Ford CSG-649 Generator Set

1. Check that the stability control is in its extreme counterclockwise position.
2. Start engine. Allow the governor to control the engine. If engine is unstable, turn the gain control counterclockwise until stability is obtained. Adjust speed screw to proper engine speed.
3. Turn the gain control clockwise until the engine becomes just unstable. Back the gain control slightly counterclockwise until the engine is again stable.
4. Turn the stability control clockwise until the engine becomes just unstable. Back the stability control slightly counterclockwise until the engine is again stable.

Tools: Frequency meter

1. Start the generator set, observe the frequency meter.
2. Loosen the fuel pump high speed screw locknut to make the adjustments.
3. To increase or decrease the frequency (at no load), rotate the screw clockwise or counterclockwise respectively.
4. Tighten the locknut.
5. Loaded droop frequency may alternately be adjusted to the operating frequency at full load.

Tools: Belt tension gauge T63L-8620-A, Model 210019 or equivalent

1. Install the belt tension tool on the drive belt and check the tension.
2. If adjustment is necessary, loosen the alternator mounting bolts and the alternator adjusting arm bolts.
3. Move the alternator toward or away from the engine until the correct tension is obtained.
4. Remove the gauge.
5. Tighten the alternator adjusting arm bolt and mounting bolts.
6. Install the tension gauge and recheck belt tension.

Tools: Plastigage, Jack, Torque wrench

1. Clean the crankshaft journals; inspect journals and thrust faces for nicks, burrs or bearing pickup.
2. If fitting a main bearing, position a jack under the counterweight adjoining the bearing being checked; do not place jack under front post.
3. Place a piece of Plastigage on the bearing surface across the full width of the bearing cap, about 1/4 inch off center.
4. Install the cap and torque the bolts to specifications; do not turn the crankshaft while Plastigage is in place.
5. Remove the cap and check the width of the Plastigage at the widest and narrowest points with the scale.
6. If clearance exceeds limits, try 0.001 or 0.002 inch undersize bearings in combination with standard bearings.
7. Remove the Plastigage and apply a light coat of engine oil to the journal and bearings; install the cap and torque bolts to specifications.
8. Repeat for the remaining bearings that require replacement.

Tools: Hand tachometer, Frequency meter

1. With the set running at full or rated load, check speed with hand tachometer or frequency meter.
2. Loosen locking nut on speed adjusting screw; turn clockwise to increase speed (and frequency) or counterclockwise to decrease; lock nut at new setting.
3. For sensitivity, loosen the nut at bottom of adjusting eyebolt and tighten the top nut to draw the head of the eyebolt closer to the governor arm pivot point (more sensitive).
4. To make governor control less sensitive, loosen the top nut and tighten the bottom nut to move the head away from the pivot point.
5. Recheck speed after sensitivity adjustment since changing this will also affect speed.

Tools: Frequency meter

1. On Microcomputer equipped generators, snip the jumper indicated in Figure A1 to convert from 60 Hz to 50 Hz.
2. Check frequency meter for a no load reading of 63 Hz for 60 Hz operation and 53 Hz for 50 Hz operation.
3. If equipped with isochronous governor, check for 60 and 50 Hz operation at no load.
4. If no frequency meter, connect meter across VO and V7 on control board terminal strip (set must not be running while making connection).

Tools: DC power supply

1. Move Generator Master Switch to AUTO position. SYSTEM READY lamp should go on.
2. Rotate potentiometers R42 (High Batt. Volts) and R25 (Low Batt. Volts) fully counterclockwise.
3. Set DC power supply at 10 volts (20 volts for 24-volt units). Slowly rotate pot R25 clockwise until BAT. LOW VOLTS lamp lights.
4. Set DC power supply at 15 volts (30 volts for 24-volt units). Slowly rotate pot R42 clockwise until BAT. HIGH VOLTS lamp lights.
5. Set DC power supply between 10 to 15 volts (20 to 30 volts for 24-volt units). SYSTEM READY lamp should be on.
6. Seal pots after settings have been established.

Tools: timing light, tachometer

1. Disconnect and plug the vacuum advance line.
2. Clean and mark the specified timing mark with chalk or paint.
3. Connect timing light to No. 1 cylinder spark plug wire.
4. Start engine and reduce idle speed to 800 rpm.
5. Adjust distributor by rotating until timing mark aligns.
6. Reconnect vacuum advance; check centrifugal advance at 2000 rpm.

Tools: Timing light, Tachometer

1. Clean and mark the specified timing mark with chalk or white paint.
2. Disconnect the vacuum line and plug the disconnected vacuum line.
3. Connect a timing light to the No. 1 cylinder spark plug wire and a tachometer to the engine.
4. Start the engine and reduce idle speed to 600 RPM to be sure centrifugal advance is not operating.
5. Direct the timing light on the timing marks; the notch on the pulley should line up between the 4 and 8.
6. If not to specification, loosen the distributor retaining bolt and rotate the distributor body until marks are in line.
7. Tighten the distributor retaining bolt and connect the vacuum hose.
8. Accelerate the engine and verify the timing mark advances; disconnect the timing light.

1. Turn the overfrequency adjustment potentiometer fully clockwise (CW).
2. Place master switch in RUN to start the generator set.
3. Adjust governor per engine operation manual, engine service manual, or governor section of this manual.
4. Slowly turn overfrequency potentiometer counterclockwise (CCW) until the LED starts flashing; after about 10 seconds the set shuts down on auxiliary fault.
5. Place master switch to OFF/RESET to reset the controller.
6. Place master switch to RUN to start the generator set.
7. Readjust the governor to the desired frequency as required.
8. Place master switch to OFF/RESET to stop the generator set.

⚠ Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.

⚠ Disconnecting the electrical load. Hazardous voltage will cause severe injury or death.

1. Disconnect generator set from load by opening line circuit breaker or disconnecting and taping output leads.
2. Determine overvoltage shutdown value based on user requirement; factory setting is 15% above nominal line-to-neutral voltage.
3. Remove the controller cover.
4. Place master switch in RUN to start the generator set.
5. Observe AC voltmeter; turn voltage adjustment potentiometer CW until generator set shuts down.
6. If the shutdown point is correct, go to step 12; otherwise continue.
7. Turn controller circuit board R42 adjustment potentiometer fully CW.
8. Place master switch to OFF/RESET to reset; then to RUN to start.
9. Observe AC voltmeter while turning voltage adjustment potentiometer to desired overvoltage shutdown point.
10. Turn R42 adjustment potentiometer slowly CCW until the generator set shuts down.
11. Turn controller voltage adjustment potentiometer slightly CCW.
12. Place master switch OFF/RESET then RUN to start; adjust for correct voltage and phase.
13. Place master switch OFF/RESET to stop.
14. Disconnect battery negative lead first; reconnect generator set to load; reconnect battery negative lead last.

Tools: Voltmeter, Wattmeter

1. Remove any load; start each generator set with master switch in RUN.
2. Set reactive droop compensator rheostat on generator set no. 1 to minimum CCW; record rpm/frequency and voltage at 1/4 load steps to full load.
3. Repeat for generator set no. 2.
4. Compare readings; adjust voltage within 1 volt and speed within 3 rpm (or 0.1 Hz) at each load step.
5. Check droop compensation on each unit with an inductive load 1/2 to full load.
6. Adjust rheostat to approximately 4% below rated voltage at full load.
7. Repeat for unit no. 2.