Generac 004373-1, 004626-0 owner manual Troubleshooting Guide, Problem Cause Correction

Page 22

Section 5 — Troubleshooting

Guardian Liquid-cooled 40 kW Generator

5.1TROUBLESHOOTING GUIDE

PROBLEM

CAUSE

CORRECTION

The engine will not crank.

1.

Fuse blown

1.

Replace fuse.

 

2.

Loose, corroded or defective

2.

Tighten, clean or replace

 

 

battery cables

 

as necessary.

 

3.

Defective starter contactor

3.

*

 

4.

Defective starter motor

4.

*

 

5.

Dead Battery

5.

Charge or replace battery.

 

 

 

 

 

The engine cranks but

1.

Out of fuel

1.

Replenish fuel.

will not start.

2.

Defective fuel solenoid (FS)

2.

*

 

3.

Open #14 wire from

3.

*

 

 

engine control board

 

 

 

4.

Defective spark plug(s)

4.

Clean, re-gap or replace plug(s).

 

5.

Dirty/Blocked air filter

5.

Clean or replace as required.

 

 

 

 

 

The engine starts hard

1.

Air cleaner

1.

Check, clean or replace air cleaner.

and runs rough.

 

plugged or damaged

 

 

 

2.

Defective spark plug(s)

2.

Clean, re-gap or replace plug(s).

 

3.

Dirty/Blocked air filter

3.

Clean or replace as required.

 

 

 

 

 

The engine starts, but then

1.

Engine oil level low

1.

Check oil and add oil as needed.

shuts down.

2.

Defective low oil

2.

*

 

 

pressure switch

 

 

 

3.

Defective high temperature

3.

*

 

 

switch

 

 

 

4.

Defective control board

4.

*

 

5.

Low coolant level

5.

Check coolant level, repair leaks

 

 

 

 

and refill.

 

 

 

 

 

The Auto/Off/Manual switch

1.

Defective switch

1.

*

is set to OFF, but the engine

2.

Defective control board

2.

*

continues to run.

 

 

 

 

 

 

 

 

 

There is no AC output from

1.

Generator main line circuit

1.

Reset circuit breaker

the generator.

 

breaker open

 

to ON (or closed).

 

2.

Generator internal failure

2.

*

 

 

 

 

 

There is no transfer to

1.

Generator main line circuit

1.

Reset circuit breaker

standby after utility

 

breaker open

 

to ON (or closed).

source failure.

2.

Defective transfer switch coil

2.

*

 

3.

Defective transfer relay

3.

*

 

4.

Transfer relay circuit open

4.

*

 

5.

Defective control logic board

5.

*

*Contact your nearest Generac/Guardian Authorized Dealer for assistance.

20 Generac® Power Systems, Inc.

Image 22
Contents Power SYSTEMS, INC Introduction Authorized Dealer LocationMaintenance Safety Rules General InformationInstallation Section Installation Drawings 56-57 Warranty Back CoverGeneral Hazards Electrical Hazards Generator AC Connection Systems UNPACKING/INSPECTIONGenerator Automatic System OperationMain Circuit Breaker SpecificationsEngine Protective Devices Engine Fuel Requirements RecommendationsGenerator and Load Compatibility Conversion to LP GAS VaporEmissions Control System CoolantAIR Fuel Ratio Controller Nfpa Standards Standby Generator InstallationBasic Standby Electric System Other Published StandardsPre-Packaged Type Switch Transfer Switch Start Signal ConnectionsGTS Type Switch Emergency Circuit Isolation MethodPreparation Before START-UP Battery InstallationVented Batteries Prior to Initial START-UP Using the AUTO/OFF/MANUAL Switch Automatic Transfer Operation OFF PositionManual Position Sequence of Automatic OperationWeekly Exercise Cycle Checking the Engine OIL LevelChanging the Engine OIL and Filter Oil and Filter Change ProcedureChanging the Engine AIR Cleaner Engine Oil RecommendationsBattery Maintenance Spark PlugsOverload Protection for Engine DC Electrical System Miscellaneous MaintenanceCleaning the Generator DC FuseRemoval From Service OUT of Service ProcedureReturn To Service Service Schedule SYSTEM/COMPONENT Procedure FrequencyTroubleshooting Guide Problem Cause CorrectionElectrical Data Section Power Systems, Inc Generac Power Systems, Inc Electrical Data Electrical Data Electrical Data Wiring Diagram RED Brush Units DPEPanel Face Switch Selector 6A AMP/V Switch Rocker Dpst 125V SPDSwitch TOG Dpdt 15/10 SP Part of Control Panel Wire HarnessGenerators Cover Plate AVR CONTROLLER, B-C #DPG-2103Screen Cover Plate EgovHousing Governor Connect Assembly Motor StepperConnector Interface Assembly Cover Conn HousingPlug Button 3 DIA BASE, Mounting ASSEMBLY, 4.3LAssembly Groundwire 10/3/8 DIRECT-COUPLED4640 31 33 Engine 4.3L GM Switch OIL PressureDC Alternator Assembly Pulley TensionerExploded Views and Parts Lists Wires Spark Plug 4.3L Retainer Plug WiresRetainer Spark Plug Wires Connector C/C VentAdd item #42 vinyl trim as shown Assembly Scroll 390 SAE FAN Assembly 390 SAE DDAssembly Brush & Shunt Carrier Rear BearingShakeproof INT M6 SS Assembly Cover AccessDuct Bottom Duct Front PanelRadiator 14 FIN/INCH Tank Coolant RecoveryBracket Coolant Recovery Tank Venturi 16 DIA 35KWGasket AIR Cleaner Plate AIR Cleanr BottomPlate AIR Cleaner TOP Gasket Carburetor AdaptorHose 1 in ID LP GAS Mixer only Natural GASNPT X Actuator Throttle 42MMNipple Pipe 3/4NPTX4.5 BLK IRN Support Solenoid NAT GASNipple TOE 3/4 NPT X Hose 1IN ID LP GASLUG Rngtng INS Regulator N/G R600SDECAL,INLET Pressure HEATER, Engine 2000W Hose Connection TEEHEATER, Engine 1800W HOSE, Preformed Block HeaterCable Battery Black #1 X Battery 12VDC 90-AH 27F OptionalHold Down Battery Cable Battery RED #1 X11 12 Relay Solenoid 12VDC PNL MNT Cover Lower Connection BOXBushing Snap SB-2.5-31 Transformer 200A to 5A 5VAExploded Views and Parts Lists Mounting Band A-GRP Catalyst Tube Straight a GroupMuffler Catalyst 4.3L Shield Heat Crossover 4.3LMuffler 2-1/2 INLET/OUTLET Clamp Band MufflerGuardian Liquid-cooled 40 kW Generators Installation Drawings 12V Battery see Note Lifting EYE Places Warranty Schedule This Warranty Shall not Apply to the Following