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

Generac Power Systems 55, 75, 65 manual Table of Contents

Models: 65 75 55

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Table of Contents

SAFETY	INSIDE FRONT COVER
SECTION 1:
GENERATOR FUNDAMENTALS		3-7
MAGNETISM		3
ELECTROMAGNETIC FIELDS		3
ELECTROMAGNETIC INDUCTION		3
A SIMPLE AC GENERATOR		4
A MORE SOPHISTICATED AC GENERATOR		4
FIELD BOOST		6
GENERATOR AC CONNECTION SYSTEM		6
	SECTION 2:
MAJOR GENERATOR COMPONENTS		8-11
ROTOR ASSEMBLY		8
STATOR ASSEMBLY		8
BRUSH HOLDER		9
BATTERY CHARGE COMPONENTS		9
EXCITATION CIRCUIT COMPONENTS		9
CRANKCASE BREATHER		10
SECTION 3:
INSULATION RESISTANCE TESTS		12-14
EFFECTS OF DIRT AND MOISTURE		12
INSULATION RESISTANCE TESTERS		12
DRYING THE GENERATOR		12
CLEANING THE GENERATOR		12
STATOR INSULATION RESISTANCE		13
TESTING ROTOR INSULATION		14
THE MEGOHMMETER		14
SECTION 4:
MEASURING ELECTRICITY		15-17
METERS		15
THE VOM		15
MEASURING AC VOLTAGE		15
MEASURING DC VOLTAGE		15
MEASURING AC FREQUENCY		16
MEASURING CURRENT		16
MEASURING RESISTANCE		16
ELECTRICAL UNITS		17
OHM’S LAW		17
SECTION 5:
ENGINE DC CONTROL SYSTEM		18-26
INTRODUCTION		18
OPERATIONAL ANALYSIS		18-23
ENGINE CONTROLLER CIRCUIT BOARD		24
BATTERY		24
7.5 AMP FUSE		25
FUEL PRIMER SWITCH		25
START-STOP SWITCH		25
STARTER CONTACTOR RELAY
& STARTER MOTOR		26

SECTION 6:
TROUBLESHOOTING FLOWCHARTS	27-37
IF PROBLEM INVOLVES AC OUTPUT	27
PROBLEM 1 -
VOLTAGE & FREQUENCY ARE BOTH
HIGH OR LOW	27
PROBLEM 2 -
GENERATOR PRODUCES ZERO VOLTAGE OR
RESIDUAL VOLTAGE (5-12 VAC)	28-29
PROBLEM 3 -
NO BATTERY CHARGE OUTPUT	29
PROBLEM 4 -
EXCESSIVE VOLTAGE/FREQUENCY DROOP
WHEN LOAD IS APPLIED	30
PROBLEM 5 -
PRIMING FUNCTION DOES NOT WORK
(GASOLINE MODELS)	30
PROBLEM 6 -
ENGINE WILL NOT CRANK	31
PROBLEM 7 -
ENGINE CRANKS BUT WILL NOT START
(GASOLINE UNITS)	32
PROBLEM 7 -
ENGINE CRANKS BUT WILL NOT START
(LP UNITS)	33
PROBLEM 8 -
ENGINE STARTS HARD AND RUNS ROUGH
(GASOLINE UNITS)	34
PROBLEM 8 -
ENGINE STARTS HARD AND RUNS ROUGH
(LP UNITS)	34
PROBLEM 9 -
ENGINE STARTS THEN SHUTS DOWN	36
PROBLEM 10 -
7.5 AMP (F1) FUSE BLOWING	37
SECTION 7:
DIAGNOSTIC TESTS	38-67
INTRODUCTION	38
TEST 1 -
Check No-Load Voltage And Frequency	38
TEST 2 -
Check Engine Governor	38
TEST 3 -
Test Excitation Circuit Breaker	39
TEST 4 -
Fixed Excitation Test/Rotor Amp Draw	39
TEST 5 -
Wire Continuity	40
TEST 6 -
Check Field Boost	41
TEST 7 -
Test Stator DPE Winding	41
TEST 8 -
Check Sensing Leads/Power Windings	42

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Generac Power Systems 55, 75, 65 manual Table of Contents

Contents

Model 4702, 4703, 4707, 4705, 4706, Diagnostic Repair ManualQUIETPACT 55/65/75 RECREATIONAL VEHICLE GENERATORSAFETY REPLACEMENT PARTSNOTICE TO USERS OF THIS MANUAL Table of Contents SECTION Table of ContentsELECTROMAGNETIC INDUCTION Section GENERATOR FUNDAMENTALSMAGNETISM ELECTROMAGNETIC FIELDSFigure 1-6.– A More Sophisticated Generator A SIMPLE AC GENERATORA MORE SOPHISTICATED AC GENERATOR Figure 1-5.– Alternating Current Sine WaveSection GENERATOR FUNDAMENTALS Figure 1-7.- Generator Operating DiagramFIELD BOOST GENERATOR AC CONNECTION SYSTEMSection GENERATOR FUNDAMENTALS Section GENERATOR FUNDAMENTALS Figure 1-8.– Connection for 120 Volts OnlyFigure 2-1.Exploded View of Generator ROTOR ASSEMBLYSTATOR ASSEMBLY Section MAJOR GENERATOR COMPONENTSBRUSH HOLDER BATTERY CHARGE COMPONENTSFigure 2-4.– Battery Charge Circuit Figure 2-5.– Schematic: Excitation CircuitCRANKCASE BREATHER Figure 2-6.– Excitation Circuit BreakerSection MAJOR GENERATOR COMPONENTS CONTROL PANEL COMPONENT IDENTIFICATION Figure 2-9.– Control Panel ComponentsSection MAJOR GENERATOR COMPONENTS INSULATION RESISTANCE TESTERS CLEANING THE GENERATORSection INSULATION RESISTANCE TESTS EFFECTS OF DIRT AND MOISTURESection INSULATION RESISTANCE TESTS STATOR INSULATION RESISTANCEFigure 3-3.– Rotor Test Points TESTING ROTOR INSULATIONTHE MEGOHMMETER Figure 3-2.– Stator LeadsMEASURING AC VOLTAGE Section MEASURING ELECTRICITYMETERS THE VOMFigure 4-3.– A Line-Splitter MEASURING AC FREQUENCYMEASURING CURRENT MEASURING RESISTANCEAMPERES = VOLTSOHMS ELECTRICAL UNITSOHMS LAW FigureSection ENGINE DC CONTROL SYSTEM INTRODUCTIONOPERATIONAL ANALYSIS Section ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION- PRIMINGPage 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 SHUTDOWNFigure 5-2.- Receptacle J1 BATTERYENGINE CONTROLLER CIRCUIT BOARD Figure 5-3.– Engine Controller Circuit Board7.5 AMP FUSE FUEL PRIMER SWITCHSTART-STOPSWITCH Figure 5-5.– Primer Switch& STARTER MOTOR Figure 5-6.– Start-StopSwitchSection ENGINE DC CONTROL SYSTEM STARTER CONTACTOR RELAYINTRODUCTION 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 FLOWCHARTSTEST 2- CHECK ENGINE GOVERNOR Section DIAGNOSTIC TESTSFigure 7-1.– Governor Adjustment Points TEST 1- CHECK NO-LOADVOLTAGE AND FREQUENCYFigure 7-3.- Fixed Excitation Test TEST 3- TEST EXCITATION CIRCUIT BREAKERTEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW Figure 7-2.– Excitation “DPE” Circuit BreakerSection DIAGNOSTIC TESTS TEST 5- WIRE CONTINUITYFigure 7-5.– Stator Excitation Winding TEST 6- CHECK FIELD BOOSTTEST 7 - TEST STATOR DPE WINDING Figure 7-4.- The Field Boost CircuitSection DIAGNOSTIC TESTS TEST 8- CHECK SENSING LEADS / POWER WINDINGSFigure 7-7.– Brush Leads Figure 7-6.– Stator Power Winding LeadsTEST 9- CHECK BRUSH LEADS TEST 10 - CHECK BRUSHES & SLIP RINGSFigure 7-9.– Main Breaker Typical TEST 11- CHECK ROTOR ASSEMBLYFigure 7-8.– Rotor Assembly TEST 12 - CHECK MAIN CIRCUIT BREAKERTEST 14- CHECK LOAD WATTS & AMPERAGE TEST 15 - CHECK BATTERY CHARGE OUTPUTTEST 16 - CHECK BATTERY CHARGE RECTIFIER TEST 13- CHECK LOAD VOLTAGE & FREQUENCYSection DIAGNOSTIC TESTS TEST 17 - CHECK BATTERY CHARGEWINDINGS / BATTERY CHARGE RESISTOR Figure 7-10.- Battery Charge RectifierTEST 18 - TRY CRANKING THE ENGINE TEST 19- TEST PRIMER SWITCHFigure 7-11.– Primer Switch Figure 7-12.– Harness End of ConnectorSection DIAGNOSTIC TESTS TEST 20- CHECK FUEL PUMPFigure 7-13.- The LPG Fuel Solenoid FS Figure 7-14.– Electric Fuel PumpFigure 7-15.– Harness to Fuel Pump TEST 22- CHECK BATTERY & CABLESTEST 23- CHECK POWER SUPPLY TO CIRCUIT BOARD TEST 21- CHECK 7.5 AMP FUSESection DIAGNOSTIC TESTS TEST 24 - CHECK START-STOPSWITCHFigure 7-17.- Start-StopSwitch Figure 7-18.– Test 24, StepSection DIAGNOSTIC TESTS TEST 25 - CHECK POWER SUPPLY TO WIRETEST 26- CHECK STARTER CONTACTOR RELAY Figure 7-19.– Starter Contactor RelaySTEP 1 TEST POINT TEST 26A - CHECK STARTER CONTACTORTEST 27 - CHECK STARTER MOTOR Figure 7-20.– The Starter Contactor SCFigure 7-21.- Starter Motor SM Figure 7-22.- Check Pinion Gear OperationSection DIAGNOSTIC TESTS Section DIAGNOSTIC TESTS Figure 7-26.– Testing Starter Motor PerformanceTEST 28- CHECK FUEL SUPPLY Figure 7-24.– TachometerFigure 7-28– LP Gas Carburetion Diagram Figure 7-27- Typical Propane Gas Fuel SystemSection DIAGNOSTIC TESTS Figure 7-29.– Fuel Regulator TEST 29 - CHECK WIRE 14 POWER SUPPLYTEST 30 - CHECK WIRE Figure 7-30.– The 4-tabConnectorSection DIAGNOSTIC TESTS Figure 7-31.– Remote Harness ConnectorTEST 31 - CHECK FUEL SOLENOID GASOLINE MODELS TEST 32 - CHECK IGNITION SPARKSection DIAGNOSTIC TESTS Figure 7-32.– Testing Ignition SystemFigure 7-33.– Checking Engine Miss Figure 7-34.– Cylinder Balance TestTEST 33 - CHECK SPARK PLUGS TEST 34 - CHECK AND ADJUST IGNITION MAGNETOSFigure 7-35– Setting Spark Plug Gap Figure 7-36.– Ignition Magneto AssemblyFigure 7-39.– Diode Failure Diagnosis Figure 7-37.– Setting Ignition MagnetoArmature Air Gap Figure 7-38.– Engine Ground HarnessSection DIAGNOSTIC TESTS TEST 35 - CHECK VALVE ADJUSTMENTFigure 7-41– Adjusting Valve Clearance Figure 7-40.- Engine Ground Harness Test PointsSection DIAGNOSTIC TESTS TEST 36 - CHECK CARBURETIONTEST 37 - CHECK CHOKE SOLENOID Figure 7-42- Tightening the Jam NutSection DIAGNOSTIC TESTS Figure 7-43.- ConnectorFigure 7-44.– Exploded View of Choke Assembly Figure 7-45.– Automatic Choke AssemblyDOWN TEST / COMPRESSION TEST TEST 38 - CHECK ENGINE / CYLINDER LEAKSection DIAGNOSTIC TESTS Figure 7-47.– Oil Temperature Switch TEST 39 - CHECK OIL PRESSURE SWITCHTEST 40 - TEST OIL TEMPERATURE SWITCH Figure 7-46.– Oil Pressure SwitchSection DIAGNOSTIC TESTS Figure 7-48.– Testing Oil Temperature SwitchTEST 41 - TEST CHOKE HEATER TEST 42 - CHECK LPG FUEL SOLENOIDSection 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 NumbersDESCRIPTION Section Exploded Views / Part NumbersITEM PART NO. QTYEnclosure – Drawing No. 0E1011-B Section Exploded Views / Part NumbersPART NO SectionExploded Views / Part Numbers ITEMSheet 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 NumbersSection Exploded Views / Part Numbers0D5694 Section SPECIFICATIONS & CHARTS Section SPECIFICATIONS & CHARTSGENERATOR SPECIFICATIONS NOMINAL RESISTANCES OF GENERATOR WINDINGS AT 68FRV TORQUE REQUIREMENTS ENGINE SPEEDS AND VOLTAGE SPECIFICATIONSLONG BLOCK TORQUE REQUIREMENTS TRIM TORQUE REQUIREMENTSPage NOTESSection ELECTRICAL DATA Page Section ELECTRICAL DATAPO BOX 297 WHITEWATER, WI P/N OE7225 REV OPRINTED IN THE USA/9.03