Generac Power Systems 65, 55, 75 manual Test 13- Check Load Voltage Frequency

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Section 7

DIAGNOSTIC TESTS

RESULTS:

1.If breaker is “ON” and “Continuity” is measured, go to Test 3.

2.If breaker is “OFF”, reset to the “ON” position and check for AC output.

3.If breaker is “ON” and “Continuity” is not measured, replace the defective circuit breaker.

TEST 13- CHECK LOAD VOLTAGE &

FREQUENCY

DISCUSSION:

If engine speed appears to drop off excessively when electrical loads are applied to the generator, the load voltage and frequency should be checked.

PROCEDURE:

Perform this test in the same manner as Test 1, but apply a load to the generator equal to its rated capaci- ty. With load applied check voltage and frequency.

Frequency should not drop below about 58 Hertz with the load applied.

Voltage should not drop below about 115 VAC with load applied.

RESULTS:

1.If voltage and/or frequency drop excessively when the load is applied, go to Test 14.

2.If load voltage and frequency are within limits, end tests.

TEST 14- CHECK LOAD WATTS & AMPERAGE

DISCUSSION:

This test will determine if the generator's rated wattage/amperage capacity has been exceeded.

Continuous electrical loading should not be greater than the unit's rated capacity.

PROCEDURE:

Add up the wattages or amperages of all loads pow- ered by the generator at one time. If desired, a clamp- on ammeter may be used to measure current flow. See “Measuring Current” on Page 16.

RESULTS:

1.If the unit is overloaded, reduce the load.

2.If load is within limits, but frequency and voltage still drop excessively, complete Test 2, “Check/Adjust Engine Governor”. If governor adjustment does not correct the problem, go to Problem 8 (Flow Chart, Pages 34 and 35).

TEST 15 - CHECK BATTERY CHARGE

OUTPUT

DISCUSSION:

The Battery Charge system consists of a center tap Battery Charge Winding, a Battery Charge Rectifier, and a Battery Charge Resistor. During normal opera- tion the battery charge output will vary between 1 to 2 amps, depending on the load applied to the genera- tor. Battery Charge Winding Stator Lead Wire 66 is tapped at the Battery Charge Rectifier and connected to the Engine Control Circuit Board at Pin location J1- 10, and is used as a signal for Starter lockout.

PROCEDURE:

1.Disconnect Wire 15 from the Battery Charge Rectifier (center terminal). Wire 15 is the fused battery supply.

2.Set a VOM to measure DC Amps. Connect the positive (+) test lead to the center terminal of the Battery Charge Rectifier. Connect the negative (-) test lead to Wire 15 previously discon- nected.

3.Start the generator. The amp reading on the VOM should be approximately 0.8 Amps. Apply full load to the generator. The amp reading should increase to approximately 2 Amps.

RESULTS:

1.If amperage was measured between 0.8 to 2 Amps in Step 2 and Step 3, the charging system is working.

2.If no amperage was measured, check the VOM fuses and veri- fy the functioning of the Amp Meter. If DC Amp Meter is good and no current is measured, go to Test 16

TEST 16 - CHECK BATTERY CHARGE

RECTIFIER

DISCUSSION:

The Battery Charge Rectifier (BCR) is a full wave rectifier.

PROCEDURE:

1.Disconnect Wire 66, Wire 15 and Wire 77 from the Battery Charge Rectifier.

2.Set the VOM to the Diode Test range. Connect the negative (-) test lead to the center terminal of the BCR. Connect the posi- tive (+) test lead to an outer terminal. The meter should mea- sure approximately 0.5 volts. Now connect the positive test lead to the other outer terminal. Again, the meter should mea- sure approximately 0.5 volts.

3.Connect the positive (+) test lead to the center terminal of the BCR. Connect the negative (-) test lead to to an outer terminal. The meter should measure “Infinity.” Connect the negative test lead to the other outer terminal. “Infinity” should once again be measured.

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Exploded Views / Part Numbers Section Specifications & ChartsElectromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Line Breakers 120 Volts only Field BoostGenerator AC Connection System Reconnection for Dual Voltage Output Connection for 120 Volts OnlyStator Assembly Rotor AssemblyGeneral Battery Charge ComponentsBrush Holder Excitation Circuit ComponentsDescription Adjustment ProcedureCrankcase Breather Voltage RegulatorCheck Breather Install BreatherInstall oil vapor collector and retainer Control Panel Component IdentificationDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersStator SHORT-TO-GROUND Tests Brushing and Vacuum CleaningStator Insulation Resistance Cloth or Compressed AIRMegohmmeter Testing Rotor InsulationTesting Stator Insulation Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC VoltageMeasuring Resistance Measuring AC FrequencyMeasuring Current Volt Electrical UnitsOhms LAW AmpereCircuit CONDITION- Rest IntroductionOperational Analysis Circuit CONDITION- Priming Circuit CONDITION- Cranking Choke Heater CH Circuit CONDITION-RUNNINGCircuit CONDITION- Shutdown Sure Switch LOP Circuit CONDITION- Fault ShutdownEngine Controller Circuit Board BatteryRecommended Battery Battery CablesAMP Fuse Fuel Primer SwitchSTART-STOP Switch 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 Discussion ProcedureTest 1- Check NO-LOAD Voltage Frequency Test 2- Check Engine GovernorIf continuity was indicated, go to Test Governor AdjustmentTest 3- Test Excitation Circuit Breaker Test 4- Fixed Excitation TEST/ROTOR AMP DrawSet a VOM to its Rx1 scale Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Set the VOM to measure AC voltageIf field boost checks good, replace the Voltage Regulator Test 6- Check Field BoostTest 7 Test Stator DPE Winding Model Ohms Test 8- Check Sensing Leads / Power WindingsAcross Wires Ohms 11S 22STest 10 Check Brushes & Slip Rings Test 9- Check Brush LeadsReplace the Rotor if it fails the test Test 11- Check Rotor AssemblyTance Tests Procedure Test 12 Check Main Circuit BreakerTest 13- Check Load Voltage Frequency Test 15 Check Battery Charge OutputTest 16 Check Battery Charge Rectifier Battery Charge Rectifier BCR is a full wave rectifierShort to Ground 10. Battery Charge RectifierTest 18 TRY Cranking the Engine Test 19- Test Primer SwitchSet a VOM to read battery voltage 12 VDC Also see Fuel Primer Switch,13. The LPG Fuel Solenoid FS Test 20- Check Fuel PumpTest 21- Check 7.5 AMP Fuse Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board 17. Start-Stop Switch Test 24 Check START-STOP SwitchSet a VOM to measure DC voltage 12 VDC Test 26- Check Starter Contactor RelayConditions Affecting Starter Motor Performance Test 26A Check Starter ContactorTest 27 Check Starter Motor Tachometer Checking the PinionTools for Starter Performance Test Measuring CurrentRemove Starter Motor Testing Starter MotorTest 28- Check Fuel Supply Test BracketDiscussion LPG Models 28 LP Gas Carburetion DiagramCrank the engine. The meter should indicate battery voltage Test 29 Check Wire 14 Power SupplyTest 30 Check Wire Battery voltage is not measured, proceed to StepTest 32 Check Ignition Spark Test 31 Check Fuel Solenoid Gasoline ModelsConclusion No cylinder is weakest of the two cylinders Cylinder Balance TestTest 33 Check Spark Plugs Test 34 Check and Adjust Ignition Magnetos37. Setting Ignition Magneto Armature Air Gap Flywheel KEY Test 35 Check Valve AdjustmentAdjusting Valve Clearance Checking Flywheel MagnetTest 37 Check Choke Solenoid Install Rocker ARM CoverTest 36 Check Carburetion 43. Connector Check Compression Adjust the regulated pressure on the gauge to 80 psiDown Test / Compression Test Repeat Steps 1 through 8 on remaining cylinderIf all steps check GOOD, go to Test Test 39 Check OIL Pressure SwitchTest 40 Test OIL Temperature Switch Short to Ground Test 41 Test Choke HeaterTest 42 Check LPG Fuel Solenoid 49. Fuel Solenoid Rotor Removal Major DisassemblyENCLOSURE/PANEL Removal Stator RemovalStarter Removal Belt TensioningEngine 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 Flywheel Assy GT-990 QTY DescriptionControl Panel Drawing No E1013-A PANEL, TOP Control Wire ASM GRD STD ConnSwitch Spdt ON-MOM-ON Switch 6A Spdt Not ShownTwin Engine Drawing No E1014-B ASSEMBLY, OIL Fill CAP ASSEMBLY, Crankcase RVASSEMBLY, Breather ASSEMBLY, Head #1LP Regulator Drawing No E1530 SPRING-SOLENOID Plunger CASTING, Twin Regulator HousingWasher Flat M4 SOLENOID, Twin RegulatorSpecifications & Charts Nominal Resistances of Generator Windings AT 68F Generator SpecificationsEngine Speeds and Voltage Specifications Page Electrical Data Electrical Data PO BOX 297 WHITEWATER, WI

65, 75, 55 specifications

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