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Generac Power Systems 9 kW NG, 10 kW LP, 13 kW NG, 7 kW NG, 8 kW LP, 17 kW LP manual Part Disassembly

Models: 18 kW NG 14 kW LP 16 kW NG 20 kW LP 17 kW LP 8 kW LP 9 kW NG 7 kW NG 13 kW NG 10 kW LP

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Page 153

PART 6

DISASSEMBLY

Air-cooled, Automatic Standby Generators

Table of contents

Part Title

6.1.Major Disassembly

6.1 Major Disassembly	152
Front Engine Access	152
Major Disassembly	156
Torque Requirements
(Unless Otherwise Specified)	162

Page 151

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Generac Power Systems 9 kW NG, 10 kW LP, 13 kW NG, 7 kW NG, 8 kW LP, 17 kW LP, 20 kW LP, 16 kW NG, 14 kW LP manual Part Disassembly

Contents

Air-Cooled Product Electrical formulas Automatic Operating Sequences Problem 12 No Battery Charge 147 Specifications Fuel Consumption EngineMounting Dimensions Right Side View Door removed Major FeaturesPart General Information Introduction Generator Identification PartNeutral Floating Rainproof Enclosure Fitted Rated Ambient Temp 40CTransfer Switch / Load Center Installation basicsSelecting a Location Grounding The GeneratorTypical Installation Installation basics PartNatural Gas Fuel Interconnections Power Source And Load Lines System Control InterconnectionsNon-Prepackaged Interconnections Part Control Wires from Transfer SwitchPRE 08 HSB AIR-COOLED Generators Single & V-TWIN Engines Non-Prepackaged InterconnectionsPreparation Before Use Part Reconfiguring The Fuel SystemGeneral Fuel RequirementsPreparation before use Install the battery, door and close the roofEngine Oil Recommendations Vom MetersMeasuring AC Voltage Measuring DC VoltageTesting, cleaning and drying Part Measuring CurrentMeasuring Resistance Electrical Units Ohm’s LawVolts Amps Ohms Insulation Resistance Visual InspectionMegohmmeter ONE 1 SecondRepeat between Wire 2 and Stator Lead Stator Insulation Resistance Test 12-20 kWStator Insulation Resistance Test 10 kW Rotor Insulation Resistance Test 10 kW Cleaning The GeneratorRotor Insulation Resistance Test 12-20 kW Drying The GeneratorHigh Temperature Switch Low BatteryLow Oil Pressure Shutdown Overspeed ShutdownOvercrank Shutdown Engine-generator protective devices PartControl Panel Operating InstructionsOperating instructions Part KW Installation AssistantTo Select Automatic Operation Manual Transfer To Standby Manual StartupSeconds then re-crank if additional crank cycles exist Automatic operating parametersManual Automatic operating parameters PartAuto ExercisePart AC Generators Rotor Assembly Engine-Generator Drive SystemAC Generator Description & components Stator AssemblyBrush Holder And Brushes 12-20 kW Description & components PartOther AC Generator Components Main Line Circuit BreakerField Boost 12-20 KW Rotor Residual MagnetismOperation 8/10 kW Operational analysis PartOperation 12-20 kW StartupTroubleshooting flowcharts Troubleshooting flowcharts Part Troubleshooting flowcharts Problem 3 Generator Produces Low Voltage at No-LoadProblem 4 Generator Produces High Voltage at No-Load Units with Test 1 Check Main Circuit Breaker SafetyTest 2 Check AC Output Voltage ResultsRemove jumper lead connected to Wire 4 and Wire 15B Diagnostic tests PartProcedure Test 4 Fixed Excitation Test Rotor Amp Draw TestTest 5 Wire Continuity 12-20 kW Diagnostic testsExample Test 7 Testing The Stator With a Vom 12-20 kW Reconnect WireTest 6 Check Field Boost 12-20 kW Repeat using stator lead Wire Test Control Panel Wires for ContinuityTest 8 Test Brushless Stator Repeat using stator lead Repeat using WireTest 9 Check Capacitor Repeat using Wires 2 Meter lead to WireTest 10 Test DPE Winding on Brushless units MeasuredTest 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 StepTest 14 Check AC Output Frequency Test 13 Test Rotor Assembly 12-20 kWRemove air cleaner cover to access stepper motor Test 16 Check Stepper Motor Control V-twin Engine UnitsLoosen the governor clamp bolt Figure Pull ARM this Direction to Close Throttle Test 17 Check And Adjust Voltage Regulator 12-20 kWTest 18 Check Voltage Frequency Under Load Refer back to flow chartTest 20 Check Engine Condition Test 21 Field Flash Alternator KW UnitsConstruction of Energizing Cord Page Transfer Item Description General EnclosureTransfer Relay Transfer MechanismManual Transfer Handle Neutral LugTerminal Block Utility N1 and N2Fuse Holder Fuses F1, F2Fuses F3 Operational Analysis Is a schematic for a typical W/V-Type transfer switchOperational analysis Is a wiring diagram for a typical W/V-Type transfer switchSW1 Utility Source Voltage AvailableUtility Source Voltage Failure Generator Power Available, Waiting to TransferTransfer Action to Standby Position Transfer To StandbyGenerator Powering Load Utility Restored, Generator Still Providing Output to Load Utility RestoredUtility Restored, Transfer Relay De-energized Utility Restored, Transfer Switch De-energizedUtility Restored, Retransfer Back to Utility Utility Restored, Retransfer Back To UtilityTransfer Switch in Utility Transfer Switch In UtilityTroubleshooting flow charts Part Introduction To TroubleshootingProblem 7 In Automatic Mode, No Transfer to Standby Problem 9 Blown F1 or F2 Fuse Troubleshooting flow chartsCheck 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 SwitchIf the generator has been shut down, proceed as follows Test 26 Check Voltage at Terminal Lugs E1, E2Manual Transfer Switch Operation Test 27 Check Manual Transfer Switch OperationTest 28 Check 23 and 15B Wiring Reconnect the J2 connector to the PCBPROCEDURE/ Results Remove the J2 connector from the circuit board Test 29 Test Transfer Relay TrSet VOM to measure DC voltage Test 30 Standby Control Circuit Test 31 Check WireSW1 Test 32 Utility Control Circuit OutputN2A Test 34 Check Fuses F1 and F2 Test 33 Test Limit Switch SW2 and SW3Test 35 Check N1 and N2 Wiring Test 36 Check N1 and N2 VoltageReplace blown fuses as needed Test 37 Check Utility Sensing Voltage at the Circuit Board Test 38 Check Utility Sense VoltageTest 39 Check Voltage at Terminal Lugs N1, N2 Generator Transfer SwitchTest 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 measuredRtsn & Rtse Transfer Switch Test 45 Check Wire 0/15B 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 CenterSection Load Shed Transfer Switch Measure across points C and D VAC should be measuredMeasure across points E and D VAC should be measured LSS ATSLSC 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 BoardAmp Fuse Description and componentsKW Printed Circuit Boards and J1 Connector Harness END Remote Wireless Connection J2 Connector PCB END J1 Connector Stepper MotorPCB END Harness END Harness END Remote Wireless Connection N1/N2 Connector17 and 20 kW Printed Circuit Board and J1 Connector Menu System Navigation Choke Solenoid Connector Pin Number IdentificationComponents DescriptionStator 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 20 7.5 Amp Fuse F1 Blown Problem 21 Generator Will Not ExerciseProblem 22 No Low Speed Exercise Test 56 Check Position Of Auto-Off Manual Switch Test 58 Auto-Off-Manual Switch Twin OnlyTest 57 Try a Manual Start Test 61 Check Battery Test 59 Test Auto OperationsTest 60 Check 7.5 Amp Fuse Typical Battery Load Tester Test Battery ConditionIf 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 voltageTest 64 Test Starter Contactor Single Cylinder Engine Reconnect Wire 13 to the SCRShorted, open or grounded armature Test 65 Test Starter MotorChecking the Pinion PinionTools for Starter Performance Test PinionTest 66 Check Fuel Supply Pressure PortSolenoid Removed 12-20 kW Gas Pressure Test point Test 67 Check Circuit Board Wire OutputDisconnect the C3 Connector Test 68 Check Fuel SolenoidTest 69 Check Choke Solenoid Solenoid De-Energized, Choke Closed KW Units Approximately 3.7 ohms should be measuredDisconnect the C3 Connector Set a VOM to measure DC voltage Disconnect C3 Connector Set a VOM to measure resistanceTest 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 CompressionDepending on engine type, do the following Test 74 Check and Adjust Ignition MagnetosMagneto Setting Ignition Magneto Armature Air GapCylinder 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 engineTest 77 Check and Adjust Valves Test 76 Check High Oil Temperature SwitchReplace switch if it fails the test Remove the High Oil Temperature SwitchTest 78 Check Wire 18 Continuity Set the AUTO-OFF-MANUAL switch to the Manual positionBall Stud JAM NUT Test 79 Test Exercise Function Test 80 Check Cranking and Running CircuitsRecord the current date and time of the unit 8kW Choke SolenoidDisconnect 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 controllerPart Operational Tests System functional tests Part Manual Transfer Switch OperationElectrical Checks Set the generator main line circuit breaker to OFF or openGenerator Tests Under Load System functional testsSetting The Exercise Timer Verify that the AUTO-OFF-MANUAL switch is set to AutoChecking Automatic Operation Part Disassembly Major Disassembly Part Front Engine AccessRemove 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 PartWiring Diagram, 8 kW Home Standby Drawing #0G8511 Schematic, 8 kW Home Standby PartPart Schematic, 8 kW Home Standby Drawing #0G7946 Wiring Diagram, 10 kW Home Standby PartPart Wiring Diagram, 10 kW Home Standby Drawing #0G8512 Schematic, 10 kW Home Standby PartPart Schematic, 10 kW Home Standby Drawing #0G7947 Wiring Diagram, 14 kW Home Standby PartPart Wiring Diagram, 14 kW Home Standby Drawing #0G8513 Schematic, 14 kW Home Standby PartPart Schematic, 14 kW Home Standby Drawing #0G7948 Wiring Diagram, 17 kW Home Standby PartPart Wiring Diagram, 17 kW Home Standby Drawing #0G8514 Schematic, 17 kW Home Standby PartPart Schematic, 17 kW Home Standby Drawing #0G8186 Wiring Diagram, 20 kW Home Standby PartPart Wiring Diagram, 20 kW Home Standby Drawing #0G8515 Schematic, 20 kW Home Standby PartPart Schematic, 20 kW Home Standby Wiring Diagram, Home Standby Transfer Switch, 9/10/12/16 circuitPart Wiring Diagram, Home Standby Drawing #0G7959 Schematic, Home StandbyPage Page Page MyGenerac.com