PART 1
GENERAL INFORMATION
Section 1.1
Generator Basics
Page 10
INTRODUCTION
This diagnostic repair manual has been prepared especially for
familiarizing service personnel with the testing, troubleshooting
and repair of the air-cooled product that utilizes the Nexus
controller. Every effort has been expended to ensure that the
information and instructions in the manual are both accurate
and current. However, the manufacture reserves the right to
change, alter or otherwise improve the product at any time
without prior notification.
The manual has been divided into several PARTS. Each PART
has been divided into SUBSECTIONS and each subsection
consists of several sub headings.
It is not the manufactures intent to provide detailed disassembly
and reassembly of the entire Residential product line. It is
the manufactures intent to (a) provide the service technician
with an understanding of how the various assemblies and
systems work, (b) assist the technician in finding the cause
of malfunctions, and (c) effect the expeditious repair of the
equipment.
PARTS
Part 1 – Provides the basic understanding of the generator as well
as basic installation information and operating instructions.
Part 2 – Provides the basics of the AC alternator design and the
AC troubleshooting portion of the manual.
Part 3 – Provides the troubleshooting and diagnostic testing
procedure for the pre-packaged 10,12,14,16 circuit EZ Switchâ„¢
transfer switches.
Part 4 – Provides the troubleshooting and diagnostic testing
procedure for engine related problems and the Nexusâ„¢
Controller.
Part 5 – Provides the basic operational and system function
testing to ensure proper operation of the unit.
Part 6 – Provides detailed step-by-step instructions for the
replacement of the rotor/stator and engine.
Part 7 – Illustrates all of the electrical and wiring diagrams for
the various kW ranges and transfer switches.
Data Plate
The data plate that is affixed to the generator contains
important information pertaining to the unit, including its model
number, serial number, amperage rating, and voltage rating.
The information from this data plate may be required when
requesting information, ordering parts, etc.
Item Number
Many home standby generators manufactured are to the unique
specifications of the buyer. The Model Number identifies the
specific generator set and its unique design specifications
Serial Number
Used for warranty tracking purposes.
GENERATOR IDENTIFICATION
The air-cooled product utilizes four different engines over
various kW ranges. It is important to know the size of the
engine before attempting a repair because some testing
procedures will be different from engine to engine.
410cc Engine 8kW
•Overhead Valve
•Single Cylinder
•Nexus™ Controller
530cc Engine 10kW
•Overhead Valve
•Twin Cylinders
•Nexus™ Controller
990cc Engine 12-17kW
•Overhead Valve
•Twin Cylinders
•Nexus™ Controller
999cc Engine 20kW
•Overhead Valve
•Twin Cylinders
•Nexus™ Controller
Figure 5. Typical Data Plates
Item # 0055555
1234567
120/240 AC
108.3/108.3
13000
Serial
Volts
Watts
1 PH, 60 HZ, RPM 3600
NEUTRAL FLOATING
CLASS H INSULATION
MAX OPERATING AMBIENT
TEMP -
25°C
FOR STANDBY SERVICE
MAX LOAD UNBALANCED - 50%
Amps
RAINPROOF ENCLOSURE FITTED
53190 U.S.A.
WHITEWATER, WI
GENERAC POWER SYSTEMS
NEUTRAL FLOATING
CLASS H INSULATION
AMPS
SERIAL
VOLTS
MODEL
RATED AMBIENT TEMP - 25°C
FOR STANDBY SERVICE
MAX LOAD UNBALANCE-50%
RAINPROOF ENCLOSURE FITTED
1 PH, 60 Hz, RPM 3600
CONTROLLER
P/N
0055555
1234567
0H6680B
120/240 AC
108.3/108.3
MODEL #
SERIAL #
WATTS
VOLTS
AMPS
1PH, 60Hz, 3600 RPM, CLASS F INSULATION
RAINPROOF ENCLOSURE FITTED
RATED AMBIENT TEMP - 40°C
FOR STANDBY SERVICE, NEUTRAL FLOATING
0055555
1234567 120/240 AC
13000
108.3/108.3
Model Number -Serial Number -
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