a i Service ManualTable of Contents Pose Introduction. i Service Assistance : Safety Procautions 4 restart Checklist... a ‘Section 1. Fact Responce il Concepts. 14 ‘General System. 4 ‘Short Circuit Performance coat ‘Section2. Operation. ee a etsy Contol Operation. rse- a Misracomputee Operation =n 2a Remote Annuneiatr. ae. Alarm Hom. So 28. Seleguara Braker. OOD 2s Line Crout Breaker. : 26 Section 3. ‘Controller Troubleshoating a eisy ContolerSequence of Operation 10, Batory High Volts- lamp ights if battry or charg Ing votage exesnde 16 vote for 12a systeme: 30 ‘oltsfor2¢-vot eysters (wi als ight aver votage ‘Secure duetobatterychargermafention not operating. 11, Battery Low Votts-lamp lights baton or enarging ‘otlage drops below 10 volts for 12k aystoms; 20, ‘ots: 2a eytars\willaleo igh funder voltage ocuts due fo baton oF charger maltunction while ‘etie not operating) 12, Low Fuel (itequipped) lamp ightsitteltanklove! spprcaches emi. 19, System Ready-lam lights when Generator Master Swen is in AUTO or TEST postion and systom senses NO faut ‘Switches: 14, Selector Switch (VoltmeterAmmeter)~ selects generator outout veuis to be maacuros Howiched {oa point wh three ret load labels, vege ‘reesured between the lower to leads ana emer {oe onthe voper load With rwtehinOFF postion AC ‘olmeter and ammeter wil not egster. 16, Seale Lamps (upper, lower) ~ indicate votimeter 16. Lamp Test= used to tet inate ames 2aMicrocomputer Controller Operation - cont'd. 17, Generator Master Switeh ~ see "Testing, Staring ‘3nd Stopping’ feiowing 15, Voltage Adjustment-used to fine-acust generator output vollage Meters: 18, Hourmeter-rocores tts! generator set operating hours for feferenco in maintenance scheduling 20. AC Ammeter ~ measures amperage trom output leads Indicate by selector switch 21, BE Voltmeter - measures voltage of starting bat: ‘enyiogycharging eystom, 22, AC Voltmeter ~ measures voltage across output Toads ndeste by selector switch 23, Oil Pressure measures engine ol pressure 24, Water Temperature ~ measures engine coolant 25. Frequency Meter - moasures frequency (He) of ‘Senertor dtp! wotane + s-amp-protect remote annunciater cet. amp ‘Sreut boars, ang alarm nom ciel eauigped). S"hamppreects conto! ccul Board and conto tol col. 1S 1eAmp-proects engine DC and primary stating Nove Enrier models usine a3 Ama. sete protect Femeteannuncatorancalarmhornceous A ‘Camp fuse protects contol and lama circuit boards ane conta lay cos “TEST” Starting ‘To stan the generator set atthe controller, move the Generator Maser Swath tthe TEST poston “AUTO” Starting Move Generator Master Swit te AUTO postion tlow Startup by automatictranster switch orrometo statstop [witch connected To controler terminale 3 ane &. NOTE “The Mirocomouter Contrller provides upto 0 seconde of cyte evanking ~ evank 10 ‘Seconds fest 10 seconds, crank 10 seconds (te Three erank/ost cyte, fora ttl of 60 ‘Seconds before overerank shutdown, ‘Stopping +. Disconnect lsd rom genertr set an allow it 9 un ‘nloaced for 5 minutes Nove unthegenertorstoloadtor$ minutes ror {e stopping to naure aceauate cooling of he ae 2, Move Generator Master Switon to OFF/RESET poston Engine wil ston engine stopiesionsledby aremotesuitchot ‘Automate Tranter Switch the generator est weil Keep running for a coordown cycle of Sminstes Emergency Stopping ‘Tun Generator Master Switch 19 OFF/RESET, or operato remota.mergenoy top etch equipped forimmediate shutdown Fault Shut-downs “The generator set wil hut own automaticaly under the following faut coneitions: OVERCRANK: ‘See “Overerank’ preceeding, HIGH TEMPERATURE: Snctdown occurs 4stconds ter faut caurion Hichtemperaturesnutcown wt notfunetionit prope calant evel ie not maintained! LOW COOLANT LEVEL Shutdown occurs 4secondsatter (equppes) faut © LOW OIL'PRESSURE: Snutsown occurs ¢seconds ater fault 68 0 108 pe (8 to 72 KPa} on dese! models) 11 t0 3859s (7010 1264) on gato- line mocets. = NoTE 4% High temperature, low coolant lve, and low ‘lbreseureshutsowre wil not funeton within ‘he frat 30 veconde afer start-up. caurion Low ll pressure shutdown wil not function {ue ofa tre en Cheek for proper ai levelat engine. ovensPEeD: Unit shuts down immediate goremedtrequency exceecs 70 HroneoHseets,or60Hs 0060 He cots OVERVOLTAGE: _Untilshutdownatter approx (iteauippes ‘mately one second af 15% oF ‘nore over nominal votace, EMERG. STOP lamp wil ight. caution Senatve equipment may suter damage in leas than one second of an overvtiage com Gton. Omtine equipment requiring taster ‘Shutdown should nave ls own overvoage betecton OperationResetting Use tne folowing procedure to recta oet ater a fale shutdown 1. Move Generator Master Suith to OFF/RESET pos: 2 Disconnect generator set fom load with line circuit breaker or automatic raneter such {8 Corect cause of fault shutdown. St 4. Move Generator Mester Switch fo TEST peation for ‘erty that eause of snutdown nas been covected 7. Move Generator Master Swite to necessary poston (AUTO or Tes torser-un “Safety Pre Remote Annunciator (De Figure 2-4. Remote Annuncistor (De 0 Monon) ‘An annunstor may be located a work station romote ‘generators to alow com thosetssonditon Decslon Montorshaveth incialor as tha Mirocompute contrat, pls the for Towing (eee Figure 2 ‘Line Power-indictes commercial uty powerinuse. 1 Generator Poner-Incioates generator owe in use. {Alarm Switen OH indicates ALARM switch in OFF ‘¢ Alarm Horn-sounds fan fautorantcioatorycond Alarm Horn (if equipped) ‘he generator set mey be equipped wih a unit mounted lar nom and alarm switen The slr saftch may Be Used sloncethe alam norma servicing Figure 25. Operation Figure 25, Alarm Hom Switoh Safeguard Breaker (if equipped) .90ard Bresker senses output curant on each for ohase, and wil st off the AC vag regu Istorinthe event ofa sustained cverioad or short ett isnot ine sveut breaker, and wil not daconnect the {generator om the load See Figue 2. A wannine ‘SHOCK HAZARD! Votage maybeincueedin fond creuts with Saeguara Srsker open. ‘Tnerels potential danger of electrocution or shock. Use line eveutt breaker of tanster ‘Ste to laconnect generator fom load Figure 26. Safeguard Breaker 25Line Circuit Breaker (if equipped) ‘event ofan overioad or short cicurt It should be opened Iranualy fo disconnect the generator from load omicng generator set Soe Pogue 27, 26 OperationSection 3 CONTROLLER TROUBLESHOOTING Relay Controller ‘Sequence of Operation (with or without meters) “The controle isthe controling point for generator set ‘operation. Te flowing sequence of operation should serve ts a good starting point in fault detection. Refer to Figure "1 and 92 olay Sequence of Operation when roubleshoting Figure 3-1, Relay Control Relay Creu Boara Sten (78) tra} for Rest Ste (175) Time Limit 8, ConnectoreP3, Pa) not used Cranking ~ Move MasterSuitchtoTEST poston or ALTOpostion If Sonneced to ransferewteh for automatotart 0) ~ Gf Relay energizes CR contacts close energizing he ‘SS fetarer solenoid) relay and the fuel solenok or ignition col FS). ~ CurrentwillowheutheTSwiten andnoemally closes S*Gn contacts. Tne optional engine gauges vorage equator nourmate: and battery charging alternator are cts close, energizing the aarter motor Starter motor ernie the eine Controller Troubleshooting 2, Connector (P8) DC to Engine through P1/J1 10. Formna Srp (ae wing agro for conections) 415. Connector (P0), O€ to Controller 436. Ton melay, 120.VoR AC Cranking Disconnect Cranking Disconnect As engine stats and generator votage bulle-up, the GR Rely wil enersize. = The SCR Relay contacts open, deenerizing the SS = 89 Relay contate will open, isconnecting the starter motor (Sh. = The TCR contects wil open, deenergzing the 17S = © Felay is energizes by Battery charging aerator. = C6 contacts open, daconnectng the SS Relay = sScontate open, disconnecting thestartermotor SM. 34Running ‘The 10R, OR and CC Relays ae enerized. Stopping ~ Move Master Switch to OFF postion. = CR Relay deoneraizes. CR Rey contacts open shut ting of te ua eotanod (FS). = CC and 1CR relays deeneroize Fault Shutdowns SAFEGUARD BREAKER (see “Operation") ~ fsaleguard breaker opens, batter voltage’ shtofto the votape regulator resulinginatossot generator AC output ~ XR Relay deonergizes 1CR Rely contacts ove 1TS ‘atch lume cutnapprexirately 80-60 seconds the STS win tepcaucing the CR relay to deenorgize Reset lamp wil ig = GR relay contacts open, shuting off fuel eolenoid or ‘gnilon call) Engine stops. LOW OlL PRESSURE ~ Low ol pressure causes LOP contacts to cose. = ATS ewten wil time out causing the GR relay to de- energize = CR relay contacts open, shuting of uel solenoid or Igntlon eal 3) ~ Reset amp ignis. 32 HIGH WATER TEMPERATURE ~ High water tomperature causes HWT contacts to close. = TTS swt wil tine out, causing the CR clay to de- energize Reset amp wil igh. ~ CR relay contacts open, shutting of fuel soencid or Ignition coi (FS). LOW COOLANT LEVEL (i equipped) low coolant evel causes coolant lave witch to cose = ATS switch wil time out. causing the CR relay to eonergie. Reset amo wil lent + CR relay contate open, shuting ot us solenoid or ‘gaiten cal 3) ‘OVERCRANK + Ate 90-60 seconds of cranking, the 168 relay wil not (neroie. Current wil stil be flowing thru TS owen STS wil tme out causing the CR rely 1 deenerpiae Reset amp wil ight + CA relay contace ope, shutting off he SS ray ue solenoid or gion co (FS). Fuse Cone 1-Amptuselocttedinthe controle protects agalnet damage in te event of wiring short ceult or cult ‘verous I the fuse “lows” geneatr set wl stop, Unit wil not erank ith blown fuse I eet has stopped due to {Causes other tne ace of fue or fat shu-cown—heck the uae blown, replace the fe and ettempt to restart Severator set te et wl not sta or the fs BOWS Spain locate and corect he cause Controtler TroubleshootingRelays 2, 88(Staner Solenoid) © Enerozes staner Each relay andthe functions it contol sted below 4. CR (Contel Relay 13. GC (Cranking Cutout ‘© Doonersizes SS relay © inte caning { cneizes intone oe gtsin) 4 son ona Ray» 2 Enon elena web «= Deenrpze 8 ely + Eramies 19 oreut © Ceenergane omer © Emacs oumeta = 2 Energon ence sen tein nh) — {enemies ter ave tyatr oe nt ee + ores cote Gea on western ouichcneat Seto 1 crerouee esate gus ortus!punp(Geeine) trun en SOR rome “Troubleshooting Figure carerve Acton Teitoce — rossneceue __| SUBSE ft Une wi nexrame [Revo or Por nts reore a ~ waemmlnercenk | Sec eneSne [native pen Crewe See eon, Ronen ete et et Seren eater Ones Batery [limi ate st r sacs 8 encarta. ETE Seer ation scomoterroe soon ° soe Ss eS Sa © Se ee Signet roar ph GomiBanan | Sramercure ioe cosene en Serb ro Sorc tw ave ee wunoterane ——[eooensonersTs onstrate sotoe o WENRSTen [Seats [Sheds crete Si Ceremmancrten | Se Sony mon sag ero | on 6 } + ‘Open foll pattern fisually inspect, make @ orion Sime BEET age | Bosch ovate ri r Srcayarratocee 6/6/6 toot am comecion fore naps pn © wopezecemen Peer AAs Soba ea srutyonromy —— (azvotcalwenanse co eae Sake ent teen Sts Notmay coe cn notre Sane een Seer Controller Troubleshooting a8Faw, Comective Action Rerence Probiom Posibis couse Gloterto Pure 3.2), fuer ‘Wat Not Crank “Low battery svotage at batery a (CR ray Battery cables tecminais mast be at Snorgizes) fr connectone in least 10 ke, poor condition recnatgef necessary Goan anc tignten battery “No votage at 88 open CR. 108 9 Co o “Solenoid cal "Semaci in series wih SS totenota Open o Ps connector (ain) pen ni connector cc) onto. stauty 3 oenokt | ochec contin of o pen colt col euotetreut Tho Volage at Sartar | origh resistance oF Ose Motor faulty $8 contact. Loose orcoreded _|Cieanand tighten 6 an “sorter lead “Faulty starter moter. | eRepairor replace. ‘Unk Cranks bat wo hat [Check orfosl at pone ‘Wil Not Stor ‘or earburetor Check for clogged fuel Iter Creck engine fuel system, anion System creck tor battery o ‘atage at gion ‘al Gneck ignition pointe Gheex engine Fantion system +Qpen In Wing ie cranking, o ‘Ramone ‘heck for battery votage ermal 70) a1 ‘Gon ca oss {saline or fel solenoid (Gesen omni, Sater (a ytace to ing, Pt connector, Bin 20 to fuel solenoié erlantion cot ‘Uni Rune For “No AG ouipat avait | Check for 120 vote AC o@ 3060 Seconds “Seto TCR roay ‘fo convlirtermina! ‘hon ShuteBown, | sol Safeguara ftp Vo and V7 Se Breaker (heauipoea) | Generate route must be closed Shooting (lo Output, realy oes nt nergue, normaly ‘Sloe contacts of felay wil energize 17S ‘Shemal ewan ane shut own unt Control TroubleshootingFigure 9-2. Rely Contra 35 Controller Troubleshooting‘Troubleshooting Figure Corrective Action Retorence Problem Possible Cause (Geterto Figure 32) ere Unit Runs For ‘sNo.ortow Engine | «Engine oll prassore ° 3080 Seconds Oi Pressure ‘mutt be avaible to ‘hen Shute Down, pon LOP. switch (Gsed'ewien Contacte il neroize 17S and snotdown Ani. Comeet engine St preseure pole, sition engine Coolant | sExceesve coolant @ ‘Temperature femperature wil so vate HW swtch heck oviant love Sheek igntion ming. heck fr coating Festietons end edator ‘eaingMicrocomputer Controller Deseription| For externa fetures, ste Section 2—"Operetion Mio omatc showing input/output eeultstor rouble rans anclconnecione Figure SA ca = Figure 28. Microcomputer Cont ower Cabinet tor Remote Start Switch (terminal 3 and) end Remote Annunciator. Terminal Step for AC Meter ane Voltage Regulator Sensing Connection, 8. A Interlock Greut Boars (or cranking sleconnect ater engine sar) Controller Troubleshooting a7Microcomputer Controller - cont'd. Figure 2-4. Microcomputer Circuit Board 1. 1e:Volt Power Supply Regulator (3) ~Incireult on 2E-Vart systems ony ‘Nott Powet Supply Reguetr (VR) Reverse Setery olay Diode (05) Bley eve ans for CR (a 8 18 (2. iWicacomoutron 069). 10. Lamp Orie Chips (ie2, 19), va 38 Controller TroubleshootingMicrocomputer Controller - cont'd. 4 CONNECTOR FINS 1, Output to high water temperature lamp, wir 36 2, Output to tow al pressure amp, wite 88 10! Output to emergency stop lamp, wire 4B - Output te overerank 2: Sutut to arerspeed am wie 38 ‘Output to slorm pom, wire 32 14. Output to low battery wot amp, wire 62 16 1 48, Stputts atipat Sah water tmperature, ie 20, Output to low tue! amp, wire 63 21. Outputte tow water temperature lamp, wie 35 PS CONNECTOR PINS = Ground (-),wire2 Surputto emergency stop, wire 30 fap to high watortompertur amp, wire 96 putt lam nor, wite 32, 3 Inpat te tow batiery vot am, wire 62 Input system reed tmp, wre 60 ipa test off lamp, wie 80 3 input to secpstoy low ol pressure lamp, wie 41 Input to highbatery volt farm, wre Bt Input aint high water temperate tam, 46, Input to ow fel mp, wire 63 47, Input to low wate temperature lamp, wite 35 Control PSCONNECTOR PINS. 2. Input rom battery (+, wie LC 3 Gouna). wie © Ground (1), wre 2 fr speed sensor 5. Gutput to spued sensor wire 24 {Input rom AC inerock bora, wie 77 input tor AC interlock boar wie 78 {Input rom speed sensor, wire 18. 9. Output to CR relay col wire (9) 101 Output to tea rete eat wre 8 (>) 11. Input trom wansfr swith, wire from romote start put rom master switch AUTO postion, wire 48 ut trom master awh, TEST pontion, wie &7 414 Input tom antipatory high water temperature swith, wire don trom low water temperature switch, wire 254 18: Inpttromanipstor iow a pressre sic, wre 19, Input from high water temperature switch and low lola level itch 1 equippet), wie 20, Ground (~), wire 82 for speed sensor 21. Ground (=), wire 3 (not used) PT CONNECTOR PINS 2. tat UP tanner seminal 4, 2. Output o annunciator sip termina 2, ground ‘ Gutput to annunetator sip terminal 60, atch ot 5, Gutput to annuncator tp terminal 12, overerank 6, Gutputte annuncato stp terminel 45, emergency 7, utp to annunciator sip terminal 365, high wator '8, Gutputto annuneietor stip terminal 39, overepesd 1: Output to annuneiator sip terminal 38, Tow ot +10, Butputtoannunciatorstipterminal 4, anti. lomo +1, Burput to annunelator strip terminal 40, ati. high water omperstre 12, Output to annunciator stip termina! 35, low water 18, Output to annuncatrstrip terminal, high battery 14, Output to annuncltor sip termina 62, low batory 415, Output to annuneiator strip terminal 63, ow fe! 418: Battery (2) rom 4amp fe, wie Lo 11, Gutputtoanmuncitoreeip terminal 60, system ready 49, input trom emergency stopover voltage, wie 30 sssemur 232332. el Figure 3-5. Microcomputer and Lamp Board Input/Output Cireults and ConnectionsController Troubleshooting Figure 8A, Logie Schematic, ‘Microcomputer Cireult Board th |Negative Ground Control System! beter connections ‘Troubleshooting Problem Possible Cause. ‘Corrective Action Engine wil not erank with ‘matter switch in TEST position (CR and 1CR relays ‘ot onorsizing) ‘= Batiory weak or dead ' Rovarsed or lose battery connections © 1am controler tse blown *# Open ccut (Pin DC ‘arness connector (Pt, fin 21) battory volage Inout t conta: Detective mastr switch coring ‘Lote DC harness connector (Prior loose creat board Connectors (PPS, PE PT) © Detective CR oF TCR reays ' Racharg or replace battery (Check battery eneroer '# Check bator for proper ‘Sonnectioninegetive ground), ‘lean ana ighten connections Replace fuse Win master ‘ston in TEST poston check forbatery vtage at"A" termingle of master ch, and “A ool terminals of CR ana AOR relays # Check conection See “Nes” folowing. *# Check fr batery votage at ‘pith terminals “A with ‘beth in TEST or AUTO Dostions check for battery ‘otage at ool terminal "A [TCR relay. Chock fr ground Sontinuty rom connector PS. bin 13 (wre a7) wth mastor ‘toh in TEST poston Mie rom master switch completes ground cet © Check comnectons. Set Connector istose or ‘connected ‘Check elay connections land operation Replace required. ‘cAUTION Use care when cantacting connector pins with meter probe! Contactoniyonepmatatime Shor creuting ins nay onus cveut board flute Controller Troubleshooting antMicrocomputer Controller - cont'd. nore. Nore Battery votagemustshow atconnectorP7,9in16,P5,pin__Circuitboard must eupolva negative grounc potential to 2.andP4,inz mordertorconralertofunction Check BS connector in 10 to energize TCR (oranking) relay ‘voltage ram each pinto ground igus 8, easurewith Dcvotmatartiom batter ooative 10S pin 10m matarauiteh mn TEST postion Figure 3-6. Voltage or Continuity Check at Connector Pn, Nove. ‘Be sure you nave checked al wig and con- action thorough. before replacing micro Computer ccut boar Probe Posable Cause Coreatve Aston al Engine cranks but = ow Fos * Check ue supp prea 1+ CR relay not enerizng Sreotrpope’ ound through PS connector an 8 ‘No pater votage to *# Check for open eeu in "anion col gas'gasoline) Pt connector pin 9, wire 70) orinscor pump ese anGanaEn 1 Encesshe peed sensorai-gnp | © Adjust 100080 in (OS08 amy See Figure 37. Open spews eensor cout © — creck continuity, wre 2 (lace trough Pa onnector 19 PS conn pin reek continity, wire png Cheek continu, wie 24 (rd trough P connecter, fo PS comestor pin |e Detectne speed sensor + See "Spo0s Sensor Test fotewing 342 Controller TroubleshootingFigute 3:7. Speed Sentor AlrGap, Speed Sensor Test ‘Todeterineit the sgnaltvom the speed sensors being eied athe controle flow the procedure outned 4. Connect OC vlimeterbatween PS connector pin on reulboerd, and ground = volmeter should reaa battery voltage an 12vel ayers or Tots on 26 2. With generator eet unning. connect DC voltmeter be tween Ps sonnectr pin B on te eeu board ane (round votimaterreasing shoul eovalvtlage read In Stap | minus approximately 2-Vots. It he speed sensor sina! is not being received atthe Generator aot contro test speed sensor 1. Connect speed sensor, voineter and OC voltage Source as snowa ia Figuo 3, 2, Touch sensing surace wih fit piece tron or stet Tetleaet 14 cube ina? mh 43. Test voteterreacing should equal voage source 4. Remove ion or ste! om sensing surface and ob Fore NO test voteter racing Controller Troubleshooting Wire 16 Whrte/Cleat fetiater Cup 1-06 Vottmeter 2: Yawort de Power Supety 3. Sensing Surtece Figure 3-8. Speed Sensor Test 343Microcomputer Controller ~ cont'd. Fast Check Features and Operation ‘ina Fest Check isan engine simulator for testing ana Operation “a Fast Cheok can be vse to tes he Microcompu Conte an the generate’ set when troublesnootng {he conti when moved tom th generator se. To operate the Fast Check the folowing eaulpment is Fast Chock snd hamess(&-201930 and 269085), ‘arable owsotage DC power supply 0t230v013 np minimom curent 0.5% maximum outout voi ge “pple st 30 vats OC. A 12+ oF 24oh battery \Gepending on svetom votage) ean alse be uses to operate Fast Check. Features (Figure 3-9) Engine conatios ae simulates bythe flowing enaine 1 OFF-lockedengine|statorenergizedbutnotturing 1 CRANK engine cranking but not stated 1 10N, ~ gion) lamp shows: = battery eitage supplied anton fel aves water ‘valve (Gy water coed ets) = ight curing eranking and runsing 1 CRK~ crane lamp shows: sary tuning ~ bons ony during “omeren yclas 1 REG. ~(regulaton tmp shows: = pattery vltage supplied o generators AC vot ‘equator gna ring eranking snd unaing (© A.D. ~fantiteae tut shutoff solenoid ams: = ight curing normalorfautshutdown oranynon-un ~ lights when engine faut simulated by one of toe Upper topple sutcheso* OVERSPEED button ATT. ~oaton) lame: = lights wnentest battentes)or DC pomersuppiy ive a4 nore LO, HW. ang OVERSPEED aimuate ma ‘ction caving engine shuteoun, LOP. ‘angie hae been running "for 30 secon ‘Engine snuteoun’-snould occur & seconds 1 L0.P.-low ol possure Haver, 1 OVERSPEED- simulate LF tow tue 1 LW. Iow engine wat TOHoverspeedconction © A.0.P.~antcicatry ow) ol ressure 1 AW-T.~ anticipatory igh wat 3 Enaine Sten Controti TroubleshootingTo.connset he Fast Cheek: ‘Unplug DGegine nameesemOCnarness connector (Ph gure 0 2, Plug Fast Check hamest onto DC harness connector find top of Fast Check Figure 3). 3, Move hiorasamputer Contre Mast” Switch to OFF 4. ove Fast Chack engine auton to OFF Clip red and blace~) hamess lead tobater(es) Sr BC power supp ol proper vltage for generat: set 12 0:24 ol, See BATT rating on namepiate Gener tor sats batteries) may be used if accessible ane cyelle Cranking fositon tester n CRANK postion Cane TOR reays Shouts energize 1 CR should cele every 10 seconds XWin voltmeter check fora reading of 05 t0 7.0 Vorsirom cannestorP6 pinto groune asehownit Figure 9 2H roading i omact, but CR clay doesn’ enorize proceed sto D. Cf reading does not fal within the range require. Check ors woteterraaging of 0 volts Hom cor Disconnect the CR relay cll Check relay with an fntemal poner supply (eatery for proper rey Replace relay f necessary. I olay Is operating bropery neck wing to CR relay eo Figure 2-10, Fast Gheck Connections Controller Troubleshooting '2.be Kamess Connector(Pt) 345Microcomputer Controller - cont'd. 2, 1oR lay est wth GenertorMasterSwtchin-TEST Dostlon i 1CR aoosnt energize 1X With voltmater, check fora reading of 05 101.0 Volts rom connector Ps, pn f0togreuns during on ‘rank cycle, battery votage during ofterank cle 1 Check ora votimeter reading of@ vot Fam car- {. Disconnect te 1CR ely cll Chack relay wth an ‘external power supply (battery) for proper relay , Replace relay necessary relays operating ore Datly check wing to 18 relay col Overcrank ocneck the controller's ably: «Detect locked engine 1 Stop a stareup attempt if starter enould lock or ‘sartr wil not engage +. Make aur Fest Check engine swine OFF 2. Move Generator Master Switeh to TEST poston 8. IGN, CR, and REG, lames of Fast Check shoulaight (Gri lamp enous ight for around 10 seconcs, 4. CK. lamp should go out or approximately 10 sec: ‘ond then light agsin fora second cranking cl. ‘ere secon intone gecond ranking cel, (GN, ik and REG. lamps on Fast Check should go out (ater approximately 25 seconde of cyee cranking) [SVERCRANE lamp on contol, plus alarm amps on Fas Check should ight nt. Figure 217, Volage Check at Connector Pin [A wth an abmmetercheckthe speedsenser crus for continu (See Figure 12 a6 1. Connector P5, gin & to DC hamess connects (home 2. Connector PS, pin 8 to DC harness connector, (eran 24 ‘8, Connector PS, pin § to DC hamess connector, Phone Replace main cheut board #you read continuity at Figure 312, Continuity Cheek Pointe ‘Connector (PPS, PE, PT) 2. be Hamess (Pi) temp if etarter works but engi wil pot un. 1. Move Fast Chook engine switch o OFF. 2. Move Ganertor Master Swite to TEST. ‘3. Move Fast Ghee’s engine to CRANK note “The main eeult boar gives 8 rstan cranking {alayf about one to two secons.CAK amp on Fast Oneck may nt ligt immesiately when or fine swtch fs moved t9 CRANK from OFF 4. 1GN, CAK and REG. amos on Fast Check shoulc ght to showoncrant ele RK lamp will go out during Softerank cytes. 5. Alter 60 seconds of eye cranking, IGN, CRI. and PREG lamouon ast Checkshouldga cu ALARM iamp ps OVERGRANK lamp on controler Should ight Bjcic cranking does not stop ter 60 saconds: 2 check ie flowing conmections fer continuity: 41 Connector PS, pn & to OC hamess connector, enone 2. Connector PS, pn & to OC hermess connector, (rbpin 28 £8. Connector PS, pin § to DC harness connector, Hane 1. Replace maincireultboardfallesanectionsin ten oneek ou, Controller TroubleshootingovensPeeD Nore ‘Te overspeed signalto the convaloris p= piled by the speed soneor. The FastCheck {ester simulates the speed censor signal To test overspeed salty feature: NOTE arierFest-Onecktestoremay require sighty ighorbatteryotage( 13-1 Valisfor12Vo ‘Systeme forts tot Move Generator Master Swtanto TEST positon Move Feet Check engine stn fun Push and held OVERSPEED buton on Fast Check (OVERSPEED lamp on contol shoul ight immes Ste} ALARM lamp on Fast Check shoul Hoh OR. fe REG lamp on Fast Check shouldbe ut. 4. engine does not shutdown: {A Checktnetolowing connection points for continuity: 1. Connecter PS, pn & to OG hetmess connector, (name 2. Connecter PS, pin 8 to DC namess connector @nvpin 28 1. Gannester PS, pin § to DG hamess connector, pine Engine Condition Indicators eter to Table 31 to test operation ofthe controllers Engine conction inciator ems “To test each indicator place master switch and Fast Check engine swith nthe postions chown inthe table {Sheek for woage atthe indicates test points with the {fopie swtenin the poston shown. Push LAMP TEST button on controller o be eure thet alt ‘amps work Lams aspear dim duet current liming by resistor on lem boar. Replace any detecve bubs Diorent bute are used on 12 and 2a-Voltcontlors. caunion Make contin enecke withOC powersource tures Nore Leave engine ewitoh in RUN postion feat Jeast 30 seconde before pushing toggle switches. = (SL [Ee ET tor hostoggeantctoLORtorewen wsnce | ogerd amie 5 2 Pressure AGP. | hat tage etch 19 ADP. = wogound PI, pin 13. ' ° Smee” [eeu ananassae or See ae] ne as SSS Ren eee oe Ee pat sas 5 Toole, Fat check Testor Eoin Conon ets on Controller TroubleshootingMicrocomputer Controller - cont'd. Emergency Stop (optional) shutdown when itis triggered bya 4-o-24-VoltC signal Smrergency stop ech, kremote omergency tops ‘ray bs connectes tothe conta via DC haress con foctor 1) pin 28. The ver votage option comers 0 Wire 20m the conaler (ae Fgute 73). Figure 218, Emergency Stop Connections "Over Votage Oation Connector 2: bo ames Connector >) High and Low Battery Voltage Indicators To adiut nigh and ow batery votape in 1 Move Generator Master Swen te AUTO postion SYS TEM READY lamp should go on. a8 2 Rotate potentiometers Raa (high Batt Vos and Ras {Low Bat Vots| tly counterclockwise Figure 5-12, ‘3. Set OC power supply at 10 vols (20 vos for 24 Uns) Slomty rotate pot R25 sockuie unt AT. VOLTS ma igms on conte. 4, Sat OC power supsty at 15 vot (80 vote fr 24 vo nts} Slomly rotate pot R42 cockerse untiBaT HIGH 6, Sei D¢ power supply between 10015 va 2019 30 tots for vol unite, SYSTEM READY ampansulene 6 Seal pots after settings have boon established Figure 214, Battery Voltage Indicator Agjustment ter Hi Volts Pototiometer (2) 2: Battery Lo Voit Potetometer (25), Controller TroubleshootingSection 4 GENERATOR TROUBLESHOOTING Generator Conditions warns UNIT STARTS WiTHOUT NOTICE! Discon- ‘This section wil serve a a guide wnen roubleshooting ect wires 3 and tom terminal spin com your generate set The generator conaons iatecboiow ‘ole to prevent remote startup while werke {recovered thie section, Ing on generator set Potential injury or oie trocution can result Deconnect battery neo- Ste (-) lead om groune on genartor set befor working near rotor or attached parts Ne Output On Any Phase 1 Over Vato Ii, Puetueting Votape Fotow al safety precautions i roto this manual and ‘be aciiona warnings within th text Figure 4-1, AC hesniipie ‘Vonage Control wil asst you when woubleshooting- In HIGH VOLTAGE! High outpst during tests Sedition Table 271 iste the varoue generator output ray endanger human if of damage Saue- onaltons and component fete to be used. ment Disconnect generate from lad when Figure 41. AC Votiage Control Generator Troubleshooting aCOMPONENTS AND GIRCUTTS Generator we | A ereor | aco |, Mae,[attece] rm |samsure] exter [ornomer tout | soars stor| Nitage: | Activator | Breaker | Armature |~ Fie | Stor bitte Board | Regulator oe 7p. Le he Gree. . . . ioe reueaa elas [eee nae ‘Table 4-1. Troubleshooting Guide ‘Mo Output On Any Phase 1. Check the sstaguard breaker i equipped). open, ‘ose, ang with et running cack AC voltmeter for ‘reper cutout votage. 2. proper ovtput does not show: a2 Check ie 15-amp fuse on contol 1 Gheskire 18 tom safoquarereakerand wire 7 (ground) t votage regulate ce Gheck wire 70 between OR rolay and Safeguard ‘rosker fi equipped) trough DC engine harness connecter (Pt, 1) pin 20. 8 ttalltemsinstop2 ar okay, .roceedto the LED cirout boatashiighttestancAVR(votapereguaton testas described n Component Testing. 4. tet ndoate LED and AVR are funetioning poverty, proceed fo the Photo Taneitor Board test as de Eeibed in Component Testing, 45: the Photo Transstor Boars tet indicates is fune- tioning propery, proceed to the Exotor Armature test ‘bs cescibed in Gompaneat Testa 6 ifthe Exciter Armature test indicates the armature is {onchoning property roveed tothe Generator Field {eat ee described mn Component Testing. 17. te Generator Fei test indicates the fled is tn tioning propery relacethe FR Activator as desorbed tn component Testing overvettage: Nore 1 vervotage occurs, Gsconect harness pug at wotage regulator vervotage com {inves grblem tesin pote ansistorceut, Adio: Freactnator If output voltage disap. pears, problem lie in voltage regulator, com Fectons or wiring, See “Component Testing” a2 1. Hoversotageiareas withthe Safeguard breaker open 0 coved check the photo transistor board for 8 ‘roundad“C" lead Cheextnphototransisorboardas esorbed in “Component Testing” 2 Hf the Pnote Transstor Board is funetioning propery Check for reverend and lease onthe FR Activator 2.1 Photo Transetor Board functions propery and is ‘repery connecteg butcalingvotapels ead eplace Fr hetvater SeeComponent Testing FRACtvator” Hf overvitage e read with the Safeguard breaker ‘osedony,checkforanopencireutinleacs 7 andV8 to the votage regulator i these cults are open or ‘hove, opal or replace. Check he volagerheostat ‘Sreut (lease 67 end 68). Repair and replace 8s nocessary. 65. ane crus n step 4 aro okay, check the vote repulatr AVR} a deeerbec in“Component Testing” Fluctuating Voltage 1. Cheek the generator ouput leads for proper connec: fon (rete fo Section 7, Wing Diagram 2 Check for lose connections to the voltage regulator, {Eb boara pote transistor board o FR Activator. 8. Check te siatorforehortedor open windings referto ‘Somponent Testing. Generator TroubleshootingComponent Testing LED circu Board Test WARNING Keep alates ight sources aay rom gener Sor end bracket cunng the folowing tests. Dangerous High VOLTAGE MAY RESULT! WARNING HIGH VOLTAGE! High outourcuringtestmay ‘ndanger human Ife or damage eauipmont Bieconnect generatortom loaawnentroub Shooting Thaline rot beakers ta°OFF ‘rremove generator output oad from cor Sections tTeae route ane Mealy iaulato ‘onde otleeds WaRNINe UNIT STARTS WITHOUT NOTICE! Discon post wee @ ane 4 fom terminal spn eon ‘ole to prevent remote statu while wok I an convo eat ote nur o nected Dleconnect battery negative (=) ead {fom ground on generator set blore working 1. Remove junction box panels from generator end of Unt igure #2), ana remove photo transistor boars 4 Photo Transistor Board Cover Generator Troubleshooting wit runing ate load, sine 8 Mashight on the exceed phote transistor Doers Figure 44, LED Flashite Test Obeere tne AC output voltmeter. Migh AC output Nottage indeatea the photo transistor board and FR Detvatorare functioning rope endthefautisinthe ‘Avmwiing.or ED creutboars(outputveltage souls Gop to tow love when fashight ls removed. no ‘utput e observa: ahack the photo transistor boars With the generator eet running, aporoximatey +2 Vote shoulste observeaat 36s)andsb(-)atthe LED board eee Figure 3). Shine aslignt on photo trenoetor DC vohage reading should op, showing that AVR is functioning propery H velages are not, tbeervereferto the AVR tos, 43Component Testing - cont'd. FR Activator Ie snored ta grouna. Replace oF repel generator rotor HIGH VOLTAGE! Do not reverse leads and ‘CAUTION Ing sutaces ae at clean ana tee of it meal chips Be sue ceramicurface on beck TER Activator snot racked or damages Apply a thin coating of thermal compound o back of cater betore mounting againet socket cap screwheas 3. Tighten FA Activator mounting serewsto 20-26 nba G2B28Nmoronlyasnacessaytocompress washers 44 Figure 45, FR Activator and Location Figure 4-3, Checking LED Board ‘anc Replacement” Observe the abel markings ontne FR Detter. Leads FS and are the genertor ld ads (Diack ithe emiterotthephotovanciterboardancleas rea te colectorfor neato vanes ber ee caution FR ACTIVATOR DAMAGE! Overghtening tre. Do not exoaad maximum forue settings. 4. Connectlesdsto FR Activator ghten Aand terminal Screws to 2025 nIbs (23:28 Nm), ‘cAuTION FR ACTIVATOR DAMAGE! Do not bend C nd terminate on FR Acar Internal oar S3e ana fore may rut ‘5. Secureleadswitnte cable. These rotor shat during operation ang m Generator Troubleshootingavr (hand 7H (=) atthe votage regulator harness plug. youdonotgetavotegeresding cnecetnewiingtotne itn he stepuars beter ose i ec.poed. Scteuard renter CR vin SoAma fase 1. Check fran open ccut Between eae VF and V8 Check or approximately 12 Vos 0 output emt Sotape soning eas romvotageosutor(AVR)Io als 3B (+) ane 5B (~) onthe LED board Separate {Srminisnpconleriserguese}iinerccrcuts SB/SB connecior and heck for bate votage Svopen oranonea.toparorrepice Check 1SAmp connector votago fro ead at comecton pons, fete i eciooes) feplaing orreace age epitor.aage © 2 ticontnuty eres check he votage meosiatcveut "SAS HOIRER LED Doar (ade 67 and 68} Repatr or rpiace as necestay 4, Tochecktorinputatter voltage tothe repuatr ith the generator runing, anesk orbarer vatage at TB I instating new vottage regulator in 24-Vo system, remave RYE Testor fom regulator real bard Figure 46. AVR and Connections “AVR 2. Hamess Plug 3. Contoter Terminal stip 4 Voltage Rnocsta stator 1. Cheek the generator output eae for proper connec: tion (ese wring diagram Section 7) 2, Check the stator windings for: (Shorted windings: nepectforbumtorhot windings. Replace stator windings are burnt or ht note Later FR models use a skewed (antes) rotor ‘nin seaigh state. When replacing her isi syle (skewea rotor wih stalght thatr or straight rotor mh skewed tate) oF Figure 47. Stator fator Troubleshooting 45Component Testing - cont'd. ach pair of lead for righ vesctance readings High resistance aooss-A" orcomtnaty across Figure #8. ULL Hye Nove Disconnest V7, V8, V8, Vo at AC ternal sro i control betore deg the fost Figure 48, Stator Winding Te ‘A Continuity /Resietanes Generator Field 1. Disconnect battery (nogatve lead fest. See “End bracket Dleconnect £9 end Fa trom FR Aetvato, 2 With an onmimeterebeck for continuity across Fan Pleads (eee Figura 48) Resisance readings shoul be 2a7s ohme,= 6% Figure 4, Field Continuity Cheok 8, Checktora grounced generar fied There shouldbe ro continuity between fed leads and rotor aaaerny (Gee Figure 2-10) WARNING HOTFIELDY Generatrfelowilgetnotitials 1S shorted. Avoid touching generator fl, HIGH VOLTAGE! Use hign votage test only ecivectod Mighveliagemay esutin acto. utlon or everenjry Follow manvtacturer’ instruction to operate teeter. 4. Aoply 1100 vote AC ether F9 oF Fla andehatt forNOTMORETHAN ONE SECOND, OONGT REPEAT Figure 410. High Vora 5. Reps F9 and Fite should show leas shores to ‘round. Soler and insulate spices. Use new teeing shen ting lead to shaft or eat sink 6, Replace generator totocassembiyftesteshowa short or proud Generator TroubleshootingExciter Armature 1, Disconnect batery (negative lend frst See “End Braciat Removal nd Replacement” Remove end Bracket Disconnect lade At and rom Activate. [2 lacs (ooe Figure #11) - Figure 411, Exelter Armature Continuity Check Repair At andA2leads damagadoropen Soler and FReulateepices. Use new sleoung won tying leads torthaftorheat ake ‘4, Vieualy ene oxciter amature for shorted wining), with an ohmmeter shack for low resistance readings (Underos-o2 ohms Figure 1 Lowrasltanooread- ings ndicates a uly excter armature -repace rotor WARNING HOT ARMATURE! Exciter amature wil get jgure 12, High Voltage Te Generator Troubleshooting HIGH VOLTAGE! Use high voltage test ony ‘scirecteathignvonagemayrecutin lector inetvctone when osrating taster 5. Check fora grounded axciter armature by apetvirg ShoovotenGtoetherat orAzanarotersheftforNOT HORE THANONESECOND See Figure.#12.00 NOT REPEAT TesT. Repair At ang A2 leads totindieates leads shorted {ground Solde and insulate spices, Use new alee: Ingunen ing lacs to shat or heat sine shored or ground, Photo Transistor Board Disconnect batery,nogtive lead fest sa E and C trom FR Aetvator. '8, Connect re and black photo tranleor leads to ohim= meter (Han (-), Cover the shotovansisto. Meter ‘Should read 300K ohee or ghar. 4 Shine a bright flsnlont on photo tensor boars 65. f onmmeter does not respond, reverse ohmmeter loads and repeat check (eter polar may Be fe versed 6, onmmeter does netreapond replace pototranisor Doard and harmose absorb 7, Reconnect (e6) and E (back photo transistor board Toads fo and € terminal of FR Activator 2, Disconnect HIGH VOLTAGE! Make sue esds °C" and "eto FR Activator are conrctes to the cor fect terminals Revers! of theoe lease oF {rounding of °C" ed) toed wil urn the FR Senator ful on roeuting I ceting output (eitage,Oamage to eauloment or personal WARNING FR ACTIVATOR DAMAGE! Oo not bend C End forminleon FR Aestr Intern Gar ge and fale may result ar‘Component Testing ~ cont'd. 4 Stat sot, shine bght Hashght on photo transistor bow (o0e Figue 2-19} AC voltmeter enous show {eling voltage tnd return te vary low votage when ‘aanight © removes Ropes test? mes f out oes not sroptolow vlageunantasnignt removes, ‘eolace FR Activator See "PR Actintor Mf cellng Figure 413, Flashlight Test End Bracket Removal and Replacement Note (On S0KW models somove the end bracket ‘mounting bots, On 49KW model the junction fox must be loosened fo alow end bracket ramaval Remove the sx (6) junction box nay tom the engine slowing end bracket 1. Ramove LED board end cover. Disconnect leads rom oeed sensor 2. Remove sere hong ectutor cup and photo tan 48 {. Reach in ana remove leas Cand trom FR Activator This wi alow slack when removing the end bracket caution FRACTIVATORDAMAGE! DonotbencCand terminals on FR ketal interel Somage 4, Remove 4 bots hong end bracket f stator, 5. Remove end bracket by using a pul, Figure 14 CAUTION Conettrytoramavetne enctracketby pound lng aarma youray owen rr 6, Pultheenabracketand exciterfiadassemblyoverine ter armature tating care not to damage exer fils magnets or oho ranitor boars, 7, Reverse ordero disassembly toreinstallendbracket~ crcter field aesomb Generator TroubleshootingSection 5 GENERATOR RECONNECTION 1. Move controler Master Switeh to OFF/RESET or OFF postion WARNING ELECTRICAL SHOCK! Battery can cause fectrcal buns and shocks. Remove 95, ‘eatenes andewar that can cause shor or ‘its When disconnecting batty, lecor- ect ground lead fret and rome st © tinimize te probability that tots wil cause Shor ets 2 Disconnect engine ing battery, negative (-) la 1, Select desire votage connection from Figure 6. Route lange rroughourenttansiormersandconnect leads per cingfam for dosed votaze. Nove. \wimeT! andCT9 place Dot “HY markside bay rom generator sot With CTZ, place Det ott mark toward generator set Nove Curent transtormere (CT) wil only be used fon generator sete with metaregulpped core trolors andor Sateguara Breakers. Figure 51. Generator Connections 4 Genorator ReconnectionReconnection ~ cont'd WARNING HiGHt VOLTAGE! Remember tht the fun Seniced only by aualifed tetnians Wines ‘hat are frayed or in poor condition. Do not In water on wet groure or when your hangs ‘over and ropeation meter seale lamp jumper (eee Figure 8-2 1 necessary to match prose postion for ‘esiredvttage ae shown in Figure. Renstalloover seater stent 1-42 postion (38 or a8 depending ‘cAUTION EQUIPMENT DAMAGE! Be sure tha ne cr- Accossores using line vollage are propery © Reconnect stating batty. Move controler master “mite 9 TEST postion to tart generator out Check ‘olmetor fr proper voltage, Aust vase, cee any, wih VOLTAGE ADJ/REGULATOR RHEOSTAT (ronmountes on Mleracomauter Controle rea ‘mounted on relay contolien, See Figue 5, Figure 53. Votage Adjustment 1. Microcomputer Controller 62 Generator ReconnectionSection 6 GENERATOR DISASSEMBLY/REASSEMBLY WARNING Before beginning to dsassomble generator {Seteufulyreadal Salty Precautions atthe begining ofthe mansat Pease donotnegiet the mportanes ofthese precautions. 1. Disconnect and remove starting batteries from work rent proven fie hazara Disconnect os uch a cater charge Bock ‘Shut of el evoply. Dean uel system as femoiying elite proper containers. Rem ontenera from work eas to revert Ti Ventlate work area to clear umes ‘ombiy or reeesembiy must be ‘enerator se check generator nameplate for Weigh Disassembly +. Disconnect lt controllerto-engine ane engine to Senerator hamosses ana wing. Disconnect slam fom crouit board connector equipped LED boars nd housing, and spees sensor dunction Box ang ‘Controle can 8eremeved as aunt Fermove bolts from generate viro-mourts. Sespendneganeratoratbotnendswitnhooksineyes. Raise genorater end with a hot iting of of bre. 4 Support the engine by placing wood blocks under tren hau, Lonegeeita er showing Tiare 6 Hota Sara 1. ook "2. Wood Blocks) Disassembly/Reassembly {5 Removefan guard. Remove ote holsingseaptertoty: {6 Remove nuts end spacers holting ve discs 1 7, Workdive cece overstudsto separate generatortrom Chain Figure 62 1 yy Jed bracket fo prvert damage to proto {ranelctor board wnen lowering Figure ©. 0, Remove dive dca andfantrom genetetor assert. Fue ss. oeDisassembly - cont'd. Fasten tng eyeand heist hooktorototlange Holst tuster fils magnets whl removing, Figue Bs +2, Wile rotor ie euspended, remove photo wansistor oard and actuator eup. Remove leads (re) and E (biace) tom FH Ratton Cut of forminale on the hot traneistor boar in cre to remove: photo ‘fansstorboardwibere-urea leave lence aang 1, Somylowerrotortomorzona poston. Sot ther fon 2 ucoden surace, Take care not to came Singing. laminations or bearing. Pigu® BS 14. In ovder to remove the adapter ane end bracket Figure 66 Removing Ads 2 Holet Hook Adapter 15, Remove asepter mounting bots: Fasten host hooks ‘bracket und rise assem sighty. Bump 0 y using a rubber mallet, ‘assembly Remove end bracket mount move endorackatfomstar2y umoingReassembly 1. Install new tolerance ring Io end bracket. Mount tnt held tomndbracketwthfourmaunting crews Fle 67 2, Blaceinestatorinavertcalposion.ondbracketsise Nore nd bracket side of stator ha four mounting ‘wth 8 stright stator Wen repacing ether SSator or tant rotor th skewea stat for th generator to unetion rope. Figure 69 Algning Aaapier & Stator 6, Allon adapter to stator and start ols and washers. {er sttor onto adasterang finish ightenina bls 8, Place nd bracket on stator, use bats oatign Noles Uses ober male to mount end bracket fuan with Bator igure 68. [Adaoterhoisting eye must be opposite of he Stator mounting braceat end direct” below Spd bracket hoisting eye. tn the end bracket end Fasten Rising nook to ene Bracket eve, owergenerstorassemblyfoahorzonta 8. tach iting naoks to adapter as shown in Figure (10, Surpend genesatr assembly. Before lowering ‘Generator, place Boar slong the edge of he end racket A one inen (254 cm) cloarance must be Stelablo underneath the center ofthe end bracket!o revert darnage fo the photo transtor board ane Figure @8, Mounting End Bracket to Stator Note End bracket nolstng eye must be opposite ot fhe stator mounting bracket 4 Install ots to mount end bracket o stator. 5. Attachhoisthooks toendbracketand suspend stator face ho aonote on the floor and lower stator 12 wehin 172-18 (127-84 mm) ofthe adapter Figure 610, Supporting Generator Assembly Fouees, 1: Wood Support Disassembly/Reassembly osReassembly - cont'd. 9. Fasten ting eye and holst hook t9 rotor tange Fue 6-1" Hout root to a verte! position tong are rotto damage windings laminations cr bearing 10. while the rote is suspended, instal he photo tra boars leadthroughactustorsupasshownin Figure6- 52. Push lead through hole In flor shat an thon through exer laminatons ending nea the FR Ret WARNING Be eure thattlliseofohot transistor boar, fesdofshatt anativended holesarecteanand free of metal particles and chips Dangerous HIGH VOLTAGE mayresuit aC volimetr must ‘Show proper output ato reconnoctestoloas! --- & ona, Figure 672. intaing Phos Transistor Board 11. attach photo tranaistorboardandactuatorcupto end (trotor ena wth wo mounting serews Figure 13. (tet excessteacwialavingenoughwietoreach FR Activator Siro 253 in (5087-62 cm) of ay Inaulstr lace from lead Cut ff ll exposed uniee fire Stipabout1/4in (635 em) af nslation nd blac loa crimp on 3/76 in (276 cm) ‘connecting to Ft Actor terminal cables ease topetner to beter secure leacn Reconnect red ead to" terminal and back las toe" teminal on FR oa Meteator Cup 12. Suspend rotor over generator assembly. Lower rotor fal nt stator. Take eare not fo damage the exer frmature, tld magnets, stator windings oF rotor laminations white towering rotor Figure 614. Care fly sign rotor bearing into sn bracket tolerance fing. Check tr an outer ace measurement of 1 Figure 614, Intaing Rotor 13, Pacetan overratortange andtorque bot 6260 a foe (24 Nm 14, Fasten arveciacs to endo otr shat Torque deve Sse mounting bots to 50 f Ibs (10848 Nm. 15, Atach hoist to acapter eye and place generator ‘assembly ina horzontal peso Take care not to rag too nto Honing ees of pneator Disassembly/Reassembly16, Tread studs int yhoo a shown igure 6-1. Figure 615, Fipnee! Stade 17, Place heist nooks into end bracket and acter eve Faise generat assem ang align fines oy tuming the fntheel Move generator 38 hecestan towork give dacs over studs When rive (Goce are about in (254 cm) over stud, intall Figure 616. instaling Spacor: Grve Discs" 3. Spacers 18, Move generator as necessary to align adaster ane ynnee! nowsing Faron anc Seatignen adapter to finahee! housing bots an lockwashers Figure 67 Disagsembiy/Reassembly 19. natal nuts on suse. 20, Hoist generator and eng Seki trom uncer ia sight to remove wood mousing Align gorerato 21, Remove chains o° ang uses to suspend generator. Fal tghten cre cece fo fhywnest 22, Intl fan guard 23. Reinstall junction bor and controlr. Reconnest al Coniollerto-engine ana engine-to-genert ‘aoses and wing FetertoSeevon 7, WeingDagrans ‘24, Reconnect fusk cooing end exhaust eyster “Gsconnectag ring sisassembly. Fe butputleade or lone ckeullcalesat generator. Open 25, Reconnect staring batteries and connect ary AC Sececsones, such battery charger, book heater ihe tue vanater puma Note Set soeed sensor gap at 0020 (0808 mn) samen rerouting. Figure 618. ~ 4. vnteciear(16) 2 he 8) 3: Black) 4.020 n. (0.508 mm) Gap S.Astwatorcup os