9-2013
4.Service
4.5.3 GovernorActuator
Governor ActuatorTesting: Disconnect the two actuator leads andapply 12VDC. Replace
theactuatoriftheactuatorarmdoes notmovesmoothlyandwithoutbindingtothewideopen
throttleposition(rotationofapproximately35degrees).
GovernorActuatorReplacement:
NOTICE
Itisbeneficialtoremovetheaircleanerincludingthebaseforthisprocedureandto
placeacleanraginthe"V"betweenthecylinderstocatchanysmallfastenersthatmay
drop.
1. Mounttheactuatoronitsbracketwiththeleverpointingdown(approximately8o'clock).Do
nottightenthescrewsatthistime.
2. Connect t one end of the ballend d throttle link k to the mixer arm, using a washer on both
facesofthearmandoneendtotheactuatorlever,tighteningbothscrewsto6in/lb-f.
3. Holda3/32"diameterrod(adrillbitworkswell)atthewideopenthrottleslot.Pushingthe
governoractuatorarmcounter-clockwisetowide-openthethrottle,slidetheactuatorinits
slotsuntilthethrottleleverjusttouchestherod.Tightenthetwoactuatormountingscrews
to6in/lb-f.
4. Whenthelinkageassemblyisreleased,the e throttleleverarmshouldrestagainstthelow
idlescrew.
5. Pushthe e link to check that the throttle arm can open fully tothe 3/32" diameter rod and
touch the low w idlescrew. . If not, readjust the position of theactuator. The throttle should
openfullyandclosefully.
A030A239(Issue10)
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4.Service
9-2013
No. Description
1
Rotatearmcounter-clockwisetofullyopenslideuntiltheleverjusttouchestherod.Tightenthefasteners.
2
3/32"rod
3
Leverjusttouchestherod
FIGURE6. GOVERNORACTUATOR-OPEN
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9-2013
4.Service
No. Description
1
Fullyclosedactuator
2
Levertouchessetscrew
FIGURE7. GOVERNORACTUATOR-CLOSED
4.5.4 GovernorLinkageAdjustment(50HzLPOnly)
NOTICE
Itisbeneficialtoremovetheaircleanerincludingthebaseforthisprocedureandto
placeacleanraginthe"V"betweenthecylinderstocatchanysmallfastenersthatmay
drop.
Due to inconsistencies s in n fuels, operating temperatures and engine variation, it may be
necessarytoadjustthelinkageinordertoachievethepropernoloadfrequency(primarilyin50
HertzLPapplications).
1. Loosenthefastenersthatholdtheactuator.
2. Slidetheactuatortoitsfurthestpointawayfromthebutterfly.
3. Tightenbothfastenersto6in-lb-f.
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4.Service
9-2013
No. Description
1
Fasteners
FIGURE8. GOVERNORACTUATOR-FASTENERS
4.5.5 GasDemandRegulator
Conduct alock-off pressuretestas followsbefore replacinga demandregulator. Replacethe
demandregulatoronlyif lock-offpressureisnotwithintherangeof0.20–0.35inches(5.1–8.9
mm)WC(Spec AandCanadianGSBBSpec B)or0.075±0.025inches(19±6.35mm)WC
(USGSBBSpecBandCanadianGSBCSpecB).
Lock-OffPressureTest:Lock-off pressureisdeterminedbypressurizingtheback(vent)side
of the e regulator diaphragm to o simulate gas-air r mixer venturi vacuum. Conduct the test as
follows:
1. Connecttheregulatorinlettoasourceofairpressureregulatedto11inches(28cm)WC.
2. Disconnectthehosefromtheenginegas-airmixerattheregulatoroutlet.Thesoapbubble
willbeplacedonthehosebarbattheregulator.
3. “T" " intwo hoses to the endof the regulatorventhose (3/8 inchI. D.). Use one hoseto
measurepressurebyconnectingittoaninclinedmanometerthatreads0–2inches(0–50
mm)WCandtheothertoprovidethetestpressure.
4. Attach h asoapbubbletothe hosebarb at theregulatoroutlet.Whilereadingthepressure
indicatedbyamanometerandwatchingthe soapbubble, blowlightly intothehosebeing
usedtopressurizetheregulator.Regulatorlock-offpressureistheminimumpressurethat
willcauseairtoflowthroughtheregulator,asindicatedbytheexpandingsoapbubble.(At
firstthesoapbubblemayexpandduetodiaphragmmovementbutwillstopexpandingifair
isnotflowingthroughtheregulator.)
28
A030A239(Issue10)
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9-2013
4.Service
NOTICE
Makesurethediaphragmisinaverticalplane(asinthegenset)whenperformingabench
test,otherwisetheweightofthediaphragmwillcauseerroneousreadingsoflock-off
pressure.
Vent Hose: Make sure e to reconnect the regulator vent t hose to o the e vent insect screen n as
required.
4.5.6 FuelSolenoid
TestforLeakage:Ifthereisasmellofgaswhenthegensetisnotrunning,oranyotherreason
tosuspect thatthevalve is leaking, connecttheinlet ofthevalve toa sourceof airpressure
regulatedtonotmorethan14inchesWC(35cm)anddisconnecttheoutlethose.Replacethe
solenoidifitleaks.Useasoapbubbletocheckforleakage.
TestforOperation:Disconnectthesolenoidfromthegeneratorsetwiringharnessandconnect
ittoa12voltbatterywhilethesourceofairpressureisstillconnected.Replacethesolenoidifit
doesnotopen.
First Start:Upon the firstconnectionof the fuel, especially inLPsystems, itis possiblefora
spikeof pressure greater than the operatingstrengthof the fuelsolenoidtopass through the
mainregulatorandtolockthesolenoidintoaninoperableposition.Thisissuecanbereduced
byusingatwo-stageregulatoratthetank.
Ifthesituationoccurs:
1. Closethemainvalveatthetankandventthefuelfromthelineatthetank.
2. Startthecrankcycleatthegensetandthenturnonthefuelatthetankwhiletheengineis
cranking.
NOTICE
Multiplecrankattemptsmayberequiredtopurgethefuelline,dependingonthe
lengthoftherun.
4.5.7 LowGasPressureSwitch(IfEquipped)
Disconnect the pressure switchfrom the generatorset wiring harness andcheckforelectrical
continuityacrossitsterminalswhileconnectedtoasourceofairpressureregulatedtonotmore
than14inchesWC(35cm).Replacetheswitchifitdoesnotclosewhenairpressureisapplied
oropenwhenpressureisreleased.
4.5.8 TestingtheFuelSystemforLeaks
WARNING
Fuelpresentsthehazardofexplosionorfirewhichcanresultinseverepersonalinjury
ordeath.Donotsmokeorallowanyflame,spark,pilotlight,arc-producingequipment,
switchorotherignitionsourcesaroundfuelorfuelcomponents.
Beforeoperatingthegeneratorset,testthefuelsystemforleaks.
• Energize e the fuel solenoid from a a separate 12-volt t DC source before e testing the fuel
system
A030A239(Issue10)
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4.Service
9-2013
NOTICE
Testingforgasleakswithaflamecancauseafireorexplosionthatcanleadtosevere
personalinjuryordeath.Useapprovedmethodsonly.
Afterassembly,andbeforeinitialoperation,allfuelsystemconnections,hosevalves,regulators
and fittings must be e tested d and proven n free of leaks s using a a soap-and-water (or equivalent)
solutionwhilethesystemisundergasorairpressureofatleast1.5timesthesupplypressure
or3psi(20.7kPa)minimum.
• Applythesoap-and-watersolutiontoallfuelsystemconnections, , hose valves, regulators
andfittings.
• Whenthesystemisrunning,bubbleswillformwhereair/pressureisleakingfromthe
system.
Otherapprovedmethodsofdetectingleakscanbeusedifappropriate.DONOTuseaflameto
testforgasleaks.
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4.6
Control
No. Description
1
Circuitbreaker
2
Rockerswitch
3
Insulationboot
4
Sensorbracket
5
Temperatureswitch
6
Batterylead
7
Electricalstrap
8
Controlcard
9
Engineharness
10
Singlepoledualrelay
FIGURE9. CONTROLCOMPONENTS
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4.Service
9-2013
4.6.1 GeneratorControl
General: The generator r control l is s an integrated microcontroller-based engine, , generator r and
transferswitchcontrol.Itprovidesallthecontrol,monitoringanddiagnosticfunctionsrequiredto
operateastandbygeneratorset.
Transfer Switch Control: When a transfer switch without a built-in controller is used, all
transferandretransfersignalscomefromthegeneratorcontrol.Transfertimesarepre-setand
notadjustable.Powertransferfromtheutilitytothegensetissetatfiveseconds.Retransferto
the utility isset for ten minutes. After retransfer,there is ageneratorcooldown periodof ten
minutes.
Connections:AllDCcontrolconnectionstothecontrolarethroughconnectorJ1.Utilitysense
andcontrolconnectionsarethroughconnectorP7.OptionalEthernetconnectionsarethrougha
Cat 5Ethernet cable connector. Referto theappropriate wiring diagrams and wiring harness
drawings.
Mounting:The controlis mountedon the left inner panel, underthe fingerguard. The finger
guardandcontrolpaneleachhave4screwsformounting.
Configuration:PerformGeneratorSetConfigurationwhenreplacingthecontrolboard.
SoftwareUpdates:Toupdatethecontrolsoftware:
1. Disconnecttheharness s tothein-homedisplayatJ4beforeupdatingthecontrolsoftware.
Refertotheappropriatewiringdiagramsformoreinformation.
2. ConnecttheInPowerOnanservicetoolharness(PN0338-4840)toremoteconnectorJ5.
3. Holdthestopbuttontowakeupthecontrol.
4. ConnectInPowerOnanandupdatethesoftware.
5. Disconnecttheservicetoolharnessandreconnectthein-homedisplaytoJ4.
4.6.2 START/STOPSwitchS2
Unsnaptheconnectorfromthebackoftheswitchforaccesstoitsterminals.Replacetheswitch
ifitdoesnot:
• closeacrossterminals2and3whentheswitchisheldintheStartposition
• closeacrossterminals1and2whenheldintheStopposition
• the e status indicatorlightdoesnotlight when 12 VDCis connected across terminals 7(-)
and8(+)
4.6.3 LineCircuitBreakerCB1/CB2
Disconnectallwiringandcheckelectricalcontinuityacrosstheterminalsofeachcircuitbreaker.
Replace acircuit breaker that does notreset orthatdoesnotclose oropen asthe handleis
turnedONandOFF.
4.6.4 CurrentTransformersCT1/CT2
Thecurrenttransformersaretiedtothelinesideofthecircuitbreakerswithpolaritydottoward
thegenerator.
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4.Service
4.6.5 AlternatorTemperatureSwitch
The alternator temperature switch contacts are normally closed. The switch contacts open at
170°F±5°.
4.7
Generator
4.7.1 Operation
Thisisasingle-bearing,two-pole,revolvingfieldgeneratorwithbrushesandsliprings.Output
voltageisregulatedbythegeneratorsetcontrol.
Stator:Thestatorconsistsofsteellaminationswithtwosetsofwindingsinthelaminationslots.
The main windings (L1-L2, Neutral) powerthe connected loads s and d the quadrature windings
(Q1-Q2)supplypowerforthegeneratorfield.
SeeTestingtheGenerator.
Rotor: The rotor consists s of a a shaft with h steel laminations s wrapped with field windings. A
moldedslipringassemblyispressedontosupplyfieldcurrenttotherotorwindingsthroughthe
brushblockassembly.Therotorshaftissupportedintheendbellbyasealedballbearing.The
rotoriscenteredonanddrivenbythetaperontheendoftheenginecrankshaft.
BrushBlock:Fieldcurrentpassesthroughthebrushblockwhichhastwospring-loadedcarbon
brushesthatmakecontactwiththerotorsliprings.
VoltageRegulator:Thegeneratorsetcontrolmaintainsconstantoutputvoltageundervarying
loadconditionsbyvaryingfieldcurrent.Powerforfieldexcitationissuppliedbythequadrature
winding(Q1-Q2).
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4.Service
9-2013
No. Description
1
Fanhousing
2
Fanguard
3
Woundarmature
4
Generatorstator
5
Alternatorbrushblock
6
Generatorendbell
7
Alternatoradapter
8
Alternatorfan
FIGURE10. GENERATOR(ALTERNATOR)
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