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

Generac Power Systems 5412 Section Exploded Views, Engine Accessories - Drawing No. 0G7718-B

Models: 5410 5414 5415 5413 5411 5412

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Engine Accessories – Drawing No. 0G7718-B

Section 9

Exploded Views

Engine Accessories – Drawing No. 0G7718-B

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Generac Power Systems 5412, 5411, 5413, 5415, 5414, 5410 Section Exploded Views, Engine Accessories - Drawing No. 0G7718-B

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