Control Board Install

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Instruction Sheet

C351e 62000

Installation of Control Board ReplacementKit 300-3950

PURPOSE OF KIT

These instructions describe the removal and re-placement of the Control Circuit board used on thefollowing generators.

BGE Spec F and G. . . . . . . . . . . . . .BGEL Spec E and G. . . . . . . . . . . . .NHE, NHEL Spec D, E and G. . . . . . . .BGM, NHM Spec A only. . . . . . . .BGD Spec A and B. . . . . . . . . . . . . .NHD Spec A, B and C. . . . . . . . . . . . . .

SAFETY PRECAUTIONS

Read these instructions completely and become fa-miliar with safety warnings, cautions, and proce-dures before starting the installation.

Always disconnect a battery chargerfrom its AC source before disconnecting the batterycables. Otherwise, disconnecting the cables can re-sult in voltage spikes high enough to damage the DCcontrol circuits of the set.

Accidental starting of the generator setwhile working on it can cause severe personal injuryor death. Prevent accidental starting by disconnect-

ing the starting battery cables (negative [] first).

KIT PARTS

Prior to installation, verify receipt of the proper partsfrom the table below.

Part Description QTY.

Splice, Window; 2216 6

Screw, Pan Head; 632 x .38 4

Harness, Wire, PCB 1

PCB, Control Assembly 1

BGM/NHM MOUNTING CONSIDERATIONS

If installing the kit on a BGM/NHM (Marquis) gener-ator set, note the following change:

The lead marked J1-12-E2 MUST be connectedto K5, pin 85 instead of the marked connection.Disregard the wire routing labels in thisinstance only.

Consult Figure 3 (J1 diagram) for more information.

This note applies only to technicians installing theControl Board kit on the BGM/NHM (Marquis) gen-sets.

Incorrect installation, service, or parts

replacement can result in severe personal injury,

death, and/or equipment damage. Service personnel

must be qualified to perform electrical and mechani-

cal installions and service.

INSTALLATION

Tools Required

Wire stripping and splicing tool

Torx screwdriver kit

Needle-nose pliers

Conventional screwdriver kit

Procedure

1. Disconnect the generator set starting batterycables (negative [] cable first) to prevent the

genset from starting.

2. Turn off and disconnect battery charger (ifequipped).

3. Pull the genset fuse from the control panel andset it aside. Disconnect the remote cable, ifpresent.

4. Remove the two screws from the top of the con-trol panel. Pull the panel down and away fromthe control box.


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5. Pull connectors J1 and J3 off the edge of theControl Circuit board. Remove the wires fromthe control panel wire retainer (Figure 1).

6. Remove the four screws securing the circuitboard to the control panel and pull the board offthe panel. Discard the old board and screws.

7. Mount the new circuit board from the kit ontothe control panel using the no. 6 screws in thekit.

CONTROL PANELATTACHMENT

SCREWS

J1CONNECTOR

J3CONNECTOR

GENSETMAIN FUSE

BATTERYPOSITIVE (+)

CONNECTION

FIGURE 1: CONTROL PANEL ASSEMBLY(EARLIER VERSION w/J1 and J3 CONNECTORS)

Build New Connector

1. Cut connectors J1 and J3 from the wires ex-tending into the generator set control. Clipwires as close to the connector as possible.

Make sure the routing labels on the wiresremain intact.

If the routing labels are missing, refer to Figure3 and Table 1, and refer to the wiring diagram/schematic for the genset.

2. Using the stripping/splicing tool, crimp the 6splices to the wires extending from the new J1connector supplied in the kit. Insert the wiresone-by-one into the connectors, then crimp theconnectors firmly onto the wires using the splic-ing tool.

Wiring

Wires on the new connector are labeled for con-necting wires in the control box. Connect the wiresone at a time. Do not cut away or obscure the la-bels on the wires, wherever possible.

1. Attach the new connector J1 to the wires in the

control box as follows:A. Using the stripping/splicing tool, strip 1/4

inch off one of the wires from the controlbox.

B. Insert the end of the wire into one of thewire splice connectors.

C. Crimp the connector firmly onto the wireusing the splicing tool.

D. Repeat this step for each of the wires at-tached to new J1 connector.

NOTE: Wire J13 is not used. Use a tie wrap tocoil and secure this wire, or remove the wire.

When installing on a Marquis(Models BGM and NHM) be sure to connectJ1-12 to K5, pin 85. Connecting this lead toE2 as marked, will short out the controlboard, and the genset will not run.

2. Remove the remaining non-terminated wiresone at a time, replacing them with new wiresfrom J1.

3. Connect the five push-on terminals from con-nector J1 to the designated connectors insidethe genset using the needle-nose pliers (Table1).

4. The terminal marked K1s may have twowires. Clip the wire tie holding them together toconnect the new K1S. Secure the terminalwith a new wire tie.

5. Plug new J1 connector onto the control board.

6. Tuck all wires neatly back into the control box. ifpossible, pull the wires back into the controlbox from the rear of the box.

7. Four of the wires connecting to new J1 passthrough the front of the control box. Clip thesewires to the retainer located on the lower, insideedge of the control board to secure them inplace (Figure 2).


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P2 BOARDCONNECTOR:ATTACH NEW

J1 HERE

CONTROLBOARD

WIRE RETAINER

FIGURE 2: BACK OF CONTROL PANEL

(REPLACEMENT PANEL)

Reassemble

1. Position the control panel on front of the controlbox. Reattach the control panel using the twoscrews removed in Step 4.

2. Connect the positive (+) battery cable to theterminal at the front of the control box.

3. Connect the negative () battery cable to theterminal on the generator set.

4. Reconnect the battery charger (if equipped).

5. Install the main fuse in the control panel.

6. Start and test the genset according to the ap-propriate operators manual.

Electrical shock can cause severe per-

sonal injury or death. Do not touch electrical wiring

or components during testing. Disconnect electrical

power by removing starting battery negative ()cable before handling electrical wiring or compo-

nents.

7

8

9

10

11

12

1

2

3

4

5

6

ROUTE LEAD TO:

J1

K11 (B+ POWER TO BOARD)

NOT USED

K1S

BGE/NHENOT USED BGEL/NHELCR6ALL OTHERSCR8

GROUND (L0)

E2 OR R7 (K5 ON BGM/NHM)

J47 (TO VR1)

B1 (FROM GENERATOR

R6 (NOT USED)

B2 (FROM GENERATOR

S2 (LOPKO)

E1 (IGNITION COIL)

ROUTE LEAD TO:

FIGURE 3. J1 PIN CONNECTIONS

TABLE 1. LABELS ON HARNESS LEADS

New Wire LabelsNear Connector J1

Original Wire LabelsFurthest From

ConnectorComponent Connection

J11 J15 J47 (to VR1)

J12 J11 B1

J13 J14 Not used on 3951 board; R6 on 3950 board

J14 J17 B2

J15 J34 S2 (LOPKO)


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New Wire LabelsNear Connector J1

Original Wire LabelsFurthest From

ConnectorComponent Connection

J16 J33 E1 (Ignition coil +)

J17 J16 K11

J18 Not used

J19 J12 L1S (May be piggybacked to CR9E2 or K685)

J110 J32BGE/NHE Not used; BGEL/NHEL CR6;BGM/NHM and BGD/NHD CR8

J111 J18 GND (L0)

J112 J36BGM/NHM K585; Models with R7 resistor R7;All others Pump E2

Documents

Control Board Install