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SECTION 6:
DIAGNOSTIC TESTS ...................................... 37-65
INTRODUCTION .............................................................. 37
TEST 1 - CHECK NO-LOAD VOLTAGE AND FREQUENCY ..
37
TEST 2 - CHECK MAIN CIRCUIT BREAKER ........................
37
TEST 3- TEST EXCITATION CIRCUIT BREAKER ...................
38
TEST 4 - FIXED EXCITATION TEST/ROTOR AMP DRAW .....
38
TEST 5 - CHECK STEPPER MOTOR CONTROL ................... 40
TEST 6 - WIRE CONTINUITY .............................................
41
TEST 7 - CHECK FIELD BOOST .........................................
41
TEST 8 - DIODE/RESISTOR ................................................
42
TEST 9 - TEST STATOR ..................................................... 43
TEST 10 - SENSING LEADS ...............................................
44
TEST 11 - EXCITATION WIRING ........................................
45
TEST 12 - CHECK BRUSH LEADS ......................................
45
TEST 13 - CHECK BRUSHES & SLIP RINGS ........................
45
TEST 14 - CHECK ROTOR ASSEMBLY ...............................
46
TEST 15 - CHECK LOAD VOLTAGE & FREQUENCY ...........
46
TEST 16 - CHECK LOAD WATTS & AMPERAGE ................
46
TEST 17 - CHECK BATTERY CHARGE OUTPUT .................
47
TEST 18 - CHECK 10 AMP BATTERY CHARGE OUTPUT ....
47
TEST 19 - CHECK BATTERY CHARGE RECTIFIER ...............
47
TEST 20 - CHECK 10 AMP CIRCUIT BREAKER ..................
48
TEST 21- CHECK 10 AMP FUSE .......................................
48
TEST 22- CHECK BATTERY & CABLES ..............................
48
TEST 23- CHECK VOLTAGE AT STARTER CONTACTOR .....
49
TEST 24 - CHECK STARTER CONTACTOR .........................
49
TEST 25 - CHECK STARTER MOTOR .................................
49
CONDITIONS AFFECTING STARTER MOTOR
PERFORMANCE: ..........................................................
49
CHECKING THE PINION: ..............................................
50
TOOLS FOR STARTER PERFORMANCE TEST: ................. 50
MEASURING CURRENT: ...............................................
50
TACHOMETER: ............................................................
50
TEST BRACKET: ...........................................................
51
REMOVE STARTER MOTOR: .........................................
51
TESTING STARTER MOTOR: .........................................
51
TEST 26 - TEST STARTER CONTACTOR RELAY (SCR) .........
51
TEST 27- CHECK START-RUN-STOP SWITCH ...................
52
TEST 28- CHECK START-RUN-STOP (SW1) WIRING ...........
52
TEST 29 - CHECK IGNITION SPARK ..................................
53
TEST 30 - CHECK SPARK PLUGS ......................................
53
TEST 31 - REMOVE WIRE 18 / SHUTDOWN LEAD ............
54
TEST 32 - TEST START STOP RELAY ..................................
54
TEST 33- TEST WIRE 167 .................................................
55
TEST 34 - TEST START STOP RELAY WIRING .....................
56
TEST 35 - CHECK AND ADJUST IGNITION MAGNETOS ....
56
TEST 36: TEST FUEL SHUTOFF SOLENOID .........................
57
TEST 37: TEST FUEL SHUTOFF SOLENOID VOLTAGE .........
57
TEST 38: CHECK FUEL PUMP ........................................... 57
TEST 39 - CHECK CARBURETION .....................................
58
TEST 40 - VALVE ADJUSTMENT ........................................
58
TEST 41 - CHECK ENGINE / CYLINDER LEAK
DOWN TEST / COMPRESSION TEST .................................
59
TEST 42 - CHECK OIL PRESSURE SWITCH AND WIRE 86 ..
60
TEST 43: CHECK START STOP RELAY (SSR) .......................
60
TEST 44: TEST STARTER CONTACTOR RELAY (SCR) ..........
61
TEST 45: CHECK WIRE 15 CIRCUIT ..................................
61
TEST 46: CHECK WIRE 14 CIRCUIT ..................................
61
TEST 47: CHECK FUEL SHUTOFF SOLENOID .....................
61
TEST 48: CHECK HOURMETER ........................................ 62
TEST 49: CHECK WIRE 15B .............................................
62
TEST 50: CHECK WIRE 167 .............................................
62
TEST 51: CHECK WIRES 11S & 44S ..................................
62
TEST 52: CHECK IDLE CONTROL SWITCH (SW2) ..............
63
TEST 53: CHECK IDLE CONTROL WIRING ........................
63
TEST 54: CHECK IDLE CONTROL TRANSFORMERS ...........
64
TEST 55: CHECK TR1 & TR2 WIRING ...............................
64
TEST 56: CHOKE TEST ...................................................
65
SECTION 7:
DISASSEMBLY AND EXPLODED VIEWS ..... 66-71
MAJOR DISASSEMBLY ..................................................... 66
GENERATOR – FIGURE A ................................................
68
FRAME, HANDLE & WHEELS – FIGURE B .........................
70
SECTION 8:
ELECTRICAL DATA ......................................... 72-79
WIRING DIAGRAM 12.5 & 15 KW (UNITS WITHOUT
HOURMETER) – DRAWING NO. 0E0228 ..........................
72
ELECTRICAL SCHEMATIC 12.5 & 15 KW (UNITS
WITHOUT HOURMETER) – DRAWING NO. 0E0229-A .......
74
WIRING DIAGRAM 12.5 & 15 KW
(UNITS WITH HOURMETER) – DRAWING NO. 0D4609-D ..
76
ELECTRICAL SCHEMATIC 12.5 & 15 KW (UNITS WITH
HOURMETER) – DRAWING NO. 0D6297-A ......................
78
WIRING DIAGRAM 17.5 KW UNITS –
DRAWING NO. 0G0731 ..................................................
80
ELECTRICAL SCHEMATIC 17.5 KW UNITS –
DRAWING NO. 0G0733 ..................................................
82
WIRING DIAGRAM, 17.5 KW MANUAL
TRANSFER SWITCH – DRAWING NO. 0G1065 ................
83
INTERCONECTION DRAWING – 17.5 KW GENERATOR ....
84
SECTION 9:
SPECIFICATIONS & CHARTS ....................... 86-87
GENERATOR SPECIFICATIONS .......................................... 86
ENGINE
SPECIFICATIONS ................................................. 86
ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS .............
86
TORQUE SPECIFICATIONS ................................................
87
TRIM TORQUE SPECIFICATIONS .......................................
87