Generac Power Systems 65, 55, 75 manual Test 31 Check Fuel Solenoid Gasoline Models

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Section 7

DIAGNOSTIC TESTS

Figure 7-31. – Remote Harness Connector

3.Connect one test lead to Pin Location J1-15. Connect the other test lead to a clean frame ground. “Infinity” should be measured.

RESULTS:

1.If “Continuity” is measured in Step 2, repair or replace shorted Wire 18 between J1 Connector and Start-Stop Switch.

2.If “Continuity” was measured in Step 3, repair or replace short- ed Wire 18 between J1 Connector and remote panel connector.

3.If Wire 18 checks GOOD, proceed to Problem 8 (Section 6).

TEST 31 - CHECK FUEL SOLENOID

(GASOLINE MODELS)

DISCUSSION:

If the Fuel Solenoid fails to open, the engine will not start.

PROCEDURE:

1.Remove Control Panel cover. Remove Wire 56 from the Starter Contactor Relay. This will prevent the unit from cranking during test (see Figure 7-19, Page 51).

2.Remove air filter cover. Disconnect Connector 2 which con- nects to the fuel pump.

3.Activate the Start-Stop Switch (SW1) to the START position and hold. This will activate the fuel solenoid. The fuel solenoid should energize and produce an audible click. If the fuel sole- noid does not operate, proceed to Step 4. Reconnect Connector 2 back to the fuel pump.

4.Set the VOM to measure DC voltage. Disconnect Wire 14 from the Fuel Solenoid. Connect the positive (+) meter test lead to Wire 14 that goes to the control panel.Connect the negative (-) test lead to a clean frame ground. Activate the Start-Stop Switch (SW1) to the START position and hold. Battery voltage should be measured.

5.Set the VOM to measure resistance. Disconnect Wire 0 from the Carburetor at the bullet connector. Connect one test lead to Wire 0 that goes to the control panel. Connect the other test lead to a clean frame ground. “Continuity” should be measured.

6.Connect one test lead to the Green Wire going to the carbure- tor. Connect the other test lead to the carburetor body. “Continuity” should be measured.

Short to Ground:

7.Set the VOM to measure resistance. Disconnect the bullet con- nector going to the Fuel Solenoid. Connect one meter test lead to the Red Wire going to the Fuel Solenoid. Connect the other meter test lead to the Fuel Solenoid housing. A reading of 38.0 ohms should be measured. If very low resistance is mea- sured, a short to ground exists. (Fuel Solenoid coil resistance is approximately 38.0 ohms. Current draw of the Fuel Solenoid at nominal voltage is approximately 331 milliamps or 0.331 amps).

RESULTS:

1.If the Fuel Solenoid passes Steps 4 & 5 but does NOT operate in Step 3, replace or repair Fuel Solenoid.

2.If battery voltage is not measured in Step 4, repair or replace Wire 14 between the 4-Tab Terminal Connector (TC) and the Fuel Solenoid.

3.If “Continuity” is not measured in Step 5, repair or replace Wire 0 between the Fuel Solenoid and ground terminal.

4.If “Continuity” is not measured in Step 6, repair or replace Carburetor ground wire.

5.If the Fuel Solenoid operates, proceed to Test 32.

TEST 32 - CHECK IGNITION SPARK

DISCUSSION:

A problem in the engine ignition system can cause any of the following:

•Engine will not start.

•Engine starts hard, runs rough.

A commercially available spark tester may be used to test the engine ignition system. One can also be pur- chased from Generac Power Systems (Part No. 0C5969).

PROCEDURE:

1.Disconnect a high tension lead from a spark plug.

2.Attach the high tension lead to the spark tester terminal.

3.Ground the spark tester clamp by attaching to the cylinder head (see Figure 7-32).

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Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Exploded Views / Part Numbers Section Specifications & ChartsElectromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Line Breakers 120 Volts only Field BoostGenerator AC Connection System Reconnection for Dual Voltage Output Connection for 120 Volts OnlyStator Assembly Rotor AssemblyGeneral Battery Charge ComponentsBrush Holder Excitation Circuit ComponentsDescription Adjustment ProcedureCrankcase Breather Voltage RegulatorCheck Breather Install BreatherInstall oil vapor collector and retainer Control Panel Component IdentificationDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersStator SHORT-TO-GROUND Tests Brushing and Vacuum CleaningStator Insulation Resistance Cloth or Compressed AIRMegohmmeter Testing Rotor InsulationTesting Stator Insulation Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC VoltageMeasuring Resistance Measuring AC FrequencyMeasuring Current Volt Electrical UnitsOhms LAW AmpereCircuit CONDITION- Rest IntroductionOperational Analysis Circuit CONDITION- Priming Circuit CONDITION- Cranking Choke Heater CH Circuit CONDITION-RUNNINGCircuit CONDITION- Shutdown Sure Switch LOP Circuit CONDITION- Fault ShutdownEngine Controller Circuit Board BatteryRecommended Battery Battery CablesAMP Fuse Fuel Primer SwitchSTART-STOP Switch 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 Discussion ProcedureTest 1- Check NO-LOAD Voltage Frequency Test 2- Check Engine GovernorIf continuity was indicated, go to Test Governor AdjustmentTest 3- Test Excitation Circuit Breaker Test 4- Fixed Excitation TEST/ROTOR AMP DrawSet a VOM to its Rx1 scale Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Set the VOM to measure AC voltageIf field boost checks good, replace the Voltage Regulator Test 6- Check Field BoostTest 7 Test Stator DPE Winding Model Ohms Test 8- Check Sensing Leads / Power WindingsAcross Wires Ohms 11S 22STest 10 Check Brushes & Slip Rings Test 9- Check Brush LeadsReplace the Rotor if it fails the test Test 11- Check Rotor AssemblyTance Tests Procedure Test 12 Check Main Circuit BreakerTest 13- Check Load Voltage Frequency Test 15 Check Battery Charge OutputTest 16 Check Battery Charge Rectifier Battery Charge Rectifier BCR is a full wave rectifierShort to Ground 10. Battery Charge RectifierTest 18 TRY Cranking the Engine Test 19- Test Primer SwitchSet a VOM to read battery voltage 12 VDC Also see Fuel Primer Switch,13. The LPG Fuel Solenoid FS Test 20- Check Fuel PumpTest 21- Check 7.5 AMP Fuse Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board 17. Start-Stop Switch Test 24 Check START-STOP SwitchSet a VOM to measure DC voltage 12 VDC Test 26- Check Starter Contactor RelayConditions Affecting Starter Motor Performance Test 26A Check Starter ContactorTest 27 Check Starter Motor Tachometer Checking the PinionTools for Starter Performance Test Measuring CurrentRemove Starter Motor Testing Starter MotorTest 28- Check Fuel Supply Test BracketDiscussion LPG Models 28 LP Gas Carburetion DiagramCrank the engine. The meter should indicate battery voltage Test 29 Check Wire 14 Power SupplyTest 30 Check Wire Battery voltage is not measured, proceed to StepTest 32 Check Ignition Spark Test 31 Check Fuel Solenoid Gasoline ModelsConclusion No cylinder is weakest of the two cylinders Cylinder Balance TestTest 33 Check Spark Plugs Test 34 Check and Adjust Ignition Magnetos37. Setting Ignition Magneto Armature Air Gap Flywheel KEY Test 35 Check Valve AdjustmentAdjusting Valve Clearance Checking Flywheel MagnetTest 37 Check Choke Solenoid Install Rocker ARM CoverTest 36 Check Carburetion 43. Connector Check Compression Adjust the regulated pressure on the gauge to 80 psiDown Test / Compression Test Repeat Steps 1 through 8 on remaining cylinderIf all steps check GOOD, go to Test Test 39 Check OIL Pressure SwitchTest 40 Test OIL Temperature Switch Short to Ground Test 41 Test Choke HeaterTest 42 Check LPG Fuel Solenoid 49. Fuel Solenoid Rotor Removal Major DisassemblyENCLOSURE/PANEL Removal Stator RemovalStarter Removal Belt TensioningEngine 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 Flywheel Assy GT-990 QTY DescriptionControl Panel Drawing No E1013-A PANEL, TOP Control Wire ASM GRD STD ConnSwitch Spdt ON-MOM-ON Switch 6A Spdt Not ShownTwin Engine Drawing No E1014-B ASSEMBLY, OIL Fill CAP ASSEMBLY, Crankcase RVASSEMBLY, Breather ASSEMBLY, Head #1LP Regulator Drawing No E1530 SPRING-SOLENOID Plunger CASTING, Twin Regulator HousingWasher Flat M4 SOLENOID, Twin RegulatorSpecifications & Charts Nominal Resistances of Generator Windings AT 68F Generator SpecificationsEngine Speeds and Voltage Specifications Page Electrical Data Electrical Data PO BOX 297 WHITEWATER, WI

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