Generac Power Systems CorePower Repair Manual
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Generac Power Systems CorePower Repair Manual

Home standby generator
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DIAGNOSTIC
REPAIR
MANUAL
CorePower Home Standby Generator
MODELS:
6/7 kW
S T A N D B Y G E N E R A T O R S

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  • Page 1 ® DIAGNOSTIC REPAIR MANUAL CorePower Home Standby Generator MODELS: 6/7 kW S T A N D B Y G E N E R A T O R S...

  • Page 2: Safety

    Foreword SAFETY READ THIS MANUAL THOROUGHLY Throughout this publication, DANGER, WARNING, and CAUTION This SERVICE MANUAL has been written and published by blocks are used to alert the mechanic to special instructions Generac to aid our dealers' technicians and company service concerning a particular service or operation that might be personnel when servicing the products described herein.

  • Page 3: Table Of Contents

    SAFETY ................2 Section 1.7 – General Troubleshooting ......22 Read This Manual Thoroughly ..........2 Introduction ............22 Specifications ..............4 Recommended Tools ..........22 Generator ............... 4 Troubleshooting Reminders and Tips ..... 22 Engine ..............4 Connectors ............22 Fuel Consumption ...........
  • Page 4 Section 3.2 – Operational Analysis ........39 Section 4.4 – Troubleshooting Flowcharts ......57 Utility Voltage Present ........... 39 Problem 20 – Engine Will Not Crank When Utility Power Source Fails ........57 Transfer to Standby ..........39 Problem 21 – Engine Will Not Crank When Transfer to Utility ...........
  • Page 5 PART 5 – Disassembly ............81 Section 5.1 – Major Disassembly ........82 Section 5.2 – Exploded Views ........... 90 PART 6 – Electrical Data ..........101 Wiring Diagram ............... 102 Electrical Schematic ............103 Electrical Formulas ............104 Appendix A – Supplemental Worksheets......105 Appendix B –...

  • Page 6: Specifications

    Specifications  Caution: Specifications are for reference only, for actual installations always use the most recent version available online. These specifications are subject to change without notice. GENERATOR Rated Voltage Rated Maximum Load Current (Amps) at 240 Volts (LP)* 29.2 Main Circuit Breaker 30 Amp Transfer Switch Load Center Circuits** 30A, 240V...

  • Page 7: Fuel Consumption

    Specifications FUEL CONSUMPTION Natural Gas* LP Vapor** Unit 1/2 Load Full Load 1/2 Load Full Load 6/7 kW 0.82/30 1.47/53 * Natural gas is in cubic feet per hour. **LP is in gallons per hour/cubic feet per hour. Values given are approximate. MAJOR FEATURES Data Label Control Panel...
  • Page 8 Specifications Page 6...
  • Page 9 Specifications Page 7...
  • Page 10 NOTES Page 8...

  • Page 11: Part 1 - General Information

    PART 1 GENERAL INFORMATION PART 1 – GENERAL INFORMATION ........9 Section 1.5 – Automatic Operating Parameters ....18 Section 1.1 – Generator Basics ......... 10 Introduction ............18 Introduction ............10 Utility Failure ............18 Parts ..............10 Cranking ............... 18 Generator Identification .........

  • Page 12: Section 1.1 - Generator Basics

    Section 1.1 PART 1 GENERAL INFORMATION Generator Basics INTRODUCTION GENERATOR IDENTIFICATION This diagnostic repair manual has been prepared especially for Data Plate familiarizing service personnel with the testing, troubleshooting and repair of the vertical home standby systems. Every The data plate that is affixed to the generator contains effort has been expended to ensure that the information and important information pertaining to the unit, including its model instructions in the manual are both accurate and current.

  • Page 13: Section 1.2 - Measuring Electricity

    Section 1.2 Section 1.2 PART 1 PART 1 GENERAL INFORMATION GENERAL INFORMATION Measuring Electricity Installation Basics METERS MEASURING AC VOLTAGE Devices used to measure electrical properties are called An accurate AC voltmeter or a VOM may be used to read the meters.

  • Page 14: Measuring Current

    Section 1.2 PART 1 GENERAL INFORMATION Measuring Electricity In-Line MEASURING CURRENT Alternatively, to read the current flow in AMPERES, an in-line Clamp-On ammeter may be used. Most Digital Volt Ohm Meters (VOM) will have the capability to measure amperes. To read the current flow, in AMPERES, a clamp-on ammeter may be used.

  • Page 15: Electrical Units

    Section 1.2 PART 1 GENERAL INFORMATION Measuring Electricity Component testing may require a specific resistance value or a test for INFINITY or CONTINUITY. Infinity is an OPEN The OHM is the unit of RESISTANCE. In every circuit there condition between two electrical points, which would read as is a natural resistance or opposition to the flow of electrons.

  • Page 16: Section 1.3 - Preparation Before Use

    Section 1.3 PART 1 GENERAL INFORMATION Preparation Before Use Verify that gas meter is capable of providing enough fuel flow INTRODUCTION to include household appliances. It is the responsibility of the installer to ensure that the Generator installation was performed properly. A careful inspection Btu Flow Requirements - Natural Gas must be performed when the installation is complete.
  • Page 17 Section 1.3 PART 1 GENERAL INFORMATION Preparation Before Use Insert the Propane fuel jet into the end of the fuel inlet. 10. Reinstall the hose and clamp onto the fuel inlet and secure. 11. Verify the hose has not been kinked in any way. Fuel Inlet O-Ring (installed) Throttle...

  • Page 18: Section 1.4 - Operating Instructions

    Section 1.4 PART 1 GENERAL INFORMATION Operating Instructions To select automatic operation CONTROL PANEL The following procedure applies only to those installations which utilize an air-cooled generator in conjunction with a transfer switch. Residential transfer switches do not have  WARNING! With the switch set to AUTO, the engine intelligent circuits of their own.
  • Page 19 Section 1.4 PART 1 GENERAL INFORMATION Operating Instructions Retransfer Back to “Utility” and Manual Shutdown To shutdown the generator and retransfer electrical loads back to the “Utility” position, the procedure is as follows: Set the generators MLCB to its OPEN position. Allow the generator to run at no-load for several minutes to cool down.

  • Page 20: Section 1.5 - Automatic Operating Parameters

    Section 1.5 PART 1 GENERAL INFORMATION Automatic Operating Parameters Once the controller sees an RPM signal it will energize the INTRODUCTION fuel solenoid and continue the crank sequence. The fuel When the generator is installed in conjunction with a transfer solenoid does not activate earlier because if the engine switch, either manual or automatic operation is possible.
  • Page 21 Section 1.5 PART 1 GENERAL INFORMATION Automatic Operating Parameters Exercise • Exercise will not function if the generator is already running in either AUTO or MANUAL mode. • During exercise, the controller will only transfer if Utility fails during exercise for 10 seconds, and will follow the steps outline above for AUTO operation.

  • Page 22: Section 1.6 - General Maintenance

    Section 1.6 PART 1 GENERAL INFORMATION General Maintenance INTRODUCTION VISUAL INSPECTION Performing proper maintenance on a Generator will ensure During all service intervals, a proper visual inspection must be proper function during a Utility failure. Once a Generator has conducted to ensure proper function, airflow, and to prevent failed, it is already too late.

  • Page 23: Battery

    Section 1.6 PART 1 GENERAL INFORMATION General Maintenance BATTERY Performing proper battery maintenance at the required intervals will allow for proper starting of the Generator during a power outage. Some common things to look for and check during maintenance are: • Inspect the battery posts and cables for tightness and corrosion.

  • Page 24: Section 1.7 - General Troubleshooting

    Section 1.7 PART 1 GENERAL INFORMATION General Troubleshooting Recommended Tools Check List INTRODUCTION This section familiarizes the service technician with the p General Mechanics Tool Box manufacturer recommended procedures for the testing and p A Meter Capable of Measuring Frequency (Hz), AC & DC evaluation of various problems that can occur on the standby volts, DC amps, and Ohms generators.

  • Page 25: Part 2 - Ac Generators

    PART 2 AC GENERATORS PART 2 – AC Generators ............23 Section 2.4 – Diagnostic Tests .......... 30 Section 2.1 – Description and Components ....... 24 Introduction ............30 Safety ..............30 Introduction ............24 AC Troubleshooting..........30 Engine-Generator Drive System ......24 Test 1 –...

  • Page 26: Section 2.1 - Description And Components

    Section 2.1 PART 2 AC GENERATORS Description and Components INTRODUCTION The alternator contained within the generator is a revolving field (rotor) type with a stationary armature (stator), and excitation to the field provided through brushes and slip rings (direct STATOR excitation).

  • Page 27: Other Ac Generator Components

    Section 2.1 PART 2 AC GENERATORS Description and Components OTHER AC GENERATOR COMPONENTS Located within the generator control panel enclosure are the voltage regulator and the main line circuit breaker. Voltage Regulator Unregulated AC output from the stator excitation winding is delivered to the regulator’s DPE circuit through the two Blue wires and C1-1 and C1-2.

  • Page 28: Section 2.2 - Operational Analysis

    Section 2.2 PART 2 AC GENERATORS Operational Analysis and regulated current flow from the regulator is delivered to the STARTUP rotor windings through the (+) Red Wire and the positive brush When the engine is started, permanent magnets embedded in and slip ring.

  • Page 29: Section 2.3 - Troubleshooting Flowcharts

    Section 2.2 PART 2 AC GENERATORS Troubleshooting Flow Charts INTRODUCTION Use the “Flow Charts” in conjunction with the detailed instructions in Section 2.4. Test numbers used in the flow charts correspond to the numbered tests in Section 2.4. The first step in using the flow charts is to identify the correct problem on the following pages. For best results, perform all tests in the exact sequence shown in the flow charts.

  • Page 30: Problem 2 - Generator Produces Low Voltage At No-Load

    Section 2.3 PART 2 AC GENERATORS Troubleshooting Flow Charts Problem 1 – Generator Produces Zero Voltage or Residual Voltage (Continued) TEST 4 – PERFORM FIXED EXCITATION / ROTOR AMP DRAW TEST 9 – TEST STATOR GOOD TEST 10 – TEST 9 – TEST TEST ROTOR STATOR ASSEMBLY...

  • Page 31: Problem 3 - Generator Produces High Voltage At No-Load

    Section 2.3 PART 2 AC GENERATORS Troubleshooting Flow Charts Problem 3 – Generator Produces High Voltage at No-Load TEST 11 – CHECK TEST 12 – CHECK TEST 13 – ADJUST AC OUTPUT AC OUTPUT ENGINE HIGH VOLTAGE FREQUENCY GOVERNOR FREQUENCY AND FREQUENCY O.K., VOLTAGE O.K.

  • Page 32: Section 2.4 - Diagnostic Tests

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Procedure INTRODUCTION The generator main circuit breaker is located in the external This section familiarizes the service technician with acceptable customer connection box. If loads are not receiving power, procedure for the testing and evaluation of various problems make sure the breaker is set to “On”...

  • Page 33: Diagnostic Tests

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Procedure BLACK WIRE RED WIRE Locate and disconnect the Red Wire and the Black Wire TO BRUSHES TO BRUSHES from the voltage regulator. Set a Volt-Ohm-Meter (VOM) to measure resistance. MALE SPADE TERMINALS Connect one meter test lead to the Red brush wire and (INSULATED) (INSULATED)

  • Page 34: Test 6 - Resistance Check Of Rotor Circuit

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests 21. Set the AUTO-OFF-MANUAL switch to the MANUAL If the VOM did not indicate the proper resistance, refer position. back to flow chart. 22. Measure and record the running DC amperage. 23. Set the AUTO-OFF-MANUAL switch to the OFF position TEST 7 –...

  • Page 35: Test 9 - Test The Stator

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Table 4. Test Points – Resistance Tests TEST 9 – TEST THE STATOR Discussion Test Point A Test Point B Stator Lead Blue Wire Stator Lead Black Wire This test will use a Volt-Ohm-Milliammeter (VOM) to test the stator windings for the following faults: Stator Lead Blue Wire C1 Pin 3 (White Wire)

  • Page 36: Test 10 - Test Rotor Assembly

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Results Resistance Test: If the VOM indicated a very high  DANGER! Use extreme caution during this test. The generator will be running. High and dangerous voltages resistance or INFINITY, the windings are open or partially will be present at the test terminals.

  • Page 37: Test 13 - Adjust Engine Governor

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Procedure TEST 14 – ADJUST VOLTAGE REGULATOR Connect an accurate AC frequency meter across the Blue Procedure and Black Wire terminals of the generator main line circuit breaker (see Figure 19). Remove two screws holding down the voltage regulator (AVR).

  • Page 38: Test 15 - Check For Overload Condition

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests TEST 15 – CHECK FOR OVERLOAD TEST 16 – CHECK VOLTAGE AND CONDITION FREQUENCY UNDER LOAD Discussion Discussion An “overload” condition is one in which the generator rated It is possible for the generator AC output frequency and voltage wattage/amperage capacity has been exceeded.

  • Page 39: Part 3 - Transfer Switch

    PART 3 TRANSFER SWITCH PART 3 – Transfer Switch ..........37 Section 3.4 – Diagnostic Tests .......... 43 Section 3.1 – Description and Components ....... 38 Introduction ............43 General ..............38 Safety ..............43 Enclosure ............. 38 Transfer Switch Troubleshooting ......43 EZ Transfer Operator ..........

  • Page 40: Section 3.1 - Description And Components

    Section 3.1 PART 3 TRANSFER SWITCH Description and Components GENERAL FUSE HOLDER The 50 amp transfer switch is designed to operate in conjunction Utility N1 and N2 with all product which utilizes the Wire 194/15B and Wire 23 control systems. Utility voltage and the control panel on the N1 and N2 provide the Utility voltage-sensing signal to the generator controls sequence delays.

  • Page 41: Section 3.2 - Operational Analysis

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis • The K1 relay is energized, contacts 11 and 13 open, and UTILITY VOLTAGE PRESENT 8 and 7 close completing a path for current to flow to the When Utility voltage is present, the circuit may be briefly servo motor.
  • Page 42 NOTES PART 3 TRANSFER SWITCH Page 40...

  • Page 43: Section 3.3 - Troubleshooting Flowcharts

    Section 3.3 PART 3 TRANSFER SWITCH Troubleshooting Flowcharts INTRODUCTION Use the “Flow Charts” in conjunction with the detailed instructions in Section 3.4. Test numbers used in the flow charts correspond to the numbered tests in Section 3.4. The first step in using the flow charts is to identify the correct problem on the following pages. For best results, perform all tests in the exact sequence shown in the flow charts.

  • Page 44: Problem 12 - Blown F1 Or F2 Fuse

    Section 3.3 PART 3 TRANSFER SWITCH Troubleshooting Flowcharts Problem 12 – Blown F1 or F2 Fuse TEST 32 – CHECK TEST 33 – CHECK INSPECT/REPLACE GOOD N1 & N2 WIRING FUSE F1 & F2 CONTROLLER GOOD FINISH REPAIR OR REPLACE WIRING Problem 13 –...

  • Page 45: Section 3.4 - Diagnostic Tests

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests INTRODUCTION TEST 27 – CHECK GENERATOR VOLTAGE AT This section familiarizes the service technician with acceptable TRANSFER SWITCH procedure for the testing and evaluation of various problems Procedure that can occur on pre-packaged transfer switches. Use this section in conjunction with Section 3.3, “Troubleshooting Flow Set Volt-Ohm-Milliammeter (VOM) to measure AC voltage Charts.”...

  • Page 46: Test 30 - Check Wire 23 Circuit

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests b. If the VOM did not indicate battery voltage, proceed to 10. Once the generator has started and warmed up, connect Step 4. one meter test lead to the XFER terminal and the other meter test lead to the BAT + terminal in the transfer Connect one meter test lead to Wire 15B and the other switch.

  • Page 47: Test 33 - Check N1 And N2 Wiring

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests TEST 33 – CHECK N1 AND N2 WIRING TEST 35 – CHECK FUSE F3 Discussion Discussion A shorted Wire N1 or N2 to ground can cause fuse F1 or F2 Connected in series with Load Wire T1, F3 provides 120 VAC to to blow.

  • Page 48: Test 38 - Check N1 And N2 Voltage

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests If the VOM indicated CONTINUITY, repair or replace the wiring in the appropriate circuit. TEST 38 – CHECK N1 AND N2 VOLTAGE Discussion Loss of utility source voltage to the generator will initiate a startup and transfer by the generator.
  • Page 49 Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests Set a VOM to measure AC voltage. Connect one meter test lead to Wire N1 at the incoming Utility sensing connector. Connect the other meter test lead to Wire N2. Approximately 240 VAC should be measured.
  • Page 50 NOTES PART 3 TRANSFER SWITCH Page 48...

  • Page 51: Part 4 - Engine/Dc Control

    PART 4 ENGINE/DC CONTROL PART 4 – Engine/DC Control ..........49 Test 53 – Try a Manual Start ........ 63 Section 4.1 – Description and Components ....... 50 Test 54 – Test Auto Operations ......63 General ..............50 Test 55 – Check 7.5 Amp Fuse......63 Terminal Strip / Interconnection Terminal ....

  • Page 52: Section 4.1 - Description And Components

    Section 4.1 PART 4 ENGINE/DC CONTROL Description and Components If the Utility sensing voltage drops below a preset value, GENERAL controller action will initiate automatic generator startup and This section will familiarize the reader with the various transfer to the “Standby” source side. components that make up the DC control system.
  • Page 53 Section 4.1 PART 4 ENGINE/DC CONTROL Description and Components J2 CONNECTOR J1 CONNECTOR (CONTROLLER END) (CONTROLLER END) 10 11 12 13 14 15 16 17 18 J1 CONNECTOR J2 CONNECTOR (HARNESS END) (HARNESS END) N1/N2 CONNECTOR N1/N2 CONNECTOR (CONTROLLER END) (HARNESS END) Figure 34.

  • Page 54: Alarms

    Section 4.2 PART 4 ENGINE/DC CONTROL Engine Protective Devices RPM Sensor Loss (Shutdown Alarm) ALARMS During cranking, if the controller does not see a valid RPM Low Oil Pressure (Shutdown Alarm) signal within three (3) seconds, it will shut down and lock out on RPM sensor loss.
  • Page 55 NOTES PART 4 ENGINE/DC CONTROL Page 53...

  • Page 56: Section 4.3 - Operational Analysis

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis UTILITY SOURCE AVAILABLE Utility voltage is available to the transfer switch terminals N1/N2 and the transfer switch in the normal utility position. Utility sensing voltage is delivered to the controller via wires N1/N2 from a transfer switch. This voltage is 240VAC sensing voltage only for the controller.

  • Page 57: Utility Failure And Engine Cranking

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis UTILITY FAILURE AND ENGINE CRANKING When the utility sensing voltage drops out the controller will start a 10 second timer. If the voltage does not return fully of is below 60 percent of normal the generator will start to crank. The controller action delivers 12 VDC to the starter contactor via wire 56.

  • Page 58: Utility Failure And Engine Running

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis UTILITY FAILURE AND ENGINE RUNNING The generator is running, the controller’s engine warm up timer is timing out and the generator is producing AC voltage. 12 VDC is delivered to the actuator motor (in the EZ Transfer Operator) via wire 15B. This 12 VDC circuit is completed back to the controller via wire 23.

  • Page 59: Section 4.4 - Troubleshooting Flowcharts

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 20 – Engine Will Not Crank When Utility Power Source Fails TEST 52 – CHECK TEST 53 – TRY A SWITCH IS VERIFY UTILITY POSITION OF MANUAL START IN “AUTO” SOURCE IS “OFF” AUTO-OFF-MANUAL SWITCH ENGINE DOES...

  • Page 60: Problem 22 - Engine Cranks But Won't Start

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 22 – Engine Cranks but Won’t Start TEST 60 – CHECK TEST 61 – CHECK TEST 62 – CHECK GOOD GOOD FUEL SUPPLY AND CONTROLLER FUEL SOLENOID PRESSURE WIRE 14 OUTPUT GOOD REPLACE FUEL SOLENOID REPLACE CONTROLLER...

  • Page 61: Problem 23 - Engine Starts Hard And Runs Rough / Lacks Power / Backfires

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 23 – Engine Starts Hard and Runs Rough / Lacks Power / Backfires IF RECONFIGURED TO LP GAS, TEST 60 – CHECK CHECK AIR FILTER - VERIFY THAT PROPER FUEL SUPPLY AND GOOD GOOD REPLACE AS NEEDED...

  • Page 62: Problem 24 - Shutdown Alarm/Fault Occurred

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 24 – Shutdown Alarm/Fault Occurred CHECK FAULT LIGHTS PROCEED TO PROBLEM 22 OVERCRANK CHECK INSTALLATION FOR TEST 69 – CHECK HIGH PROPER AIRFLOW OR OIL TEMPERATURE HIGH TEMP REPLACE DEFECTIVE SWITCH SWITCH REPAIR LINKAGE IF BINDING.

  • Page 63: Problem 25 - 7.5 Amp Fuse (F1) Blown

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 25 – 7.5 Amp Fuse (F1) Blown TEST 74 & 75 – FUSE BLOWS WHEN CHECK CRANKING PLACED IN “AUTO” AND RUNNING OR “MANUAL” CIRCUITS Problem 26 – Generator Will Not Exercise TEST 72 –...

  • Page 64: Section 4.5 - Diagnostic Tests

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests When working on this equipment, use common sense and INTRODUCTION remain alert at all times. Never work on this equipment This section familiarizes the service technician with acceptable while you are physically or mentally fatigued. If you do not procedures for the testing and evaluation of various problems understand a component, device or system, do not work on it.

  • Page 65: Test 53 - Try A Manual Start

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests standby generator should crank and start. Following startup, TEST 54 – TEST AUTO OPERATIONS transfer to the standby source should occur. Refer to Section 1.5 in this manual. Discussion Following generator startup and transfer to the standby source, Initial Conditions: The generator is in AUTO, ready to run, and turn ON the utility power supply to the transfer switch.
  • Page 66 Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Procedure C. Test Battery State of Charge: (Non-Maintenance Free Battery) A. Inspect Battery Cables: 1. Use an automotive type battery hydrometer to test Visually inspect battery cables and battery posts. battery state of charge. If cable clamps or terminals are corroded, clean away all 2.

  • Page 67: Test 57 - Check Wire 56 Voltage

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Test Battery Condition: TEST 58 – TEST STARTER CONTACTOR a. If the difference between the highest and lowest Discussion reading cells is greater than 0.050 (50 points), battery condition has deteriorated and the battery should be The starter contactor (SC) must energize and its heavy duty replaced.

  • Page 68: Test 59 - Test Starter Motor

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests TEST 59 – TEST STARTER MOTOR Conditions Affecting Starter Motor Performance A binding or seizing condition in the starter motor bearings. A shorted, open or grounded armature. a. Shor ted armature (wire insulation worn and wires touching one another).

  • Page 69: Test 60 - Check Fuel Supply And Pressure

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Remove Starter Motor It is recommended that the starter motor be removed from the engine when testing starter motor performance. Assemble starter to test bracket and clamp test bracket in vise, Figure 46. Testing Starter Motor A fully charged 12 volt battery is required.

  • Page 70: Test 61 - Check Circuit Board Wire 14 Output

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests • Maximum gaseous fuel pressure at the generator fuel inlet Results connection is 7 inches water column for natural gas or 12 If fuel supply and pressure are adequate, but engine will inches water column for LP gas. not start refer back to flow chart.

  • Page 71: Test 62 - Check Fuel Solenoid

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Disconnect the Choke Solenoid Connector. TEST 62 – CHECK FUEL SOLENOID Set a VOM to measure DC voltage. Discussion Connect the positive (+) test lead to Wire 56 (Pin 1) In Test 61, if battery voltage was delivered to Wire 14, the of the connector going to the controller (Female Side) fuel solenoid should have energized open.

  • Page 72: Test 65 - Check Spark Plugs

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Crank the engine while observing the spark tester. If spark NOTE: A sheared flywheel key may change ignition timing but sparking will still occur across the spark jumps the tester gap, you may assume the engine ignition tester gap.

  • Page 73: Test 66 - Check Engine / Cylinder Leak

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Procedure NORMAL MISFIRES Remove the spark plug from the front cylinder. Gain access to the flywheel. Remove the valve cover. Rotate the engine crankshaft until the piston reaches top dead center (TDC). In this position, both the intake and exhaust valves will be closed.

  • Page 74: Test 67 - Check Ignition Coil

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests • Blown or leaking cylinder head gasket Solid-state components encapsulated in the ignition coil are not accessible and cannot be serviced. If the coil is defective, the • Improperly seated or sticking-valves entire assembly must be replaced. The air gap between the coil • Worn piston rings or cylinder.

  • Page 75: Test 69 - Check High Oil Temperature Switch

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Procedure b. Connect one test lead to Wire 86 (disconnected from LOP). Connect the other test lead to Pin Location 4 Check engine crankcase oil level. (Wire 86) of the J1 Connector at the controller. CONTINUITY should be measured.

  • Page 76: Test 70 - Check And Adjust Valves

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Testing High Oil Temperature Switch piston at TDC, remove the intake screen at the top of the engine to gain access to the flywheel nut. Use a large Remove the High Oil Temperature Switch. socket and socket wrench to rotate the nut and hence the Immerse the sensing tip of the switch in oil as shown in engine in a clockwise direction.

  • Page 77: Test 71 - Check Wire 18 Continuity

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests to Table 8 throughout the procedure for the known resistance TEST 71 – CHECK WIRE 18 CONTINUITY values of components. Discussion Figure 60 shows the Volt-Ohm-Milliammeter (VOM) in two different states. The left VOM indicates an OPEN circuit or During cranking and running the controller receives a pulse from the ignition magneto via Wire 18.

  • Page 78: Test 74 - Test Run Circuit

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Results TEST 75 – TEST CRANK CIRCUIT Compare the results of Step 3 with Table 9. Discussion a. If the VOM indicated CONTINUITY at Test Point 1 Wire 56 provides 12 VDC during cranking only. If the VOM proceed to Test 67 indicated CONTINUITY in the previous test, one of the possible b.

  • Page 79: Test 77 - Check Battery Charger Output Voltage

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests a. If 12 VDC is measured, proceed to Step 8. TEST 77 – CHECK BATTERY CHARGER b. If 12 VDC is not measured, proceed to Step 7. OUTPUT VOLTAGE Measure across point H and ground lug. 12 VDC should Discussion be measured.
  • Page 80 Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Procedure Disconnect Wire 18 at the bullet connector. See Figure 61. Connect a jumper wire from the stud to which Wire 56 is connected on the Starter Contactor (SC) and 12 VDC Wire 15B at TB1 (Customer Connection).
  • Page 81 Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Figure 62. Test 76, 77, and 78 Test Points. Page 79...
  • Page 82 NOTES PART 4 ENGINE/DC CONTROL Page 80...
  • Page 83 PART 5 DISASSEMBLY PART 5 – Disassembly ............81 Section 5.1 – Major Disassembly ........82 Section 5.2 – Exploded Views ........... 90 Page 81...
  • Page 84 Section 5.1 PART 5 DISASSEMBLY Major Disassembly Disconnect and remove the battery. DISASSEMBLY Using a 10mm socket remove the front two enclosures Tools Required: braces. • 7mm Socket • 8mm Socket • 10mm Socket • 13mm Socket • Harmonic Balancer or Steering Wheel Puller • Replacement Rotor Bolt (Part No. 0H6930) • Replacement Exhaust Gasket (Part No.
  • Page 85 Section 5.1 PART 5 DISASSEMBLY Major Disassembly Using a 10mm socket remove the remaining exhaust enclosure pieces on each side. Figure 67. Using a 10mm socket remove the three (3) bolts holding the exhaust housing from the engine support and base. Figure 70.
  • Page 86 Section 5.1 PART 5 DISASSEMBLY Major Disassembly Disconnect the voltage regulator. Figure 75. Figure 73. 10. Disconnect the ground and neutral connections. Figure 76. 12. Disconnect the fuel supply hose from the air box assembly. Figure 74. 11. Using an 8mm socket remove the two bolts supporting the muffler.
  • Page 87 Section 5.1 PART 5 DISASSEMBLY Major Disassembly 13. Disconnect the choke solenoid. Figure 80. Figure 78. 16. Carefully slide out the support structure from the base and position assembly horizontally. 14. Using an 8mm socket remove the remaining bolt. Figure 81. Figure 79.
  • Page 88 Section 5.1 PART 5 DISASSEMBLY Major Disassembly Figure 82. Figure 85. Figure 86. Figure 83. 19. Using a 13mm socket remove the four stator bolts. 18. Install a harmonic balancer or steering wheel puller onto the fan assembly. Figure 87. Figure 84.
  • Page 89 Section 5.1 PART 5 DISASSEMBLY Major Disassembly Note: Make a note of the orientation of the brush wire exit passage on the stator. During re-assembly, if the stator is not bolted together with the exit passage in the same loca- tion, the brush wires will not be long enough to reconnect to the wire harness.
  • Page 90 Section 5.1 PART 5 DISASSEMBLY Major Disassembly Figure 93. 23. For engine replacement remove the four bolts connecting the engine cradle to the engine casting. Page 88...
  • Page 91 NOTES PART 5 DISASSEMBLY Page 89...
  • Page 92 Section 5.2 PART 5 DISASSEMBLY Exploded Views Control Panel Page 90...
  • Page 93 Section 5.2 PART 5 DISASSEMBLY Exploded Views ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION COVER,.CUSTOMER CONNECT BOX EYE HASP CNTRL PNL 2008 HSB BOX CUSTOMER CONNECT SCREW PPPH #10 X 1/2" LG BUSHING, SNAP SB-1000-12 CB 0030A 2P 240V 5 BQ2 LB WASHER, LOCK M5 SCREW HHC M5-0.8 X 12 C8.8 WASHER FLAT M5...
  • Page 94 Section 5.2 PART 5 DISASSEMBLY Exploded Views EV Powerhead, Corepower Page 92...
  • Page 95 CABLE, SC TO SM (NOT SHOWN) GASKET, ALT AIR OUT WIRE, ENG TO GND (NOT SHOWN) WASHER FLAT .406ID X1.620D BATT POS. CABLE COREPOWER (NOT SHOWN) SCREW IHHC 5116·24 X 12 G8 ZP BATT NEG. CABLE COREPOWER (NOT SCREW HHTT M8-1.2 X16 YC...
  • Page 96 Section 5.2 PART 5 DISASSEMBLY Exploded Views Enclosure Page 94...
  • Page 97 Section 5.2 PART 5 DISASSEMBLY Exploded Views ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ASSY EXHAUST PANEL AIRBOX SIDE ASSY., SNAP BARB W/SCREEN BASE GROMMET,38.1 CROSS SLIT W/HOLE ASSY FRONT PANEL BISQUE ASSY., BACK PANEL ASSY FRONT PANEL GREY WASHER, FLAT1/4-M6 BRACKET, CORNER POST WASHER, LOCK M6-1I4 SCREW HHFC M6-1.0X 12...
  • Page 98 Section 5.2 PART 5 DISASSEMBLY Exploded Views Engine Page 96...
  • Page 99 Section 5.2 PART 5 DISASSEMBLY Exploded Views ITEM QTY. DESCRIPTION SHROUD COVER, FAN STUD, LIFTING STUD, LIFTING SCREEN, FAN COIL ASSY., IGNITION BOLT, FLANGE 6X25 FLYWHEEL, COMPLETE FAN, COOLING PLATE, FAN NUT, SPECIAL M16 CLIP , WIRE HARNESS CRANKCASE, UPPER STARTER BOLT, FLANGE, M8X80 NUT, FLANGE M6...
  • Page 100 Section 5.2 PART 5 DISASSEMBLY Exploded Views Air/Fuel System Page 98...
  • Page 101 Section 5.2 PART 5 DISASSEMBLY Exploded Views ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ENGINE 432CC GASEOUS 1.8FT LPG HOSE ASSEMBLY SCREW, HHFCS M6·1 X16 G8.8 NUT HEX LOCK M3-0.5 NY INS NUT HEX LOCK M5-0.8 NYINS ZINC BALL STUD,10 MM BRACKET, 432CC GOVERNOR ADJUST ASSY THROTTLE ROD SPRING, GOV MAIN LV432 EHSB...
  • Page 102 NOTES PART 5 DISASSEMBLY Page 100...
  • Page 103 PART 6 ELECTRICAL DATA PART 6 – Electrical Data ..........101 Wiring Diagram ............... 102 Electrical Schematic ............103 Electrical Formulas ............104 Page 101...

  • Page 104: Wiring Diagram

    Section 6 PART 6 ELECTRICAL DATA Wiring Diagram – Drawing 0H7182-C Page 102...

  • Page 105: Electrical Schematic

    Section 6 PART 6 ELECTRICAL DATA Electrical Schematic – Drawing 0H7182-C Page 103...

  • Page 106: Electrical Formulas

    Electrical Formulas TO FIND KNOWN VALUES 1-PHASE E x I KILOWATTS (kW) Volts, Current, Power Factor 1000 E x I Volts, Current 1000 kW x 1000 AMPERES kW, Volts, Power Factor WATTS Volts, Amps, Power Factor Volts x Amps 2 x 60 x Frequency NO.
  • Page 107 APPENDIX A SUPPLEMENTAL WORKSHEETS Appendix A – Supplemental Worksheets......105 Page 105...
  • Page 108 Table 9 APPENDIX A SUPPLEMENTAL WORKSHEETS Test 4 Results Test 4 Results, Serial #_________________________ Test 4 Results, Serial #_________________________ Test Point Results Test Point Results Rotor Resistance Rotor Resistance Ohms Ohms Battery Voltage Battery Voltage Blue to Blue Voltage Blue to Blue Voltage White and Blue Voltage White and Blue Voltage Static Rotor Amp Draw...
  • Page 109 Table 14 SUPPLEMENTAL WORKSHEETS APPENDIX A Test 9 Stator Results Test 9 Stator Results, Serial #_______________________ Test 9 Stator Results, Serial #_______________________ Test Point A Test Point B Results Test Point A Test Point B Results Resistance Tests Resistance Tests Stator Lead Blue Wire Stator Lead Black Wire Stator Lead Blue Wire...
  • Page 110 Table 9 APPENDIX A SUPPLEMENTAL WORKSHEETS Test 73 Results Test 73 Results, Serial #_________________________ Test 73 Results, Serial #_________________________ Test Point Pin Location Circuit Result Test Point Pin Location Circuit Result J2 Pin 4 Wire 14 J2 Pin 4 Wire 14 J2 Pin 11 Wire 56 J2 Pin 11...
  • Page 111 APPENDIX B INDEX OF FIGURES AND TABLES Appendix B – Index of Figures and Tables .......109 Index of Figures .............. 110 Index of Tables ..............111 Page 109...

  • Page 112: Index Of Figures

    Index of Figures APPENDIX B INDEX OF FIGURES AND TABLES Figure # Page # Figure # Page # Figure # Page # Figure # Page # Figure # Page # Figure 1 Figure 20 Figure 39 Figure 58 Figure 77 Figure 2 Figure 21 Figure 40.

  • Page 113: Index Of Tables

    Index of Tables INDEX OF FIGURES AND TABLES APPENDIX B Table # Page Table # Page Table # Page Table # Page Table 1 Table 4 Table 7 Table 10 Table 2 Table 5 Table 8 Table 3 Table 6 Table 9 Page 111...
  • Page 114 NOTES Page 112...
  • Page 116 ©2011 Generac Power Systems, Inc. All rights reserved. Specifications are subject to change without notice g e n e r a c . c o m No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc.

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