Troubleshooting Guide for Stamford Generators TB056

Bulletin Number: TB056

Type of Bulletin: Troubleshooting
Products Affected: TracStar 630/900/1200
Dates Manufactured: All
Date of Notification: July 2009

Description of Bulletin
This is a troubleshooting guide for Stamford generators BCI184E (McElroy #MDC00025), PI144E
(McElroy #MDC00074), and PI144J (McElroy #MDC00077). This document will guide you through
verifying proper engine RPM and adjusting the generator voltage. It also instructs how to check the
residual voltage and perform a field flash.

Reason for Bulletin

To make a preliminary evaluation in order to determine if the unit is providing adequate power.

Tools Required
 True RMS digital multimeter with frequency measuring capability
 Needle nose pliers
 #2 Cross tip (Phillips) screw driver
 8mm or 5/16 nut driver or socket with driver
 1/8” wide flat blade screwdriver
 1 amp (minimum) diode (1N4007 or equivalent)

Procedure
Engine RPM - Model BCI184

1. Open engine hood. Remove front fiberglass cowling.

2. Remove generator cover to measure with multimeter.

3. Set multimeter to measure frequency (Hz).

4. Start engine and put in high throttle.

5. Measure from output W to output V as indicated by arrows.

6. Adjust throttle linkage to obtain reading of 60 (+/-1) Hz.

Technical Bulletin: TB056 1 REV. C 12/10/20

 Troubleshooting Guide for Stamford Generators TB056

Engine RPM - Model PI144

1. Start engine and set to high throttle.

2. View engine RPM displayed on console.

3. Verify engine speed is 1800 (+/-25) RPM.

4. If the RPM is out of spec, call McElroy Tech Support.

Output Voltage - Model BCI184

1. Open engine hood. Remove front fiberglass cowling.

2. Unplug heater cable.

3. Remove generator top cover to access terminals and outboard

side cover to access Automatic Voltage Regulator (AVR).

4. Start engine and put in high throttle.

5. Measure phase-to phase voltages at generator terminals:

Measure from W to V, then from W to U, then from V to U. Each
phase should read 240(+/-5) volts.

NOTE: If voltage is very low or zero, shut off engine

and go to “Check Residual Voltage.”

6. Locate voltage potentiometer at bottom left side of AVR. Adjust

potentiometer until meter reads 240(+/-5) volts.

7. Shut off engine and reinstall covers.

8. Re-connect the heater power cable.

Output Voltage - Model PI144

1. Remove front fiberglass cowling.

2. Remove generator outboard side cover to access Automatic

Voltage Regulator (AVR).

3. Start engine and set to high throttle. Turn heater off.

4. Make sure GFCI is not tripped.

5. View displayed voltage on front panel meter. Reading should be

240(+/-5) volts AC.

Technical Bulletin: TB056 2 REV. C 12/10/20

 Troubleshooting Guide for Stamford Generators TB056

6. Locate voltage potentiometer at top left of AVR. Adjust

potentiometer until meter reads 240(+/-5) volts.

7. Shut off engine and reinstall covers.

Residual Voltage Check

Perform this test if voltage is very low (or zero) and fuses are
good/GFCI is not tripped. 8

1. With engine OFF, remove covers from top and outboard side 7
from generator.

2. Inspect all connections. Make sure crimps are good and

generator terminals are tight. F1

3. Inspect wires for worn places of signs of shorting against F2

generator enclosure. Repair any damage.
BCI184
4. Disconnect wires F1 & F2 from Automatic Voltage Regulator E
(AVR). Secure wires to insure terminals cannot touch anything.

5. Start the engine and set to high speed.

6. Measure AC volts from terminal 7 to terminal 8. Reading should

be at least 5 volts. If not, proceed to Field Flashing.

PI144
Field Flashing
E
1. Reconnect leads F1 & F2 to their respective terminals.

2. Connect a wire from negative battery terminal to F2.

WARNING! Do not use TracStar’s battery for field flashing.
Battery cannot be connected to chassis ground.

3. Connect a wire from cathode of diode (end with stripe) to F1.

4. Connect a wire from positive battery terminal to anode of diode

(end without stripe).
WARNING! A diode must be used to prevent AVR damage.

5. Start engine and measure voltage from terminal 7 to terminal 8.

It should be between 170 and 250 volts.

6. Turn off engine.

7. Remove wires and diode. Re-install all covers.

Technical Bulletin: TB056 3 REV. C 12/10/20

 Troubleshooting Guide for Stamford Generators TB056

Downloads

For more in-depth troubleshooting, go to www.stamford-avk.com and download these two

manuals. Follow the instructions within to determine and repair the generator fault.

Replacement AVR Part Numbers:

McElroy #MDC00060 AVR for BCI184

McElroy #MDC00061 AVR for PI144

If no problem is found and the generator is still not producing adequate power, check the
machines In-Service date on the McElroy website (www.mcelroy.com). If it is less than one year
from that date, contact McElroy Manufacturing for possible warranty evaluation. If it is after that
period, contact Cummins Generator Technologies (Newage) at 1-800-367-2764 for further
troubleshooting.

Technical Bulletin: TB056 4 REV. C 12/10/20

 TECHNICAL BULLETIN REVISION HISTORY LISTING
PART NO: TB056
DESCRIPTION: TROUBLESHOOTING GUIDE FOR STAMFORD GENERATORS

CHK/APR REV DATE BY DESCRIPTION OF REVISION

MRP A 5/10/11 RLT ON SHEET 3, NOTE #6 CORRECTED ’50 TO 61 HERTZ’ TO ’59 TO 61 HERTZ’.
SRB/JAL B 9/25/15 RLT REVISED TO CHANGE THE WARRANTY MENTIONED IN THE DOCUMENT
FROM TWO YEARS TO ONE YEAR.
BEA/BWJ C 12/10/20 BEA RE-WRITTEN TO INCLUDE GENERATORS FOR T630/T900 SERIES 1,
T630/T900 SERIES 2, AND T1200.