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Generac Power Systems 5412, 5411, 5413, 5415, 5414, 5410 manual Section TROUBLESHOOTING FLOWCHARTS

Models: 5410 5414 5415 5413 5411 5412

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Section 6

TROUBLESHOOTING FLOWCHARTS

Problem 9 – High Oil Temperature Fault (6 Flashes) or Low Oil Pressure Fault (5 Flashes)

LOW OIL

PRESSURE –

5FLASHES ON SW1 LED

TEST 25 –

CHECK FUEL

SUPPLY

NO FUEL

REPLENISH FUEL

		CHECK
		CHECK
GOOD		ENGINE OIL
GOOD		ENGINE OIL
		LEVEL
		LEVEL


	OIL LEVEL LOW
	OIL LEVEL LOW		GOOD





	REPLENISH OIL

TEST 36 – CHECK

OIL PRESSURE

SWITCH

BAD

GOOD

REPLACE SWITCH

TEST 37 – CHECK				REPLACE
TEST 37 – CHECK				REPLACE
WIRE 86 FOR			GOOD	PRINTED CIRCUIT
WIRE 86 FOR			GOOD	PRINTED CIRCUIT
CONTINUITY				BOARD
CONTINUITY


	BAD
		REPAIR OR REPLACE

HIGH OIL

TEMPERATURE

–6 FLASHES ON SW1 LED

	CHECK
	CHECK
	ENGINE OIL	OIL LEVEL O.K.
	LEVEL


OIL LEVEL LOW



REPLENISH OIL

TEST 38 – CHECK

OIL TEMPERATURE

SWITCH

BAD

GOOD

REPLACE SWITCH

TEST 39 – CHECK
				REPLACE
				REPLACE
WIRE 85 FOR			GOOD	PRINTED CIRCUIT
CONTINUITY			GOOD	PRINTED CIRCUIT
CONTINUITY				BOARD
				BOARD

	BAD
	BAD
		REPAIR OR REPLACE

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Generac Power Systems 5412, 5411, 5413, 5415, 5414, 5410 manual Section TROUBLESHOOTING FLOWCHARTS

Contents

Diagnostic Repair Manual RECREATIONAL VEHICLE GENERATORRV 45/55/65 ModelS 5410, 5411, 5412, 5413, 5414SAFETY REPLACEMENT PARTSNOTICE TO USERS OF THIS MANUAL Table of Contents SafetyTroubleshooting Flowcharts Diagnostic TestsSpecifications & Charts Exploded Views / Part Numbers64-83 76-86Section GENERATOR FUNDAMENTALS MagnetismElectromagnetic Fields Electromagnetic InductionA Simple AC Generator A More Sophisticated AC GeneratorFigure 1-4. - A Simple AC Generator Figure 1-5. - Alternating Current Sine WaveFigure 1-7. - Generator Operating Diagram Section GENERATOR FUNDAMENTALSGenerator operation may be described briefly as fol- lows Field Boost Generator AC Connection SystemSection GENERATOR FUNDAMENTALS Figure 1-8. - Connection for 120 Volts Only Figure 1-9 - Connection for 120/240 VoltsSection GENERATOR FUNDAMENTALS Reconnection for Dual Voltage OutputRotor Assembly Stator AssemblySection Major Generator Components Figure 2-1. Exploded View of GeneratorFigure 2-5. - Schematic Excitation Circuit Section MAJOR GENERATOR COMPONENTSBrush Holder Excitation Circuit ComponentsCrankcase Breather Figure 2-8. - Crankcase BreatherNote Push oil vapor collector and retainer in until it bottoms Section Major Generator ComponentsControl Panel Component Identification Figure 2-9. - Control Panel ComponentsSection Major Generator Components REAR VIEWCleaning the Generator Section Insulation Resistance TestsEffects of Dirt and Moisture Insulation Resistance TestersSection 3 Insulation Resistance Tests Stator Insulation Resistancevents that will not attack such materials Connect the tester leads to the Stator or Rotor leads onlyTesting Rotor Insulation The MegohmmeterFigure 3-2. - Stator Leads Figure 3-3. - Rotor Test PointsSection MEASURING ELECTRICITY MetersThe VOM Measuring AC VoltageMeasuring Current Measuring ResistanceFigure 4-2. - Clamp-On Ammeter Figure 4-3. - A Line-SplitterElectrical Units Ohm’s LawAMPERES = VOLTSOHMS VOLTS = AMPERES x OHMSSection ENGINE DC CONTROL SYSTEM IntroductionOperational Analysis Section ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION - CRANKINGSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION - RUNNINGSection ENGINE DC CONTROL SYSTEM CIRCUIT CONDITION - SHUTDOWNBattery Figure 5-3. - J1 Connector, Harness EndPrinted Circuit Board Figure 5-1. - Receptacle J1Start-Stop Switch 7.5 Amp FuseNOTE Water cannot be added to some “mainte- nance-free” batteries Figure 5-4. - Typical FuseFigure 5-5. - Start-Stop Switch Starter Contactor Relay Starter MotorFigure 5-6. - Starter Motor Figure 5-7. - Starter Contactor RelaySection TROUBLESHOOTING FLOWCHARTS If Problem Involves AC OutputProblem 1 - Voltage & Frequency Are Both High or Low IntroductionSection TROUBLESHOOTING FLOWCHARTS Problem 3 - Excessive Voltage/Frequency Droop When Load is Applied continuedUnderspeed Warning - 4 Flashes on SW1 LED Section TROUBLESHOOTING FLOWCHARTSProble 5 - Priming Function Does Not Work Gasoline Models Section TROUBLESHOOTING FLOWCHARTSProblem 6 - Engine Will Not Crank Section TROUBLESHOOTING FLOWCHARTSSection TROUBLESHOOTING FLOWCHARTS START-STOPSection TROUBLESHOOTING FLOWCHARTS Problem 8 - Engine Starts Hard and Runs Rough Gasoline Units Section TROUBLESHOOTING FLOWCHARTSProblem 8 - Engine Starts Hard and Runs Rough LP Units Section TROUBLESHOOTING FLOWCHARTSSection TROUBLESHOOTING FLOWCHARTS Problem 10 - 7.5A F1 Fuse Blowing Section TROUBLESHOOTING FLOWCHARTSUsing a small flathead screwdriver, slide black Gently bend red tabs outward and remove redSection DIAGNOSTIC TESTS Test 1 - Check No-Load Voltage and FrequencyTest 2 - Check Stepper Motor Control Figure 7-1. Throttle PositionFigure 7-2. Six Pin J2 Connector Wire Colors Test 4 - Fixed Excitation Test/Rotor Amp DrawFigure 7-3. - Fixed Excitation Test, Step A Section DIAGNOSTIC TESTSFigure 7-4. - Fixed Excitation Test, Step B Figure 7-5. - Fixed Excitation Test, Step CSection DIAGNOSTIC TESTS 5. Re-connect Wire 2 and Wire 6 to the Voltage RegulatorTest 5 - Check Field Boost Test 6 - Test Stator DPE WindingFigure 7-6. - Fixed Excitation Test, Step D Figure 7-7. - The Field Boost CircuitTest 7 - Check Sensing Leads / Power Windings Figure 7-8. - Stator Excitation WindingSection DIAGNOSTIC TESTS Figure 7-9. - Stator Power Winding Leads Test 8 - Check Brush LeadsSection DIAGNOSTIC TESTS Test 10 - Check Rotor Assembly Test 9 - Check Brushes & Slip RingsFigure 7-10. - Brush Leads Section DIAGNOSTIC TESTSFigure 7-11. - Rotor Assembly Test 11 - Check Main Circuit BreakerTest 12 - Check Load Voltage Frequency Test 13 - Check Load Watts AmperageTest 14 - Try Cranking the Engine Test 15 - Check Fuel PumpFigure 7-13. - Electric Fuel Pump Figure 7-14. - Harness to Fuel PumpTest 17 - Check Battery & Cables Test 18 - Check Power Supply to Printed Circuit BoardTest 16 - Check 7.5 Amp Fuse Figure 7-15. - 7.5 Amp FuseTest 19 - Check Continuity of Wire Test 20 - Check Start-Stop SwitchFigure 7-16. - Start-Stop Switch Figure 7-17. - Test 20, StepTest 21 - Check Power Supply to Wire Test 22 - Check Starter Contactor RelayFigure 7-18. - Test 20, Step Figure 7-19. - Starter Contactor RelayTest 23 - Check Starter Contactor Test 24 - Check Starter MotorFigure 7-20. - The Starter Contactor SC Section DIAGNOSTIC TESTSFigure 7-21. - Starter Motor SM Figure 7-22. - Check Pinion Gear OperationSection DIAGNOSTIC TESTS Figure 7-26. - Testing Starter Motor Performance Figure 7-23. - Clamp-On AmmeterFigure 7-24. - Tachometer Figure 7-25. - Test BracketFigure 7-28 - LP Gas Carburetion Diagram Test 25 - Check Fuel SupplyFigure 7-27 - Typical Propane Gas Fuel System Section DIAGNOSTIC TESTSTest 26 - Check Wire 14 Power Supply Figure 7-30. - The 4-tab ConnectorFigure 7-29. - Fuel Regulator Section DIAGNOSTIC TESTSTest 27 - Check Wire Figure 7-31. - Remote Harness ConnectorTest 28 - Check Fuel Solenoid Gasoline Models Section DIAGNOSTIC TESTSFigure 7-32. - Testing Ignition System Test 29 - Check Ignition SparkFigure 7-33. - Checking Engine Miss Tools RequiredTwo Ignition Testers Generac P/N 0C5969Test 31 - Check and Adjust Ignition Magnetos Figure 7-35 - Setting Spark Plug GapFigure 7-36. - Ignition Magneto Assembly Test 30 - Check Spark PlugsFigure 7-37. - Setting Ignition Magneto Armature Air Gap Note If VOM was set to Diode test, a reading ofFigure 7-38. - Engine Ground Harness Test Points Section DIAGNOSTIC TESTSTest 32 - Check Valve Adjustment TORQUE SPECIFICATION ROCKER ARM JAM NUT 174 inch-poundsFigure 7-39 - Adjusting Valve Clearance Note Before replacing the Ignition Magneto, check the Flywheel MagnetFigure 7-41. - Automatic Choke Assembly Test 33 - Check CarburetionTest 34 - Check Choke Solenoid Section DIAGNOSTIC TESTSFigure 7-42. - Choke Solenoid Adjustment Figure 7-43. - ConnectorTest 35 - Check Engine / Cylinder Leak Down Test / Compression Test Section DIAGNOSTIC TESTSTest 36 - Check Oil Pressure Switch Section DIAGNOSTIC TESTSTest 37 - Check Wire 86 for Continuity Test 38 - Test Oil Temperature SwitchFigure 7-44. - Oil Pressure Switch Figure 7-45. - Oil Temperature SwitchTest 39 - Check Wire 85 for Continuity Figure 7-46. - Testing Oil Temperature SwitchTest 40 - Test Choke Heater Section DIAGNOSTIC TESTSTEST 41 - CHECK LPG FUEL SOLENOID Figure 7-49. - Fuel SolenoidSection DIAGNOSTIC TESTS Section Exploded Views Base & Pulley - Drawing No. 0G7720-BSection 9 Exploded Views DESCRIPTIONDESCRIPTION Section Exploded Views Enclosure - Drawing No. 0G3881-CSection 9 Exploded Views DESCRIPTIONDESCRIPTION Section Views4145 33,34Section 9 Exploded Views DESCRIPTIONDESCRIPTION 28.75”Engine Accessories - Drawing No. 0G7718-B Section Exploded ViewsSection 9 Exploded Views DESCRIPTIONDESCRIPTION 48,49 Section 9 Exploded Views530 RV Engine - Drawing No. 0G7719-B Section 9 Exploded Views DESCRIPTIONDESCRIPTION Section 9 Exploded Views Rotor & Stator - Drawing No. 0G3953-bSection Exploded Views DESCRIPTIONCHARTS SPECIFICATIONSMajor Features and Dimensions - Drawing No. 0G5519-b SectionSection SPECIFICATIONS & CHARTS Generator SpecificationsNominal Resistances of Generator Windings at 68f Section ELECTRICAL DATA Electrical Schematic and Wiring Diagram - Drawing No. 0G4221-BElectrical Schematic and Wiring Diagram - Drawing No. 0G4221-B Section ELECTRICAL DATAP/N OG7515 REV. A PRINTED IN THE USA