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This service manual has been written and published by the Product Manufacturer to aid dealers’

mechanics and company service personnel when servicing the products described herein.

 
This is a complete Service Manual for the GENERAC "GP" Series Portable Generator Diagnostic Repair Manual on a CD.  This CD is filled with pages of very well detailed easy to read troubleshooting, rebuilding, servicing, maintenance and repair information complete with many charts, diagrams, schematics, specifications and pictures.  This manual covers all aspects of servicing this equipment in a very clear and concise format with the convenience of having all this information at your fingertips in the form of a CD.  This manual will allow you to completely troubleshoot, disassemble, inspect, repair and reassemble your equipment.
NOTICE*
The photo depicted is a generalization of the entire series of manuals.
Each individual CD is printed with the information specific to that piece of equipment. 
 
This Manual Applies To The Following:
GP1800, GP3250, GP5000, GP5500, GP6500, GP7000, GP8000
 
The Contents of The Manual Are As Follows 
 
 

Specifications...........................................................2

Part 1 – General Information...................................9

 

Section 1.1 – Generator Fundamentals.................10

Magnetism........................................................10

Electromagnetic Fields.....................................10

Electromagnetic Induction................................10

A Simple AC Generator....................................11

A More Sophisticated AC Generator.................11

Section 1.2 – Measuring Electricity........................13

Meters..............................................................13

The VOM...........................................................13

Measuring AC Voltage......................................13

Measuring DC Voltage......................................13

Measuring AC Frequency.................................13

Measuring Current............................................14

Measuring Resistance......................................14

Electrical Units..................................................15

Ohm's Law........................................................15

Section 1.3 – Brushless, CapacitorExcitation System.............................16

Introduction.......................................................16

Stator Assembly................................................16

Rotor Assembly.................................................16

Circuit Breakers................................................16

Operation..........................................................17

Section 1.4 – Brushed Excitation System..............18

Introduction.......................................................18

Stator Assembly................................................18

Brush Holder and Brushes................................18

Rotor Residual Magnetism...............................18

Voltage Regulator.............................................18

Operation..........................................................18

Section 1.5 – Testing, Cleaning and Drying...........20

Insulation Resistance........................................20

The Megohmmeter...........................................20

Stator Insulation Resistance Test......................20

Cleaning the Generator.....................................21

Drying the Generator........................................21

Part 2 – AC Generators..........................................21

Section 2.1 – Brushless CapacitorTroubleshooting Flowcharts..............22

Section 2.2 – Brushed ExcitationTroubleshooting Flowcharts..............24

Section 2.3 – AC Diagnostic Tests.........................26

 

Introduction.......................................................26

Test 1 – Check No-Load Voltageand Frequency.....................................26

Test 2 – Check Circuit Breaker.........................26

Test 3 – Check Continuity ofReceptacle Panel.................................26

Test 4 – Field Flash Alternator(Configuration "A" Only)........................27

Test 5 – Check Brushed Rotor Circuit...............28

Test 6 – Check Capacitor..................................29

Test 7 – Test Brushless DPE Winding...............30

Test 8 – Test Brushless Stator Windings...........30

Test 9 – Test Brushed Stator Windings.............31

Test 10 – Check Load Voltage & Frequency.....31

Test 11 – Check Load Watts & Amperage........31

Test 12 – Adjust Voltage Regulator...................31

Part 3 – Engine Troubleshooting...........................33

Section 3.1 – 389/206/163cc Troubleshooting Flowcharts........................................34

Section 3.2 – 410cc Troubleshooting Flowcharts...37

Section 3.3 – Diagnostic Tests...............................42

 

Test 20 – Check 1.5 Amp Fuse.........................42

Test 21 – Check Battery & Cables....................42

Test 22 – Check Voltage atStarter Contactor (SC).........................42

Test 23 – Check Start-Run-Stop Switch...........42

Test 24 – Test OFF-ON Switch..........................43

Test 25 – Check Starter Motor..........................43

Test 25 – Check Ignition Spark.........................45

Test 26 – Check Spark Plugs............................46

Test 29 – Check Carburetion............................46

Test 30 – Choke Test.........................................47

Test 33 – Check Valve Adjustment....................47

Test 36 – Check Engine / Cylinder Leak Down Test / Compression Test.......................48

Test 38 – Check Flywheel.................................48

Test 39 – Remove Wire 18 / Shutdown Lead....49

Test 40 – Check / Adjust Governor (389cc Engine).....................................49

Test 41 – Check / Adjust Governor (410cc Engine).....................................50

Test 45 – Check Oil Level Switch......................51

Test 46 – Check Oil Pressure Switch................51

Test 49 – Test Recoil Function..........................52

Test 50 – Test Engine Function.........................52

Part 4 – Disassembly..............................................53

Section 4.1 – Major Disassembly...........................54

Part 5 – Electrical Data...........................................71

Electrical Schematic, GP1850...............................72

Electrical Schematic, GP3250...............................73

Electrical Schematic, GP5000/5500/GP6500........74

Wiring Diagram, GP5000/5500/GP6500................75

Electrical Schematic, GP7000E/GP8000E............76

Wiring Diagram, GP7000E/GP8000E....................77

 

 

 

 

 

Electrical Formulas................................................78

 
 
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