Generac Power Systems 5410 Test 32 Check Valve Adjustment, Checking Flywheel Magnet, Flywheel KEY

Page 59

Section 7

DIAGNOSTIC TESTS

3.If “Infinity” was not measured in Step 15, repair or replace grounded Wire 18A between the J1 Connector and the insulated terminal stud or defective insulated terminal stud.

4.If sparking still does not occur after adjusting the armature air gap, testing the ground wires and performing the basic flywheel test, replace the ignition magneto(s).

Note: Before replacing the Ignition Magneto, check the Flywheel Magnet.

CHECKING FLYWHEEL MAGNET:

The flywheel magnet rarely loses its magnetism. If you suspect a magnet might be defective, a rough test can be performed as follows:

1.Place the flywheel on a wooden surface.

2.Hold a screwdriver at the extreme end of its han- dle and with its point down.

3.Move the tip of the screwdriver to about 3/4 inch (19mm) from the magnet. The screwdriver blade should be pulled in against the magnet.

FLYWHEEL KEY:

In all cases, the flywheel taper is locked on the crank- shaft taper by the torque of the flywheel nut. A keyway is provided for alignment only and theoretically carries no load.

If the flywheel key becomes sheared or even partially sheared, ignition timing can change. Incorrect timing can result in hard starting or failure to start.

Remove and inspect flywheel key for damage.

Test 32 – Check Valve Adjustment

Discussion:

The valve lash must be adjusted correctly in order to pro- vide the proper air/fuel mixture to the combustion chamber.

Adjusting Valve Clearance:

Adjust valve clearance with the engine at room tem- perature. The piston should be at top dead center (TDC) of its compression stroke (both valves closed).

An alternative method is to turn the engine over and position the intake valve fully open (intake valve spring compressed) and adjust the exhaust valve clearance. Turn the engine over and position the exhaust valve fully open (exhaust valve spring compressed) and adjust the intake valve clearance.

Correct valve clearance is given below, in INCHES (MILLIMETERS).

Intake Valve

0.002-0.004 (0.05-0.1)

Exhaust Valve

0.002-0.004 (0.05-0.1)

1.Loosen the rocker arm jam nut. Use a 10mm allen wrench to turn the pivot ball stud while checking the clearance between the rocker arm and valve stem with a feeler gauge (see Figure 7-39).

2.When clearance is correct, hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut to the specified torque with a crow’s foot. After tightening the jam nut, recheck valve clear- ance to make sure it did not change.

TORQUE SPECIFICATION ROCKER ARM JAM NUT 174 inch-pounds

FEELER GAUGE

ALLEN WRENCH

Figure 7-39 – Adjusting Valve Clearance

CROW'S FOOT

Figure 7-40 – Tightening the Jam Nut

Install Rocker Arm Cover

1.Use a new rocker arm cover gasket. Install the rocker arm cover and retain with four screws.

Results:

Adjust valves to specification and retest. If problem continues, go to Test 35.

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