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

65, 75, 55 specifications

Generac Power Systems has established itself as a leader in power generation, offering a range of high-performance generators suited for residential and commercial applications. Among its lineup, the Generac 55, 65, and 75 kW generators stand out for their reliability, efficiency, and advanced features.

The Generac 55 kW generator is designed to provide a powerful backup solution for medium to large homes or small businesses. It features a robust engine that delivers dependable performance while maintaining fuel efficiency. One of its key characteristics is the True Power Technology, which produces clean and stable power, ensuring that sensitive electronic devices run smoothly without risk of damage. This generator is equipped with a fully automatic transfer switch, allowing for seamless power transition during outages, with minimal disruption.

Moving to the 65 kW model, it offers increased capacity while retaining the fundamental qualities of the 55 kW version. This unit is particularly suited for larger homes or commercial applications that require greater power demands. The 65 kW generator utilizes Generac’s G-Force engine, known for its durability and reduced maintenance needs. Advanced features such as remote monitoring capabilities allow users to check the generator's status from anywhere, providing peace of mind and convenience.

The 75 kW generator takes performance to the next level, making it ideal for even more significant power needs. It is engineered for both quiet operation and enhanced performance, accommodating a wide range of requirements from residential to larger commercial operations. The 75 kW model includes a full-load voltage regulation system that maintains stable power output under varying loads, safeguarding appliances and equipment.

All three models incorporate advanced air-cooled technology, which enhances their efficiency and operational lifespan. Additionally, their corrosion-resistant enclosures ensure durability even in harsh weather conditions, making them suitable for diverse environments. The intuitive LCD display on each unit provides critical information, including runtime hours and maintenance reminders, empowering users with easy access to the generator's performance data.

Overall, Generac Power Systems' 55, 65, and 75 kW generators represent a commitment to quality, reliability, and innovation in backup power solutions. They are designed to meet the demands of modern power consumption while ensuring peace of mind through robust engineering and advanced technology. Whether for home use or commercial applications, these generators provide an effective means to stay prepared for unexpected power outages.