Generac Power Systems 7 kW NG Repair Manual page 5

Initial Dropout of Utility Source Voltage .................. 98
Utility Voltage Failure and Engine Cranking ........... 100
Engine Startup and Running ................................ 102
Transfer to Standby ............................................. 104
Utility Voltage Restored and Re-transfer to Utility . 106
Engine Shutdown ................................................ 108
Section 4.4 - Troubleshooting Flowcharts ....................... 110
Problem 14 - Engine Will Not Crank
When Utility Voltage Fails .............. 110
Problem 15 - Engine Will Not Crank When
AUTO-OFF-MANUAL Switch
is Set To MANUAL ........................ 110
Problem 16 - Engine Cranks But Will Not Start .... 111
Problem 17 - Engine Starts Hard And Runs
Rough / Lacks Power / Backfires ... 112
Problem 18 - Shutdown Alarm/Fault Occurred .... 113
Problem 19 - 7.5 Amp Fuse (F1) Blown .............. 114
Problem 20 - Generator Will Not Exercise ........... 114
Problem 21 - No Low Speed Exercise ................. 114
Problem 22 - Battery is Dead ............................. 114
Section 4.5 - Diagnostic Tests ........................................ 115
Introduction ........................................................ 115
Safety ................................................................. 115
Engine/DC Troubleshooting ................................ 115
Test 40 - Check position of
AUTO-OFF-MANUAL Switch ................. 115
Test 41 - Try a Manual Start ............................... 116
Test 42 - Test the AUTO-OFF-MANUAL Switch .... 116
Test 43 - Test Auto Operations of Controller ........ 116
Test 44 - Check 7.5 Amp Fuse............................ 117
Test 45 - Check Battery ...................................... 117
Test 46 - Check Wire 56 Voltage ......................... 118
Test 47 - Test Starter Contactor Relay
(V-Twin Only) ....................................... 119
Test 48 - Test Starter Contactor .......................... 119
Test 49 - Test Starter Motor ................................ 120
Test 50 - Check Fuel Supply and Pressure .......... 122
Test 51 - Check Controller Wire 14 Outputs ........ 123
Test 52 - Check Fuel Solenoid ............................ 124
Test 53 - Check Choke Solenoid ......................... 125
Test 55 - Check for Ignition Spark ....................... 127
Test 57 - Check Condition of Spark Plugs ........... 128
Test 58 - Check Engine / Cylinder Leak
Down Test / Compression Test ............ 129
Test 59 - Check Shutdown Wire ......................... 130
Test 60 - Check and Adjust Ignition Magnetos .... 131
Test 61 - Check Oil Pressure Switch And Wire 86 . 133
Test 62 - Check High Oil Temperature Switch ...... 134
Test 63 - Check and Adjust Valves ...................... 135
Test 64 - Check Wire 18 Continuity ..................... 135
Test 65 - Test Exercise Function ......................... 136
Test 66 - Test Cranking and Running Circuits ...... 137
Test 67 - Test Run Circuit ................................... 137
Test 68 - Test Crank Circuit ................................ 138
Test 69 - Test TRANSFER RELAY Circuit ............. 139
Test 70 - Check to see if Low Speed
Function is enabled .............................. 139
Test 71 - Check operation of the Choke Solenoid 139
Test 75 - Test 120 Volt Input (T1) ....................... 140
Test 76 - Verify DC Voltage Output
of the Controller ................................... 140
Test 77 - Check Wire 13 and Wire 0 ................... 140
Test 78 - Test DC Charge Current to the Battery .. 140
Test 79 - Check T1 Voltage at
Customer Connections ......................... 141
Test 80 - Check T1 Voltage at J5 Connector ........ 141
Test 81 - Check T1 Voltage in Transfer Switch .... 141
Test 82 - Test F3 Fuse Circuit ............................. 142
PART 5 - Operational Tests ..............................................143
Section 5.1 - System Functional Tests ............................ 144
Introduction ........................................................ 144
Manual Transfer Switch Operation ....................... 144
Electrical Checks ................................................ 144
Generator Tests Under Load ................................ 145
Checking Automatic Operation ............................ 146
Section 5.2 - Setup Procedures ...................................... 147
Setting the Exercise Time .................................... 147
Activation Process .............................................. 147
PART 6 - Disassembly .....................................................149
Section 6.1 - Major Disassembly .................................... 150
Front Engine Access ........................................... 150
Major Disassembly ............................................. 154
Torque Requirements .......................................... 160
PART 7 - Electrical Data ..................................................175
Wiring Diagram, 8 kW Home Standby ............................. 176
Electrical Schematic, 8 kW Home Standby ...................... 178
Wiring Diagram, 10-14 kW Home Standby ...................... 179
Electrical Schematic, 10-14 kW Home Standby ............... 180
Electrical Schematic, 17 kW Home Standby .................... 182
Wiring Diagram, 17 kW Home Standby ........................... 184
Electrical Schematic, 20 kW Home Standby .................... 186
Electrical Schematic, Home Standby Transfer Switch....... 188
Wiring Diagram, Home Standby Transfer Switch .............. 190
Electrical Formulas ......................................................... 192
Appendix A Supplemental Worksheets.............................193
Appendix B Index of Figures and Tables ..........................203
Index of Figures .............................................................. 204
Index of Tables ................................................................ 205
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