Generac Power Systems 75, 55, 65 manual Test 24 Check START-STOP Switch, Start-Stop Switch

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Section 7

DIAGNOSTIC TESTS

RESULTS:

1.If battery voltage is NOT indicated in Step 1, check continuity of:

a.Wire 13 between Starter Contactor and Starter Contactor Relay.

b.Wire 13 between Starter Contactor Relay and 7.5 Amp Fuse (F1).

c.Wire 15 between the 7.5 Amp fuse (F1) and the Battery Charge Rectifier.

d.Wire 15 between the Battery Charge Rectifier and the Engine Controller Board.

Repair, reconnect or Replace bad wiring as necessary.

2.If battery voltage is indicated but engine will not crank, go to Test 24.

3.If “Continuity” was not measured in Step 3, repair or replace Wire 0 between the Engine Controller Circuit Board and the Ground Terminal.

TEST 24 - CHECK START-STOP SWITCH

DISCUSSION:

Engine cranking and startup is initiated when Wire 17 from the Engine Controller board is connected to frame ground by setting the Start-Stop Switch to “START”.

Engine shutdown occurs when circuit board Wire 18 is connected to frame ground by the Start-Stop Switch.

Figure 7-17. – Start-Stop Switch

A defective Start-Stop Switch can result in (a) failure to crank when the switch is set to “START”, and/or (b) failure to shut down when the switch is set to “STOP”.

PROCEDURE:

For Problem 6 (Section 6), perform all steps. For Problem 9, perform Step 1 and Step 5 ONLY.

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

2.Inspect the ground Wire 0B, between the Start-Stop Switch and the grounding terminal. Connect one meter test lead to Wire 0B on SW1. Connect the other test lead to a clean frame ground. “Continuity” should be measured.

3.Disconnect Wire 17 from its Switch terminal and connect it to frame ground. The engine should crank.

4.Remove the 7.5 amp fuse. Disconnect Wire 18, Wire 0B and Wire 17 from the Start-Stop Switch (SW1).

5.Connect one test lead to the center terminal of SW1. Connect the other test lead to an outer terminal of SW1. “Infinity” should be measured. Remove the test lead from the outer terminal of SW1 and connect it to the opposite outer terminal. “Infinity” should be measured.

6.Leave the test lead connected to the center terminal of SW1 from Step 5. Connect the other test lead to an outer terminal. Depress the switch away from the terminal being tested (see Figure 7-18). “Continuity” should be measured. Repeat the pro- cedure with the test lead connected to the other outer terminal. “Continuity” should be measured.

Figure 7-18. – Test 24, Step 6

RESULTS:

1.If “Continuity” is not measured in Step 2, repair, reconnect or replace Wire 0B (between Start-Stop Switch and ground termi- nal) as necessary.

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Specifications & Charts Section Exploded Views / Part NumbersElectromagnetic Fields MagnetismElectromagnetic Induction Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostLine Breakers 120 Volts only Connection for 120 Volts Only Reconnection for Dual Voltage OutputRotor Assembly Stator AssemblyBattery Charge Components Brush HolderExcitation Circuit Components GeneralAdjustment Procedure Crankcase BreatherVoltage Regulator DescriptionInstall Breather Install oil vapor collector and retainerControl Panel Component Identification Check BreatherCleaning the Generator Effects of Dirt and MoistureInsulation Resistance Testers Drying the GeneratorBrushing and Vacuum Cleaning Stator Insulation ResistanceCloth or Compressed AIR Stator SHORT-TO-GROUND TestsTesting Rotor Insulation Testing Stator InsulationTesting Rotor Insulation MegohmmeterMeters VOMMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring AC FrequencyMeasuring Resistance Electrical Units Ohms LAWAmpere VoltOperational Analysis IntroductionCircuit CONDITION- Rest Circuit CONDITION- Priming Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Choke Heater CHCircuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdown Sure Switch LOPBattery Recommended BatteryBattery Cables Engine Controller Circuit BoardSTART-STOP Switch Fuel Primer SwitchAMP Fuse Starter Contactor Relay Starter Motor Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Procedure Test 1- Check NO-LOAD Voltage FrequencyTest 2- Check Engine Governor DiscussionGovernor Adjustment Test 3- Test Excitation Circuit BreakerTest 4- Fixed Excitation TEST/ROTOR AMP Draw If continuity was indicated, go to TestTest 5- Wire Continuity Re-connect Wire 11 and Wire 22 to the Voltage RegulatorSet the VOM to measure AC voltage Set a VOM to its Rx1 scaleTest 7 Test Stator DPE Winding Test 6- Check Field BoostIf field boost checks good, replace the Voltage Regulator Test 8- Check Sensing Leads / Power Windings Across Wires Ohms11S 22S Model OhmsTest 9- Check Brush Leads Test 10 Check Brushes & Slip RingsTest 11- Check Rotor Assembly Tance Tests ProcedureTest 12 Check Main Circuit Breaker Replace the Rotor if it fails the testTest 15 Check Battery Charge Output Test 16 Check Battery Charge RectifierBattery Charge Rectifier BCR is a full wave rectifier Test 13- Check Load Voltage Frequency10. Battery Charge Rectifier Short to GroundTest 19- Test Primer Switch Set a VOM to read battery voltage 12 VDCAlso see Fuel Primer Switch, Test 18 TRY Cranking the EngineTest 20- Check Fuel Pump 13. The LPG Fuel Solenoid FSTest 23- Check Power Supply to Circuit Board Test 22- Check Battery & CablesTest 21- Check 7.5 AMP Fuse Test 24 Check START-STOP Switch 17. Start-Stop SwitchTest 26- Check Starter Contactor Relay Set a VOM to measure DC voltage 12 VDCTest 27 Check Starter Motor Test 26A Check Starter ContactorConditions Affecting Starter Motor Performance Checking the Pinion Tools for Starter Performance TestMeasuring Current TachometerTesting Starter Motor Test 28- Check Fuel SupplyTest Bracket Remove Starter Motor28 LP Gas Carburetion Diagram Discussion LPG ModelsTest 29 Check Wire 14 Power Supply Test 30 Check WireBattery voltage is not measured, proceed to Step Crank the engine. The meter should indicate battery voltageTest 31 Check Fuel Solenoid Gasoline Models Test 32 Check Ignition SparkCylinder Balance Test Conclusion No cylinder is weakest of the two cylindersTest 34 Check and Adjust Ignition Magnetos Test 33 Check Spark Plugs37. Setting Ignition Magneto Armature Air Gap Test 35 Check Valve Adjustment Adjusting Valve ClearanceChecking Flywheel Magnet Flywheel KEYTest 36 Check Carburetion Install Rocker ARM CoverTest 37 Check Choke Solenoid 43. Connector Adjust the regulated pressure on the gauge to 80 psi Down Test / Compression TestRepeat Steps 1 through 8 on remaining cylinder Check CompressionTest 40 Test OIL Temperature Switch Test 39 Check OIL Pressure SwitchIf all steps check GOOD, go to Test Test 42 Check LPG Fuel Solenoid Test 41 Test Choke HeaterShort to Ground 49. Fuel Solenoid Major Disassembly ENCLOSURE/PANEL RemovalStator Removal Rotor RemovalEngine Removal Belt TensioningStarter Removal FLYWHEEL/MAGNETO Removal Page Section Exploded Views / Part Numbers Part NO. QTY Description Enclosure Drawing No E1011-B QTY Description Sheet Metal Drawing No E1012-E QTY Description Flywheel Assy GT-990Control Panel Drawing No E1013-A Wire ASM GRD STD Conn Switch Spdt ON-MOM-ONSwitch 6A Spdt Not Shown PANEL, TOP ControlTwin Engine Drawing No E1014-B ASSEMBLY, Crankcase RV ASSEMBLY, BreatherASSEMBLY, Head #1 ASSEMBLY, OIL Fill CAPLP Regulator Drawing No E1530 CASTING, Twin Regulator Housing Washer Flat M4SOLENOID, Twin Regulator SPRING-SOLENOID PlungerSpecifications & Charts Generator Specifications Nominal Resistances of Generator Windings AT 68FEngine Speeds and Voltage Specifications Page Electrical Data Electrical Data PO BOX 297 WHITEWATER, WI

65, 75, 55 specifications

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