Generac Power Systems 5411 Problem 10 - 7.5A F1 Fuse Blowing, Section TROUBLESHOOTING FLOWCHARTS

Section 6

TROUBLESHOOTING FLOWCHARTS

Problem 10 – 7.5A (F1) Fuse Blowing

INSTALL NEW 7.5 AMP FUSE

FUSE BLOWS UPON

INSTALLATION

CHECK THAT FUSE

HOLDER IS NOT

GROUNDED

PASS

FAIL

REPLACE HOLDER

REMOVE WIRE 15

FROM JI HARNESS

CONNECTOR.

DOES FUSE BLOW?

REPLACE

NOTE A:

(SEE NOTE A)

NO

PRINTED CIRCUIT

Disconnect harness from engine controller

BOARD

circuit board.

Gently bend red tabs outward and remove red

YES

plastic pin guide.

Using a small flathead screwdriver, slide black

retainer tabs out away from Wire 15 pin

(orange).

CHECK WIRE 15

Gently push pin out of harness and pull wire

FOR SHORT TO

out from back of plug, noting it’s location for

GROUND

reinstallation later.

Replace red pin guide and plug J1 harness

back into engine controller circuit board.

FUSE IS GOOD BUT

CHECK REMOTE

Replace fuse.

If fuse does not blow, replace engine controller

BLOWS WHEN START-

HARNESS WIRE 15

circuit board.

STOP SWITCH IS

FOR SHORT TO

If fuse still blows, continue to next section of

PRESSED

GROUND

Problem 10 flow chart.

		PERFORM RESISTANCE TESTS ON FUEL PUMP, FUEL SOLENOID,
DISCONNECT JI HARNESS
	YES	CHOKE HEATER AND REMOTE HARNESS WIRE 14 (SEE * BELOW).
FROM ENGINE CONTROL-
		ALSO CHECK WIRE 14 TO EACH COMPONENT FOR SHORT TO GROUND.
LER CIRCUIT BOARD AND
CHECK WIRE 14 FOR		* CHECK FOR CONTINUITY TO FRAME GROUND. CONNECT ONE TEST
SHORT TO GROUND.
		LEAD TO THE POSITIVE WIRE FOR EACH COMPONENT. CONNECT THE
IS CONTINUITY PRESENT?
		OTHER TEST LEAD TO FRAME GROUND. RESISTANCE SHOULD BE
		MEASURED. IF CONTINUITY “0” IS MEASURED TO GROUND, THAT
		COMPONENT OR WIRE IS SHORTED.
		ALSO, REFER TO THE INDIVIDUAL TESTS FOR EACH COMPONENT IN
		SECTION 7, UNDER “PROCEDURE – SHORT TO GROUND”.

NO

REPLACE COMPONENT OR WIRE

CHECK CHOKE SOLENOID AND STARTER CONTACTOR RELAY

STARTER CONTACTOR RELAY PIN LOCATION J1-1 TEST TO GROUND

CHOKE SOLENOID PIN LOCATION J1-2

TEST TO GROUND

FAIL

FAIL

CHECK WIRE 56 FOR SHORT TO GROUND

CHECK WIRE 90 FOR SHORT TO GROUND

REPAIR OR

REPLACE COMPONENT OR WIRE

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