Generac Power Systems 4582 & 4987 Manuals

Manuals and User Guides for Generac Power Systems 4582 & 4987. We have 1 Generac Power Systems 4582 & 4987 manual available for free PDF download: Repair Manual

Generac Power Systems 4582 & 4987 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

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