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Generac Power Systems G0070420 Diagnostic Repair Manual
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Generac Power Systems G0070420 Diagnostic Repair Manual

Generac Power Systems G0070420 Diagnostic Repair Manual

50 hz and 60 hz 3-phase air-cooled product with evolution 2.0 control
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DIAGNOSTIC
REPAIR
MANUAL
50 Hz and 60 Hz 3-Phase Air-Cooled Product
with Evolution™ 2.0 Control
S TA N D B Y G E N E R AT O R S

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Summary of Contents for Generac Power Systems G0070420

  • Page 1 ® DIAGNOSTIC REPAIR MANUAL 50 Hz and 60 Hz 3-Phase Air-Cooled Product with Evolution™ 2.0 Control S TA N D B Y G E N E R AT O R S...

  • Page 2: Frequently Asked Questions

    Frequently Asked Questions A: Yes, they are restrictions to gas flow. You must add 2.5ft. (.76m) per each elbow, tee, etc. to the overall Q: Do I have to supply the generator with the 100% calculated distance from the source to the generator. loaded BTU rated fuel supply and pipe size? Q: Can I leave the unit on the shipping pallet and A: Yes, the generator needs the 100% loaded BTU fuel...
  • Page 3 Problem Things to Check Active Alarm Solution Unit will not start in Check the LED’s/ LOW OIL Check Oil Level/Add Oil Per AUTO with utility loss. Screen for alarms. PRESSURE Owners Manual. If oil level is correct contact servicing dealer. Unit will not start in Check the LED’s/ RPM SENSE LOSS...
  • Page 4 Problem Things to Check Active Alarm Solution Yellow LED illuminated YELLOW Check the screen for LOW BATTERY Clear alarm. Check the in any state. additional battery using the control information. panel under the MAIN menu using the BATTERY MENU option. If it states battery is GOOD contact servicing dealer.

  • Page 5: Safety

    Safety It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar Throughout this publication and on tags and decals products manufactured and marketed by Generac, and affixed to the generator, DANGER, WARNING, and that they have been trained in the recommended CAUTION blocks are used to alert personnel to special servicing procedures for these products, including the...
  • Page 6 This page intentionally left blank. Diagnostic Repair Manual...

  • Page 7: Table Of Contents

    Table of Contents Frequently Asked Questions ........ii Test FB2 – Test Wire 4A ........29 Quick Reference Guide (Evolution Controllers) ..ii Test FB3 – Diode Test ..........29 Safety ................v Test 4 – Fixed Excitation Test/Rotor Amp Draw Test ...............30 Read This Manual Thoroughly ........v Test 5 –...
  • Page 8 Table of Contents Utility Voltage Restored and Re-transfer to Utility ...59 Test 65 – Test Exercise Function ......85 Engine Shutdown ............61 Test 66 – Test Cranking and Running Circuits ..86 Test 67 – Test Run Circuit ........86 Section 3.4 Troubleshooting Flowcharts....63 Test 68 –...

  • Page 9: Section 1.1 Generator Basics

    – Provides the basics of the AC alternator design and the AC troubleshooting portion of the manual. Section 3 – Engine/DC Control – Provides the GENERAC POWER SYSTEMS, INC 004954 WAUKESHA, WI USA 53189 0L2157 troubleshooting and diagnostic testing procedure for Figure 1-1.

  • Page 10: Specifications

    Section 1.1 Generator Basics Specifications Table 1-1. 50/60 Hz – Stator Winding Resistance Values / Rotor Resistance* 60 Hz 20 kW (208 VAC 3-Phase) 50 Hz 20 kVA (380/400/416 VAC 3-Phase) Power Windings Across S1-00 0.0504-0.0583 0.2643-0.3071 Power Windings Across S2-00 0.0504-0.0583 0.2643-0.3071 Power Windings Across S3-00...

  • Page 11: Section 1.2 Menu System Navigation

    Menu System Navigation Section 1.2 Navigation Keys System There are four selection and navigation keys below the Selecting SYSTEM returns to the Main Display. display. Date/Time Escape Selecting DATE/TIME displays current date and time. The ESCAPE key will cause the display to move back Sub Menus toward the main menu.

  • Page 12: Evolution Dealer Menu

    Section 1.2 Menu System Navigation Use the UP and DOWN triangle keys to move from the most recent Run event (1) to the oldest (50). DEALER: DISPLAY Maint DEALER EDIT TEST The MAINT Menu displays four selections: Battery, Maint Log, Run Hrs, and Scheduled. 002468 Figure 1-9.
  • Page 13 Section 1.2 Menu System Navigation A “1” represents a relay that is energized (ON). This screen will also display the Generator Output Table 1-3. Digital Inputs and Outputs Voltage. Position Digital Inputs Digital Outputs • Display provides two flashing bars that test the display LEDs.
  • Page 14 Section 1.2 Menu System Navigation EVOLUTION 2.0/ SYNC 3.0 MENU MAP EVOLUTION 2.0 HSB MENU MAP Switched to “OFF” Hours of Protection Note: Menu functions and features may vary 0 (H) depending on unit model and firmware revision. Running Manual Running-Utility Lost Running-Remote Start SYSTEM...
  • Page 15 Section 1.2 Menu System Navigation Current Date/Time 02/14/16 07:40 UP ARROW = ENTER Run Hours (H) DOWN ARROW = Battery Condition “Good” “Inspect Battery” or “Check Battery” ENTER ENTER BATTERY Run Hrs ENTER Maint. Log Scheduled DEALER Access Requires Password ENTER ENTER - 1 thru 50 +...
  • Page 16 Section 1.2 Menu System Navigation EVOLUTION 2.0/ SYNC 3.0 MENU MAP EVOLUTION 2.0 HSB MENU MAP Switched to “OFF” Note: Menu functions and features may vary Hours of Protection 0 (H) depending on unit model and firmware revision. Running Manual Running-Utility Lost ENTER SYSTEM...
  • Page 17 Section 1.2 Menu System Navigation Current Date/Time 02/14/16 07:40 (mm/dd/yy hr:min format) UP ARROW = ENTER DOWN ARROW = Run Hours (H) Battery Condition “Good” “Inspect Battery” or “Check Battery” ENTER ENTER Run Hrs BATTERY ENTER Scheduled Maint. Log Access Requires Password ENTER ENTER - 1 thru 50 +...
  • Page 18 Section 1.2 Menu System Navigation Power Up Unit Note: If language was previously programmed this goes directly FIRMWARE V 1.01 to “Select Hour” HARDWARE V 1.05 Language UP ARROW = Install Wizard + English - + Espanol - + Francais - Defaults to English if + Portuguese - not selected.
  • Page 19 Section 1.2 Menu System Navigation Power Up Unit Note: If language was previously programmed this goes directly FIRMWARE V 1.01 to “Select Hour” HARDWARE V 1.05 Language UP ARROW = Install Wizard + English - + Espanol - + Francais - Defaults to English if + Portuguese - not selected.
  • Page 20 Section 1.2 Menu System Navigation EVOLUTION 2.0/ SYNC 3.0 FIRMWARE MENU MAP EVOLUTION/SYNC2.0 HSB FIRMWARE MENU MAP Note: Menu functions and features may vary Switched to “OFF” depending on unit model and firmware revision. Hours of Protection 0 (H) ENTER SYSTEM DATE/TIME SUB MENUS...
  • Page 21 Section 1.2 Menu System Navigation UP ARROW = DOWN ARROW = Alternate Firmware Update Method: Control unit at main screen and Insert Thumb drive with Firmware Power the unit down completely. Disconnect AC power. Repower the controller allow unit to complete the update process. During update process the Blue “Manual”...
  • Page 22 Section 1.2 Menu System Navigation EVOLUTION 2.0/SYNC 3.0 DEALER MENU MAP EVOLUTION/SYNC2.0 HSB DEALER MENU MAP Switched to “OFF” Note: Menu functions and features may vary Hours of Protection MAIN DISPLAY 0 (H) depending on unit model and firmware revision. To access Dealer Menu enter Password from MAIN DISPLAY: Up, Up, ESC, DN, Up, ESC, Up, ENTER Note:Unit needs to be activated to access the Dealer Menu.
  • Page 23 Section 1.2 Menu System Navigation “Battery Voltage” 0 - 13.7 “Charging Status” “Charging” or “Not Charging” Run Hours (H) Output Volts” “Output Frequency (Hz)” Engine Speed (RPM) MAINT DEALER Utility Input Volts ENTER ENTER Ambient Temperature (deg F) DISPLAY DEALER: DEALER EDIT TEST FIRMWARE V 1.01...
  • Page 24 Section 1.2 Menu System Navigation This page intentionally left blank. Diagnostic Repair Manual...

  • Page 25: Section 1.3 Testing, Cleaning And Drying

    Testing, Cleaning and Drying Section 1.3 Visual Inspection Testing Stator Insulation Perform a thorough visual inspection before testing or Figure 1-22. Isolate all stator leads and connect all troubleshooting an alternator. Remove the access covers the stator leads together. and look closely for any obvious problems. Look for the Use a Megohmmeter power setting of 500 volts.

  • Page 26: Testing Rotor Insulation

    Section 1.3 Testing, Cleaning and Drying Testing Rotor Insulation Drying the Generator Apply a voltage of 500 volts across the rotor positive slip The procedure for drying an alternator is as follows: ring (nearest the rotor bearing), and a ground (i.e. the Open the generator main circuit breaker.

  • Page 27: Section 2.1 Operational Analysis

    Operational Analysis Section 2.1 Field Boost Operation During the engine's crank cycle, the control panel Engine Cranking provides battery voltage (12 VDC) on Wire 56 to energize See Figure 2-2. When the engine is cranking (Evolution the starter contactor relay (SCR). 2200 rpm), field boost voltage causes the rotor to Figure 2-1.

  • Page 28: Ac Power Winding Output

    Section 2.1 Operational Analysis Regulated excitation from the regulator is delivered to the rotor windings through Wire 4 and the positive brush and slip ring. This results in current flowing through the field windings to the negative slip ring and brush, and then to ground.

  • Page 29: Preliminary Output Voltage Test

    Troubleshooting Flow Charts Section 2.2 Preliminary Output Voltage Test General Theory the transfer switch to ensure that the generator DOES NOT transfer power to the load (structure) When an Alarm of the 1900 group (Undervoltage) is during testing. displayed on the controller, certain tests need to be Navigate to the voltage display using the dealer performed to determine the actual fault.

  • Page 30: Introduction

    Section 2.2 Troubleshooting Flow Charts Table 2-2. Output Voltage Test Results Voltage Voltage Voltage Indicated Indicated Indicated Controller Controller Controller Measured Measured Measured Output Output Output Introduction Use the “Flow Charts” in conjunction with the detailed The first step in using the flow charts is to identify the correct instructions in Section 2.3 Diagnostic Tests .

  • Page 31: Problem 1 - Generator Shuts Down For Under Voltage

    Section 2.2 Troubleshooting Flow Charts Problem 1 – Generator Shuts Down for Under Voltage NOTE: Perform the Preliminary Output Voltage Test. RE-TEST TEST 4 – PERFORM FIXED EXCITATION / REPAIR ROTOR AMP DRAW OR REPLACE FUSES INSTALL LATEST FIRMWARE RETEST CHECK IF SAME RESULT REPLACE CONTROLLER...

  • Page 32: Problem 1 - Generator Shuts Down For Under Voltage (Continued)

    Section 2.2 Troubleshooting Flow Charts Problem 1 – Generator Shuts Down for Under Voltage (Continued) NOTE: Perform the Preliminary Output Voltage Test. TEST 4 – PERFORM TEST 7 – FIXED EXCITATION TEST STATOR / ROTOR AMP DRAW GOOD PERFORM TEST 10 – STATOR TEST ROTOR INSULATION...

  • Page 33: Problem 3 - Voltage And Frequency Drop Excessively When Loads Are Applied

    Section 2.2 Troubleshooting Flow Charts Problem 3 – Voltage and Frequency Drop Excessively When Loads Are Applied IF RECONFIGURED TO LP GAS, TEST 14 - CHECK TEST 15 - CHECK VERIFY THAT PROPER BOTH VOLTAGE AND FOR OVERLOAD OVERLOADED PROCEDURE WAS FOLLOWED FREQUENCY CONDITION (REFER TO SECTION 1.3)
  • Page 34 Section 2.2 Troubleshooting Flow Charts This page intentionally left blank. Diagnostic Repair Manual...

  • Page 35: Section 2.3 Diagnostic Tests

    Diagnostic Tests Section 2.3 Introduction • When does the fault occur? • After the fault occurred what was displayed in the This section familiarizes the service technician with LCD? acceptable procedures for the testing and evaluation of various problems that can occur on the standby •...

  • Page 36: Test 3 - Calibrate Voltage

    Section 2.3 Diagnostic Tests Procedure Set DMM to measure AC voltage. Open the Main Line Circuit Breaker (MLCB) on the generator. On the controller, press the ESC key until the main menu is present. (Refer to the Menu Navigation found in Section 1.10) While at this screen proceed to enter the password: UP, UP, ESC, DOWN, UP, ESC, UP, ENTER...

  • Page 37: Field Boost Circuit Tests

    Section 2.3 Diagnostic Tests Field Boost Circuit Tests If 0 VDC was measured during field flash, refer back to the flow chart. Test FB1 – Test Wire 4 Test FB3 – Diode Test General Theory General Theory This test is to verify that Wire 4 is receiving field flash This test is to verify that the field flash diode is working voltage during startup of the generator.

  • Page 38: Test 4 - Fixed Excitation Test/Rotor Amp Draw Test

    Section 2.3 Diagnostic Tests If readings of INFINITY (OL) on Step 7 and INFINITY on Step 12, Diode or wire is bad (open), Table 2-5. Test 4 Results wire harness/diode needs to be repaired/replaced. If readings of approximately 0.5 Volts (in Diode Test Point Results setting) or CONTINUITY (Resistance in “Ohms”...
  • Page 39 Section 2.3 Diagnostic Tests Set the controller to MANUAL. Acknowledge and reset the under-voltage alarm present on the controller. Measure and record the voltage indicated between Wire S15A and S16A as indicated by the DMM. Set the controller to OFF. Acknowledge and reset the under-voltage alarm Results present on the controller.

  • Page 40: Test 5 - Test Sensing Circuit Transformer, Windings And Wires S15/S16 And S15A/S16A

    Section 2.3 Diagnostic Tests Table 2-7. TEST 4 Results – Fixed Excitation Test/Rotor Amp Draw Test (20 kW) Results: Size Voltage Results Above 50 Above 50 Below 50 Zero or Below 50 Below 50 Above 50 Below 50 Wire 2 & 6 Residual Volts Voltage Results Above 50...

  • Page 41: Test 6 - Test Excitation Winding Circuit 2A And

    Section 2.3 Diagnostic Tests Procedure consistent with the values found in Section 1.1 Specifications, stop testing and refer back to IMPORTANT NOTE: The excitation circuit breaker may the flow chart (Good). be hot. b. If the meter indicated an OPEN, proceed back With the generator shut down for at least two to the flow chart.
  • Page 42 Section 2.3 Diagnostic Tests Results Table 2-8. Resistance Test Points Resistance Test: If the DMM indicated a very high resistance or INFINITY, the windings are open or Test Point A Test Point B partially open. Stator Lead Wire S1 Stator Lead Wire S2 Grounded Condition: Any resistance value other Stator Lead Wire S2 Stator Lead Wire S3...

  • Page 43: Test 8 - Resistance Check Of Rotor Circuit

    Section 2.3 Diagnostic Tests Test 8 – Resistance Check of Rotor Inspect the rotor slip rings. If their appearance is dull or tarnished, polish with a fine grade abrasive Circuit material. General Theory IMPORTANT NOTE: Do not use metallic grit to polish slip rings.

  • Page 44: Test 10 - Test Rotor Assembly

    Section 2.3 Diagnostic Tests Test 10 – Test Rotor Assembly Test 12 – Check Stepper Motor Control General Theory Procedure Remove air cleaner cover to access stepper motor A rotor having open windings will cause loss of excitation and/or visually see throttle plates. current flow and as a result generator AC output voltage Physically move the throttle and verify the stepper will drop to “residual”...

  • Page 45: Test 14 - Check Voltage And Frequency Under Load

    Section 2.3 Diagnostic Tests Table 2-12. Stepper Motor Testing Test Point A Test Point B Resistance Value Red wire Orange wire approx. 10-11Ω Red wire Yellow wire approx. 10-11Ω Red wire Brown wire approx. 10-11Ω Red wire Black wire approx. 10-11Ω Red wire Ground INFINITY...

  • Page 46: Test 15 - Check For An Overload Condition

    Section 2.3 Diagnostic Tests Test 15 – Check for an Overload If the ammeter indicated amperage readings that were below the unit’s specified ratings, but rpm and Condition frequency dropped excessively refer back to General Theory flowchart. An “overload” condition exists when the generator rated Test 16 –...

  • Page 47: Section 3.1 Description And Major Components

    Description and Major Components Section 3.1 Introduction This section describes the various components that controller harness connectors used make up the Engine and DC Control systems. interconnect the controller with the various circuits of the DC and AC systems. Connector pin locations, numbers, Topics covered in this section are: associated wires and circuit functions are listed in the •...

  • Page 48: Battery Charger

    Section 3.1 Description and Major Components Table 3-4. Control Wire Recommended Length and Size (Copper conductors only) Maximum Wire Length Recommended Wire Size 1–115 ft (1–35 m) No. 18 AWG 115–185 ft (35–56 m) No. 16 AWG 185–295 ft (56–89 m) No.

  • Page 49: Auto-Off-Manual

    Section 3.1 Description and Major Components AUTO-OFF-MANUAL Starter Contactor Relay/Solenoid Figure 3-2. This feature permits the operator to (a) Figure 3-4. The starter contactor relay (SCR) select fully automatic operation, (b) start the generator provides a safe and controlled method of energizing the manually, or (c) stop the engine and prevent the solenoid located on the starter.
  • Page 50 Section 3.1 Description and Major Components Table 3-6. Evolution™ Controller e-Codes Displayed Alarm/ e-Code Description Action Step Alarm Warning Breakdown Controller Fault ALARM No E-code on HSB Replace Controller Condition - Engine Cranks but will not Start Overcrank ALARM 1100 Problem 17 Unit turns over but will not start.
  • Page 51 Section 3.1 Description and Major Components Table 3-6. Evolution™ Controller e-Codes Overloaded - Default (Output Current Method) Overload ALARM 2100 Unit is overloaded, one of the two CTs is detecting an overload condition. Check Remove Load Remove Load transfer switch loadshed functionality. (Change load dynamics or utilize loadshed). Unit was overloaded and attempted to start with a large load connected.
  • Page 52 Section 3.1 Description and Major Components This page intentionally left blank. Diagnostic Repair Manual...

  • Page 53: Section 3.2

    Section 3.2 Engine Protective Devices Section 3.2 Engine Protective Devices terminated, followed by the grounding of the ignition circuit. This will result in closure of the fuel shutoff Standby power generators will often run unattended for solenoid and subsequent loss of engine ignition. long periods.

  • Page 54: Overcrank (Evolution E-Code 1100)

    Section 3.2 Engine Protective Devices Overcrank Once the control board sees an rpm signal it will energize the fuel solenoid, drive the throttle open (Evolution e-Code 1100) and continue the crank sequence. This feature prevents the generator from damage when it Starter motor will disengage when speed reaches continually attempts to start and another problem, such as starter dropout.
  • Page 55 Section 3.2 Engine Protective Devices Table 3-8. Evolution Warnings and Alarm Parameters Continuous or 2 Description Hold-off Time Duration Time Upper threshold Lower threshold Lockout Type looks Low Oil Pressure 5 seconds 8 seconds 2 looks Digital input Digital input Hard Lockout 3 seconds 2 Re crank, Hard...
  • Page 56 Section 3.2 Engine Protective Devices This page intentionally left blank. Diagnostic Repair Manual...

  • Page 57: Section 3.3 Operational Analysis

    Operational Analysis Section 3.3 Introduction The “Operational Analysis” is intended to familiarize the service technician with the operation of the DC and AC control system. A thorough understanding of how the system works is essential to sound and logical troubleshooting. Utility Source Voltage Available Figure 3-8.
  • Page 58 Section 3.3 Operational Analysis 004874 Figure 3-8. Utility Source Voltage Available Diagnostic Repair Manual...

  • Page 59: Initial Dropout Of Utility Source Voltage

    Section 3.3 Operational Analysis Initial Dropout of Utility Source Voltage Figure 3-10. Should a Utility power failure occur, circuit condition may be briefly described as follows: • The controller continually monitors for acceptable Utility voltage via N1 and N2. Should Utility voltage drop below a percentage of nominal (adjustable, see chart) of the nominal source voltage, a programmable timer on the controller will turn on.
  • Page 60 Section 3.3 Operational Analysis 004875 Figure 3-10. Initial Dropout of Utility Source Voltage Diagnostic Repair Manual...

  • Page 61: Utility Voltage Failure And Engine Cranking

    Section 3.3 Operational Analysis Utility Voltage Failure and Engine Cranking Figure 3-11. After the controller’s adjustable programmed timer has timed out, if Utility voltage is still below the programmed utility drop out level, the controller's logic will energize the internal crank relay followed by the internal run relay.
  • Page 62 Section 3.3 Operational Analysis 004876 Figure 3-12. Utility Voltage Failure and Engine Cranking Diagnostic Repair Manual...

  • Page 63: Engine Startup And Running

    Section 3.3 Operational Analysis Engine Startup and Running Figure 3-13 Figure 3-14. With the fuel solenoid open and ignition occurring, the engine starts. Engine startup and running may be briefly described as follows: • The ignition magneto(s) deliver a speed reference signal to the controller via Wire 18. Once the controller determines that the engine is running, the controller: a.
  • Page 64 Section 3.3 Operational Analysis 004877 Figure 3-14. Engine Startup and Running Diagnostic Repair Manual...

  • Page 65: Transfer To Standby

    Section 3.3 Operational Analysis Transfer to Standby Figure 3-16 the Generator is running, the controller's “engine warm-up” timer has expired and generator AC output is available to the transfer switch Terminal Lugs E1 and E2 and to the open contacts on the transfer relay. Transfer to Standby may be briefly described as follows: •...
  • Page 66 Section 3.3 Operational Analysis 004878 Figure 3-16. Transfer to Standby Diagnostic Repair Manual...

  • Page 67: Utility Voltage Restored And Re-Transfer To Utility

    Section 3.3 Operational Analysis Utility Voltage Restored and Re-transfer to Utility Figure 3-18. The Load is powered by Generator voltage. On restoration of Utility voltage, the following events will occur: • On restoration of Utility voltage above a percentage of nominal (programmable, see chart for range) of the nominal rated voltage, a “re-transfer time delay”...
  • Page 68 Section 3.3 Operational Analysis 004879 Figure 3-18. Utility Voltage Restored and Re-transfer to Utility Diagnostic Repair Manual...

  • Page 69: Engine Shutdown

    Section 3.3 Operational Analysis Engine Shutdown Figure 3-20. Following re-transfer back to the Utility source an “engine cool-down timer” on the controller starts timing. When the timer has expired (approximately one minute), the controller will de-energize the internal run relay removing fuel from the engine.
  • Page 70 Section 3.3 Operational Analysis 004880 Figure 3-20. Engine Shutdown Diagnostic Repair Manual...

  • Page 71: Section 3.4 Troubleshooting Flowcharts

    Troubleshooting Flowcharts Section 3.4 Problem 14 – Shutdown Alarm/Fault Occurred During Crank Attempt, Start or Run OVERCRANK GO TO PROBLEM 17 E-CODE 1100 - Evolution CHECK INSTALLATION FOR TEST 62 – CHECK HIGH HIGH TEMP PROPER AIRFLOW OR OIL TEMPERATURE E-CODE 1400 - Evolution REPLACE DEFECTIVE SWITCH SWITCH...

  • Page 72: Problem 15 - Engine Will Not Crank When Utility Power Source Fails

    Section 3.4 Troubleshooting Flowcharts Problem 15 – Engine Will Not Crank When Utility Power Source Fails TEST 40 – CHECK SWITCH IS IN “AUTO” TEST 41 – TRY A VERIFY UTILITY POSITION OF AND UNIT IS NOT IN 2 MANUAL START SOURCE IS “OFF”...

  • Page 73: Problem 17 - Engine Cranks But Will Not Start

    Section 3.4 Troubleshooting Flowcharts Problem 17 – Engine Cranks but Will Not Start IMPORTANT NOTE: Verify the correct fuel is selected! TEST 50 – CHECK TEST 51 – CHECK TEST 52 – CHECK GOOD GOOD FUEL SUPPLY AND CONTROLLER FUEL SOLENOID PRESSURE WIRE 14 OUTPUT REPLACE FUEL SOLENOID...

  • Page 74: Problem 18 - Engine Starts Hard And/Or

    Section 3.4 Troubleshooting Flowcharts Problem 18 – Engine Starts Hard and/or Runs Rough / Lacks Power / Backfires / Hunting / Erratic Operation IF RECONFIGURED TO LP GAS, TEST 50 – CHECK CHECK AIR FILTER - VERIFY THAT PROPER FUEL SUPPLY AND GOOD GOOD REPLACE AS NEEDED...

  • Page 75: Problem 19 - 7.5 Amp Fuse (F1) Blown (E-Code 2400)

    Section 3.4 Troubleshooting Flowcharts Problem 19 – 7.5 Amp Fuse (F1) Blown (e-Code 2400) FUSE BLOWS WHEN TEST 66 – CHECK PLACED IN “AUTO” CRANKING AND OR “MANUAL” RUNNING CIRCUITS Problem 20 – Generator Will Not Exercise TEST 65 – TEST EXERCISE FUNCTION Problem 21 –...
  • Page 76 Section 3.4 Troubleshooting Flowcharts This page intentionally left blank. Diagnostic Repair Manual...

  • Page 77: Section 3.5 Diagnostic Tests

    Diagnostic Tests Section 3.5 Introduction When working on this equipment, use common sense and remain alert at all times. Never work on this This section familiarizes the service technician with equipment while you are physically or mentally fatigued. acceptable procedures for the testing and evaluation of If you do not understand a component, device or system, various problems that can occur on standby generators do not work on it.

  • Page 78: Test 41 - Try A Manual Start

    Section 3.5 Diagnostic Tests Results With the Inputs Screen displayed place the controller to MANUAL. If the controller reads an input from the normal automatic operation obtained, Switch, Input 8 will change from “0” to “1”. discontinue tests. With the controller set to OFF, both inputs will read If the engine does not crank when Utility power is zero.

  • Page 79: Test 45 - Check Battery And Cables

    Section 3.5 Diagnostic Tests General Theory Set the controller to MANUAL. Measure and record the voltage. The 7.5 amp fuse is located on the generator control Record readings from test points A, B and C as console. A blown fuse will prevent battery power from depicted in Figure 3-23.

  • Page 80: Test 46 - Check Wire 56 Voltage

    Section 3.5 Diagnostic Tests NOTE: Disconnect negative cable first. Using a lead acid battery load tester test the load capability of the battery. Follow the load tester’s manufacturer’s instructions carefully. Connect both positive and negative cables. NOTE: Connect positive cable first. 002411 A.

  • Page 81: Test 47 - Test Starter Contactor Relay

    Section 3.5 Diagnostic Tests NOTE: If the unit does not crank the Alarm Log will If the DMM did NOT indicate CONTINUITY in Step display, “Stopped-Alarm RPM Sense Loss.” 11, repair or replace Wire 56 between the controller side of the harness and the relay. Procedure Set the DMM to measure DC voltage.

  • Page 82: Test 48 - Test Starter Contactor

    Section 3.5 Diagnostic Tests Results Results: V-Twin Engine If battery voltage was NOT measured in Step 3, repair If the DMM did not indicate battery voltage in Step or replace Wire 13 between the SCR and the SC. 5, measure the resistance on Wire 16 between the SCR and the contactor.

  • Page 83: Test 50 - Check Fuel Supply And Pressure

    Section 3.5 Diagnostic Tests Results DANGER If battery voltage is indicated on the meter but Explosion and fire.Fuel and vapors are extremely starter motor did not operate, remove and bench flammable and explosive. No leakage of fuel is test the starter motor. permitted.

  • Page 84: Test 51 - Check Controller Wire 14 Outputs

    Section 3.5 Diagnostic Tests NOTE: If pressure is above specifications correct/adjust Set a DMM to measure resistance. supply regulator to generator to maintain proper fuel Connect one meter test lead to Wire 14 pressure. (disconnected in Step 3). Connect the other meter test lead to Wire 14 at the controller side of the Test 51 –...

  • Page 85: Test 57 - Check Spark Plug Condition

    Section 3.5 Diagnostic Tests Figure 3-34. When using this style spark tester the adjustment screw must be set to the proper distance for the type of ignition system being tested. For the magneto system used on the HSB engines, set the distance of the adjustment screw tip at the 10kV mark.

  • Page 86: Test 58 - Check Engine / Compression Test / Cylinder Leak Down Test

    Section 3.5 Diagnostic Tests Check Compression General Theory Lost or reduced engine compression can result in a failure of the engine to start, or rough operation. One or more of the following will usually cause loss of compression: • Blown or leaking cylinder head gasket. •...

  • Page 87: Cylinder Leak Down Test

    Section 3.5 Diagnostic Tests Cylinder Leak Down Test Adjust the regulated pressure on the gauge to the manufactures setting for the tool that you are using— General Theory typically 90 psi. Verify flywheel/fan has not rotated. Read the gauge on the tester for cylinder percent The Cylinder Leak Down Tester checks the sealing of leakage.

  • Page 88: Test 60 - Check And Adjust Ignition Magnetos

    Section 3.5 Diagnostic Tests If spark is now present with Wire 18 removed, meter lead to the spark plug wire or to ground proceed to check for a short to ground (Steps 4 following Table 3-11. through 7). On V-twin generators, repeat Steps 5 and 6 on Disconnect the harness connector from the Cylinder Two.
  • Page 89 Section 3.5 Diagnostic Tests Figure 3-41. Rotate the flywheel (by hand) NOTE: If gap is only adjusted, properly test the until the magnet is under the module (armature) magnetos by cranking the engine before reassembly. laminations. Spark should be present on both cylinders. Place a 0.008-0.012 inch (0.20-0.30mm) non If air gap was not out of adjustment, test ground metallic thickness gauge between the flywheel...

  • Page 90: Test 61 - Check Oil Pressure Switch And Wire 86 (Evolution E-Code 1300)

    Section 3.5 Diagnostic Tests Once the magnetos are visible, make note of how they are connected. NOTE: Each magneto has its own part number. Verify the part number prior to installation. Figure 3-43. Cylinder one is the back cylinder. Figure 3-44.
  • Page 91 Section 3.5 Diagnostic Tests Procedure Navigate to the Digital inputs display screen of the controller being worked on. a. See Figure 3-48. Digital Input 2 is Wire 86 from the Low Oil Pressure switch to the board. b. Set the controller to MANUAL. Observe Input 2 for a change from “1”...

  • Page 92: Test 62 - Check High Oil Temperature Switch (E-Code 1400)

    Section 3.5 Diagnostic Tests Results If the switch operated properly and proper oil pressure was measured, and Wires 86 and 0 tested good, and/or the Input would not change on the controller, replace the controller. Test 62 – Check High Oil Temperature Switch (e-Code 1400) General Theory...

  • Page 93: Test 64 - Check Wire 18 Continuity

    Section 3.5 Diagnostic Tests Figure 3-52. Wire 18 Connection 002380 Disconnect Wire 18 from magneto sensing lead. Figure 3-51. Valve Clearance Adjustment a. Connect one meter test lead to an engine Turn the pivot ball stud (D) using a 10 mm Allen ground and connect the other meter test lead wrench while checking clearance between the to the magneto lead terminal.

  • Page 94: Test 66 - Test Cranking And Running Circuits

    Section 3.5 Diagnostic Tests NOTE: CONTINUITY is equal to 0.01 ohms of resistance or a dead short. Table 3-12. Component Resistance Values Starter Contactor Relay 155 - 158Ω 004956 Fuel Solenoid 15 - 16Ω Figure 3-53. The Exercise Screen Procedure Procedure Utility voltage must be present.

  • Page 95: Test 68 - Test Crank Circuit

    Section 3.5 Diagnostic Tests Test 75 – Test 120 Volt Input (T1) 60 Hz Refer to Table 3-13 and if the DMM indicated the correct resistance for the component, a short to 220 Volt Input (T1) 50 Hz ground exists on Wire 14. Repair and replace Wire 14 as needed.

  • Page 96: Test 77 - Check Wire 13 And Wire 0

    Section 3.5 Diagnostic Tests Test 77 – Check Wire 13 and Wire 0 General Theory The previous test indicated that battery voltage was not available to the controller and it was operating only off of the 120 VAC input from T1. 002435 Figure 3-55.

  • Page 97: Test 81 - Check T1 Voltage In Transfer Switch

    Section 3.5 Diagnostic Tests Test 82 – Test F3 Fuse Circuit proceed to Step 3. If voltage is not present check the T1 wire from the customer Procedure connection block to the controller harness connector. Set a DMM to measure AC voltage. b.
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  • Page 99: Section 4.1 Major Disassembly

    Major Disassembly Section 4.1 Major Disassembly Safety Remove Side Exhaust Enclosure Cover: See Figure 4-3. Use a 10 mm socket to remove the five Set the controller to OFF. bolts from the exhaust side cover. Remove side Figure 4-1. Remove the 7.5 amp main fuse. covers.
  • Page 100 Section 4.1 Major Disassembly 002661 Figure 4-5. Figure 4-7. Muffler Assembly: See Figure 4-6. Depending on the clamp, use a ½” or 10 mm socket to remove the muffler clamp and flex pipe. Leave muffler attached to the divider panel. 002662 Figure 4-8.
  • Page 101 Section 4.1 Major Disassembly 003156 003159 Figure 4-10. Figure 4-12. Remove Rotor Fan: See Figure 4-11. Attach a vibration dampener or suitable puller to the fan using two M8 x 1.25 bolts. Remove the fan from the rotor. 003163 Figure 4-13. Brushes on Evolution Unit Remove Brush Wires: See Figure 4-14.
  • Page 102 Section 4.1 Major Disassembly Remove Controls Cover: See Figure 4-15. Use a Alternator Air Intake Bellows Removal: See 4 mm Allen wrench to remove cover bolts and Figure 4-18. Remove alternator intake bellows. ground washer from the controls cover. Remove the controls cover.

  • Page 103: Rotor Removal

    Section 4.1 Major Disassembly Rotor Removal: NOTE: Each model uses a specific rotor bolt. Verify the correct bolt is being used for the rotor being serviced. a. Cut 0.5 inches from the rotor bolt. Slot the end of the bolt to suit a flat blade screwdriver. b.

  • Page 104: Torque Specifications

    Section 4.1 Major Disassembly Torque Specifications Figure 4-25. Using proper lifting equipment remove the engine. Stator Bolts 6 ft-lbs (+1 / -0) Rotor Bolt 30 ft-lbs Engine Adapter 25 ft-lbs Exhaust Manifold 18 ft-lbs M5-0.8 Taptite Screw Into Aluminum 25-50 in-lbs M5-0.8 Taptite Screw Into Pierced Hole 25-50 in-lbs M6-1.0 Taptite Screw Into Aluminum...

  • Page 105: Appendix A Controller And Electrical Data

    Controller and Electrical Data Appendix A Important Note Use wire numbers only and disregard any specific “J” Connector references. Utilize the wire numbers and controller pin out chart in this appendix per specific connector styles! Probing and Pin Extraction Use the special tool (P/N 0J09460SRV) to back probe the connector.

  • Page 106: Evolution Controller

    Appendix A Controller and Electrical Data Evolution Controller Figure 1-5 – Evolution Air-cooled Panel has 3 Molex style connectors on the back (J1, J2, & J3), one actuator connector (J5), a battery charger connector (J8 & J9), and a connector socket for a remote annunciator (optional accessory).
  • Page 107 Appendix A Controller and Electrical Data J2 Connector J3 Connector Wire Circuit Function Wire Circuit Function J2-1 Auxiliary Shutdown Ground J3-1 Common Ground (DC) DC Field Excitation Ground J2-2 Common Alarm Relay Output J3-2 DC (+) Field Excitation J2-3 Common Alarm Relay Input J3-3 DPE Winding (AC Excitation power) J2-4...

  • Page 108: Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase – Drawing 100000003828-D Diagnostic Repair Manual...

  • Page 109: Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase – Drawing 100000003828-D Diagnostic Repair Manual...

  • Page 110: Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase – Drawing 100000003828-D Diagnostic Repair Manual...

  • Page 111: Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase – Drawing 100000003828-D Diagnostic Repair Manual...

  • Page 112: Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase – Drawing 100000003828-D Diagnostic Repair Manual...

  • Page 113: Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase – Drawing 100000003828-D Diagnostic Repair Manual...

  • Page 114: Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase – Drawing 100000003829-D Diagnostic Repair Manual...

  • Page 115: Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase – Drawing 100000003829-D Diagnostic Repair Manual...

  • Page 116: Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase – Drawing 100000003829-D Diagnostic Repair Manual...

  • Page 117: Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase – Drawing 100000003829-D Diagnostic Repair Manual...

  • Page 118: Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase – Drawing 100000003829-D Diagnostic Repair Manual...

  • Page 119: Appendix A Controller And Electrical Data

    Appendix A Controller and Electrical Data Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase – Drawing 100000003829-D Diagnostic Repair Manual...
  • Page 120 Appendix A Controller and Electrical Data This page intentionally left blank. Diagnostic Repair Manual...

  • Page 121: 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 122 ©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.