GP2500B THRU GP8000BS Operators Manual
Contents
1. AUTION Disconnect and ground the spark plug lead wire 3 NOTE Close the fuel vaive at the base of the fuel tank 4 NOTE Check the fuel strainer never operate without a fuel strainer 5 CAUTION Always wipe up all spilled fuel 6 NOTE Replace spark plug lead wire 7 NOTE Open the fuel valve Ensure the circuit breakers are in the pushed in or Reset position 1 WARNING Before starting disconnect all power cords from the AC receptacles on 2 WARNING the alternator panel The alternator may be hard to start if a load is connected and it 15 dangerous if electric tools are powered during start up This could result in personal injury or damage the electric tools IV ENGINE STARTING STOPPING All Models Check and fuel levels Make sure the appliance is disconnected Move engine Choke A Matic control as far forward as possible toward or Start position When engine is warm or temperature is high start engine with choke in the run position NOTE model GP8000BS the choke is ring tab located just under the engine air cleaner and must be fully extended during starting Place the panel mounted Stop Run switch the position Should the generator have the Economizer option ensure the Economizer switch is the Off position Models GP2500B GP4000B GP4000BE GP5000B GP5000BE A B Grasp2. Instruction Manual GASOLINE ELECTRIC PLANT AIR COOLED MODELS GP2500B GP4000B GP4000BE GP4000BS GP5000B GP5000BE GP5000BS GP8000BS GENERATOR DIVISION A SUBSIDIARY OF AVIS INDUSTRIAL CORPORATION P O BOX 2000 UPLAND INDIANA 46989 PHONE 317 998 2712 II IV V VI VII VIH TABLE OF CONTENTS DESCRIPTION INTRODUCTION SAFETY PRECAUTIONS PRE START PROCEDURES ENGINE STARTING STOPPING OPERATION MAINTENANCE TROUBLE SHOOTING DIAGRAMS AND PARTS LISTS WARRANTY PAGE N M O 42 INTRODUCTION Thank you for purchasing a PIERCE CO WINPOWER alternator This manual covers the operation and maintenance of models GP2500B GP4000B GP4000BE GP4000BS GP5000B GP5000BE GP5000BS GP8000BS This manual is based upon the latest product information available at the time of printing The Pierce Co Inc reserves the right to make changes at any time without notice and without incurring any obligation This manual shall not be reproduced without written permission The manual is the only means of obtaining the necessary information for operating and servicing the alternator 1 therefore should be considered as a part of the alternator and should remain with the alternator when sold WARNING Indicates a strong possibility of severe personal injury loss of life or a A serious hazard condition could occur if instructions given in the manual are not followed CAUTION Indicates a possibil
3. cuit has Check circuit for loose been disabled connections Engine speed hunts 1 Economizer coil is loose Tighten economizer coil cycles up and down or misaligned 2 Engine runs inconsistently Consult engine manual for is rough running repair or adjustments C DIODE TESTING A diode is an electrical device which will conduct the flow of current in one direction but will block the of current in the opposite direction A diode is faulty when it loses this characteristic To test for this characteristic proceed as follows Cathode K Anode Fig 1 The schematic symbol in Fig 1 indicates the proper polarity orientation of a diode Using an ohmmeter or a VOM connect the positive lead to the anode and the negative lead to the cathode Your VOM should read a low resistance Then reverse the meter lead connections and your VOM should read a very high or infinite resistance Any other result to the above test is unacceptable and the diode should be considered defective and must be replaced 9 D CAPACITOR TESTING A capacitor is an electrical device which stores electrical energy A simple test can be made to determine if the capacitor is functional Set the ohmmeter to read a high resistance and connect test leads across the capacite __ leads with capacitor leads disconnected from connection block Note the reading on the ohmmeter If the capacitor is shorted you will read zero re
4. do not over fill 2 CAUTION Engine oil is a major factor affecting engine performance and service life Use only recommended types and grades of lubricating oil B Recommended lubricating oil See engine manual 1 Supplementary guide if engine manual is misplaced Summer SAE 20 30 Winter SAE 10W 30 2 CAUTION NOTE Engine is shipped WITHOUT oil Use a high quality detergent oil classified For service SF SE SD or SC Detergent oils keep the engine cleaner and retard the formation of gum and varnish deposits Use 4 stroke oil do not use 2 stroke oil capacity GP2500B 1 25 Pints 59 liters GP4000B GP4000BE GP4000BS 3 Pints 1 42 liters GP5000B GP5000BE GP5000BS 3 Pints 1 42 liters GP8000BS 3 Pints 1 42 liters 1 CAUTION Running the engine with insufficient oil can cause serious engine damage D Fueling of the engine The engine manufacturer recommends the use of clean fresh lead free gasoline Leaded gasoline may be used if lead free is not available The use of lead free gasoline results in fewer combustion deposits and longer valve life If long time storage is expected a fuel stabilizer such as STA BIL should be used to eliminate the formation of fuel gum deposits in fuel system Fuel capacity GP2500B 3 5 Gallons 13 2 liters All other Models 6 0 Gallons 22 7 liters NOTE When refueling the following steps are recommended 1 WARNING Always stop the engine 2 C
5. ew the status of the fuel supply and oil level If both are satisfactory then review the engine manual for additional information ENGINE STOPPING A B Remove all electrical load by disconnecting all power cords from the side alternator panel Place the side panel Stop Run switch into the Stop position Should generator have the Economizer option ensure the Economizer switch is in the position V OPERATION A B The electrical alternator is comprised of a rotating magnetic field winding bolted to the engine output shaft situated in the center of a set of stationary windings which provide the electrical power output The alternator is totally brushiess which means there is not a physical connection between these rotating and non rotating components The only wear item im the alternator is the rear anti friction sealed ball bearing which requires no maintenance but should be replaced after 10 000 hours of operation The alternator excitation system is a static auxiliary winding connected to a capacitor which 1 very sensitive to armature reaction The rotating diodes connected to the field windings rectify this excitation current which is a series of current pulses to create the necessary magnetic field The alternator output is very sensitive to engine speed as far as a proper output voltage is concerned The design no load speed is 3720 rpm or a frequency of 62 Hz This has been factory set and s
6. hould perform satisfactorily However in the event engine maintenance has been performed ensure the engine speed is adjusted in accordance with the engine manual After the engine has been started the alternator is ready for loading The available load can now be plugged into the appropriate receptacle WARNING Ensure the load to be plugged into the receptacle is turned Off at its Q control switch Never energize a load by plugging it into a generator receptacle Energize the load by turning its control switch On subse quent to plugging into a receptacle CAUTION Models with full power output switch only When full rated output power is required at 120vac ensure the full power switch is in the 120 volt posi tion The alternator windings are protected from overloading by circuit breakers Should overloading occur the circuit breaker will interrupt the overcurrent condition by discon necting the winding from the load This will be visually indicated by an extending of the push to reset buttons out beyond their normal length To reset the circuit breaker allow few minutes for the circuit breaker to cool down then push the circuit breaker in until it seats into its original position CAUTION Never energize the load by resetting the circuit breaker Always discon nect the load before circuit breaker is reset li Models GP4000BE GP4000BS GP5000BE 5000 5 The Econom
7. istance must be very high and near infinity or off scale Resistances of the Alternator Windings ss WINDING RESISTANCE CHART STATOR WINDINGS ROTOR WINDINGS Main Auxiliary Winding Winding Field Winding Damping Winding FIELD FLASHING To re establish the rotor residual magnetism so the alternator will build a voltage the following procedure is recommended Step 1 Slightly overspeed the engine by manually manipulating the throttle to a higher engine rpm approx 4100 Measure the output voltage to observe if proper voltage develops If it does NOT proceed to step 2 Step 2 Remove rear alternator panel so that you can access the link board A 6 9 or 12 volt DC battery will be needed Start engine and run at proper speed Momentarily con nect the DC battery to the auxiliary winding terminals T5 and 8 to build the alter nator output voltage No particular polarity need be observed WARNING Do not leave the external DC source connected to the auxiliary winding A for more than 1 second A large AC voltage will develop when alternator voltage builds that will be detrimental to the external DC source imperative that the external source be just momentarily connected to the auxiliary winding Vill DIAGRAMS AND PARTS LISTS 10
8. it and check for abnormal noise and vibrations Correct any abnorma condition 7 Inspect exhaust system 8 Ensure the generator cooling slots are clear for proper ventilation Refer to the engine manual for the manufacturer s recommended maintenance procedures To ensure reliable starting start and run unit periodically to minimize carburetor clogging and fuel varnishing Should it be known that the engine will be stored for long periods of time without exercising drain all fuel from carburetor and fuel system Vil TROUBLE SHOOTING A MECHANICAL Should an engine difficulty arise to necessitate adjustment see the adjustment section of the engine operation and maintenance instructions provided Should service be required see the service and repair information section for details B ELECTRICAL TROUBLE SHOOTING CHART PROBLEM CAUSE DISPOSITION Low or no alternator 1 Engine operating speed is Increase engine no load speed output voltage low _ to 3720 rpm or 62 Hz Remove load and reset circuit breakers Circuit breakers have __opened due to overload Alternator output lead has Remove side alternator panel been disconnected from the and inspect for and reconnect circuit breaker or receptacle leads _ 4 Alternator rotor has lost its Flash field to re establish mag residual magnetism netism See flashing 8 PROBLEM CAUSE DISPOSITION 5 Rotor thru bolt has loosened and ro
9. ity of personal injury equipment damage or other property damage could occur if the instructions are noi followed NOTE Lists helpful information which should assist you in getting satisfactory performance with your new alternator If you have a problem with your alternator or have any questions about the alternator consult authorized WINPOWER distributor dealer or service center Should you require additional infor mation please consult the factory service department The WINPOWER alternator is designed to give safe and dependable service if operated according to the instructions given in this manual Read and understand the owner s operation and service manual before operating the alternator Failure to do so could result in personal injury or equipment damage PRECAUTIONS FOR SAFE USE To avoid fires 1 WARNING Do not store combustible material such as straw waste paper scrap wood etc where the alternator is stored WARNING Do not store dangerous or flammable materials such as lubricants celluloid gasoline explosives etc nearby WARNING Operate the alternator a level surface If the alternator is tilted moved during use there is the danger of fuel spillage and or a chance the alternator will overturn D CAUTION During operation maintain a safe distance of at least 3 feet 1 meter from building or other equipment When an alternator is located close to a building or nea
10. izer operates as an idling device which will sense the generator load and slow the engine speed down when a generator no load condition exists This is to save fuel create less engine noise and reduce wear and tear on the engine when the generator is not required to supply power on an intermittent basis If the generator will be unloaded for extended periods of time the engine should be shut off The Economizer switch on the side panel controls this device and with the switch in the position the engine runs at rated speed continuously The switch should be in the Off position when starting or stopping the engine During starting allow the engine to run for 5 five minutes before using the Economizer This will allow the engine to warm up such that it runs smooth at the lower speed as well as ensure proper engine lubrication The proper down engine speed is 2600 rpm VI MAINTENANCE A Preventive Maintenance Before start up perform the following routine maintenance items 1 Check fue supply 2 Check engine oil level if not full add as required or if at service interval start up engine to warm oil drain and replace 3 Check air cleaner service if required 4 Inspect for loose bolts and screws Retighten loose items Replace all missing or broken items Inspect for broken receptacles replace broken items 5 Inspect for fuel and oil leaks Service as required to stop leakage 6 Start up un
11. ow Pee 2 CAUTION Do not touch the muffler during operation or just after stopping for a serious burn could result The exhaust system operates at a very high temperature 3 CAUTION Do not get water on the alternator If the unit becomes wet allow it to completely dry before operating Also a wet spark plug may prevent the engine from starting gt CAUTION Do not connect the alternator to the household electrical system without using a U L listed double throw disconnect switch Any such installation should only be made by a licensed electrician in accordance with all city county province state regional and national electric codes CAUTION if you should observe an abnormal noise odor vibration etc when the unit is operating it should be stopped immediately and the reason for the condition be determined Failure to do so could permanently damage the unit as well as associated equipment If the cause cannot be determined the unit should be taken to the nearest service center for proper diagnosis WARNING Make sure that the unit is grounded properly and is in accordance with all applicable regulating codes lil PRESTART PROCEDURES A Check the engine oil level 1 CAUTION Remove the oil filler cap or dipstick to check the oil level If level is low add a high quality motor oil to the point of overflowing or to the full mark when applicable On units equipped with a dipstick
12. rby other equipment heat and exhaust from the engine will cause the surrounding temperature to rise This will reduce the cool ing and could cause the engine or alternator to overheat CAUTION Do not enclose the or cover with a structure for this will cause it to overheat creating a possible equipment damaging condition 6 WARNING stop the engine when refueling because of the extreme danger from the fuel vapor or spilled fuel being ignited 7 CAUTION Be careful not to spill fuel when refueling If fuel is spilled completely _ wipe up and let dry before starting the engine 8 CAUTION Do not overfill the fuel tank 9 WARNING Never refuel in the presence of a lighted cigarette or an open fire 10 WARNING Never refuel a hot engine Always allow the engine to cool before refuel ing B Exhaust gases WARNING not operate the alternator in locations with poor ventilation such as home interiors warehouses tunneis wells pits tanks ship hold etc Fatal levels of gaseous fumes can accumulate in poorly ventilated areas and increase the danger of carbon monoxide poisoning Always pay strict attention to the fire codes building codes and safety regulations if the alternator is operated inside a building Other precautions 1 WARNING Do not operate the alternator with wet hands Possibility of severe elec trical shock may be experienced Do not operate in the rain or sn
13. sistance If the capacitor is good the meter will point momentarily to a low value and then fall back to a high value resistance E WINDING TESTING The primary winding faults that normally occur are winding to winding short circuits and winding to ground short circuits When these faults occur they can usually be detected by an ohmmeter The first check for winding failure is a visual inspection for burned winding conductors If there is no evidence of this then the following checks can be performed Main Windings These are the windings which are terminated by T1 T2 T3 and T4 Remove these conductors from the link board and measure the resistances between T1 and ground alternator rear bearing support casting T1 and T3 and T3 and ground All of these measurements must be very high resistances near the infinity or off scale range Auxiliary Exciter Windings These windings are terminated at the capacitor by ter minals 5 and T8 Remove these conductors from the link board and measure the resistances between T5 and ground T5 and T1 and T5 and T3 All of these measurements must be very high resistances near the infinity or off scale range Rotor Windings These windings are terminated at the diodes on the rotating compo nent of the alternator The diode studs must be removed from the diode bracket to facilitate a proper measurement Measure the resistance between the connection end of the diode to the rotor shaft This res
14. the starter grip as illustrated and pull on the rope until you feel the max imum resistance Then allow the rope to recoil to its original position and pull it again vigorously When engine starts open choke gradually These units are equipped with a low oil level shutdown If the oil level is low this device will not allow the engine to start The red annunciator light will blink during the attempt to start engine Models GP4000BS GP5000BS A With the choke fully closed press firmly on the Stop Run Start switch pushing into the momentary Start position Never crank for more than 5 second intervals and allow 20 seconds rest cycles between crank cycles Never crank the engine more than 5 cycles the engine does not start review the status of the fuel supply and oil level These unit are equipped with low oil level shutdown If the oil level is low this device will not allow the engine to start The red annunciator light will blink during the attempt to start engine If both are satisfactory then review the engine manual for additional information When engine starts open choke gradually 6 Model GP8000BS A With the choke fully closed press firmly on the starter switch Release when engine Starts and slowly open choke Never crank for more than 5 second intervals and allow 20 second rest cycles between crank cycles Never crank the engine more than 5 cycles If the engine does not start revi
15. tor shaft has backed off of engine shaft male taper Inspect tapers for damage replace component if necessary re torque rotor thru bolt Replace both rotating rectifiers _ Then must flash field Replace capacitor Determine defective winding and replace component 6 Rotor diode has shorted or opened See Diode Testing Low or no alternator Output voltage 7 Capacitor is defective See Capacitor Testing 8 Winding failure main wind ing auxiliary winding or rotor winding has opened or shorted See Winding Test ing Alternator output 1 Engine operating speed is Decrease engine no load speed voltage 15 too high too high _ to 3720 rpm 62 Hz __ Engine speed and 1 Alternator is overloaded Reduce load to a level below nator output decrease nameplate rating substantially when 2 Engine governor is out of Reference service and repair in loaded adjustment or malfunctioning formation in operating and maintenance instructions Models GP4000BE GP4000BS GP5000BE GP5000BS only PROBLEM CAUSE __ DISPCSITION Economizer is 1 Economizer switch is in Place economizer switch in the inoperative the off position on position 2 Load is constantly Remove all load from applied to alternator alternator 3 Economizer circuit fuse Remove rear panel and has blown replace fuse 1 5 amp 125 volt 4 Economizer cir
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