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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
Utility Voltage Dropout and
Engine Cranking ................................108
Engine Startup and Running ..........................110
Initial Transfer to the “Standby” Source ..........112
Utility Voltage Restored /
Re-transfer to Utility ...........................114
Engine Shutdown ...........................................116
4.3 Troubleshooting Flowcharts ........................... 118
Problem 15 – Engine Will Not Crank
When Utility Power Source Fails ................118
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
Test 56 – Check Position Of
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
Test 65 – Test Starter Motor ...........................128
Test 66 – Check Fuel Supply and Pressure ...130
Test 67 – Check Circuit Board
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
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
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
Choke Solenoid .................................146
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
Torque Requirements
(Unless Otherwise Specified) ............162
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
Wiring Diagram, Home Standby Transfer Switch,
9/10/12/16 Circuit ................................................ 184
Schematic, Home Standby Transfer Switch,
9/10/12/16 Circuit ................................................ 186