Generac Power Systems 5414, 5412, 5411, 5413, 5415, 5410 Setting Ignition Magneto Armature Air Gap

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Section 7

DIAGNOSTIC TESTS

to Step 2. If the unit does not produce spark or has weak spark go to Step 4.

2.Do the following:

a.Set a VOM to measure resistance. Connect the positive (+) meter test lead to Wire 18A (Wire 18A still removed from the J1 connec- tor) Connect the negative (-) meter test lead to a clean frame ground. “Infinity” should be measured, or 0.5 to 1M ohms, depending upon the type of VOM used. If “Continuity” is measured proceed to Step 12.

b.Set a VOM to the diode test range. Attach the negative (-) meter test lead to Pin Location J1-14 on the Printed Circuit Board. (Wire 18A still removed from the J1 connector) Attach the positive (+) meter test lead to frame ground. Set the Start-Stop Switch to “start”. “Infinity” should be measure during crank- ing and running. If the VOM does not have a diode test range, set VOM to measure resis- tance again. “Infinity” should be measured.

3.If Step 1 produced spark and Step 2 tested good, set the VOM to measure DC voltage. Connect one test lead to Wire 15 (J1-4) on PCB. Connect the other test lead to frame ground. Battery voltage should be measured. Verify that Wire 15 is con- nected to J1 and that Wire 14 is connected to J1- 5; if reversed the unit will produce no spark.

4.Rotate the flywheel until the magnet is under the module (armature) laminations (see Figure 7-37).

5.Place a 0.012-0.015 inch thickness gauge between the flywheel magnet and the module laminations.

Figure 7-37. – Setting Ignition Magneto

(Armature) Air Gap

6.Loosen the mounting screws and let the magnet pull the magneto down against the thickness gauge.

7.Tighten both mounting screws.

8.To remove the thickness gauge, rotate the fly- wheel.

9.Repeat the above procedure for the second mag- neto.

10.Repeat Test 55 and check for spark across the spark tester gap.

11.If air gap was not out of adjustment, test ground wires.

12.Set the VOM to the diode test position. The meter will display forward voltage drop across the diode. If the voltage drop is less than 0.7 volts, the meter will “Beep” once as well as display the voltage drop. A continuous tone indicates “Continuity” (shorted diode). An incomplete circuit (open diode) will be displayed as “OL.”

13.Disconnect the engine ground harness from the ignition magnetos and stud connector (see Figure 7-38).

Results:

1.If “Infinity” was not measured in Step 2b, replace the Printed Circuit Board.

Note: If VOM was set to Diode test, a reading of

0.5volts would be observed when the Start-Stop Switch is set to “STOP”. If the VOM was set to resistance, a reading of 0.5 to 1.5M ohms would be measured. During cranking and running this reading should go to “Infinity”. Verify that the meter leads were properly connected as per Step 2 instructions.

2.If battery voltage was not measured in Step 3, reconnect Wire 15 and Wire 14 to their correct terminal locations.

 

C

ENGINE

NEGATIVE METER

TEST LEAD

GROUND

 

HARNESS

B

 

 

A

 

POSITIVE METER

 

TEST LEAD

Figure 7-38. – Engine Ground Harness Test Points

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Fields MagnetismElectromagnetic Induction 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 18 Check Power Supply to Printed Circuit Board Test 17 Check Battery & CablesTest 16 Check 7.5 Amp Fuse 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 MotorPinion Checking the PinionTools for Starter Performance Test 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 Checking Flywheel Magnet Test 32 Check Valve AdjustmentFlywheel KEY 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

5410, 5414, 5415, 5413, 5411 specifications

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