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Generac Power Systems 5255, 5252, 5254, 5251, 5253 Troubleshooting Guide, Problem, Cause, Correction

Models: 5253 5255 5251 5254 5252

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Section 5 — Troubleshooting

Section 5 — Troubleshooting

Air-cooled Generators

5.1TROUBLESHOOTING GUIDE

Problem	Cause		Correction
The engine will not crank.	1.	Fuse blown.	1.	Correct short circuit condition,
				replace 15A fuse in generator
				control panel.
	2.	Loose, corroded or defective	2.	Tighten, clean or replace
		battery cables.		as necessary.
	3.	Defective starter contactor. (7 kW)	3.	*
	4.	Defective starter motor.	4.	*
	5.	Dead Battery.	5.	Charge or replace battery.

The engine cranks but	1.	Out of fuel.	1.	Replenish fuel/Turn on fuel valve.
will not start.	2.	Defective fuel solenoid (FS).	2.	*
	3.	Open #14 wire from	3.	*
		engine control board.

4.Defective spark plug(s).

5.Valve lash out of adjustment.

6.Choke not operating.

4.Clean, re-gap or replace plug(s).

5.Reset valve lash.

6.Verify choke plate moves freely.

The engine starts hard	1.	Air cleaner plugged	1.	Check, replace air cleaner.
and runs rough.		or damaged.
	2.	Defective spark plug(s).	2.	Clean, re-gap or replace plug(s).
	3.	Fuel regulator not set.	3.	Set Fuel Regulator.
	4.	Fuel pressure incorrect.	4.	Confirm fuel pressure to regulator
				is 10-12” water column (0.36-0.43
				psi) for LP, and 5-7” water column
				(0.18-0.25 psi) for natural gas.

5.Fuel selector in wrong position.

6.Choke remains closed.

5.Move selector to correct position.

6.Verify choke plate moves freely.

The AUTO/OFF/MANUAL switch 1.		Defective switch.	1.	*
is set to OFF, but the engine	2.	AUTO/OFF/MANUAL switch	2.	*
continues to run.		wired incorrectly.
	3.	Defective control board.	3.	*

There is no AC output from	1.	Main line circuit breaker is in	1.	Reset circuit breaker
the generator.		the OFF (or OPEN) position.		to ON (or CLOSED).
	2.	Generator internal failure.	2.	*

There is no transfer to	1.	Defective transfer switch coil.	1.	*
standby after utility	2.	Defective transfer relay.	2.	*
source failure.	3.	Transfer relay circuit open.	3.	*
	4.	Defective control logic board.	4.	*

Unit consumes large	1.	Engine over filled with oil.	1.	Adjust oil to proper level.
amounts of oil.	2.	Engine breather defective.	2.	*

*Contact the nearest Authorized Dealer for assistance.

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Generac Power Systems 5255, 5252, 5254, 5251, 5253 owner manual Troubleshooting Guide, Problem, Cause, Correction

Contents

Installation and Owner’s Manual DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLYNot intended for use as Primary Power in place of utility or in C US LISTED‹ CONTENTS ‹ OPERATION AND MAINTENANCE‹ HOW TO OBTAIN SERVICE INTRODUCTIONSection 2 - Post Installation Start-up and AdjustmentsSection 4 - Maintenance Section 5 - TroubleshootingIMPORTANT SAFETY INSTRUCTIONS  GENERAL HAZARDS This product contains or emits chemicals known to the state of California to cause ELECTRICAL HAZARDS   FIRE HAZARDS  EXPLOSION HAZARDS  ‹ STANDARDS INDEX1.3 NEC REQUIREMENT FOR ARC FAULT CIRCUIT INTERRUPTION ‹ 1.3.1 SECTION 210.12 ARC FAULT CIRCUIT INTERRUPTER PROTECTION1.1 UNPACKING/INSPECTION 1.2 PROTECTION SYSTEMS1.4 THE GENERATOR Figure 1.1 - 7kW, Single Cylinder GH-410 EngineFigure 1.3 - 13kW and 16kW, V-twin GT-990 Engine Figure 1.2 - 10kW, V-twin GT-530 Engine1.5 SPECIFICATIONS ‹ 1.5.1 GENERATOR‹ 1.5.2 ENGINE Section 1 - General Information1.6 SYSTEM SET LED 1.7 FUEL REQUIREMENTS AND RECOMMENDATIONS1.8 FUEL CONSUMPTION DANGER1.9 RECONFIGURING THE FUEL SYSTEM ‹ 1.9.1 7 KW, 410CC ENGINE‹ 1.9.2 10, 13 AND 16KW, V-TWIN ENGINES Figure 1.4 - Demand Regulator1.10 LOCATION ‹ 1.10.1 GENERATORFigure 1.5 - 10kW, GT-530 Inlet Hose Slid Back Figure 1.6 - 10kW, GT-530 Inlet Hose Slid Back1.11 BATTERY REQUIREMENTS 1.12 BATTERY INSTALLATION‹ 1.10.2 TRANSFER SWITCH 1.10.2.1 7, 10, 13, and 16 kW Units if equipped1.13 THE BATTERY Figure 1.10 - Battery Cable ConnectionsDANGER Section 1 - General Information2.2 CHECK TRANSFER SWITCH OPERATION Section 2 - Post Installation Start-up and Adjustments2.1 BEFORE INITIAL START-UP 2.3 ELECTRICAL CHECKS2.6 ADJUSTING THE FUEL REGULATOR 2.4 GENERATOR TESTS UNDER LOAD2.5 CHECKING AUTOMATIC OPERATION 7KW NATURAL GAS ONLY2.7 ENGINE GOVERNOR ADJUSTMENT Figure 2.2 - Engine Governor Adjustment Single Cylinder Engines‹ 2.7.1 7 KW UNITS Figure 2.1 - 7kW Fuel Regulator2.8 VOLTAGE REGULATOR ADJUSTMENT Figure 2.3 - Voltage Adjustment PotentiometerTurn to adjust voltage ‹ 2.7.2 13 KW AND 16 KW UNITS‹ 3.4.1 TRANSFER TO GENERATOR POWER SOURCE 3.2 AUTOMATIC TRANSFER OPERATION3.3 SEQUENCE OF AUTOMATIC OPERATION 3.4 MANUAL TRANSFER OPERATION3.5 SETTING THE EXERCISE TIMER ‹ 3.4.2 TRANSFER BACK TO UTILITY POWER SOURCEFigure 3.2 - Manual Transfer Switch Operation DANGER‹ 3.6.1 LOW OIL PRESSURE SWITCH ‹ 3.6.2 HIGH TEMPERATURE SWITCHHigh Temperature Switches Low Oil Switch‹ 3.6.6 LOW BATTERY Section 4 - Maintenance4.2 CHECKING THE ENGINE OIL LEVEL 4.1 FUSES‹ 4.3.3 OIL & OIL FILTER CHANGE PROCEDURE 4.3 CHANGING THE ENGINE OIL‹ 4.3.1 OIL CHANGE INTERVALS ‹ 4.3.2 ENGINE OIL RECOMMENDATIONS4.4 CHANGING THE ENGINE AIR CLEANER Figure 4.7 - 10kW Engine Air CleanerFigure 4.6 - 7 kW, Engine Air Cleaner Location Air Cleaner4.6 BATTERY MAINTENANCE 4.7 ADJUSTING GH-410/GT-530/990 VALVE CLEARANCEFigure 4.9 - Setting the Spark Plug Gap Section 4 - MaintenanceFigure 4.10 - Valve Clearance Adjustment 4.8 COOLING SYSTEM4.9 ATTENTION AFTER SUBMERSION Figure 4.11 - Cooling Vent Locations4.11 OUT OF SERVICE PROCEDURE ‹ 4.11.2 RETURN TO SERVICE‹ 4.11.1 REMOVAL FROM SERVICE 4.10 CORROSION PROTECTION4.12 SERVICE SCHEDULE ATTENTION It is recommended that all service workSection 4 - Maintenance be performed by the nearest Authorized Dealer5.1 TROUBLESHOOTING GUIDE ProblemSection 5 - Troubleshooting CauseSection 6 - Notes Air-cooled GeneratorsSection 6 - Notes Air-cooled GeneratorsSection 6 - Notes Air-cooled GeneratorsSection 7 - Mounting Dimensions Air-cooled Generators Drawing No. 0F9424Section 8 - Electrical Data TS-TERMINAL STRIP XA,XB-LIMIT SWITCHESATS-AUTOMATIC TRANSFER SWITCH C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIERWiring Diagram - 10, 13 & 16kW, V-Twin - Drawing No. 0F7822 ENGINE WIRINGSection 8 - Electrical Data Air-cooled GeneratorsSection 8 - Electrical Data CONTROL PANEL BOXCUSTOMER CONNECTION CLOSEST TO BEARINGElectrical Schematic - 10, 13 & 16kW, V-Twin - Drawing No. 0F7823 Section 8 - Electrical DataAir-cooled Generators ELECTRONICENGINE AND ALTERNATOR Section 8 - Electrical DataWiring Diagram - 7kW, Single Cylinder - Drawing No. 0F7820 ENGINE WIRINGSection 8 - Electrical Data Air-cooled GeneratorsWiring Diagram - 7kW, Single Cylinder - Drawing No. 0F7820 Section 8 - Electrical DataAir-cooled Generators CONTROL PANEL BOXSection 8 - Electrical Data Electrical Schematic - 7kW, Single Cylinder - Drawing No. 0F7821Air-cooled Generators Electrical Schematic - 7kW, Single Cylinder - Drawing No. 0F7821 ENGINE AND ALTERNATORSection 8 - Electrical Data Air-cooled GeneratorsSection 8 - Electrical Data Air-cooled GeneratorsSection 8 - Electrical Data Section 9 - Exploded Views and Parts Lists SHEET METAL PAINT/MATERIAL CODE LEGENDAir-cooled Generators Enclosure - Drawing No. 0F9431-C MaterialPART NO. QTY. DESCRIPTION Section 9 - Exploded Views and Parts ListsPART NO. QTY. DESCRIPTION Air-cooled GeneratorsSection 9 - Exploded Views and Parts Lists Air-cooled Generators Control Panel - Drawing No. 0F9695-CDESCRIPTION Section 9 - Exploded Views and Parts ListsASSEMBLY, BATTERY CHARGER ENGINE DESCRIPTIONSection 9 - Exploded Views and Parts Lists Air-cooled Generators Transfer Switch Assembly - Drawing No. 0F9774-ASection 9 - Exploded Views and Parts Lists Transfer Switch Assembly - Drawing No. 0F9774-APART NO. QTY. DESCRIPTION PART NO. QTY. DESCRIPTIONAir-cooled Generators Section 9 - Exploded Views and Parts Lists13 & 16kW, GT-990 Engine - Drawing No. 0F9430-E - Part Section 9 - Exploded Views and Parts Lists DESCRIPTIONDESCRIPTION Air-cooled GeneratorsAir-cooled Generators Section 9 - Exploded Views and Parts Lists13 & 16kW, GT-990 Engine - Drawing No. 0F9430-E - Part Section 9 - Exploded Views and Parts Lists DESCRIPTIONDESCRIPTION Air-cooled GeneratorsAir-cooled Generators Section 9 - Exploded Views and Parts Lists10kW, GT-530 Engine - Drawing No. 0F9429-D - Part Section 9 - Exploded Views and Parts Lists DESCRIPTIONAir-cooled Generators 10kW, GT-530 Engine - Drawing No. 0F9429-D - PartAir-cooled Generators Section 9 - Exploded Views and Parts Lists10kW, GT-530 Engine - Drawing No. 0F9429-D - Part Section 9 - Exploded Views and Parts Lists DESCRIPTIONDESCRIPTION Air-cooled GeneratorsSection 9 - Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine - Drawing No. 0F9428 - PartSection 9 - Exploded Views and Parts Lists DESCRIPTIONAir-cooled Generators 7kW, GN-410 Engine - Drawing No. 0F9428 - PartSection 9 - Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine - Drawing No. 0F9428 - PartSection 9 - Exploded Views and Parts Lists DESCRIPTIONAir-cooled Generators 7kW, GN-410 Engine - Drawing No. 0F9428 - PartSection 9 - Exploded Views and Parts Lists Air-cooled Generators 7kW, GN-410 Engine - Drawing No. 0F9422-BSection 9 - Exploded Views and Parts Lists DESCRIPTIONAir-cooled Generators 7kW, GN-410 Engine - Drawing No. 0F9422-BAir-cooled Generators Section 9 - Exploded Views and Parts Lists10, 13, and 16kW, V-twin Generators - Drawing No. 0F9423-C Section 9 - Exploded Views and Parts Lists DESCRIPTIONDESCRIPTION Air-cooled GeneratorsAir-cooled Generators Section 9 - Exploded Views and Parts Lists7 & 10kW, GN-410/GT-530 Regulator - Drawing No. 0F9425 Section 9 - Exploded Views and Parts Lists DESCRIPTIONAir-cooled Generators 7 & 10kW, GN-410/GT-530 Regulator - Drawing No. 0F9425Air-cooled Generators Section 9 - Exploded Views and Parts Lists13 & 16kW, GT-990 Regulator - Drawing No. 0F9426 Section 9 - Exploded Views and Parts Lists DESCRIPTIONAir-cooled Generators 13 & 16kW, GT-990 Regulator - Drawing No. 0F9426YOUR WARRANTY RIGHTS AND OBLIGATIONS MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGEPURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES Section 10 - WarrantyEMISSION CONTROL SYSTEM WARRANTY EMISSION RELATED PARTS INCLUDE THE FOLLOWINGSection 10 - Warranty Air-cooled GeneratorsGENERAC POWER SYSTEMS STANDARD LIMITED WARRANTY FOR HOME STANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELOWSection 10 - Warranty WARRANTY SCHEDULE