I

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Service
I

!
Ma.nual
i

! UR
I Generator I
r,

i
I

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I

I
I
I
.-

i UR Generator
I
:
I
with Torque Match-2'" Regulator
i

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I v
982-0002
I 3-87
i W M ii U S A
Redistribution or publication of this document
i by any means, is strictly prohibited.
1
 Safety Precautions
The following symbols in this manual highlight con- Do not work on this equipment when mentally or
ditions potentially dangerousto service personnel, or physically fatigued.
equipment. Read this manual carefully. Know when
these conditions can exist. Then take necessary
steps to protect personnel as well as equipment.
GUARD AGAINST ELECTRIC SHOCK
This symbol warns of immediate
hazards which will result in severe Disconnect electric power before removing protec-
personal injury or death. tive shields or touching electrical equipment. Use
rubber insulative mats placed on dry wood platforms
This symbol refers to a hazard or over floors that are metal or concrete when around
laWAR"Gj unsafe practice which can result in electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surfaces to be
severe personal injury or death.
damp when handling electrical equipment.
I
I
1- This symbol refers to a hazard or
unsafe practice which can result in
Disconnect batteries to prevent accidental engine
start. Jewelry is a good conductor of electricity and
personal injury or product or property damage. should be removed before working on electrical
equipment.
PROTECT AGAINST MOVING PARTS
Avoid moving parts of the unit. Avoid use of loose Use extreme caution when working on electrical
~ jackets, shirts or sleeves due to danger of becoming components. High voltages cause injury or death.
caught in moving parts.
Follow all state and local codes. To avoid possible
~

Make sure all nuts and bolts are secure. Keep power personal injury or equipment damage, a qualified
shields and guards ih position. electrician or an authorized service representative
must perform installation and all service.
If you must make adjustments while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.

I
EXHAUST GAS IS DEADLY! I
Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon
monoxide is poisonous and can cause unconsciousness and death. Symptoms of
carbon monoxide poisoning can include:
I
1 a Dizziness Throbbing in Temples
a Nausea Muscular Twitching
j a Headache Vomiting
' a Weakness and Sleepiness Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT

INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical atten-
tion. Shut down the unit and do not operate until i t has been inspected and
repaired.

Protection against carbon monoxide inhalation includes proper installation and

regular, frequent visual and audible inspections of the complete exhaust system.

ii
Redistribution or publication of this document
by any means, is strictly prohibited.
 Table of Contents
SECTION TITLE PAGE

SAFETY PRECAUTIONS ................................................................. ii

1 INTRODUCTION ...................................................................... 1-1
About This Manual .................................................................. 1-1
Test Equipment ..................................................................... 1-1
How to Obtain Service .............................................................. 1-1
2 GENERATOR AND VOLTAGE REGULATOR ............................................. 2-1
Generator Description ............................................................... 2-1
Generator Operation ................................................................ 2-6
Voltage Regulator Description ........................................................ 2-7
Voltage Regulator Adjustments ........ ..............................................
: 2-7
3 GENERATOR/REGULATOR TROUBLESHOOTING ...................................... 3-1
Control Locations................................................................... 3-1
Preparation ........................................................................ 3-1
Troubleshooting Procedures ......................................................... 3-1
.
Flow Chart A No AC Output Voltage at Rated Engine Speed ............................ 3-2
i Flow Chart B. Unstable Voltage. Engine Speed Stable at Rated Speed .................... 3-3
Flow Chart C. Output Voltage Too High or Too Low .................................... 3-3

I
i
~
Flow Chart D. Exciter Field Breaker Trips..............................................
Flow Chart E. Unbalanced Generator Output Voltage ...................................
Flow Chart F. No AC Output Through Set Mounted Circuit Breaker .......................
3-4
3-5
3-6
.1

I
! 4 GENERATOR/REGULATOR TESTSIADJUSTMENTS .................................... 4-1
(A) Testing AC Residual Voltage ...................................................... 4-1
(B)Flashing the Field................................................................ 4-1
I
(C) Voltage Regulator VRAS-2 Replacement ........................................... 4-2
1
! ................................................
(D) Testing Rotating Rectifiers (Diodes) 4-2
............................................................
(E) Testing Exciter Stator 4-3
~

.............................................................
(F) Testing Exciter Rotor 4-3
(G) Testing Generator Stator......................................................... 4-4
(H) Testing Generator Rotor.......................................................... 4-5
i
(J) Wiring Harness Check ............................................................ 4-6
(K) Voltage Regulator VRAS-2 Adjustment ............................................. 4-6
(L) Generator Voltage Adjust (R21).................................................... 4-6
(M) Testing Circuit Breaker.......................................................... 4-7
5 GENERATOR DISASSEMBLY/ASSEMBLY .............................................. 5-1
Generator Disassembly .............................................................. 5-1
Generator Assembly ................................................................ 5-2
6 WIRING DIAGRAMS .................................................................. 6-1

iii Redistribution or publication of this document

by any means, is strictly prohibited.
 Section 1 Introduction
ABOUT THIS MANUAL HOW TO OBTAIN SERVICE
This manual provides troubleshooting and repair infor- In the event the generator requiresservicing beyondthe
mation for the Onan series UR generator with a Torque scope of information contained in this manual, contact
Match-2 (VRAS-2) voltage regulator. For further opera- an Onan Distributor for assistance. Onan factory trained
tion, service, and troubleshooting informationregarding Parts and Service representatives are ready to handle
engine or controller components, refer to support man- all your service needs.
uals specific to your generator set.
When contacting an Onan Distributor, always supply
Study all manuals carefully and observe all warnings the complete Model number and Serial number as
and cautionsfound on page ii and throughoutthis man- shown on the Onan nameplate. The Onan nameplate is
ual. Knowing your generator set, using it properly, and located on the side of the generator control box. I
I

following a regular maintenance schedule will help you

-
obtain longer unit life, better performance, and safer
operation.

Repair information in this manual for printed circuit

board components other than fuses is not extensive as
solid state printed circuit boards lend themselves more
to replacement than repair. Application of meters or hot
soldering irons to printed circuit boards by other than
Service Rating:
I
qualified personnel can cause unnecessaryand expen-
sive damage. Repair of the printed circuit boards is not
I recommended except by the factory.

High voltage testing or high potential

11 ACAUT~ON (or Megger) .testing of generator
I 1
windings can cause damage to solid state compo-
nents. Isolate these components before testing.

TEST EQUIPMENT
Most of the test procedures in this manual can be per-
formed with an AC-DC multimeter such as a Simpson
Model 260 VOM or a digital VOM. Some other instru-
ments to have available are:

Onan Multitester
Jumper Leads M-1641

I AC Voltmeter
0 DC Voltmeter
0 Frequency Meter FIGURE 1-1. ONAN NAMEPLATE
Wheatstone or Kelvin Bridge

See Onan Tool Catalog 900-00

IAWARNI_NG_ I
INCORRECT INSTALLATION, SERVICE, OR REPLACEMENT OF PARTS CAN
RESULT IN SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE.
SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND
MECHANICAL COMPONENT INSTALLATION.

1-1 Redistribution or publication of this document

by any means, is strictly prohibited.
 Section 2. Generator and
Voltage Regulator
I GENERATOR DESCRIPTION ~

The UR generator is a four pole, revolving field genera- AC output leads extending from the stator housing are
tor designed for 1500 (50 Hz) or 1800 (60 Hz) r/min tapped with control wires (leads: 4,7,8,9 and IO). These
operation. Excitation is provided with a brushless exci- control wires are routed into the control box and used
ter mounted inboard of the generator endbell. The for control input and metering, Figure 2-3.
generator rotor is directly coupled to the engine fly-
wheel with a flexible drive disc. Engine speed deter- The brushless exciter stator mounts in the end bell while
mines generator frequency. A centrifugal blower (on the the exciter rotor and its rotating rectifier assemblies
drive disc) circulates dkcharged air through an outlet in mount on the generator rotor shaft. Within the endbell,
the blower end. See Figure 2-1. leads F1+ and F2- from the exciter stator winding are
connected to the output terminals of the voltage regula-
As specified in Voltage/Current Options, Table 2-1, tor, Figure 2-3. ~~

generators are reconnectible to provide the listed volt-

age options. Output rating is 0.8 PF. See Figure 2-2 and
Table 2-1.__
~~

I
BLOWER STATOR ROTOR END BELL BRUSHLESS
EXCITER STATOR

ROTATING
RECTIFIER
I

I D

I
II

BRUSHLESS
EXCITER ROTOR

/ G-1180
SCREEN

FIGURE 2-1. UR GENERATOR

2-1 Redistribution or publication of this document

by any means, is strictly prohibited.
 VOLTAGE CODE:
T OR7 - 2201380 VOLT. 3 PHASE M) HERTZ
-
"H" OR 9X 347/600 VOLT.3 PHASE 60 HERTZ

CONNECTION GENERATOR CONNECTION W I R I N G D I A G R A M

/
SCHEMATIC (WITH CURRENT TRANSFORMERS WHEN USED)
DIAGRAM

LO 11 12

LO

1 1 1 2 16 111 18 112 14 19 1 s 17 13 110

LO 12

I. 13 11 110 16 17 12 111 14 18 13 112 15 19

LO 11 12 13

- 13 4 16 111 12 18 13 19
110/190 3 50 15 110 11211 l7
R 32
115/200 3
--
50

240/416 3 bo
I L 15 254/k40 3 bo
LO 11 12 13
277beo 3 bo
-I

22#380 3 50
w

515'
30/400 3 50
5 LO

I
240/416
254/440
3

3 50
50
- 19
VI

220/380 3 60 110Tll 112 11 17 14 12 18 15 13 19 11

R 32
230/400 3 60
-
R 523 2001346 3
- 50

NOTE This figure is for reference only. Refer to electrical schematic specific to your generator for further connection information.
ES-1567

FfGURE 2-2 VOLTAGE CONNECTIONS

Redistribution or publication of this document

by any means, is strictly prohibited.
c
Ba
a
3'
0
3
Q
2
g
>
i'

iai
13

41 x x x x x x x x x x x X X x x x x x

W
I x x x x x Z x x x x x x x x x x x

0
z
F
4
K

2-3 Redistribution or publication of this document

by any means, is strictly prohibited.
 FIGURE 2-3 is a composite Nustration showing four output leads for
single-phase units, 12 output leads for 3-phase broad range units, 0 The magnetic trip action of the circuit breaker is
and four output leads for c o d e 7, F, 9X and H 3-phase generators. caused by an electromagnet which partially sur-
rounds the internal bimetal strips. In the event of a
CONTROL AND
short circuit, the high current through the electro-
magnet will attract the bimetal armature and trip the
breaker. Some circuit breaker models provide front-
adjustability of the magnetic trip action. These adjus-
tors are normally set at the factory at the high position,
10(2*1 4
but provide for individual conductor settings to suit
customer requirements.

The shunt trip mechanism (if equipped) consists of a

TO VOLTAGE solenoid tripping device mounted in the circuit
' REGULATOR breaker and external lead connections for remote
CIRCUIT
signaling. A momentary signal to the solenoid coil will
cause the breaker to trip.
__
This feature is available inAC and DC voltages, and is
normally installed at the factory to meet customer
requirements. 'For paralleled generator set installa-
' tions, the shunt trip mechanism is most often con-
nected to a common fault shutdown circuit of the
*SINGLE-PHASE ONLY generator set; in order to quickly disconnect the set
ES-1315
from the load during a fault shutdown and thereby
I FIGURE 2-3. SINGLE AND THREE PHASE GENERATOR
SCHEMATIC (COMPOSITE)
avoid a reverse power condition. Refer to site
requirements for further information regarding the
I -~ ~
intended use of this feature.
Optional Circuit Breaker 0 Auxiliary contacts (if equipped) consist of a set of
Depending on site specifications and any applicable contacts (one normally-open, and one normally-
code requirements, an optional circuit breaker may be ' closed) iptended for local or remote annunciation of
mounted on the generator housing. The location of the breaker status. Refer to site requirements and proper
circuit breaker varies by generator set application, wiring diagram for further information. I
either side or top mount.

, All Onan supplied circuit breakers are thermal and

0 The trip actuator.is for periodic exercise of the
breaker to clean and maintain its proper operation. I
' magnetic trip type. Depending on customer require- i Rotating this actuator mechanically simulates over-
ments, the circuit breaker may also include shunt trip current tripping through actuation of linkages not
and remote alarm connections. Review the following operated by the On/Off handle. Refer to Section 4 -
and refer to Figure 2-4. Tests/Adjustments for further information. I

0 Generator set output is connectedto the load through i 0 Operation of the circuit breaker is determined bysite-
the circuit breaker. 1 established procedures. In emergency standby
installations, the circuit breaker is most often placed
0 When an overload or short circuit occurs on any one to the On position, and is intended for safety trip
conductor, a common trip bar will disconnect all three actuation in the event of a fault condition. When9he
conductors. breaker is caused to trip open, operator action is
required; firstly, to investigate the cause of the trip
0 The thermal trip action of the circuit breaker is and perform remedial steps required (see Trouble-
accomplished by bimetal strips (inside breaker). A shooting), and secondly, the circuit breaker handle
sustained overcurrent condition will cause a thermal I must be placed to the Reset position and then to On to
reaction of the bimetal, and thereby trip the breaker. reclose 'the breaker. Refer 'to Troubleshooting, and
Response of the bimetal is proportional to current; 1 Tests/Adjustments sectionsfor further information.
high current - fast response, low current - slow
response. This action provides a time delay for nor- 1

mal inrush current and temporary overload condi-'

tions (i.e., motor starting).

2-4 Redistribution or publication of this document

by any means, is strictly prohibited.
 I-- --
TOP MOUNT

...
\
-5.
\
... 1

\
\
\
\
\
\
AUXILIARY CONTACT SHUNT TRIP
~

B + COMMON ALARM
C OA M ML
G- GROUND
~
1 SIDEMOUNT '
n
I
I
TRANSFORMER

SHUNTTRIP ,
+ COMMON ALARM

AljXILIARY CONTACTS
RESET e

LOAD _ - -
I
-
~~
~

' SIDE VIEW HANDLE POSITIONS I I

, ES-1564-1 \
j FIGURE 2-4. GENERATOR-MOUNTED CIRCUIT BREAKER ~

2-5 Redistribution or publication of this document

by any means, is strictly prohibited.
 GENERATOR OPERATION 3. Single-phase AC voltage is taken from the main
With the generator directly coupled to the engine fly- stator winding and fed to theTorque Match-2 Volt-
wheel, full rated output voltage is accomplished in a age Regulator WRAS-2) as a reference voltage.
matter of seconds. The following briefly describes 4. The voltage regulator compares the input with the
generator operation and voltage regulator interaction, preset requirements, rectifiesAC to DC, and sends a
in reference to Figure 2-5. DC voltage to the exciter field.
5. The exciter stator field inducesvoltage in the exciter
Refer to Voltage Regulator Description for further spe- rotor.
cifics regarding regulator operating modes. 6. Three-phase AC voltage is tapped from the exciter
-
and fed to the rotating full-wave bridge rectifiers.
1. Demandfor power startsthe engine, thereby turning
7. DC voltage from the rotating rectifiers is fed to the
the generator rotor. main field of the generator rotor.
2. Residual magnetism in the rotor's main field, indu- 8. The main field continues to build until rated (or
ces voltage in the main stator. preset) voltage is reached.

- - -*-

* FULL WAVE
BRIDGE
RECTIFIERS

-- STATOR
BRUSHLESS EXCITER
FIELD r
I
VOLTAGE LOAD
REGULATOR

2-6 Redistribution or publication of this document

by any means, is strictly prohibited.
 VOLTAGE REGULATOR DESCRIPTION setfrom stalling during momentaryoverload conditions,
The design of the Torque Match-2 Voltage Regulator and is not recommended for use. Consult an Onan ser-
(VRAS-2) provides switch selections that alter its sens- vice representativebeforeselecting thisvoltage regula-
ing and command signals in orderto achieve maximum tion mode to ensure that load demands specific to your
operating performance in a variety of generator sizes installation would not cause an unstable operation of
and applications. Review the following, then refer to the generator set.
1 Voltage RegulatorAdjustments for switch locations and
settings specific to your generator set model. Operating Stability
Becauseof the differences in exciter and main field time
Operating Modes constants, different gain compensation is required for
Torque-Matching:In most applications, in order for the the various generator sizes and applications. The
generator set to accept the application of a large VRAS-2 voltage regulator is switch-selectable to a kW
momentary overload, such as motor starting, matching range of operation that best suits the generator set
the torque characteristicsof the engine and generator is application.
required.
VOLTAGE REGULATOR ADJUSTMENTS
Because of the differences in engine characteristics, The VRAS-2 Voltage Regulator is shown in Figure 2-6.
different torque matching may be used for various There are three switches that require actuation and two
enginelgenerator combinations.The switch-selectable potentiometers on the voltage regulator as follows:
design of the VRAS-2 provides Onan the flexibility to test
and set the torque-matching function to best suit each 0 Switch SI - Selects the overall range of operation
enginelgenerator configuration. for the regulator. Refer to Table 2-2.
When set to the proper torque-matching switch set-
tings, the VRAS-2 voltage regulator is able to maintain
0 -
Switches S2and S3 Determinethe mode of regula-
' tion (Torque-Matched, or Non-Torque-Matched).
output voltage, within reasonable limits, by reducing the Refer to Table 2-2.
voltage just enough to take full advantage of the
engine's full available power under transient conditions 0 Potentiometer R32 - Provides adjustability to in-
and prevent an unstable response.
1
crease or decrease generator voltage to achieve
I
proper setting.
j Non-Torque-Matching:Eventhough the voltage regula-
1
~ tor can also be switch-selected to a non-torque-
matching constant voltage mode, independent of
0 -
Potentiometer R34 Is adjusted at the factory to set
the frequency breakpoint, and does not require
~ engine speed, this mode will not prevent the generator further adjustment.

2-7 Redistribution or publication of this document

by any means, is strictly prohibited.
 TABLE 2-2. VRAS-2 SWITCH SEITINGS
REGULATION MODE
STABILITY
GENSET RANGE 60 HZ 50 Hz NON-
kW TORQUE-MATCHING TORQUE-MATCHING TORQUE-MATCHING
RATING S1-1 S1-2 S2 S3-1 53-2 S2 53-1 S3-2 52 S3-1 S3-2

20-35 OFF OFF POS2 OFF ON POS2 ON ON POS2 OFF OFF

40-50 OFF ON POS2 OFF ON POS2 ON ON POS2 OFF OFF
60-100 ON OFF POS2 OFF ON POS2 ON ON POS2 OFF OFF
150-180 ON ON POS2 OFF ON POS2 ON ON POS2 OFF OFF

^. .

s3
R34 SC-1516-2
TB1-2, -3 AC INPUT VOLTS
TBI-3. -4 CROSS-CURRENT COMPENSATION
TBI-7. -8 VOLTAGE ADJUSTING RHEOSTAT
TB1-9. -10 EXCITER FIELD
F1 -TBI-9
F2 -TBI-10

F~GURE2-6. VOLTAGE REGULATOR

2-8 Redistribution or publication of this document

by any means, is strictly prohibited.
 Section 3. Generator/Regulator
Troubleshooting
To prevent meter damage,
ohmmeter checks mustbe made
with the unit stopped.

' Generator Set Outnut Circuit Breaker: Mounted on out-

side of generator iontrol output box housing.
TROUBLESHOOTING PROCEDURES
The information in this section is divided into Trouble-
shooting Flow Charts as follows:

-
Voltage Regulator VRAS-2: Inside control box. A. No AC Output Voltage at Rated Engine Speed.
Terminal Board TB21: Inside control box. B. Unstable Output Voltage, Engine Speed Stable at
Field Breaker CB21: On AC control box door. , Rated Speed.
, Current Transformer CT21,22, and 23: Inside housing,
~ behind control box. C. Output Voltage Too High or Low.
I Rotating Rectifiers: Inside generator end bell, beneath D. Exciter Field Breaker Trips. I
control box. E. Unbalanced Generator Output Voltage. I
Accidental generator set starting can F. No AC Output Through Set Mounted Circuit
l3!iEEl result in severe personal injury or
death during service procedures. Disconnect battery
Breaker.
To troubleshoot a problem, determine the problem and
cable before performing any checks on generator. then refer to the appropriate troubleshooting flow chart.
Start at the upper left-hand corner of chart, and answer
PREPARATION all the questions with either a YES or NO. Follow the
A few simple checks and a proper troubleshooting chart until the problem is found, performing the refer-
procedure can locate the probable source of trouble enced Adjustment and Test Procedures following the
and cut down service time. flow charts.

1. Check all modifications, repairs, and replacements The referenced components in the flow charts and in
performed since the last satisfactory operation of the Adjustment and Test Procedures can be found on
the set to ensure that all generator leads are cor- the electrical schematic in Figure 3-1, and on assembly
rectly connected. A loose wire connection over- and wiring diagrams.
looked when installing a replacement part could
cause problems, as could an incorrect connection, I
an opened circuit breaker, or a loose connection on
a printed circuit board. A thorough visual check can 1
quickly eliminate these potential problems. This figure is for reference , I
2. Visually inspectthe components of Voltage Regula- only. Use electricalschematic
specific to your application
tor VRAS-2. Look for dust, dirt, or moisture and when troubleshooting. , ;
cracks in the printed solder conductors. Burned
resistors and arcing tracks are readily identifiable. I
Do not mark on PC boards with a pencil; graphite I
I lines conduct and can cause leakage or short cir-
cuits between components.
3. Visually inspect the exciter rotor assembly for
I
I burned components, broken wires, loose connec-
tions, and carbon tracks caused by arcing between
~
parts or between parts and ground. Also check for
shorted paths between terminals caused by dust,
dirt, and moisture.
Unless absolutely sure that panelinstrumentsare accurate, use
portable test meters for troubleshooting.

-5 LI"C # '
-I
FIGURE 3-1. ELECTRICAL SCHEMATIC
(Includes Detector AC Meter Option)

3-1 Redistribution or publication of this document

by any means, is strictly prohibited.
 FLOW CHART A. NO AC OUTPUT VOLTAGE AT RATED ENGINE SPEED

I
I ,
Is control panel field breaker CB21 on
(fully-in position)?
I 1
Replacedefectivefield breaker.
A
T

No

I
I
I t
Remove one lead from breaker and
check continuity with ohmmeter. Is
breaker open? -
Push to reset breaker. Does generator If voltage is unstable, high or low, or
AC output voltage build up?
c causes breaker to trip, see Flow Charts .
B, C, D or E.

I I Yes
No I I 1 1

+
Flash exciter field per TEST (B). Does
generator output voltage build up? I
Is residual voltage across TB21-22 and
23 equal to 5 to 10 VAC or more per
TEST (A)?

- Yes across the leads 5 to 10 VAC or more

I
Yes
I
2iTB1-2 and T7 on the generator and
between VRAS-2iTB1-3 and generator

I , lead T8 as per TEST (J).

I
Yes
I I Check exciter field wiring for shorts per
TEST (J). Replace bad wiring.
I
Check exciter field wiring for opens per
TEST (J). Replace bad wiring. rotor per TEST (D). Replace if bad.

Replace voltage regulator VRAS-2 per

procedure (C).

I
Check exciter field winding per TEST
(E). Replace if bad.
I
I Check exciter rotor winding per TEST
(F). Replace if bad.
1
I
I

To avoid possible damage to new

1- regulator board, do not replace Volt-
age Regulator VRAS-2 until external trouble has been
Check generator stator windings per

~-

3-2 Redistribution or publication of this document

by any means, is strictly prohibited.
 FLOW CHART B. UNSTABLE VOLTAGE, ENGINE SPEED STABLE AT RATED SPEED.
I

Check wiring harness from regulator

assembly to end bell per Test (J). Check
ok?
-NO Repair wiring or replace as required.

Check voltage regulator adjustment/ Is voltage stable within specifications

switch settings per adjustment (K). Yes at no load to full load range of
Check ok? generator set?

Replace Voltage Regulator VRAS-2

per procedure (C). To avoid possible damage to new
regulator board, do not replace Volt-
age Regulator VRAS-2 until external trouble has been
corrected.

FLOW CHART C. OUTPUT VOLTAGE TOO HIGH OR LOW.

-
~

Are generator output connections Refer to Generator Description,

Optional Voltage Connections, and
correct and secure?

Check condition of rotating diodes. l e s t rotating diodes per TEST (D).

Visually inspect for loose connections. No Replace if defective.
faulty diodes, etc. Check ok?

3-3
Redistribution or publication of this document
by any means, is strictly prohibited.
 FLOW CHART D. EXCITER FIELD BREAKER TRIPS.

,
1 , Does AC output voltage build up
t o 150% o r more of rated voltage Yes t
Check for any loose or broken wires
or connections on VRAS-2 assembly.
before breaker trips?
J J
NO

Check diodes in rotor assembly

I Check Voltage Regulator adjustments
per Test (D). Replace if bad. and connections per Test (K).

c 1
Check exciter stator winding
per Test (E).Replace if bad. Check generator stator leads for
proper, and secure connection. Refer
to Generator Description, Optional Voltage
i Connections, and appropriate electrical
schematic.

I Check exciter rotor winding

per Test (F). Replace if bad.
I
winding per Text (H). Replace

‘I I
Check generator stator windings
per Test (G). Replace if bad.

+ 1

, I
I
Replace voltage regulator VRAS-2
per procedure (C).
1
I
J 1

To avoid possible damage to new

regulator board, do not replace Volt- ,
age Regulator VRAS-2 until external trouble has been I
corrected.

3-4 Redistribution or publication of this document

by any means, is strictly prohibited.
 FLOW CHART E. UNBALANCED GENERATOR OUTPUT VOLTAGE

Remove load at generator terminals. Is output

still unbalanced? redistribute load.

S
I Check for correct grounding of generator
and load. I
t _I I i

Are generator leads connected and

Correct as necessary.
grounded properly?

3-5 Redistribution or publication of this document

by any means, is strictly prohibited.
 FLOW CHART F. NO AC OUTPUT THROUGH SET MOUNTED CIRCUIT BREAKER.

Is set-mounted output breaker at

Tripped position?
- ~ -
I
&-(
J
Is set-mounted output breaker at
OFF position? 1I
I L
Yes
7-
I-
Detsmine cause of breakertrip.If not
immediately known, stop generator
I Confirm that no maintenance is
being performed, or other
set and investigate cause of breaker purpose for breaker at OFF
tripping. position, and that set is available
0 Circuit overload (per site- for use.
established procedures).
0 S h o r t c i r c u i t (per site-
established procedures).
0 Shunt trip (check for generator
set fault shutdown, or other sig- '
nal source).
If set is operating and available
for use, place breaker handle to
ON position. I
1 j Review Testing Circuit Breaker in
section 4. .1 ~. I I
Correct fault condition and reset 1
circuit breaker to ON position.
I I:

3-6 Redistribution or publication of this document

by any means, is strictly prohibited.
I
Section 4. Generator/Regulator
~ Tests/Adjustments
3. Check generator voltage, and shut down generator
set. Restart generator set and run at no load. Unit
should be used for testing generator and regulator must build up voltage without field flashing. If not,
components in conjunction with the troubleshooting shut down generator set and perform continuity
flow charts. All ohmmeter tests must be made with the check of all related wiring.
unit stopped to prevent meter damage.
With Generator Set Shut Down

1. Touch the positive battery lead to TB1-9 and the

TESTING AC RESIDUAL VOLTAGE negative lead to TBI -10 of VRAS-2.
Generator residual AC voltage should be checked first if 2. Hold the leads in place for no longer than 5 seconds.
there is no AC power output. A good place to check is at 3. Start generator and run at no load. Unit must build
terminal blockTB21,across terminals 22 and 23. Resid- up voltage without field flashing. If it does not, shut
ual voltage should be 5 to 10 VAC (no-load) at normal down generator set and perform continuity check of
operating r/min. If none, flash the field following the all related wiring.
instructions in Test B. i

If residual voltage is present at TB21, then check the

' Incorrect field flashing proce-
dures can damage regulator. Do
continuity of circuit breaker CB21. If CB21 is okay, pro- not maintain field flash connection to exciter cir- 1
ceed to voltage regulator VRAS-2 and check for resid- cuit longer than 5 seconds.
ual voltage between terminal numbers 2 and 3. If none,
check continuity between these points with the genera-
tor set shut down.

PLACE RESISTOR HERE FOR

FLASHING THE FIELD 12V OR 24V BATTERY

If output voltage does not build up, it may be necessary

10 4 DC
to restore residual magnetism by flashing the field. This TO ,SOURCE
12 AMP.
requires a 6-volt battery and a 12-ampere 300-volt VRAS-2
300 V.
TB l
diode wired as shown in Figure 4-1. TERMINAL.S DIODE

A 3-volt source will also work, as will a 12- or 24-volt

source. However, if a 12- or 24-volt source is used, a
2-watt, 20- or 40-ohm resistor, respectively, must be in
series with the diode to drop the voltage to 6-volts.

Flashing the field can be accomplished with generator

set operating or not. Either of the following procedures
should be sufficient to restore residual magnetism.
6 VOLT
DRY CELL
With Generator Set in Operation BATTERY

1. Start the generator set and operate at normal rimin.

2. Touch the positive battery lead to TBI -9 of VRAS-2,
and the negative lead to TBI -10. Hold the leads in
place just long enough for the voltage to build up to
FIGURE 4-1. FIELD FLASHING CIRCUIT
the normal operating level, then remove the leads.

4-1 Redistribution or publication of this document

by any means, is strictly prohibited.
 OHMMETER
VOLTAGE REGULATOR
VRAS-2 REPLACEMENT
Use the following procedure for replacing the voltage
regulator assembly:

1. Stop the engine, and disconnect starter batteries.

2. Disconnect, and if necessary label the wires from
VRAS-2/TBl. Refer to AC control wiring diagram.
3. Remove the mounting screws, replace old VRAS-2
with new, and secure in place with mounting
screws.
4. Reconnect wires removed in step 2 to proper
terminals.
5. Perform voltage regulator adjustment/switch set-
tings for specific voltage and method of regulation
desired per procedure (K).

TESTING ROTATING
RECTIFIERS (DIODES)
The six diodes mount on the rotating exciter assembly
and are tested as follows:
LEAD
1. Disconnect one diode at a time by removing diode
from heatsink.

A. Use proper size wrenches to hold the diode

body while removing the nut. -1569

B. Push the diode free of the heatsink mounting

hole. i FIGURE 4-2. TESTING DIODES

Escessive dust or dirt on

I I k@@@l diodes and other components
will cause overheating and eventual failure. I
Keep these assemblies clean! 3. To replace diodes, use the following procedure:

A. Unsolder leadwires of defective diodes from

2. Test that diode before proceeding to the next one. I
flag terminals.
I
i B. Insert new diode into heatsink mounting hole.
A. Use an accurate ohmmeter to check the resist-
ance of the diode. Connect one lead to the flag Using nut and washer provided, secure diode to
of the diode and the other lead to the stud. See heatsink.
I Figure 4-2. Observe reading. C. Use proper size wrenches to hold the diode
B. Now reverse leads and again observe reading. body while tightening the nut. Torquediodes on
A good diode should have a much higher read- rotating exciter assembly to 24 in-lb (2.7 Nom).
ing in one direction than the other. If both read- D. Solder leadwires to new diode flag terminals.
ingsare high or if both readings are low, diode is
defective and must be replaced with a new, Excessive heat on these rec-
identical part. tifiers (diodes) will destroy
them. Use a 40 watt soldering iron. Hold a
needlenose pliers between diode and solder-
ing point to prevent destructive heating.

4-2 Redistribution or publication of this document

by any means, is strictly prohibited.
 TESTING EXCITER STATOR TESTING EXCITER ROTOR
Testing for Grounds
Testing for Grounds Remove diodes CRI, CR2, CR3, CR4, CR5, and CR6
Using an ohmmeter (R x 100scale), measurethe insula- from diode heat sinkassemblies. Using an ohmmeter (R
tion resistance between either lead F1 or F2 and the x 100 scale), measure insulation resistance between
laminations. A reading of less than one megohm indi- any of the leads and the laminations (excludethe diodes
cates a ground. from the test circuit). A reading of less than one megohm
indicates a ground.

Testing Winding Resistance

OHMMETER, Using a Kelvin Bridge meter, measure resistance
between leads pairs T I -T2, T2-T3, and T I -T3. Resist-
ance should be 0.464 to 0.567 ohms at 20°C (68OF). See
Figure 4-5. -
I
-

! 88-1574
I
CRI CR4

FIGURE 4-3. TESTING EXCITER FIELD

I

, Testing Winding Resistance

~ Measure coil resistance between leads F1 and F2 with
~ an ohmmeter (scale R x 1). Resistance should be
approximately 20 ohms at 20°C (68°F).

dR5

ES-1573

FIGURE 4-5. TESTING EXCITER ARMATURE

ES-1575

FIGURE 4-4. TESTING EXCITER FIELD

4-3 Redistribution or publication of this document

by any means, is strictly prohibited.
1
I
1

TESTING GENERATOR STATOR Measure resistance of windings using a Kelvin Bridge

Testing for Grounds meter. Refer to Figure 4-6 and Table 4-1. If any windings
are shorted, open, or grounded, replace the stator
Before testing stator, disconnect control wire 4,7, 8, 9, assembly. Before replacing the assembly, check the
and 10 from TB21. Isolate from ground and each other. leads for broken wires or damaged insulation.
Connect all stator output leads (Tl -T12) together. Use Stator output leads 14,T7, T8, T9 and T10 are intercon-
an ohmmeter set on the R x 100 scale and measure the nected (within the stator) to five stranded #10 aircraft '
insulation resistance between these windings and the control wires. These wires are labeled 4,7,8,9,and 10
II stator frame. A reading of less than one megohm indi-
cates a ground. Field circuit breaker can b e either open
or closed for this test.
respectively and terminate at TB21 (terminals22-26).

KELVIN
FROM
Testing for Shorts BRIDGE

I To check for shorts between individual windings, first

refer to electrical schematicto determine individual coil
lead wires (T1-T4, T7-T10, etc.). Be sure to disconnect
the instrumentation leads and stator leadsT4,T7,T8, T9,
and T10. Connect an ohmmeter, R x 100 scale, to one
lead of a stator winding (leaving the other end of coil
winding being tested open), and the other ohmmeter
lead to all other stator leads connected together.
Example:
I
Ohmmeter lead to: T1 coil winding lead. I
Ohmmeter lead to: T9, 12, 7,10, 2, 5, 3, 6, 8, and 11 I
ES-1572 I
connected together. I
~

',

I
' 0 Coil windings lead T4: Open

A reading of less than infinity indicates a short. Repeat

test for all six coils. ,
l FIGURE 4-6. TESTING STATOR WINDINGS
~

TABLE 4-1.
1 RESISTANCE VALUES FOR STATORS*
I

kW RATING VOLTAGE CODE (Resistance in Ohms)

I
1
7 L,R,15, & 32 E&6D

I 25.0 30.0 0.1 16-0.1 41 0.425-0.520 0.432-0.528

40.0 0.047-0.058 0.284-0.348
37.0 45.0 0.047-0.058 0.1 93-0.236 0.202-0.248
40.0 50.0 0.047-0.058 0.193-0.236 0.1 50-0.1 84
55.0 0.028-0.035 0.1 50-0.1 84
I 45.0 55.0 0.038-0.047 0.1 56-0.1 91 0.1 50-0.1 84
50.0 60.0 0.028-0.035 0.113-0.138 0.1 11-0.135
55.0 65.0 0.028-0.035 0.1 13-0.138 0.1 11-0.1 35

I 60.0
70.0
75.0
75.0
85.0
90.0
0.022-0.027
0.019-0.024
0.019-0.024
0.089-0.108
0.072-0.089
0.072-0.089
0.094-0.1 14
0.074-0.090
0.057-0.069
80.0 100.0 0.015-0.01 8 0.054-0.067 0.057-0.069
95.0 115.0 0.012-0.015 0.045-0.055 0.054-0.066
I
110.0 125.0 0.009-0.01 1 0.039-0.048 0.040-0.048
115.0 140.0 0.009-0.01 1 0.039-0.048 0.039-0.047
125.0 150.0 0.0075-0.0092 0.027-0.033 0.039-0.047
140.0 170.0 0.0059-0.0072 0.01 8-0.023 0.024-0.030
145.0 175.0 0.0059-0.0072 0.01 8-0.023 0.024-0.030

, * - All resistances should be within the values shown at 20% (68OF)

I Use an accurate instrument such as a Kelvin Bridge for this test

I T l-T4
T9-T12
T7-T10
T2-T5
T3-T6
T8-T11
I 4-4 Redistribution or publication of this document
by any means, is strictly prohibited.
1
 TESTING GENERATOR ROTOR Testing for an Open Circuit
Testing for Grounds
Use an ohmmeter (R x 100 scale) and measure as 1. Disconnect and test between F1 and F2 leads. See
follows: Figure 4-8.
2. Refer to resistance values given in Table 4-2.
1. Disconnect F1 and F2 rotor leads from the rotating 3. Replacethe rotor if it is grounded or has an open or
diodes. short.
2. Measure between either lead and the rotor shaft.
See Figure 4-7.
3. A reading of less than one megohm indicates a
ground.

0 H M M ETER

CONTACT ONE PROD TO ONE FIELD LEAD A N D

~ T H E SECOND PROD T O T H E OTHER FIELD LEAD
ES-1571

C O N T A C T ONE PROD T O EACH O F T H E FIELD

LEADS A N D T H E OTHER PROD T O T H E ROTOR 1 FIGURE 4-8. TESTING ROTOR FOR AN OPEN CIRCUIT
SHAFT.
IF ROTOR I S GOOD THERE S H O U L D B E NO
READING O N OHMMETER
ES-1570

FIGURE 4-7. TESTING ROTOR FOR GROUNDS

TABLE 4-2.
RESISTANCE VALUES FOR ROTORS

kW RATING RESISTANCE IN OHMS

50 HERTZ 60 HERTZ FROM TO
25.0 30.0 3.32 I 4.06
40.0 2.49 3.05
37.0 45.0 2.49 3.05
40.0 50.0 2.49 3.05
55.0 2.76 3.38
45.0 55.0 2.76 3.38
50.0 60.0 3.02 3.70
55.0 65.0 3.02 3.70
60.0 75.0 3.1 6 3.86
70.0 85.0 2.76 3.38
75.0 90.0 2.76 3.38
80.0 100.0 3.1 9 3.90
95.0 115.0 3.26 3.99
110.0 125.0 3.96 4.40
115.0 140.0 3.96 4.40
125.0 150.0 3.09 3.78
140.0 170.0 3.42 4.1 8
145.0 175.0 3.42 4.1 8

All resistances should be within the values specified

at 20°C (68OF)between field leads (with rectifiers
disconnected). Use Wheatstone Bridge for testing.

4-5 Redistribution or publication of this document

by any means, is strictly prohibited.
 (J) Regulator Specifications
Inpuf Power
WIRING HARNESS CHECK Input voltage across terminals 2 and 4
Carefully check wiring harnesses as follows: 208 to 240 Volts RMS +/-I 0%,
depending on wiring configuration

'
I 1. Inspect all wires for breaks, loose connections, and
reversed connections. Refer to applicable wiring
diagram.
Input frequency: 45 to 65 Hz
Maximum burden: 800 VA

Output Power
2. Remove wires from terminals at each end and using Continuous Rating: 3.OA
an ohmmeter, check wire end to end for continuity One minute rating: 6.5A (in current limit)
or opens. Current limit: 6.5A +/-0.75A
3. Using an ohmmeter, check each wire against each
of the other wires for possible shorts or insulation Minimum Field Resistance
breaks under areas covered by wrapping material. 0.6 ohms @ 25°C copper winding exciter
4. Reconnector replace wires according to applicable
wiring diagram. Regulator Sensing .
Single-phase average voltage directly proportional
to generator frequency to breakpoint. Independent
of frequency after breakpoint. Nominally set to 59 Hz
(49 Hz for 50 Hz sets).
VOLTAGE REGULATOR (VRAS-2)
ADJUSTMENT Operating Temperature
-40" to +80°C (-40"to 176°F)
After replacement, voltage regulator VRAS-2 adjust-
ment is performed as follows:

1. Loosen locking nut of Voltage Adjust potentiometer

R21. Locate adjustment screw to mid-position and
retighten locking nut. GENERATOR VOLTAGE ADJUST (R21) I
2. Open controller panel doors. The following procedure pertains to generator sets ,
equipped with Detector AC option only.
''
AWARN"G I
, High voltages in the control I
,
present an electrical shock 1. Start generator set. I
hazard which can cause severe personal injury or 2. Prepare installation equipment for Test Without
death. Proceed with care! Load.
3. Refer to Figure 2-6 Voltage Regulator for proper 3. Operate Phase Selector switch to read generator
Stability Range (Sl) and Mode Selection (S2 and S3) output current and voltage, while performing the
switch settings. following steps:
4. Ensure that all connections are proper and secure. A. Insert a screwdriver into the Voltage Adjust con-
5. Controller with Detector AC meter option: Refer trol on the front of the generator set control and
also to adjustment (L). carefully loosen the locking nut.
Controller without Detector AC meter option: Con- B. Slowly turn the screwdriver clockwise to
nect an accurate voltmeter to VRAS-2/TB1-2 and increase voltage, or counterclockwise to de-
-3 terminals. crease voltage.
6. Start generator set. C. When set at correct voltage, tighten the locking
7. Using a screwdriver, turn R32 potentiometer on nut. Be careful not to change adjustment.
printed circuit board VRAS-2 to increase or
j' decrease the voltage as required to achieve proper If correct voltage cannot be attained by R21
setting. Observe voltmeter while making adjust- adjustment refer to VRAS-2 adjustment proce-
ment. Set voltage with no load connectedto genera- dure (K).
'
~

tor. (Example: For a 120/240 volt connection, set at

no-load voltage for approximately 246 volts). If volt- Observe that ammeter does not register any
age is unstable or tends to hunt, refer to trouble- output current. If output current is observed on
the ammeter, contact an Onan representative.
~

I shooting section.
I 8. Stop generator set, and prepare all installation and
generator set controls for operation readiness. 4. Move the Phase Selector switch to the Off position.
5. Stop generator set, and prepare all installation and
generator set controls for operation readiness.

4-6 Redistribution or publication of this document

by any means, is strictly prohibited.
 2. Voltage Drop Check.
TESTING CIRCUIT BREAKER A. Ensure that line and load wire connections are
proper and secure.
General ,
Common maintenance practices is normally all the B. Start generator set
attention the circuit breaker should require. Such as C. Place breaker handle to Reset and then to ON
periodic exercise of breaker, and checking conductor ;I position.
connections cleanliness and security. Circuit breaker D. Perform voltage check at line connection then
options vary by customer requirements. Review the load connection.
Optional Circuit Breaker description in Section 2 and
perform the following checks and adjustment as appli-
,
I
E. Compare the voltage drop readings across
each pole. The comparisons should show each
cable to your specific breaker model. I
polesvoltage drop as being only slight variation.
And also the comparisons of phase to phase
When performing tests and adjustments of the circuit should be relatively equal. Unequal or exces-
breaker, remove the generator set from available ser- sive millivolt drops across a complete breaker
vice by placing the Remote-Stop-Run switch to Stop can be an indication of contaminated contacts
position and disconnect the battery negative (-) cable to or loose connections.
avoid accidental start-up of unit.
1 ___-- Checking Shunt-Trip Operation: The shunt-trip feature
Accidentalgenerator set starting can
LlSEEiEI result in sewere personal injury or
death during service procedures. Place the Remote-
is available in varying AC or DC voltages. Proper circuit
breaker model is selected and installed at the factory to
meet customer requirements.
Stop-Run switch to Stop position, and disconnect bat-
tery cable before performing circuit breaker tests and To check shunt-trip operation, perform the following:
adjustments.
1. Refer to original equipmentorder, installationwiring
Exercising Breaker: Actuate the breaker handle to the - diagrams, and unit wire routing to identify and con-
ON and OFF positions several times. If the breaker is firm proper AC or DC signal source,_connections.
equipped with a Trip Test button, the breaker should be
tripped, reset and actuated to ON several times. This will 2. Check that wire connections are secure.
remove any dust accumulation on the mechanism and 3. Place circuit breaker to ON position.
latch surfaces. 4. Apply appropriate signal voltage (DC: 12-, 24-volts,
i etc.; or AC: 120/240-, 480-volts). The shunt-trip
i Checking Insulation Resistance: Disconnect the load solenoid should energize, and trip open the breaker.
!
and line conductors from the breaker, and place the
breaker to the ON position. Using an ohmmeter (Rx 1OK 5. If breaker did not trip open, remove signal source
and perform continuity check of interconnect wiring
I
scale), measurethe insulation resistance between each
I and shunt-trip solenoid lead wires. Replace inter-
pole and ground. Tests should be made between
I phases of opposite polarity as well as current carrying connect wiring if defective. Replace shunt-trip
parts of the circuit breaker to ground. Also, a test should solenoid if found to be shorted or open. Contact
Onan distributor for assistance.
be made between the line and load terminals with the

1 breaker in the OFF position. A resistance reading of less

than one megohm indicates a ground. Investigation
should be made for possible contamination on the case
Checking Auxiliary Contacts: If equipped, the circuit
breaker will havethree leads for wiring interconnect of a
set of internal contacts (form C; 1 -normally-open, and 1
surfaces of the breaker.
I Checking Contact Resistance: Extensive operations of
- normally-closed). This feature provides for remote
annunciator connections. Review installation wiring
diagrams for specifics of interconnect. Perform conti-

I
the breaker under load conditions may cause deteriora-
nuity checks of wiring with breaker at ON and OFF
tion of the contacts. Testing for contact deterioration
position to confirm proper lead selection for intercon-
can be accomplished by performinga resistancecheck
nect. Replace internal contact circuits if shorted or
or voltage drop check across the breaker poles.
1 1. Resistance Check.
open. Contact an Onan distributor for assistance.

Adjusting Magnetic Trip Operation: If equipped with

I A. Isolatethe breaker by placing the Remote-Stop- front-adjustable magnetic trip controls, the short circuit
Run switch to Stop position, disconnecting the protection feature for each pole of the circuit breaker

I generator set starting battery, and disconnect-

ing the line and load wires from circuit breaker.
B. Place circuit breaker handle to ON position.
I

i
can be adjusted equally or individually to best suit cus-
tomer requirements. Any current surge above the trip
settings will actuate the trip mechanism. These adjus-
tors are set equally to the high position at the factory.
C. Check resistancevalues across each pole (line Consult on-site requirements and adjust to proper
to load). position.
D. Resistance readings should be relatively equal
for all three phases. 4-7 Redistribution or publication of this document

I by any means, is strictly prohibited.

I

I
Section 5, Generator
Disassembly/Assem bly
If testing determines that the generator needs disas- 3. Disconnect lead wires from the control box. Check
sembly for service, use the following procedure. Note wire markings for legibility to ease assembly.
I that Figure5-2 shows a generatorfor 100 kW and larger. Arrange leads so they can be withdrawn easily from
However, the smaller generators are very similar and the control box.
differences of procedures are noted. This procedure
covers disassembly of all major components. Disconnect all engine and generator control wire
I leads from inside control box as follows:
GENERATOR DISASSEMBLY DC Wiring
1. Disconnectthe negative (-) battery cable to prevent 0 A I 1/TB1-8,-10, and terminals -1 through -7 as
1 accidental starting of the generator set while
servicing. I 0
required.
Unplug AI 1/Jl,J2.
-~ __ I
I
0 Unplug P5, P6 (battery charge connections).
Accidental starting of the gen-
1 - erator set during this procedure AC Wiring-
1 presents the hazard of severe personal injury or '
death. Make sure to disconnect the negative bat- * VRAS-2/TB1-9, and -10.
I tery cable before beginning. TB21-22 to -30.
4. Remove the sheet metal from around the
2. Disconnect and remove the load wires. generator.
5. Removethe overspeed switch and bracket from the

1
!
:
GENERATOR
rl end bell and rotor shaft. See Figure 5-1.

AIRGAP
0.050-0.060 INCH
(1.27 - 1.52 mm)
\'
I

I ADJUST
I

(NOT LESS THAN

0.005 IN.1.13 MM)

MAGNETIC PICKUP SENSOR

MECHANICAL OVERSPEED SWITCH MAGNETIC PICKUP OVERSPEED SENSING

(STANDARD) (OPTIONAL)
I
ES-1576
FIGURE 5-1. OVERSPEEDSWITCH, AND MAGNETICPICKUP SENSOR

5-1 Redistribution or publication of this document

by any means, is strictly prohibited.
 6. Block the rear of the engine in place by supporting 5. Using a hoist and sling to supportthe rotor, align the
the flywheel housing. holes in the drive disk and fan with the correspond-
7. Remove the four nuts and washers from the studs ing holes in the flywheel.
I that secure the end bell. 6. Install the bolts that hold the drive disk to the engine
8. Remove end bell with oil seal from stator assembly. flywheel and tighten to a torque of 85ft-lb (115 Nom)
It might be necessary to tap around end bell joint to for generators 100 kW and larger, 55tO 60ft-lb (75tO
separate end bell from stator. 84 Nom) for generators less than 100 kW.
9. Remove the four 1/4-inch bolts and lock washers Do not allow the rotor to hang
I securing the exciter stator to the end bell. unsupported for any extended
I period. Otherwise, drive disk damage can occur.
IO. Remove the narrow generator air screen.
11. Remove the large capscrews securing the genera- 7. Using a hoist and safe lifting device, carefully move
tor to the skid base. the stator into position over the rotor assembly. The
stator leads should be at the 12 o'clock position
12. Remove the bolts securing the stator to engine fly- when viewed from the end bell position. For genera-
wheel housing.
tors under 100 kW with the long studs in the flywheel
13. Using an overhead hoist and sling, slide the stator housing, make sure the short hose pieces are in
assembly off being careful not to touch or drag on I place next to the flywheel housing before installing
the rotor. On generators below 100 kW, slide the stator.
stator off the long through-studs (note position of
8. Align the holes of the stator with the engine flywheel
hose pieces on the studs, and proper orientation of

'
housing and install the bolts. Use a torque of 35ft-lb
the stator).
(47 Nom).
The studs can b e removed if you want to do so. 9. Install the exciter stator in the end bell using the
1/4-inch bolts and lock washers. Tighten to a
To prevent personal injury, use
lport
aWAR"G1 adequate liffing devices to sup-
torque of 7 ft-lb (8 Nom).
10. Apply a thin film of Molykote grease or equivalentto
heavy components.Keep hands and feet clear
while liffing.
1 the mating surfaces of the end bearing and end bell
bearing hole.
1 Do not allow the rotor to hang 11. Install the end bell assembly, lock washers, and nuts
1 unsupported for any extended on the studs. Tighten nuts to 35 ft-lb (47 Nom).
period. Ofherwise, drive disk damage can occur. 1 12. Using a lead hammer, tap the end bell at the horizon-
tal and vertical plane to relieve stress. Retorque end
14. Attach the hoist and sling to the rotor assembly and bell stud nuts.
apply a slight lift to support the rotor. Remove the 13. Install the generator air screen.
bolts securing the drive disk to the engine flywheel 14. Refer to Figure 5-1. Mount and adjust Mechanical
and remove the rotor from the engine. Set on wood 1'
Overspeed Switch.
blocks so fan is not supporting any of the rotor
weight. When installing the overspeed switch assembly
15. Remove bearing bolt, flat washer, and lock washer. (capscrew, lock washer, switch, small flat washers,
Then remove bearing. If required, remove fan from large flat washer, and spacer) on the rotor shaft,
the rotor. tighten to 53 ft-lb (72 Nom) torque.
16. Disconnect rotor field leads from heat sinks F1 and
F2 on the exciter rotor. Remove exciter rotor. Install the overspeed switch assembly bracket and
secure using two capscrews and lock washers.
GENERATOR ASSEMBLY Tighten to 4.5 ft-lb (6 Nom) torque. Refer to Figure
5-2, and set to proper gap.
1. If any diodes are replaced in the exciter rotor, Connect overspeed switch lead wire to terminal on
secure the new diode using a lock washer and nut, overspeed switch bracket.
and tighten to a torque of 12 to 15 in.-lb (1.4 to 1.7
, Nom).- 15. Install the control sheet metal back on the gen-
erator.
16. Reconnect generator output leads to load connec-
tions, and all control wire leads and plug-ins to
proper terminals or plug-in jacks. Refer to proper
wiring diagram, and Voltage Connections, Figure
2-2.
17. Verify that all connections are secure and then
install the output box cover,
18. Connect the negative (-) battery cable and test the
generator for operation.
5-2 ' Redistribution or publication of this document
by any means, is strictly prohibited.
I

DISK

6-1116

I
1
FIGURE 5-2. GENERATOR ASSEMBLY

5-3 Redistribution or publication of this document

by any means, is strictly prohibited.
 Section 6.
i Wiring Diagrams
I WIRING DIAGRAM DRAWING NUMBER PAGE
i
1 GenSet AC Control (with meter option).............................. 612-6269 6-213
1 GenSet AC Control (without meter option) ........................... 612-6270 6-415
1 GenSet AC Control (voltage code 9X) ............................... 612-6311 6-6

6-1 Redistribution or publication of this document

by any means, is strictly prohibited.
 I 1
I

tl

I
I

6-2 Redistribution or publication of this document

by any means, is strictly prohibited.
 +

i -1
I

r
n

i'

6-3
Redistribution or publication of this document
by any means, is strictly prohibited.
 \

H
a

1
x
3
5
3
3
5
L
z

6-4 Redistribution or publication of this document

by any means, is strictly prohibited.
I
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0 0 1 m a
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