Generac Power Systems 65, 55, 75 manual Test 41 Test Choke Heater, Test 42 Check LPG Fuel Solenoid

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Section 7

DIAGNOSTIC TESTS

Figure 7-48. – 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 installation 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 24.

TEST 41 - 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 perfor- mance 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 posi- tion. 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 1 at the Choke Assembly. Connect the positive (+) meter test lead to Wire 14 (Connector 1, 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 1 at the Choke Assembly. Connect one meter test lead to Wire 14 (Connector 1, Pin 3) going to the control panel. Connect the other meter test lead to the 4-tab Terminal for Wire 14 in the control panel. “Continuity” should be measured.

SHORT TO GROUND:

Set the VOM to measure resistance. Connect one meter test lead to Wire 14 (Connector 1, 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.

RESULTS:

1.If Choke Plate is binding in Step 1, repair or replace binding Choke Plate. If Bi-Metal Heater Assembly tests good, go to Test 35.

2.If continuity was not measured in Step 3, repair or replace Wire 14 between the 4-tab Terminal and Connector 1.

3.If the resistance value is incorrect in the Short to Ground step, or the Bi-Metal Heater Assembly does not function with voltage present, replace the Bi-Metal Heater Assembly.

TEST 42 - CHECK LPG FUEL SOLENOID

DISCUSSION:

If the LPG Fuel Solenoid (FS) fails to open, fuel will not be available to the engine and it will not start.

PROCEDURE:

1.Place one hand on the top of the LPG Fuel Solenoid. Activate the Fuel Prime Switch. You should be able to feel as well as hear the solenoid energize. If solenoid energizes discontinue testing.

2.Set VOM to measure resistance. Disconnect Wire 0 from the LPG Fuel Solenoid. Connect one meter test lead to Wire 0. Connect the other test lead to a clean frame ground. “Continuity” should be measured. Reconnect Wire 0 to LPG shut off valve.

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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 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 Resistance Measuring AC FrequencyMeasuring Current Electrical Units Ohms LAWAmpere 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 Recommended BatteryBattery Cables 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 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 scaleIf field boost checks good, replace the Voltage Regulator Test 6- Check Field BoostTest 7 Test Stator DPE Winding 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 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 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 37 Check Choke Solenoid Install Rocker ARM CoverTest 36 Check Carburetion 43. Connector Adjust the regulated pressure on the gauge to 80 psi Down Test / Compression TestRepeat Steps 1 through 8 on remaining cylinder 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 Major Disassembly ENCLOSURE/PANEL RemovalStator 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 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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