Section 3 Engine Diagnostic Tests
Diagnostic Repair Manual
37
Figure 1-16. Oil Level Switch
Test 33 – Test Recoil Function
Procedure
1.
Attempt to pull start engine and observe the follow-
ing:
a. Does cord pull easily and smoothly?
b. Does cord return with no assistance?
c. Does engine turn over as cord is pulled?
Results
If recoil did not perform correctly, possible problems
could be:
•
Engine could be seized.
•
Recoil could have become detached from flywheel.
•
Recoil mechanism could be broken and not
properly retracting back into engine.
Test 34 – Test Engine Function
Procedure
1.
Remove recoil and front cover assembly.
2.
Remove spark plug from unit.
3.
Attempt to turn engine over by hand.
Results
1.
If engine cannot turn over freely with spark plug
removed, the engine has suffered an internal fail-
ure and seized.
2.
Refer to flow chart.
Test 35 – Test Battery Charger
General Theory
The battery will not charge when the generator is
running.
There is a 120 VAC “wall” charger that comes with the
generator to plug into a 120 VAC outlet to charge the
battery when the generator is not running.
1.
Check power to the AC charger at the outlet. If volt-
age is not present try another outlet. If voltage is
present move to step 2.
NOTE:
Unplug wall charger from generator panel
between each step outlined below!
2.
Check in-line fuse. If fuse is bad, replace. If fuse is
good, continue to step 3.
3.
Remove black negative (-) cable from battery. Set
DMM to read DC volts and place the positive lead
on the positive (+) batter connection, and the
negative lead to the control panel ground. The
voltage should be 13.5 to 14VDC. If voltage is not
present, replace charger. If voltage is present,
install the black negative (-) cable to the battery
and allow 24 hours to charge.
4.
If battery will not accept a charge, replace battery.
Test 36 – Test Idle control
General Theory
Certain units are equipped with a low idle control system.
There is a coil mounted near the engines governor. When
the switch is in low idle position, generator voltage (120
VAC) is fed through the SW switch to system control
board. The control board will rectify AC voltage to DC
and sends DC voltage to the coil. The ITC is fed into the
control board and when current starts to flow, the control
board will remove DC voltage from coil to allow engine to
run at rated speed.
Procedure
1.
Remove all loads from generator.
2.
Test low idle switch.
3.
Remove wires and set DMM to Ohms and zero out
meter.
4.
With wires removed, place meter leads on the
switch. Place switch to (ON) low idle. The meter
should read continuity.
5.
Place low idle switch to OFF. The meter should
read open.
6.
If continuity was measured in step 6, continue
testing.
7.
If continuity was not measured, replace switch and
test.
8.
Set DMM to read AC volts and remove wire 11B
from low idle switch. Place one meter lead on wire
11B and the other lead to the ground in control
panel. 120 VAC should be measured. If voltage
was measured, go to step 10.
9.
If 120 VAC is not measured, set DMM to measure
Ohms. Remove wire 11B from circuit breaker and
low idle switch. The wire should have continuity. If
wire does not have continuity, repair or replace
wire.
