Generac 005030-0, 005028-0, 005031-0 owner manual Troubleshooting Points, Problem Cause Correction

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Section 5 — Troubleshooting

Liquid-cooled 15, 20 and 25 kW Generators

TROUBLESHOOTING POINTS

PROBLEM

CAUSE

CORRECTION

Engine won’t crank.

1.

15 amp fuse blown.

1.

Replace fuse.

 

2.

Loose or corroded or defective

2.

Tighten, clean or replace

 

 

battery cables.

 

battery cables as necessary.

 

3.

Defective starter contactor.

3.

Replace contactor.

 

4.

Defective starter motor.

4.

Replace starter motor.

 

5.

Dead or Defective Battery.

5.

Remove, change or replace battery.

 

6.

5 amp fuse blown.

6.

Replace fuse.

 

 

 

 

 

Engine cranks but won't start

1.

Out of fuel.

1.

Replenish fuel.

 

2.

Fuel solenoid (FS) is defective

2.

Replace solenoid.

 

3.

Open Wire #14A from Engine Control

3.

Reconnect wire.

 

 

circuit board.

 

 

 

4.

Spark plugs defective.

4.

Clean, regap or replace plugs.

 

 

 

 

 

Engine starts hard, runs rough.

1.

Flame arrestor (air cleaner) plugged or

1.

Clean or replace as needed.

 

 

damaged.

 

 

 

2.

Plugged fuel line.

2.

Unclog fuel line.

 

3.

Defective spark plugs.

3.

Clean, regap or replace plugs.

 

 

 

 

 

Engine starts then shuts down.

1.

Engine oil level is low.

1.

Check oil and add oil as needed.

 

2.

Engine is overheated.

2.

Check cooling system for leaks.

 

3.

Defective Low Oil Pressure Switch

3.

Replace switch.

 

4.

Defective Coolant Temperature Switch

4.

Replace switch.

 

5.

Defective Control Module circuit board.

5.

Replace board.

 

6.

Coolant Level is Low.

6.

Repair leak - Add coolant.

 

7.

Defective Low Coolant Level Switch

7.

Replace Switch.

 

 

 

 

AUTO/OFF/MANUAL Switch at OFF,

1. Defective AUTO/OFF/MANUAL switch

1.

Replace switch.

engine continues to run

2. Open/disconnected wire #15A between

2.

Reconnect/close wire.

 

 

AUTO/OFF/MANUAL switch and Control

 

 

 

 

Module circuit board.

 

 

 

3.

Defective Control Module circuit board

3.

Replace board.

 

 

 

 

No AC output from generator.

1. Main line circuit breaker open.

1.

Reset to ON or CLOSED.

 

2.

Circuit breakers & fuses open.

2.

Reset and replace, if necessary.

 

3.

Transfer switch set to NORMAL position

3.

Set to GENERATOR position.

 

4.

Generator internal failure.

4.

Contact an Authorized Service Dealer.

 

5.

Thermal circuit breaker open.

5.

Auto-reset - Wait 5 min. and attempt restart.

27

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Contents This manual should remain with the unit ‹ Operation and Maintenance Authorized Service Dealer Location‹ HOW to Obtain Service IntroductionTable of Contents General Hazards ‹ Standards Index Electrical HazardsAutomatic Transfer Switch ATS Mode Transfer SwitchEngineered Transfer Switch Wire Start GTS Mode Generator‹ 1.8.2 High Coolant Temperature Switch ‹ 1.8.1 LOW OIL Pressure SwitchMain Circuit Breaker Generator Fuel SystemLifting the Generator UnpackingAWSF-52-C SpecificationsFuel Consumption Engine OIL Recommendations Before InstallationCoolant Recommendations Generator Mounting Support Generator Location‹ 2.1.1 Nfpa Standards ‹ 2.1.2 Other Published StandardsTotal Circuit Isolation Method Basic Standby Electric SystemGrounding the Generator Emergency Circuit Isolation MethodGenerator AC Neutral Connections Connection Diagram ATS ModeConnection Diagram GTS Mode ‹ 2.11.1 Vented Batteries Battery InstallationPreparation Before START-UP Manual Transfer START-UP Control Console ComponentsBat Red Oil Red Temp Red Speed Red Crank Red Engine Governor Gain AdjustmentsWeekly Exercise Cycle Manual Retransfer ShutdownAutomatic Operation Voltage Regulator Adjustment Control Board DIP Switch SettingsIntake Manifold Procedure Exhaust Manifold ProcedureCooling System Cylinder Head ProcedureOverload Protection for Engine DC Electrical System Checking Fluid Levels‹ 4.8.2 Check Battery ‹ 4.7.2 Battery Fluid ‹ 4.8.6 Perform Visual Inspection‹ 4.7.3 Engine Coolant ‹ 4.8.1 Check Engine OIL Level‹ 4.8.11 Changing the Engine AIR Cleaner Miscellaneous Maintenance‹ 4.9.1 Cleaning the Generator ‹ 4.8.13 Coolant ChangePeriodic Replacement Parts ‹ 4.9.3 Battery Maintenance‹ 4.9.4 Battery Replacement Service Maintenance Interval Information Scheduled MaintenanceLevel Maintenance Level Problem Cause Correction Troubleshooting PointsLiquid-cooled 15, 20 and 25 kW Generators Liquid-cooled 15, 20 and 25 kW Generators Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Electrical Data Page Hold Down Battery Support Battery TrayAssembly Battery Tray Battery Post Cover BlackTo B Door Battery Compartment Assy Wire 14AWG 7.5 #0 GRN/YELDuct Intake MID AL 2.5L Duct Discharge RH AL 2.5LPage Switch ROC Dpdt ON-OFF-ON Switch ROC Dpst 125V SPDHang TAG 2 Wire Start not Shown TOP, Control PanelPage Harness Ctrl PNL 2.5L Ford AL not Shown 13 17 Engine 2.5L Ford Tank Coolant RecoverySTARTER, 12 Volt NUT HEX M10-1.5 G8 YEL CHRTo Engine Cover AIR Cleaner Body Carburetor AssemblyGASKET, AIR Cleaner Adapter Bracket Fuel RegulatorLocktight Rotor 390 20KW 1P Direct HSB 2.5L Ford Rotor 390 15KW 1P Direct HSB 2.5L FordRotor 390 25KW 1P Direct HSB 2.5L Ford Rotor 390 40KW 1P Direct HSB 3.9L ChryslerPipe Exhaust 2.5L Ford Pipe Muffler OUTMuffler 2.5L Ford Saddle 2 InchCover Connector Housing Housing Governor ConnectorASM Motor Stepper Harn GOV 2.5L FordBarbed STR 1/4 NPT X 3/8 HOSE, 2.5L Ford LowerALM Radiator 2.5L FordInstallation Diagram PURCHASER’S/OWNER’S Warranty Responsibilities Your Warranty Rights and ObligationsMANUFACTURER’S Emission Control System Warranty Coverage Emission Related Parts Include the Following Emission Control System WarrantyThis Warranty Shall not Apply to the Following

005028-0, 005030-0, 005028-0, 005031-0 specifications

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