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Onan/Cummins gen. set Wiring Diagram Needed


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Old 03-28-2017, 11:43:55 AM
Mooncuser Mooncuser is offline
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Default Onan/Cummins gen. set Wiring Diagram Needed

I am in need of a set of wiring diagrams for a transfer switch and generator
The engine is a Cummins 750 DFHA serial # H960612688 Spec. 82459A wiring diagram 0612-6700 the transfer switch is a Onan OT 1200 serial # H960612943 spec. 12229J diagram 0626-1912 with features AO26, AO35, AO42, AO44, AO46, AO50, BO01, DO02, KO03, and RO26.
Any help or input would be appreciated
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Old 03-28-2017, 02:31:56 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Here are the wiring diagrams for the switch. Dont have time to look up the others.
Attached Files
File Type: pdf 626-1912-1.pdf (146.5 KB, 23 views)
File Type: pdf 626-1912-2.pdf (164.7 KB, 17 views)
File Type: pdf 626-1912-3.pdf (171.5 KB, 17 views)
File Type: pdf 626-1912-4.pdf (126.7 KB, 16 views)
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Old 03-28-2017, 05:18:15 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

There are three sections to 612-6700. Which do you need.
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Old 03-28-2017, 06:40:47 PM
Max Thompson Max Thompson is offline
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Default Re: Onan/Cummins gen. set wiring diagram needed

Billy, me and Mike get paid by the file, we just give him ALL of them.
Attached Files
File Type: pdf 612-6700 A.pdf (151.8 KB, 21 views)
File Type: pdf 612-6700 B.pdf (124.1 KB, 13 views)
File Type: pdf 612-6700 C.pdf (99.3 KB, 17 views)
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Old 03-28-2017, 06:51:34 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Max I don't work that cheap.

No I only have them in the master file and service manual. Fold out sheets and not sure how to scan them to a single page. Just be aware there is a 12 lead and 6 lead generator. The most common is the 12 lead.

manual is 960-0509

gotta pay for that jet somehow
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Old 03-28-2017, 07:04:03 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

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Originally Posted by Billy J Shafer View Post
Max I don't work that cheap.

gotta pay for that jet somehow
Just keep rubbing it in. I think Mike and I are going to pool our wages for this year, borrow $2 and buy a lottery ticket. We will either end up with a bigger jet than yours or $2 in debt.
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Old 03-28-2017, 09:26:15 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Sorry guys took all the money I made and went out of town. Billy it's about time you picked up the slack. I'm on a well deserved R and R. By the way Thanks for letting me use your plane . Not quite as nice as Trump's but close
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Old 03-29-2017, 09:29:46 AM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Thank you all for the input there is one more print I would like to see on print 626-1912 there is a note that reads (see sheet 3 for transfer switch motor wiring) I pretty much know what is going on in it but I would like to see it proper.
Also does anyone have an idea where I might be able to get a circuit card for the power sentry unit the card # 300-3121-DS-0956166H01?
Thanks
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Old 03-29-2017, 11:21:53 AM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Try Flight Systems for the board.I had to fold up the print. But I believe this is what you are looking for.
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Old 03-29-2017, 11:51:13 AM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Thank you very much I do have it already you have been a great help.
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Old 03-30-2017, 08:30:03 AM
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Default Re: Onan/Cummins gen. set wiring diagram needed

I have a question about this transfer switch I hope one of you might be able to explain. Why is there no fuse protection on the control wiring leads I mean on this unit there are # 16 AWG wires tied to the mains normal lines and emergency side also that gives them 1200A potential. Does the inrush current too the actuators have something to do with it?
I was thinking of adding in fuse blocks for each side but will that cause problems with auto starts?
That is how I got involved with this in the first place when it blew up I had to replace around 50 feet of # 16 the only reason it stopped burning was all three leads burnt through and shut it down.
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Old 04-07-2017, 01:26:02 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Gentlemen OK I have the transfer switch all put back together and now I know why it blue up I need a new /used solenoid in the parts list for this switch it states that the model # is 306-3623-02 but the solenoid in my switch reads 306-3617-22 also I will need one set of bridge rectifiers the part is listed as 305-0653 it is made up with four rectifiers #45XB377-1 is this the right place to start looking I have been to the E bay site and Crag's list but no luck
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Old 04-07-2017, 05:44:30 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Look at the individual rectifiers and see if you can find a value (or any info) printed on them. One of the electrical gurus here can probably help you find replacements.

Can you tell from the wiring diagram what the configuration and coil voltage of the relay is (should be)? And how it is different from what is there now? Most of the relays Onan used can be replaced with a non-OEM relay. They did not make anything special, just bought them without the manufactures info on them and an Onan part number instead.
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Old 04-07-2017, 06:28:30 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Are you talking about the linear motor? the one that throws the switch? You're almost certainly going to have to buy that from Onan. You MIGHT get lucky an find an identical, complete ATS on Ebay or something. There really are no salvage yards with this stuff, most always these things hang on the wall till they die of old age, and yours is just an unruly teen yet.
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Old 04-07-2017, 09:57:42 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

Quote:
Originally Posted by Mooncuser View Post
Gentlemen OK I have the transfer switch all put back together and now I know why it blue up I need a new /used solenoid in the parts list for this switch it states that the model # is 306-3623-02 but the solenoid in my switch reads 306-3617-22 also I will need one set of bridge rectifiers the part is listed as 305-0653 it is made up with four rectifiers #45XB377-1 is this the right place to start looking I have been to the E bay site and Crag's list but no luck
Mooncuser,

Perhaps that 306-3617-22 number was inappropriately placed on the transfer solenoid motor? That number is for the entire switch mechanism hanging on the back wall of the cabinet, which is obsolete, and would have been well into the 5-digit price category. Maybe look around that solenoid motor for a Zenith sticker or stamped number. Don't know if it would be cheaper through them or not. I have a bad one from I believe a 1200 out in the shop, I'll look tomorrow to see if it has any identifying marks on it.

The 306-3623-02 transfer motor, listed +$3400 in 2015. Rectifier, 35Amp, #305-0653, listed for $9.18.

Another thing about these big Dual motor ATS's: They need regular lubrication. You need to disable genset/kill utility input to ATS/<<lockout>> ALL power, and climb up to where you can see all the pivot points behind the mechanism, and spray lube them. I use moly chain lube. Put a lite spritz at the pivot points, and give the crescent gear/linkage the solenoid drives a healthy dose, and work by hand several times. Try moving it with the handle before lubing, you may be surprised at the difference. When these get dry and bind, the solenoids will actually still transfer, they just don't fly out to fully extended positions, to allow proper micro-switch activation. If you're not confident in properly performing lockout procedures, employ the assistance of a commercial electrician--you only get one chance to do this stuff wrong.



Quote:
Originally Posted by Mooncuser;
....Why is there no fuse protection on the control wiring leads I mean on this unit there are # 16 AWG wires tied to the mains normal lines and emergency side also that gives them 1200A potential. Does the inrush current too the actuators have something to do with it?_
I was thinking of adding in fuse blocks for each side but will that cause problems with auto starts?...
Transfer switches are built to operate under a somewhat sacrificial duty. Among their primary duties, assuming most are connected to emergency and/or life safety applications, is to withstand fault current, and get switched over to a more preferable power source whenever possible. I'd hate to see a bunch of ventilators or dialysis machines eventually shut down in an outage after their batteries die, because a fuse took a nuisance spike and blew.

Will respond back tomorrow whether I can find out anything about the solenoid or not.
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Old 04-07-2017, 10:31:20 PM
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Default Re: Onan/Cummins gen. set wiring diagram needed

The one problem I ran into with Zenith switches. Was getting the correct parts. Had one where they sent me the wrong harness. Even after giving them the part tag number and model and serial number from the switch. Just check the parts before you install them.
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Old 04-08-2017, 10:56:36 AM
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Default Re: Onan/Cummins gen. set wiring diagram needed

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.....Will respond back tomorrow whether I can find out anything about the solenoid or not.

Well, I found my old solenoid, it was a K-2147, (same size ATS, but it's a 208/240V solenoid), and a Zenith master price list from 2011 list it for $3023. Did you happen to find a label on yours with a K-2157 number? That is the Zenith number for the 480V, and on the same table it listed for $3298.

Here's a site, just as an example, selling it now for that price:
http://www.radwell.com/Buy/ZENITH/K2157?reload=1

Sorry, but I don't think there are any cheap solutions for this. I am presuming this is a commercial installation of some type, and unfortunately, is the cost of doing business.
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Old 04-08-2017, 01:41:43 PM
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Default Re: Onan/Cummins gen. set Wiring Diagram Needed

CRAP! I have a K2147 too, brand new pull out from a ATS that got field converted to 480. Guy just threw all the 208/240 parts at me and told me to make them go away.
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Old 04-10-2017, 08:52:21 AM
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Default Re: Onan/Cummins gen. set Wiring Diagram Needed

Once again thank you all I have not found the number on my solenoid yet but it sure does look like that K-2157 unit and as far as that price being high our Onan guy wants to charge us $9,000.00 (I have found a complete used transfer switch for $3500.00)for one they are asking $20.00 for the cap. I have an electronics department that can make up a capacitor so I think I will be calling Radwell if they still have the solenoid.
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Old 04-10-2017, 09:20:20 AM
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Default Re: Onan/Cummins gen. set Wiring Diagram Needed

When you do change it out. Make sure the solenoid is lined up. With no drag of any kind and it must pull all the way through. They have a short duty cycle. Easy to destroy one.
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