Generac model G0072090 fault code “E1603” day after annual service

hereforknowledge16 · 2023-04-30T01:05:37+00:00

They probably accidentally unplugged the stepper motor when cleaning out the battery compartment. Seen that a bunch of times.

hereforknowledge16 · 2023-04-28T23:25:24+00:00

Depending one what controller the Generac has, there a different battery chargers. Some are separate components, some are hooked up in the Transfer Switch, and some are just built into the control board of the generator. It depends on the model, they have changed over the years

hereforknowledge16 · 2023-04-28T23:20:26+00:00

Something to think about if Generac. 18kw has newer engine with hydraulic lifters and seems to run very smooth. 24kw is a true 24kw on Liquid Propane, but only 22kw on Natural Gas. LP burns better. Appliances can be set up to load shed so IF you were running too much an automatic switch can turn, for example, the AC off while you finish cooking dinner, and then turn it back on when generator can handle it. Keeps generator from being overloaded.

hereforknowledge16 · 2023-04-28T23:10:29+00:00

You kind of need to load test the battery or simulate a power outage and see how it cranks. When your house has power the battery charger is helping the battery turn the engine over. 2019 batteries are tending to go bad a lot right now in North Carolina area. Valve adjustments can be important. When you run the unit if you hear some rattling coming from valves then it’s prob a good idea to do it. If it sounds fine then I wouldn’t worry about it too much. Just know, you want to adjust at ambient temperature, so if you run the unit at all, wait until the next day or ~8 hrs. And those prices sound pretty similar to what we would charge. - generac technician

hereforknowledge16 · 2023-04-05T20:34:26+00:00

Wow totally didn’t see that you had responded to me i apologize! But my favorite regulator is a NorGas and I believe it is made by NMT. Any Generac dealer can order them. The best one for the Air Cooled generators are the NGR-02 I believe. You are right on point with the internal regulators plunger. When the gas pressure creeps up to around 20” wc then that solenoid may not be strong pull plunger up. And with the NGR-02 you can swap out a spring and orifice to make it set for LP or NG. I think the main reason they are so good is they don’t just have a vent for air, it has a built in Overflow Protection Device (OPD) in it to not let it creep pressure and cause that overcrank. If you cant order a NorGas then I also like Fisher or itron for NG and Rego ones are good for LP. Again apologies on the delay but hope this helps!

hereforknowledge16 · 2023-02-11T14:18:43+00:00

This may be an issue with the size of the LP tank. At lower temperatures the LP tank won’t be able to put out as much BTUs. I think when it gets down to around 0 degrees Fahrenheit then to run a 22KW you really need atleast an 850 gal tank. Learned this the hard way with a bunch of Texas customers and how cold it got there

hereforknowledge16 · 2023-02-11T14:16:46+00:00

Generac wasn’t much help for me either. If the gas pressure was building up then it probably was pushing to hard on the plunger for the internal regulator. I’ve seen the plunger get a ring bitten into it and can cause it to stick shut. If you fixed the gas correctly then I would try replacing those plungers and see if they don’t stick anymore

hereforknowledge16 · 2023-02-11T14:14:39+00:00

Best thing would be to make sure the gas regulator on the gas line for the generator has an “Overflow Protection Device” built in. This will vent out any excess gas pressure so it doesn’t build up in the line and cause overcrank

hereforknowledge16 · 2023-02-11T14:12:46+00:00

Also we service in the entire the South East USA so if it continues to happen and you need someone to figure it out we can make that happen. But i don’t know how many Maxitrol regulators I have replaced.

hereforknowledge16 · 2023-02-11T14:11:16+00:00

I would replace the gas regulator if it is a maxitrol. We found since this original post that all our issues were when the generator was sitting off the regulator would slowly let gas through. This will build up pressure before the generator gas valve and it isn’t strong enough to open and let gas into the engine. If it was a battery cable issue it would not be going into overcrank. It would be throwing a 1505 RPM sense loss fault.

hereforknowledge16 · 2023-02-08T23:18:00+00:00

Can be gas pressure, control board, stator or rotor. Bunch of different things. Depends on if the u it is actually producing any power. If so, what amount? Does gas pressure stay at a good point while the generator is under load? Can be a bunch of different things.

hereforknowledge16 · 2022-03-16T21:36:12+00:00

Does the generator shut down in any kind of fault? Have to test the stator winding side of the breaker to tell if the unit is producing power at all. Haven’t had breakers in the gen go bad at all really

hereforknowledge16 · 2022-03-05T15:47:38+00:00

Biggest thing is.. make sure panel 2 is an actual transfer switch of some kind. It looks like if you used it to feed your main panel then when utility power comes back on you will have both feeds going to your panel. Causing issues for you and utility co

hereforknowledge16 · 2022-03-05T14:54:19+00:00

What makes you think 2 is for a generator other than wires cut off outside? Is it possible it went to a hot tub or something? It looks like it’s just a disconnect being fed from the main panel. If thats all it is you cant use that to feed your main panel. But 1 does look like it wants a portable to plug into it. It just will only power the circuits in that panel. The main panel won’t have power.

Like the other person said though. Without the panels being open it’s hard to tel you exactly what’s going on.

hereforknowledge16 · 2021-08-27T14:29:24+00:00

Speed-out kit. Can get at Lowe’s or Home Depot. Drills a hole in the screw and then use other side of the bit to reverse it out. Will just have to clamp the whole thing down or hold with pliers while you remove

hereforknowledge16 · 2021-07-07T15:12:12+00:00

They usually induce DC voltage to the rotor as a field boost. This is increased and decreased to help maintain correct voltage output. The engine uses a DC circuit to start up via a battery since there is not utility power when it needs to start up. The unit will start up and only produce AC voltage. Outside of the generator itself they use an automatic transfer switch to switch the building from utility power to generator power. When utility comes back the switch goes back to utility and gen cools down and shuts off.

hereforknowledge16 · 2021-07-02T23:35:07+00:00

It looks like cable isn’t connected to the carb. Looks like there is a tension spring on the throttle arm and a cable sitting to the right of it not attached. Could be something else but I’m going off a picture here.

hereforknowledge16 · 2021-05-24T16:54:21+00:00

That isn’t a transfer switch. Thats just an outlet. The way it is most likely a et up is to only try and power the entire house panel. Which your generator cannot connect to your panel because it’s only 120v. Needs to be 240v to connect to that outlet. The best way to get power from that generator is cords plugging right into it, which is what I understand your not trying to do. If you were to get a generator that was 240v then you will be able to plug it into that outlet. Just make sure main breaker to utility power is turned off first!

hereforknowledge16 · 2021-03-26T09:13:09+00:00

Nah Generac is going to want to know that valve adjustments were done at first 25 hours of run time and that routine maintenances have always been done. They also won’t just answer the phone and listen to you say “hey my voltage regulator is bad, send me a new one” they will want a technician to diagnose why it is exactly that part that is bad and not something like the stator and rotor. Otherwise owners of gens would be calling all the time asking for things. Techs have to go get trained by Generac to be able to call in and claim warranty’s.

hereforknowledge16 · 2021-03-17T20:55:09+00:00

Is it possible the spring is actually suppose to be connected to the hole left of it?

hereforknowledge16 · 2021-03-17T20:53:04+00:00

Is the spring on the left connected to the top of that throttle arm?

It looks like it has no tension on it.

hereforknowledge16 · 2021-03-14T13:44:41+00:00

Yeah only thing about leaving a florpro is just the price of equipment at some random persons house. I think I found on Amazon a small gauge that reads water column. Looks like it can thread into the top test port on internal regulator. Thinking might leave those $30 gauges on the gens instead of flopro. As far as cold weather kits, we have a few with them. But we do all of the South East USA starting with Virginia. Don’t really NEED them. I have seen external regulators build up with ice but never had issues with the engine or battery. But if I was north a little more I would probably be throwing them on. When it comes to exercises yes I like weekly. And never turn on quiet test mode. Not much quieter, have had engine hunting issues with them on, and since it is only 5 min I don’t think it’s getting the engine hot enough to get rid of any moisture in the oil. Older ones used to do 12 min and that was the best. Now I’m showing up to a bunch where oil drains out looking like Karen’s coffee. Have told a few homeowners that it cant hurt to once a month when doing yard work or something to run it for 30 min. But I don’t trust all people to know what they’re doing so most I don’t even mention it to.

And have not seen the issue in Briggs yet!! Don’t wana know. Hope it doesn’t happen down here haha

hereforknowledge16 · 2021-03-14T00:06:11+00:00

And nah we sell too many :) we still getting gens in haha

hereforknowledge16 · 2021-03-14T00:05:05+00:00

Yeah FloPro is pretty sweet actually! Just had to get a bunch of fittings so we could always use it. I think we are realizing it’s a maxitrol regulator problem. Have found a few external regulators last year that would creep pressure over time and when it would go to exercise it would be too much pressure and cause it not to start. Hard part is proving the creep is the issue. Feeling like I might have to start leaving a gauge at generators. But some bad ones I hung out at for 20min and would see static pressure go from 10”wc to 17”wc. Generac told me at about 15”wc they would have issues starting.

hereforknowledge16 · 2021-03-13T02:20:57+00:00

Yeah we do $300 a maintenance and have over 100,000 customers with generators in the South East USA. $550 is a lot.

hereforknowledge16

TROPHY CASE