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 Service
Manual

1200,- 6500 Watts

50 and 60 Hertz

L ON 120/240V
Testing Procedures
Repairs
ooip
, p @@@
‘-20A-’ f 120 ONLY 30A L15AJ
I
Wiring Diagrams C

I -5ABGenSet

900-0193
6-82
Printed in U.S.A.

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 Safety Precautions
Before operatlng the generator set, read the Operator's 0 Do not wear loose clothing or jewelry while servicing any
Manual and become familiar with it and the equipment. Safe part of the generator set. Loose clothing and jewelry can
and efflclent operatlon can be achleved only If the unlt Is become caught in moving parts. Jewelry can short out
properly operated and malntalned. Many accidents are electrical contacts and cause shock or burning.
caused by failure to follow fundamental rules and precautions.
0 If adjustment mustbe made while the unit is running, use
The following symbols, found throughout this manual, alert you extreme caution around hot manifolds, moving parts, etc.
to potentially dangerousconditions to the operator, service per-
sonnel, or the equipment. ELECTRICAL SHOCK WILL CAUSE SEVERE
PERSONAL INJURY OR DEATH
.
D * This symbol warns of Immediate hat:
0 Remove electric power before removing protective shields
ards whlch will result In severe personal injury or
or touching electrical equipment. Use rubber insulative
death. mats placed on dry wood platforms over floors that are
metal or concrete when around electrical equipment. Do
1- This symbol refers to a hazard or unsafe not wear damp clothing (particularly wet shoes) or allow
practice whlch can result in severe personal lnjufy skin surfaces to be damp when handling electrical equip-
or death. ment.
Use extreme caution when working on electrical compo-
1- This symbol refers to a hazard or unsafe
0
nents. High voltages can cause injury or death. DO NOT
practice whlch can result In personal I n j u v or prod- tamper with interlocks.
uct or property damage.
0 Follow all state and local electrical codes. Have all electri-
FUEL AND FUMES ARE FLAMMABLE. Fire, explosion, and cal installations performed by a qualified licensed electri-
personal injury can result from improper practices. cian. Tag open switches to avoid accidental closure.

DO NOT fill fuel tankswith the engine runningunlesstanks 0 DO NOT CONNECTTHE GENERATOR SET DIRECTLY
are outside the engine compartment. Fuel contact with hot TO ANY BUILDING ELECTRICAL POWER SYSTEM.
engine or exhaust is a potential fire hazard. Hazardous voltages can flow from the generator set into
the utility line. This creates a potentialfor electrocutionor
DO NOT SMOKE OR ALLOW AN OPEN FLAME near the property damage. Connect only through an approvedde-
generator set or fuel tank. Internal combustion engine fu- vice and after building main switch is open. Consult an
els are highly flammable. electrician in regard to emergency power use.
Fuel lines must be adequately secured and free of leaks. GENERAL SAFETY PRECAUTIONS
Fuel connectionsatthe engine should be made with anap-
proved flexible line. Do not use copper piping on flexible 0 Provide appropriate fire extinguishers and install them in
lines as copper will work harden and become brittle. convenient locations. Consult your local fire department
for the correct type of extinguisher to use. Do not use foam
Be sure that all fuel supplies have a positive shutoff valve. on electrical fires. Use extinguisher rated ABC by NFPA.
DO NOTSMOKEwhile servicing batteries. Lead acid bat- 0 Usedengine oils have been identifiedby some state orfed-
teries emit a highly explosive hydrogen gas that can be ig- era1 agencies as causing cancer or reproductive toxicity.
nited by electrical arcing or by smoking. - -
When checking or changing engine oil, take care not to in-
gest, breathe the fumes, or contact used oil.
EXHAUST GASES ARE DEADLY
Providean adequate exhaust system to properly expel dis- Benzene and lead, found in some gasoline, have been
charged gases. Inspectthe exhaust system daily for leaks identified by some state and federal agencies as causing
per the maintenance schedule. See that exhaust mani- cancer or reproductive toxicity. When checking, draining
folds are secure and are not warped. Do not use exhaust or adding gasoline, take care not to ingest, breathe the
gases to heat a compartment. fumes, or contact gasoline.
Be sure the unit is well ventilated. 0 Make sure that rags are not left on or near the engine.
MOVING PARTS CAN CAUSE SEVERE PERSONAL 0 Remove all unnecessarygrease and oil from the unit. Ac-
INJURY OR DEATH cumulated grease and oil can cause over heating and en-
Keep your hands away from moving parts. gine damage, and present a potentialfire hazard.

Before performing any maintenance on the generator set, Keep the generator set and the surrounding area clean
disconnect the starting battery negative (-) ground lead and free from obstructions. Remove any debris from the
lead first. This will prevent accidental starting. set and keep the floor clean and dry. I

Make sure that fasteners on the generator set are secure, Do notwork on this equipmentwhen mentallyor physically
Tighten supportsandclamps, keepguardsinposition over fatigued, or after consuming any alcohol or drug that
fans, drive belts, etc. makes the operation of equipment unsafe.
ss-7

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Table of Contents
TITLE PAGE
SAFETY PRECAUTIONS ......................... Inside Front Cover
ELECTRICAL DATA .PORTABLE ALTERNATOR SETS
60 Hertz Models .......................................... 2
50HertzModels .......................................... 3
ELECTRICAL DATA .BELT DRIVEN ALTERNATORS
All Models................................................ 4
ALTERNATOR SPECIFICATIONS ................................ 5
DESCRIPTION ............................................... 6
Test Equipment........................................... 6
................................
Alternator Design Description 6
..............................................
Receptacles 6
....................................
Battery Charging Option 8 .
Vokmeter................................................. 8
..............................
External Receptacle Box Option 8
ldlematic Speed Control Option
.............................................
Operation 8
................................
Initial Linkage Adjustment 9
Carburetor Throttle Stop Screw Adjustment................. 9
.ALTERNATOR DISASSEMBLY .................................. 12
AssemblyTorques ........................................ 12
TROUB~ESHOOTINGCHART .................... i .............. 16
SERVICE AND TESTING PROCEDURES .......................... 17
.Brushes................................................ 17
Wiring.................................................. 18
Fuses.................................................. 18
................................................
Receptacles 18
........................................
Flashing the Field 18 ..
Diodes.................................................. 19
..........................................
Bridge Rectifier 20
Capacitor.............................................. 20
....................................
Testing Rotor Windings 21 ..
...................................
Testing Stator Windings 22
..................................
Testing Exciter Windings 23
WIRING DIAGRAMS
.............................
120 Volt. Receptacles in End Bell 24
.........................
120/240 Volt. Receptacles in End Bell 25
...............................
60 Hertz. Remote Receptacles 26
...............................
50 Hertz. Remote Receptacles 27
.....................................
Generator Set Control 28
Remote Receptacle Box with Fuses .......................... 29
....................
Generator Set Control Spec F (Sheet 1 of 2) 30
....................
Generator Set Control Spec F (Sheet 2 of 2) 31
...................
Generator Set Control Spec H (Sheet 1 of 2) 32
...................
Generator Set Control Spec H (Sheet 2 of 2) 33
...................
Generator Set Control Spec J (Sheet 1 of 2) .34-
....................
Generator Set Control Spec J (Sheet 2 of 2) 35
...........................
Dictionary of Basic Electrical Terms 36
7)
ONAN RECOMMENDS THATALL SERVICEINCLUDING INSTALLATION OF REPLACEMENTPARTS
ONLY BE DONE BY PERSONS QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANICAL
.
SERVICE TO PREVENT PERSONAL INJURY AND/OR EQUIPMENT DAMAGE I T IS IMPERATIVE
THAT THE SERVICE PERSON BE QUALIFIED .
Redistribution or publication of this document
by any means, is strictly prohibited.
 Electrical Data = Portable Alternators
Spec A Through F 60 Hz Models Only -
GENERATOR SET
SERIES** 1
I
WATTS I
I
AMPERES I
I
VOLTAGE* I
I
RPM I
I
PHASE

PD TM 1200 10 120 3600 1

PC TN 1750 14.6 120 3600 1
PE TP 2000 16.7 120 3600 1
PF TR 3000 25/12.5 120/240 3600 1
PG TS . 4500 38/19 120/240 3600 1
PH TT 5500 45.8122.9 120/240 3600 1
PK TS 4500 39/19 ' . 120/240 3600 1
PM 5500 45.~22.9 ' 120/240 3600 1

5.0 PK/3P 5000 120/240 *41/20.5 3 3600 1

5.0 PK/3E. 5000 120/240 *41/20.5 3 3600 1
6.5 PM/3P 6500 120/240 '54/27 3 3600 1
6.5 PM/3E* 6500 120/240 '54/27 3 3600 1
"5.0 PM/3P* 5000 120/240 '41/20.5 3 3600 1
"6.5 PM/3P* 6500 120/240 '54/27 3 3600 1

-
Spec J 60 Hz Models Only
Models . I Watts I Volts I Amps
RESIDENTIAL MODELS
I wire I . Phase I RPM 1

2 Redistribution or publication of this document

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 Electrical Data Portable Alternators -
Spec A Through F 50 Hz Models Only -
GENERATOR SET
SERIES** I WATTS AM PERES VOLTAGE RPM PHASE

PD TM 1000 10/5 100/200 3000 1

1000 914.5 110/220 3000 1
1000 8.4/4.2 120/240 3000 1
PC TN 1400 14/7 100/200 3000 1
1400 12.616.3 1101220 3000 1
1400 11.615.8 120/240 3000 1
PE TP 1600 1618 100/200 3000 1
1600 14.417.2 1101220 3000 1
1600 1326.6 120/240 3000 1
.PF TR 2500 25112.5 1001200 . 3000 1
2500 22.811 1.4 1101220 3000 1
2500 20.8110.4 1201240 3000 1
PG TS 3700 37118.5 1001200 3000 1
3700 33.6116.8 1101220 3000 1
PK - 3700 30.8115.4 1201240 . 3000 1
PH TT . 4500 45122.5 1001200 3000 1
PM - 4500 41/20.5 1101220 3000 1
4500 37.5/18.7 1201240 3000 1

-
Spec H 50 Hz Models Only
1.8PE-53AP 2.7PL-53AP 3.1PF-53AP 4.1PK-53AP 4.1PK-53AE 5.4PM-53AP - 5.4PW-53AE
I 4.1PK-53BP I
~

MODEL NO. 1.8PE-53BP 2.7PL-53BP 3.1PF-53BP 4.1PK-53BE I 5.4PM-53BP I 5.4PM-53BE

1.4PC-53CP 1.8PE-53CP 27PL-53CP 3.1PF-53CP I 4.1PK-53CP I 4.1PK-SCE I 5.4PM-53CP I 5.4PM-53CE 1
WATTS 1400 1800 . 2700 3100 4100 4100 5400

Amperes
53A , 1417.0 18/9.0 27A3.5 31115.5 I 41f20.5 I 41120.5 I 54127 54127
(Code) 538 12.716.3 16.4/8.2 24.5112.3 28.2f14.1 I 37.3118.6 I 37.3118.6 I 49124.5 I 49f24.5 1

PI
,

53C 11.615.8 15/7.5 22.511 1.3 25.8/12.9 34.2f17.1 34.2l17.1 45f22.5

1001200 100/200 1001200 1001200 100/200 100/200 100/200
Voltage ’
(Code) 1101220 1101220 1101220 11Of220 11Of220 1101220 11Of220 1101220
53’c i20i240 120/240 120/240 120/240 I 1201240 I 120f240 I 1201240 I 120f240 I
RPM I I 3000 3000 3000 3000 I 3000 30WJ 3000 I 3000 !

-
Spec J 50 Hz Models Only
Generator Set 1.4PE-53AP 1.8PE-53AP I I 2.7PL-53AP I 3.1PP-53AP I 3.1PFI-53AP I 4.1PN-53AP I 4.1PN-53AE 1 4.1PKI-53AP
Model Nom 1.4PE-53BP I 1.8PE-53BP I 2.7PL-53BP 1 3.1 PP-53BP I 3.1 PFI-53BP I 4.1 PN-53BP 1 4.1 PN-53BE I 4.1PKI-53BP
1.4PE-53CP 1.8PE-53CP 2.7PL-53CP 3.1 PP-53CP 3.1 PFI-53CP 4.1 PN-53CP 4.1 PN-53CE 4.1 PKI-53CP
Watts 1400 1800 2700 3100 3100 4100 4100 4100
53A 14/7.0 18/9.0 27/13.5 31/15 ’ 31/15.5 41/20.5 41/20.5 4V20.5
Amperes 538 12.7/6.3 16.418.2 24.611 2.3 28.2114.1 2a.2114.i 37.2178.6 37.2/18.6 37.2/18.6
53C 11.6/5.8 1517.5 22111 25.8112.9 25.811 2.9 34117 34.2117.1 34.2117.1
53A 1001200 1001200 1001200 100/200 1001200 1001200 1001200 100/200
Voltage 5381 1101220 1101220 I I 1101220 1 1101220 I 110/220 I 1101220 I 110/220 I 1101220
53Cl120/240 120/240 I I 1201240 I 1201240 I 1201240 I 120/240 I 1201240 I 1201240
RPM I3000 I3000 I 3000 I 3000 I 3000 I 3000 I 3000 I 3000

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 Electrical Data - Belt Driven Alternators
NET
ALTERNATOR CAPACITY WEIGHT
MODEL WATTS VOLTS AMP WIRE RPM LB (MASS)

1.2YCB-1s 1250 120 10.4 2 3600 33.5 (15.2)

2.OYCB-IS 2000 120 16.6 2 3600 41.0 (18.6)
3.0Y CB-3s 3000 1201240 25.0112.5 3 3600 47.5 (21.5)
4.5YCB-3s 4500 1201240 37.5118.8 3 3600 63.5 (28.8)
6.0Y CB-3s 6000 1201240 50.0125.0 3 3600 80.0 (36.3)

-
Single-phase, ** 50-Hertz Models Spec A Through C Only

* * Three-phase, 50-hz, 127/220 and 2201380-volt models are available by special order only.

Single-phase, 60-Hertz Models Spec H and J - .

..

* - Indicates 120 volt current rating.

Shaft diameter is 7/8 inches (22.2cm) on all models

4
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Alternator Specifications
Design: Revolving field, two pole, compound wound Rotor: Laminated steel stack, press fitted to shaft.
for improved voltage regulation. Self-excited. Drip Heavy polyester with insulated copper wire field
proof construction. Connected directly to the engine coils. Balanced.
and permanently aligned. Stator: Laminated electrical steel welded stack.
Bearing: Prelubricated, double-sealed needle Machine wound and laced AC windings in class Fslot
bearing. liners.
Exciter: Isolated exciter winding, solicon diodes or Brushes: Electrographitic. Long life, easily serviced.
bridge rectifier, no commutator. Collector rings and Collector Rings: Sintered copper alloy, concentric
brushes carry only rectified excitation current to the annular rings molded in phenolic.
field coils.
Frequency Regulation: 3 hertz maximum, no load to
Insulation: Class F per NEMA MG1-1.65 definition. rated load.
Insulating varnish conforms to MIL-1-24092. Type M,
Voltage Regulation: k 5%.
Class 155.
Battery Charging Circuit: A separate alternator wind-
Ternperafure Rise: Temperature rise at rated load is
ing internally wired to an insulated terminal inside the
within NEMA MGl-22.40 definition.
generator end bell. This simplifies installation of the
Cooling: Direct drive centrifugal blower. Air required optional, customer installed battery charging kit.
67-cf m . Output is 12 volts only at 5-8 amperes of continuous
charging current.

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5 by any means, is strictly prohibited.
Description
INTRODUCTION
This manual provides detailed disassembly, trouble- The rotor connects directly to the engine crankshaft
shooting, service and testing procedures for Onan with a tapered f i t on portable generator sets. On two
“P”-series portable generator sets and belt driven, bearing belt driven separate generators, a gasoline
two-bearing YCB alternators. Service and testing engine is the usual power source driven through a
procedures are illustrated and explained on most pulley/\/-belt connection. Enginespeed in both types
electrical components. Optional accessory items are is 3600 RPM f o r 60 hertz and 3000 RPM for 50 hertz
also covered. This manual covers ONLY the genera- operation.
tor portion of the portable generator sets. Contact the
engine manufacturer’s authorized dealer for service
and parts information on the engine. The prime
RECEPTACLES
mover may be either Briggs & Stratton or Tecumseh. Two, 120 volt duplex receptacles are standard on all
Information i s also applicable to all Onan manufac- 120 volt only models. One, 120 duplex and one, 240
tured private label models. This manual is intended volt duplex receptacle are standard on all 120/240
f o r use by authorized Onan distributors and dealers. volt models. Location and types of receptacles, fuses,
circuit breakers, switches and optional accessories
such as battery charging, voltmeters, ldlematic speed ._
TEST EQUIPMENT control, etc. vary according to Spec letter and kilo-
Most tests outlined in this manual can’be made with watt size. See Figures 1through Gfortypical recepta-
an AC-DC multimeter, such as Simpson 270. Other cle panel variations on Onan portable generator sets.
suggested instruments are: All belt-driven two bearing alternators have a voltme-
ter in the receptacle panel as shown in Figures 7 and
Onan Multitester 420-0303 8.
0 Wheatstone or Kelvin bridge-(Testing Resist-
ance Values below 1 ohm)
0 Jumper Wires

ALTERNATOR DESIGN DESCRIPTION

The YCB alternator family is a two pole, revolving
field (rotor) unit, with a stationary armature (stator)
containing t w o 120 volt AC windings as the power
source. The stator contains a separate AC excitation
winding. AC voltage of this winding is rectified to DC
by two silicon diodes that are mounted in the end bell
(Spec A and B models ONLY). These diodes were
replaced by a bridge rectifier (beginning Spec C). DC
passes to the field (rotor) through slip rings and low
current brushes allowing the alternator to produce its
o w n excitation current. Current is taken from the
statorthrough a connector plug on the end bell (Spec
A and 6 ONLY) to the receptacles. On later models
(beginning Spec C) current is taken from the stator
through individual internal output l o a d wires
(Tl,T2,T3 and T4) directly t o each receptacle. Some
models have fuses or circuit breakers in series with
the output load wires. Larger dual voltage models ES-1262

may have a full power voltage selector switch on the

control panel which allows full nameplate current to FIGURE 1. STANDARD RECEPTACLE PANEL
b e drawn from the 120 volt receptacles. Refer to (SPEC A AND B ONLY)
appropriate wiring diagram according to Spec letter
and nameplate rating. Alternator output leads are
individually marked and color coded f o r positive
identification.

6
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 FIGURE 2. OPTIONAL RECEPTACLE PANEL
EM263
I, j 0

WITH VOLTMETER
(SPEC A AND B ONLY) ES-1266
FIGURE 5. STANDARD RECEPTACLE BOX
FOR 120 VOLT MODELS
(SPEC J ONLY)

0
240V ;@ 12OV
ON 120/240V

ES-1264

FIGURE 3. STANDARD RECEPTACLE BOX - -

FOR 120 VOLT MODELS WITH VOLTMETER FIGURE 6. STANDARD RECEPTACLE PANEL
(SPEC C THROUGH F ONLY) AND WRAP AROUND HOUSING
(3.0kW AND LARGER DUAL VOLTAGE MODELS
SPEC H AND J ONLY)

ES-1265

FIGURE 4. STANDARD RECEPTACLE BOX ES-1267

FOR 120 VOLT MODELS. (SPEC H ONLY)
FIGURE 7. TYPICAL RECEPTACLE PANEL FOR
SPEC H BELT DRIVEN ALTERNATORS

7 Redistribution or publication of this document

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 20 AMP 15 AMP 30 AMP
FUSE FUSE FUSE
R
I 1 r I I I

M-1326

FIGURE 8. TYPICAL RECEPTACLE BOX FOR SPEC J BELT

DRIVEN, TWO BEARING ALTERNATORS

1 L ES-1268

FIGURE 9. OPTIONAL EXTERNAL RECEPTACLE

BATTERY CHARGING (Optional) BOX FOR SPEC A AND B PORTABLE
Most models can be equipped with a 12 volt, fused GENERATOR SETS
battery charging circuit. This circuit operates from a
separate alternator winding and charges at 5-8 amps
continuous charging current. See Figure 6.
A number of design changes and linkage modifica-
VOLTMETER tions have been made to various ldlematic kits since
All 120 volt portable generator set models (through the first external models were offered as a factory
Spec C ONLY) may be equipped with a voltmeter as a installed option on Spec A and B units ONLY. See
factory installed optional receptacle panel. All separ- Figure 10.
ate two bearing belt driven alternators have a voltme-
ter as standard equipment. Alternator output voltage
and frequency are directly proportional to engine
speed. Engine (governed) speed must be constant
and not fluctuate under varying loads. Adjust engine
governor to maintain proper output on voltmeter.

EXTERNAL RECEPTACLE BOX (Optional)

Spec A and B portable generator sets were available
with a blank cover in the end bell and a separate
receptacle box mounted on top or either side of the
end bell. This optional receptacle box has one, 120
volt, 30-amp twistlock receptacle; one, 240 volt, 20-
amp twistlock receptacle and one, 120 volt, 15 amp
duplex receptacle. They are available with or without
fuse protection corresponding to the ampere rating
of each receptacle. See Figure 9.
ES-1269
IDLEMATIC SPEED CONTROL (Optional) ON POSITION: PROVIDES A U T O M A T I C
I D L E CONTROL. WITH N O L O A D CON-
This solid state idle speed control device slows N E C T E D T O SET. S E T RUNS A T A P P R O X I -
engine speed from the normal 3600 RPM operating M A T E L Y 1800 RPM. WITH L O A D CONNECT-
speed t o 2250 RPM (aftera 12-15 second time delay) ED, S E T RUNS A T 3600 RPM.
when electrical load is removed from the generator
set. This allows longer engine life, lower fuel con-
sumption and a lower average noise level.
FIGURE 10. EXTERNAL IDLEMATIC SPEED CONTROL
(SPEC A AND B ONLY)

8
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 The 150-1667 ldlematic kit (Optional in Spec C I NlTIAL LINKAGE ADJUSTMENT
through F ONLY) or 150-1763 ldlematic kit (Optional
in Spec H ONLY); are obsolete and no longer availa- 1. Push solenoid plunger completely into solenoid
ble. Both kits are superseded by Replacement P.C. case (by hand) until plunger is completely bot-
Board kit 150-1905. When servicing any ldlematic tomed out (seated). See Figure 11 or 12.
equipped unit in Spec C through H that requires 2. Depresssolenoid plunger until fully seated. If low
replacement of the original printed circuit board: speed throttle stop screw on engine carburetor
order kit 150-1905. does not touch throttle stop on carburetor,
loosen jam nut on the solenoid plunger to allow
If asked to install a complete ldlematic kit on any for additional travel as required. Be careful not to
4
Spec H or J model, order kit 150-1904. All electrical stretch linkage spring.
components in these kits (except the on/off switch) 3. Adjust inside jam nut (closest to plunger) until it
are installed inside the control (receptacle) panel. touches the solenoid linkage spring. See Figure
11 or 12.
Complete ldlematic kits are no longer available for 4. While holding solenoid plunger, linkage spring
any Spec A through C generator sets. and inside jam nut from rotating, torque outside
jam nut to 8 inch pounds. See Figure 11 or 12.
IDLEMATIC CONTROL OPTION
(1.7 Through 6.5 kW Proper solenoid adjustment is
critical for speed control to
Briggs 8t Stratton Powered Models Only) function. If linkage spring is too taut, engine
The operating characteristics, initial linkage and car- solenoid will not remain seated in idle mode of
buretor throttle stop screw adjustments are critical in operation.
diagnosing proper operation or troubleshooting and
repair of any Spec H or J models equipped with the CARBURETOR THROTTLE STOP SCREW
150-1904 kit. Any Spec C through H modelsequipped
with an obsolete 300-1801 printed circuit board and ADJUSTMENT
solid wire throttle linkage MUST be converted to the Start the generator set and place the Idlematic on/off
new linkage and 300-2298 printed circuit board sup- switch in “off” (down) position with no load con-
plied in the 150-1905 kit. nected to set. Connect an accurate AC voltmeter to
any 120 volt duplex receptacle. Manually over-ride
IDLEMATIC CONTROL OPERATION engine governor by holding the throttle stop screw
against stop on carburetor at idle speed. Adjust throt-
When a load is placed on thealternator, the ldlematic tle stop screw for 75 volts AC output. Release gover-
control senses the load and opens the throttle so the nor and allow engine to come up to governed RPM.
set runs at 3600 RPM. A toggle switch mounted on the
receptacle panel turns the ldlematic on or off. Turning throttle stop screw inward (clockwise) increasesvoltage
and backing screw out (counter-clockwise) decreases the output
Using the Idlematic Control: Place the ldlematic voltage.
switch in the Off (down) position and start the gener-
ator set. place the switch in the ON (up) position with Torque locknut on throttle stop screw of carburetor
no load connected to the generator set. Within 30 to 20-24 inch pounds (2.3-2.7 Nom) to hold the proper
seconds, the engine RPM should drop from full load adjustment.
speed to idle speed. Connecting a load of at least 30
watts or more will cause the engine RPM to increase Place the ldlematic switch in “on” (up) position and
I
’
immediately to full load speed. After the first load/no within 30 seconds RPM should drop from full load
load cycle, time delay from full load speed to idle speed to idle speed with no load connected to the set.
speed is approximately 15 seconds. Remove load and
t place ldlematic switch in OFF position prior to stop-
ping the generator set.
If unit is operated with the ldlematic circuit inoperative, place the
ldlematic on/off switch in “off” (down) position to protect circuits
from any further electrical damage.

9 Redistribution or publication of this document

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Connecta lightbulb,fan ordrill toany 120voltduplex Too low an idle speed (solenoid
receptacle for a momentary load. Solenoid should energized) will result in low A C volt-
now de-energize and RPM should increase t o age to the engine solenoid which in turn may cause
accommodate load. After initial start-up, cycle time the Idlematic speed to vary (cycle) up and down con- -

from full load speed to no load speed is approxi- tinuously. AC output voltage (no load) MUST be
mately 15 seconds after load is removed. adjusted for 75 volts AC by adjusting throttle stop
screw o n carburetor to obtain this voltage.
An electrical load less than 30 watts If control does not reduce set speed at all, stop unit, remove
will not be sensed by the Idlematic receptacle panel and recheck all wiring step by step for proper and
control. Application of such a small load will result in tight connections. If all connections are correct, check one amp
improper engine speed fluctuations. fuse on printed circuit board which controls solenoid operation. If
speed control still does not operate and external governor linkage
is not binding and throttle stop screw is properly adjusted for 75
If the unit idle speed is not stable, but the output volts AC, replace printedcircuit board with a known good 300-2298
voltage is correct (75volts AC at idle without load and .P.C. Board.
throttle held on idle stop); the engine solenoid
plunger was not fully seated during initial linkage
spring adjustment. Loosen jam nuts on plunger rod
and readjust spring setting on plunger. rod per
instructions under INITIAL LINKAGE ADJUST-
MENT Section. Then repeat steps3and 4and besure
locknut is tightened properly to hold this adjustment.

- SOLENOID PLUNGER
RETAINER BRACKET

PLUNGER
SPRING

LOCKWASHER JAM NUTS

/
PLUNGER b< 0

-PLUNGER
ROD

LINKAGE COUPLING
SPRING

4-BEAD CHAIN

ENGINE GOVERNOR
ARM
-
GOVERNOR BRACKET
(CUT-AWAY)
FS-1241

FIGURE 11. SOLENOID LINKAGE ASSEMBLY O N

3.0, 3.2,3.7, and 5.0 kW MODELS
(8,lO and 11 HORSEPOWER)

10 Redistribution or publication of this document

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 I
GOVERNOR BRACKET
FS-1242

FIGURE 12. SOLENOID LINKAGE ADJUSTMENT AND

MOUNTING BRACKET INSTALLATION
ON 6.5 kW MODELS ONLY

11 Redistribution or publication of this document

by any means, is strictly prohibited.
Alternator Disassembly
Disassembly procedures for stator to end bell con- ALL PARTS INSIDE OF END BELL INCLUDING
nections and physical location of receptacle panel DIODES, CAPA CI TOR, R ECE P TACLES, BEAR-
components vary between models depending on ING, WIRES AND CONNECTIONS CAN BE
kilowatt size and Spec letter. Battery charging wind- TESTED AT THIS TIME. ROTOR, STATORAND
ing B1 (large orange lead with large insulated termi- COLLECTOR RINGS C A N A L S 0 BE CHECKED
nal) is not always used and the ground terminal strip OR TESTED AT THIS TIME WITHOUT FUR-
physical location and number of terminals varies THER DISASSEMBLY. BRUSHES MAY BE
according to model, Spec letter and number of REM 0 VED FOR INSPE C T I 0N.
accessory options installed. Figure 13 illustrates typ-
ical disassembly sequence for Spec A or B sets. Fig- 4. Remove internal allen screw, sleeve and rotor
ure 14 illustrates typical disassembly sequence for through stud. Tap rotor gently with a soft faced
Spec C through F models. Figure 15 illustratestypical hammer (brass or lead) to loosen rotor from the
disassembly sequence for Spec H and J models. tapered engine crankshaft. When loose, pull
Alternator disassembly .for separate, two-bearing, straight out.
belt driven alternators is similar to portable generator
sets except for the end bell and bearing on the shaft Internal wrenching allen screw and rotor through stud may
come out as one piece or separately.
(driving power) end of the alternator. Receptacle
(control) panel components vary according to kilo- 5. Some models (primarily 8 horsepower Tecumseh
watt rating and Spec letter. Proceed as follows: and 13 and 16 horsepower Briggs & Stratton
powered generator sets prior to Spec H) may use
1. Remove receptacle panel or cover (Spec A .& B), a tapered adapter sleeve on engine crankshaft
receptacle box (Smaller kW models Spec C ahead of rotor. Remove this sleeve when used.
through J) or receptacle panel with wrap around
housing (Larger kW models Spec F through J). 6. Remove four capscrews securing the alternator
Some Private Label larger kW models have a adapter to engine block and remove adapter.
blank cover over the end bell with aside mounted 7. Alternator assembly is the reverse of disassem-
wrap around housing and receptacle panel bly, following torque values listed below. Be sure
rotated 90"(toward service side) on generator internal wrenching allen nut isfullythreaded onto
end of set. rotor through stud (course thread end) prior to
2. Disconnect plug between stator and end bell on installing r o t o r t h r o u g h .stud into engine
Spec A ynd B models ONLY. On all other models, crankshaft.
disconnect the individual internal leads between
stator and various components on receptacle ASSEMBLY TORQUES
panels. Also disconnect the Positive (+Black) and DIODES (End Bell Spec A & B Only) 12-15 in. Ibs.
Negative (-White) brush leads. Rotor Through Stud
3. Remove the four long capscrews, lockwashers All Models except BFAB 19ft. Ibs.
and nuts that fasten end bell, stator and generator BFAB (Spec J ONLY) 27 ft. Ibs.
adapter together. Pull end bel1,straight out from
stator and set it aside. All other bolt torques are the same as SAE grade 5
hardware'according to nominal size and threads per
inch.

12 Redistribution or publication of this document

by any means, is strictly prohibited.
 ENG. TO
GENERATOR
ADAPTER
ROTOR I

- -~

A-,,,A
/.
---Y

GENERATOR
t i t N t K A IUK
ADAPTER
.IF..

bHAP I
ADAPTER
P
.--R

ENGINE BRIGGS & STRATTON .

OR TECUMSEH

/ \
STI
TPa
CONNE CTO R
LOCAT ION P 1-E I-A
RECEPTACLE
CAPACITOR COVER

ES-1270

FIGURE 13. TYPICAL EXPLODED VIEW OF ALTERNATOR

(SPEC A AND B ONLY)

13 Redistribution or publication of this document

by any means, is strictly prohibited.
 ENG. T O
GENERATOR
ROTOR
rob
ROLLER ROTOR I
BEARING SLEEVE THROUGH

\
\
NUT

-1-
-
\ A - lERAToR
GENERATOR
GENERATOR
SHAFT
ADAPTER ADAPTER

ENGINE BRIGGS & STRATTON

OR TECUMSEH

WIRE
CONNECTORS
sTA'v, BRUSH
GUIDE
LOCAT ION
PIN
BRUSH
CAPACITOR GROUNDING
TERMINAL
RECEPTACLE

ES-1271

FIGURE 14. TYPICAL EXPLODED VIEW OF ALTERNATOR

(SPEC C THROUGH F ONLY)

14
Redistribution or publication of this document
by any means, is strictly prohibited.
\

GENERATOR ENGINE (1.7 THROUGH 5.0 KW)SPEC J BRIGGS

& STRATTON. ENGINE 6.5 KW ONAN

15-1272

120/240 VOLT MODELS 120 VOLT MODELS 120 VOLT MODELS

SPEC H AND J ONLY SPEC H ONLY SPEC J ONLY

FIGURE 15. TYPICAL EXPLODED VIEW OF ALTERNATOR

(SPEC H AND J ONLY)

15 Redistribution or publication of this document

by any means, is strictly prohibited.
Troubleshooting Chart
*Letter in column refers to specific section in SERVICE AND TESTING PROCEDURES portion
of this manual.

-
SYMPTOM POSSIBLE CAUSE(S) I CORRECTIVE ACTION *
-
No Output 1. Open fuse(s) or circuit breaker (s) 1. Replace C
i n receptacle box (if used).
2. Faulty receptacle. (60 Hz only) 2. Replace D
3. Brushes worn excessively. 3. Replace A
4. Brushes sticking or broken spring. 4. Replace A
5. Loss of residual. 5. See Troubleshooting Procedures E
6. Dirty collector rings. 6. Clean or replace A
7. Loose or broken wire. 7. Repair B
8. One or both diodes shorted or 8. Replace F
defective bridge rectifier (if used).
9. Faulty capacitor. 9. Replace G
10. Faulty rotor. 10. Replace H
11. Faulty stator. 11. Replace . J
-
Low output 1. Alternator speed too low. 1. Speed should be 3600 rpm. (3000 rF I
(Requires Frequent 2. Engine low on power. 2. See Engine Manual. 50 Hz)
Field Flashing) 3. Worn brushes. 3. Replace A
4. One open diode. 4. Replace F
5. Open Capacitor. 5. Replace F
6. Rotor windings shorted. 6. Replace H
7. Stator windings shorted. 7. Replace J
8. Loss of Residual. 8. See Troubleshooting Procedures E
Alternator 1. Overloaded. 1. Remove part of load.. C
Overheats 2. Alternator air intake plugged, 2. Clean
with dirt, leaves, etc.
3. Windings covered with dirt or '3. Clean .
oil.

16 Redistribution or publication of this document

by any means, is strictly prohibited.
Service and Testing Procedures

ALTERNATOR TROUBLESHOOTING
There are four main items to check if generator out-
put does not build up to nameplate rating.

1. Brushes in end bell.

2. Diode rectifiers (2) or bridge rectifier in end bell.
3. Capacitor (Cl)inside end bell.
4. Loss of residual magnetism which requiresflash-
ing the field.

[AI
ALTERNATOR BRUSHES
To inspect the brushes, refer to Figure 16 using the
following procedures:
I
1. Remove receptacle cover plate, receptacle box or
receptacle panel (NOT wrap around sheet metal
e
housing) from end bell.
Some modelswill have duplex receptacles,a ground terminal
strip ora bridge rectifier mounted in the end bell. These items NEW REPLACE
will not interfere with brush removal and replacement. ALTERNATOR BRUSH WEAR LIMITS
ES-1273
2. Unfasten brush mounting (Phillips) screws.
3. Slide brushes out of their holders. FIGURE 16. BRUSH REMOVAL AND REPLACEMENT
4. Replace if worn to 5/16 inch or less as shown in (ALL MODELS)
Figure 16.

Use only the replacement brushes specified in the

parts manual. Other brushes may have entirely dif-
ferent electrical characteristics. Be sure brushes
slide freely in their holders, without any binding.

If collector rings are rough, smooth the ring surfaces

with #240 sandpaper. Do not use emery cloth.

17
Redistribution or publication of this document
by any means, is strictly prohibited.
BROKEN WIRE OR LOOSE CONNECTION FAULTY RECEPTACLE(S)
Check all internal wiring for loose or broken connec- Receptacles mounted on or within the end bell can be
tions or terminals. Check especiallyaround all recep- removed and replaced without removing the end bell
tacles and switches, terminal strip or circuit board from the generator. Remove the receptacle cover
connections, stator output leads (T1 through T4), plate or receptacle box from endbell, then remove
ground connections, etc. mounting screws of each individual receptacle. On
larger size 120/240 volt models, remove the side
mounting screws which secure the receptacle panel
to the sheetmetal wrap around housing. Pull the
FUSES receptacle panel out as far as the interconnecting
wiring allows. Each receptacle can now be removed
Some models with separate receptacle boxes are by disconnecting wiresand removing screw(s) which
equipped with fuses. If fuse is open or blown, turn secure receptacle to panel. Mark all wires for easier
fuse cover counterclockwise and replace (Figure 17) replacement before disconnecting.
with an identical fuse. Blown fuses are caused by too
much load on the receptacle, or an external short
Do NOT attempt to remove any
circuit. recep tacles with unit running.
Touching “live” wires or terminals could cause
Don’t exceed c u r r e n t rating serious injury or death.
stamped belowreceptacles. Be sure
to replace with the correct rated fuse to avoid damage
to power tools. [El
LOSS OF RESIDUAL MAGNETISM
(Flashing the Field)
20 A M P FUSE If there is a loss of residual magnetism (voltage will
not build up), it may be necessary to flash the field.

1. Remove receptacle cover plate, receptacle box or

receptacle panel (NOT wrap around sheetmetal
housing) from end bell.
2. Construct a field flashing circuit as shown in Fig-
ure 18. The diode and resistor in series with the
positive 6 volt lantern battery lead prevents the
possibliity of damage t o the field flashing
components.
3. Connect a 6 volt lantern battery with leads as
shown in Figure 18.
18-1274
4. Start unit with no load connected to alternator.
5. Momentarily touch positive brush with positive
(+) lead of lantern battery while grounding the
FIGURE 17. FUSE REPLACEMENT IN EXTERNAL
RECEPTACLE BOX (SPEC A AND B) negative (-) lead to generator frame. Remove as
soon as voltage starts to build up. (Use a plug-in
voltmeter in one of the receptacles if unit is not
equipped with a voltmeter.)
Positive brush is on the left side when facing the end bell.

6. Stop set. Start generator set again and check

output voltage with a voltmeter before reassem-
bling receptacles to generator end bell. If it is
necessary to flash the field daily or each time the
generator set is used, the problem is most likelya
defective capacitor.

18
Redistribution or publication of this document
by any means, is strictly prohibited.
 BRUSHES
10 OHM, 10 WATT 120 AMP (DC)
RESISTOR 300 VOLT DIODE

I TOGETHER

CAPACITOR OUTSIDEVIEW
OF ENDBELL
(RECEPTACLE PANEL
REMOVED)
C:ITOR

TOUCH ("+") LEAD TO

POSITIVE BRUSH
AND ('I-") LEAD TO
FRAME. HOLD JUST
LONG ENOUGH UNTIL
VOLTAGE STARTS DIODES
TO BUILD UP

DIODE LOCATION IN END BELL

(SPEC A AND B ONLY)

6 VOLT DRY
ELL BATTERY

ES-1275 SOLDERING DIODE LEAD

FIGURE 18. FIELD FLASHING CIRCUIT AND CONNECTIONS

When unsoldering or soldering wire
to diode, hold a needle-noise pliers
(Figure 19) between diode terminal and soldering
point to prevent heat from destroying diode.

[FI
DIODES (Spec A and B Models ONLY)
. Diodes can be tested without removal from end bell
or unsoldering wire leads. Disconnect plug between
' stator and end bell located underneath end bell.
0 Diodes and connector plug are shown in Figure 19.
Using an accurate ohmmeter, connect one lead to
LEAD
each end of each diode and observe reading. Reverse
ohmmeter leads and again observe resistance read-
ings as shown in Figure 19.

A good diode will have a high resistance reading in

one direction and a low reading when ohmmeter
leads are reversed. If both readings are high, or low,
diode is defective and must be replaced with a new,
ESl277
identical part.
FIGURE 19. DIODE LOCATION, TESTING AND REPLACEMENT

19
Redistribution or publication of this document
by any means, is strictly prohibited.
 POSiTlVE TERMINAL

CHECKING BRIDGE RECTIFIER RECEPTACLE I

PANEL
(Begin Spec C)
Remove the two small AC leads (X2 & X3) and the
positive (+) DC lead from the bridge rectifier. Con-
nect one lead of the ohmmeter to one of the AC
terminals and the other ohmmeter lead to the positive
(+) DC terminal of the bridge rectifier. Observe read-
ing. Now reverse ohmmeter leads and again observe
the meter. (Check both AC terminals to positive (+) in TERMINAL .
this manner.) A good rectifier will have a higher read- (NOT USED)
ing in one direction than the other. If both readings
(on one AC termina1)'are high or low, the rectifier is
defective and must be replaced with a new identical
part. Bridge rectifier location varies according to
, kilowatt size and spec letter as.shown in Figures 20
through 23. RIDGE RECTIFIER
GROUND
POSITIVE(+) ' , TERMINAL
CAPACITOR / BRUSH, ,
ES-1280

POSiTlVE TERMINAL
I FIGURE 22. BRIDGE RECTIFIER LOCATION ON
120/240 VOLT MODELS IN SPEC H ONLY

' GROUND. ' DUMMY

TERMINAL
. . . . .TERMINAL: . .
STRIP. ,. ' , ._
' ' '. (NOT USED) .'
.ES-1278 . . .
FIGURE 20. BRIDGE..RECTIFIER LOCATI,ON ..
1 SPEC c THROUGH' F MODELS ONLY
< .

e - *
. .

. . . . ES-1281
FIGURE 23. BRIDGE RECTIFIER LOCATION
ON SPEC J MODELS .
..

' [GI
CAPACITOR
If it is necessary t o flash the field daily or each time
the alternator is used, the problem is probably a
defective capacitor. Capacitor is located in end bell
(Figure 20). If generator set is running at a constant
speed (no fluctuation) but voltage rises and falls, the
capacitor may also be defective. If suspecting a
ES-1279
defective capacitor, replace with one known to be
FIGURE 21. BRIDGE RECTIFIER LOCATION ON good.
120 VOLT MODELS IN SPEC H ONLY

20
Redistribution or publication of this document
by any means, is strictly prohibited.
Replacing the Capacitor 5. Install the capacitorinto position with themount-
To replace the capacitor: ing bracket-
1. Remove the screw that secures the capacitor 6. Fasten the screw through the mounting bracket
mounting bracket t o the end bell. Remove the t o the end bell. Be sure the grounding wire is in
bracket. See Figure 20. position.
2. Free the capacitor from its position.
3. Slide the two terminal wires off the terminal posts
at the bottom of the capacitor.
CHI
TESTING ROTOR WINDINGS
4. Connect terminal wires onto the terminal posts of
the new capacitor. Be sure to attach the ground- Measuring Rotor Winding Resistance
ing wire (white) to the unpainted terminal post. Use an accurate ohmmeter for this test. Connect
The black wire attaches to the terminal post with meter leads to each collector ring (Figure 24). Resist-
the red marking. ances should be within the values specified in Table
1. Readings are taken at 68F (20C).

TABLE 1. RESISTANCE VALUES FOR ROTORS

WATTS STACK LENGTH *ROTOR RESISTANCE

up to 1200 1-1/2" 25.7-31.5 Ohms
1201-2000 2-1/4" 18.5-22.6 Ohms
2001-3000 3" 21.O-25.6 Ohms
3700 3-1/2" 22.5-27.5 Ohms
3001-4500 4-1/2" 26.2-32.0 Ohms
4501-6500 6" 31.O-37.9 Ohms
*Measured between collector rings.

21 Redistribution or publication of this document

by any means, is strictly prohibited.
Testing for Grounds A Wheatstone or Kelvin bridge is required for testing
low resistance values (below 1 ohm).
Connect an ohmmeter from each collector ring to
rotor shaft (ground). If rotor is serviceable, there
should be no reading on ohmmeter (Figure 25).

If either of the above testsdo not comply, replace with

a new rotor.

FIGURE 24. MEASURING ROTOR RESISTANCE

MEASURE BETWEEN
T 1-T4 WITH T2-T3
I U M P E R E D TOGETHER.
V A L U E S A R E GIVEN
I N T A B L E 2- SPEC A AND B MODELS ONLY

81 -Orange
xo -Black
X2 - Lt. Blue
x3 - Ll. Blue
T1 -Blue
T2 -Black
T3 -Red
T4 -Yellow

FIGURE 25. CHECKING ROTOR WINDINGS FOR GROUND

ES-1282

[JI 81 XO X 2 X3 T4 T3 T2 T1

TESTING STATOR WINDINGS MEASURE BETWEEN ALL MODELS BEGINNING

T l - T 4 WITH T2-T3 SPEC C AND LATER
Check stator windings by co.nnecting ohmmeter JUMPERED TOGETHER
leads between terminals on stator plug. Figure 26 VALUES ARE GIVEN
I N TABLE 2.
illustrates location of terminals on early and later ES-1283 *
single phase units. Table 2 lists stator winding
resistance values. FIGURE 26. TESTING STATOR WINDINGS

TABLE 2. RESISTANCE VALUES FOR STATOR WINDINGS

RESISTANCE (OHMS) (1 4 ONLY)

RATING OF
ALTERNATOR IN WATTS STACK LENGTH 60 HERTZ 50 HERTZ

up to 1200 1-112" 2.57-3.30Ohms 2.56-4.54Ohms

1 201-2000 2-114" 1.22-1.57Ohms 1.22-2.15Ohms
2001-3000 3 0.75-0.96 Ohms 0.75-1.32Ohms
3750 3-1/2" 0.55-0.67Ohms
3001-4500 4-112" 0.37-0.47Ohms 0.37-0.66Ohms
4500-6500 6 0:25-0.33 Ohms 0.25-0.93Ohms

22 Redistribution or publication of this document

by any means, is strictly prohibited.
 fK1
EXCITER WINDINGS
Check exciter windings by connecting ohmmeter
across X1 and X2 (early models) or X2 and X3 (later
models). Figure 27illustrates location of terminals on
single phase units. Table 3 lists exciter winding
resistance values.

81 -Orange
XO -Black
X2 - L l . Blue
X3 - L I Blue
T1 -Blue
T2 -Black
TD -Red
T4 -Yellow

61 XO X 2 X3 T4 T3 T2 T1
ALL MODELS BEGINNING SPEC C
AND LATER

FIGURE 27. TESTING EXCITER WINDINGS ES-1284

TABLE 3. RESISTANCE VALUES FOR EXCITER WINDINGS

RATING OF RESISTAN E (QHMS)

ALTERNATOR IN WATTS STACK LENGTH 60 HERTZ 50 HERTZ
u p to 1200 1-112" 2.04-3.30 Ohms 4.10-5.02 Ohms
1201-2000 2-114' 1.54-2.75 Ohms 3.11-3.71 Ohms
2001-3000 3" 1.54-2.31 Ohms 2.07-2.53 Ohms
3750 3-112" 1.52-1.86 Ohms
3001-4500 4-112" 1.29-2.20 Ohms 1.98-2.42 Ohms
4500-6500 6" 1.14-2.20 Ohms 1.98-2.42 Ohms

23 Redistribution or publication of this document

by any means, is strictly prohibited.
 n
0 0-
0
(v
0
4
I 0
'
I W
0 n
(D
cn
w

A
A
W
m

I
I

24 Redistribution or publication of this document

by any means, is strictly prohibited.
 601-0204
(SPEC A-C)

120V, 15A RECEPTACLE

I
I
I
I
I
I
I 240V, 15A RECEPTACLE
I
I
I

REF QTY DESCRIPTION

DES '

120/240 VOLT, RECEPTACLES IN END BELL

Redistribution or publication of this document
by any means, is strictly prohibited.
 GENERATOR
601-0205
--
STATOR
-- I
END BELL
1 (SPEC A-C)
!1 P1
T1 T1
I-

I 6 6

T2
818
I RECEPTACLE
T3 I BOX
2
T4
4

3----
-
-
I-
1

5 .
I
I
I I

1 1 -
-- -- CR1
I ROTOR
I

MAGNETO ASSY.
I--
I
, CHARGER I
i--A
- (OPTIONAL)

SPARK
PLUG ~1

RECONNECTION CHART
12ov, 2w 120/240, 3W
REF
c1
IQTY
I 1
I
I CAPACITOR
DESCRIPTION
II
CR1,2 2 RECTIFIER - DIODE
T3 El SPARK PLUG
G1 MAGNETO ASSY.
T4
J1 1 CONNECTOR
P1 1 CONNECTOR
s1 -
SWITCH STOP

60 HERTZ, REMOTE RECEPTACLES

Redistribution or publication of this document

by any means, is strictly prohibited.
26
 GENERATOR
601-0207

RECEPTACLE

I ROTOR

- SPARK
PLUG

50 HERTZ, REMOTE RECEPTACLES

-
NOTE:
T2 MUST BE GROUNDED
RECONNECTION CHART
X Y
2W, 50 Hz 3W, 50 Hz 2W, 50 Hz
120v 120/24ov 240V
11ov 11OI22OV 220v
1oov 100/200v 200v

i:-T
T4
T1

T4
..
t
c

t
T3
T1
f Y
I

--
Redistribution or publication of this document
27 by any means, is strictly prohibited.
 601-0212
(SPEC A-C)
iI T1
I

' BLUE
-- r --
RECEPTACLE
-- - I

BOX
T2 BLACK (OPTIONAL)
-

- REF
DES
QTY DESCRIPTION

c1 1 CAPACITOR (REF)
CR1 1 BRDIGE-RECTIFIER (REF)
El 1 SPARKPLUG
G1 1 MAGNETO

-
1- CONTROL - GEN SET s1
S2
1
1
SWITCH-ON OFF (WHEN USED)
SWITCH-STOP (WHEN USED)

Redistribution or publication of this document

by any means, is strictly prohibited.
 625-1 302
EXlSTlNG
GENERATOR (SPEC A-C)

T4
:I* I

v
F1

52
rw7
F2

r'

REAR VIEW OF BOX

I
DESCRIPTION I
I
I

/i 1 I~/SONNECTOR I
F1 I 1 lFUSE-30AMP
1 -
F2
F3 1
1 IFUSE 15 AMP
-
1 IFUSE 20 AMP I
-
1 RCPT LOCKING (30A, 225V)
-
1 RCPT DUPLEX (15A, 125V)
-
1 RCPT TWIST LOCK (20A. 250V)
PI I 1 JCONNECTOR
I 1 RECEPTACLE
BOX ASSY WIFUSE .

REMOTE RECEPTACLE BOX WITH FUSES

29 Redistribution or publication of this document

by any means, is strictly prohibited.
 CONTROL PANELS; REAR AND SIDE MOUNTED ENGINE DRIVEN -
STD CONTRACTORS PANEL
STD PANEL 1.2 THRU 2 kW STD PANEL 3 kW THRU 6 kW NlTH FULL PWR AT 120 VOLT SWITCH STD 50 HZ PANEL

15A 15A 15A 15A 20A 30A 15A

125V 125V 125V 1
2
%' 250V 125V 125V
I

-
CB
ZOA
20A
15A
--
CB
25A
30A -
251

323-1052
max W @
120v
3750 CSA 323-1061
:El Y2:
3750 3750 CSA 323-1051 CSA 323-1045

-
STD HOME STANDBY: CANADA BLANK PANEL STD CONTRACTORS PANEL
STD HOME STANDBY: USA

n
WITH FULL PWR AT 120 VOLT SWITCH
15A 20A 15A 30A
125V 125f250V 125V 125l25OV 30A 1SA 20A .
I 125V 125V '250V
CB

w
0

20A

323-1063
15A
30A

323-1062 301-4331
C t

323-1066
I
15A,250V

30A,125V
181 1
G o w
6-15R

L5-30R

STD CONTRACTORS PANEL

WITH FULL PWR AT 120 VOLT SWITCH
20A 30A 15A
25OV 125V 125V

a0
15A
30A
20A
20A

323-1073
601-0211
SHEET 1 OF 2

-
CONTROL GEN SET (W ~RlNGDIAGRAM)
SPEC F OF LY

Redistribution or publication of this document

by any means, is strictly prohibited.
 W

(T2) BLK
(T3) RED

(T4) Y E S

f
- **
- 240V

T21BLz>-
*FOR 2 WIRE UNGROUNDED USE 332-1556

(Tl) BLUE t
(TZ) ELK> 4
-
(T3) RED
(Tl) BLUE

(T3) RED
(T3) RED

L12ov
(T4)YEL 20A (T4)YEL 30A

If,
t
*FOR 2 WIRE UNGRDUNDED USE 332-1556
STATOR -- END BELL

ENGINE WIRING DIAGRAM ENGINE WI 1G DIAGRAM

ELECTRIC START MAN1 START
MAGNETO ASSY

L__
PLUG CONTROL GEM SET - 601-0211
(WIRING DIAGRAM) SHEET 2 OF 2
SPEC F ONLY Redistribution or publication of this document
by any means, is strictly prohibited.
 :RONT VIEW OF PANEL CONTROL GEN SET-
15A. 15A
(WIRING DIAGRAM)
15A 15A . 15A
240V 120v 12ov 120v SPEC H ONLY

0 0
0
(30
rl NOTES:
1. FUSES AND SWITCHES SHOWN ON
PANEL

3KW TO 5 K W 120v
1.7KW TO 3DKW 120V e240V 3 K W TO 5KW 240V r; 2 BEARING C

I5A 15A 15A 15A 15A 15A

240V 120v 120v 120v IZOV 12ov
J2 JI J2 JI

0 0
w
h)
. a (n"O)
00
4 . 4
E r n

\
3 K W TO 6.5KW 240V r
,IE
r
2 BEARING ( [ 1.7KW TO 2.2KW 120v 3.0 KW 240V
CONTRACTORS PANEL CONTRACTORS PANEL
WITH FULL POWER AT 120V RATING WITH FULL POWER AT 120v RATING
2OA 30A 15A 20A S A 15A

I
240V 120v 120v 240V 120v 120v
I I I

601-0214
3.2KW TO 6.5KW c 3.2KW T O 6.5KW r 200,220,240 V
1.4KW TO 5.4KW Id, SoHz SHEET 1 OF 2

Redistribution or publication of this document

1 * by any means, is strictly prohibited.
 w .
SCHEMATIC(Stl0WN REAR VIEW 9F N J - , -. . -- ,

r 5EE
NOTE I

t
TZfBLKl
TJLRED)
t
T4(YEL) T4(YEU T 4 Y EL)
1.7 KW TO 2.2 KW 120V 3KW 2 4 0 V 3KW TO 5KW 240V p 3 K H TO 5 K W 120V 3KW TO 6 S K W 2 4 0 V
TII
15A 15A
l20V I20V

I I I 1 I

T4(YEL)
1.7KW g 2 2 K W 120V 6.5 KW 240V H IJI

NOTES
1. IF NO BREAKER IS IN THE CONTROL
THE LEADS GO DIRECTLY TO THE LOAD.
2. 50 HZ GENERATORS: GROUND TERMINAL 2,
DO NOT GROUND TERMINAL 1.
CONTROL GEN SET -
(WIRING DIAGRAM)
SPEC H ONLY

3.2KW-6.5KW 240V

ENGINE WIRING DIAGRAM

MANUAL START
ENGINE WIRING DIAGRAM
ELECTRIC START
STATOR
ENDBELL
I __ RECEPTACLE
BOX ,

CUSTOMER
CONNECTION

601-0214
SHEET 2 OF 2
Redistribution or publication of this document
by any means, is strictly prohibited.
 15A 15A
15A 15A 120v 12ov
12ov IZOV
F
(o.o)(o.o) 00

2.2 PE-IPIIJ 3.0 PL-3PAJ

1.7 PE-IPAJ 3.0 P L - Y / 1 4 0 0 0 J
3.0 PL-IPAJ
m
15A 15A 15A ISA 15A I5A 20A 30A 15A
12ov 12ov 12ov l2OV 12ov 120v 240V IZOV l2OV
r 1

30 A
200/240v

u 5.0 PN-3E/IJ 6.5 BFAB-3E/IJ

. .

i
I

2.2F€I-IPIIJ
3.2PFI- 3 P l l J
3.7 PFI-3PIIJ
-
F
5.0 PKI 3P/ IJ m
.E .
. -. .- .-. .
I
I
15A I5A
12ov l2OV 30A 3OA ISA
240V I20V 12ov

'
CONTROL GENSET
(WIRING DIAGRAM)
-
SPEC J ONLY

601-021 5
ISHEET 1 OF 2

1.7 YCB -IS/IJ 6.5 BFAB-3PIIJ

2.2 YCB-IS/IJ
3.0 YCB - 3 S I
5.0 YCB-3S/ . oc

Redistribution or publication of this document

* by any means, is strictly prohibited.
 V b .
CONTROL GENSET -
(WIRING DIAGRAM)
SPEC J ONLY
0
SEE MI
NOTE I
*4 r--A,
SEE NOTE
c
T2 (BLKI +
I

5 T I (BWEI

17
. KW TO 2.2 KW 12OV 3KW 12OV 1-10
i-
3 KW 120/240V -
20 A
120/240V

T I (BLUE)

T 2 (BLKI
T3 (REO1
E N
T 4 (YELI

SEE NOTE 6

3.W3.7 KW 120/240V

T4 ( Y E L I
3.7/5.0 KW 120/240V
6.5 KW 120/240V
3.7/5.OKW 120/240V ( 23 0 A )
idKW 120/240V SAME AS ABOVE E X C E T m d

ENGIFE WlRNG DIAGRAM ENGINE WIRING DIAGRAM --_- STATOR-- END BELL _______-
RECEPTACLE BOX I

MANUAL START ELECTRIC START NOTES:

5 2 53 m BAT I. IF NO BREAKER IS IN THE CONTROL
THE LEADS GO DIRECTLY TO THE U14D
2. 50 HZ GENERATORS: GROUND TERMINAL
2, DO NOT GROUND TERMINAL I
3. WIRING DlAG REFLECTS REAR VIEW OF
RECEPTACLES.

4. MLTMETER USED ON 2 BRG ONLY.

A
NOTE: SI IN
RECEPTACLE
PANEL
i 5. [ -1 DENOTES BREAKER LOCATIONWHEN USED.
4 0 SWITCH ~
6. USE BLANK CONTROL PANEL
~ ~ ~
SI -STOP SWITCH OR START-STOP
SP-VACUUM SWITCH
SI-LOPKO
KI -START SOLENOID
81 -STARTER 601-0215
SHEET 2 OF 2
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by any means, is strictly prohibited.
 DICTIONARY OF BASIC ELECTRICAL TERMS

ALTERNATING CURRENT - Electricity that flows INSULATOR - Any material which has a very high
in one direction, then in the reversedirection through resistance to current flow. .L
kconductors. The current reverses at regular inter-
.
vals as each wire becomes positive then negative, .KILOWATT - 1000 Watts.
reversing polarity typically 60 times per second.

ALTERNATOR - A machine that generates AC OHM - A unit of measurement of resistance in an

electrical circuit.
current.

AMPERE - A unit of measurement of electrical PARALLEL CIRCUIT - Acircuit where thepartsare

current flowing in a given time under a pressure of. so connected that the current divides between them.
one volt, when there is a resistance of one OHM in the
circuit. RESISTANCE - The opposing o r retarding force
offered by a circuit or component of a circuit to the
CIRCUIT - The course 'followed by an electric passage of electrical current through it. Resistance is
current passing from its source through a succession measured in ohms.
of conductors, through a load, and back to its starting
point.
ROTOR - The rotating part of an electrical machine
.such as a generator, motor, or alternator.
CIRCUIT BREAKER - An automatic switch that
opens its circuit upon detecting excess current. The
circuit breaker replaces a fuse. SERIES CIRCUIT - A circuit in which the current
has only one path to take.
CONDUCTOR - Any material which conducts
current readily. A material having low resistance. STATOR - The stationary.part of an alternator in
which another part (the rotor) revolves.
DIODE - An electrical device that will allow current
to pass through itself in one direction only.
VOLT - A unit of measurement of electrical
DIRECT CURRENT - Current that always flows in pressure required to force one ampere through a
resistance of one ohm.
the same direction.

FUSE - A ribbon of fusible metal that burns and VOLTAGE DROP - The voltage required to force :
opens its associated circuit on detecting excess current through the resistance of line wires or the
current. power consuming device.

GROUNDING WIRE - Usually green in color and is WATT - A unit of measurement of electrical power
used to ground electrical equipment to prevent supplied to the circuit when one volt is forcing one <
electrical shock. ampere through one ohm resistance.

36
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Redistribution or publication of this document
by any means, is strictly prohibited.
Onan Corporation
1400 73rd Avenue N. E.
Minneapolis,MN 55432
612-574-5000
Telex: 275477
Fax: 612-574-8087
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