Generac Power Systems 5413, 5412 Test 9 Check Brushes & Slip Rings, Test 10 Check Rotor Assembly

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Section 7

DIAGNOSTIC TESTS

40

Figure 7-10. – Brush Leads

Test 9 – Check Brushes & Slip Rings

DISCUSSION:

Brushes and slip rings are made of special materials that will provide hundreds of hours of service with little wear. However, when the generator has been idle for some time, an oxide film can develop on the slip rings. This film acts as an insulator and impedes the flow of excitation current to the Rotor.

If Test 4 resulted in less than one-half rated output voltage, it is possible that the brushes and slip rings are at fault.

PROCEDURE:

1.Gain access to the brushes and slip rings.

2.Remove Wire 4 from the positive (+) brush termi- nal.

3.Remove the ground wire (Wire 0) from the nega- tive (-) brush.

4.Remove the brush holder, with brushes.

5.Inspect the brushes for excessive wear, damage, cracks, chipping, etc.

6.Inspect the brush holder, replace if damaged.

7.Inspect the slip rings.

a.If slip rings appear dull or tarnished they may be cleaned and polished with fine sandpaper. DO NOT USE ANY METALLIC GRIT TO CLEAN SLIP RINGS. (A 400 grit wet sandpaper is rec- ommended).

b.After cleaning slip rings, blow away any sandpa- per residue.

RESULTS:

1.Replace bad brushes. Clean slip rings, if neces- sary.

2.If brushes and rings are good, go to Test 10.

Test 10 – Check Rotor Assembly

DISCUSSION:

During the “Test 4 – Fixed Excitation Test,” if AC out- put voltage did not come up to about one-half rated volts, one possible cause might be a defective Rotor. The Rotor can be tested for an open or shorted condi- tion using a volt-ohm-milliammeter (VOM).

Also see Chapter Three, “INSULATION RESISTANCE TESTS”.

PROCEDURE:

Gain access to the brushes and slip rings. Disconnect Wire 4 and Wire 0 from their respective brushes and remove the brush holder. Then, test the Rotor as fol- lows:

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

2.Connect the positive (+) meter test lead to the positive (+) slip ring (nearest the Rotor bearing). Connect the common (-) test lead to the nega- tive (-) slip ring. Read the resistance of the Rotor windings, in OHMS.

 

ROTOR RESISTANCE *

 

 

 

MODEL

 

OHMS

 

 

 

RV45 5410/5411

 

13.4Ω

 

 

 

RV55 5412/5413

 

14.88Ω

 

 

 

RV65 5414/5415

 

10.81Ω

 

 

 

*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.

3.Set the VOM to its “Rx1 K” or “Rx10,000” scale and zero the meter.

4.Connect the positive (+) meter test lead to the positive (+) slip ring, the common (-) test lead to a clean frame ground (such as the Rotor shaft). The meter should read “Infinity”.

RESULTS:

1.Replace the Rotor if it fails the test.

2.If Rotor checks good, perform “Insulation Resistance Test,” on Page 14.

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemConnection for 120 Volts Only Rotor Assembly Stator AssemblyBrush Holder Excitation Circuit ComponentsCrankcase Breather DescriptionControl Panel Component Identification Control Panel ComponentsCleaning the Generator Effects of Dirt and MoistureInsulation Resistance Testers Drying the GeneratorStator Insulation Resistance Testing Rotor Insulation Testing Stator InsulationTesting Rotor Insulation MegohmmeterMeters VOMMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohm’s LawIntroduction Operational AnalysisCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Battery Recommended BatteryBattery Cables Printed Circuit BoardStart-Stop Switch Amp FuseStart-Stop Switch Starter Contactor Relay Starter MotorIf Problem Involves AC Output Problem 1 Voltage & Frequency Are Both High or LowTest 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 Problem 10 7.5A F1 Fuse Blowing YESProcedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Stepper Motor Control DiscussionSix Pin J2 Connector Wire Colors Test 4 Fixed Excitation Test/Rotor Amp DrawFixed Excitation Test, Step B Test 5 Check Field Boost Test 6 Test Stator DPE WindingTest 7 Check Sensing Leads / Power Windings Stator Excitation WindingStator Power Winding Leads Test 8 Check Brush LeadsTest 10 Check Rotor Assembly Test 9 Check Brushes & Slip RingsSchematic Test 11 Check Main Circuit BreakerTest 12 Check Load Voltage Frequency Test 13 Check Load Watts AmperageTest 14 Try Cranking the Engine Test 15 Check Fuel PumpTest 16 Check 7.5 Amp Fuse Test 17 Check Battery & CablesTest 18 Check Power Supply to Printed Circuit Board Test 19 Check Continuity of Wire Test 20 Check Start-Stop SwitchTest 21 Check Power Supply to Wire Test 22 Check Starter Contactor RelayTest 23 Check Starter Contactor Test 24 Check Starter MotorTools for Starter Performance Test Checking the PinionPinion Minimum rpm 4500 Maximum Amps Test 25 Check Fuel Supply To Carburetor GASTest 26 Check Wire 14 Power Supply 29. Fuel RegulatorTest 27 Check Wire Test 28 Check Fuel Solenoid Gasoline ModelsTest 29 Check Ignition Spark Tools RequiredTwo Ignition Testers Generac P/N 0C5969Test 31 Check and Adjust Ignition Magnetos Test 30 Check Spark Plugs37. Setting Ignition Magneto Armature Air Gap Flywheel KEY Test 32 Check Valve AdjustmentChecking Flywheel Magnet Test 33 Check Carburetion Test 34 Check Choke SolenoidTo Control Solenoid PanelTest 36 Check Oil Pressure Switch Test 37 Check Wire 86 for Continuity Test 38 Test Oil Temperature SwitchTest 39 Check Wire 85 for Continuity Test 40 Test Choke HeaterTest 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 Generator Specifications Nominal Resistances of Generator Windings at 68fElectrical Data Electrical Data OG7515 REV. a

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