GP Series

®
DIAGNOSTIC
REPAIR
MANUAL
GP Series and UltraSource

Portable Generators
MODELS:
Model 4451, 4986 (12.5 kW)
5734, 4582, 4987 (15 kW)
5735, 4583, 5308 (17.5 kW)
P O R T A B L E G E N E R AT O R S
Safety Read This Manual Thoroughly
Throughout this publication and on tags and decals This diagnostic manual has been written and published
affixed to the generator, DANGER, WARNING, and by Generac to aid dealer technicians and company
CAUTION blocks are used to alert personnel to special service personnel when servicing the products described
instructions about a particular operation that may be herein.
hazardous if performed incorrectly or carelessly. Observe It is assumed that these personnel are familiar with the
them carefully. Their definitions are as follows: servicing procedures for these products, or like or similar
products manufactured and marketed by Generac, and
DANGER that they have been trained in the recommended
servicing procedures for these products, including the
Indicates a hazardous situation which, if not avoided, use of common hand tools and any special Generac tools
will result in death or serious injury. or tools from other suppliers.
(000001) Generac could not possibly know of and advise the
service trade of all conceivable procedures by which a
service might be performed and of the possible hazards
WARNING and/or results of each method. We have not undertaken
any such wide evaluation. Therefore, anyone who uses a
Indicates a hazardous situation which, if not avoided, procedure or tool not recommended by Generac must
could result in death or serious injury. first satisfy themselves that neither his nor the products
safety will be endangered by the service procedure
(000002)
selected.
All information, illustrations and specifications in this
CAUTION manual are based on the latest product information
available at the time of publication.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury. When working on these products, remember that the
electrical system and engine ignition system are capable
(000003) of violent and damaging short circuits or severe electrical
shocks. If you intend to perform work where electrical
NOTE: Notes provide additional information important to terminals could be grounded or touched, the battery
a procedure or component. cables should be disconnected at the battery.
Any time the intake or exhaust openings of the engine
These safety alerts cannot eliminate the hazards they
are exposed during service, they should be covered to
indicate. Observing safety precautions and strict
prevent accidental entry of foreign material. Entry of such
compliance with the special instructions while performing
materials will result in extensive damage when the
the action or service are essential to preventing
engine Is started.
accidents.
During any maintenance procedure, replacement
fasteners must have the same measurements and
WARNING strength as the fasteners that were removed. Metric bolts
California Proposition 65. Engine exhaust and some and nuts have numbers that indicate their strength.
of its constituents are known to the state of California Customary bolts use radial lines to indicate strength
to cause cancer, birth defects, and other reproductive while most customary nuts do not have strength
harm. (000004) markings. Mismatched or incorrect fasteners can cause
damage, malfunction and possible injury.
WARNING
Replacement Parts
California Proposition 65. This product contains or
When servicing this equipment, it is extremely important
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive that all components be properly installed and tightened. If
harm. improperly installed and tightened, sparks could ignite
(000005) fuel vapors from fuel system leaks.
ii Diagnostic Repair Manual

Table of Contents
Safety .......................................................................... ii Section 3 Troubleshooting Flowcharts ....................27
Read This Manual Thoroughly .................................... ii Introduction ...............................................................27
Replacement Parts ..................................................... ii Section 4 AC Diagnostic Tests .................................35
Section 1 Description and Components ....................1 Introduction ...............................................................35
Introduction .................................................................1 Safety .......................................................................35
Engine-Generator Drive System .................................1 Important Note Concerning Connectors ...................35
The AC Generator ......................................................1 Test 1 – Check No-Load Voltage and Frequency ....35
Rotor Assembly ..........................................................1 Test 2 – Check Main Circuit Breaker ........................36
Stator Assembly ..........................................................1 Test 3 – Test Excitation Circuit Breaker ...................36
Brush Holder and Brushes .....................................2 Test 4 – Fixed Excitation Test/Rotor Amp Draw Test 36
Other AC Generator Components ..............................2 Test 5 – Check Stepper Motor Control .....................38
Excitation Circuit Breaker .......................................2 Test 6 – Wire Continuity ...........................................39
Voltage Regulator ...................................................2 Test 7 – Check Field Boost ......................................40
Adjustment Procedure Test 8 – Diode/Resistor ............................................40
(12.5 kW and Older 15 kW Units) ............................3
Test 9 – Test Stator ..................................................41
Adjustment Procedure
Test 10 – Sensing Leads ..........................................42
(Newer 15 kW and All 17.5 kW Units) .....................3
Test 11 – Excitation Wiring .......................................43
Circuit Breakers ......................................................3
Test 12 – Check Brush Leads ..................................43
Rotor Residual Magnetism .........................................3
Test 13 – Check Brushes & Slip Rings .....................44
Field Boost Circuit .......................................................3
Test 14 – Check Rotor Assembly .............................44
Operation ....................................................................4
Startup ....................................................................4 Test 15 – Check Load Voltage & Frequency ............45
On-Speed Operation ..............................................4 Test 16 – Check Load Watts and Amperage ............45
Field Excitation .......................................................4 Test 17 – Check Battery Charge Output ..................45
AC Power Winding Output ......................................4 Test 18 – Check 10 Amp Battery Charge Output .....45
Battery Charge Winding Output ..............................4 Test 19 – Check Battery Charge Rectifier (BCR2) ...46
10 Amp Battery Charge Winding Output ................4 Test 20 – Check 10 Amp Circuit Breaker .................46
Specifications ..............................................................5 Test 21 – Check 10 Amp Fuse .................................47
Test 22 – Check Battery and Cables ........................47
Section 2 Engine DC Control System ........................7
Test 23 – Check Voltage At Starter Contactor (SC) .48
Printed Circuit Board ...................................................7
General Theory .......................................................7 Test 24 – Check Starter Contactor (SC) ...................48
Test 25 – Check Starter Motor .................................48
Circuit Board Connections ......................................7
Dip Switch Positions ...............................................7 Test 26 – Test Starter Contactor Relay (SCR) .........49
Battery ........................................................................7 Test 27 – Check Start-Run-Stop Switch (SW1) ........50
Recommended Battery ...........................................7 Test 28 – Check Start-Run-Stop Switch (SW1) Wiring .50
Control Panel Component Identification .....................8 Test 29 – Check Ignition Spark ................................50
Operational Analysis (Older Units) ...........................10 Test 30 – Check Spark Plugs ...................................51
Circuit Condition - Rest .........................................10 Test 31 – Remove Wire 18 / Shutdown Lead ...........51
Circuit Condition - Start ........................................12 Test 32 – Test Start Stop Relay (SSR) .....................51
Circuit Condition - Run .........................................14 Test 33 – Test Wire 167 ...........................................52
Circuit Condition - Stop .........................................16 Test 34 – Test Start Stop Relay Wiring ....................53
Fault Shutdown .....................................................17 Test 35 – Check and Adjust Ignition Magnetos ........54
Operational Analysis (Newer Units) ..........................18 Test 36 – Test Fuel Shutoff Solenoid (FSS) .............55
Circuit Condition - Rest .........................................18 Test 37 –Test Fuel Shutoff Solenoid Voltage ...........55
Circuit Condition - Start ........................................20 Test 38 – Check Fuel Pump .....................................55
Circuit Condition - Run .........................................22 Test 39 – Check Carburetion ....................................55
Circuit Condition - Stop .........................................24 Test 40 – Valve Adjustment ......................................56
Fault Shutdown .....................................................24 Test 41 – Check Engine / Cylinder Leak
Down Test / Compression Test ................................57
Test 42 – Check Oil Pressure Switch and Wire 86 ...58
Diagnostic Repair Manual iii

Table of Contents
Test 43 - Check Start Stop Relay (SSR) ..................58 Section 6 Electrical Data ...........................................75
Test 44 – Test Starter Contactor Relay (SCR) .........59 Introduction ...............................................................75
Test 45 – Check Wire 15 Circuit ...............................59 Wiring Diagram 12.5 & 15 kW
Test 46 – Check Wire 14 Circuit ...............................59 (Units Without Hourmeter) –
Test 47 – Check Fuel Shutoff Solenoid (FSS) ..........59 Drawing No. 0E0228 .............................................76
Test 48 – Check Hour Meter .....................................60 Wiring Diagram 12.5 & 15 kW
(Units Without Hourmeter) –
Test 49 – Check Wire 15B ........................................60
Drawing No. 0E0228 .............................................77
Test 50 – Check Wire 167 ........................................60
Electrical Schematic 12.5 & 15 kW
Test 51 – Check Wires 11S & 44S or 11S & 22S .....60 (Units Without Hourmeter) –
Test 52 – Check Idle Control Switch (SW2) .............61 Drawing No. 0E0229-A ..........................................78
Test 53 – Check Idle Control Wiring .........................61 Electrical Schematic 12.5 & 15 kW
Test 54 – Check Idle Control Transformers (ICT) .....62 (Units Without Hourmeter) –
Test 55 – Check TR1 & TR2 Wiring .........................62 Drawing No. 0E0229-A ..........................................79
Test 56 – Choke Test ...............................................63 Wiring Diagram 12.5 & 15 kW
Insulation Resistance ................................................63 (Units With Hourmeter) –
Drawing No. 0D4609-D .........................................80
The Megohmmeter ...................................................63
Wiring Diagram 12.5 & 15 kW
Introduction ...........................................................63
(Units With Hourmeter) –
Testing Stator Insulation .......................................63 Drawing No. 0D4609-D .........................................81
Testing Rotor Insulation ........................................63 Electrical Schematic 12.5 & 15 kW
Hi-Pot Tester .............................................................64 (Units With Hourmeter) –
Stator Insulation Resistance Test .............................64 Drawing No. 0D6297-A .........................................82
Testing All Stator Windings To Ground ................64 Electrical Schematic 12.5 & 15 kW
Test Between Windings ........................................65 (Units With Hourmeter) –
Rotor Insulation Resistance Test ..............................65 Drawing No. 0D6297-A .........................................83
Cleaning the Generator ............................................65 Wiring Diagram 17.5 kW –
Drying the Generator ................................................65 Drawing No. 0G0731 .............................................84
Wattage Reference Guide ....................................66 Wiring Diagram 17.5 kW –
Drawing No. 0G0731 .............................................85
Section 5 Disassembly ..............................................67
Electrical Schematic 17.5 kW –
Major Disassembly ...................................................67
Drawing No. 0G0733 .............................................86
Electrical Schematic 17.5 kW –
Drawing No. 0H0729 .............................................87
Wiring Diagram 17.5 kW –
Drawing No. 0H0730 .............................................88
Wiring Diagram 17.5 kW –
Drawing No. 0H0730 .............................................89
Wiring Diagram, 17.5 kW Manual Transfer
Switch – Drawing No. 0G1065 ..............................90
Interconnection Drawing – 17.5 kW generator
connected to the external connection box, manual
transfer switch and home’s main electrical
distribution panel ...................................................91
Diagnostic Repair Manual iv

Section 1 Description and Components
Introduction Engine-Generator Drive System
The generator revolving field (rotor) is driven by an air- See Figure 1-1. The generator revolving field is driven by
cooled engine at 3600 rpm. an air-cooled, horizontal crankshaft engine. The
The generator may be used to supply electrical power for generator is directly coupled to the engine crankshaft.
the operation of 120 and, or 240 volts, single-phase, 60 Both the engine and generator rotor are driven at
Hz, AC loads. approximately 3600 rpm, to provide a 60 Hz AC output.
The AC Generator
Figure 1-1 shows major components of the AC
generator.
A. Brush Holder Assembly

B. Rotor
C. Stator
D. Rear Bearing Carrier
E. Engine Adapter C
F. Engine
A B
004715
Figure 1-1. AC Generator Major Components
Rotor Assembly Stator Assembly

The 2-pole rotor must maintain 3600 rpm to supply a 60 The stator can houses the dual AC power windings, an
Hertz AC frequency. The term “2-pole” means the rotor excitation winding, and two battery charge windings.
has a single north magnetic pole and a single south See Figure 1-2. A total of thirteen (13) stator leads
magnetic pole. As the rotor rotates, the lines of magnetic extend from the stator can.
flux cut across the stator assembly windings and a
voltage is induced into the stator windings. The rotor NOTE: On older style generators the sense leads are
shaft mounts a positive (+) and a negative (-) slip ring, 11S and 44S. On newer style generators the sense leads
with the positive (+) slip ring nearest the rear bearing are 11S and 22S.
carrier. The rotor bearing is pressed onto the end of the The stator can is positioned between an engine adapter
rotor shaft. The tapered rotor shaft is mounted to a and a rear bearing carrier. It is retained in position by four
tapered crankshaft and is held in place with a single stator studs.
through bolt.
Diagnostic Repair Manual 1

Other AC Generator Components

Some AC generator components are housed in the
E
generator control panel enclosure. These are the
A B C D G H I J K L M
F
excitation circuit breaker, the voltage regulator, and the
main line circuit breaker.
Excitation Circuit Breaker

See Figure 1-4. The excitation circuit breaker (CB2) is
housed in the generator control panel enclosure and
electrically connected in series with the excitation (DPE)
winding output to the voltage regulator. The breaker is
Item Wire Number Winding
004714 self-resetting, therefore its contacts will close again when
A 11 Power Winding
excitation current drops to a safe value.
B 44 Power Winding
C 22 Power Winding If the circuit breaker has failed open, excitation current
D 11S Sense Lead Power flow to the voltage regulator and rotor windings will be
E 44S Sense Lead Power (Older Style) lost. Without excitation current flow, AC voltage induced
F 22S Sense Lead Power (Newer Style) into the stator AC power windings will drop to a value in
G 55A Battery Charge proportion with the rotor residual magnetism.
H 66A Battery Charge
I 77A Battery Charge 162
J 2 Excitation 2
K 6 Excitation
L 55 10 Amp Battery Charge
M 66 10 Amp Battery Charge
N 77 10 Amp Battery Charge
Figure 1-2. Stator Assembly Leads
Brush Holder and Brushes

The brush holder is retained to the rear bearing carrier 003292
003292
with two self-tapping screws. A positive (+) and a
negative (-) brush are retained in the brush holder, with Figure 1-4. Excitation Circuit Breaker
the positive (+) brush riding on the slip ring nearest the
rotor bearing. Voltage Regulator
See Figure 1-3. Wire 4 connects to the positive (+) brush A typical Voltage Regulator is shown in Figure 1-5 (12.5
and wire 0 to the negative (-) brush. Wire 0 connects to kW & Older 15 kW Units) or Figure 1-6 (Newer 15 kW
frame ground. Rectified and regulated excitation current, and all 17.5 kW Units). See Figure 1-4. Unregulated AC
as well as current from a field boost circuit, are delivered output from the stator excitation winding is delivered to
to the rotor windings via wire 4, and the positive (+) brush the regulator’s DPE terminals, via wire 2, the excitation
and slip ring. The excitation and field boost current circuit breaker and wire 162, and wire 6. The voltage
passes through the windings and to frame ground via the regulator rectifies the current and based on stator AC
negative (-) slip ring and brush, and wire 0. This current power winding sensing, regulates it. The rectified and
flow creates a magnetic field around the rotor having a regulated excitation current is then delivered to the rotor
flux concentration that is proportional to the amount of windings from the positive (+) and negative (-) regulator
current flow. terminals, via wire 4 and wire 0. Stator AC power winding
sensing is delivered to the regulator “SEN” terminals via
wires 11S and 44S, or 11S and 22S, depending on the
model.
The regulator provides over-voltage protection, but does
not protect against under-voltage. On occurrence of an
over-voltage condition, the regulator will shut down and
complete loss of excitation current to the rotor will occur.
Without excitation current, the generator AC output
voltage will drop to approximately one-half (or lower) of
004644
the unit’s rated voltage.
Figure 1-3. Brush Holder and Brushes
2 Diagnostic Repair Manual

4. Turn the regulator voltage adjust pot clockwise to

obtain a line to line voltage of 238-242 VAC.
NOTE: If the red regulator LED is flashing, slowly turn
the Stability pot either direction until flashing stops.
Adjustment Procedure (Newer 15 kW and All

17.5 kW Units)
A single red lamp (LED) illuminates during normal
004711 operation. The lamp will become dim if excitation winding
Figure 1-5. Voltage Regulator Found on 12.5 kW and AC output diminishes. It will extinguish on occurrence of
Older Style 15 kW Units (Typical) an open condition in the sensing AC output circuit.
An adjustment potentiometer permits the stator AC
power winding voltage to be adjusted. Perform this
adjustment with the generator running at no-load, and
with a 62 Hz AC frequency (62 Hz equals 3720 rpm). At
the stated no-load frequency, adjust to obtain a line-to-
line AC voltage of approximately 252 volts.
Circuit Breakers
004712 Each individual outlet on the generator is protected by a
circuit breaker to prevent overload.
Figure 1-6. Voltage Regulator Found on Newer Style
15 kW Units and All 17.5 kW Units (Typical)
Rotor Residual Magnetism
Adjustment Procedure (12.5 kW and Older 15 The generator revolving field (rotor) may be considered
to be a permanent magnet. Some residual magnetism is
kW Units)
always present in the rotor. This residual magnetism is
The voltage regulator is equipped with three light emitting sufficient to induce a voltage into the stator AC power
diodes (LED’s). These LED’s are normally on during windings of approximately 2-12 VAC.
operation when no system faults exist. The red regulator
LED is on when the regulator is on and functioning. The
yellow sensing LED is powered by sensing input to the
Field Boost Circuit
regulator from the stator AC power windings. The green When the engine is cranked during start-up, the start stop
excitation LED is powered by stator excitation winding relay (SSR) will be energized. The normally open contacts
output. of the SSR will close and wire 15 will supply 12 VDC to
wire 14. Connected to wire 14 is a resistor (R1) and a
The following four adjustment potentiometers are
diode (D1). The resistor will limit current flow, and the
provided:
diode will block voltage regulator DC output. Once
• Voltage Adjust through the resistor and diode it becomes wire 4, and wire
• Gain 4 then connects to the positive brush. The effect is to flash
the field every time the engine is cranked. Field boost
• Stability
current ensures sufficient pickup voltage is available on
• Under Frequency Adjust every startup to turn the voltage regulator on and build AC
1. Connect an AC voltage/frequency meter across output voltage.
wires 11 and 44 at the 50A main circuit breaker. While the SSR remains energized, field boost current is
Verify frequency is between 59-61Hz. always available during cranking and running. Diode D1
2. On the regulator, set the adjustment pots as prevents or blocks the higher voltage regulator DC output
follows: from reaching the wire 14 run circuit.
• Voltage Adjust – turn fully counterclockwise Field boost voltage is reduced from battery voltage by
resistor R1. A digital multimeter will indicate
• Gain – turn to midpoint (12 O’clock)
approximately 9 to 10 VDC.
• Stability – turn to midpoint (12 O’clock)
• Under Frequency – turn to midpoint (12 O’clock)
3. Start the generator. This adjustment will be done
under a no-load condition.

Operation The AC power winding voltage initially sensed by the

regulator is low. The regulator reacts by increasing the
Startup flow of field excitation current to the rotor until voltage
increases to a desired level. The regulator then monitors
When the engine is started, residual plus field boost
and maintains the desired voltage. For example, if
magnetism from the rotor induces a voltage into the
voltage exceeds the desired level, the regulator will
stator AC power windings, the stator excitation or DPE
decrease the flow of field excitation current. However, if
windings, and the stator battery charge windings. In an
voltage drops below the desired level, the regulator
“on-speed” (engine cranking) condition, residual plus
responds by increasing the flow of field excitation current.
field boost magnetism are capable of creating
approximately one-half the rated unit voltage.
AC Power Winding Output
On-Speed Operation A regulated voltage is induced into the stator AC power
windings. When electrical loads are connected across
As the engine accelerates, the voltage induced into the
the AC power windings to complete the circuit, current
stator windings increases rapidly, with the increasing
can flow in the circuit. The regulated AC power winding
rotor speed.
output voltage will be in direct proportion to the AC
Field Excitation frequency. For example, on units rated 120/240 volts at
60 Hz, the regulator will try to maintain 240 volts (line-to-
An AC voltage is induced into the stator excitation (DPE) line) at 60 Hz. This type of regulation system provides
windings. The DPE winding circuit is completed to the greatly improved motor starting capability over other
voltage regulator, via wire 2, excitation circuit breaker, types of systems.
wire 162, and wire 6. Unregulated alternating current can
flow from the winding to the regulator. Battery Charge Winding Output
The voltage regulator senses AC power winding output A voltage is induced into the battery charge winding.
voltage and frequency via stator wires 11S and 44S, or Output from these windings is delivered to a battery
11S and 22S. charge rectifier (BCR2), via wires 55A, 66A and 77A. The
The regulator changes the AC from the excitation resulting direct current from the BCR is delivered to the
winding to DC. In addition, based on the sensing signals, unit battery, via wire 15, a 10 amp fuse, and wire 13. This
it regulates the flow of direct current to the rotor. output is used to maintain battery state of charge during
The rectified and regulated current flow from the operation.
regulator is delivered to the rotor windings, via wire 4,
and the positive brush and slip ring. This field excitation 10 Amp Battery Charge Winding Output
current flows through the rotor windings and is directed to A voltage is induced into the battery charge winding.
ground through the negative (-) slip ring and brush, and Output from these windings is delivered to a battery
wire 0. charge rectifier (BCR1), via wires 55, 66 and 77. The
The greater the current flow through the rotor windings, resulting direct current from the BCR is delivered to the
the more concentrated the lines of flux around the rotor 12 VDC receptacle, via wire 13A, CB1, and wire 15A.
become. This receptacle allows the capability to recharge a 12
VDC storage battery with provided battery charge cables.
The more concentrated the lines of flux around the rotor
that cut across the stationary stator windings, the greater
the voltage that is induced into the stator windings.

Specifications
GPS 15000
GPS 12500 GPS 17500
MODEL Ultra Source/Guardian/
Ultra Source/Centurion Ultra Source/Guardian
Centurion
004582
004583
004451 004987
Model # 005308
004986 005209
005735
005734
GENERATOR SPECIFICATIONS
Rated Max. Power 12.5 kW 15.0 kW 17.5 kW
Surge Power 18.75 kW 22.5 kW 26.25 kW
Rated AC Voltage 120/240 120/240 120/240
Rated Max AC Load – – –
Current @ 240V 52.0 Amps 62.5 Amps 72.9 Amps
Current @ 120V 104.0 Amps 125.0 Amps 145.8 Amps
Rated Frequency 60 Hz @ 3600 RPM 60 Hz @ 3600 RPM 60 Hz @ 3600 RPM
Phase Single Phase Single Phase Single Phase
Rated DC Voltage 12 Volts 12 Volts 12 Volts
Rated Max DC Load Current @ 12 Volts 10 Amperes 10 Amperes 10 Amperes
ENGINE SPECIFICATIONS
Rated Horsepower @3600 RPM 27 30 33
Displacement 763 cc 992 cc 992 cc
Spark Plug Type Champion RC14YC or Equivalent
Spark Plug Gap 0.040 inch or (1.01 mm)
Gasoline Capacity 16 U.S. gallons (60.56 liters)
Summer – SAE 30 or 10W-30

Oil Type
Winter – Synthetic 5W-20 or 5W-30
Oil Capacity w/ Filter Change = 1.7 Qts. (1.6 liters) w/o Filter Change = 1.4 Qts. (1.32 liters)
Run Time/Fuel Consumption-1/2 Load 10 Hours / 1.6 gallons (6.05 liters) per hour
ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS
LOAD % VOLTAGE (VAC) FREQUENCY (Hz)
0 238-242 59-61
50 238-242 59-61
100 238-242 59-61
Refer to Engine Service Manual No. 0F6923 for complete GTV-760/990 V-Twin OHVI engine service information.

TORQUE SPECIFICATIONS
Flywheel Nut 150 ft-lbs
Cylinder Head Bolts 22 ft-lbs
Valve Cover Bolts 4.8-5.5 ft-lbs
Rocker Arm Jam Nut 14 ft-lbs
Ignition Coil 9 ft-lbs
Intake Manifold 14 ft-lbs
Exhaust Manifold 14 ft-lbs
Stator Bolts 6 ft-lbs
Rotor Bolt 30 ft-lbs
Spark Plug 15 ft. lbs.
Starter Bracket To Block 18 ft-lbs
TRIM TORQUE SPECIFICATIONS
M3-.5 Phillips Pan Head Screw Into Aluminum 50 in-lbs
M6-1 Taptite Screw Into Aluminum 96 in-lbs
M6-1 Taptite Screw Into Weldnut 96 in-lbs
M8-1.25 Taptite Screw Into Aluminum 18 ft-lbs

Section 2 Engine DC Control System
Printed Circuit Board
General Theory Table 2-1. Receptacle J2 Functions
Terminal Wire Function
The printed circuit board is responsible for cranking,
startup, running and shutdown operations. It 12 VDC input when the start stop relay
interconnects with other components of the DC control 1 15B
(SSR) is energized.
system to cycle them on and off at the proper times. It is
powered by fused 12 VDC power from the unit battery. Ground input when the idle control switch
2 83
(SW2) is placed in the CLOSED position
Circuit Board Connections AC voltage input from the idle control
3 TR1
transformers.
See Figure 2-1. The circuit board mounts 12-pin
receptacle J2 and 5-pin receptacle J1. Table 2-1 shows 4 0 Common ground for the PCB
12-pin receptacle J2, the associated wires and the
function of each pin and wire. 12 VDC input when SW1 is placed in
the START position. Ground input
5 167
Dip Switch Positions when SW1 is placed in the STOP
position.
NOTE: See Figure 2-1. These switches must remain in
AC voltage input from the idle control
the factory settings. 6 TR2
transformers.
1. Stepper Motor Rotation
Fault shutdown circuit. When grounded
a. Switch set to ON for clockwise rotation 7 86 by closure of the low oil pressure
(Factory Position). switch (LOP) engine will shut down.
b. Switch set to OFF for counterclockwise
Switched to ground for start stop relay
rotation. 8 229
(SSR) operation.
2. Frequency Setting
9 NOT USED
a. Switch set to OFF for 60 Hertz (Factory
Position). AC input for frequency control. 11S/
10 44S
b. Switch set to ON for 50 Hertz. 44S 240VAC (Older Style)
AC input for frequency control. 11S/

A 22S
22S 240 VAC (Newer Style)
11 NOT USED
AC input for frequency control. 11S/

12 11S
B 44S 240 VAC or 11S/22S 240 VAC
NOTE: J1 connector is utilized for governor control.
Battery
Recommended Battery
When anticipated ambient temperatures will be
consistently above 32 °F. (0 °C.), use a 12 VDC Group
U1 storage battery capable of delivering at least 360
C CCA (cold cranking amperes).
A. Dip Switches C. J2 Connector

B. Sensing LED D. J1 Connector
004571
Figure 2-1. Printed Circuit Board

Control Panel Component Identification

B C
F G H I J K L M N O
004572
Figure 2-2. Control Panel Component Identification (Older Units)
A. Voltage Regulator I. 10 Amp Auto Reset Breaker (CB1)

B. 10 Amp Fuse (F1) J. Connector (C2)
C. 50 Amp Circuit Breaker K. Starter Contactor Relay (SCR)
D. Start Stop Relay (SSR) L. Connector (C1)
E. Printed Circuit Board M. Resistor (R1)
F. Terminal Board (TB2) N. Diode (D1)
G. Excitation Circuit Breaker (CB2) O. Battery Charge Rectifiers (BCR1 & BCR2)
H. Terminal Board (TB2) P. Idle Control Transformers (ICT)
B C N
K
E G I P L J M O
004573
Figure 2-3. Control Panel Component Identification (Newer Units)

44S OLDER
55A
22S NEWER 44S OLDER 55A 66A 77A
77A 2
66A 22S NEWER
11S 11S PIN
PIN 2 PIN LOCATION
LOCATION LOCATION 6
6 1
C1 FEMALE SIDE C1 MALE SIDE
PIN
PIN 55 0 LOCATION
LOCATION 77 12 77
0 55 PIN
7 6 66 4
4 66 6 LOCATION
7
86 PIN
0
86 0 18 PIN LOCATION
18 6
LOCATION 15 167 13
13 167 15
PIN 1
LOCATION
6
C2 FEMALE SIDE C2 MALE SIDE
PIN 17
LOCATION 15
0
7 14 13 PIN PIN
16 17
LOCATION 0 15 LOCATION
12 14 7
13 16
44S OLDER
22S NEWER
86 15B 167 BLK
0 229 83 BLK 11S
TERMINAL BLOCK
TERMINAL BLOCK (TB2)
(TB1)
TR2
TR1
004574
Figure 2-4. Connector Pin Identification

Operational Analysis (Older Units)

Circuit Condition - Rest
Battery voltage is supplied to components of the control system from the unit battery via the red battery cable
connected to the contacts of the starter contactor (SC), wire 13, a 10 Amp fuse (F1), and wire 15.
Wire 13 is unfused battery supply voltage and is connected to the contacts of the starter contactor relay (SCR).
Wire 15 is 12 VDC fused battery supply voltage to the SCR. DC voltage flows through the SCR coil and exits the coil as
wire 17. Wire 17 is connected to the start-run-stop switch (SW1) and is held open to ground. Current does not flow
through the circuit and the SCR is de-energized.
Wire 15 is 12 VDC fused battery voltage supplied to the SW1 and is held open to wire 167.
Wire 15 is 12 VDC fused battery voltage to the start stop relay (SSR). DC voltage flows through the SSR coil and exits
as wire 229. Wire 229 will be 12 VDC held open from ground by the printed circuit board. Current does not flow through
the circuit and the SSR is de-energized.
004576

Wire 15 is 12 VDC fused battery supply voltage supplied Wire 18 connects to the ignition magnetos and to the
to the normally open contacts of the SSR. One set of normally closed contacts of the SSR. The normally
normally open contacts are connected to wire 15B, the closed contacts are also connected to wire 0. Wire 0 is
other set of normally open contacts are connected to wire frame ground.
14. The SSR is de-energized and no voltage is available The SSR is de-energized and the magnetos are
through the contacts. grounded out at this time. No spark is available.
Wire 15 is 12 VDC fused battery supply voltage supplied
to the battery charge rectifier 2 (BCR2). This is a return
current path for battery charging. No current flows at this
time.
004576

Circuit Condition - Start

With the start-run-stop switch (SW1) held in the START position, wire 17 is internally closed to ground via wire 0. By
grounding wire 17, current is allowed to flow through the SCR and energize the SCR coil. The SCR contacts internally
close wire 13 to wire 16. Wire 16 then delivers battery voltage to the starter contactor (SC) on the starter motor (SM).
The SC is energized and the contacts close, delivering battery voltage to the starter motor and the engine will start
cranking.
004577

With the start-run-stop switch (SW1) held in the START position, wire 15 is connected to wire 167. Wire 15 supplies
fused battery power via wire 167 to the printed circuit board. This 12 VDC input signals the printed circuit board to
internally ground wire 229 which is connected to the coil of the start stop relay (SSR). This action allows current to flow
and the SSR is energized. The normally open contacts close, supplying battery power from wire 15 to wire 14. Wire 14
supplies power to the fuel shutoff solenoid (FSS). It is energized and fuel is available to the engine. Wire 14 also
supplies power through resistor R1 and diode D1 to wire 4. Wire 4 connects to the field or the rotor assembly and is
used as field boost. The second set of normally open contacts on the SSR also close connecting wire 15 to wire 15B.
Wire 15B now supplies 12 VDC to the printed circuit board for use with the governor control system. The normally
closed contacts now open, wire 18 is no longer connected to wire 0 and the magnetos are no longer grounded out,
allowing voltage to flow to the spark plugs.
004577

Circuit Condition - Run

Once the engine has started, the start-run-stop switch (SW1) is released and returns to the run position. At his point
SW1 is not activated. This action will de-energize the starter contactor relay (SCR) causing the starter motor to
disengage.
The printed circuit board holds wire 229 to ground. This action holds the start stop relay (SSR) energized. With the
SSR energized, wire 14 maintains 12 VDC to the fuel shutoff solenoid. Once the voltage regulator starts functioning,
the field boost circuit is no longer a factor in operation. With the SSR energized wire 15B maintains 12 VDC to the
printed circuit board. With the SSR energized, wire 18 is not grounded and the magnetos continue to produce voltage
to the spark plugs.
The two independent battery charge windings are now producing AC voltage and supplying this to BCR1 and BCR2.
The AC voltage is rectified through BCR1 and used to supply DC voltage to the 12 VDC accessory outlet.
The AC voltage is rectified through BCR2 and used to supply DC voltage to the battery for battery charging.
004578

The printed circuit board is supplied with AC voltage from wires 11S and 44S. This voltage, frequency signal is used by
the printed circuit board for governor control operation.
When the idle control switch (SW2) is activated to the ON position, wire 83 from the printed circuit board will be
connected to wire 0 (frame ground). There are two idle control transformers (ICT) that sense current flow off the main
power windings. The voltage signal from the ICT’s connect to the printed circuit board via wires TR1/TR2 and are used
for sensing load on the generator. With no-load on the generator there is no current supplied from the ICT’s and the
engine will run at a lower RPM. When a load is applied to the generator, the ICT’s supply a voltage signal to the printed
circuit board and the engine RPM will be increased to running RPM, approximately 3600 RPM.
004578

Circuit Condition - Stop

With the start-run-stop switch (SW1) placed in the STOP position, wire 167 is connected to wire 0 (frame ground). The
ground signal is supplied via wire 167 to the printed circuit board. The printed circuit board will internally open wire 229
from ground. This action will de-energize the start stop relay (SSR). With the SSR de-energized, wire 14 will no longer
have 12 VDC supplied to it through the relay. This de-energizes the fuel shutoff solenoid (FSS), stopping fuel to the
engine. With the SSR de-energized, wire 18 will now be connected to wire 0.
This action will ground the magnetos out through wire 18 causing loss of spark to the engine. With the loss of fuel and
loss of spark the engine will shutdown.
004579

Fault Shutdown
With the generator running, if the low oil pressure (LOP) closes, wire 86 will be connected to wire 0 (frame ground).
Printed circuit board action will open wire 229 from ground; this action will de-energize the start stop relay (SSR). This
action will cause a shutdown.
004579

Operational Analysis (Newer Units)

Circuit Condition - Rest
Battery voltage is supplied to components of the control Wire 15 is 12 VDC fused battery supply voltage supplied
system from the unit battery via the red battery cable to the normally open contacts of the SSR. One set of
connected to the contacts of the starter contactor (SC), normally open contacts are connected to wire 15B, the
wire 13, a 10 Amp fuse (F1), and wire 15. other set of normally open contacts are connected to wire
Wire 13 is unfused battery supply voltage and is 14. The SSR is de-energized and no voltage is available
connected to the contacts of the starter contactor relay through the contacts.
(SCR). Wire 15 is 12 VDC fused battery supply voltage supplied
Wire 15 is 12 VDC fused battery supply voltage to the to the battery charge rectifier 2 (BCR2). This is a return
SCR. DC voltage flows through the SCR coil and exits current path for battery charging. No current flows at this
the coil as wire 17. Wire 17 is connected to the start-run- time.
stop switch (SW1) and is held OPEN to ground. Current Wire 18 connects to the ignition magnetos and to the
does not flow through the circuit and the SCR is de- normally closed contacts of the SSR. The normally
energized. closed contacts are also connected to wire 0 (frame
Wire 15 is 12 VDC fused battery voltage supplied to the ground).
SW1 and is held open to wire 167. The SSR is de-energized and the magnetos are
Wire 15 is 12 VDC fused battery voltage to the start stop grounded out at this time. No spark is available.
relay (SSR). DC voltage flows through the SSR coil and
exits as wire 229. Wire 229 will be 12 VDC held OPEN
from ground by the printed circuit board. Current does not
flow through the circuit and the SSR is de-energized.

004580

Circuit Condition - Start

With the start-run-stop switch (SW1) held in the START
position, wire 17 is internally closed to ground via wire 0.
By grounding wire 17, current is allowed to flow through
the SCR and energize the SCR coil. The SCR contacts
internally close wire 13 to wire 16.
Wire 16 then delivers battery voltage to the starter
contactor (SC) on the starter motor (SM). The SC is
energized and the contacts close, delivering battery
voltage to the starter motor and the engine will start
cranking.
With the start-run-stop switch (SW1) held in the START
position, wire 15 is connected to wire 167. Wire 15
supplies fused battery power via wire 167 to the printed
circuit board. This 12 VDC input signals the printed circuit
board to internally ground wire 229 which is connected to
the coil of the start stop relay (SSR). This action allows
current to flow and the SSR is energized. The normally
open contacts close supplying battery power from wire 15
to wire 14. Wire 14 supplies power to the fuel shutoff
solenoid (FSS).
The FSS is energized and fuel is available to the engine.
Wire 14 also supplies power through resistor (R1) and
diode (D1) to wire 4. Wire 4 connects to the field or the
rotor assembly and is used as field boost. The second
set of normally open contacts on the SSR also close
connecting wire 15 to wire 15B.
Wire 15B now supplies 12 VDC to the printed circuit
board for use with the governor control system. The
normally closed contacts now open, wire 18 is no longer
connected to wire 0 and the magnetos are no longer
grounded out, allowing voltage to flow to the spark plugs.

004581

Circuit Condition - Run

Once the engine has started, the start-run-stop switch
(SW1) is released and returns to the RUN position. At
this point SW1 is not activated. This action will de-
energize the starter contactor relay (SCR) causing the
starter motor to disengage.
The printed circuit board holds wire 229 to ground. This
action holds the start stop relay (SSR) energized. With
the SSR energized, wire 14 maintains 12 VDC to the fuel
shutoff solenoid. Once the voltage regulator starts
functioning the field boost circuit is no longer a factor in
operation. With the SSR energized, wire 15B maintains
12 VDC to the printed circuit board. With the SSR
energized, wire 18 is not grounded and the magnetos
continue to produce voltage to the spark plug.
The two independent battery charge windings are now
producing AC voltage and supplying this to BCR1 and
BCR2. The AC voltage is rectified through BCR1 and
used to supply DC voltage to the 12 VDC accessory
outlet. The AC voltage is rectified through BCR2 and
used to supply DC voltage to the battery for battery
charging.
The printed circuit board is supplied with AC voltage from
wires 11S and 22S. This voltage, frequency signal is
used by the printed circuit board for governor control
operation.
When the idle control switch (SW2) is activated to the ON
position, wire 83 from the printed circuit board will be
connected to wire 0 frame ground. There are two idle
control transformers (ICT) that sense current flow off the
main power windings. The voltage signal from the ICT’s
connect to the printed circuit board via wires TR1/TR2
and are used for sensing load on the generator. With no-
load on the generator there is no current supplied from
the ICT’s and the engine will run at a lower RPM. When a
load is applied to the generator, the ICT’s supply a
voltage signal to the printed circuit board and the engine
RPM will be increased to running RPM, approximately
3600 RPM.

004582

Circuit Condition - Stop

With the start-run-stop switch (SW1) placed in the STOP
position, wire 167 is connected to wire 0 (frame ground).
The ground signal is supplied via wire 167 to the printed
circuit board. The printed circuit board will internally open
wire 229 from ground. This action will de-energize the
start stop relay (SSR). With the SSR de-energized, wire
14 will no longer have 12 VDC supplied to it through the
relay. This de-energizes the fuel shutoff solenoid (FSS)
stopping fuel to the engine. With the SSR de-energized,
wire 18 will now be connected to wire 0. This action will
ground the magnetos out through wire 18 causing loss of
spark to the engine. With the loss of fuel and loss of
spark the engine will shutdown.
Fault Shutdown
With the generator running, if the low oil pressure (LOP)
closes, wire 86 will be connected to wire 0 frame ground.
Printed circuit board action will open wire 229 from
ground; this action will de-energize the start stop relay
(SSR). This action will cause a shutdown.

004583

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Section 3 Troubleshooting Flowcharts
Introduction
The most important step in troubleshooting is identifying Use the flow charts in conjunction with the detailed
the actual problem. The next step is to determine the instructions in section 4. Test numbers used in the flow
applicable flow chart to use to help diagnose the charts correspond to the numbered tests in section 4. For
problem. best results, perform all tests in the exact sequence
For each flow chart, start at the top and use the indicated shown in the flow charts.
test to verify whether or not a component or control item
is working properly. At the end of each test follow the
GOOD or BAD arrows and perform the next test.
If Problem Involves AC Output

TEST 1 - CHECK NO
LOAD VOLTAGE &
FREQUENCY
NO-LOAD VOLTAGE &

FREQUENCY GOOD - FREQUENCY GOOD -
VOLTAGE & FREQUENCY GOOD - ZERO VOLTAGE AND
VOLTAGE HIGH
FREQUENCY BOTH ZERO OR RESIDUAL ZERO FREQUENCY
OR
HIGH OR LOW VOLTAGE VOLTAGE/FREQUENCY
VOLTAGE LOW
FALLS OFF UNDER LOAD
GO TO PROBLEM 1 GO TO VOLTAGE GO TO PROBLEM 2 GO TO PROBLEM 2 GO TO PROBLEM 3

(BELOW) REGULATOR
ADJUSTMENT,
PAGE 11
Problem 1 – Voltage and Frequency Are Both High or Low
FREQUENCY IS GOOD, GO TO VOLTAGE

TEST 5 - CHECK BUT NO-LOAD REGULATOR
STEPPER MOTOR VOLTAGE IS HIGH ADJUSTMENT,
CONTROL OR VOLTAGE PAGE 11
IS LOW

Problem 2 – Generator Produces Zero Voltage or Residual Voltage (2-12 VAC)
TEST 2 - CHECK TEST 3 - TEST GOOD -PROCEED

MAIN CIRCUIT GOOD EXCITATION BAD -PROCEED, REPLACE AFTER TESTS
BREAKER CIRCUIT BREAKER CONCLUDE
RESET TO
“ON”
OR REPLACE
IF BAD
TEST 4 -
PERFORM FIXED
EXCITATION /
A ROTOR AMP D
DRAW
B C TEST 12 -
CHECK
BRUSH BAD
TEST 6 - WIRE LEADS
CONTINUITY
TEST 9 - TEST
BAD
STATOR
GOOD BAD GOOD
GOOD
TEST 7 -
FIELD BOOST REPAIR
TEST 11 - TEST 13 -
EXCITATION BAD OR CHECK
REPLACE BAD
WIRING BRUSHES &
BAD SLIP RINGS
REPAIR
OR GOOD
GOOD
REPLACE, REPAIR
THEN OR
INSULATION GOOD
RETEST REPLACE
RESISTANCE BAD
REPLACE
VOLTAGE TEST PAGE 13
REGULATOR
TEST 14 -
TEST 9 - TEST BAD CHECK ROTOR BAD
STATOR ASSEMBLY
TEST 8 -
DIODE/RESISTOR
GOOD
GOOD
BAD
TEST 10 - REPAIR
SENSING BAD OR
REPAIR LEADS REPLACE
OR INSULATION
REPLACE, GOOD RESISTANCE BAD
THEN TEST PAGE 14
RETEST
INSULATION BAD
RESISTANCE
TEST PAGE 13

Problem 2 – Generator Produces Zero Voltage or Residual Voltage (2-12 VAC) (continued)
TEST 4 -
PERFORM FIXED
EXCITATION / CHECK VOLTMETER
REPLACE FUSES
E ROTOR AMP
DRAW G FUSES - VERIFY AMP
METER FUNCTIONS
- THEN RETEST
TEST 14 -
F
CHECK ROTOR BAD
ASSEMBLY
TEST 9 - TEST REPAIR
REPAIR STATOR DPE BAD OR
OR WINDING REPLACE
REPLACE
GOOD
INSULATION INSULATION
RESISTANCE BAD RESISTANCE BAD
TEST PAGE 14 TEST PAGE 13
Problem 3 – Excessive Voltage/Frequency Droop When Load is Applied
TEST 15 -
TEST 16 - CHECK
CHECK LOAD NOT OVERLOADED
BAD LOAD WATTS &
VOLTAGE &
AMPERAGE
FREQUENCY
GOOD OVERLOADED REDUCE LOAD
END TEST
TEST 2 - CHECK /
STEPPER MOTOR GOOD GO TO PROBLEM 8
CONTROL
Problem 4 – No Battery Charge Output

TEST 17 - TEST 19 -
CHECK CHECK TEST 9 - TEST
BATTERY BAD BATTERY GOOD STATOR
CHARGE CHARGE
OUTPUT RECTIFIER
BAD
GOOD BAD
REPLACE REPAIR
FINISHED OR REPLACE
INSULATION
REPAIR
GOOD RESISTANCE BAD OR
TEST PAGE 13 REPLACE

Problem 5 - No 10A Battery Charge Output
TEST 18 - TEST 19 - TEST 20 -

CHECK 10A CHECK CHECK 10A
BATTERY BAD BATTERY GOOD CIRCUIT
CHARGE CHARGE BREAKER
OUTPUT RECTIFIER
BAD BAD
GOOD
REPLACE REPLACE
FINISHED
GOOD
REPAIR TEST 9 - TEST

OR REPLACE BAD
STATOR
INSULATION
REPAIR
GOOD RESISTANCE BAD OR
TEST PAGE 13 REPLACE
Problem 6 – Engine Will Not Crank

TEST 21 - TEST 22 - CHECK
CHECK 10 BATTERY
AMP FUSE & CABLES
FUSE BAD RECHARGE OR REPLACE BATTERY

BAD - CLEAN, REPAIR OR REPLACE BAD
REPLACE FUSE CABLE(S)
FUSE BLOWS GO TO PROBLEM 9
GOOD
TEST 23 - CHECK TEST 26 - CHECK TEST 27 - CHECK

NO VOLTAGE STARTER
VOLTAGE AT GOOD START-RUN-STOP BAD REPLACE
MEASURED CONTACTOR
STARTER SWITCH (SW1)
CONTACTOR RELAY (SCR)
BAD GOOD
12 VDC
MEASURED
REPAIR OR TEST 28 - CHECK
REPLACE WIRING START-RUN-STOP REPAIR
TEST 24 - CHECK OR SCR BAD
SWITCH (SW1) WIRING
STARTER BAD REPLACE WIRING
CONTACTOR
GOOD
GOOD
REPAIR OR
TEST 25 - CHECK REPLACE STARTER REPLACE WIRE 16
STARTER MOTOR BAD MOTOR IF DEFECTIVE
GOOD
CHECK FOR MECHANICAL BINDING
OF THE ENGINE OR ROTOR

Problem 7 – Engine Cranks But Will Not Start
CHECK VERIFY THAT IDLE

CHECK
FUEL CONTROL SWITCH PULL CHOKE
FUEL GOOD GOOD OFF
SHUTOFF IS IN THE “OFF” FULL OUT
SUPPLY
VALVE POSITION
OFF ON
REPLENISH PULL OUT FULL OUT
FUEL
SUPPLY TURN ON TURN OFF
TEST 38 - TEST 30 - TEST 29 -

TEST 36 - CHECK CHECK
CHECK GOOD FUEL SHUTOFF GOOD GOOD CHECK
FUEL PUMP SPARK SPARK
SOLENOID (FSS) PLUGS
BAD
BAD BAD
REPLACE BAD
REPAIR
TEST 37 - CHECK
OR
FUEL SHUTOFF GOOD
REPLACE BAD
SOLENOID VOLTAGE
TEST 32 - CHECK
START STOP
GOOD DC VOLTAGE RELAY (SSR)
MEASURED AT
TWO PIN
CONNECTOR TEST 31 - REMOVE
NO WIRE 18 /
TEST 39 -
SPARK SHUTDOWN LEAD
CHECK BAD
CARBURETION REPAIR
OR REPLACE SPARK
FSS
GOOD
TEST 35 - CHECK AND
ADJUST IGNITION TEST 32 - TEST
MAGNETOS BAD START STOP
RELAY (SSR)
TEST 5 - CHECK REPAIR
STEPPER REPLACE
BAD OR
MOTOR GOOD
REPLACE
CONTROL ADJUST
OR REPLACE
GOOD TEST 33 - TEST
BAD WIRE 167
TEST 40 - CHECK TEST 41 - CHECK REPAIR GOOD

VALVE GOOD ENGINE / CYLINDER OR REPLACE
ADJUSTMENT LEAK DOWN TEST /
COMPRESSION TEST TEST 34 - TEST
GOOD START STOP
BAD
BAD RELAY WIRING
GOOD
ADJUST AND REPAIR OR REPLACE AS NECESSARY
RE-TEST REFER TO ENGINE SERVICE MANUAL CHECK
P/N 0E2081 FOR FURTHER ENGINE FLYWHEEL KEY - REPLACE
SERVICE INFORMATION SEE TEST 35 PRINTED CIRCUIT
BOARD

Problem 8 – Engine Starts Hard and Runs Rough
CHECK CHECK CHOKE TEST 30 -

TEST 29 -
FUEL POSITION AND GOOD CHECK GOOD
GOOD GOOD CHECK
SUPPLY OPERATION SPARK
SPARK
PLUG
LOW FUEL ENGINE MISS BAD

IS APPARENT
PUSH IN AFTER STARTING
REPLENISH REPLACE SPARK PLUG
FUEL TEST 35 - CHECK AND
SUPPLY ADJUST IGNITION
BAD ADJUST
MAGNETOS OR REPLACE
TEST 38 - TEST 5 - CHECK

TEST 39 - CHECK TEST 40 - CHECK
CHECK GOOD GOOD STEPPER GOOD
CARBURETION VALVE
FUEL PUMP MOTOR
ADJUSTMENT
CONTROL
BAD BAD
BAD
BAD GOOD
REPAIR
REPAIR OR REPLACE REPAIR ADJUST VALVES
OR REPLACE OR REPLACE AND RETEST
CHECK
TEST 41 - CHECK GOOD FLYWHEEL KEY -
ENGINE / SEE TEST 35
CYLINDER LEAK
DOWN TEST / REPAIR OR REPLACE AS NECESSARY
COMPRESSION REFER TO ENGINE SERVICE MANUAL P/N
BAD
TEST 0E2081 FOR FURTHER ENGINE SERVICE
INFORMATION
Problem 9 – Engine Starts Then Shuts Down

CHECK TEST 42 - CHECK OIL TEST 27 - TEST
ENGINE OIL OIL LEVEL O.K. PRESSURE SWITCH GOOD START-RUN-STOP
LEVEL AND WIRE 86 SWITCH (SW1)
OIL LEVEL LOW BAD BAD
REPLACE SWITCH
REPLENISH OIL REPLACE SWITCH
VERIFY START STOP RELAY (SSR)

GO TO PROBLEM 8 IS WIRED PROPERLY

Problem 10 – 10 Amp Fuse (F1) Blowing

CHECK FUEL
INSTALL NEW FUSE BLOWS TEST 43 - CHECK SOLENOID
FUSE BLOWS
WHEN RUNNING 10 AMP FUSE UPON START STOP GOOD (TEST 47)
INSTALLATION RELAY (SSR) AND STARTER
CONTACTOR RELAY
(TEST 44)
FUSE IS GOOD BUT BAD
BLOWS WHEN PLACED BAD
TO START GOOD
REPLACE
REPLACE
TEST 19 - CHECK
TEST 45 - CHECK BATTERY CHARGE
GOOD
WIRE 15 RECTIFIER 2
VERIFY START-RUN-STOP (BCR2)
SWITCH IS WIRED CORRECTLY
(SEE FIGURE 6-46, pg. 55)
BAD
BAD
REPAIR
OR REPLACE
REPLACE
TEST 46 - CHECK TEST 49 - CHECK TEST 50 - CHECK

GOOD GOOD
WIRE 14 CIRCUIT WIRE 15B WIRE 167
BAD BAD
CONTINUITY
MEASURED REPAIR REPAIR
OR OR
REPLACE REPLACE
TEST 47 - CHECK TEST 48 - CHECK

GOOD BAD REPLACE
FUEL SHUTOFF (WITH HM) HOURMETER (HM) GOOD
SOLENOID (FSS) IF EQUIPPED
BAD GOOD
GOOD REPAIR OR REPLACE
(WITHOUT HM) WIRE 14
REPLACE
VERIFY BCR1
TEST 8 - DIODE / AND BCR2 ARE
GOOD WIRED
RESISTOR
CORRECTLY
BAD
BAD
REPLACE
CORRECT
WIRING

Problem 11 – Engine Overspeeds

TEST 1 - CHECK TEST 51 - CHECK TEST 5 - CHECK REPLACE
NO-LOAD PRODUCING WIRES 11S & 44S
GOOD STEPPER MOTOR GOOD CIRCUIT
VOLTAGE & VOLTAGE OR OPERATION BOARD
FREQUENCY WIRES 11S & 22S
NO BAD
VOLTAGE
BAD REPAIR OR REPLACE

GO TO PROBLEM 2
Problem 12 – Idle Control “RPM Does Not Decrease”

VERIFY THAT
THERE IS NO LOAD TEST 52 - CHECK TEST 53 - CHECK
ON THE IDLE CONTROL IDLE CONTROL GOOD REPLACE PRINTED
GOOD
GENERATOR SWITCH WIRING CIRCUIT BOARD
BAD
BAD
REPLACE
REPAIR OR REPLACE
Problem 13 – Idle Control “RPM Does Not Increase When Load Is Applied”
VERIFY THAT WIRE 11 & TEST 54 - CHECK TEST 55 - CHECK REPLACE

WIRE 44 ARE ROUTED GOOD IDLE CONTROL GOOD TR1 & TR2 GOOD PRINTED
THROUGH IDLE CONTROL TRANSFORMERS WIRING CIRCUIT BOARD
TRANSFORMERS (ICT) (ICT)
BAD BAD
ROUTE THROUGH IDLE

CONTROL TRANSFORMERS
AND RE-TEST REPLACE REPAIR OR REPLACE
Problem 14 - Engine “Hunts” / Erratic Idle
TEST 56 - CHOKE STILL TEST 40 - CHECK / TEST 29 - CHECK

SURGING GOOD
TEST ADJUST VALVES SPARK
BAD - ENGINE MISS
NO BAD APPARENT
GOOD
SURGING
ADJUST / RE-TEST TEST 30 - CHECK

GOOD TEST 35 - CHECK /
TEST 39 - CHECK SPARK PLUG ADJUST IGNITION
CARBURETION MAGNETOS
REPLACE TEST 5 - CHECK BAD
PRINTED GOOD STEPPER MOTOR BAD
CIRCUIT BOARD OPERATION
REPLACE
REPAIR ADJUST OR REPLACE
OR BAD
REPLACE

Section 4 AC Diagnostic Tests
Introduction work with AMP connector plugs. Another alternative is to
use approved back probes from the back side of the
This section familiarizes the service technician with connector.
acceptable procedures for the testing and evaluation of
various problems that can occur on portable generators.
Use this section in conjunction with the Troubleshooting Test 1 – Check No-Load Voltage and
Flow Charts. The numbered tests in this section Frequency
correspond with those of the flow charts.
Procedure
These test procedures require a basic knowledge of
electricity and electrical safety, hand tool skills, and use 1. Disconnect or turn all electrical loads connected to
of multimeters. the generator OFF.
Some test procedures in this section require the use of 2. Reset all circuit breakers to ON.
specialized test equipment, meters or tools. Most tests 3. Turn the idle control switch to OFF.
can be performed with a digital multimeter (DMM). An AC 4. Start engine and let stabilize and warm up.
frequency meter is required where frequency readings
must be taken. To measure AC loads it is acceptable to NOTE: If the generator is not producing AC power, loss of
use a clamp-on ammeter. governor control may occur causing an extremely high
RPM condition (overspeed). If this condition occurs
Testing and troubleshooting methods covered in this
manually control throttle (60 Hz /3600 rpm) to perform test.
manual are not exhaustive. No attempt has been made to
discuss, evaluate and advise the home standby service 5. Set a digital multimeter (DMM) to measure AC
trade of all conceivable ways in which service and trouble voltage.
diagnosis must be performed. Any test method not 6. See Figure 4-1. Place the meter test leads into the
recommended herein must be deemed safe for 50A outlet.
personnel and equipment.
Safety
Service personnel who work on this equipment should be
50A 240
aware of the dangers of such equipment. Lethal voltages
are present and can kill or cause serious injury. Gaseous
fuels are highly explosive and can ignite by the slightest
spark. Engine exhaust gases contain deadly carbon
monoxide gas that can cause unconsciousness or even
death. Contact with moving parts can cause serious
injury.
When working on this equipment, use common sense
004584
and remain alert at all times. Never work on this
equipment while you are physically or mentally fatigued. Figure 4-1. DMM Test Leads Connected to 50A Outlet
If you do not understand a component, device or system,
do not work on it. 7. Read AC voltage.
8. Connect an AC frequency meter as described in
step 6.
Important Note Concerning
Connectors 9. Read AC frequency.
A number of the tests require the use of a multimeter and Results
a set of test probes.
For units rated 60 Hertz, no load voltage and frequency
It is very easy to damage the female pins in the
should be approximately 238-242 VAC at 59-61 Hertz.
connectors on the control panel. Do not attempt to push
See Problem 1 – Voltage and Frequency Are Both
probe tips into the connector pins of any connectors.
High or Lowin section 3.
Doing so will damage the female pin which will create
additional problems. Use the appropriate probes on
specific wires to check voltage. Use the flexible pin leads,
available from the manufacturer (PN 0J09460SRV) to

Test 2 – Check Main Circuit Breaker 4. Set DMM to measure resistance.

5. Connect the DMM test probes across the circuit
Procedure breaker terminals. Continuity should be measured.
The generator has seven circuit breakers located on the
control panel. If outlets are not receiving power, verify the Results
breakers are set to the ON or CLOSED position. 1. If circuit breaker tests bad (meter reads Continuity)
See Figure 4-2. If a breaker failure is suspected, it can proceed to Test 4 and replace the breaker after
be tested as follows: completing Test 4.
1. Set DMM to measure resistance. 2. If circuit breaker is good, proceed to Test 4.
2. With generator shut down, disconnect all wires
from suspected circuit breaker terminals to prevent 00.00
interaction. 162
3. See Figure 4-2. With the generator shut down, 2
connect one meter test lead to one terminal of the
breaker and the other meter test lead to the other
terminal.
4. Set breaker to ON or CLOSED. Continuity should
be measured.
5. Set breaker to OFF or OPEN. Infinity should be
measured.
004590
Results Figure 4-4. Testing Excitation Circuit Breaker
1. If circuit breaker tests good, refer to flow chart.
2. If breaker tests bad, replace.
Test 4 – Fixed Excitation Test/Rotor
Amp Draw Test
NOTE: If the generator is not producing AC power, loss of
A B governor control may occur causing an extremely high
00.00
RPM condition (overspeed). If this condition occurs
ON
50A manually control throttle (60 Hz /3600 rpm) to perform test.
OFF
C.B.
Procedure
A B 1. If testing a unit with the older style voltage regula-
tor, unplug the six pin connector from the voltage
004585
regulator.
Figure 4-2. 50 Amp Breaker Test Points
2. If testing a unit with the newer style voltage
regulator, disconnect wires 11S, 22S, 4, 0, 6 and
20/30A 162 from the voltage regulator.
00.00 C.B.
NOTE: For testing purposes the six pin connector
reference is the same as the six individual wires on the
newer style voltage regulator.
3. Connect a jumper from wire 0 to a good ground.
004588 4. Disconnect wire 14 from resistor R1.
Figure 4-3. 20/30 Amp Breaker Test Points 5. See Figure 4-5. Connect a jumper wire between
the removed end of wire 14 and wire 4 where it is
soldered at diode D1.
Test 3 – Test Excitation Circuit Breaker
6. Set DMM to measure AC voltage
Procedure 7. See Figure 4-6 or Figure 4-7. Disconnect wire 2
1. Shut down the generator and allow to cool for at from the excitation circuit breaker and connect one
least two minutes. meter test lead to it.
2. Locate the excitation circuit breaker in the control 8. Connect the other meter test lead to wire 6.
panel. NOTE: If testing older style voltage regulator, be careful
3. Disconnect wires from the breaker to prevent not to damage the pin connectors with the test leads.
interaction.


3
2 3

$

004700
Figure 4-7. New Style Voltage Regulator Wire

7)2% Number Locations
2%-/6%$ 2
19. Shut down the generator.
20. Remove the jumper lead between wire 14 and
*5-0%2 ,%!$ Diode D1.
$ 21. Set the DMM to measure DC amperage (10 amp
range).
a. Switch the test leads on the meter if required.
004593
22. See Figure 4-8. Connect the positive meter test
Figure 4-5. Fixed Excitation Test/Rotor Amp Draw Test lead to wire 14.
23. Connect the negative test lead to wire 4 at diode
9. Set idle control switch to OFF.
D1.
10. Start the generator.
11. Measure and record the output voltage across wire
25. Measure and record the DC rotor amp draw.
2 and wire 6.
AC voltage across wires 2 and 6 = _____________ Rotor Amp Draw = _____________________
12. Shut down the generator. 26. Shutdown the generator.
13. Connect wire 2 to the excitation circuit breaker. 27. Connect the six pin connector, or wires to
terminals.
14. See Figure 4-6 or Figure 4-7. Connect one meter
test lead to wire 11S. 28. Connect wire 14 to the resistor R1.
15. Connect the other meter test lead to wire 44S or
Results
22S, depending on older or newer style voltage
regulator. Refer to Table 4-1.
17. Measure and record the output voltage across
wires 11S and 44S, or 11S and 22S.
1.5 A
AC Voltage across wires 11S and 44S = __________
AC Voltage across wires 11S and 22S = __________
18. Set start-run-stop switch (SW1) to STOP.
14
WIRE 14
REMOVED R1
14
0).
0).
3 0). D2
0).
3 0).
0). 4
4
004601
004594
Figure 4-8. Measuring Amp Draw
Figure 4-6. Old Style Voltage Regulator Wire Number
Locations

Table 4-1. Test 4 Results – Fixed Excitation Test/Rotor Amp Draw Test (8-20 kW)
Results: A B C D E F G
Voltage Results Wire 2 & 6 Above 60 Above 60 Below 60 Below 60 Below 60

Zero or Residual Volts Above 60 VAC
Excitation Winding VAC VAC VAC VAC VAC
Above 50 Below 50 Above 50 Below 50 Below 50

Voltage Results Wire 11S & 44S Zero or Residual Volts Above 50 VAC
VAC VAC VAC VAC VAC
Above 50 Below 50 Above 50 Below 50 Below 50

Voltage Results Wire 11S & 44S Zero or Residual Volts Above 50 VAC
VAC VAC VAC VAC VAC
Zero Current
Rotor Amp Draw 12.5 kW 1.76-2.05 1.76-2.05 1.76-2.05 Zero Current Draw Above 2.5A 1.76-2.05
Draw
Zero Current
Rotor Amp Draw 15 kW 1.76-2.05 1.76-2.05 1.76-2.05 Zero Current Draw Above 2.5A 1.76-2.05
Draw
Zero Current
Rotor Amp Draw 17.5 kW 1.76-2.05 1.76-2.05 1.76-2.05 Zero Current Draw Above 2.5A 1.76-2.05
Draw
Match results with letter and refer to flow chart “Problem 2” 
Test 5 – Check Stepper Motor Control a. Set the idle control switch to OFF.
b. Set the start-run-stop switch (SW1) to START.
Procedure c. Watch for stepper motor movement. It should
1. Remove air cleaner cover to access stepper motor. move to the wide open position during
2. Move throttle by hand and verify stepper motor, cranking. Once the unit starts the stepper
linkage and throttle do not bind in any way. If any motor should move the throttle to a position to
binding is felt, repair or replace components as maintain 60 Hertz.
needed. Some resistance should be felt as the 4. If no movement is seen in step 3 remove the
stepper motor is moved. control panel cover.
a. Verify the six pin connector on the printed
A B circuit board is seated properly. Remove the
connector and then replace it and test again.
C b. See Figure 2-1. Verify the switches are set
correctly.
5. See Figure 4-11. If problem continues remove six
pin connector from printed circuit board.
6. Set DMM to measure resistance (ohms).
004657 7. Carefully measure from the end of the six pin
harness as follows:
A. Stepper Motor B. Linkage C. Throttle
Figure 4-9. Stepper Motor, Linkage and Throttle NOTE: Press down with the meter leads on the exposed
connector terminals. Do not probe into the connector.
C
A B
D
F
A. Full Throttle 004640
B. Closed Throttle 004641
A. Black D. Orange
Figure 4-10. Throttle Positions
B. Brown E. Red
C. Yellow F. Empty
3. Move the throttle to the closed position by pushing
the throttle down as looking from above. Figure 4-11. Six Pin Connector Wire Colors

a. Connect one meter lead to red. Connect the Results

remaining test lead to orange. Approximately
1. If the stepper motor fails any part of step 5, replace
10 ohms should be measured.
the stepper motor.
b. Connect one meter lead to red. Connect the
2. If step 7 fails repair or replace wire 15B between
remaining test lead to yellow. Approximately 10
the start stop relay (SSR) and terminal block TB1.
ohms should be measured.
3. If the stepper motor passes all steps replace the
c. Connect one meter lead to red. Connect the
printed circuit board.
remaining test lead to brown. Approximately 10
d. Connect one meter lead to red. Connect the 86 15B 167 BLK 00.00
remaining test lead to black. Approximately 10 0 229 83 BLK
e. Connect one meter lead to red. Connect the
remaining test to the stepper motor case.
Infinity should be measured.
8. Set DMM to measure DC voltage.
TB1 TR2
9. See Figure 4-12. TR1
a. Connect the positive meter test lead to wire
15B at terminal block 1 (TB1).
NOTE: Where terminal block is not present, place meter
test lead on the wire at the termination point. If
J2-1 J2-12
necessary, use a small paper clip to probe beside the
wire so as not to damage the terminal in the connector.
b. Connect the negative meter test lead to
ground.
c. Set the start-run-stop switch (SW1) to START.
d. If 12 VDC was measured proceed to step 8.
e. If voltage was not measured, proceed to 004603
results.
Figure 4-13. Testing J2-1
86 15B 167 BLK
0 229 83 BLK 12.00 Test 6 – Wire Continuity

Procedure
1. Set DMM to measure resistance.
2. Remove the six pin connector from the voltage
TERMINAL TR2 regulator.
BLOCK TR1 3. See Figure 4-11. Connect one meter test lead to
(TB1)
wire 0 in the six pin connector removed from the
voltage regulator.
004602
4. Connect the other test lead to the ground terminal
Figure 4-12. Testing Wire 15B in the control panel.
a. Continuity should be measured.
5. See Figure 4-11. Connect one meter test lead to
11. See Figure 4-13. Disconnect the J2 connector
wire 162 in the six pin connector removed from the
from the printed circuit board.
voltage regulator.
a. Connect one meter test lead to pin location J2-
1 (wire 15B). 6. Remove wire 162 from the excitation circuit
breaker (CB1).
b. Connect the other meter test lead to wire 15B
at terminal block 1 (TB1). 7. Connect the other meter test lead to wire 162.
c. Continuity should be measured. a. Continuity should be measured.
NOTE: Verify the test probe connector is sharp and is

making contact the with the connector.
Results 8. Connect the C1 connector.

If Continuity was not measured across each wire, repair 9. Connect wire 16 to the starter contactor relay.
or replace the wires as needed. If Continuity was
measured refer back to flow chart. Results
1. If 12 VDC was measured in step 6 the field boost
Test 7 – Check Field Boost circuit is working. Refer back to the flow chart.
2. If field boost voltage was not measured refer back
Procedure to the flow chart.
2. Disconnect the six pin connector from the voltage Test 8 – Diode/Resistor
regulator.
3. Disconnect connector C1. See Control Panel Procedure
Component Identification for connector location. 1. Set DMM to the diode test range.
4. See Figure 4-14. Disconnect wire 16 from the 2. Disconnect the six pin connector from the voltage
starter contactor relay (SCR). This will prevent the regulator.
unit from cranking when placed in the START
3. Disconnect connector C1. See Control Panel
position.
Component Identification for connector location.
4. Disconnect both wires from resistor R1.
5. See Figure 4-16.
a. Connect the positive meter test lead to the top

A

terminal of diode D1.
a. Connect the negative meter test lead to the
bottom of the diode.
a. Infinity or “Open” should be measured.
004606
Figure 4-14. Starter Contactor Relay OL
5. See Figure 4-15. 14
a. Connect the positive meter test lead to wire 4 at WIRE 14
diode D1. Wire 4 is soldered to the diode. REMOVED
b. Connect the negative meter test lead to the 14

ground terminal.
R1
14
R1
D2
14
4
D2 4 004608
Figure 4-16. Diode Test Step 5

4
4 6. See Figure 4-17.
a. Connect the positive meter test lead to the
004607 bottom terminal of diode D1.
Figure 4-15. Testing Field Boost b. Connect the negative meter test lead to the top
of the diode.
6. Set the start-run-stop switch (SW1) to START and c. Approximately 0.5 volts should be measured.
measure the DC voltage. 7. Set DMM to measure resistance.
a. Approximately 12 VDC should be measured.
a. Connect one meter test lead to the top terminal
7. Connect the six pin connector to the voltage of diode D1.
regulator.

b. Connect the other meter test lead to the 12. Connect the C1 connector.
ground terminal. 13. Connect the two wires removed from resistor R1.
c. Infinity or “Open” should be measured.
Results
1. If the diode or resistor failed any step it should be
replaced.

7)2% Test 9 – Test Stator
2%-/6%$
Procedure
1. Disconnect wires 11 and 44 from the 50 amp circuit
2 breaker.
2. Disconnect wire 22 from the 50 amp receptacle.
Component Identification for connector location.
$
5. Connect the meter test leads across stator leads
11 and 22.

004610
a. Normal power winding resistance should be
measured.
8. See Figure 4-18. 44 and 22.
a. Connect one meter test lead to one terminal of a. Normal power winding resistance should be
resistor R1. measured.
b. Connect the other meter lead to the remaining See Figure 4-19 for the following steps.
terminal of resistor. 7. Connect the meter test leads across stator leads
c. Approximately 25 ohms should be measured. 11S (pin 1) and stator lead 44S (pin 2) at the C1
connector female side.
a. Normal power winding resistance should be
14 measured.
WIRE 14
REMOVED OLDER 44S
22S NEWER
14 77A 66A
55A 11S
2
R1 6 5 4 3 2 1
7 8 9 10 11 12
D2 55
77 0
6 66 4
4
004642
4 004611
Figure 4-19. C1 Connector, Female Side
9. Connect one meter test lead to the top terminal of
66A (pin 4) and stator lead 77A (pin 5) at the C1
resistor R1.
10. Connect the other meter test lead to the ground
a. Normal battery charge winding resistance
terminal.
should be measured.
a. Infinity or “Open” should be measured.
9. Connect the meter test leads across stator leads 2
11. Connect the six pin connector, or wires to (pin 6) and stator lead 6 (pin 7) at the C1 connector
terminals. female side.

a. Normal excitation winding resistance should be

measured.
Winding Wire Numbers 12.5 kW 15 kW 17.5 kW
Power 11 & 22 0.125 Ω 0.0852 Ω 0.067 Ω
66 (pin 9) and stator lead 77 (pin 10) at the C1
connector female side. Power 44 & 22 0.125 Ω 0.088 Ω 0.067 Ω
a. Normal 10 amp battery charge winding Sensing 11S & 44S 0.25 Ω 0.176 Ω 0.134 Ω
resistance should be measured.
Sensing 11S & 22S 0.25 Ω 0.176 Ω 0.134 Ω
11. Connect the meter test leads across stator lead 11 Excitation 2&6 0.576 Ω 0.824 Ω 0.80 Ω
and frame ground.
Battery Charge 66A & 77A 0.132 Ω 0.107 Ω 0.0939 Ω
a. Infinity should be measured.
10A Battery Charge 66 & 77 0.145 Ω 0.124 Ω 0.117 Ω
12. Connect the meter test leads across stator lead
66A (pin 4) and stator lead 2 (pin 6) at the C1 * Resistance values In ohms at 20 °C. (68 °F.). Actual readings
connector female side and frame ground. may vary depending on ambient temperature. A tolerance of
plus or minus 5% is allowed.
13. Connect the meter test leads across stator lead 2
(pin 6) at the C1 connector female side and frame
Test 10 – Sensing Leads
ground. Procedure
a. Infinity should be measured. 1. Set a DMM to measure resistance.
14. Connect the meter test leads across stator lead 66 2. Disconnect connector C1. See Control Panel
(pin 9) at the C1 connector female side and frame Component Identification for connector location.
ground.


wire 11 and stator lead 66A (pin 4) at the C1
wire 11 and stator lead 2 (pin 6) at the C1

! ! 3
17. Connect the meter test leads across stator leads !
3 .%7%2
wire 11 and stator lead 66 (pin 9) at the C1
connector female side. /,$%2 3 004643
a. Infinity should be measured. Figure 4-20. C1 Connector, Male Side

18. Connect the meter test leads across stator lead
3. See Figure 4-20. Locate the male side of the
66A (pin 4) and stator lead 2 (pin 6) at the C1
connector located on the bottom of the control panel.
a. Connect one meter test lead to pin 1 wire 11S.
It may be helpful to connect a small jumper
19. Connect the meter test leads across stator lead lead to the individual pin.
66A (pin 4) and stator lead 66 (pin 9) at the C1 b. Connect the other meter test lead to wire 11S
connector female side. at terminal block 2 (TB2). See Control Panel
a. Infinity should be measured. Component Identification for terminal block 2
20. Connect the meter test leads across stator lead 2 location.
(pin 6) and stator lead 66 (pin 9) at the C1 c. Continuity should be measured.
connector female side. 4. See Figure 4-20. Locate the male side of the
a. Infinity should be measured. connector located on the bottom of the control panel.
a. Connect one meter test lead to pin 2 wire 44S.
Results It may be helpful to connect a small jumper
If the stator fails any step replace it. For steps 1-10 keep lead to the individual pin.
in mind resistance values may vary depending on b. Connect the other meter test lead to wire 44S
ambient temperature and calibration of the meter used. If at terminal block 2 (TB2).
the stator passes all tests refer back to the flow chart. c. Continuity should be measured.

5. Unplug the six pin connector, or wires to terminals, Results

at the voltage regulator.
1. If continuity was not measured in any of the steps
6. See Figure 4-20. repair or replace defective wire.
a. Connect the one meter test lead to wire 11S at 2. If all steps pass refer back to flow chart.
terminal block 2 (TB2).
b. Connect the other meter test lead to wire 11S Test 12 – Check Brush Leads
at the six pin connector previously removed
from the voltage regulator. Procedure
c. Continuity should be measured. 1. Set DMM to measure resistance.
7. See Figure 4-20. 2. Disconnect connector C1. See Control Panel
a. Connect the one meter test lead to wire 44S at Component Identification for connector location.
terminal block 2 (TB2). 3. See Figure 4-19. Connect the meter test leads
b. Connect the other meter test lead to wire 44S across wire 4 (pin 11) and wire 0 (pin 12) at the C1
at the six pin connector previously removed connector female side.
from the voltage regulator. a. Rotor resistance should be measured
c. Continuity should be measured. approximately 7-14 ohms.
b. If resistance is measured proceed to step 6.
Results
c. If no resistance is measured continue.
1. If continuity was not measured in any of the steps
4. See Figure 4-22. Remove the control panel
repair or replace defective wire.
assembly to access the brushes.
2. If all steps pass refer back to flow chart.
a. Connect one meter test lead across wire 4 (pin
11) at the C1 connector female side.
Test 11 – Excitation Wiring b. Connect the other meter test lead to wire 4 at
the brush assembly.
Procedure
c. Continuity should be measured.
d. If Infinity is measured repair or replace wire 4.
Component Identification for connector location. 5. See Figure 4-19.
3. See Figure 4-20. Locate the male side of the a. Connect one meter test lead across wire 0 (pin
connector located on the bottom of the control 12) at the C1 connector female side.
panel. b. Connect the other meter test lead to wire 0 at
a. Connect one meter test lead to pin 6 wire 2. It the brush assembly.
may be helpful to connect a small jumper lead c. Continuity should be measured.
to the individual pin. d. If Infinity is measured repair or replace wire 0.
b. Disconnect wire 2 from the excitation circuit 6. Unplug the six pin connector at the voltage
breaker (CB1). See Control Panel regulator.
Component Identification for excitation
7. See Figure 4-20. Locate the male side of
circuit breaker location.
connector C1 located on the bottom of the control
c. Connect the other meter test lead to wire 2. panel.
d. Continuity should be measured. a. Connect one meter test lead to pin 11 wire 4.
4. Unplug the six pin connector at the voltage b. See Figure 4-11. Connect the other meter test
regulator. lead to wire 4 at the six pin connector
5. Locate the male side of the C1 connector located previously removed from the voltage regulator.
on the bottom of the control panel. c. Continuity should be measured.
a. Connect one meter test lead to pin 7, wire 6. It d. If continuity is not measured repair or replace
may be helpful to connect a small jumper lead wire 4 between the C1 connector and the six
to the individual pin. pin voltage regulator connector.
b. Connect the other meter test lead to wire 6 8. Connect one meter test lead to pin 12 wire 0.
located in the six pin connector previously Connect the other meter test lead to the ground
removed from the voltage regulator. terminal in the control panel.
c. Continuity should be measured. a. Continuity should be measured.

b. If continuity is not measured repair or replace Results

wire 0 between the C1 connector and the
1. Replace bad brushes. Clean slip rings, if neces-
ground terminal.
sary.
Results 2. If brushes and rings are good, go to Test 14.
1. Repair or replace wiring/terminals as needed.
2. If no faults are found refer to flow chart.
Test 14 – Check Rotor Assembly
Procedure
Gain access to the brushes and slip rings. Disconnect
wire 4 and wire 0 from their respective brushes and
remove the brush holder. Then, test the Rotor as follows:
2. Connect the positive (+) meter test lead to the
positive (+) slip ring (nearest the rotor bearing).
004644 3. Connect the common (-) test lead to the negative (-)
slip ring.
Figure 4-21. Brush Leads
4. Read the resistance of the rotor windings, in ohms.
Test 13 – Check Brushes & Slip Rings 5. Connect the positive (+) meter test lead to the
positive (+) slip ring.
Procedure 6. Connect the common (-) test lead to a clean frame
1. Gain access to the brushes and slip rings. ground (such as the rotor shaft).
Rotor Resistance *
kW Ohms
12.5 7.01 Ω
15.0 8.48 Ω
17.5 9.33 Ω
* Resistance values in ohms at 20 °C. (68 °F.). Actual readings

004648 may vary depending on ambient temperature. A tolerance of
plus or minus 5% is allowed.
Figure 4-22. Brush Location
2. Remove wire 4 from the positive (+) brush terminal. Results

3. Remove the ground wire (0) from the negative (-) 1. Replace the rotor if it fails the test.
brush. 2. If rotor checks good, perform Rotor Insulation
4. Remove the brush holder, with brushes. Resistance Test.
5. Inspect the brushes for excessive wear, damage,
cracks, chipping, etc.
6. Inspect the brush holder. Replace if damaged.
7. Inspect the slip rings.
a. If slip rings appear dull or tarnished they may
be cleaned and polished with fine sandpaper.
DO NOT USE ANY METALLIC GRIT TO
CLEAN SLIP RINGS. (A 400 grit wet POSITIVE (+)
TEST LEAD
sandpaper is recommended). 004649
b. After cleaning slip rings, blow away any Figure 4-23. Testing at Slip Rings
sandpaper residue.

Test 15 – Check Load Voltage and 2. Set DMM to measure DC Amps.

Frequency a. Connect the positive (+) test lead to the center
terminal of the battery charge rectifier.
Procedure b. Connect the negative (-) test lead to wire 15
Perform this test in the same manner as Test 1, but apply disconnected in step 1.
a load to the generator equal to its rated capacity. With 3. Start the generator.
load applied check voltage and frequency.
a. The amp reading on the meter should be
Frequency should not drop below about 59 Hertz with the approximately 0.6 Amps.
load applied.
b. Apply full load to the generator.
Voltage should not drop below about 235 VAC with load
c. The amp reading should increase to
applied.
approximately 2 Amps.
Results Results
1. If voltage and/or frequency drop excessively when
1. If amperage was measured between 0.6 to 2 Amps
the load is applied, go to Test 16.
in step 2 and step 3, the charging system is working.
2. If load voltage and frequency are within limits, end
2. If no amperage was measured, check the meter
tests.
fuses and verify the functioning of the meter. If
meter is good and no current is measured refer to
Test 16 – Check Load Watts and flow chart.
Amperage
Test 18 – Check 10 Amp Battery
Procedure
Charge Output
Add up the wattages or amperages of all loads powered
by the generator at one time. If desired, a clamp-on Procedure
ammeter may be used to measure current flow.
NOTE: The battery charge cable must be connected to
Results the 12 VDC panel receptacle and be charging a separate
battery to perform this test.
1. If the unit is overloaded, reduce the load.
2. If load is within limits, but frequency and voltage 1. Disconnect wire 13A (center terminal) from battery
still drop excessively, refer back to flow chart. charge rectifier 1 (BCR1), which is located on top
of BCR2. See Control Panel Component
Identification for BCR1 and BCR2 location.
Test 17 – Check Battery Charge Output 2. See Figure 4-25. Set DMM to measure DC
Procedure Amperage.
a. Connect the positive (+) test lead to the center
1. Disconnect wire 15 (center terminal) from battery
terminal of the battery charge rectifier.
charge rectifier 2 (BCR2), which is located under
BCR1. They are stacked. b. Connect the negative (-) test lead to wire 13A
previously disconnected.
See Control Panel Component Identification for BCR1
and BCR2 location.
13A
15 2.0 A
15
66 77
66A 77A
BCR1
BCR2
004614
004613
Figure 4-25. Testing BCR1
Figure 4-24. Testing BCR2

3. Start the generator. Short to Ground

a. The amp reading on the meter should be 9. Set the DMM to measure resistance.
approximately 0.2 Amps.
10. Connect the positive (+) test lead to the case
b. Apply full load to the generator. housing of BCR2.
c. The amp reading should increase.
11. Connect the negative (-) test lead to an outer
d. Normal ranges at full load can be 3-7 amps, terminal.
but can get as high as 10 amps depending on
a. The meter should measure Infinity.
the state of charge of the battery.
12. Connect the negative test lead to the BCR center
Results terminal.
1. If amperage was measured between 0.2 to 10 a. The meter should measure Infinity.
Amps in step 2 and step 3, the charging system is 13. Connect the negative test lead to the remaining
working. outer BCR terminal.
2. If no amperage was measured, check the meter fuses a. The meter should measure Infinity.
and verify the functioning of the meter. If meter is
good and no current is measured refer to flow chart. Results
1. If any of the previous steps failed, replace BCR2.
Test 19 – Check Battery Charge 2. If BCR2 tests good, refer back to the flow chart.
Rectifier (BCR2)
Procedure Test 20 – Check 10 Amp Circuit
1. Disconnect all wires from battery charge rectifier 2
Breaker
(BCR2). Procedure
2. Set the DMM to the Diode Test range.
3. Connect the negative (-) test lead to the center
terminal of BCR2. 2. Locate the 10 Amp circuit breaker (CB1) in the
control panel. See Control Panel Component
4. Connect the positive (+) test lead to an outer
Identification for circuit breaker location.
terminal.
3. See Figure 4-27. Disconnect wire 15A and wire
a. The meter should measure approximately 0.5
13A from the circuit breaker.
volts.
5. Connect the positive test lead to the other outer 4. Connect one meter test lead to one terminal of the
terminal. circuit breaker.
a. The meter should measure approximately 0.5 5. Connect the other meter test lead to the remaining
volts. terminal on the circuit breaker.
6. Connect the positive (+) test lead to the center a. Continuity should be measured.
terminal of BCR2.
7. Connect the negative (-) test lead to an outer
terminal.
a. The meter should measure Infinity. 13A
8. Connect the negative test lead to the other outer 15A
terminal.
a. The meter should measure Infinity.
!
!
!
10A CIRCUIT BREAKER (CB1)

004616
Figure 4-27. Testing 10 Amp Breaker

"#2 "#2 004651
Figure 4-26. Battery Charge Rectifier

Results 3. To inhibit any possible startup, turn off the fuel

source and ground wire 18 at the stud located
1. If continuity was measured the breaker is good
above the oil cooler. See Figure 4-39.
refer back to the flow chart.
4. Refer to battery post and starter connections in
2. If Infinity or a open condition was measured
Figure 4-29 and Figure 4-30 then perform a
replace the circuit breaker.
voltage drop test as indicated.
5. Set the start-run-stop switch to START. Allow the
Test 21 – Check 10 Amp Fuse engine to crank long enough to obtain a steady
Procedure measurement.
6. Record voltage readings from test points V1, V2,
Push in on fuse holder cap and turn counterclockwise to
V3 and V4. Although resistance-free connections,
remove the cap with fuse. Inspect the fuse.
wires and cables would be ideal, most of them will
contain at least some voltage drop. The maximum
voltage readings should be as follows:
a. 0.00-0.10 VDC across a connection or battery
post (V4).
b. 0.10-0.20 VDC on a ground connection.
003971 c. 0.20-0.30 VDC across a wire or cable (V1, V2).
Figure 4-28. 10 Amp Fuse (Located in Rear of Control
d. 0.20-0.30 VDC across a switch or starter
Panel)
contactor (V3).
Results e. 0.40-0.50 VDC across the entire circuit
If the fuse element has melted open, replace with an
identical size fuse. If fuse is good, refer back to flow chart. B
A
Test 22 – Check Battery and Cables

General Theory
Battery power is used to (a) crank the engine and (b) to
power the circuit board. Low or no battery voltage can
C
result in failure of the engine to crank.
The battery charging circuit is not designed to recharge a A. V1
dead battery. As well, if there is a loose connection or B. V2
corrosion associated with a wire (positive or negative), C. V3
battery voltage may be present, but due to high 002399
resistance, will not allow current to flow. Figure 4-29.
Electrical voltage drop varies according to current flow.
Voltage drop cannot be measured unless the circuit is
operated so current can flow through it. A crank attempt
will need to be performed to properly measure voltage
drop. This test will determine whether the battery, battery
cables, or both are at fault.
Procedure A – Perform Starter Circuit Voltage

Drop Test
1. Set a DMM to measure DC voltage. D
2. Connect the red meter test lead to the positive
battery post and connect the black meter test lead D. V4 004741
to the negative battery post. Figure 4-30.
a. If battery voltage is 12.1 VDC or below,
recharge the battery and retest. 7. If voltage drop is greater than the above, based on
b. If battery voltage is 12.2 VDC or above, the circuit or component, clean or replace the failed
proceed to next step. (For this test, battery connection or component. If voltage drop test
voltage should be at least 12.2 VDC) results are within the above, based on the circuit or
component, refer back to the flowchart.
Test 23 – Check Voltage At Starter 7. Connect the negative (-) meter test lead to a clean
Contactor (SC) frame ground.
8. Set the start-run-stop switch to START.
Procedure a. Battery voltage should be measured.
2. Disconnect wire 16 from the starter contactor Results
located on the starter motor. 1. If battery voltage was not measured in step 1,
3. Connect the positive meter test lead to wire 16 repeat Test 22.
removed in step 2. 2. If battery voltage was measured in step 4a, but not
4. Connect the negative meter test lead to frame in step 8a, replace the starter contactor.
ground. 3. If battery voltage was measured in step 8a but the
5. Set the start-run-stop switch to START. engine still does not crank, refer back to the flow
a. 12 VDC should be measured. chart.
6. Connect wire 16 to the starter motor.
Test 25 – Check Starter Motor
Results
Refer back to flow chart.
Conditions Affecting Starter Motor Performance
1. A binding or seizing condition in the starter motor
bearings.
Test 24 – Check Starter Contactor (SC)
2. A shorted, open or grounded armature.
Procedure • Shorted, armature (wire insulation worn and wires
1. Carefully inspect the starter motor cable that runs touching one another). Will be indicated by low or
from the battery to the starter motor. no RPM.
a. Cable connections should be clean and tight. • Open armature (wire broken) will be indicated by
low or no RPM and excessive current draw.
b. If connections are dirty or corroded, remove
cable and clean cable terminals and studs. • Grounded armature (wire insulation worn and wire
touching armature lamination or shaft). Will be
c. Replace any cable that is defective or badly
indicated by excessive current draw or no RPM.
corroded.
3. A defective starter motor switch.
4. Broken, damaged or weak magnets.
3. See Figure 4-31, Test Point 1. Connect the
5. Starter drive dirty or binding.
positive (+) meter test lead to the starter contactor
stud that the battery cable is connected to. Procedure
4. Connect the negative (-) meter test lead to a clean
The battery should be fully charged and checked prior to
frame ground.
this test.
a. Battery voltage should be measured.
Set DMM to measure DC voltage (12 VDC).
C Connect the meter positive (+) test lead to the starter
A D
contactor stud which has the small jumper wire
connected to the starter. Connect the common (-) test
lead to the starter motor frame.
Set the start-run-stop switch to START and observe the
meter. Meter should indicate battery voltage, starter
B
motor should operate and engine should crank.
Results
A. Starter Contactor C. Test Point 1 1. If battery voltage is indicated on the meter but
B. Starter Motor D. Test Point 2 004652 starter motor did not operate, remove and bench
Figure 4-31. The Starter Contactor (SC) test the starter motor.
2. If battery voltage was indicated and the starter
5. Set DMM to measure DC voltage. motor tried to engage (pinion engaged), but engine
6. See Figure 4-31, Test Point 2. Connect the did not crank, check for mechanical binding of the
positive (+) meter test lead to the starter contactor engine or rotor.
stud that has the small jumper wire connected to
the starter.

NOTE: If a starting problem is encountered, check the 2. Remove wire 15 from the starter contactor relay
engine for freedom of rotation. Remove the spark plugs (SCR).
and turn the crankshaft over slowly by hand, to verify that 3. Connect the positive meter test lead to wire 15
it rotates freely. removed in step 2.
4. Connect the negative meter test lead to frame
WARNING Ground.
Explosion. Turn fuel supply OFF before a. 12 VDC should be measured.
checking for spark. Failure to do so could b. If 12 VDC is not measured on wire 15 stop
result in death or severe injury. testing and repair or replace wire 15 between
(000333) the fuse (F1) and the SCR.
5. Connect wire 15 to the SCR.
DANGER
6. Remove wire 13 from the starter contactor relay
Explosion and fire.Fuel and vapors are extremely
(SCR).
flammable and explosive. No leakage of fuel is
permitted. Keep fire and spark away. Failure to do 7. Connect the positive meter test lead to wire 13
so will result in death or serious injury. previously removed.
(000192)
IMPORTANT NOTE: On engines with electric starter, Ground.
rotating the crankshaft too quickly can cause arcing at a. 12 VDC should be measured.
the spark plug ends. Arcing may ignite the gasoline vapor
exiting the spark plug hole. b. If 12 VDC is not measured on wire 13 stop
testing and repair or replace wire 13 between
the starter contactor (SC) and the starter
contactor relay (SCR).
9. Connect wire 13 to the SCR.
NOTE: Jumper leads may be used if necessary.
11. Remove wire 13, wire 16, and wire 17 from the
starter contactor relay (SCR)
002405
12. See Figure 4-34. Connect the meter leads across
Figure 4-32. Starter Motor (SM)
terminal 87 and terminal 30 of the SCR.
Checking The Pinion
16
When the starter motor is activated, the pinion gear
should move and engage the flywheel ring gear. If the
pinion does not move normally, inspect the pinion for SCR
binding or sticking.
87
15 87a
86 85
30 17
002403
13 004617
Figure 4-33. Check Pinion Gear Operation Figure 4-34. Starter Contactor Relay Test
Test 26 – Test Starter Contactor Relay 13. See Figure 4-34. Connect a jumper wire from
terminal 85 to ground.
(SCR)
a. The relay should energize and Continuity
Procedure should be measured.
1. Set DMM to measure DC voltage. 14. Connect all wires.

Results Test 28 – Check Start-Run-Stop

If Continuity was not measured in step 13 replace the Switch (SW1) Wiring
starter contactor relay. If all steps passed refer back to
flow chart. Procedure
Test 27 – Check Start-Run-Stop 2. Remove wire 17 from the starter contactor relay
Switch (SW1) (SCR).
3. Connect one meter test lead to wire 17.
Procedure
4. Remove wire 17 from the start-run-stop switch
1. Set DMM to measure resistance. (SW1).
2. Remove all wires from the start-run-stop switch 5. Connect the other meter test lead to wire 17.
(SW1).
3. Use the chart below to check the condition of the
6. See Figure 4-35. Remove wire 0 from both
start-run-stop switch.
positions on the start-run-stop switch (SW1).
4. Connect one meter test lead to one terminal and
7. Connect a meter test lead to each wire 0.
the other meter test lead to the other terminal.
5. With meter leads connected activate the switch to
START, STOP or RUN and follow the chart. 8. Connect one meter test lead to one wire 0 and
connect the other meter test lead to frame ground.
6. Connect all wires to the switch.
CONDITION TERMINALS RESULT
10. Remove wire 15 from the start-run-stop switch
STOP 5,4 OPEN (SW1).
STOP 5,6 CLOSED 11. Connect the positive meter test lead to wire 15.
STOP 2,1 OPEN ground.
STOP 2,3 CLOSED a. 12 VDC should be measured.
RUN ALL CONDITIONS OPEN Results
START 5,4 CLOSED Repair or replace any wiring that did not have continuity.
START 5,6 OPEN If voltage was not measured in step 12 repair wiring
between the starter contactor relay (SCR) and the start-
START 2,1 CLOSED run-stop switch (SW1).
START 2,3 OPEN If all steps passed, repair or replace wire 16 between the
starter contactor (SC) and the starter contactor relay
(SCR).
0
STOP 0 Test 29 – Check Ignition Spark
6 3
RUN
5 2
167
Procedure
4 1
A commercially available spark tester may be used to
START 15 test the engine ignition system. One can also be
purchased from Generac Power Systems (Part No.
17 15 004653
0C5969).
Figure 4-35. Start-Run-Stop Switch (SW1) 1. Disconnect a high tension lead from a spark plug.
2. Attach the high tension lead to the spark tester
Results terminal.
If the switch fails any part of the test procedure replace 3. See Figure 4-36. Ground the spark tester clamp by
the switch. attaching to the cylinder head.

000211
Figure 4-38. Setting Spark Plug Gap
002075
Results
1. Clean and re-gap or replace sparks plug as
Figure 4-36. Testing Ignition System
necessary.
4. Crank the engine rapidly. Engine must be cranking 2. Refer back to the flow chart.
at 350 rpm or more.
a. If spark jumps the tester gap, the ignition Test 31 – Remove Wire 18 / Shutdown
system is working properly. Lead
b. Repeat on remaining cylinder spark plug.
Procedure
5. If spark jumps the tester gap intermittently, the
problem may be in the ignition magneto. 1. See Figure 4-39. Disconnect wire 18 from the stud
located above the oil cooler.
2. Perform Test 29 again checking for spark.
Results
002074
Figure 4-37. Checking Engine Miss
Results
Refer back to the flow chart.
004658
Test 30 – Check Spark Plugs Figure 4-39. Wire 18
Procedure
1. Remove spark plugs. Test 32 – Test Start Stop Relay (SSR)
2. Clean with a commercial solvent. DO NOT BLAST Procedure
CLEAN SPARK PLUGS.
3. Replace spark plugs if badly fouled, if ceramic is
2. See Figure 4-40. Remove wire 15 from Terminal
cracked, or if badly worn or damaged.
13 on the start stop relay (SSR).
4. Set gap to 0.040 inch (1.016 mm). 3. Connect the positive meter test lead to wire 15
5. Use a Champion RC14YC (or equivalent) removed in step 2.
replacement spark plug. 4. Connect the negative meter test lead to frame
ground.
a. If 12 VDC is measured proceed to step 5.
b. If 12 VDC is not measured repair or replace
wire 15 between the SSR and battery charge
rectifier 2 (BCR2).
14 18 TEST POINTS C 18
14 TEST POINTS B
1 2 4 TEST POINTS A
5 6 8
15B
15 1 2 4
9 10 12
5 6 8
15B
15
0 9 10 12
13 14
15 SSR
0
13 14
15 SSR
15 229
004654
Figure 4-40. Start Stop Relay (SSR)

15 229
JUMPER LEAD
5. See Figure 4-40. Connect wire 15 to the SSR and
ADDED TO GROUND 004656
remove wire 229 from the SSR.
Figure 4-42. Start Stop Relay (SSR) Energized
6. Connect a jumper lead from the terminal of the
SSR where wire 229 was just removed and to
frame ground.
a. The relay should energize closed. Visually 17. Connect meter test leads across TEST POINTS A
inspect it to see if it closes. a. Infinity should be measured.
b. If the relay energizes closed proceed to step 4. 18. Connect meter test leads across TEST POINTS B
c. If the relay does not energize closed replace it. a. Continuity (closed) should be measured.
7. See Figure 4-41. Remove wire 0, wire 18, wire 15, 19. Connect meter test leads across TEST POINTS C
wire 15B, wire 15, and wire 14. a. Continuity (closed) should be measured.
20. If the SSR fails any test replace it.
9. Remove jumper lead from step 6.
10. Connect meter test leads across TEST POINTS A Results
a. Continuity (closed) should be measured. Refer to Flow Chart.
11. Connect meter test leads across TEST POINTS B
a. Infinity should be measured. Test 33 – Test Wire 167
12. Connect meter test leads across TEST POINTS C.
a. Infinity should be measured. Procedure
13. If the SSR fails any test replace it. 1. Set DMM to measure DC voltage.
2. See Figure 4-43. Remove the J2 connector from
TEST POINTS C
14 18 the circuit board.
TEST POINTS B
3. Connect the positive meter test lead to pin location
TEST POINTS A
J2-5, wire 167 on the removed harness connector.
1 2 4 4. Connect the negative meter test lead to frame
5 6 8
15B ground.
15
9 10 12 5. Set the start-run-stop switch (SW1) to START. The
engine will crank and 12 VDC should be measured.
0
13 14 a. If 12 VDC is measured, stop testing.
15 SSR
b. If 12 VDC is not measured continue testing.
229 6. See Figure 4-44. Connect the positive test lead to
15
004655 wire 167 at terminal block 1 (TB1).
Figure 4-41. Start Stop Relay (SSR) Not Energized NOTE: Where terminal block is not present, place meter
test lead on the wire at the termination point. If
14. See Figure 4-42. Remove wire 229 from the SSR. necessary, use a small paper clip to probe beside the
15. Connect a jumper lead from the terminal of the wire so as not to damage the terminal in the connector.
SSR that wire 229 was just removed from and to
frame ground.
a. The relay should energize closed.

STOP 0 STEP 4
6 3
5 2
RUN 167
STEP 5
J2-1 J2-12 4 1
START 15
17 15 004623
Figure 4-45. Test Wire 167, Steps 9-13

ground. 12 VDC should be measured.
J2 HARNESS CONNECTOR
004619 a. If 12 VDC is measured, replace SW1.
Figure 4-43. Test Wire 167, Steps 2-5 b. If 12 VDC is not measured repair or replace
wire 15 between SW1 and the Starter
7. Connect the negative meter test lead to frame Contactor Relay (SCR).
ground.
8. Set the start-run-stop switch (SW1) to START. 12 Test 34 – Test Start Stop Relay Wiring
VDC should be measured.
Procedure
a. If 12 VDC is measured, replace wire 167
1. Set DMM to the diode test range.
between TB1 and the J2 connector.
2. Disconnect wire 229 from the start stop relay
b. If 12 VDC is not measured continue testing. (SSR).
9. Connect the positive test lead to wire 167 3. Connect the positive meter test lead to wire 229
connected at the start-run-stop switch (SW1). removed in step 2.
10. Connect the negative meter test lead to frame 4. Connect the negative meter test lead to frame
ground. ground.
5. See Figure 4-46. Set the start-run-stop switch
86 15B 167 BLK
(SW1) to START. The meter should read
0 229 83 BLK
approximately 1.0 VDC.
a. If the correct voltage is indicated, stop testing.
TERMINAL TR2
BLOCK TR1 18
(TB1) 14
004620
Figure 4-44. Test Wire 167, Steps 6-8 1 2 4
5 6 8
15B
15
Set the start-run-stop switch (SW1) to START. 12
9 10 12
11.
VDC should be measured. 13 14
0
15 SSR
a. If 12 VDC is measured, repair or replace wire
167 between SW1 and the TB1.
b. If 12 VDC is not measured continue testing. 15 229 004624
12. See Figure 4-45. Connect the positive meter test
to wire 15 at SW1. Figure 4-46. Testing Wire 229 to Ground

7. If voltage was not measured in step 3 connect one Test 35 – Check and Adjust Ignition
meter test lead to wire 229 removed from the SSR. Magnetos
8. Connect the other meter test lead to wire 229 at the
terminal block 1 (TB1). Continuity should be Procedure
measured. 1. See Figure 4-48. Rotate the flywheel until the
a. If continuity is not measured repair or replace magnet is under the module (armature)
wire 229 between SSR and TB1. laminations.
NOTE: Where terminal block is not present, place meter 2. Place a 0.008-0.012 inch (0.20-0.30mm) thickness
test lead on the wire at the termination point. If gauge between the flywheel magnet and the
necessary, use a small paper clip to probe beside the module laminations.
9. Remove the J2 connector the printed circuit board.
10. Connect one meter test lead to pin location J2-8
(wire 229)
86 15B 167 BLK
0 229 83 BLK
00.00
TB1 TR2
TR1
Figure 4-48. Setting Ignition Magneto Air Gap
J2-1 J2-12
3. Loosen the mounting screws and let the magnet
pull the magneto down against the thickness
gauge.
4. Tighten both mounting screws.
5. To remove the thickness gauge, rotate the
flywheel.
6. Repeat the above procedure for the second
magneto.
J2 HARNESS CONNECTOR 004629
7. Repeat Test 29 – Check Ignition Spark and
Figure 4-47. Testing Wire 229 Between J2 Connector check for spark across the spark tester gap.
and Terminal Block 1 (TB1)
8. If air gap was not out of adjustment, remove engine
ground harness from magnetos. Repeat Test 29 –
11. See Figure 4-47. Connect the other meter test
Check Ignition Spark. If sparking now occurs
lead to wire 229 at TB1. Continuity should be
replace engine ground harness.
measured.
9. Check the flywheel magnet by holding a
a. If continuity is not measured repair or replace
screwdriver at the extreme end of its handle and
wire 229 between the J2 connector and TB1.
with its point down. When the tip of the screwdriver
Results is moved to within 3/4 inch (19 mm) of the magnet,
the blade should be pulled in against the magnet.
1. If step 5 passed refer to Flow Chart.
10. Check the flywheel key. The flywheel’s taper is
2. If step 5 failed and step 11 passed replace the locked on the crankshaft taper by the torque of the
printed circuit board. flywheel nut. A keyway is provided for alignment
only and theoretically carries no load.
NOTE: If the flywheel key becomes sheared or even
partially sheared, ignition timing can change. Incorrect
timing can result in hard starting or failure to start.

Results 13. Set the start-run-stop switch (SW1) to START. 12

VDC should be measured.
If sparking still does not occur after adjusting the
armature air gap, testing the ground wires and a. If 12 VDC is measured repair or replace wire
performing the basic flywheel test, replace the ignition 14 between the SSR and resistor R1 or
magneto(s). between resistor R1 and the FSS.
Results
Test 36 – Test Fuel Shutoff Solenoid
Refer to flow chart.
(FSS)
Procedure Test 38 – Check Fuel Pump
1. Disconnect wire 16 from the starter contactor (SC)
located on the starter motor.
Procedure
2. Remove the air cleaner cover. 1. Remove the fuel line from the fuel filter on the inlet
side of the carburetor. Use a suitable container to
3. Set the start-run-stop switch (SW1) to STOP then
catch fuel.
to START. When SW1 is activated a click should be
heard and or activation of the fuel shutoff solenoid
should be felt, indicating that the fuel shutoff A
solenoid is functioning.
Results
Refer to flow chart.
B
C
Test 37 –Test Fuel Shutoff Solenoid
Voltage
Procedure
1. Set DMM to measure DC voltage. D
2. Disconnect the two pin connector from the fuel 004661

shutoff solenoid (FSS). A. Fuel pump C. Pulse line
3. Connect the positive meter test lead to the red B. Fuel to carburetor D. Fuel from tank
wire. Figure 4-49. Fuel Pump and Fuel Lines
4. Connect the negative meter test lead to the black
wire. 2. Crank the engine. Fuel should flow from the fuel
line.
5. Set the start-run-stop switch (SW1) to START.
During cranking, 12 VDC should be measured. a. If fuel does not flow, verify that fuel is available
to the pump.
a. If DC voltage is not measured continue testing.
b. If fuel is available to the pump inspect the fuel
6. Set DMM to measure resistance. filter, pulse line, and or replace the fuel pump.
7. Connect one meter test lead to the black wire.
8. Connect the other meter test lead to frame ground. Results
Continuity should be measured. Refer to flow chart.
a. If continuity is not measured repair or replace
the black ground wire or correct poor ground Test 39 – Check Carburetion
connection.
9. Set DMM to measure DC voltage. Procedure
10. See Figure 4-53. Remove wire 14 from the Start Before making a carburetion check, verify the fuel supply
Stop Relay (SSR). tank has an ample supply of fresh, clean gasoline.
11. Connect the positive meter test lead to the terminal Check that all shutoff valves are open and fuel flows
of the SSR that wire 14 was just removed. freely through the fuel line.
12. Connect the negative meter test lead to frame Verify the choke operates properly.
ground.

If the engine will not start, remove and inspect the spark An alternative method is to turn the engine over and
plug. If the spark plug is wet, look for the following: position the intake valve fully open (intake valve spring
• Overchoking compressed) and adjust the exhaust valve clearance.
Turn the engine over and position the exhaust valve fully
• Excessively rich fuel mixture open (exhaust valve spring compressed) and adjust the
• Water in fuel intake valve clearance.
• Intake valve stuck open The correct clearance for intake and exhaust valves is
• Needle/float stuck open 0.002-0.004 inch (0.05-0.1 mm).
If the spark plug is dry look for the following:

• Leaking carburetor mounting gaskets
• Intake valve stuck closed
• Inoperative fuel pump
• Plugged fuel filter(s)
• Varnished carburetor
If the engine starts hard or will not start, look for the
following:
• Physical damage to the AC generator. Check the 000258
rotor for contact with the stator. Figure 4-50. Adjusting Valve Clearance
• Starting under load. Verify all loads are
disconnected or turned off before attempting to 1. See Figure 4-50. Loosen the rocker arm jam nut.
crank and start the engine. Use a 10mm allen wrench to turn the pivot ball stud
while checking the clearance between the rocker
• Check that the choke is working properly.
arm and valve stem with a feeler gauge.
1. Remove fuel line at carburetor and verify that there
2. When clearance is correct, hold the pivot ball stud
is an adequate amount of fuel entering the carbu-
with the allen wrench and tighten the rocker arm
retor.
jam nut to the specified torque with a suitable
2. Remove the float bowl and check to see if there is wrench. After tightening the jam nut, check valve
any foreign matter in bottom of carburetor bowl. clearance again to verify it did not change.
3. The float is plastic and can be removed to access Torque Specification Rocker Arm Jam Nut:
the needle for cleaning.
168 in-lbs (19 Nm)
4. Carburetor cleaner can be used to clean the rest of
the carburetor before assembly.
5. After cleaning carburetor with an approved
carburetor cleaner, blow dry with compressed air
and assemble.
Shelf life of gasoline is 30 days. Proper procedures need
to be taken prevent fuel from varnishing over time. Use a
fuel stabilizer to ensure that the fuel remains fresh.
Results
If carburetor is varnished, clean or replace.
Refer to Flow Chart. 002946
002946
Figure 4-51. Tightening the Jam Nut
Test 40 – Valve Adjustment Install Rocker Arm Cover
Adjusting Valve Clearance 1. Use a new rocker arm cover gasket. Install the
The valve lash must be adjusted correctly in order to rocker arm cover and retain with four screws.
provide the proper air/fuel mixture to the combustion
chamber.
Results
Adjust valve clearance with the engine at room Adjust valves to specification and repeat test. If problem
temperature. The piston should be at top dead center continues, refer to flow chart.
(TDC) of its compression stroke (both valves closed).

Test 41 – Check Engine / Cylinder Check Compression

Leak Down Test / Compression Test Lost or reduced engine compression can result in failure
Most engine problems may be classified as one or a of the engine to start, or rough operation. One or more of
combination of the following: the following will usually cause loss of compression:
• Will not start • Blown or leaking cylinder head gasket.
• Starts hard • Improperly seated or sticking-valves.
• Lack of power • Worn piston rings or cylinder. (This will also result
in high oil consumption).
• Runs rough
• Vibration Procedure
• Overheating 1. Remove both spark plugs.
• High oil consumption. 2. Insert a compression gauge into either cylinder.
The cylinder leak down tester (Generac P/N 3. Crank the engine until there is no further increase
0F77000SRV) checks the sealing (compression) ability of in pressure.
the engine by measuring air leakage from the 4. Record the highest reading obtained.
combustion chamber. Compression loss can present 5. Repeat the procedure for the remaining cylinder
many different symptoms. This test is designed to detect and record the highest reading.
the section of the engine where the fault lies before
disassembling the engine. Results
Procedure Normal compression is approximately 150 psi. The
difference in pressure between the two cylinders should
1. Remove a spark plug. not exceed 25 percent. If the difference is greater than 25
2. Gain access to the flywheel. percent, loss of compression in the lowest reading
3. Remove the valve cover. cylinder is indicated.
4. Rotate the engine crankshaft until the piston Example 1: If the pressure reading of cylinder 1 is 165
reaches top dead center (TDC). Both valves psi and of cylinder 2, 160 psi, the difference is 5 psi.
should be closed. Divide “5” by the highest reading (165) to obtain the
percentage of 3.0 percent.
5. Lock the flywheel at top dead center.
Example 2: Cylinder 1 reads 160 psi; cylinder 2 reads
6. Attach cylinder leak down tester adapter to spark
100 psi. The difference is 60 psi. Divide “60” by “160” to
plug hole.
obtain “37.5” percent. Loss of compression in cylinder 2
7. Connect an air source of at least 90 psi to the leak is indicated.
down tester.
If compression is poor, look for one or more of the
8. Adjust the regulated pressure on the gauge to 80 following causes:
psi.
• Loose cylinder head bolts
9. Read the right hand gauge on the tester for
cylinder pressure. 20 percent leakage is normally • Failed cylinder head gasket
acceptable. • Burned valves or valve seats
NOTE: Use good judgment, and listen for air escaping at • Insufficient valve clearance
the carburetor, the exhaust, and the crankcase breather. • Warped cylinder head
This will determine where the fault lies. • Warped valve stem
10. Repeat steps 1 through 9 on remaining cylinder. • Worn or broken piston ring(s)
• Worn or damaged cylinder bore
Results
• Broken connecting rod
• Air escapes at the carburetor – check intake valve. • Worn valve seats or valves
• Air escapes through the exhaust – check exhaust • Worn valve guides
valve.
NOTE: Refer to Engine Service Manual Generac P/N
• Air escapes through the breather – check piston 0F6923 for further engine service information.
rings.
• Air escapes from the cylinder head – the head
gasket should be replaced.

Test 42 – Check Oil Pressure Switch 8. Crank and start the engine.
and Wire 86 a. Infinity should be measured.
• If the engine cranks and starts, then shuts down 9. Connect one test lead to wire 0 (disconnected from
almost immediately, the cause may be one or more LOP).
of the following: 10. Connect the other test lead to a clean frame
• Low engine oil level ground.
• Low oil pressure a. Continuity should be measured.
• A defective oil pressure switch b. If continuity is not measured repair or replace
wire 0 between the LOP and the ground
terminal connection on the engine mount.
11. If the LOP switch tests good in steps 5-10 and oil
pressure is good in steps 2-4, but the unit still shuts
down with a LOP fault, check wire 86 for a short to
ground.
13. Disconnect the J2 connector from the circuit board.
14. Remove wire 86 from the LOP switch.
15. Connect one test lead to wire 86.
004663
16. Connect the other test lead to a clean frame
ground.
Figure 4-52. Low Oil Pressure Switch
Procedure b. If Continuity is measured, repair or replace
1. Check engine crankcase oil level. If necessary, add wire 86 between the LOP switch and the J2
the recommended oil to the dipstick FULL mark. connector.
NOTE: Do not overfill above the full mark. Results

2. Disconnect wire 86 and wire 0 from the oil pressure 1. If switch tests good, refer to Flow Chart.
switch terminals. 2. Replace switch if it fails the test.
3. Remove the switch and install an oil pressure
gauge in its place. Test 43 - Check Start Stop Relay (SSR)
4. Start the engine while observing the oil pressure
reading on gauge. Normal oil pressure is Procedure
approximately 35-40 psi with engine running. 1. Set DMM to measure resistance.
a. If normal oil pressure is indicated, go to step 2. See Figure 4-53. Disconnect wire 15 and wire 229
11 of this test. from the Start Stop Relay (SSR).
b. If oil pressure is below about 10 psi, shut
engine down immediately. A problem exists in 14 18
the engine lubrication system.
NOTE: The oil pressure switch is rated at 10 psi for v- 1 2 4
twin engines. 5 6 8
15B
15
9 10 12
NOTE: Refer to Service Manual, Generac P/N 0F6923 0
for engine service recommendations. 13 14
15 SSR
5. Remove the oil pressure gauge and install the oil 229
pressure switch.
15
NOTE: Do not connect wire 86 or wire 0 to the switch 004630
terminals. Figure 4-53. Testing Start Stop Relay (SSR)
3. Connect one meter test lead to the terminal that
7. Connect the meter test leads across the switch
wire 15 was removed from.
terminals.
4. Connect the other meter test lead to the terminal
a. With engine shut down, Continuity should be
that wire 229 was removed from.
measured.
a. Resistance measured should be approximately 5. Disconnect wire 15 from the start-run-stop switch
100 ohms. (SW1).
6. Disconnect wire 15 from the battery charge rectifier
Results
2 (BCR2).
1. If the SSR measures continuity or zero resistance it 7. Remove wire 15 from the fuse holder (F1).
is shorted to ground and should be replaced.
8. Connect one meter test lead to wire 15 just
2. If the SSR resistance is correct refer to flow chart. removed.
9. Connect the other meter test lead to frame ground.
Test 44 – Test Starter Contactor Relay 10. Infinity should be measured.
(SCR)
Results
Procedure
If Infinity was not measured a short on wire 15 to ground
1. Set DMM to measure resistance. exists. Inspect each wire 15 for a shorted condition.
2. See Figure 4-54. Disconnect wire 15 and wire 17 Repair or replace as needed.
from the starter contactor relay (SCR).
3. Connect one meter test lead to the terminal that Test 46 – Check Wire 14 Circuit
wire 15 was removed from.
Procedure
2. Disconnect wire 14 from the start stop relay (SSR).
SCR 3. Connect one meter test lead to wire 14 previously
16 removed. Connect the other meter test lead to frame
ground. Approximately 38 ohms should be measured.
87 Results
15 87a
86 85 Refer back to flow chart.
30 17
Test 47 – Check Fuel Shutoff Solenoid
13 (FSS)
004631
Procedure
Figure 4-54. Testing Starter Contactor Relay (SCR) 1. Set DMM to measure resistance.
2. Disconnect the plug from the fuel shutoff solenoid
4. Connect the other meter test lead to the terminal
(FSS).
that wire 17 was removed from.
3. Connect one meter test lead to one pin on the
a. Resistance measured should be approximately
FSS.
75 ohms.
4. Connect the other meter test lead to the remaining
Results pin on the FSS.
1. If the SCR measures continuity or zero resistance a. Approximately 38 ohms should be measured.
it is shorted to ground and should be replaced. 5. Connect one meter test lead to one pin on the
2. If the SCR resistance is correct refer to flow chart. FSS.
Test 45 – Check Wire 15 Circuit a. Infinity should be measured.
Procedure Results
1. Set DMM to measure resistance. 1. If continuity or zero was measured in step 3 or step
2. Remove fuse F1. 6 replace the FSS.
3. Disconnect wire 15 from the start stop relay (SSR). 2. (Units without hour meter) If correct resistance was
measured refer to flow chart, repair or replace wire
NOTE: See Figure 4-53. wire 15 connects to the SSR at 14 between the FSS and resistor R1.
three terminals.
3. (Units with hour meter) Refer back to flow chart.
4. Disconnect wire 15 from the starter contactor (SC).

Test 48 – Check Hour Meter Test 50 – Check Wire 167

Procedure Procedure
1. Disconnect wire 14 from the hour meter. 1. Set DMM to measure resistance.
2. Install new 10 Amp fuse. 2. See Figure 4-56. Disconnect wire 167 from the
3. Set start-run-stop switch (SW1) to START. start-run-stop switch (SW1).
4. Check to see if fuse blows open. 3. Connect one meter test lead to wire 167 previously
removed.
Results 4. Connect the other meter test lead to frame ground.
1. If fuse did not blow open replace the hour meter. a. Infinity should be measured.
2. If fuse blows open repair or replace wire 14 5. If continuity or zero resistance was measured
between the resistor (R1) and the hour meter (HM) remove the J2 connector from the printed circuit
or between the HM and the fuel shutoff solenoid board and repeat steps 3 and 4.
(FSS).
Test 49 – Check Wire 15B 0

0
Procedure
1. Set DMM to measure resistance. (START)
6 3
2. See Figure 4-55. Disconnect wire 15B from the 5 2
Start Stop Relay (SSR). RUN
167
3. Connect one meter test lead to wire 15B previously 4 1
removed. STOP 15
a. Approximately 20K ohms should be measured. 17 15 004633
5. If continuity or zero resistance was measured Figure 4-56. Check Wire 167
remove the J2 connector from the printed circuit
board and repeat steps 3 and 4. Results
1. If continuity was measured in step 4 but not in step
5, replace the printed circuit board.
2. If continuity was measured in step 5 wire 167 is
14 shorted to ground. Repair or replace wire 167
18
between the SW1 and printed circuit board.
1 2 4
15B Test 51 – Check Wires 11S & 44S or
11S & 22S
5 6 8
15
9 10 12
0
15
13
SSR
14 Procedure
15 229 2. Disconnect the J2 connector from the printed
004632
circuit board.
Figure 4-55. Check Wire 15B 3. Connect one meter test lead to pin location J2-10
wire 44S of the connector just removed.
Results 4. Connect the other meter test lead to wire 44S at
1. If continuity was measured in step 4 but not in step terminal block 2 (TB2).
5, replace the printed circuit board. a. Continuity should be measured.
2. If continuity was measured in step 5, wire 15B is 5. Connect one meter test lead to pin location J2-12
shorted to ground, repair or replace wire 15B wire 11S.
between the SSR and printed circuit board.

44S OLDER
22S NEWER 11S
SW2
TB2
STEP 2
STEP 3
STEP 2
STEP 3
J2-1 J2-12
004635
Figure 4-58. Check Idle Control Switch (SW2)
Test 53 – Check Idle Control Wiring

Procedure
J2 HARNESS CONNECTOR 004634 2. Disconnect wire 0 from the Idle Control Switch
Figure 4-57. Check Wires 11S & 44S or 11S & 22S (SW2).
3. Connect one meter test lead to wire 0.
6. Connect the other meter test lead to wire 11S at 4. Connect the other meter test lead to frame ground.
terminal block 2 (TB2). Continuity should be measured.
a. Continuity should be measured. a. If continuity is not measured repair or replace
NOTE: Where terminal block is not present, place meter wire 0 between SW2 and the ground terminal.
test lead on the wire at the termination point. If 5. Disconnect wire 83 from SW2.
necessary, use a small paper clip to probe beside the 6. Disconnect the J2 connector from the printed
wire so as not to damage the terminal in the connector. circuit board.
Results
1. If Continuity was not measured, repair or replace
the wire harness.
SW2
2. If Continuity was measured, refer back to the flow
chart.
Test 52 – Check Idle Control Switch 83
(SW2)
0
Procedure
2. Disconnect wire 0 and wire 83 from the idle control
switch (SW2).
3. See Figure 4-58. Connect meter test leads across J2-1 J2-12
both terminals of SW2.

a. In the OFF position Infinity should be
measured.
b. In the ON position Continuity should be
measured.
Results
004636
1. If the switch fails step 3 replace it. J2 HARNESS CONNECTOR
2. If the switch is good refer back to the flow chart. Figure 4-59. Check Idle Control Wiring

7. Connect one meter test lead to wire 83 previously 10. When the drill is activated measure the voltage
removed from SW2. output. The AC voltage should measure around 1-
8. See Figure 4-59. Connect the other meter test 2 VAC.
lead to pin location J2-2 on the J2 connector.
Results
b. If Continuity is not measured repair or replace
wire 83 between the J2 connector and terminal
block or between the terminal block and SW2. Test 55 – Check TR1 & TR2 Wiring
Procedure
Results
Repair or replace wiring as needed. Refer back to the
flow chart. 2. Disconnect the J2 connector from the printed
circuit board.
3. See Figure 4-61. Connect one meter test lead to
Test 54 – Check Idle Control wire TR2 at terminal block 1 (TB1).
Transformers (ICT)
NOTE: Where terminal block is not present, place meter
Procedure test lead on the wire at the termination point. If
1. Set DMM to measure resistance. necessary, use a small paper clip to probe beside the
2. See Figure 4-60. Remove the two idle control
transformer (ICT) wires from terminal block 1 4. Connect the other meter test lead to pin location
(TB1). J2-6 on the J2 connector previously removed.
NOTE: Where terminal block is not present, place meter a. Continuity should be measured.
test lead on the wire at the termination point. If 5. See Figure 4-62. Connect one meter test lead to
necessary, use a small paper clip to probe beside the wire TR1 at terminal block 1 (TB1).
wire so as not to damage the terminal in the connector. 6. Connect the other meter test lead to pin location
J2-3 on the J2 connector previously removed.
BLK BLK a. Continuity should be measured.
86 15B 167
86 15B 167 BLK
0 229 83
0 229 83 BLK
TR2
TB1 TR2
TR1
TR1
004637
Figure 4-60. Check Idle Transformer Wiring
3. Connect one meter test lead to one wire.

4. Connect the other meter test lead to the other wire. J2-1 J2-12
a. Approximately 100 ohms should be measured.

b. If resistance is not measured repair or replace
the idle control transformers.
c. If resistance was measured proceed with step 5.
5. Set DMM to measure AC Voltage.
6. Connect one meter test lead to one wire.
7. Connect the other meter test lead to the other wire. J2 HARNESS CONNECTOR 004638
8. Turn the idle control switch (SW2) to OFF. The Figure 4-61. Check TR2 Wiring
generator should be running at about 60 HZ.
9. Apply a light load to the generator, such as an Results
electric drill. 1. Repair or replace defective wiring.
2. If wiring tests good replace printed circuit board.

IMPORTANT NOTE: When testing stators and rotors,

86 15B 167 BLK set Megohmmeter to 500 volts and apply voltage for a
0 229 83 BLK maximum of one second. Follow the megohmmeter
manufacturers instructions carefully. Do not exceed 500
volts or apply voltage longer than 1 second.
megohmmeter high voltages could cause damage to
other components on the generator. Take the proper
precautions before testing.
TB1 TR2
TR1
Testing Stator Insulation
See Figure 4-64. All parts that might be damaged by the
high megger voltages must be disconnected before
testing. Isolate all stator leads and connect all of the
J2-1 J2-12 stator leads together.
IMPORTANT NOTE: Follow the megger manufacturer’s
instructions carefully.
Use a megohmmeter power setting of 500 volts. Connect
one megohmmeter test lead to the junction of all the
stator leads. Connect the other test lead to a frame
ground on the stator can. Read the number of megohms
on the meter.
J2 HARNESS CONNECTOR
004639 To calculate the minimum acceptable megohmmeter
Figure 4-62. Check TR1 Wiring readings use the following formula:
Minimum Insulation Generator Rated Volts

Test 56 – Choke Test Resistance (In “Megohms”)
=
1000
+1
Procedure
EXAMPLE: Generator is rated at 120 volts AC. Divide
If the generator is surging it may have a carburetion “120” by “1000” to obtain “0.12”. Then add “1” to obtain
problem. A lean condition can cause erratic RPM. Slowly “1.12” megohms. Minimum insulation resistance for a
pull the choke out to see if surging stops. If it does stop, 120 VAC stator is 1.12 megohms.
carburetion should be checked.
If the stator insulation resistance is less than the calculated
minimum resistance, clean and dry the stator. Then, repeat
Insulation Resistance the test. If resistance is still low, replace the stator.
The insulation resistances of stator and rotor windings are Use the megohmmeter to test for shorts between isolated
a measurement of the integrity of the insulating material windings as outlined in Stator Insulation Resistance
that separates the electrical windings from the generator Test.
steel core. This resistance can degrade over time or due
Also test between parallel windings. See Test Between
to such contaminates as dust, dirt, oil, grease and
Windings.
especially moisture. In most cases, failures of stator and
rotor windings are due to a break down in the insulation. Testing Rotor Insulation
In many cases, a low insulation resistance is caused by
moisture that collects while the generator is shut down. Apply a voltage of 500 volts across the rotor positive slip
ring (nearest the rotor bearing), and a ground (i.e. the
When problems are caused by moisture buildup on the
rotor shaft).
windings, this can usually be corrected by drying the
windings. Cleaning and drying the windings can usually IMPORTANT NOTE: When testing stators and rotors,
eliminate dirt and moisture that has built up in the set megohmmeter to 500 volts and apply voltage for a
generator windings. maximum of one second. Follow the megohmmeter
manufacturers instructions carefully. Do not exceed 500
The Megohmmeter volts or apply voltage longer than 1 second.
megohmmeter high voltages could cause damage to
Introduction other components on the generator. Take the proper
precautions before testing.
A megohmmeter (often called a megger), consists of a
meter calibrated in megohms and a power supply. Rotor Minimum Insulation Resistance:
1.5 Megohms

IMPORTANT NOTE: Before attempting to measure

Insulation resistance, first disconnect and Isolate all
leads of the winding to be tested. electronic components, E
diodes, surge protectors, relays, voltage regulators, etc., A B C D G H I J K L M
can be destroyed if subjected to high megger voltages. F
Hi-Pot Tester
A hi-pot tester is shown in Figure 4-63. The model shown
is only one of many that are commercially available. The
tester shown is equipped with a voltage selector switch
that permits the power supply voltage to be selected. It
Item Wire Number Winding
also mounts a breakdown lamp that will illuminate to 004714
A 11 Power Winding
indicate an insulation breakdown during the test.
B 44 Power Winding
C 22 Power Winding
D 11S Sense Lead Power
E 44S Sense Lead Power (Older Style)
F 22S Sense Lead Power (Newer Style)
G 55A Battery Charge
H 66A Battery Charge
I 77A Battery Charge
J 2 Excitation
K 6 Excitation
L 55 10 Amp Battery Charge
004713
M 66 10 Amp Battery Charge
Figure 4-63. One Type of Hi-Pot Tester N 77 10 Amp Battery Charge
Figure 4-64. Stator Assembly Leads

Stator Insulation Resistance Test
Units with air-cooled engines are equipped with center 5. Connect the red test probe of the Hi-Pot tester to
tapped AC power windings, an excitation or DPE the joined terminal ends of stator leads 11, 22, and
winding, a center tapped battery charge winding and a 10 44. Connect the black tester lead to a clean frame
Amp center tapped battery charge winding. Insulation ground on the stator can. With tester leads
tests of the stator consist of testing all windings to connected in this manner, proceed as follows:
ground, testing between isolated windings, and testing a. Turn the hi-pot tester switch OFF.
between parallel windings. Figure 4-64 is a pictorial
b. Plug the tester cord into a 120 volt AC wall
representation of the various stator leads on units with
socket and set its voltage selector switch to
air-cooled engine.
“1500 volts”.
Testing All Stator Windings To Ground c. Turn the tester switch ON and observe the
breakdown lamp on tester. DO NOT APPLY
1. Disconnect stator output leads wire 11 and wire 44
VOLTAGE LONGER THAN 1 SECOND. After
from the generator 50A circuit breaker.
one (1) second, turn the tester switch OFF.
2. Remove stator output lead wire 22 from the neutral
If the breakdown lamp comes on during the one-second
terminal on the back of the 50A outlet.
test, the stator should be cleaned and dried. After
3. Disconnect the C1 connector from the bottom of cleaning and drying, repeat the insulation test. If, after
the control panel. See Control Panel Component cleaning and drying, the stator fails the second test, the
Identification. The C1 connector is on the right stator assembly should be replaced.
when facing the control panel.
6. Now proceed to the C1 connector (female side –
4. Connect the terminal ends of wires 11, 22, and 44 just removed). Each winding will be individually
together. Make sure the wire ends are not touching tested for a short to ground. Insert a large paper
any part of the generator frame or any terminal. clip (or similar item) into the C1 connector at the
following pin locations:
Next refer to steps 5a through 5c of the hi-pot procedure.
Example: Insert paper clip into pin 1, hi-pot from pin 1
(wire 11S) to ground. Proceed to pin 2, pin 3, etc. through
pin 10.

OLDER 44S
2. Connect the black tester probe to a clean frame
22S NEWER
ground, such as a clean metal part of the rotor
77A 66A
55A 11S
shaft.
2
6 5 4 3 2 1
7 8 9 10 11 12
55 0
77
6 66 4 004642 POSITIVE (+)
TEST LEAD
004649
Figure 4-65. C1 Connector Pin Location Numbers
(Female Side) Figure 4-66. Testing Rotor Insulation
Test Between Windings 3. Turn the tester switch OFF.

1. Insert a paper clip into pin Location 3 (wire 55A). 4. Plug the tester into a 120 volts AC wall socket and
Connect the red tester probe to the paper clip. set the voltage switch to “1500 volts”.
Connect the black tester probe to stator lead 11. 5. Turn the tester switch ON and make sure the pilot
Refer to steps 5a through 5c of Testing All Stator light has turned on.
Windings To Ground. 6. Observe the breakdown lamp, then turn the tester
2. Repeat step 1 at pin Location 6 (wire 2) and stator switch OFF. DO NOT APPLY VOLTAGE LONGER
Lead 11. THAN ONE (1) SECOND.
3. Repeat step 1 at pin Location 8 (wire 55) and stator If the breakdown lamp came on during the one (1)
lead 11. second test, cleaning and drying of the rotor may be
For the following steps (4 through 6) an additional paper necessary. After cleaning and drying, repeat the
clip (or similar item) will be needed: insulation breakdown test. If breakdown lamp comes on
during the second test, replace the rotor assembly.
4. Insert a paper clip into pin Location 3 (wire 55A).
Connect the red tester probe to the paper clip.
Insert additional paper clip into pin Location 6 (wire Cleaning the Generator
2). Connect the black tester probe to this paper Caked or greasy dirt may be loosened with a soft brush
clip. Refer to steps 5a through 5c of Testing All or a damp cloth. A vacuum system may be used to clean
Stator Windings To Ground. up loosened dirt. Dust and dirt may also be removed
5. Insert a paper clip into pin Location 3 (wire 55A). using dry, low-pressure air (25 psi maximum).
Connect the red tester probe to the paper clip. IMPORTANT NOTE: Do not use sprayed water to clean
Insert additional paper clip into pin Location 8 (wire the generator. Some of the water will be retained on
55). Connect the black tester probe to this paper generator windings and terminals, and may cause very
clip. Refer to steps 5a through 5c of Testing All serious problems.
Stator Windings To Ground.
Insert a paper clip into pin Location 6 (wire 2).
6.
Connect the red tester probe to the paper clip.
Drying the Generator
Insert the additional paper clip into pin Location 8 To dry a generator, proceed as follows:
(wire 55). Connect the black tester probe to this 1. Open the generator main circuit breaker. NO
paper clip. Refer to steps 5a through 5c of Testing ELECTRICAL LOADS MUST BE APPLIED TO
All Stator Windings To Ground. THE GENERATOR WHILE DRYING.
2. Provide an external source to blow warm, dry air
Rotor Insulation Resistance Test through the generator interior (around the rotor and
stator windings. DO NOT EXCEED 185 °F. (85
Before attempting to test rotor insulation, the brush holder
°C.).
must be completely removed. The rotor must be
completely isolated from other components before starting 3. Start the generator and let it run for 2 or 3 hours.
the test. Attach all leads of all stator windings to ground. 4. Shut the generator down and repeat the stator and
1. Connect the red tester lead to the positive (+) slip rotor insulation resistance tests.
ring (nearest the rotor bearing).

Wattage Reference Guide

Device Running Watts Device Running Watts
*Air Conditioner (12,000 Btu) 1700 Hand Drill 250 to 1100
*Air Conditioner (24,000 Btu) 3800 Hedge Trimmer 450
*Air Conditioner (40,000 Btu) 6000 Impact Wrench 500
Battery Charger (20 Amp) 500 Iron 1200
Belt Sander (3") 1000 *Jet Pump 800
Chain Saw 1200 Lawn Mower 1200
Circular Saw (6-1/2") 800 to 1000 Light Bulb 100

*Clothes Dryer (Electric) 5750 Microwave Oven 700 to 1000
*Clothes Dryer (Gas) 700 *Milk Cooler 1100
*Clothes Washer 1150 Oil Burner on Furnace 300
Coffee Maker 1750 Oil Fired Space Heater (140,000 Btu) 400
*Compressor (1 HP) 2000 Oil Fired Space Heater (85,000 Btu) 225
*Compressor (3/4 HP) 1800 Oil Fired Space Heater (30,000 Btu) 150
*Compressor (1/2 HP) 1400 *Paint Sprayer, Airless (1/3 HP) 600
Curling Iron 700 Paint Sprayer, Airless (hand held) 150
*Dehumidifier 650 Radio 50 to 200
Disc Sander (9") 1200 *Refrigerator 700
Edge Trimmer 500 Slow Cooker 200
Electric Blanket 400 *Submersible Pump (1-1/2 HP) 2800
Electric Nail Gun 1200 *Submersible Pump (1 HP) 2000
Electric Range (per element) 1500 *Submersible Pump (1/2 HP) 1500
Electric Skillet 1250 *Sump Pump 800 to 1050
*Freezer 700 *Table Saw (10") 1750 to 2000

*Furnace Fan (3/5 HP) 875 Television 200 to 500
*Garage Door Opener 500 to 750 Toaster 1000 to 1650
Hair Dryer 1200 Weed Trimmer 500

* Allow 3 times the listed watts for starting these devices.

Section 5 Disassembly
Major Disassembly Figure 5-2. Stepper Motor Harness
Stator, Rotor, and Engine Removal

See Figure 5-11 and Figure 5-12 for component
location.
1. Disconnect and remove the battery from the
generator. (Figure 5-12, Item 15)
2. Remove Fuel Tank. Use proper safety precautions
when handling gasoline. (Figure 5-12, Item 4)
004668
Figure 5-3. Control Panel Removed
004665
Figure 5-1. Fuel Tank Removed
Remove Control Panel

1. Disconnect wire 11 and wire 44 from the 50 Amp
circuit breaker.
2. Disconnect wire 22 from the 50 Amp receptacle.
3. Disconnect the stepper motor harness from the
printed circuit board. 004669
4. Disconnect the C1 and C2 connectors below the Figure 5-4. Remove Air Deflector
control panel.
5. Remove the control panel. Remove the Muffler
1. Remove air deflector from cross member. (Figure
5-12, Item 45)
2. Remove the four screws holding the alternator air
cover on the rear of the alternator. (Figure 5-11,
Item 8)
3. Remove the muffler heat shield labeled HOT.
(Figure 5-11, Item 34)
4. Remove the rear muffler box end panel. (Figure 5-
11, Item 38)
5. Remove the nut and washers from the top of the
rear rubber mounts attached to the rear bearing
carrier. (Figure 5-11, Item 32)
6. Remove the back muffler box back panel. (Figure
004667
5-11, Item 37)

7. Remove the M8 bolt from the rear bearing carrier. 2. Cut 2.5 inches from the hex head end of the rotor
(Figure 5-11, Item 15) bolt.
8. Remove the exhaust clamp. (Figure 5-11, Item 35) 3. Slot the end of the bolt to suit a flat blade
9. Remove the muffler. (Figure 5-11, Item 6) screwdriver.
4. Slide the rotor bolt back through the rotor and use
a screwdriver to screw it into the crankshaft.
5. Use a 3” M12 x 1.75 bolt to screw into the rotor.
6. Apply torque to the 3” bolt until the taper breaks.
NOTE: If necessary use a rubber mallet on the end of
the rotor shaft to break the taper when torque is applied
to the 3” bolt.
004670
Figure 5-5. Remove Muffler
Remove Stator
1. Disconnect wire 4 and wire 0 from the brush
assembly. (Figure 5-11, Item 21)
2. Remove the brush assembly. Remove the four
stator hold down bolts. (Figure 5-11, Item 12)
3. Lift the rear end of the alternator up to clear the 004672
muffler frame from the rubber alternator mount. Figure 5-7. Remove Bearing Carrier
Place a 2x4 under the front bearing carrier for
support.
4. Using a rubber mallet carefully remove the rear
bearing carrier. (Figure 5-11, Item 4)
5. Rotate the rotor so that the steel laminations face
the top and bottom.
6. Remove the stator can.
004673
Figure 5-8. Remove Stator
004671
Figure 5-6. Support Alternator
Remove Rotor
1. Remove rotor bolt. (Figure 5-11, Item 11)

004674
Figure 5-9. Remove Rotor
004675
Figure 5-10. Engine Ready for Removal
Remove Engine
7. Remove the four nuts from rubber engine mounts.
(Figure 5-11, Item 29)
8. Remove engine.
Reverse procedure for assembly.

5 7
35
31
29
1 36
2 28
29
3 30 26 18
24
4 22
9 20
21 25
46 40 32
37
15 10
14 19
6
23 31 17 28
24 32 31
11 28 42 10 16 27
19
12 43
44 32
8
33 13
39
38 40
41
30 45
28
34 31
32
004676
Figure 5-11. Exploded View Generator

Item Qty. Description Item Qty. Description

1 1 Adaptor, Engine 24 5 Washer Lock 3/8
2 1 Stator 25 4 Screw HHC 3/8-16 X 1-1/4 G5
3 1 Assembly, Rotor W/Fan 26 4 Washer Flat 3/8-M10 Zinc
4 1 Carrier, Rear Bearing 27 4 Screw HHC M8-1.25 X 50 G8.8
5 1 Exhaust Manifold 28 21 Washer Flat 5/16 Zinc
6 1 Muffler 29 4 Nut Lock Hex M8-1.25 Nylon Insert
7 1 Gasket, Exhaust 30 7 Screw HHC M6-1.0 X 12
8 1 Cover, Alternator Air Intake 31 18 Washer Lock M8-5/16
9 1 Bearing 32 12 Nut Hex 5/16-18 Steel
10 3 5/16 Special Lock Washer 33 2 Screw Taptite 3/8-16 X 3/4 BP
11 1 Screw IHHC 3/8-24 X 15.50 G5 34 1 Shield, Muffler Heat
12 4 Screw IHHC M8-1.25 X 400 G8.8 35 1 U-bolt & Saddle
13 1 Bracket, ALT Mounting 36 4 Screw SHC M8-1.25 X 18
14 4 Screw HHTT #10-32 X 1.75 37 1 Panel, Muffler Box Back
15 1 Screw HHTT M8-1.2 X 20 38 1 Panel, Muffler Box End
16 1 Engine Mounting Plate 39 3 Screw HHTT M6-1.0 X 12
17 6 Rubber Mount 40 7 Washer Flat M6-1/4
18 1 Battery Cable, Black 41 7 Washer Lock M6-1/4
19 1 Earth Strap 3/8x 3/8 42 1 Spark Arrestor Screen
20 1 Clip-j Vinyl Coat .625 ID 43 1 Retainer, Spark Arrest Screen
21 1 Assembly, Brush Holder 44 1 Screw HHTT M4-0.7 X 8
22 1 Screw Tap-R #10-32 X 9/16 45 1 Shield, Rubber Mount
23 1 Washer Flat 3/8 Zinc 46 2 Screw HHTT M5-0.8 X 16

1
3
4 23
47
6 44
5 7
25 2
45
48
9
8
12
13 43
11
10
14
15
46
37
7
33
36
16
7 17 6
35
18 40 31
17 41 30
19 39
29 51
26 32
29
17
20
21
52
34 22
42 27
28
26
7
24 6
36
39
38
004677
Figure 5-12. Exploded View Frame, Handle, and Wheels

ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION

1 4 Screw HHC M6-1.0 X 55 28 1 Axle, 3/4” Dia X 30” (15 kW)
2 4 Rubber Tank Mount 1 Axle, 3/4” Dia X 27.25” (12.5 kW)
3 1 Cap, Fuel With Gauge & Vent 29 2 Washer Flat 3/4” (15 kW)
4 1 Kit, Fuel Tank 4 Washer Flat 3/4” (12.5 kW)
5 4 Nut Hex M8-1.25 30 2 12.3” Pneum Wheel 3/4” Axle (15 kW)
6 10 Washer Lock M8-5/16 2 10” Pneum Wheel 3/4” Axle (12.5 kW)
7 14 Washer Flat 5/16 31 2 Pin Cotter 1/8 X 1-1/4
8 1 Bracket Battery 32 2 Bracket, Wheel Spacer
9 2 Bolt, Battery J-Bolt 33 4 Nut Flange M6-1.0 Nylok
10 2 Screw HHC 1/4-20 X 3/4 G5 34 1 Handle
11 2 Washer Flat 1/4 35 4 Screw HHC 5/16-18 X 2-1/2 G5
12 2 Washer Lock M6-1/4 36 6 Nut Lock Hex 5/16-18 Nylon Insert
13 2 Nut Hex 1/4-20 37 1 Frame
14 1 Battery Cable, Red 38 4 Screw HHC M5-0.8 X 45 G8.8
15 1 Battery U1 39 8 Washer Flat M5
16 1 Nut Wing 5/16-18 Brass 40 4 Washer Lock M5
17 4 Washer Flat 5/16 Brass 41 4 Nut Hex M5-0.8
18 1 Nut Hex 5/16-18 Brass 42 2 Washer Flat 1”
19 1 5/16 Special L/wash 43 1 Bushing Tank Dextor
20 1 Screw HHC 5/16-18 X 1.5 Brass 44 1 Valve, Plastic Tank
21 1 Bracket Front Foot 45 1 Air Deflector
22 2 Vib Mount 46 2 Grommet .75 X .06 X .50
23 4 Washer Flat .25ID X 1”OD 47 2 Clamp Hose Band ¼
24 2 Screw HHC M8-1.25 X 30 48 18” Hose ¼ Id
25 4 Screw HHTT M6-1.0 X 12 49 1 Boot Battery Cable
25 4 Screw HHTT M6-1.0 X 12 50 1 Boot Starter Cable
26 6 Nut Lock Fl 3/8-16 51 2 Spacer, Axle (15 kW)
27 6 Bolt Carr 3/8-16 X 1 52 2 Screw HHC 5/16”-18 X 1”


Section 6 Electrical Data
Introduction
The diagrams in this section are provided for general reference only. For unit specific diagrams refer to the Service and
Support page at the manufacturer’s website.

Wiring Diagram 12.5 & 15 kW (Units Without Hourmeter) – Drawing No. 0E0228
22
120/240V
120V/20A 120V/20A
120V/30A 120V/30A 30A TWISTLOK
DUPLEX GFCI
TWISTLOK TWISTLOK 22 0
22
WHITE WHITE
0
X G
WHITE
WHITE
HOT
HOT
1 2 22 1 LOAD 2
22 G G WHITE
22
WHITE
WHITE
22
HOT
HOT
3 4 22 3 LINE 4 22 Y
0 0 0
5 5
22
0 0 0 0
44C
22
0 22
44D 0 0
11A
22 22
0 0
44
22 22 22 44B 44
11B 30A 44
C.B.
11D 11C
30A 30A 20A 20A 44 11

C.B. C.B. C.B. C.B.
44 11
11 11
30A
C.B.
44 50A
0 C.B.
11 11 44
11A
11
11
44
ENGINE WIRING
14
GOVERNOR
ACTUATOR
18
1 2 4
5 6 8 1
9 10 12
IC 15 SSR
1 18 13 14
D 15 2
SP1 15
0
15
IM1
0
0 0
(START) 0 3 0 0
RUN 167 4 167
D STOP 0
SP2 15
5 86
15 15
86
IM2
17 6 13 F1 0 0 0
0 0
LOP 0
14 7 14
0
8 17 0
FSS 9 16 GND
15
0 15
0 55A
87 55
86
10 15 87a
85
13 0 0
11 30 SCR
0 12 0
14
PIN #
0
0
BLACK RED
13
16
SM
- + 13
12V
BATTERY
SC

Wiring Diagram 12.5 & 15 kW (Units Without Hourmeter) – Drawing No. 0E0228
120/240V
50A OUTLET
0
0
GREEN
X Y
IDLE CONTROL STATOR
22 TRANSFORMERS
WHITE
11
22
2 11
11
11A
44 22
11S
44 44A 44S
RED
11 55A
1
44 77A
44 2 66A
3
1 4 2 6
83 5
11
167
ON 6 55
229
OFF 7 66 77
50A 15B BLK 8 CLOSEST TO BEARING
C.B.
0 BLK 9
TB1 55 BA
11A 2 10
TB2 11 4
12 0
PIN #
44A 86
CB1
83
14
ON/OFF 44S 55A 66A 66
IDLE 12 11 10 9 8 7 6 5 4 3 2 1 6
CONTROL J2
SWITCH 11S 55
18 ELECTRONIC GOVERNOR /
4
162 77
15B ENGINE SHUTDOWN P.C.B.
8
77A
12 0
0 PIN 1
R
14 229 162 PIN 2 VOLTAGE
11S PIN 3 REGULATOR
14
4 4 PIN 4
J1
0 44S PIN 5
167 14 6 PIN 6
0
0 4
14
86
0 0
14
0 77
15 R1
55A
4
D2
0 66
55
4
0 77A
14 14 14 LEGEND
55A BA - BRUSH ASSEMBLY
5 CB1 - 5AMP AUTO RESET BREAKER
15 BATTERY
15 CHARGE D - ENGINE SHUTDOWN DIODE
RECTIFIER D2 - 600V 12A DIODE
14 10A AUTO 66A
RESET BKR F1 - 10A FUSE
77 FSS - FUEL SHUT OFF SOLENOID
0 GND - GROUND BAR
12Vdc OUTLET BATTERY IM1 - IGNITION MODULE, CYL. 1
13A CHARGE
RECTIFIER IM2 - IGNITION MODULE, CYL. 2
66 LOP - LOW OIL PRESSURE
R1 - 25 OHM, 25W RESISTOR
SC - STARTER CONTACTOR
SCR - STARTER CONTACTOR RELAY
0 SM - STARTER MOTOR
SP1 - SPARK PLUG, CYL. 1
15A SP2 - SPARK PLUG, CYL. 2
SSR - START / STOP RELAY
TB1, TB2 - TERMINAL BLOCK

Electrical Schematic 12.5 & 15 kW (Units Without Hourmeter) – Drawing No. 0E0229-A
POWER WINDING BA
DPE WINDING
BATTERY CHARGE WINDING FIELD
77A 66A
55A
2 6 4
C1-5 C1-4 44S 44 22 11 11S
C1-3
C1-1 C1-6 C1-7 C1-11 C1-12
10A BATTERY CHARGE WINDING C1-2

I.C.
77 66
RED
C1-10 55 C1-9
44S 11S 2 6 4
I.C.T.
66A
C1-8
77A
I.C.T.
11
22
66 BLK 0
77 44 44
66A 0
15
77A
BCR1 BCR2 12Vdc
66 CB1 0
13A 15A 0
77 77
BLK 2
1 0 0 15
CB2
4 1
2 162 162 2
6
ELECTRONIC 3 11S 11S
VOLTAGE 0 D1 R1
REGULATOR 4 4 4 4 14
5 44S 44S
6 6 6
15 15
86 86
0 0
86 15B
0 229
15B 167 167
229 83 0
167 SW2
83 15
1
TB1 TB2
18 18
14 14
15 13
F1
15 15
15
GOVERNOR
ACTUATOR
18 14 229
0 15B
44S 86 167 TR1 15B 14 15
11S 229 TR2 0 83 4 6 5
12 11 10 9 8 7 6 5 4 3 2 1
SSR
12 10 9
13
J2 15
0 15 15
CONTROL
PRINTED CIRCUIT
BOARD
J1

Electrical Schematic 12.5 & 15 kW (Units Without Hourmeter) – Drawing No. 0E0229-A
120V 120V
DUPLEX GFCI
11B
11B
0 22 22 22
120/240V 120/240V
50A 30A 120V/30A 120V/30A TEST RESET
0
TWISTLOK TWISTLOK TWISTLOK TEST RESET
C1-12
0 0 44A 11A 0 44B 0 11D 0 44D 22 0 11C 22 0 44C
22
C.B. C.B. C.B. C.B. C.B. C.B.
30A C.B. 30A 30A 30A 20A 20A
50A
11 11 11
22 22 22
0 0 0
44 44 44
LEGEND
C2-12
BA - BRUSH ASSEMBLY
0 0 0
BCR1 - BATTERY CHARGE RECTIFIER, 10A
C2-7
0 BCR2 - BATTERY CHARGE RECTIFIER
14 14
CB1 - 10AMP AUTO RESET BREAKER
C2-5 FSS
14 86 86
D1 - 600V 12A DIODE
LOP 0
D2, D3 - ENGINE SHUTDOWN DIODE
F1 - 10A FUSE
0
86
0 GND - GROUND BAR
C2-2
I.C.T. - IDLE CONTROL TRANSFORMER
15 15 IM1 - IGNITION MODULE, CYL. 1
C2-10 IM2 - IGNITION MODULE, CYL. 2
15 15 LOP - LOW OIL PRESSURE
C2-4
15 R1 - 25 OHM, 25W RESISTOR
167 167 SC - STARTER CONTACTOR
C2-3 SW1 SCR - STARTER CONTACTOR RELAY
0 0 17
0
SM - STARTER MOTOR
14 15 SP1 - SPARK PLUG, CYL. 1
C2-8 0
17 17 SP2 - SPARK PLUG, CYL. 2
18
C2-1 D2 SSR - START / STOP RELAY
13 18 18 IM1 SW1 - START-RUN-STOP RELAY
SP1
SW2 - IDLE CONTROL SWITCH
D3 TB1, TB2 - TERMINAL BLOCK
IM2
17
SP2
OR C2-6
OR 13 13 RED
C2-11 SC
15
13 13
13
SCR SC SM
C2-9 BATTERY
16
12V
16 BLACK
17

Wiring Diagram 12.5 & 15 kW (Units With Hourmeter) – Drawing No. 0D4609-D
22
120/240V
120V/20A 120V/20A
DUPLEX GFCI
TWISTLOK TWISTLOK 22 0
22
WHITE WHITE
0
X G
WHITE
WHITE
HOT
HOT
1 2 22 1 LOAD 2
22 G G WHITE
22
WHITE
WHITE
22
HOT
HOT
3 4 22 3 LINE 4 22 Y
0 0 0
5 5
22
0 0 0 0
44C
22
0 22
44D 0 0
11A
22 22
0 0
44
22 22 22 44B 44
11B 30A 44
C.B.
11D 11C
30A 30A 20A 20A 44 11

C.B. C.B. C.B. C.B.
44 11
11 11
30A
C.B.
44 50A
0 C.B.
11 11 44
11A
11
11
44
ENGINE WIRING
14
GOVERNOR
ACTUATOR
18
1 2 4
5 6 8 1
9 10 12
IC 15 SSR
1 18 13 14
D 15 2
SP1 15
0
15
IM1
0
0 0
(START) 0 3 0 0
RUN 167 4 167
D STOP 0
SP2 15
5 86
15 15
86
IM2
17 6 13 F1 0 0 0
0 0
LOP 0
14 7 14
0
8 17 0
FSS 9 16 GND
15
0 15
0 55A
87 55
86
10 15 87a
85
13 0 0
11 30 SCR
0
0 12 0
14
PIN #
0
0
BLACK RED
13
16
SM
- + 13
12V
BATTERY
SC

Wiring Diagram 12.5 & 15 kW (Units With Hourmeter) – Drawing No. 0D4609-D
120/240V
50A OUTLET
GREEN
X Y
IDLE CONTROL STATOR
22 TRANSFORMERS
WHITE
11
22
11
11
11A
44 22
11S
4 44A 44S
RED
11 55A
1
44 77A
44 2 66A
3
4 2 6
83 5
11
167
ON 6 55
229
OFF 7 66 77
50A 15B BLK 8 CLOSEST TO BEARING
C.B.
0 BLK 9
TB1 55 BA
11A 2 10
TB2 11 4
12 0
PIN #
44A 86
CB1
83
ON/OFF 44S 55A 66A 66

IDLE 12 11 10 9 8 7 6 5 4 3 2 1 6
CONTROL J2
SWITCH
11S 55
18 ELECTRONIC GOVERNOR /
4
162 77
15B ENGINE SHUTDOWN P.C.B.
8
77A
12 0
0 PIN 1
14 229 162 PIN 2 VOLTAGE
11S PIN 3 REGULATOR
14
4 4 PIN 4
J1
0 44S PIN 5
167 14 6 PIN 6
0
0 4
14
86
0 0
14
0 77
15 R1
55A
HOURMETER 4
D2
0 66
55
4
0 77A
14 14 14 14 LEGEND
55A BA - BRUSH ASSEMBLY
BATTERY
15
0 15 CHARGE D - ENGINE SHUTDOWN DIODE
RECTIFIER D2 - 600V 12A DIODE
10A AUTO 66A
RESET BKR F1 - 10A FUSE
0 GND - GROUND BAR
12Vdc OUTLET BATTERY IM1 - IGNITION MODULE, CYL. 1
13A CHARGE
RECTIFIER IM2 - IGNITION MODULE, CYL. 2
66 LOP - LOW OIL PRESSURE
0 SM - STARTER MOTOR
15A SP2 - SPARK PLUG, CYL. 2

Electrical Schematic 12.5 & 15 kW (Units With Hourmeter) – Drawing No. 0D6297-A
POWER WINDING BA
DPE WINDING
BATTERY CHARGE WINDING FIELD
77A 66A
55A
2 6 4
C1-5 C1-4 44S 44 22 11 11S
C1-3
C1-1 C1-6 C1-7 C1-11 C1
10A BATTERY CHARGE WINDING C1-2

I.C.
77 66
RED
C1-10 55 C1-9
44S 11S 2 6 4
I.C.T.
66A
C1-8
77A
I.C.T.
11
22
66 BLK 0
77 44 44
66A 0
15
77A
BCR1 BCR2 12Vdc
66 CB1 0
13A 15A 0
77 77
0 HM 14
BLK 2
1 0 0 15
CB2
4
2 162 162 2
6
ELECTRONIC 3 11S 11S
VOLTAGE 0 D1 R1
REGULATOR 4 4 4 4 14
5 44S 44S
6 6 6
15 15
86 86
0 0
86 15B
0 229
15B 167 167
229 83 0
167 SW2
83 15
TB1 TB2
18 18
14 14
15 13
F1
15 15
15
GOVERNOR
ACTUATOR
18 14 229
0 15B
44S 86 167 TR1 15B 14 15
11S 229 TR2 0 83 4 6 5
12 11 10 9 8 7 6 5 4 3 2 1
SSR
12 10 9
13
J2 15
0 15 15
CONTROL
PRINTED CIRCUIT
BOARD
J1

Electrical Schematic 12.5 & 15 kW (Units With Hourmeter) – Drawing No. 0D6297-A
120V 120V
DUPLEX GFCI
11B
11B
0 22 22 22
120/240V 120/240V
50A 30A 120V/30A 120V/30A TEST RESET
0
TWISTLOK TWISTLOK TWISTLOK TEST RESET
C1-12
0 0 44A 11A 0 44B 0 11D 0 44D 22 0 11C 22 0 44C
22
C.B. C.B. C.B. C.B. C.B. C.B.
30A C.B. 30A 30A 30A 20A 20A
50A
11 11 11
22 22 22
0 0 0
44 44 44
C2-12
0 0 0 LEGEND
BA - BRUSH ASSEMBLY
C2-7 BCR1 - BATTERY CHARGE RECTIFIER, 10A
0
HM 14 14 14 BCR2 - BATTERY CHARGE RECTIFIER
C2-5 FSS CB2 - 5AMP AUTO RESET BREAKER
86 86 D1 - 600V 12A DIODE
14
D2, D3 - ENGINE SHUTDOWN DIODE
LOP 0
F1 - 10A FUSE
FSS - FUEL SHUT OFF SOLENOID
R1 GND - GROUND BAR
0
14 HM - HOURMETER
86 I.C.T. - IDLE CONTROL TRANSFORMER
0
IM1 - IGNITION MODULE, CYL. 1
C2-2 LOP - LOW OIL PRESSURE
15 15 R1 - 25 OHM, 25W RESISTOR
C2-10 SCR - STARTER CONTACTOR RELAY
15 15 SM - STARTER MOTOR
15 SP1 - SPARK PLUG, CYL. 1
C2-4 SP2 - SPARK PLUG, CYL. 2
167 167 SSR - START / STOP RELAY
SW1 - START-RUN-STOP RELAY
C2-3 SW1 SW2 - IDLE CONTROL SWITCH
0 0 17 TB1, TB2 - TERMINAL BLOCK
0
14 15
C2-8 0
17 17
18
C2-1 D2
13 18 18 IM1
F1 SP1
D3
IM2
17
SP2
NOR C2-6
TOR 13 13 RED
C2-11 SC
15
13 13
SCR SC
C2-9 16
16 SM
17
BATTERY
12V
BLACK

Wiring Diagram 17.5 kW – Drawing No. 0G0731
22 120/240V
(50A/60A) OUTLET
120/240V
120V/20A 120V/20A
DUPLEX GFCI
TWISTLOK TWISTLOK 0
22 22
WHITE WHITE
0 0
X G
GREEN
WHITE
WHITE
HOT
HOT
1 2 22 1 LOAD 2
22 G G WHITE
X Y
11B 0
22 WHITE
WHITE
WHITE
22
HOT
HOT
Y
3 4 22 3 LINE 4 22
0 0
5 5
44D 0 11D 0 11C 44C 22

0 0 22
22
0 22
0 0
22 22 11A 44A
0 0
44
22 22 44
30A 44
11B 44B 44 11
C.B.
0 11 44
44
44D
30A 11D
30A 11C
20A 44C
20A 44 11
C.B. C.B. C.B. C.B.
44 11 50A/
60A
30A 11 C.B. ON
11B 11
C.B. OFF
11A
44 11 11 44
44
11
11
11A 44A
44
ENGINE WIRING 14
GOVERNOR 18
ACTUATOR
14 18
1 2 4
5 15B
15 6 8
0
IC 15
9 10 12
18 1 18 13 SSR 14 229
D 15 2 15 14
SP1
0
0
0 167
IM1
(START) 0 3 0 0
0 0 0 0 15 86
RUN 167 4 167
0
STOP
D 17 15 15
SP2
86 86 5 86
0
13 6 13 F1
IM2 LOP
15 15 15
0 14 14 7 14
0 0 0 0 0 0
17 8 17
FSS 16 9 16
GND
15
17 14 0 0 0 0 55 55A
87
86 55
15 10 15 87a
85
13 11 13 30 SCR
0 0 12 0 0
14
PIN #
0
0
BLACK RED
13
SM 13 16
- +
12V
BATTERY
SC

Wiring Diagram 17.5 kW – Drawing No. 0G0731
22
IDLE CONTROL STATOR
TRANSFORMERS
22
11 11
22
11
44 22
11S
RED 22S
11
55A
1
44 44 44 77A
2 66A
11S 3
22S 4 2 6
83 5
167 55A 6 55
229
7 66 77
15B BLK CLOSEST TO BEARING
8
0 BLK 9
86 55
TB1
10 BA
2
TB2 11 4
12 0
PIN #
83 229 0
167 15B 86
CB1
ON/OFF 11S 55A 162 4 77A 77

12 11 10 9 8 7 6 5 4 3 2 1
IDLE
CONTROL J2
SWITCH
22S 55 0 66A 66 6
ELECTRONIC GOVERNOR /
ENGINE SHUTDOWN P.C.B.
15B
229
14
J1
0
167 14 14 14
0
86 14
0 0
R1
15 55A 162 4 77A 77 14

VOLTAGE
REGULATOR 11S D2
55 0 66A 66 6
22S
4 4
15 0
6
162
0
0
14
55A 55A
55 55 77A
15 15 BATTERY
CHARGE
15 15 RECTIFIER
66A
0 0 10A AUTO LEGEND
RESET BKR BA - BRUSH ASSEMBLY
14 77 BATTERY
13A 13A CHARGE CB1 - 6AMP AUTO RESET BREAKER
RECTIFIER D - ENGINE SHUTDOWN DIODE
66
D2 - 600V 12A DIODE
F1 - 10A FUSE
GND - GROUND BAR
12Vdc OUTLET IM1 - IGNITION MODULE, CYL. 1
0 15A 15A 0 LOP - LOW OIL PRESSURE
SM - STARTER MOTOR

Electrical Schematic 17.5 kW – Drawing No. 0G0733
POWER WINDING BA
BATTERY CHARGE WINDING DPE WINDING
FIELD
77A 55A 66A 11S 11 22S 44 2 6 4 0

C1-5 C1-4 C1-1 C1-2 22 C1-6 C1-7 C1-11 C1-12
C1-3
10A BATTERY CHARGE WINDING

I.C.
RED
77 55 66
I.C.T.
C1-10 C1-9
C1-8 66A 22S
77 66 11S I.C.T. 22 2 6 4 0
77A 44
22
BLK 0
11 11
66A 0
15
77A
66 BCR2
13A 15A
77 77 CB1
12Vdc
BCR1 0
ELECTRONIC BLK BLK 22S 15 4
11S
VOLTAGE 22S
REGULATOR 4 4
0 0
6 6
162 162 2
CB2
C2-5 LOP
86 86 86 86
0 0
0
15B
0
229
167 167 C2-12
83 83 0 0 0 0
BLK SW2
0
BLK 15
15
F1 C2-6
229 0 15 15 4
86 15B 167 11S 13 13 RED
15B 15
0 229 83 TB2 22S 13
D1 SC
12 10 9
SSR
22S 4 6 5 15 BATTERY
11S 18 14 14 C2-11 SM 12V
TB1 15B 229 R1 13 13
0 229 83 11S
86 15B 167 22S SCR C2-9 BLACK
14 16 16 SC
15 0
D2 17
14 167 15
18 IM1 C2-8
15B 1
C2-1 SP1 17 17
83 2 CONTROL
0
TR1 3 PRINTED CIRCUIT
D3 C2-3
0 4 BOARD 0
IM2 0 0 17
167 5
TR2 6 SP2 C2-4 SW1
86 7 167 167
229 8
22S 9 C2-10 15
GOVERNOR 15
10 15
J1 ACTUATOR
11S 11
J2
12
C2-2
15 15
C2-7
120V 120V 14 14 0
GFCI DUPLEX FSS
22 22 22 11B 0
120/240V 120/240V
RESET TEST
120V/30A 120V/30A 30A 50A/60A
RESET TEST
TWISTLOK TWISTLOK TWISTLOK
44C 0 22 11C 0 22 44D 0 11D 0 44B 0 11B 11A 44A 0
22
C.B. C.B. C.B. C.B. C.B. C.B. C.B.

20A 20A 30A 30A 30A 30A 50A/60A
11 11 11
22 22 22
0 0 0
44 44 44
LEGEND
BA - BRUSH ASSEMBLY FSS - FUEL SHUT OFF SOLENOID SCR - STARTER CONTACTOR RELAY
BCR1 - BATTERY CHARGE RECTIFIER, 10A GND - GROUND BAR SM - STARTER MOTOR
BCR2 - BATTERY CHARGE RECTIFIER I.C.T. - IDLE CONTROL TRANSFORMER SP1 - SPARK PLUG, CYL. 1
CB1 - 10AMP AUTO RESET BREAKER IM1 - IGNITION MODULE, CYL. 1 SP2 - SPARK PLUG, CYL. 2
CB2 - 6AMP AUTO RESET BREAKER IM2 - IGNITION MODULE, CYL. 2 SSR - START / STOP RELAY
D1 - 600V 12A DIODE LOP - LOW OIL PRESSURE SW1 - START-RUN-STOP RELAY
D2, D3 - ENGINE SHUTDOWN DIODE R1 - 25 OHM, 25W RESISTOR SW2 - IDLE CONTROL SWITCH
F1 - 10A FUSE SC - STARTER CONTACTOR TB1, TB2 - TERMINAL BLOCK

Electrical Schematic 17.5 kW – Drawing No. 0H0729
POWER WINDING
BATTERY CHARGE WINDING DPE WINDING
FIELD
77A 55A 66A

11S 11 22S 44 2 6 4 BA 0
C1-5 C1-3 C1-4
C1-1 C1-2 22 C1-6 C1-7
C1-11 C1-12
11
10A BATTERY CHARGE WINDING RED
22S
(BLK)
77 55 66 I.C.T.
11S 2 6 4 0
C1-10 C1-8 C1-9 (RED) (BLU/ (PNK) (BLU) (BLK)
BLK WHT)
77A 66A
(VIO) (VIO) 11
77 66 11
(YEL) (YEL)
44
22
0
11
66A(VIO)
15(ORG)
77A(VIO)
66(YEL) BCR2
13A(RED) 15A(ORG)
77(YEL) CB2
12Vdc
BCR1
11S(RED)
11S(RED) RED BLK 0
ELECTRONIC 22S(BLK) (BLK)
VOLTAGE 22S(BLK)
REGULATOR 4(BLU) 4(BLU)
0(BLK) 0(BLK)
6(PNK) 6(PNK)
162(BLU/WHT) 2(BLU/WHT)
CB1 C2-5 LOP
86(BLU) 86(BLU) 86
0(BLK) 0(BLK)
0
15B(ORG) 4
229(BLU) (BLU)
167(BLU) C2-12
83(BLU) 0(BLK) 0(BLK) 0
BLK SW2
0
RED 15(ORG)
0 15(ORG)
(BLK) F1 C2-6
15B 15 13(RED) 13 RED
(ORG) (ORG) 13
12 10 9 D1 SC
229
(BLU) SSR 15
4 6 5 BATTERY
(ORG)
18 14 14 C2-11 SM 12V
(BRN) (BLU) R1 13(RED) 13
SCR C2-9 BLACK
16(BLU) 16 SC
IM1 14 C2-8
C2-1 D2 SP1 (BLU) 17(BRN) 17
15B(ORG) 1 0
83(BLU) 2 CONTROL C2-3
TR1(RED) 3 PRINTED CIRCUIT IM2 0(BLK) 0 17 0
0(BLK) 4 BOARD D3 SP2
C2-4 SW1
167(BLU) 5
TR2(BLK) 6 167(BLU) 167
86(BLU) 7 C2-10 15
229(BLU) 8
GOVERNOR
22S 15(ORG) 15
9
(BLK) J1 ACTUATOR
10 C2-2
11S
(RED) 11 15(ORG) 15
J2
12
C2-7
120V/20A 120V/20A 14(BLU) 14 0
GFCI DUPLEX FSS
WHT HM RED
22 22 22 120/240V 11B 0
120/240V
RESET TEST
120V/30A 120V/30A 30A 50A
TWISTLOK TWISTLOK TWISTLOK
RESET TEST
44C 0 22 11C 0 22 44D 0 11D 0 44B 0 11B 11 11A 44A 0

22
C.B. C.B. C.B. C.B. C.B. C.B. C.B.

20A 20A 30A 30A 30A 30A 50A
11 11 11
22 22 22
0 0 0
44 44 44
LEGEND
BA - BRUSH ASSEMBLY FSS - FUEL SHUT OFF SOLENOID SC - STARTER CONTACTOR
BCR1 - BATTERY CHARGE RECTIFIER GND - GROUND STUD SCR - STARTER CONTACTOR RELAY
BCR2 - BATTERY CHARGE RECTIFIER, 10A HM - HOUR METER SM - STARTER MOTOR
CB1 - 6AMP AUTO RESET BREAKER I.C.T. - IDLE CONTROL TRANSFORMER SP1 - SPARK PLUG, CYL. 1
CB2 - 10AMP AUTO RESET BREAKER IM1 - IGNITION MODULE, CYL. 1 SP2 - SPARK PLUG, CYL. 2
D1 - 600V 12A DIODE IM2 - IGNITION MODULE, CYL. 2 SSR - START / STOP RELAY
D2, D3 - ENGINE SHUTDOWN DIODE LOP - LOW OIL PRESSURE SW1 - START-RUN-STOP SWITCH
F1 - 10A FUSE R1 - 25 OHM, 25W RESISTOR SW2 - IDLE CONTROL SWITCH

Wiring Diagram 17.5 kW – Drawing No. 0H0730
22
120/240V
120/240V 50A OUTLET
120V/30A 120V/30A
DUPLEX GFCI
TWISTLOK TWISTLOK 0
22 22
WHITE WHITE
0 0
X G
GREEN
WHITE
WHITE
HOT
HOT
1 2 22 1 LOAD 2
22 G G WHITE
X Y
11B 0
WHITE
WHITE
22 22 WHITE
HOT
HOT
Y
3 4 22 3 LINE 4 22
0 5 5
WHT
44D 0 22
0 0 0 22
11D 0 11C 44C 22
0 22
0 0
22 22 11A 44A
0 0
44
22 22 44
30A 44
11B 44B 44 11
C.B.
0 11 44
WHT 44
44D 30A 30A 11D 11C 20A 20A 44C HM 44 11
C.B. C.B. C.B. C.B.
44 11
50A
30A 11 C.B. ON
11B 11
C.B. OFF
44 11 11 44 11A
RED
44
11
11
11A 44A
44
ENGINE WIRING 14(BLU)
GOVERNOR 18(BRN)
ACTUATOR
1 2 4
5 15B(ORG)
6 8
9 10 12
18 1 18(BRN) SSR
13 14 229(BLU)
D2
SP1 15 2 15(ORG) 14(BLU)
0(BLK) 0(BLK)
SW1 0
IM1 0 167(BLU)
(START) 0 3 0(BLK) 0(BLK)
RUN 167 4 167(BLU)

0(BLK)
STOP
D3 17 15 0 0 15(ORG)
SP2 (BLK) (BLK)
86 86 5 86(BLU) 86(BLU)
13 6 13(RED) F1 0 0 0
IM2 (BLK) (BLK)
LOP
15(ORG) 15(ORG)
0 14 14 7 14(BLU) 0(BLK)
0(BLK)
17 8 17(BRN)
FSS 16 9 16(BLU)
GND
17 55A(BLK)
87 0
86 (BLK) 55(BLK)
15 10 15(ORG)
87a
85 0
13 11 13(RED) (BLK)
30 SCR
0 0 12 0(BLK) 0(BLK)
14(BLU)
PIN #
BLACK RED
13
SM 13 16
- +
12V
BATTERY
SC

Wiring Diagram 17.5 kW – Drawing No. 0H0730
STATOR
22 22
11 22
11
44 22
11
11S
22S
11 11 11
55A
1
44 44 44 77A
2 66A
I.C.T. 11S(RED) 3
RED
BLK 22S(BLK) 4 2 6
5
55A(BLK) 6 55
7 66 77
8 CLOSEST TO BEARING
TR1
(RED) 9
TR2 55(BLK)
(BLK) 10 BA
2(BLU/WHT)
15B(ORG) 11 4
83(BLU)
0(BLK) 12 0
167(BLU) PIN #
86(BLU)
83 CB1
(BLU)
SW2
229 86 12 11 10 9 8 7 6 5 4 3 2 1
(BLU) (BLU) J2
0 167 0 ELECTRONIC GOVERNOR /

(BLK) (BLU) (BLK)
15B(ORG) ENGINE SHUTDOWN P.C.B.
11S 11S 55A 162 4 77A 77

229(BLU) (RED) (RED) (BLK) (BLU/ (BLU) (VIO) (YEL)
WHT)
14(BLU)
J1 22S 22S 55 0 66A 66 6
0(BLK) (BLK) (BLK) (BLK) (BLK) (VIO) (YEL) (PNK)
167(BLU) 14(BLU)
0(BLK)
86(BLU) 14
(BLU)
0(BLK) 0(BLK)
R1
14 4A
(BLU) (BLU)
15(ORG)
ELECTRIC
VOLTAGE
REGULATOR D1
4
4(BLU) (BLU)
15(ORG)
6PNK)
162(BLU/WHT)
0(BLK)
0(BLK)
14(BLU)
55A(BLK) 55A(BLK)
55(BLK) 55(BLK) 77A(VIO)
LEGEND
15(ORG) 15(ORG) BA - BRUSH ASSEMBLY
BCR2
15(ORG) 15(ORG) BCR1 - BATTERY CHARGE RECTIFIER
66A(VIO) BCR2 - BATTERY CHARGE RECTIFIER, 10A
0(BLK) 0(BLK) CB1 - 6AMP AUTO RESET BREAKER
14(BLU) CB2 - 10AMP AUTO RESET BREAKER
66(YEL) D1 - 600V 12A DIODE
13A(RED) 13A(RED) BCR1 D2, D3 - ENGINE SHUTDOWN DIODE
77(YEL) F1 - 10A FUSE
CB2
GND - GROUND STUD
HM - HOUR METER
I.C.T. - IDLE CURRENT TRANSFORMER
12Vdc OUTLET IM1 - IGNITION MODULE, CYL. 1
0 15A 15A
(BLK) (ORG) (ORG) 0 LOP - LOW OIL PRESSURE
(BLK) R1 - 25 OHM, 25W RESISTOR
SM - STARTER MOTOR
SW1 - START-RUN-STOP SWITCH
SW2 - IDLE CONTROL SWITCH

Wiring Diagram, 17.5 kW Manual Transfer Switch – Drawing No. 0G1065
GROUND (GRN)
NEUTRAL (WHT)
NEUTRAL (WHT)
CIRCUIT 9
NEUTRAL (WHT)
CIRCUIT 11 GROUND BAR
NEUTRAL (WHT)
CIRCUIT 13
NEUTRAL (WHT)
CIRCUIT 15
CIRCUIT 1 (BRN)
CIRCUIT 3 (BRN/WHT) GROUND(GRN)*
CIRCUIT 5 (YEL) GEN2(RED)*
CIRCUIT 7 (YEL/WHT) GEN1(BLK)*
CIRCUIT 9 (LT BLU) NEUTRAL(WHT)*
CIRCUIT 11 (ORG) *-CUSTOMER SUPPLIED
CIRCUIT 13 (DRK BLU)
CIRCUIT 15 (PNK)
NEUTRAL BAR
STANDBY
LOAD CENTER
UTILITY
NEUTRAL BAR
CIRCUIT 16 (PNK/YEL)
CIRCUIT 14 (BLU/YEL)
CIRCUIT 12 (ORG/YEL)
CIRCUIT 10 (GRY/YEL)
CIRCUIT 8 (VIO/YEL)
CIRCUIT 6 (VIO)
CIRCUIT 4 (ORG/WHT)
CIRCUIT 2 (ORG)
MAIN 2 (RED)
MAIN 1 (BLK)
NEUTRAL (WHT)
CIRCUIT 16
NEUTRAL (WHT)
CIRCUIT 14
NEUTRAL (WHT)
CIRCUIT 12
NEUTRAL (WHT)
CIRCUIT 10
NEUTRAL (WHT)
CIRCUIT 8
NEUTRAL (WHT)
CIRCUIT 6

Interconnection Drawing – 17.5 kW generator connected to the external connection box, manual
transfer switch and home’s main electrical distribution panel


Part No. 0F7713 Rev. C 05/09/2017
©2017 Generac Power Systems, Inc. Generac Power Systems, Inc.
All rights reserved S45 W29290 Hwy. 59
Specifications are subject to change without notice. Waukesha, WI 53189
No reproduction allowed in any form without prior written 1-888-GENERAC (1-888-436-3722)
consent from Generac Power Systems, Inc. www.generac.com

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GP Series and UltraSource

ii Diagnostic Repair Manual

Diagnostic Repair Manual iii

Diagnostic Repair Manual iv

A. Brush Holder Assembly

Figure 1-1. AC Generator Major Components

Rotor Assembly Stator Assembly

Diagnostic Repair Manual 1

Other AC Generator Components

Excitation Circuit Breaker

Figure 1-2. Stator Assembly Leads

Brush Holder and Brushes

2 Diagnostic Repair Manual

4. Turn the regulator voltage adjust pot clockwise to

Adjustment Procedure (Newer 15 kW and All

Diagnostic Repair Manual 3

Operation The AC power winding voltage initially sensed by the

4 Diagnostic Repair Manual

Rated Max. Power 12.5 kW 15.0 kW 17.5 kW

Surge Power 18.75 kW 22.5 kW 26.25 kW

Rated AC Voltage 120/240 120/240 120/240

Rated Max AC Load – – –

Current @ 240V 52.0 Amps 62.5 Amps 72.9 Amps

Current @ 120V 104.0 Amps 125.0 Amps 145.8 Amps

Rated Frequency 60 Hz @ 3600 RPM 60 Hz @ 3600 RPM 60 Hz @ 3600 RPM

Phase Single Phase Single Phase Single Phase

Rated DC Voltage 12 Volts 12 Volts 12 Volts

Rated Max DC Load Current @ 12 Volts 10 Amperes 10 Amperes 10 Amperes

Rated Horsepower @3600 RPM 27 30 33

Displacement 763 cc 992 cc 992 cc

Spark Plug Type Champion RC14YC or Equivalent

Spark Plug Gap 0.040 inch or (1.01 mm)

Gasoline Capacity 16 U.S. gallons (60.56 liters)

Summer – SAE 30 or 10W-30

ENGINE SPEEDS AND VOLTAGE SPECIFICATIONS

LOAD % VOLTAGE (VAC) FREQUENCY (Hz)

100 238-242 59-61

Diagnostic Repair Manual 5

Flywheel Nut 150 ft-lbs

Cylinder Head Bolts 22 ft-lbs

Valve Cover Bolts 4.8-5.5 ft-lbs

Rocker Arm Jam Nut 14 ft-lbs

Ignition Coil 9 ft-lbs

Intake Manifold 14 ft-lbs

Exhaust Manifold 14 ft-lbs

Stator Bolts 6 ft-lbs

Rotor Bolt 30 ft-lbs

Spark Plug 15 ft. lbs.

Starter Bracket To Block 18 ft-lbs

TRIM TORQUE SPECIFICATIONS

M3-.5 Phillips Pan Head Screw Into Aluminum 50 in-lbs

M6-1 Taptite Screw Into Aluminum 96 in-lbs

M6-1 Taptite Screw Into Weldnut 96 in-lbs

M8-1.25 Taptite Screw Into Aluminum 18 ft-lbs

6 Diagnostic Repair Manual

AC input for frequency control. 11S/

AC input for frequency control. 11S/

NOTE: J1 connector is utilized for governor control.