Table Of Contents - Generac Power Systems 4451 & 4986 Repair Manual

table of contents

section 6:
Diagnostic tests ...................................... 37-65
INTROdUCTION .............................................................. 37
TEST 1 - CHECK NO-LOAd VOLTAgE ANd FREqUENCy .. 37
TEST 2 - CHECK MAIN CIRCUIT bREAKER ........................ 37
TEST 3- TEST EXCITATION CIRCUIT bREAKER ................... 38
TEST 4 - FIXEd EXCITATION TEST/ROTOR AMP dRAw ..... 38
TEST 5 - CHECK STEPPER MOTOR CONTROL ................... 40
TEST 6 - wIRE CONTINUITy ............................................. 41
TEST 7 - CHECK FIELd bOOST ......................................... 41
TEST 8 - dIOdE/RESISTOR ................................................ 42
TEST 9 - TEST STATOR ..................................................... 43
TEST 10 - SENSINg LEAdS ............................................... 44
TEST 11 - EXCITATION wIRINg ........................................ 45
TEST 12 - CHECK bRUSH LEAdS ...................................... 45
TEST 13 - CHECK bRUSHES & SLIP RINgS ........................ 45
TEST 14 - CHECK ROTOR ASSEMbLy ............................... 46
TEST 15 - CHECK LOAd VOLTAgE & FREqUENCy ........... 46
TEST 16 - CHECK LOAd wATTS & AMPERAgE ................ 46
TEST 17 - CHECK bATTERy CHARgE OUTPUT ................. 47
TEST 18 - CHECK 10 AMP bATTERy CHARgE OUTPUT .... 47
TEST 19 - CHECK bATTERy CHARgE RECTIFIER ............... 47
TEST 20 - CHECK 10 AMP CIRCUIT bREAKER .................. 48
TEST 21- CHECK 10 AMP FUSE ....................................... 48
TEST 22- CHECK bATTERy & CAbLES .............................. 48
TEST 23- CHECK VOLTAgE AT STARTER CONTACTOR ..... 49
TEST 24 - CHECK STARTER CONTACTOR ......................... 49
TEST 25 - CHECK STARTER MOTOR ................................. 49
CONdITIONS AFFECTINg STARTER MOTOR
PERFORMANCE: .......................................................... 49
CHECKINg THE PINION: .............................................. 50
TOOLS FOR STARTER PERFORMANCE TEST: ................. 50
MEASURINg CURRENT: ............................................... 50
TACHOMETER: ............................................................ 50
TEST bRACKET: ........................................................... 51
REMOVE STARTER MOTOR: ......................................... 51
TESTINg STARTER MOTOR: ......................................... 51
TEST 26 - TEST STARTER CONTACTOR RELAy (SCR) ......... 51
TEST 27- CHECK START-RUN-STOP SwITCH ................... 52
TEST 28- CHECK START-RUN-STOP (Sw1) wIRINg ........... 52
TEST 29 - CHECK IgNITION SPARK .................................. 53
TEST 30 - CHECK SPARK PLUgS ...................................... 53
TEST 31 - REMOVE wIRE 18 / SHUTdOwN LEAd ............ 54
TEST 32 - TEST START STOP RELAy .................................. 54
TEST 33- TEST wIRE 167 ................................................. 55
TEST 34 - TEST START STOP RELAy wIRINg ..................... 56
TEST 35 - CHECK ANd AdJUST IgNITION MAgNETOS .... 56
TEST 36: TEST FUEL SHUTOFF SOLENOId ......................... 57
TEST 37: TEST FUEL SHUTOFF SOLENOId VOLTAgE ......... 57
TEST 38: CHECK FUEL PUMP ........................................... 57
Page 2
TEST 39 - CHECK CARbURETION ..................................... 58
TEST 40 - VALVE AdJUSTMENT ........................................ 58
TEST 41 - CHECK ENgINE / CyLINdER LEAK
dOwN TEST / COMPRESSION TEST ................................. 59
TEST 42 - CHECK OIL PRESSURE SwITCH ANd wIRE 86 .. 60
TEST 43: CHECK START STOP RELAy (SSR) ....................... 60
TEST 44: TEST STARTER CONTACTOR RELAy (SCR) .......... 61
TEST 45: CHECK wIRE 15 CIRCUIT .................................. 61
TEST 46: CHECK wIRE 14 CIRCUIT .................................. 61
TEST 47: CHECK FUEL SHUTOFF SOLENOId ..................... 61
TEST 48: CHECK HOURMETER ........................................ 62
TEST 49: CHECK wIRE 15b ............................................. 62
TEST 50: CHECK wIRE 167 ............................................. 62
TEST 51: CHECK wIRES 11S & 44S .................................. 62
TEST 52: CHECK IdLE CONTROL SwITCH (Sw2) .............. 63
TEST 53: CHECK IdLE CONTROL wIRINg ........................ 63
TEST 54: CHECK IdLE CONTROL TRANSFORMERS ........... 64
TEST 55: CHECK TR1 & TR2 wIRINg ............................... 64
TEST 56: CHOKE TEST ................................................... 65
section 7:
DisasseMblY anD exploDeD vieWs ..... 66-71
MAJOR dISASSEMbLy ..................................................... 66
gENERATOR - FIgURE A ................................................ 68
FRAME, HANdLE & wHEELS - FIgURE b ......................... 70
section 8:
electRical Data ......................................... 72-79
wIRINg dIAgRAM 12.5 & 15 Kw (UNITS wITHOUT
HOURMETER) - dRAwINg NO. 0E0228 .......................... 72
ELECTRICAL SCHEMATIC 12.5 & 15 Kw (UNITS
wITHOUT HOURMETER) - dRAwINg NO. 0E0229-A ....... 74
wIRINg dIAgRAM 12.5 & 15 Kw
(UNITS wITH HOURMETER) - dRAwINg NO. 0d4609-d .. 76
ELECTRICAL SCHEMATIC 12.5 & 15 Kw (UNITS wITH
HOURMETER) - dRAwINg NO. 0d6297-A ...................... 78
wIRINg dIAgRAM 17.5 Kw UNITS -
dRAwINg NO. 0g0731 .................................................. 80
ELECTRICAL SCHEMATIC 17.5 Kw UNITS -
dRAwINg NO. 0g0733 .................................................. 82
wIRINg dIAgRAM, 17.5 Kw MANUAL
TRANSFER SwITCH - dRAwINg NO. 0g1065 ................ 83
INTERCONECTION dRAwINg - 17.5 Kw gENERATOR .... 84
section 9:
speciFications & cHaRts ....................... 86-87
gENERATOR SPECIFICATIONS .......................................... 86
ENgINE SPECIFICATIONS ................................................. 86
ENgINE SPEEdS ANd VOLTAgE SPECIFICATIONS ............. 86
TORqUE SPECIFICATIONS ................................................ 87
TRIM TORqUE SPECIFICATIONS ....................................... 87