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

Generac Power Systems GP Series Diagnostic Repair Manual

50/60 hertz portable generators
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DIAGNOSTIC
REPAIR
MANUAL
50/60 Hertz GP, LP and HW Series
GP/LP Models
GP1800
GP7500E
GP3250
GP7500E DF
GP3250
GP8000E
GP3300
COSTCO
GP3600
LP3250
GP5500
LP5500
GP6500
GP6500E
Important Note: Always use the unit specific Schematics and
P O R T A B L E G E N E R AT O R S
Portable Generators
Honeywell Models
International Models
HW3250
GP1000
HW5500
GP1100
HW5500E
GP2000
HW6500
GP2200
HW7500E
GP2600
GP2800
Wiring Diagrams for troubleshooting.
GP3300
GP5000
GP5500
GP6000E
GP6500E

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Summary of Contents for Generac Power Systems GP Series

  • Page 1 DIAGNOSTIC REPAIR MANUAL 50/60 Hertz GP, LP and HW Series Portable Generators GP/LP Models Honeywell Models International Models GP1800 GP7500E HW3250 GP1000 GP3300 GP3250 GP7500E DF HW5500 GP1100 GP5000 GP3250 GP8000E HW5500E GP2000 GP5500 GP3300 COSTCO HW6500 GP2200 GP6000E GP3600 LP3250 HW7500E GP2600...

  • 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 Section 4 Engine Diagnostic Tests ......17 Safety ................ ii Read This Manual Thoroughly ........ii Diagnostic Flow Charts ...........17 Replacement Parts ........... ii Introduction ............. 25 Rotor and Stator Resistance Tables ......iv Test 13 – Check Fuse ..........25 Test 14 –...

  • Page 4: Rotor And Stator Resistance Tables

    Table of Contents Rotor and Stator Resistance Tables Rotor Windings Power Windings Exciter Windings Series Model SD/WD Alternator (Ohms) (Ohms) (Ohms) GP1800 5981 0H8255 0J0819 29.4 0.798 2.53 GP3250 5982 0H2626 0H3578 0.62 1.72 GP3250 5789 0H2271 0H0401 0.389 2.58 LP3250 6000 0J2561...
  • Page 5 Table of Contents Rotor Windings Power Windings Exciter Windings Series Model SD/WD Alternator (Ohms) (Ohms) (Ohms) GP1000 6751 0K6394 0L1434 GP1100 6844 0K9436 0L0144 GP1100 6740 GP1100 6741 0K9437 0L1434 GP2000 6742 0K9438 0L0146 2.28 2.45 GP2200 6845 0K3165 0L0145 0.57 2.45 GP2200...
  • Page 6 Table of Contents 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 7: Section 1 Brushless Capacitor Excitation

    Brushless Capacitor Excitation Section 1 Introduction NOTE: The voltage of a brushless capacitive discharge generator will start low and increase as load is applied. Figure 1-1. A typical brushless type portable generator needs 4 major components to function: a prime Stator Assembly mover, stator, rotor, and capacitor.

  • Page 8: Operation

    Section 1 Brushless Capacitor Excitation Operation AC Power Winding Output A maintained voltage is induced into the stator AC power Startup windings. When electrical loads are connected across When engine started, residual/permanent the AC power windings to complete the circuit, current magnetism from the rotor induces a voltage into (a) the can flow in the circuit.

  • Page 9: Troubleshooting Flowcharts

    Section 1 Brushless Capacitor Excitation Troubleshooting Flowcharts Introduction Use the Flow Charts in conjunction with the . Test numbers used in the flow charts correspond to AC Diagnostic Tests the numbered tests in the AC Diagnostic Tests . The first step in using the flow charts is to identify the correct problem on the following pages.
  • Page 10 Section 1 Brushless Capacitor Excitation Problem 2 – Voltage & Frequency Are Both High or Low GO TO FREQUENCY GOOD, LOW OR PROBLEM 1 RESIDUAL VOLTAGE TEST 27 – CHECK & ADJUST GO TO NO-LOAD FREQUENCY & VOLTAGE GOOD BUT ENGINE GOVERNOR PROBLEM 3 THEY DROOP TO MUCH WHEN LOAD IS APPLIED...

  • Page 11: Section 2 Direct Excitation (Brush Type)

    Direct Excitation (Brush Type) Section 2 Introduction the rotor windings via Wire 4, and the positive (+) brush and slip ring. The excitation current passes through the Figure 2-1. A typical brush type portable generator windings to the negative (-) slip ring and brush on Wire 0. needs 4 major components to function: prime mover, This current flow creates a magnetic field around the rotor rotor, stator, and voltage regulator.
  • Page 12 Section 2 Direct Excitation (Brush Type) AC Power Winding Output The regulator changes the AC from the excitation winding to DC. In addition, based on the Wire S15 and A regulated voltage is induced into the stator AC power Wire S16 sensing signals, it regulates the flow of direct windings.

  • Page 13: Troubleshooting Flowcharts

    Section 2 Direct Excitation (Brush Type) Troubleshooting Flowcharts Introduction Use the Flow Charts in conjunction with the . Test numbers used in the flow charts correspond to AC Diagnostic Tests the numbered tests in the AC Diagnostic Tests . The first step in using the flow charts is to identify the correct problem on the following pages.
  • Page 14 Section 2 Direct Excitation (Brush Type) Problem 6 – Voltage & Frequency Are Both High or Low FREQUENCY GO TO GOOD, LOW OR PROBLEM 5 RESIDUAL VOLTAGE NO-LOAD FREQUENCY & TEST 27 – CHECK & ADJUST GO TO VOLTAGE GOOD BUT ENGINE GOVERNOR PROBLEM 7 THEY DROOP TOO MUCH...

  • Page 15: Section 3 Ac Diagnostic Tests

    AC Diagnostic Tests Section 3 Test 2 – Check Main Circuit Breaker Introduction Perform the Diagnostic Tests in this section in Procedure conjunction with Brushless Troubleshooting The generator has circuit breakers located on the control Flowcharts or the Brush Type Troubleshooting panel.

  • Page 16: Test 4 - Fixed Excitation Test/Rotor Amp Draw Test

    Section 1 AC Diagnostic Tests Results Procedure If any other reading than CONTINUITY was Remove positive and negative wires connected to measured, further troubleshooting needs to be done the brush assembly. to determine if it is the receptacle or the wiring. Connect one jumper wire to where the positive If receptacles test good, refer to flow chart.
  • Page 17 Section 1 AC Diagnostic Tests While the unit is running connect one jumper wire Record DC amperage measured. Approximately to the negative terminal of the battery and connect 0.22 DC amps should be measured. the other jumper wire to the positive terminal. NOTE: The DC voltage of the battery divided by the Record voltage measured on Wires 2 and 6 on the resistance measured in Step 17 will give a calculated...

  • Page 18: Test 5 - Field Flash Alternator

    Section 1 AC Diagnostic Tests Test 5 – Field Flash Alternator IMPORTANT NOTE: Do NOT energize the capacitor for more than 1 second at a time. (Configuration “A” Only) Momentarily turn on energizing cord (one second). General Theory Disconnect energizing cord from capacitor. The alternator utilizes residual magnetism within the Carefully re-connect the DPE winding leads to the windings to charge the capacitor.

  • Page 19: Test 6 - Check Capacitor

    Section 1 AC Diagnostic Tests Test 6 – Check Capacitor IMPORTANT NOTE: A capacitor that has gone bad has a tendency to explode. Use caution when dealing with an General Theory exploded capacitor. The gel from inside a capacitor can cause skin irritation.

  • Page 20: Test 8 - Test Brushless Stator Windings

    Section 1 AC Diagnostic Tests Test 8 – Test Brushless Stator Test 9 – Test Brushed Stator Windings Windings General Theory General Theory The brushless stator has three internal windings, two Most brushed stators have three main windings that are main power windings and a DPE winding.

  • Page 21: Test 12 - Adjust Voltage Regulator

    Section 1 AC Diagnostic Tests NOTE: All figures are approximate. See data label on appliance for wattage requirements. Results If unit is overloaded, reduce load. If load is within limits but frequency and voltage still drop excessively, refer to flow chart. Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to connected electrical devices.
  • Page 22 Section 1 AC Diagnostic Tests This page intentionally left blank. Diagnostic Repair Manual...

  • Page 23: Section 4 Engine Diagnostic Tests

    Diagnostic Flow Charts There are multiple types of engines on the GP Series generators: 407cc, 389cc, 208cc, 196cc, 163cc, 420cc. Section 3 is divided into difference subsections that provide engine troubleshooting for each type of engine. It is imperative to identify what type of engine is used in order to effectively troubleshoot the problem.
  • Page 24 Section 4 Engine Diagnostic Tests Problem 11 – Engine Turns Over But Will Not Start CHECK TEST 19 – TEST 26 – REMOVE CHECK FUEL FUEL GOOD CHECK SHUTOFF WIRE 18 / GOOD SUPPLY SPARK VALVE SHUTDOWN LEAD SPARK SPARK REPLENISH TEST 25 –...
  • Page 25 Section 4 Engine Diagnostic Tests Problem 12 – Engine “Hunts” / Erratic Idle *Acceptable running limits for the engine are between 59-61 Hertz. TEST 19 – TEST 23 – CHECK TEST 22 – STILL CHECK VALVE GOOD CHOKE TEST SURGING IGNTION ADJUSTMENT SPARK...
  • Page 26 Section 4 Engine Diagnostic Tests Problem 14 – Recoil Cord Will Not Pull (If So Equipped) TEST 31 – TEST TEST 32 – VISUALLY INSPECT FOR OBSTRUCTIONS RECOIL GOOD TEST ENGINE GOOD THAT WOULD CAUSE BINDING OF THE FUNCTION FUNCTION RECOIL ONCE INSTALLED VISUALLY INSPECT EXTERNAL REPLACE...
  • Page 27 Section 4 Engine Diagnostic Tests Problem 16 – Engine Starts Hard and Runs Rough TEST 20 – TEST 19 – CHECK CHOKE CHECK FUEL CHECK CHECK GOOD POSITION AND GOOD GOOD GOOD SUPPLY SPARK PLUG SPARK OPERATION LOW FUEL ENGINE MISFIRE PUSH IN AFTER IS APPARENT STARTING...
  • Page 28 Section 4 Engine Diagnostic Tests Problem 17 – Engine Starts Then Shuts Down TEST 29 – TEST 16 – TEST OIL LEVEL CHECK CO CHECK ENGINE TEST OIL START-RUN-STOP GOOD O.K. SENSE LIGHT LIGHT PRESSURE OIL LEVEL SWITCH SWITCH BLINKING OIL LEVEL LOW YELLOW LIGHT...
  • Page 29 Section 4 Engine Diagnostic Tests Problem 18 – Battery Will Not Charge (410cc Engines) TEST 13 – REPLACE CHECK CONNECTIONS GOOD GOOD CHECK 1.5 BATTERY ON BATTERY CHARGE AMP FUSE CHARGER SOCKET REPLACE REPLACE FUSE Problem 19 – Engine “Hunts” / Erratic Idle (410cc Engines) *Acceptable running limits for the engine are between 59-62 Hertz.
  • Page 30 Section 4 Engine Diagnostic Tests Problem 20 – Engine Turns Over But Will Not Start (410cc Engines) ENGINE STARTED NO PROBLEM CHECK LP ATTEMPT STARTING TEST 19 – FUEL TANK GENERATOR AS INSTRUCTED GOOD IGNITION GOOD START SUPPLY IN OWNER’S MANUAL SPARK LOW FUEL GOOD...

  • Page 31: Introduction

    Section 4 Engine Diagnostic Tests Introduction Procedure A. Inspect Battery Cables, Terminals, and Connections Perform the Diagnostic Tests in this section in Inspect battery cables and battery posts. conjunction with the Charts. Test Diagnostic Flow If cable clamps or terminals are corroded, clean numbers in this chapter correspond to numbered tests in away all corrosion.

  • Page 32: Test 15 - Check Voltage At Starter Contactor (Sc)

    Section 4 Engine Diagnostic Tests Connect the test leads to the positive and negative Table 4-1. Maximum Voltage Readings posts of the battery being tested and follow the conductance battery tester manufacturer's DC Volts Connection Test instructions. Test results should not indicate anything lower than 60% of the battery's rated 0.00-0.10 Battery Post to...

  • Page 33: Test 17 - Test Off-On Switch

    Section 4 Engine Diagnostic Tests Procedure STOP START Figure 4-6. Disconnect Point A from switch. GROUND TO STARTER 0 GD TO MAGNETO CONTACTOR 008727 003996 Figure 4-5. START-RUN-STOP Switch Figure 4-6. OFF-ON Switch Test Points Procedure Connect one meter lead to male connector on Set a digital multimeter (DMM) to measure switch and the other meter test lead to a clean resistance.

  • Page 34: Test 19 - Check Ignition Spark

    Section 4 Engine Diagnostic Tests Test 19 – Check Ignition Spark Set a DMM to measure DC voltage (12 VDC). Connect meter positive (+) test lead to starter contactor stud (the Procedure small jumper wire connected to starter). Connect common (-) test lead to starter motor frame. A commercially available spark tester may be used to Set Start-Stop Switch to START and observe meter.

  • Page 35: Test 20 - Check Spark Plugs

    Section 4 Engine Diagnostic Tests Test 20 – Check Spark Plugs • Water in fuel • Intake valve stuck open Procedure • Needle/float stuck open Figure 4-12 Figure 4-13. Remove spark plugs. If spark plug is dry, look for the following: Clean with commercial solvent.

  • Page 36: Test 24 - Check Engine / Cylinder Leak Down Test / Compression Test

    Section 4 Engine Diagnostic Tests Another method is to turn engine over and position intake valve fully open (intake valve spring compressed) and adjust exhaust valve clearance. Turn engine over and position exhaust valve fully open (exhaust valve spring compressed) and adjust intake valve clearance. Figure 4-14.

  • Page 37: Test 25 - Check Flywheel

    Section 4 Engine Diagnostic Tests plug hole. Crank engine until there is no further in pressure. The highest reading obtained is engine compression pressure. Minimum Allowable Compression Pressure Cold Engine – 60 psi If compression is poor, look the following causes: •...

  • Page 38: Test 28 - Remove Shutdown Wire

    Section 4 Engine Diagnostic Tests Results A keyway is provided for alignment only and theoretically carries no load. If spark now occurs, Wire 18 has a short to ground. Trace Wire 18 back to START-RUN-STOP switch NOTE: If flywheel key becomes sheared or even partially and Oil Pressure Module (if equipped).

  • Page 39: Test 28 - Check Oil Level Switch

    Section 4 Engine Diagnostic Tests Running Adjustment Set DMM to measure resistance. Connect one meter test lead to disconnected wire After completing initial adjustment, final adjustment is from oil level switch. Connect the other meter test accomplished with engine running under no-load. lead to frame ground.

  • Page 40: Test 33 - Test Recoil Function

    Section 4 Engine Diagnostic Tests Remove oil pressure gauge and install oil pressure Remove spark plug from unit. switch. Do NOT connect Wire 86 or Wire 0 to Attempt to turn engine over by hand. switch terminals. Results a. Set a DMM to measure resistance. b.

  • Page 41: Test 41 - Co Module Verification Test

    Section 4 Engine Diagnostic Tests Procedure UP position to the DOWN position without binding, the switch is functioning mechanically. NOTE: Do not install CO badging (decal) prior to Proceed to the next step. performing this test Turn ON the utility power supply (if currently off) to NOTE: The generator must run under normal operation the transfer switch, using the means provided with no CO module notifications for a minimum of 65...
  • Page 42 Section 4 Engine Diagnostic Tests This page intentionally left blank. Diagnostic Repair Manual...

  • Page 43: Section 5 Major Disassembly

    Major Disassembly Section 5 Introduction Each generator model has a unique method of disassembly. Figure 5-1 is a simplified version of disassembly that does not go into step by step instructions. The figure below represents the basic disassembly and sequence of steps needed to remove the fuel tank, stator, rotor, and the engine.
  • Page 44 Section 5 Major Disassembly Exploded View – GP1800 – Drawing No. 0H0609-A Diagnostic Repair Manual...
  • Page 45 Section 5 Major Disassembly ITEM DESCRIPTION ENGINE, 196CC RECOIL ASSEMBLY CARBURETOR AIR CLEANER COVER AIR FILTER CARBURETOR GASKET SPARK PLUG BOOT OIL LEVEL SENSOR FRAME, 1800W FUEL SHUTOFF VALVE VIBRATION MOUNT, #1 VIBRATION MOUNT, #2 BRUSH ASSEMBLY SPARK ARRESTOR MUFFLER ASSEMBLY FUEL TANK ASSEMBLY FUEL TANK CAP ASSEMBLY CONTROL PANEL ASSEMBLY...
  • Page 46 Section 5 Major Disassembly Exploded View – GP3250 – Drawing No. 0H0522-C PORTABLE KIT Diagnostic Repair Manual...
  • Page 47 Section 5 Major Disassembly ITEM QTY. DESCRIPTION ENGINE, 208CC RECOIL ASSEMBLY CARBURETOR AIR CLEANER COVER AIR FILTER CARBURETOR GASKET SPARK PLUG BOOT OIL LEVEL SENSOR FRAME, 3250W FUEL SHUTOFF VALVE VIBRATION MOUNT, #1 VIBRATION MOUNT, #2 BRUSH ASSEMBLY SPARK ARRESTOR MUFFLER ASSEMBLY FUEL TANK ASSEMBLY FUEL TANK CAP ASSEMBLY...
  • Page 48 Section 5 Major Disassembly Exploded View – GP5000 – Drawing No. 0G9384A-C Diagnostic Repair Manual...
  • Page 49 Section 5 Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION FRAME PARTS EXHAUST PARTS ASSY CRADLE BASE BRACKET, MUFFLER SHIELD, BOTTOM CRADLE END ASSY MUFFLER, 389cc PANEL RAIL BRACKET, MUFFLER SHIELD TOP BACK RAIL GASKET, EXHUAST. 389cc CURVED HEAD BOLT 5/16-18 x 1.625"...
  • Page 50 Section 5 Major Disassembly Exploded View – GP5500 – Drawing No. 0H1253-A Diagnostic Repair Manual...
  • Page 51 Section 5 Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ASSY CRADLE BASE SCREW HHTT M6-1.0 X 25 CRADLE END FUEL TANK ASSY 6.6 GAL PORTABLE ASSEMBLY, FRAME 1 PIECE SCREW HHTT M8-1.25 X 20 PANEL RAIL FUEL CAP, VENTED BACK RAIL SHIELD, HEAT, SKU CURVED HEAD BOLT M8-1.25 X...
  • Page 52 Section 5 Major Disassembly Exploded View – GP6500 – Drawing No. 0G9384B-C 36 37 Diagnostic Repair Manual...
  • Page 53 Section 5 Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION FRAME PARTS SCREW HHTT M8-1.25 x 20 ASSY CRADLE BASE EXHAUST PARTS CRADLE END BRACKET, MUFFLER SHIELD, BOTTOM PANEL RAIL ASSY MUFFLER, 389cc BACK RAIL BRACKET, MUFFLER SHIELD TOP CURVED HEAD BOLT 5/16-18 x 1.625"...
  • Page 54 Section 5 Major Disassembly Exploded View – GP7000 – Drawing No. 0G9384D-B Diagnostic Repair Manual...
  • Page 55 Section 5 Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION CRADLE END LUG SLDLSS #2-#8 X 17/64 CU BACK RAIL WASHER LOCK SPECIAL 1/4” CURVED HEAD BOLT 5/16-18 x SCREW PPPH #8-16 x 1/2” BZC 1.625" LONG ASSY GND WIRE ALT TO BASE CAP NUT LOCKING 5/16-18 RECEPTACLE PANEL 30A RND W/ THREAD, 5/16”...
  • Page 56 Section 5 Major Disassembly Exploded View – GP8000 – Drawing No. 0G9384F-B Diagnostic Repair Manual...
  • Page 57 Section 5 Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION CRADLE END TIRE 9.5" DIA RUN FLAT PLASTIC HUB/RUBBER TREAD BACK RAIL SCREW, HHC 1/2”-13 x 4-1/2” LONG CURVED HEAD BOLT 5/16-18 x 1.625" LONG NUT, HEX LOCK 1-2”-13 NYLON INSERT CAP NUT LOCKING 5/16-18 THREAD) 5/16”...
  • Page 58 Section 5 Major Disassembly Exploded View – GP7500E DF – Drawing No. A0003081286-A Diagnostic Repair Manual...
  • Page 59 Section 5 Major Disassembly ITEM DESCRIPTION ITEM DESCRIPTION WHEEL ENGINE DHLG420 GROUNDING WIRE ALTERNATOR KIT ASSEMBLY BOLT M6*20 ALTERNATOR END BRACKET BEARING Φ6 BOLT M10*1.25*283 PLAIN WASHER φ6 GASKET, ROTOR BOLT Φ10.5×Φ30×4 SPRING WASHER Φ6 SPRING WASHER φ10 BUTTERFLY NUT M6 STATOR FASTEN BOLT M6*195 NUT M6 BOLT M5*230...
  • Page 60 Section 5 Major Disassembly ITEM DESCRIPTION ITEM DESCRIPTION PAPER GASKET CO MODULE MOUNTING BRACKET PRESSURE REDUCING VALVE PANEL SUPPORT PLATE DUAL FUEL SELECTION SWITCH BOLT ST5.4*16mm PLAIN WASHER φ5*Φ10 BOLT M6X12 SPRING WASHER Φ5 ACTIVE TORQUE TULE ASSEMBLY UPPER COVER BOLT M6X12 LASSO ACTIVE TORQUE TULE...
  • Page 61 Section 5 Major Disassembly ITEM DESCRIPTION BOLT M6X12 TRIM PANEL HANDLE ASSEMBLY HANDLE HANDLE GRIP NUT M8 BOLT M8X50 AIR FILTER BRACKET ASSEMBLY BOLT M6X12 AIR FILTER BRACKET THE OIL BOTTLE DECAL THE OIL BOTTLE OIL BOTTLE NYLON BRAIDED TUBE Diagnostic Repair Manual...
  • Page 62 Section 5 Major Disassembly Exploded View – LP3250 – Drawing No. 0J2562 Diagnostic Repair Manual...
  • Page 63 Section 5 Major Disassembly ITEM DESCRIPTION ITEM DESCRIPTION SCREW PPHM M6-1.0 X 16 AXLE PIN, 1/2”X 4", 3/4” HEAD GROMMET 5/8”X 1 1/8”X 5/16” GROUND WIRE LP3250 HOSE, FUEL LP TANK WASHER LOCK SPECIAL 1/4” SCREW BHSC M8-1.25 X 20 SS LUG, SOLDERLESS #2-#8 TOP WRAPPER SCREW HHC M6-1.0 X 20 C8.8...
  • Page 64 Section 5 Major Disassembly Exploded View – LP5500 ITEM DESCRIPTION ITEM DESCRIPTION CONTROL SIDE PANEL - DARK GRAY COVER, OUTLET SCREW PPPH #8-16 X 0.66" BZC PLATE, CNTL PNL FACE CURVED HEAD M8-1.25 X 41MM LNG METER, HOUR ASSEMBLY CONTROL PANEL LP5500 OUTLET 30A 120/250V SPCGR CIRCUIT BREAKER, ON/OFF SWITCH OUTLET 20A 120V DPLX 6342BK...
  • Page 65 Section 5 Major Disassembly ITEM DESCRIPTION ITEM DESCRIPTION BOLT, M5X12 BRACKET, FOOT BOLT, M5X16 NUT, M8 BOLT,ROTOR M10X255 FOOT, RUBBER BOLT, M6X170 NUT, M6 BRACKET, MUFFLER BOLT, FLANGE M6X28 BOLT, M8X16 PIN, AXLE MUFFLER WHEEL 10"D X 3" NVR FLT IND GR GASKET EXHAUST 389 BOLT, M8X45 BOLT, M8X25...
  • Page 66 Section 5 Major Disassembly This page intentionally left blank. Diagnostic Repair Manual...

  • Page 67: Section 6 Electrical Data

    Electrical Data Section 6 Introduction Go to www.generac.com (http://www.generac.com/service-support/product-support-lookup) for the most current wiring diagrams and electrical schematics. Use model or serial number. Diagnostic Repair Manual...
  • Page 68 Section 6 Electrical Data Electrical Schematic, GP1850 Brushed Alternator Drawing No. 0H0612-A SENSING Diagnostic Repair Manual...
  • Page 69 Section 6 Electrical Data Electrical Schematic, GP3250 Brushed Alternator Drawing No. 0H0523-A SENSING Diagnostic Repair Manual...
  • Page 70 Section 6 Electrical Data Electrical Schematic, GP5000/5500/6500 Brushed Alternator Drawing No. 0G9769-D SCHEMATIC - DIAGRAM Diagnostic Repair Manual...
  • Page 71 Section 6 Electrical Data Wiring Diagram, GP5000/5500/6500 Brushed Alternator Drawing No. 0G9769-D WIRING - DIAGRAM Diagnostic Repair Manual...
  • Page 72 Section 6 Electrical Data Electrical Schematic, GP7000E/8000E Brushless Alternator Drawing No. 0G9849-A Diagnostic Repair Manual...
  • Page 73 Section 6 Electrical Data Wiring Diagram, GP7000E/8000E Brushless Alternator Drawing No. 0G9849-A Diagnostic Repair Manual...
  • Page 74 Section 6 Electrical Data Wiring Diagram, LP3250 Brushless Alternator Drawing No. 0J2561-B CONTROL PANEL BLOCK ALTERNATOR BLOCK (33) (44) (11) (44) (11) (22) 120/240V L14-20R 15A/1P 15A/1P TERMINAL TWISTLOCK C.B. C.B. BLOCK (WY) 120V 120V STATOR 5-20R 5-20R DUPLEX DUPLEX C2-PLUG C2-CAP BRUSH...
  • Page 75 Section 6 Electrical Data Electrical Schematic, LP3250 Brushless Alternator Drawing No. 0J2561-B ALTERNATOR BLOCK CONTROL PANEL BLOCK AC OUTPUT W (33) Gy (44) 15A/1P C.B. R (11) 15A/1P C.B. W (22) MAIN WINDINGS W (33) W (22) 120/240V 20A L14-20R TWISTLOCK 120V 20A 120V 20A...
  • Page 76 Section 6 Electrical Data Wiring Diagram, LP5500 Brushless Alternator Drawing No. 0J7910-B ALTERNATOR BLOCK (44) (11) TERMINAL BLOCK NEUTRALS BONDED CHASSIS GROUND GROUND (55) (YW) STATOR CONNECTOR BRUSH ASSEMBLY CLOSEST BEARING AUTOMATIC VOLTAGE REGULATOR WIRE LEGEND IGNITION SWITCH LEGEND WHITE BROWN GREEN YELLOW...
  • Page 77 Section 6 Electrical Data Electrical Schematic, LP5500 Brushless Alternator Drawing No. 0J7910-B CONTROL PANEL BLOCK (44) (11) 120/240V L14-30R TWISTLOCK 25A/2P HOUR METER 20A/1P 20A/1P 120V 5-20R DUPLEX 120V 5-20R DUPLEX SINGLE POINT CONTROLLER IGNITION SWITCH Bl Bl SPARK PLUG IGNITION COIL LEVEL...
  • Page 78 Section 6 Electrical Data Wiring Diagram Drawing No. 0K5879-B Diagnostic Repair Manual...
  • Page 79 Section 6 Electrical Data Electrical Schematic Drawing No. 0K5879-B Diagnostic Repair Manual...
  • Page 80 Section 6 Electrical Data Wiring Diagram GP Series Drawing No. 10000032713-A Diagnostic Repair Manual...
  • Page 81 Section 6 Electrical Data Wiring Diagram GP7500E DF Drawing No. A0001920613-B (1 of 2) Diagnostic Repair Manual...
  • Page 82 Section 6 Electrical Data Wiring Diagram GP7500E DF Drawing No. A0001920613-B (2 of 2) Diagnostic Repair Manual...

  • Page 83: Electrical Formulas

    Electrical Formulas To Find Known Values 1-phase 3-phase E X I E x I x 1.73 x PF Kilowatts (kW) Volts, Current, Power Factor 1000 1000 E x I E x I x 1.73 Volts, Current 1000 1000 kW x 1000 kW x 1000 Amperes kW, Volts, Power Factor...
  • Page 84 ©2023 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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