Generac Power Systems 5414, 5412 Test 39 Check Wire 85 for Continuity, Test 40 Test Choke Heater

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Section 7

DIAGNOSTIC TESTS

3.Connect the test leads of a VOM across the switch terminals. The meter should read “Infinity”.

4.Heat the oil. When oil temperature reach- es approximately 270-284° F., the switch con- tacts should close and the meter should read “Continuity”.

Figure 7-46. – Testing Oil Temperature Switch

RESULTS:

1.If the Oil Temperature Switch fails Step 3 or Step 4, replace the Oil Temperature Switch.

2.If the Oil Temperature Switch is good, an overheat condition may be occurring. Verify that the installa- tion of the generator is within specified tolerances. The generator must receive the proper amount of incoming air, and also be able to exhaust the cooling air with NO RESTRICTIONS. Check to be sure that the exhaust pipe is not under the air intake. Refer to the Owner’s and Installation Manual for proper installation specifications. If installation is correct, go to Test 20.

Test 39 – Check Wire 85 for Continuity

PROCEDURE:

1.Disconnect the J1 Connector from the Printed Circuit Board.

2.Locate Pin Location J1-7 on the harness end of the J1 Connector.

3.Remove Wire 85 from the High Oil Temperature switch (HOT).

4.Set a VOM to its “Rx1” scale and zero the meter.

5.Insert one meter test lead into the end of Wire 85 disconnected from the HOT. Insert the other meter test lead into Pin Location J1-7 on the har- ness end of the J1 Connector.

RESULTS:

1.If “Continuity” is not indicated, repair or replace Wire 85.

2.If “Continuity” is indicated, replace the Printed Circuit Board.

Test 40 – Test Choke Heater

DISCUSSION:

The Choke Heater is a sensitive heating element wrapped around a temperature sensitive Bi-Metal strip. The Bi-Metal Heater Assembly positions the Choke Plate during startup. Once running, the Bi- Metal Heater Assembly will also allow the Choke Plate to fully open. Power for the heater element is supplied from Wire 14 to assist the Bi-Metal Heater Assembly in opening the Choke Plate after starting. Failure of the Choke Plate to open will cause an excessively rich fuel-air mixture and engine performance will suffer.

PROCEDURE:

1.Verify that the Choke Plate on the carburetor is mechanically free to move and is not binding. If the engine runs rough, check the operation of the Bi-Metal Heater Assembly. Allow the engine to run for five minutes, then inspect the choke position. The Bi-Metal strip should have been heated by the Choke Heater and should have expanded to allow the Choke Plate to open fully.

2.If the Choke Plate did not open in Step 1, check the Choke Heater. Set the VOM to measure DC voltage. Disconnect Connector 3 at the Choke Assembly. Connect the positive (+) meter test lead to Wire 14 (Connector 3, Pin 3) going to the control panel. Connect the negative (-) meter test lead to a clean frame ground. Set the Start-Stop Switch to “START.” Battery voltage should be measured (see Figure 7-43 on Page 63).

3.If battery voltage was not measured in Step 2, set the VOM to measure resistance. Disconnect Connector 3 at the Choke Assembly. Connect one meter test lead to Wire 14 (Connector 3, Pin

3)going to the control panel. Connect the other meter test lead to the 4-tab Connector for Wire 14 in the control panel. “Continuity” should be mea- sured.

Short to Ground:

Set the VOM to measure resistance. Connect one meter test lead to Wire 14 (Connector 3, Pin 3) going to the Bi-Metal Heater Assembly. Connect the other meter test lead to the exposed steel portion of the Bi- Metal Heater Assembly. Approximately 37 ohms (±20%) should be measured. (Current draw of the Bi-Metal Heater Assembly at nominal voltage is approximately 340 milliamps or 0.340 amps). If “Continuity” is present the Bi-Metal Heater Assembly has a short to ground.

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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 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 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

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