Generac Power Systems Guardian 5410 Operating instructions

RV 45/55/65
Diagnostic
RepaiR Manual
Diagnostic
RepaiR Manual
RECREATIONAL VEHICLE GENERATOR
MoDels 5410, 5411, 5412,
5413, 5414 & 5415

SAFETY
Throughout this publication, “DANGER!” and “CAUTION!” blocks are used to alert the mechanic to special
instructions concerning a particular service or operation that might be hazardous if performed incorrectly or
carelessly. PAY CLOSE ATTENTION TO THEM.
*DANGER! UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCTIONS WHICH, IF NOT COMPLIED
WITH, COULD RESULT IN PERSONAL INJURY OR DEATH.
*CAUTION! Under this heading will be found special instructions which, if not complied with, could result
in damage to equipment and/or property.
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance with these special
Instructions plus “common sense” are major accident prevention measures.
NOTICE TO USERS OF THIS MANUAL
This SERVICE MANUAL has been written and published by Generac to aid our dealers’ mechanics and com-
pany service personnel when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing procedures for these products, or like or
similar products manufactured and marketed by Generac. That they have been trained in the recommended
servicing procedures for these products, including the use of common hand tools and any special Generac
tools or tools from other suppliers.
Generac could not possibly know of and advise the service trade of all conceivable procedures by which a
service might be performed and of the possible hazards and/or results of each method. We have not under-
taken any such wide evaluation. Therefore, anyone who uses a procedure or tool not recommended by
Generac must first satisfy himself that neither his nor the products safety will be endangered by the service
procedure selected.
All information, illustrations and specifications in this manual are based on the latest product information
available at the time of publication.
When working on these products, remember that the electrical system and engine ignition system are capa-
ble of violent and damaging short circuits or severe electrical shocks. If you intend to perform work where
electrical terminals could be grounded or touched, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings of the engine are exposed during service, they should be covered to
prevent accidental entry of foreign material. Entry of such materials will result in extensive damage when the
engine Is started.
During any maintenance procedure, replacement fasteners must have the same measurements and
strength as the fasteners that were removed. Metric bolts and nuts have numbers that indicate their strength.
Customary bolts use radial lines to indicate strength while most customary nuts do not have strength mark-
ings. Mismatched or incorrect fasteners can cause damage, malfunction and possible injury.
REPLACEMENT PARTS
Components on Generac recreational vehicle generators are designed and manufactured to comply with
Recreational Vehicle Industry Association (RVIA) Rules and Regulations to minimize the risk of fire or explo-
sion. The use of replacement parts that are not in compliance with such Rules and Regulations could result
in a fire or explosion hazard. When servicing this equipment, It is extremely important that all components be
properly installed and tightened. If Improperly Installed and tightened, sparks could Ignite fuel vapors from
fuel system leaks.

Table of Contents
Page 1
SAFETY ........................... INSIDE FRONT COVER
SECTION 1:
GENERATOR FUNDAMENTALS ....................... 3-7
MAGNETISM ................................................................ 3
ELECTROMAGNETIC FIELDS .................................... 3
ELECTROMAGNETIC INDUCTION ............................. 3
A SIMPLE AC GENERATOR ........................................ 4
A MORE SOPHISTICATED AC GENERATOR ............. 4
FIELD BOOST .............................................................. 6
GENERATOR AC CONNECTION SYSTEM ................. 6
SECTION 2:
MAJOR GENERATOR COMPONENTS ............ 8-11
ROTOR ASSEMBLY ...................................................... 8
STATOR ASSEMBLY ..................................................... 8
BRUSH HOLDER ......................................................... 9
EXCITATION CIRCUIT COMPONENTS ....................... 9
CRANKCASE BREATHER ......................................... 10
CONTROL PANEL COMPONENT IDENTIFICATION . 11
SECTION 3:
INSULATION RESISTANCE TESTS .............. 12-14
EFFECTS OF DIRT AND MOISTURE ........................ 12
INSULATION RESISTANCE TESTERS ...................... 12
DRYING THE GENERATOR ....................................... 12
CLEANING THE GENERATOR .................................. 12
STATOR INSULATION RESISTANCE ......................... 13
TESTING ROTOR INSULATION ................................ 14
THE MEGOHMMETER .............................................. 14
SECTION 4:
MEASURING ELECTRICITY ......................... 15-17
METERS ..................................................................... 15
THE VOM .................................................................... 15
MEASURING AC VOLTAGE ....................................... 15
MEASURING DC VOLTAGE ....................................... 15
MEASURING AC FREQUENCY ................................. 15
MEASURING CURRENT ........................................... 16
MEASURING RESISTANCE ...................................... 16
ELECTRICAL UNITS .................................................. 17
OHM’S LAW ................................................................ 17
SECTION 5:
ENGINE DC CONTROL SYSTEM ................. 18-26
INTRODUCTION ........................................................ 18
OPERATIONAL ANALYSIS .................................... 18-21
PRINTED CIRCUIT BOARD ....................................... 22
BATTERY .................................................................... 22
7.5 AMP FUSE ........................................................... 23
START-STOP SWITCH ............................................... 23
STARTER CONTACTOR RELAY
& STARTER MOTOR ................................................. 24
SECTION 6:
TROUBLESHOOTING FLOWCHARTS .................. 25-34
IF PROBLEM INVOLVES AC OUTPUT ...................... 25
PROBLEM 1 –
VOLTAGE & FREQUENCY ARE BOTH
HIGH OR LOW ........................................................... 25
PROBLEM 2 –
GENERATOR PRODUCES ZERO VOLTAGE OR
RESIDUAL VOLTAGE (5-12 VAC) .......................... 26-27
PROBLEM 3 –
EXCESSIVE VOLTAGE/FREQUENCY DROOP
WHEN LOAD IS APPLIED .......................................... 27
PROBLEM 4 –
ENGINE OVERSPEED WARNING CODE
FLASHING ON SW1 LED (4 FLASHES)....................... 28
PROBLEM 5 –
PRIMING FUNCTION DOES NOT WORK
(GASOLINE MODELS) ............................................... 28
PROBLEM 6 –
ENGINE WILL NOT CRANK ....................................... 29
PROBLEM 7 –
ENGINE CRANKS BUT WILL NOT START
(GASOLINE UNITS) ................................................... 30
PROBLEM 7 –
ENGINE CRANKS BUT WILL NOT START
(LP UNITS) ................................................................. 31
PROBLEM 8 –
ENGINE STARTS HARD AND RUNS ROUGH
(GASOLINE UNITS) ................................................... 32
PROBLEM 8 –
ENGINE STARTS HARD AND RUNS ROUGH
(LP UNITS) ................................................................. 33
PROBLEM 9 –
HIGH OIL TEMPERATURE FAULT (6 FLASHES)
OR LOW OIL PRESSURE FAULT (5 FLASHES) ....... 34
PROBLEM 10 –
7.5 AMP (F1) FUSE BLOWING .................................. 35
SECTION 7:
DIAGNOSTIC TESTS ...................................... 36-63
INTRODUCTION ........................................................ 36
TEST 1 –
Check No-Load Voltage And Frequency...................... 36
TEST 2 –
Check Stepper Motor Control ...................................... 36
TEST 4 –
Fixed Excitation Test/Rotor Amp Draw ........................ 37
TEST 5 –
Check Field Boost........................................................ 39
TEST 6 –
Test Stator DPE Winding ............................................. 39
TEST 7 –
Check Sensing Leads/Power Windings ...................... 40
TEST 8 –
Check Brush Leads ..................................................... 41
TEST 9 –
Check Brushes & Slip Rings........................................ 42

TEST 10 –
Check Rotor Assembly ................................................ 42
TEST 11 –
Check Main Circuit Breaker ......................................... 43
TEST 12 –
Check Load Voltage & Frequency................................ 43
TEST 13 –
Check Load Watts & Amperage................................... 43
TEST 14 –
Try Cranking the Engine .............................................. 44
TEST 15 –
Check Fuel Pump ........................................................ 44
TEST 16 –
Check 7.5 Amp Fuse ................................................... 45
TEST 17 –
Check Battery & Cables............................................... 45
TEST 18 –
Check Power Supply to Printed Circuit Board.............. 45
Test 19 –
Check Continuity of Wire 17 .......................................... 46
TEST 20 –
Check Start-Stop Switch.............................................. 46
TEST 21 –
Check Power Supply to Wire 56................................... 47
TEST 22 –
Check Starter Contactor Relay .................................... 47
TEST 23 –
Check Starter Contactor ............................................. 48
TEST 24 –
Check Starter Motor .................................................... 48
TEST 25 –
Check Fuel Supply....................................................... 51
TEST 26 –
Check Wire 14 Power Supply....................................... 52
TEST 27 –
Check Wire 18 ............................................................. 53
TEST 28 –
Check Fuel Solenoid
(Gasoline Models) ....................................................... 53
TEST 29 –
Check Ignition Spark.................................................... 54
TEST 30 –
Check Spark Plugs ...................................................... 55
TEST 31 –
Check and Adjust Ignition Magnetos .......................... 55
TEST 32 –
Check Valve Adjustment ............................................. 57
TEST 33 –
Check Carburetion ...................................................... 58
TEST 34 –
Check Choke Solenoid ................................................ 58
TEST 35 –
Check Engine / Cylinder Leak Down Test /
Compression Test ........................................................ 59
TEST 36 –
Check Oil Pressure Switch .......................................... 60
TEST 37 –
Test Wire 86 for Continuity............................................. 61
TEST 38 –
Test Oil Temperature Switch ........................................ 61
TEST 39 –
Test Wire 85 for Continuity............................................. 62
TEST 40 –
Test Choke Heater ...................................................... 62
TEST 41 –
Check LPG Fuel Solenoid............................................ 63
SECTION 8:
EXPLODED VIEWS / PART NUMBERS......... 64-83
BASE & PULLEY DRAWING ...................................... 64
ENCLOSURE DRAWING ........................................... 66
CONTROL PANEL DRAWING..................................... 68
ENGINE ACCESSORIES DRAWING ............................ 70
530 RV ENGINE DRAWING ....................................... 72
ROTOR AND STATOR DRAWING .............................. 74
SECTION 9:
SPECIFICATIONS & CHARTS ....................... 76-86
MAJOR FEATURES AND DIMENSIONS ................... 76
GENERATOR SPECIFICATIONS ............................... 77
NOMINAL RESISTANCES OF
GENERATOR WINDINGS AT 68°F ............................. 77
TORQUE REQUIREMENTS........................................ 77
SECTION 10:
ELECTRICAL DATA........................................ 78-79
ELECTRICAL SCHEMATIC AND
WIRING DIAGRAM ..................................................... 78
Page 2
Table of Contents

Section 1
GENERATOR FUNDAMENTALS
MAGNETISM
Magnetism can be used to produce electricity and
electricity can be used to produce magnetism.
Much about magnetism cannot be explained by our
present knowledge. However, there are certain pat-
terns of behavior that are known. Application of these
behavior patterns has led to the development of gen-
erators, motors and numerous other devices that uti-
lize magnetism to produce and use electrical energy.
See Figure 1-1. The space surrounding a magnet is
permeated by magnetic lines of force called “flux”.
These lines of force are concentrated at the magnet’s
north and south poles. They are directed away from
the magnet at its north pole, travel in a loop and re-
enter the magnet at its south pole. The lines of force
form definite patterns which vary in intensity depend-
ing on the strength of the magnet. The lines of force
never cross one another. The area surrounding a
magnet in which its lines of force are effective is called
a “magnetic field”.
Like poles of a magnet repel each other, while unlike
poles attract each other.
Figure 1-1. – Magnetic Lines of Force
ELECTROMAGNETIC FIELDS
All conductors through which an electric current is
flowing have a magnetic field surrounding them. This
field is always at right angles to the conductor. If a
compass is placed near the conductor, the compass
needle will move to a right angle with the conductor.
The following rules apply:
• The greater the current flow through the conductor,
the stronger the magnetic field around the conductor.
• The increase in the number of lines of force is
directly proportional to the increase in current flow
and the field is distributed along the full length of
the conductor.
• Thedirectionofthelinesofforcearoundaconduc-
tor can be determined by what is called the “right
hand rule”. To apply this rule, place your right hand
around the conductor with the thumb pointing in
the direction of current flow. The fingers will then be
pointing in the direction of the lines of force.
NOTE: The “right hand rule” is based on the “cur-
rent flow” theory which assumes that current
flows from positive to negative. This is opposite
the “electron” theory, which states that current
flows from negative to positive.
Figure 1-2. – The Right Hand Rule
ELECTROMAGNETIC INDUCTION
An electromotive force (EMF) or voltage can be pro-
duced in a conductor by moving the conductor so that
it cuts across the lines of force of a magnetic field.
Similarly, if the magnetic lines of force are moved so
that they cut across a conductor, an EMF (voltage)
will be produced in the conductor. This is the basic
principal of the revolving field generator.
Figure 1-3, below, illustrates a simple revolving field
generator. The magnetic field (Rotor) is rotated so that
its lines of magnetic force cut across a coil of wires
called a Stator. A voltage is then induced into the
Stator windings. If the Stator circuit is completed by
connecting a load (such as a light bulb), current will
flow in the circuit and the bulb will light.
LOAD
ROTOR
STATOR
Figure 1-3. – A Simple Revolving Field Generator
Page 3

Section 1
GENERATOR FUNDAMENTALS
A SIMPLE AC GENERATOR
Figure 1-4 shows a very simple AC Generator. The
generator consists of a rotating magnetic field called a
ROTOR and a stationary coil of wire called a STATOR.
The ROTOR is a permanent magnet which consists
of a SOUTH magnetic pole and a NORTH magnetic
pole.
As the ROTOR turns, its magnetic field cuts across
the stationary STATOR. A voltage is induced Into
the STATOR windings. When the magnet’s NORTH
pole passes the STATOR, current flows in one direc-
tion. Current flows in the opposite direction when the
magnet’s SOUTH pole passes the STATOR. This con-
stant reversal of current flow results in an alternating
current (AC) waveform that can be diagrammed as
shown in Figure 1-5.
The ROTOR may be a 2-pole type having a single
NORTH and a single SOUTH magnetic pole. Some
ROTORS are 4-pole type with two SOUTH and two
NORTH magnetic poles. The following apply:
1. The 2-pole ROTOR must be turned at 3600 rpm
to produce an AC frequency of 60 Hertz, or at
3000 rpm to deliver an AC frequency of 50 Hertz.
2. The 4-pole ROTOR must operate at 1800 rpm to
deliver a 60 Hertz AC frequency or at 1500 rpm to
deliver a 50 Hertz AC frequency.
S
TAT
O
R
R
O
T
OR
MA
G
NETI
C
FIEL
D
Figure 1-4. – A Simple AC Generator
CURRENT VOLTAGE
ONE CYCLE
0180 360
(+)
(-)
Figure 1-5. – Alternating Current Sine Wave
A MORE SOPHISTICATED AC GENERATOR
Figure 1-6 represents a more sophisticated generator.
A regulated direct current is delivered into the ROTOR
windings via carbon BRUSHES AND SLIP RINGS.
This results in the creation of a regulated magnetic
field around the ROTOR. As a result, a regulated volt-
age is induced into the STATOR. Regulated current
delivered to the ROTOR is called “EXCITATION” cur-
rent.
S
TAT
OR
BR
US
HE
S
12
0
V
12
0
V
S
LI
P
RIN
GS
AC
OU
TP
U
T
DC
CU
RRENT
S
TAT
OR
24
0
V
Figure 1-6. – A More Sophisticated Generator
See Figure 1-7 (next page). The revolving magnet-
ic field (ROTOR) is driven by the engine at a con-
stant speed. This constant speed is maintained by a
mechanical engine governor. Units with a 2-pole rotor
require an operating speed of 3600 rpm to deliver
a 60 Hertz AC output. Engine governors are set to
maintain approximately 3720 rpm when no electrical
loads are connected to the generator.
Page 4

Section 1
GENERATOR FUNDAMENTALS
NOTE: AC output frequency at 3720 rpm will be
about 60 Hertz. The “No-Load” is set slightly high
to prevent excessive rpm, frequency and voltage
droop under heavy electrical loading.
Generator operation may be described briefly as fol-
lows:
1. Some “residual” magnetism is normally present in
the Rotor and is sufficient to induce approximately
7 to 12 volts AC Into the STATOR’s AC power
windings.
2. During startup, a Printed Circuit Board (PCB)
delivers battery voltage to the ROTOR, via the
brushes and slip rings.
a. The battery voltage is called “Field Boost”.
b. Flow of direct current through the ROTOR
increases the strength of the magnetic field
above that of “residual” magnetism alone.
3. “Residual” plus “Field Boost” magnetism induces
a voltage into the Stator excitation (DPE) and AC
Power windings.
4. Excitation winding unregulated AC output is deliv-
ered to an electronic voltage regulator, via an
excitation circuit breaker.
a. A “Reference” voltage has been preset into
the Voltage Regulator.
b. An “Actual” (“sensing”) voltage is delivered to
the Voltage Regulator via sensing leads from
the Stator AC power windings.
c. The Regulator “compares” the actual (sens-
ing) voltage to its pre-set reference voltage.
(1) If the actual (sensing) voltage is great-
er than the pre-set reference voltage, the
Regulator will decrease the regulated current
flow to the Rotor.
(2) If the actual (sensing) voltage is less than
the pre-set reference voltage, the Regulator
will increase the regulated current flow to the
Rotor.
(3) In the manner described, the Regulator
maintains an actual (sensing) voltage that is
equal to the pre-set reference voltage.
NOTE: The Voltage Regulator also changes the
Stator excitation windings alternating current (AC)
output to direct current (DC).
5. When an electrical load is connected across the
Stator power windings, the circuit is completed
and an electrical current will flow.
6. The Rotor’s magnetic field also induces a voltage
into the Stator battery charge windings.
Page 5
Figure 1-7. – Generator Operating Diagram

Section 1
GENERATOR FUNDAMENTALS
FIELD BOOST
When the engine is cranked during startup, the starter
contactor is energized closed. Battery voltage is then
delivered to the starter motor and the engine cranks.
During cranking, battery voltage flows through a resis-
tor and a field boost diode in the Printed Circuit Board,
then to the Rotor via brushes and slip rings. This is
called “Field Boost” voltage.
Field boost voltage is delivered to the Rotor only while
the engine is cranking. The effect is to “flash the field”
every time the engine is cranked. Field boost voltage
helps ensure that sufficient “pickup” voltage is avail-
able on every startup to turn the Voltage Regulator on
and build AC output voltage.
NOTE: Loss of the Field Boost function may or
may not result in loss of AC power winding output.
If Rotor residual magnetism alone is sufficient to
turn the Regulator on, loss of Field Boost may go
unnoticed. However, if residual magnetism alone
is not enough to turn the Regulator on, loss of the
Field Boost function will result in loss of AC power
winding output to the load. The AC output voltage
will then drop to a value commensurate with the
Rotor’s residual magnetism (about 7-12 VAC).
GENERATOR AC CONNECTION SYSTEM
These air-cooled generator sets are equipped with
dual stator AC power windings. These two stator wind-
ings supply electrical power to customer electrical
loads by means of a dual 2-wire connection system.
Generators may be installed to provide the following
outputs:
1. 120 VAC loads only — one load with a maximum
total wattage requirement equal to the generator’s
rated power output (in watts), and 120 VAC across
the generator output terminals. Figure 1-8, page
7, shows the generator lead wire connections for
120 VAC ONLY.
2. 120/240 VAC loads — one load with a maximum
total wattage requirement equal to the generator’s
rated power output, and 240 VAC across the gen-
erator output terminals; or two separate loads,
each with a maximum total wattage requirement
equal to half of the generator’s rated power out-
put (in watts), and 120 VAC across the generator
output terminals. Figure 1-9 on page 7, shows the
generator lead wire connections for 120/240 VAC
loads.
You can use your generator set to supply electrical
power for operating one of the following electrical
loads:
• RV 45G & LP: 120 and/or 240 volts, single phase,
60 Hz electrical loads. These loads can require up
to 4500 watts (4.5 kW) of total power, but cannot
exceed 45.8 AC amperes of current at 120 volts or
exceed 22.9 AC amperes at 240 volts.
• RV 55G & LP: 120 and/or 240 volts, single phase,
60 Hz electrical loads. These loads can require up
to 5500 watts (5.5 kW) of total power, but cannot
exceed 54.1 AC amperes of current at 120 volts or
exceed 27 AC amperes at 240 volts.
• RV 65G & LP: 120 and/or 240 volts, single phase,
60 Hz electrical loads. These loads can require up
to 6500 watts (6.5 kW) of total power, but cannot
exceed 62.5 AC amperes of current at 120 volts or
exceed 31.2 AC amperes at 240 volts.
*Caution! Do not overload the generator. Some
installations may require that electrical loads
be alternated to avoid overloading. Applying
excessively high electrical loads may damage
the generator and may shorten its life. Add up
the rated watts of all electrical lighting, appli-
ance, tool and motor loads the generator will
power at one time. This total should not be
greater than the wattage capacity of the gen-
erator. If an electrical device nameplate gives
only volts and amps, multiply volts times
amps to obtain watts (volts x amps = watts).
Some electric motors require more watts of
power (or amps of current) for starting than
for continuous operation.
LINE BREAKERS (120 VOLTS ONLY):
Protects generator’s AC output circuit against
overload, i.e., prevents unit from exceeding wattage/
amperage capacity. The circuit breaker ratings are as
follows:
Model Cir. Breaker 1 Cir. Breaker 2 240 Volt
RV 45 20A 20A 20A 2P
RV 55 20A 30A 25A 2P
RV 65 30A 30A 30A 2P
Page 6

Section 1
GENERATOR FUNDAMENTALS
Figure 1-8. – Connection for 120 Volts Only
RECONNECTION FOR DUAL VOLTAGE OUTPUT:
When connected for dual voltage output, Stator output
leads 11 and 44 form two “hot” leads (T1 – Red, and
T3 – Black). The junction of leads 22 and 33 form the
“Neutral” line (T2 – White).
For dual voltage output, the “Neutral” line remains
grounded.
NOTE: For units with two 20 amp or two 30 amp
main breakers, the existing breakers may be re-
used when reconnecting for dual voltage output.
However, on units with a 30 amp and a 20 amp
main breaker, you may wish to install a 2-pole
breaker that is rated closer to the unit’s rated
capacity (use two 25 amp main breakers).
T1
RED
T2
WHITE
T3
BLACK
GROUNDED NEUTRAL
STATOR WINDINGS
CB1
CB2
Figure 1-9 - Connection for 120/240 Volts
NOTE: If this generator has been reconnected
for dual voltage AC output (120/240 volts), the
replacement line breakers should consist of
two separate breakers with a connecting piece
between the breaker handles (so that both break-
ers operate at the same time). If the unit is recon-
nected for dual voltage, it is no longer RVIA listed.
Page 7

Section 2
MAJOR GENERATOR COMPONENTS
ROTOR ASSEMBLY
The Rotor is sometimes called the “revolving field”,
since it provides the magnetic field that induces a
voltage into the stationary Stator windings. Slip rings
on the Rotor shaft allow excitation current from the
voltage regulator to be delivered to the Rotor wind-
ings. The Rotor is driven by the engine at a constant
speed through a pulley and belt arrangement.
All generator models in this manual utilize a 2-pole
Rotor, i.e., one having a single north and a single
south pole. This type of Rotor must be driven at 3600
rpm for a 60 Hertz AC output, or at 3000 rpm for a 50
Hertz output.
Slip rings may be cleaned. If dull or tarnished, clean them
with fine sandpaper (a 400 grit wet sandpaper is recom-
mended). DO NOT USE ANY MATERIAL CONTAINING
METALLIC GRIT TO CLEAN SLIP RINGS.
STATOR ASSEMBLY
The Stator is “sandwiched” between the upper and
lower bearing carriers and retained in that position by
four Stator studs. A total of eight (8) leads are brought
out of the Stator as follows:
1. Four (4) Stator power winding output leads (Wires
No. 11, 22, 33 and 44). These leads deliver power
to connected electrical loads.
2. Stator power winding “sensing” leads (11S and
22S). These leads deliver an “actual voltage sig-
nal to the electronic Voltage Regulator.
3. Two excitation winding output leads (No. 2 and 6).
These leads deliver unregulated excitation current
to the voltage regulator.
Page 8
Figure 2-1. Exploded View of Generator
1
6
8
2
4
5
7
1. BRUSH HOLDER
2. UPPER BEARING CARRIER
3. STATOR
4. ROTOR
5. LOWER BEARING CARRIER
6. ENGINE
7. PULLEYS AND BELT
8. FANS
8
3

Section 2
MAJOR GENERATOR COMPONENTS
Leads 2 & 6 = Stator Excitation Winding
Leads 11S & 22S = Voltage Sensing Leads
Leads 11 & 22, 33 & 44 = AC Power Windings
Stator
2
6
11
22
33
44
11S
22S
Figure 2-2. – Stator Output Leads
BRUSH HOLDER
The brush holder is retained in the rear bearing car-
rier by two M5 screws. It retains two brushes, which
contact the Rotor slip rings and allow current flow
from stationary parts to the revolving Rotor. The posi-
tive (+) brush is located nearest the Rotor bearing.
BRUSHES
Figure 2-3. – Brush Holder
EXCITATION CIRCUIT COMPONENTS
GENERAL:
During operation, the Rotor’s magnetic field induces
a voltage and current flow into the Stator excitation
winding. This results in AC output delivered to a volt-
age regulator via Wires 2 and 6.
REGULATOR
VOLTAGE
22
0
6
22S
4
11S
22S
11S
6
0
4
22S
11S
BA
DPE WINDING
6240
FIELD
0
+
-
Figure 2-5. – Schematic: Excitation Circuit
VOLTAGE REGULATOR:
Six (6) leads are connected to the voltage regulator
as follows:
• Two(2)SENSINGleadsdeliverACTUALACoutput
voltage signals to the regulator. These are Wires
11S and 22S.
• Two(2)leads(Wires4and0)delivertheregulated
direct current to the Rotor, via brushes and slip
rings.
• Two(2)leads(Wires6and2)deliverStatorexcita-
tion winding AC output to the regulator.
VOLTAGE
ADJUST POT
LED
6
0
2
422S 11S
Figure 2-7. – Voltage Regulator
The regulator mounts a “VOLTAGE ADJUST”
potentiometer, used for adjustment of the pre-set
REFERENCE voltage. A lamp (LED) will turn on to
indicate that SENSING voltage is available to the
regulator and that the regulator is turned on.
ADJUSTMENT PROCEDURE:
With the frequency set at 60 Hertz and no load on the
generator, slowly turn the voltage adjust pot on the volt-
age regulator until 122-126 VAC is measured. If voltage is
not adjustable, proceed to Section 6 – Troubleshooting.
Page 9

Section 2
MAJOR GENERATOR COMPONENTS
NOTE: If, for any reason, sensing voltage to the
regulator is lost, the regulator will shut down and
excitation output to the Rotor will be lost. The
AC output voltage will then drop to a value that
is commensurate with Rotor residual magnetism
(about 7-12 VAC). Without this automatic shut-
down feature, loss of sensing (actual) voltage to
the regulator would result in a “full field” or “full
excitation” condition and an extremely high AC
output voltage.
NOTE: Adjustment of the regulator’s “VOLTAGE
ADJUST” potentiometer must be done only when
the unit is running at its correct governed no-load
speed. Speed is correct when the unit’s no-load
AC output frequency is about 60.0-60.5 Hertz. At
the stated frequency, AC output voltage should be
about 124 volts.
CRANKCASE BREATHER
CRANKCASE
BREATHER
GASKET
SCREEN
OIL VAPOR
COLLECTOR
Figure 2-8. – Crankcase Breather
DESCRIPTION:
The crankcase breather is equipped with a reed valve
to control and maintain a partial vacuum in the crank-
case. The breather is vented to the airbox. The breath-
er chamber contains a removable oil vapor collector.
Oil vapor is condensed on the collector material and
drains back into the crankcase, which minimizes the
amount of oil vapor entering the breather.
CHECK BREATHER:
1. Disconnect breather tube and remove two screws
and breather. Discard gasket.
2. Remove oil vapor collector and retainer.
3. Check collector for deterioration and replace if
necessary.
INSTALL BREATHER:
1. Install oil vapor collector and retainer.
Note: Push oil vapor collector and retainer in until
it bottoms.
2. Install breather with new gasket (Figure 2-8).
a. Torque screws to 5-8 ft-lbs.
3. Assemble breather tube to intake elbow.
Page 10

Section 2
MAJOR GENERATOR COMPONENTS
Page 11
REAR VIEW
CONTROL BOARD (PCB)
WITH J1 CONNECTOR
GOVERNOR ACTUATOR
J2 CONNECTOR
STARTER CONTACTOR RELAY (SCR)
TERMINAL BLOCK (TB)
“4-TAB CONNECTOR”
VOLTAGE REGULATOR
(VR) WITH RED LED
START/STOP SWITCH (SW1)
WITH RED LED
7.5 AMP DC FUSE (F1)
CIRCUIT BREAKERS
(CB1 & CB2)
ENGINE CONNECTOR (C1)
6 WIRE GROUND TERMINAL
CONTROL PANEL COMPONENT IDENTIFICATION
Figure 2-9. – Control Panel Components

Section 3
INSULATION RESISTANCE TESTS
EFFECTS OF DIRT AND MOISTURE
Moisture and dirt are detrimental to the continued
good operation of any generator set.
If moisture is allowed to remain in contact with the
Stator and Rotor windings, some of the moisture will
be retained in voids and cracks of the winding insula-
tion. This will result in a reduced Insulation resistance
and, eventually, the unit’s AC output will be affected.
Insulation used in the generator is moisture resistant.
However, prolonged exposure to moisture will gradu-
ally reduce the resistance of the winding insulation.
Dirt can make the problem worse, since it tends to
hold moisture Into contact with the windings. Salt, as
from sea air, contributes to the problem since salt can
absorb moisture from the air. When salt and moisture
combine, they make a good electrical conductor.
Because of the detrimental affects of dirt and mois-
ture, the generator should be kept as clean and as
dry as possible. Rotor and Stator windings should be
tested periodically with an insulation resistance tester
(such as a megohmmeter or hi-pot tester).
If the Insulation resistance is excessively low, drying
may be required to remove accumulated moisture.
After drying, perform a second insulation resistance
test. If resistance is still low after drying, replacement
of the defective Rotor or Stator may be required.
INSULATION RESISTANCE TESTERS
Figure 3-1 shows one kind of hi-pot tester. The tester
shown has a “Breakdown” lamp that will glow during
the test procedure to indicate an insulation breakdown
in the winding being tested.
Figure 3-1. – One Type of Hi-Pot Tester
*DANGER! INSULATION RESISTANCE
TESTERS SUCH AS HI-POT TESTERS AND
MEGOHMMETERS ARE A SOURCE OF HIGH
AND DANGEROUS ELECTRICAL VOLTAGE.
FOLLOW THE TESTER MANUFACTURER’S
INSTRUCTIONS CAREFULLY. USE COMMON
SENSE TO AVOID DANGEROUS ELECTRICAL
SHOCK
DRYING THE GENERATOR
GENERAL:
If tests indicate the insulation resistance of a winding
is below a safe value, the winding should be dried
before operating the generator. Some recommended
drying procedures include (a) heating units and (b)
forced air.
HEATING UNITS:
If drying is needed, the generator can be enclosed in
a covering. Heating units can then be installed to raise
the temperature about 15°-18° F (8°-10° C) above
ambient temperature.
FORCED AIR:
Portable forced air heaters can be used to dry the
generator. Direct the heated air into the generator’s
air intake openings. Remove the voltage regulator and
run the unit at no-load. Air temperature at the point
of entry into the generator should not exceed 150° F.
(66° C.).
CLEANING THE GENERATOR
GENERAL:
The generator can be cleaned properly only while it is
disassembled. The cleaning method used should be
determined by the type of dirt to be removed. Be sure
to dry the unit after it has been cleaned.
NOTE: A shop that repairs electric motors may
be able to assist you with the proper cleaning of
generator windings. Such shops are often expe-
rienced in special problems such as a sea coast
environment, marine or wetland applications, min-
ing, etc.
USING SOLVENTS FOR CLEANING:
If dirt contains oil or grease a solvent is generally
required. Only petroleum distillates should be used to
clean electrical components. Recommended are safe-
ty type petroleum solvents having a flash point greater
than 100° F. (38° C.).
*CAUTION!: Some generators may use epoxy
or polyester base winding varnishes. Use sol-
Page 12

Section 3
INSULATION RESISTANCE TESTS
vents that will not attack such materials.
Use a soft brush or cloth to apply the solvent. Be
careful to avoid damage to wire or winding insulation.
After cleaning, dry all components thoroughly using
moisture-free, low-pressure compressed air.
*DANGER!: DO NOT ATTEMPT TO WORK
WITH SOLVENTS IN ANY ENCLOSED AREA.
PROVIDE ADEQUATE VENTILATION WHEN
WORKING WITH SOLVENTS. WITHOUT
ADEQUATE VENTILATION, FIRE, EXPLOSION
OR HEALTH HAZARDS MAY EXIST . WEAR
EYE PROTECTION. WEAR RUBBER GLOVES
TO PROTECT THE HANDS.
CLOTH OR COMPRESSED AIR:
For small parts or when dry dirt is to be removed, a
dry cloth may be sufficient. Wipe the parts clean, then
use low pressure air at 30 psi (206 Kpa) to blow dust
away.
BRUSHING AND VACUUM CLEANING:
Brushing with a soft bristle brush followed by vacuum
cleaning is a good method of removing dust and dirt.
Use the soft brush to loosen the dirt, then remove it
with the vacuum.
STATOR INSULATION RESISTANCE
GENERAL:
Insulation resistance is a measure of the integrity of
the insulating materials that separate electrical wind-
ings from the generator’s steel core. This resistance
can degrade over time due to the presence of con-
taminants, dust, dirt, grease and especially moisture.
The normal insulation resistance for generator wind-
ings is on the order of “millions of ohms” or “mego-
hms”.
When checking the insulation resistance, follow the
tester manufacturer’s Instructions carefully. Do NOT
exceed the applied voltages recommended in this
manual. Do NOT apply the voltage longer than one
(1) second.
*CAUTION!: DO NOT connect the Hi-Pot Tester
or Megohmmeter test leads to any leads that
are routed into the generator control panel.
Connect the tester leads to the Stator or Rotor
leads only.
STATOR SHORT-TO-GROUND TESTS:
See Figure 3-2. To test the Stator for a short-to-ground
condition, proceed as follows:
1. Disconnect and Isolate all Stator leads as follows:
a. Disconnect sensing leads 11S and 22S from
the voltage regulator.
b. Disconnect excitation winding lead No. 6 from
the voltage regulator.
c. Disconnect excitation lead No. 2 from the volt-
age regulator (VR).
e. At the main circuit breakers, disconnect AC
power leads No. 11 and 33.
f. At the 4-tab ground terminal (GRD2), discon-
nect Stator power leads No. 22 and 44.
2. When all leads have been disconnected as out-
lined in Step 1 above, test for a short-to-ground
condition as follows:
a. Connect the terminal ends of all Stator leads
together (11S, 22S, 11, 22, 33, 44, 2, & 6).
b. Follow the tester manufacturer’s instructions
carefully. Connect the tester leads across
all Stator leads and to frame ground on the
Stator can. Apply a voltage of 1500 volts. Do
NOT apply voltage longer than one (1) sec-
ond.
If the test indicates a breakdown in insulation, the
Stator should be cleaned, dried and re-tested. If the
winding fails the second test (after cleaning and dry-
ing), replace the Stator assembly.
TEST BETWEEN ISOLATED WINDINGS:
1. Follow the tester manufacturer’s instructions care-
fully. Connect the tester test leads across Stator
leads No. 11 and 2. Apply a voltage of 1500 volts-
DO NOT EXCEED 1 SECOND.
2. Repeat Step 1 with the tester leads connected
across the following Stator leads:
a. Across Wires No. 33 and 2.
b. Across Wires No. 11 and 33.
c. Across Wires No. 11 and 2.
If a breakdown in the insulation between isolated
windings is indicated, clean and dry the Stator. Then,
repeat the test. If the Stator fails the second test,
replace the Stator assembly.
TEST BETWEEN PARALLEL WINDINGS:
Connect the tester leads across Stator leads No. 11
and 33. Apply a voltage of 1500 volts. If an insula-
tion breakdown is indicated, clean and dry the Stator.
Then, repeat the test between parallel windings. If the
Stator fails the second test, replace it.
Page 13

Section 3
INSULATION RESISTANCE TESTS
Leads 2 & 6 = Stator Excitation Winding
Leads 11S & 22S = Voltage Sensing Leads
Leads 11 & 22, 33 & 44 = AC Power Windings
Stator
2
6
11
22
33
44
11S
22S
Figure 3-2. – Stator Leads
TESTING ROTOR INSULATION
To test the Rotor for insulation breakdown, proceed as
follows:
1. Disconnect wires from the Rotor brushes or
remove the brush holders with brushes.
2. Connect the tester positive (+) test lead to the
positive (+) slip ring (nearest the Rotor bearing).
Connect the tester negative (-) test lead to a clean
frame ground (like the Rotor shaft).
POSITIVE (+)
TEST LEAD
Figure 3-3. – Rotor Test Points
3. Apply 1000 volts. DO NOT APPLY VOLTAGE
LONGER THAN 1 SECOND.
If an insulation breakdown is indicated, clean and dry
the Rotor then repeat the test. Replace the Rotor if it
fails the second test (after cleaning and drying).
THE MEGOHMMETER
GENERAL:
A megohmmeter, often called a “megger”, consists
of a meter calibrated in megohms and a power sup-
ply. Use a power supply of 1500 volts when testing
Stators; or 1000 volts when testing the Rotor. 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 3-2) and connect all of
the Stator leads together. FOLLOW THE MEGGER
MANUFACTURER’S INSTRUCTIONS CAREFULLY.
Use a megger power setting of 1500 volts. Connect
one megger test lead to the junction of all Stator
leads, the other test lead to frame ground on the
Stator can. Read the number of megohms on the
meter.
MINIMUM INSULATION GENERATOR RATED VOLTS
RESISTANCE = __________________________ +1
(in “Megohms”) 1000
The MINIMUM acceptable megger reading for Stators
may be calculated using the following formula:
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.
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 Resistance”.
Also test between parallel windings. See “Test
Between Parallel Windings” on this page.
TESTING ROTOR INSULATION:
Apply a voltage of 1000 volts across the Rotor pos-
itive (+) slip ring (nearest the rotor bearing), and
a clean frame ground (i.e. the Rotor Shaft). DO
NOT EXCEED 1000 VOLTS AND DO NOT APPLY
VOLTAGE LONGER THAN 1 SECOND. FOLLOW
THE MEGGER MANUFACTURER’S INSTRUCTIONS
CAREFULLY.
ROTOR MINIMUM INSULATION RESISTANCE:
1.5 megohms
Page 14

Section 4
MEASURING ELECTRICITY
METERS
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:
❏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”..
❏Use an ohmmeter to read circuit resistance, in
“ohms”.
THE VOM
A meter that will permit both voltage and resistance to
be read is the “volt-ohm-milliammeter” or “VOM”.
Some VOM’s 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 4-1) are also available and
are generally very accurate. Digital meters display the
measured values directly by converting the values to
numbers.
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).
Figure 4-1. – Digital VOM
MEASURING AC VOLTAGE
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.
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 frequen-
cy.
3. Only an AC voltmeter may be used to measure
AC voltage. DO NOT USE A DC VOLTMETER
FOR THIS PURPOSE.
*DANGER!: RV GENERATORS PRODUCE HIGH
AND DANGEROUS VOLTAGES. CONTACT
WITH HIGH VOLTAGE TERMINALS WILL
RESULT IN DANGEROUS AND POSSIBLY
LETHAL ELECTRICAL SHOCK.
MEASURING DC VOLTAGE
A DC voltmeter or a VOM may be used to measure
DC voltages. Always observe the following rules:
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 anticipat-
ed reading. If in doubt, start at the highest scale
and adjust the scale downward until correct read-
ings are obtained.
3. The design of some meters is based on the “cur-
rent 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 cur-
rent 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.
Page 15

Section 4
MEASURING ELECTRICITY
Correct engine and Rotor speed is maintained by a
stepper motor governor. For models rated 60 Hertz,
the governor is generally set to maintain a no-load fre-
quency of about 60 Hertz with a corresponding output
voltage of about 124 volts AC line-to-neutral.
MEASURING CURRENT
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.
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.
Figure 4-2. – Clamp-On Ammeter
Figure 4-3. – A Line-Splitter
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.
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.
❏Shorting together of any two parallel Stator wind-
ings.
❏Shorting together of any two isolated Stator wind-
ings.
❏An open condition in any Stator or Rotor winding.
Component testing may require a specific resistance
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 resistance or “ZERO”
on a VOM.
Page 16

Section 4
MEASURING ELECTRICITY
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.
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”.
VO LT:
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.
-+
AMPERE - Unit measuring rate of
current flow (number of electrons
past a given point)
OHM - Unit measuring resistance
or opposition to flow
VOLT - Unit measuring force or
difference in potential
causing current flow
Conductor of a
Circuit
Figure 4-4. – Electrical Units
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.
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 resis-
tance remains the same, and current will decrease
when resistance Increases and voltage remains the
same.
VOLTS
(E)
AMPS
(I)
OHMS
(R)
Figure 4-5.
If AMPERES is unknown while VOLTS and OHMS are
known, use the following formula:
AMPERES = VOLTS
OHMS
If VOLTS is unknown while AMPERES and OHMS are
known, use the following formula:
VOLTS = AMPERES x OHMS
If OHMS is unknown but VOLTS and AMPERES are
known, use the following:
OHMS = VOLTS
AMPERES
Page 17

SC - STARTER CONTACTOR
TB - TERMINAL BLOCK, 4 TA B
SP2 - SPARK PLUG, CYL. 2
SP1 - SPARK PLUG, CYL. 1
LED - ALARM INDICATOR
LOP - LOW OIL PRESSURE SWITCH
SCR - STARTER CONTACTOR RELAY
SM - STARTER MOTOR
SW1 - PRIME/START- RUN-OFF SWITCH
FS - FUEL SOLENOID
FP - FUEL PUMP
F1 - FUSE, 7.5A
CH - CHOKE HEATER
CS - CHOKE SOLENOID
IMS - IGNITION MODULE STUD
IM2 - IGNITION MODULE, CYL. 2
HTO - HIGH OIL TEMPERATURE SWITCH
IM1 - IGNITION MODULE, CYL. 1
GRD1 - CONTROL PANEL GROUND
GRD2 - UNIT GROUND STUD
BA - BRUSH ASSEMBLY
CB 1 / CB 2 - SEE CHART
LEGEND
= 12 VOLTS DC
= ALARM CONTROL (PCB)
= DC CONTROL VOLTAGE (PCB)
= SHUTDOWN CONTROL (PCB)
= GROUND
= GROUND CONTROL (PCB)
= FIELD BOOST
= VOLTAGE REGULATOR
DC OUTPUT
= AC VOLTAGE
IM1
IM2
SP1
SP2
12
J1
12345678109111314
PRINTED CIRCUIT BOARD
J2
CONTROL
ACTUATOR
GOVERNOR
SW1
START
PRIME STOP
18
17
0
SCR
56 16
F1
0131656
FP
LOPHTO
BLK RED18A
086085
REGULATOR
VOLTAGE
22
0
6
22S
4
11S
6
0
4
22S
11S
LED
0712
CH
CS
0
90
14
RED
BLACK
SM
SC
BATTERY
+
-
12V
SC
0
0
16
160
13
POWER WINDINGS
11
BA
33
DPE WINDING
6240
44
CB2
CB1
FIELD
BLACKRED
18
17
0
56
712
0
18
11S
22S
13
16
0
17
REMOTE
PANEL
CONNECTOR
14
712
D
E
G
F
C
B18
17
H
A0
GREENWHITE
0
13
712
14
0
GREEN
WHITE
0
NEUTRAL CONNECTION
AC CONNECTION
CUSTOMER
BY CUSTOMER
18 15
17
71286 90
14 85 56 0
18A
4
15
11S
0
14
0 241
FS
14
712
22
44
44
22
22S 22
00
0
+
-
Section 5
ENGINE DC CONTROL SYSTEM
INTRODUCTION
The engine DC control system includes all com-
ponents necessary for the operation of the engine.
Operation includes rest, priming, cranking, starting,
running and shutdown. The system is shown sche-
matically.
OPERATIONAL ANALYSIS
CIRCUIT CONDITION – REST:
Battery voltage is available to the Printed Circuit Board (PCB)
from the vehicle BATTERY via the positive (RED) battery cable
to the isolated positive (RED) terminal stud, located in the control
panel. The power is supplied to Wire 13, a 7.5 amp FUSE (F1),
the STARTER CONTACTOR RELAY (SCR) and Wire 15/Pin 4 on
the PCB. However, PCB action is holding the circuits open, and no
action can occur.
Printed Circuit Board action (only) allows voltage to be supplied
to Wires 17 and 18 for start and stop actions on the START-STOP
SWITCH (SW1) and remote panel connector.
Page 18