Manuals / Generac Power Systems / Lawn and Garden / Portable Generator

Generac Power Systems 75, 55 Section ENGINE DC CONTROL SYSTEM, Circuit Condition- Fault Shutdown

Models: 65 75 55

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Section 5

ENGINE DC CONTROL SYSTEM

CIRCUIT CONDITION- FAULT SHUTDOWN:

The engine mounts a HIGH OIL TEMPERA- TURE SWITCH (HTO) and a LOW OIL PRES-

SURE SWITCH (LOP).

Should engine oil temperature exceed a pre- set value, the switch contacts will close. Wire 85 from the circuit board will connect to frame ground. Circuit board action will then initiate a shutdown.

Should engine oil pressure drop below a safe pre-set value, the switch contacts will close. On contact closure, Wire 85 will be connected to frame ground and circuit board action will initiate an engine shutdown.

The circuit board has a time delay built into it for the Wire 85 fault shutdowns. At STARTUP ONLY the circuit board will wait approximately 6 seconds before looking at the Wire 85 fault shutdowns. Once running after the 6 second time delay, grounding Wire 85 thru either switch will cause an immediate shutdown.

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Generac Power Systems 75, 55, 65 manual Section ENGINE DC CONTROL SYSTEM, Circuit Condition- Fault Shutdown

Contents

QUIETPACT 55/65/75 Diagnostic Repair ManualRECREATIONAL VEHICLE GENERATOR Model 4702, 4703, 4707, 4705, 4706,REPLACEMENT PARTS SAFETYNOTICE TO USERS OF THIS MANUAL Table of Contents SECTION Table of ContentsMAGNETISM Section GENERATOR FUNDAMENTALSELECTROMAGNETIC FIELDS ELECTROMAGNETIC INDUCTIONA MORE SOPHISTICATED AC GENERATOR A SIMPLE AC GENERATORFigure 1-5.– Alternating Current Sine Wave Figure 1-6.– A More Sophisticated GeneratorSection GENERATOR FUNDAMENTALS Figure 1-7.- Generator Operating DiagramGENERATOR AC CONNECTION SYSTEM FIELD BOOSTSection GENERATOR FUNDAMENTALS Section GENERATOR FUNDAMENTALS Figure 1-8.– Connection for 120 Volts OnlySTATOR ASSEMBLY ROTOR ASSEMBLYSection MAJOR GENERATOR COMPONENTS Figure 2-1.Exploded View of GeneratorFigure 2-4.– Battery Charge Circuit BATTERY CHARGE COMPONENTSFigure 2-5.– Schematic: Excitation Circuit BRUSH HOLDERFigure 2-6.– Excitation Circuit Breaker CRANKCASE BREATHERSection MAJOR GENERATOR COMPONENTS Figure 2-9.– Control Panel Components CONTROL PANEL COMPONENT IDENTIFICATIONSection MAJOR GENERATOR COMPONENTS Section INSULATION RESISTANCE TESTS CLEANING THE GENERATOREFFECTS OF DIRT AND MOISTURE INSULATION RESISTANCE TESTERSSection INSULATION RESISTANCE TESTS STATOR INSULATION RESISTANCETHE MEGOHMMETER TESTING ROTOR INSULATIONFigure 3-2.– Stator Leads Figure 3-3.– Rotor Test PointsMETERS Section MEASURING ELECTRICITYTHE VOM MEASURING AC VOLTAGEMEASURING CURRENT MEASURING AC FREQUENCYMEASURING RESISTANCE Figure 4-3.– A Line-SplitterOHMS LAW ELECTRICAL UNITSFigure AMPERES = VOLTSOHMSINTRODUCTION Section ENGINE DC CONTROL SYSTEMOPERATIONAL ANALYSIS CIRCUIT CONDITION- PRIMING Section ENGINE DC CONTROL SYSTEMPage CIRCUIT CONDITION- CRANKING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION-RUNNING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION- SHUTDOWN Section ENGINE DC CONTROL SYSTEMSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- FAULT SHUTDOWNENGINE CONTROLLER CIRCUIT BOARD BATTERYFigure 5-3.– Engine Controller Circuit Board Figure 5-2.- Receptacle J1START-STOPSWITCH FUEL PRIMER SWITCHFigure 5-5.– Primer Switch 7.5 AMP FUSESection ENGINE DC CONTROL SYSTEM Figure 5-6.– Start-StopSwitchSTARTER CONTACTOR RELAY & STARTER MOTORINTRODUCTION Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSPage Section TROUBLESHOOTING FLOWCHARTSFigure 7-1.– Governor Adjustment Points Section DIAGNOSTIC TESTSTEST 1- CHECK NO-LOADVOLTAGE AND FREQUENCY TEST 2- CHECK ENGINE GOVERNORTEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW TEST 3- TEST EXCITATION CIRCUIT BREAKERFigure 7-2.– Excitation “DPE” Circuit Breaker Figure 7-3.- Fixed Excitation TestSection DIAGNOSTIC TESTS TEST 5- WIRE CONTINUITYTEST 7 - TEST STATOR DPE WINDING TEST 6- CHECK FIELD BOOSTFigure 7-4.- The Field Boost Circuit Figure 7-5.– Stator Excitation WindingSection DIAGNOSTIC TESTS TEST 8- CHECK SENSING LEADS / POWER WINDINGSTEST 9- CHECK BRUSH LEADS Figure 7-6.– Stator Power Winding LeadsTEST 10 - CHECK BRUSHES & SLIP RINGS Figure 7-7.– Brush LeadsFigure 7-8.– Rotor Assembly TEST 11- CHECK ROTOR ASSEMBLYTEST 12 - CHECK MAIN CIRCUIT BREAKER Figure 7-9.– Main Breaker TypicalTEST 16 - CHECK BATTERY CHARGE RECTIFIER TEST 15 - CHECK BATTERY CHARGE OUTPUTTEST 13- CHECK LOAD VOLTAGE & FREQUENCY TEST 14- CHECK LOAD WATTS & AMPERAGEWINDINGS / BATTERY CHARGE RESISTOR TEST 17 - CHECK BATTERY CHARGEFigure 7-10.- Battery Charge Rectifier Section DIAGNOSTIC TESTSFigure 7-11.– Primer Switch TEST 19- TEST PRIMER SWITCHFigure 7-12.– Harness End of Connector TEST 18 - TRY CRANKING THE ENGINEFigure 7-13.- The LPG Fuel Solenoid FS TEST 20- CHECK FUEL PUMPFigure 7-14.– Electric Fuel Pump Section DIAGNOSTIC TESTSTEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD TEST 22- CHECK BATTERY & CABLESTEST 21- CHECK 7.5 AMP FUSE Figure 7-15.– Harness to Fuel PumpFigure 7-17.- Start-StopSwitch TEST 24 - CHECK START-STOPSWITCHFigure 7-18.– Test 24, Step Section DIAGNOSTIC TESTSTEST 26- CHECK STARTER CONTACTOR RELAY TEST 25 - CHECK POWER SUPPLY TO WIREFigure 7-19.– Starter Contactor Relay Section DIAGNOSTIC TESTSTEST 27 - CHECK STARTER MOTOR TEST 26A - CHECK STARTER CONTACTORFigure 7-20.– The Starter Contactor SC STEP 1 TEST POINTFigure 7-22.- Check Pinion Gear Operation Figure 7-21.- Starter Motor SMSection DIAGNOSTIC TESTS TEST 28- CHECK FUEL SUPPLY Figure 7-26.– Testing Starter Motor PerformanceFigure 7-24.– Tachometer Section DIAGNOSTIC TESTSFigure 7-27- Typical Propane Gas Fuel System Figure 7-28– LP Gas Carburetion DiagramSection DIAGNOSTIC TESTS TEST 30 - CHECK WIRE TEST 29 - CHECK WIRE 14 POWER SUPPLYFigure 7-30.– The 4-tabConnector Figure 7-29.– Fuel RegulatorTEST 31 - CHECK FUEL SOLENOID GASOLINE MODELS Figure 7-31.– Remote Harness ConnectorTEST 32 - CHECK IGNITION SPARK Section DIAGNOSTIC TESTSFigure 7-33.– Checking Engine Miss Figure 7-32.– Testing Ignition SystemFigure 7-34.– Cylinder Balance Test Section DIAGNOSTIC TESTSFigure 7-35– Setting Spark Plug Gap TEST 34 - CHECK AND ADJUST IGNITION MAGNETOSFigure 7-36.– Ignition Magneto Assembly TEST 33 - CHECK SPARK PLUGSArmature Air Gap Figure 7-37.– Setting Ignition MagnetoFigure 7-38.– Engine Ground Harness Figure 7-39.– Diode Failure DiagnosisFigure 7-41– Adjusting Valve Clearance TEST 35 - CHECK VALVE ADJUSTMENTFigure 7-40.- Engine Ground Harness Test Points Section DIAGNOSTIC TESTSTEST 37 - CHECK CHOKE SOLENOID TEST 36 - CHECK CARBURETIONFigure 7-42- Tightening the Jam Nut Section DIAGNOSTIC TESTSFigure 7-44.– Exploded View of Choke Assembly Figure 7-43.- ConnectorFigure 7-45.– Automatic Choke Assembly Section DIAGNOSTIC TESTSTEST 38 - CHECK ENGINE / CYLINDER LEAK DOWN TEST / COMPRESSION TESTSection DIAGNOSTIC TESTS TEST 40 - TEST OIL TEMPERATURE SWITCH TEST 39 - CHECK OIL PRESSURE SWITCHFigure 7-46.– Oil Pressure Switch Figure 7-47.– Oil Temperature SwitchTEST 41 - TEST CHOKE HEATER Figure 7-48.– Testing Oil Temperature SwitchTEST 42 - CHECK LPG FUEL SOLENOID Section DIAGNOSTIC TESTSSection DIAGNOSTIC TESTS Figure 7-49.– Fuel SolenoidMAJOR DISASSEMBLY Section ASSEMBLYSection ASSEMBLY Figure 8-1.– Drive Belt Tension10.Remove blower housing Section ASSEMBLYPage NOTESBase & Pulley – Drawing No. 0E1323-A Section Exploded Views / Part NumbersITEM Section Exploded Views / Part NumbersPART NO. QTY DESCRIPTIONEnclosure – Drawing No. 0E1011-B Section Exploded Views / Part NumbersExploded Views / Part Numbers SectionITEM PART NOSheet Metal – Drawing No. 0E1012-E Section Exploded Views / Part NumbersITEM Section Exploded Views / Part NumbersControl Panel - Drawing No. 0E1013-A Section Exploded Views / Part Numbers0C2375 Section Exploded Views / Part Numbers760 V-TwinEngine – Drawing No. 0E1014-B Section Exploded Views / Part Numbers0C5730A Section Exploded Views / Part NumbersLP Regulator - Drawing No. 0E1530 Section Exploded Views / Part NumbersExploded Views / Part Numbers Section0D5694 Section SPECIFICATIONS & CHARTS GENERATOR SPECIFICATIONS SPECIFICATIONS & CHARTSNOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68F SectionLONG BLOCK TORQUE REQUIREMENTS ENGINE SPEEDS AND VOLTAGE SPECIFICATIONSTRIM TORQUE REQUIREMENTS RV TORQUE REQUIREMENTSPage NOTESSection ELECTRICAL DATA Page Section ELECTRICAL DATAP/N OE7225 REV O PO BOX 297 WHITEWATER, WIPRINTED IN THE USA/9.03