Generac Power Systems 55, 75, 65 manual Table of Contents

Page 3

Table of Contents

SAFETY

INSIDE FRONT COVER

SECTION 1:

 

 

GENERATOR FUNDAMENTALS

3-7

MAGNETISM

3

ELECTROMAGNETIC FIELDS

3

ELECTROMAGNETIC INDUCTION

3

A SIMPLE AC GENERATOR

4

A MORE SOPHISTICATED AC GENERATOR

4

FIELD BOOST

6

GENERATOR AC CONNECTION SYSTEM

6

 

SECTION 2:

MAJOR GENERATOR COMPONENTS

8-11

ROTOR ASSEMBLY

8

STATOR ASSEMBLY

8

BRUSH HOLDER

9

BATTERY CHARGE COMPONENTS

9

EXCITATION CIRCUIT COMPONENTS

9

CRANKCASE BREATHER

10

SECTION 3:

 

 

INSULATION RESISTANCE TESTS

12-14

EFFECTS OF DIRT AND MOISTURE

12

INSULATION RESISTANCE TESTERS

12

DRYING THE GENERATOR

12

CLEANING THE GENERATOR

12

STATOR INSULATION RESISTANCE

13

TESTING ROTOR INSULATION

14

THE MEGOHMMETER

14

SECTION 4:

 

 

MEASURING ELECTRICITY

15-17

METERS

15

THE VOM

15

MEASURING AC VOLTAGE

15

MEASURING DC VOLTAGE

15

MEASURING AC FREQUENCY

16

MEASURING CURRENT

16

MEASURING RESISTANCE

16

ELECTRICAL UNITS

17

OHM’S LAW

17

SECTION 5:

 

 

ENGINE DC CONTROL SYSTEM

18-26

INTRODUCTION

18

OPERATIONAL ANALYSIS

18-23

ENGINE CONTROLLER CIRCUIT BOARD

24

BATTERY

24

7.5 AMP FUSE

25

FUEL PRIMER SWITCH

25

START-STOP SWITCH

25

STARTER CONTACTOR RELAY

 

& STARTER MOTOR

26

SECTION 6:

 

TROUBLESHOOTING FLOWCHARTS

27-37

IF PROBLEM INVOLVES AC OUTPUT

27

PROBLEM 1 -

 

VOLTAGE & FREQUENCY ARE BOTH

 

HIGH OR LOW

27

PROBLEM 2 -

 

GENERATOR PRODUCES ZERO VOLTAGE OR

 

RESIDUAL VOLTAGE (5-12 VAC)

28-29

PROBLEM 3 -

 

NO BATTERY CHARGE OUTPUT

29

PROBLEM 4 -

 

EXCESSIVE VOLTAGE/FREQUENCY DROOP

 

WHEN LOAD IS APPLIED

30

PROBLEM 5 -

 

PRIMING FUNCTION DOES NOT WORK

 

(GASOLINE MODELS)

30

PROBLEM 6 -

 

ENGINE WILL NOT CRANK

31

PROBLEM 7 -

 

ENGINE CRANKS BUT WILL NOT START

 

(GASOLINE UNITS)

32

PROBLEM 7 -

 

ENGINE CRANKS BUT WILL NOT START

 

(LP UNITS)

33

PROBLEM 8 -

 

ENGINE STARTS HARD AND RUNS ROUGH

 

(GASOLINE UNITS)

34

PROBLEM 8 -

 

ENGINE STARTS HARD AND RUNS ROUGH

 

(LP UNITS)

34

PROBLEM 9 -

 

ENGINE STARTS THEN SHUTS DOWN

36

PROBLEM 10 -

 

7.5 AMP (F1) FUSE BLOWING

37

SECTION 7:

 

DIAGNOSTIC TESTS

38-67

INTRODUCTION

38

TEST 1 -

 

Check No-Load Voltage And Frequency

38

TEST 2 -

 

Check Engine Governor

38

TEST 3 -

 

Test Excitation Circuit Breaker

39

TEST 4 -

 

Fixed Excitation Test/Rotor Amp Draw

39

TEST 5 -

 

Wire Continuity

40

TEST 6 -

 

Check Field Boost

41

TEST 7 -

 

Test Stator DPE Winding

41

TEST 8 -

 

Check Sensing Leads/Power Windings

42

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Exploded Views / Part Numbers Section Specifications & ChartsMagnetism Electromagnetic FieldsElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemLine Breakers 120 Volts only Reconnection for Dual Voltage Output Connection for 120 Volts OnlyStator Assembly Rotor AssemblyGeneral Battery Charge ComponentsBrush Holder Excitation Circuit ComponentsDescription Adjustment ProcedureCrankcase Breather Voltage RegulatorCheck Breather Install BreatherInstall oil vapor collector and retainer Control Panel Component IdentificationDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersStator SHORT-TO-GROUND Tests Brushing and Vacuum CleaningStator Insulation Resistance Cloth or Compressed AIRMegohmmeter Testing Rotor InsulationTesting Stator Insulation Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC VoltageMeasuring AC Frequency Measuring CurrentMeasuring Resistance Volt Electrical UnitsOhms LAW AmpereIntroduction Operational AnalysisCircuit CONDITION- Rest Circuit CONDITION- Priming Circuit CONDITION- Cranking Choke Heater CH Circuit CONDITION-RUNNINGCircuit CONDITION- Shutdown Sure Switch LOP Circuit CONDITION- Fault ShutdownEngine Controller Circuit Board BatteryRecommended Battery Battery CablesFuel Primer Switch START-STOP SwitchAMP Fuse Starter Contactor Relay Starter Motor Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Discussion ProcedureTest 1- Check NO-LOAD Voltage Frequency Test 2- Check Engine GovernorIf continuity was indicated, go to Test Governor AdjustmentTest 3- Test Excitation Circuit Breaker Test 4- Fixed Excitation TEST/ROTOR AMP DrawSet a VOM to its Rx1 scale Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Set the VOM to measure AC voltageTest 6- Check Field Boost Test 7 Test Stator DPE WindingIf field boost checks good, replace the Voltage Regulator Model Ohms Test 8- Check Sensing Leads / Power WindingsAcross Wires Ohms 11S 22STest 10 Check Brushes & Slip Rings Test 9- Check Brush LeadsReplace the Rotor if it fails the test Test 11- Check Rotor AssemblyTance Tests Procedure Test 12 Check Main Circuit BreakerTest 13- Check Load Voltage Frequency Test 15 Check Battery Charge OutputTest 16 Check Battery Charge Rectifier Battery Charge Rectifier BCR is a full wave rectifierShort to Ground 10. Battery Charge RectifierTest 18 TRY Cranking the Engine Test 19- Test Primer SwitchSet a VOM to read battery voltage 12 VDC Also see Fuel Primer Switch,13. The LPG Fuel Solenoid FS Test 20- Check Fuel PumpTest 22- Check Battery & Cables Test 23- Check Power Supply to Circuit BoardTest 21- Check 7.5 AMP Fuse 17. Start-Stop Switch Test 24 Check START-STOP SwitchSet a VOM to measure DC voltage 12 VDC Test 26- Check Starter Contactor RelayTest 26A Check Starter Contactor Test 27 Check Starter MotorConditions Affecting Starter Motor Performance Tachometer Checking the PinionTools for Starter Performance Test Measuring CurrentRemove Starter Motor Testing Starter MotorTest 28- Check Fuel Supply Test BracketDiscussion LPG Models 28 LP Gas Carburetion DiagramCrank the engine. The meter should indicate battery voltage Test 29 Check Wire 14 Power SupplyTest 30 Check Wire Battery voltage is not measured, proceed to StepTest 32 Check Ignition Spark Test 31 Check Fuel Solenoid Gasoline ModelsConclusion No cylinder is weakest of the two cylinders Cylinder Balance TestTest 33 Check Spark Plugs Test 34 Check and Adjust Ignition Magnetos37. Setting Ignition Magneto Armature Air Gap Flywheel KEY Test 35 Check Valve AdjustmentAdjusting Valve Clearance Checking Flywheel MagnetInstall Rocker ARM Cover Test 36 Check CarburetionTest 37 Check Choke Solenoid 43. Connector Check Compression Adjust the regulated pressure on the gauge to 80 psiDown Test / Compression Test Repeat Steps 1 through 8 on remaining cylinderTest 39 Check OIL Pressure Switch Test 40 Test OIL Temperature SwitchIf all steps check GOOD, go to Test Test 41 Test Choke Heater Test 42 Check LPG Fuel SolenoidShort to Ground 49. Fuel Solenoid Rotor Removal Major DisassemblyENCLOSURE/PANEL Removal Stator RemovalBelt Tensioning Engine RemovalStarter Removal FLYWHEEL/MAGNETO Removal Page Section Exploded Views / Part Numbers Part NO. QTY Description Enclosure Drawing No E1011-B QTY Description Sheet Metal Drawing No E1012-E Flywheel Assy GT-990 QTY DescriptionControl Panel Drawing No E1013-A PANEL, TOP Control Wire ASM GRD STD ConnSwitch Spdt ON-MOM-ON Switch 6A Spdt Not ShownTwin Engine Drawing No E1014-B ASSEMBLY, OIL Fill CAP ASSEMBLY, Crankcase RVASSEMBLY, Breather ASSEMBLY, Head #1LP Regulator Drawing No E1530 SPRING-SOLENOID Plunger CASTING, Twin Regulator HousingWasher Flat M4 SOLENOID, Twin RegulatorSpecifications & Charts Nominal Resistances of Generator Windings AT 68F Generator SpecificationsEngine Speeds and Voltage Specifications Page Electrical Data Electrical Data PO BOX 297 WHITEWATER, WI

65, 75, 55 specifications

Generac Power Systems has established itself as a leader in power generation, offering a range of high-performance generators suited for residential and commercial applications. Among its lineup, the Generac 55, 65, and 75 kW generators stand out for their reliability, efficiency, and advanced features.

The Generac 55 kW generator is designed to provide a powerful backup solution for medium to large homes or small businesses. It features a robust engine that delivers dependable performance while maintaining fuel efficiency. One of its key characteristics is the True Power Technology, which produces clean and stable power, ensuring that sensitive electronic devices run smoothly without risk of damage. This generator is equipped with a fully automatic transfer switch, allowing for seamless power transition during outages, with minimal disruption.

Moving to the 65 kW model, it offers increased capacity while retaining the fundamental qualities of the 55 kW version. This unit is particularly suited for larger homes or commercial applications that require greater power demands. The 65 kW generator utilizes Generac’s G-Force engine, known for its durability and reduced maintenance needs. Advanced features such as remote monitoring capabilities allow users to check the generator's status from anywhere, providing peace of mind and convenience.

The 75 kW generator takes performance to the next level, making it ideal for even more significant power needs. It is engineered for both quiet operation and enhanced performance, accommodating a wide range of requirements from residential to larger commercial operations. The 75 kW model includes a full-load voltage regulation system that maintains stable power output under varying loads, safeguarding appliances and equipment.

All three models incorporate advanced air-cooled technology, which enhances their efficiency and operational lifespan. Additionally, their corrosion-resistant enclosures ensure durability even in harsh weather conditions, making them suitable for diverse environments. The intuitive LCD display on each unit provides critical information, including runtime hours and maintenance reminders, empowering users with easy access to the generator's performance data.

Overall, Generac Power Systems' 55, 65, and 75 kW generators represent a commitment to quality, reliability, and innovation in backup power solutions. They are designed to meet the demands of modern power consumption while ensuring peace of mind through robust engineering and advanced technology. Whether for home use or commercial applications, these generators provide an effective means to stay prepared for unexpected power outages.
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