Generac Power Systems 5415, 5412, 5411 Checking the Pinion, Tools for Starter Performance Test

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Section 7

DIAGNOSTIC TESTS

be indicated by excessive current draw or no RPM.

3.A defective Starter Motor switch.

4.Broken, damaged or weak magnets.

5.Starter drive dirty or binding.

DISCUSSION:

Test 21 verified that Printed Circuit Board action is delivering DC voltage to the Starter Contactor Relay (SCR). Test 22 verified the operation of the SCR. Test 23 verified the operation of the Starter Contactor (SC). Another possible cause of an “engine won’t crank” problem is a failure of the Starter Motor.

PROCEDURE:

The battery should have been checked prior to this test and should be fully charged.

Set a VOM to measure DC voltage (12 VDC). Connect the meter positive (+) test lead to the Starter Contactor stud which has the small jumper wire con- nected to the Starter. Connect the common (-) test lead to the Starter Motor frame.

Set the Start-Stop Switch to its “Start” position and observe the meter. Meter should Indicate battery volt- age, Starter Motor should operate and engine should crank.

RESULTS:

1.If battery voltage is indicated on the meter but Starter Motor did not operate, remove and bench test the Starter Motor (see following test).

2.If battery voltage was indicated and the Starter Motor tried to engage (pinion engaged), but engine did not crank, check for mechanical bind- ing of the engine or rotor.

If engine turns over slightly, go to Test 32 “Check and Adjust Valves.”

NOTE: If a starting problem is encountered, the engine itself should be thoroughly checked to eliminate it as the cause of starting difficulty. It is a good practice to check the engine for freedom of rotation by removing the spark plugs and turn- ing the crankshaft over slowly by hand, to be sure it rotates freely.

*WARNING! DO NOT ROTATE ENGINE WITH ELECTRIC STARTER WITH SPARK PLUGS REMOVED. ARCING AT THE SPARK PLUG ENDS MAY IGNITE THE GASOLINE VAPOR EXITING THE SPARK PLUG HOLE.

Figure 7-21. – Starter Motor (SM)

CHECKING THE PINION:

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 binding or sticking.

PINION

Figure 7-22. – Check Pinion Gear Operation

TOOLS FOR STARTER PERFORMANCE TEST:

The following equipment may be used to complete a performance test of the Starter Motor:

❏A clamp-on ammeter.

❏A tachometer capable of reading up to 10,000 rpm.

❏A fully charged 12-volt battery.

Measuring Current:

To read the current flow, in AMPERES, a clamp-on ammeter may be used. This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor.

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Magnetism Electromagnetic FieldsElectromagnetic 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 IdentificationDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersStator Insulation Resistance Megohmmeter Testing Rotor InsulationTesting Stator Insulation Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC VoltageMeasuring Resistance Measuring CurrentOhm’s Law Electrical UnitsOperational Analysis IntroductionCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Printed Circuit Board BatteryRecommended Battery Battery CablesAmp 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 BlowingDiscussion ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Stepper Motor ControlTest 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 13 Check Load Watts Amperage SchematicTest 11 Check Main Circuit Breaker Test 12 Check Load Voltage FrequencyTest 15 Check Fuel Pump Test 14 Try Cranking the EngineTest 17 Check Battery & Cables Test 18 Check Power Supply to Printed Circuit BoardTest 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 ContactorChecking the Pinion 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 Test 32 Check Valve Adjustment Checking Flywheel MagnetFlywheel 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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