Generac Power Systems 5411, 5412, 5413, 5415, 5414, 5410 manual Test 22 Check Starter Contactor Relay

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Section 7

DIAGNOSTIC TESTS

0000

CONTINUITY

87

14

25

36

DEPRESSED

AWAY FROM

TERMINAL BEING

TESTED

5.Connect the VOM positive (+) test lead to Wire 56 (Pin Location J1-9) at the Printed Circuit Board. Connect the other test lead to frame ground.

6.Actuate the Start-Stop Switch to the “START” position. The meter should indicate battery volt- age.

RESULTS:

1.If battery voltage was measured in Step 6, but not in Step 4, repair or replace Wire 56 between the Printed Circuit Board and Starter Contactor Relay.

2.If battery voltage was not available in Step 6, replace the Printed Circuit Board.

3.If battery voltage is available in Step 4 but engine does not crank, go to Test 22.

Test 22 – Check Starter Contactor

Relay

Figure 7-18. – Test 20, Step 6

RESULTS:

1.If “Continuity” is not measured in Step 3, repair, reconnect or replace Wire 0 (between Start-Stop Switch and ground terminal) as necessary.

2.If the Start-Stop Switch (SW1) failed any part of Steps 2 or 3, replace the switch.

5. If switch tests GOOD, go to Test 21.

Test 21 – Check Power Supply to

Wire 56

DISCUSSION:

If battery voltage is available to the Printed Circuit Board in Test 18, then DC voltage should be deliv- ered to Wire 56 when the Start-Stop Switch is set to “START” (Test 20). This test will check to see if the Printed Circuit Board is delivering battery voltage to the Wire 56 terminal.

PROCEDURE:

1.Set a VOM to measure DC voltage (12 VDC).

2.Disconnect Wire 56 from its Starter Contactor Relay terminal.

3.Connect the meter positive (+) test lead to the disconnected end of Wire 56. Connect the other test lead to frame ground. No voltage should be indicated.

4.Actuate the Start-Stop Switch to its “START” posi- tion. The meter should indicate battery voltage. If battery voltage is present, stop the procedure.

DISCUSSION:

If battery voltage is available to Wire 56 but the engine won’t crank, the possible cause could be a failed Starter Contactor Relay.

1316

13

16

COM

NO

56

56

0

0

Figure 7-19. – Starter Contactor Relay

PROCEDURE:

1.Set the VOM to measure resistance (“R x 1” scale). Remove Wire 0 from the Starter Contactor Relay (SCR). Connect one meter test lead to Wire 0, and connect the other meter test lead to frame ground. “Continuity” should be measured. Reconnect Wire 0.

2.Set the VOM to measure resistance (“R x 1” scale). Disconnect Wire 16 and Wire 13 (Wire 13 is 12 VDC isolate from ground) from the Starter Contactor Relay (SCR). Connect one meter test lead to an SCR terminal, and connect the other meter test lead to the remaining SCR terminal.

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Fields MagnetismElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostConnection for 120 Volts Only Stator Assembly Rotor AssemblyExcitation Circuit Components Brush HolderDescription Crankcase BreatherControl Panel Components Control Panel Component IdentificationEffects of Dirt and Moisture Cleaning the GeneratorInsulation Resistance Testers Drying the GeneratorStator Insulation Resistance Testing Stator Insulation Testing Rotor InsulationTesting Rotor Insulation MegohmmeterVOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Resistance Measuring CurrentOhm’s Law Electrical UnitsOperational Analysis IntroductionCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Recommended Battery BatteryBattery Cables Printed Circuit BoardAmp Fuse Start-Stop SwitchStarter Contactor Relay Starter Motor Start-Stop SwitchProblem 1 Voltage & Frequency Are Both High or Low If Problem Involves AC OutputTest Troubleshooting Flowcharts Proble 5 Priming Function Does Not Work Gasoline Models Problem 6 Engine Will Not Crank Test 26 Check Test 20 Check Check Fuel Wire 14 Power Good Troubleshooting Flowcharts Problem 8 Engine Starts Hard and Runs Rough Gasoline Units Problem 8 Engine Starts Hard and Runs Rough LP Units LOW OIL Pressure Flashes on SW1 LED YES Problem 10 7.5A F1 Fuse BlowingTest 1 Check No-Load Voltage Frequency ProcedureTest 2 Check Stepper Motor Control DiscussionTest 4 Fixed Excitation Test/Rotor Amp Draw Six Pin J2 Connector Wire ColorsFixed Excitation Test, Step B Test 6 Test Stator DPE Winding Test 5 Check Field BoostStator Excitation Winding Test 7 Check Sensing Leads / Power WindingsTest 8 Check Brush Leads Stator Power Winding LeadsTest 9 Check Brushes & Slip Rings Test 10 Check Rotor AssemblyTest 11 Check Main Circuit Breaker SchematicTest 12 Check Load Voltage Frequency Test 13 Check Load Watts AmperageTest 15 Check Fuel Pump Test 14 Try Cranking the EngineTest 18 Check Power Supply to Printed Circuit Board Test 17 Check Battery & CablesTest 16 Check 7.5 Amp Fuse Test 20 Check Start-Stop Switch Test 19 Check Continuity of WireTest 22 Check Starter Contactor Relay Test 21 Check Power Supply to WireTest 24 Check Starter Motor Test 23 Check Starter ContactorPinion Checking the PinionTools for Starter Performance Test Minimum rpm 4500 Maximum Amps To Carburetor GAS Test 25 Check Fuel Supply29. Fuel Regulator Test 26 Check Wire 14 Power SupplyTest 28 Check Fuel Solenoid Gasoline Models Test 27 Check WireTools RequiredTwo Ignition Testers Generac P/N 0C5969 Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 31 Check and Adjust Ignition Magnetos37. Setting Ignition Magneto Armature Air Gap Checking Flywheel Magnet Test 32 Check Valve AdjustmentFlywheel KEY Test 34 Check Choke Solenoid Test 33 Check CarburetionSolenoid Panel To ControlTest 36 Check Oil Pressure Switch Test 38 Test Oil Temperature Switch Test 37 Check Wire 86 for ContinuityTest 40 Test Choke Heater Test 39 Check Wire 85 for ContinuityTest 41 Check LPG Fuel Solenoid Section Exploded Views QTY Description Enclosure Drawing No G3881-C Enclosure Door Views Screw Plastite HI-LOW #10X3/8 Engine Accessories Drawing No G7718-B QTY Description 48,49 Square Head Plug Rotor & Stator Drawing No G3953-b NUT TOP Lock FL M8-1.25 Charts Nominal Resistances of Generator Windings at 68f Generator SpecificationsElectrical Data Electrical Data OG7515 REV. a

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