Generac Power Systems 5411, 5412 Test 27 Check Wire, Test 28 Check Fuel Solenoid Gasoline Models

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Section 7

DIAGNOSTIC TESTS

Test 27 – Check Wire 18

DISCUSSION:

Wire 18 controls sending the STOP signal to the Printed Circuit Board. Coach manufacturers some- times install a 15 to 30 foot remote harness. If unit shuts down or will not start, a possible ground exists on Wire 18.

PROCEDURE:

1.Disconnect the customer installed remote harness connector from the generator. Then press the gen- erator Start-Stop switch to the “Start” position. If generator starts and continues to run, a short is present in the coach remote harness. Repair or replace the remote harness.

2.Remove the J1 connector from the Printed Circuit Board. Set the VOM to measure resis- tance. Connect one test lead to Pin Location J1- 2. Connect the other test lead to a clean frame ground. “Infinity” should be measured.

WIRE 18

AT PIN LOCATION B

A H

B G

C F

D E

Figure 7-31. – Remote Harness Connector

3.Connect one test lead to Pin Location B on the Remote Harness connector (see Figure 7-31). Connect the other test lead to a clean frame ground. “Infinity” should be measured.

RESULTS:

1.If “Continuity” is measured in Step 2, repair or replace shorted Wire 18 between J1 Connector and Start-Stop Switch.

2.If “Continuity” was measured in Step 3, repair or replace shorted Wire 18 between J1 Connector and remote panel connector.

3.If Wire 18 checks GOOD, proceed to Problem 8 (Section 6).

Test 28 – Check Fuel Solenoid

(Gasoline Models)

DISCUSSION:

If the Fuel Solenoid fails to open, the engine will not start.

PROCEDURE:

1.Remove Control Panel cover. Remove Wire 56 from the Starter Contactor Relay. This will prevent the unit from cranking during test (see Figure 7- 19, Page 47).

2.Remove air filter cover. Disconnect Connector 2 which connects to the fuel pump.

3.Activate the Start-Stop Switch (SW1) to the “Start” position and hold. This will activate the fuel solenoid. The fuel solenoid should energize and produce an audible click. If the fuel solenoid does not operate, proceed to Step 4. Reconnect Connector 2 back to the fuel pump.

4.Set the VOM to measure DC voltage. Disconnect Wire 14 from the Fuel Solenoid. Connect the posi- tive (+) meter test lead to Wire 14 that goes to the control panel. Connect the negative (-) test lead to a clean frame ground. Activate the Start-Stop Switch (SW1) to the “START” position and hold. Battery voltage should be measured.

5.Set the VOM to measure resistance. Disconnect Wire 0 from the Carburetor at the bullet connec- tor. Connect one test lead to Wire 0 that goes to the control panel. Connect the other test lead to a clean frame ground. “Continuity” should be mea- sured.

6.Connect one test lead to the Green Wire going to the carburetor. Connect the other test lead to the carburetor body. “Continuity” should be measured.

Short to Ground:

7.Set the VOM to measure resistance. Disconnect the bullet connector going to the Fuel Solenoid. Connect one meter test lead to the Red Wire going to the Fuel Solenoid. Connect the other meter test lead to the Fuel Solenoid housing. A reading of 38.0 ohms should be measured. If very low resistance is measured, a short to ground exists. (Fuel Solenoid coil resistance is approximately 38.0 ohms. Current draw of the Fuel Solenoid at nominal voltage is approximately 331 milliamps or 0.331 amps).

RESULTS:

1.If the Fuel Solenoid passes Steps 4 & 5 but does NOT operate in Step 3, replace or repair Fuel Solenoid.

2.If battery voltage is not measured in Step 4, repair or replace Wire 14 between the 4-tab Connector and the Fuel Solenoid.

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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 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 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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