Service

Manual
Generator
and Control

DL Series Generatar Sets

with Torque Match-2'" Regulator

943-0020
8-88
PdnW In USA. Redistribution or publication of this document
by any means, is strictly prohibited.
 Safety Precautions
Before operatlng the generator set, read the Operator's Do not wear loose clothing or jewelry in the vicinity of mov-
Manual and become familiar with it and the equipment. Safe ing parts, or while working on electrical equipment. Loose
and efflclent operatlon can be achleved only If the e q u l p clothing and jewelry can become caught in moving parts.
ment Is properly operated and malntalned. Many accidents Jewelry can short out electrical contacts and cause shock
are caused by failure to follow fundamental rules and precau- or burning.
tions.
If adjustment must be made while the unit is running, use
The following symbols, found throughout this manual, alert you extreme caution around hot manifolds, moving parts, etc.
to potentiallydangerousconditions to the operator, service per-
sonnel, or the equipment. ELECTRICAL SHOCK CAN CAUSE SEVERE PER-
SONAL INJURY OR DEATH
B t This symbol warns of Immediate haz- Remove electric power before removingprotectiveshields
ards whlch will result In severe personal Injury or or touching electrical equipment. Use rubber insulative
death. mats placed on dry wood platforms over floors that are
metal or concrete when around electrical equipment. Do
lirWAR"Gl Thissymbol refers to a hazard or unsafe not wear damp clothing (particularly wet shoes) or allow
practlce whlch can result in severe personal Injury skin surface to be damp when handling electrical equip-
or death. ment.
U s e extreme caution when working on electrical cornpo-
1- This symbol refers to a hazard or unsafe nents. High voltages can cause injury or death. DO NOT
practlce whlch can result in personal Injury orprod- tamper with interlocks.
uct or property damage.
Follow all applicable state and localelectrical codes. Have
all electrical installationsperformed by aqualified licensed
FUEL AND FUMES ARE FLAMMABLE. Fire and explosion electrician. Tag open switches to avoid accidental closure.
can result from improper practices.
DO NOT CONNECT GENERATOR SET DIRECTLY TO
DO NOTfillfueltankswhile engine is running, unlesstanks ANY BUILDINGELECTRICALSYSTEM. Hazardousvolt-
are outside the engine compartment. Fuel contactwithhot ages can flow from the generator set into the utility line.
engine or exhaust is a potential fire hazard. This creates a potentialfor electrocution or property dam-
age. Connectonly through an approvedisolation switch or
DO NOT permit any flame, cigarette, pilot light, spark, or an approved parallelingdevice.
other ignition source near the generator set or fuel tank.
GENERAL SAFETY PRECAUTIONS
Fuel lines must be adequately secured and free of leaks.
Fuel connection at the engine should be made with an ap- Coolants under pressure have a higher boiling point than
proved flexible line. Do not use copper piping on flexible water. DO NOT open a radiator or heat exchanger pres-
lines as copper will become brittle if continuouslyvibrated sure cap while the engine is running. Allow the generator
or repeatedly bent. set to cool and bleed the system pressure first.
Be sure all fuel supplies have a positive shutoff valve. Benzene and lead, found in some gasoline, have been
Do not smoke while servicing lead acid batteries. Lead identified by some state and federal agencies as causing
acid batteries emit a highly explosive hydrogen gas that cancer or reproductive toxicity. When checking, draining
can be ignited by electrical arcing or by smoking. or adding gasoline, take care not to ingest, breathe the
fumes, or contact gasoline.
EXHAUST GASES ARE DEADLY
Used engine oils havebeen identifiedby somestate orfed-
Provide an adequate exhaust systemto properly expeldis- era1 agencies as causing cancer or reproductive toxicity.
charged gases. Visually and audibly inspect the exhaust When checking or changing engine oil, take care not to in-
daily for leaks per the maintenanceschedule. Ensure that gest, breathe the fumes, or contact used oil.
exhaust manifolds are secured and not warped. Do not
use exhaust gases to heat a compartment. Provide appropriate fire extinguishers and install them in
convenient locations. Consult the localfire department for
Be sure the unit is well ventilated. the correct type of extinguisherto use. Do not use foam on
electrical fires. Use extinguishers rated ABC by NFPA.
MOVING PARTS CAN CAUSE SEVERE PERSONAL
Make sure that rags are not left on or near the engine.
INJURY OR DEATH
Remove all unnecessary grease and oil from the unit. Ac-
Keep your hands, clothing, and jewelry away from moving cumulated grease and oil can cause overheating and en-
parts. gine damage which present a potential fire hazard.
Before starting workon the generator set, disconnedstart- Keep the generator set and the surrounding area clean
ing batteries, negative (-) cable first. This will preventacci- and free from obstructions. Remove any debris from the
dental starting. set and keep the floor clean and dry.
Make sure that fasteners on the generator set are secure. Do notworkonthisequipment when mentally or physically
Tighten supports and clamps, keep guards in position over fatigued, or after consuming any alcohol or drug that
fans, drive belts, etc. makes the operation of equipment unsafe.
Ls-9

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 Table of Contents
SECTION TITLE PAGE
SAFETY PRECAUTIONS ................................................ ii
1 INTRODUCTION .................................................... 1-1
AboutThisManual ................................................. 1-1
. TestEquipment ............................. :..................... 1-1
How to Obtain Help ................................................. 1-1
...................................
Y

2 GENERATORIVOLTAGEREGULATOR 2-1
Generator Description .............................................. 2-1
Generator Operation ................................................ 2-2
Voltage Regulator.................................................. 2-3
............................................. 2-5
Optional Circuit Breaker
3 GENERATORIREGULATOR TROUBLESHOOTING ............ ............. 3-1
:
ComponentLocations ............................................... 3-1
Preparation ...................................................... 3-1
Troubleshooting Procedures........................................... 3-2
.................. 3-3
Flow Chart A. No AC Output Voltage at Rated Engine Speed
........3-4
Flow Chart B. Unstable AC Output Voltage. Engine Stable at Rated Speed
...................... 3-4
Flow Chart C. AC Output Voltage Too High or Too Low
................................ 3-5
Flow Chart D. Exciter Field Breaker Trips
Flow Chart E. Unbalanced AC Output Voltage............................. 3-6
............. 3-7
Flow Chart F. No AC Output Through Set Mounted Circuit Breaker
4 GENERATORIREGULATOR TESTSIADJUSTMENTS ..... ..................4-1
i
General .......................................................... 4.1. .
[A] Testing AC Residual Voltage...................................... 4-1
................................................
[B] Flashing the Field 4-1
[C] AC Voltage Regulator Replacement ................................. 4-2
........................................ 4-2
[D] Testing Rotating Rectifiers
....................................
[E] Testing Exciter Stator ....... 4-3
!

............................................
[F] Testing Exciter Rotor 4-4
[GI Testing Main Rotor Windings...................................... 4-5
....................................... 4-6
[HI Testing Main Stator Winding
[J] Wiring Harness Check ........................................... 4-7
[K] Voltage Regulator VRAS-2 Adjustment............................... 4-7 .
................................... 4-9
[L] Voltage Adjust Potentiometer R21
................................... 4-10
[MI Testing AC Load Circuit Breaker
.GENERATOR DISASSEMBLYIASSEMBLY ............ ................... 5-1
General .......................................................... 5-1
Disassembly ...................................................... 5.1 .
Reassembly ...................................................... 5-3
WIRING DIAGRAMS ................................................. 6-1

iii
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.

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Section 1 Introduction
ABOUT THIS MANUAL TEST EQUIPMENT
This manual has troubleshootingand repair information Most of the test procedures in this manual can be per-
for the Onan series YD generators using the Torque formed with an AC-DC multimeter such as a Simpson
Match-2 (VRAS-2) AC voltage regulator. For operation, Model 260 VOM or a digital VOM. Some other instru-
service, and troubleshooting information on the engine . ments to have available are:
or DC control components, refer to support manuals
specific to the generator set model. 0 Onan Multitester
Wheatstone Bridge
Study this manual carefully and observe all warnings 0 Jumper Leads
and cautions found in the Safety Precautions (page ii) 0 Onan Load Test Panel
and other pages of this manual. Knowing the generator 0 Variac
set and instructing the operator on how to follow a 0 AC Voltmeter
regular maintenance schedule will help obtain longer 0 DC Voltmeter
unit life, better performance, and safer operation.
See Tool Catalog 900-0019.
Repair information for solid state printed circuit board
components (other than fuses) is not provided as the HOW TO OBTAIN HELP
board lends itself to replacement rather than repair.
Application of meters or hot soldering irons can cause Always supply the complete model number and serial
unnecessary and expensive damage. Repair of the number on the generator set nameplate(see Figure1-1)
printed circuit boards is not recommended except by when seeking additional service information or re-
the factory. placementparts. The nameplateis located on the side of
the control box.
High voltage resistance testing of
l2EEEl generator windings can cause dam-
age to solid state components. Isolate these compo-
nents before testing.

M-1641
FIGURE 1-1. ONAN NAMEPLATE

lAWARNING I
INCORRECTSERVICEOR REPLACEMENTOFPARTS CANRESULTINSEVERE
PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PER-
SONNELMUSTBE QUALIFIED TO PERFORM ELECTRICALAND/OR MECHAN-
ICAL SERVICE.

1-1 Redistribution or publication of this document

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Redistribution or publication of this document
by any means, is strictly prohibited.
 Section 2. GeneratorNoltage Regulator
GENERATOR DESCRIPTION in the end bell, the exciter rotor and its rotating rectifier
The YD generator is a four-pole, revolvingfield, brush- assembliesmount on the rotor shaft. Within the end bell,
less exciter design. Single and three phase generators leads Fl(+) and F2(-) from the exciter stator winding
are available in both 50 and 60 hertz. connect to the output terminals of the voltage regulator.

The generator rotor is directly coupled to the engine The composite illustration in Figure 2-2 shows the
flywheel with a flexible drive disc. The engine speed generator output and control/meter leads for the var-
- determines output frequency. A centrifugal blower on ious voltage codes that may appear on the nameplate.
the drive disc pulls cooling air through the end bell and The number of wires is dependent upon the model and
discharges it through an outlet near the blower. selected code options. Voltage codes B and N (single-
phase units), and F and H (3-phase units) have four
A ball bearing in the end bell supports the rotor shaft. leads. Voltage codes L and Z have 12 output leads for ,

The end bell is attached with four studs that thread into 3-phase, broad-range connections.
the generator adapter casting. The exciter stator mounts

DRIVE
DISC END BELL
BLOWER m

6-1202-1

FIGURE 2-1. TYPICAL YD SERIES GENERATOR

2-1
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Voltage code reconnection diagrams appear in Section GENERATOR OPERATION
4. Generator/Regulator Tests/Adjustment, and in Sec- Power generation involves the generator components
tion 6. Wiring Diagrams. Generator sets ordered from shown in Figure 2-3. These componentsare italicized in
Onan with the optional circuit breaker have the leads the following text. A permanentmagnetembedded in an
connected for the nameplate voltage. exciterstatorfield pole beginsthe voltage build-up pro-
cess as the generator set starts. Single-phase AC volt-
CONTROL AND METER LEADS- age, taken from a main stator winding, is connected to
TAPS OFF MAIN STATOR WINDING the VRAS-2 voltage regulatoras a referencefor regulat-
*SINGLE PHASE ONLY ing the generator output voltage. The regulator DC out-
CODES B AND N (3,53)
*1,4
put is coupled to the exciter stator.
THREE PHASE
CODES LAND Z (15,515): 4,7,8,9,10 The exciter rotor producesthree-phase AC voltage that
CODES F AND H (7,9X): 7,8,9,10
is converted to DC by the full wave rotating rectifier
assemblies. The DC voltage excites the rotor main field
winding to produce main stator AC for the load.

SINGLE PHASE

REGULATOR

CODES F, N (17,9X
THREE PHASE

OLD CODES SHOWN IN PARENTHESIS FOR REFERENCE ONLY

ES-1315-1

FIGURE 2-2. SINGLE AND THREE PHASE

GENERATOR SCHEMATIC (COMPOSITE)

-----
LAMJ
_.

*
I - __ ---m---
--0- DC

STATOR STATOR

ES-1322-2

FIGURE 2-3. GENERATOR EXCITATION BLOCK DIAGRAM

2-2
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 VOLTAGE REGULATOR Switches on the regulator provide flexibility to test and
Description set the torque-matching function for different engine/
generator combinations.When properly set, the regula-
The VRAS-2 voltage regulator (Figure 2-4) provides tor is able to maintain output voltage within reasonable
switch selections that alter its sensing and command limits under transient conditions. It allows use of the
signals for maximum performancein a variety of genera- engine's full power to prevent an unstable response.
tor sizes and applications. Review the sections titled
Operation Modes and Operating Stability, then the Non- Torque-Matching:Even though the voltage regula-
Adjustments section for switch locations and settings tor can also be switch-selected to a non-torque-
specific for the generator set kilowatt rating. matching constant voltage mode, independent of
9

engine speed, this mode will not prevent the generator

set from stallingduring momentary overload conditions.
GENERATOR SET CONTROL This setting is not recommended. Consult an Onan ser-
VRAS-2 (TOP VIEW) vice representative before selecting this mode to be
VOLTAGE
REGULATOR sure that load demands specific to the installationwould
not cause unstable operation of the generator set.

Operating Stability
Different regulator gain compensation is required
because of differences in the exciter and main field time
constants of various generator sizes. The VRAS-2 volt-
age regulator is switch-selectable to a kilowatt range
that best suits the generator set application.

Voltage Regulator Adjustments

The VRAS-2 Voltage Regulator board is shown in Fig-
ure 2-5. Three switches and two potentiometersprovide
the follo.wing functions:

0 Switch S1 - Selects the overall range of operation for

the regulator. Refer to Table 2-1.

0 -
.SwitchesS2 and S3 Determine the mode of regula-
tion (Torque-Matched or Non-Torque-Matched).
Refer to Table 2-1.

0 PotentiometerR32 - Providesadjustment to increase

V
FRONT METER
ESl7¶3
or decrease generator voltage to proper setting.
PANELS
0 PotentiometerR34-is adjusted at the factory to set the
frequency breakpoint, and does not require further
FIGURE 2-4. LOCATION OF VOLTAGE REGULATOR
adiustment.
(CONTROL TOP VIEW)
See Section 4 of this manual for replacement and
adjustment procedures.
Operating Modes
.' Torque-Matching: Matching the torque characteristics
of the engine and generator is required to properly
manage momentary application of overloads such as
motor starting. Becauseof variance in engine character-
istics, different torque matching may be applied.

2-3 Redistribution or publication of this document

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 TABLE 2-1. VRAS-2 SWITCH SETTINGS

REGULATION MODE
GENSET STABILITY 60 Hz 50 Hz NON-
kW RANGE TORQUE-MATCHING TORQUE-MATCHING TORQUE-MATCHING
SI-1 S1-2 s2 S3-1 S3-2 S2 S3-1 S3-2 52 S3-1 S3-2

16-35 OFF OFF POS2 OFF ON POS2 ON ON POS2 OFF OFF

40-50 OFF ON POS2 OFF ON POS2 ON ON POS2 OFF OFF

R32
VOLTAGE ADJUST _.
. .
c

SC-1516-4

s3 ’ R34
DO NOT ADJUST
(SEE TEXT)

TB1-2, -3 AC INPUT VOLTS

TBI-3, -4 CROSS-CURRENT COMPENSATION
TB1-7. -8 VOLTAGE ADJUSTING RHEOSTAT
TB1-9, -10 EXCITER FIELD
F1- TB1-9
F2 - TB1-IO

FIGURE 2-5. VRAS-2 VOLTAGE REGULATOR ADJUSTMENTS

2-4 Redistribution or publication of this document

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 OPTIONAL CIRCUIT BREAKER 0 The magnetic trip action of the breaker is caused by
Depending on site specifications and applicable code an electromagnetwhich partiallysurroundsthe inter-
requirements, an optional circuit breaker may be nal bimetal strips. If a short circuit occurs, the high
mounted in the generator AC output box. current through the electromagnet will attract the
bimetal armature and trip the breaker. Some breaker
models provide front adjustment of the magnetic trip
Description action. These adjustments are normally set at the
All Onan supplied breakers are thermal and magnetic factory at the high position, but providefor individual
trip type. Depending on customer requirements, the conductor settings to suit customer needs.
breaker may also include shunt trip and remote alarm
connections. Review the following functions/require- 0 The shunt trip mechanism (if equipped) consists of a
ments and Figure 2-6. solenoid tripping device mounted in the breaker with
external lead connections for remote signaling. A
Generatorset output is connectedto the load through momentary signal to the solenoid coil will cause the
the circuit breaker. breaker to trip.
0 When an overload or short circuit occurs on any one 0 This feature is available in AC or DC voltages, and is
conductor, a common trip bar will disconnect all three normally installed at the factory to meet customer
conductors. needs. The shunt trip mechanism is most often con-
nected to a common fault shutdown circuit of the
0 The thermal trip action of the breaker is accomp- generator set. This quickly disconnects the set from
lished by bimetalstrips. A sustained overcurrentcon- the load on shutdown and avoids a reverse power
dition will cause a thermal reactionof the bimetaland condition.
trip the breaker. Response of the bimetal is propor-
tional to current; high current-fast response, low cur-
rent slow response. This action provides a time delay
for normal inrush current and temporary overload
conditions such as motor starting. r--1
I SHUNT TRIP
+COMMON AURM
-GROUND
AUXILIARY CONTACTS
A
COMMON
0

ON
"
1r' GENERATOR
OUTPUT
TRIP
OFF
.RESEl

ES-1564-4
-
SIDE VIEW HANDLE POSITIONS

TRANSFORMER

I
ES-1564-3 FIGURE 2-6- GENERATOR-MOUNTED CIRCUIT BREAKER

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0 Auxiliary contacts (if equipped) are used for local or e Operation of the circuit breaker is determined by
remote annunciation of the breaker status. They usu- site-established procedures. In emergency standby
ally have one normally-open and one normally- installations, the breaker is often placed to the On
closed contact (1 form C contacts) to comply with the position, and is intendedfor safety trip actuation in the
annunciator requirement. event of a fault condition. If the breaker trips open,
investigate the cause and perform remedial steps per
0 The trip actuator is for periodic exercise of the the troubleshooting procedures. To close the
breaker to clean and maintain its proper operation. breaker, the handle must be placed to the Reset posi-
Rotating this actuator mechanically simulates over- tion and then to On. Refer to Sections 3 and 4 for
current tripping through actuation of linkages not troubleshooting and further information.
operated by the On/Off handle. See Section 4.
Generator/Regu/ator Tests/Adjustments for further
information.

.i I. ....... ,.. .-.

. .
, I.
. ...

2-6
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Section 3. Generator/Regulatoa
Troubleshooting
COMPONENT LOCATIONS A few simple checks and a valid troubleshooting proce-
The following listing of components with their locations dure can quickly locate the trouble source and cut ser-
are referenced in the troubleshooting charts of the Trou- vice time. The following are inspectionareas often over-
bleshooting Procedures section. The charts will only be looked when troubleshooting.
calling them by name, so become familiar with their loca-
tions before proceeding. Other components are located 0 Check modifications, repairs, and replacements per-
on the control panel and are not listed here. formed since the last satisfactory operation of the set
to be sure that all generator leads are correctly con-
0 AC Output Circuit Breaker: Mounted in the generator nected. A loose or incorrect wire terminal connection,
AC output box. or an open circuit breaker overlooked when replac-
ing a part could cause problems. A thorough visual
0 Voltage Regulator VRAS-2: Inside the control box. check can quickly eliminate these potential problems.

0 Terminal Board TB27: Inside the control box. 0 Visually inspect the components of the VRAS-2 Volt-
age Regulator. Look for dust, dirt, or moisture and
0 Current Transformers CT27, 22, and 23: Inside the cracks in the printed conductors or solder connec-
generator AC output box. tions. Burned resistors and arcing tracks are readily
identifiable. Do not mark on the board with a graphite
0 Rotating Rectifiers: Within the generator end bell on pencil as this can cause leakage or short circuit
the exciter rotor. between components. Visually inspect the exciter
rotor assembly for burned components, broken wires,
loose connections, and carbon tracks caused by arc-
PREPARATION ing between parts or between parts and ground. Also
Before preparing or starting any troubleshooting proce- check for shorted paths between terminals caused by
dure, be sure to disable the generator set by disconnect- dust, dirt, and moisture.
ing the starting battery cables (negative [-] cable first).
Unless absolutely sure that panel instruments are accurate, use
portable test meters for troubleshooting.
Accidental starting of the generator
l33EiGl set can cause severe personal injury
or death during service procedures. Be sure to disable
ACAUT~ON To prevent meter damage,
ohmmeter checks must be made
the generator set by disconnecting the starting battery with the generator set stopped and the starting bat-
cables (negative1-1cable first). tery disconnected.

3-1
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 TROUBLESHOOTING PROCEDURES After determining the problem, refer to the applicable
The information in this section is divided into Trouble- troubleshooting flow chart. Start at the chart upper left-
shooting Flow Charts as follows: hand corner and answer all the questions either YES or
NO. Follow the chart until the problem is found, perform-
A. No AC output Voltage at Rated Engine Speed ing the referenced Adjustment and Test Procedure(s)
following the flow charts.
B. Unstable AC Output Voltage, Engine Stable at
Rated Speed. The referenced components in the flow charts and in the
C. AC Output Voltage Too High or Low. Adjustment and Test Procedures can be found on the
D. Exciter Field Breaker Trips. electrical schematic in Figure 3-1, and on assembly and *
E. Unbalanced AC Output Voltage. wiring diagrams.
F. No AC Output Through Set-Mounted Circuit
Breaker.
COMPONENT DESCRIPTION

REF DESCRIPTION

CB21 Field Circuit Breaker

CT21-23 Current Transformer Assembly
DS21-22 Lamp Assembly (Upper/Lower Scale)
G21 Generator
M21 AC Voltmeter
M22 AC Ammeter
M23 Frequency Meter
R21 Volts Adjust Potentiometer
s21 Rotary Switch, Volt & Ammeter
TB21 Terminal Block
VR21 Voltage Regulator

S21 PHASE SELECTOR SWITCH

POSITION CONTACTS CLOSED

L1-L2 3 0 11-18 C-22 32-M 44-N 334

L2-L3 3 0 A-12 C-22 44-N 42-41 43-P
L3-L1 3 0 11-18 6-J 34-31 42-41 33-R
L1-LO 3 0 11-18 21-14 44-N 42-41 33-R
OFF - - 44-N 42-41 33-R
Ll-L2 10 11-18 C-22 32-M 44-N 33-R
LI-L2 10 11-18 C-22 44-N 42-41 43-P

1. See generator connection diagram 625-2108 in Section 6 for

.
input connections.
2. Dashed components and leads indicate when used.
3. This figure is for reference only. Use the electrical schematic b
.

specific to the application when troubleshooting.

SC-1618

FIGURE 3-1. AC ELECTRICAL SCHEMATIC (INCLUDES METER OPTIONS)

3-2
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 FLOW CHART A. NO AC OUTPUT VOLTAGE AT RATED ENGINE SPEED

(BWARNING] Many troubleshootingprocedures present hazards which can result in severe personal injury or
death. Only qualifiedsenricepersonnel with knowledge of fuels, electricity, andmachineryhazards
should perform service procedures. Review safety precautions on inside cover page.

Is control panei field breaker CB21 on

(fully-in position)?
-Ye

I
I
Remove one lead from breaker and
No check continuity with ohmmeter. Is
I breaker open?

N-
do If voltage is unstable, high or low. or
Push to reset breaker. Does generator Yes
AC output voltage build up7 causes breaker to trip, see Flow Charts
B. C. D or E.

No
Flash the exciter stator per TEST
[B]. Does AC output voltage build up?

Is residual voltage across TB21-22

and 23 equal to 5 to 10 VAC or NO
more per TEST [A]?
Disconnect main stator leads 7
I and 8 from TB21-22 and 23.Is
residual voltage across the leads 5 to
10 VAC or more now?
I
I
I

Yes No
.)

voltage regulator/TBl-2 and main

Is exciter stator voltage across stator lead 7, and between voltage
voltage regulator/TB-9 and 10 equal -No regulatorITB1-3 and stator lead 8
to 5 to 10 VDC or more? per test [J].

I
Yes
Check exciter stator wiring for
shorts per TEST [J]. Replace bad
wiring.

Check exciter stator wiring for

Check rectifiers CR1 - CR6 on
opens per TEST [J]. Replace bad
exciter rotor per TEST [D]. Replace
wiring.
if bad.

. - I Replace voltage regulator

per procedure [C]. I
e-t
! *

I Check exciter stator winding per

I Check exciter rotor winding per
TEST [F]. Replace if bad.

+
TEST [E]. Replace if bad.

Check main rotor winding per TEST

[GI. Replace if bad.

ACAUTION To avoidpossible damage to the new

voltage regulator board, do not
replace until all external problems have been
corrected. Test [HI. Replace if bad.

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Redistribution or publication of this document
by any means, is strictly prohibited.
 FLOW CHART D. EXCITER FIELD BREAKER TRIPS

Many troubleshooting procedures present hazards which can result in severe personal injury or
death. Only qualified service personnel with knowledge of fuels, electric@, and machinery hazards
should perform service procedures. Review safety precautions on inside cover page.

‘I
Does AC output voltage build up Check for any loose or broken wires
to 15096 or more of rated voltage y
-es+
-, or connections on voltage regulator
before breaker trips? assembly.
I

No

Check rotating rectifiers in

exciter rotor per TEST [D]. adjustments and connections
Replace if bad. per TEST [K].

IC
Check exciter stator winding
per TEST [E]. Replace if bad. I proper, and secure connection. Refer

+
Check exciter rotor winding
to Generator Description, Optional
Voltage Connections, and appropriate
electrical schematic.

per TEST [F]. Replace if bad.

1
Check main rotor winding
per TEST [GI. Replace if bad.

1
Check main stator windings
per TEST [HI. Replace if bad.

+
Replace voltage regulator
per TEST [C].

Toavoidpossibledamage to the new

voltage regulator board, do not
replace until all external problems have been
corrected.

3-5 Redistribution or publication of this document

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 FLOW CHART E. UNBALANCED AC OUTPUT VOLTAGE

1- Many troubleshooting procedures present hazards which can result in severe personal injury or
death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards
should perform service procedures. Review safety precautions on inside cover page.

Disconnect load from generator (trip Reconnect load and check each phase *.
AC breaker if used). Is output for balanced current. If not within
still unbalanced? 10% of each other, redistribute the load.

I-'
Yes.; Check for correct grounding of generator
+ and'load.

..
..... . . . . . .

Correct'as necessary.
. .
. .

yes

3-6
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 FLOW CHART F. NO AC OUTPUT THROUGH SET MOUNTED CIRCLIIT BREAKER

n~WARN~NG Many troubleshooting procedures present hazards which can result in severe personal injury or
death. Only qualified sewice personnel with knowledge offuels, elecbicity, and machinery hazards
should perfonn sewice procedums. Review safeiyprecautions on inside cover page.

Is set-mounted output breaker at No Is set-mounted output breaker to

Tripped position? OFF position?

I
: Determine cause of breaker trip. If
not immediately known, stop
generator set and investigate cause.
Circuit overload (per site-
established procedures).

Short circuit (per site-

established procedures). ,
Shunt trip (check for
generator set fault shutdown,
or other signal source).

Review TEST [MI. TESTING AC LOAD

CIRCUIT BREAKER.

Correct fault condition and reset

circuit breaker to ON position.

3-7 Redistribution or publication of this document

by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
 Section 4. GeneratoVRegulator
Tests/Ad justments
* Many troubleshootingprocedures present hazards which can result in severe personal injury or
death. Only qualified servicepersonnel with knowledge of fuels, electricity, and machinery hazards
should perform service procedures. Review safety precautions on inside cover page.

GENERAL
The following tests and adjustments can be performed FLASHING THE FIELD
without disassembly of the generator. They should be
used for testing the generator components and regula- If the residual voltage is missing, it may be necessary to
tor in conjunction with the Troubleshooting Flow Charts restore magnetism by flashing the exciter field. This
in Section 3. All resistance measurements must be requires a 12-volt battery, IO-ampere fuse, momentary-
made with the unit stopped to prevent instrument on switch, and diode assembled as shown in Figure4-2.
damage.
Field flashing can be done during generator set opera-
[AI tion or when stopped. Either method should be suffi-
cient to restore magnetism.
TESTING AC RESIDUAL VOLTAGE
Test for generator residual AC voltage if there is no Incorrect flashing procedure can
power output. A good check point is across terminals 22 damage the voltageregulator. Do not
and 23 at terminal block TB21. See Figure 4-1. Residual keep excitation circuitry connected longer than five
voltage should be 5 to 10 VAC minimum at normal oper- seconds.
ating r/min and no load. The voltage can be as high as
35 to 50 VAC. During Generator Set Operation
If residual voltage is present at TB21, check voltage at 1. Connect the positive lead to VRAS-2 terminal 9 (+)
VRAS-2 terminals 2 and 3.If none, check continuity of and the negative lead to terminal 10 (D) (Figure4-1).
field circuit breaker CB21, wiring, and connections with 2. Start the generator set and operate at normal speed.
the generator set shut down. Close the switch just long enough for the generator
output voltage to build up, but not longer than five
seconds.

R21 (USED WHEN VOLT

ADJUST POT IS NOT
ON CONTROL PANEL) VOLTAGE REGULATOR

Ff I;! TO EXCITER F I E L D
TO DC CONTROL
J I - l .JI-2

cB21
FIELD TB21
CIRCUIT TERMINAL BOARD ES-1792
BREAKER

FIGURE 4-1. COMPONENT LOCATION

Redistribution or publication of this document

4-1 by any means, is strictly prohibited.
 3. Check the output voltage, then shut down the
generator set. Restartthe generator set and operate
[CI
at no load. Output voltage must build up withoutfield AC VOLTAGE REGULATOR REPLACEMENT
flashing. If not, shut down the generator set and Use the following procedure to replace the VRAS-2
perform continuity check of all related wiring. voltage regulator assembly (Figure 4-1).

1. Stop the generator set and disconnect the starting

With Generator Set Stopped battery leads, negative (-) lead first.
2. Disconnect (and label if necessary) the wires from I
1. Connect the positive lead to VRAS-2 terminal 9 (+) voltage regulatorVRAS-2/TBI. Refer to the AC con-
and and the negative lead to terminal 10 (-) (Figure trol wiring diagram.
4-1). 3. Remove mounting screws from the old VRAS-2 b
2. Hold the switch closed no longer than five seconds. regulator, then install new regulator.
3. Disconnect the flash circuit leads. Startthegenera- 4. Reconnect wires removed in Step 2 to the proper
tor set and operate at no load. The output voltage terminals.
must build up without field flashing. If not, shut down 5. Perform the voltage regulator adjustment/switch
the generator set and perform continuity check of all settings for specific voltage and method of regula-
re1ate.dwiring. tion desired.per procedure [J].

TO VRAS-2
TERM. TB1-10 TESTING ROTATING RECTIFIERS
F2-)
Two differentrectifier assemblies make up the rotat-
ing rectifier bridge assembly, Figure 4-3. Using an
MOMENTARY-ON
ohmmeter, test each CR rectifier using negative (-)
and positive (+) polarities. Use the following proce-
dure.
TO VRAS-2 12-AMP
TERM. TB1-9
(F1+) DIODE

OHMMETER
10-AMP
FUSE
TFil

ES-1658-2
CR5

CA-1010-9

FIGURE 4-2. FIELD-FLASHING CIRCUIT

FIGURE 4-3. TESTING ROTATING RECTIFIERS

4-2
Redistribution or publication of this document
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1- Disconnectall leadsfrom the assemblyto be tested.
2- Connect one ohmmeter test lead to F1+ stud and
[El
connect the other test leadto CRl, CR2, and CR3 in
TESTING EXCITER STATOR
turn. Record resistance value of each rectifier. Test the exciter stator (Figure 4-4) for open or shorted
3. Connect one lead to F2- stud and connect other test windings and grounds as follows.
lead in turn to CR4, CR5, and CR6. Record resist-
ance value of each rectifier. Testing For Open or Shorted Winding
4. Reverse ohmmeter test leads in Steps 2 and 3 and Use a Wheatstone Bridge or digital ohmmeter for this
record resistancevalue of each rectifier. test. Disconnect F1+ and F2- exciter field leads from the
terminal block in the generator end bell. Resistance
5. All resistance readings should be high in one test should be 14.5 ohms f10% at 77OF (25OC).
and low in the other test. If any reading is high or low
in both tests, rectifier assembly is defective.
Testing for Grounds
Use23 to 26 inch pounds(2.6 to 2.9 Nom) torque when replacing Connect a megger or insulation resistance meter that
nuts of F1+ and F2- leads, CRl, CR2, CR3, CR4, CR5, and CR6. applies 500 VDC or more between the field and the
exciter stator lamination. Be sure both exciter leads are
disconnected from the terminal block. Reading should
be 100,000 ohms or greater. If not, the exciter stator is
F1. F2 questionable and may require removal for oven drying
LEADS
and retest. A shorted stator must be replaced.

F1. F2
STATOR LEADS
LAMINATIONS I

WHEATSTONE
CA-1010-10 BRIDGE OR
DIGITALOHMMETER

TESTING FOR OPEN OR SHORTED WINDING

MEGGER OR
INSULATION
RESISTANCE
METER CA-1010-11

%STING FOR GROUND TO LAMINATION

FIGURE 4-4. TESTINGEXCITER STATOR WINDING

4-3 Redistribution or publication of this document

by any means, is strictly prohibited.
 Testing For Grounds
Test with an insulation resistance meter or Megger that
TESTING EXCITER ROTOR appliesat least 500 volts to the test leads. With all gener-
Test the exciter rotor winding (Figure 4-5) for open or ator leads disconnected from rotating rectifiers CR1
shorted winding, or grounds as follows: through CR6, apply test leads between any CR lead and
the rotor laminations, Readingshould be 100,000 ohms or
Testing For Open or Shorted Windings higher. If not, the exciter rotor is questionable and may
Use a Wheatstone Bridge or digital ohmmeter for this require removal for oven drying and retest. A 'shorted
test. Disconnect the main rotor leads that connect to rotor must be replaced. 1

rotating rectifier assemblies at terminals F1+ and F2-.

Use23to 26 inch pounds (2.6 to 2.9 N.m) torque when replacingnuts
Disconnect exciter rotor leads from diodes CR1, CR2,
CR3, CR4, CR5 and CR6. Test between exciter lead
pairs T1-T2, T2-T3, and T1-T3. See connection diagram
of F1+ and F2- leads, CR1, CR2, CR3, CR4, CR5, and CR6.
.
in Figure 4-5. Resistance readings should be 0.645
ohms 510% at 77OF (25OC).

EXCITER ROTOR
ASSEMBLY

EXCITER ROTOR

CRl
MEGGER OR
INSULATION
WHEATSTONE RESISTANCE
BRIDGE OR METER
DIGITAL OHMMETER
TESTING WINDING FOR GROUNDS
TESTING WINDING RESISTANCE

CONNECTIONDIAGRAM
ES-1794

FIGURE 4-5. TESTING EXCITER ROTOR

Redistribution or publication of this document

by any means, is strictly prohibited.
 [GI - Testing for Grounds
Check for grounds between the rotor winding and the
TESTING MAIN ROTOR WINDING rotor shaft as shown. Usea Megger or insulation resist-
Test the main rotor winding (Figure 4-6) for grounds, ance meter which applies 500 VDC or more at the test
opens, and shorts as follows. leads. Perform test as follows:

Testing For Open or Shorted Winding 1. Remove rotor leads F1+ and F2- from the rotating
Perform this test with a known, accurate instrument rectifier assemblies.
such as a digital ohmmeter.
Be sure to remove both rotor
1. Remove rotor leads
rectifier assemblies.
i+ and F2- from the rotating 7. leads so the rotating rectifiers
are isolated. Failure to do this will damage the
rectifiers.
2. Check resistance across F1+ and F2- leads. The
resistance values at 77OF (25OC) should be as 2. Connect test leads between one of the two leads
shown in Table 4-1. If not, replace the defective and the rotor shaft. Meter shouldread 100,000 ohms
rotor with a new, identical part. or greater.
3. If less than 100,000 ohms, the rotor is questionable
and may require removal for oven drying and retest.
4. Replace a grounded rotor with a new identical part.

!
DIGITAL
OHMMETER
t c y ]
MAIN ROTOR
LEADS F1+. F2-

CA-1010-8

TESTING WINDING RESISTANCE

RESISTANCE
METER

TESTING WINDING FOR GROUNDS

FIGURE 4-6. TESTING MAIN ROTOR WINDING

4-5
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 TABLE 4-1. MAIN ROTOR RESISTANCE

ZRESISTANCE VS CODE

kW 'STACK LENGTH N (53) Z (515)

~

16 5.88 (149) 2.75

16 7.12 (181) 1.80 1.80
20 5.88 (149) 2.75 2.75 2.75 2.75
20
25
7.12 (181)
7.12 (181)
1.80 1.80
1.80 1.80 1.80 .
.
25 8.75 (222) 2.04 2.04
25 10.50 (267) 2.55
30 8.75 (222) 2.04 2.04 2.04
30 10.50 (267) 2.55 2.55
32 10.50 (267) 2.55
4.0 10.50 (267) 2.55 2.55 2.55
-
lamination Stack Length in Inches (mm)
Wesistance in Ohms @ 77°F (25OC)&lo%;Old Voltage Code.in ( )

[HI If a winding is shorted, open or grounded, replace the

stator assembly. Before replacing the assembly, check
TESTING MAIN STATOR WINDINGS the leads for broken wires or insulation.
Test the main stator (Figure 4-7) for opens, shorted
windings, and grounds as follows. Testing For Grounds
Use a Megger or insulation resistance meter which app-
Testing For Open or Shorted Windings lies 500 VDC or more at the test leads. Test each stator
Test for continuity across coil leads. Each coil should winding for short to laminations. If less than 100,000
have equal resistance. Use an accurate instrument for ohms, the stator is questionable and may require remo-
this test such as a Wheatstone Bridge. Resistance read- val for oven drying and retest.
ings should be as shown in Table 4-2 at 77OF (25°C)
*I 0%.

MEGGER OR
INSULATION
RESISTANCE
METER
THREE PHASE MODEL.S
EST BETWEEN WIRE P I4IRS
Tl-T4 T7-Tl0 T3-,T6

TESTING WINDING FOR GROUNDS T9-Tl2 T2-T5 T8-Tll WEATSTONE

BRIDGE
SINGLE PHASE MODELS
TEST BETWEEN WIRE PAIRS TESTING FOR RESISTANCE
Tl-T2 T3-T4

ES-1795

FIGURE 4-7. TESTING MAIN STATOR WINDINGS

4-6
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by any means, is strictly prohibited.
 TABLE 4-2. MAIN STATOR RESISTANCE

'RESISTANCE VS CODE

kW 'STACK LENGTH Z (515)

-
16 5.75 (146) 0.186
16 7.00 (178) 0.071
20 5.75 (146) 0.127
20 7.00 (178) 0.049
25 7.00 (178) 0.100
25 8.62 (219) 0.039
25 8.62 (219) 0.084
25 10.38 (264) 0.036
30 8.62 (219) 0.072
30 10.38 (264) 0.029
32 10.38 (264) 0.059
40 10.38 (264) 0.045

tamination Stack Length in Inches (mm)

2Resistance in Ohms @ 77OF (25°C) *lo%;Old Voltage Code in ( )

[Jl
WIRING HARNESS CHECK VOLTAGE REGULATOR VRAS-2
ADJUSTMENT
1. Inspect all wires for breaks, loose connections, and After replacement, the voltage regulator VRAS-2
reversed connections. Refer to applicable wiring adjustment is performed as follows. Also refer to the
diagram. VRAS-2 Regulator Specifications in this section.
2. Removewires from terminals at each end and using
an ohmmeter, check each wire end to end for conti- 1. Open the control panel doors. Refer to Figure 4-8
nuity or opens. for the proper setting of SI (Stability Range) and S2,
3. Using an ohmmeter, check each wire to other wires S3 (Mode Selection) switches.
and to ground for possible shorts or insulation 2. Control with AC meter option: Refer also to adjust-
breaks under areas covered by wrapping material. ment [K]. Control without ACmeter option:Connect
4. Reconnect or replace wireslharness per the appli- an accurate voltmeter to VRAS-2/TB1-2 and -3
cable wiring,diagram. terminals.
3. Startthe generator set and operate to bring temper-
ature up to normal.
4. As a precaution against electrical shock, place an
insulating mat or a dry wood platformon the floor in
front of the control panel.

4-7 Redistribution or publication of this document

by any means, is strictly prohibited.
 I I REGULATION MODE I
GENSET STABILITY
60 Hz 50 Hz NON-
kW RANGE TORQUE-MATCHING TORQUE-MATCHING TORQUE-MATCHING
RATING
S2 I S3-1 I 53-2 I S2 I S3-1 I S3-2 I
16-35
40-50
POS2
POS2
1 I I I I 1
ON
ON
ON
ON
POS2
POS2
OFF
OFF
OFF
OFF

GENERATOR SET CONTROL

(TOP VIEW)

FRONT METER
s2 +
PANELS
S l l

R32
IOLTAGE'ADJUST

L'

TB1-2 -3 AC INPUT VOLTS R34

TB1-3 -4 CROSS-CURRENT COMPENSATION DO NOT ADJUST
TB1-7 -8 VOLTAGE ADJUSTING RHEOSTAT (SEE TEXT)
TB1-9 -10 EXCITER FIELD
F1-T14
FP-TB1-10 SC-1516-5

FIGURE 4-8. VRAS-2 VOLTAGE REGULATOR LOCATION/ADJUSTMENTS

4-8 Redistribution or publication of this document

by any means, is strictly prohibited.
 Confact With high volfage can
AWARN~NG cause severe personal injury or
rL1
death. Do not touchany exposed wiring or compo- VOLTAGE ADJUST POTENTIOMETER R21
nents with any body part, clothing, tool or jewelry. The following procedure is for generator sets equipped
Do not use non-insulated tools inside the control. with the DetectorAC option only. Performadjustmentas
Stand on an insulating mat or dry wood platform follows:
when the control doors are open.
1. Loosenthe locking nut of R21 Voltage Adjust poten-
5. Using an insulated screwdriver, turn R32 potenti- tiometer on the control front panel. Adjust R21 to
ometer on VRAS-2 to increase or decreasethe volt- mid-range.
age for proper setting with no load. Example: For a 2. Startthe generator set and operate to bring temper-
I20/240 volt generator connection, set no-load volt-
ature up to normal.
age for approximately 246 volts. If voltage is unsta-
ble or tends to hunt, refer to the applicable trouble- 3. As a precaution against electrical shock, place an
shooting flow chart. insulating caution mat or a dry wood platform on the
floor in front of the control panel.
Potentiometer R34 is for ! g o r y adjustment only. Setting
requires special calibration equipment. Do not adjust. ~ W A R N ~ N GContact with high voltage can
cause severe personal injury or
6. Stop the generator set and close the control panel death. Do not touch any exposed wiring or compo-
doors. Set control for operation readiness. nents with any body part, clothing, tool or je welry.
Do not use non-insulated tools inside the control.
VRAS-2 Regulator Specifications Stand on an insulating mat or dry wood platform
Input Power when the control doors are open.
Input voltage across TBI terminals 2 and 3: 208 to
240 volts RMS f 1 0 % (depending on wiring 4. With no load on the generator, turn the Phase Selec-
configuration) tor switch to read output voltage/current while per-
Input frequency: 45 to 65 Hz forming the following adjustments.
. Maximum burden: 800 VA
Output Power A. Open the control panel doors and adjust R32 on
Continuous Rating: 3.0 A VRAS-2 for the approximate desired voltage.
One Minute Rating: 6.5 A (in current limit)
Current Limit: 6.5 A, f0.75 A B. Fine-adjust the voltage with R21 on the control
Minimum Field Resistance panel. When set at correct voltage, carefully
0.6 ohms @ 77°F (25°C) copper winding exciter tighten the locking nut using care not to change
Regulator Sensing the setting.
Single-phase average voltage directly proportional to
generator frequency to breakpoint. Independent of C. If correct voltage cannot be obtained by R21
frequency after breakpoint. Nominally set to 59 Hz (49 refer to voltage adjustment procedure [K].
Hz for 50 Hz sets).
Operating Temperature 5. Move the Phase Selector switch to the Off position.
-40" to +176"F (-40" to +80°C)
6. Stop the generator set and set the control for unit
sta,ndby readiness.

4-9 Redistribution or publication of this document

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 TESTING AC LOAD CIRCUIT BREAKER
General
The AC circuit breaker does not require any special
maintenance other than periodic exercise and a check
of conductor security. Circuit breaker options vary by
customer requirements.

Review the Optional Circuit Breaker Description in Sec-

tion 2. GeneratorNoltage Regulator and perform
checks and adjustment applicable to the breaker. A
typical breaker diagram is repeated in Figure 4-9 for -
SIDE VIEW HANDLEPOSITIONS
reference.

When performingtests and adjustments,avoid acciden-

tal start-up by placing the Run'-Stop-Remote switch in
Stop position and disconnecting the battery negative (-)
cable.
---1 SHUNT TRIP
+ COMMONALARM
- GROUND
Accidental starting of the generator AUXILIARY CONTACTS
laWAR"Gl set during service procedures can
result in severe personal injury or death. Place the
A
COMMON
0
Run-Stop-Remote switch in Stopposition, and discon-
nect the battery negative (-)cable.

Exercising Breaker; Actuate the breaker handle to the ES-1564

On and Off positions several times. If the breaker is
equipped with a Trip Test button, the breaker should be
tripped, resetand actuated to On several times. This will FIGURE 4-9. OPTIONAL CIRCUIT BREAKER DIAGRAM
remove any dust from the mechanism and latch
surfaces.

Checking Insulation Resistance: Disconnect the load A resistance reading lessthan 100,000 ohms indicatesa
and line conductors from the breaker, and place the ground. Investigatefor possible contamination on the
breaker in the On position. Use an insulation resistance breaker case surfaces, clean if necessary and retest.
meter that will apply at least 500 volts to the test leads.
Measure the insulation resistance between each pole, Checking Contact Resistance: Extensive operation of
and to ground. Also test between the line and load the breaker under load may eventually cause contacts
terminals with the breaker in the Off position. to deteriorate. Test by a Resistance Check, or by a
Voltage Drop Check across the breaker poles.

Except when generator set operation is required for

testing, avoid accidental start-up by placing the Run-
Stop-Remote switch in Stop position and disconnecting
the battery negative (-) cable.

Accidental starting of the generator

set during service procedures can
result in severe personal injury or death. Place the
Run-Stop-Remoteswitch in Stop position, and discon-
nect the battery negative (-1 cable.

4-1Q
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 Resistance Check: Checking Shunt-Trip 0pemfion:The shunt-trip feature
is available in varying AC or DC voltages. Proper circuit
1. Disconnect the line and load wires from the circuit breaker model is selected and installed at the factory to
breaker. meet customer requirements.
2. Move the breaker handle to the On position and
checkthe resistanceacrosseach pole (lineto load). Check the shunt-trip function as follows:
3. Resistanceshould be very low (near zero) and rela- 1. Refer to the original equipment order, installation
tively equal across all poles. wiring diagrams, and unit wire routing to identify
and confirm proper AC or DC signal source
Voltage Drop Check: connections.
This test is done with the conductors connected, gener- 2. Check security of the wire connections.
ator set operating, and load applied. As a precaution 3. Apply the appropriate signal voltage (12-, 24-VDC;
against electricalshock, place an insulatingmat or a dry 240-, 480-VAC). The shunt-trip solenoid should
wood platform on the floor to stand on when taking energize and trip the breaker open.
measurements. 4. If the breaker did not trip open, remove the signal
1- Contact with high voltage can cause
severe personal injury or death. Do
source. Perform continuity check of interconnect
wiring and shunt-trip solenoid lead wires. Replace
interconnect wiring if defective.
not touch any exposed wiring or components with any
body part, clothing, tool or jewelry. Do not use non- Checking Auxiliary Contacts: If equipped, the breaker
insulated tools inside the control. Stand on an insulat- will have three leads for wiring to an internal single-
ing mat or dry wood plafform when taking measure- pole, double throw switch. The switch allows connec-
ments. tion of a remote annunciator (see installation wiring
diagrams).
1. Operatethe generator set with the breaker in the On
position and load applied. Perform continuity checks of the switch with the breaker
, 2. Take voltage readings at the line connections, then
the load connections.
in On and Off positions to confirm operation.

3. There should only be slight variation in the voltage Adjusting Magnetic Trip Operation: If equipped with
dropped across each pole of the breaker. Unequal front-adjustable magnetic trip controls, the short circuit
or excessive millivolt drops across the complete protection feature for each pole of the breaker can be
breaker, or one pole, indicates contaminated con- adjusted equally or individually as required. Surge cur-
tacts or loose connections. rent above the trip settings will actuate the trip mecha-
nism. These adjustors are set equally to the high posi-
4. Stop the generator set by placing the Run-Stop- tion at the factory. Consult on-site requirements and
Remote switch in Stop position and disconnecting adjust to proper position.
the battery negative (-) cable.

Accidental starting o i the

generator set during service
procedures can result in severe personal injury or
death. Place the Run-Stop-Remoteswitch in Stop
position, and disconnect the battery negative (-)
cable.

4-1 1 Redistribution or publication of this document

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Redistribution or publication of this document
by any means, is strictly prohibited.
 Section 5. Generator
Disassembly/Assembly
GENERAL 7. Remove four 3/8-inch nuts securing the upper and
If testing determines that the generator needs service, lower output box brackets at the rear of the end bell.
use the following disassembly and assembly proce-
dures. The procedures cover major components of the 8. Remove three capscrews at the front of the output
generator as shown in Figure 5-1. box (two on the outside [5/16-18 x 1.25 and flat-
washers], and one inside the output box beside the
breaker [5/16-18 x 0.621).
DISASSEMBLY
Access to the generator requires removal of the control 9. Slide the engine harness/grommet free as the out-
box and the generator output box. put box is removed from the generator.

I. Disconnect the generator set starting battery 10. Remove lead from the overspeed switch (if used),
(negative [-I cable first) before performing service and control leads F l + and F2- from the end bell
procedure. terminal board.

Accidental starting of the 11. Removethe overspeed switch and bracket (if used)
AWARNING aenerator set can cause severe from.the end bell and rotor shaft.
personal injury 0'; death during service proce-
dures. Be sure to disable the generator set by dis- 12. Remove the end bell and exciter stator assembly. It
connecting the starting battery cables (negative[-] may be necessary to pry or jar the assembly loose
cable first). from the main stator assembly.

2. Remove the back grille from the rear of the genera- 13. Use a hoist and safe lifting device (stator handling
tor (six l/4-20 screws). tongs, nylon lifting strap or chain and lifting hooks)
to support the main stator assembly.
3. Remove output box cover by removing four screws
(1/4-20). 14. Remove 12 (M10) screws and lockwashers secur-
ing the main stator assembly to the engine adapter.
4. Open the control box doors and disconnect genera-
.
tor control wires. Check wire stamping legibility to 15. Removethe main stator being careful notto touch or
ease reassembly. If necessary, attach identification drag it on the rotor. Place the stator on its side and
with tape. Arrange leads so they can be .withdrawn block to prevent rolling, especially if placed on a
easily through the control box grommet opening. workbench.

5. Remove four screws (5116-18) and lockwashers Falling, heavy objects can cause
I securing the control box to the generator output
AWARNING severe personal injury or death.
box. Carefully lift the control box free of leads and Be sure to block or support heavy objects to pre-
set aside. vent falling. Wearprotective shoes and keep hands
and feet clear.

. 6. Remove all leads from the circuit breaker and free

the output box of all electric conduit.

5-1 Redistribution or publication of this document

by any means, is strictly prohibited.
 .

END BELLNUT STATOR LIFT

6-1153

FIGURE 5-1. GENERATOR DISASSEMBLY/ASSEMBLY

5-2
Redistribution or publication of this document
by any means, is strictly prohibited.
 16. Usinga hoistand sling to supportthe rotor, carefully REASSEMBLY
remove the capscrews that attach the drive disk to Reassembly procedures are basically the reverse of
the engine flywheel (Figure 5-1). disassembly. The following steps should be used as a
guide. Apply the torque specs as specified.
17. Remove the rotor assembly and place upon wood
block in the horizontal position. The drive disk and 1. Slide the exciter rotor over the generator shaft and
fan should not be resting on anything or distortion woodruff key. Installthe exciter nut and apply torque
may occur. values specified in Figure 5-3.
18. Remove bolts that hold the drive disk and fan to the 2. Connect the main rotor leads to terminals F1+ and
rotor shaft. F2- on the exciter rotor. Torque to values shown.
19. Use a gear puller to remove the end bearing from 3. Press the end bearing onto the rotor shaft. Spacing
the rotor shaft (Figure 5-2). If bearing is to be reused, between the shaft end and bearing side surface
be sure to apply puller to the inner race. must be as specified in Figure 5-3.
lmproper removal of the end 4. Assemble rotor fan and drive disk to the engine
A C A U T ~ O ~ bearing will damage it. If flywheel. Use a hoist and sling to support the rotor.
intended for reuse, the bearing must be pulled off Be sure the drive disk is assembled with the chamfer
by the inner race. on the flywheel side. Apply torque values as shown.
20. Clamp the rotor in a fixed position and remove the 5. With a hoist and safe lifting device, carefully move
exciter rotor lock nut. the main stator into position over the rotor. The
stator leads should exit in the 4 o’clock position.
21. Remove the generator field leads from the exciter
rotor and slide the exciter off the rotor shaft. 6. Secure the main stator to the engine adapter with 12
(M10 x 1.5) screws and lockwashers. Torque bolts
to 39 ft-lb (52 Nom).

7. Apply a thin film of grease to the mating surfaces of

the end bearing and the end bell. Installthe end bell
over the stator stud bolts. Do not install nuts and
lockwashers until later.

8. Installthe overspeed switch and bracket to the rotor

shaft and end bell. Apply torque values from Figure
5-3.

9. Connect control leads to,the F1+, F2- terminals,and

to the overspeed switch.

ES-1495

FIGURE 5-2. END BEARING REMOVAL

5-3 Redistribution or publication of this document

by any means, is strictly prohibited.
 ASSEMBLE DRIVE DISK WOODRUFF
WITH CHAMFER THIS SIDE KEY

FLAT WASHER

,
DETAIL A

TORQUE TO TORQUE DETAILB

TORQUETO DRIVE DISK

70-80 IT LBS TO FLYWHEEL
'(95 to IOSNrm)

'FIGURE5 3 . ROTOR 'ASSEMBLYTOROUEAWUES

10: Place the AC output box .into position.Slide the '15. Carefully'connect all control leads to'their marked
engine harness/grommetrinto the slot lopening. -1erm'inations.

11. Install four (3/8-16) nuts and lockwashers to the 16. Close and secure the control box doors. Do not
end bell studs; then three capscrews and flat install the output box back grille until the overspeed
washers at the front of the AC box. Torque.the end switch setting has been checked.
bell nuts to 20 ft-lb (27 Nam).
17. Connect the generator set starting battery (positive
12. Tighten the output box capscrews. Using a lead [+] lead first) and test generator operation.
hammer, tapthe end bell at the horizontaland verti-
cal plane to relieve stress. Retorque the four end 18. The rimin at which the overspeed switch shuts
bell nuts. down the generator set can be changed by the
adjust screw. Turning this screw in or out changes
13. Assemble wire,conduit to the generator output box. the magnetic air gap. When set correctly, the switch
Connect the generator, 1oad;and auxiliary wires to closes and shuts down 60 hertz units at 2100 r/min
the AC circuit breaker (if used). +90 r/min; 50 hertz units at 1800 r/min +90 rimin.
An accurate frequency meter or strobotach is
14. Set the control box on the .output box. Route all needed to check the overspeed trip point when the
control leads through grommet in control box bot- engine speed is increased (see the engine service
tom. Secure control box with four screws (5/16-18) manual). The air gap must not be less than 0.005
and lockwashers. inch (0.13 mm).

5-4
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by any means, is strictly prohibited.
Section 6.Wiring Diagrams
WIRING DIAGRAM DRAWING NUMBER PAGE
Generator Set AC Control Schematic Diagram (W/O Meters)............. 612-6489 . 6-2
Generator Set AC Control Wiring Diagram (W/O Meters) ................. 612-6489 6-3
Generator Set AC Control Schematic Diagram (Meter) .................... 612-6490 6-4
Generator Set AC Control Wiring Diagram (Meter) ......................... 612-6490 6-5
Generator ReconnectionWiring Diagram .................................. 625-2108 6-6
Voltage Regulator InstallationWiring Diagram ............................. 300-3303 6-8
Generator Reconnection Diagram........................................... 98C2193 6-9

6-1 Redistribution or publication of this document

by any means, is strictly prohibited.
I ' 2-6489 ID[ SCHEMATIC DIAGRAM
DOOR (REAR INSIDE VIEW)
-.

. .
VR2 I I I
A 1 I
I
I
I
I
I
.I
I
I jl
I I
I I

612-6489 GENERATOR SET AC CONTROL SCHEMATIC DIAGRAM (W/O METERS)

6-2
Redistribution or publication of this document
by any means, is strictly prohibited.
 WIRING DIAGRAM
_- __
[ =
( I N S I D E VIEW)
I ( I N S I D E VIEW1

H $ $ ~ ~ $
~ ~ ~ ~ , , ~ \ ~ E BACK~WALL
I
& OF~ CABINET
~ ~-VERTICA
L E F T WALL OF TRAY-HORIZONTAI

li
I I
I I
I I
I I
I I
A I
I
I
I
ENERATOR I I
I I NOTES:
GENERATOR I I I . ALL COMPONENTS SHOWN I N DE-ENERGIZED POSITION.
I VR21
GENERATOR

GENERATOR
I A I
I

GENERATOR
4. SEE GENERATOR CONNECTION DIAGRAM FOR INPUT CONNECTION

II
A 5. SEE VOLTAGE REGULATOR INSTALLATION FOR CONNECTIONS
TO VR21.CB21 AND T 6 2 1 .
II

COMPONENT IDENTIFICATION

REF. I DESCRIPTION

CB21 Field Circuit Breaker

G21 Generator
TB21 Terminal Block
VR21 Voltage Regulator, VRAS-2
I
I 3
_
___
1) FI 1x1 TI
- (ubl
- -
G2 I GENERATOR T2-IVbl /
T3-IWbl

. T5-lV51
Tb-lW51
T7-lU21
!
I

T9-lW21
w

EXCITER ARMATURE FULL WAVE

TIO-IUII

TII-IVII I
/
/
A
BRIDGE RECTIFIER
9 F2(XXl T12-IWII !, /
U

612-6489 GENERATOR SET AC CONTROL WIRING DIAGRAM (W/O METERS)

Redistribution or publication of this document

6-3 by any means, is strictly prohibited.
612-6490 101 SCHEMATIC DIAGRAM
IG 2 I (GENERATORI A

M2 I
-n+

52 I
I POSITION I COluTACTS CLOSE0

612-6490 GENERATOR SET AC CONTROL SCHEMATIC DIAGRAM (METER)

6-4
Redistribution or publication of this document
by any means, is strictly prohibited.
WIRING DIAGRAM
--
1
I1
!I
(INSIDE VIEW1
I L F T S I D E WALL -VERTICAL

!IROTTOM OF TRAY-HORIZONTAL

S2 I -44
TB2 I
t INSIDE

~--------------
I
I
VIEW)
BACK WALL OF CABINET-VERTICAL
LEFT W A L L OF rRAY IlOliILONTAl

II
I
I
t

s21-43

1.
S21 42
M22- ( +
521-14 I
I A
DS2 I -2 I VR21
us22-2
NOTES:

- c20&’ET!ETE3
DISCONNECT 5. SEE VOLTAGE REGULATOR INSTALLATION FOR CONNECTIONS
TO VR21 .CB21 .R21 AND TB21.

BOTTOM OF CABINET
(INSIDE VIEW)
COMPONENT IDENTIFICATION

REF. DESCRIPTION
TI-IU61 CB21 Field Circuit Breaker
T2-IV6l
CT21-
r4-1~51 I CT23 Current Trans. Assy.
II T5-IV51 ;I
TO CURRENT DS21-
TRANSFORMER
INSTALLATION DS22 Lamp, UpperILower Scale
G21 Generator
M21 Voltmeter, AC
M22 Ammeter, AC
M23 Meter, Frequency
/ R21 Potentiometer, Volt Adjust
/
s21 Switch, Rotary
G2 I GENERATOR
TB21 Terminal Block
VR21 Voltage Regulator, VRAS-2

612-6490 GENERATOR SET AC CONTROL WIRING DIAGRAM (METER)

6-5 Redistribution or publication of this document

by any means, is strictly prohibited.
 625-2108 ID]
YD GENERATORS

-
18 -
518
L Z

SECOMJARY CURRENT TRANSFORMER C O W . 1.3

I10/220V. 50HZ I10/190V. 50HZ 120/208V. 60HZ 220/380V. 50HZ 240/416V. 60HZ

I20/240V. 60HZ' I20/208V. 50HZ I39/24OVI 601-12 240/416V, 50HZ 277/480V. 6OHZ
I27/220V, 501-12 254/440V. 50HZ

.
CT21 CT2I

I
L2
LO
7

3
. . ..
I
I
12 b2 io
8
I
9-!

T5

0 L3

6:.270/380V 60HZ

%:347/600V 60HZ

, .

:
SECOMARY CURRENT TRANSFORMER C O W . 1-2

Tw
CT2 I

I
IA' L I
CT22

L2

LO

T3

625-2108 GENERATOR RECONNECTION WIRING DIAGRAM

6-6
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i of this document
by any means, is strictly prohibited.
I PHASE RECONNECTABLE

I SECONDARY UmRENT
IRANSFORWER C O " . 1-3 I
I I10/220V.
115/23OV.
50HZ
60HZ I
120/240V. 60HZ
z: 120/24OV 60HZ
I PHASE
SECONDARY CURRENT

CT2 I

10

L2

CT22

NOTES :

I. CURRENT TQANSFORMER SECONDARY MUST BE MANUALLY SELECTED.

HIGH VOLTAGE (ABOVE 300 VOLTS) TERMINALS I&2,LOW VOLTAGE
BELOW 300 VOLTS USE TERMINALS 1&3. TERMINAL # I I S COMMON

2. GENERATORS 7 / F AND 9 X ARE NOT RECONNECTABLE AND ARE

WOUND FOR A S P E C I F I C VOLTAGE

3. THESE CONNECTIONS ARE FOR SPEC E "L" WITH THE STANDARDIZED

CONTROL

VOLTAGE COOE

625-2108 GENERATOR RECONNECTION WIRING DIAGRAM

6-7 Redistribution or publication of this document

by any means, is strictly prohibited.
9 DASHED LEADS INDICATEWHEN USED

$EFT 0OOR.REAR VIEk

I
PP LEFT SIDE TRAY WALL

7
CBP I

I 'TO DC CONTROL
JI-I ,JI-2

COMPONENT IDENTIFICATION

DESCRIPTION

Voltage Adjust Potentiometer

Resistor (Used W/O R21)

300-3303 VOLTAGE REGULATOR INSTALLATION WIRING DIAGRAM

6-8
Redistribution or publication of this document
by any means, is strictly prohibited.
 2201380 VOLT. 3 PHASEGO HBRTZ(c0DE FJ
1201240 VOLT. 3 PHASE60HERTZ (CODE e) 3471600 VOLT. 3 PHASE 60HERTZ (CODE HI

1
CT 21 CT 22 I

SECONDARY CURRENTTRANSFORMER CONN. 1-3 SECONDARY CURRENTTRANSFORMER CONN. 1-2

GplERAToRCO"E~WlWNGDIAGRAM
(wrmCURRPrrlRAMFORMERSWHP(USED)

LO 11 11

11 I 2 16 1 1 1 1 8 1 1 2 14 I9 1 5 1 7 1.3 110

LO 11 13

E 240/480 3 60 1-2
2
L 120/240 3 60 1-3

115/11O 1 50 1-3 In
:z Ly
110/210 3 50 1-3

I LJ I 11 110 16 1 7 12 Ill 14 I 8 13 112 15 19

120/101 1 60 1-3 LO 11 11 11

L 117/120 1 60 1-3

1 1 4 2 4 0 1 60 1-3 5
110/190 3 50 1-3

-
d

115/200 1 5 0 1-3
z
114208 3 50 1-3 2
14 76 111
127/210 3 50 1-3 13 1 1 18 13 19
I5 110 lnT1

140/41b 3 60 1-2 LO -
L 1&40 3 60 1-2 I L1 L2 L3

5
Y

177180 3 60 1-2

l2e/380 3 50 1-2 ,
I
ia0/400 3 so 1-2 5
2
140/41b 1 50 1-2
,,,
154/440 1 50 1-2 T2 T3 T5 T8 T6 T9 T4 T7

I I

98C2193 GENERATOR RECONNECTION DIAGRAM

6-9
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by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
Redistribution or publication of this document
by any means, is strictly prohibited.
Onan Corporation
1400 73rd Avenue N. E.
Minneapolis, MN 55432
612-574-5000
Telex: 275477
Fax: 612-574-8087
Onan is a registered trademark of Onan Corporation

Redistribution or publication of this document

by any means, is strictly prohibited.