DPE Voltage Test Procedure for 520 MACE Alternators

Tools required:
Digital Multimeter and test leads, both of Cat III 600V rating or higher
Electrical tape
3-5 cable ties of 6” in length or longer
10mm socket with wrench (other tools may be required)
Appropriate PPE

Warning: The voltages to be measured in this procedure may be in excess of 400V. Use properly-rated
equipment and wear appropriate PPE where required.

Procedure:
Open the MLCB on the generator and disconnect the negative battery cable inside the unit to prevent
accidental startup during servicing. Locate the alternator tower at the rear of the unit and remove the
access panel by removing the 10mm bolts that hold it to the enclosure. Note: Some units may require
removal of the rear enclosure panel(s) to access the alternator tower access panel. Locate the 4-pin
exciter connectors within the alternator tower and disconnect them. Remove the cable ties that hold
the male connector to the rest of the harness for ease of access if necessary. Locate black wires 2 and 6
entering the male connector and insert multimeter probes in the rear of the connector such that they
make contact with each pin for wires 2 and 6. Note: DO NOT force the probes into the rear of the
connector! Move the wire to one side within the connector to make room for the probes if necessary. Be
sure that the probes are spread as far apart as possible so that there is no risk of them crossing.

With the probes in position, use electrical tape to secure them to the rear of the male exciter connector
and cover any exposed length of the probes. Connect the two exciter connectors together and secure
them to the harness with electrical tape. Make sure that that all wires, including multimeter leads, are
secure and not in danger of getting tangled with the rotor assembly. Note: If environmental conditions
are such that the tape does not adhere well, use cable ties in addition to the electrical tape for
reinforcement.
With the probes and connectors in place, connect a multimeter and set it to measure AC volts. Place the
meter in a secure yet visible location. Reconnect the negative battery terminal and prepare to start the
unit. Verify that the generator MLCB is open. Note: The generator must NOT be loaded during this test!
Stand clear of the exposed alternator tower and start the unit. As soon as the engine comes up to speed,
quickly verify that there is no load on the generator and record the DPE voltage read on the multimeter
as soon as it stabilizes. Once this value is recorded, shut down the unit immediately and disconnect the
negative battery cable. If the DPE voltage measured was greater than 255V, call the Generac technical
service department to report the reading. DO NOT attempt to start or run the generator again until
being told it is safe to do so by the service department.
With the generator MLCB open and the negative battery cable disconnected, remove the tape and
multimeter probes from the 4-pin exciter connector. Inspect the connectors, pins and wires for damage.
Remove any damaged wire and crimp new pins (pin P/N 059257 and connector P/N 053650) if
necessary. Re-secure the connectors and wires to the rest of the harness with cable ties positioned as
they were prior to removal. Reattach the alternator tower access panel and any other enclosure panels
that were removed during disassembly.