Section 7

DIAGNOSTIC TESTS

in its coil, tighten the two screws. Verify that the choke solenoid plunger and linkage move freely without any drag or resistance that may restrict movement.

CHOKE CONTROL ROD

PLUNGER

CHOKE SOLENOID

MOVES VERTICALLY

Figure 7-42. – Choke Solenoid Adjustment

4.Disconnect Connector 3: Set the VOM to measure DC voltage. Connect the positive (+) test lead to Wire 90 (Pin 2) of Connector 3 going to the control panel. Connect the negative (-) test lead to frame ground. Activate the Start-Stop Switch to “START.” During cranking, battery voltage should be mea- sured cyclically every two seconds.

5.If battery voltage was not measured in Step 4, check at J1 Connector: Connect positive (+) test lead to Pin Location J1-2 at the Printed Circuit Board. Connect the negative (-) test lead to frame ground. Activate the Start-Stop Switch to “START.” During cranking, battery voltage should be mea- sured cyclically every two seconds.

 

 

1

1

90

2

 

 

2

14

3

 

3

14

 

TO CHOkE

 

TO CONTROL

SOLENOID

 

PANEL

Figure 7-43. – Connector 3

6.Set the VOM to measure resistance. Disconnect Connector 3 from the Choke Solenoid. Connect one test lead to Wire 0 (Pin 1) of Connector 3, going to the control panel. Connect the other test lead to frame ground. “Continuity” should be mea- sured.

7.Set the VOM to measure resistance. Disconnect Connector 3. Connect one meter test lead to Wire 90 (Connector 3, Pin 2) going to the Choke Solenoid. Connect the other meter test lead to Wire 0 (Connector 3, Pin 1). Approximately 3.7 ohms should be measured. (Current draw of Choke Solenoid at nominal voltage is 3.4 amps).

Short to Ground:

8.Set the VOM to measure resistance. Disconnect Connector 3. Connect one meter test lead to Wire 90 (Connector 3, Pin 2). Connect the other meter test lead to the metal Choke Solenoid housing. “Infinity” should be measured. If “Continuity” is measured, a short to ground exists.

RESULTS:

1.If Choke operation is good, go to Test 32 for Problem 7, “Engine Cranks but Won’t Start” (Section 6). Go to Test 41 for Problem 8, “Engine Starts Hard and Runs Rough”.

2.If battery voltage was measured in Step 5 but not measured in Step 4, repair or replace Wire 90 between Printed Circuit Board (PCB) and Connector 3.

3.If battery voltage is not measured in Step 5 during engine cranking, replace PCB.

4.If “Continuity” is not measured in Step 6, repair or replace Wire 0 between the ground terminal and Connector 3.

5.If Choke Solenoid coil resistance is not mea- sured or is incorrect in Step 7, replace the Choke Solenoid.

Test 35 – Check Engine / Cylinder Leak

Down Test / Compression Test

GENERAL:

Most engine problems may be classified as one or a combination of the following:

❏Will not start.

❏Starts hard.

❏Lack of power.

❏Runs rough.

❏Vibration.

❏Overheating.

❏High oil consumption.

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Generac Power Systems 5411, 5412, 5413, 5415, 5414, 5410 manual To Control, Solenoid Panel
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