Page 22
PART 2
AC GENERATORS
SECTION 2.1
BRUSHLESS CAPACITOR TROUBLESHOOTING FLOWCHARTS
The GP series portable generators currently use
three different types of alternators. Two of the alterna-
tors are brushless capacitor type with different style of
capacitors (Configuration “A” and “B”). The third uti-
lizes a voltage regulator and a brushed excitation sys-
tem (Configuration “C”). To help with troubleshooting,
two sets of flow charts have been created for these
different styles of alternators.
Identify the configuration of the alternator being ser-
viced using Sections 1.3 and 1.4 of this manual and
proceed to the appropriate flowchart section.
Configuration “A” – Brushless Capacitor, use Section 2.1
Configuration “B” – Brushless Capacitor, use Section 2.1
Configuration “C” – Brushed Excitation, use Section 2.2
GO TO PROBLEM 2 GO TO PROBLEM 1GO TO PROBLEM 4 VERIFY ROTOR IS SPINNING,
GO TO PROBLEM 1
GO TO PROBLEM 3
VOLTAGE &
FREQUENCY BOTH
HIGH OR LOW
FREQUENCY GOOD
VOLTAGE HIGH
ZERO VOLTAGE
ZERO FREQUENCY
FREQUENCY GOOD,
LOW OR RESIDUAL
VOLTAGE
TEST 1 - CHECK
NO LOAD VOLTAGE
& FREQUENCY
NO LOAD VOLTAGE &
FREQUENCY GOOD -
VOLTAGE/FREQUENCY
FALLS OFF UNDER LOAD
If Problem Involves AC Output
REPLACE
ALTERNATOR
REPLACE
ROTOR
STOP TESTING
BAD
BAD
GOOD
GOOD
CONFIGURATION “B”
GOOD
CONFIGURATION “A”
BAD
CONFIGURATION “B”
BAD
CONFIGURATION “A”
Problem 1 – Generator Produces Zero Voltage or Residual Voltage
TEST 2 – CHECK
MAIN CIRCUIT
BREAKER
RESET TO “ON”
OR REPLACE IF BAD
REPLACE COMPONENT
AS NEEDED
STOP
TESTING
TEST 3 – CHECK
CONTINUITY OF
RECEPTACLE PANEL
RE-CHECK VOLTAGE
AT RECEPTACLE
PANEL
RE-CHECK VOLTAGE
AT RECEPTACLE
PANEL
TEST 4 – FIELD
FLASH
ALTERNATOR
REPLACE
BAD
BAD
BAD
REPLACE
S TATO R
BAD
REPLACE
ALTERNATOR
REPLACE
CAPACITOR
ON
GOOD
GOODGOODGOOD
TEST 6 –
CHECK
CAPACITOR
TEST 7 – TEST
BRUSHLESS
DPE WINDING
TEST 8 – TEST
BRUSHLESS
STATOR
WINDINGS
TEST STATOR
FOR SHORTS
TO GROUND
GOOD
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