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G12-150 Diesel Battery Charger Run Problem

PostPosted: Fri Jul 24, 2009 8:35 am
by jbemer
I installed a “new” Genie wiring controller (S/N 20090706 ordered 6Jul2009 invoice #14570) to replace a controller I believed to be defective. My G12-150 engine cranks but does not start and the red controller LED is lit indicating an error. This is the same problem I had with the previous controller.

I added wiring and a switch to hotwire the fuel solenoid (TB5-1/B+ to TB5-3/fuel solenoid) and the engine starts and runs normally. The engine shuts down when I switch off/disconnect the hotwire. I measured the wiring/run controller (RC) inputs/outputs with engine running and obtained the following results:

Fuel solenoid hotwired (hotwire switch on)
• RC-1/TB5-1: B+
• RC-2: Continuity to ground
• RC-3,4: N/A (Crank circuit)
• RC-5: Continuity to ground (NO oil pressure switch)
• RC-6: B+ (fuel solenoid)
• RC-7: B+ (water pump)
• RC-8: B+ (fuel pump)
• RC-9: B+ (hour meter)
• RC-10: Continuity to ground (NC coolant temperature switch)

Fuel solenoid NOT hotwired (hotwire switch off momentarily to make the
measurement)
• RC-1/TB5-1: B+
• RC-2: Continuity to ground
• RC-3,4: N/A (Crank circuit)
• RC-5: Continuity to ground (NO oil pressure switch)
• RC-6: 0v (fuel solenoid)
• RC-7: 0v (water pump)
• RC-8: 0v (fuel pump)
• RC-9: 0v (hour meter)
• RC-10: Continuity to ground (NC coolant temperature switch)

These measurements, I believe, show this “new” run controller was defective as received. The controller should supply B+ (battery volts) to RC-6,7,8,9 when its inputs, RC-1,2,5,10, are the values listed above. I assume the controller is also not supplying B+ to RC-6,7,8 when the engine is being cranked because it will crank but not start if the fuel solenoid isn’t hotwired.

Receiving a new run controller that is defective is surprising, to me, since I assumed these devices would be functioned after they are assembled. Am I missing something here?

Jan Bemer

Re: G12-150 Diesel Battery Charger Run Problem

PostPosted: Fri Jul 24, 2009 5:58 pm
by Coulomb
Why do you say that contacts 3 and 4 are N/A? In fact they are an input, and output. As an input they bypass the oil pressure requirement while cranking. At the same time while cranking, the fuel pump and water pump are actuated along with whatever you have connected to the run terminal.

Please follow the wiring diagram exactly.

Re: G12-150 Diesel Battery Charger Run Problem

PostPosted: Sat Jul 25, 2009 7:26 am
by jbemer
Thanks fo the reply. I listed RC-3,4 as N/A because the control panel stop start switch was in the run position and the engine was running when I made the measurements listed in my note.

The engine cranks but does not start unless the fuel solenoid is hotwired. This tells me the stop start switch, in the start position, is supplying B+ to RC-4 and RC-5 is supplying B+ to the starter motor solenoid. It also tells me the run controller is not functioning in the start mode because it is not supplying B+ to the fuel solenoid and the engine will not start without fuel.

I measure little or no resistance between RC-4 and RC-5. The starter motor would continue to crank with the engine running if either one of these terminals is hot (at B+) in the run mode. This is not the case and it indicates the start stop switch is functioning properly and TB-1 (B+) and TB-4 (crank) is, as it should be, an open circuit in the run mode.

All my measurements indicate the run controller is faulty. The NC coolant temperature and NO oil pressure switches are working properly - both show continuity to ground when the engine is running. I also shorted these switches to ground as described in troubleshooting guide and obtained the same results.

Re: G12-150 Diesel Battery Charger Run Problem

PostPosted: Sat Jul 25, 2009 12:29 pm
by Coulomb
Disconnect the wire from the starter solenoid, and then you can test it in both start and run conditions.

"I measure little or no resistance between RC-4 and RC-5." Did you mean 3 and 4? Tabs 3 and 4 are internally connected to make it convenient to wire the crank signal from the switch to the controller and then on to the starter solenoid.

Re: G12-150 Diesel Battery Charger Run Problem

PostPosted: Sun Jul 26, 2009 9:28 am
by jbemer
In my last note I did mean RC-3 and RC-4 (run controller crank tabs 3 and 4). Sorry about the error.

I disconnected the starter solenoid wire and obtained the following results with the start stop switch in the start position: B+ at RC-1,3,4,6,7,8,9; continuity to ground at RC-2,10; no continuity to ground at RC-5. I believe these measurements show it run controller is working properly in the start mode. Evidently the engine is starting but shuts down when the start stop switch key is released to the run position. I was wrong when I assumed the engine was not starting. I could hear the Tyco coil switch working with the absence of engine cranking/running noise.

I then shorted the NO oil pressure switch (RC-5) to ground and obtained the following results with the stop start switch in the run position: B+ at RC-1; continuity ground at RC-2,5,10; 0 volts at RC-3,4,6,7,8,9. I would have measured B+ at RC-6,7,8,9 If the run controller was functioning properly. The was no audible Tyco switch click. The red controller LED was lit.

Do these measurements show the replcaement run controller switch is faulty?

Re: G12-150 Diesel Battery Charger Run Problem

PostPosted: Mon Jul 27, 2009 10:08 am
by Coulomb
I'm convinced. We'll ship another one ASAP.