Generac Power Systems CorePower Repair Manual page 4

Section 3.2 - Operational Analysis .................................... 39
Utility Voltage Present ........................................... 39
Transfer to Standby ............................................... 39
Transfer to Utility ................................................... 39
Section 3.3 - Troubleshooting Flowcharts ......................... 41
Introduction .......................................................... 41
Problem 10 - In Automatic Mode,
No Transfer to Standby ......................................... 41
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 ...... 41
Problem 12 - Blown F1 or F2 Fuse ........................ 42
Problem 13 - Blown T1 Fuse ................................ 42
Problem 14 - Unit Starts and Transfer Occurs
When Utility Power is On ....................................... 42
Section 3.4 - Diagnostic Tests .......................................... 43
Introduction .......................................................... 43
Safety ................................................................... 43
Transfer Switch Troubleshooting .......................... 43
Test 27 - Check Generator Voltage at
Transfer Switch ...................................... 43
Test 28 - Test Transfer Operator ............................ 43
Test 29 - Check 15B/194 Circuit .......................... 43
Test 30 - Check Wire 23 Circuit ............................ 44
Test 32 - Check Fuses F1 and F2 .......................... 44
Test 33 - Check N1 and N2 Wiring ........................ 45
Test 35 - Check Fuse F3 ...................................... 45
Test 36 - Check T1 Wiring .................................... 45
Test 38 - Check N1 and N2 Voltage ...................... 46
Test 39 - Check Utility Sense Voltage .................... 46
Test 40 - Check Utility Voltage at Transfer Switch .. 46
Test 41 - Check Utility Sensing Voltage
at the Controller ..................................... 46
PART 4 - Engine/DC Control ..............................................49
Section 4.1 - Description and Components ....................... 50
General ................................................................. 50
Terminal Strip / Interconnection Terminal ............... 50
Controller ............................................................. 50
Auto-Off-Manual Switch ........................................ 50
7.5 Amp Fuse ....................................................... 50
Alarms ................................................................. 52
Clear Alarms ......................................................... 52
Warnings .............................................................. 52
Section 4.3 - Operational Analysis .................................... 54
Utility Source Available .......................................... 54
Utility Failure and Engine Cranking ......................... 55
Utility Failure and Engine Running .......................... 56
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Section 4.4 - Troubleshooting Flowcharts ......................... 57
Problem 20 - Engine Will Not Crank When
Utility Power Source Fails ...................................... 57
Problem 21 - Engine Will Not Crank When
AUTO-OFF-MANUAL Switch is Set to "MANUAL" ... 57
Problem 22 - Engine Cranks but Won't Start ......... 58
Problem 23 - Engine Starts Hard and
Runs Rough / Lacks Power / Backfires .................. 59
Problem 24 - Shutdown Alarm/Fault Occurred ...... 60
Problem 25 - 7.5 Amp Fuse (F1) Blown ................ 61
Problem 26 - Generator Will Not Exercise ............. 61
Problem 27 - No Battery Charge ........................... 61
Section 4.5 - Diagnostic Tests .......................................... 62
Introduction .......................................................... 62
Safety ................................................................... 62
Engine/DC Troubleshooting .................................. 62
Test 52 - Check Position Of
Auto-Off-Manual Switch ....................... 62
Test 53 - Try a Manual Start ................................ 63
Test 54 - Test Auto Operations .............................. 63
Test 55 - Check 7.5 Amp Fuse.............................. 63
Test 56 - Check Battery ........................................ 63
Test 57 - Check Wire 56 Voltage ........................... 65
Test 58 - Test Starter Contactor ............................ 65
Test 59 - Test Starter Motor .................................. 66
Test 60 - Check Fuel Supply and Pressure ............ 67
Test 61 - Check Circuit Board Wire 14 Output ....... 68
Test 62 - Check Fuel Solenoid .............................. 69
Test 63 - Check Choke Solenoid ........................... 69
Test 64 - Check for Ignition Spark ......................... 69
Test 65 - Check Spark Plugs ................................ 70
Test 66 - Check Engine / Cylinder Leak
Down Test / Compression Test ............... 71
Cylinder Leak Down Test ........................ 71
Check Compression ............................... 71
Test 67 - Check Ignition Coil ................................. 72
Test 68 - Check Oil Pressure Switch And Wire 86 . 72
Test 69 - Check High Oil Temperature Switch ........ 73
Test 70 - Check and Adjust Valves ........................ 74
Test 71 - Check Wire 18 Continuity ....................... 75
Test 72 - Test Exercise Function ........................... 75
Test 73 - Test Cranking and Running Circuits ........ 75
Test 74 - Test Run Circuit ..................................... 76
Test 75 - Test Crank Circuit .................................. 76
Test 76 - Check Battery Charger Supply Voltage.... 76
Test 77 - Check Battery Charger Output Voltage .... 77
Test 78 - Check Wire 0/15B.................................. 77
Test 79 - Check Shutdown Wire ........................... 77