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Guardian Technologies 4270 Portable Generator User Manual

1. ES ji 2 E eg z oo a 0 CN 2 95 sh 5 5 S NAG kk 1 aT Z 54 55 S a lt 5 CN z pe 5 sg 8 2 5 5 2 e amp 11 120 553 Me WIRE FOR ONLY B LEGEND 5 SE OUTPUT COONNECTIONS E j 0 AVR A UTOMIATIC VOLTAGE REGULATOR H GH WAT ER TEMP SWITCH e 1 O D BCR BATTERY CHAR RECTIFER LOS LOW OIL PRESSURE SWITCH S EL a se BEW BATTERY CHAR GER PHC PR XEHEAT COONTACTOR H Q Bic LO 1 UIT BREAKER 353 R1 R ESISTOR 1 OHM 25W gt CB2 CIRC UITBREAKER 4A R2 5 5 20 OHM 12W LEGEND Fonction N d n o 91 DIDE 600W 6AMP S STARR WHITE S O D2 DIDE 600W SC START CH 413 og p DPE EXCITATION WINDING SW PR SWITCH BROWN e H Zo Fi FUSE 14 SFE SWI SWITCH START SITOP ee NSING SEL FS FUEL SOLENOID L 4 z FP FUEL PUMP GP GLOW P LUGS O c HM HOOURME TER 0 1 0L RV SCHEMATIC 1 01 DIESEL C4945 A 95 120V 120W 35 ELECTRICAL DATA Section 11 2 LAdLNO 2 2 021 ITONIS V 9v6VO 101 NVHOVIQ LHHHS SDNTA AA PI
2. CLAMP ON STARTER AMP METER CONTACTOR 12 VOLT BATTERY Figure 7 19 Testing Starter Motor Performance Section 7 DIAGNOSTIC TESTS TEST 28 CHECK FUEL SUPPLY DISCUSSION If the engine cranks but won t start don t overlook the obvious The fuel supply may be low Many RV gen erator installations share the fuel tank with the vehi cles engine When such is the case the installer may have used a generator fuel pickup tube that is shorter than the vehicle engines pickup tube Therefore the generator will run out of fuel before the vehicle engine does PROCEDURE 1 Check the fuel level in the supply tank 2 Attach a fresh fuel supply if necessary and restart Fuel may be stale causing a hard start RESULTS 1 If necessary replenish fuel supply 2 f fuel is good proceed to test 29 TEST 29 CHECK WIRE 14 POWER SUPPLY DISCUSSION When the engine is cranked Engine Controller Circuit Board action must deliver battery voltage to the Wire 14 circuit or the engine will not start This is because the Wire 14 circuit will operate the Fuel Pump and Fuel Solenoid PROCEDURE 1 Set a VOM to read battery voltage 12 VDC 2 Connect the meter positive test lead to Pin 9 on the PCB the common test lead to ground 3 Crank the engine and the meter should read battery voltage RESULTS 1 If the meter indicated battery voltage go to Test 19 2 f batt
3. ON 28 Ur TITO 13 21 26 30 29 DESCRIPTION COMPLETE CYLINDER BLOCK EXPANSION PLUG EXPANSION PLUG EXPANSION PLUG EXPANSION PLUG EXPANSION PLUG PLUG PLUG IDLE GEAR SHAFT BUSHING BUSHING STANDARD 0 25MM U S BUSHING 0 50MM U S BUSHING BALL BEARING EXPANSION PLUG BALL BEARING DOWEL PIN QTY ech eck eck NDN N 2 DESCRIPTION DOWEL PIN DOWEL PIN SPRING PIN STUD STUD STUD SNAP RING OIL SEAL DRAIN COCK CONNECTOR OIL FILTER TAPPET PUSH ROD RELIEF VALVE O RING MM MILLIMETER U S UNDERSIZE Page 77 Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Cylinder Head Drawing No 0D2794 11 10 T 9 e 6 Y 3 C 13 14 2 c NG 10 f Y Ca N KA WV BAL LA S 8 ug 22 4 7 E cb CD QD o e Eu S REA o Gs c vd NG Tog 18 23 DESCRIPTION ITEM DESCRIPTION 1 1 CYLINDER HEAD ASSEMBLY 13 11 BOLT 2 6 EXPANSION PLUG 14 3 BOLT 3 3 EXPANSION PLUG 15 2 LIFTING EYE 4 2 XPANSION PLUG 16 2 5 3 INTAKE VALVE 17 1 TUBING 6 3 EXHAUST VALVE 18 2 BOLT 7 3 VALVE GUIDE SEAL EXHAUST 19 1 OIL SWITCH 3 VALVE GUIDE SEAL INTAKE 20 1 THERMO SWITCH 8 6 SPRING 21 4 GASKET 9 6 RETAINER Do 1 WASHER 10 12
4. by Generac Power Systems Inc GUARDIAN 22 MODEL 4270 LO m ef AAA m Throughout this publication DANGER and CAUTION blocks are used to alert the mechanic for special instructions concerning a particular service or operation that might be hazardous if performed incorrectly or carelessly PAY CLOSE ATTENTION TO THEM DANGER UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCTIONS WHICH IF NOT COM PLIED WITH COULD RESULT IN PERSONAL INJURY OR DEATH CAUTION Under this heading will be found special instructions which if not complied with could result in damage to equipment and or property These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these spe cial Instructions plus common sense are major accident prevention measures NOTICE TO USERS OF THIS MANUAL This SERVICE MANUAL has been written and published by Generac to aid our dealers mechanics and company service personnel when servicing the products described herein It is assumed that these personnel are familiar with the servicing procedures for these products or similar products manufactured and marketed by Generac that they have been trained in the recommended servic ing procedures for these products including the use of common hand tools special Generac tools or tools from other suppliers Gene
5. 27 FUEL NOZZLES INJECTORS 27 GLOW PLUGS PT NET 27 ENGINE PROTECTIVE DEVICES 28 LOW OIL PRESSURE SWITCH maat 28 HIGH COOLANT TEMPERATURE SWITCH 28 OVERSPEED PROTECTION aasa tetas 28 SECTION 6 TROUBLESHOOTING FLOWCHARTS 29 36 IF PROBLEM INVOLVES AC OUTPUT 29 PROBLEM 1 VOLTAGE amp FREQUENCY ARE BOTH HIGH OR LOW 29 PROBLEM 2 GENERATOR PRODUCES ZERO VOLTAGE OR RESIDUAL VOLTAGE 5 12 30 31 PROBLEM 3 NO BATTERY CHARGE OUTPUT 5 5 ictor 31 PROBLEM 4 EXCESSIVE VOLTAGE FREQUENCY DROOP WHEN LOAD IS APPLIED 32 PROBLEM 5 PRIMING FUNCTION DOES NOT WORK 32 PROBLEM 6 ENGINE WILL NOT CRANK 33 PROBLEM 7 ENGINE CRANKS BUT WILL NOT START RUNS HARD 34 PROBLEM 8 ENGINE STARTS THEN SHUTS DOWN 35 PROBLEM 9 14 AMP F1 FUSE BLOWING 36 SECTION 7 DIAGNOSTIC 37 57 INTRODUCTION 37 TEST 1 Check No Load Voltage And Frequency 37 TEST 2 Check Engine Governor 37 38 TEST 3 Test Excitation Circuit Breaker 38 TEST 4 Fixed Excit
6. WINDING F1 FUSE 14 SFE 12 VDC CONTROL FS FUEL SOLENOID FP FUEL PUMP VOLTAGE REGULATOR GP GLOW PLUGS HM HOURMETER DC OUTPUT HWT HIGH WATER TEMP SWITCH LOS LOW OIL PRESSURE SWITCH 44A POWER PHC PREHEAT CONTACTOR 1 R1 RESISTOR 1 OHM 25W R2 RESISTOR 20 OHM 12W A C OUTPUT CUSTOMER CONNECTION GROUND S STARTER T1 T2 T2 SC START CONTACTOR 240V 120 120V Page 18 SW PREHEAT SWITCH SW1 SWITCH START STOP Section 5 ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION PRE HEAT When the PRE HEAT SWITCH SW or the REMOTE PANEL PRE HEAT SWITCH is closed by the operator battery voltage is delivered across the closed switch contacts to the PRE HEAT CONTAC TOR PHO via Wire 150 The PRE HEAT CONTAC TOR PHO is now energized The normally open PHC contacts close battery voltage is now avail able to Wire 157 The GLOW PLUGS GP are energized via Wire 157 Wire 157 is also connected to a DIODE D1 current is allowed to pass through D1 and Wire 14 will now have battery voltage applied to it Engine Controller Terminals 9 10 and 11 are connected The FUEL PUMP FP FUEL SOLENOID FS and HOURMETER HM will be energized via Wire 14 Wire 14 is also connected to RESISTOR R2 and DIODE D2 After passing through R2 and D2 reduced voltage is applied to Wire 4 1 4 a 14 180 18 KAR LEGEND AVA AUTOMATIC V
7. HAS ISNI 14 ANY A009 Za 1009 44010 0 HII M 5 JO 1 1500 N3WYWHH INTO 280 NANYINA AVM9 HOLO3NNOO Owi MING YZ Hg AYUS WOLOS NNOO YIM 9nia 8SOLOS NNOO YIMA VIHG MOV a 310971430235 HOLO3NNOO Qv3H MING 188 381410 BN ANALLYA MOLVIn9 39VITIOA ALYNOLNY YAY 014 VSI DYL MI OSIW OWV ONISNSS IVNOIS 14118 815 8 1 1 SI FI Section 11 ELECTRICAL DATA 2 Dual 120VAC 35A Output 8 56 200 104100 OVAOTC OCcL ITONIS 102290 18 101 INVHOVIG 3HIM HO 4 ILTHHS SDNTA LA W LA OHINOO ST a 22220011 dad A MANOLS NI 4 OANNOD AZI 40 NJS LNSAIUVdWOO HHYLIOA PT Se 1 8 4 PI cm E Ui 2 LNSAIUVdWOO PI 0 DANNOD MANOLS NI S NLIS SI NG 0 HOLMS ZMS 4015 1 156 TMS MOLON 31 15 WS AIOLOVINNOO LUYIS 25 02 NSOLSSWH Zu mez wyo MOLSISJSN THY WOLOVINNOO Lg 8 SYNGS TO MOM 5
8. UIT BREAKER 4A R2 RESISTOR 20 OHM LE GEND d 4 9 5 N 31 DIDE 600W 6AMP 5 START ER m 52 DIODE 600W 6AMP SC START COC ONTACTOR Sax E 5 EXCITATION WINDING SW PR EHEAT SWITCH _ SIGNAL SENSING 44 56 85 150 3 F1 FUSE 14 SFE SWITCH START STOP o SF FUEL SOLENO j 2 FP FUEL PUMP GP GLOW PP LUGS O HM a 04270 1 SCHEMATIC 1 0L DIESEL D2792 A YY 94 Section 11 ELECTRICAL DATA CTION F P TAILS F P DIAGRAM FOR DI e LO STOP CO ONN 1 1207 2 e H e 3 iS H T WI la 03 gt Kg o7 US 4 E e 1 1 s C a ta E A m 21 a m I e N Lo i CN m d a WI d LO Oo EN lt T 9 AN at E 4 E 3 de z RED 17 BH2 14 BH2 L 157 157 14 14 4 22 240V BH2 2 4 D e 13 120w 35
9. Ground Polarity GENERATOR SPECIFICATIONS Rated Maximum Continuous AC Output at 85 F 29 C Ambient 100 F 38 C Ambient 120 F 49 C Ambient Negative 7 500 Watts 7 5 kW 7 000 Watts 7 0 kW 6 000 Watts 6 0 kW Rated Voltage 120 240 Volts AC Rated Maximum Continuous AC Current at 7 500 Watts 120 Volts 240 Volts 62 5 Amps 31 2 Amps 7 000 Watts 120 Volts 240 Volts 58 3 Amps 29 2 Amps 6 000 Watts 120 Volts 240 Volts 50 0 Amps 25 0 Amps Phase Single Rotor Speed at No Load 3 80 rpm Number of Rotor Poles 2 Engine RPM 1 950 Rated AC Frequency 60 Hz Battery Charge Voltage 14 Volts DC Battery Charge Current 2 Amps max Weight 486 Pounds Dry Length 36 6 inches 929 mm Width 23 8 inches 604 mm Height 22 3 inches 567 mm All units are reconnectable to 120 volt only AC output Page 89 Section 10 SPECIFICATIONS amp CHARTS ROTOR STATOR RESISTANCE VALUES TYPE QUIETPACT 75 MODEL 4270 Rotor resistance 15 25 ohms Stator Winding 11 22 159 ohms Stator Winding 33 44 184 ohms DPE Winding 2 6 1 24 ohms Battery charge Winding 55 66 132 ohms Battery charge Winding 55 77 153 ohms TORQUE SPECIFICATIONS Starter 75 in lbs Flywheel 16 2 19 ft lbs Rotor Pulley 34 2 41 8 ft lbs Stator Bolts 16 2 19 8 ft lbs Tensi
10. Resistance values in ohms at 20 C 68 F Actual readings may vary depending on ambient temperature A tolerance of plus or minus 5 is allowed RESULTS 1 For Steps 2 amp 3 keep in mind that the resistance values are very low Depending upon the quality of the VOM it may read Continuity across these windings Exercise good judgement with these values 2 f Steps 2 3 4 5 amp 6 fail any test replace the Stator 3 In Step 7 if Wire 0 reads Continuity but resistor does not measure 1 ohm replace the Battery Charge Resistor 4 f all of the Steps in this test pass perform Insulation Resistance Test on page 13 TEST 18 TRY CRANKING THE ENGINE DISCUSSION If the Pre Heat Switch on the generator panel is actu ated but the Fuel Pump does not run priming func tion doesn t work perhaps battery voltage is not available PROCEDURE Hold the Start Stop Switch at START The engine should crank and start RESULTS 1 If the engine cranks normally but the pre heat function still doesn t work go to Test 19 2 f engine will not crank go to Test 21 Refer to Problem 6 of Section 6 3 If engine cranks but won t start go to Problem 7 of Section 6 4 f engine starts hard and runs rough go to Problem 8 of Section 6 TEST 19 TEST PRE HEAT SWITCH DISCUSSION A defective pre heat switch can prevent the pre heat function from occurring Also see Pre Heat Switch page 26 NOT
11. Movie oma HOLOSNNOO yin No 0 4946 1 of 2 Model 04270 0 Single 120 240 Output HOLOSINNNOO wing 81 341 O34 HB3OHVHO 08 NAY GNHOHI To 2 OL 1595079 1 AYAT HSNaa 014 MI OSIW OV E 061 S8 NISNdS IVNDIS AA LENSES iagram S 4 TAIM UN353 1 40 109 iring W Section 11 ELECTRICAL DATA 104100 YSE OvAOZL ISO 10 WYHOVIG 3HIM V 9v6VO SINTA MOTO 2 HO LTHES LA W W D SI ey NuWOLZSDO NOIIOHNNN OO AMALIWA ACT 1 1 x 0 I soLVIn9UN AOVLIOA T Q gana LST WS 1 0 mj E 9T lt o Alg ANING Set C clLiL dl B gt 2 o O _ LMH 0 SE 2 i 1 ANIONH 1 58 58 EM 98 CN e st ha e 091 OST Dm Em E 111 5 d
12. If the Fuse element has melted open replace the Fuse with an identical size fuse If Fuse is good go to Test 22 Page 46 TEST 22 CHECK BATTERY amp CABLES DISCUSSION If the engine won t crank or cranks too slowly the bat tery may be weak or discharged See Battery on Page 24 PROCEDURE Inspect the battery cables and battery posts or terminals for corrosion or tightness Measure the voltage at the terminal of the starter contactor and verify 11 12 VDC is available to the generator during cranking If voltage is below 11 VDC mea sure at the battery terminals during cranking If battery voltage is below 11 VDC recharge replace battery If battery voltage is above 11 VDC check for proper battery cable sizing see BATTERY CABLES on Page 24 If battery or cables are still suspected connect an alternate battery and cables to the gen erator and retest 2 Use battery hydrometer to test the battery for a state of charge and b condition Follow the hydrometer manufactur er s instructions carefully RESULTS 1 Clean battery posts and cables as necessary Make sure bat tery cables are tight 2 Recharge the battery if necessary 3 Replace the battery if necessary 4 f battery is good but engine will not crank go to Test 23 TEST 23 CHECK POWER SUPPLY TO CIRCUIT BOARD DISCUSSION If battery voltage is not available to the circuit board engine cranking and running will not be po
13. 0 ACT Bee 0 LNSWILHOVdWOSOS HOLV IQOHNH ADVLIOA G8 LC LST WS JS 9T e E E PT Benk TAIGN 21101 amp d NTH E LMH 0 PI Ut vi RU ST 091 L NQLOINNOD HN3NOISnO JUIS TYNWHSL SI HOLIMS 1V3H3dd MANYANA I0n2H2 ZAI ver THI worms MOION meets NG 02 018544 T LI MSZ WYO HOISSHN TA 57 NOLOVINOO IT a i HOLIMS JYNSSINd 10 501 MEALAWNNOH NH Zon HOLMS YILY MH anoo 031 35 anis c wae Y dNOO YIS NON anis GONO TANYA 1108 NAHL qnis 20 a ANNON9 IGNO IXN Vd p TONTOS TANA Sa Tana 0 HAS ANYPI 504 4 9 009 dNY9 A009 NOILO3NNOO 3LONW3M M3NOLSOQO INNOO onid HOLOSINNOO WING I A O 412 143234 Qv3H MING
14. Low Oil Pressure Switch Page 28 HIGH COOLANT TEMPERATURE SWITCH The high coolant temperature switch has normally open contacts This switch is immersed in engine coolant If the coolant temperature should exceed 245 266 degrees F the switches contacts will close to ground sending a signal to the printed circuit board to shut down the unit via wire 85 Figure 5 13 High Coolant Temperature Switch OVERSPEED PROTECTION Generator A C frequency signals are delivered to Terminals 5 and 6 of the engine control circuit board via wires 22 and 44 Should engine generator speed exceed 69 to 71 Hertz for longer than 4 seconds the circuit board will cause an engine shutdown Section 6 TROUBLESHOOTING FLOWCHARTS INTRODUCTION The Flow Charts in this section can be used in con Problems 1 through 4 apply to the AC generator only junction with the Diagnostic Tests of Section 7 TENE Numbered tests in the Flow Charts correspond to identically numbered tests of Section 7 Problem involves AC Output TEST 1 CHECK NO LOAD VOLTAGE amp FREQUENCY VOLTAGE amp FREQUENCY GOOD FREQUENCY GOOD ZERO VOLTAGE AND NO LOAD VOLTAGE FREQUENCY BOTH VOLTAGE HIGH ZERO OR RESIDUAL ZERO FREQUENCY amp FREQUENCY HIGH OR LOW OR VOLTAGE GOOD VOLTAGE LOW GO TO PROBLEM 1 GO TO VOLTAGE GO TO PROBLEM 2 GO TO PROBLEM 2 GO TO PROBLEM 4 REGULATOR ADJUSTMENT PAGE 10 Problem 1 Voltage amp Frequency Are B
15. crank the engine If Wire 56 or the starter contactor is shorted to ground the 14 amp fuse will blow PROCEDURE 1 Set a VOM to measure continuity 2 testing Wire 56 to ground Disconnect Wire 56 from the circuit board on Terminal 7 and from the starter contactor 3 Place one test lead on one end of Wire 56 and the other test lead to clean ground Infinity should be measured 4 testing starter contactor to ground Place one test lead on ter minal where Wire 56 was previously connected and the other test lead to clean ground Infinity should be measured Starter contactor resistance should be 4 6 ohms across the 2 small terminals RESULTS 1 If continuity was measured in steps 3 or 4 replace faulty wire or starter contactor 2 f no fault was indicated proceed to next test on flow chart TEST 43 CHECK WIRE 15 FOR SHORT TO GROUND DISCUSSION If Wire 15 is shorted to ground the fuse will blow immediately when replaced This test will determine if Wire 15 is bad PROCEDURE 1 Set a VOM to measure continuity 2 Disconnect Wire 15 from the fuse holder and from the battery charge rectifier 3 Place one test lead on Wire 15 previously disconnected from fuse and place the other test lead to clean ground Meter should read infinity RESULTS 1 If continuity was measured replace bad wire 2 f infinity was measured proceed to next test on the flow chart Section 8 ASSEMBLY MAJOR DISASSEM
16. 34 5 TEST 33 TEST BAD DIODE 1 OR WIRES EAM D1 DIODE GLOW PLUGS BAD REPLACE BAD TEST 31 TEST 20 CHECK 2 See REPLACE BAD CHECK FUEL FUEL PUMP INJECTOR SOLENOID OPERATION Zeng BAD BAD REPLACE PE GOOD TEST 37 CHECK ENGINE CYLINDER TEST 35 CHECK VALVE ADJUSTMENT See Page 27 GOOD 011 NO START COMPRESSION TEST REPAIR OR REPLACE BAD AS NECESSARY ADJUST VALVES Page 34 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 8 Engine Starts Then Shuts Down AS SOON AS ADJUST CIRCUIT TEST 39 CHECK START BUTTON IS BOARD CIRCUIT BOARD FOR BAD RELEASED SEE PAGE 24 ADJUSTABLE GROUND GOOD Y REPLACE GOOD SEE CIRCUIT BELOW REPLACE WIRES BOARD TEST 1 CHECK NO LOAD VOLTAGE IF BAD REFER TO AC TROUBLESHOOTING FLOWCHARTS AFTER RUNNING CHECK FOR FEW ENGINE SECONDS LEVEL TEST 38 CHECK SWITCH OIL LEVEL LOW BAD GOOD REPLENISH OIL REPLACE SWITCH TEST 40 TEST TEST 24 TEST TEMPERATURE SWITCH SWITCH 8 FROM ABOVE REPLACE BAD REPLACE BAD BAD SWITCH BAD SWITCH REPLACE CIRCUIT BOARD NOTE IF REPLACEMENT OF BOARD DOESN T SOLVE THE PROBLEM AND RUNNING THE REPLACE UNIT OUT OF FUEL HAS OCCURED SEE TEST BAD 44 36 FOR BLEEDING THE INJECTOR PUMP WIRES Page 35 Section 6 TROUBLESHOOTING FLOWCHAR
17. PUMP NOT WORKING TEST 34 TEST d REPLACE D1 DIODE TEST 20 CHECK FUEL PUMP BAD OPERATION GOOD TEST 31 TEST FUEL SOLENOID REPLACE FUEL PUMP IF DEFECTIVE Page 32 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 6 Engine Will Not Crank TEST 22 CHECK BATTERY TEST 21 CHECK 14 amp CABLES AMP FUSE FUSE BAD OR REPLACE BATTERY BAD gt CLEAN REPAIR OR REPLACE BAD CABLE S REPLACE FUSE TEST 23 CHECK TEST 24 POWER SUPPLY CHECK GOOD TO ENGINE START STOP CIRCUIT BOARD SWITCH REPLACE BAD BAD DEFECTIVE 1 SWITCH CHECK WIRING AND WIRE CONNECTIONS REPAIR RECONNECT OR REPLACE BAD WIRES AS REQUIRED TEST 25 CHECK POWER SUPPLY TO WIRE 56 BAD REPLACE ENGINE CONTROLLER CIRCUIT lt BOARD TEST 26 TEST GOOD STARTER CONTACTOR TEST 27 CHECK BAD STARTER MOTOR BAD 1 GOOD REPLACE STARTER CONTACTOR REPLACE STARTER CHECKEOR MOTOR IF DEFECTIVE MECHANICAL BINDING OF THE ENGINE OR ROTOR Page 33 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 7 Engine Cranks But Will Not Start Runs Rough TEST 19 TEST TEST 29 CHECK TEST 28 CHECK FUEL WIRE 14 POWER GOOD cl PRE HEAT SUPPLY SUPPLY SWITCH LOW FUEL BAD BAD REPLACE 1 SWITCH ECOD REPLENISH FUEL SUPPLY REPLACE ENGINE CONTROLLER CIRCUIT BOARD TEST 32 TEST PREHEAT CONTACTOR 5
18. Rx1 or 10 000 scale and zero the meter 4 Connect the positive meter test lead to the positive slip ring the common test lead to a clean ground such as the Rotor shaft The meter should read Infinity POSITIVE TEST LEAD Figure 7 7 Rotor Assembly Section 7 DIAGNOSTIC TESTS RESULTS 1 Replace the Rotor if it fails the test 2 f Rotor checks good perform Insulation Resistance Test on Page 14 TEST 12 CHECK MAIN CIRCUIT BREAKER DISCUSSION The main circuit breaker on the generator panel must be closed or no output to the load will be available A defective breaker may not be able to pass current even though it is in the ON position B Pictorial A Schematic Figure 7 8 Main Breaker Typical PROCEDURE Set the coach main breaker to it s OFF position Check that the appropriate main breaker on the gen erator panel is set to its ON closed position Set a VOM to measure resistance and use it to check for continuity across the breaker terminals RESULTS 1 If breaker is ON and Continuity is measured go to Test 3 2 f breaker is OFF reset to the ON position and check for output 3 If breaker is ON and Continuity is not measured replace the defective circuit breaker TEST 13 CHECK LOAD VOLTAGE amp FREQUENCY DISCUSSION If engine speed appears to drop off excessively when electri
19. Rx1 scale and zero the meter 2 Disconnect Wire 4 from the Voltage Regulator and from the Rotor brush terminal 3 Connect the VOM test leads across each end of the wire The meter should read Continuity 4 Disconnect Wire 1 from the Rotor Brush Terminal Connect Page 41 Section 7 DIAGNOSTIC TESTS one meter test lead to Wire 1 Connect the other test lead to a clean ground The meter should read Continuity RESULTS 1 Repair reconnect or replace any defective wire s 2 f wires check good go to Test 10 Figure 7 6 Brush Leads TEST 10 CHECK BRUSHES amp SLIP RINGS DISCUSSION Brushes and slip rings are made of special materials that will provide hundreds of hours of service with little wear However when the generator has been idle for some time an oxide film can develop on the slip rings This film acts as an insulator and impedes the flow of excitation current to the Rotor If Test 4 resulted in less than one half rated output voltage it is possible that the brushes and slip rings are at fault PROCEDURE 1 Gain access to the brushes and slip rings 2 Remove Wire 4 from the positive brush terminal 3 Remove the ground wire 1 from the negative brush 4 Remove the brush holder with brushes 5 Inspect the brushes for excessive wear damage cracks chip ping etc 6 Inspect the brush holder replace if damaged 7 Inspect the sli
20. Test for a short to ground condition as follows a Connect one meter test lead to Stator lead No 2 the other test lead to a clean frame ground b The meter should read Infinity Any other read ing indicates a short to ground condition and the Stator should be replaced 6 Test for a short between windings as follows a Meter should be set to its Rx1 or Rx10 000 scale b Connect one meter test lead to Stator Wire 2 the other test lead to Stator lead No 11 The meter should read Infinity c Connect one VOM test lead to Stator lead No 2 the other test lead to Stator lead No 33 Infinity should be indicated d Connect one VOM test lead to Stator lead No 2 and connect the other test lead to Stator lead No 66 Infinity should be indicated RESULTS 1 If the Stator excitation DPE windings are open or shorted replace the Stator assembly 2 f the excitation windings are good perform Insulation Resistance Test page 13 Section 7 DIAGNOSTIC TESTS TEST 8 CHECK SENSING LEADS POWER WINDINGS DISCUSSION The Voltage Regulator regulates excitation current flow to the Rotor by electronically comparing sensing voltage to a pre set reference voltage The sensing voltage is delivered to the Voltage Regulator via Wires 11 and 22 If an open circuit exists in sensing leads 115 or 225 the normal reaction of an unprotected Regulator would be to increase the excitation current to
21. 1 Set a volt ohm milliammeter VOM to its 1 scale and zero the meter 2A 2 A Schematic Figure 7 2 Excitation DPE Circuit Breaker B Pictorial 2 In the generator panel locate the excitation circuit breaker Disconnect Wire 2 and Wire 162 from the breaker terminals 3 Connect the meter test leads across the two circuit breaker CB3 terminals The meter should indicate continuity Page 38 RESULTS 1 If the meter did NOT read continuity replace the excitation DPE circuit breaker CB2 and go to Test 4 2 f continuity was indicated go to Test 4 TEST 4 FIXED EXCITATION TEST ROTOR AMP DRAW DISCUSSION The fixed excitation test consists of applying battery voltage 12 VDC to the Rotor windings This allows that portion of the excitation circuit between the Voltage Regulator and the Rotor including the Rotor itself to be checked as a possible cause of the prob lem When battery voltage is applied to the Rotor the resulting magnetic field around the Rotor should induce a Stator power winding voltage equal to about one half the unit s rated output voltage WIRE NO 4 TO ROTOR AND TO ECB CONNECT POSITIVE 4 BATTERY SUPPLY TO WIRE 4 0 6 VOLTAGE REGULATOR TERMINALS Figure 7 3 Fixed Excitation Test PROCEDURE 1 Disconnect Wire 4 from the Voltage Regulator VR Third ter minal from the top of VR 2 Connect a jumper wire to Wire 4 and
22. 13 Flange Nut 50 2 Flat Washer 5 16 Page 61 Section 9 Exploded Views Part Numbers Base Frame Drawing No 0D2357 A Page 62 Section 9 Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 Base Frame Weldment 2 1 Door Service Rear 3 1 Door Service Front 4 4 Slide Latch Flush 5 2 Vinyl Trim Black 180mm 6 677mm Rubber Tape 1 8 x 1 2 7 4 Grommet 1 8 x 13 32 8 4 Vibration Mount 9 1 Gasket Cleanout 10 1 Plate Cleanout 11 8 HHCS 8 1 25 x 16 12 8 Washer Split Lk M8 13 3 Washer Split Lk 1 4 M6 14 2 HHCS M6 1 00 x 10 15 1 Carriage Bolt 3 8 16 x 55mm 16 1 3 8 Special Lock Washer 17 3 Hex Nut 3 8 16 Brass 18 2 HHCS M6 1 00 x 16 19 2 Nut Hex 6 0 1 0 20 1 Block Terminal Battery Post 21 1 Stud 3 8 16 x 55mm 22 1 Washer 3 8 Flat 23 1 Washer Split Lk 3 8 mm Millimetres Page 63 Section 9 Exploded Views Part Numbers Enclosure Drawing 0D2358 D Page 64 Section 9 Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 Enclosure Panel RH 2 1 Enclosure Panel Top 1 Enclosure Panel LH 4 1 Enclosure Panel Front 5 1 Enclosure Rear Panel 6 1 Insulation Front Panel 7 1 Insulation LH Side Panel 8 1 Insulation RH Side Panel 9 1 Insulation Top Front Panel 10 1 Insulation Top Rear Panel 11 1 Insulation Lifting Lug Cover 12 1 Cover Access Lift 13 1 Cover Radiator Fill 14 1 Cover Access Electri
23. 17 37 BOLT 18 5 BOLT 19 1 OIL SEAL 20 4 BOLT 21 5 BOLT 22 1 ARM 23 1 SNAP RING 24 1 O RING 25 1 GOVERNOR LEVER ASSEMBLY 26 1 TENSION LEVER 27 1 SNAP RING 28 1 WASHER 29 1 COTTER PIN 30 1 SPRING 31 1 SPRING 32 1 ARM 33 1 O RING 34 1 SNAP RING 35 1 BRACKET 36 3 BOLT 37 2 BOLT 38 1 SCREW HHC M6 1 0 X 25 39 1 O RING 40 O RING 41 14 SPACER 42 1 GASKET 43 HOLDER OIL FILL 44 15 O RING 45 15 46 IS BOLT 47 3 NUT 48 1 BRACKET FUEL FILTER MODEL 04270 amp 04614 49 3 SCREW HHC 8 1 25 X 60 G8 8 MODEL 04270 amp 04614 50 1 SCREW HHC 8 1 25 X 65 G8 8 MODEL 04270 amp 04614 51 4 NUT HEX M8 1 25 G8 MODEL 04270 amp 04614 52 4 WASHER LOCK 8 5 16 MODEL 04270 amp 04614 NOT USED ON MODEL 04270 amp 04614 Page 85 Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Engine Block Drawing No 082961 C ITEM 14 15 Page 86 QTY 20 2 DESCRIPTION OIL PAN BOLT O RING MODELS 04270 amp 04614 ONLY DIPSTICK TUBE ALL MODELS EXCEPT 04270 amp 04614 DIPSTICK TUBE MODELS 04270 amp 04614 ONLY O RING ALL MODELS EXCEPT 04270 amp 04614 BOLT DIPSTICK ALL MODELS EXCEPT 04270 amp 04614 I lI lI lI lo m ol ol sl a DESCRIPTION ROCKER COVER GASKET ROCKER COVER OIL STOPPER SCREEN GASKET NUT CAP O RING 1 4 PIPE PLUG SQ HD O RING TUBING SUCTION FILTER GASKET Section 9 Exploded Views Part Numbers 1 0
24. Board 3 If battery voltage is available in Step 4 but engine does not crank go to Test 26 TEST 26 TEST STARTER CONTACTOR DISCUSSION If battery voltage is available to the Wire 56 circuit but engine will not crank one possibility of the prob lem is a failed starter contactor PROCEDURE 1 Set a VOM to measure resistance 2 Connect one test lead to Wire 0 on the starter contactor termi nal Connect the other test lead to frame ground Continuity should be measured 3 Momentarily connect a suitable jumper cable across the two large terminal studs of the starter contactor The engine should crank 4 Set the VOM to measure resistance 5 Disconnect Wire 56 and 0 from the starter contactor from termi nals 6 Connect one test lead to the starter contactor terminal from which Wire 56 was removed Connect the other test lead to where Wire 0 was removed starter contactor coil resistance of 4 6 ohms should be measured RESULTS 1 If continuity is not measured in step 1 repair or replace Wire 0 between the starter contactor and the ground terminal 2 f engine cranks during step 3 but would not crank in test 25 remove and replace starter contactor 3 If resistance is incorrect in step 6 replace starter contactor 4 f starter contactor checks good proceed to next step in flow chart TEST 27 CHECK STARTER MOTOR CONDITIONS AFFECTING STARTER MOTOR PERFORMANCE 1 A binding or seizing conditio
25. Flanged 23 1 Bracket Rotary Tensioner 24 2 HHCS M8 1 25 x 20mm 25 6 Washer Split Lk M8 26 1 61 Green Belt 27 1 Filler Neck Assembly Radiator Remote 28 1 Hose Tee 29 1 Coupling Hose 30 1 Hose Radiator Lower 31 1 Hose Water Pump Lower 32 1 Hose Top NG 1 Hose Lower Intermediate 34 8 Hose Clamp Hi Trq 1 3 4 Max 35 2 12 36 720mm Hose 34 SAE 20R3 37 1 10 1 5 x 30mm HHCS 38 1 M10 Lockwasher 39 2 HHCS M6 1 00 x 16mm 40 270mm Hose 5 16 SAE 20R4 41 4 Hose Clamp 7 8 3 8 42 4 HHCS M8 1 25 x 16mm 43 1 Cap Coolant Fill 44 1 Tank Coolant Overflow 45 510mm Hose 5 16 SAE 20R4 46 2 Clamp Vinyl Coated 1 5 8 47 Cap Radiator Pressure 1 1 Gasket Radiator Base 1 Nut Hex M8 1 25 52 1 Bracket Support 1 12 13 x 1 34 HHCS 1 Tensioner SE 18 3 1 1 2 13 Flange Nut mm Millimeters Page 67 Section 9 Exploded Views Part Numbers Electrical Enclosure Assembly Drawing No 002361 Page 68 Section 9 Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 Weldment Electrical Enclosure 2 1 Terminal Block 4 Position 3 1 Assembly Potted Regulator 4 1 Resistor 20 5 12W 5 1 Assembly Marine Control Board 6 1 Rectifier Battery Charging 7 1 Circuit Breaker 5 Amp 8 A R Tape Glass Insulated 9 2 Taptite M5
26. KEY 23 1 ADAPTOR 11 6 CAP 12 1 CYLINDER HEAD GASKET 1 2MM THICK MM MILLIMETER 1 CYLINDER HEAD GASKET 1 3MM THICK Page 78 Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Crankshaft Piston and Flywheel Drawing No 075679 ITEM O RON sesch QTY AD ech sch EN 3 28 30 DESCRIPTION ITEM QTY CRANKSHAFT ASSEMBLY 17 3 CRANKSHAFT GEAR AR KEY AR DOWEL PIN 18 3 SPRING PIN 19 6 BEARING HOLDER ASSEMBLY 20 3 BEARING HOLDER ASSEMBLY 21 3 BEARING HOLDER ASSEMBLY 22 6 BOLT 23 6 DOWEL PIN 24 6 STANDARD BEARING AR 0 25MM U S BEARING AR 0 50MM U S BEARING 28 1 STANDARD BEARING 30 1 0 25MM U S BEARING 0 50MM U S BEARING THRUST WASHER BOLT BOLT STANDARD PISTON ASSEMBLY PISTON ASSEMBLY 0 5MM O S PISTON ASSEMBLY 1 0MM 5 DESCRIPTION STANDARD PISTON RING SET PISTON RING SET 0 5MM 5 PISTON RING SET 1 0MM 5 PISTON PIN SNAP RING CONNECTING ROD ASSEMBLY BUSHING CONNECTING ROD BOLT NUT CONNECTING ROD BOLT STANDARD BEARING BEARING 0 25MM 1 5 BEARING 0 50MM U S PULLEY NUT U S UNDERSIZE O S OVERSIZE AR AS REQUIRED MM MILLIMETER Page 79 Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Oil Pump Drawing No 75682 p 2 aa Ch u c ec IN ITEM QTY 1 1 2 1 3 1 4 1 5 1 6 AR AR AR AR 7 1 8 1 9 1 10
27. Liter Diesel Water Pump Drawing No 082962 ITEM OK ON IN 2 4 7 OLI Ng ia 2577 M vf 2 bx eck eck sch eck eck o o DESCRIPTION WATER PUMP ASSEMBLY PLUG THERMOSTAT SPRING GASKET SET PLATE BOLT GASKET BOLT BOLT NUT PULLEY BOLT Page 87 0D2650 A ing SPECIFICATIONS amp CHARTS Major Features and Dimensions Draw Section 10 uHOOG 21 4 45 INOYA WOI AWHS AY HA L C 22 146 sees candi LA TINO LSOWHXd 00 22 966 8 684 La4 u LOI TI Zb 119711 TLE 5014 7 LINY 10029 SATOH ONILNNOW 91 8 6 T SMHHOS HATAC LLIIDGNOO LHOIL GINOIT 2 1 5 56 BHAILVOSN 282621 v09 OV SMHHOS YTO NOILOANNOO AUdILILVG au ZOT uLS9El 626 2 lwp OSES HAILISOd LETI u 127961 NOILOSNNOO AMA LIVE Wen 1 SSHOOW TIVOINIOSHTZ M 1 Jo O mO0PTI 4682 1 05 9TJ 0 e SMANOS YAN lo 6 7 c Cat NOILIOSNNOO C NANYANG LIIDOMNIJ pee LVH
28. O X a n 18 L REMOTE START STOP CONNECTION SEEWIRNG DIAGRAM FOR DETAILS INTRODUCTION The engine DC control system includes all compo nents necessary for the operation of the engine Operation includes off preheat cranking starting running shutdown and fault shutdown The system is shown schematically OPERATIONAL ANALYSIS CIRCUIT CONDITION OFF Battery voltage is available to the engine controller circuit board from the unit BATTERY and via a the RED battery cable Wire 13 14 amp FUSE F1 Wire 15 and engine controller Terminal 1 However circuit board action is holding the circuit open and no action can occur Battery voltage is available to the contacts of a SIARTER CONTACTOR SC but the contacts are open Battery voltage is available to the contacts of a PRE HEAT CONTACTOR PHC but the contacts are open Battery voltage is available to the PREHEAT SWITCH SW The switch is open and the circuit is incomplete Battery voltage is also available to the remote con nection for a remote preheat switch Battery voltage is available to the BATTERY CHARGE RECTIFIER BCR This is used as a return path for Battery Charge Winding current LEGEND AVR AUTOMATIC VOLTAGE REGULATOR BCR BATTERY CHARGE RECTIFIER BCW BATTERY CHARGER CB1 CIRCUIT BREAKER 35A CB2 CIRCUIT BREAKER 4A D1 DIODE 600V 6AMP m 12 VDC SUPPLY D2 DIODE 600 6AMP
29. PREHEAT SWITCH SW1 SWITCH START STOP Page 23 Section 5 ENGINE DC CONTROL SYSTEM ENGINE CONTROL CIRCUIT BOARD GENERAL The ENGINE CONTROL circuit board is responsible for cranking startup running and shutdown opera tions The board interconnects with other components of the DC control system to turn them on and off at the proper times It is powered by fused 12 VDC power from the unit battery CIRCUIT BOARD CONNECTIONS The circuit board mounts two six wire terminal strips They are labeled 1 6 and 7 12 The following chart shows the associated wires and the function s of each terminal and wire FUNCTION Power supply 12VDC for the circuit board and DC control system Common Ground To Start Stop Switch and remote connector When grounded by setting Start Stop Switch to START engine will crank To Start Stop Switch and remote connector When grounded by setting Start Stop Switch to STOP engine shuts down Frequency signal for overspeed shutdown starter disengage Frequency signal for overspeed shutdown starter disengage Delivers 12 VDC to Starter Contactor SC while cranking only Not Used Engine run circuit Delivers 12 VDC during cranking and running Connected to Fuel Pump Fuel Solenoid Hourmeter and field boost circuit Engine run circuit Delivers 12 VDC during cranking and running Connected to Fuel Pump Fuel Solenoid Hourmeter and fiel
30. The fingers will then be pointing in the direction of the lines of force NOTE The right hand rule is based on the rent flow theory which assumes that current flows from positive to negative This is opposite the electron theory which states that current flows from negative to positive Figure 1 2 The Right Hand Rule ELECTROMAGNETIC INDUCTION An electromotive force EMF or voltage can be pro duced in a conductor by moving the conductor so that it cuts across the lines of force of a magnetic field Similarly if the magnetic lines of force are moved so that they cut across a conductor an EMF voltage will be produced in the conductor This is the basic principal of the revolving field generator Figure 1 3 below illustrates a simple revolving field generator The permanent magnet Rotor is rotated so that its lines of magnetic force cut across a coil of wires called a Stator A voltage is then induced into the Stator windings If the Stator circuit is completed by connecting a load such as a light bulb current will flow in the circuit and the bulb will illuminate Figure 1 3 A Simple Revolving Field Generator Page 3 Section 1 GENERATOR FUNDAMENTALS A SIMPLE AC GENERATOR Figure 1 4 shows a very simple AC Generator The generator consists of a rotating magnetic field called a ROTOR and a stationary coil of wire called a STA TOR The ROTOR is a permanent magnet which con sist
31. a Battery Charge Resistor During normal opera tion the battery charge output will vary between 1 to 2 amps depending on the load applied to the generator PROCEDURE 1 Disconnect Wire 15 from the Battery Charge Rectifier center terminal Wire 15 is the fused battery supply 2 Set a VOM to measure DC Amps Connect the positive test lead to the center terminal of the Battery Charge Rectifier Connect the negative test lead to Wire 15 previously discon nected 3 Start the generator The amp reading on the VOM should be Page 43 Section 7 DIAGNOSTIC TESTS approximately 0 8 Amps Apply full load to the generator The amp reading should increase to approximately 2 Amps RESULTS 1 If amperage was measured between 0 8 to 2 Amps in Step 2 and Step 3 the charging system is working 2 no amperage was measured check the VOM fuses veri fy the functioning of the Amp Meter If DC Amp Meter is good and no current is measured go to Test 16 TEST 16 CHECK BATTERY CHARGE RECTIFIER DISCUSSION The Battery Charge Rectifier is a full wave rectifier PROCEDURE 1 Disconnect Wire 66 Wire 15 and Wire 77 from the Battery Charge Rectifier 2 Set the VOM to the Diode Test range Connect the negative test lead to the center terminal of the BCR Connect the posi tive 4 test lead to an outer terminal The meter should mea sure approximately 0 47 to 0 5 volts 3 Connect the positive
32. directly pro portional to engine speed Low governor speed will result in a reduced A C frequency and voltage and high governor speed will produce an increased fre quency and voltage FUEL INJECTION PUMP CONTROL RACK SHIM INJECTOR PUMP Figure 5 8 Fuel Injection Pump The fuel injection pump is mounted on the side of the engine and rides on a three lobe camshaft The lobes on the camshaft press the bottom of the pump which mechanically opens the fuel path to deliver fuel to the fuel injectors Timing for the fuel injector pump is determined by the distance between the camshaft lobes and the pump This distance is regulated by metal shims the shim space is incorrect the fuel pressure will be incorrect and combustion will not occur When the fuel injector pump is removed for maintenance be sure to reassemble with the same number of shims The engine governor controls the fuel injector pump by linkage connecting the two FUEL NOZZLES INJECTORS Fuel supplied by the injector pump is delivered to the nozzle holder and to the nozzle body When fuel pressure is sufficient to compress the spring fuel is supplied from the nozzle and into the combustion chamber Due to the high pressure of fuel being ejected from the nozzle there is no safe test If faulty fuel is suspected and a clogged injector pump was diagnosed the replacement of the injector nozzles would be needed INJECTOR AN 7 fes BA N p
33. in each individual line Then add the individual readings MEASURING RESISTANCE The volt ohm milliammeter may be used to measure the resistance in a circuit Resistance values can be very valuable when testing coils or windings such as the Stator and Rotor windings When testing Stator windings keep in mind that the resistance of these windings is very low Some meters are not capable of reading such a low resis tance and will simply read continuity If proper procedures are used the following condi tions can be detected using a VOM short to ground condition in any Stator or Rotor winding Shorting together of any two parallel Stator wind ings Shorting together of any two isolated Stator wind ings An open condition in any Stator or Rotor winding Component testing may require a specific resistance value or a test for infinity or continuity Infinity is an OPEN condition between two electrical points which would read as no resistance on a VOM Continuity is a closed condition between two electrical points which would be indicated as very low resistance or ZERO on a VOM Section 4 MEASURING ELECTRICITY ELECTRICAL UNITS AMPERE The rate of electron flow in a circuit is represented by the AMPERE The ampere is the number of electrons flowing past a given point at a given time One AMPERE is equal to just slightly more than six thou sand million billion electrons per second With alternati
34. indicates a breakdown in insulation the Stator should be cleaned dried and re tested If the winding fails the second test after cleaning and dry ing replace the Stator assembly TEST BETWEEN ISOLATED WINDINGS Follow the tester manufacturer s instructions carefully Connect the tester test leads across Stator leads No 11 POWER and No 2 Apply a voltage of 1500 volts DO NOT EXCEED ONE SECOND Leads 2 amp 6 Stator Excitation Winding Leads 11 amp 22 Voltage Sensing Leads Leads 11 amp 22 33 amp 44 AC Power Windings Leads 55 66 77 Battery Charge Windings Figure 3 2 Stator Leads 2 Repeat Step 1 with the tester leads connected across the fol lowing Stator leads Page 13 Section 3 INSULATION RESISTANCE TESTS a Across Wires No 33 and 2 b Across Wires No 11 POWER and 66 C Across Wires No 33 and 66 d Across Wires No 2 and 66 If a breakdown in the insulation between isolated windings is indicated clean and dry the Stator Then repeat the test If the Stator fails the second test replace the Stator assembly TEST BETWEEN PARALLEL WINDINGS Connect the tester leads across Stator leads No 11 POWER and 33 Apply a voltage of 1500 volts If an insulation breakdown is indicated clean and dry the Stator Then repeat the test between parallel wind ings If the Stator fails the second test replace it TESTING ROTOR INSULATION To test the Rotor for insula
35. plugs PROCEDURE 1 Set a VOM to measure resistance 2 Disconnect Wire 157 from glow plugs 3 Place positive test lead to center electrode and the nega tive test lead to ground Resistance should be 1 0 ohm 4 f resistance is good remove glow plug from engine the sheath for damage RESULTS 1 If sheath is chipped or broken replace glow plug resistance and sheath are good proceed to next step on flowchart TEST 34 TEST D1 DIODE DISCUSSION The D1 diode is a protective device that prohibits the return flow of DC current to the glow plugs while the unit is running If this diode is bad or shorted to ground power will not be available to Wire 14 off the other end of the diode If Wire 14 does not receive voltage the fuel solenoid fuel pump and hourmeter will not operate PROCEDURE 1 Set a VOM to measure continuity 2 Place the test leads on each end of the diode then reverse the leads to the opposite ends Continuity should be measured only in one direction RESULTS 1 If continuity is measured in both directions replace the diode 2 f diode checks good then battery voltage should be measured on Wire 14 to the board on Pin 10 If it is not measured then Wire 14 needs to be replace Section 7 DIAGNOSTIC TESTS TEST 35 CHECK VALVE ADJUSTMENT DISCUSSION If the engine is having a hard start no start or rough running condition then the valves will n
36. remove the bottom center panel The battery will need to be disconnected prior to removing the starter if found to be faulty The panel is held on by 2 latch es Lift latches and remove lower panel Remove positive battery cable from the starter Remove the 2 allen bolts mounting the starter to front cross member frame Remove starter FUEL INJECTOR PUMP REMOVAL Prior to removing the injector pump the top and side panels will need to be removed Remove rubber fuel lines going to the brass fittings located at the top of the fuel injector pump CAUTION Fuel is haz ardous Disconnect Wire 14 going to the fuel sole noid that is mounted to the left of the fuel injector pump Remove the fuel solenoid by using a small channel lock wrench and turn the solenoid counter clockwise Remove the metal fuel lines located at the top of the fuel injector pump Remove the other end of the metal lines going to the nozzle injectors the two retaining screws and two nuts hold ing injector pump to the governor assembly Lift and remove fuel injector pump and spacer shims RADIATOR REMOVAL Prior to removing the radiator the top panel will need to be removed SQUIRRELL CAGE MOUNTING SEA 5 t RADIATOR 4 Figure 8 3 Radiator Removal Points 1 Lift unit by engine lifting bracket to gain access to the bottom hole under radiator Page 58 2 Loosen drain plug and drain coolan
37. the Rotor an effort to increase the actual AC output voltage This would result in a full field condition and an extremely high AC output voltage To protect the system against such a high AC output voltage the Voltage Regulator will shut down if sens ing voltage signals are lost If the regulator shuts down the generator s AC output voltage will decrease to a value that is equal to the Rotor s residual magnetism about 5 12 VAC PROCEDURE Gain access to the generator control panel interior Test the Stator power windings as follows 1 From main breaker disconnect Wires 11 and 44 2 Also disconnect Wires 22 and 33 from the ground terminal 3 Disconnect Wires 11 and 22 sensing leads from the Voltage Regulator 4 Set a VOM to its Rx1 scale and zero the meter 5 Connect the meter test leads across Stator leads 11 and 22 Normal power winding resistance should be read 6 Connect the meter test leads across Stator leads 33 and 44 Normal power winding resistance should be read 7 Connect the meter test leads across Stator sensing leads 11 and 22 Normal Power Winding resistance should be read AC POWER WINDING RESISTANCE QP75D ACROSS WIRES 11 amp 22 33 amp 44 Resistance values in ohms at 20 C 68 F Actual readings may vary depending on ambient temperature A tolerance of plus or minus 5 is allowed 8 Now set the VOM to its 1 or Rx10 000 scal
38. the proper generator leads 2 Start the engine let it stabilize and warm up at no load 3 Frequency meter should read between 62 63 HERTZ Line to Page 37 Section 7 DIAGNOSTIC TESTS line voltage should read between 242 252 VAC If voltage and frequency are good no adjustment is needed If voltage and frequency are low or high proceed to next step 4 Turn the governor adjusting screws to obtain a no load frequen Cy as close as possible to 62 63 HERTZ With no load frequen Cy set apply an electrical load as close as possible to the unit s rated load Frequency with load applied should not fall below 58 HERTZ units frequency continues to drop below 58 HERTZ while under load check for an overload condition TEST 3 TEST EXCITATION CIRCUIT BREAKER DISCUSSION This circuit breaker CB2 is normally closed and self resetting It will open in the event of excessive current from the Stator excitation DPE winding The circuit breaker should re close or reset automatically after it cools down takes approximately two minutes When the breaker CB2 is open excitation current to the Regulator and to the Rotor will be lost The unit s AC output voltage will then drop to a value that is equal to the Rotor s residual magnetism about 5 12 volts AC This test will determine if the breaker has failed in its open position PROCEDURE Note After running the unit allow two minutes for the breaker to reset
39. to the 12 volt fused battery positive supply Wire 15 Wire 15 located at fuse F1 holder 3 Set the VOM to measure AC voltage 4 Disconnect Wire 2 from the DPE breaker CB2 and connect one test lead to that wire Disconnect Wire 6 from the Voltage Regulator and connect the other test lead to that wire Start the generator and measure the AC voltage It should be above 60 VAC Record the results and stop the generator 5 Re connect Wire 2 to the DPE Circuit Breaker CB2 and re connect Wire 6 to the Voltage Regulator Section 7 DIAGNOSTIC TESTS TEST 4 RESULTS A C D E VOLTAGE RESULTS WIRE2 amp 6 EXCITATION WINDING ABOVE 60 VAC BELOW 60 VAC ZERO OR RESIDUAL VOLTAGE 5 12 VAC BELOW 60 VAC VOLTAGE RESULTS WIRE 11 amp 22 POWER WINDING SENSE LEADS ABOVE 60 VAC ZERO OR RESIDUAL VOLTAGE 5 12 VAC ROTOR AMP DRAW 87 79 A 87 79 A MODEL 4270 87 79 A QP75D 2096 2096 2096 ZERO 87 79 A ZERO CURRENT 2096 CURRENT DRAW DRAW MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART Problem 2 on Pages 30 amp 31 6 Disconnect Wire 11 from the Voltage Regulator VR and con nect one test lead to that wire Disconnect Wire 22 from the Voltage Regulator and connect the other test lead to that wire Start the generator and measure the AC voltage It should be above 60 VAC Record the results and stop the generator 7 Re connect Wire 11 and Wire 22 to the Voltage Regu
40. 0 8 x 30 10 1 Taptite M5 0 8 x 16 11 3 Lockwasher M5 12 2 Nut Hex M4 0 7 13 4 Pcb Support Snap In 14 1 HHMS 48 32 x 2 25 15 1 Washer Flat M5 16 1 Harness 17 4 M4 0 7 x 16 HHCS Taptite 18 1 Decal Customer Connection 19 4 Washer Flat 8 20 1 Gasket Electrical Enclosure 21 Wire Assembly 32 22 Wire Assembly 22 23 1 Diode Assembly 24 1 Wire Assembly 162 25 2 Ja Special Lockwasher 26 2 Washer Flat 14 M6 27 7 Washer Split Lk M6 28 7 Nut Hex 6 1 29 3 Bushing Snap 31 4 HHCS M4 0 7 x 16mm 32 1 Gasket Electrical Enclosure Divider 33 1 Harness Ac Output A R As Required Not shown refer to Wiring Diagram C4946 Page 69 Section 9 Exploded Views Part Numbers Intake and Exhaust System Drawing No 0D2362 B Page 70 Section 9 Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 Exhaust Gasket 2 1 Chamber Air Intake 3 1 Air Filter 4 1 Hose Air Inlet 5 1 Muffler Weldment 6 2 U Bolt amp Saddle 1 25 7 1 Rail Engine LH Weldment 8 1 Insulation Exhaust 9 3 Hose Clamp 28 10 1 Outlet Exhaust Flex 11 1 Gasket Exhaust Outlet 12 1 Plate Exhaust Outlet 13 2 HHCS M8 1 25 x 55 14 2 Washer Vibration Isolator 15 10 Washer Split Lk M8 16 5 Nut Hex M8 1 25 17 3 Crimptite 12 20 x 5 8 18 1 Bracket Support 19 4 Washer Flat M8 20 2 HHCS M8 1 25 x 20 21 4 HHCS M8 1 25 x 25 22 2 Hose Clamp 20 23 1 HHCS M8 1 25 x 30 24 1 H
41. 01 SNYd IT Page 93 No 0D2793 B 2 of 2 Models 04270 1 amp 04270 ing Draw iagram D dinala YILAN WH OWINOO 3 M3IVM LMH VI gt ANIS ININNOYD 9 P a pa NB pa ANCOD NON GNIS MINDOSD SMNI 1 amp o TANYA oui HO TOE pro 8 0015 SNYN4 ZCONO H JMINDOHD SNLOSNH 1 Hi ii wd d T 34S ANYPI 504 i 009 za 1 ONT OL 15450132 dWv9 A009 3000 La AYAT 49 HII M NNOO SLOWSY 715102 INNOZ Wooo 2680 VG Hjxvdd8 1019490 189 9 NOLO DENNOD QY HH NTIOH AYUD WIOVI JADIY MOLO DENNOD HH 20074 MOLD OHNNO2 OY 2 18 HOLO3NNOO Qv3H o NGA LOOM MUN AHHIIYC d HAP TA ALVWOLNY NAY iring W JAN NOI LONN A 0109 1 0 77 O SE p 77555 bl ELECTRICAL DATA Section 11 HO o H w lu ze 0 Z H x O
42. 0V R1 RESISTOR 1 OHM 25W 2 RESISTOR 20 OHM 12W 12 VDC SUPPLY D2 DIODE 800V EXCITATION WINDING F1 FUSE 14AMP SFE FP FUEL PUMP VOLTAGE REGULATOR DC OUTPUT HWT WATER TEMP SWITCH 11A 22 33 LOS LOW OIL PRESSURE SWITCH Xs AC POWER PHC PREHEAT CONTACTOR A C OUTPUT CUSTO ER RN STIR GROUND 8 STARTER TS T2 T2 SC START CONTACTOR SW PREHEAT SWITCH 240V 7 120v 5401 SWITCH START STOP 120V Page 21 Section 5 ENGINE DC CONTROL SYSTEM i 1 15 XA REMOTE START STOP CONNECTION 17014 150 18 CIRCUIT CONDITION SHUTDOWN Setting the START STOP SWITCH SW1 or the REMOTE PANEL START STOP SWITCH to its STOP position connects the Wire 18 circuit to ground ENGINE CONTROL circuit board action de energizes DC output to Terminal 9 10 amp 11 Wire 14 The FUEL PUMP FP FUEL SOLENOID FS and HOURMETER HM are de energized by the loss of DC to Wire 14 Fuel flow terminates and the engine shuts down 1 4 3 11 22 33 T3 240V 7 i Page 22 SEE WIRING DIAGRAM FOR DETAILS LEGEND AVR AUTOMATIC VOLTAGE REGULATOR BCR BATTERY CHARGE RECTIFIER BCW BATTERY CHARGER CIRCUIT BREAKER 35A CIRCUIT BREAKER 4A 01 DIODE 800V DIODE 800V DPE EXCITATION WINDING F1 FUSE 14AMP SFE
43. 1 11 1 12 3 AR AS REQUIRED Page 80 DESCRIPTION IDLER GEAR ASSEMBLY SPRING THRUST WASHER ROTOR OIL PUMP COVER 0 10MM SHIM 0 15MM SHIM 0 20MM SHIM 0 50MM SHIM SPRING COLLAR SNAP RING FRONT PLATE GASKET BOLT Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Rocker Arm Assembly Drawing No 075683 4 2 11 6 NG Ss 9 26 12 y 9 era SI L E bs l C uk ER O s wn KEN Ry Gs SR 2 A Zi M E TARY E ru d 10 d ITEM QTY DESCRIPTION 1 1 ROCKER ARM ASSEMBLY INCLUDES ALL COMPONENTS SHOWN BELOW INTAKE ROCKER ARM EXHAUST ROCKER ARM NUT STUD ROCKER ARM BRACKET ROCKER ARM SHAFT SPRING SCREW SPRING PIN NUT STUD Corn 10 CO zk CO CO CO 12 81 Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Injector Pump Drawing No 075686 C 13 b MODEL 04270 amp 04614 ONLY D ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 INJECTOR PUMP ASSEMBLY 13 1 CLAMP 2 AR SHIM 0 2MM 14 1 BOLT AR SHIM 0 3MM 16 3 GLOW PLUG AR SHIM 0 5MM 17 1 CONNECTOR AR SHIM 1 0MM 18 1 GASKET 3 3 NUT 19 1 COVER ALL MODELS EXCEPT 4 2 BOLT 04270 amp 04614 5 3 GASKET 1 TUBE ENGINE OIL FILL MODEL 6 3 INSERT 04270 amp 04614 7 3 CAP 20 2 BOLT 8 3 INJECTOR 26 1 SOLENOID 9 1 TUBING 27 1 WASHER 10 1 TUBING 28 1 WASHER 11 1 T
44. 4 test lead to the center terminal of the BCR Connect the negative test lead to to an outer terminal The meter should measure Infinity Connect the negative test lead to the other outer terminal Infinity should once again be measured Short to Ground 4 Set the VOM to measure resistance Connect the positive test lead to the case housing of the BCR Connect the negative test lead to an outer terminal Infinity should be measured Now connect the negative test lead to the BCR center terminal Infinity should be measured Next connect the negative test lead to the remaining outer BCR terminal Once again Infinity should be measured Figure 7 9 Battery Charge Rectifier Page 44 RESULTS 1 If any of the previous steps has failed replace the Battery Charge Rectifier TEST 17 CHECK BATTERY CHARGE WINDINGS BATTERY CHARGE RESISTOR DISCUSSION The Battery Charge Winding BCW produces AC voltage that is delivered to the Battery Charge The Battery Charge Winding is a center tapped winding consisting of the following Stator Leads Wire 66 Wire 77 and Wire 55 The Battery Charge Resistor is used as a current limiting resistor PROCEDURE 1 Disconnect the Stator Leads Wire 66 and Wire 77 from the Battery Charge Rectifier Be sure to disconnect Stator Lead Wire 66 Black from Wire 66 connector for this test Disconnect the Stator Lead Wire 55 from the Battery
45. ACTUAL AC out put voltage signals to the regulator These are Wires No 11 and 22 Two 2 leads 4 and 1 deliver the regulated direct current to the Rotor via brushes and slip rings Two 2 leads No 6 and 162 deliver Stator excita tion winding AC output to the regulator The regulator mounts a VOLTAGE ADJUST poten tiometer used for adjustment of the pre set REFER ENCE voltage An LED will turn on to indicate that SENSING voltage is available to the regulator and the regulator is turned on Page 10 VOLTAGE ADJUST POT Figure 2 7 Voltage Regulator ADJUSTMENT PROCEDURE With the frequency set at 62 5 Hertz and no load on the generator slowly turn the voltage adjust pot on the voltage regulator until 124 VAC is measured If voltage is not adjustable proceed to Section 6 Troubleshooting NOTE If for any reason sensing voltage to the regulator is lost the regulator will shut down and excitation output to the Rotor will be lost The AC output voltage will then drop to a value that is equal to Rotor residual magnetism about 7 12 VAC Without this automatic shutdown feature loss of sensing actual voltage to the regulator would result in a full field or full excitation condition and an extremely high AC output volt age NOTE Adjustment of the regulator s VOLTAGE ADJUST potentiometer must be done only when the unit is running at its correct governed no load speed Speed is correct when the u
46. BLY ENCLOSURE PANEL REMOVAL Using a 10 mm socket remove all screws on all pan els except the lower screws on the radiator side panel Remove the top panel first then the side and rear When removing the front panel the main con trol panel is mounted onto the front sheet metal There are five nuts holding them together that will need to be removed in order to separate The wiring harness connections will need to be disconnected to completely separate the two pieces STATOR ROTOR ENGINE REMOVAL After the panel assemblies are removed the tech will have full access to the components of the unit for easier removal STATOR 1 Remove the front belt tensioner by using a 34 socket and wrench 2 Loosen bolt and nut and remove 3 Use a 16 mm socket for the rear tensioner 4 Remove the rear and front belts 5 Remove the two screws mounting the electric fuel pump to the bottom frame by using a 10 mm socket 6 Disconnect the wiring harness from the fuel pump 7 Remove air filter and rubber hose from the metal cross mem ber frame by using a flat tip screwdriver 8 Place a block of wood under the rear of the engine for support REAR OF ENGINE Figure 8 1 Block of Wood Under Rear of Engine 9 Remove the two bolts that mount the rear cross member frame to the bottom frame through the rubber mount 10 Remove the four bolts that mount the engine to the cross member 11 Remove the two hold down bolts m
47. CHECK FUEL PUMP DISCUSSION The fuel pump delivers fuel to the fuel injector pump It is powered by Wire 14 when the pre heat switch is pressed or when the unit is running Without fuel to the engine combustion will not occur Page 45 Section 7 DIAGNOSTIC TESTS PROCEDURE 1 Set a VOM to measure DC voltage 2 Disconnect the connector from the wires of the fuel pump 3 Place the positive test lead on Wire 14 and the negative test lead to clean ground Press the pre heat switch battery voltage should be measured if not disconnect the other end of Wire 14 Place test leads on each end of Wire 14 Set a VOM to measure continuity Continuity should be measured 4 Disconnect Wire 0 from the black wire of the fuel pump Place one test lead on Wire 0 and the other test lead to ground Continuity should be measured If continuity is not measured replace Wire 0 5 Jump 12 VDC to white wire of fuel pump and jump black wire to clean frame ground Fuel pump should pump RESULTS 1 If battery voltage and continuity are not measured in step 3 then replace bad wire 2 f pump does not pump in step 5 replace the pump TEST 21 CHECK 14 AMP FUSE DISCUSSION If the panel mounted 14 amp fuse F1 has blown engine cranking will not be possible Figure 7 11 14 Amp Fuse PROCEDURE Push in on fuse holder cap and turn counterclock wise Then remove the cap with fuse Inspect the Fuse RESULTS
48. Charge Resistor 2 Set the VOM to measure resistance at the R x 1 scale Connect one test lead to Stator Lead Wire 66 Connect the other test lead to Stator Lead Wire 55 Normal Battery Charge Winding resistance should be measured 3 Connect one test lead to Stator Lead Wire 77 Connect the other test lead to Stator Lead Wire 55 Normal Battery Charge Winding resistance should be measured 4 Connect one test lead to Stator Lead Wire 55 Connect the other test lead to Stator Leads Wire 11 amp 33 at the back of CB1 Infinity should be measured 5 Connect one test lead to Stator Lead Wire 55 Disconnect Stator Lead Wire 2 from the DPE circuit breaker CB2 and connect the other test lead to Wire 2 Infinity should be mea sured 6 Connect one test lead to Stator Lead Wire 55 Connect the other test lead to frame ground Infinity should be measured 7 Connect one test lead to the Battery Charge Resistor terminal that Wire 55 was removed from Connect the other test lead to frame ground One 1 ohm should be measured If 1 ohm was not measured remove Wire 0 from the Battery Charge Resistor Connect one test lead to Wire 0 and the other test lead to frame ground Continuity should be measured Repair or replace Wire 0 if defective and retest the Battery Charge Resistor BATTERY CHARGE WINDING RESISTANCE QP75D Model 4270 ACROSS WIRES OHMS 99 amp 66 0 702 55 8 77 0 50 Section 7 DIAGNOSTIC TESTS
49. D pil out gung 01 163507102 UNHDHT 1 4931 20334 HSNAE E CE TT vv iagram D iring W COTH UST Wir VLL ISIW OV X oV 1g OG rv UNISNIS ana UN3031 0 97 GUARDIAN by Generac Power Systems Inc VY PO 297 WHITEWATER WI 53190 www guardiangenerators com P N OF4996 REV O PRINTED IN THE USA 1 05
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51. E The glow plugs can be damaged by exces sive use of the preheat switch Press the preheat switch for 30 seconds or less to prevent such damage PROCEDURE 1 Set a VOM to read battery voltage 12 VDC 2 Connect the positive meter test lead to the Wire 15 terminal of the Pre Heat Switch leave Wire 15 connected to the switch Connect the negative meter test lead to ground The meter should indicate battery voltage 3 Connect the positive meter test lead to the Wire 150 termi nal of the Pre Heat Switch the negative meter test lead to frame ground a With the Pre Heat Switch NOT actuated no voltage should be indicated b Actuate the switch to its PRE HEAT position and the meter should read battery voltage 4 Set VOM to measure ohms 5 Connect the positive meter test lead to the Wire 150 termi nal of the Pre Heat Switch leave Wire 150 connected to the switch Connect the negative meter test lead to a clean frame ground Continuity should be measured Figure 7 10 Pre Heat Switch RESULTS 1 If battery voltage is not indicated in Step 2 and the battery and fuse are both good Wire 15 will need to be checked for an open condition 2 If Infinity is measured in Step 5 Wire 150 will need to be replaced 3 If battery voltage is not present in Step 3 replace the switch 4 f battery voltage is present in Step 3 proceed to the next test in the Flow Chart TEST 20
52. Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 otart Stop Switch 2 1 Cover Engine Control Box 3 1 4 1 Fuse Holder SFE 14 5 1 Switch Pushbutton SPST 6 2 PPHMS M3 0 5 x 10 7 2 Lockwasher M3 8 1 Fuse SFE 14 9 1 Decal 10 1 Boot Nut Preheat Switch 11 4 Lockwasher M5 12 1 Boot Circuit Breaker 13 1 Harness 14 2 Hex Nut M3 15 1 Box Engine Control 16 1 Frame Control Panel 17 1 Plug Oil Fill 18 1 Dipstick Assembly 19 1 Hose Dipstick Tube 20 1 Hose Filler Tube 21 2 Hose Clamp 7 8 3 8 22 2 Hose Clamp 5126 16 23 4 4 0 7 x 16 HHCS Taptite 24 4 Washer Flat 6 25 1 Grommet 26 2 Gasket Engine Control Box 27 1 Circuit Breaker 35A 2 Pole 28 2 Nut Hex M6 1 0 29 4 PHMS 5 0 8 x 12 30 4 Flatwasher 8 31 2 Washer Split Lock 14 M6 32 4 Screw PPHM 46 39 x 1 4 33 1 Gasket Hourmeter 34 1 Gasket Switch Page 75 Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Camshaft Drawing No 075677 E EON d pa 15555 e AES SESCH DS FT YN SH gt s SE zc d NI 13 12 QTY 1 1 1 1 3 1 1 1 1 1 1 1 1 O 01 50 Page 76 DESCRIPTION CAMSHAFT ASSEMBLY CAMSHAFT GEAR KEY GEAR SPACER BALL BEARING SLIDER PLATE TACHOMETER SHAFT BOLT BOLT GASKET NUT Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Cylinder Block Drawing No 075676 23
53. F8 FUEL SOLENOID FP FUEL PLIMP GP GLOW PLUGS HM HOURMETER HWT WATER TEMP SWITCH 12 VDC SUPPLY 12 VDC CONTROL VOLTAGE REGULATOR DC OUTPUT AC POWER GROUND LOS LOW PRESSURE SWITCH PHC PREHEAT CONTACTOR 1 RESISTOR 1 OHM 25W R2 RESISTOR 20 OHM 12W 8 8 SC START CONTACTOR SW PREHEAT SWITCH SW SWITCH START STOP Section 5 ENGINE DC CONTROL SYSTEM 15 17 14 150 181 AA X REMOTE START STOP CONNECTION 1 CIRCUIT CONDITION FAULT SHUTDOWNS The engine has mounted to it a HIGH WATER TEM PERATURE SWITCH HWT and a LOW OIL PRES SURE SWITCH LOS While running ENGINE CONTROL circuit board action keeps Terminal 12 Wire 85 energized with battery voltage Connected in parallel to Wire 85 are the LOW OIL PRESSURE SWITCH LOS and HIGH WATER TEMP SWITCH HWT The LOS has normally closed contacts After start up engine oil pressure will open the con tacts The HWT has normally open contacts High coolant temperature will close the contacts Should engine water temperature exceed a preset value the switch contacts will close Wire 85 from the 150 circuit board will connect to ground Circuit board action will then initiate a shutdown Should engine oil pressure drop below a safe pre set value the switch contacts will close On contact closure Wire 85 will be connected to ground and circuit board action will initiate an engi
54. H aud b 29 ISNA 60 YT LT 11 5 1 15 4015 5 9 TANA TANA MOILSAdIG TIO 1114 LNVT OOS imd de YALAN 28 F1 Core 71991 ALIAVAD JO M3INS3O BST lu 162 51 EF LET o o HHAOO lt SSHOOV HHAOO lt 65820 ONILAIT Q Q 88 Type of Engine ENGINE SPECIFICATIONS Section 10 SPECIFICATIONS amp CHARTS ISM Diesel Oylinder Arrangement 3 in line Displacement 58 2 in 954 cc Bore 2 95 in 75 mm Stroke 2 83 in 72 mm Compression Ratio 23 to 1 Combustion Chamber Type Pre Combustion Rated Horsepower 13 9 1 950 rpm Cylinder Block Cast Iron Number of Main Bearings 4 Number of Teeth on Flywheel 104 Type of Governor Mechanical Fixed Speed Fuel Filter Full Flow Spin On Oil Filter Full Flow with Bypass Valve Oil Pressure 29 71 psi Type of Cooling System Pressurized Closed Recovery Cooling Method Liquid cooled Type of Cooling Fan Centrifugal Puller Cooling System Capacity 1 4 U S gals 5 3 L Air Cleaner Disposable Filter Part C4880 Starter 12 volt DC Electric Recommended Battery 70 Ah 360 Cold cranking Amps Minimum ratings Maximum Cranking Current 220 Amps
55. HCS M8 1 25 x 16 25 2 Flatwasher 5 16 26 1 Manifold Gasket 27 1 Horizontal Exhaust Manifold 28 1 Grommet 1 3 4 x 1 8 x 2 29 1 WASHER FLAT 0 336 ID X 0 876 OD Page 71 Section 9 Exploded Views Part Numbers Fuel and Electrical Systems Drawing No 0D2363 C TO STARTER MOTOR BOLT TO STARTER MOTOR TO GLOW PLUGS Page 72 Section 9 Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 Fuel Pump Assembly 2 3 1 8 NPT x 5 16 Barbed Straight Fitting 3 2 Bulkhead Adaptor Fitting 4 Washer Split Lk 14 M6 5 1 HHCS M6 1 00 x 30 6 2 Relay Solenoid 7 5 Nut Hex 6 1 8 1 Clamp Vinyl Coat 1 1 16 9 5 Washer Flat M6 10 2 Hose Clamp 11 1 1 8 NPT x 1 4 Barbed Straight Fitting 12 3 Hose Clamp 7 8 3 8 13 1 5 6 1 00 16 14 1 Hex Nut 3 8 16 Brass 15 1 Washer Split Lk 3 8 16 3 Boot Battery Cable 17 d Boot Battery Cable 18 2 Bushing 1 19 1 Hex Nut 20 20 1 Cable Battery 21 1 Cable Starter 22 1 HHCS M6 1 x 65 23 1 Wire Assembly Black 84 Ground 24 1 Resistor 25 1 04M Hose 1 4 ID SAE 30R7 26 635mm Hose 5 16 ID SAE 30R7 27 375mm Hose 5 16 ID SAE 30R7 28 1 Clamp Fuel Pump 29 1 Wire Assy 0 PHC SC M Meters mm Millimetres Page 73 Section 9 Exploded Views Part Numbers Customer Controls Assembly Drawing No 0D2364 D Page 74 Section 9
56. INIMUM acceptable megger reading for Stators may be calculated using the following formula EXAMPLE Generator is rated at 120 VAC Divide 120 by 1000 to obtain 0 12 Then add 1 to obtain 1 12 megohms Minimum insulation resistance for 120 VAC Stator is 1 12 megohms If the Stator insulation resistance is less than the cal culated minimum resistance clean and dry the Stator Then repeat the test If resistance is still low replace the Stator Use the Megger to test for shorts between isolated windings as outlined Stator Insulation Resistance Also test between parallel windings See Test Between Parallel Windings on this page TESTING ROTOR INSULATION Apply a voltage of 1000 volts across the Rotor posi tive slip ring nearest the rotor bearing and a clean frame ground i e the Rotor Shaft DO NOT EXCEED 1000 VOLTS AND DO NOT APPLY VOLT AGE LONGER THAN ONE SECOND FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY ROTOR MINIMUM INSULATION RESISTANCE 1 5 megohms Section 4 MEASURING ELECTRICITY METERS Devices used to measure electrical properties are called meters Meters are available that allow one to measure a AC voltage b DC voltage c AC fre quency and d resistance in ohms The following apply To measure AC voltage use an AC voltmeter To measure DC voltage use a DC voltmeter Use a frequency meter to measure AC frequency in Hertz or cycles per se
57. INSULATION RESISTANCE TESTS 12 14 EFFECTS OF DIRT AND MOISTURE 12 INSULATION RESISTANCE TESTERS 12 DRYING THE GENERATOR aasa 12 CLEANING THE GENERATOR 12 STATOR INSULATION RESISTANCE 13 TESTING ROTOR INSULATION 14 THE MEGOHMMETER 14 SECTION 4 MEASURING ELECTRICITY 15 17 AA OR 15 20 25 21101 0 15 MEASURING AC VOLTAGE 15 MEASURING DG VOLTAGE 15 MEASURING AC FREQUENCY 16 MEASURING CURRENT a potuere roses Re 16 MEASURING RESISTANCE 16 ELECTRICAL UNITS 17 OAM S LAW RR 17 SECTION 5 ENGINE DC CONTROL SYSTEM 18 28 INTRODUCTION 18 OPERATIONAL ANALYSIS 18 23 ENGINE CONTROLLER CIRCUIT BOARD 24 BATTERY enee d ss 2212 44 4442442444424444244644414 4 1 24 4 AMP FUSE Rem 26 PRE HEAT SWITCH E 26 STARI STOP SWITCH ME 26 STARTER CONTACTOR 8 MOTOR 26 Table of Contents ENGINE GOVERNOR ssaseiinnsssanuteavcsapnniiensiunotondmesaneantnnns 27 FUEL INJECTION PUMP
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59. OLTAGE REGULATOR BATTERY CHARGE RECTIFIER BOW BATTERY CHARGER CB1 CIRCUIT BREAKER 35 CB CIRCUIT BREAKER SA D1 DIODE 600V 12 VDC SUPPLY D2 DIODE 800V DPE EXCITATION WINDING 12 VDC CONTROL FS FUEL SOLENOID VOLTAGE REGULATOR E e DC OUTPUT HWT HIGH WATER TEMP SWITCH LOS LOW OIL PRESSURE SWITCH 44A AC POWER BI REESE 1 ale R2 RESISTOR 20 12W NEL M GROUND 9 ed 9 START CONTACTOR E 8W PREHEAT SWITCH 240V 7 2 120v Ch SW1 SWITCH START STOP 120V 2 2 11 22 33 19 Section 5 ENGINE DC CONTROL SYSTEM 11A 22 33 1 OUTPUT CUSTOMER CONNECTION T3 T1 T2 T 240V LU 120 20 om 17 14 150 18 REMOTE START 1 STOP CONNECTION SEE WIRING DIAGRAM CIRCUIT CONDITION CRANKING When the START STOP SWITCH SW1 or REMOTE PANEL START STOP SWITCH is held at START position Wire 17 from the Engine Control circuit board is connected to Ground Engine control circuit board action will then deliver battery voltage to a STARTER CONTACTOR 50 via Terminal 7 Wire 56 The STARTER CONTACTOR SC energizes and its contacts close battery output is delivered to the STARTER MOTOR SM via Wire 16 The STARTER MOTOR energizes and the engine cranks Also while cranking engine control circuit board action energizes Terminals 9 10 and 11 wh
60. R FUNCTIONS REPLACE FUSES THEN RETEST TEST 11 CHECK ROTOR BAD ASSEMBLY TEST 7 TEST TEST 8 CHECK EITHER OR REPAIR REPAIR STATOR DPE SENSING LEADS gt OR OR WINDING POWER WINDINGS REPLACE PERFORM BOTH TEST 7 amp 8 REPLACE INSULATION A GOOD INSULATION Ly RESISTANCE BAD RESISTANCE BAD TEST PAGE 14 TEST PAGE 13 Problem 3 No Battery Charge Output TEST 15 TEST 16 TEST 17 CHECK CHECK CHECK BATTERY CHARGE BATTERY BAD BATTERY WINDING CHARGE BATTERY CHARGE RECTIFIER RESISTOR CHARGE OUTPUT GOOD BAD BAD REPLACE REPAIR FINISHED OR REPLACE INSULATION REPAIR GOOD RESISTANCE BAD mali OR TEST PAGE 13 REPLACE Page 31 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 4 Excessive Voltage Frequency Droop When Load is Applied TEST 13 TEST 14 CHECK CHECK LOAD BAD LOAD WATTS amp NOT OVERLOADED VOLTAGE amp AMPERAGE FREQUENCY GOOD OVERLOADED REDUCE LOAD END TEST TEST 2 CHECK ADJUST ENGINE GOOD GO TO PROBLEM 8 GOVERNOR Problem 5 Pre Heat Function Does Not Work TEST 18 TRY ENGINE TEST 19 TEST CRANKING CRANKS PRE HEAT THE ENGINE NORMALLY SWITCH WON T CRANK 1 REPLACE BAD lt BAD GO TO PROBLEM 6 SWITCH BAD TEST 32 TEST BAD PRE HEAT CONTACTOR TEST 33 TEST REPLACE BAD DIODE 005 OR WIRES GLOW PLUGS BAD GOOD BUT FUEL
61. RTER CONTACTOR SC which then de ener gizes the SC to end cranking While running engine control circuit board action keeps Terminals 9 10 and 11 energized which deliv ers battery voltage to the Wire 14 circuit This ener gizes the FUEL PUMP FP FUEL SOLENOID FS HOURMETER HM and optional light or hourmeter in remote panel This will maintain engine operation While running engine control circuit board action keeps Terminal 12 Wire 85 energized with battery voltage Connected in parallel to Wire 85 are the LOW OIL PRESSURE SWITCH LOS and HIGH WATER TEMP SWITCH HWT The LOS has nor mally closed contacts After start up engine oil pres sure will open the contacts The HWT has normally open contacts High coolant temperature will close the contacts Refer to Circuit Condition Fault Shutdown for operation 14 A voltage is induced into the Stator s POWER WIND ING This voltage is delivered to the Engine control circuit board Terminals 5 amp 6 via Wires 22 amp 44 The engine control circuit board uses this frequency o signal to determine engine speed for overspeed sensing and starter disengage 4 10 16 17 14 150 18 1 i REMOTE START STOP CONNECTION 777 SEE WIRING DIAGRAM FOR DETAILS LEGEND AVR AUTOMA TIC VOLTAGE REGULATOR BCR BATTERY CHARGE RECTIFIER BCW CHARGER CB1 CIRCUIT BREAKER 35A CB CIRCUIT BREAKER 4A DH DIODE 80
62. Starter Motor did not operate remove and bench test the Starter Motor see fol lowing test 2 f battery voltage was indicated and the Starter Motor tried to engage pinion engaged but engine did not crank check for mechanical binding of the engine or rotor If engine turns over slightly go to Test 35 Check and Adjust Valves NOTE If a starting problem is encountered the engine itself should be thoroughly checked to eliminate it as the cause of starting difficulty It is a good practice to check the engine for freedom of rotation by removing the spark plugs and turn ing the crankshaft over slowly by hand to be sure it rotates freely WARNING DO NOT ROTATE ENGINE WITH ELECTRIC STARTER WITH SPARK PLUGS REMOVED ARCING AT THE SPARK PLUG ENDS MAY IGNITE THE GASOLINE VAPOR EXITING THE SPARK PLUG HOLE CHECKING THE PINION When the Starter Motor is activated the pinion gear should move and engage the flywheel ring gear If the pinion does not move normally inspect the pinion for binding or sticking PINION CIL Figure 7 15 Check Starter Pinion TOOLS FOR STARTER PERFORMANCE TEST The following equipment may be used to complete a performance test of the Starter Motor clamp on ammeter A tachometer capable of reading up to 10 000 rpm A fully charged 12 VDC battery MEASURING CURRENT To read the current flow in AMPERES a clamp on ammeter may be used This type of meter indic
63. TS INSTALL NEW 14 AMP FUSE FUSE IS GOOD BUT BLOWS WHEN START STOP SWITCH IS PRESSED TEST 41 CHECK WIRE 14 AND CONNECTING COMPONENTS FOR SHORT TO GROUND GOOD TEST 42 CHECK WIRE 56 AND STARTER CONTACTOR FOR SHORT TO GROUND BAD REPLACE BAD WIRE 36 Problem 9 14 Amp F1 Fuse Blowing REMOVE REMOTE START STOP FUSE BLOWS HARNESS FUSE GOOD REPAIR OR REPLACE BAD P HARNESS CHECK THAT FUSE REPLACE HOLDER 4 amp FAIL HOLDER IS NOT GROUNDED REPLACE FAILED PASS BAD WIRE OR COMPONENTS DISCONNECT REPLACE FUSE GOOD WIRE 15 FROM PCB PIN 1 ON PCB FUSE BLOWS GOOD TEST 43 CHECK ee 4 FUSE WIRE 15 FOR SHORT TO GROUND CHECK REMOTESTART ST OP HARNESS FOR FUSE BLOWS SHORT TEST 16 CHECK lt RECTIFIER Section 7 DIAGNOSTIC TESTS INTRODUCTION The Diagnostic Tests in this chapter may be per formed in conjunction with the Charts of Section 6 Test numbers in this chapter correspond to the numbered tests in the Charts Tests 1 through 17 are procedures involving problems with the generator s AC output voltage and frequency Problems 1 through 4 in the Flow Charts Tests 18 through 42 are procedures involving prob lems with engine operation Problems 5 through 9 in the Troubleshooting Flow Charts Heview and
64. UBING 29 1 SCREW 12 1 TUBING AR AS REQUIRED Page 82 Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Fuel Supply Drawing No 075693 14 10 To Fuel 14 Tank Return 45 sa 14 1 10 9 ni s D 9 19 15 1 13 Model 04270 amp 04614 v 8 6 0 2 To Injection Pump 3 To Fuel Pump ITEM DESCRIPTION ITEM DESCRIPTION 1 1 FUEL FILTER SUPPORT 11 pos 1 8 NPT x 3 16 BARBED STRAIGHT 2 1 FUEL FILTER FITTING 3 AR HOSE 5 16 SAE 30R7 12 275MM HOSE 3 16 SAE 3082 4 250MM HOSE 5 16 SAE 30R7 13 240MM HOSE 3 16 SAE 3082 5 3 HOSE CLAMP 14 4 HOSE CLAMP 6 2 GASKET 15 1 FUEL BLEED FITTING 7 1 BANJO FITTING 16 5 FUEL BLEED GASKET 8 1 FUEL BLEED FITTING 17 2 HOLLOW BOLT 9 2 1 8 NPT TEE BRASS 18 2 BANJO FITTING 10 2 1 8 NPT x 3 16 90 DEG BARBED 19 1 1 8 NPT x 1 4 BARBED STRAIGHT FITTING FITTING MODEL 04270 amp 04614 QTY 1 MODEL 04270 amp 04614 AR AS REQUIRED Page 83 Section 9 Exploded Views Part Numbers 1 0 Liter Diesel Timing and Governor Drawing No 082067 Model 04270 amp 04614 amp N 5 Page 84 Section 9 Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 HOUSING TIMING GEAR 2 1 SPRING PIN 3 1 GASKET 4 1 SPRING 5 1 WASHER 6 2 NUT 7 1 STOP LEVER 8 2 COVER 11 1 GOVERNOR LEVER 12 1 BOLT 13 1 NUT 14 1 SHAFT 15 1 O RING 16 1 SNAP RING
65. apply the voltage longer than one 1 second CAUTION DO NOT connect the Hi Pot Tester or Megohmmeter test leads to any leads that are routed into the generator control panel Connect the tester leads to the Stator or Rotor leads only SHORT TO GROUND TESTS See Figure 3 2 To test the Stator for a short to ground condition proceed as follows 1 Disconnect and isolate all Stator leads as follows a Disconnect sensing leads 11 and 22 from the voltage regulator b Disconnect excitation winding lead No 6 from the voltage regulator Disconnect excitation lead No 2 from the excitation circuit breaker CB2 d Disconnect battery charge winding leads No 66 and 77 from the battery charge recti fier BCHR e Disconnect battery charge winding lead No 55 from the battery charge resistor R1 f main circuit breakers disconnect sta tor power leads No 11P and 33 g At the ground stud GND5 disconnect Stator power leads No 22 and 33 2 When all leads have been disconnected as outlined in Step 1 above test for a short to ground condition as follows Connect the terminal ends of all Stator leads together 11 22 33 44 2 6 55 66 77 b Follow the tester manufacturer s instructions carefully Connect the tester leads across all Stator leads and to frame ground on the Stator can Apply a voltage of 1500 volts Do NOT apply voltage longer than one 1 second If the test
66. ates current flow through a conductor by measuring the strength of the magnetic field around that conductor Page 49 Section 7 DIAGNOSTIC TESTS CONDUCTOR CLAMP ON AMMETER ATTACHMENT on Oo T7 MIT po 7 4 M SIT Figure 7 16 Clamp On Ammeter TACHOMETER A tachometer is available from your Generac Power Systems source of supply Order as P N 042223 The tachometer measures from 800 to 50 000 RPM see Figure 7 17 Figure 7 18 Test Bracket Page 50 TEST BRACKET A starter motor test bracket may be made as shown in Figure 7 18 REMOVE STARTER MOTOR It is recommended that the Starter Motor be removed from the engine when testing Starter Motor perfor mance Assemble starter to test bracket and clamp test bracket in vise Figure 7 19 TESTING STARTER MOTOR 1 A fully charged 12 battery is required 2 Connect jumper cables and clamp on ammeter as shown in Figure 7 19 3 With the Starter Motor activated jump the terminal on the Starter Contactor to battery voltage note the reading on the clamp on ammeter and on the tachometer rpm Note Take the reading after the ammeter and tachometer are stabilized approximately 2 4 seconds 4 starter motor in good condition will be within the following specifications Minimum rpm 4500 Maximum Amps 50 Note Nominal amp draw of starter in generator is 60 amps
67. ation Test Rotor Amp Draw 38 39 TEST 5 Lures 39 TEST 6 Check Field Boost LNAG 39 40 TEST 7 Test Stator Winding 40 41 TEST 8 Check Sensing Leads Power Windings 41 TEST 9 Check Brush Leads 41 42 Page 1 Table of Contents TEST 10 TEST 35 Check Brushes A Slip Rings 42 Check Valve Adjustment 59 TEST 11 TEST 36 Check Rotor Assembly 42 43 Fuel Injector Pump 53 54 TEST 12 TEST 37 Check Main Circuit Breaker 43 Check Engine Cylinder Leak Down Test TEST 13 Compression Test 54 55 Check Load Voltage amp Frequency 43 TEST 38 TEST 14 Check Oil Pressure Switch 99 Check Load Watts amp Amperage 43 TEST 39 TEST 15 Check Circuit Board for Ground 55 Check Battery Charge Output 43 44 TEST 40 TEST 16 Test Water Temperature Switch 55 56 Check Battery Charge Rect
68. b forced air HEATING UNITS If drying is needed the generator can be enclosed in a covering Heating units can then be installed to raise the temperature about 15 18 8 10 above ambient temperature FORCED AIR Portable forced air heaters can be used to dry the generator Direct the heated air into the generator s air intake openings Remove the voltage regulator and run the unit at no load Air temperature at the point of entry into the generator should not exceed 150 F 66 C CLEANING THE GENERATOR GENERAL The generator can be cleaned properly only while it is disassembled The cleaning method used should be determined by the type of dirt to be removed Be sure to dry the unit after it has been cleaned NOTE A shop that repairs electric motors may be able to assist you with the proper cleaning of gen erator windings Such shops are often experi enced in special problems such as a sea coast environment marine or wetland applications mining etc USING SOLVENTS FOR CLEANING If dirt contains oil or grease a solvent is generally required Only petroleum distillates should be used to clean electrical components Recommended are safety type petroleum solvents having a flash point greater than 100 F 38 CAUTION Some generators may use epoxy or polyester base winding varnishes Use sol vents that will not attack such materials Use a soft brush or cloth to apply the solvent Be care
69. back to previ ous test on flow chart 4 f continuity is measured in step 9 replace solenoid 5 If 12 4 ohms was measured in step 9 proceed to next test on flow chart TEST 32 TEST PREHEAT CONTACTOR DISCUSSION If battery voltage is available to the preheat contactor via Wire 150 and the glow plugs and fuel pump do not work a possibility could be a failed contactor PROCEDURE 1 Set a VOM to measure continuity 2 Disconnect Wire 0 from the preheat contactor 3 Place one test lead on the previously disconnected Wire 0 and the other to clean ground Continuity should be measured 4 Set a VOM to measure resistance 5 Disconnect Wire 150 and 0 from the preheat contactor front terminals 6 Place one test lead to the terminal where Wire 150 was previ ously disconnected and the other test lead where Wire 0 was previously disconnected 7 Place a jumper lead from Wire 15 battery positive to the ter minal where Wire 150 was previously Prime function should occur RESULTS 1 If infinity is measured in step 3 repair or replace Wire 0 and retest Page 52 2 11 resistance is incorrect in step 6 then replace preheat contacior 3 If prime function did not occur in step 7 and resistance was incorrect in step 6 proceed to next test on flow chart TEST 33 TEST GLOW PLUGS DISCUSSION Once the preheat contactors contacts close positive battery voltage from Wire 13 to Wire 157 will power the glow
70. battery may be considered fully charged when the specific gravity of its electrolyte is 1 260 If the hydrometer used does not have a Percentage of Charge scale compare the readings obtained with the following PERCENTAGE OF CHARGE CHARGING A BATTERY Use an automotive type battery charger to recharge a battery Battery fluid is an extremely corrosive sulfu ric acid solution that can cause severe burns For that reason the following precautions must be observed e The area in which the battery is being charged must be well ventilated When charging a battery an explosive gas mixture forms in each cell Do not smoke or break a live circuit near the top of the battery Sparking could cause an explosion Avoid spillage of battery fluid If spillage occurs flush the affected area with clear water immediately Wear eye protection when handling a battery Page 25 Section 5 ENGINE DC CONTROL SYSTEM 14 AMP FUSE This panel mounted Fuse protects the DC control cir cuit against overload and possible damage If the Fuse has melted open due to an overload neither the priming function nor the cranking function will be available Figure5 4 PREHEAT SWITCH The diesel engine is equipped with glow plugs one for each cylinder When the preheat switch is pressed voltage will go through the switch to the pre heat contactor The preheat contactor normally open now closes allowing battery voltage to go to the g
71. become familiar with Section 4 Measuring Electricity NOTE Test procedures in this Manual are not nec essarily the only acceptable methods for diagnos ing the condition of components and circuits All possible methods that might be used for system diagnosis have not been evaluated If any diagnos tic method other than the method presented in this Manual is utilized ensure that neither personnel safety nor the product s safety will be endangered by the procedure or method utilized TEST 1 CHECK NO LOAD VOLTAGE AND FREQUENCY DISCUSSION The first step in analyzing any problem with the AC generator is to determine the unit s AC output voltage and frequency PROCEDURE 1 Set a volt ohm milliammeter VOM to read AC voltage Connect the meter test leads across customer connection leads T1 Red and T2 White 2 Disconnect or turn OFF all electrical loads Initial checks and adjustments are accomplished at no load 3 Start the engine let it stabilize and warm up 4 Read the AC voltage 5 Connect an AC frequency meter across AC output leads T1 Red and T2 White on the customer connection Repeat the above procedure RESULTS For units rated 60 Hertz no load voltage and frequen cy should be approximately 122 126 VAC and 61 63 Hertz respectively 1 If AC voltage and frequency are BOTH correspondingly high or low go to Test 2 2 f AC frequency is good but low or residual voltage is indicated go to T
72. cal 15 1 Gasket Electrical Access 16 33 Washer Self Locking 17 57 14 20 x 5 8 W Washer 18 1 Frame Control Panel Refer to Drawing C8005 19 1 Decal Battery 20 1 Decal Radiator Cap 21 1 Decal Remote 22 1 Decal Coolant 23 1 Decal Fuel Return Supply 24 1 Decal Oil Fill Level 20 1 Decal Lifting Lug 26 1 Decal Hot Min Coolant 27 1 Decal Warning Rv 28 1 Support Coolant Tank 29 3 Nut Hex M6 1 0 30 1 Foam Air Duct Face 31 1 Foam Air Duct Side 32 1 Decal Unit 33 3 Washer Split Lock 1 4 M6 34 1 Decal Engine Data 25 1 Decal CSA Approval 36 2 Washer Nylon 0 250 37 2 Screw SW 14 20 X 3 8 Long 38 1 Clamp Vinyl 1 5 X 0 281 Page 65 Exploded Views Part Numbers Cooling System Drawing No 0D2360 B Section 9 gG NA 2 m ZI Page 66 Section 9 Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 Cover Plate Scroll Weldment 2 1 Housing Fan Scroll Weldment 3 1 Fan Squirrel Cage 4 1 Shaft Fan 5 1 Carrier Bearing 6 1 Key Square 3 16 x 3 16 12 7 1 Pulley Fan 4 7 8 8 1 Bearing 2 Row Ball 9 1 Fender Washer M16 10 1 Nut Hex M16 0 1 5mm 11 1 LockWasher M16 0 12 7 Crimptite 14 20 x 5 8 13 2 HHCS M6 1 00 x 10mm 14 7 Washer Split Lk 14 M6 15 4 HHCS M5 0 8 x 16mm 16 4 Washer Split Lk 10 17 4 Hex Nut M5 18 12 Nut Top Lock Flange M6 1 0 19 1 Radiator 1 0L RV 20 3 HHCS M6 1 00 x 12mm 21 5 Washer 4 M6 22 1 Pulley 3 Flat
73. cal loads are applied to the generator the load voltage and frequency should be checked PROCEDURE Perform this test in the same manner as Test 1 but apply a load to the generator equal to its rated capac ity With load applied check voltage and frequency Frequency should not drop below about 58 Hertz with the load applied Voltage should not drop below about 115 VAC with load applied RESULTS 1 If voltage and or frequency drop excessively when the load is applied go to Test 14 2 f load voltage and frequency are within limits end tests TEST 14 CHECK LOAD WATTS amp AMPERAGE DISCUSSION This test will determine if the generator s rated wattage amperage capacity has been exceeded Continuous electrical loading should not be greater than the unit s rated capacity PROCEDURE Add up the wattages or amperages of all loads pow ered by the generator at one time If desired a clamp on ammeter may be used to measure current flow See Measuring Current on Page 16 RESULTS 1 If the unit is overloaded reduce the load f load is within limits but frequency and voltage still drop excessively complete Test 2 Check Adjust Engine Governor If governor adjustment does not correct the problem go to Problem 8 Flow Chart Page 35 TEST 15 CHECK BATTERY CHARGE OUTPUT DISCUSSION The Battery Charge system consists of a center tap Battery Charge Winding a Battery Charge Rectifier and
74. causing the unit to stop WIRE 0 Connects the switch to ground 17 START SW1i o 0 18 Lo STOP 18 0 Schematic B Pictorial Figure 5 6 Start Stop Switch STARTER CONTACTOR amp MOTOR 0 TO BATTERY GROUND Figure 5 7 Starter Contactor and Connections Section 5 ENGINE DC CONTROL SYSTEM The positive battery cable 13 attaches to one of the outer posts of the contactor along with Wire 13 for the DC supply to the fuse F1 The starter cable 16 attaches to the remaining outer post Attached to the small 2 lugs are Wires 56 and 0 When the start stop switch is set to start the circuit board delivers battery voltage to the contactor coil via Wire 56 The contac tor energizes and its contacts close Battery voltage is then delivered from the positive battery cable across contacts and to the starter motor via Wire 16 ENGINE GOVERNOR A mechanical all speed governor is used on the diesel engine lt is housed in the gear case A fly weight movement is transmitted to the injection pump control rack by way of the slider control lever and link A spring is attached to the arm and the tension lever The spring regulates flyweight movement By changing the set angle of the governor lever tension on the tension lever spring is changed In this man ner engine speed can be regulated by the governor lever The generators A C output frequency is
75. cond Use an ohmmeter to read circuit resistance in ohms THE VOM A meter that allows both voltage and resistance to be read is the volt ohm milliammeter or VOM Some VONM s are of the analog type not shown These meters display the value being measured by physically deflecting a needle across a graduated scale The scale used must be interpreted by the user Digital VOM s Figure 4 1 are also available and are generally very accurate Digital meters display the measured values directly by converting the values to numbers NOTE Standard AC voltmeters react to the AGE value of alternating current When working with AC the effective value is used For that son a different scale is used on an AC voltmeter The scale is marked with the effective or rms value even though the meter actually reacts to the average value This is why the AC voltmeter will give an incorrect reading if used to measure direct current DC Figure 4 1 Digital VOM MEASURING AC VOLTAGE An accurate AC voltmeter or a VOM can be used to read the generators AC output voltage The following apply 1 Always read the generator s AC output voltage only at the unit s rated operating speed and AC frequency 2 The generator s voltage regulator can be adjusted for correct output voltage only while the unit is operating at its correct rated speed and frequency 3 Only an AC voltmeter may be used to measur
76. connect Wire 162 from the Voltage Regulator sixth terminal from the top Disconnect the other end of this wire from the Excitation Circuit Breaker CB2 Connect one test lead to one end of Wire 162 and the other test lead to the other end of the same wire The meter should read continuity RESULTS If continuity was NOT measured across each wire repair or replace the wires as needed If continuity WAS measured proceed to Test 6 TEST 6 CHECK FIELD BOOST DISCUSSION Field boost current is delivered to the Rotor only while the engine is being cranked This current helps ensure that adequate pickup voltage is available to turn the Voltage Regulator on and build AC output voltage Loss of the field boost function may or may not result in a problem with AC output voltage If the Rotor s residual magnetism is sufficient to turn the Regulator on loss of the function may go unnoticed However if the Rotor s residual magnetism is not enough to turn the Regulator on loss of field boost can result in fail ure of the unit to generate an output voltage PROCEDURE 1 Set VOM to measure DC voltage 2 Disconnect Wire 4 from the Voltage Regulator and connect the positive 4 test lead to it Connect the negative test lead to a clean frame ground Page 39 Section 7 DIAGNOSTIC TESTS 3 Set the Start Stop Switch to START During cranking only measure DC voltage It should read 3 5 VDC Reconnect Wire 4 to the Voltage R
77. ctor pump is assumed to being faulty remove the fuel lines going to the nozzle injectors 2 Prime the engine for 15 20 seconds 3 Crank the engine and watch to see if fuel is coming out of the fuel lines CAUTION Fuel is hazardous NOTE Bleeding the fuel injector pump takes time Crank the engine for 15 second intervals for as long as 5 minutes 4 f no fuel is coming out remove the four 4 screws mounting the injector pump to the engine 5 Unscrew the fuel solenoid from the side of the injector pump 6 Lift fuel injector pump out and remove one shim 7 Reinstall fuel injector pump and retaining screws Page 53 Section 7 DIAGNOSTIC TESTS 8 Crank engine again and see if fuel is coming out of the fuel lines RESULTS 1 If no fuel is noted in Steps 3 or 8 replace fuel injector pump Reinstallation of all original shims will be required 2 f fuel is noted proceed to next step in flowchart TEST 37 CHECK ENGINE CYLINDER LEAK DOWN TEST COMPRESSION TEST GENERAL Most engine problems may be classified as one or a combination of the following Will not start Starts hard Lack of power Runs rough Vibration Overheating High oil consumption DISCUSSION The Cylinder Leak Down Tester checks the sealing compression ability of the engine by measuring air leakage from the combustion chamber Compression loss can present many different symptoms This test is designed to detect th
78. current Select the battery cables based on total cable length and prevailing ambient temperature Generally the longer the cable and the colder the weather the larg er the required cable diameter The following chart applies CABLE LENGTH IN FEET EFFECTS OF TEMPERATURE Battery efficiency is greatly reduced by a decreased electrolyte temperature Such low temperatures have a decided numbing effect on the electrochemical action Under high discharge rates such as crank ing battery voltage will drop to much lower values in cold temperatures than in warmer temperatures The freezing point of battery electrolyte fluid is affected by the state of charge of the electrolyte as indicated below SPECIFIC GRAVITY FREEZING POINT 1 220 35 F 37 C 20 29 C ADDING WATER Water is lost from a battery as a result of charging and discharging and must be replaced If the water is not replaced and the plates become exposed they may become permanently sulfated addition the plates cannot take full part in the battery action unless they are completely immersed in electrolyte Add only DISTILLED WATER to the battery DO NOT USE TAP WATER NOTE Water cannot be added to some mainte nance free batteries CHECKING BATTERY STATE OF CHARGE Use an automotive type battery hydrometer to test the battery state of charge Follow the hydrometer manu facturer s instructions carefully Generally a
79. d boost circuit Engine run circuit Delivers 12 VDC during cranking and running Connected to Fuel Pump Fuel Solenoid Hourmeter and field boost circuit Fault shutdown circuit When grounded by High Water Temperature or Low Oil Pressure switch engine will shut down LED FUNCTIONS Green LED will be illuminated when Wire 14 is ener gized during cranking and running LED will be illuminated when Wire 56 is ener gized during cranking only Page 24 OVERSPEED SHUTDOWN POTENTIOMETER The overspeed shutdown potentiometer is used to set the frequency at which the board will initiate a engine shutdown Proper setting of the potentiometer is criti cal to the correct operation of the generator ADJUSTMENT PROCEDURE The overspeed shutdown potentiometer MUST be adjusted on replacement circuit boards If not replacing a board start at STEP 6 1 Remove 14 amp fuse F1 from control panel 2 Disconnect all wires from circuit board terminals 3 Remove old circuit board and install new circuit board 4 Connect all wires to proper circuit board terminals Follow elec trical schematic if needed 5 Reinstall 14 amp F1 fuse into control panel 6 Turn the overspeed shutdown potentiometer slowly counter clockwise until it stops DO NOT FORCE Note If immediate shutdown occurs when the engine starts and the 5 5 switch 15 released reverse overspeed shutdown pot set ting turn p
80. d is mounted to the side of the injector pump Once energized it pulls a plunger in from the fuel injector pump and fuel will be allowed to flow to the injectors If the fuel solenoid is faulty fuel will never flow to the injector pump and the engine won t run PROCEDURE 1 Set a VOM to measure D C voltage 2 Disconnect Wire 14 to the fuel solenoid 3 Place the positive test lead on Wire 14 and the negative test lead on clean ground 4 Press the prime switch battery voltage should be measured measured skip to Step 8 If not proceed to next Step 5 If battery voltage is not measured disconnect other end of Wire 14 going to the printed circuit board on Pin 9 Page 51 Section 7 DIAGNOSTIC TESTS 6 Place test leads on each end of wire continuity should be measured 7 lf continuity is measured test battery voltage on Wire 14 going to circuit board on Pin 10 with prime switch pressed Meter should read battery voltage 8 Set a VOM to measure resistance 9 Place a test lead on the terminal of the fuel solenoid where Wire 14 was previously located Place the other test lead to clean ground meter should read 12 4 ohms RESULTS 1 If battery voltage is not measured in step 4 and continuity is measured in step 6 and battery voltage is measured in step 7 than replace the circuit board 2 f infinity is measured in step 6 replace wire 3 If battery voltage is not measured in step 7 work
81. delivered to the ROTOR is called EXCITATION current STATOR STATOR D A D O O lt BRUSHES SLIP RINGS DC CURRENT Figure 1 6 A More Sophisticated Generator oee Figure 1 7 next page The revolving magnetic field ROTOR is driven by the engine at a constant speed This constant speed is maintained by a mechanical engine governor Units with a 2 pole rotor require an operating speed of 3600 rpm to deliver a 60 Hertz AC output Engine governors are set to maintain approximately 3720 rpm when no electrical loads are connected to the generator TO LOAD ENGINE BELT DRIVE STATOR POWER WINDING so KI x NN 4 m MO va I ka BATTERY CHARGE RECTIFIER CB2 EXCITATION CIRCUIT BREAKER Vi Ws STATOR BATTERY CHARGE WINDING TO BATTERY STATOR POWER WINDING Section 1 GENERATOR FUNDAMENTALS SENSING FIELD BOOST FROM ENGINE CONTROLLER CIRCUIT BOARD BATTERY VOLTAGE VOLTAGE REGULATOR Figure 1 7 Generator Operating Diagram NOTE AC output frequency at 3720 rpm will be about 62 Hertz The No Load is set slightly high to prevent excessive rpm frequency and voltage droop under heavy electrical loading Generator operation may be described briefly as fol lows 1 Some residual magnetism is normally present in the rotor and 15 sufficient to induce approx
82. e unit s rated wattage amperage capacity e40 V 120 120 V 1 Te T3 REDD e BLACK WHITE 11 Be 33 GROUNDED NEUTRAL Figure 1 8 Connection for 120 240 VAC Dual Voltage m 120 V mu 120 V C BLACK GROUNDED 40007 44 JUMPER WIRE Ge Figure 1 9 Connection for 120 VAC Only Dual Circuits Page 7 Section 2 MAJOR GENERATOR COMPONENTS ENGINE BRUSH HOLDER STATOR BEARING BEARING CARRIER FLYWHEEL PULLEY PULLEY Figure 2 1 Exploded View of Generator ROTOR ASSEMBLY The Rotor is sometimes called the revolving field since it provides the magnetic field that induces a voltage into the stationary Stator windings Slip rings on the Rotor shaft allow excitation current from the voltage regulator to be delivered to the Rotor wind ings The Rotor is driven by the engine at a constant speed through a pulley and belt arrangement The QUIETPACT 75D utilizes a 2 pole Rotor This type of Rotor must be driven at 3600 rpm for a 60 Hertz AC output or at 3000 rpm for a 50 Hertz output Slip rings should be cleaned If dull or tarnished clean them with fine sandpaper a 400 grit wet sand paper is recommended DO NOT USE ANY METAL LIC GRIT OR ABRASIVE TO CLEAN SLIP RINGS Page 8 STATOR ASSEMBLY The Stator is assembled between the front and rear bearing carriers and retained in that position by four Stator studs Windings included in t
83. e AC voltage DO NOT USE A DC VOLTMETER FOR THIS PURPOSE DANGER RV GENERATORS PRODUCE HIGH AND DANGEROUS VOLTAGES CON TACT WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSI BLY LETHAL ELECTRICAL SHOCK MEASURING DC VOLTAGE A DC voltmeter or a VOM can be used to measure DC voltages Always observe the following rules 1 Always observe correct DC polarity a Some VOM s may be equipped with a polar ity switch b On meters that do not have a polarity switch DC polarity must be reversed by reversing the test leads 2 Before reading a DC voltage always set the meter to a higher voltage scale than the anticipated reading If in doubt start at the highest scale and adjust the scale downward until correct readings are obtained 3 The design of some meters is based on the current flow theo ry while others are based on the electron flow theory a current flow theory assumes that direct current flows from the positive to the negative b The electron flow theory assumes that current flows from negative to positive NOTE When testing generators the current flow theory is applied That is current is assumed to flow from positive to negative Page 15 Section 4 MEASURING ELECTRICITY MEASURING AC FREQUENCY The generators AC output frequency is proportional to Rotor speed Generators equipped with a 2 pole Rotor must operate at 3600 rpm to supply a fre
84. e and zero the meter 9 Connect the meter test leads across Stator lead 11 and ground Infinity should be read 10 Connect the meter test leads across Stator lead 33 and ground The reading should be Infinity 11 Connect the meter test leads across Stator leads Wire 11 and Wire 33 The reading should be Infinity 12 Connect the meter test leads across Stator leads Wire 11 and Wire 66 The reading should be Infinity 13 Connect the meter test leads across Stator leads Wire 33 and Wire 66 The reading should be Infinity 14 Connect the meter test leads across Stator leads Wire 11 and Wire 2 The reading should be Infinity 15 Connect the meter test leads across Stator leads Wire 33 and Wire 2 The reading should be Infinity RESULTS 1 If the Stator passes all steps except Step 7 repair re connect or replace Sensing leads 11 and 22 2 Replace the Stator if it s power windings fail the test Note Result No 1 3 If the Power Windings test good perform the Insulation Resistance Test on 13 B Pictorial A Schematic Figure 7 5 Stator Power Winding Leads TEST 9 CHECK BRUSH LEADS DISCUSSION In Test 4 if application of battery voltage to the Rotor did NOT result in an output of about one half rated voltage the brush leads could be one possible cause of the problem This test will check Wires 4 and 1 for an open circuit condition PROCEDURE 1 Set a VOM to its
85. e called flux These lines of force are concentrated at the magnet s north and south poles They are directed away from the magnet at its north pole travel in a loop and re enter the magnet at its south pole The lines of force form definite patterns which vary in intensity depend ing on the strength of the magnet The lines of force never cross one another The area surrounding a magnet in which its lines of force are effective is called a magnetic field Like poles of a magnet repel each other while unlike poles attract each other MAGNETIC LINES OF FORCE Figure 1 1 Magnetic Lines of Force ELECTROMAGNETIC FIELDS All conductors through which an electric current is flowing have a magnetic field surrounding them This field is always at right angles to the conductor If a compass is placed near the conductor the compass needle will move to a right angle with the conductor The following rules apply The greater the current flow through the conductor the stronger the magnetic field around the conductor The increase in the number of lines of force is directly proportional to the increase in current flow and the field is distributed along the full length of the conductor The direction of the lines of force around a conduc tor can be determined by what is called the right hand rule To apply this rule place your right hand around the conductor with the thumb pointing in the direction of current flow
86. e section of the engine where the fault lies before disassembling the engine PROCEDURE 1 Remove a fuel injector 2 Gain access to the flywheel Remove the valve cover 3 Rotate the engine crankshaft until the piston reaches top dead center TDC Both valves should be closed 4 Lock the flywheel at top dead center 5 Attach cylinder leak down tester adapter to spark plug hole 6 Connect an air source of at least 90 psi to the leak down tester 7 Adjust the regulated pressure on the gauge to 80 psi 8 Read the right hand gauge on the tester for cylinder pressure 20 percent leakage is normally acceptable Use good judgement and listen for air escaping at the carburetor the exhaust and the crankcase breather This will determine where the fault lies 9 Repeat Steps 1 through 8 on remaining cylinder RESULTS Air escapes at the air intake chamber check intake valve Air escapes through the exhaust check exhaust valve Page 54 Air escapes to the crankcase check piston rings Air escapes from the cylinder head the head gas ket should be replaced CHECK COMPRESSION Lost or reduced engine compression can result in a failure of the engine to start or b rough operation One or more of the following will usually cause loss of compression Blown or leaking cylinder head gasket Improperly seated or sticking valves Worn Piston rings or cylinder This will also result i
87. ead from the outer terminal of SW1 and connect it to the opposite outer terminal Infinity should be measured 6 Leave the test lead connected to the center terminal of SW1 from Step 5 Connect the other test lead to an outer terminal Depress the switch away from the terminal being tested see Figure 7 13 Continuity should be measured Repeat the pro cedure with the test lead connected to the other outer terminal Continuity should be measured INFINITY NOT ACTIVATED INFINITY DEPRESSED AWAY FROM TERMINAL BEING TESTED DEPRESSED AWAY FROM TERMINAL BEING TESTED Figure 7 13 Test 24 Step 6 Page 47 Section 7 DIAGNOSTIC TESTS RESULTS 1 If Continuity is not measured in Step 2 repair reconnect replace Wire 0 between Start Stop Switch and ground termi nal as necessary 2 f engine cranks in Step 3 when Wire 17 is grounded but will not crank when the Switch is set to START replace the Start Stop Switch 3 If the Start Stop Switch SW1 failed any part of Steps 5 or 6 replace the switch 4 f engine will not crank when Wire 17 is grounded proceed as follows a Use a jumper wire to connect the circuit board s Wire 17 Pin Location 3 to ground engine does NOT crank proceed to Test 25 DH engine cranks now but would not crank in Step 3 of the procedure check Wire 17 for con tinuity between the circuit board and Start Stop owitch If Continuity is not m
88. easured repair or replace Wire 17 between the engine control board and the Start Stop Switch 5 For Problem 9 Section 6 if switch tests GOOD go to Test 30 TEST 25 CHECK POWER SUPPLY TO WIRE 56 DISCUSSION If battery voltage is available to the Engine Controller board in Test 23 then DC voltage should be deliv ered to Wire 56 when the Start Stop Switch is set to START Test 24 This test will check to see if the circuit board is delivering battery voltage to the Wire 56 terminal PROCEDURE 1 Set a VOM to measure DC voltage 12 VDC 2 Disconnect Wire 56 from its Starter Contactor terminal 3 Connect the meter positive test lead to Wire 56 just discon nected Connect the other test lead to ground No voltage should be indicated 4 Actuate the Start Stop Switch to its START position The meter should indicate battery voltage If battery voltage is pre sent stop the procedure 5 Connect the VOM positive test lead to Wire 56 Pin Location 7 at the Engine Controller Circuit Board Connect the other test lead to frame ground 6 Actuate the Start Stop Switch to the START position The meter should indicate battery voltage RESULTS 1 If battery voltage was measured in Step 6 but not in Step 4 repair or replace Wire 56 between the Engine Controller Circuit Page 48 Board and Starter Contactor Relay 2 f battery voltage was not available in Step 6 replace the Engine Controller Circuit
89. eed to be checked for proper clearance a unit has a lot of hours on it the valves will need to be readjusted PROCEDURE 1 Remove the valve cover from engine 2 Disconnect the battery 3 Manually turn flywheel until cylinder 1 furthest from flywheel 15 at top dead center and adjust the clearances of the intake and exhaust valves of the No 1 cylinder and the exhaust valve of the No 2 cylinder MARK AT TOP DEAD CENTER faerten _ Figure 7 22 Valve Adjustment Points 4 Check valve clearance using a feeler gauge Both should have a clearance of 0 008 0 012 5 Adjust by loosening the nut and turning the adjustment screw 6 Turn the crankshaft counterclockwise by 204 view from front to adjust the clearance of the intake valve of No 2 cylinder and the intake and exhaust valves of the No 3 cylinder La mm ki P Figure 7 23 Checking Valve Adjustment RESULTS 1 If clearance is incorrect readjust 2 f clearance is correct proceed to next test on flow chart TEST 36 FUEL INJECTOR PUMP DISCUSSION The fuel injector pump takes the fuel that is provided by the electric fuel pump and delivers it to the fuel injector nozzles Given that the fuel solenoid is oper ating correctly and the linkage from the governor is not binding the fuel injector pump will need little to no maintenance PROCEDURE 1 If fuel inje
90. egulator If voltage is measured it can be assumed that the Field Boost is working Stop testing If volt age is not measured proceed to Step 4 4 Test D2 diode Place a VOM to measure continuity Place one test lead on one end of the diode and the other test lead on the other end Check for continuity then reverse the leads and retest Continuity should only be measured in one direction and when it is measured it should have a single beep and not a constant tone If continuity is measured in both directions then the diode will need to be replaced If diode tests good proceed to Step 5 Test R2 resistor Place a VOM to measure resistance Disconnect wires going to the terminals of the resistor Place the test leads on each terminal of the resistor Resistance should be 20 Ohms If resistance is bad replace the resistor If resistor is good proceed to Step 6 e Test Wire 14 Place VOM to measure continuity Disconnect Wire 14 from the R2 resistor Unplug the BH2 connector Place one test lead on the Wire 14 end that was previously on the resistor Place the other test lead on Pin 7 of the BH2 con nector Continuity should be measured If wire is open replace it If wire is good disconnect Wire 14 from the circuit board located on Terminal 11 Place one test lead on this end and the other test lead on the other BH2 connector Pin 7 Continuity should be measured If continuity is not measured replace the wire If continuit
91. eners can cause damage malfunction and possible injury REPLACEMENT PARTS Components on Generac recreational vehicle generators are designed and manufactured to comply with Recreational Vehicle Industry Association RVIA Rules and Regulations to minimize the risk of fire or explo sion The use of replacement parts that are not in compliance with such Rules and Regulations could result in a fire or explosion hazard When servicing this equipment It is extremely important that all components be properly installed and tightened If parts are improperly installed or tightened sparks could ignite fuel vapors from fuel system leaks SAFETY INSIDE FRONT COVER SECTION 1 GENERATOR FUNDAMENTALS 3 7 MAGNETISM 2 Seat een Les RE 3 ELECTROMAGNETIC INDUCTION 3 A SIMPLE AC GENERATOR 4 MORE SOPHISTICATED AC GENERATOR 4 FIELD BOOST MP 6 GENERATOR AC CONNECTION SYSTEM 6 SECTION 2 MAJOR GENERATOR COMPONENTS 8 11 ROTOR ASSEMBLY EE 8 STATOR ASSEMBLY 8 BRUSH HOLDER ALNG 9 BATTERY CHARGE COMPONENTS 9 EXCITATION CIRCUIT COMPONENTS 9 VOLTAGE REGULATOR 10 CONTROL PANEL COMPONENT IDENTIFICATION 11 SECTION 3
92. ery voltage was NOT indicated in Step 3 replace the Engine Controller Circuit Board TEST 30 CHECK WIRE 18 DISCUSSION Wire 18 controls sending the STOP signal to the Engine Controller Circuit Board If Wire 18 contacts ground it will initiate a shutdown Coach manufactur ers sometimes install a 15 to 30 foot remote harness A ground on Wire 18 in a remote harness can also cause a shutdown PROCEDURE 1 Remove the remote harness connector from the generator and re test generator continues to run a short is present in the remote harness Repair or replace the remote harness 2 Remove the J1 connector from the Engine Controller Circuit Board Set the VOM to measure resistance Connect one test lead to Pin Location 4 Connect the other test lead to a clean frame ground Infinity should be measured Figure 7 20 Remote Harness Connector 3 Connect one test lead to Pin Location J1 15 Connect the other test lead to a clean frame ground Infinity should be measured RESULTS 1 If Continuity is measured in Step 2 repair or replace shorted Wire 18 between J1 Connector and Start Stop Switch 2 f Continuity was measured in Step 3 repair or replace short ed Wire 18 between J1 Connector and remote panel connector 3 If Wire 18 checks GOOD proceed to Problem 8 Section 6 TEST 31 CHECK FUEL SOLENOID DISCUSSION The fuel solenoi
93. est 3 3 If AC output voltage and frequency are both zero go to Test 12 4 f the no load voltage and frequency are within the stated limits go to Test 13 NOTE The term low voltage refers to any volt age reading that is lower than the unit s rated volt age The term residual voltage refers to the out put voltage supplied as a result of Rotor residual magnetism approximately 5 12 VAC TEST 2 CHECK amp ADJUST ENGINE GOVERNOR DISCUSSION Rotor operating speed and A C output frequency is proportional The generator will deliver a frequency of 60 HERTZ at 1950 RPM or 62 HERTZ at 2015 RPM The voltage regulator should be adjusted to deliver 120 VAC line to neutral at a frequency of 60 HERTZ or 124 VAC line to neutral at 62 HERTZ It is appar ent that if governor speed is high or low A C frequen cy and voltage will be correspondingly high or low Governor speed at no load is usually set slightly above the rated speed of GOHERTZ to 62 8 HERTZ to prevent excessive RPM frequency and voltage droop under heavy electrical loading ENGINE GOVERNOR ADJUSTMENT Initial adjustment of governed speed should be accomplished at no load condition Prior to engine startup turn off all electrical loads by whatever means available such as generator main circuit breaker GOVERNOR ADJUSTING SCREW Figure 7 1 Governor Adjustment Points PROCEDURE 1 Connect an accurate A C frequency meter and voltmeter to
94. eved tighten hold down bolt to 49 ft los using a 16mm socket Figure 8 9 Tensioning Fan Belt Tensioner Page 59 Section 9 Exploded Views Part Numbers Engine Alternator Drive amp Starter Drawing No 0D2355 B Page 60 Section 9 Exploded Views Part Numbers ITEM QTY DESCRIPTION 1 1 Bearing Carrier Front 2 1 Bearing Carrier Upper 3 1 Rotor Assembly 4 1 Stator Assembly 5 1 Ball Bearing 6 1 Ball Bearing 7 1 Brush Holder 8 2 M5 0 8 16mm 9 4 Bolt Stator 10 6 5 16 Special Lock Washer 11 1 Lug Lift 12 1 Rail Engine RH 18 1 Pulley 4 5 Flat 14 1 Belt V Rib 15 1 Starter Motor 16 1 Spacer Starter 17 1 Pulley Alternator 18 1 Flywheel Assembly 19 2 HHCS 8 1 25 x 55mm 20 2 Washer Vibration Isolator 21 8 Washer Split Lk M8 22 8 Nut Hex M8 1 25 23 2 SHCS 5 16 18 x 1 1 2 24 1 Guard Flywheel 25 4 HHCS M12 1 25 x 20mm 26 6 Washer Split Lk M12 27 2 Engine Bracket 28 2 washer 29 1 1 2 18 x 4 HHCS 30 1 Fender Washer 7GA 31 1 HHCS 3 8 24 x 1 32 11 Lockwasher M10 33 6 HHCS M10 1 25 x 25mm 34 2 5 16 Flange Nut 35 5 HHCS M10 1 25 x 20mm 36 1 M6 Hex Nut 37 2 HHCS M8 1 25 x 25mm 38 1 Earth Strap 39 4 HHCS 8 1 25 x 20mm 40 1 Va Special Lock Washer 41 4 M8 Flange Nut 42 3 Taptite M6 1 0 x 8mm 43 1 Engine 1 0L Diesel 44 2 Washer Flat M12 45 1 Clamp Vinyl Coated 1 1 16 46 2 HHCS M12 1 25 x 25mm 47 1 Tensioner SE F18 4 5 48 1 12 13 x1 3 4 HHCS 49 2 1 2
95. from sea air contributes to the problem since salt can absorb moisture from the air When salt and moisture combine they make a good electrical conductor Due to the detrimental affects of dirt and moisture the generator should be kept as clean and as dry as pos sible Rotor and Stator windings should be tested periodically with an insulation resistance tester such as a megohmmeter or hi pot tester If the insulation resistance is excessively low drying may be required to remove accumulated moisture After drying perform a second insulation resistance test If resistance is still low after drying replacement of the defective Rotor or Stator may be required INSULATION RESISTANCE TESTERS Figure 3 1 shows one kind of hi pot tester The tester shown has a Breakdown lamp that will glow during the test procedure to indicate an insulation break down in the winding being tested Figure 3 1 One Type of Hi Pot Tester DANGER INSULATION RESISTANCE TESTERS SUCH AS HI POT TESTERS AND MEGOHMMETERS ARE A SOURCE OF HIGH AND DANGEROUS ELECTRICAL VOLTAGE Page 12 FOLLOW THE TESTER MANUFACTURER S INSTRUCTIONS CAREFULLY USE COMMON SENSE TO AVOID DANGEROUS ELECTRICAL SHOCK DRYING THE GENERATOR GENERAL If tests indicate the insulation resistance of a winding is below a safe value the winding should be dried before operating the generator Some recommended drying procedures include a heating units and
96. ful to avoid damage to wire or winding insulation After cleaning dry all components thoroughly using moisture free low pressure compressed air Section 3 INSULATION RESISTANCE TESTS DANGER DO NOT ATTEMPT TO WORK WITH SOLVENTS IN ANY ENCLOSED AREA PROVIDE ADEQUATE VENTILATION WHEN WORKING WITH SOLVENTS WITHOUT ADE QUATE VENTILATION FIRE EXPLOSION OR HEALTH HAZARDS MAY EXIST WEAR EYE PROTECTION WEAR RUBBER GLOVES TO PROTECT THE HANDS CLOTH OR COMPRESSED AIR For small parts or when dry dirt is to be removed a dry cloth may be satisfactory Wipe the parts clean then use low pressure air at 30 psi 206 Kpa to blow dust away BRUSHING AND VACUUM CLEANING Brushing with a soft bristle brush followed by vacuum cleaning is a good method of removing dust and dirt Use the soft brush to loosen the dirt then remove it with the vacuum STATOR INSULATION RESISTANCE GENERAL Insulation resistance is a measure of the integrity of the insulating materials that separate electrical wind ings from the generator s steel core This resistance can degrade over time due to the presence of conta minants dust dirt grease and especially moisture The normal insulation resistance for generator wind ings is on the order of millions of ohms or megohms When checking the insulation resistance follow the tester manufacturer s instructions carefully Do NOT exceed the applied voltages recommended in this manual Do NOT
97. he Stator assem bly are a dual AC power windings b an excitation or DPE winding and c a battery charge winding A total of eleven 11 leads are brought out of the Stator as follows 1 Four 4 Stator power winding output leads Wires No 11 22 33 and 44 These leads deliver power to connected electrical loads 2 Stator Power winding sensing leads 11 and 22 These leads deliver an actual voltage signal to the electronic Voltage Regulator Section 2 MAJOR GENERATOR COMPONENTS 3 Two excitation winding output leads No 2 and 6 These leads deliver unregulated excitation current to the voltage regulator 4 Three 3 battery charge output leads No 55 66 and 77 Leads 2 8 6 Stator Excitation Winding Leads 11 amp 22 Voltage Sensing Leads Leads 11 amp 22 33 amp 44 AC Power Windings Leads 55 66 77 Battery Charge Windings Figure 2 2 Stator Output Leads BRUSH HOLDER The brush holder is retained in the rear bearing carri er by two M5 screws It retains two brushes which contact the Rotor slip rings and allow current flow from stationary parts to the revolving Rotor The posi tive brush is located nearest the Rotor bearing Tes Ss aaa SS ID AGA AGG Si SS TS BRUSHES Figure 2 3 Brush Holder BATTERY CHARGE COMPONENTS The Stator incorporates dual battery charge windings A battery charge rectifier BCR changes the AC out put of t
98. heck Starter Motor sand 48 50 NG TEST 28 FEHSIORIUG 58 59 Check Fuel 51 SECTION 9 TEST 29 EXPLODED VIEWS PART NUMBERS 60 87 Check Wire 14 Power Supply 51 Check Wire 18 51 2 1 2 Is SPECIFICATIONS amp CHARTS 212221 88 90 Check Fuel Solenoid 51 52 MAJOR FEATURES AND DIMENSIONS 88 TEST 32 ENGINE SPECIFICATIONS aapakan 89 Test Pre Heat Contactor 52 GENERATOR SPECIFICATIONS 89 TEST 33 ROTOR STATOR RESISTANCE VALUES 90 Test Glow Plugs TUMULI 52 TORQUE SPECIFICATIONS 90 TEST 34 Test D1 Diode E 52 SECTION 11 ELECTRICAL DATA 92 Page 2 Section 1 GENERATOR FUNDAMENTALS MAGNETISM Magnetism can be used to produce electricity and electricity can be used to produce magnetism Much about magnetism cannot be explained by our present knowledge However there are certain pat terns of behavior that are known Application of these behavior patterns has led to the development of gen erators motors and numerous other devices that uti lize magnetism to produce and use electrical energy See Figure 1 1 The space surrounding a magnet is permeated by magnetic lines of forc
99. hese windings to direct current Battery charge winding output is delivered to the unit battery via the rectifier a 14 amp fuse and Wire No 15 A one ohm 25 watt resistor is connected in series with the grounded side of the circuit O ENGINE CONTROLLER CIRCUIT BOARD BCR TO BATTERY m d 66 77 66 BATTERY CHARGE WINDING Battery Charge Rectifier R1 OneOhm 25 Watt Resistor Figure 2 4 Battery Charge Circuit EXCITATION CIRCUIT COMPONENTS GENERAL During operation the Rotor s magnetic field induces a voltage and current flow into the Stator excitation winding The resultant AC output is delivered to a voltage regulator via an excitation circuit breaker CB2 POWER WINDING fT Wwe 225 115 ELECTRONIC VOLTAGE REGULATOR 2A x T veers DPE WINDING G Ww OF 4 FIELD Figure 2 5 Schematic Excitation Circuit EXCITATION CIRCUIT BREAKER The excitation circuit breaker CB2 is self resetting and cannot be reset manually Should the breaker open for any reason excitation current flow to the Rotor is lost The unit s AC output voltage will then drop to a value equal to the Rotor s residual magnet ism about 7 12 VAC Page 9 Section 2 MAJOR GENERATOR COMPONENTS Figure 2 6 Excitation Circuit Breaker VOLTAGE REGULATOR Six 6 leads are connected to the voltage regulator as follows e Two 2 SENSING leads deliver
100. ich deliv ers battery voltage to the Wire 14 circuit This ener gizes the FUEL PUMP FP FUEL SOLENOID FS HOURMETER HM and optional light or hourmeter in remote panel Wire 14 is also connected to RESISTOR R2 and DIODE D2 After passing through R2 and D2 reduced voltage is applied to Wire 4 The reduced voltage approximately 3 5VDC is sent to the ROTOR via The BRUSHES and SLIP RINGS This voltage is used for Field Boost Also while cranking engine control circuit board action energizes Terminal 12 which delivers battery voltage to Wire 85 Refer to Circuit Condition Fault Shutdown for operation 1 4 FOR DETAILS LEGEND AVR AUTOMATIC VOLTAGE REGULATOR BATTER Y CHARGE RECTIFIER BOW BATTERY CHARGER GB CIRCUIT BREAKER 35A CB2 CIRGUIT BREAKER 4 D1 DIODE 600V 12 VDC SUPPLY D2 DIODE DPE EXCITATION WINDING 12 VDC CONTROL FP FUEL PUMP VOLTAGE REGULATOR GP GLOW PLUGS DC OUTPUT HWT HIGH WATER TEMP SWITCH LOS LOW OIL PRESSURE SWITCH AC POWER PHC PREHEAT CONTACTOR Ai AESISTOR 1 OHM 25W GROUND oo 5TART SW PREHEAT SWITCH 5W1 SWITCH START STOP Section 5 ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION RUNNING With the FUEL PUMP FP and FUEL SOLENOID FS operating the engine should start The START STOP SWITCH 5 1 is then released Engine con trol circuit board action terminates DC output to the SIA
101. ifier 44 TEST 44 TEST 175 Check Wire 14 and Connecting Check Battery Charge Windings Components for Ground 56 Battery Charge Resistor 44 45 TEST 42 TEST 18 Check Wire 56 and Starter Contactor Try Cranking the Engine 45 for Short to Ground eatem 56 TEST 19 TEST 43 Test Pre Heat Switch 45 Check Wire 15 for Short to Ground 96 TEST 20 Check Fuel Lah 45 46 Pec nal y 57 59 21 Check 14 Amp Fuse 46 MAJOR DISASSEMBLY 57 TEST 22 Enclosure Panel Removal 57 2 Slalok REMOVE E 57 Check Power Supply to Circuit Board 46 A7 Rotor Removal 57 TEST 24 Belt Tensioning 57 Check Start Stop 4 2 4 1 4 11 41 48 Engine Removal 57 oe Starter Removal 58 Check Power Supply to Wire 56 48 rmm TEST 26 teg Pump Te TE 58 Check Starter Contactor 48 Radiator Removal 58 TEST 27 Re assembly 58 C
102. imately 7 to 12 VAC Into the sta tor s AC power windings 2 During startup an engine controller circuit board delivers bat tery voltage to the rotor via the brushes and slip rings a The battery voltage is called Field Boost b Flow of direct current through the ROTOR increases the strength of the magnetic field above that of residual magnetism alone 3 Residual plus Field Boost magnetism induces a voltage into the Stator excitation DPE battery charge and AC Power windings 4 Excitation winding unregulated AC output is delivered to an electronic voltage regulator via an excitation circuit breaker a A Reference voltage has been pre set into the Voltage Regulator b An Actual sensing voltage is delivered to the Voltage Regulator via sensing leads from the Stator AC power windings c Regulator compares the actual sens ing voltage to its pre set reference voltage 1 If the actual sensing voltage is greater than the pre set reference voltage the Regulator will decrease the regulated cur rent flow to the Rotor 2 If the actual sensing voltage is less than the pre set reference voltage the Regulator will increase the regulated cur rent flow to the Rotor 3 In the manner described the Regulator maintains an actual sensing voltage that is equal to the pre set reference voltage NOTE The Voltage Regulator also changes the Stator excitation windings alternating cu
103. in step 3 replace wire 2 f continuity was measured in step 3 replace the circuit board TEST 40 TEST WATER TEMPERATURE SWITCH DISCUSSION This normally open thermostatic switch has a sensing tip which is immersed in engine coolant Should coolant temperature exceed approximately 245 266 F the switch contacts will close to ground Terminal 12 on the circuit board Circuit board action will then shutdown the engine PROCEDURE 1 Disconnect Wire 85 from the switch terminal 2 Set a VOM to measure continuity 3 Place one test lead on switch and the other on clean ground Infinity should be measured Page 55 Section 7 DIAGNOSTIC TESTS RESULTS 1 If continuity is measure replace the switch 2 f infinity is measured proceed to next test on the flow chart TEST 41 CHECK WIRE 14 AND CONNECTING COMPONENTS FOR SHORT TO GROUND DISCUSSION Once the start stop switch is pressed the circuit board will take battery voltage from Wire 15 on Pin 1 and provide it to Wires 14 on Pins 9 10 11 If Wire 14 or any components attached to 14 are shorted to ground the 14 amp fuse will blow This test will check the wires and components in this cranking circuit PROCEDURE 1 Set VOM to measure continuity 2 Pin 9 Wire 14 Remove Wire 14 from Terminal 9 fuel sole noid hourmeter and fuel pump 3 Testing Wire 14 to ground Place one test lead on Wire 14 disconnected from the circuit board and the other te
104. ithin the unit enclosure It is rec ommended that this conversion be performed by a Generac Authorized Service Dealer Figure 1 9 shows the stator power winding connec tions for 120 VAC only dual circuits Two stator power windings are used with each winding capable of supplying half of the unit s rated wattage amperage capacity The circuit from each winding is protected against overload by a line breaker CB1 and Line breakers CB1 and CB14A have a trip rating of 35 amps To convert from 120 240 VAC dual voltage to 120 VAC only dual circuits disconnect battery power from the generator and reverse stator lead Wires 33 and 44 as follows NOTE It is necessary to feed stator lead Wires 33 and 44 through grommets on the electrical enclo sure and engine control box in order to perform the rerouting outlined below The front and top unit enclosure panels as well as the user control panel must be removed to perform this After re routing wires should be properly tied down to prevent chafing or contact with moving internal components 1 Remove stator lead Wire 33 as shown in Figure 1 8 from the ground stud adjacent to the four position terminal block Section 1 GENERATOR FUNDAMENTALS Reroute stator lead 44 from the line side terminal of CB1 renamed as CB1A in Figure 1 9 to the ground stud location previously occupied by stator lead Wire 33 2 Move smaller gauge 18 AWG Wire labeled 44 not shown f
105. l power for operating one of the following electrical loads QUIETPACT 75D 120 and or 240 VAC single phase 60 Hertz electrical loads These loads can require up to 7500 watts 7 5 kW of total power but cannot exceed 62 5 AC amperes of current at 120 VAC or exceed 31 2 AC amperes at 240 VAC Page 6 CAUTION Do not overload the generator Some installations may require that electrical loads be alternated to avoid overloading Applying excessively high electrical loads may damage the generator and may shorten its life Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the wattage capacity of the gener ator If an electrical device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of current for starting than for continu ous operation LINE BREAKERS 120 VAC ONLY Protects generator s AC output circuit against overload i e prevents unit from exceeding wattage amperage capacity The circuit breaker rat ings are as follows Circuit Breaker 1 Circuit Breaker 2 Model QuietPact 75D 85A GENERATOR CONVERSION TO 120 VAC ONLY DUAL CIRCUITS NOTE Conversion of a QUIETPACT generator from 120 240 VAC dual voltage to 120 VAC only dual circuits or vice versa requires rerouting wires w
106. lator 8 Remove the jumper wire between Wire 4 and 12 volt supply 9 Set the VOM to measure DC amps 10 Connect one test lead to the 12 volt fused battery supply Wire 15 and connect the other test lead to Wire 4 should still be disconnected from the VR 11 Start the generator Measure the DC current Record the rotor amp draw 12 Stop the generator Re connect Wire 4 to the Voltage Regulator RESULTS Proceed to TEST 4 RESULTS top of page 40 Match all results to corresponding column in the chart The column letter refers to the Problem 4 flow charts on pages 28 and 29 TEST 5 WIRE CONTINUITY DISCUSSION The Voltage Regulator receives unregulated alternat ing current from the Stator Excitation Winding via Wires 2 162 and CB2 and 6 It also receives volt age sensing from the Stator AC Power Windings via Wires 11 and 22 The regulator rectifies the AC from the Excitation Winding and based on the sensing sig nals regulates that DC current flow to the Rotor The rectified and regulated current flow is delivered to the Rotor Brushes via Wires 4 and 0 This test will verify the integrity of Wires 0 and 162 PROCEDURE 1 Set a VOM to its Rx1 scale 2 Remove Wire 0 from the Voltage Regulator fourth terminal from the top identified by a negative sign next to terminal 3 Connect one test lead to Wire 0 and the other test lead to a clean ground The meter should read continuity 4 Dis
107. low plugs via Wire 157 Power from Wire 157 goes through a diode and changes to Wire 14 This Wire 14 goes to the circuit board powering the fuel pump fuel solenoid hourmeter and field boost through another diode and resistor The glow plugs now heat the engine combustion chamber and the injector pump is primed with fuel for starting Figure 5 5 Pre heat Switch START STOP SWITCH The start stop switch allows the operator to control cranking startup and shutdown The following wires connect to the start stop switch Page 26 WIRE 17 FROM THE ENGINE CONTROL BOARD This is the crank and start circuit When the switch is set to start Wire 17 is connected to ground via Wire 0 With Wire 17 grounded a crank relay on the circuit board energizes and battery voltage is delivered to the starter contactor via Wire 56 The starter contac tor energizes and its normally open contacts close allowing battery voltage through Wire 16 to the starter motor and the engine will now crank With Wire 17 grounded a run relay on the circuit board energizes and battery voltage is delivered to the Wire 14 circuit Now the fuel pump fuel solenoid hourmeter and field boost has battery voltage for operation WIRE 18 FROM THE ENGINE CONTROL BOARD This is the engine stop circuit When the start stop switch is set to stop Wire 18 is connected to ground via Wire 0 Circuit board action then opens the circuit to Wire 14 stopping fuel flow
108. n high oil consumption NOTE It is extremely difficult to obtain an accu rate compression reading without special equip ment For that reason compression values are not published Testing has proven that an accu rate compression indication can be obtained using the following method PROCEDURE 1 Remove fuel injectors 2 Insert a compression gauge into one of the cylinders 3 Crank the engine until there is no further increase in pressure 4 Record the highest reading obtained 5 Repeat the procedure for the remaining cylinder and record the highest reading RESULTS The difference in pressure between the three cylin ders should not exceed 25 percent If the difference is greater than 25 percent loss of compression in the lowest reading cylinder is indicated Example 1 If the pressure reading of cylinder 1 is 165 psi and of cylinder 2 160 psi the difference is 5 psi Divide 5 by the highest reading 165 to obtain the percentage of 3 0 percent Example 2 No 1 cylinder reads 160 psi 2 cylin der reads 100 psi The difference is 60 psi Divide 60 by 160 to obtain 37 5 percent Loss of compression in No 2 cylinder is indicated If compression is poor look for one or more of the fol lowing causes Loose cylinder head bolts Failed cylinder head gasket Burned valves or valve seats Insufficient valve clearance Warped cylinder head Warped valve stem Worn or broken piston ring s Worn
109. n in the Starter Motor bearings 2 shorted open or grounded armature Shorted armature wire insulation worn and wires touching one another Will be indicated by low or no RPM Section 7 DIAGNOSTIC TESTS b Open armature wire broken will be indicated by low or no RPM and excessive current draw c Grounded armature wire insulation worn and wire touching armature lamination or shaft Will be indicated by excessive current draw or no 3 A defective Starter Motor switch 4 Broken damaged or weak magnets 5 Starter drive dirty or binding DISCUSSION Test 25 verified that circuit board action is delivering DC voltage to the Starter Contactor Relay SCH Test 26 verified the operation of the Starter Contactor SC Another possible cause of an engine won t crank problem is a failure of the Starter Motor Figure 7 14 Starter Motor SM PROCEDURE The battery should have been checked prior to this test and should be fully charged Set a VOM to measure DC voltage 12 VDC Connect the meter positive test lead to the Starter Contactor stud which has the small jumper wire con nected to the Starter Connect the common test lead to the Starter Motor frame Set the Start Stop Switch to its START position and observe the meter Meter should indicate battery volt age Starter Motor should operate and engine should crank RESULTS 1 If battery voltage is indicated on the meter but
110. ne shutdown The circuit board has a time delay built into it for the Wire 85 fault shutdowns At STARTUP ONLY the cir 14 cuit board will wait approximately six 6 seconds before looking at the Wire 85 fault shutdowns Once Y 2 running after the six 6 second time delay grounding 18 Wire 85 through either switch will cause immedi Ge ate shutdown The ENGINE CONTROL circuit board also has over speed protection The circuit board senses the AC output from the stators POWER winding at Terminals d 5 amp 6 Wires 22 amp 44 This AC voltage and fre quency signal is used indirectly to monitor engine If the frequency should increase above a pre set adjustable limit the ENGINE CONTROL circuit SH board will cause an immediate shutdown BH1 4 emen en SEE WIRING FOR DETAILS 44A l A C OUTPUT DIAGRAM LEGEND AVR AUTOMATIC VOLTAGE REGULATOR BCR BATTERY CHARGE RECTIFIER BCW BATTERY CHARGER CB1 CIRCUIT BREAKER 35A CB2 CIRCUIT BREAKER 4A D1 DIODE 600V 6AMP m 12 VDC SUPPLY D2 DIODE 600V 6AMP DPE EXCITATION WINDING F1 FUSE 14AMP SFE FP FUEL PUMP VOLTAGE REGULATOR DC OUTPUT HWT HIGH WATER TEMP SWITCH LOS LOW OIL PRESSURE SWITCH POWER PHC PREHEAT CONTACTOR R1 RESISTOR 1 OHM 25W R2 RESISTOR 20 OHM 12W GROUND S STARTER SC START CONTACTOR SW
111. ne will not crank go to Test 24 3 If Continuity was not measured in Step 3 repair or replace Wire 0 between the Engine Controller Circuit Board and the Ground Terminal TEST 24 CHECK START STOP SWITCH DISCUSSION Engine cranking and startup is initiated when Wire 17 from the Engine Controller board is connected to 2 ground by setting the Start Stop Switch to START Engine shutdown occurs when circuit board Wire 18 is connected to ground by the Start Stop Switch Figure 7 12 Start Stop Switch A defective Start Stop Switch can result in a failure to crank when the switch is set to START and or b failure to shut down when the switch is set to STOP PROCEDURE For Problem 6 Section 6 perform all steps For Problem 9 perform Step 1 and Step 5 ONLY 1 Set a VOM to its Rx1 scale and zero the meter 2 Inspect the ground Wire 0 between the Start Stop Switch and the grounding terminal Connect one meter test lead to Wire 0 on SW1 Connect the other test lead to a clean frame ground Continuity should be measured 3 Disconnect Wire 17 from its Switch terminal and connect it to ground The engine should crank 4 Remove the 14 amp fuse Disconnect Wire 18 Wire 0 and Wire 17 from the Start Stop Switch SW1 5 Connect one test lead to the center terminal of SW1 Connect the other test lead to an outer terminal of SW1 Infinity should be measured Remove the test l
112. ng current AC the electrons flow first in one direction then reverse and move in the oppo site direction They will repeat this cycle at regular intervals A wave diagram called a sine wave shows that current goes from zero to maximum posi tive value then reverses and goes from zero to maxi mum negative value Two reversals of current flow is called a cycle The number of cycles per second is called frequency and is usually stated in Hertz VOLT The VOLT is the unit used to measure electrical PRESSURE or the difference in electrical potential that causes electrons to flow Very few electrons will flow when voltage is weak More electrons will flow as voltage becomes stronger VOLTAGE is considered to be a state of unbalance and current flow as an attempt to regain balance One volt is the amount of EMF that will cause a current of one ampere to flow through one ohm of resistance Conductor of a Circuit X OHM Unit measuring resistance or opposition to flow AMPERE Unit measuring rate of current flow number of electrons past a given point VOLT Unit measuring force or difference in potential causing current flow Figure 4 4 Electrical Units OHM The OHM is the unit of RESISTANCE In every circuit there is a natural resistance or opposition to the flow of electrons When an EMF is applied to a complete circuit the electrons are forced to flow in a single direction rather than their free or orbi
113. nit s no load AC output frequency is about 62 5 Hertz At the stated frequency AC output voltage should be about 125 volts Section 2 MAJOR GENERATOR COMPONENTS CONTROL PANEL COMPONENT IDENTIFICATION PRINTED CIRCUIT BOARD HOUR METER GuUARTZH tror HOURS Ti d o E E 4 ng P Be 3 D 1 i 1 kan ta S r ee 1 D 1 4 ri Ld lt lt g me i ELE m UE ero mm SA due E PREHEAT PF 1 w 305 MAX 14 FUSE MAIN CIRCUIT BREAKER PREHEAT SWITCH Figure 2 9 Control Panel Components Page 11 Section 3 INSULATION RESISTANCE TESTS EFFECTS OF DIRT AND MOISTURE Moisture and dirt are harmful to the continued good operation of any generator set If moisture is allowed to remain in contact with the Stator and Rotor windings some of the moisture will be retained in voids and cracks of the winding insula tion This will result in a reduced insulation resistance and eventually the unit s AC output will be affected Insulation used in the generator is moisture resistant However prolonged exposure to moisture will gradu ally reduce the resistance of the winding insulation Dirt can enhance the problem since it tends to hold moisture into contact with the windings Salt as
114. on Bolt 44 1 53 9 ft lbs Pulley Tension 44 1 53 9 ft lbs Weld Stud Nut 32 4 39 6 ft lbs Injector Nozzles 58 61 ft lbs Page 90 NOTES Page 91 Section 11 ELECTRICAL DATA 2 Single 120 240VAC Output No 0D2793 B 1 of 2 Models 04270 1 amp 04270 ing Draw iagram D iring W d 6 c10 1 0 070 1041 0 0 3 T19NIS ISO 1011 WVHOVIG 3HIM HO T LHAHS SINTA 9 LN W WW PI INAN LA OO YOLYVTN DAA HOY LIO 3NIDN3 LIE UL 5 8 CMS THN TOULNOO quc AQHd MANOLS NI NOILOWN OL 1545010 AT OO AMALIYA ACT dii l mm dH ng VI T 454 0 HXNOILIS DO 415 SI 0 HOLZMS LYSH3Hd ZIMS 4015 14 15 1 1 5 1 5 NHINYISS WS WOLOVINOOS 1491595 OS QZ OLCSISNH MGZ LWO NOLCSISNH TY YOLOVINOO 1V3H3Yd OHd HOLMS ENNSSSENA SOT WH HOLIMS ANAL YALYM LMH vas GALS ONNOYI 90N9 ES NON GNIS SOND TANYA TONLNOO 1108 NAHI POND GNNOYD anis ANING 05 TANA 54 TINA
115. or damaged cylinder bore Broken connecting rod Worn valve seats or valves Worn valve guides Section 7 DIAGNOSTIC TESTS NOTE For units out of warranty refer to Quicksilver Diagnostic amp Service Manual Diesel P N 082034 for further engine service information This manual can be found at www guardiangener ators com under Brochures Manual amp Specs Recreational Vehicle Manuals TEST 38 CHECK OIL PRESSURE SWITCH DISCUSSION Also see Operational Analysis on Pages 18 23 The Low Oil Pressure Switch is normally closed but is held open by engine oil pressure during cranking and startup Should oil pressure drop below a safe level the switch contacts will close to ground the Wire 85 circuit Engine controller board action will then initiate an automatic shutdown If the switch fails CLOSED the engine will crank and start but will then shut down after a few seconds If the switch fails OPEN low oil pressure will not result in automatic shutdown Figure 7 23 Oil Pressure Switch PROCEDURE 1 Check engine oil level If necessary replenish oil level to the dipstick FULL mark 2 Set a VOM to its Rx1 scale and zero the meter 3 Connect the meter test leads across the switch terminals with engine shut down The meter should read Continuity A small amount of resistance is acceptable 4 Crank the engine Oil pressure should open the switch contacts at some point
116. ot clockwise and proceed In Step 10 and Step 11 turn the overspeed shutdown pot counterclockwise 7 Connect an accurate AC frequency meter across the genera tors AC output leads 8 Start the generator let it stabilize and warm up 9 Use the injection throttle lever to SLOWLY increase engine speed until the frequency meter reads 64 hertz 10 Hold the throttle at 64 hertz and SLOWLY turn the overspeed shutdown potentiometer clockwise until engine shutdown OCCUIS 11 Turn the overspeed shutdown potentiometer clockwise an additional 1 8 turn The overspeed setting is now correct BATTERY RECOMMENDED BATTERY When anticipated ambient temperatures will be con sistently above 32 F 0 C use a 12 VDC automo tive type storage battery rated 70 amp hours and capable of delivering at least 360 cold cranking amperes The QUIETPACT 75D generator is rated at about 160 DC Amps of cranking current to operate the starter and glow plugs BATTERY CABLES Use of battery cables that are too long or too small in diameter will result in excessive voltage drop For best cold weather starting voltage drop between the Section 5 ENGINE DC CONTROL SYSTEM TERMINALS 7 8 9 10 GREEN LED RED LED TERMINALS 1 2 23 4 S OVERSPEED SHUTDOWN POTENTIOMETER 6 Figure 5 4 Engine Control Circuit Board battery and starter should not exceed 0 12 VDC per 100 amperes of cranking
117. oth High or Low TEST 2 CHECK amp FREQUENCY GOOD GO TO GOVERNOR AC VOLTAGE NO LOAD FREQUENCY amp VOLTAGE GOOD BUT THEY 3 DROOP MUCH WHEN PROBLEM 4 LOAD IS APPLIED FREQUENCY IS GOOD 1 GO TO VOLTAGE VOLTAGE IS mamay REGULATOR ADJUSTMENT OR VOLTAGE IS LOW Page 29 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 2 Generator Produces Zero Voltage or Residual Voltage 5 12 VAC TEST 12 CHECK MAIN CIRCUIT TEST 3 TEST GOOD PROCEED EXCITATION BAD PROCEED REPLACE AFTER TESTS CIRCUIT BREAKER CONCLUDE BREAKER RESET TO OR REPLACE IF BAD TEST 4 PERFORM FIXED EXCITATION ROTOR AMP DRAW BAD TEST 5 WIRE CONTINUITY GOOD TEST 7 TEST TESTO STATOR BAD FIELD BOOST WINDING TEST 10 CHECK DS BRUSHES BAD SLIP RINGS REPAIR REPLACE BG REPLACE REPAIR THEN INSULATION GOOD OR GOOD RETEST RESISTANCE BAD REPLACE n TEST PAGE 13 REPLACE VOLTAGE TEST 11 REGULATOR CHECK ROTOR BAD ASSEMBLY TEST 8 CHECK SENSING LEADS BAD POWER WINDINGS GOOD REPAIR GOOD OR REPLACE INSULATION RESISTANCE BAD INSULATION TEST PAGE 14 RESISTANCE BAD TEST PAGE 13 Page 30 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 2 Generator Produces Zero Voltage or Residual Voltage 5 12 VAC continued TEST 4 PERFORM FIXED EXCITATION CHECK VOM FUSES ROTOR AMP VERIFY AMP METE
118. ounting the brush assem bly to the rear bearing carrier 12 Remove Wire 55 going to the battery charge resistor right below the stator 13 Using a 13 mm remove the four stator hold down bolts The bottom two run through the rear cross member frame With the bottom two removed the rear cross member will be able to be removed 14 Using a rubber mallet tap off the rear bearing carrier 15 Remove the stator be careful not to hit the battery charge resistor ROTOR 1 Use a prybar to stabilize the rotor pulley and loosen from rotor bolt 2 Using a rubber mallet tap off the rotor pulley 3 Remove the rotor The front bearing carrier is now available for removal as well ENGINE In order for the engine to be removed the flywheel will need to be removed first 1 Using a prybar stabilize the flywheel and remove the 6 bolts mounting the flywheel to the engine 2 Remove flywheel 3 Remove rubber fuel lines mounting to the top of the fuel injec tor pump Figure 8 2 Using Prybar to Stabilize Flywheel CAUTION Fuel is hazardous Page 57 Section 8 ASSEMBLY 4 Attach a hoist hook to the top lifting bracket attached to the engine 5 Slightly lift the engine to take pressure off of the block of wood 6 Remove the bolts holding front cross member frame to the engine STARTER REMOVAL To get access to the starter for either testing or removal the unit will need to be lifted in order to
119. p rings a lf slip rings appear dull or tarnished they may be cleaned and polished with fine sandpaper DO NOT USE ANY METALLIC GRIT TO CLEAN SLIP RINGS A 400 grit wet sandpaper is rec ommended b After cleaning slip rings blow away any sandpa per residue Page 42 RESULTS 1 Replace bad brushes Clean slip rings if necessary 2 If brushes and rings good go to Test 11 TEST 11 CHECK ROTOR ASSEMBLY DISCUSSION During the Fixed Excitation Test Test 4 if AC out put voltage did not come up to about one half rated volts one possible cause might be a defective Rotor The Rotor can be tested for an open or shorted condi tion using a volt ohm milliammeter VOM Also see Chapter Three INSULATION RESIS TANCE TESTS PROCEDURE Gain access to the brushes and slip rings Disconnect Wire 4 and Wire 1 from their respective brushes and remove the brush holder Then test the Rotor as fol lows 1 Set a VOM to its Rx1 scale and zero the meter 2 Connect the positive meter test lead to the positive slip ring nearest the Rotor bearing Connect the common test lead to the negative slip ring Read the resistance of the Rotor windings in OHMS ROTOR RESISTANCE MODEL QP75D 15 25 OHMS Resistance values in ohms at 20 C 68 F Actual readings may vary depending on ambient temperature A tolerance of plus or minus 5 is allowed 3 Set the VOM to its
120. power winding out put If Rotor residual magnetism alone is suffi cient to turn the Regulator on loss of Field Boost may go unnoticed However if residual magnet ism alone is not enough to turn the Regulator on loss of the Field Boost function will result in loss of AC power winding output to the load The AC output voltage will then drop to a value commen surate with the Rotor s residual magnetism about 7 12 VAC GENERATOR AC CONNECTION SYSTEM The generator set is equipped with dual stator AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dual two wire connection system Generators may be installed to provide the following outputs 120 240 VAC loads one load with a maximum total wattage requirement equal to the generator s rated power output and 240 VAC across the generator output terminals or two separate loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120VAC across the generator output terminals Figure 1 9 shows the gen erator lead wire connections for 120 240 VAC loads 120 VAC loads only one load with a maximum total wattage requirement equal to the generators rated power output watts and 120V across the generator output terminals Figure 1 8 shows the generator lead wire connections for 120VAC ONLY The generator set can be used to supply electrica
121. quen cy of 60 Hertz Correct engine and Rotor speed is maintained by an engine speed governor For models rated 60 Hertz the governor is generally set to maintain a no load frequency of about 62 Hertz with a corresponding output voltage of about 125 VAC line to neutral Engine speed and frequency at no load are set slight ly high to prevent excessive rpm and frequency droop under heavy electrical loading MEASURING CURRENT To read the current flow in AMPERES a clamp on ammeter can be used This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor The meter consists essentially of a current trans former with a split core and a rectifier type instrument connected to the secondary The primary of the cur rent transformer is the conductor through which the current to be measured flows The split core allows the instrument to be clamped around the conductor without disconnecting it Current flowing through a conductor may be mea sured safely and easily A line splitter can be used to measure current in a cord without separating the con ductors CONDUCTOR CLAMP ON bi FIELD 5 AMMETER ATTACHMENT Figure 4 2 Clamp On Ammeter Page 16 SPLITTER Figure 4 3 A Line Splitter NOTE If the physical size of the conductor or ammeter capacity does not allow all lines to be measured simultaneously measure current flow
122. rac could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and or results of each method Generac has not undertaken any such wide evaluation Therefore anyone who uses a procedure or tool not recommended by Generac must ensure that neither personal safety nor the products safety will be endangered by the service procedure selected All information illustrations and specifications in this manual are based on the latest product information available at the time of publication When working on these products remember that the electrical system and engine ignition system are capa ble of violent and damaging short circuits or severe electrical shocks If work must be done where electrical terminals could be grounded or touched the battery cables should be disconnected at the battery Any time the intake or exhaust openings of the engine are exposed during service they should be covered to prevent accidental entry of foreign material Entry of such materials will result in extensive damage when the engine is started During any maintenance procedure replacement fasteners must have the same measurements and strength as the fasteners that were removed Metric bolts and nuts have numbers that indicate their strength Customary bolts use radial lines to indicate strength while most customary nuts do not have strength mark ings Mismatched or incorrect fast
123. rom the top of CB1A to the top of CB1 Renumber this Wire 11 3 Reroute stator lead Wire 33 removed in step 1 to the line side terminal on CB1A 4 Renumber ground Wire 33 located between the four position terminal block and ground in Figure 1 8 as ground Wire 44 as shown in Figure 1 9 5 Renumber Wire 44A from Figure 1 8 as Wire 33A in Figure 1 9 6 Connect a 12 AWG jumper wire between line breakers CB1 and CB1A as shown in Figure 1 9 7 Remove the tie bar between the two line breaker switch han dles When connecting vehicle load leads the following rules apply Connect 120 VAC single phase 60 Hertz AC electrical loads requiring up to the trip rating of cir cuit breaker CB1 across AC output leads T1 red and T2 white Connect 120 VAC single phase 60 Hertz AC electrical loads requiring up to the trip rating of cir cuit breaker CB1A across AC output leads T3 black and T2 white Try to keep the load balanced between the two cir cuit breakers and the stator windings The neutral line T2 white on all units is a ground ed neutral Do NOT connect electrical loads in excess of any circuit breaker rating or problems will develop with circuit breaker tripping which causes a loss of AC output Also do NOT exceed the generator s rated wattage capacity Add the watts or amps of all lighting appliance tool and motor loads the generator will operate at one time This total should be less than th
124. rrent AC output to direct current DC 5 When an electrical load is connected across the Stator power windings the circuit is completed and an electrical current will flow 6 The Rotor s magnetic field also induces a voltage Into the Stator battery charge windings a Battery charge winding AC output is deliv ered to a battery charge rectifier BCR which changes the AC to direct current DC b The rectified DC is then delivered to the unit battery to maintain the battery in a charged state c A one ohm 25 watt Resistor is installed in series with the grounded side of the battery charge circuit Page 5 Section 1 GENERATOR FUNDAMENTALS FIELD BOOST When the engine is cranked during startup the engine control circuit board Terminals 9 10 and 11 Wire 14 are energized with 12 VDC Connected to a Wire 14 is a resistor R2 and a diode D2 Battery current flows through the 20 ohm 12 watt resistor and the field boost diode D2 the voltage is reduced to 3 5 VDC After passing through R2 and D2 it becomes Wire 4 and current travels to the Rotor via brushes and slip rings This is called Field Boost current The effect is to flash the field every time the engine is cranked Field boost current helps ensure that suffi cient pickup voltage is available on every startup to turn the Voltage Regulator on and build AC output voltage NOTE Loss of the Field Boost function may or may not result in loss of AC
125. s of a SOUTH magnetic pole and a NORTH mag netic pole As the MOTOR turns its magnetic field cuts across the stationary A voltage is induced into the windings When the magnet s NORTH pole passes the STATOR current flows in one direction Current flows in the opposite direction when the mag net s SOUTH pole passes the 5 This con stant reversal of current flow results in an alternating current AC waveform that can be diagrammed as shown in Figure 1 5 The may be a 2 pole type having a single NORTH and a single SOUTH magnetic pole Some ROTORS are 4 pole type with two SOUTH and two NORTH magnetic poles The following apply 1 The 2 pole ROTOR must be turned at 3600 rpm to produce an AC frequency of 60 Hertz or at 3000 rpm to deliver an AC fre quency of 50 Hertz 2 The 4 pole ROTOR must operate at 1800 rpm to deliver a 60 Hertz AC frequency or at 1500 rpm to deliver a 50 Hertz AC frequency MAGNETIC FIELD 7 Figure 1 4 A Simple AC Generator Page 4 ONE CYCLE Figure 1 5 Alternating Current Sine Wave A MORE SOPHISTICATED AC GENERATOR Figure 1 6 represents a more sophisticated genera tor A regulated direct current is delivered into the windings via carbon BRUSHES AND SLIP RINGS This results in the creation of a regulated magnetic field around the ROTOR As a result a reg ulated voltage is induced into the STATOR Regulated current
126. ssible If battery voltage is available to the board but no DC output is delivered to the board s Wire 56 terminal while attempting to crank either the circuit board is defective or the Start Stop Switch has failed This test will determine if battery voltage is available to the Engine Controller circuit board Test 24 will check the Start Stop Switch Test 25 will check the DC power supply to the circuit board s Wire 56 termi nal Receptacle J1 Pin 1 PROCEDURE 1 On the Engine Controller Circuit Board locate Terminal 1 to which Wire 15 connects see chart on Page 24 2 Set a VOM to read battery voltage Connect the meter test leads across circuit board Terminal 1 and ground The meter should read battery voltage Section 7 DIAGNOSTIC TESTS 3 Set the VOM to measure resistance Rx1 scale Connect one meter test lead to Wire 0 Terminal 2 on the Engine Controller Circuit Board Connect the other test lead to a clean frame ground Continuity should be measured RESULTS 1 If battery voltage is NOT indicated in Step 1 check continuity of a Wire 13 between Starter Contactor and Preheat Contactor b Wire 13 between Preheat Contactor and 14 Amp Fuse F1 c Wire 15 between the 14 Amp fuse F1 and the Battery Charge Rectifier d Wire 15 between the Battery Charge Rectifier and the Engine Controller Board Repair reconnect or Replace bad wiring as necessary 2 battery voltage is indicated but engi
127. st lead on clean ground Meter should read infinity 4 Testing fuel solenoid to ground If wire checks good but fuse still blows when Wire 14 is connected place one test lead on the fuel solenoid where Wire 14 was connected Place the other test lead on clean ground Fuel solenoid resistance should be 12 4 ohms 5 Testing hourmeter to ground Place on test lead on the hourmeter where Wire 14 was previously connected Place the other test lead on clean ground Infinity should be measured Hourmeter resistance should be 3 21 ohms 6 Testing fuel pump to ground Place one test lead on the fuel pumps white wire Place the other test lead on clean ground Infinity should be measured 7 Pin 10 Wire 14 Remove Wire 14 from Pin 10 on the circuit board Place one test lead on Wire 14 previously on Pin 10 and the other test lead on clean ground Infinity should be measured 8 Pin 11 Wire 14 See test 6 for testing field boost RESULTS 1 If continuity was measured in Steps 3 6 replace faulty wires are components 2 f continuity was measured in Step 7 see test 34 testing D1 diode 3 If Wire 14 and components check to be good proceed to next test on the flow chart Page 56 TEST 42 CHECK WIRE 56 AND STARTER CONTACTOR FOR SHORT TO GROUND DISCUSSION Once the start stop switch is pressed the circuit board will send battery voltage to Wire 56 to energize the starter contactor in order for the starter motor to
128. t PT yrs 22211 ro d d FULLY Figure 5 10 Fuel Injector Nozzles GLOW PLUGS The glow plug consists of a thin coiled heat wire that is encased in sintered magnesium oxide powder and enclosed by a stainless steel sheath One end of the wire is welded to the sheath and the other end is welded to the center electrode When voltage is applied to the center electrode it heats the heat wire which in turn heats the combustion chamber Glow plugs are connected in parallel For that rea son if one plug fails open the other plugs will contin ue to operate However loss of one plug will increase the possibility of the heat wire melting open in the remaining plugs Page 27 Section 5 ENGINE DC CONTROL SYSTEM SHEATH ASBESTOS HEAT WIRE MAGNESIUM OXIDE INSULATING POWDER BUSHING CENTER ELECTRODE Figure 5 11 Glow Plug ENGINE PROTECTIVE DEVICES The engine will shut down automatically in the event of anyone or more of the following occurrences Low oil High engine coolant temperature e Engine overspeed LOW OIL PRESSURE SWITCH The oil pressure switch has normally closed contacts When the engine is cranking or running oil will pass through the switch which opens the contacts If oil pressure should drop below 10 PSI the contacts will close to ground sending a signal to the printed circuit board to shut unit down on wire 85 ADAPTER LOW OIL PRESSURE Figure 5 12
129. t into appropriate container able to hold 1 4 gallons 3 With the coolant drained lower the unit and remove the lower and 2 upper coolant hoses 4 Remove the 4 screws and 2 nuts mounting the radiator to the side panel and squirrel cage shroud 5 Lift radiator out of unit When replacing the radiator use a RTV sealant when attaching the radiator hoses When refilling the radia tor use a 50 50 mixture of coolant and water RE ASSEMBLY To re assemble the generator reverse the previous procedures BELT TENSIONING DRIVE BELT 1 Install drive belt tensioner as shown in Figure 8 4 Snug mount ing bolt but do not tighten 2 Using a 3 4 wrench apply tension to the belt as shown in Figure 8 5 Figure 8 4 Drive Belt Tensioner 3 Belt tension should be between 5 10 see Figure 8 6 When the proper tension is achieved tighten the mounting bolt to 49 ft lbs Section 8 ASSEMBLY Figure 8 5 Applying Tension to Drive Belt Tensioner 7 UNE CORNER Figure 8 6 Position of Drive Belt Tensioner FAN BELT 1 Install fan belt tensioner as shown in Figure 8 7 Snug mount ing bolt but do not tighten 2 Using a small bubble level verify that tensioner is level hori zontally If needed tap the mounting bracket to level it see Figure 8 8 3 Using a 36mm wrench or equivalent apply tension to the belt see Figure 8 9 Belt tension should be 15 Figure 8 7 Once proper tension is achi
130. ting pattern The resistance of a conductor depends on a its physical makeup b its cross sectional area c its length and d its temperature As the conductor s tempera ture increases its resistance increases in direct pro portion One 1 ohm of resistance allows one 1 ampere of current to flow when one 1 volt of electro motive force EMF is applied OHM S LAW A definite and exact relationship exists between VOLTS OHMS and AMPERES The value of one can be calculated when the value of the other two are known Ohm s Law states that in any circuit the current will increase when voltage increases but resistance remains the same and current will decrease when resistance increases and voltage remains the same Figure 4 5 If AMPERES is unknown while VOLTS and OHMS are known use the following formula _ VOLTS AMPERES OHMS If VOLTS is unknown while AMPERES and OHMS are known use the following formula VOLTS AMPERES x OHMS If OHMS is unknown but VOLTS and AMPERES are known use the following OHMS VOLTS AMPERES Page 17 Section 5 ENGINE DC CONTROL SYSTEM 12VDC SC GP 1 10 157 16 1 4 C iz T OUT 1 de O 0 lt lt STOP 18 1 BH1 18 1 7 14 sel 0 14 BH2 4 BH1 LL ims 2 4 R2 18 Hell i See BH2 17 14 14 BHEE 1110 ENGINE CONTROL 0 1 12 6 5 4 85 22 44 56
131. tion breakdown proceed as follows 1 Remove the brush holders with brushes 2 Connect the tester positive test lead to the positive slip ring nearest the Rotor bearing Connect the tester negative test lead to a clean frame ground like the Rotor shaft A UI KK G MA a POSITIVE TEST LEAD Figure 3 3 Rotor Test Points 3 Apply 1000 volts DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND If an insulation breakdown is indicated clean and dry the Rotor then repeat the test Replace the Rotor if it fails the second test after cleaning and drying Page 14 THE MEGOHMMETER GENERAL megohmmeter often called a megger consists of a meter calibrated in megohms and a power supply Use a power supply of 1500 volts when testing Stators or 1000 volts when testing the Rotor DO NOT APPLY VOLTAGE LONGER THAN ONE 1 SECOND TESTING STATOR INSULATION All parts that might be damaged by the high megger voltages must be disconnected before testing Isolate all Stator leads Figure 3 2 and connect all of the Stator leads together FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY Use a megger power setting of 1500 volts Connect one megger test lead to the junction of all Stator leads the other test lead to frame ground on the Stator can Read the number of megohms on the meter MINIMUM INSULATION RESISTANCE in Megohms GENERATOR RATED VOLTS 1000 The M
132. while cranking and starting Meter should then indicate Infinity 5 If the contacts did not open in Step 5 remove the low oil pres sure switch and connect an oil pressure gauge in it s place Start the engine and measure oil pressure Pressure should be above 10 psi RESULTS 1 In Step 3 if Continuity is not indicated replace the switch 2 f oil pressure checked good in Step 5 but Step 4 measured Infinity replace the low oil pressure switch 3 If oil pressure is below 10 psi determine cause of low oil pres sure Refer to Engine Service manual No 0E2081 for further engine service information Verify that the oil is the proper vis cosity for the climate and season 4 f all steps check GOOD go to Test 40 TEST 39 CHECK CIRCUIT BOARD FOR GROUND DISCUSSION If the engine shuts down immediately after start switch is released a possible cause would be the ground wire is faulty forcing the unit to ground the cir cuit board through the start stop switch Once the switch is released the ground is removed from the board causing the unit to shut down PROCEDURE 1 Remove Wire 0 from the circuit board on Terminal 2 2 Set a VOM to measure continuity 3 Place one test lead on Wire 0 previously removed and the other test lead on clean ground Continuity should be mea sured 4 Reconnect wire making sure it has good contact on Pin 2 of the circuit board RESULTS 1 If continuity was not measured
133. y is measured make sure that the connection on BH2 is good If the connection appears to be good then replace the circuit board RESULTS 1 If field boost voltage checks good in step 3 than replace the voltage regulator 2 f field boost is not measured replace failed parts in Steps 4 6 TEST 7 TEST STATOR DPE WINDING DISCUSSION An open circuit in the Stator excitation windings will result in a loss of unregulated excitation current to the Voltage Regulator The flow of regulated excitation current to the Rotor will then terminate and the unit s AC output voltage will drop to a value that is equal to the rotor s residual magnetism about 5 12 VAC PROCEDURE 1 Disconnect Wire 2 from the Excitation Circuit Breaker 2 Disconnect Wire 6 from the Voltage Regulator 3 Set a VOM to its Rx1 scale and zero the meter Page 40 Na A Schematic Figure 7 4 Stator Excitation Winding 4 Connect the VOM test leads across the terminal ends of Wires 2 and 6 The VOM should indicate the resistance of the Stator Excitation DPE Windings EXCITATION WINDING RESISTANCE Measured Across Wires 2 8 6 MODEL P75D 1 24 OHMS Resistance values in ohms at 20 C 68 F Actual readings may vary depending on ambient temperature A tolerance of plus or minus 596 is allowed 5 Now set the meter to its Rx1 or Rx10 000 scale and zero the meter

Guardian Technologies 4270 Portable Generator User Manual

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