RV 45/55/65
Diagnostic Repair Manual
RECREATIONAL VEHICLE GENERATOR
ModelS 5410, 5411, 5412, 5413, 5414
SAFETY
REPLACEMENT PARTS
NOTICE TO USERS OF THIS MANUAL
Troubleshooting Flowcharts
Table of Contents
Safety
Diagnostic Tests
64-83
Specifications & Charts
Exploded Views / Part Numbers
76-86
Electromagnetic Fields
Section GENERATOR FUNDAMENTALS
Magnetism
Electromagnetic Induction
Figure 1-4. - A Simple AC Generator
A Simple AC Generator
A More Sophisticated AC Generator
Figure 1-5. - Alternating Current Sine Wave
Figure 1-7. - Generator Operating Diagram
Section GENERATOR FUNDAMENTALS
Generator operation may be described briefly as fol- lows
Field Boost
Generator AC Connection System
Section GENERATOR FUNDAMENTALS
Section GENERATOR FUNDAMENTALS
Figure 1-8. - Connection for 120 Volts Only
Figure 1-9 - Connection for 120/240 Volts
Reconnection for Dual Voltage Output
Section Major Generator Components
Rotor Assembly
Stator Assembly
Figure 2-1. Exploded View of Generator
Brush Holder
Figure 2-5. - Schematic Excitation Circuit
Section MAJOR GENERATOR COMPONENTS
Excitation Circuit Components
Note Push oil vapor collector and retainer in until it bottoms
Crankcase Breather
Figure 2-8. - Crankcase Breather
Section Major Generator Components
Section Major Generator Components
Control Panel Component Identification
Figure 2-9. - Control Panel Components
REAR VIEW
Effects of Dirt and Moisture
Cleaning the Generator
Section Insulation Resistance Tests
Insulation Resistance Testers
vents that will not attack such materials
Section 3 Insulation Resistance Tests
Stator Insulation Resistance
Connect the tester leads to the Stator or Rotor leads only
Figure 3-2. - Stator Leads
Testing Rotor Insulation
The Megohmmeter
Figure 3-3. - Rotor Test Points
The VOM
Section MEASURING ELECTRICITY
Meters
Measuring AC Voltage
Figure 4-2. - Clamp-On Ammeter
Measuring Current
Measuring Resistance
Figure 4-3. - A Line-Splitter
AMPERES = VOLTSOHMS
Electrical Units
Ohm’s Law
VOLTS = AMPERES x OHMS
Section ENGINE DC CONTROL SYSTEM
Introduction
Operational Analysis
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION - CRANKING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION - RUNNING
Section ENGINE DC CONTROL SYSTEM
CIRCUIT CONDITION - SHUTDOWN
Printed Circuit Board
Battery
Figure 5-3. - J1 Connector, Harness End
Figure 5-1. - Receptacle J1
NOTE Water cannot be added to some “mainte- nance-free” batteries
Start-Stop Switch
7.5 Amp Fuse
Figure 5-4. - Typical Fuse
Figure 5-6. - Starter Motor
Figure 5-5. - Start-Stop Switch
Starter Contactor Relay Starter Motor
Figure 5-7. - Starter Contactor Relay
Problem 1 - Voltage & Frequency Are Both High or Low
Section TROUBLESHOOTING FLOWCHARTS
If Problem Involves AC Output
Introduction
Section TROUBLESHOOTING FLOWCHARTS
Underspeed Warning - 4 Flashes on SW1 LED
Problem 3 - Excessive Voltage/Frequency Droop When Load is Applied
continued
Section TROUBLESHOOTING FLOWCHARTS
Proble 5 - Priming Function Does Not Work Gasoline Models
Section TROUBLESHOOTING FLOWCHARTS
Problem 6 - Engine Will Not Crank
Section TROUBLESHOOTING FLOWCHARTS
Section TROUBLESHOOTING FLOWCHARTS
START-STOP
Section TROUBLESHOOTING FLOWCHARTS
Problem 8 - Engine Starts Hard and Runs Rough Gasoline Units
Section TROUBLESHOOTING FLOWCHARTS
Problem 8 - Engine Starts Hard and Runs Rough LP Units
Section TROUBLESHOOTING FLOWCHARTS
Section TROUBLESHOOTING FLOWCHARTS
Using a small flathead screwdriver, slide black
Problem 10 - 7.5A F1 Fuse Blowing
Section TROUBLESHOOTING FLOWCHARTS
Gently bend red tabs outward and remove red
Test 2 - Check Stepper Motor Control
Section DIAGNOSTIC TESTS
Test 1 - Check No-Load Voltage and Frequency
Figure 7-1. Throttle Position
Figure 7-3. - Fixed Excitation Test, Step A
Figure 7-2. Six Pin J2 Connector Wire Colors
Test 4 - Fixed Excitation Test/Rotor Amp Draw
Section DIAGNOSTIC TESTS
Section DIAGNOSTIC TESTS
Figure 7-4. - Fixed Excitation Test, Step B
Figure 7-5. - Fixed Excitation Test, Step C
5. Re-connect Wire 2 and Wire 6 to the Voltage Regulator
Figure 7-6. - Fixed Excitation Test, Step D
Test 5 - Check Field Boost
Test 6 - Test Stator DPE Winding
Figure 7-7. - The Field Boost Circuit
Test 7 - Check Sensing Leads / Power Windings
Figure 7-8. - Stator Excitation Winding
Section DIAGNOSTIC TESTS
Figure 7-9. - Stator Power Winding Leads
Test 8 - Check Brush Leads
Section DIAGNOSTIC TESTS
Figure 7-10. - Brush Leads
Test 10 - Check Rotor Assembly
Test 9 - Check Brushes & Slip Rings
Section DIAGNOSTIC TESTS
Test 12 - Check Load Voltage Frequency
Figure 7-11. - Rotor Assembly
Test 11 - Check Main Circuit Breaker
Test 13 - Check Load Watts Amperage
Figure 7-13. - Electric Fuel Pump
Test 14 - Try Cranking the Engine
Test 15 - Check Fuel Pump
Figure 7-14. - Harness to Fuel Pump
Test 16 - Check 7.5 Amp Fuse
Test 17 - Check Battery & Cables
Test 18 - Check Power Supply to Printed Circuit Board
Figure 7-15. - 7.5 Amp Fuse
Figure 7-16. - Start-Stop Switch
Test 19 - Check Continuity of Wire
Test 20 - Check Start-Stop Switch
Figure 7-17. - Test 20, Step
Figure 7-18. - Test 20, Step
Test 21 - Check Power Supply to Wire
Test 22 - Check Starter Contactor Relay
Figure 7-19. - Starter Contactor Relay
Figure 7-20. - The Starter Contactor SC
Test 23 - Check Starter Contactor
Test 24 - Check Starter Motor
Section DIAGNOSTIC TESTS
Figure 7-21. - Starter Motor SM
Figure 7-22. - Check Pinion Gear Operation
Section DIAGNOSTIC TESTS
Figure 7-24. - Tachometer
Figure 7-26. - Testing Starter Motor Performance
Figure 7-23. - Clamp-On Ammeter
Figure 7-25. - Test Bracket
Figure 7-27 - Typical Propane Gas Fuel System
Figure 7-28 - LP Gas Carburetion Diagram
Test 25 - Check Fuel Supply
Section DIAGNOSTIC TESTS
Figure 7-29. - Fuel Regulator
Test 26 - Check Wire 14 Power Supply
Figure 7-30. - The 4-tab Connector
Section DIAGNOSTIC TESTS
Test 28 - Check Fuel Solenoid Gasoline Models
Test 27 - Check Wire
Figure 7-31. - Remote Harness Connector
Section DIAGNOSTIC TESTS
Figure 7-33. - Checking Engine Miss
Figure 7-32. - Testing Ignition System
Test 29 - Check Ignition Spark
Tools RequiredTwo Ignition Testers Generac P/N 0C5969
Figure 7-36. - Ignition Magneto Assembly
Test 31 - Check and Adjust Ignition Magnetos
Figure 7-35 - Setting Spark Plug Gap
Test 30 - Check Spark Plugs
Figure 7-38. - Engine Ground Harness Test Points
Figure 7-37. - Setting Ignition Magneto Armature Air Gap
Note If VOM was set to Diode test, a reading of
Section DIAGNOSTIC TESTS
Figure 7-39 - Adjusting Valve Clearance
Test 32 - Check Valve Adjustment
TORQUE SPECIFICATION ROCKER ARM JAM NUT 174 inch-pounds
Note Before replacing the Ignition Magneto, check the Flywheel Magnet
Test 34 - Check Choke Solenoid
Figure 7-41. - Automatic Choke Assembly
Test 33 - Check Carburetion
Section DIAGNOSTIC TESTS
Test 35 - Check Engine / Cylinder Leak Down Test / Compression Test
Figure 7-42. - Choke Solenoid Adjustment
Figure 7-43. - Connector
Section DIAGNOSTIC TESTS
Test 36 - Check Oil Pressure Switch
Section DIAGNOSTIC TESTS
Figure 7-44. - Oil Pressure Switch
Test 37 - Check Wire 86 for Continuity
Test 38 - Test Oil Temperature Switch
Figure 7-45. - Oil Temperature Switch
Test 40 - Test Choke Heater
Test 39 - Check Wire 85 for Continuity
Figure 7-46. - Testing Oil Temperature Switch
Section DIAGNOSTIC TESTS
TEST 41 - CHECK LPG FUEL SOLENOID
Figure 7-49. - Fuel Solenoid
Section DIAGNOSTIC TESTS
Section Exploded Views
Base & Pulley - Drawing No. 0G7720-B
Section 9 Exploded Views
DESCRIPTION
DESCRIPTION
Section Exploded Views
Enclosure - Drawing No. 0G3881-C
Section 9 Exploded Views
DESCRIPTION
DESCRIPTION
4145
Section
Views
33,34
DESCRIPTION
Section 9 Exploded Views
DESCRIPTION
28.75”
Engine Accessories - Drawing No. 0G7718-B
Section Exploded Views
Section 9 Exploded Views
DESCRIPTION
DESCRIPTION
48,49
Section 9 Exploded Views
530 RV Engine - Drawing No. 0G7719-B
Section 9 Exploded Views
DESCRIPTION
DESCRIPTION
Section 9 Exploded Views
Rotor & Stator - Drawing No. 0G3953-b
Section Exploded Views
DESCRIPTION
Major Features and Dimensions - Drawing No. 0G5519-b
CHARTS
SPECIFICATIONS
Section
Section SPECIFICATIONS & CHARTS
Generator Specifications
Nominal Resistances of Generator Windings at 68f
Section ELECTRICAL DATA
Electrical Schematic and Wiring Diagram - Drawing No. 0G4221-B
Electrical Schematic and Wiring Diagram - Drawing No. 0G4221-B
Section ELECTRICAL DATA
P/N OG7515 REV. A
PRINTED IN THE USA
