Section 7

DIAGNOSTIC TESTS

Figure 7-34. – Cylinder Balance Test

The cylinder balance test will also detect a cylinder that is not functioning. When grounding out one cylin- der there will be no RPM loss. When the other cylin- der is grounded out the engine will stop.

Test 30 - Check Spark Plugs

DISCUSSION:

During Test 29, if spark jumped the tester gap, the ignition system must be functioning properly. However, if the engine misses the spark plug itself may be fouled.

PROCEDURE:

Remove spark plugs. Clean with a commercial sol- vent. DO NOT BLAST CLEAN SPARK PLUGS. Replace spark plugs if badly fouled, if ceramic is cracked, or if badly worn or damaged. Set gap to 0.030 inch (0.76mm). Use a NGK BPR6HS (or equiv- alent) replacement spark plug.

SET PLUG GAP AT 0.030 inch

(0.76 mm)

Figure 7-35 – Setting Spark Plug Gap

RESULTS:

1.Clean and regap or replace sparks plug as neces- sary.

2.If spark plugs are good for gasoline models, go to Test 33. For LPG models, go to Test 32.

Test 31 – Check and Adjust Ignition

Magnetos

DISCUSSION:

The ignition system used on GT-530 engines is a solid-state (breakerless) type. The system utilizes a magnet on the engine flywheel to induce a relatively low voltage into an ignition magneto assembly. Ignition magneto internal components increase the voltage and deliver the resulting high voltage across the spark plug gap.

The ignition magneto houses a solid state-circuit board that controls ignition timing. Timing is fixed and spark advance is automatic.

Major components of the ignition system include (a) two ignition magneto assemblies, (b) the spark plugs,

(c)the engine control printed circuit board and (d) the engine flywheel.

Solid-state components encapsulated in the ignition magneto are not accessible and cannot be serviced. If the magneto is defective, the entire assembly must be replaced. The air gap between the magneto and the flywheel magnet is between 0.012” to 0.015”.

The ignition magneto assembly (Figure 7-36) consists of (a) ignition magneto, (b) spark plug high tension lead and (c) spark plug boot.

SPARk PLUG

 

HIGH TENSION

SPARk

LEAD

PLUG

 

BOOT

 

IGNITION COIL

Figure 7-36. – Ignition Magneto Assembly

In Test 29, a spark tester was used to check for engine ignition. If sparking or weak spark occurred, one possible cause might be the ignition magneto(s). This test consists of adjusting the air gap between the ignition magneto(s) and the flywheel. The flywheel and flywheel key will also be checked during this test. If no sparking occurs, the ground harness may be at fault.

Procedure:

1.Disconnect the J1 connector from the Printed Circuit Board. Carefully remove Wire 18A from Pin Location J1-14. Connect the J1 connector back to the Printed Circuit Board. Repeat Test 29 “Check Ignition Spark”. If the unit now produces spark go

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Generac Power Systems 5415, 5412, 5411, 5413, 5414, 5410 Test 30 Check Spark Plugs, Test 31 Check and Adjust Ignition Magnetos
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