Generac Power Systems 9 kW NG, 10 kW LP, 13 kW NG, 7 kW NG, 8 kW LP

Disassembly

Part 6

Section 6.1

Major Disassembly

Figure 39.

Figure 40.

Figure 41.

17.Rotor Removal: Cut 2.5 inches from the rotor bolt. Slot the end of the bolt to suit a flat blade screwdriver. Slide the rotor bolt back through the rotor and use a screw- driver to screw it into the crankshaft. Use a 3” M12x1.75 bolt to screw into rotor. Apply torque to the 3” M12x1.75 bolt until taper breaks. See Figure 43.

Figure 42.

11.Remove Engine: Using a 13mm socket, remove the two

engine mount nuts with ground wires. See Figure 43.

Figure 43.

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Image 163

Generac Power Systems 9 kW NG, 10 kW LP, 13 kW NG, 7 kW NG, 8 kW LP, 17 kW LP Engine mount nuts with ground wires. See Figure

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 Rainproof Enclosure Fitted Rated Ambient Temp 40C Generator Identification PartIntroduction Neutral Floating Grounding The Generator Installation basicsTransfer Switch / Load Center Selecting a Location 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 Fuel Requirements Reconfiguring The Fuel SystemPreparation Before Use Part General Preparation before use Install the battery, door and close the roof Engine Oil Recommendations Measuring DC Voltage MetersVom Measuring AC Voltage Measuring Current Testing, cleaning and drying PartMeasuring Resistance Ohm’s Law Electrical UnitsVolts Amps Ohms ONE 1 Second Visual InspectionInsulation Resistance Megohmmeter Stator Insulation Resistance Test 12-20 kW Repeat between Wire 2 and Stator LeadStator Insulation Resistance Test 10 kW Drying The Generator Cleaning The GeneratorRotor Insulation Resistance Test 10 kW Rotor Insulation Resistance Test 12-20 kW Overspeed Shutdown Low BatteryHigh Temperature Switch Low Oil Pressure Shutdown Overcrank Shutdown Engine-generator protective devices Part Control Panel Operating Instructions Manual Transfer To Standby Manual Startup KW Installation AssistantOperating instructions Part To Select Automatic Operation Seconds then re-crank if additional crank cycles exist Automatic operating parameters Exercise Automatic operating parameters PartManual Auto Part AC Generators Engine-Generator Drive System Rotor AssemblyAC Generator Description & components Stator Assembly Main Line Circuit Breaker Description & components PartBrush Holder And Brushes 12-20 kW Other AC Generator Components Field Boost 12-20 KW Rotor Residual Magnetism Startup Operational analysis PartOperation 8/10 kW Operation 12-20 kW 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 Results SafetyTest 1 Check Main Circuit Breaker Test 2 Check AC Output Voltage Test 4 Fixed Excitation Test Rotor Amp Draw Test Diagnostic tests PartRemove jumper lead connected to Wire 4 and Wire 15B Procedure 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 Measured Meter lead to WireRepeat using Wires 2 Test 10 Test DPE Winding on Brushless units If Continuity was measured in Steps 5 and 6 proceed to Step Remove Wire 4 from the voltage regulatorTest 11 Resistance Check Rotor Circuit 12-20 kW Test 12 Check Brushes And Slip Rings 12-20 kW 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 21 Field Flash Alternator KW Units Refer back to flow chartTest 18 Check Voltage Frequency Under Load Test 20 Check Engine Condition Construction of Energizing Cord Page Transfer Item Description General Enclosure Transfer Relay Transfer Mechanism Utility N1 and N2 Neutral LugManual Transfer Handle Terminal Block 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 14 No Battery Charge Load Shed Transfer Switch Problem 11 No Battery Charge Pre-Wire Load CenterProblem 12 No Battery Charge Rtsn & Rtse Transfer Switch Problem 13 No Battery Charge GenReady Load Center 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 Measure across points M and N VDC should be measured Test 40 Check Battery ChargerTest 42 Check Wire 0 and Wire15B Pre-wire load center Measure across points a and C VAC 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 Circuit Board Auto-Off-Manual SwitchDescription and components Part Terminal Strip / Interconnection 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 Set a VOM to measure DC voltage Test 62 Check Wire 56 VoltageIf battery voltage is indicated in refer back to flow chart Test 63 Test Starter Contactor Relay V-twin Only Test 64 Test Starter Contactor Single Cylinder Engine Reconnect Wire 13 to the SCR Pinion Test 65 Test Starter MotorShorted, open or grounded armature Checking the 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 Check Compression Test 73 Check Shutdown WireRemove a spark plug Repeat Steps 1 through 8 on remaining cylinder 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 With oil level correct, try starting the engine Test 75 Check Oil Pressure Switch WireNavigate to the Digital inputs display screen Check engine crankcase oil level Remove the High Oil Temperature Switch Test 76 Check High Oil Temperature SwitchTest 77 Check and Adjust Valves Replace switch if it fails the test 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 If the solenoid closed, replace the controller Test 81 Check to see if Low Speed Function is enabledDisconnect Wire 4 and Wire 0 from the Voltage Regulator VR Test 82 Check operation Choke Solenoid Part Operational Tests Set the generator main line circuit breaker to OFF or open Manual Transfer Switch OperationSystem functional tests Part Electrical Checks 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