onan® rv generator quick troubleshooting guide
Contents
1. gor SHOA 28 18 SHOA 9 19 MO sS g9p UO UO U IM UO Y IM UO ji uo uo SOWOD ui uo uo UO 9Jnss9Jc 9JnsS9JG IO ssoooe ON 9Jnss9Jd 55 MO 9 9 MO 55 HO S909 uo SBWOD jl uo DUIXUBJO DUI yUeIO uO Buunp Buunp Buunp pajoeuuoo pajoeuuoo pojoeuuoo pojoeuuoo pojoeuuoo pojoeuuoo pojooeuuoo pajoeuuoo pojoeuuoo pojoeuuoo SE UOOS SE UOOS SB se UOOS se UG se UOOS se Se uoos se Se uoos se UG se uoos se Se uoos se Se uoos se Se uoos se se uoos se se uoos se 7229 005 9705 00 2005 00 9 00 067 008 L06t 00 026 00 161 00 7926 00 891 008 9508 00 782 008 _____ 6625 00 9 28 00 LEES 00E 002 951 007 2725 002 8925 00 189 008 762 00 N d 1ONLINOO Pe ______ ____ ______ 06 ______ NVIN O AHL SYOLVYANAD AY ONILOOHSATENOUL NOILVINHOHNI 1531 ADVLIOA ONIONHVHO uo pue 6 uo pue 6 SLIOA OV YOLVLS2. LOCATION OIL PRESSURE LEVEL SWITCHES ON RV GENERATORS SERIES MODEL SPEC LOCATION AND ACCESS OF SWITCH Emerald e Oil Level switch located at base of oil filter Remove sheet metal panel R NHE ____ NHEL surrounding oil filter to gain access NHEL Marquis af SE Microlite Oil Level switch located inside of oil pan KY Al Oil level switch located on right side of oil pan Camp M Oil level switch located inside of oil pan KYD Oil level switch located on right side of oil pan HGJAB Oil pressure switch located on main bearing cover above oil filter Mobile HGJAC PLEASE NOTE Due to their size charts on following 2 pages are shown lengthwise landscape format If you are downloading this document from our website for optimum viewing we suggest printing on legal size paper BOYD 911999 01 OCA Cl JOUJB AOS 21U0J129 3 0 ZL xx LO 8Z E uny sJOWSsY SALON L L ______ _ 9wa gt _ TW erir ezt eid Ol ld Sid oer oer oer oza 1 WILOLAWIL eir erit ver ou oid ser ser sz sza saiswi1va8 er sir Scr id Tav vr ter za Nanay 310W3H vri std eld Orid eer ee eer
3. EG fo 3003058 meoez Mechones EASAG Mechancal a e rd Franstormer Mechanica S Mechanica SB A TE Mechanica E Taner mee es mme eeens esa reel DEES 300 3056 TETEE 305 07527 _ Mechanical St LE Ges 301 3055 Ep a 405 x ecenical Z AJBU J455 909 0025 TEE 13 1 89 300 3754 zB AJRO 3754 905 0826 15 0752 300 4002 5E AJED 3754 105 0929 155 0757 Juss 205 075 E Ge EEE Mechanical Br ___ es Ga 300 3754 305 TES 161 070 6 1 9 Lem ET SCA qu Nore 305 0057 Bechara ky ESS ont EE CIEGSSERE Te Gente 5 205 0051 Verri X pe os c Sex 305 0051 _ ere Gents Can Pome TER as a i b fa 25 8 imi Eri E H al icC Gas 300 5374 APPLICATION CHART FOR 120 240 60 Hz COMMERCIAL MOBILE GENERATORS eee EDITED BOD ___ Das P 322 3066 __305 0806 05 Machan ical _ Emeraid cammara 300 9069 07 05 0001
4. dOl 0 GAYINOAY 4440 S3H HOLOM ZH09 Q3NH3AO9 101 SWHO St 6 8Z ZZ SWHO 8 SWHO 22 81 SWHO 82 22 SWHO 82 22 SWHO 1 81 SWHO 2 81 SWHO 82 22 SWHO 82 22 SWHO 82 22 SWHO 872 22 009 009 0081 009 0084 008 009 009 008 008 0081 0081 OLANOVW OLANOVW MOO OLANSVW MOO MOO OLANOVW OLANSVW MOO MOO NOILINS 30 uedo 101 OVA 9SH 8 SION 951 9 91ON OVA 9SI 9 910 OVA 9L vl 9SH g OVA OVA 91 OVA 96 8 OV CHA GND 9 1VE Z Zd 0 Fed 9 4 1VE t idOZld GND 0 1 8 11 1709 6 1 ONS 9 1v8 O Z ld 9 1 Lid 91 8 Ld AYSALLVE 10 28 18 VN VN 5 GND OV rir GNOME1d _ 1 L5 1531 534 OHO NENNEN ____________ ____ _______________________ L 9gAvII OGAvIIL ogAvi __ VN VN VN OGA0c8 si va sseo
5. lt OGA SE lt GE lt lt lt lt lt lt 9 UO SHOA UO SHIOA UO SHOA J uo SHOA J UO SHOA uo SHOA UO SHOA J uo 9 19 SHOA 9 19 ounsseudjo UO SOWOD UO uo sawo eJnssoJd o oJnssoJd jio AV 138 9Jnss9Jd JIO S909 YIM UO UO uo seuio DUINUEJO DUIMUeIO DUIXUBJO HOLIMS dO 1O1 uoneoiput ON ASV dil cl NOILVOIGNI NVW 9
6. eza 1 doisarowss zur eer 9 64d ee ec eza 1 19vis 310N3H sw se sta err 1 bed NHAL3M WOOT rir var e 1 LL 228 dors woo zi or ena bir j avis W907 S RENS MEN __ MOM Mal MEME RENE MEINE SUUM Seen OREN ou ou eed LET gu rid ou cp 2a ou red etd ld tid ou v g vC era ou ou om zed eed el zi 9316 ou Std Sid z id zi Sid Std ved vid zi MSdovio1 o ez orir lez vir om zita Old om ola eed etd bb NOILINO 16 ei wid zia zia ota ovr zid zid 91d Ol __ izo su sir ezda eld 6 Sir era ba Std Sid 6 HSviaaai 1 ou ped ou ou our ou ou ou ou ou ou ou ou ou ela om om om eta wld bid 2 538 1v8 oar b 9d eld eld Old oir zid 9 GIONSIOS 1sVIS eur orer zid tid iid old vif tld eld S ____ vir vw ou ou ou via ou ou ou __ Thei
7. 15 CHECK CONTROL BOARD MODULE If the engine runs with the G MAN and all indications are normal but not when the control board or module is plugged in then it is very likely that the control is defective If there is AC volt age present on B1 B2 or L1 AC as applicable and the correct oil pressure level signal is present at the OIL LOL LOP SW input of the control board and the engine will not keep running the control board 15 defective GENERATOR TESTS Generator Resistance Tests non running 1 Disconnect the regulator and plug the G MAN s GENERATOR harness into the plug just removed from the regulator DO NOT connect the REGULATOR harness to the regulator 2 Connect the DMM between the red MAIN STATOR test jack T2 T4 and the GROUND test jack and measure ap proximately 0 0 to 0 1 ohms 3 Connect the DMM between the red MAIN STATOR test jacks T1 T3 T2 T4 and measure approx 0 3 to 0 4 ohms 4 Connect the DMM between the yellow AUX STATOR test jacks Q1 Q2 and measure approximately 2 0 to 3 5 ohms 5 Connect the DMM between the blue BAT STATOR test jacks B1 B2 and measure approximately 0 1 to 0 2 ohms models with battery charging stator only 6 Connect the DMM between the green FIELD test jacks F1 F2 and measure the rotor resistance see chart for values Values are specified at 77 F 25 C 10 If resistance varies with rotor position this usually indicates slip ring or brush problems Tap the starter button and take several
8. 9 to 12 0 VDC This is one way to determine if pin 7 is making contact If pin 7 is known to be making contact and the regulator will not start check the wiring between ground and regulator pin 3 If the field flash circuit is working properly pressing the FIELD FLASH button with the generator running will cause a sudden rise in voltage to 160 VAC at the MAIN STATOR test jacks If not the regulator 1s likely defective Do step 5 to be sure 5 This step tests the generator without the regulator by supplying field current from an outside source DISCONNECT REGULATOR Connect the red patch cord between the FIELD FLASH test jack and the F1 test jack Connect the black patch cord between GROUND and the F2 test jack Connect the DMM to the MAIN STATOR test jacks Start the engine and observe that there is little or no voltage being produced Press and hold the FIELD FLASH button If the generator 1s working properly the DMM should read approximately 50 VAC and the STATOR AC VOLTS indicator will glow dimly it may not be bright enough to see in direct sunlight The AUX STATOR Q1 Q2 should read approxi mately 60 VAC and the BAT STATOR B1 B2 1f equipped should read approximately 8 0 VAC These voltages are approximately 40 of rated voltage If step 4 above failed and this step succeeds the regulator is defective 6 When all regulator problems have been resolved the genset should be load tested with the regulator that is to remain insta
9. a flying open A slight apparent rise 1 3 ohms in field resistance 1s normal and is due to the small induced voltage in the spinning rotor influencing the VOM A defective rotor must be repaired or replaced Generator Leakage Tests non running 1 Disconnect generator leads T2 and T4 and regulator LO pin 3 from the terminal block Neutral AC LO or ground Some models require additional leads to be disconnected 2 Open the AC circuit breaker to isolate the generator from all external circuits 3 Set the LEAKAGE TEST selector to MAIN STATOR and press the LEAKAGE button If the LEAKAGE indicator does not come on the leakage is OK If LEAKAGE indicator comes on the leakage resistance to ground is below 1 Meg ohm If the STATOR AC VOLTS indicator comes on it means the LO wire has not been disconnected step 2 above Connect the black patch cord to the GROUND test jack and leave it there Connect the other end to the Q2 test jack and repeat the leakage test If the LEAKAGE indicator comes on the leakage resistance from T1 T2 to Q1 Q2 is below 1 Meg ohm Connect the patch cord to B2 and repeat the leakage test If the LEAKAGE indicator comes on the leakage resistance from T1 T2 to 2 is below 1 Meg ohm The test voltage may be read by connecting the DMM between the T1 T2 and GROUND test jacks The test voltage should be at least 200 VDC A leakage resistance if present will load this voltage down The lower this voltage goes the mor
10. eration 15 normal with the G MAN but not with the control board plugged in then you know right away that you have a bad control board This is known as testing by exception DISCLAIMER The G MAN service tool 1s designed for use by generator service professionals and others who are familiar with engine generator sets and their controls Working on engines generators and their controls presents certain hazards to equipment and personnel It is assumed that the G MAN user is adequately trained in the proper use of test equipment and the management of risks inherent in generator servicing The G MAN is not intended for use by the gen eral public Flight Systems is not responsible for damage to equipment or injury to personnel direct or consequential arising from the use of the G MAN service tool Liability is limited to repair or replacement of defective product under the terms of the standard warranty This service tool is designed for use ONLY on 120 volt 50 or 60 Hz single phase generators using a 12 volt negative ground electrical system GETTING STARTED Determine the control board part number directly from the board or from the Application Chart Refer to the Trouble shooting Chart for test information specific to that board G MAN responses are different for different control boards Connect the appropriate adapter to the G MAN control harness CAUTION Some adapters look similar and have iden tical connectors but a different pin assi
11. readings If the reading 1s high and or not constant clean the slip rings use the Slick Stick or similar tool and repeat the test If this does not correct the problem check the brushes Exces sively low resistance indicates a possible rotor short while a high resistance indicates slip ring and or brush problems Either a high or low resistance condition can lead to regulator failure and must be corrected NOTE All windings should read infinity to each other at the test jacks Rotor Resistance Test Flying Short Open It is possible although uncommon to have a mechanically induced short partial short or open in the rotor that shows up only when it is spinning This type of fault occurs when rotor windings shift slightly due to centrifugal force and or temperature rise and can be difficult to track down To perform this test proceed as follows 1 Follow step 6 above under Generator Resistance Tests except use a VOM analog type meter such as a Simpson 260 in place of the DMM The DMM will give an erroneous reading because of the small DC voltage induced in the rotor when it is spinning Connect the VOM positive lead to the F1 test jack and the negative lead to the F2 test jack Obtain a stable reading within the range specified and record 2 Start the engine and observe which way the needle moves A significant drop in resistance indicates a flying short es pecially if it is repeatable A high reading or infinity indicates
12. zem echericel ERA 3005976 Deri pane fas ferro Gast P antara seama 35 1 Ga EF aa a CO A 165 Diesel 305 0053 15 eee Poca a 88 7 necs te cuns s 20 8 Mobi 102 Dem 15 IDCM NN ATENE NAE PCAC otf deei ariaa FON Diesel 305 0853 03 ee ey Eee ee eeb J 120 Dea 327 1a28 12 2577708 _327 1440 CONTROL BOARD P N SUPERCEDENCE 300 2784 300 2943 ___ 300 3056 300 3687 300 3950 300 3763 300 5260 o 300 3764 300 5342 300 3797 300 4155 E 00 4506 300 5002 01 3004901 300 5337 300 4902 300 5276 NENNEN T Q9 00 4902 300 5299 ain _ 327 faa Q REGULATOR PIN ASSIGNMENT FSI Model Number uus 055 sm s _ osoon 3050851 305 060905 305 0897 305 0826 305 0911 300 5046 V AC Sense HI 3 3 3 3 3 3 ms Voltage Adjust 4 ae E E Voltage Adjust Return 313 E E E E 7 SS
13. FLIGHT SYSTEMS INC Technical Service Dept 717 932 9900 8 4 30 ET M F www flightsystems com FLIGHT SYSTEMS OMIN Jiwe p LL b 1 c F T b y h P R 4 f gt i RV GEN SET SERVICE TOOL Made in USA www flightsystems com ONAN RV GENERATOR QUICK TROUBLESHOOTING GUIDE USING THE G MAN INTRODUCTION The G MAN is designed with the RV generator service technician in mind Diagnosis can account for up to 80 of ser vice labor cost This versatile service tool speeds the troubleshooting process by eliminating guesswork and pinpointing problems Troubleshooting is broken down into the four specific areas of the ENGINE ENGINE CONTROL GENER ATOR and REGULATOR Generator control troubleshooting can be complicated by the normal action of the control to prevent starting or cause a shutdown in the event of a problem This can be a dead end that prevents the troubleshoot ing process from moving forward without guesswork jumper wires and or parts substitution This approach can be both time consuming and expensive What makes the G MAN unique is its ability to plug in to the generator s control system and become a part of it instead of being a circuit board or component tester You can run the engine without the control board because the G MAN takes over most of its functions If any of the signals to the control board are missing the G MAN will tell you If op
14. GE indicator comes on the leakage resistance to ground is below 1 Meg ohm 6 Set the LEAKAGE TEST selector to FIELD F1 F2 and press the LEAKAGE button If the LEAKAGE indicator does not come on the leakage is OK If the LEAKAGE indicator comes on the leakage resistance to ground 1s below 1 Meg ohm Rotor Leakage Test Flying Ground It is possible although uncommon to have a mechanically induced ground in the rotor that shows up only when it 15 spinning This type of fault occurs when rotor windings shift slightly due to centrifugal force and or temperature rise and can be difficult to track down To perform this test proceed as follows 1 Set the LEAKAGE TEST selector to FIELD F1 F2 and press the LEAKAGE button If the LEAKAGE indicator does not come on the leakage is OK If LEAKAGE indicator comes on the leakage resistance to ground is below 1 Meg ohm 2 Start the engine and repeat step 2 above If the LEAKAGE indicator comes on only when the engine is running this indicates a flying ground If possible verify results with a VOM such as a Simpson 260 connected between the F1 and GROUND test jacks Repeat the test to be certain before replacing an expensive rotor NOTE A digital meter such as a Fluke will not give accurate resistance readings on low ohms if there 15 any residual voltage present in the circuit even a few millivolts GENERATOR VOLTAGE TESTS To prevent possible damage to external circuits or appliances MA
15. KE SURE that the AC CIRCUIT BREAKER IS OFF during control and generator testing 1 The engine should be running normally and the FIELD VOLTS and STATOR AC VOLTS indicators should be on showing that the regulator is working properly 2 Connect the DMM to the red MAIN STATOR T1 T3 T2 T4 test jacks Read 118 128 VAC at no load The ideal no load voltage is approximately 123 VAC 3 Connect the DMM to the yellow AUX STATOR Q1 Q2 test jacks Read 140 160 VAC at no load 4 Connect the DMM to the blue BAT STATOR B1 B2 test jacks Read 18 20 VAC at no load Connect the DMM to the green FIELD F1 F2 test jacks observing polarity Read 28 35 VDC at no load If the field voltage is abnormally high at no load check for brush and or slip ring problems The field voltage should rise in re sponse to an AC load applied to the generator at approximately 8 volts per KW of load The field voltage will also rise with temperature because of an increase in rotor resistance REGULATOR TESTS To prevent possible damage to external circuits or appliances MAKE SURE that the AC CIRCUIT BREAKER IS OFF during control and generator testing 1 Connect the G MAN CONTROL GENERATOR and REGULATOR harnesses 2 Start the engine If the FIELD VOLTS and STATOR AC VOLTS indicators are not on proceed to step 4 Otherwise measure the frequency at the MAIN STATOR T1 T3 T2 T4 test jacks and adjust the governor if necessary for 60 62 Hz If the frequenc
16. apping on the switch can sometimes cure this If the LOL LOP indicator fails to come on a broken wire from the switch to the LOL LOP input of the control board can also be the cause Electronic governor only When the LOP switch opens the governor module places a ground on the oil pressure input of the control board P1 5 It is OK to temporarily ground P1 5 on this model to keep the engine running for troubleshooting purposes NOTE See chart for oil pressure and oil level switch locations 12 CHECK FIELD VOLTS The FIELD VOLTS indicator should be on indicating that the regulator 1s producing at least 28 35 VDC If not proceed to the Generator and or Regulator section 13 CHECK AC OUTPUT The STATOR AC VOLTS indicator should be on indicating that the main stator 1s pro ducing at least minimum voltage On some models the L1 AC VOLTS indicator should also be on see chart If not proceed to the Generator and or Regulator section 14 CHECK BATTERY CHARGING If there is normal AC output except PMG measure the voltage at the BAT CHG VOLTS test jack where applicable see chart Some models use a charging resistor and some models use a PMG and a charging regulator VR2 see G MAN manual for details On all models equipped with battery charging the volt age at the 12 VDC POWER test jack should slowly rise with the control board in place and the genset running A slowly rising voltage indicates that the battery charging function 1s working
17. e severe the leak This principle also applies to the leakage tests below Disconnect the patch cord from B2 and leave the other end connected to GROUND NOTE On some models the LEAKAGE indicator will come on along with the L1 AC LINE indicator because of the small current drawn by the indicator While this 15 normal the MAIN STATOR leakage test 15 still inconclusive In this case and just for this test isolate the main stator as above and disconnect the GENERATOR harness Connect the red alligator clip to one end of the red patch cord and clip onto the stator terminal or wire 1 Connect the other end to the T1 T3 jack on the G MAN Set the LEAKAGE TEST selector to MAIN STATOR and press the LEAKAGE button If the LEAKAGE indicator does not come on the leakage is OK If the LEAKAGE indicator comes on the leakage resis tance to ground is below 1 Meg ohm 4 Set the LEAKAGE TEST selector to AUX STATOR Q1 Q2 and press the LEAKAGE button If the LEAKAGE in dicator does not come on the leakage is OK If the LEAKAGE light comes on the leakage resistance to ground is below 1 Meg ohm Connect the patch cord to the B2 test jack and repeat the leakage test If the LEAKAGE indicator comes on the leakage resistance from Q1 Q2 to B1 B2 is below 1 Meg ohm Disconnect the patch cord at both ends 5 Set the LEAKAGE TEST selector to BAT STATOR B1 B2 and press the LEAKAGE button If the LEAKAGE indicator does not come on the leakage is OK If the LEAKA
18. eoN 90150 0 sseoeoN OGAvILL _ __ DALOL OGALLOL oaao sseoeoN Hsviddidd __ 8 ZLI Zh 82192 OOA 871 971 JOGA 821 97 ezi ozi ezi 9zi OGA ezi ezi oaA ezi ezi oaA 19 1 82 92 GA 1 9 21 2192 __ SMOVf 1531 9 uo pue uo pue 6 uo pue u6 uo pue 6 uo pue 6 V N sseooe SA 09 NMOGLNHS d7 dO LS U9UM dO LS uo U9UM JJO 5905 UBYM yo S905 o 5900 UBYM yo 5905 UBYM yo saog UBYM JJO S905 U9UM JJO 5905 JJO 5905 id GZ lt S OA GZ lt S OA 92 lt S OA 510 SUR oy O ks un YN w SM JOjE S UO JOJEYS UD JOJEYS UM GZ lt S OA GZ lt S OA GZ lt S OA GZ lt S HJOA GZ lt S OA GZ lt S OA 67 lt S OA GZ lt SJOA GZ lt S OA GZ lt S JOA GZ lt SJOA GZ lt S JOA 10305 UQ JO JE S j UQ JOJEYS UD JOJE S JI UO 10 8 S UO 101215 UO 10 8 S Jl UO 10 81S UO 10 8 S UO 10 8 S Jl UO 10 8 S jl UO 10 8 S Jl UO GE lt S OA lt OCA lt SE lt J UO S JOA J UO S1IO UO SHOA J uo S HOA C8 L8
19. gnment Improper connections can cause damage to the generator controls and or to the G MAN Such damage 15 not covered by the warranty Before proceeding with evaluation of the controls regulator or generator the Onan engine must have oil and fuel be in running condition and the 12 volt battery charged The electronic governor 151 0752 on Models BGM and NHM Spec B and later must be functioning properly This guide does not cover engine maintenance and repair procedures please refer to the applicable Onan Service Manual for this information The most common genset problems are caused mainly by lack of use and or lack of regular monthly exercise and include the following e Low battery voltage because of insufficient charge worn out battery faulty cables partly broken or corroded or poor connections resulting in slow cranking and hard starting Old contaminated fuel that has gummed up the lines fuel filter and carburetor This can cause clogged jets mixture too lean and or a stuck carburetor float resulting in an improper mixture too rich or too lean or flooding e Weak spark and or fouled spark plug s causing hard starting and rough running Stuck automatic choke causing an excessively rich mixture and smoking e Stuck oil pressure switch causing shutdown as soon as the start button 1s released Dirty air filter causing an excessively mixture and smoking e Low oil level preventing starting on models equip
20. isconnect the regulator and plug the G MAN s GENERATOR harness into the plug just removed from the regulator Plug the G MAN s REGULATOR harness into the regulator or a known good regulator 5 CHECK BATTERY VOLTAGE Connect the negative voltmeter lead to the GROUND jack and the positive lead to the 12 VDC POWER jack on the G MAN and read the battery voltage A fully charged battery in good condition should read 12 6 to 12 8 VDC Charge the battery 1f necessary IMPORTANT Disconnect battery charger before proceeding with tests 6 CHECK CRANKING ENGINE START Turn on the IGNITION FUEL switch The fuel pump should be heard working Apply 12 volts directly to the pump if necessary Press the START button and the engine cranks If not check the wiring to the start solenoid The battery voltage should not fall below 9 5 VDC during cranking If so check the battery condition and cables The IGNITION FUEL switch on the G MAN is used to stop the engine If the engine starts and runs OK proceed to step 9 7 CHECK SPARK If the engine cranks but does not start remove a spark plug and check for spark during cranking Problems such as dirty worn points or a defective coil can cause loss of spark On models where the oil level switch is hard wired to the magneto KV Spec C F KVC and KVD low oil level or a stuck switch will inhibit the spark and prevent starting To check the level switch unplug the control board and verify that the MAGNETO KILL circu
21. it on the control harness is not grounded Refer to the Troubleshooting Chart 8 CHECK FUEL SYSTEM If the engine cranks and has spark but does not start the problem is likely fuel related This can be confirmed by injecting a small amount of starting fluid into the air intake If the engine fires and tries to run it is starving for fuel Listen for the fuel pump running during cranking The pressure and flow of the fuel pump and fuel filter can be checked by temporarily disconnecting the fuel line to the carburetor Take adequate precautions when handling fuel If pressure and flow are normal reconnect fuel line Note If the generator has not been run for several months the carburetor float may be stuck closed and or the jets and needle valves may be gummed up by old fuel that has turned to varnish These conditions interfere with normal fuel delivery The automatic choke may be stuck closed or binding so that it does not open as the choke heater warms up causes smoking On Models BGM and NHM spec B and later make sure that the electronic governor goes to full throttle one second after cranking begins Any of these conditions will prevent the engine from starting or running smoothly and must be corrected before proceeding 9 CHECK FIELD FLASH Field flash is energized automatically during cranking and until generator voltage builds During cranking the FIELD FLASH indicator should be on showing that the field flash voltage is actually reachi
22. lled Proceed as follows a Connect the DMM at the MAIN STATOR test jacks b Make sure that there is no commercial power connected to the system Connect a convenient load such as a ceramic type electric heater to the external circuit outlet and close the AC line circuit breaker More than one heater may be needed c Start the generator and add load in approximately 1 KW increments d The MAIN STATOR voltage should ideally be within 123 VAC at no load and 117 VAC at full rated load The quadrature voltage between the Q1 and Q2 test jacks should remain nearly constant at 140 150 VAC The rectified quadrature voltage between the F1 test jack and the GROUND test jack should remain nearly constant at 195 205 VDC e The field voltage at the 1 and F2 test jacks should start out at 28 35 VDC with a cold generator at no load and increase as load is added A typical rate of rise of field voltage for a 4 KW generator is about 7 5 to 8 0 VDC for each 1 KW of load At a load of 4 KW the field voltage should be approximately 62 66 VDC This voltage will rise slightly as the windings heat up even at constant load because of the increase of winding resistance with rising temperature NOTE A series of useful charts appear on the following pages APPLICATION CHART 120V 60 Hz RV GENERATORS SS Lu mu I EEISAUMARD ml FUEL BOARD ADAPTER REGULATOR GOVERNOR Emerald ae 40 C
23. ng pin 7 ofthe regulator The field flash can also be tested manually at any time by pressing the FIELD FLASH button Mea sure the field flash voltage at the FIELD FLASH test jack It should be 10 11 VDC If not check the wiring between the control board field flash output pin on the harness and regulator plug pin 7 10 CHECK RUN RELAY After the engine starts the FIELD FLASH indicator goes off and the RUN RLY indicator comes on This indicates that the signal required to pull in the run relay in the G MAN is present see chart and that the starter 1s locked out If the RUN RELAY indicator does not come on there may be a problem with the generator regu lator electronic governor or oil pressure switch depending on the model In this case proceed to the Generator and or Regulator section except 300 2784 2943 Also if the RUN RLY indicator is not on then the starter is not locked out and damage could result if the starter button on the G MAN 15 pressed while the engine is running 11 CHECK LOL LOP SWITCH As soon as oil pressure builds the LOL LOP SWITCH indicator will come on or go off depending on model indicating that the oil pressure switch has been actuated see chart Some models use a low oil level switch instead see step 7 above Check the voltage at the LOL LOP SWITCH test jack see chart If the LOL LOP SWITCH indicator does not come on or go off the cause is likely a stuck switch Starting the engine sev eral times or t
24. ped with low oil level switch Wiring harness damage from rodents chewing on the wires e Corrosion of control board or connections from salty air or road chemicals Dirty and or oxidized slip rings causing high field circuit resistance After the engine has been running for a few minutes the electric choke heater should begin to open the choke The choke will take longer to open fully in cold weather If the choke does not open it is either stuck or the choke heater is not working The choke mechanism can be freed up and maintained with Mouse Milk a high temperature penetrating lubricant Available from Flight Systems If the engine surges or hunts does not stay at a constant RPM the cause is likely a gummed up carburetor or an improperly adjusted governor These conditions must be corrected SYSTEM TESTS 1 CHECK OIL Check engine oil level before starting 2 GAIN ACCESS Remove panel or cover to gain access to the control board Some disassembly may be required The exact procedure depends on the model Detailed procedures are given in the G MAN manual 3 CONNECT G MAN CONTROL HARNESS Unplug the control board and connect the G MAN adapter in its place the G MAN does not connect to the remote harness As soon as the G MAN has 12 volt power the 12VDC POWER indicator will come on The LOL LOP SWITCH indicator may also come on depending on the model See Chart 4 CONNECT G MAN REGULATOR amp GENERATOR HARNESS D
25. r rar sur ou lw Old om ola om ou om 1303 erir eir rid vid eid erid 9ed z dWNd gu ou ou ou oid om ou om Gia om om vid 1NOOATHNDH or NOLON a v1 6 00 9705 00 1z00S 00 l9Srr 00 12067 00 1106 00 loZ v 00 Z6Z 00 791 00 9 00 950 00 v822 00 NVW 9 Q3VO8 10311NO 665 00 9229 00 25 008 626 00 917 00 2729 002 8926 00 Z89E 00 62 002 V h LI LL L L eeeos LN3IANSISSV GYVOd 1IOYLNOD I 80 8L Z4 AlUO S BPOW dT x siy uo 9 iy peJw pJeu s 101 YOUMS 949 0 v 4 G 00 Livi 7 1160 60 2680 502 9280 502 10 6090 s0 1s90 s0 tse0 soe __ __ 9280 502 10 6080 s0 0 6080 502 W30 YOLVINOSY jeoeuoe 29 0 19 Ieomeuoew jeoueysaw zoz0 1g1 Ieo euoew N d HONSJAOO9 SHOA OV L1 SIOA OV L1 SHOAOV L1 QN9 n r Zd O amp Id SHOAca 1a Soa zgra GND SoA 9 ONINNNY 8239 OL uedo 9 uedo dO1 107
26. y is out of tolerance with an electronic governor replace the governor 3 Measure the voltage at the MAIN STATOR T1 T3 T2 T4 test jacks If this voltage 15 below 115 VAC or above 130 VAC at no load shut down the engine Substitute a known good regulator and repeat the test If the voltage is now within tolerance the regulator 15 faulty and must be replaced If the voltage is still high check the wiring between gen erator terminal T1 and regulator pin 2 An open circuit on this wire will cause an overvoltage condition If the voltage is low check the wiring between AC LO or NEUTRAL and regulator pin 3 and the wiring between regulator pins 4 and 5 or 1 and 5 as applicable NOTE Some models use a potentiometer between these pins instead of a jumper If the circuit between 4 5 or 1 5 1s open the generator output will only be about 70 VAC 4 This step applies only if the regulator will not start no voltage buildup Substitute a known good regulator and repeat the test If the MAIN STATOR voltage is now within tolerance the regulator is faulty and must be replaced If the FIELD VOLTS and STATOR AC VOLTS indicators are still not on check the wiring between the control board and regulator pin 7 NOTE Pressing the FIELD FLASH button applies approximately 11 5 VDC directly to regulator pin 7 and the FIELD FLASH test jack If the regulator is disconnected or not making contact at pin 7 the voltage at this jack will be slightly higher typically 11
Download Pdf Manuals
Related Search