Table Of Contents - Generac Power Systems CorePower Repair Manual

SAFETY .............................................................................. 2
Read This Manual Thoroughly ............................................. 2
Specifications ......................................................................4
Generator ............................................................... 4
Engine .................................................................... 4
Fuel Consumption ................................................... 5
Major Features ........................................................ 5
PART 1 - GENERAL INFORMATION ......................................9
Section 1.1 - Generator Basics ......................................... 10
Introduction .......................................................... 10
Parts .................................................................... 10
Generator Identification ......................................... 10
Section 1.2 - Measuring Electricity ................................... 11
Meters .................................................................. 11
The VOM .............................................................. 11
Measuring AC Voltage ........................................... 11
Measuring DC Voltage ........................................... 11
Measuring AC Frequency ...................................... 11
Measuring Current ................................................ 12
Measuring Resistance ........................................... 12
Electrical Units ...................................................... 13
Ohm's Law ........................................................... 13
Section 1.3 - Preparation Before Use ................................ 14
Introduction .......................................................... 14
Fuel Consumption ................................................. 14
Reconfigure the fuel system .................................. 14
Section 1.4 - Operating Instructions ................................. 16
Control Panel ........................................................ 16
User Interface ....................................................... 16
Automatic Operation ............................................. 16
Manual Operation.................................................. 16
Section 1.5 - Automatic Operating Parameters .................. 18
Introduction .......................................................... 18
Utility Failure ......................................................... 18
Cranking ............................................................... 18
Cranking conditions .............................................. 18
Load Transfer Parameters ..................................... 18
Section 1.6 - General Maintenance ................................... 20
Introduction .......................................................... 20
Engine Oil ............................................................. 20
Engine Oil Recommendations ................................ 20
Air Filter ................................................................ 20
Spark Plugs .......................................................... 20
Visual Inspection .................................................. 20
Corrosion Protection ............................................. 20
Valve Clearance .................................................... 20
Battery ................................................................. 21
Section 1.7 - General Troubleshooting .............................. 22
Introduction .......................................................... 22
Recommended Tools ............................................ 22
Troubleshooting Reminders and Tips ..................... 22
Connectors ........................................................... 22
PART 2 - AC Generators ....................................................23
Section 2.1 - Description and Components ....................... 24
Introduction .......................................................... 24
Engine-Generator Drive System ............................. 24
Alternator Assembly ............................................. 24
Brush Holder and Brushes .................................... 24
Other AC Generator Components .......................... 25
Section 2.2 - Operational Analysis .................................... 26
Startup ................................................................. 26
On-Speed Operation .............................................. 26
Field Excitation ...................................................... 26
AC Power Winding Output ..................................... 26
Section 2.3 - Troubleshooting Flowcharts ......................... 27
Introduction .......................................................... 27
Problem 1 - Generator Produces Zero Voltage
or Residual Voltage ............................................... 27
Problem 2 - Generator Produces
Low Voltage at No-Load ........................................ 28
Problem 3 - Generator Produces
High Voltage at No-Load ....................................... 29
Problem 4 - Voltage and Frequency
Drop Excessively When Loads Are Applied ............ 29
Section 2.4 - Diagnostic Tests .......................................... 30
Introduction .......................................................... 30
Safety ................................................................... 30
AC Troubleshooting............................................... 30
Test 1 - Check Main Circuit Breaker ...................... 30
Test 4 - Fixed Excitation /Rotor Amp Draw Test ..... 30
Test 6 - Resistance Check of Rotor Circuit ............ 32
Test 7 - Check Brushes and Slip Rings ................. 32
Test 9 - Test the Stator ......................................... 33
Test 10 - Test Rotor Assembly .............................. 34
Test 11 - Check AC Output Voltage ....................... 34
Test 12 - Check AC Output Frequency ................... 34
Test 13 - Adjust Engine Governor ......................... 35
Test 14 - Adjust Voltage Regulator ....................... 35
Test 15 - Check for Overload Condition ................. 36
Test 16 - Check Voltage and
Frequency Under Load ........................... 36
PART 3 - Transfer Switch ..................................................37
Section 3.1 - Description and Components ....................... 38
General ................................................................. 38
Enclosure ............................................................. 38
EZ Transfer Operator ............................................. 38
Fuse Holder .......................................................... 38
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