cummins960-0504 (1)

7/28/2019 CUMMINS960-0504 (1)

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Servie Manual

GENERTOR ND CONTROL

9 9

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7/28/2019 CUMMINS960-0504 (1)


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SCT TTL E PREAON •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• i

NRODON

hs Maa

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11Te i . .. . . . . ... . . . .. . . . . .. . . . .. . . . . . . . . . .. . . .. . . . .. .. . . . . . ... . . . . .. . . . .. . . . . . . . . . . . . . .. . . . ... . . . .. .... ... .. . .. ... . . .. ...... 11

n .. . . .. . . . ... ...... .. . . . . .. . .... ... .. .. . . . .. . . .. .. . . .. .. . . ...... .. .. . . . . .. . . . . .. . . . . . ... .. . . .. .. . . . . . . . .. . . . 11Cls a e ................................................................................................... 12

2 OOGeneal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1l De . .. . . . . .. .. . . ... .. ... . .. . .. . . . .. . . . ... . . . ... . . . . .. . . . . . . ... ... .. . . . . . . .. . . .. .. . . . .. . . . . .. . . . . .. . .. . .. ... . .. ...... ... . . . ... 21Cl Pa Ie .. ....... ... ..... ..... 2-Gee n ..... ...... ...... .... ...... .. ...... ...... .... .... ...... .... . ...... ... ..... ..... ....... .. ..... ..... ...... ..... 2

3 GENERAORGe Dens . .. . . . .. .. .. . ... ... .. . . . . .. .... .. . . . . . . . .. . . .. .. .. . .. . . . . .. . . . . .. . . . .. . . . . ... . . . .. . . .. .. .. .. ... ... .. . . . . . . .... .... 1Geat Cnl Cnts . .. .. ..... -2Genea n .... ..... ..... ..... ..... .... ..... ..... .... ..... ..... .... .... ..... ..... ..... .... ...... ..... .... .... .......... .. -nal C Breae .

.......... ........... ............ ........................ .......... ROBEHOOINGGeneal ......................................................................... 1

MPEN E AND ADJNGenea .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

E C M ECM .......................................................................................... 51n Rel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5e Rey s .... ...... ..... . m lay a M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55C Mee a a ....... ..... ..... ..... ..... ..... ... ...... ...... ..... .... ..... ...... ... ...... ....... 5-5

Vl Rlat. at n Re ......... . . V

M... 5-10

e M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510e e Den M le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10R Re ssely . . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .. .. . . .. . . . . . . . . . . .. . . . . .. . . . . . . . . . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . ... . . ... . . .. 511Pe nt M ne Exe .... ..... .. ...... ...... . .... ..... ..... ..... ..... .. ..... .... ..... ..... . ...... ...... ..... ..... ..... ...... ..... . 5-1 1E xe R . .... .... ...... ..... .... ..... ..... ..... ..... ..... .... ...... ..... . ...... ... .... ..... ... ... ...... .... ..... ..... ...... ...... ....... .. 5-12E xe Sa .. . . . . .. . . . . .. . . . . . .. . . . . . . .. . . . . . .. .. . . . . .. . . . .. . . .. . . . . ... . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. 512Ge .. .. .. ... ..... . 5-1 2Ge atr . . ..... .... ..... ..... ..... .. .. ...... ..... ...... ..... ..... ...... . ....... .. ... .. ..... ... ........ ... .. . . ...... . ............. 5Recnnecn . .... ...... . .... .... ........ 5-14

Eg Elc ver . . ... . . . ... 5-1Batees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Be Cas . .. . . . . .. . . . . .. . . . . . . . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . . . .. . . .. 51Alenar . ... .. ... ....... 5-18 le . . . . . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . . . . . . .. . . . . .. . . . . .. . . . . . . . . . .. . . . . .. 5-1Fel e .... .. ..... ... ....... .... ........ . .. .. ..... ..... .... ....... ... ...... ..... .. . ..... .... ....... ... ...... ....... ..... .. ...... ...... ... .. 518Cl ch . . ......... .. ... ....... . ... ........ ... . . . ......... ... ..... .. . .. ....... ..... .. . . ........ ... ...... ... . ... .. ...... ... . .. . . . .... .... 5-18

he esTest AC La C Breaer .. ... .. .. .. .. . .... .. .. . .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . . . .. .. .. .. . . . . ... . . . .. 518

GNRAOR DAMB/RAEMBGeer Dsasse ..... . .. ..... . ... .. .. Genear eassey ... ... .. .. ... ... ... . .. ... ... ... . .. ... ... ... ... ... ... ... ... .. .... ... .. . .. .. . ... . . ... ... ... . .. .. .. .. .... . ..... .... . ..

7 WIRING DIAGRAM/HEMAIC ••••••••••••••••••••••••••••••••••••• eer Ust

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Safety Preautinsere perting the genertr et, read the Operator's Manual and become familiar with it and theequipment e nd ecent rtn cn be

che ny the eqet rpry per t nd mntin. Many accidents are causedby failure to follow fundamental les and precau tions.

The following symbols, found troughout this manual, alert you to potentially dangerous conditions to

the operator, serice personnel or te equipment

•M# This symbo was of Immate hazards which wlresut In severe peona/In- ju or dth.

AWRNINGTh/s symbol fers to a hard or unsafe practce which can sut In seve per sona nju or dth

A CAUON This symbo fers to a hrd or un safe practce whch can resut In persona/Injuor product or ppe damage

UL US

Fire, explosion, and personal injury or deat can result from improper practices

• DO NOT fill fuel tanks while engine is nning,unless tanks are outside the enine compaent Fel onta wth ot egne o exaustis a tential re hzard

• DO NOT permit any flame ciaree pilot light,spark, arcing equipment, or tr igninsource near the generator t el tank

• Fuel lines must be adequatey ured andfree of leaks Fuel cnnecn at te engineshould be made it an av leile lineDo not use copper pipin n fleile lines ascopper ill become brile if ntinuusy vibrat or repeatedly nt

• Be sure all fuel supplies have a positive shutoff ale

•Do not smoke hile icing lead acid batteries Lead acid batteries emit a highly explosiehydrogen gas tat can ignited by electricalarcing or by smoking

XHUST SS

• Proide an adequate exhaust system to properly expel discharg gases away from enclosed or sheltered areas and areas where individuals are likely to congregate Visually andaudibly inspect the exhaust daily for leaks per the maintenance scedule Ensure that ex

haust manifolds are secured and not warpedDo not use exhaust gases t heat a compament

• Be sure the unit is well entilat

TS C CS SS J TH

• Keep your hands, clothing, and jewelry awayfrom moing pas

• Before staing work on the generator set, disconnect staing batteries negative () cable

rst This will preent accidental staing• Make sure that steners on the generator set

are secure Titen supps and clamps,keep guars in position ve fans, drive lts,etc

• Do not wear lse clothing or jewelry in te icinity of mving pas o ile working on elec

trical equipment Lse clothin and jewelcan become cauht in moving pas Jewelcan so out electcal contacts and causeshock r burning

•If adjustment must be made while the unit isnning, use etreme cation around hot maniolds, moving pas, etc

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LCTCL CK C CS L JY T

• Ree ele pwer befre reing pr eie shields r uhng electrical equipen Use rubber insulatie mats placed n

dy wd plafrs er flrs that are meal or nrete when arund electrcal uipmentD not wear dap lthing (paculaly weshoes) r allw skn surface to be damp whenhandlng eral equipment

• se extree cauton when woing on elecral opnens Hgh oltages can cause inu or deah DO NOT tamr with intelks

• Fllw all appliable state and lal electialodes Hae all electrcal installations perfored b a qualifed licensed eleian Tagopen swihes ad aidental closure

• DO NOT CONNCT GNATO ST DIRCTY TO ANY BUIDING CTICA SYST. Hazardus oltages can flow from he generar se n the utlity line This reates a ptenial r eltrution or propedamage Cnne nl through an approedisolation switch r an appro palleling deie

T T SSk 5k

•igh ltage acs dierently than low oltageScial equipent and training is requir towo on r around high oltage equipmentOratin and aintenane must be dneonly by persons rained and qualied to wrk on such deies Improper use or predureswill resul n seere prsnal n r a

• D nt w n enerized equipment Unauhrized persnnel us nt peritednear energzed equipent Due he naureof high lage elecrical equipmen, induedltage remains een aer the equipen is

disnneed fr he pwer soure Plan he ie r aintenan with authorized persnnel s that the equipment can be de-energzedand safel grunded

TY CUT

• Clans under pressure hae a hgher bilingpin han waer DO NOT pen a radiar hea exhanger pressure cap while the engine

s nning Allow he generar se t cl anbleed the sste pressure rs

• Benzene and lead, fund in me gasolinehae been idenied b sme state and eraagencies as ausing aner r repructie xiit When hecking, draining or adding

gasline, take care n ingest, breathe thefumes, r ntat gasline

• Used engine ils hae bn identied by somese r federal agenies as ausing cacer o

reprduce xiiy When hecking ohanging engine il, take care n to ingestbreahe the fumes, r nact us oil

• Prde appropiate re extinguishers and install hem in nenient laons Cosult thlal re depaent r the coect ype of ex

nguisher to use Do not use am o electal res se exnguishes t byNFP

• ake sure that rags are not le on or ar he

engine

• Reoe all unneessary grease ad oil fom he uni Auulated grease and oil canause erheaing and engine damage whichpresen a ptential fire hazard

• Keep he generar set and the suundingarea lean and ree fro bsns Reoe an debris from the t and keep theflr lean and d

•D n w n his equipen when menallr phsicall faigued, r aer nsuing analhl r dg that makes the opetion o

equpent unsafe

KEE TH ANUA NEAR THE ENET FR EA REFERENE

S-10

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Section 1 Introducion

B niS ULTs maa pdes tublest a epa noon gad te tos a geneatos u on te

olw geneo sets

GENERAOR

MODE RANGDEGNAON

DFAA 1 75 200DFAB 200 230DFAC 220 250

DFBC N 1 75 200

DFBD N 175 200DFBD N 200 230DFBE N5 220 250

DFBF N6 250 275DFCB NA2 275 300DFCC NA3 31 0 350

DFEB KA1 2 330 00DFEC 00 50DFFA K1 1 00 50DFFB K1 2 450 500

DFGA VA1 0 500DFGB VA2 600DFGC VA3 550

DFA KA31 620 750DFB KA32 660 800 K 8 DFD 00 1000

DFA KA51 00 10DFB KA52 1 1 0 0DFC KA53 1 1 20 1 250DFD K5 1200DFMA KT1 1100 120DFMB KT2 1280 1500

Fo ue oaton se a toublest noaton egad ene nents ee to ptmanuals scc to you geato set.

Study ts manual caeully a obsee all wangs acaons. su to evew Sfety Pcautns. on ages a . s te geneato set ey a oo a

la mantee ule s mant to e unt e e oae a se a

Fo epace pas deon ee to apte Pas aa h ut

Repa o pnt t a nts ote t uses us wetaned ua e t tp eupt epa o te p t t e exce by te o onmetes o ot lde to pnt t ads ote tan uaed n can cae uneaa exnve ge

Hgh og g o hg (o g) g o g

u dg c. ah g.

y pa, main o f is ml • ms wi un, r n yr diibur.

ST t te te e s a o h a AC te a e 2 VO o ta VO t to h e a:

Btey te ate Fe ete ea Weatstone Bdge o gta Ote Vaac oad est Pane Mee o nlaton essae Mete

T BT SCays gve te mplete Mode a Seal num o t

geneato set as sown on te naplate wen seeaddonal sece nomaon o eement pats. Tnapate s ated on te sde o te geneato outx

& nc c o pacn s n rsl v a nu dan ipmn mag. Sc nnl m quafi o l ad mniic. ad and w f ransgs and

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CTLS TS

eneralDependng on customer order, the control optons andgenerator type may dffer Read through ths manua to dentfy the control optons, and generator type A more n-depth descrpton of the contro an generator comnents follow n the Conrols and Generaor sectonsRead ths nformaton wel and u nderstand the functon ofeach comnent

lso perodcally revew ths manual and the untperator's Manua when no fault condton s present Youwl want to bee famar wth the generator set component locatons, ther proper operaton and nteractonwth other comnents n order to be effeve trou-bleshootng a faut condton f one ccurs

@

§ = [

OTH GT T NTS

i.e, VOTAG AN FQUY

� A ATS UT X. TO STO

A TG U TANSOS

T S UT O TO SO 2

O O SS O OTA

T SS

ontrol anelThe contro panel s unted nsde the front rton of thegenerator output x wth vbraton solators on th topand ttom he contros are separated nto a DC panelfor ntong the engne and an AC panel for ntorngthe generator. See gure 1 and Secton 2

eneratorThe generators ftted to ths seres of generator sets area Permanent Magnet Generator (PMG) type

he generatos are controlled by an Automatc VoltageReguator (AVR) Te AVR s mounted on the nsde backwall of the contro pane See gure1 1 and Seon 3.

VTAG GUTO(AT NS

T PAN) TO ST

PA {F TO STO 2

PO

FGURE 11 TYPAL PG GEERATOR AD OTROL

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Secton 2 Controls

GENERADei on stome ode the nt naton

a options y ffe his sion ideies the ntnfiaons us Deteo7 a Dto12 (NPA)DC Pane, a AC Pa oons.

he nt panes ae sepat in an AC pa fonito the geo ui th te oons)a a pane fo nito the e Revi gue21 to identify the nt non a o aefe to Co Descipons that fow fo futhe infomation.

ONTRO ERON ahe fo des the fuon a on of theoona AC pane fo to the geneto Revithe fowi mnent des a igu 21

o (): a it i- i n AC Masue in useswn on io

(): a ae instnt -es AC ato n e Measu e in

us on iato a (): es ato fe in he e s in tnsmite (RPM).

(): Conousy ves e of thegeo outt in atts

o u (): Rh vi xiey ps o nus ve justnt of the atedout vo

S o

es wh to u on the AC vote ACammete

P (): Ss as oo out to mea by AC vote a ACammete.

Ps o ete ot f oee n the e o an o

PGAGE

PETESC

P

ACVTTE

ACAETE

PAEELECTR

WITC

FREQUECY/RPMMETER

WAMETER

TEPTAL

METER

J P J

IDATAPS

CATTEMPERATRE\ GAUGE

C

UR 2·

(TOR2 D C MR

2

R TMETER

TACMEER

TEMREAUE

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DC anelhe wng descrbes the unctn and operatn o theDC panel cmponents The Detectr? panel s standard,and Detectr 2 panel ncludes ptns t re e ec- ey ntr the generatr set and ancllary equpmentrng peratn th cntrls nclude prealarm mn-trng to n the perator that a shutdwn mght occur

attenton s not gven to an aspect o engne peratonsn Review the llowng comnent descrptns andgure 2 .

anel Lamp Illumnates control panel.

Ol ressu Gauge: Indcates pressure o lubrcatng l n engne (wred to a sensr unt lcated n the engne)

Waer emperaure Gauge: Indcates temperature crculatng clant n engne (wred to a sensr untlcated on the engne).

DC olmeer: Indcates the battery cndton Proper

readng shuld be apprxmately 26 t 28 volts when set s nnng

achomeer(Oplonal}:Provdes constant mntorng engne rmn

O emperaure Gauge (Oponal) Indcates tempera ure lubrcatng ol n engne (wred t a sensr un tcated n the engne).

unSopemoe Swch: Stas and stops the untlcally, r rm a remte locatn that s wred t the contrlengne n tr ard

ese Lamp es anel Lamp Swch: Resets the aultcrcut only when the RunStopRemote swtch s n theStp (Reset) ston Tests ault lamps and turns n thecntrl panel lamp

requencdus (poal): Potentmeter pvdngengne speed adustment to acheve prper AC requency

unng me er: Regsters the total number ohours the un t has n Use t to keep a record perodcservcng me s cumulatve meter cannot be reset

Emergenc Sop Pushbuo (poal): Stops thegenerator set mmedately wen depressed ust bereset (pulled out) beore restang generator set

ndicator Deor7 (Sada): e standard cntlpanel has seven montor system ndcator lamps

RUN (green) PRE LO OIL PRES (yellow) PRE I EN G TEP (yellow)• LO OIL PRES (red) I ENG E P (red)

OVERCRANK (red)

OVERSPEED (red)

22

The green Run lamp cmes on as sn as bth prmaryand seconda starer crcuts are opened ater unt stars.The yellw prealarm lamps ndcate that engne ol pres-sure s margnally lw, r coolant temperature s margnally hgh and should be attended to when the geneatrset s shut dwn. The red ault lamps ndcate a shutdwn the generatr set r lw ol pressure, hgh engne tem-

perature, overspeed, or overcrank ault cndtn

Deecor2 Conrol {Oponal) The optonal cntrlpanel has a 2 lamp mntorng system The llwng de-scrbes each lamp uncton.

RUN (green) lamp comes on when both starer crcutsare opened ater unt stars.

PRE LO OIL PRES (yellow) ndcates engne ol pressure s margnally lw

PRE I ENG TEP (yellow) ndcates engne temper-ature s margnally hgh

LO OIL PRES (red) ndcates engne has shut dwnbecause crtcally low ol pressure.

I ENG TEMP (red) ndcates engne has shut dwnbecause o crtcally hgh temperature.

OVERSPEED (red) ndcates engne has shut dwn because o excessve speed

OVERCRANK (red) ndcates the starer has beenlcked out because o excessve crankng tme.

AUL 1 (red) an uedcated ault ay be program-

med as a tmed or nntmed shutdown or aut lght only(normally acty set or tmd shutdown)

ues as aul (nally act set r nntmed shutdwn)

LOW ENG TEP (yellow) engne temperature s mar-gnally low r stang Icates ssble noperatvecoolant heater Lamp l gts when engne water ackettemperature s 70° (21 C) r lwer e lamp maystay on during ntal generator set peratn but shuldg out ater the engne warms up

LO UEL (yellow) ndcates ue l supply s margnally lw

( equpped)

SWIC O (lasng red) ndcates generator set snt n autmatc sta operatn de

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ONTRO PANE NTERORRefe to igue 22 fo comnent ocations ins ide contopane Review the foowing comnent desciptions tobette undestand the opeation of the geneato setshoud a faut condition o Aso efe to Seion 5Compnen ess a djsmens, fo e indepth

infomation aut these comnents

ARDTB21

AUTT VOTAGEREGULAT (AVR)

VR21(E SECT 3

ENG IT (ECM)

A

T YDST/

A5

FU 2·2 NTL PANL NT

PD

(

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ngine ntl ontorhis rcuit a assembly ntains the basic -nents for ma eine staup a shutwn, tenalsfor rete ntl intennecon, pugin nnecor foroption us a eine senr is The ECMprovides the folwi fuions of unit protecon

erank ts eine cnki to 7 ss. H

eine fails to sta, the ue ights a fau lamp aons the cranki ciuit. This cycle canki cirit al-ws the 1 s crai ces with two 1 s-o res s

• vepeed Shuts wn the ei imiatey anoversed ion rs a lights a faut a. Thegeneor sets are uid th an overs (fque teion) ue, insi the pane Theule is faory set to shut wn the generator set ataxitely 21 00 rin z units), or 1 80 rmin(0 z unts) Refer to mnen e a - secon for fuher infoation

• ow Presre Shus n the ei imiatey o pressu drops w 1 4 psi (97 kPa) a ghts afaut lamp The fau is inhited dui cranki atime deayed 1 0 ses folwi stater disnnect The lay aws oil eure to se to afo the electnic ntl ule nitor thissystem.

The e oi preure sensor a lamp pvides analarm that oi pssu is mainally w, 20 i (1 kPa) or ess The cau shou fou a tas sn as ibe

•igh Ene Teru Shuts wn the e immediatey ant teu rises ave 21 ° (1 02° C) an ights a fau a. The fau i inhitdu ci a eay 10 s fo t nn ay a lnt ina ot eine to rate a tu the water aetto o the enic ule resnto this system

The prehigh ei terure nr a a p-vide an aam that eine terre is mainayhigh, 20° (97° C) or higher The cau s fou a cted as as ibe

A CUTION T high ine p t s- n v w e high gine rmn L a a t gi ve ung v t giJ inin e v i high engi wn

ow Clant Level Shutn (onal) A statesenr inall into the rior pvies eine sh wn if ant eve falls t w It also ights the high

eine temrature fau lamp. 2

Fu he ECM has ve placeable fuses to prote itfrom oveads a gu fauts. They are

F Staer leid ciuit, 20 asF2 ue ei (itched +) ciits, 20 asF3 Connuous out to te ciits, 1 asF ECM ciits, aF Eine guage its, as

Fuin n Te ECM has x selec- on m that can retioned to vide thefowi m or nm wais or timed or n m shns th wais

umr Position ur st in the B -tion)

A Nont wa uer FL 2 itions.B Non utwn a wai uer FL 2

conditions Ti wai uer FL 2 itionsD Tid shutwn a wa ur FL 2 n

ditions

W2 umr Postion ur st in the B -tion)

A Nonti wai uer FL itionsB Nod shutwn a wai uer FL 1

conditions Tid wai uer FL itionsD T shutwn a wa ur FL n-

itions

Jr ition

A Wa ur PHigh Engi enditions

B Sut a wa uer PHigh Engiepru ntions

Jr Pition

A Wa uer PL Ps -tions

B Sh a wa uer PL Oil P ns

Jmr Pn:

A Wa aby uer FL 2 ionsB Alws on of n th ur.

Jr Pn:

A Wa aby uer FL itionsB Al sen of ons ur

e ECM aso has soer nk a ree that n reion to pde other fuio ch as negavesignal e, 1O cle cnk, 7 s ncyce an a s ncycle cnki

7/28/2019 CUMMINS960-0504 (1)


TI

9a.s7 s:_ -1_ _11_2_1 P]" o 1

T

.L _ "N:.o.1 6 3 2 1 r-

RGUE . Ei C O (DCT 12 CM SWN

2

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ng genertor et orton, ll fety ye futon to prott ntor et orton e of thegenertor et dty cyce, when genertor outt dn-need from d the rete n gnl dintiued the tme delyed top fuon of ule A conue the engneenertor n t for the ecengne clwn r of to rnute fore decvt the n cirit of the ECM

taeronnect arameterh ty of ntl ue two n of aerinn n order to ptect the ter in the e one an hou fi he fir ue DC rey K4); B gnltken from the bttey chrgi atetor n t ceenerze the rey to dnnec the ter he meth ue n AC rey K0) ltge fm the genetor eneze th reay to provide bckup to the rely he contro ue thi meth to pvde unnter-ed generor et orton even ony one mean of t dnne i ortionl owever the l Runmp e t ght une th tt dinnect reyorate H the generator et u with a reeRun the orator n then deterrne which meanof t dinnt ha fl for h an urre H therete Run amp ight the Run a e t),the DC lay i t fuon

gh Ene eture E a L l PrereLP) faut are dey 10 fow ter dnnt inhited du crnk ilw the lnt in a eine me to cirlte retu the water et to r terature forethe ECM gn to nitor thi prameter It a alwthe oi preu o i to fore to thi ytem oli th deay hee fau me im-dite t for eine t

H ion a the eine wi ta a he taer wi dinn H t an ove fau byU1 ha ci ot thugh dve trantor oeneize au Reay K6 which the ta ri ofthe ECM e Re itch S1 ) t h o arthe fau fore ttei to ret

tan When he ror e fm he aeor eze San ay K14 Enez- i K1 4 hen c it N . wich ht hen pa Run a A wen the geor

ta votage fm he generaor tor enezeSaernne ay K1 0 Eizi K1 0 henc i N a Ree Rn feuipped)

7

After the trer dinnect the LP f hut wl remn inh ted for ther 0 lw oi pre temrte to twithin the ora r

a tin amerAfter a ucfu eine rtup, wth a io , the ene wl gin in to ver troed oron Shou the ene into an oveitn either an er/Uer rue Senor, ered Mu or mharca oe td on genetor ty a ton oered) wgr the ove nt ut to the ECM to cuehutwn a ght the er fut ter tpbm i ected tr wi t ur unl the Re tch i pre

Contiou rtion of the genertor et a deon the pr oi preu a eine terature intained any tor requir fu on nnected to the ECM

toin ePl the RuStoRete tc to the Stop todeneze Run Reay K) wh on the e hugh the ECM K2) to deeneize he gene or unt fuel oeid top fue fw whh othe eine)

mery hutdown he K6 fu reay i enez when fu enr to o of the fo fau tio: overanw oi preure hgh ene teratu ovea over/uer e/fry i) Ene i the K6 fau reay t NC a a c

it N. nta ni the NC cB fm he Per Reay K a i t ai he e i i c a hut o the fue fC o of the N.. nac of K6 acvate the Kreay wich break er to the fau inteace y h ony the ior a with e fau wi ve Ci he oher N nt of K6 n r tena

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Section 3 Generator

T SCTShe AC enerators are brushless, rotatn fel type, on-

trolle by an automat voltae reulator (AV). Permanent manet exter (PMG) types are se n tese seesof enerator sets he AV of tese enerator sets swee by the permanent manet plot exter whhproves a soure of onstant extaton wer, nepenent of loa anes or loa urrent stoons

BWE

CI

EDBCKETEIEADAPT

T

An exter/rotatn retfer assembly s mounte ntenally to te nonrveen bearn whle te permane

manet exter s overhun rom the nonrvee bean

Removable aess vers are prove at ea e otenerators an on eah se o the ont x leann a nspeton, an easy aess to te out ternals a other anllary eqpment See res 3a 32

EXCITETAT

T

ED BEAI

ATIECTIFIEAEMBLY

FUE 31 TYAL EAT

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T CTL CMPTShe ollo brefly esrbes eeraor elae oroooes ha affe he proper operao or shuoo he eeraor se See Fure 32 or ompoeloaos

uomac olage egulaor

he AVR s ue o he se bak all of he orolbo Refer o Geeraor Operao follo for fuher AVR operao formao a o Compnen Tess and Adusmens seo for fuher espo a ajus-e proeure of he AV

er/nder olage enor odulehs s a ajusabe voHaesesve relay ypallyoee o he Ee Corol Moor (ECM) Faul 1u o shu o he eeraor se he he oupu

OR

PMGVOLTAGE

REGULATORS

PIA GEERATRCTR CPE VEDER

VTAGE A REQECYDUlE) ARE lATED

IIDE CDUIT BX

AC METERIGCURRE TFRMER

(lATED II CIT BX)REFER T ECT

CVER PLATEFR ACCE RATIG

RECTIFER AEMBY)

(

voHae s over or uer he omal volae by hepreselee au (ypally 1 0 pere) he oule -lues a ajusable e elay relay o preve usae rpp (ypally se a 25 pere or approaely 25seos) he moule a e elay relay are moueo a brake he eeraor ou x .

ver/nder requency enor odule

hs s a ajusabe frequeysesve relay ypallyoee o he Ee Corol Moor (ECM) Faul 2 ru f he Over/Uer Volae moule s also salleor Faul 1 or overrequey a Faul 2 for uere-quey sae aloe o shu o e eeraor se he he oupu requey s over or uer e omal frequey by he preselee amou (Also Faul 2 musbe ovee for me shuo) he moule smoue o a brake e eeraor ou x.

VlTAGE REGULATRI lATED IDE

CTR PAEl ADAUIliAR TERMIAl

BARD I lATED IICDUIT BX

CTR PAEl(REFER T ECTI 2)

PACIRCI BREAKER

(T I UTED IDE

CT BX

IURE 3-2 ENERTOR CONTROL COMPONENT LONS

2

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T PTA peret et eertor eter (PMG oute

to the e of the rotor shft, poves wer by wyo the AV to the eter sttor. xtto wer s

therefore epeet of outpu volte result stve vole bulup wthout ele o resulets he eter stto outs he ebell, he exte oto ts ot etfer sse-bly mut o he oo sht. Wh he e bel, es X

+ stve a XX (, eve o he exe so , e o he outu emls o he voe

EXCER

STAT

eulto ( ulry terl blok). The AV opr the sto output wth efee vlue feesotolle exto uet to the exter sttohe AC output o the ete roo s ovete to by he efe ssebly, oprse o s ooue o wo hetsks to fom sve et l o r prd aul ovvo r exple, by sw u oou� y e�e s

M u mb v o m o

l

STAT

E

GSTAT-�I -�-S P

DS

U

33

.

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7/28/2019 CUMMINS960-0504 (1)


Section 4 Troubleshooting

Lhis sen cntai tuleshti infomatn for eieneror c sye.

re to v the

trousoting information as tlined in the unitOr(s Maal bfore r t res in this sn. Refer t e a j�n for fur eierator ifo

tn e ei see als for tonal ifrn t t ei.

Bause this sn cnai inforn vascntl , thgh th n bfore a fl to iy w r a to yr t. This will sa tesi t t ual ne ases.

eo stai a testi re, e a fsle s th m exse t pm. C llif, rirs, r as reants os the lat fo oratn f t gerator setA s or _ot�re i wire cnn, an oned r ui eaker, r a os gin are al l tentialp t b elin ual Wn tsi pm, r t ke r pm a st all e ess. H& s n b cstly, l t yr a,das t ot, y t t pm.

Rass f t c l gerr h t

f pm s are fual

Identfy t fu cn tn s the ci t tke. er, Dt7cntller s ve ll t io th t Dttr-12 h t in fy ther or rir f c i.e., fuel, fau 1 and 2) th y ve sd Yr ial pm

anass fore viei t taes in this n sb to urse the foli qe:

1. W t ei nni when st ? f wstn t e t ove.

2. tn r whin o mite er s u? d, t s e to ressure.

3. Ws ei n ey err r fa ual? I w, t sd w v.

I the i tas , t il , ei teru a e e tter util

s, t ei

ause.Th sn d i eirel tsi tas a gerorrel tue ti f

hs t a y. Ty

Tale 41. Eine .T 4-2. E as b es t.T 4-3. Ei ts, b t ter nni s

ti.T Eirr n, tn a f

C 41 AC r e

sedF C 42. U , i t r s.

F Cha a h or .F Ca Exer fie ker t iF Ca 5 Ula or va C AC th s

aker

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A WRG tblg p t I l I d O q l o l, c, a ld pu R P o d l

TAB ENGINE ES N CRANK

SYMPTOM CAUSE CORREVE ACON

1 C OFF top/ot Pss to s o a s top o t stfas sto

2 fa a Rt stc P a t scto a t t to ft b a ps fa as EC a fat xs tot tc

s p to t s

3. No Fss o EC C fs F1 a F4.a 11 p

s t

p fs:F1 F4 5 A

Ey tto o st c a s OP/EOE c to OP

st s tst t toEE!a s

ta sta t t

Ps f C 1 1 19

11. fo

st t t 1 of a 11

B � o C pa s ssa 11 1 asa

ay EC a 1 1 1-8 a

s

EC fy

4. m y Ps ft C 15 1-4s b m y ta fo a sa 15 C 15 1-5 fos m ay a oap o at 15

1-6 s B+ a ay

C a f 15 1-6 1 1 1-6

4-

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�WRNING M tbltg s t s h I e Idth O q el h kge o l etc, a mh s s s e P d

TABLE 2 ENGINE CRANK B NT TART

YMPTM CAUE CRREE A

1 e la li

Fuel laal li Iie fuel i l Fill wih fueltak

Fuel le es Fu o E fu F2 R t eeize A11 F2 20 re

ssle defeie he for oae a B1 1 0 A11 w ei i

Be wiri or r h a i as bee eessaa A11 B110 afuel le

Fel e Be of fel sl fuel semeeizes, b sstem (fuel l ta, stoffel fws aes, lis a s

fie a trafer et)

�i ha to sa eer sem heer sem rdue to aer keepi ee wa ls , aair terare r s

2. Fau st rs, amp Pla RoRee shb fau la to p si, the depreidiat ae i to est si

to fau lam

3. S ki r Dee a A 1 1 la (A11) .

ote:he a A1 1P ad ls aeto pe e ai,b eerator set sto bore 15 ± s

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I A WR NING Mny bleting pus pt s whi cn In l Inju or

th. On q r pnnel wih kwlge of l ec, an mah sld p R Ps o ll

TABLE ENGINE B STO AER RUNNING SHT

SYMPTOM CAUSE COEcVE AcON

1 e l e le Refer to initil tn Peorm u of OS

dule

Peo t or ei to e tn

I n bfo reint ret OS leI jtnt r fun

u

ei Ei ver fl or Refer to ioertion o jtnt Peo e tet

2 Low l Preure L oil level in eine Reenih el l

LOP ch fl C oil vel, o t nor oil e guI gge i within lre, 1 fu Re

3. Hh E L lnt vel n ei Reenih eTerre l l

HET ch fl C lnt level o t,

nitor ei ter geI gge i within lre, ful R

het defive Rel ttt

Fn b l Jhten fn b

4 fu Inteie l C itn of ll l wiriwiri n m n

44

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�ARNING M tblt pus pt wh l uh O q l wh kwl o ls tc h s s pus w s o p

TABLE ENGINE-ENERAT IS IN OPERATION, THEN A FAULT SHUTWN

SYMTOM CAUSE CORREIV AION

LOP H e A . Refe T 3lamp l

2 Fa 1 Fa 2 e/Ue Vage Refe Tsts a n,a . Fe a a eay adn

by Rea n n gage.

w e e/age ge el i adn fay Refe Ts a n fad epa

faly

w e e/efe e e e y ad fay Refe Ts a j n fadn fay

Refe a geeF a t f

3. fa a be defe f a F f A1 1 A1 1

F an 5 e nn

Pe ea a f a n 1 1-1 0 e

1-10 t 110,M 1 1

y s

4-

7/28/2019 CUMMINS960-0504 (1)


[ A WAR NING Mny te pu prt hs wi cn In v l Inj o

dth. On ql pl wih kge of ls, etc, a mhr s sld

ri pu Revw Sf Pns, o II ad l.

FLOW CHART NO AC OUUT VOLTAGE AT RAD SPEED

Is f CB21 at

vpsin? f r.

No

vcu m Is ?

No

P swk si v I ve uns, h o o r AC t k up? F Ch.

No vh er ut

v k up?

Is ve TB21- NoNo

10 VAC ?

v sl U2 V2 v2122 23. Is 15 VAC �?

No

NoIs e f s VX at x 24 32 VD? Ch c xT ( 6 7

vTB21, ,

C exr w f . b .

C e f s C CR1 C b b

ex C e b

g f w.

AU b.

D n Vo utR21 t l too to u Ch slr s

ad.

46

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AWRNING M tbt pu pt w I e p Iu deat O q l w kowe o et s e pu eew e ut, o pa II d II

FLOW ART UNSTABLE VOLTAGE ENGINE SPD STABLE AT RATED SPEED

A e ay be

o Y as ui C els o u sy ust st plac v m o)ouput NoCh wi s a Noassb C ok

ig o as Y

Ch e ula ust s Y Is e i ss C d g

No Noc ul 1

/ACUTION I D Vo utoV1 utl el t to to u

FL CHAR 3 O VAGE HIGH LO

s n at mNo Aq

v rt ns No f

Y t No p vge?

r• u s

v Is at n l

?

g

JNo o o

Tes cs f ?

Y AUI D n V u 1

V1 utl l t

a t u .

4-

7/28/2019 CUMMINS960-0504 (1)


AWRG M blg ps p s whch I e pl I dh. O l l wh ge o ls ec h s l p Rew Ps o II Ill.

O CA EXCER FIELD BREER I

AC 15

o1 •m s? C f o

ocs V1 .

N

C n . iad.

C ex s . i.

C e b.

C gr . b.

C Sl s. ad.

V r V1.

C V r nns

C g C1. .

A go 19 o 150 p l o l l h. g es l e u b Ioge wh t ge welql o wo wh solges.

A CUTO D n rl Vg Rut V 1 unti exl tr hs b crt u

4-8

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/AWRG M blg ps p s whch I l dh O ql el wh wlge o ls ec hle s s ps Rew Ps o Ill.

FLOW UNBALANCED GENERAT O VOLTAGE

l g l

Y

g p?

Y

I ' w ?

Y

C l f f� na.

No

No

No

C

10 of o d

C r f l

s

A DNGER ge 19 1 h g b Iog t eq o

og

9

7/28/2019 CUMMINS960-0504 (1)


AWRG M lg p s I / I dh O l wh lge o h s sl p Re e Ps o II Ill.

FL NO AC ROUGH SET UND CIRCU BREAKER

s b No s t-l b Fps? ps?Y• Y

D b n k g b t av uprs).

epr).

g e

T

40

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Sec 5 Cmpe essad Adjusmes

GENERALhi en n e a admen nan fthe GenSet ntl, gene, a ene nenRe t th fgue lud wth th nfin a althe Diag ein when nru

ADGER Hih-oae, , to 0 opresent sial s o e nal inu odeah e aer ent shdon, an ellsk h may stil exis us by Indoae hin the enetor See el must eltiquai to o h disributionoltaes

I A CUTION I h inatlo Is pve r nets h as t 's O qlnnel h p uipt sld u this ot to apt i o pt ciu basbles tacti y disto lme s is

GIE ONTRO MOITOR (M)uen ration - ttor7 Ree t hemat dagam n Dg en

when ew h ntn.

Start ntia by aly B gu t P4-7de n the n f �nk a W4

Pn A G ignal n Pn B B+ gnal n

Th eneze n elay whh e N.O nta (9, 14) nne B+ tae ay K3 swh B+elay K aul t, enye a t U1 ,a HET/LOP elay hgh N. f layK8 (16,9). Th al n N. K7 (9,16), nneB+ t the ee (K6)

K enee NO 3 nneB+ ena 110 f F a P-9rg fe F

K3 ee, NO 3 nB+ enal TB18 g fe F1 ll me U1 g ye elay K1 U1 an bpamd ge 3 by mn ea U1 n 1 , a 1 R6 n 1 wh R8 n1 = 3 a

U1 ll enee a -enee K1 n n f a pamd, K1 N. (1n a e t eneze a de-eneze K3, K3 Nnta (,3 n a e n a B m TB1-8.

H the t ail t ta ae h pe-et nm anU1 n 1 0, 1 1 , a 1 hgh a te th dtani U4 n 6 a 1 1 whch gu K6 al tppi the tating euee nng it N tat (9,8 deenegiz K3 a K. U1 n 1 0, 1 1 1 2 i hgh a te U4 n 1 a weneze eank lamp de eay K9. K9 NO. ta (9,13 a 4,8 e t a gu n 2

te itin a al the DS18 amp

H the e at, lage i p n he D (K14) (K1) a dinnec eay. K14 energze at ately 14 VD K1 egze at aitey VA Regade whh ne egze fit, eth ewll beak he gu path t tae elay K3 K3 eneze n it NO nat (,3 e fm TB1 . th K1 0 a K1 4 enezate the n la DS1 . he elay ll al nhnk t U1 by mak U1 n hgh. hiahe by the gu path fm U1 thgh U3 6-1 1 , N. K14 nta (1 6,9) a NK1 0 ntt (3, A e hen alw hgh

K3 l, . K6 nta (3,7), N. K1 na (1U3 n 6-1 1 n n U1 a R, U3 n 6-1 1 tn K6 faul elay ha aed By ki n hhe t eet a n a taby Ee K1 K1 4 wll nae U LOP/HET me dme. T ahe by he g fm 3 a a a s the Ths te U4 nt g U n Ae a 1 0 dela neze K1 thgh 1 a 16 K1 NO (a (9,14) e, lat n au K1 n t lah U n an ne e by B fm n a g th

a U n a 1 (K1 NO (,8)

p hn h K6 fal ela

H fu g n e fl

, f Pe- l Pe (POP) P-3, f PeHg E Tee (PH) P-4 f l Pe (LOP) P- f H Ene Tea (HT P-6 enal 11, f O (OS)

Pe-LOP a pe-HT ly ate a wa la p the

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, HET, OS te mp a h wn he

rlay K6 n ee with the K1 3 (HET), K 15 (LOP),K1 1 (OS), K (F 1 ) a K5 (Fa ) fa eTefe, when a g pa n the ee pgt t w e th he K6 ea a he aatedt e t eneze. K6 N n (9,8) n t de

eeze K ea, he e. K6 NO ntat1 1 1 0) e eneze K8 ea K8 n t Nt ( 1 6,9) ee B fm he na pa fthe The ted fat ea b p aniat a a a nnet a g ne f the emn f a ete n TB-1 1 , f PLOP TB-8, f HET TB-10, f PHET TB7, f ee TB-9, f LOP TB6, f enk

T eet f the n gna e fm P- t e-enegze K7, t N. . na (9, 1 6) ne B t he f ee t. A g paed n41 1 whh g a f the he f a et

fw

K6 - F Rea

K 15 LOP

K9 - eank K 17 PHET K1 1 eed K 19 OP K1 3 - HET

Thi ee K6 fa a a an fa ea ha aethed n an e tae.

T tp the et , the n gna eed fm47 whh de-eneze K7 K7 NO nat (9,1) t ee B fm K a K de-ezen t NO. (5,3) e B+ fm TB1-10,tpng he e

ue of tion eto12 efe hemat dagam n W Dm onwhen eiew h nfn.

St nated b a B g P7epe n he tn �nk a W

Pitin A G gn t n Pn B B+ gna t n

h enegze n e whh e N.O n (9, 1) nne B+ t tae a K3, h B+

relay K fa t, ene nk U1 ,n HET/LOP dea t U5 thgh N. fa K8 16,9) Th a n N. K7 (9,16), dnnet+ t the ee it (K6).

2

K eneze, t N.O. ntat (5,3) nneB+ t ena TB1 -1 0 thgh fe F a t -9hgh fe F5

K3 enegze, t N.O. ntat (5,3) nneB+ en TB1 8 thgh fe F1 K3 ne bme U1 thgh e nk ea K1 hgh N ftea K6 n (,3) U1 t pe 3 ank

hgh 6 a The mi et t 15 n, a 15 ff hgh at it 3, a et U3 (3,6), (15,), a (16,1)The ta ank t 75

U1 w eneze a deeneze K1 thgh U (7,10).K1 N a (10,7) n a e eneize ade-enegze K3, K3 NO nta (5,3) n a enne a B+ fm TB1-8.

H the et fi t t te he hee a, U1 n 1 0,a 1 hgh a te he de tnt U n 6a 1 1 whh g K6 fa ea, the tatee b n t N ntt (9,8) deenegz

K3 a U1 n 1 1 1 , a 1 hgh agge U n 1 a 5 wh eneze e mpdie ea K9 K9 N.O nta (9,13 a ,8) ett a g n TB-6 f a e an a n -8 t gh he DS18 amp.

H he ta, tage p n he D (K1) a A(K1 0) dnnet ea. K1 enze at ate 1 VD K10 eze a ae 100VA Rege f whh ne egze f, ethe ew bek the g pth ae a K3, K3 deeneze n NO nat (5,3) e B+fm TB18. h K10 a K1 enez tte he n a DS1. Ehe e nh he

enk t U1 b mak U1 n hgh. Th ahe b he g pth fm U1 n hgh U3 61 1 , N K1 na (16,9) a N.K1 0 cns (3,5). A ptiv is hn al thugh thK3 , N. K6 na (3,7), N.. K1 n (10, 7),U3 n 6-1 1 n n U1 a R6, U3 n 61 1 t U1n K6 fat e h t. B k n hghthe me ee a t nt a b Ehe K10 K1 w tae U5 LOP/HET tme eame. Th ahe b the g fm U4n 3 a aw a tie he. Th te U n 1 tg U5 n Afte a 1 0 dea U5 n 1eneze K1 thgh U n 1

a1 6. K1 N.O ntt

(9,15) e, nne B he ft t. K1 N.(1 ,8) nta n th U5 nt an nate tatd n, de e B+ fm n 5 a g hgh R8 a U a 15 (K1 NO. ntt(,8) a pd hwn ph K6 fea fm apate fa )

7/28/2019 CUMMINS960-0504 (1)


f a fa h ur a run i pla n th fwinp pint 21 fr Lw Enin Tmpratur (LET 22 fr rLw il rur (L 23 fr r-ih Enin Tmpratur (E 24 fr Lw il rr (L 2-5 fr ih Enin Tmpratur (ET 2-6 trminal T1 -1 fr rp (S

T214 fr Lw Ful

T-1 fr Fault 2

T2-3 fr Fault 1 T2-1 6 fr htwn f utmr rui rmnt

Lw ful p-L pr-ET an LT nly atiat awarnin lamp an nt tp th t.

L ET S Falt 1 Fault 2 an mt hutwn(2-1 6 atiat a lamp an al hut wn th t

Fat rlay K6 i paratly in ri with th K 13 (ETK 5 (L K1 1 (S K4 (Faut 2 an K5 (Fault 1 faultrlay. Thrfr whn a run i plad n th rp

t pl inpt it wil au bth th K6 rlay an thaiat fault ray t nriz. K6 N.C ntat (98pn t -nriz K lay tppin th t. K6 N.ntat (1 1 1 0 l t niz K8 lay K8 pn itN.C. ntat ( 1 69 t rm + frm th pratinalpart f th iruit . Th aiat fault rlay will bn upan iniatin lamp and al nnt a n t nf thflwin rminal fr a rmt iniatin T22 f Fat T-8 f ET T4 fr Fa 1 T-9 f L T-6 fr Orrank T-1 0 f HT T7 f Op T-1 1 f P

T a fa h n inal mu b fm P4-7 t nriz K7 in it N C nta 91 6 nn + th fa ii A nd i pla n4-1 1 whih ndall f h lah ab fa lay i a fllws: K6 - Fl Rely K 1 3 - HT K4 - Fal K 1 5 - P K5 Flt 1 K 1 7 - PH T K9 - verank K 1 9 K1 1 Overeed

This esets K6 fl ely ny fal relays that areltched in cve state

T sp the set y the sigl is eved fP4 which deenizes K NO ntcs (9,14) ee + e K deges s NO s e+f1 -1 0 the st.

LY F QPPEDCheckng elay ColCnnt + ar rlay il trminal lay hatiat if il i kay.

Checkng elay ContactCnnt + t n i f rlay ntat. Cnnt a

mtr t th i f lay nta. If + i prnt wrlay i nriz ntat i kay Th + rainprn in rr whn hkin nrmally l(NC. ntat Typial win iaram i hwn in Fi5-1 .

OP

AINP

s-F 51.

7/28/2019 CUMMINS960-0504 (1)


NTERFAE RELAY MOULESF EQUPPE)

W the ste ps ete ctl e ts wee y ste AC DCsc Mle A 3 lys) M A14 (5 elys)c p ece wt the C (A1 1 ) cctsycl w g e shw Fe 5-2

4 5 6 7 8

K1 K K K4 K5

1 6 7 8 9 1 0 1

TB1

- K K2 K K4 K

6 7 8 9 1 0

1

I T(IP

K6 K7

4

1 1 1 4 6

7

8 B+

1

T

4

6B+

1

FIGURE 2 NERFCE REY MODULES

T1 T

45

67

89

1 01

1 1

1 4

45

67

89

1 0

1

7/28/2019 CUMMINS960-0504 (1)


TM DLYD STT/STP MDLF QPPD

s mul cnans ajusabl nmrs fr ma sa (1 1 5 scns, an m la sp (1 1 5 mnus m la ausmn s ma b urnng apprpa pnmr lkws ncras rcunrclcs cras m lay S h m

la sar pr s urmns, an h m lay spfr apprmaly 3 5 mnus ypcal wng agams shwn n Fg 5-3. Rf Wng Dagams senf furhr nfman.

TI AY STAT TET

T1

P STA-DINECT (A - TB-2)

CY STAT-DICT (A - TB)

2

(A TB5)

C MTS DCT TSFMS

f a mr malfuncns, h prblm mg b a lwng cnncn, h mr s, h phas slcswh r h currn ransfrmr fr ha m f mhan n m s malfuncnng yu ma ha cf prp an scr gnra ap cnnns Ch

apprpa AC wng agram/schma fr wr land ermnal nnns Chck nnuy f wn and mpnns shuld denfy h pblRpa pla any fauly wn plae fay mn ansfe swh e. Refe apppwn d aasema Dagam

Y ST TE

4 6

UN SGL T (A B) (A - TB-7

UN S N STAT/SOP ON FGURE ME DEYED SR/SO MODULE

7/28/2019 CUMMINS960-0504 (1)


C L LThe aut ltage regulator (AV) is a threephase full wave utput tpe device which forms part of theecitati ss for the generator.

adti egulating the generator voltage the AVc1rcu s a number of protective features which

provi s iabl control of the generator. Ecitatiowe is fom a permanent maget generator (PMG i w Radi Frequenc Inteerence (R FI )and i thristr tpe loads.

Th A_R s einked with the main statr widings

ec1tef PMG to provide closed loop control f theout a ith load regulation at apprimate±05% RS

The A sses the output voltage from the main stator windigs a response to this controls the power fed to the

exite ad the main field in such a wa as to

mata ahe output voltage within the specified

limits saing for load speed temperature andpower fat the generaor.

oft sta uit is included to provide a smooth controlled bui f generator output voltage.

ustin ltage situations caused b open rcuitseng as or shor circuit power device arevo1ded b eltage deecion circuir which proviesterna sn and circui breaker trp signals focircui it if equired.

A freque easuring circuit continuall monitors theshaft s e generator and prvides undespeed

prote excitatin sstem b reducing th generato ag prtinall with sped below a!ese A further enhancement f this feature r-des ga tage roll off in resnse o rate of fallingspeed improve frequenc recover time on

turca gines.

Curre 6i i rcuitr (optional) provides control ver the a sr circuit current flowing durg three-phase a sephase sorts on the generator output.

Ove ex situations left uncontrolled are limited to asa u b i ternal shutdwn f the AV utputde1 S to remains latched until the generatr

has b

Baic ionThe ine k diagram f the AV bard is shown inFigure ain functins f the AV are as fllws.

Ses sos: Take a i of te geeratoutpu attenuate it t a suiable wer evel.This i f resistrs includes the had trimmer adjuse

-6

Qde Doop Cc Opol)Cnves the cur-rent input from a CT into a voltage which is phase mied with sensing voltage. The result is a net i ncrease in theoutp t from th sensing ntwo as the wer factor lagscausg a reduction in ecitation

RS Coee: Is a square law precision recifier circuit

hat cnverts the AC signals frm the sesing networks1nto a cmsit DC signa reprsenting the meansquared value of the wavefrm

The utput of the RM convrter incldes a variabletential divider which frms the vltage range cntrol for the AV.

Ce Coee: Is a threephase precision rectifier and amplifier that cnverts the inputs frm current trans- formers int a DC signal represeting the mean value of the current waveform.

Ose Cool: Prvides an interface between the AV

and accessories and alows the genraor's ecitation tobe controlled b adding r subtracting the accessor DCutput voltage to the AV rectified sensing voltage.

Powe Sppl: Comnents consist of zener diodesdropper resistors and smthing to prvide the requiredvoltages for the integrated circuits.

Pcso ole Reece: Is a highl stable tem-perature compensted zener diode used for DC compari-son.

So C!: Overrides the precisin voltageeferene unng run up prvide a inea rising vtage.

M CooAple Cmpares the conditionedsesg vlta

s with he pecisio referece vltage and

ampf1s the dfference (err) o pvde a controllingsigalfo th wer evice in suc a wa as to suppl theexc1ter wt the requ1rd aun of wer to maintain thegeneratr vltage within te spefid limits.

Sb C:Prvides adjustable ngative AC feed-back to prevent voage hunting and ensure good steadstate and transient peormanc f the ntrol sstem.

Powe Cool De Prvides the means to infinitecntrl the cnductio perd f the output device. This is

achieved b pedestal and ramp cntol followed b a leveldetector an driv stage

Powe Cool Deces d Rece Ar nfiguredas thre phas 4 dde brdge wer mosfet and freweel dide t va the aunt of exiter field currentin respse t te eror signals prducd b the maincpart

7/28/2019 CUMMINS960-0504 (1)


ncCi cuit povids sot puls t zo it ofo of t pss o t d is usd to sycoizt Ud qucy ollff (U d w cotolcicuits to t gto cycl piod.

ndr rqnc O Cicut msus t piodof c lcticl cycl d cuss t fc voltgto b ducd ppoimtly li wit spd blow

psttbl thsold A ligt mitti diod (LD) givsdictio of udspd ig

Boc ReeCicuit msus t t of fll ig spd oft gto (dHz/dt d cuss gt voltg oll off(mks th V/Hz slop stp to d g spdcovy ft pplctio of "block lod

OVRVOLAGE

DTECTOR

ACCESSORYINPT

GENETORVOAGESENNG

REMOTEVOLAGETMMER

RRP

.

SENSNG RESISORS

OVRVOLTAGEMONIOR

OFFSTCONTOL

RMS

COETER

QADDRP

RRERTR

Oe oltge nito Cotiuously moitos t vg t t gto tmils d povids siglssut dow t output dvic d tp optiol cicbk to isolt w fom t cit d AVvt of sustid ovoltgs A o scod timicludd i t cicuit to pvt opto duig tsiovoltgs wic oml ft lod movl

Oeld Detect Cotiuously moitos t lvlcitto d povids sigls to sut dow t outdvic vt of sustid ovlods lstig gth t scods. Both th ovlod d ovoltcodtos ltcd fults quig th gto tostopped fo st.

UF+ K

REUE

SAR

CIRCUIT

PRECSON

10 H G

WERRECFIE

KER C

DRIVE ClITATONRCTKERIONA

INHIBT (OPT

. VOLAGE PR

REERENCE

- R v

SABUCIU

SUES

OWERCRO

DRIVER

OVLODECOR

NHB

ECTROLDICES

,

C FE

ERFGURE PMG VOLTGE REGULTOR BLK DGRM

57

7/28/2019 CUMMINS960-0504 (1)


GEETO OPETO EVEWe P provides power via te AV to te ain exciterstato see Figure . xcitation power is theefore indeedent of _output voltage, resulting in positive voltagebuldup, wthout reliance on residual agnetism. TheAV copares the main stator output with a referencevae and feeds a controlled excitation current to the main

exciter stator The AC output of the main exciter rotor isc?ee to DC y the rectifier assemly, comprse ofsx ddes mounte o two heatsiks to form sitive aegatve plates Te ioes are protecte against armfulovevoltges (cause fo example, y switchig ci rcuits orotofphase paalleling) by a metaloxide varistorV).

_Th

_e DC output of the rectifer assembly povides

te exctato onto the main otor.

V enng and ower upply3-hase SesgWith rated output voltage o the maiterinals, the reference suppy to this unit should bebetwee 1 70 and 20 volts AC across 67, 78 and 86.

Tis supply can e y way of a quadrature droop urdenresistor and/o dropper transforme These should bechecked for continuity

we Sppl PG) Power supply is derived from theeanent magnet exciter. Its output leads are connectedat AV terminals P2 , P3 and P These must first e disconnected. With the macin e at rate spee the outputvotage etween leads P2P3, P3P4, an PP2 souldbe balaced at appximately 1 6 volts for 0 z 100rp) units o 200 volts for 60 Hz (1 800 rpm) units.

Volage egulator djutment

eneator voltage s cotrolle y the optioal otagecontrol heostat (21) locate o the ntrol fot paeland the solistate otage egulato locate isie trolpae see Fiue 5-6).

EXCTERSTAR

AUTTVTAGE

EGTR

wo, sm ar M votage regulators have been used n per-manent magnet exciter generator sets ne Is a forposition ount and the newer of the two has sx mountngholes o hich ony four are used. djustment proce-ures are he sae or both even though the potentloneters are lae ifferenly eer o igure to Identfywhich M the uni is equipped

The geeato oltage may e ajusted within 3 percentof the rate nameplate voltage via the optional controlpael mouted votage control heostat 21 ) f theadustment caot be made with 21 , o r if 21 is not installe, ajust the voltage regulator as follows

1 . Adjust votage control rheostat 21 (if available) tote mid sition. Loose th e lockig nut. With a screwdver, turn

rheostat 21 fully unterclockwise, then fuyclockwise, then to mi sition .

2. pen te control panel doors to gain access to the

oltage egulator.3 With the generator set opeatig, and the voltage

eing monitored (e ithe by meters on the set or witremote metering), adjust voltage regulator boadVolts tetiometer to the desire generator voltage

4 eo fie votage adjustment (±3 percent) by adtg rheostat 21 , retighten locking nut.

. Sto an estart generator set to cofirm proper operat

6 f ajustng the Vots tentiometer of the voltage

egulato r o�s ot allow te geneato oltageo e ! �se age, refe to wirg iagamlue wth ut an check fo prope cectios.Reet te ajust

ent roceue. f pope aduste s stll ot ss le, ee te follog ega

TPUT

ISTATR-Jm- J�ING LF

PERMAETGETSTATR

DIDES RR

GERR

EXCRRTR

FIGURE 55. PERMANENT MAGNET GENERATOR (PMG) EXCITATION SYSTEM (BOCK DIAGRAMS)5

7/28/2019 CUMMINS960-0504 (1)


ig ot ttiomts o t AV (ot tt o gulto s ot v ll t sm ttiomts s gulto plc voltg gulto o t you svic pstiv fossistc

CAUTION ) S voe uaor poe

iomee oibe opeioh his eeo Ay jume o ohecoms c u eo eisbi o oei Fuhe jusmesshou o me by q e pseie

bi If e oltage s stable afte a b dedo um e Salty tol cse pm setg sld fou au dt. Aysay adustt affects e geeao out oltage. ese e ot ltage afte ay stal adusme.

Ue F Ro (UFRO) it:Ts l s se a o 59 Hz H us o o 9 Hz (50 H us. Te LD (g ett deadja e UF etomee l e eoltage egulao s e e fqey e offs e aa o e To cegeeo fe fm aed o e e LD gs o me. Noe se feqey Tu e UF eoe se s ek fe a e LD es.e se o fe

R

T

A

(PRR , 19

D P STABLY

M

MS(FCORY

S)

D oe Dip Lim is cotol is pst t ppoimtly 30 pt of t opti voltguig t tol clis icss t voltgdip o lg d picup is will m it si fo ti to pi up lod uig t tl utcis dus t voltg dip (ms t AVif gi my t b bl to pic up t

d if t Voltg Dip imit is st too f utcws

D: o st gto dop to 5% full lod PF uig tis tl ccs icss tdp (t my lso d to adjused i ts muc dpTm: To mtc AV t to aeo oTu ts tol cse als aeseke a V APF tlle e t oe e AV

N: To se e oeoltage poeo off leeT s t cse eases e oeo

age off leel.: To se e mamm so cT s to cse eases e sot e.

1 R e se fao as eqe ay ads. ace AV.

ET A(R 1 19

F 1 -2

6 6

§

2 -3, 5 4 1 -364

[

§ MUM RESPOSE SELE NKNG:

- B, FRMS 6 & 7B -C FS 3, 4 & 5 - C FRMS & 2

GURE G VOTAGE RUTO

9

7/28/2019 CUMMINS960-0504 (1)


� T SS F QPP

oa h aoa aow indicao o adjus hmodul h commndd aoxima sings a:

Und % os S% os Rs

v % ols S% ols Rs

90

5

05

Th dl iclus n djs im dly ly ovn usc iing (yicy s 25 c oaoxmly2.5 scods Syclg digm inFigu 5-7

014 1 1 12 21 24

18 15 16 L N 26 280 0 0 0 0 0TB21-

71 3

GND

:A1 1 TB23

A1 1 TBH A

TB

GND

7

1FIGURE 5 OVEUNDER VOLGE SENSOR MODULE

� FQC SS F Q

Roa ao o co o djs hmodl ommd ss a

Nominal Hz Ud Hz S 45 55

Rs 47 57

v Hz S 55 Rs 53

S yical wing agm n gu 5-8

A 1 B1

014 1 1 1 2 21 24

18 1 5 16 L N 25 280 0 0 0 0 0TB21

1

1FIGURE 5 OVERUNDER FR EQUENCY SENSOR MODLE

SP FQC TCT

Ts mol vs sd (Hz sgl om h PMGu s d om no s A smll mdy ycy on s s od n h ovs uo o alo o n ovshoo T modulcons wo s ioms sd dCkg ( cnkng onom s o usd ho

T sd niom s djsl om 500 o

2500 RPM. us h vsd nom ocv osd a oxmly 800 o 900 PMo50 Hz s d 2 00 o 2200 RPM o 60 Hz us Sycl diagm ig 5-9.

0

CNKIPENTETER

@

0 0O

@ o

VERS PEEDPTENTIMEER

AUXILIARY10 (P3) } TERMINAL9 (P2) BLK

B1-B+ (A11 TBH)

SIGNAL (A11 TB15)

NT USED

�B+ R B (A1 1 TB1 1 )

NT USED

FGURE 5· OVERSEED (FREQUENCY DEECON) MODULE

7/28/2019 CUMMINS960-0504 (1)


OTG CTF MBLYe ectie assebly, gue 0, is split into o plates,te sitie and negatie, a te in to is conneedacs tese plates ac pat ies 3 diodes, tenegate plate yi negatie based diodes, a tesitie plate es sitie based dies. e elaity diodes st be ied to tei esie plate.

URE 1 R RER BLY

u us () g s g t f d i

z ll n

d H df g of g f fsoui) adi Replace defie.

ifir Diosi an u ot, tes ac CR si ate a se lates. est fies (des) sollos

. Dine a lea asbly to tes.

2 Co ne la to si (X) st nnc ot ld CR1 , CR2, CR3 t; esisa lue o ch fie.

3. Conn o nate (XX) stu aec oe lad t CR, CR, a CR6 in u·ed s l of eac ii

'

. Reee oete eads o Steps 2 an 3 aned esistae aue o eac ectiie ststud (X) to CR1 , CR2, and CR3; a negative stu(XX) to CR4, CR5, a CR6.

. ll te esistance eadis soud ig in one tea in e ote tes. I any eading is ig o i t ests, eie ssely is deie.

6. pl dfcti e assebly it , d

IA CUTION I Ece du or di on ds o ll og l . e h c!

24 J Nm) t w i nut f iv (d ne () tu d CR1 t C

lin ifir f f

1 f

2. z f

3 f c N

4 e 362 (44N)

Rc e a . sebs. (2 N) o s.

X

a agn xci is ai w syfo PMG VR nd is sold fo a widingso s son e o fo xci s b siy aoss ts einal, wc cnco axliy inal boad (xcite lads 2 P3, a P).Wi a u o fl sp, o ltg

acss s P2 3 and P soul b bac xiy 6 ols o 100 (0 z) 200 olsfo 1800 (60 z) ben nls gn xc i oduc o oltg clyd fo t es of c an offc o t sp excitao es a flow Rfo o n gascc i Sction mat magnt xcH tat it I hm n

ti.

511

7/28/2019 CUMMINS960-0504 (1)


R ROTOReting for rondonn a of ohmt tn ah CR a axtr rotor amnatons Us an ohmtr st at thghst rsta a n ohmmt a thanon mgohm (1 000,000 ohs) nats ftvgo nsaon S F 5-1 1

eting for pn or Windis a Whatston B fo ths tst Dnn manoor f as hh nn to ta assms at th stv a nav ss Dnnt awrs from s CR1, CR2, CR3, CR4 CR5, a CR6st twn a U6-6, 6-W6 a U6-W Rfr to a 51 fo ssta vas

Be su t It m kW ra gtme z f r n ngTe 5.

C

URE 1 ER OR

R ATORting for rondU an ohmtr, R 100 a, mas th naton ssta tn th a X or X a th anatons, 5-1 2 a of ss than nfnty a

-

URE 5 R SOR R G

tin ndi inMas sa n s X a X th anot, R 1 S 5-1 3 Rf to T5-1 fo sa vas

B I m kW g z f r n bf ng 51

ETE

URE 13 ER SOR F O

GENERATOR ROTORtin for ondU an ot (R 100 ) a ar asfoos

1 Dn to as f th t s

2 Mas n th rotor shaf, 514

3 a of ss than nfnty ts a

7/28/2019 CUMMINS960-0504 (1)


ACT P T ER P TR SF. T O W GREAER SISE 11

FURE 14 GETOR RR GRO

ii1 D a tt t , 5-

1 5

2 R t t

R t 51 t

B I mo, kW a g f g a n b gTab 1

ETER

11E GA T R

GENERAOR AOR

ADNGE Higvge, 19 150 p l f ve l Inju rh. En a gen h an ek y i exi u by Ivge hi ge nl mu liquf w wh dbuinve

ei fo odB tt tt, t xt con . m c t

C a U V W) t ut tteU mt et t 00 a at a sa beee e ws ttt am A ad es t ny es g Fe cu bee ca e cse t tst

i for hoT e , t t t mt t t U5U6, U1U2, tc.) t t tmt t U 1 , U2, U, V2, 2 Ct t, R 1 00 t tt t t tt ), t t t t t tt

Emple: mt t U6 t t: U1 , 2, 1 , 2, 5, 6, 1 , 2, 5, ct t C U,

t Rt

M t o K R 516 H , , t t H s t t t t R t 51 t v

m, kW a f r a n T

P

TEE SE tLS EN RE AIR

U1U V1V W1· VV6 W5

FURE 16 GERATOR STATOR WN

7/28/2019 CUMMINS960-0504 (1)


TABLE WDG RESSTAE VALUES*

GESET GE. EXITERMODE RATG FRAME STATOR ROTOR

DESIGATIONS SIZE

OFAA 75 200 4C 25 014OFBC NT4 175 200 4C 25 014OFBO NT4 75 200 4C 25 0 4

OFAB 200 230 4 25 0 4OFBO NT4 200 230 40 25 0.4OFBE NT 220 250 40 25 0 .14OFAC 220 250 4 25 014OFBE NT 220 4E 25 04OFBF NT6 250 275 4E 25 04OFCB NTA2 300 4E 25 0 4OFCB NTA2 275 4F 25 0 4

OFCC NTA3 31 0 350 25 0 .7OFEB KTA2 330 400 25 0.17OFFA KTT1 1 400 450 50 25 0.17OFEC 400 450 5 25 017OFFB KTT2 450 500 E 25 0 7

OFGA TA 440 500 E 25 0 . 7OFGB TA2 600 F 25 0. 7OFGC TA3 550 6A 7"" 0 . 1 6

OFJA KTA3 620 750 6B 7"" 0 . 6OFJB KTA32 660 800 6B 7"" 0 6OFJC KTA33 800 900 6C 7"" 0 6OFJO 900 000 6C 17"" 0 6OFA KTA5 900 1000 6 7"" 0 6OFLB KTA52 0 0 6 7"" 0 6

OFLC KTA53 2 0 250 7B 7"" 020OFLO KTA54 200 7G 17"* 020OFMA KT5 0 0 250 7G 7"" 020OFMB KTT52 280 500 7G 1 7** 020

* Restae es a omates a °F (20°C ±** Uts o o Noem 989 ee ohms

CC

STATOR(er h: Wye ROTOR

or e)

0.07-0.023 090.070023 090070.023 091

0014-0020 040014-0020 0400140020 1040.04-0020 1.040.00-0015 1 1 70.00-0015 1 . 1 70.00-0.05 7

00097-0.010 135

00-00090 550.006800090 550.0058-0.0080 1 .770.0058-00080 .7700043-00069 96

00043-00069 1 .960003-00042 2.160003700053 37

00030-0.0033 4700030-00033 4700023-00028 660002300028 660.0018-00023 1890008-00023 1.89

0.002-0008 2290002-0008 2290.0012-0.0018 229000200018 2.29

gue 5- 7 shs he eea eo ses o he eeo. Whe e fo a iee oteefe o AC R am So 7 a AC iams ha h u

51

7/28/2019 CUMMINS960-0504 (1)


c L 1 20/240 1 �wwz 1 1 /230 1 0

1 1 0/220 1

�c L 1 20/24 3 <z

1 1 /220

1 1 /230

3

3

0

1 20/208 3

ww

ENEATOONNETONSEAT

DAA

GENEATO ONNETONWN DIAA

ASE SEQUENE UW WENOTATN LOSE IEWED

AT TE DE END

FAE 4 FAE 6, 7

W

L L t6(N)

. P' W L(WJF r:Tu u J• �

W U

W

U L2(V)

V f3=cL( J(NJ

2 1==.T

V2 V W W5 V6

8--�: V I _ U6

W2

W5 •V2 r VV5 -V"2 5"

W6 7 V

4 V6 6U 6

8W

'w _-w6i2 • V2

W •

l r 71

V fW2 W 4V6

V L6 86

w 6 7W2 W 4

V2-. V 6V. u2' u 6C w 8

1 27/01 39/240

33

66c v L2(V ) 4 ==\ U I

V V I6 W W I

W2 W6W

.'-W�1- iV I

V5-l

l

wW2�W6 6<

c

z

L

z

110/190

1 1 /200

1 228

1 27/220

220/80

240/416

24/440

277/480

220/380

230/4

240/16

24/440

3

3

3

3

3

3

3

0

60

6

w

0 w0 w

0

347/6 6

V -LO(N )

W-L W)

7 V2 V6

86

W 5V 26-� W5-f

7 V2

8V 2 -

W • w6v •V6•6

FURE 7 RENNETN DRM

55

•

v27

2

8

rw 5+ 2: W

6W5

•&7 2: 65 U

•r-u&

_ '

7/28/2019 CUMMINS960-0504 (1)


ELECTOC GOVEOenertor requenc s n drect rto to engne speedwc s controlled b te goernor. e goernor controls our potentoeters or ng djustents. Seegure 18. Use requenc eter or tcoeter toontor te unt durng djustent procedure.:

:tt z : z> > ¢ z t t

�1�@1�1��1�1��1@ 7 8 9 10

IDLES PEED U SPEED

GAIN 1 DROP@

FIGURE 1 8 ELECTRONIC GOVERNOR

Gain e Gn control s oneturn potentoeter. It sused to djust te senstt o te goernor. A clocwserotton o te potentoeter wll soren te response

te to lod cnges.Droop e Droop control s onetu tentoeter. ts dustble or zero % socronous) to ore tn %speed droop. ull counterclocwse rotton s 0% speeddroop.

Ide Spee e Idle Speed control s 20turn tentoeter or djustng te dle speed. A clocwserotton wll ncrese te dle speed.

n Speed e un Speed control s 20tu tentoeter or settng te desre nolod goernedspeed. A clocwse rotton wll ncrese te un speed.

eer to te ollowng justent procedures.

djutmentremina Admen

. requenc Adjust engne speed) potentoeter oncontrol pnel equpped) .A. oosen te locng nut.B. t screwdrer turn te potentoeter ull

counterclocwse ten ull clocwse ten tod poston

C old d poston settng wt screwdrer ndtgten locng nut.

51

2. Idle Speed potentoeterA. u te screw counterclocwse 20 tus.B u te screw clocwse 1 0 tus.C s wl l set te dle speed tentoeter to ts

d ston.

3 Run Speed tentoeterA. u te screw counterclocwse 20 tus.

B. u te screw clocwse 1 0 tus.C. s wl l set te un spee potentoeter to ts dston.

. Gan tentoeter.A. Set te Gn djustent t te t r dson

zero.

. Doop potentoeter.A. or socronous operton te droop tent

oeter ust be turned ull counterclocwsen wll not requre n urter djustent.

B. u te screw to pproxtel 0 or 3 percentdroop.

C u te screw to pprox tel 80 or percentdroop

ibio hck . St te genertor set.

2. or proper ul llod genertor set operton teengne nolod spee ust rst be djusted to teesred llowble speed droop. or exple socronous operton set to 60.0 Hz/1 800 r/n 0.0Hz/1 00 r/n ) or 3% spee droop set to 61 .8 Hz/1 8 r/n 1 . Hz/1 r/n) or % speeddroop set to 63.0 z/1890 r/n 2. z/17 r/n.)

Wt te genertor set wred up to p roper opertng teperture just te un Spee potentoeter untl te engne s opertng t te desredrequenc or r/n .

3. Wt no lod connected to tegenertor set turn teGAIN djustent clocwse slowl untl te ctutorleer osclltes. educe te GAIN djustentslowl counterclocwse untl te leer s stble.Upset te leer b nd. I te leer osclltes up to3 densng osclltons nd stops te settng scorrect.

. Appl n reoe lods to cec genertor set resnse I genertor set operton s stsctorte goernor s now clbrte. I genertor setresnse s not stscto ree Step 3. elecrc goernor cnnot e roperl clbrtedcontct our sece representte or ssstnce.

Fine Spee Admen Ater te GAIN djustent sde te ull lod goerned un Speed requre nor djustent to equl te desred speed . e 60 z1800 r/n or 0 z 00 r/n) Use te SP AUS tentoeter wen suppled) on te engne nstruent pnel or ne speed djustents o less tn00 r/n.

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tri l nol {C veorte ription EC v sysm coti gnc uplctoic tl th ful p cuo. S gu5-9.

EL MPACUAO

GOVEOCOOL

GEPUP

SESO

EGEFLHEE GEA

URE 59 OVR SST

mgtic up sss gi s t th flig g ss ltti t (AC lcticlsigl to t gov ntl.

v tol mps t ll sigl fmt mgtic cup wit pst f int. H this diff i t

sigls th ntol will h

cut to th ctuto (td o th d of ful .

c i cut i th ctuto il will thuo st ott ful fw i d ow will w th uto shf tts

eace Chksf t gto st otio is ugh o sug viwt foowi

t gto st chc voltg dist v tl tls fo; mgtic up( .5 VAC im c to 30 VAC imt gst oti sd bty

B(2 VDC

ul tuo (920 VDC.

2 Stop gto st di th lds to thctuto (s gu 520 c bt B+voltg dictly o t cuto studs. A udibli i th ctuto shou b hd w B isppli vd. is c oy sows tht tuo is otig (otti o o sd sitio t t if its i fut disssmbly of ful my b qui to isi igs ump

ACTUAOSUS

FUEF

FESHUT

VALVE

FURE 5. FUEL PUMP BL

3 H fuh tsts pi is ui yoCummi diso fo fu infomo us py o Elc ul Contl vbu (li 337923 03.

SCh th cios cl tight. A ligt tiof uiv gs will hlp t oo tils.

Ch th chg itio of th stti btts w hydot. Kp th lyt t th p lvv th pls by i distill wt. Chc sci

gty chg if b .2. t t Is at In an ara ambtatu sisty av F (° C a s gravf .22 is mmn u A WR NING Ignin of explsive ber ga v na . secg baeres. Wear precve apr agges he chkg s gv ad aids

H t bty ss css wt t ltto chmy b t igh. wis

ibtty st of cg is

iti h ch t my t w. Altto tis sio. Also i t btty will t ch plc it.

Y CSWit t stt to oti ch th voltg d( fom t btty gtiv st (t cbl cl t goui stud (2 fm t bt sitiv s o bt il stud o lid omlly ts sould b lss t 03 vot H g bttbls usd sligy ig vog ds y uhougly l ll ctios i y pt of t iswig sJv volg dop

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LTTO e eine nning ceck te battery coition Dvometer te alteator is orati propey tevomeer reading sou be between 26 a volts. volmeter reading is nstantly re or less tan tisso e generator set a ceck or a ose or sliingdve belt r ternal conneions or broken lead

wires. epair or replace as required Also ceck tecodition o e batteries and baey cables.

verying cks out okay use a separate voltmeer todrmine te aeator output voage and to veriyracy o panel mounted D voltmeter onect teve (+ lead to te output termial a connec tenegative ) lead to ground. Sta te generator set and nor a few minutes to allow te voltage to stabilize. A properorating system wll ave nominal output volage o 26 to28 volts

te output voltage is ig over 28 vols) te regulatoris pbably soed a sou replaced.

e outt ltage is w equas batey voltage) teproblem uld wom or bken bses an on regulaor or an open ield die. furer tests a pair isreuired contact your ummins/nan distitor orreplace alteator.

S SOOAly + to te teinal ma "S ur a gwre to te leid unti braet. Soleid souactivate.

e ntts are B+ ou present een

teinal edI

a gu. e vote p asur across te ntas s never ex one vo incirit alicaton.

UL SOLI tere is uel to te injeion mp ut fue injionnozzle te fue ei migt efive

o ceck fue solenoid oratio remove te B+

lead nnection rom te soleid a jumr a separate+ nneion to tis teal. Te injion mp souclick. I no click is ea te uel slei must replaced.

OO SHeve bate ble Place mter leads acssswtc. n a cse itc wie ose te ommeter. A rmally on switc sou iicate niniteresista wen open a nuity wen csed. Aormally csed itc sou icate ntinuity wenclosed and ininite resistance wen open. eplace switci decive.

TST O U BKenealTe A ciuit breaker does t require any specialmaintenae oter tan riodic exerse a a ceck ocouctor nti. irit breaker opions vary bycustomer requiments. eview te ptional ircuitreaker Description in Section 6. eneratorolage

egulator a peorm cecks a adjustment applibleto te breaker. A typical breaker iagram is sown inFigure 52 or reeree. Wen perorming tests aadjustments avoid aidetal staup by plang teun/Stop/ete switc in Stop stion and disnnecting te bate negative ) ble.

�WRNING Ael sg of he geeor dg e ps s I e/ I o dh P Ropoeswch I s d d he ee ) ble

5

FF;:EET

. HNT TCMMN AMGNAXJAACMMNB

D EW ND

URE 5 O CIUIT BRKER IARAM

e/slg B Acuate te breaker andle to ten a f sitions several times. I te breaker isequied wt a rip est tto te breaker sould betried reset a acuated to n sevel times. Tis willreve any ust rom te canim and latc suaces.

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Section 6 Generator Disassebly/Reassebly

TO SSSMBYe fol pedus pve foat fo evala eassely of te geeo PM ecte, tolus a stato/to asmles su to eadtoug ts se ft, foe fo peduslsted to detee te eps st aopate fo tesee atet u

ADGER Higvge, t ,0 vpnt l s f ve nl n th. Even gent stn n eltrilshk st exist, b nd

vge hin t genet. See nnel st eltinqfi t h distribtnvltges.

ermanent t cter emoval Dsec te egve ( attey le to e

ve aetal sta of te geeato set lesecg

A cnl sing f t geet dng this p pnts t f v l nj th innt t te ( t b inning.

CTRS ASS

CVERS

GENRARAR DS

CVERS

GENERATRAR D

ACCESSCVRS

2. Reve te geeato a let pael a aesves fm tl us (see ue 6

3 Reve te t M2mm a ase fom te PM ecte asmy vea ve ve.

Doect te PM ae co

Reve te f ls a clas a tecte stato us to te edaet

6. Tap te stato us out of ts t a ully eve fom geeato eacket

Te hhy g t att t st cmut b ta ad y m de wndngs

7 Reve te e e tug f t tsa a fy ll te e to efm s a Keep te to ca y avotac t mtal du o paes

J A ION I T t ab shnde ciusts dit, tgt p i d.

Sm

PEXCER

ASSEMY

URE �1 ETOR AN I ABL

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tato ad oto emoal1 eve the air inlet and schae panels and ac

cess vers rm cntrl husing a generatrsee Figure 6).

2 rank r bar the engine/generatr t sitin thetr ch that a ull le ace s at the tm theman satr . Pr tn can be ewdthrugh the neratr ess nings. eer tengine serv manual r prr craing r barng pdure

Disnn the negative (-) bae cable t event acdeta sart the generatr set whilesecng

WAR NING Acnal sng o h gn-or dung hs pu pns h o v l nju or dh su o donn h ng -) bl gnnng

4 Dinne all ad wires rm the rennectintermnal blck assembly (see gure 6-2). Iequpped wth the cirit breaker ptn, disnnect lad wires rm cirit breaker. he that allleads are labeled t ease eaely

PCE SLI STPSTHRH SI

I

ECONNECTONTERMINALS

IJ

AUXILARYTERMNAL

BLK

GENEATORFTI EYES

FURE 6 ROVI ROL HOI

5. Dsnnect all re leads rm the auliary ternal block, insde uit (see gure 6-2), thatwuld inteere wth ntrl husi reval.ale: eciter statr leads X a XX.) eredsnnectng, check wire maings r legibilty tease reassembly

2

6. eer t the prr wirig dagraschematic Diag sectn and nsite speciics rremte cntrl/mnitring. pe cntrl brs a che wire markings r legblty teas reassembly. snnect all engne, generatr, a n-site ntrl wire leads rm insde cntrl a uit such as:

g AB-8-0, a erals - thugh -7 a2 as rrd. Uug A / a 2.

AC g V2-X a X T2 o -0

Aan eads hey ca easiy thdwnfrom the cntrl .

7 Use a hst r silar liting devic t supt thecntl hus assembly (see Fre 6-2)

WR NING To prvn nal Injuu d lng dv o sup hcs. e nds nd clr wlng

Lse he fasteers ha secure he ntl hous de a tom aes o geeraor Makesu h host de s egh t us ssey

9 eve l hou faseea

vee l hou smby fm he geeraorela ae fasee o he es sos for e kee, a ghe fegh

0 eve ro hou u bckes fmh des of geeor a ssele l eyeso geator

. eve as esry ar take mts oee ha y nterere th sassmbly areassmbly generatr.

To reve th ator and rot at th me time, refer toGnerato Asmb Rval lat thi tn. To re-

v t ator and tor Individually ctinu with tep

2. eve he four s rea he ar carre hous te ebcket (uter ur s).

. eve he egh s h the ebracket tthe generatr hus.

4 Inse to s 0) in the tw hles prvded rjai ses n the ebcket center le.Sce s n untl ebracket spigt is clear cati ress.

. areully tap the whle assebly the beaig

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carridge housing, ensuring the endbracket issued to prevent the exciter stor from damaging the windings on the exciter tor

I I AW� prv a i ada ig dvi p mp Kp ad a r w

iig

The exciter ator is now cessible for inspecionnd real fm endbreengi dptor

1 7 . he end bearing can w be reed if requiredRefer to Bearng Real

Ree the faseners fom the two genraorunting feet braes

Using n adequate ifin deice lif the genertor(a lifing eyes pided, n min sttor housng)uni the unting feet brckets are cler of theframe member (see Figures 3 a 4

GRAORLIG PIIS

IG RACS

LKI URGI LL

OUSG

IUE ENEAT FN Pi

20 If generaor set es ot he chass unts tgenerator end (N855 and K bl the rear of

the eine in place by suping the flheelousing A leng of seel cnnel wdenblocin is required o sup e rer of heengine. Plce e channel bloing under eflyweel housing Lower the generaor until mosof the se weight is supd by the blocking (seeFigure 3

21 Disconnec he gunding srp from he flheelhousing

22 . Using a fkli siion lifting bar of the foifsid d inline wih e generaor) uer he sft if he haf lighl so hat or

6

is resti on inside of stao assebl Sgu 6-4

23 Vefy tht the stator is dquately sued anthen carefully ree the caprews from stator atachnt ri

WIG T prvt al iu adte lifing devic to sup heapons. K nds and cr wiiig.

CUTIO mpr tar ably ggig ad adig ag r ad tr abli. Lg y ma b at trfgv i f aab , lig ad mvig ar am a by iig a iiy pt a f ld mbaa; alwig n d d ad

t . k t tar i ad maitai vl l r b wil lg ad mvig

24 Bei creful to drg e ndi on the oe he stor ssembly ffienly ay feine o sli a su e roor ssely low roor ssemly o h on eine flwee

[CUTION D di mag d by allwig t tr bly t . U ua it ad lig t tr ab

25 Reion or hois sli su for tmin roor ree he foli ee gure 6Rotor deil

jAWRNNG pv a u a iig vi t p K d ad r wiig.

26 Ree te sator assembly, i creful n drag the wiings on the rotor. Plce stator asely away fm the chsss in the rzonsiion

27 Usin g the hois nd sling o sup the rotor, fully ree the cprews n fl wsers hsre he dre dis o he eine flheel

A WRNN T prvt al I adat liig dvi p amp Kp ad ad r wlg

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FK HERADEQTE VETO S Y RRSH RR C BESUORTED BY J.

STATOASSY

STATORASSEMBLY

IT

ROTORASSELY

T

l

OTOASY

U 6 IV T SBLY

28 Reve te tr assely a p n s n te rzntal tn T ad ssle a te e a an tes an

6-4

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OWR

COG

AR (EXMPLE)

RCOCIORMIALS

R

AIR COVRS

FURE 65 CAL ENERATOR ABL

XCRSAOR

P

XCIRAOR

PXCIROOR

D A

ROAIGRCIFIRASSMLY

XCIRROO

l G11

R

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Geneator Asmbly Removal9 eve the fasers from the two genetor

unti feet braets

0 Usng an adequate lfng devce, lft the generato(at lf eyes pvded and man stator hous)untl the untng feet backets are clear of the

frame member (see gures 65 a 6-6).

GENERATOR

LIFTI POSrTIS

MNTING FEET

BRACKETSBLKI UNDR

EINE FLYEE

HOUSING

FIGURE 6. GENERATO PI1

If generator set does t have chassis us atgenetor end (N855 a K1 9 b the rear ofhe ene n place by ri the flywheelhousing. A leth of steel channel and wenlocing s equred to sup the rear of thengne Place the channel and blong unde thelheel housng Loe he generato untl mos he et gh utd y he blocng (eeFue 6)

32 Donn h gundng sap from he flheelhung

Cfully v h acrews and fla ashehat secue he dve ds o he engne flheel.

Vefy ha he generao assely s adequatelysuped Caefully remove the capscrews secunghe engne adao ebaet to the eneflywheel housng.

AYARNING ; To prevent / Inju, uauate liin eve to uphnen Keep an an ft clr wle liin

6-6

35.

CAUTION J Impr getor asbl ing and ling n lt In ae tostor tor blies. Ling eyes may

b cnrf-v psition of tar sbly. Therefo, ling and moving te enetor by hoitin t ling eyes only, p-en the r of l Imb,· alwing

o end to d nd other end to . Mkeu te gnertor equaty oket to minin lev ntl of abwile lin moving.

Reve the generor assely away from engne. Place generator assembly on floor wh a of d beneath the stator housng (owardPMG end) to allow for ebracket removal i desred.

Bearing Removal

The e beari s esed n a pre-paed arridgehoung a must only be dsmanled as n�essary for rlubon replament or when a majr ovehaul S

cared out on the generator set.

eval of the ari can only aolhed afereval of the ebraet as folws:

1 . eve the four screws holdng beang cap

2. Reve c.

3 Reve cilp.

4 Reve ari re housi letewith ari

W replang baring onto rot shaft, be su to apply prsingforc to te In fc of the ba only.

Bn Lubt: When relucatng or elacnghe beag reew the followng.

• emended Lubran: Lthum based geaoblux No. 2 or Shell Alvana .

• Temeraue ange -2F to +48°F (0°C +20C}.

• Quany: 274 oz. (8 ml). Aut a hd of he

ase shou be nseed n he beang hang p cavity, and the beang adge cavy

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GEETO EEMBLYGeeto ressel is the evee of ssseloceue

T asb the sato and oto at t e ti tinuewth step o ab the stato a oto Indivuayskp to ep

1 si n eue lifi evi e the ge

eto ssel into sion ne the eine fwheel housi Align the holes of the tor iveis with the holes of the eine fwheel Insllthe ccews flt wshe tht se therive is to the eine flwheel h tighten

AWR NING To pvent nal Inju, u te ing vic to nts. e s cl wiliing

[ACUTION mp gto mbgging ng n n ge tosto to blies. Ling eyes mynot t centefv sion of stto ssbly. Teefo ing nd moving tegeneto by oisting ling eyes on pents t of m lwingone e d ot e . esu te geneto s utely k to mnin v t of bwe ling moving.

2 Align the holes

othe eine apo ebket

with the holes in the flheel housi a inllthe apws a washers Tighten to f-l. 614 m toue

3 . Sere the roto ssembl to the fwheel. Tightencpsrews to 190200 ft-lbs 22 •mtoue

4 the genetor slightl a eve an bifom uer the fwheel housi Lower the geneto (see gue -3

o the gui stp to the fheel hous s ew EIT wshe· tighten se

6 Istl the unti feet brket fstene tighten see.

I hs e r, i with st 7 otiskip to stp 5.

ft sligh o e of oto shaft instll woenshi to ho otor on center th sttor

8 ss be oo to shft li foce othe ie fce of the nsl wo res

e e to i bseuen

pues. osion the e i cte sel cse to o sion fo hoe igewth ebet.

9 Aee ecier sto if eve to in ebet. Tighten stee to 4 ft. 6 toue

1 0 Install ebraet to the aor fme usi tr prews a wshe ghten seel as et

1 1 Inse stat the thres of the a fastene a ve the lignnt stuthrough the ebet into the rte hu

2 slight on eret a ve wwhi i oto o nter with staor

1 3. Se ghten the eaet fteners.

1 4 ghten the ie faes to 4bs. 6 N•m torue.

Install the PMG eiter asem if revRefer to Penet Mgnet Eite Istlltilate this setion.

i to ' pu, t t

o sb t o u to 6 I eve pl eiter tor a t e

fier ssemb to in to shaf Rnn

min tor we lea to sitive a negatterminls of retifier assemb

I reve intall the ive spae ve a pessure plate on the tor shaf Inll eight s a fla washers tighten32 ft-l. 46 •m on fa sies 4 to 6 60l. ( m n fa te 00 W f uses 2 ews

1 si a hoist sli to su the roto lthe holes in the ve wth the rresholes in the fheel.

A WRNING

To prvent l Injuu dte ing vi su ponts. e s cl wiing.

19 Sure the tor ssemb to the flhee uspppte pcews fl washers ighto 90200 lbs. 22 •m toe. alw to assel to hng on eine flwh(Refer to Figure -4.

CTO Dve di dmge n u by ling t to bly to on

te olst slin

t r bly.

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0 eeble eie dpt ebket t tt i eved. U deqte li devi efll ve the tt it ti vethe t ebl i e t t dg thewii the t.

I A A

To prvent nal Inju, u e ng cpn e a r whng

/A CAUTION J Ipr o asbly rggng d ng n In ge r a r ab Lng e a - n f rab , mng a , b ng a nge n, n a; ang d a h d

Mke eo nn e r sb e ng a mng

21 . U t t te (ide e tt h t t t ty tht i t eti de tt ml. Sege

22 Ree te t e Ag t e ebet h te t t te e te t

4 . (674 N•m) t2. U dte l e, gty e

geet tt te e teehe e m e te eeh the e e get te g th ee e.

Pe 'i i Ithi , S 2

4 eee te e e te et he

2. Ce the g te e h pe E e tgte ey.

26 Itll the eet t ee tighte e

27 Pe t , e tthe e e te Itll thededtd it e e t id e

68

pde. Piti the e e e e t iti hle ligetwith ebet.

28 Aee exite t ev t eet ghte tee t 4. tl (6 N)trqe

29 It ee t the t me i the e gte ey ye.

0 e te t etee e th g td,thg the eet the e .

31 ghtl et a e e t ee t

2 Sey tg e e te

ghte e e ee 45 ft (6 N•m

34 R Ree t e eet e y

35 Ue e e t R ig 2 (27 N•m t

\A T pen na Inju

u e ng t e a cr ng.

36 Reem y ee ike ete d get die.

37 C t eet the e et AC DC dgemt

Ree t Pe Mt Ext

39.

H t t k

e k Re e e t e e p e gm S 7.

40 e tt l e p e he he i et eve t tl (ee g 61)

41 C th egve () tte bl tet thegeet .

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emnent gnet xite nttion1 stall the lete exter rtr assely t the

e f the ma rtr shaf us the hex headtrughlt. Keep the tr clean avd ntact th tal dust r pacle

2 Carefully ate the exter atr hus t stn the geeratr ebracket. Faen n placeusng the 4 lts a clas a tighten srey

highly g rot wi attrt t stator r cmust b ta to avoid any n which may m windings.

Cnnect the MG w haess ctr.

4 stall the MG exter assely ver ug thethree M5x12mm care a ashe aghten srey.

ignin ee with nginr algn f the genetr a ee asseles

s eesa t ad premu wear a rtn f the genet. Revew the fl algmentitn a prdures r alg the geeratrassey t ene fywheel hus.

Agu Agmet Is the rel f the generatr ar ceter ax t alg wth axs f the enge crakshaft. Th in create an ale een thegeeratr sha axs a the craksh a. The usef ths ty f mlgmen ualy shmn errr.

A gt Is the resu f the generatr hafaxs t algn wh ee crankshaft a. The tleraes the ed flheel a drve nnen

may a up t displae the generatr axaly relatve t thecrankshaft s.

SHIMS

gt ps the asmbly allwedru u er these cts the d st flex aleadrectins twice fr each ee evlut. mmze the aunt f d fex se it xsve the dve d wl crack. Althugh fe aalgme s derable t s re an t keep ddefle t the m!m sble. Th prduasme that the t re f th dve dsc are exa ceer a the flywheel ctere ( has pral . Uer thee i rect Aualgnment will attai whe defln f the ds asur

Exceve al salgnmen will cause re geeravbn than Aular salgnn.

mignnt s b ly a ti Eher ff mlgnment may preen n a genetr et assely wth agular nalgnmen mn bm Aular algnmen may al

eff by et ntallin n ar ha h f the genet.

Agu Agmet Pu V28 e ggesets)

AWRi Accde stg o t get dug ts pu ts te ju o Mke to dt t te ) tte s) .

Fasten a dal catr t ether the genetr haft r fan wih the n re the

head r the flat uace f the drive at the t rdater ee Fgure 7. Bar the e ver n

L A

FIGURE 6 AULR AM MUM

6

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