diagnostic
repair
manual
air-cooled Product
MODELS:
7 kW NG, 8 kW LP
9 kW NG, 10 kW LP
13 kW NG, 14 kW LP
16 kW NG, 17 kW LP
18 kW NG, 20 kW LP
a u t o m a t i c s ta n d b y g e n e r a t o r s
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contents
1.6 Engine-Generator Protective Devices ............. 25
General ............................................................25
Low Battery......................................................25
Low Oil Pressure Shutdown.............................25
High Temperature Switch.................................25
Overspeed Shutdown ......................................25
Rpm Sensor Failure.........................................25
Overcrank Shutdown .......................................26
1.7 Operating Instructions ..................................... 27
Control Panel ...................................................27
To Select Automatic Operation ........................28
specifications .......................................................... 4
Generator ................................................................ 4
Engine ..................................................................... 5
Fuel Consumption ................................................... 5
Mounting Dimensions.............................................. 6
Mounting Dimensions.............................................. 7
Major Features ........................................................ 8
Part 1 - GENEral iNformatioN ....................... 9
1.1 Generator Identification................................... 10
Introduction......................................................10
1.2 Installation Basics............................................ 11
Introduction......................................................11
Selecting A Location........................................11
Grounding The Generator................................11
The Fuel Supply...............................................11
The Transfer Switch / Load Center...................11
Power Source And Load Lines.........................13
System Control Interconnections.....................13
Natural Gas Fuel Interconnections ..................13
1.3 Non-prepackaged Interconnections ................ 14
Manual Transfer To “Standby”
and Manual Startup.....................................28
Manual Shutdown And
Retransfer Back To “Utility” ..........................28
1.8 Automatic Operating Parameters .................... 29
Introduction......................................................29
Automatic Operating Sequences .....................29
Part 2 - ac GENErators.................................. 31
2.1 Description and Components.......................... 32
Introduction......................................................32
Engine-Generator Drive System......................32
The AC Generator............................................32
Rotor Assembly................................................32
Stator Assembly...............................................33
Brush Holder And Brushes (12-20 kW) ...........34
Other AC Generator Components ...................34
2.2 Operational Analysis ....................................... 35
Rotor Residual Magnetism...............................35
Field Boost (12-20 kW)....................................35
Operation (8/10 kW).........................................36
Operation (12-20 kW) ......................................36
2.3 Troubleshooting Flowcharts............................. 37
Connect a Pre-2008 Load Center Switch
To a Current or Future
Air-Cooled Generator...................................14
Connect a 2008 And Later Load Center
Switch to a Pre-2008
Air-Cooled Generator...................................15
1.4 Preparation Before Use................................... 16
General ............................................................16
Fuel Requirements...........................................16
Fuel Consumption............................................16
Reconfiguring The Fuel System.......................16
Engine Oil Recommendations .........................18
1.5 Testing, Cleaning and Drying........................... 19
Meters ............................................................19
The Vom...........................................................19
Measuring AC Voltage .....................................19
Measuring DC Voltage.....................................19
Measuring AC Frequency ................................19
Measuring Current...........................................20
Measuring Resistance .....................................20
Electrical Units.................................................21
Ohm’s Law .......................................................21
Visual Inspection..............................................22
Insulation Resistance.......................................22
The Megohmmeter...........................................22
Stator Insulation Resistance Test (12-20 kW) .....23
Stator Insulation Resistance Test (8-10 kW) .......23
Rotor Insulation Resistance Test (8-10 kW) ........24
Rotor Insulation Resistance Test (12-20 kW) ......24
Cleaning The Generator...................................24
Drying The Generator ......................................24
Problem 1 – Generator Produces Zero
Voltage or Residual Voltage (12-20 kW)...37-38
Problem 2 – Generator Produces Zero
Voltage or Residual Voltage (8/10 kW) ........38
Problem 3 – Generator Produces
Low Voltage at No-Load...............................39
Problem 4 – Generator Produces
High Voltage at No-Load..............................39
Problem 5 – Voltage and Frequency Drop
Excessively When Loads are Applied..........40
2.4 Diagnostic Tests .............................................. 41
Introduction......................................................41
Safety ............................................................41
Test 1 – Check Main Circuit Breaker................41
Test 2 – Check AC Output Voltage...................41
Test 4 – Fixed Excitation Test/Rotor
Amp Draw Test ....................................42
Test 5 – Wire Continuity (12-20 kW) ................43
Test 6 – Check Field Boost (12-20 kW) ...........44
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Test 7 – Testing The Stator With A Vom
(12-20 kW)...........................................44
Problem 11 – No Battery Charge
(Pre-Packed Load Center)...........................73
Test 8 – Test Brushless Stator..........................45
Test 9 – Check Capacitor.................................46
Problem 12 – No Battery Charge
(RTSN & RTSE Transfer Switch) .................73
Problem 13 – No Battery Charge
(Gen-Ready Load Center)...........................73
Test 10 – Test DPE Winding on
Brushless units....................................47
Problem 14 – No Battery Charge
(Load Shed Transfer Switch)........................73
Test 11 – Resistance Check Of Rotor Circuit
(12-20 kW)...........................................48
3.4 Diagnostic Tests .............................................. 74
General ............................................................74
Test 12 – Check Brushes And Slip Rings
(12-20 kW)...........................................48
Test 26 – Check Voltage at
Test 13 – Test Rotor Assembly(12-20 kW).......49
Test 14 – Check AC Output Frequency............49
Terminal Lugs E1, E2..........................74
Test 27 – Check Manual Transfer Switch
Operation.............................................75
Test 15 – Check and Adjust Engine Governor
(Single Cylinder Units).........................49
Test 28 – Check 23 And 15B
Test 16 – Check Stepper Motor Control
(V-twin Engine Units)...........................50
Wiring/Connections.............................76
Test 29 – Test Transfer Relay TR......................77
Test 30 – Standby Control Circuit ....................78
Test 31 – Check Wire 23..................................78
Test 32 – Utility Control Circuit.........................80
Test 33 – Test Limit Switch SW2 and SW3 ......82
Test 34 – Check Fuses F1 and F2...................82
Test 35 – Check N1 and N2 Wiring..................83
Test 36 – Check N1 and N2 Voltage ................83
Test 17 – Check And Adjust Voltage
Regulator (12-20 kW)..........................51
Test 18 – Check Voltage And Frequency
Under Load..........................................52
Test 19 – Check For Overload Condition...........52
Test 20 – Check Engine Condition...................52
Test 21 – Field Flash Alternator (8-10 kW) ......52
Part 3 - traNsfEr sWitcH............................... 55
3.1 Description and Components.......................... 56
General ............................................................56
Enclosure.........................................................56
Transfer Mechanism.........................................57
Transfer Relay..................................................57
Neutral Lug ......................................................58
Manual Transfer Handle ..................................58
Terminal Block .................................................58
Fuse Holder .....................................................59
3.2 Operational Analysis ....................................... 60
Operational Analysis........................................60
Utility Source Voltage Available .......................62
Utility Source Voltage Failure ..........................63
Transfer To Standby .........................................64
Transfer To Standby .........................................65
Utility Restored.................................................66
Utility Restored, Transfer Switch De-energized ...67
Utility Restored, Retransfer Back To Utility.......68
Transfer Switch In Utility...................................69
3.3 – Troubleshooting Flowcharts.......................... 70
Introduction To Troubleshooting .......................70
Test 37 – Check Utility Sensing Voltage
at the Circuit Board..............................84
Test 38 – Check Utility Sense Voltage .............84
Test 39 – Check Voltage at
Terminal Lugs N1, N2..........................84
Test 40 – Check Battery Charger Supply
Voltage “Pre-Wire Load Center”..........86
Test 41 – Check Battery Charger Output
Voltage “Pre-Wire Load Center”..........86
Test 42 – Check Wire 0 and Wire15B
“Pre-Wire Load Center”.......................86
Test 43 – Check Battery Charger
Supply Voltage
“RTSN & RTSE Transfer Switch”.........87
Test 44 – Check Battery Charger
Output Voltage
“RTSN & RTSE Transfer Switch”.........87
Test 45 – Check Wire 0/
“RTSN & RTSE Transfer Switch” ........87
Test 46 – Check Battery Charger
Supply Voltage
“GenReady Load Center”....................90
Test 47 – Check Battery Charger
Output Voltage
“GenReady Load Center”....................90
Test 48 – Check Wire 0/15B
Problem 7 – In Automatic Mode,
No Transfer to Standby ................................70
“GenReady Load Center”....................90
Test 49 – Check Battery Charger
Supply Voltage
Problem 8 – In Automatic Mode, Generator
Starts When Loss of Utility Occurs,
“Load Shed Transfer Switch” ...............92
Generator Shuts Down When Utility
Test 50 – Check Battery Charger
Output Voltage
Returns But There Is No Retransfer To Utility
Power / or Generator Transfers to Standby
During Exercise Or In Manual Mode............71
“Load Shed Transfer Switch” ...............92
Test 51 – Check Wire 0 and Wire 15B
“Load Shed Transfer Switch” ...............94
Problem 9 – Blown F1 or F2 Fuse...............71
Problem 10 – Units Starts And Transfer
Occurs When Utility Power Is On.................72
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Part 4 - Dc coNtrol......................................... 95
4.1 Description and Components.......................... 96
General ............................................................96
Terminal Strip / Interconnection Terminal.........96
Circuit Board....................................................96
Auto-Off-Manual Switch...................................96
7.5 Amp Fuse...................................................96
Menu System Navigation...............................102
4.2 Operational Analysis ..................................... 104
Introduction....................................................104
Utility Source Voltage Available......................104
Initial Dropout of Utility Source Voltage..........106
Test 68 – Check Fuel Solenoid ......................132
Test 69 – Check Choke Solenoid...................132
Test 70 – Check for Ignition Spark.................134
Test 71 – Check Spark Plugs.........................136
Test 72 – Check Engine / Cylinder Leak
Down Test / Compression Test ..........136
Test 73 – Check Shutdown Wire....................137
Test 74 – Check and Adjust
Ignition Magnetos..............................138
Test 75 – Check Oil Pressure Switch
and Wire 86.......................................141
Test 76 – Check High Oil
Temperature Switch...........................142
Test 77 – Check and Adjust Valves................142
Test 78 – Check Wire 18 Continuity...............143
Test 79 – Test Exercise Function ...................144
Utility Voltage Dropout and
Engine Cranking................................108
Engine Startup and Running..........................110
Initial Transfer to the “Standby” Source ..........112
Test 80 – Check Cranking and
Running Circuits................................144
Utility Voltage Restored /
Re-transfer to Utility...........................114
Test 81 – Check to see if Low Speed
Function is enabled ...........................146
Engine Shutdown...........................................116
4.3 Troubleshooting Flowcharts........................... 118
Test 82 – Check operation of the
Choke Solenoid.................................146
Problem 15 – Engine Will Not Crank
When Utility Power Source Fails................118
Part 5 - oPEratioNal tEsts ........................ 147
5.1 System Functional Tests................................ 148
Introduction....................................................148
Manual Transfer Switch Operation .................148
Electrical Checks ...........................................148
Generator Tests Under Load..........................149
Checking Automatic Operation ......................150
Setting The Exercise Timer............................150
Part 6 - DisassEmBlY ..................................... 151
6.1 Major Disassembly........................................ 152
Front Engine Access......................................152
Major Disassembly.........................................156
Problem 16 – Engine Will Not Crank When
AUTO-OFF-MANUAL Switch
is Set to “MANUAL.....................................118
Problem 17 – Engine Cranks
but Won’t Start...........................................119
Problem 18 – Engine Starts Hard and
Runs Rough / Lacks Power / Backfires......120
Problem 19 – Shutdown Alarm /
Fault Occurred...........................................121
Problem 20 – 7.5 Amp Fuse (F1) Blown ..... 122
Problem 21 – Generator Will Not Exercise... 122
Problem 22 – No Low Speed Exercise........ 122
4.4 Diagnostic Tests ............................................ 123
Introduction ...................................................123
Torque Requirements
(Unless Otherwise Specified)............162
Test 56 – Check Position Of
Part 7 - ElEctrical Data.............................. 163
Wiring Diagram, 8 kW Home Standby................. 164
Schematic, 8 kW Home Standby......................... 166
Wiring Diagram, 10 kW Home Standby............... 168
Schematic, 10 kW Home Standby....................... 170
Wiring Diagram, 14 kW Home Standby............... 172
Schematic, 14 kW Home Standby....................... 174
Wiring Diagram, 17 kW Home Standby............... 176
Schematic, 17 kW Home Standby....................... 178
Wiring Diagram, 20 kW Home Standby............... 180
Schematic, 20 kW Home Standby....................... 182
Auto-Off- Manual Switch ..................123
Test 57 – Try a Manual Start .........................123
Test 58 – Auto-Off-Manual Switch
(V-Twin Only).....................................123
Test 59 – Test Auto Operations......................124
Test 60 – Check 7.5 Amp Fuse......................124
Test 61 – Check Battery.................................124
Test 62 – Check Wire 56 Voltage ...................126
Test 63 – Test Starter Contactor Relay
(V-twin Only)......................................126
Test 64 – Test Starter Contactor
(Single Cylinder Engine)....................127
Wiring Diagram, Home Standby Transfer Switch,
9/10/12/16 Circuit ................................................ 184
Test 65 – Test Starter Motor...........................128
Test 66 – Check Fuel Supply and Pressure...130
Schematic, Home Standby Transfer Switch,
9/10/12/16 Circuit ................................................ 186
Test 67 – Check Circuit Board
Wire 14 Output..................................131
Page 3
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sPEcificatioNs
Generator
Unit
8 kW
10 kW
12 kW
14 kW
16 kW
17 kW
20 kW
Rated Max. Continuous
Power Capacity (Watts*)
7,000 NG
8,000 LP
9,000 NG
10,000 LP
12,000 NG
12,000 LP
13,000 NG
14,000 LP
16,000 NG
16,000 LP
16,000 NG
17,000 LP
18,000 NG
20,000 LP
Rated Voltage
120/240
Rated Voltage at No-Load
(NG)
220-235
247-249
Rated Max. Continuous Load
Current (Amps)
120 Volts** (NG/LP)
240 Volts (NG/LP)
58.3/66.6
29.2/33.3
75.0/83.3
37.5/41.6
100.0/100.0
50.0/50.0
108.3/116.6
54.2/58.3
133.3/133.3
66.6/66.6
133.3/141.6
66.6/70.8
150.0/166.6
75.0/83.3
Main Line Circuit Breaker
Circuits*** 50A, 240V
40A, 240V
35 Amp
45 Amp
50 Amp
60 Amp
65 Amp
65 Amp
100 Amp
-
-
-
-
-
1
1
-
1
1
1
-
1
1
-
-
-
-
-
-
-
1
30A, 240V
1
-
1
1
3
3
-
20A, 240V
1
1
5
5
1
5
5
20A, 120V
1
5
3
5
4
15A, 120V
4
Phase
1
2
Number of Rotor Poles
Rated AC Frequency
Power Factor
60 Hz
1
Battery Requirement
Group 26R, 12
Volts and 350 CCA
Minimum
Group 26R, 12 Volts and 525 CCA Minimum
Weight (unit only in lbs.)
Enclosure
340
387
439
439
Steel
455
455/421
450
Steel
Steel
Steel
Steel
Steel/Aluminum
Aluminum
Normal Operating Range
-20° F (-28.8° C) to 77° F (25° C)
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc.
Maximum power decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6 C (10 F) above 16 C (60 F)
ambient temperature.
** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value
stated for the 240 volts.
*** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in the main panel must be a 15 amp circuit in the transfer switch.
Stator WindinG reSiStance ValueS / rotor reSiStance
8 kW
10 kW
12 kW
14 kW
16 kW
17 kW
20 kW
Power Winding: Across 11 & 22
Power Winding: Across 33 & 44
Excitation Winding: Across 2 & 6
Rotor Resistance
0.123-0.1439
0.090-0.105
0.100-0.116
0.100-0.116
0.074-0.086
0.074-0.086
0.0415-0.0483
0.123-0.1439
0.776-0.902
3.01-3.49
0.090-0.105
0.511-0.594
3.22-3.74
0.100-0.116
0.876-1.018
7.96-9.25
0.100-0.116
0.876-1.018
7.96-9.25
0.074-0.086
0.780-0.906
8.79-10.21
0.074-0.086
0.780-0.906
8.79-10.21
0.0415-0.0483
0.731-0.850
10.02-11.65
Page 4
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SpecificationS
engine
Model
8 kW
GH-410
1
10 kW
12/14/16/17 kW
20 kW
GT-999
2
Type of Engine
GT-530
2
GT-990
2
Number of Cylinders
Rated Horsepower @ 3,600 rpm
Displacement
14.8
18
32
34
407cc
530cc
992cc
999cc
Cylinder Block
Aluminum w/Cast Iron Sleeve
Valve Arrangement
Ignition System
Overhead Valves
Solid-state w/Magneto
Recommended Spark Plug
Spark Plug Gap
RC14YC
0.76 mm (0.030 inch)
9.4:1
BPR6HS
RC14YCA
1.02 mm (0.040 inch)
9.5:1
RC12YC
1.02 mm (0.040 inch)
9.5:1
0.76 mm (0.030 inch)
9.5:1
Compression Ratio
Starter
12 VDC
Part # 070185F
3,600
Oil Capacity Including Filter
Recommended Oil Filter
Recommended Air Filter
Operating RPM
Approx. 1.5 Qts
Part # 0G3332
Approx. 1.8 Qts
Part # 0E9581
Approx. 1.9 Qts
Part # 0C8127
Approx. 1.9 Qts
Part # 0G5894
Fuel Consumption
Model #
Natural Gas*
Full Load
140
LP Vapor**
Full Load
1.68/62
1.93/70
2.08/76
2.30/84
2.51/91
2.57/94
2.90/106
1/2 Load
77
1/2 Load
0.94/34
1.25/46
1.53/56
1.56/58
1.59/58
1.61/59
1.89/69
7/8 kW
9/10 kW
12/12 kW
13/14 kW
16/16 kW
16/17 kW
18/20 kW
102
156
152
215
156
220
183
261
183
261
206
294
* Natural gas is in cubic feet per hour.
**LP is in gallons per hour/cubic feet per hour.
Values given are approximate.
Page 5
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sPEcificatioNs
mountinG dimenSionS
299
[11.8]
1079.5
[42.5]
698
[27.5]
997
[39.3]
747
[29.4]
207
[8.2]
454
[17.9]
508
[20.0]
TRANSFER
SWITCH
8KW - 17KW
(IF SUPPLIED)
Ø30.2 [Ø1.2]
LIFTING HOLES 4 CORNERS
TRANSFER
SWITCH
20KW
(IF SUPPLIED)
"DO NOT LIFT BY ROOF"
637.6
[25.1]
1218
[47.9]
731.9
[28.8]
642
[25.3]
76.2 [3.0]
PEA GRAVEL
MINIMUM
1226
[48.3]
FRONT VIEW
LEFT SIDE VIEW
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sPEcificatioNs
mountinG dimenSionS
AIR INTAKE
457.2
[18.0]
MINIMUM DISTANCE
914 [36.0]
MINIMUM OPEN AREA
ON SIDES AND FRONT
AIR OUTLET
AIR INTAKE
250.0
[9.8]
575.3
[22.7]
530.0
[20.9]
HOLE LOCATIONS FOR
OPTIONAL MOUNTING TO
A CONCRETE PAD
446.6
[17.6]
378.7
[14.9]
44.8
[1.8]
FRONT OF UNIT
FUEL INLET - 12-20KW (1/2" NPT)
8 & 10KW (3/4" NPT) - USE SUPPLIED ADAPTER
REQUIRED FUEL PRESSURE: NATURAL GAS = 5-7" WATER COLUMN
LIQUID PROPANE (VAPOR) = 10-12" WATER COLUMN
CABLE ACCESS HOLE
178.9
[7.0]
244.4
[9.6]
GROUNDING LUG
REAR VIEW
RIGHT SIDE VIEW
Page 7
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sPEcificatioNs
major FeatureS
8kW, Single Cylinder, GH-410 Engine
10kW, V-twin, GT-530 Engine
(door removed)
(door removed)
Circuit
Breaker
Oil
Dipstick
Data Label
(see sample)
Control
Panel
Oil
Dipstick
Data Label
(see sample)
Control
Panel
Circuit
Breaker
Exhaust
Enclosure
Exhaust
Enclosure
Air
Filter
Air Filter
Fuel Inlet
(back)
Fuel Inlet
(back)
Fuel
Regulator
Fuel
Regulator
Composite Base
Oil Filter
Battery Compartment
Composite Base
Oil Filter
Battery Compartment
Figure 1.3 – 12, 14, 16, 17 and 20kW, V-twin,
GT-990/GT-999 Engine (door removed)
Data Label
(see sample)
Oil
Dipstick
Control
Panel
Circuit Breakers
GFCI Outlet
(All 17 & 20kW)
Air Filter
Exhaust
Enclosure
Fuel Inlet
(back)
Fuel
Regulator
Composite Base
Oil Filter
Battery Compartment
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taBlE of coNtENts
Part
titlE
PaGE
10
1.1
1.2
1.3
Generator identification
installation Basics
Non-Prepackaged
interconnections
11
Part 1
GENEral
iNformatioN
14
1.3
1.4
1.5
Preparation Before use
testing, cleaning and Drying
Engine-Generator Protective
Devices
16
18
25
1.6
1.7
operating instructions
automatic operating
Parameters
27
29
air-cooled, automatic
standby Generators
1.1 Generator Identification................................... 10
Introduction......................................................10
1.2 Installation Basics............................................ 11
Introduction......................................................11
Selecting A Location........................................11
Grounding The Generator................................11
The Fuel Supply...............................................11
The Transfer Switch / Load Center...................11
Power Source And Load Lines.........................13
System Control Interconnections.....................13
Natural Gas Fuel Interconnections ..................13
1.3 Non-prepackaged Interconnections ................ 14
Measuring Resistance .....................................20
Electrical Units.................................................21
Ohm’s Law .......................................................21
Visual Inspection..............................................22
Insulation Resistance.......................................22
The Megohmmeter...........................................22
Stator Insulation Resistance Test (12-20kW)...23
Stator Insulation Resistance Test (8-10kW).....23
Rotor Insulation Resistance Test (8-10kW)......24
Rotor Insulation Resistance Test (12-20kW)....24
Cleaning The Generator...................................24
Drying The Generator ......................................24
1.6 Engine-Generator Protective Devices ............. 25
General ............................................................25
Low Battery......................................................25
Low Oil Pressure Shutdown.............................25
High Temperature Switch.................................25
Overspeed Shutdown ......................................25
Rpm Sensor Failure.........................................25
Overcrank Shutdown .......................................26
1.7 Operating Instructions ..................................... 27
Control Panel ...................................................27
To Select Automatic Operation ........................28
Connect a Pre-2008 Load Center Switch
To a Current or Future
Air-Cooled Generator...................................14
Connect a 2008 And Later Load Center
Switch to a Pre-2008
Air-Cooled Generator...................................15
1.4 Preparation Before Use................................... 16
General ............................................................16
Fuel Requirements...........................................16
Fuel Consumption............................................16
Reconfiguring The Fuel System.......................16
Engine Oil Recommendations .........................18
1.5 Testing, Cleaning and Drying........................... 19
Meters ............................................................19
The Vom...........................................................19
Measuring AC Voltage .....................................19
Measuring DC Voltage.....................................19
Measuring AC Frequency ................................19
Measuring Current...........................................20
Manual Transfer To “Standby”
and Manual Startup.....................................28
Manual Shutdown And
Retransfer Back To “Utility” ..........................28
1.8 Automatic Operating Parameters .................... 29
Introduction......................................................29
Automatic Operating Sequences .....................29
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sEctioN 1.1
GENErator iDENtificatioN
GENERAL INFORMATION
Part 1
It is not our intent to provide detailed disassembly and
reassemble instructions in this manual. It is our intent
to (a) provide the service technician with an under-
standing of how the various assemblies and systems
work, (b) assist the technician in finding the cause of
malfunctions, and (c) effect the expeditious repair of
the equipment.
introduction
This Diagnostic Repair Manual has been prepared
especially for the purpose of familiarizing service per-
sonnel with the testing, troubleshooting and repair of
air-cooled, automatic standby generators. Every effort
has been expended to ensure that information and
instructions in the manual are both accurate and cur-
rent. However, changes, alterations or other improve-
ments may be made to the product at any time with-
out prior notification.
ITEM NUMBER:
Many home standby generators are manufactured
to the unique specifications of the buyer. The Model
Number identifies the specific generator set and its
unique design specifications.
The manual has been divided into PARTS. Each PART
has been divided into SECTIONS. Each SECTION
consists of two or more SUBSECTIONS.
SERIAL NUMBER:
Used for warranty tracking purposes.
Item # 0055555
Serial
Volts
1234567
120/240 AC
108.3/108.3
13000
Amps
Watts
MODEL #
SERIAL #
WATTS
VOLTS
AMPS
13000
0055555
1234567
120/240 AC
108.3/108.3
1 PH, 60 HZ, RPM 3600
1PH, 60Hz, 3600 RPM, CLASS F INSULATION
RAINPROOF ENCLOSURE FITTED
RATED AMBIENT TEMP - 40°C
CLASS F INSULATION
MAX OPERATING AMBIENT
TEMP - 120F/49C
FOR STANDBY SERVICE, NEUTRAL FLOATING
FOR STANDBY SERVICE
NEUTRAL FLOATING
Model Number -
Serial Number -
MAX LOAD UNBALANCED - 50%
Figure 1. Typical Data Plates
Page 10
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sEctioN 1.2
iNstallatioN Basics
GENERAL INFORMATION
Part 1
LP (propane) gas is usually supplied as a liquid in
pressure tanks. Both the air-cooled and the liquid
cooled units require a “vapor withdrawal” type of fuel
supply system when LP (propane) gas is used. The
vapor withdrawal system utilizes the gaseous fuel
vapors that form at the top of the supply tank.
introduction
Information in this section is provided so that the
service technician will have a basic knowledge of
installation requirements for home standby systems.
Problems that arise are often related to poor or unau-
thorized installation practices.
The pressure at which LP gas is delivered to the
generator fuel solenoid valve may vary considerably,
depending on ambient temperatures. In cold weather,
supply pressures may drop to “zero”. In warm weath-
er, extremely high gas pressures may be encountered.
A primary regulator is required to maintain correct gas
supply pressures.
A typical home standby electric system is shown in
Figure 1 (next page). Installation of such a system
includes the following:
• Selecting a Location
• Grounding the generator.
• Providing a fuel supply.
Current recommended gaseous fuel pressure at the inlet
side of the generator fuel solenoid valve is as follows:
• Mounting the load center.
• Connecting power source and load lines.
• Connecting system control wiring.
• Post installation tests and adjustments.
lP
NG
Minimum water column
Maximum water column
10 inches 5 inches
12 inches 7 inches
SelectinG a location
A primary regulator is required to ensure that proper
fuel supply pressures are maintained.
Install the generator set as close as possible to the
electrical load distribution panel(s) that will be pow-
ered by the unit, ensuring that there is proper ventila-
tion for cooling air and exhaust gases. This will reduce
wiring and conduit lengths. Wiring and conduit not
only add to the cost of the installation, but excessively
long wiring runs can result in a voltage drop.
DaNGEr: lP aND Natural Gas arE BotH
HiGHlY EXPlosiVE. GasEous fuEl liNEs
must BE ProPErlY PurGED aNDtEstED
for lEaKs BEforEtHis EQuiPmENt is
PlacED iNto sErVicE aND PErioDicallY
tHErEaftEr. ProcEDurEs usED iN
*
Control system interconnections between the transfer
switch and generator consist of N1 and N2, and leads
23, 15B and 0. Control system interconnection leads
must be run in a conduit that is separate from the AC
power leads. Recommended wire gauge size depends
on the length of the wire:
GasEous fuEl lEaKaGEtEsts must
comPlY strictlY WitH aPPlicaBlE fuEl
Gas coDEs. Do Not usE flamE or aNY
sourcE of HEattotEst for Gas lEaKs.
No Gas lEaKaGE is PErmittED. lP Gas is
HEaViErtHaN air aNDtENDsto sEttlE iN
loW arEas. Natural Gas is liGHtErtHaN
air aNDtENDsto sEttlE iN HiGH PlacEs.
EVENtHE sliGHtEst sParK caN iGNitE
tHEsE fuEls aND causE aN EXPlosioN.
max. cable length
35 feet (10.67m)
recommended Wire size
No. 16 AWG.
60 feet (I8.29m)
No. 14 AWG.
90 feet (27.43m)
No. 12 AWG.
Use of a flexible length of hose between the genera-
tor fuel line connection and rigid fuel lines is required.
This will help prevent line breakage that might be
caused by vibration or if the generator shifts or settles.
The flexible fuel line must be approved for use with
gaseous fuels.
GroundinG the Generator
The National Electric Code requires that the frame
and external electrically conductive parts of the gen-
erator be property connected to an approved earth
ground. Local electrical codes may also require prop-
er grounding of the unit. For that purpose, a ground-
ing lug is attached to the unit. Grounding may be
accomplished by attaching a stranded copper wire of
the proper size to the generator grounding lug and to
an earth-driven copper or brass grounding-rod (elec-
trode). Consult with a local electrician for grounding
requirements in your area.
Flexible fuel line should be kept as straight as possi-
ble between connections. The bend radius for flexible
fuel line is nine (9) inches. Exceeding the bend radius
can cause the fittings to crack.
the tranSFer SWitch / load center
A transfer switch is required by electrical code, to pre-
vent electrical feedback between the utility and stand-
by power sources, and to transfer electrical loads from
one power supply to another safely.
the Fuel Supply
Units with air-cooled engines were operated, tested
and adjusted at the factory using natural gas as a
fuel. These air-cooled engine units can be converted
to use LP (propane) gas by making a few adjustments
for best operation and power.
TRANSFER SWITCHES:
Instructions and information on transfer switches may
be found in Part 3 of this manual.
Page 11
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sEctioN 1.2
iNstallatioN Basics
GENERAL INFORMATION
Part 1
Figure 1. Typical Installation
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sEctioN 1.2
iNstallatioN Basics
GENERAL INFORMATION
Part 1
poWer Source and load lineS
SyStem control interconnectionS
The utility power supply lines, the standby (genera-
tor) supply lines, and electrical load lines must all be
connected to the proper terminal lugs in the transfer
switch. The following rules apply: In 1-phase systems
with a 2-pole transfer switch, connect the two utility
source hot lines to Transfer Switch Terminal Lugs N1
and N2. Connect the standby source hot lines (E1,
E2) to Transfer Switch Terminal Lugs E1 and E2.
Connect the load lines from Transfer Switch Terminal
Lugs T1 and T2 to the electrical load circuit. Connect
UTILITY, STANDBY and LOAD neutral lines to the
neutral block in the transfer switch.
Home standby generators are equipped with a termi-
nal board identified with the following terminals: (a)
UTILITY 1, (b) UTILITY 2, (c) 23, and (d) 15B. Load
centers house an identically marked terminal board.
When these four terminals are properly interconnect-
ed, dropout of utility source voltage below a preset
value will result in automatic generator startup and
transfer of electrical loads to the “Standby” source.
On restoration of utility source voltage above a preset
value will result in retransfer back to that source and
generator shutdown.
natural GaS Fuel interconnectionS
5-7” WC REGULATOR
TO HOUSEHOLD
GAS METER CAPABLE
OF PROVIDING NATURAL GAS
FUEL FLOW OF:
140,000 (7 kW)
156,000 (9 kW)
215,000 (12 kW)
220,000 (13 kW)
261,000 (16 kW)
294,000 (18 kW)
BTU/HOUR
SAFETY
SHUT OFF
VALVE
0000001
+HOUSEHOLD APPLIANCES
(BASED ON 1000 BTU/CU FT)
GAS MAIN
2-5 PSI
Figure 2. Proper Fuel Installation
Page 13
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Section 1.3
non-PrePackaged interconnectionS
General information
Part 1
Discussion:
3. Using the following diagram and UL approved wire nuts
connect the following wires together. Wire 0 will not be
utilized for this setup.
on the current model air-cooled generators Wire 194
was changed to 15B. Wire 15B is still utilized for posi-
tive voltage for the transfer relay and Wire 23 is still the
control ground for transferring the generator. By follow-
ing the procedures below it is possible to connect new
product with Wire 15B to old or current product that
still utilize Wire 194, such as an rts switch.
CONTROL WIRES FROM
TRANSFER SWITCH
N1 (BLU)
N2 (YEL)
23 (BRN)
194 (ORG)
N1 (YEL)
N2 (YEL)
23 (WHT)
15B (RED)
0 (BLK)
ConneCt a pre-2008 load Center switCh to a
Current or Future air-Cooled generator.
ProceDure:
1. Follow all instructions located in the Installation Manual
that was supplied with the unit regarding mounting of the
switch, junction box, and generator.
note: when installing a standalone 5500 series
generator, the battery charger will be located in the
generator on the side of the control assembly.
WIRE NUTS
CONTROL WIRES FROM
ENGINE GENERATOR
2. Inside the Junction box between the generator and the
transfer switch there will be 5 wires coming from the
generator and 4 wires from the transfer switch.
Figure 1. Wire Connections
“08” & LATER HSB AIR-COOLED GENERATORS
SINGLE & V-TWIN ENGINES
PRE “08” LOAD CENTER
TRANSFER SWITCH
WIRE
NUTS
CONTROL WIRES FROM ENGINE GENERATOR
CONTROL WIRES FROM TRANSFER SWITCH
N1 (YEL)
N2 (YEL)
23 (WHT)
15B (RED)
0 (BLK)
N1 (BLU)
N2 (YEL)
23 (BRN)
194 (ORG)
EXTERNAL CUSTOMER
CONNECTION BOX
INSTALL BATTERY CHARGER GENERAC P/N 0G8023
Figure 2. Post 2008 HSB Interconnections
Page 14
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sEctioN 1.3
NoN-PrEPacKaGED iNtErcoNNEctioNs
GENERAL INFORMATION
Part 1
connect a 2008 and later load center SWitch
to a pre-2008 air-cooled Generator.
CONTROL WIRES FROM
ENGINE GENERATOR
PROCEDURE:
N1 (BLU)
N2 (YEL)
23 (BRN)
194 (ORG)
N1 (YEL)
N2 (YEL)
23 (WHT)
15B (RED)
0 (BLK)
1. Follow all instructions located in the Installation Manual
that was supplied with the unit regarding mounting of the
switch, junction box, and generator.
note: When installing a standalone pre-2008 gen-
erator, the battery charger will be located in the
generator utilizing the 12 Vdc trickle charger.
2. Inside the Junction box between the generator and the
transfer switch there will be 4 wires coming from the
generator and 5 wires from the transfer switch.
3. Using the following diagram and UL approved wire nuts
connect the following wires together. Wire 0 will not be
utilized for this setup.
CONTROL WIRES FROM
TRANSFER SWITCH
WIRE NUTS
note: remove the battery charger from the trans-
fer switch; it will not be utilized in the operation of
the generator.
Figure 3. Wire Connections
PRE “08” HSB AIR-COOLED GENERATORS
SINGLE & V-TWIN ENGINES
“08” & LATER LOAD CENTER
TRANSFER SWITCH
WIRE
NUTS
CONTROL WIRES FROM ENGINE GENERATOR
CONTROL WIRES FROM TRANSFER SWITCH
N1 (YEL)
N2 (YEL)
23 (WHT)
15B (RED)
0 (BLK)
N1 (BLU)
N2 (YEL)
23 (BRN)
194 (ORG)
EXTERNAL CUSTOMER
CONNECTION BOX
Figure 4. Pre-2008 HSB Interconnections
Page 15
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sEctioN 1.4
PrEParatioN BEforE usE
GENERAL INFORMATION
Part 1
All installed gaseous fuel piping must be purged and
leak tested prior to initial start-up in accordance with
local codes, standards and regulations.
General
The installer must ensure that the home standby gen-
erator has been properly installed. The system must
be inspected carefully following installation. All appli-
cable codes, standards and regulations pertaining to
such installations must be strictly complied with. In
addition, regulations established by the Occupational
Safety and Health Administration (OSHA) must be
complied with.
Fuel conSumption
The fuel consumption rates are listed in the
SPECIFICATIONS section at the front of this manual.
BTU FLOW REqUIREMENTS - NATURAL GAS:
Prior to initial startup of the unit, the installer must
ensure that the engine-generator has been properly
prepared for use. This includes the following:
BTU flow required for each unit based on 1000 BTU
per cubic foot.
• An adequate supply of the correct fuel must be
7 kW -
9 kW -
12 kW -
13 kW -
16 kW -
18 kW -
140,000 BTU/Hour
156,000 BTU/Hour
215,000 BTU/Hour
220,000 BTU/Hour
261,000 BTU/Hour
294,000 BTU/Hour
available for generator operation.
• The engine must be properly serviced with the rec-
ommended oil.
Fuel requirementS
With LP gas, use only the vapor withdrawal system.
This type of system uses the vapors formed above
the liquid fuel in the storage tank.
DANGER
The engine has been fitted with a fuel carburetion
system that meets the specifications of the 1997
California Air Resources Board for tamper-proof dual
fuel systems. The unit will run on natural gas or LP
gas, but it has been factory set to run on natural gas.
Should the primary fuel need to be changed to LP
gas, the fuel system needs to be reconfigured. See
the Reconfiguring the Fuel System section for instruc-
tions on reconfiguration of the fuel system.
Gaseous fuels such as natural gas and liquid
propane (lP) gas are highly explosive. Even
the slightest spark can ignite such fuels and
cause an explosion. No leakage of fuel is per-
mitted. Natural gas, which is lighter than air,
tends to collect in high areas. lP gas is heavi-
er than air and tends to settle in low areas.
$
Recommended fuels should have a Btu content of
at least 1,000 Btus per cubic foot for natural gas; or
at least 2,520 Btus per cubic foot for LP gas. Ask the
fuel supplier for the Btu content of the fuel.
note: a minimum of one approved manual shut-
off valve must be installed in the gaseous fuel
supply line. the valve must be easily accessible.
local codes determine the proper location.
Required fuel pressure for natural gas is 5 inches to
7 inches water column (0.18 to 0.25 psi); and for liq-
uid propane, 10 inches to 12 inches of water column
(0.36 to 0.43 psi).
reconFiGurinG the Fuel SyStem
note: all pipe sizing, construction and layout
must comply with nFpa 54 for natural gas applica-
tions and nFpa 58 for liquid propane applications.
once the generator is installed, verify that the
fuel pressure neVer drops below four (4) inches
water column for natural gas or 10 inches water
column for liquid propane.
8 kW, 410CC ENGINE:
To reconfigure the fuel system from NG to LP, follow
these steps (Figure 1):
note: the primary regulator for the propane sup-
ply is not included with the generator. a fuel
pressure of 10 to 12 inches of water column (0.36
to 0.43 psi) to the fuel inlet of the generator must
be supplied.
Prior to installation of the generator, the installer
should consult local fuel suppliers or the fire marshal
to check codes and regulations for proper installation.
Local codes will mandate correct routing of gaseous
fuel line piping around gardens, shrubs and other
landscaping to prevent any damage.
1. Turn off the main gas supply (if connected).
2. Open the roof and remove the door.
3. Remove the battery (if installed).
Special considerations should be given when install-
ing the unit where local conditions include flood-
ing, tornados, hurricanes, earthquakes and unstable
ground for the flexibility and strength of piping and
their connections.
4. Locate the plastic T-handle fuel selector in the poly bag
supplied with the generator.
Use an approved pipe sealant or joint compound on
all threaded fitting.
5. Locate the selector knob on the air box cover, behind
the yellow air filter door and power bulge. The unit
comes from the factory in the NG (Natural Gas) position.
Grasping the T-handle, insert the pin end into the hole
Page 16
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sEctioN 1.4
PrEParatioN BEforE usE
GENERAL INFORMATION
Part 1
in the selector knob and pull out to overcome spring
pressure and then twist clockwise 90 degrees and allow
the selector to return in once aligned with the LP (Liquid
Propane) position.
FUEL SELECTION
LEVER -
6. Save this tool with the Owner's Manual.
“OUT” POSITION FOR
LIQUID PROPANE
(VAPOR) FUEL
7. Install the battery, door and close the roof.
8. Reverse the procedure to convert back to natural gas.
Figure 3. 10 kW, GT-530 (Inlet Hose Slid Back)
1. Open the roof.
2. for 10 kW units: Loosen clamp and slide back the
air inlet hose.
• Slide fuel selector on carburetor out towards the
back of the enclosure (Figures 2 and 3).
• Return the inlet hose and tighten clamp securely.
for 12, 14, 16, 17 and 20 kW units: remove the air
cleaner cover.
• Slide the selector lever out towards the back of the
enclosure (Figures 4 and 5).
Figure 1. Demand Regulator
10, 12, 14, 16, 17 AND 20 kW, V-TWIN ENGINES:
• Return the air cleaner cover and tighten the two
thumb screws.
To reconfigure the fuel system from NG to LP, follow
these steps:
3. Close the roof.
note: the primary regulator for the propane sup-
ply is not included with the generator. a fuel
pressure of 10 to 12 inches of water column (0.36
to 0.43 psi) to the fuel inlet of the generator muSt
Be Supplied.
4. Reverse the procedure to convert back to natural gas.
FUEL SELECTION
LEVER -
“IN” POSITION FOR
NATURAL GAS
FUEL SELECTION
LEVER -
“IN” POSITION FOR
NATURAL GAS
Figure 4. 12/14/16/17/20 kW, GT-990/GT-999
(Airbox Cover Removed)
Figure 2. 10 kW, GT-530 (Inlet Hose Slid Back)
Page 17
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sEctioN 1.4
PrEParatioN BEforE usE
GENERAL INFORMATION
Part 1
enGine oil recommendationS
All oil should meet minimum American Petroleum
Institute (API) Service Class SJ, SL or better. Use
no special additives. Select the oil's viscosity grade
according to the expected operating temperature.
FUEL SELECTION
LEVER -
“OUT” POSITION FOR
LIQUID PROPANE
(VAPOR) FUEL
• SAE 30 è Above 32° F
• 10W-30 è Between 40° F and -10° F
• Synthetic 5W-30 è 10° F and below
Engine crankcase oil capacities for the engines cov-
ered in this manual can be found in the specifications
section at the beginning of the book.
any attempt to crank or start the engine
before it has been properly serviced with
the recommended oil may result in an
*
engine failure.
Figure 5. 12/14/16/17/20 kW, GT-990/GT-999
(Airbox Cover Removed)
SAE 30
10W-30
Synthetic 5W-30
Page 18
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sEctioN 1.5
tEstiNG, clEaNiNG aND DrYiNG
GENERAL INFORMATION
Part 1
meterS
meaSurinG ac VoltaGe
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:
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.
• To measure AC voltage, use an AC voltmeter.
• To measure DC voltage, use a DC voltmeter.
• Use a frequency meter to measure AC frequency In
“Hertz” or “cycles per second”.
2. The generator’s Voltage Regulator can be adjusted for
correct output voltage only while the unit is operating at
its correct rated speed and frequency.
3. Only an AC voltmeter may be used to measure AC
voltage. DO NOT USE A DC VOLTMETER FOR THIS
PURPOSE.
• Use an ohmmeter to read circuit resistance, in “ohms”.
the Vom
DaNGEr!: GENErators ProDucE HiGH
aND DaNGErous VoltaGEs. coNtact
WitH HiGH VoltaGE tErmiNals Will
rEsult iN DaNGErous aND PossiBlY
lEtHal ElEctrical sHocK.
A meter that will permit both voltage and resistance to
be read is the “volt-ohm-milliammeter” or “VOM”.
*
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 1) are also available and are
generally very accurate. Digital meters display the
measured values directly by converting the values to
numbers.
meaSurinG dc VoltaGe
A DC voltmeter or a VOM may be used to measure
DC voltages. Always observe the following rules:
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).
1. Always observe correct DC polarity.
a. Some VOM’s may be equipped with a polarity
switch.
b. On meters that do not have a polarity switch,
DC polarity must be reversed by reversing the
test leads.
2. Before reading a DC voltage, always set the meter to a
higher voltage scale than the anticipated reading. If in
doubt, start at the highest scale and adjust the scale
downward until correct readings are obtained.
3. The design of some meters is based on the “current
flow” 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 nega-
tive (-).
b. The “electron flow” theory assumes that current
flows from negative (-) to positive (+).
note: When testing generators, the “current flow”
theory is applied. that is, current is assumed to
flow from positive (+) to negative (-).
meaSurinG ac Frequency
The generator’s AC output frequency is proportional
to Rotor speed. Generators equipped with a 2-pole
Rotor must operate at 3600 rpm to supply a frequency
of 60 Hertz. Units with 4-pole Rotor must run at 1800
rpm to deliver 60 Hertz.
Figure 1. Digital VOM
Page 19
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sEctioN 1.5
tEstiNG, clEaNiNG aND DrYiNG
GENERAL INFORMATION
Part 1
IN-LINE:
meaSurinG current
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 measure
amperes.
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.
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 measured.
In Figure 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.
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.
1.00
A
BATTERY
-
+
RELAY
Figure 4. A VOM as an In-line meter
Figure 2. Clamp-On Ammeter
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 a VOM:
• A “short-to-ground” condition in any Stator or Rotor
winding.
Figure 3. A Line-Splitter
• Shorting together of any two parallel Stator windings.
• Shorting together of any two isolated Stator windings.
• An open condition in any Stator or Rotor winding.
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.
Page 20
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sEctioN 1.5
tEstiNG, clEaNiNG aND DrYiNG
GENERAL INFORMATION
Part 1
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 electrical
points, which would be indicated as very low resis-
tance or “ZERO” on a VOM.
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.
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.
ohm’S laW
A definite and exact relationship exists between
VOLTS, OHMS and AMPERES. The value of one can
be calculated when the value of the other two are
known. Ohm’s Law states that in any circuit the current
will increase when voltage increases but resistance
remains the same, and current will decrease when
resistance Increases and voltage remains the same.
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:
VOLTS
(E)
The VOLT is the unit used to measure electrical
PRESSURE, or the difference in electrical potential
that causes electrons to flow. Very few electrons will
flow when voltage is weak. More electrons will flow as
voltage becomes stronger. VOLTAGE 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.
AMPS
(I)
OHMS
(R)
Conductor of a
Circuit
Figure 6. Ohm’s Law
oHm - Unit measuring resistance
or opposition to flow
If AMPERES is unknown while VOLTS and OHMS are
known, use the following formula:
VoltS
+
ampereS =
-
ohmS
amPErE - Unit measuring rate of
current flow (number of electrons
past a given point)
If VOLTS is unknown while AMPERES and OHMS are
known, use the following formula:
VoltS = ampereS x ohmS
Volt - Unit measuring force or
difference in potential
If OHMS is unknown but VOLTS and AMPERES are
known, use the following:
causing current flow
VoltS
ampereS
=
ohmS
Figure 5. Electrical Units
Page 21
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sEctioN 1.5
tEstiNG, clEaNiNG aND DrYiNG
GENERAL INFORMATION
Part 1
The MINIMUM acceptable megger reading for stators
may be calculated using the following formula:
ViSual inSpection
When it becomes necessary to test or troubleshoot a
generator, it is a good practice to complete a thorough
visual inspection. Remove the access covers and look
closely for any obvious problems. Look for the following:
MINIMUM INSULATION
RESISTANCE
(in “Megohms”)
GENERATOR RATED VOLTS
__________________________
=
+1
1000
• Burned or broken wires, broken wire connectors,
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.
damaged mounting brackets, etc.
• Loose or frayed wiring insulation, loose or dirty
connections.
• Check that all wiring is well clear of rotating parts.
• Verify that the Generator properly connected for the
correct rated voltage. This is especially important on
new installations. See Section 1.2, “AC Connection
Systems”.
• Look for foreign objects, loose nuts, bolts and other
fasteners.
• Clean the area around the Generator. Clear away
paper, leaves, snow, and other objects that might
blow against the generator and obstruct its air
openings.
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 (12-20kW):
Apply a voltage of 500 volts across the rotor posi-
tive (+) slip ring (nearest the rotor bearing), and
a clean frame ground (i.e. the rotor shaft). DO
NOT EXCEED 500 VOLTS AND DO NOT APPLY
VOLTAGE LONGER THAN 1 SECOND. FOLLOW
THE MEGGER MANUFACTURER’S INSTRUCTIONS
CAREFULLY.
inSulation reSiStance
The insulation resistance of stator and rotor windings
is a measurement of the integrity of the insulating
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 break-
down in the insulation. And, in many cases, a low insu-
lation 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 usually eliminate dirt and
moisture built up in the generator windings.
rotor miNimum iNsulatioN rEsistaNcE:
1.5 megohms
TESTING ROTOR INSULATION (8-10kW):
No test available.
cautioN: Before attempting to measure insu-
lation resistance, first disconnect and isolate
all leads of the winding to be tested. Electronic
components, diodes, surge protectors, relays,
voltage regulators, etc., can be destroyed if
subjected to high megger voltages.
*
the meGohmmeter
GENERAL:
A 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 8) 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 frame ground on the sta-
tor can. Read the number of megohms on the meter.
Figure 7. One Type of Hi-Pot Tester
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GENERAL INFORMATION
Part 1
HI-POT TESTER:
b. Plug the tester cord into a 120 volt AC wall
socket and set its voltage selector switch to
“1500 volts”.
A “Hi-Pot” tester is shown in Figure 7. 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.
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
cleaning and drying, the stator fails the second test,
the stator assembly should be replaced.
Stator inSulation reSiStance teSt
(12-20 kW)
6. Proceed to the Voltage Regulator. Each winding will be
individually tested for a short to ground. Refer to Steps
5a-5c and perform the same test on the following wires:
GENERAL:
Units with air-cooled engine are equipped with (a)
dual stator AC power windings, and (b) excitation or
DPE winding. Insulation tests of the stator consist of
(a) testing all windings to ground, (b) testing between
isolated windings, and (c) testing between parallel
windings. Figure 8 is a pictorial representation of the
various stator leads on units with air-cooled engines.
Wire
Number
Winding
22S
11S
6
Sense Lead Power
Sense Lead Power
Excitation
TESTING ALL STATOR WINDINGS TO GROUND:
2
Excitation
1. Disconnect stator output leads 11 and 44 from the gen-
erator main line circuit breaker.
0
Ground
4
Positive to Brush Ground
2. Remove stator output leads 22 and 33 from the neutral
connection and separate the two leads.
TEST BETWEEN WINDINGS:
3. Disconnect Wires 11 and 22 from Voltage Regulator.
Ensure these wires are not touching any other compo-
nents on the generator.
1. Disconnect Stator Output Leads 11 and 44 from the
generator main line circuit breaker.
2. Remove Stator Output Leads 22 and 33 from the neutral
connection and separate the two leads.
2
6
3. Disconnect Wires 11, 22, 2, and 6 from Voltage
Regulator. Ensure these wires are not touching any
other components on the generator.
11P
11S (12-20 kW)
22P
4. Connect the red tester probe to Wire 2. Connect the
black tester probe to Stator Lead 11. Refer to Steps 5a
through 5c of “TESTING ALL STATOR WINDINGS TO
GROUND” on previous page.
22S (12-20 kW)
33
5. Repeat Step 4 between Wire 2 and Stator Lead 33.
6. Repeat Step 4 between Stator Lead 11 and Stator Lead 33.
44
Figure 8. Stator Winding Leads
Stator inSulation reSiStance teSt
4. Connect the terminal ends of Wires 11, 22, 33 and 44
together. Make sure the wire ends are not touching any
part of the generator frame or any terminal.
(8-10 kW)
GENERAL:
Units with air-cooled engine are equipped with (a)
dual stator AC power windings, and (b) excitation or
DPE winding. Insulation tests of the stator consist of
(a) testing all windings to ground, (b) testing between
isolated windings, and (c) testing between parallel
windings. Figure 8 is a pictorial representation of the
various stator leads on units with air-cooled engines.
5. Connect the red test probe of the Hi-Pot tester to the
joined terminal ends of stator leads 11, 22, 33 and 44.
Connect the black tester lead to a clean frame ground
on the stator can. With tester leads connected in this
manner, proceed as follows:
a. Turn the Hi-Pot tester switch OFF.
Page 23
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tEstiNG, clEaNiNG aND DrYiNG
GENERAL INFORMATION
Part 1
TESTING ALL STATOR WINDINGS TO GROUND:
4. Plug the tester into a 120 volts AC wall socket and set
the voltage switch to “1500 volts”.
1. Disconnect Stator Output Leads 11 and 44 from the
generator main line circuit breaker.
5. Turn the tester switch “On” and make sure the pilot light
has turned on.
2. Disconnect Stator Output Leads 2 and 6 from the
capacitor located on the end of the stator assembly.
6. Observe the breakdown lamp, then turn the tester switch
OFF. DO NOT APPLY VOLTAGE LONGER THAN ONE
(1) SECOND.
3. Remove Stator Output Leads 22 and 33 from the neutral
connection and separate the two leads.
If the breakdown lamp came on during the one (1)
second test, cleaning and drying of the 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.
4. Connect the terminal ends of Wires 11, 22, 33, and 44
together. Make sure the wire ends are not touching any
part of the generator 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, 33, and 44.
Connect the black tester lead to a clean frame ground
on the stator can. With tester 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
socket 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.
POSITIVE (+)
TEST LEAD
6. Connect the terminal ends of Wires 2 and 6 together.
Make sure the wire ends are not touching any part of
the generator frame or any terminal.
Figure 9. Testing Rotor Insulation (12-20kW)
7. Repeat Step 5.
cleaninG the Generator
If the breakdown lamp came on during the one (1)
second test, cleaning and drying of the 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.
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
rotor inSulation reSiStance teSt
the generator. some of the water will be
retained on generator windings and terminals,
and may cause very serious problems.
*
(8-10 kW)
No test available.
dryinG the Generator
rotor inSulation reSiStance teSt
(12-20 kW)
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.
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.
2. Disconnect all Wires 6 from the voltage regulator.
1. Connect the red tester lead to the positive (+) slip ring
(nearest the rotor bearing).
3. Provide an external source to blow warm, dry air through
the generator interior (around the rotor and stator wind-
ings. DO NOT EXCEED 185° F. (85° C.).
2. Connect the black tester probe to a clean frame ground,
such as a clean metal part of the rotor shaft.
4. Start the generator and let it run for 2 or 3 hours.
3. Turn the tester switch OFF.
5. Shut the generator down and repeat the stator and rotor
insulation resistance tests.
Page 24
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sEctioN 1.6
ENGiNE-GENErator ProtEctiVE DEVicEs
GENERAL INFORMATION
Part 1
General
oVerSpeed ShutdoWn
Standby electric power generators will often run
unattended for long periods of time. Such operating
parameters as (a) battery voltage, (b) engine oil pres-
sure, (c) engine temperature, (d) engine operating
speed, and (e) engine cranking and startup are not
monitored by an operator during automatic operation.
Because engine operation will not be monitored, the
use of engine protective safety devices is required to
prevent engine damage in the event of a problem.
During engine cranking and operation, the circuit
board receives AC voltage and frequency signals
from the ignition magneto, via Wire 18. Should the
speed exceed approximately 72 Hz (4320 rpm),
circuit board action will de-energize a “run relay”
(mounted on the circuit board). The relay’s contacts
will open, to terminate engine ignition and close a
fuel shutoff solenoid. The engine will then shut down.
This feature protects the engine-generator against
damaging overspeeds.
Generator engines mount several engine protec-
tive devices. These devices work in conjunction with
a circuit board, to protect the engine against such
operating faults as (a) low battery, (b) low engine oil
pressure, (c) high temperature, (d) overspeed, and
(e) overcrank. On occurrence of any one or more of
those operating faults, circuit board action will effect
an engine shutdown.
note: the circuit board also uses rpm sensing to
terminate engine cranking.
rpm SenSor Failure
During cranking, if the board does not see a valid
RPM signal within three (3) seconds, it will shut down
and latch out on RPM sensor loss.
loW Battery
During running, if the RPM signal is lost for one full
second the board will shut down the engine, wait 15
seconds, then re-crank the engine.
• If an RPM signal is not detected within the first three
(3) seconds of cranking, the control board will shut
the engine down and latch out on RPM sensor loss.
• If the RPM signal is detected the engine will start
and run normally. If the RPM signal is subsequently
lost again, the control board will try one more re-
crank attempt before latching out and flashing the
overspeed LED or RPM Sensor Failure.
The microprocessor will continually monitor the bat-
tery voltage and turn on the Low Battery Warning
if the battery voltage falls below 10.8 volts for one
(1) minute. No other action is taken on a low battery
condition. Low battery voltage is a non-latching alarm
which will automatically clear if the battery voltage
rises above 11.0 volts. Battery voltage is NOT moni-
tored during the crank cycle.
loW oil preSSure ShutdoWn
See Figure 1. An oil pressure switch is mounted on
the engine oil filter adapter. This switch has normally
closed contacts that are held open by engine oil pres-
sure during cranking and startup. Should oil pressure
drop below approximately 5 psi, the switch contacts
will close. On closure of the switch contacts, a Wire
86 circuit from the circuit board will be connected to
ground. Circuit board action will then de-energize
a “run relay” (on the circuit board). The run relay’s
normally open contacts will then open and a 12 volts
DC power supply to a Wire 14 circuit will then be
terminated. This will result in closure of a fuel shutoff
solenoid and loss of engine ignition.
LOW OIL SWITCH
HIGH TEMP SWITCH
OIL FILTER
OIL
DRAIN
HOSE
hiGh temperature SWitch
This switch’s contacts (Figure 1) close if the tempera-
ture should exceed approximately 144° C (293° F),
initiating an engine shutdown. The generator will auto-
matically restart and the fault on the generator control
panel will reset once the temperature has returned to
a safe operating level.
Figure 1. Engine Protective Switches on an
Air-Cooled Engine
Page 25
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sEctioN 1.6
ENGiNE-GENErator ProtEctiVE DEVicEs
GENERAL INFORMATION
Part 1
CRANkING CONDITIONS:
oVercrank ShutdoWn
The following notes apply during cranking cycle.
This feature prevents the generator from damaging
itself when it continually attempts to start and another
problem, such as no fuel supply, prevents it from start-
ing. The unit will crank and rest for a preset time limit.
Then, it will stop cranking, and the LCD screen or the
LED on the generator control panel will light indicating
an overcrank failure. The AUTO-OFF-MANUAL switch
will need to be set to OFF and then back to AUTO to
reset the generator control board.
1. Starter motor will not engage within five (5) seconds of
the engine shutting down.
2. The fuel output will not be energized with the starter.
3. The starter and magneto outputs will be energized
together.
4. Once the starter is energized the control board will begin
looking for engine rotation. If it does not see an RPM
signal within three (3) seconds it will shut down and
latch out on RPM sensor loss.
note: if the fault is not repaired, the overcrank
feature will continue to activate.
The system will control the cyclic cranking as follows:
16 second crank, seven (7) second rest, 16 second
crank, seven (7) second rest followed by three (3)
additional cycles of seven (7) second cranks followed
by seven (7) second rests.
5. Once the control board sees an RPM signal it will
energize the fuel solenoid, drive the throttle open and
continue the crank sequence.
CHOkE OPERATION:
6. Starter motor will disengage when speed reaches
starter dropout.
1. The 990/999cc engines have an electric choke in the
air box that is automatically controlled by the electronic
control board.
7. If the generator does not reach 2200 RPM within 15
seconds, re-crank cycle will occur.
2. The 530cc engines have an electric choke on the divider
panel air inlet hose that is automatically controlled by
the electronic control board.
8. If engine stops turning between starter dropout and 2200
RPM, the board will go into a rest cycle for seven (7)
seconds then re-crank (if additional crank cycles exist).
3. The 410cc engines have a choke behind the air box that
is automatically controlled by the electronic control board.
9. Once started, the generator will wait for a hold-off
period before starting to monitor oil pressure and oil
temperature (refer to the Alarm Messages section for
hold-off times).
FAILURE TO START:
This is defined as any of the following occurrences
during cranking.
10.During Manual start cranking, if the Mode switch is
moved from the Manual position, the cranking stops
immediately.
1. Not reaching starter dropout within the specified crank
cycle. Starter dropout is defined as four (4) cycles at
1,500 RPM (1,800 RPM for 8 kW units).
11.During Auto mode cranking, if the Utility returns, the
cranking cycle does NOT abort but continues until
complete. Once the engine starts, it will run for one (1)
minute, then shut down.
2. Reaching starter dropout, but then not reaching 2200
RPM within 15 seconds. In this case the control board
will go into a rest cycle for seven (7) seconds, then con-
tinue the rest of the crank cycle.
During a rest cycle the start and fuel outputs are de-
energized and the magneto output is shorted to ground.
Page 26
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sEctioN 1.7
oPEratiNG iNstructioNs
GENERAL INFORMATION
Part 1
control panel
DaNGEr:WHEN tHE GENErator is
iNstallED iN coNJuNctioN WitH aN
automatic traNsfEr sWitcH, ENGiNE
craNKiNG aND startuP caN occur at
aNY timE WitHout WarNiNG (ProViDiNG
tHE auto-off-maNual sWitcH is sEt to
auto).to PrEVENt automatic startuP
aND PossiBlE iNJurY tHat miGHt BE
causED BY sucH startuP, alWaYs sEt
tHE auto-off-maNual sWitcH to its
off PositioN BEforE WorKiNG oN or
arouND tHis EQuiPmENt.
*
SYSTEM READY
LOW BATTERY
LOW OIL PRESSURE
HIGH OIL TEMPERATURE
OVERSPEED
SET
EXERCISE
ECS
ENTER
RPM SENSOR LOSS
OVERCRANK
7.5 AMP FUSE:
This fuse protects the DC control circuit (including the
circuit board) against overload. If the fuse element
has melted open due to an overload, engine cranking
or running will not be possible. Should fuse replace-
ment become necessary, use only an identical 7.5
amp replacement fuse.
8 kW UNITS
10-20 kW UNITS
Figure 1. Generator Control Panel
SETTING THE EXERCISE TIMER:
AUTO-OFF-MANUAL SWITCH:
This generator is equipped with an exercise timer.
Once it is set, the generator will start and exercise
every seven days, on the day of the week and at the
time of day specified. During this exercise period,
the unit runs for approximately 12 minutes and then
shuts down. Transfer of loads to the generator output
does not occur during the exercise cycle unless utility
power is lost.
Use this switch to (a) select fully automatic operation,
(b) to crank and start the engine manually, and (c) to
shut the unit down or to prevent automatic startup.
1. AUTO position:
a. Select AUTO for fully automatic operation.
b. When AUTO is selected, circuit board will moni-
tor utility power source voltage.
8kW:
c. Should utility voltage drop below a preset level
and remain at such a low level for a preset time,
circuit board action will initiate engine cranking
and startup.
A switch on the control panel (see Figure1) permits
selection of the day and time for the system to exercise.
At the chosen time, perform the following sequence to
select the desired day and time of day the system will
exercise. Remember seasonal time changes affect the
exercise settings.
d. Following engine startup, circuit board action
will initiate transfer of electrical loads to the
“Standby” source side.
1. Verify that the AUTO-OFF-MANUAL switch is set to AUTO.
e. On restoration of utility source voltage above
a preset level, circuit board action will initiate
retransfer back to the “Utility Source” side.
2. Press and hold the “Set Exercise” switch for several
seconds. All the red LED’s will stop flashing immediately
and the generator will start.
f. Following retransfer, circuit board will shut the
engine down and will then continue to monitor
utility source voltage.
3. The generator will start and run for approximately 12
minutes and then shut down. The exerciser is now set to
run at this time of day each week.
2. OFF Position:
a. Set the switch to OFF to stop an operating engine.
Example: If the “Set Exercise” pressed on Saturday
afternoon at 2:00 p.m., the generator will start and
exercise for approximately 12 minutes every Saturday
at 2:00 p.m.
b. To prevent an automatic startup from occurring,
set the switch to OFF.
3. MANUAL Position:
note: the exerciser will only work in the auto
mode and will not work unless this procedure
is performed. the exerciser will need to be reset
every time the 12 Volt battery is disconnected and
then reconnected, and when the fuse is removed
and/or replaced.
a. Set switch to MANUAL to crank and start unit
manually.
b. Engine will crank cyclically and start (same as
automatic startup, but without transfer). The unit
will transfer if utility voltage is not available.
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sEctioN 1.7
oPEratiNG iNstructioNs
GENERAL INFORMATION
Part 1
10-20 kW – INSTALLATION ASSISTANT:
manual tranSFer to “StandBy” and
manual Startup
Upon first power up of the generator, the display inter-
face will begin an installation assistant. The assistant
will prompt the user to set the minimum settings to
operate. These settings are simply: Current Date/Time
and Exercise Day/Time. The maintenance intervals
will be initialized when the exercise time is entered for
the first time (Figure 3.2).
To transfer electrical loads to the “Standby” (generator)
source and start the generator manually, proceed as
follows:
1. On the generator panel, set the AUTO-OFF-MANUAL
switch to OFF.
The exercise settings can be changed at any time via
the "EDIT" menu (see Appendix, "Menu System").
2. On the generator, set the main line circuit breaker to it’s
OFF or “Open” position.
If the 12 Volt battery is disconnected or the fuse
removed, the Installation Assistant will operate upon
power restoration. The only difference is the display
will only prompt the customer for the current Time
and Date.
3. Turn OFF the power supply to the transfer switch, using
whatever means provided (such as a utility source line
circuit breaker).
if the installer tests the generator prior to instal-
lation, press the “enter” key to avoid setting
up the exercise time. this will ensure that when
the customer powers up the unit, he will still be
prompted to enter an exercise time.
4. Manually actuate the transfer switch main contacts to
their “Standby” position, i.e., loads connected to the
“Standby” power source side.
note: For instructions on manual operation of
transfer switches, see part 3.
note:the exerciser will only work in the auto mode
and will not work unless this procedure is performed.
the current date/time will need to be reset every time
the 12 Volt battery is disconnected and then recon-
nected, and/or when the fuse is removed.
5. On the generator panel, set the AUTO-OFF-MANUAL
switch to MANUAL. The engine should crank and start.
6. Let the engine warm up and stabilize for a minute or two
at no-load.
to Select automatic operation
7. Set the generator main line circuit breaker to its “On”
or “Closed” position. The generator now powers the
electrical loads.
The following procedure applies only to those instal-
lations in which the air-cooled, automatic standby
generator is installed in conjunction with a transfer
switch. Transfer switches do not have an intelligence
circuit of their own. Automatic operation on transfer
switch and generator combinations is controlled by
circuit board action.
manual ShutdoWn and retranSFer
Back to “utility”
To select automatic operation when a transfer switch
is installed along with a home standby generator,
proceed as follows:
To shut the generator down and retransfer electrical
loads back to the UTILITY position, proceed as follows:
1. Set the generator main line circuit breaker to its OFF or
“Open” position.
1. Check that the transfer switch main contacts are at
their UTILITY position, i.e., the load is connected to the
power supply. If necessary, manually actuate the switch
main contacts to their UTILITY source side. See Part 3
of this manual, as appropriate, for instructions.
2. Let the generator run at no-load for a few minutes, to cool.
3. Set the generator AUTO-OFF-MANUAL switch to OFF.
Wait for the engine to come to a complete stop.
2. Check that utility source voltage is available to transfer
switch terminal lugs N1 and N2 (2-pole, 1-phase transfer
switches).
4. Turn off the utility power supply to the transfer switch
using whatever means provided (such as a utility source
main line circuit breaker)
3. Set the generator AUTO-OFF-MANUAL switch to its
AUTO position.
5. Manually actuate the transfer switch to its UTILITY
source side, i.e., load connected to the utility source.
4. Actuate the generator main line circuit breaker to its “On”
or “Closed” position. With the preceding Steps 1 through
4 completed, a dropout in utility supply voltage below a
preset level will result in automatic generator cranking
and start-up. Following startup, the transfer switch will be
actuated to its “Standby” source side, i.e., loads powered
6. Turn on the utility power supply to the transfer switch,
using whatever means provided.
7. Set the generator AUTO-OFF-MANUAL switch to AUTO.
by the standby generator.
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sEctioN 1.8
automatic oPEratiNG ParamEtErs
GENERAL INFORMATION
Part 1
FAILURE TO START:
introduction
This is defined as any of the following occurrences
during cranking.
When the generator is installed in conjunction with
a transfer switch, either manual or automatic opera-
tion is possible. Manual transfer and engine startup,
as well as manual shutdown and re-transfer are
covered in Section 1.7. Selection of fully automatic
operation is also discussed in that section. This
section will provide a step-by-step description of the
sequence of events that will occur during automatic
operation of the system.
1. Not reaching starter dropout within the specified crank
cycle. Starter dropout is defined as four (4) cycles at
1,000 RPM.
2. Reaching starter dropout, but then not reaching 2200
RPM within 15 seconds. In this case the control board
will go into a rest cycle for seven (7) seconds, then
continue the rest of the crank cycle.
utility Failure
During a rest cycle the start and fuel outputs are
de-energized and the magneto output is shorted to
ground.
Initial Conditions: Generator in Auto, ready to run,
load being supplied by utility source. When utility
fails (below 65% of nominal), a 10 second (optionally
programmable on the 17 and 20 kW only) line inter-
rupt delay time is started. If the utility is still gone
when the timer expires, the engine will crank and
start. Once started, a five (5) second engine warmup
timer will be initiated.
CRANkING CONDITIONS:
The following notes apply during cranking cycle.
1. Starter motor will not engage within five (5) seconds of
the engine shutting down.
When the warm-up timer expires, the control will
transfer the load to the generator. If the utility power
is restored (above 75% of nominal) at any time from
the initiation of the engine start until the generator
is ready to accept load (5 second warm-up time has
not elapsed), the controller will complete the start
cycle and run the generator through its normal cool
down cycle; however, the load will remain on the utility
source.
2. The fuel output will not be energized with the starter.
3. The starter and magneto outputs will be energized
together.
4. Once the starter is energized the control board will begin
looking for engine rotation. If it does not see an RPM
signal within three (3) seconds it will shut down and
latch out on RPM sensor loss.
5. Once the control board sees an RPM signal it will
energize the fuel solenoid, drive the throttle open and
continue the crank sequence.
crankinG
The system will control the cyclic cranking as follows:
16 second crank, seven (7) second rest, 16 second
crank, seven (7) second rest followed by three (3)
additional cycles of seven (7) second cranks followed
by seven (7) second rests.
6. Starter motor will disengage when speed reaches starter
dropout.
7. If the generator does not reach 2200 RPM within 15
seconds, re-crank cycle will occur.
CHOkE OPERATION:
8. If engine stops turning between starter dropout and
2200 RPM, the board will go into a rest cycle for seven
(7) seconds then re-crank (if additional crank cycles
exist).
1. The 990/999cc engines have an electric choke in the
air box that is automatically controlled by the electronic
control board.
2. The 530cc engines have an electric choke on the divider
panel air inlet hose that is automatically controlled by
the electronic control board.
9. Once started, the generator will wait for a holdoff period
before starting to monitor oil pressure and oil temperature
(refer to the Alarm Messages section for hold-off times).
3. The 410cc engines have a choke behind the air box
that is automatically controlled by the electronic control
board.
10.During Manual start cranking, if the Mode switch is
moved from the Manual position, the cranking stops
immediately.
11.During Auto mode cranking, if the Utility returns, the
cranking cycle does NOT abort but continues until
complete. Once the engine starts, it will run for one (1)
minute, then shut down.
Page 29
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sEctioN 1.8
automatic oPEratiNG ParamEtErs
GENERAL INFORMATION
Part 1
load tranSFer
The transfer of load when the generator is running is
dependent upon the operating mode as follows:
1. Manual
• Will not transfer to generator if utility is present.
• Will transfer to generator if utility fails (below 65% of
nominal for 10 consecutive seconds.
• Will transfer back when utility returns for 15 consec-
utive seconds. The engine will continue to run until
removed from the Manual mode.
2. Auto
• Will start and run if Utility fails for 10 consecutive
seconds.
• Will start a five (5) second engine warm-up timer.
• Will not transfer if utility subsequently returns.
• Will transfer to generator if utility is still not present.
• Will transfer back to utility once utility returns (above
75% of nominal) for 15 seconds.
• Will transfer back to utility if the generator is shut
down for any reason (such as the switch is in the
OFF position or a shutdown alarm.
• After transfer, will shut down engine after one (1)
minute cool-down time.
3. Exercise
• Will not exercise if generator is already running in
either Auto or Manual mode.
• During exercise, the controller will only transfer if
utility fails during exercise for 10 seconds, and will
switch to Auto mode.
utility reStored
Initial Condition: Generator supplying power to cus-
tomer load. When the utility returns (above 75% of
nominal), a 15 second return to utility timer will start.
At the completion of this timer, if the utility supply is
still present and acceptable, the control will transfer
the load back to the utility and run the engine through
a one (1) minute cool down period and then shut
down. If utility fails for three (3) seconds during this
cool down period, the control will transfer load back to
the generator and continue to run while monitoring for
utility to return.
Page 30
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taBlE of coNtENts
Part
titlE
PaGE#
30
2.1. Description and components
2.2 operational analysis
2.3 troubleshooting flow charts
33
35
Part 2
2.4 Diagnostic tests
39
ac GENErators
air-cooled, automatic
standby Generators
2.1 Description and Components.......................... 32
Introduction......................................................32
Engine-Generator Drive System......................32
The AC Generator............................................32
Rotor Assembly................................................32
Stator Assembly...............................................33
Brush Holder And Brushes (12-20 kW) ...........34
Other AC Generator Components ...................34
2.2 Operational Analysis ....................................... 35
Rotor Residual Magnetism...............................35
Field Boost (12-20 kW Units) ..........................35
Operation (8/10 kW).........................................36
Operation (12-20 kW) ......................................36
2.3 Troubleshooting Flowcharts............................. 37
Test 1 – Check Main Circuit Breaker................41
Test 2 – Check AC Output Voltage...................41
Test 4 – Fixed Excitation Test/Rotor
Amp Draw Test ....................................42
Test 5 – Wire Continuity (12-20 kW) ................43
Test 6 – Check Field Boost (12-20 kW) ...........44
Test 7 – Testing The Stator With A Vom
(12-20 kW)...........................................44
Test 8 – Test Brushless Stator..........................45
Test 9 – Check Capacitor.................................46
Test 10 – Test DPE Winding on
Brushless units....................................47
Test 11 – Resistance Check Of Rotor Circuit
(12-20 kW)...........................................48
Test 12 – Check Brushes And Slip Rings
(12-20 kW)...........................................48
Problem 1 – Generator Produces Zero
Voltage or Residual Voltage 12-20 kW.... 37-38
Test 13 – Test Rotor Assembly(12-20 kW).......49
Test 14 – Check AC Output Frequency............49
Problem 2 – Generator Produces Zero
Voltage or Residual Voltage 8/10 kW ............38
Test 15 – Check and Adjust Engine Governor
(Single Cylinder Units).........................49
Problem 3 – Generator Produces
Low Voltage at No-Load ................................39
Test 16 – Check Stepper Motor Control
(V-twin Engine Units)...........................50
Problem 4 – Generator Produces
High Voltage at No-Load ...............................39
Test 17 – Check And Adjust Voltage
Regulator (12-20 kW)..........................51
Problem 5 – Voltage and Frequency Drop
Excessively When Loads are Applied ...........40
Test 18 – Check Voltage And Frequency
Under Load..........................................52
2.4 Diagnostic Tests .............................................. 41
Introduction......................................................41
Safety ............................................................41
Test 19 – Check For Overload Condition...........52
Test 20 – Check Engine Condition...................52
Test 21 – Field Flash Alternator (8-10 kW) ......52
Page 31
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sEctioN 2.1
DEscriPtioN & comPoNENts
AC GENERATORS
Part 2
1), and mounted in an enclosure. Both the engine and
generator rotor are driven at approximately 3600 rpm,
to provide a 60 Hz AC output.
introduction
The air-cooled, automatic standby system is an easy
to install, fully enclosed and self-sufficient electric
power system. It is designed especially for homeown-
ers, but may be used in other applications as well.
On occurrence of a utility power failure, this high
performance system will (a) crank and start automati-
cally, and (b) automatically transfer electrical loads to
generator AC output.
the ac Generator
Figure 1 shows the major components of the AC
generator.
The generator revolving field (rotor) is driven by an
air-cooled engine at about 3600 rpm.
rotor aSSemBly
The generator may be used to supply electrical power
for the operation of 120 and/or 240 volts, 1-phase, 60
Hz, AC loads.
12-20 kW:
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 pole 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. 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.
A 2-pole, “W/V-Type” transfer switch is offered (see
Part 3). The transfer switch does not include an “intel-
ligence circuit” of it’s own. Instead, automatic startup,
transfer, running, retransfer and shutdown operations
are controlled by a solid state circuit board in the
generator control panel.
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
"8KW"
"C"
"D"
0.8
"12KW - 20KW"
"D"
ENGINE ADAPTOR
"10KW"
"8KW - 10KW"
"C"
"D"
BRUSH HOLDER
ASSEMBLY
"B"
"C"
"D"
STATOR
9
"C"
"B"
"B"
ROTOR
ENGINE ADAPTOR
"12KW - 20KW"
BEARING CARRIER
Figure 1. AC Generator Exploded View
Page 32
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sEctioN 2.1
DEscriPtioN & comPoNENts
AC GENERATORS
Part 2
Stator aSSemBly
SLIP RINGS
The stator can houses and retains (a) dual AC power
windings, and (b) excitation winding. A total of six (6)
or eight (8) stator leads are brought out of the stator
can as shown in Figure 4.
The stator can is sandwiched between an engine
adapter and a rear bearing carrier. It is retained in that
position by four stator studs.
2
BEARING
6
11P
11S (12-20 kW)
22P
Figure 2. The 2-Pole Rotor Assembly 12-20 kW
8/10kW:
Like the 12-20 kW rotor, the 8/10 kW 2-pole rotor must
be operated at 3600 rpm to supply a 60 Hertz AC fre-
quency. However, the 8/10kW rotor uses no slip rings.
As the rotor rotates in the generator voltage is induced
from the Excitation winding using a capacitor that is in
turn excited by the rotor. A continuous loop of charging
and discharging of the capacitor is maintained that
acts as a voltage regulation system. 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.
22S (12-20 kW)
33
44
Figure 4. Stator Assembly Leads
DIODE A
COIL 1
COIL 2
BEARING
DIODE B
DIODE B
DIODE A
ANODE
ANODE
CATHODE
CATHODE
Figure 3. The 2-Pole Rotor Assembly 8/10kW
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sEctioN 2.1
DEscriPtioN & comPoNENts
AC GENERATORS
Part 2
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.
BruSh holder and BruSheS
(12-20 kW)
The brush holder is retained to the rear bearing car-
rier by means of two #10-32 x 9/16 Taptite screws. A
positive (+) and a negative (-) brush are retained in
the brush holder, with the positive (+) brush riding on
the slip ring nearest the rotor bearing.
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.
4
0
Figure 5. Typical Voltage Regulator
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
with a frequency of 60 Hz
+
-
At the stated no-load frequency, adjust to obtain a
line-to-line AC voltage of 247-249 volts.
MAIN LINE CIRCUIT BREAkER:
Figure 4. Brush Holder and Brushes (12-20 kW)
The main line circuit breaker protects the generator
against electrical overload. See “Specifications” in
front of manual for amp ratings.
other ac Generator componentS
Some AC generator components are housed in the
generator control panel enclosure, and are not shown
in Figure 1. These are (a) a voltage regulator, and (b)
a main line circuit breaker.
VOLTAGE REGULATOR (12-20 kW):
A typical voltage regulator is shown in Figure 5.
Unregulated AC output from the stator excitation
winding is delivered to the regulator’s DPE terminals,
via Wire 2 and Wire 6. The voltage regulator rectifies
that current and, based on stator AC power winding
sensing, regulates it. The rectified and regulated
excitation current is then delivered to the rotor wind-
ings from the positive (+) and negative (-) regulator
terminals, via Wire 4 and Wire 0. Stator AC power
winding “sensing” is delivered to the regulator “SEN”
terminals via Wires 11 and 22.
Page 34
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sEctioN 2.2
oPEratioNal aNalYsis
AC GENERATORS
Part 2
Field boost voltage is reduced from that of battery
voltage by the resistor action and, when read with a
DC voltmeter, will be approximately 9 or 10 volts DC.
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 residual
magnetism is sufficient to induce a voltage into the
stator AC power windings that is approximately 2-12
volts AC.
+12 VDC
13
PIN 5
Field BooSt (12-20 kW)
TO
STARTER
56
FIELD
BOOST
RESISTOR
FIELD BOOST CIRCUIT:
DIODE
When the engine is cranking, direct current flow is
delivered from a circuit board to the generator rotor
windings, via Wire 4.
PIN 1
STARTER
CONTACTOR
CRANk
FIELD
BOOST
DIODE
4
RELAY k1
BASE
TRANSISTOR
The field boost system is shown schematically in
Figure 2. Manual and automatic engine cranking
is initiated by circuit board action, when that circuit
board energizes a crank relay. Battery voltage is then
delivered to field boost Wire 4 (and to the rotor), via
a field boost resistor and diode. The crank relay, field
boost resistor and diode are all located on the circuit
board.
FIELD
BOOST
TO
CIRCUIT BOARD
ROTOR
Notice that field boost current is available only while
the crank relay is energized, i.e., while the engine is
cranking.
Figure 2. Field Boost Circuit Schematic
TO LOAD
MLB = MAIN LINE
MLB
CIRCUIT BREAKER
TO LOAD
MLB
MLB = MAIN LINE CIRCUIT BREAKER
STATOR
POWER
STATOR
POWER
SENSING
WINDING
WINDING
STATOR
POWER
WINDING
STATOR
POWER
WINDING
MAGNETIC
FIELD
FIELD BOOST FROM
CONTROL LOGIC
CIRCUIT BOARD
ENGINE -
DIRECT
DRIVE
MAGNETIC
FIELD
ROTOR
ENGINE -
DIRECT
DRIVE
MAGNETIC
FIELD
ROTOR
VOLTAGE
REGULATOR
STATOR
EXCITATION
WINDING
MAGNETIC
FIELD
STATOR
EXCITATION
WINDING
CAPACITOR
12-20 kW Units
8/10 kW Units
Figure 1. Operating Diagram of AC Generator
Page 35
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sEctioN 2.2
oPEratioNal aNalYsis
AC GENERATORS
Part 2
FIELD EXCITATION:
operation (8/10 kW)
An AC voltage is induced into the stator excitation
(DPE) windings. The DPE winding circuit is complet-
ed to the voltage regulator, via Wire 2 and Wire 6.
Unregulated alternating current can flow from the wind-
ing to the regulator.
STARTUP:
When the engine is started, residual magnetism from
the rotor induces a voltage into (a) the stator AC
power windings, and (b) the stator excitation or DPE
windings. The capacitor on the DPE winding will be
charged and then will discharge causing a voltage to
be induced back into the rotor.
The voltage regulator “senses” AC power winding out-
put voltage and frequency via stator Wires 11 and 22.
The regulator changes the AC from the excitation
winding to DC. In addition, based on the Wires 11
and 22 sensing signals, it regulates the flow of direct
current to the rotor.
FIELD EXCITATION:
An AC voltage is induced into the stator excitation
(DPE) windings. The DPE winding circuit is completed
to the capacitor, via Wire 2 and Wire 6.
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 capacitor will charge at a rate that is dependant
on the amount of voltage that is being induced into it.
Once the capacitor is fully charged the voltage that
it discharges is a constant voltage and will in-turn
increase the size of the magnetic field of the rotor.
The greater the current flow through the rotor windings,
the more concentrated the lines of flux around the rotor
become.
The greater the current flow through the rotor windings,
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.
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 desired 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 circuit,
current can flow in the circuit.
operation (12-20 kW)
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
proportion to the AC frequency. For example, on units
rated 120/240 volts at 60 Hz, the regulator will try to
maintain 240 volts (line-to-line) at 60 Hz. This type of
regulation system provides greatly improved motor
starting capability over other types of systems.
STARTUP:
When the engine is started, residual plus field boost
magnetism from the rotor induces a voltage into
(a) the stator AC power windings, and (b) the sta-
tor excitation or DPE windings. In an “on-speed”
condition, residual plus field boost magnetism are
capable of creating approximately one-half the unit’s
rated voltage.
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 36
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sEctioN 2.3
trouBlEsHootiNG floWcHarts
AC GENERATORS
Part 2
General
Use the “Flow Charts” in conjunction with the detailed
instructions in Section 2.4. Test numbers used in
the flow charts correspond to the numbered tests in
Section 2.4.
The first step in using the flow charts is to correctly
identify the problem. Once that has been done, locate
the problem on the following pages. For best results,
perform all tests in the exact sequence shown in the
flow charts.
Problem 1 - Generator Produces Zero Voltage or Residual Voltage
(12-20 kW)
TEST 1 - CHECK
MAIN CIRCUIT
BREAKER
RESET TO
“ON”
OR REPLACE
IF BAD
RE-TEST
TEST 4 - PERFORM
FIXED EXCITATION /
ROTOR AMP DRAW
A
G
REPAIR
OR REPLACE
FUSES
D
B
C
CHECK
VOM
FUSES
GOOD
TEST 11 -
CHECK
ROTOR
TEST 7 - TEST
STATOR
GOOD
RESISTANCE
BAD
PERFORM STATOR
INSULATION
RESISTANCE TEST
-
BAD
TEST 5 - WIRE
CONTINUITY
TEST 12 -
CHECK
BAD
SECTION 1.4
BRUSHES &
SLIP RINGS
BAD
GOOD
BAD
GOOD
REPAIR
OR
TEST 6 -
FIELD BOOST
REPLACE
REPAIR
OR
REPLACE
TEST 13 -
TEST ROTOR
ASSEMBLY
BAD
BAD
REPAIR
OR
REPLACE
THEN
GOOD
GOOD
RETEST
PERFORM ROTOR
INSULATION
RESISTANCE TEST
-
BAD
REPLACE
VOLTAGE
REGULATOR
SECTION 1.4
Page 37
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sEctioN 2.3
trouBlEsHootiNG floWcHarts
AC GENERATORS
Part 2
Problem 1 - Generator Produces Zero Voltage or Residual Voltage
(12-20 kW Continued)
TEST 4 - PERFORM
TEST 7 - TEST
BAD
FIXED EXCITATION /
ROTOR AMP DRAW
F
E
STATOR
GOOD
H
PERFORM STATOR
INSULATION
RESISTANCE TEST -
SECTION 1.4
TEST 13 -
TEST ROTOR
ASSEMBLY
BAD
BAD
GOOD
REPAIR
OR
GOOD
REPLACE
PERFORM ROTOR
INSULATION
RESISTANCE TEST -
SECTION 1.4
TEST 13 -
TEST ROTOR
ASSEMBLY
BAD
BAD
BAD
REPAIR
OR
REPLACE
GOOD
GOOD
TEST 7 - TEST
STATOR
PERFORM ROTOR
INSULATION
BAD
RESISTANCE TEST -
SECTION 1.4
GOOD
GOOD
PERFORM STATOR
INSULATION
RESISTANCE TEST -
SECTION 1.4
BAD
RE-TEST
TEST 4
RE-TEST
TEST 4
GOOD
Problem 2 - Generator Produces Zero Voltage or Residual Voltage
(8/10 kW)
TEST 9 -
CHECK
CAPACITOR
TEST 1 - CHECK
MAIN CIRCUIT
BREAKER
TEST 8 - TEST
BRUSHLESS
STATOR
TEST 10 - TEST
DPE WINDING
ON
GOOD
GOOD
BAD
GOOD
BAD
BAD
RESET TO
“ON”
REPLACE
STATOR
OR REPLACE
IF BAD
REPLACE
STATOR
REPLACE
REPLACE
CAPACITOR
REPLACE
ROTOR
TEST 2 -
CHECK AC
OUTPUT
BAD
TEST 21 -
FIELD FLASH
ALTERNATOR
STOP
TESTING
VOLTAGE
GOOD
Page 38
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trouBlEsHootiNG floWcHarts
AC GENERATORS
Part 2
Problem 3 - Generator Produces Low Voltage at No-Load
LOW -
SINGLE CYLINDER
UNITS
TEST 15 - ADJUST
ENGINE GOVERNOR
TEST 2 - CHECK
AC OUTPUT
VOLTAGE
TEST 14 - CHECK
AC OUTPUT
FREQUENCY
LOW
TEST 16 - CHECK
STEPPER MOTOR
CONTROL
LOW -
V-TWIN UNITS
NO VOLTAGE
12-20 kW UNITS
8/10 kW UNITS
GO TO TEST 4
GO TO “PROBLEM 2”
TEST 9 -
CHECK
8/10 kW UNITS
CAPACITOR
FREQUENCY AND
FREQUENCY O.K.,
BUT VOLTAGE LOW
VOLTAGE O.K.
TEST 17 - ADJUST
12-20 kW UNITS
VOLTAGE
REGULATOR
STOP
TESTS
VOLTAGE AND FREQUENCY O.K.
FREQUENCY O.K.,
BUT VOLTAGE IS
STILL LOW
GO TO “PROBLEM 1” FLOW CHART -
START AT “TEST 4 - F/E”
12-20 kW UNITS
GO TO “PROBLEM 2”
8/10 kW UNITS
Problem 4 - Generator Produces High Voltage at No-Load
HIGH -
SINGLE CYLINDER
UNITS
TEST 15 - ADJUST
ENGINE GOVERNOR
TEST 2 - CHECK
AC OUTPUT
VOLTAGE
TEST 14 - CHECK
AC OUTPUT
FREQUENCY
HIGH
TEST 16 - CHECK
STEPPER MOTOR
CONTROL
HIGH -
V-TWIN UNITS
TEST 9 -
CHECK
CAPACITOR
8/10 kW UNITS
FREQUENCY AND
VOLTAGE O.K.
FREQUENCY O.K.,
BUT VOLTAGE HIGH
TEST 17 - ADJUST
VOLTAGE
12-20 kW UNITS
REGULATOR
STOP
TESTS
VOLTAGE AND FREQUENCY O.K.
FREQUENCY O.K.,
BUT VOLTAGE IS
STILL HIGH
REPLACE DEFECTIVE
VOLTAGE REGULATOR
12-20 kW UNITS
GO TO “PROBLEM 2”
8/10 kW UNITS
Page 39
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AC GENERATORS
Part 2
Problem 4 - Voltage and Frequency Drop Excessively When Loads Are Applied
IF RECONFIGURED TO LP GAS,
VERIFY THAT PROPER
PROCEDURE WAS FOLLOWED
(REFER TO SECTION 1.3)
TEST 18 - CHECK
VOLTAGE AND
FREQUENCY
TEST 19 - CHECK
FOR OVERLOAD
CONDITION
NOT
OVERLOADED
BOTH
LOW
UNDER LOAD
OVERLOADED
GOOD
UNITS WITH
UNITS WITH
SINGLE
V-TWIN
CYLINDER
REDUCE LOADS TO UNIT’S
RATED CAPACITY
ENGINES
ENGINES
DISCONTINUE
TESTING
TEST 16 - CHECK
STEPPER MOTOR
CONTROL
GOOD
BAD
TEST 15 - CHECK AND
ADJUST ENGINE
GOVERNOR
REPAIR OR REPLACE
GOOD
TEST 20 - CHECK
ENGINE CONDITION
REPLACE
BAD
BAD
TEST 8 - TEST
BRUSHLESS
STATOR
GOOD
TEST 10 - TEST
DPE WINDING
GOOD
8/10 kW UNITS
GO TO “PROBLEM 18 -
ENGINE STARTS HARD
AND RUNS
ROUGH/LACKS POWER”
SECTION 4.3
GOOD
ENGINE
CONDITION
GOOD
12-20 kW UNITS
TEST 7 - CHECK
STATOR AC
POWER WINDINGS
LOOK FOR A SHORTED
CONDITION IN A
CONNECTED LOAD OR
IN ONE OF THE LOAD
CIRCUITS
GOOD
BAD
REPAIR OR REPLACE
Page 40
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sEctioN 2.4
DiaGNostic tEsts
AC GENERATORS
Part 2
1. Set a volt-ohm-milliammeter (VOM) to its “R x 1” scale
and zero the meter.
introduction
This section is provided to familiarize the service
technician with acceptable procedures for the test-
ing and evaluation of various problems that could be
encountered on standby generators with air-cooled
engine. Use this section of the manual in conjunction
with Section 2.3, “Troubleshooting Flow Charts”. The
numbered tests in this section correspond with those
of Section 2.3.
2. With the generator shut down, disconnect all wires from
the main circuit breaker terminals, to prevent interaction.
3. With the generator shut down, connect one VOM test
probe to the Wire 11 terminal of the breaker and the
other test probe to the Wire E1 terminal.
4. Set the breaker to its “On” or “Closed” position. The VOM
should read CONTINUITY.
Test procedures in this section do not require the use
of specialized test equipment, meters or tools. Most
tests can be performed with an inexpensive volt-
ohm-milliammeter (VOM). An AC frequency meter is
required, where frequency readings must be taken. A
clamp-on ammeter may be used to measure AC loads
on the generator.
5. Set the breaker to its OFF or “Open” position and the
VOMshould indicate INFINITY.
6. Repeat Steps 4 and 5 with the VOM test probes con-
nected across the breaker’s Wire 44 terminal and the E2
terminal.
Testing and troubleshooting methods covered in this
section are not exhaustive. We have not attempted to
discuss, evaluate and advise the home standby ser-
vice trade of all conceivable ways in which service and
trouble diagnosis might be performed. We have not
undertaken any such broad evaluation. Accordingly,
anyone who uses a test method not recommended
herein must first satisfy himself that the procedure or
method he has selected will jeopardize neither his nor
the product’s safety.
RESULTS:
1. If the circuit breaker tests good, go on to Test 2.
2. If the breaker tests bad, it should be replaced.
E2 TERMINAL
E1 TERMINAL
SaFety
Service personnel who work on this equipment must
be made aware of the dangers of such equipment.
Extremely high and dangerous voltages are present
that can kill or cause serious injury. Gaseous fuels are
highly explosive and can be ignited by the slightest
spark. Engine exhaust gases contain deadly carbon
monoxide gas that can cause unconsciousness or
even death. Contact with moving parts can cause seri-
ous injury. The list of hazards is seemingly endless.
OFF
When working on this equipment, use common
sense and remain alert at all times. Never work on
this equipment while you are physically or mentally
fatigued. If you don’t understand a component, device
or system, do not work on it.
WIRE 11
TERMINAL
WIRE 44
TERMINAL
teSt 1 – check main circuit Breaker
DISCUSSION:
Figure 1. Generator Main Circuit Breaker Test Points
Often the most obvious cause of a problem is over-
looked. If the generator main line circuit breaker is set
to OFF or “Open”, no electrical power will be supplied
to electrical loads. If loads are not receiving power,
perhaps the main circuit breaker is open or has failed.
teSt 2 – check ac output VoltaGe
DISCUSSION:
PROCEDURE:
A volt-ohm-milliammeter (VOM) may be used to check
the generator output voltage. Output voltage may be
checked at the unit’s main circuit breaker terminals.
Refer to the unit’s DATA PLATE for rated line-to-line
and line-to-neutral voltages.
The generator main circuit breaker is located on the
control panel. If loads are not receiving power, make
sure the breaker is set to “On” or “Closed”.
If you suspect the breaker may have failed, it can be
tested as follows (see Figure 1):
Page 41
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sEctioN 2.4
DiaGNostic tEsts
AC GENERATORS
Part 2
PROCEDURE:
DaNGEr: usE EXtrEmE cautioN
1. Disconnect Wire 4 from the voltage regulator, 3rd
terminal from the top. See Figure 2.
DuriNG tHis tEst.tHE GENErator Will
BE ruNNiNG. HiGH aND DaNGErous
VoltaGEs Will BE PrEsENt at tHE
tEst tErmiNals. coNNEct mEtEr tEst
clamPs to tHE HiGH VoltaGE tErmiNals
WHilE tHE GENErator is sHut DoWN.
staY clEar of PoWEr tErmiNals
DuriNG tHE tEst. maKE surE mEtEr
clamPs arE sEcurElY attacHED aND
Will Not sHaKE loosE.
*
2. Connect a jumper wire to the disconnected Wire 4 and
to the 12 volt fused battery supply Wire 15B (located at
TB1 terminal board).
3. Set VOM to AC volts.
4
4
22
PROCEDURE:
0
11
1. With the engine shut down, connect the AC voltmeter
test leads across the Wires 11 and 44 terminals of the
generator main circuit breaker (see Figure 1). These
connections will permit line-to-line voltages to be read.
6
2
2. Set the generator main circuit breaker to its OFF or
“Open” position. This test will be conducted with the
generator running at no-load.
3. Start the generator, let it stabilize and warm up for a
minute or two.
4. Take the meter reading. On 12-20 kW units the no-load
voltage should be between 249-247 VAC. On 8-10 kW
units the no-load voltage should be between 220-235 VAC.
Figure 2. Voltage Regulator
5. Shut the engine down and remove the meter test leads.
4. Disconnect Wire 2 from the voltage regulator and con-
nect one meter test lead to that wire. Disconnect Wire
6 from the voltage regulator and connect the other
meter test lead to that wire. Wires 2 and 6 are located
at the bottom two terminals of the voltage regulator
(see Figure 2).
RESULTS:
1. If Step 4 indicated proper voltages, discontinue testing.
2. If any other readings were measured, refer back to flow
chart.
note: “residual” voltage may be defined as the
voltage that is produced by rotor residual mag-
netism alone. the amount of voltage induced into
the stator ac power windings by residual volt-
age alone will be approximately 2 to 16 volts ac,
depending on the characteristics of the specific
generator. if a unit is supplying residual voltage
only, either excitation current is not reaching the
rotor or the rotor windings are open and the exci-
tation current cannot pass. on current units with
air-cooled engine, “field boost” current flow is
available to the rotor only during engine cranking.
5. Set the AUTO-OFF-MANUAL switch to MANUAL. Once
the engine starts, record the AC voltage.
6. Set the AUTO-OFF-MANUAL switch to OFF. Reconnect
Wire 2 and Wire 6.
7. Disconnect Wire 11 from the voltage regulator and con-
nect one meter test lead to that wire. Disconnect Wire
22 from the voltage regulator and connect the other
meter test lead to that wire (both wires are located at the
top two terminals of the voltage regulator, see Figure 2).
8. Set the AUTO-OFF-MANUAL switch to MANUAL. Once
the engine starts, record the AC voltage.
teSt 4 – FiXed eXcitation teSt/
rotor amp draW teSt
9. Set the AUTO-OFF-MANUAL switch to OFF. Reconnect
Wire 11 and Wire 22.
DISCUSSION:
10.Set VOM to DC amperage.
Supplying a fixed DC current to the rotor will induce a
magnetic field in the rotor. With the generator running,
this should create a proportional voltage output from
the stator windings.
11.Remove jumper lead connected to Wire 4 and Wire 15B.
12.Connect one meter test lead to battery positive 12
VDC supply Wire 15B, located at TB1 terminal board.
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DiaGNostic tEsts
AC GENERATORS
Part 2
Connect the other meter test lead to Wire 4 (still dis-
connected from previous tests). Measure and record
static rotor amp draw.
13.Set the AUTO-OFF-MANUAL switch to the MANUAL
position. Once the engine starts, repeat Step 12.
Measure and record running rotor amp draw with the
engine running.
14.Set the AUTO-OFF-MANUAL switch to OFF. Reconnect
Wire 4 to the voltage regulator.
RESULTS:
Refer to the chart on this page: “Results - Fixed
Excitation Test/Rotor Amp Draw Test”.
note: a calculated amp draw can be done by taking
the battery voltage that is applied divided by the
actual resistance reading of the rotor. a resistance
reading can be taken by measuring ohms between
Wires 4 and 0 at the voltage regulator.
EXAMPLE:
moDEl
5517
WIRE 2 & 6 VOLTAGE
WIRE 11 & 22 VOLTAGE
STATIC ROTOR AMP DRAW
RUNNING ROTOR AMP DRAW
87 VAC
31 VAC
1.0 AMP
1.0 AMP
These results match Column B in the chart. Refer
back to Problem 1 Flow Chart and follow Letter B.
teSt 5 – Wire continuity (12-20 kW)
DISCUSSION:
The voltage regulator receives unregulated alternating
current from the stator excitation winding, via Wires 2
and 6. It also receives voltage sensing from the sta-
tor AC power windings, via Wires 11 and 22. The
regulator rectifies the AC from the excitation winding
and based on the sensing signals, regulates the DC
current flow to the rotor. The rectified and regulated
current flow is delivered to the rotor brushes via Wires
4 (positive) and 0 (negative). This test will verify the
integrity of Wire 0.
PROCEDURE:
1. Set VOM to its “R x 1” scale.
2. Remove Wire 0 from the voltage regulator, 4th terminal
from the top. Also voltage regulator is labeled (-) next to
terminal.
3. Connect one test lead to Wire 0, connect the other test
lead to a clean frame ground. The meter should read
CONTINUITY.
RESULTS:
If CONTINUITY was not measured, repair or replace
the wire as needed.
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DiaGNostic tEsts
AC GENERATORS
Part 2
6. Reconnect Wire 4.
teSt 6 – check Field BooSt (12-20 kW)
DISCUSSION:
RESULTS:
See “Field Boost Circuit” in Section 2.2. Field boost
current (from the circuit board) is available to the
rotor only while the engine is cranking. Loss of field
boost output to the rotor may or may not affect power
winding AC output voltage. The following facts apply:
• A small amount of voltage must be induced into the
DPE winding to turn the voltage regulator on.
• If rotor residual magnetism is sufficient to
induce a voltage into the DPE winding that is
high enough to turn the voltage regulator on,
regulator excitation current will be supplied
even if field boost has failed. Normal AC output
voltage will then be supplied.
1. If normal field boost voltage is indicated in Step 6,
replace the voltage regulator.
2. If normal field boost voltage is NOT indicated in Step 6,
check Wire 4 (between regulator and circuit board) for
open or shorted condition. If wire is good, replace the
circuit board.
teSt 7 – teStinG the Stator With a Vom
(12-20 kW)
DISCUSSION:
• If rotor residual magnetism has been lost or is not
sufficient to turn the regulator on, and field boost
has also been lost, excitation current will not be
supplied to the rotor. Generator AC output voltage
will then drop to zero or nearly zero.
A Volt-OHM-Milliammmeter (VOM) can be used to test
the stator windings for the following faults:
• An open circuit condition
• A “short-to-ground” condition
• A short circuit between windings
5.54 VDC
note: the resistance of stator windings is very
low. Some meters will not read such a low resis-
tance, and will simply indicate continuity.
recommended is a high quality, digital type meter
capable of reading very low resistances.
LINE
LOAD
WIRE 44 TEST POINT
WIRE 11 TEST POINT
Figure 3. Field Boost Test Points
Figure 4. Test 7 Test Points
PROCEDURE:
PROCEDURE:
1. Disconnect Wire 4 from the voltage regulator, third
terminal from the top (see Figure 3).
1. Isolate the generator from the transfer switch by dis-
connecting the load wires from the main breaker inside
the generator.
2. Set a VOM to read DC volts.
3. Connect the positive (+) VOM test probe to the terminal
end of disconnected Wire 4.
2. Disconnect Stator Leads 22 and 33 from the neutral
connection and separate the leads.
4. Connect the common (-) VOM test probe to the
grounding lug.
3. Disconnect and isolate Wires 2 and 6 and Wires 11 and 22
from the voltage regulator.
5. Crank the engine while observing the VOM reading.
While the engine is cranking, the VOM should read
approximately 4-6 Volts DC. When engine is not crank-
ing, VOM should indicate “zero” volts (see Figure 3).
4. Make sure all of the disconnected leads are isolated
from each other and are not touching the frame during
the test.
Page 44
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AC GENERATORS
Part 2
TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS:
5. Turn the Main Breaker to the "ON" or CLOSED position.
15. Connect one test lead to stator lead Wire 11 on the load
side of the main circuit breaker. Connect the other test
lead to stator lead Wire 33.
6. Set a VOM to measure resistance.
7. Connect one meter test lead to Wire 11 on the load side
of the main breaker. Connect the other meter test lead
to Wire 22 (power winding). Note the resistance read-
ing and compare to the specifications in the front of this
manual.
a. The meter should read INFINITY.
b. Any reading other than INFINITY indicates a
short circuit between windings.
16.Repeat Step 15 using stator lead Wire 11; Wire 6.
17.Repeat Step 15 using stator lead Wire 33; Wire 6.
8. Connect one test lead to stator lead Wire 44 on the load
side of the main breaker. Connect the other test lead to
stator lead Wire 33 (power winding). Note the resistance
reading and compare to the specifications in the front of
this manual.
18.Repeat Step 15 using Wire 11 at the voltage regulator;
Wire 6 at the voltage regulator.
TEST CONTROL PANEL WIRES FOR CONTINUITY:
note: Wire 11 and Wire 44 could be switched on
the main breaker. if an inFinity reading is indi-
cated try putting the meter leads on the other
output terminal of the breaker. if inFinity is still
read then an actual fault may exist.
19.Connect one test lead to Wire 11 at the voltage regulator
and the other test lead at stator lead Wire 11. Continuity
should be measured.
20.Connect one test lead to Wire 22 at the voltage regulator
and the other test lead at stator lead Wire 22. Continuity
9. Connect one test lead to Wire 22 at the voltage regula-
tor. Connect the other test lead to Wire 11 at the voltage
regulator (power winding sense leads). Note the resis-
tance reading and compare to the specifications in the
front of this manual.
should be measured.
RESULTS:
1. Stator winding resistance values is a test of winding conti-
nuity and resistance. If a very high resistance or INFINITY
is indicated, the winding is open or partially open.
TEST WINDINGS FOR A SHORT TO GROUND:
10. Make sure all leads are isolated from each other and
are not touching the frame.
2. Testing for a “grounded” condition: Any resistance
reading indicates the winding is grounded.
11. Connect one test lead to a clean frame ground. Connect
the other test lead to stator lead Wire 11 on the load
side of the main circuit breaker.
3. Testing for a “shorted” condition: Any resistance
reading indicates the winding is shorted.
a. The meter should read INFINITY.
4. If the stator tests good and wire continuity tests good,
perform “Insulation Resistance Test” in Section 1.5.
b. Any reading other than INFINITY indicates a
“short-to-ground” condition.
5. If any test of wire continuity failed in the control panel,
repair or replace the wire, terminal or pin connectors for
that associated wire as needed.
12. Repeat Step 11 using stator lead Wire 33.
13.Repeat Step 11 using Wire 22 at the voltage regulator.
14.Repeat Step 11 using Wire 6 at the voltage regulator.
note: read Section 1.5, “testing, cleaning and
drying” carefully. if the winding tests good, per-
form an insulation resistance test. if the winding
fails the insulation resistance test, clean and dry
the stator as outlined in Section 1.5. then, repeat
the insulation resistance test. if the winding fails
the second resistance test (after cleaning and
drying), replace the stator assembly.
2
6
11P
11S (12-20 kW)
22P
teSt 8 – teSt BruShleSS Stator
22S (12-20 kW)
33
DISCUSSION:
The brushless stator has three internal windings,
two main power windings and a DPE winding. This
test will ensure that there are no shorts between the
power windings or shorts to ground.
44
A VOM meter can be used to test the stator windings
for the following faults:
Figure 5. Stator Assembly Leads
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AC GENERATORS
Part 2
• An open circuit condition
• A “short-to-ground” condition
• A short circuit between windings
note: Wire 11 and Wire 44 could be switched on
the main breaker. if an inFinity reading is indi-
cated try putting the meter leads on the other
output terminal of the breaker. if inFinity is still
read then an actual fault may exist.
note: the resistance of stator windings is very low.
Some meters will not read such a low resistance,
and will simply indicate continuity. recommended
is a high quality, digital type meter capable of read-
ing very low resistances.
TEST WINDINGS FOR A SHORT TO GROUND:
7. Make sure all leads are isolated from each other and are
not touching the frame.
8. Connect one test lead to a clean frame ground. Connect
the other test lead to stator lead Wire 11.
PROCEDURE, 8 kW:
1. Disconnect Stator Leads 11 and 44 from the main circuit
breaker.
a. The meter should read INFINITY.
b. Any reading other than INFINITY indicates a
“short to ground” condition.
2. Disconnect Stator Leads 22 and 33 from the neutral
connection separate the leads.
9. Repeat Step 7 using stator lead 44
3. Make sure all of the disconnected leads are isolated
from each other and are not touching the frame during
the test.
TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS:
10.Connect one test lead to stator lead 11. Connect the
other test lead to stator lead 33.
4. Set a VOM to measure resistance.
5. Connect one test lead to Stator Lead 11. Connect the
other test lead to Stator Lead 22. Note the resistance
reading and compare to the specifications in the front of
this manual.
a. The meter should read INFINITY.
b. Any reading other that INFINITY indicates a
short between windings.
11.Repeat Step 10 using Wire 44.
6. Connect one test lead to Stator Lead 33. Connect the
other test lead to Stator Lead 44. Note the resistance
reading and compare to the specifications in the front of
this manual.
RESULTS:
1. Stator winding resistance values is a test of winding conti-
nuity and resistance. If a very high resistance or INFINITY
is indicated, the winding is open or partially open.
PROCEDURE, 10 kW:
2. Testing for a “grounded” condition: Any resistance
reading indicated the winding is grounded.
1. Isolate the generator from the transfer switch by dis-
connecting the load wires from the main breaker inside
the generator.
3. Testing for a “shorted” condition: Any resistance reading
indicated the winding is shorted.
2. Disconnect Stator Leads 22 and 33 from the neutral
connection and separate the leads.
4. If stator tests good and wire continuity tests good, refer
back to flow chart.
3. Make sure all of the disconnected leads are isolated
from each other and are not touching the frame during
the test.
teSt 9 – check capacitor
4. Turn the Main Breaker to the "ON" or CLOSED position.
DISCUSSION:
5. Set a VOM to measure resistance.
The brushless rotor system relies on the charging and
discharging of a capacitor to induce voltage into the
rotor and also to regulate voltage once 240 VAC is
achieved. If the capacitor fails, only residual magnetism
of the rotor will be measured at the Main Breaker.
6. See Figure 4 for proper testing points. Connect one
meter test lead to Wire 11 on the load side of the main
breaker. Connect the other meter test lead to Wire 22
(power winding). Note the resistance reading and com-
pare to the specifications in the front of this manual.
Danger:the capacitor may need to be dis-
charged before testing. a capacitor can be
discharged by crossing the terminals with
a metal insulated screw driver.
*
7. Connect one test lead to Stator Lead 44 on the load
side of the main breaker. Connect the other test lead
to Stator Lead 33 (power winding). Note the resistance
reading and compare to the specifications in the front of
this manual.
Danger: use proper protective equipment
when dealing with a capacitor that has
exploded.
*
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DiaGNostic tEsts
AC GENERATORS
Part 2
PROCEDURE:
a. A capacitor that has gone bad can have a
tendency to explode. Use caution when deal-
ing with an exploded capacitor, the gel from
inside a capacitor can cause skin irritation.
1. Consult the owner’s manual of the meter being used for
directions on measuring capacitance. Figure 7 shows a
typical meter and how to check capacitance.
b. A capacitor is defective if the terminal connec-
tions are loose on the canister.
2. Connect the meter leads directly across the terminals of
the capacitor. The rated µf (micro farad) of the capacitor
is marked on the side of the canister.
c. A capacitor is defective if it wobbles while sitting
on a flat surface.
d. If any of the above observations are observed,
replace the capacitor.
3. The meter should display the correct µf reading 5µf.
If anything other than the indicated rating is displayed,
replace the capacitor.
teSt 10 – teSt dpe WindinG on
BruShleSS unitS
DISCUSSION:
A DPE winding or Displaced Phase Excitation wind-
ing is used to charge a capacitor that discharges and
charges releasing a voltage that is induced into the
rotor. If the DPE winding fails, only residual magnetism
of the rotor will be measured at the Main Breaker.
note: the resistance of stator windings is very
low. Some meters will not read such a low resis-
tance, and will simply indicate continuity.
recommended is a high quality, digital type meter
capable of reading very low resistances.
Warning: the capacitor may need to be
discharged before testing. a capacitor can
be discharged by crossing the terminals
with a metal insulated screw driver.
*
Figure 6. Capacitor
SET TO READ
CAPACITANCE
PROCEDURE:
59.0 µf
1. Disconnect Wire 2 and Wire 6 from the capacitor.
2. Set VOM to measure resistance.
3. Connect one meter lead to Wire 2 and connect the other
meter lead to Wire 6.
a. Refer to the specifications in the front of this
manual for the correct resistance reading.
+
-
4. Connect one meter lead to Wire 2 and connect the other
meter lead to a clean frame ground, INFINITY should be
measured.
+ -
5. Disconnect Wires 11 and 44 from the main line circuit
breaker.
CAPACITOR
6. Disconnect Wire 22 and Wire 33 from the neutral connection
note: isolate all main stator leads before proceeding.
7. Connect one meter lead to Wire 2 and connect the other
meter lead to Wire 11. INFINITY should be measured.
Figure 7. Field Boost Test Points
8. Repeat Step 7 using Wires 2 and 44.
RESULTS:
RESULTS:
1. Refer back to flow chart
1. Stator winding resistance values is a test of winding conti-
nuity and resistance. If a very high resistance or INFINITY
is indicated, the winding is open or partially open.
Page 47
2. Common observations can be made by visually
inspecting the capacitor.
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2. Testing for a “grounded” condition: Any resistance
reading indicated the winding is grounded.
CONTINUITY should be measured. If INFINITY is
measured repair or replace Wire 0 between the brush
assembly and the voltage regulator.
3. Testing for a “shorted” condition: Any resistance reading
indicated the winding is shorted.
4. If stator tests good and wire continuity tests good, refer
back to flow chart.
4
0
teSt 11 – reSiStance check oF
rotor circuit (12-20 kW)
DISCUSSION:
To verify the zero current draw reading and measure
the rotor circuit.
+
-
PROCEDURE:
1. Disconnect Wire 4 and Wire 0 from the voltage regulator,
located third and fourth terminals from the top of the
voltage regulator.
Figure 8. Checking Brushes and Slip Rings
3. Wire 4 from the positive (+) brush terminal connects to
Wire 4 at the voltage regulator. Test this wire for an open
condition. Remove Wire 4 from the brush assembly.
Connect one meter test lead to Wire 4. Connect the
other meter test lead to Wire 4 at the voltage regula-
tor. CONTINUITY should be measured. If INFINITY is
measured repair or replace Wire 4 between the brush
assembly and the voltage regulator.
2. Set VOM to measure resistance.
3. Connect one test lead to Wire 4. Connect the other test
lead to a clean frame ground. Note the resistance reading.
Compare to specifications in the front of this manual.
RESULTS:
1. If the resistance reading is correct, check the VOM meter
fuse and repeat Test 4.
4. Connect one meter test lead to Wire 4 Connect the
other meter test lead to frame ground. INFINITY should
be measured. If CONTINUITY is measured a short
to ground exists on Wire 4 repair or replace Wire 4
between the brush assembly and the voltage regulator.
2. If INFINITY or a high reading is measured on the VOM,
refer back to flow chart.
teSt 12 – check BruSheS and Slip
rinGS (12-20 kW)
5. If CONTINUITY was measured in Steps 5 and 6 proceed
to Step 9.
DISCUSSION:
6. Disconnect Wire 0 and Wire 4 from the brush assembly.
Remove the brush assembly from the bearing carrier.
Inspect the brushes for excessive wear, or damage.
The function of the brushes and slip rings is to provide
for passage of excitation current from stationary compo-
nents to the rotating rotor. Brushes are made of a spe-
cial long lasting material and seldom wear out or fail.
However, slip rings can develop a tarnish or film that
can inhibit or offer a resistance to the flow of electric-
ity. Such a non-conducting film usually develops during
non-operating periods. Broken or disconnected wiring
can also cause loss of excitation current to the rotor.
7. Inspect the rotor slip rings. If they appear dull or tarnished,
they may be polished with fine sandpaper. DO NOT USE
METALLIC GRIT TO POLISH SLIP RINGS.
8. If brush assembly and slip rings look good proceed to
Test 13 (Test Rotor Assembly)
PROCEDURE:
9. Wire 0 connects from the voltage regulator in the control
panel ground lug. Connect one meter test lead to Wire 0
at the voltage regulator. Connect the other meter test lead
to the ground terminal in the control panel. CONTINUITY
should be measured. If INFINITY is measured repair or
replace Wire 0 between the voltage regulator and the
ground terminal.
1. See Figure 8. Carefully inspect brush wires; make sure
they are properly and securely connected.
2. Wire 0 from the negative (-) brush terminal connects
to Wire 0 at the voltage regulator. Test this wire for an
open condition. Remove Wire 0 from the brush assem-
bly. Connect one meter test lead to Wire 0. Connect
the other test lead to Wire 0 at the voltage regulator.
10.Remove Wire 4 from the voltage regulator.
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AC GENERATORS
Part 2
RESULTS:
rotor if it fails that test.Then, repeat the test. If the rotor
fails the second insulation resistance test, it should be
replaced.
1. Repair, replace or reconnect wires as necessary.
2. Replace any damaged slip rings or brush holder.
3. Clean and polish slip rings as required.
teSt 14 – check ac output Frequency
teSt 13 – teSt rotor aSSemBly
DISCUSSION:
(12-20 kW)
The generator AC frequency is proportional to the
operating speed of the rotor. The 2-pole rotor will sup-
ply a 60 Hertz AC frequency at 3600 rpm. The unit’s
AC output voltage is proportional to the AC frequency.
For example, a unit rated 240 volts (line-to-line) will
supply that rated voltage (plus or minus 2 percent)
at a frequency of 60 Hertz. If, for any reason, the
frequency should drop to 30 Hertz, the line-to-line
voltage will drop to a matching voltage of 120 volts
AC. Thus, if the AC voltage output is high or low and
the AC frequency is correspondingly high or low, the
engine speed governor may require adjustment.
DISCUSSION:
A rotor having completely open windings will cause
loss of excitation current flow and, as a result,
generator AC output voltage will drop to “residual”
voltage. A “shorted” rotor winding can result in a
low voltage condition.
PROCEDURE:
I. Disconnect the brush wires or remove the brush holder,
to prevent interaction.
PROCEDURE:
2. Set a VOM to measure resistance.
1. Connect an accurate AC frequency meter across the
Wires 11 and 44 terminals of the generator main line
circuit breaker (see Figure 1, Section 2.4).
3. Connect the positive (+) VOM test lead to the posi-
tive (+) rotor slip ring (nearest the rotor bearing); and
the common (-) test lead to the negative (-) slip ring.
The meter should read rotor resistance. Compare to
“Specifications,” in the front of this manual.
2. Start the engine, let it stabilize and warm up at no-load.
3. When engine has stabilized, read the frequency meter.
The no-load frequency for single cylinder units should
be about 62-63 Hertz. For V-Twin units, the no-load
frequency should be about 60 Hertz.
4. Connect the positive (+) VOM test lead to the positive (+)
slip ring and the common (-) test lead to a clean frame
ground. The meter should indicate INFINITY.
RESULTS:
RESULTS:
1. If the AC frequency is high or low, go on to Test 15 for
single cylinder units, or Test 16 for V-Twin units.
1. Replace rotor assembly if it is open or shorted.
2. If frequency is good, but voltage is high or low, go to
Test 17.
2. If rotor tests good, perform “Insulation Resistance Test”
in Section 1.5.
3. If frequency and voltage are both good, tests may be
discontinued.
SLIP RINGS
teSt 15 – check and adjuSt enGine
GoVernor (SinGle cylinder unitS)
DISCUSSION:
The generator AC frequency output is directly pro-
portional to the speed of the rotor. A two-pole rotor
(having a single north and a single south magnetic
pole) will produce an AC frequency of 60 hertz at
3600 RPM.
BEARING
The generator is equipped with a “voltage over fre-
quency” type AC voltage regulator. The units AC
output voltage is generally proportional to AC fre-
quency. A low or high governor speed will result in a
correspondingly low or high AC frequency and voltage
output. The governed speed must be adjusted before
any attempt to adjust the voltage regulator is made.
Figure 9. The Rotor Assembly
NOTE: Be sure to read Section 1.5, “Testing, Cleaning
and Drying”, carefully. If the rotor tests good, try per-
forming an insulation resistance test. Clean and dry the
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sEctioN 2.4
DiaGNostic tEsts
AC GENERATORS
Part 2
teSt 16 – check Stepper motor
control (V-tWin enGine unitS)
SECONDARY
ADJUST SCREW
GOVERNOR
SHAFT
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.
GOVERNOR
CLAMP
BOLT
PRIMARY
ADJUST
SCREW
3. Physically move the throttle to the closed position by
pulling the stepper motor arm towards the idle stop. See
Figures 11 and 12 (for 9/10 kW units) or Figure 13 (for
12-20 kW Units).
4. Place the AUTO-OFF-MANUAL switch to MANUAL 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.
Figure 10. Engine Governor Adjustment Single
Cylinder Engines
PROCEDURE
(8 kW UNITS WITH DUAL GOVERNOR SPRINGS):
5. If no movement is seen in Step 4 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.
1. Loosen the governor clamp bolt (Figure 10).
2. Hold the governor lever at its wide open throttle position,
and rotate the governor shaft clockwise as far as it will
go. Then, tighten the governor lever clamp bolt to 70
inch-pounds (8 N-m).
6. If problem continues the remove six pin connector from
the printed circuit board. Set Volt meter to measure
ohms. Carefully measure from the end of the six pin
harness as follows:
3. Start the generator; let it stabilize and warm up at
no-load.
4. Connect a frequency meter across the generators AC
output leads.
note: press down with the meter leads on the
connectors exposed terminals, do not probe into
the connector.
5. Turn the primary adjust screw to obtain a frequency
reading of 61.5 Hz. Turn the secondary adjust screw to
obtain a frequency reading of 62.5 Hz.
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.
6. When frequency is correct at no load, check the AC
voltage reading. If voltage is incorrect, the voltage
regulator may require adjustment.
c. Connect one meter lead to Red, connect the
remaining test lead to Brown, approximately 10
ohms should be measured.
RESULTS:
1. If, after adjusting the engine governor, frequency and
voltage are good, tests may be discontinued.
d. Connect one meter lead to Red, connect the
remaining test lead to Black, approximately 10
ohms should be measured.
2. If frequency is now good, but voltage is high or low, refer
back to flow chart.
e. Connect one meter lead to Red, connect the
remaining test to the stepper motor case. No resis-
tance should be measured INFINITY or Open.
3. If engine was overspeeding, check linkage and throttle
for binding. If no governor response is indicated refer to
engine service manual.
RESULTS:
1. If the stepper motor fails any part of Step 6 replace the
stepper motor.
4. If engine appears to run rough and results in low fre-
quency, proceed to Problem 18, Section 4.3.
2. If the stepper motor passes all steps replace the Printed
Circuit Board.
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sEctioN 2.4
DiaGNostic tEsts
AC GENERATORS
Part 2
STEPPER MOTOR
BLACK
BROWN
YELLOW
ORANGE
RED
EMPTY
PULL ARM THIS
DIRECTION TO
Figure 14. Six Pin Connector Wire Colors
CLOSE THROTTLE
teSt 17 – check and adjuSt VoltaGe
reGulator (12-20 kW)
Figure 11. Throttle Positions 9/10 kW Units
DISCUSSION:
For additional information, refer to description and
components Section 2.1.
STEPPER MOTOR
PROCEDURE (V-TWIN ENGINE UNITS):
With the frequency at 60 Hertz, slowly turn the
slotted potentiometer (Figure 15) until line voltage
reads 247-249 volts.
note:the access panel on top of the control panel
must be removed to adjust the voltage regulator.
PULL ARM THIS
DIRECTION TO
CLOSE THROTTLE
note: the voltage regulator is housed in the
back of the generator control panel. the regula-
tor maintains a voltage in direct proportion to
frequency at a 2-to-1 ratio. For example, at 60
hertz, line-to-neutral voltage will be 120 volts.
STEPPER MOTOR ARM
Figure 12. Throttle Positions 9/10 kW Units
PULL ARM THIS
DIRECTION TO
CLOSE THROTTLE
Figure 15. Voltage Adjustment Potentiometer
RESULTS:
STEPPER MOTOR
1. If the frequency and voltage are now good, discontinue tests.
2. If frequency is now good but voltage is high or low, refer
back to flow chart.
STEPPER MOTOR ARM
Figure 13. Throttle Positions 12-20 kW Units
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sEctioN 2.4
DiaGNostic tEsts
AC GENERATORS
Part 2
teSt 18 – check VoltaGe and
Frequency under load
teSt 20 – check enGine condition
DISCUSSION:
DISCUSSION:
If engine speed and frequency drop excessively
under load, the engine may be under-powered. An
under-powered engine can be the result of a dirty air
cleaner, loss of engine compression, faulty fuel set-
tings, incorrect ignition timing, etc.
It is possible for the generator AC output frequency
and voltage to be good at no-load, but they may drop
excessively when electrical loads are applied. This
condition, in which voltage and frequency drop exces-
sively when loads are applied, can be caused by (a)
overloading the generator, (b) loss of engine power, or
(c) a shorted condition in the stator windings or in one
or more connected loads.
PROCEDURE:
For engine testing, troubleshooting and repair
procedures refer to Problem 11 in Section 4.3.
For further engine repair information refer to the
PROCEDURE:
appropriate engine service manuals
.
1. Connect an accurate AC frequency meter and an AC
voltmeter across the stator AC power winding leads.
teSt 21 – Field FlaSh alternator
2. Start the engine, let it stabilize and warm-up.
(8-10 kW unitS)
3. Apply electrical loads to the generator equal to the rated
capacity of the unit.
DISCUSSION:
The alternator utilizes residual magnetism within the
windings to charge the capacitor. If the generator has
been sitting for a long period of time with no activity
the residual magnetism could be lost within the rotor.
Field flashing the rotor while connected in parallel with
the capacitor will force a charge of electricity through
the DPE winding. The voltage that is induced into the
rotor will return and charge the capacitor enough to
take over voltage regulation of the unit.
4. Check the AC frequency and voltage.
a. Single Cylinder Units: Frequency should not
drop below approximately 58 Hertz. Voltage
should not drop below about 230 volts.
b. V-Twin Engine Units: Frequency should not drop
below approximately 60 Hertz. Voltage should
not drop below about 240 volts.
note: it is crucial that the generator exercise once
a week to help maintain this residual magnetism.
RESULTS:
1. If frequency and voltage drop excessively under load,
refer back to flow chart.
Warning: Please keep safety in mind while
performing this test.
*
1. Construct an energizing cord that is similar to that shown
in Figure 17 and connect it as shown in Figure 18.
2. If frequency and voltage under load are good, dis-
continue tests.
PROCEDURE:
teSt 19 – check For oVerload
2. Set the AUTO-OFF-MANUAL switch to the OFF position.
condition
Warning: Do Not energize the capacitor for
more than 1 second at a time.
DISCUSSION:
*
An “overload” condition is one in which the generator
rated wattage/amperage capacity has been exceed-
ed. To test for an overload condition on an installed
unit, the best method is to use an ammeter. See
“Measuring Current” in Section 1.5.
3. Momentarily turn on the energizing cord (one second).
4. Disconnect the energizing cord from the capacitor.
5. If the field flash was successful, the generator should
now be producing approximately 240 VAC at the main
circuit breaker of the generator when the AUTO-OFF-
MANUAL is set to the MANUAL position.
PROCEDURE:
Use a clamp-on ammeter to measure load current draw, with
the generator running and all normal electrical loads turned on.
Warning: Do not field flash alternator more
than two times in sequence. if the unit has
not produced power after two attempts, other
issues exist and need to be addressed.
RESULTS:
*
1. If the unit is overloaded, reduce loads to the unit’s rated
capacity.
2. If unit is not overloaded, but rpm and frequency drop
excessively when loads are applied, go to Test 16.
RESULTS:
1. Refer back to flow chart.
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sEctioN 2.4
DiaGNostic tEsts
AC GENERATORS
Part 2
CRIMP ON STANDARD FEMALE BLADE CONNECTORS
4 ft.
12 AWG
MOMENTARY PUSHBUTTON ON/OFF SWITCH
SINGLE POLE SWITCH ON LIVE SIDE
12 AWG
DO NOT SUBSTITUTE ANY OTHER DEVICE
STANDARD MALE PLUG
Figure 17. Construction of Energizing Cord
DEPRESS SWITCH FOR
ONE SECOND
PLUG ENERGIZING CORD
INTO AC OUTLET
CAPACITOR
WIRES 2 & 6 TO
DPE WINDING
CAPICITOR REMAINS CONNECTED
TO GENERATOR
Danger:The capacitor may need to be dis-
charged before testing. A capacitor can be
discharged by crossing the terminals with a
metal insulated screw driver.
Danger: Use proper protective equipment
when dealing with a capacitor that has
exploded.
GENERATOR
Figure 18. Energizing Cord Connection
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NotEs
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taBlE of coNtENts
Part
titlE
PG#
50
54
64
3.1. Description and components
3.2 operational analysis
3.3 troubleshooting flow charts
Part 3
traNsfEr
sWitcH
3.4 Diagnostic tests
66
air-cooled, automatic
standby Generators
Test 28 – Check 23 And 15B
3.1 Description and Components ...............................................56
General 56
Wiring/Connections.............................................76
Test 29 – Test Transfer Relay TR ........................................77
Test 30 – Standby Control Circuit .......................................78
Test 31 – Check Wire 23.....................................................78
Test 32 – Utility Control Circuit............................................80
Test 33 – Test Limit Switch SW2 and SW3.........................82
Test 34 – Check Fuses F1 and F2......................................82
Test 35 – Check N1 and N2 Wiring.....................................83
Test 36 – Check N1 and N2 Voltage...................................83
Test 37 – Check Utility Sensing Voltage
at the Circuit Board .............................................84
Test 38 – Check Utility Sense Voltage ................................84
Test 39 – Check Voltage at
Terminal Lugs N1, N2 .........................................84
Test 40 – Check Battery Charger Supply
Voltage “Pre-Wire Load Center”..........................86
Test 41 – Check Battery Charger Output
Voltage “Pre-Wire Load Center”..........................86
Test 42 – Check Wire 0 and Wire15B
Enclosure............................................................................56
Transfer Mechanism............................................................57
Transfer Relay.....................................................................57
Neutral Lug .........................................................................58
Manual Transfer Handle .....................................................58
Terminal Block ...................................................................58
Fuse Holder ........................................................................59
3.2 Operational Analysis.............................................................60
Operational Analysis...........................................................60
Utility Source Voltage Available ..........................................62
Utility Source Voltage Failure .............................................63
Transfer To Standby ............................................................64
Transfer To Standby ............................................................65
Utility Restored ...................................................................66
Utility Restored, Transfer Switch
De-energized ......................................................67
Utility Restored, Retransfer Back To Utility .........................68
Transfer Switch In Utility......................................................69
3.3 – Troubleshooting Flowcharts ...............................................70
Introduction To Troubleshooting ..........................................70
Problem 7 – In Automatic Mode,
“Pre-Wire Load Center”.......................................86
Test 43 – Check Battery Charger
Supply Voltage
“RTSN & RTSE Transfer Switch”.........................87
Test 44 – Check Battery Charger
No Transfer to Standby..................................................70
Problem 8 – In Automatic Mode, Generator
Output Voltage
Starts When Loss of Utility Occurs,
“RTSN & RTSE Transfer Switch”.........................87
Test 45 – Check Wire 0/
“RTSN & RTSE Transfer Switch”........................87
Test 46 – Check Battery Charger
Generator Shuts Down When Utility
Returns But There Is No Retransfer To Utility Power / or
Generator Transfers to Standby During Exercise Or In
Manual Mode.................................................................71
Problem 9 – Blown F1 or F2 Fuse.................................71
Problem 10 – Units Starts And Transfer
Supply Voltage
“GenReady Load Center”....................................90
Test 47 – Check Battery Charger
Occurs When Utility Power Is On ..................................72
Problem 11 – No Battery Charge
Output Voltage
“GenReady Load Center”....................................90
Test 48 – Check Wire 0/15B
(Pre-Packed Load Center).............................................73
Problem 12 – No Battery Charge
“GenReady Load Center”....................................90
Test 49 – Check Battery Charger
(RTSN + RTSE Transfer Switch) ...................................73
Problem 13 – No Battery Charge
Supply Voltage
(Gen-Ready Load Center).............................................73
Problem 14 – No Battery Charge
(Load Shed Transfer Switch) .........................................73
3.4 Diagnostic Tests....................................................................74
General ............................................................................74
Test 26 – Check Voltage at
“Load Shed Transfer Switch”...............................92
Test 50 – Check Battery Charger
Output Voltage
“Load Shed Transfer Switch”...............................92
Test 51 – Check Wire 0 and Wire 15B
“Load Shed Transfer Switch”...............................94
Terminal Lugs E1, E2..........................................74
Test 27 – Check Manual Transfer Switch Operation ...........75
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sEctioN 3.1
DEscriPtioN & comPoNENts
TRANSFER SWITCH
Part 3
General
encloSure
The “W/V-Type” transfer switch is rated 100 amps at
250 volts maximum. It is available in 2-pole configura-
tion only and, for that reason, is usable with 1-phase
systems only.
The “W/V-Type” transfer switch enclosure is a NEMA
1 type (“NEMA” stands for “National Electrical
Manufacturer’s Association”). Based on NEMA
Standard 250, the NEMA 1 enclosure may be defined
as one that is intended for indoor use primarily to
provide a degree of protection against contact with
the enclosed equipment and where unusual service
conditions do not exist.
Transfer switches do not have an intelligence sys-
tem of their own. Instead, automatic operation of
these transfer switches is controlled by a circuit board
housed in the generator control panel.
39
6
11
5
7
12
9
itEm DEscriPtioN
1
GTS LOAD CENTER ENCLOSURE
COVER GTS LOAD CTR
TRANSFER SWITCH HOME STANDBY
COIL UTILITY
2
3
26
29
2
3A
3
4
3A
3B
4
COIL STANDBY
SCREW
26
22
16
23
5
SCREW
LOCK WASHER”
9
30
38
6
7
RELAY PANEL 12VDC DPDT 10A@240VAC
LOAD CENTER
SCREW
24
20
10
8
15
26
9
13
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
26
27
28
29
30
31
RIVET”
WASHER
PLUG
3B
19
16
21
22
17
23
31
HARNESS ADAPTER PLATE
SUBPLATE GTS LOAD CENTER
U-CHANNEL
18
WASHER
GROMMET
ARM EXTENDER PIN
CABLE TIE SELF MOUNTING 4.3LG
HARNESS GTS-MAIN PANEL W/NEUTRAL
LUG QUICK DISCONNECT
SCREW
14
8
LUG
27
BLOCK TERMINAL
SCREW WITH WASHER
SCREW
ITEMS 32-37
HARNESS LOAD CENTER INT. CONN (NOT SHOWN)
FUSEBLOCK
FUSE 5A
BATTERY CHARGER
32-37 CIRCUIT BREAKERS
38
39
HARNESS ENTRY COVER
HARNESS GTS, EXTERNAL CONNECTION BOX
Figure 1. Exploded View of W/V-Type Transfer Switch
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sEctioN 3.1
DEscriPtioN & comPoNENts
TRANSFER SWITCH
Part 3
source side. Energizing the coil moves the load con-
tacts to an overcenter position; limit switch action then
opens the circuit and spring force will complete the
transfer action to “Standby”. This coil’s bridge rectifier
is also sealed in the coil wrappings. Replace the coil
and bridge rectifier as a unit.
tranSFer mechaniSm
The 2-pole transfer mechanism consists of a pair
of moveable LOAD contacts, a pair of stationary
UTILITY contacts, and a pair of stationary STANDBY
contacts. The load contacts can be connected to
the utility contacts by a utility closing coil; or to the
standby contacts by a standby closing coil. In addi-
tion, the load contacts can be actuated to either the
UTILITY or STANDBY side by means of a manual
transfer handle. See Figures 2 and 3.
LIMIT SWITCHES SW2 AND SW3:
Switches are mechanically actuated by load contacts
movement. When the load contacts are connected to
the utility contacts, limit switch SW2 opens the utility
circuit to utility closing coil C1 and limit switch SW3
closes the standby circuit to standby closing coil C2.
The limit switches “arm” the system for retransfer
back to UTILITY when the load contacts are con-
nected to the STANDBY side. Conversely, when the
load contacts are connected to the UTILITY side, the
switches “arm” the system for transfer to STANDBY.
An open condition in limit switch SW2 will prevent
retransfer to “Utility”. An open switch SW3 will prevent
transfer to STANDBY.
STANDBY
UTILITY
LOAD
N2A
A
BRIDGE
RECTIFIER
N1
UTILITY
N2
CLOSING
COIL (C1)
LIMIT
SWITCH
(SW2)
Figure 2. Load Connected to Utility Power Source
A
126
205
MANUAL
STANDBY
UTILITY
TRANSFER
LEVER
B
E1
E2
LIMIT
SWITCH
(SW3)
STANDBY
CLOSING
COIL (C2)
T2
T1
BRIDGE
RECTIFIER
E2
B
LOAD
Figure 4. The “W/V-Type” Transfer Mechanism
Figure 3. Load Connected to Standby Power Source
tranSFer relay
Transfer relay operation is controlled by a circuit
board. That circuit board is a part of a control panel
assembly, mounted on the standby generator set.
UTILITY CLOSING COIL C1:
See Figure 4. This coil is energized by rectified util-
ity source power, to actuate the load contacts to the
UTILITY power source side. When energized, the coil
will move the main contacts to an “overcenter” posi-
tion. A limit switch will then be actuated to open the
circuit and spring force will complete the retransfer to
STANDBY. A bridge rectifier, which changes the utility
source alternating current (AC) to direct current (DC),
is sealed in the coil wrappings. If coil or bridge rectifier
replacement becomes necessary, the entire coil and
bridge assembly should be replaced.
Figure 5 shows the transfer relay pictorially and
schematically. Relay operation may be briefly
described as follows:
1. Generator battery voltage (12 volts DC) is available to
the transfer relay coil from the generator circuit board,
via Wire 15B and Relay Terminal A.
a. The 12 volts DC circuit is completed through
the transfer relay coil and back to the generator
circuit board, via Wire 23.
STANDBY CLOSING COIL C2:
b. Circuit board action normally holds the Wire
23 circuit open to ground and the relay is
de-energized.
Coil C2 is energized by rectified standby source
power, to actuate the load contacts to their “Standby”
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sEctioN 3.1
DEscriPtioN & comPoNENts
TRANSFER SWITCH
Part 3
c. When de-energized, the relay’s normally open
contacts are open and its normally-closed
contacts are closed.
neutral luG
The standby generator is equipped with an
UNGROUNDED neutral. The neutral lug in the transfer
switch is isolated from the switch enclosure.
d. The normally-closed relay contacts will deliver
utility source power to the utility closing circuit
of the transfer mechanism.
e. The normally open relay contacts will deliver
standby source power to the transfer mecha-
nism’s standby closing circuit.
manual tranSFer handle
The manual transfer handle is retained in the transfer
switch enclosure by means of a wing stud. Use the
handle to manually actuate the transfer mechanism
load contacts to either the UTILITY or STANDBY
source side.
194
Instructions on use of the manual transfer handle
may be found in Part 5, “Operational Tests and
Adjustments”.
A
B
23
terminal Block
During system installation, this 3-point terminal block
must be properly interconnected with an identically
labeled terminal block in the generator control panel
assembly.
1
6
7
9
N1A
E1
126
205
0
15B
23
Figure 5. Transfer Relay Schematic
2. During automatic system operation, when the genera-
tor circuit board “senses” that utility source voltage
has dropped out, the circuit board will initiate engine
cranking and startup.
3. When the circuit board “senses” that the engine has
started, an “engine warm-up timer” on the circuit board
starts timing.
4. When the “engine warm-up timer” has timed out, circuit
board action completes the Wire 23 circuit to ground.
Figure 6. Transfer Switch Terminal Block
a. The transfer relay then energizes.
Terminals used on the terminal block are identified as
0, 15B and 23.
b. The relay’s normally-closed contacts open and
its normally open contacts close.
c. When the normally open contacts close, standby
source power is delivered to the standby closing
coil and transfer to “Standby” occurs.
UTILITY N1 AND N2:
Interconnect with identically labeled terminals in the
generator control panel assembly. This is the utility
voltage signal to the circuit board. The signal is deliv-
ered to a step-down transformer in the control module
assembly and the resultant reduced voltage is then
delivered to the circuit board. Utility 1 and 2 power is
used by the circuit board as follows:
• If utility source voltage should drop below a pre-
set level, circuit board action will initiate automatic
cranking and startup, followed by automatic transfer
to the standby source.
5. When the generator circuit board “senses” that utility
source voltage has been restored above a preset level,
the board will open the Wire 23 circuit to ground.
a. The transfer relay will de-energize, its normally-
closed contacts will close and its normally open
contacts will open.
b. When the normally-closed relay contacts close,
utility source voltage is delivered to the utility
closing coil to energize that coil.
• Utility source voltage is used to operate a battery
trickle charge circuit which helps to maintain battery
state of charge during non-operating periods.
c. Retransfer back to UTILITY occurs.
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sEctioN 3.1
DEscriPtioN & comPoNENts
TRANSFER SWITCH
Part 3
TERMINALS 0, 15B AND 23:
F2
These terminals connect the transfer relay to the
generator circuit board. See “Transfer Relay” in
Section 3.1.
N1A
N2A
BLACK
FuSe holder
The fuse holder holds three (3) fuses, designated as
fuses F1, F2 and F3. Each fuse is rated 5 amperes.
F3
F1
FUSES F1, F2:
These two fuses protect the UTILITY 1 and UTILITY 2
circuit against overload.
FUSES F3:
This fuse protects the battery charger against overload.
N1
N2
T1
Figure 7. The Fuse Holder
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
operational analySiS
Figure 1 is a schematic for a typical “W/V-Type” transfer switch.
0
0
0
15B
E1
N1A
CONTROL
TRANSFER
15B
15B
23
15B
23
A
23
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
N1A
BLK
WIRE
RED
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
LC
TR1-TRANSFER RELAY
Figure 1. Schematic
Page 60
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
Figure 2 is a wiring diagram for a typical “W/V-Type” transfer switch.
RED
BLK
BLK
RED
RED
BLK
N2A
N1A
126
126
GRN
GRN
A
N2A
N1A
N2A
TR1
N2A
1
4
7
3
6
9
1
2
C1
126
A
N1
N2
205
E1
A
B
15B
23
N1A
SW2
SW3
E1
RED
BLK
N1A
N2A
N1A
N2A
SW1
205
BLK
BLK
RED
RED
E1
T1
E2
T2
205
2
B
C2
1
N1A N2A
E2
B
E1
E2
205
BC
A
A
A
BLK
23
F1 F2 F3
RED
BLK
RED
E1
15B
B
B
B
-
+
BLK
WIRE
RED
WIRE
N1 N2
T1
T1
15B
0
0D4698-T
1
2
3
TB1
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
TR1-TRANSFER RELAY
Figure 2. Wiring Diagram
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
utility Source VoltaGe aVailaBle
Figure 3 is a schematic representation of the transfer switch with utility source power available. The circuit
condition may be briefly described as follows:
• Utility source voltage is available to terminal lugs N1 and N2 of the transfer mechanism, transfer switch is in the
UTILITY position and source voltage is available to T1, T2 and customer load.
• Utility source voltage is available to limit switch (SW2) via the normally-closed transfer relay contacts (1 and 7)
and Wire 126. However, SW2 is open and the Circuit to the utility closing coil is open.
• Utility voltage “sensing” signals are delivered to a circuit board on the generator, via Wire N1A, a 5 amp fuse
(F1). The second line of the utility voltage “sensing” circuit is via Wire N2A, a 5 amp Fuse (F2).
0
15B
23
0
0
15B
23
15B
E1
N1A
CONTROL
TRANSFER
15B
23
A
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
RED
WIRE
N1A
BLK
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
UTILITY
DC
LC
TR1-TRANSFER RELAY
GROUND
GENERATOR
Figure 3. Utility Source Power Available
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
utility Source VoltaGe Failure
If utility source voltage should drop below a preset value, the generator circuit board will sense the dropout. The
circuit board will then initiate generator cranking and startup after a time delay circuit times out.
Figure 4 is a schematic representation of the transfer switch with generator power available, waiting to transfer.
• Generator voltage available E1, E2.
• Circuit board action holding Wire 23 open to ground.
• Power available to standby coil C2, upon closure of TR1, normally open contacts (9 & 6) will close and initiate a
transfer.
0
15B
23
0
0
15B
23
15B
E1
N1A
CONTROL
TRANSFER
15B
23
A
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
RED
WIRE
N1A
BLK
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
UTILITY
DC
LC
TR1-TRANSFER RELAY
GROUND
GENERATOR
Figure 4. Generator Power Available, Waiting to Transfer.
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
tranSFer to StandBy
12 VDC is delivered to the transfer relay via Wire 15B and back to the circuit board via Wire 23. However, circuit
board action holds the Wire 23 circuit open and the transfer relay remains de-energized. On generator startup, an
“engine warm-up timer” on the generator circuit board starts timing. When that timer has timed out, circuit board
action completes the Wire 23 circuit to ground. The transfer relay then energizes, its normally open contacts
close, and standby source voltage is delivered to the standby closing coil via Wires E1 and E2, the transfer relay
(TR1) contacts, limit switch (SW3), Wire “B”, and a bridge rectifier. The standby closing coil energizes and the
main contacts actuate to their “Standby” side.
0
15B
23
0
0
15B
23
15B
E1
N1A
CONTROL
TRANSFER
15B
23
A
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
RED
WIRE
N1A
BLK
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
UTILITY
DC
LC
TR1-TRANSFER RELAY
GROUND
GENERATOR
Figure 5. Transfer Action to Standby Position
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
tranSFer to StandBy
When the standby coil is energized it pulls the transfer switch mechanism to a overcenter position towards the
standby power source side, the transfer switch mechanically snaps to the standby position. On closure of the
main contacts to the standby power source side, limit switches SW2 and SW3 are mechanically actuated to “arm”
the circuit for re- transfer to utility power source side.
Generator power from E1 and E2 is now connected to the customer load through T1 and T2.
0
15B
23
0
0
15B
23
15B
E1
N1A
CONTROL
TRANSFER
15B
23
A
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
RED
WIRE
N1A
BLK
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
UTILITY
DC
LC
TR1-TRANSFER RELAY
GROUND
GENERATOR
Figure 6. Generator Powering Load.
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
utility reStored
Utility voltage is restored and is available to Terminals N1 and N2. The utility voltage is sensed by the generators
circuit board. If it is above a preset value for a preset time interval a transfer back to utility power will occur.
0
15B
23
0
0
15B
23
15B
E1
N1A
CONTROL
TRANSFER
15B
23
A
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
RED
WIRE
N1A
BLK
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
UTILITY
DC
LC
TR1-TRANSFER RELAY
GROUND
GENERATOR
Figure 7. Utility Restored, Generator Still Providing Output to Load.
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
utility reStored,tranSFer SWitch de-enerGized
After the preset time interval expires the circuit board will open the Wire 23 circuit to ground. The transfer relay
de-energizes, it’s normally closed contacts close, and utility source voltage is delivered to the utility closing coil
(C1), via Wires N1A and N2A, closed Transfer Relay Contacts 1 and 7, and Limit Switch SW2.
0
15B
23
0
0
15B
23
15B
E1
N1A
CONTROL
TRANSFER
15B
23
A
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
RED
WIRE
N1A
BLK
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
UTILITY
DC
LC
TR1-TRANSFER RELAY
GROUND
GENERATOR
Figure 8. Utility Restored, Transfer Relay De-energized.
Page 67
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
utility reStored, retranSFer Back to utility
As the utility coil pulls the transfer switch to an OVER CENTER position, the switch mechanically snaps to Utility.
On closure of the main contacts to the utility power source side, Limit Switches SW2 and SW3 are mechanically
actuated to “arm” the circuit for transfer to standby.
0
15B
23
0
0
15B
23
15B
E1
N1A
CONTROL
TRANSFER
15B
23
A
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
RED
WIRE
N1A
BLK
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
UTILITY
DC
LC
TR1-TRANSFER RELAY
GROUND
GENERATOR
Figure 9. Utility Restored, Retransfer Back to Utility.
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sEctioN 3.2
oPEratioNal aNalYsis
TRANSFER SWITCH
Part 3
tranSFer SWitch in utility
When the transfer switch returns to the utility side, generator shutdown occurs after approximately one (1) minute.
0
15B
23
0
0
15B
23
15B
E1
N1A
CONTROL
TRANSFER
15B
23
A
7
7
9
9
E1
TR1
TS TO
1
4
3
6
GENERATOR
CONTROL PANEL
B
N1A
23
F2
N2
N1
E1
E2
N2
UTILITY
126
205
SENSING
N2A
F1
240VAC
OUTPUT
N1A
N1A
N1
-
+
RED
WIRE
N1A
BLK
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
B
GROUND (GREEN)
NEUTRAL (WHITE)
SWITCH
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
COM
SW2
COM
E2
B
VR1
C1
VR2
C2
N2A
A
T1 T1 T2
SW1
N2A
B
E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
UTILITY
DC
LC
TR1-TRANSFER RELAY
GROUND
GENERATOR
Figure 10. Transfer Switch in UTILITy.
Page 69
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sEctioN 3.3
trouBlEsHootiNG floW cHarts
TRANSFER SWITCH
Part 3
introduction to trouBleShootinG
The first step in troubleshooting is to correctly identify the problem. Once that is done, the cause of the an be
found by performing the tests in the appropriate flow chart.
Test numbers assigned in the flow charts are identical to test numbers in Section 3.4, “Diagnostic Tests.” Section
3.4 provides detailed instructions for performance of each test.
Problem 7 – In Automatic Mode, No Transfer to Standby
TEST 26 – CHECK
VOLTAGE AT
TERMINAL LUGS
E1 & E2
FIND CAUSE OF NO AC OUTPUT TO
TRANSFER SWITCH FROM GENERATOR
BAD
GOOD
TEST 27 – CHECK
MANUAL TRANSFER
SWITCH OPERATION
REPAIR OR REPLACE MECHANISM
REPAIR OR REPLACE AS NEEDED
REPLACE
BAD
GOOD
TEST 28 – CHECK #23
AND #15B WIRING
CONNECTIONS
BAD
BAD
BAD
GOOD
TEST 29 – TEST
TRANSFER
RELAY
GOOD
TEST 30 – CHECK
STANDBY CONTROL
CIRCUIT
REPAIR AS NEEDED
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TRANSFER SWITCH
Part 3
Problem 8 – In Automatic Mode, Generator Starts When Loss of Utility Occurs, Generator
Shuts Down When Utility Returns But There Is No Retransfer To Utility Power
OR
Generator Transfers to Standby During Excercise or in Manual Mode
TEST 27 – CHECK
MANUAL TRANSFER
SWITCH OPERATION
REPAIR OR REPLACE MECHANISM
REPAIR OR REPLACE AS NEEDED
REPLACE
BAD
BAD
BAD
GOOD
TEST 31 – CHECK
WIRE 23
GOOD
TEST 29 – TEST
TRANSFER
RELAY
GOOD
TEST 32 – CHECK
UTILITY CONTROL
CIRCUIT
REPAIR OR REPLACE AS NEEDED
BAD
Problem 9 – Blown F1 or F2 Fuse
TEST 35 – CHECK
N1 & N2 WIRING
TEST 34 – CHECK
FUSE F1 & F2
INSPECT/REPLACE
PRINTED CIRCUIT BOARD
BAD
GOOD
GOOD
BAD
FINISH
REPAIR OR REPLACE
WIRING
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TRANSFER SWITCH
Part 3
Problem 10 – Unit Starts and Transfer Occurs When Utility Power Is On
8 kW: Green LED Flashes
10-20 kW: Status – Utility Lost
REPLACE
CIRCUIT
BOARD
TEST 36 –
CHECK N1 & N2
VOLTAGE
TEST 37 – CHECK
UTILITY SENSING
VOLTAGE AT
GOOD
GOOD
CIRCUIT BOARD
REPAIR OR
REPLACE
WIRING
BAD
BAD
CORRECT
TEST 38 – CHECK
UTILITY SENSE
VOLTAGE
TEST 39 –
CHECK VOLTAGE
AT TERMINAL
UTILITY
SOURCE
VOLTAGE
TEST 34 –
CHECK FUSE
F1 & F2
BAD
BAD
GOOD
LUGS N1 & N2
GOOD
BAD
GOOD
REPAIR OR REPLACE WIRE
N1A/N2A BETWEEN N1/N2
LUGS AND FUSE HOLDER
REPAIR N1/N2 OPEN WIRING
BETWEEN TRANSFER
SWITCH AND GENERATOR
REPLACE
GO TO PROBLEM 7
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TRANSFER SWITCH
Part 3
Problem 11 – No Battery Charge
“Pre-Wire Load Center”
TEST 40 – CHECK
BATTERY CHARGER
SUPPLY VOLTAGE
TEST 41 – CHECK
BATTERY CHARGER
OUTPUT VOLTAGE
TEST 42 – CHECK
WIRE 0/15B
NO BATTERY
SUPPLY VOLTAGE
GOOD
BAD
GOOD
BAD
BAD
REPLACE PRINTED
CIRCUIT BOARD
REPAIR OR
REPLACE
REPAIR OR REPLACE
REPLACE CHARGER
Problem 12 – No Battery Charge
“RTSN & RTSE Transfer Switch”
TEST 43 – CHECK
BATTERY CHARGER
SUPPLY VOLTAGE
TEST 44 – CHECK
TEST 45 – CHECK
WIRE 0/15B
NO BATTERY
GOOD
BATTERY CHARGER
SUPPLY VOLTAGE
OUTPUT VOLTAGE
BAD
GOOD
BAD
BAD
REPLACE PRINTED
CIRCUIT BOARD
REPAIR OR
REPLACE
REPAIR OR REPLACE
REPLACE CHARGER
Problem 13 – No Battery Charge
“GenReady Load Center”
TEST 46 – CHECK
BATTERY CHARGER
SUPPLY VOLTAGE
TEST 47 – CHECK
TEST 48 – CHECK
WIRE 0/15B
NO BATTERY
GOOD
BATTERY CHARGER
SUPPLY VOLTAGE
OUTPUT VOLTAGE
BAD
GOOD
BAD
BAD
REPLACE PRINTED
CIRCUIT BOARD
REPAIR OR
REPLACE
REPAIR OR REPLACE
REPLACE CHARGER
Problem 14 – No Battery Charge
“Load Shed Transfer Switch”
TEST 49 – CHECK
BATTERY CHARGER
SUPPLY VOLTAGE
TEST 50 – CHECK
BATTERY CHARGER
OUTPUT VOLTAGE
TEST 51 – CHECK
WIRE 0/15B
NO BATTERY
SUPPLY VOLTAGE
GOOD
BAD
GOOD
BAD
BAD
REPLACE PRINTED
CIRCUIT BOARD
REPAIR OR
REPLACE
REPAIR OR REPLACE
REPLACE CHARGER
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DiaGNostic tEsts
TRANSFER SWITCH
Part 3
PROCEDURE:
General
1. If the generator engine has started automatically (due to
a utility power source outage) and is running, check the
position of the generator main circuit breaker. The circuit
breaker must be set to its “On” or “Closed” position.
After confirming that the generator main circuit breaker
is set to ON (or closed), check the voltage at transfer
mechanism Terminal Lugs E1 and E2 with an accurate
AC voltmeter or with an accurate volt-ohm-milliammeter
(VOM). The generator line-to line voltage should be
indicated.
Test numbers in this section correspond to the
numbered tests in Section 3.3, “Troubleshooting
Flow Charts”. When troubleshooting, first identify
the problem. Then, perform the diagnostic tests in
the sequence given in the flow charts.
teSt 26 – check VoltaGe at terminal
luGS e1, e2
DISCUSSION:
2. If the generator has been shut down, proceed as follows:
In automatic mode, the standby closing coil (C2) must
be energized by standby generator output if transfer to
the “Standby” source is to occur. Transfer to “Standby”
cannot occur unless that power supply is available to
the transfer switch.
a. On the generator control panel, set the AUTO-
OFF-MANUAL switch to OFF.
b. Turn off all power voltage supplies to the trans-
fer switch. Both the utility and standby power
supplies must be positively turned off before
proceeding.
DaNGEr: BE carEful! HiGH aND
DaNGErous VoltaGEs arE PrEsENt
at tErmiNal luGs E1 aND E2 WHEN
*
c. Check the position of the transfer mechanism
main contacts. The moveable LOAD contacts must
be connected to the stationary UTILITY source
contacts. If necessary, manually actuate the main
contacts to the “Utility” power source side.
tHE GENErator is ruNNiNG. aVoiD
coNtact WitH HiGH VoltaGE tErmiNals
or DaNGErous aND PossiBlY lEtHal
ElEctrical sHocK maY rEsult. Do
Not PErform tHis VoltaGE tEst WHilE
staNDiNG oN WEt or DamP GrouND,
WHilE BarEfoot, or WHilE HaNDs or
fEEt arE WEt.
d. Actuate the generator main line circuit breaker
to its “On” or “Closed” position. The utility power
supply to the transfer switch must be turned off.
N2A
A
BRIDGE
RECTIFIER
N1
UTILITY
N2
CLOSING
COIL (C1)
LIMIT
SWITCH
(SW2)
A
126
205
MANUAL
TRANSFER
LEVER
B
E1
LIMIT
E2
SWITCH
(SW3)
STANDBY
CLOSING
COIL (C2)
T2
T1
E2
BRIDGE
RECTIFIER
B
Figure 1. The Transfer Mechanism
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TRANSFER SWITCH
Part 3
e. Set the generator AUTO-OFF-MANUAL switch
to AUTO.
utility source voltage is available to the standby closing
coil terminals, but transfer to Standby does not occur,
the cause of the failure may be (a) a failed standby
closing coil and/or bridge rectifier, or (b) a seized or
sticking actuating coil or load contact. This test will help
you evaluate whether any sticking or binding is present
in the transfer mechanism.
(1) The generator should crank and start.
(2) When the generator starts, an “engine
warm-up timer” should start timing. After
about 15 seconds, the transfer relay should
energize and transfer to the “Standby”
source should occur.
PROCEDURE:
f. If transfer to “Standby” does NOT occur, check
the voltage across transfer switch Terminal Lugs
E1 and E2. The generator line-to-line voltage
should be indicated.
1. With the generator shut down, set the generator
AUTO-OFF-MANUAL switch to OFF.
2. Set the generator main circuit breaker to OFF or “Open”.
3. Turn off the utility power supply to the transfer switch,
using whatever means provided (such as a utility source
main line breaker).
RESULTS:
1. If normal transfer to “Standby” occurs, discontinue tests.
2. If transfer to “Standby” does NOT occur and no voltage
is indicated across Terminal Lugs E1/E2, determine why
generator AC output has failed.
DaNGEr: Do Not attEmPt maNual
traNsfEr sWitcH oPEratioN uNtil
all PoWEr VoltaGE suPPliEs to tHE
sWitcH HaVE BEEN PositiVElY turNED
off. failurE to turN off all PoWEr
VoltaGE suPPliEs maY rEsult iN
EXtrEmElY HaZarDous aND PossiBlY
lEtHal ElEctrical sHocK.
*
3. If transfer to “Standby” does NOT occur and voltage
reading across Terminal Lugs E1/E2 is good, refer to
Flow Chart.
teSt 27 – check manual tranSFer
4. In the transfer switch enclosure, locate the manual
transfer handle. Handle is retained in the enclosure
with a wing nut. Remove the wing nut and handle.
SWitch operation
DISCUSSION:
In automatic operating mode, when utility source volt-
age drops below a preset level, the engine should
crank and start. On engine startup, an “engine warm-up
timer” on the generator circuit board should start timing.
When that timer has timed out (about 15 seconds), the
transfer relay should energize to deliver utility source
power to the standby closing coil terminals. If normal
5. See Figure 2. Insert the un-insulated end of the handle
over the transfer switch operating lever.
a. Move the transfer switch operating lever up to
actuate the load contacts to the Utility position,
i.e., load connected to the utility source.
LOAD CONNECTED TO
LOAD CONNECTED TO
UTILITY POWER SOURCE
STANDBY POWER SOURCE
TRANSFER
SWITCH
OPERATING
LEVER
MANUAL
TRANSFER
HANDLE
MANUAL
TRANSFER
HANDLE
TRANSFER
SWITCH
OPERATING
LEVER
Figure 2. Manual Transfer Switch Operation
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TRANSFER SWITCH
Part 3
b. Actuate the operating lever down to move the
load contacts against the standby contacts, i.e.,
load connected to the Standby source.
caution: after removing the fuse from the bat-
tery charger, wait 5 minutes before proceeding.
*
5. Set VOM to measure DC voltage.
6. Repeat Step 5 several times. As the transfer switch
operating lever is moved slight force should be needed
until the lever reaches its center position. As the lever
moves past its center position, an over-center spring
should snap the moveable load contacts against the
stationary STANDBY or UTILITY contacts.
6. Connect the negative (-) test lead to Wire 0 at the termi-
nal strip in the transfer switch. Connect the positive (+)
test lead to Wire 15B at the terminal strip in the transfer
switch.
a. If voltage is present, proceed to Step 7.
7. Finally, actuate the main contacts to their UTILITY power
source side, i.e., load contacts against the UTILITY contacts
(upward movement of the operating lever).
b. If voltage is not present proceed to Step 17.
7. Connect the positive (+) test lead to Wire 23 at the termi-
nal strip in the transfer switch.
RESULTS:
a. If voltage is present, proceed to Step 8.
1. If there is no evidence of binding, sticking, or excessive
force required, refer back to flow chart.
b. If voltage is not present, set VOM to measure
resistance.
c. Remove Wire 23 and Wire 15B going to the
transfer relay from the transfer switch terminal
strip. Connect the meter test leads across Wire
23 and Wire 15B.
2. If evidence of sticking, binding, excessive force required
to move main contacts, find cause of binding or sticking
and repair or replace damaged part(s).
d. Transfer coil resistance of approximately 115
ohms should be measured.
teSt 28 – check 23 and 15B WirinG/
e. If coil resistance is not measured, remove
Wire 23 and Wire 15B from the transfer relay.
Measure across Terminal A and Terminal B of
the transfer relay.
connectionS
DISCUSSION:
An open circuit in the transfer switch control wir-
ing can prevent a transfer action from occurring.
Battery voltage +12 VDC is supplied on Wire 15B.
This DC voltage is supplied to the transfer relay (TR)
at Terminal Location “A”. The opposite side of the
transfer relay (TR) coil (Terminal B) is connected
to Wire 23. Positive 12 VDC is present on this also.
Circuit board action will allow current to flow through
the circuit and the (TR) is energized.
f. If coil resistance is measured repair or replace
Wire 23 or Wire 15B between the terminal strip
and the transfer relay.
g. If coil resistance is not measured replace trans-
fer relay and retest.
8. Connect the negative (-) test lead to the ground lug in
the generator control panel. Connect the positive (+)
test lead to Wire 23 in the generator control panel at the
terminal strip.
PROCEDURE/ RESULTS:
Refer to Figure 3.
a. If voltage is present, proceed to Step 9.
1. Remove transfer relay mounting screws so that contact
movement can be visually observed.
b. If voltage is not present, repair wiring between
transfer switch and generator control panel.
9. Remove the J2 connector from the circuit board.
10.Set VOM to measure resistance.
2. Set the generator AUTO-OFF-MANUAL switch to the
AUTO position. Turn off utility power supply to the
transfer switch, simulating a utility failure. Visually
watch the transfer relay for contact movement. The
relay should be energized and contact movement seen
approximately 10 seconds after the generator starts.
11.Connect one meter test lead to Wire 23 Pin Location
J2-5. Connect the other meter test lead to Wire 15B
Pin Location J2-8. Approximately 115 ohms should be
measured. (see Figures 4 through 7, Section 4.1).
a. If the transfer relay energizes, discontinue
testing. Refer to flow chart.
a. If approximately 115 ohms is measured proceed
to Step 12.
b. If the transfer relay does not energize, continue
to Step 3.
b. If infinity or an open is measured, repair Wire 23
between PCB Connector J2 and the generator
terminal strip.
3. Set the generator AUTO-OFF-MANUAL switch to the
OFF position.
c. If resistance is not within specification, go to
Test 29 – Test Transfer Relay.
4. Remove the battery charger fuse (F3) from the transfer
switch to disable the battery charge circuit.
12.Reconnect the J2 connector to the PCB.
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Part 3
13.Set VOM to measure DC voltage.
caution: after installing the 7.5a fuse and dis-
connecting Wire 15B from the generator termi-
nal strip, wait 5 minutes before proceeding.
14.Connect the (-) negative meter test lead to Wire 0 at the
terminal strip in the generator. Connect the (+) positive
meter test lead to Wire 23 at the terminal strip in the
generator. 12 VDC should be measured.
*
27.Connect one meter test lead to Wire 15B. Connect the other
meter test lead to Wire 0. 12 VDC should be measured.
15.Place generator AUTO-OFF-MANUAL switch to the
AUTO position. Turn off utility power supply to the
transfer switch, simulating a utility failure. After the
generator starts 10 seconds should elapse before
transfer occurs. At that time the VOM DC voltage
should drop to zero. This indicates the PCB energized
the transfer relay.
a. If 12 VDC is not measured, replace the printed
circuit board.
b. If 12 VDC is measured, a short exists on Wire
15B or the transfer relay is shorted. Repair or
replace as needed.
teSt 29 – teSt tranSFer relay tr
a. If DC voltage drops to zero, refer to Flow Chart.
b. If DC voltage remains constant at 12 VDC, pro-
ceed to Step 16.
DISCUSSION:
In automatic operating mode, the transfer relay must
be energized by circuit board action or standby source
power will not be available to the standby closing coil.
Without standby source power, the closing coil will
remain de-energized and transfer to “Standby” will not
occur. This test will determine if the transfer relay is
functioning normally.
16.With the generator running and utility off, ground Wire 23
in the control panel at the terminal strip. If transfer relay
energizes and or transfer occurs, replace the PCB.
17.Set VOM to measure DC voltage.
18.Connect the negative (-) test lead to the ground lug in
the transfer switch. Connect the positive (+) test lead to
Wire 15B at the terminal strip in the transfer switch.
126
205
a. If voltage is present repair or replace Wire 0
between transfer switch and generator ground
lug.
E1
b. If voltage is not present proceed to Step 19.
19.Connect the negative (-) test lead to the ground lug in
the generator control panel. Connect the positive (+) test
lead to Wire 15B at the terminal strip in the generator
control panel.
a. If voltage is present, repair Wire 15B between
generator terminal strip and transfer switch
terminal strip.
N1A
23
15B
b. If voltage is not present, proceed to Step 20.
COIL NOMINAL RESISTANCE = 120 Ohms
20.Remove the J2 connector from the circuit board.
Figure 3. Transfer Relay Test Points
21.Set VOM to measure ohms. Connect one meter test lead
to Wire 15B at the control panel terminal strip. Connect
the other meter test lead to Wire 15B Pin Location J2-8.
Continuity should be measured.
PROCEDURE:
1. See Figure 3. Disconnect all wires from the transfer
relay, to prevent interaction.
a. If continuity is not measured, repair pin connection
and or Wire 15B between the J2 connector and
terminal strip.
2. Set a VOM to its “R x 1” scale and zero the meter.
3. Connect the VOM test leads across Relay Terminals 6
and 9 with the relay de-energized. The VOM should read
INFINITY.
b. If continuity is measured proceed to Step 22.
22.Remove the 7.5A fuse.
23.Reconnect J2 connector.
DESIRED METER READING
CONNECT VOM TEST
LEADS ACROSS
24.Install the 7.5A fuse.
ENERGIZED
Continuity
Infinity
DE-ENERGIZED
25.Disconnect Wire 15B from the generator terminal strip.
26.Set VOM to measure DC voltage.
Terminals 6 and 9
Terminals 1 and 7
Infinity
Continuity
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Part 3
a. If 240 VAC is not measured, replace transfer
relay.
4. Using jumper wires, connect the positive (+) post of a
12 volt battery to relay Terminal “A” and the negative
(-) battery post to Relay Terminal “B”. The relay should
energize and the VOM should read CONTINUITY.
b. If 240 VAC is measured, proceed to Step 9.
9. Measure across points A and F. 240 VAC should be
measured.
5. Now, connect the VOM test leads across Relay Terminals
1 and 7.
a. If 240 VAC is not measured, repair or replace
Wire 205.
a. Energize the relay and the meter should
indicate INFINITY.
b. If 240 VAC is measured, proceed to Step 10.
b. De-energize the relay and the VOM should read
CONTINUITY.
10.Measure across points A and G. 240 VAC should be
measured.
a. If 240 VAC is not measured, verify limit switch
SW3 is wired correctly. Proceed to Test 33.
RESULTS:
1. Replace transfer relay if it is defective.
b. If 240 VAC is measured, proceed to Step 11.
2. If transfer relay checks good go to Test 31.
11.Measure across points A and H. 240 VAC should be
measured.
a. If 240 VAC is not measured, repair or replace
Wire B.
teSt 30 – StandBy control circuit
b. If 240VAC is measured, replace standby coil C2.
DISCUSSION:
coil nominal resistance is 1-2 megohms.
Refer to Figure 4. The standby coil (C2) requires 240
VAC to energize. When the transfer relay is energized,
240 VAC is applied to standby coil C2. Once energized,
the coil will pull the transfer switch down to the standby
position. Once in the standby position, limit switch SW3
will open, removing AC to standby coil C2.
teSt 31 – check Wire 23
DISCUSSION:
Printed circuit board action controls grounding Wire
23 to initiate a transfer to standby. When Wire 23 is
grounded the transfer relay (TR1) is energized. To
initiate a transfer back to utility the TR1 relay must be
de-energized. If Wire 23 is grounded, TR1 will always
be energized.
PROCEDURE/ RESULTS:
1. Set VOM to measure AC voltage.
2. Verify the transfer switch is up in the utility position.
3. Remove Wire E2 from standby coil C2.
4. Set the generator AUTO-OFF-MANUAL switch in the
AUTO position. Turn off the utility power supply to the
transfer switch, simulating a utility failure. The generator
should start and the transfer relay should energize.
PROCEDURE/ RESULTS:
1. Set VOM to measure DC voltage.
2. Set the generator AUTO-OFF-MANUAL switch in the
OFF position.
5. Measure across points A and B. 240 VAC should be
measured.
3. Connect the positive (+) meter test lead to Wire 15B
at the terminal strip in the transfer switch. Connect the
negative (-) meter test lead to Wire 23 at the terminal
strip in the transfer switch.
a. If 240 VAC is not measured go back to Test 26.
b. If 240 VAC is measured, proceed to Step 6.
6. Measure across points C (Wire E2 previously removed)
and B. 240 VAC should be measured.
a. If 0 VDC is measured, proceed to Step 4.
b. If 12 VDC is measured, proceed to Step 6.
a. If 240 VAC is not measured, repair or replace
Wire E2.
4. Set the generator AUTO-OFF-MANUAL switch in the
AUTO position.
b. If 240 VAC is measured, proceed to Step 7.
5. Connect the positive (+) meter test lead to Wire 15B
at the terminal strip in the transfer switch. Connect the
negative (-) meter test lead to Wire 23 at the terminal
strip in the transfer switch
7. Measure across points A and D. 240 VAC should be
measured.
a. If 240 VAC is not measured, repair or replace
Wire E1.
a. If 12 VDC is measured, procced to Step b.
b. If 240 VAC is measured, proceed to Step 8.
b. Navigate to the Digital Output Display Screen
(see Figure 5).
8. Measure across points A and E. 240 VAC should be
measured.
(1) Press “ESC” until the main menu is reached.
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Figure 4. Standby Control Circuit Test Points
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(2) Press the right arrow key until “Debug” is
flashing.
CUSTOMER SIDE
(3) Press “Enter”.
N1/N2
(4) Press the right arrow key until “Outputs” is
flashing.
CONTROL BOARD
CONNECTION
(5) Press “Enter”.
N1 N2
(6) Digital Output 8 is Wire 23 output from the
board. Refer to Figure 5.
(7) If Output 8 shows a “1” then the control
board is grounding Wire 23. Replace the
printed circuit board.
GENERATOR
TERMINAL STRIP
c. If 0 VDC is measured, the Wire 23 circuit is
good. Refer to flow chart.
DEBUG
Figure 6. Transfer Relay Test Points
9. Disconnect the J2 connector from the printed circuit board.
10.Set VOM to measure resistance.
OUTPUTS
11.Connect one meter test lead to Wire 23 connected at
generator terminal strip. See Figure 6. Connect the other
meter test lead to control panel ground.
OUTPUTS 1 - 8:
1 0 1 1 0 0 0 1
a. If INFINITY or open is measured, replace the
printed circuit board
OUTPUT 8
b. If continuity measured, Wire 23 is shorted to
ground. Repair or replace Wire 23 between the
J2 connector and the generator terminal strip.
Figure 5. The Home Page, Debug and Output Screens
6. Locate the terminal strip in the generator control panel.
Disconnect Wire 23 coming in from the transfer switch
(customer connection, side-see Figure 6).
teSt 32 – utility control circuit
DISCUSSION:
7. Connect the positive (+) meter test lead to Wire 15B at
the terminal strip in the generator. Connect the nega-
tive (-) meter test lead to Wire 23 just removed from
the terminal strip.
Printed circuit board action controls grounding Wire
23 to initiate a transfer to standby. When Wire 23 is
grounded the transfer relay (TR1) is energized. To
initiate a transfer back to utility the TR1 relay must be
de-energized. If Wire 23 is grounded, TR1 will always
be energized.
a. If 0 VDC is measured, proceed to Step 8.
b. If 12 VDC is measured, a short to ground exists
on Wire 23 between the generator and transfer
switch. Repair or replace Wire 23 as needed
between generator control panel and transfer
switch relay (TR1).
PROCEDURE/ RESULTS:
Refer to Figure 7.
1. Turn off utility supply voltage to the transfer switch.
2. Set VOM to measure AC voltage.
8. Locate the terminal strip in the generator control panel.
Disconnect Wire 23 coming in from the transfer switch
(customer connection, side - see Figure 6).
3. Set the generator AUTO-OFF-MANUAL switch in the
OFF position. Remove Wire 15B from the transfer switch
terminal strip.
4. Verify the transfer switch is down in the standby position.
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Figure 7. Utility Control Circuit Test Points
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5. Remove Wire N2A from the utility coil C1.
teSt 33 – teSt limit SWitch SW2 and SW3
6. Turn on utility power supply to the transfer switch.
DISCUSSION:
a. If transfer to utility occurs, Wire 23 is grounded.
Proceed to Test 31.
The limit switches are wired to the normally closed
contacts. When the switches are activated the
contacts open.
b. If transfer to utility does not occur, proceed to
Step 7.
PROCEDURE:
7. Measure across points A and B. 240 VAC should be
measured.
With the generator shut down, the generator main
circuit breaker turned OFF, and with the utility power
supply to the transfer switch turned OFF, test limit
switch SW2/SW3 as follows:
a. If 240 VAC is not measured, verify utility source.
b. If 240 VAC is measured, proceed to Step 8.
1. To prevent interaction, disconnect Wire 126 and Wire A
from limit switch SW2 terminals.
8. Measure across points C (Wire N2A previously removed)
and B. 240 VAC should be measured.
2. Set a VOM to its “R x 1” scale and zero the meter.
a. If 240 VAC is not measured, repair or replace
Wire N2A.
3. See Figure 1. Connect the VOM meter test leads
across the two outer terminals from which the wires
were disconnected.
b. If 240 VAC is measured, proceed to Step 9.
9. Measure across points A and D. 240 VAC should be
measured.
4. Manually actuate the main contacts to their Standby
position. The meter should read CONTINUITY.
a. If 240 VAC is not measured, repair or replace
Wire N1A.
5. Manually actuate the main contacts to their Utility
position. The meter should read INFINITY.
b. If 240 VAC is measured, proceed to Step 10.
10.Measure across points A and E. 240 VAC should be
measured.
6. Repeat Steps 4 and 5 several times and verify the VOM
reading at each switch position.
a. If 240 VAC is not measured, repair or replace
Wire N1A.
7. To prevent interaction, disconnect Wire 205 and Wire B
from limit switch SW3 terminals.
b. If 240 VAC is measured, proceed to Step 11.
11.Measure across points A and F. 240 VAC should be
measured.
8. See Figure 1. Connect the VOM meter test leads
across the two outer terminals from which the wires
were disconnected.
a. If 240 VAC is not measured, replace transfer
relay.
9. Manually actuate the main contacts to their Standby
position. The meter should read INFINITY.
b. If 240 VAC is measured, proceed to Step 12.
12.Measure across points A and G. 240 VAC should be
measured.
10.Manually actuate the main contacts to their Utility
position. The meter should read CONTINUITY.
a. If 240 VAC is not measured, repair or replace
Wire 126.
11.Repeat Steps 4 and 5 several times and verify the VOM
reading at each switch position.
b. If 240 VAC is measured, proceed to Step 13.
13.Measure across points A and H. 240 VAC should be
measured.
RESULTS:
1. If Limit Switch SW2 or SW3 fails the test, remove and
replace the switch or adjust switch until it is actuated
properly.
a. If 240 VAC is not measured, verify limit switch
SW2 is wired correctly. Proceed to Test 33.
b. If 240 VAC is measured, proceed to Step 14.
14.Measure across points A and I. 240 VAC should be
measured.
teSt 34 – check FuSeS F1 and F2
a. If 240 VAC is not measured, repair or replace
Wire A.
DISCUSSION:
Fuses F1 and F2 are connected in series with the N1
and N2 circuits, respectively. A blown fuse will open
the applicable circuit and will result in (a) generator
startup and transfer to “Standby”, or (b) failure to
retransfer back to the utility source.
b. If 240 VAC is measured, replace utility coil C1.
Coil nominal resistance is 1-2 megohms.
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PROCEDURE:
6. Connect the positive meter test lead to Wire N1 at the
terminal block in the control panel.
1. On the generator panel, set the AUTO-OFF-MANUAL
switch to OFF.
a. Connect the negative meter lead to the ground
lug. INFINITY should be measured.
2. Turn off the utility power supply to the transfer switch,
using whatever means provided.
b. Connect the negative meter lead to Wire
23 at the terminal strip. INFINITY should be
measured.
3. Remove fuses F1 and F2 from the fuse holder (see
Figure 8).
c. Connect the negative meter lead to Wire 15B at
the terminal strip. INFINITY should be measured.
4. Inspect and test fuses for blown condition. With a VOM
set to measure resistance, CONTINUITY should be
measured across the fuse.
d. Connect the negative meter lead to Wire 0 at the
terminal strip. INFINITY should be measured.
e. Connect the negative meter lead to Wire N2 at the
terminal block. INFINITY should be measured.
F2
f. Connect the negative meter lead to the neutral
connection. INFINITY should be measured.
N1A
N2A
BLACK
7. Connect the positive meter test lead to Wire N2 at the
terminal block in the control panel.
a. Connect the negative meter lead to the ground
lug. INFINITY should be measured.
F3
b. Connect the negative meter lead to Wire 23 at
the terminal strip. INFINITY should be measured.
F1
c. Connect the negative meter lead to Wire 15B at
the terminal strip. INFINITY should be measured.
d. Connect the negative meter lead to Wire
0 at the terminal strip. INFINITY should be
measured.
N1
N2
T1
e. Connect the negative meter lead to the neutral
connection. INFINITY should be measured.
RESULTS:
Figure 8. Fuse Holder and Fuses
If a short is indicated in Step 6 or Step 7, repair wiring
and re-test.
RESULTS:
1. Replace blown fuse(s) as needed.
teSt 36 – check n1 and n2 VoltaGe
teSt 35 – check n1 and n2 WirinG
DISCUSSION:
Loss of utility source voltage to the generator will initi-
ate a startup and transfer by the generator. Testing at
the control panel terminal block will divide the system
in two, thereby reducing troubleshooting time.
DISCUSSION:
A shorted Wire N1 or N2 to ground can cause fuse F1
or F2 to blow.
PROCEDURE:
PROCEDURE:
1. On the generator panel, set the AUTO-OFF-MANUAL
switch to OFF.
1. Set the AUTO-OFF-MANUAL switch to OFF.
2. Set a VOM to measure AC voltage.
2. Turn off the utility power supply to the transfer switch,
using whatever means provided.
3. See Figure 9. Connect one test lead to Wire N1 at the
terminal block in the generator control panel. Connect
the other test lead to Wire N2. Utility line-to-line voltage
should be measured.
3. Remove fuses F1, F2, and F3 from the fuse holder (see
Figure 7).
4. Remove the generator control panel cover. Disconnect
the N1/N2 connector that supplies the printed circuit
board located in the control panel (see Figure 6).
RESULTS:
Refer to Flow Chart
5. Set VOM to measure resistance.
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PROCEDURE:
With utility source voltage available to terminal lugs
N1 and N2, use a VOM to test for utility source line-
to-line voltage across terminal locations N1 and N2
terminals. Normal line-to-line utility source voltage
should be indicated.
240 VAC
TEST POINTS
N1A N2A
N2
N1
A
A
A
F1 F2 F3
Figure 9. Terminal Block Test Points
B
B
B
teSt 37 – check utility SenSinG
VoltaGe at the circuit Board
N1
N2
T1
DISCUSSION:
Figure 10. Transfer Switch Fuse Block
If the generator starts and transfer to STANDBY
occurs in the automatic mode when acceptable
UTILITY source voltage is available at the terminal
block, the next step is to determine if sensing voltage
is reaching the printed circuit board.
RESULTS:
1. If voltage reading across the N1 and N2 terminals is
zero or low, refer to Flow Chart.
note:the System ready led will flash in auto or
utility loSt will display on the panel.
2. If voltage reading is good, refer to Flow Chart.
PROCEDURE:
1. Set the AUTO-OFF-MANUAL switch to OFF.
teSt 39 – check VoltaGe at terminal
2. Disconnect the N1/N2 connector in the control panel
(see Figure 6).
luGS n1, n2
DISCUSSION:
3. Set a VOM to measure AC voltage.
If source voltage is not available to N1/N2 terminals,
automatic startup and transfer to STANDBY will occur
when the generator AUTO-OFF-MANUAL switch is
set to AUTO. This test will prove that “Utility” voltage is
available to those terminals, or is not available.
4. Connect one meter test lead to Wire N1. Connect the
other meter test lead to Wire N2. Approximately 240
VAC should be measured. See Figure 9.
RESULTS:
DaNGEr: ProcEED WitH cautioN! HiGH
aND DaNGErous VoltaGEs arE PrEsENt
at tErmiNal luGs N1/N2. coNtact WitH
HiGH VoltaGE tErmiNals Will rEsult
iN DaNGErous aND PossiBlY lEtHal
ElEctrical sHocK. Do Not attEmPt
tHis tEst WHilE staNDiNG oN WEt or
DamP GrouND, WHilE BarEfoot, or
WHilE HaNDs or fEEt arE WEt.
1. If voltage was measured in Step 4 and the pin connec-
tions are good, replace the circuit board.
*
2. If voltage was NOT measured in Step 4, repair or replace
Wire N1/N2 between connector and terminal block.
teSt 38 – check utility SenSe VoltaGe
The N1 and N2 terminals in the transfer switch deliver
utility voltage “sensing” to a circuit board. If voltage at
the terminals is zero or low, standby generator startup
and transfer to the “Standby” source will occur auto-
matically as controlled by the circuit board. A zero
or low voltage at these terminals will also prevent
retransfer back to the “Utility” source.
PROCEDURE:
1. Make sure that all main line circuit breakers in the utility
line to the transfer switch are “On” or “Closed.”
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1
2
TRANSFER SWITCH
C1
E
A
N1
N2
N
SW2
SW3
LC
SW1
B
A
E1
T1
E2
T2
B
C2
1
2
BC
A
A
A
D
C
B
A
F1 F2 F3
B
B
B
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
-
+
BLK
WIRE
RED
WIRE
T1
15B
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
TB1-TERMINAL STRIP
0
G
I
F
1
2
3
TB1
H
GENERATOR
1
MAIN
CONTROLLER
2
3
4
J1
J3
K
J
J2
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18
L
0
M
0
0
0
0
0
PANEL GND
0
0
0
N
Figure 11. Test 40, 41, and 42 “Pre-Wire Load Center” Test Points.
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PROCEDURE:
2. Test for utility source line-to-line voltage across Terminal
Lugs N1 and N2 (see Figure 1). Normal utility source
voltage should be indicated.
Refer to Figure 11.
1. Set VOM to measure DC voltage.
2. Remove Wire 0 and Wire 15B from transfer switch
terminal strip points F and G.
RESULTS:
1. If low or no voltage is indicated, find the cause of the
problem and correct.
3. Measure across points H and I. Battery supply voltage
(12 VDC) should be measured.
2. If normal utility source voltage is indicated, refer to
Flow Chart.
a. If battery voltage is not measured, wait 5 minutes
and repeat Step 3.
b. If battery supply voltage is still not available,
refer to Flow Chart.
teSt 40 – check Battery charGer
Supply VoltaGe
c. If battery voltage is measured, proceed to Step 4.
4. Reconnect Wire 0 and Wire 15B previously removed
in Step 2.
“pre-Wire load center”
DISCUSSION:
5. Measure across points H and I. 13.4 VDC should
be measured.
The battery charger is supplied with 120 VAC. The
output of the battery charger is 13.4 VDC / 2.5A.
a. If 13.4 VDC is not measured, replace the
battery charger
PROCEDURE:
b. If 13.4 VDC is measured, the charger is working.
Refer to Figure 11.
*note: Battery charger voltage will be higher than
battery supply voltage.
1. Set VOM to measure AC voltage.
2. Measure across points A and B. 240 VAC should be
measured.
teSt 42 – check Wire 0 and Wire15B
a. If 240 VAC is not measured, verify load source
voltage.
“pre-Wire load center”
b. If 240 VAC is measured go to Step 3.
DISCUSSION:
3. Measure across points A and C. 240 VAC should be
measured.
In order for the battery charger to function, battery supply
voltage must be available to the battery charger.
a. If 240 VAC is not measured, repair or replace
Wire T1.
PROCEDURE:
Refer to Figure 11.
b. If 240VAC is measured, proceed to Step 4.
1. Set VOM to measure DC voltage.
4. Measure across points A and D. 240 VAC should be
measured.
2. Disconnect Wire 0 and Wire 15B from generator terminal
strips, locations J and K.
a. If 240 VAC is not measured, replace fuse F3.
b. If 240VAC is measured, proceed to Step 5.
3. Wait five (5) minutes after removing wires.
5. Remove Fuse F3. Measure across points D and C.
120 VAC should be measured.
4. Measure across points L and M on the terminal strip.
12 VDC should be measured.
a. If 120 VAC is not measured, verify neutral wire
is connected at point E. If good, replace battery
charger, then retest.
a. If 12 VDC is measured, proceed to Step 6.
b. If 12 VDC is not measured, proceed to Step 5.
5. Measure across points M and N. 12 VDC should be
measured.
b. If 120VAC is measured, refer to Flow Chart.
a. If 12 VDC is measured, repair or replace Wire
0 between the generator terminal strip and the
ground lug.
teSt 41 – check Battery charGer
output VoltaGe
“pre-Wire load center”
b. If 12 VDC is not measured, proceed to Step 8.
6. Set VOM to measure resistance.
DISCUSSION:
7. Connect the meter test leads across the disconnected
Wire 0 and Wire 15B. Approximately 115 Ohms should
be measured.
The battery charger is supplied with 120VAC. The out-
put of the battery charger is 13.4 VDC / 2.5A.
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a. If 115 Ohms is measured, proceed to Step 10.
teSt 44 – check Battery charGer
output VoltaGe
“rtSn & rtSe tranSFer SWitch”
b. If zero resistance or CONTINUITY is measured,
connect the meter test leads across Terminals
A and B on the transfer relay (TR1)
c. If zero resistance is measured, a short exists.
Replace TR1.
DISCUSSION:
The battery charger is supplied with 120 VAC. The
output of the battery charger is 13.4 VDC/2.5A.
d. If 115 Ohms is measured, repair or replace
Wire 15B between the generator and the
transfer switch.
PROCEDURE:
8. Set VOM to measure resistance.
Refer to Figure 12 or Figure 12A.
1. Set VOM to measure DC voltage.
9. Disconnect the J2 connector from the printed circuit board.
10.Measure across point M and pin location J2-8 of the con-
nector just removed. Continuity should be measured.
2. Remove and isolate battery charger black and red leads
from generator terminal strip points G and H.
a. If continuity is not measured, repair or replace
Wire 15B between the J2 connector and the
terminal strip.
3. Measure across points G and H. Battery supply voltage
(12 VDC) should be measured.
a. If battery voltage is not measured, wait 5 minutes
and repeat Step 3. If battery supply voltage is still
not available, refer to Flow Chart.
b. If continuity is measured and the pin connection
looks good, the internal fuse on the PCB has
failed. Replace printed circuit board.
b. If battery voltage is measured, proceed to Step 4.
4. Reconnect battery charger black and red lead wires
previously removed in Step 2.
teSt 43 – check Battery charGer
Supply VoltaGe
“rtSn & rtSe tranSFer SWitch”
5. Measure across points G and H. 13.4 VDC should be
measured.
a. If 13.4 VDC is not measured, replace the
battery charger
DISCUSSION:
The battery charger is supplied with 120 VAC. The
output of the battery charger is 13.4 VDC/2.5A.
b. If 13.4 VDC is measured, the charger is working.
*note : Battery charger voltage will be higher
than battery supply voltage.
PROCEDURE:
Refer to Figure 12 or Figure 12A.
1. Set VOM to measure AC voltage.
teSt 45 – check Wire 0/15B
2. Measure across points A and B. 240 VAC should be
measured.
“rtSn & rtSe tranSFer SWitch”
a. If 240 VAC is not measured, verify load source
voltage.
DISCUSSION:
In order for the battery charger to function, battery supply
voltage must be available to the battery charger.
b. If 240 VAC is measured, proceed to Step 3.
3. Measure across points A and C. 240 VAC should be
measured.
PROCEDURE:
Refer to Figure 12 or Figure 12A.
1. Set VOM to measure DC voltage.
a. If 240 VAC is not measured, repair or replace
wire between fuse block and T1 terminal.
2. Remove and isolate battery charger black and red leads
from generator terminal strip points G and H.
b. If 240VAC is measured, proceed to Step 4.
4. Measure across points A and D. 240 VAC should be
measured.
3. Measure across points G and H on the terminal strip.
12VDC should be measured.
a. If 240 VAC is not measured, replace 5A fuse.
b. If 240 VAC is measured, proceed to Step 5.
a. If 12 VDC is measured, the charger should be
functioning.
5. Measure across points E and F. 120 VAC should be
measured.
b. If 12 VDC is not measured, proceed to Step 4.
4. Remove Wire 0 and Wire 15B from generator terminal
strip locations G and H.
a. If 120 VAC is not measured, repair or replace
supply wires BC line and BC 00.
5. Wait five (5) minutes after removing wires.
b. If 120 VAC is measured, refer to flow chart.
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F U S E
5 A M P
1 9 4
2 3
1 5 B
2 3
N 2
N 1
N 2
N 1
2 3
1 5 B
0
B C L I N E
B C 0 0
2 3
1 5 B
0
Figure 12. Test 43, 44, and 45 “RTSN Transfer Switch” Test Points.
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1 5 B
2 3
N 2
N 1
F U S E
5 A M P
B C L I N E
B C 0 0
2 3
1 5 B
0
B C L I N E
B C 0 0
2 3
1 5 B
0
Figure 12A. Test 43, 44, and 45 “RTSE Transfer Switch” Test Points.
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b. If 120 VAC is measured, proceed to Step 3.
6. Measure across points G and H on the terminal strip.
12 VDC should be measured.
3. Measure across points C and D. 120 VAC
should be measured.
a. If 12 VDC is measured, proceed to Step 8.
b. If 12 VDC is not measured, proceed to Step 7.
a. If 120 VAC is not measured, repair or replace
Wire BC LINE or BC 00 between the load cen-
ter and the generator.
7. Measure across point H and ground lug. 12 VDC should
be measured.
b. If 120 VAC is measured, refer to Flow Chart.
a. If 12 VDC is measured, repair or replace Wire
0 between the generator terminal strip and the
ground lug.
teSt 47 – check Battery charGer
output VoltaGe
b. If 12 VDC is not measured, proceed to Step 8.
“Genready load center”
8. Set VOM to measure resistance.
9. Connect the meter test leads across the disconnected
Wire 0 and Wire 15B. Approximately 115 Ohms should
be measured.
DISCUSSION:
The battery charger is supplied with 120VAC. The
output of the battery charger is 13.4 VDC / 2.5A.
a. If 115 Ohms is measured, proceed to Step 11.
PROCEDURE:
b. If zero resistance or CONTINUITY is measured,
connect the meter test leads across Terminals
A and B on the transfer relay (TR1)
Refer to Figure 13.
1. Set VOM to measure DC voltage.
c. If zero resistance is measured, a short exists.
Replace TR1.
2. Remove and isolate battery charger black and red leads
from generator terminal strip points E and F.
d. If 115 Ohms is measured, repair or replace
Wire 15B between the generator and the
transfer switch.
3. Measure across points E and F. Battery supply voltage
(12 VDC) should be measured.
10.Disconnect the J2 connector from the printed circuit
board.
a. If battery voltage is not measured, wait 5 min-
utes and repeat Step 3. If battery supply voltage
is still not available, refer to Flow Chart.
11.Measure across point M and pin location J2-8 of the con-
nector just removed. CONTINUITY should be measured.
b. If battery voltage is measured, proceed to Step 4.
4. Reconnect battery charger black and red lead wires
previously removed in Step 2.
a. If CONTINUITY is not measured, repair or
replace Wire 15B between the J2 connector
and the terminal strip.
5. Measure across points E and F. 13.4 VDC should be
measured.
b. If CONTINUITY was measured and the pin con-
nection looks good, the internal fuse on the PCB
has failed. Replace the printed circuit board.
a. If 13.4 VDC is not measured, replace the
battery charger.
b. If 13.4 VDC is measured, the charger is working.
teSt 46 – check Battery charGer
Supply VoltaGe
*note: Battery charger voltage will be higher than
battery supply voltage.
“Genready load center”
teSt 48 – check Wire 0/15B
“Genready load center”
DISCUSSION:
The battery charger is supplied with 120VAC. The
output of the battery charger is 13.4 VDC / 2.5A.
DISCUSSION:
PROCEDURE:
In order for the battery charger to function, battery supply
voltage must be available to the battery charger.
Refer to Figure 13.
1. Set VOM to measure AC voltage.
PROCEDURE:
2. Measure across points A and B. 120 VAC should be
measured.
Refer to Figure 13.
1. Set VOM to measure DC voltage.
a. If 120 VAC is not measured, verify that load
source voltage is available, and that the duplex
circuit breaker in ON.
2. Remove and isolate battery charger black and red leads
from generator terminal strip points E and F.
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B C L I N E
B C 0 0
B C L I N E
B C 0 0
2 3
1 5 B
0
2 3
1 5 B
0
B C - 0 0
B C - L I N E
Figure 13. Test 46, 47, and 48 “GenReady Load Center” Test Points.
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PROCEDURE:
3. Measure across points G and H on the terminal strip.
12VDC should be measured.
Refer to Figure 14.
1. Set VOM to measure AC voltage.
a. If 12 VDC is measured, the charger should be
functioning.
2. Measure across points A and B. 240 VAC should be
measured.
b. If 12 VDC is not measured, proceed to Step 4.
4. Remove Wire 0 and Wire 15B from generator terminal
strip locations E and F.
a. If 240 VAC is not measured, verify load source
voltage at ATS.
b. If 240 VAC is measured, proceed to Step 3.
5. Wait five (5) minutes after removing wires.
3. Measure across points A and C. 240 VAC should be
measured.
6. Measure across points E and F on the terminal strip.
12 VDC should be measured.
a. If 240 VAC is not measured, repair or replace
Wire T1 between LSS and J3 terminal of load
shed controller.
a. If 12 VDC is measured, proceed to Step 8.
b. If 12 VDC is not measured, proceed to Step 7.
7. Measure across point H and ground lug. 12 VDC should
be measured.
b. If 240VAC is measured, proceed to Step 4.
4. Measure across points C and D. 120 VAC should be
measured.
a. If 12 VDC is measured, repair or replace Wire
0 between the generator terminal strip and the
ground lug.
a. If 120 VAC is not measured, repair or replace
Wire 00 between J3 terminal and neutral block
(NB).
b. If 12 VDC is not measured, proceed to Step 8.
8. Set VOM to measure resistance.
b. If 120 VAC is measured, proceed to Step 5.
9. Connect the meter test leads across the disconnected
Wire 0 and Wire 15B. Approximately 200 Ohms should
be measured.
5. Measure across points E and D. 120 VAC should be
measured.
a. If 120 VAC is not measured, replace fuse F3 on
load shed controller.
a. If 200 Ohms is measured, proceed to Step 11.
b. If 120 VAC is measured, proceed to Step 6.
b. If zero resistance or CONTINUITY is measured,
connect the meter test leads across BAT- and
XFER on the load center motor.
6. Measure across points E and F. 120 VAC should be
measured.
c. If zero resistance is measured, a short exists.
Replace the load center motor.
a. If 120 VAC is not measured, replace load shed
controller.
d. If 200 Ohms to INFINITY is measured, repair
or replace Wire 15B between the generator and
the load center.
b. If 120 VAC is measured, refer to Flow Chart.
teSt 50 – check Battery charGer
output VoltaGe
10.Disconnect the J2 connector from the printed circuit board.
11.Measure across point M and pin location J2-8 of the
connector just removed. CONTINUITY should be
measured.
“load Shed tranSFer SWitch”
DISCUSSION:
a. If CONTINUITY is not measured, repair or
replace Wire 15B between the J2 connector
and the terminal strip.
The battery charger is supplied with 120 VAC. The
output of the battery charger is 13.4 VDC/2.5A.
b. If CONTINUITY is measured and the pin con-
nection looks good, the internal fuse on the PCB
has failed. Replace the printed circuit board.
PROCEDURE:
Refer to Figure 14.
1. Set VOM to measure DC voltage.
2. Remove and isolate battery charger black and red leads
from generator terminal strip points G and H.
teSt 49 – check Battery charGer
Supply VoltaGe
3. Measure across points G and H. Battery supply voltage
(12 VDC) should be measured.
“load Shed tranSFer SWitch”
a. If battery voltage is not measured, wait 5 min-
utes and repeat Step 3. If battery supply voltage
is still not available, refer to Flow Chart.
DISCUSSION:
The battery charger is supplied with 120 VAC. The
output of the battery charger is 13.4 VDC/2.5A.
b. If battery voltage is measured, proceed to Step 4.
Page 92
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sEctioN 3.4
DiaGNostic tEsts
TRANSFER SWITCH
Part 3
A D L C O O N N E C T I O N
N O N - E S S E N T I A L
O U T P U T C O N N E C T I O N
G E N E R A
O T R
E 1 A
6
5
4
3
2
1
7
6
5
4
3
2
1
3
6
2
5
1
4
3
2
5
1
4
6
9
B
9
8
7
8
7
B
A
A
1
2
3
Figure 14. Test 49, 50, and 51 “Load Shed Transfer Switch” Test Points.
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sEctioN 3.4
DiaGNostic tEsts
TRANSFER SWITCH
Part 3
4. Reconnect battery charger black and red lead wires
previously removed in Step 2.
7. In the generator control panel, measure across Wire 15B
and Wire 0 at the customer connection. 12 VDC should
be measured.
5. Measure across points G and H. 13.4 VDC should be
measured.
a. If 12 VDC is measured, repair or replace Wire
0 or Wire 15B between the generator terminal
strip and the ground lug.
a. If 13.4 VDC is not measured, replace the
battery charger.
b. If 12 VDC is not measured, proceed to Step 5.
b. If 13.4 VDC is measured, the charger is working.
8. Set VOM to measure resistance.
*note: Battery charger voltage will be higher than
battery supply voltage.
9. Connect the meter test leads across the disconnected
Wire 0 and Wire 15B. Approximately 115 Ohms should
be measured.
teSt 51 – check Wire 0 and Wire 15B
a. If 115 Ohms is measured, proceed to Step 11.
“load Shed tranSFer SWitch”
b. If zero resistance or CONTINUITY is measured,
connect the meter test leads across locations J
and k on the load shed controller, Figure 12.
DISCUSSION:
In order for the battery charger to function, battery supply
voltage must be available to the battery charger.
c. If zero resistance is measured, a short exists.
Replace the transfer relay (TR).
d. If 200 115 is measured, repair or replace Wire
15B between the generator and the transfer
switch.
PROCEDURE:
Refer to Figure 14.
1. Set VOM to measure DC voltage.
10.Disconnect the J2 connector from the printed circuit
board.
2. Remove and isolate battery charger black and red leads
from terminal strip points G and H.
11.In the generator control panel, measure across Wire
15B at the customer connection and pin location J2-8
of the connector just removed. CONTINUITY should be
measured.
3. Measure across points I and J on the terminal strip. 12
VDC should be measured.
a. If 12 VDC is measured, the charger should be
functioning.
a. If CONTINUITY is not measured, repair or
replace Wire 15B between the J2 connector
and the terminal strip.
b. If 12 VDC is not measured, proceed to Step 4.
4. Remove Wire 0 and Wire 15B from generator terminal
strip. Refer to Figure 6.
b. If CONTINUITY is measured, proceed to Step 12.
12. In the generator control panel, measure across Wire
0 at the customer connection and the ground lug.
CONTINUITY should be measured.
5. Wait five (5) minutes after removing wires.
6. Measure across points J and K on the terminal strip.
Refer to Figure 6. 12 VDC should be measured.
a. If CONTINUITY is not measured, repair or
replace Wire 0 between the customer connection
and the ground lug.
a. If 12 VDC is measured, proceed to Step 8.
b. If 12 VDC is not measured, proceed to Step 7.
b. If CONTINUITY is measured and the pin con-
nection of J2 looks good, the internal fuse on the
PCB has failed. Replace the printed circuit board.
Page 94
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taBlE of coNtENts
Part
titlE
PaGE#
76
4.1. Description and components
4.2 operational analysis
82
Part 4
Dc coNtrol
4.3
troubleshooting flow charts
96
4.4 Diagnostic tests
103
air-cooled, automatic
standby Generators
4.1 Description and Components....................................96
General ...................................................................96
Terminal Strip / Interconnection Terminal.................96
Circuit Board ............................................................96
Auto-Off-Manual Switch...........................................96
7.5 Amp Fuse...........................................................96
Menu System Navigation.......................................102
4.2 Operational Analysis ...............................................104
Introduction ............................................................104
Utility Source Voltage Available..............................104
Initial Dropout of Utility Source Voltage..................106
Test 57 – Try a Manual Start .................................123
Test 58 – Auto-Off-Manual Switch
(V-Twin Only)............................................123
Test 59 – Test Auto Operations ..............................124
Test 60 – Check 7.5 Amp Fuse..............................124
Test 61 – Check Battery.........................................124
Test 62 – Check Wire 56 Voltage ...........................126
Test 63 – Test Starter Contactor Relay
(V-twin Only) ............................................126
Test 64 – Test Starter Contactor
(Single Cylinder Engine) ..........................127
Test 65 – Test Starter Motor...................................128
Test 66 – Check Fuel Supply and Pressure...........130
Utility Voltage Dropout and
Engine Cranking ......................................108
Test 67 – Check Circuit Board
Engine Startup and Running..................................110
Initial Transfer to the “Standby” Source ..................112
Wire 14 Output.........................................131
Test 68 – Check Fuel Solenoid ..............................132
Test 69 – Check Choke Solenoid...........................132
Test 70 – Check for Ignition Spark.........................134
Test 71 – Check Spark Plugs.................................136
Utility Voltage Restored /
Re-transfer to Utility .................................114
Engine Shutdown...................................................116
4.3 Troubleshooting Flowcharts.....................................118
Test 72 – Check Engine / Cylinder Leak
Problem 15 – Engine Will Not Crank
When Utility Power Source Fails .......................118
Down Test / Compression Test.................136
Test 73 – Check Shutdown Wire............................137
Problem 16 – Engine Will Not Crank When
AUTO-OFF-MANUAL Switch
is Set to “MANUAL ............................................118
Test 74 – Check and Adjust
Ignition Magnetos.....................................138
Test 75 – Check Oil Pressure Switch
Problem 17 – Engine Cranks
but Won’t Start...................................................119
and Wire 86..............................................141
Test 76 – Check High Oil
Problem 18 – Engine Starts Hard and
Runs Rough / Lacks Power / Backfires .............120
Temperature Switch .................................142
Test 77 – Check and Adjust Valves........................142
Test 78 – Check Wire 18 Continuity.......................143
Test 79 – Test Exercise Function............................144
Problem 19 – Shutdown Alarm /
Fault Occurred...................................................121
Problem 20 – 7.5 Amp Fuse (F1) Blown...........122
Problem 21 – Generator Will Not Exercise........122
Problem 22 – No Low Speed Exercise..............122
4.4 Diagnostic Tests ......................................................123
Introduction ...........................................................123
Test 80 – Check Cranking and
Running Circuits.......................................144
Test 81 – Check to see if Low Speed
Function is enabled..................................146
Test 82 – Check operation of the
Test 56 – Check Position Of
Choke Solenoid........................................146
Auto-Off- Manual Switch .........................123
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sEctioN 4.1
DEscriPtioN aND comPoNENts
DC CONTROL
Part 4
General
circuit Board
This section will familiarize the reader with the various
components that make up the DC control system.
The circuit board controls all standby electric system
operations including (a) engine startup, (b) engine
running, (c) automatic transfer, (d) automatic retrans-
fer, and (e) engine shutdown. In addition, the circuit
board performs the following functions:
• Delivers “field boost” current to the generator rotor
windings (see “Field Boost Circuit” in Section 2.2).
Major DC control system components that will be
covered include the following:
• A Terminal Strip / Interconnection Terminal
• A Circuit Board.
• An AUTO-OFF-MANUAL Switch.
• A 7.5 Amp Fuse.
• Starts and “exercises” the generator once every
seven days.
• Provides automatic engine shutdown in the event of
low oil pressure, high oil temperature, overspeed,
no RPM sense, overcrank, or low battery.
terminal Strip / interconnection
terminal
An 18-pin and a 4-pin connector are used to inter-
connect the circuit board with the various circuits of
the DC systems. Connector pin numbers, associated
wires and circuit functions are listed in the CHART on
the next page.
The terminals of this terminal strip are connected to
identically numbered terminals on a transfer switch
terminal board. The terminal board connects the
transfer switch to the circuit board.
If the Utility sensing voltage drops below a preset
value, circuit board action will initiate automatic
generator startup and transfer to the “Standby”
source side.
The terminal board provides the following connection
points:
A. UTILITY 1 and UTILITY 2
The crank relay and fuel solenoid valve are energized
by circuit board action at the same time.
1. Connect to identically marked terminals on a
transfer switch terminal board.
B. 23 and 15B
DIGITAL INPUT/OUTPUT FUNCTIONS:
1. Connect to identically numbered terminals on
the terminal board of the transfer switch.
Postion Digital inputs
Digital outputs
Not Used
Not Used
Not Used
Not Used
Fuel
1
2
3
4
5
6
7
8
Low Oil Pressure
High Temperature
Internal Use
Internal Use
Internal Use
Not Used
2. This circuit connects the circuit board to the
transfer relay coil in the transfer switch.
N1 N2
Starter
Auto
Ignition
Manual
Transfer
DaNGEr:tHE GENErator ENGiNE Will
craNK aND start WHEN tHE 7-DaY
EXErcisEr sWitcH is actuatED.tHE uNit
Will also craNK aND start EVErY 7
DaYs tHErEaftEr, oN tHE DaY aND at tHE
timE of DaY tHE sWitcH Was actuatED.
*
TERMINAL STRIP
auto-oFF-manual SWitch
This 3-position switch permits the operator to (a)
select fully automatic operation, (b) start the generator
manually, or (c) stop the engine and prevent automatic
startup. Switch terminals are shown pictorially and
schematically in Figure 6, below.
Figure 1. Terminal Strip
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sEctioN 4.1
DEscriPtioN aND comPoNENts
DC CONTROL
Part 4
7.5 amp FuSe
This fuse protects the circuit board against excessive
current. If the fuse has blown, engine cranking and
operation will not be possible. Should fuse replace-
ment become necessary, use only an identical 7.5
amp replacement fuse.
Figure 2. A Typical 7.5 Amp Fuse
1
2
1. CONTROL PANEL
2. 7.5 AMP FUSE
3. STARTER CONTACTOR RELAY
(10-20 KW)
5
4
3
4. 4 POSITION TERMINAL BLOCK
5. TERMINAL BLOCK
6. CIRCUIT BREAKER (8KW)
7. 15 AMP GFCI DUPLEX OUTLET
(17 & 20 KW)
8. CIRCUIT BREAKER (17 & 20 KW)
9. CIRCUIT BREAKER (10-20 KW)
10. LED DISPLAY
TO ENGINE
DIVIDER PANEL
6
8
7
TO ENGINE
DIVIDER PANEL
10
9
Figure 3. Control Panel Component Identification
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sEctioN 4.1
DEscriPtioN aND comPoNENts
DC CONTROL
Part 4
18 17 16 15 14 13 12 11 10
4
2
3
1
18 17 16 15 14 13 12 11 10
4
2
3
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
J2
J1
J2 CONNECTOR
(PCB END)
J1 CONNECTOR
(PCB END)
3
4
10 11 12 13 14 15 16 17 18
1
2
1
2
3
4
5
6
7
8
9
J1 CONNECTOR
(HARNESS END)
J2 CONNECTOR
(HARNESS END)
1
2
N1/N2 CONNECTOR
(PCB END)
N1/N2 CONNECTOR
(HARNESS END)
Figure 4. 8 kW Printed Circuit Boards and J1 Connector
8 kW J1 connector Pin Descriptions
PiN
WirE
circuit fuNctioN
PiN
J2-7
J2-8
WirE
circuit fuNctioN
J1-1
85
High temperature shutdown:
Shutdown occurs when Wire 85 is
grounded by contact closure in HTO
NOT USED
15B
Provides an electrical connection for
charge current to reach the battery
from the battery charger. Provides
12VDC to the Transfer Relay
J1-2
86
Low oil pressure shutdown: Shutdown
occurs when Wire 86 is grounded by
loss of oil pressure to the LOP
J2-9
J2-10
J2-11
NOT USED
J1-3
J1-4
13
18
12 VDC source voltage for the circuit
board
0
Common Ground
56
12 VDC output to starter contactor for
single cylinder engines.
Ignition Shutdown: Circuit board
action grounds Wire 18 for ignition
shutdown.
J2-15
J2-16
NOT USED
NOT USED
J2-1
J2-2
J2-3
0
0
INTERNAL USE
INTERNAL USE
J2-17
NOT USED
J2-18
NOT USED
14
12 VDC output for engine run condi-
tion. Used for fuel solenoid.
Wired Plug 1
Wired Plug 2
N1
N2
240 VAC sensing for control board.
240 VAC sensing for control board.
J2-5
23
Switched to ground for transfer relay
operation
J2-6
NOT USED
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sEctioN 4.1
DEscriPtioN aND comPoNENts
DC CONTROL
Part 4
18 17 16 15 14 13 12 11 10
4
2
3
1
18 17 16 15 14 13 12 11 10
4
2
3
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
J2
J1
J2 CONNECTOR
(PCB END)
J1 CONNECTOR
(PCB END)
3
4
10 11 12 13 14 15 16 17 18
1
2
1
2
3
4
5
6
7
8
9
J3
(STEPPER MOTOR)
J1 CONNECTOR
(HARNESS END)
J2 CONNECTOR
(HARNESS END)
1
2
N1/N2 CONNECTOR
(PCB END)
N1/N2 CONNECTOR
(HARNESS END)
REMOTE WIRELESS CONNECTION
Figure 5. 10 kW Printed Circuit Board and J1 Connector
10 kW J1 connector Pin Descriptions
PiN
WirE
circuit fuNctioN
PiN
WirE
circuit fuNctioN
J1-1
85
High temperature shutdown:
Shutdown occurs when Wire 85 is
grounded by contact closure in HTO
J2-8
15B
Provides an electrical connection for
charge current to reach the battery
from the battery charger. Provides 12
VDC to the Transfer Relay
J1-2
86
Low oil pressure shutdown: Shutdown
occurs when Wire 86 is grounded by
loss of oil pressure to the LOP
J2-9
820
Positive voltage (+5 VDC) for status
LEDs.
J1-3
J1-4
13
18
12 VDC source voltage for the circuit
board
J2-10
J2-11
0
Common Ground
56
12 VDC output to starter contactor
relay for V-Twin engines
Ignition Shutdown: Circuit board
action grounds Wire 18 for ignition
shutdown.
J2-12
J2-13
NOT USED
818
90
Grounded by board to turn on the
Alarm (Red) LED.
J2-1
J2-2
J2-3
INTERNAL USE ONLY
INTERNAL USE ONLY
J2-14
J2-15
NOT USED
14
12 VDC output for engine run condi-
tion. Used for fuel solenoid and choke
solenoid operation.
Switched to ground for choke sole-
noid operation
J2-16
J2-17
INTERNAL USE ONLY
NOT USED
J2-4
J2-5
817
23
Grounded by printed circuit board to
turn on System Ready (Green) LED.
J2-18
NOT USED
Switched to ground for transfer relay
operation
J3
Control wires for Stepper Motor
240 VAC sensing for control board.
240 VAC sensing for control board.
J2-6
J2-7
NOT USED
NOT USED
Wired Plug-1
Wired Plug-2
N1
N2
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sEctioN 4.1
DEscriPtioN aND comPoNENts
DC CONTROL
Part 4
18 17 16 15 14 13 12 11 10
4
2
3
1
18 17 16 15 14 13 12 11 10
4
3
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
2
1
J2
J1
J2 CONNECTOR
(PCB END)
J1 CONNECTOR
(PCB END)
3
4
10 11 12 13 14 15 16 17 18
1
2
1
2
3
4
5
6
7
8
9
J3
(STEPPER MOTOR)
J1 CONNECTOR
(HARNESS END)
J2 CONNECTOR
(HARNESS END)
1
2
N1/N2 CONNECTOR
(PCB END)
N1/N2 CONNECTOR
(HARNESS END)
REMOTE WIRELESS CONNECTION
Figure 6. 12/14 kW Printed Circuit Board and J1 Connector
12/14 kW J1 connector Pin Descriptions
PiN
WirE
circuit fuNctioN
PiN
WirE
circuit fuNctioN
J1-1
85
High temperature shutdown:
Shutdown occurs when Wire 85 is
grounded by contact closure in HTO
J2-8
15B
Provides an electrical connection for
charge current to reach the battery
from the battery charger. Provides 12
VDC to the Transfer Relay
J1-2
86
Low oil pressure shutdown: Shutdown
occurs when Wire 86 is grounded by
loss of oil pressure to the LOP
J2-9
820
Positive voltage (+5 VDC) for status
LEDs.
J1-3
J1-4
13
18
12 VDC source voltage for the circuit
board
J2-10
J2-11
0
Common Ground
56
12 VDC output to starter contactor
relay for V-Twin engines
Ignition Shutdown: Circuit board
action grounds Wire 18 for ignition
shutdown.
J2-12
J2-13
NOT USED
818
90
Grounded by board to turn on the
Alarm (Red) LED.
J2-1
J2-2
J2-3
INTERNAL USE ONLY
INTERNAL USE ONLY
J2-14
J2-15
NOT USED
14
12 VDC output for engine run condi-
tion. Used for fuel solenoid and choke
solenoid operation.
Switched to ground for choke sole-
noid operation
J2-16
J2-17
INTERNAL USE ONLY
NOT USED
J2-4
J2-5
817
23
Grounded by printed circuit board to
turn on System Ready (Green) LED.
J2-18
NOT USED
Switched to ground for transfer relay
operation
J3
Control wires for Stepper Motor
240 VAC sensing for control board.
240 VAC sensing for control board.
J2-6
J2-7
NOT USED
NOT USED
Wired Plug-1
Wired Plug-2
N1
N2
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sEctioN 4.1
DEscriPtioN aND comPoNENts
DC CONTROL
Part 4
18 17 16 15 14 13 12 11 10
4
2
3
1
18 17 16 15 14 13 12 11 10
4
2
3
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
J2
J1
J2 CONNECTOR
(PCB END)
J1 CONNECTOR
(PCB END)
3
4
10 11 12 13 14 15 16 17 18
1
2
1
2
3
4
5
6
7
8
9
J3
(STEPPER MOTOR)
J1 CONNECTOR
(HARNESS END)
J2 CONNECTOR
(HARNESS END)
1
2
N1/N2 CONNECTOR
(PCB END)
N1/N2 CONNECTOR
(HARNESS END)
REMOTE WIRELESS CONNECTION
Figure 7. 16, 17 and 20 kW Printed Circuit Board and J1 Connector
16, 17 and 20 kW J1 connector Pin Descriptions
PiN
WirE
circuit fuNctioN
PiN
WirE
circuit fuNctioN
J1-1
85
High temperature shutdown:
Shutdown occurs when Wire 85 is
grounded by contact closure in HTO
J2-8
15B
Provides an electrical connection for
charge current to reach the battery
from the battery charger. Provides 12
VDC to the Transfer Relay
J1-2
86
Low oil pressure shutdown: Shutdown
occurs when Wire 86 is grounded by
loss of oil pressure to the LOP
J2-9
820
Positive voltage (+5 VDC) for status
LEDs.
J1-3
J1-4
13
18
12 VDC source voltage for the circuit
board
J2-10
J2-11
0
Common Ground
56
12 VDC output to starter contactor
relay for V-Twin engines
Ignition Shutdown: Circuit board
action grounds Wire 18 for ignition
shutdown.
J2-12
J2-13
4
Field Boost output
818
Grounded by board to turn on the
Alarm (Red) LED.
J2-1
J2-2
J2-3
INTERNAL USE ONLY
INTERNAL USE ONLY
J2-14
J2-15
819
90
Grounded by board to turn on the
Maintenance Required (Yellow) LED.
14
12VDC output for engine run condi-
tion. Used for fuel solenoid and choke
solenoid operation.
Switched to ground for choke sole-
noid operation
J2-4
J2-5
817
23
Grounded by printed circuit board to
turn on System Ready (Green) LED.
J2-16
J2-17
INTERNAL USE ONLY
NOT USED
Switched to ground for transfer relay
operation
J2-18
NOT USED
J3
Control wires for Stepper Motor
240 VAC sensing for control board.
240 VAC sensing for control board.
J2-6
J2-7
NOT USED
NOT USED
Wired Plug-1
Wired Plug-2
N1
N2
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sEctioN 4.1
DEscriPtioN aND comPoNENts
DC CONTROL
Part 4
2
1
FEMALE SIDE
MALE SIDE
C3
1
2
Figure 8. Choke Solenoid Connector Pin Number Identification
CHANGING SETTINGS (EDIT MENU):
menu SyStem naViGation
To change a setting such as display contrast, go to
the EDIT menu and use the +/- keys to navigate to
the setting to change. Once this setting is displayed
(e.g. Contrast), press the ENTER key to go into the
edit mode. Use the +/- keys to change the setting,
press the ENTER key to store the new setting.
To get to the MENU, use the "Esc" key from any page.
It may need to be pressed many times before getting
to the menu page. The currently selected menu is
displayed as a flashing word. Navigate to the menu
required by using the +/- keys. When the menu required
is flashing, press the ENTER key. Depending on the
menu selected, there may be a list of choices pre-
sented. Use the same navigation method to select the
desired screen (refer to the Menu System diagram).
note: if the enter key is not pressed to save the
new setting, it will only be saved temporarily. the
next time the battery is disconnected, the setting
will revert back to the old setting.
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sEctioN 4.1
DEscriPtioN aND comPoNENts
DC CONTROL
Part 4
Page 103
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
introduction
This “Operational Analysis” is intended to familiarize the service technician with the operation of the DC control
system on units with air-cooled engine. A thorough understanding of how the system works is essential to sound
and logical troubleshooting. The DC control system illustrations on the following pages represent a 14 kW unit.
utility Source VoltaGe aVailaBle
See Figure 1, below. The circuit condition with the AUTO-OFF-MANUAL switch set to AUTO and with “Utility”
source power available can be briefly described as follows:
2
6
2
6
0
4
0
VOLTAGE
REGULATOR
0
4
4
22
11
22
11
POWER
WINDING
44
33
22
STATOR
6
2
11
POWER
WINDING
BA
0
4
0
4
IM2
18
SP2
IM1
18
SP1
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
0
13
13
BATTERY
12V
SCR
16
SC
SM
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
• Utility source voltage is available to transfer switch Terminal Lugs N1/N2. With the transfer switch main contacts
at their “Utility” side, this source voltage is available to Terminal Lugs T1/T2 and to the “Load” circuits.
• Utility voltage is delivered to the Control Board Wires N1/N2, fuses F1/F2, connected wiring, and Control Panel
UTILITY 1 and UTILITY 2 terminals. A voltage of 240 AC is delivered to the circuit board.
• Battery output is delivered to the circuit board via Wire 13 when the Battery is installed.
Figure 1. circuit condition - utility Source Voltage available
CB
44
240 VAC
GENERATOR
OUTPUT
11
NEUTRAL
33
22
00
CONTROLLER DISPLAY
Ready to Run
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N1
CONTROLLER
PRINTED CIRCUIT BOARD
N1 N2
LED BOARD
1
85
J1
2
3
4
86
13
820
1
2
3
4
TO
PCB
7.5 AMP FUSE
L1
L2
817
818
819
18
SELF RESETTING FUSE
GOVERNOR
ACTUATOR
J3
J2
10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9
4
0
14
23
15B
0
56
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
= 12 VDC ALWAYS PRESENT
= AC VOLTAGE
0
= GROUND FOR CONTROL PURPOSES
= 12 VDC DURING CRANKING ONLY
= 12 VDC DURING ENGINE RUN CONDITION
= DC FIELD EXCITATION
LEGEND
BA - BRUSH ASSEMBLY
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
= 5 VDC TO LED
Page 105
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
initial dropout oF utility Source VoltaGe
Refer to Figure 2, below. Should a “Utility” power source failure occur, circuit condition may be briefly described
as follows:
• The circuit board constantly senses for an acceptable “Utility” source voltage, via transfer switch fuses F1/F2,
transfer switch UTILITY 1 and UTILITY 2 terminals, connected wiring, control panel UTILITY 1 and UTILITY 2
terminals, and Wires N1/N2.
2
6
2
6
0
4
0
VOLTAGE
REGULATOR
0
4
4
22
11
22
11
POWER
WINDING
44
33
22
STATOR
6
2
11
POWER
WINDING
BA
0
4
0
4
IM2
18
SP2
IM1
18
SP1
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
0
13
13
BATTERY
12V
SCR
16
SC
SM
Page 106
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
• Should utility voltage drop below approximately 65 percent of the nominal source voltage, a programmable
timer on the circuit board will turn on.
• In Figure 2, the 10-second timer is still timing and engine cranking has not yet begun.
• The AUTO-OFF-MANUAL switch is shown in its AUTO position. Battery voltage is available to the circuit board
via Wire 13, a 7.5 amp fuse (F1), and Wire 15B.
Figure 2. circuit condition - initial dropout of utility Source Voltage
CB
44
240 VAC
GENERATOR
OUTPUT
11
NEUTRAL
33
22
00
CONTROLLER DISPLAY
Utility Loss Delay
Pausing 10 sec
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N1
CONTROLLER
PRINTED CIRCUIT BOARD
N1 N2
LED BOARD
1
85
J1
2
3
4
86
13
820
1
2
3
4
TO
PCB
7.5 AMP FUSE
L1
L2
817
818
819
18
SELF RESETTING FUSE
GOVERNOR
ACTUATOR
J3
J2
10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9
4
0
14
23
15B
0
56
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
= 12 VDC ALWAYS PRESENT
= AC VOLTAGE
0
= GROUND FOR CONTROL PURPOSES
= 12 VDC DURING CRANKING ONLY
= 12 VDC DURING ENGINE RUN CONDITION
= DC FIELD EXCITATION
LEGEND
BA - BRUSH ASSEMBLY
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
= 5 VDC TO LED
Page 107
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
utility VoltaGe dropout and enGine crankinG
• After ten (10) seconds and when the circuit board’s 10-second timer has timed out, if utility voltage is still below
65 percent of nominal, circuit board action will energize the circuit board’s crank and run relays simultaneously.
• Printed circuit board action delivers 12 volts DC to a starter contactor relay (SCR), via Wire 56. When the SCR
energizes, its contacts close and battery power is delivered to a starter contactor (SC). When the SC energizes,
its contacts close and battery power is delivered to the starter motor (SM). The engine cranks.
2
6
2
6
0
4
0
VOLTAGE
REGULATOR
0
4
4
22
11
22
11
POWER
WINDING
44
33
22
STATOR
6
2
11
POWER
WINDING
BA
0
4
0
4
IM2
18
SP2
IM1
18
SP1
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
0
13
13
BATTERY
12V
SCR
16
SC
SM
Page 108
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
• Printed circuit board action delivers 12 volts DC to the fuel solenoids (FS1 & FS2), via Wire 14. The fuel solenoids
energize open and fuel is available to the engine. Wire 14 supplies power to the choke solenoid (CS). Circuit board
action grounds Wire 90, energizing the choke solenoid cyclically during cranking and continuously while running.
• As the engine cranks, magnets on the engine flywheel induce a high voltage into the engine ignition magnetos
(IM1/IM2). A spark is produced that jumps the spark plug (SP1/SP2) gap.
• During cranking, Wire 4 supplies 3-5 VDC (9-10 VDC isolated) to the rotor for field flash.
• With ignition and fuel flow available the engine can start.
Figure 3. circuit condition - engine cranking
CB
44
240 VAC
GENERATOR
OUTPUT
11
NEUTRAL
33
22
00
CONTROLLER DISPLAY
Cranking Attempt #1
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N1
CONTROLLER
PRINTED CIRCUIT BOARD
N1 N2
LED BOARD
1
85
J1
2
3
4
86
13
820
1
2
3
4
TO
PCB
7.5 AMP FUSE
L1
L2
817
818
819
18
SELF RESETTING FUSE
GOVERNOR
ACTUATOR
J3
J2
10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9
4
0
14
23
15B
0
56
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
= 12 VDC ALWAYS PRESENT
= AC VOLTAGE
0
= GROUND FOR CONTROL PURPOSES
= 12 VDC DURING CRANKING ONLY
= 12 VDC DURING ENGINE RUN CONDITION
= DC FIELD EXCITATION
LEGEND
BA - BRUSH ASSEMBLY
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
= 5 VDC TO LED
Page 109
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
enGine Startup and runninG
With the fuel solenoids open and ignition occurring, the engine starts. Engine startup and running may be briefly
described as follows:
• Voltage pulses from the ignition magnetos are delivered to the circuit board via Wire 18. Once the circuit board
determines that the engine is running, the circuit board (a) terminates cranking, and (b) terminates the choke
solenoid (CS), and (c) turns on an “engine warm-up timer”.
2
6
2
6
0
4
0
VOLTAGE
REGULATOR
0
4
4
22
11
22
11
POWER
WINDING
44
33
22
STATOR
6
2
11
POWER
WINDING
BA
0
4
0
4
IM2
18
SP2
IM1
18
SP1
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
0
13
13
BATTERY
12V
SCR
16
SC
SM
Page 110
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
• The “engine warm-up timer” will run for about 5 seconds. When this timer finishes timing, board action will
initiate transfer to the STANDBY power source. As shown in Figure 4 (below), the timer is still running and
transfer has not yet occurred.
• Generator AC output is available to transfer switch Terminal Lugs E1/E2 and to the normally open contacts of a
transfer relay. However, the transfer relay is de-energized and its contacts are open.
Figure 4. circuit condition - engine Startup and running
CB
44
240 VAC
GENERATOR
OUTPUT
11
NEUTRAL
33
22
00
CONTROLLER DISPLAY
Running - Utility Lost
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N1
CONTROLLER
PRINTED CIRCUIT BOARD
N1 N2
LED BOARD
1
85
J1
2
3
4
86
13
820
1
2
3
4
TO
PCB
7.5 AMP FUSE
L1
L2
817
818
819
18
SELF RESETTING FUSE
GOVERNOR
ACTUATOR
J3
J2
10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9
4
0
14
23
15B
0
56
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
= 12 VDC ALWAYS PRESENT
= AC VOLTAGE
0
= GROUND FOR CONTROL PURPOSES
= 12 VDC DURING CRANKING ONLY
= 12 VDC DURING ENGINE RUN CONDITION
= DC FIELD EXCITATION
LEGEND
BA - BRUSH ASSEMBLY
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
= 5 VDC TO LED
Page 111
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
initial tranSFer to the “StandBy” Source
The generator is running, the circuit board’s “engine warm-up timer” is timing, and generator AC output is avail-
able to transfer switch terminal lugs E1 and E2 and to the open contacts on the transfer relay. Initial transfer to
the STANDBY power supply may be briefly described as follows:
• 12 volts DC output is delivered to the transfer relay (TR) actuating coil, via Wire 15B, and terminal A of the
transfer relay (TR) in the transfer switch. This 12 volts DC circuit is completed back to the board, via transfer
relay terminal B and Wire 23. However, circuit board action holds the Wire 23 circuit open to ground and the
transfer relay (TR) is de-energized.
2
6
2
6
0
4
0
VOLTAGE
REGULATOR
0
4
4
22
11
22
11
POWER
WINDING
44
33
22
STATOR
6
2
11
POWER
WINDING
BA
0
4
0
4
IM2
18
SP2
IM1
18
SP1
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
0
13
13
BATTERY
12V
SCR
16
SC
SM
Page 112
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
• When the circuit board’s “engine warm-up timer” times out, circuit board action completes the Wire 23 circuit to
ground. The transfer relay then energizes and its normally open contacts close.
• Standby power is now delivered to the standby closing coil (C2), via Wires E1/E2, the normally open transfer
relay contacts, Wire 205, limit switch XB1, Wire B, and a bridge rectifier. The standby closing coil energizes and
the main current carrying contacts of the transfer switch are actuated to their STANDBY source side.
• As the main contacts move to their STANDBY source side, a mechanical interlock actuates limit switch XB1 to
its open position and limit switch XA1 to its “Utility” side position. When XB1 opens, standby closing coil C2 3
de-energizes.
• Standby power is delivered to the LOAD terminals (T1/T2) of the transfer switch.
Figure 5. circuit condition - initial transfer to Standby
CB
44
240 VAC
GENERATOR
OUTPUT
11
NEUTRAL
33
22
00
CONTROLLER DISPLAY
Running - Utility Lost
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N1
CONTROLLER
PRINTED CIRCUIT BOARD
N1 N2
LED BOARD
1
85
J1
2
3
4
86
13
820
1
2
3
4
TO
PCB
7.5 AMP FUSE
L1
L2
817
818
819
18
SELF RESETTING FUSE
GOVERNOR
ACTUATOR
J3
J2
10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9
4
0
14
23
15B
0
56
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
= 12 VDC ALWAYS PRESENT
= AC VOLTAGE
0
= GROUND FOR CONTROL PURPOSES
= 12 VDC DURING CRANKING ONLY
= 12 VDC DURING ENGINE RUN CONDITION
= DC FIELD EXCITATION
LEGEND
BA - BRUSH ASSEMBLY
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
= 5 VDC TO LED
Page 113
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
utility VoltaGe reStored / re-tranSFer to utility
The “Load” is powered by the standby power supply. The circuit board continues to seek an acceptable utility
source voltage. On restoration of utility source voltage, the following events will occur:
• On restoration of utility source voltage above 75 percent of the nominal rated voltage, a “retransfer time delay”
on the circuit board starts timing. The timer will run for about fifteen (15) seconds.
• At the end of fifteen (15) seconds, the “retransfer time delay” will stop timing and circuit board action will open
the Wire 23 circuit to ground. The transfer relay (TR) will then de-energize.
• When the transfer relay (TR) de-energizes, its normally-closed contacts close. Utility source voltage is then
delivered to the utility closing coil (C1), via Wires N1A/N2A, the closed TR contacts, Wire 126, limit switch XA1,
and a bridge rectifier.
2
6
2
6
0
4
0
VOLTAGE
REGULATOR
0
4
4
22
11
22
11
POWER
WINDING
44
33
22
STATOR
6
2
11
POWER
WINDING
BA
0
4
0
4
IM2
18
SP2
IM1
18
SP1
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
0
13
13
BATTERY
12V
SCR
16
SC
SM
Page 114
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
• The utility closing coil (C1) energizes and moves the main current carrying contacts to their NEUTRAL
position. The main contacts move to an over center position past NEUTRAL and spring force closes them
to their UTILITY side. LOAD terminals are now powered by the UTILITY source.
• Movement of the main contacts to UTILITY actuates limit switches XA1/XB1. XA1 opens and XB1 actuates to
its STANDBY source side.
• The generator continues to run.
Figure 6. circuit condition - utility Voltage restored
CB
44
240 VAC
GENERATOR
OUTPUT
11
NEUTRAL
33
22
00
CONTROLLER DISPLAY
Running / Cooling Down
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N1
CONTROLLER
PRINTED CIRCUIT BOARD
N1 N2
LED BOARD
1
85
J1
2
3
4
86
13
820
1
2
3
4
TO
PCB
7.5 AMP FUSE
L1
L2
817
818
819
18
SELF RESETTING FUSE
GOVERNOR
ACTUATOR
J3
J2
10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9
4
0
14
23
15B
0
56
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
= 12 VDC ALWAYS PRESENT
= AC VOLTAGE
0
= GROUND FOR CONTROL PURPOSES
= 12 VDC DURING CRANKING ONLY
= 12 VDC DURING ENGINE RUN CONDITION
= DC FIELD EXCITATION
LEGEND
BA - BRUSH ASSEMBLY
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
= 5 VDC TO LED
Page 115
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
enGine ShutdoWn
Following retransfer back to the utility source, an “engine cool-down timer” on the circuit board starts timing. When
that timer has timed out (approximately one minute), circuit board action will de-energize the circuit board’s run
relay. The following events will then occur:
• The DC circuit to Wire 14 and the fuel solenoids (FS1 & FS2) will be opened. The fuel solenoids will de-
energize and close to terminate the engine fuel supply.
2
6
2
6
0
4
0
VOLTAGE
REGULATOR
0
4
4
22
11
22
11
POWER
WINDING
44
33
22
STATOR
6
2
11
POWER
WINDING
BA
0
4
0
4
IM2
18
SP2
IM1
18
SP1
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
0
13
13
BATTERY
12V
SCR
16
SC
SM
Page 116
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sEctioN 4.2
oPEratioNal aNalYsis
DC CONTROL
Part 4
• Circuit board action will connect the engine’s ignition magnetos (IM1 & IM2) to ground, via Wire 18. Ignition will
be terminated.
• Without fuel flow and without ignition, the engine will shut down.
Figure 7. circuit condition - retransfer to “utility” and engine Shutdown
CB
44
240 VAC
GENERATOR
OUTPUT
11
NEUTRAL
33
22
00
CONTROLLER DISPLAY
Ready to Run
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N1
CONTROLLER
PRINTED CIRCUIT BOARD
N1 N2
LED BOARD
1
85
J1
2
3
4
86
13
820
1
2
3
4
TO
PCB
7.5 AMP FUSE
L1
L2
817
818
819
18
SELF RESETTING FUSE
GOVERNOR
ACTUATOR
J3
J2
10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9
4
0
14
23
15B
0
56
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
= 12 VDC ALWAYS PRESENT
= AC VOLTAGE
0
= GROUND FOR CONTROL PURPOSES
= 12 VDC DURING CRANKING ONLY
= 12 VDC DURING ENGINE RUN CONDITION
= DC FIELD EXCITATION
LEGEND
BA - BRUSH ASSEMBLY
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
= 5 VDC TO LED
Page 117
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sEctioN 4.3
trouBlEsHootiNG floW cHarts
DC CONTROL
Part 4
Problem 15 – Engine Will Not Crank When Utility Power Source Fails
*8 kW system ready
light will be flashing
TEST 56 – CHECK
POSITION OF
AUTO-OFF-MANUAL
SWITCH
TEST 57 – TRY A
MANUAL START
SWITCH IS
IN “AUTO”
VERIFY UTILITY
SOURCE IS “OFF”*
OFF
ENGINE DOES
NOT CRANK
ON
ENGINE
CRANKS
SWITCH IS “OFF”
TURN “OFF” -
RETEST
GO TO PROBLEM 16
SET TO “AUTO” -
RETEST
REPLACE CONTROLLER
8 kW
ASSEMBLY
TEST 58 – TEST
AUTO-OFF-MANUAL
SWITCH
TEST 59 – CHECK
AUTO OPERATION
OF CONTROLLER
REPLACE CONTROLLER
ASSEMBLY
10 kW - 20 kW
BAD
BAD
REPLACE CONTROLLER
ASSEMBLY
Problem 16 – Engine Will Not Crank When AUTO-OFF-MANUAL Switch is Set to “MANUAL”
*8 kW - battery led should be off
TEST 62 – CHECK
GOOD
TEST 61 – CHECK
BATTERY
GOOD
TEST 60 – CHECK
7.5 AMP FUSE
WIRE 56 VOLTAGE
GOOD
BAD
RECHARGE /
REPLACE
TEST 63 – CHECK
STARTER
BAD
BAD
CONTACTOR RELAY
(V-TWIN ONLY)
REPLACE
REPLACE
8 kW
CONTROLLER
ASSEMBLY
BAD
GOOD
BAD
TEST 59 – TEST
AUTO-OFF-MANUAL
SWITCH
10 kW - 20 kW
REPLACE
NOTE: If a starting problem is encountered,
the engine itself should be thoroughly
checked to eliminate it as the cause of starting
difficulty. It is a good practice to check the
engine for freedom of rotation by removing the
spark plugs and turning the crankshaft over
slowly by hand, to be sure it rotates freely.
TEST 64 –
CHECK STARTER
CONTACTOR
TEST 65 – TEST
STARTER MOTOR
GOOD
GOOD
WARNING: DO NOT ROTATE
ENGINE WITH ELECTRIC STARTER
REPLACE
BAD
WITH
BAD
SPARK PLUGS REMOVED.
ARCING AT THE PLUG ENDS MAY
IGNITE THE LP OR NG VAPOR
EXITING THE SPARK PLUG HOLE.
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Part 4
Problem 17 – Engine Cranks but Won’t Start
TEST 66 – CHECK
FUEL SUPPLY AND
PRESSURE
TEST 67 – CHECK
TEST 68 – CHECK
GOOD
GOOD
CIRCUIT BOARD
FUEL SOLENOID
WIRE 14 OUTPUT
BAD
BAD
BAD
GOOD
REPLACE FUEL SOLENOID
REPLACE CIRCUIT BOARD
FIND AND CORRECT
CAUSE OF NO FUEL
OR LOW PRESSURE
TEST 16 – CHECK
STEPPER MOTOR
CONTROL
TEST 69 – CHECK
CHOKE SOLENOID
V-TWIN UNITS
GOOD
GOOD
BAD
BAD
REPAIR OR REPLACE
REPLACE CHOKE
SOLENOID
CHECK AIR FILTER -
REPLACE AS NEEDED
SINGLE CYLINDER UNITS
TEST 70 –
CHECK FOR
IGNITION
SPARK
TEST 72 –
CHECK ENGINE
COMPRESSION
TEST 77 –
CHECK AND
ADJUST VALVES
TEST 71 –
CHECK SPARK
PLUGS
GOOD
GOOD
GOOD
BAD
BAD
BAD
GOOD
BAD
CLEAN,
REGAP OR
REPLACE
READJUST
CHECK
FLYWHEEL
KEY
REPLACE FUEL
REGULATOR
GOOD
TEST 73 – CHECK
SHUTDOWN WIRE
TEST 74 – CHECK
IGNITION
GOOD
MAGNETOS
BAD
BAD
REPAIR OR
REPLACE SHORTED
WIRE 18 OR CIRCUIT
BOARD
REFER TO ENGINE
SERVICE MANUAL
ADJUST OR
REPLACE
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Problem 18 – Engine Starts Hard and Runs Rough / Lacks Power / Backfires
IF RECONFIGURED TO LP GAS,
TEST 66 – CHECK
FUEL SUPPLY AND
PRESSURE
CHECK AIR FILTER -
REPLACE AS NEEDED
VERIFY THAT PROPER
PROCEDURE WAS FOLLOWED.
(REFER TO SECTION 1.3)
GOOD
GOOD
BAD
FIND AND CORRECT
CAUSE OF NO FUEL
OR LOW PRESSURE
TEST 69 – CHECK
CHOKE SOLENOID
BAD
READJUST
REPLACE CHOKE SOLENOID
TEST 71 –
BAD
TEST 77 –
CHECK AND
ADJUST VALVES
TEST 70 –
CHECK FOR
IGNITION SPARK
GOOD
GOOD
CHECK SPARK
BAD
PLUGS
BAD
TEST 74 – CHECK
IGNITION MAGNETOS
CLEAN, REGAP
OR REPLACE
GOOD
GOOD
BAD
TEST 15 - CHECK
AND ADJUST
ENGINE
GOVERNOR
SINGLE CYLINDER UNITS
BAD
READJUST
ADJUST OR
REPLACE
TEST 16 – CHECK
STEPPER MOTOR
CONTROL
GOOD
V-TWIN UNITS
TEST 72 – CHECK
ENGINE
COMPRESSION
BAD
TEST 78 – CHECK
FUEL REGULATOR
GOOD
REPAIR OR
REPLACE
GOOD
BAD
BAD
REPAIR OR
REPLACE
REFER TO ENGINE
SERVICE MANUAL
CHECK
FLYWHEEL
KEY
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Problem 19 – Shutdown Alarm/Fault Occured
CHECK FAULT LIGHTS
OVERCRANK
PROCEED TO PROBLEM 16
CHECK INSTALLATION FOR
PROPER AIRFLOW OR
REPLACE DEFECTIVE SWITCH
TEST 76 – CHECK HIGH
OIL TEMPERATURE
SWITCH
HIGH TEMP
REPAIR LINKAGE IF BINDING.
CHECK THROTTLE OPERATION.
REFER TO ENGINE SERVICE
MANUAL
TEST 15 – CHECK
AND ADJUST
ENGINE GOVERNOR
TEST 14 - CHECK
AC OUTPUT
FREQUENCY
OVERSPEED
SINGLE CYLINDER UNITS
BAD
TEST 16 – CHECK
STEPPER MOTOR
REPAIR OR
REPLACE
V-TWIN UNITS
BAD
BAD
CONTROL
TEST 73 – CHECK
SHUTDOWN
WIRE
TEST 70 –
TEST 78 – CHECK
WIRE 18
CONTINUITY
GOOD
OR
BAD
CHECK FOR
IGNITION
SPARK
NO RPM
SENSE
GOOD
GOOD
BAD
BAD
REPAIR OR
REPLACE SHORTED
WIRE 18 OR CIRCUIT
BOARD
REPAIR OR
REPLACE
NO SIGNAL
TEST 74 – CHECK
IGNITION
MAGNETOS
TEST 75 – CHECK OIL
PRESSURE SWITCH
AND WIRE 86
LOW OIL
PROCEED TO PROBLEMS 10-13
LOW BATTERY
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Problem 20 – 7.5 Amp Fuse (F1) Blown
FUSE BLOWS WHEN
PLACED IN “AUTO”
OR “MANUAL”
TEST 80 – CHECK
CRANKING AND
RUNNING CIRCUITS
Problem 21 – Generator Will Not Exercise
TEST 79 – TEST
EXERCISE
FUNCTION
Problem 22 – No Low Speed Exercise
TEST 81 - CHECK TO SEE
DISABLED
ENABLE
IF LOW SPEED FUNCTION
IS ENABLED
ENABLED
TEST 82 - CHECK
OPERATION OF
CHOKE SOLENOID
REPLACE
CONTROLLER
GOOD
OPERATING NORMALLY
TEST 69 – TEST
CHOKE
SOLENOID
BAD
REPLACE
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3. If engine cranks but won’t start, go to Problem 17 in
Section 4.3.
introduction
Perform these “Diagnostic Tests” in conjunction with
the “Troubleshooting Flow Charts” of Section 4.3.
4. If engine cranks and starts, but transfer to “Standby”
does NOT occur, go to Problem 7 in Section 3.3.
The test procedures and methods presented in this
section are not exhaustive. The manufacturer could not
possibly know of, evaluate and advise the service trade
of all conceivable ways in which testing and trouble
diagnosis might be performed. The manufacturer has
not undertaken any such broad evaluation.
5. If transfer to “Standby” occurs, but retransfer back to
“Utility” does NOT occur when utility source voltage is
restored, go to Problem 8 in Section 3.3.
teSt 57 – try a manual Start
teSt 56 – check poSition oF auto-oFF-
manual SWitch
DISCUSSION:
The first step in troubleshooting for an “engine won’t
crank” condition is to determine if the problem is
peculiar to automatic operations only or if the engine
won’t crank manually either.
DISCUSSION:
If the standby system is to operate automatically, the
generator AUTO-OFF-MANUAL switch must be set to
AUTO. That is, the generator will not crank and start
on occurrence of a “Utility” power outage unless that
switch is at AUTO. In addition, the generator will not
exercise every seven (7) days as programmed unless
the switch is at AUTO.
PROCEDURE:
1. On the generator panel, set the AUTO-OFF-MANUAL
switch to OFF.
2. Set the generator main line circuit breaker to its OFF (or
open) position.
AUTO
3. Set the generator AUTO-OFF-MANUAL switch to MANUAL.
a. The engine should crank cyclically through it’s
“crank-rest” cycles until it starts.
OFF
b. Let the engine stabilize and warm up for a few
minutes after it starts.
MANUAL
RESULTS:
1. If the engine cranks manually but does not crank
automatically, go to Problem 15, Section 4.3.
2. If the engine does not crank manually, proceed to
Problem 16 in the “Troubleshooting Flow Charts”.
Figure 1. AUTO-OFF-MANUAL Switch Positions
PROCEDURE:
teSt 58 – auto-oFF-manual SWitch
(V-tWin only)
With the AUTO-OFF-MANUAL switch set to AUTO,
test automatic operation. Testing of automatic opera-
tion can be accomplished by turning off the Utility
power supply to the transfer switch. When the utility
power is turned off, the standby generator should
crank and start. Following startup, transfer to the
standby source should occur. Refer to Section 1.8 in
this manual.
PROCEDURE:
1. Press the “ESC” key on the controller until the home
page is reached.
2. Press the right arrow key until “Debug” flashes. Press
“Enter” and the following screen will appear. See Figure
2, Screen 2.
Following generator startup and transfer to the standby
source, turn ON the utility power supply to the transfer
switch. Retransfer back to the “Utility” source should
occur. After an “engine cooldown timer” has timed out,
generator shutdown should occur.
3. Press “Enter” when “Inputs” is flashing.
4. With the Inputs Screen displayed, place the AUTO-
OFF-MANUAL switch to the AUTO Position. If the
controller reads an input from the switch, Input 7 will
change from “0” to “1”.
RESULTS:
1. If normal automatic operation is obtained, discontinue
tests.
2. If engine does not crank when utility power is turned off,
proceed to Problem 15 Flow Chart, Section 4.3.
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PROCEDURE:
1. Simulate a power failure by disconnecting main breaker.
2. If the generator does not perform the sequence of
events listed in the above discussion, replace the
printed circuit board.
1
2
DEBUG
INPUTS
RESULTS:
Refer back to flow chart
teSt 60 – check 7.5 amp FuSe
DISCUSSION:
The 7.5 amp fuse is located on the generator control
console. A blown fuse will prevent battery power from
reaching the circuit board, with the same result as
setting the AUTO-OFF-MANUAL switch to OFF.
3
INPUT 7
INPUT 8
PROCEDURE:
Remove the 7.5 amp fuse (F1) by pushing the fuse.
Figure 2. The Home Page, Debug and Input Screens
RESULTS:
1. If the fuse if good, refer back to Flow Chart.
5. With the Inputs Screen displayed place the AUTO-OFF-
MANUAL switch to the MANUAL Position. If the control-
ler reads an input from the switch input 8 will change
from “0” to “1”.
2. If the fuse is bad, it should be replaced. Use only an
identical 7.5 amp replacement fuse.
3. If fuse continues to blow, proceed to Problem 20
Flow Chart.
6. With the AUTO-OFF-MANUAL Switch in the OFF
position, both inputs will read zero.
RESULTS:
teSt 61 – check Battery
1. If controller failed either Step 4 or Step 5 ,replace the
controller assembly.
DISCUSSION:
Battery power is used to (a) crank the engine and
(b) to power the circuit board. Low or no battery
voltage can result in failure of the engine to crank,
either manually or during automatic operation. The
trickle charger that is included in the generator will not
recharge a dead battery.
2. If the controller passed Step 4 and Step 5, refer back
to flow chart.
teSt 59 – teSt auto operationS
PROCEDURE:
DISCUSSION:
a. inspect Battery cables:
1. Visually inspect battery cables and battery posts.
initial conditions: The generator is in AUTO, ready
to run, and load is being supplied by the utility source.
When utility fails (below 65% of nominal), a 10 second
(optionally programmable) line interrupt delay time is
started. If the utility is still gone when the timer expires,
the engine will crank and start. Once started, a five (5)
second engine warm-up timer will be initiated. When
the warm-up timer expires, the control will transfer the
load to the generator. If the utility power is restored
(above 75% of nominal) at any time from the initiation
of the engine start until the generator is ready to accept
a load (5 second warm-up time has not elapsed), the
controller will complete the start cycle and run the
generator through its normal cool down cycle; however,
the load will remain on the utility source.
2. If cable clamps or terminals are corroded, clean away all
corrosion.
3. Install battery cables, making sure all cable clamps are
tight.The red battery cable from the starter contactor (SC)
must be securely attached to the positive (+) battery post;
the black cable from the frame ground stud must be tightly
attached to the negative (-) battery post.
4. Disconnect both negative and positive cables.
*note: disconnect negative battery cable first.
5. Using a DC Volt meter, measure DC volts on the battery.
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B. perform a load test on the Battery:
(maintenance Free Battery)
b. An average reading of 1.230 means the battery
is 75% charged.
1. Using a lead acid battery load tester test the load
capability of the battery.
c. An average reading of 1.200 means the battery
is 50% charged.
d. An average reading of 1.170 indicates the bat-
tery is 25% charged.
2. Follow the load tester’s manufacturer’s instructions carefully.
USE A TEMPERATURE
COMPENSATED
HYDROMETER
CHECK EACH CELL
AFTER CHARGING
Figure 3. A Typical Battery Load Tester
Figure 4. Using a Battery Hydrometer
5. Test Battery Condition:
c. te s t B a t t e r y S t a t e o f c h a r g e :
(non-maintenance Free Battery)
a. If the difference between the highest and lowest
reading cells is greater than 0.050 (50 points),
battery condition has deteriorated and the bat-
tery should be replaced.
1. Use an automotive type battery hydrometer to test
battery state of charge.
b. However, if the highest reading cell has a
specific gravity of less than 1.230, the test
for condition is questionable. Recharge the
battery to a 100 percent state of charge, and
then repeat the test for condition.
2. Follow the hydrometer manufacturer’s instructions
carefully. Read the specific gravity of the electrolyte
fluid in all battery cells.
3. If cells are low, distilled water can be added to refill cell
compartment.
RESULTS:
4. If the hydrometer does not have a “percentage of charge”
scale, compare the reading obtained to the following:
1. Remove the battery and recharge with an automotive
battery charger, if necessary.
a. An average reading of 1.260 indicates the
battery is 100% charged.
2. If battery condition is bad, replace with a new battery.
1220
1230
1240
1250
1260
Cell #
Specific Gravity
32
28
24
20
16
12
8
LIQUID
LEVEL
1
2
3
4
5
6
1.255
1.260
1.235
1.250
1.240
1.225
HIGH READING
1270
4
80°
0
4
26.6°
35 POINTS DIFFERENCE
LOW READING
8
12
16
20
24
28
32
Figure 5. Reading a Battery Hydrometer
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RESULTS:
teSt 62 – check Wire 56 VoltaGe
1. If battery voltage is indicated in Step 3 refer back to
flow chart.
DISCUSSION:
During an automatic start or when starting manually,
a crank relay on the circuit board should energize.
Each time the crank relay energizes, the circuit board
should deliver 12 VDC to a starter contactor relay
(SCR), or starter contactor (SC), and the engine
should crank. This test will verify (a) that the crank
relay on the circuit board is energizing, and (b) that
circuit board action is delivering 12 VDC to the starter
contactor relay or starter contactor.
DEBUG
PROCEDURE:
1. Set a VOM to measure DC voltage.
2. Connect the positive (+) test probe of a DC voltmeter
(or VOM) to the Wire 56 connector of the starter
contactor relay (SCR, on models with V-twin engines)
or the starter contactor (SC, on models with single
cylinder engines). Connect the common (-) test probe
to frame ground.
OUTPUTS
OUTPUTS 1 - 8:
1 0 1 1 0 0 0 1
3. Observe the meter. Then, set the AUTO-OFF-MANUAL
switch to the MANUAL position. The meter should
indicate battery voltage. If battery voltage is measured,
stop testing and refer back to flow chart.
OUTPUT 6
Figure 6. The Home Page, Debug and Output Screens
4. Navigate to the Digital output display screen.
a. Press “ESC” until the main menu is reached.
b. Press the right arrow key until “Debug” is flashing.
c. Press “Enter”.
teSt 63 – teSt Starter contactor
relay (V-tWin only)
d. Press the right arrow key until “Outputs” is flashing.
e. Press “Enter”.
DISCUSSION:
f. Digital Output 6 is Wire 56 output from the
board. Refer to Figure 6.
The starter contactor relay (SCR) located in the con-
trol panel must be energized for cranking to occur.
Once the SCR is energized, it’s normally open con-
tacts will close and battery voltage will be available
to Wire 16 and to the starter contactor (SC).
5. Actuate the AUTO-OFF-MANUAL switch to the MANUAL
position and observe digital output Number 6. If the
printed circuit board is working correctly output Number
6 will change from a “0” to a “1”. If output did not change
replace printed circuit board.
16
13
6. Set a VOM to measure resistance.
note: remove 7.5 amp fuse before disconnecting
j1 connector.
16
13
COM
7. Remove Wire 56 from the starter contactor relay (V-twin
units) or from the starter contactor (single cylinder
units). Connect one meter test lead to disconnected
Wire 56. Remove the J2 Connector from the printed
circuit board. Connect the other test lead to Wire 56 at
J2. CONTINUITY should be measured. If CONTINUITY
is not measured, repair or replace Wire 56.
NO
56
0
56
0
Figure 7. The Starter Contactor Relay
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PROCEDURE:
1. Connect the positive (+) meter test lead to the starter
contactor stud (to which the red battery cable connects).
Connect the common (-) meter test lead to a clean frame
ground. Battery voltage (12 VDC) should be indicated.
1. Set a VOM to measure DC voltage.
2. Remove Wire 13 from the Starter Contactor Relay located
under the printed circuit board.
2. Connect the positive (+) meter test lead to the starter
contactor stud to which the starter motor cable attaches
(see Figure 8 or Figure 9). Connect the common (-) test
lead to frame ground.
3. Connect the positive (+) meter test lead to the Wire 13
connector. Connect the negative (-) meter test lead to a
clean frame ground. Battery voltage should be measured.
4. Reconnect Wire 13 to the SCR.
a. No voltage should be indicated initially.
5. Remove Wire 16 from the SCR. Connect the positive (+)
meter test lead to the SCR terminal from which Wire 16
was removed. Connect the negative (-) meter test lead
to a clean frame ground.
b. Set the AUTO-OFF-MANUAL switch to MANUAL.
The meter should now indicate battery voltage
as the starter contactor energizes.
56
TO ECB
16
6. Set the AUTO-OFF-MANUAL switch to MANUAL.
Observe the meter reading. Battery voltage should be
measured. If battery voltage is not measured, proceed
to Step 7.
TO STARTER
stEP 2
TEST POINT
7. Set the VOM to measure resistance.
stEP 1
TEST POINT
8. Remove Wire 0 from the SCR. Connect the positive (+)
meter test lead to the disconnected Wire 0. Connect
the negative (-) meter test lead to a clean frame ground.
CONTINUITY should be measured.
13
0
TO FUSE (F1)
RESULTS:
13
TO GROUND
1. If battery voltage is not measured in Step 3, repair or
replace wiring between the starter contactor relay and
the starter solenoid.
TO BATTERY
Figure 8. The Starter Contactor (Single Cylinder Units)
2. If battery voltage is not measured in Step 6 and
CONTINUITY is measured in Step 8, replace the starter
contactor relay.
RESULTS:
1. If battery voltage was indicated in Step 1, but NOT in
Step 2b, replace the starter contactor.
3. If battery voltage is measured in Step 6 refer back to
flow chart.
2. If battery voltage was indicated in Step 2b, but the
engine did NOT crank, refer back to flow chart.
teSt 64 – teSt Starter contactor
(SinGle cylinder enGine)
stEP 1
TEST POINT
STARTER
CONTACTOR
DISCUSSION:
The starter contactor (SC) must energize and its
heavy duty contacts must close or the engine will not
crank. This test will determine if the starter contactor
is in working order.
stEP 2
TEST POINT
STARTER
MOTOR
PROCEDURE:
Carefully inspect the starter motor cable that runs
from the battery to the starter motor. Cable connec-
tions must be clean and tight. If connections are
dirty or corroded, remove the cable and clean cable
terminals and terminal studs. Replace any cable that
is defective or badly corroded.
Figure 9. The Starter Contactor (V-twin Units)
Use a DC voltmeter (or a VOM) to perform this test.
Test the starter contactor as follows:
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teSt 65 – teSt Starter motor
CONDITIONS AFFECTING STARTER MOTOR
PERFORMANCE:
1. A binding or seizing condition in the starter motor bearings.
2. A shorted, open or grounded armature.
a. Shorted armature (wire insulation worn and
wires touching one another). Will be indicated
by low or no RPM.
b. Open armature (wire broken) will be indicated
by low or no RPM and excessive current draw.
c. Grounded armature (wire insulation worn and wire
touching armature lamination or shaft). Will be
indicated by excessive current draw or no RPM.
Figure 10. Starter Motor (V-Twin Engines)
3. A defective starter motor switch.
4. Broken, damaged or weak magnets.
5. Starter drive dirty or binding.
DISCUSSION:
Test 62 verified that circuit board action is delivering
DC voltage to the starter contactor relay (SCR). Test
63 verified the operation of the SCR. Test 64 verified
the operation of the starter contactor (SC). Another
possible cause of an “engine won’t crank” problem is
a failure of the starter motor.
PROCEDURE:
The battery should have been checked prior to this
test and should be fully charged.
Set a VOM to measure DC voltage (12 VDC). Connect
the meter positive (+) test lead to the starter contactor
stud which has the small jumper wire connected to
the starter. Connect the common (-) test lead to the
starter motor frame.
Figure 11. Starter Motor (Single Cylinder Engines)
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.
Set the AUTO-OFF MANUAL Switch to its “MANUAL”
position and observe the meter. Meter should indicate
battery voltage, 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 following 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.
If engine turns over slightly, go to Test 77 “Check and
Adjust Valves.”
PINION
Figure 12. Check Pinion Gear Operation (V-Twin)
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Figure 15. Tachometer
PINION
TEST BRACkET:
A starter motor test bracket may be made as shown
in Figure 16. A growler or armature tester is available
from an automobile diagnostic service supplier.
Figure 13. Check Pinion Gear Operation
(Single Cylinder)
METAL STOCK
1/4" THICK STEEL
2.625"
0.5"
TOOLS FOR STARTER PERFORMANCE TEST:
3.5"
The following equipment may be used to complete a
performance test of the starter motor:
1.0"
4"
• A clamp-on ammeter.
• A tachometer capable of reading up to 10,000 rpm.
• A fully charged 12 volt battery.
12"
DRILL TWO HOLES — 1/2"
FOR STARTER
MOUNTING BRACKET
2"
MEASURING CURRENT:
DRILL TWO HOLES — 1/2"
FOR MOUNTING TACHOMETER
TAP FOR 1/4-20 NC SCREWS
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.
Figure 16. Test Bracket
REMOVE STARTER MOTOR:
It is recommended that the starter motor be removed
from the engine when testing starter motor perfor-
mance. Assemble starter to test bracket and clamp
test bracket in vise, Figure 17.
TESTING STARTER MOTOR:
1. A fully charged 12 volt battery is required.
2. Connect jumper cables and clamp-on ammeter as
shown in Figure 17.
3. With the starter motor activated (jump the terminal on the
starter contactor to battery voltage), note the reading on
the clamp-on ammeter and on the tachometer (rpm).
note: take the reading after the ammeter and
tachometer are stabilized, approximately 2-4
seconds.
Figure 14. Clamp-On Ammeter
4. A starter motor in good condition will be within the fol-
lowing specifications:
TACHOMETER:
A tachometer is available from your parts source.
The tachometer measures from 800 to 50,000 rpm,
(see Figure 15).
V-twin
3250
62
Single Cylinder
Minimum rpm
4500
9
Maximum Amps
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tENDs to sEttlE iN HiGH PlacEs. lP
(ProPaNE) Gas is HEaViEr tHaN air, aND
tENDs to sEttlE iN loW arEas. EVEN
tHE sliGHtEst sParK caN iGNitE tHEsE
GasEs aND causE aN EXPlosioN.
PROCEDURE:
A water manometer or a gauge that is calibrated in
“ounces per square inch” may be used to measure
the fuel pressure. Fuel pressure at the inlet side of
the fuel solenoid valve should be between 5-7 inches
water column for natural gas (NG) or 10-12 inches
water column for LP gas.
CLAMP ON
AMP METER
STARTER
CONTACTOR
STARTER
MOTOR
1. See Figures 18, 19 or 20 for the gas pressure test point on
the fuel regulator. The fuel pressure can be checked at Port
1 on all fuel regulators, and at Port 3 on 12-20 kW units.
2. With the manometer connected properly, crank the engine.
Nominal fuel pressure should be measured. If pressure is
not measured while cranking refer back to flow chart.
TACHOMETER
VISE
12 VOLT
BATTERY
Figure 17. Testing Starter Motor Performance
PORT 1
PORT 2
teSt 66 – check Fuel Supply and
preSSure
DISCUSSION:
The air-cooled generator was factory tested and
adjusted using natural gas as a fuel. If desired, LP
(propane) gas may be used. However, when convert-
ing to propane, some minor adjustments are required.
The following facts apply:
• An adequate gas supply and sufficient fuel pressure
must be available or the engine will not start.
Figure 18 (8 kW) Gas Pressure Test point
• Minimum recommended gaseous fuel pressure
at the generator fuel inlet connection is 5 inches
water column for natural gas (NG) or 10 inches
water column for LP gas.
• Maximum gaseous fuel pressure at the generator
fuel inlet connection is 7 inches water column for
natural gas or 12 inches water column for LP gas.
PORT 1
PORT 2
• When propane gas is used, only a “vapor withdrawal”
system may be used. This type of system utilizes
the gas that forms above the liquid fuel. The vapor
pressure must be high enough to ensure engine
operation.
• The gaseous fuel system must be properly tested for
leaks following installation and periodically thereafter.
No leakage is permitted. Leak test methods must
comply strictly with gas codes.
SOLENOID REMOVED
DaNGEr: GasEous fuEls arE HiGHlY
EXPlosiVE. Do Not usE flamE or HEat
to tEst tHE fuEl sYstEm for lEaKs.
Natural Gas is liGHtEr tHaN air, aND
*
Figure 19 (10 kW) Gas Pressure Test point
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PROCEDURE: 12-20 kW UNITS
1. Set the AUTO-OFF-MANUAL switch to OFF.
2. Set a VOM to measure DC voltage.
PORT 3
3. Disconnect Wire 14 from the fuel solenoid (FS).
4. Connect the positive test lead to the disconnected Wire
14 from Step 3. Connect the negative test lead to a
clean frame ground.
PORT 1
PORT 2
5. Set AUTO-OFF-MANUAL switch to the MANUAL position.
The meter should indicate battery voltage.
a. If battery voltage is indicated, refer back to
flow chart.
b. If battery voltage is not measured, navigate to
the Digital Output display.
c. Press “ESC” until the display screen is present.
d. Press the right arrow key until “Debug” is flashing.
Press “Enter”.
e. Press the right arrow key until “Outputs” is
flashing. Press “Enter”.
Figure 20 (12-20 kW) Gas Pressure Test point
note: Where a primary regulator is used to estab-
lish fuel inlet pressure, adjustment of that regula-
tor is usually the responsibility of the fuel supplier
or the fuel supply system installer.
12-20 kW UNITS ONLY:
note:the test port (port 3) below the fuel solenoid
maybe used to take a fuel pressure reading before
the fuel solenoid. consistent pressure should be
measured at this port while the generator is run-
ning and when the generator is off.
DEBUG
RESULTS:
1. If fuel supply and pressure are adequate, but engine will
not start refer back to flow chart.
OUTPUTS
OUTPUTS 1 - 8:
2. If generator starts but runs rough or lacks power, repeat
the above procedure with the generator running and
under load. The fuel system must be able to maintain
10-12 inches water column at all load requirements for
propane, and 5-7 inches water column for natural gas.
If proper fuel supply and pressure is maintained, refer to
Problem 18 Flow Chart.
1 0 1 1 0 0 0 1
OUTPUT 5
Figure 21. The Home Page, Debug and Output
Screens
f. Output 5 is Wire 14 out from the printed circuit
board. If the printed circuit board is functioning
properly, Output 5 will change from a “0” to a “1”
while the unit is cranking.
teSt 67 – check circuit Board Wire 14
output
g. If voltage was not measured in Step 5 and
output did not change in Step 5f, replace the
printed circuit board.
DISCUSSION:
During any cranking action, the circuit board’s crank
relay and run relay both energize simultaneously.
When the run relay energizes, it’s contacts close and
12 VDC is delivered to Wire 14 and to a fuel solenoid.
The solenoid energizes open to allow fuel flow to the
engine. This test will determine if the circuit board is
working properly.
note: disconnect the 7.5 amp Fuse before dis-
connecting the j2 connector.
h. If voltage was not measured in Step 5 and out-
put changed in Step 5f, remove the J1 connec-
tor from the printed circuit board. See Figures
on Pages 92-95.
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i. Set a VOM to measure resistance.
If gas pressure is measured, the fuel solenoid is operat-
ing. If gas pressure is not measured, repair or replace the
fuel solenoid.
j. Connect one meter test lead to Wire 14 that
was disconnected in Step 3.
k. Connect the other meter test lead to Wire 14 at
J2-3. See Figures on Pages 92-95.
PROCEDURE: 10 kW UNITS
l. CONTINUITY should be measured. If
CONTINUITY is measured, repeat Step 5 and
then retest.
1. Remove the hose from fuel solenoid (FS2) and install a
manometer to Port 2 on the fuel regulator. See Figure 19.
2. Set the AUTO-OFF-MANUAL Switch to MANUAL.
m. If CONTINUITY is not measured, repair or
replace Wire 14 between the J2 Connector and
the fuel solenoid.
3. Proper gas pressure should be measured during crank-
ing. If gas pressure is measured, both fuel solenoids are
operating. Discontinue testing.
PROCEDURE: 8 kW UNITS
4. If gas pressure was not measured in Step 3, remove fuel
solenoid FS2 and install a manometer to the bottom port
of the fuel regulator.
1. Set AUTO-OFF-MANUAL switch to OFF.
2. Set a VOM to measure DC voltage.
3. Disconnect Wire 14 from the fuel solenoid.
5. Set the AUTO-OFF-MANUAL Switch to MANUAL.
4. Connect the positive test lead to disconnected Wire 14
and the negative test lead to a clean frame ground.
6. Proper gas pressure should be measured during crank-
ing. If gas pressure is measured, fuel solenoid FS1 is
operating. Replace fuel solenoid FS2. If gas pressure is
not measured, repair or replace fuel solenoid FS1.
5. Set the AUTO-OFF-MANUAL switch to the MANUAL
position.
6. Battery voltage should be measured. If battery voltage is
measured, refer back to flow chart.
RESULTS:
Refer to flow chart.
note: disconnect the 7.5 amp fuse before discon-
necting the j2 connector.
teSt 69 – check choke Solenoid
7. Disconnect the J2 connector from printed circuit board.
8. Set VOM to measure resistance.
DISCUSSION:
9. Connect the positive test lead to disconnected Wire 14
and the negative test lead to J2 Pin 3.
The automatic choke is active cyclically during crank-
ing and energized ON during running. For low speed
exercise the choke will be closed.
10.CONTINUITY should be measured. If CONTINUITY is
not measured, repair or replace Wire 14 between J2 Pin
3 and the fuel solenoid.
The 12-20 kW units utilize a plate that covers the
throttle bores. The choke is closed if the solenoid is
not energized.
The 10 kW unit utilizes a throttle plate located in
the choke housing and the choke is open when the
solenoid is de-energized.
RESULTS:
Refer to flow chart.
The 8 kW unit has a choke solenoid that is closed
during the entire crank cycle when the solenoid is
energized and the engine is cranking.
teSt 68 – check Fuel Solenoid
PROCEDURE: 10-20 kW UNITS
DISCUSSION:
1. Operational Check: Set the AUTO-OFF-MANUAL
Switch to MANUAL. While cranking, the choke solenoid
should pull the choke plate open cyclically. The dura-
tion of the cycle will vary depending on it’s position in
the crank cycle sequence. Refer to the Crank Cycle
Sequence Table on the following page for crank cycle
sequences and duration times. If the choke solenoid
does not pull in, verify that the choke can be manually
opened. There should be no binding or interference.
In Test 67, if battery voltage was delivered to Wire 14,
the fuel solenoid should have energized open. This test
will verify whether or not the fuel solenoid is operating.
Fuel Solenoid FS1 nominal resistance – 27-33 ohms.
Fuel Solenoid FS2 nominal resistance – 29 ohms.
PROCEDURE: 8 AND 12-20 kW UNITS
1. Install a manometer to Port 2 on the fuel regulator. See
Figure 18 or Figure 20.
2. Disconnect the C3 Connector.
2. Set the AUTO-OFF-MANUAL Switch to MANUAL.
3. Proper gas pressure should be measured during cranking.
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7. With the generator running at a speed of approximately
60 Hertz, verify that the choke is energized and hold-
ing the choke plate open. Repeat Step 2 procedure,
however, once the unit starts, manually hold the choke
open while taking the voltage measurement.
CHOKE PLATE
CHOKE SOLENOID
CHOKE SOLENOID
CHOKE PLATE
Figure 22. Solenoid De-Energized, Choke Closed
12-20 kW Units
CHOKE HOUSING
CHOKE PLATE
Figure 24. Exploded View Showing Location of Choke
Plate - 10 kW Units
14
90
14
90
CHOKE SOLENOID
Figure 23. Solenoid Energized, Choke Open
12-20 kW Units
2
1
1
2
3. Set a VOM to measure DC voltage.
MALE SIDE
FEMALE SIDE
4. Connect the positive (+) test lead to Wire 14 (Pin 1) of the
C3 Connector going to the control panel (Female Side).
Connect the negative (-) test lead to Wire 90 (Pin 2).
Figure 25. C3 Choke Solenoid Connector
5. Set the AUTO-OFF-MANUAL Switch to MANUAL. While
cranking, battery voltage should be measured cyclically.
If battery voltage was not measured, verify continuity
of Wire 90 between the C3 Connector and the printed
circuit board J1 Connector, Pin Location J1-23. Verify
continuity of Wire 14 between the C3 Connector and
J2 connector Pin Location J2-3. Repair or replace any
wiring as needed.
RESULTS:
1. If Battery voltage was not measured in Step 5 and wire
continuity is good, replace the printed circuit board.
2. If Choke Solenoid coil resistance is not measured in
Step 6, replace the Choke Solenoid.
PROCEDURE: 8 kW UNITS
6. Disconnect C3 Connector. Set a VOM to measure resis-
tance. Connect the positive (+) test lead to Wire 14 (Pin
1) of C3 Connector going to the choke solenoid (Male
Side). Connect the negative (-) test lead to Wire 90 (Pin
2). Approximately 3.7 ohms should be measured.
1. Operational Check: Set the AUTO-OFF-MANUAL
Switch to MANUAL. While cranking the choke solenoid
should energize and pull the choke plate closed. If the
choke solenoid does not pull in, verify that the choke
can be manually closed. There should be no binding or
interference.
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2. Disconnect the C3 Connector.
2. If Choke Solenoid coil resistance is not measured in
Step 8, replace the Choke Solenoid.
3. Set a VOM to measure DC voltage.
3. If battery voltage was not measured in Step 4, replace
the printed circuit board.
4. Connect the positive (+) test lead to Wire 56 (Pin 1) of
C3 Connector going to the control panel (Female Side)
Connect the negative (-) test lead to Wire 0 (Pin 2).
teSt 70 – check For iGnition Spark
5. Set the AUTO-OFF-MANUAL Switch to MANUAL. While
cranking, battery voltage should be measured. If battery
voltage was not measured, verify continuity of Wire
0 between C3 Connector and a clean frame ground.
Verify continuity of Wire 56 between the C3 Connector
and Wire 56 connector and J2 Connector Pin Location
J2-11. Repair or replace any wiring as needed.
DISCUSSION:
If the engine cranks but will not start, perhaps an
ignition system failure has occurred. A special “spark
tester” can be used to check for ignition spark.
PROCEDURE:
6. Disconnect C3 Connector.
1. Remove spark plug leads from the spark plugs
(Figure 28).
7. Set a VOM to measure resistance.
2. Attach the clamp of the spark tester to the engine
cylinder head.
8. Connect the positive (+) test lead to Wire 56 (Pin 1) of
C3 Connector going to the choke solenoid (Male Side).
Connect the negative (-) test lead to Wire 0 (Pin 2).
Approximately 3.7 ohms should be measured.
3. Attach the spark plug lead to the spark tester terminal.
4. Crank the engine while observing the spark tester. If
spark jumps the tester gap, you may assume the engine
ignition system is operating satisfactorily.
RESULTS:
1. If Battery voltage was not measured in Step 5 and wire
continuity is good, replace the printed circuit board.
note: the engine flywheel must rotate at 350 rpm
(or higher) to obtain a good test of the solid state
ignition system.
crank cycle sequence table
1=CHOkED
Note:the first second of each crank cycle is equal to two (2) revolutions of the engine.
0=OPEN
Seconds
crank cycle 1
10 kW
1
0
0
2
0
1
3
0
1
4
0
0
5
1
0
6
0
1
7
0
1
8
0
1
9
0
0
10
1
11
1
12
0
13
0
14
0
15
0
16
0
12 kW-20 kW
0
0
1
1
1
1
1
crank cycle 2
10 kW
Seconds
0
0
0
1
0
1
0
0
1
0
0
0
0
0
0
0
0
0
1
0
1
0
0
1
0
1
0
1
0
1
0
1
12 kW-20 kW
crank cycle 3
10 kW
Seconds
Seconds
Seconds
0
0
1
0
1
1
1
1
1
1
0
1
0
1
12 kW-20 kW
crank cycle 4
10 kW
0
0
1
1
0
0
0
0
0
0
0
0
0
0
12 kW-20 kW
crank cycle 5
10 kW
0
0
1
1
1
0
1
0
1
0
0
0
0
1
12 kW-20 kW
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CHOKE VALVE IN OPEN POSITION
CHOKE SOLENOID
AIR BOX
CHOKE VALVE IN CLOSED POSITION
Figure 26. 8kW Choke Solenoid
Figure 28. Checking Ignition Spark
To determine if an engine miss is ignition related,
connect the spark tester in series with the spark plug
wire and the spark plug (Figure 29). Then, crank and
start the engine. A spark miss will be readily apparent.
If spark jumps the spark tester gap regularly but the
engine miss continues, the problem is in the spark
plug or in the fuel system.
Figure 27. Spark Tester
note: a sheared flywheel key may change
ignition timing but sparking will still occur
across the spark tester gap.
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NORMAL
MISFIRES
Figure 29. Checking Engine Miss
RESULTS:
1. If no spark or very weak spark occurs, go to Test 73.
PRE-IGNITION
DETONATION
2. If sparking occurs but engine still won’t start, go to Test 71.
3. When checking for engine miss, if sparking occurs at
regular intervals but engine miss continues, go to Test 20.
Figure 30. Spark Plug Conditions
4. When checking for engine miss, if a spark miss is readily
apparent, go to Test 74.
teSt 71 – check Spark pluGS
DISCUSSION:
If the engine will not start and Test 70 indicated good
ignition spark, perhaps the spark plug(s) are fouled or
otherwise damaged. Engine miss may also be caused
by defective spark plug(s).
PROCEDURE:
1. Remove spark plugs and clean with a penknife or use a
wire brush and solvent.
Figure 31. Checking Spark Plug Gap
2. Replace any spark plug having burned electrodes or
cracked porcelain.
3. Set gap on new or used spark plugs as follows:
teSt 72 – check enGine / cylinder leak
doWn teSt / compreSSion teSt
kW
rating
recommended
Plug
Engine size
Plug Gap
GENERAL:
410 cc
530 cc
990 cc
999 cc
8 kW
0.030 inch
0.030 inch
RC14YC
BPR6HS
RC14YC
RC12YC
Most engine problems may be classified as one or a
combination of the following:
• Will not start
• Starts hard
• Lack of power
• Runs rough
• Vibration
• Overheating
• High oil consumption
10 kW
10-17 kW 0.040 inch
20 kW 0.030 inch
RESULTS:
1. Clean, re-gap or replace spark plugs as necessary.
2. If spark plugs are good, refer back to flow chart.
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DISCUSSION:
PROCEDURE:
The Cylinder Leak Down Tester checks the sealing
(compression) ability of the engine by measuring air
leakage from the combustion chamber. Compression
loss can present many different symptoms. This test
is designed to detect the section of the engine where
the fault lies before disassembling the engine.
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.
PROCEDURE:
5. Repeat the procedure for the remaining cylinder and
record the highest reading.
1. Remove a spark plug.
2. Gain access to the flywheel. Remove the valve cover.
RESULTS:
3. Rotate the engine crankshaft until the piston reaches top
dead center (TDC). Both valves should be closed.
The difference in pressure between the two cylinders
should not exceed 25 percent. If the difference is
greater than 25 percent, loss of compression in the
lowest reading cylinder is indicated.
4. Lock the flywheel at top dead center.
5. Attach cylinder leak down tester adapter to spark plug
hole.
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.
6. Connect an air source of at least 90 psi to the leak
down tester.
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.
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.
If compression is poor, look for one or more of the fol-
lowing causes:
• Loose cylinder head bolts
• Failed cylinder head gasket
• Burned valves or valve seats
• Insufficient valve clearance
• Warped cylinder head
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
gasket should be replaced.
• Warped 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 for further
engine service information.
CHECk COMPRESSION:
Lost or reduced engine compression can result in (a)
failure of the engine to start, or (b) rough operation.
One or more of the following will usually cause loss of
compression:
teSt 73 – check ShutdoWn Wire
• Blown or leaking cylinder head gasket
• Improperly seated or sticking-valves
DISCUSSION:
Circuit board action during shutdown will ground Wire
18. Wire 18 is connected to the Ignition Magneto(s).
The grounded magneto will not be able to produce
spark.
• Worn Piston rings or cylinder. (This will also result in
high oil consumption)
note: For the single cylinder engine, the minimum
allowable compression pressure for a cold engine
is 60 psi.
PROCEDURE:
1. On V-twin generators, remove Wire 18 from the stud
located above the oil cooler. On single cylinder gen-
erators, disconnect Wire 18 at the bullet connector. See
Figures 32 or 33.
note: it is extremely difficult to obtain an accu-
rate compression reading without special equip-
ment. For that reason, compression values are
not published for the V-twin engine. testing has
proven that an accurate compression indication
can be obtained using the following method.
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RESULTS:
WIRE 18 CONNECTION
1. If INFINITY was not measured in Step 4, repair or replace
shorted ground Wire 18 between the J1 Connector from
the circuit board to the stud or bullet connector.
2. If INFINITY was measured in Step 4, replace the circuit
board and retest for spark.
3. If ignition spark still has not occurred, proceed to Test 74.
teSt 74 – check and adjuSt iGnition
maGnetoS
DISCUSSION:
In Test 70, a spark tester was used to check for
engine ignition. If sparking or weak spark occurred,
one possible cause might be the ignition magneto(s).
This test consists of checking ohm values across the
primary and secondary windings of the magneto and
adjusting the air gap between the ignition magneto(s)
and the flywheel. The flywheel and flywheel key will
also be checked during this test. A diode is installed
before the primary winding inside the coil. This is
done to inhibit a spark occurring on both magnetos at
the same time.
Figure 32. Wire 18 Connection 10-20 kW Units
2. Depending on engine type, do the following:
a. On V-twin units, remove Wire 56 from the
Starter Contactor Relay (SCR). Using a jumper
lead, jump 12 VDC from Wire 15B at TB1
(Customer Connection) to the terminal on the
SCR from which Wire 56 was removed. The
generator will start cranking. As it is cranking,
repeat Test 70. Reconnect Wire 56 when done.
PROCEDURE: TESTING MAGNETOS V-TWIN ONLY
b. On single cylinder units, connect a jumper lead
from the stud to which Wire 56 is connected
on the Starter Contactor (SC) and 12 VDC
Wire 15B at TB1 (Customer Connection). The
generator will start cranking. As it is cranking,
repeat Test 70.
1. Disconnect the J1 connector from the printed circuit
board.
2. Disconnect spark plug wires from the spark plugs on
cylinder one and two.
3. Set VOM to measure resistance.
WIRE 18
CONNECTION
4. Connect the positive (red) meter lead to the bolt connec-
tor where Wire 18 was disconnected in Step 1. Connect
the negative (black) meter lead to a clean frame ground.
A resistance of approximately 300K 10K ohms should
be measured. This reading is the primary winding of
both coils in parallel.
5. Connect the positive meter lead to the spark plug
wire and connect the negative meter lead to a clean
frame ground. Approximately 14K 3 ohms should be
measured. This reading is the secondary winding of
both coils in parallel. If INFINITY, or a low or high ohm
reading is measured, replace the magnetos.
6. Connect the negative (black) meter lead to the bolt
connector where Wire 18 was disconnected in Step 1.
Connect the positive (red) meter lead to the spark plug
wire on cylinder number two. The meter should indicate
INFINITY.This step is testing the diodes in both magnetos
to ensure they are still functioning.
Figure 33. Wire 18 Connection 8 kW Units
3. If spark now occurs with Wire 18 removed, check for
a short to ground. Remove the J1 Connector from the
circuit board.
4. Set a VOM to measure resistance. Connect one test lead
to Wire 18 (disconnected in Step 1). Connect the other
test lead to a clean frame ground. INFINITY should be
measured.
7. Repeat Step 6 on cylinder two. If INFINITY is not
measured, replace the magnetos.
note: it is recommended to replace magnetos
in pairs.
5. Reconnect the J1 Connector to the circuit board.
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PROCEDURE, ADJUSTING MAGNETO FLYWHEEL GAP:
where Wire 56 was disconnected in Step 7. The
engine should crank once the jumper from 15B
is connected.
note: the air gap between the ignition magneto
and the flywheel on single cylinder engines is not
adjustable. proceed directly to Step 10 for single
cylinder engines. For V-twin engines, proceed as
follows.
8. If spark was not indicated, replace magnetos.
note: if gap is only adjusted, ensure to properly
test the magnetos by cranking the engine over
before reassembly occurs. Spark should be
present on both cylinders before reassembly
should be completed.
1. See Figure 34. 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.
9. If air gap was not out of adjustment, test ground wires.
10.Set a VOM to the measure resistance.
note: a business card is approximately 0.010
inch thick.
11.Disconnect the engine wire harness from the ignition
magnetos (Figure 35).
3. Loosen the mounting screws and let the magnet pull the
magneto down against the thickness gauge.
a. On V-twin generators, remove Wire 18 from the
stud located above the oil cooler. See Figure 45.
4. Tighten both mounting screws.
b. On single cylinder generators, disconnect Wire
18 at the bullet connector. See Figure 44.
5. To remove the thickness gauge, rotate the flywheel.
6. Repeat the above procedure for the second magneto.
ENGINE
WIRE
STUD CONNECTOR
HARNESS
0.008-0.012" GAUGE
SPARk PLUG
WIRE 18 TO
CIRCUIT BOARD
REMOVE LEADS
SPARk PLUG
Figure 35. Engine Ground Harness
12.Connect one meter test lead to one of the wires removed
from the ignition magneto(s). Connect the other test
lead to frame ground. INFINITY should be measured. If
CONTINUITY is measured, replace the shutdown harness.
MAGNETO
Figure 34. Setting Ignition Magneto (Armature)
Air Gap
13.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.
7. Repeat Test 70 and check for spark across the spark
tester gap
a. A spark test may be conducted with unit dis-
sembled by following this procedure.
14.For rough running or hard starting engines check the fly-
wheel 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.
b. Battery must be connected.
c. J2 Connector must be connected to the printed
circuit board.
d. Remove Wire 56 from the SCR located beneath
the printed circuit board.
note: if the flywheel key becomes sheared
or even partially sheared, ignition timing can
change. incorrect timing can result in hard start-
ing or failure to start.
Warning: make sure all debris is cleared from the
engine compartment and all body parts are clear
from flywheel before proceeding.
15.As stated earlier, the armature air gap is fixed for single
cylinder engine models and is not adjustable. Visually
inspect the armature air gap and hold down bolts.
e. Refer to Test 70 to check for spark.
f. Utilizing a jumper wire, connect a wire to the
15B terminal block. Connect the other end to
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RESULTS:
If sparking still does not occur after adjusting the
armature air gap, testing the ground wires and
performing the basic flywheel test, replace the
ignition magneto(s).
PROCEDURE, REPLACING MAGNETOS:
1. Follow all steps of the Major Disassembly procedures
that are located in Section 6.
2. Once the magnetos are visible, make note to how
they are connected.
Figure 38.
note: each magneto has its own part number.
Verify the part number prior to installation.
note: magneto gap between flywheel needs to
be 0.010 inch.
3. Cylinder one is the back cylinder (Figure 36) and
cylinder two is the front cylinder (Figure 37).
5. Long plug wire (B) will be installed on front cylinder
number two.
6. Short plug Wire (A) will be installed on back cylinder
number one.
7. Verify installation of magnetos correctly by ensuring both
spark plug wires point to the back of the enclosure and
shutdown terminals are nearest cylinder head as shown
in Figures 39 and 40.
Figure 36. Cylinder One (Back, Short)
Figure 39.
Figure 37. Cylinder Two (Front, Long)
4. When installing new magnetos there will be one
with a short plug wire and one with a longer plug
wire (Figure 38).
Figure 40.
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2. Check engine crankcase oil level.
teSt 75 – check oil preSSure SWitch
and Wire 86
a. Check engine oil level.
b. If necessary, add the recommended oil to
the dipstick FULL mark. DO NOT OVERFILL
ABOVE THE FULL MARk.
DISCUSSION:
If the oil pressure switch contacts have failed in their
closed position, the engine will probably crank and
start. However, shutdown will then occur within about
5 (five) seconds. If the engine cranks and starts, then
shuts down almost immediately with a LOP fault light,
the cause may be one or more of the following:
3. With oil level correct, try starting the engine.
a. If engine still cranks and starts, but then shuts
down, go to Step 4.
b. If engine cranks and starts normally, discon-
tinue tests.
• Low engine oil level.
• Low oil pressure.
4. Do the following:
• A defective oil pressure switch.
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.
PROCEDURE:
1. Navigate to the Digital inputs display screen.
a. Press “ESC” until the main menu is reached.
b. Press the right arrow key until “Debug” is flashing.
c. Press “Enter”.
b. Start the engine while observing the oil pres-
sure 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.
d. Press the right arrow key until “Inputs” is flashing.
e. Press “Enter”.
(2) If oil pressure is below about 4.5 psi, shut
engine down immediately. A problem exists
in the engine lubrication system.
note: the oil pressure switch is rated at 10 psi
for V-twin engines, and 8 psi for single cylinder
engines.
DEBUG
INPUTS
INPUTS 1 - 8:
1 0 1 1 0 0 0 1
INPUT 1
Figure 42. Oil Pressure Switch
Figure 41. The Home Page, Debug and Input Screens
5. Remove the oil pressure gauge and reinstall the oil
pressure switch. Do NOT connect Wire 86 or Wire 0 to
the switch terminals.
f. Digital Input 1 is Wire 86 from the Low Oil
Pressure switch to the board. Refer to Figure 41.
a. Set a VOM to measure resistance.
g. Set the AUTO-OFF-MANUAL switch to the
MANUAL position.
b. Connect the VOM test leads across the switch
terminals. With engine shut down, the meter
should read CONTINUITY. If INFINITY is
measured with the engine shutdown, replace
the LOP switch.
h. Observe Input 1 for a change from "1" to "0". A
change from "1" to "0" indicates that the control
board sensed the LOP switch change states. If
the generator still shuts down, replace printed
circuit board.
c. Crank and start the engine. The meter should
read INFINITY.
i. If the input did not change states, proceed
to Step 2
6. Set a VOM to measure resistance.
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a. Disconnect the J1 Connector from the printed
circuit board.
short to ground. Remove J1 Connector from the circuit
board. Set the VOM to measure resistance. Connect
one test lead to Wire 85 (disconnected from High Oil
Temperature Switch). Connect the other test lead to a
clean frame ground. INFINITY should be measured.
b. Connect one test lead to Wire 86 (disconnected
from LOP). Connect the other test lead to Pin
Location 4 (Wire 86) of the J1 Connector at the
Circuit Board (for all models). CONTINUITY
should be measured. If CONTINUITY is not
measured, repair or replace Wire 86 between
the LOP switch and the J1 Connector.
TESTING HIGH OIL TEMPERATURE SWITCH:
6. Remove the High Oil Temperature Switch.
c. 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 CONTINUITY is NOT measured repair or replace
Wire 0 between the LOP and the ground terminal
connection on the engine mount.
7. Immerse the sensing tip of the switch in oil as shown in
Figure 43, along with a suitable thermometer.
8. Set a VOM to measure resistance. Then, connect the
VOM test leads across the switch terminal and the
switch body. The meter should read INFINITY.
7. If the LOP switch tests good in Step 5 and oil pressure
is good in Step 4 but the unit still shuts down with a LOP
fault, check Wire 86 for a short to ground. Set a VOM to
measure resistance. Disconnect the J1 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 J1 Connector.
9. Heat the oil in the container. When the thermometer
reads approximately 283°-305° F. (139°-151° C.), the
VOM should indicate CONTINUITY.
RESULTS:
1. Replace switch if it fails the test.
teSt 76 – check hiGh oil temperature
SWitch
DISCUSSION:
If the temperature switch contacts have failed in a closed
position, the engine will fault out on “OVERTEMP”. If the
unit is in an overheated condition, the switch contacts will
close at 293° F. This will normally occur from inadequate
airflow through the generator.
Figure 43. Testing the Oil Temperature Switch
PROCEDURE:
RESULTS:
1. Verify that the engine has cooled down (engine block
is cool to the touch). This will allow the contacts in the
High Oil Temperature Switch to close.
1. If the switch fails Step 4, or Steps 8-9, replace the
switch.
2. If INFINITY was NOT measured in Step 5, repair or
replace Wire 85 between the Circuit Board and the High
Oil Temperature Switch.
2. Check the installation and area surrounding the generator.
There should be at least three feet of clear area around
the entire unit. Make sure that there are no obstructions
preventing incoming and outgoing air.
3. Disconnect Wire 85 and Wire 0 from the High Oil
Temperature Switch.
teSt 77 – check and adjuSt ValVeS
DISCUSSION:
4. Set a VOM to measure resistance. Connect the test
leads across the switch terminals. The meter should
read INFINITY.
Improperly adjusted valves can cause various engine
related problems including, but not limited to, hard
starting, rough running and lack of power. The valve
adjustment procedure for both the single cylinder and
the V-twin engines is the same.
5. If the switch tested good in Step 4, and a true overtem-
perature condition has not occurred, check Wire 85 for a
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PROCEDURE: (INTAkE AND EXHAUST)
2. Connect one meter test lead to Wire 18 that is connected
to the bolt connector shown in Figure 46. Connect the
other meter test lead to a clean frame ground.
Make sure that the piston is at Top Dead Center
(TDC) of it’s compression stroke (both valves
closed). The valve clearance should be 0.05-0.1mm
(0.002-0.004 in.) cold.
3. Set the AUTO-OFF-MANUAL switch to the MANUAL
position.
Check and adjust the valve to rocker arm clearance
as follows:
4. When the generator comes up to rated speed, measure and
record the voltage reading. 4-6 VAC should be measured.
1. Remove the four (4) screws from the rocker cover.
2. Remove the rocker cover and rocker cover gasket.
5. If the correct voltage was not measured in Step 4, refer
back to flow chart. If the correct voltage was measured,
proceed to Step 6.
3. Loosen the rocker arm jam nut. Use a 10mm allen wrench
to turn the pivot ball stud and check the clearance
between the rocker arm and the valve stem with a flat
feeler gauge (see Figure 44).
WIRE 18
CONNECTION
4. When the valve clearance is correct, hold the pivot ball
stud with the allen wrench and tighten the rocker arm
jam nut. Torque the jam nut to 174 inch pounds. After
tightening the jam nut, recheck the valve clearance to
make sure it did not change.
BALL STUD
Figure 45. Wire 18 Connection 8 kW Units
JAM NUT
WIRE 18 CONNECTION
0.076 mm
(0.003") SHIM
Figure 44
5. Re-install the rocker cover gasket, rocker cover and
the four (4) screws.
Figure 46. Wire 18 Connection 10-20 kW Units
RESULTS:
Adjust valve clearance as necessary, then retest.
6. Set a VOM to measure resistance.
7. Disconnect the J1 Connector from the printed circuit
board.
teSt 78 – check Wire 18 continuity
8. Verify the continuity of Wire 18. Connect one meter
test lead to a clean frame ground. Connect the other
meter test lead to Pin Location J1-4 for all models. A
reading of 275K - 325K ohms should be measured. If
CONTINUITY is measured (0.1 ohms) a short to ground
could be present.
DISCUSSION:
During cranking and running the printed circuit board
receives a pulse from the ignition magnetos via Wire
18. This signal has an AC voltage of 4-6 volts on
V-Twin engines only. If this signal is not received by
the printed circuit board the unit will shut down due to
no RPM sensing.
9. Disconnect Wire 18 from the stud connector. Continue to
leave J1 disconnected from Step 7.
PROCEDURE: (V-TWIN ONLY)
1. Set a VOM to measure AC voltage.
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10.Connect one meter test lead to Wire 18 removed from
the stud connector. Connect the other meter test lead to
a clean frame ground. INFINITY should be measured.
If CONTINUITY is measured, repair or replace Wire 18
between the stud connector and the J1 Connector.
3. Press the right arrow key till a line is present under “EDIT”.
4. Press “Enter”.
5. Press the right arrow key until “EXERCISE TIME/DAY” is
displayed.
6. Press “Enter”.
RESULTS:
Refer to flow chart.
READY TO RUN
PROCEDURE: (SINGLE CYLINDER)
1. Set a VOM to measure resistance.
1 2 / 1 0 / 0 8 0 9 : 3 0 M o n
2. Remove Wire 18 from the in-line bullet connector.
Disconnect the J1 Connector from the printed circuit
board.
DATE AND TIME
3. Verify the continuity of Wire 18. Connect one meter test
lead to Wire 18 removed from the stud connector or
bullet connector. Connect the other meter test lead to
Pin Location J1-4. CONTINUITY should be measured.
If CONTINUITY is not measured, repair or replace Wire
18 as needed.
MAIN
MENU
RESULTS:
Refer to flow chart.
EDIT
teSt 79 – teSt eXerciSe Function
Figure 47. The Date and Time, and Main Menu
Screens
DISCUSSION:
The following parameters must be met in order for the
weekly exercise to occur:
• AUTO-OFF-MANUAL switch set to AUTO.
7. Adjust exercise time to about 3 to 4 minutes ahead of
the date and time noted in Step 1.
8. Press “ESC” until “READY TO RUN” is displayed. The
AUTO-OFF-MANUAL switch must be in AUTO for the
unit to exercise.
PROCEDURE: 8kW
1. Set the AUTO-OFF-MANUAL switch to MANUAL. The
generator should start. Set AUTO-OFF-MANUAL switch
back to AUTO. Verify that AUTO-OFF-MANUAL switch
has been in AUTO for weekly exercise to function.
9. Watch the generator display and note the time. When the
date and time reaches the time that was programmed
for exercise, the unit will display "Running in Exercise" if
the exercise feature is working properly.
2. Hold the Set Exercise switch until the generator starts
(approximately 10 seconds) and then release. All of
the red LEDs will flash for approximately 10 seconds
and then stop. The generator will start and run for
approximately 12 minutes and then shutdown on it’s
own. The exerciser will then be set to start and run at
that time of that day each week. If the unit does not
start, replace the circuit board.
RESULTS:
1. In all models, if the unit starts in MANUAL, but fails to
exercise without any ALARMS present, replace the
printed circuit board.
teSt 80 – check crankinG and runninG
PROCEDURE: 10kW-20kW
circuitS
note: make a record of the date and time the
generator is set to exercise.
DISCUSSION:
1. Record the current date and time of the unit.
This test will check all of the circuits that are “HOT”
with battery voltage and which could cause the Main
Fuse to blow.
2. Press the “ESC” key till the main menu is displayed.
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PROCEDURE:
a. Connect one meter test lead to the SC terminal
from which Wire 56 was removed. Connect the
other meter test lead to the ground terminal, 4
ohms should be measured. If zero resistance
was measured, replace the SC.
1. Set a VOM to measure resistance.
2. Disconnect the J2 Connector from the controller.
3. Connect one meter test lead to the ground terminal.
Connect the other meter test lead to each of the follow-
ing J2 connector pin locations.
b. Connect one meter test lead to the CS connec-
tor Wire 56. Connect the other meter test lead
to the CS connector Wire 90. 4 ohms should
be measured. If zero resistance was measured,
replace the Choke Solenoid.
J2-11 Wire 56
8kW
If CONTINUITY was measured,
go to Step 4. Average nominal
resistance reading is 4 ohms:
Single Cylinder Starter Contactor
(SC) 4 ohms,
c. If coil resistance was measured in the Starter
Contactor, and Choke Solenoid Wire 56 is short-
ed to ground between the J2 Connector and SC
or CS, repair or replace the shorted wire.
5. Disconnect Wire 56 from the Starter Contactor Relay
(SCR). Disconnect the Choke Solenoid (CS) connector.
Choke Solenoid (CS) is 4 ohms.
a. Connect one meter test lead to the SCR terminal
from which Wire 56 was removed. Connect the
other meter test lead to the ground terminal. 4
ohms should be measured. If zero resistance was
10 kW - 20 kW If CONTINUITY was measured,
go to Step 5.
Average nominal resistance reading
is 150-160 ohms.
measured, replace the Starter Contactor Relay
.
b. Connect one meter test lead to the CS connec-
tor Wire 56. Connect the other meter test lead
to the CS connector Wire 90. 4 ohms should
be measured. If zero resistance was measured,
V-twin Starter Contact Relay
(SCR): 150-160 ohms.
Choke Solenoid (CS) 4 ohms.
replace the Choke Solenoid.
J2-3 Wire 14
If coil resistance was measured in SCR and CS Wire
56 is shorted to ground between J2 connector and SC
or CS, repair or replace the shorted wire.
8kW
If CONTINUITY was measured,
go to Step 6. Average nominal
resistance reading is 16 ohms:
Fuel Solenoid (FS): 16 ohms.
6. Disconnect Wire 14 from the Fuel Solenoid (FS).
a. Connect one meter test lead to the FS terminal
from which Wire 14 was removed. Connect the
other meter test lead to the ground terminal. 16
ohms should be measured. If zero resistance
was measured, replace the Fuel Solenoid.
10kw
If CONTINUITY was measured,
go to Step 7. Average nominal
resistance reading is 16 ohms.
Fuel Solenoids (FS) 16 ohms,
(FS2) 7 ohms. Choke Solenoid
(CS) 4 ohms.
b. If coil resistance was measured in FS Wire 14
is shorted to ground between J2 connector and
FS, repair or replace the shorted wire.
10 kW - 20 kW If CONTINUITY was measured,
go to Step 8. Average nominal
7. Disconnect Wire 14 from the Fuel Solenoid (FS), Fuel
Solenoid 2 (FS2), and Choke Solenoid (CS),
resistance reading is 16 ohms.
a. Connect one meter test lead to the FS terminal
from which Wire 14 was removed. Connect the
other meter test lead to the ground terminal. 16
ohms should be measured. If zero resistance
was measured, replace the Fuel Solenoid.
Fuel Solenoid (FS) 16 ohms.
Choke Solenoid (CS) 4 ohms.
J2-12 Wire 4
b. Connect one meter test lead to the FS2 termi-
nal from which Wire 14 was removed. Connect
the other meter test lead to the ground terminal.
7 ohms should be measured. If zero resistance
10 kW - 20 kW If RESISTANCE was measured,
go to Step 9.
For average nominal resistance
reading of the rotor, refer to the
front of the manual.
was measured, replace Fuel Solenoid 1.
c. At the CS connector, connect one meter test
lead to Wire 14 connect the other meter test
lead to Wire 90. 4 ohms should be measured.
If zero resistance was measured, replace the
4. Disconnect Wire 56 and Wire 0 from the Starter
Contactor (SC). Disconnect the Choke Solenoid
(CS) connector.
Choke Solenoid.
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DC CONTROL
Part 4
d. If coil resistance was measured in CS and FS,
and FS2 Wire 14 is shorted to ground between
J2 connector and CS, FS, or FS2, repair or
replace the shorted wire.
PROCEDURE:
1. Press the “ESC” key till the main menu is reached.
2. Press the right arrow key until “Edit” is flashing.
3. Press “Enter”
8. Disconnect Wire 14 from the Fuel Solenoid (FS) and
Choke Solenoid (CS).
4. Press the right arrow key until “Exercise Time” appears
on the controller.
a. Connect one meter test lead to the FS terminal
from which Wire 14 was removed. Connect the
other meter test lead to the ground terminal. 16
ohms should be measured. If zero resistance
was measured, replace the FS.
5. Press “Enter”.
6. Press the right arrow key until the Low speed exercise
option is displayed.
b. At the CS connector, connect one meter test
lead to Wire 14. Connect the other meter test
lead to Wire 90. 4 ohms should be measured.
If zero resistance was measured, replace the
Choke Solenoid.
7. Ensure that it is enabled.
RESULTS:
Refer back to flow chart.
c. If coil resistance was measured in the Choke
Solenoid, and FS Wire 14 is shorted to ground
between the J2 Connector and CS or FS, repair
or replace the shorted wire.
teSt 82 – check operation oF the
choke Solenoid
9. Disconnect Wire 4 and Wire 0 from the Voltage Regulator
(VR).
DISCUSSION:
a. At the J2 connector, connect one meter test
lead to Wire 4. Connect the other meter
test lead to a clean frame ground. Note the
resistance reading and compare to the rotor
resistance in the front of this manual. If zero
resistance was measured, test Wire 4 for a
short to ground. Check brushes, slip rings,
and rotor.
The choke solenoid should be closed when it is in low
speed exercise.
PROCEDURE:
1. Remove the air box cover and filter from the engine.
2. Refer to test 79 for Test Exercise Function
3. When the generator starts and the display reflects that
it is exercising, confirm that the choke solenoid is fully
closed over one port.
teSt 81 – check to See iF loW Speed
Function iS enaBled
RESULTS:
DISCUSSION:
1. If the solenoid did not close, confirm that utility voltage is
present. If the generator believes that there is a power
outage it will run at full speed until utility is returned.
The Low speed exercise function when it is
enabled allows the generator to exercise at 2400
rpm. If it is disabled it will exercise at its 3600 rpm
during exercise.
2. If the solenoid closed, replace the controller.
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taBlE of coNtENts
titlE
Part
5.1. system functional tests
Part 5
oPEratioNal
tEsts
air-cooled, automatic
standby Generators
5.1 System Functional Tests................................ 148
Introduction....................................................148
Manual Transfer Switch Operation .................148
Electrical Checks ...........................................148
Generator Tests Under Load..........................149
Checking Automatic Operation ......................150
Setting The Exercise Timer............................150
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sEctioN 5.1
sYstEm fuNctioNal tEsts
OPERATIONAL TESTS
AND ADJUSTMENTS
Part 5
iN DaNGErous aND PossiBlY lEtHal
ElEctrical sHocK.
introduction
Following home standby electric system installation
and periodically thereafter, the system should be
tested Functional tests of the system include the
following:
4. Remove the manual transfer handle from the enclosure.
5. Place open end of the manual transfer handle over
transfer switch operating lever.
• Manual transfer switch operation.
• System voltage tests.
• Generator Tests Under Load.
• Testing automatic operation.
6. To connect LOAD terminal lugs to the utility power
source, move, the handle upward.
7. To connect LOAD terminals to the standby power source,
move the handle downward.
Before proceeding with functional tests, read instruc-
tions and information on tags or decals affixed to the
generator and transfer switch. Perform all tests in the
exact order given in this section.
8. Actuate the switch to UTILITY and to MANUAL several
times. Make sure no evidence of binding or interference
is felt.
manual tranSFer SWitch operation
9. When satisfied that manual transfer switch operation
is correct, actuate the main contacts to their UTILITY
position (Load connected to the utility power supply).
“W/V-TYPE” TRANSFER SWITCHES:
1. On the generator panel, set the AUTO-OFF-MANUAL
switch to OFF.
electrical checkS
2. Turn OFF the utility power supply to the transfer switch
using whatever means provided (such as a “Utility” main
line circuit breaker).
Complete electrical checks as follows:
1. Set the generator main circuit breaker to its OFF (or
open) position.
3. Set the generator main line circuit breaker to OFF
(or open).
2. Set the generator AUTO-OFF-MANUAL switch to the
OFF position.
DaNGEr: BE surE to turN off all
PoWEr VoltaGE suPPliEs to tHE
traNsfEr sWitcH BEforE attEmPtiNG
3. Turn off all loads connected to the transfer switch
Terminals T1 and T2.
*
maNual oPEratioN. failurE to turN
off PoWEr VoltaGE suPPliEs to
tHE traNsfEr sWitcH maY rEsult
4. Turn on the utility power supply to the transfer switch
using the means provided (such as a utility main line
circuit breaker).
LOAD CONNECTED TO
LOAD CONNECTED TO
UTILITY POWER SOURCE
STANDBY POWER SOURCE
TRANSFER
SWITCH
OPERATING
LEVER
MANUAL
TRANSFER
HANDLE
MANUAL
TRANSFER
HANDLE
TRANSFER
SWITCH
OPERATING
LEVER
Figure 1. Manual Operation “V-Type” Switch
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sEctioN 5.1
sYstEm fuNctioNal tEsts
OPERATIONAL TESTS
AND ADJUSTMENTS
Part 5
Generally, if both ac frequency and voltage are
high or low, the engine governor requires adjust-
ment. if frequency is correct, but voltage is high
or low, the generator voltage regulator requires
adjustment.
DANGER
tHE traNsfEr sWitcH is NoW ElEctri-
callY “Hot”, coNtact WitH “Hot” Parts
Will rEsult iN EXtrEmElY HaZarDous
aND PossiBlY fatal ElEctrical sHocK.
ProcEED WitH cautioN.
+
Generator teStS under load
To test the generator set with electrical loads applied,
proceed as follows:
5. Use an accurate AC voltmeter to check utility power
source voltage across transfer switch Terminals N1 and
N2. Nominal line-to-line voltage should be 240 volts AC.
1. Set generator main circuit breaker to its OFF (or
open) position.
2. Turn OFF all loads connected to the Transfer Switch
Terminals T1 and T2.
6. Check utility power source voltage across Terminals N1
and the transfer switch neutral lug; then across Terminal
N2 and neutral. Nominal line-to-neutral voltage should
be 120 volts AC.
3. Set the generator AUTO-OFF-MANUAL switch to OFF.
4. Turn off the utility power supply to the transfer switch,
using the means provided (such as a utility main line
circuit breaker).
7. When certain that utility supply voltage is compatible
with transfer switch and load circuit ratings, turn off the
utility power supply to the transfer switch.
8. On the generator panel, set the AUTO-OFF-MANUAL
switch to MANUAL. The engine should crank and start.
9. Let the engine warm up for about five minutes to allow
internal temperatures to stabilize. Then, set the generator
main circuit breaker to its “ON” (or closed) position.
Do Not attEmPt maNual traNsfEr
sWitcH oPEratioN uNtil all PoWEr
VoltaGE suPPliEs to tHE traNsfEr
sWitcH HaVE BEEN PositiVElY turNED
off. failurE to turN off all PoWEr
VoltaGE suPPliEs Will rEsult iN
EXtrEmElY HaZarDous aND PossiBlY
fatal ElEctrical sHocK.
+
DANGER
ProcEED WitH cautioN! GENErator
PoWEr VoltaGE is NoW suPPliED to
tHE traNsfEr sWitcH. coNtact WitH
liVE traNsfEr sWitcH Parts Will
rEsult iN DaNGErous aND PossiBlY
fatal ElEctrical sHocK.
+
5. Manually set the transfer switch to the STANDBY posi-
tion, i.e., load terminals connected to the generator
E1/E2 terminals. The transfer switch operating lever
should be down.
6. Set the generator AUTO-OFF-MANUAL switch to
MANUAL. The engine should crank and start immediately.
10.Connect an accurate AC voltmeter and a frequency
meter across transfer switch Terminal Lugs E1 and E2.
Voltage should be 242-252 volts; frequency should read
about 61-63 Hertz (7/8 kW units) and about 60 Hertz on
10-20 kW units.
7. Let the engine stabilize and warm up for a few minutes.
8. Set the generator main circuit breaker to its ON (or
closed) position. Loads are now powered by the standby
generator.
11.Connect the AC voltmeter test leads across Terminal
Lug E1 and neutral; then across E2 and neutral. In both
cases, voltage reading should be 121-126 volts AC.
9. Turn ON electrical loads connected to transfer switch T1
and T2. Apply an electrical load equal to the full rated
wattage/amperage capacity of the installed generator.
12.Set the generator main circuit breaker to its OFF (or open)
position. Let the engine run at no-load for a few minutes to
stabilize internal engine generator temperatures.
10.Connect an accurate AC voltmeter and a frequency
meter across Terminal Lugs E1 and E2.
13.Set the generator AUTO-OFF-MANUAL switch to OFF.
The engine should shut down.
a. 7/8kW voltage should be greater than 230 volts
and frequency should be greater than 58 Hz.
note: it is important that you do not proceed until
you are certain that generator ac voltage and fre-
quency are correct and within the stated limits.
b. 10-20 kW voltage should be greater than 240
volts and frequency should be 60 Hz.
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sEctioN 5.1
sYstEm fuNctioNal tEsts
OPERATIONAL TESTS
AND ADJUSTMENTS
Part 5
the unit runs for approximately 12 minutes and then
shuts down. Transfer of loads to the generator output
does not occur during the exercise cycle unless utility
power is lost.
11.Let the generator run at full rated load for 20-30 minutes.
Listen for unusual noises, vibration or other indications
of abnormal operation. Check for oil leaks, evidence of
overheating, etc.
PROCEDURE 8 kW UNITS:
12.When testing under load is complete, turn off electrical
loads.
A switch on the control panel (see Figure 3.1) permits
selection of the day and time for the system to exercise.
At the chosen time, perform the following sequence to
select the desired day and time of day the system will
exercise. Remember, seasonal time changes affect the
exercise settings.
13.Set the generator main circuit breaker to its OFF (or
open) position.
14.Let the engine run at no-load for a few minutes.
1. Verify that the AUTO-OFF-MANUAL switch is set to
AUTO.
15.Set the AUTO-OFF-MANUAL switch to OFF. The engine
should shut down.
2. Press and hold the “Set Exercise” switch for several
seconds. All the red LED’s will stop flashing immediately
and the generator will start.
checkinG automatic operation
To check the system for proper automatic operation,
proceed as follows:
3. The generator will start and run for approximately 12
minutes and then shut down. The exerciser is now set to
run at this time of day each week. Example: If the “Set
Exercise” is pressed on Saturday afternoon at 2:00 p.m.
the generator will start and exercise for approximately
12 minutes every Saturday at 2:00 p.m.
1. Set generator main circuit breaker to its OFF (or open)
position.
2. Check that the AUTO-OFF-MANUAL switch is set to OFF.
3. Turn off the utility power supply to the transfer switch,
using means provided (such as a utility main line circuit
breaker).
10-20 kW - INSTALLATION ASSISTANT:
Upon first power up of the generator, the display inter-
face will enter an installation assistant. The assistant
will prompt the user to set the minimum settings to
operate.These settings are simply: “Current Date/Time”
and “Exercise Day/Time”. The maintenance intervals
will be initialized when the exercise time is entered.
4. Manually set the transfer switch to the UTILITY position, i.e.,
load terminals connected to the utility power source side.
5. Turn on the utility power supply to the transfer switch,
using the means provided (such as a utility main line
circuit breaker).
The exercise settings can be changed at any time
via the “EDIT” menu (see Appendix, “Menu System”).
If the 12 volt battery is disconnected or the fuse
removed, the Installation Assistant will operate upon
power restoration. The only difference being that the
display will only prompt the customer for the current
Time and Date.
6. Set the AUTO-OFF-MANUAL switch to AUTO. The
system is now ready for automatic operation.
7. Turn off the utility power supply to the transfer switch.
With the AUTO-OFF-MANUAL switch at AUTO, the
engine should crank and start when the utility source
power is turned off. After starting, the transfer switch
should connect load circuits to the standby side. Let
the system go through its entire automatic sequence
of operation.
ALL UNITS:
note: if the installer tests the generator prior to
installation, press the “enter” key to avoid set-
ting the exercise time. this will ensure that the
customer will still be prompted to enter an exercise
time when the unit is first powered up.
With the generator running and loads powered by
generator AC output, turn ON the utility power supply
to the transfer switch. The following should occur:
• After about fifteen seconds, the switch should
transfer loads back to the utility power source.
note: the exerciser will only work in the auto
mode and will not work unless this procedure
is performed. the current date/time will need to
be reset every time the 12 volt battery is discon-
nected and then reconnected, and/or when the
fuse is removed.
• About one minute after retransfer, the engine should
shut down.
SettinG the eXerciSe timer
This generator is equipped with an exercise timer.
Once it is set, the generator will start and exercise
every seven days, on the day of the week and at the
time of day specified. During this exercise period,
Page 150
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taBlE of coNtENts
titlE
Part
6.1. major Disassembly
Part 6
DisassEmBlY
air-cooled, automatic
standby Generators
6.1 Major Disassembly........................................ 152
Front Engine Access......................................152
Major Disassembly.........................................156
Torque Requirements
(Unless Otherwise Specified)............162
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
2. Remove controller: Using a Phillips screwdriver remove the
four mounting screws from the controller. See Figure 3.
Front enGine acceSS
SAFETY:
1. Set the AUTO-OFF-MANUAL switch to OFF.
2. Remove the 7.5 amp main fuse. See Figure 1.
3. Remove the N1 and N2 fuse from the transfer switch.
Figure 3.
3. Remove control harnesses:
a. Remove engine wiring harness at the J1 port.
b. Remove control wiring harness at the J2 port.
Figure 1. Remove 7.5 Amp Fuse
c. Remove stepper motor wiring harness at the J3
4. Turn off fuel supply to the generator and remove the flex-
line from the fuel regulator.
port. See Figure 4.
5. Remove utility power from the generator.
6. Remove front door.
7. Remove battery from the generator.
FRONT ENGINE ACCESS:
1. Remove Controls Cover: Using a Torx T-27 socket
remove two bolts and ground washer from the controls
cover. Remove the controls cover. See Figure 2.
Figure 4.
Figure 2.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
4. Remove Stator Wires: Remove all wires from the voltage
regulator, remove the neutral and ground wires from
landing lugs, and remove N1 & N2 wires from main bea-
kers. See Figure 5.
5. Remove Control Wires: Remove Wires #N1,#N2, #0,
#15B, #23, GFCI Outlet, and unit status lights from the
control box. See Figure 6.
Figure 7.
Figure 5.
Figure 8.
7. Remove engine intake baffle: Using a 10mm socket
remove the two bolts from the engine intake baffle. Pull
baffle toward you carefully, there are tabs holding the
backside of the baffle to the divider panel. See Figure 9.
Figure 6.
6. Remove controller mounting box: Using an 8mm socket
remove the two screws from the rear of the control-
ler mounting box. See Figure 7. Using a 10mm socket
remove the two bolts from under the front of the control-
ler mounting box. See Figure 8.
Figure 9.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
8. Loosen side panel: Using a 10mm socket remove the
two bolts from the base of the enclosure side panel. See
Figure 10.
10.Remove fuel regulator: Remove the two fuel hoses at
the top of the regulator. Using a 10mm socket remove
one 10mm bolt from the base of the plenum and one
10mm bolt from the base of the fuel regulator. Flex
the enclosure side out to allow for room to remove the
regulator assemble. See Figure 12.
9. Unbolt enclosure side panel mounting bracket: Using a
10mm socket remove the two bolts from the enclosure
side panel mounting bracket. See Figure 11.
Figure 12.
Figure 10.
11.Remove engine divider panel: Using a 10mm socket
remove the rear 10mm bolt from the base of the
enclosure. See Figure 13. Remove the front 10mm
bolt from the base of the enclosure. See Figure 14.
Figure 11.
Figure 13.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
Figure 16.
13.Unbolt Oil Cooler: Using a 10mm socket remove the two
10mm bolts from the front of the oil cooler. See Figure
17. Remove the two 10mm bolts from the rear of the oil
cooler. See Figure 18.
Figure 14.
12.Remove Air Box: Using a 6mm allen wrench remove the
four intake manifold socket head cap screws. See Figure
15. Using a 4mm allen wrench, remove the four airbox
allen head shoulder bolts. While removing the airbox
remove the four rubber washers. See Figure 16.
Figure 17.
Figure 15.
Figure 18.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
14.Remove Blower Housing: Using a 4mm allen wrench
remove one button head cap screw from top of blower
housing. Using a 10mm socket remove one 10mm bolt
from the top of the blower housing. See Figure 19. Using
a 10mm socket remove four 10mm bolts from the right-
side of the blower housing, (see Figure 20) and four
10mm bolts from the left-side of the blower housing. See
Figure 21. Remove blower housing.
Figure 21.
major diSaSSemBly
SAFETY:
1. Set the AUTO-OFF-MANUAL switch to OFF.
2. Remove the 7.5 amp main fuse. See Figure 22.
3. Remove the N1 and N2 fuse from the transfer switch.
Figure 19.
Figure 22. Remove 7.5 Amp Fuse
4. Turn off fuel supply to the generator and remove the flex-
line from the fuel regulator.
5. Remove utility power from the generator.
6. Remove front door.
Figure 20.
7. Remove battery from the generator.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
STATOR/ROTOR/ENGINE REMOVAL:
1. Remove Top Exhaust Enclosure Covers: Using a 10mm
socket, remove the nine bolts from the exhaust top cov-
ers. Remove covers. See Figure 23.
Figure 25.
4. Remove Exhaust Flex Pipe: Using a ½” socket remove
the front and rear muffler clamp. Slide exhaust flex
toward engine completely exposing the muffler flange.
See Figure 26.
Figure 23.
2. Remove Side Exhaust Enclosure Cover: Using a 10mm
socket, remove the five bolts from the exhaust side
cover. Remove side covers. See Figure 24.
Figure 26.
5. Remove Muffler and Tail Pipe: Using a ½” socket remove
the muffler clamp and tail pipe. Using a 10mm socket,
remove the four bolts from the muffler mounts and
remove muffler. See Figure 27.
Figure 24.
3. Remove Exhaust Flex Cover: Using a 10mm socket,
remove the two bolts from the exhaust flex pipe cover.
Remove the cover. See Figure 25.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
Figure 27.
Figure 29.
6. Remove Left-side enclosure: Using a 10mm ratchet
wrench remove the horizontal 10mm bolt that connects
the side panel to the back panel. Using a 10mm socket,
remove three bolts from the base of the enclosure. See
Figure 28. Using a 10mm socket and wrench remove
the top hinge bolt and loosen the bottom bolt. See
Figure 29. Holding the roof, remove the bottom hinge
bolt, remove the side panel by sliding it forward then re-
install the hinge bolt.
7. Remove Fan Housing Cover: Using a 10mm socket
remove four bolts from the fan housing cover. Remove
the fan housing cover. See Figure 30.
Figure 30.
8. Remove Rotor Bolt: Using a 9/16” socket, remove rotor
bolt. Figure 31.
Figure 28.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
10.Remove Brushes: Using a 7mm socket remove brushes.
See Figure 33.
Figure 31.
9. Remove Fan: Attach a steering wheel puller to the fan
using two M8 x 1.25 bolts. Remove the fan from the
rotor. Figure 32.
Figure 33.
11.Remove Alternator Divider Panel: Using a 10mm socket
remove two bottom base bolts. Using a T27 torx driver
remove one top rear bolt. Remove the panel. See Figure 34.
Figure 32.
Figure 34.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
12.Remove Brush Wires: Using a side cutters remove the
tie wraps securing the brush wires to the outside of sta-
tor. See Figure 35.
Figure 37.
15.Alternator Air Intake Bellows Removal: Remove alterna-
tor intake bellows. See Figure 38.
Figure 35.
13.Remove Controls Cover: Using a Torx T-27 socket
remove two bolts and ground washer from the controls
cover. Remove the controls cover. See Figure 36.
Figure 38.
16.Rear Bearing Carrier Removal: Using a 13mm socket,
remove the two nuts from the alternator mounting brack-
et rubber mounts. Lift the back end of the alternator up
and place a 2”x 4” piece of wood under the engine. See
Figure 40. Using a 13mm socket, remove the four stator
hold down bolts. See Figure 41. Using a small rubber
mallet remove the rear bearing carrier. See Figure 42.
Remove stator. See Figure 43.
Figure 36.
14.Remove Stator Wires: Remove all wires from the voltage
regulator, remove the common and ground wires from
landing lugs, and remove N1 & N2 wires from main bea-
kers. See Figure 37.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
17.Rotor Removal: Cut 2.5 inches from the rotor bolt. Slot
the end of the bolt to suit a flat blade screwdriver. Slide
the rotor bolt back through the rotor and use a screw-
driver to screw it into the crankshaft. Use a 3” M12x1.75
bolt to screw into rotor. Apply torque to the 3” M12x1.75
bolt until taper breaks. See Figure 43.
Figure 39.
Figure 42.
11.Remove Engine: Using a 13mm socket, remove the two
engine mount nuts with ground wires. See Figure 43.
Figure 40.
Figure 43.
Figure 41.
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sEctioN 6.1
maJor DisassEmBlY
DISASSEMBLY
Part 6
12.Remove Engine: Using proper lifting equipment remove
the engine. See Figure 44.
torque requirementS
(unleSS otherWiSe SpeciFied)
STATOR BOLTS ................................................ 6 ft-lbs ( +1 / -0 )
ROTOR BOLT ................................................................ 30 ft-lbs
ENGINE ADAPTOR ....................................................... 25 ft-lbs
EXHAUST MANIFOLD .................................................. 18 ft-lbs
M5-0.8 TAPTITE SCREW INTO ALUMINUM .......... 25-50 in-lbs
M5-0.8 TAPTITE SCREW INTO PIERCED HOLE ... 25-50 in-lbs
M6-1.0 TAPTITE SCREW INTO ALUMINUM .......... 50-96 in-lbs
M6-1.0 TAPTITE SCREW INTO PIERCED HOLE ... 50-96 in-lbs
M6-1.0 TAPTITE SCREW INTO WELDNUT ............ 50-96 in-lbs
M8-1.25 TAPTITE SCREW INTO ALUMINUM ......... 12-18 ft-lbs
M8-1.25 TAPTITE SCREW INTO PIERCED HOLE ... 12-18 ft-lbs
M6-1.0 NYLOK NUT ONTO WELD STUD .............. 16-65 in-lbs
M6-1.0 NYLOK NUT ONTO HINGE STUD ............. 30-36 in-lbs
note: torques are dynamic values with ±10% toler-
ance unless otherwise noted.
Figure 44.
Page 162
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taBlE of coNtENts
titlE
DWG#
0G7945
0G8511
0G7946
0G8512
0G7947
0G8513
0G7948
0G8514
0G8186
0G8515
0G7958
WiriNG DiaGram, 8 KW HsB
scHEmatic, 8 KW HsB
WiriNG DiaGram, 10 KW HsB
scHEmatic, 10 KW HsB
Part 7
ElEctrical
Data
WiriNG DiaGram, 14 KW HsB
scHEmatic, 14 KW HsB
WiriNG DiaGram, 17 KW HsB
scHEmatic, 17 KW HsB
WiriNG DiaGram, 20 KW HsB
scHEmatic, 20 KW HsB
WiriNG DiaGram
9/10/12/16 circuit traNsfEr sWitcH
air-cooled, automatic
standby Generators
0G7959
scHEmatic
9/10/12/16 circuit traNsfEr sWitcH
Page 163
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ELECTRICAL DATA
WiriNG DiaGram, 8 KW HomE staNDBY
Part 7
DraWiNG #0G7945
CONTROL PANEL
ENGINE COMPARTMENT
CAPACITOR
6
2
10
22
10
33
44
11
STATOR
10
10
SP1
IM1
18
N2
N1
1
2
85
1
85
86
13
18
MAIN
CONTROLLER
2
3
4
86
J1
HTO
LOP
0
J2
0
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
15B
23
1
RED
56
2
0
CHOKE
SOLENOID
BLK
13
0
14
0
0
56
16
SM
SC
56
56
0
0
0
0
0
0
0
0
PANEL GND
6
6
13
ENGINE
GND
FRAME
GND
0
0
Page 164
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ELECTRICAL DATA
Part 7
WiriNG DiaGram, 8 KW HomE staNDBY
DraWiNG #0G7945
CUSTOMER CONNECT AREA
240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR
CB
44
11
LEGEND
CB - CIRCUIT BREAKER, MAIN OUTPUT
GND - GROUND
HTO - HIGH TEMPERATURE SWITCH
IM1 - IGNITON MODULE
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SM - STARTER MOTOR
SP1 - SPARK PLUG
- SPLICE
14
14
FUEL
SOLENOID
14
N1
00
0
BATTERY
WARMER
14
OPTIONAL
BLACK
RED
0
13
NOTE: ALL WIRES 18 AWG
300V UL LISTED UNLESS
SHOWN OTHERWISE
+ -
12V
BATTERY
0
0
AWG SIZE
12
CUSTOMER SUPPLIED
Page 165
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ELECTRICAL DATA
scHEmatic, 8 KW HomE staNDBY
Part 7
DraWiNG #0G8511
EXCITATION WINDING
CB
2
6
CAPACITOR
44
11
240 VAC
GENERATOR
OUTPUT
POWER
WINDING
44
NEUTRAL
33
33
STATOR
22
22
00
11
POWER
WINDING
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N2
N1
N1
IM
18
SP
1
85
86
13
18
2
J1
CONTROLLER
PRINTED CIRCUIT BOARD
3
4
J2
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
85
86
14
23
15B 0 56
HTO
LOP
56
56
0
0
GROUND
0
CS
0
SC
FS
0
15B
23
+ BATTERY
TRANSFER
0
0
13
0
13
BATTERY
12V
SC
16
0
SM
LEGEND
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SM - STARTER MOTOR
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM - IGNITION MODULE
SP - SPARK PLUG
Page 166
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ELECTRICAL DATA
Part 7
scHEmatic, 8 KW HomE staNDBY
DraWiNG #0G8511
PAGE LEFT PLANK INTENTIONALLY
Page 167
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ELECTRICAL DATA
WiriNG DiaGram, 10 KW HomE staNDBY
Part 7
DraWiNG #0G7946
CONTROL PANEL
ENGINE COMPARTMENT
CAPACITOR
6
2
10
22
10
33
STATOR
44
10
10
11
N.C. N.C.
IC
IC
SP1
SP2
0
4
IM1
IM2
18
N2
N1
1
2
85
1
85
86
13
18
MAIN
CONTROLLER
2
3
4
86
J1
HTO
LOP
0
J3
0
J2
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
15B
23
820
817
818
819
1
RED
14
14
2
90
90
CHOKE
SOLENOID
0
0
BLK
0
GOVERNOR
ACTUATOR
0
14
14
0
0
13
16
13
SCR
SM
A
B
0
0 0
13
SC
16
0
0
56
0
0
16
13
0
16
0
PANEL GND
6
6
ENGINE
GND
FRAME
GND
0
Page 168
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ELECTRICAL DATA
Part 7
WiriNG DiaGram, 10 KW HomE staNDBY
DraWiNG #0G7946
CUSTOMER CONNECT AREA
240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR
CB
44
11
LEGEND
CB - CIRCUIT BREAKER, MAIN OUTPUT
GND - GROUND
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITON MODULE
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
SP_ - SPARK PLUG
- SPLICE
- DISCONNECT SPLICE
IC
LED BOARD
20
20
20
20
1
820
L1
2
3
4
817
818
819
L3
L1: GREEN = SYSTEM READY
L3: RED = ALARM
14
14
FUEL
SOLENOID
14
FUEL
SOLENOID
14
0
N1
00
0
BATTERY
WARMER
14
OPTIONAL
BLACK
RED
0
13
NOTE: ALL WIRES 18 AWG
300V UL LISTED UNLESS
SHOWN OTHERWISE
+ -
12V
BATTERY
0
0
AWG SIZE
12
CUSTOMER SUPPLIED
Page 169
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ELECTRICAL DATA
scHEmatic, 10 KW HomE staNDBY
Part 7
DraWiNG #0G8512
EXCITATION WINDING
2
6
CB
CAPACITOR
44
11
240 VAC
GENERATOR
OUTPUT
POWER
WINDING
44
NEUTRAL
33
33
STATOR
22
22
00
11
POWER
WINDING
N1
240 VAC
UTILITY
INPUT
IM2
IM1
18
18
OPTIONAL
BATTERY WARMER
SP2
SP1
N2
N2
N1
N1
LED BOARD
1
85
86
13
18
2
J1
CONTROLLER
PRINTED CIRCUIT BOARD
3
4
1 2 3 4
J3
J2
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
85
86
0
14
23
15B 0 56
0
GOVERNOR
ACTUATOR
HTO
0
LOP
820
14
0
817
818
14
FS
SCR
CS
90
FS
0
819
0
GROUND
0
15B
23
0
+ BATTERY
TRANSFER
0
13
13
0
13
BATTERY
12V
13
SCR
0
16
SC
SM
LEGEND
CB - CIRCUIT BREAKER, MAIN OUTPUT LOP - LOW OIL PRESSURE SWITCH
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
SP_ - SPARK PLUG
Page 170
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ELECTRICAL DATA
Part 7
scHEmatic, 10 KW HomE staNDBY
DraWiNG #0G8512
PAGE LEFT BLANK INTENTIONALLY
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ELECTRICAL DATA
WiriNG DiaGram, 14 KW HomE staNDBY
Part 7
DraWiNG #0G7947
CONTROL PANEL
ENGINE COMPARTMENT
2
2
6
6
0
4
VOLTAGE
REGULATOR
0
4
22
11
22
11
11
IC
IC
22
10
6
22
33
2
10
STATOR
CLOSEST TO BEARING
10
44
11
BA
10
4
0
4
0
0
SP1
IM1
18
N2
N1
1
2
SP2
IM2
85
1
85
86
13
18
MAIN
CONTROLLER
86
2
J1
3
4
HTO
LOP
0
J3
0
J2
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
4
15B
23
820
817
818
819
1
RED
14
14
90
2
90
CHOKE
SOLENOID
0
0
BLK
0
GOVERNOR
ACTUATOR
0
14
14
0
0
13
16
13
SCR
A
SM
B
0
0
13
0
SC
16
0
0
56
0
0
16
13
0
16
PANEL GND
6
6
ENGINE
GND
FRAME
GND
0
0
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ELECTRICAL DATA
Part 7
WiriNG DiaGram, 14 KW HomE staNDBY
DraWiNG #0G7947
CUSTOMER CONNECT AREA
240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR
CB
44
11
LEGEND
BA - BRUSH ASSEMBLY
CB - CIRCUIT BREAKER, MAIN OUTPUT
GND - GROUND
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITON MODULE
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
SP_ - SPARK PLUG
- SPLICE
- DISCONNECT SPLICE
LED BOARD
IC
20
20
20
20
1
820
L1
2
3
4
817
818
L3
L1: GREEN = SYSTEM READY
L3: RED = ALARM
819
14
14
FUEL
SOLENOID
14
N1
00
0
BATTERY
WARMER
14
OPTIONAL
BLACK
RED
0
13
NOTE: ALL WIRES 18 AWG
300V UL LISTED UNLESS
SHOWN OTHERWISE
+ -
12V
BATTERY
0
0
AWG SIZE
12
CUSTOMER SUPPLIED
Page 173
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ELECTRICAL DATA
scHEmatic, 14 KW HomE staNDBY
Part 7
DraWiNG #0G8513
2
6
2
6
0
4
0
4
VOLTAGE
REGULATOR
0
4
22
11
22
11
POWER
WINDING
44
33
STATOR
6
2
22
11
POWER
WINDING
BA
0
4
0
4
IM2
18
SP2
IM1
18
SP1
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
0
13
13
BATTERY
12V
SCR
16
SC
SM
Page 174
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ELECTRICAL DATA
Part 7
scHEmatic, 14 KW HomE staNDBY
DraWiNG #0G8513
CB
44
240 VAC
GENERATOR
OUTPUT
11
NEUTRAL
33
22
00
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N1
N1 N2
LED BOARD
1
85
86
13
18
2
J1
820
1
2
3
4
CONTROLLER
PRINTED CIRCUIT BOARD
3
L1
817
818
819
4
L2
GOVERNOR
ACTUATOR
J3
J2
1 2 3 4
0 14
5
6 7 8 9 10 1112 1314 15 16 1718
4
23
15B 0 56
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
0
LEGEND
BA - BRUSH ASSEMBLY
CB - CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
Page 175
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ELECTRICAL DATA
WiriNG DiaGram, 17 KW HomE staNDBY
Part 7
DraWiNG #0G7948
CONTROL PANEL
ENGINE COMPARTMENT
2
2
6
6
0
4
VOLTAGE
REGULATOR
0
4
22
11
22
11
11
IC
IC
22
10
6
22
33
2
10
STATOR
CLOSEST TO BEARING
10
44
11
BA
10
4
0
4
0
0
SP1
IM1
18
N2
N1
1
2
SP2
IM2
85
1
85
MAIN
CONTROLLER
2
86
86
13
18
J1
3
4
HTO
LOP
0
J3
0
J2
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
4
15B
23
820
817
818
819
1
RED
14
14
90
2
90
CHOKE
SOLENOID
0 0
0
BLK
0
GOVERNOR
ACTUATOR
0
14
14
0
0
13
16
13
SCR
A
SM
B
0
0
13
0
SC
16
0
0
56
0
0
16
13
0
16
PANEL GND
6
6
ENGINE
GND
FRAME
GND
0
0
Page 176
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ELECTRICAL DATA
Part 7
WiriNG DiaGram, 17 KW HomE staNDBY
DraWiNG #0G7948
CUSTOMER CONNECT AREA
240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR
CB
11C
00
14
44
14
11
14
0
0
11C
5
4
14
00
00
3
1
2
LED BOARD
120V/15A
DUPLEX
20
20
20
20
1
820
L1
2
3
4
817
818
L3
L1: GREEN = SYSTEM READY
L2: YELLOW = MAINTENANCE REQ'D
L3: RED = ALARM
LEGEND
BA - BRUSH ASSEMBLY
L2
819
CB - CIRCUIT BREAKER, MAIN OUTPUT
GND - GROUND
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITON MODULE
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
SP_ - SPARK PLUG
- SPLICE
- DISCONNECT SPLICE
IC
14
14
FUEL
SOLENOID
14
N1
00
0
14
BLACK
BATTERY
WARMER
RED
0
13
OPTIONAL
+ -
12V
BATTERY
0
0
NOTE: ALL WIRES 18 AWG
300V UL LISTED UNLESS
SHOWN OTHERWISE
CUSTOMER SUPPLIED
AWG SIZE
12
Page 177
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ELECTRICAL DATA
scHEmatic, 17 KW HomE staNDBY
Part 7
DraWiNG #0G8514
2
6
2
6
0
4
0
4
VOLTAGE
REGULATOR
0
4
22
11
22
11
POWER
WINDING
44
33
STATOR
6
2
22
11
POWER
WINDING
BA
0
4
IM2
IM1
18
18
SP2
SP1
0
4
18
85
86
13
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
13
13
BATTERY
12V
SCR
16
0
SC
13
0
SM
Page 178
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ELECTRICAL DATA
Part 7
scHEmatic, 17 KW HomE staNDBY
DraWiNG #0G8514
CB1
44
240 VAC
GENERATOR
OUTPUT
11
CB2
33
22
00
NEUTRAL
00
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N2
N1
N1
11C
120 VAC
ACCESSORY
POWER
1
00
0
2
J1
CONTROLLER
PRINTED CIRCUIT BOARD
OUTPUT
3
4
GOVERNOR
ACTUATOR
J3
J2
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
LED BOARD
4
820
1
2
3
4
14
23
15B 0 56
L1
L2
L3
817
818
819
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
0
LEGEND
BA - BRUSH ASSEMBLY
CB_- CIRCUIT BREAKER, MAIN OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
SP_ - SPARK PLUG
Page 179
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ELECTRICAL DATA
WiriNG DiaGram, 20 KW HomE staNDBY
Part 7
DraWiNG #0G8186
CONTROL PANEL
ENGINE COMPARTMENT
2
2
6
6
0
4
VOLTAGE
REGULATOR
0
4
22
11
22
11
11
IC
IC
22
8
6
22
33
2
8
STATOR
CLOSEST TO BEARING
8
44
11
BA
8
4
0
4
0
0
SP1
IM1
18
N2
N1
1
2
SP2
IM2
85
1
85
MAIN
CONTROLLER
86
86
13
18
2
J1
3
4
HTO
LOP
0
J3
0
J2
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
4
15B
23
820
817
818
819
1
RED
14
14
90
2
90
CHOKE
SOLENOID
0
BLK
0
14
GOVERNOR
ACTUATOR
0
14
0
0
13
16
13
SCR
A
SM
B
0
0
13
0
SC
16
0
0
56
0
0
16
13
0
16
PANEL GND
6
6
ENGINE
GND
FRAME
GND
0
0
Page 180
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ELECTRICAL DATA
Part 7
WiriNG DiaGram, 20 KW HomE staNDBY
DraWiNG #0G8186
CUSTOMER CONNECT AREA
240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR
CB
11C
00
14
44
11
14
14
0
0
11C
5
14
4
00
00
3
1
2
LED BOARD
120V/15A
DUPLEX
20
20
20
20
1
820
L1
2
3
4
817
818
L3
L1: GREEN = SYSTEM READY
L2: YELLOW = MAINTENANCE REQ'D
L3: RED = ALARM
LEGEND
L2
819
BA - BRUSH ASSEMBLY
CB - CIRCUIT BREAKER, MAIN OUTPUT
GND - GROUND
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITON MODULE
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
SP_ - SPARK PLUG
- SPLICE
- DISCONNECT SPLICE
IC
14
14
FUEL
SOLENOID
14
0
N1
00
14
BLACK
RED
0
13
BATTERY
WARMER
OPTIONAL
+ -
12V
BATTERY
0
0
NOTE: ALL WIRES 18 AWG
300V UL LISTED UNLESS
SHOWN OTHERWISE
CUSTOMER SUPPLIED
AWG SIZE
12
Page 181
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ELECTRICAL DATA
scHEmatic, 20 KW HomE staNDBY
Part 7
DraWiNG #0G8515
2
6
2
6
0
4
0
4
VOLTAGE
REGULATOR
22
11
22
11
POWER
WINDING
44
33
STATOR
22
6
2
11
POWER
WINDING
BA
0
4
IM2
IM1
18
18
SP2
SP1
0
4
18
85
86
13
85
86
HTO
LOP
56
0
0
SCR
0
0
13
13
13
13
BATTERY
12V
SCR
16
0
SC
SM
13
0
Page 182
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ELECTRICAL DATA
Part 7
scHEmatic, 20 KW HomE staNDBY
DraWiNG #0G8515
CB1
44
240 VAC
GENERATOR
OUTPUT
11
CB2
33
22
00
NEUTRAL
00
N1
240 VAC
UTILITY
INPUT
OPTIONAL
BATTERY WARMER
N2
N2
N1
N1
11C
120 VAC
ACCESSORY
POWER
OUTPUT
1
00
0
2
J1
CONTROLLER
PRINTED CIRCUIT BOARD
3
4
GOVERNOR
ACTUATOR
J3
J2
1 2 3 4
5
6 7 8 9 10 1112 1314 15 16 1718
LED BOARD
4
820
1
2
3
4
14
23
15B 0 56
L1
L2
L3
817
818
819
820
817
818
14
14
FS
CS
90
819
GROUND
0
0
15B
23
+ BATTERY
TRANSFER
0
0
LEGEND
BA - BRUSCH ASSEMBLY
CB_ - CIRCUIT BREAKER OUTPUT
CS - CHOKE SOLENOID
FS - FUEL SOLENOID
HTO - HIGH TEMPERATURE SWITCH
IM_ - IGNITION MODULE
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
SCR - STARTER CONTROL RELAY
SM - STARTER MOTOR
SP_ - SPARK PLUG
Page 183
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WiriNG DiaGram, HomE staNDBY
traNsfEr sWitcH, 9/10/12/16 circuit
ELECTRICAL DATA
Part 7
DraWiNG #0G7958
WHT
WHT
RED
BLK
BLK
RED
BLK
WHT
RED
WHT
N
ALL CIRCUIT
LC
GROUNDED
CONDUCTORS NOT
SHOWN FOR
CLARITY
B
A
16 CIRCUIT LOAD CENTER
14 CIRCUIT LOAD CENTER
12 CIRCUIT LOAD CENTER
10 CIRCUIT LOAD CENTER
8 CIRCUIT LOAD CENTER
Page 184
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WiriNG DiaGram, HomE staNDBY
traNsfEr sWitcH, 9/10/12/16 circuit
ELECTRICAL DATA
Part 7
DraWiNG #0G7958
RED
RED
BLK
BLK
RED
BLK
N2A
N1A
126
126
GRN
GRN
A
N2A
N2A
N1A
TR1
N2A
1 3
4 6
7 9
1
2
C1
126
A
N1
N2
205
E1
A B
15B
23
N1A
SW2
SW3
E1 BLK
RED
N1A
N2A
N1A
N2A
SW1
205
BLK
RED
BLK
RED
E1
T1
E2
T2
205
2
B
C2
1
N1AN2A
E2 B
205
E1
E2
BC
A
A
A
BLK
RED
BLK
RED
E1
23
15B
F1 F2 F3
B
B
B
-
BLK
WIRE
+
RED
WIRE
N1 N2
T1
T1
15B
0
0D4698-T
1 2 3
TB1
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
TR1-TRANSFER RELAY
Page 185
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scHEmatic, HomE staNDBY
traNsfEr sWitcH, 9/10/12/16 circuit
ELECTRICAL DATA
Part 7
DraWiNG #0G7959
0
0
0
15B
E1
N1A
CONTROL
TRANSFER
15B
15B
23
15B
23
A
23
7 7 9 9
E1
N1A
TR1
TS TO
GENERATOR
CONTROL PANEL
1 4 3 6
B
23
F2
N2
N1
E1
E2
N2
UTILITY
SENSING
240VAC
OUTPUT
126
205
N2A
F1
N1A
N1A
N1
-
+
N1A
BLK
WIRE
RED
WIRE
E1
BLACK
RED
TO GENERATOR
OUTPUT
BC
E1
NEUTRAL (WHITE)
GROUND (GREEN)
E2
NEUTRAL
CONNECTION
INSIDE
SWITCH
B
GROUND (GREEN)
NEUTRAL (WHITE)
N2A
N1A
240VAC TO
MAIN DISTRIBUTION
PANEL
RED (MAIN 2)
205
B
126
N2A
NO
BLACK (MAIN 1)
E1
NO
NC
NC
CIRCUIT 14
CIRCUIT 13
CIRCUIT 10
CIRCUIT 9
CIRCUIT 6
CIRCUIT 5
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 4
CIRCUIT 7
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
E2
SW3
SW2
COM
E2
COM
B
VR1
C1
VR2
C2
N2A
A
T1T1T2
SW1
N2A
B E2
F3
T1
T1
T2
B
E2
LEGEND
BC-BATTERY CHARGER
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
LC
TR1-TRANSFER RELAY
Page 186
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Page 187
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Page 188
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Generac Power Systems, Inc.
Highway 59 & Hillside Rd.
P.O. Box 8
Waukesha, WI 53187
1-888-GENERAC
MyGenerac.com
©2008 Generac Power Systems, Inc. All rights reserved.
Specifications are subject to change without notice.
Part No. 0G9266 rev. A / Printed in USA 09.08
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