Page 3
Problem 15 - Generator Starts
Immediately in Auto - No Transfer to
Standby. Utility Voltage is Present .....101
Problem 16 - 15 Amp Fuse (F1) Blown ..........102
Problem 17 - Generator Will Not Exercise .....102
Problem 18 - No Low Speed Exercise ...........102
4.4 Diagnostic Tests ............................................ 103
Introduction .................................................. 103
Test 41 - Check Position Of
AUTO-OFF-MANUAL Switch ........... 103
Test 42 - Try A Manual Start ......................... 103
Test 43 - Test AUTO-OFF-MANUAL Switch . 103
Test 44 - Check Wire 15/15A/15B/239/0
Voltage ..............................................104
Test 45 - Check 15 Amp Fuse ........................105
Test 46 - Check Battery .................................105
Test 47 - Check Wire 56 Voltage ...................106
Test 48 - Test Starter Contactor Relay
(V-twin Only) ......................................106
Test 49 - Test Starter Contactor .....................106
Test 50 - Test Starter Motor ............................107
Test 51 - Check Fuel Supply
And Pressure.....................................109
Test 52 - Check Circuit Board
Wire 14 Output ..................................110
Test 53 - Check Fuel Solenoid .......................111
Test 54 - Check Choke Solenoid
(V-twins Units Only) ...........................112
Test 55 - Check For Ignition Spark .................113
Test 56 - Check Spark Plugs ..........................114
Test 57 - Check Engine / Cylinder Leak Down
Test / Compression Test114
Test 58 - Check Shutdown Wire .....................115
Test 59 - Check And Adjust
Ignition Magnetos ..............................116
Test 60 - Check Oil Pressure Switch
And Wire 86 .......................................117
Test 61 - Check High Oil
Temperature Switch ...........................118
Test 62 - Check And Adjust Valves ................119
Test 63 - Check Fuel Regulator
(7 Kw Natural Gas Units Only) ..........117
Test 64 - Check Battery Charge Output .........120
Test 65 - Check Transformer (TX)
Voltage Output ...................................118
Test 66 - Check AC Voltage At
Battery Charger .................................121
Test 67 - Check Battery Charge
Relay (BCR) ......................................122
Test 68 - Check Battery Charge
Winding Harness ...............................122
Test 69 - Check Battery Charger Wiring .......123
Test 70 - Check Wire 18 Continuity ................123
Test 71 - Check N1 And N2 Voltage ...............123
Test 72 - Check Utility Sensing Voltage
At The Circuit Board ..........................124
Test 73 - Test Set Exercise Switch .................124
Test 75 - Check Battery Voltage Circuit ..........124
Test 76 - Check Cranking And
Running Circuits ................................124
Test 77 - Test Exercise Function ....................126
Test 78 - Check Dip Switch Settings ..............126
Test 79 - Check Idle Control Transformer
(V-twin Units Only) .............................126
Test 80 - Check LC1 & LC2 Wiring ................126
Test 81 - Check Idle Control Transformer
Primar y Wir ing ...................................127
PART 5 - OPERATIONAL TESTS......................... 129
5.1 System Functional Tests ................................ 130
Introduction ....................................................130
Manual Transfer Switch Operation .................130
Electrical Checks ...........................................130
Generator Tests Under Load ..........................131
Checking Automatic Operation ......................132
Setting The Exercise Timer ............................132
PART 6 - DISASSEMBLY ..................................... 133
6.1 Major Disassembly ........................................ 134
Major Disassembly .........................................134
Front Engine Access. .....................................136
Torque Requirements
(Unless Otherwise Specified) ............136
PART 7 - ELECTRICAL DATA .............................. 137
Drawing 0F7820 Wiring Diagram,
7kWHSB
Models 005240 & 005280 ................................... 138
Drawing 0F7821 Wiring Schematic,
7kWHSB
Models 005240 & 005280 ................................... 140
Drawing 0F7822 Wiring Diagram,
10, 13 & 16 kW HSB
Models 005241 & 005281
Models 005242 & 005282
Models 005243 & 005283
Models 005244 & 005284 ................................... 142
Drawing 0F7823 Schematic,
10, 13 & 16 kW HSB
Models 005241 & 005281
Models 005242 & 005282
Models 005243 & 005283
Models 005244 & 005284 ................................... 144
Drawing 0F9070 Wiring Diagram,
Transfer Switch
8 Circuit/16 Circuit ............................................... 146
Drawing 0F9775 Wiring Diagram,
Schematic
8 Circuit/16 Circuit ............................................... 147
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