Generac Power Systems 65, 55, 75 manual Setting Ignition Magneto Armature Air Gap

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Section 7

DIAGNOSTIC TESTS

3.If Step 1 produced spark and Step 2 tested good, set the VOM to measure DC voltage. Connect one test lead to Wire 15 (J3 Terminal) on ECB. Connect the other test lead to frame ground. Battery voltage should be measured. Verify that Wire 15 is connected to J3 and that Wire 14 is connected to J2; if reversed the unit will produce no spark.

4.Rotate the flywheel until the magnet is under the module (armature) laminations (see Figure 7-37).

5.Place a 0.012-0.015 inch thickness gauge between the fly- wheel magnet and the module laminations.

6.Loosen the mounting screws and let the magnet pull the mag- neto down against the thickness gauge.

7.Tighten both mounting screws.

8.To remove the thickness gauge, rotate the flywheel.

9.Repeat the above procedure for the second magneto.

Figure 7-37. – Setting Ignition Magneto

(Armature) Air Gap

10.Repeat Test 55 and check for spark across the spark tester gap.

11.If air gap was not out of adjustment, test ground wires.

12.Set the VOM to the diode test position. The meter will display forward voltage drop across the diode. If the voltage drop is less than 0.7 volts, the meter will “Beep” once as well as dis- play the voltage drop. A continuous tone indicates “Continuity” (shorted diode). An incomplete circuit (open diode) will be dis- played as “OL.”

13.Disconnect the engine ground harness from the ignition mag- netos and stud connector (see Figure 7-38).

Figure 7-38. – Engine Ground Harness

Figure 7-39. – Diode Failure Diagnosis

14.Connect the positive (+) test lead to Connector ”A” (as shown in Figure 7-40). Connect the negative (-) test lead to Connector “B.”

a.If meter “Beeps” once and displays voltage drop, then the diode is good.

b.If the meter makes a continuous tone, the diode is bad (shorted) and the harness must be replaced.

c.If the meter displays “OL,” the diode is defective (open) and the harness must be replaced.

d.Now repeat Steps 14a through 14c with the negative meter test lead connected to Connector “C” (Figure 7-40).

15.If the ground harness tested good, check Wire 18A between the insulated terminal stud and the J1 Connector for a short to ground. Set a VOM to measure resistance The ground harness should still be disconnected from the ignition magnetos. Connect one meter test lead to Wire 18A which is still removed from the J1 Connector. Connect the other meter test lead to frame ground. “Infinity” should be measured.

RESULTS:

1.If “Infinity” was not measured in Step 2b, replace the Engine Control Board.

Note: If VOM was set to Diode test, a reading of

0.5volts would be observed when the Start-Stop Switch is set to STOP. If the VOM was set to resis- tance, a reading of 0.5 to 1.5M ohms would be

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Specifications & Charts Section Exploded Views / Part NumbersElectromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Line Breakers 120 Volts only Field BoostGenerator AC Connection System Connection for 120 Volts Only Reconnection for Dual Voltage OutputRotor Assembly Stator AssemblyExcitation Circuit Components Battery Charge ComponentsBrush Holder GeneralVoltage Regulator Adjustment ProcedureCrankcase Breather DescriptionControl Panel Component Identification Install BreatherInstall oil vapor collector and retainer Check BreatherInsulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the GeneratorCloth or Compressed AIR Brushing and Vacuum CleaningStator Insulation Resistance Stator SHORT-TO-GROUND TestsTesting Rotor Insulation Testing Rotor InsulationTesting Stator Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Resistance Measuring AC FrequencyMeasuring Current Ampere Electrical UnitsOhms LAW VoltCircuit CONDITION- Rest IntroductionOperational Analysis Circuit CONDITION- Priming Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Choke Heater CHCircuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdown Sure Switch LOPBattery Cables BatteryRecommended Battery Engine Controller Circuit BoardAMP 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 Test 2- Check Engine Governor ProcedureTest 1- Check NO-LOAD Voltage Frequency DiscussionTest 4- Fixed Excitation TEST/ROTOR AMP Draw Governor AdjustmentTest 3- Test Excitation Circuit Breaker If continuity was indicated, go to TestSet the VOM to measure AC voltage Test 5- Wire ContinuityRe-connect Wire 11 and Wire 22 to the Voltage Regulator Set a VOM to its Rx1 scaleIf field boost checks good, replace the Voltage Regulator Test 6- Check Field BoostTest 7 Test Stator DPE Winding 11S 22S Test 8- Check Sensing Leads / Power WindingsAcross Wires Ohms Model OhmsTest 9- Check Brush Leads Test 10 Check Brushes & Slip RingsTest 12 Check Main Circuit Breaker Test 11- Check Rotor AssemblyTance Tests Procedure Replace the Rotor if it fails the testBattery Charge Rectifier BCR is a full wave rectifier Test 15 Check Battery Charge OutputTest 16 Check Battery Charge Rectifier Test 13- Check Load Voltage Frequency10. Battery Charge Rectifier Short to GroundAlso see Fuel Primer Switch, Test 19- Test Primer SwitchSet a VOM to read battery voltage 12 VDC Test 18 TRY Cranking the EngineTest 20- Check Fuel Pump 13. The LPG Fuel Solenoid FSTest 21- Check 7.5 AMP Fuse Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board Test 24 Check START-STOP Switch 17. Start-Stop SwitchTest 26- Check Starter Contactor Relay Set a VOM to measure DC voltage 12 VDCConditions Affecting Starter Motor Performance Test 26A Check Starter ContactorTest 27 Check Starter Motor Measuring Current Checking the PinionTools for Starter Performance Test TachometerTest Bracket Testing Starter MotorTest 28- Check Fuel Supply Remove Starter Motor28 LP Gas Carburetion Diagram Discussion LPG ModelsBattery voltage is not measured, proceed to Step Test 29 Check Wire 14 Power SupplyTest 30 Check Wire 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 Checking Flywheel Magnet Test 35 Check Valve AdjustmentAdjusting Valve Clearance Flywheel KEYTest 37 Check Choke Solenoid Install Rocker ARM CoverTest 36 Check Carburetion 43. Connector Repeat Steps 1 through 8 on remaining cylinder Adjust the regulated pressure on the gauge to 80 psiDown Test / Compression Test Check CompressionIf 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 Stator Removal Major DisassemblyENCLOSURE/PANEL Removal Rotor 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 QTY Description Flywheel Assy GT-990Control Panel Drawing No E1013-A Switch 6A Spdt Not Shown Wire ASM GRD STD ConnSwitch Spdt ON-MOM-ON PANEL, TOP ControlTwin Engine Drawing No E1014-B ASSEMBLY, Head #1 ASSEMBLY, Crankcase RVASSEMBLY, Breather ASSEMBLY, OIL Fill CAPLP Regulator Drawing No E1530 SOLENOID, Twin Regulator CASTING, Twin Regulator HousingWasher Flat M4 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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