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.' TABLE OF CONTENTS . TITLE PAGE Safety Precautions .................................................. .Inside Cover Introduction ................................................................... 2 GENERATOR TROUBLESHOOTING ............................................ 5 Part 1 4.5 to 25 kW Range ................................................ 5 Part II 25 to 30 kW Range ................................................. 21 Generator Repair. J-Series ................................................. 35 Disassembly .......................................................... 35 Assembly .................................. ............................ 36 PTO ALTERNATORS .......................................................... 37 Specifications .. ............................................................. 38 Wiring Connections, 15-25 kW ............................................. 40 Troubleshooting ........................................................... 41 Service and Maintenance ................................................... 42 TWO BEARING ALTERNATORS ................................................ 43 .. . Specifications .................................... : ........................ 45 Troubleshooting .................................... i ..................... 46 Alternator Repair .......................................................... 47 Gear Case Disassembly ................................................ 47 Alternator Disassembly ................................................ 49 Alternator Assembly ................................................... 54 CONTROL SYSTEMS ......................................................... 55 Engine Control System Operation .......................................... 58 Gasoline Powered Sets ................................................ 58 Diesel Powered Sets ................................................... 58 Radiator Cooled Sets .................................................. 62 Engine Control Troubleshooting ............................................ 67 Control Component Checkout ............................................. 70 WIRING DIAGRAMS .......................... ; ............................... 72 TO AVOID POSSISLE PERSONAL INJURY OR EQUIPMENT DAMAGE. A QUALIFIED ELECTRI- CIAN OR AN AUTHORIZED SERVICE . REPRESENTATIVE MUST PERFORM IN- STALLATION AND ALL SERVICE . . 1
GENERAL This manual contains troubleshooting and repair procedures for the YD generators and controls.. Engine information is in the applicable engine manual. Three systems which could cause the electric generating set to malfunction are the generator, the control and the engine. The YD generator information includes description, troubleshooting, adjustments and tests for repairing the generator, exciter and voltage regulator. The majorsection of this manual applies to most, but not all, YD generators. In the development of larger capacity generators in the YD family, Onan has included some modifications so that the generator would have adequate motor-starting capability. These modificationsinvolve two basic areas: 1. The rotating exciter (rotor and stator) is about 112 inch thicker than standard. This results in the JB JC '' MJC RJC JC I MJC RJC SK Diesel DJB DJE MDJE DJC MDJC RDJC MDJF RDJF MDTA DTA YD PTO Alternator YD Two Bearing I NTROD UCTl ON winding resistances being different from the majority of generators. 2. The "UR" regulation system is used rather than the standard YD regulator. The generator set models affected by the above modifications include: 25 kW MDTNDTA'generator sets 30 kW SK generator sets 30 kW YD PTO generators . ' Separate sections of this manual should be referred to for information on these models which is different from that provided in the main body of the manual. The Controlsystem informatipn includes description and troubleshooting procedures for repairing the set if the trouble is in starting, stopping, or if thesetshuts down because of an emergency condition. MANUAL REFERENCE FOR YD GENERATOR SETS AND ALTERNATORS 60 Hz 7.5 12.5 10.0 12.5 15.0 15.0 15.0 30.0 k 6.0 6.0 7.5 12.0 120 15.0 15.0 17.5 25.0 25.0 15.0-30.0 5.0-20.0 I 50 Hz 6.0 10.0 12.5 . 125 25.0 : 4.5 x 4.5 6.0 9.0 10.0 12.5 12.0 14.5 15.0-30.0 5.0-16.0 STATOR STACK LENGTH 2.88 4.31 3.44 4.31 5.00 , 5.00 4.31 '7.00-10.38 . . 2.19, 2.19 ' 2.88 4.31 4.31 5.00 5.00 5.75 8.62 8.62 5.00-8.62 2.1 97-00 2 PARTS CATALOG 967-0223 967-0220 968-0340 974-0220 967-0220 968-0340 974-0220 946-0220 967-0221 967-0225 968-0224 967-0222 968-0222 974-0221 968-om 974-0222 961-0222 961 -0220 929-0002 929-0004 OPERATOR'S MANUAL 967-01 23 '* 967-01 20 968-0340 974-01 20 -. . 967-01 20 968-0340 974-01 20 946-01 20 967-01 21 967-01 25 . 968-0120 967-0122 968-01 22 974-0121 968-0121 974-0122 961-0122 961-0120 929-0002 929-0004
Page 1 and 2: Caution: This document contains mix
Page 3 and 4: The following symbols in this manua
Page 5 and 6: FLOW CHART A. NO AC OUTPUT VOLTAGE
Page 7 and 8: STMT Check exciter stator winding p
Page 9 and 10: -1 Contact with high voltage can ca
Page 11 and 12: The preferred test is with a megger
Page 13 and 14: are given in Table 1 (lead length b
Page 15 and 16: L - Wiring Harness Check Stop engin
Page 17: T I I I I I I I - I I I I I I I I I
Page 23 and 24: generator adapter. The brushless ex
Page 25 and 26: Is control panel field breaker CB21
Page 27 and 28: FLOW CHART D. AC OUTPUT VOLTAGE BUI
Page 29 and 30: GENERAL All of the following Adjust
Page 31 and 32: . FIGURE 6. MSHlNGTHEFiELD voltage
Page 33 and 34: MULTIMETER FIGURE 11. SCR VOLTAGE T
Page 35 and 36: TABLE 2 RESISTANCE VALUES FOR ROTOR
Page 37 and 38: VOLTAGE REGULATOR The line-voltage
Page 39 and 40: VI v2 v3 v4 - VI v2 v4 VI v2 \R v4
Page 41 and 42: START Is control panel field breake
Page 43 and 44: . FLOW CHART D. EXCITER FIELD BREAK
Page 45 and 46: GENERAL All of the following Adjust
Page 47 and 48: The winding schematic (Figure 25) s
Page 49 and 50: CONTACT ONE PROD TO EACE OF M E FIE
Page 51 and 52: [a1 RECONNECTION WIRE W12 Figure 36
Page 53 and 54: 1201240 VOLT, 1 PHASE, 60 HERTZ NAM
Page 55 and 56: ASSEMBLY 9. Torque down rotor-throu
Page 57 and 58: . Starting Watts ..................
Page 59 and 60: WIRING CONNECTIONS, 15-25 kW SINGLE
Page 61 and 62: PERIODIC SERVICE AND INSPECTION SER
Page 63 and 64: I I I I CYRZI-2 I 7821-1 I - I t I
Page 65 and 66: NOTE: For detailed troubleshooting
Page 67 and 68: 3. Removesix5/16x l-inch capscrewsa
Page 69 and 70:
4. Remove end bell by tapping upwar
Page 71 and 72:
9. Remove rotor and fan .by using a
Page 73 and 74:
14. If bearing, shaft, or oil seal
Page 75 and 76:
AC .AMMETERS WATER TEMPERATURE GAU
Page 77 and 78:
ENGINE CONTROL SYST.EM OPERATION De
Page 79 and 80:
Umlt cranking 15 to 20reconds to co
Page 81 and 82:
RADIATOR-COOLED DIESEL SETS The con
Page 83 and 84:
Start-Disconnect Sequence When cran
Page 85 and 86:
a a W a 9 W z f 66 6 b w a 3 0 E
Page 87 and 88:
START Does fuel transfer pump El an
Page 89 and 90:
CONTROL COMPONENT CHECKOUT The foll
Page 91 and 92:
WIRING DIAGRAMS The wiring and sche
Page 93 and 94:
I I I L I I m 74
Page 95 and 96:
I 1 ' t I I U
Page 97:
IW I- CE o_ u) z I It I 3 w
Page 100 and 101:
I I I I I I I I 3 $1 :I a 1 I I tl
Page 102 and 103:
P 83
Page 104 and 105:
- --1 I" .- I . I - 1 85
Page 106 and 107:
87 ~ " - .I \ e 6 a i- z 0 0 a E a
Page 108 and 109:
I I I I I I I I I 7 6 Et 4 3 2 I RE
Page 111:
Onan Corporation 1400 73rd Avenue N
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Caution: This document contains mixed page sizes ... - Igor Chudov

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