Generac Power Systems 5412, 5411, 5413 Test 33 Check Carburetion, Test 34 Check Choke Solenoid

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Section 7

DIAGNOSTIC TESTS

Test 33 – Check Carburetion

DISCUSSION:

If the engine cranks but will not start, one possible cause of the problem might be the carburetion system.

PROCEDURE:

Before making a carburetion check, be sure the fuel sup- ply tank has an ample supply of fresh, clean gasoline.

Check that all shutoff valves are open and fuel flows freely through the fuel line.

Make sure the automatic choke operates properly.

If the engine will not start, remove and inspect the spark plug. If the spark plug is wet, look for the following:

❏Overchoking.

❏Excessively rich fuel mixture.

❏Water in fuel.

❏Intake valve stuck open.

❏Needle/float stuck open.

If the spark plug is dry look for the following:

❏Leaking carburetor mounting gaskets.

❏Intake valve stuck closed.

❏Inoperative fuel pump.

❏Plugged fuel filter(s).

❏Varnished carburetor

If the engine starts hard or will not start, look for the following:

❏Physical damage to the AC generator. Check the Rotor for contact with the Stator.

❏Starting under load. Make sure all loads are discon- nected or turned off before attempting to crank and start the engine.

❏Check that the automatic choke is working properly.

RESULTS:

If problem has not been solved, go to Test 34. If car- buretor is varnished, clean or replace.

1.Remove fuel line at carburetor and ensure that there is an adequate amount of fuel entering the carburetor.

2.Remove the float bowl and check to see if there is any foreign matter in bottom of carburetor bowl.

3.The float is plastic and can be removed for access to the needle so it can be cleaned.

4.With all of this removed carburetor cleaner can be used to clean the rest of the carburetor before reassembly.

5.After cleaning carburetor with an approved carbu- retor cleaner, blow dry with compressed air and reassemble.

Shelf life on gasoline is 30 days. Proper procedures need to be taken for carburetors so that the fuel doesn’t varnish over time. A fuel stabilizer must be used at all times in order to ensure that the fuel is fresh at all times.

Test 34 – Check Choke Solenoid

DISCUSSION:

The automatic choke is active only during cranking. When the Start-Stop Switch is held at “START”, a crank relay on the Printed Circuit Board is energized closed to (a) crank the engine and (b) deliver a cyclic voltage to the Choke Solenoid via Wire 14. The Choke Solenoid will be pulled in for about two seconds, then deactivate for about two seconds. This cyclic choking action will continue as long as the engine is being cranked.

PROCEDURE:

1.Operational Check: Crank the engine. While cranking, the choke solenoid should pull in about every 2 seconds (2 seconds ON, 2 seconds OFF). If the choke solenoid does not pull in, try adjusting the choke as follows.

2.Pre-Choke Adjustment: With the CHOKE SOLENOID not actuated, the carburetor CHOKE PLATE should be approximately 1/8 Inch from its full open position. Verify choke is completely open once engine is warmed up. If not, power will be down and emissions will be up. Adjust position of bi-metal HEATER Assembly by loosening screws until unit starts when cold and the choke closes when engine is up to temperature. Tighten the screws to complete the adjustment.

BI-METAL

HEATER

SCREWS

STEPPER

MOTOR

CHOKE

SOLENOID

Figure 7-41. – Automatic Choke Assembly

3.Choke Solenoid Adjustment: Loosen the screws that retain the CHOKE SOLENOID to its brack- et. Slide the CHOKE SOLENOID in the slotted holes of the bracket to adjust axial movement of the SOLENOID PLUNGER. Adjust SOLENOID PLUNGER movement until, with the carburetor CHOKE PLATE 0.5mm from closed, the CHOKE SOLENOID is bottomed in its coil (plunger at full actuated position). With the CHOKE PLATE 0.5mm from closed and the plunger bottomed

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Magnetism Electromagnetic FieldsElectromagnetic 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 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 17 Check Battery & Cables Test 18 Check Power Supply to Printed Circuit BoardTest 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 MotorChecking the Pinion 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 Test 32 Check Valve Adjustment Checking Flywheel MagnetFlywheel 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

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