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0% found this document useful (0 votes)

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20 Es

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Mauricio Olaya

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Caution: This document contains mixed page sizes (8.

5 x 11 or 11 x
17), which may affect printing. Please adjust your printer settings
according to the size of each page you wishRedistribution
to print. or publication of this document
by any means, is strictly prohibited.
Service Manual l

20 ES
(Begin Spec G)

Printed U.S.A. 9280504 695

Redistribution or publication of this document

by any means, is strictly prohibited.
Safety Precautions
Before operating the generator set, read the Opera- • Be sure battery area has been well-ventilated prior
tor’s Manual and become familiar with it and the equip- to servicing near it. Lead-acid batteries emit a highly
ment. Safe and efficient operation can be achieved explosive hydrogen gas that can be ignited by arc-
only if the equipment is properly operated and main- ing, sparking, smoking, etc..
tained. Many accidents are caused by failure to follow
fundamental rules and precautions. EXHAUST GASES ARE DEADLY
The following symbols, found throughout this manual, • Provide an adequate exhaust system to properly
alert you to potentially dangerous conditions to the oper- expel discharged gases away from enclosed or
ator, service personnel, or the equipment. sheltered areas and areas where individuals are
likely to congregate. Visually and audibly inspect
This symbol warns of immediate haz- the exhaust daily for leaks per the maintenance
ards which will result in severe personal injury or schedule. Ensure that exhaust manifolds are se-
death. cured and not warped. Do not use exhaust gases to
WARNING This symbol refers to a hazard or unsafe
heat a compartment.
practice which can result in severe personal injury or • Be sure the unit is well ventilated.
death.
• Engine exhaust and some of its constituents are
CAUTION This symbol refers to a hazard or unsafe known to the state of California to cause cancer,
practice which can result in personal injury or prod- birth defects, and other reproductive harm.
uct or property damage.
MOVING PARTS CAN CAUSE SEVERE
FUEL AND FUMES ARE FLAMMABLE PERSONAL INJURY OR DEATH
Fire, explosion, and personal injury or death can result • Keep your hands, clothing, and jewelry away from
from improper practices. moving parts.
• DO NOT fill fuel tanks while engine is running, un- • Before starting work on the generator set, discon-
less tanks are outside the engine compartment. nect battery charger from its AC source, then dis-
Fuel contact with hot engine or exhaust is a potential connect starting batteries, negative (-) cable first.
fire hazard. This will prevent accidental starting.
• DO NOT permit any flame, cigarette, pilot light, • Make sure that fasteners on the generator set are
spark, arcing equipment, or other ignition source secure. Tighten supports and clamps, keep guards
near the generator set or fuel tank. in position over fans, drive belts, etc.
• Fuel lines must be adequately secured and free of • Do not wear loose clothing or jewelry in the vicinity of
leaks. Fuel connection at the engine should be moving parts, or while working on electrical equip-
made with an approved flexible line. Do not use ment. Loose clothing and jewelry can become
copper piping on flexible lines as copper will be- caught in moving parts. Jewelry can short out elec-
come brittle if continuously vibrated or repeatedly trical contacts and cause shock or burning.
bent. • If adjustment must be made while the unit is run-
• Be sure all fuel supplies have a positive shutoff ning, use extreme caution around hot manifolds,
valve. moving parts, etc.

LS-11a
i Redistribution or publication of this document
by any means, is strictly prohibited.
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH
• Coolants under pressure have a higher boiling point
• Remove electric power before removing protective than water. DO NOT open a radiator or heat ex-
shields or touching electrical equipment. Use rub- changer pressure cap while the engine is running.
ber insulative mats placed on dry wood platforms Allow the generator set to cool and bleed the system
over floors that are metal or concrete when around pressure first.
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be • Benzene and lead, found in some gasoline, have
damp when handling electrical equipment. been identified by some state and federal agencies
as causing cancer or reproductive toxicity. When
• Use extreme caution when working on electrical checking, draining or adding gasoline, take care not
components. High voltages can cause injury or
to ingest, breathe the fumes, or contact gasoline.
death. DO NOT tamper with interlocks.
• Follow all applicable state and local electrical • Used engine oils have been identified by some state
codes. Have all electrical installations performed by or federal agencies as causing cancer or reproduc-
a qualified licensed electrician. Tag and lock open tive toxicity. When checking or changing engine oil,
switches to avoid accidental closure. take care not to ingest, breathe the fumes, or con-
tact used oil.
• DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM. • Provide appropriate fire extinguishers and install
Hazardous voltages can flow from the generator set them in convenient locations. Consult the local fire
into the utility line. This creates a potential for elec- department for the correct type of extinguisher to
trocution or property damage. Connect only use. Do not use foam on electrical fires. Use extin-
through an approved isolation switch or an ap- guishers rated ABC by NFPA.
proved paralleling device.
• Make sure that rags are not left on or near the en-
HIGH VOLTAGE GENERATOR SETS gine.
(1.9kV to 15kV) • Remove all unnecessary grease and oil from the
unit. Accumulated grease and oil can cause over-
• High voltage acts differently than low voltage. Spe- heating and engine damage which present a poten-
cial equipment and training is required to work on or tial fire hazard.
around high voltage equipment. Operation and
maintenance must be done only by persons trained • Keep the generator set and the surrounding area
and qualified to work on such devices. Improper use clean and free from obstructions. Remove any de-
or procedures will result in severe personal injury or bris from the set and keep the floor clean and dry.
death.
• Do not work on this equipment when mentally or
• Do not work on energized equipment. Unauthorized physically fatigued, or after consuming any alcohol
personnel must not be permitted near energized or drug that makes the operation of equipment un-
equipment. Due to the nature of high voltage electri- safe.
cal equipment, induced voltage remains even after
the equipment is disconnected from the power • Substances in exhaust gases have been identified
source. Plan the time for maintenance with autho- by some state or federal agencies as causing can-
rized personnel so that the equipment can be de-en- cer or reproductive toxicity. Take care not to breath
ergized and safely grounded. or ingest or come into contact with exhaust gases.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

ii Redistribution or publication of this document

by any means, is strictly prohibited.
Table of Contents

TITLE PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Voltage Reconnection with Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERATOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Flow Chart A. No Build Up of AC Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Flow Chart B. AC Output Voltage Builds Up, But is Unstable . . . . . . . . . . . . . . . . . . . 6
Flow Chart C. AC Output Voltage Builds Up, But High or Low . . . . . . . . . . . . . . . . . . 6
Flow Chart D. AC Output Voltage Builds Up, But Field Breaker Trips . . . . . . . . . . . 7
Flow Chart E. Unbalanced Generator Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . .8
ADJUSTMENTS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Optional Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine Accessories and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ENGINE CONTROL SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Start-Disconnect Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Stopping Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENGINE CONTROL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Troubleshooting Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CONTROL COMPONENT CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FUEL SYSTEM / GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
Gasoline Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
Gas Mixture and Idle Speed Stop Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Electronic Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1 Redistribution or publication of this document

by any means, is strictly prohibited.
Introduction
SERVICE MANUAL VOM, or a digital VOM. Other instruments that should be
available are:
This section contains troubleshooting and repair infor-
mation for the ES series generator sets. The generator AC Voltmeter
set is divided into three basic parts, the generator, the DC Voltmeter
controls and the engine. Use the engine information in Frequency Meter
the applicable engine manual for service. Jumper Leads
Load Test Panel
The manual is divided into sections for the generator and Variac
AC controls, DC controls, governor adjustments, and wir- Tachometer or Strobotach
ing diagrams. This manual contains basic (generic) wir- Megger or Insulation Resistance Meter
ing diagrams and schematics that are included to help in Wheatstone Bridge or Digital Ohmmeter
troubleshooting. Service personnel should use the actual
wiring diagram and schematic shipped with each unit.
The wiring diagrams and schematics that are maintained GENERATOR DESCRIPTION
with the unit should be updated when modifications are
made to the unit. The YD generator (Figure 1) is a four-pole, revolving
field, brushless exciter, reconnectible model of drip-proof
This manual does not have instructions for servicing construction. Design includes both single and three-
printed circuit board assemblies. After determining that a phase, 60 hertz type generators. The generator rotor
printed circuit board assembly is faulty, replace it. Do not connects to the engine flywheel via a flex disc; therefore
repair it. Attempts to repair a printed circuit board can engine speed determines generator output and frequen-
lead to costly damage to the equipment. cy.

TEST EQUIPMENT A centrifugal blower, on the front end of the rotor shaft,
circulates the generator cooling air which is drawn in
Most of the test procedures in this manual can be per- through the end bell cover and discharged through an
formed with a multimeter like the Simpson Model 260 outlet at the blower end.

BRUSHLESS TORQUE TO
BLOWER
EXCITER ROTOR 130-150 FT. LBS
(176-203 N•m)

TORQUE TO
55-60 FT. LBS
(75-81 N•m)

ROTOR-
THROUGH-STUD

KEY O-RING
SEAL
ENGINE-GENERATOR
ROTATING
ADAPTER
RECTIFIER
ASSEMBLIES

AIR BAFFLE COVER

(HOUSED)

STATOR- BRUSHLESS
THROUGH-STUD STATOR ROTOR EXCITER STATOR
END BELL TORQUE TO 19-21
FT. LBS (26-28 N•m)

FIGURE 1. GENERATOR

2 Redistribution or publication of this document

by any means, is strictly prohibited.
A ball bearing in the end bell supports the outer end of the Generator sets without a control panel or switchboard
rotor shaft. The end bell and generator stator housing are containing AC instruments such as voltmeters, amme-
attached by four through-studs which pass through the ters, running time meter, frequency meters, and line cir-
stator assembly to the engine generator adapter. The cuit breakers are shipped from the factory with the AC
brushless exciter stator mounts in the end bell while the output leads separated in the output box. On generator
exciter rotor and its rotating rectifier assemblies mount sets with switchboards containing AC instruments, the
on the generator rotor shaft. AC output leads are wired as specified on the customer’s
purchase order to deliver only the voltage specified.
All generators have four wires extending from the stator VOLTAGE RECONNECTION WITH
housing in addition to the AC output leads. Figure 2. Lead
F1 and F2 are from the exciter field winding and are con- OPTIONAL INSTRUMENTS
nected to the output terminals of the voltage regulator. The optional AC instruments on the control panel (such
Leads 1 and 2 are connected to the stator windings and as voltmeters, ammeters, transformers, and running
provide reference voltage and input power to the voltage time meters) are intended for use with specific nameplate
regulator. These four leads are connected at the factory. voltages. Control components may have to be changed
to match new current ratings when field reconnection for
other voltage codes or voltages are made.
Figure 2 is a composite illustration showing four output
leads for single phase units, 12 output leads for 3 phase CAUTION To prevent instrument damage, contact
broad range units, and four output leads for code 9X, 3 the Onan factory for required instrument changes,
phase 347/600 volt generators. new wiring diagrams, new nameplate with proper
specification number and voltage before attempting
to reconnect a generator with instruments on the
control panel.
Do not connect the generator in any other manner than
shown in the applicable wiring and reconnection dia-
grams.
Severe damage will result if leads are incorrectly con-
nected or improperly insulated. Use extreme care in check-
ing leads to assure proper connections.

FIGURE 2. SINGLE AND THREE PHASE GENERATOR

SCHEMATIC (COMPOSITE)

GENERATOR OPERATION

Operation of the generator involves the stator, voltage

regulator, exciter field and armature, a full wave bridge
rectifier, and the generator rotor (Figure 3). Residual
magnetism in the generator rotor and a permanent mag-
net embedded in one exciter field pole begin the voltage
build-up process as the generator set starts. Single-
phase AC voltage, taken from one of the stator windings,
is fed to the voltage regulator as a reference for maintain-
ing the generator output voltage. AC voltage is converted
to DC by a silicon controlled rectifier bridge on the voltage
regulator printed circuit board and fed into the exciter FIGURE 3. EXCITATION BLOCK DIAGRAM
field windings. The exciter armature produces three-
phase AC voltage that is converted to DC by the rotating
PREPARATION
rectifier assembly. The resultant DC voltage excites the A few simple checks and a proper troubleshooting proce-
generator rotor winding to produce the stator output volt- dure can locate the probable source of trouble and cut
age for the AC load. down service time.

3 Redistribution or publication of this document

by any means, is strictly prohibited.
• Check all modifications, repairs and replacements TROUBLESHOOTING PROCEDURES
performed since last satisfactory operation of set to (STANDARD YD GENERATOR AND REGULATOR)
make sure that connection of generator leads are
correct. A loose wire connection overlooked when The information in this section is divided into Flow Charts
installing a replacement part could cause problems. A, B, C, D, and E as follows:
An incorrect connection, an opened circuit breaker,
or a loose connection on printed circuit board are all A. NO AC OUTPUT VOLTAGE AT RATED ENGINE
potential malfunction areas to be eliminated by a RPM.
visual check. B. UNSTABLE OUTPUT VOLTAGE. ENGINE SPEED
STABLE 1800 RPM.
• Unless absolutely sure that panel instruments are
accurate, use portable test meters for troubleshoot- C. OUTPUT VOLTAGE TOO HIGH OR LOW.
ing. D. EXCITER FIELD BREAKER TRIPS.
• Visually inspect components on VR21. Look for dirt, E. UNBALANCED GENERATOR OUTPUT VOLT-
dust, or moisture and cracks in the printed solder AGE.
conductors. Burned resistors, arcing tracks are all
identifiable. Do not mark on printed circuit boards To troubleshoot a problem, start at upper-left corner of
with a pencil. Graphite lines are conductive and can the chart related to problem, and answer all questions ei-
cause leakage or short circuits between compo- ther YES or NO. Follow the chart until the problem is
nents. found, performing referenced Adjustment and Test pro-
cedures following the Flow Charts.
WARNING Troubleshooting procedures presents
hazards of electrocution, asphyxiation, burns, cuts, CAUTION Do not replace the printed circuit board
and other personal injury or death. Review Safety until the trouble not on the PC board has been lo-
Precautions. Service personnel must be trained and cated and corrected to avoid damage to new PC
experienced. board.

FIGURE 4. ELECTRICAL SCHEMATIC, STANDARD YD GENERATOR AND REGULATOR

4 Redistribution or publication of this document

by any means, is strictly prohibited.
WARNING Many troubleshooting procedures present hazards that can result in severe personal injury or
death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should per-
form service procedures. Review Safety Precautions on pages i and ii.

FLOW CHART A. NO BUILD UP OF AC OUTPUT VOLTAGE

START
Remove one lead from breaker
Is control panel field Replace defective
yes and check continuity with yes
breaker CB21 ON? field breaker.
ohmmeter. Is breaker open?

no no

Push to reset beaker. Does generator If voltage is unstable, high or low, or causes breaker
AC output voltage build up? yes to trip, see Flow Charts B, C, or D.

no
yes

Is reference voltage across TB21-1 & 2 Flash exciter field per TEST [D]. Does generator
no output voltage build up?
20 VAC or more?

yes no

Check commutating reactor L21 Disconnect stator leads 1 & 2 from TB21- 1 & 2. Is
per TEST [H]. Replace if bad. yes reference voltage across leads 20 VAC or more now?

Check reference transformer T21 Check diodes CR1 through CR6 on rotor per TEST [E].
per TEST [I]. Replace if bad. Replace if bad.

Is exciter field voltage across Check wiring harness for shorts per Check exciter rotor winding per
TB21-7 & 8 7.0VDC or more? no TEST [K]. Replace if bad.
TEST [N]. Replace bad wiring.

yes

Check wiring harness for opens per Check SCR’s CR13 & CR16 Check generator rotor field winding
TEST [N]. Replace bad wiring. per TEST [G]. Replace if bad. per TEST [L]. Replace if bad.

Check exciter field winding Check diodes CR12, 14, & 15 Check generator stator windings
per TEST [J]. Replace if bad. per TEST [F]. Replace if bad. per TEST [M]. Replace if bad.

Replace voltage regulator PC

board per procedure [O[.

5 Redistribution or publication of this document

FLOW CHART B. AC OUTPUT VOLTAGE BUILDS UP, BUT IS UNSTABLE

START
Are there any broken wires or loose connections
yes Repair as required.
on voltage regulator assembly VR21?

Check wiring harness from VR21 to

no Repair wiring or replace as required.
end bell per TEST [N]. Check OK?

yes

Does adjustment of Dampening Control R27 on Is voltage stable within spec at no load to full load range
VR21 per adjustment [B] result in stable voltage? yes of generator set?

no no

Replace voltage regulator PC board per

procedure [O].

FLOW CHART C. AC OUTPUT VOLTAGE BUILDS UP, BUT IS HIGH OR LOW

START

Set RPM per instructions if ‘Governor

Is engine running at correct RPM? no
Adjustment section of manual.

yes

Does adjustment of Voltage Adjust control R22

yes Set control per Voltage Calibration Adjustment [A].
on VR21 result in correct output voltage?

Does adjustment of control R28 on VR21

yes Set per Voltage Calibration Adjustment [A].
result in correct output voltage?

Is jumper wire W10 connected correctly on Are generator output leads properly connected?
VR21 for desired voltage? See Figure 19 on See Figure 19 and correct if needed.
page 18 and correct if needed..

Replace voltage regulator PC board

VR21 per procedure [O].

6 Redistribution or publication of this document

FLOW CHART D. AC OUTPUT VOLTAGE BUILDS UP, BUT FIELD BREAKER TRIPS

START
Does AC output voltage build up to 140% or Check for any loose or broken wires
more of rated voltage before breaker trips? yes or connections on VR21 assembly.

Check diodes CR1 through 6 in rotor Check diode CR15 on VR21 per
assembly per TEST [E]. Replace if bad. TEST [F]. Replace if bad.

Check exciter stator winding Check reference transformer T21 and connections
per TEST [J]. Replace if bad. per TEST [I]. Replace if bad.

Check exciter rotor winding per Check generator stator leads for proper
TEST [K]. Replace if bad. connection. See Figure 19, page 18.

Check generator rotor field winding Check generator stator windings

per TEST [L]. Replace if bad. per TEST [M]. Replace if bad.

Replace voltage regulator PC board

VR21 per procedure [O].

7 Redistribution or publication of this document

FLOW CHART E. UNBALANCED GENERATOR OUTPUT VOLTAGE

START
Remove load at generator terminals. Check for correct grounding
Is output still unbalanced? no
of generator and load.

yes

Are generator leads connected and grounded no

properly? See Figure 19, page 18. Correct as necessary.

yes

Is generator stator winding

continuous per TEST [J]? no Replace stator assembly.

yes

Check load for ground faults

and correct as necessary.

8 Redistribution or publication of this document

by any means, is strictly prohibited.
Adjustments and Tests

GENERAL
[C]
All of the following Adjustments and Tests can be per-
formed without disassembly of the generator. They
should be used for testing generator and regulator com- VOLTAGE REGULATOR CHECKOUT
ponents in conjunction with the troubleshooting flow
charts. The solid state voltage regulators (VR21) can be
checked out on the bench for proper operation or location
WARNING Troubleshooting procedures presents of faulty components. The following test equipment (one-
hazards of electrocution, asphyxiation, burns, cuts, each) is required for a proper checkout.
and other personal injury or death. Review Safety
Precautions. Service personnel must be trained and REF. DESIGNATION TEST EQUIPMENT
experienced.
S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch

[A]
L21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reactor
F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse, 5 Amps
T1 . . . . . . . . . . . . . Transformer, Variable 2 Amp 0-150V
V2 . . . . . . . . . . . . . . Voltmeter, DC ± 2% of Full Scale 3,
VOLTAGE CALIBRATION ADJUSTMENT Scale 0-50 and 0-150V and 0-10V
V1 . . . . . . . Voltmeter, AC ± 2% @ 10VAC, 1% @ 150V
The calibration adjustment is made using an accurate AC R1 . . . . . . . . . . . . . . . . . . . . . . Resistor, 100-Ohm 400W
voltmeter to observe generator output voltage and to set T21 . . . . . . . . . . . . . . . . . . . Transformer, Input 315-0386
the correct no load voltage. If voltage regulator VR21
printed circuit board has been replaced, it may be neces- Transformer T21 and reactor L21 are a part of the voltage
sary to make a calibration adjustment. To obtain the cor- regulator assembly (VRA21); these are the only parts ob-
rect output voltage, proceed as follows: tainable with an Onan part number. the big 100 ohm 400
watt resistor (R1) serves as the field during checkout.
1. If set has a voltage adjust potentiometer (R22) on
the meter panel, set pointer halfway between mini- Bench Check:
mum and maximum positions.
1. Remove voltage regulator from unit according to
2. With unit running at no load, turn generator voltage
procedure given for voltage regulator replacement.
potentiometer R26 on VR21 (Figure 5) clockwise to
increase output voltage; turn R26 counterclockwise 2. Referring to Figure 5 and Table 1, connect test
to decrease output voltage. equipment to the printed circuit board VR21 termi-
nals as follows:

[B] CONNECT FROM TO

Jumper VR21-V1 VR21-V4

Jumper VR21-1 VR21-2
VOLTAGE STABILITY ADJUSTMENT Lead L21-1 VR21-10
Lead L21-4 VR21-9
Voltage stability is set at the factory, but if printed circuit Lead T21-X1 VR21-6
board VR21 has been replaced or if damping potentiom- Lead T21-X2 VR21-4
eter R27 has been unnecessarily adjusted, it may be AC Voltmeter Across T21-H1 & H2
necessary to reset stability. Set stability as follows: DC Voltmeter Across VR21-7 & 8
VARIAC Across T21-H1 (fused)
1. With generator set running at no load, turn poten- and H2
tiometer R27 (Figure 5) to a position where voltage R1 Across VR21-7 & 8
tends to be unstable or hunt.
3. Open switch in 120 VAC supply to VARIAC.
2. Turn R27 clockwise slowly until voltage first stabi-
lizes. this setting will result in stable voltage under 4. Plug VARIAC into 120 VAC source.
all conditions in maximum voltage regulator re- 5. Proceed with checkout according to steps in Table
sponse time. 1.

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FIGURE 5. VOLTAGE REGULATOR CHECKOUT TEST EQUIPMENT CONNECTIONS

[D] field is usually necessary when installing a new brush-

less exciter stator wound assembly, but seldom is neces-
sary under other circumstances. Always check generator
FLASHING THE FIELD residual voltage at terminals 1 and 2 to be certain wheth-
er or not flashing the field is necessary. Generator residu-
The following procedure is used for momentarily flashing al voltage should be at least 20 VAC at rated speed. If re-
the exciter field with a low voltage which restores the residual is too low and the output voltage will not build up,
sidual magnetism in the alternator rotor. Flashing the flash the field as follows:

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- + 6 VOLT DRY
PIN 7 (–) CELL BATTERY

PIN 8 (+)
12 AMP
300 VOLT DIODE

FIGURE 6. FLASHING THE FIELD

1. Locate terminals 7 (–) and 8 (+) on voltage regulator 1. Disconnect all leads from assembly to be tested.
printed circuit board (VR21). 2. Connect one test lead to F1+ stud and connect other
2. Use a six volt dry cell battery with two clip leads and lead to CR1, CR2, and CR3 in turn; record resist-
a 12 amp, 300 volt diode as shown in Figure 6. If a ance value of each rectifier.
six volt battery is not available, a 12 volt automotive 3. Connect one lead to F2– stud and connect other
battery can be used by adding a 20-ohm resistor in lead to CR4, CR5, and CR6 in turn; record resist-
series; or a 24 volt automotive battery can be used ance value of each rectifier.
by increasing the resistance to 40-ohms.
4. Reverse ohmmeter leads from steps 2 and 3 and re-
3. After starting engine, touch positive (+) battery lead cord resistance value of each rectifier F1+ to CR1,
to the +8, and negative (–) lead to –7 terminals just CR2, and CR3 and F2– to CR4, CR5, and CR6.
long enough until voltage starts to build up or dam-
age may occur to exciter-regulator system. 5. All the resistance readings should be high in one
test and low in the other test. If any reading is high or
WARNING HAZARDOUS VOLTAGE. Touching low in both tests, rectifier assembly is defective.
uninsulated high voltage parts inside the control box
can result in severe personal injury or death. Mea- 6. Replace defective rectifier assembly with new, iden-
surements and adjustments must be done with care tical part.
to avoid touching high voltage parts. Use 24 lbs-in. (2.7 Nm) torque when tightening nuts on F1+
For your protection, stand on a dry wooden platform and F2–, and CR1 through CR6.
or rubber insulating mat, make sure your clothing
and shoes are dry, remove jewelry from your hands
and wear elbow length insulating gloves. DIGITAL
OHMMETER

TEST PROCEDURES
All of the following tests can be performed without disas-
sembly of the generator. Use the following test proce-
dures for testing generator components in conjunction
with the troubleshooting charts.

[E]
TESTING ROTATING RECTIFIERS
Two different rectifier assemblies make up the rotating
rectifier bridge assembly, Figure 7. Using an accurate
ohmmeter, test each CR using negative and positive po-
larities. Test rectifiers as follows: FIGURE 7. TESTING ROTATING RECTIFIERS

11 Redistribution or publication of this document

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[G]
TESTING SCR’S

Two identical silicon controlled rectifiers (SCR’s), CR13

and CR16, control the DC output voltage to the exciter
field. These SCR’s are mounted in heat sinks on the volt-
age regulator and are tested as follows:

1. Using high scale on ohmmeter, connect ohmmeter

leads to anode and cathode of the SCR as shown in
Figure 10. The resistance reading should be one
megohm or greater. Reverse ohmmeter leads to
anode and cathode; resistance should again be one
megohm or greater.
FIGURE 8. SILICON CONTROLLED RECTIFIER BRIDGE

[F]
DIGITAL
TESTING OUTPUT BRIDGE DIODES OHMMETER
The output bridge rectifier diodes (Figure 8), CR12,
CR14, and CR15, are located on the voltage regulator
printed circuit board. Using an accurate ohmmeter, test
diodes CR12, CR14, and CR15 as follows:
1. Connect one ohmmeter lead to each end of diode
and observe resistance reading, Figure 9.
2. Reverse ohmmeter leads and again observe resist-
ance readings.
A good diode has a higher reading in one direction
than the other. If both readings are high, or low, diode
is defective.
3. Replace defective diodes with new, identical parts.

DIGITAL
OHMMETER

FIGURE 10. SCR RESISTANCE TEST

2. Using a 6 volt dry cell battery and a 200 ohm series

resistor, observe correct polarity and connect bat-
tery leads to anode and cathode as shown in Figure
11. Observe polarity and connect a DC voltmeter
across the 200 ohm resistor. The voltmeter should
now read zero. Jumper anode to gate; voltmeter
should now read 6 volts. Remove jumper; voltmeter
should still read 6 volts because the SCR remains
turned on until voltage is removed from anode to
cathode.
3. If the SCR does not pass either test, it is defective.
FIGURE 9, TESTING DIODES Replace defective SCR with a new, identical part.

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H1 H2
1 TO 1 RATIO
T21

X1 X2

Resistance between H1-H2 should be 113 to 139 ohms,

between X1-X2 133 to 163 ohms at 77° F (25° C). Resist-
ance between coils and from any terminal to transformer
frame should be infinity.

[J]
TESTING BRUSHLESS EXCITER STATOR
Like the generator, the brushless exciter stator (Figure
12) can be tested for open or shorted windings and
grounds.
Testing for Open or Shorted Windings:
Disconnect F1+ and F2– exciter field leads from terminal
block in generator end bell. The resistance between field
leads should be 10.98 to 13.42 ohms at 68° F (20° C).

FIGURE 11. SCR VOLTAGE TEST

[H]
TESTING REACTOR
The reactor assembly L21 leads are marked 1, 2, 3 and 4. MEGGER OR
Wires 1-2 and 3-4 are wound on the same iron core. INSULATION
RESISTANCE
METER
1 2

L21 FIGURE 12. TESTING EXCITER FIELD FOR OPEN OR SHORTED

WINDINGS

3 4 Testing for Grounds:

Connect Megger or insulation resistance meter between
either laminations. Reading should be 1 megohm or
Resistance between 1-2 and 3-4 should be 0.33 to 0.39
greater. In not, the exciter stator is questionable and
ohms and 0.38 to 0.46 ohms respectively at 77° F (25°
might require removal for oven drying and retest.
C). Resistance between coils (e.g. 1-3) and from any ter-
minal to reactor frame should be infinity.

[I] [K]
TESTING REFERENCE TRANSFORMER TESTING BRUSHLESS EXCITOR ROTOR
(ARMATURE)
The transformer T21 has four leads marked H1, H2, X1,
and X2. H1-H2 are the primary leads. X1-X2 are the sec- The brushless exciter rotor (Figure 13), can be tested for
ondary leads. open or shorted windings, or grounds.

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DIGITAL
OHMMETER

MAIN ROTOR
LEADS F1+, F2–

FIGURE 14. TESTING ROTOR FOR GROUNDS

FIGURE 13. TESTING EXCITER ARMATURE Testing for Open or Shorted Winding:
Testing for Open or Shorted Windings: All resistance values should be within ±10% of values
specified in Table 2 at 77° F (25° C). Perform tests as fol-
Use a Wheatstone Bridge for this test. Disconnect main lows:
rotor field leads which connect to rotating rectifier assem-
blies at F1+ and F2–. Disconnect lead wires from diodes 1. Remove rotor leads F1+ and F2–0 from rotating rec-
CR1 through CR6. Test between exciter lead pairs tifier assemblies.
T1-T2, T2-T3 and T1-T3. Resistance should be 0.5 to 0.6 2. Using ohmmeter, check resistance between F1 and
at 68° F (20° C). F2 leads, Figure 15.
Testing for Grounds: 3. Replace defective rotor with new, identical part if re-
sistance readings are not within limits shown in
Use a Megger or insulation resistance meter that applies Table 2.
500 VDC or more for this test.
With all generator leads disconnected from rotating recti- DIGITAL
fiers CR1 through CR6, apply test leads between any CR OHMMETER
lead and the rotor lamination. Reading should be 1 meg-
ohm (1,000,000 ohms) or greater. If not, the exciter rotor
is questionable and might require removal for oven dry- MAIN ROTOR
ing and retest. A shorted rotor must be replaced. LEADS F1+, F2–

[L]
TESTING GENERATOR ROTOR
For these tests, use an ohmmeter on R x 100 scale.
Testing for Grounds:
On brushless type generators, check for grounds be-
tween each rotor lead and the rotor shaft, Figure 14. Per- FIGURE 15. TESTING ROTOR FOR AN OPEN CIRCUIT
form tests as follows:
TABLE 2. RESISTANCE VALUES FOR ROTORS
1. Remove rotor leads F1+ and F2– from rotating recti-
fier assemblies.
ROTOR RESISTANCE
2. Connect ohmmeter leads between F1+ and rotor
ROTOR STACK LENGTH OHMS @77° F (25° C)
shaft and between F2– and rotor shaft. Meter
should not register. 201-2984 5.8765 2.75
3. If meter registers, rotor is grounded. 201-2985 7.125 1.80
4. Replace grounded rotor with new, identical part.

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[M] [N]
TESTING GENERATOR STATOR WIRING HARNESS CHECK
Using proper test equipment, check the stator for
grounds, opens, and shorts in the windings. Carefully check wiring harnesses as follows:

Testing for Grounds: 1. Inspect all wires for breaks, loose connections, and
reversed connections. Refer to applicable wiring
Some generators have ground connections to the frame. diagram.
Check wiring diagram. 2. Remove wires from terminals at each end and using
Using an ohmmeter set at R x 100, test each stator wind- an ohmmeter, check each wire end to end for conti-
ing for shorts to laminations. A reading less than one nuity or opens.
megohm indicates a ground. 3. Using an ohmmeter, check each wire against each
of the other wires for possible shorts or insulation
Testing for Open or Shorted Windings: breaks under areas covered by wrapping material.
Test for continuity between coil leads shown in Figure 16; 4. Reconnect or replace wires according to applicable
all parts should have equal resistance. Use an accurate wiring diagram.
instrument for this test such as a Kelvin Bridge. The prop-
er resistance values for the ES generator set are given in
Table 3. All resistances should be ±10% of value shown. [O]
If any windings are shorted, open or grounded, replace
the stator assembly. Before replacing the assembly, VR21 REPLACEMENT
check the leads for broken wires or insulation.
Use the following procedure for replacing the voltage
regulator PC board.
1. Stop engine.
2. Disconnect and if necessary, label the following
wires: 3, 4, 5 or 6, 7, 8, 9, and 10.
3. Remove four screws at corners.
4. Remove used PC board.
5. Install new PC board; secure with four screws.
6. Reconnect wires removed in step 2 at the proper
terminals.
7. Place jumper W10 at proper terminals for your par-
ticular voltage code and voltage connection. See
Figures 17 and 19.
WHEATSTONE 8. Perform Voltage Calibration and Stability Adjust-
BRIDGE ment procedures [A] and [B] to obtain the correct
generator output voltage and stability with new PC
FIGURE 16. TESTING STATOR WINDINGS board in set.

TABLE 3. RESISTANCE VALUES FOR STATORS

STATOR STACK
LENGTH IN RESISTANCE
STATOR PHASE INCHES (mm) OHMS @68° F (20° C)

220-3691 1 5.75 (146) .0686 ±10%

220-3685 3 5.75 (146) .127 ±10%
220-3686 3 7.00 (178) .104 ±10%

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VOLTAGE REGULATOR Figure 17 shows the above components for typical con-
trol boxes. The electrical schematic and printed circuit
The line-voltage regulator assembly VRA21 for the ES
board are shown in Figure 18.
generator set is a solid state device. Basic components
are: The voltage adjust control R22 is optional on the VRA21
• Printed circuit board VR21 voltage regulator. When R22 is used, it is connected be-
tween VR21-1 and VR21-3 (Figure 17) and the jumper
• Voltage reference transformer T21
between VR21-1 and VR21-2 is removed.
• Commutating reactor L21
• Field circuit breaker CB21
• Voltage adjust rheostat R22 (Optional)

FIGURE 17. STANDARD YD VOLTAGE REGULATOR ASSEMBLY

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FIGURE 18. STANDARD YD REGULATOR PC BOARD 300-1540

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FIGURE 19. GENERATOR WIRING AND CONNECTION DIAGRAMS

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DC Control
GENERAL 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.
The control box is mounted on vibration isolators on top
of the generator output box. It can be mounted to face ei- Reset / Lamp Test Switch. The switch is pushed to the
ther side or the rear. Figure 20 illustrates a control panel Reset position (momentary contact) to reset the engine
that includes all the optional components. control to restore operation following a fault shutdown.
The Start / Stop / Remote switch must be in the Stop
position for reset to occur. The Lamp Test position (mo-
The following components are standard on the control mentary contact) lights all the fault indicator lamps. Re-
panel. place lamps that do not light.
Oil Pressure Gauge. The oil pressure gauge indicates
Start / Stop / Remote Switch. The switch is pushed to engine oil pressure.
the Start 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.

RESET / LAMP OUTPUT VOLTAGE AC OUTPUT

TEST SWITCH TRIMMER METERS

START / STOP /
REMOTE SCALE INDICATOR
SWITCH LAMPS

INDICATOR
LAMPS PHASE SELECTOR
SWITCH

CIRCUIT HOUR
BREAKERS METER

DC VOLTMETER OIL PRESSURE COOLANT

GAUGE TEMPERATURE GAUGE
SC1635c

FIGURE 20. CONTROL PANEL

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Coolant Temperature Gauge. The coolant temperature Frequency Meter. The frequency meter indicates output
gauge indicates engine coolant temperature. frequency in Hertz (Hz). Note that engine RPM is 30
times hertz.
DC Voltmeter. The DC voltmeter indicates battery
charging voltage during operation. Scale Indicator Lamps. The scale indicator lamps indi-
cate whether to read the upper or lower scales of the volt-
Hour Meter. The hour meter indicates the accumulated meter and ammeter.
number of hours the set has run. It cannot be reset.
Phase Selector Switch. The selector switch is used to
Field Circuit Breaker. This circuit breaker protects the select the phase for voltage and amperage readings.
generator from over excitation. Output Voltage Trimmer. The output voltage trimmer
can be used to adjust output voltage plus or minus five
Control Circuit Breaker. This circuit breaker protects
percent of nominal voltage.
the generator control circuits.
Nine Indicator Lamps:
Remote Circuit Breaker. This circuit breaker protects
the remote control circuits. • Run (Green). This lamp indicates that the generator
set is running and that the starter has been discon-
Auxiliary Circuit Breaker. This circuit breaker protects nected.
the governor and fuel solenoid circuits.
• Pre-Low Oil Pressure Warning (Amber). This
Two Indicator Lamps. lamp indicates that engine oil pressure is abnormal-
ly low (less than 20 psi [137 kPA]).
• Run (Green). This lamp indicates that the generator • Low Oil Pressure Shutdown (Red). This lamp in-
set is running and that the starter has been discon- dicates that the engine shut down because of ex-
nected. cessively low engine oil pressure (less than 14 psi
• Fault Shutdown (Red). This lamp indicates that the [97 kPA]).
engine shut down because of one of the following • Pre-High Engine Temperature Warning (Amber).
faults. This lamp indicates that engine coolant temperature
• Low Oil Pressure. Engine oil pressure is abnormally high (greater than 215° F [102° C]).
dropped to less than 14 psi (97 kPA). • High Engine Temperature Shutdown (Red). This
lamp indicates that the engine shut down because
• High Engine Temperature. Engine coolant
of excessively high engine coolant temperature
temperature exceeded 222° F (106° C). (greater than 222° F [106° C]).
• Overcrank. The engine shut down because it • Overcrank Shutdown (Red). This lamp indicates
did not start during the timed cranking period. that the engine shut down because it did not start
• Overspeed. The engine shut down because of during the timed cranking period.
overspeed. • Overspeed Shutdown (Red). This lamp indicates
that the engine shut down because of overspeed. It
OPTIONAL CONTROL PANEL is factory adjusted to shut down 60 hertz units at
COMPONENTS 2100 ±90 r/min, 50 hertz units at 1850 ±50 r/min.
• Low Engine Temperature Warning (Amber). This
The following components are optional on the control lamp indicates that engine temperature is less than
panel. 70° F (21° C) and the possibility that the engine
might not start.
AC Voltmeter. The voltmeter indicates output voltage for
the phase selected. • Switch-off Warning (Flashing Red). This lamp in-
dicates that the Start/Stop/Remote switch is in the
AC Ammeter. The ammeter indicates output amperage Stop position, which prevents remote, automatic
for the phase selected. operation.

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Starter Solenoid Relay when energized (during crank- Fault terminal of the Engine Monitor Circuit Board (Figure
ing), provides full battery voltage to the starter. 21).
Overcranking Circuit, a solid state circuit on the engine
Start Disconnect Relay disconnects the cranking circuit Monitor Circuit Board, limits engine cranking time from
when the engine starts. The relay, energized by output 45 to 75 seconds. If the engine fails start within this time
voltage from the field flash terminal of the belt driven al- span, the fault Relay energizes to stop cranking. The red
ternator, also turns the green Run indicator lamp on. overcrank indicator lamp (optional) and common fault
alarm are turned on.
Fault Relay, when energized, turns the engine off and Voltage Regulator Assembly (Generator AC) controls
prevents a restart until the fault condition is corrected and AC generator output voltage at a predetermined level
the Reset switch pressed. The relay can also operate a within load limits. Regulation is plus or minus1 percent
remote DC alarm (5 ampere maximum) connected to the from no load to full load with isochronous governing.

VOLTAGE REGULATOR
ASSEMBLY (GENERATOR AC)

FRONT PANEL

CONNECTOR P1
FAULT RELAY

ENGINE MONITOR
CONNECTOR P2 CIRCUIT BOARD

REM PRE PRE FAULT

B+ START RUN HET LOP LET HET OS OC LOP ALARM GND

REMOTE REMOTE 5A COMMON

SWITCH LIGHTS COMMON GROUND
(OPTIONAL) ALARM

FIGURE 21. CONTROL PANEL INTERIOR COMPONENTS AND REMOTE CONNECTIONS

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ENGINE ACCESSORIES AND SENSORS The optional pre-low oil pressure switch closes at 20 psi
(138 kPa) and turns on the amber Pre Lo Oil Pres lamp.
The following briefly describes the engine mounted sen- The engine does not shut down, but the warning lamp re-
sors and switches (Figure 22), and how they protect the mains on until the Reset switch is pressed (verify condi-
engine from unfavorable operating conditions. tion is corrected).
All cut-off switches close and energize the Fault Relay to
stop the engine if abnormal operating conditions exist.
Engine Temperature Monitors
The respective control panel red lamp (optional) lights to The resistance of the temperature sender unit changes
indicate cause of the shutdown. The red Switch Off Lamp with the engine coolant temperature and causes a read-
(optional) flashes ON and OFF if the Start Switch is left in ing on the Water Temp meter. The meter range is 100° to
the stop position (preventing automatic starting of set). 250° F (40° to 121° C). If coolant temperature rises to
The optional remote fault alarm can be connected to the 222° F (106° C, the high engine temperature cut-off
terminal shown in Figure 21. Current limitations for op- switch closes, stops the engine, and lights the (optional)
tional equipment not suppled by ONAN are 100 milli-am- red High Engine Temperature Light.
peres for each indicator lamp and 5 amperes for the fault
CAUTION The High Engine Temperature Cutoff
alarm.
will shut down the engine only if coolant level is suffi-
CAUTION Control components can be damaged if ciently high to physically contact shutdown switch.
these current limits are exceeded for the optional Loss of coolant will allow engine to overheat without
equipment. protection of shutdown devices, causing severe
damage to the engine. Make sure to maintain ade-
Resistance units and switches in the monitoring and quate engine coolant levels to provide proper opera-
shutdown systems are sealed units and not repairable. tion of the cooling system and engine coolant over-
When replacing a sensor, do not use a substitute item, heat shutdown protection.
since resistance units are matched to the gauge they
supply. Cutoff switches are close tolerance actuation The optional pre-high engine temperature switch closes
parts made for a specific application. at a nominal 215° F (102° C) and turns on the amber Pre/
Hi Eng Temp lamp. The engine does not shut down, but
Oil Pressure Monitors the warning lamp remains on until the Reset switch is
pressed (verify condition is corrected).
The oil pressure sender resistance changes with oil pres-
sure and results in a reading on the oil pressure meter. The optional low engine temperature switch closes if
The meter range is 0 to 100 psi (0 to 700 kPa). The low oil coolant temperature drops below 70° F (21° C) to turn on
pressure switch closes if pressure drops to 14 psi (97 the red Lo Eng Temp light. In locations where ambient
kPa), stopping the engine and activating the optional low temperatures drop below 70° F (21° C), the lamp indi-
oil pressure fault lamp. cates malfunction of the optional coolant heater.

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PRE HIGH ENGINE
HIGH ENGINE TEMPERATURE
TEMPERATURE SWITCH (S5)
SWITCH (S1) LOW OIL
PRESSURE SWITCH OIL PRESSURE
(S6) SENDER (E1)

WATER
TEMPERATURE
SENDER (E2)

PRE LOW OIL

PRESSURE
SWITCH (S2)

LOW ENGINE
TEMPERATURE
SWITCH (S4)

SENDER/ WIRE COLOR

SWITCH
E1 BROWN / ORANGE
E2 DARK BLUE / ORANGE
S1 DARK BLUE / LIGHT BLUE
S2 BROWN / LIGHT BLUE
S4 DARK BLUE / RED
S5 DARK BLUE / GRAY
S6 BROWN

FIGURE 22. ENGINE ACCESSORIES AND SENSORS

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Overspeed Switch
The overspeed switch (Figure 23) is a mechanical switch
which grounds the overspeed circuit on the Engine Moni-
tor Circuit Board, causing an engine shutdown and acti-
vating the optional overspeed fault lamp if an overspeed
condition exists. After the problem is corrected, starting
GENERATOR OVERSPEED ADJUST
will not occur until the Reset switch is pressed.
SHAFT SWITCH SCREW

AIR GAP

END BELL

SWITCH
CONTACTS

FIGURE 23. OVERSPEED SWITCH

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Engine Control System Operation
GENERAL K2 of the engine monitor board (EMB), which sup-
plies B+ to relay K5 (starter solenoid pilot relay) and
Dependable, trouble-free operation of the control system EMB relay K2 which supplies B+ to relay K4 (switch
should be a major goal of generator set service person- B+ relay).
nel. Service personnel must thoroughly understand how 2. Energizing K5, energizes the starter solenoid.
the controls operate, know how to check for troubles, and
know how to make the proper adjustments, replace- 3. Energizing K4 supplies B+to the governor and also
ments, or repairs in a reasonable amount of time. energizes the fuel solenoid.

The circuitry, control components, and operating cycles START-DISCONNECT SEQUENCE

for the ES generator set are described below.
When the engine starts, B+ from the field flash terminal of
Prior to starting the generator set, review pre-start check- the alternator energizes the EMB Start Disconnect Relay
list in the Operator’s manual, including checking for ex- K5. Energizing EMB relay K5 removes the B+ from EMB
haust and fuel leaks, check the fuel supply, engine oil lev- Start Relay K3. Also, AC disconnect through K11, breaks
el, and all battery connections for loose or broken wires. If B+ to the start solenoid relay K5.
an automatic demand control is in use, check for correct
connections. STOPPING SEQUENCE
The DC start and run circuits are supplied by the 12 volt Pressing S10 to Stop position de-energizes EMB relays
battery and charging alternator. The control circuits are K2 and K4 which opens B+ circuit to the ignition system,
completed by returning to ground (negative post of bat- fuel solenoid and governor control.
tery).
EMERGENCY SHUTDOWN
The wiring diagram on Pages 41 or 42 shows the wiring
diagram for the ES generator set described in the follow- EMB Fault Relay K6 is directly energized by one of the
ing Starting, Start-Disconnect and Stopping sequences. following fault sensors; S6 low oil pressure switch, S1
Relay contact references normally open (NO) and nor- high engine temperature switch, S3 overspeed switch,
mally closed (NC) refer to position of contacts with the OC (overcrank) Limiter.
unit at rest (not energized).
When jEMB relay K6 is energized a NC set of contacts
open B+ to the EMB Power Relay K2 and another set
STARTING SEQUENCE closes to connect B+ to an optional fault alarm. The en-
Press the Start-Stop switch to the Start position. The engine sensor causing the fault, triggers a solid state circuit
gine will start and run. Release the Start-Stop switch that lights up the appropriate fault lamp on the control
when engine starts. panel. The engine cannot be started until fault condition
is corrected and the Reset Switch S12 pressed.
CAUTION Do not hold switch longer than 30 sec-
The Low Oil Pressure Delay circuit is not actuated until
onds during any attempt to start. Longer periods
the Start-Disconnect Relay is energized. The circuit al-
may damage the starter motor and discharge battery
lows a delay of 7.5 to 12.5 seconds before LOP shutdown
needlessly.
and pre-alarm are functional. Following this initial delay,
1. The start circuit is completed by Start-Stop switch both the LOP shutdown and pre-alarm functions are im-
S10 at the Start position. This action energizes relay mediate.

25 Redistribution or publication of this document

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Engine Control Troubleshooting
GENERAL loose wire connection overlooked when installing a
replacement part could cause problems. An incor-
The data in this section is divided into three flow charts, rect connection, an opened switch or circuit breaker,
and information on troubleshooting the ES solid-state en- or a loose plug-in are all potential problems that can
gine control (page 28). The flow charts consists of: be eliminated by a visual check.
A. Engine does not crank. • Unless absolutely sure that panel instruments are
B. Engine cranks but does not start. accurate, use portable test meters for troubleshoot-
ing.
C. Engine starts but stops when start switch is re-
leased. To troubleshoot a problem, start at the upper-left corner
Before starting a troubleshooting procedure, make a few of chart and answer all questions either YES or NO. Fol-
simple checks that may expose the problem and cut low the chart until the problem is found, performing refer-
down on troubleshooting time. enced Control Component Checkout procedures on
page 29. Refer to wiring diagrams in last section in manu-
• Check all modifications, repairs, replacements per- al for locating control component leads, terminals and
formed since last satisfactory operation of set. A other check points.
WARNING Many troubleshooting procedures present hazards that can result in severe personal injury or
death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should per-
form service procedures. Review Safety Precautions on pages i and ii.

FLOW CHART A. ENGINE DOES NOT CRANK

START

Check battery per Checkout [A] and recharge or

Is battery dead? yes replace. See Checkout [C].

Check engine oil level, water level, etc. If okay, reset

Is fault light on? yes
relay.

Jumper battery cable B+ connection to B+ starter Check battery cables for clean and tight connections
solenoid terminal. Does engine crank? no (ref. Checkout [B]. Check B+ starter solenoid and motor-if
bad, repair or replace.

yes

Check Starter Relay K5, Start/Stop switch S10 and

With S10 in Start position, does Starter Relay K5 energize? no associated wiring and connection per Checkouts [D] and
[F].

yes

Check for loose wire or wiring error between K5 and the

starter solenoid.

26 Redistribution or publication of this document

FLOW CHART B. ENGINE CRANKS BUT DOES NOT START

START

Does fuel solenoid energize when S10 is in Start Check fuel solenoid and related wiring. Repair or
position? no replace as needed.

yes

Check electric choke components and wiring (if

Is carburetor choke operation proper? no
used). Adjust per Operator’s Manual instructions.

yes

Is there a spark at the spark plug? no Check ignition wiring and components.

yes

Is fuel pump OK? Does fuel pulsate from line removed at

Check fuel supply system: fuel tank, shutoff valves, fuel
carburetor? (Gasoline sets.) Refer to Engine Service no lines and connections, fuel filters and pumps.
Manual.

27 Redistribution or publication of this document

FLOW CHART C. ENGINE STARTS BUT STOPS WHEN START SWITCH IS RELEASED

START

Does K4 Power Relay stay energized when start Check all wiring to K4. Check for fault condition.
switch is released? no check if fault relay A11, K6 is energized.

yes

Does terminal 26 stay energized when Start switch is

no Check K4 to T26 wiring.
released?

yes

Is there a spark at the spark plugs? no Check ignition wiring and components.

yes

Is appropriate fuel solenoid/choke energized: no Check wiring.

yes

Is there adequate fuel?

TROUBLESHOOTING ENGINE CONTROL breakers, DC voltage regulator, etc,. plug into the board.
If an external component is suspected of causing a prob-
Refer to Engine Control System Operation and the sche- lem, disconnect its associated jack (J1, J2 or J3) from the
matics on pages 40 and 41 when troubleshooting this board (Figures 30 and 31) and check continuity of wiring
control. Repair information is not extensive since the sol- and the component. Note some switches are NC and
id-state printed circuit board lends itself more to replace- some NO with unit at rest. Individual components can be
ment than repair. External components such as leads, checked out as referenced in “Control Component
switches, indicator lights, relays gauge senders, circuit Checkout” on page 29.

28 Redistribution or publication of this document

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Control Component Checkout
The following component checkouts are referenced in
the Control Troubleshooting flow charts, pages 26 to 29. [C]
They are an aid to isolating circuit problems caused by
faulty engine control components.
CHARGING CIRCUIT CHECKOUT
WARNING Troubleshooting procedures presents With the engine running at rated speed, check alternator
hazards of electrocution, asphyxiation, burns, cuts, output at battery positive (+). Voltage should indicate be-
and other personal injury or death. Review Safety tween 13.9 and 14.7 volts depending on regulator ambi-
Precautions. Service personnel must be trained and ent temperature. A voltage higher than 15 volts may indi-
experienced. cate a bad ground or defective voltage regulator.

[A] [D]
BATTERY CHECKOUT RELAY CHECKOUT
Check charge condition of the battery with a hydrometer. 1. Connect 12 volts across relay coil terminals. Relay
The electrolyte specific gravity should be about 1.260 for should activate if coil is okay.
a fully charged battery at 80° F (27° C). If not, add distilled 2. Connect 12 volts to one side of relay contacts.
water to keep electrolyte at proper level and recharge the 3. Connect a voltmeter to other side of relay contact
battery. If battery will not recharge, replace it. and 12 volt source. If 12 volts appear when relay is
If the battery loses excess water, the generator charge energized, contact is okay. The 12 volt reading ap-
rate may be too high. Likewise, if battery state of charge pears in reverse order when checking normally
is not maintained, the charge rate may be too low. Refer closed (NC) contacts.
to CHARGING CIRCUIT CHECKOUT [C].

WARNING Ignition of explosive gases can

[E]
cause severe personal injury. Do not smoke
RESISTOR CHECKOUT
while servicing the batteries.
1. Remove battery B+ cable.
[B] 2. Disconnect one side of resistor and using an ohm-
meter measure across resistor for an accurate read-
ing.

[F]
BATTERY CABLE CHECKOUT
With the starter motor operating, check the voltage drops
(1) from the battery negative post (not the cable clamp) to
the cylinder block, (2) from the battery positive post to the SWITCH CHECKOUT
battery terminal stud on the solenoid. Normally, each of
1. Remove battery B+cable.
these should be less than 0.3 volt. If extra long battery
cables are used, slightly higher voltage drops may result. 2. Place ohmmeter leads across switch.
Thoroughly clean all connections in any part of the circuit 3. Activate switch. If meter reads continuity, switch is
showing excessive voltage drop. good.

29 Redistribution or publication of this document

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Fuel System / Governor
FUEL SYSTEM switch determines which solenoid valve will open for op-
eration. If not equipped with a fuel selector switch, fuel
WARNING Fuel is highly flammable and may changeover occurs automatically. (While the engine is
cause severe personal injury and property damage. running, a gas pressure switch causes the natural gas
Do not allow cigarettes, flame, pilot lights, arching solenoid valve to close and the propane solenoid valve to
switches or equipment in area or areas sharing ven- open when natural gas pressure is lost, without stopping
tilation. the engine. When natural gas pressure is restored, the
natural gas solenoid valve opens and the propane sole-
These units can be equipped to operate on gasoline only, noid valve closes.)
LPG (propane), gasoline/natural gas, gasoline/LPG and
LPG/natural gas combinations. Figures 24 and 25 illus- The fuel regulators in each line provide constant gas
trate the fuel system components for various generator pressure at the gas mixer under varying load conditions
set configurations. A fuel selector switch may be pro- (approximately 5 inches WC for natural gas and –1.5
vided for fuel changeover. (The position of the switch de- inches WC for LPG). The throttle assembly is controlled
termines which fuel valve, gasoline, natural gas or LPG, by an electronic governor.
will open when the set is operated).
The maximum permissible fuel supply pressure is 20
An engine equipped for gasoline and natural gas or pro- inches WC (water column) and the minimum is 10
pane has a regular gasoline carburetor with a gas mixer inches WC. This applies to LPG as well as to natural gas.
mounted on the horn of the carburetor. The carburetor The minimum pressure refers to supply pressure under
throttle serves both fuels. Each fuel has a separate shut- rated load (maximum gas flow). There is a pressure test
off solenoid valve. The position of the fuel selector switch port on the supply side of each fuel regulator for measur-
located on the governor control mounting bracket, deter- ing fuel supply pressure.
mines which solenoid valve will open for operation.
The recommendations in Onan publication T030, the Ap-
An engine equipped for natural gas and propane has a plication Manual for Liquid-Cooled Generator Sets,
gas mixer that serves both fuels. Each fuel has a sepa- should be followed in regard to fuel supply system pipe
rate shutoff solenoid valve. If the generator set is sizes, manual shutoff valves, fuel filters and gas pressure
equipped with a fuel selector switch, the position of the regulators.

30 Redistribution or publication of this document

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GAS MIXER
LPG FLOW NATURAL GAS
ADJUSTMENT FUEL REGULATOR
COCK

NATURAL GAS
FUEL VALVE

PRESSURE
SWITCH

LPG FUEL
REGULATOR

LPG FUEL
VALVE

FUEL
SELECTION
SWITCH PLUG IN
NATURAL GAS
SUPPLY INLET

PLUG IN LPG
SUPPLY INLET

CARBURETOR

GASOLINE FUEL
FILTER

FUEL PUMP

GASOLINE
SUPPLY INLET

FIGURE 24. GASOLINE/NATURAL GAS/LPG VAPOR FUEL SYSTEM

31 Redistribution or publication of this document

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NATURAL GAS
FUEL REGULATOR

LPG FLOW
ADJUSTMENT NATURAL GAS
COCK FUEL VALVE
GAS MIXER
PRESSURE
SWITCH

LPG LIQUID
CONVERTOR

FUEL
SELECTION
SWITCH

PLUG IN
NATURAL GAS
SUPPLY INLET

PLUG IN LPG
CARBURETOR
GASOLINE FUEL SUPPLY INLET
FILTER

FUEL PUMP

GASOLINE
SUPPLY INLET

FIGURE 25. GASOLINE/NATURAL GAS/LPG LIQUID FUEL SYSTEM

32 Redistribution or publication of this document

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GASOLINE CARBURETOR ADJUSTMENT terisk (*). For normal adjustments, the asterisk (*) should
line up with the line cast in the edge of the housing.
A gasoline carburetor is provided for gasoline fuel sys- 1. For better starting in cold weather, loosen the three
tems. The idle mixture and choke are adjustable on the cover screws and rotate the cover clockwise so that
gasoline carburetor. the asterisk (*) is one or two lines past the line on the
Idle Mixture Adjustment: If the adjustment has been housing and re-tighten the cover screws.
disturbed or the engine performs poorly under light load, 2. For better starting in warm weather, loosen the three
make the following adjustments. cover screws and rotate the cover counterclockwise
so that the asterisk (*) is one or two lines past the line
1. Shut off the engine and turn the idle adjustment on the housing and re-tighten the cover screws.
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 eas-
ily damaged. Do not force the adjustment screw.
2. Start the engine and let the set warm up under a par-
tial load (at least 1/4 rated load) and then disconnect
all loads.
3. Turn the idle adjustment screw out (counterclock-
wise) approximately one half turn and jounce the
throttle. If the engine begins to hunt, turn the adjust-
ment 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 re- CHOKE
peat the procedure.
Choke Adjustment: The gasoline carburetor is
equipped with an automatic choke for easier cold weath- FUEL
er starting. The choke has a bi-metal coil that progres- FILTER
sively closes the choke plate as ambient temperature
drops, in preparation for the next start. It also has an elec- IDLE ADJUSTMENT
FUEL SHUTOFF
tric heating element that heats the bi-metal coil to fully SCREW (ON OTHER SIDE)
SOLENOID
open the choke soon after the engine starts.
FS-1252s
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 as- FIGURE 26. GASOLINE CARBURETOR

33 Redistribution or publication of this document

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GAS MIXTURE AND IDLE SPEED STOP 2. Disconnect the set from all loads, carefully discon-
ADJUSTMENTS nect the governor linkage by unsnapping the ball
and socket joint at the throttle lever and close the
The gas mixer has power and idle mixture adjustments, throttle by hand. (The set will shut down if the engine
the throttle assembly an idle speed stop screw, the natu- is allowed to overspeed, and then the engine control
ral gas fuel regulator a pressure adjusting screw and the will have to be reset.) While holding the throttle
LPG line a flow cock. See Figure 27. closed, adjust the idle speed stop screw to obtain an
engine speed of 900 RPM. Reconnect the governor
Before starting adjustments, it is recommended that nat- linkage.
ural gas and LPG supply pressures be checked by re-
moving the 1/8 NPT plugs in the pressure test ports at the 3. While the engine is still running, turn the idle mixture
fuel regulator inlets and connecting a water manometer. screw clockwise (richer) until the engine begins to
It is recommended that the service pressure regulators miss and then counterclockwise (leaner) until it
be adjusted to the maximum supply pressure of 20 inch- again begins to miss. Then turn the screw to a posi-
es WC under no-flow conditions (set not operating). tion midway between the two extreme positions.

CAUTION During the course of these tests Main Mixture Adjustment

wide excursions in voltage and frequency can 1. Connect the manometer to the outlet pressure test
be expected. Make sure all voltage and frequen- port of the natural gas fuel regulator, start the set
cy sensitive equipment have been discon- up on natural gas and let the engine warm up un-
nected prior to conducting these tests to pro- der approximately 1/4 rated load.
tect from damage. Consequential damage to
equipment as a result of failing to observe this 2. While the engine is warming up, check the manom-
precaution is not covered under the Onan war- eter, and if necessary, adjust the pressure to 5 inch-
ranty policy. es WC by turning the regulator pressure adjusting
screw located under the screw-on cap. Be sure to
WARNING Natural gas and LPG are explosive. replace the cap.
Do not allow any cigarettes, flames, pilot lights, 3. Connect rated load and turn the power mixture cock
sparks, arcing equipment or switches or other counterclockwise (richer) until the engine begins to
sources of ignition around the generator set or miss and then clockwise (leaner) until it again be-
in areas with common ventilation when per- gins to miss. Then turn the cock to a position mid-
forming maintenance or adjustments. way between the two extreme positions.

Idle Speed Stop and Mixture Adjustments 4. Switch to LPG (which may be done under load) and
turn the LPG flow cock counter clockwise (richer)
1. Connect a tachometer if the set does not have a until the engine begins to miss and then clockwise
Hertz/RPM meter, start the set up on natural gas (leaner) until it again begins to miss. Then turn the
and let the engine warm up under approximately 1/4 cock to a position midway between the two extreme
rated load. positions.

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GAS MIXER

AIR INLET

IDLE SPEED STOP

SCREW

THROTTLE
GAS INLET LEVER

POWER MIXTURE
COCK

NATURAL GAS FUEL REGULATOR

IDLE MIXTURE
ADJUSTING
SCREW PRESSURE
ADJUSTING
SCREW CAP

GAS INLET

LPG FLOW ADJUSTMENT COCK

INLET AND OUTLET GAS

PRESSURE TEST PORTS

FIGURE 27. GAS MIXER AND IDLE SPEED STOP ADJUSTMENTS

35 Redistribution or publication of this document

by any means, is strictly prohibited.
ELECTRONIC GOVERNOR 2. Start the set, let the engine warm up under a partial
load (at least 1/4 rated load) and then disconnect all
If necessary, adjust the gas mixture and governor linkage loads. (If the governor has been replaced, adjust the
as instructed in this section before adjusting the governor gain 1 and stability 1 pots to their center settings.)
controller. Make sure that the governor assembly is se-
curely mounted. Also make sure that the governor link- 3. Adjust the gain 1 pot until the engine is stable and
age does not bind or have excessive play in it. responsive to governor control. (Adjust the gain 1
pot counterclockwise to eliminate hunting.) Bump
1. Check the dip switch settings (Figure 28) to make the throttle lever a couple of times to check for hunt-
sure they are set properly, as follows: ing. The unit should respond quickly but should not
hunt.
SW1 SW2 SW3 SW4
50/60 Hz OFF ON ON OFF 4. Apply full load to the genset and adjust the stability 1
60 Hz OFF ON ON ON pot to minimize overshoot. (Adjust the stability 1 pot
clockwise to increase stability.) Check stability un-
60 Hz gensets only: If the governor has been re- der a range of loads; from no-load to full-load.
placed, begin the following adjustment with the
5. Attach a tachometer or frequency meter to the gen-
50/60 Hz switch settings. If 60 Hz (1800 RPM)
erator output leads if control panel does not come
cannot be obtained after completing the follow-
equipped with one of these meters. Adjust the
ing steps, set switch settings to the 60 Hz posi-
Speed Trim pot until the desired speed is obtained.
tion and repeat the following steps.
6. Shut down and restart the genset to check for over-
speed shutdown on startup.

GAIN 1

STABILITY 1

SPEED
TRIM

VIEW AA

DIP
SWITCHES

FIGURE 28. GOVERNOR CONTROLLER

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GOVERNOR LINKAGE 2. While holding the throttle lever against the idle
speed stop, verify that the throttle lever is at a 60 de-
Figure 29 illustrates the governor linkage. Make sure that gree angle as shown in Figure 29. Loosen the
the governor controller is securely mounted to the engine throttle lever screw, if necessary, to adjust throttle
bracket. To adjust the linkage: lever.
1. Remove the governor ball joint from the ball stud of 3. Adjust the length of the governor linkage to the
the governor lever. approximate length indicated in Figure 29.
4. Snap the ball joint back onto the governor lever.
Check mounting nuts to make sure that they are se-
cure.

GOVERNOR
ROD

BALL STUD
GOVERNOR (MOUNTED TO CENTER
THROTTLE LEVER OF GOVERNOR LEVER)
LEVER
THROTTLE LEVER
SCREW

GOVERNOR
ROD LENGTH

49 MM
60°
AT CLOSED
THROTTLE
POSITION

FIGURE 29. GOVERNOR LINKAGE

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Wiring Diagrams
The electrical schematics and wiring diagrams listed below are applicable to the ES
Series Engine and Generator Controls
FIGURE 30. ENGINE MONITOR (2 LIGHT)
FIGURE 31. ENGINE MONITOR (9 LIGHT)
FIGURE 32. ENGINE MONITOR (2 LIGHT) SCHEMATIC DIAGRAM
FIGURE 33. ENGINE MONITOR (9 LIGHT) SCHEMATIC DIAGRAM
FIGURE 34. DC CONTROL (2 LIGHT) SHEET 1
FIGURE 35. DC CONTROL (2 LIGHT) SHEET 2
FIGURE 36. DC CONTROL (9 LIGHT) SHEET 1
FIGURE 37. DC CONTROL (9 LIGHT) SHEET 2
FIGURE 38. SINGLE PHASE GENERATOR CONTROL
FIGURE 39. THREE PHASE GENERATOR CONTROL
FIGURE 40. ENGINE HARNESS
FIGURE 41. DC HARNESS