Tech Tip

Construction Technique Service

1. General information

Troubleshooting No Start QAS 38-58-78-138 Generators

Tech Tip # : TTUSAGEN002
Priority : Information Only
Applicable to : QAS58-78JD Generators with the 1089 9455 73 Blandon Controller
PGC :
Responsible person : Scott Malm

2. Document overview
This document describes the following:
1. General information ................................................................................................................................................. 1
2. Document overview ................................................................................................................................................. 1
3. Subject ................................................................................................................................................................... 1
4. Reason for this bulletin ............................................................................................................................................ 1
5. Description.............................................................................................................................................................. 1
6. Application .............................................................................................................................................................. 8
7. Required parts ........................................................................................................................................................ 8
8. Planning ordering parts............................................................................................................................................ 8
9. Reporting ................................................................................................................................................................ 8
10. Safety precautions................................................................................................................................................... 8

3. Subject
Troubleshooting a no start condition from the Atlas Copco controller.

4. Reason for Tech Tip

This tip will aid the technician in troubleshooting and understanding the operation of the Atlas Copco controller on these
models.
Use this tip as a reference only. If you need additional assistance call Atlas Copco Technical Service at 1-800-732-6762.

5. Description

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• Check the emergency stop button to make sure it has not been depressed,
• Check the 10 amp DC circuit breaker to make sure it hasn’t tripped.
• Check the status of the oil pressure switch before powering up. This is to ensure the engine is not already running
and engaging the starter motor and causing damage. The standard configuration for Atlas Copco generators is a
normally open oil switch, which closes when running.

So the oil pressure switch must be in the engine stationary position for the module to work. The oil pressure input is
terminal 4 of the module, bottom left of the 5 way green block (wire number 6).
• Once the module is powered up, it will not engage the starter motor unless the D+ or WL signal (terminal 9, wire
number 2) is grounded. Again this is a safety feature to ensure the engine is not running and engaging the starter
motor. If terminal 9 is not grounded the starter will not engage.
• Check the circuit for the high coolant temp switch which will be normally closed during normal operation

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 • Check the positions of the DIP switches on the back of the controller to see if they are in the proper position. The
switches are very small but can be seen in the upper right corner of the back of the controller.

S4 is pre-heat delay, Long or short.

OFF = NO pH delay go straight to start
ON = PH delay (15 seconds of PH)

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 This is the start sequence for the module for local start:

1. Power on LED lights up.

2. The module checks to see if the engine is not running by looking for an open circuit to ground through the oil
pressure switch.
3. The module checks to see if the engine is not running by looking for a ground to the D+ terminal of the alternator.
4. The module checks the circuit for the normally closed coolant temperature switch.
5. The fuel solenoid circuit is energized.
6. The Pre-heat LED lights up and the pre-heat relay is energized for 1 to 12 seconds.
7. The starter relay is activated for a maximum of 12 seconds. If the engine fails to start, the starting sequence is
completed two more times if needed. If the engine still fails to start, the undervoltage LED is energised and power
to the fuel circuit is de energized.
8. When the engine starts and runs the alternator charge fail lamp is de energized.

There are no user servicible parts inside the module other than the rocker switch wich is Atlas Copco part number
2914 8264 00 and can be replaced using the following procedure:

The controller can be left in the control panel but the battery should be disconnected.

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Remove the plastic trim around the face of the controller.

Carefully peel the corner of the front decal enough to remove the phillips head screw from each corner.

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Push down on the locking tabs while forcing the the switch out. Repeat for the bottom set of tabs until the switch is free from
the module face.

You can spray the switch with electrical contact cleaner if a new switch is is not available and see if this cleans the contacts
sufficiently. Otherwise pull the leads one at a time and install them in the new switch. Care must be taken as neither the
wires nor the connectors are labled. The switch is a DPDT (double pole, double throw) on-off-on configeration. Assemble
the module in reverse order.

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6. Application
QAS 38-58- 78 and 138 Generators

7. Required parts
2914 8264 00 rocker switch if needed

8. Planning ordering parts

N/A

9. Reporting
N/A

10. Safety precautions

The operator must employ safe working practices and observe all related local work safety requirements and
regulations, also the technical documentation (such as operators manual and safety instructions) has to be followed.
• Maintenance must only be performed by authorized, trained and specialized personnel.
• Before maintenance, repair work, adjustment or any other non-routine checks, stop the equipment, switch off the
voltage, press the emergency button and depressurize the compressor/ equipment. In addition, the power insolating
switch must be opened and locked or removed.
• Use only the correct tools for maintenance and repair work.
• All maintenance work shall only be undertaken when the machine has cooled down.
• A warning sign bearing a legend such as ‘Work in progress; do not start’ shall be attached to the starting equipment.
• Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.
• For compressors, close the compressor air outlet valve before connecting or disconnecting a pipe.
Hydraulic attachments connecting hoses has to be disconnected before service will be provided
• Pneumatic hoses have to be disconnected before any service/maintenance/repair work is done on Pneumatic driven
Machines.
• For generators in parallel and when working on the electrical system, ensure that voltage from other units is not
reaching the unit, or that adequate and protection material for working under voltage is used.
• Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve
the entire system of pressure.
• Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed
openings with a clean cloth, paper or tape.
• Make sure that no tools, loose parts or rags are left in or on the machine.
• All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may
not be put out of action.
• Always wear the following personal protective equipment: Work clothing, safety shoes, safety goggles, ear protection
and safety gloves when there is a cutting risk or a risk for a heat injury.

Revision Log:

2/25/2015 SM changed description of coolant temperature switch to normally closed

9/10/15 SM minor graphical and layout changes. Included QAS 38 and 138.

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