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Generac Power Systems
Portable Generator
5735
Generac Power Systems 5735 User Manual
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Section 5 Disassembly
Diagnostic Repair Manual
69
Figure 5-
9. Remove R
otor
Figure 5-10. Engine Ready for Remo
val
Remove Engine
7.
Remove the fo
ur nuts from rubb
er engine mo
unts.
(
Figure 5-1
1
, Item 29)
8.
Remove engine.
Reverse procedure for assemb
ly
.
004674
004675
72
74
Table of Contents
Default Chapter
2
Read this Manual Thoroughly
2
Replacement Parts
2
Table of Contents
3
Section 1 Description and Components
5
Introduction
5
Engine-Generator Drive System
5
The AC Generator
5
Rotor Assembly
5
Stator Assembly
5
Brush Holder and Brushes
6
Other AC Generator Components
6
Excitation Circuit Breaker
6
Voltage Regulator
6
Adjustment Procedure (12.5 Kw and Older 15 Kw Units)
7
Adjustment Procedure (Newer 15 Kw and All 17.5 Kw Units)
7
Circuit Breakers
7
Rotor Residual Magnetism
7
Field Boost Circuit
7
Operation
8
Startup
8
On-Speed Operation
8
Field Excitation
8
AC Power Winding Output
8
Battery Charge Winding Output
8
10 Amp Battery Charge Winding Output
8
Specifications
9
Section 2 Engine DC Control System
11
Printed Circuit Board
11
General Theory
11
Circuit Board Connections
11
Dip Switch Positions
11
Battery
11
Recommended Battery
11
Control Panel Component Identification
12
Operational Analysis (Older Units)
14
Circuit Condition - Rest
14
Circuit Condition - Start
16
Circuit Condition - Run
18
Circuit Condition - Stop
20
Fault Shutdown
21
Operational Analysis (Newer Units)
22
Circuit Condition - Rest
22
Circuit Condition - Start
24
Circuit Condition - Run
26
Circuit Condition - Stop
28
Fault Shutdown
28
Section 3 Troubleshooting Flowcharts
31
Introduction
31
Section 4 AC Diagnostic Tests
39
Introduction
39
Safety
39
Important Note Concerning Connectors
39
Test 1 - Check No-Load Voltage and Frequency
39
Test 2 - Check Main Circuit Breaker
40
Test 3 - Test Excitation Circuit Breaker
40
Test 4 - Fixed Excitation Test/Rotor Amp Draw Test
40
Test 5 - Check Stepper Motor Control
42
Test 6 - Wire Continuity
43
Test 7 - Check Field Boost
44
Test 8 - Diode/Resistor
44
Test 9 - Test Stator
45
Test 10 - Sensing Leads
46
Test 11 - Excitation Wiring
47
Test 12 - Check Brush Leads
47
Test 13 - Check Brushes & Slip Rings
48
Test 14 - Check Rotor Assembly
48
Test 15 - Check Load Voltage & Frequency
49
Test 16 - Check Load Watts and Amperage
49
Test 17 - Check Battery Charge Output
49
Test 18 - Check 10 Amp Battery Charge Output
49
Test 19 - Check Battery Charge Rectifier (BCR2)
50
Test 20 - Check 10 Amp Circuit Breaker
50
Test 21 - Check 10 Amp Fuse
51
Test 22 - Check Battery and Cables
51
Test 23 - Check Voltage at Starter Contactor (SC)
52
Test 24 - Check Starter Contactor (SC)
52
Test 25 - Check Starter Motor
52
Test 26 - Test Starter Contactor Relay (SCR)
53
Test 27 - Check Start-Run-Stop Switch (SW1)
54
Test 28 - Check Start-Run-Stop Switch (SW1) Wiring
54
Test 29 - Check Ignition Spark
54
Test 30 - Check Spark Plugs
55
Test 31 - Remove Wire 18 / Shutdown Lead
55
Test 32 - Test Start Stop Relay (SSR)
55
Test 33 - Test Wire 167
56
Test 34 - Test Start Stop Relay Wiring
57
Test 35 - Check and Adjust Ignition Magnetos
58
Test 36 - Test Fuel Shutoff Solenoid (FSS)
59
Test 37 -Test Fuel Shutoff Solenoid Voltage
59
Test 38 - Check Fuel Pump
59
Test 39 - Check Carburetion
59
Test 40 - Valve Adjustment
60
Test 41 - Check Engine / Cylinder Leak down Test / Compression Test
61
Test 42 - Check Oil Pressure Switch and Wire 86
62
Test 43 - Check Start Stop Relay (SSR)
62
Test 44 - Test Starter Contactor Relay (SCR)
63
Test 45 - Check Wire 15 Circuit
63
Test 46 - Check Wire 14 Circuit
63
Test 47 - Check Fuel Shutoff Solenoid (FSS)
63
Test 48 - Check Hour Meter
64
Test 49 - Check Wire 15B
64
Test 50 - Check Wire 167
64
Test 51 - Check Wires 11S & 44S or 11S & 22S
64
Test 52 - Check Idle Control Switch (SW2)
65
Test 53 - Check Idle Control Wiring
65
Test 54 - Check Idle Control Transformers (ICT)
66
Test 55 - Check TR1 & TR2 Wiring
66
Test 56 - Choke Test
67
Insulation Resistance
67
The Megohmmeter
67
Introduction
67
Testing Stator Insulation
67
Testing Rotor Insulation
67
Hi-Pot Tester
68
Stator Insulation Resistance Test
68
Testing All Stator Windings to Ground
68
Test between Windings
69
Rotor Insulation Resistance Test
69
Cleaning the Generator
69
Drying the Generator
69
Wattage Reference Guide
70
Section 5 Disassembly
71
Major Disassembly
71
Section 6 Electrical Data
79
Introduction
79
Wiring Diagram 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0228
80
Wiring Diagram 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0228
81
Electrical Schematic 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0229-A
82
Electrical Schematic 12.5 & 15 Kw (Units Without Hourmeter) - Drawing No. 0E0229-A
83
Wiring Diagram 12.5 & 15 Kw (Units with Hourmeter) - Drawing No. 0D4609-D
84
Wiring Diagram 12.5 & 15 Kw (Units with Hourmeter) - Drawing No. 0D4609-D
85
Electrical Schematic 12.5 & 15 Kw (Units with Hourmeter) - Drawing No. 0D6297-A
86
Electrical Schematic 12.5 & 15 Kw (Units with Hourmeter) - Drawing No. 0D6297-A
87
Wiring Diagram 17.5 Kw - Drawing No. 0G0731
88
Wiring Diagram 17.5 Kw - Drawing No. 0G0731
89
Electrical Schematic 17.5 Kw - Drawing No. 0G0733
90
Electrical Schematic 17.5 Kw - Drawing No. 0H0729
91
Wiring Diagram 17.5 Kw - Drawing No. 0H0730
92
Wiring Diagram 17.5 Kw - Drawing No. 0H0730
93
Wiring Diagram, 17.5 Kw Manual Transfer Switch - Drawing No. 0G1065
94
Interconnection Drawing - 17.5 Kw Generator Connected to the External Connection Box, Manual Transfer Switch and Home's Main Electrical Distribution Panel
95
4
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Generac Power Systems 5735 Specifications
General
Brand
Generac Power Systems
Model
5735
Category
Portable Generator
Language
English
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