Generac Power Systems CorePower, Repair Manual

Page 1: ...DIAGNOSTIC REPAIR MANUAL S TA N D BY G E N E R AT O R S CorePower Home Standby Generator MODELS 6 7 kW ...

Page 2: ...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 product...

Page 3: ... and Tips 22 Connectors 22 PART 2 AC Generators 23 Section 2 1 Description and Components 24 Introduction 24 Engine Generator Drive System 24 Alternator Assembly 24 Brush Holder and Brushes 24 Other AC Generator Components 25 Section 2 2 Operational Analysis 26 Startup 26 On Speed Operation 26 Field Excitation 26 AC Power Winding Output 26 Section 2 3 Troubleshooting Flowcharts 27 Introduction 27 ...

Page 4: ...Utility Failure and Engine Running 56 Section 4 4 Troubleshooting Flowcharts 57 Problem 20 Engine Will Not Crank When Utility Power Source Fails 57 Problem 21 Engine Will Not Crank When AUTO OFF MANUAL Switch is Set to MANUAL 57 Problem 22 Engine Cranks but Won t Start 58 Problem 23 Engine Starts Hard and Runs Rough Lacks Power Backfires 59 Problem 24 Shutdown Alarm Fault Occurred 60 Problem 25 7 ...

Page 5: ...assembly 82 Section 5 2 Exploded Views 90 PART 6 Electrical Data 101 Wiring Diagram 102 Electrical Schematic 103 Electrical Formulas 104 Appendix A Supplemental Worksheets 105 Appendix B Index of Figures and Tables 109 Index of Figures 110 Index of Tables 111 ...

Page 6: ...l Btu content Typical derates are between 10 20 off the LP gas rating Circuits to be moved must be protected by same size breaker For example a 15 amp circuit in the main panel must be a 15 amp circuit in the transfer switch ENGINE Type of Engine OHV 432 Number of Cylinders 1 Rated Horsepower 3 600 rpm 14 8 Displacement 432cc Cylinder Block Aluminum w Cast Iron Sleeve Valve Arrangement Overhead Va...

Page 7: ...ad 6 7 kW 66 119 0 82 30 1 47 53 Natural gas is in cubic feet per hour LP is in gallons per hour cubic feet per hour Values given are approximate MAJOR FEATURES Exhaust Enclosure Base Fuel Regulator Battery Fuel Inlet Ground Lug Oil Filter Data Label see sample Air Filter Circuit Breaker Control Panel ...

Page 8: ...Page 6 Specifications ...

Page 9: ...Page 7 Specifications ...

Page 10: ...Page 8 NOTES ...

Page 11: ...tion 14 Reconfigure the fuel system 14 Section 1 4 Operating Instructions 16 Control Panel 16 User Interface 16 Automatic Operation 16 Manual Operation 16 Section 1 5 Automatic Operating Parameters 18 Introduction 18 Utility Failure 18 Cranking 18 Cranking conditions 18 Load Transfer Parameters 18 Section 1 6 General Maintenance 20 Introduction 20 Engine Oil 20 Engine Oil Recommendations 20 Air Fi...

Page 12: ... the basic understanding of the generator as well as operating instructions for commons tasks Part 2 Provides the basics of the AC alternator design and the AC troubleshooting portion of the manual Part 3 Provides the troubleshooting and diagnostic testing procedure for the 50 amp transfer switch with the EZ Transfer Operator Part 4 Provides the troubleshooting and diagnostic procedure for the eng...

Page 13: ...ltage The following guidelines apply 1 Always read the generator s AC output voltage at the unit s rated operating speed and AC frequency 2 The generator s rated AC output voltage is 250 to 254 VAC and is not adjustable 3 Only an AC voltmeter may be used to measure AC voltage DO NOT USE A DC VOLTMETER FOR THIS PURPOSE Generators produce high and dangerous voltages Contact with high voltage termina...

Page 14: ...o 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 In Figure 5 the control wire to a relay has been removed The...

Page 15: ...Electromotive Force EMF that will cause a current of 1 ampere to flow through 1 ohm of resistance AMPERE Unit measuring rate of current flow number of electrons past a given point OHM Unit measuring resistance or opposition to flow VOLT Unit measuring force or difference in potential causing current flow Conductor of a Circuit Figure 6 Electrical Units Ohm The OHM is the unit of RESISTANCE In ever...

Page 16: ... All pipe sizing construction and layout must comply with NFPA 54 for natural gas applications and NFPA 58 for liquid propane applications After installation verify that the fuel pressure NEVER drops below five 5 inches water col umn for natural gas or ten 10 inches water column for LPV Prior to installation of the Generator the installer should consult local fuel suppliers or the fire marshal to ...

Page 17: ...the owners manual 8 Verify that the O ring supplied loose with the owners manual is installed into the groove of the fuel jet 9 Insert the Propane fuel jet into the end of the fuel inlet 10 Reinstall the hose and clamp onto the fuel inlet and secure 11 Verify the hose has not been kinked in any way Throttle Assembly Fuel Jet Fuel Inlet O Ring installed Hose Clamp Regulator Hose Figure 11 12 The ge...

Page 18: ...ency must be verified with the Generator Main Line Circuit Breaker MLCB OFF or OPEN Prior to selecting Automatic or Manual operation To select automatic operation The following procedure applies only to those installations which utilize an air cooled generator in conjunction with a transfer switch Residential transfer switches do not have intelligent circuits of their own Printed circuit board log...

Page 19: ... the OFF position 4 Locate a means of Utility disconnect and set it to the OFF position 5 Manually actuate the breaker in the transfer switch to the Utility position 6 Restore Utility voltage to the transfer switch by the means that was utilized in Step 4 7 Set the generator s AUTO OFF MANUAL switch to the AUTO position With the generator in AUTO a dropout in Utility voltage below a preset level w...

Page 20: ...n and latch out on RPM Sensor loss 5 Once the controller sees an RPM signal it will energize the fuel solenoid and continue the crank sequence The fuel solenoid does not activate earlier because if the engine does not crank this would potentially fill the engine exhaust up with unspent fuel It takes at least 3 seconds to detect cranking on the engine with a magneto RPM measurement This would resul...

Page 21: ...ition running in Utility failure When the Utility returns above 75 of nominal a 15 second return to Utility timer will start At the completion of this timer if the Utility supply is still present and acceptable the controller will transfer the load back to the Utility and run the engine through a one minute cool down period and then shutdown If Utility fails for three seconds during this cool down...

Page 22: ...ir filter may cause severe damage to the engine SPARK PLUGS Good spark is essential to properly maintaining the engine Although replacement may not be required inspection of the plugs during routine maintenance is critical Always verify that spark plugs are gapped according to the specifications Improperly gaped spark plugs will effect the operation of the engine See Test 65 for diagnosing spark p...

Page 23: ...st dealer for assistance if necessary Change oil and filter after first eight 8 hours of operation and then every 100 hours thereafter or 1 year whichever occurs first Change sooner when operating under a heavy load or in a dusty or dirty environment or in high ambient temperatures GENERAL INFORMATION PART 1 Page 21 Section 1 6 General Maintenance BATTERY Performing proper battery maintenance at t...

Page 24: ...ocedure or method he has selected will jeopardize neither his nor the products safety and will not cause damage to any connectors or components Recommended Tools Check List p General Mechanics Tool Box p A Meter Capable of Measuring Frequency Hz AC DC volts DC amps and Ohms p A Clamp on Ammeter p A 1 4 3 8 Metric SAE Socket Set p Allen Wrenches Metric SAE p Manometer p Spark Tester p Compression G...

Page 25: ...es Low Voltage at No Load 28 Problem 3 Generator Produces High Voltage at No Load 29 Problem 4 Voltage and Frequency Drop Excessively When Loads Are Applied 29 Section 2 4 Diagnostic Tests 30 Introduction 30 Safety 30 AC Troubleshooting 30 Test 1 Check Main Circuit Breaker 30 Test 4 Fixed Excitation Rotor Amp Draw Test 30 Test 6 Resistance Check of Rotor Circuit 32 Test 7 Check Brushes and Slip Ri...

Page 26: ...the rotor rotates its lines of magnetic flux cut across the stator windings and induce a voltage into the stator windings The rotor shaft has a positive and negative slip ring with the positive slip ring nearest the lower bearing carrier The bearing is pressed onto the end of the rotor shaft SLIP RINGS BEARING Figure 14 Rotor Stator The stator houses a dual power winding and an excitation winding ...

Page 27: ...ensing regulates it The rectified and regulated field excitation current is then delivered to the rotor windings from the positive Red Wire and negative Black Wire originates as White Wire from regulator and changes to Black at the C1 connector Stator AC power winding sensing is delivered to the regulator through the Green and White Wires Main Line Circuit Breaker The main line circuit breaker pro...

Page 28: ...d Wire and the positive brush and slip ring This excitation voltage flows through the rotor windings and through the negative slip ring and brush on the negative Black Wire The greater the current flow through the rotor windings the more concentrated the lines of flux around the rotor become The more concentrated the lines of flux around the rotor that cut across the stationary stator windings the...

Page 29: ...LACE ROTOR ONLY RESET TO ON OR REPLACE IF BAD GOOD GOOD REPLACE STATOR ONLY REPLACE ROTOR AND STATOR PERFORM INSULATION RESISTANCE TEST PERFORM INSULATION RESISTANCE TEST TEST 9 TEST STATOR CHECK VOM FUSES REPAIR OR REPLACE FUSES RE TEST BAD BAD BAD GOOD GOOD GOOD GOOD ON Problem 1 Generator Produces Zero Voltage or Residual Voltage TEST 4 PERFORM FIXED EXCITATION ROTOR AMP DRAW D G A C B REPLACE ...

Page 30: ...AMP DRAW F E H BAD BAD REPLACE ROTOR AND STATOR BAD TEST 10 TEST ROTOR ASSEMBLY TEST 10 TEST ROTOR ASSEMBLY TEST 9 TEST STATOR GOOD STOP TESTS Problem 2 Generator Produces Low Voltage at No Load LOW LOW FREQUENCY AND VOLTAGE O K FREQUENCY O K BUT VOLTAGE LOW VOLTAGE O K BUT VOLTAGE IS STLL LOW GO TO PROBLEM 1 FLOW CHART START AT TEST 4 VOLTAGE AND FREQUENCY O K TEST 11 CHECK AC OUTPUT VOLTAGE TEST...

Page 31: ...OLTAGE O K FREQUENCY O K BUT VOLTAGE HIGH TEST 13 ADJUST ENGINE GOVERNOR DISCONTINUE TESTING TEST 13 CHECK AND ADJUST ENGINE GOVERNOR TEST 16 CHECK VOLTAGE AND FREQUENCY UNDER LOAD TEST 15 CHECK FOR OVERLAOD CONDITION GO TO PROBLEM 23 ENGINE STARTS HARD AND RUNS ROUGH LACKS POWER BOTH LOW NOT OVERLOADED GOOD GOOD BAD GOOD ENGINE CONDITION GOOD REPAIR OR REPLACE LOOK FOR A SHORTED CONDITION IN A CO...

Page 32: ...to ask questions during the troubleshooting process When evaluating the problem asking some of these questions may help identify the problem quicker What is the generator supposed to do What fault Alarm is shutting the generator down Is the fault a symptom of another problem Does the generator have the same fault consistently When does the fault occur Why would this happen How would this happen Wh...

Page 33: ...the MANUAL position 16 Once the engine reaches rated speed measure and record the voltage 17 Set the AUTO OFF MANUAL switch to the OFF position BATTERY FUSE MALE SPADE TERMINALS BLACK WIRE TO BRUSHES RED WIRE TO BRUSHES INSULATED INSULATED 5 AMP FUSE Figure 20 Jumper Wires Connected STATOR C1 BLUE WHITE BLUE GREEN 1 2 3 4 Figure 21 C1 Test Points 18 Remove the jumper wire that was connected in Ste...

Page 34: ...unction to provide an electrical connection for excitation current from the stationary components to the rotating rotor Made of a special long lasting material brushes seldom wear out or fail However slip rings can develop a tarnish or film that can inhibit or offer a resistance to the flow of current Such a non conducting film usually develops during non operating periods Broken or disconnected w...

Page 35: ...ons Table 4 Test Points Resistance Tests Test Point A Test Point B Stator Lead Blue Wire Stator Lead Black Wire Stator Lead Blue Wire C1 Pin 3 White Wire Stator Lead Blue Wire C1 Pin 4 Green Wire Test Windings for a Short to Ground 6 Make sure all stator leads are isolated from each other and are not touching the frame 7 Measure and record the resistance values for each set of windings between the...

Page 36: ...ng High and dangerous voltages will be present at the test terminals Connect meter test clamps to the high voltage terminals while the generator is shut down Stay clear of power terminals during the test Make sure meter clamps are securely attached and will not shake loose Procedure 1 With the engine shut down connect the AC voltmeter test leads across the Blue and Black Wire terminals of the gene...

Page 37: ...hten the governor lever clamp bolt to 70 inch pounds 8 N m 3 Start the generator let it stabilize and warm up at no load 4 Connect a frequency meter across the generators AC output leads 5 Turn the adjust nut to obtain a frequency reading of 62 5 Hz Figure 23 Engine Governor Adjustment Points TEST 14 ADJUST VOLTAGE REGULATOR Procedure 1 Remove two screws holding down the voltage regulator AVR 2 Le...

Page 38: ...e generator AC output frequency and voltage to be good at no load but they may drop excessively when electrical loads are applied This condition in which voltage and frequency drop excessively when loads are applied can be caused by a overloading the generator b loss of engine power or c a shorted condition in the stator windings or in one or more connected loads Procedure 1 Connect an accurate AC...

Page 39: ...enerator Transfers to Standby During Exercise or in Manual Mode 41 Problem 12 Blown F1 or F2 Fuse 42 Problem 13 Blown T1 Fuse 42 Problem 14 Unit Starts and Transfer Occurs When Utility Power is On 42 Section 3 4 Diagnostic Tests 43 Introduction 43 Safety 43 Transfer Switch Troubleshooting 43 Test 27 Check Generator Voltage at Transfer Switch 43 Test 28 Test Transfer Operator 43 Test 29 Check 15B 1...

Page 40: ... be connected to a Neutral Lug and is not to be switched Internal Components Three components make up the operator the servomotor Limit Switch 1 LS1 and Limit Switch 2 LS2 The servomotor is responsible for changing the position of the breakers inside the switch Both limit switches are responsible for interrupting current flow to the servomotor once the transfer cycle is complete Figure 26 EZ Trans...

Page 41: ...eting a path for current to flow to the servo motor The servo motor will operate till LS2 is mechanically opened interrupting the current flow to the servo motor TRANSFER TO UTILITY With the Generator running and Utility restored the circuit maybe described as Battery voltage is available to B and B from the generator The return to utility timer has expired and the ground has been removed from the...

Page 42: ...NOTES PART 3 TRANSFER SWITCH Page 40 ...

Page 43: ...n Loss of Utility Occurs Generator Shuts Down When Utility Returns But There Is No Retransfer To Utility Power OR Generator Transfers to Standby During Excercise or in Manual Mode REPAIR OR REPLACE AS NEEDED RE TEST GOOD GOOD BAD BAD TEST 28 TEST TRANSFER OPERATOR TEST 30 CHECK WIRE 23 CIRCUIT REPLACE TRANSFER OPERATOR BAD REPLACE TRANSFER OPERATOR REPLACE CONTROLLER GOOD GOOD FIND CAUSE OF NO AC ...

Page 44: ... TESTING Problem 13 Blown T1 Fuse REPLACE CONTROLLER CORRECT UTILITY SOURCE VOLTAGE REPLACE GO TO PROBLEM 7 REPAIR OR REPLACE WIRING REPAIR OR REPLACE WIRE N1A N2A BETWEEN N1 N2 LUGS AND FUSE HOLDER REPAIR N1 N2 OPEN WIRING BETWEEN TRANSFER SWITCH AND GENERATOR Problem 14 Unit Starts and Transfer Occurs When Utility Power Is On TEST 41 CHECK UTILITY SENSING VOLTAGE AT CONTROLLER TEST 38 CHECK N1 N...

Page 45: ...g the troubleshooting process When evaluating the problem asking some of these questions may help identify the problem quicker What is the transfer switch doing What was the transfer switch supposed to do Does the transfer switch have the same fault consistently and when does it occur Who is controlling it Exactly what is occurring When is it happening Why would this happen How would this happen W...

Page 46: ...stomer connection block b If the VOM indicate INFINITY replace controller 8 Set VOM to measure DC voltage 9 Set the AUTO OFF MANUAL switch to the AUTO position and simulate a Utility Failure 10 Once the generator has started and warmed up connect one meter test lead to the XFER terminal and the other meter test lead to the BAT terminal in the transfer switch Measure and record the voltage a If the...

Page 47: ...INFINITY should be measured Results If a short is indicated in Step 6 or Step 7 repair wiring and re test TEST 35 CHECK FUSE F3 Discussion Connected in series with Load Wire T1 F3 provides 120 VAC to the generator to operate the battery charger A blown fuse will result in a possible dead battery situation Procedure 1 On the generator panel set the AUTO OFF MANUAL switch to the OFF position 2 Disco...

Page 48: ... Utility source Procedure With utility source voltage available to terminal lugs N1 and N2 use a VOM to test for utility source line to line voltage across terminal locations N1 and N2 terminals Normal line to line utility source voltage should be indicated T1 N2 N1 Figure 31 Transfer Switch Fuse Block Results 1 If voltage reading across the N1 and N2 terminals is zero or low refer to Flow Chart 2...

Page 49: ...ng connector Connect the other meter test lead to Wire N2 Approximately 240 VAC should be measured Results 1 If voltage was measured in Step 4 and the pin connections are good replace the circuit board 2 If voltage was NOT measured in Step 4 repair or replace Wire N1 N2 between connector and terminal block Section 3 4 Diagnostic Tests ...

Page 50: ...Page 48 NOTES PART 3 TRANSFER SWITCH ...

Page 51: ...ngine DC Troubleshooting 62 Test 52 Check Position Of Auto Off Manual Switch 62 Test 53 Try a Manual Start 63 Test 54 Test Auto Operations 63 Test 55 Check 7 5 Amp Fuse 63 Test 56 Check Battery 63 Test 57 Check Wire 56 Voltage 65 Test 58 Test Starter Contactor 65 Test 59 Test Starter Motor 66 Test 60 Check Fuel Supply and Pressure 67 Test 61 Check Circuit Board Wire 14 Output 68 Test 62 Check Fuel...

Page 52: ...ts and exercises the generator once every seven days Provides automatic engine shutdown in the event of low oil pressure high oil temperature overspeed no RPM sense overcrank or low battery An 18 pin and a 4 pin connector are used to interconnect the controller with the various circuits of the DC systems Connector pin numbers associated wires and circuit functions are listed in the CHART on the ne...

Page 53: ... the battery from the battery charger Provides 12 VDC to the Transfer Relay J2 9 NOT USED J2 10 0 Common Ground J2 11 56 12 VDC output to starter contactor and the choke solenoid J2 15 Used to operate the choke solenoid and is active during cranking only J2 16 NOT USED J2 17 NOT USED J2 18 NOT USED Wired Plug 1 N1 240 VAC sensing for controller Wired Plug 2 N2 240 VAC sensing for controller 6 7 kW...

Page 54: ... from supplying an output that could potentially damage appliances connected to the generator circuit RPM Sensor Loss Shutdown Alarm During cranking if the controller does not see a valid RPM signal within three 3 seconds it will shut down and lock out on RPM sensor loss While engine is running if RPM signal is lost for two 2 seconds the controller will shut the engine down wait 15 seconds then re...

Page 55: ...ENGINE DC CONTROL PART 4 Page 53 NOTES ...

Page 56: ...XCITATION 5 VDC PCB GROUND CONTROL RED WHT C1 IC IC INPUT UTILITY 240 VAC TRANSFER BATTERY GROUND 56 0 15B 23 23 0 0 BLK 0 56 RED FS 16 13 SC 0 86 85 HTO LOP 18 WHT WHT CB 15B 14 BLK RED BLK 12V BATTERY SC 0 CS IM SP 2 1 N2 N1 18 13 86 85 4 3 2 1 J1 CONTROLLER J2 18 17 16 15 14 13 12 10 9 11 8 6 7 4 3 5 SM GROUND NEUTRAL STATOR WHT BLK WHT BLU WHT GRN BLU BLU BLK BA RED BC RED WIRE BLK WIRE 0 0 0 ...

Page 57: ...90 90 N1 N2 T1 RED WHT RED BLK YLW YLW AVR UTILITY FAILURE AND ENGINE CRANKING When the utility sensing voltage drops out the controller will start a 10 second timer If the voltage does not return fully of is below 60 percent of normal the generator will start to crank The controller action delivers 12 VDC to the starter contactor via wire 56 When the starter contactor energizes it delivers batter...

Page 58: ... BRUSH ASSEMBLY AWG SIZE 12 SHOWN OTHERWISE 300V UL LISTED UNLESS NOTE ALL WIRES 18 AWG 90 90 N1 N2 T1 RED WHT RED BLK YLW YLW AVR UTILITY FAILURE AND ENGINE RUNNING The generator is running the controller s engine warm up timer is timing out and the generator is producing AC voltage 12 VDC is delivered to the actuator motor in the EZ Transfer Operator via wire 15B This 12 VDC circuit is completed...

Page 59: ...y checked to eliminate it as the cause of starting difficulty It is a good practice to check the engine for freedom of rotation by removing the spark plugs and turning the crankshaft over slowly by hand to be sure it rotates freely WARNING DO NOT ROTATE ENGINE WITH ELECTRIC STARTER WITH SPARK PLUGS REMOVED ARCING AT THE PLUG ENDS MAY IGNITE THE LP OR NG VAPOR EXITING THE SPARK PLUG HOLE TEST 56 CH...

Page 60: ... 67 CHECK IGNITION MAGNETO TEST 79 CHECK SHUTDOWN WIRE TEST 70 CHECK AND ADJUST VALVES TEST 65 CHECK SPARK PLUGS TEST 66 CHECK ENGINE COMPRESSION TEST 62 CHECK FUEL SOLENOID TEST 61 CHECK CONTROLLER WIRE 14 OUTPUT GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD BAD BAD BAD BAD BAD BAD BAD BAD BAD ADJUST OR REPLACE REPAIR OR REPLACE SHORTED WIRE 18 OR CONTROLLER CHECK FLYWHEEL KEY FIND AND CORREC...

Page 61: ... Starts Hard and Runs Rough Lacks Power Backfires CHECK FLYWHEEL KEY BAD REPLACE CHOKE SOLENOID TEST 60 CHECK FUEL SUPPLY AND PRESSURE IF RECONFIGURED TO LP GAS VERIFY THAT PROPER PROCEDURE WAS FOLLOWED REFER TO SECTION 1 3 TEST 64 CHECK FOR IGNITION SPARK TEST 67 CHECK IGNITION MAGNETOS TEST 70 CHECK AND ADJUST VALVES TEST 65 CHECK SPARK PLUGS TEST 66 CHECK ENGINE COMPRESSION TEST 63 CHECK CHOKE ...

Page 62: ... 13 CHECK AND ADJUST ENGINE GOVERNOR TEST 71 CHECK WIRE 18 CONTINUITY TEST 12 CHECK AC OUTPUT FREQUENCY BAD Problem 24 Shutdown Alarm Fault Occurred TEST 68 CHECK OIL PRESSURE SWITCH AND WIRE 86 TEST 69 CHECK HIGH OIL TEMPERATURE SWITCH CHECK FAULT LIGHTS LOW OIL LOW BATTERY HIGH TEMP OVERSPEED NO RPM SENSE OVERCRANK TEST 64 CHECK FOR IGNITION SPARK TEST 67 CHECK IGNITION MAGNETO TEST 79 CHECK SHU...

Page 63: ...NKING AND RUNNING CIRCUITS Problem 26 Generator Will Not Exercise TEST 72 TEST EXERCISE FUNCTION REPLACE PRINTED CONTROLLER REPAIR OR REPLACE REPLACE CHARGER Problem 27 No Battery Charge TEST 76 CHECK BATTERY CHARGER SUPPLY VOLTAGE TEST 77 CHECK BATTERY CHARGER OUTPUT VOLTAGE TEST 78 CHECK WIRE 0 15B GOOD GOOD BAD REPAIR OR REPLACE BAD BAD NO BATTERY SUPPLY VOLTAGE ...

Page 64: ... voltages are present that can kill or cause serious injury Gaseous fuels are highly explosive and can ignite by the slightest spark Engine exhaust gases contain deadly carbon monoxide gas that can cause unconsciousness or even death Contact with moving parts can cause serious injury The list of hazards is seemingly endless When working on this equipment use common sense and remain alert at all ti...

Page 65: ...oblem 21 in Section 4 4 TEST 54 TEST AUTO OPERATIONS Discussion Initial Conditions The generator is in AUTO ready to run and load is being supplied by the utility source When utility fails below 65 of nominal a 10 second optionally programmable line interrupt delay time is started If the utility is still gone when the timer expires the engine will crank and start Once started a five 5 second engin...

Page 66: ...ry Load Tester C Test Battery State of Charge Non Maintenance Free Battery 1 Use an automotive type battery hydrometer to test battery state of charge 2 Follow the hydrometer manufacturer s instructions carefully Read the specific gravity of the electrolyte fluid in all battery cells 3 If cells are low distilled water can be added to refill cell compartment 4 If the hydrometer does not have a perc...

Page 67: ... starter contactor Connect one meter test lead to disconnected Wire 56 Remove the J2 Connector from the controller Connect the other test lead to J2 11 Wire 56 CONTINUITY should be measured If CONTINUITY is not measured repair or replace Wire 56 Results 1 If battery voltage is indicated in Step 3 refer back to flow chart TEST 58 TEST STARTER CONTACTOR Discussion The starter contactor SC must energ...

Page 68: ...jumper wire connected to the starter Connect the common test lead to the starter motor frame Set the AUTO OFF MANUAL Switch to its MANUAL position and observe the meter Meter should indicate battery voltage starter motor should operate and engine should crank Results 1 If battery voltage is indicated on the meter but starter motor did NOT operate remove and bench test the starter motor see followi...

Page 69: ...s shown in Figure 46 Note The starter motor will activate immediately once the cables are connected 3 With the starter motor activated jump the terminal on the starter contactor to battery voltage note the reading on the clamp on ammeter and on the tachometer rpm STARTER MOTOR TACHOMETER 12 VOLT BATTERY CLAMP ON AMP METER VISE Figure 46 Testing Starter Motor Performance Note Take the reading after...

Page 70: ...regulator is usually the responsibility of the fuel supplier or the fuel supply system installer PORT 1 PORT 2 Figure 47 Gas Pressure Test point Results 1 If fuel supply and pressure are adequate but engine will not start refer back to flow chart 2 If generator starts but runs rough or lacks power repeat the above procedure with the generator running and under load The fuel system must be able to ...

Page 71: ...t a VOM to measure DC voltage 6 Connect the positive test lead to Wire 56 Pin 1 of the connector going to the controller Female Side Connect the negative test lead to Wire 90 Pin 2 7 Set the AUTO OFF MANUAL Switch to MANUAL While cranking battery voltage should be measured If battery voltage was not measured verify continuity of Wire 90 between the Choke Solenoid Connector and J2 15 Wire 90 at the...

Page 72: ...may change ignition timing but sparking will still occur across the spark tester gap Results 1 If no spark or very weak spark occurs go to Test 79 2 If sparking occurs but engine still won t start go to Test 65 3 When checking for engine miss if sparking occurs at regular intervals but engine miss continues go to Test 57 4 When checking for engine miss if a spark miss is readily apparent go to Tes...

Page 73: ... TDC the results of the test may be inaccurate at diagnosing a problem INLET GUAGE PRESSURE SET POINT RED RANGE INDICATES UNACCEPTABLE LEAKAGE GREEN RANGE INDICATES ACCEPTABLE LEAKAGE NEEDLE INDICATES MINIMAL AIR LEAKAGE AIR PRESSURE REGULATOR REGULATOR ADJUSTMENT KNOB COMPRESSED AIR IN OUTLET GUAGE PRESSURE TO SPARK PLUG HOLE OUTLET GUAGE 0 0 0 Figure 55 Cylinder Leakdown Tester 4 Lock the flywhe...

Page 74: ... circuit that controls ignition timing Timing is fixed air gap is non adjustable and spark advance is automatic Major components of the ignition system include a the ignition coil assembly b the spark plug and c the engine flywheel Solid state components encapsulated in the ignition coil are not accessible and cannot be serviced If the coil is defective the entire assembly must be replaced The air...

Page 75: ... lead to Wire 0 disconnected from LOP Connect the other test lead to a clean frame ground CONTINUITY should be measured If CONTINUITY is NOT measured repair or replace Wire 0 between the LOP and the ground terminal connection on the engine mount 6 If the LOP switch tests good in Step 5 and oil pressure is good in Step 4 but the unit still shuts down with a LOP fault check Wire 86 for a short to gr...

Page 76: ... is at Top Dead Center TDC of its compression stroke both valves closed To get the piston at TDC remove the intake screen at the top of the engine to gain access to the flywheel nut Use a large socket and socket wrench to rotate the nut and hence the engine in a clockwise direction While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it...

Page 77: ...each week If the unit does not start replace the controller Results 1 In all models if the unit starts in MANUAL but fails to exercise without any ALARMS present replace the controller TEST 73 TEST CRANKING AND RUNNING CIRCUITS Discussion This test will check all of the circuits that are Hot with battery voltage and which could cause the Main Fuse to blow Refer to Table 8 throughout the procedure ...

Page 78: ...stance for the component a short to ground exists on Wire 14 Repair and replace Wire 14 as needed TEST 75 TEST CRANK CIRCUIT Discussion Wire 56 provides 12 VDC during cranking only If the VOM indicated CONTINUITY in the previous test one of the possible causes could be a faulty relay or solenoid Procedure 1 Set a Volt Ohm Milliammeter VOM to measure resistance 2 Disconnect Wire 56 from the starter...

Page 79: ...roceed to Step 4 4 Remove Wire 0 and Wire 15B from generator terminal strip locations E and F 5 Wait five 5 minutes after removing wires 6 Measure across points E and F on the terminal strip 12 VDC should be measured a If 12 VDC is measured proceed to Step 8 b If 12 VDC is not measured proceed to Step 7 7 Measure across point H and ground lug 12 VDC should be measured a If 12 VDC is measured repai...

Page 80: ...k for a short to ground Remove the J1 Connector from the circuit board 4 Set a VOM to measure resistance Connect one test lead to Wire 18 disconnected in Step 1 Connect the other test lead to a clean frame ground INFINITY should be measured 5 Reconnect the J1 Connector to the controller Results 1 If INFINITY was not measured in Step 4 repair or replace shorted ground Wire 18 between the J1 Connect...

Page 81: ...sts Page 79 GENERATOR CUSTOMER E1 E2 CONNECTION N2 N1 E1 E2 8 CIRCUIT TRANSFER SWITCH T1 N2 N1 E1 E2 0 N1 N2 T1 194 23 194 15B 0 23 N2 N1 T1 50A 2 POLE CIRCUIT BREAKER HOUSE MAIN SERVICE 100A OR 200A C A B F D E Figure 62 Test 76 77 and 78 Test Points ...

Page 82: ...Page 80 PART 4 ENGINE DC CONTROL NOTES ...

Page 83: ...PART 5 DISASSEMBLY Page 81 PART 5 Disassembly 81 Section 5 1 Major Disassembly 82 Section 5 2 Exploded Views 90 ...

Page 84: ...ues Stator Bolts 6 ft lbs Rotor Bolt 30 ft lbs 1 Remove lid from the top of the enclosure Figure 63 2 Remove the three removable sides of the enclosure Refer to Figure 64 for the side that will remain during the disassembly Figure 64 3 Disconnect and remove the battery 4 Using a 10mm socket remove the front two enclosures braces Figure 65 5 Using an 8mm socket and a 10mm socket remove the three bo...

Page 85: ...lding the exhaust housing from the engine support and base Refer to Figure 68 and 69 Figure 68 Figure 69 7 Using a 10mm socket remove the remaining exhaust enclosure pieces on each side Figure 70 Figure 71 8 Disconnect the red and black brush wires Figure 72 Section 5 1 Major Disassembly ...

Page 86: ... Disconnect the voltage regulator Figure 73 10 Disconnect the ground and neutral connections Figure 74 11 Using an 8mm socket remove the two bolts supporting the muffler Figure 75 Figure 76 12 Disconnect the fuel supply hose from the air box assembly Figure 77 ...

Page 87: ...emaining bolt Figure 79 15 Using a 10mm socket remove the two bolts connecting support to the base Figure 80 16 Carefully slide out the support structure from the base and position assembly horizontally Figure 81 17 Using a 13mm wrench remove the rotor bolt from the alternator Section 5 1 Major Disassembly ...

Page 88: ...e 86 Section 5 1 Major Disassembly Figure 82 Figure 83 18 Install a harmonic balancer or steering wheel puller onto the fan assembly Figure 84 Figure 85 Figure 86 19 Using a 13mm socket remove the four stator bolts Figure 87 ...

Page 89: ...m socket Figure 88 21 Slide the stator assembly off the rotor Figure 89 Warning Do not cut the rotor bolt unless you have a replacement rotor bolt 22 Rotor Removal Cut 2 5 inches from the rotor bolt Slot the end of the bolt to suit a flat blade screwdriver Slide the rotor bolt back through the rotor and use a screwdriver to screw it into the crankshaft Use a 55mm M6 x1 00 bolt to screw into rotor ...

Page 90: ...PART 5 DISASSEMBLY Page 88 Section 5 1 Major Disassembly Figure 93 23 For engine replacement remove the four bolts connecting the engine cradle to the engine casting ...

Page 91: ...Page 89 NOTES DISASSEMBLY PART 5 ...

Page 92: ...Page 90 PART 5 DISASSEMBLY Section 5 2 Exploded Views Control Panel ...

Page 93: ...16 1 PLATE DEAD FRONT CUST CONNECT 17 1 WASHER LOCK EXT 10 STL 18 1 SCREW HHTT M5 0 8 x 10 BP ITEM QTY DESCRIPTION 19 1 EYE HASP CNTRL PNL 2008 HSB 20 1 SCREW PPPH 10 X 1 2 LG 21 1 CB 0030A 2P 240V 5 BQ2 LB 22 2 SCREW HHC M5 0 8 X 12 C8 8 23 1 BRKT CB MTG BACK 24 2 GROUND BAR 5 4 14 AWG CONN 25 4 SCREW HHC Ml1 0 7 X 25 SEMS 26 2 NUT HEX M6 1 0 G8 CLEAR ZINC 27 2 WASHER LOCK M6 1 4 28 4 SCREW PPHM ...

Page 94: ...Page 92 EV Powerhead Corepower PART 5 DISASSEMBLY Section 5 2 Exploded Views ...

Page 95: ...ZP 22 2 SCREW HHTT M8 1 2 X16 YC 23 1 MUFFLER ECONOMY HSB 24 2 SCREW SHC 5118 18 X3 4 ITEM QTY DESCRIPTION 25 1 EXHAUST GASKET 26 13 SCREW HHTT M6 1 0 X10 VEL CHR 27 1 EXHAUST SHIELD ALTERNATOR 28 4 VlB MNT 1 3axl 0X5116 18 MXM 29 1 WASHER LOCK SPECIAL 5116 30 1 FRAME WELDMENT 31 2 SCREW HHTT M6 1 0 X20 ZINC 32 4 SCREW HHFC M6 1 0X 12 G8 8 33 1 EXHAUST SHIELD RIGHT SIDE 34 1 EXHAUST SHIELD MUFFLER...

Page 96: ...Page 94 Enclosure PART 5 DISASSEMBLY Section 5 2 Exploded Views ...

Page 97: ...TOR 7KWVERT HSB 13 1 HOSE REGULATOR VENT 14 2 CLAMP HOSE BAND 66 ITEM QTY DESCRIPTION 15 1 ASSY SNAP BARB W SCREEN 16 1 GROMMET 38 1 CROSS SLIT W HOLE 17 1 ASSY BACK PANEL 18 4 WASHER FLAT1 4 M6 19 4 WASHER LOCK M6 1I4 20 4 SCREW BHSC M6 1 0X16ZP 21 1 GASKET AIRBOX PANELIROOF 22 1 GASKET BLOWER HOUSING 23 1 GASKET ENGINE AIR IN BACK 24 1 GASKET ENGINE AIR IN FRONT 25 2 SCREW HHTI M6 1 0X12 ZINC 26...

Page 98: ...Page 96 Engine A B Date 4 5 2011 Revision C Page 1 of 4 GROUP EV Exploded View EV LV432 ENGINE Drawing No 0J0194 PART 5 DISASSEMBLY Section 5 2 Exploded Views ...

Page 99: ...15 1 CRANKCASE UPPER 16 1 STARTER 17 2 BOLT FLANGE M8X80 18 1 NUT FLANGE M6 19 1 BOLT GOVERNOR ARM 20 1 ARM GOVERNOR 21 1 PIN LOCK 22 1 SEAL OlL 23 1 WASHER 24 1 SHAFT GOVERNOR ARM 25 2 BEARING EDDP GROOVE BALL 26 1 O RING 12X2 5 27 1 BEARING EDDP GROOVE BALL 28 3 BOLT FLANGE 6X12 29 1 CAP BREATHER CHAMBER 30 1 GASKET BREATHER CHAMBER 31 1 OIL SEAL 32 1 VALVE REED 33 1 CAP ASSY NOISE SUPRESS DISAS...

Page 100: ...Page 98 Air Fuel System PART 5 DISASSEMBLY Section 5 2 Exploded Views ...

Page 101: ...TING ROD 432CC 23 2 NUT FLANGE M6 1 0 NYLOK 24 2 CLAMP HOSE BAND 75 ITEM QTY DESCRIPTION 25 1 8FT LPG HOSE ASSEMBLY 26 1 NUT HEX LOCK M3 0 5 NY INS 27 1 BALL STUD 10 MM 28 1 ASSY THROTTLE ROD 29 1 GASKET INTAKE 432CC OHV 30 1 ASSY THROTTLE BODY 432CC OHV 31 1 GASKET INTAKE 432CC OHV 32 1 HOSE 3 18ID SAE J30R7 METRIC 33 1 SPRING GOV ANTI LASH 34 1 SCREW HHFC M6 1 0 X12 G8 8 35 1 TIE WRAP BEADED REL...

Page 102: ...Page 100 PART 5 DISASSEMBLY NOTES ...

Page 103: ...PART 6 ELECTRICAL DATA Page 101 PART 6 Electrical Data 101 Wiring Diagram 102 Electrical Schematic 103 Electrical Formulas 104 ...

Page 104: ...Section 6 Page 102 Wiring Diagram Drawing 0H7182 C ELECTRICAL DATA PART 6 ...

Page 105: ...Section 6 Page 103 Electrical Schematic Drawing 0H7182 C ELECTRICAL DATA PART 6 ...

Page 106: ...s Power Factor Volts x Amps NO OF ROTOR POLES Frequency RPM 2 x 60 x Frequency RPM FREQUENCY RPM No of Rotor Poles RPM x Poles 2 x 60 RPM Frequency No of Rotor Poles 2 x 60 x Frequency Rotor Poles kW required for Motor Motor Horsepower Efficiency HP x 0 746 Efficiency RESISTANCE Volts Amperes E I VOLTS Ohm Amperes I x R AMPERES Ohms Volts E R E VOLTS I AMPERES R RESISTANCE OHMS PF POWER FACTOR ...

Page 107: ...APPENDIX A SUPPLEMENTAL WORKSHEETS Page 105 Appendix A Supplemental Worksheets 105 ...

Page 108: ... VDC Blue to Blue Voltage VAC White and Blue Voltage VAC Static Rotor Amp Draw Amps Running Rotor Amp Draw Amps Column Identified Test 4 Results Serial _________________________ Test Point Results Rotor Resistance Ohms Battery Voltage VDC Blue to Blue Voltage VAC White and Blue Voltage VAC Static Rotor Amp Draw Amps Running Rotor Amp Draw Amps Column Identified Test 4 Results Serial ______________...

Page 109: ... Black Wire Ground C1 Pin 1 Wire 44 Blue Wire Ground C1 Pin 4 Green Wire Ground Shorted Condition C1 Pin 1 Blue Wire Stator Lead Blue Wire Test 9 Stator Results Serial _______________________ Test Point A Test Point B Results Resistance Tests Stator Lead Blue Wire Stator Lead Black Wire Stator Lead Blue Wire C1 Pin 3 White Wire Stator Lead Blue Wire C1 Pin 4 Green Wire Shorts to Ground Stator Lead...

Page 110: ...lts Serial _________________________ Test Point Pin Location Circuit Result 1 J2 Pin 4 Wire 14 2 J2 Pin 11 Wire 56 3 J2 Pin 8 Wire 15B Test 73 Results Serial _________________________ Test Point Pin Location Circuit Result 1 J2 Pin 4 Wire 14 2 J2 Pin 11 Wire 56 3 J2 Pin 8 Wire 15B Test 73 Results Serial _________________________ Test Point Pin Location Circuit Result 1 J2 Pin 4 Wire 14 2 J2 Pin 11...

Page 111: ...APPENDIX B INDEX OF FIGURES AND TABLES Page 109 Appendix B Index of Figures and Tables 109 Index of Figures 110 Index of Tables 111 ...

Page 112: ...Figure 38 64 Figure Page Figure 39 64 Figure 40 65 Figure 41 66 Figure 42 66 Figure 43 67 Figure 44 67 Figure 45 67 Figure 46 67 Figure 47 68 Figure 48 69 Figure 49 69 Figure 50 70 Figure 51 70 Figure 52 70 Figure 53 70 Figure 54 71 Figure 55 71 Figure 56 72 Figure 57 73 Figure Page Figure 58 74 Figure 59 74 Figure 60 75 Figure 61 77 Figure 62 79 Figure 63 82 Figure 64 82 Figure 65 82 Figure 66 82...

Page 113: ... Index of Tables INDEX OF FIGURES AND TABLES APPENDIX B Table Page Table 1 21 Table 2 31 Table 3 32 Table Page Table 4 33 Table 5 33 Table 6 33 Table Page Table 7 33 Table 8 75 Table 9 75 Table Page Table 10 76 ...

Page 114: ...Page 112 NOTES ...

Page 115: ......

Page 116: ...AC 1 888 436 3722 generac com Part No 0H9174 Printed in USA Rev B 07 14 11 2011 Generac Power Systems Inc All rights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Power Systems Inc ...