WACKER NEUSON Generator _ How to check voltage at plug – voltage at generator terminals strip
TROUBLESHOOTING If a generator problem is not an obvious engine or wire fault, the cause of the problem will be associated with one of two things:
A malfunctioning generator or faults in the circuit supplying voltage to the receptacles. By starting the troubleshooting procedures at the generator output terminal strip (z) you can determine whether the problem lies within the generator or the circuit supplying the receptacles. For troubleshooting a no-voltage condition, you’ll need to rule out problems with the stator windings (1) and the rotor windings (13). For a low-voltage condition (any voltage less than 120V), you’ll need to rule out problems with the stator and rotor windings, a malfunctioning voltage regulator (16), and problems with the brushes (13) and/or the excitation winding (15). For a high-voltage condition, you’ll need to rule out a malfunctioning voltage regulator and/or problems with the voltage regulator’s sensing wires (y).
For troubleshooting the receptacle circuits, you’ll need to rule out problems with the main circuit breaker (3), the individual circuit breakers (5, 6, and 7), and the wiring that connects all the components. For troubleshooting a malfunctioning auto idle circuit, you’ll need to rule out a blown fuse (9) and problems with the idle solenoid, the DC winding (15), the rectifier (12), the auto idle switch (8), the auto idle unit (2), and the wiring that connects all the components. For troubleshooting a malfunctioning anti-after fire circuit, you’ll need to rule out a faulty DC winding (15), a blown fuse (9), a faulty engine ON/OFF switch (11), or a faulty capacitor (10).
Checking Continuity
Conduct continuity tests when the engine is shut down. When checking continuity, use the Ohm setting on your multimeter. Place a lead of the multimeter on one end of the wiring or component and the other lead on the opposite end. If your meter reads “OL” or “OPEN”, there is no continuity and the wiring or component must be repaired or replaced.
Note: Some multimeters also have an audio signal setting for determining continuity. This setting may also be used.
If your meter reads less than 1.0 Ohm, or the audio signal sounds, the wiring or component has continuity and should be OK.
If your meter reads more than 1.0 Ohm, the wiring is faulty and must be repaired or replaced.
Checking Resistance
Conduct resistance checks when the engine is shut down. Use the Ohm setting on your multimeter. Conduct resistance checks when the machine is as close to 21°C (70°F) as possible. Higher temperatures can affect resistance values. Most digital multimeters have some internal resistance. To obtain your
multimeter’s internal resistance, simply cross the two leads of your multimeter and read the display. When conducting a resistance check, subtract your multimeter’s internal resistance from the value you measure to obtain the true resistance of the component you are checking
Checking Voltage
Conduct voltage checks when the engine is running. Use the Volt setting on your multimeter. To prevent damage to your instrument, start with the highest scale available on your multimeter. Adjust to a lower scale as readings dictate. Use extreme caution when checking voltage to reduce the risk of
electric shock.
Checking Voltage at Generator Terminal Strip
Remove the two screws (a) that secure the end cover to the generator and remove the end cover.
Start the engine.
Using the AC voltage setting on the multimeter, measure the voltage between the wire with the yellow marking (b) and the wire with the red marking (c). There should be 120V±10%. [If zero (0) volts is measured, it indicates a problem with main winding 2 or the rotor winding. If 120V±10% is measured, main winding 2 and the rotor are functioning; continue]
Using the AC voltage setting on the multimeter, measure the voltage between the wire with the green marking and the wire with the black marking. There should be 120V±10%. [If zero (0) volts is measured, it indicates a problem with main winding 1. If 120V±10% is measured, main winding 1 and the rotor are functioning; any problems with the receptacles receiving voltage are in the circuit to the receptacles.]
Checking Voltage at Plug - GP 2500A, GP 2600
By starting the troubleshooting procedures at the generator output plug (d), you can determine whether the problem lies within the generator or the circuit supplying the receptacles. To check the voltage at the output plug, carry out the following procedures:
Remove the two screws which secure the end cover to the generator and remove the end cover.
Start the engine.
Using the AC voltage setting on the multimeter, measure the voltage between the red wire and the white. There should be 120V±10%. [If zero (0) volts is measured, it indicates a problem with main winding 2 or the rotor winding. If 120V±10% is measured, main winding 2 and the rotor are functioning; continue.]
Using the AC voltage setting on the multimeter, measure the voltage between the brown wire and the blue wire. There should be 120V±10% [If zero (0) volts is measured, it indicates a problem with main winding 1. If 120V±10% is measured, main winding 1 and the rotor are functioning; any problems with the receptacles receiving voltage are in the circuit to the receptacles]
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