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VANAIR.COM • 800-526-881 START•ALL
®
HYDRAULIC SERIES TROUBLESHOOTING GUIDE
TOOLS REQUIRED FOR THE JOB
Digital Volt Ohm Meter/Multi Meter
(2) Jumper Wires that are 6-12” long, 14 gauge or better wire, with clamps at both ends
12 volt battery or jump pack that is in good working order
Set of jumper cables (if using a 12 volt battery for testing)
GENERAL INSPECTION
• Inspect the cable/clamp assembly; look for cuts, abrasions, or breaks in the cable.
• Check for worn jaws on clamp ends.
• Check for excessive corrosion on all terminal end connections.
• Check for proper belt tension. Belts should deflect approximately 3/8” under light finger pressure
PLEASE NOTE: THIS TROUBLESHOOTING GUIDE HAS BEEN DESIGNED TO TEST YOUR START
•
ALL
®
UNIT IN THE ORDER WRITTEN. IT IS NECESSARY TO FOLLOW THE TROUBLESHOOTING STEPS
IN ORDER FROM BEGINNING TO END. FAILURE TO DO SO WILL RESULT IN FALSE READINGS AND
MAY CAUSE DELAYS IN THE TROUBLESHOOTING PROCESS.
For Proper Testing Procedure And To Ensure Proper Output Of The Generators, Please
Do The Test With The Generators On The Machine (
Not Being Bench Tested
).
NOTICE
!
TESTING THE GENERATORS
1. Inspect the generator for a solder ring, solder flakes or drops inside the generator housing just behind the brushes. If a
ring of solder is found near the brush plate, the generator needs to be replaced; the generators have been overheated.
If no solder ring is found, each generator needs to be tested.
When testing the 79-406/79-510 isolated ground generator, the ground stud on the
bottom of the generator must be grounded by running a jumper wire from the
ground stud to a good ground connection (such as a generator mounting bolt). You
will also need to jump the field post and the armature post together. These isolated
ground generators are only used on 12/24 volt single cable starting units.
(Fig. 1)
2. Remove all the wires from the generators and label them for re-installation. Install a bypass lead between the field post
(small terminal on top of the generator) and armature post (large terminal on top of the generator).
(FIG. 2)
3. Attach the positive probe from a volt meter to the armature post, and the negative probe to a good ground connection
(such as a generator mounting bolt).
4. With the flow control at maximum, the voltage should read
22-28 VOLTS
on the volt meter. If the voltage reads 22, check
the brushes for excessive wear. Brush length should be a minimum of 1/4”. If brushes are less than 1/4”, replace the
brushes. Retest generator to confirm 22-28 Volts until all generators pass the test.
5. If little or no voltage is present, replace or rebuild the generator.
6. Test the remaining generators by following the above steps for each generator. If all generators perform satisfactorily,
reconnect the wires to each of the generators.
DO NOT HOOK UP THE VOLTAGE CONTROL WIRES AT THIS TIME.
NOTICE
!
FIG. 2
FIELD POST
ARMATURE POST
FIG. 1
FIELD POST
GROUND
GROUND POST
ARMATURE POST
