Generac Power Systems GP Series Diagnostic And Repair Manual
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Generac Power Systems GP Series Diagnostic And Repair Manual

Portable generators
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DIAGNOSTIC
DIAGNOSTIC
REPAIR
REPAIR
MANUAL
MANUAL
GP Series and UltraSource
GP Series and UltraSource
Portable Generators
Portable Generators
P O R T A B L E G E N E R AT O R S
P O R T A B L E G E N E R AT O R S
MODELS:
MODELS:
Model 4451, 4986 (12.5 kW)
Model 4451, 4986 (12.5 kW)
5734, 4582, 4987 (15 kW)
5734, 4582, 4987 (15 kW)
5735, 4583, 5308 (17.5 kW)
5735, 4583, 5308 (17.5 kW)
®
®

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Summary of Contents for Generac Power Systems GP Series

  • Page 1 ® ® DIAGNOSTIC DIAGNOSTIC REPAIR REPAIR MANUAL MANUAL GP Series and UltraSource GP Series and UltraSource Portable Generators Portable Generators MODELS: MODELS: Model 4451, 4986 (12.5 kW) Model 4451, 4986 (12.5 kW) 5734, 4582, 4987 (15 kW) 5734, 4582, 4987 (15 kW) 5735, 4583, 5308 (17.5 kW)

  • Page 2: Read This Manual Thoroughly

    Safety Read This Manual Thoroughly Throughout this publication and on tags and decals This diagnostic manual has been written and published affixed to the generator, DANGER, WARNING, and by Generac to aid dealer technicians and company CAUTION blocks are used to alert personnel to special service personnel when servicing the products described instructions about a particular operation that may be herein.

  • Page 3: Table Of Contents

    Table of Contents Safety ................ii Section 3 Troubleshooting Flowcharts ....27 Read This Manual Thoroughly ........ii Introduction ...............27 Replacement Parts ............. ii Section 4 AC Diagnostic Tests .........35 Section 1 Description and Components ....1 Introduction ...............35 Introduction ..............1 Safety ...............35 Engine-Generator Drive System .........1 Important Note Concerning Connectors ....35 The AC Generator ............1...
  • Page 4 Table of Contents Test 43 - Check Start Stop Relay (SSR) ....58 Section 6 Electrical Data ...........75 Test 44 – Test Starter Contactor Relay (SCR) ..59 Introduction ...............75 Wiring Diagram 12.5 & 15 kW Test 45 – Check Wire 15 Circuit .......59 (Units Without Hourmeter) –...

  • Page 5: Section 1 Description And Components

    Description and Components Section 1 Introduction Engine-Generator Drive System The generator revolving field (rotor) is driven by an air- Figure 1-1. The generator revolving field is driven by cooled engine at 3600 rpm. air-cooled, horizontal crankshaft engine. The generator is directly coupled to the engine crankshaft. The generator may be used to supply electrical power for Both the engine and generator rotor are driven at the operation of 120 and, or 240 volts, single-phase, 60...

  • Page 6: Brush Holder And Brushes

    Section 1 Description and Components Other AC Generator Components Some AC generator components are housed in the generator control panel enclosure. These are the excitation circuit breaker, the voltage regulator, and the main line circuit breaker. Excitation Circuit Breaker Figure 1-4.

  • Page 7: Adjustment Procedure (12.5 Kw And Older 15 Kw Units)

    Section 1 Description and Components Turn the regulator voltage adjust pot clockwise to obtain a line to line voltage of 238-242 VAC. NOTE: If the red regulator LED is flashing, slowly turn the Stability pot either direction until flashing stops. Adjustment Procedure (Newer 15 kW and All 17.5 kW Units) A single red lamp (LED) illuminates during normal...

  • Page 8: Operation

    Section 1 Description and Components Operation The AC power winding voltage initially sensed by the regulator is low. The regulator reacts by increasing the Startup flow of field excitation current to the rotor until voltage increases to a desired level. The regulator then monitors When the engine is started, residual plus field boost and maintains the desired voltage.

  • Page 9: Specifications

    Section 1 Description and Components Specifications GPS 15000 GPS 12500 GPS 17500 MODEL Ultra Source/Guardian/ Ultra Source/Centurion Ultra Source/Guardian Centurion 004582 004583 004451 004987 Model # 005308 004986 005209 005735 005734 GENERATOR SPECIFICATIONS Rated Max. Power 12.5 kW 15.0 kW 17.5 kW Surge Power 18.75 kW...
  • Page 10 Section 1 Description and Components TORQUE SPECIFICATIONS Flywheel Nut 150 ft-lbs Cylinder Head Bolts 22 ft-lbs Valve Cover Bolts 4.8-5.5 ft-lbs Rocker Arm Jam Nut 14 ft-lbs Ignition Coil 9 ft-lbs Intake Manifold 14 ft-lbs Exhaust Manifold 14 ft-lbs Stator Bolts 6 ft-lbs Rotor Bolt 30 ft-lbs...

  • Page 11: Section 2 Engine Dc Control System

    Engine DC Control System Section 2 Printed Circuit Board Table 2-1. Receptacle J2 Functions General Theory Terminal Wire Function The printed circuit board is responsible for cranking, startup, running shutdown operations. 12 VDC input when the start stop relay interconnects with other components of the DC control (SSR) is energized.

  • Page 12: Control Panel Component Identification

    Section 2 Engine DC Control System Control Panel Component Identification 004572 Figure 2-2. Control Panel Component Identification (Older Units) A. Voltage Regulator I. 10 Amp Auto Reset Breaker (CB1) B. 10 Amp Fuse (F1) J. Connector (C2) C. 50 Amp Circuit Breaker K.
  • Page 13 Section 2 Engine DC Control System 44S OLDER NEWER 44S OLDER NEWER LOCATION LOCATION LOCATION C1 FEMALE SIDE C1 MALE SIDE LOCATION LOCATION LOCATION LOCATION LOCATION LOCATION C2 FEMALE SIDE C2 MALE SIDE LOCATION LOCATION LOCATION OLDER NEWER TERMINAL BLOCK TERMINAL BLOCK (TB2) (TB1)

  • Page 14: Operational Analysis (Older Units)

    Section 2 Engine DC Control System Operational Analysis (Older Units) Circuit Condition - Rest Battery voltage is supplied to components of the control system from the unit battery via the red battery cable connected to the contacts of the starter contactor (SC), wire 13, a 10 Amp fuse (F1), and wire 15. Wire 13 is unfused battery supply voltage and is connected to the contacts of the starter contactor relay (SCR).
  • Page 15 Section 2 Engine DC Control System Wire 15 is 12 VDC fused battery supply voltage supplied Wire 18 connects to the ignition magnetos and to the to the normally open contacts of the SSR. One set of normally closed contacts of the SSR. The normally normally open contacts are connected to wire 15B, the closed contacts are also connected to wire 0.

  • Page 16: Circuit Condition - Start

    Section 2 Engine DC Control System Circuit Condition - Start With the start-run-stop switch (SW1) held in the START position, wire 17 is internally closed to ground via wire 0. By grounding wire 17, current is allowed to flow through the SCR and energize the SCR coil. The SCR contacts internally close wire 13 to wire 16.
  • Page 17 Section 2 Engine DC Control System With the start-run-stop switch (SW1) held in the START position, wire 15 is connected to wire 167. Wire 15 supplies fused battery power via wire 167 to the printed circuit board. This 12 VDC input signals the printed circuit board to internally ground wire 229 which is connected to the coil of the start stop relay (SSR).

  • Page 18: Circuit Condition - Run

    Section 2 Engine DC Control System Circuit Condition - Run Once the engine has started, the start-run-stop switch (SW1) is released and returns to the run position. At his point SW1 is not activated. This action will de-energize the starter contactor relay (SCR) causing the starter motor to disengage.
  • Page 19 Section 2 Engine DC Control System The printed circuit board is supplied with AC voltage from wires 11S and 44S. This voltage, frequency signal is used by the printed circuit board for governor control operation. When the idle control switch (SW2) is activated to the ON position, wire 83 from the printed circuit board will be connected to wire 0 (frame ground).

  • Page 20: Circuit Condition - Stop

    Section 2 Engine DC Control System Circuit Condition - Stop With the start-run-stop switch (SW1) placed in the STOP position, wire 167 is connected to wire 0 (frame ground). The ground signal is supplied via wire 167 to the printed circuit board. The printed circuit board will internally open wire 229 from ground.

  • Page 21: Fault Shutdown

    Section 2 Engine DC Control System Fault Shutdown With the generator running, if the low oil pressure (LOP) closes, wire 86 will be connected to wire 0 (frame ground). Printed circuit board action will open wire 229 from ground; this action will de-energize the start stop relay (SSR). This action will cause a shutdown.

  • Page 22: Operational Analysis (Newer Units)

    Section 2 Engine DC Control System Operational Analysis (Newer Units) Circuit Condition - Rest Battery voltage is supplied to components of the control Wire 15 is 12 VDC fused battery supply voltage supplied system from the unit battery via the red battery cable to the normally open contacts of the SSR.
  • Page 23 Section 2 Engine DC Control System 004580 Diagnostic Repair Manual...

  • Page 24: Circuit Condition - Start

    Section 2 Engine DC Control System Circuit Condition - Start With the start-run-stop switch (SW1) held in the START position, wire 17 is internally closed to ground via wire 0. By grounding wire 17, current is allowed to flow through the SCR and energize the SCR coil.
  • Page 25 Section 2 Engine DC Control System 004581 Diagnostic Repair Manual...

  • Page 26: Circuit Condition - Run

    Section 2 Engine DC Control System Circuit Condition - Run Once the engine has started, the start-run-stop switch (SW1) is released and returns to the RUN position. At this point SW1 is not activated. This action will de- energize the starter contactor relay (SCR) causing the starter motor to disengage.
  • Page 27 Section 2 Engine DC Control System 004582 Diagnostic Repair Manual...

  • Page 28: Circuit Condition - Stop

    Section 2 Engine DC Control System Circuit Condition - Stop With the start-run-stop switch (SW1) placed in the STOP position, wire 167 is connected to wire 0 (frame ground). The ground signal is supplied via wire 167 to the printed circuit board.
  • Page 29 Section 2 Engine DC Control System 004583 Diagnostic Repair Manual...
  • Page 30 Section 2 Engine DC Control System This page intentionally left blank. Diagnostic Repair Manual...

  • Page 31: Section 3 Troubleshooting Flowcharts

    Troubleshooting Flowcharts Section 3 Introduction The most important step in troubleshooting is identifying Use the flow charts in conjunction with the detailed the actual problem. The next step is to determine the instructions in section 4. Test numbers used in the flow applicable flow chart to use to help diagnose the charts correspond to the numbered tests in section 4.
  • Page 32 Section 3 Troubleshooting Flowcharts Problem 2 – Generator Produces Zero Voltage or Residual Voltage (2-12 VAC) TEST 2 - CHECK TEST 3 - TEST GOOD -PROCEED GOOD MAIN CIRCUIT EXCITATION BAD -PROCEED, REPLACE AFTER TESTS BREAKER CIRCUIT BREAKER CONCLUDE RESET TO “ON”...
  • Page 33 Section 3 Troubleshooting Flowcharts Problem 2 – Generator Produces Zero Voltage or Residual Voltage (2-12 VAC) (continued) TEST 4 - PERFORM FIXED EXCITATION / CHECK VOLTMETER REPLACE FUSES ROTOR AMP FUSES - VERIFY AMP - THEN RETEST DRAW METER FUNCTIONS TEST 14 - CHECK ROTOR ASSEMBLY...
  • Page 34 Section 3 Troubleshooting Flowcharts Problem 5 - No 10A Battery Charge Output TEST 18 - TEST 19 - TEST 20 - CHECK 10A CHECK CHECK 10A BATTERY BATTERY GOOD CIRCUIT CHARGE CHARGE BREAKER OUTPUT RECTIFIER GOOD REPLACE REPLACE FINISHED GOOD REPAIR TEST 9 - TEST OR REPLACE...
  • Page 35 Section 3 Troubleshooting Flowcharts Problem 7 – Engine Cranks But Will Not Start CHECK VERIFY THAT IDLE CHECK FUEL CONTROL SWITCH PULL CHOKE FUEL GOOD GOOD SHUTOFF IS IN THE “OFF” FULL OUT SUPPLY VALVE POSITION REPLENISH PULL OUT FULL OUT FUEL TURN ON TURN OFF...
  • Page 36 Section 3 Troubleshooting Flowcharts Problem 8 – Engine Starts Hard and Runs Rough TEST 30 - CHECK CHECK CHOKE TEST 29 - CHECK GOOD GOOD FUEL POSITION AND GOOD GOOD CHECK SPARK SUPPLY OPERATION SPARK PLUG ENGINE MISS LOW FUEL IS APPARENT PUSH IN AFTER STARTING REPLACE SPARK PLUG...
  • Page 37 Section 3 Troubleshooting Flowcharts Problem 10 – 10 Amp Fuse (F1) Blowing CHECK FUEL TEST 43 - CHECK FUSE BLOWS INSTALL NEW SOLENOID FUSE BLOWS UPON GOOD START STOP 10 AMP FUSE WHEN RUNNING (TEST 47) INSTALLATION RELAY (SSR) AND STARTER CONTACTOR RELAY (TEST 44) FUSE IS GOOD BUT...
  • Page 38 Section 3 Troubleshooting Flowcharts Problem 11 – Engine Overspeeds TEST 1 - CHECK TEST 51 - CHECK TEST 5 - CHECK REPLACE NO-LOAD WIRES 11S & 44S PRODUCING STEPPER MOTOR GOOD CIRCUIT GOOD VOLTAGE & VOLTAGE OPERATION BOARD FREQUENCY WIRES 11S & 22S VOLTAGE REPAIR OR REPLACE GO TO PROBLEM 2...

  • Page 39: Section 4 Ac Diagnostic Tests

    AC Diagnostic Tests Section 4 Introduction work with AMP connector plugs. Another alternative is to use approved back probes from the back side of the This section familiarizes the service technician with connector. acceptable procedures for the testing and evaluation of various problems that can occur on portable generators.

  • Page 40: Test 2 - Check Main Circuit Breaker

    Section 4 AC Diagnostic Tests Test 2 – Check Main Circuit Breaker Set DMM to measure resistance. Connect the DMM test probes across the circuit Procedure breaker terminals. Continuity should be measured. The generator has seven circuit breakers located on the Results control panel.
  • Page 41 Section 4 AC Diagnostic Tests 004700 Figure 4-7. New Style Voltage Regulator Wire Number Locations Shut down the generator. Remove the jumper lead between wire 14 and Diode D1. Set the DMM to measure DC amperage (10 amp range). a. Switch the test leads on the meter if required. 004593 Figure 4-8.

  • Page 42: Test 5 - Check Stepper Motor Control

    Section 4 AC Diagnostic Tests Table 4-1. Test 4 Results – Fixed Excitation Test/Rotor Amp Draw Test (8-20 kW) Results: Voltage Results Wire 2 & 6 Above 60 Above 60 Below 60 Below 60 Below 60 Zero or Residual Volts Above 60 VAC Excitation Winding Above 50...

  • Page 43: Test 6 - Wire Continuity

    Section 4 AC Diagnostic Tests Results a. Connect one meter lead to red. Connect the remaining test lead to orange. Approximately If the stepper motor fails any part of step 5, replace 10 ohms should be measured. the stepper motor. b.

  • Page 44: Test 7 - Check Field Boost

    Section 4 AC Diagnostic Tests Results Connect the C1 connector. Connect wire 16 to the starter contactor relay. If Continuity was not measured across each wire, repair or replace the wires as needed. If Continuity was Results measured refer back to flow chart. If 12 VDC was measured in step 6 the field boost Test 7 –...

  • Page 45: Test 9 - Test Stator

    Section 4 AC Diagnostic Tests b. Connect the other meter test lead to the Connect the C1 connector. ground terminal. Connect the two wires removed from resistor R1. c. Infinity or “Open” should be measured. Results If the diode or resistor failed any step it should be replaced.

  • Page 46: Test 10 - Sensing Leads

    Section 4 AC Diagnostic Tests a. Normal excitation winding resistance should be measured. Winding Wire Numbers 12.5 kW 15 kW 17.5 kW Connect the meter test leads across stator leads Power 11 & 22 0.125 Ω 0.0852 Ω 0.067 Ω 66 (pin 9) and stator lead 77 (pin 10) at the C1 connector female side.

  • Page 47: Test 11 - Excitation Wiring

    Section 4 AC Diagnostic Tests Results Unplug the six pin connector, or wires to terminals, at the voltage regulator. If continuity was not measured in any of the steps Figure 4-20. repair or replace defective wire. a. Connect the one meter test lead to wire 11S at If all steps pass refer back to flow chart.

  • Page 48: Test 13 - Check Brushes & Slip Rings

    Section 4 AC Diagnostic Tests Results b. If continuity is not measured repair or replace wire 0 between the C1 connector and the Replace bad brushes. Clean slip rings, if neces- ground terminal. sary. If brushes and rings are good, go to Test 14. Results Repair or replace wiring/terminals as needed.

  • Page 49: Test 15 - Check Load Voltage & Frequency

    Section 4 AC Diagnostic Tests Test 15 – Check Load Voltage and Set DMM to measure DC Amps. Frequency a. Connect the positive (+) test lead to the center terminal of the battery charge rectifier. Procedure b. Connect the negative (-) test lead to wire 15 disconnected in step 1.

  • Page 50: Test 19 - Check Battery Charge Rectifier (Bcr2)

    Section 4 AC Diagnostic Tests Short to Ground Start the generator. a. The amp reading on the meter should be Set the DMM to measure resistance. approximately 0.2 Amps. Connect the positive (+) test lead to the case b. Apply full load to the generator. housing of BCR2.

  • Page 51: Test 21 - Check 10 Amp Fuse

    Section 4 AC Diagnostic Tests Results To inhibit any possible startup, turn off the fuel source and ground wire 18 at the stud located If continuity was measured the breaker is good above the oil cooler. See Figure 4-39. refer back to the flow chart. Refer to battery post and starter connections in If Infinity or a open condition was measured Figure 4-29...

  • Page 52: Test 23 - Check Voltage At Starter Contactor (Sc)

    Section 4 AC Diagnostic Tests Test 23 – Check Voltage At Starter Connect the negative (-) meter test lead to a clean frame ground. Contactor (SC) Set the start-run-stop switch to START. Procedure a. Battery voltage should be measured. Set DMM to measure DC voltage. Results Disconnect wire 16 from the starter contactor located on the starter motor.

  • Page 53: Test 26 - Test Starter Contactor Relay (Scr)

    Section 4 AC Diagnostic Tests NOTE: If a starting problem is encountered, check the Remove wire 15 from the starter contactor relay engine for freedom of rotation. Remove the spark plugs (SCR). and turn the crankshaft over slowly by hand, to verify that Connect the positive meter test lead to wire 15 it rotates freely.

  • Page 54: Test 27 - Check Start-Run-Stop Switch (Sw1)

    Procedure A commercially available spark tester may be used to test the engine ignition system. One can also be START purchased from Generac Power Systems (Part No. 0C5969). 004653 Disconnect a high tension lead from a spark plug. Figure 4-35. Start-Run-Stop Switch (SW1)

  • Page 55: Test 30 - Check Spark Plugs

    Section 4 AC Diagnostic Tests 000211 Figure 4-38. Setting Spark Plug Gap Results 002075 Clean and re-gap or replace sparks plug as Figure 4-36. Testing Ignition System necessary. Refer back to the flow chart. Crank the engine rapidly. Engine must be cranking at 350 rpm or more.

  • Page 56: Test 33 - Test Wire 167

    Section 4 AC Diagnostic Tests TEST POINTS C TEST POINTS B TEST POINTS A 004654 Figure 4-40. Start Stop Relay (SSR) JUMPER LEAD Figure 4-40. Connect wire 15 to the SSR and 004656 ADDED TO GROUND remove wire 229 from the SSR. Figure 4-42.

  • Page 57: Test 34 - Test Start Stop Relay Wiring

    Section 4 AC Diagnostic Tests STOP STEP 4 STEP 5 J2-1 J2-12 START 004623 Figure 4-45. Test Wire 167, Steps 9-13 Connect the negative meter test lead to frame ground. 12 VDC should be measured. J2 HARNESS CONNECTOR a. If 12 VDC is measured, replace SW1. 004619 b.

  • Page 58: Test 35 - Check And Adjust Ignition Magnetos

    Section 4 AC Diagnostic Tests Test 35 – Check and Adjust Ignition If voltage was not measured in step 3 connect one meter test lead to wire 229 removed from the SSR. Magnetos Connect the other meter test lead to wire 229 at the Procedure terminal block 1 (TB1).

  • Page 59: Test 36 - Test Fuel Shutoff Solenoid (Fss)

    Section 4 AC Diagnostic Tests Results Set the start-run-stop switch (SW1) to START. 12 VDC should be measured. If sparking still does not occur after adjusting the a. If 12 VDC is measured repair or replace wire armature air gap, testing the ground wires and 14 between the SSR and resistor R1 or performing the basic flywheel test, replace the ignition between resistor R1 and the FSS.

  • Page 60: Test 40 - Valve Adjustment

    Section 4 AC Diagnostic Tests If the engine will not start, remove and inspect the spark An alternative method is to turn the engine over and plug. If the spark plug is wet, look for the following: position the intake valve fully open (intake valve spring compressed) and adjust the exhaust valve clearance.

  • Page 61: Test 41 - Check Engine / Cylinder Leak Down Test / Compression Test

    Section 4 AC Diagnostic Tests Test 41 – Check Engine / Cylinder Check Compression Leak Down Test / Compression Test Lost or reduced engine compression can result in failure of the engine to start, or rough operation. One or more of Most engine problems may be classified as one or a the following will usually cause loss of compression: combination of the following:...

  • Page 62: Test 42 - Check Oil Pressure Switch And Wire 86

    Section 4 AC Diagnostic Tests Test 42 – Check Oil Pressure Switch Crank and start the engine. and Wire 86 a. Infinity should be measured. Connect one test lead to wire 0 (disconnected from • If the engine cranks and starts, then shuts down LOP).

  • Page 63: Test 44 - Test Starter Contactor Relay (Scr)

    Section 4 AC Diagnostic Tests a. Resistance measured should be approximately Disconnect wire 15 from the start-run-stop switch 100 ohms. (SW1). Disconnect wire 15 from the battery charge rectifier Results 2 (BCR2). If the SSR measures continuity or zero resistance it Remove wire 15 from the fuse holder (F1).

  • Page 64: Test 48 - Check Hour Meter

    Section 4 AC Diagnostic Tests Test 48 – Check Hour Meter Test 50 – Check Wire 167 Procedure Procedure Disconnect wire 14 from the hour meter. Set DMM to measure resistance. Install new 10 Amp fuse. Figure 4-56. Disconnect wire 167 from the start-run-stop switch (SW1).

  • Page 65: Test 52 - Check Idle Control Switch (Sw2)

    Section 4 AC Diagnostic Tests 44S OLDER 22S NEWER STEP 2 STEP 3 STEP 2 STEP 3 J2-1 J2-12 004635 Figure 4-58. Check Idle Control Switch (SW2) Test 53 – Check Idle Control Wiring Procedure Set DMM to measure resistance. J2 HARNESS CONNECTOR 004634 Disconnect wire 0 from the Idle Control Switch...

  • Page 66: Test 54 - Check Idle Control Transformers (Ict)

    Section 4 AC Diagnostic Tests Connect one meter test lead to wire 83 previously When the drill is activated measure the voltage removed from SW2. output. The AC voltage should measure around 1- 2 VAC. Figure 4-59. Connect the other meter test lead to pin location J2-2 on the J2 connector.

  • Page 67: Test 56 - Choke Test

    Section 4 AC Diagnostic Tests IMPORTANT NOTE: When testing stators and rotors, set Megohmmeter to 500 volts and apply voltage for a maximum of one second. Follow the megohmmeter manufacturers instructions carefully. Do not exceed 500 volts apply voltage longer than second.

  • Page 68: Hi-Pot Tester

    Section 4 AC Diagnostic Tests IMPORTANT NOTE: Before attempting to measure Insulation resistance, first disconnect and Isolate all leads of the winding to be tested. electronic components, diodes, surge protectors, relays, voltage regulators, etc., can be destroyed if subjected to high megger voltages. Hi-Pot Tester A hi-pot tester is shown in Figure...

  • Page 69: Test Between Windings

    Section 4 AC Diagnostic Tests Connect the black tester probe to a clean frame OLDER ground, such as a clean metal part of the rotor NEWER shaft. 11 12 POSITIVE (+) 004642 TEST LEAD 004649 Figure 4-65. C1 Connector Pin Location Numbers Figure 4-66.

  • Page 70: Wattage Reference Guide

    Section 4 AC Diagnostic Tests Wattage Reference Guide Device Running Watts Device Running Watts *Air Conditioner (12,000 Btu) 1700 Hand Drill 250 to 1100 *Air Conditioner (24,000 Btu) 3800 Hedge Trimmer *Air Conditioner (40,000 Btu) 6000 Impact Wrench Battery Charger (20 Amp) Iron 1200 Belt Sander (3")

  • Page 71: Section 5 Disassembly

    Disassembly Section 5 Major Disassembly Figure 5-2. Stepper Motor Harness Stator, Rotor, and Engine Removal Figure 5-11 Figure 5-12 for component location. Disconnect and remove the battery from the generator. (Figure 5-12, Item 15) Remove Fuel Tank. Use proper safety precautions when handling gasoline.
  • Page 72 Section 5 Disassembly Remove the M8 bolt from the rear bearing carrier. Cut 2.5 inches from the hex head end of the rotor (Figure 5-11, Item 15) bolt. Remove the exhaust clamp. (Figure 5-11, Item 35) Slot the end of the bolt to suit a flat blade screwdriver.
  • Page 73 Section 5 Disassembly 004674 Figure 5-9. Remove Rotor 004675 Figure 5-10. Engine Ready for Removal Remove Engine Remove the four nuts from rubber engine mounts. (Figure 5-11, Item 29) Remove engine. Reverse procedure for assembly. Diagnostic Repair Manual...
  • Page 74 Section 5 Disassembly 004676 Figure 5-11. Exploded View Generator Diagnostic Repair Manual...
  • Page 75 Section 5 Disassembly Item Qty. Description Item Qty. Description Adaptor, Engine Washer Lock 3/8 Stator Screw HHC 3/8-16 X 1-1/4 G5 Assembly, Rotor W/Fan Washer Flat 3/8-M10 Zinc Carrier, Rear Bearing Screw HHC M8-1.25 X 50 G8.8 Exhaust Manifold Washer Flat 5/16 Zinc Muffler Nut Lock Hex M8-1.25 Nylon Insert Gasket, Exhaust...
  • Page 76 Section 5 Disassembly 29 51 004677 Figure 5-12. Exploded View Frame, Handle, and Wheels Diagnostic Repair Manual...
  • Page 77 Section 5 Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION Screw HHC M6-1.0 X 55 Axle, 3/4” Dia X 30” (15 kW) Rubber Tank Mount Axle, 3/4” Dia X 27.25” (12.5 kW) Cap, Fuel With Gauge & Vent Washer Flat 3/4” (15 kW) Kit, Fuel Tank Washer Flat 3/4”...
  • Page 78 Section 5 Disassembly This page intentionally left blank. Diagnostic Repair Manual...

  • Page 79: Section 6 Electrical Data

    Electrical Data Section 6 Introduction The diagrams in this section are provided for general reference only. For unit specific diagrams refer to the Service and Support page at the manufacturer’s website. Diagnostic Repair Manual...

  • Page 80: Wiring Diagram 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0228

    Section 6 Electrical Data Wiring Diagram 12.5 & 15 kW (Units Without Hourmeter) – Drawing No. 0E0228 120/240V 120V/20A 120V/20A 30A TWISTLOK 120V/30A 120V/30A DUPLEX GFCI TWISTLOK TWISTLOK WHITE WHITE LOAD WHITE LINE C.B. C.B. C.B. C.B. C.B. C.B. C.B. ENGINE WIRING GOVERNOR ACTUATOR...

  • Page 81: Wiring Diagram 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0228

    Section 6 Electrical Data Wiring Diagram 12.5 & 15 kW (Units Without Hourmeter) – Drawing No. 0E0228 120/240V 50A OUTLET GREEN IDLE CONTROL STATOR TRANSFORMERS WHITE CLOSEST TO BEARING C.B. PIN # ON/OFF IDLE CONTROL SWITCH ELECTRONIC GOVERNOR / ENGINE SHUTDOWN P.C.B. PIN 1 PIN 2 VOLTAGE...

  • Page 82: Electrical Schematic 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0229-A

    Section 6 Electrical Data Electrical Schematic 12.5 & 15 kW (Units Without Hourmeter) – Drawing No. 0E0229-A POWER WINDING DPE WINDING FIELD BATTERY CHARGE WINDING C1-5 C1-4 C1-3 C1-1 C1-6 C1-7 C1-11 C1-12 C1-2 10A BATTERY CHARGE WINDING I.C. C1-10 C1-9 I.C.T.

  • Page 83: Electrical Schematic 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0229-A

    Section 6 Electrical Data Electrical Schematic 12.5 & 15 kW (Units Without Hourmeter) – Drawing No. 0E0229-A 120V 120V DUPLEX GFCI 120/240V 120/240V 120V/30A 120V/30A TWISTLOK TWISTLOK TWISTLOK TEST RESET C1-12 C.B. C.B. C.B. C.B. C.B. C.B. C.B. LEGEND C2-12 BA - BRUSH ASSEMBLY BCR1 - BATTERY CHARGE RECTIFIER, 10A C2-7...

  • Page 84: Wiring Diagram 12.5 & 15 Kw (Units With Hourmeter) - Drawing No. 0D4609-D

    Section 6 Electrical Data Wiring Diagram 12.5 & 15 kW (Units With Hourmeter) – Drawing No. 0D4609-D 120/240V 120V/20A 120V/20A 30A TWISTLOK 120V/30A 120V/30A DUPLEX GFCI TWISTLOK TWISTLOK WHITE WHITE LOAD WHITE LINE C.B. C.B. C.B. C.B. C.B. C.B. C.B. ENGINE WIRING GOVERNOR ACTUATOR...

  • Page 85: Wiring Diagram 12.5 & 15 Kw (Units With Hourmeter) - Drawing No. 0D4609-D

    Section 6 Electrical Data Wiring Diagram 12.5 & 15 kW (Units With Hourmeter) – Drawing No. 0D4609-D 120/240V 50A OUTLET GREEN IDLE CONTROL STATOR TRANSFORMERS WHITE CLOSEST TO BEARING C.B. PIN # ON/OFF IDLE CONTROL SWITCH ELECTRONIC GOVERNOR / ENGINE SHUTDOWN P.C.B. PIN 1 PIN 2 VOLTAGE...

  • Page 86: Electrical Schematic 12.5 & 15 Kw (Units With Hourmeter) - Drawing No. 0D6297-A

    Section 6 Electrical Data Electrical Schematic 12.5 & 15 kW (Units With Hourmeter) – Drawing No. 0D6297-A POWER WINDING DPE WINDING FIELD BATTERY CHARGE WINDING C1-5 C1-4 C1-3 C1-1 C1-6 C1-7 C1-11 C1-2 10A BATTERY CHARGE WINDING I.C. C1-10 C1-9 I.C.T.

  • Page 87: Electrical Schematic 12.5 & 15 Kw (Units With Hourmeter) - Drawing No. 0D6297-A

    Section 6 Electrical Data Electrical Schematic 12.5 & 15 kW (Units With Hourmeter) – Drawing No. 0D6297-A 120V 120V DUPLEX GFCI 120/240V 120/240V 120V/30A 120V/30A TWISTLOK TWISTLOK TWISTLOK TEST RESET C1-12 C.B. C.B. C.B. C.B. C.B. C.B. C.B. C2-12 LEGEND BA - BRUSH ASSEMBLY C2-7 BCR1 - BATTERY CHARGE RECTIFIER, 10A...

  • Page 88: Wiring Diagram 17.5 Kw - Drawing No. 0G0731

    Section 6 Electrical Data Wiring Diagram 17.5 kW – Drawing No. 0G0731 120/240V (50A/60A) OUTLET 120/240V 120V/20A 120V/20A 30A TWISTLOK 120V/30A 120V/30A DUPLEX GFCI TWISTLOK TWISTLOK WHITE WHITE GREEN LOAD WHITE WHITE LINE C.B. C.B. C.B. C.B. C.B. 50A/ C.B. C.B.

  • Page 89: Wiring Diagram 17.5 Kw - Drawing No. 0G0731

    Section 6 Electrical Data Wiring Diagram 17.5 kW – Drawing No. 0G0731 IDLE CONTROL STATOR TRANSFORMERS CLOSEST TO BEARING PIN # ON/OFF 12 11 IDLE CONTROL SWITCH ELECTRONIC GOVERNOR / ENGINE SHUTDOWN P.C.B. VOLTAGE REGULATOR BATTERY CHARGE RECTIFIER 10A AUTO LEGEND RESET BKR BA - BRUSH ASSEMBLY...

  • Page 90: Electrical Schematic 17.5 Kw - Drawing No. 0G0733

    Section 6 Electrical Data Electrical Schematic 17.5 kW – Drawing No. 0G0733 POWER WINDING DPE WINDING BATTERY CHARGE WINDING FIELD C1-5 C1-4 C1-1 C1-2 C1-6 C1-7 C1-11 C1-12 C1-3 10A BATTERY CHARGE WINDING I.C. I.C.T. C1-10 C1-9 C1-8 I.C.T. BCR2 12Vdc BCR1 ELECTRONIC...

  • Page 91: Electrical Schematic 17.5 Kw - Drawing No. 0H0729

    Section 6 Electrical Data Electrical Schematic 17.5 kW – Drawing No. 0H0729 POWER WINDING DPE WINDING BATTERY CHARGE WINDING FIELD C1-5 C1-4 C1-3 C1-1 C1-2 C1-6 C1-7 C1-11 C1-12 10A BATTERY CHARGE WINDING (BLK) I.C.T. C1-10 C1-9 (RED) (BLU/ (PNK) (BLU) (BLK) C1-8...

  • Page 92: Wiring Diagram 17.5 Kw - Drawing No. 0H0730

    Section 6 Electrical Data Wiring Diagram 17.5 kW – Drawing No. 0H0730 120/240V 50A OUTLET 120/240V 120V/20A 120V/20A 30A TWISTLOK 120V/30A 120V/30A DUPLEX GFCI TWISTLOK TWISTLOK WHITE WHITE GREEN LOAD WHITE WHITE LINE C.B. C.B. C.B. C.B. C.B. C.B. C.B. ENGINE WIRING 14(BLU) 18(BRN)

  • Page 93: Wiring Diagram 17.5 Kw - Drawing No. 0H0730

    Section 6 Electrical Data Wiring Diagram 17.5 kW – Drawing No. 0H0730 STATOR I.C.T. 11S(RED) 22S(BLK) 55A(BLK) CLOSEST TO BEARING (RED) 55(BLK) (BLK) 2(BLU/WHT) 15B(ORG) 83(BLU) 0(BLK) 167(BLU) PIN # 86(BLU) (BLU) 12 11 (BLU) (BLU) ELECTRONIC GOVERNOR / (BLK) (BLU) (BLK) ENGINE SHUTDOWN P.C.B.

  • Page 94: Wiring Diagram, 17.5 Kw Manual Transfer Switch - Drawing No. 0G1065

    Section 6 Electrical Data Wiring Diagram, 17.5 kW Manual Transfer Switch – Drawing No. 0G1065 GROUND (GRN) NEUTRAL (WHT) NEUTRAL (WHT) CIRCUIT 9 NEUTRAL (WHT) GROUND BAR CIRCUIT 11 NEUTRAL (WHT) CIRCUIT 13 NEUTRAL (WHT) CIRCUIT 15 CIRCUIT 1 (BRN) CIRCUIT 3 (BRN/WHT) GROUND(GRN)*...

  • Page 95: Interconnection Drawing - 17.5 Kw Generator Connected To The External Connection Box, Manual Transfer Switch And Home's Main Electrical Distribution Panel

    Section 6 Electrical Data Interconnection Drawing – 17.5 kW generator connected to the external connection box, manual transfer switch and home’s main electrical distribution panel Diagnostic Repair Manual...
  • Page 96 Section 6 Electrical Data This page intentionally left blank. Diagnostic Repair Manual...
  • Page 98 ©2017 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved Waukesha, WI 53189 Specifications are subject to change without notice. 1-888-GENERAC (1-888-436-3722) No reproduction allowed in any form without prior written www.generac.com consent from Generac Power Systems, Inc.

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