genset, manually rotate the ring gear until a tooth
TO GOVERNOR
MAGNETIC SPEED
PICKUP UNIT
GENERATOR
ADAPTER
FIGURE 6-7. MAGNETIC SPEED PICKUP UNIT
6-7
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jounce the throttle. If the engine begins to hunt,
turn the adjustment screw in slowly until engine
speed becomes stable. If one half turn does not
cause instability, turn the adjustment screw out
one half turn more and repeat the procedure.
CARBURETORS
The engine is equipped with a carburetor to run on
regular gasoline and/or a gas mixer to run on natural gas or propane or both.
WARNING Fuel is highly flammable and may
cause severe personal injury and property damage. Do not allow cigarettes, flame, pilot lights,
arching switches or equipment in area or areas
sharing ventilation.
Choke Adjustment: The gasoline carburetor is
equipped with an automatic choke for easier cold
weather starting. The choke has a bi-metal coil that
progressively closes the choke plate as ambient
temperature drops, in preparation for the next start.
It also has an electric heating element that heats the
bi-metal coil to fully open the choke soon after the
engine starts.
Gasoline Fuel System
A gasoline carburetor is provided for gasoline fuel
systems. The idle mixture and choke are adjustable
on the gasoline carburetor.
The choke housing cover can be rotated to adjust
the choke. The perimeter of the cover is graduated
with evenly spaced lines cast in it. One of the lines
has an asterisk (*). For normal adjustments, the asterisk (*) should line up with the line cast in the edge
of the housing.
Idle Mixture Adjustment: If the adjustment has
been disturbed or the engine performs poorly under
light load, make the following adjustments.
1. Shut off the engine and turn the idle adjustment
screw in gently until it bottoms, and then turn it
out 2-1/2 turns so that the engine will run.
CAUTION The adjustment screw and seat
are easily damaged. Do not force the adjustment screw.
1. For better starting in cold weather, loosen the
three cover screws and rotate the cover clockwise (richer) so that the asterisk (*) is one or
two lines past the line on the housing and retighten the cover screws.
2. Start the engine and let the set warm up under
a partial load (at least 1/4 rated load) and then
disconnect all loads.
3. Turn the idle adjustment screw out (counterclockwise) approximately one half turn and
2. For better starting in warm weather, loosen the
three cover screws and rotate the cover counterclockwise (leaner) so that the asterisk (*) is
one or two lines past the line on the housing
and re-tighten the cover screws.
FUEL
FILTER
FUEL
SHUTOFF
SOLENOID
CHOKE
IDLE ADJUSTMENT
SCREW (ON OTHER SIDE)
FIGURE 6-8. GASOLINE CARBURETOR
6-8
Redistribution or publication of this document,
by any means, is strictly prohibited.
Gaseous and Combination Fuel Systems
GASOLINE AND GASEOUS
An engine equipped for gasoline and natural gas or
propane has a regular gasoline carburetor with a
gas mixer mounted on the horn of the carburetor.
The carburetor throttle serves both fuels. Each fuel
has a separate shutoff solenoid valve. The position
of the fuel selector switch (mounted at the base of
the carburetor) determines which solenoid valve
will open for operation.
An engine equipped for natural gas and propane
has a gas mixer that serves both fuels. Each fuel
has a separate shutoff solenoid valve and either
and a manual fuel selector switch or a fuel pressure
switch for automatic fuel changeover. (While the engine is running, the gas pressure switch causes the
natural gas solenoid valve to close and the propane
solenoid valve to open when natural gas pressure is
lost, without stopping the engine. When natural gas
pressure is restored, the natural gas solenoid valve
opens and the propane solenoid valve closes.)
FS-1251s
NATURAL GAS AND PROPANE
FS-1250s
FIGURE 6-9. COMBINATION FUEL SYSTEMS
6-9
Redistribution or publication of this document,
by any means, is strictly prohibited.
Gaseous Fuel Adjustments: Gas mixers have
power and idle adjustment screws. Engines
equipped for natural gas and propane also have a
propane flow adjustment valve. If necessary, make
the following adjustments.
1. Start the engine and let the set warm up under
a partial load (at least 1/4 rated load). If the engine is equipped for natural gas and propane,
start with natural gas.
2. Disconnect all loads, shut down the set, connect a tachometer and disconnect the governor linkage at the carburetor. Start the engine
and close the throttle by hand so that the engine does not overspeed. While holding the
throttle closed, adjust the throttle idle position
screw (the one next to the throttle lever) to obtain an engine speed of 900 RPM. Then turn
the idle adjusting screw counterclockwise until
engine speed becomes unstable. Turn the
screw clockwise just enough to regain stability
and reconnect the governor linkage.
3. Next, connect full rated load and turn the power
adjusting screw clockwise until the engine begins to lose speed and then slowly back out the
screw (counterclockwise) until the engine carries the full load smoothly.
4. If the set is equipped for natural gas and propane, switch to propane by means of the control panel switch (if provided) or by closing the
manual shutoff valve in the natural gas supply
line.
5. Reconnect full rated load and turn the propane
flow adjustment valve clockwise until the engine begins to lose speed and then slowly turn
it back counterclockwise until the engine carries full load smoothly.
GAS MIXER
IDLE
ADJUSTING
SCREW
POWER
ADJUSTING
SCREW
THROTTLE
STOP
SCREW
PROPANE FLOW ADJUSTMENT VALVE
FIGURE 6-10. GASEOUS FUEL ADJUSTMENTS
FS-1176s
6-10
Redistribution or publication of this document,
by any means, is strictly prohibited.
7. Wiring Diagrams
• Page 7-9 – 12-light DC Wiring, Sheet 1 (Prior to
This section consists of the schematic and connection wiring diagrams referenced in the text.
•
The following diagrams are typical. Your genset may
differ. Wiring and component specifications are subject to change. Contact your Distributor if you do not
have the wiring diagrams applicable to your equipment.
•
•
•
The following drawings are included:
• Page 7-3 – AC Wiring (without meters)
•
• Page 7-4 – AC Wiring (with meters)
• Page 7-5 – Voltage Regulator Connections
•
(MX321, PMG-excited generators))
• Page 7-6 – Voltage Regulator Connections
•
(SX440, self-excited generators)
•
•
• Page 7-7 – 7-light DC Wiring, Sheet 1 (Prior to
Spec F)
• Page 7-8 – 7-light DC Wiring, Sheet 2 (Prior to
•
Spec F)
7-1
Spec F)
Page 7-10 – 12-light DC Wiring, Sheet 2 (Prior
to Spec F)
Page 7-11 – 7-light DC Wiring, Sheet 1 (Begin
Spec F)
Page 7-12 – 7-light DC Wiring, Sheet 2 (Begin
Spec F)
Page 7-13 – 12-light DC Wiring, Sheet 1 (Begin
Spec F)
Page 7-14 – 12-light DC Wiring, Sheet 2 (Begin
Spec F)
Pages 7-15 and 7-16 – Reconnection Diagram
(Prior to Spec E)
Pages 7-17 and 7-18 – Reconnection Diagram
(Begin Spec E)
Page 7-19 – Typical Connections to the ECM
Page 7-20 – Customer Connections at the Auxiliary Relay Board
Page 7-21 – Engine Harness (Begin Spec F)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-2
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
NO. 6126489
REV. D
MODIFIED
AC CONTROL WIRING DIAGRAM (WITHOUT METERS)
7-3
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
NO. 6126490
REV. J
MODIFIED
AC CONTROL WIRING DIAGRAM (WITH METERS)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-4
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
NO. 3003606
REV. G
MODIFIED
VOLTAGE REGULATOR INSTALLATION (PMG-EXCITED GENERATORS)
7-5
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
NO. 3003607
REV. D
MODIFIED
VOLTAGE REGULATOR INSTALLATION (SELF-EXCITED GENERATORS)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-6
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6487 sh 1 of 2
Rev. N Sys:CADAM
Modified 8/3/95
7-LIGHT DC WIRING, SHEET 1 (PRIOR TO SPEC F)
7-7
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6487 sh 2of 2
Rev. N Sys: CADAM
Modified 8/3/95
7-LIGHT DC WIRING, SHEET 2 (PRIOR TO SPEC F)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-8
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6488 sh 1of 2
Rev. N Sys: CADAM
Modified 8/3/95
12-LIGHT DC WIRING, SHEET 1 (PRIOR TO SPEC F)
7-9
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6688 sh 2of 2
Rev. N Sys: CADAM
Modified 8/3/95
12-LIGHT DC WIRING, SHEET 2 (PRIOR TO SPEC F)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-10
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6686 sh 1of 2
Rev. A Sys: CADAM
Modified 8/7/95
7-LIGHT DC WIRING, SHEET 1 (BEGIN SPEC F)
7-11
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6686 sh 2 of 2
Rev. A Sys: CADAM
Modified 8/7/95
7-LIGHT DC WIRING, SHEET 2 (BEGIN SPEC F)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-12
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6687 sh 1 of 2
Rev. A Sys: CADAM
Modified 8/7/95
12-LIGHT DC WIRING, SHEET 1, (BEGIN SPEC F)
7-13
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 612-6687 sh 2 of 2
Rev. A Sys: CADAM
Modified 8/7/95
12-LIGHT DC WIRING, SHEET 2 (BEGIN SPEC F)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-14
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 625-2164 sh 1of 2
Rev. K Sys: CADAM
Modified 8/3/95
GENERATOR RECONNECTION DIAGRAM, SHEET 1 (PRIOR TO SPEC E)
7-15
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 625-2164 sh 2of 2
Rev. K Sys: CADAM
Modified 8/3/95
GENERATOR RECONNECTION DIAGRAM, SHEET 2 (PROIR TO SPEC E)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-16
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 625-3061 sh 1 of 2
Rev. A Sys: CADAM
Modified 8/3/95
GENERATOR RECONNECTION DIAGRAM, SHEET 1 (BEGIN SPEC E)
7-17
Redistribution or publication of this document,
by any means, is strictly prohibited.
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 625-3016 sh 2 of 2
Rev. A Sys: CADAM
Modified 8/3/95
GENERATOR RECONNECTION DIAGRAM, SHEET 2 (BEGIN SPEC E)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-18
TB1-10 (SWITCHED B+ OUTPUT) OUTPUT TO RELAY K12, FUSED AT 20 AMPS, ENERGIZED WHEN THE
START SIGNAL IS APPLIED AND DE-ENERGIZED AT SHUTDOWN (NORMAL AND FAULT)
–
+
K12
TB1-9 (B+ INPUT) BATTERY POSITIVE (+) CONNECTION
TB1-8 (START SOLENOID) OUTPUT TO RELAY K11, FUSED AT 20 AMPS
K11
A15
TB1-7 (B+ OUTPUT) OUTPUT TO TIME DELAY START/STOP MODULE A15,
FUSED AT 15 AMPS, AVAILABLE WHEN THE STARTING BATTERIES ARE CONNECTED
TB1-6 (REMOTE START) CONNECTED TO TIME DELAY START/STOP MODULE A15. CONNECT REMOTE START
CONTACT OF THE AUTOMATIC TRANSFER SWITCH TO TERMINAL TB1-5 OF MODULE A15.
TB1-5 (GROUND)
TB1-4 (COMMON ALARM B+ OUTPUT) 4 AMP RATED DEVICE MAXIMUM
TB1-3 (RUN) CONNECTED TO TIME DELAY START/STOP MODULE A15
TB1-2 (DC DISCONNECT) CONNECTED TO TIME DELAY START/STOP MODULE A15
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
TB2-1 (FAULT 2) GROUND INPUT FROM SENDER
TB2-2 (FAULT 2) GROUND OUTPUT TO LIGHT/RELAY*
TB2-3 (FAULT 1) GROUND INPUT FROM SENDER
TB2-4 (FAULT 1) GROUND OUTPUT TO LIGHT/RELAY*
TB2-5 (REMOTE RESET) MOMENTARY CONTACT TO GROUND
TB2-6 (OVERCRANK FAULT) GROUND OUTPUT TO LIGHT/RELAY*
TB2-7 (OVERSPEED FAULT) GROUND OUTPUT TO LIGHT/RELAY*
TB2-8 (HIGH ENGINE TEMPERATURE FAULT) GROUND OUTPUT TO LIGHT/RELAY*
TB2-9 (LOW OIL PRESSURE FAULT) GROUND OUTPUT TO LIGHT/RELAY*
TB2-10 (PRE-HIGH ENGINE TEMPERATURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*
TB2-11 (PRE-LOW OIL PRESSURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*
CUSTOMER SUPPLIED WIRING
TB2-12 (SWITCH OFF WARNING) GROUND OUTPUT TO LIGHT/RELAY*
FACTORY WIRING
TB2-13 (LOW ENGINE TEMPERATURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*
* 0.5 AMP RATED DEVICE MAXIMUM
TB2-14 (LOW FUEL WARNING) GROUND INPUT FROM SENDER
TB2-15 (LOW FUEL WARNING) GROUND OUTPUT TO LIGHT/RELAY*
TB2-16 (EMERGENCY SHUT DOWN) MOMENTARY CONTACT TO GROUND
FACTORY AND CUSTOMER CONNECTIONS AT THE ENGINE MONITOR BOARD TERMINALS
Redistribution or publication of this document,
by any means, is strictly prohibited.
7–19
THE TERMINALS IN THE SHADED BOXES ARE FOR CUSTOMER CONNECTIONS
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE
WAS
NO.THAT
3004111
INCLUDED WITH YOUR GENSET.
REV. B
MODIFIED
625-2712
CUSTOMER CONNECTIONS AT THE AUXILIARY RELAY BOARD (DETECTOR CONTROL)
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-20
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 338-3308 sh 1of 1
Rev. A Sys: CADAM
Modified 7/24/95
ENGINE HARNESS (BEGIN SPEC F)
7-21
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by any means, is strictly prohibited.
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.
Redistribution or publication of this document,
by any means, is strictly prohibited.
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