Readjust Replace Choke Solenoid BAD | Generac Power Systems 7 kW NG

Section 4.3

Troubleshooting flow charts

Part 4

DC control

Problem 18 – Engine Starts Hard and Runs Rough / Lacks Power / Backfires

IF RECONFIGURED TO LP GAS,

TEST 66 – CHECK

CHECK AIR FILTER -

GOOD

VERIFY THAT PROPER

GOOD

FUEL SUPPLY AND

PROCEDURE WAS FOLLOWED.

REPLACE AS NEEDED

PRESSURE

(REFER TO SECTION 1.3)

BAD

FIND AND CORRECT

TEST 69 – CHECK

CAUSE OF NO FUEL

CHOKE SOLENOID

OR LOW PRESSURE

BAD

READJUST

REPLACE CHOKE SOLENOID

BAD

TEST 70 –

TEST 71 –

TEST 77 –

GOOD

GOOD

CHECK AND

CHECK FOR

CHECK SPARK

BAD

PLUGS

ADJUST VALVES

IGNITION SPARK

BAD

TEST 74 – CHECK

IGNITION MAGNETOS

CLEAN, REGAP

GOOD

GOOD

OR REPLACE

BAD

TEST 15 - CHECK

AND ADJUST

ADJUST OR

READJUST

BAD

SINGLE CYLINDER UNITS

ENGINE

REPLACE

GOVERNOR

TEST 16 – CHECK

GOOD

STEPPER MOTOR

V-TWIN UNITS

CONTROL

TEST 78 – CHECK

TEST 72 – CHECK

BAD

GOOD

ENGINE

FUEL REGULATOR

COMPRESSION

GOOD

REPAIR OR

BAD

BAD

REPLACE

REPAIR OR

CHECK

REFER TO ENGINE

REPLACE

FLYWHEEL

SERVICE MANUAL

KEY

Page 120

Image 122

Generac Power Systems 7 kW NG, 10 kW LP, 13 kW NG, 9 kW NG, 8 kW LP, 17 kW LP, 20 kW LP Readjust Replace Choke Solenoid BAD

Contents

Air-Cooled Product Electrical formulas Automatic Operating Sequences Problem 12 No Battery Charge 147 Specifications Engine Fuel Consumption Mounting Dimensions Right Side View Major Features Door removed Part General Information Neutral Floating Generator Identification PartIntroduction Rainproof Enclosure Fitted Rated Ambient Temp 40C Selecting a Location Installation basicsTransfer Switch / Load Center Grounding The Generator Installation basics Part Typical Installation Power Source And Load Lines System Control Interconnections Natural Gas Fuel Interconnections Control Wires from Transfer Switch Non-Prepackaged Interconnections Part Non-Prepackaged Interconnections PRE 08 HSB AIR-COOLED Generators Single & V-TWIN Engines General Reconfiguring The Fuel SystemPreparation Before Use Part Fuel Requirements Install the battery, door and close the roof Preparation before use Engine Oil Recommendations Measuring AC Voltage MetersVom Measuring DC Voltage Measuring Resistance Testing, cleaning and drying PartMeasuring Current Volts Amps Ohms Electrical UnitsOhm’s Law Megohmmeter Visual InspectionInsulation Resistance ONE 1 Second Stator Insulation Resistance Test 10 kW Repeat between Wire 2 and Stator LeadStator Insulation Resistance Test 12-20 kW Rotor Insulation Resistance Test 12-20 kW Cleaning The GeneratorRotor Insulation Resistance Test 10 kW Drying The Generator Low Oil Pressure Shutdown Low BatteryHigh Temperature Switch Overspeed Shutdown Engine-generator protective devices Part Overcrank Shutdown Operating Instructions Control Panel To Select Automatic Operation KW Installation AssistantOperating instructions Part Manual Transfer To Standby Manual Startup Automatic operating parameters Seconds then re-crank if additional crank cycles exist Auto Automatic operating parameters PartManual Exercise Part AC Generators AC Generator Rotor AssemblyEngine-Generator Drive System Stator Assembly Description & components Other AC Generator Components Description & components PartBrush Holder And Brushes 12-20 kW Main Line Circuit Breaker Rotor Residual Magnetism Field Boost 12-20 KW Operation 12-20 kW Operational analysis PartOperation 8/10 kW Startup Troubleshooting flowcharts Troubleshooting flowcharts Part Problem 4 Generator Produces High Voltage at No-Load Troubleshooting flowchartsProblem 3 Generator Produces Low Voltage at No-Load Units with Test 2 Check AC Output Voltage SafetyTest 1 Check Main Circuit Breaker Results Procedure Diagnostic tests PartRemove jumper lead connected to Wire 4 and Wire 15B Test 4 Fixed Excitation Test Rotor Amp Draw Test Example Test 5 Wire Continuity 12-20 kWDiagnostic tests Test 6 Check Field Boost 12-20 kW Test 7 Testing The Stator With a Vom 12-20 kWReconnect Wire Test 8 Test Brushless Stator Repeat using stator lead WireTest Control Panel Wires for Continuity Test 9 Check Capacitor Repeat using stator leadRepeat using Wire Test 10 Test DPE Winding on Brushless units Meter lead to WireRepeat using Wires 2 Measured Test 12 Check Brushes And Slip Rings 12-20 kW Remove Wire 4 from the voltage regulatorTest 11 Resistance Check Rotor Circuit 12-20 kW If Continuity was measured in Steps 5 and 6 proceed to Step Test 13 Test Rotor Assembly 12-20 kW Test 14 Check AC Output Frequency Loosen the governor clamp bolt Figure Remove air cleaner cover to access stepper motorTest 16 Check Stepper Motor Control V-twin Engine Units Test 17 Check And Adjust Voltage Regulator 12-20 kW Pull ARM this Direction to Close Throttle Test 20 Check Engine Condition Refer back to flow chartTest 18 Check Voltage Frequency Under Load Test 21 Field Flash Alternator KW Units Construction of Energizing Cord Page Transfer General Enclosure Item Description Transfer Mechanism Transfer Relay Terminal Block Neutral LugManual Transfer Handle Utility N1 and N2 Fuses F3 Fuse HolderFuses F1, F2 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 Operational analysis Utility Source Voltage Available SW1 Generator Power Available, Waiting to Transfer Utility Source Voltage Failure Transfer To Standby Transfer Action to Standby Position Generator Powering Load Utility Restored Utility Restored, Generator Still Providing Output to Load Utility Restored, Transfer Switch De-energized Utility Restored, Transfer Relay De-energized Utility Restored, Retransfer Back To Utility Utility Restored, Retransfer Back to Utility Transfer Switch In Utility Transfer Switch in Utility Problem 7 In Automatic Mode, No Transfer to Standby Troubleshooting flow charts PartIntroduction To Troubleshooting Troubleshooting flow charts Problem 9 Blown F1 or F2 Fuse Check N1 & N2 Problem 13 No Battery Charge GenReady Load Center Problem 11 No Battery Charge Pre-Wire Load CenterProblem 12 No Battery Charge Rtsn & Rtse Transfer Switch Problem 14 No Battery Charge Load Shed Transfer Switch Test 26 Check Voltage at Terminal Lugs E1, E2 If the generator has been shut down, proceed as follows Test 27 Check Manual Transfer Switch Operation Manual Transfer Switch Operation PROCEDURE/ Results Test 28 Check 23 and 15B WiringReconnect the J2 connector to the PCB Set VOM to measure DC voltage Remove the J2 connector from the circuit boardTest 29 Test Transfer Relay Tr Test 31 Check Wire Test 30 Standby Control Circuit SW1 Output Test 32 Utility Control Circuit N2A Test 33 Test Limit Switch SW2 and SW3 Test 34 Check Fuses F1 and F2 Replace blown fuses as needed Test 35 Check N1 and N2 WiringTest 36 Check N1 and N2 Voltage Test 39 Check Voltage at Terminal Lugs N1, N2 Test 37 Check Utility Sensing Voltage at the Circuit BoardTest 38 Check Utility Sense Voltage Transfer Switch Generator Measure across points a and C VAC should be measured Test 40 Check Battery ChargerTest 42 Check Wire 0 and Wire15B Pre-wire load center Measure across points M and N VDC should be measured Measure across points E and F VAC should be measured Rtsn & Rtse Transfer SwitchTest 45 Check Wire 0/15B Rtsn & Rtse Transfer Switch 15B Test 43, 44, and 45 Rtse Transfer Switch Test Points Test 48 Check Wire 0/15B GenReady Load Center Disconnect the J2 connector from the printed circuit board Section Measure across points E and D VAC should be measured Load Shed Transfer SwitchMeasure across points C and D VAC should be measured LSC LSSATS Test 51 Check Wire 0 and Wire 15B Load Shed Transfer Switch Part DC Control Terminal Strip / Interconnection Auto-Off-Manual SwitchDescription and components Part Circuit Board Description and components Amp Fuse KW Printed Circuit Boards and J1 Connector J2 Connector PCB END J1 Connector Stepper Motor Harness END Remote Wireless Connection Harness END Remote Wireless Connection N1/N2 Connector PCB END Harness END 17 and 20 kW Printed Circuit Board and J1 Connector Choke Solenoid Connector Pin Number Identification Menu System Navigation Description Components 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 22 No Low Speed Exercise Problem 20 7.5 Amp Fuse F1 BlownProblem 21 Generator Will Not Exercise Test 57 Try a Manual Start Test 56 Check Position Of Auto-Off Manual SwitchTest 58 Auto-Off-Manual Switch Twin Only Test 60 Check 7.5 Amp Fuse Test 61 Check BatteryTest 59 Test Auto Operations Test Battery Condition Typical Battery Load Tester Test 63 Test Starter Contactor Relay V-twin Only Test 62 Check Wire 56 VoltageIf battery voltage is indicated in refer back to flow chart Set a VOM to measure DC voltage Reconnect Wire 13 to the SCR Test 64 Test Starter Contactor Single Cylinder Engine Checking the Pinion Test 65 Test Starter MotorShorted, open or grounded armature Pinion Pinion Tools for Starter Performance Test Solenoid Removed Test 66 Check Fuel Supply PressurePort Test 67 Check Circuit Board Wire Output 12-20 kW Gas Pressure Test point Test 69 Check Choke Solenoid Disconnect the C3 ConnectorTest 68 Check Fuel Solenoid Approximately 3.7 ohms should be measured Solenoid De-Energized, Choke Closed KW Units Test 70 Check for Ignition Spark Disconnect the C3 Connector Set a VOM to measure DC voltageDisconnect C3 Connector Set a VOM to measure resistance KW Choke Solenoid Test 71 Check Spark Plugs Repeat Steps 1 through 8 on remaining cylinder Test 73 Check Shutdown WireRemove a spark plug Check Compression Test 74 Check and Adjust Ignition Magnetos Depending on engine type, do the following Setting Ignition Magneto Armature Air Gap Magneto Cylinder One Back, Short Check engine crankcase oil level Test 75 Check Oil Pressure Switch WireNavigate to the Digital inputs display screen With oil level correct, try starting the engine Replace switch if it fails the test Test 76 Check High Oil Temperature SwitchTest 77 Check and Adjust Valves Remove the High Oil Temperature Switch Ball Stud JAM NUT Test 78 Check Wire 18 ContinuitySet the AUTO-OFF-MANUAL switch to the Manual position Record the current date and time of the unit Test 79 Test Exercise FunctionTest 80 Check Cranking and Running Circuits Choke Solenoid 8kW Test 82 Check operation Choke Solenoid Test 81 Check to see if Low Speed Function is enabledDisconnect Wire 4 and Wire 0 from the Voltage Regulator VR If the solenoid closed, replace the controller Part Operational Tests Electrical Checks Manual Transfer Switch OperationSystem functional tests Part Set the generator main line circuit breaker to OFF or open System functional tests Generator Tests Under Load Checking Automatic Operation Setting The Exercise TimerVerify that the AUTO-OFF-MANUAL switch is set to Auto Part Disassembly Remove control harnesses Major Disassembly PartFront Engine Access 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 Wiring Diagram, 8 kW Home Standby Part Drawing #0G7945 Wiring Diagram, 8 kW Home Standby Schematic, 8 kW Home Standby Part Drawing #0G8511 Part Schematic, 8 kW Home Standby Wiring Diagram, 10 kW Home Standby Part Drawing #0G7946 Part Wiring Diagram, 10 kW Home Standby Schematic, 10 kW Home Standby Part Drawing #0G8512 Part Schematic, 10 kW Home Standby Wiring Diagram, 14 kW Home Standby Part Drawing #0G7947 Part Wiring Diagram, 14 kW Home Standby Schematic, 14 kW Home Standby Part Drawing #0G8513 Part Schematic, 14 kW Home Standby Wiring Diagram, 17 kW Home Standby Part Drawing #0G7948 Part Wiring Diagram, 17 kW Home Standby Schematic, 17 kW Home Standby Part Drawing #0G8514 Part Schematic, 17 kW Home Standby Wiring Diagram, 20 kW Home Standby Part Drawing #0G8186 Part Wiring Diagram, 20 kW Home Standby Schematic, 20 kW Home Standby Part Drawing #0G8515 Part Schematic, 20 kW Home Standby Transfer Switch, 9/10/12/16 circuit Wiring Diagram, Home Standby Part Wiring Diagram, Home Standby Schematic, Home Standby Drawing #0G7959Page Page Page MyGenerac.com