Manuals / Generac Power Systems / Lawn and Garden / Portable Generator

Generac Power Systems 5411 Control Panel Component Identification, 9. - Control Panel Components

Models: 5410 5414 5415 5413 5411 5412

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Section 2

Major Generator Components

Control Panel Component Identification

STARTER CONTACTOR RELAY (SCR)

TERMINAL BLOCK (TB) “4-TAB CONNECTOR”

CONTROL BOARD (PCB)

WITH J1 CONNECTOR

GOVERNOR ACTUATOR

J2 CONNECTOR

VOLTAGE REGULATOR

(VR) WITH RED LED

START/STOP SWITCH (SW1)

WITH RED LED

	CIRCUIT BREAKERS
7.5 AMP DC FUSE (F1)	(CB1 & CB2)

ENGINE CONNECTOR (C1)

6 WIRE GROUND TERMINAL

REAR VIEW

Figure 2-9. – Control Panel Components

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Generac Power Systems 5411, 5412, 5413 Control Panel Component Identification, 9. - Control Panel Components, Rear View

Contents

RECREATIONAL VEHICLE GENERATOR Diagnostic Repair ManualRV 45/55/65 ModelS 5410, 5411, 5412, 5413, 5414REPLACEMENT PARTS SAFETYNOTICE TO USERS OF THIS MANUAL Safety Table of ContentsTroubleshooting Flowcharts Diagnostic TestsExploded Views / Part Numbers Specifications & Charts64-83 76-86Magnetism Section GENERATOR FUNDAMENTALSElectromagnetic Fields Electromagnetic InductionA More Sophisticated AC Generator A Simple AC GeneratorFigure 1-4. - A Simple AC Generator Figure 1-5. - Alternating Current Sine WaveSection GENERATOR FUNDAMENTALS Figure 1-7. - Generator Operating DiagramGenerator operation may be described briefly as fol- lows Generator AC Connection System Field BoostSection GENERATOR FUNDAMENTALS Figure 1-9 - Connection for 120/240 Volts Figure 1-8. - Connection for 120 Volts OnlySection GENERATOR FUNDAMENTALS Reconnection for Dual Voltage OutputStator Assembly Rotor AssemblySection Major Generator Components Figure 2-1. Exploded View of GeneratorSection MAJOR GENERATOR COMPONENTS Figure 2-5. - Schematic Excitation CircuitBrush Holder Excitation Circuit ComponentsFigure 2-8. - Crankcase Breather Crankcase BreatherNote Push oil vapor collector and retainer in until it bottoms Section Major Generator ComponentsFigure 2-9. - Control Panel Components Control Panel Component IdentificationSection Major Generator Components REAR VIEWSection Insulation Resistance Tests Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersStator Insulation Resistance Section 3 Insulation Resistance Testsvents that will not attack such materials Connect the tester leads to the Stator or Rotor leads onlyThe Megohmmeter Testing Rotor InsulationFigure 3-2. - Stator Leads Figure 3-3. - Rotor Test PointsMeters Section MEASURING ELECTRICITYThe VOM Measuring AC VoltageMeasuring Resistance Measuring CurrentFigure 4-2. - Clamp-On Ammeter Figure 4-3. - A Line-SplitterOhm’s Law Electrical UnitsAMPERES = VOLTSOHMS VOLTS = AMPERES x OHMSIntroduction Section ENGINE DC CONTROL SYSTEMOperational Analysis CIRCUIT CONDITION - CRANKING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION - RUNNING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION - SHUTDOWN Section ENGINE DC CONTROL SYSTEMFigure 5-3. - J1 Connector, Harness End BatteryPrinted Circuit Board Figure 5-1. - Receptacle J17.5 Amp Fuse Start-Stop SwitchNOTE Water cannot be added to some “mainte- nance-free” batteries Figure 5-4. - Typical FuseStarter Contactor Relay Starter Motor Figure 5-5. - Start-Stop SwitchFigure 5-6. - Starter Motor Figure 5-7. - Starter Contactor RelayIf Problem Involves AC Output Section TROUBLESHOOTING FLOWCHARTSProblem 1 - Voltage & Frequency Are Both High or Low IntroductionSection TROUBLESHOOTING FLOWCHARTS continued Problem 3 - Excessive Voltage/Frequency Droop When Load is AppliedUnderspeed Warning - 4 Flashes on SW1 LED Section TROUBLESHOOTING FLOWCHARTSSection TROUBLESHOOTING FLOWCHARTS Proble 5 - Priming Function Does Not Work Gasoline ModelsSection TROUBLESHOOTING FLOWCHARTS Problem 6 - Engine Will Not CrankSTART-STOP Section TROUBLESHOOTING FLOWCHARTSSection TROUBLESHOOTING FLOWCHARTS Section TROUBLESHOOTING FLOWCHARTS Problem 8 - Engine Starts Hard and Runs Rough Gasoline UnitsSection TROUBLESHOOTING FLOWCHARTS Problem 8 - Engine Starts Hard and Runs Rough LP UnitsSection TROUBLESHOOTING FLOWCHARTS Section TROUBLESHOOTING FLOWCHARTS Problem 10 - 7.5A F1 Fuse BlowingUsing a small flathead screwdriver, slide black Gently bend red tabs outward and remove redTest 1 - Check No-Load Voltage and Frequency Section DIAGNOSTIC TESTSTest 2 - Check Stepper Motor Control Figure 7-1. Throttle PositionTest 4 - Fixed Excitation Test/Rotor Amp Draw Figure 7-2. Six Pin J2 Connector Wire ColorsFigure 7-3. - Fixed Excitation Test, Step A Section DIAGNOSTIC TESTSFigure 7-5. - Fixed Excitation Test, Step C Figure 7-4. - Fixed Excitation Test, Step BSection DIAGNOSTIC TESTS 5. Re-connect Wire 2 and Wire 6 to the Voltage RegulatorTest 6 - Test Stator DPE Winding Test 5 - Check Field BoostFigure 7-6. - Fixed Excitation Test, Step D Figure 7-7. - The Field Boost CircuitFigure 7-8. - Stator Excitation Winding Test 7 - Check Sensing Leads / Power WindingsSection DIAGNOSTIC TESTS Test 8 - Check Brush Leads Figure 7-9. - Stator Power Winding LeadsSection DIAGNOSTIC TESTS Test 9 - Check Brushes & Slip Rings Test 10 - Check Rotor AssemblyFigure 7-10. - Brush Leads Section DIAGNOSTIC TESTSTest 11 - Check Main Circuit Breaker Figure 7-11. - Rotor AssemblyTest 12 - Check Load Voltage Frequency Test 13 - Check Load Watts AmperageTest 15 - Check Fuel Pump Test 14 - Try Cranking the EngineFigure 7-13. - Electric Fuel Pump Figure 7-14. - Harness to Fuel PumpTest 18 - Check Power Supply to Printed Circuit Board Test 17 - Check Battery & CablesTest 16 - Check 7.5 Amp Fuse Figure 7-15. - 7.5 Amp FuseTest 20 - Check Start-Stop Switch Test 19 - Check Continuity of WireFigure 7-16. - Start-Stop Switch Figure 7-17. - Test 20, StepTest 22 - Check Starter Contactor Relay Test 21 - Check Power Supply to WireFigure 7-18. - Test 20, Step Figure 7-19. - Starter Contactor RelayTest 24 - Check Starter Motor Test 23 - Check Starter ContactorFigure 7-20. - The Starter Contactor SC Section DIAGNOSTIC TESTSFigure 7-22. - Check Pinion Gear Operation Figure 7-21. - Starter Motor SMSection DIAGNOSTIC TESTS Figure 7-23. - Clamp-On Ammeter Figure 7-26. - Testing Starter Motor PerformanceFigure 7-24. - Tachometer Figure 7-25. - Test BracketTest 25 - Check Fuel Supply Figure 7-28 - LP Gas Carburetion DiagramFigure 7-27 - Typical Propane Gas Fuel System Section DIAGNOSTIC TESTSFigure 7-30. - The 4-tab Connector Test 26 - Check Wire 14 Power SupplyFigure 7-29. - Fuel Regulator Section DIAGNOSTIC TESTSFigure 7-31. - Remote Harness Connector Test 27 - Check WireTest 28 - Check Fuel Solenoid Gasoline Models Section DIAGNOSTIC TESTSTest 29 - Check Ignition Spark Figure 7-32. - Testing Ignition SystemFigure 7-33. - Checking Engine Miss Tools RequiredTwo Ignition Testers Generac P/N 0C5969Figure 7-35 - Setting Spark Plug Gap Test 31 - Check and Adjust Ignition MagnetosFigure 7-36. - Ignition Magneto Assembly Test 30 - Check Spark PlugsNote If VOM was set to Diode test, a reading of Figure 7-37. - Setting Ignition Magneto Armature Air GapFigure 7-38. - Engine Ground Harness Test Points Section DIAGNOSTIC TESTSTORQUE SPECIFICATION ROCKER ARM JAM NUT 174 inch-pounds Test 32 - Check Valve AdjustmentFigure 7-39 - Adjusting Valve Clearance Note Before replacing the Ignition Magneto, check the Flywheel MagnetTest 33 - Check Carburetion Figure 7-41. - Automatic Choke AssemblyTest 34 - Check Choke Solenoid Section DIAGNOSTIC TESTSFigure 7-43. - Connector Figure 7-42. - Choke Solenoid AdjustmentTest 35 - Check Engine / Cylinder Leak Down Test / Compression Test Section DIAGNOSTIC TESTSSection DIAGNOSTIC TESTS Test 36 - Check Oil Pressure SwitchTest 38 - Test Oil Temperature Switch Test 37 - Check Wire 86 for ContinuityFigure 7-44. - Oil Pressure Switch Figure 7-45. - Oil Temperature SwitchFigure 7-46. - Testing Oil Temperature Switch Test 39 - Check Wire 85 for ContinuityTest 40 - Test Choke Heater Section DIAGNOSTIC TESTSFigure 7-49. - Fuel Solenoid TEST 41 - CHECK LPG FUEL SOLENOIDSection DIAGNOSTIC TESTS Base & Pulley - Drawing No. 0G7720-B Section Exploded ViewsDESCRIPTION Section 9 Exploded ViewsDESCRIPTION Enclosure - Drawing No. 0G3881-C Section Exploded ViewsDESCRIPTION Section 9 Exploded ViewsDESCRIPTION Views Section4145 33,34DESCRIPTION Section 9 Exploded ViewsDESCRIPTION 28.75”Section Exploded Views Engine Accessories - Drawing No. 0G7718-BDESCRIPTION Section 9 Exploded ViewsDESCRIPTION Section 9 Exploded Views 48,49530 RV Engine - Drawing No. 0G7719-B DESCRIPTION Section 9 Exploded ViewsDESCRIPTION Rotor & Stator - Drawing No. 0G3953-b Section 9 Exploded ViewsDESCRIPTION Section Exploded ViewsSPECIFICATIONS CHARTSMajor Features and Dimensions - Drawing No. 0G5519-b SectionGenerator Specifications Section SPECIFICATIONS & CHARTSNominal Resistances of Generator Windings at 68f Electrical Schematic and Wiring Diagram - Drawing No. 0G4221-B Section ELECTRICAL DATASection ELECTRICAL DATA Electrical Schematic and Wiring Diagram - Drawing No. 0G4221-BPRINTED IN THE USA P/N OG7515 REV. 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