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Generac Power Systems 55 Portable Generator User Manual

1. TO 12V QO 0 13 mM 16 115 4 OK 6 ELECTRONIC O 4 VOLTAGE REGULATOR 16 16 0 13 SCR 13 A B 0 16 56 0 J3 15 15 J2 14 1 4 0 56 2 0 17 17 4 90 14 2 i 0 13 18 Ilo 1 77 2 BCR 2A E H 66 1 2 66 15 18A 18 2 0 1 85 18 0 1 0 14 2 90 gt 3 gt 14 14 14 14 2 14A 0 CONN 2 15 bes q 15 CONNECTOR T2 FS FP F1 L RED 15 0 Q 11P 14 90 c 13 H BLACK 18 CB2 14 ig 18A 14A 14A 85 15 15 85 1 LOP E WHITE T GREEN CUSTOMER Ac CONNECTION NEUTRAL CONNECTION BLACK L CUSTOMER WHITE RED L 90 cs 14 CH Page 89 GUARDIAN IV PO BOX 297 WHITEWATER WI 53190 www guardiangenerators com P N 067225 REV PRINTED IN THE USA 9 03
2. 84 86 MAJOR FEATURES AND DIMENSIONS 84 GENERATOR SPECIFICATIONS 85 NOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68 F 85 ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS 86 TORQUE SPECIFICATIONS 86 SECTION 11 ELECTRICAL DATA 88 89 ELECTRICAL SCHEMATIC AND WIRING DIAGRAM 1111177 aaa 88 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 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 force 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 i
3. 38 TEST Test Excitation Circuit Breaker 39 TEST 4 Fixed Excitation Test Rotor Amp Draw 39 TEST 5 NAA 40 TEST 6 Check Field 41 TEST 7 Test Stator DPE Winding 41 TEST 8 Check Sensing Leads Power Windings 42 Page 1 Table of Contents TEST 9 Check Brush Leads 43 TEST 10 Check Brushes amp Slip Rings 43 TEST 11 Check Rotor Assembly 44 TEST 12 Check Main Circuit 44 TEST 13 Check Load Voltage amp 45 TEST 14 Check Load Watts 8 Amperage 45 TEST 15 Check Battery Charge Output 45 TEST 16 Check Battery Charge Rectifier 45 TEST 17 Check Battery Charge Windings Battery Charge Resistor 46 TEST 18 Try Cranking the Engine 47 TEST 19 Primer Switch 47 TEST 20 Check Fuel
4. 9 S c w 5 D a I GUARDIAN 7 v nn o QUIETPACT 55 65 75 r D r lt t N lt t To D N RE r lt t r N D N lt t Oo GUARDIAN SAFETY Throughout this publication DANGER and CAUTION blocks are used to alert the mechanic to 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 COMPLIED 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 dam age 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 com pany service personnel when servicing the products described herein is assumed that these personnel are familiar with servicing procedures for these products or like similar products manufactured and marketed by Generac Tha
5. PART QTY DESCRIPTION 1 005694 1 CASTING TWIN REGULATOR HOUSING 2 075475 4 SCREW PPHM M4 0 7 X 10 3 022264 4 WASHER LOCK 8 M4 4 043180 4 WASHER FLAT M4 5 0C5765 1 SOLENOID TWIN REGULATOR 6 0C6070 1 SPRING SOLENOID PLUNGER 7 0C4680 1 PLUNGER LP REG ASSY 8 0 4647 1 GASKET SOLENOID 9 0 4643 1 INLET TWIN REGULATOR 10 0D3973 1 PLUG EXPANSION 16MM TWINREG 11 0 6606 1 BARBED STR 1 2 X 1 2NPT W VS 12 026073 2 PLUG STD PIPE 1 8 STEEL SQ HD 13 003308 2 WASHER FLAT 3 2MM ID X 10MM OD 14 070728 2 SCREW PFILHM M3 0 5 X 5 15 0C5764 1 SPRING REGULATOR 45N M 32MM 16 0C4643A 1 INLET TWIN REG 11 11 DIA 17 0C6066 1 SEAL INLET REGULATOR 18 0C5968 1 SUPPORT INLET SEAL 19 0C5759 1 PIN PIVOT ARM 20 0C5761 1 LEVER REGULATOR 21 0C6069 1 GASKET DIAPHRAGM 22 0C6731 1 RIVET 118 X 125 ALUMINUM 23 0C6067 1 SUPPORT DIAPHRAGM 24 004706 1 DIAPHRAGM TWIN REGULATOR 25 0 6068 1 CAP DIAPHRAGM SUPPORT 26 0C5762 1 COVER TWIN REGULATOR 27 045764 8 SCREW 4 0 7 X 8 BP ITEMS 6 AND 7 NOT SOLD SEPARATELY ORDER KIT P N 0D4166 Page 83 Major Features and Dimensions Drawing 0 1058 SPECIFICATIONS amp CHARTS Section 10 dqatilnO3ti SS399V YOLOANNOO SLOWSY 212 m 131NI 1303 SS3NHVH Andino ov v 46v d3u 29 1 Sa0V1d 8 SINNOTAM 91 8 131NI DNITOO
6. Figure 2 7 Vollage Regulator The regulator mounts a VOLTAGE ADJUST poten tiometer used for adjustment of the pre set REFER ENCE voltage A lamp LED will turn on to indicate that SENSING voltage is available to the regulator and the regulator is turned on Page 10 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 Problem 2 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 commensurate with Rotor residual magnetism about 7 12 VAC Without this automatic shut down 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 voltage 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 unit s no load AC output frequency is about 62 5 Hertz At the stated frequency AC output voltage should be about 124 volts CRANKCASE BREATHER REED VALVE CRANKCASE BREATHER GASKET 5 OIL VAPOR COLLECTOR Figure 2 8
7. gt J1 10 2 66 J1 11 2 85 J1 12 gt 0 gt 14A J1 15 X 18 BCR 66 77 66 WINDING 55 ON Oa HON POWER WINDING ELECTRONIC VOLTAGE REGULATOR 2A 6 as 2 ON DPE WINDING 4 FIELD 120V 20A QP55 T e 120V 30A QP65 120V 35A QP75 120V 30A QP55 amp QP65 120 75 NEUTRAL CONNECTION BY CUSTOMER J143 2 REMOTE J1 14 gt 18 PANEL CONNECTOR gt i mem N REMOTE PANEL OPTIONAL CIRCUIT CONDITION RUNNING With the FUEL PUMP FP and FUEL SOLENOID FS operating and ignition occurring the engine should start and the START STOP SWITCH SW1 is released A voltage is induced into the Stator s BATTERY CHARGE WINDING This voltage is delivered to the ENGINE CONTROLLER BOARD PCB via Wire 66 to prevent STARTER MOTOR engagement above a tain rpm Circuit board action terminates DC output to the STARTER CONTACTOR RELAY SCR which then de energizes to end cranking Circuit board action ter minates DC output to the CHOKE SOLENOID CS The choke will go to a position determined by the CHOKE HEATER CH The LOW OIL PRESSURE SWITCH LOP is nor mally closed After start up engine oil pressure will open the LOP 17VDC SUPPLY BROWN ms 12VDC CONTROL s VOLTAGE REGULATOR DC OUTPUT as AC POWER ms
8. m 12 0 SUPPLY o 12VDC CONTROL 3 5 VDC FIELD BOOST mu GROUND LEGEND BCR BATTERY CHARGE RECTIFIER CB1 CIRCUIT BREAKER 30A QP55 amp QP65 MODELS CIRCUIT BREAKER 35A QP75 MODEL FUEL PRIME CB2 CIRCUIT BREAKER 20 55 MODEL CIRCUIT 30A QP65 MODEL CIRCUIT BREAKER 35A QP75 MODEL CIRCUIT BREAKER 3 0A QP65 8 QP75 MODELS CH CHOKE HEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 FP FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IM1 IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO 2 CYL LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE ENGINE CONTROLLER Ri RESISTOR 1 OHM 25W SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SW1 SWITCH START STOP SW2 SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 CONNECTOR 5 ENGINE CONTROL SYSTEM BATTERY nb 4lll BLIK w wm wm wm w m m m m m m I SC l APAT 13 16 0 SCR did 2 J2 M2 2 99 9 o 2 16 18A 1 1 SP1 15 J1 4 gt 18A N15 gt 18A IM2 J1 6 3 17 RFo START Swi O N7 2 17 O A STOP J8 gt NMN
9. 62 TEST 38 Check Engine Cylinder Leak Down Test Compression Test 64 TEST 39 Check Oil Pressure Switch 65 TEST 40 Test Oil Temperature Switch 65 TEST 44 Test Choke Heater 66 TEST 42 Check LPG Fuel Solenoid 66 SECTION 8 ASSEMBLY 68 70 MAJOR DISASSEMBLY 68 Enclosure Panel Removal 68 Stator Removal 68 Rotor Removal u 68 Belt Tensioning 69 69 Startor Removal 69 Flywheel Magneto Removal 70 SECTION 9 EXPLODED VIEWS PART NUMBERS 72 83 BASE amp PULLEY DRAWING enne 72 ENCLOSURE DRAWING uuu u u aR L u uQ na 74 SHEET METAL DRAWING 76 CONTROL PANEL DRAWING 78 760 V TWIN ENGINE DRAWING 80 LP REGULATOR DRAWING 82 SECTION 10 SPECIFICATIONS amp CHARTS
10. 25 STARTER CONTACTOR RELAY amp STARTER MOTOR 26 SECTION 6 TROUBLESHOOTING FLOWCHARTS 27 37 IF PROBLEM INVOLVES AC OUTPUT 27 PROBLEM 1 VOLTAGE 8 FREQUENCY BOTH COW eec 27 PROBLEM 2 GENERATOR PRODUCES ZERO VOLTAGE OR RESIDUAL VOLTAGE 5 12 28 29 PROBLEM 3 NO BATTERY CHARGE OUTPUT 29 PROBLEM 4 EXCESSIVE VOLTAGE FREQUENCY DROOP WHEN LOAD IS APPLIED use 30 PROBLEM 5 PRIMING FUNCTION DOES NOT WORK GASOLINE MODELS es 30 PROBLEM 6 ENGINE WILL NOT CRANK 31 PROBLEM 7 ENGINE CRANKS BUT WILL NOT START GASOLINE UNITS nmam 32 PROBLEM 7 ENGINE CRANKS BUT WILL NOT START LP UNITS 33 PROBLEM 8 ENGINE STARTS HARD AND RUNS ROUGH GASOLINE UNITS nennen 34 PROBLEM 8 ENGINE STARTS HARD AND RUNS ROUGH LP UNITS c cccccccccssescecsessesesecsecsessesetsessrssesensetstesteeeeees 34 PROBLEM 9 ENGINE STARTS THEN SHUTS DOWN 36 PROBLEM 10 7 5 AMP F1 FUSE BLOWING 37 SECTION 7 DIAGNOSTIC TESTS 38 67 INTRODUCTION Mee Cc 38 TEST 1 Check No Load Voltage And Frequency 38 TEST2 Check Engine Governor
11. 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 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 STATOR SHORT TO GROUND TESTS oee 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 115 and 225 from the voltage regulator b Disconnect excitation winding lead No 6 from the voltage regulator c Disconnect excitation lead No 2 from the excitation circuit breaker CB3 d Disconnect battery charge winding l
12. START During cranking only measure DC voltage It should read 3 5 VDC Reconnect Wire 4 to the Voltage Regulator If voltage is measured it can be assumed that the Field Boost is working Stop testing If volt age 15 not measured proceed to Step 4 4 Connect the positive test lead to Wire 16 at pin location J1 13 on the PCB see Figure 7 4 J1 J2 amp J3 connectors remain connected to PCB Connect the negative test lead to a clean frame ground 5 Set the Start Stop Switch to START During cranking only battery voltage should measure 11 12 VDC 6 Connect the positive test lead to Wire 4 at pin location J1 9 on the PCB see Figure 7 4 J1 J2 amp J3 connectors remain connected to PCB Connect the negative test lead to a clean frame ground 7 Set the Start Stop Switch to START During cranking only measure the DC voltage It should measure 3 5 VDC RESULTS 1 If battery voltage was not measured in Step 5 repair or replace Wire 16 between the Starter Contactor Relay and PCB 2 f field boost voltage was measured in Step 7 but not measured in Step 3 repair or replace Wire 4 between PCB and Voltage Regulator 3 If battery voltage was measured in Step 5 but field boost age was not measured in Step 7 replace PCB 4 f field boost checks good replace the Voltage Regulator TO VOLTAGE REGULATOR AND TO ROTOR TO STARTER CONTACTOR 12 VDC o E 00900909090900
13. 082025 0E1247 055173 022129 022145 0D9403 0E1246 0D9400 Ss AB HS N s DESCRIPTION SCREW HHTT M6 1 0 X 10 YC GUARD FAN 12KW HSB HOUSING BLOWER V TWIN RV NUT GROMMET 1 4 PLUG HOSE BREATHER NUT HEX M24 2 0 G8 YEL CHR WASHER BELLEVILLE 25MM BOLT SCREW HHC M8 1 25 X 12 G8 8 WASHER SHAKEPROOF INT SS PLATE FAN GTV 990 FAN NYLON GTV 990 FLYWHEEL ASSY GT 990 PLATE BACKING GT990 W OIL COOL BUSHING SNAP WRAP CRANKCASE GTV760 RV SPCC GT760 VERTICAL SHAFT RV ENGINE WRAP CYL 1 GTV760 RV SPCC SCREW CRIMPTITE 10 24 X SPARK PLUG CLAMP VINYL 9 5 0 0 TUBE TUBE OIL DRAIN amp CHECK BARBED EL 90 3 8NPT X 3 8 VS ASSEMBLY OIL DRAIN HOSE OIL DRAIN DIPSTICK TUBE VTW ASSEMBLY CAP amp DIP STICK SCREW TAP R 10 32 X 9 16 GASO LINE ONLY SCREW TAP R 10 32 X 9 16 LP ONLY SPRING CLIP HOLDER 37 62 SCREW HHTT 3 8 16 X 1 1 4 CZ WASHER LOCK SPECIAL 3 8 SCREW SWAGE 1 4 20 X 1 ZYC FILTER OIL D 69X64 LG SWITCH OIL PRESSURE HOBBS SUPPORT OIL FLTR FLARE WASHER LOCK M3 SCREW PPHM M3 0 5 X 8 SWITCH OIL HIGH TEMP GASOLINE ONLY SWITCH OIL HIGH TEMP LP ONLY ASSEMBLY GOVERNOR LEVER SPRING GOV 5 5 KW amp 5 0 KW 50HZ ONLY SPRING GOV 6 5 7 5 KW amp 7 0 KW 50HZ ONLY BUSHING GOVERNOR ROD ROD GOVERNOR BOOT CHOKE SOLENOID GASOLINE ONLY RHMS 4 40 X 1 4 SEMS GASOLINE ONLY ASSY BI METAL HEAT
14. 6 1 0 NYLOK GASO ONLY LINE ONLY 022097 1 WASHER LOCK M6 1 4 6 5 8 7 5 KW 003700 1 NUT FLANGE M6 1 0 NYLOK LP ONLY ONLY 27 022473 3 WASHER FLAT 1 4 6 ZINC 5 5 KW 54 087769 1 FILTER FUEL 1 8P 5 16H GASOLINE ONLY ONLY 28 0C1751 1 FANNYLON 7 DIA 5 5 KW ONLY 55 0 0570 1 ASSEMBLY NON SHTOFF FUEL 29 0C1753B 1 PULLEY ALTERNATOR 2200 RPM PUMP GASOLINE ONLY 5 5 KW ONLY 56 009919 1 ASSEMBLY RV V TWIN FUEL LINE 073106B 1 PULLEY ALTERNATOR 2500 RPM GASOLINE ONLY 6 5 amp 7 5 KW ONLY 57 0 1330 1 GROMMET 38 1 DIA CROSS SLIT 30 075224A 1 PULLEY ENGINE 2100 RPM 5 5 KW GASOLINE ONLY ONLY 0E1534A 1 PLUG PLASTIC 1 50 LP ONLY 075224B 1 PULLEY ENGINE 2500 RPM 6 5 8 58 0 1658 1 WASHER LOCK SPECIAL 1 4 7 5 KW ONLY 59 005133 1 SCREEN SPARK ARRESTOR 31 0 0586 1 GASKET BOTTOM AIR OUT QPRV 60 0D5133A 1 RETAINER SPARK ARREST SCREEN 61 045764 12 SCREW HHTT M4 0 7 X 8 BP Page 73 Section 9 Exploded Views Numbers Enclosure Drawing No 0E1011 B 30 GROUND 31 Pa TO ENGINE CONT PANEL 32 Ni 29 3 28 30 27 34 BA STARTER D N 2 1 Page 74 Section 9 Views Numbers PART QTY DESCRIPTION 1 008827 1 PANEL ENCLOSURE ROOF 2 0A7215 22 SCREW SW 1 4 20X5 8 N WA JS500 3 029451 11 5 FT TAPE ELEC UL FOAM 1 8 X 1 2 4 0D8825 1 PANEL SIDE AND BACK ENCLOSURE
15. CONTROLLER CIRCUIT BOARD BCR TO BATTERY s 66 77 66 BATTERY CHARGE WINDING BCR Battery Charge Rectifier H1 1 Ohm 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 POWER WINDING 225 115 ELECTRONIC VOLTAGE REGULATOR Figure 2 5 Schematic Excitation Circuit EXCITATION CIRCUIT BREAKER The excitation circuit breaker CB3 is self resetting and cannot be reset manually Should the breaker open for any reason excitation current flow to the Page 9 Section 2 MAJOR GENERATOR COMPONENTS Rotor will be lost The unit s AC output voltage will then drop to a value commensurate with the Rotor s residual magnetism about 7 12 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 ACTUAL AC out put voltage signals to the regulator These are Wires No 11S and 22S Two 2 leads 4 and 0K deliver the regulated direct current to the Rotor via brushes and slip rings Two 2 leads No 6 and 2A deliver Stator excita tion winding AC output to the regulator VOLTAGE ADJUST POT
16. For that rea 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 That 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 may 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 measure AC voltage DO NOT USE A DC VOLTMETER FOR THIS PURPOSE DANGER RV GENERATORS PRODUCE HIGH AND DANGEROUS VOLTAGES CONTACT WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MEASURING DC VOLTAGE A DC voltmeter or a VOM may 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
17. a Battery charge winding AC output is deliv ered to a battery charge rectifier BCR which changes the AC to direct current DC b Therectified DC is then delivered to the unit battery to maintain the battery in a charged state C A1 ohm 25 watt Resistor is installed in series with the grounded side of the battery charge circuit Page 5 Section 1 GENERATOR FUNDAMENTALS BOOST When the engine is cranked during startup engine s starter contactor is energized closed Battery current is then delivered to the starter motor and the engine cranks Closure of the starter contactor contacts also delivers battery voltage to Pin 13 of an Engine Controller cir cuit board The battery current flows through a 47 ohm 2 watt resistor and a field boost diode then to the Rotor via brushes and slip rings This is called Field Boost current Field boost current is delivered to the Rotor only while the engine is cranking The effect is to flash the field every time the engine is cranked Field boost current helps ensure that sufficient pickup voltage is avail able on every startup to turn the Voltage Regulator on and build AC output voltage NOTE Loss of the Field Boost function may may not result in loss of AC 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 e
18. 12 VDC electric 12 VDC electric IGNITION SYSTEM Solid State Solid State Solid State SPARK PLUG Champion RC12YC or equivalent Champion RC12YC or equivalent Champion RC12YC or equivalent SPARK PLUG GAP 0 030 inch 0 76mm 0 030 inch 0 76mm 0 030 inch 0 76mm NOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68 F TYPE QUIETPACT 55 QUIETPACT 65 QUIETPACT 75 MODEL 4702 4703 4704 4705 4706 4707 Power Windings Lead 11 to 22 Lead 11S to 225 Lead 33 to 44 0 280 0 320 ohms 0 209 0 242 ohms 0 157 0 182 ohms Excitation Winding Lead 2 to 6 1 41 1 63 ohms 1 59 1 84 ohms 1 12 1 30 ohms Battery Charge Windings Lead 55 to 66 Lead 55 to 77 0 100 0 116 ohms 0 100 0 116 ohms 0 104 0 107 ohms 0 087 0 101 ohms 0 092 0 107 ohms 0 076 0 088 ohms Rotor Winding Slip Ring to Slip Ring 14 88 ohms 10 81ohms 14 50 16 0 ohms Page 85 Section 10 SPECIFICATIONS 8 CHARTS Listed below are normal running voltages load voltages and frequency ranges LOAD 0 50 ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS VOLTAGE VAC 123 126 118 122 112 118 TORQUE SPECIFICATIONS LONG BLOCK TORQUE REQUIREMENTS FREQUENCY Hz 62 63 62 59 57 61 HEAD BOLTS 22 ft lbs 590 SUMP COVER BOLTS 36 ft Ibs CONNECTING ROD CAP BOLTS 16 2 19 8 ft lbs VALVE COVER BO
19. 2 CYL 11 LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE PCB ENGINE CONTROLLER Ri RESISTOR 1 OHM 25W SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SW1 SWITCH START STOP SW2 SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 TAB E CONNECTOR 5 ENGINE CONTROL SYSTEM BATTERY 15 J2 n2 X 90 9 16 SP1 15 Jt4 3 18A 1 5 gt 18A gt SP2 X 17 F eran Hy gt 17 gt gt 4 J1 10 X 66 J1 11 2 85 41 12 2 0 14 J143 2 REMOTE J1 14 gt 18 PANEL CONNECTOR J1 15 D 18 ON O O RON z LLI lt 3 mx m 1 O 66 15 77 66 BATTERY CHARGE WINDING POWER WINDING REMOTE PANEL OPTIONAL ELECTRONIC VOLTAGE REGULATOR 120V 20A QP55 120V 30A QP65 120V 35A QP75 T2 Lo NEUTRAL CONNECTION BY CUSTOMER 120V 30A QP55 amp QP65 120V 35A QP75 FUEL PRIME m5 CIRCUIT BREAKER 30A QP65 MODEL CIRCUIT CONDITION FAULT SHUTDOWN The engine mounts a HIGH OIL TEMPERA TURE SWITCH HTO and a LOW OIL PRES SURE SWITCH LOP Should engine oil temperature exceed a pre set value the switch contacts will close Wire 85 from the circuit board will connect to frame ground Circuit board action will then initiate a shutdown
20. 25 BP O RING 59 92 X 66 98 X 3 53MM O RING 21 89 X 27 13 X 2 62MM KEY WOODRFF 4 X 19D ADPTR PAD FLARE TUBE ENGINE OIL RETURN TUBE ENGINE OIL OUT O RING 20 35 X 23 91 X 1 78MM BOLT OIL ADAPTOR WRAP CYL 2 GTV760 RV SPCC INTAKE TUBE 1 25 X 20 GA HOSE CLMP BAND 1 5 8 BOOT INTAKE AIRBOX BOOT CARB ADAPTOR BOLT CARB MOUNT 6 X 1 0 85LG ADAPTER AIR INTAKE CARB GASKET CARB TO ADAPTOR CARBURETOR GT 760 GASOLINE ONLY CARBURETOR GT 760 LP ONLY GASKET CARB TO INTAKE MANIFOLD GASKET INTAKE PORT GT990 MANIFOLD INTAKE 760 RV SCREW SHC 8 1 25 X 30 G12 9 WASHER FLAT M8 SS WASHER LOCK M8 SS BARBED STR 1 4NPT X 3 8 WVS CLAMP HOSE 0 38 0 87 HOSE 3 8 IDX6 L 300F COOLER OIL GTV 990 DUCT OIL CLR GTV760 RV SPCC PLASTITE 1 4 15 X SCREW PPHM 10 32 X 3 8 SCREW HHTT 4 40 X PLATE THROTTLE WASHER LOCK 10 NUT HEX 10 32 STEEL SCREW HHC M6 1 0 X 12 G8 8 WASHER FLAT M6 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHTT M5 0 8 X 8 BP CLAMP HOSE 8 53 1 00 LP ONLY HOSE 1 2 ID LP ONLY SCREW PPHM M4 0 7 X 16 GASOLINE ONLY CLIP J VINYL COAT 375 ID GASOLINE ONLY WASHER FLAT 8 GASOLINE ONLY WASHER LOCK 8 GASOLINE ONLY NUT HEX M4 0 7 G8 YC GASOLINE ONLY SCREW HHTT M6 1 0 X 16 YC CLAMP VINYL 1 06 X 406 LP ONLY WASHER FLAT 1 4 6 LP ONLY SCREW M6 1 0 X 12 LP ONLY CLAMP VINYL 437 X 281 Page 77 Section 9 Exploded Views Numbers Control Panel Dr
21. 5 0D3700 14 NUT FLANGE M6 1 0 NYLOK GASOLINE ONLY 0D3700 17 NUT FLANGE M6 1 0 NYLOK LP ONLY 6 090388 8 SCREW HHTT M6 1 0 X 12 YC 7 0D8979 1 PANEL AIR IN DUCT BASE 8 0D8960 1 PANEL CUSTOMER CONNECTION 9 023484D 1 BUSHING SNAP SB 875 11 10 0E0594 1 COVER RV AIR CLEANER BOX 11 064113 1 STUD WINGNUT M6 1 0 X 20MM NY 12 0E0575 1 FOAM SEALING STRIP 1 X 12FT 13 008980 1 PANEL AIR IN DUCT BACK 14 0E1376 1 BAFFLE V TWIN RV SHORT 15 0E1377 1 BAFFLE V TWIN RV LONG 16 0D8628 3 5 17 008910 1 PANEL MUFFLER SHIELD 18 0D8826 1 PANEL ENCLOSURE SIDE 19 0D9162 1 PANEL FRONT amp SIDE ENCLOSURE 20 0C5644 2 SLIDE LATCH FLUSH 21 0D8828 1 PANEL ENCLOSURE DOOR 22 0E0585 1 FOAM PANEL DOOR 1 2 THK QP RV 29 0E1486 1 HARNESS AC OUTPUT 5 5 6 5 amp 7 5 KW ONLY 0E1774 1 HARNESS AC OUTPUT 5 0 amp 7 0 KW 50 Hz ONLY 24 0D9099 1 CUST CONN 4KW RV REMOTE 25 074908 4 SCREW HHTT M5 0 8 X 10 BP 26 022473 1 WASHER FLAT 1 4 M6 ZINC 27 022097 1 WASHER LOCK M6 1 4 28 022507 1 SCREW HHC 1 4 20 X 1 2 G5 29 0742600149 1 WIRE ASM BATT NEG QP RV 30 0C7968 4 NUT HEX JAM 3 8 16 BRASS 31 022237 2 WASHER LOCK 3 8 32 0 7423 1 STUD 3 8 16 X 2 1 4 BRASS 33 0742600151 1 GND WIRE C PNL TO STUD V T RV 34 0A4456 1 WASHER LOCK SPECIAL 3 8 35 0D8502 1 NEUTRAL CONNETCTOR UL 36 0E0593 1 STUD 1 4 20 TO 5 16 18 37 0742600148 1 WIRE ASM BATT POS QP RV 38 022129 2 WASHER LOCK M8 5 16 GASOLINE ONLY 022129 4 WASHER LOCK
22. Figure 2 9 Control Panel Components Page 11 Section 3 INSULATION RESISTANCE TESTS EFFECTS OF DIRT AND MOISTURE Moisture and dirt are detrimental 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 Insulation 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 make the problem worse since it tends to hold moisture Into contact with the windings Salt as 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 Because of the detrimental affects of dirt and mois ture the generator should be kept as clean and as dry as possible 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 T
23. GOVERNOR SPRING is properly located in the slot of the GOVERNOR LEVER as follows droop is excessive move the GOVERNOR SPRING down one slot on LEVER b For greater stability move the GOVERNOR SPRING up one slot on LEVER 6 After repositioning the SPRING on a LEVER slot recheck fre quency reading and if necessary readjust ADJUSTER NUT to obtain 62 Hertz at no load 7 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the voltage regulator may require adjustment See VOLTAGE ADJUSTMENT Page 10 TEST 3 TEST EXCITATION CIRCUIT BREAKER DISCUSSION This circuit breaker CB3 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 CB3 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 commensurate with 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 1 Set a volt ohm milliammeter VOM to its Rx1 scale and zero the meter 2A j I A Schematlic B Pictorial Figure 7 2 Excitation DPE Ci
24. Off Valve should be between 11 14 inches Page 55 Section 7 DIAGNOSTIC TESTS water column as measured with a manometer The LP system must be able to maintain 11 14 inches water column under all load requirements 1 Turn LP supply to generator off 2 Remove the Gas Pressure from fuel regulator and install manometer to this port 3 Turn LP supply to generator on the gauge should read 11 14 inches water column 4 For Problem 8 only Section 6 start the engine and the gauge should read 11 14 inches water column RESULTS 1 If the LP gas pressure is less than 11 14 inches water column the fuel supply system must be corrected in order to maintain 11 14 inches water column 2 f the LP gas pressure is between 11 14 inches water Column proceed to Test 29 for Problem 7 Section 6 Proceed to Test 32 for Problem 8 Section 6 FUEL HOSE BRASS HOSE FITTING Figure 7 29 Fuel Regulator 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 on Gasoline models On LP models it operates the LPG Shut off valve PROCEDURE Inside the generator panel locate the 4 tab terminal connector Figure 7 30 Then proceed as follows 1 Set a VOM to read battery voltage 12
25. PUMP AA 48 TEST 21 Check 7 5 Amp Fuse 49 TEST 22 Check Battery amp Cables 49 TEST 23 Check Power Supply to Circuit Board 49 TEST 24 Check Start Stop Switch une 50 TEST 25 Check Power Supply to Wire 56 51 TEST 26 Check Starter Contactor Relay 51 TEST 26A Check Starter Contactor 52 TEST 27 Check Starter Motor 52 TEST 28 Check Fuel SUDDIV unecac sese ee tia aten en 54 TEST 29 Check Wire 14 Power Supply 56 TEST 30 Check Wire 18 56 TEST 31 Check Fuel Solenoid Gasoline Models 57 TEST 32 Check Ignition Spark 57 TEST 33 Check Spark PlUGS 59 TEST 34 Check and Adjust Ignition Magnetos 59 Page 2 TEST 35 Check Valve Adjustment en 61 TEST 36 Check Carburetion 62 TEST 37 Check Choke Solenoid
26. Step 4 Reconnect Connector 2 back to the fuel pump 4 Set the VOM to measure DC voltage Disconnect Wire 14 from the Fuel Solenoid Connect the positive meter test lead to Wire 14 that goes to the control panel Connect the negative test lead to a clean frame ground Activate the Start Stop Switch SW1 to the START position and hold Battery voltage should be measured 5 Set the VOM to measure resistance Disconnect Wire 0 from the Carburetor at the bullet connector Connect one test lead to Wire 0 that goes to the control panel Connect the other test lead to a clean frame ground Continuity should be measured 6 Connect one test lead to the Green Wire going to the carbure tor Connect the other test lead to the carburetor body Continuity should be measured Short to Ground 7 Set the VOM to measure resistance Disconnect the bullet con nector going to the Fuel Solenoid Connect one meter test lead to the Red Wire going to the Fuel Solenoid Connect the other meter test lead to the Fuel Solenoid housing A reading of 38 0 ohms should be measured If very low resistance is mea sured a short to ground exists Fuel Solenoid coil resistance is approximately 38 0 ohms Current draw of the Fuel Solenoid at nominal voltage is approximately 331 milliamps or 0 331 amps RESULTS 1 If the Fuel Solenoid passes Steps 4 amp 5 but does NOT operate in Step 3 replace or repair Fuel Solenoid 2 f battery volta
27. VDC 2 Connect the meter positive test lead to the 4 tab terminal connector the common test lead to frame ground 3 Crank the engine and the meter should read battery voltage Page 56 battery voltage is not measured proceed to Step 4 4 Connect the positive meter test lead to Terminal J2 on the Engine Controller Circuit Board Connect the negative test lead to a clean frame ground see Figure 5 3 Page 24 5 Crank the engine The meter should indicate battery voltage Figure 7 30 The 4 tab Connector RESULTS 1 If the meter indicated battery voltage go to Test 19 2 f battery voltage was NOT indicated in Step 3 but is indicated in Step 5 check Wire 14 between the 4 tab connector and the Engine Controller circuit board a Repair reconnect or replace Wire 14 as neces sary 3 If battery voltage was not indicated in Step 5 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 If generator continues to run a short is present in the remote harness Repair or replace the remote harness 2 Remove t
28. away from the terminal being tested see Figure 7 18 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 18 Test 24 Step 6 RESULTS 1 If Continuity is not measured in Step 2 repair reconnect replace Wire between Start Stop Switch and ground termi nal as necessary Section 7 DIAGNOSTIC TESTS 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 J1 6 to ground If engine does NOT crank proceed to Test 25 b If 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 measured 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
29. 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 cle engine When such is the case the Installer may have used a generator fuel pickup tube that is shorter than the vehicle engine s pickup tube Thus gen erator will run out of gas before the vehicle engine PROCEDURE Check fuel level in the supply tank 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 go to Test 29 for Problem 7 Section 6 Go to Test 32 for Problem 8 Section 6 Section 7 DIAGNOSTIC TESTS DISCUSSION LPG MODELS LP gas is stored in pressure tanks as a liquid The gas systems used with these generators were designed only for vapor withdrawal type systems Vapor withdrawal systems use the gas vapors that form above the liquid fuel in the tank Do NOT attempt to use the generator with any liquid withdrawal type system Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regula tor Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank The following rules apply e For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inch es water column Do NOT exceed 14 inches water column e The installer must be sur
30. flywheel nut A key way is provided for alignment only and theoretically carries no load If the flywheel key becomes sheared or even partially sheared ignition timing can change Incorrect timing can result in hard starting or failure to start Remove and inspect flywheel key for damage TEST 35 CHECK VALVE ADJUSTMENT DISCUSSION The valve lash must be adjusted correctly in order to pro vide the proper air fuel mixture to the combustion chamber ADJUSTING VALVE CLEARANCE Adjust valve clearance with the engine at room tem perature The piston should be at top dead center TDC of its compression stroke both valves closed An alternative method is to turn the engine over and position the intake valve fully open intake valve spring compressed and adjust the exhaust valve clearance Turn the engine over and position the exhaust valve fully open exhaust valve spring com pressed and adjust the intake valve clearance Correct valve clearance is given below in INCHES MILLIMETERS Intake Valve 0 002 0 004 0 05 0 1 Exhaust Valve 0 002 0 004 0 05 0 1 1 Loosen the rocker arm jam nut Use a 10mm allen wrench to turn the pivot ball stud while checking the clearance between the rocker arm and valve stem with a feeler gauge see Figure 7 41 ALLEN WRENCH Figure 7 41 Adjusting Valve Clearance 2 When clearance is correct hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut to th
31. is indicated clean and dry the Stator Then repeat the test If the Stator fails the second test replace the Stator assembly Page 13 Section 3 INSULATION RESISTANCE TESTS TEST BETWEEN PARALLEL WINDINGS Connect the tester leads across Stator leads No 11P 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 windings If the Stator fails the second test replace it Leads 2 8 6 Stator Excitation Winding Leads 115 8 225 Voltage Sensing Leads Leads 11P amp 22P 33 amp 44 AC Power Windings Leads 55 66 77 Battery Charge Windings Figure 3 2 Stator Leads TESTING ROTOR INSULATION To test the Rotor for insulation breakdown proceed as follows 1 Disconnect wires from the Rotor brushes or 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 TEST LEAD Figure 3 3 Rotor Test Points Page 14 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 THE MEGOHMMETER GENERAL A megohmmeter often called a megger consists of a meter calibrated in mego
32. of CB1 Infinity should be measured 5 Connect one test lead to Stator Lead Wire 55 Disconnect otator Lead Wire 2 from the DPE circuit breaker CB3 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 QP55 Model 4702 4703 ACROSS WIRES 55 amp 66 55 amp 77 OHMS 0 1000 0 1160 0 10002 0 1160 BATTERY CHARGE WINDING RESISTANCE QP65 Model 4704 4705 ACROSS WIRES 55 amp 66 55 amp 77 OHMS 0 104 0 1200 0 0870 0 1019 BATTERY CHARGE WINDING RESISTANCE QP75 Model 4706 4707 ACROSS WIRES OHMS 0 092 0 107 2 0 0760 0 0860 55 amp 66 55 77 Resistance values In ohms at 20 68 F Actual readings may vary depending on ambient temperature tolerance of plus or minus 5 is allowed RESULTS 1 For Steps 2 amp 3 keep in min
33. of 1000 volts across the Rotor posi tive slip ring nearest the rotor bearing and clean frame ground i e the Rotor Shaft DO NOT EXCEED 1000 VOLTS AND DO NOT APPLY VOLT AGE LONGER THAN 1 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 measure AC voltage use an AC voltmeter _1To measure DC voltage use a DC voltmeter Use a frequency meter to measure AC frequency In Hertz or cycles per second LIUse ohmmeter to read circuit resistance in ohms THE VOM A meter that will permit both voltage and resistance to be read is the volt ohm milliammeter or VOM Some VOM 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 AVER AGE value of alternating current When working with AC the effective value is used
34. panel nuts two 2 on the top and one 1 on the side Remove enclosure side panel a 10mm socket is required 4 Remove one 1 front amp side panel enclosure nut located in the inside corner Remove front amp side enclosure panel a 10mm socket is required 5 Remove four 4 muffler bolts a 18mm socket is required 6 Loosen muffler clamp Remove muffler a 15mm wrench is required 7 Remove three 3 side mounted muffler shield bolts Remove two 2 muffler shield nuts located on the inside Remove muf fler shield a 10mm socket is required 8 Remove five 5 side and back enclosure panel bolts Remove wing nut for control panel access Remove three 3 upper con trol panel bolts Remove one 1 upper control panel nut a 10mm socket is required Move control panel down cut tie wraps on red and black wires to the circuit breaker 9 Remove red and black wires from the circuit breaker Remove two 2 white and one 1 green wire from the ground lug using a 10mm deep well socket 10 Remove customer wiring conduit 11 Remove one 1 upper control panel nut Remove one 1 lower panel nut in corner Remove two 2 nuts behind upper control panel 12 Remove six 6 air in duct base bolts from top of stator Remove air in duct base a 10mm socket is required STATOR REMOVAL 1 Perform enclosure panel removal steps 1 12 2 Remove six 6 air in duct base panel bolts from top of stator Remove air in duct b
35. the Engine Controller board is connected to frame ground by setting the Start Stop Switch to START Engine shutdown occurs when circuit board Wire 18 is connected to frame ground by the Start Stop Switch Figure 7 17 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 Page 50 2 Inspect the ground Wire OB between the Start Stop Switch and the grounding terminal Connect one meter test lead to Wire 0B 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 frame ground The engine should crank 4 Remove the 7 5 amp fuse Disconnect Wire 18 Wire 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 lead 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
36. the engine controller cir cuit board PCB from the unit BATTERY and via a the RED battery cable Wire 13 a 7 5 amp FUSE F1 Wire 15 and circuit board Terminal J3 However circuit board action is holding the circuit open and no action can occur Battery output is available to the contacts of a STARTER CONTACTOR SC and STARTER CON TACTOR RELAY SCR but the contacts are open Battery voltage is also delivered to the FUEL PRIMER SWITCH SW2 The switch is open and the circuit is incomplete Battery voltage is also available to the REMOTE FUEL PRIMER SWITCH The switch is open and the circuit is incomplete 17 VDC SUPPLY BROWN e 12VDC CONTROL ma GROUND LEGEND BCR BATTERY CHARGE RECTIFIER CB1 CIRCUIT BREAKER 30A QP55 amp QP65 MODELS FUEL CIRCUIT BREAKER 35A QP75 MODEL PRIME CB2 CIRCUIT BREAKER 20 QP55 MODEL CIRCUIT BREAKER 30A QP65 MODEL CIRCUIT BREAKER 35A QP75 MODEL CIRCUIT BREAKER 2 5A QP55 MODEL CIRCUIT BREAKER 3 0 QP65 amp QP75 MODELS CH CHOKE HEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 5A FP FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IM1 IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO 2 CYL LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE ENGIN
37. to Wire 90 Pin 2 of Connector 1 going to the control panel Connect the negative test lead to frame ground Activate the Start Stop Switch to START During cranking battery voltage should be measured cyclically every two seconds TO CHOKE SOLENOID TO CONTROL PANEL Figure 7 43 Connector 1 en If battery voltage was not measured in Step 4 check at J1 Connector Connect positive test lead to Pin Location J1 2 at the engine control board Connect the negative test lead to frame ground Activate the Start Stop Switch to START During cranking battery voltage should be measured cyclically every two seconds 6 Set the VOM to measure resistance Disconnect Connector 1 from the Choke Solenoid Connect one test lead to Wire 0 Pin 1 of Connector 1 going to the control panel Connect the other test lead to frame ground Continuity should be measured 7 Set the VOM to measure resistance Disconnect Connector 1 Connect one meter test lead to Wire 90 Connector 1 Pin 2 going to the Choke Solenoid Connect the other meter test lead to Wire 0 Connector 1 Pin 1 Approximately 3 7 ohms should be measured Current draw of Choke Solenoid at nominal volt age is 3 4 amps Short to Ground 8 Set the VOM to measure resistance Disconnect Connector 1 Connect one meter test lead to Wire 90 Connector 1 Pin 2 Connect the other meter test lead to the metal Choke Solenoid housing Infinity should be meas
38. 0 X 35 G8 8 BLK 077004H 1 ROTOR ASSEMBLY 6 5 KW ONLY 50 0 1658 2 WASHER LOCK SPECIAL 1 4 073163H 1 ROTOR ASSEMBLY 7 5 KW ONLY 51 0742600146 1 WIRE ASM GRD STD CONN 17 031971 1 BEARING 52 049813 4 NUTHEX M6 X 1 0 G8 YEL CHR 18 077006 4 STUD RV STATOR DIC 53 023484D 1 _ BUSHING SNAP 19 0C9675 1 BEARING CARRIER LOW 54 0742600151 1 GROUND WIRE TO STUD V T 20 0A5351 1 NYLON SLIDE RV 21 073146 2 SLIDE NYLON 55 084867 1 RUBBER U CHANNEL 22 0 1878 2 SUPPORT SLIDE 56 043181 2 SCREW PHM M3 0 5 X 10MM 23 075242 4 SPRING GEN MOUNT 57 075210A 1 BLOCK 1 POSITION 24 075237 4 WASHER SPRING CENTER 58 022264 2 WASHER LOCK 8 4 25 090145 1 CIRCUIT BREAKER 30 X 1 5 5 amp 6 5 59 051715 2 NUT HEX M4 0 7 G8 YEL CHR KW ONLY 60 0 7605 2 SCREW HHC M5 0 8 X 60 G8 8 0E1529 1 CIRCUIT BREAKER 35 X 1 7 5 KW 61 083049 1 ASY POTTED REG W FIN ONLY 62 089047 2 SPACER 25 X 43 55 ST ZNC 26 090144 1 CIRCUIT BREAKER 20 X 1 5 5 KW 63 075234 1 RESISTOR WW LUG 1R 5 25W ONLY 64 042053 1 SCREW HHC M6 1 0 X 65 08 8 090145 1 CIRCUIT BREAKER 30 X 1 6 5 KW 65 058000 2 NUTTRIC M5 X 8 ONLY 66 008941 1 COMPARTMENT AIR BOX 0E1529 1 CIRCUIT BREAKER 35 X 1 7 5 KW 67 029451 23FT TAPE 1 2 X 1 16 CLOSED CELL ONLY 68 0 0583 1 WIRE HARNESS QP RV GASOLINE 27 025105 4 SCREW RHM 6 32 X 1 4 SIMS ONLY NOT SHOWN 28 0 9611 1 FUSE7 5 0 1812 1 WIRE HARNESS RV LP ONLY 29 032300 1 HOLDER FUSE NOT SHOWN 30 092113 1 SWITCH SPDT ON MOM ON 69 0 1375
39. 00060 J3 J2 J1 ENGINE CONTROLLER CIRCUIT BOARD PCB DIODE RESISTOR Figure 7 4 The Field Boost Circuit 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 cur rent to the Rotor will then terminate and the unit s AC output voltage will drop to a value that is commensurate with the rotor s residual magnetism about 5 12 mn Bl A Schematic B Pictorial Figure 7 5 Stator Excitation Winding Page 41 Section 7 DIAGNOSTIC TESTS PROCEDURE 1 Disconnect Wire 2 from the Excitation Circuit Breaker 2 Disconnect Wire 6 from the Voltage Regulator 3 Set a to its Rx1 scale and zero the meter 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 Windings EXCITATION WINDING RESISTANCE Measured Across Wires 2 8 6 MODEL OHMS 1 410 1 6302 1 590 1 8402 1 1202 1 300 QP55 4702 4703 QP65 4704 4705 QP75 4706 4707 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 5 Now set the meter to its Rx1 or Rx10 000 scale and zero the meter Test for a short to ground c
40. 1 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 QP55 4702 4703 QP65 4704 4705 QP75 4706 4707 OHMS 14 88 10 819 14 500 16 00 Resistance values In ohms at 20 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 Rx1 or Rx10 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 frame ground such as the Rotor shaft The meter should read Infinity RESULTS 1 Replace the Rotor if it fails the test Page 44 2 f Rotor checks good perform Insulation Resistance Test on Page 14 TEST LEAD Figure 7 8 Rotor Assembly 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 A Schematic B Pictorial Figure 7 9 Main Breaker Typical PROCEDURE Set the coach main breaker to it s OFF position Check that the appropriate main breaker on the gen e
41. 1 WIRE ASS Y STARTER TO C PNL 31 087798 1 SWITCH 6A SPDT NOT SHOWN Page 79 N NI ZI EN 2x sm Q SI C I q lt Section 9 Exploded Views Part Numbers 760 V Twin Engine Drawing No 0E1014 B 62 63 64 Page 80 Section 9 Views Numbers ITEM PART QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0C5730A 1 ASSEMBLY CRANKCASE RV 33 0 2991 2 E RING GOVERNOR ARM 2 0C3008 1 SEAL 38 I D CRANKCASE 34 0D1667A 1 ARM GOVERNOR 3 090388 6 SCREW HHTT M6 1 0 X 12mm 35 062988 1 THRUST WASHER GOVERNOR 4 065372 1 ASSEMBLY BREATHER 36 00299 1 BUSHING GOVERNOR LOWER 5 0C3005 1 GASKET BREATHER COVER 37 065732 1 ASSEMBLY SUMP WITH SLEEVE 6 0C3003 3 SEPARATOR OIL BREATHER 38 0062993 1 SEAL GOVERNOR SHAFT 7 008067 1 ASSEMBLY HEAD 1 39 0C3007 1 SEAL 42 1 0 CRANKSHAFT 8 0C2981C 1 COVER ROCKER 40 009756 1 CONNECTOR 3 8NPT TO INVTD 9 071983 4 RETAINER PISTON PIN 20 FLR 3 80D 10 0C5848 2 PISTON HC 41 0C3006 10 SCREW HHFC M10 1 5 X 55mm 11 021533 2 SET PISTON RING 90mm 42 0C8566 8 SCREW M6 1 0 X 20mm 12 071980 2 PIN PISTON D20 43 0C2982 1 COVER ROCKER WITH OIL FILL 13 004041 1 ASSEMBLY CAMSHAFT 8 GEAR 44 093064 1 ASSEMBLY OIL FILL CAP 14 0 2983 1 SHAFT GOVERNOR 45 062979 2 GASKET VALVE COVER 15A 0 2985 2 ROLLER BEARIN
42. 14 LI Lo sw2 C 16 PCB scs d 15 lt J3 gt 56 lt J2 N2 gt 90 0 N3 16 18A M1 gt 5 1 15 14 gt t nt N5 gt 18 IM2 SP2 N6 2 17 H 8TARN SW1 0 0B 15 41 7 17 0 2 gt 177777 J1 9 4 HTO 14 2 85 00 1 10 gt 66 J1 11 gt 85 85 1 0 0 J1 12 X 0 11 13 2 66 4144 gt 18 4 PANEL CONNECTOR J1 15 2 18 17 ol 1 1 17 2 2 14 14 3 3 15 18 4 4 14 15 lt BCR 14 m FET 15 T77 66 18 14 BATTERY CHARGE WINDING 55 STOP R1 ON NW x V AL AA AJ uy POWER WINDING 4 V ALA AA 33 44 ON 228 115 11 008 FUEL 22 Q PRIME ELECTRONIC REMOTE PANEL VOLTAGE 2 OPTIONAL ok REGULATOR O RED T A BLACK ON 9 4 T1 2 6 T3 WINDING OF O A AA O 4 77 FIELD WHITE 120V 20 QP55 BLACK 120V 30 QP65 T2 120V QP75 RED 120V 30A QP55 amp QP65 120V 35A QP75 NEUTRAL CONNECTION BY CUSTOMER LEGEND BCR BATTERY CHARGE RECTIFIER CB1 CIRCUIT BREAKER 30A 55 amp QP85 MODELS CIRCUIT BREAKER 35A QP75 MODEL CB2 CIRCUIT BREAKER 20A QP55 MODEL CIRCUIT BREAKER 30A QP85 MODEL CIRCUIT BREAKER 35A CBS CIRCUIT BREAKER 2 54 QP55 MODEL CIRCUIT BREAKER 3 0A QP65 amp QP75 MODELS CH CHO
43. 3 Section 7 DIAGNOSTIC TESTS Figure 7 24 Tachometer TEST BRACKET A starter motor test bracket may be made as shown in Figure 7 25 METAL STOCK 1 4 THICK STEEL DRILL TWO HOLES 1 2 MOUNTING M DRILL TWO HOLES 1 2 FOR MOUNTING TACHOMETER TAP FOR 1 4 20 NC SCREWS Figure 7 25 Test Bracket 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 26 TESTING STARTER MOTOR 1 A fully charged 12 volt battery is required 2 Connect jumper cables and clamp on ammeter as shown in Figure 7 26 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 Page 54 4 A 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 18 60 amps CLAMP ON AMP METER STARTER CONTACTOR STARTER 12 VOLT BATTERY Figure 7 26 Testing Starter Motor Performance TEST 28 CHECK FUEL SUPPLY DISCUSSION GASOLINE MODELS If the engine cranks
44. 4 in the control panel Continuity should be measured SHORT TO GROUND Set the VOM to measure resistance Connect one meter test lead to Wire 14 Connector 1 Pin 3 going to the Bi Metal Heater Assembly Connect the other meter test lead to the exposed steel portion of the Bi Metal Heater Assembly Approximately 37 ohms 20 should be measured Current draw of the Bi Metal Heater Assembly at nominal voltage is approximately 340 milliamps or 0 340 amps If Continuity is present the Bi Metal Heater Assembly has a short to ground RESULTS 1 Choke Plate is binding in Step 1 repair or replace binding Choke Plate If Bi Metal Heater Assembly tests good go to Test 35 2 f continuity was not measured in Step 3 repair or replace Wire 14 between the 4 tab Terminal and Connector 1 3 If the resistance value is incorrect in the Short to Ground step or the Bi Metal Heater Assembly does not function with voltage present replace the Bi Metal Heater Assembly TEST 42 CHECK LPG FUEL SOLENOID DISCUSSION If the LPG Fuel Solenoid FS fails to open fuel will not be available to the engine and it will not start PROCEDURE 1 Place one hand on the top of the LPG Fuel Solenoid Activate the Fuel Prime Switch You should be able to feel as well as hear the solenoid energize If solenoid energizes discontinue testing 2 Set VOM to measure resistance Disconnect Wire 0 from the LPG Fuel Solenoid Connect one met
45. 5 MODEL CIRCUIT CONDITION CRANKING When the START STOP SWITCH SW1 or REMOTE PANEL START SWITCH is held at START position Wire 17 from the Engine controller circuit board is con nected to frame Ground Circuit board action will then deliver battery voltage to a STARTER CONTACTOR RELAY SCR wire 56 and to a automatic CHOKE SOLENOID CS via Wire 90 When battery voltage energizes the STARTER CON TACTOR RELAY SCR Its contacts close and battery output is delivered to the STARTER CONTACTOR SC via Wire 16 The STARTER CONTACTOR SC gizes and its contacts close battery output is delivered to the STARTER MOTOR SM via Wire 16 The STARTER MOTOR energizes and the engine cranks When the STARTER CONTACTOR RELAY SCR closes Battery voltage is also delivered to the circuit board pin location J1 13 via Wire 16 This voltage is reduced and used for field boost and is outputted from pin location J1 9 While cranking the CHOKE SOLENOID CS is ener gized cyclically by circuit board action two seconds on two seconds off Also while cranking circuit board action energizes CIRCUIT BOARD TERMINAL J2 and delivers battery voltage to the Wire 14 14A circuit This energizes the FUEL PUMP FUEL SOLENOID FS and CHOKE HEATER CH and optional light or hourmeter in remote panel Circuit board action holds open Wire 18A to common ground The Magneto will induce a spark during cranking BROWN LLI
46. 60 volts Record the results and stop the generator 7 Re connect Wire 11 and Wire 22 to the Voltage Regulator 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 Page 40 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 6 and 2A It also receives voltage 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 signals 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 2A 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 on
47. 894595 8 BRUSA HOLDER 9 BATTERY CHARGE COMPONENTS 9 EXCITATION CIRCUIT COMPONENTS 9 CRANKCASE BREATHER 10 SECTION 3 INSULATION RESISTANCE TESTS 12 14 EFFECTS OF DIRT AND MOISTURE 12 INSULATION RESISTANCE TESTERS 12 DRYING THE GENERATOR 12 CLEANING THE GENERATOR 12 STATOR INSULATION RESISTANCE 13 TESTING ROTOR INSULATION 14 THE MEGOHMMETER 14 SECTION 4 MEASURING ELECTRICITY 15 17 METER maa ee rene nee 15 THE AA 15 MEASURING AC VOLTAGE 15 MEASURING DC VOLTAGE 15 MEASURING AC FREQUENCY 16 MEASURING CURRENT 16 MEASURING RESISTANCE 16 ELECTRICAL UNITS ee 17 kea S M cm Tf SECTION 5 ENGINE DC CONTROL SYSTEM 18 26 INTRODUCTION aa errr eee eee 18 OPERATIONAL ANALYSIS 18 23 ENGINE CONTROLLER CIRCUIT BOARD 24 MC cR 24 AMP FUSE ss 25 FUEL PRIMER SWITCH zes ee 25 START STOP SWITCH
48. AD TEST 26 CHECK WIRES AS REQUIRED TESTA E STARTER CONTACTOR TO WIRE 56 REPLACE BAD REPLACE ENGINE BAD STARTER CONTROLLER CIRCUIT 4 1 CONTACTOR RELAY BOARD TEST 26A TEST GOOD STARTER CONTACTOR TEST 27 CHECK BAD STARTER MOTOR BAD GOOD REPLACE STARTER CONTACTOR REPLACE STARTER CUECIUEDR MOTOR IF DEFECTIVE MECHANICAL BINDING OF THE ENGINE OR ROTOR Page 31 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 7 Engine Cranks But Will Not Start Gasoline Units TEST 19 TEST GOOD PRIMER SWITCH TEST 28 TEST 29 CHECK CHECK FUEL O K ali WIRE 14 POWER SUPPLY SUPPLY REPLACE ENGINE BAD LOW FUEL BAD CONTROLLER CIRCUIT BOARD REPLACE BAD SWITCH REPLENISH FUEL SUPPLY TEST 20 CHECK TEST 31 CHECK FUEL SOLENOID FUEL PUMP GOOD M 9 OPERATION GOOD BAD BAD REPLACE gt TEST 32 k sa CHECK IGNITION PUMP 5 TEST 33 a CHECK SPARK GOOD PLUG WEAK SPARK NO SPARK INTERMITTENT SPARK TEST 34 CLEAN AND COIL BAD REPLACE COIL REPLACE SPARK PLUG TEST 36 CHECK EST 37 CHECK CARBURETION GOOD CHOKE GOOD SOLENOID BAD ADJUST OR REPAIR ADJUST OR REPAIR CHECK TEST 35 CHECK TEST 38 CHECK FLYWHEEL KEY VALVE NO START ENGINE CYLINDER ADJUSTMENT LEAK DOWN TEST COMPRESSION TEST GOOD SEE TE
49. 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 38 Section 3 INSULATION RESISTANCE TESTS CAUTION Some generators may use epoxy polyester base winding varnishes Use solvents that will not attack such materials Use a soft brush or cloth to apply the solvent Be care ful to avoid damage to wire or winding insulation After cleaning dry all components thoroughly using mois ture free low pressure compressed air DANGER DO NOT ATTEMPT TO WORK WITH SOLVENTS IN ANY ENCLOSED AREA PRO VIDE 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
50. CEDURE 1 Set a VOM to read battery voltage 12 VDC 2 Connect the positive meter test lead to the Wire 15 terminal of the Primer Switch leave Wire 15 connected to the switch Connect the negative meter test lead to frame ground The meter should indicate battery voltage 3 Connect the positive meter test lead to the Wire 14 terminal of the Primer Switch leave Wire 14 connected to the switch Connect the negative meter test lead to a clean frame ground Set the Start Stop switch to START The engine should crank and battery voltage should be measured 4 Connect the positive meter test lead to the Wire 14A termi nal of the Primer Switch the negative meter test lead to frame ground a With the Primer Switch NOT actuated no voltage should be indicated b Actuate the switch to its PRIME position and the meter should read battery voltage For gasoline models disconnect Connector 2 at the Fuel Pump Connect the VOM positive test lead to Wire 14A Pin 2 of Connector 2 going up to the Control Panel see Figure 7 12 Connect the VOM negative test lead to frame ground Repeat Steps 4a and 4b Battery Voltage should be measured when the Primer Switch is activated PIN 2 WIRE NO 14A PIN 1 WIRE NO Figure 7 12 Harness End of Connector 2 For LPG models disconnect Wire 14A from the LPG Fuel Solenoid FS see Figure 7 13 Connect the VO
51. CK 6 0C3188 1 WASHER LOCK SPECIAL 5 16 36 073118 1 SCREW HHC 3 8 24 X 2 1 4 G8 7 0C2417 1 EARTH STRAP 37 046526 1 WASHER LOCK M10 8 077603 2 SCREW HHC 5 16 18 X 3 5 SPC 38 022131 1 WASHER FLAT 3 8 M10 ZINC 9 0 0588 1 SPACER SAFETY BOLT 375 1 0 39 0 2824 7 SCREW TAP R 10 32 10 029451 15 TAPE ELEC UL FOAM 1 8 X 40 0 1077 1 BLOWER HOUSING GTV760 RV 11 008912 1 DUCT AIR OUT 41 042633 1 SCREWHHC 3 8 24 X 1 G5 12 0 0571 2 GASKET AIR OUT DUCT 42 022237 1 WASHER LOCK 3 8 13 008911 1 BRACKET MUFFLER SUPPORT 43 049451 1 WASHER FLAT 4060 X 1 6200 14 043107 7 SCREW HHC M8 1 25 X 25 G8 8 44 0 1441 1 SET BLOWER HOUSING GASKET 15 009021 1 MUFFLER GTV760 RV 45 0C1112 1 BELT V RIB 4LX42 5 16 096289 1 CLAMP EXHAUST 1 25 46 023484 1 BUSHING SNAP GASOLINE ONLY 17 008940 1 MANIFOLD EXHAUST 0E1534 1 PLUG PLASTIC 0 687 LP ONLY 18 070006 4 WASHER LOCK M8 SS 47 007530 1 STUD M6 1 0 OFFSET 19 070008 4 WASHER FLAT M8 SS 48 009723 1 ELEMENTAIR FILTER 20 040976 4 SCREW M8 1 25 X 20 G12 9 49 004511 12 PRECLEANER AIR GTH990 GASO 21 056893 6 SCREW CRIMPTITE 10 24 X LINE 22 023897 6 WASHER FLAT 10 ZINC 50 008981 2 FILTER GASKET RV GASOLINE 23 0 1078 2 GASKET EXH BASE GTV760 RV ONLY 24 004138 2 GASKET EXHAUST PORT 008981 1 FILTER GASKET RV LP ONLY 25 043116 SCREW HHC 6 1 0 X 12 G8 8 5 5 51 008451 1 WASHER FLAT 281 ID X 1 25 OD KW ONLY 52 087680 2 NUT WING M6 1 0 26 022097 4 WASHER LOCK M6 1 4 5 5 KW 53 003700 NUTFLANGE
52. Connect the other test lead to frame ground Battery voltage should be measured Verify that Wire 15 is connected to J3 and that Wire 14 is connected to J2 if reversed the unit will produce no spark 4 Rotate the flywheel until the magnet is under the module armature laminations see Figure 7 37 5 Place a 0 012 0 015 inch thickness gauge between the fly wheel magnet and the module laminations 6 Loosen the mounting screws and let the magnet pull the mag neto down against the thickness gauge 7 Tighten both mounting screws 8 To remove the thickness gauge rotate the flywheel 9 Repeat the above procedure for the second magneto Figure 7 37 Setting Ignition Magneto Armature Air Gap 10 Repeat Test 55 and check for spark across the spark tester gap 11 If air gap was not out of adjustment test ground wires 12 Set the VOM to the diode test position The meter will display forward voltage drop across the diode If the voltage drop is less than 0 7 volts the meter will Beep once as well as dis play the voltage drop A continuous tone indicates Continuity shorted diode An incomplete circuit open diode will be dis played as OL 13 Disconnect the engine ground harness from the ignition mag netos and stud connector see Figure 7 38 Page 60 SPARK PLUG WIRE 18A TO CIRCUIT BOARD ENGINE GROUND HARNESS Figure 7 38 Engine Ground Harness SWITCH ON TURNED OFF CAUSE E
53. Continuity was not measured in Step 2 when the Start Stop switch was activated to START replace the Starter Contactor Relay 3 If Continuity is measured in Step 2 go to Test 26A TEST 26A CHECK STARTER CONTACTOR DISCUSSION The Starter Contactor SC must energize and it s heavy duty contacts must close or the engine will not crank This test will determine if the Starter Contactor is in working order The Starter Contactor is connect ed to the Starter Motor see Figure 7 20 STARTER SWITCH CONNECTING DIAGRAM STARTER CONTACTOR STEP 1 LA TEST POINT STARTER MOTOR Figure 7 20 The Starter Contactor SC PROCEDURE 1 Carefully inspect the starter motor cable that runs from the Battery to the Starter Motor Cable connections should be clean and tight If connections are dirty or corroded remove cable and clean cable terminals and studs Replace any cable that is defective or badly corroded Set the VOM to measure voltage Connect the positive meter test lead to the Starter Contactor stud that the battery cable is connected to Connect the negative meter test lead to a clean frame ground Battery voltage should be measured see Figure 7 20 STEP 1 TEST POINT Page 52 2 Set the VOM to measure DC voltage Disconnect Wire 16 from the Starter Contactor Connect the positive meter test lead to Wire 16 Connect the negative meter test lead to a clean frame ground Set the Star
54. Crankcase Breather DESCRIPTION The crankcase breather is equipped with a reed valve to control and maintain a partial vacuum in the crankcase The breather is vented to the intake Section 2 MAJOR GENERATOR COMPONENTS elbow The breather chamber contains a removable oil vapor collector Oil vapor is condensed on the col lector material and drains back into the crankcase which minimizes the amount of oil vapor entering the breather CHECK BREATHER 1 Disconnect breather tube and remove four screws and breather Discard gasket 2 Check to see that reed valve is not deformed Figure 2 8 Note Reed valve must form a complete seal around vent hole 3 Remove oil vapor collector and retainer 4 Check collector for deterioration and replace if necessary INSTALL BREATHER 1 Install oil vapor collector and retainer Note Push oil vapor collector and retainer in until it bottoms 2 Install breather with new gasket Figure 2 8 a Torque screws to 5 8 ft Ibs 3 Assemble breather tube to intake elbow CONTROL PANEL IDENTIFICATION 4 TAB TERMINAL CONNECTOR TC BATTERY CHARGE RECTIFIER BCR BATTERY CHARGE RESISTOR RI FUSE F1 CIRCUIT BREAKERS CB1 amp CB2 START STOP SWITCH SWITCH SW2 SW1 FUEL PRIME STARTER CONTACTOR RELAY SCR GROUND TERMINALS VOLTAGE REGULATOR VR EXCITATION CIRCUIT BREAKER CB3 ENGINE CONTROL BOARD PCB
55. D shs gt CHOKE GOOD SOLENOID ENGINE RUNS O K NOW STOP TESTS ADJUST REPAIR OR BAD gt REPLACE AS NECESSARY REPAIR OR REPLACE lt BAD TEST 41 TEST en CHOKE HEATER TEST 38 CHECK CHECK VALVE GOOD gt SEE TEST 34 GOOD gt CYLINDER LEAK ADJUSTMENT ON PAGE 61 DOWN TEST COMPRESSION TEST BAD 4 BAD REPAIR OR REPLACE 41 ADJUST VALVES AS NECESSARY Page 34 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 8 Engine Starts Hard and Runs Rough LP Units TEST 28 TEST 32 TEST 33 CHECK CHECK CHECK FUEL IGNITION coop Spark GOOD SUPPLY SPARK PLUG BAD LOW LP ENGINE MISS IS APPARENT S PRESSURE CLEAN AND REGAP OR REPLACE SPARK PLUG E TEST 34 SUPPLY isi BAD TP REPLACE COIL IGNITION COIL TEST 38 CHECK TEST 35 CHECK ENGINE VALVE GOOD gt CYLINDER LEAK ADJUSTMENT SIDE DOWN TEST COMPRESSION TEST BAD ADJUST VALVES REPAIR OR merce GOOD AS NECESSARY CHECK FUEL REGULATOR AND CARBURETOR Page 35 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 9 Engine Starts Then Shuts Down CHECK TEST 39 CHECK ENGINE OIL LEVEL GOOD SWITCH OIL LEVEL LOW BAD REPLENISH OIL REPLACE SWITCH TEST 40 TEST OIL TEST 24 TEST SWITCH SWITCH REPLACE BAD BAD REPLACE BAD SWITCH BAD SWITCH GO TO PROBLEM 8 GOOD
56. E CONTROLLER Ri RESISTOR 1 OHM 25W SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SW1 SWITCH START STOP SW2 SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 TAB CONNECTOR Section 5 ENGINE CONTROL SYSTEM BATTERY ee 7 a00 4 71 6 gt N7 3 17 gt N9 2 4 J1 10 2 66 11 11 2 85 J1 12 gt 0 14A J1 15 18 ON oa Q N AN O Q Q N POWER WINDING ELECTRONIC VOLTAGE REGULATOR WHITE 120V 20A QP55 e 120V 30A QP65 RED 120V 35A QP75 T2 120V 55 amp 65 120V 35A QP75 NEUTRAL CONNECTION BY CUSTOMER J1 43 2 REMOTE J1 14 gt 18 PANEL CONNECTOR REMOTE PANEL OPTIONAL CB3 CIRCUIT BREAKER 2 5 QP55 MODEL CIRCUIT CONDITION PRIMING When the FUEL PRIMER SWITCH SW2 or the REMOTE PANEL FUEL PRIMER is closed by the oper ator battery voltage is delivered across the closed switch contacts and to the FUEL PUMP via Wire 14A The FUEL SOLENOID FS will be energized via Wire 14 during cranking and running BROWN LLI 12VDC SUPPLY r 12 0 CONTROL s GROUND LEGEND BCR BATTERY CHARGE RECTIFIER CB1 CIRCUIT BREAKER 30A QP55 amp QP65 MODELS CIRCUIT BREAKER 35A QP75 MODEL CB2 CIRCUIT BREAKER 20A QP55 MODEL CIRCUIT BREAKER 30A QP65 MODEL CIRCUIT BREAKER 35A QP75 MODEL C
57. ER GASOLINE ONLY SOLENOID CHOKE GASOLINE ONLY SCREW HHC M5 0 8 X 10 G8 8 WASHER LOCK M5 WASHER FLAT M5 LINKAGE CHOKE GASOLINE ONLY COTTER PIN GASOLINE ONLY NUT LOCK HEX M5 0 8 SS NYL INS ASSEMBLY GOV ADJUSTMENT SCREW HHC M8 1 25 X 20 G10 9 WASHER LOCK 8 5 16 WASHER FLAT 5 16 M8 ZINC LINKAGE CHOKE BELLCRANK CARB ASSEM CHOKE BRACKET GASOLINE ONLY BRACKET CHOKE LP ONLY 109 110 111 112 113 114 115 116 117 0 7095 009404 0D9801A 0C3018A 0D9680A 0D1143A 0C3053 085011 0D9852 022097 092079 0C1546 0C1547 082774 0A5358 0D9312 0D9314 0C1557 0A9028 0D9682A 0D9270 048031A 0D9269 0E0142 078643B 0D9219 0E0573 0D8807 0 1217 0 0572 0C3043 008836 049821 070008 070006 035461A 0C7649 0C9806 0C3026 0D9683A 0C9764 036933 0E0246 0D9394 022152 022158 043116 049811 047411 066849B 057822 074994 075476 082121A 038150 022264 051715 0D6029 055934D 022473 090388 0E3200 NO OI N 4 OO BD DESCRIPTION RHMS 4 40 X 5 16SEMS SPRING CHOKE RETURN WRAP VALLEY UPPER SPCC WRAPPER UPR 1 W M8 WELD NUT WRAP VALLEY GTV760 RV SPCC WRAPPER UPR 2 W M8 WELD NUT ASSY GROUND WIRE GTV990 INSULATOR ASM IGN ASSY IGNITION COIL GT760 RV WASHER LOCK M6 1 4 SCREW HHTT M6 1 0 X
58. ESTERS 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 Page 12 DANGER INSULATION RESISTANCE TESTERS SUCH AS HI POT TESTERS AND MEGOHMMETERS ARE A SOURCE OF HIGH AND DANGEROUS ELECTRICAL VOLTAGE FOLLOW THE TESTER MANUFACTURER S INSTRUCTIONS CAREFULLY USE COMMON SENSE TO AVOID DANGEROUS ELECTRI CAL 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 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 F 8 10 C 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 66 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
59. G GOVERNOR 46 086515 8 KEEPER VALVE SPRING PLATE 47 002274 4 RETAINER VALVE SPRING 158 0 2985 1 ROLLER BEARING GOVERNOR 48 003867 4 SPRING VALVE 16 004042 1 ASSEMBLY GOVERNOR GEAR 49 078672 2 SEAL VALVE STEM D7 17 OA7811 1 SPOOL GOVERNOR MACHINED 50 0C5371 4 WASHER VALVE SPRING 18 062977 1 GASKET CRANK CASE 51 005326 4 JAM ROCKER ARM 19 0C5943 1 SEAL OIL PASSAGE 52 005354 4 PIVOT ROCKER ARM 20 0D4122A 1 ASSEMBLY CRANKSHAFT 53 0D5313 4 ARM 21 003961 2 ASSEMBLY CONNECTING ROD 54 0D6023 4 STUD ROCKER ARM M8 1 0 x 22 062978 2 GASKET HEAD 57mm 23 093873 3 WASHER LOCK RIB M6 55 006024 2 PLATE PUSH ROD GUIDE 24 021374 3 SCREW SHC M6 1 0 X 30mm 56 0C2976 12 SCREW 8 1 25 X 65mm 25 062994 1 SCREEN OIL PICKUP 57 008067 1 ASSEMBLY HEAD 2 26 002997 1 COVER GEROTOR 58 062229 2 VALVE INTAKE 27 0C2995 1 INNER 59 086516 2 VALVE EXHAUST 28 0 2996 1 OUTER 60 009853 4 PUSHROD 147 29 0C3011 2 COVER OIL RELIEF 61 083897 4 TAPPET SOLID 30 003009 2 SPRING OIL RELIEF 62 0C3017 1 STARTER V TWIN ENGINE 31 003010 2 BALL 1 2D OIL RELIEF 63 022129 2 WASHER LOCK M8 32 050873A 1 1 4 NPT PIPE PLUG 64 061906 2 SCREW HHC M8 1 25 X 85mm Page 81 Section 9 Exploded Views Numbers LP Regulator Drawing 0E1530 DY 11 A X LN EPA PY ON KEIN AJ Near y 27 82 Section 9 Views Numbers
60. GROUND LEGEND BCR BATTERY CHARGE RECTIFIER CB1 CIRCUIT BREAKER 30A QP55 amp QP65 MODELS FUEL CIRCUIT BREAKER 35A QP75 MODEL PRIME CB2 CIRCUIT BREAKER 20A QP55 MODEL _ CIRCUIT BREAKER 30A QP65 MODEL CIRCUIT BREAKER 35A QP75 MODEL CIRCUIT BREAKER 2 5A QP55 MODEL CIRCUIT BREAKER 3 0A QP65 8 QP75 MODELS CH CHOKE HEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 FP FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL HTO SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IM1 IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO 2 CYL LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE PCB ENGINE CONTROLLER R1 RESISTOR 1 OHM 25W SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SW1 SWITCH START STOP SW2 SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 TAB CONNECTOR Page 21 Section 5 ENGINE CONTROL SYSTEM BATTERY 4 BLK 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 frame ground Circuit board action then closes the circuit to Wire 18A grounding the ignition magneto Circuit board action de energizes DC o
61. HECK FUEL PUMP DISCUSSION An inoperative Fuel Pump will a prevent the priming function from working and b prevent the engine from starting PROCEDURE 1 Remove Fuel Filter and verify that filter is not clogged Replace filter if necessary 2 Verify that fuel is available to Fuel Filter inlet Use an alterna tive fuel supply if questionable Page 48 3 Remove air filter access panel and air filter Remove fuel hose from pump Place a suitable container to catch fuel from fuel pump line Activate fuel primer switch Pump should operate and fuel should flow If pump does not operate proceed to Step 4 4 n Test 19 Battery Voltage was checked at Connector 2 This step will test the ground wire Disconnect Connector 2 at the Fuel Pump Set the VOM to measure resistance Connect one test lead to Wire O Pin 1 of Connector 2 that goes to the Control Panel see Figure 7 12 Connect the other test lead to a clean frame ground Continuity should be measured To test for open fuel pump coil connect one test lead to Red Wire Pin 2 of Connector 2 going to the fuel pump Connect the other test lead to the Black Wire Pin 1 of Connector 2 going to the Fuel Pump see Figure 7 15 The VOM should indicate Fuel Pump coil resistance of about 29 5 kW Current draw of the pump at nominal voltage is approxi mately 1 4 amperes MAXIMUM Short to Ground 6 To test for a shorted fuel pump coil conne
62. ING CARRIER STATOR BEARING ROTOR BEARING LOWER BEARING CARRIER ENGINE PULLEYS AND BELT 1 2 3 4 5 6 f 8 9 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 All generator models in this manual utilize a 2 pole Rotor 1 one having a single north and a single south pole 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 may be cleaned dull or tarnished clean them with fine sandpaper a 400 grit wet sandpaper is recommended DO NOT USE ANY METALLIC GRIT OR ABRASIVE TO CLEAN SLIP RINGS Page 8 STATOR ASSEMBLY The Stator is sandwiched between the upper and lower bearing carriers and retained in that position by four Stator studs Windings Included in the Stator assembly 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 11P 22 33 and 44 These leads de
63. ING RESISTANCE QP75 Model 4706 4707 ACROSS WIRES OHMS 11P amp 22P 0 157 0 1829 115 amp 225 0 157 0 1829 33 amp 44 0 157 0 1829 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 8 Now set the VOM to its Rx1 or Rx10 000 scale and zero the meter Section 7 DIAGNOSTIC TESTS 9 Connect the meter test leads across Stator lead 11P and frame ground Infinity should be read 10 Connect the meter test leads across Stator lead 33 and frame 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 11P 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 115 and 225 2 Replace the Stator if it s power windings fail the test Note Result No 1 3 If the Powe
64. IRCUIT BREAKER 3 0 QP65 amp QP75 MODELS CH CHOKEHEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 5A FP FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IM1 IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO 2 CYL LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE ENGINE CONTROLLER Ri RESISTOR 1 OHM 25W SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SW1 SWITCH START STOP SW2 SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 TAB E IL CONNECTOR Page 19 Section 5 ENGINE CONTROL SYSTEM BATTERY I BLK Ha 2 J2 Ji2 gt 90 nn 0 13 16 Ma SP1 15 Na 3 18A N15 gt i SP2 X 17 TO sa N7 2 17 5 ON O Od Q N POWER WINDING ELECTRONIC VOLTAGE REGULATOR ON 120V 20A QP55 T e 120V 30A QP65 120V 35A QP75 120V 30A QP55 amp QP65 120V 35A QP75 NEUTRAL CONNECTION BY CUSTOMER Page 20 gt I i CU J1 9 3 4 HTO 14A PIE 85 m O I LOP 18 11 2 85 J1 12 gt 0 J1437 REMOTE J1 14 gt 18 PANEL 17 1 14 18 REMOTE PANEL OPTIONAL CB3 CIRCUIT BREAKER 2 5 QP5
65. KE HEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 5A FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL HTO SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IM1 IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO 2 CYL L1 LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE PCB ENGINE CONTROLLER R1 RESISTOR 1 OHM 25W SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SW1 SWITCH START STOP SW SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 TAB CONNECTOR Page 88 Section 11 ELECTRICAL DATA Electrical Schematic and Wiring Diagram Drawing No 0E1057 D SCHEMATIC DIAGRAM
66. L PRIMER SPARK PLUG 1 CYL SPARK PLUG 2 CYL TERMINAL CONN 4 TAB CONNECTOR Page 23 Section 5 ENGINE CONTROL SYSTEM ENGINE CONTROLLER CIRCUIT BOARD GENERAL The engine controller board is responsible for crank ing startup running and shutdown operations 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 a 15 pin receptacle J1 and two single pin terminals J2 and J3 see Figure 5 3 Figure 5 2 shows the 15 pin receptacle J1 the asso ciated wires and the function s of each pin and wire PIN WIRE FUNCTION Delivers 12 VDC to Starter Contactor SC ah while cranking only Delivers 12 VDC to Choke Solenoid coil while cranking only Two seconds ON Two seconds OFF Not used wes Grounds Magneto for Shutdown used To Start Stop switch When wire is grounded by setting Start Stop switch to START engine will crank To Start Stop switch on optional Remote ura used Field Boost DC to Voltage Regulator and to Rotor windings Starter Lockout Prevents cranking while engine is running Fault shutdown circuit When grounded by clo sure of High Oil Temperature or Low Oil Switch engine will shut down Ground 12 VDC Input to Field Boost circ
67. LTS 4 8 5 5 ft lbs ROCKER ARM JAM NUTS 156 6 191 4 in Ibs OIL PRESSURE RELIEF COVER BOLT 7 4 ft lbs OIL FILTER ADAPTER 9 ft lbs IGNITION COILS 6 7 8 1 ft lbs INTAKE MANIFOLD 12 6 15 4 ft lbs FAN RETAINER 16 20 ft lbs LARGE AND SMALL PULLEY 34 2 41 8 ft lbs TRIM TORQUE REQUIREMENTS Refer to Engine Service Manual No OE2081 for complete GTV 760 990 V Twin engine service information Page 86 M3 5 PHILLIPS PAN HEAD SCREW INTO ALUMINUM 50 in Ibs 6 1 TAPTITE SCREW INTO ALUMINUM 96 in Ibs 6 1 TAPTITE SCREW INTO WELDNUT 96 in Ibs 8 1 25 TAPTITE SCREW INTO ALUMINUM 18 ft lbs STARTER BRACKET TO BLOCK 18 ft lbs GOVERNOR LEVER PINCH BOLT 120 in Ibs FLYWHEEL NUT 135 165 ft lbs SPARK PLUG 15 ft lbs RV TORQUE REQUIREMENTS EXHAUST OUTLET BOLTS 18 ft lbs STATOR BOLTS 7 2 8 8 ft lbs 6 1 TAPTITE SCREW INTO PIERCED HOLE 96 in Ibs NOTES Page 87 Section 11 ELECTRICAL DATA Electrical Schematic and Wiring Diagram Drawing No 0E1057 D SCHEMATIC DIAGRAM BATTERY RED I BLK sc 13 RED 16 0 9 13 16 e sc 0 SCR 15 P di 14 FP 0
68. M positive test lead to Wire 14A Connect the VOM negative test lead to frame ground Repeat Steps 4a and 4b Battery Voltage should be measured when the Primer Switch is activated O 7 Set the VOM to measure resistance at the Rx1 scale and zero the meter a Disconnect Wire 14 from the Primer Switch b Connect the meter test leads across the Wires 14 and 14A terminals of the switch c With the switch NOT actuated the meter should read Continuity Page 47 Section 7 DIAGNOSTIC TESTS Figure 7 13 The LPG Fuel Solenoid FS RESULTS 1 If battery voltage is not indicated in Step 2 check Wire 15 between the Primer Switch and the 7 5 amp fuse for an open condition 2 If battery voltage is indicated in Step 2 but not in Step 4 replace the Primer Switch If battery voltage is NOT indicated in Step 3 repair or replace Wire 14 between the 4 tab Terminal Connector TC and the Fuel Primer Switch SW2 3 If battery voltage was indicated in Step 4 but not in Step 5 a For gasoline models repair or replace Wire 14A between the Primer Switch SW2 and Fuel Pump Connector 2 b For LPG models repair or replace Wire 14A between the Fuel Prime Switch SW2 and the LPG Fuel Solenoid FS 4 f the meter reads anything other than Continuity in Step 7 replace the Primer Switch 5 If the Primer Switch checks good go to Test 20 for Gasoline models For LPG models go to Test 42 TEST 20 C
69. M8 5 16 LP ONLY 39 022259 2 NUT HEX 5 16 18 STEEL 40 045756 8 SCREW HHTT M6 1 0 X 10 YC 41 0A2115 1 WASHER NYLON 250 42 029451A 6 5 FT TAPE 1 2 X 1 16 CLOSED CELL 43 0E1534A 1 PLUG PLASTIC 1 50 GASOLINE ONLY 44 0A5606 1 ELBOW 90DEG 3 8X3 4 LP ONLY 45 0E1528 1 BRACKET LP REGULATOR MOUNTING LP ONLY 46 0A1495 2 SCREW M4 0 7 X 10 BP LP ONLY 47 042907 2 SCREW M8 1 25 X 16 G8 8 LP ONLY 48 022145 1 WASHER FLAT 5 16 M8 ZINC GASOLINE ONLY 022145 3 WASHER FLAT 5 16 M8 ZINC LP ONLY 49 0D8979A 1 PANEL AIR IN DUCT Page 75 Section 9 Exploded Views Numbers Sheet Metal Drawing 0 1012 TO LP _ REGULATOR b Q f NG AU th di L ST ir NA gt NT T ils fis u KO Page 76 Section 9 Views Numbers PART NO ITEM PARTNO NO ION 045756 001131 0C3022G 0C9763 0D9782 0C3034 0C3033 051754 0A5992 0C3032 0C3031 0C3725A 0C3016A 0234845 009679 009708 009681 056893 072347 0E0998 0D8384 043790A 0D3083 0E0361A 0E0393 0C2824 0C2824 065852 075246 0A4456 0A2311 070185 0A8584 0A5360 043182 0C1085 0E1497 075281 0D9399 0D9513 0E1498 0D1366 009395 077075 0 7094 008590 008591 045770 049226 051713 0D9402 077091
70. O SI nn opo 98 33V LNI HIV dAL sev 2919 Nd3dO SNOILONYLSEO dO HV3 IO Lda 869 LSNW 5131110 15 ANY SFMVLNI HIV TIY 3LON YS _1 peg MIIA NOLLVOOT 128 1SNVHX3 HIV LOH Page 84 GENERATOR SPECIFICATIONS QUIETPACT 55 QUIETPACT 65 Section 10 SPECIFICATIONS amp CHARTS QUIETPACT 75 MODEL 4702 4703 4704 4705 4706 4707 WEIGHT 326 329 pounds 328 331 pounds 330 333 pounds TYPE OF ROTOR Two pole Two pole Two pole RATED WATTS 5500 6500 7500 RATED VOLTS 120 120 120 PHASE 1 Phase 1 Phase 1 Phase RATED MAXIMUM LOAD AMPERES 45 8 54 2 62 5 RATED FREQUENCY 60 Hz 60 Hz 60 Hz OPERATING SPEED 2200 rpm 2571 rpm 2571 rpm ENGINE MODEL GTV 760 GTV 760 GTV 760 TYPE OF ENGINE Vertical Shaft Vertical Shaft Vertical Shaft FUEL SYSTEM Gasoline LP Gasoline LP Gasoline LP COOLING SYSTEM Air Cooled Air Cooled Air Cooled OIL SYSTEM Pressurized with Filter Pressurized with Filter Pressurized with Filter OIL PUMP Trochoid Type Trochoid Type Trochoid Type AIR CLEANER Paper element w foam pre cleaner Paper element w foam pre cleaner Paper element w foam pre cleaner STARTER 12 VDC electric
71. OR EACH COMPONENT IN SECTION 7 UNDER PROCEDURE SHORT TO GROUND REPLACE COMPONENT OR WIRE CHECK WIRE 56 RELAY PIN LOCATION FAIL gt SHORT TO J1 1 TEST TO GROUND GROUND REPAIR OR REPLACE COMPONENT OR WIRE CHECK WIRE 90 PIN LOCATION J1 2 FAIL SHORT TO TEST TO GROUND GROUND Page 37 Section 7 DIAGNOSTIC TESTS INTRODUCTION The Diagnostic Tests in this chapter may be per formed in conjunction with the Flow Charts of Section 6 Test numbers in this chapter correspond to the numbered tests in the Flow Charts Tests 1 through 17 are procedures Involving prob lems with the generator s AC output voltage and fre quency 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 You may wish to read Section 4 Measuring Electricity NOTE Test procedures in this Manual are not necessarily the only acceptable methods for diag nosing the condition of components and circuits All possible methods that might be used for sys tem diagnosis have not been evaluated If you use any diagnostic method other than the method presented in this Manual you must ensure that neither your safety nor the product s safety will be endangered by the procedure or method you have selected TEST 1 CHECK NO LOAD VOLTAGE AND FREQUENCY DISCUSSION The first step in ana
72. P WATER NOTE Water cannot be added to some mainte nance free batteries CHECKING STATE OF 0 F 18 C Use an automotive type battery hydrometer to test the battery state of charge Follow the hydrometer manu facturer s instructions carefully Generally a 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 c the en obtained with the CHARGING 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 Uu 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 _IDo 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 7 5 AMP FUSE This panel mounted Fuse protects the DC control circuit against overload and possible damage If the Fuse has melted open due to an overload nei ther the priming function nor the cranking function will be available Figure5 4 FUEL PRIMER SWITCH Following generator inst
73. R RESIDUAL VOLTAGE 5 12 VAC ROTOR AMP DRAW 85 A 85 A 85 A 55 2090 20 2090 MODEL 4702 4703 CURRENT DRAW ZERO CURRENT DRAW ROTOR AMP DRAW 1 2 A 1 2 A 1 2 A QP65 20 20 20 MODEL 4704 4705 ZERO CURRENT DRAW ZERO CURRENT DRAW ROTOR AMP DRAW 87 79A 87 79A 87 79 A ZERO 87 79 A ZERO QP75 20 20 20 CURRENT 20 CURRENT DRAW DRAW MODEL 4706 4707 MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART Problem 2 on Pages 28 8 29 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 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 CB3 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 volts Record the results and stop the generator 5 Re connect Wire 2 to the DPE Circuit Breaker CB3 and re connect Wire 6 to the Voltage Regulator 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
74. ST 34 ON PAGE 61 BAD pp REPAIR OR REPLACE AS NECESSARY ADJUST VALVES Page 32 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 7 Engine Cranks But Will Not Start LP Units TEST 19 TEST GOOD PRIMER SWITCH TEST 28 TEST 29 CHECK CHECK FUEL O K J WIRE 14 POWER SUPPLY SUPPLY REPLACE ENGINE LOW LP PRESSURE BAD CONTROLLER CIRCUIT HAYAN REPLACE BAD SWITCH REPLENISH FUEL SUPPLY moa GOOD TEST 42 CHECK LPG FUEL SOLENOID BAD TEST 32 i CHECK IGNITION TEST 33 REPAIR OR SPARK GOOD CHECK SPARK GOOD REPLACE PLUG WEAK SPARK NO SPARK INTERMITTENT SPARK CLEAN AND REGAP OR REPLACE SPARK PLUG TEST 34 CHECK IGNITION OL BAD REPLACE COIL GOOD CHECK TEST 35 CHECK TEST 38 CHECK FLYWHEEL KEY VALVE NO START ENGINE CYLINDER ADJUSTMENT LEAK DOWN TEST COMPRESSION TEST GOOD SEE TEST 34 ON PAGE 61 BAD REPAIR OR REPLACE AS NECESSARY ADJUST VALVES Page 33 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 8 Engine Starts Hard and Runs Rough Gasoline Units TEST 28 CHECK TEST 32 CHECK IGNITION SPARK TEST 33 SPARK GOOD PLUG FUEL SUPPLY BAD LOW FUEL ENGINE MISS IS APPARENT CLEAN REPLACE SPARK PLUG REPLENISH TEST 34 FUEL CHECK BAD SUPPLY IGNITION REPLACE COIL COIL TEST 36 CHECK EST 37 CHECK CARBURETION GOO
75. 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 frame ground and circuit board action will initiate an engine shutdown The circuit board has a time delay built into it for the Wire 85 fault shutdowns At STARTUP ONLY the circuit board will wait approximately 6 seconds before looking at the Wire 85 fault shutdowns Once running after the 6 second time delay grounding Wire 85 thru either switch will cause an immediate shutdown 2 0 SUPPLY WHITE ms 12VDC CONTROL GROUND LEGEND BATTERY CHARGE RECTIFIER CIRCUIT BREAKER 30A QP55 amp QP65 MODELS CIRCUIT BREAKER 35A QP75 MODEL CIRCUIT BREAKER 20 55 MODEL CIRCUIT BREAKER 35A QP75 MODEL CIRCUIT BREAKER 2 5A QP55 MODEL CIRCUIT BREAKER 3 0A QP65 amp QP75 MODELS CHOKE HEATER GASOLINE MODELS ONLY CHOKE SOLENOID GASOLINE MODELS ONLY 1 FUSE 7 5A FP FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IM1 IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO 2 CYL LIGHT RUN OPTIONAL SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE ENGINE CONTROLLER Ri RESISTOR 1 OHM 25W STARTER CONTACTOR STARTER CONTACTOR RELAY STARTER MOTOR SWITCH START STOP SWITCH FUE
76. T TEST 3 TEST GOOD PROCEED EXCITATION BAD PROCEED REPLACE AFTER TESTS BREAKER CIRCUIT BREAKER CONCLUDE RESET TO ON OR REPLACE IF BAD TEST 4 PERFORM FIXED EXCITATION ROTOR AMP DRAW BAD TEST 5 WIRE CONTINUITY TEST 7 TEST TEST 6 STATOR DPE BAD FIELD BOOST WINDING TEST 10 CHECK BRUSHES amp fr BAD GOOD SLIP RINGS REPAIR REPLACE OR REPLACE REPAIR THEN INSULATION GOOD OR GOOD RETEST RESISTANCE f BAD REPLACE 4 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 28 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 2 Generator Zero Voltage Residual Voltage 5 12 VAC continued TEST 4 PERFORM FIXED EXCITATION CHECK VOM FUSES ROTOR AMP VERIFY AMP METER DRAW FUNCTIONS THEN RETEST TEST 11 CHECK ROTOR BAD ASSEMBLY TEST 7 TEST TEST 8 CHECK EITHER OR REPAIR REPAIR STATOR DPE SENSING LEADS BOTH BAD p gt OR OR WINDING POWER WINDINGS REPLACE REPLACE INSULATION A en GOOD INSULATION RESISTANCE BAD L L RESISTANCE BAD TEST PAGE 14 PERFORM BOTH TEST 7 amp 8 TEST PAGE 13 Problem 3 No Battery Charge Output TEST 15
77. TEST 16 TEST 17 CHECK CHECK CHECK BATTERY CHARGE BATTERY BAD BATTERY WINDING CHARGE BATTERY CHARGE RECTIFIER RESISTOR CHARGE OUTPUT GOD BAD BAD FINISHED REPAIR OR REPLACE INSULATION REPAIR GOOD RESISTANCE BAD OR TEST PAGE 13 REPLACE Page 29 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 4 Excessive Voltage Frequency Droop When Load is Applied TEST 13 TEST 14 CHECK CHECK LOAD LOAD WATTS 8 NOT OVERLOADED VOLTAGE 8 AMPERAGE FREQUENCY GOOD OVERLOADED REDUCE LOAD END TEST TEST 2 CHECK ADJUST ENGINE GOOD GO TO PROBLEM 8 GOVERNOR Problem 5 Priming Function Does Not Work Gasoline Models TEST 19 TEST TEST 18 TRY ENGINE STILL THE ENGINE NORMALLY PRIME SWITCH MOSE DEREN REPLACE BAD SWITCH 44 GOOD GO TO PROBLEM 6 ass REPLACE FUEL PUMP FUEL PUMP OPERATION IF DEFECTIVE Page 30 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 6 Engine Will Not Crank TEST 22 CHECK BATTERY TEST 21 CHECK 7 5 amp CABLES AMP FUSE RECHARGE OR REPLACE BATTERY BAD gt CLEAN REPAIR OR REPLACE BAD CABLE S FUSE BAD REPLACE FUSE I FUSE BLOWS GO TO PROBLEM 9 TEST 23 CHECK TEST 24 POWER SUPPLY CHECK GOOD TO ENGINE START STOP CIRCUIT BOARD SWITCH REPLACE BAD BAD e DEFECTIVE 1 SWITCH CHECK WIRING AND WIRE CONNECTIONS REPAIR RECONNECT OR REPLACE B
78. TEST 30 CHECK WIRE 18 REPAIR OR BAD REPLACE NOTE IF OIL PRESSURE IS LOW FIND THE CAUSE AND CORRECT IF OIL TEMPERATURE IS HIGH DETERMINE THE CAUSE AND CORRECT Page 36 Section 6 TROUBLESHOOTING FLOWCHARTS INSTALL NEW 7 5 AMP FUSE DISCONNECT WIRE 15 FUSE BLOWS UPON INSTALLATION Problem 10 7 5A F1 Fuse Blowing CHECK THAT FUSE HOLDER IS NOT PASS GROUNDED FAIL REPLACE HOLDER AT J3 TERMINAL FROM ENGINE CONTROLLER REPLACE ENGINE CIRCUIT BOARD NO CONTROLLER DOES FUSE BLOW CIRCUIT BOARD FUSE IS GOOD BUT BLOWS WHEN START STOP SWITCH IS PRESSED DISCONNECT WIRE 14 AT J2 TERMINAL ON ENGINE CONTROLLER CIRCUIT BOARD AND CHECK WIRE 14 FOR SHORT TO GROUND IS CONTINUITY PRESENT CHECK CHOKE SOLENOID AND STARTER CONTACTOR RELAY STARTER CONTACTOR CHOKE SOLENOID CHECK WIRE 15 CHECK REMOTE TEST 16 CHECK FOR SHORT TO HARNESS WIRE 15 BATTERY CHARGE GROUND FOR SHORT TO RECTIFIER GROUND PERFORM RESISTANCE TESTS ON FUEL PUMP FUEL SOLENOID CHOKE HEATER AND REMOTE HARNESS WIRE 14 SEE BELOW ALSO CHECK WIRE 14 TO EACH COMPONENT FOR SHORT TO GROUND CHECK FOR CONTINUITY TO FRAME GROUND CONNECT ONE TEST LEAD TO THE POSITIVE WIRE FOR EACH COMPONENT CONNECT THE OTHER TEST LEAD TO FRAME GROUND RESISTANCE SHOULD BE MEASURED IF CONTINUITY 0 IS MEASURED TO GROUND THAT COMPONENT OR WIRE IS SHORTED ALSO REFER TO THE INDIVIDUAL TESTS F
79. VOM was set to resis tance a reading of 0 5 to 1 5M ohms would be Section 7 DIAGNOSTIC TESTS measured During cranking and running this read ing should go to Infinity Verify that the meter leads were properly connected as per Step 2 instructions 2 f battery voltage was not measured in Step 3 reconnect Wire 15 and Wire 14 to their correct terminal locations NEGATIVE METER TEST LEAD POSITIVE METER TEST LEAD Figure 7 40 Engine Ground Harness Test Points 3 If Infinity was not measured in Step 15 repair or replace grounded Wire 18A between the J1 Connector and the insulat ed terminal stud or defective insulated terminal stud 4 f sparking still does not occur after adjusting the armature air gap testing the ground wires and performing the basic flywheel test replace the ignition magneto s Note Before replacing the Ignition Magneto check the Flywheel Magnet CHECKING FLYWHEEL MAGNET The flywheel magnet rarely loses its magnetism If you suspect a magnet might be defective a rough test can be performed as follows 1 Place the flywheel on a wooden surface 2 Hold a screwdriver at the extreme end of its handle and with its point down 3 Move the tip of the screwdriver to about 3 4 inch 19mm from the magnet The screwdriver blade should be pulled in against the magnet FLYWHEEL KEY In all cases the flywheel taper is locked on the crank shaft taper by the torque of the
80. a failed Starter Contactor Relay PROCEDURE Set the VOM to measure resistance x 1 scale Remove Wire 0 from the Starter Contactor Relay SCR Connect one meter test lead to Wire 0 and connect the other meter test lead to frame ground Continuity should be measured Reconnect Wire 0 2 Set the VOM to measure resistance R x 1 scale Disconnect Wire 16 and Wire 13 Wire 13 is 12VDC isolate from ground from the Starter Contactor Relay SCR Connect one meter test lead to an SCR terminal and connect the other meter test lead to the remaining SCR terminal Infinity should be mea sured Set the Start Stop Switch to START The meter should now read Continuity Short to Ground 3 Set the VOM to measure resistance R x 1 scale Disconnect Wire 56 from the Starter Contactor Relay SCR Connect one meter test lead to the SCR terminal from which Wire 56 was just removed Connect the other meter test lead to a clean frame ground Starter Contactor Relay coil resistance of 155 ohms should be measured If Continuity is measured a short to ground exists Note Current draw of the Starter Contactor Relay coil at nominal voltage is approximately 80ma Figure 7 19 Starter Contactor Relay Page 51 Section 7 DIAGNOSTIC TESTS RESULTS 1 If Continuity is not measured in Step 1 repair or replace Wire 0 between the Starter Contactor Relay and the ground terminal 2 f
81. actor is energized via wire 16 contacts close and battery voltage is available to the starter motor and the engine cranks Figure 5 8 Starter Contactor Relay Section 6 TROUBLESHOOTING FLOWCHARTS INTRODUCTION The Flow Charts in this section may be used in con Problems 1 through 4 apply to the AC generator only junction with the Diagnostic Tests of Section 7 TR _ Numbered tests in the Flow Charts correspond to EDS identically numbered tests of Section 7 If 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 O TO PROBLEM 2 GO TO PROBLEM 2 GO TO PROBLEM 4 REGULATOR ADJUSTMENT PAGE 10 Problem 1 Voltage amp Frequency Are Both High or Low TEST 2 CHECK amp FREQUENCY GOOD ADJUST ENGINE LOW OR RESIDUAL a PROBLEM 2 GOVERNOR AC VOLTAGE NO LOAD FREQUENCY amp VOLTAGE GOOD BUT THEY DROOP TOO MUCH WHEN LOAD IS APPLIED GO TO PROBLEM 4 FREQUENCY IS GOOD GO TO VOLTAGE BUT NO LOAD REGULATOR ADJUSTMENT OR VOLTAGE PAGE 10 IS LOW Page 27 Section 6 TROUBLESHOOTING FLOWCHARTS Problem 2 Generator Produces Zero Voltage or Residual Voltage 5 12 VAC TEST 12 CHECK MAIN CIRCUI
82. 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 The 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 generator s AC output frequency is proportional to Rotor speed Generators equipped with a 2 pole Rotor must operate at 3600 rpm to supply a frequen cy of 60 Hertz Units with 4 pole Rotor must run at 1800 rpm to deliver 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 out put voltage of about 124 volts AC 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 may be used This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that con
83. allation and after the unit has been idle for some time the fuel supply line may be empty This condition will require a long cranking peri od before fuel can reach the carburetor The Fuel Primer Switch when actuated to its PRIME position will deliver battery voltage across the closed switch contacts to the Fuel Pump FP to turn the Pump on Pump action will then draw fuel from the supply tank to prime the fuel lines and carburetor w 14 cee 14 c m 15 A Schematic B Pictorial Figure 5 5 Primer 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 1 Wire No 17 from the Engine Controller circuit board This Is the CRANK and START circuit When the Switch is set to START Wire 17 is connected to frame ground via Wire OB a With wire 17 grounded a Crank Relay on the circuit board energizes and battery volt Page 25 Section 5 ENGINE CONTROL SYSTEM age is delivered to Starter Contactor Relay via Wire 56 The Starter Contactor Relay energizes its contacts close and the Starter Contactor is energized via wire 16 Its contacts close and the engine cranks b With Wire 17 grounded a Run Relay on the circuit board energizes and battery voltage is delivered to the Wire 14 circuit Battery voltage is delivered to the Fuel Pump Fuel Solenoid Choke Heater and
84. ase using a 10mm socket 3 Remove four 4 standoff bolts from top of stator a 13mm wrench is required Page 68 4 Disconnect Wire 4 and Wire 0 from the brush holder assembly 5 Remove two 2 brush holder assembly screws Remove the brush holder assembly a 7mm socket is required 6 Remove Wire 11 and Wire 33 from the circuit breaker 7 Remove Wire 66 and Wire 77 from the Battery Charge Rectifier BCR 8 Remove Wire 55 from the R1 resistor 9 Remove Wire 11 Wire 22 and Wire 6 from the Voltage Regulator VR 10 Remove Wire 2 from the DPE circuit breaker CB2 11 Remove Wire 22 and Wire 44 from the ground lug 12 Remove upper bearing carrier 13 Remove stator ROTOR REMOVAL 1 Perform Stator removal procedure steps 1 13 2 Remove carburetor air tube 3 Remove fuel line 4 Remove two 2 lower control panel nuts a 10mm socket is required 5 Unplug choke solenoid connector 6 Disconnect Wire 0 and Wire 14 from bullet connectors to fuel solenoid Disconnect Wire 0 and Wire 85 from Low Oil Pressure LOS and High Temperature HT switches Remove positive and negative battery cables from remote box Unplug Wires 13 16 amp 18 from bullet connectors Remove control panel 7 Remove four 4 vibration mount nuts using a 13mm socket 8 Remove two safety nuts using a 15 mm socket 9 Lift generator out of bottom tray 10 Remove seven 7 blower housing screws Remove blower housing usi
85. ating 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 the section of the engine where the fault lies before disassembling the engine PROCEDURE 1 Remove a spark plug 2 Gain access to the flywheel Remove the valve cover 3 Rotate the engine crankshaft until the piston reaches top dead center 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 7T 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 carburetor check intake valve Air escapes through the exhaust check exhaust valve escapes through the breather 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
86. ator at one time If desired a clamp on ammeter may be used to measure current flow Measuring Current on Page 16 HESULTS 1 If the unit is overloaded reduce the load 2 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 Pages 34 and 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 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 genera tor Battery Charge Winding Stator Lead Wire 66 is tapped at the Battery Charge Rectifier and connected to the Engine Control Circuit Board at Pin location J1 10 and is used as a signal for Starter lockout 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 approximately 0 8 Amps Apply full load to the generator The amp reading should increase to approximately 2 Amps RESULTS 1 If ampe
87. awing No 0 1013 LO st LO Page 78 Section 9 Views Numbers ITEM PART DESCRIPTION ITEM PART QTY DESCRIPTION 1 002375 2 SCREW HHC M8 1 25 X 90 G8 8 32 055440 2 SCREW HHC M5 0 8 X 25 G8 8 2 022145 2 WASHER FLAT 5 16 M8 ZINC 33 009377 1 PANEL TOP CONTROL 3 029459 2 TENSION SPRING 34 054502 1 CIRCUIT BREAKER 3X 1 4 075215 2 WASHER SPRING CENTER 35 031879 4 WASHER FLAT 4 ZINC 5 052858 6 NUTLOCK FL M8 1 25 36 043182 4 WASHER LOCK 6 047411 7 SCREW HHC M6 1 0 X 16 G8 8 37 051714 4 HEX M3 0 5 G8 YEL CHR 7 022097 13 WASHER LOCK M6 1 4 38 092234 1 ASSY POTTED RV CNTL 8 022473 10 WASHER FLAT 1 4 M6 ZINC 39 049226 5 WASHER LOCK M5 9 080925 8 WASHER NYLON 404 40 051716 3 NUTHEX M5 0 8 G8 YEL CHR 10 009921 4 STANDOFF 1 2 HEX 41 0234848 2 BUSHING SNAP 11 066849 2 SCREW HHTT M5 0 8 X 16 42 003700 1 NUT FLANGE M6 1 0 NYLOK 12 066386 1 ASSY BRUSH HOLDER 43 009378 1 PANEL BOTTOM CONTROL 13 0C9674 1 BEARING CARRIER UP 44 052619 1 SCREW HHC M5 0 8 X 20 G8 8 14 0 0 6 1 STATOR ASSEMBLY 5 5 KW ONLY 45 075476 2 SCREW PPHM M4 0 7 X 16 0E0364H 1 STATOR ASSEMBLY 6 5 KW ONLY 46 065795 12 RECTIFIER BATTERY CHARGE 0E0362H 1 STATOR ASSEMBLY 7 5 KW ONLY 47 0C2174 1 RELAY 12V 25A SPST 15 073159 1 BEARING BALL 48 092120 4 NUTLOCK TRIC M6 X 1 0 Y ZNC 16 077005H 1 ROTOR ASSEMBLY 5 5 KW ONLY 49 049721 2 SCREW HHC M6 1
88. boot from spark plug left side cylinder 1 3 Remove nine 9 bolts from cylinder 1 wrap Remove cylinder 1wrap using an 8mm socket 4 Remove five 5 bolts from crankcase wrap using an 8mm socket 5 Remove four 4 bolts from oil cooler oil duct Remove oil duct both a 10mm socket and an 8mm socket are required 6 Remove crankcase wrap 7 Remove five 5 bolts holding blower housing using an 8mm socket 5 8 INCH 16 MM ADJUSTING BOLTS MOUNTING BASE L 1 2 INCH 1 27 MM BELT TENSIONING SPRINGS Figure 8 1 Drive Belt Tension Page 69 Section 8 ASSEMBLY 8 Remove two 2 bolts holding blower housing on each cylinder head a 10mm socket is required 9 Loosen four 4 allen head bolts for intake manifold Tilt mani fold forward to gain clearance using a 6mm allen wrench 10 Remove blower housing 11 Remove negative cable from starter motor using 13mm socket 12 Remove positive cable and Wire 13 from starter contactor on starter motor using 13mm socket 13 Remove Wire 16 from spade terminal on starter contactor 14 Remove two 2 starter bolts using 13mm socket 15 Remove starter motor watch for possible shim washer on right side mounting bolt FLYWHEEL MAGNETO REMOVAL 1 Perform enclosure panel removal steps 1 7 2 Remove spark plug boot from spark plug on left side Cylinder 1 Page 70 3 Remove nine 9 bolts from cylinder 1 wrap Remov
89. c 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 fasteners can cause damage malfunction and possible injury REPLACEMENT PARTS Components Generac recreational vehicle generators are designed and manufactured to comply with Recreational Vehicle Industry Association 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 Improperly Installed and tightened sparks could Ignite fuel vapors from fuel system leaks Table of Contents SAFETY INSIDE FRONT COVER SECTION 1 GENERATOR FUNDAMENTALS 3 7 MAGNE FIOM esse 3 ELECTROMAGNETIC FIELDS 3 ELECTROMAGNETIC INDUCTION 3 A SIMPLE AC GENERATOR 4 A MORE SOPHISTICATED AC GENERATOR 4 FIELD BOOST a 6 GENERATOR CONNECTION SYSTEM 6 SECTION 2 MAJOR GENERATOR COMPONENTS 8 11 ROTOR ASSEMBLY 8 STATOR ASSEMBLY lU 5 35 69 2 9
90. ct one test lead to the Red Wire Pin 2 of Connector 2 see Figure 7 15 Connect the other test lead to the fuel pump housing Infinity should be measured Figure 7 14 Electric Fuel Pump RESULTS 1 If Continuity was not measured in Step 4 repair or replace Wire 0 between Connector 2 and the ground terminal 2 f Continuity is measured in Step 4 but pump does not oper ate in Step 3 replace the Fuel Pump Section 7 DIAGNOSTIC TESTS 3 If the pump fails Step 5 or Step 6 replace the Fuel Pump Note If desired a pressure gauge can be attached to the pumps outlet side Pump outlet pressure should be 2 0 to 3 5 psi 4 f the pump operates normally go to Test 31 a O PIN 2 RED WIRE C PIN 1 BLACK WIRE Figure 7 15 Harness to Fuel Pump TEST 21 CHECK 7 5 AMP FUSE DISCUSSION If the panel mounted 7 5 amp fuse F1 has blown engine cranking will not be possible Figure 7 16 7 5 Amp Fuse PROCEDURE Push In on fuse holder cap and turn counterclock wise Then remove the cap with fuse Inspect the Fuse RESULTS the Fuse element has melted open replace the Fuse with an identical size fuse If Fuse is good go to Test 22 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 1 Inspect the battery cables and ba
91. d 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 BCR BATTERY CHARGE RECTIFIER CB3 EXCITATION CIRCUIT BREAKER STATOR BATTERY CHARGE WINDING Ha 7 h TO BATTERY STATOR POWER WINDING s wi amp w lt non DN PE 1 2 Nga Ea BA PVP T MSN 7222542 SIM 27 sx WATA A se pee s VA Ji 4 Section 1 GENERATOR FUNDAMENTALS SENSING FIELD BOOST FROM ENGINE CONTROLLER CIRCUIT BOARD BATTERY VOLTAGE VOLTAGE REGULATOR STATOR EXCITATION WINDING 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 is sufficient to induce approximately 7 to 12 volts AC Into the STATOR 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
92. d 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 Section 7 DIAGNOSTIC TESTS 3 In Step 7 if Wire 0 reads Continuity but resistor does 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 Fuel Primer Switch on the generator panel is actuated but the Fuel Pump does not run priming function 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 the engine cranks normally but the priming function still doesn t work go to Test 19 2 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 PRIMER SWITCH DISCUSSION A defective primer switch can prevent the priming function from occurring Switch failure can also prevent the engine from start ing since the switch is in series with the Wire14 circuit Also see Fuel Primer Switch page 25 Figure 7 11 Primer Switch PRO
93. ductor 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 MAGNETIC lt CLAMP ON 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 ammeter capacity does not permit all lines to be measured simultaneously measure current flow 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 IShorting tog
94. e AC generator Check the Rotor for contact with the Stator Page 62 La Starting under load Make sure all loads are discon nected or turned off before attempting to crank and start the engine Uu Check that the automatic choke is working properly RESULTS If problem has not been solved go to Test 37 If car buretor is varnished clean or replace 1 Remove fuel line at carburetor and ensure that there is an ade quate amount of fuel entering the carburetor 2 Remove the float bowl and check to see if there is any foreign matter in bottom of carburetor bowl 3 The float is plastic and can be removed for access to the nee dle so it can be cleaned 4 With all of this removed carburetor cleaner can be used to clean the rest of the carburetor before reassembly 5 After cleaning carburetor with an approved carburetor cleaner blow dry with compressed air and reassemble Shelf life on gasoline is 30 days Proper procedures need to be taken for carburetors so that the fuel doesn t varnish over time A fuel stabilizer must be used at all times in order to ensure that the fuel is fresh at all times TEST 37 CHECK CHOKE SOLENOID DISCUSSION The automatic choke is active only during cranking When the Start Stop Switch is held at START a crank relay on the Engine Controller circuit board is energized closed to a crank the engine and b deliver a cyclic voltage to the Choke Solenoid via Wire 90 The Choke S
95. e Cylinder 1 wrap using an 8mm socket 4 Remove five 5 bolts from crankcase wrap using an 8mm socket 5 Remove four 4 bolts from oil cooler oil duct Remove oil duct both a 10mm socket and an 8mm socket are required 6 Remove crankcase wrap 7 Remove five 5 bolts holding blower housing using an 8mm socket 8 Remove two 2 bolts holding blower housing on each cylinder head a 10mm socket is required 9 Loosen four 4 allen head bolts for intake manifold Tilt mani fold forward to gain clearance using a6mm allen wrench 10 Remove blower housing Adjust or replace magnetos as needed 11 Remove two 2 bolts from plastic fan on flywheel using a 13mm socket 12 Remove flywheel nut 36mm socket Use steering wheel puller to remove flywheel using M8 x 1 25 bolts for puller NOTES Page 71 Section 9 Exploded Views Numbers Base amp Pulley Drawing 0 1323 26 52 49 5051 5 48 Q TO CARB Page 72 Section 9 Views Numbers ITEM PART QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 0 0196 1 FRAME 760 ENGINE 32 007176 4 WASHER SELF LOCKING 1 DIA 2 022129 12 WASHER LOCK M8 5 16 12GA 3 022145 15 WASHER FLAT 5 16 M8 ZINC 33 0E1334 1 SCREEN BOTTOM AIR OUT 4 022259 6 HEX 5 16 18 STEEL 34 008824 1 TRAY V TWIN RV 5 0C7758 4 1 5 X 1 38 X 5 16 18 35 081105 2 NUTFLG 5 16 18 LO
96. e 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 J3 to which Wire 15 connects see Figure 5 3 on Page 24 2 Set a VOM to read battery voltage Connect the meter test leads across circuit board Terminal J3 and frame ground The meter should read battery voltage 3 Set the VOM to measure resistance Rx1 scale Connect one meter test lead to Wire 0 Pin location J1 12 on the Engine Controller Circuit Board Connect the other test lead to a clean frame ground Continuity should be measured Page 49 Section 7 DIAGNOSTIC TESTS RESULTS 1 11 battery voltage is NOT indicated in Step 1 check continuity of a Wire 13 between Starter Contactor and Starter Contactor Relay b Wire 13 between Starter Contactor Relay and 7 5 Amp Fuse F1 c Wire 15 between the 7 5 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 f battery voltage is indicated but engine 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
97. e 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 Figure 7 21 Starter Motor SM 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 Figure 7 22 Check Pinion Gear Operation TOOLS FOR STARTER PERFORMANCE TEST The following equipment may be used to complete a performance test of the Starter Motor clamp on ammeter tachometer capable of reading up to 10 000 rpm LIA fully charged 12 volt battery MEASURING CURRENT To read the current flow in AMPERES a clamp on ammeter may be used This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor CONDUCTOR MAGNETIC lt lt CLAMP ON CE AMMETER Figure 7 23 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 24 Page 5
98. e speci fied torque with a crow s foot After tightening the jam nut recheck valve clearance to make sure it did not change TORQUE SPECIFICATION ROCKER ARM JAM NUT 174 inch pounds Page 61 Section 7 DIAGNOSTIC TESTS CROW S FOOT Figure 7 42 Tightening the Jam Nut INSTALL ROCKER ARM COVER 1 Use a new rocker arm cover gasket Install the rocker arm cover and retain with four screws RESULTS Adjust valves to specification and retest If problem continues go to Test 38 TEST 36 CHECK CARBURETION DISCUSSION If the engine cranks but will not start one possible cause of the problem might be the carburetion system PROCEDURE Before making a carburetion check be sure the fuel sup ply tank has an ample supply of fresh clean gasoline Check that all shutoff valves are open and fuel flows freely through the fuel line Make sure the automatic choke operates properly If the engine will not start remove and inspect the spark plug If the spark plug is wet look for the following L Overchoking 1 Excessively rich fuel mixture L1 Water in fuel LJ Intake valve stuck open Needle float stuck open If the spark plug is dry look for the following Leaking carburetor mounting gaskets Intake valve stuck closed L Inoperative fuel pump L1 Plugged fuel filter s Varnished carburetor If the engine starts hard or will not start look for the following Physical damage to th
99. e test lead to Wire 0 and the other test lead to a clean frame ground The meter should read continuity 4 Disconnect Wire 2A from the Voltage Regulator sixth terminal from the top Disconnect the other end of this wire from the Section 7 DIAGNOSTIC TESTS Excitation Circuit Breaker CB3 Connect one test lead to one end of Wire 2 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 test lead to it Connect the negative test lead to a clean frame ground 3 Set the Start Stop Switch to
100. e the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit 11 14 WATER COLUMN REGULATOR PRIMARY REGULATOR VAPOR WITHDRAWAL TANK CARBURETOR Figure 7 27 Typical Propane Gas Fuel System NOTE Recommended MINIMUM gas flow rate for all air cooled QUIETPACT series generators is 67 cubic feet per hour If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit a install a pri mary regulator with adequate flow rate or b install a separate regulator only and rated at least 67 cubic feet per hour The inlet side of any prima ry regulator that supplies the generator must con nect directly to a gas pressure tank Do NOT tee the generator line into a gas circuit feeding other areas CAUTION Use only approved components in the fuel supply system All components must be properly installed in accordance with applicable codes Improper installation or use of unautho rized components may result in fire or an explo sion Follow approved methods to test the sys tem for leaks No leakage is permitted Do not allow fuel vapors to enter the vehicle interior LP gas vapors should be supplied to the secondary regulator inlet at about 11 inches water column posi tive pressure The engine pistons draw air in during the intake stroke Figure 7 28 This air pas
101. eads No 66 and 77 from the battery charge recti fier e Disconnect battery charge winding lead No 55 from the battery charge resistor R1 f the main circuit breakers disconnect power leads No 11P and 33 g At the 4 tab ground terminal GT discon nect Stator power leads No 22P and 44 2 When all leads have been disconnected as outlined in Step 1 above test for a short to ground condition as follows a Connect the terminal ends of all Stator leads together 115 225 11P 22P 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 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 1 Follow the tester manufacturer s instructions carefully Connect the tester test leads across Stator leads No 11P and 2 Apply a voltage of 1500 volts DO NOT EXCEED 1 SECOND 2 Repeat Step 1 with the tester leads connected across the fol lowing Stator leads a Across Wires No 33 and 2 b Across Wires No 11P 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
102. ease 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 OHMS is unknown but VOLTS and AMPERES are known use the following OHMS VOLTS AMPERES Page 17 Section 5 ENGINE CONTROL SYSTEM RED 4 m m m m m m _ Jie gt J2 gt 1 3 gt 16 Na gt N5 gt 6 2 J1 7 gt 17 48 gt gt 4 J1 10 2 66 1 11 gt 85 J1 42 2 0 J1 43 gt J1 14 gt 18 J1 15 18 14 REMOTE PANEL CONNECTOR _ ON oa Q N 66 15 77 66 BATTERY CHARGE WINDING POWER WINDING ELECTRONIC VOLTAGE REGULATOR 120V 20A QP55 120V QP65 120V QP75 120V 30A 55 amp QP65 120V 35A QP75 NEUTRAL CONNECTION BY CUSTOMER Page 18 REMOTE PANEL OPTIONAL INTRODUCTION The engine DC control system includes all com ponents necessary for the operation of the engine Operation includes rest priming crank Ing starting running and shutdown The system is shown schematically OPERATIONAL ANALYSIS CIRCUIT CONDITION REST Battery voltage is available to
103. els go to Test 35 TEST 34 CHECK AND ADJUST IGNITION MAGNETOS DISCUSSION The ignition system used on GTV 760 engines is a solid state breakerless type The system utilizes a magnet on the engine flywheel to induce a relatively low voltage into an ignition magneto assembly Ignition magneto internal components increase the voltage and deliver the resulting high voltage across the spark plug gap The ignition magneto houses a solid state circuit board that controls ignition timing Timing is fixed and spark advance is automatic Major components of the ignition system include a two ignition magneto assemblies b the spark plugs c the engine control board and d the engine fly wheel Solid state components encapsulated in the ignition magneto are not accessible and cannot be serviced If the magneto is defective the entire assembly must be replaced The air gap between the magneto and the flywheel magnet is between 0 012 to 0 015 The ignition magneto assembly Figure 7 36 consists of a ignition magneto b spark plug high tension lead and c spark plug boot SPARK PLUG HIGH TENSION IGNITION COIL Figure 7 36 Ignition Magneto Assembly In Test 32 a spark tester was used to check for engine ignition If sparking or weak spark occurred one possible cause might be the ignition magneto s This test consists of adjusting the air gap between the ignition magneto s and the flywheel The flyw
104. er test lead to Wire 0 Connect the other test lead to a clean frame ground Continuity should be measured Reconnect Wire 0 to LPG shut off valve Section 7 DIAGNOSTIC TESTS SHORT TO GROUND Set VOM to measure resistance Disconnect Wire 14 from the LPG Fuel Solenoid Connect one meter test lead to LPG Fuel Solenoid terminal that Wire 14 was just removed from Connect the other meter test lead to a clean frame ground LPG Fuel Solenoid coil resistance of approximately 30 32 ohms Should be measured Current draw of the LPG Fuel Solenoid at nominal voltage Is approximately 380 milliamps or 0 380 amps RESULTS 1 If the solenoid energized in Step 1 proceed to Test 32 2 f Continuity was not measured in Step 2 repair or replace Wire 0 between the LPG Fuel Solenoid FS and the Ground Terminal GT in the control panel 3 If Continuity was measured in Step 2 repair or replace the Fuel Solenoid FS Figure 7 49 Fuel Solenoid Page 67 Section 8 ASSEMBLY MAJOR DISASSEMBLY ENCLOSURE PANEL REMOVAL 1 Remove enclosure door 2 Remove the nine 9 enclosure roof bolts from the perimeter of the enclosure roof a 10mm socket is required 3 Remove six 6 enclosure side panel bolts from the outside perimeter Remove two 2 front amp side enclosure panel bolts from the outside perimeter Remove three 3 enclosure side panel bolts located on the inside Remove three 3 enclosure side
105. ether of any two parallel Stator wind ings Shorting together of any two isolated Stator wind ings 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 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 alternating 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 elect
106. 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 light Figure 1 3 Simple Revolving Field Generator Page 3 Section 1 GENERATOR FUNDAMENTALS SIMPLE GENERATOR Figure 1 4 shows very simple 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 sists of a SOUTH magnetic pole and a NORTH mag netic pole As the MOTOR turns its magnetic field cuts across the stationary STATOR A voltage is induced Into the STATOR 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 STATOR This stant reversal of current flow resul
107. ge capacity The circuit breaker ings are as follows Circuit Breaker 1 Circuit Breaker 2 QuietPact 55 30A QuietPact 65 30A QuietPact 75 35A Section 1 GENERATOR FUNDAMENTALS o 0 2 52 lt GROUNDED NEUTRAL Figure 1 8 Connection for 120 Volts Only RECONNECTION FOR DUAL VOLTAGE OUTPUT When connected for dual voltage output Stator out put leads 11P and 44 form two hot leads T1 Red and T3 Black The junction of leads 22 and 33 form the Neutral line T2 White For dual voltage output the Neutral line remains grounded NOTE For units with two 30 amp or two 35 amp main breakers the existing breakers may be re used when reconnecting for dual voltage output However on units with a 30 amp and a 20 amp main breaker you may wish to install a 2 pole breaker that is rated closer to the unit s rated capacity use two 25 amp main breakers T3 BLACK GROUNDED NEUTRAL STATOR WINDINGS Figure 1 9 Connection for 120 240 Volts NOTE If this generator has been reconnected for dual voltage AC output 120 240 volts the replacement line breakers should consist of two separate breakers with a connecting piece between the breaker handles so that both break ers operate at the same time If the unit is recon nected for dual voltage it is no longer RVIA listed Page 7 Section 2 MAJOR GENERATOR COMPONENTS BRUSH HOLDER UPPER BEAR
108. ge is not measured in Step 4 repair or replace Wire 14 between the 4 Tab Terminal Connector TC and the Fuel Solenoid 3 If Continuity is not measured in Step 5 repair or replace Wire 0 between the Fuel Solenoid and ground terminal 4 f Continuity is not measured in Step 6 repair or replace Carburetor ground wire 5 If the Fuel Solenoid operates proceed to Test 32 TEST 32 CHECK IGNITION SPARK DISCUSSION A problem in the engine ignition system can cause any of the following e Engine will not start e Engine starts hard runs rough A commercially available spark tester may be used to test the engine ignition system One can also be pur chased from Generac Power Systems Part No 0C5969 PROCEDURE 1 Disconnect a high tension lead from a spark plug 2 Attach the high tension lead to the spark tester terminal 3 Ground the spark tester clamp by attaching to the cylinder head see Figure 7 32 Page 57 Section 7 DIAGNOSTIC TESTS 4 Crank the engine rapidly Engine must be cranking at 350 rpm or more If spark jumps the tester gap you may assume the ignition system is working properly Repeat on remaining cylin der spark plug 5 To determine if an engine miss is ignition related connect the spark tester in series with the high tension lead and the spark plug Then start the engine If spark jumps the tester gap regular Intervals but the engine miss continues the problem may be in t
109. he 1 connector from the Engine Controller Circuit Board Set the VOM to measure resistance Connect one test lead to Pin Location J1 14 Connect the other test lead to a clean frame ground Infinity should be measured Section 7 DIAGNOSTIC TESTS Figure 7 31 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 GASOLINE MODELS DISCUSSION If the Fuel Solenoid fails to open the engine will not Start PROCEDURE 1 Remove Control Panel cover Remove Wire 56 from the Starter Contactor Relay This will prevent the unit from cranking during test See Figure 7 19 Page 51 2 Remove air filter cover Disconnect Connector 2 which con nects to the fuel pump 3 Activate the Start Stop Switch SW1 to the START position and hold This will activate the fuel solenoid The fuel solenoid should energize and produce an audible click If the fuel sole noid does not operate proceed to
110. he spark plug or fuel system Repeat on remaining cylinder spark plug Proceed to Test 33 O gt If spark jumps the tester gap intermittently the problem may be in the Ignition Magneto Proceed to Test 34 SPARK TESTER SPARK TESTER CLAMP GROUNDED TO CYLINDER HEAD SPARK PLUG Figure 7 32 Testing Ignition System SPARK TESTER CLAMP CONNECTED TO SPARK PLUG SPARK TESTER SPARK PLUG Figure 7 33 Checking Engine Miss RESULTS 1 If no spark or if engine miss is apparent go to Test 34 2 f ignition spark is good go to Test 33 Page 58 CYLINDER BALANCE TEST If the engine is hard starting runs rough misses lacks power perform a cylinder balance test to deter mine whether both cylinders are operating to their full potential Tools Required 1 Two Ignition Testers Generac P N OC5969 Attach an ignition tester between the spark plug lead and each spark plug Figure 7 33 Start and run engine running at top no load speed and note spark at ignition testers If the spark is equal at both ignition testers the problem is not ignition related A spark miss will be readily apparent Now note RPM of engine Ground out one cylinder by con tacting ignition tester and a good ground on engine Figure 7 34 Note RPM loss Then ground out the other spark plug and note the RPM loss If the differ ence between the two cylinders does not exceed 75 RPM the amount of work the two cylinders are doi
111. heel and flywheel key will also be checked during this test If no sparking occurs the ground harness may be at fault PROCEDURE Disconnect the J1 connector from the Engine Control Board Carefully remove Wire 18A from Pin Location J1 4 Connect the J1 connector back to the engine control board Repeat Test 32 Check Ignition Spark If the unit now produces spark go to Step 2 If the unit does not produce spark or has weak spark go to Step 4 2 Do the following a Seta VOM to measure resistance Connect the positive meter test lead to Wire No 18A Wire 18 still removed from the J1 connector Connect the negative meter test lead to a clean frame ground Infinity should be measured or 0 5 to 1M ohms depending upon the type of VOM used Continuity is measured proceed to Step12 b Set a VOM to the diode test range Attach the negative meter test lead to Pin Location J1 4 on the Engine Control Board Wire 18A still removed from the J1 connec tor Attach the positive meter test lead to frame ground Set the Start Stop Switch to START Infinity should be measure dur ing cranking and running If the VOM does not have a diode test range set VOM to measure resistance again Infinity should be measured Page 59 Section 7 DIAGNOSTIC TESTS 3 If Step 1 produced spark and Step 2 tested good set the VOM to measure DC voltage Connect one test lead to Wire 15 J3 Terminal on ECB
112. hms 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 otator can Read the number of megohms on the meter MINIMUM INSULATION RESISTANCE in Megohms GENERATOR RATED VOLTS The MINIMUM acceptable megger reading for Stators may be calculated using the following formula EXAMPLE Generator is rated at 120 volts AC Divide 120 by 1000 to obtain 0 12 Then add 1 to obtain 1 12 megohms Minimum Insulation resistance for a 120 VAC Stator 15 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
113. l 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 generators AC output voltage will decrease to a value that is commensurate with 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 P and 33 2 Also disconnect Wires 22P and 44 from the ground terminal 3 Disconnect Wires 115 and 225 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 11P and 22P 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 leads 11S and 229 Normal Power Winding resistance should be read AC POWER WINDING RESISTANCE QP55 Model 4702 4703 ACROSS WIRES OHMS 11P amp 22P 0 28Q 0 3202 115 amp 225 0 2802 0 320 33 amp 44 0 2802 0 320 POWER WINDING RESISTANCE 65 Model 4704 4705 ACROSS WIRES 11P amp 22P OHMS 0 209 0 2429 115 amp 225 0 209 0 2420 33 amp 44 0 209 0 2429 AC POWER WIND
114. liver power to connected elec trical loads 2 Stator Power winding sensing leads 115 and 225 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 amp 6 Stator Excitation Winding Leads 115 8 225 Voltage Sensing Leads Leads 11P amp 22P 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 c mmm w ANNNNNNININENENNN gt a WES TN s 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 these windings to direct current DC Battery charge winding output is delivered to the unit battery via the rectifier a 7 5 amp fuse and Wire No 13 A 1 ohm 25 watt resistor is connected in series with the grounded side of the circuit TO ENGINE
115. lyzing any problem with the AC generator is to determine the unit s AC output voltage and frequency Once that has been done you will know how to proceed with specific diagnostic tests 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 voltage 5 Connect frequency meter across output leads 1 Red and T2 White 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 Test 3 Page 38 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 voltage The term residual voltage refers to the output voltage supplied as a result of Rotor resid ual magnetism approximately 5 12 VAC TEST 2 CHECK ENGINE GOVERNOR DISCUSSION Rotor operating speed and AC output f
116. n require up to 5500 watts 5 5 kW of total power but cannot exceed 45 8 AC amperes of current at 120 volts or exceed 22 9 AC amperes at 240 volts QUIETPACT 65G amp LP 120 and or 240 volts sin gle phase 60 Hz electrical loads These loads can require up to 6500 watts 6 5 kW of total power but cannot exceed 54 1 AC amperes of current at 120 volts or exceed 27 AC amperes at 240 volts QUIETPACT 75G 8 LP 120 and or 240 volts sin gle phase 60 Hz 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 volts or exceed 31 2 AC amperes at 240 volts CAUTION Do not overload the generator Some A installations may require that electrical loads be alternated to avoid overloading Applying exces sively high electrical loads may damage the gen erator 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 generator 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 continuous operation LINE BREAKERS 120 VOLTS ONLY Protects generator s AC output circuit against overload 1 prevents unit from exceeding wattage ampera
117. n Wire 85 is connected to the switch terminal the fol lowing possibilities exist a Oil temperature is too high b The oil temperature switch has failed closed or is shorted to ground 2 Remove the switch and place its sensing tip into oil Figure 7 48 Place a thermometer into the oil 3 Connect the test leads of a VOM across the switch terminals The meter should read Infinity 4 Heat the oil When oil temperature reaches approximately 270 284 F the switch contacts should close and the meter should read Continuity Page 65 Section 7 DIAGNOSTIC TESTS Figure 7 48 Testing Oil Temperature Switch RESULTS 1 If the Oil Temperature Switch fails Step 3 or Step 4 replace the Oil Temperature Switch 2 f the Oil Temperature Switch is good an overheat condition may be occurring Verify that the installation of the generator is within specified tolerances The generator must receive the proper amount of incoming air and also be able to exhaust the cooling air with NO RESTRICTIONS Check to be sure that the exhaust pipe is not under the air intake Refer to the Owner s and Installation Manual for proper installation specifications If installation is correct go to Test 24 TEST 41 TEST CHOKE HEATER DISCUSSION The Choke Heater is a sensitive heating element wrapped around a temperature sensitive Bi Metal strip The HEATER ASSEMBLY positions the Choke Plate during startu
118. n 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 OF 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 Page 43 Section 7 DIAGNOSTIC TESTS 7 Inspect the slip rings 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 RESULTS 1 Replace bad brushes Clean slip rings if necessary 2 f brushes and rings are 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 OF from their respective brushes and remove the brush holder Then test the Rotor as follows 1 Set a VOM to its Rx
119. nals 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 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 40 TEST OIL TEMPERATURE SWITCH DISCUSSION If the engine cranks starts and then shuts down one possible cause of the problem may be a high oil tem perature condition Protective shutdown is a normal occurrence if the oil temperature switch exceeds approximately 270 F for gasoline units or 284 F for LP units Figure 7 47 Oil Temperature Switch PROCEDURE Remove Wire 85 from Oil Temperature Switch terminal and start the generator If engine starts and runs now but shuts down whe
120. ng should be considered equal If the RPM loss is greater than 75 RPM this indicates that the grounded cylinder with the least RPM loss is the weakest of the two cylinders Look to that cylinder for a problem Example Engine RPM Both Cylinders 2 2570 RPM Engine RPM No 1 Cylinder Grounded 2500 RPM Engine RPM No 2 Cylinder Grounded 2300 RPM Conclusion No 1 cylinder is weakest of the two cylinders Figure 7 34 Cylinder Balance Test The cylinder balance test will also detect a cylinder that is not functioning When grounding out one cylin der there will be no RPM loss When the other cylin der is grounded out the engine will stop Section 7 DIAGNOSTIC TESTS TEST 33 CHECK SPARK PLUGS DISCUSSION During Test 32 if spark jumped the tester gap the ignition system must be functioning properly However if the engine misses the spark plug itself may be fouled PROCEDURE Remove spark plugs Clean with a commercial sol vent DO NOT BLAST CLEAN SPARK PLUGS Replace spark plugs if badly fouled if ceramic is cracked or if badly worn or damaged Set gap to 0 030 inch 0 76mm Use a Champion RC12YC or equivalent replacement spark plug SET PLUG GAP AT 0 030 inch 0 76 mm NT a lls Ba ae 7 NG TY Figure 7 35 Setting Spark Plug Gap RESULTS 1 Clean and regap or replace sparks plug as necessary 2 f spark plugs are good for gasoline models go to Test 36 For LPG mod
121. ng a 1 4 socket 11 Remove two 2 side belt tensioner bolts Remove belt a 13mm socket is required 12 Remove rotor pulley bolt 14 mm socket Use steering wheel puller to remove pulley use M6 x 1 bolts for puller 13 Lift rotor and bottom bearing carrier out Press rotor bearing from bottom bearing carrier Section 8 ASSEMBLY BELT TENSIONING Tighten all four stator stud nuts to compress the spring to one half inch 1 2 between the washer and support slide Tighten the two side bolts to compress the spring to 5 8 of an inch between the washer and bearing carrier see Figure 8 1 ENGINE REMOVAL 1 Perform rotor removal steps 1 17 2 Drain engine oil 3 Remove engine pulley bolt using a 14mm socket 4 Remove engine pulley using steering wheel puller using 5 16 18 bolts for puller 5 Remove 5 of 6 screws holding exhaust gaskets to tray an 8mm socket is required 6 Remove four 4 exhaust manifold bolts using a 6mm allen wrench 7 Remove last screw holding exhaust gasket to tray an 8mm socket is required STATOR BOLT REAR BEARING CARRIER uM pug NYLON SLIDE NYLON SLIDE SUPPORT ADJUSTING BOLT NS 8 Remove four 4 engine mounting bolts using a 14mm socket 9 Remove oil fill line mounting clamp 10 Remove two 2 oil lines to oil filter adapter 11 Remove engine STARTER REMOVAL 1 Perform enclosure panel removal steps 1 7 2 Remove spark plug
122. ngine Runs Shuts Off OK 1 Closed Diode On One Cylinder Engine Runs Only One Cylinder 1 Open Diode Both Cylinders Shuts Off Won t Run 2 Closed Diodes No Spark Engine Runs Engine Won t 2 Open Diodes Both Cylinders Shut Off Figure 7 39 Diode Failure Diagnosis 14 Connect the positive test lead to Connector as shown in Figure 7 40 Connect the negative test lead to Connector B a lf meter Beeps once and displays voltage drop then the diode is good b If the meter makes a continuous tone the diode is bad shorted and the harness must be replaced c If the meter displays OL the diode is defective open and the harness must be replaced d Now repeat Steps 14a through 14c with the negative meter test lead connected to Connector C Figure 7 40 15 If the ground harness tested good check Wire 18A between the insulated terminal stud and the J1 Connector for a short to ground Set a VOM to measure resistance The ground harness should still be disconnected from the ignition magnetos Connect one meter test lead to Wire 18A which is still removed from the J1 Connector Connect the other meter test lead to frame ground Infinity should be measured RESULTS 1 If Infinity was not measured in Step 2b replace the Engine Control Board Note If VOM was set to Diode test a reading of 0 5 volts would be observed when the Start Stop Switch is set to STOP If the
123. nough 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 These air cooled generator sets are equipped with dual stator AC power windings These two stator wind ings supply electrical power to customer electrical loads by means of a dual 2 wire connection system Generators may be installed to provide the following outputs 1 120 VAC loads only one load with a maximum total wattage requirement equal to the generator s rated power output in watts and 120V across the generator output terminals Figure 1 8 page 7 shows the generator lead wire connections for 120VAC ONLY 2 120 240 VAC loads one load with a maximum total wattage requirement equal to the generator s rated power output and 240V 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 120V across the generator output terminals Figure 1 9 on page 7 shows the generator lead wire connections for 120 240 VAC loads Page 6 You can use your generator set to supply electrical power for operating one of the following electrical loads e QUIETPACT 55G 8 LP 120 and or 240 volts sin gle phase 60 Hz electrical loads These loads ca
124. olenoid will be pulled in for about two seconds then deactivate for about two seconds This cyclic choking action will continue as long as the engine is being cranked PROCEDURE Operational Check Crank the engine While cranking the choke solenoid should pull in about every 2 seconds 2 sec onds ON 2 seconds OFF If the choke solenoid does not pull in try adjusting the choke as follows Pre Choke Adjustment With the CHOKE SOLENOID not actu ated the carburetor CHOKE PLATE should be approximately 1 8 Inch from its full open position Verify choke is completely open once engine is warmed up If not power will be down and emissions will be up Adjust position of BI METAL HEATER ASSEMBLY by loosening screws until unit starts when cold and the choke closes when engine is up to temperature Tighten the screws to complete the adjustment NI 3 Choke Solenoid Adjustment Loosen the screws that retain the CHOKE SOLENOID to its bracket Slide the CHOKE SOLE NOID in the slotted holes of the bracket to adjust axial move Section 7 DIAGNOSTIC TESTS ment of the SOLENOID PLUNGER Adjust SOLENOID PLUNGER movement until with the carburetor CHOKE PLATE closed the CHOKE SOLENOID is bottomed in its coil plunger at full actuated position With the CHOKE PLATE closed and the plunger bottomed in its coil tighten the two screws 4 Disconnect Connector 1 Set the VOM to measure DC voltage Connect the positive test lead
125. ondition 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 K 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 HESULTS 1 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 TEST 8 CHECK SENSING LEADS POWER WINDINGS DISCUSSION The Voltage Regulator regulates excitation current flow to the Rotor by electronically comparing sensing Page 42 voltage to a pre set reference voltage The sensing voltage is delivered to the Voltage Regulator Wires 115 and 225 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 the Hotor in an effort to increase the actua
126. p Once running the Bi Metal Heater Assembly will also allow the Choke Plate to fully open Power for the heater element is supplied from Wire 14 to assist the Bi Metal Heater Assembly in opening the Choke Plate after starting Failure of the Choke Plate to open will cause an excessively rich fuel air mixture and engine perfor mance will suffer PROCEDURE 1 Verify that the Choke Plate on the carburetor is mechanically free to move and is not binding If the engine runs rough check the operation of the BI METAL HEATER ASSEMBLY Allow the engine to run for five minutes then inspect the choke posi tion The Bi Metal strip should have been heated by the Choke Heater and should have expanded to allow the Choke Plate to open fully Page 66 2 If the Choke Plate did not open in Step 1 check the Choke Heater Set the VOM to measure DC voltage Disconnect Connector 1 at the Choke Assembly Connect the positive meter test lead to Wire 14 Connector 1 Pin 3 going to the control panel Connect the negative meter test lead to a clean frame ground Set the Start Stop Switch to START Battery voltage should be measured see Figure 7 43 on Page 63 3 If battery voltage was not measured in Step 2 set the VOM to measure resistance Disconnect Connector 1 at the Choke Assembly Connect one meter test lead to Wire 14 Connector 1 Pin 3 going to the control panel Connect the other meter test lead to the 4 tab Terminal for Wire 1
127. r Windings test good perform the Insulation Resistance Test on Page 13 B Pictorial A Schematic Figure 7 6 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 OK for an open circuit condition PROCEDURE 1 Set a VOM to its 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 OF from the Rotor Brush Terminal Connect one meter test lead to Wire OF Connect the other test lead to a clean frame 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 O Figure 7 7 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 tha
128. rage was measured between 0 8 to 2 Amps in Step 2 and Step 3 the charging system is working 2 f no amperage was measured check the VOM fuses and 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 BCR 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 test lead to an outer terminal The meter should mea sure approximately 0 5 volts Now connect the positive test lead to the other outer terminal Again the meter should mea sure approximately 0 5 volts 3 Connect the positive 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 Page 45 Section 7 DIAGNOSTIC TESTS 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 nega
129. rator 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 Section 7 DIAGNOSTIC TESTS RESULTS 1 If breaker is ON and Continuity is measured go to Test 3 2 If breaker is OFF reset to the ON position and check for AC 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 electrical 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 capaci ty 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 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 gener
130. rcuit Breaker 2 In the generator panel locate the excitation circuit breaker Disconnect Wire 2 and Wire 2A from the breaker terminals 3 Connect the meter test leads across the two circuit breaker CB3 terminals The meter should indicate continuity RESULTS 1 If the meter did NOT read continuity replace the excitation DPE circuit breaker CB3 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 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 BATTERY SUPPLY TO WIRE 4 0 6 VOLTAGE REGULATOR TERMINALS Figure 7 3 Fixed Excitation Test Page 39 Section 7 DIAGNOSTIC TESTS TEST 4 RESULTS A B C D E VOLTAGE RESULTS ABOVE ABOVE BELOW WIRE 2 amp 6 60 VAC 60 VAC 60 VAC EXCITATION WINDING ZERO OR RESIDUAL VOLTAGE 5 12 VAC BELOW 60 VAC VOLTAGE RESULTS ABOVE WIRE 118 22 60 POWER WINDING SENSE LEADS ZERO O
131. requency are proportional The generator will deliver a frequency of 60 Hertz at 3600 Rotor rom or 62 Hertz at 3720 Rotor 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 apparent that if governed speed is high or low AC frequency and voltage will be correspondingly high or low Governed speed at no load is usually set slightly above the rated speed of 60 Hertz to 62 Hertz to prevent excessive rpm frequency and voltage droop under heavy electrical loading FREQUENCY ADJUSTING NUT GOVERNOR LEVER GOVERNOR CLAMP BOLT GOVERNOR SHAFT Figure 7 1 Governor Adjustment Points Section 7 DIAGNOSTIC TESTS GOVERNOR ADJUSTMENT 1 Loosen the GOVERNOR CLAMP BOLT 2 Push Spring end of GOVERNOR LEVER clockwise to wide open throttle position of lever a Hold the GOVERNOR LEVER at wide open throttle and with a pair of pliers rotate the GOVERNOR SHAFT fully clockwise CW Use a minimum amount of force against the gover nor shaft b While holding the GOVERNOR SHAFT fully clockwise and the GOVERNOR LEVER at wide open throttle tighten the GOVERNOR CLAMP BOLT to 70 inch pounds 8 N m 3 Start engine let it stabilize and warm up at no load 4 Turn the ADJUSTER NUT to obtain a frequency reading of 62 Hertz 5 Determine if the
132. rons will flow when voltage is weak More electrons will flow as voltage becomes stronger VOLTAGE may be consid ered 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 1 ampere to flow through 1 ohm of resistance Conductor of a Circuit TUN 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 orbiting 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 will permit one 1 ampere of current to flow when one 1 volt of electro motive force EMF is applied 5 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 incr
133. s indicated If compression is poor look for one or more of the fol lowing causes Loose cylinder head bolts Failed cylinder head gasket LU Burned valves or valve seats U Insufficient valve clearance 1Warped cylinder head Warped valve stem L1 Worn or broken piston ring s 1Worn or damaged cylinder bore L1 Broken connecting rod L1 Worn valve seats or valves 1Worn valve guides NOTE Hefer to Engine Service manual No 0 2081 for further engine service information Section 7 DIAGNOSTIC TESTS TEST 39 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 startup Should oil pressure drop below 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 few seconds If the switch fails OPEN low oil pressure will not result in automatic shutdown SESS CU EE MSA CA P5 be SASS Figure 7 46 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 termi
134. ses through a carburetor venturi which creates a low pressure that is proportional to the quantity of air being pumped The low pressure from the carburetor venturi acts on the regulator diaphragm to pull the diaphragm toward the source of low pressure lever attached to the diaphragm opens a valve to permit gas glow through the carburetor TO CARBURETOR 2 Figure 7 28 LP Gas Carburetion Diagram The greater the airflow through the carburetor venturi the lower the pressure at the venturi throat The lower the pressure at the venturi throat the greater the diaphragm movement and the greater the move ment of the regulator valve The more the regulator valve opens the greater the gas flow that is propor tional to airflow through the generator The following facts about the secondary regulator must be emphasized e The regulator must be sensitive to venturi throat pressure changes throughout the operating range e The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running no air flow through the carburetor e The slightest airflow and vacuum in the venturi throat should move the regulator valve off its seat and permit gas to flow PROCEDURE A water manometer or a gauge that is calibrated in ounces per square inch may be used to measure the fuel pressure Fuel pressure at the inlet side of the LPG Shut
135. 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 SCR Test 26 verified the operation of the SCR Test 26A 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 Section 7 DIAGNOSTIC TESTS 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 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 18 encountered the engine itself should be thoroughly checked to eliminate it as th
136. t Stop Switch to START Battery voltage should be indicated Reconnect Wire 16 to the Starter Contactor 3 Set the VOM to measure voltage Connect the positive meter test lead to the Starter Contactor stud that has the small jumper wire connected to the Starter Connect the negative meter test lead to a clean frame ground Set the Start Stop Switch to START Battery voltage should be measured see Figure 7 20 STEP 2 TEST POINT RESULTS 1 If battery voltage was not measured in Step 1 repeat Test 22 2 f battery voltage was not measured in Step 2 repair or replace Wire 16 between the Starter Contactor Relay SCR and the Starter Contactor SC 3 If battery voltage was measured in Step 1 but not in Step 3 replace the Starter Contactor 4 f battery voltage was measured in Step 3 but the engine still does not crank go to test 27 TEST 27 CHECK STARTER MOTOR CONDITIONS AFFECTING STARTER MOTOR PERFORMANCE 1 A binding or seizing condition in the Starter Motor bearings 2 A shorted open or grounded armature a Shorted armature wire insulation worn and wires touching one another Will be indicated by low or no RPM 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 RPM 3 A defective Starter Motor
137. t they have been trained in the recommended servicing procedures for these products including the use of common hand tools and any special Generac tools or tools from other suppliers Generac could not possibly know of and advise the service trade of all conceivable procedures by which service might be performed and of the possible hazards and or results of each method We have not under taken any such wide evaluation Therefore anyone who uses a procedure or tool not recommended by Generac must first satisfy himself that neither his 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 you intend to perform work 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 Metri
138. ter will result in excessive voltage drop For best cold weather starting voltage drop between the battery and starter should not exceed 0 12 volt per 100 amperes of cranking 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 5 ENGINE CONTROL SYSTEM The following chart applies CABLE LENGTH IN FEET RECOMMENDED CABLE SIZE No 2 No 000 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 1 200 20 F 29 C 1 160 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 In addition the plates cannot take lull part in the battery action unless they are completely immersed in electrolyte Add only DISTILLED WATER to the battery DO NOT USE TA
139. the Engine Controller board in Test 23 then DC voltage should be delivered 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 Relay terminal 3 Connect the meter positive test lead to Wire 56 just discon nected Connect the other test lead to frame ground No volt age 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 J1 1 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 Board and Starter Contactor Relay 2 f battery voltage was not available in Step 6 replace the Engine Controller Circuit Board 3 If battery voltage is available in Step 4 but engine does not crank go to Test 26 TEST 26 CHECK STARTER CONTACTOR RELAY DISCUSSION If battery voltage is available to Wire 56 but the engine won t crank the possible cause could be
140. the ROTOR increases the strength of the magnetic field above that of residual magnetism alone 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 preset into the Voltage Regulator b An Actual sensing voltage is delivered to the Voltage Regulator via sensing leads from the Stator AC power windings The 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 current 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 otator battery charge windings
141. the Remote Harness 2 Wire 18 from the Engine Controller board This Is the ENGINE STOP circuit When the Start Stop Switch is set to STOP Wire 18 is connected to frame ground via Wire No Circuit board action then opens the circuit to Wire 14 and grounds Wire 18A Fuel flow to the carburetor and igni tion are terminated 3 Wire 0B connects the Switch to frame ground 1 17 r y START SW1 On 18 Lo A STOP lt x 18 l 0 m 17 A Schematic B Pictorial Figure 5 6 Start Stop Switch STARTER CONTACTOR RELAY amp STARTER MOTOR The positive battery cable attaches to the large lug on the STARTER CONTACTOR Wire 13 then attaches to one side of the STARTER CONTACTOR RELAY contact from this point Wire 13 attaches to the fuse F1 to supply battery voltage to the DC con trol system The opposite side of the starter contactor relay contact is connected to Wire 16 Page 26 Wire 16 will supply battery power to the starter con tactor and to the engine controller board for field flash when the starter contactor relay is energized Attached to the starter contactor relay coil is wire 56 positive supply during cranking and wire O ground When the Start Stop switch is set to START the cir cuit board delivers battery voltage to the Starter Contactor Relay via Wire 56 The Starter Contactor Relay energizes its contacts close and the Starter Cont
142. the engine to start or b rough operation Page 64 One or more of the following will usually cause loss of compression Blown or leaking cylinder head gasket seated or sticking valves L1Worn Piston rings or cylinder This will also result in 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 for the V Twin engine Testing has proven that an accurate compression indication can be obtained using the following method PROCEDURE 1 Remove both spark plugs 2 Insert a compression gauge into either cylinder 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 two cylinders 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 No 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 i
143. tive test lead to the remaining outer BCR terminal Once again Infinity should be measured Figure 7 10 Battery Charge Rectifier RESULTS 1 If any of the previous steps has failed replace the Battery Charge Rectifier 2 If the BCR tests good go to Test 17 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 Rectifier 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 Blue connector for this test Disconnect the Stator Lead Wire 55 from the Battery 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 Page 46 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
144. ts in an alternating current AC waveform that can be diagrammed as shown in Figure 1 5 The ROTOR 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 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 regulated direct current is delivered into the ROTOR 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 Hegulated current delivered to the ROTOR is called EXCITATION current STATOR STATOR j D an H D O O lt BRUSHES SLIP RINGS DC CURRENT Figure 1 6 A More Sophisticated Generator See 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 spee
145. ts 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 e The greater the current flow through the conductor the stronger the magnetic field around the conductor e 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 The fingers will then be pointing in the direction of the lines of force NOTE The right hand rule is based on the cur 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
146. ttery posts or terminals for corrosion or tightness Measure the voltage at the terminal of the starter contactor and verify 11 12 volts DC is available to the generator during cranking If voltage is below 11 volts DC measure at the battery terminals during cranking If battery voltage is below 11 volts DC recharge replace battery If bat tery voltage is above 11 volts DC 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 generator and retest 2 Use a 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 possible 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 th
147. uit while cranking only To Start Stop switch When grounded by set ting Switch to STOP engine shuts down Start Stop Switch optional Remote Panel Figure 5 2 Receptacle J1 In addition to the 15 pin receptacle J1 the circuit board is equipped with two single pin terminals J2 and J3 These terminals may be identified as follows 1 Wire 14 connects to Terminal J2 During cranking and running the circuit board delivers battery voltage to the Wire 14 circuit for the following functions Page 24 To operate the electric Fuel Pump FP To energize the Fuel Solenoid To operate the Choke Heater To the Remote Wire Harness to operate an hourmeter or a light 2 Wire 15 connects to Terminal J3 This is the power supply 12 VDC for the circuit board and the DC control system J3 J2 Ji PIN LOCATIONS J1 1 thru J1 15 Figure 5 3 Engine Controller Circuit Board BATTERY RECOMMENDED BATTERY When anticipated ambient temperatures will be con sistently above 32 F 0 C use a 12 volts automo tive type storage battery rated 70 amp hours and capable of delivering at least 400 cold cranking amperes If ambient temperatures will be below 32 0 C use a 12 volt battery rated 95 amp hours and having a cold cranking capacity of 400 amperes BATTERY CABLES Use of battery cables that are too long or too small in diame
148. ured If Continuity is mea sured a short to ground exists RESULTS 1 If Choke operation is good go to Test 35 for Problem 7 Engine Cranks but Won t Start Section 6 Go to Test 41 for Problem 8 Engine Starts Hard and Runs Rough 2 f battery voltage was measured in Step 5 but not measured in otep 4 repair or replace Wire 90 between Engine Control Board ECB and Connector 1 3 If battery voltage is not measured in Step 5 during engine cranking replace Engine Control Board 4 f Continuity is not measured in Step 6 repair or replace Wire 0 between the ground terminal and Connector 1 5 f Choke Solenoid coil resistance is not measured or is incor rect in Step 7 replace the Choke Solenoid CHOKE SOLENOID BRACKET CHOKE CONTROL ROD BI METAL amp HEATER COTTER PIN _ ASSEMBLY lt Ng CHOKE SOLENOID CHOKE SOLENOID PLASTIC BOOT Figure 7 44 Exploded View of Choke Assembly CHOKE SOLENOID BRACKET CHOKE CONTROL ROD BI METAL HEATER ASSEMBLY CHOKE SOLENOID LOOSEN SCREWS ADJUST BI METAL HEATER ASSEMBLY FORWARD OR BACKWARD Figure 7 45 Automatic Choke Assembly Page 63 Section 7 DIAGNOSTIC TESTS TEST 38 CHECK ENGINE CYLINDER LEAK DOWN TEST COMPRESSION TEST GENERAL Most engine problems may be classified as one or a combination of the following U Will not start Starts hard Lack of power Runs rough Vibration L1 Overhe
149. utput to Terminal J2 The FUEL PUMP FP FUEL SOLENOID FS and CHOKE HEATER CH are de energized by the loss of DC to Wire 14 Ignition and fuel flow terminate and the engine shuts down 90 o 0 18 IM1 gt SP1 18 gt 5 2 0B REMOTE PANEL 12 SUPPLY CONNECTOR 1 17 2 14 3 18 4 14 15 5 2 14A 6 7 2 i 66 15 77 BATTERY CHARGE WINDING 55 R1 ON POWER WINDING ELECTRONIC VOLTAGE REGULATOR DPE WINDING OF LI RAA UKA LA FIELD WHITE 120V 30A QP55 amp QP65 120V 35A QP75 NEUTRAL CONNECTION BY CUSTOMER Page 22 120V 20A QP55 ha 120V 30A QP65 TO 120V 35A QP75 x maaa 12 CONTROL ma GROUND LEGEND BCR BATTERY CHARGE RECTIFIER CB1 CIRCUIT BREAKER 30A QP55 amp QP65 MODELS FUEL CIRCUIT BREAKER 35A QP75 MODEL PRIME CB2 CIRCUIT BREAKER 20A QP55 MODEL CIRCUIT BREAKER 30A QP65 MODEL REMOTE PANEL CIRCUIT BREAKER QP75 MODEL OPTIONAL CB3 CIRCUIT BREAKER 2 5A QP55 MODEL CIRCUIT BREAKER 3 0A QP65 amp QP75 MODELS CH CHOKEHEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 5A FP FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IM1 IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO

Generac Power Systems 55 Portable Generator User Manual

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