Troubleshooting flow charts | Generac Power Systems 13 kW NG

DC control

Part 4

Section 4.3

Troubleshooting flow charts

Problem 17 – Engine Cranks but Won’t Start

TEST 66 – CHECK
TEST 66 – CHECK					GOOD
FUEL SUPPLY AND					GOOD
FUEL SUPPLY AND
PRESSURE


	BAD

TEST 67 – CHECK CIRCUIT BOARD WIRE 14 OUTPUT

BAD

			TEST 68 – CHECK
GOOD			TEST 68 – CHECK
			FUEL SOLENOID
			FUEL SOLENOID


				BAD



		REPLACE FUEL SOLENOID						GOOD
		REPLACE FUEL SOLENOID

FIND AND CORRECT

CAUSE OF NO FUEL

OR LOW PRESSURE

GOOD

CHECK AIR FILTER -

REPLACE AS NEEDED

REPLACE CIRCUIT BOARD

	TEST 16 – CHECK
	TEST 16 – CHECK					V-TWIN UNITS	GOOD
	STEPPER MOTOR					V-TWIN UNITS	GOOD
	STEPPER MOTOR
	CONTROL


		BAD

REPAIR OR REPLACE

SINGLE CYLINDER UNITS

TEST 69 – CHECK CHOKE SOLENOID

BAD

REPLACE CHOKE

SOLENOID

TEST 70 –

CHECK FOR

IGNITION

SPARK

BAD

GOOD

TEST 71 –

CHECK SPARK

PLUGS

BAD

CLEAN,

REGAP OR

REPLACE

			TEST 77 –
GOOD

			CHECK AND			GOOD
			CHECK AND			GOOD
			ADJUST VALVES

BAD

READJUST

CHECK

FLYWHEEL GOOD

KEY

TEST 72 –

CHECK ENGINE

COMPRESSION

GOOD BAD

REPLACE FUEL

REGULATOR

TEST 73 – CHECK SHUTDOWN WIRE

BAD

REPAIR OR

REPLACE SHORTED WIRE 18 OR CIRCUIT BOARD

GOOD

TEST 74 – CHECK

IGNITION

MAGNETOS

	BAD
				REFER TO ENGINE

ADJUST OR
REPLACE				SERVICE MANUAL

Page 119

Image 121

Generac Power Systems 13 kW NG, 10 kW LP, 7 kW NG Troubleshooting flow charts, Problem 17 Engine Cranks but Won’t Start

Contents

Air-Cooled Product Electrical formulas Automatic Operating Sequences Problem 12 No Battery Charge 147 Specifications Fuel Consumption Engine Mounting Dimensions Right Side View Door removed Major Features Part General Information Introduction Generator Identification PartNeutral Floating Rainproof Enclosure Fitted Rated Ambient Temp 40C Transfer Switch / Load Center Installation basicsSelecting a Location Grounding The Generator Typical Installation Installation basics Part Natural Gas Fuel Interconnections Power Source And Load Lines System Control Interconnections Non-Prepackaged Interconnections Part Control Wires from Transfer Switch PRE 08 HSB AIR-COOLED Generators Single & V-TWIN Engines Non-Prepackaged Interconnections Preparation Before Use Part Reconfiguring The Fuel SystemGeneral Fuel Requirements Preparation before use Install the battery, door and close the roof Engine Oil Recommendations Vom MetersMeasuring AC Voltage Measuring DC Voltage Measuring Current Testing, cleaning and drying PartMeasuring Resistance Ohm’s Law Electrical UnitsVolts Amps Ohms Insulation Resistance Visual InspectionMegohmmeter ONE 1 Second Stator Insulation Resistance Test 12-20 kW Repeat between Wire 2 and Stator LeadStator Insulation Resistance Test 10 kW Rotor Insulation Resistance Test 10 kW Cleaning The GeneratorRotor Insulation Resistance Test 12-20 kW Drying The Generator High Temperature Switch Low BatteryLow Oil Pressure Shutdown Overspeed Shutdown Overcrank Shutdown Engine-generator protective devices Part Control Panel Operating Instructions Operating instructions Part KW Installation AssistantTo Select Automatic Operation Manual Transfer To Standby Manual Startup Seconds then re-crank if additional crank cycles exist Automatic operating parameters Manual Automatic operating parameters PartAuto Exercise Part AC Generators Engine-Generator Drive System Rotor AssemblyAC Generator Description & components Stator Assembly Brush Holder And Brushes 12-20 kW Description & components PartOther AC Generator Components Main Line Circuit Breaker Field Boost 12-20 KW Rotor Residual Magnetism Operation 8/10 kW Operational analysis PartOperation 12-20 kW Startup Troubleshooting flowcharts Troubleshooting flowcharts Part Problem 3 Generator Produces Low Voltage at No-Load Troubleshooting flowchartsProblem 4 Generator Produces High Voltage at No-Load Units with Test 1 Check Main Circuit Breaker SafetyTest 2 Check AC Output Voltage Results Remove jumper lead connected to Wire 4 and Wire 15B Diagnostic tests PartProcedure Test 4 Fixed Excitation Test Rotor Amp Draw Test Diagnostic tests Test 5 Wire Continuity 12-20 kWExample Reconnect Wire Test 7 Testing The Stator With a Vom 12-20 kWTest 6 Check Field Boost 12-20 kW Test Control Panel Wires for Continuity Repeat using stator lead WireTest 8 Test Brushless Stator Repeat using Wire Repeat using stator leadTest 9 Check Capacitor Repeat using Wires 2 Meter lead to WireTest 10 Test DPE Winding on Brushless units Measured Test 11 Resistance Check Rotor Circuit 12-20 kW Remove Wire 4 from the voltage regulatorTest 12 Check Brushes And Slip Rings 12-20 kW If Continuity was measured in Steps 5 and 6 proceed to Step Test 14 Check AC Output Frequency Test 13 Test Rotor Assembly 12-20 kW Test 16 Check Stepper Motor Control V-twin Engine Units Remove air cleaner cover to access stepper motorLoosen the governor clamp bolt Figure Pull ARM this Direction to Close Throttle Test 17 Check And Adjust Voltage Regulator 12-20 kW Test 18 Check Voltage Frequency Under Load Refer back to flow chartTest 20 Check Engine Condition Test 21 Field Flash Alternator KW Units Construction of Energizing Cord Page Transfer Item Description General Enclosure Transfer Relay Transfer Mechanism Manual Transfer Handle Neutral LugTerminal Block Utility N1 and N2 Fuses F1, F2 Fuse HolderFuses F3 Operational Analysis Is a schematic for a typical W/V-Type transfer switch Operational analysis Is a wiring diagram for a typical W/V-Type transfer switch SW1 Utility Source Voltage Available Utility Source Voltage Failure Generator Power Available, Waiting to Transfer Transfer Action to Standby Position Transfer To Standby Generator Powering Load Utility Restored, Generator Still Providing Output to Load Utility Restored Utility Restored, Transfer Relay De-energized Utility Restored, Transfer Switch De-energized Utility Restored, Retransfer Back to Utility Utility Restored, Retransfer Back To Utility Transfer Switch in Utility Transfer Switch In Utility Introduction To Troubleshooting Troubleshooting flow charts PartProblem 7 In Automatic Mode, No Transfer to Standby Problem 9 Blown F1 or F2 Fuse Troubleshooting flow charts Check N1 & N2 Problem 12 No Battery Charge Rtsn & Rtse Transfer Switch Problem 11 No Battery Charge Pre-Wire Load CenterProblem 13 No Battery Charge GenReady Load Center Problem 14 No Battery Charge Load Shed Transfer Switch If the generator has been shut down, proceed as follows Test 26 Check Voltage at Terminal Lugs E1, E2 Manual Transfer Switch Operation Test 27 Check Manual Transfer Switch Operation Reconnect the J2 connector to the PCB Test 28 Check 23 and 15B WiringPROCEDURE/ Results Test 29 Test Transfer Relay Tr Remove the J2 connector from the circuit boardSet VOM to measure DC voltage Test 30 Standby Control Circuit Test 31 Check Wire SW1 Test 32 Utility Control Circuit Output N2A Test 34 Check Fuses F1 and F2 Test 33 Test Limit Switch SW2 and SW3 Test 36 Check N1 and N2 Voltage Test 35 Check N1 and N2 WiringReplace blown fuses as needed Test 38 Check Utility Sense Voltage Test 37 Check Utility Sensing Voltage at the Circuit BoardTest 39 Check Voltage at Terminal Lugs N1, N2 Generator Transfer Switch Test 42 Check Wire 0 and Wire15B Pre-wire load center Test 40 Check Battery ChargerMeasure across points a and C VAC should be measured Measure across points M and N VDC should be measured Test 45 Check Wire 0/15B Rtsn & Rtse Transfer Switch Rtsn & Rtse Transfer SwitchMeasure across points E and F VAC should be measured 15B Test 43, 44, and 45 Rtse Transfer Switch Test Points Disconnect the J2 connector from the printed circuit board Test 48 Check Wire 0/15B GenReady Load Center Section Measure across points C and D VAC should be measured Load Shed Transfer SwitchMeasure across points E and D VAC should be measured ATS LSSLSC Test 51 Check Wire 0 and Wire 15B Load Shed Transfer Switch Part DC Control Description and components Part Auto-Off-Manual SwitchTerminal Strip / Interconnection Circuit Board Amp Fuse Description and components KW Printed Circuit Boards and J1 Connector Harness END Remote Wireless Connection J2 Connector PCB END J1 Connector Stepper Motor PCB END Harness END Harness END Remote Wireless Connection N1/N2 Connector 17 and 20 kW Printed Circuit Board and J1 Connector Menu System Navigation Choke Solenoid Connector Pin Number Identification Components Description Stator Circuit Condition Utility Source Voltage Available Initial Dropout of Utility Source Voltage Circuit Condition Initial Dropout of Utility Source Voltage Utility Voltage Dropout and Engine Cranking Circuit Condition Engine Cranking Engine Startup and Running Circuit Condition Engine Startup and Running Initial Transfer to the Standby Source Circuit Condition Initial Transfer to Standby Utility Voltage Restored / Re-transfer to Utility Circuit Condition Utility Voltage Restored Engine Shutdown Circuit Condition Retransfer to Utility and Engine Shutdown Controller Switch BAD Replace Controller Assembly Problem 17 Engine Cranks but Won’t Start Readjust Replace Choke Solenoid BAD Problem 19 Shutdown Alarm/Fault Occured Problem 21 Generator Will Not Exercise Problem 20 7.5 Amp Fuse F1 BlownProblem 22 No Low Speed Exercise Test 58 Auto-Off-Manual Switch Twin Only Test 56 Check Position Of Auto-Off Manual SwitchTest 57 Try a Manual Start Test 59 Test Auto Operations Test 61 Check BatteryTest 60 Check 7.5 Amp Fuse Typical Battery Load Tester Test Battery Condition If battery voltage is indicated in refer back to flow chart Test 62 Check Wire 56 VoltageTest 63 Test Starter Contactor Relay V-twin Only Set a VOM to measure DC voltage Test 64 Test Starter Contactor Single Cylinder Engine Reconnect Wire 13 to the SCR Shorted, open or grounded armature Test 65 Test Starter MotorChecking the Pinion Pinion Tools for Starter Performance Test Pinion Port Test 66 Check Fuel Supply PressureSolenoid Removed 12-20 kW Gas Pressure Test point Test 67 Check Circuit Board Wire Output Test 68 Check Fuel Solenoid Disconnect the C3 ConnectorTest 69 Check Choke Solenoid Solenoid De-Energized, Choke Closed KW Units Approximately 3.7 ohms should be measured Disconnect C3 Connector Set a VOM to measure resistance Disconnect the C3 Connector Set a VOM to measure DC voltageTest 70 Check for Ignition Spark KW Choke Solenoid Test 71 Check Spark Plugs Remove a spark plug Test 73 Check Shutdown WireRepeat Steps 1 through 8 on remaining cylinder Check Compression Depending on engine type, do the following Test 74 Check and Adjust Ignition Magnetos Magneto Setting Ignition Magneto Armature Air Gap Cylinder One Back, Short Navigate to the Digital inputs display screen Test 75 Check Oil Pressure Switch WireCheck engine crankcase oil level With oil level correct, try starting the engine Test 77 Check and Adjust Valves Test 76 Check High Oil Temperature SwitchReplace switch if it fails the test Remove the High Oil Temperature Switch Set the AUTO-OFF-MANUAL switch to the Manual position Test 78 Check Wire 18 ContinuityBall Stud JAM NUT Test 80 Check Cranking and Running Circuits Test 79 Test Exercise FunctionRecord the current date and time of the unit 8kW Choke Solenoid Disconnect Wire 4 and Wire 0 from the Voltage Regulator VR Test 81 Check to see if Low Speed Function is enabledTest 82 Check operation Choke Solenoid If the solenoid closed, replace the controller Part Operational Tests System functional tests Part Manual Transfer Switch OperationElectrical Checks Set the generator main line circuit breaker to OFF or open Generator Tests Under Load System functional tests Verify that the AUTO-OFF-MANUAL switch is set to Auto Setting The Exercise TimerChecking Automatic Operation Part Disassembly Front Engine Access Major Disassembly PartRemove control harnesses Major Disassembly Section Section Major Disassembly Section Section Section Section Engine mount nuts with ground wires. See Figure Torque Requirements Unless Otherwise Specified Part Electrical Data Drawing #0G7945 Wiring Diagram, 8 kW Home Standby Part Wiring Diagram, 8 kW Home Standby Drawing #0G8511 Schematic, 8 kW Home Standby Part Part Schematic, 8 kW Home Standby Drawing #0G7946 Wiring Diagram, 10 kW Home Standby Part Part Wiring Diagram, 10 kW Home Standby Drawing #0G8512 Schematic, 10 kW Home Standby Part Part Schematic, 10 kW Home Standby Drawing #0G7947 Wiring Diagram, 14 kW Home Standby Part Part Wiring Diagram, 14 kW Home Standby Drawing #0G8513 Schematic, 14 kW Home Standby Part Part Schematic, 14 kW Home Standby Drawing #0G7948 Wiring Diagram, 17 kW Home Standby Part Part Wiring Diagram, 17 kW Home Standby Drawing #0G8514 Schematic, 17 kW Home Standby Part Part Schematic, 17 kW Home Standby Drawing #0G8186 Wiring Diagram, 20 kW Home Standby Part Part Wiring Diagram, 20 kW Home Standby Drawing #0G8515 Schematic, 20 kW Home Standby Part Part Schematic, 20 kW Home Standby Wiring Diagram, Home Standby Transfer Switch, 9/10/12/16 circuit Part Wiring Diagram, Home Standby Drawing #0G7959 Schematic, Home StandbyPage Page Page MyGenerac.com