Generac Power Systems 5415 Test 30 Check Spark Plugs, Test 31 Check and Adjust Ignition Magnetos

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Section 7

DIAGNOSTIC TESTS

Figure 7-34. – Cylinder Balance Test

The cylinder balance test will also detect a cylinder that is not functioning. When grounding out one cylin- der there will be no RPM loss. When the other cylin- der is grounded out the engine will stop.

Test 30 - Check Spark Plugs

DISCUSSION:

During Test 29, if spark jumped the tester gap, the ignition system must be functioning properly. However, if the engine misses the spark plug itself may be fouled.

PROCEDURE:

Remove spark plugs. Clean with a commercial sol- vent. DO NOT BLAST CLEAN SPARK PLUGS. Replace spark plugs if badly fouled, if ceramic is cracked, or if badly worn or damaged. Set gap to 0.030 inch (0.76mm). Use a NGK BPR6HS (or equiv- alent) replacement spark plug.

SET PLUG GAP AT 0.030 inch

(0.76 mm)

Figure 7-35 – Setting Spark Plug Gap

RESULTS:

1.Clean and regap or replace sparks plug as neces- sary.

2.If spark plugs are good for gasoline models, go to Test 33. For LPG models, go to Test 32.

Test 31 – Check and Adjust Ignition

Magnetos

DISCUSSION:

The ignition system used on GT-530 engines is a solid-state (breakerless) type. The system utilizes a magnet on the engine flywheel to induce a relatively low voltage into an ignition magneto assembly. Ignition magneto internal components increase the voltage and deliver the resulting high voltage across the spark plug gap.

The ignition magneto houses a solid state-circuit board that controls ignition timing. Timing is fixed and spark advance is automatic.

Major components of the ignition system include (a) two ignition magneto assemblies, (b) the spark plugs,

(c)the engine control printed circuit board and (d) the engine flywheel.

Solid-state components encapsulated in the ignition magneto are not accessible and cannot be serviced. If the magneto is defective, the entire assembly must be replaced. The air gap between the magneto and the flywheel magnet is between 0.012” to 0.015”.

The ignition magneto assembly (Figure 7-36) consists of (a) ignition magneto, (b) spark plug high tension lead and (c) spark plug boot.

SPARk PLUG

 

HIGH TENSION

SPARk

LEAD

PLUG

 

BOOT

 

IGNITION COIL

Figure 7-36. – Ignition Magneto Assembly

In Test 29, a spark tester was used to check for engine ignition. If sparking or weak spark occurred, one possible cause might be the ignition magneto(s). This test consists of adjusting the air gap between the ignition magneto(s) and the flywheel. The flywheel and flywheel key will also be checked during this test. If no sparking occurs, the ground harness may be at fault.

Procedure:

1.Disconnect the J1 connector from the Printed Circuit Board. Carefully remove Wire 18A from Pin Location J1-14. Connect the J1 connector back to the Printed Circuit Board. Repeat Test 29 “Check Ignition Spark”. If the unit now produces spark go

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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 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 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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