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Page 1
SSAAFFEETTYY ........................................................ IINNSSIIDDEE FFRROONNTT CCOOVVEERR
SSEECCTTIIOONN 11::
GGEENNEERRAATTOORR FFUUNNDDAAMMEENNTTAALLSS ............................................ 33--77
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
SSEECCTTIIOONN 22::
MMAAJJOORR GGEENNEERRAATTOORR CCOOMMPPOONNEENNTTSS ........................ 88--1111
ROTOR ASSEMBLY ...................................................... 8
STATOR ASSEMBLY .................................................... 8
BRUSH HOLDER .......................................................... 9
BATTERY CHARGE COMPONENTS .......................... 9
EXCITATION CIRCUIT COMPONENTS ...................... 9
CRANKCASE BREATHER .......................................... 10
SSEECCTTIIOONN 33::
IINNSSUULLAATTIIOONN RREESSIISSTTAANNCCEE TTEESSTTSS ............................ 1122--1144
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
SSEECCTTIIOONN 44::
MMEEAASSUURRIINNGG EELLEECCTTRRIICCIITTYY .................................................... 1155--1177
METERS ...................................................................... 15
THE VOM .................................................................... 15
MEASURING AC VOLTAGE ...................................... 15
MEASURING DC VOLTAGE ...................................... 15
MEASURING AC FREQUENCY ................................ 16
MEASURING CURRENT ............................................ 16
MEASURING RESISTANCE ...................................... 16
ELECTRICAL UNITS .................................................. 17
OHM’S LAW ................................................................ 17
SSEECCTTIIOONN 55::
EENNGGIINNEE DDCC CCOONNTTRROOLL SSYYSSTTEEMM ................................ 1188--2266
INTRODUCTION ........................................................ 18
OPERATIONAL ANALYSIS .................................. 18-23
ENGINE CONTROLLER CIRCUIT BOARD ................ 24
BATTERY .................................................................... 24
7.5 AMP FUSE ............................................................ 25
FUEL PRIMER SWITCH ............................................ 25
START-STOP SWITCH .............................................. 25
STARTER CONTACTOR RELAY
& STARTER MOTOR ................................................ 26
SSEECCTTIIOONN 66::
TTRROOUUBBLLEESSHHOOOOTTIINNGG FFLLOOWWCCHHAARRTTSS ........................................ 2277--3377
IF PROBLEM INVOLVES AC OUTPUT ...................... 27
PROBLEM 1 -
VOLTAGE & FREQUENCY ARE BOTH
HIGH OR LOW ............................................................ 27
PROBLEM 2 -
GENERATOR PRODUCES ZERO VOLTAGE OR
RESIDUAL VOLTAGE (5-12 VAC) ........................ 28-29
PROBLEM 3 -
NO BATTERY CHARGE OUTPUT .............................. 29
PROBLEM 4 -
EXCESSIVE VOLTAGE/FREQUENCY DROOP
WHEN LOAD IS APPLIED .......................................... 30
PROBLEM 5 -
PRIMING FUNCTION DOES NOT WORK
(GASOLINE MODELS) ................................................ 30
PROBLEM 6 -
ENGINE WILL NOT CRANK ...................................... 31
PROBLEM 7 -
ENGINE CRANKS BUT WILL NOT START
(GASOLINE UNITS) .................................................... 32
PROBLEM 7 -
ENGINE CRANKS BUT WILL NOT START
(LP UNITS) .................................................................. 33
PROBLEM 8 -
ENGINE STARTS HARD AND RUNS ROUGH
(GASOLINE UNITS) .................................................... 34
PROBLEM 8 -
ENGINE STARTS HARD AND RUNS ROUGH
(LP UNITS) .................................................................. 34
PROBLEM 9 -
ENGINE STARTS THEN SHUTS DOWN .................. 36
PROBLEM 10 -
7.5 AMP (F1) FUSE BLOWING .................................. 37
SSEECCTTIIOONN 77::
DDIIAAGGNNOOSSTTIICC TTEESSTTSS............................................................................ 3388--6677
INTRODUCTION ........................................................ 38
TEST 1 -
Check No-Load Voltage And Frequency...................... 38
TEST 2 -
Check Engine Governor .............................................. 38
TEST 3 -
Test Excitation Circuit Breaker .................................... 39
TEST 4 -
Fixed Excitation Test/Rotor Amp Draw ........................ 39
TEST 5 -
Wire Continuity ............................................................ 40
TEST 6 -
Check Field Boost ........................................................ 41
TEST 7 -
Test Stator DPE Winding.............................................. 41
TEST 8 -
Check Sensing Leads/Power Windings ...................... 42