service repair manual

1. -
E
m ~ m Service Manual
*
GEA SERIES
GENERATOR SETS
Printed U.S.A. 928-0501 5-94

2. Table of Contents
....................................................................Safety Precautions ii
1.Introduction
ABOUT THIS MANUAL ..................................................................... 1-1
........................................................................TESTEQUIPMENT 1-1
2.AC Control
AC CONTROL PANELCOMPONENTS ....................................................... 2-1
CONTROLBOX ........................................................................... 2-2
AC CONNECTIONS INSIDE MOUNTED AUTOMATIC TRANSFER SWITCH (ATS) ................ 2-3
AC CONNECTIONS WHEN AUTOMATIC TRANSFER swrrcH (ATS) NOT PROVIDED . . . . . . . . . . . . 2-4
VOLTAGEREGULATOR .................................................................... 2-5
PRINCIPLEOFGENERATOROPERATION ................................................... 2-8
3.DC Control
CONTROL PANEL COMPONENTS .......................................................... 3-1
............................ENGINEACCESSORIES. SENSORSAND SHUTDOWN SWITCHES 3-4
ENGlNEMONlTOR(Al1) ................................................................... 3-6
AUXILIARY RELAY BOARD (A28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
EMERGENCYO'!E!?R!DE MODULE (A29) ................................................... 3-10
ELECTRONICOVERSPEEDISTART DISCONNECTMODULE .................................. 3-11
COOLANT TEMPERATURE GAUGEASSEMBLY .............................................. 3-12
RELAYSKllANDK12 ..................................................................... 3-13
MANUAL FUEL SELECTOR SWITCH (S10) ................................................... 3-14
LOW GAS PRESSURESWITCH (E4) ........................................................ 3-14
...............................................................SEQUENCEOFOPERATION 3-14
4.Troubleshooting
............................................THE ENGINE DOES NOT CRANK IN RUN MODE 4-1
.........................................THE ENGINE DOES NOT CRANK IN REMOTE MODE 4-3
..............................................THE ENGINE CRANKS BUT DOES NOT START 4-4
THE ENGINE RUNS UNTIL FAULTSHUTDOWN ............................................. 4-6
............................................THE ENGINE LACKS POWER OR IS UNSTABLE 4-7
ANAMBERWARNINGLAMP ISON ........................................................ 4-8
........................THE GREEN RUN LAMP STAYS OFF BUT THE SET RUNS NORMALLY 4-9
NOOUTPUTVOLTAGE ................................................................. 4-10
OUTPUT VOLTAGE ISTOO HIGH OR TOO LOW ............................................ 4-13
.........................................................OUTPUT VOLTAGE IS UNSTABLE 4-14
..........................................THE FIELD CIRCUIT BREAKER KEEPSTRIPPING 4-15
THE PHASE CURRENTSARE UNBALANCED ............................................... 4-16
5.Generator
TESTINGTHEGENERATOR ................................................................ 5-1
............................................GENERATOR DISASSEMBLYAND REASSEMBLY 5-8
6.Fuel System1 Governor
FUELSYSTEM ............................................................................ 6-1
......................................GAS MIXTURE AND IDLE SPEED STOP ADJUSTMENTS 6-4
ELECTRONICGOVERNOR ................................................................. 6-6
GOVERNOR LINKAGE ..................................................................... 6-7
7.Wiring Diagrams

3. Safety Precautions
Before operating the generator set, readthe Operator's Manualand becomefamiliar with it andthe equip-
ment. Safe and efficient operatlon can be achieved only if the equlpment is properly operated and
maintained. Many accidents are caused by failure to follow fundamental rules and precautions.
The following symbols, foundthroughoutthis manual, alertyouto potentiallydangerousconditionsto the op-
erator, service personnel, or the equipment.
Thls symbol warns of lmmedlate hazards whlch wlll result In severe personal Injury or
death.
IAWARNINGI Thlssymbol refers to a hazaM or unsafepractice whlch can result In severepersonal In-
jury or death.
ACAUTION 1 Thls symbol refers to a hazard or unsafepractice which can result In personal injury or
product or property damage.
FUEL AND FUMESARE FLAMMABLE. Fire and explosion can result from improper practices.
DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compartment. Fuel
contact with hot engine or exhaust is a potential fire hazard.
DONOTpermitany flame, cigarette, pilotlight, spark, or other ignitionsource nearthegeneratorsetor fuel
tank.
Fuel lines must be adequately secured and free of leaks. Fuelconnection at the engine should be made
with an approved flexible line. Do not use copper pipingon flexible lines as copper will become brittle if
continuously vibrated or repeatedly bent.
Be sure all fuel supplies have a positive shutoff valve.
Donotsmokewhileservicingleadacidbatteries. Leadacidbatteriesemita highlyexplosivehydrogengas
that can be ignited by electrical arcing or by smoking.
EXHAUSTGASES ARE DEADLY
Provideanadequateexhaust systemto properlyexpeldischargedgases. Visuallyandaudibly inspectthe
exhaustdaily for leaksperthe maintenanceschedule. Ensurethat exhaust manifoldsaresecuredand not
warped. Do not use exhaust gases to heat a compartment.
Be sure the unit is well ventilated.
MOVINGPARTSCAN CAUSESEVERE PERSONALINJURY OR DEATH
Keep your hands, clothing, and jewelry away from moving parts.
Before startingwork on the generator set, disconnect starting batteries, negative (-) cable first. This will
prevent accidental starting.
Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in
positionover fans, drive belts, etc.
Do not wear loose clothing or jewelry in the vicinity of movingparts, or while working on electricalequip-
ment. Loose clothing and jewelry can become caught in moving parts. Jewelry can short out electrical
contacts and cause shock or burning.
If adjustment must be made while the unit is running, use extremecaution around hot manifolds,moving
parts, etc.
ELECTRICALSHOCK CAN CAUSESEVERE PERSONALINJURY OR DEATH
o Remove electric power before removingprotective shields or touching electricalequipment. Use rubber
insulativematsplacedondrywoodplatformsoverfloorsthat are metalor concretewhen around electrical
equipment. Do not wear damp clothing (particularlywet shoes) or allow skin surface to be damp when
har~dlirsgelectrical equipment.

4. Useextremecautionwhenworkingonelectricalcomponents.Highvoltagescancauseinjuryordeath. DO
NOT tamper with interlocks.
Followallapplicable stateand localelectricalcodes. Haveallelectricalinstallationsperformedbyaquali-
fied licensedelectrician. Tag open switches to avoidaccidental closure.
DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICALSYSTEM. Haz-
ardous voltages canflow fromthe generator set intothe utility line. Thiscreatesa potentialfor electrocu-
tion or property damage. Connect only through an approved isolationswitch or an approved paralleling
device.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat ex-
changer pressure capwhile the engine is running. Allow the generator set to cool and bleedthe system
pressure first.
Benzeneand lead, found in some gasoline, have been identifiedby some state and federal agencies as
causingcancer or reproductivetoxicity. When checking, drainingor addinggasoline,take care not to in-
gest, breathe the fumes, or contact gasoline.
Usedengineoilshavebeenidentifiedbysome stateorfederalagenciesascausingcanceror reproductive
toxicity. Whencheckingorchangingengineoil, takecarenotto ingest,breathethefumes, orcontactused
oil.
Provide appropriatefire extinguishers and installthem in convenient locations. Consult the localfire de-
partmentfor thecorrecttype of extinguisherto use. Do not usefoam onelectricalfires. Useextinguishers
ratedABC by NFPA.
Make sure that rags are not left on or near the engine.
Removeallunnecessarygreaseandoilfromthe unit. Accumulatedgreaseandoilcancauseoverheating
and engine damage which presenta potential fire hazard.
- Keep the generator set and the surrounding area clean and free from obstructions. Removeany debris
from the set and keepthe floor clean and dry.
Do not work on this equipment when mentally or physically fatigued, or after consumingany alcohol or
drug that makesthe operationof equipment unsafe.
iii

5. 1. Introduction
ABOUT THIS MANUAL
ThisservicemanualisfortheGEA Seriesgenerator
sets. Itincludesengineandgeneratortroubleshoot-
ing guides. Engine service instructions are in the
applicable engine service manual. Operating and
maintenanceinstructionsare inthe applicable Op-
erator's Manual.
This manualdoes not have instructionsfor servic-
ing printed circuit board assemblies. Always re-
place a faulty printed circuit board assembly. At-
tempts to repair a printedcircuit board can lead to
costly damage to the equipment.
ReadSafetyPrecautionsandcarefullyobserveall
instructionsand precautions in this manual.
TEST EQUIPMENT
Most of thetestsinthis manualcanbedonewith an
AC-DC multimeter, frequency meter, Wheatstone
bridge(0.001ohmprecisionis necessaryfor meas-
uringstatorwindingresistance)andloadtest panel.
~AWARNING]Improper Servicecanlead to quip-
ment damage, severepersonal injury or death.
Service must be performed by qualified per-
sons who know about fuel, electrical and me-
chanical hazards. Read the safety precautions
page and carefully observeall instructions and
precautions in this manual.
~AWARNING1 LPG and propane are heavier than
air. Explosive, leaking gas will settle in low
areas. If there is a possibility of leaking gas,
notify the operatorof theadjacentbelow-grade
vauit.

6. 2.AC Control
AC CONTROL PANEL COMPONENTS
The generator set control box is mountedon top of
the generator enclosure, facing the rear or either
side. Figure 2-1 points out the components on the
controlpanelthat haveto dowith AC output control.
See Page 7-3 for the connection diagram.
Field Clrcult Breaker (CB21): The field circuit
breaker protects the generator from over-excita-
tion.
AC Voltmeter (M21): The voltmeter indicates out-
put voltage for the phase selected.
ACAmmeter(M22):The ammeterindicatesoutput
amperage for the phase selected. Input to the am-
meterisfromcurrenttransformers CT21, CT22and
CT23. (CT23 is providedfor 3-phase only.)
PhaseSelector Switch(521):The selector switch
is used to select the phase for voltage and amper-
age readings.
Scale Indicator Lamps (0521 and DS22): The
scale indicator lamps indicate whether to read the
upperor lowerscalesof thevoltmeter andammeter.
Frequency/RPMMeter (M23):The frequency me-
ter indicatesoutput frequency in Hertz (Hz) and en-
gine speed in RPM.
Output Voltage Trimmer (R21): The output volt-
age trimmer can be used to adjust output voltage
plus or minus five percent of nominal voltage.
FIGURE 2-1. TYPICAL AC CONTROL PANEL COMPONENTS

7. CONTROL BOX
Figure2-2 illustratesthe controlbox withthe control
panelhingedopen. Notethe lexan (redplastic)cov-
er secured over the metersto protect from electric
shock.
~AWARNING]HAZARDOUS VOLTAGE! Touching
unlnsulatedllveparts insidethecontrolboxcan
result In severe personal Injury or death. Reln-
stall the protective cover to prevent contact
wlth bare, llve meter tennlnals.
TOP VIEW OF CONTROL BOX SIDE VIEW CONTROLBOX
LEXANCOVER SECURED BY INSU
THIS COVER MUST ALWAYS BE REINSTAUED FOLLOWINGSERVICE TO PROTECT FROMELECTRICSHOCK
FIGURE2-2. CONTROL BOX
2-2

8. CONTROL BOX
Figure2-2 illustratesthe controlbox withthe control
panelhingedopen. Notethe lexan (redplastic)cov-
er secured over the metersto protect from electric
shock.
[AWARNING1 HAZARDOUS VOLTAGE! Touching
unlnsulatedllveparts Insidethecontrolboxcan
result In severe personal Injury or death. Reln-
stall the protective cover to prevent contact
with bare, llve meter temlnals.
TOP VIEW OF CONTROL BOX SIDE VIEW CONTROL BOX
LEXANCOVER SECURED BY INSU OVER THE AC METER TERMINALS
THIS COVER MUSTALWAYS BE REINSTALLEDFOLLOWING SERVICE TO PROTECT FROMELECTRICSHOCK
FIGURE2-2. CONTROL BOX

9. 2.AC Control
AC CONTROL PANEL COMPONENTS
The generator set control box is mounted on top of
the generator enclosure, facing the rear or either
side. Figure 2-1 points out the components on the
controlpanelthat haveto dowith AC output control.
See Page 7-3 for the connection diagram.
Field Circuit Breaker (CB21): The field circuit
breaker protects the generator from over-excita-
tion.
AC Voltmeter (M21): The voltmeter indicates out-
put voltage for the phase selected.
ACAmmeter(M22):The ammeterindicatesoutput
amperage for the phase selected. Inputto the am-
meterisfrom currenttransformersCT21, CT22and
CT23. (CT23 is providedfor 3-phase only.)
PhaseSelector Switch(S21): The selector switch
is used to select the phase for voltage and amper-
age readings.
Scale indicator Lamps (DS21 and DS22): The
scale indicator lamps indicate whether to read the
upperor lowerscalesofthevoltmeter andammeter.
Frequency/RPM Meter(M23): The frequency me-
ter indicatesoutput frequency in Hertz (Hz) and en-
gine speed in RPM.
Output Voltage Trimmer (R21): The output volt-
age trimmer can be used to adjust output voltage
plus or minus five percent of nominalvoltage.
FIELD CIRCUIT BREAKER
(CB21)
AC VOLTMETER AC AMMETER
(M22)
FREQUENCYIRPM METER
(M23)
SCALE INDICATOR LAMPS
(DS21 AND DS22)
FIGURE 2-1. TYPICAL AC CONTROL PANELCOMPONENTS

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11. AC CONNECTIONSINSIDE MOUNTED -1 HAZARDOUS VOLTAGE!Touching
AUTOMATICTRANSFER SWITCH (ATS) uninsuiated live parts inside the automatic
Figure2-3illustratesthe AC powerand controlcon- tmnsfer witchcan in severepersonaib-
nections inside the mounted automatic transfer juryordeath. Shutdown thesetanddisCOnnect
switch. See Pages 7-3, 7-6 and 7-7 for the control, ALL power sources to thegenerator set before
generator and ATS connection diagrams. opening the door.
ATS TERMINAL AUTOMATIC TRANSFER PHASE CONNECTIONS
BLOCKSTB2 AND TB3 SWITCH FOR NORMAL SUPPLY
0 0 0
0 0 0
0 0 0
0 0 0
GROUNDING LUGS CONTROL TRANSFORMERS HEATER CIRCUITS GENERATOR LINE
CT21, CT22 CIRCUIT BREAKER CIRCUIT BREAKER
FIGURE2-3. TYPICAL CONNECTIONS INSIDE MOUNTEDAUTOMATIC TRANSFER SWITCH

12. AC CONNECTIONSWHEN AUTOMATIC
TRANSFER SWITCH (ATS) NOT
PROVIDED
Figure2-4illustratesthe poweroutput box, which is
part of the right-hand side of the generator enclo-
sure (facing generator end). See Pages 7-3, 7-6
and 7-7 for the control, generatorand ATS connec-
tion diagrams.
(AWARNING1 HAZARDOUS VOLTAGE! Touching
uninsulated liveparts inside theAC power out-
put box can result In severe personal Injury or
death. Shut down the set and disconnect ALL
power sources to the generator set before re-
movlng the cover of the AC power output box.
See Figure 2-4.
GENERATOR CURRENT TRANSFORMERS TERMINAL BLOCK BREAKER TERMINALS LINECIRCUIT
LEAD CT21, CT22AND CT23 FOR CONNECTING FOR CONNECTING BREAKER
ENTRANCE (3-PHONLY) M E POLARITY GENERATOR LEADS GENERATOR LEADS
DOTSMUST BE UP
HEATERS (CONNECTEDTO
NORMAL SOURCE)
THESETERMNALSARE
LIVEWHEN THE SET ISNOT
RUNNING-DISCONNECT LOAD WIRING CONTROL FOR CONTROLLEADS BREAKER TERMINALS
POWER BEFOREREMOVING STUB-UP WIRING FROMAUTOMATIC FOR LOAD
AC OUTPUT BOX COVER. SPACE HARNESS TRANSFER SWITCH CONNECTIONS
L
FIGURE2-4. POWER OUTPUT BOX

13. VOLTAGE REGULATOR
Figure 2-5 shows the terminals, the three selector
switches and the voltage adjusting potentiometer
on the voltage regulator board. Figure 2-6 shows
the connections.
The voltage regulatorisaccessibleby removingthe
top coverof the controlbox. Itis mountedon a plate
on the wall opposite the control panel. Note the
orientation of the voltage regulatoron its mounting
plate with terminal block VR21 at the bottom.
Setting Selector Switches
Check and, if necessary, reposition the selector
switches as follows when replacinga voltage regu-
lator:
1. Press S1-(1-4)and S1-(2-3)down on the
side marked OFF. (S1 is a rocker switch.)
2. Slide S2 to the left-hand position. (S2 is a
slide switch.)
3. For 60 Hertz operation: Press S3-(1-4)to 4
(OFF) and S3-(2-3)to 2 (ON). (S3 is a rocker
switch.)
4. For 50 Hertz operation: Press S3-(1-4)to 1
(ON) and S3-(2-3)to 2 (ON). (S3 is a rocker
switch.)
Adjusting Voltage
Use the control panel mounted voltage trimmer, if
provided, for small voltage adjustments. Measure
generator output voltage while the set is running
without loadatthe nominalfrequency. Ifthetrimmer
does not provide enough adjustment, lock it at its
midpoint. Then turn voltage adjusting pot R32 on
the regulatorboard until rated voltage is obtained.
If there is no output voltage, flash the field as fol-
lows:
1. Assemble a 6 volt battery, 10 ohm resistor,
18 volt voltage suppressor and 12 amp, 300
volt diode as shown in Figure 2-6.
2. While the set is running at nominalfrequency,
momentarily connect the positive (+) side of
the the circuit to voltage regulatorterminal
VR21-F1 and the negative side (-) to voltage
regulator terminal VR21-F2.
1ACAUTIONI The voltage regulator could be
damagedIf theflashingcircuitis connected
for more than 5 seconds.
3. Check output voltage, shut down the set and
restart it. See Troubleshootingif output volt-
age does not build up without field flashing.
. D .p.HAZARDOUS VOLTAGE! Touching
uninsulated live parts inside the control and
power output boxes can result In severe per-
sonal Injury or death. Measurements and ad-
justments must be done with care to avoid
touching unlnsulated live parts.
Stand ona dry woodenplatform or rubber Insu-
lating mat, make sure your clothing and shoes
are dry, removejewelry and use toolswithInsu-
lated handles.

14. 6 8 L 9 S P
SELECTOR S
FIGURE2-5. VOLTAGE REGULATOR TERMINALS, SELECTOR SWITCHES AND VOLTAGE ADJUSTING POT