Generac Power Systems 55, 75, 65 manual Test 5- Wire Continuity, Set the VOM to measure AC voltage

Page 42

Section 7

DIAGNOSTIC TESTS

 

 

 

TEST 4 RESULTS

 

 

 

 

A

B

C

D

E

F

G

 

 

 

 

 

 

 

 

VOLTAGE RESULTS

ABOVE

ABOVE

BELOW

ZERO OR

BELOW

BELOW

ABOVE

WIRE 2 & 6

60 VAC

60 VAC

60 VAC

RESIDUAL

60 VAC

60 VAC

60 VAC

EXCITATION WINDING

 

 

 

VOLTAGE

 

 

 

 

 

 

 

(5-12 VAC)

 

 

 

 

 

 

 

 

 

 

 

VOLTAGE RESULTS

ABOVE

BELOW

ABOVE

ZERO OR

BELOW

BELOW

ABOVE

WIRE 11 & 22

60 VAC

60 VAC

60 VAC

RESIDUAL

60 VAC

60 VAC

60 VAC

POWER WINDING

 

 

 

VOLTAGE

 

 

 

SENSE LEADS

 

 

 

(5-12 VAC)

 

 

 

 

 

 

 

 

 

 

 

ROTOR AMP DRAW

.85 A

.85 A

.85 A

ZERO

≥1.2 A

.85 A

ZERO

QP55

± 20%

± 20%

± 20%

CURRENT

 

± 20%

CURRENT

(MODEL 4702/4703)

 

 

 

DRAW

 

 

DRAW

 

 

 

 

 

 

 

 

ROTOR AMP DRAW

1.2 A

1.2 A

1.2 A

ZERO

≥1.5 A

1.2 A

ZERO

QP65

± 20%

± 20%

± 20%

CURRENT

 

± 20%

CURRENT

(MODEL 4704/4705)

 

 

 

DRAW

 

 

DRAW

 

 

 

 

 

 

 

 

ROTOR AMP DRAW

.87-.79 A

.87-.79 A

.87-.79 A

ZERO

≥1.2 A

.87-.79 A

ZERO

QP75

± 20%

± 20%

± 20%

CURRENT

 

± 20%

CURRENT

(MODEL 4706/4707)

 

 

 

DRAW

 

 

DRAW

 

 

 

 

 

 

 

 

(MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART – Problem 2 on Pages 28 & 29)

PROCEDURE:

1.Disconnect Wire 4 from the Voltage Regulator (VR). (Third ter- minal from the top of VR).

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

3.Set the VOM to measure AC voltage.

4.Disconnect Wire 2 from the DPE breaker (CB3) and connect one test lead to that wire. Disconnect Wire 6 from the Voltage Regulator and connect the other test lead to that wire. Start the generator and measure the AC voltage. It should be above 60 volts. Record the results and stop the generator.

5.Re-connect Wire 2 to the DPE Circuit Breaker (CB3) and re- connect Wire 6 to the Voltage Regulator.

6.Disconnect Wire 11 from the Voltage Regulator (VR) and con- nect one test lead to that wire. Disconnect Wire 22 from the Voltage Regulator and connect the other test lead to that wire. Start the generator and measure the AC voltage. It should be above 60 volts. Record the results and stop the generator.

7.Re-connect Wire 11 and Wire 22 to the Voltage Regulator.

8.Remove the jumper wire between Wire 4 and 12 volt supply.

9.Set the VOM to measure DC amps.

10.Connect one test lead to the 12 volt fused battery supply Wire 15, and connect the other test lead to Wire 4 (should still be disconnected from the VR).

11.Start the generator. Measure the DC current. Record the rotor amp draw.

12.Stop the generator. Re-connect Wire 4 to the Voltage Regulator.

RESULTS:

Proceed to “TEST 4 RESULTS” (top of page 40). Match all results to corresponding column in the chart. The column letter refers to the Problem 4 flow charts on pages 28 and 29.

TEST 5- WIRE CONTINUITY

DISCUSSION:

The Voltage Regulator receives unregulated alternat- ing current from the Stator Excitation Winding via Wires 2, 6 and 2A. It also receives voltage sensing from the Stator AC Power Windings via Wires 11 and

22.The regulator rectifies the AC from the Excitation Winding and, based on the sensing signals, regulates that DC current flow to the Rotor. The rectified and regulated current flow is delivered to the Rotor Brushes via Wires 4 (+) and 0 (-). This test will verify the integrity of Wires 0 and 2A.

PROCEDURE:

1.Set a VOM to its “Rx1” scale.

2.Remove Wire 0 from the Voltage Regulator, fourth terminal from the top (identified by a negative (-) sign next to terminal).

3.Connect one test lead to Wire 0 and the other test lead to a clean frame ground. The meter should read continuity.

4.Disconnect Wire 2A from the Voltage Regulator, sixth terminal from the top. Disconnect the other end of this wire from the

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Specifications & Charts Section Exploded Views / Part NumbersMagnetism Electromagnetic FieldsElectromagnetic Induction Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemLine Breakers 120 Volts only Connection for 120 Volts Only Reconnection for Dual Voltage OutputRotor Assembly Stator AssemblyExcitation Circuit Components Battery Charge ComponentsBrush Holder GeneralVoltage Regulator Adjustment ProcedureCrankcase Breather DescriptionControl Panel Component Identification Install BreatherInstall oil vapor collector and retainer Check BreatherInsulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the GeneratorCloth or Compressed AIR Brushing and Vacuum CleaningStator Insulation Resistance Stator SHORT-TO-GROUND TestsTesting Rotor Insulation Testing Rotor InsulationTesting Stator Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring AC Frequency Measuring CurrentMeasuring Resistance Ampere Electrical UnitsOhms LAW VoltIntroduction Operational AnalysisCircuit CONDITION- Rest Circuit CONDITION- Priming Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Choke Heater CHCircuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdown Sure Switch LOPBattery Cables BatteryRecommended Battery Engine Controller Circuit BoardFuel Primer Switch START-STOP SwitchAMP Fuse Starter Contactor Relay Starter Motor Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Test 2- Check Engine Governor ProcedureTest 1- Check NO-LOAD Voltage Frequency DiscussionTest 4- Fixed Excitation TEST/ROTOR AMP Draw Governor AdjustmentTest 3- Test Excitation Circuit Breaker If continuity was indicated, go to TestSet the VOM to measure AC voltage Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Set a VOM to its Rx1 scaleTest 6- Check Field Boost Test 7 Test Stator DPE WindingIf field boost checks good, replace the Voltage Regulator 11S 22S Test 8- Check Sensing Leads / Power WindingsAcross Wires Ohms Model OhmsTest 9- Check Brush Leads Test 10 Check Brushes & Slip RingsTest 12 Check Main Circuit Breaker Test 11- Check Rotor AssemblyTance Tests Procedure Replace the Rotor if it fails the testBattery Charge Rectifier BCR is a full wave rectifier Test 15 Check Battery Charge OutputTest 16 Check Battery Charge Rectifier Test 13- Check Load Voltage Frequency10. Battery Charge Rectifier Short to GroundAlso see Fuel Primer Switch, Test 19- Test Primer SwitchSet a VOM to read battery voltage 12 VDC Test 18 TRY Cranking the EngineTest 20- Check Fuel Pump 13. The LPG Fuel Solenoid FSTest 22- Check Battery & Cables Test 23- Check Power Supply to Circuit BoardTest 21- Check 7.5 AMP Fuse Test 24 Check START-STOP Switch 17. Start-Stop SwitchTest 26- Check Starter Contactor Relay Set a VOM to measure DC voltage 12 VDCTest 26A Check Starter Contactor Test 27 Check Starter MotorConditions Affecting Starter Motor Performance Measuring Current Checking the PinionTools for Starter Performance Test TachometerTest Bracket Testing Starter MotorTest 28- Check Fuel Supply Remove Starter Motor28 LP Gas Carburetion Diagram Discussion LPG ModelsBattery voltage is not measured, proceed to Step Test 29 Check Wire 14 Power SupplyTest 30 Check Wire Crank the engine. The meter should indicate battery voltageTest 31 Check Fuel Solenoid Gasoline Models Test 32 Check Ignition SparkCylinder Balance Test Conclusion No cylinder is weakest of the two cylindersTest 34 Check and Adjust Ignition Magnetos Test 33 Check Spark Plugs37. Setting Ignition Magneto Armature Air Gap Checking Flywheel Magnet Test 35 Check Valve AdjustmentAdjusting Valve Clearance Flywheel KEYInstall Rocker ARM Cover Test 36 Check CarburetionTest 37 Check Choke Solenoid 43. Connector Repeat Steps 1 through 8 on remaining cylinder Adjust the regulated pressure on the gauge to 80 psiDown Test / Compression Test Check CompressionTest 39 Check OIL Pressure Switch Test 40 Test OIL Temperature SwitchIf all steps check GOOD, go to Test Test 41 Test Choke Heater Test 42 Check LPG Fuel SolenoidShort to Ground 49. Fuel Solenoid Stator Removal Major DisassemblyENCLOSURE/PANEL Removal Rotor RemovalBelt Tensioning Engine RemovalStarter Removal FLYWHEEL/MAGNETO Removal Page Section Exploded Views / Part Numbers Part NO. QTY Description Enclosure Drawing No E1011-B QTY Description Sheet Metal Drawing No E1012-E QTY Description Flywheel Assy GT-990Control Panel Drawing No E1013-A Switch 6A Spdt Not Shown Wire ASM GRD STD ConnSwitch Spdt ON-MOM-ON PANEL, TOP ControlTwin Engine Drawing No E1014-B ASSEMBLY, Head #1 ASSEMBLY, Crankcase RVASSEMBLY, Breather ASSEMBLY, OIL Fill CAPLP Regulator Drawing No E1530 SOLENOID, Twin Regulator CASTING, Twin Regulator HousingWasher Flat M4 SPRING-SOLENOID PlungerSpecifications & Charts Generator Specifications Nominal Resistances of Generator Windings AT 68FEngine Speeds and Voltage Specifications Page Electrical Data Electrical Data PO BOX 297 WHITEWATER, WI

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