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ACS BD Blender User Manual

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1. BA BATTERY CHARGE WINDING DPEWINDING FIELD Y C NT TIS SY P a INA 55A 66A 113 11 228 44 2 6 4 0 1 5 1 4 Ct4 17 1 11 1 12 Am A9 A 10A BATTERY CHARGE WINDING SOOO LC RED 7 55 66 ioe C1 10 C1 9 A 66A 228 7 777 66 22 2 6 4 0 44 22 0 11 66A 0 15 77 BCR2 18A 6 O 15A 77 ELECTRONIC iis 555 15 4 VOLTAGE 225 REGULATOR 4 4 1 0 0 1 6 6 162 162 2 CB2 C25 LOP 86 o T gt 0 0 b 15B C2 12 167 167 83 83 0 o BLK sw2 1 BLK 15 2 0 4 1 n 118 158 Y 9 13 13 RED V SR o 28 15 BATTERY 118 14 2 11 SM 12V 229 R1 13 13 cas BLACK 14 16 16 b 5 0 14 167 15 17 1 gt d 77 166 17 17 Lj m CONTROL 2 1 L PRINTED CIRCUIT BOARD o 17 167 5 gt A 6 SP2 C24 SW1 H 86 167 167 o 209 8
2. 120V 30A TWISTLOK 1 22 0 44C LEGEND BA BRUSH ASSEMBLY BCR1 BATTERY CHARGE RECTIFIER 10A BCR2 BATTERY CHARGE RECTIFIER 1 10 AUTO RESET BREAKER CB2 5 AUTO RESET BREAKER D1 600 12A DIODE D2 D3 ENGINE SHUTDOWN DIODE F1 10A FUSE FSS FUEL SHUT OFF SOLENOID GND GROUND BAR IDLE CONTROL TRANSFORMER IM1 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 LOP LOW OIL PRESSURE R1 25 OHM 25W RESISTOR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 SP2 SPARK PLUG CYL 2 SSR START STOP RELAY D gt SW1 START RUN STOP SWITCH a SW2 IDLE CONTROL SWITCH bs TB1 TB2 TERMINAL BLOCK p r SP2 nepen BED 12 VDC SUPPLY 12 VDC CONTROL 54 us AC POWER 1 GROUND FAULT SHUTDOWN With the generator running if the Low Oil Pressure LOP closes Wire 86 will be connected to Wire 0 frame ground Printed Circuit Board action will open Wire 229 from ground this action will de energize the Start Stop Relay SSR This action will cause a shutdown as described on Page 26 Page 27 Section 5 TROUBLESHOOTING FLOWCHARTS INTRODUCTION The Flow Charts in this section may be used in Problems 1 through 5 apply to the AC genera
3. CLOSEST TO BEARING BA 22 IDLE CONTROL TRANSFORMERS 22 11 11 RED 11 44 44 44 83 167 229 15B BLK 0 BLK 86 TB1 TB2 115 55A 162 J2 ELECTRONIC GOVERNOR ENGINE SHUTDOWN P C B 22S 55 0 66 R1 15 d VOLTAGE 77 77 14 REGULATOR n 2 0 66A 66 6 15 14 Lessa 55A 55 55 Lj BATTERY CHARGE 15 RECTIFIER 66A 10A AUTO RESET BKR 7T BATTERY 13A 13A d Op CHARGE RECTIFIER 66 12Vdc OUTLET 15A LEGEND BA BRUSH ASSEMBLY AUTO RESET BREAKER D ENGINE SHUTDOWN DIODE D2 600V 12A DIODE F1 10A FUSE FSS FUEL SHUT OFF SOLENOID GND GROUND BAR IM1 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 LOP LOW OIL PRESSURE R1 25 OHM 25W RESISTOR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 SP2 SPARK PLUG CYL 2 SSR START STOP RELAY TB1 TB2 TERMINAL BLOCK Page 81 Section 8 ELECTRICAL DATA Electrical Schematic 17 5 kW Drawing No 0G0733 POWER WINDING
4. GUARDIAN by Generac Power Systems Inc NN MODELS 4451 amp 4986 12 500 Watt 4582 amp 4987 15 000 Watt 4583 17 500 Watt GENERAC POWER SYSTEMS INC 5209 15 000 Watt 9308 17 500 Watt COMMERCIAL INDUSTRIAL RESIDENTIAL www guardiangenerators com 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 damage to equipment and or property These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these spe cial instructions plus common sense are major accident prevention measures NOTICE TO USERS OF THIS MANUAL This SERVICE MANUAL has been written and published by Generac to aid our dealers mechanics and com pany service personnel when servicing the products described herein It is assumed that these personnel are familiar with the servicing procedures for these products or like or similar products manufactured and marketed by Generac That they have been trained in the recommended s
5. Page 19 Section 4 ENGINE DC CONTROL SYSTEM POWER WINDING DPE WINDING BATTERY CHARGE WINDING FIELD 77A 66 4 t NNN 55A 2 6 4 0 1 5 445 44 22 11 118 4I C16 C17 Acti C1 12 77 DN A 10A BATTERY CHARGE WINDING AN CER i6 T 66 RED C1 10 C1 9 A 446 MS 2 6 4 0 LCT HA 1 11 22 66 BLK 77 44 44 66 0 15 77 1 12Vdc m 13A O 15 77 77 BLK J CB2 14 2 162 162 ELECTRONIC Hiis VOLTAGE D1 R1 REGULATOR 4 14 5 6 GOVERNOR ACTUATOR 9 8 7 6 5 4 3 2 1 S J2 CONTROL PRINTED CIRCUIT J1 CIRCUIT CONDITION REST Battery voltage is supplied to components of the control system from the unit BATTERY via the RED battery cable connected to the contacts of the starter contactor SC wire 13 a 10 Amp fuse F1 and Wire 15 Wire 13 is unfused battery supply voltage and is connected to the contacts of the Starter Contactor Relay SCR Wire 15 12 VDC fused battery supply voltage is supplied to the SCR coil it goes through the coil and co
6. 12 VDC SUPPLY 12 VDC CONTROL 54 Te AC POER 1 fg d GROUND IDLE CONTROL TRANSFORMER OUTPUT The printed circuit board is supplied with AC voltage from Wires 11S and 448 this voltage frequency signal is used by the printed circuit board for governor control operation When the Idle Control Switch SW2 is activated to the ON position Wire 83 from the printed circuit board will be connected to Wire 0 frame ground There are two Idle Control Transformers ICT that sense current flow off the main power windings The voltage signal from the ICT s connect to the Printed Circuit Board via Wires TR1 TR2 and are used for sensing load on the generator With no load on the generator there is no current supplied from the ICT s and the engine will run at a lower RPM When a load is applied to the generator the ICT s supply a voltage signal to the Printed Circuit Board and the engine RPM will be increased to running RPM approximately 3600RPM Page 25 Section 4 ENGINE DC CONTROL SYSTEM POWER WINDING DPE WINDING BATTERY CHARGE WINDING FIELD 77A 66 4 t 55A 2 6 4 0 1 5 14 445 44 22 11 118 py A AS C14 C16 C1 11 C1 12 77 AA 10A BATTERY CHARGE WINDING AN CER i6 T 66 RED C1
7. ON SPEED OPERATION 12 PROBIEMO9 0 0 FIELD EXCITATIOIN 12 ENGINE STARTS THEN SHUTS DOWN 34 AC POWER WINDING OUTPUT 12 PROBLEM 10 BATTERY CHARGE WINDING OUTPUT 12 10 AMP FUSE F1 BLOWING 35 10 AMP BATTERY CHARGE WINDING OUTPUT 12 36 INSULATION RESISTANCE coven 13 PROBLEM 12 THE MEGOFIMMETER J atasi t t eee 13 IDLE CONTROL RPM DOES NOT DECREASE 36 GENERAL eee tetendit 13 PROBLEM 13 TESTING STATOR INSULATION 13 2 NOT INCREASE TESTING ROTOR INSULATION 13 PROBLEM 14 f ua 13 ENGINE HUNTS ERRATIC IDLE 36 Table of Contents SECTION 6 DIAGNOSTIC TESTS 37 65 INTRODUCTION ces 37 TEST 1 CHECK NO LOAD VOLTAGE AND FREQUENCY 37 TEST 2 CHECK MAIN CIRCUIT 37 TEST 3 TEST EXCITATION CIRCUIT BREAKER 38 TEST 4 FIXED EXCITATION TEST ROTOR AMP DRAW 38 TEST 5 CHECK STEPPER MOTOR CONTROL 40 TEST 6 WIRE CONTINUITY aaa 41 TEST Z CHECK FIELD BOOST uu
8. Figure 3 9 Stator Winding Leads 4 Connect the terminal ends of Wires 11 22 and 44 together Make sure the wire ends are not touching any part of the gen erator frame or any terminal 5 Connect the red test probe of the Hi Pot tester to the joined terminal ends of stator leads 11 22 and 44 Connect the black tester lead to a clean frame ground on the stator can With tes ter leads connected in this manner proceed as follows a Turn the Hi Pot tester switch OFF b Plug the tester cord into a 120 volt AC wall sock et and set its voltage selector switch to 1500 volts c Turn the tester switch ON and observe the breakdown lamp on tester DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND After one 1 second turn the tester switch OFF If the breakdown lamp comes on during the one sec ond test the stator should be cleaned and dried After cleaning and drying repeat the insulation test If after Page 14 cleaning and drying the stator fails the second test the stator assembly should be replaced 6 Now proceed to the C1 connector Female side Just removed Each winding will be individually tested for a short to ground Insert a large paper clip or similar item into the C1 connector at the following pin locations PWP Ksa 2 s Sense Lead Power sa Battry Charge 4 Battery Charge Ls eem to Arp Battery Cham
9. 28 36 SECTION 3 DESCRIPTION AND COMPONENTS 9 15 INTRODUCTION 28 IF PROBLEM INVOLVES AC OUTPUT 28 INTRODUCTION rH 9 1 ENGINE GENERATOR DRIVE SYSTEM 9 VOLTAGE amp FREQUENCY ARE BOTH HIGH OR LOW 28 AC GENERATOR uu uu u uu u a a 9 PROBLEM 2 ROTOR ASSE BIY 9 GENERATOR PRODUCES ZERO VOLTAGE STATOR ASSEMBLY 10 2 VOLTAGE 2 12 29 30 BRUSH HOLDER AND BRUSHES 10 EXCESSIVE VOLTAGE FREQUENCY OTHER AC GENERATOR COMPONENTS 10 DROOP WHEN LOAD IS APPLIED 30 EXCITATION CIRCUIT BREAKER 10 PROBLEM 4 VOLTAGE REGULATOR 11 NO BATTERY CHARGE OUTPUT 31 ADJUSTMENT PROCEDURE 11 PROBLEM 5 a 10 AMP BATTERY CHARGE OUTPUT 31 CIRCUIT BREAKERS iden 12 PROBLEM 6 ROTOR RESIDUAL MAGNETISM 12 ENGINE WILL NOT CRANK 32 FIELD BOOST CIRCUI P i 2 cs au Qani masaqa 12 PROBLEM 7 OPERATION 12 ENGINE CRANKS BUT WILL NOT START 33 STARTUP LL dettes taa ient C dr tide 12
10. a CORP WAUKESHA WICONSIN usa 2 EXCITATION Figure 3 6 Typical Voltage Regulator Found on 12 5 kW and 15 kW Units Section 3 DESCRIPTION amp COMPONENTS Figure 3 7 Typical Voltage Regulator Found on 17 5 Units ADJUSTMENT PROCEDURE 12 5 AND 15 KW UNITS The Voltage Regulator is equipped with three light emitting diodes LED s These LED s are normally on during operation with no faults in the system The RED regulator LED is on when the regulator is on and functioning The Yellow sensing LED is powered by sensing input to the regulator from the stator AC power windings The GREEN excitation LED is pow ered by stator excitation winding output Four adjustment potentiometers are provided They are VOLTAGE ADJUST GAIN STABILITY and UNDERFREQUENCY ADJUST 1 Connect an AC Voltage Frequency meter across wires 11 amp 44 at the 50A Main circuit breaker Verify frequency is between 59 61Hz 2 On the regulator set the adjustment pots as follows a Voltage Adjust Pot turn fully counterclockwise b Gain turn to midpoint 12 O clock c Stability turn to midpoint 12 O clock d Under Frequency turn to midpoint 12 O clock 3 Start the generator This adjustment will be done under a no load condition 4 Turn the regulator s Voltage Adjust pot clockwise to obtain a line to line voltage of 238 242 VAC 5 If the red regulator LED is flas
11. YJ 2222 1 C 69 lt TERMINAL BLOCK TB1 Figure 6 61 Check Idle Transformer Wiring TEST 55 CHECK TR1 amp TR2 WIRING MAKE SURE THE TEST PROBE CONNECTOR IS MAKING CONTACT WITH THE CONNECTOR DOUBLE CHECK TO J2 HARNESS CONNECTOR MAKE SURE THAT THE TIP IS SHARP Figure 6 62 Check TR2 Wiring Section 6 DIAGNOSTIC TESTS PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect the J2 connector from the printed circuit board 3 Connect one meter test lead to Wire TR2 at Terminal Block 1 TB1 See Figure 6 62 Connect the other meter test lead to pin location J2 6 on the J2 Connector previously removed Be careful not to damage the pin connectors with the test leads Continuity should be measured 4 Connect one meter test lead to Wire TR1 at Terminal Block 1 TB1 See Figure 6 63 Connect the other meter test lead to pin location J2 3 on the J2 Connector previously removed Be careful not to damage the pin connectors with the test leads Continuity should be measured RESULTS 1 Repair or replace defective wiring 2 If wiring tests good replace printed circuit board TEST 56 CHOKE TEST PROCEDURE If the generator is surging it may have a carburetion problem A lean condition can cause errati
12. 0 1 86 15B 167 0 Sw2 15 18 14 18 V s F1 15 15 GOVERNOR ACTUATOR J2 CONTROL PRINTED CIRCUIT BOARD Page 74 Section 8 ELECTRICAL DATA 120V DUPLEX gE 11B d 22 22 22 n 120 240V 120 240V 50A 30A 120V 30A 120V 30A 0 TWISTLOK TWISTLOK TWISTLOK 61 42 0 0 0 11D 0 44D 22 0 11C 22 0 44C CB aE C B CB C B CB C B 0 30A lo CB 30A lo 30A 30 20 j 20A 50A is I 5 iom 1 1 o 1 0 1 1 0 44 44 44 LEGEND P BA BRUSH ASSEMBLY BATTERY CHARGE RECTIFIER 10A i 0 2 BATTERY CHARGE RECTIFIER gt i 4 CB1 10AMP AUTO RESET BREAKER CB2 5AMP AUTO RESET BREAKER 14 T 1 D1 600V 12A DIODE j D2 D3 ENGINE SHUTDOWN DIODE 1 F1 10A FUSE 4 4 FSS FUEL SHUT OFF SOLENOID 0 al GND GROUND BAR 25 I C T IDLE CONTROL TRANSFORMER 155 15 IM1 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 i LOP LOW OIL PRESSURE 254 15 R1 25 OHM 25W RESISTOR 167 167 SC STARTER CONTACTOR swi SCR STARTER CONTACTOR RELAY o SM STARTER MOTOR 14 15 SP1 SPARK PLUG CYL 1 17 17 SP2 SPARK PLUG CYL 2 C24 be SSR START STOP RELAY 13 gt SW1
13. Figure 1 1 Magnetic Lines of Force ELECTROMAGNETIC FIELDS All conductors through which an electric current Is flowing have a magnetic field surrounding them This field is always at right angles to the conductor If a compass is placed near the conductor the compass needle will move to a right angle with the conductor The following rules apply The greater the current flow through the conductor the stronger the magnetic field around the conductor The increase in the number of lines of force is directly proportional to the increase in current flow and the field is distributed along the full length of the conductor The direction of the lines of force around a conduc tor can be determined by what is called the right hand rule To apply this rule place your right hand around the conductor with the thumb pointing in the direction of current flow 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 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 mo
14. 2 Perform Test 29 again checking for Spark RESULTS Refer back to Flow Chart WIRE 18 SHUTDOWN RESULTS Refer to Flow Chart Figure 6 40 Wire 18 TEST 32 TEST START STOP RELAY SSR PROCEDURE 1 Set a voltmeter to measure DC voltage 2 Remove Wire 15 from Terminal 13 on the Start Stop Relay SSR Connect the positive meter test lead to Wire 15 previ ously removed Connect the negative meter test lead to frame TEST POINTS C ground 12 VDC should be measured if it is proceed to Step 3 JEST POINTS If 12 VDC is not measured repair or replace Wire 15 between i TEST POINTS the SSR and the Battery Charge Rectifier 2 BCR2 27 3 With Wire 15 reconnected to the SSR remove Wire 229 from the SSR Connect a jumper lead from the terminal of the SSR that Wire 229 was just removed from and to frame ground See Figure 6 43 The relay should energize closed visually inspect it to see if it closes If the relay energizes closed proceed to Step 4 If the relay does not energize closed replace it 4 Remove Wire 0 Wire 18 Wire 15 Wire 15B Wire 15 and Wire 14 See Figure 6 42 5 Set a voltmeter to measure resistance Remove jumper lead from Step 3 Connect meter test leads across TEST POINTS continuity closed should be measured Connect meter test Figure 6 42 Start Stop Relay SSR Not Energized Page 54 Section 6 DIAGNOSTIC TESTS TEST POINTS C TEST
15. 3OIAH3S NIV 57002 HO 001 WHLNAN aariaans YaWOLSNO 3704 2 voo dm du 2 SHOLONGNOD AONSOYSNS J Jl B SLAN ONISN J d SSNOH OL 7 2 540 021 201 3909 2 1 1 1 04 Vd3N LAAW LSNW HOS 1 S9NV0L WHLNAN 3HIM NHH1 9 SONILLIS v LINGNOOS WLAW 3 T181X3 14 v 31VIQ3IH3LINI IVIH3IIVIN 31599915 dO1VH3N39 5 HOIVH3N39S aaridans YAWOLSNO vos 148 NMOHS SV 3OV1d OLNI HOIVH3N39 OLNI 05 31995 OLLON NOTIV TIIM H LDN3 1 GHOO H3MOd SV AVMV SV Q InOHS HOIVH3N39 34VS HOS Page 84 NOTES Page 85 Section 9 SPECIFICATI
16. e 10 Amp Battery Charge Negative ead to Brush Next refer to Steps 5a through 5c of the Hi Pot proce dure Example Insert paper clip into Pin 1 Hi Pot from Pin 1 Wire 11S to ground Proceed to Pin 2 Pin 3 etc through Pin 10 PIN PIN Ma LOCATIO 6 Lj LOCATION 7 Figure 3 10 C1 Connector Pin Location Numbers Female Side Located to the Right When Facing the Control Panel TEST BETWEEN WINDINGS 1 Insert paper clip into Pin Location 3 Wire 55A Connect the red tester probe to the paper clip Connect the black tes ter probe to Stator Lead 11 Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND 2 Repeat Step 1 at Pin Location 6 Wire 2 and Stator Lead 11 Section 3 DESCRIPTION amp COMPONENTS 3 Repeat Step 1 at Pin Location 8 Wire 55 and Stator Lead 11 For the following steps 4 through 6 an additional paper clip or similar item will be needed 4 Insert a paper clip into Pin Location 3 Wire 55A Connect the red tester probe to the paper clip Insert additional paper clip into Pin Location 6 Wire 2 Connect the black tester probe to this paper clip Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page 5 Insert a paper clip into Pin Location 3 Wire 55A Connect the red tester probe to the paper clip Insert additional
17. L GROUND GRN CIRCUIT5 YEL m GEN2 RED CIRCUIT 7 YEL WHT gt gt CIRCUIT9 LT BLU 7 NEUTRAL WHT CIRCUIT11 ORG x CUSTOMER SUPPLIED CIRCUIT 13 DRK BLU Y CIRCUIT 15 PNK x GROUND BAR NEUTRAL BAR 5 r i OOOGDOO pan LOAD CENTER DOAA NEUTRAL BAR Fey L CIRCUIT 16 PNK YEL ME CIRCUIT14 BLU YEL CIRCUIT 12 ORG YEL CIRCUIT 10 GRY YEL CIRCUIT8 VIO YEL CIRCUIT6 VIO CIRCUIT 4 ORG WHT CIRCUIT 2 ORG MAIN 2 RED H AAA MAIN1 BLK EEE NEUTRAL ee ar ese a ath er 16 WHT LET TN NEUTRAL ciRcUIT 14 WHT NEUTRAL Me 12 WHT NEUTRAL Ree um sn rete Ya
18. GOOD Y REPAIR OR REPLACE WIRE 16 Section 5 TROUBLESHOOTING FLOWCHARTS Problem 7 Engine Cranks But Will Not Start CHECK FUEL gt SUPPLY OFF REPLENISH FUEL M SUPPLY TURN ON TEST 38 CHECK FUEL PUMP TEST 36 CHECK SOLENOID FSS BAD E d TEST 37 CHECK ae FUEL SHUTOFF SOLENOID VOLTAGE GOOD DC VOLTAGE MEASURED AT TWO PIN CONNECTOR TEST 39 CHECK BAD CARBURETION REPAIR OR REPLACE FSS GOOD TEST 5 CHECK REPAIR STEPPER BAD OR MOTOR REPLACE CONTROL GOOD TEST 41 CHECK GOOD gt ENGINE CYLINDER LEAK DOWN TEST COMPRESSION TEST TEST 40 CHECK VALVE ADJUSTMENT BAD 4 BAD ADJUST AND REPAIR OR REPLACE AS NECESSARY RE TEST REFER TO ENGINE SERVICE MANUAL P N 0E2081 FOR FURTHER ENGINE SERVICE INFORMATION VERIFY THAT IDLE FUEL SHUTOFF CONTROL SWITCH PULL CHOKE IS IN THE OFF OFF FULL POSITION ON PULLOUT TEST 30 TEST 29 CHECK coop SPARK SPARK PLUGS BAD REPLACE BAD BAD TEST 32 CHECK START STOP RELAY SSR TEST 31 REMOVE WIRE 18 SPARK SHUTDOWN LEAD SPARK TEST 35 CHECK AND ADJUST IGNITION TEST 32 TEST MAGNETOS BAD START STOP RELAY SSR REPLACE GOOD ADJUST OR REPLACE TEST 33 TEST BAD WIRE 167 REPAIR OR REPLACE TEST 34 TEST START STOP RELAY WIR
19. c The Regulator compares the actual sens ing voltage to its pre set reference voltage 1 If the actual sensing voltage is great er 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 current 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 Stator battery charge windings a Battery charge winding AC output is deliv ered to the battery charge rectifiers BCR which changes the AC to direct current DC The rectified DC is then delivered to the units battery and battery charge outlet to maintain the battery in a charged state Page 5 Section 2 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 frequency and d resistance in ohms The following apply To measure AC voltage
20. nected or turned off before attempting to crank and start the engine Check that the choke is working properly Remove fuel line at carburetor and ensure that there is an adequate amount of fuel entering the carburetor 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 needle 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 Page 58 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 RESULTS If carburetor is varnished clean or replace Refer to Flow Chart TEST 40 VALVE ADJUSTMENT ADJUSTING VALVE CLEARANCE The valve lash must be adjusted correctly in order to pro vide the proper air fuel mixture to the combustion chamber 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 ex
21. 62 TEST SOS CHECK WIRE u ua n tee 62 TEST 51 CHECK WIRES 115 amp 44S 62 TEST 52 CHECK IDLE CONTROL SWITCH SW2 63 TEST 53 CHECK IDLE CONTROL WIRING 63 TEST 54 CHECK IDLE CONTROL TRANSFORMERS 64 TEST 55 CHECK TR1 amp TR2 WIRING 64 TEST 56 CHOKE TEST ratto teh ges 65 SECTION 7 DISASSEMBLY AND EXPLODED VIEWS 66 71 MAJOR DISASSEMBLY Dn tette 66 2 ene 68 FRAME HANDLE amp WHEELS FIGURE B 70 SECTION 8 ELECTRICAL 72 79 WIRING DIAGRAM 12 5 amp 15 KW UNITS WITHOUT HOURMETER DRAWING NO 0E0228 72 ELECTRICAL SCHEMATIC 12 5 amp 15 KW UNITS WITHOUT HOURMETER DRAWING NO 0 0229 74 WIRING DIAGRAM 12 5 amp 15 KW UNITS WITH HOURMETER DRAWING NO 0D4609 D 76 ELECTRICAL SCHEMATIC 12 5 amp 15 KW UNITS WITH HOURMETER DRAWING NO 0D6297 A 78 WIRING DIAGRAM 17 5 KW UNITS DRAWING 060731 80 ELECTRICAL SCHEMATIC 17 5 KW UNITS DRAWING NO 060733 82 WIRING DIAGRAM 17 5 KW MANUAL TRANSFER SWITCH DRAWING NO 0G1065 83 INTERCONECTION DRAWING 17 5 KW GENERATOR 84 SECTION
22. 86 86 0 4 86 15B 0 229 167 165 83 o o 0 Sw2 15 TB2 18 18 o 14 14 t 15 NP F1 15 15 GOVERNOR ACTUATOR 445 86 167 TR1 15B 15 115 229 12 11 10 9 8 1 J2 CONTROL PRINTED CIRCUIT BOARD Page 78 Section 8 ELECTRICAL DATA 120V 120V DUPLEX GFCI 11B 1 11 22 22 n 120 240V 120 240V 50A 30A 120V 30A 120V 30A TWISTLOK TWISTLOK TWISTLOK 20A El C2 12 0 0 gt gt 0 LEGEND BA BRUSH ASSEMBLY C2 7 0 BCR1 BATTERY CHARGE RECTIFIER 10A 14 14 BCR2 BATTERY CHARGE RECTIFIER 1 CB1 10AMP AUTO RESET BREAKER 2 5 FSS 2 2 AUTO RESET BREAKER 44 86 86 D1 600V 12 DIODE D2 D3 ENGINE SHUTDOWN DIODE LOP 0 F1 10A FUSE FSS FUEL SHUT OFF SOLENOID GND GROUND BAR 14 0 86 5 A IDLE CONTROL TRANSFORMER 1 1 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 C2 2 LOP LOW OIL PRESSURE 15 15 R1 25 OHM 25W RESISTOR SC STARTER CONTACTOR C2 10 SCR STARTER CONTACTOR RELAY 15 gt 15 SM STARTER MOTOR 15 5 1 SPARK PLUG CYL 1 C2 4 SP2 SPARK PLUG CYL 2 167 gt 167 SSR START STOP RELAY 1 SW1 START RUN STOP RELAY 2 3 swt 0 7 SW2 IDLE CONTROL SWITCH 17 0 TB1 2 TERMINAL BLOCK 14 15 C2 8 1 17 n C2 1 D2 13 18 18 gt
23. D1 Connect the negative meter test lead to the top of the diode D1 Approximately 0 5 Volts should be measured 14 WIRE 14 REMOVED 14 Figure 6 14 Testing Field Boost TEST 8 DIODE RESISTOR PROCEDURE Figure 6 16 Diode Test Step 6 1 Set volt meter to the diode test range 7 Set volt mater to measure resistance 2 Disconnect the six pin connector from the Voltage Regulator 8 Connect one meter test lead to the top terminal of the diode 3 Disconnect Connector C1 See Page 17 for connector location D1 Connect the other meter test lead to the ground terminal 4 Disconnect both wires from the Resistor R1 INFINITY or an open condition should be measured 9 Connect one meter test lead to one terminal of the resistor R1 Connect the other meter lead to the remaining terminal of resistor R1 See Figure 6 17 Approximately 25 ohms should be measured 5 Connect the positive meter test lead to the top terminal of the diode D1 Connect the negative meter test lead to the bottom of the diode D1 See Figure 6 15 INFINITY or an open condi tion should be measured Page 42 14 WIRE 14 REMOVED Figure 6 17 Diode Test Step 9 10 Connect one meter test lead to the top terminal of the resistor R1 Connect the other meter test lead to the ground terminal INFINITY or an open condition should be measured 11 Reconnect the six pin connector reconnect the C1 connector reconnect the
24. Replace bad brushes Clean slip rings if necessary 2 If brushes and rings are good go to Test 14 TEST 14 CHECK ROTOR ASSEMBLY PROCEDURE Gain access to the brushes and slip rings Disconnect Wire 4 and Wire O from their respective brushes and remove the brush holder Then test the Rotor as fol lows 1 Set a voltmeter to measure resistance 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 won 004582 0 1 004987 0 005209 0 7110 004582 2 004987 1 13 10 004583 0 005308 0 14 20 46 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 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 2 If Rotor checks good perform Rotor Insulation Resistance Test on Page 15 POSITIVE TEST LEAD Figure 6 22 Te
25. WASHER FLAT 3 4 15 kW EE KIT FUEL TANK 12 3 PNEUM WHEEL 3 4 AXLE 15 kW AXLE 3 4 DIA X 30 15 kW AXLE 3 4 DIA X 27 25 12 5 kW 10 PNEUM WHEEL 3 4 AXLE 12 5 kW s INSERT weena Se _ 71 Section 8 ELECTRICAL DATA Wiring Diagram 12 5 amp 15 kW Units Without Hourmeter Drawing No 0E0228 120 240V 120V 20A 120V 30A 120V 30A DUPLEX 30A TWISTLOK TWISTLOK TWISTLOK 22 e 2 Q SIG 30A C B ENGINE WIRING GOVERNOR ACTUATOR START 13 Page 72 Section 8 ELECTRICAL DATA 120 240V 50A OUTLET IDLE CONTROL TRANSFORMERS ELECTRONIC GOVERNOR ENGINE SHUTDOWN P C B 66 77 94 CLOSEST TO BEARING 0 11 gt 4 PIN VOLTAGE REGULATOR PIN3 14 14 12Vdc OUTLET 15A 10A AUTO 66A RESET BKR EF 13A o BATTERY CHARGE RECTIFIER
26. WO P D3 2 gt 17 lt SP2 C2 6 13 13 N RED 15 C2 11 sc 13 13 C2 9 16 1 BLACK 1 Page 79 Section 8 ELECTRICAL DATA Wiring Diagram 17 5 kW Drawing 0G0731 120 240V 30A TWISTLOK 120V 20A 120V 30A DUPLEX TWISTLOK 120V 30A 120 240V 50A 60A OUTLET 22 30A 20A C B C B 20 C B 50A 60 C B ENGINE WIRING GOVERNOR ACTUATOR BLACK BATTERY 16 O 12V sc IE 18 1 lt 18 spi lt D 15 2 15 IM1 START 0 3 lt 0 167 lt 4 167 _1 STOP 17 15 86 86 5 lt lt 13 0 14 1 7 7 8 lt 17 TE 16 9 16 15 10 15 13 11 lt 13 PIN 80 Section 8 ELECTRICAL DATA
27. or b rough operation One or more of the following will usually cause loss of compression Blown or leaking cylinder head gasket Improperly seated or sticking valves Worn Piston rings or cylinder This will also result in high oil consumption 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 Normal compression is approximately 150 psi The dif ference 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 cylinder reads 100 psi The difference is 60 psi Divide 60 by 160 to obtain 37 5 percent Loss of compression in No 2 cylinder is indicated If compression is poor look for one or more of the fol lowing causes Page 59 Section 6 DIAGNOSTIC TESTS Loose cylinder head bolts Failed cylinder head gasket Burned valves or valve seats Insufficient valve clearance Warped cylinder head W
28. the Start Run Stop Switch SW1 Connect the negative meter test lead to frame ground Place the Start Run Stop Switch SW1 to start 12 VDC should be measured If 12 VDC is mea sured repair or replace Wire 167 between SW1 and the TB1 If 12 VDC is not measured continue testing Figure 6 46 Test Wire 167 Steps 4 amp 5 5 Connect the positive meter test to Wire 15 at SW1 See Figure 6 46 Connect the negative meter test lead to frame ground 12 VDC should be measured If 12 VDC is measured replace SW1 If 12 VDC is not measured repair or replace wire 15 between SW1 and the Starter Contactor Relay SCR Page 55 Section 6 DIAGNOSTIC TESTS TEST 34 TEST START STOP RELAY WIRING PROCEDURE 1 Set voltmeter to the diode test range 2 Disconnect Wire 229 from the Start Stop Relay SSR 3 Connect the positive meter test lead to Wire 229 previous ly removed Connect the negative meter test lead to frame ground See Figure 6 47 Place the Start Run Stop Switch to the start position The meter should read approximately 1 0 VDC If the correct voltage is indicated stop testing Figure 6 47 Testing Wire 229 to Ground 4 Set voltmeter to measure resistance 5 If voltage was not measured in Step 3 connect one meter test lead to Wire 229 removed from the SSR Connect the other meter test lead to Wire 229 at the Terminal Block 1 TB1 Continuity should be measured If continu
29. use AC voltmeter To measure DC voltage use a DC voltmeter Use a frequency meter to measure AC frequency in Hertz or cycles per second Use an 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 Some VOMs 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 2 1 are also available and are generally very accurate Digital meters display the measured values directly by converting the values to numbers NOTE Standard AC voltmeters react to the AVERAGE value of alternating current When working with AC the effective value is used For that reason 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 2 1 Digital VOM Page 6 MEASURING AC VOLTAGE An accurate AC voltmeter or a VOM may be used to read the generator s 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
30. 10 C1 9 55 A 448 115 2 6 4 0 LCT 1 11 22 66 BLK 77 44 44 66 0 15 77 1 12Vdc 13A O 15 77 77 BLK J CB2 14 2 162 162 ELECTRONIC Hiis VOLTAGE D1 R1 REGULATOR 4 K 14 5 6 167 awa GOVERNOR ACTUATOR 9 8 7 6 5 4 3 2 1 J2 CONTROL PRINTED CIRCUIT S J1 CIRCUIT CONDITION STOP With the Start Run Stop Switch SW1 placed in the Stop position Wire 167 is connected to Wire 0 which is frame ground The ground signal is supplied via Wire 167 to the Printed Circuit Board The Printed Circuit Board will open Wire 229 from ground this action will de energize the Start Stop Relay SSR With the SSR de energized Wire 14 will no longer have 12 VDC supplied to it through the relay this de energizes the Fuel Shutoff Solenoid FSS stopping fuel to the engine With the SSR de energized Wire 18 will now be connected to Wire O this action will ground the magnetos out through Wire 18 causing loss of spark to the engine With the loss of fuel and loss of spark the engine will shutdown Page 26 Section 4 ENGINE DC CONTROL SYSTEM 11B 1 11B 120V DUPLEX GFCI 411 120V 22 22 120 240V 120 240V 120V 30A TWISTLOK
31. 15 eee 77 77 BLK 2 1 CB2 gt 2 162 162 5 2 ELECTRONIC 115 115 VOLTAGE REGULATOR 4 4 5 446 445 6 6 6 15 0 167 83 St 0 sw2 GOVERNOR ACTUATOR 115 9 8 7 6 5 4 3 2 1 J2 CONTROL PRINTED CIRCUIT Ji BOARD CIRCUIT CONDITION START With the Start Run Stop Switch SW1 held in the start position Wire 17 from the Starter Contactor Relay SCR is now connected to Wire 0 which is frame ground This allows current to flow and the SCR is energized The SCR contacts close connecting Wire 13 battery power to Wire 16 Wire 16 now supplies battery power to the starter contactor SC on the Starter Motor SM the SC is energized and its contacts close battery power is available to the Starter Motor SM and the engine is cranking Page 22 Section 4 ENGINE DC CONTROL SYSTEM 120V 120V DUPLEX GFCI is 0 11B T 22 120 240V 120 240V n Q 50A 120V 30A 120V 30A TWISTLOK TWISTLOK LEGEND Poe BA BRUSH ASSEMBLY BATTERY CHARGE RECTIFIER 10A Pa 0 BCR2 BATTERY CHARGE RECTIFIER 4 CB1 10AMP AUTO RESET BREAKER CB2 AUTO RESET BREAKER mme I D1 600V 12A DIODE EOR 02 03 ENGINE SHUTDOWN DIODE 4 10A FUSE 1 FSS FUEL SHUT OFF
32. 3 A Line Splitter NOTE If the physical size of the conductor or ammeter capacity does not permit all lines to be measured simultaneously measure current flow in each individual line Then add the individual readings IN LINE Alternatively to read the current flow in AMPERES an in line ammeter may be used Most Digital Volt Ohm Meters VOM will have the capability to mea sure amperes This usually requires the positive meter test lead to be connected to the correct amperes plug and the meter to be set to the amperes position Once the meter is properly set up to measure amperes the circuit being measured must be physically broken The meter will be in line or in series with the component being mea sured In Figure 2 4 the control wire to a relay has been removed The meter is used to connect and supply voltage to the relay to energize it and measure the amperes going to it BATTERY Figure 2 4 VOM as an In line meter 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 resistance and will simply read CONTINUITY If proper procedures are used the following condi tions can be detected using
33. 9 Connect the meter test leads across Stator leads 2 Pin 6 and Stator lead 6 Pin 7 at the C1 connector female side See Figure 6 18 Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into con nectors Normal excitation winding resistance should be read 10 Connect the meter test leads across Stator leads 66 Pin 9 and Stator lead 77 Pin 10 at the C1 connector female side See Figure 6 18 Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors Normal 10 Amp battery charge winding resistance should be read Winding Wire Models Models Models Numbers 004451 0 004582 0 1 004582 2 004583 0 004986 0 004987 1 005308 0 mer vas sm vr Battery 66A amp 77A 0 132 0 111 0 111 0 103 Charge 10A 66 amp 77 0 145 0 125 0 125 0 117 Battery Charge Resistance values In ohms at 20 C 68 F Actual readings may vary depending on ambient tempera ture A tolerance of plus or minus 5 is allowed 11 Connect the meter test leads across Stator lead 11 and frame ground INFINITY should be read 10 Connect the meter test leads across Stator lead 66A Pin 4 and Stator lead 2 Pin 6 at the C1 connector female side and frame ground Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read
34. BATTERY CHARGE RECTIFIER LEGEND BA BRUSH ASSEMBLY CB1 5AMP AUTO RESET BREAKER D ENGINE SHUTDOWN DIODE D2 600V 12A DIODE F1 10A FUSE FSS FUEL SHUT OFF SOLENOID GND GROUND BAR IM1 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 LOP LOW OIL PRESSURE R1 25 OHM 25W RESISTOR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 SP2 SPARK PLUG CYL 2 SSR START STOP RELAY TB1 TB2 TERMINAL BLOCK Page 73 Section 8 ELECTRICAL DATA Electrical Schematic 12 5 amp 15 kW Units Without Hourmeter Drawing No 0E0229 A POWER WINDING DPE WINDING BATTERY CHARGE WINDING jus 77 66 1 OY SA 2 6 4 C1 5 C1 4 44S 44 22 11 115 Jj c1 11 777 10 BATTERY CHARGE WINDING AC d 66 RED C1 10 C1 9 55 445 115 2 6 4 ade LCT 77 11 22 66 BLK 77 44 44 66A 0 15 77 BCR1 BCR2 12Vdc CB1 13A O O 15A 0 1 77 77 BLK 2 1 Lo 15 CB2 1 2 162 162 5 2 4 ELECTRONIC 118 VOLTAGE 0 D1 R1 REGULATOR 4 4 4 4 KK 5 448 44S 6 6 6 15 15 86 86
35. If CONTINUITY was measured refer back to the flow chart TEST 52 CHECK IDLE CONTROL SWITCH SW2 PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Wire 0 and Wire 83 from the Idle Control Switch SW2 3 Connect meter test leads across both terminals of SW2 See Figure 6 59 4 In the OFF position the meter should read INFINITY or Open In the ON position the meter should read CONTINUITY or Closed RESULTS 1 If the switch fails Step 4 replace it 2 If the switch is good refer back to the flow chart Figure 6 59 Check Idle Control Switch SW2 TEST 53 CHECK IDLE CONTROL WIRING PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Wire 0 from the Idle Control Switch SW2 3 Connect one meter test lead to Wire 0 Connect the other meter test lead to frame ground CONTINUITY should be measured If continuity is not measured repair or replace Wire 0 between SW2 and the ground terminal 4 Disconnect Wire 83 from SW2 Disconnect the J2 connector from the printed circuit board 5 Connect one meter test lead to Wire 83 previously removed from SW2 Connect the other meter test lead to pin location J2 2 on the J2 connector See Figure 6 60 Be careful not to damage the pin connectors with the test leads CONTINUITY should be measured If CONTINUITY is not measured repair or replace Wire 83 between the J2 connector and Terminal Block or between the Terminal Bloc
36. Page 43 Section 6 DIAGNOSTIC TESTS 12 Connect the meter test leads across Stator lead 2 Pin 6 at the C1 connector female side and frame ground Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read 13 Connect the meter test leads across Stator lead 66 Pin 9 at the C1 connector female side and frame ground Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read 14 Connect the meter test leads across Stator leads Wire 11 and Stator lead 66A Pin 4 at the C1 connector female side Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read 15 Connect the meter test leads across Stator leads Wire 11 and Stator lead 2 Pin 6 at the C1 connector female side Be care ful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read 16 Connect the meter test leads across Stator leads Wire 11 and Stator lead 66 Pin 9 at the C1 connector female side Be care ful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read 17 Connect the m
37. SOLENOID GND GROUND BAR T I C T IDLE CONTROL TRANSFORMER 15 fe 15 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 15 15 LOP LOW OIL PRESSURE ae 15 1 25 OHM 25W RESISTOR E SC STARTER CONTACTOR swi SCR STARTER CONTACTOR RELAY SM STARTER MOTOR L F SP1 SPARK PLUG CYL 1 vy SP2 SPARK PLUG CYL 2 7 SSR START STOP RELAY E SW1 START RUN STOP SWITCH a SW2 IDLE CONTROL SWITCH bs TB1 TB2 TERMINAL BLOCK IM2 2 6 p ix 12 VDC SUPPLY 18 C2 11 sc 13 mis 12 VDC CONTROL 13 91 _ C29 16 16 BLACK GROUND With the Start Run Stop Switch SW1 held in the start position Wire 15 is now connected to Wire 167 Wire 15 supplies fused battery power via Wire 167 to the Printed Circuit Board This 12 VDC input signals the Printed Circuit Board to internally ground Wire 229 which is connected to the coil of the Start Stop Relay SSR This action allows current to flow and the SSR is energized The normally open contacts close supplying battery power from Wire 15 to Wire 14 Wire 14 supplies power to the Fuel Shutoff Solenoid FSS it is energized and fuel is available to the engine Wire 14 supplies power through Resistor R1 and Diode D1 to Wire 4 Wire 4 connects to the field or the Rotor assembly and is used as Field Boost The second set of normally open contacts als
38. THE gt IDLE CONTROL IDLE CONTROL GOOD gt REPLACE PRINTED GENERATOR SWITCH gt WIRING CIRCUIT BOARD BAD BAD Y REPLACE REPAIR OR REPLACE Problem 13 Idle Control RPM Does Not Increase When Load Is Applied VERIFY THAT WIRE 11 amp TEST 54 CHECK TEST 55 CHECK REPLACE WIRE 44 ARE ROUTED IDLE CONTROL GOOD gt TR1 amp TR2 GOOD PRINTED THROUGH IDLE CONTROL TRANSFORMERS WIRING CIRCUIT BOARD TRANSFORMERS ICT ICT BAD BAD ROUTE THROUGH IDLE 4 1 CONTROL TRANSFORMERS AND RE TEST REPLACE REPAIR OR REPLACE Problem 14 Engine Hunts Erratic Idle Acceptable running limits for the engine are between 59 61 Hertz TEST 56 CHOKE STILL TEST 40 CHECK TEST 29 CHECK TEST SURGING gt ADJUST VALVES SPARK NO BAD GOOD n ADJUST RE TEST TEST 35 CHECK GOOD TEST 30 CHECK TEST 39 CHECK SPARK PLUG ADJUST IGNITION CARBURETION MAGNETOS BAD ENGINE MISS APPARENT REPLACE TEST 5 CHECK BAD PRINTED lt GOOD STEPPER MOTOR BAD CIRCUIT BOARD OPERATION REPLACE REPAIR ADJUST OR REPLACE OR REPLACE Page 36 Section 6 DIAGNOSTIC TESTS INTRODUCTION The Diagnostic Tests in this chapter may be per formed in conjunction with the Flow Charts of Section 5 Test numbers in this chapter correspond to the numbered tests in the Flow Charts Tests 1 through 19 are procedures Involving problems with the generator s AC output
39. VOLTAGE TEST PAGE 13 REGULATOR BAD GOOD BAD TEST 10 REPAIR SENSING OR REPAIR LEADS REPLACE OR REPLACE THEN RETEST INSULATION BAD RESISTANCE TEST PAGE 13 TEST 12 CHECK BRUSH BAD LEADS GOOD TEST 13 CHECK BRUSHES amp SLIP RINGS BAD GOOD OR REPLACE TEST 14 CHECK ROTOR ASSEMBLY GOOD INSULATION RESISTANCE BAD TEST PAGE 14 Page 29 Section 5 TROUBLESHOOTING FLOWCHARTS Problem 2 Generator Produces Zero Voltage or Residual Voltage 2 12 VAC continued TEST 4 PERFORM FIXED EXCITATION ROTOR AMP DRAW CHECK VOLTMETER FUSES VERIFY AMP METER FUNCTIONS REPLACE FUSES THEN RETEST TEST 14 CHECK ROTOR BAD ASSEMBLY TEST 9 TEST REPAIR REPAIR STATOR DPE BAD OR WINDING REPLACE OR REPLACE INSULATION INSULATION RESISTANCE BAD RESISTANCE BAD TEST PAGE 14 TEST PAGE 13 Problem 3 Excessive Voltage Frequency Droop When Load is Applied 4 ae TEST 16 CHECK P gt LoAD WATTS amp NOT OVERLOADED VOLTAGE amp FREQUENCY AMPERAGE GOOD OVERLOADED REDUCE LOAD END TEST TEST 2 CHECK STEPPER MOTOR GOOD GO TO PROBLEM 8 CONTROL Page 30 Section 5 TROUBLESHOOTING FLOWCHARTS TEST 17 CHECK BATTERY CHARGE OUTPUT GOOD FINISHED TEST 18 CHECK 10A BATTERY CHARGE OUTPUT GOOD FINI
40. 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 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 polar ity switch DC polarity must be reversed by reversing the test leads 2 Before reading a DC voltage always set the meter to a higher voltage scale than the anticipated reading If in doubt start at the highest scale and adjust the scale downward until correct readings are obtained 3 The design of some meters is based on the current flow theory 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 cur rent flows from negative to positive NOTE When testing generators the current flow theory is applied That is current is assumed to flow from positive 4 to negative MEASURING AC FREQUENCY The generator s AC output frequency is propor
41. bearing Page 10 Wire 4 connects to the positive brush and Wire 0 to the negative brush Wire 0 connects to frame ground Rectified and regulated excitation current as well as current from a field boost circuit are delivered to the rotor windings via Wire 4 and the positive brush and slip ring The excitation and field boost cur rent passes through the windings and to frame ground via the negative slip ring and brush and Wire 0 This current flow creates a magnetic field around the rotor having a flux concentration that is proportional to the amount of current flow Figure 3 4 Brush Holder and Brushes OTHER AC GENERATOR COMPONENTS Some AC generator components are housed in the generator control panel enclosure These are a an Excitation Circuit Breaker b a Voltage Regulator and c a main line circuit breaker EXCITATION CIRCUIT BREAKER The Excitation Circuit Breaker CB2 is housed in the generator control panel enclosure and electrically connected in series with the excitation DPE wind ing output to the Voltage Regulator The breaker is self resetting i e its contacts will close again when excitation current drops to a safe value If the circuit breaker has failed open excitation current flow to the Voltage Regulator and subsequently to the rotor windings will be lost Without excitation cur rent flow AC voltage induced into the stator AC power wind
42. careful not to damage the pin connectors with the test leads Continuity should be measured If continuity is not measured repair or replace Wire 4 between the C1 connector and the six pin Voltage Regulator connector 8 Connect one meter test lead to Pin 12 Wire 0 See Figure 6 19 Connect the other meter test lead to the ground terminal in the control panel Continuity should be measured If continuity is not measured repair or replace Wire 0 between the C1 connec tor and the ground terminal RESULTS 1 Repair or replace wiring terminals as needed 2 If no faults are found refer to flow chart Figure 6 20 Brush Leads TEST 13 CHECK BRUSHES amp SLIP RINGS PROCEDURE 1 Gain access to the brushes and slip rings Page 45 Section 6 DIAGNOSTIC TESTS BRUSHES Figure 6 21 Brush Location 2 Remove Wire 4 from the positive brush terminal 3 Remove the ground wire 0 from the negative brush 4 Remove the brush holder with brushes 5 Inspect the brushes for excessive wear damage cracks chip ping etc 6 Inspect the brush holder replace if damaged 7 Inspect the 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
43. for governor control Figure 4 2 Receptacle J2 BATTERY RECOMMENDED BATTERY When anticipated ambient temperatures will be con sistently above 32 F 0 C use a 12 volts Type U1 storage battery capable of delivering at least 300 cold cranking amperes Section 4 ENGINE DC CONTROL SYSTEM CONTROL PANEL COMPONENT IDENTIFICATION SHAISILOSY 39HVHO AH3 LIVS 19 HOLSIS3H 182 1353 OLNV OL uos HOLOVLNOO 18 19 20 HOLO3NNOO HOLO3NNOO 181 QHvOa 1VNIIAH3 L 280 LINDYIO NOILVLIOX3 91 TVNIIAH3 L 1 GALNIdd 40158 1HVLS YOLVINDAY 3SVLTOA Page 17 TANVd dO tiVat NI Q31V9O1 08 14 SSNS OL Section 4 ENGINE DC CONTROL SYSTEM PIN LOCATION 6 C1 FEMALE SIDE C1 MALE SIDE C2 FEMALE SIDE PIN LOCATION 7 PIN LOCATION 6 0 C2 MALE SIDE TERMINAL BLOCK TB1 Page 18 TERMINAL BLOCK TB2 NOTES
44. for the second magneto 7 Repeat Test 29 and check for spark across the spark tester gap 8 If air gap was not out of adjustment remove engine ground harness from magnetos Repeat Test 29 If sparking now occurs replace engine ground harness Section 6 DIAGNOSTIC TESTS 9 Now check the flywheel magnet by holding a screwdriver at the extreme end of its handle and with its point down When the tip of the screwdriver is moved to within 3 4 inch 19mm of the magnet the blade should be pulled in against the magnet 10 Now check the flywheel key The flywheel s taper is locked on the crankshaft taper by the torque of the flywheel nut A keyway is provided for alignment only and theoretically carries no load Note If the flywheel key becomes sheared or even partially sheared ignition timing can change Incorrect timing can result in hard starting or fail ure to start RESULTS If sparking still does not occur after adjusting the armature air gap testing the ground wires and per forming the basic flywheel test replace the ignition magneto s MAGNETO E Figure 6 49 Setting Ignition Magneto Armature Air Gap TEST 36 TEST FUEL SHUTOFF SOLENOID FSS PROCEDURE 1 Disconnect Wire 16 from the Starter Contactor SC located on the starter motor 2 Remove the air cleaner cover 3 Place the Start Run Stop Switch SW1 to STOP then to START When SW1 is activated a click should be heard
45. induce approximately 7 to 12 volts AC Into the STATOR s AC power windings ENGINE DIRECT DRIVE 4 BATTERY lt 12 DC Section 1 GENERATOR FUNDAMENTALS TO LOAD SENSING STATOR POWER STATOR POWER WINDING FIELD BOOST FROM START STOP RELAY SSR VOLTAGE REGULATOR STATOR kos TATOR BATTERY CHARGE WINDING ee WINDING 10A STATOR OUTLET OF BATTERY CHARGE WINDING BCR1 amp BCR2 BATTERY CHARGE RECTIFIER CB2 EXCITATION CIRCUIT BREAKER Figure 1 7 Generator Operating Diagram 2 During startup printed circuit board action controls the START STOP RELAY to deliver battery voltage to the ROTOR via the brushes and slip rings a The battery voltage is called Field Boost b Flow of direct current through the ROTOR increases the strength of the magnetic field above that of residual magnetism alone 3 Residual plus Field Boost magnetism induces a voltage into the Stator excitation DPE battery charge and AC Power wind ings 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
46. paper clip into Pin Location 8 Wire 55 Connect the black tester probe to this paper clip Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page 6 Insert a paper clip into Pin Location 6 Wire 2 Connect the red tester probe to the paper clip Insert the additional paper clip into Pin Location 8 Wire 55 Connect the black tester probe to this paper clip Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page ROTOR INSULATION RESISTANCE TEST Before attempting to test rotor insulation the brush holder must be completely removed The rotor must be completely isolated from other components before starting the test Attach all leads of all stator windings to ground 1 Connect the red tester lead to the positive slip ring nearest the rotor bearing 2 Connect the black tester probe to a clean frame ground such as a clean metal part of the rotor shaft POSITIVE TEST LEAD Figure 3 10 Testing Rotor Insulation 3 Turn the tester switch OFF 4 Plug the tester into a 120 volts AC wall socket and set the volt age switch to 1500 volts 5 Turn the tester switch On and make sure the pilot light has turned on 6 Observe the breakdown lamp then turn the tester switch OFF DO NOT APPLY VOLTAGE LONGER THAN ONE 1 SECOND If the breakdown lamp came on during the one 1 second test cleaning and drying of the
47. results Rotor Amp Draw 20 Shutdown the generator 21 Reconnect the six pin connector 22 Reconnect Wire 14 to the resistor R1 RESULTS Refer to TEST 4 RESULTS chart TEST 4 RESULTS Lo A B ece E VOLTAGE RESULTS WIRE2 amp 6 EXCITATION WINDING ABOVE 60 VAC ABOVE 60 VAC BELOW 120 VAC 1 8A 2096 1 6A x 2096 60 VAC VOLTAGE RESULTS WIRE 11 amp 44 ABOVE 120 VAC ABOVE 120 VAC ROTOR AMP DRAW 12 5 kW MODEL 004451 0 MODEL 004986 0 ROTOR AMP DRAW 15 kW MODEL 004582 0 1 MODEL 004987 0 MODEL 005209 0 ROTOR AMP DRAW 15 kW MODEL 004582 2 MODEL 004987 1 1 8A x 2096 1 8A x 20 1 6A x 2096 1 6A x 20 0 96 A x 2096 0 96 A 2096 0 96 x 20 ROTOR AMP DRAW 17 5 kW MODEL 004583 0 MODEL 005308 0 0 89 A 20 0 89 20 0 89 20 BELOW ZERO OR RESIDUAL VOLTAGE ZERO OR RESIDUAL VOLTAGE BELOW BELOW 2 12 VAC 120VAC 120VAC 1 8A ZERO CURRENT DRAW gt 2 20 BELOW 60 VAC BELOW 60 VAC ABOVE 2 12 VAC 60 VAC ABOVE 120 VAC ZERO CURRENT DRAW ZERO CURRENT DRAW 1 6A ZERO CURRENT DRAW 20 ZERO CURRENT DRAW ZERO CURRENT DRAW Ones 20 ZERO CURRENT DRAW 0 89 A ZERO CURRENT DRAW 20 gt 1 4 MATCH RESULTS WITH LETTER AND REFER FLOW CHART Problem 2 Pages 29 amp 30 Page 39 Section 6 DIAGNOSTIC TESTS TEST 5 CHECK S
48. u aa ees 41 TEST 8 DIODE RESISTOR u l pen tete 42 TEST 9 TEST STATOR iieri 43 TEST 10 s SENSING EEADS oberen 44 TEST 11 EXCITATION WIRING uuu 45 TEST 12 CHECK BRUSH LEADS opisno etian tne ct en 45 TEST 13 CHECK BRUSHES amp SLIP RINGS 45 TEST 14 CHECK ROTOR ASSEMBLY 46 TEST 15 CHECK LOAD VOLTAGE amp FREQUENCY 46 TEST 16 CHECK LOAD WATTS amp AMPERAGE 46 TEST 17 CHECK BATTERY CHARGE OUTPUT 47 TEST 18 CHECK 10 AMP BATTERY CHARGE OUTPUT 47 TEST 19 CHECK BATTERY CHARGE RECTIFIER 47 TEST 20 CHECK 10 AMP CIRCUIT BREAKER 48 JTEST 21 CHECK 10 AMP FUSE ete 48 TEST 22 CHECK BATTERY amp CABLES 48 TEST 23 CHECK VOLTAGE AT STARTER CONTACTOR 49 TEST 24 CHECK STARTER CONTACTOR 49 TEST 25 CHECK STARTER MOTOR 49 CHECKING THE PINION TOOLS FOR STARTER PERFORMANCE TEST 50 MEASURING CURREN F eoa ruunt 50 50 TEST BRACKET pani ette a 51 REMOVE STARTER 51 TESTING STARTER MO VOR 51 TEST 26 TEST STARTER CONTACTOR RELAY SCR 51 TEST 27 C
49. u ua aaa 3 ENGINE DC CONTROL SYSTEM 16 27 ELECTROMAGNETIC FIELDS 3 ELECTROMAGNETIC INDUCTION PEREP SEP TIRE 3 PRINTED CIRCUIT BOARD 16 A SIMPLE AC GENERATOR 4 GENERA e a PLE 16 A MORE SOPHISTICATED AC GENERATOR 4 CIRCUIT BOARD CONNECTIONS 16 DIP SWITCH POSITIONS 16 SECTION 2 BATTERY 16 MEASURING ELECTRICITY 6 8 BATTERY RECOMMENDED BATTERY 16 6 CONTROL PANEL COMPONENT IDENTIFICATION 17 18 TEE VOM aG ama an iet e t tos 6 OPERATIONAL ANALYSIS 20 27 MEASURING AC VOLTAGE BARN MEER AREE 6 CIRCUIT CONDITION REST 20 MEASURING DC VOLTAGE 6 CIRCUIT CONDITION START LLLA 22 MEASURING FREQUENCY aa 6 CIRCUIT CONDITION RUN 24 MEASURING CURRENT z a a aa iii qu a mM MEASURING RESISTANCE 7 29 ELECTRICAL UNITS caisse 8 FAULT WN sa a a eed 8 SECTION 5 TROUBLESHOOTING FLOWCHARTS
50. volts DC is available to the generator during cranking If voltage is below 11 volts DC Section 6 DIAGNOSTIC TESTS measure at the battery terminals during cranking If battery voltage is below 11 volts DC recharge replace battery If bat tery 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 manufacturer 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 If battery is good but engine will not crank refer back to Flow Charts TEST 23 CHECK VOLTAGE AT STARTER CONTACTOR SC PROCEDURE 1 Set voltmeter to measure DC voltage 2 Disconnect Wire 16 from the Starter Contactor located on the Starter motor 3 Connect the positive meter test lead to Wire 16 previous ly removed Connect the negative meter test lead to frame Ground 4 Place the Start Run Stop Switch to Start 12 VDC should be measured 5 Reconnect Wire 16 to the Starter Motor RESULTS Refer back to flow chart TEST 24 CHECK 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 corrode
51. 0 15 OS ciang D ENGINE SHUTDOWN DIODE 10 AUTO 66A RECTIFIER D2 600V 12A DIODE RESET BKR F1 10A FUSE 77 FSS FUEL SHUT OFF SOLENOID o GND GROUND BAR OUTLET BATTERY IM1I IGNITION MODULE CYL 1 CHARGE IM2 IGNITION MODULE CYL 2 6 1 LOP LOW OIL PRESSURE R1 25 OHM 25W RESISTOR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 15A SP2 SPARK PLUG CYL 2 SSR START STOP RELAY TB1 TB2 TERMINAL BLOCK Page 77 Section 8 ELECTRICAL DATA Electrical Schematic 12 5 amp 15 kW Units With Hourmeter Drawing No 0D6297 A POWER WINDING BA DPE WINDING BATTERY CHARGE WINDING FIELD 77 66 non 1 5 Wi C1 4 44 22 11 2 d 445 115 16 C17 c1 11 77 AA 10 BATTERY CHARGE WINDING ACCU d 66 pa RED ce C1 10 C1 9 55 me 66A 7 LCT 66 77 77A BCR BCR2 12Vdc Ll ee CB1 18A 0 15 0 7 7 BLK 1 1 19 CB2 4 2 162 162 5 2 4 ELECTRONIC His 113 VOLTAGE 0 Di Hi REGULATOR 4 4 4 4 NINN 5 448 44S 6 6 6 15 15
52. 5 was removed from Connect the other meter test lead to the terminal that Wire 229 was removed from Resistance measured should be approximately 100 ohms Section 6 DIAGNOSTIC TESTS RESULTS 1 If the SSR measures continuity or zero resistance it is shorted to ground and should be replaced 2 If the SSR resistance is correct refer flow chart Figure 6 54 Testing Start Stop Relay SSR TEST 44 TEST STARTER CONTACTOR RELAY SCR PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Wire 15 and Wire 17 from the Starter Contactor Relay SCR 3 Connect one meter test lead to the terminal that Wire 15 was removed from Connect the other meter test lead to the ter minal that Wire 17 was removed from Resistance measured should be approximately 75 ohms Figure 6 55 Testing Starter Contactor Relay SCR RESULTS 1 If the SCR measures continuity or zero resistance it is shorted to ground and should be replaced 2 If the SCR resistance is correct refer to flow chart TEST 45 CHECK WIRE 15 CIRCUIT PROCEDURE 1 Set a voltmeter to measure resistance 2 Remove the Fuse F1 3 Disconnect all Wire 15 s from the Start Stop Relay SSR dis connect Wire 15 from the Starter Contactor SC Disconnect Wire 15 from the Start Run Stop Switch SW1 and disconnect Wire 15 from the Battery Charge Rectifier 2 BCR2 4 Remove Wire 15 from the fuse holder F1 Connect o
53. 6 25 Battery Charge Rectifier RESULTS 1 any of the previous steps has failed replace the Battery Charge Rectifier 2 If the BCR tests good refer back to the flow chart TEST 20 CHECK 10 AMP CIRCUIT BREAKER PROCEDURE 1 Set a voltmeter to measure resistance 2 Locate the 10 Amp circuit breaker CB1 in the control panel See Page 17 for Circuit breaker location 3 Disconnect Wire 15A and Wire 13A from the circuit breaker 4 Connect one meter test lead to one terminal of the circuit breaker Connect the other meter test lead to the remaining terminal on the circuit breaker Continuity should be measured See Figure 6 26 RESULTS 1 If continuity was measured the breaker is good refer back to the flow chart 2 If INFINITY or a open condition was measured replace the circuit breaker Page 48 Figure 6 26 Testing 10 Amp Breaker TEST 21 CHECK 10 AMP FUSE Figure 6 27 10 Amp Fuse Located in Rear of Control Panel PROCEDURE Push in on fuse holder cap and turn counterclockwise Then remove the cap with fuse Inspect the Fuse RESULTS If the Fuse element has melted open replace the Fuse with an identical size fuse If Fuse is good refer back to flow chart TEST 22 CHECK BATTERY amp CABLES PROCEDURE 1 Inspect the battery cables and battery posts or terminals for corrosion or tightness Measure the voltage at the terminal of the Starter Contactor and verify 11 12
54. 6 38 Checking Engine Miss RESULTS Refer back to the Flow Chart TEST 30 CHECK SPARK PLUGS 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 0 040 inch 1 016 mm Use a Champion RC14YC or equivalent replacement spark plug SET PLUG GAP AT 0 040 inch 1 016 mm Figure 6 39 Setting Spark Plug Gap RESULTS 1 Clean and regap or replace sparks plug as necessary 2 Refer back to the Flow Chart Page 53 Section 6 DIAGNOSTIC TESTS TEST 31 REMOVE WIRE 18 SHUTDOWN leads across TEST POINTS B INFINITY should be measured LEAD Connect meter test leads across TEST POINTS C INFINITY should be measured See Figure 6 42 If the SSR fails any test PROCEDURE 1 Disconnect Wire 18 from the Stud located above the cooler 6 Remove Wire 229 from the SSR Connect a jumper lead that extends out From the shrouding from the terminal of the SSR that Wire 229 was just removed from and to frame ground The relay should energize closed Set a voltmeter to measure resistance Connect meter test leads across TEST POINTS A INFINITY should be measured Connect meter test leads across TEST POINTS B continuity closed should be measured Connect meter test leads across TEST POINTS C continuity closed should be measured See Figure 6 43 If the SSR fails any test replace it
55. 9 SPECIFICATIONS amp CHARTS 86 87 GENERATOR iiid acit teres 86 ENGINE SPECIFICATIONS aus 86 ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS 86 TORQUE SPECIRFICATIONS 1 2 5 22 tnit teet tok 87 TRIM TORQUE SPECIFICATIONS 87 Section 1 GENERATOR FUNDAMENTALS MAGNETISM Magnetism can be used to produce electricity and electricity can be used to produce magnetism Much about magnetism cannot be explained by our present knowledge However there are certain pat terns of behavior that are known Application of these behavior patterns has led to the development of gen erators motors and numerous other devices that uti lize magnetism to produce and use electrical energy See Figure 1 1 The space surrounding a magnet is permeated by magnetic lines of 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 depending on the strength of the magnet The lines of force never cross one another The area surround ing a magnet in which its lines of force are effective is called a magnetic field Like poles of a magnet repel each other while unlike poles attract each other MAGNETIC LINES OF FORCE
56. ESSURE or the difference in electrical potential that causes electrons to flow Very few electrons will flow when voltage is weak More electrons will flow as voltage becomes stronger VOLTAGE 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 X OHM Unit measuring resistance or opposition to flow AMPERE Unit measuring rate of current flow number of electrons past a given point VOLT Unit measuring force or difference in potential causing current flow Figure 2 5 Electrical Units Page 8 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 OHM S LAW A definite and exact relationship exists between VOLTS OHMS and AMPERES The value of one can be calculated wh
57. HECK START RUN STOP SWITCH 52 TEST 28 CHECK START RUN STOP SW1 WIRING 52 TEST 29 CHECK IGNITION 53 TEST 30 CHECK SPARK PLUGS 53 TEST 31 REMOVE WIRE 18 SHUTDOWN LEAD 54 TEST 32 TEST START STOP RELAY iint 54 TEST 33 TEST WIRE eer ete tn 55 TEST 34 TEST START STOP RELAY WIRING 56 TEST 35 CHECK AND ADJUST IGNITION MAGNETOS 56 TEST 36 TEST FUEL SHUTOFF SOLENOLD 57 TEST 37 TEST FUEL SHUTOFF SOLENOID VOLTAGE 57 TEST 38 CHECK 57 Page 2 TEST 39 CHECK CARBURETION 58 TEST 40 VALVE 58 TEST 41 CHECK ENGINE CYLINDER LEAK DOWN TEST COMPRESSION TEST 59 TEST 42 CHECK OIL PRESSURE SWITCH AND WIRE 86 60 TEST 43 CHECK START STOP RELAY SSR 60 TEST 44 TEST STARTER CONTACTOR RELAY SCR 61 TEST 45 CHECK WIRE 15 CIRCUIT 61 TEST 46 CHECK WIRE 14 61 TEST 47 CHECK FUEL SHUTOFF SOLENOID 61 TEST 48 CHECK 62 TEST 49 CHECK WIRE 15B
58. ING GOOD GOOD CHECK FLYWHEEL KEY REPLACE SEE TEST 35 PRINTED CIRCUIT BOARD Page 33 Section 5 TROUBLESHOOTING FLOWCHARTS Problem 8 Engine Starts Hard and Runs Rough TEST 29 TEST 30 coop CHECK GOOD CHECK GOOD SPARK CHECK CHECK CHOKE FUEL GOOD gt POSITION AND OPERATION SPARK SUPPLY PLUG LOW FUEL ENGINE MISS BAD IS APPARENT PUSH IN AFTER STARTING REPLENISH REPLACE SPARK PLUG FUEL TEST 35 CHECK AND SUPPLY ADJUST IGNITION BAD gt ADJUST MAGNETOS OR REPLACE TEST 38 TEST 5 CHECK CHECK 2 STEPPER FUEL PUMP MOTOR CONTROL TEST 40 CHECK VALVE ADJUSTMENT BAD GOOD Y REPAIR 1 REPAIR OR REPLACE REPAIR ADJUST VALVES OR REPLACE OR REPLACE AND RETEST CHECK TEST 41 CHECK GOOD FLYWHEEL KEY ENGINE SEE TEST 35 CYLINDER LEAK DOWN TEST REPAIR OR REPLACE AS NECESSARY COMPRESSION BAD REFER TO ENGINE SERVICE MANUAL P N TEST 0 2081 FOR FURTHER ENGINE SERVICE INFORMATION Problem 9 Engine Starts Then Shuts Down TEST27 TEST START RUN STOP CHECK TEST 42 CHECK OIL ENGINE OIL OIL LEVEL O K PRESSURE SWITCH LEVEL AND WIRE 86 OIL LEVEL LOW BAD BAD Y REPLACE SWITCH Y REPLENISH OIL REPLACE SWITCH SWITCH SW1 VERIFY START STOP RELAY SSR GO TO PROBLEM 8 IS WIRED PROPERLY Page 34 Section 5 TROUBLESHOOTING FLOWCHARTS Problem 10 10 Amp Fuse F1 Blowing SE BLOWS TES
59. J2 connector from the printed circuit board and repeat Step 2 Figure 6 57 Check Wire 167 RESULTS 1 If continuity was measured in Step 2 but not in Step 3 replace the printed circuit board 2 If continuity was measured in Step 3 wire 167 is shorted to ground repair or replace Wire 167 between the SW1 and printed circuit board TEST 51 CHECK WIRES 11S amp 44S PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect the J2 connector from the printed circuit board Section 6 DIAGNOSTIC TESTS Connect one meter test lead to pin location J2 10 Wire 44S of the connector just removed Be careful not to damage the pin connectors with the test leads Connect the other meter test lead to Wire 44S at Terminal Block 2 TB2 CONTINUITY should be measured 3 Connect one meter test lead to pin location J2 12 Wire 11S Be careful not to damage the pin connectors with the test leads Connect the other meter test lead to Wire 11S at Terminal Block 2 TB2 CONTINUITY should be measured MAKE SURE THE TEST PROBE CONNECTOR IS MAKING CONTACT WITH THE CONNECTOR DOUBLE CHECK TO TIP IS SHARP Figure 6 58 Check Wires 11S amp 44S RESULTS 1 CONTINUITY was not measured repair or replace the wire harness 2
60. NTROL SWITCH TB1 TB2 TERMINAL BLOCK 12 VDC SUPPLY 12 VDC CONTROL AC POWER GROUND Wire 15 12 VDC fused battery supply voltage is supplied to the normally open contacts of the SSR One set of normally open contacts are connected to Wire 15B the other set of normally open contacts are connected to Wire 14 The SSR is de energized and no voltage is available through the contacts Wire 15 12 VDC fused battery supply voltage is supplied to the Battery Charge Rectifier number 2 BCR2 This is a return current path for battery charging No current flows at this time Wire 18 connects to the ignition magnetos and to the normally closed contacts of the SSR The normally closed contacts are also connected to Wire 0 Wire 0 is frame ground The SSR is de energized and the magnetos are grounded out at this time no spark is available Page 21 Section 4 ENGINE DC CONTROL SYSTEM POWER WINDING BA DPE WINDING BATTERY CHARGE WINDING fe FIELD 77 66A 1 55A 2 6 4 0 1 5 14 445 44 22 11 118 cit Ct6 1 7 C1 11 C1 12 77 AA A 10A BATTERY CHARGE WINDING AN CER i6 77 VA AAA ja A AAA 66 Sad RED C1 10 1 9 A 445 115 2 6 4 0 PA LC T C18 7 LCT 66 BLK 77 44 66A 15 77 1 BCR2 12Vdc jt gg CB1 13A O
61. Note Nominal amp draw of starter in generator is 60 amps TEST 26 TEST STARTER CONTACTOR RELAY SCR PROCEDURE 1 Set voltmeter to measure DC voltage 2 Remove Wire 15 from the Starter Contactor Relay SCR Connect the positive meter test lead to Wire 15 previous ly removed Connect the negative meter test lead to frame Ground 12 VDC should be measured Reconnect Wire 15 to the SCR If 12 VDC is NOT measured on Wire 15 Stop Testing and repair or replace Wire 15 between the Fuse F1 and the SCR 3 Remove Wire 13 from the Starter Contactor Relay SCR Connect the positive meter test lead to Wire 13 previous ly removed Connect the negative meter test lead to frame Page 51 Section 6 DIAGNOSTIC TESTS Ground 12 VDC should be measured Reconnect Wire 13 to the SCR If 12 VDC is NOT measured on Wire 13 Stop Testing and repair or replace Wire 13 between the Starter Contactor SC and the Starter Contactor Relay SCR Note Jumper leads may be used if necessary 4 Set voltmeter to measure resistance 5 Remove Wire 13 Wire 16 and Wire 17 from the Starter Contactor Relay SCR 6 Connect the meter leads across Terminal 87 and Terminal 30 of the SCR See Figure 6 35 Figure 6 35 Starter Contactor Relay Test 7 Connect a jumper wire from Terminal 85 to ground The relay should energize and the voltmeter should read continuity See Figure 6 35 8 Reconnect all Wires RESULTS If continuity was not m
62. ONS amp CHARTS GENERATOR SPECIFICATIONS GPS 15000 GPS 17500 004582 004451 004583 Model 004987 004986 005308 005209 12 5 kW 15 0 kW 17 5 kW 18 75 kW 22 5 kW 26 25 kW 120 240 120 240 120 240 52 0 Amps 62 5 Amps 72 9 Amps 104 0 Amps 125 0 Amps 145 8 Amps 60 Hz 3600 RPM Single Phase 12 Volts MODEL Rated Max Power Surge Power Rated AC Voltage Rated Max AC Load Current 240V Current 120V Rated Frequency Phase Rated DC Voltage Rated Max DC Load Current 12 Volts 10 Amperes ENGINE SPECIFICATIONS Champion RC14YC or Equivalent 0 040 inch or 1 01 mm 16 U S gallons Summer SAE 30 or 10W 30 Winter Synthetic 5W 20 or 5W 30 w Filter Change 1 7 Qts w o Filter Change 1 4 Qts Rated Horsepower 3600 RPM Displacement I i Spark Plug Type Spark Plug Gap Gasoline Capacity Oil Type Oil Capacity Run Time Fuel Consumption 1 2 Load 10 Hours 1 6 gallons per hour ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS Listed below are normal running voltages load voltages and frequency ranges LOAD VOLTAGE VAC FREQUENCY HZ 0 238 242 59 61 50 238 242 59 61 238 242 59 61 Refer to Engine Service Manual No 0F6923 for complete GTV 760 990 V Twin OHVI engine service information Page 86 Section 9 SPECIFICATIONS amp CHARTS TORQUE SPECIFICATIONS Flywheel Nut 150 ft Ibs Cylinder Head Bolts 22 ft Ibs Valve Cover Bolts 4 8 5 5 ft Ibs Rocker Ar
63. POINTS E TEST POINTS A JUMPER LEAD ADDED TO GROUND Figure 6 43 Start Stop Relay SSR Energized TEST 33 TEST WIRE 167 PROCEDURE 1 Set a voltmeter to measure DC voltage 2 Remove the J2 connector from the circuit board Connect the positive meter test lead to Pin Location J2 5 Wire 167 on the removed harness connector See Figure 6 44 Connect the negative meter test lead to frame ground Place the Start Run Stop switch SW1 to start The engine will crank and 12 VDC should be measured If 12 VDC is measured stop testing If 12 VDC is not measured continue testing MAKE SURE THE TEST PROBE CONNECTOR IS MAKING CONTACT WITH THE CONNECTOR DOUBLE CHECK TO MAKE SURE THAT THE TIP IS SHARP J2 HARNESS CONNECTOR Figure 6 44 Test Wire 167 Step 2 3 Connect the positive test lead to Wire 167 at Terminal Block 1 TB1 Connect the negative meter test lead to frame ground Place the Start Run Stop Switch SW1 to start 12 VDC should be measured If 12 VDC is measured replace Wire 167 between TB1 and the J2 connector If 12 VDC is not measured continue testing Lol Lol Ld Lej 222 2 22 4 Z 2 ata TERMINAL BLOCK TB1 Figure 6 45 Test Wire 167 Step 3 4 Connect the positive test lead to Wire 167 with it connected at
64. PULSE LINE WES lt Figure 6 50 Fuel Pump and Fuel Lines Page 57 Section 6 DIAGNOSTIC TESTS PROCEDURE 1 Remove the fuel line from the fuel filter on the inlet side of the carburetor Use a suitable catch can to catch fuel 2 Crank the engine over fuel should flow from the fuel line If fuel does not flow verify that fuel is available to the pump If fuel is available to the pump inspect the fuel filter pulse line and or replace the fuel pump RESULTS Refer to flow chart TEST 39 CHECK CARBURETION 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 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 Overchoking Excessively rich fuel mixture Water in fuel e 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 noperative fuel pump Plugged fuel filter s Varnished carburetor If the engine starts hard or will not start look for the following Physical damage to the AC generator Check the Rotor for contact with the Stator Starting under load Make sure all loads are discon
65. SHED REPAIR OR REPLACE 4 Problem 4 No Battery Charge Output TEST 19 CHECK BAD BATTERY TEST 9 TEST CHARGE RECTIFIER BAD BAD REPLACE REPAIR OR REPLACE INSULATION REPAIR GOOD RESISTANCE BAD OR TEST PAGE 13 REPLACE Problem 5 No 10A Battery Charge Output TEST 20 10 BAD BATTERY GOOD h CHARGE BREAKER RECTIFIER BAD BAD REPLACE REPLACE GOOD TEST 9 TEST STATOR INSULATION REPAIR RESISTANCE BAD OR TEST PAGE 13 REPLACE Page 31 Section 5 TROUBLESHOOTING FLOWCHARTS Problem 6 Engine Will Not Crank FUSE BAD REPLACE FUSE L _ FUSE BLOWS P gt TO PROBLEM 9 TEST 23 CHECK TEST 26 CHECK NO VOLTAGE STARTER VOLTAGE AT gt STARTER MEASURED CONTACTOR CONTACTOR RELAY SCR BAD 12 VDC MEASURED REPAIR OR 1 REPLACE WIRING OR SCR TEST 24 CHECK STARTER BAD REPLACE CONTACTOR GOOD TEST 25 CHECK REPLACE STARTER STARTER MOTOR BAD gt MOTOR IF DEFECTIVE GOOD CHECK FOR MECHANICAL BINDING OF THE ENGINE OR ROTOR Page 32 TEST 21 TEST 22 CHECK CHECK 10 BATTERY AMP FUSE amp CABLES RECHARGE OR REPLACE BATTERY BAD CLEAN REPAIR OR REPLACE BAD CABLE S TEST 27 CHECK BAD gt REPLACE SWITCH SW1 GOOD TEST 28 CHECK START RUN STOP L_ ap REPAIR SWITCH SW1 WIRING WIRING
66. START RUN STOP RELAY SW2 IDLE CONTROL SWITCH bs TB1 TB2 TERMINAL BLOCK gt 17 C2 6 5 C29 16 13 13 RED C2 11 V SC 13 13 BATTERY BLACK 12V Page 75 Section 8 ELECTRICAL DATA Wiring Diagram 12 5 amp 15 kW Units With Hourmeter Drawing No 0D4609 D 120 240V 120V 20A 120V 30A 120V 30A DUPLEX 30A TWISTLOK TWISTLOK TWISTLOK 22 11D 20 C B C B C B ENGINE WIRING GOVERNOR ACTUATOR START Page 76 Section 8 ELECTRICAL DATA 120 240V 50A OUTLET IDLE CONTROL 22 TRANSFORMERS CLOSEST TO BEARING BA 4 ON OFF IDLE CONTROL SWITCH ELECTRONIC GOVERNOR ENGINE SHUTDOWN 229 VOLTAGE Li PIN3 REGULATOR PIN4 77 PIN5 167 14 7 PIN6 F Y 14 86 Z HOURMETER LEGEND BA BRUSH ASSEMBLY CB1 SAMP AUTO RESET BREAKER 15 BATTERY
67. Systems source of supply Order as P N 042223 The tachometer measures from 800 to 50 000 RPM see Figure 6 32 Figure 6 32 Tachometer TEST BRACKET A starter motor test bracket may be made as shown in Figure 6 33 METAL STOCK 7 1 4 THICK STEEL D DRILL TWO HOLES 1 2 FOR STARTER MOUNTING BRACKET DRILL TWO HOLES 1 2 FOR MOUNTING TACHOMETER TAP FOR 1 4 20 NC SCREWS Figure 6 33 Test Bracket Dimensions 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 6 34 TESTING STARTER MOTOR 1 A fully charged 12 volt battery is required 2 Connect jumper cables and clamp on ammeter as shown in Figure 6 34 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 Section 6 DIAGNOSTIC TESTS CLAMP ON STARTER AMP METER CONTACTOR STARTER MOTOR 12 VOLT BATTERY Figure 6 34 Testing Starter Motor Performance Note Take the reading after the ammeter and tachometer are stabilized approximately 2 4 seconds 4 starter motor in good condition will be within the following specifications Minimum rpm 4500 Maximum Amps 50
68. T 43 CHECK FUSE BLOWS INSTALL NEW FUSE BLOW SOLENOID WHEN RUNNING INSTALLATION SIART STOF aoon TEST 47 RELAY SSR AND STARTER CONTACTOR RELAY TEST 44 FUSE IS GOOD BUT BAD BLOWS WHEN PLACED START GOOD REPLACE Y REPLACE TEST 19 CHECK BATTERY CHARGE TEST 45 CHECK WIRE 15 RECTIFIER 2 BCR2 VERIFY START RUN STOP SWITCH IS WIRED CORRECTLY SEE FIGURE 6 46 pg 55 BAD BAD REPAIR Y OR REPLACE REPLACE TEST 49 CHECK TEST 50 CHECK WIRE 15B WIRE 167 TEST 46 CHECK WIRE 14 CIRCUIT BAD BAD 2 hA MEASURED 1 de REPLACE REPLACE TEST 47 CHECK GooD TEST 48 CHECK FUEL SHUTOFF WITH HM HOURMETER SOLENOID FSS IF EQUIPPED BAD REPLACE gt GOOD BAD GOOD GOOD Y WirHOUT HM gt REPAIR OR REPLACE REPLACE VERIFY BCR1 TEST 8 DIODE AND BCR2 ARE RESISTOR WIRED CORRECTLY BAD BAD REPLACE M CORRECT WIRING Page 35 Section 5 TROUBLESHOOTING FLOWCHARTS Problem 11 Unit Overspeeds TEST 1 CHECK CHECK TO SEE IF NO LOAD VOLTAGE PRODUCING y c ED LED ON oN amp FREQUENCY VOLTAGE TEST 5 CHECK REPLACE NO STEPPER MOTOR GOOD gt CIRCUIT VOLTAGE OPERATION BOARD GO TO PROBLEM 2 GOOD BAD TEST 51 CHECK WIRES 11 44 gt REPAIR OR REPLACE Problem 12 Idle Control RPM Does Not Decrease VERIFY THAT THERE IS NO LOAD TEST 52 CHECK TEST 53 CHECK ON
69. TEPPER MOTOR CONTROL PROCEDURE 1 Remove air cleaner cover to access stepper motor 2 Physically grab the throttle and verify the stepper motor linkage and throttle do not bind in any way if any binding is felt repair or replace components as needed Some resistance should be felt as the stepper motor moves through it s travel 3 Physically move the throttle to the closed position by pushing the throttle down as looking from above a Place the idle control switch to off b Place the start switch to start and watch for stepper motor movement it should move to the wide open position during cranking Once the unit starts the stepper motor should move the throttle to a position to maintain 60 Hertz STEPPER Figure 6 2 Stepper Motor Linkage and Throttle Seen From Above FULL THROTTLE CLOSED THROTTLE Figure 6 3 Throttle Positions 4 If no movement is seen in Step remove the control panel cover Verify the six pin connector on the printed circuit board is seated properly remove the connector and then replace it and test again Verify the switches are correctly set See Figure 4 1 on Page 16 for positioning Page 40 5 If problem continues remove six pin connector from printed cir cuit board Set Volt meter to measure ohms Carefully measure from the end of the six pin harness as follows BLACK BROWN ORANGE
70. W HHTT 10 32 X 1 75 SCREW 8 1 2 X 20 ENGINE MOUNTING PLATE EARTH STRAP 3 8X 3 8 CLIP J VINYL COAT 625 ID ASSEMBLY BRUSH HOLDER SCREW TAP R 10 32 X 9 16 WASHER FLAT 3 8 ZINC RUBBER MOUNT BATTERY CABLE BLACK Section 7 DISASSEMBLY AND EXPLODED VIEWS ITEM 24 25 7 28 29 30 3 32 3 4 6 37 38 39 0 41 42 43 44 45 46 WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 1 4 G5 WASHER FLAT 3 8 M10 ZINC SCREW HHC M8 1 25 X 50 G8 8 WASHER FLAT 5 16 ZINC NUT LOCK HEX 8 1 25 NYLON INSERT SCREW HHC M6 1 0 X 12 WASHER LOCK M8 5 16 NUT HEX 5 16 18 STEEL SCREW TAPTITE 3 8 16 X 3 4 BP SHIELD MUFFLER HEAT U BOLT amp SADDLE SCREW SHC M8 1 25 X 18 PANEL MUFFLER BOX BACK PANEL MUFFLER BOX END SCREW HHTT M6 1 0 X 12 WASHER FLAT M6 1 4 WASHER LOCK M6 1 4 SPARK ARRESTOR SCREEN RETAINER SPARK ARREST SCREEN SCREW HHTT M4 0 7 X 8 SHIELD RUBBER MOUNT SCREW HHTT M5 0 8 X 16 Page 69 Section 7 DISASSEMBLY AND EXPLODED VIEWS Frame Handle amp Wheels Figure Detail of Battery Tray Page 70 45 1 i 47 44 25 48 43 46 CONTROL PANEL Section 7 DISASSEMBLY AND EXPLODED VIEWS ITEM DESCRIPTION DESCRIPTION 1 Gr RUBBER MOUNT
71. YELLOW RED EMPTY Figure 6 4 Six Pin Connector Wire Colors NOTE Press down with the meter leads on the connectors exposed terminals do not probe into the connector a Connect one meter lead to Red connect the remaining test lead to Orange approximately 10 ohms should be measured b Connect one meter lead to Red connect the remaining test lead to Yellow approximately 10 ohms should be measured c Connect one meter lead to Red connect the remaining test lead to Brown approximately 10 ohms should be measured d Connect one meter lead to Red connect the remaining test lead to Black approximately 10 ohms should be measured e Connect one meter lead to Red connect the remaining test to the stepper motor case No resistance should be measured INFINITY or Open See Figure 6 4 6 Set a voltmeter to measure DC voltage 7 Connect the positive meter test lead to Wire 15B at Terminal Block 1 TB1 Connect the negative meter test lead to ground See Figure 6 5 Place the Start Run Stop Switch SW1 to START 12 VDC should be measured If voltage was measured proceed to Step 8 If voltage was not measured proceed to RESULTS 8 Set a voltmeter to measure resistance 9 Disconnect the J2 connector from the printed circuit board Connect one meter test lead to Pin Location J2 1 Wire 15B Connect the other meter test lead to Wire 15B at Termina
72. a zs R C2 10 15 5 GOVERNOR 15 15 ACTUATOR mud 02 2 15 15 C27 120V 120V 14 14 0 GFCI DUPLEX Fss 22 22 22 0 a 120 240V 120 240 120V 30A 120V 30A 30A TWISTLOK TWISTLOK TWISTLOK 44 0 22 0 22 440 11D 0 44B 0 MB l 9 9 9 20 20 30A 30A 30A 30A 11 22 22 i 44 4 LEGEND BA BRUSH ASSEMBLY BCR1 BATTERY CHARGE RECTIFIER 10A BCR2 BATTERY CHARGE RECTIFIER CB1 10AMP AUTO RESET BREAKER CB2 6AMP AUTO RESET BREAKER D1 600V 12A DIODE D2 D3 ENGINE SHUTDOWN DIODE F1 10A FUSE FSS FUEL SHUT OFF SOLENOID GND GROUND BAR 1 C T IDLE CONTROL TRANSFORMER IM1 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 LOP LOW OIL PRESSURE R1 25 OHM 25W RESISTOR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 SP2 SPARK PLUG CYL 2 SSR START STOP RELAY SW1 START RUN STOP RELAY SW2 IDLE CONTROL SWITCH TB1 TB2 TERMINAL BLOCK Page 82 Section 8 ELECTRICAL DATA Wiring Diagram 17 5 kW Manual Transfer Switch Drawing No 0G1065 GROUND GRN NEUTRAL WHT NEUTRAL ciRcumg WHT NEUTRAL 11 WHT NEUTRAL CIRCUIT 13 WAT NEUTRAL E E E CIRCUIT 15 WHT CIRCUIT 1 BRN CIRCUIT3 BRN WHT
73. a VOM A short to ground condition in any Stator or Rotor winding Shorting together of any two parallel Stator wind ings Shorting together of any two isolated Stator wind ings An open condition in any Stator or Rotor winding Page 7 Section 2 MEASURING ELECTRICITY Component testing may require a specific resis tance 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 elec trical points which would be indicated as very low resistance or ZERO on a VOM ELECTRICAL UNITS AMPERE The rate of electron flow in a circuit is represented by the AMPERE The ampere is the number of elec trons 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 6 25 x 1018 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 positive value then reverses and goes from zero to maximum 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 PR
74. age 8 Connect a AC frequency meter as described in Step 6 9 Read the AC frequency RESULTS For units rated 60 Hertz no load voltage and frequen cy should be approximately 238 242 VAC and 59 61 Hertz See Flow Chart Problem 1 TEST 2 CHECK MAIN CIRCUIT BREAKER PROCEDURE The generator has seven circuit breakers located on the control panel If outlets are not receiving power make sure the breakers are set to ON or Closed If a breaker is suspected to have failed it can be tested as follows see Figure 6 7 1 Set a Volt meter to measure resistance 2 With the generator shut down disconnect all wires from the suspected circuit breaker terminals to prevent interaction 3 With the generator shut down connect one meter test lead to a one terminal of the breaker and the other meter test lead to the other terminal See Figure 6 7 4 Set the breaker to its ON or Closed position The meter should read CONTINUITY 5 Set the breaker to its OFF or Open position and the meter should indicate INFINITY RESULTS 1 If the circuit breaker tests good refer back to the flow chart 2 If the breaker tests bad it should be replaced Figure 6 7 50 Amp Breaker Test Points Page 37 Section 6 DIAGNOSTIC TESTS 20 30A C B Figure 6 8 20 30 Amp Breaker Test Points TEST 3 TEST EXCITATION CIRCUIT BREAKER PROCEDURE 1 With the generator shut down for at l
75. and or activation of the Fuel Shutoff Solenoid should be felt It can then be assumed that the Fuel Shutoff Solenoid is functioning RESULTS Refer to flow chart TEST 37 TEST FUEL SHUTOFF SOLENOID VOLTAGE PROCEDURE 1 Set a voltmeter to measure DC voltage 2 Disconnect the two pin connector from the Fuel Shutoff Solenoid FSS 3 Connect the positive meter test lead to the red wire Connect the negative meter test lead to the black wire Place the Start Run Stop switch SW1 to START During cranking 12 VDC should be measured If DC voltage is not measured continue testing 4 Set a voltmeter to measure resistance 5 Connect one meter test lead to the black wire Connect the other meter test lead to frame ground Continuity should be measured If continuity is not measured repair or replace the black ground wire or correct poor ground connection 6 Set a voltmeter to measure DC voltage 7 Remove Wire 14 from the Start Stop Relay SSR Refer to Figure 6 41 on Page 54 Connect the positive meter test lead to the terminal of the SSR that Wire 14 was just removed Connect the negative meter test lead to frame ground Place the Start Run Stop Switch SW1 to the start position 12 VDC should be measured If 12 VDC is measured repair or replace Wire 14 between the SSR and Resistor 1 or between Resistor 1 and the FSS RESULTS Refer to flow chart TEST 38 CHECK FUEL PUMP FUEL TO 4 CARBURETOR E
76. and connect the other meter test lead to frame ground Continuity should be measured Section 6 DIAGNOSTIC TESTS 5 Set voltmeter to measure DC voltage 6 Remove Wire 15 from the Start Run Stop Switch SW1 Connect the positive meter test lead to Wire 15 Connect the negative meter test lead to frame ground 12 VDC should be measured RESULTS Repair or replace any wiring that did not have continu ity If voltage was not measured in Step 6 repair wiring between the Starter Contactor Relay SCR and the Start Run Stop Switch SW1 If all steps passed repair or replace Wire 16 between the Starter Contactor SC and the Starter contactor Relay SCR TEST 29 CHECK IGNITION SPARK PROCEDURE A commercially available spark tester may be used to test the engine ignition system One can also be purchased from Generac Power Systems Part No 0C5969 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 6 37 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 If spark jumps the tester gap intermittently the problem may be in the Ignition Magneto Figure 6 37 Testing Ignition System N n Figure
77. arped valve stem Worn or broken piston ring s Worn or damaged cylinder bore Broken connecting rod Worn valve seats or valves Worn valve guides NOTE Refer to Engine Service manual No 0F6923 for further engine service information TEST 42 CHECK OIL PRESSURE SWITCH AND WIRE 86 If the engine cranks and starts then shuts down almost immediately the cause may be one or more of the following Low engine oil level Low oil pressure A defective oil pressure switch x LOW OIL SWITCH Figure 6 53 Low Oil Pressure Switch PROCEDURE 1 Check engine crankcase oil level a Check engine oil level b If necessary add the recommended oil to the dipstick FULL mark DO NOT OVERFILL ABOVE THE FULL MARK 2 Do the following a Disconnect Wire 86 and Wire 0 from the oil pressure switch terminals Remove the switch and install an oil pressure gauge in its place Page 60 b Start the engine while observing the oil pressure reading on gauge c Note the oil pressure 1 Normal oil pressure is approximately 35 40 psi with engine running If normal oil pres sure is indicated go to Step 4 of this test 2 If oil pressure is below about 10 psi shut engine down immediately A problem exists in the engine lubrication system Refer to Service Manual Generac P N 0 6923 for engine service recommendations Note The oil pressure switch is rated at 10 psi for v twin engines 3 Remove the oil
78. between 0 2 to 10 Amps in Step 2 and Step 3 the charging system is working no amperage was measured check the voltmeter fuses and verify the functioning of the Amp Meter If DC Amp Meter is good and no current is measured refer to flow chart TEST 19 CHECK BATTERY CHARGE RECTIFIER BCR2 PROCEDURE 1 Disconnect all wires 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 measure approximately 0 5 volts 3 Connect the positive test lead to the center terminal of the BCR Connect the negative test lead 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 47 Section 6 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 mea sured Now connect the negative test lead to the BCR center terminal INFINITY should be measured Next connect the negative test lead to the remaining outer BCR terminal Once again INFINITY should be measured Figure
79. c RPM Slowly pull the choke out to see if surging stops If it does stop carburetion should be checked MAKE SURE THE TEST PROBE CONNECTOR IS MAKING CONTACT WITH THE CONNECTOR DOUBLE CHECK TO J2 HARNESS CONNECTOR MAKE SURE THAT THE TIP IS SHARP Figure 6 63 Check TR1 Wiring Page 65 Section 7 DISASSEMBLY AND EXPLODED VIEWS MAJOR DISASSEMBLY STATOR ROTOR AND ENGINE REMOVAL Reference Figures A and B on Pages 68 71 for com ponent location 1 Disconnect and remove the battery Figure B Item 15 from the generator 2 Remove Fuel Tank Figure B 4 Use proper safety pre cautions when handling gasoline m N Figure 7 1 Fuel Tank Removed 3 Remove Control Panel Figure The front control panel should be removed and Wires 11 amp 44 will need to be discon nected from the 50 Amp circuit breaker and Wire 22 from the 50 Amp receptacle Disconnect the stepper motor harness from the printed circuit board Disconnect the C1 and C2 connectors below the control panel Remove the control panel 089490 Lava 39vi30A y 39v130 Wi Figure 7 2 Stepper Motor Harness Page 66 Figure 7 4 Remove Air Deflector Remove air def
80. connectors with the test leads See Figure 6 11 6 Set Idle control switch to OFF 7 Start the generator 8 Measure the output voltage across Wire 2 and Wire 6 and record the results AC Voltage across Wires 2 and 6 Section 6 DIAGNOSTIC TESTS 9 Shutdown the generator 10 Reconnect Wire 2 to the Excitation Circuit Breaker 11 Connect one meter test lead to Wire 11S located in the six pin connector previously removed from the Voltage Regulator Connect the other meter test lead to Wire 44S located in the six pin connector previously removed from the Voltage Regulator See Figure 6 11 Be careful not to damage the pin connectors with the test leads 5 VOLTAGE REGULATOR Figure 6 11 Vollage Regulator Pin Connector Wire Number Locations 12 Start the generator 13 Measure the output voltage across wires 11S and 44S and record the results AC Voltage across Wires 11S and 44S 14 Shutdown the generator 15 Remove the Jumper lead between Wire 14 and Diode D1 16 Set the voltmeter to measure DC amperage 10 Amp Range Switch the test leads on the meter if required 14 WIRE 14 REMOVED 14 Figure 6 12 Measuring Amp Draw 17 Connect the positive meter test lead to Wire 14 Connect the negative test lead to Wire 4 at Diode D1 See Figure 6 12 18 Start the generator 19 Measure the DC Rotor Amp draw and record the
81. ct Wire 14 from the hourmeter Install new 10 Amp fuse Set Start Run Stop Switch SW1 to start 2 Check to see if fuse blew open RESULTS 1 If fuse did not blow open replace the hour meter 2 If fuse still blew repair or replace Wire 14 between the Resistor R1 and the Hour Meter HM or between the HM and the Fuel Shutoff Solenoid FSS TEST 49 CHECK WIRE 15B PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Wire 15B from the Start Stop Relay SSR see Figure 6 56 Connect one meter test lead to Wire 15B previ ously removed Connect the other meter test lead to frame ground Approximately 20K ohms should be measured 3 If continuity or zero resistance was measured remove the J2 connector from the printed circuit board and repeat Step 2 Figure 6 56 Check Wire 15B Page 62 RESULTS 1 If continuity was measured in Step 2 but not in Step 3 replace the printed circuit board 2 If continuity was measured in Step 3 Wire 15B is shorted to ground repair or replace Wire 15B between the SSR and printed circuit board TEST 50 CHECK WIRE 167 PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Wire 167 from the Start Run Stop Switch SW1 Connect one meter test lead to Wire 167 previously removed Connect the other meter test lead to frame ground See Figure 6 57 INFINITY should be measured 3 If continuity or zero resistance was measured remove the
82. cuit Breaker CB1 Connect the other meter test lead to Wire 162 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 refer back to flow chart TEST 7 CHECK FIELD BOOST PROCEDURE 1 Set VOM to measure DC voltage 2 Disconnect the six pin connector from the Voltage Regulator 3 Disconnect Connector C1 See Page 17 for connector location 4 Disconnect Wire 16 from the Starter Contactor Relay SCR See Figure 6 13 This will cause the unit not to crank when placed in the Start position 5 Connect the positive meter test lead to Wire 4 at the diode D1 Wire 4 is soldered to the diode See Figure 6 14 Connect the negative meter test lead to the ground terminal 6 Set the Start Run Stop Switch SW1 to START Measure the DC voltage It should read approximately 12 VDC 7 Reconnect the Six Pin connector to the Voltage Regulator Reconnect the C1 connector and reconnect Wire 16 to the Starter Contactor Relay RESULTS 1 lf 12 VDC was measured in Step 5 the field boost circuit is working refer back to the flow chart 2 If field boost voltage was not measured refer back to the flow chart Page 41 Section 6 DIAGNOSTIC TESTS 14 WIRE 14 REMOVED Figure 6 15 Diode Test Step 5 6 Connect the positive meter test lead to the bottom terminal of the diode
83. d remove cable and clean cable terminals and studs Replace any cable that is defective or badly corroded Set the voltmeter to mea sure DC 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 6 28 STEP 1 TEST POINT STARTER SWITCH CONNECTING DIAGRAM STARTER STEP 1 TEST POINT CONTACTOR 9 STEP 2 TEST POINT STARTER MOTOR Figure 6 28 The Starter Contactor SC 2 Set the voltmeter to measure DC voltage Connect the positive meter test lead to the Starter Contactor stud that has the small jumper wire connected to the Starter Connect the nega tive meter test lead to a clean frame ground Set the Start Stop Switch to START Battery voltage should be measured see Figure 6 28 STEP 2 TEST POINT RESULTS 1 If battery voltage was not measured in Step 1 repeat Test 22 2 f battery voltage was measured in Step 1 but not in Step 2 replace the Starter Contactor 4 f battery voltage was measured in Step 2 but the engine still does not crank refer back to the Flow Chart TEST 25 CHECK STARTER MOTOR CONDITIONS AFFECTING STARTER MOTOR PERFORMANCE 1 A binding or seizing condition in the Starter Motor bearings 2 A shorted open o
84. e ground on the stator can Read the number of megohms on the meter The MINIMUM acceptable megger reading for stators may be calculated using the following formula MINIMUM INSULATION RATED VOLT RESISTANCE GENERATOR OLTS 1000 in Megohms 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 is 1 12 megohms If the stator insulation resistance is less than the cal culated minimum resistance clean and dry the stator Then repeat the test If resistance is still low replace the stator Use the Megger to test for shorts between isolated windings as outlined Stator Insulation Tests Also test between parallel windings See Test Between Windings on next page TESTING ROTOR INSULATION Apply a voltage of 500 volts across the rotor positive slip ring nearest the rotor bearing and a clean frame ground i e the rotor shaft DO NOT EXCEED 500 VOLTS AND DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY ROTOR MINIMUM INSULATION RESISTANCE 1 5 megohms CAUTION Before attempting to measure Insulation resistance first disconnect and Isolate all leads of the winding to be tested Electronic components diodes surge protec tors relays Voltage Regulators etc can be destroyed if subjected to
85. e 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 on Generac recreational vehicle generators are designed and manufactured to comply with Recreational Vehicle Industry Association RVIA Rules and Regulations to minimize the risk of fire or explo sion The use of replacement parts that are not in compliance with such Rules and Regulations could result in a fire or explosion hazard When servicing this equipment it is extremely important that all components be properly installed and tightened If improperly installed and tightened sparks could ignite fuel vapors from fuel system leaks Table of Contents SAFETY INSIDE FRONT COVER IFC STATOR INSULATION RESISTANCE TEST 13 NOTICE TO USERS OF THIS MANUAL 0 0 IFC GENERAL toc a 13 REPLACEMENT PARTS e IFC TESTING ALL STATOR WINDINGS TO GROUND 14 TEST BETWEEN WINDINGS 14 TABLE OF CONTENTS 1 2 ROTOR INSULATION RESISTANCE TEST 15 CLEANING THE GENERATOR 15 SECTION 1 DRYING THE GENERATOR 15 GENERATOR FUNDAMENTALS 3 5 SECTION 4 MAGNETISM
86. east two minutes locate the Excitation Circuit Breaker in the control panel Disconnect wires from the breaker to prevent interaction 2 Set a volt meter to measure resistance 3 Connect the VOM test probes across the circuit breaker termi nals The meter should read CONTINUITY RESULTS 1 If circuit breaker tests bad meter reads then proceed to Test 4 and replace the breaker after completing Test 4 2 If circuit breaker is good go on to Test 4 Figure 6 9 Testing Excitation Circuit Breaker Page 38 TEST 4 FIXED EXCITATION TEST ROTOR AMP DRAW PROCEDURE NOTE If the generator is not producing AC Power loss of governor control may occur caus ing an overspeed or extremely high RPM condi tion If this condition occurs manually control throttle 60Hz 3600 RPM to perform test 1 Unplug the six pin connector at the Voltage Regulator 2 Disconnect Wire 14 from the Resistor R1 3 Connect a jumper wire between the removed end of Wire 14 and Wire 4 where it is soldered at the Diode D1 See Figure 6 10 WIRE 14 REMOVED 14 JUMPER LEAD Figure 6 10 Jumper Lead From Wire 14 to Diode 4 Set voltmeter to measure AC voltage 5 Disconnect Wire 2 from the Excitation Circuit Breaker and con nect one meter test lead to it Connect the other meter test lead to Wire 6 located in the six pin connector previously removed from the Voltage Regulator Be careful not to damage the pin
87. easured in Step 7 replace the Starter Contactor Relay If all steps passed refer back to flow chart TEST 27 CHECK START RUN STOP SWITCH SW1 PROCEDURE 1 Set a voltmeter to measure resistance 2 Remove all wires from the Start Run Stop Switch SW1 3 Using the chart below ohm out the Start Run Stop Switch Connect one meter test lead to one terminal and the other meter test lead to the other terminal With meter leads connected acti vate the switch to Start Stop or Run and follow the chart 4 Reconnect all wires to the switch Page 52 Figure 6 36 Start Run Stop Switch SW1 RESULTS If the switch fails any part of the test procedure replace the switch TEST 28 CHECK START RUN STOP SWITCH SW1 WIRING PROCEDURE 1 Set voltmeter to measure resistance 2 Remove Wire 17 from the Starter Contactor Relay SCR Connect one meter test lead to Wire 17 Remove Wire 17 from the Start Run Stop Switch SW1 Connect the other meter test lead to wire 17 Continuity should be measured 3 Remove both Wire 0 from the Start Run Stop switch SW1 it is located in two positions on the switch Connect one meter test lead to one Wire 0 and connect the other meter test lead to the other Wire 0 Continuity should be measured 4 Remove Wire 0 from the Start Run Stop switch SW1 it is located in two positions on the switch Connect one meter test lead to one Wire 0
88. ecked to eliminate it as the cause of starting difficulty It is a good practice to check the engine for freedom of rotation by removing the spark plugs and turn ing the crankshaft over slowly by hand to be sure it rotates freely WARNING DO NOT ROTATE ENGINE WITH ELECTRIC STARTER WITH SPARK PLUGS REMOVED ARCING AT THE SPARK PLUG ENDS MAY IGNITE THE GASOLINE VAPOR EXITING THE SPARK PLUG HOLE Figure 6 29 Starter Motor SM Page 50 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 6 30 Check Pinion Gear Operation TOOLS FOR STARTER PERFORMANCE TEST The following equipment may be used to complete a performance test of the Starter Motor A clamp on ammeter e A tachometer capable of reading up to 10 000 rpm A 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 CLAMP ON AMMETER ATTACHMENT Figure 6 31 Clamp On Ammeter TACHOMETER A tachometer is available from your Generac Power
89. efer back to flow chart Section 6 DIAGNOSTIC TESTS TEST 11 EXCITATION WIRING PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Connector C1 See Page 17 for connector location 3 Locate the male side of the connector located on the bottom of the control panel See Figure 6 19 Connect one meter test lead to Pin 6 Wire 2 it may be helpful to connect a small jumper lead to the individual pin Disconnect Wire 2 from the Excitation Circuit Breaker CB1 Connect the other meter test lead to Wire 2 See Page 17 for Excitation Circuit Breaker loca tion Continuity should be measured 4 Unplug the six pin connector at the Voltage Regulator 5 Locate the male side of the C1 connector located on the bot tom of the control panel Connect one meter test lead to Pin 7 Wire 6 It may be helpful to connect a small jumper lead to the individual pin Connect the other meter Test lead to Wire 6 located in the six pin connector previously removed from the Voltage Regulator Be careful not to damage the pin connectors with the test leads Continuity should be measured RESULTS 1 If continuity was not measured in any of the steps repair or replace wire 2 If all steps pass refer back to flow chart TEST 12 CHECK BRUSH LEADS PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Connector C1 See Page 17 for connector location 3 See Figure 6 18 Connect the meter test leads across Wire 4 Pi
90. en the value of the other two are known Ohm s Law states that in any circuit the current will increase when voltage increases but resistance remains the same and current will decrease when resistance Increases and voltage remains the same Figure 2 6 Ohm s Law If AMPERES is unknown while VOLTS and OHMS are known use the following formula VOLTS AMPERES OHMS If VOLTS is unknown while AMPERES and OHMS are known use the following formula VOLTS AMPERES x OHMS If OHMS is unknown but VOLTS and AMPERES are known use the following VOLTS OHMS AMPERES Section 3 DESCRIPTION amp COMPONENTS INTRODUCTION The generator revolving field rotor is driven by an air cooled engine at about 3600 rpm The generator may be used to supply electrical power for the operation of 120 and or 240 volts 1 phase 60 Hz AC loads ENGINE GENERATOR DRIVE SYSTEM The generator revolving field is driven by an air cooled horizontal crankshaft engine The generator is directly coupled to the engine crankshaft see Figure 1 Both the engine and generator rotor are driven at approximately 3600 rpm to provide a 60 Hz AC out put STATOR ROTOR BRUSH HOLDER ASSEMBLY THE AC GENERATOR Figure 3 1 shows the major components of the AC generator ROTOR ASSEMBLY The 2 pole rotor must be operated at 3600 rpm to supply a 60 Hertz AC frequency The term 2 pole means the rotor has a single north magnetic p
91. er meter test lead to Wire 11S at Terminal Block 2 TB2 See Page 17 for Terminal Block 2 location Continuity should be measured LOCATION 7 LOCATION O O PIN LOCATION 1 LOCATION 6 Figure 6 19 C1 Connector Male Side 4 Locate the male side of the connector located on the bottom of the control panel See Figure 6 19 Connect one meter test lead to Pin 2 Wire 44S It may be helpful to connect a small jumper lead to the individual pin Connect the other meter test lead to Wire 44S at Terminal Block 2 TB2 Continuity should be measured 5 Unplug the six pin connector at the Voltage Regulator 6 Connect the one meter test lead to Wire 11S at Terminal Block 2 TB2 Connect the other meter test lead to Wire 11S at the six pin connector previously removed from the Voltage Regulator See Figure 6 11 Be careful not to damage the pin connectors with the test leads Continuity should be measured Connect the meter test lead to Wire 445 at Terminal Block 2 TB2 Connect the other meter test lead to Wire 44S at the six pin connector previously removed from the Voltage Regulator See Figure 6 11 Be careful not to damage the pin connectors with the test leads Continuity should be measured RESULTS 1 continuity was not measured in any of the steps repair or replace wire 2 If all steps pass r
92. ervicing 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 a 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 themselves that neither his nor the products safety will be endangered by the ser vice 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 Metric bolts and nuts have numbers that indicat
93. eter test leads across Stator lead 66A Pin 4 and Stator lead 2 Pin 6 at the C1 connector female side Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read 18 Connect the meter test leads across Stator lead 66A Pin 4 and Stator lead 66 Pin 9 at the C1 connector female side Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read 19 Connect the meter test leads across Stator lead 2 Pin 6 and Stator lead 66 Pin 9 at the C1 connector female side Be care ful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors See Figure 6 18 INFINITY should be read RESULTS If the stator fails any step replace it for Steps 1 10 keep in mind resistance values may vary depending on ambient temperature and calibration of the meter used If the stator passes all tests refer back to the flow chart Page 44 TEST 10 SENSING LEADS PROCEDURE 1 Set a VOM to measure resistance 2 Disconnect Connector C1 See Page 17 for connector location 3 Locate the male side of the connector located on the bottom of the control panel See Figure 6 19 Connect one meter test lead to Pin 1 Wire 11S It may be helpful to connect a small jumper lead to the individual pin Connect the oth
94. haust valve clearance Turn the engine over and position the exhaust valve fully open exhaust valve spring compressed and adjust the intake valve clearance Correct valve clearance is given below Intake Valve 0 002 0 004 inch 0 05 0 1 mm Exhaust Valve 0 002 0 004 inch 0 05 0 1 ALLEN WRENCH Figure 6 51 Adjusting Valve Clearance 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 6 51 2 When clearance is correct hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut to the specified torque with a crow s foot After tightening the jam nut recheck valve clearance to make sure it did not change Section 6 DIAGNOSTIC TESTS TORQUE SPECIFICATION ROCKER ARM JAM NUT 168 inch pounds 19 Nm CROW S FOOT th gt Figure 6 52 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 refer to Flow Chart TEST 41 CHECK ENGINE CYLINDER LEAK DOWN TEST COMPRESSION TEST Most engine problems may be classified as one or a combination of the following Will not start Starts hard Lack of power Runs rough e Vibration Overheating High oil c
95. high megger volt ages HI POT TESTER A Hi Pot tester is shown in Figure 3 8 The model shown is only one of many that are commercially available The tester shown is equipped with a voltage selector switch that permits the power supply voltage to be selected It also mounts a breakdown lamp that will illuminate to indicate an insulation breakdown dur ing the test Figure 3 8 One Type of Hi Pot Tester STATOR INSULATION RESISTANCE TEST GENERAL Units with air cooled engines are equipped with a center tapped AC power windings b an excitation Page 13 Section 3 DESCRIPTION amp COMPONENTS or DPE winding c a center tapped battery charge winding and d a 10 Amp center tapped battery charge winding Insulation tests of the stator con sist of a testing all windings to ground b testing between isolated windings and c testing between parallel windings Figure 3 9 is a pictorial representa tion of the various stator leads on units with air cooled engine TESTING ALL STATOR WINDINGS TO GROUND 1 Disconnect stator output leads Wire 11 and Wire 44 from the generator 50A circuit breaker 2 Remove stator output lead Wire 22 from the neutral terminal on the back of the 50A outlet 3 Disconnect the C1 connector from the bottom of the control panel See Figure 3 10 The C1 connector is on the right when facing the control panel
96. hing slowly turn the stability pot either direction until flashing stops ADJUSTMENT PROCEDURE 17 5 KW UNITS A single red lamp LED glows during normal opera tion The lamp will become dim if excitation winding AC output diminishes It will go out on occurrence of an open condition in the sensing AC output circuit An adjustment potentiometer permits the stator AC power winding voltage to be adjusted Perform this adjustment with the generator running at no load and Page 11 Section 3 DESCRIPTION amp COMPONENTS with a 62 Hz AC frequency 62 Hz equals 3720 rpm At the stated no load frequency adjust to obtain a line to line AC voltage of about 252 volts CIRCUIT BREAKERS Each individual outlet on the generator is protected by a circuit breaker to prevent overload ROTOR RESIDUAL MAGNETISM The generator revolving field rotor may be consid ered to be a permanent magnet Some residual magnetism is always present in the rotor This residu al magnetism is sufficient to induce a voltage into the stator AC power windings that is approximately 2 12 volts AC FIELD BOOST CIRCUIT When the engine is cranked during start up the START STOP RELAY SSR will be energized The normally open contacts of the SSR will close and Wire 15 will supply 12 VDC to Wire 14 Connected to Wire 14 is a resistor R1 and a diode D1 The resistor will limit current flow and the diode will block Voltage Regulator DC out
97. ide the rotor bolt back through the rotor and use a screwdriver to screw it into the crankshaft Use a 3 M12 x 1 75 bolt to screw into the rotor Apply torque to the 3 bolt until the taper breaks If necessary when torque is applied to the 3 bolt use a rubber mallet on the end of the rotor shaft to break the taper eS s Figure 7 10 Engine Ready for Removal 8 Remove Engine Remove the four nuts from rubber engine mounts Figure A Item 29 Remove engine Figure 7 7 Remove Bearing Carrier Reverse procedure for assembly Page 67 Section 7 DISASSEMBLY AND EXPLODED VIEWS Generator Figure 28 31 34 e 0 8 g AN q d 55 A 15 N N o 5 a On e o 9 2 V T k N M NA 59 9 S gt q E e EN e y 8 p N QN ds Q 8 2 Page 68 32 ITEM 1 1 12 1 14 16 df 18 9 0 21 22 23 ADAPTOR ENGINE STATOR ASSEMBLY ROTOR W FAN CARRIER REAR BEARING EXHAUST MANIFOLD MUFFLER GASKET EXHAUST COVER ALTERNATOR AIR INTAKE BEARING 5 16 SPECIAL LOCK WASHER SCREW IHHC 3 8 24 X 15 50 G5 ES SCREW IHHC 8 1 25 X 400 G8 8 BRACKET ALT MOUNTING EN SCRE
98. ings will drop to a value that is commensurate with the rotor residual magnetism see Figure 3 5 Figure 3 5 Excitation Circuit Breaker VOLTAGE REGULATOR A typical Voltage Regulator is shown in Figure 3 6 12 5 amp 15 kW Units or Figure 3 7 17 5 kW Units Unregulated AC output from the stator excitation winding is delivered to the regulator s DPE termi nals via Wire 2 the Excitation Circuit Breaker and Wire 162 and Wire 6 The Voltage Regulator recti fies that current and based on stator AC power winding sensing regulates it The rectified and regulated excitation current is then delivered to the rotor windings from the positive and negative regulator terminals via Wire 4 and Wire 0 Stator AC power winding sensing is delivered to the reg ulator SEN terminals via Wires 11S and 44S The regulator provides over voltage protection but does not protect against under voltage On occur rence of an over voltage condition the regulator will shut down and complete loss of excitation current to the rotor will occur Without excitation current the generator AC output voltage will drop to approximately one half or lower of the unit s rated voltage VOLTAGE ADJUST inc EL VOLTAGE REGULAT OR PART NO 67680 GAIN j inc pes Ma STABILITY inc UNDERFREQUENCY fa Y ADJUST inc REGULATOR og SENSING OPEHATING
99. ired level the regulator responds by increasing the flow of excitation current AC POWER WINDING OUTPUT A regulated voltage is induced into the stator AC power windings When electrical loads are connected across the AC power windings to complete the cir cuit current can flow in the circuit The regulated AC power winding output voltage will be in direct propor tion to the AC frequency For example on units rated 120 240 volts at 60 Hz the regulator will try to main tain 240 volts line to line at 60 Hz This type of regu lation system provides greatly improved motor starting capability over other types of systems BATTERY CHARGE WINDING OUTPUT A voltage is induced into the battery charge winding Output from these windings is delivered to a Battery Charge Rectifier BCR2 via Wires 55A 66A and 77A The resulting direct current from the BCR is delivered to the unit battery via Wire 15 a 10 amp fuse and Wire 13 This output is used to maintain bat tery state of charge during operation 10 AMP BATTERY CHARGE WINDING OUTPUT A voltage is induced into the battery charge winding Output from these windings is delivered to a Battery Charge Rectifier BCR1 via Wires 55 66 and 77 Section 3 DESCRIPTION amp COMPONENTS The resulting direct current from the BCR is delivered to the 12 VDC receptacle via Wire 13A CB1 and Wire 15A This receptacle allows the capability to recharge a 12 volt DC storage batter
100. ity is not measured repair or replace Wire 229 between SSR and TB1 Remove the J2 connector the printed circuit board Connect one meter test lead to pin location J2 8 Wire 229 connect the other meter test lead to Wire 229 at TB1 See Figure 6 48 Be careful not to damage the pin connectors with the test leads Continuity should be measured If continuity is not measured repair or replace Wire 229 between the J2 connector and TB1 RESULTS 1 If Step 3 passed refer to Flow Chart 2 If Step 3 failed and Step 5 passed replace the printed circuit board Page 56 MAKE SURE THE TEST PROBE CONNECTOR IS MAKING CONTACT WITH THE CONNECTOR DOUBLE CHECK TO MAKE SURE THAT THE TIP IS SHARP J2 HARNESS CONNECTOR Figure 6 48 Testing Wire 229 Between J2 Connector and Terminal Block 1 TB1 TEST 35 CHECK AND ADJUST IGNITION MAGNETOS PROCEDURE 1 See Figure 6 49 Rotate the flywheel until the magnet is under the module armature laminations 2 Place a 0 008 0 012 inch 0 20 0 30mm thickness gauge between the flywheel magnet and the module laminations 3 Loosen the mounting screws and let the magnet pull the mag neto down against the thickness gauge 4 Tighten both mounting screws 5 To remove the thickness gauge rotate the flywheel 6 Repeat the above procedure
101. k and SW2 Page 63 Section 6 DIAGNOSTIC TESTS MAKE SURE THE TEST H apan 15 MAKING CONTACT WITH THE CONNECTOR DOUBLE CHECK TO J2 HARNESS CONNECTOR MAKE SURE THAT THE TIP IS SHARP Figure 6 60 Check Idle Control Wiring RESULTS Repair or replace wiring as needed Refer back to the flow chart TEST 54 CHECK IDLE CONTROL TRANSFORMERS ICT PROCEDURE 1 Set a voltmeter to measure resistance 2 Remove the two Idle Control Transformer ICT Wires from Terminal Block 1 TB1 See Figure 6 61 3 Connect one meter test lead to one wire and connect the other meter test lead to the other wire Approximately 100 ohms should be measured If resistance is not measured repair or replace the Idle Control Transformers If resistance was mea sured proceed with Step 4 4 Set a voltmeter to measure AC Voltage 5 Connect one meter test lead to one wire and connect the other meter test lead to the other wire 6 Turn the Idle Control Switch SW2 to OFF The generator should be running at about 60 HZ Page 64 7 Apply a light load to the generator such as a electric drill 8 When the drill is activated measure the voltage output The AC voltage should measure around 1 2 VAC RESULTS Refer back to flow chart IDD DHP amp SY AAC
102. l Block 1 TB1 See Figure 6 6 Continuity should be measured Section 6 DIAGNOSTIC TESTS ela KAKA TERMINAL BLOCK TB1 MAKE SURE THE TEST PROBE CONNECTOR IS MAKING CONTACT WITH THE CONNECTOR DOUBLE CHECK TO MAKE SURE THAT THE TIP IS SHARP J2 HARNESS CONNECTOR Figure 6 6 Testing J2 1 RESULTS 1 If the stepper motor fails any part of Step 5 replace the stepper motor 2 If Step 7 fails repair or replace Wire 15B between the Start Run Stop Relay SSR and Terminal Block TB1 3 If the stepper motor passes all steps replace the Printed Circuit Board TEST 6 WIRE CONTINUITY PROCEDURE 1 Set a Voltmeter to measure resistance 2 Remove the six pin connector from the Voltage Regulator 3 Connect one meter test lead to Wire 0 in the six pin connector previously removed from the Voltage Regulator See Figure 6 11 Be careful not to damage the pin connectors with the test leads 3 Connect the other test lead to the ground terminal in the control panel The meter should read continuity 4 Connect one meter test lead to Wire 162 in the six pin connec tor previously removed from the Voltage Regulator See Figure 6 11 Be careful not to damage the pin connectors with the test leads 5 Remove Wire 162 from the Excitation Cir
103. lector Figure B Item 45 from cross member Remove the Muffler Remove the four screws holding the alter nator air cover on the rear of the alternator Figure A Item 8 Remove the muffler heat shield labeled HOT Figure A 34 Remove the rear muffler box end panel Figure A Item 38 Remove the nut and washers from the top of the rear rub ber mounts attached to the rear bearing carrier Figure A Item 32 Remove the back muffler box back panel Figure A Item 37 Remove the 8 bolt from the rear bearing carrier Figure A Item 15 Remove the exhaust clamp Figure A Item 35 Remove the muffler Figure A Item 6 Figure 7 5 Remove Muffler Section 7 DISASSEMBLY AND EXPLODED VIEWS 6 Remove Stator Disconnect Wire 4 and Wire 0 from the brush assembly Figure A Item 21 Remove the brush assembly Remove the four stator hold down bolts Figure A Item 12 Lift the rear end of the alternator up to clear the muffler frame from the rubber alternator mount place a 2x4 under the front bear ing carrier for support Using a rubber mallet carefully remove the rear bearing carrier Figure A Item 4 Rotate the rotor so that the steel laminations face the top and bottom Remove the stator can Figure 7 6 Support Alternator N Remove Rotor Remove rotor bolt Figure A Item 11 Cut 2 5 inches from the hex head end of the rotor bolt Slot the end of the bolt to suit a flat blade screwdriver Sl
104. m Jam Nut 14 ft Ibs Ignition Coil 9 ft Intake Manifold 14 ft Exhaust Manifold 4 ft Stator Bolt 2 ft Rotor Bolt 30 ft Spark Plug 15 ft Starter Bracket To Block 8 ft TRIM TORQUE SPECIFICATIONS M3 5 PHILLIPS PAN HEAD SCREW INTO ALUMINUM 50 in 105 Mo 1 TAPTITE SCREW INTO ALUMINUM 9 6in 1 5 Mo 1 TAPTITE SCREW INTO WELDNUT 96 in 165 8 1 25 TAPTITE SCREW INTO ALUMINUM 18 ft Ibs Page 87 GUARDIAN by Generac Power Systems Inc PO BOX 297 WHITEWATER WI 53190 www guardiangenerators com
105. mes out as wire 17 12 VDC wire 17 is connected to the Start Run Stop switch SW1 and is held open to ground No cur rent flows through the circuit and the SCR is de energized Wire 15 12 VDC fused battery supply voltage is supplied to SW1 and is held open to Wire 167 Wire 15 12 VDC fused battery supply voltage is supplied to the Start Stop Relay SSR it goes through the coil and comes out as wire 229 12 VDC wire 229 is connected to the printed circuit board and is held open to ground No current flows through the circuit and the SSR is de energized Page 20 Section 4 ENGINE DC CONTROL SYSTEM 120V 120V DUPLEX GFCI 22 n n 120V 30A TWISTLOK reu D 1 22 0 44C 15 17 LEGEND BA BRUSH ASSEMBLY BCR1 BATTERY CHARGE RECTIFIER 10A BCR2 BATTERY CHARGE RECTIFIER 1 10 AUTO RESET BREAKER CB2 5 AUTO RESET BREAKER D1 600 12A DIODE D2 D3 ENGINE SHUTDOWN DIODE F1 10A FUSE FSS FUEL SHUT OFF SOLENOID GND GROUND BAR IDLE CONTROL TRANSFORMER IM1 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 LOP LOW OIL PRESSURE R1 25 OHM 25W RESISTOR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 SP2 SPARK PLUG CYL 2 SSR START STOP RELAY SW1 START RUN STOP SWITCH SW2 IDLE CO
106. n 11 and Wire 0 Pin 12 at the C1 connector female side Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors Rotor resistance should be measured approximately 7 14 ohms If resistance is measured proceed to Step 6 If no resis tance is measured continue Remove the control panel assembly to access the brushes See Figure 6 21 Connect one meter test lead across Wire 4 Pin 11 at the C1 connector female side Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors Connect the other meter test lead to Wire 4 at the brush assembly Continuity should be measured If INFINITY is measured repair or replace Wire 4 5 Connect one meter test lead across Wire 0 Pin 12 at the C1 connector female side Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors Connect the other meter test lead to Wire 0 at the brush assembly Continuity should be measured If INFINITY is measured repair or replace Wire 0 Unplug the six pin connector at the Voltage Regulator Locate the male side of Connector 1 located the bottom of the control panel See Figure 6 19 Connect one meter test lead to Pin 11 Wire 4 Connect the other meter test lead to Wire 4 at the six pin connector previously removed from the Voltage Regulator See Figure 6 11 Be
107. ne meter test lead to wire 15 just removed Connect the other meter test lead to frame ground INFINITY should be measured RESULTS If INFINITY was not measured a short on Wire 15 to ground exists Inspect each wire 15 for a shorted con dition Repair or replace as needed TEST 46 CHECK WIRE 14 CIRCUIT PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Wire 14 from the Start Stop relay SSR 3 Connect one meter test lead to Wire 14 previously removed Connect the other meter test lead to frame ground Approximately 38 ohms should be read RESULTS Refer back to flow chart TEST 47 CHECK FUEL SHUTOFF SOLENOID FSS PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect the plug from the Fuel Shutoff Solenoid FSS 3 Connect one meter test lead to one pin on the FSS Connect the other meter test lead to the remaining pin in the FSS Approximately 38 ohms should be measured 4 Connect one meter test lead to one pin on the FSS Connect the other meter test lead to frame ground INFINITY should be measured Page 61 Section 6 DIAGNOSTIC TESTS RESULTS 1 If continuity or zero was measured in Step 3 or Step 4 replace the FSS 2 Units without Hourmeter If correct resistance was measured refer to flow chart repair or replace Wire 14 between the FSS and Resistor R1 3 Units with Hourmeter Refer back to flow chart TEST 48 CHECK HOURMETER PROCEDURE 1 Disconne
108. o close connecting Wire 15 12 VDC battery supply to Wire 15B Wire 15B now supplies 12 VDC to the printed circuit board for use with the governor control system The normally closed contacts now open Wire 18 is no longer con nected to Wire 0 and the magnetos are no longer grounded out and can produce spark Page 23 Section 4 ENGINE DC CONTROL SYSTEM 22 11 118 1 5 C1 12 4 C1 10 4 S 44 C1 2 RED POWER WINDING BA DPE WINDING BATTERY CHARGE WINDING FIELD 77 herendi r 55A 2 6 4 0 C1 4 4 C1 3 10A BATTERY CHARGE WINDING 66 22 C1 9 55 e 77 44 44 66A II 15 77 E BOR 12 4 II 13A ORISA Gem 0 77 y A 1 mmo 2 B162 JL ELECTRONIC Bs II ri REGULATOR 4 6 TH LE GOVERNOR ACTUATOR 86 167 158 115 229 TR2 0 83 9 8 7 6 5 4 3 2 1 J2 CONTROL PRINTED CIRCUIT J1 CIRCUIT CONDITION RUN Once the engine has started the Start Run Stop Switch SW1 is released and will be in the run position at this point SW1 is not activated This action will de energize the Starter Contactor Relay SCR causing the Starter Motor to disengage Printed circuit board action keeps Wire 229 held to ground this action holds the Start Stop Relay SSR energized With the SSR energized Wire 14 maintains 12 VDC to the Fuel Shutoff Solenoid Once the V
109. ole and a single south magnetic pole As the rotor rotates its lines of magnetic flux cut across the stator assem bly windings and a voltage is induced into the stator windings The rotor shaft mounts a positive and a negative slip ring with the positive slip ring nearest the rear bearing carrier Figure 3 2 The rotor bearing is pressed onto the end of the rotor shaft The tapered rotor shaft is mounted to a tapered crankshaft and is held in place with a single through bolt ADAPTOR 7 REAR BEARING CARRIER Figure 3 1 AC Generator Exploded View Page 9 Section 3 DESCRIPTION amp COMPONENTS Figure 3 2 The 2 Pole Rotor Assembly STATOR ASSEMBLY The stator can houses and retains a dual AC power windings b an excitation winding and c two bat tery charge windings A total of thirteen 13 stator leads are brought out of the stator can as shown in Figure 3 3 The stator can is sandwiched between an engine adapter and a rear bearing carrier It is retained in that position by four stator studs Figure 3 3 Stator Assembly Leads BRUSH HOLDER AND BRUSHES The brush holder is retained to the rear bearing car rier by means of two Taptite screws A positive and a negative brush are retained in the brush holder with the positive brush riding on the slip ring near est the rotor
110. oltage Regulator starts functioning the field boost circuit is no longer a factor in operation With the SSR energized Wire 15B main tains 12 VDC to the printed circuit board With the SSR energized Wire 18 is not grounded and the magnetos con tinue to produce spark The two independent battery charge windings are now producing AC voltage and supplying this to BCR1 and BCR2 The AC voltage is rectified through BCR1 and used to supply DC voltage to the 12 VDC accessory outlet The AC voltage is rectified through BCR2 and used to supply DC voltage to the battery for battery charging Page 24 Section 4 ENGINE DC CONTROL SYSTEM 120V 120V DUPLEX GFCI 22 n 120V 30A 120V 30A TWISTLOK TWISTLOK LEGEND BA BRUSH ASSEMBLY BCR1 BATTERY CHARGE RECTIFIER 10A BCR2 BATTERY CHARGE RECTIFIER CB1 10 AUTO RESET BREAKER CB2 5 AUTO RESET BREAKER D1 600 12A DIODE D2 D3 ENGINE SHUTDOWN DIODE F1 10A FUSE FSS FUEL SHUT OFF SOLENOID GND GROUND BAR 1 IDLE CONTROL TRANSFORMER IM1 IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 LOP LOW OIL PRESSURE R1 25 OHM 25W RESISTOR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 SP2 SPARK PLUG CYL 2 SSR START STOP RELAY SW1 START RUN STOP SWITCH SW2 IDLE CONTROL SWITCH TB1 TB2 TERMINAL BLOCK
111. onsumption The Cylinder Leak Down Tester Generac P N 0F77000SRV checks the sealing compression abil ity 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 TDC Both valves should be closed 4 Lock the flywheel at top dead center 5 Attach cylinder leak down tester adapter to spark plug hole 6 Connect an air source of at least 90 psi to the leak down tester 7 Adjust the regulated pressure on the gauge to 80 psi 8 Read the right hand gauge on the tester for cylinder pressure 20 percent leakage is normally acceptable Use good judgement and listen for air escaping at the carburetor the exhaust and the crankcase breather This will determine where the fault lies 9 Repeat Steps 1 through 8 on remaining cylinder RESULTS Air escapes at the carburetor check intake valve Air escapes through the exhaust check exhaust valve Air 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 the engine to start
112. pe 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 frequency 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 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 generator A 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 regulated volt age is induced into the STATOR Regulated current delivered to the ROTOR is called EXCITATION cur rent STATOR STATOR AC OUTPUT BRUSHES SLIP RINGS z ao Q Figure 1 6 A More Sophisticated Generator See Figure 1 7 next page The revolving magnet ic field ROTOR is driven by the engine at a con stant speed This constant speed is maintained by a mechanical engine governor Units with a 2 pole rotor require an operating speed of 3600 rpm to deliver a 60 Hertz AC output Generator operation may be described briefly as fol lows 1 Some residual magnetism is normally present in the Rotor and is sufficient to
113. pressure gauge and reinstall the oil pressure Switch Do NOT connect Wire 86 or Wire 0 to the switch termi nals a Set a voltmeter to measure resistance b Connect the meter test leads across the switch terminals With engine shut down the meter should read CONTINUITY c Crank and start the engine The meter should read INFINITY d Connect one test lead to Wire 0 disconnected from LOP Connect the other test lead to a clean frame ground CONTINUITY should be measured If CON TINUITY is NOT measured repair or replace Wire 0 between the LOP and the ground terminal connection on the engine mount If the LOP switch tests good in Step 3 and oil pressure is good in Step 2 but the unit still shuts down with a LOP fault check Wire 86 for a short to ground Set a voltmeter to measure resistance Disconnect the J2 Connector from the circuit board Remove Wire 86 from the LOP switch Connect one test lead to Wire 86 Connect the other test lead to a clean frame ground INFINITY should be measured If CONTINUITY is measured repair or replace Wire 86 between the LOP switch and the J2 Connector B RESULTS 1 If switch tests good refer to Flow Chart 2 Replace switch if it fails the test TEST 43 CHECK START STOP RELAY SSR PROCEDURE 1 Set a voltmeter to measure resistance 2 Disconnect Wire 15 and Wire 229 from the Start Stop Relay SSR See Figure 6 54 3 Connect one meter test lead to the terminal that Wire 1
114. put Once through the resistor and diode it becomes Wire 4 and Wire 4 then connects to the positive brush 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 Notice that field boost current is always available dur ing cranking and running this is because the SSR is energized the whole time The diode D1 prevents or blocks the Voltage Regulators higher DC output from reaching the Wire 14 run circuit Field boost voltage is reduced from that of battery voltage by the resistor R1 and when read with a DC voltmeter will be approximately 9 or 10 volts DC OPERATION STARTUP When the engine is started residual plus field boost magnetism from the rotor induces a voltage into a the stator AC power windings b the stator excitation or DPE windings c the stator battery charge wind ings In on speed engine cranking condition residual plus field boost magnetism are capable of creating approximately one half the unit s rated volt age ON SPEED OPERATION As the engine accelerates the voltage that is induced into the stator windings increases rapidly due to the increasing speed at which the rotor operates Page 12 FIELD EXCITATION An AC voltage is induced into the stator excitation DPE windings The DPE winding circ
115. r grounded armature 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 Page 49 Section 6 DIAGNOSTIC TESTS 3 A defective Starter Motor switch 4 Broken damaged or weak magnets 5 Starter drive dirty or binding PROCEDURE The battery should have been checked prior to this test and should be fully charged Set a voltmeter 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 If 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 NOTE If a starting problem is encountered the engine itself should be thoroughly ch
116. rotor may be necessary After cleaning and drying repeat the insu lation breakdown test If breakdown lamp comes on during the second test replace the rotor assembly CLEANING THE GENERATOR Caked or greasy dirt may be loosened with a soft brush or a damp cloth A vacuum system may be used to clean up loosened dirt Dust and dirt may also be removed using dry low pressure air 25 psi maximum CAUTION Do not use sprayed water to clean the generator Some of the water will be retained on generator windings and terminals and may cause very serious problems DRYING THE GENERATOR To dry a generator proceed as follows 1 Open the generator main circuit breaker NO ELECTRICAL LOADS MUST BE APPLIED TO THE GENERATOR WHILE DRYING 2 Provide an external source to blow warm dry air through the generator interior around the rotor and stator windings DO NOT EXCEED 185 F 85 C 3 Start the generator and let it run for 2 or 3 hours 4 Shut the generator down and repeat the stator and rotor insula tion resistance tests Page 15 Section 4 ENGINE DC CONTROL SYSTEM PRINTED CIRCUIT BOARD GENERAL The printed board is responsible for cranking startup running and shutdown operations The board intercon nects with other components of the DC control system to turn them on and off at the proper times It is pow ered by fused 12 VDC power from the unit battery CIRCUIT BOARD CONNECTIONS The circuit board mo
117. rt the generator The amp reading on the voltmeter should be approximately 0 6 Amps Apply full load to the generator The amp reading should increase to approximately 2 Amps RESULTS 1 If amperage was measured between 0 6 to 2 Amps in Step 2 and Step 3 the charging system is working 2 If no amperage was measured check the voltmeter fuses and verify the functioning of the Amp Meter If DC Amp Meter is good and no current is measured refer to flow chart TEST 18 CHECK 10 AMP BATTERY CHARGE OUTPUT PROCEDURE NOTE The battery charge cable must be connect ed to the 12 VDC panel receptacle and be charging a separate battery to perform this test 1 Disconnect Wire 13A center terminal from the Battery Charge Rectifier 1 BCR1 which is located on top of BCR2 they are stacked See Page 17 for BCR1 location 2 Set a voltmeter to measure DC Amperage Connect the posi tive test lead to the center terminal of the Battery Charge Rectifier Connect the negative test lead to Wire 13A previ ously disconnected See Figure 6 24 Figure 6 24 Testing BCR1 3 Start the generator The amp reading on the voltmeter should be approximately 0 2 Amps Apply full load to the generator The amp reading should increase It will depend upon the state of charge of the battery as to how high current will get Normal ranges at full load can be 3 7 amps but can get as high as 10 amps RESULTS 1 If amperage was measured
118. sting at Slip Rings TEST 15 CHECK LOAD VOLTAGE amp FREQUENCY PROCEDURE Perform this test in the same manner as Test 1 but apply a load to the generator equal to its rated capac ity With load applied check voltage and frequency Frequency should not drop below about 59 Hertz with the load applied Voltage should not drop below about 235 VAC with load applied RESULTS 1 If voltage and or frequency drop excessively when the load is applied go to Test 16 2 If load voltage and frequency are within limits end tests TEST 16 CHECK LOAD WATTS amp AMPERAGE PROCEDURE Add up the wattages or amperages of all loads pow ered by the generator at one time If desired a clamp on ammeter may be used to measure current flow See Measuring Current on Page 7 RESULTS 1 If the unit is overloaded reduce the load Section 6 DIAGNOSTIC TESTS 2 If load is within limits but frequency and voltage still drop excessively refer back to Flow Chart TEST 17 CHECK BATTERY CHARGE OUTPUT PROCEDURE 1 Disconnect Wire 15 center terminal from the Battery Charge Rectifier 2 BCR2 which is located under BCR1 They are stacked See Page 17 for BCR2 location Figure 6 23 Testing BCR2 2 Set a voltmeter 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 Sta
119. t ger ciRcUIT 10 WHT id NEUTRAL CIRCUIT 8 NEUTRAL Rc circuit 6 Page 83 Section 8 ELECTRICAL DATA INTERCONNECTION DRAWING 17 5 KW GENERATOR CONNECTED TO THE EXTERNAL CONNECTION BOX MANUAL TRANSFER SWITCH AND HOME S MAIN ELECTRICAL DISTRIBUTION PANEL 61 y o a 41 o 91 T al Sac o SEE i CS 22 e Suvg WHLNAN 9 9 GNNOYD uaxvauga HOLIMS H34SNYH L 8 9
120. tional to Rotor speed Generators equipped with a 2 pole Rotor must operate at 3600 rpm to supply a frequency 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 Section 2 MEASURING ELECTRICITY engine speed governor For models rated 60 Hertz the governor is generally set to maintain a no load fre quency of about 62 Hertz with a corresponding output voltage of about 124 volts AC line to neutral Engine speed and frequency at no load are set slightly high to prevent excessive rpm and frequency droop under heavy electrical loading MEASURING CURRENT CLAMP ON 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 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 conductors CONDUCTOR MAGNETIC FIELD CLAMP ON AMMETER ATTACHMENT LINE SPLITTER Figure 2
121. tor only conjunction with the Diagnostic Tests of Section 6 iani i i Numbered tests the Flow Charts correspond to connor aye identically numbered tests of Section 6 If Problem Involves AC Output TEST 1 CHECK NO LOAD VOLTAGE amp FREQUENCY NO LOAD VOLTAGE amp VOLTAGE amp FREQUENCY GOOD FREQUENCY GOOD ZEROVOLTAGEAND FREQUENCY GOOD FREQUENCY BOTH ZERO RESIDUAL HIGH LOW ME LN VOLTAGE VOLTAGE FREQUENCY l FALLS OFF UNDER LOAD GO TO PROBLEM 1 GO TO VOLTAGE GO TO PROBLEM 2 GOTOPROBLEM2 GOTO PROBLEM 3 BELOW REGULATOR ADJUSTMENT PAGE 11 Problem 1 Voltage amp Frequency Are Both High or Low FREQUENCY IS GOOD TEST 5 CHECK BUT NO LOAD EAT STEPPER MOTOR VOLTAGE IS DjUSTMENT CONTROL PR PAGE 11 Page 28 Section 5 TROUBLESHOOTING FLOWCHARTS Problem 2 Generator Produces Zero Voltage or Residual Voltage 2 12 VAC TEST 2 CHECK MAIN CIRCUIT TEST 3 TEST EXCITATION BREAKER CIRCUIT BREAKER RESET TO ON GOOD PROCEED BAD PROCEED REPLACE AFTER TESTS CONCLUDE OR REPLACE IF BAD TEST 4 PERFORM FIXED EXCITATION D ROTOR 4 DRAW TEST 6 WIRE CONTINUITY aon BAD STATOR o REPAIR TEST 11 EXCITATION 0 WIRING REPLACE BAD REPAIR GOOD OR REPLACE THEN RETEST INSULATION REPLACE RESISTANCE BAD
122. two wires removed from the resistor R1 RESULTS 1 If the diode or resistor failed any step it should be replaced TEST 9 TEST STATOR PROCEDURE 1 From the 50 Amp circuit breaker disconnect Wires 11 and 44 2 From the 50 Amp receptacle disconnect Wire 22 3 Disconnect Connector C1 See Page 17 for connector location 4 Set a voltmeter to measure resistance 5 Connect the meter test leads across Stator leads 11 and 22 Normal power winding resistance should be read 6 Connect the meter test leads across Stator leads 44 and 22 Normal power winding resistance should be read 7 Connect the meter test leads across Stator leads 11S Pin 1 and Stator lead 44S Pin 2 at the C1 connector female side See Figure 6 18 Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors Normal power winding resistance should be read 8 Connect the meter test leads across Stator leads 66A Pin 4 and Stator lead 77A Pin 5 at the C1 connector female side See Figure 6 18 Be careful not to damage the pin connectors with the test leads use paper clips do not force probes into connectors Normal battery charge winding resistance should be read Section 6 DIAGNOSTIC TESTS PIN LOCATION 1 PIN LOCATION 6 PIN PIN LOCATION LOCATION 12 7 Figure 6 18 C1 Connector Female Side
123. uit is completed to the Voltage Regulator via Wire 2 Excitation Circuit Breaker Wire 162 and Wire 6 Unregulated alternat ing current can flow from the winding to the regulator The Voltage Regulator senses AC power winding output voltage and frequency via stator Wires 11S and 44S The regulator changes the AC from the excitation winding to DC In addition based on the Wires 11S and 44S sensing signals it regulates the flow of direct current to the rotor The rectified and regulated current flow from the regu lator is delivered to the rotor windings via Wire 4 and the positive brush and slip ring This excitation current flows through the rotor windings and is directed to ground through the negative slip ring and brush and Wire 0 The greater the current flow through the rotor wind ings the more concentrated the lines of flux around the rotor become The more concentrated the lines of flux around the rotor that cut across the stationary stator windings the greater the voltage that is induced into the stator windings Initially the AC power winding voltage sensed by the regulator is low The regulator reacts by increasing the flow of excitation current to the rotor until volt age increases to a desired level The regulator then maintains the desired voltage For example if voltage exceeds the desired level the regulator will decrease the flow of excitation current Conversely if voltage drops below the des
124. unts a 12 pin receptacle J2 and a 5 pin receptacle J1 Figure 4 2 shows the 12 pin receptacle J2 the associated wires and the function of each pin and wire DIP SWITCH POSITIONS Note These switches must remain in the positions set at the factory 1 Stepper Motor Rotation Switch set to ON for clockwise rotation Factory Position b Switch set to OFF for counterclockwise rotation 2 Frequency Setting a Switch set to OFF for 60 Hertz Factory Position b Switch set to ON for 50 Hertz o o o o o o o o o o o o J2 CONNECTOR J1 CONNECTOR Figure 4 1 Printed Circuit Board Page 16 TERMINAL WIRE FUNCTION 1 15B 12 VDC input when the Start Stop Relay SSR is energized 2 83 Ground input when the idle control switch SW2 is placed in the closed position 3 TR1 AC voltage input from the idle control transformers 4 0 Common ground for the PCB 5 167 12 VDC input when SW1 is placed in the Start position Ground input when SW1 is placed in the Stop position 6 TR2 AC voltage input from the idle control transformers 86 7 Fault shutdown circuit When grounded by closure of the Low Oil pressure switch LOP engine will shut down 8 229 Switched to ground for Start Stop Relay SSR operation 9 NOT USED 1 44S input for frequency control 115 445 240VAC 1 0 1 NOT USED 2 1 118 input for frequency control 115 445 240VAC Note J1 Connector is utilized
125. ved 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 A Simple Revolving Field Generator Page 3 Section 1 GENERATOR FUNDAMIENTALS A SIMPLE AC GENERATOR Figure 1 4 shows a very simple AC Generator The generator consists of a rotating magnetic field called a ROTOR and a stationary coil of wire called a STATOR The ROTOR is a permanent magnet which consists of a SOUTH magnetic pole and a NORTH magnetic 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 direc tion Current flows in the opposite direction when the magnet s SOUTH pole passes the STATOR This con stant reversal of current flow results in an alternating current AC waveform that can be diagrammed as shown in Figure 1 5 The ROTOR may be a 2 pole type having a single NORTH and a single SOUTH magnetic pole Some ROTORS are 4 pole ty
126. voltage and frequency Problems 1 through 5 in the Flow Charts Tests 19 through 54 are procedures involving prob lems with engine operation Problems 6 through 14 in the Troubleshooting Flow Charts It may be helpful to read Section 2 Measuring Electricity NOTE Test procedures in this Manual are not nec essarily the only acceptable methods for diagnos ing the condition of components and circuits All possible methods that might be used for system diagnosis have not been evaluated If any diag nostic method is used other than the method pre sented in this Manual the technician must ensure that neither his personal safety nor the product s safety will be endangered by the procedure or method that has been selected TEST 1 CHECK NO LOAD VOLTAGE AND FREQUENCY PROCEDURE 1 Disconnect or turn OFF all electrical loads connected to the generator 2 Set a volt meter to measure AC voltage 3 Reset all circuit breakers to the on position 4 Turn the Idle Control switch to OFF 5 Start the engine and let it stabilize and warm up Figure 6 1 VOM Test Leads Connected to 50A Outlet NOTE If the generator is not producing AC Power loss of governor control may occur caus ing an overspeed or extremely high RPM condi tion If this condition occurs manually control throttle 60Hz 3600 RPM to perform test 6 Place the meter test leads into the 50A outlet See Figure 6 1 7 Read the AC volt
127. y with provided battery charge cables INSULATION RESISTANCE The insulation resistance of stator and rotor wind ings is a measurement of the integrity of the insulat ing materials that separate the electrical windings from the generator steel core This resistance can degrade over time or due to such contaminants as dust dirt oil grease and especially moisture In most cases failures of stator and rotor windings is due to a breakdown in the insulation In many cases a low insulation resistance is caused by moisture that collects while the generator is shut down When problems are caused by moisture buildup on the windings they can usually be corrected by drying the windings Cleaning and drying the windings can usu ally eliminate dirt and moisture built up in the genera tor windings THE MEGOHMMETER GENERAL megohmmeter often called a megger consists of a meter calibrated in megohms and a power supply Use a power supply of 500 volts when testing stators or rotors DO NOT APPLY VOLTAGE LONGER THAN ONE 1 SECOND TESTING STATOR INSULATION All parts that might be damaged by the high meg ger voltages must be disconnected before testing Isolate all stator leads Figure 3 9 and connect all of the stator leads together FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY Use a megger power setting of 500 volts Connect one megger test lead to the junction of all stator leads the other test lead to fram

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