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Generac Power Systems 5411, 5412, 5413 Section SPECIFICATIONS & CHARTS, Generator Specifications

Models: 5410 5414 5415 5413 5411 5412

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Section 10

SPECIFICATIONS & CHARTS

Generator Specifications

TYPE		RV 45G/LP		RV 55G/LP		RV 65G/LP

MODEL	5410/5411		5412/5413			5414/5415

WEIGHT		278/281 pounds		285/288 pounds		293/296 pounds

TYPE OF ROTOR		Two-pole		Two-pole		Two-pole

RATED WATTS	4500		5500			6500

RATED VOLTS	120		120			120

PHASE		1-Phase		1-Phase		1-Phase

RATED MAX.
CONTINUOUS CURRENT	37.5 (18.7)		45.8 (22.9)			54.1 (27)
AMPS (240V)

RATED FREQUENCY		60 Hz		60 Hz		60 Hz

OPERATING SPEED		2571 rpm		2571 rpm		2571 rpm

ENGINE MODEL		GT-530		GT-530		GT-530

TYPE OF ENGINE		Vertical Shaft		Vertical Shaft		Vertical Shaft

FUEL SYSTEM		Gasoline/LP		Gasoline/LP		Gasoline/LP

COOLING SYSTEM		Air-Cooled		Air-Cooled		Air-Cooled

OIL SYSTEM		Pressurized with Filter		Pressurized with Filter		Pressurized with Filter

OIL PUMP		Trochoid Type		Trochoid Type		Trochoid Type

AIR CLEANER		Paper element		Paper element		Paper element

STARTER		12 VDC electric		12 VDC electric		12 VDC electric

IGNITION SYSTEM		Solid State/Flywheel		Solid State/Flywheel		Solid State/Flywheel
		Magneto		Magneto		Magneto

SPARK PLUG		NGK BPR6HS		NGK BPR6HS		NGK BPR6HS

SPARK PLUG GAP		0.030 inch (0.76mm)		0.030 inch (0.76mm)		0.030 inch (0.76mm)

Nominal Resistances of Generator Windings at 68°f

TYPE		RV 45G/LP		RV 55G/LP		RV 65G/LP

MODEL		5410/5411		5412/5413		5414/5415

Power Windings
Lead 11 to 22		0.376 - 0.416 ohms		0.28 - 0.32 ohms		0.209 - 0.242 ohms
Lead 11S to 22S		0.376 - 0.416 ohms		0.28 - 0.32 ohms		0.209 - 0.242 ohms
Lead 11S to 22S
Lead 33 to 44

Excitation “DPE” Winding		2.59 ohms		1.41 - 1.63 ohms		1.59 - 1.84 ohms
Lead 2 to 6		2.59 ohms		1.41 - 1.63 ohms		1.59 - 1.84 ohms
Lead 2 to 6

Rotor Winding		13.4 ohms		14.88 ohms		10.81 ohms
Slip Ring to Slip Ring		13.4 ohms		14.88 ohms		10.81 ohms
Slip Ring to Slip Ring

		Torque Requirements (unless otherwise specified)

Stator Bolts	8 ft-lbs
Alternator Pulley	38 ft-lbs
Engine Pulley	38 ft-lbs
Oil Adaptor Bolt	4.5 ft-lbs
Oil Lines	70 in-lbs
Intake Manifold	18 ft-lbs
Exhaust Manifold	18 ft-lbs
M5-0.8 taptite screw into aluminum	25-50 in-lbs
M5-0.8 taptite screw into pierced hole	25-50 in-lbs

M6-1.0 taptite screw into aluminum	50-96 in-lbs
M6-1.0 taptite screw into pierced hole	50-96 in-lbs
M6-1.0 taptite screw into weldnut	50-96 in-lbs
M8-1.25 taptite screw into aluminum	12-18 ft-lbs
M6-1.0 nylok nut onto stud	16-65 in-lbs
Dipstick Casting Oil Line	250 in-lbs

Note: Torques are dynamic values with ±10 % tolerance unless otherwise noted.

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Generac Power Systems 5411, 5412, 5413, 5415, 5414, 5410 manual Section SPECIFICATIONS & CHARTS, Generator Specifications

Contents

ModelS 5410, 5411, 5412, 5413, 5414 Diagnostic Repair ManualRECREATIONAL VEHICLE GENERATOR RV 45/55/65REPLACEMENT PARTS SAFETYNOTICE TO USERS OF THIS MANUAL Diagnostic Tests Table of ContentsSafety Troubleshooting Flowcharts76-86 Specifications & ChartsExploded Views / Part Numbers 64-83Electromagnetic Induction Section GENERATOR FUNDAMENTALSMagnetism Electromagnetic FieldsFigure 1-5. - Alternating Current Sine Wave A Simple AC GeneratorA More Sophisticated AC Generator Figure 1-4. - A Simple AC GeneratorSection GENERATOR FUNDAMENTALS Figure 1-7. - Generator Operating DiagramGenerator operation may be described briefly as fol- lows Generator AC Connection System Field BoostSection GENERATOR FUNDAMENTALS Reconnection for Dual Voltage Output Figure 1-8. - Connection for 120 Volts OnlyFigure 1-9 - Connection for 120/240 Volts Section GENERATOR FUNDAMENTALSFigure 2-1. Exploded View of Generator Rotor AssemblyStator Assembly Section Major Generator ComponentsExcitation Circuit Components Figure 2-5. - Schematic Excitation CircuitSection MAJOR GENERATOR COMPONENTS Brush HolderSection Major Generator Components Crankcase BreatherFigure 2-8. - Crankcase Breather Note Push oil vapor collector and retainer in until it bottomsREAR VIEW Control Panel Component IdentificationFigure 2-9. - Control Panel Components Section Major Generator ComponentsInsulation Resistance Testers Cleaning the GeneratorSection Insulation Resistance Tests Effects of Dirt and MoistureConnect the tester leads to the Stator or Rotor leads only Section 3 Insulation Resistance TestsStator Insulation Resistance vents that will not attack such materialsFigure 3-3. - Rotor Test Points Testing Rotor InsulationThe Megohmmeter Figure 3-2. - Stator LeadsMeasuring AC Voltage Section MEASURING ELECTRICITYMeters The VOMFigure 4-3. - A Line-Splitter Measuring CurrentMeasuring Resistance Figure 4-2. - Clamp-On AmmeterVOLTS = AMPERES x OHMS Electrical UnitsOhm’s Law AMPERES = VOLTSOHMSIntroduction Section ENGINE DC CONTROL SYSTEMOperational Analysis CIRCUIT CONDITION - CRANKING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION - RUNNING Section ENGINE DC CONTROL SYSTEMCIRCUIT CONDITION - SHUTDOWN Section ENGINE DC CONTROL SYSTEMFigure 5-1. - Receptacle J1 BatteryFigure 5-3. - J1 Connector, Harness End Printed Circuit BoardFigure 5-4. - Typical Fuse Start-Stop Switch7.5 Amp Fuse NOTE Water cannot be added to some “mainte- nance-free” batteriesFigure 5-7. - Starter Contactor Relay Figure 5-5. - Start-Stop SwitchStarter Contactor Relay Starter Motor Figure 5-6. - Starter MotorIntroduction Section TROUBLESHOOTING FLOWCHARTSIf Problem Involves AC Output Problem 1 - Voltage & Frequency Are Both High or LowSection TROUBLESHOOTING FLOWCHARTS Section TROUBLESHOOTING FLOWCHARTS Problem 3 - Excessive Voltage/Frequency Droop When Load is Appliedcontinued Underspeed Warning - 4 Flashes on SW1 LEDSection TROUBLESHOOTING FLOWCHARTS Proble 5 - Priming Function Does Not Work Gasoline ModelsSection TROUBLESHOOTING FLOWCHARTS Problem 6 - Engine Will Not CrankSTART-STOP Section TROUBLESHOOTING FLOWCHARTSSection TROUBLESHOOTING FLOWCHARTS Section TROUBLESHOOTING FLOWCHARTS Problem 8 - Engine Starts Hard and Runs Rough Gasoline UnitsSection TROUBLESHOOTING FLOWCHARTS Problem 8 - Engine Starts Hard and Runs Rough LP UnitsSection TROUBLESHOOTING FLOWCHARTS Gently bend red tabs outward and remove red Problem 10 - 7.5A F1 Fuse BlowingSection TROUBLESHOOTING FLOWCHARTS Using a small flathead screwdriver, slide blackFigure 7-1. Throttle Position Section DIAGNOSTIC TESTSTest 1 - Check No-Load Voltage and Frequency Test 2 - Check Stepper Motor ControlSection DIAGNOSTIC TESTS Figure 7-2. Six Pin J2 Connector Wire ColorsTest 4 - Fixed Excitation Test/Rotor Amp Draw Figure 7-3. - Fixed Excitation Test, Step A5. Re-connect Wire 2 and Wire 6 to the Voltage Regulator Figure 7-4. - Fixed Excitation Test, Step BFigure 7-5. - Fixed Excitation Test, Step C Section DIAGNOSTIC TESTSFigure 7-7. - The Field Boost Circuit Test 5 - Check Field BoostTest 6 - Test Stator DPE Winding Figure 7-6. - Fixed Excitation Test, Step DFigure 7-8. - Stator Excitation Winding Test 7 - Check Sensing Leads / Power WindingsSection DIAGNOSTIC TESTS Test 8 - Check Brush Leads Figure 7-9. - Stator Power Winding LeadsSection DIAGNOSTIC TESTS Section DIAGNOSTIC TESTS Test 10 - Check Rotor AssemblyTest 9 - Check Brushes & Slip Rings Figure 7-10. - Brush LeadsTest 13 - Check Load Watts Amperage Figure 7-11. - Rotor AssemblyTest 11 - Check Main Circuit Breaker Test 12 - Check Load Voltage FrequencyFigure 7-14. - Harness to Fuel Pump Test 14 - Try Cranking the EngineTest 15 - Check Fuel Pump Figure 7-13. - Electric Fuel PumpFigure 7-15. - 7.5 Amp Fuse Test 17 - Check Battery & CablesTest 18 - Check Power Supply to Printed Circuit Board Test 16 - Check 7.5 Amp FuseFigure 7-17. - Test 20, Step Test 19 - Check Continuity of WireTest 20 - Check Start-Stop Switch Figure 7-16. - Start-Stop SwitchFigure 7-19. - Starter Contactor Relay Test 21 - Check Power Supply to WireTest 22 - Check Starter Contactor Relay Figure 7-18. - Test 20, StepSection DIAGNOSTIC TESTS Test 23 - Check Starter ContactorTest 24 - Check Starter Motor Figure 7-20. - The Starter Contactor SCFigure 7-22. - Check Pinion Gear Operation Figure 7-21. - Starter Motor SMSection DIAGNOSTIC TESTS Figure 7-25. - Test Bracket Figure 7-26. - Testing Starter Motor PerformanceFigure 7-23. - Clamp-On Ammeter Figure 7-24. - TachometerSection DIAGNOSTIC TESTS Figure 7-28 - LP Gas Carburetion DiagramTest 25 - Check Fuel Supply Figure 7-27 - Typical Propane Gas Fuel SystemSection DIAGNOSTIC TESTS Test 26 - Check Wire 14 Power SupplyFigure 7-30. - The 4-tab Connector Figure 7-29. - Fuel RegulatorSection DIAGNOSTIC TESTS Test 27 - Check WireFigure 7-31. - Remote Harness Connector Test 28 - Check Fuel Solenoid Gasoline ModelsTools RequiredTwo Ignition Testers Generac P/N 0C5969 Figure 7-32. - Testing Ignition SystemTest 29 - Check Ignition Spark Figure 7-33. - Checking Engine MissTest 30 - Check Spark Plugs Test 31 - Check and Adjust Ignition MagnetosFigure 7-35 - Setting Spark Plug Gap Figure 7-36. - Ignition Magneto AssemblySection DIAGNOSTIC TESTS Figure 7-37. - Setting Ignition Magneto Armature Air GapNote If VOM was set to Diode test, a reading of Figure 7-38. - Engine Ground Harness Test PointsNote Before replacing the Ignition Magneto, check the Flywheel Magnet Test 32 - Check Valve AdjustmentTORQUE SPECIFICATION ROCKER ARM JAM NUT 174 inch-pounds Figure 7-39 - Adjusting Valve ClearanceSection DIAGNOSTIC TESTS Figure 7-41. - Automatic Choke AssemblyTest 33 - Check Carburetion Test 34 - Check Choke SolenoidSection DIAGNOSTIC TESTS Figure 7-42. - Choke Solenoid AdjustmentFigure 7-43. - Connector Test 35 - Check Engine / Cylinder Leak Down Test / Compression TestSection DIAGNOSTIC TESTS Test 36 - Check Oil Pressure SwitchFigure 7-45. - Oil Temperature Switch Test 37 - Check Wire 86 for ContinuityTest 38 - Test Oil Temperature Switch Figure 7-44. - Oil Pressure SwitchSection DIAGNOSTIC TESTS Test 39 - Check Wire 85 for ContinuityFigure 7-46. - Testing Oil Temperature Switch Test 40 - Test Choke HeaterFigure 7-49. - Fuel Solenoid TEST 41 - CHECK LPG FUEL SOLENOIDSection DIAGNOSTIC TESTS Base & Pulley - Drawing No. 0G7720-B Section Exploded ViewsDESCRIPTION Section 9 Exploded ViewsDESCRIPTION Enclosure - Drawing No. 0G3881-C Section Exploded ViewsDESCRIPTION Section 9 Exploded ViewsDESCRIPTION 33,34 SectionViews 414528.75” Section 9 Exploded ViewsDESCRIPTION DESCRIPTIONSection Exploded Views Engine Accessories - Drawing No. 0G7718-BDESCRIPTION Section 9 Exploded ViewsDESCRIPTION Section 9 Exploded Views 48,49530 RV Engine - Drawing No. 0G7719-B DESCRIPTION Section 9 Exploded ViewsDESCRIPTION Rotor & Stator - Drawing No. 0G3953-b Section 9 Exploded ViewsDESCRIPTION Section Exploded ViewsSection CHARTSSPECIFICATIONS Major Features and Dimensions - Drawing No. 0G5519-bGenerator Specifications Section SPECIFICATIONS & CHARTSNominal Resistances of Generator Windings at 68f Electrical Schematic and Wiring Diagram - Drawing No. 0G4221-B Section ELECTRICAL DATASection ELECTRICAL DATA Electrical Schematic and Wiring Diagram - Drawing No. 0G4221-BPRINTED IN THE USA P/N OG7515 REV. 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