Generac Power Systems 65, 55, 75 manual Belt Tensioning, Engine Removal, Starter Removal

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Section 8

ASSEMBLY

BELT TENSIONING:

Tighten all four stator stud nuts to compress the spring to one half inch (1/2”) between the washer and support slide.

Tighten the two side bolts to compress the spring to 5/8 of an inch between the washer and bearing carrier (see Figure 8-1).

ENGINE REMOVAL:

1.Perform rotor removal steps 1-17.

2.Drain engine oil.

3.Remove engine pulley bolt (using a 14mm socket).

4.Remove engine pulley using steering wheel puller (using 5/16"- 18 bolts for puller).

5.Remove 5 of 6 screws holding exhaust gaskets to tray (an 8mm socket is required).

6.Remove four (4) exhaust manifold bolts (using a 6mm allen wrench).

7.Remove last screw holding exhaust gasket to tray (an 8mm socket is required).

8.Remove four (4) engine mounting bolts (using a 14mm socket).

9.Remove oil fill line mounting clamp.

10.Remove two (2) oil lines to oil filter adapter.

11.Remove engine.

STARTER REMOVAL:

1.Perform enclosure/panel removal steps 1-7.

2.Remove spark plug boot from spark plug left side/cylinder 1.

3.Remove nine (9) bolts from cylinder 1 wrap. Remove cylinder 1wrap (using an 8mm socket).

4.Remove five (5) bolts from crankcase wrap (using an 8mm socket).

5.Remove four (4) bolts from oil cooler oil duct. Remove oil duct (both a 10mm socket and an 8mm socket are required).

6.Remove crankcase wrap.

7.Remove five (5) bolts holding blower housing (using an 8mm socket).

Figure 8-1. – Drive Belt Tension

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Exploded Views / Part Numbers Section Specifications & ChartsElectromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Line Breakers 120 Volts only Field BoostGenerator AC Connection System 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 Resistance Measuring AC FrequencyMeasuring Current Volt Electrical UnitsOhms LAW AmpereCircuit CONDITION- Rest IntroductionOperational Analysis 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 CablesAMP Fuse Fuel Primer SwitchSTART-STOP Switch 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 voltageIf field boost checks good, replace the Voltage Regulator Test 6- Check Field BoostTest 7 Test Stator DPE Winding 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 21- Check 7.5 AMP Fuse Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board 17. Start-Stop Switch Test 24 Check START-STOP SwitchSet a VOM to measure DC voltage 12 VDC Test 26- Check Starter Contactor RelayConditions Affecting Starter Motor Performance Test 26A Check Starter ContactorTest 27 Check Starter Motor 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 MagnetTest 37 Check Choke Solenoid Install Rocker ARM CoverTest 36 Check Carburetion 43. Connector Check Compression Adjust the regulated pressure on the gauge to 80 psiDown Test / Compression Test Repeat Steps 1 through 8 on remaining cylinderIf all steps check GOOD, go to Test Test 39 Check OIL Pressure SwitchTest 40 Test OIL Temperature Switch Short to Ground Test 41 Test Choke HeaterTest 42 Check LPG Fuel Solenoid 49. Fuel Solenoid Rotor Removal Major DisassemblyENCLOSURE/PANEL Removal Stator RemovalStarter Removal Belt TensioningEngine 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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