Special Diagnostic Tools - Yamaha EF4500iSE Theory & Diagnostics Manual

Yamaha Generator Theory & Diagnostics Guide

Special Diagnostic Tools

Utilizing the correct diagnostic tool for the job is
critical to our main goal, Customer Satisfaction.
Having the correct tools will ensure that the problem
is fixed right the first time. There are 5 important
diagnostic tools the Service Department should
have to properly diagnose and repair most Inverter
and Conventional generators.
1. Load Bank Tester /
Generator Test Set
The load bank main use is to duplicate prob-
lems, and verify the generator works properly
after a repair. It can apply an adjustable load
between 1-50amps. Many generators are capa-
ble of producing large amounts of power, so it is
necessary to use a tool to create a large, mea-
surable load to simulate any output issues. Heat
guns, drills, fans, and grinders are not good
diagnostic tools as there is no way to measure
and maintain a large load. As a dealer techni-
cian it is difficult to determine exactly how much
load you are applying when not using a load
bank tester. The load bank can also be used as
a sales tool to determine if a generator has
enough capacity to meet the customer's needs.
Generator Test (Load Bank) Uses
Typically, the only way to test the generator if
you don't have a load bank, is to plug some type
of tool into it and turn it on. If it operates the tool,
you assume that it's making electricity and must
be fixed.
This is not necessarily true .
Just because one appliance works, it does not
guarantee that the unit will work for the cus-
tomer. If the customer gets the unit home or to a
construction site and immediately finds out that
it still does not work for his application, your
Customer Satisfaction level with this customer
will be in serious jeopardy.
This can be easily avoided by the use of a gen-
erator test set. The generator test set will make
it possible to select the amount of current used
by a particular customer under real world condi-
tions.
You can even select the amount of current for a
given generators rated output and let it run for
awhile at that power load. If it passes that test
you are practically guaranteed that it will work
for your customer.
Most generator test sets also feature a frequen-
cy meter to enable you to make that adjust-
ment.
Another excellent use for the generator test set,
which very often becomes a major problem in
customer satisfaction, is for the proper selection
of a generator for a given application.
If there is any question as to the amount of cur-
rent that a certain appliance or a combination of
tools will require, all the guess work can be
eliminated by plugging the generator test set
into an external power source with high amper-
age capabilities and then plugging the appli-
ance or tools into the generator test set.
The generator test set's amp meter will not only
tell you the required amount of current for nor-
mal operation, but will also tell you what the
start up current requirements are.
Start up current requirements are an often over-
looked step in proper generator selection and
should always be taken into consideration.
You will need to take the start up amperage plus
a cushion, to determine the generator size. The
cushion will allow for the possibility of future
requirement increases.
The customer will be much happier with your
dealership if you were able to foresee his future
needs. Especially when his needs do change
and he would have had to purchase another
generator, if you had not made him aware of that
possibility.
2. Hertz (Hz) Meter
The hertz meter is used to properly set the fre-
quency. U.S. applications will be 60 Hz adjusted
by increasing or decreasing engine rpm.
3. Pulse Tachometer
A tachometer is used to set the rpm on all gaso-
line powered models.
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