Generac Power Systems 4451 & 4986 Manuals

Manuals and User Guides for Generac Power Systems 4451 & 4986. We have 1 Generac Power Systems 4451 & 4986 manual available for free PDF download: Repair Manual

Generac Power Systems 4451 & 4986 Repair Manual (90 pages)

ULTRA SOURCE PORTABLE GENERATOR

Brand: Generac Power Systems | Category: Portable Generator | Size: 15.55 MB

Notice to Users of this Manual
2
Replacement Parts
2
Table of Contents
3
Table of Contents
4
Generator Fundamentals
5
Section 1: Generator Fundamentals
5
Magnetism
5
Electromagnetic Fields
5
Electromagnetic Induction
5
A SIMPLE AC Generator
6
A more Sophisticated AC Generator
6
Section 1: Generator Fundamentals
7
Measuring Electricity
8
Section 2: Measuring Electricity
8
Meters
8
The vom
8
Measuring AC Voltage
8
Measuring DC Voltage
8
Measuring AC Frequency
8
Measuring CURRENT
9
Measuring RESISTANCE
9
Section 2: Measuring Electricity
10
Electrical Units
10
OHM'S Law
10
Description and Components
11
Introduction
11
Engine-Generator Drive System
11
THE AC Generator
11
ROTOR Assembly
11
STATOR Assembly
12
Brush Holder and Brushes
12
OTHER AC Generator COMPONENTS
12
- EXCITATION CIRCUIT Breaker
  12
- Voltage Regulator
  13
- Adjustment Procedure
  13
- CIRCUIT Breakers
  14
ROTOR Residual Magnetism
14
Field Boost CIRCUIT
14
Operation
14
- Startup
  14
- ON-Speed OPERATION
  14
- Field EXCITATION
  14
- AC Power Winding OUTPUT
  14
- Battery Charge Winding OUTPUT
  14
- 10 Amp Battery Charge Winding Output
  14
Insulation Resistance
15
THE Megohmmeter
15
- General
  15
- Testing STATOR INSULATION
  15
- Testing ROTOR INSULATION
  15
- Hi-Pot Tester
  15
Stator Insulation Resistance Test
15
- "Testing All Stator Windings To Ground
  16
- TEST between Windings
  16
Rotor Insulation Resistance Test
17
Cleaning the Generator
17
Drying the Generator
17
Engine DC Control System
18
Printed CIRCUIT Board
18
- General
  18
- CIRCUIT Board CONNECTIONS
  18
- Dip Switch POSITIONS
  18
Battery
18
- Recommended Battery
  18
CONTROL PANEL COMPONENT Identification
19
Terminal Block
20
OPERATIONAL Analysis
22
- CIRCUIT Condition - REST
  22
- CIRCUIT Condition - START
  24
- CIRCUIT Condition - RUN
  26
- CIRCUIT Condition - STOP
  28
- FAULT Shutdown
  29
- Section 4: Engine DC Control System
  29
- Troubleshooting Flowcharts
  30
Section 5: Troubleshooting Flowcharts
30
Introduction
30
IF Problem INVOLVES AC OUTPUT
30
Problem
32
Problem
35
- Engine STARTS Hard and RUNS Rough
  36
- Engine STARTS then SHUTS down
  36
Problem 10 - 10 AMP FUSE (F1) Blowing
37
Engine "HUNTS" / ERRATIC Idle
38
Section 5: Troubleshooting Flowcharts
38
Idle CONTROL "RPM Does NOT Decrease
38
Idle CONTROL "RPM Does NOT INCREASE When Load IS Applied
38
Problem 11 - UNIT Overspeeds
38
Diagnostic Tests
39
Introduction
39
Section 6: Diagnostic Tests
39
TEST 1 - CHECK NO-Load Voltage and Frequency
39
TEST 2 - CHECK MAIN CIRCUIT Breaker
39
TEST 3- TEST EXCITATION CIRCUIT Breaker
40
TEST 4 - Fixed EXCITATION TEST/ROTOR AMP Draw
40
Test 5 - Check Stepper Motor Control
42
TEST 6 - Wire Continuity
43
TEST 7 - CHECK Field Boost
43
TEST 8 - Diode/Resistor
44
Test 9 - Test Stator
45
TEST 10 - Sensing Leads
46
TEST 11 - EXCITATION Wiring
47
TEST 12 - CHECK Brush Leads
47
TEST 13 - CHECK Brushes & SLIP Rings
47
TEST 14 - CHECK ROTOR Assembly
48
TEST 15 - CHECK Load Voltage & Frequency
48
TEST 16 - CHECK Load Watts & Amperage
48
TEST 17 - CHECK Battery Charge OUTPUT
49
TEST 18 - CHECK 10 AMP Battery Charge OUTPUT
49
TEST 19 - CHECK Battery Charge RECTIFIER
49
TEST 20 - CHECK 10 AMP CIRCUIT Breaker
50
Test 21- Check 10 Amp Fuse
50
TEST 22- CHECK Battery & Cables
50
TEST 23- CHECK Voltage at STARTER CONTACTOR
51
Test 24 - Check Starter Contactor
51
Test 25 - Check Starter Motor
51
- Conditions Affecting STARTER MOTOR PERFORMANCE
  51
- Checking the PINION
  52
- Tools for Starter Performance Test
  52
- Measuring CURRENT
  52
- Tachometer
  52
- TEST Bracket
  53
- Remove Starter Motor
  53
- Testing STARTER MOTOR
  53
TEST 26 - TEST STARTER CONTACTOR Relay (SCR)
53
TEST 27- CHECK START-RUN-STOP Switch
54
TEST 28- CHECK START-RUN-STOP (Sw1) Wiring
54
TEST 29 - CHECK Ignition SPARK
55
TEST 30 - CHECK SPARK Plugs
55
TEST 31 - REMOVE Wire 18 / Shutdown Lead
56
TEST 32 - TEST START STOP Relay
56
TEST 33- TEST Wire 167
57
TEST 34 - TEST START STOP Relay Wiring
58
TEST 35 - CHECK and Adjust Ignition Magnetos
58
TEST 36: TEST FUEL SHUTOFF Solenoid
59
TEST 37: TEST FUEL SHUTOFF Solenoid Voltage
59
Test 38: Check Fuel Pump
59
TEST 39 - CHECK Carburetion
60
TEST 40 - VALVE Adjustment
60
TEST 41 - CHECK Engine / Cylinder LEAK down TEST / COMPRESSION TEST
61
TEST 42 - CHECK OIL PRESSURE Switch and Wire
62
TEST 43: CHECK START STOP Relay (SSR)
62
TEST 44: TEST STARTER CONTACTOR Relay (SCR)
63
TEST 45: CHECK Wire 15 CIRCUIT
63
TEST 46: CHECK Wire 14 CIRCUIT
63
TEST 47: CHECK FUEL SHUTOFF Solenoid
63
Test 48: Check Hourmeter
64
TEST 49: CHECK Wire 15B
64
TEST 50: CHECK Wire 167
64
TEST 51: CHECK Wires 11S & 44S
64
TEST 52: CHECK Idle CONTROL Switch (Sw2)
65
TEST 53: CHECK Idle CONTROL Wiring
65
TEST 54: CHECK Idle CONTROL TRANSFORMERS
66
TEST 55: CHECK TR1 & TR2 Wiring
66
Section 6: Diagnostic Tests
67
Test 56: Choke Test
67
Disassembly and Exploded Views
68
MAJOR Disassembly
68
Generator - Figure a
70
FRAME, Handle & Wheels - Figure B
72
Section 8: Electrical Data
74
Electrical Data
74
Wiring Diagram 12.5 & 15 Kw (UNITS Without HOURMETER) - Drawing NO. 0E0228
74
ELECTRICAL SCHEMATIC 12.5 & 15 Kw (UNITS Without HOURMETER) - Drawing NO. 0E0229-A
76
Wiring Diagram 12.5 & 15 Kw (UNITS with HOURMETER) - Drawing NO. 0D4609-D
78
ELECTRICAL SCHEMATIC 12.5 & 15 Kw (UNITS with HOURMETER) - Drawing NO. 0D6297-A
80
- Section 8: Electrical Data
  81
- Engine Wiring
  82
Wiring Diagram 17.5 Kw UNITS - Drawing NO. 0G0731
82
ELECTRICAL SCHEMATIC 17.5 Kw UNITS - Drawing NO. 0G0733
84
Wiring Diagram, 17.5 Kw MANUAL TRANSFER Switch - Drawing NO. 0G1065
85
INTERCONECTION Drawing - 17.5 Kw Generator
86
Specifications & Charts
88
Generator SPECIFICATIONS
88
Engine SPECIFICATIONS
88
Engine Speeds and Voltage SPECIFICATIONS
88
Torque SPECIFICATIONS
89
TRIM Torque SPECIFICATIONS
89

Generac Power Systems Categories

Portable Generator Inverter Pressure Washer

Switch Lighting Equipment

More Generac Power Systems Manuals

Generac Power Systems 4451 & 4986 Manuals

Generac Power Systems 4451 & 4986 Repair Manual (90 pages)

Table of Contents

Related Products

Generac Power Systems Categories