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S S A A F F E E T T Y Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I N N S S I I D D E E F F R R O O N N T T C C O O V V E E R R
S S E E C C T T I I O O N N 1 1 : :
G G E E N N E E R R A A T T O O R R F F U U N N D D A A M M E E N N T T A A L L S S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 - - 7 7
MAGNETISM ................................................................ 3
ELECTROMAGNETIC FIELDS .................................... 3
ELECTROMAGNETIC INDUCTION .............................. 3
A SIMPLE AC GENERATOR ........................................ 4
A MORE SOPHISTICATED AC GENERATOR ............ 4
FIELD BOOST .............................................................. 6
GENERATOR AC CONNECTION SYSTEM ................ 6
M M A A J J O O R R G G E E N N E E R R A A T T O O R R C C O O M M P P O O N N E E N N T T S S . . . . . . . . . . . . . . . . . . . . . . . . 8 8 - - 1 1 1 1
ROTOR ASSEMBLY ...................................................... 8
STATOR ASSEMBLY .................................................... 8
BRUSH HOLDER .......................................................... 9
BATTERY CHARGE COMPONENTS .......................... 9
EXCITATION CIRCUIT COMPONENTS ...................... 9
CRANKCASE BREATHER .......................................... 10
S S E E C C T T I I O O N N 3 3 : :
I I N N S S U U L L A A T T I I O O N N R R E E S S I I S S T T A A N N C C E E T T E E S S T T S S . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 2 - - 1 1 4 4
EFFECTS OF DIRT AND MOISTURE ........................ 12
INSULATION RESISTANCE TESTERS ...................... 12
DRYING THE GENERATOR ...................................... 12
CLEANING THE GENERATOR .................................. 12
STATOR INSULATION RESISTANCE ........................ 13
TESTING ROTOR INSULATION ................................ 14
THE MEGOHMMETER .............................................. 14
S S E E C C T T I I O O N N 4 4 : :
M M E E A A S S U U R R I I N N G G E E L L E E C C T T R R I I C C I I T T Y Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 5 5 - - 1 1 7 7
METERS ...................................................................... 15
THE VOM .................................................................... 15
MEASURING AC VOLTAGE ...................................... 15
MEASURING DC VOLTAGE ...................................... 15
MEASURING AC FREQUENCY ................................ 16
MEASURING CURRENT ............................................ 16
MEASURING RESISTANCE ...................................... 16
ELECTRICAL UNITS .................................................. 17
OHM'S LAW ................................................................ 17
S S E E C C T T I I O O N N 5 5 : :
E E N N G G I I N N E E D D C C C C O O N N T T R R O O L L S S Y Y S S T T E E M M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 8 8 - - 2 2 6 6
INTRODUCTION ........................................................ 18
OPERATIONAL ANALYSIS .................................. 18-23
ENGINE CONTROLLER CIRCUIT BOARD ................ 24
BATTERY .................................................................... 24
7.5 AMP FUSE ............................................................ 25
FUEL PRIMER SWITCH ............................................ 25
START-STOP SWITCH .............................................. 25
& STARTER MOTOR ................................................ 26
S S E E C C T T I I O O N N 6 6 : :
T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G F F L L O O W W C C H H A A R R T T S S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 7 7 - - 3 3 7 7
IF PROBLEM INVOLVES AC OUTPUT ...................... 27
PROBLEM 1 -
HIGH OR LOW ............................................................ 27
PROBLEM 2 -
RESIDUAL VOLTAGE (5-12 VAC) ........................ 28-29
PROBLEM 3 -
NO BATTERY CHARGE OUTPUT .............................. 29
PROBLEM 4 -
S S E E C C T T I I O O N N 2 2 : :
WHEN LOAD IS APPLIED .......................................... 30
PROBLEM 5 -
(GASOLINE MODELS) ................................................ 30
PROBLEM 6 -
ENGINE WILL NOT CRANK ...................................... 31
PROBLEM 7 -
(GASOLINE UNITS) .................................................... 32
PROBLEM 7 -
(LP UNITS) .................................................................. 33
PROBLEM 8 -
(GASOLINE UNITS) .................................................... 34
PROBLEM 8 -
(LP UNITS) .................................................................. 34
PROBLEM 9 -
ENGINE STARTS THEN SHUTS DOWN .................. 36
7.5 AMP (F1) FUSE BLOWING .................................. 37
S S E E C C T T I I O O N N 7 7 : :
D D I I A A G G N N O O S S T T I I C C T T E E S S T T S S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 8 8 - - 6 6 7 7
INTRODUCTION ........................................................ 38
TEST 1 -
Check No-Load Voltage And Frequency ...................... 38
TEST 2 -
Check Engine Governor .............................................. 38
TEST 3 -
Test Excitation Circuit Breaker .................................... 39
TEST 4 -
Fixed Excitation Test/Rotor Amp Draw ........................ 39
TEST 5 -
Wire Continuity ............................................................ 40
TEST 6 -
Check Field Boost ........................................................ 41
TEST 7 -
Test Stator DPE Winding.............................................. 41
TEST 8 -
Check Sensing Leads/Power Windings ...................... 42
T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s
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