Onan Mobile GenSet Service Manual Download Page 2 | Manualshive

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982-0001
9-2002

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Summary of Contents for Mobile GenSet

Page 1: ...Caution This document contains mixed page sizes 8 5 x 11 or 11 x 17 which may affect printing Please adjust your printer settings according to the size of each page you wish to print...

Page 2: ...982 0001 9 2002...

Page 3: ...n aroundelectrical equipment Donotwear dampclothing particularlywet shoes or allow skinsurfacestobedampwhen handling electrical equipment Disconnectbatteriesto preventaccidental enginestart Jewelry is...

Page 4: ...ce 3 12 Starter Disconnect Parameters 3 12 Start DisconnectSequence 3 12 I Normal Operating Parameters 3 12 StoppingSequence 3 13 EmergencyShutdown 3 13 I ENGINECONTROLSERVICE 4 1 Troubleshooting 4 1...

Page 5: ...f generator windings cae cause damage to solid state compo nents Isolate these componentsbefore testing TEST EQUIPMENT Most of the test procedures in this manual can be per formed with an AC DC multim...

Page 6: ...itor the generator set Its name refers to the two DC operating ndicator lamps 0 The green RUN lamp which lights when unit is operating 0 The red FAULT lamp which lights in the event of shutdownfor alo...

Page 7: ...adingof thegenerator output in kilowatts VoltageAdjust Rheostat providing approximatelyplus or minus five percent adjustment of the rated output voltage FieldBreaker Providesgeneratorexciterand regula...

Page 8: ...outputleadsthroughthecurrenttransformersasecond or third winding to accomplish proper amplificationfor accurate meter movement readings An output wire passing through a current transformer is consider...

Page 9: ...their effectivenessvJhen the generatorset issubjectedtovaryingambientair condi tions during extended periods of non use Figure2 3 The element is controlled by an adjustablethermostat TO 120 VAC SUPPL...

Page 10: ...nitor system indicator lamps Thegreen RUNlampcomesonassoon asbothprimary and secondary starter disconnect circuits are opened after unit starting The red FAULT lamp will come on when an emergency shut...

Page 11: ...ICATOR LAMPS COOLANT TEMPERATURE GAUGE PREHEATSWITCH DCAMMETER RUNNINGTIME GAUGE TACHOMETER AC PANEL DC PANEL FIGURE 3 1 DC CONTROL M 1590 1 3 2 Redistribution or publication of this document by any m...

Page 12: ...RFACE A14 RELAY MODULEI VERTICALCONTROLLER VOLTAGE REGULATOR VRAS 2 VOLTAGESENSOR A I7 IIY ICill HClC LAY MODULES 0 0 MAGNETIC PICKUP A16 XES 1561 FIGURE 3 2 CONTROLINTERIOR 3 3 Redistribution or publ...

Page 13: ...t is delayed with low oil pres sure function HighEngineTemperature shutsdownthe engine immediately if coolant temperature rises above 227 F or 108 C above 222 F or 106 C for Onan TechStar generatorset...

Page 14: ...B TO START A I GND TO START I KI TDZ I BLOCK DIAGRAM I_ B PRE HET FLT 2 SW OFF 8 5TOP 2 P4 LAMP TESTaESET HATER TEMP Id TB2 FIGURE 3 3 ENGINE CONTROL MONITOR 3 5 Redistribution or publication of this...

Page 15: ...he relay base provide for either closing a circuit or opening a circuit upon energizing and de energizing the K11 relay depending on the desired function wires to the base connections Run Relay K11 is...

Page 16: ...the engine control monitor and allow the use of either ACorDCforalarm drives The relays areconfigured for low side switching by the control and supply sets of contacts for external alarm connections 6...

Page 17: ...e for automatic cool down runningof theengineforprescribed amount of time approximately3to 5minutes is recommended Preheat This function is included on the time delayed start stop modules used on indi...

Page 18: ...o operateatthe following output values 0 Start Disconnect 510 L 60 r min 0 OverspeedTrip Point 2200 r min zt 8 for 4 pole 50 60Hz 4400 r min f8 for 2 pole 50 60Hz The adjustable setpoint version has t...

Page 19: ...this module might first indicate a failureof voltage regulator VRAS 2 I 1 I I I i i I ADJUSTMENTS 1 LIMIT SET POINT ADJUSTMENTS DROPOUT SETPOINT DROPOUT TIME DELAY The adjustments available on this mo...

Page 20: ...s of the controller Regardlessofthecontrollermodelyou have theengine control monitorincludestheshutdownfaultcommands Controllers with options provide delineation and pre alarm of the shutdown faults t...

Page 21: ...ECMareprotectedbyfuses so that the circuit board paths cannot bedestroyedby excessivecurrent F1 Starter circuit fuse 20 ampere to protect cir cuit board paths K3 and associatedwiring F2 Switched B fus...

Page 22: ...e energize the generator set mounted fuel solenoid stops fuel flow which stops the engine Emergency Shutdown The K6 fault relay is energized when fault sensors respondto one of the following fault con...

Page 23: ...lug in are all potential prob lemsthat can be eliminated by a visual check 0 Unless absolutely sure that panel instruments are accurate use portable test meters for trouble shooting Whentroubleshootin...

Page 24: ...CRANK CORRECTIVEACTION Pressto desired Run or Remoteposition Press Lamp Reset switch to de energize fault lamp relaysof ECM after Run Stop Remote switch is pressedto Stop position Check fuses F1 and...

Page 25: ...ng Preheat solenoid for glow plugs IESNOTSTART CORRECTIVEACTION Fill with correct fuel Check fuse F2 Replace if necessary with proper fuse F2 20 Ampere Check for voltage out at A11TB1 10 when engine i...

Page 26: ...but stops cranking before75 f 15seconds 2 ENGINE CRANKS BUT DOES r CAUSE Fuelsupply line freeze to engine Lamp burned out Possibledefective ECM board A11 DefectiveECM board A11 DefectiveECM board A11...

Page 27: ...s of fixed setpoint or adjustable setpoint Performstart up and monitor engine speed to overspeed shutdown FixedSetpoint If shutdown occurs before limit replace AI6 module Adjustable Setpoint If shutdo...

Page 28: ...ions RSRlERAL SECONDS IContinuedl CORRECTIVEACTION Replenishas necessary Check coolant level perform restart and monitor engine temperaturegauge M12 If gauge readingis within normal range switch S2is...

Page 29: ...efer to Table 4 As required Check fuses F4and F2 of ECM board A11 F4 Main 5 Ampere F2 Fuelsolerioid or ignition 20 ampere Perf0r mrestartand check for B vqltage in at TBI 9 and voltsge out at TBl 10 t...

Page 30: ...checks out use a voltmeter to determine the alternator output voltage Connect the positive leadto the output terminal and connect the negative leadto ground Startthe generatorset and run for a few mi...

Page 31: ...etector 2 612 6280 5 6 DC Control Wire Diagram Vertical Detector 2 612 6283 5 7 DC Control Wire Diagram Horizontal Detector 12 612 6278 5 8 DC Control Wire Diagram Vertical Detector 12 612 6281 5 9 EM...

Page 32: ...5 2 AC Control Wire Diagram Horizontal w Detector AC...

Page 33: ...5 3 AC Control Wire Diagram Vertical w Detector AC Sheet 1 of 3...

Page 34: ...5 4 AC Control Wire Diagram Vertical w Detector AC Sheet 2 of 3...

Page 35: ...5 5 AC Control Wire Diagram Vertical w Detector AC Sheet 3 of 3...

Page 36: ...5 6 DC Control Wire Diagram Horizontal w Detector 2...

Page 37: ...5 7 DC Control Wire Diagram Vertical w Detector 2...

Page 38: ...5 8 DC Control Wire Diagram Horizontal Detector 12...

Page 39: ...5 9 DC Control Wire Diagram Vertical Detector 12...

Page 40: ...5 10 EMC P C B Assembly A11 Detector 2 12V...

Page 41: ...5 1 1 EMC P C B Assembly A11 Detector 2 24V...

Page 42: ...5 12 EMC P C B Assembly A11 Detector 12 12V...

Page 43: ...5 13 EMC P C B Assembly A11 Detector 12 24V...

Page 44: ...5 14 Redistribution or publication of this document by any means is strictly prohibited...

Page 45: ...RE OPTL LOW OIL PRESSURE I MODEL DVA DVB GENSETS HIGH COOLANT TEMPERATURE OIL PRESSURE E PRE LOW OIL HIGH COOLANT TEMPERATURE COOLANTTEMPERATURE SENDER PRE HIGH COOLANTTEMPERATURE OPTL BETAIL A MODELD...

Page 46: ...HIGH COOLANT 1 MODEL DVF DVG GENSETS PRE LOW OIL PRESSURE OIL PRESSURE OPTL I SENDER i LOW ENGINE TEMPERATURE OPTL COOLANT dEMPERATURE L LOW ENGINE TEMPERATURE OPTL M 1644 i MODELDVH DVJ GENSETS 6 2 R...

Page 47: ...Onan Corporation 140073rdAvenue N E Minneapolis MN 55432 Telex 275477 F x 612 574 8087 Redistribution or publication of this document by any means is strictly prohibited...

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