Section 7.2

ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTING

TEST 11- TEST STARTER CONTACTOR

DISCUSSION:

See "Starter Contactor" on Page 6.3-2. Replace Starter Contactor if bad.

TEST 12- TEST START-STOP SWITCH

DISCUSSION:

Engine cranking and startup are initiated when the Start-Stop switch is held at "START" to ground Wire 17.

Engine shutdown is normally initiated when the Start- Stop switch is set to "STOP" to ground Wire 18.

A defective switch can prevent normal startup or nor- mal shutdown.

Figure 7. Start-Stop Switch

TEST PROCEDURE:

1.Carefully inspect Wire 0 (Ground) between the Start-Stop switch and the ground terminal. Repair, reconnect or replace the wire if necessary.

2.Disconnect Wire 17 from its terminal on the Start-Stop switch. Connect Wire 17 to a clean frame ground. The engine should crank.

3.Start the engine, using the Start-Stop switch or by grounding Wire 17.

4.Stop the engine by holding the Start-Stop switch at "STOP". If engine will not shut down with switch at "STOP", ground Wire 18 to stop engine.

RESULTS:

1.If engine cranks when Wire 17 is grounded, but won't crank with Start-Stop switch, replace the Start-Stop switch.

2.If engine stops when Wire 18 is grounded but will not shut down with Start-Stop switch, replace the Switch.

3.If engine will not crank when Wire 17 is grounded, replace the A6060 circuit board.

4.If engine will not stop when Wire 18 is grounded, replace the A6060 circuit board.

TEST 13- CHECK FUEL SUPPLY

DISCUSSION:

If the engine cranks but won't start, don't overlook the obvious. The engine won't start without fuel.

TEST PROCEDURE:

Check fuel level.

RESULTS:

1.If fuel level is low, replenish fuel supply.

2.If fuel quantity is good, go to Test 14.

TEST 14- CHECK FUEL FILTER

Refer to Section 3.3.

TEST 15- CHECK IGNITION SPARK

Refer to Section 6.4, "ENGINE IGNITION SYSTEM".

TEST 16- CHECK SPARK PLUG

DISCUSSION:

A badly fouled spark plug can prevent the engine from starting. A defective spark plug may allow the engine to be started, but rough operation or an "engine miss" may be observed.

A commercially available spark tester can be used to check for ignition spark. When the spark tester is con- nected in series with the spark plug and its high ten- sion lead, the cause of an engine miss can be nar- rowed down to either (a) the ignition system, or (b) the spark plug or fuel system. Use of the spark tester is discussed in Test 16.

TEST PROCEDURE:

Remove the spark plug.

Clean by scraping or wire brushing and by using a commercial solvent. DO NOT BLAST CLEAN THE PLUG. Set spark plug gap to 0.030 inch (0.76mm). Replace spark plug if badly fouled, if ceramic is cracked, or if damaged.

Page 7.2-13

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Generac Power Systems 941-2 Test 11- Test Starter Contactor, Test 12- Test START-STOP Switch, Test 13- Check Fuel Supply
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941-2, 940-2 specifications

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