Generac Power Systems 8KW - Diagnostic Repair Manual

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Generator Specifications5
Stator Winding Resistance Values5
Air-Cooler V-Twin Engine Specifications6
Liquid-Cooled 1.2 Liter Engine Specifications6
The 8 KW, Air-Cooled Prepackaged Generator7
Typical Prepackaged Generator with 1.2 Liter Engine8
General Information9
Table of Contents9
Generator Identification11
Units with Air-Cooled V-Twin Engine11
Units with Liquid Cooled Engine11
Voltage Codes11
Generator Identification Code12
Typical Data Plate13
Typical Data Card13
AC Connection Systems15
Dual Stator Power Windings15
Prepackaged Installation Basics17
Selecting a Location17
Mounting the Generator17
Grounding the Generator17
Lp/Natural Gas System (Air-Cooled Units)18
LP Gas System18
Natural Gas System-Liquid Cooled Units18
The Transfer Switch19
Power Source and Load Lines19
System Control Interconnections19
Installation with a GTS Transfer Switch20
Preparation before Use21
Fuel Requirements21
Engine Oil Recommendations21
Recommended Engine Coolant22
Engine Governor Oiling22
Visual Inspection23
Measuring Voltages23
Measuring Current23
Measuring Resistance23
Stator Insulation Tests-Air Cooled Units24
Stator Insulation Tests - Liquid Cooled Units with 1-Phase Stator25
Stator Insulation Tests - Liquid Cooled Units with 3-Phase Stator26
Testing Rotor Insulation26
Cleaning the Generator27
Drying the Generator27
Engine - Generator Protective Devices29
Units with Air-Cooled Engine29
Protective Devices on Liquid Cooled Engine30
Operating Instructions31
Control Panel - Units with Air-Cooled Engine31
Control Panel - Units with Liquid Cooled Engine31
To Select Automatic Operation33
Manual Transfer to "Standby" and Manual Startup33
Manual Shutdown and Retransfer Back to "Utility"34
The Set Exercise Time Switch34
Automatic Operating Parameters35
Automatic Operating Sequences35
Automatic Operating Sequences Chart36
Prepackaged Air-Cooled AC Generators37
Other AC Generator Components39
Field Boost Circuit40
Operational Analysis41
Rotor Residual Magnetism41
Field Boost41
Operation41
Troubleshooting Flow Charts43
Generator Produces Zero or Residual Voltage43
Generator Produces Low Voltage at No-Load44
Generator Produces High Voltage at No-Load44
Voltage and Frequency Drop Excessively When Loads and Applied45
Description and Components47
Engine-Generator Drive System47
The AC Generator47
Lower Bearing Carrier47
Rotor Assembly48
Stator Assembly48
Upper Bearing Carrier48
Brush Holder and Brushes48
Diagnostic Tests49
Safety49
Check Main Circuit Breaker49
Check AC Output Voltage49
Test Excitation Circuit Breaker50
Test Stator DPE Winding50
Check Brushes and Slip Rings51
Test Rotor Assembly52
Check Field Boost52
Check Voltage Regulator53
Check AC Output Frequency53
Check and Adjust Engine Governor53
Check and Adjust Voltage Regulator54
Check Voltage and Frequency under Load54
Check for Overload Condition54
Prepackaged Liquid-Cooled AC Generators55
Description and Major Components57
Blower Housing57
Fan and Ring Gear Assembly57
Rear Bearing Carrier57
Exploded View of AC Generator Components58
The Excitation Circuit59
AC Meters60
Schematic Diagram of AC Generator61
Block Diagram of AC Generator62
Check Voltage-Phase Selector Switch Position67
Check AC Voltmeter67
Test Thermal Protector68
Test Voltage Regulator69
Check Leads 1 and 469
Test Rotor Windings70
Test Voltage-Phase Selector Switch70
"V-Type" Prepackaged Transfer Switches75
Transfer Switch Major Components77
Exploded View of V-Type Prepackaged Transfer Switch77
Enclosure78
Transfer Mechanism78
Transfer Relay79
Neutral Lug79
Manual Transfer Handle79
Terminal Block79
Fuse Holder80
Utility Source Voltage Available81
Utility Source Voltage Dropout81
Transfer to Standby81
Retransfer Back to Utility82
In Automatic Mode, no Transfer to Standby83
In Automatic Mode, no Retransfer Back to Utility83
In Automatic Mode, Generator Starts and Transfer to Standby Occurs When Utility Source Voltage Is Available84
Check Voltage at Terminal Lugs E1, E285
Check Voltage at Standby Closing Coil C285
Test Transfer Relay TR86
Check Manual Transfer Switch Operation86
Test Limit Switch XB187
Check Voltage at Terminal Lugs N1, N287
Check Voltage at Utility 1 and Utility 2 Terminals88
Check Voltage at Utility Closing Coil C188
Check Fuses F1 and F289
Test Limit Switch XA189
"Y-Type" Prepackaged Transfer Switches91
Prepackaged Terminal Strip96
3-Phase Power Monitor97
Switch Enclosure97
Utility Voltage Available (2-Pole Units)99
Utility Voltage Available (3-Pole Units)99
Utility Voltage Dropout (2-Pole Units)100
Utility Power Outage (3-Pole Units)100
Initial Transfer to Standby (2-Pole Units)101
Initial Transfer to Standby (3-Pole Units)101
Final Transfer to Standby (2-Pole Units)102
Final Transfer to Standby (3-Pole Units)102
Retransfer to Utility (2-Pole Units)103
Retransfer to Utility (3-Pole Units)103
In Automatic Mode, will Not Transfer to "Standby"105
In Automatic Mode, will Not Retransfer to "Utility"106
Genset Starts and Transfer Occurs When Utility Power Is Available (3-Phase Transfer Switches)107
Test Automatic Operation109
Check Voltage at Terminals E1/E2/E3110
Check Voltage at Terminals B1/B2110
Check Wiring111
Test Limit Switch LS3111
Test Limit Switch LS1112
Test Limit Switch LS2113
Test Bridge Rectifier113
Test Solenoid Coil115
Check Manual Operation115
Inspect Main Contacts115
Check Voltage at Terminals N1/N2/N3116
Check Voltage at Terminals A1/A2116
Check Voltage at Terminals N1A/N2 of Customer Terminal Strip116
Test 3-Phase Power Monitor116
Transfer Mechanism Removal119
Electrical Section Disassembly119
Stationary Main Contacts Removal122
Moveable Main Contacts122
Testing and Inspection122
Reassembly122
DC Control (Units with Air Cooled Engine)123
Auto-Off-Manual Switch125
15 Amp Fuse125
Initial Dropout of Utility Source Voltage128
Utility Voltage Dropout and Engine Cranking129
Engine Startup and Running130
Initial Transfer to the "Standby" Source131
Utility Voltage Restored and Retransfer to "Utility"132
Engine Shutdown133
Engine will Not Crank When Utility Power Source Fails135
Engine will Not Crank When Auto-Off-Manual Switch Is Set to "Manual"135
Engine Cranks and Starts but no Transfer to Standby137
No Automatic Retransfer Back to Utility138
Unit Starts & Transfer Occurs When Utility Power Is Available139
Generator Does Not Start and Exercise as Programmed139
Check Position of Auto-Off-Manual Switch141
Try a Manual Start141
Test Auto-Off-Manual Switch141
Check Wires 15A142
Check 15 Amp Fuse142
Check Battery142
Check Wires 15/15A Voltage143
Check Wire 56 Voltage143
Test Starter Contactor144
Test Starter Motor144
Check Fuel Supply and Pressure145
Check CMA Circuit Board Power Supply and Output to Wire 56146
Check CMA Board Wire 14 Output146
Check Fuel Solenoid146
Check for Ignition Spark147
Check Spark Plugs147
Check Engine Compression148
Check Engine I.S.D. Module148
Check and Adjust Ignition Modules149
Check Oil Pressure Switch149
Check High Oil Temperature Switch150
Check Wire 18150
Check Generator Main Circuit Breakers150
Test Stator Battery Charge Winding Output150
Ground CMA Terminal 23151
Test Terminals 23 and 194 Circuit151
Test Sensing Transformer152
Disconnect Wire 23 from CMA Terminal Strip152
Check Utility Sensing Voltage at CMA Circuit Board152
Check Transfer Switch Fuses F3 and F4153
Check Voltage at CMA Utility 1 and 2 Terminals153
Check Voltage at Transfer Switch Load 1 and Load 2 Terminals153
Reset Exercise Timer153
DC Control Liquid Cooled Engine Units155
Control Module Assembly157
Control Console Components158
Engine Mounted Components160
Transfer Switch161
DC Control System Schematic163
Circuit Condition-Utility Source Voltage Available164
Circuit Condition - Initial Utility Voltage Dropout166
Circuit Condition - Cranking and Initial Startup168
Circuit Condition - Initial Transfer to Standby170
Circuit Condition - Utility Voltage Restored174
Circuit Condition - Initial Retransfer Back to Utility176
Circuit Condition - Final Retransfer to Utility178
Circuit Condition - Generator Shutdown180
Check Auto-Off-Manual Switch Position187
Try to Start Engine Manually187
Inspect Auto-Off-Manual Switch to CMA Circuit Board Wiring188
Check 30 Amp Fuse F1188
Test Control Contactor CC188
Test Starter Motor SM189
Check CMA Circuit Board Power and Wire 56 Output190
Check for Mechanical Damage190
Check Fuel Supply190
Check Wire 14 Output to Ignition192
Test Ignition Coil193
Test Ignition Condensor193
Inspect Distributor Cap and Rotor Head193
Inspect Contact Points194
Check Governor Advance194
Check Ignition Wires194
Check Ignition Timing195
Check DC Volts at Terminal 14 of TB1195
Test Fuel Solenoid FS195
Check Engine Compression and Condition195
Check Generator Main Line Circuit Breaker196
Check Sensing to CMA Circuit Board196
Check Voltage at Terminal Lugs E1, E2, E3197
Check Voltage at Terminal Lugs N1, N2, N3197
Check Voltage at CMA Terminals N1A and N2197
Operational Tests and Adjustments199
Manual Transfer Switch Operation201
System Voltage Tests202
Generator Tests under Load202
Testing Automatic Operation203
The 7-Dat Exercise Cycle205
Adjusting the Engine Governor205
Voltage Regulator Checks and Adjustments206
Load Block Adjustments206
Adjusting Drive Belt Tension208
Setting Weel;Y Exercise Cycle209
Engine Governor Adjustment209
Voltage Regulator Adjustment210
Adjustment of 3-Phase Power Monitor211
Electrical Data213
Schematic Diagram215
Wiring Diagram216

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