CD2500, CD4400E, CD5500E, CD5500ES Operators
Contents
1. i L Pi 4 y INSTRUCTION MANUAL MODELS CD2500 CD4400E CD5500E CD5500ES VIDA ED wy NEVE Wee EK A Division of DTE Dyna Technology nc P O BOX 495 ST PETER MINNESOTA 56082 PHONE 507 357 6700 FAX 507 357 6580 SECTION Il II IV V VI VII VIII Xl XII TABLE OF CONTENTS DESCRIPTION INTRODUCTION SAFETY PRECAUTIONS PRE START PROCEDURES ENGINE STARTING STOPPING ECONOMIZER OPERATION MAINTENANCE TROUBLE SHOOTING WARRANTY EXCLUSIONS TO WARRANTY DIAGRAMS AND PARTS LISTS WARRANTY REGISTRATION PAGE N N O O o A N 10 11 24 INTRODUCTION Thank you for purchasing a Pierce Company Winpower alternator This manual covers the operation and maintenance of models CD2500 CD4400E CD5500E and CD5500ES This manual is based upon the latest product information available at the time of printing The Pierce Company Inc reserves the right to make changes at any time without notice and without incurring any obligation WARNING Indicates a strong possibility that severe personal injury loss of life or a serious hazard condition could occur if instructions given in this manual are not followed CAUTION Indicates a possibility that personal injury equipment damage or other property damage could occur if the instructions are not followed NOTE Lists helpful information which should assist you in getting satisfactory performance with your new alternator If you have a pr2. The economizer switch on the side panel controls this device With the switch in the Off 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 five minutes before using the Economizer This will allow the engine to warm up so that is runs smoothly at the lower speed as well as ensure proper engine lubrication The proper idled down engine speed is 2300 RPM OPERATION The electrical generator is comprised of a rotating magnetic field winding that is bolted to the engine output shaft and is situated in the center of a set of stationary windings which provide the electrical power output The generator is totally brushless which means there is not a physical connection between these rotating and non rotating components The only wear item in the generator is the rear anti friction sealed ball bearing which requires no maintenance However it should be replaced after 10 000 hours of operation The excitation system is a static auxiliary winding connected to a capacitor which is 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 generator 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
3. If your engine manual has been misplaced then the following is recommended CD4400E CD5500E CD5500ES CD2500 Summer SAE 20 30 Summer SAE 10W 30 Winter SAE 10W 30 Winter SAE 5W 30 CAUTION The 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 Oil capacity CD4400E CD5500E CD5500ES 3 Pints 1 42 liters CD2500 1 1 4 Pints 0 59 liters CAUTION Running the engine with insufficient oil can cause serious engine damage B Fueling 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 term storage is expected a fuel stabilizer such as STA BIL should be used to eliminate the formation of fuel gum deposits in the fuel system Fuel Capacity CD4400E CD5500E CD5500ES 6 0 Gallons 22 7 liters CD2500 3 5 Gallons 13 25 liters When refueling the following steps are recommended 1 WARNING CAUTION NOTE NOTE CAUTION Always stop the engine Disconnect and ground the spark plug lead wire Close the fuel valve at the base of the fuel tank Check the fuel strainer Never operate without a fuel strainer Always wipe up all spill
4. 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 4 CAUTION Do not connect the alternator to the household electrical system without using a U L listed and or CSA approved double throw disconnect switch Any such installation should be made only by a licensed electrician in accordance with all city county province state regional and national electrical codes 5 CAUTION Ifyou should notice an abnormal noise odor vibration etc when the unit is operating it should be stopped immediately and the reason for the condition 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 6 WARNING Make sure that the unit is grounded properly and in accordance with all applicable regulating codes 3 lI PRESTART PROCEDURES A Check the engine oil level 1 2 3 4 CAUTION Remove the oil filler cap to check the oil level If the oil level is low add a high quality motor oil to the point of overflowing CAUTION Engine oil is a major factor affecting engine performance and service life Use only recommended types and grades of lubrication oil see engine manual for manufacturer s recommendation
5. recreational vehicle or cover with a structure because this will cause it to overheat creating a possible equipment damaging condition 6 WARNING Always stop the engine when refueling due to the extreme danger that fuel vapor or spilled fuel may be ignited 7 CAUTION Bae 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 refueling Exhaust gases 1 WARNING Do not operate the alternator in locations with poor ventilation such as home interiors warehouses tunnels wells pits tanks ship holds 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 2 WARNING Engine exhaust from this product contains chemicals known in certain quantities to cause cancer birth defect or other reproductive harm Other precautions 1 WARNING Do not operate the alternator with wet hands severe electrical shock may occur Do not operate in the rain or snow 2 CAUTION Do not touch the muffler during operation or just after stopping a serious burn could result The
6. 62 Hz This has been factory set and should 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 generator 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 to Off at its control switch Never energize a load by plugging it into a generator receptacle Energize the load by turning its control switch On subsequent to plugging into a receptacle c CAUTION When the 120 VAC receptacles are utilized ensure that the load applied does not exceed one half 1 2 the nameplate rating of generator output If various 120 VAC loads are applied they can be plugged into several of the accessible outlets for load balancing and to utilize all the available generator output power D The generator windings are protected from overloading by circuit breakers Should overloading occur the circuit breaker will interrupt the overcurrent condition by disconnecting 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 a 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 resettin
7. SE DISPOSITION Low or no 1 Engine operating Increase engine no load generator speed is too low speed to 3720RPM or 62Hz output voltage Generator output voltage is too high Engine speed and generator output decrease substantially when loaded 2 Circuit breakers have opened due to overload 3 Generator output lead has been disconnected from the circuit breaker or receptacle 4 Rotor thru bolt has loosened and rotor shaft has backed off of engine shaft male taper 5 Capacitor is defective See Capacitor Testing 6 Winding failure main winding auxiliary winding or rotor winding has opened or shorted See Winding Testing 1 Engine operating speed is too high 1 Generator is overloaded 2 Engine governor is out of adjustment or malfunctioning C Capacitor Testing Remove load and reset circuit breakers Remove generator end panel and inspect for and reconnect leads Inspect tapers for damage replace component if necessary re torque rotor thru bolt Replace capacitor Determine defective winding and replace Decrease engine no load speed to 3720RPM or 62Hz Reduce load to a level below nameplate rating Reference service and repair information in operation and maintenance instructions 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 res
8. and fitness for any if and to the extent that such disclaimer is not forbidden by any applicable law Implied warranties including but not fimited to warranties of merchantability and fitness for any particular purpose which The Pierce Company Inc is so forbidden to disclaim by any applicable law are warranted one year from the date of purchase This is the Purchaser s sole and exclusive remedy hereunder Liability for consequential incidental or special damages and or expenses under any and all warranties are excluded to the extent exclusion is permitted by law All applications for warranty must have the model and serial number of the unit for which the application s is being filed customer s name address phone number and date of sale otherwise the warranty application and payment may be rejected or delayed EXCLUSIONS TO WARRANTY The Alternator Set is equipped with an engine which is not covered by this warranty The engine is covered exclusively by the engine manufacturer s warranty presented in the enclosed engine manual The Alternator Set is intended to be used as constructed by the factory Any modifications to the assembly such as conversion to LP gas fuel will void the warranty The Pierce Company Inc Generator Division does not warrant any modifications to the unit 10
9. ed fuel 10 NOTE Replace spark plug lead wire NOTE Open the fuel valve NOTE Ensure the circuit breakers are in the pushed in or Reset position WARNING Before starting disconnect all power cords from the AC receptacles on the alternator panel WARNING The alternator may be hard to start if a load is connected It is dangerous if electric tools are powered during start up This could result in personal injury IV ENGINE STARTING STOPPING A Engine Starting manual 1 2 Check oi and fuel levels Make sure the appliance is disconnected Move engine Choke A Matic control as far forward as possible toward Choke or Start position When the engine is warm or the temperature is high start the engine with the choke in the run position Place the engine stop switch in the On position if applicable Grasp the starter grip and pull on the rope until you feel the maximum resistance Allow the rope to recoil to its original position then pull it again vigorously When the engine starts open choke gradually If the engine does not start review the status of the fuel supply and oil level The CD4400E CD5500E and CD5500ES are equipped with a low oil level shutdown device 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 the engine B Engine Starting electrical CD5500ES only With the choke fully closed press fi
10. g the circuit breaker Always disconnect the load before the circuit breaker is reset VIL MAINTENANCE Before start up perform the following routine maintenance items f Check fuel supply 2 Check engine oil level if not full add as required If at service interval start engine to warm oil drain and replace 3 Check air cleaner service if required 4 Inspect for loose bolts and screws Re tighten all 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 unit and check for abnormal noise and vibrations Correct any abnormal 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 engine maintenance procedures To ensure reliable starting start and run the unit periodically to minimize carburetor clogging and fuel varnishing When the engine will be stored for long periods of time without exercising drain all fuel from the carburetor and fuel system Vill 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 l B Electrical TROUBLE SHOOTING CHART PROBLEM CAU
11. istance and connect test leads across the capacitor leads with capacitor leads disconnected Note the reading on the ohmmeter If the capacitor is shorted you will read zero resistance If the capacitor is good the meter will point momentarily to a low value and then fall back to a high value resistance D 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 1 Main Windings These are the windings which are terminated by BLACK leads with 1 2 3 and 4 tag designations Measure resistance between leads 1 3 and ground as well as between 2 and 4 All of these measurements must be very high resistances near infinity or off scale range 2 Auxiliary Windings These windings are terminated at the capacitor Disconnect these conductors from the capacitor and measure between winding lead and ground Also measure resistance between the capacitor winding lead and the main windings All of these measurements must be very high resistances near infinity or off scale range 3 Rotor Windings These windings are terminated at the diode circuit Measure resistance between one connection point and the rotor shaft on each circuit board o
12. oblem with your alternator or have any questions about the alternator consult an authorized Winpower distributor dealer or service center Should you require additional information 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 ll PRECAUTIONS FOR SAFE USE A To avoid fires 1 WARNING Do not store combustible material such as straw waste paper scrap wool etc where the alternator is to be stored 2 WARNING Do not store dangerous or flammable materials such as lubricants celluloid gasoline explosives etc near the alternator 3 WARNING Operate the alternator on a level surface Ifthe alternator is tilted or moved during use there is the danger of fuel spillage and or a chance the alternator will overturn 4 CAUTION During operation maintain a safe distance of at least three feet one meter from buildings or other equipment When an alternator is located too close to a building or other equipment the heat and exhaust from the engine will cause the surrounding air temperature to rise This will reduce the alternator s cooling capability and could cause the engine or alternator to overheat 5 CAUTION Do not enclose the alternator install in a
13. r disc The measurement must be very high resistance near infinity or off scale range Resistances of the Generator Windings WINDING RESISTANCE CHART MAIN AUXILIARY ROTOR WINDING WINDING WINDING CD2500 CD4400E CD5500E CD5500ES IX LIMITED WARRANTY The Pierce Company Inc Generator Division hereby warrants for one year the Alternator Set described herein to be free from defects in material and workmanship if properly installed serviced and operated under normal conditions according to our instructions This warranty covers parts and labor and is extended to the original purchaser for a period of one year 365 days from the date of purchase During that period The Pierce Company Inc Generator Division will replace free of charge upon examination by the factory or an authorized service center any part or parts found to be defective in material or workmanship This warranty does not obligate the manufacturer to bear any transportation charges in connection with the replacement or repair of defective parts or delivery of the defective alternator set This warranty does not cover rental charges for replacements while defective unit is being repaired The replacement of parts and or service arising out of abuse neglect or normal wear and tear is not covered by this warranty The Pierce Company Inc Generator Division hereby disclaims any and all implied warranties including but not limited to warranties of merchantability
14. rmly on the Stop Run Start switch pushing into the momentary Start position 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 review the status of the fuel supply and oil level 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 the engine If both are satisfactory then review the engine manual for additional information When the engine starts open choke gradually 5 C V Engine stopping 1 Remove all electrical load by disconnecting all power cords from the alternator panel 2 Ensure the Economizer switch is in the Off position if applicable 3 Place the Stop Run switch at the Stop position for the CD4400E CD5500E and oo models Push the piercing shorting bar against the spark plug boot on the ECONOMIZER Models CD4400E CD5500E and CD5500ES VI The economizer 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
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