Generac Power Systems Comprehensive Generac Troubleshooting Guide for Your Portable Generator Needs
Page 28

Section 5 — Troubleshooting

Air-cooled Generators

5.1TROUBLESHOOTING GUIDE

Problem

Cause

Correction

The engine will not crank.

1.

Fuse blown.

1.

Correct short circuit condition,

 

 

 

 

replace 15A fuse in generator

 

 

 

 

control panel.

 

2.

Loose, corroded or defective

2.

Tighten, clean or replace

 

 

battery cables.

 

as necessary.

 

3.

Defective starter contactor. (7 kW)

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/Turn on fuel valve.

will not start.

2.

Defective fuel solenoid (FS).

2.

*

 

3.

Open #14 wire from

3.

*

 

 

engine control board.

 

 

4.Defective spark plug(s).

5.Valve lash out of adjustment.

6.Choke not operating.

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

5.Reset valve lash.

6.Verify choke plate moves freely.

The engine starts hard

1.

Air cleaner plugged

1.

Check, replace air cleaner.

and runs rough.

 

or damaged.

 

 

 

2.

Defective spark plug(s).

2.

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

 

3.

Fuel regulator not set.

3.

Set Fuel Regulator.

 

4.

Fuel pressure incorrect.

4.

Confirm fuel pressure to regulator

 

 

 

 

is 10-12” water column (0.36-0.43

 

 

 

 

psi) for LP, and 5-7” water column

 

 

 

 

(0.18-0.25 psi) for natural gas.

5.Fuel selector in wrong position.

6.Choke remains closed.

5.Move selector to correct position.

6.Verify choke plate moves freely.

The AUTO/OFF/MANUAL switch 1.

Defective switch.

1.

*

is set to OFF, but the engine

2.

AUTO/OFF/MANUAL switch

2.

*

continues to run.

 

wired incorrectly.

 

 

 

3.

Defective control board.

3.

*

 

 

 

 

 

There is no AC output from

1.

Main line circuit breaker is in

1.

Reset circuit breaker

the generator.

 

the OFF (or OPEN) position.

 

to ON (or CLOSED).

 

2.

Generator internal failure.

2.

*

 

 

 

 

 

There is no transfer to

1.

Defective transfer switch coil.

1.

*

standby after utility

2.

Defective transfer relay.

2.

*

source failure.

3.

Transfer relay circuit open.

3.

*

 

4.

Defective control logic board.

4.

*

 

 

 

 

 

Unit consumes large

1.

Engine over filled with oil.

1.

Adjust oil to proper level.

amounts of oil.

2.

Engine breather defective.

2.

*

*Contact the nearest Authorized Dealer for assistance.

26

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Contents Listed Introduction Authorized Dealer LocationPost Installation Start-up Adjustments MaintenanceTroubleshooting Introduction Inside Front Cover Warning   Electrical Hazards  ‹ Standards IndexProtection Systems UNPACKING/INSPECTIONBreaker for Bedrooms Generator 7kW, Single Cylinder GH-410 Engine‹ 1.5.1 Generator Specifications‹ 1.5.2 Engine System SET LED Fuel Requirements RecommendationsFuel Consumption ‹ 1.8.1 BTU Flow Requirements Natural GAS‹ 1.9.1 7 KW, 410CC Engine Reconfiguring the Fuel System‹ 1.9.2 10, 13 and 16KW, V-TWIN Engines Location ‹ 1.10.1 GeneratorBattery Requirements Battery Installation‹ 1.10.2 Transfer Switch 10.2.1 7, 10, 13, and 16 kW Units if equippedBattery 10 Battery Cable ConnectionsBefore Initial START-UP Check Transfer Switch OperationElectrical Checks Checking Automatic Operation Generator Tests Under Load7KW Natural GAS only Engine Governor Adjustment ‹ 2.7.1 7 KW Units‹ 3.1.1 Auto Position ‹ 3.1.3 Manual PositionAutomatic Transfer Operation Sequence of Automatic OperationManual Transfer Operation ‹ 3.1.4 Choke OperationSetting the Exercise Timer ‹ 3.4.2 Transfer Back to Utility Power Source‹ 3.6.1 LOW OIL Pressure Switch ‹ 3.6.2 High Temperature Switch‹ 3.6.3 Overcrank Approximate Crank Cycle Times‹ 3.6.6 LOW Battery Checking the Engine OIL LevelFuses ‹ 3.6.5 RPM Sensor Failure‹ 4.3.1 OIL Change Intervals Changing the Engine OIL‹ 4.3.2 Engine OIL Recommendations ‹ 4.4.1 7, 13, and 16KW Generators Spark Plugs‹ 4.4.2 10KW Generators Battery Maintenance Valve ClearanceCooling System 11 Cooling Vent LocationsOUT of Service Procedure ‹ 4.11.2 Return to Service‹ 4.11.1 Removal from Service Corrosion ProtectionService Schedule Be performed by the nearest Authorized DealerTroubleshooting Guide Problem Cause CorrectionAir-cooled Generators Air-cooled Generators Air-cooled Generators Mounting Dimensions Electrical Data Engine Wiring Customer Connection Battery Charger Engine Alternator Engine Wiring Stator Electronic Voltage Regulator Manual Auto Scsm Neutral Electrical Data Electrical Data Sheet Metal PAINT/MATERIAL Code Legend Part NO. QTY. Description Air-cooled Generators Control Panel Drawing No F9695-C QTY Description Exploded Views and Parts Lists BOX Load Center Exploded Views and Parts Lists Description QTY Exploded Views and Parts Lists Washer Flat M8 5/16 Exploded Views and Parts Lists Crankcase Exploded Views and Parts Lists Intake Adapter Exploded Views and Parts Lists PIN, Piston D20 Exploded Views and Parts Lists SCREW, Taptite M6-1.0X8 Yellow Chrome Air-cooled Generators 7kW, GN-410 Engine Drawing No F9422-B ADAPTOR, Engine Exploded Views and Parts Lists ADATOR, Engine 7KW CASTING, Twin Regulator Housing 7KW Exploded Views and Parts Lists Brkt Regulator Mounting MANUFACTURER’S Emission Control System Warranty Coverage Your Warranty Rights and ObligationsPURCHASER’S/OWNER’S Warranty Responsibilities Emission Control System Warranty Emission Related Parts Include the FollowingGenerac Power Systems Standard Limited Warranty for
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