Documente Academic
Documente Profesional
Documente Cultură
N pr
Portable Generator
ot o
Models LP030344-0, LP030345-0, LP030419-0
R
279598
fo du
e
WARNING
Failure to read and follow the
Service Manual and all operating
instructions can result in death, bodily
injury, and/or equipment damage.
Save this manual for future reference.
injury.
A signal word (DANGER, WARNING, or CAUTION) is
used with the alert symbol to indicate the likelihood and
the potential severity of injury. In addition, a hazard
symbol may be used to represent the type of hazard.
1
WARNING Starter cord kickback (rapid
retraction) will pull hand and arm toward
engine faster than you can let go which could
cause broken bones, fractures, bruises, or
sprains resulting in serious injury.
• When starting engine, pull cord slowly until resistance
is felt and then pull rapidly to avoid kickback.
• NEVER start or stop engine with electrical devices
plugged in and turned on.
• DO NOT operate this product inside any building, • Keep fuel away from sparks, open flames, pilot
carport, porch, mobile equipment, marine lights, heat, and other ignition sources.
fo du
applications, or enclosure, even if windows and doors • Check fuel lines, tank, cap, and fittings
e
2
WARNING Generator voltage could cause WARNING Starter and other rotating parts
electrical shock or burn resulting in death or could entangle hands, hair clothing, or
serious injury. accessories resulting in serious injury.
• Use approved transfer equipment to prevent • NEVER operate generator without protective housing
backfeed by isolating generator from electric utility or covers.
workers. • DO NOT wear loose clothing, jewelry or anything that
• When using generator for backup power, notify utility could be caught in the starter or other rotating parts.
company. • Tie up long hair and remove jewelry.
• Use a ground fault circuit interrupter (GFCI) in any
damp or highly conductive area, such as metal
decking or steel work.
• DO NOT touch bare wires or receptacles.
• DO NOT use generator with electrical cords which
are worn, frayed, bare, or otherwise damaged. CAUTION Excessively high operating speeds
•
•
DO NOT operate generator in the rain or wet weather.
DO NOT handle generator or electrical cords while
could result in minor injury and/or generator
damage. Excessively low speeds impose a heavy
1
standing in water, while barefoot, or while hands and load.
feet are wet. • DO NOT tamper with governor spring, links, or other
• DO NOT allow unqualified persons or children to parts to increase engine speed. Generator supplies
operate or service generator. correct rated frequency and voltage when running at
governed speed.
• DO NOT modify generator in any way.
N pr
WARNING Exhaust heat/gases could ignite
combustibles, structures or damage fuel tank
NOTICE: Exceeding generator’s wattage/amperage
causing a fire, resulting in death, serious injury
ot o
capacity could damage generator and/or electrical
and/or property damage. Contact with muffler
devices connected to it.
R
• Replacement parts must be the same and installed in contact your authorized dealer.
the same position as the original parts.
• Operate generator only on level surfaces.
• DO NOT expose generator to excessive
n
3
Generator Components
1 N pr
ot o
R
fo du
e
r ct
A - 120/240Volt AC, 30 Amp Locking Receptacle — H - Air Cleaner — Protects engine by filtering dust and
May be used to supply electrical power for the debris out of intake air.
operation of 120 and/or 240 Volt AC, 30 Amp, J - Recoil Starter — Used to start the engine.
single phase, 60 Hz electrical, lighting, appliance, K - Identification Label — Provides model, revision,
tool, and motor loads. and serial number of generator. Please have these
B - 120 Volt AC, 20 Amp, Duplex Receptacles — readily available when calling for assistance.
io
May be used to supply electrical power for the L - Oil Drain Plug — Drain engine oil here.
operation of 120 Volt AC, 20 Amp, single phase, 60 M - Oil Fill Cap — Check and fill engine with oil here.
Hz electrical, lighting, appliance, tool, and motor N - Fuel Tank — Capacity of seven (7_ U.S. gallons
n
4
Alternator Components
H - Air Cleaner —
J - Recoil Starter —
N pr 1
ot o
R
fo du
e
r ct
5
Automatic Voltage Regulator (AVR)
The voltage regulator acts to increase or decrease
current flow to the rotor windings based on the
demands of the load connected to the generator. The
increase or decrease in current flow through the rotor
results in a proportional increase or decrease in the
rotor’s magnetic field strength, which is what induces
(AC) current in the power windings of the stator.
The operating sequence for this type of voltage
regulator is as follows:
1 N pr
ot o
R
fo du
e
r ct
Figure 1
11A and 22A, to the voltage regulator at wire (F). The (DC) output from the voltage
sensing terminals 11(A, Figure 1) and 22 regulator to the rotor is based on the voltage
(B). If for any reason sensing or frequency is and frequency signals received from sensing
lost, the voltage regulator will turn off, and it wires 11A and 22A.
will only turn back on when the generator is
shut down and restarted.
6
Troubleshooting
Refer to Figure 2 for wire identification and locations
when performing the following tests.
N pr 1
ot o
R
fo du
e
r ct
Figure 2
io
n
7
TEST 1 - Check Voltage and Frequency Output output voltage that will remain at zero. This usually
1. Disconnect any electrical loads. occurs if the unit is out of use for a long period of time. If
2. Check all circuit breakers and verify they are residual magnetism is lost, it can usually be restored by
ON. “flashing the field” with a simple process involving a
3. Set meter to measure AC volts. (DC) battery.
4. Connect the meter test leads into a 120 VAC 1. Obtain a 12VDC battery and two jumper leads
generator receptacle. with alligator clip ends.
5. Connect a frequency meter into a generator 2. Remove the four screws and remove the rear
receptacle. bearing cover.
6. Start the generator engine, let it stabilize and 3. Gain access to the AVR and disconnect the
warm up. brush wires.
NOTICE: Isolate brush leads from each other and do
7. Read the “no-load” voltage and frequency, and
not allow them to touch grounded parts.
analyze the results as follows:
1 • If zero volts or less than 1VAC is indicated
4. Connect the battery positive (+), to the positive
brush, which will be the brush closest to the
proceed to Test 2 - Flash the Field.
rotor bearing.
• If low voltage is indicated, but readings is
5. Connect the battery negative (-), to the negative
above 1VAC and AC frequency is normal
brush, which is the brush farthest away from the
proceed to Test 3 - Isolate the Control Panel.
rotor bearing (Figure 3).
• If low voltage is indicated, but reading is
above 6VAC and AC frequency is low the
N pr
engine governor may need adjustment.
Refer to the appropriate engine manual for
ot o
further governor troubleshooting.
R
could be caught in the starter or other rotating parts. 8. Disconnect the battery wires from the
• Tie up long hair and remove jewelry. brushes.(Disconnect negative (-) battery wire
• DO NOT allow unqualified persons to service
n
last).
generator.
9. Restart the unit and check once again for
proper (AC) output voltage.
WARNING Generator voltage could cause • If output voltage is within specifications,
electrical shock or burn resulting in death or troubleshooting is complete.
serious injury. • If output voltage is not within specifications,
• DO NOT touch bare wires or receptacles. proceed to Test 3- Isolate Control Panel.
• DO NOT allow unqualified persons to service
generator. TEST 3 - Isolate Control Panel
A “No Output” condition may or may not be related to
the alternator windings. To help isolate where the issue
is, follow these steps:
In normal generator operation, upon startup there is
1. With the engine OFF, disconnect the power
some “residual” magnetism in the rotor to get the
lead harness from the back of the control panel.
generating process started. Residual magnetism is
what is left in the rotor after the unit has shut down. 2. Set meter to measure AC volts.
When residual magnetism is lost, the unit will have an
8
3. Connect the test leads to the stator wires #11
and #22 located in the control panel connector.
Polarity does not matter (Figure 4).
4. Start the engine and measure the voltage
output.
5. Shut off the engine.
• A voltage output of 120VAC indicates the
alternator is functioning, and the no output
condition is likely in the control panel.
Disassemble the control panel and inspect
for any indication of what may cause no
output. Refer to the unit wiring diagram to
verify connections.
• A low voltage output indicates the alternator
needs to be tested. Proceed to Check
1
Alternator.
Figure 4
Check Alternator
N pr
Alternator Disassembly
ot o
There are two methods of testing the alternator
The alternator can be diagnosed without complete
R
windings:
disassembly. To access the power winding, disconnect
1. Measuring the winding resistance and
the connector from the back of the control panel. The
fo du
comparing them to the specifications.
e
9
Measure Winding Resistance
Test Stator AC Power Winding Resistance
1. Set meter to measure Ohms.
2. Connect the test leads to stator wires #11 and
#22 located in the harness going to the control
panel connector (Figures 2 and 5).
1 N pr
ot o
Figure 6
R
manual.
• A reading within the specifications listed is
acceptable.
r ct
• A reading of infinity or high resistance
Figure 5
indicates an opening in the power winding.
3. Measure the resistance and compare it the Replace the stator.
nominal resistance from the specifications • A low reading indicates a shorted stator
listed in the back of this manual. winding. Replace the stator.
4. Connect the test leads to stator wires #33 and 6. Connect one meter test lead to a proper ground
#44 located in the control panel connector on alternator. Connect the other test lead to the
(Figures 2 and 6). stator power winding.
• A reading of infinity should be measured. If a
reading of infinity is measured and the stator
io
10
Test Stator Excitation Winding Resistance • A reading other than infinity indicates a
The excitation wires may be colored (red and blue) or power winding shorted to an excitation
numbered (#2 and #6). Colored excitation wires must winding. Replace the stator.
not be confused with the colored power wires. The 5. Connect one test lead to an excitation wire.
excitation wires were disconnect earlier from the Connect the other test lead to a proper metal
voltage regulator earlier in Measuring Winding ground.
Resistance.
• A reading of infinity should be measured.
1. Set meter to measure Ohms.
• A reading other than infinity indicates a
2. Connect the test lead to the stator excitation winding shorted to ground. Replace the
wires #2 and #6 (Figure 7). These wires were stator.
previously disconnected from the AVR.
fo du
e
r ct
Figure 8
• A reading within the specifications listed is replacing the rotor, proceed to Bypass the
acceptable. Automatic Voltage Regulator.
• A reading of infinity or high resistance • A very low resistance indicates a shorted
indicates an opening in the power winding. rotor. Replace the rotor.
Replace the stator. • If resistance is within specifications, proceed
• A low reading indicates a shorted winding. to Step 4.
Replace the stator. 4. Connect one test lead to a proper metal ground
4. Connect one test lead to a stator power wire. on the engine or alternator and the other test
Connect the other test lead to one of the stator lead to either slip ring.
excitation wires. • A reading of infinity should be measured. If a
• A reading of infinity should be measured. If a reading of infinity is measured and the rotor
reading of infinity is measured and the stator resistance is within specifications, the rotor
resistance is within specifications, the stator is functioning properly.
is functioning properly. • A reading other than infinity indicates a rotor
winding shorted to the rotor shaft. Replace
the rotor.
11
Bypass the Automatic Voltage
Regulator
Bypassing the Automatic Voltage Regulator (AVR) will
test all wiring and windings within the alternator without
disassembly of the generator. There are three AC
Voltage checks and one DC Amperage test to be
performed. The exact readings may very depending on
ambient temperature, battery voltage, meter
calibration, etc.
1. Disconnect Wires #1, #4, #11A, #22A, #2, and 4. Connect a jumper wire from battery positive (+)
#6 from the AVR. Set AVR aside. to the positive brush terminal. Then connect
another jumper wire from battery negative (-) to
negative brush terminal (Figure 10).
io
Figure 10
12
5. Manually start the unit. The AC voltage measured across Wire #2 and Wire #6
6. Measure AC voltage across Wire #2 and Wire should be higher that the AC Voltage measured across
#6. A minimum of 60VAC should be measured. Wire #11A and Wire #22A. Refer to Figure 13 when
7. Shut the unit OFF. performing the following test.
There is one DC Amperage test to perform. The exact
8. Connect one test lead to Wire #11 and the other
amperage readings may vary depending on ambient
lead to Wire #22. Wires #11 and #22 are
temperature, battery voltage, meter calibration, etc.
located in the control panel connector (Figure
11).
1. Set meter to read DC Amperage.
2. Connect the meter in series between battery
positive (+) and wire #4 (Figure 13). Refer to the
operation/instruction manual for the meter you
are using for correct test lead locations and
meter settings.
3. Connect the meter in series between the 12V
1
battery negative (-) and Wire #1.
4. Manually start the unit and measure DC
Amperage. Reading should be 1.0 - 1.5 Amps.
N pr
ot o
R
Figure 11
fo du
e
13
GENERATOR SPECIFICATIONS
1
RESISTANCE VALUES
Rotor (at the slip rings) 7.7 - 9.6 OHM 6.3 - 7.6 OHM 6.3 - 7.6 OHM
N pr
Power (wires 11-22 & 33-44) 0.16 - 0.19 / 0.16 - 0.19 0.26 - 0.31 / 0.26 - 0.31 0.26 - 0.31 / 0.26 - 0.31
OHM OHM OHM
ot o
R
Excitation (wires 2-6) 2.01 - 2.39 OHM 1.53 - 1.81 OHM 1.53 - 1.81 OHM
fo du
e
r ct
io
n
14