DiagnosticRepaiRManualPORTABLE GENERATORSGP Series Portable GeneratorsMODELS:GP1800GP3250GP5000GP5500GP6500GP7000GP8000®
Page 8Product Series GP8000/GP8000EA/C Rated Output Watts: 8000A/C Maximum Output Watts: 10000A/C Voltage 120/240VACA/C Frequency 60 HzRated 120/240 V
PART 1 GENERAL INFORMATIONGP Series Portable GeneratorsPage 9TABLE OF CONTENTSPART TITLE PAGE1.1 Generator Fundamentals 101.2 Measuring Electricity
MAGNETISMMagnetism can be used to produce electricity and electricity can be used to produce magnetism.Much about magnetism cannot be expl
Page 11GENERAL INFORMATIONSECTION 1.1GENERATOR FUNDAMENTALSA SIMPLE AC GENERATORFigure 4 shows a very simple AC Generator. The gen-erator consists o
The revolving magnetic field is driven by the engine at constant speed. This constant speed is maintained by a mechanical engine governor. Uni
GENERAL INFORMATIONSECTION 1.2MEASURING ELECTRICITYPART 1Page 13METERSDevices used to measure electrical properties are called meters. Meters are avai
Page 14PART 1GENERAL INFORMATIONSECTION 1.2MEASURING ELECTRICITYCorrect engine and Rotor speed is maintained by an engine speed governor. Fo
GENERAL INFORMATIONSECTION 1.2MEASURING ELECTRICITYPART 1Component testing may require a specific resis-tance value or a test for INFINITY
INTRODUCTIONA typical brushless type portable generator will need 4 major components to function—a prime mover, a stator, a rotor, and a capac
GENERAL INFORMATIONSECTION 1.3BRUSHLESS, CAPACITOR EXCITATION SYSTEMOPERATIONSTARTUP:When the engine is started, residual magnetism from the rotor i
SAFETYThroughout this publication, “DANGER!” and “CAUTION!” blocks are used to alert the mechanic to special instructions concerning a particula
INTRODUCTIONA typical brushed type portable generator will need 4 major components to function: a prime mover, a sta-tor, a rotor, and a voltage reg
Page 19GENERAL INFORMATIONSection 1.4BRUSHED EXCITATION SYSTEMwindings and through the negative (-) slip ring and brush on Wire 0.The greater
Page 20NOTES
Page 21GP Series Portable GeneratorsPART 2 AC GENERATORSTABLE OF CONTENTSPART TITLE PAGE#2.1 Brushless Excitation Troubleshooting Flowcharts222.2 Bru
Page 22PART 2AC GENERATORSSECTION 2.1BRUSHLESS CAPACITOR TROUBLESHOOTING FLOWCHARTSThe GP series portable generators currently use three differe
AC GENERATORSSECTION 2.1BRUSHLESS CAPACITOR TROUBLESHOOTING FLOWCHARTSPART 2Page 23TEST 40 – CHECK & ADJUST ENGINE GOVERNOR, 389cc ENGINETEST 41 –
PART 2Page 24AC GENERATORSSECTION 2.2BRUSHED EXCITATION TROUBLESHOOTING FLOWCHARTSGO TO PROBLEM 6 GO TO PROBLEM 5GO TO PROBLEM 5 GO TO PROBLEM 7VOLTAG
AC GENERATORSSECTION 2.4BRUSHED EXCITATION TROUBLESHOOTING FLOWCHARTSPART 2Page 25TEST 40 – CHECK & ADJUST ENGINE GOVERNOR, 389cc ENGINETEST 41 –
INTRODUCTIONThe “Diagnostic Tests” in this chapter may be per-formed in conjunction with the “Flow Charts” of Section 2.1 and Section
AC GENERATORSSECTION 2.3AC DIAGNOSTIC TESTS2. Connect a VOM as shown in Figure 3 to each receptacle on the unit.Note: Only one outlet on each recepta
Page 1Specifications ... 2Part 1 – General Information ... 9Sect
* Warning: Do not field flash alternator more than two times in sequence. If the unit has not produced power after two attempts, other issues exist a
AC GENERATORSSECTION 2.3AC DIAGNOSTIC TESTSTEST 6 – CHECK CAPACITORDISCUSSION:The brushless rotor system relies on the charging and discharging of a
TEST 7 – TEST BRUSHLESS DPE WINDINGDISCUSSION:A DPE or Displaced Phase Excitation winding is used to charge a capacitor, which discharges and charges,
AC GENERATORSSECTION 2.3AC DIAGNOSTIC TESTSTEST 9 – TEST BRUSHED STATOR WINDINGSDISCUSSION:Most brushed stators have three main windings that a
6. Ensure all material is clear of the alternator before pro-ceeding.7. Set START-STOP-RUN switch to START8. Refer to Figure 10 for location of ad
PART 3 ENGINE TROUBLESHOOTINGGP Series Portable GeneratorsPage 33TABLE OF CONTENTSPART TITLE PAGE#3.1 389/206/163cc Troubleshooting Flow Charts343.2
Page 34PART 3ENGINE TROUBLESHOOTINGSECTION 3.1389/206/163cc TROUBLESHOOTING FLOW CHARTSNOTHING FOUNDFIX BAD COMPONENTBADVISUALLY INSPECT FOR OBSTRUCTI
Page 35SECTION 3.1389/206/163cc TROUBLESHOOTING FLOW CHARTSENGINE TROUBLESHOOTINGPART 3ADJUST AND RE-TESTREPAIR OR REPLACEOFFTURN ONGOODGOODSPARKGOODG
Page 36PART 3ENGINE TROUBLESHOOTINGSECTION 3.1389/206/163cc TROUBLESHOOTING FLOW CHARTSBADREPLACEBADBADREPLACEREPLACE MAGNETOREPAIR OR REPLACEGOODGOOD
SECTION 3.2410cc TROUBLESHOOTING FLOW CHARTSPage 37ENGINE TROUBLESHOOTINGPART 3RECHARGE OR REPLACE BATTERY– CLEAN, REPAIR OR REPLACE BAD CABLE(S)BADRE
Page 2SPECIFICATIONS – GP1800AHMOutletsA(2) 5-20R 120VCircuit BreakersM(1) 20AOther FeaturesHOn/Off SwitchProduct Series GP1800A/C Rated Output Watts:
PART 3Page 38DC CONTROLSECTION 3.2410cc TROUBLESHOOTING FLOW CHARTSBADPULL OUTADJUST AND RE-TESTREPAIR OR REPLACEREPLACEREPLACEOFFTURN ONGOODGOODSPARK
Page 39SECTION 3.2410cc TROUBLESHOOTING FLOW CHARTSDC CONTROLPART 3REPAIR OR REPLACEREPAIR OR REPLACEBADBADGOODGOODGOODTEST 26 – CHECK SPARKCHECK FUEL
Page 40 PART 3ENGINE TROUBLESHOOTINGSECTION 3.2410cc TROUBLESHOOTING FLOW CHARTSBADBADREPLACEREPAIR OR REPLACEGOODGOODBADBAD - ENGINE MISS APPARENTGOO
Page 41NOTES
Page 42TEST 20 – CHECK 1.5 AMP FUSEFigure 1. A Typical 1.5 Amp FuseDISCUSSION:The fuse protects the wiring and the battery charger from a short
SECTION 3.3DIAGNOSTIC TESTSPage 433. Connect one meter lead to Terminal 2 and connect the other meter lead to Terminal 1. Actuate switch to
Page 44PROCEDURE:The battery should have been checked prior to this test and should be fully charged.Set a voltmeter to measure DC volta
SECTION 3.3DIAGNOSTIC TESTSPage 45Figure 7. TachometerMETAL STOCK1/4" THICK STEEL12"1.0"4"2"2.625"3.5"0.5"0.5&
Page 46SPARK TESTER CLAMPGROUNDED TOCYLINDER HEADSPARK TESTER SPARK PLUGBOOTFigure 10. Testing Ignition SystemSPARK TESTER CLAMPCONNECTED TOSPARK PLUG
SECTION 3.3DIAGNOSTIC TESTSPage 47• Waterinfuel.• Intakevalvestuckopen.• Needle/floatstuckopen.If the spark plug is dry look for the follow
SPECIFICATIONS – GP3250Page 3HAMOutletsA(4) 5-20R 120VCircuit BreakersM(2) 20AOther FeaturesHOn/Off SwitchProduct Series GP3250A/C Rated Output Watts:
Page 48CROW'S FOOTFigure 15. Tightening the Jam NutINSTALL ROCKER ARM COVER1. Use a new rocker arm cover gasket. Install the rocker arm
SECTION 3.3DIAGNOSTIC TESTSPage 49SPARK PLUGENGINE WIRE HARNESSREMOVE LEADFLYWHEEL KEYWIRE 18 TO START-RUN-STOP SWITCH (SHUTDOWN LEAD)Figure 16. Engin
Page 503. Tighten the governor lever clamp bolt to 110 inch-pounds.RUNNING ADJUSTMENT:After completing the initial adjustment, final ad
SECTION 3.3DIAGNOSTIC TESTSPage 51GOVERNORSHAFTPRIMARYADJUSTSCREWGOVERNORCLAMPBOLTFigure 20. Engine Governor Adjustment (410cc Engine)4. Connect a
Page 52(2) If oil pressure is below about 10 psi, shut engine down immediately. A problem exists in the engine lubrication system. Refe
PART 4 DISASSEMBLYGP Series Portable GeneratorsPage 53TABLE OF CONTENTSPART TITLE4.1. Major Disassembly
MAJOR DISASSEMBLYDISCUSSION.Each generator will have its own unique method of disassembly. Provided is a simplified version of disassembly that does
DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPART 4Page 55
PART 4Page 56DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYExploded View – GP1800 – Drawing No. 0H0609-A
Page 57DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPART 4ITEM QTY. DESCRIPTION1 1 ENGINE, 196CC2 1 RECOIL ASSEMBLY3 1 CARBURETOR4 1 AIR CLEANER COVER5 1 AI
Page 4SPECIFICATIONS – GP5000HBNMAReceptaclesA(4) 5-20R 120VBL14-30R Twist-Lock 120/240VCircuit BreakersM(2) 20AN(2) 25AOther FeaturesHHour Meter with
Page 58PART 4DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPORTABLE KITExploded View – GP3250 – Drawing No. 0H0522-C
Page 59DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPART 4ITEM QTY. DESCRIPTION1 1 ENGINE, 208CC2 1 RECOIL ASSEMBLY3 1 CARBURETOR4 1 AIR CLEANER COVER5 1 AI
Page 60PART 4DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLY1232324255484647505118492064717525354551945434441421615131112810353637143293027282638333931342940E
Page 61DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPART 4ITEM QTY. DESCRIPTION1 1 FRAME PARTS2 1 ASSY CRADLE BASE3 1 CRADLE END4 1 PANEL RAIL5 1 BACK RAIL6
Page 62PART 4DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYExploded View – GP5500 – Drawing No. 0H1253-A
Page 63DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPART 4ITEM QTY. DESCRIPTION2 1 ASSY CRADLE BASE3 1 CRADLE END3A 1 ASSEMBLY, FRAME 1 PIECE4 1 PANEL RAIL5
Page 64PART 4DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLY123232425548464750511849206471752531945434441421615131112810353637143293027282638333931342940Explo
Page 65DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPART 4ITEM QTY. DESCRIPTION1 1 FRAME PARTS2 1 ASSY CRADLE BASE3 1 CRADLE END4 1 PANEL RAIL5 1 BACK RAIL6
Page 66PART 4DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYExploded View – GP7000 – Drawing No. 0G9384D-B
Page 67DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPART 4ITEM QTY. DESCRIPTION1 1 CRADLE END2 1 BACK RAIL3 10CURVED HEAD BOLT 5/16-18 x 1.625" LONG4 1
Page 5SPECIFICATIONS – GP5500HBNMAReceptaclesA(4) 5-20R 120VBL14-30R Twist-Lock 120/240VCircuit BreakersM(2) 20AN(2) 25AOther FeaturesHHour Meter with
Page 68PART 4DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYExploded View – GP8000 – Drawing No. 0G9384F-B
Page 69DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLYPART 4ITEM QTY. DESCRIPTION1 1 CRADLE END2 1 BACK RAIL3 10 CURVED HEAD BOLT 5/16-18 x 1.625" LONG4
Page 70PART 4DISASSEMBLYSECTION 4.1MAJOR DISASSEMBLY
PART 5 ELECTRICAL DATAGP Series Portable GeneratorsPage 71TABLE OF CONTENTSDWG# TITLE PAGE0H0612-AElectrical Schematic, GP1850 720H0523-AElectrical S
PART 5ELECTRICAL DATAELECTRICAL SCHEMATIC, GP1850Page 72SENSINGDPEBrushed Alternator Drawing No. 0H0612-A
ELECTRICAL DATAELECTRICAL SCHEMATIC, GP3250PART 5Page 73Brushed Alternator Drawing No. 0H0523-ASENSINGDPE
PART 5ELECTRICAL DATAELECTRICAL SCHEMATIC, GP5000/5500/6500Page 74Brushed Alternator Drawing No. 0G9769-C
ELECTRICAL DATAWIRING DIAGRAM, GP5000/5500/6500PART 5Page 75Brushed Alternator Drawing No. 0G9769-C
PART 5 ELECTRICAL DATAELECTRICAL SCHEMATIC, GP7000E/8000EBrushless Alternator Drawing No. 0G9849-APage 76
ELECTRICAL DATAWIRING DIAGRAM, GP7000E/8000EPART 5Brushless Alternator Drawing No. 0G9849-APage 77
SPECIFICATIONS – GP6500Page 6Product Series GP6500A/C Rated Output Watts: 6500A/C Maximum Output Watts: 8000A/C Voltage 120/240VACA/C Frequency 60 HzR
Page 78ELECTRICAL FORMULASTO FIND KNOWN VALUES 1-PHASEKILOWATTS (kW)Volts, Current, Power FactorE x I1000KVAVolts, CurrentE x I1000AMPERESkW, Volts, P
Page 80NOTES
Generac Power Systems, Inc.S45 W29290 Hwy. 59 • Waukesha, WI 531891-888-GENERAC (1-888-436-3722) • generac.comPart No. 0H0285 rev. A / Printed in USA
Page 7SPECIFICATIONS – GP7000/GP7000EProduct Series GP7000A/C Rated Output Watts: 7000A/C Maximum Output Watts: 8750A/C Voltage 120/240VACA/C Frequenc
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