Generac Power Systems 5413, 5412, 5411, 5415, 5414, 5410 manual Test 29 Check Ignition Spark

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Section 7

DIAGNOSTIC TESTS

3.If “Continuity” is not measured in Step 5, repair or replace Wire 0 between the Fuel Solenoid and ground terminal.

4.If “Continuity” is not measured in Step 6, repair or replace Carburetor ground wire.

5.If the Fuel Solenoid operates, proceed to Test 29.

Test 29 – Check Ignition Spark

DISCUSSION:

A problem in the engine ignition system can cause any of the following:

•Engine will not start.

•Engine starts hard, runs rough.

A commercially available spark tester may be used to test the engine ignition system. One can also be pur- chased from Generac Power Systems (P/N 0C5969).

PROCEDURE:

1.Disconnect a high tension lead from a spark plug.

2.Attach the high tension lead to the spark tester terminal.

3.Ground the spark tester clamp by attaching to the cylinder head (see Figure 7-32).

SPARk TESTER CLAMP

SPARk TESTER

 

GROUNDED TO

SPARk PLUG

CYLINDER HEAD

BOOT

 

Figure 7-32. – Testing Ignition System

4.Crank the engine rapidly. Engine must be crank- ing at 350 rpm or more. If spark jumps the tester gap, you may assume the ignition system is work- ing properly. Repeat on remaining cylinder spark plug.

5.To determine if an engine miss is ignition related, connect the spark tester in series with the high tension lead and the spark plug. Then, start the engine. If spark jumps the tester gap at regu- lar Intervals, but the engine miss continues, the problem may be in the spark plug or fuel system. Repeat on remaining cylinder spark plug. Proceed to Test 30.

6.If spark jumps the tester gap intermittently, the problem may be in the Ignition Magneto. Proceed to Test 31.

SPARk TESTER CLAMP

CONNECTED TO

SPARk TESTER

SPARk PLUG

 

SPARk PLUG

 

BOOT

Figure 7-33. – Checking Engine Miss

RESULTS:

1.If no spark or if engine miss is apparent, go to Test 31.

2.If ignition spark is good, go to Test 30.

Cylinder Balance Test:

If the engine is hard starting, runs rough, misses or lacks power, perform a cylinder balance test to deter- mine whether both cylinders are operating to their full potential.

Tools Required:Two Ignition Testers (Generac P/N 0C5969)

Attach an ignition tester between the spark plug lead and each spark plug (Figure 7-33).

Start and run engine running at top no load speed and note spark at ignition testers. If the spark is equal at both ignition testers, the problem is not ignition related. A spark miss will be readily apparent. Now note RPM of engine. Ground out one cylinder by con- tacting ignition tester and a good ground on engine as shown in Figure 7-34. Note RPM loss. Reattach plug wire then repeat procedure with the other cylinder. Note the RPM loss. If the difference between the two cylinders does not exceed 75 RPM, the amount of work the two cylinders are doing should be consid- ered equal.

If the RPM loss is greater than 75 RPM this indicates that the grounded cylinder with the least RPM loss is the weakest of the two cylinders. Look to that cylinder for a problem.

Example:

Engine RPM - Both Cylinders = 2570 RPM

Engine RPM - No. 1 Cylinder Grounded = 2500 RPM Engine RPM - No. 2 Cylinder Grounded = 2300 RPM

Conclusion: No. 1 cylinder is weakest of the two cylinders.

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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 ComponentsCleaning the Generator Effects of Dirt and MoistureInsulation Resistance Testers Drying the GeneratorStator Insulation Resistance Testing Rotor Insulation Testing Stator InsulationTesting Rotor Insulation MegohmmeterMeters VOMMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohm’s LawIntroduction Operational AnalysisCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Battery Recommended BatteryBattery Cables 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 YESProcedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Stepper Motor Control 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 RingsSchematic Test 11 Check Main Circuit BreakerTest 12 Check Load Voltage Frequency 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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