Service Manual

Generator Set
with PowerCommand[ 3200 Controller

DQKB (Spec A−G)

DQKC (Spec A−G)

English 3−2010 960−0512 (Issue 3)

Table of Contents

SECTION TITLE PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How To Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Menu Display and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Menu Units Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Engine Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Alternator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
History/About Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Bus Data Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3 CONTROL CALIBRATION AND ADJUSTMENT
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Modifying Setup/Adjust Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Paralleling − Non−Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Adjust Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Electronics Box Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Magnetic Speed Pickup Unit (MPU) Installation . . . . . . . . . . . . . . . . . . . . . 3-20

i
SECTION TITLE PAGE
4 SERVICING THE GENERATOR
Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Insulation Resistance (Megger) & Polarization Index (PI) Testing . . . . . . . 4-2
Drying the Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Generator/PCC Control Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Exciter Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Exciter Rectifier Bridge (Rotating Rectifier Assembly) . . . . . . . . . . . . . . . . 4-7
Exciter Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Main Rotor (Generator Field) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Main Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Test the PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Frame 7 Bearing Inspection/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Frame 7 Generator Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . 4-14
Frame 8 Bearing Inspection/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Frame 8 Generator Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . 4-25
Aligning Generator with Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
5 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

ii
 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator and batter- • Provide an adequate exhaust system to properly
ies. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operator’s Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
• Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the op-
• Engine exhaust and some of its constituents are
erator, service personnel, or the equipment. known to the state of California to cause cancer,
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un-
moving parts.
safe practice which can result in severe per-
sonal injury or death. • Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative (−) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage. • Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result • Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
• DO NOT fill fuel tanks while engine is running, un- caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential • If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
• Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
• Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
• Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.

LS-14M
iii
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH • Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
• Remove electric power before removing protective changer pressure cap while the engine is running.
shields or touching electrical equipment. Use rub- Allow the generator set to cool and bleed the system
ber insulative mats placed on dry wood platforms pressure first.
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing • Used engine oils have been identified by some state
(particularly wet shoes) or allow skin surface to be or federal agencies as causing cancer or reproduc-
damp when handling electrical equipment. Do not tive toxicity. When checking or changing engine oil,
wear jewelry. Jewelry can short out electrical con- take care not to ingest, breathe the fumes, or con-
tacts and cause shock or burning. tact used oil.

• Use extreme caution when working on electrical • Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
components. High voltages can cause injury or
such as wood and cloth; Class B fires, combustible
death. DO NOT tamper with interlocks.
and flammable liquid fuels and gaseous fuels; Class
• Follow all applicable state and local electrical C fires, live electrical equipment. (ref. NFPA No. 10).
codes. Have all electrical installations performed by • Make sure that rags are not left on or near the en-
a qualified licensed electrician. Tag and lock open gine.
switches to avoid accidental closure.
• Make sure generator set is mounted in a manner to
• DO NOT CONNECT GENERATOR SET DI- prevent combustible materials from accumulating
RECTLY TO ANY BUILDING ELECTRICAL SYS- under the unit.
TEM. Hazardous voltages can flow from the gen- • Remove all unnecessary grease and oil from the
erator set into the utility line. This creates a potential unit. Accumulated grease and oil can cause over-
for electrocution or property damage. Connect only heating and engine damage which present a poten-
through an approved isolation switch or an ap- tial fire hazard.
proved paralleling device.
• Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
MEDIUM VOLTAGE GENERATOR SETS
bris from the set and keep the floor clean and dry.
(601V to 15kV) • Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
• Medium voltage acts differently than low voltage. or drug that makes the operation of equipment un-
Special equipment and training is required to work safe.
on or around medium voltage equipment. Operation • Substances in exhaust gases have been identified
and maintenance must be done only by persons by some state or federal agencies as causing can-
trained and qualified to work on such devices. Im- cer or reproductive toxicity. Take care not to breath
proper use or procedures will result in severe per- or ingest or come into contact with exhaust gases.
sonal injury or death.
• Do not store any flammable liquids, such as fuel,
• Do not work on energized equipment. Unauthorized cleaners, oil, etc., near the generator set. A fire or
personnel must not be permitted near energized explosion could result.
equipment. Due to the nature of medium voltage
electrical equipment, induced voltage remains even
• Wear hearing protection when going near an oper-
after the equipment is disconnected from the power ating generator set.
source. Plan the time for maintenance with author- • To prevent serious burns, avoid contact with hot
ized personnel so that the equipment can be de-en- metal parts such as radiator, turbo charger and ex-
ergized and safely grounded. haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv
 1. Introduction
ABOUT THIS MANUAL • True RMS meter for accurate measurement of
small AC and DC voltages. Fluke models 87 or
This manual covers models produced under the 8060A are good choices.
Cummins®/Onan® and Cummins Power Genera-
• Battery Hydrometer
tion brand names.
• Powr Factor Indicator
This manual provides PowerCommand® Control • Jumper Leads
3200 (PCC) calibration and adjustment
procedures, control operation, alternator test and • Tachometer or Frequency Meter
repair procedures and initial startup and test of • Wheatstone Bridge or Digital Ohmmeter
paralleled generator sets. • Variac
Operating and maintenance instructions are in the • Load Test Panel
applicable Operator’s Manual. Generator set • Megger or Insulation Resistance Meter
troubleshooting and repair (control and engine)
information is provided in the following manuals. HOW TO OBTAIN SERVICE
• Troubleshooting and Repair Manual Power- Always give the complete Model, Specification and
Command Control QSK45, QSK60, QSX15 Serial number of the generator set as shown on the
Generator Sets, Bulletin No. 3666394 nameplate when seeking additional service
• Operation and Maintenance Manual QSK 45 information or replacement parts. The nameplate is
and QSK60 Series Engines (engine repair and located on the side of the generator output box.
service) Bulletin No. 3666260 WARNING Incorrect service or replacement of
Read Safety Precautions and carefully observe all parts can result in severe personal injury or
instructions and precautions in this manual. death, and/or equipment damage. Service per-
sonnel must be trained and experienced to per-
TEST EQUIPMENT
form electrical and mechanical service. Read
To perform the test procedures in this manual, the and follow Safety Precautions, on pages iii and
following test equipment must be available iv.

1-1
THIS PAGE LEFT INTENTIONALLY BLANK

1-2
 2. Control Operation
GENERAL present, it will wait for a pulse from a remote Master
First Start Sensor. On receiving that pulse, the con-
The following describes the function and operation trol will signal the paralleling breaker to close.
of the PowerCommand generator set control. All in-
dicators, control switches/buttons and graphical If bus voltage is present, the control will check for
display are located on the face of the control panel proper phase rotation, adjust the generator set to
as illustrated in Figure 2-1. the bus voltage and frequency level, and then syn-
Normally, generator set configuration options are chronize the generator set to the system bus. When
set at the factory. When a new control is installed on a synchronous condition is achieved, the control will
a generator set or when parts are replaced, the con- send a signal to close the paralleling breaker.
trol must be configured for that generator set. Setup
and calibration procedures are described in Sec- When the paralleling breaker is closed, the genera-
tion 3. tor set will assume it’s proportional share of the total
load on the system bus.
SEQUENCE OF OPERATION
CONTROL PANEL POWER ON/OFF
When the PowerCommand control is in the AUTO
mode, it will cause the generator set to start on re- MODES
ceiving a signal from a remote device. The control
will initiate a starter cranking signal and verify that The power on/off modes of the control panel and op-
the engine is rotating. The control will provide suffi- erating software are Power On, Screen Saver and
cient fuel to the engine to accelerate to start discon- Sleep/Awake.
nect speed. On reaching that speed, the control will
ramp the generator set to idle (warm-up) or rated Power On Mode: In this mode, power is continu-
speed and voltage. ously supplied to the control panel. The control’s
operating software and control panel LEDs/graphi-
On reaching rated speed and voltage, the control cal display will remain active until the Screen Saver
checks the system bus voltage. If no bus voltage is mode is activated.

2-1
Screen Saver Mode: Power to the graphical dis- If these conditions are not met, Sleep mode is dis-
play will be removed after 10 minutes (generator set abled in Auto mode.
not running or running). The 10 minute timer resets
and begins after each control panel action (any but- The graphical display can enter Screen Saver mode
ton or switch selection) or signal received by the op- even if Sleep mode is disabled.
erating software. The bottom LEDs of the Analog
AC Metering Panel (bar graphs) may remain on dur- If Sleep mode is enabled in Auto mode, Sleep mode
ing Screen Saver mode, indicating that the operat- is activated when there are no unacknowledged
ing software is active (Awake mode). faults and Screen Saver mode is active.
When a “Warning” signal is sensed by the PCC (for
example, low coolant temp), the control will display The operating software is initialized and the control
the warning message. The control will remain active panel LEDs and graphical display are turned on in
until the Fault Acknowledge button is pressed to response to one of the following:
clear the warning message and start the 10 minute
timer. • Moving/pressing any control panel switch/but-
ton. (If Sleep mode is enabled in Auto mode,
Sleep/Awake Mode: In the Sleep mode, the con- the control will remain asleep if Sleep mode
trol’s operating software is inactive and the LEDs was previously active in Off mode.)
and the graphical display on the control panel are all • Receiving a remote start input signal (genera-
off. Sleep mode is a feature that is used to reduce tor set in Auto mode)
battery power consumption when the control is not
being used. • Receiving an active DCD signal on the RS-232
port.
In Off mode, Sleep mode is activated when there
are no unacknowledged faults and Screen Saver • Modem RI latch becoming active.
mode is active. • Digital display waking up.
In Auto mode, Sleep mode can be enabled or dis- • Lonworks (backplane) wakeup becoming ac-
abled. When shipped from the factory, it is disabled. tive.
You can enable Sleep mode by making these
changes: • Customer fault 2 or 3 only (shutdown or warn-
ing indicator is on).
• Use InPower service tool to set Auto Sleep En-
able to Sleep in Auto. • Dial Out process becoming active.
• Set switch S1 on the Genset/Paralleling Card To activate the control and view the menu display
to Sleep/Off. This switch is located next to con- without starting the generator set, press any button
nector J8 and relay K9. on the control panel.

2-2
 OPERATOR PANEL SWITCH PANEL

REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
ANALOG AC PANEL LAMP/ FAULT EMERGENCY
METERING LAMP TEST ACKNOWLEDGE STOP PUSH
PANEL BUTTON BUTTON BUTTON

DISPLAY MENU EXERCISE MANUAL RUN/

SELECTION BUTTONS BUTTON & STOP BUTTON
(1 of 6) INDICATOR & INDICATOR

GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH

FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

2-3
 CONTROL PANEL ASSEMBLY normal range values, amber for warning levels and
red for shutdown conditions.
The control panel assembly (Figure 2-1) consist of
two panels, the Operator Panel and the Switch Pan- Scales for each function are in % of nominal values.
el. The control panel assembly can be mounted on Resolution is 1% for values close to nominal, and in-
the genset or in a freestanding cabinet located near creases at values further from nominal.
the genset. In either location, the function of the Graphical Display: The graphical display is capa-
control panel assembly switches and indicators re- ble of displaying up to 9-lines of data with approxi-
main the same. mately 27 characters per line. The display is used to
Dependent on site requirements, the Operator Pan- view the menus of the menu-driven operating sys-
el is either mounted on the control panel assembly tem.
(full-featured) as shown in Figure 2-1 or is con- The top three lines of the graphical display contain
tained in a separate enclosure and mounted re- the following control information in the order de-
motely of the control panel assembly. scribed:
The function of several buttons on the control panel • State Line − modes of operation, such as
will vary dependent on the location of the control Stopped, Time Delay To Start, Warm Up At
panel (remote or local of the control panel assem- Idle, etc. (see Figure 2-2), and paralleling op-
bly). If the function differs, it is noted as either “re-
erations, such as Standby, Dead BUS Close,
mote” or “local operator panel” in the button de-
scription. Synchronize, Load Share and Load Govern.
• Action Line − system actions, such as Warning,
Operator Panel Derate, Shutdown Cool-down and Shutdown,
and fault codes.
The operator panel contains the following compo-
nents: • Description Line − Fault code messages.
Analog AC Metering Panel: This panel simulta- Display Menu Selection Buttons: Six momentary
neously displays 3-phase line to line AC volts and buttons—three on each side of the graphical dis-
current, kW, power factor and frequency. play window—are used to navigate through the sys-
tem control menus and to adjust generator set pa-
The meter panel is composed of a series of LEDs, rameters. The button is active when the message
that are configured in bar graphs for each function. adjacent to the button is highlighted (displayed in in-
The LEDs are color coded, with green indicating verse video).

2-4
Switch Panel Fault Acknowledge: Press this button to acknowl-
edge warning and shutdown messages after the
The switch panel contains the following compo- fault has been corrected.
nents:
To acknowledge a Warning message, the 0/Manu-
Emergency Stop Button: Push the button in for al/Auto switch can be in any position. (It is not nec-
emergency shutdown of the engine. If the engine is essary to stop the generator set to acknowledge an
not running, pushing the button in will prevent the inactive Warning condition.) To acknowledge a
starting of the engine, regardless of the start signal shutdown message with this button, the 0/Manual/
source (local or remote). Auto switch must be in the 0 (Off) position.

To reset: This button is also used to blink a fault code if the

1. Pull the button out. Shutdown or Warning Status Indicator is lit. (This
2. Move the 0/Manual/Auto switch to 0. function is used when the control does not contain a
3. Press the front panel Fault Acknowledge graphical display.) Refer to Reading Fault Codes in
button. this section, which describes how to use this button
4. Select Manual or Auto, as required. for interpreting fault codes.

Remote Start Indicator: This green lamp is lit Panel Lamp/Lamp Test Button: Press this button
whenever the control is receiving a remote run sig- to turn on or off the panel lamp. Press and hold
nal. When flashing, it indicates a load demand stop down this button for three seconds or more to turn
mode. all control panel LEDs on to make sure all lamps illu-
minate. The illumination will shut off after releasing
Not in Auto Indicator: This red lamp flashes con- the button.
tinuously when the 0/Manual/Auto switch is not in Exercise Button: Press this button to initiate a pre-
the Auto position. (If in Auto position and lamp is programmed exercise sequence. To start the exer-
flashing, service is required.) cise sequence, press and hold down the Exercise
button and move the O/Manual/Auto switch from
Shutdown Status Indicator: This red lamp is lit
Auto to Manual and back to Auto or from Manual to
whenever the control detects a shutdown condition.
Auto.
The generator set can not be started when this lamp
is on. After the condition is corrected, shutdown in- Manual Run/Stop Button: This button starts and
dicators can be reset by turning the 0/Manual/Auto stops the set locally and will bypass Time Delay to
switch to the 0 position, and pressing the Fault Ac- Start and Stop sequences. The 0/Manual/Auto
knowledge button. switch must be in the Manual position to enable this
button.
Dependent upon the specific fault that occurs, the
engine may or may not shut down immediately. A 0/Manual/Auto Switch: Manual position enables
fault that could cause engine damage, causes an the use of the switch panel Manual Run/Stop but-
immediate engine shutdown (bypasses engine ton.
cool-down sequence). All other faults would allow Auto position enables start/stop control of the en-
the engine to run during the cool-down sequence gine from a remote location. (Disables the use of the
before engine shutdown. switch panel Manual Run/Stop button.)
Warning Status Indicator: This yellow lamp is lit 0 (Off) position prevents the starting of the set (local
whenever the control detects a warning condition. or remote). If moved to 0 during set operation, will
After the condition is corrected, warning indicators cause an immediate engine shutdown (bypasses
can be reset by pressing the Fault Acknowledge cool-down timers). This hot shutdown should be
button. (It is not necessary to stop the generator set avoided, if possible, to help prolong the life of the
if the fault becomes inactive during genset opera- engine. Hot shutdowns are logged by the system
tion.) software.

2-5
 READING FAULT CODES A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
If the genset contains the optional graphical display set corresponds to the hundreds position, the sec-
and a fault occurs, the fault code/message will be ond to the tens position and the third to the ones dig-
displayed in the display Description Line (Figure it. Example for Code No. 213:
2-2). If the control does not contain the graphical
display, the fault code is read from the Warning and Shutdown LED:
Shutdown status indicators. blink-blink-pause-blink-pause-blink-blink-blink

Reading Fault codes Using Warning/Shutdown Warning LED:

Indicators: If the Warning or Shutdown status indi- blink (2 seconds)
cator is lit, press and hold the Fault Acknowledge The light will display the fault codes (active or inac-
button and release after one second or more. After tive) in succession, starting with the most recent. Up
one second, the Shutdown lamp will begin to blink to 32 (unacknowledged) fault codes can be stored
the active fault code(s) as follows. in control panel memory.
The Warning lamp is used to indicate the start of a To return the control to the most recent fault code,
new code. The Warning lamp will remain on for 2 press and release the Fault Acknowledge button
seconds, followed by the Shutdown lamp blinking (less than one second) and repeat procedure.
the fault code. This sequence occurs three times for
each code. The fourth flash of the Warning lamp in- When the fault code is acknowledged and cor-
dicates the beginning of the second fault code. rected, the recorded fault will be deleted from the
LED fault log, but will remain in a data log that main-
There are distinct pauses between repetitions of the tains a fault code history. (The InPower service tool
code blink transmissions of the Shutdown lamp. is required to view this data log.)

2-6
 MENU DISPLAY AND SWITCHES Menu Buttons: Six momentary buttons—three on
each side of the graphical display window—are
Figure 2-2 shows the graphical display and the used to navigate through the system control menus
menu selection buttons. and to adjust generator set parameters. The button
Graphical Display: The graphical display is capa- is active when the message or symbol adjacent to
ble of displaying up to 9-lines of data with approxi- the switch is highlighted (displayed in inverse vid-
mately 27 characters per line. The display is used to eo). The displayed message or symbol indicates
view the menus of the menu-driven operating sys- the function of the button.
tem. Refer to the menu trees later in this section.
The display is also used to show the following sys- In the graphical display, the “B” symbol indicates
tem information: that selecting the adjacent button causes the operat-
ing program to go to the next menu display—as
• State Line − modes of operation, such as shown in the menu diagrams.
Stopped, Time Delay To Start, Warm Up At
Idle, etc., and paralleling operations, such as
Standby, Dead BUS Close, Synchronize, etc. In the graphical display, the “Y” symbol indicates
that selecting the adjacent button causes the operat-
• Action Line − system actions, such as Warning, ing program to go back to the previous menu display.
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
In the graphical display, the “ ” symbol indicates
• Description Line − Fault code/status mes- that selecting the adjacent button causes the operat-
sages. ing program to go back to Main Menu A (Figure 2-4).

STATE LINE
ACTION LINE
DESCRIPTION LINE

MENU DISPLAY
AREA

GRAPHICAL
DISPLAY

MENU MENU
BUTTONS BUTTONS

FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

2-7
 MENU UNITS SELECTION
During any control panel operation, you can change
how units are displayed by pressing the two lower
menu buttons (one on each side of display). When LOCATION LOCAL
pressing these two buttons simultaneously, the + TEMP °F
PRESS FLD PSI
units submenu will appear (Figure 2-3). After select- PRESS GAS INHG ENTER
ing the desired units, press the ENTER button in this → FLOW AIR CFM
submenu to change and save the selections.
Use the + buttons to select the desired option for
each field. Use the arrow (→) button to move to the
next field. Selected field is highlighted.
FIGURE 2-3. UNITS SUBMENU
Local/Remote Field: This selection must be set to
Local when the graphical display is mounted on the
generator set front control panel or Remote when
mounted remotely from the generator set.
The Local/Remote selection determines which but-
tons in the Control submenu (page 2-12) are active
(displayed).
Temp Field: Used to select °F or °C for temperature
readings.
Pressure Fluid: Used to select PSI, KPA, BAR or
IN for pressure readings.
Pressure Gas: Used to select INHG or MMHG for
pressure readings.
Flow Air: Used to select CFM or CMM for air flow
readings.

2-8
 MAIN MENU _\_ Button: (Paralleling applications only). Used to
open and close the generator set circuit breaker
Figure 2-4 shows the main menus (Menu A and (CB). The symbol indicates if the CB is opened or
Menu B) of the system control. The two main menus closed. Opened _\_, push to close. Closed _−_,
are used to divide the system submenus into major push to open.
categories, such as, Engine Data, Alternator Data,
Control, etc. With the control panel 0/Manual/Auto switch in the
Manual position, the CB can only be closed by us-
To view system data, simply press the appropriate ing this button. When manually closed and the CB
menu button to select the category. After pressing opens, it must be closed again by using this button.
the desired menu button, refer to the page number To close the CB, press and hold the button until the
shown in Figure 2-4 for detailed information related symbol indicates a closed CB. (CB close will occur
to the selected category. only when setup conditions allow − dead bus or
Adjust Button: The Adjust submenu is intended for generator synchronized with bus.)
qualified site personnel only. Note that a password
may be assigned to allow only authorized operators In the Auto position, the opening and closing of the
to modify this data. (Password is not required if not CB is controlled by the control system software. The
assigned.) CB symbol will indicate an open or closed CB, but
the button will be inactive when the control is in
Setup Button: The Setup submenu is described in Auto.
Section 3.
In the following figures, the boxed/highlighted field
The “Adjust” and “Setup” submenus can be viewed, indicates that the adjacent menu button is active.
but not modified without entering the correct pass- Also, the submenus are shown in the order in which
words. they are displayed when scrolling up Y or down B.

MENU A
MENU MENU
BUTTONS PAGE MENU BUTTONS
2-10 B

ENGINE MORE>>
PAGE ALTERNATOR _\_ See
2-11 CONTROL HISTORY/ABOUT Above

PAGE PAGE
2-12 2-13

MENU B

Section
3

ADJUST
BUS DATA PAGE
SETUP BACK<< 2-15

GRAPHICAL
Section DISPLAY MENU
3 A

FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B

2-9
 ENGINE SUBMENUS

If you press the “ENGINE” button in Menu A, the En-

gine submenus will appear (Figure 2-5). ENGINE
The first submenu displays general information that
applies to all gensets (coolant temp, oil pressure,
etc.) The data in the remaining submenu(s) will vary
according to the type and number of sensors pro- COOLANT TEMP 180 °F
vided with the engine. OIL PRESSURE 75 PSI Y
ENGINE SPEED 1800 RPM
BATTERY 29.1 VDC B

MANF TEMP 75 °F
MANF PRESS ABS 180 INHG Y
RAIL PRESS ABS 180 PSI
PUMP PRESS ABS 291 PSI B
FUEL INLET TEMP 172 °F
COOLANT PRESSURE 59 PSI

BLOWBY FLOW 25 CFM

TIMING PRESS 50 PSI Y
AFTERCOOLER TEMP 76 °F
AMBIENT PRESS 88 INHG

FIGURE 2-5. ENGINE SUBMENUS

2-10
 ALTERNATOR SUBMENUS

If you press the “ALTERNATOR” button in Menu A,

the Alternator Data submenus will appear (Figure ALTERNATOR
2-6).
Voltage L-L and L-N: Indicates voltage Line-to
Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340 Y
L2 480 277 1290
The voltage Line-to-Line (L1, L2 and L3) are mea- L3 480 277 1260 B
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively. AVR DUTY CYCLE 10.3 %

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.
AVR DUTY CYCLE: Displays voltage regulator kW kVA PF
(drive) level in percentage of maximum. L1 350 500 .80 Y
L2 350 500 .80
kW, kVA and PF: Displays generator set kW and L3 350 500 .80
kVA output (average and individual phase, and di- TOT 1050 1500 .80
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
The PF reading will contain an asterisk if the power
factor is leading (for example, *.30). FIGURE 2-6. ALTERNATOR SUBMENUS

2-11
 CONTROL SUBMENU

If you press the “CONTROL” button in Menu A, the

Control submenu will appear (Figure 2-7). CONTROL
(Local)

Local CONTROL Submenu Function

When the operator panel is mounted on the control

panel assembly, the Run Mode Idle/Rated button is + RUN MODE IDLE Y
active (displayed). Note in Figure 2-7 that this but- BARGRAPH TEST
ton is not displayed in remote applications.

The shaded area in Figure 2-7 displays the se-

lected/active mode of operation, either IDLE or
RATED.
CONTROL
(Remote)
Remote CONTROL Submenu Functions

When the operator panel (Figure 2-1) is mounted

remotely of the control panel assembly, the menu
buttons in the Control submenu are used to perform START GENSET Y
the following remote operations. (To activate these BARGRAPH TEST
menu buttons for remote/local use, refer to page FAULT ACKNOWLEDGE
2-8.)

The 0/Manual/Auto switch must be in the Auto posi-

tion to activate the Remote Menu Buttons of the Con- FIGURE 2-7. CONTROL SUBMENU
trol submenu.

Remote START or STOP Button: This button is

used to start and stop the generator set when the
operator panel is mounted in a remote location.

When the generator set is operating, Stop will be

displayed for this button and Start will be displayed
when not operating.

Fault Acknowledge Button: Used to reset inactive

Warning messages, not Shutdown messages.

Local/Remote CONTROL Submenu

Function

Bargraph Test: The function of this button remains

the same and is not dependent on operator panel
location. This button sequentially lights the LEDs to
test the bar graph display.

2-12
 HISTORY/ABOUT SUBMENUS

If you press the “HISTORY/ABOUT” button in Menu

A, the History/About submenus will appear (Figure HISTORY/ABOUT
2-8).
HISTORY: The control maintains a data log of the
number of engine starts and number of operating
hours for the engine and control, and the megawatt STARTS 533
and maximum torque hours of the generator set. ENGINE HOURS 1236 Y
This information is stored in non-volatile memory CONTROL HOURS 7879
KWHRS 890 B
and will not be deleted due to loss of battery power.
ABOUT: The About submenus provide the follow-
ing generator set information.
• Genset model and wattage (kW/MW)
• Output voltage and WYE, DELTA or SINGLE
HISTORY-HRS@ %MAX TORQUE
• Frequency 50 or 60 Hz 12345@0-9 23455@50-59 Y
• Rating: Standby, Prime or Base 12345@10-19 12345@60-69
12345@20-29 12345@70-79 B
• Version level of the controller and panel operat- 12345@30-39 12345@80-89
ing software.

MODEL 1750DQKB Y
VOLTAGE 416 WYE
FREQUENCY 60 B
RATING STANDBY

CONTROLLER VERSION
RTOP DN30008.DFA Y
BATS APR 23 1999
OP PANEL VERSION B
RTOP 1.09 AUG 17 1999
BATS 1.02 MAY 6 1999

CONTINUED TO NEXT PAGE

FIGURE 2-8. HISTORY/ABOUT SUBMENUS

2-13
 HISTORY/ABOUT SUBMENUS (CONT.)

FAULT HISTORY: The control maintains a data log

of all fault conditions as they occur, and time stamps HISTORY/ABOUT (CONT.)
them with the control and engine operating hours.
Up to 32 (unacknowledged) fault codes can be
stored in control panel memory. After the fault is ac-
knowledged and corrected, the recorded fault will
be deleted from the control panel memory, but will FAULT HISTORY: 1 OF 24
+ CNTL HOURS 459 Y
remain in a data log that maintains a fault code his- OCCURRENCES 5
tory. (The InPower service tool is required to view ENGINE HOURS 334
this data log.) FAULT CODE 1437
(FAULT DESCRIPTION)
The Fault History display line: 1 of 24 indicates that
24 faults are recorded and that the most recent fault
(1) detected by the controller is displayed.
The Occurrences display line: In this example, 5 in- FIGURE 2-8. HISTORY/ABOUT SUBMENUS (CONT.)
dicates that this is the fifth occurrence of this fault.
(The InPower service tool is required to review the
last four faults of this code.)
The Occurrences number is incremented for each
new occurrence of the same fault. The controller
must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
For example, when a Low Oil Pressure fault is de-
tected, the controller will increment the Occurrences
number by 1. This fault will remain active until the
fault is acknowledged and the controller detects that
the fault is corrected. An active fault will prevent the
controller from incrementing the Occurrences num-
ber each time the engine is started. When the con-
troller detects that the oil pressure is normal the fault
will become inactive, allowing the occurrences num-
ber to be incremented for the next detected Low Oil
Pressure fault.

2-14
 BUS DATA SUBMENU
If you press the “BUS DATA” button in Menu B, the
Bus Data submenu will appear (Figure 2-9) (paral- BUS DATA
leling applications only).
BUS DATA STATUS LINE: The top line of the
graphical display is used to indicate the following LOAD GOVERN
BUS DATA status:
V BUS GEN
− STANDBY L1 480 480 Y
− DEAD BUS CLOSE: Indicates first genset in L2 480 480
_\_
system to close to bus. L3 480 480
HZ 60.1 60.1
− SYNCHRONIZE: Genset is synchronizing to DEG −122 NOT SYNCHRONIZING
bus.
− LOAD SHARE: Genset has closed to bus and
is sharing load with other gensets in system.
− LOAD GOVERN: Genset closed to bus in par-
allel with utility (mains). FIGURE 2-9. BUS DATA SUBMENU
BUS Voltage L-L: The BUS voltage Line-to-Line
(L1, L2 and L3) are measured between L1 to L2, L2
to L3 and L3 to L1, respectively.
BUS/GEN HZ: BUS and genset frequency.
BUS/GEN SYNC STATUS: The bottom line of the
graphical display is used to indicate the following
BUS/GEN Sync status:
− NOT SYNCHRONIZING: Genset is in service
mode that does not allow auto sync feature.
(Selected via InPower service tool − deactivate
to allow synchronization.)
− SYNCHRONIZING: Genset is synchronizing to
bus.
− READY TO CLOSE: In manual mode, push cir-
cuit breaker close button to close breaker.
_\_ Button: Used to open and close the genset cir-
cuit breaker (CB) when the 0/Manual/Auto switch
is in Manual position. The symbol indicates if the CB
is opened or closed. Opened _\_, push to close.
Closed _−_, push to open.
In the Manual position, the CB must be closed by
this button. When manually closed and the CB
opens, it must be closed again by using this button.
To close the CB, press and hold the button until the
symbol indicates a closed CB. (CB close will occur
only when setup conditions allow − dead bus or
generator synchronized with bus.)
In the Auto position, the opening and closing of the
CB is controlled by the control system software. The
CB symbol will indicate an open or closed CB, but
the button will be inactive when the control is in
Auto.

2-15
THIS PAGE LEFT INTENTIONALLY BLANK

2-16
 3. Control Calibration and Adjustment
GENERAL CAUTION If the base card has software as-
sembly A026 F566 v1.0 on the U33 flash memory
This section contains calibration and adjustment chip, you must use the latest software calibra-
procedures for the generator set control. tion for the control, or the board will lock up per-
manently.
SOFTWARE CALIBRATIONS
If the base card has software assembly A026 F566 MODIFYING SETUP/ADJUST SUBMENUS
v1.0 on the U33 flash memory chip, you must use
the latest software calibration for the control. If you The Setup and Adjust submenus allow you to cali-
load an earlier software calibration onto a base card brate the graphical display meters and to adjust
with software assembly A026 F566 v1.0, the soft- system parameters, customer defined faults, gen-
ware calibration will fail, and the board will lock up erator set voltage/frequency and paralleling ap-
permanently. plications.

CAUTION Improper calibration or adjustment

of the control can cause equipment malfunction
or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.

The Setup submenus are intended for qualified ser-

vice personnel only. The Adjust submenu is in-
tended for qualified service and site personnel only.
For this reason, a password must be entered before
this data can be modified. The Setup and Adjust
submenus can be viewed, but not modified without
entering the correct password.

Saving Menu Changes

Changes are automatically saved when the menu is

FIGURE 3-1. U33 FLASH MEMORY CHIP exited.

3-1
PASSWORD Menu When viewing a Setup menu, pressing the + or −
button will always display the Application Password
To allow the site personnel to modify only the Adjust menu.
submenu and not the Setup submenus, two pass-
After entering the correct password, the system will
words are assigned within the system software. An
allow you to modify the submenus. To help prevent
Application password is used for the Setup sub-
unauthorized adjustment, the entered password is
menus and a User password is used for the Adjust
valid for only 10 minutes after the last button is
submenu.
pressed.
The two passwords are assigned during the initial Entering Password
installation of the generator set (via InPower) and
will vary between sites. The installer must make To enter the password:
sure that the passwords are available to the ap- 1. Display submenu to modify.
propriate personnel.
2. Press either the + or − button within the dis-
played submenu. The Password menu ap-
When the generator set is first installed, the Applica- pears.
tion password is set to GENSET to allow initial modi-
fication of the Setup submenus. The User password 3. Press the + and − button to select the first char-
is initially left blank and does not require a password acter of the password (A−Z or 0−9). (Enter Ap-
to modify the Adjust submenu. The entering of the plication password for Setup submenus; En-
User password is not required unless a password is ter User password for Adjust submenu.)
assigned to this field. (User password is site depen- 4. Press the → button to select the next character
dent.) Assign the password(s) when site installation
field. Selected character field is highlighted.
is complete.
5. Repeat steps 3 and 4 to enter remaining pass-
word characters.
When viewing the Adjust menu, pressing the + or −
button will display the User Password menu if a user 6. Press the Enter button after entering the pass-
password has been installed with InPower soft- word. The submenu selected in step 1 will re-
ware. If a password is not assigned to the Adjust appear.
menu, changes can be made without entering a 7. After making desired changes to submenu, exit
password. submenu to save changes.

+ OR − BUTTON + OR − BUTTON

ENTER APPLICATION PASSWORD ENTER USER PASSWORD

+ ENTER + ENTER
− −
→ XXXXXXXX → XXXXXXXX

SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU

FIGURE 3-2. PASSWORD MENUS

3-2
 SETUP MENUS in this section to enter password and to save menu
changes.
Figure 3-3 shows the main menus (Menu A and
Menu B) of the system control and the two Setup To display the two Setup menus, press the
menus. MORE>> button in Menu A and then the SETUP
button in Menu B.
Paralleling − Non−ParallelingIf the generator
set was purchased for a paralling application but will To view system data or to adjust system parame-
be used for a non−paralling application, entering ters, press the appropriate Setup menu button to
the checksum data into the Dataplate Checksum display the desired Setup submenu(s). Refer to the
dialog in InPowert is not required. However, the page number shown in Figure 3-4 for detailed infor-
Adjustments Paralleling − Paralleling Level must be mation related to the selected submenu(s).
set to Basic.
CAUTION Improper calibration or adjustment
The Setup procedure is intended for qualified ser- of the control can cause equipment malfunction
vice personnel only. The APPLICATION password or damage. Calibration and adjustment must be
must be entered to modify the Setup submenu performed by technically qualified personnel
fields. Refer to Modifying Setup/Adjust Submenus only.

MENU A MENU B

MENU
ENGINE MORE>> B ADJUST
ALTERNATOR _\_ BUS DATA
MENU
CONTROL HISTORY/ABOUT SETUP BACK<<
A

PAGE MENU
3-5 B

GOVERNING/VOLT REG Y
PAGE CUSTOMER FAULTS B NEXT
3-6 MENU
CALIBRATION

PAGE MENU
3-7 A

ABOVE
MENU

Y
PAGE ISOLATED BUS
3-8 UTILITY

PAGE MENU
3-12 A

FIGURE 3-3. SETUP SUBMENUS

3-3
GOVERNING/VOLT REG Submenu
If you press the “GOVERNING/VOLT REG” button GOVERNING/VOLT REG
in the Setup menu, the Governing/Volt Regulator
submenu will appear (Figure 3-4).
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) but-
ton to move the cursor within a field or to the next + GOV GAIN 80% Y
field. Exit menu to safe changes. − AVR GAIN 100%
→
GOV GAIN: If the gain adjustment is set too high,
engine speed will “hunt” or oscillate. If gain is set too
low, the engine will respond too slowly to changes in
load and overspeed may result. (Gain should be re-
duced to 80% for paralleling installations.)
FIGURE 3-4. GOVERNING/VOLT REG SUBMENU
AVR GAIN: If the gain adjustment is set too high,
output voltage will be unstable. If gain is set too low,
the output voltage will respond sluggishly to
changes in load and overshoot may result.

3-4
CUSTOMER FAULTS Submenus
If you press the “CUSTOMER FAULTS” button in CUSTOMER FAULTS
the Setup menu, the Customer Faults submenus
will appear (Figure 3-5).
There are a total of four customer fault inputs.
(Faults 3 and 4 paralleling only.) The message dis-
CUSTOMER FAULT1:
played at the bottom of the menu can be modified + ENABLE ON Y
for each of these faults in addition to selecting the − ACTIVE CLOSED B
following operating parameters for each fault. RESPONSE WARNING
→
• Enable − On or Off ***CUSTOMER FAULT1 ******************
• Active − Closed or Open
• Response − Shutdown, Cooldown, Derate or
Warning
Shutdown: Genset will immediately shut
down. Normally used for engine faults. CUSTOMER FAULT2:
+ Y
Cooldown: Cooldown sequence will be initi-
− B
ated before shutdown. Should not be used for RESPONSE WARNING
→
engine faults.
***CUSTOMER FAULT2 ******************
Derate: Used to lower kW output of genset for
warnings such as pre-high coolant tempera-
ture, etc. Paralleling application − controller will
CONTINUES THROUGH TWO
reduce precentage of kW load sharing on the ADDITIONAL MENUS FOR A
set. Non-paralleling application − controller will TOTAL OF FOUR POSSIBLE
lower percentage of kW load by operating load CUSTOMER FAULT MESSAGES
shed relay contacts.
Warning: Display message, genset continues
to operate. FIGURE 3-5. CUSTOMER FAULTS SUBMENUS
The Enable and the Active fields apply to the Fault 1
and 4 submenus only.
With the Active field selected, pressing the + or −
buttons will toggle the selection between CLOSED
and OPEN. Use same operation for remaining field
selections.
To enter the desired customer fault message, press
the B or Y button to display the submenu that con-
tains the customer fault message (1 through 4) to be
changed. Use the → button to scroll down through
the menu selections to the editable fault message
(bottom menu line).
Use the → button to move to each character posi-
tion within the fault message line.
With the desired character position selected, use +
or − buttons to select the appropriate character.
If these messages are changed, you should note
these changes in the Troubleshooting section of the
Operator’s manual for this generator set.

3-5
CALIBRATION Submenus
If you press the “CALIBRATION” button in the Setup CALIBRATION
menu, the Calibration submenus will appear (Fig-
ure 3-6).
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) but- VOLTAGE CALIBRATION
ton to move the cursor within a field or to the next + L1 480 -X.X% Y
L2 480 -X.X%
field. Exit menu to safe changes. − L3 480 -X.X% B
→
The Calibration submenus allow you to calibrate the
control with the reading from a calibrated meter.
Calibration is accomplished by using this section of
the menu software to adjust the display so that it
matches the reading taken on an accurate, recently
calibrated meter.
CURRENT CALIBRATION
Calibration is normally only required when replac- + L1 234 -X.X% Y
L2 123 -X.X%
ing certain circuit cards. Refer to the Calibration − L3 562 -X.X% B
Procedure in this section which contains a list of the →
cards that require control calibration.
When performing Bus Voltage Calibration from the
graphical display, the genset must be off and the Bus
live. If the genset is running, it will synchronize to the
Bus.
BUS VOLTAGE CALIBRATION
+ L1 480 -X.X% Y
L2 480 -X.X%
− L3 480 -X.X%
→

FIGURE 3-6. CALIBRATION SUBMENUS

3-6
ISO BUS / UTILITY Submenus (Paralleling and frequency in a range of minus 40% to plus 10%
Application) of normal bus conditions. When the paralleling
breaker has closed, the control will bring the gener-
The Isolated BUS submenus (Figure 3-7) and the ator set back to normal voltage and frequency.
Utility submenus (Figure 3-8) adjust the control pa-
rameters for generator set protection, synchroniz- When the generator set is paralleled to another
ing and load sharing for both isolated bus and utility generator set, the control provides automatic load
(mains) paralleling applications. Utility (mains) par- sharing functions for both real (kW) and reactive
allel applications may require adjustment of both (kVAR) loads. Load sharing is proportional between
the Isolated BUS and Utility submenus. generator sets based on their standby ratings. If two
generator sets of different sizes are paralleled, they
Always perform ISO BUS calibration before Utility will assume the same percentage of the system
BUS calibration.
load automatically. This can easily be verified on the
The sync check (permissive) function is operational kW Load LED bar graph on the front of the control
in both automatic and manual (RUN) modes. The panel.
control will make sure that the generator set is at
When the utility paralleling mode is enabled and the
proper voltage, within the defined sync check win-
generator set paralleling breaker is closed, the gen-
dow for the defined period of time and that phase
erator set will assume load based on external ana-
rotation is correct. When all criteria are met, the par-
log input signal. The input signal must be calibrated
alleling breaker is closed automatically by the con-
from 0−5 VDC. When the signal is at 0.5 to 1 VDC,
trol (auto mode), or by operation of the breaker
the control will operate the generator at no load in
close switch by the operator (manual mode).
parallel with the utility (mains) source. At 4.5 VDC
The synchronizing function of the control is enabled and greater, the control will operate the generator
when the control has brought the generator set to set at 110% of the generator set base load setting.
90% of rated speed and voltage, and has sensed When the load govern signal is between 1 VDC and
that bus voltage is available. The control automati- 4.5 VDC the control will operate the generator set at
cally adjusts the generator set speed and voltage to a load level which is determined by a linear relation-
match the bus frequency and voltage. The control ship between the kW reference and the load govern
can force the generator set to match bus voltage signal.

3-7
ISO BUS Submenus
If you press the “ISO BUS” button in the Setup ISOLATED BUS
menu, the Isolated BUS submenus will appear (Fig-
ure 3-7).
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) but-
ISOLATED BUS:
ton to move the cursor within a field or to the next SYNC TIME LIMIT 120 SEC
+ Y
field. Exit menu to safe changes. REV PWR LMT 10 %
− REV PWR TIME 3 SEC B
SYNC TIME LIMIT: This parameter adjusts the time
→ PERM WIN-PH 20 DEG
delay in seconds before the Fail To Synchronize PERM WIN-TIME .5 SEC
alarm will operate.
REVERSE PWR LMT: Adjusts the reverse power
set point. For PowerCommand generator sets, a CONTINUED TO NEXT PAGE
typical set point is 10-15%.
REVERSE PWR TIME: Adjusts the reverse power
function time delay. A typical time delay which is
suitable for PowerCommand generator sets is 3 se- FIGURE 3-7. ISO BUS SUBMENUS
conds.
Lower reverse power set points can result in nui-
sance reverse power shutdown faults.
PERM WIN-PHASE: Adjusts the width of the per-
missive (sync-check) acceptance window. The ad-
justment range is from five to twenty electrical de-
grees. Recommended set point is 20 degrees for
isolated bus applications, and 15 degrees for utility
(mains) paralleling applications.
PERM WIN-TIME: Adjusts the time period (in se-
conds) for which the generator set must be synchro-
nized with the system bus, before a breaker close
signal is issued by the PowerCommand control.
Available range is 0.5 to 5 seconds. Recommended
value for PowerCommand generator sets is 0.5 se-
conds for isolated bus applications.

3-8
Adjusting the control for a smaller sync-check win-
dow or longer time delay will cause synchronizing
ISOLATED BUS (CONT.)
time to be extended.
SYNC GAIN: The sync gain adjustment controls
how quickly the governor will respond to try to mini-
mize the bus/generator phase difference. Increas-
ing the gain speeds up the response. If the gain is ISOLATED BUS:
too high instability can result. + SYNC GAIN 1.0 Y
KW BALANCE 0.3
KW Balance and KVAR Balance changes should be − KVAR BALANCE 1.2 B
equally shared among all generator sets. → KW GAIN 1.0
KVAR GAIN 1.0
KW BALANCE: This function adjusts the kW load
sharing function of the generator set. Before adjust-
ing this value, all generator set calibrations should
be performed. If the total load on the system is not CONTINUED TO NEXT PAGE
shared proportionately, the kW Balance can be
used to adjust the generator set for more precise
load sharing. Increasing the kW Balance value will
cause the generator set to reduce the percentage of FIGURE 3-7. ISO BUS SUBMENUS (CONT.)
the total kW load on that set.
KVAR BALANCE: This function adjusts the kVAR
load sharing function of the generator set. Before
adjusting this value, all generator set calibrations
should be performed. If the total load on the system
is not shared proportionately, the kVAR balance can
be used to adjust the generator set for more precise
load sharing. Increasing the kVAR balance value
will cause the generator set to reduce the percent-
age of the total kVAR load on that set.
KW GAIN: Adjusts the rate of change of kW load on
the generator set. With a constant load on the sys-
tem, if the generator set load is constantly chang-
ing, reduce the gain adjustment on the generator
set. This also allows modification of the rate of load
assumption on transient load change.
KVAR GAIN: Adjusts the rate of change of kVAR
load on the generator set. With a constant load on
the system, if the generator set load is constantly
changing, reduce the gain adjustment on the gener-
ator set. This also allows modification of the rate of
load assumption on transient load change.

3-9
1ST FAIL TIME: Time delay in seconds after a sig-
nal from the first start master is not sensed by the ISOLATED BUS (CONT.)
PCC that a FIRST START FAIL warning is dis-
played.
RAMP UNLOAD TIME: When a load demand stop
input is sensed the load is ramped down from the
present load level on the set to the ramp unload lev- ISOLATED BUS:
+ 1ST FAIL TIME 12 SEC Y
el in the time specified in seconds. RAMP UNLD 20 SEC
− RAMP UNLD LEVEL 10 %
RAMP UNLOAD LEVEL: The load demand ramp
→ RAMP LOAD TIME 3 SEC
unload function will ramp the load down from the LOSS FIELD 20 SEC
present level on the set to this level before opening
the set circuit breaker. Value shown is in % of genset
standby rating.
FIGURE 3-7. ISO BUS SUBMENUS (CONT.)
RAMP LOAD TIME: When the load demand stop
signal is removed the load is ramped from 0kW to
the load share level in the specified time after the
circuit breaker closes.
LOSS FIELD TIME: Adjusts the loss of field func-
tion time delay. A typical delay which is suitable for
PowerCommand generator sets is 2 seconds.

3-10
UTILITY Submenus
If you press the “UTILITY” button in the Setup UTILITY
menu, the Utility submenus will appear (Figure 3-8).
Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) but-
ton to move the cursor within a field or to the next
UTILITY:
field. Exit menu to safe changes.
+ BASE LOAD 80% Y
BASE LOAD (%): This controls the maximum kW −
PF LEVEL 1.00
B
load level that the generator set will operate at when RAMP LOAD 3
→ RAMP UNLD 20
paralleled with the utility (mains). The value shown MODE MULTIPLE
indicates the steady state load on the generator as
a percent of the generator set standby rating.
Check generator set ratings for maximum load level
at which the generator set should operate when
paralleled with the utility (mains). Extended opera- UTILITY:
tion at load levels in excess of the generator set rat- + KW GOVERN GAIN 1.00 Y
ing can cause abnormal engine wear or premature KVAR GOVERN GAIN 1.00
−
engine failure. →
PF LEVEL: Adjusts the power factor that the gener-
ator set will run at when paralleled to the utility
(mains). Recommended setting is 1.0.
RAMP LOAD TIME: This is the ramp time from
FIGURE 3-8. UTILITY SUBMENUS
present set load to level determined by the load set
analog input. This is active when the control first en-
ters the load govern mode.
RAMP UNLOAD TIME: This is the ramp time from
present set load to 0 kW. This ramp is active when
the load set analog input is less than 0.5 volts.
MODE − MULTIPLE/SINGLE: This controls wheth-
er the set is to operate as part of a multiple set or
single set (PLTE or PLTF) system. (Refer to “LOAD
DEMAND SHUTDOWN” and “SINGLE MODE
VERIFY” function descriptions in wiring diagram,
page 5-6.)
KW GOVERN GAIN: This controls the rate that the
generator set kW load is increased after the genera-
tor set has closed to the system bus when utility
(mains) paralleled. Decreasing this value will result
in slower loading of the generator set.
KVAR GOVERN GAIN: This controls the rate that
the generator set kVAR load is increased after the
generator set has closed to the system bus when
utility (mains) paralleled. Decreasing this value will
result in slower loading of the generator set.

3-11
 ADJUST SUBMENU are disabled to prevent inadvertent misadjustment
of the paralleling load sharing functions.
Figure 3-9 shows the main menus (Menu A and
Menu B) of the system control and the Adjust sub- Use the + and − buttons to increase or decrease the
values in the following fields. Use the arrow (→) but-
menu. ton to move the cursor within a field or to the next
field. Exit menu to safe changes.
To display the Adjust submenu, press the MORE>>
button in Menu A and then the ADJUST button in VOLTAGE: Used to adjust the output voltage ±5%.
Menu B.
FREQUENCY: Used to adjust the frequency ±3 Hz.
The Adjust procedure is intended for qualified ser- START DELAY: This delay applies only to remote
vice personnel and site personnel only. The USER starting in the Auto mode (0/Manual/Auto switch in
password must be entered to modify the Adjust sub- Auto). The Start Delay adjustment range is 0 to 300
menu fields. Refer to Modifying Setup/Adjust Sub- seconds.
menus in this section to enter password and to save
menu changes. STOP DELAY: This delay applies only to remote
stopping in the Auto mode (0/Manual/Auto switch in
If the generator set is operating in parallel with a Auto). The Stop Delay adjustment range is 0 to 600
system bus, the voltage and frequency adjustments seconds.

MENU A

MENU
ENGINE MORE>> B
ALTERNATOR _\_
CONTROL HISTORY/ABOUT

MENU B

ADJUST
BUS DATA
MENU
SETUP BACK<<
A

ADJUST:
+ VOLTAGE 208 1.2 % Y
FREQ 60.0 HZ -0.0 HZ
− START DELAY 5 SEC
→ STOP DELAY 11 SEC

FIGURE 3-9. ADJUST SUBMENU

3-12
 CALIBRATION PROCEDURE able and the genset is running. Consequently, it is
not possible to calibrate the genset output voltage
There are several circuit cards/modules that, when display of the genset that is running when the bus is
removed and replaced, require you to recalibrate energized. If it is necessary to adjust the output volt-
the control panel display for genset voltage and cur- age display of the genset that is running, the InPower
rent and bus voltage. service tool must be used to switch off the synchro-
nizer function of the control.
Note that the type of calibration to perform varies for
each card. The letters A, B and C are used to desig- 1. Display the Voltage Calibration submenu
nate which of the following three calibration proce- (Page 3-7).
dures are required for each card/module. 2. With the genset OFF, attach a calibrated volt-
meter to the AC output from L1 to L2. (L1 to
• Genset board (A, B & C) No adjustments re- Neutral for single phase alternators.)
quired for Genset board if controller contains
the Parallel board. 3. Start the genset and allow it to reach normal
operating speed.
• Parallel board (A, B & C)
4. Calibrate voltage reading for L1 so that the
• PT/CT board (A & B) reading on the display agrees with the cali-
• Bus PT (C) brated voltmeter.
5. Shut the generator set OFF.
• CT’s (B)
6. Repeat steps 2 through 5 for L2 and L3. (In step
2 attach meter to the AC output from L2 to L3 to
calibrate L2 and L3 to L1 to calibrate L3.)
WARNING Contacting high voltage compo-
nents can cause electrocution, resulting in se- 7. Exit menu to safe changes.
vere personal injury or death. Calibration and (B) Genset Ammeter Display Calibration
adjustment must be performed by technically
qualified personnel only. Read and observe all 1. Display the Current Calibration submenu
WARNINGS and CAUTIONS in your generator (Page 3-7).
set manuals. 2. With the genset OFF, attach a calibrated am-
CAUTION Improper calibration or adjustment meter to L1.
of the PowerCommand control can cause 3. Start the genset and allow it to reach normal
equipment malfunction or damage. Calibration operating speed.
and adjustment must be performed by techni- 4. Load the genset to maximum rated kVA at
cally qualified personnel only. rated voltage.
Use a calibrated RMS multimeter for accurate mea- 5. Calibrate the reading for L1 current so that the
surements. Fluke models 87 or 8060A are good reading on the display agrees with calibrated
choices. ammeter.
6. Repeat steps 2 through 5 for L2 and L3. (In step
(A) Genset Voltage Display Calibration 2, attach meter to L2 to calibrate L2 current and
The PowerCommand control automatically synchro- L3 to calibrate L3 current.)
nizes to the system bus when bus voltage is avail- 7. Exit menu to safe changes.

3-13
(C) Bus Voltage Calibration
The PowerCommand control automatically synchro-
nizes to the system bus when bus voltage is avail-
able and the genset is running. Consequently, it is
not possible to calibrate the genset bus voltage dis-
play of the genset that is running when the bus is en-
ergized. If it is necessary to adjust the bus voltage
display of the genset that is running, the InPower
service tool must be used to switch off the synchro-
nizer function of the control.
1. Display the Bus Voltage Calibration submenu
(Page 3-7).
2. With all gensets OFF, attach a calibrated volt-
meter to TB1-A (L1) and TB1-B (L2) of the bus
PT module (Figure 3-10).
3. Start another genset and allow it to reach nor-
mal operating speed and voltage. Connect op-
erating genset to the bus.
4. Calibrate the voltage reading for Bus Volts L1
so that the reading on the display matches the
reading on the calibrated meter.
TB1-A − L1
5. Shut the generator set OFF. TB1-B − L2
6. Repeat steps 2 through 5 for Bus Volts L2 and TB1-C − L3
L3. (In step 2 attach meter to the AC output
from L2 to L3 to calibrate L2; L3 to L1 to cali-
FIGURE 3-10. BUS PT MODULE
brate L3.)
7. Exit menu to safe changes.

3-14
 ELECTRONICS BOX CONTROL WIRING Customer monitor/control connections are at-
The generator set electronics box, which is located tached to terminal blocks TB3, TB4 TB5 and TB8.
on the engine side of the control housing, contains Optional equipment such as sensing devices used
connection points for remote control and monitor to monitor genset operation, remote start/stop
options. These connection points are located in two switches, control box heater, battery charger and
different locations within the electronics box as etc. are attached to these terminal blocks. Refer to
shown in Figure 3-11. Customer Connections diagram in Section 5.

3-15
 TB12

ELECTRONICS
OPTIONAL BOX
TB3 COMMON ALARM
RELAY K10

OPTIONAL RUN
RELAYS K11, K12 &
K13

TB13

TB5
TB4

CARD
CAGE

TB8

FIGURE 3-11. ELECTRONICS BOX

3-16
TB3, TB4, TB5, and TB8 Customer The three-pole, double-throw run relays (Figure
Connections 3-12) are used to control auxiliary equipment such
as fans, pumps and motorized air dampers. The run
Refer to pages 5-6 and 5-7 for typical connections relays are energized when the generator set reach-
to TB3, TB4, TB5, and TB8. es operating speed.
Run Relays (K11, K12, 13)
The contacts are rated:
The optional run relays are rail mounted inside the
electronics box (Figure 3-11). The rail mount allows • 10 amps at 28 VDC or 120 VAC, 80%PF
you to easily remove and replace the snap-on re- • 6 amps at 240 VAC, 80%PF
lays. The generator set can be equipped with one,
two or three run relays. • 3 amps at 480/600 VAC, 80%PF

K11, K12, K13

CUSTOMER
K11, K12, K13
CONNECTIONS

K11, K12, K13

K11 K12 K13

RUN RELAY RUN RELAY RUN RELAY

NO NO NO
NC NC NC

COIL TB3-7
TB3-5
(SWITCHED B+) COM (B-)

FIGURE 3-12. OPTIONAL RUN RELAYS (K11, K12, K13)

3-17
Alarm Relay (K10) such as audible alarms. Any generator set warning
or shutdown will energize the alarm relay.
The optional alarm relay is rail mounted inside the
electronics box (Figure 3-11). The rail mount allows The contacts are rated:
you to easily remove and replace the snap-on relay. • 10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw alarm relay (Figure • 6 amps at 240 VAC, 80%PF
3-13) is often used to energize warning devices • 3 amps at 480/600 VAC, 80%PF

K10

CUSTOMER
K10
CONNECTIONS

K10

K10
COMMON ALARM

NO
NC

COIL TB3-10
TB3-32
(COM ALARM) COM (B-)

FIGURE 3-13. OPTIONAL ALARM RELAY (K10)

3-18
 MAGNETIC SPEED PICKUP UNIT (MPU)
INSTALLATION
To install the MPU sensor, bar the engine until a MAGNETIC
gear tooth on the flywheel lines up in the center of PICKUP
the mounting hole. Thread the sensor in gently by SENSOR
hand until it just touches the gear tooth. Back it out
one quarter turn and set the locknut.
CAUTION Do not use fan blade to bar over en-
gine. That can damage blades and cause prop-
erty damage and personal injury.

ENGINE
FLYWHEEL
RING GEAR

FIGURE 3-14. MPU SENSOR

3-19
THIS PAGE LEFT INTENTIONALLY BLANK

3-20
4. Servicing the Generator
TESTING THE GENERATOR Make certain battery area has been well-venti-
These tests can be performed without removing the lated before servicing battery. Arcing can ignite
generator. Before starting tests, disconnect the explosive hydrogen gas given off by batteries,
starting battery cables (negative [−] first) to make causing severe personal injury. Arcing can oc-
sure the engine will not start while performing these cur when cable is removed or re-attached, or
tests. when negative (−) battery cable is connected
and a tool used to connect or disconnect posi-
CAUTION Always disconnect battery charger tive (+) battery cable touches frame or other
from its AC source before disconnecting the grounded metal part of the set. Always remove
battery cables. Otherwise, disconnecting the negative (−) cable first, and reconnect it last.
cables can result in voltage spikes high enough Make certain hydrogen from the battery, engine
to damage the DC control circuits of the set. fuel, and other explosive fumes are fully dissi-
WARNING Accidental starting of the generator pated. This is especially important if battery has
set while working on it can cause severe per- been connected to a battery charger.
sonal injury or death. Prevent accidental start-
ing by disconnecting the starting battery cables
(negative [−] first).

EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET

PMG
STATOR

END
STATOR BEARING

BLOWER PMG
ROTOR

COUPLING

EXCITER
ROTOR

ROTATING
RECTIFIER
ASSEMBLY

DRIVE ROTOR
DISCS
FRAME

END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT

FIGURE 4-1. GENERATOR

4-1
 INSULATION RESISTANCE (MEGGER) & air-powered starting system, close air
POLARIZATION INDEX (PI) TESTING valve and install valve locking device.)
3. Put on high voltage gloves with leather protec-
Megger and PI testing must be performed on all tors.
medium voltage (601 through 15,000 volts) genera-
4. Using two pre-tested voltage detection devices
tor sets before initial start-up. PI testing for low volt-
(of the proper rating), verify de-energized con-
age (less than 600 volts) generator sets is recom-
dition in the work area. (Retest voltage detec-
mended by Onan.
tion devices immediately after verification of
These tests are used to verify that the windings are de-energized condition.)
dry before the generator set is operated and devel- 5, Remove the metal cover from the generator
ops a base line for future test comparison. output box to gain access to generator load ter-
minals.
Before these tests can be performed on medium 6. Securely install the Grounding Cluster ground
voltage generator sets, you must first perform the clamp to a verified “grounded” conductor.
generator grounding procedure.
WARNING Hazardous voltage. Can cause
Generator Set Grounding Procedure severe personal injury or death. After DC
voltage from the test equipment has been
Prior to performing service or inspection proce- applied to the windings and ground, there
dures that may expose personnel to conductors will be a definite static charge on the wind-
normally energized with voltages greater than 600 ings. Reconnect Grounding Cluster to re-
volts, the following generator set grounding proce- move static charge from the winding after
dure must be followed. each generator test.
7. With the Grounding Cluster in place, you are
Do not perform these procedures
protected from static and/or induced charges
unless fully trained in medium voltage ground-
that may have been present in the generator
ing procedures and have necessary safety
stator.
equipment. Severe injury or death due to high
voltage electrical shock may result. Leave grounds connected for at least one min-
ute so static charge can dissipate. Remove
1. Open, lock-out and tag-out all sources of power ground cluster and perform PI and/or any other
to the immediate work area. tests required on the stator winding. Reconnect
2. Disable the starting system of the generator grounds if additional generator service is nec-
set: essary.
a. Move the 0/Manual/Auto switch to the 0 8. When work on the generator set is complete,
(Off) position and wait for the controller to remove the Grounding Cluster in the reverse
power down (approximately 10 minutes). order of installation.
b. Disconnect the battery charger from its AC 9. After getting clearance from all personnel in-
source. volved in the lock-out/tag-out procedure, re-
move all lock-out devices in reverse order of
c. Remove the negative battery cable from installation.
the battery.
d. Install a lockout device on the battery
cable end. (For engines equipped with an

4-2
Megger and PI Test ing in megohms. A ratio of two or greater is consid-
ered good for new and in service sets.
Medium-voltage, 601 to 15,000
volts, present special hazards of severe person- 1. Perform the Generator Set Grounding Proce-
al injury or death. Even after genset shutdown, dure.
an electrical shock hazard may still exist, 2. Remove the housing cover of the electronics
caused by induced voltage within the generator box and remove connector 10 from the regula-
or cables. Service personnel must be well- tor output module. See Figure 3-10.
trained/qualified to work with distribution volt- 3. Disconnect the AC control input leads from the
ages. (See Generator Set Grounding Proce- generator output terminals. The AC control
dures, Page 4-2.) leads are marked 5, 6, 7 and 8. Refer to the ap-
WARNING The windings of medium-voltage propriate Reconnection Diagram in Section 6.
(601 through 15,000 volts) generator sets must 4. If the RTD (resistive thermal device) option is
be dry before the generator is operated. Failure installed, ground all six RTD temperature
to make sure windings are dry before start-up leads. Each RTD has three leads, one red and
may result in catastrophic equipment failure, two white leads. Total of 18 leads must be
severe personal injury or death. grounded.
Megger Test: The megger test consists of applying 5. Perform the Winding Resistance Test proce-
voltage for up to one minute (Figure 4-2, 4-4, 4-5 dure for the desired windings as noted in this
and 4-6. The highest resistance values shown in section.
Table 4-1 should be obtained for a new generator 6. Perform the Insulation Resistance Test and PI
with dry windings. For a set that has been in service, Test procedures for the desired windings as
the resistance reading should not be less than the noted in this section.
lower value shown.
If low readings are obtained, the cause should be in-
PI Test: The PI test consists of applying a voltage vestigated and corrected before the generator set is
between the winding and ground for ten mInutes returned to service.
and recording resistance values at one minute and
at ten minutes. The PI is the ratio of a ten minute If moisture is determined to be the cause of low test
reading in megohms divided by a one minute read- readings, a winding drying process will be required.

TABLE 4-1. GENERATOR WINDING RESISTANCE

MINIMUM RESISTANCE (MEGOHMS)

GENERATOR VOLTAGE MEGGER VDC MAIN STATOR MAIN ROTOR EXCITOR STATOR/
SETTING ROTOR
600 VAC or less 500 5.0 − 1.0 5.0 − 1.0 5.0 − 1.0

601 thru 5000 VAC 2500 400 − 50

1000 5.0 − 1.0 5.0 − 1.0

5001 thru 15000 VAC 5000 1000 − 200

1000 5.0 − 1.0 5.0 − 1.0

4-3
 DRYING THE WINDINGS Skip steps 3, 4 and 5 if using the generator fan to
dry the windings.
If low readings are obtained and moisture is deter- 3. Bolt the generator three phase output termi-
mined to be the problem, the windings should be nals together.
dried out and the test repeated. Use the generator
heaters or blow warm air through the generator with 4. Connect the positive and negative leads of a
a fan. variable 12 VDC source to connector 10 as fol-
lows:
A more effective way is to run the genset without ex- Positive lead − Red wire of connector 10-6 (X)
citation to use the generator fan to blow air over the Negative lead − Brown wire of connector 10-3
windings or use a bolted 3-phase short across the (XX)
generator terminals to heat the windings. This pro-
cedure must be done as described or equipment CAUTION Voltage must begin at zero
damage can result. To do this: volts and be gradually increased or equip-
ment damage will result. The current will in-
1. Remove the housing cover of the electronics crease rapidly and it must be monitored to
box and remove connector 10 from the regula- prevent exceeding the generator rating.
tor output module. See Figure 3-10.
5. Attach a clamp-on ammeter to the generator
2. Disable generator excitation using the InPower leads to measure generator current, adjust the
service tool. In the Test/Manual Operation 12 VDC source for zero voltage, start the set
group, set the parameter Excitation Disable and very slowly increase the excitation voltage.
Override to Excitation Off. (Note that this pa- Obtain the highest current possible without ex-
rameter will return to Excitation On whenever ceeding generator rating.
the controller powers down.) 6. Run the genset for approximately one hour,
Without disabling excitation, the controller will then repeat the insulation resistance tests. If
shutdown the genset and display Low AC Volt- further drying time is indicated, continue the
age. drying process.

4-4
GENERATOR/PCC CONTROL ISOLATION grounded side of the system to avoid inadver-
PROCEDURE tently imposing 24 volts on the system.
5. Check polarity again. Polarity must be correct
The following procedure is used to determine if the or this test will be inconclusive because the in-
generator or the PCC control circuitry is causing a duced and residual magnetic polarities in the
high AC voltage shutdown fault. exciter stator will be opposed.
1. Throw the line circuit breaker OFF and shut WARNING HIGH VOLTAGE. Touching uninsu-
down the set. lated high voltage parts inside the control box
CAUTION This test involves unregulated ex- can result in severe personal injury or death.
citation of the generator. To prevent damage to Measurements and adjustments must be done
the generator due to overcurrent, make sure with care to avoid touching high voltage parts.
that all loads have been disconnected and that
For your protection, stand on a dry wooden plat-
all faults have been cleared from the power out-
form or rubber insulating mat, make sure your
put terminals of the generator.
clothing and shoes are dry, remove jewelry and
2. Remove the housing cover of the electronics wear elbow length insulating gloves intended
box and remove connector 10 from the regula- for hazardous voltages.
tor output module. See Figure 3-10.
6. Start the set and connect the jumper from the
3. Prepare to measure output voltage across the battery negative (−) terminal to the XX lead.
generator terminals while the set is running.
7. The generator circuitry is probably okay if rated
4. Bring two jumpers from a 12 volt battery for output voltage or higher is obtained and the
connection to the X (Field +) and XX (Field −) voltages for all phases are balanced when the
pins of plug P10. exciter is powered by a 12 volt battery. Refer to
X = Red wire of connector 10-6 Troubleshooting and Repair PCC Manual to
XX = Brown wire of connector 10-3 troubleshoot the PCC control circuitry. (Normal
Connect the jumper from the positive (+) post excitation voltage ranges from approximately
of the battery to the X pin (red wire) of connec- 10 VDC at no-load to approximately 40 VDC at
tor 10-6. Be prepared to connect the jumper full−load.)
from the negative (−) post of the battery to the 8. If the voltages are unbalanced, troubleshoot
XX pin (brown wire) of connector 10-3. If one of the main stator first. If the voltages are uniform-
the 12 volt cranking batteries is used, bring the ly low, troubleshoot the exciter and field circuits
jumpers from the battery connected on the first.

4-5
 EXCITER STATOR Testing Winding Insulation Resistance: Discon-
nect exciter stator leads F1 and F2 from their con-
Testing Winding Resistance: Measure winding nectors in the AC generator wiring harness and iso-
resistance with a Wheatstone bridge or digital ohm- late them from ground.
meter. Replace the stator if winding resistance is
not as specified in Tables 4-2/4-3.
Connect the megger between one of the leads and
Before performing the following insulation resis- ground and conduct the test. Refer to Table 4-1 for
tance test, refer to the Insulation Resistance and Po- megger voltage selection and required resistance
larization Index Test procedure at the beginning of values.
this section.

MEASURE WINDING INSULATION

RESISTANCE BETWEEN EITHER
LEAD AND THE STATOR
LAMINATIONS

MEASURE WINDING RESISTANCE

BETWEEN THE TWO STATOR
LEADS, F1 (X) AND F2 (XX)

FIGURE 4-2. TESTING THE EXCITER STATOR

4-6
EXCITER RECTIFIER BRIDGE (ROTATING Replacing Diodes: Make sure the replacement di-
RECTIFIER ASSEMBLY) ode is of the correct polarity. Disconnect the pigtail
from the terminal post and unscrew the old diode.
The exciter rectifier bridge is mounted on the exciter Apply heat-sink compound under the head of the di-
rotor, inboard, facing the main rotor. It consists of a ode. Make sure the compound does not get on the
positive plate and a negative plate, split diametri- threads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8
cally. Each carries three diodes, three terminal N•m) and the pigtail terminals to 24 in-lbs (2.7 N•m)
posts for connecting exciter rotor leads to the diode when reassembling.
pigtails and a terminal for the main rotor (generator
field) lead. A surge suppresser is connected across
Surge Suppresser Testing and Replacement:
the two plates to prevent transient voltages that
Remove the suppresser. Replace the suppresser if
could damage the diodes.
it appears to have overheated or if ohmmeter read-
ings indicate less than infinite resistance (end of
Testing Diodes: Disconnect the diode pigtails from
scale) in both directions. Torque the terminals to 24
the terminal posts. Using an ohmmeter, measure
in-lbs (2.6 N•m) when reassembling.
electrical resistance between each diode pigtail and
the plate on which the diode is mounted. Reverse
the meter test probes and repeat the tests. The CAUTION Layers of dust can cause diodes to
electrical resistance across each diode should be overheat and fail. Brush dust off regularly.
high in one direction and low in the other. If the re-
sistance is high or low in both directions, replace the
diode.

DIODE (ONE OF SIX) TERMINAL

DISCONNECT THE DIODE PIG- (ONE OF SIX)
TAIL FROM THE TERMINAL
AND MEASURE ELECTRICAL
RESISTANCE BETWEEN THE
PIGTAIL AND THE METAL DIODE PLATES
PLATE UNDER THE DIODE (TWO)

SURGE SUPPRESSER
REMOVE TO TEST

FIGURE 4-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

4-7
 EXCITER ROTOR Before performing the following insulation resis-
tance test, refer to the Insulation Resistance and Po-
Testing Winding Resistance: Disconnect the six larization Index Test procedure at the beginning of
rotor winding leads from the terminal posts on the this section.
rectifier assembly. With a Wheatstone bridge, mea-
sure electrical resistance across each pair of rotor Testing Winding Insulation Resistance: Discon-
windings: U (CR1 or CR4) and V (CR2 or CR5), V nect all six exciter rotor leads from diode terminals
(CR2 or CR5) and W (CR3 or CR6), W (CR3 or CR1 through CR6 and isloate them from ground.
CR6) and U (CR1 or CR4). See the winding sche-
matic. Replace the whole rotor shaft assembly if the Connect the megger between one of the leads and
resistance of any winding is not as specified in ground and conduct the test. Refer to Table 4-1 for
Tables 4-2/4-3. megger voltage selection and required resistance
values.

MEASURE WINDING INSULATION

RESISTANCE BETWEEN ANY LEAD
OR THE TERMINAL TO WHICH IT IS
CONNECTED AND THE ROTOR
LAMINATIONS
MAIN ROTOR
LEADS

WINDING SCHEMATIC

DISCONNECT THE SIX ROTOR WINDING

LEADS FROM THEIR TERMINALS AND
MEASURE ELECTRICAL RESISTANCE
ACROSS EACH PAIR OF WINDINGS: U-V,
V-W, W-U

FIGURE 4-4. TESTING THE EXCITER ROTOR

4-8
 MAIN ROTOR (GENERATOR FIELD) larization Index Test procedure at the beginning of
this section.
Testing Winding Resistance: Disconnect the two
leads of the main rotor from the terminals on the ro- Insulation Resistance and PI Test: Disconnect
tating rectifier assembly. See Figure 4-5. Measure the main rotor and voltage suppressor leads from
electrical resistance between the two leads with a terminals F1+ and F2− on the rotating rectifier as-
Wheatstone bridge or digital ohmmeter. Replace semblies and isolate them from ground. Tag and
the rotor if the resistance is not as specified in mark each lead with its terminal number (F1+ or
Tables 4-2/4-3. Connect the rotor leads and torque F2−).
the terminals to 24 in-lbs (2.6 N•m) when reassem-
bling. Connect the megger between one of the rotor leads
and ground and conduct the test. Refer to Table 4-1
Before performing the following insulation resis- for megger voltage selection and required resis-
tance test, refer to the Insulation Resistance and Po- tance values.

MEASURE WINDING INSULATION RESIS-

TANCE BETWEEN EITHER ROTOR LEAD AND
THE ROTOR LAMMINATIONS

DISCONNECT THE MAIN ROTOR LEADS

FROM THE ROTATING RECTIFIER ASSEMBLY
AND MEASURE THE WINDING RESISTANCE
BETWEEN THEM

FIGURE 4-5. TESTING THE MAIN ROTOR

4-9
 MAIN STATOR Insulation Resistance and PI Test: Remove and
separate all leads of the generator from the genera-
Testing Main Stator Winding Resistance: Dis- tor load terminal block. Number of neutral leads
connect all stator leads from the terminals to which (three or six) to remove will vary between low and
they are connected. Using a Wheatstone bridge medium voltage generators.
having at least 0.001 ohm precision, measure elec-
trical resistance across each pair of stator leads:
U1-U2, V1-V2, W1-W2, U5-U6, V5-V6 and W5-W6. Connect the megger between one phase of the sta-
Replace the stator if the resistance of any winding is tor and ground while grounding the other two
not as specified in Tables 4-2/4-3. phases and conduct the test. Refer to Table 4-1 for
megger voltage selection and required resistance
Before performing the following insulation resis- values.
tance test, refer to the Insulation Resistance and Po-
larization Index Test procedure at the beginning of
this section. Repeat this step in turn for the other two phases.

WHEATSTONE
BRIDGE

FIGURE 4-6. TESTING THE GENERATOR STATOR

4-10
 TABLE 4-2. WINDING RESISTANCE VALUES (FRAME 7)*

MAIN STATOR MAIN EXCITER EXCITER

FRAME SIZE
WINDING 12 WINDING 07 ROTOR STATOR ROTOR

7G 0.0044 0.006 1.64 17 0.096

7H 0.0036 0.0044 1.75 17 0.096

TABLE 4-3. WINDING RESISTANCE VALUES (FRAME 8)*

VOLTS MAIN EXCITER EXCITER

FRAME SIZE HZ MAIN ROTOR
L-L STATOR STATOR ROTOR
380-415 50 0.000483
LV814C 440-480 60 0.000483 1.33 15 0.096
600 60 0.000700
380-415 50 0.000368
LV814D 440-480 60 0.000368 1.426 15 0.096
600 60 0.000500
3.3K 50 0.0544
MV814C 4.16K 60 0.0544 1.164 15 0.084
2.4K 60 0.0200
3.3K 50 0.0429
MV814D 4.16K 60 0.0429 1.229 15 0.084
2.4K 60 0.0140
6.6K 50 0.340
11K 50 0.945
HV814C 1.21 15 0.084
7.2K 60 0.340
13.8K 60 0.945
6.6K 50 0.280
11K 50 0.780
HV814D 1.28 15 0.084
7.2K 60 0.280
13.8K 60 0.780
6.6K 50 0.220
11K 50 0.615
HV814E 1.38 15 0.084
7.2K 60 0.220
13.8K 60 0.615

* Resistance figures are approximates, at 68° F (20° C) + 10%.

4-11
 TESTING THE PMG be at least 150 VAC for 50 Hz sets and at least
180 VAC for 60 Hz sets, and should be approxi-
HIGH VOLTAGE. Touching mately the same for each set of leads. If the
uninsulated high voltage parts inside the voltages are low or uneven, check all the leads
control and power output boxes will result and connections between the voltage regulator
in severe personal injury or death. Mea- output stage module and the PMG and repair
surements and adjustments must be done as necessary before disassembling the PMG.
with care to avoid touching high voltage
parts. 4. Stop the set and measure electrical resistance
across lead pairs 10-1 & 10-4, 10-4 & 10-5, and
For your protection, stand on a dry wooden 10-5 & 10-1 with a Wheatstone bridge or digital
platform or rubber insulating mat, make ohmmeter. Refer to Generator Reassembly in
sure your clothing and shoes are dry, re- this section for frame size.
move jewelry and wear elbow length insu-
lating gloves intended for hazardous volt- TABLE 4-3 PMG STATOR RESISTANCE
ages.
1. Disconnect connector 10 from the regulator
FRAME SIZE PMG STATOR RESISTANCE
output module.
2. Start the engine at the set and let the speed sta- 7 2.6
bilize.
3. Measure voltage across lead pairs 10-1 & 10-4, 8 1.1
10-4 & 10-5, and 10-5 & 10-1. Voltage should

4-12
 FRAME 7 BEARING Bearing Replacement: The instruction sheet pro-
INSPECTION/REMOVAL vided with the bearing kit is required to complete the
following procedure.
The end bearing is enclosed in a pre-packed ma-
chined cartridge. A grease fitting is provided to al- Frame 7 generator component parts cannot be or-
low re-greasing of the bearing with a grease gun dered from Onan. Refer to the Newage nameplate
(see Operator’s manual for grease quantities, and supply all available information. Contact your
maintenance intervals, and procedure). nearest Newage distributor for assistance in order-
ing component parts.
Bearing Inspection: If a situation occurs which al-
lows an opportunity to visually inspect the end bear- 1. Lift slightly on end of rotor shaft and install
ing with it installed, check the color of the grease. wooden shims to hold rotor on center with sta-
The color of the grease is the only indication that tor.
can be used to determine if the bearing is defective.
2. Install bearing onto rotor shaft. Refer to bearing
New grease is a whitish-beige color but some mild kit instruction sheet.
discoloration will occur with use. If the grease
shows signs of gross discoloration, the bearing 3. Install two threaded studs into end bearing car-
should be replaced. tridge to aid subsequent procedures. Position
Bearing Removal: The bearing is press fitted onto the end bearing cartridge assembly close to
the shaft and can be removed with standard work- proper position for hole alignment with end-
shop tools (i.e., two or three legged manual or hy- bracket.
draulic bearing pullers). The bearing should only be
removed for replacement (bearing is destroyed dur- 4. Install endbracket to the stator frame using the
ing removal and must be replaced). proper screws and lock washers, but do not
The end bearing is enclosed in a pre-packed car- tighten securely as yet.
tridge housing and must only be dismantled as nec-
essary for relubrication, replacement, or when a 5. Insert and start the threads of the bearing car-
major overhaul is carried out on the generator set. tridge fasteners, and remove threaded align-
ment studs, through the endbracket into the
Removal of the bearing can only be accomplished cartridge housing.
after removal of the endbracket, as follows:
1. Remove the endbracket (complete steps 1 6. Lift slightly on endbracket and remove wooden
through 21 of the Main Stator and Rotor Re- shims holding rotor on center with stator.
moval (Frame 7) procedure.
7. Securely tighten the endbracket fasteners.
2. Remove the four screws holding bearing cap.
8. Tighten the bearing cartridge fasteners to 4.5
3. Remove cap.
ft-lbs. (6 N•m) torque.
4. Remove circlip.
9. Install the PMG assembly. Refer to Permanent
5. Remove bearing cartridge housing complete Magnet (PMG) Installation (Frame 7) proce-
with bearing. dure.

4-13
 FRAME 7 GENERATOR DISASSEMBLY 3. Remove the two front frame separators.
The following procedures provide information for
4. Remove the three M5X12mm capscrews and
removal and reassembly of the generator PMG ex-
lockwashers from the PMG cover, and remove
citer, the control housing and stator/rotor assem-
blies. Be sure to read through this section first, be- cover.
fore performing procedures listed, to determine the
5. Disconnect the PMG wiring harness connector.
steps most appropriate for the service attention re-
quired. 6. Remove the four bolts and clamps retaining the
Medium-voltage, 601 to 15,000 exciter stator housing to the endbracket.
volts, present special hazards of severe per-
sonal injury or death. Even after genset shut- 7. Tap the stator housing out of its spigot, and
down, an electrical shock hazard may still exist, carefully remove from generator endbracket.
caused by induced voltage within the genera-
tor. Service personnel must be well-trained/ The highly magnetic rotor will attract the stator
core; care must be taken to avoid any contact
qualified to work with distribution voltages. which may damage the windings.
Permanent Magnet (PMG) Removal
8. Remove the hex head through-bolt from the ro-
(Frame 7)
tor shaft and firmly pull the complete rotor as-
1. Disconnect the negative (-) battery cable to sembly from its location. Keep the rotor clean
prevent accidental starting of the generator set by avoiding contact with metal dust or particles.
while servicing. Place in a plastic bag as soon as is practicable.
WARNING Arcing at battery terminals, arc- CAUTION The rotor assembly must not be
ing in light switch or other equipment, dismantled, or the magnetic properties will
flame, pilot lights and sparks can ignite bat- be destroyed.
tery gas causing severe personal injury.
Permanent Magnet (PMG) Installation
Ventilate battery area before working on or (Frame 7)
near battery—Wear safety glasses—Do not
smoke—Switch trouble light ON or OFF 1. Install the complete rotor assembly to the end
away from battery—Stop genset and dis- of the main rotor shaft using the hex head
connect charger before disconnecting bat- through-bolt. Keep the rotor clean by avoiding
tery cables—Disconnect negative (−) cable contact with metal dust or particles.
first and reconnect last.
2. Carefully locate the stator housing to position
CAUTION Disconnect battery charger on the generator endbracket. (The leads must
from AC source before disconnecting bat- be located at the top and facing out, Figure
tery cables. Otherwise, disconnecting 4-2.) Fasten in place using the 4 bolts and
cables can result in voltage spikes damag- clamps, and tighten securely.
ing to DC control circuits of the set.
The highly magnetic rotor will attract the stator
WARNING Accidental starting of the gen- core, care must be taken to avoid any contact
erator set while working on it can cause se- which may damage the windings.
vere personal injury or death. Prevent acci-
dental starting by disconnecting the nega- 3. Connect the PMG wiring harness connector.
tive (−) cable from the battery terminal.
4. Install the PMG assembly cover using the three
2. Remove the control housing lower and middle M5x12mm capscrews and lockwashers, and
front panels (see Figure 4-7). tighten securely.

4-14
 CENTER FRAME
SEPARATOR

UPPER SIDE
PANEL

MIDDLE FRONT
PANEL

SCREWS (4) TO
CENTER FRAME
SEPARATOR

FRONT FRAME
SEPARATORS

LOWER FRONT
PANEL

LOWER HOUSING TO SKID ISOLATOR

MOUNTING SCREWS
LOWER SIDE
PANEL

FIGURE 4-7. REMOVING FRAME 7 CONTROL HOUSING

4-15
Main Stator and Rotor Removal (Frame 7) nector for the engine block heaters (INLINE F)
and place harness on top of control housing.
1. Remove the PMG, refer to Permanent Magnet
Exciter Removal, earlier this section. 9. Disconnect and remove PT/CT harness as-
sembly (connectors 08 and 09) from inside
2. Remove the upper and lower side panels of the electronics box.
control housing. To remove the upper side pan-
els, note that there are four screws (M6) that 10. Use a hoist or similar lifting device to support
secure the panel to a center frame separator. the control housing assembly (see Figure 4-8).
3. Remove the generator air discharge covers WARNING To prevent personal injury, use
(see Figure 4-1).
adequate lifting devices to support heavy
CAUTION Do not use fan blade to bar over components. Keep hands and feet clear
engine. That can damage blades and cause while lifting.
property damage and personal injury.
11. Remove the center screw of the four mounting
4. Crank or bar the engine/generator to position isolators to separate the upper housing from
the rotor such that a full pole face is at the bot- the lower housing assembly. The upper and
tom of the main stator core. Proper positioning lower housing assemblies must be removed as
can be viewed through the generator access two separate items to prevent damaging the
openings. Refer to engine service manual for mounting isolators.
proper cranking or barring procedure.
12. Using the hoist, remove the upper control
5. Disconnect all load wires from the reconnec- housing assembly from the generator.
tion terminal block assembly. If equipped with
the circuit breaker option, disconnect load 13. Remove the fasteners that secure the lower
wires from circuit breaker. Check that all leads housing assembly to the skid (four screws per
are labeled to ease reassembly. side) and using the hoist, remove lower hous-
ing from generator.
6. Disconnect the remote control wiring and con-
duit from the control housing. For reconnec- 14. Remove as necessary, air intake components
tions later, make sure each wire is clearly to engine that may interfere with disassembly
marked to indicate the correct terminal. and reassembly of generator.

7. Disconnect the three ground cables inside the To remove the stator and rotor at the same time,
control housing that attach to the following as- refer to Generator Assembly Removal, later this
semblies: front panel control box, electronics section. To remove the stator and rotor individu-
box and the control housing. Disconnect the ally, continue with step 15.
cables from the generator saddle.
15. Remove the four bolts retaining the bearing
8. Disconnect the engine harness connectors cartridge housing in the endbracket (outer four
(INLINE A, B, and C) and the DC power con- bolts).

4-16
16. Remove the eight bolts holding the endbracket
GENERATOR
to the generator housing. (BRACKET NOT LIFTING
SUPPLIED) POSITIONS
17. Insert two bolts (M10) in the two holes provided
for “jacking” purposes, on the endbracket cen-
ter line. Screw bolts in until endbracket spigot
is clear of locating recess.

18. Carefully tap the whole assembly off the bear-

ing cartridge housing, ensuring the endbracket
is supported to prevent the exciter stator from
damaging the windings on the exciter rotor.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
19. Assemble lifting eyes to generator (see Figure MOUNTING FEET
4-8). Rear of generator requires a bracket (not BRACKETS
supplied) with three holes, to attach lifting eye
to rear of generator. Secure this bracket to the
top of the generator housing using two of the FIGURE 4-8. FRAME 7 LIFTING POSITIONS
bolts removed in Step 16.

4-17
20. The exciter stator is now accessible for inspec- until the mounting feet brackets are clear of the
tion and removal from endbracket/engine frame member (see Figure 4-8).
adaptor.
24. Disconnect the grounding strap from the fly-
21. The end bearing can now be removed if re- wheel housing.
quired. Refer to Bearing Removal (Frame 7).

22. Remove the fasteners from the four generator 25. Using a forklift, position a lifting bar of the forklift
mounting feet brackets. (inside and inline with the generator) under the
rotor shaft. Lift the rotor shaft slightly so that ro-
23. Using an adequate lifting device, lift the gener- tor is not resting on inside of stator assembly.
ator (at lifting eyes, and main stator housing) See Figure 4-9.

USE FORKLIFT OR STATOR ROTOR

OTHER ADEQUATE ASSEMBLY ASSEMBLY
LIFTING DEVICE TO LIFT LIFT
SLIGHTLY LIFT ROTOR
SHAFT UNTIL ROTOR
CAN BE SUPPORTED
BY HOIST/SLING.

STATOR ROTOR
ASSEMBLY ASSEMBLY

FIGURE 4-9. REMOVING STATOR ASSEMBLY (FRAME 7)

4-18
26. Verify that the stator is adequately supported 28. Reposition or add hoist and sling support for
and then carefully remove the capscrews from the main rotor, and remove the forklift. See Fig-
the stator attachment ring. ure 4-10, Rotor Lift detail.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy WARNING To prevent personal injury, use
components. Keep hands and feet clear adequate lifting devices to support heavy
while lifting. components. Keep hands and feet clear
while lifting.
CAUTION Improper stator assembly rig-
ging and handling can result in damage to
stator and rotor assemblies. Lifting eyes 29. Remove the stator assembly, being careful not
may not be at center-of-gravity position of to drag the windings on the rotor. Place stator
stator assembly. Therefore, lifting and mov- assembly away from the chassis in the horizon-
ing the stator assembly alone, by hoisting tal position.
at lifting eyes only, presents the hazard of
load imbalance; allowing one end to drop
30. Using the hoist and sling to support the rotor,
and other end to rise. Make sure the stator
carefully remove the capscrews and flat wash-
is adequately hooked/strapped to maintain
ers that secure the drive discs to the engine fly-
level control of stator assembly while lifting
wheel.
and moving.

27. Being careful not to drag the windings on the WARNING To prevent personal injury, use
rotor, move the stator assembly sufficiently adequate lifting devices to support heavy
away from engine to sling and support the rotor components. Keep hands and feet clear
assembly. Do not allow rotor assembly to hang while lifting.
on engine flywheel.

CAUTION Drive disc damage can be 31. Remove the rotor assembly and place it on
caused by allowing the rotor assembly to wood blocks in the horizontal position. To avoid
hang on flywheel. Use adequate hoist and possible distortion, do not allow the drive discs
sling to support the rotor assembly. and fan to rest on anything.

STATOR LIFT
(EXAMPLE)

ROTOR LIFT
(EXAMPLE)

FIGURE 4-10. STATOR/ROTOR LIFT EXAMPLE

4-19
Generator Assembly Removal (Frame 7) gine flywheel housing. Align the holes of the ro-
tor drive discs with the holes of the engine fly-
32. Remove the fasteners from the four generator wheel. Install the capscrews and flat washers
mounting feet brackets. that secure the drive discs to the engine fly-
wheel, hand tighten.
33. Using an adequate lifting device, lift the gener-
ator (refer to Step 19). WARNING To prevent personal injury, use
adequate lifting devices to support heavy
34. Disconnect the grounding strap from the fly-
components. Keep hands and feet clear
wheel housing.
while lifting.
35. Carefully remove the capscrews and flat wash- CAUTION Improper generator assembly
ers that secure the drive discs to the engine fly- rigging and handling can result in damage
wheel. to stator and rotor assemblies. Lifting eyes
36. Verify that the generator assembly is ade- may not be at center-of-gravity position of
quately supported. Carefully remove the caps- stator assembly. Therefore, lifting and mov-
crews securing the engine adaptor endbracket ing the generator by hoisting at lifting eyes
to the engine flywheel housing. only, presents the hazard of load imbal-
ance; allowing one end to drop and other
WARNING To prevent personal injury, use end to rise. Make sure the generator is ade-
adequate lifting devices to support heavy quately hooked/strapped to maintain level
components. Keep hands and feet clear control of assembly while lifting and mov-
while lifting. ing.

CAUTION Improper generator assembly 2. Align the holes of the engine adaptor end-
rigging and handling can result in damage bracket with the holes in the flywheel housing
to stator and rotor assemblies. Lifting eyes and install the capscrews and lock washers.
may not be at center-of-gravity position of Tighten fasteners to 85-100 ft-lbs. (116-136
stator assembly. Therefore, lifting and mov- N•m).
ing the generator by hoisting at lifting eyes
only, presents the hazard of load imbal- 3. Secure the rotor assembly to the flywheel.
ance; allowing one end to drop and other Tighten fasteners to 150-180 ft-lbs. (204-245
end to rise. Make sure the generator is ade- N•m).
quately hooked/strapped to maintain level
control of assembly while lifting and mov- 4. Connect the grounding strap to the flywheel
ing. housing using a capscrew and EIT locking
washer; and tighten securely.
37. Remove the generator assembly away from
engine. Place generator assembly on floor with 5. Install the mounting feet bracket fasteners; and
a piece of wood beneath the stator housing (to- tighten securely.
ward PMG end) to allow for endbracket remov-
al, if desired. If endbracket has been removed, continue with
step 6, otherwise skip to step 14.
Generator Reassembly (Frame 7)
6. Lift slightly on end of rotor shaft and install
Generator reassembly is the reverse of disassem- wooden shims to hold rotor on center with sta-
bly procedure. tor.
To assemble the stator and rotor at the same time,
continue with step 1. To assemble the stator and ro- 7. Install two threaded studs into end bearing car-
tor individually, skip to step 15. tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to
1. Using an adequate lifting device, locate the proper position for hole alignment with end-
generator assembly into position near the en- bracket

4-20
 8. Assemble exciter stator, if removed, to inside of WARNING To prevent personal injury, use
endbracket. Tighten fasteners to 4.5 ft-lbs. (6 adequate lifting devices to support heavy
N•m) torque. components. Keep hands and feet clear
while lifting.
9. Install endbracket to the stator frame using the
proper capscrews and lock washers, but do not 18. Secure the rotor assembly drive disc to the fly-
tighten securely as yet. wheel using appropriate capscrews and flat
washers. Tighten fasteners to 150-180 ft-lbs.
10. Insert and start the threads of the bearing car-
(204-245 N•m). Do not allow rotor assembly to
tridge fasteners, and remove threaded align-
hang on engine flywheel.
ment studs, through the endbracket into the
cartridge housing.
CAUTION Drive disc damage can be
11. Lift slightly on endbracket and remove wooden caused by allowing the rotor assembly to
shims holding rotor on center with stator. hang on flywheel. Use adequate hoist and
sling to support the rotor assembly.
12. Securely tighten the endbracket fasteners.
19. Reassemble engine adaptor endbracket to
13. Tighten the bearing cartridge fasteners to 4.5 stator frame if removed. Using an adequate lift-
ft-lbs. (6 N•m) torque. ing device, carefully move the stator into posi-
tion over the rotor assembly, being careful not
14. Install the PMG assembly, if removed. Refer to to drag the windings on the rotor.
Permanent Magnet Exciter Installation.
WARNING To prevent personal injury, use
Perform the ‘Aligning Generator with Engine’
procedures, later in this section, then return to adequate lifting devices to support heavy
the following steps. components. Keep hands and feet clear
while lifting.
To assemble the control housing, skip to step
32. CAUTION Improper stator assembly rig-
ging and handling can result in damage to
To assemble the stator and rotor individually be- stator and rotor assemblies. Lifting eyes
gin here. may not be at center-of-gravity position of
15. If removed, replace exciter rotor and rotating stator assembly. Therefore, lifting and mov-
rectifier assembly to main rotor shaft. Recon- ing the stator assembly alone, by hoisting
nect main rotor wire leads to positive and nega- at lifting eyes only, presents the hazard of
tive terminals of rectifier assembly. load imbalance; allowing one end to drop
and other end to rise. Make sure the stator
16. If removed, install the drive disk spacer, drive is adequately hooked/strapped to maintain
disc and pressure plate on the rotor shaft. level control of stator assembly while lifting
Install the cap screws and flat washers and and moving.
tighten to 607 ft-lbs. (822 N•m).
20. Using a forklift, position a lifting bar of the forklift
17. Using a hoist and sling to support the rotor, (inside and inline with the generator) under the
align the holes in the drive disc with the corre- rotor shaft. Lift the rotor shaft slightly so that ro-
sponding holes in the flywheel. tor is not resting on inside of stator assembly.

4-21
21. Remove the hoist/sling support of the rotor as- 29. Lift slightly on endbracket and remove wooden
sembly. Align the holes of the engine adaptor shims holding rotor on center with stator.
endbracket with the holes in the flywheel hous-
ing and install the capscrews and lock wash- 30. Securely tighten the endbracket fasteners.
ers. Tighten fasteners to 95-105 ft-lbs.
(129-142 N•m). 31. Tighten the bearing cartridge fasteners to 4.5
ft-lbs. (6 N•m) torque.
Perform the ‘Aligning Generator with Engine’ 32. Remove generator lifting eyes. Reassemble
procedures, later in this section, then return to
control housing mounting brackets to sides of
step 22.
generator and fasten securely.
22. Reassemble the covers over the generator air 33. Use an adequate lifting device to lift the control
discharge openings and fasten securely. housing in position for mounting to the stator
frame. Replace the capscrews and lock wash-
23. Connect the grounding strap to the flywheel ers and tighten to 20 ft-lbs. (27 N•m) torque.
housing using a capscrew and EIT locking
washer; and tighten securely. WARNING To prevent personal injury, use
adequate lifting devices to support heavy
24. Install the mounting feet bracket fasteners; and components. Keep hands and feet clear
tighten securely. while lifting.
34. Reassemble any engine air intake compo-
25. Install two threaded studs into end bearing car- nents removed during generator disassembly.
tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to 35. Connect all control wires and generator leads
proper position for hole alignment with end- using the proper generator set AC and DC wir-
bracket. ing diagram/schematic.

26. Assemble exciter stator, if removed, to inside of 36. Refer to Permanent Magnet Installation.
endbracket. Tighten fasteners to 4.5 ft-lbs. (6
N•m) torque. 37. If equipped with the circuit breaker option, re-
connect load wires to circuit breaker. Recon-
nect all lead wires to the terminal block assem-
27. Install endbracket to the stator frame using the
bly.
proper capscrews and lock washers, but do not
tighten securely as yet. 38. Verify that all connections are proper and se-
cure and then install the air inlet panel and ac-
28. Insert and start the threads of the bearing car- cess covers to control housing.
tridge fasteners, and remove threaded align-
ment studs, through the endbracket into the 39. Connect the negative (-) battery cable and test
cartridge housing. the generator set for operation.

4-22
 FRAME 8 BEARING 6. Crank or bar the engine/generator to position
INSPECTION/REMOVAL the rotor such that a full pole face is at the bot-
tom of the main stator core. Refer to engine
The end bearing is enclosed in a pre-packed ma- service manual for proper cranking or barring
chined cartridge. A grease fitting is provided to al- procedure.
low re-greasing of the bearing with a grease gun
(see Operator’s manual for grease quantities, 7. Remove the four bolts retaining the bearing
maintenance intervals, and procedure). cartridge housing in the endbracket (outer four
Bearing Inspection: If a situation occurs which al- bolts).
lows an opportunity to visually inspect the end bear-
ing with it installed, check the color of the grease. 8. Remove the eight bolts holding the endbracket
The color of the grease is the only indication that to the generator housing.
can be used to determine if the bearing is defective.
9. To support the end bracket and rotor during end
New grease is a whitish-beige color but some mild bracket to frame removal, attach a suitable
discoloration will occur with use. If the grease sling with a pair of hooks located into two of the
shows signs of gross discoloration, the bearing end bracket inspection holes. The lifting capac-
should be replaced. ity will vary according to the generators core
length, but could be as much as 4,000 pounds.
Bearing Removal: The bearing is press fitted onto
the shaft and can be removed with standard work- 10. Insert two bolts (M10) in the two holes provided
shop tools (i.e., two or three legged manual or hy- for “jacking” purposes, on the endbracket cen-
draulic bearing pullers). The bearing should only be ter line. Screw bolts in until endbracket spigot
removed for replacement (bearing is destroyed dur- is clear of locating recess.
ing removal and must be replaced).
1. Remove the PMG (see Permanent Magnet Re- 11. Carefully tap the whole assembly off the bear-
moval procedure). ing cartridge housing, ensuring the endbracket
is supported to prevent the exciter rotor from
2. Disconnect PMG stator leads P2, P3, and P4. dropping onto the exciter field bore.

3. Remove external bearing lubricating pipe. WARNING To prevent personal injury, use
Note component locations before removal to adequate lifting devices to support heavy
aid in re-assembly. components. Keep hands and feet clear
while lifting.
4. Remove the four bolts retaining the outer bear-
ing cap and remove the outer bearing cap and 12. Remove bearing cartridge housing complete
PMG stator as an assembly, taking care not to with bearing.
damage the PMG stator windings.
13. The cartridge housing contains an O-ring
5. Remove wave washer and circlip on the outer which should be examined and replaced if
side of the bearing inner race. worn.

4-23
Bearing Replacement: The instruction sheet pro- 4. Install endbracket to the stator frame using the
vided with the bearing kit is required to complete the proper screws and lock washers, but do not
following procedure. tighten securely as yet.
Frame 8 generator component parts cannot be or-
dered from Onan. Refer to the Newage nameplate 5. Insert and start the threads of the bearing car-
and supply all available information. Contact your tridge fasteners, and remove threaded align-
nearest Newage distributor for assistance in order- ment studs, through the endbracket into the
ing component parts. cartridge housing.
1. Lift slightly on end of rotor shaft and install
wooden shims to hold rotor on center with sta- 6. Lift slightly on endbracket and remove wooden
tor. shims holding rotor on center with stator.

2. Install bearing onto rotor shaft. Refer to bearing 7. Securely tighten the endbracket fasteners.
kit instruction sheet.

3. Install two threaded studs into end bearing car- 8. Tighten the bearing cartridge fasteners to 4.5
tridge to aid subsequent procedures. Position ft-lbs. (6 N•m) torque.
the end bearing cartridge assembly close to
proper position for hole alignment with end- 9. Install the PMG assembly. Refer to Permanent
bracket. Magnet (PMG) Frame 8.

4-24
 FRAME 8 GENERATOR DISASSEMBLY CAUTION Use shims between all poles to
The following procedures provide information for maintain air gap between rotor and stator
removal and reassembly of the generator PMG ex- during generator removal or permanent
citer and generator assembly from the engine and damage to exciter and PMG assembly will
removal of end bearing. Be sure to read through this occur.
section first, before performing procedures listed, to
determine the steps most appropriate for the serv- 3. Place shims (non-compressible material such
ice attention required. as plastic) between all four poles. Minimum air
gap must be maintained in all radial directions
Medium-voltage, 601 to 15,000 from the center of the bore to prevent damage
volts, present special hazards of severe per- to the exciter and PMG assembly. Minimum air
sonal injury or death. Even after genset shut- gap is 0.2 inch (5 mm). Normal air gap is
down, an electrical shock hazard may still exist, approximately 0.3 inch (7.5 mm).
caused by induced voltage within the genera-
tor. Service personnel must be well-trained/ 4. Disconnect all load wires from the reconnec-
qualified to work with distribution voltages. tion terminal block assembly. If equipped with
the circuit breaker option, disconnect load
Generator Assembly Removal (Frame 8) wires from circuit breaker. Check that all leads
are labeled to ease reassembly.
1. Remove the generator air discharge covers
(see Figure 4-7). 5. Disconnect remote control wiring between
generator and control box. For reconnections
CAUTION Do not use fan blade to bar over later, make sure each wire/plug is clearly
engine. That can damage blades and cause marked to indicate the correct terminal.
property damage and personal injury
6. Remove as necessary, air intake components
2. Crank or bar the engine/generator to position to engine that may interfere with removal of the
the rotor such that a full pole face is at the bot- generator assembly.
tom of the main stator core. Proper positioning
can be viewed through the generator access 7. Attach cables of lifting device to generator lift-
openings. Refer to engine service manual for ing points shown in Figure 4-11. (Two lifting
proper cranking or barring procedure. points per end-plate).

GENERATOR
LIFTING
POSITIONS
(BOTH ENDS)

END-PLATE

WOOD
BLOCKS

FIGURE 4-11. FRAME 8 LIFTING POSITIONS

4-25
 8. Remove the fasteners from the four generator WARNING To prevent personal injury, use
mounting feet brackets. adequate lifting devices to support heavy
components. Keep hands and feet clear
9. Disconnect the grounding strap from the fly- while lifting.
wheel housing.
CAUTION Improper generator assembly
10. Remove the capscrews and flat washers that rigging and handling can result in damage
secure the drive discs to the engine flywheel. to stator and rotor assemblies. Make sure
the generator is adequately hooked/
11. Remove the capscrews securing the engine strapped to maintain level control of as-
adaptor endbracket to the engine flywheel sembly while lifting and moving.
housing.
2. Align the holes of the engine adaptor endbrack-
WARNING To prevent personal injury, use et with the holes in the flywheel housing and
adequate lifting devices to support heavy install the capscrews and lock washers. Tight-
components. Keep hands and feet clear en fasteners to 85-100 ft-lbs. (116-136 N•m).
while lifting.
3. Secure the rotor assembly to the flywheel.
CAUTION Improper generator assembly Tighten fasteners to 150-180 ft-lbs. (204-245
rigging and handling can result in damage N•m).
to stator and rotor assemblies. Make sure
Perform the ‘Aligning Generator with Engine’
the generator is adequately hooked/ procedures, later in this section, then return to
strapped to maintain level control of as- the following steps.
sembly while lifting and moving.
WARNING To prevent personal injury, use
12. Remove the generator assembly away from adequate lifting devices to support heavy
engine. Place generator assembly on the floor components. Keep hands and feet clear
using wood blocks under the four mounting feet while lifting.
brackets so that the stator does not rest on the
floor and also to prevent the generator from 4. Reassemble any engine air intake compo-
rolling. nents removed during generator disassembly.

Generator Reassembly (Frame 8) 5. Connect all control wires and generator leads.

Generator reassembly is the reverse of disassem- 6. If equipped with the circuit breaker option, re-
bly procedure. connect load wires to circuit breaker. Recon-
nect all lead wires to the terminal block assem-
1. Using an adequate lifting device, locate the bly.
generator assembly into position near the en-
gine flywheel housing. Align the holes of the ro- 7. Perform the Aligning Generator with Engine
tor drive discs with the holes of the engine fly- procedure, later in this section.
wheel. Install the capscrews and flat washers
that secure the drive discs to the engine fly- 8. Connect the negative (-) battery cable and test
wheel, hand tighten. the generator set for operation.

4-26
Permanent Magnet (PMG) Removal 5. Tap the stator housing out of its spigot, and
(Frame 8) carefully remove from generator endbracket.

1. Disconnect the negative (-) battery cable to The highly magnetic rotor will attract the stator
prevent accidental starting of the generator set core; care must be taken to avoid any contact
while servicing. which may damage the windings.

WARNING Arcing at battery terminals, arc- 6. Remove the hex head through-bolt from the ro-
ing in light switch or other equipment, tor shaft and firmly pull the complete rotor as-
flame, pilot lights and sparks can ignite bat- sembly from its location. Keep the rotor clean
tery gas causing severe personal injury. by avoiding contact with metal dust or particles.
Ventilate battery area before working on or Place in a plastic bag as soon as is practicable.
near battery—Wear safety glasses—Do not
CAUTION The rotor assembly must not be
smoke—Switch trouble light ON or OFF
dismantled, or the magnetic properties will
away from battery—Stop genset and dis-
be destroyed.
connect charger before disconnecting bat-
tery cables—Disconnect negative (−) cable Permanent Magnet (PMG) Installation
first and reconnect last. (Frame 8)
CAUTION Disconnect battery charger
1. Install the complete rotor assembly to the end
from AC source before disconnecting bat-
of the main rotor shaft using the hex head
tery cables. Otherwise, disconnecting
through-bolt. Keep the rotor clean by avoiding
cables can result in voltage spikes damag-
contact with metal dust or particles.
ing to DC control circuits of the set.
WARNING Accidental starting of the gen- 2. Carefully locate the stator housing to position
erator set while working on it can cause se- on the generator endbracket. Fasten in place
vere personal injury or death. Prevent acci- using the 4 bolts and clamps, and tighten se-
dental starting by disconnecting the nega- curely.
tive (−) cable from the battery terminal.
The highly magnetic rotor will attract the stator
2. Remove the four screws and lockwashers from core, care must be taken to avoid any contact
the PMG cover, and remove cover. which may damage the windings.

3. Disconnect the PMG wiring harness connector. 3. Connect the PMG wiring harness connector.

4. Remove the four bolts and clamps retaining the 4. Install the PMG assembly cover using the four
exciter stator housing to the endbracket. screws and lockwashers, and tighten securely.

4-27
 ALIGNING GENERATOR WITH ENGINE flex in alternate directions twice for each engine rev-
olution. It is important to minimize the amount of
Proper alignment of the generator and engine as- disc flexing since, if it is excessive, the drive disc will
semblies is necessary to avoid premature wear and crack. Although perfect bearing alignment is desir-
improper operation of the genset. Review the fol- able, it is more important to keep disc deflection to
lowing alignment conditions and procedures for the minimum possible. This procedure assumes
aligning the generator assembly to engine flywheel that the pilot bore of the drive discs are in the exact
housing. center and the flywheel counterbore (pilot) has no
Angular Misalignment: Is the result of the genera- practical runout. Under these conditions, perfect
tor bearing center axis not aligning with axis of the Angular alignment will be attained when no deflec-
engine crankshaft. This condition creates an angle tion of the disks is measured.
between the generator shaft axis and the crank- Excessive Axial misalignment will cause more gen-
shaft axis. The cause of this type of misalignment is erator vibration than Angular misalignment.
usually shimming error.
Axial misalignment should be checked only when an
Axial Misalignment: Is the result of the generator objectionable vibration is present.
shaft axis not aligning with engine crankshaft axis. Either type of misalignment may be present in a
The tolerances in the bolted flywheel and drive disc generator set assembly, with angular misalignment
connection may add up to displace the generator being the most common problem. Angular align-
axially relative to the crankshaft axis. ment may also be effected by set installation condi-
Misalignment Symptoms: If the assembly is al- tions and/or mishandling during shipping of the gen-
lowed to run under these conditions, the discs must set.

4-28
Angular Alignment Procedure disc at the bolt circle diameter, see Figure 4-12. Bar
the engine over in a clockwise rotation as viewed
WARNING Accidental starting of the generator from engine flywheel. Do not allow it to roll back on
set during this procedure presents the hazard compression at the end of the travel of each read-
of severe personal injury or death. Make sure to ing. It is unnecessary to zero the indicator since the
disconnect the negative (−) battery cable(s) be- total indicator reading (T.I.R.) of the deflection mea-
fore beginning. surement to the bolt heads is what is required. T.I.R.
Fasten a dial indicator to either the generator shaft will be the sum of the maximum positive and nega-
or the cooling fan with the sensing point resting on tive dial indicator readings as the engine completes
the capscrew head or the flat surface of the drive one revolution.

DIAL
CLAMP INDICATOR

GENERATOR AND
ENGINE AXIAL
CRANKSHAFT ALIGNMENT, SEE
CENTERLINE FIGURE 4-14
SHIMS FLEX
DISCS

FIGURE 4-12. ANGULAR ALIGNMENT MEASUREMENT

4-29
Sample Generator Runout Readings 2. Measure the distance from the generator side
of the flex discs to the center of the generator
When taking the deflection readings described, mounting bolt, refer to Figure 4-12. (For exam-
make a diagram similar to the example shown in ple; a HC6 Frame’s distance is 28.4”.)
Figure 4-13, where a total indicator reading of .025”. 3. Compare the distance measured in steps 1 and
(The highest positive value of +.010 and the largest 2. (28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiply
negative value of -.015”.) The indicator is closer to this ratio times one half the T.I.R. (In our exam-
the top and further away at the bottom. This exam- ple, .025” divided by 2 is .0125”. This, times
ple indicates that the generator bearing is high. 2.65 equals .033”. Therefore, remove .033” of
Since the side readings are equal, the generator is shims from under the four mounting feet of the
centered side to side. To lower the generator, re- generator.)
move equal shims from under the four generator
In general, the T.I.R. should not be more than .001”
mounting feet. To approximate the amount of shims
for each inch of radius (center of shaft to indicator
to remove or add:
axis). If we use our example of 10.7”, then the maxi-
1. Measure the distance between the center of mum T.I.R. would be .011”. This would only require
the generator shaft to the point the indicator is a correction of .014” from the T.I.R. of .025”. (A read-
measuring at. (For example; a SAE 18 Disc ing of +.002 at the top and -.009 at the bottom would
coupling distance is 10.7”). fall within the satisfactory range.)

+.010
+.010
MEASURED AT
BOLT CIRCLE
DIAMETER

-.002
-.004

10.7 IN.

-.010
-.010

-.015
-.015

FIGURE 4-13. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example)

4-30
Axial Alignment Procedure the varying surface quality of the generator shaft’s
drive disc mountain hub.
Axial misalignment needs to be checked only when
an objectionable vibration is present. The goal of the Axial realignment is to reduce the
vibration level of the genset while it is operating. A
If excessive vibration remains after the angular small improvement in the T.I.R. runout may have
alignment, check for concentric alignment of the dramatic effects in the mechanically measured or
generator shaft/engine crankshaft axes. physically observed vibration levels.
Fasten dial indicator holding device to skid base, To correct for an out of tolerance T.I.R. indication,
engine block, or generator shell with a magnetic remove the capscrews connecting drive discs and
base or clamp and position so the sensor point of in- flywheel. Mark the drive discs and flywheel with re-
dicator rests on the generator shaft hub, see Figure spect to each other. Rotate either the engine or gen-
4-14. Bar the engine over in a clockwise rotation as erator so that drive discs holes are repositioned
viewed from engine flywheel, through a couple of 180 degrees from their original location. Put the
rotations. Record indicator readings in eight equally drive discs capscrews back in and retorque. Re-
spaced points around the shaft diameter. This will check shaft alignment as before. If shaft T.I.R. run-
provide a T.I.R. for Axial shaft misalignment. out remains unchanged then the discs should be ro-
The maximum allowable T.I.R. runout is subjective, tated to either 30, 60, or 90 degrees from original
the optimal T.I.R. for runout would be .000”, how- location to correct the out of tolerance condition. If
ever, that may not be attainable. The recommenda- the T.I.R. does not improve after repositioning, a
tion of this procedure will be to reduce the meas- closer inspection of the flywheel pilot and drive disc
ured T.I.R. runout by one half. Specific out-of-toler- runouts is required. This will help determine the
ance runout levels are difficult to establish due to cause of the Axial misalignment.

DIAL GENERATOR
ANGULAR ALIGNMENT, SHAFT HUB
INDICATOR
SEE FIGURE 4-12

CLAMP

GENERATOR
AND ENGINE
CRANKSHAFT
CENTERLINE FAN HOUSING

FIGURE 4-14. AXIAL ALIGNMENT MEASUREMENT

4-31
THIS PAGE LEFT INTENTIONALLY BLANK

4-32
 5. Wiring Diagrams
GENERAL
This section consists of the schematic and connec-
tion wiring diagrams referenced in the text. The fol-
lowing drawings are included.
• Page 5-2 through 5-9, Genset Wiring Diagram

5-1
 No. 612-6744 sh 1 of 8
Rev. D
Modified 4/02

GENSET WIRING DIAGRAM (1 OF 8)

5-2
 No. 612-6744 sh 2 of 8
Rev. D
Modified 4/02

GENSET WIRING DIAGRAM (2 OF 8)

5-3
 No. 612-6744 sh 3 of 8
Rev. D
Modified 4/02

GENSET WIRING DIAGRAM (3 OF 8)

5-4
 No. 612-6744 sh 4 of 8
Rev. D
Modified 4/02

GENSET WIRING DIAGRAM (4 OF 8)

5-5
 No. 612-6744 sh 5 of 8
Rev. D
Modified 4/02

GENSET WIRING DIAGRAM (5 OF 8)

5-6
 No. 612-6744 sh 6 of 8
Rev. D
Modified 4/02

GENSET WIRING DIAGRAM (6 OF 8)

5-7
 No. 612-6744 sh 7 of 8
Rev. D
Modified 4/02

GENSET WIRING DIAGRAM (7 OF 8)

5-8
 No. 612-6744 sh 8 of 8
Rev. D
Modified 4/02

GENSET WIRING DIAGRAM (8 OF 8)

5-9
Cummins Power Generation
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Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email ask.powergen@cummins.com
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