Use and Care Manual

Tsurumi’s Operation, Service and Repair Manual
Troubleshooting
35
5-0 TROUBLESHOOTING
5-1 General
(1) The procedures that follow, together with the troubleshooting tables, can be used as a guide to
isolate generator faults. Refer to these procedures when the engine fails to start after several
attempts, or when electricity is not available at the receptacles.
(2) Before testing generator components, determine if the failure is located in the generator head or
in the control panel. If after following these procedures, your generator fails to start or generate
electricity, contact the nearest Tsurumi generator dealer.
5-2 Isolating Fault to the Generator or to the Control Panel
(1) This unit uses permanent magnets built into the rotor for initial excitation. Do not “flash the fields”
to try to re-excite the field.
(2) Isolate the defect by disconnecting the red, gray, orange and blue wires from the stator (do not
disconnect the two yellow wires). Then measure the AC voltage of each AC coil.
(3) Check for 120 vac (±5%) from the red-gray wires and then check for 120 vac (±5%) from the
orange-blue wires.
(4) If the voltage is correct, the failure is in the control panel. If the voltage is too low from either coil,
the defect lies in the rotor, stator, or condensers.
5-3 Measuring Insulation Resistance
(1) No AC output – Measuring Insulation Resistance
(2) Use a megger tester to test each component for proper insulation. An insulation resistance of 1
MΩ or greater is normal. The insulation resistance from the factory is at least 10 MΩ.
(3) Insulation Resistance - Stator
(a) Measure the insulation resistance between BLUE lead
and the core.(AC coil)
(b) Measure the insulation resistance between RED lead
and the core.(AC coil)
(c) Measure the insulation resistance between YELLOW
lead and the core.
(d) Measure the insulation resistance between BROWN
lead and the core.(DC coil)
(4) Insulation Resistance - Rotor
(a) Measure the insulation across one of the soldered
terminals of the rotor and the core.
(b) Parts with insulation resistance of less than 1MΩ have
faulty insulation, and may cause electric leakage and
electric shock. Replace the faulty part.
Figure 5-1: Measuring Resistance