Table of Contents
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saFetY .................. insiDe FRont coveR (iFc)
NOTICE TO USERS OF THIS MANUAL ..............................IFC
REPLACEMENT PARTS .....................................................IFC
table oF contents ...................................... 1-2
section 1:
geneRatoR FunDaMentals ....................... 3-5
MAgNETISM ..................................................................... 3
ELECTROMAgNETIC FIELdS .............................................. 3
ELECTROMAgNETIC INdUCTION ...................................... 3
A SIMPLE AC gENERATOR ................................................ 4
A MORE SOPHISTICATEd AC gENERATOR ......................... 4
section 2:
MeasuRing electRicitY ............................. 6-8
METERS .......................................................................... 6
THE VOM ........................................................................ 6
MEASURINg AC VOLTAgE .............................................. 6
MEASURINg dC VOLTAgE .............................................. 6
MEASURINg AC FREqUENCy ......................................... 6
MEASURINg CURRENT .................................................... 7
MEASURINg RESISTANCE ................................................ 7
ELECTRICAL UNITS .......................................................... 8
OHM'S LAw .................................................................... 8
section 3:
DescRiption anD coMponents ............. 9-15
INTROdUCTION .............................................................. 9
ENgINE-gENERATOR dRIVE SySTEM ............................... 9
THE AC gENERATOR ....................................................... 9
ROTOR ASSEMbLy .......................................................... 9
STATOR ASSEMbLy ........................................................ 10
bRUSH HOLdER ANd bRUSHES ..................................... 10
OTHER AC gENERATOR COMPONENTS ........................ 10
EXCITATION CIRCUIT bREAKER .................................. 10
VOLTAgE REgULATOR .............................................. 11
AdJUSTMENT PROCEdURE ....................................... 11
CIRCUIT bREAKERS ................................................... 12
ROTOR RESIdUAL MAgNETISM ..................................... 12
FIELd bOOST CIRCUIT ................................................... 12
OPERATION ................................................................... 12
STARTUP ................................................................... 12
ON-SPEEd OPERATION .............................................. 12
FIELd EXCITATION ..................................................... 12
AC POwER wINdINg OUTPUT .................................. 12
bATTERy CHARgE wINdINg OUTPUT ....................... 12
10 AMP bATTERy CHARgE wINdINg OUTPUT .......... 12
INSULATION RESISTANCE .............................................. 13
THE MEgOHMMETER ................................................... 13
gENERAL .................................................................. 13
TESTINg STATOR INSULATION ................................... 13
TESTINg ROTOR INSULATION .................................... 13
HI-POT TESTER .......................................................... 13
STATOR INSULATION RESISTANCE TEST .......................... 13
gENERAL .................................................................. 13
TESTINg ALL STATOR wINdINgS TO gROUNd .......... 14
TEST bETwEEN wINdINgS: ....................................... 14
ROTOR INSULATION RESISTANCE TEST .......................... 15
CLEANINg THE gENERATOR ......................................... 15
dRyINg THE gENERATOR ............................................. 15
section 4:
engine Dc contRol sYsteM .................. 16-27
PRINTEd CIRCUIT bOARd .............................................. 16
gENERAL .................................................................. 16
CIRCUIT bOARd CONNECTIONS ............................... 16
dIP SwITCH POSITIONS ............................................. 16
bATTERy ....................................................................... 16
RECOMMENdEd bATTERy ........................................ 16
CONTROL PANEL COMPONENT IdENTIFICATION ...... 17-18
OPERATIONAL ANALySIS .......................................... 20-27
CIRCUIT CONdITION - REST ...................................... 20
CIRCUIT CONdITION - START .................................... 22
CIRCUIT CONdITION - RUN ....................................... 24
CIRCUIT CONdITION - STOP ...................................... 26
FAULT SHUTdOwN ................................................... 27
section 5:
tRoublesHooting FloWcHaRts .......... 28-36
INTROdUCTION ............................................................ 28
PRObLEM 1 -
PRObLEM 2 -
OR RESIdUAL VOLTAgE (2-12 VAC) ...................... 29-30
PRObLEM 3 -
dROOP wHEN LOAd IS APPLIEd ............................... 30
PRObLEM 4 -
NO bATTERy CHARgE OUTPUT ................................. 31
PRObLEM 5 -
NO 10 AMP bATTERy CHARgE OUTPUT ................... 31
PRObLEM 6 -
ENgINE wILL NOT CRANK ........................................ 32
PRObLEM 7 -
ENgINE CRANKS bUT wILL NOT START ..................... 33
PRObLEM 8 -
ENgINE STARTS HARd ANd RUNS ROUgH ................ 34
PRObLEM 9 -
ENgINE STARTS THEN SHUTS dOwN ........................ 34
10 AMP FUSE (F1) bLOwINg ..................................... 35
UNIT OVERSPEEdS .................................................... 36
PRObLEM 12 -
PRObLEM 13 -
PRObLEM 14 -
ENgINE "HUNTS" / ERRATIC IdLE .............................. 36
table of contents
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Page 1
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Table of Contents
Troubleshooting
