Generac Power Systems 5415 Table of Contents, Safety, Inside Front Cover, Section, 8-11, 12-14

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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