Generac Power Systems 5413, 5412, 5411 Starter Contactor Relay Starter Motor, Start-Stop Switch

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Section 5

ENGINE DC CONTROL SYSTEM

a.With Wire 17 grounded, a Crank Relay on the circuit board energizes and battery voltage is delivered to the Starter Contactor Relay via Wire 56. The Starter Contactor Relay energizes, its contacts close and the Starter Contactor is energized via wire 16. Its con- tacts close and the engine cranks.

b.With Wire 17 grounded, a Run Relay on the circuit board energizes and battery voltage is delivered to the Wire 14 circuit. Battery voltage is delivered to the Fuel Pump, Fuel Solenoid, Choke Heater and the Remote Harness.

2.Wire 18 from the Printed Circuit Board. This Is the ENGINE STOP circuit. When the Start-Stop Switch is set to “STOP”, Wire 18 is connected to frame ground via Wire No. 0. Circuit board action then opens the circuit to Wire 14, and grounds Wire 18A. Fuel flow to the carburetor and igni- tion are terminated.

3.Wire 0 connects the Switch to frame ground.

712

712

JUMPER WIRE

18

8

7

0

 

1

4

25

18

36

0

17

LED

 

 

 

 

712

0

 

 

18

 

START 17

STOP

 

PRIME

 

 

 

 

SW1

 

0

0

 

0

 

Figure 5-5. – Start-Stop Switch

Starter Contactor Relay

& Starter Motor

The positive (+) battery cable attaches to the large lug on the starter contactor. Wire 13 then attach- es to one side of the starter contactor relay contact, from this point Wire 13 attaches to the fuse F1 to supply battery voltage to the DC control system. The opposite side of the starter contactor relay con- tact is connected to Wire 16.

Wire 16 will supply battery power to the starter contactor and to the Printed Circuit Board for field flash when the starter contactor relay is energized. Attached to the starter contactor relay coil is Wire 56 (positive supply during cranking) and Wire 0 (ground).

When the Start-Stop switch is set to “START”, the circuit board delivers battery voltage to the Starter Contactor Relay via Wire 56. The Starter Contactor Relay energizes, its contacts close and the Starter Contactor is energized via wire 16. Its contacts close and battery voltage is available to the starter motor, and the engine cranks.

Figure 5-6. – Starter Motor

1316

1316

COM NO

56

0

56

0

 

 

 

Figure 5-7. – Starter Contactor Relay

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemConnection for 120 Volts Only Rotor Assembly Stator AssemblyBrush Holder Excitation Circuit ComponentsCrankcase Breather DescriptionControl Panel Component Identification Control Panel ComponentsInsulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the GeneratorStator Insulation Resistance Testing Rotor Insulation Testing Rotor InsulationTesting Stator Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohm’s LawIntroduction Operational AnalysisCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Battery Cables BatteryRecommended Battery Printed Circuit BoardStart-Stop Switch Amp FuseStart-Stop Switch Starter Contactor Relay Starter MotorIf Problem Involves AC Output Problem 1 Voltage & Frequency Are Both High or LowTest Troubleshooting Flowcharts Proble 5 Priming Function Does Not Work Gasoline Models Problem 6 Engine Will Not Crank Test 26 Check Test 20 Check Check Fuel Wire 14 Power Good Troubleshooting Flowcharts Problem 8 Engine Starts Hard and Runs Rough Gasoline Units Problem 8 Engine Starts Hard and Runs Rough LP Units LOW OIL Pressure Flashes on SW1 LED Problem 10 7.5A F1 Fuse Blowing YESTest 2 Check Stepper Motor Control ProcedureTest 1 Check No-Load Voltage Frequency DiscussionSix Pin J2 Connector Wire Colors Test 4 Fixed Excitation Test/Rotor Amp DrawFixed Excitation Test, Step B Test 5 Check Field Boost Test 6 Test Stator DPE WindingTest 7 Check Sensing Leads / Power Windings Stator Excitation WindingStator Power Winding Leads Test 8 Check Brush LeadsTest 10 Check Rotor Assembly Test 9 Check Brushes & Slip RingsTest 12 Check Load Voltage Frequency SchematicTest 11 Check Main Circuit Breaker Test 13 Check Load Watts AmperageTest 14 Try Cranking the Engine Test 15 Check Fuel PumpTest 16 Check 7.5 Amp Fuse Test 17 Check Battery & CablesTest 18 Check Power Supply to Printed Circuit Board Test 19 Check Continuity of Wire Test 20 Check Start-Stop SwitchTest 21 Check Power Supply to Wire Test 22 Check Starter Contactor RelayTest 23 Check Starter Contactor Test 24 Check Starter MotorTools for Starter Performance Test Checking the PinionPinion Minimum rpm 4500 Maximum Amps Test 25 Check Fuel Supply To Carburetor GASTest 26 Check Wire 14 Power Supply 29. Fuel RegulatorTest 27 Check Wire Test 28 Check Fuel Solenoid Gasoline ModelsTest 29 Check Ignition Spark Tools RequiredTwo Ignition Testers Generac P/N 0C5969Test 31 Check and Adjust Ignition Magnetos Test 30 Check Spark Plugs37. Setting Ignition Magneto Armature Air Gap Flywheel KEY Test 32 Check Valve AdjustmentChecking Flywheel Magnet Test 33 Check Carburetion Test 34 Check Choke SolenoidTo Control Solenoid PanelTest 36 Check Oil Pressure Switch Test 37 Check Wire 86 for Continuity Test 38 Test Oil Temperature SwitchTest 39 Check Wire 85 for Continuity Test 40 Test Choke HeaterTest 41 Check LPG Fuel Solenoid Section Exploded Views QTY Description Enclosure Drawing No G3881-C Enclosure Door Views Screw Plastite HI-LOW #10X3/8 Engine Accessories Drawing No G7718-B QTY Description 48,49 Square Head Plug Rotor & Stator Drawing No G3953-b NUT TOP Lock FL M8-1.25 Charts Generator Specifications Nominal Resistances of Generator Windings at 68fElectrical Data Electrical Data OG7515 REV. a

5410, 5414, 5415, 5413, 5411 specifications

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