Generac Power Systems 5735 - User Manual

DIAGNOSTIC
REPAIR
MANUAL
PORTABLE GENERATORS
GP Series and UltraSource
Portable Generators
MODELS:
Model 4451, 4986 (12.5 kW)
5734, 4582, 4987 (15 kW)
5735, 4583, 5308 (17.5 kW)
®
DIAGNOSTIC
REPAIR
MANUAL
PORTABLE GENERATORS
GP Series and UltraSource
Portable Generators
MODELS:
Model 4451, 4986 (12.5 kW)
5734, 4582, 4987 (15 kW)
5735, 4583, 5308 (17.5 kW)
®

Generac Power Systems 5735 Specifications

General

Model	5735
Type	Portable Generator
Starting Watts	7, 375 watts
Engine Displacement	389cc
Fuel Tank Capacity	7.5 Gallons
Starting System	Electric Start
Fuel Type	Gasoline
Weight	192 lbs
Voltage	120/240V
Wheel Kit	Included
Engine	Generac OHV
Outlets	Four 120V 20 Amp Outlets, One 120/240V Twist Lock Outlet
Outlet Types	Four 120V 20 Amp Outlets, One 120/240V Twist Lock Outlet

Summary

Section 1 Description and Components

Adjustment Procedure (12.5 kW and Older 15 kW Units)

Adjustment Procedure (Newer 15 kW and All 17.5 kW Units)

Specifications

Section 2 Engine DC Control System

Circuit Condition - Start

Circuit Condition - Run

Circuit Condition - Stop

Fault Shutdown

Section 3 Troubleshooting Flowcharts

If Problem Involves AC Output

Directs users to the first troubleshooting path for AC output issues.

Problem 1 - Voltage and Frequency Are Both High or Low

Identifies a specific AC output problem and directs to further tests.

Problem 2 - Generator Produces Zero Voltage or Residual Voltage (2-12 VAC)

Outlines troubleshooting steps for zero or residual AC voltage output.

Problem 2 - Generator Produces Zero Voltage or Residual Voltage (2-12 VAC) (continued)

Continues troubleshooting steps for low AC voltage issues.

Problem 3 - Excessive Voltage;Frequency Droop When Load is Applied

Addresses voltage/frequency drop under load conditions.

Problem 4 - No Battery Charge Output

Guides troubleshooting for lack of battery charging.

Problem 5 - No 10 A Battery Charge Output

Details troubleshooting for the 10A battery charge circuit.

Problem 6 - Engine Will Not Crank

Provides a flowchart for diagnosing an engine that won't crank.

Problem 7 - Engine Cranks But Will Not Start

Outlines steps for diagnosing an engine that cranks but won't start.

Problem 8 - Engine Starts Hard and Runs Rough

Addresses issues with difficult starting or rough engine operation.

Problem 9 - Engine Starts Then Shuts Down

Guides troubleshooting for engines that start and then stop.

Problem 10 - 10 Amp Fuse (F1) Blowing

Details troubleshooting steps for a blowing 10A fuse.

Problem 11 - Engine Overspeeds

Addresses generator overspeed conditions.

Problem 12 - Idle Control RPM Does Not Decrease

Troubleshoots issues where idle RPM does not reduce.

Problem 13 - Idle Control “RPM Does Not Increase When Load Is Applied

Diagnoses problems with idle RPM not increasing under load.

Problem 14 - Engine “Hunts”; Erratic Idle

Guides troubleshooting for hunting or erratic engine idle.

Section 4 AC Diagnostic Tests

Safety

Test 1 - Check No-Load Voltage and Frequency

Details how to check voltage and frequency without a load.

Test 2 - Check Main Circuit Breaker

Test 3 - Test Excitation Circuit Breaker

Test 4 - Fixed Excitation Test;Rotor Amp Draw Test

Describes tests for fixed excitation and rotor amp draw.

Test 4 - Fixed Excitation Test;Rotor Amp Draw Test (8-20 kW)

Presents results for Test 4 based on generator size.

Test 5 - Check Stepper Motor Control

Provides steps to check the stepper motor and its control.

Test 6 - Wire Continuity

Test 7 - Check Field Boost

Test 8 - Diode;Resistor

Test 9 - Test Stator

Describes how to test stator windings for resistance and continuity.

Test 10 - Sensing Leads

Test 11 - Excitation Wiring

Test 12 - Check Brush Leads

Test 13 - Check Brushes & Slip Rings

Test 14 - Check Rotor Assembly

Describes how to test the rotor for resistance and insulation.

Test 15 - Check Load Voltage and Frequency

Details checking voltage and frequency under load.

Test 16 - Check Load Watts and Amperage

Test 17 - Check Battery Charge Output

Test 18 - Check 10 Amp Battery Charge Output

Test 19 - Check Battery Charge Rectifier (BCR2)

Test 20 - Check 10 Amp Circuit Breaker

Test 21 - Check 10 Amp Fuse

Test 22 - Check Battery and Cables

Details procedures for checking battery and cables, including voltage drop tests.

Test 23 - Check Voltage At Starter Contactor (SC)

Test 24 - Check Starter Contactor (SC)

Test 25 - Check Starter Motor

Covers conditions affecting starter motor performance and testing.

Test 26 - Test Starter Contactor Relay (SCR)

Test 27 - Check Start-Run-Stop Switch (SW1)

Test 28 - Check Start-Run-Stop Switch (SW1) Wiring

Test 29 - Check Ignition Spark

Describes how to test for ignition spark.

Test 30 - Check Spark Plugs

Test 31 - Remove Wire 18; Shutdown Lead

Test 32 - Test Start Stop Relay (SSR)

Test 33 - Test Wire 167

Test 34 - Test Start Stop Relay Wiring

Test 35 - Check and Adjust Ignition Magnetos

Covers checking and adjusting ignition magneto air gaps.

Test 36 - Test Fuel Shutoff Solenoid (FSS)

Test 37-Test Fuel Shutoff Solenoid Voltage

Test 38 - Check Fuel Pump

Test 39 - Check Carburetion

Test 40 - Valve Adjustment

Provides instructions for adjusting valve clearance.

Test 41 - Check Engine; Cylinder Leak Down Test; Compression Test

Details procedures for engine leak-down and compression testing.

Test 42 - Check Oil Pressure Switch and Wire 86

Explains how to test the oil pressure switch and associated wiring.

Test 43 - Check Start Stop Relay (SSR)

Test 44 - Test Starter Contactor Relay (SCR)

Test 45 - Check Wire 15 Circuit

Test 46 - Check Wire 14 Circuit

Test 47 - Check Fuel Shutoff Solenoid (FSS)

Test 48 - Check Hour Meter

Test 49 - Check Wire 15 B

Test 50 - Check Wire 167

Test 51 - Check Wires 11 S & 44 S or 11 S & 22 S

Test 52 - Check Idle Control Switch (SW2)

Test 53 - Check Idle Control Wiring

Test 54 - Check Idle Control Transformers (ICT)

Test 55 - Check TR1 & TR2 Wiring

Test 56 - Choke Test

Insulation Resistance

Introduces insulation resistance testing for windings.

Testing Stator Insulation

Details procedures for testing stator insulation to ground.

Testing All Stator Windings To Ground

Provides specific steps for testing stator windings against ground.

Test Between Windings

Rotor Insulation Resistance Test

Details how to perform a rotor insulation resistance test.

Section 5 Disassembly

Stator, Rotor, and Engine Removal

Remove Stator

Remove Rotor

Remove Engine

Section 6 Electrical Data

Wiring Diagram 12.5 & 15 kW (Units Without Hourmeter) - Drawing No. 0 E0228

Provides a wiring diagram for specific models.

Electrical Schematic 12.5 & 15 kW (Units Without Hourmeter) - Drawing No. 0 E0229-A

Presents an electrical schematic for specific models.

Wiring Diagram 12.5 & 15 kW (Units With Hourmeter) - Drawing No. 0 D4609-D

Provides a wiring diagram for models with hourmeters.

Electrical Schematic 12.5 & 15 kW (Units With Hourmeter) - Drawing No. 0 D6297-A

Presents an electrical schematic for models with hourmeters.

Wiring Diagram 17.5 kW - Drawing No. 0 G0731

Provides a wiring diagram for the 17.5 kW model.

Electrical Schematic 17.5 kW - Drawing No. 0 G0733

Presents an electrical schematic for the 17.5 kW model.

Wiring Diagram 17.5 kW - Drawing No. 0 H0729

Provides an alternative wiring diagram for the 17.5 kW model.

Wiring Diagram 17.5 kW - Drawing No. 0 H0730

Provides another alternative wiring diagram for the 17.5 kW model.

Wiring Diagram, 17.5 kW Manual Transfer Switch - Drawing No. 0 G1065

Interconnection Drawing - 17.5 kW generator connected to the external connection box, manual transfer switch and homes main electrical distribution panel