Generac Power Systems 5411, 5412, 5413, 5415 Test 8 Check Brush Leads, Stator Power Winding Leads

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Section 7

DIAGNOSTIC TESTS

AC POWER WINDING RESISTANCE * RV45 (Model 5410/5411)

ACROSS WIRES:

OHMS

 

 

11 & 22

0.396Ω

 

 

11S & 22S

0.396Ω

 

 

33 & 44

0.396Ω

 

 

AC POWER WINDING RESISTANCE * RV55 (Model 5412/5413)

ACROSS WIRES:

OHMS

 

 

11 & 22

0.28Ω − 0.32Ω

 

 

11S & 22S

0.28Ω − 0.32Ω

 

 

33 & 44

0.28Ω − 0.32Ω

 

 

AC POWER WINDING RESISTANCE * RV65 (Model 5414/5415)

ACROSS WIRES:

OHMS

 

 

11 & 22

0.209Ω − 0.242Ω

 

 

11S & 22S

0.209Ω − 0.242Ω

 

 

33 & 44

0.209Ω − 0.242Ω

 

 

*Resistance values In ohms at 20° C. (68° F.). Actual readings may vary depending on ambient temperature. A tolerance of plus or minus 5% is allowed.

8.Now, set the VOM to its “Rx1 K” or “Rx10,000” scale and zero the meter.

9.Connect the meter test leads across Stator lead 11 and frame ground. “Infinity” should be read.

10.Connect the meter test leads across Stator lead 33 and frame ground. The reading should be “Infinity”.

11.Connect the meter test leads across Stator leads Wire 11 and Wire 33. The reading should be “Infinity”.

12.Connect the meter test leads across Stator leads Wire 11 and Wire 2. The reading should be “Infinity”.

13.Connect the meter test leads across Stator leads Wire 33 and Wire 2. The reading should be “Infinity”.

RESULTS:

1.If the Stator passes all steps except Step 7, repair, re-connect or replace Sensing leads 11S and 22S.

2.Replace the Stator if it’s power windings fail the test. (Note Result No. 1).

3.If the Power Windings test good, perform the “Insulation Resistance Test” on Page 13.

 

 

 

 

 

 

CB1

 

CB2

 

 

 

 

 

 

11

11S

22S

22

44

33

RED

BLACk

 

 

 

 

 

Figure 7-9. – Stator Power Winding Leads

Test 8 – Check Brush Leads

DISCUSSION:

In Test 4, if application of battery voltage to the Rotor did NOT result in an output of about one-half rated voltage, the brush leads could be one possible cause of the problem. This test will check Wires 4 and 0 for an open circuit condition.

PROCEDURE:

1.Set a VOM to its “Rx1” scale and zero the meter.

2.Disconnect Wire 4 from the Voltage Regulator and from the Rotor brush terminal.

3.Connect the VOM test leads across each end of the wire. The meter should read “Continuity”.

4.Disconnect Wire 0 from the Rotor Brush Terminal. Connect one meter test lead to Wire 0. Connect the other test lead to a clean frame ground. The meter should read “Continuity”.

RESULTS:

1.Repair, reconnect or replace any defective wire(s).

2.If wires check good, go to Test 9.

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Fields MagnetismElectromagnetic 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 18 Check Power Supply to Printed Circuit Board Test 17 Check Battery & CablesTest 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 ContactorPinion Checking the 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 Checking Flywheel Magnet Test 32 Check Valve AdjustmentFlywheel 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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