Vortec 1600 - Industrial 1.6 L Engine Electrical 3-1 Section 3 Engine Electrical

Industrial 1.6L Engine Electrical 3-1
Fastener Notice ........................................................ 3-2
Engine Electrical - 1.6L .......................................... 3-3
Specifications ......................................................... 3-3
Fastener Tightening Specifications ........................... 3-3
Battery Usage........................................................... 3-3
Starter Motor Usage ................................................. 3-3
Generator Usage ...................................................... 3-3
Spark Plug Usage..................................................... 3-3
Schematic and Routing Diagrams ..........................3-3
Wiring Schematic - Genie 1.6L GM Dual Fuel ............ 3-4
Wiring Diagram - 1.6L Generic.................................... 3-5
Wiring Schematic - Tennant 1.6L GM GAS/L.P.G. ......3-6
Component Locator ................................................. 3-7
Engine Electrical Components ...................................3-7
Engine Electrical Component Locator Views ..............3-7
Diagnostic Information and Procedures .................3-8
Charging System Check ............................................3-8
Starting System Check.............................................. 3-8
Battery Common Causes of Failure ............................3-9
Battery Cautions ........................................................3-9
Important Battery Diagnosis Information ....................3-9
Battery Check .......................................................... 3-10
Battery Terminal Check ............................................ 3-11
Battery Not Operating Properly ................................ 3-12
Battery Electrical Drain/Parasitic Load ..................... 3-13
Current Drain Test..................................................... 3-16
Battery Hydrometer Displays Dark or Yellow Dot ...... 3-18
Battery is Undercharged or Overcharged .................. 3-18
Engine Cranks/Cranks Slowly but Does Not Start .... 3-19
Generator Noise Test ................................................ 3-20
Generator Not Operating Properly ............................ 3-20
Generator Assembly Bench Check .......................... 3-23
Starter Motor Noise Diagnosis ................................. 3-23
High-Pitched Whine During Cranking ........................ 3-23
High-Pitched Whine after the Engine Fires ............... 3-23
Loud Whoop Sound after the Engine Fires................ 3-24
Rumble Growl or Knock ........................................... 3-24
Starter No Load Test ................................................ 3-24
Starter Solenoid Does Not Click............................... 3-25
Starter Solenoid Clicks, Engine Does Not Crank or
Cranks Slowly .................................................... 3-26
Section 3
Engine Electrical
Spark Plug Wires Not Operating Properly ................. 3-28
Spark Plug Wire Resistance Test.............................. 3-28
Spark Plug Wire Routing .......................................... 3-28
Repair Instructions................................................. 3-28
Battery Cable Replacement...................................... 3-29
Battery Charging ...................................................... 3-30
Charging Procedure.................................................. 3-30
Charging Time Required ........................................... 3-31
Battery Charge Low or Completely Discharged......... 3-32
Battery Replacement ............................................... 3-32
Jump Starting in Case of Emergency....................... 3-33
Jump Starting Procedure ......................................... 3-33
Starter Motor Inspection .......................................... 3-34
Cleaning Procedure .................................................. 3-34
Component Electrical Testing ................................... 3-34
Armature Bearing Replacement................................ 3-34
Starter Motor Replacement ...................................... 3-35
Generator Replacement ........................................... 3-36
DIS Ignition Module Replacement ............................ 3-37
Setting Ignition Timing.............................................. 3-37
Crankshaft Position (CKP) Sensor Replacement ...... 3-37
Description and Operation .................................... 3-39
Starting System Description .................................... 3-39
Cranking Circuit ....................................................... 3-39
Starter Motor............................................................ 3-39
Starting System Circuit Description ......................... 3-39
Batteries .................................................................. 3-40
Built-In Hydrometer - If Equipped ........................ 3-40
Charging System Description ................................... 3-41
SI Series Generators ............................................... 3-41
Voltage Regulator ..................................................... 3-42
Charging System Circuit Description ........................ 3-42
Ignition System Description ..................................... 3-43
Ignition Switch ......................................................... 3-43
DIS Ignition Module.................................................. 3-43
Spark Plugs ............................................................. 3-44
Secondary Wiring ..................................................... 3-44
Crankshaft Position (CKP) Sensor ........................... 3-44
Special Tools and Equipment ............................... 3-45