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Section 5
ENGINE DC CONTROL SYSTEM
cold weather starting, voltage drop between the bat-
tery and starter should not exceed 0.12 volt per 100
amperes of cranking current.
Select the battery cables based on total cable length
and prevailing ambient temperature. Generally, the
longer the cable and the colder the weather, the larger
the required cable diameter.
The following chart applies:
CABLE LENGTH (IN FEET) RECOMMENDED CABLE SIZE
0-10 No. 2
11-15 No. 0
16-20 No. 000
EFFECTS OF TEMPERATURE:
Battery efficiency is greatly reduced by a decreased
electrolyte temperature. Such low temperatures have
a decided numbing effect on the electrochemical
action. Under high discharge rates (such as cranking),
battery voltage will drop to much lower values in cold
temperatures than in warmer temperatures. The freez-
ing point of battery electrolyte fluid is affected by the
state of charge of the electrolyte as indicated below:
SPECIFIC GRAVITY FREEZING POINT
1.220 -35° F. (-37° C.)
1.200 --20° F. (-29° C.)
1.160 0° F. (-18° C.)
ADDING WATER:
Water is lost from a battery as a result of charging
and discharging and must be replaced. If the water
is not replaced and the plates become exposed, they
may become permanently sulfated. In addition, the
plates cannot take full part in the battery action unless
they are completely immersed in electrolyte. Add only
DISTILLED WATER to the battery. DO NOT USE TAP
WATER.
NOTE: Water cannot be added to some “mainte-
nance-free” batteries.
CHECKING BATTERY STATE OF CHARGE:
Use an automotive type battery hydrometer to test
the battery state of charge. Follow the hydrometer
manufacturer’s instructions carefully. Generally, a bat-
tery may be considered fully charged when the spe-
cific gravity of its electrolyte is 1.260. If the hydrometer
used does not have a “Percentage of Charge” scale,
compare the readings obtained with the following:
SPECIFIC GRAVITY PERCENTAGE OF CHARGE
1.260 100%
1.230 75%
1.200 50%
1.170 25%
CHARGING A BATTERY:
Use an automotive type battery charger to recharge a
battery. Battery fluid is an extremely corrosive, sulfuric
acid solution that can cause severe burns. For that
reason, the following precautions must be observed:
❏ The area in which the battery is being charged must
be well ventilated. When charging a battery, an
explosive gas mixture forms in each cell.
❏ Do not smoke or break a live circuit near the top of
the battery. Sparking could cause an explosion.
❏ Avoid spillage of battery fluid. If spillage occurs, flush
the affected area with clear water immediately.
❏ Wear eye protection when handling a battery.
7.5 AMP FUSE
This panel-mounted Fuse protects the DC control
circuit against overload and possible damage. If the
Fuse has melted open due to an overload, neither
the priming function nor the cranking function will be
available.
Figure 5-4. – Typical Fuse
START-STOP SWITCH
The Start-Stop Switch allows the operator to control
cranking, startup and shutdown. The top half of this
momentary switch is pushed and held for one (1) sec-
ond and then released. An indicator light on the switch
begins to flash. The fuel pump engages automatically
for a three (3) to five (5) second delay before the start-
er motor cranks the engine for 16 seconds or until the
engine starts. If the engine does not start, the starter
will cool for seven (7) seconds and crank the engine
again for 16 seconds. If the engine does not start, the
starter will cool for seven (7) seconds before cranking
for seven (7) seconds to a maximum cycle total of 90
seconds. Once started, the light on the switch stays
on continuously. If the generator does not start at the
end of the start sequence, a fault code will flash on
the switch (see Diagnostics).
The switch center position is the RUN position.
A running engine is stopped by momentarily pressing
the bottom half of the switch to kill the ignition.
The following wires connect to the Start-Stop Switch:
1. Wire No. 17 from the Printed Circuit Board. This Is
the CRANK and START circuit. When the Switch
is set to “START”, Wire 17 is connected to frame
ground via Wire 0.
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