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RV 45/55/65
Diagnostic
Diagnostic
RepR Manual
RepR Manual
RECREATIONAL VEHICLE GENERATOR
MoDsel 5410, 5411, 5412,
5413, 5414 & 5415
ai
ai
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SAFETY Throughout this publication, “DANGER!” and “CAUTION!” blocks are used to alert the mechanic to special instructions concerning a particular service or operation that might be hazardous if performed incorrectly or carelessly. PAY CLOSE ATTENTION TO THEM. D ANGER! UNDER THIS HEADING WILL BE FOUND SPECIAL INSTRUCTIONS WHICH, IF NOT COMPLIED WITH, COULD RESULT IN PERSONAL INJURY OR DEATH. * CAUTION! Under this heading will be found special instructions which, if not complied with, cou
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Table of Contents SAFETY ........................... INSIDE FRONT COvER SECTION 6: TROUBLESHOOTING FLOWCHARTS .................. 25-34 SECTION 1: IF PROBLEM INVOLVES AC OUTPUT ...................... 25 GENERATOR FUNDAMENTALS ....................... 3-7 PROBLEM 1 – MAGNETISM ................................................................ 3 VOLTAGE & FREq UENCY ARE BOTH HIGH OR LOW ........................................................... 25 ELECTROMAGNETIC FIELDS ..........
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Table of Contents TEST 10 – TEST 32 – Check Rotor Assembly ................................................ 42 Check Valve Adjustment ............................................. 57 TEST 11 – TEST 33 – Check Main Circuit Breaker ......................................... 43 Check Carburetion ...................................................... 58 TEST 12 – TEST 34 – Check Load Voltage & Frequency ................................ 43 Check Choke Solenoid .........................
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Section 1 GENERATOR FUNDAMENTALS NOTE: The “right hand rule” is based on the “cur- MAgNETISM rent flow” theory which assumes that current flows from positive to negative. This is opposite Magnetism can be used to produce electricity and the “electron” theory, which states that current electricity can be used to produce magnetism. flows from negative to positive. Much about magnetism cannot be explained by our present knowledge. However, there are certain pat- terns of behavior that are know
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Section 1 GENERATOR FUNDAMENTALS A SIMPLE AC gENERATOR Figure 1-4 shows a very simple AC Generator. The CURRENT VOLTAGE generator consists of a rotating magnetic field called a ROTOR and a stationary coil of wire called a STATOR. (+) The ROTOR is a permanent magnet which consists of a SOUTH magnetic pole and a NORTH magnetic 0 360 180 pole. As the ROTOR turns, its magnetic field cuts across the stationary STATOR. A voltage is induced Into the STATOR windings. When the magnet’s NORTH (-) p
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Section 1 GENERATOR FUNDAMENTALS Figure 1-7. – Generator Operating Diagram NOTE: AC output frequency at 3720 rpm will be b. An “Actual” (“sensing”) voltage is delivered to about 60 Hertz. The “No-Load” is set slightly high the Voltage Regulator via sensing leads from to prevent excessive rpm, frequency and voltage the Stator AC power windings. droop under heavy electrical loading. c. The Regulator “compares” the actual (sens- Generator operation may be described briefly as fol- ing) voltage t
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Section 1 GENERATOR FUNDAMENTALS You can use your generator set to supply electrical FIELd BOOST power for operating one of the following electrical When the engine is cranked during startup, the starter loads: contactor is energized closed. Battery voltage is then • R V 45G & LP: 120 and/or 240 v olts , single phase , delivered to the starter motor and the engine cranks. 60 Hz electrical loads. These loads can require up to 4500 watts (4.5 kW) of total power, but cannot During
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Section 1 GENERATOR FUNDAMENTALS T1 RED CB1 T2 WHITE CB2 T3 Figure 1-8. – Connection for 120 Volts Only BLACk STATOR WINDINGS GROUNDED NEUTRAL RECONNECTION FOR DUAL VOLTAGE OUTPUT: When connected for dual voltage output, Stator output leads 11 and 44 form two “hot” leads (T1 – Red, and Figure 1-9 - Connection for 120/240 Volts T3 – Black). The junction of leads 22 and 33 form the “Neutral” line (T2 – White). NOTE: If this generator has been reconnected for dual voltage AC output (120/240 vol
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Section 2 MAJOR GENERATOR COMPONENTS 8 1. BRUSH HOLDER 1 2. UPPER BEARING CARRIER 3. STATOR 4. ROTOR 2 5. LOWER BEARING CARRIER 6. ENGINE 7. PULLEYS AND BELT 3 8. FANS 6 4 5 8 7 Figure 2-1. Exploded View of Generator ROTOR ASSEMBLY STATOR ASSEMBLY The Rotor is sometimes called the “revolving field”, The Stator is “sandwiched” between the upper and since it provides the magnetic field that induces a lower bearing carriers and retained in that position by voltage into the stationary Stator wind
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Section 2 MAJOR GENERATOR COMPONENTS 11S 11S 11S 2 22S 22S 22S 4 4 6 + 0 0 0 - 6 6 11 2 2 22 VOLTAGE REGULATOR 33 6240 Stator 44 11S DPE WINDING FIELD BA 22S Figure 2-5. – Schematic: Excitation Circuit Leads 2 & 6 = Stator Excitation Winding Leads 11S & 22S = Voltage Sensing Leads VOLTAGE REGULATOR: Leads 11 & 22, 33 & 44 = AC Power Windings Six (6) leads are connected to the voltage regulator as follows: Figure 2-2. – Stator Output Leads • T w o (2) SENSING leads deliv er A CTU AL A C
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Section 2 MAJOR GENERATOR COMPONENTS NOTE: If, for any reason, sensing voltage to the DESCRIPTION: regulator is lost, the regulator will shut down and The crankcase breather is equipped with a reed valve excitation output to the Rotor will be lost. The to control and maintain a partial vacuum in the crank- AC output voltage will then drop to a value that case. The breather is vented to the airbox. The breath- is commensurate with Rotor residual magnetism er chamber contains a removable oil
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Section 2 MAJOR GENERATOR COMPONENTS CONTROL PANEL COMPONENT IdENTIFICATION STARTER CONTACTOR RELAY (SCR) TERMINAL BLOCK (TB) “4-TAB CONNECTOR” CONTROL BOARD (PCB) WITH J1 CONNECTOR GOVERNOR ACTUATOR J2 CONNECTOR VOLTAGE REGULATOR (VR) WITH RED LED START/STOP SWITCH (SW1) WITH RED LED CIRCUIT BREAKERS 7.5 AMP DC FUSE (F1) (CB1 & CB2) ENGINE CONNECTOR (C1) 6 WIRE GROUND TERMINAL REAR VIEW Figure 2-9. – Control Panel Components Page 11
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Section 3 INSULATION RESISTANCE TESTS MEGOHMMETERS ARE A SOURCE OF HIGH EFFECTS OF dIRT ANd MOISTURE AND DANGEROUS ELECTRICAL vOLTAGE. Moisture and dirt are detrimental to the continued FOLLOW THE TESTER MANUFACTURER’S good operation of any generator set. INSTRUCTIONS CAREFULLY. USE COMMON If moisture is allowed to remain in contact with the SENSE TO AvOID DANGEROUS ELECTRICAL Stator and Rotor windings, some of the moisture will SHOCK be retained in voids and cracks of the winding insula
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Section 3 INSULATION RESISTANCE TESTS vents that will not attack such materials. STATOR SHORT-TO-GROUND TESTS: See Figure 3-2. To test the Stator for a short-to-ground Use a soft brush or cloth to apply the solvent. Be condition, proceed as follows: careful to avoid damage to wire or winding insulation. 1. Disconnect and Isolate all Stator leads as follows: After cleaning, dry all components thoroughly using moisture-free, low-pressure compressed air. a. Disconnect sensing leads 11S and 22S
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Section 3 INSULATION RESISTANCE TESTS 3. Apply 1000 volts. DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. 2 If an insulation breakdown is indicated, clean and dry 6 the Rotor then repeat the test. Replace the Rotor if it fails the second test (after cleaning and drying). 11 22 THE MEgOHMMETER 33 Stator 44 GENERAL: 11S A megohmmeter, often called a “megger”, consists of a meter calibrated in megohms and a power sup- 22S ply. Use a power supply of 1500 volts when testing Stators; or 1000 volts wh
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Section 4 MEASURING ELECTRICITY METERS MEASURINg AC VOLTAgE Devices used to measure electrical properties are An accurate AC voltmeter or a VOM may be used to called meters. Meters are available that allow one read the generator’s AC output voltage. The following to measure (a) AC voltage, (b) DC voltage, (c) AC apply: frequency, and (d) resistance in ohms. The following 1. Always read the generator’s AC output voltage apply: only at the unit’s rated operating speed and AC ❏ To measure AC v
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Section 4 MEASURING ELECTRICITY Correct engine and Rotor speed is maintained by a stepper motor governor. For models rated 60 Hertz, the governor is generally set to maintain a no-load fre- quency of about 60 Hertz with a corresponding output voltage of about 124 volts AC line-to-neutral. MEASURINg CURRENT To read the current flow, in AMPERES, a clamp-on ammeter may be used. This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field aroun
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Section 4 MEASURING ELECTRICITY OHM: ELECTRICAL UNITS The OHM is the unit of RESISTANCE. In every circuit there is a natural resistance or opposition to the flow AMPERE: of electrons. When an EMF is applied to a complete The rate of electron flow in a circuit is represented circuit, the electrons are forced to flow in a single by the AMPERE. The ampere is the number of elec- direction rather than their free or orbiting pattern. The trons flowing past a given point at a given time. One res
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Section 5 ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION – REST: INTROdUCTION Battery voltage is available to the Printed Circuit Board (PCB) The engine DC control system includes all com- from the vehicle BATTERY via the positive (RED) battery cable ponents necessary for the operation of the engine. to the isolated positive (RED) terminal stud, located in the control Operation includes rest, priming, cranking, starting, panel. The power is supplied to Wire 13, a 7.5 amp FUSE (F1), running and
