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Table of Contents
Page 1
SAFETY .................. INSIDE FRONT COVER (IFC)
NOTICE TO USERS OF THIS MANUAL ..............................IFC
REPLACEMENT PARTS .....................................................IFC
TABLE OF CONTENTS ...................................... 1-2
SECTION 1:
GENERATOR FUNDAMENTALS ....................... 3-5
MAGNETISM ..................................................................... 3
ELECTROMAGNETIC FIELDS ..............................................
3
ELECTROMAGNETIC INDUCTION ......................................
3
A SIMPLE AC GENERATOR ................................................
4
A MORE SOPHISTICATED AC GENERATOR .........................
4
SECTION 2:
MEASURING ELECTRICITY ............................. 6-8
METERS .......................................................................... 6
THE VOM ........................................................................
6
MEASURING AC VOLTAGE ..............................................
6
MEASURING DC VOLTAGE ..............................................
6
MEASURING AC FREQUENCY .........................................
6
MEASURING CURRENT ....................................................
7
MEASURING RESISTANCE ................................................
7
ELECTRICAL UNITS ..........................................................
8
OHM'S LAW
.................................................................... 8
SECTION 3:
DESCRIPTION AND COMPONENTS ............. 9-15
INTRODUCTION .............................................................. 9
ENGINE-GENERATOR DRIVE SYSTEM ...............................
9
THE AC GENERATOR .......................................................
9
ROTOR ASSEMBLY ..........................................................
9
STATOR ASSEMBLY
........................................................ 10
BRUSH HOLDER AND BRUSHES .....................................
10
OTHER AC GENERATOR COMPONENTS ........................
10
EXCITATION CIRCUIT BREAKER
.................................. 10
VOLTAGE REGULATOR ..............................................
11
ADJUSTMENT PROCEDURE .......................................
11
CIRCUIT BREAKERS ................................................... 12
ROTOR RESIDUAL MAGNETISM ..................................... 12
FIELD BOOST CIRCUIT ...................................................
12
OPERATION ...................................................................
12
STARTUP ................................................................... 12
ON-SPEED OPERATION .............................................. 12
FIELD EXCITATION .....................................................
12
AC POWER WINDING OUTPUT ..................................
12
BATTERY CHARGE WINDING OUTPUT .......................
12
10 AMP BATTERY CHARGE WINDING OUTPUT
.......... 12
INSULATION RESISTANCE ..............................................
13
THE MEGOHMMETER ...................................................
13
GENERAL ..................................................................
13
TESTING STATOR INSULATION ...................................
13
TESTING ROTOR INSULATION ....................................
13
HI-POT TESTER .......................................................... 13
STATOR INSULATION RESISTANCE TEST ..........................
13
GENERAL ..................................................................
13
TESTING ALL STATOR WINDINGS TO GROUND ..........
14
TEST BETWEEN WINDINGS: .......................................
14
ROTOR INSULATION RESISTANCE TEST ..........................
15
CLEANING THE GENERATOR .........................................
15
DRYING THE GENERATOR .............................................
15
SECTION 4:
ENGINE DC CONTROL SYSTEM .................. 16-27
PRINTED CIRCUIT BOARD .............................................. 16
GENERAL ..................................................................
16
CIRCUIT BOARD CONNECTIONS ...............................
16
DIP SWITCH POSITIONS .............................................
16
BATTERY .......................................................................
16
RECOMMENDED BATTERY ........................................
16
CONTROL PANEL COMPONENT IDENTIFICATION ......
17-18
OPERATIONAL ANALYSIS ..........................................
20-27
CIRCUIT CONDITION - REST ......................................
20
CIRCUIT CONDITION - START ....................................
22
CIRCUIT CONDITION - RUN .......................................
24
CIRCUIT CONDITION - STOP ...................................... 26
FAULT SHUTDOWN ...................................................
27
SECTION 5:
TROUBLESHOOTING FLOWCHARTS .......... 28-36
INTRODUCTION ............................................................ 28
IF PROBLEM INVOLVES AC OUTPUT
............................... 28
PROBLEM 1 -
VOLTAGE & FREQUENCY ARE BOTH HIGH OR LOW ..
28
PROBLEM 2 -
GENERATOR PRODUCES ZERO VOLTAGE
OR RESIDUAL VOLTAGE (2-12 VAC) ......................
29-30
PROBLEM 3 -
EXCESSIVE VOLTAGE/FREQUENCY
DROOP WHEN LOAD IS APPLIED ...............................
30
PROBLEM 4 -
NO BATTERY CHARGE OUTPUT .................................
31
PROBLEM 5 -
NO 10 AMP BATTERY CHARGE OUTPUT ...................
31
PROBLEM 6 -
ENGINE WILL NOT CRANK ........................................
32
PROBLEM 7 -
ENGINE CRANKS BUT WILL NOT START .....................
33
PROBLEM 8 -
ENGINE STARTS HARD AND RUNS ROUGH ................
34
PROBLEM 9 -
ENGINE STARTS THEN SHUTS DOWN ........................
34
PROBLEM 10 -
10 AMP FUSE (F1) BLOWING .....................................
35
PROBLEM 11 -
UNIT OVERSPEEDS ....................................................
36
PROBLEM 12 -
IDLE CONTROL “RPM DOES NOT DECREASE” ...........
36
PROBLEM 13 -
IDLE CONTROL “RPM DOES NOT INCREASE
WHEN LOAD IS APPLIED” ..........................................
36
PROBLEM 14 -
ENGINE “HUNTS” / ERRATIC IDLE ..............................
36