Generac Power Systems 5415, 5412, 5411, 5413, 5414, 5410 manual Table of Contents

Page 3

Table of Contents

Safety

Inside Front Cover

Section 1:

 

 

Generator Fundamentals

3-7

Magnetism

3

Electromagnetic Fields

3

Electromagnetic Induction

3

A Simple AC Generator

4

A More Sophisticated AC Generator

4

Field Boost

6

Generator AC Connection System

6

Section 2:

 

 

Major Generator Components

8-11

Rotor Assembly

8

Stator Assembly

8

Brush Holder

9

Excitation Circuit Components

9

Crankcase Breather

10

Control Panel Component Identification.. 11

Section 3:

 

 

Insulation Resistance Tests

12-14

Effects of Dirt and Moisture

12

Insulation Resistance Testers

12

Drying the Generator

12

Cleaning the Generator

12

Stator Insulation Resistance

13

Testing Rotor Insulation

14

The Megohmmeter

14

Section 4:

 

 

Measuring Electricity

15-17

Meters

15

The VOM

15

Measuring AC Voltage

15

Measuring DC Voltage

15

Measuring AC Frequency

15

Measuring Current

16

Measuring Resistance

16

Electrical Units

17

Ohm’s Law

17

Section 5:

 

 

Engine DC Control System

18-26

Introduction

18

Operational Analysis

18-21

Printed Circuit Board

22

Battery

22

7.5 Amp Fuse

23

Start-Stop Switch

23

Starter Contactor Relay

 

& Starter Motor

24

Section 6:

 

Troubleshooting Flowcharts

25-34

If Problem Involves AC Output

25

Problem 1 –

 

Voltage & Frequency are Both

 

High or Low

25

Problem 2 –

 

Generator Produces Zero Voltage or

 

Residual Voltage (5-12 VAC)

26-27

Problem 3 –

 

Excessive Voltage/Frequency Droop

 

When Load Is Applied

27

Problem 4 –

 

Engine Overspeed Warning Code

 

Flashing on SW1 LEd (4 Flashes)

28

Problem 5 –

 

Priming Function Does Not Work

 

(Gasoline Models)

28

Problem 6 –

 

Engine Will Not Crank

29

Problem 7 –

 

Engine Cranks but Will Not Start

 

(Gasoline Units)

30

Problem 7 –

 

Engine Cranks but Will Not Start

 

(LP Units)

31

Problem 8 –

 

Engine Starts Hard and Runs Rough

 

(Gasoline Units)

32

Problem 8 –

 

Engine Starts Hard and Runs Rough

 

(LP Units)

33

Problem 9 –

 

High Oil Temperature Fault (6 Flashes)

 

or Low Oil Pressure Fault (5 Flashes)

34

Problem 10 –

 

7.5 Amp (F1) Fuse Blowing

35

Section 7:

 

Diagnostic Tests

36-63

Introduction

36

Test 1 –

 

Check No-Load Voltage And Frequency

36

Test 2 –

 

Check Stepper Motor Control

36

Test 4 –

 

Fixed Excitation Test/Rotor Amp Draw

37

Test 5 –

 

Check Field Boost

39

Test 6 –

 

Test Stator DPE Winding

39

Test 7 –

 

Check Sensing Leads/Power Windings

40

Test 8 –

 

Check Brush Leads

41

Test 9 –

 

Check Brushes & Slip Rings

42

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Magnetism Electromagnetic FieldsElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostConnection for 120 Volts Only Stator Assembly Rotor AssemblyExcitation Circuit Components Brush HolderDescription Crankcase BreatherControl Panel Components Control Panel Component IdentificationDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersStator Insulation Resistance Megohmmeter Testing Rotor InsulationTesting Stator Insulation Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC VoltageMeasuring Resistance Measuring CurrentOhm’s Law Electrical UnitsOperational Analysis IntroductionCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Printed Circuit Board BatteryRecommended Battery Battery CablesAmp Fuse Start-Stop SwitchStarter Contactor Relay Starter Motor Start-Stop SwitchProblem 1 Voltage & Frequency Are Both High or Low If Problem Involves AC OutputTest 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 YES Problem 10 7.5A F1 Fuse BlowingDiscussion ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Stepper Motor ControlTest 4 Fixed Excitation Test/Rotor Amp Draw Six Pin J2 Connector Wire ColorsFixed Excitation Test, Step B Test 6 Test Stator DPE Winding Test 5 Check Field BoostStator Excitation Winding Test 7 Check Sensing Leads / Power WindingsTest 8 Check Brush Leads Stator Power Winding LeadsTest 9 Check Brushes & Slip Rings Test 10 Check Rotor AssemblyTest 13 Check Load Watts Amperage SchematicTest 11 Check Main Circuit Breaker Test 12 Check Load Voltage FrequencyTest 15 Check Fuel Pump Test 14 Try Cranking the EngineTest 17 Check Battery & Cables Test 18 Check Power Supply to Printed Circuit BoardTest 16 Check 7.5 Amp Fuse Test 20 Check Start-Stop Switch Test 19 Check Continuity of WireTest 22 Check Starter Contactor Relay Test 21 Check Power Supply to WireTest 24 Check Starter Motor Test 23 Check Starter ContactorChecking the Pinion PinionTools for Starter Performance Test Minimum rpm 4500 Maximum Amps To Carburetor GAS Test 25 Check Fuel Supply29. Fuel Regulator Test 26 Check Wire 14 Power SupplyTest 28 Check Fuel Solenoid Gasoline Models Test 27 Check WireTools RequiredTwo Ignition Testers Generac P/N 0C5969 Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 31 Check and Adjust Ignition Magnetos37. Setting Ignition Magneto Armature Air Gap Test 32 Check Valve Adjustment Checking Flywheel MagnetFlywheel KEY Test 34 Check Choke Solenoid Test 33 Check CarburetionSolenoid Panel To ControlTest 36 Check Oil Pressure Switch Test 38 Test Oil Temperature Switch Test 37 Check Wire 86 for ContinuityTest 40 Test Choke Heater Test 39 Check Wire 85 for ContinuityTest 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 Nominal Resistances of Generator Windings at 68f Generator SpecificationsElectrical Data Electrical Data OG7515 REV. a

5410, 5414, 5415, 5413, 5411 specifications

Generac Power Systems has established itself as a leading manufacturer of backup power solutions, particularly known for its range of generators designed for both residential and commercial use. Among their noteworthy products are the Generac models 5412, 5411, 5413, 5415, and 5414. Each of these generators showcases innovative technologies and features that enhance reliability, efficiency, and ease of use.

The Generac 5412 is a versatile model equipped with a robust 10 kW output, making it suitable for powering essential home appliances during outages. It operates using a 1.0 L engine that runs on natural gas or propane, providing flexibility in fuel options. The Quiet-Test feature is a notable characteristic, as it allows for a self-test at a reduced volume, minimizing noise disruptions during routine checks.

Moving to the Generac 5411, this generator offers a higher output capacity of 13 kW. It integrates advanced load management technology, which ensures that power is allocated efficiently among connected devices. This model also features a Mobile Link remote monitoring system, enabling users to check generator status and performance from anywhere via a smartphone app.

The Generac 5413 is tailored for larger residential needs, delivering an impressive 16 kW output. It boasts a durable all-weather aluminum enclosure designed for longevity against the elements. The 5413's integrated wifi connectivity allows for real-time monitoring and alerts, ensuring that homeowners are always informed of their generator's operating status.

For those seeking a balance of power and efficiency, the Generac 5415 offers 20 kW of output while maintaining a compact design. This model is enriched with the patented G-Flex technology, allowing it to adjust engine speed based on the load requirements, thereby conserving fuel and reducing noise levels. Additionally, the 5415 comes with an intuitive user interface for effortless operation and programming.

Finally, the Generac 5414 rounds out the lineup with its strong 24 kW capability. This model is particularly known for its Smart Management modules, which facilitate the safe and efficient distribution of power. Its intuitive design also includes a user-friendly control panel for straightforward operation, ensuring that homeowners, regardless of technical expertise, can utilize the system effectively.

In summary, Generac Power Systems’ 5412, 5411, 5413, 5415, and 5414 generators exemplify advanced power technology, tailored for reliability and user convenience. Whether for essential home functions or more extensive power needs, these models provide effective solutions to ensure that homes remain powered during outages.
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