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Generac Generators (SEARS, etc.)

10,000 EXL with New Stepper Motor, Still No Idle


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  #1  
Old 08-18-2014, 12:03:55 PM
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Default 10,000 EXL with New Stepper Motor, Still No Idle

The idle mode and throttle isn't working on my 10000EXL.

I inspected the stepper motor and noticed that some of the windings were burnt and frayed. I replaced the stepper motor with Generac Part# 098290.

Idle was still not working.

I inspected the board that the stepper motor plugs into. I believe it is the idle control board. It appears to have been burnt out too.

The battery charge charge system is also non-functional.

Bass, you seem to know your way around these generators pretty well. Can you help me find the root of the problem, and help me find the correct replacement parts?


Generator Info:
Model: 09801-4
Series: 10K EXL
Serial: 6321302

In the photo below, you can see where the board is cooked, just to the left of the white stepper motor plug.
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Old 08-18-2014, 12:12:57 PM
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Default Re: 10,000 EXL with New Stepper Motor, Still No Idle

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Old 08-18-2014, 07:01:05 PM
Bassplayer1985 Bassplayer1985 is offline
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Default Re: 10,000 EXL with New Stepper Motor, Still No Idle

Station. Been MIA today. Ill look over tonight or tomorrow. looks like control transistor is fried.
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Old 08-18-2014, 09:44:25 PM
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Default Re: 10,000 EXL with New Stepper Motor, Still No Idle

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Originally Posted by Bassplayer1985 View Post
Station. Been MIA today. Ill look over tonight or tomorrow. looks like control transistor is fried.
Thanks Bass. No worries. Just whenever you get around to it.
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Old 08-19-2014, 09:48:42 AM
Bassplayer1985 Bassplayer1985 is offline
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Default Re: 10,000 EXL with New Stepper Motor, Still No Idle

Station.

Okay, a few things. I need pictures of the generator end bell please.

I will provide background of what I'm seeing in the pics and how the generator works so you are up to speed. Obviously the ICB (idle control board) is fried. The next question I'm asking is why. I see transistors burnt, and I see the main power filter cap is swollen, possibly dried/old or overstressed.

This particular revision the battery charge windings power both the starter battery and the DC outlet/ICB. Each of these circuits have a rectifier converting VAC to VDC.

1. Off the stator, you should have two wires to a rectifier 66a/77a which the middle pin is 13A that heads to the starter battery via a 10 amp fuse.

2. Off the stator as well you have wires 66/77 to a rectifier, the middle pin is wire 13 that heads to a 10 amp auto reset circuit breaker.

***The LINE side of the this breaker has wire 13 spliced and connected to J2 on the ICB.

***The LOAD side of the auto reset breaker goes to the positive terminal of the DC outlet on the control panel.

--------

1. So the first thing you need to do is you need to disconnect the ICB completely and remove it from the generator.

2. Next remove/disconnect both rectifier wires as you need to take the ohms resistance of the battery charge windings out of circuit to see if they are burnt.

3. With a multimeter, measure ohms between wires 66 & 77...tell me the reading.

4. Now measure between 66a & 77a...tell me the reading

That's all for now. post back, tell me what you find. The next step will be to fire up the generator and measure AC voltage at 66/77 and 66a/77a. Hold off on that till I see your results and more pictures.
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  #6  
Old 08-19-2014, 10:17:28 PM
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Default Re: 10,000 EXL with New Stepper Motor, Still No Idle

Ok, I have the pictures you requested. I opened her up to track down the wires you mentioned. I found wire 77a and I believe I found 77. They are hard to identify because the writing on the wires was worn off. 77a and what I think is 77 both lead up to the control panel and are capped off with wire nuts. Is this normal? (see photo below)




I could not find 66 or 66a coming from the stator. Possibly due to no legible writing on the wires.

I did find 2 wires labeled with a 66, along with wire 13 in the middle pin, connected to an aluminum heatsink device behind the control panel. (see photo below)




Wire 13 coming from the starter battery is also capped off. (see below)

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Old 08-19-2014, 10:22:00 PM
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Default Re: 10,000 EXL with New Stepper Motor, Still No Idle

Below are pictures of the windings.







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Old 08-20-2014, 09:48:00 AM
Bassplayer1985 Bassplayer1985 is offline
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Exclamation Re: 10,000 EXL with New Stepper Motor, Still No Idle

Shit wow, somebody did a real hack job to your genset. If wire 13 is capped off that explains why your starter battery is not charging. That aluminum finned heat sink device is your bridge rectifier that converts VAC from your battery charge windings into DC for the battery and ICB to use. There should be a 2nd bridge rectifier in there with 66a/77a and 13a going to the starter battery through the fuse. Looks as though its missing.

If 66 and 66A are connected to the outer terminals of the bridge rectifier that's wrong. The rectifier you have with its middle pin going to the ICB/Auto reset breaker should have wires 66 & 77 on the outer pins, no preference on which side is which.

Okay, lets start off with identifying the wires. The wire numbers should be stamped along the entire wire length. The ohms resistance between 66/77 and 66a/77a should be 0.175 ohms. Measure this w/o the generator running. That's pretty low for most meters to read unless its a really good one. If you have a higher resistance it could mean a mismatch between those 4 wires.

Action: Report back your ohm readings to me. We need to properly match these wires together, label them, then move on to the next step once we confirm ohm readings are in spec. Judging by the look of your stator/rotor the insulation looks to be in good shape.

Last edited by Bassplayer1985; 08-20-2014 at 10:05:06 AM.
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Old 08-20-2014, 10:55:18 AM
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Default Re: 10,000 EXL with New Stepper Motor, Still No Idle

here is the specs for your stator/rotor combo. Posting it here for future readers and our reference during the troubleshooting process.

Rotor: 92381GS - 14.8 ohms slip ring to slip ring

Stator: 94983GS
- Power Windings: 0.148/0.148 ohms (measured hot to neutral of each leg)
- DPE Winding: 1.70 ohms (measured btw wire 2 & 6)
- Battery Charge Windings: 0.175 ohms (btw 66/77 and 66a/77a)


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