Generac Power Systems G0070420 Manuals

Manuals and User Guides for Generac Power Systems G0070420. We have 1 Generac Power Systems G0070420 manual available for free PDF download: Diagnostic Repair Manual

Generac Power Systems G0070420 Diagnostic Repair Manual (122 pages)

50 Hz and 60 Hz 3-Phase Air-Cooled Product with Evolution 2.0 Control

Brand: Generac Power Systems | Category: Portable Generator | Size: 35 MB

Frequently Asked Questions
2
Quick Reference Guide (Evolution Controllers)
2
Safety
5
Read this Manual Thoroughly
5
Replacement Parts
5
Table of Contents
7
Section 1.1 Generator Basics
9
Introduction
9
Parts
9
Data Plate
9
Serial Number
9
Generator Identification
9
Specifications
10
Section 1.2 Menu System Navigation
11
Navigation Keys
11
Main Menu
11
Evolution Dealer Menu
12
Section 1.3 Testing, Cleaning and Drying
25
Visual Inspection
25
Insulation Resistance
25
The Megohmmeter
25
Testing Stator Insulation
25
Testing Rotor Insulation
26
Cleaning the Generator
26
Drying the Generator
26
Section 2.1 Operational Analysis
27
Field Boost
27
Operation
27
AC Power Winding Output
28
Preliminary Output Voltage Test
29
General Theory
29
Section 2.2 Troubleshooting Flow Charts
29
Introduction
30
Field Boost Circuit Test - Evolution
30
Problem 1 - Generator Shuts down for under Voltage
31
Problem 1 - Generator Shuts down for under Voltage (Continued)
32
Problem 2 - Generator Produces High Voltage
32
Problem 3 - Voltage and Frequency Drop Excessively When Loads Are Applied
33
Problem 4 - Unstable Voltage or Incorrect Output Which Is Not Triggering a Shutdown
33
Section 2.3 Diagnostic Tests
35
Introduction
35
Safety
35
AC Troubleshooting
35
Test 1 - Check AC Output Voltage
35
Test 3 - Calibrate Voltage
36
Field Boost Circuit Tests
37
Test FB1 - Test Wire 4
37
Test FB2 - Test Wire 4A
37
Test FB3 - Diode Test
37
Test 4 - Fixed Excitation Test/Rotor Amp Draw Test
38
Required Tools
38
Test 5 - Test Sensing Circuit Transformer, Windings and Wires S15/S16 and S15A/S16A
40
Test 6A - Test Excitation Circuit Breaker (CB2)
40
Test 6 - Test Excitation Winding Circuit 2A and
41
Test 7 - Test the Stator with a DMM
41
Test 8 - Resistance Check of Rotor Circuit
43
Test 9 - Check Brushes and Slip Rings
43
Test 10 - Test Rotor Assembly
44
Test 11 - Check AC Output Frequency
44
Test 12 - Check Stepper Motor Control
44
Test 14 - Check Voltage and Frequency under Load
45
Test 15 - Check for an Overload Condition
46
Test 16 - Check Engine Condition
46
Section 3.1 Description and Major Components
47
Introduction
47
Customer Connection
47
Controller
47
LED Display
47
Battery Charger
48
Auto-Off-Manual
49
Fuse
49
Starter Contactor Relay/Solenoid
49
Common Alarm Relay
49
Section 3.2
53
Section 3.2 Engine Protective Devices
53
Engine Protective Devices
53
Low Battery Warning
53
Low Oil Pressure
53
(Evolution E-Code 1300)
53
High Temperature Switch (Evolution E-Code 1400)
53
Overspeed
53
RPM Sensor Failure (Evolution E-Code 1501, 1505, 1511, 1515)
53
Overcrank (Evolution E-Code 1100)
54
Cranking Conditions
54
Under-Frequency
54
Clearing an Alarm
54
Section 3.3 Operational Analysis
57
Introduction
57
Utility Source Voltage Available
57
Initial Dropout of Utility Source Voltage
59
Utility Voltage Failure and Engine Cranking
61
Engine Startup and Running
63
Transfer to Standby
65
Utility Voltage Restored and Re-Transfer to Utility
67
Engine Shutdown
69
Section 3.4 Troubleshooting Flowcharts
71
Problem 14 - Shutdown Alarm/Fault Occurred During Crank Attempt, Start or Run
71
Problem 15 - Engine will Not Crank When Utility Power Source Fails
72
Problem 16 - Engine will Not Crank When Controller Switch Is Set to MANUAL
72
Problem 17 - Engine Cranks but will Not Start
73
Problem 18 - Engine Starts Hard And/Or
74
Hunting / Erratic Operation
74
Problem 19 - 7.5 Amp Fuse (F1) Blown (E-Code 2400)
75
Problem 20 - Generator will Not Exercise
75
Problem 21 - no Low Speed Exercise
75
Problem 22 - Battery Is Dead
75
Section 3.5 Diagnostic Tests
77
Introduction
77
Safety
77
Engine/DC Troubleshooting
77
Test 40 - Check Position of AUTO-OFF-MANUAL Mode
77
Test 41 - Try a Manual Start
78
Test 42 - Test the Function of the AUTO-OFF-MANUAL Mode
78
Test 43 - Test Auto Operations of Controller
78
Test 44 - Check 7.5 Amp Fuse
78
Test 45 - Check Battery and Cables
79
Test 46 - Check Wire 56 Voltage
80
General Theory
80
Test 47 - Test Starter Contactor Relay
81
Test 48 - Test Starter Contactor
82
Test 49 - Test Starter Motor
82
Test 50 - Check Fuel Supply and Pressure
83
Test 51 - Check Controller Wire 14 Outputs
84
Test 52 - Check Fuel Solenoid
84
Test 55 - Check for Ignition Spark
84
Test 57 - Check Spark Plug Condition
85
Test 58 - Check Engine / Compression Test / Cylinder Leak down Test
86
Check Compression
86
Cylinder Leak down Test
87
Test 59 - Check Shutdown Wire
87
Test 60 - Check and Adjust Ignition Magnetos
88
Test 61 - Check Oil Pressure Switch and Wire 86 (Evolution E-Code 1300)
90
Test 62 - Check High Oil Temperature Switch (E-Code 1400)
92
Test 63 - Check and Adjust Valves
92
Test 64 - Check Wire 18 Continuity
93
Test 65 - Test Exercise Function
93
Test 66 - Test Cranking and Running Circuits
94
Test 67 - Test Run Circuit
94
Test 68 - Test Crank Circuit
95
Test 70 - Check to See if Low Speed Function Is Enabled
95
Test 75 - Test 120 Volt Input (T1) 60 Hz 220 Volt Input (T1) 50 Hz
95
Test 76 - Verify DC Voltage Output of the Controller
95
Test 77 - Check Wire 13 and Wire 0
96
Test 78 - Test DC Charge Current to the Battery
96
Test 79 - Check T1 Voltage at Customer Connections
96
TEST 80 - Check T1 Voltage at Controller Connector
96
Test 81 - Check T1 Voltage in Transfer Switch
97
Test 82 - Test F3 Fuse Circuit
97
Section 4.1 Major Disassembly
99
Major Disassembly
99
Rotor Removal
103
Torque Specifications
104
Appendix A Controller and Electrical Data
105
Important Note
105
Probing and Pin Extraction
105
Evolution Controller
106
Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D
108
Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D
109
Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D
110
Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D
111
Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D
112
Wiring Diagram/Electrical Schematic Air-Cooled 60 Hz 3-Phase - Drawing 100000003828-D
113
Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D
114
Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D
115
Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D
116
Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D
117
Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D
118
Appendix A Controller and Electrical Data
119
Wiring Diagram/Electrical Schematic Air-Cooled 50 Hz 3-Phase - Drawing 100000003829-D
119
Electrical Formulas
121

Generac Power Systems Categories

Portable Generator Inverter Pressure Washer

Switch Lighting Equipment

More Generac Power Systems Manuals

Generac Power Systems G0070420 Manuals

Generac Power Systems G0070420 Diagnostic Repair Manual (122 pages)

Table of Contents

Related Products

Generac Power Systems Categories