Carrier 2.4L 45kW Reparaturanleitung

DiagnosticRepaiRManualAUTOMATIC STANDBY GENERATORSLiquid-Cooled ProductMODELS:2.4 LitEr EnginE r-200B COntrOLLEr22kW27kW36kW45kW60kW®

Page 8SPECIFICATIONSKW RATING 45ENGINE SIZE2.4 Liter Inline 4GENERATOR OUTPUT VOLTAGE/KW - 60Hz KW AMP CB Size120/240V, 1-phase, 1.0 pf 45 188 200120/

PART 3DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.3TROUBLESHOOTING FLOW CHARTSPage 98REPLACE PCBREPLACE OR ADJUSTGOOD GOODGOODTEST 67 – CHECK CRANK

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 99INTRODUCTIONThis section is provided to familiarize the service techn

PART 3Page 100DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSTEST 28 – CHECK BATTERY VOLTAGE AT 15 AMP FUSE (F1)PROCEDURE:1. Open the

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 101AUTOCONTINUITY1/42/53/61/42/53/61/42/53/6INFINITYOFFINFINITYINFINITYDEPR

PART 3Page 102DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPROCEDURE:1. Locate the Engine Start Relay (RL1 BLACK), it is located in

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 103TEST 34 – CHECK BATTERY VOLTAGE AT STARTER CONTACTOR RELAY (SCR)DISCUSSI

PART 3Page 104DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTS13.70+1.0-1.0AT REST PINION POSITION23.0-25.5ENERGIZED POSITION29.88+1.6

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 105100 150 200 250 300 350 40005001000150020002500300035004000RPMCURRENT0.0

PART 3Page 106DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSing and a transfer occurring while a technician is working on a p

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 107RESULTS:1. Battery voltage should be measured in Steps 2 and 4.

Page 9SPECIFICATIONSKW RATING 60ENGINE SIZE2.4 Liter Inline 4GENERATOR OUTPUT VOLTAGE/KW - 60Hz KW AMP CB Size120/240V, 1-phase, 1.0 pf 60 250 300120/

PART 3Page 108DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSRESULTS:1. A voltage of 5 VDC should be measured in Step 3. Refer back t

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 109NORMAL MISFIRESPRE-IGNITION DETONATIONFigure 14. Spark Plug ConditionsTE

PART 3Page 110DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSindicate if the ignition has been energized. The LED will flash at a 0.5

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 111Wires 15, 14 (NG Only), and 56 proceed to investigate the follo

4. Disconnect Wire 14 from the fuel solenoid to disable starting 5. Set a VOM to measure AC voltage.6. Set the AUTO-OFF-MANUAL Switch to MANUAL.* Cau

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 113TEST 69 – CHECK WIRE 14 FOR BATTERY VOLTAGEDISCUSSION:Wire 14 is used t

PART 3DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPage 114• Iflittleornobatteryvoltageispresent,verifythatWire 15A is

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 115ACBPAFigure 22. Fuel Regulator Test PointsPROCEDURE:1. Disconnect the ho

Page 116PART 3DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSRESULTS:1. If voltage was not measured in Step 5, replace the printed ci

Page 117DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3e. When the defective wire(s) has been repaired verify CONTINUITY for

ROTOR/STATOR RESISTANCE TABLES Page 10SPECIFICATIONSRotors Resistance22 kW 1-Phase 4 Pole 1800 RPM 6.81 Ohms22 kW 3-Phase 4 Pole 1800 RPM 6.46 Ohms27

Page 118PART 3DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSTEST 75 – CHECKING WIRING HARNESSDISCUSSION:Starting or running issues a

Page 119DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3RESULTS:1. If 240 or 208 VAC was measured in Step 2, and 16-19

Page 120PART 3DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSUPPER RADIATOR HOSE(TO THERMOSTAT HOUSING)LOWER RADIATOR HOSE(TO WATER P

Page 121DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 34. Observe if the fault occurred again.* Warning: This procedure is for

Page 122PART 3DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTS5. Place the positive lead to Wire 86 and the negative lead to J1 Connec

Page 123DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 33. Wait one (1) minute and observe.RESULTS:1. If low battery LED returns

Page 124PART 3DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTS6. Repeat Step 4, however this time CONTINUITY should be measured

Page 125DC CONTROL LIQUID COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 33. Set a VOM to measure resistance (Ω).4. Connect one meter test lead

16. Push circuit breaker to the Closed position or re-install the fuse. • Ifthe breakertripped orthefuseblew,proceedto Step 17.• If

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTSPART 3Page 127• Ifthebreakertrippedorthefuseblew,theshortis located in the

Page 112.4 LITER STANDBYGENERATORSPART 1 GENERAL INFORMATIONTABLE OF CONTENTSPART TITLE PAGE1.1 Generator Basics 121.2 Installation Basics 141.3 Pre

PART 3Page 128DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.4DIAGNOSTIC TESTS30. Push circuit breaker to the Closed position or re-install th

Page 1292.4 LITER STANDBYGENERATORSPART 4 GENERATOR ADJUSTMENTS AND ACCESSORIESTABLE OF CONTENTSPART TITLE PAGE4.1 Adjustments 1304.2 Accessories 1354

PART 4Page 130GENERATOR ADJUSTMENTS AND ACCESSORIESSECTION 4.1ADJUSTMENTSVOLTAGE REGULATOR ADJUSTMENT AND INSTALLATIONTwo dip switches are provide

GENERATOR ADJUSTMENTS AND ACCESSORIESSECTION 4.1ADJUSTMENTSPART 4Page 1318. Slowly turn the Under Frequency pot (U/F) CCW until the alternator output

12. With the unit running at (Rated Speed: 3600RPM or 1800RPM), slowly adjust the magnetic pick-up to provide the specific voltage for the app

GENERATOR ADJUSTMENTS AND ACCESSORIESSECTION 4.1ADJUSTMENTSRESULTS:1. If the gap is not within specifications, adjust cam sensor to the gap specific

PART 4Page 134GENERATOR ADJUSTMENTS AND ACCESSORIESSECTION 4.1ADJUSTMENTS6. Using an inspection mirror, visually inspect that the cam pin is al

Page 135GENERATOR ADJUSTMENTS AND ACCESSORIESSECTION 4.2ACCESSORIESPART 4COLD WEATHER START INSTALL INSTRUCTIONSBATTERY WARMER:1. Verify that a 120V A

Item Qty Description1 1 HEATER BLOCK 1500W 120V2 1 HOSE COOL 5/8 ID 20R3 (48” LG)3 4 SCREW HHC M6-1.0 X 20 G8.84 4 WASHER FLAT 1/4-M6 ZINC5 1 BRACKET

GENERATOR ADJUSTMENTS AND ACCESSORIESSECTION 4.2ACCESSORIESPART 4Page 13710. Install coolant hose (Item 2) to block heater as shown. Clamp t

SERVICE ITEM ACCESSIBILITY CHARTOIL FILL CAPOIL DIP STICKOIL FILTEROIL DRAIN HOSEAIR CLEANER ELEMENTSPARK PLUGSMUFFLERSFAN BELTSERVICE ITEMTHRU LEFT D

PART 4Page 138GENERATOR ADJUSTMENTS AND ACCESSORIESSECTION 4.3TORQUE SPECIFICATIONSItemSpecification (ft-lbs)Ignition system Crankshaft pulley bolts

OPERATIONAL TESTS AND ADJUSTMENTSSECTION 4.3TORQUE SPECIFICATIONSPART 445 ft-lbs56 ft-lbs30 ft-lbs16 ft-lbs45 ft-lbs45 ft-lbs56 ft-lbs144 ft-lbsFigure

Page 140NOTES

PART 5 ELECTRICALDATA2.4 LITER STANDBYGENERATORSPage 141TABLE OF CONTENTSDWG # TITLE PAGE0G8839-B Wiring Diagram 1420G8840-B Electrical Schematic 1440

PART 5ELECTRICAL DATAWIRING DIAGRAMPage 142OSAFSECICMCYL2CYL3CYL4CYL1Y2Y1Y3DRAWING #0G8839-B

ELECTRICAL DATAWIRING DIAGRAMPART 5Page 143OSAFSECICMCYL2CYL3CYL4CYL1Y2Y1Y3DRAWING #0G8839-B

Page 144PART 5ELECTRICAL DATAELECTRICAL SCHEMATICDRAWING #0G8840-B

ELECTRICAL DATAELECTRICAL SCHEMATICPART 5Page 145DRAWING #0G8840-B

PART 5Page 146ELECTRICAL DATAALTERNATOR CONFIGURATIONSDRAWING #0F6839-D

ELECTRICAL DATAALTERNATOR CONFIGURATIONSPART 5Page 147DRAWING #0F6839-D

PART 1GENERAL INFORMATIONSECTION 1.1GENERATOR BASICSINTRODUCTIONThis Diagnostic Repair Manual has been prepared especially for the purpose of fam

PART 5Page 148ELECTRICAL DATAALTERNATOR CONFIGURATIONSDRAWING #0F6839-D

ELECTRICAL DATAALTERNATOR CONFIGURATIONSPART 5Page 149DRAWING #0F6839-D

Page 150PART 5ELECTRICAL DATAALTERNATOR CONFIGURATIONSDRAWING #0F6839-D

Page 151ELECTRICAL DATAALTERNATOR CONFIGURATIONSPART 5DRAWING #0F6839-D

Page 152TO FIND KNOWN VALUES 1-PHASE 3-PHASEKILOWATTS (kW) Volts, Current, Power FactorE x I 1000E x I x 1.73 x PF 1000KVA Volts, CurrentE x I 1000E x

Generac Power Systems, Inc.S45 W29290 Hwy. 59Waukesha, WI 531891-888-GENERAC (1-888-436-3722) generac.comPart No. 0H0983 rev. B / Printed in USA

INTRODUCTIONInformation in this section is provided so that the service technician will have a basic knowledge of installation requirements

Gas ActuatorPrimary Regulator(Supplied byInstallingContractor)11 - 14" Water Column (>= 70 kW)5 - 14" Water Column (< 70 kW)Flex F

THE TRANSFER SWITCHA transfer switch is required by electrical code, to pre-vent electrical feedback between the utility and stand-by power sources, a

GENERAL INFORMATIONSECTION 1.3PREPARATION BEFORE USEPART 1Page 17GENERALThe installer must ensure that the home standby gen-erator has been properly

Page iiSAFETYThroughout this publication the safety alert symbol (*) is used with signal words. DANGER, WARNING, and CAUTION blocks are used to alert

NOTESPage 18

GENERAL INFORMATIONSECTION 1.4TESTING, CLEANING AND DRYINGVISUAL INSPECTIONWhen it becomes necessary to test or troubleshoot a generator, it is a good

PART 1Page 20GENERAL INFORMATIONSECTION 1.4TESTING, CLEANING AND DRYINGHI-POT TESTER:A “Hi-Pot” tester is shown in Figure 1. The model shown is on

GENERAL INFORMATIONSECTION 1.4TESTING, CLEANING AND DRYINGbreakdown lamp. After one (1) second, turn the tester switch OFF.d. Repeat a, b and c for ea

PART 1Page 22GENERAL INFORMATIONSECTION 1.5OPERATING INSTRUCTIONSCONTROL PANELGENERAL:See Figure 1. A typical control panel on units with liquid

Page 23GENERAL INFORMATIONSECTION 1.5OPERATING INSTRUCTIONSPART 1* DANGER: When the generator is installed in conjunction with an automatic transfer

SECTION 1.5OPERATING INSTRUCTIONSPART 1Page 24GENERAL INFORMATIONEXERCISE FEATUREThe 2.4 liter standby generator with an R-200B con-trol panel will

Page 25GENERAL INFORMATIONSECTION 1.6AUTOMATIC OPERATING PARAMETERSPART 1INTRODUCTIONWhen the R-200B control panel is installed in conjunction

SECTION 1.6AUTOMATIC OPERATING PARAMETERSPART 1GENERAL INFORMATIONPage 26AUTOMATIC OPERATING SEQUENCES CHARTSEQ. CONDITION ACTION SENSOR, TIMER OR OTH

Page 27GENERAL INFORMATIONSECTION 1.7WIRE REMOVAL, REPLACEMENT & TESTINGPART 1GENERAL INFORMATIONAMP STYLE CONNECTORWires can be removed from the

Page 1TABLE OF CONTENTSSpecifications ... 4Generator Specifications ...

PART 1Page 28GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONSERVICE MAINTENANCE INTERVAL INFORMATION:The various service maintenance inter

GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONFIRST 30 OPERATING HOURS:1. Change engine “break-in” oil and filter.FIRST 100 OPERATING HOU

PART 1Page 30GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONTO BE PERFORMED EVERY 6 MONTHS:Safety precautions need to be taken.• Wearrub

GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONBATTERY CLEANING:* CAUTION: When removing clamps, always loosen and remove the Negative (-)

PART 1Page 32GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONFigure 10. A Typical Battery Load TesterState of Charge Specific Gravity Volt

GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONthe engine.• Carefully inspect the belts along their edges andundersides for any s

PART 1Page 34GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONCHUNKING: Parts of the belt break off when cracks worsen.• Cause:Chunkingca

GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONPART 1* CAUTION: Generac does not recommend the cleaning of air filter elements. Since all

PART 1GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONHEAT RANGE:The most basic function of the spark plug is to ignite the air/fuel mixtu

Page 37GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONPART 1TROUBLESHOOTING:Diagnosing spark plugs is really pretty straight for-ward, b

TABLE OF CONTENTSPage 2Test 2 – Test Excitation Circuit Breaker ...55Test 3 – Test Field Boost Circuit ...56Test 4 – Fi

Page 38PART 1GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONfor possible internal engine damage as well (pis-tons, cylinder walls, valves

Page 39GENERAL INFORMATIONSECTION 1.8BASIC MAINTENANCE INFORMATIONPART 1LEAKAGE:Moisture, seepage or drips form on or around clamps or connectors.• C

Page 40PART 1GENERAL INFORMATIONSECTION 1.9TURBOCHARGER SYSTEMSINTRODUCTIONThere are two generators currently in the 2.4L family thatareequippedwit

Page 41GENERAL INFORMATIONSECTION 1.9TURBOCHARGER SYSTEMSPART 1Engine Lacks PowerBlack Exhaust SmokeExcessive Engine Oil ConsumptionBlue Exhaust Smoke

Page 42NOTES

Page 432.4 LITER STANDBYGENERATORSPART 2 LIQUID-COOLED AC GENERATORSTABLE OF CONTENTSPART TITLE PAGE2.1 Description and Components 442.2 AC Output Ope

INTRODUCTIONThis section covers the major components of the AC generator proper, i.e., those generator assemblies that provide for the production

LIQUID-COOLEDAC GENERATORSSECTION 2.1DESCRIPTION AND MAJOR COMPONENTSPART 2Page 45STATO RROTORFLEXIBLE COUPLINGENGINE ADAPTORFAN AND RINGGEAR ASSEMBLY

THE EXCITATION CIRCUITAC output from the stator excitation (DPE) winding is delivered to the voltage regulator, via a thermal pro-tector (TP), Wire

LIQUID-COOLEDAC GENERATORSSECTION 2.1DESCRIPTION AND MAJOR COMPONENTSPART 2Page 47DIP 1 = STDDIP 2 = HIGHPM HIGHSTD LOWVOLTAGE POTUNDER FREQUENCY POTG

TABLE OF CONTENTSPage 3Test 55 – Attempt a 2-Wire Start ...107Test 56 – Check Voltage on Wire 183 ...107Test 57 – Check W

Page 483. If the red “Regulator” lamp goes OUT, a voltage regulator fault exists or the regulator has shut down due to occur-rence of one or more shu

SECTION 2.2OPERATIONAL ANALYSISPage 49LIQUID-COOLEDAC GENERATORSPART 2MAGNETISMAlthough magnetism is invisible, some of the effects it produces can be

CB2 = EXCITATION CIRCUIT BREAKERCB2VOLTAGEREGULATORFIELD BOOSTMLB = MAIN LINE CIRCUIT BREAKERBELT DRIVENALTERNATORENGINE MOUNTSTATOREXCITATIONWINDINGR

LIQUID-COOLEDAC GENERATORSSECTION 2.3TROUBLESHOOTING FLOW CHARTSPART 2Page 51Use the “Flow Charts” in conjunction with the detailed instructions in

PART 2Page 52LIQUID-COOLEDAC GENERATORSSECTION 2.3TROUBLESHOOTING FLOW CHARTSTEST 4 –PERFORM FIXEDEXCITATION /ROTOR AMP DRAWREPAIRORREPLACEFEHRE-TESTT

LIQUID-COOLEDAC GENERATORSSECTION 2.3TROUBLESHOOTING FLOW CHARTSPART 2Page 53FREQUENCY ANDVOLTAGE O.K.FREQUENCY O.K.,BUT VOLTAGE ISSTILL LOWGO TO “PRO

PART 2Page 54LIQUID-COOLEDAC GENERATORSSECTION 2.3TROUBLESHOOTING FLOW CHARTSREDUCE LOADS TO UNIT”S RATED CAPACITYDISCONTINUE TESTINGENGINE CONDITION

LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSPART 2Page 55INTRODUCTIONThis section is provided to familiarize the service technician with

PART 2Page 56LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTS1. With the generator shut down, locate the excitation circuit breaker in the con

LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSPART 2Page 5711. Connect one meter lead to Terminal 10 (Wire 15) of TB1 and the other lead to

Page 4SPECIFICATIONSGENERATOR SPECIFICATIONSTYPE ...Sync

PART 2Page 58LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSTEST 5 – TEST THERMAL PROTECTORDISCUSSION:An open thermal protector will result in l

LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSPART 2Page 59TEST 6 – TEST R4 RESISTORDISCUSSION:The R4 resistor is installed with the field boos

PART 2Page 60LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSRESULTS:1. If battery voltage was measured, repair or replace Wire 14 between BR

LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSPART 2Page 61based on the sensing lead signals, regulates the DC current output.A 12V DC signal i

PART 2Page 62LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTS Tech Tip: If the DPE winding is open it can be temporarily bypassed by connecting

LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSPART 2Page 634. If a short between two windings was measured, ensure the circuit is com

a. Connect one meter test lead to Stator Lead S1 and connect the other meter test lead to S5. INFINITY should be measured.b. Repeat Step 5a between

LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSPART 2Page 65a clear indication that there is an alignment issue with the brushes and

Page 66PART 2LIQUID-COOLEDAC GENERATORSSECTION 2.4DIAGNOSTIC TESTSPROCEDURE:1. Connect an accurate AC frequency meter across Terminal 6 (Wire 11) of T

Page 67TABLE OF CONTENTSPART TITLE PAGE3.1 Description and Components 673.2 Operational Analysis 793.3 Troubleshooting Flow Charts 903.4 Diagnostic Te

SPECIFICATIONSKW RATING 22ENGINE SIZE2.4 Liter Inline 4GENERATOR OUTPUT VOLTAGE/KW - 60Hz KW AMP CB Size120/240V, 1-phase, 1.0 pf 22 92 100120/208V, 3

PART 3Page 68DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTSInformation in this section is provided to familiarize the rea

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTSPART 3Page 69OVERCRANKOVERSPEEDLOW COOLANT LEVELHI COOLANT TEMPERATURELOW OI

PART 3Page 70DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTSCONTROL BOARD DIP SWITCH SETTINGS:The Switch “ON” position l

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTSPART 3Page 71Pin # Wire # Description1 Empty2 Empty3 454 Ignition Module wil

PART 3DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTS1515A1414A1515A5656ARL1RL2ENGINE STARTRELAYENGINE RUNRELAYFigure 6. En

Page 73DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTSPART 3STARTER MOTOR AND CONTROL CONTACTOR:During manual or automat

PART 3DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTSAIR/FUEL SOLENOID (AFS):On emissions enabled units a variable 12 VDC s

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTSPART 3Page 75LOW OILPRESSURESWITCHHIGH COOLANTTEMPERATURESWITCHFRONTFRONTLOW

Page 76PART 3DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.1DESCRIPTION AND COMPONENTSA 5 kΩ resister is added to the circuit in parallel with the t

Page 77 Switch PositionCondition System Low Low Low High Over Over Manual Auto OffknarC deepS pmeT liO taB leuF ydaeR Generator Switch is

Page 6SPECIFICATIONSKW RATING 27ENGINE SIZE2.4 Liter Inline 4GENERATOR OUTPUT VOLTAGE/KW - 60Hz KW Nat. Gas AMP KW LPG AMP CB Size (Both)120/240V, 1-p

Page 78NOTES

Page 79INTRODUCTIONThe schematic diagram on this and the following pages show the DC control system in three (3) modes of operation:• Utility

PART 3Page 80DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISSW1 IN AUTO, UTILITY VOLTAGE PRESENT*16 VAC240 VAC2.4L4 3 12FAN22COIL

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISPART 3Page 81SW1 IN AUTO, UTILITY VOLTAGE PRESENT*16 VAC240 VAC2.4L4 3 12FAN22COIL

PART 3Page 82DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISINITIAL POWER LOSS.For RTS transfer switches, line-to-line volta

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISPART 3Page 83VDC power supply to governor Pin 3 for the actuator position feedback

PART 3Page 84DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISICMFAU LTINDICATORSW1 IN AUTO, UTILITY FAILUREENGINE CRANKING2.4L4 3

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISPART 3Page 85ICMFAU LTINDICATORSW1 IN AUTO, UTILITY FAILUREENGINE CRANKING2.4L4 3

PART 3Page 86DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISENGINE RUNNING:When the engine reaches 600 to 800 RPM the control boa

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISPART 3Page 87R416214116BANBCB11144491429BR13456AVR2111STATOR55663322441144564212CB

Page 7SPECIFICATIONSKW RATING 36/35ENGINE SIZE2.4 Liter Inline 4GENERATOR OUTPUT VOLTAGE/KW - 60Hz KW LPG AMP KW Nat. Gas AMP CB Size (Both)120/240V,

PART 3Page 88DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISSW1 IN AUTO, UTILITY FAILUREENGINE RUNNINGICMFAU LTINDICATOR2.4L4 3 1

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.2OPERATIONAL ANALYSISPART 3Page 89SW1 IN AUTO, UTILITY FAILUREENGINE RUNNINGICMFAU LTINDICATOR2.4L4 3 1

PART 3Page 90DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.3TROUBLESHOOTING FLOW CHARTSREPAIR OR REPLACE WIREREPAIR OR REPLACE WIRECONTACT TECHNICAL

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.3TROUBLESHOOTING FLOW CHARTSPART 3Page 91REPLACEREPAIR OR REPLACE WIRERESET SWITCH TO AUTO AND RE-TESTD

PART 3DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.3TROUBLESHOOTING FLOW CHARTSPage 92REPLACE PCBREPAIR OR REPLACE WIREPROBLEM IS LOCATED IN TRANSFE

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.3TROUBLESHOOTING FLOW CHARTSPART 3Page 93GOODREPLACE AND RE-TESTIF FAULT STILL EXISTS, REPLACE IGNITION

Page 94PART 3DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.3TROUBLESHOOTING FLOW CHARTSGOODGO TO “PROBLEM 15”CORRECT FUEL SUPPLY ISSUETEST 68 – CHECK

DC CONTROL LIQUID-COOLED ENGINE UNITSSECTION 3.3TROUBLESHOOTING FLOW CHARTSPage 95PART 3REPAIR OR REPLACE WIREREPLACE PCBGOODGOODCHECK FUSES IN TRANSF

Page 96REPLACE PCBGOOD GOODREPAIR OR REPLACEREPLACE LOW COOLANT LEVEL SENSORADD COOLANT AND CHECK FOR LEAKSTEST 96 – CHECK COOLANT LEVELTEST 100 – CHE

Page 97STOP TESTING. CHARGING SYSTEM IS WORKING PROPERLY.CHECK WIRES AND CONNECTION BETWEEN THE GENERATOR AND THE DISTRIBUTION PANEL.ALARM WAS LATCHED