Generac Power Systems 5410, 5412, 5411 Test 16 Check 7.5 Amp Fuse, Test 17 Check Battery & Cables

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Section 7

DIAGNOSTIC TESTS

Test 16 – Check 7.5 Amp Fuse

DISCUSSION:

If the panel-mounted 7.5 amp fuse (F1) has blown, engine cranking will not be possible.

Figure 7-15. – 7.5 Amp Fuse

PROCEDURE:

Push In on fuse holder cap and turn counterclockwise. Then, remove the cap with fuse. Inspect the Fuse.

RESULTS:

If the Fuse element has melted open, replace the Fuse with an identical size fuse. If Fuse is good, go to Test 17.

Test 17 – Check Battery & Cables

DISCUSSION:

If the engine won’t crank or cranks too slowly, the battery may be weak or discharged. See “Battery” on Page 22.

PROCEDURE:

1.Inspect the battery cables and battery posts or terminals for corrosion or tightness. Measure the voltage at the terminal of the starter contac- tor and verify 11-12 volts DC is available to the generator during cranking. If voltage is below 11 volts DC, measure at the battery terminals dur- ing cranking. If battery voltage is below 11 volts DC, recharge/replace battery. If battery voltage is above 11 volts DC, check for proper battery cable sizing (see “BATTERY CABLES” on Page 24). If battery or cables are still suspected, connect an alternate battery and cables to the generator and retest.

2.Use a battery hydrometer to test the battery for

(a)state of charge and (b) condition. Follow the hydrometer manufacturer’s instructions carefully.

RESULTS:

1.Clean battery posts and cables as necessary. Make sure battery cables are tight.

2.Recharge the battery, if necessary.

3.Replace the battery, if necessary.

4.If battery is good, but engine will not crank, go to Test 18.

Test 18 – Check Power Supply to

Printed Circuit Board

DISCUSSION:

If battery voltage is not available to the Printed Circuit Board (PCB), engine cranking and running will not be possible.

If battery voltage is available to the PCB, but no DC output is delivered to the board’s Wire 56 terminal while attempting to crank, either the Printed Circuit Board is defective or the Start-Stop Switch has failed.

This test will determine if battery voltage is available to the Printed Circuit Board. Test 20 will check the Start-Stop Switch. Test 21 will check the DC power supply to the Printed Circuit Board’s Wire 56 terminal (J1 Connector, Pin 9).

PROCEDURE:

1.Disconnect J1 Connector from the PCB.

2.On the harness end of the J1 Connector, locate J1, Pin 4 (Wire 15) (see Figure 5-3 on Page 22).

3.Set a VOM to read battery voltage. Connect the meter test leads across Printed Circuit Board Terminal J1, Pin 4 and frame ground. The meter should read battery voltage.

4.Set the VOM to measure resistance (“Rx1” scale). Connect one meter test lead to Wire 0, Pin loca- tion J1-11 on the Printed Circuit Board. Connect the other test lead to a clean frame ground. “Continuity” should be measured.

RESULTS:

1.If battery voltage is NOT indicated in Step 3, check continuity of:

a.Wire 13 between Starter Contactor and Starter Contactor Relay.

b.Wire 13 between Starter Contactor Relay and 7.5 Amp Fuse (F1).

c.Wire 15 to Wire 13 on the 7.5 Amp fuse hold- er (F1).

Repair, reconnect or Replace bad wiring as nec- essary.

2.If battery voltage is indicated but engine will not crank, go to Test 20.

3.If “Continuity” was not measured in Step 4, repair or replace Wire 0 between the Printed Circuit Board and the Ground Terminal.

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Induction MagnetismElectromagnetic Fields 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 16 Check 7.5 Amp Fuse Test 17 Check Battery & CablesTest 18 Check Power Supply to Printed Circuit Board 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 ContactorTools for Starter Performance Test Checking the PinionPinion 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 Flywheel KEY Test 32 Check Valve AdjustmentChecking Flywheel Magnet 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

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