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diagnostic
repair
manual
air- cooled Product
MODELS:
7 kW NG, 8 kW LP
9 kW NG, 10 kW LP
13 kW NG, 14 kW LP
16 kW NG, 17 kW LP
18 kW NG, 20 kW LP
automatic standby generators
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ElEctrical formulas TO FIND KNOWN VALUES 1-PHASE 3-PHASE E x I E x I x 1.73 x PF KILOWATTS (kW) Volts, Current, Power Factor 1000 1000 E x I E x I x 1.73 KVA Volts, Current 1000 1000 kW x 1000 kW x 1000 AMPERES kW, Volts, Power Factor E E x 1.73 x PF WATTS Volts, Amps, Power Factor Volts x Amps E x I x 1.73 x PF 2 x 60 x Frequency 2 x 60 x Frequency NO. OF ROTOR POLES Frequency, RPM RPM RPM RPM x Poles RPM x Poles FREQUENCY RPM, No. of Rotor Poles 2 x 60 2 x 60 2 x 60 x Frequency 2 x 60 x Freque
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contents 1.6 Engine-Generator Protective Devices ............. 25 General ............................................................25 specifications .......................................................... 4 Low Battery ......................................................25 Generator ................................................................ 4 Low Oil Pressure Shutdown .............................25 Engine ..................................................................... 5 High
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Test 7 – Testing The Stator With A Vom Problem 11 – No Battery Charge (12-20 kW)...........................................44 (Pre-Packed Load Center) ...........................73 Test 8 – Test Brushless Stator..........................45 Problem 12 – No Battery Charge (RTSN & RTSE Transfer Switch) .................73 Test 9 – Check Capacitor .................................46 Problem 13 – No Battery Charge Test 10 – Test DPE Winding on (Gen-Ready Load Center) ...........................73
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Part 4 - Dc coNtrol ......................................... 95 Test 68 – Check Fuel Solenoid ......................132 4.1 Description and Components .......................... 96 Test 69 – Check Choke Solenoid ...................132 General ............................................................96 Test 70 – Check for Ignition Spark .................134 Terminal Strip / Interconnection Terminal .........96 Test 71 – Check Spark Plugs .........................136 Circuit Board ............
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sPEcificatioNs Generator Unit 8 kW 10 kW 12 kW 14 kW 16 kW 17 kW 20 kW Rated Max. Continuous 7,000 NG 9,000 NG 12,000 NG 13,000 NG 16,000 NG 16,000 NG 18,000 NG Power Capacity (Watts*) 8,000 LP 10,000 LP 12,000 LP 14,000 LP 16,000 LP 17,000 LP 20,000 LP Rated Voltage 120/240 Rated Voltage at No-Load (NG) 220-235 247-249 Rated Max. Continuous Load Current (Amps) 120 Volts** (NG/LP) 58.3/66.6 75.0/83.3 100.0/100.0 108.3/116.6 133.3/133.3 133.3/141.6 150.0/166.6 240 Volts (NG/LP) 29.2/33.3 37.5/4
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SpecificationS nginee Model 8 kW 10 kW 12/14/16/17 kW 20 kW Type of Engine GH-410 GT-530 GT-990 GT-999 Number of Cylinders 1 2 2 2 Rated Horsepower @ 3,600 rpm 14.8 18 32 34 Displacement 407cc 530cc 992cc 999cc Cylinder Block Aluminum w/Cast Iron Sleeve Valve Arrangement Overhead Valves Ignition System Solid-state w/Magneto Recommended Spark Plug RC14YC BPR6HS RC14YCA RC12YC Spark Plug Gap 0.76 mm (0.030 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch) 1.02 mm (0.040 inch) Compression Ratio 9.4:1
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sPEcificatioNs mountinG dimenSionS AIR INTAKE 457.2 299 MINIMUM DISTANCE [18.0] [11.8] 914 [36.0] MINIMUM OPEN AREA 1079.5 ON SIDES AND FRONT [42.5] 698 [27.5] AIR OUTLET AIR INTAKE 997 [39.3] 747 [29.4] 250.0 575.3 207 [9.8] [22.7] 454 [8.2] [17.9] 508 [20.0] TRANSFER Ø30.2 [Ø1.2] LIFTING HOLES 4 CORNERS TRANSFER SWITCH 530.0 SWITCH HOLE LOCATIONS FOR 8KW - 17KW [20.9] OPTIONAL MOUNTING TO 20KW (IF SUPPLIED) A CONCRETE PAD (IF SUPPLIED) 446.6 378.7 44.8 [17.6] [14.9] [1.8] "DO NOT LIFT BY ROO
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sPEcificatioNs mountinG dimenSionS AIR INTAKE 457.2 299 MINIMUM DISTANCE [18.0] [11.8] 914 [36.0] MINIMUM OPEN AREA 1079.5 ON SIDES AND FRONT [42.5] 698 [27.5] AIR OUTLET AIR INTAKE 997 [39.3] 747 [29.4] 250.0 575.3 207 [9.8] [22.7] 454 [8.2] [17.9] 508 [20.0] TRANSFER Ø30.2 [Ø1.2] LIFTING HOLES 4 CORNERS TRANSFER SWITCH 530.0 SWITCH HOLE LOCATIONS FOR 8KW - 17KW [20.9] OPTIONAL MOUNTING TO 20KW (IF SUPPLIED) A CONCRETE PAD (IF SUPPLIED) 446.6 378.7 44.8 [17.6] [14.9] [1.8] "DO NOT LIFT BY ROO
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sPEcificatioNs major FeatureS 8kW, Single Cylinder, GH-410 Engine 10kW, V-twin, GT-530 Engine (door removed) (door removed) Circuit Oil Data Label Control Breaker Oil Data Label Control Dipstick (see sample) Panel Dipstick (see sample) Panel Circuit Breaker Exhaust Exhaust Enclosure Enclosure Air Air Filter Filter Fuel Inlet Fuel Inlet (back) (back) Fuel Fuel Regulator Regulator Composite Base Oil Filter Battery Compartment Composite Base Oil Filter Battery Compartment Figure 1.3 – 12, 14, 16,
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t aBlE of coNtENts Part titlE PaGE 1.1 Generator identification 10 1.2 installation Basics 11 Part 1 1.3 Non-Prepackaged 14 interconnections GENEral 1.3 Preparation Before use 16 1.4 t esting, cleaning and Drying 18 iNformatioN 1.5 Engine-Generator Protective 25 Devices 1.6 operating instructions 27 1.7 automatic operating 29 Parameters air-cooled, a utomatic standby Generators 1.1 Generator Identification ................................... 10 Measuring Resistance ........................
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sEctioN 1.1 GENERAL INFORMATION Part 1 GENErator iDENtificatioN It is not our intent to provide detailed disassembly and introduction reassemble instructions in this manual. It is our intent This Diagnostic Repair Manual has been prepared to (a) provide the service technician with an under- especially for the purpose of familiarizing service per- standing of how the various assemblies and systems sonnel with the testing, troubleshooting and repair of work, (b) assist the technician in finding
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sEctioN 1.2 GENERAL INFORMATION Part 1 iNstallatioN B asics LP (propane) gas is usually supplied as a liquid in introduction pressure tanks. Both the air-cooled and the liquid Information in this section is provided so that the cooled units require a “vapor withdrawal” type of fuel service technician will have a basic knowledge of supply system when LP (propane) gas is used. The installation requirements for home standby systems. vapor withdrawal system utilizes the gaseous fuel Problems
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sEctioN 1.2 GENERAL INFORMATION Part 1 iNstallatioN B asics Figure 1. Typical Installation Page 12
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sEctioN 1.2 GENERAL INFORMATION Part 1 iNstallatioN B asics po Wer Source and load lineS SyStem control interconnectionS The utility power supply lines, the standby (genera- Home standby generators are equipped with a termi- tor) supply lines, and electrical load lines must all be nal board identified with the following terminals: (a) connected to the proper terminal lugs in the transfer UTILITY 1, (b) UTILITY 2, (c) 23, and (d) 15B. Load switch. The following rules apply: In 1-phase systems c
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Section 1.3 General information Part 1 non-PreP ackaged interconnectionS Discussion: 3. Using the following diagram and UL approved wire nuts on the current model air-cooled generators Wire 194 connect the following wires together. Wire 0 will not be was changed to 15B. Wire 15B is still utilized for posi- utilized for this setup. tive voltage for the transfer relay and Wire 23 is still the CONTROL WIRES FROM control ground for transferring the generator. By follow- TRANSFER SWITCH ing the p
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sEctioN 1.3 GENERAL INFORMATION Part 1 NoN-PrEP acKa GED iNtErcoNNEctioNs connect a 2008 and later load center SWitch CONTROL WIRES FROM to a pre-2008 air-cooled Generator. ENGINE GENERATOR PROCEDURE: N1 (BLU) N1 (YEL) 1. Follow all instructions located in the Installation Manual that was supplied with the unit regarding mounting of the N2 (YEL) N2 (YEL) switch, junction box, and generator. note: When installing a standalone pre-2008 gen- 23 (BRN) 23 (WHT) erator, the battery charger will b
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sEctioN 1.4 GENERAL INFORMATION Part 1 PrEP aratioN BEforE usE All installed gaseous fuel piping must be purged and General leak tested prior to initial start-up in accordance with The installer must ensure that the home standby gen- local codes, standards and regulations. erator has been properly installed. The system must be inspected carefully following installation. All appli- cable codes, standards and regulations pertaining to Fuel conSumption such installations must be strictly complie
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sEctioN 1.4 GENERAL INFORMATION Part 1 PrEP aratioN BEforE usE in the selector knob and pull out to overcome spring pressure and then twist clockwise 90 degrees and allow the selector to return in once aligned with the LP (Liquid Propane) position. FUEL SELECTION LEVER - 6. Save this tool with the Owner's Manual. “OUT” POSITION FOR 7. Install the battery, door and close the roof. LIQUID PROPANE (VAPOR) FUEL 8. Reverse the procedure to convert back to natural gas. Figure 3. 10 kW, GT-530 (I
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sEctioN 1.4 GENERAL INFORMATION Part 1 PrEP aratioN BEforE usE enGine oil recommendationS All oil should meet minimum American Petroleum FUEL SELECTION Institute (API) Service Class SJ, SL or better. Use LEVER - no special additives. Select the oil's viscosity grade “OUT” POSITION FOR according to the expected operating temperature. LIQUID PROPANE • SAE 30 è Above 32° F (VAPOR) FUEL • 10W -30 è Between 40° F and -10° F • Synthetic 5W -30 è 10° F and below Engine crankcase oil capacities
