Generac Power Systems 5415, 5412, 5411, 5413, 5414, 5410 Test 4 Fixed Excitation Test/Rotor Amp Draw

Page 39

Section 7

DIAGNOSTIC TESTS

4.If no movement is seen in Step 3 remove the con- trol panel cover. Verify the six pin connector (J2) on the Printed Circuit Board is seated properly, remove the connector and then replace it and test again. Verify the dip switches are correctly set.

NOTE: The dip switches on the Printed Circuit Board are factory set in the “OFF” or DOWN posi- tion. Refer to Figure 5.2 on Page 22.

5.If problem continues remove six pin connector (J2) from Printed Circuit Board. Set Volt meter to measure ohms. Carefully measure from the end of the six pin harness as follows:

BLACK

Test 4 – Fixed Excitation Test/Rotor

Amp Draw

DISCUSSION:

The fixed excitation test consists of applying bat- tery voltage (12 VDC) to the Rotor windings. This allows that portion of the excitation circuit between the Voltage Regulator and the Rotor (including the Rotor itself) to be checked as a possible cause of the problem. When battery voltage is applied to the Rotor, the resulting magnetic field around the Rotor should induce a Stator power winding voltage equal to about one-half the unit’s rated output voltage.

BROWN

YELLOW ORANGE RED

EMPTY

RED TEST LEAD

BLACK TEST LEAD

2

6

0

13 13

VOLTAGE REGULATOR

Figure 7-2. Six Pin J2 Connector Wire Colors

NOTE: Press down with the meter leads on the connectors exposed terminals, do not probe into the connector.

a. Connect one meter lead to Red, connect the remaining test lead to Orange, approximately 10 ohms should be measured.

b. Connect one meter lead to Red, connect the remaining test lead to Yellow, approximately 10 ohms should be measured.

c. Connect one meter lead to Red, connect the remaining test lead to Brown, approximately 10 ohms should be measured.

d. Connect one meter lead to Red, connect the remaining test lead to Black, approximately 10 ohms should be measured.

e. Connect one meter lead to Red, connect the remaining test to the stepper motor case. No resistance should be measured (“Infinity” or Open).

RESULTS:

1.If the stepper motor fails any part of Step 5 replace the stepper motor.

2.If the stepper motor passes all steps replace the Printed Circuit Board.

15

 

JUMPER WIRE

22S

11S

FUSE HOLDER (F1)

4

WIRES 4 REMOVED FROM

 

 

4VOLTAGE REGULATOR

Figure 7-3. – Fixed Excitation Test, Step A

PROCEDURE:

1.Disconnect Wire 4 from the Voltage Regulator (VR). (Third terminal from the right side of VR).

2.Connect a jumper wire to Wire 4 and to the 12 volt fused battery positive supply Wire 15, located at the fuse (F1) holder (see Figure 7-3).

NOTE: During this test, Wire 15 must remain con- nected to the fuse (F1) holder.

3. Set the VOM to measure AC voltage.

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Magnetism Electromagnetic FieldsElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostConnection for 120 Volts Only Stator Assembly Rotor AssemblyExcitation Circuit Components Brush HolderDescription Crankcase BreatherControl Panel Components Control Panel Component IdentificationDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersStator Insulation Resistance Megohmmeter Testing Rotor InsulationTesting Stator Insulation Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC VoltageMeasuring Resistance Measuring CurrentOhm’s Law Electrical UnitsOperational Analysis IntroductionCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Printed Circuit Board BatteryRecommended Battery Battery CablesAmp Fuse Start-Stop SwitchStarter Contactor Relay Starter Motor Start-Stop SwitchProblem 1 Voltage & Frequency Are Both High or Low If Problem Involves AC OutputTest Troubleshooting Flowcharts Proble 5 Priming Function Does Not Work Gasoline Models Problem 6 Engine Will Not Crank Test 26 Check Test 20 Check Check Fuel Wire 14 Power Good Troubleshooting Flowcharts Problem 8 Engine Starts Hard and Runs Rough Gasoline Units Problem 8 Engine Starts Hard and Runs Rough LP Units LOW OIL Pressure Flashes on SW1 LED YES Problem 10 7.5A F1 Fuse BlowingDiscussion ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Stepper Motor ControlTest 4 Fixed Excitation Test/Rotor Amp Draw Six Pin J2 Connector Wire ColorsFixed Excitation Test, Step B Test 6 Test Stator DPE Winding Test 5 Check Field BoostStator Excitation Winding Test 7 Check Sensing Leads / Power WindingsTest 8 Check Brush Leads Stator Power Winding LeadsTest 9 Check Brushes & Slip Rings Test 10 Check Rotor AssemblyTest 13 Check Load Watts Amperage SchematicTest 11 Check Main Circuit Breaker Test 12 Check Load Voltage FrequencyTest 15 Check Fuel Pump Test 14 Try Cranking the EngineTest 17 Check Battery & Cables Test 18 Check Power Supply to Printed Circuit BoardTest 16 Check 7.5 Amp Fuse Test 20 Check Start-Stop Switch Test 19 Check Continuity of WireTest 22 Check Starter Contactor Relay Test 21 Check Power Supply to WireTest 24 Check Starter Motor Test 23 Check Starter ContactorChecking the Pinion PinionTools for Starter Performance Test Minimum rpm 4500 Maximum Amps To Carburetor GAS Test 25 Check Fuel Supply29. Fuel Regulator Test 26 Check Wire 14 Power SupplyTest 28 Check Fuel Solenoid Gasoline Models Test 27 Check WireTools RequiredTwo Ignition Testers Generac P/N 0C5969 Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 31 Check and Adjust Ignition Magnetos37. Setting Ignition Magneto Armature Air Gap Test 32 Check Valve Adjustment Checking Flywheel MagnetFlywheel KEY Test 34 Check Choke Solenoid Test 33 Check CarburetionSolenoid Panel To ControlTest 36 Check Oil Pressure Switch Test 38 Test Oil Temperature Switch Test 37 Check Wire 86 for ContinuityTest 40 Test Choke Heater Test 39 Check Wire 85 for ContinuityTest 41 Check LPG Fuel Solenoid Section Exploded Views QTY Description Enclosure Drawing No G3881-C Enclosure Door Views Screw Plastite HI-LOW #10X3/8 Engine Accessories Drawing No G7718-B QTY Description 48,49 Square Head Plug Rotor & Stator Drawing No G3953-b NUT TOP Lock FL M8-1.25 Charts Nominal Resistances of Generator Windings at 68f Generator SpecificationsElectrical Data Electrical Data OG7515 REV. a

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