background image

35

T

T

T

T

R

R

R

R

O

O

O

O

U

U

U

U

B

B

B

B

L

L

L

L

E

E

E

E

S

S

S

S

H

H

H

H

O

O

O

O

O

O

O

O

T

T

T

T

II

II

N

N

N

N

G

G

G

G

SYMPTOM

POSSIBLE CAUSE

CORRECTIVE ACTION

Low generator output voltage

Low engine speed

• Verify correct engine speed.  Remove excess 
loads or adjust speed as required.

Excitation capacitor failure

• Contact a qualified generator dealer for service 
assistance.

Generator diode or varistor failure

• Contact a qualified generator dealer for service 
assistance.

Overspeed light stays lit

Shutdown due to high engine 
speed

• Verify correct engine speed setting. Adjust 
engine speed as required.

Underspeed light stays lit

Shutdown due to low engine speed • Reduce loads connected to generator

• Check engine speed setting at no load.  Adjust 
as required.

Overcrank light stays lit

Failure to start 

• See "Engine cranks without starting" 

Not In Auto light stays lit

Generator not set for unattended 
operation

• Place mode switch into AUTO position if 
automatic function is required

Low oil pressure light stays lit

Shutdown due to low engine oil 
pressure

• Check engine oil level.

• Verify correct type of engine oil for ambient 
temperature conditions

Low battery light stays lit

Low battery

• Test battery. Replace as necessary.
• Ensure charger is plugged into GFCI receptacle

• Check for tripped GFCI receptacle.  Reset if 
required.
• Check for tripped breaker in branch circuit 
supplying GFCI.  Reset if required.
• Check all charger cable connections for 
cleanness and tightness.
• Check battery charger inline fuse
• Check charger lights to verify correct operation.  
See Table A, Page 29.

Blown charger circuit fuse

• Check engine alternator fuse

High engine temperature light 
stays lit

Shutdown due to high engine 
temperature

• Allow engine to cool, then restart

• Decrease loads on generator
• Check enclosure openings for blockage
• Check oil cooler for blockage

Summary of Contents for PM400911

Page 1: ...aintenance of the generator and battery Record the model and serial numbers of your generator below Model Number ____________________ Serial Number ____________________ Date Purchased ________________...

Page 2: ...al 20 Fuel 20 Generator feature identification 21 Generator operation 22 24 Control panel features 22 Starting the generator 23 Cyclic crank 23 Run state 23 Shutdown 23 Status indicators 24 Faults 24...

Page 3: ...Do not use exhaust air to heat a room Do not allow exhaust air to enter a building through windows doors air intakes or other means Avoid breathing exhaust air while installing operating or servicing...

Page 4: ...on Units with broken or missing parts without protective housing or covers should never be operated Contact your service center for replacement parts Inspect the generator regularly and contact your n...

Page 5: ...s and labor and lower future maintenance Some items to consider in planning generator installation are safe generator operation use of an Automatic Transfer Switch load requirements generator location...

Page 6: ...at and may create a fire hazard Do not allow snow or leaves to cover enclosure openings Leave a three foot open area around all sides of the unit Do not plant trees or plants which may grow within thr...

Page 7: ...generator power and required generator control system Due to the complex nature of electrical distribution systems the sizing selection and installation of a switch is best handled by a licensed elect...

Page 8: ...mensions at least six inches larger than the base size in all directions are recommended It is possible to use a standard concrete pad if desired When using this method a reinforced pad a minimum of 2...

Page 9: ...9 I I I IN N N NS S S ST T T TA A A AL L L LL L L LA A A AT T T TI I I IO O O ON N N N D D D DR R R RA A A AW W W WI I I IN N N NG G G GS S S S...

Page 10: ...es given in Table 310 16 of the latest revision of The National Electric Code NFPA 70 To connect the wires strip the insulation back approximately from the end of the wire insert the stripped end into...

Page 11: ...approximately from the end of the wire insert the stripped end under the screw and washer on the terminal block then torque the terminal block screw to 20 in lbs 2 3 N m When the control panel mode s...

Page 12: ...ART 22 HIGH TEMPERATURE SENDER 32 120V UTILITY HOT 3 GENERATOR GROUND 13 STARTER SHIFT SIGNAL 23 ALARM SWITCH GROUND 33 120V UTILITY NEUTRAL 4 CONTROLLER START SIGNAL 14 MODE SWITCH AUTO 24 LOW OIL SE...

Page 13: ...using Propane Vapor F F F FU U U UE E E EL L L L S S S SP P P PE E E EC C C CI I I IF F F FI I I IC C C CA A A AT T T TI I I IO O O ON N N NS S S S A A A AN N N ND D D D C C C CO O O ON N N NS S S SU...

Page 14: ...inimum pressure of 7 water column 4 oz Per the National Gas Code NFPA 54 ANSI 2223 1 a manual shutoff valve in the fuel supply line to the generator is recommended Once all external connections are co...

Page 15: ...supply connections verify proper positioning of the flexible engine supply hose on the fuel pressure regulator output as shown in Fig F The factory default position is for natural gas NG requiring a...

Page 16: ...g liquid is to be flushed with water and the area dried A battery presents a risk of electrical shock and a high short circuit current The following precautions are to be observed when working on batt...

Page 17: ...providing consistent starting A quick check of charger connections will verify that factory connections are correct so the charger can function as intended Insure that the charger is connected by chec...

Page 18: ...tes then move the main line circuit breaker handle to the ON position 8 Check across the terminals of the main line power output block Red to Black for proper frequency and voltage Frequency should re...

Page 19: ...in x27 in 42 1 2 in x32 in x27 in Weight 478 lb 476 lb PM401211 PM400911 Manufacturer Honda Honda Manufacturer Engine Model VXC GDACM VXC GDADM Style Air cooled V twin 2 cylinder Air cooled V twin 2 c...

Page 20: ...age 6 Amp 3 stage Fuse 14 Amp 32 VDC Type SFE 14 Amp 32 VDC Type SFE Engine Alternator 10 Amp regulated 10 Amp regulated Fuse 25 Amp 32 VDC Type 3AG 25 Amp 32 VDC Type 3AG Fuel Solenoids Opening Volta...

Page 21: ...EGULATOR LOCKOFF SOLENOIDS Controls fuel flow to engine 8 INTERCONNECTION TERMINAL BLOCKS Provided for quick connection of generator wiring to transfer switch during generator installation 9 OIL LEVEL...

Page 22: ...F position Placing the breaker in this position does not prevent startup of the generator C Status Indicator Lights Status indicator lights are provided to communicate the status of the generator to t...

Page 23: ...iods crank attempts are halted and the controller begins monitoring for proper function of the generator In the event that three 10 second start attempts occur without the engine starting cranking att...

Page 24: ...to the troubleshooting section of this manual or contact a qualified service technician for assistance C OVERCRANK The Overcrank light is lit if all three 10 second cyclic crank attempts are unsucces...

Page 25: ...st X Fuel System Check X Cooling Air Openings Check X To ensure reliable generator operation it is critical to periodically inspect all components The following chart is provided as a guide for servic...

Page 26: ...kin allow unit to cool before touching internal generator or engine components Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the generator before rem...

Page 27: ...from the filter into the drain pan 6 Apply a light film of oil to the gasket on the new oil filter then screw the filter onto the adapter until the gasket lightly touches the adapter face Tighten the...

Page 28: ...ower to crank the engine fast enough for reliable starts The steps below are suggested to care for the battery and charger 1 Access the battery A by removing the 3 access panel screws B shown in Fig E...

Page 29: ...r is recharging at the BULK rate of 6 Amps While the red LED is on the voltage measured will be 11 8 to 14 volts If the red LED stays on for more than 24 hours refer to the troubleshooting section of...

Page 30: ...and front panel I as indicated in Fig I to access the front engine spark plug J 6 Pull the spark plug boots loose then clean any dirt from the area around the spark plugs Remove the spark plugs with...

Page 31: ...lid paint 2 Open the battery access panel by removing the 3 screws and rotating the panel outward see Fig E on page 28 2 Remove the 2 screws C fastening the exhaust chamber panel D to the rear engine...

Page 32: ...shown in Fig K Turn the screw clockwise to increase frequency and counterclockwise to decrease frequency 4 Turn the engine off by moving the control panel Mode switch back to the OFF position E E E EN...

Page 33: ...n fittings or clamps Check all connections for leaks while the generator is running using approved equipment and methods DO NOT use a flame to check for leaks V V V VA A A AL L L LV V V VE E E E C C C...

Page 34: ...upplying GFCI Reset if required Check all charger cable connections for cleanness and tightness Check charger lights to verify correct operation See Table A Page 29 Poor fuel supply Ensure all manual...

Page 35: ...out starting Not In Auto light stays lit Generator not set for unattended operation Place mode switch into AUTO position if automatic function is required Low oil pressure light stays lit Shutdown due...

Page 36: ...muffler Honda 11 N A 1 Nut 1 4 20 Nylon stop 12 094 0093 1 Isolator muffler bracket to panel 13 145 0418 1 Tail pipe 14 N A 6 Lock washer 5 16 Item Part No Qty Description 15 N A 2 Screw m8 x 13 mm lg...

Page 37: ...panel bottom portion includes item 15 18 10 S115 0218 1 Door assembly includes inner door panel 11 094 0075 1 Insulation not shown Item Part No Qty Description 12 103 0121 1 Clip hood rod 13 0056905 1...

Page 38: ...5 0056766 1 Lock hooked pawl 6 114 0571 1 Bracket lid stop 7 0058221 4 Screw M5 8 x 8MM 8 N A 1 Nut 1 4 20 Nylon stop Item Part No Qty Description 9 026 0535 1 Ground strap 17 lg 10 107 0062 2 Hinge i...

Page 39: ...03 2 Diode varistor assembly 5 059 0348 1 Rotor bolt 6 160 0312 1 Stator assembly 7 166 0133 2 Capacitor 40 F 500V 8 077 0168 1 Terminal box cover 9 098 2827 1 Warning label Item Part No Qty Descripti...

Page 40: ...anel assembly see pages 41 42 43 for details 19 094 0095 2 Spacer 20 N A 2 Screw 10 x 1 2 sheet metal Item Part No Qty Description 21 109 0100 1 Base plastic 22 071 0031 1 Hose clamp 23 N A 1 Screw 10...

Page 41: ...75 lg 21 026 0539 1 Terminal block 2 row 20A 4 pole 22 098 2800 1 Warning label 23 N A 1 Elbow 1 2 NPT x 1 2 NPT Item Part No Qty Description 24 019 0211 1 Regulator assy GX670 PM401211 or 019 0213 1...

Page 42: ...l box top includes item 14 8 0056884 1 Switch momentary 9 060 0175 4 Standoff 6 32 x 75 lg 10 026 0534 1 Controller board CP200 11 N A 4 Nut 6 32 Nylon stop Item Part No Qty Description 12 002 0060 1...

Page 43: ...ve 5 N A 1 Battery BCI Group 26 or 26R 6 059 0344 2 J bolt 1 4 20 7 S115 0229 1 Battery shelf 8 0057024 4 Battery standoff rubber 9 N A 2 Bolt 1 4 20 x 625 lg 10 N A 2 Screw 1 4 20 x 1 lg 11 0057217 1...

Page 44: ...44 NOTES...

Page 45: ...45 NOTES...

Page 46: ...e caused by operation with improper fuel or at speeds loads conditions modifications or installation contrary to published specifications or recommendations Damage caused by negligent maintenance such...

Page 47: ...atrice de r serve Coleman Powermate que vous avez achet e peut n cessiter occasionnellement des pi ces de rechange pour demeurer en parfait tat de marche au fil des ann es Pour commander des pi ces ve...

Page 48: ...48...

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