Table Of Contents - Generac Power Systems GP Series Diagnostic Repair Manual

Safety ........................................................................ ii
Read This Manual Thoroughly .................................. ii
Replacement Parts ................................................... ii
Rotor and Stator Resistance Tables ........................ iv
Section 1 Brushless Capacitor Excitation..................1
Introduction ...............................................................1
Stator Assembly ........................................................1
Rotor Assembly ........................................................1
Circuit Breakers ........................................................1
Operation ..................................................................2
Troubleshooting Flowcharts ......................................3
Section 2 Direct Excitation (Brush Type)....................5
Introduction ...............................................................5
Stator Assembly ........................................................5
Brush Holder and Brushes ........................................5
Rotor Residual Magnetism ........................................5
Voltage Regulator .....................................................5
Operation ..................................................................5
Troubleshooting Flowcharts ......................................7
Section 3 AC Diagnostic Tests ....................................9
Test 1 - Check No-Load Voltage and Frequency .....9
Test 2 - Check Main Circuit Breaker ........................9
Test 3 - Check Continuity of Receptacle Panel ........9
Test 4 - Fixed Excitation Test/Rotor Amp
Draw Test ................................................................10
Test 5 - Field Flash Alternator ................................12
Test 6 - Check Capacitor .......................................13
Test 7 - Test Brushless DPE Windings ..................13
Test 8 - Test Brushless Stator Windings ................14
Test 9 - Test Brushed Stator Windings ..................14
Test 10 - Check Load Voltage and Frequency .......14
Test 11 - Check Load Watts and Amperage ..........14
Test 12 - Adjust Voltage Regulator ........................15
Diagnostic Repair Manual
Section 4 Engine Diagnostic Tests ...........................17
Diagnostic Flow Charts ...........................................17
Introduction ............................................................. 25
Test 13 - Check Fuse .............................................25
Test 14 - Check Battery and Cables ......................25
Test 15 - Check Voltage at Starter Contactor (SC) 26
Test 16 - Check START-RUN-STOP Switch ......... 26
Test 17 - Test OFF-ON Switch .............................. 27
Test 18 - Check Starter Motor ................................27
Test 19 - Check Ignition Spark ...............................28
Test 20 - Check Spark Plugs .................................29
Test 21 - Check Carburetion ..................................29
Test 22 - Choke Test .............................................29
Test 23 - Check Valve Adjustment ......................... 29
Test 24 - Check Engine / Cylinder Leak Down
Test / Compression Test .........................................30
Test 25 - Check Flywheel ......................................31
Test 28 - Remove Shutdown Wire ......................... 32
Test 27 - Check / Adjust Governor ......................... 32
Test 28 - Check Oil Level Switch ...........................33
Test 29 - Check Oil Pressure Switch .....................33
Test 33 - Test Recoil Function ...............................34
Test 34 - Test Engine Function .............................. 34
Test 35 - Check For Fuel Delivery ......................... 34
Test 40 - Transfer Switch Test Operation ..............34
Test 41 - CO Module Verification Test ...................35
Section 5 Major Disassembly ....................................37
Introduction ............................................................. 37
Section 6 Electrical Data ............................................ 61
Introduction ............................................................. 61
Electrical Formulas ................................................. 77

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