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