Generac Power Systems 5413, 5412 Test 23 Check Starter Contactor, Test 24 Check Starter Motor

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Section 7

DIAGNOSTIC TESTS

“Infinity” should be measured. Set the Start-Stop Switch to “START”. The meter should now read “Continuity”.

Short to Ground:

3.Set the VOM to measure resistance (“R x 1” scale). Disconnect Wire 56 from the Starter Contactor Relay (SCR). Connect one meter test lead to the SCR terminal from which Wire 56 was just removed. Connect the other meter test lead to a clean frame ground. Starter Contactor Relay coil resistance of 155 ohms should be measured. If “Continuity” is measured a short to ground exists.

Note: Current draw of the Starter Contactor Relay coil at nominal voltage is approximately 80ma.

RESULTS:

1.If “Continuity” is not measured in Step 1, repair or replace Wire 0 between the Starter Contactor Relay and the ground terminal.

2.If “Continuity” was not measured in Step 2 when the Start-Stop switch was activated to “start”, replace the Starter Contactor Relay.

3.If “Continuity” is measured in Step 2, go to Test 23.

Test 23 – Check Starter Contactor

DISCUSSION:

The Starter Contactor (SC) must energize and it’s heavy duty contacts must close or the engine will not crank. This test will determine if the Starter Contactor is in working order. The Starter Contactor is connect- ed to the Starter Motor (see Figure 7-20).

 

STARTER

16

 

 

 

SWITCH

50

 

 

BATTERY

30

 

12V

 

 

CONNECTING

DIAGRAM

 

PERMANENT MAGNET

STARTER

STEP 1

TEST POINT

CONTACTOR

 

 

STEP 2

 

TEST POINT

STARTER

 

MOTOR

 

Figure 7-20. – The Starter Contactor (SC)

PROCEDURE:

1.Carefully inspect the starter motor cable that runs from the Battery to the Starter Motor. Cable con- nections should be clean and tight. If connections are dirty or corroded, remove cable and clean cable terminals and studs. Replace any cable that is defective or badly corroded. Set the VOM to measure DC voltage. Connect the positive

(+)meter test lead to the Starter Contactor stud that the battery cable is connected to. Connect the negative (-) meter test lead to a clean frame ground. Battery voltage should be measured (see Figure 7-20, STEP 1 TEST POINT).

2.Set the VOM to measure DC voltage. Disconnect Wire 16 from the Starter Contactor. Connect the positive (+) meter test lead to Wire 16. Connect the negative (-) meter test lead to a clean frame ground. Set the Start-Stop Switch to “Start”. Battery voltage should be indicated. Reconnect Wire 16 to the Starter Contactor.

3.Set the VOM to measure DC voltage. Connect the positive (+) meter test lead to the Starter Contactor stud that has the small jumper wire connected to the Starter. Connect the negative (-) meter test lead to a clean frame ground. Set the Start-Stop Switch to “Start”. Battery volt- age should be measured (see Figure 7-20, STEP 2 TEST POINT).

RESULTS:

1.If battery voltage was not measured in Step 1, repeat Test 17.

2.If battery voltage was not measured in Step 2,

repair or replace Wire 16 between the Starter Contactor Relay (SCR) and the Starter Contactor (SC).

3If battery voltage was measured in Step 1, but not in Step 3, replace the Starter Contactor.

4.If battery voltage was measured in Step 3 but the engine still does not crank, go to Test 24.

Test 24 – Check Starter Motor

Conditions Affecting Starter Motor Performance:

1.A binding or seizing condition in the Starter Motor bearings.

2.A shorted, open or grounded armature.

a.Shorted, armature (wire insulation worn and wires touching one another). Will be indicated by low or no RPM.

b.Open armature (wire broken) will be indicated by low or no RPM and excessive current draw.

c.Grounded armature (wire insulation worn and wire touching armature lamination or shaft). Will

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemConnection for 120 Volts Only Rotor Assembly Stator AssemblyBrush Holder Excitation Circuit ComponentsCrankcase Breather DescriptionControl Panel Component Identification Control Panel ComponentsInsulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the GeneratorStator Insulation Resistance Testing Rotor Insulation Testing Rotor InsulationTesting Stator Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohm’s LawIntroduction Operational AnalysisCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Battery Cables BatteryRecommended Battery Printed Circuit BoardStart-Stop Switch Amp FuseStart-Stop Switch Starter Contactor Relay Starter MotorIf Problem Involves AC Output Problem 1 Voltage & Frequency Are Both High or LowTest 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 Problem 10 7.5A F1 Fuse Blowing YESTest 2 Check Stepper Motor Control ProcedureTest 1 Check No-Load Voltage Frequency DiscussionSix Pin J2 Connector Wire Colors Test 4 Fixed Excitation Test/Rotor Amp DrawFixed Excitation Test, Step B Test 5 Check Field Boost Test 6 Test Stator DPE WindingTest 7 Check Sensing Leads / Power Windings Stator Excitation WindingStator Power Winding Leads Test 8 Check Brush LeadsTest 10 Check Rotor Assembly Test 9 Check Brushes & Slip RingsTest 12 Check Load Voltage Frequency SchematicTest 11 Check Main Circuit Breaker Test 13 Check Load Watts AmperageTest 14 Try Cranking the Engine Test 15 Check Fuel PumpTest 16 Check 7.5 Amp Fuse Test 17 Check Battery & CablesTest 18 Check Power Supply to Printed Circuit Board Test 19 Check Continuity of Wire Test 20 Check Start-Stop SwitchTest 21 Check Power Supply to Wire Test 22 Check Starter Contactor RelayTest 23 Check Starter Contactor Test 24 Check Starter MotorTools for Starter Performance Test Checking the PinionPinion Minimum rpm 4500 Maximum Amps Test 25 Check Fuel Supply To Carburetor GASTest 26 Check Wire 14 Power Supply 29. Fuel RegulatorTest 27 Check Wire Test 28 Check Fuel Solenoid Gasoline ModelsTest 29 Check Ignition Spark Tools RequiredTwo Ignition Testers Generac P/N 0C5969Test 31 Check and Adjust Ignition Magnetos Test 30 Check Spark Plugs37. Setting Ignition Magneto Armature Air Gap Flywheel KEY Test 32 Check Valve AdjustmentChecking Flywheel Magnet Test 33 Check Carburetion Test 34 Check Choke SolenoidTo Control Solenoid PanelTest 36 Check Oil Pressure Switch Test 37 Check Wire 86 for Continuity Test 38 Test Oil Temperature SwitchTest 39 Check Wire 85 for Continuity Test 40 Test Choke HeaterTest 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 Generator Specifications Nominal Resistances of Generator Windings at 68fElectrical Data Electrical Data OG7515 REV. a

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