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Service
Manual
Generators
and Controls
4.5 to 30.0 kW
USED ON:
J-SERIES SETS
SK AND DTA SERIES SETS
PTO ALTERNATORS
TWO BEARING ALTERNATORS
900-0184
Reprinted 11-83
Printed in USA
SAFETY PRECAUTIONS
The following symbols in this manual highlight con- moving parts, etc.
ditions potentially dangerous to service personnel, or
equipment. Read this manual carefully. Know when Do not work on this equipment when mentally or
these conditions can exist. Then take necessary physically fatigued.
steps to protect personnel as well as equipment.
GUARD AGAINST ELECTRIC SHOCK
This symbol warns of immediate Disconnect electric power before removing protec-
@!@!%I hazards which will result in severe
personal injury or death.
tive shields or touching electrical equipment. Use
rubber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
This symbol refers to a hazard or electrical equipment. Do not wear damp clothing
@ % !!@
unsafe I can result in
practice which
severe personal injury or death.
(particularly wet shoes) or allow skin surfaces to be
damp when handling electrical equipment.
IAWARNING I
EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon
monoxideis poisonous and can cause unconsciousnessand death. Symptoms of
carbon monoxidepoisoning can include:
1-PIEM
Redistribution or publication of this document,
by any means, is strictly prohibited.
Supplement 900-1002
Date: 12-94
lnsett with-
Tile: YD Generators and Controls
Service Manual
Number: 900-0184 Date: 11-83
~~ ~ ~ ~
This supplementto the YD Service Manualadds information specific to the Onan PROTECseries of
YD PTO AC generator/voltage regulator systems.
NOTE: The YD PTO product referred to in the YD Service Manual is an earlier Onan product,
no longer being manufactured.
CONTENTS OF SUPPLEMENT
TITLE PAGE
1
FLOW CHART A. NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM
START
Is control panel field Replace defective
breaker CB21 on? and check continuity with
ohmmeter. Is breaker open?
no
.)
Push to reset breaker. Does generator If voltage is unstable, high or
AC outputvoltage build up? I
Yes - low, or causes breaker to trip,
no see Flow Charts B, C, D or E.
1
Check diodes CR1 through CR6 on
rotor per TEST F. Replace if bad.
Check exciter field wiring for shorts
across WE1 terminals 4 per TEST L Replace bad wiring.
and 5 5 VDC or more? Check exciter rotor winding
I per TEST H. Replace if bad.
Yes I I
Check exciter fidd wiring Replace fhe regulator PC board Check generator rotor winding
per procedure E if defective. per TEST K. Replace if bad.
Replace bad wiring. I
1 1
Check exciter field winding
I Check generator stator windings
Der TEST J. ReDlace if bad. I
1- Conbct wifh high vol&ge can cause severe
personal injury or death. Do nof touch any exposed wir-
ing or components wiih any parf of the body, clothing,
tool orjewelry-. Do not usenon-insulated toolsinside the
control. Sbnd onaninsulating mat or dry woodplaffom
when the control doors are open.
1- A newprinfedcircuitboardcan be dam-
aged bymalrUnctioningcomponents within thecon-
trol. Do not insiall the new PC board until all other
problems have been located and corrected.
1-1 Contact with high voltage can cause severe personal injury or death. Do nof
touch any exposed wiring or componentswifh anypart of the body, clofhing, fool orjewel-
v. Do nof use non-insulated fools inside fhe confml. Stand on an insulafing mat or dry
wood platform when fhe control doors are open.
I
3 Redistribution or publication of this document,
by any means, is strictly prohibited.
FLOW CHART D. FIELD BREAKER TRIPS
STMT
Check exciter stator winding per TEST G. Check reference transformer T21 per
Replace if bad. TEST E.
b w ( Contact with high volfage can cause severepersonal injury or death. Do nof
touch any exposed wiring or components withanypart of the body,clothing, tool orjewel-
y. Do not use non-insulated tools inside the control. Stand on an insulating mat or dry
wood platfonn when the control doors are open.
;i
PTO and generator and operate at normal
speed.
1-1 Accidental sfarting of the gen-
erator can cause severe personal injury or
death, Disconnect the propulsion engine
batterycables,negative (-)lead firs& before
connecting test leads to the controls or
generator. I-
I
MOMENTARYaN
SWITCH
> H1
FIGURE 3. REFERENCETRANSFORMER
-
E VR21 Replacement
Use the following procedure for replacing the
voltage regulator PC board or VR chassis.
1. Stop engine and PTO unit. Disconnect
leads to engine starting battery, negative
FIGURE 2. FIELD FLASHING CIRCUIT (-) lead first.
1-1 Accidenfal sfarfing of ihe
genemtor can cause severe personal
-
D Testing Reference Transformer injury or deafh. Disconnect thepropul-
sion enginebatfery cabies, negative (-1
Reference transformer T21 is located inside lead first, before conflnulng with this
the voltage regulator housing, mounted near PC board mplacement procedure-
the generator. T21 h a s four leads;two primary 2. Open the voltage regulator housing. Dis-
leads marked HI and H2 and two secondary connect the regulator and if necessary, la-
leads marked X i and X2. See Figure 3. bel wires. Refer to the AC control wiring
diagram included later in this supplement. t
-
F Testing Rotating Rectifiers
1. Stop engine and PTO unit. Disconnect FIGURE 4. TESTING ROTATING RECTIFIERS
leads to engine starting battery, negative
(-) lead first.
-
G Testing Exciter Stator
IBWAR"G1 Accidental starting of the Test the exciter stator (Figure 5) for open or
generator can cause severe personal shorted windings and grounds as follows:
injury or death. Disconnect the propul-
sion engine battery cables, negative (-) Testing forOpen or Shorted WindingsStop
lead firsf, before continuing with this engine and PTO unit. Disconnect leads to en-
test procedure, gine starting battery, negative (-) lead first.
EXCITER ROTOR
MEGGER OR INSULATION
WHEATSTONE
RESISTANCE METER
BRIDGE OR DIGITAL
OHMMRER TESTING WINDING
FORGROUNDS
TESTlNG WINDING
RESISTANCE
ES-17oOs
CONNECTION DIAGRAM
~ ~
-
J Testing Generator Stator diagram. All stator leads must be isolated for
testing.
Stopengine and PTO unit. Disconnect leads to
engine starting battery, negative (-} lead first. Use a megger or insulation resistance meter
which applies 500 VDC or more to the test
IBWAR"GI Accidenfal sfarfing of the gen- leads. Test each stator winding for a short to
erator can cause severe personal injury or the laminations. A reading less than 100,000
death, Dlmnneci ihe pmpulsion engine ohms indicates a questionable stator. Thor-
baiierycables, negative(-)lead firs$before oughly dry the stator and retest.
continuing wifhthese fest procedure.
Testing for Open or Shorted Wlndings:Test
Using proper test equipment, check the stator for continuity between coil leads shown in Fig-
for grounds, opens, and shorts in the windings. ure 7:wire pairs TI -T2and T3-T4 should have
equal resistance. U s e an accurate instrument
Testing for Grounds:Some generators have for this test such as a Kelvin bridge or digital
ground connections tothe frame. Checkwiring ohmmeter. Resistance values at 77" F (25"C)
I n
. . ....
t.1.. w I
ESl79SS
WHEATSTONE
RESISTANCE MRER BRIDGE
16/20
LaWAR"i;l Accidental starting of the gen- 20124
erator can cause severe personal injury or
death. Disconnect &e pmpulsion engine I 24130 ~
I 2.24 I
bafterycables, negative (-)lead firsf, before
continuing with these test procedure, I 30135 2.91
3. If less than 100,OOO ohms, rotor is ques- FIGURE 8. TESTING ROTOR FOR GROUNDS
tionable. Thoroughly dry the rotor and re-
test.
4. Replace a grounded rotorwitha new iden- DIGITAL (7-7
r -1 I
tical part.
When checking output voltage, be surethat the FIGURE 10. VOLTAGE REGULATOR BOARD
generator has stabilized and is running at the INSIDECONTROL BOX
correct speed (frequency).
-
I I
I I 1
I I ,
I I TO LOAD
LO
I
I
1 L2
I
TO
GENERATOR
I
T2, T3
I
TI-
I
@-@ z M3 I M4
T4- L
I
I
I I
METER-FREQUENCY
METER-AC VOLT
NO. 615-0426
REV. A
MODIFIED
I I
13
I 7L1
I I
I I
I I
I I
I- -I
I I
I I
I
I
I
I
I
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I
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II
I It!
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(‘I
7
TT
M4
t
-1
I
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I
I
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I
I
I
I
REAR VIEW
-
7 TERMINAL BLOCK TB 1
6 CIRCUIT BREAKER CB I
5 TRANSFORMER-CURRENT CT1 , CT2
4 METER-FREOUENCY M5
3 METER-TIME TOTALIZING M4
2 METER-AC VOLTAGE M3
I \METER-AC AMMETER / M I .2 .
ITEM^ DESCWPTION OR MATERAL RF
DES
TITLE PAGE
Safety Precautions ..................................................
.Inside Cover
Introduction...................................................................
2
GENERATOR TROUBLESHOOTING ............................................ 5
Part 1 4.5 to 25 kW Range ................................................
5
Part II 25 to 30 kW Range .................................................
21
Generator Repair. J-Series .................................................
35
Disassembly ..........................................................
35
Assembly.................................. ............................
36
PTO ALTERNATORS
.. ..........................................................
37
.............................................................
Specifications 38
Wiring Connections, 15-25 kW .............................................
40
Troubleshooting ...........................................................
41
Service and Maintenance ...................................................
42
TWO BEARING ALTERNATORS ................................................ 43
.
.. ....................................
Specifications : ........................
45
Troubleshooting .................................... .....................
i 46
Alternator Repair..........................................................
47
Gear Case Disassembly ................................................
47
Alternator Disassembly ................................................
49
Alternator Assembly ...................................................
54
CONTROL SYSTEMS .........................................................
55
Engine Control System Operation ..........................................
58
Gasoline Powered Sets ................................................
58
Diesel Powered Sets ...................................................
58
Radiator Cooled Sets ..................................................
62
Engine Control Troubleshooting ............................................
67
Control Component Checkout .............................................
70
WIRING DIAGRAMS ..........................
; ...............................
72
STATOR
STACK
k I LENGTH PARTS CATALOG OPERATOR'S MANUAL
60 Hz 50 Hz
JB 7.5 6.0 2.88 967-0223 967-0123
JC '' 12.5 4.31 967-0220 *' 967-0120
MJC 10.0 3.44 968-0340 968-0340
RJC 12.5 10.0 4.31 974-0220 974-0120
JC 15.0 12.5 . 5.00 , 967-0220 - .. 967-0120
I MJC 15.0 5.00 968-0340 968-0340
RJC 15.0 125 4.31 974-0220 974-0120
SK 30.0 25.0 : '7.00-10.38 946-0220 946-0120
. .
Diesel
DJB 6.0 4.5 x 2.19, 967-0221 967-0121
DJE 6.0 4.5 2.19' 967-0225 967-0125
MDJE 7.5 6.0 2.88 968-0224 . 968-0120
DJC 12.0 9.0 4.31 967-0222 967-0122
MDJC 120 10.0 4.31 968-0222 968-0122
RDJC 15.0 12.5 5.00 974-0221 974-0121
MDJF 15.0 12.0 5.00 968-om 968-0121
RDJF 17.5 14.5 5.75 974-0222 974-0122
MDTA 25.0 8.62 961-0222 961-0122
DTA 25.0 8.62 961-0220 961-0120
YD PTO Alternator 15.0-30.0 15.0-30.0 5.00-8.62 929-0002 929-0002
YD Two Bearing 5.0-20.0 5.0-16.0 2.197-00 929-0004 929-0004
ENGIN€CENEf
ADIAPTER
THROUGH-STUD
3
Redistribution or publication of this document,
by any means, is strictly prohibited.
generator adapter. The brushless exciter stator Generator sets without a control panel or
mounts in the end bell while the exciter rotor and its switchboard containing A C instruments such as
rotating rectifier assemblies mount on the generator voltmeters, ammeters, running time meter, frequency
rotor shaft. meters, and line circuit breakers are shipped from the
factory with the A C output leads separated in the
All generators have four wires extending from the output box. On generator sets with switchboards
stator housing in addition to the A C output leads, containing A C instruments, the A C output leads are
Figure 2. Lead B2is from the battery charge winding wired as specified on the customer's purchase order
and connects to terminal 7 of the engine control.
Lead F1+ and F2-are from the exciter field winding
to deliver only the voltage specified. -
and are connected to the output terminals of the
voltage regulator. Leads 1and Pare connected to the VOLTAGE RECONNECTION WITH
stator windings and provide reference voltage and OPTIONAL INSTRUMENTS
input powerto thevoltage regulator. These four leads
are connected at the factory. The optional A C instruments on the control panel
(such as voltmeters, ammeters, transformers, and
Figure 2 is a composite illustrationshowing four output leadsfor running time meters) are intended for use with
single-phase units, l2output leadsfor *phase broad rangeunits,
and four output leadsforcode9x3-phase 347l600volt generators.
specific nameplate voltages. Control components
may have to be changed to match new current ratings
when field reconnection for other voltage codes or
voltages are made.
CHARGING
RESISTOR
BAlTERY
CHARGING
-CONTROL
TO
ENGINE a CAUT,ON
To prevent instrument damage contact the
Onan factory for required instrument
changes, new wiring diagrams, new plant nameplate with proper
specificationnumber and voltagebeforeattemptingto reconnecta
F 2 - n
TO VOLTAGE
REGULATOR
1 r 7 7 generator with instrumentson the control panel.
GENERATOR OPERATION
Operation of the generator involves the stator, vol- h
FULL WAVE
tage regulator, exciter field and armature, a full wave BRIDGE
bridge rectifier, and the generator rotor, Figure 3. RECTI FIER
Residual magnetism in the generator rotor and a
I
permanent magnet embedded in one exciter field RESIDUAL .
MAGNETISM ROTOh
pole begin thevoltage build-up processasthe gener- IN ROTOR
ator set starts. Single-phase AC voltage, taken from STARTS
one of the stator windings, is fed to the voltage regu-
lator as a reference for maintaining the generator
output voltage. AC voltage is converted to DC by a
silicon controlled rectifier bridge on the voltage regu-
lator printed circuit board and fed into the exciter
field windings. The exciter armature producesthree- REFERENCE B RUSHLESS
phase AC voltage that is converted to DC by the VOLTAGE EXCITER
FIELD
rotating rectifier assembly. The resultant DC voltage
excites the generator rotor winding to produce the
stator output voltage for the AC load.
I
The generator rotor also produces AC voltage in the '
4
Redistribution or publication of this document,
by any means, is strictly prohibited.
GENERATOR TROUBLESHOQTING
PREPARATION PART I
A few simple checks and a proper troubleshooting
procedure can locatethe probable source of trouble TROUBLESHOOTING
and cut down service time.
Check all modifications, repairs, replacements PROCEDURES
performed since last satisfactory operation of set (STANDARD YD GENERATOR AND REGULATOR)
to ensure that connection of generator leads are
correct. A loose wire connection, overlooked
when installing a replacement part could cause The information in this section is divided into Flow
problems. An incorrect connection, an opened Charts A, 6,C, D, and E as follows:
circuit breaker, or a loose connection on printed
circuit board are all potential malfunction areas A. NO AC OUTPUT VOLTAGE AT RATED ENGINE
to be eliminated by a visual check. RPM.
Unlessabsolutelysure that panel instrumentsare B. UNSTABLE OUTPUT VOLTAGE, ENGINE
accurate, use portable test meters for trouble- SPEED STABLE 1800 RPM.
shooting.
C. OUTPUT VOLTAGE TOO HIGH OR LOW.
Visually inspect components on VR21. Look for
dirt, dust, or moisture and cracks in the printed D. EXCITER FIELD BREAKER TRIPS.
solder conductors. Burned resistors, arcing E. UNBALANCED GENERATOR OUTPUT VOLT-
tracks are all identifiable. Do not mark on printed AGE.
circuit boards with a pencil. Graphite lines are
conductive and can cause leakage or short cir-
cuits between components. To troubleshoot a problem, start at upper-left corner
of the chart related to problem, and answer all ques-
The PART I TROUBLESHOOTING PROCEDURES tions either YES or NO. Follow the chart until the
are for YD generators in the 4.5 to 25 kW size range problem is found, performing referencedAdjustment
using the standard YD regulator and generator. and Test procedures following the Flow Charts.
The PART I1TROUBLESHOOTING PROCEDURES Referenced components in the Flow Charts and
(page 21) are for YD generators inthe 25 to 30 kW size Adjustment and Test procedures can be found on the
range. These units have thicker exciters and use the electrical schematic Figure 4, and on assembly draw-
UR type regulation system. ings and wiring diagrams on pages 18-20.
DC VOLT. REG.
OUTPUT PC BOARD
VOLTAGE VR21
"
EXCITER
ROTOR RECTIFlER
(M,M E ) ASSEMBLIES
REGULATOR
ASSEMBLY
FIGURE 4. ELECTRICAL SCHEMATIC, STANDARD YD GENERATOR AND REGULATOR
Is reference voltage across TB21-1 & 2 -no Flash exciter field per TEST [E]. Does
20 VAC or more? generator output voltage build up?
I no
Check commutating reactor CMR21 per Disconnect stator leads 1& 2 from TB21-
1 & 2. Is reference voltage across leads
TEST [I].Replace if bad. 20 VAC or more now?
I
1
Check reference transformer T21 per Check diodes CR1 through CR6 on rotor
TEST [J]. Replace if bad. per TEST [F]. Replace if bad.
I
I I
Is exciter field voltage Check wiring harness W9 for Check exciter rotor winding
across TB21-3 & 4 7.0VDC shorts per TEST [O].Replace per TEST [L]. Replace if bad.
bad wiring.
d
I
I
I Check SCRs CR13 & CR16per
TEST [HI. Replace if bad.
I ,
Check generator rotor field
winding per TEST [MI. Replace
if bad. I
Check exciter field winding Check generator stator wind-
Check diodes CR12,14 & 15 per ings per TEST [N].Replace
per TEST [K].Replace if TEST [GI.Replace if bad.
bad.
I 1
I Replace voltage regulator PC
board per procedure IP].
I
Do not replace the printed cir-
cuit boarduntil thetroublenot
on the PC board has been located and corrected to
avold damage to new PC board.
-
Are there any broken wires or loose
connections on voltage regulator -Yes + Repair as required.
assembly V R Z ?
I
no
1
I 1 I I
L
I Check wiring harness from VR22 to end bell
per TEST [O]. Check OK?
I
I
t
1 I
Repair wiring or replace as required.
I
Replace voltage regulator PC board per Do not replace the printed circuit board
procedure [PI. _ _ ~ _ _ ~ _until ~ the
_ trouble not on the PC board has
been located and corrected to avoid damage to new PC board.
START
Is engine running at correct RPM? -no-+ Set RPM per instructions in appropriate
engine manual.
Does adjustment of Voltage Adjust control Set control per Voltage Calibration
R22 on VR22 result in correct output Adjustment [A].
voltage?
Does AC output voltage build up to 140%or Check for any loose or broken wires or connections
more of rated voltage before breaker trips? on VR22 assembly.
no
f
I I
Check exciter rotor winding per TEST [L]. Check generator stator leads for proper
Replace if bad. connection. See Figure 19, page 20.
I I
D O nOt replam the printed CiEUit board Replace voltage regulator PC board VR21
until the trouble not on the PC board has per procedure [PI.
been locatedand corrected to avoiddamage to new PC board.
.*
r-
1
Check load for ground faults and correct as
necessary.
10
I Redistribution or publication of this document,
by any means, is strictly prohibited.
Bench Check 3. Open switch in 120 VAC supply to VARIAC.
1. Remove voltage regulator from unit according to 4. Piug VARIAC into 120 VAC source.
procedure given for voltage regulator replace- 5. Proceed with checkout according to steps in
ment. Table 1.
2. Referring to Figure 5 and Table 1, connect test
equipment to the printed circuit board VR21 ter-
minals as follows:
[El
CONNECT FROM TO . FLASHING THE FIELD
Jumper VR21-V1 VR21-V4 The following procedure is used for momentarily
Jumper VR21-1 vR21-2 flashing the exciter field with a low voltage which
Lead CMR21-1 vR21-10 restores the. residual magnetism in the alternator
Lead CMR21-4 vR21-9 rotor. Flashing the field is usually necessary when
Lead T21-X1 VR21-6
T21-X2 vR21-4
installing a new brushless exciter stator wound
Lead
AC Voltmeter Across T21-H1 & H2 assembly, but seldom is necessary under other
DC Voltmeter Across VR21-78 8 . circumstances. Always check generator residual
VARIAC Across T21-H1 (fused) voltage at terminals 1 and 2 to be certain whether or
and H2 not flashing the field is necessary. Generator residual
R1 Across. VR21-7 h 8
r----------I
WIOJUMPER
VOLT , I
AC INPUT
VOLTMETER
El
DAMPING
'1
C k
I
I
WioJuwER
a 0
I
7 0
I v
I
I
VR21 I
L---------d
FIGURE 5. VOLTAGE REGULATOR CHECKOUT EST EQUIPMENT CONNECTIONS
Redistribution or publication of this document,
11 by any means, is strictly prohibited.
6 VOLT
DRY CELL
BATTERY '
. FIGURE 6. MSHlNGTHEFiELD
- .
voltage should be at least 20 VAC at rated speed. If 2. Connect one test lead to F1+ stud and connect
residual is too low and the output voltage will not- other lead toCR1, CR2, and CR3 in turn; record
build up, flash the field as follows: resistance value of each rectifier.
Locate terminals 7(-) and 8(+) on .voltage . - 3. Connect one lead to F2- stud and connect other
regulator printed circuit board (VR21). lead to CR3, CR4 and CR5 in turn; record resist-
Use a six volt dry cell battery with two clip leads ance value of each rectifier.
anda12amp,300voltdiodeasshown in Figure6. 4. Reverse ohmmeter leads from step 2 and record
If a six volt battery is not available, a 12 volt auto- resistance value of each rectifier F1+ to CR1,
motive battery can be used by adding a 20-ohm CR2, and CR3 and F2-to CR4, CR5, and CR6.
resistor in series; or a 24 volt automotive battery 5. All three resistance readings should be high in
can be used by increasing the resistance to one test and low in the other test. If any reading is
40-oh ms. high or low in both tests, rectifier assembly is
After starting engine, touch positive (+) battery defective.
lead to the+8, and negative (-) lead to -7 terminals . 6. Replace defective rectifier assembly with new,
just long enough until voltage startsto build up or identical part.
damage may occur to exciter-regulator system.
Use 24 Ibs-In. (27 N w ) toque when tightening nuts on F1+ and
1-1 Be cautious when worklng on a generator
that is running to avoid electricalshacks.
F2-, CR1, CR2, CR3, CR4, CRS, and CR6.
TEST PROCEDURES
All o f the following tests can be petformed without
disassembly of the generator. Use the following test
procedures for testing generator components in con-
junction with the troubleshooting charts.
R17
F1+ F2-
EXCITER FIELD
i I
I CR15
I
I
8
FIGURE 9. TESTING DIODES
TESTING SCR'S
Two identical silicon controlled rectifiers (SCR's),
CR13and CR16, control the DC output voltage to the
exciter field. These SCR's are mounted in heat sinks
on the voltage regulator and are tested as follows:
1. Using high scale on ohmmeter, connect ohmme-
ter leads to anode and cathode of the SCR as
shown in Figure 10. The resistance reading
should be one megohm or greater. Reverseohm-
meter leads to anode and cathode; resistance
should again be one megohm or greater. FIGURE 10. SCR RESISTANCE TEST
Redistribution or publication of this document,
by any means, is strictly prohibited.
13
X1, and X2. H1-H2 are the primary leads. Xl-X2 are
the secondary leads.
MULTIMETER
1 TO 1 RATIO
LLkJ T21
XI x2
/KI
TESTING BRUSHLESS EXCITER STATOR
Like the generator, the brushless exciter stator (Fig-
ure 12) can be tested for open or shorted windings
and grounds.
Testing for Open or Shorted Windings:
Disconnect Fl+ and F2- exciter field leads from ter-
minal block in generator end bell. The resistance
FIGURE 11. SCR VOLTAGE TEST
between field leads should be 10.98 to 13.42 ohms at
68" F (20' C).
1 2'
CMRPI
rn
3 . 4
OHMMETER RESISTANCE BETWEEN
F1 AND F2 SHOULD BE
10.98 TO 13.42 OHMS
Resistance between 1-2 and 3-4 should be 0.33 to
0.39 o h m s and 0.38 to 0.46 ohms respectively at 77" F FIGURE 12 TESTING EXCITER FIELD
(25°C). Resistance between coils (e.g. 1-3) and from
any terminal to reactor frame should be infinity.
[LI .
[Jl TESTING BRUSHLESS EXCITER
ROTOR (ARMATURE)
TESTING REFERENCE TRANSFORMER
The brushless exciter rotor (Figure 13),can be tested
The transformer T21 has four leads marked H1, H2, for open or shorted windings, or grounds.
FI
Testing for Open or Shorted Windings: Testing for Open or Shorted Winding:
Use a Wheatstone Bridge for this test. Disconnect All resistancevalues should be within rfr 10%ofvalues
main rotor field leads which connect to rotating recti- specified in Tables 2 and 4 at 77OF (25°C). Perform
fierassemblies at Flcand F2-. Disconnect lead wires tests as follows:
from diodesCR1, CR2, CR3, CR4, CR5and CR6. Test 1. Remove rotor leads F1+ and F2- from rotating
between exciter lead pairs T1-T2, T2-T3 and Tl-T3. . rectifier assemblies.
Resistanceshould be 0.5 to 0.6 ohms at 68OF (2OOC). 2. Using ohmmeter, check resistance between F1
and F2 leads, Figure 15.
Testing for Grounds:
Connect leads of ohmmeter between each CR lead If resistance Is low, there are shorted turns. If resistance is
and exciter rotor laminations; use RX 100 scale on hlgh, rotor winding Is open. In either case, rotor must be
replaced.
ohmmeter. An ohmmeter reading less than infinity
(00) indicates defective ground insulation.
3. Replace defective rotor with new, identical part.
OHMMETER -
THREEPHASEMODELS
TEST BETWEEN WIRE PAIRS
t
TI-T4 T7-TIO T3-Tb .
T9-TI2 TZ-TS =TI1
./
/ WIO
\
VR22
(W/O VOLT ADJ
Y
JVR23
(W/VOLT ADJ) VR21 C
- CB2 I
.FEU)
BREAKER
I-) L - N0TE:FIEU)
BREAKER IS
VOLTAGE REFERENCE
/ MOUNTED ON
ADJUST PANEL
VOLTAGE COMMUTATING
(OPTIONAL)
TRANSFORMER REACTOR
AIR-COOLED AND
8203 MARINE SETS RADIATOR-COOLED SETS
DES. I DESCRIPTION
721 I Transformer. Ref Voltare
I I
CR5 IW
cR3.4.6-I 11 RECTI FI ER-OI WE Id. 400V
0IO;E-ZEHER 2oY
5.w NOTE: The 2500ohm external voltage adjust potentio-
CAPACITOR .47MmlOW meter connects between pin I and pin 3. See regulator
CAPACITOR 3YFO z!i4&
schematic. If your set does not have an external
lYF0
voltage adjust potentiometer, pin I is jumpered to
'.lUFOZSORI pin 2.
1
19 Redistribution or publication of this document,
by any means, is strictly prohibited.
SCHEMATIC MAGRAM WIRING DIAGRAM
CONNECT X I TO VRZI-5 FOR
50 HERTZ: CONNECT X I T O
VR21-6 FOR 60 HERTZ
GENERATORS.
5240
VI
v2
v3
-
v4
VI
v2
v4
VI
y
LI
J
v2
\R
v4
VI
h K A. 1A A
T4 T7 R TI0 T5 T8 T3 TI1 T6 T9 T I TI2
T I l7 T6 TI2
~~~ T3 T9 T5 Tll T4 T I O R T8
i2
LI u L3 LO
T I R T 3 T O
ASSEMBLY I
ES1067
no ti0
I
A
v
1
I
4 I I
I
P
Push to reset breaker. Does generator
AC output voltage build up?
I
no
t- -t-l
I
1
I I
If voltage is unstable, high or low, or
causes breaker to trip, see Flow Charts
B. C, D. or E
t
I
Is residual voltage across 1621-62and 63 Flash exciter field per TEST [D]. Does
5 to 10 VAC or more? generator output voltage build up?
Check reactor L21 and transformer T21 per Disconnect stator leads 7 and 8 from TB21-62
and 63. Is residual voltage across leads 5
TESTS [B] and [E].
to 10 VAC or more now?
I
Is exciter field voltage Check diodes and SCR's on Check lead continuity between
across VR21-5 & 6 5 VDC bridge assembly CR21 per VR21-12 & l7 on generator,
TEST [C].
<
START
Check wiring harness from regulator assembly Repair wiring or replace as required.
to end bell per TEST [MI. Check OK?
yes
J- ~~ ~~~
Does adjustment of Dampening Control R26 on VR21 Is voltage stable within spec at no
per adjustment [PI result in stable --Yes- . load to full load range of generator
voltage? set?
Replace voltage regulator PC board per Do not replace the printed circuit board
procedure [F]. untll the trouble not on the PC board has
been located and corrected to avold damage to new PC board.
START
_I
Is engine running at correct RPM? - no---, Set RPM per instructions in appropriate
engine manual.
I I I 1
I
I
Does adjustment of control R18 on VR21 result
in correct output voltage?
I
t
I I
Set per Voltage Calibration Adjustment [PI.
I
I
f
Do not replace the prlnted clrcult board
until the trouble not on the PC board has
been located and corrected to avold damage to new PC board.
’
Replace voltage regulator PC board VR21 per
procedure [F].
I
Redistribution or publication of this document,
23 by any means, is strictly prohibited.
. FLOW CHART D. EXCITER FIELD BREAKER TRIPS
START
I t I i
Does AC output voltage build up to 150% or Check for any loose or broken wires or connections
-yes-
more of rated voltage before breaker trips? on VR21 assembly.
I t
no
I i
START
Remove load at generator terminals. Is output Check for correct grounding of generator
still unbalanced? and load.
Yes
I
. I I 1
I
I
Are generator leads connected and grounded
properly? See Figure 36, page 34. tno-l
I t
Correctas necessary.
I
I
GENERAL
All of the following Adjustments and Tests can be
performed without disassembly of the generator.
They should be used for testing generator and regu-
tator components in conjunction with the trouble-
shooting flow charts.
TESTING.L2f REACTOR
The t21 eommutating reactor (Figure 21) mounts
inside the control box
The coils 1-2 and 3-4 are wound on the same core. I
CRI
C )
I
Resistance between 1-2 and 3-4 should be .031 to
,037and .037to .046 ohms respectivelyat 77OF (25').
Resistance between coils and from any terminal to
frame of the reactor should be infinity.
DRY E L L
BATTERY
TABLE 5. TESTING RECTIFIER BRIDGE series respectivelywith the 12amp300 Vdiode. Start
ASSEMBLY CR21 the generator setand operate at normal rpm. Touch
positive lead to + terminal on rectifier bridge, and
TEST OHMUEERLEAD RECTlFIER
+ - TERMINUS
TEmNG
CR ISCR REMARKS METER SCUE
-
negative lead to the terminal. Hold leads on termi-
1 x + u 1 3 Infmily RXlOK
nals just long enough for voltage to build up.
X
5
4 1
x
x x ~I I ~ vI
- CRl
Infmily RXlOK
RXl
I PLACE RESISTOR HERE FOR
12V OR 24V BATTERY
x ACI
vR21-9
m
x1
531-649 OHMS
x2
Tzl
vR21-10
6. Replace defective rectifier assembly with new,
identical part.
CR3
FIGURE 25. T21 WINDING SCHEMATIC
. .
VR21 REPLACEMENT
Usethefollowing procedurefor replacing the voltage
regulator PC board or VI? chassis.
1. Stop engine.
2. Disconnect and if necessary, label wires: VR21-1
through VR21-12 Refer to AC control wiring
diagram.
3. Remove four screws at corners. FIGURE 26. TESTING ROTATING RECTIFIERS
FIGURE 30. TESTING ROTOR FOR GROUNDS FIGURE 31. TESTING ROTOR FOR AN OPEN CIRCUIT
1.62 to 1.98 ohms for 30 kW SK models. A temporary overload with a non-frequency sen-
sitive reference could cause the engine to reduce
If resistance is low, there are shorted turns. If resistance Is speed, and then require a 50- to 60-percent load
high, rotor winding is open. In either case, rotor must be reduction before it could return to rated speed.
replaced.
3. Semi-frequency sensitive - voltage output
3. Replace defective rotor with new, identical part. decreases as engine speed decreases, but not as
P
L
. I
CONNECT LOOSEWIRE
FROM TB2-2 TO TB2-
I 1 I
1
HI,HZ H3,H4. H5
OR H6 DEPENDING ON
VOLTAGE SELECTED.
VOLTAGE ADJUSTMENT
After replacement of the regulator printed circuit
board (VR21), voltage adjustment is performed as
follows (see Figure 32):
m2
1. Center the voltage adjust knob so pointer is in a 25 kW DTA SETS
vertical position.
2. Start unit and operate at correct rpm. FIGURE 33. CONNECTING LOOSE WIRE W12
VR MOUNTINGPANU
\ PC BOARD VR21
TERMINAL BLOCK TB2
RESISTOR ASSEMBLY
R7 -
Resistor 112 Watt, 3.000-0hm
R8. R16 -
Resistor 112 Watt, 330.000-0hm
R10 -
Resistor 112 Watt, 51.100-0hm
R11 R9 -
Resistor Fixed3 Watt,
15,000-0hm
R12 -
Resistor 112 Watt, 90,900-0hm
R13 -
Resistor 112 Watt, 10.000-0hm
R14 Resistor- 112Watt. 220,000-0hm
R15, R27 Resistor- 1RWatt. 100.000-Ohm
R17 Resistor, Metal Film
114 Watt, 11.000-0hm
-
R18 Potentiometer-5,0hm. 112Watt
R20.22
29 & 30
R21
-
Resistor 114 Watt, 28.000-0hm
-
Resistor Metal Film - 1
114 Watt, 5.1 1W h m
R24 -
Resistor Metal Film -
114 Watt, 8,870-0hm
PC BOARD ASSEMBLY
-- --- - //.%a
SCHEMATIC ES-1068
1- Lo
L2
LO
L2
TO
I 1L3 I
TO H5TERMlNAL
I .
TO 12 LEAD GENERATORS ONLY
LO 11 12
LO 11 12 13
LO 11 12 13
LO 11 12 13
1101li 112 11 17 14 12 18 7 5 13 19 1
5. Remove stator-through-stud nuts, end bell, and FIGURE 39. ROTOR REMOVAL
ALTERNATOR DESCRIPTION mounted gear box and splined driveshaft and control
The 15 kW through 30 kW alternators are four-pole, box,which includes voltmeter and a full output load
revolvingfield, brushlessexciter, 1800rpmmodelsof Plug-
drip-proof construction. Alternator design includes
both single and three-phase, 60 hertz type alterna- Control Box
tors. The alternator rotor is fastened to the gear case The control box includes the voltage regulator,
by the rotor through-stud which passes through the voltmeter, 15 amp duplex receptacle with circuit
rotor shaft, Figure 40. breaker, 50 amp welder receptacle with circuit
breakers, a full output load connector with load
The end bell and stator housing are attached by four circuit breakers, and a field circuit breaker. The load
through-studs which pass through the stator circuit breakers can be used as an onoff switch.
assembly to the gear case alternator adapter. The Alternator power must feed into the farm electrical
brushless exciter stator mounts in the end bell while system through an approved double throw load
the exciter rotor and its rotating rectifier assemblies transfer switch.
mount on the alternator rotor shaft. The shaft is
supported at both ends by lubricated ball bearings. A
centrifugal blower on the drive end of the alternator
Gear Box
draws air through the alternator for cooling. The gear box and alternator adapter contain two
helical gears supported by heavy duty ball bearings.
The bearings and gears are lubricatedby the gear box
The complete alternator includes a built-in exciter oil. The gear box requires 1.0-pint (-47 litre) of SAE
and voltage regulator, mounting feet, lifting eye, 90 EP (extreme pressure) gear lubricant.
ORIGINAL EQUIPMENT
MANUFACTURERS PRODUCTS
Onan manufactures several versions of YD PTO
alternators which are sold nationally under other
brand names. The major difference in these units are
location of control components and the form of
mounting hardware.
b'
SINGLE PHASE ALTERNATORS
.
15.OYD-3G 20.OYD-3G 25.OYD-3G 30.0Y D-3G
Starting Watts ...................... 37.500 . 52,000 62,500 80,000
Running. Watts.. .................... 15,000 20,000 25,000 30,000
Volts ............................... 1201240 1201240 120/240 1201240
Phase.. ............................ 1 1 1 1
Hertz .............................. 60 60 60 60
Current (Amperes). ................. 62.5 83.3. 104.2 125
Power Factor ....................... 1.o 1.0 1.o 1.o
Wire ............................... 4 4 4 4
Brushless .......................... Yes Yes Yes Yes
Alternator Speed (Nominal) ......... 1800 1800 1800 1800 .
Tractor Speed (Nominal) ............ 540 540 540 540
Minimum Horsepower Required
Driving Source ................. 30 35 45 . 55
Gear Box Oil Capacity, Pints ........ 1.0 Pt (0.47 litre) 1.O Pt (0.47 litre) 1.0 Pt (0.47 litre) 1.0 Pt (0.47 litre)
Gear Lubricant ..................... SAE 90 EP SA€ 90 EP SA€ 90 EP SAE 90 EP
Weight ............................. 354 Ibs. (161 kg) 398 Ibs. (181 kg) 438 Ibs. (198 kg) 483 Ibs. (219 kg)
VOLTMETER
\ RECEPTACLE
/
BREAKER
PTO SHAFT
ALTERNATOR
ALTERNATOR
STATOR
EXCITER STATOR
EXCITER ROTOR
DRIVE
ROTOR-THROUGH-STUD
TORQUE TO 55-60 FT. LES
MOUNTING FOOT
VOLTAGE REGULATOR
VOLTAGE REGULATOR '
EXCITER
WINDING
&:
F;
G i
? F
-'-
,e3 to. 1
FIELD BREAKER
EXCITER
WINDING
FIELD BREA.KER
ALTERNATOR
GI( I ) ALTERNATOR
OUTPUT
LEADS T4
?I
VOLTMETER
LINE I
CIRCUIT c85 CBi CB2
BREA KE R POWER
POWER CABLE
CAB LE RECEPTACLE
RECEPTACLE
240 V.
240 v. RECEPTACLE
RECEPTACLE
1-,q
RECEPTACLE
&
r
GROUND
w I20 v.
RECEPTACLE
FIGURE 41.120/240 VOLT, SINGLE PHASE CONNECTION FIGURE 4 2 THREE PHASE 240 VOLT DELTA CONNECTIONS
TABLE 7. TROUBLESHOOTING
u
No Voltage Output, or
Voltage Builds Up But Refer to GENERATOR Refer to GENERATOR
Is High, Low, Unstable, TROUBLESHOOTING, Page 5. . TROUBLESHOOTING, Page 5.
. Trips Field Breaker. . .
EzxCAUTION
Overfilling will causefoaming,which can lead
to an oil kak.
=
possibly every 4 to 8 hours.
GENERAL end bell while the exciter rotor and its rotating
Onan YDtwo bearing alternators 5.0 through 20.0 kW rectifier assemblies mount on the rotor shaft.
. are 50 and 60 hertz units designed for belt and pulley
or direct coupling to a separate prime mover.
VOLTAGE REGULATOR
Acentrifugal bloweron the frontend of the rotorshaft The line voltage regulator is an all solid state device.
circulatesthe alternator cooling air. The air is drawn Basic components of the voltage regulator are:
in through the end bell cover, over the rotor, and Printed circuit board
discharged through an outlet at the blower end, Fig- Voltage reference transformer T21
ure 4.4. 0 Commutating reactor CMR21
Field circuit breaker
A ball bearing at each end supports the rotor shaft. Voltage adjust rheostat (optional)
The end bell and stator housing are attached by four-
through-studs which pass through the stator Figure 45 shows the above components in a typical
assembly. The brushless exciter stator mounts in the control on standard units.
/FIELD
STATOR, BREAKER
---
ASSEMBLIES
ROTO R-SHAFT
STATOR-THROUGH-STUD
mu
11
ROTORI 1 \
. END BELL TORQUE TO 19-21 FT. LBS
a ’ . ( S 2 8 Wm)
REGULATOR MOUNTING
PANEL
FIELD CIRCUIT
BREAKER
I
I
I CYRZI-2
I
I 7821-1 I -I
I
CONTROL BOX
I -I The control box (on top of the alternator) contains the
t I
II CURZI-3 I 7821-2
voltage regulator and the lowerportionof the junction
I -I
I
1I CURZI-4 I
I
VR2l-9
I box for making alternator to load line connections.
CBZI-2 VRZ 1-1 0
OPTIONAL SWITCHBOARDS
Switchboards (Figure 46) are optional equipment
which can be purchased at added cost. They contain
a voltmeter; ammeters, line circuit breakers and
marked terminals. The switchboard is used to check
alternator voltage, load current and.voltage regula-
tion with a varying load.
NO= All units are two-bearing alternatorsdesignedfor clockwise mtation with belt andpulley drive or direct drive coupled to a
separateprime mover- Thedirection of rotation is clockwiseonly; it is determined when facing the drive shaft end. The60 hertz
units operate at 1800 rpm while the 50 hertz units operate at 1500 rpm.
NOTE: The3CSland 53CSlmodelsare 1201240 voltsinglephaseunits. The lSSland518Slmodels are threephasebroadrange
reconnectible units.
See Figure 19,page 20, for voltage codes, wiring diagram, and connection diagrams.
A few simple checks and a proper troubleshooting 2. Unless absolutely sure that panel instrumentsare
procedure can locate the probable source of trouble accurate, use portable test meters for
and cut down troubleshooting time. troubleshooting. c
TABLE 7. TROUBLESffOOTING:
RETAININGRING
..
IR OUTLET GRILL
. PTO SHAFT
TUMBLING ROD
PLATE
GUARD
47 Redistribution or publication
f of this document,
by any means, is strictly prohibited.
3. Removesix5/16x l-inch capscrewsandWo5/16 5. Block up gear case plate as shown in Figure 51
- l-l&inch cap screws and gear case plate, Fig- and tap PTO shaft out of plate.
ure 49.
To assure a good seal always we a new gear case gasket
when gear case plate Is assembled.
FIGURE 49. GEAR CASE PIATE REMOVED FIGURE 51. REMOVAL OF PTO SHAFT FROM
GEAR CASE PLATE
4. If necessary, remove seal and snap ring from
around input shaft, Figure 50.
Oldsealmutt bereplacedwith a new sealwhen reassembled 6. Remove snap ring and tap bearing through gear
A
box plate, Figure 52
FIGURE 50. INPUT SHAFT SEAL AND SNAP FIGURE 5 2 GEAR PLATEBEARING REMOVAL
RING REMOVAL
ALTERNATOR DISASSEMBLY
The alternator disassembly and reassembly is safer
and easier with thealternator in the vertical position
as shown in following sequence of illustrations. FIGURE 55. END BELL REMOVAL
BRUSHLESS
EXCITER f
A ' R E A FLE STATOR
I
BLOWER
, KEY ROTOR
STATOR
THROUGH-STUD
/ ROTOR
THROUGH-STUD
.
COVER
The tongs shown were made from one inch steel bar.
stock. The tongs should be a suitable size for han-
dling several different size stators.
Iz3
CAUT~ON Uie care to prevent damage to the fan
blades. Broken bladeswillthrow the fan
out of balanceand reduce the air flow rate.
0455
ALTERNATOR ASSEMBLY
Use care to prevent damage to the fan
Assemble alternator components in reverse order blades. Broken fan blades will throw the
from disassembly using additional instructions that fan out of balance and reduce the air flow rate.
follow:
1. Clean and inspect all mating surfaces. 6. Install two stator throughstuds in adapter for
2. Coat mating area between alternator bearing and aligning stator assembly over rotor during
end bell bearing hole with a thin film of Molykote assembly.
or equal. 7. Install baffle ring.
8. Install remaining two stator throughstuds in
3. Install rotor-through-stud in drive pinion shaft, if adapter.
it was removed.
9. Install stator and end. bell. Torque nuts on
4. Install rotor and fan assembly on adapter. Guide through-studs to 19 to 21 ft-lbs (26 to 28 Nom).
key ‘lotin fan Onto key in drive pinion shaft. A
raised line on the fan body casting indicates the 10. Torque down rotor-through-stud nut to 55-60 ft.
location of key slot inside. The drive shaft and key Ib. (75-81 Nom).
can be seen through the air outlet in the adapter. lnsta’l mounting feet and controlbox-
5. If they were removed, install exciter rotor and l2 Connect alternator Output and control leads
shaft bearing. Hold fan with wooden stick and according to appropriate wiring diagram.
torque shaft nut against exciter rotor 130to 15Oft. 13. Replace end bell cover.
Ibs. (176 to 203 Nom). 14. Replace control box cover.
*
GENERAL
YD generatorsets use several forms of control boxes
and panels as shown in Figures 69 through 72.
Instrumentation and control functions vary because
of set design,different needs of each installation,and
optional equipment ordered by the customer.
AC AMMETERS
*
For description and troubleshooting information on
the 30 kW SK engine DC controls, see Section 8Aof
Master Service Manual 900-0218.
FIELD
VOLTAGE ADJUST BREcKER
CIRCUIT AC
RHEOSTAT, VOLTMETER
RESET BUTTONS. \ \
LINE
CIRCUIT
BREAKER
PHASE
SELECTOR
WIT-
B218
FAULT LAMP
\ METER Pre-Heat Switch: Provides pre-heat conttol for
manifold heater and glow plugs for cold diesel engine
FIGURE 69. TYPICAL AIR-COOLED’AND MARINE starting.
SET CONTROL PANEL
Oil Pressure Gauge: Indicates pressure of lubricating
CONTROL PANEL COMPONENTS oil in engine (wired to a sensor unit located on the
. The following is a brief description of typical controls
and instruments on the face of the panels; these may
engine).
Frequency Meter: Indicates the frequency of the Line Circuit Breaker: Protects generator from line
generator output in hertz. It can be used to check overloads.
engine speed. (Each hertz equals 30 rpm.)
Water Temperature Gauge: Indicates temperature of
Wzrning Lights: Indicator lights are used on some circulating coolant in engine. (Wired to a sensor unit
controls to give warning of: located on the engine.)
\-/
RESEi
START PRIME WPTESl
STOP
REMOTE
@ @ @-
~~
MDTA SERIES
RUN
PRE HI ENG TEMP
PRE LO OIL PRES
LO ENG TEMP
8 0
HI ENG TEMP
m -
0 0
3 PHASE- VOLTAGE ADJUST RESET OVERSPEED
START PRIME LAMPTEST
OVERCRANK
LO OIL PRES
a
SWITCH OFF
REMOTE
1 PHASE
@@@
FlELLl CONTROL REMOTE
DTA SERIES
cycles for air-cooled and marine generator sets are tacts of K12 now opens the K11 start circuit. The NO
similar, however the gasoline and diesel-powered contacts of K12 close to connect B+ (via K14 con-
sets are different enough to be described separately. tacts) to the ignition circuit and fuel control .com-
ponents.
Prior to starting the generator set, check the fuel
supply, engine oil level, and all battery connections Stopping Sequence
for loose or broken wires. If an automatic demand Holding S11 in Stop position de-energizes K12 which
control is in use, check for correct connections. opens B+ circuit to the ignition system and fuel con-
trol components.
I 1- I
~~~
MOTE:
U L E S OTHERWISE 1I1)TED. ALL
COIPONEWTS ARE SHOW IN THE
~ M - E W ~ O Zmsiiiow.
ED
~~
Emergency Shutdown
Emergency Shutdown Relay K15is controlled by any
one of three switches: S1 low oil pressure, S2 high
Starting Sequence water temperature, and S3 overspeed. Contacts of
The following sequence of electrical functions occur K15 control two circuits: one normally closed set of
during the starting operation. Relay contact text ref- K15 contacts controls the fuel solenoid relay coil to
erences normally open (NO) and normally closed shut off the fuel supply to the engine; the other nor-
(NC) refer to position of contacts with the unit at rest mallyopensetclosestolightthe pilot lightandsetoff
(not energized). . the emergency alarm whenever the emergency shut-
down relay energizes.
With S12 in the Remote position, the operator can
start the set from a remote location, or by an auto-
matic demand control. Inthis position only is engine
preheating controlled automatically by 20 second
Time Delay Relay K17. Relay K17 is energized by B+
connected through the remote switch, and through CONTROL OPERATION
S12 in the Remote position.
(DTNMDTA SERIES)
Manual starting at the set involves the following Figures 76and 77show the PC board and DCcontrol'
sequence of electrical and mechanical functions: schematics for the solid state control. Relay contact
1. For cold engine starting, the Pre-Heat Switch S13 text references normally open (NO)and normally
is held in the Heat position for 30seconds if below closed (NC) referto position of contacts with the unit
55°F (13OC); 60 seconds if below 55OF. This at rest (not energized).
action energizes the Heater Relay K1 which con-
nects B+ to the manifold and glow plug heaters Starting Sequence
HR1-5. After proper pre-heattime, Sl3is released The start circuit is completed by switch S10 in the.
and the start circuit energized (Step 2). Start position. This action energizes On/Off Relay K2
, 2. The start circuit is completed when the selector which puts B+atStopSolenoid KSand Fuel Pump E l '
switch is moved to the Run position. This action (via contacts K2, K1 and J1-4). As K5 energizes, its
energizes Fuel Relay K11 via normally closed NC contacts open and allow the Starter Pilot Relay K4
contacts K14 and K15 (Cranking Limiter and to energize (via contacts K2, K1, K3, J1-6, K6, P1-16
Emergency Shutdown Relays). When K11 con- and K5 auxiliary coil to ground). The K4 contacts
tacts close, B+ energizes the following com- connect B+ to the Starter Motor Solenoid K and
ponents. cranking begins.
.'
I t I I
_- -- -.-
-. . I - ma
6
b
w
a
3
0
E
-
Check engine oil level. If OK, reset relay. Check oil
Is LOP emergency relay K14 tripped? pressure switch S4 and related wiring. ’
1 +
Check battery cables for clean and tight connections
Jumper battery cable B+ connection to 61starker + (ref. Checkout [B]). Check B7 starter solenoidand
solenoid terminal. Does engine crank? -
motor if bad, repair or replace.
With Si1 in Start position, does start solenoid K11 Check solenoid K11, relay K12, Start/Stop switch S11
energize? (Is at least 7 volts DC present between + and associated wiring and connections per Checkouts
K11 terminal S and ground?) P I , [El and [GI.
Is at least 7volts DC present between B1 starter Check wiring and connections between K11 terminal S
solenoid terminal and ground? and the solenoid terminal of 81.
L
Does fuel transfer pump El and solenoid K1 operate no Check relays K11, K12 and K14 per Checkouts [D]and
when SI1 is in Start position? [E].Check wiring. Replacetransfer pump El if defective.
Yes
3
I
I Isengine getting fuel? (Exhaust smoke should be
blue-whiie. and fuel flow steady from fuel return
line.)
Check fuel supply system: fuel tank, shutoff valves, fuel
lines and connections, fuel filters and pumps.
I
Is preheat system operating properly? - Check heatersolenoid K13 and switch S12per Checkouts
[D]and [GI.Check wiring and heater elements.
GASOLINE ENGINE
Is carburetor choke operation proper? -no-, Check electric choke components and wiring (if used).
.Adjust per Operator's Manual instructions.
I
Yes
' 1
I Is ample spark ignition voltage available at
spark plugs?
L
Check ignition components: points, condenser, plugs,
distributor, wiring, and HETCO. Battery voltage must
appear at coil during cranking. I
I
START
Connect voltmeter to other side of resistor R11 (either at Check resistor R11 per Checkout [FJ.If OK, check relay
relay KlPor Stop terminal of S11). Is batteryvoltage read K12 switch S11 and relatedwiring for short to
at rpm increase? ground.
Jumper normally open contacts of relay K12 no---, ' Check wire between relay K12 and ammeter M11.
Does engine start and run?
Yes
1
SWITCH CHECKOUT
RECTIFIER CHECKOUT
1. Remove battery B+ cable.
Disconnect one lead from, or remove, each rectifier
for its individual test. 2. Place ohmmeter leads across switch.
3. Activate switch. If meter reads continuity, switch
Note carefully the direction of mounting of is good.
any rectifier removed. I1must be remounted
in its original direction.
IMPORTANT!
KEEP ENTIRE FUEL SYSTEM CLEAN AND FREE FROM
WATER
DIESEL INJECTION PUMPS WILL FAIL IF SYSTEM
CLEANLINESS IS NEGLECTED
L
FUEL TRANSFER
INJECTION PUMPS AND NOZZLES ARE NOT FIELD
REPAIRABLE
.-
=
WHEN TROUBLESHOOTING. CHECK ALL OTHER
COMPONENTS FIRST FUEL RETURN
NE CONNECTION
WARNING DO NOT I E E ETHER STARTING
AIDS! ETHER IS EXTREMELY EX- INJECTION PUMP
PLOSIVE AND MAY CAUSE SERIOUS PERSONAL IN-
JURY. ENGINE DAMAGE IS ALSO LIKELY. .
BEFORE STARTING: I CHECK FUEL SUPPLY. BE SURE SHUTOFF VALVES ARE OPEN. I
PRIMEFUELSYSTEMIF:FUELFILTERSWERE DRAINEDOR CHANGED,
SYSTEM WAS JUST INSTALLED. FUEL TANK RAN DRY. I
a TO PRIME PUMP. MOVE PRIMING LEVER UP AND DOWN UNTIL FUEL
FLOWS STEADILY FROM RETURN LINE (DISCONNECTED).
TO START
I RELEASE PREHEAT ' ENGAGE START SWITCH
STOP
I LIMIT CRANKING TO 15 TO 20 SECONDS TO CONSERVE BARRY. ALLOW? MINUTE BEFORE RE- CRANKING. I '
IF ENGINE DOES NOT STARE IF ENGINE FIRED, REPEAT ABOVE PROCEDURES, INCLUDING PRE-
HEAT. IF IT STILL DOES NOT START, PROCEED AS FOLLOWS
I
TEMPERATURES BELOW 3 2 0 (ooc]:
I
~ USE NUMBER 1 DIESEL FUEL USE CORRECT VISCOSITY OIL.
KEEP BATTERIES FULLY CHARGED. DO NOT USE ETHER STARTING AID.
_. I
I
OBSERVE ENGINE EXHAUST "SIGNALS":
1I
I I
LITTLE OR NO EXHAUST SMOKE ENGINE IS NOT GETTING FUEL.
BLUE-WHITE EXHAUST SMOKE:
ENGINEIS GETTING FUEL PRIME FUEL SYSTEM AS SHOWN ABOVE
OBSERVE FUEL FLOW FROM RETURN LINE
I 1
I
I I
I
I
I
IF ENGINE IS STILL NOT GETTING FUEL, CHECK TRANSFER PUMP:
1. CRANK ENGINE AND OBSERVE FUEL FLOW FROM RETURN LINE.
2. IF FUEL DOES NOT SPURT OUT. PUMP MAY BE DEFECTIVE.
I IF ENGINE STILL DOES NOT START. CONTACT AUTHORIZED ONAN SERVICE REPRESENTATIVE I
Redistribution or publication of this document,
71 by any means, is strictly prohibited.
WIRING DIAGRAMS
The wiring and schematic diagrams in this section represent typical air-cooled, marine, and radiator cooled
engine driven YD generator sets. Wiring diagrams for special order generator sets are shipped with the units and
should be referred to whenever possible.
- -
NOTE:Special order generatorsets with optional specificationcodes such as, 4R-,4XR-, and 5 D R 60 Hertz: 5R and 55R 50 Hertz; and
- - - -
many others are basic 18R 60 Hertz or 518R 50 Hertz and 3C 60 Hertz or 53C 50 Hertz generators. Optional meter equipment and
voltage output capabilities change the specification codes of these units and each wiring arrangement is slightly different.
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4 t4 E TER - F R EQ U ENC 7 M5
3 METER-T I ME T O T A L I Z I NG 1.14
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NOTES:
A C SCHEMATIC - ELECTRONIC REG 50/60HZ
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REGULATOR-ASSY V O L T
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16
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
1-800-888-ONAN
612-!574-5000 International Use
Telex: 275477
Fax: 612-574-8087
Onan is a registered trademark of Onan Corporation