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

Generac Power Systems 5412, 5411, 5413, 5415, 5414, 5410 manual Charts, Specifications, Section

Models: 5410 5414 5415 5413 5411 5412

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Major Features and Dimensions – Drawing No. 0G5519-b

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3/8"-16 THD. (4 PLACES)

543.8

[21 7/16"]

BATTERY CONNECTION	AC OUTPUT
(NEGATIVE)	HARNESS
469.9	HARNESS

[18 1/2"]

REMOTE START CONNECTION		424.8
REMOTE START CONNECTION		[16 3/4"]
BATTERY CONNECTION
(POSITIVE)
FUEL	50
INLET	50
	[1 15/16"]
	TYP.
29.6
[1 3/16"]
41.1
[1 5/8"]
109.1
[4 5/16"]

3/8"-16 THD.

(4 PLACES)

EVAPORATIVE

PORT FITTING

	853.4
	[33 5/8"]
	[33 5/8"]	FRONT DOOR ACCESS FOR
COOLING	ENGINE	FRONT DOOR ACCESS FOR
COOLING	ENGINE	REQUIRED MAINTENANCE
AIR IN	AIR IN	REQUIRED MAINTENANCE
AIR IN	AIR IN
		OIL FILTER ACCESS

EXHAUST OUTLET

31.8

[1 1/4"]

Major Features and Dimensions – Drawing No. 0G5519-b

COOLING

AIR OUT

SPECIFICATIONS	Section 10
& CHARTS

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Generac Power Systems 5412, 5411 Charts, Specifications, Section, Major Features and Dimensions - Drawing No. 0G5519-b

Contents

RV 45/55/65 Diagnostic Repair ManualRECREATIONAL VEHICLE GENERATOR ModelS 5410, 5411, 5412, 5413, 5414SAFETY REPLACEMENT PARTSNOTICE TO USERS OF THIS MANUAL Troubleshooting Flowcharts Table of ContentsSafety Diagnostic Tests64-83 Specifications & ChartsExploded Views / Part Numbers 76-86Electromagnetic Fields Section GENERATOR FUNDAMENTALSMagnetism Electromagnetic InductionFigure 1-4. - A Simple AC Generator A Simple AC GeneratorA More Sophisticated 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 Section GENERATOR FUNDAMENTALS Figure 1-8. - Connection for 120 Volts OnlyFigure 1-9 - Connection for 120/240 Volts Reconnection for Dual Voltage OutputSection Major Generator Components Rotor AssemblyStator Assembly Figure 2-1. Exploded View of GeneratorBrush Holder Figure 2-5. - Schematic Excitation CircuitSection MAJOR GENERATOR COMPONENTS Excitation Circuit ComponentsNote Push oil vapor collector and retainer in until it bottoms Crankcase BreatherFigure 2-8. - Crankcase Breather Section Major Generator ComponentsSection Major Generator Components Control Panel Component IdentificationFigure 2-9. - Control Panel Components REAR VIEWEffects of Dirt and Moisture Cleaning the GeneratorSection Insulation Resistance Tests Insulation Resistance Testersvents that will not attack such materials Section 3 Insulation Resistance TestsStator Insulation Resistance Connect the tester leads to the Stator or Rotor leads onlyFigure 3-2. - Stator Leads Testing Rotor InsulationThe Megohmmeter Figure 3-3. - Rotor Test PointsThe VOM Section MEASURING ELECTRICITYMeters Measuring AC VoltageFigure 4-2. - Clamp-On Ammeter Measuring CurrentMeasuring Resistance Figure 4-3. - A Line-SplitterAMPERES = VOLTSOHMS Electrical UnitsOhm’s Law 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 - SHUTDOWNPrinted Circuit Board BatteryFigure 5-3. - J1 Connector, Harness End Figure 5-1. - Receptacle J1NOTE Water cannot be added to some “mainte- nance-free” batteries Start-Stop Switch7.5 Amp Fuse Figure 5-4. - Typical FuseFigure 5-6. - Starter Motor Figure 5-5. - Start-Stop SwitchStarter Contactor Relay Starter Motor Figure 5-7. - Starter Contactor RelayProblem 1 - Voltage & Frequency Are Both High or Low Section TROUBLESHOOTING FLOWCHARTSIf Problem Involves AC Output IntroductionSection TROUBLESHOOTING FLOWCHARTS Underspeed Warning - 4 Flashes on SW1 LED Problem 3 - Excessive Voltage/Frequency Droop When Load is Appliedcontinued 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 Using a small flathead screwdriver, slide black Problem 10 - 7.5A F1 Fuse BlowingSection TROUBLESHOOTING FLOWCHARTS Gently bend red tabs outward and remove redTest 2 - Check Stepper Motor Control Section DIAGNOSTIC TESTSTest 1 - Check No-Load Voltage and Frequency Figure 7-1. Throttle PositionFigure 7-3. - Fixed Excitation Test, Step A Figure 7-2. Six Pin J2 Connector Wire ColorsTest 4 - Fixed Excitation Test/Rotor Amp Draw Section DIAGNOSTIC TESTSSection DIAGNOSTIC TESTS Figure 7-4. - Fixed Excitation Test, Step BFigure 7-5. - Fixed Excitation Test, Step C 5. Re-connect Wire 2 and Wire 6 to the Voltage RegulatorFigure 7-6. - Fixed Excitation Test, Step D Test 5 - Check Field BoostTest 6 - Test Stator DPE Winding 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 Figure 7-10. - Brush Leads Test 10 - Check Rotor AssemblyTest 9 - Check Brushes & Slip Rings Section DIAGNOSTIC TESTSTest 12 - Check Load Voltage Frequency Figure 7-11. - Rotor AssemblyTest 11 - Check Main Circuit Breaker Test 13 - Check Load Watts AmperageFigure 7-13. - Electric Fuel Pump Test 14 - Try Cranking the EngineTest 15 - Check Fuel Pump Figure 7-14. - Harness to Fuel PumpTest 16 - Check 7.5 Amp Fuse Test 17 - Check Battery & CablesTest 18 - Check Power Supply to Printed Circuit Board Figure 7-15. - 7.5 Amp FuseFigure 7-16. - Start-Stop Switch Test 19 - Check Continuity of WireTest 20 - Check Start-Stop Switch Figure 7-17. - Test 20, StepFigure 7-18. - Test 20, Step Test 21 - Check Power Supply to WireTest 22 - Check Starter Contactor Relay Figure 7-19. - Starter Contactor RelayFigure 7-20. - The Starter Contactor SC Test 23 - Check Starter ContactorTest 24 - Check Starter Motor Section DIAGNOSTIC TESTSFigure 7-21. - Starter Motor SM Figure 7-22. - Check Pinion Gear OperationSection DIAGNOSTIC TESTS Figure 7-24. - Tachometer Figure 7-26. - Testing Starter Motor PerformanceFigure 7-23. - Clamp-On Ammeter Figure 7-25. - Test BracketFigure 7-27 - Typical Propane Gas Fuel System Figure 7-28 - LP Gas Carburetion DiagramTest 25 - Check Fuel Supply Section DIAGNOSTIC TESTSFigure 7-29. - Fuel Regulator Test 26 - Check Wire 14 Power SupplyFigure 7-30. - The 4-tab Connector Section DIAGNOSTIC TESTSTest 28 - Check Fuel Solenoid Gasoline Models Test 27 - Check WireFigure 7-31. - Remote Harness Connector Section DIAGNOSTIC TESTSFigure 7-33. - Checking Engine Miss Figure 7-32. - Testing Ignition SystemTest 29 - Check Ignition Spark Tools RequiredTwo Ignition Testers Generac P/N 0C5969Figure 7-36. - Ignition Magneto Assembly Test 31 - Check and Adjust Ignition MagnetosFigure 7-35 - Setting Spark Plug Gap Test 30 - Check Spark PlugsFigure 7-38. - Engine Ground Harness Test Points Figure 7-37. - Setting Ignition Magneto Armature Air GapNote If VOM was set to Diode test, a reading of Section DIAGNOSTIC TESTSFigure 7-39 - Adjusting Valve Clearance Test 32 - Check Valve AdjustmentTORQUE SPECIFICATION ROCKER ARM JAM NUT 174 inch-pounds Note Before replacing the Ignition Magneto, check the Flywheel MagnetTest 34 - Check Choke Solenoid Figure 7-41. - Automatic Choke AssemblyTest 33 - Check Carburetion Section DIAGNOSTIC TESTSTest 35 - Check Engine / Cylinder Leak Down Test / Compression Test Figure 7-42. - Choke Solenoid AdjustmentFigure 7-43. - Connector Section DIAGNOSTIC TESTSTest 36 - Check Oil Pressure Switch Section DIAGNOSTIC TESTSFigure 7-44. - Oil Pressure Switch Test 37 - Check Wire 86 for ContinuityTest 38 - Test Oil Temperature Switch Figure 7-45. - Oil Temperature SwitchTest 40 - Test Choke Heater Test 39 - Check Wire 85 for ContinuityFigure 7-46. - Testing Oil Temperature Switch 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 4145 SectionViews 33,34DESCRIPTION Section 9 Exploded ViewsDESCRIPTION 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 DESCRIPTIONMajor Features and Dimensions - Drawing No. 0G5519-b CHARTSSPECIFICATIONS 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