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Generator Control Box

This is a 97 with the 8KW generator. I noted a couple of threads lately regarding loose wires in the control box so I took a look at mine (gen was working fine). In the process of cleaning and reseating I found two wires not connected. I don't have the proper schematic for this thing. Anyone have it?

Anyhow, There's a little tranformer (blue oval) in the control box. It has 2 black wires on top, one to a switch and the other to ground. It has 2 green wires on the bottom. One trails off into the box with a female spade terminal on it. No place to plug it that I could see. The other green wire (yellow arrow) runs to the control module on the face (the part with the hour meter, circuit breakers and fuse). It is skinned on the end and it is laying adjacent to another green wire that goes to the ground terminal on the control module. I think it just fell out.

So my questions are: Anyone have the proper schematic and anyone know if this green wire just combines with the other green on the control module?
Thanks.
jor
93 225
95 300
97 270
99 320

Re: Generator Control Box

Reply #1 –

On the controller I have a wire connected to terminals 5,6,7,10,11,12.  This is on a 1999 10KW generator so they may be the same, or not.  Not sure about the transformer since the one in mine is disconnected.
I'm in the process of re-doing the wires in mine since I keep having broken wires.  I'll be using these wiring ferrules which I used during my work days. 
KANGORA Wire Crimping Tool Kit w/800 Terminal Connector Sleeves | Electrician...

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Forest & Cindy Olivier
1987 log cabin
2011 Roadtrek C210P
no longer 1999 36' U320 build #5522
2013 Rzr 570 & 2018 Ranger XP1000
2006 Lexus GX470
2011 Tahoe LT 4x4
Previous 1998 45' 2 slide Newell, 1993 39' Newell

Re: Generator Control Box

Reply #2 –
Looks like a ground wire. Try testing it with a voltmeter to see if there is continuity with ground.
Sorry, don't have the wire diagram for it.
On a side note, how do you get the generator to slide out? Mine seems stuck. But not sure how to unlock it. There also seems to have some bolts missing. And my electrical box is missing 3 of the 4 screws.
Bob
'99 U320 40 WTFE
Build #5462,
1500 Watts Solar 600 amp Victron lithium
2012 Jeep Grand Cherokee Overland Hemi
Instagram bobfnbw
Retired

Re: Generator Control Box

Reply #3 –
Look for 2 bolts (1/2in I think?), 1 on each side at the bottom slide rails.  Remove those bolts and the gen should slide forward.  That's how mine is anyway.

Re: Generator Control Box

Reply #4 –
Here are the two bolts that bdale is referring to. They are 1/2". Just remove them and really yank on the base plate handle. Some get really stuck. If you can't get it out, you can remove the rubber cover on the bottom and attack it more aggressively.
jor
93 225
95 300
97 270
99 320

Re: Generator Control Box

Reply #5 –
Jor,

Call Cummins if it's an Onan generator.  The engine is probably a Kubota.  They service then as part of their Coach Care program.  They will have a wiring diagram.

Keith
Keith, Joyce & Smokey the Australian Cattle Dog
1995 U320 SE Extreme 40' WTBI Build # 4780, with a Honda CR-V hopefully still following behind.
Motorcade # 17030
FMCA # F422159

Re: Generator Control Box

Reply #6 –
Thanks for the tip. I just got the info I need on the transformer. Turns out it is not needed. That explains why folivier's is disconnected.
jor
93 225
95 300
97 270
99 320

Re: Generator Control Box

Reply #7 –
Closing out this thread. I ended up removing the transformer and throwing it. Thanks to BillW I learned that the transformer was for the speed control and that function is now handled by the newer ES52 control module. Everything was nice and tight but I went ahead and cleaned and reseated all the wires. I did find two (on the new ES52) which were just wrapped around the screw so I added ring terminals to those. Anyhow, glad to have gotten in there and poked around for awhile.
jor
93 225
95 300
97 270
99 320

Re: Generator Control Box

Reply #8 –
Jor, is that ES52 an autostart board?  Also, I understand there was at one time a kit for relocating the control box to the drivers side bay.  Each start and shutdown sequence causes the genset to go into paint shaker mode....be nice to get these controls isolated from that.  Anyone done that?
"Not so  long ago we were a nation of risk takers, riding five million pounds of  thrust straight into space."  Joe Gresh
Chuck Pearson
1996 U295
2018 Can Am X3 TurboRS

Re: Generator Control Box

Reply #9 –
From my research the ES52 is not an autostart board, that would be a different component.  The ES52 performs the preheat, alarm, shutdown, and other functions but not autostart based on battery low voltage or high inside temperature.
Forest & Cindy Olivier
1987 log cabin
2011 Roadtrek C210P
no longer 1999 36' U320 build #5522
2013 Rzr 570 & 2018 Ranger XP1000
2006 Lexus GX470
2011 Tahoe LT 4x4
Previous 1998 45' 2 slide Newell, 1993 39' Newell

Re: Generator Control Box

Reply #10 –
goggle dynagen es52 autostart, the es52 I have in my 97 U270 is the low voltage start.
The selected media item is not currently available.Bill&Doris 97 U270 36'
University of Parris Island Class of 66
Semper Fi  Build# 5174 MC#17094

Re: Generator Control Box

Reply #11 –
Quote from: Chuck Pearson –
I understand there was at one time a kit for relocating the control box to the drivers side bay.  Each start and shutdown sequence causes the genset to go into paint shaker mode....be nice to get these controls isolated from that.  Anyone done that?
Chuck,

When I bought my coach the previous owner had had FOT move the auto-start function to the driver side bay, leaving the control board, circuit breaker for the cooling fan and the two big main circuit breakers in the box on the generator.  Over Time I had to replace the control board and repair several broken wires.  I finally decided to move everything but the two main 120 volt circuit breakers off the generator and into the driver side bay.  There was already a flexible conduit run from the box on the generator to that bay so all I had to do was pull half a dozen wires through the conduit (it was a tight fit) and mount a small box to contain the components.  Now the brains for the generator are accessible and ride smoothly and quietly in that side bay. 

Richard
Jan & Richard Witt
1999 U-320  36ft WTFE
Build Number: 5478 Motorcade: 16599
2011 Jeep Wrangler Unlimited w/Air Force One
Jan: NO5U, Richard:KA5RIW
The selected media item is not currently available.

Re: Generator Control Box

Reply #12 –
On my 1999 36' U320 the ES52 is the starting and control module which handles preheating, starting, and alarm/shutdown, but not a low battery voltage auto start.  I also have the factory installed separate autostart module under the dash which does AFAIK provide a low voltage startup.  This module sends a start signal to the ES52.
I think there may be a misunderstanding of what "autostart" means.  In my case I'm referring to the autostart module under the dash which does autostart the generator on low battery voltage.  The Dynagen ES52 manual states that it is an autostart controller but I'm understanding that to mean that once the ES52 receives a start signal (from whatever source) that it controls preheat, startup, and alarm/shutdown functions.
Again this is what my coach has, and since I'm the 3rd owner I have no way to know if this is how the factory built it or if it was modified in some way by a PO.
Forest & Cindy Olivier
1987 log cabin
2011 Roadtrek C210P
no longer 1999 36' U320 build #5522
2013 Rzr 570 & 2018 Ranger XP1000
2006 Lexus GX470
2011 Tahoe LT 4x4
Previous 1998 45' 2 slide Newell, 1993 39' Newell

Re: Generator Control Box

Reply #13 –
Quote from: Jan & Richard –
Chuck,

Now the brains for the generator are accessible and ride smoothly and quietly in that side bay. 

Richard

That's what we're talking about!  Thanks for upgrading my next coach.  (inside joke)
"Not so  long ago we were a nation of risk takers, riding five million pounds of  thrust straight into space."  Joe Gresh
Chuck Pearson
1996 U295
2018 Can Am X3 TurboRS

Re: Generator Control Box

Reply #14 –
This drawing may help to clarify the auto start function.  The "auto start module" is the Dynagen ES52.  In the lower right corner is the BCM-12 which is what senses the battery voltage and sends a start signal to the ES52 when the low voltage setpoint is reached.
Hopes this helps.
Forest & Cindy Olivier
1987 log cabin
2011 Roadtrek C210P
no longer 1999 36' U320 build #5522
2013 Rzr 570 & 2018 Ranger XP1000
2006 Lexus GX470
2011 Tahoe LT 4x4
Previous 1998 45' 2 slide Newell, 1993 39' Newell