Generac Power Systems CorePower 6/7 kW 60 Hz Diagnostic Repair Manual page 4

Contents
Setting Priorities .......................................................... 44
Tests ...................................................................... 44
Troubleshooting .......................................................... 45
Section 3.2 – Operational Analysis .......................................... 46
Utility Voltage Present ................................................. 46
Transfer to Standby .................................................... 46
Transfer to Utility ......................................................... 46
Section 3.3 – Troubleshooting Flowcharts ............................... 47
Introduction ................................................................. 47
Problem 10 – In Automatic Mode,
No Transfer to Standby ................................. 47
Problem 11– In Automatic Mode, Generator
Starts When Loss of Utility Occurs,
Generator Shuts Down When
Utility Returns But There is
No Retransfer to Utility Power Or
Generator Transfers To Standby During
Exercise or in Manual Mode ......................... 47
Problem 12 – Blown F1 Or F2 Fuse ........................... 48
Problem 13 – Blown T1 Fuse ..................................... 48
Problem 14 – Unit Starts and Transfer Occurs When
Utility Power is On ......................................... 48
Smm Problem 1 – Load Management Module
(SMM) LED Is Off, Load Not Powered .......... 48
Smm Problem 2 – Load Management Module
(SMM) LED Is On, Load Not Powered .......... 49
Smm Problem 3 – Load Management Module
(SMM) LED is Flashing, Load Not Powered . 49
Smm Problem 4 – Load Management Module
(SMM) is Humming or Buzzing ..................... 49
Section 3.4 – Diagnostic Tests ................................................. 50
Introduction ................................................................. 50
Safety ...................................................................... 50
Transfer Switch Troubleshooting ............................... 50
Test 26 – Check Manual Transfer Switch Operation ... 50
Test 27 – Check Generator Voltage At Transfer Switch 51
Test 28 – Test Transfer Operator
(GenReady Switch Only) .............................. 51
Test 29 – Check 15B/194 Circuit ............................... 51
Test 30 – Check Wire 23 Circuit ................................. 51
Test 32 – Check Fuses F1 and F2 .............................. 52
Test 33 – Check N1 and N2 Wiring ............................. 53
Test 35 – Check Fuse F3 ........................................... 53
Test 36 – Check T1 Wiring (60 Hz) ............................. 53
Test 36A – Check T1 and T2 Wiring (50 Hz)............... 53
Test 37 – Test SMM Contactor
Line, Load and Control .................................. 54
Test 38 – Check N1 and N2 Voltage ........................... 54
Test 39 – Check Utility Sense Voltage ........................ 54
Test 40 – Check Utility Voltage at Transfer Switch ..... 55
Test 41 – Check Utility Sensing Voltage
at the Controller ............................................ 55
Page 2
Part 4 – Engine/DC Control ......................................................59
Section 4.1 – Description And Components ............................ 60
General ...................................................................... 60
Terminal Strip / Interconnection Terminal
(Corepower Only) .......................................... 60
Controller .................................................................... 60
Auto-Off-Manual Control ............................................. 60
7.5 Amp Fuse .............................................................. 60
Battery Charger (Corepower Only) ............................. 60
Section 4.2 – Engine Protective Devices ................................. 63
Alarms ...................................................................... 63
Clear Alarms ............................................................... 63
Warnings ..................................................................... 63
Section 4.3 – Operational Analysis .......................................... 64
Utility Source Available - Corepower .......................... 64
Utility Failure and Engine Cranking - Corepower ........ 64
Utility Failure and Engine Running - Corepower ......... 66
Utility Source Available - Powerpact ........................... 67
Utility Failure and Engine Cranking - Powerpact ........ 68
Utility Failure and Engine Running - Powerpact ......... 69
Section 4.4 – Troubleshooting Flowcharts ............................... 70
Problem 20 – Engine Will Not Crank When
Utility Power Source Fails ............................. 70
Problem 21 – Engine Will Not Crank When
Controller is Set to "Manual" Mode ............... 70
Problem 22 – Engine Cranks But Won't Start ............. 71
Problem 23 – Engine Starts Hard and
Runs Rough / Lacks Power / Backfires ......... 72
Problem 24 – Shutdown Alarm/Fault Occurred .......... 73
Problem 25 – 7.5 Amp Fuse (F1) Blown ..................... 74
Problem 26 – Generator Will Not Exercise ................. 74
Problem 27 – No Battery Charge ................................ 74
Section 4.5 – Diagnostic Tests ................................................. 75
Introduction ................................................................. 75
Safety ...................................................................... 75
Engine/DC Troubleshooting ....................................... 75
Test 52 – Check Controller Switch Position ................ 75
Test 53 – Try a Manual Start ...................................... 76
Test 54 – Test Auto Operations ................................... 76
Test 55 – Check 7.5 Amp Fuse ................................... 76
Test 56 – Check Battery and Cables .......................... 77
Test 57 – Check Wire 56 Voltage ................................ 78
Test 58 – Test Starter Contactor ................................. 79
Test 59 – Test Starter Motor ........................................ 79
Test 60 – Check Fuel Supply and Pressure ................ 80
Test 61 – Check Controller Wire 14 Output ................ 81
Test 62 – Check Fuel Solenoid ................................... 81
Test 63 – Check Choke Solenoid ................................ 81
Test 64 – Check For Ignition Spark ............................. 82
Test 65 – Check Spark Plugs ...................................... 83
Test 66 – Check Engine / Cylinder Leak Down Test /
Compression Test ......................................... 83
Cylinder Leak Down Test ............................................ 84