Page 5 - the stronger the magnetic field around the conductor.; ELECTROMAGNETIC INDUCTION; Figure 1-3. – A Simple Revolving Field Generator
S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S MAGNETISM Magnetism can be used to produce electricity andelectricity can be used to produce magnetism.Much about magnetism cannot be explained by ourpresent knowledge. However, there are certain pat-terns of be...
Page 6 - A SIMPLE AC GENERATOR; The 2-pole ROTOR must be turned at 3600 rpm to produce an; Figure 1-5. – Alternating Current Sine Wave; A MORE SOPHISTICATED AC GENERATOR; Figure 1-6. – A More Sophisticated Generator
S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S A SIMPLE AC GENERATOR Figure 1-4 shows a very simple AC Generator. Thegenerator consists of a rotating magnetic field calleda ROTOR and a stationary coil of wire called a STA-TOR. The ROTOR is a permanent magnet...
Page 7 - Figure 1-7. – Generator Operating Diagram
S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S NOTE: AC output frequency at 3720 rpm will beabout 62 Hertz. The “No-Load” is set slightly highto prevent excessive rpm, frequency and voltagedroop under heavy electrical loading. Generator operation may be desc...
Page 9 - Figure 1-8. – Connection for 120 Volts Only
S Se ec cttiio on n 1 1 G GE EN NE ER RA AT TO OR R F FU UN ND DA AM ME EN NT TA AL LS S Figure 1-8. – Connection for 120 Volts Only RECONNECTION FOR DUAL VOLTAGE OUTPUT:When connected for dual voltage output, Stator out-put leads 11P and 44 form two “hot” leads (T1- Redand T3- Black). The junction ...
Page 12 - tion winding AC output to the regulator.; CRANKCASE BREATHER
S Se ec cttiio on n 2 2 M MA AJ JO OR R G GE EN NE ER RA AT TO OR R C CO OM MP PO ON NE EN NT TS S Rotor will be lost. The unit’s AC output voltage willthen drop to a value commensurate with the Rotor'sresidual magnetism (about 7-12 VAC). Figure 2-6. – Excitation Circuit Breaker VOLTAGE REGULATOR:Si...
Page 13 - CONTROL PANEL COMPONENT IDENTIFICATION
S Se ec cttiio on n 2 2 M MA AJ JO OR R G GE EN NE ER RA AT TO OR R C CO OM MP PO ON NE EN NT TS S elbow. The breather chamber contains a removableoil vapor collector. Oil vapor is condensed on the col-lector material and drains back into the crankcase,which minimizes the amount of oil vapor enterin...
Page 15 - STATOR INSULATION RESISTANCE
S Se ec cttiio on n 3 3 IIN NS SU UL LA AT TIIO ON N R RE ES SIIS ST TA AN NC CE E T TE ES ST TS S C CA AU UT TIIO ON N!!:: S So om me e g ge en ne erra atto orrs s m ma ay y u us se e e ep po ox xy y o orr p po olly ye es stte err b ba as se e w wiin nd diin ng g v va arrn niis sh he es s.. U Us se...
Page 16 - TESTING ROTOR INSULATION; Disconnect wires from the Rotor brushes or remove the brush; THE MEGOHMMETER
S Se ec cttiio on n 3 3 IIN NS SU UL LA AT TIIO ON N R RE ES SIIS ST TA AN NC CE E T TE ES ST TS S TEST BETWEEN PARALLEL WINDINGS:Connect the tester leads across Stator leads No. 11Pand 33. Apply a voltage of 1500 volts. If an insulationbreakdown is indicated, clean and dry the Stator.Then, repeat t...
Page 18 - An open condition in any Stator or Rotor winding.
S Se ec cttiio on n 4 4 M ME EA AS SU UR RIIN NG G E EL LE EC CT TR RIIC CIIT TY Y MEASURING AC FREQUENCY The generator's AC output frequency is proportionalto Rotor speed. Generators equipped with a 2-poleRotor must operate at 3600 rpm to supply a frequen-cy of 60 Hertz. Units with 4-pole Rotor mus...
Page 19 - ELECTRICAL UNITS; OHMS
S Se ec cttiio on n 4 4 M ME EA AS SU UR RIIN NG G E EL LE EC CT TR RIIC CIIT TY Y ELECTRICAL UNITS AMPERE:The rate of electron flow in a circuit is represented bythe AMPERE. The ampere is the number of electronsf l o w i n g p a s t a g i v e n p o i n t a t a g i v e n t i m e . O n eAMPERE is equ...
Page 26 - ENGINE CONTROLLER CIRCUIT BOARD; Wire 14 connects to Terminal J2. During cranking and running,; Figure 5-3. – Engine Controller Circuit Board; BATTERY
S Se ec cttiio on n 5 5 E EN NG GIIN NE E D DC C C CO ON NT TR RO OL L S SY YS ST TE EM M ENGINE CONTROLLER CIRCUIT BOARD GENERAL:The engine controller board is responsible for crank-ing, startup, running and shutdown operations. Theboard interconnects with other components of the DCcontrol system t...
Page 27 - FUEL PRIMER SWITCH; Wire No. 17 from the Engine Controller circuit board. This Is
S Se ec cttiio on n 5 5 E EN NG GIIN NE E D DC C C CO ON NT TR RO OL L S SY YS ST TE EM M The following chart applies: C CA AB BL LE E L LE EN NG GT TH H ((IIN N F FE EE ET T)) R RE EC CO OM MM ME EN ND DE ED D C CA AB BL LE E S SIIZ ZE E 0-10 No. 2 11-15 No. 0 16-20 No. 000 EFFECTS OF TEMPERATURE:B...
Page 28 - STARTER CONTACTOR RELAY
S Se ec cttiio on n 5 5 E EN NG GIIN NE E D DC C C CO ON NT TR RO OL L S SY YS ST TE EM M age is delivered to the Starter ContactorRelay via Wire 56.The Starter ContactorRelay energizes, its contacts close and theStarter Contactor is energized via wire 16.Its contacts close and the engine cranks. b....
Page 29 - INTRODUCTION
S Se ec cttiio on n 6 6 T TR RO OU UB BL LE ES SH HO OO OT TIIN NG G F FL LO OW WC CH HA AR RT TS S The “Flow Charts” in this section may be used in con-junction with the “Diagnostic Tests” of Section 7.Numbered tests in the Flow Charts correspond toidentically numbered tests of Section 7. Problems ...
Page 41 - Figure 7-2. – Excitation “DPE” Circuit Breaker; AMP DRAW
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S GOVERNOR ADJUSTMENT 1. Loosen the GOVERNOR CLAMP BOLT. 2. Push Spring end of GOVERNOR LEVER clockwise to wide open throttle position of lever. a. Hold the GOVERNOR LEVER at wide open throttle and, with a pair of pliers, rotate theG...
Page 42 - TEST 5- WIRE CONTINUITY
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S PROCEDURE: 1. Disconnect Wire 4 from the Voltage Regulator (VR). (Third ter- minal from the top of VR). 2. Connect a jumper wire to Wire 4 and to the 12 volt fused battery positive supply Wire 15 (Wire 15 located at fuse (F1) holde...
Page 44 - EXCITATION “DPE” WINDING RESISTANCE; WINDINGS; AC POWER WINDING RESISTANCE
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S PROCEDURE: 1. Disconnect Wire 2 from the Excitation Circuit Breaker. 2. Disconnect Wire 6 from the Voltage Regulator. 3. Set a VOM to its “Rx1” scale and zero the meter. 4. Connect the VOM test leads across the terminal ends of Wir...
Page 45 - TEST 9- CHECK BRUSH LEADS
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S 9. Connect the meter test leads across Stator lead 11P and frame ground. “Infinity” should be read. 10. Connect the meter test leads across Stator lead 33 and frame ground. The reading should be “Infinity”. 11. Connect the meter te...
Page 46 - a. If slip rings appear dull or tarnished they may be; TEST 11- CHECK ROTOR ASSEMBLY; Set a VOM to its “Rx1” scale and zero the meter.; ROTOR RESISTANCE; Set the VOM to its “Rx1 K” or “Rx10,000” scale and zero the; TEST 12 - CHECK MAIN CIRCUIT BREAKER
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S 7. Inspect the slip rings. a. If slip rings appear dull or tarnished they may be cleaned and polished with fine sandpaper. DONOT USE ANY METALLIC GRIT TO CLEANSLIP RINGS. (A 400 grit wet sandpaper is rec-ommended). b. After cleanin...
Page 48 - BATTERY CHARGE WINDING RESISTANCE
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S Short to Ground: 4. Set the VOM to measure resistance. Connect the positive (+) test lead to the case housing of the BCR. Connect the negative(-) test lead to an outer terminal. “Infinity” should be measured.Now connect the negativ...
Page 49 - Figure 7-12. – Harness End of Connector 2
Page 47 S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S 3. In Step 7, if Wire 0 reads “Continuity”, but resistor does not measure 1 ohm, replace the Battery Charge Resistor. 4. I f a l l o f t h e S t e p s i n t h i s t e s t p a s s , p e r f o r m “ I n s u l a t i o n Resist...
Page 50 - TEST 20- CHECK FUEL PUMP
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S Figure 7-13. – The LPG Fuel Solenoid (FS) RESULTS: 1. If battery voltage is not indicated in Step 2, check Wire 15 between the Primer Switch and the 7.5 amp fuse for an open condition. 2. If battery voltage is indicated in Step 2 b...
Page 54 - TEST 26A - CHECK STARTER CONTACTOR; STEP 1 TEST POINT; TEST 27 - CHECK STARTER MOTOR
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S RESULTS: 1. If “Continuity” is not measured in Step 1, repair or replace Wire 0 between the Starter Contactor Relay and the ground terminal. 2. If “Continuity” was not measured in Step 2 when the Start-Stop switch was activated to ...
Page 55 - Figure 7-22. – Check Pinion Gear Operation
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S PROCEDURE:The battery should have been checked prior to thistest and should be fully charged.S e t a V O M t o m e a s u r e D C v o l t a g e ( 1 2 V D C ) .Connect the meter positive (+) test lead to the StarterContactor stud whi...
Page 56 - Figure 7-26. – Testing Starter Motor Performance; TEST 28- CHECK FUEL SUPPLY
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S Figure 7-24. – Tachometer TEST BRACKET:A starter motor test bracket may be made as shownin Figure 7-25. Figure 7-25. – Test Bracket REMOVE STARTER MOTOR:It is recommended that the Starter Motor be removedfrom the engine when testin...
Page 58 - TEST 29 - CHECK WIRE 14 POWER SUPPLY
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S water column as measured with a manometer. TheLP system must be able to maintain 11-14 incheswater column under all load requirements. 1. Turn LP supply to generator off. 2. Remove the Gas Pressure Tap from the fuel regulator and i...
Page 61 - TEST 33 - CHECK SPARK PLUGS; Figure 7-35 – Setting Spark Plug Gap; Clean and regap or replace sparks plug as necessary.; TEST 34 - CHECK AND ADJUST IGNITION; Disconnect the J1 connector from the Engine Control Board.
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S TEST 33 - CHECK SPARK PLUGS DISCUSSION:During Test 32, if spark jumped the tester gap, thei g n i t i o n s y s t e m m u s t b e f u n c t i o n i n g p r o p e r l y .However, if the engine misses the spark plug itselfmay be foul...
Page 63 - Figure 7-40. – Engine Ground Harness Test Points; TEST 35 - CHECK VALVE ADJUSTMENT; Figure 7-41 – Adjusting Valve Clearance
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S measured. During cranking and running this read-ing should go to “Infinity”. Verify that the meterl e a d s w e r e p r o p e r l y c o n n e c t e d a s p e r S t e p 2instructions. 2. If battery voltage was not measured in Step 3...
Page 64 - Figure 7-42 – Tightening the Jam Nut; TEST 36 - CHECK CARBURETION
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S Figure 7-42 – Tightening the Jam Nut INSTALL ROCKER ARM COVER 1. Use a new rocker arm cover gasket. Install the rocker arm cover and retain with four screws. RESULTS:Adjust valves to specification and retest. If problemcontinues, g...
Page 65 - Figure 7-44. – Exploded View of Choke Assembly
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S m e n t o f t h e S O L E N O I D P L U N G E R . A d j u s t S O L E N O I DPLUNGER movement until, with the carburetor CHOKE PLATEclosed, the CHOKE SOLENOID is bottomed in its coil (plungerat full actuated position). With the CHO...
Page 66 - DOWN TEST / COMPRESSION TEST
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S TEST 38 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TEST GENERAL:Most engine problems may be classified as one or acombination of the following: ❏ Will not start. ❏ Starts hard. ❏ Lack of power. ❏ Runs rough. ❏ Vibration...
Page 68 - Figure 7-48. – Testing Oil Temperature Switch; TEST 41 - TEST CHOKE HEATER
S Se ec cttiio on n 7 7 D DIIA AG GN NO OS ST TIIC C T TE ES ST TS S Figure 7-48. – Testing Oil Temperature Switch RESULTS: 1. If the Oil Temperature Switch fails Step 3 or Step 4, replace the Oil Temperature Switch. 2. If the Oil Temperature Switch is good, an overheat condition may be occurring. V...
Page 70 - MAJOR DISASSEMBLY
S Se ec cttiio on n 8 8 A AS SS SE EM MB BL LY Y MAJOR DISASSEMBLY ENCLOSURE/PANEL REMOVAL: 1. Remove enclosure door. 2. Remove the nine (9) enclosure roof bolts from the perimeter of the enclosure roof (a 10mm socket is required). 3. Remove six (6) enclosure side panel bolts from the outside perime...
Page 73 - OT
Page 86 - Major Features and Dimensions – Drawing No. 0E1058-C
S Se ec cttiio on n 1 10 0 S SP PE EC CIIF FIIC CA AT TIIO ON NS S & & C CH HA AR RT TS S Page 84 Major Features and Dimensions – Drawing No. 0E1058-C
Page 88 - TORQUE SPECIFICATIONS; LONG BLOCK TORQUE REQUIREMENTS; ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS
S Se ec cttiio on n 1 10 0 S SP PE EC CIIF FIIC CA AT TIIO ON NS S & & C CH HA AR RT TS S Page 86 TORQUE SPECIFICATIONS LONG BLOCK TORQUE REQUIREMENTS HEAD BOLTS 22 ft-lbs (±5%) SUMP COVER BOLTS 36 ft-lbs CONNECTING ROD CAP BOLTS 16.2 - 19.8 ft-lbs VALVE COVER BOLTS 4.8 - 5.5 ft-lbs ROCKER A...
Page 90 - Electrical Schematic and Wiring Diagram – Drawing No. 0E1057-D
S Se ec cttiio on n 1 11 1 E EL LE EC CT TR RIIC CA AL L D DA AT TA A Page 88 Electrical Schematic and Wiring Diagram – Drawing No. 0E1057-D