iX Series Inverter - Jacks Small Engines
Contents
1. 9 Test 15 Test Ignition Goil 24 Measuring AC 9 Test 16 Test Fuel Shutoff Switch 24 Measuring 9 Test 17 Check Choke Assembly 25 Measuring Resistanc 10 Test 18 Test Stepper 25 Section Major 11 Test 19 Test Oil Level Switch 25 THICOGUCEOI a ite terrre etat 11 Test 20 Test Ignition Coil Winding 26 UNIT Identification iis 11 Test 21 Test FlexPower Switch 26 Internal Major Engine Components 12 Section 5 0 27 Internal Major Electrical Components 13 Disassembly sss 27 Operational Analysis 14 Section 6 Electrical Data 36 Electrical Formulas i si un tente 38 Page 1 Specifications iX800 Frequency 0 Rated 120 Amperage 66 Yes Fuel Tank Capacity Gal Run Time at 50 Hours Lang 02. f Du 121126 HIGH o di EEE 1 ORANGE 2 BROWN 3 EMPTY Figure 36 FlexPower Switch Test Points Test Points ECO HIGH Pin 1 to Pin 2 INFINITY CONTINUITY Results 1 If INFINITY was measured in Step 4 and CONTINUITY in Step 5 replace inverter module 2 If either CONTINUITY was measured in Step 4 or INFINITY in Step 5 replace FPS switch Section 5 Disassembly Discussion During the process of tearing the unit apart it is critical to make special notes as to the way the different parts are located inside There is no room for error when putting the unit back together When re assembling the unit it is good to be proactive and always thinking about the next step to eliminate back tracking It is also a good idea to continually re check what parts are left for reassembly to ensure that no parts are forgotten during the process DISASSEMBLY Muffler Removal 1 Drain all fuel and oil from unit 2 Remove four 4 Phillips screws located on the black exhaust cover 3 Remove the rubber muffler gasket and note orientation of 9 Remove the retaining clip underneath the fuel fill cap the seal before removing COVer Figure 38 Enclosure Removal 4 Remove one 1 flat head screw holding the service access panel Figure 39 6 Remove four 4 Phillips screws holding the control panel to the housing Figure 37 The following items are ab
3. FlexPower Switch This switch slows the engine speed when the load is reduced to save fuel and engine wear 12 VDC Circuit Breaker if equipped Overload protection for the 12 VDC charging system 20 21 Section 3 Major Components Ground Earth Connection Lug Grounding point for the generator consult state and local electrical codes before use floating ground 120 VAC Receptacles Two 2 receptacles for connecting accessories Figure 13 Unit Identification iX1600 iX2000 SN MEC sa u 16 15 15 163 14 19 20 21 Figure 14 Control Panel Identification Page 11 Section 3 Major Components INTERNAL MAJOR ENGINE COMPONENTS Engine A 4 stroke engine attached to the rotor creates the mechanical energy necessary to maintain current flow at the receptacles Ignition Coil The ignition coil provides spark for the engine Spark timing is determined by LED module and the Trigger Assembly Hall Effect Sensor IGNITION COIL Figure 15 Ignition Coil Trigger Assembly Hall Effect Sensor The trigger assembly is located directly underneath the stator The stator sends timing pulses to the trigger assembly depending on the position of the engine to determine the correct timing for spark This voltage is delivered to the LED module Figure 16
4. burned or seriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately Be careful not to touch the muffler while itis HOT 3 Remove the electrical box assembly and back window and upper enclosure half 4 out the C4 connector Note Do not remove the harness of the control panel C4 CONNECTOR Figure 23 C4 Connector Pin Locations Male Side Section 4 Troubleshooting and Diagnostic Tests uy 4125 38 3 ORANGE 4 GRAY 4 9 Figure 24 C4 Connector Pin Locations Male Side Set VOM to measure resistance 6 Disconnect the C4 connector On the female side of the connector connect one meter test lead to Pin 1 and connect the other meter test lead to Pin 4 Measure and record the resistance Results 1 The resistance measured between Pin 1 and Pin 4 should be as follows iX 800 0 5 Ohms iX 1600 0 7 Ohms iX 2000 0 3 Ohms 2 f the resistance measured is between the specified values refer back to flow chart 3 If the resistance reading is outside the tolerance replace stator TEST 3 TEST MAIN COIL OF STATOR Procedure 1 Stop the engine 2 Drain the fuel from the tank WARNING A Gasoline is highly flammable and explosive You can ZA be burned or seriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately Be careful not to to
5. The iX inverter units are computer controlled generators that use an inverter to create a superior sine wave and maintain a steady frequency of 60 Hz The PERMANENT MAGNET ROTOR is directly coupled to the ENGINE and rotates at the same speed as the engine 2 Asthe ROTOR turns its magnetic field cuts across a number of STATOR windings to induce a voltage into those windings as follows a The MAIN COIL WINDING provides the AC voltage necessary for the inverter to supply rated output voltage to the receptacles b The SUB COIL WINDING provides the AC voltage needed to operate the Inverter c The DC COIL WINDING provides the AC voltage necessary to provide the DC Charging outlet with 12 VDC d The IGNITION WINDING provides the voltage needed for the LED module to fire the ignition coil 3 While the unit is running it continues to monitor the current on the receptacles and make the needed adjustments to the engine speed by changing the output signals to the STEPPER MOTOR to either increase or decrease engine speed based on load demand LED OUTLET MODULE BRIDGE RECTIFIER INVERTOR MODULE OUTLETS Figure 22 iX Inverter Operating Diagram Page 14 Section 4 Troubleshooting and Diagnostic Tests IS THE OVERLOAD LIGHT ON WHILE ENGINE IS RUNNING IS THE LOAD CONNECTED YES Y DISCONNECT THE LOAD THEN RESTART THE ENGINE AND CHECK THE AC OUTPUT AGAIN TEST 1 CHECK E
6. VOMs Figure 9 are also available and are generally very accurate Digital meters display the measured values directly by converting the values to numbers NOTE Standard AC voltmeters react to the AVERAGE value of alternating current When working with AC the effective value is used For that reason a different scale is used on an AC voltmeter The scale is marked with the effective or rms value even though the meter actually reacts to the average value That is why the AC voltmeter will give an incorrect reading if used to measure direct current DC Figure 9 Digital VOM MEASURING AC VOLTAGE An accurate AC voltmeter or a VOM may be used to read the generator s AC output voltage The following apply Section 2 Measuring Electricity 1 Always read the generator s AC output voltage only at the unit s rated operating speed and AC frequency 2 The generator s Voltage Regulator can be adjusted for correct output voltage only while the unit is operating at its correct rated speed and frequency 3 Only an AC voltmeter may be used to measure AC voltage DO NOT USE A DC VOLTMETER FOR THIS PURPOSE DANGER GENERATORS PRODUCE HIGH AND DANGEROUS VOLTAGES CONTACT WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MEASURING DC VOLTAGE A DC voltmeter or a VOM may be used to measure DC voltages Always observe the following rules 1 Always observe correct DC polarity a Some VOMs m
7. 60 psi Section 4 Troubleshooting and Diagnostic Tests TEST 14 TEST IGNITION TRIGGER ASSEMBLY Procedure 1 Remove the electrical panel so that the LED module is exposed and disconnect the J1 connector Set VOM to measure resistance 3 Locate Pin 3 on the J1 connector Connect one meter test lead to Pin 3 and the other meter test lead to engine ground Measure and record the resistance Table 1 J1 Connector Pin Chart Ignition Coil Low Oil Switch Trigger Assembly Ground Ignition Winding Fuel Shutoff Switch Inverter Inverter Inverter Inverter Results 1 If the meter reading is within 5 ohms of the correct resistance refer back to flow chart iX 800 30 Ohms iX 1600 30 Ohms iX 2000 129 Ohms 2 Ifthe meter did not indicate the correct resistance replace trigger assembly Page 23 Section 4 Troubleshooting and Diagnostic Tests TEST 15 TEST IGNITION COIL Procedure 1 Open up the electrical panel so that the control panel wiring is exposed 2 Disconnect the J1 connector and disconnect the ignition coil boot from the spark plug 3 Set VOM to measure resistance 4 Connect one meter test lead to ground and connect the other meter test lead to Pin 1 on the J1 connector Measure and record the resistance Figure 31 5 Connect one meter test lead to the spark plug wire and connect the other meter test lead to engine ground Measure and record
8. The Trigger Assembly Page 12 Ignition Shutoff Switch The ignition shutoff switch is mechanically connected to the fuel shutoff valve The internal contacts of the ignition shutoff switch are open when the fuel shutoff valve is in its ON position The contacts are closed when the fuel shutoff valve is in its OFF position When the contacts are closed it completes a path to ground to the LED module that will inhibit spark and shutdown the engine Figure 17 Low Oil Level Switch The low oil level switch is a float type switch located inside the engine on the bottom of the crank case casting When the internal contact is closed it completes a path to ground to the LED module that will inhibit spark and shutdown the engine SWITCH OPEN 4 dub cto r SWITCH CLOSED Figure 18 Carburetor The carburetor provides a sufficient air fuel mixture to the engine to maintain the required speed A stepper motor incorporated in the carburetor allows the engine to run at variable speeds The speed of the engine is maintained by the inverter which will increase or decrease speed to maintain the output current necessary for loads Fuel Pum The mechanical fuel pump is located on the exterior of the plastic housing around the engine and is accessible by removing the side panels Changes in pressure from the crankcase actuates a diaphragm inside the pump which then supplies fuel to the carburetor Figure 19
9. and Diagnostic Tests d Pin 2 and Pin 3 approximately 50 ohms should be measured e Pin 2 and Pin 4 INFINITY should be measured f Pin 3 and Pin 4 INFINITY should be measured Results 1 If the values in steps through 3f are good refer back to flow chart 2 If any one of the values in steps through 3f tested bad replace stepper motor iX1600 iX2000 Procedure 1 Disconnect the C3 connector Stepper motor from the Inverter module 2 SetVOM to measure resistance 3 Connect a VOM test leads across the following test points a Pin 1 to Pin 5 approximately 195 ohms should be measured b Pin 2 to Pin 5 approximately 195 ohms should be measured c Pin 3 to Pin 5 approximately 195 ohms should be measured d Pin 4 to Pin 5 approximately 195 ohms should be measured 112 31415 1 RED 4 YELLOW 2 ORANGE 5 BLUE 3 WHITE Figure 34 C3 Connector Female Side iX1600 iX2000 Results 1 If the values in steps through 3d are good refer back to flow chart 2 If any one of the values in steps through tested bad replace stepper motor TEST 19 TEST OIL LEVEL SWITCH Procedure 1 Verify that the engine is filled with the appropriate amount of oil 2 Locate the low oil shutdown wire on the engine and isolate it from the rest of the harness 3 SetVOM to measure resistance Page 25 Section 4 Tr
10. catch fuel slowly pull on the recoil cord and turn the engine over Fuel should flow from the fuel line If fuel does not flow verify that fuel is available to the pump If fuel is available to the pump inspect the fuel filter and pulse line RESULTS 1 If fuel does not flow replace the fuel pump 2 If fuel flow has been verified proceed to Test 12 Page 22 Figure 29 TEST 12 CHECK CARBURETION Before checking the carburetor be sure the fuel tank has an ample supply of fresh clean gasoline Check that all shutoff valves are open and fuel flows freely through the fuel line Make sure the choke operates properly If the engine will not start remove and inspect the spark plug If the spark plug is wet look for the following Over choking Excessively rich fuel mixture Water in fuel Intake valve stuck open Needle float stuck open If the spark plug is dry look for the following Leaking carburetor mounting gaskets Intake valve stuck closed noperative fuel pump Plugged fuel filter s Varnished carburetor Check that the choke is working properly 1 Remove the fuel line at the carburetor and ensure that there is an adequate amount of fuel entering the carburetor 2 Remove the float bowl and check to see if there is any foreign matter in the bottom of the bowl Remove the plastic float to gain access to the needle Remove the needle so it can be cleaned 5 Use a suitabl
11. iX 2000 0 3 Ohms 2 If the resistance measured is within the specified values refer back to flow chart 3 If the resistance reading is outside the tolerance replace the stator TEST 7 TEST RECOIL FUNCTION Procedure 1 Attempt to pull start the engine and make the following observations while doing 50 Does the cord pull easily and smoothly Does the cord return with no assistance Does the engine turn over as the cord is pulled Results If the recoil did not perform as the observations are stated above possible problems that could be present are The engine could be seized The recoil could have become detached from the flywheel The recoil mechanism could be broken and not retracting properly TEST 8 TEST ENGINE FUNCTION Procedure 1 Remove the recoil and front cover assembly 2 Remove the spark plug from the unit 3 Attempt to turn the engine over by hand Results 1 If the engine can not turn over freely with the spark plug removed the engine has suffered some type of internal failure that has seized it and is inhibiting it from running 2 Refer back to flow chart TEST 9 CHECK SPARK PROCEDURE A commercially available spark tester may be used to test the engine ignition system 1 Disconnect the spark plug lead from the spark plug Section 4 Troubleshooting and Diagnostic Tests 2 Attach high tension lead to the spark tester terminal 3 Groun
12. load An AC voltage is delivered to the module from the stator for firing of the ignition coil The module determines when to deliver spark to the ignition coil by receiving timing pulses from the trigger assembly and fires the coil using the voltage from the stator winding Figure 21 Page 13 Section 3 Major Components Permanent Magnet Rotor Sixteen permanent magnets have been affixed to the Rotor The Rotor and Hub are balanced at the factory as an assembly and must be replaced as an assembly Stator The stator has 4 separate windings that provide AC voltage to several different components The DC Coil provides AC voltage to the bridge rectifier where 12 VDC is provided for charging The Main Coil provides voltage to the inverter which provides the 120 VAC to the receptacles The Sub Coil provides operating voltage to the Inverter for operation Finally the Ignition winding provides AC voltage to the LED module which triggers the ignition coil to fire at the correct position OPERATIONAL ANALYSIS General Figure 22 below is a block diagram of the iX inverter generator The diagram is intended only for the purpose of illustrating generator operation Refer to the actual wiring diagram for wiring interconnections TRIGGER ASSEMBLY IGNITION COIL ENGINE STATOR mes SUB COIL WINDING STEPPER MOTOR MAGNETIC j IGNITION WINDING DC CHARGE WINDING MAIN WINDING Operational Description 1
13. the resistance Results 1 Refer to the following chart If the correct values were measured in Steps 4 and 5 refer back to flow chart 1 7 Ohms 0 5 Ohms 12 5K Ohms 2K Ohms Pin 1 to Ground Spark Plug to Ground 2 If the incorrect values were measured in Steps 4 and 5 inspect ignition coil connector for bad connection If the connection is verified good replace ignition coil 3 If the incorrect value was measured in Step 5 then inspect the ground connection on Pin 2 of the C2 connector going to the ignition coil Page 24 Figure 32 TEST 16 TEST FUEL SHUTOFF SWITCH Procedure 1 Open up the electrical panel so that the control panel wiring is exposed Set fuel shutoff valve to the CLOSED position Disconnect the J1 connector from the LED module Set VOM to measure resistance Connect one meter test lead to J1 Pin 6 and the other test lead to ground Measure and record the resistance Set fuel shutoff valve to the OPEN position Repeat Step 5 Fuel Shutoff Valve Position Fuel Shutoff Switch Reading CLOSED OPEN INFINITY CLOSED CONTINUITY aor wo D Results 1 If INFINITY was measured when the shutoff valve was CLOSED and CONTINUITY was indicated when the valve was OPEN refer back to flow chart 2 f CONTINUITY to ground was not measured when the valve was in the OPEN position verify the mechanical connection between the valve and the switc
14. the strength of the Rotor s magnetic field The iX inverter generators use a Rotor having a fixed permanent magnetic field The strength of this magnetic field is fixed and cannot be regulated The output voltage of an iX inverter will tend to droop with increasing electrical loads The inverter maintains a constant AC output voltage by increasing engine and Rotor speed as the load current increases to offset this inherent voltage droop LED MODULE IGNITION WINDING DC CHARGE WINDING BRIDGE RECTIFIER ENGINE ROTOR MAIN WINDING INVERTOR MODULE SUB COIL WINDING p STEPPER MOTOR Figure 8 Inverter Block Diagram METERS Devices used to measure electrical properties are called meters Meters are available that allow one to measure a AC voltage b DC voltage c AC frequency and d resistance in ohms The following apply To measure AC voltage use an AC voltmeter To measure DC voltage use a DC voltmeter Use a frequency meter to measure AC frequency in Hertz or cycles per second Use an ohmmeter to read circuit resistance in Ohms THE VOM A meter that will permit both voltage and resistance to be read is the volt ohm milliammeter or Some VOMs are of the analog type not shown These meters display the value being measured by physically deflecting a needle across a graduated scale The scale used must be interpreted by the user Digital
15. 6 WASHER FLAT M4 WASHER LOCK m4 78 SCREW CROSSED RECESSED PAN HEAD Section 5 Disassembly 1 81 82 SCREW TAPPING CROSS RECSD P HEAD ST4 2X13 8 o messa ______ GASPIPE FUEL PUMP 85 OUTLET PIPE FUEL PUMP SCREW PHILIPS ST4 8X19 87 SHELL LOW 88 SWITCH IGNITION ON OFF COVER SWITC 2 SCREW TAP CRS RECSD STA 8X19 m c 1 2 CONNECTION PEG GROUNDED 3 4 5 7 KNOB ON OFF FUEL SWITCH COVER LOWER SHELL SEAL LOWER SHELL COVER SCREW M6X14 SCREW TAP CRS REC ST4 2X16 0 10 1 SHIM MUFFLER 0 10 10 10 0 0 0 MUFFLER ASSY SPRING WASHER STANDARD TYPE PANEL ASSY CONTROL 1 10 11 1 1 11 114 115 0 1 2 3 4 5 6 7 8 9 0 1 3 2 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 am ES EH m am EN Em s EY am Em w por En EN EN ed Ea EN Em Em 116 1 Page 31 Section 5 Disassembly Exploded View iX1600 gt SLIT EG 2247 Wy 727 Page 32 2 cover rue rua ron lt s emsa T 5 RECESSED PAN HEAD SCREW ST6 3X19 ALIGNMENT PIN BOLT HEX W FLANGE M6X12 CASING LOWER ENGINE SLEEVE DAMPING SEAL COVER OIL SENSOR KEY WOODRUFF 3X5X13 BOLT HEX W FLANGE M5X30 FLYWHEEL ROTOR ASSY NUT HEX FLANGED M10X1 25 8 JAW SEA
16. AD M6X120 1 COVER UPPER SHELL T 2 SCREW CROSS RECESSED PAN HEAD M6X14 2 LOCKSLICE SCREW CLIP ALIGNMENT PIN FEET VIBRATION MOUNTS BOLT HEX FLANGE FACE M6X12 LOWER CASING ENGINE BOLT HEX FLANGE FACE M5X16 19 4 SLEEVE DAMPING VIBRATION MOUNTS KEY WOODRUFF 3X5X13 BOLT HEX FLANGE FACE 5 25 FLYWHEEL ROTOR ASSY 24 1 NUT HEX FLANGE 10 1 25 8 SEAT STARTING JAW BOLT HEX FLANGE FACE M6X14 TET BOLT HEX FLANGE FACE M6X18 COWLING amp INLET COVER ASSY 32 2 SCREW CROSS RECESSED PAN HEAD TAPPING COIL IGNITION SLEEVE RUBBER HIGH VOLTAGE SPONGE AIR FILTER COVER AIR FILTER ALIGNMENT PIN ITEM DESCRIPTION DAMPING RING POTHOOK GASKET POTHOOK PIN HOLLOW FIXED POSITION BLOCK CARBURETOR CUSHION SEAL GASKET CARBURETOR IN 46 1 CARBURETOR REGULATING ASSY SEAL GASKET CARBURETOR IN 48 1 FILTER ADAPTER BOX BREATHER TUBE BREATHER CIRCLIP ADAPTER SLEEVE FILTER ADAPTER ALIGNMENT PIN ADAPTER BOX NUT HEX FLANGE FACE STARTER ASSY SAFEGUARD TUBE 56 3 REC PAN HEAD SCREWWASHER ASSY M5X12 HANDLE PANEL 58 RECESSED HEAD BOLT amp WASHER ASSY HANDLE RECOIL ASSY STARTER HANDLE HOOD jeo 1 RECOLL assy 6 FRAME FRONT PANEL 8 ADAPTER SLEEVE RESPIRATOR jeo 1 IeNrTER WITH INDICATOR BACKOIL ASSY RESPIRATOR n 4 SCREW CROSS RECESSED PAN HEAD M5X12 WASHER FLAT 5 SWITCH FLEXPOWER NUT I TYPE HEX M4 7
17. ATTERY Figure 12 A VOM as In line meter MEASURING RESISTANCE The volt ohm milliammeter may be used to measure the resistance in a circuit Resistance values can be very valuable when testing coils or windings such as the Stator and Rotor windings When testing Stator windings keep in mind that the resistance of these windings is very low Some meters are not capable of reading such a low resistance and will simply read CONTINUITY If proper procedures are used the following conditions can be detected using a VOM short to ground condition in any Stator or Rotor winding Shorting together of any two parallel Stator windings Shorting together of any two isolated Stator windings An open condition in any Stator or Rotor winding Component testing may require a specific resistance value or a test for INFINITY or CONTINUITY Infinity is OPEN condition between two electrical points which would read as no resistance on a VOM Continuity is a CLOSED condition between two electrical points which would be indicated as very low resistance or ZERO on a VOM INTRODUCTION The unit components and the major internal components of the generator are discussed in this section Unit identification is broken down into two basic categories items located that are visual from the outside and items located on the electrical control panel The internal major components are grouped into two separate cate
18. AX12 50 SWITCH FUEL 60 SCREW CROSS PAN HEAD M6X14 e r 1 HOSE FUEL PUMP OIL INJEC TIONA alr ome Section 5 Disassembly HOSE FUEL PUMP OIL INJEC TION B BOLT HEX HEAD W FLANGE M6X60 BOLT HEX HEAD W FLANGE M6X80 SCREW PHILIPS W WASHER 5 12 wee sme semere ITEM N N 103 104 105 106 107 108 o zi 35 Section 6 Electrical Data iX800 NOILINSI XIGWASSV 8299141 GQVOTd3AO SNLWLS HOLIMS ASOLNHS Tana T3 31 MOTI3A YOLOW udddals ONIGNIM NOI LINDI E 31IHM MOTI3A qaq AVHO MOTISA 22 ol LED MODULE HOLIMS H 3MOd 3SNVHO Al8Na3SSv Sd oVLdO3u OV AVHO 3 AVHO AVHO SNIGNIM 7109 915 35NVHO 3oNvuo Y Y 3SNVHO SNIGNIM 1109 N
19. Breaker Other Features u perar Recommended 0il nthetic 5W 30 40 60 80 100 10 0 10 20 30 40 Temperature Range of Expected Use Page 4 NOTES Page 5 Section 1 Generator Fundamentals MAGNETISM Magnetism can be used to produce electricity and electricity can be used to produce magnetism Much about magnetism cannot be explained by our present knowledge However there are certain patterns of behavior that are known Application of these behavior patterns has led to the development of generators motors and numerous other devices that utilize magnetism to produce and use electrical energy See Figure 1 The space surrounding a magnet is permeated by magnetic lines of force called flux These lines of force are concentrated at the magnets north and south poles They are directed away from the magnet at its north pole travel in a loop and re enter the magnet at its south pole The lines of force form definite patterns which vary in intensity depending on the strength of the magnet The lines of force never cross one another The area surrounding a magnet in which its lines of force are effective is called a magnetic field Like poles of a magnet repel each other while unlike poles attract each other pel MAGNETIC K LINES OF E FORCE gt Sl aree ce N 6 lt 7 Figure 1 Magnetic Lines of Force ELECTROMAGNETIC FIELDS All conductors through which an electric c
20. ECESSED PAN HEAD 5 20 RETAINING CLIP SHELL BAFFLE THERMAL 3 4 5 gt o 7 1 CONTROL PLATE ASSEMBLY NUT HEX FLANGED M5 3 IGNITION LED INDICATOR RECTIFIER 1010A BOLT IGNITION APPARATUS BOLT HEX WITH FLANGE 1 BOLT HEX WITH FLANGE 7 1 CONTROL PLATE ASSEMBLY 1 SCREW RECESSED PAN HEAD 12VDC PLUG ASSY SWITCH FLEXPOWER 120V OUTLET ASSY WASHER SPRING STANDARD 15 WASHER FLAT 15 16 PEG GROUND CONNECTION 17 DECAL CONTROL PLATE 1 1 1 1 1 1 Page 33 Section 5 Disassembly Exploded View iX2000 2 Y gt gt VE SJ N Se n Q yp WL 4 Mi 29 WEN N Page 34 5 1 Pe Ls eoe _ 5 s o 10 4 SHOCK ABSORBER FOOT OF CHASSIS SCREW PHILIPS ST6 3X19 MOUNTING PIN BOTTOM 13 5 BOLT HEX HEAD W FLANGE M6X12 19 4 BOLT HEX HEAD W FLANGE 5 30 FLYWHEEL ROTOR ASSY NUT HEX SCREW W FLANGE SEAT STARTING JAW 24 3 BOLT HEX HEAD W FLANGE M6X16 34 BOLT HEX HEAD W FLANGE 5 16 GASKET CARBURETOR OUT B GASKET CARBURETOR OUT A urnur 52 4 SCREW CROSSED PAN HEAD 5 25 4 WASHER 54 2 REW CROSSED PAN HEAD M6X130 55 SCREW CROSS PAN HEAD M
21. GENERAC sss sama IX Series Inverter models iX800 iX1600 iX2000 PORTABLE GENERATORS Foreword SAFETY Throughout this publication DANGER WARNING 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 Observe them carefully Their definitions are as follows A DANGER After this heading read instructions that if not strictly complied with will result in serious personal injury including death WARNING After this heading read instructions that if not strictly complied with could result in serious personal injury including death A CAUTION After this heading read instructions that if not strictly complied with might result in minor or moderate injury Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows This symbol points out important safety information that if not followed could endanger personal safety and or property of others 2 This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special instructions plus common sense are major accid
22. IVIN Page 36 Section 6 Electrical Data iX1600 and iX2000 Sd ovLdO3u OV XIGWASSV H399lu L NOILINSI SNLWLS LED MODULE Tana HOLIMS O HOLIMS O J4O1nHS 21 13 31 MOT MOTI3A HOLON d3dd31S ONIGNIM NOI LINDI 31IHM qaq AVHO MOTISA 62 ol HOLIMS 3MOd 3ONVHO 9934933 od Al8INN3SSV d3lgd3ANI 3 AVHO AVHO SNIGNIM 7109 8ns 39NVHO Y N 3SNVHO SNIGNIM 1109 NIVIN C c LATLNO H33V3Hu8 LINDY 9 O m NA 1109 37 Electrical Formulas TO FIND KNOWN VALUES 1 PHASE ExI KILOWATTS kW Volts Current Power Factor 1000 ExI 1000 kW x 1000 kW Volts Power Factor Vol
23. N FUNCTION RECOIL ONCE INSTALLED BAD v REPLACE VISUALLY INSPECT EXTERNAL COMPONENTS FOR A FAILURE NOTHING AN INTERNAL ENGINE FAILURE THAT WOULD CAUSE THE FOUND HAS POSSIBLY OCCURRED ENGINE TO BE SIEZED BAD REPLACE COMPONENT Problem 5 Flex Power Feature is Not Responding TEST 21 TEST REPLACE FLEX POWER GOOD gt INVERTER SWITCH MODULE BAD REPLACE SWITCH Page 16 Section 4 Troubleshooting and Diagnostic Tests Problem 6 Engine Will Not Start CHECK FUEL CHECK FUEL TEST 17 QUALITY AND GOOD sHurorr GOOD CHECK CHOKE GOOD SUPPLY VALVE ASSEMBLY BAD OFF BAD BAD REPLENISH FUEL TURN ON REPLACE CHOKE SUPPLY HANG TEST 15 TEST IGNITION TEST 14 TEST TRIGGER lt GOOD TEST 16 TEST 4 IS LOW OIL SWITCH LIGHT ON COIL ASSEMBLY BAD BAD BAD LI REPLACE 5 gt REPLACE IGNITION COIL CHECK OIL GO TO PROBLEM 8 lt GOOD BAD TEST 20 GOOD gt REPLACE LED MODULE REPLENISH OIL TEST 10 TEST CHECK IGNITION WINDING BAD gt REPLACE STATOR SPARK PLUG REPAIR OR REPLACE lt BAD GOOD TEST 13 CHECK TEST 12 TEST 11 ENGINE GOOD CHECK 6 GOOD CHECK FUEL COMPRESSION CARBURETOR PUMP BAD REPLACE BAD BAD L j ENGINE GOOD REPLACE REPLACE FUEL CARBURETOR PUMP CONTACT TECHNICAL SERVICE Page 17 Section 4 Troubleshooting and Diagnostic Test
24. NGINE RPM BAD Y GO TO PROBLEM 6 GOOD THE DC CIRCUIT Problem 1 No AC Output IS THE GREEN STATUS LIGHT ON WHILE OFF gt ENGINE IS RUNNING OFF TEST 1 BAD CHECK i ENGINE RPM GO TO GOOD PROBLEM 6 TEST 2 TEST SUBCOIL OF STATOR GOOD BAD REPLACE INVERTER MODULE GOOD REPLACE 4 STATOR REMOVE RECEPTACLE PANEL AND VERIFY CONNECTIONS OF RECEPTACLES AND WIRING BAD GOOD REPAIR OR REPLACE COMPONENT TEST 3 TEST MAIN COIL OF GOOD STATOR REPLACE INVERTER BAD MODULE CHECK HARNESS FOR GOOD CONNECTIONS BAD REPAIR OR REPLACE WIRE Problem 2 No DC Output TEST 4 CHECK BREAKER BAD Y REPLACE DC CIRCUIT BREAKER CHECK HARNESS FOR 4 GOOD GOOD CONNECTIONS GOOD REPLACE 4 STATOR BAD REPAIR OR gt REPLACE WIRE TEST 5 5 GOOD DC RECTIFIER BAD Y REPLACE DC RECTIFIER TEST 6 TEST DC COIL ON STATOR BAD REPLACE L gt INVERTER MODULE Page 15 Section 4 Troubleshooting and Diagnostic Tests Problem 3 Overload Light is On IS THE LOAD CONNECTED YES 2 DISCONNECT THE LOAD THEN RESTART THE ENGINE AND CHECK THE AC OUTPUT AGAIN NO M GO TO PROBLEM 1 TEST 2 Problem 4 Engine Will Not Pull Start TEST 7 TEST 8 5 VISUALLY INSPECT FOR OBSTRUCTIONS TEST RECOIL ENGINE GOOD gt THAT WOULD CAUSE BINDING OF THE FUNCTIO
25. Stepper Motor The Stepper Motor consists of a motor along with a gear and cam arrangement which allows motor movement to change the engine carburetor throttle setting The Motor is controlled by output signals from the inverter assembly which calculates the number of steps the stepper needs to take and generates the required signals to the Motor The inverter signals the Motor to actuate in response to changes in AC output voltage Thus in response to decreasing AC output voltages the Motor will increase the throttle setting and engine speed will increase Conversely increasing AC output voltages will cause the Motor to decrease throttle setting and engine speed will decrease Recoil Assembl The recoil assembly connected directly to the crank shaft of the engine and allows the engine to spin over when pulled and reach a speed that allows the engine to maintain that speed INTERNAL MAJOR ELECTRICAL COMPONENTS Inverter Module The inverter module receives voltage from two windings in the stator and produces a sine wave where the voltage is 120 VAC and the frequency is 60 Hz It is also responsible for maintaining the correct engine speed needed to maintain current flow to the connected loads Section 3 Major Components Figure 20 LED Module The LED module receives inputs from the inverter assembly to monitor an Overload condition It also illuminates the Green Ready light when unit is producing voltage and ready to accept
26. T STARTING BOLT HEX FLANGED 16 COUPLER STARTING JAW BOLT HEX FLANGED 14 28 1 COVER ASSY COWLING AND INLET 32 2 TAPPING SCREW RECESSED PAN HD STR 8X14 33 1 PIN MOUNTING POTHOOK PILLAR 37 SCREW PAN HEAD TAPPING STR 8X32 ITEM DESCRIPTION GASKET CARBURETOR B OUT 39 1 BLOCK CARBURETOR SPACER CUSHION 40 1 CARBURETOR SEAL GASKET OUT REGULATING ASSY CARBURETOR GASKET CARBURETOR IN NUT HEX FLANGED M5 SPACER FILTER CASE LINER CASE FILTER FILTER ADAPTER SLEEVE l4 STARTER RECOIL ASSY 50 1 BOLT HEX HEAD W WASHER 5 12 54 4 SCREW PAN HEAD RECESSED 5 25 56 2 SCREW PAN HEAD RECESSED M6X120 SEAL COVER LOWER SHELL 58 SCREW M6X14 59 COVER UPPER SHELL SCREW PAN HEAD M4X12 SWITCH FUEL ON OFF 62 3 SCREW PAN HEAD RECESSED M6x14 SWITCH IGNITION ON OFF COVER SWITCH 2 SCREW RECESSED PAN HEAD ST4 2X9 5 TAPPING 1 HOSE OIL DISCHARGE 9 1 SHIELD PIPE SPRING HOSE FUEL PUMPI OIL INJ COVER OIL WIDIPSTICK Section 5 Disassembly EB 6 7 8 9 SCREW PAN HEAD RECESSED CLAMP FUEL HOSE CASING UPPER ENGINE SCREW TAPPING PAN HEAD RECESSEDSTA 2X16 1 1 1 1 1 1 10 1 1 4 1 1 1 3 1 2 SLEEVE RESPERATOR ADAPTOR SHIM MUFFLER MUFFLER ASSY BOLT HEX HEAD FLANGED M6X55 RUBBER SEAL BACK WINDOW 1 WINDOW BACK EXHAUST COVER 4 SCREW R
27. Width W Height H Unit Weight Dry Ibs M Internal Not Shown Receptacles A 2x5 15R Circuit Breakers M Internal Overload Protection Other Features H FlePower O Recommended Oil SAE 30 nthetic 5W 30 60 80 100 32 40 0 10 20 Temperature Range of Expected Use Page 2 11127777 Low Oil Shutdown Method ot Unit Weight Dry Ibs Fuel Tank Capacity Gal Run Time at 50 Hours Length L Width W Specifications iX1600 GENERAC 1600 M Internal Not Shown e v Go gt Receptacles A 2x5 15R B 1x12VDC Circuit Breakers M AC Internal Overload Protection DC 5 Amp Circuit Breaker Other Features H FlexPower Recommended Oil nthetic 5W 30 40 60 80 100 C 30 20 10 0 10 20 30 40 Temperature Range of Expected Use Page 3 Specifications iX2000 120 VAG Amperage 1 1 1 1 1 1 ue Tank Ga o 20 6 6 8 3 0 T 0 e P i M Internal Not Shown Receptacles A 2 5 20R 120V B 1x12VDC Circuit Breakers M AC Internal Overload Protection DC 5 Amp Circuit
28. at the battery Any time the intake or exhaust openings of the engine are exposed during service they should be covered to prevent accidental entry of foreign material Entry of such materials will result in extensive damage when the engine Is started During any maintenance procedure replacement fasteners must have the same measurements and strength as the fasteners that were removed Metric bolts and nuts have numbers that indicate their strength Customary bolts use radial lines to indicate strength while most customary nuts do not have strength markings Mismatched or incorrect fasteners can cause damage malfunction and possible injury NOTE Special NOTES appear in bold type throughout this publication While not pertaining to safety they emphasize procedures circumstances or specifications that require special altention REPLACEMENT PARTS When servicing this equipment it is extremely important that all components be properly installed and tightened If improperly installed and tightened sparks could ignite fuel vapors from fuel system leaks Table of Contents SpacIfICallorIs s ki kk o eR ee eene 2 Section 4 Troubleshooting and Diagnostic Tests 15 Section 1 Generator Fundamentals 6 Test 1 Check Engine 19 Magneti BI 6 Test 2 Test Sub Coil of Stator 19 Elect
29. ay be equipped with a polarity switch b On meters that do not have a polarity switch DC polarity must be reversed by reversing the test leads 2 Before reading a DC voltage always set the meter to a higher voltage scale than the anticipated reading If in doubt start at the highest scale and adjust the scale downward until correct readings are obtained 3 The design of some meters is based on the current flow theory while others are based on the electron flow theory a The current flow theory assumes that direct current flows from the positive to the negative b The electron flow theory assumes that current flows from negative to positive NOTE When testing generators the current flow theory is applied That is current is assumed to flow from positive to negative MEASURING AC FREQUENCY VOM s may also measure the frequency of an AC voltage if equipped The iX Inverter will produce AC frequencies that are exactly 60Hz Since the inverter module controls the frequency their will not be any direct relation to the speed of the engine and the output of the unit MEASURING CURRENT Clamp on 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 around that conductor The meter consists essentially of a current transformer with a split core and a rectifier type inst
30. d the spark tester clamp by attaching it to the cylinder head see Figure 26 4 Attempt to pull start the engine If spark jumps the tester gap the ignition system is working properly Note The fuel shutoff switch should be in the closed position Note It may take several start attempts before a good Spark is noticed in the tester Figure 26 Results 1 Refer back flow chart TEST 10 CHECK SPARK PLUG PROCEDURE Remove spark plug Clean with a commercial solvent DO NOT BLAST CLEAN SPARK PLUG Replace spark plug if badly fouled if ceramic is cracked or if badly worn or damaged Refer to specifications in the front of this manual for proper replacement spark plugs and spark plug gaps eai Figure 27 Setting Spark Plug Gap Page 21 Section 4 Troubleshooting and Diagnostic Tests MISFIRES NORMAL N DETONATION PRE IGNITION Figure 28 Spark Plug Conditions RESULTS 1 Clean and regap or replace sparks plug as necessary 2 Refer back to the Flow Chart TEST 11 CHECK FUEL PUMP Procedure 1 Open up the side panel that exposes the carburetor and fuel pump 2 Carefully remove the fuel line from the filter on the inlet side of the carburetor WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Wipe up spills immediately 3 Using a suitable container to
31. e carburetor cleaner to clean the carburetor before reassembly 6 After cleaning the carburetor blow dry with compressed air and reassemble Note The shelf life of gasoline is about 30 days Proper procedures need to be taken so that the fuel doesn t var nish over time A fuel stabilizer should be used at all times in order to ensure that the fuel stays fresh RESULTS 1 If carburetor is varnished clean or replace Refer to back to Flow Chart TEST 13 CHECK ENGINE COMPRESSION Discussion Most engine problems may be classified as one or a combination of the following Will not start Starts hard Lack of power Runs rough Vibration Overheating High oil consumption Check Compression To check engine compression remove the spark plug Insert an automotive type compression gauge into the spark plug hole Crank the engine until there is no further increase in pressure The highest reading obtained is the engine compression pressure Minimum allowable compression pressure cold engine If compression is poor look for one or more of the following Causes Loose cylinder head bolts e Failed cylinder head gasket Burned valves or valve seats Insufficient valve clearance Warped cylinder head Warped valve stem Worn or broken piston ring s Worn or damaged cylinder bore Broken connecting rod Worn valve seats or valves Worn valve guides
32. ent prevention measures READ THIS MANUAL THOROUGHLY This SERVICE MANUAL has been written and published by Generac to aid our dealers mechanics and company service personnel when servicing the products described herein Itis assumed that these personnel are familiar with the servicing procedures for these products or like or similar products manufactured and marketed by Generac That they have been trained in the recommended servicing procedures for these products including the use of common hand tools and any special Generac tools or tools from other suppliers Generac could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and or results of each method We have not undertaken any such wide evaluation Therefore anyone who uses a procedure or tool not recommended by Generac must first satisfy themselves that neither his nor the products safety will be endangered by the service procedure selected All information illustrations and specifications in this manual are based on the latest product information available at the time of publication When working on these products remember that the electrical system and engine ignition system are capable of violent and damaging short circuits or severe electrical shocks If you intend to perform work where electrical terminals could be grounded or touched the battery cables should be disconnected
33. g Current Sine Wave WHAT IS AN IX INVERTER UNIT The iX portable is a computer controlled generator that uses an inverter to create a superior sine wave and maintain a steady frequency These units are different from conventional generators in that the performance of the engine and AC generator are more accurately matched over a wide range of power needs The iX computer controlled generator provides greater efficiency of both the engine and the generator while maintaining electrical output within an acceptable voltage range The frequency is controlled by the inverter and is maintained at a steady 60 Hz signal throughout the load range Computer controlled generator units have the ability to operate the engine over a wide range of speeds while conventional generators will deliver correct AC frequency and voltage only at a fixed RPM Unlike conventional AC generators the iX unit can match engine speed to load requirements This provides several advantages as follows Smaller engines can be used to produce more power than on a conventional generator since they can be allowed to run at a higher speed When the load is reduced the engine can run at slower than the conventional speeds This improves fuel economy and reduces engine noise e The iX unit can be operated closer to its peak power point at all times because output voltage and current are a function of engine speed This allows for a much more compact generator desi
34. gn IX INVERTER SYSTEM OVERVIEW Figure 8 is a block diagram of the iX system The major elements of the system are represented in the diagram Operation of the system may be described briefly as follows 1 The engine is directly coupled to a permanent magnet type Rotor so the Rotor runs at the same speed as the engine 2 As the Rotor turns its magnetic field cuts across the Stator windings to induce a voltage into the Stator Page 8 3 AC voltage is delivered to the Inverter Assembly from the Stator which maintains voltage to the 120 VAC receptacles 4 AC voltage is delivered to the bridge rectifier from the DC Charge Coil for the 12VDC outlet available for battery charging if equipped 5 AC voltage is delivered to the Inverter Assembly from the sub coil for inverter operation 6 AC voltage is delivered to the LED module for ignition spark to the magneto WHY VARIABLE SPEED CONTROL Most electrical loads will operate satisfactorily only within a relatively small voltage band In order to provide useful voltage at larger load currents it is necessary to increase engine speed In conventional AC generators some form of voltage regulation is needed to provide correct voltage in the full range of load current This is often accomplished by regulating excitation current to the Rotor field which then regulates the strength of the Rotor s magnetic field The voltage induced into the Stator windings is proportional to
35. gories mechanical and engine related items and electrical items 10 11 12 13 UNIT IDENTIFICATION Carrying Handle Lift the generator by this handle only Spark Plug Cover Allows access to the engine spark plug Fuel System Primer Used to prime the fuel system for starting Fuel Cap Pressure Valve Allows air to enter the fuel tank to equalize pressure Fuel Tank Cap Access to fuel tank for filling Control Panel location of generator controls and output receptacles Air Intake Slats Allows for cooling air to enter the housing Muffler Lowers engine exhaust noise Choke Cold engine starting aid Left Side Service Cover Allows access to air filter fuel filter and oil fill Vent Hoses Allow venting of the carburetor Fuel Shutoff Controls fuel supply to the carburetor Starter Rope Pull rope for starting engine Control Panel 14 15 Low Oil Level LED yellow Lights up when oil level is below safe operating level and the engine shuts down Overload LED red Lights up if the generator experiences a load greater than the rated output low voltage overheats or the powered circuit experiences a short The output is stopped even though the engine keeps running Ready LED green Indicates output from the generator unless there is a low oil or overload condition 12 VDC Plug if equipped Connection for re charging 12VDC automotive style batteries while generator is in operation
36. h mechanical connection is good replace switch 3 Ifthe meter read CONTINUITY when the shutoff valve was in either the open or closed position verify mechanical connection between the valve and the switch mechanical connection is good replace shutoff switch Note A fuel shutoff switch that does not read INFINITY when the fuel shutoff valve is in the closed position will cause a no spark condition TEST 17 CHECK CHOKE ASSEMBLY Procedure 1 If the generator is surging it may have a carburetion problem A lean condition can cause erratic RPM Slowly slide the choke to see if surging stops If it does stop carburetion should be checked 2 Verify the mechanical connection to the carburetor and that the choke is functioning properly Results 1 Ifthe choke is functioning correctly refer back to flow chart 2 Ifthe choke is not functioning correctly replace the choke assembly TEST 18 TEST STEPPER MOTOR 1 800 Procedure 1 Disconnect the J2 connector Stepper Motor from the Inverter module 2 SetVOM to measure resistance vow 1 2 3 BLUE 3 4 4 ORANGE Figure 33 C3 Connector Female Side iX800 3 Connect VOM test leads across the following test points a Pin 1 and Pin 4 approximately 50 ohms should be measured b Pin 1 and Pin 3 INFINITY should be measured c Pin 1 and Pin 2 INFINITY should be measured Section 4 Troubleshooting
37. idge Rectifier Page 20 Results 1 If CONTINUITY is measured across the circuit breaker refer back to flow chart 2 the circuit breaker reads open replace the DC circuit breaker and re test TEST 5 TEST DC RECTIFIER Procedure 1 With the electrical panel still exposed remove the wires on the DC rectifier and mark the location of each wire on the rectifier 2 SetVOM to the Diode test feature marked on most meters by the diode symbol gt 3 Connect the meter test leads according to the chart below and record the results 4 Test Lead 1 2 3 4 Test Lead 1 INFINITY INFINITY INFINITY 2 CONTINUITY INFINITY INFINITY 3 CONTINUITY INFINITY INFINITY 4 CONTINUITY CONTINUITY CONTINUITY Results 1 If the meter indicated the correct readings at all test points refer back to flow chart If the meter indicated any reading other than what was specified replace the rectifier TEST 6 TEST DC COIL ON STATOR Procedure 1 Locate the two white wires coming from the stator One of them will be located on the DC circuit breaker and the other one will be located on the rectifier Set VOM to measure resistance Connect one meter lead to one wire and the other meter lead to the other wire Measure and record the resistance Results 1 The resistance measured between the all tests points should be as follows iX 1600 0 2 Ohms
38. incipal of the revolving field generator Figure 3 below illustrates a simple revolving field generator The permanent magnet Rotor is rotated so that its lines of magnetic force cut across a coil of wires called a Stator A voltage is then induced into the Stator windings If the Stator circuit is completed by connecting a load such as a light bulb current will flow in the circuit and the bulb will light Figure 3 A Simple Revolving Field Generator ELECTRICAL UNITS AMPERE The rate of electron flow in a circuit is represented by the AMPERE The ampere is the number of electrons flowing past a given point at a given time One AMPERE is equal to just slightly more than 6 25 x 1018 electrons per second With alternating current AC the electrons flow first in one direction then reverse and move in the opposite direction They will repeat this cycle at regular intervals A wave diagram called a sine wave shows that current goes from zero to maximum positive value then reverses and goes from zero to maximum negative value Two reversals of current flow is called a cycle The number of cycles per second is called frequency and is usually stated in Hertz VOLT The VOLT is the unit used to measure electrical PRESSURE or the difference in electrical potential that causes electrons to flow Very few electrons will flow when voltage is weak More electrons will flow as voltage becomes stronger VOLTAGE may be conside
39. le to be serviced and replaced at this point Fuel Pump Stepper Motor Carburetor Air Filter Figure 40 Page 27 Section 5 Disassembly Disconnect the connectors and ground wires and remove control panel 8 Remove one 1 Phillips screw to remove the fuel shutoff knob 9 Remove one 1 Phillips screw from recoil access area 10 Remove three 3 Phillips screws located on the handle two on iX 800 11 Carefully orient the assembly so that the side with the access cover is facing down See Figure 38 12 Remove two 2 Phillips bolts on the underside of the plastic housing 13 The side with the spark plug access should be facing up at this point remove this half of the enclosure Figure 41 14 Disconnect the fuel tank by removing the hose clamp and removing the hose from fuel shutoff valve 15 Remove one 1 Phillips screw from the fuel shutoff valve so it is isolated from the enclosure Note Make note of the orientation of the fuel shutoff valve for re assembly 16 On the iX 1400 iX 1600 and iX 2000 disconnect connectors and remove inverter On the iX 800 the inverter is connected to the fuel shutoff switch and can not be removed 17 Feed the recoil cord through the lower enclosure piece 18 The engine assembly should be able to be lifted out of the unit and set aside Time to reach this point 15 minutes The following items are able to be serviced and replaced at this
40. oubleshooting and Diagnostic Tests 4 Connect one meter lead to the wire that runs through the plastic engine housing to the oil level switch and the other test lead to engine frame ground Measure and record the resistance Results 1 If oil level was good and the meter indicated an open circuit check for a short to ground on the wire between the low oil level switch and the LED module 2 f oil level was good and the meter indicated a closed circuit to ground replace the engine TEST 20 TEST IGNITION COIL WINDING Procedure 1 Remove the electrical panel so the components are exposed 2 Disconnectthe J1 Connector 3 Set VOM to measure resistance 4 Connect one meter lead to Pin 5 of the J1 connector and the other meter test lead to ground Measure and record the resistance Refer to Table 1 on Page 23 Figure 35 J1 Connector on LED Module Page 26 Results 1 Refer to the following chart If the meter reading is within 0 2 ohms refer back to flow chart iX 800 0 8 Ohms iX 1600 0 5 Ohms iX 2000 0 7 Ohms TEST 21 TEST FLEXPOWER SWITCH Procedure 1 Disconnect the orange and brown wires from the FlexPower switch FPS Set VOM to measure resistance Set FPS to ECO position Connect one meter test lead to Pin 1 and the other meter test lead to Pin 2 Measure resistance and record results 5 Set FPS to HIGH position Repeat Step 4 Measure resistance and record results
41. point Inverter Assembly Fuel Shutoff Valve Fuel Shutoff Switch Page 28 Lower and Upper Enclosures Ignition Coil Recoil Assembly Engine Housing Removal 19 Remove one 1 Phillips screw from the fuel pump housing 20 Remove two 2 8 mm nuts from the carburetor plastic intake assembly and remove the fuel pump and the carburetor as one assembly and isolate the fuel hose from the fuel shutoff valve Note Keep the two spacers with the housing once it has been removed 21 Remove ten 10 Phillips screws around the top and bottom seams of the housing There are two different sizes of screws Make note of which one is which for reassembly 22 Isolate the wiring harness from the housing and remove the low oil plug and pull the wire through for removal 23 Separate the two housings to expose the engine Figure 42 Time to reach this point 25 minutes The following items are able to be serviced at this point Engine Rotor Stator Low Oil Switch Fan Trigger Assembly The following items are able to be replaced at this point Low Oil Switch Trigger Assembly Rotor Stator Removal 24 Remove the 8mm bolt in the center of the recoil jaw Figure 43 25 Remove two 8mm bolts from the starting jaw seat 26 Remove the fan 27 Remove the 15mm nut in the center of the rotor by inserting the socket wrench first and install a steering wheel puller over the socket wrench as sho
42. red to be a state of unbalance and current flow as an attempt to regain balance One volt is the amount of EMF that will cause a current of 1 ampere to flow through 1 ohm of resistance Conductor of OHM Unit measuring resistanc Circuit or opposition to flow eal AMPERE Unit measuring rate of current flow number of electrons 1 1 1 past a given point VOLT Unit measuring force or difference in potential causing current flow Figure 4 Electrical Units OHM The OHM is the unit of RESISTANCE In every circuit there is a natural resistance or opposition to the flow of electrons When an EMF is applied to a complete circuit the electrons are forced to flow in a single direction rather than their free or orbiting pattern The resistance of a conductor depends on a its physical makeup b its cross sectional area C its length and d its temperature As the conductor s temperature increases its resistance increases in direct proportion One 1 ohm of resistance will permit one 1 ampere of current to flow when one 1 volt of electromotive force EMF is applied OHM S LAW Figure 5 Ohm s Law Section 1 Generator Fundamentals A definite and exact relationship exists between VOLTS OHMS and AMPERES The value of one can be calculated when the value of the other two are known Ohm s Law states that in any circuit the current will increase when voltage increa
43. romagnetic Fields 6 Test 3 Test Main Coil of StatOr 19 Electromagnetic InductiON 6 Test 4 Test DC Circuit Breaker 20 Electrical N oo 6 Test 5 Test DC Rectifier 20 A 7 Test 6 Test DC Coil on Stator 20 A Simple AC 7 Test 7 Test Recoil Function 21 What is an iX Inverter Unit 8 Test 8 Test Engine 21 iX Inverter System Overview 8 Test 9 Check 21 Why Variable Speed Control 8 Test 10 Check Spark Plug 21 Section 2 Measuring Electricity 9 Test 11 Check Fuel 22 MGC PEE 9 Test 12 Check Carburetion 22 Ti MOMS zc et 9 Test 13 Check Engine Compression 23 Measuring AC 9 Test 14 Test Ignition Trigger Assembly 23 Measuring DC
44. rument connected to the secondary The primary of the Page 9 Section 2 Measuring Electricity current transformer is the conductor through which the current to be measured flows The split core allows the instrument to be clamped around the conductor without disconnecting it Current flowing through a conductor may be measured safely and easily A line splitter can be used to measure current in a cord without separating the conductors CONDUCTOR MAGNETIC FIELD CLAMP ON AMMETER ATTACHMENT ke x lt Figure 11 A Line Splitter NOTE If the physical size of the conductor or ammeter capac ity does not permit all lines to be measured simultaneously measure current flow in each individual line Then add the individual readings In Line Alternatively to read the current flow in AMPERES an in line ammeter may be used Most Digital Volt Ohm Meters VOM will have the capability to measure amperes This usually requires the positive meter test lead to be connected to the correct amperes plug and the meter to be set to the amperes position Once the meter is properly set up to measure amperes the circuit being measured must be physically broken The meter will be in line or in series with the component being measured Page 10 In Figure 12 the control wire to a relay has been removed The meter is used to connect and supply voltage to the relay to energize it and measure the amperes going to it B
45. s Problem 7 Engine Hunts Erratic Idle or Will Not Come Up to Speed IS THE UNIT IS THE ENGINE TEST 17 TEST 11 PRODUCING RUNNING CHECK CHOKE GOOD CHECK FUEL AC POWER ERRATICALLY ASSEMBLY PUMP NO BAD BAD GOOD GO TO PROBLEM 1 NO REPLACE CHOKE REPLACE FUEL ASSEMBLY PUMP REPLACE TEST 18 TEST TEST 12 INVERTER lt GOOD STEPPER lt 4 GOOD CHECK MODULE MOTOR CARBURETOR BAD BAD ENGINE MISS APPARENT REPLACE REPLACE STEPPER CARBURETOR MOTOR TEST 14 TEST TRIGGER BAD gt REPLACE ASSEMBLY GOOD REPLACE REPLACE TEST 15 TEST LED lt GOOD IGNITION COIL BAD gt IGNITION MODULE COIL Problem 8 Unit Shuts Down for Low Oil TEST 20 TEST CHECK OIL REPLACE LEVEL GOOD J j OIL LEVEL BAD gt ENGINE SWITCH BAD REPLACE LED GOOD REPLENISH OIL MODULE Page 18 TEST 1 CHECK ENGINE RPM Tools Required Small Engine Tachometer Procedure DD NP 1 With the engine running connect the engine tachometer according to the manufactures instructions and record the engine RPM Results 1 If the engine rpm was 3000 200 rpm it is running within rated specs refer back to flow chart 2 If the engine rpm was outside the range of 3000 200 rpm go to Problem 7 TEST 2 TEST SUB COIL OF STATOR Procedure 1 Stopthe engine 2 Drain the fuel from the tank WARNING A Gasoline is highly flammable and explosive You can SA
46. ses but resistance remains the same and current will decrease when resistance Increases and voltage remains the same If AMPERES is unknown while VOLTS and OHMS are known use the following formula VOLTS OHMS If VOLTS is unknown while AMPERES and OHMS are known use the following formula AMPERES VOLTS AMPERES x OHMS If OHMS is unknown but VOLTS and AMPERES are known use the following _ VOLTS OHMS AMPERES A SIMPLE AC GENERATOR Figure 6 shows a very simple AC Generator The 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 pole MAGNETIC FIELD Figure 6 A Simple AC Generator As the MOTOR turns its magnetic field cuts across the stationary STATOR A voltage is induced into the STATOR windings When the magnet s NORTH pole passes the STATOR current flows in one direction Current flows in the opposite direction when the magnet s SOUTH pole passes the STATOR This constant reversal of current flow results in an alternating current AC waveform that can be diagrammed as shown in Figure 7 The ROTOR may be a 2 pole type having a single NORTH and a single SOUTH magnetic pole The 2 pole ROTOR must be turned at 3600 rpm to produce an AC frequency of 60 Hertz Page 7 Section 1 Generator Fundamentals CURRENT ONE CYCLE Figure 7 Alternatin
47. ts Amps Power Factor Volts x Amps 2 x 60 x Frequency RPM Volts Current NO OF ROTOR POLES Frequency RPM RPM x Poles FREQUENCY RPM No of Rotor Poles BEDV 2x60 2 x 60 x Frequency RPM Frequency No of Rotor Poles Rotor Poles HP x 0 746 Efficiency kW required for Motor Motor Horsepower Efficiency RESISTANCE Volts Amperes Ohm Amperes Ohms Volts E VOLTS I AMPERES R RESISTANCE OHMS PF POWER FACTOR Page 38 NOTES NOTES Page 40 GENERAC haz Generac Power Systems Inc 45 W29290 Hwy 59 Waukesha 53189 Part 0H5039 Printed in USA Rev A 04 30 10 888 2010 Generac Power Systems Inc All rights reserved 1 888 GENERAC 1 888 436 3722 Specifications are subject to change without notice reproduction allowed in any form without prior written consent from Generac Power Systems Inc generac com
48. uch the muffler while it is HOT 3 Remove the electrical box assembly and back window and upper enclosure half 4 Take outthe 6 pin connector Note Do not remove the harness of the control panel 5 Set VOM to measure resistance Page 19 Section 4 Troubleshooting and Diagnostic Tests 6 7 Disconnect the C4 connector On the female side of the connector connect one meter test lead to Pin 3 and connect the other meter test lead Pin 5 measure and record the resistance Repeat Step 6 between the following test points Pin 3 and Pin 6 e Pin 6 and Pin 5 Results 1 The resistance measured between the all tests points should be as follows iX 800 2 1 0hms 0 3 0hms iX 1600 TBA 0 3 Ohms iX 2000 2 5 Ohms 0 3 Ohms If the resistance measured is within the specified values refer back to flow chart If the resistance reading is outside the tolerance replace the stator TEST 4 TEST DC CIRCUIT BREAKER Procedure 1 Remove the electrical panel so that the DC circuit breaker is exposed and remove both wires from the breaker Ensure that the breaker is reset from the front of the panel and is not tripped Set VOM to measure resistance Connect one meter test lead to one side of the breaker and the other meter test lead to the other side of the breaker and measure resistance CONTINUITY should be measured i IFIER Figure 25 DC Breaker and DC Br
49. urrent is flowing have a magnetic field surrounding them This field is always at right angles to the conductor If a compass is placed near the conductor the compass needle will move to a right angle with the conductor The following rules apply The greater the current flow through the conductor the stron ger the magnetic field around the conductor The increase in the number of lines of force is directly proportional to the increase in current flow and the field is distributed along the full length of the conductor The direction of the lines of force around a conductor can be determined by what is called the right hand rule To apply this rule place your right hand around the conductor with the thumb pointing in the direction of current flow The Tou will then be pointing in the direction of the lines of NOTE The right hand rule is based on the current flow theory which assumes that current flows from positive to negative This is opposite the electron theory which states that current flows from negative to positive Page 6 Figure 2 The Right Hand Rule ELECTROMAGNETIC INDUCTION An electromotive force EMF or voltage can be produced in a conductor by moving the conductor so that it cuts across the lines of force of a magnetic field Similarly if the magnetic lines of force are moved so that they cut across a conductor an EMF voltage will be produced in the conductor This is the basic pr
50. wn in Figure 41 Use an adjustable wrench to counter the torque from the socket to break the nut free Figure 44 28 With the nut removed install the steering puller with the center bolt tight against the center shaft and remove the rotor assembly Section 5 Disassembly Figure 45 29 Remove two 2 8mm bolts holding stator to engine casting 30 Remove stator Time to reach this point 45 minutes The following items are able to be replaced at this point Engine Stator Rotor Reassembly Notes The above procedure should be reversed to re assemble unit Order of reassembly Engine Stator Rotor Engine Housing Fuel Pump e p ge ce Carburetor 7 Place Engine Housing in lower Enclosure Note Be sure to locate all harnesses and fuel lines to ensure they will not be obstructed during the reassembly process The stepper motor harness must be able to reach the inverter 8 Fuel Shutoff Switch Note Test Fuel Switch for correct orientation before putting the two halves together 9 Fuel Tank 10 Inverter 11 Upper Enclosure 12 Retaining Clip below fuel cap 13 Receptacle panel Page 29 Section 5 Disassembly Exploded View iX800 5 98 99 Page 30 ITEM DESCRIPTION ENGINE ASSY 2 1 SUPERCHARGED ASSY FUEL TANK FUEL FILLER INLET RUBBER RING 4 CLAMP FUEL HOSE CUP FUEL FILTER SHOCK ABSORBER BLOCK 2 SCREW CROSS RECESSED PAN HE
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