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Table of Contents
Page 1
SAFETY ........................... INSIDE FRONT COVER
SECTION 1:
GENERATOR FUNDAMENTALS ....................... 3-7
MAGNETISM ................................................................ 3
ELECTROMAGNETIC FIELDS .................................... 3
ELECTROMAGNETIC INDUCTION ............................. 3
A SIMPLE AC GENERATOR ........................................ 4
A MORE SOPHISTICATED AC GENERATOR ............. 4
FIELD BOOST .............................................................. 6
GENERATOR AC CONNECTION SYSTEM ................. 6
SECTION 2:
MAJOR GENERATOR COMPONENTS ............ 8-11
ROTOR ASSEMBLY ...................................................... 8
STATOR ASSEMBLY ..................................................... 8
BRUSH HOLDER ......................................................... 9
EXCITATION CIRCUIT COMPONENTS ....................... 9
CRANKCASE BREATHER ......................................... 10
CONTROL PANEL COMPONENT IDENTIFICATION . 11
SECTION 3:
INSULATION RESISTANCE TESTS .............. 12-14
EFFECTS OF DIRT AND MOISTURE ........................ 12
INSULATION RESISTANCE TESTERS ...................... 12
DRYING THE GENERATOR ....................................... 12
CLEANING THE GENERATOR .................................. 12
STATOR INSULATION RESISTANCE ......................... 13
TESTING ROTOR INSULATION ................................ 14
THE MEGOHMMETER .............................................. 14
SECTION 4:
MEASURING ELECTRICITY ......................... 15-17
METERS ..................................................................... 15
THE VOM .................................................................... 15
MEASURING AC VOLTAGE ....................................... 15
MEASURING DC VOLTAGE ....................................... 15
MEASURING AC FREQUENCY ................................. 15
MEASURING CURRENT ........................................... 16
MEASURING RESISTANCE ...................................... 16
ELECTRICAL UNITS .................................................. 17
OHM’S LAW ................................................................ 17
SECTION 5:
ENGINE DC CONTROL SYSTEM ................. 18-26
INTRODUCTION ........................................................ 18
OPERATIONAL ANALYSIS .................................... 18-21
PRINTED CIRCUIT BOARD ....................................... 22
BATTERY .................................................................... 22
7.5 AMP FUSE ........................................................... 23
START-STOP SWITCH ............................................... 23
STARTER CONTACTOR RELAY
& STARTER MOTOR ................................................. 24
SECTION 6:
TROUBLESHOOTING FLOWCHARTS .................. 25-34
IF PROBLEM INVOLVES AC OUTPUT ...................... 25
PROBLEM 1 –
VOLTAGE & FREQUENCY ARE BOTH
HIGH OR LOW ........................................................... 25
PROBLEM 2 –
GENERATOR PRODUCES ZERO VOLTAGE OR
RESIDUAL VOLTAGE (5-12 VAC) .......................... 26-27
PROBLEM 3 –
EXCESSIVE VOLTAGE/FREQUENCY DROOP
WHEN LOAD IS APPLIED .......................................... 27
PROBLEM 4 –
ENGINE OVERSPEED WARNING CODE
FLASHING ON SW1 LED (4 FLASHES) ....................... 28
PROBLEM 5 –
PRIMING FUNCTION DOES NOT WORK
(GASOLINE MODELS) ............................................... 28
PROBLEM 6 –
ENGINE WILL NOT CRANK ....................................... 29
PROBLEM 7 –
ENGINE CRANKS BUT WILL NOT START
(GASOLINE UNITS) ................................................... 30
PROBLEM 7 –
ENGINE CRANKS BUT WILL NOT START
(LP UNITS) ................................................................. 31
PROBLEM 8 –
ENGINE STARTS HARD AND RUNS ROUGH
(GASOLINE UNITS) ................................................... 32
PROBLEM 8 –
ENGINE STARTS HARD AND RUNS ROUGH
(LP UNITS) ................................................................. 33
PROBLEM 9 –
HIGH OIL TEMPERATURE FAULT (6 FLASHES)
OR LOW OIL PRESSURE FAULT (5 FLASHES) ....... 34
PROBLEM 10 –
7.5 AMP (F1) FUSE BLOWING .................................. 35
SECTION 7:
DIAGNOSTIC TESTS ...................................... 36-63
INTRODUCTION ........................................................ 36
TEST 1 –
Check No-Load Voltage And Frequency ...................... 36
TEST 2 –
Check Stepper Motor Control ...................................... 36
TEST 4 –
Fixed Excitation Test/Rotor Amp Draw ........................ 37
TEST 5 –
Check Field Boost ........................................................ 39
TEST 6 –
Test Stator DPE Winding ............................................. 39
TEST 7 –
Check Sensing Leads/Power Windings ...................... 40
TEST 8 –
Check Brush Leads ..................................................... 41
TEST 9 –
Check Brushes & Slip Rings ........................................ 42