Generac GP1800, GP3250, GP5000, GP5500, GP6500 Service Manual

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Diagnostic
RepaiR
Manual
GP Series Portable Generators
MODELS:
GP1800 GP3250 GP5000 GP5500 GP6500 GP7000 GP8000
PORTABLE GENERATORS
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Throughout this publication, “DANGER!” and “CAUTION!” blocks are used to alert the mechanic to special instructions concerning a particular service or operation that might be hazardous if performed incorrectly or carelessly. PAY CLOSE ATTENTION TO THEM.
DANGER! UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCTIONS WHICH, IF NOT COMPLIED
WITH, COULD RESULT IN PERSONAL INJURY OR DEATH.
*
CAUTION! Under this heading will be found special instructions which, if not complied with, could result
in damage to equipment and/or property.
*
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions plus “common sense” are major accident prevention measures.
SAFETY
NOTICE TO USERS OF THIS MANUAL
This SERVICE MANUAL has been written and published by Generac to aid our dealers' mechanics and com­pany service personnel when servicing the products described herein.
It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products manufactured and marketed by Generac. That they have been trained in the recommended servicing procedures for these products, including the use of common hand tools and any special Generac tools or tools from other suppliers.
Generac could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not under­taken any such wide evaluation. Therefore, anyone who uses a procedure or tool not recommended by Generac must first satisfy themselves that neither his nor the products safety will be endangered by the ser­vice procedure selected.
All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication.
When working on these products, remember that the electrical system and engine ignition system are capa­ble of violent and damaging short circuits or severe electrical shocks. If you intend to perform work where electrical terminals could be grounded or touched, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings of the engine are exposed during service, they should be covered to prevent accidental entry of foreign material. Entry of such materials will result in extensive damage when the engine Is started.
During any maintenance procedure, replacement fasteners must have the same measurements and strength as the fasteners that were removed. Metric bolts and nuts have numbers that indicate their strength. Customary bolts use radial lines to indicate strength while most customary nuts do not have strength mark­ings. Mismatched or incorrect fasteners can cause damage, malfunction and possible injury.
REPLACEMENT PARTS
Components on Generac recreational vehicle generators are designed and manufactured to comply with Recreational Vehicle Industry Association (RVIA) Rules and Regulations to minimize the risk of fire or explo­sion. The use of replacement parts that are not in compliance with such Rules and Regulations could result in a fire or explosion hazard. When servicing this equipment, it is extremely important that all components be properly installed and tightened. If improperly installed and tightened, sparks could ignite fuel vapors from fuel system leaks.
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Specifications .......................................................... 2
Part 1 – General Information .................................. 9
Section 1.1 – Generator Fundamentals ................ 10
Magnetism .......................................................10
Electromagnetic Fields.....................................10
Electromagnetic Induction................................10
A Simple AC Generator ...................................11
A More Sophisticated AC Generator ................11
Section 1.2 – Measuring Electricity ....................... 13
Meters ............................................................13
The VOM ..........................................................13
Measuring AC Voltage .....................................13
Measuring DC Voltage .....................................13
Measuring AC Frequency ................................13
Measuring Current ...........................................14
Measuring Resistance .....................................14
Electrical Units .................................................15
Ohm's Law .......................................................15
Section 1.3 – Brushless, Capacitor
Excitation System ............................ 16
Introduction ......................................................16
Stator Assembly ...............................................16
Rotor Assembly ................................................16
Circuit Breakers ...............................................16
Operation .........................................................17
Section 1.4 – Brushed Excitation System ............. 18
Introduction ......................................................18
Stator Assembly ...............................................18
Brush Holder and Brushes ...............................18
Rotor Residual Magnetism...............................18
Voltage Regulator ............................................18
Operation .........................................................18
Section 1.5 – Testing, Cleaning and Drying .......... 20
Insulation Resistance .......................................20
The Megohmmeter...........................................20
Stator Insulation Resistance Test .....................20
Cleaning the Generator ....................................21
Drying the Generator .......................................21
Part 2 – AC Generators ......................................... 21
Section 2.1 – Brushless Capacitor
Troubleshooting Flowcharts ............. 22
Section 2.2 – Brushed Excitation
Troubleshooting Flowcharts ............. 24
Section 2.3 – AC Diagnostic Tests ........................ 26
Introduction ......................................................26
Test 1 – Check No-Load Voltage
and Frequency ....................................26
Test 2 – Check Circuit Breaker.........................26
Test 3 – Check Continuity of
Receptacle Panel ................................26
Test 4 – Field Flash Alternator
(Configuration “A” Only) .......................27
Test 5 – Check Brushed Rotor Circuit ..............28
Test 6 – Check Capacitor .................................29
Test 7 – Test Brushless DPE Winding ..............30
Test 8 – Test Brushless Stator Windings ..........30
Test 9 – Test Brushed Stator Windings ............31
Test 10 – Check Load Voltage & Frequency ....31
Test 11 – Check Load Watts & Amperage .......31
Test 12 – Adjust Voltage Regulator ..................31
Part 3 – Engine Troubleshooting .......................... 33
Section 3.1 – 389/206/163cc Troubleshooting
Flowcharts ....................................... 34
Section 3.2 – 410cc Troubleshooting Flowcharts .. 37
Section 3.3 – Diagnostic Tests .............................. 42
Test 20 – Check 1.5 Amp Fuse ........................42
Test 21 – Check Battery & Cables ...................42
Test 22 – Check Voltage at
Starter Contactor (SC) ........................42
Test 23 – Check Start-Run-Stop Switch ..........42
Test 24 – Test OFF-ON Switch .........................43
Test 25 – Check Starter Motor .........................43
Test 25 – Check Ignition Spark ........................45
Test 26 – Check Spark Plugs ...........................46
Test 29 – Check Carburetion ...........................46
Test 30 – Choke Test ........................................47
Test 33 – Check Valve Adjustment ...................47
Test 36 – Check Engine / Cylinder Leak Down
Test / Compression Test ......................48
Test 38 – Check Flywheel ................................48
Test 39 – Remove Wire 18 / Shutdown Lead ...49 Test 40 – Check / Adjust Governor
(389cc Engine) ....................................49
Test 41 – Check / Adjust Governor
(410cc Engine) ....................................50
Test 45 – Check Oil Level Switch .....................51
Test 46 – Check Oil Pressure Switch ...............51
Test 49 – Test Recoil Function .........................52
Test 50 – Test Engine Function ........................52
Part 4 – Disassembly ............................................. 53
Section 4.1 – Major Disassembly .......................... 54
Part 5 – Electrical Data .......................................... 71
Electrical Schematic, GP1850 .............................. 72
Electrical Schematic, GP3250 .............................. 73
Electrical Schematic, GP5000/5500/GP6500 ....... 74
Wiring Diagram, GP5000/5500/GP6500 ............... 75
Electrical Schematic, GP7000E/GP8000E ........... 76
Wiring Diagram, GP7000E/GP8000E ................... 77
Electrical Formulas ............................................... 78
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AH
M
SPECIFICATIONS – GP1800
Outlets
A
Circuit Breakers
M
Other Features
H
(2) 5-20R 120V
(1) 20A
On/Off Switch
Product Series GP1800
A/C Rated Output Watts: 1800
A/C Maximum Output Watts: 2050
A/C Voltage 120VAC
A/C Frequency 60 Hz
Rated 120 VAC Amperage 7.5
Max 120 VAC Amperage 8.5
Engine Displacement 163cc
Engine Type OHV
Engine RPM 3600
Recommended Oil 5W30
Lubrication Method Splash Sump
Choke Type Manual Lever
Fuel Shut Off Manual Lever
Idle Control Full Speed
Starting Method Manual
Battery n/a
Battery Size n/a
Low Oil Shutdown Method Low Level
Start Switch Type On/Off Toggle
Switch Location Control Panel
Single-Point Lifting Eye N/A
Fuel Gauge Built-In
Fuel Tank Capacity (Gal) 4
Fuel Tank Capacity (Liters) 15.14
Run Time at 50% (Hours) 14
Cord Set No
Handle Style Folding
Wheel type n/a
Length (L) 23.5
Width (W) 17
Height (H) 17.5
Extended Length (EL) 23.5
Unit Weight (lbs) 79
Spark Plug Type NGK BPR4ES
or Champion RN14YC
Spark Plug Gap 0.028"-0.031"
(0.7-0.8mm)
Oil Capacity 0.634 quart
(0.6 liter)
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H
A
M
Product Series GP3250
A/C Rated Output Watts: 3250
A/C Maximum Output Watts: 3750
A/C Voltage 120VAC
A/C Frequency 60 Hz
Rated 120 VAC Amperage 13.5
Max 120 VAC Amperage 15.6
Engine Displacement 206cc
Engine Type OHV
Engine RPM 3600
Recommended Oil 5W30
Lubrication Method Splash Sump
Choke Type Manual Lever
Fuel Shut Off Manual Lever
Idle Control Full Speed
Starting Method Manual
Battery n/a
Battery Size n/a
Low Oil Shutdown Method Low Level
Start Switch Type On/Off Toggle
Switch Location Control Panel
Single-Point Lifting Eye N/A
Fuel Gauge Built-In
Fuel Tank Capacity (Gal) 4
Fuel Tank Capacity (Liters) 15.14
Run Time at 50% (Hours) 13.5
Cord Set No
Handle Style Folding
Wheel type 7.0" Solid Wheels
Length (L) 25.5
Width (W) 21
Height (H) 19
Extended Length (EL) 39.5
Unit Weight (lbs) 91
Spark Plug Type NGK BPR4ES
or Champion RN14YC
Spark Plug Gap 0.028"-0.031"
(0.7-0.8mm)
Oil Capacity 0.634 quart
(0.6 liter)
SPECIFICATIONS – GP3250
Outlets
A
Circuit Breakers
M
Other Features
H
(4) 5-20R 120V
(2) 20A
On/Off Switch
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H
B
N
M
A
SPECIFICATIONS – GP5000
Receptacles
A
B
Circuit Breakers
M
N
Other Features
H
(4) 5-20R 120V
L14-30R Twist-Lock 120/240V
(2) 20A
(2) 25A
Hour Meter with
Maintenance Reset
Product Series GP5000
A/C Rated Output Watts: 5000
A/C Maximum Output Watts: 6250
A/C Voltage 120/240VAC
A/C Frequency 60 Hz
Rated 120/240 VAC Amperage 20.8
Max 120/240 VAC Amperage 26.0
Engine Displacement 389cc
Engine Type OHV
Engine RPM 3600
Recommended Oil 5W30
Lubrication Method Splash Sump
Choke Type Manual Lever
Fuel Shut Off Manual Lever
Idle Control Full Speed
Starting Method Manual
Battery n/a
Battery Size n/a
Low Oil Shutdown Method Low Level
Start Switch Type 3-Position
Switch Location On Engine
Single-Point Lifting Eye N/A
Fuel Gauge Built-In
Fuel Tank Capacity (Gal) 6.6
Fuel Tank Capacity (Liters) 24.981
Run Time at 50% (Hours) 10
Cord Set No
Handle Style Folding Interlocked
Wheel type 9.5" Solid Wheels
Length (L) 33.5
Width (W) 26.5
Height (H) 27.5
Extended Length (EL) 47
Unit Weight (lbs) 167
Spark Plug Type NHSP F7RTC or
Champion RN9YC
Spark Plug Gap 0.028"-0.031"
(0.7-0.8mm)
Oil Capacity 1.16 quart
(1.1 liter)
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H
B
N
M
A
Product Series GP5500
A/C Rated Output Watts: 5000
A/C Maximum Output Watts: 6875
A/C Voltage 120/240VAC
A/C Frequency 60 Hz
Rated 120/240 VAC Amperage 22.9
Max 120/240 VAC Amperage 28.6
Engine Displacement 389cc
Engine Type OHV
Engine RPM 3600
Recommended Oil 5W30
Lubrication Method Splash Sump
Choke Type Manual Lever
Fuel Shut Off Manual Lever
Idle Control Full Speed
Starting Method Manual
Battery n/a
Battery Size n/a
Low Oil Shutdown Method Low Level
Start Switch Type 3-Position
Switch Location On Engine
Single-Point Lifting Eye N/A
Fuel Gauge Built-In
Fuel Tank Capacity (Gal) 6.6
Fuel Tank Capacity (Liters) 24.98
Run Time at 50% (Hours) 10
Cord Set No
Handle Style Folding Interlocked
Wheel type 9.5" Solid Wheels
Length (L) 33.5
Width (W) 26.5
Height (H) 27.5
Extended Length (EL) 47
Unit Weight (lbs) 167
Spark Plug Type NHSP F7RTC or
Champion RN9YC
Spark Plug Gap 0.028"-0.031"
Oil Capacity 1.16 quart
(0.7-0.8mm)
(1.1 liter)
SPECIFICATIONS – GP5500
Receptacles
A
B
Circuit Breakers
M
N
Other Features
H
(4) 5-20R 120V
L14-30R Twist-Lock 120/240V
(2) 20A
(2) 25A
Hour Meter with
Maintenance Reset
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H
B
N
M
A
SPECIFICATIONS – GP6500
Outlets
A
B
Circuit Breakers
M
N
Other Features
H
Hour Meter with Maintenance Reset
(4) 5-20R 120V
L14-30R Twist-Lock 120/240V
(2) 20A
(2) 30A
Product Series GP6500
A/C Rated Output Watts: 6500
A/C Maximum Output Watts: 8000
A/C Voltage 120/240VAC
A/C Frequency 60 Hz
Rated 120/240 VAC Amperage 27.1
Max 120/240 VAC Amperage 33.3
Engine Displacement 389cc
Engine Type OHV
Engine RPM 3600
Recommended Oil 5W30
Lubrication Method Splash Sump
Choke Type Manual Lever
Fuel Shut Off Manual Lever
Idle Control Full Speed
Starting Method Manual
Battery n/a
Battery Size n/a
Low Oil Shutdown Method Low Level
Start Switch Type 3-Position
Switch Location On Engine
Single-Point Lifting Eye N/A
Fuel Gauge Built-In
Fuel Tank Capacity (Gal) 6.6
Fuel Tank Capacity (Liters) 24.98
Run Time at 50% (Hours) 9
Cord Set No
Handle Style Folding Interlocked
Wheel type 9.5" Solid Wheels
Length (L) 33.5
Width (W) 26.5
Height (H) 27.5
Extended Length (EL) 47
Unit Weight (lbs) 172
Spark Plug Type NHSP F7RTC or
Champion RN9YC
Spark Plug Gap 0.028"-0.031"
(0.7-0.8mm)
Oil Capacity 1.16 quart
(1.1 liter)
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H
B
N
M
A
Product Series GP7000
A/C Rated Output Watts: 7000
A/C Maximum Output Watts: 8750
A/C Voltage 120/240VAC
A/C Frequency 60 Hz
Rated 120/240 VAC Amperage 29.2
Max 120/240 VAC Amperage 36.5
Engine Displacement 410cc
Engine Type OHVI
Engine RPM 3600
Recommended Oil 5W30
Lubrication Method Full Pressure
Choke Type Manual Lever
Fuel Shut Off Manual Lever
Idle Control Full Speed
Starting Method GP7000 Manual
Starting Method GP7000E Manual or Electric
Battery Size (if equipped) 12VDC 10 Ahr
Low Oil Shutdown Method Low Pressure
Start Switch Type 3-Position
Switch Location On Engine
Single-Point Lifting Eye N/A
Fuel Gauge Built-In
Fuel Tank Capacity (Gal) 8
Fuel Tank Capacity (Liters) 30.28
Run Time at 50% (Hours) 11
Cord Set No
Handle Style Folding Interlocked
Wheel type 9.5" Solid Wheels
Spark Plug Type Champion RC14YC
Spark Plug Gap 0.030" (0.76mm)
Oil Capacity 1.5 quart w/filter
SPECIFICATIONS – GP7000/GP7000E
Outlets
A
B
Circuit Breakers
M
N
Other Features
H
Hour Meter with Maintenance Reset
(4) 5-20R 120V
L14-30R Twist-Lock 120/240V
(2) 20A
(2) 30A
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H
B
N
M
A
SPECIFICATIONS – GP8000/GP8000E
Outlets
A
B
Circuit Breakers
M
N
Other Features
H
Hour Meter with Maintenance Reset
(4) 5-20R 120V
L14-30R Twist-Lock 120/240V
(2) 20A
(2) 30A
Product Series GP8000/GP8000E
A/C Rated Output Watts: 8000
A/C Maximum Output Watts: 10000
A/C Voltage 120/240VAC
A/C Frequency 60 Hz
Rated 120/240 VAC Amperage 33.3
Max 120/240 VAC Amperage 41.7
Engine Displacement 410cc
Engine Type OHVI
Engine RPM 3600
Recommended Oil 5W30
Lubrication Method Full Pressure
Choke Type Manual Lever
Fuel Shut Off Manual Lever
Idle Control Full Speed
Starting Method GP8000 Manual
Starting Method GP8000E Manual or Electric
Battery Size (if equipped) 12VDC 10 Ahr
Low Oil Shutdown Method Low Pressure
Start Switch Type 3-Position
Switch Location On Engine
Single-Point Lifting Eye N/A
Fuel Gauge Built-In
Fuel Tank Capacity (Gal) 8
Fuel Tank Capacity (Liters) 30.28
Run Time at 50% (Hours) 8
Cord Set No
Handle Style Folding Interlocked
Wheel type 9.5" Solid Wheels
Spark Plug Type Champion RC14YC
Spark Plug Gap 0.030" (0.76mm)
Oil Capacity 1.5 quart w/filter
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PART 1
GENERAL
INFORMATION
GP Series Portable Generators
TABLE OF CONTENTS
PART TITLE PAGE
1.1 Generator Fundamentals 10
1.2 Measuring Electricity 13
1.3 Brushless, Capacitor Excitation System
1.4 Brushed Excitation System 18
1.5 Testing, Cleaning and Drying 20
16
Part 1 – General Information .................................. 9
Section 1.1 – Generator Fundamentals ................ 10
Magnetism .......................................................10
Electromagnetic Fields.....................................10
Electromagnetic Induction................................10
A Simple AC Generator ...................................11
A More Sophisticated AC Generator ................11
Section 1.2 – Measuring Electricity ....................... 13
Meters ............................................................13
The VOM ..........................................................13
Measuring AC Voltage .....................................13
Measuring DC Voltage .....................................13
Measuring AC Frequency ................................13
Measuring Current ...........................................14
Measuring Resistance .....................................14
Electrical Units .................................................15
Ohm's Law .......................................................15
Section 1.3 – Brushless, Capacitor
Excitation System ............................ 16
Introduction ......................................................16
Stator Assembly ...............................................16
Rotor Assembly ................................................16
Circuit Breakers ...............................................16
Operation .........................................................17
Section 1.4 – Brushed Excitation System ............. 18
Introduction ......................................................18
Stator Assembly ...............................................18
Brush Holder and Brushes ...............................18
Rotor Residual Magnetism...............................18
Voltage Regulator ............................................18
Operation .........................................................18
Section 1.5 – Testing, Cleaning and Drying .......... 20
Insulation Resistance .......................................20
The Megohmmeter...........................................20
Stator Insulation Resistance Test .....................20
Cleaning the Generator ....................................21
Drying the Generator .......................................21
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SECTION 1.1
GENERATOR FUNDAMENTALS
MAGNETISM
Magnetism can be used to produce electricity and electricity can be used to produce magnetism.
Much about magnetism cannot be explained by our present knowledge. However, there are certain pat­terns of behavior that are known. Application of these behavior patterns has led to the development of gen­erators, motors and numerous other devices that uti­lize magnetism to produce and use electrical energy.
See Figure 1. The space surrounding a magnet is per­meated by magnetic lines of force called “flux”. These lines of force are concentrated at the magnet's north and south poles. They are directed away from the magnet at its north pole, travel in a loop and re-enter the magnet at its south pole. The lines of force form definite patterns which vary in intensity depending on the strength of the magnet. The lines of force never cross one another. The area surrounding a magnet in which its lines of force are effective is called a “mag­netic field”.
Like poles of a magnet repel each other, while unlike poles attract each other.
PART 1
NOTE: The “right hand rule” is based on the “cur­rent flow” theory which assumes that current flows from positive to negative. This is opposite the “electron” theory, which states that current flows from negative to positive.
Figure 2. The Right Hand Rule
GENERAL INFORMATION
Figure 1. Magnetic Lines of Force
ELECTROMAGNETIC FIELDS
All conductors through which an electric current is flowing have a magnetic field surrounding them. This field is always at right angles to the conductor. If a compass is placed near the conductor, the compass needle will move to a right angle with the conductor. The following rules apply:
• Thegreater thecurrent flowthrough theconductor,
the stronger the magnetic field around the conductor.
• The increase inthe number of linesof force is
directly proportional to the increase in current flow and the field is distributed along the full length of the conductor.
• Thedirectionofthelinesofforcearoundaconduc­tor can be determined by what is called the “right hand rule”. To apply this rule, place your right hand around the conductor with the thumb pointing in the direction of current flow. The fingers will then be pointing in the direction of the lines of force.
ELECTROMAGNETIC INDUCTION
An electromotive force (EMF) or voltage can be pro­duced in a conductor by moving the conductor so that it cuts across the lines of force of a magnetic field.
Similarly, if the magnetic lines of force are moved so that they cut across a conductor, an EMF (voltage) will be produced in the conductor. This is the basic principal of the revolving field generator.
Figure 3, below, illustrates a simple revolving field generator. The permanent magnet (Rotor) is rotated so that its lines of magnetic force cut across a coil of wires called a Stator. A voltage is then induced into the Stator windings. If the Stator circuit is completed by connecting a load (such as a light bulb), current will flow in the circuit and the bulb will light.
Figure 3. A Simple Revolving Field Generator
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S
TATOR
ROT
OR
MAGNETIC FIEL
D
CURRENT
VOLTAGE
ONE CYCLE
0
180
360
(+)
(-)
STATOR
ROTOR
GENERATOR
120 VAC
120 VAC
+
-
AC OUTPUT
STATOR
240 VAC
CAPACITOR
STATOR
BRUSHES
120 V
120 V
+
-
SLIP RINGS
AC OUTPUTDC CURRENT
STATOR
240 V
GENERAL INFORMATION
PART 1
A SIMPLE AC GENERATOR
Figure 4 shows a very simple AC Generator. The gen­erator consists of a rotating magnetic field called a ROTOR and a stationary coil of wire called a STATOR. The ROTOR is a permanent magnet which consists of a SOUTH magnetic pole and a NORTH magnetic pole.
As the MOTOR turns, its magnetic field cuts across the stationary STATOR. A voltage is induced Into the STATOR windings. When the magnet's NORTH pole passes the STATOR, current flows in one direc­tion. Current flows in the opposite direction when the magnet's SOUTH pole passes the STATOR. This con­stant reversal of current flow results in an alternating current (AC) waveform that can be diagrammed as shown in Figure 5.
The ROTOR may be a 2-pole type having a single NORTH and a single SOUTH magnetic pole. Some ROTORS are 4-pole type with two SOUTH and two NORTH magnetic poles. The following apply:
1. The 2-pole ROTOR must be turned at 3600 rpm to pro­duce an AC frequency of 60 Hertz, or at 3000 rpm to deliver an AC frequency of 50 Hertz.
SECTION 1.1
GENERATOR FUNDAMENTALS
A MORE SOPHISTICATED AC GENERATOR
Figure 6 and 7 show two methods of creating alternat­ing current that are implemented on GP Series por­table generator product.
Figure 6 shows a consistent voltage being induced to the rotor from a capacitor which is installed in series with the DPE winding. As a result a regulated voltage is induced into the STATOR.
2. The 4-pole ROTOR must operate at 1800 rpm to deliver a 60 Hertz AC frequency or at 1500 rpm to deliver a 50 Hertz AC frequency.
Figure 4. A Simple AC Generator
Figure 6. Capacitive Discharge
Figure 7 shows a regulated direct current being deliv­ered into the ROTOR windings via carbon BRUSHES AND SLIP RINGS. This results in the creation of a regulated magnetic field around the ROTOR. As a result, a regulated voltage is induced into the STATOR. Regulated current delivered to the ROTOR is called “EXCITATION” current.
Figure 5. Alternating Current Sine Wave
Figure 7. Direct Excitation
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CAPACITOR
STATOR
EXCITATION
WINDING
STATOR POWER
WINDING
STATOR
POWER
WINDING
MAGNETIC
FIELD
MAGNETIC
FIELD
MLB = MAIN LINE CIRCUIT BREAKER
ROTOR
TO LOAD
MLB
ENGINE ­DIRECT DRIVE
AUTOMATIC
VOLTAGE
REGULATOR
+-
STATOR
EXCITATION
WINDING
STATOR POWER
WINDING
STATOR POWER
WINDING
MAGNETIC
FIELD
MAGNETIC
FIELD
SENSING
MLB = MAIN LINE CIRCUIT BREAKER
ROTOR
TO LOAD
MLB
ENGINE ­DIRECT DRIVE
120 VAC 120 VAC
240 VAC
120 VAC 120 VAC
240 VAC
A B
CAPACITIVE DISCHARGE DIRECT EXCITATION
SECTION 1.1
GENERATOR FUNDAMENTALS
PART 1
GENERAL INFORMATION
Figure 8. Generator Operating Diagram
The revolving magnetic field is driven by the engine at constant speed. This constant speed is maintained by a mechanical engine governor. Units with a 2-pole rotor require an operation speed of 3600 rpm to deliv­er a 60 Hertz AC output.
Generator operation may be described briefly as follows.
1. Some “residual” magnetism is normally present in the Rotor, which is sufficient to induce approximately 1 to 2 Volts AC in to the Stator’s AC Power Windings and DPE winding.
2. See Figure 8.
A. Dur ing startup, the “residual” voltage that
is induced into the DPE winding will initially charge the capacitor to a greater potential. When the capacitor is discharged the voltage is in turn induced back into the Rotor which will exponen tially raise the voltage to 120/240.
B. During startup, the “residual” voltage that is
induced into the DPE winding will turn on the voltage regulator allowing DC excitation current to be delivered to the rotor and raise the voltage to 120/240.
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GENERAL INFORMATION
PART 1
METERS
Devices used to measure electrical properties are called meters. Meters are available that allow one to measure (a) AC voltage, (b) DC voltage, (c) AC frequency, and (d) resistance in ohms. The following apply:
• TomeasureACvoltage,useanACvoltmeter.
• TomeasureDCvoltage,useaDCvoltmeter.
• UseafrequencymetertomeasureACfrequencyin
“Hertz” or “cycles per second”.
• Use an ohmmeter to read circuit resistance, in
“Ohms”.
THE VOM
A meter that will permit both voltage and resistance to be read is the “volt-ohm-milliammeter” or “VOM”.
Some VOMs are of the “analog” type (not shown). These meters display the value being measured by physically deflecting a needle across a graduated scale. The scale used must be interpreted by the user.
“Digital” VOMs (Figure 1) are also available and are generally very accurate. Digital meters display the measured values directly by converting the values to numbers.
NOTE: Standard AC volt me te rs react to the AVERAGE value of alternating current. When work­ing with AC, the effective value is used. For that reason a different scale is used on an AC voltme­ter. The scale is marked with the effective or “rms” value even though the meter actually reacts to the average value. That is why the AC voltmeter will give an incorrect reading if used to measure direct current (DC).
SECTION 1.2
MEASURING ELECTRICITY
MEASURING AC VOLTAGE
An accurate AC voltmeter or a VOM may be used to read the generator's AC output voltage. The following apply:
1. Always read the generator's AC output voltage only at the unit's rated operating speed and AC frequency.
2. The generator's Voltage Regulator can be adjusted for correct output voltage only while the unit is operating at its correct rated speed and frequency.
3. Only an AC voltmeter may be used to measure AC voltage. DO NOT USE A DC VOLTMETER FOR THIS PURPOSE.
DANGER! GENERATORS PRODUCE HIGH
AND DANGEROUS VOLTAGES. CONTACT
*
WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK.
MEASURING DC VOLTAGE
A DC voltmeter or a VOM may be used to measure DC voltages. Always observe the following rules:
1. Always observe correct DC polarity.
a. Some VOM's may be equipped with a polar-
ity switch.
b. On meters that do not have a polarity switch,
DC polarity must be reversed by reversing the test leads.
2. Before reading a DC voltage, always set the meter to a higher voltage scale than the anticipated reading. If in doubt, start at the highest scale and adjust the scale downward until correct readings are obtained.
Figure 1. Digital VOM
3. The design of some meters is based on the “current flow” theory while others are based on the “electron flow” theory.
a. The “current flow” theory assumes that direct
current flows from the positive (+) to the negative (-).
b. The “electron flow” theory assumes that cur-
rent flows from negative (-) to positive (+).
NOTE: When testing generators, the “current flow” theory is applied. That is, current is assumed to flow from positive (+) to negative (-).
MEASURING AC FREQUENCY
The generator's AC output frequency is proportional to Rotor speed. Generators equipped with a 2-pole Rotor must operate at 3600 rpm to supply a frequency of 60 Hertz. Units with 4-pole Rotor must run at 1800 rpm to deliver 60 Hertz.
Page 13
Page 16
1.00 A
BATTERY
+-
RELAY
SECTION 1.2
MEASURING ELECTRICITY
Correct engine and Rotor speed is maintained by an engine speed governor. For models rated 60 Hertz, the governor is generally set to maintain a no-load fre­quency of about 62 Hertz with a corresponding output voltage of about 124 volts AC line-to-neutral. Engine speed and frequency at no-load are set slightly high to prevent excessive rpm and frequency droop under heavy electrical loading.
MEASURING CURRENT
CLAMP-ON: To read the current flow, in AMPERES, a clamp-on
ammeter may be used. This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor. The meter consists essentially of a current transform­er with a split core and a rectifier type instrument con­nected to the secondary. The primary of the current transformer is the conductor through which the current to be measured flows. The split core allows the instru­ment to be clamped around the conductor without disconnecting it.
Current flowing through a conductor may be measured safely and easily. A line-splitter can be used to measure current in a cord without separating the conductors.
PART 1
NOTE: If the physical size of the conductor or amme­ter capacity does not permit all lines to be measured simultaneously, measure current flow in each indi­vidual line. Then, add the individual readings.
IN-LINE: Alternatively, to read the current flow in AMPERES, an
in-line ammeter may be used. Most Digital Volt Ohm Meters (VOM) will have the capability to measure amperes.
This usually requires the positive meter test lead to be connected to the correct amperes plug, and the meter to be set to the amperes position. Once the meter is properly set up to measure amperes the circuit being measured must be physically broken. The meter will be in-line or in series with the component being mea­sured.
In Figure 4 the control wire to a relay has been removed. The meter is used to connect and supply voltage to the relay to energize it and measure the amperes going to it.
GENERAL INFORMATION
Page 14
Figure 2. Clamp-On Ammeter
Figure 3. A Line-Splitter
Figure 4. A VOM as an In-line meter
MEASURING RESISTANCE
The volt-ohm-milliammeter may be used to measure the resistance in a circuit. Resistance values can be very valuable when testing coils or windings, such as the Stator and Rotor windings.
When testing Stator windings, keep in mind that the resistance of these windings is very low. Some meters are not capable of reading such a low resistance and will simply read CONTINUITY.
If proper procedures are used, the following conditions can be detected using a VOM:
• A“short-to-ground”condition inanyStatoror Rotor
winding.
•
Shorting together of any two parallel Stator windings.
•
Shorting together of any two isolated Stator windings.
• AnopenconditioninanyStatororRotorwinding.
Page 17
-
+
AMPERE - Unit measuring rate of
current flow (number of electrons past a given point)
OHM - Unit measuring resistance
or opposition to flow
VOLT - Unit measuring force or
difference in potential causing current flow
Conductor of a Circuit
VOLTS
(E)
AMPS
(I)
OHMS
(R)
GENERAL INFORMATION
Component testing may require a specific resis­tance value or a test for INFINITY or CONTINUITY. Infinity is an OPEN condition between two electrical points, which would read as no resistance on a VOM. Continuity is a CLOSED condition between two electri­cal points, which would be indicated as very low resis­tance or “ZERO” on a VOM.
PART 1
ELECTRICAL UNITS
AMPERE: The rate of electron flow in a circuit is represented
by the AMPERE. The ampere is the number of elec­trons flowing past a given point at a given time. One AMPERE is equal to just slightly more than six thou­sand million billion electrons per second (6.25 x 1018).
With alternating current (AC), the electrons flow first in one direction, then reverse and move in the opposite direction. They will repeat this cycle at regular inter­vals. A wave diagram, called a “sine wave” shows that current goes from zero to maximum positive value, then reverses and goes from zero to maximum nega­tive value. Two reversals of current flow is called a cycle. The number of cycles per second is called fre­quency and is usually stated in “Hertz”.
SECTION 1.2
MEASURING ELECTRICITY
OHM: The OHM is the unit of RESISTANCE. In every circuit
there is a natural resistance or opposition to the flow of electrons. When an EMF is applied to a complete circuit, the electrons are forced to flow in a single direction rather than their free or orbiting pattern. The resistance of a conductor depends on (a) its physical makeup, (b) its cross-sectional area, (c) its length, and (d) its temperature. As the conductor's temperature increases, its resistance increases in direct proportion. One (1) ohm of resistance will permit one (1) ampere of current to flow when one (1) volt of electromotive force (EMF) is applied.
OHM'S LAW
A definite and exact relationship exists between VOLTS, OHMS and AMPERES. The value of one can be calcu­lated when the value of the other two are known. Ohm's Law states that in any circuit the current will increase when voltage increases but resistance remains the same, and current will decrease when resistance Increases and voltage remains the same.
VOLT : The VOLT is the unit used to measure electrical
PRESSURE, or the difference in electrical potential that causes electrons to flow. Very few electrons will flow when voltage is weak. More electrons will flow as voltage becomes stronger. VOLTAGE may be consid­ered to be a state of unbalance and current flow as an attempt to regain balance. One volt is the amount of EMF that will cause a current of 1 ampere to flow through 1 ohm of resistance.
Figure 5. Electrical Units
Figure 6. Ohm's Law
If AMPERES is unknown while VOLTS and OHMS are known, use the following formula:
OHMS
If VOLTS is unknown while AMPERES and OHMS are known, use the following formula:
If OHMS is unknown but VOLTS and AMPERES are known, use the following:
AMPERES
AMPERES =
VOLTS = AMPERES x OHMS
OHMS
VOLTS
VOLTS
=
Page 15
Page 18
STATOR
ROTOR
ENGINE
CAPACITOR
DIODE B
COIL 2
COIL 1
DIODE A
CAPACITOR
STATOR
EXCITATION
WINDING
STATOR
POWER
WINDING
STATOR POWER
WINDING
MAGNETIC
FIELD
MAGNETIC
FIELD
MLB = MAIN LINE CIRCUIT BREAKER
ROTOR
TO LOAD
MLB
ENGINE ­DIRECT DRIVE
AUTOMATIC
VOLTAGE
REGULATOR
+-
STATOR
EXCITATION
WINDING
STATOR POWER
WINDING
STATOR POWER
WINDING
MAGNETIC
FIELD
MAGNETIC
FIELD
SENSING
MLB = MAIN LINE CIRCUIT BREAKER
ROTOR
TO LOAD
MLB
ENGINE - DIRECT DRIVE
120 VAC 120 VAC
240 VAC
120 VAC 120 VAC
240 VAC
SECTION 1.3
BRUSHLESS, CAPACITOR EXCITATION SYSTEM
INTRODUCTION
A typical brushless type portable generator will need 4 major components to function—a prime mover, a stator, a rotor, and a capacitor.
As the engine starts to crank, residual magnetism from the rotor creates magnetic lines of flux. The lines begin to cut the excitation winding and induce a small voltage into the winding. The voltage causes the capacitor to charge. When the capacitor has fully charged it will discharge a voltage that will be induced back into the rotor. The AC voltage induced into the rotor is rectified using a diode. The magnetic lines of flux from the rotor will increase, causing output volt­age to increase. The charge and discharge relation­ship that the capacitor and rotor share is the voltage regulation system that allows the generator to main­tain 240 volts.
Figure 1 shows the major components of a typical GP Series brushless AC generator.
a tapered crankshaft and is held in place with a single through bolt.
Note: Some Rotors have a magnet placed inside to help excite the rotor after it has been left idle for a long period of time.
PART 1
GENERAL INFORMATION
The stator has three windings wound separately inside the can. Two are the power windings and are located on Wire 44 (Hot) and Wire 33 (Neutral), the other winding is located on Wire 11 (Hot) and Wire 22 (Neutral). The third winding is called the DPE winding or Displaced Phase Excitation winding and is located on Wire 2 and Wire 6.
The 2-pole rotor must be operated at 3600 rpm to supply a 60 Hertz AC frequency. The term “2-pole” means the rotor has a single north magnetic pole and a single south magnetic pole. It spins freely inside the stator can and is excited by the charging and dis­charging of the capacitor. It has two diodes that rec­tify voltage induced from the Excitation winding to DC voltage. The rotor bearing is pressed onto the end of the rotor shaft. The tapered rotor shaft is mounted to
Page 16
Figure 1. AC Generator Exploded View
STATOR ASSEMBLY
ROTOR ASSEMBLY
Figure 2. Rotor and Diodes
CIRCUIT BREAKERS
Each individual circuit on the generator is protected by a circuit breaker to prevent overload.
Figure 3. Generator Operating Diagram
Page 19
CAPACITOR 28µf
WIRE 2
WIRE 6
RED (R2 – 33)
BLUE (R1 – 44)
BROWN (L2 – 22)
WHITE (L1 – 11)
WIRE 2
WIRE 6
11 22 33 44
CAPACITOR 47µf (440 VAC)
GENERAL INFORMATION
PART 1
BRUSHLESS, CAPACITOR EXCITATION SYSTEM
OPERATION
STARTUP: When the engine is started, residual magnetism from
the rotor induces a voltage into (a) the stator AC power windings, (b) the stator excitation or DPE wind­ings. In an “On-speed” (engine cranking) condition, residual magnetism is capable of creating approxi­mately one to three Volts AC.
ON-SPEED OPERATION: As the engine accelerates, the voltage that is induced
into the stator windings increases rapidly, due to the increasing speed at which the rotor operates.
SECTION 1.3
FIELD EXCITATION: An AC voltage is induced into the stator excitation
(DPE) windings. The DPE winding circuit is completed to the capacitor where the charging and discharging causes a voltage to be induced back in to the rotor which will regulate voltage. The greater the current flow through the rotor windings, the more concen­trated the lines of flux around the rotor become. The more concentrated the lines of flux around the rotor that cut across the stationary stator windings, the greater the voltage that is induced into the stator windings. Initially, the AC power winding voltage is low, but as the capacitor is charged and discharged this relationship between the rotor and the capacitor is what will regulate voltage at a desired level.
AC POWER WINDING OUTPUT: A regulated voltage is induced into the stator AC
power windings. When electrical loads are connected across the AC power windings to complete the circuit, current can flow in the circuit.
A
Figure 4. Alternator Configuration A
B
Figure 5. Alternator Configuration B
Page 17
Page 20
STATOR
ROTOR
ENGINE
BRUSHES
VOLTAGE REGULATOR
Section 1.4 BRUSHED EXCITATION SYSTEM
INTRODUCTION
A typical brushed type portable generator will need 4 major components to function: a prime mover, a sta­tor, a rotor, and a voltage regulator.
As the engine starts to crank, residual magnetism from the rotor creates magnetic lines of flux. The lines begin to cut the excitation winding and induce a small voltage into the voltage regulator. The excitation volt­age will power the voltage regulator and the voltage regulator will start to sense AC voltage from Wires S15 and S16. The lower voltage from the sensing wires will cause DC excitation to the rotor to be driven up until AC output is at desired level of 240VAC. Once the generator has reached 240VAC it will maintain the DC voltage, regulating the alternator when loads are applied and removed.
PART 1
to the negative (-) slip ring and brush on Wire 0. This current flow creates a magnetic field around the rotor having a flux concentration that is proportional to the amount of current flow.
GENERAL INFORMATION
ROTOR RESIDUAL MAGNETISM
The generator revolving field (rotor) may be consid­ered to be a permanent magnet. Some “residual” magnetism is always present in the rotor. This residu­al magnetism is sufficient to induce a voltage into the stator AC power windings that is approximately 2-5 volts AC.
Note: Some Rotors have a magnet placed inside to help excite the rotor after it has been left idle for a long period of time.
VOLTAGE REGULATOR
Refer to Figure 3 for the proper identification of the voltage regulator. Unregulated AC output from the stator excitation winding is delivered to the regulator’s DPE terminals, via Wire 2 and Wire 6. The voltage regulator rectifies that current and, based on stator AC power winding sensing, regulates it. The rectified and regulated excitation current is then delivered to the rotor windings from the positive (+) and negative (-) regulator terminals, via Wire 4 and Wire 0. Stator AC power winding “sensing” is delivered to the regula­tor via Wires S15 and S16.
Figure 1. AC Generator Exploded View
STATOR ASSEMBLY
The stator has three windings wound separately inside the can. Two are the power windings and are located on Wire 44 (Hot) and Wire 33 (Neutral); the other winding is located on Wire 11 (Hot) and Wire 22 (neutral). The third winding is called DPE winding or Displaced Phase Excitation winding and is located on Wire 2 and Wire 6.
BRUSH HOLDER AND BRUSHES
The brush holder is retained to the rear bearing car­rier by means of two Taptite screws. A positive (+) and a negative (-) brush are retained in the brush holder. Wire 4 connects to the positive (+) brush and Wire 0 to the negative (-) brush. Rectified and regulated excitation current are delivered to the rotor windings via Wire 4, and the positive (+) brush and slip ring. The excitation current passes through the windings
Page 18
OPERATION
STARTUP: When the engine is started, residual magnetism from
the rotor induces a voltage into (a) the stator AC power windings, (b) the stator excitation or DPE wind­ings. In an “on-speed” (engine cranking) condition, residual magnetism is capable of creating approxi­mately one to three volts AC.
ON-SPEED OPERATION: As the engine accelerates, the voltage that is induced
into the stator windings increases rapidly, due to the increasing speed at which the rotor operates.
FIELD EXCITATION: An AC voltage is induced into the stator excitation
(DPE) windings. The DPE winding circuit is com­pleted to the voltage regulator, via Wire 2 and Wire
6. Unregulated alternating current can flow from the winding to the regulator. The voltage regulator “sens­es” AC power winding output voltage and frequency via stator Wires S15 and S16.
The regulator changes the AC from the excitation winding to DC. In addition, based on the Wire S15 and Wire S16 sensing signals, it regulates the flow of direct current to the rotor. The rectified and regulated current flow from the regulator is delivered to the rotor windings, via Wire 4, and the positive brush and slip ring. This excitation current flows through the rotor
Page 21
AUTOMATIC
VOLTAGE
REGULATOR
+-
STATOR
EXCITATION
WINDING
STATOR POWER
WINDING
STATOR POWER
WINDING
MAGNETIC
FIELD
MAGNETIC
FIELD
SENSING
MLB = MAIN LINE CIRCUIT BREAKER
ROTOR
TO LOAD
MLB
ENGINE ­DIRECT DRIVE
120 VAC 120 VAC
240 VAC
VOLTAGE REGULATOR
AVR SENSING
DPE
NOT USED
RED (R2 – 11)
BLUE (R1 – 22)
BLUE
BLUE
4 (+) RED
S15
2
S16
6
0 (-) WHITE
BROWN (L2 – 33)
WHITE (L1 – 44)
WHITE
GREEN
C1 FEMALE
C1 MALE
GENERAL INFORMATION
PART 1
windings and through the negative (-) slip ring and brush on Wire 0.
The greater the current flow through the rotor wind­ings, the more concentrated the lines of flux around the rotor become. The more concentrated the lines of flux around the rotor that cut across the stationary stator windings, the greater the voltage that is induced into the stator windings.
Initially, the AC power winding voltage sensed by the regulator is low. The regulator reacts by increasing the flow of excitation current to the rotor until volt­age increases to a desired level. The regulator then maintains the desired voltage. For example, if voltage exceeds the desired level, the regulator will decrease the flow of excitation current. Conversely, if voltage drops below the desired level, the regulator responds by increasing the flow of excitation current.
AC POWER WINDING OUTPUT: A regulated voltage is induced into the stator AC
power windings. When electrical loads are connected across the AC power windings to complete the circuit, current can flow in the circuit.
Section 1.4
BRUSHED EXCITATION SYSTEM
Figure 2. 240 VAC Sensing Alternator
C
Figure 3. Alternator Configuration C
Page 19
Page 22
NOTES
Page 20
Page 23
PART 2
AC GENERATORS
GP Series Portable Generators
TABLE OF CONTENTS
PART TITLE PAGE#
2.1 Brushless Excitation Troubleshooting Flowcharts
2.2 Brushed Capacitor Troubleshooting Flowcharts
2.3 AC Diagnostic Tests 26
22
24
Part 2 – AC Generators ......................................... 21
Section 2.1 – Brushless Capacitor
Troubleshooting Flowcharts ............. 22
Section 2.2 – Brushed Excitation
Troubleshooting Flowcharts ............. 24
Section 2.3 – AC Diagnostic Tests ........................ 26
Introduction ......................................................26
Test 1 – Check No-Load Voltage
and Frequency ....................................26
Test 2 – Check Circuit Breaker.........................26
Test 3 – Check Continuity of
Receptacle Panel ................................26
Test 4 – Field Flash Alternator
(Configuration “A” Only) .......................27
Test 5 – Check Brushed Rotor Circuit ..............28
Test 6 – Check Capacitor .................................29
Test 7 – Test Brushless DPE Winding ..............30
Test 8 – Test Brushless Stator Windings ..........30
Test 9 – Test Brushed Stator Windings ............31
Test 10 – Check Load Voltage & Frequency ....31
Test 11 – Check Load Watts & Amperage .......31
Test 12 – Adjust Voltage Regulator ..................31
Page 21
Page 24
GO TO PROBLEM 2 GO TO PROBLEM 1GO TO PROBLEM 4 VERIFY ROTOR IS SPINNING,
GO TO PROBLEM 1
GO TO PROBLEM 3
VOLTAGE &
FREQUENCY BOTH
HIGH OR LOW
FREQUENCY GOOD
VOLTAGE HIGH
ZERO VOLTAGE
ZERO FREQUENCY
FREQUENCY GOOD,
LOW OR RESIDUAL
VOLTAGE
TEST 1 - CHECK
NO LOAD VOLTAGE
& FREQUENCY
NO LOAD VOLTAGE &
FREQUENCY GOOD -
VOLTAGE/FREQUENCY
FALLS OFF UNDER LOAD
If Problem Involves AC Output
REPLACE
ALTERNATOR
REPLACE
ROTOR
STOP TESTING
BAD
BAD
GOOD
GOOD
CONFIGURATION “B”
GOOD
CONFIGURATION “A”
BAD
CONFIGURATION “B”
BAD
CONFIGURATION “A”
Problem 1 – Generator Produces Zero Voltage or Residual Voltage
TEST 2 – CHECK
MAIN CIRCUIT
BREAKER
RESET TO “ON”
OR REPLACE IF BAD
REPLACE COMPONENT
AS NEEDED
STOP
TESTING
TEST 3 – CHECK
CONTINUITY OF
RECEPTACLE PANEL
RE-CHECK VOLTAGE
AT RECEPTACLE
PANEL
RE-CHECK VOLTAGE
AT RECEPTACLE
PANEL
TEST 4 – FIELD
FLASH
ALTERNATOR
REPLACE
BAD
BAD
BAD
REPLACE
S TATO R
BAD
REPLACE
ALTERNATOR
REPLACE
CAPACITOR
ON
GOOD
GOODGOODGOOD
TEST 6 –
CHECK
CAPACITOR
TEST 7 – TEST
BRUSHLESS
DPE WINDING
TEST 8 – TEST
BRUSHLESS
STATOR
WINDINGS
TEST STATOR FOR SHORTS
TO GROUND
GOOD
SECTION 2.1
BRUSHLESS CAPACITOR TROUBLESHOOTING FLOWCHARTS
The GP series portable generators currently use three different types of alternators. Two of the alterna­tors are brushless capacitor type with different style of capacitors (Configuration “A” and “B”). The third uti­lizes a voltage regulator and a brushed excitation sys­tem (Configuration “C”). To help with troubleshooting, two sets of flow charts have been created for these different styles of alternators.
Identify the configuration of the alternator being ser­viced using Sections 1.3 and 1.4 of this manual and proceed to the appropriate flowchart section.
Configuration “A” – Brushless Capacitor, use Section 2.1
Configuration “B” – Brushless Capacitor, use Section 2.1
Configuration “C” – Brushed Excitation, use Section 2.2
PART 2
AC GENERATORS
Page 22
Page 25
ELECTRICAL FORMULAS
TO FIND KNOWN VALUES 1-PHASE
KILOWATTS (kW)
KVA
AMPERES
WATTS
NO. OF ROTOR POLES
FREQUENCY
RPM
kW (required for Motor)
Volts, Current, Power Factor
Volts, Current
kW, Volts, Power Factor
Volts, Amps, Power Factor Volts x Amps
Frequency, RPM
RPM, No. of Rotor Poles
Frequency, No. of Rotor Poles
Motor Horsepower, Efficiency
E x I
1000
E x I
1000
kW x 1000
E
2 x 60 x Frequency
RPM
RPM x Poles
2 x 60
2 x 60 x Frequency
Rotor Poles
HP x 0.746
Efficiency
RESISTANCE
VOLTS
AMPERES
E = VOLTS I = AMPERES R = RESISTANCE (OHMS) PF = POWER FACTOR
Volts, Amperes
Ohm, Amperes I x R
Ohms, Volts
E
I
E
R
Page 78
Page 26
NOTES
Page 27
NOTES
Page 80
Page 28
Page 29
Part No. 0H0285 rev. A / Printed in USA 02.09 © 2009 Generac Power Systems, Inc. All rights reserved.
Generac Power Systems, Inc.
S45 W29290 Hwy. 59 • Waukesha, WI 53189
1-888-GENERAC (1-888-436-3722) • generac.com
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