Generac Power Systems 5411 manual

RV 45/55/65 Diagnostic Rep aiR Manual Diagnostic Rep aiR Manual RECREA TIONAL VEHICLE GENERA TOR MoDels 5410, 5411, 5412, 5413, 5414 & 5415[...]

SAFETY Throughout this publication, “D ANGER!” and “CA UTION!” blocks are used to aler t the mechanic to special instructions concerning a par ticular ser vice or operation that might be hazardous if perf or med incorrectly or carelessly . P A Y CLOSE A TTENTION T O THEM. * D ANGER! UNDER THIS HEADING WILL BE FOUND SPECIAL INSTR UCTIONS WHI[...]

T able of Contents P age 1 SAFETY ........................... INSIDE FRONT CO VER SECTION 1: GENERA T OR FUNDAMENT ALS ....................... 3-7 MA GNETISM ................................................................ 3 ELECTROMA GNETIC FIELDS .................................... 3 ELECTROMA GNETIC INDUCTION ............................. 3 A S[...]

TEST 10 – Check Rotor Assemb ly ................................................ 42 TEST 11 – Check Main Circuit Break er ......................................... 43 TEST 12 – Check Load V oltage & Frequency ................................ 43 TEST 13 – Check Load W atts & Amperage ................................... 43 TEST 14 –[...]

Section 1 GENERA T OR FUND AMENT ALS MA GNETISM Magnetism can be used to produce electricity and electricity can be used to produce magnetism. Much about magnetism cannot be explained by our present knowledge. How e ver , there are cer tain pat - ter ns of beha vior that are known. Application of these behavior patter ns has led to the de velopment[...]

Section 1 GENERA T OR FUND AMENT ALS A SIMPLE A C GENERA T OR Figure 1-4 shows a very simple A C Generator . The generator consists of a rotating magnetic field called a RO T OR and a stationar y coil of wire called a ST A TOR. The RO T OR is a per manent magnet which consists of a SOUTH magnetic pole and a NORTH magnetic pole. As the RO TOR tur ns[...]

Section 1 GENERA T OR FUND AMENT ALS NO TE: AC output frequency at 3720 rpm will be about 60 Her tz. The “No-Load” is set slightly high to prevent excessive rpm, frequency and volta ge droop under hea vy electrical loading. Generator operation may be descr ibed br iefly as fol- lows: 1. Some “residual” magnetism is nor mally present in the [...]

Section 1 GENERA T OR FUND AMENT ALS FIELD BOOST When the engine is cranked during star tup , the star ter contactor is energized closed. Batter y v oltage is then deliv ered to the star ter motor and the engine cranks . During cranking, batter y v oltage flows through a resis- tor and a field boost diode in the Pr inted Circuit Board, then to the [...]

Section 1 GENERA T OR FUND AMENT ALS Figure 1-8. – Connection f or 120 V olts Only RECONNECTION FOR DU AL VOL T A GE OUTPUT: When connected f or dual voltage output, Stator output leads 11 and 44 form two “hot” leads (T1 – Red, and T3 – Black). The junction of leads 22 and 33 form the “Neutral” line (T2 – White). F or dual voltage o[...]

Section 2 MAJOR GENERA T OR COMPONENTS RO TOR ASSEMBL Y The Rotor is sometimes called the “rev olving field”, si nc e it pr ovi des t he m ag net ic f iel d t ha t in du ces a v oltage into the stationary Stator windings. Slip r ings on the Rotor shaft allow excitation current from the voltage regulator to be delivered to the Rotor wind - ings.[...]

Section 2 MAJOR GENERA T OR COMPONENTS Leads 2 & 6 = Stator Excitation Winding Leads 11S & 22S = Vo ltage Sensing Leads Leads 11 & 22, 33 & 44 = AC Po wer Windings Stator 2 6 11 22 33 44 11S 22S Figure 2-2. – Stator Output Leads BRUSH HOLDER The br ush holder is retained in the rear bear ing car- rier by two M5 screws . It retains[...]

Section 2 MAJOR GENERA T OR COMPONENTS NO TE: If, for any reason, sensing v oltage to the regulator is lost, the regulator will shut do wn and excitation output to the Rotor will be lost. The A C output volta ge will then drop to a value that is commensurate with Rotor residual magnetism (about 7-12 V A C). Without this automatic shut - down featur[...]

Section 2 MAJOR GENERA T OR COMPONENTS P age 11 REAR VIEW CONTROL BO ARD (PCB) WITH J1 CONNECT OR GO VERNOR ACTU AT OR J2 CONNECT OR ST AR TER CONT AC TOR REL AY (SCR) TERMINAL BLOCK (TB) “4-T AB CONNECT OR” VO LT AG E REGULA TO R (VR) WITH RED LED ST AR T/ST OP SWITCH (SW1) WITH RED LED 7.5 AMP DC FUSE (F1) CIRCUIT BREAKERS (CB1 & CB2) ENG[...]

Section 3 INSULA TION RESIST ANCE TESTS EFFECTS OF DIRT AND MOISTURE Moisture and dir t are detrimental to the continued good operation of an y generator set. If moisture is allowed to remain in contact with the Stator and Rotor windings, some of the moisture will be retained in voids and cracks of the winding insula- tion. This will result in a re[...]

Section 3 INSULA TION RESIST ANCE TESTS vents that will not attack suc h materials. Use a soft brush or cloth to apply the solvent. Be careful to a void damage to wire or winding insulation. After cleaning, dr y all components thoroughly using moisture-free, lo w-pressure compressed air . * D ANGER!: DO NO T A TTEMPT T O W ORK WITH SOL VENTS IN ANY[...]

Section 3 INSULA TION RESIST ANCE TESTS Leads 2 & 6 = Stator Excitation Winding Leads 11S & 22S = Vo ltage Sensing Leads Leads 11 & 22, 33 & 44 = AC Po wer Windings Stator 2 6 11 22 33 44 11S 22S Figure 3-2. – Stator Leads TESTING RO TOR INSULA TION T o test the Rotor f or insulation breakdown, proceed as f ollows: 1 . Disconnect [...]

Section 4 MEASURING ELECTRICITY METERS De vices used to measure electr ical proper ties are called meters. Meters are av ailable that allow one to measure (a) A C voltage , (b) DC voltage , (c) AC frequency , and (d) resistance in ohms. The follo wing apply: ❏ T o measure A C voltage , use an AC v oltmeter . ❏ T o measure DC v oltage, use a DC [...]

Section 4 MEASURING ELECTRICITY Correct engine and Rotor speed is maintained by a steppe r motor gov er nor . F or m odels rated 6 0 Her tz, the gov er nor is generally set to maintain a no-load fre- quency of about 60 Her tz with a corresponding output v oltage of about 124 volts A C line-to-neutral. MEASURING CURRENT T o read the current flow , i[...]

Section 4 MEASURING ELECTRICITY ELECTRICAL UNITS AMPERE: The rate of electron flow in a circuit is represented by the AMPERE. The ampere is the number of elec- trons flowing past a given point at a given time. One AMPERE is equal to just slightly more than six thou- sand million billion electrons per second. With alter nating current (AC), the elec[...]

SC - ST ARTER CONT AC TO R TB - TERMINAL BLOCK, 4 TA B SP2 - SP ARK PLUG, CYL. 2 SP1 - SP ARK PLUG, CYL. 1 LED - ALARM INDICA TO R LOP - LOW OIL PRESSURE SWITCH SCR - ST ARTER CONT AC TOR RELA Y SM - ST ARTER MO T O R SW1 - PRIME/ST AR T- R UN-OFF SWITCH FS - FUEL SOLENOID FP - FUEL PUMP F1 - FUSE, 7.5A CH - CHOKE HEA TER CS - CHOKE SOLENOID IMS - [...]

Section 5 ENGINE DC CONTROL SYSTEM P age 19 SC - ST ARTER CONT AC TO R TB - TERMINAL BLOCK, 4 TA B SP2 - SP ARK PLUG, CYL. 2 SP1 - SP ARK PLUG, CYL. 1 LED - ALARM INDICA TO R LOP - LOW OIL PRESSURE SWITCH SCR - ST ARTER CONT AC TOR RELA Y SM - ST ARTER MO T O R SW1 - PRIME/ST AR T- R UN-OFF SWITCH FS - FUEL SOLENOID FP - FUEL PUMP F1 - FUSE, 7.5A C[...]

Section 5 ENGINE DC CONTROL SYSTEM P age 20 SC - ST ARTER CONT AC TO R TB - TERMINAL BLOCK, 4 TA B SP2 - SP ARK PLUG, CYL. 2 SP1 - SP ARK PLUG, CYL. 1 LED - ALARM INDICA TO R LOP - LOW OIL PRESSURE SWITCH SCR - ST ARTER CONT AC TOR RELA Y SM - ST ARTER MO T O R SW1 - PRIME/ST AR T- R UN-OFF SWITCH FS - FUEL SOLENOID FP - FUEL PUMP F1 - FUSE, 7.5A C[...]

Section 5 ENGINE DC CONTROL SYSTEM P age 21 5 Flashes = Low Oil Pressure 4 Flashes = Overspeed 3 Flashes = Overcrank 2 Flashes = Low Battery 6 Flashes = High Oil T emperature SC - ST ARTER CONT AC TO R TB - TERMINAL BLOCK, 4 TA B SP2 - SP ARK PLUG, CYL. 2 SP1 - SP ARK PLUG, CYL. 1 LED - ALARM INDICA TO R LOP - LOW OIL PRESSURE SWITCH SCR - ST ARTER[...]

Section 5 ENGINE DC CONTROL SYSTEM PRINTED CIRCUIT BO ARD GENERAL: The Pr inted Circuit Board (PCB) mounted inside the generator control panel is responsible for crank - ing, star tup , running and shutdown operations. The board interconnects with other components of the DC control system to turn them on and off at the proper times. It is pow ered [...]

Section 5 ENGINE DC CONTROL SYSTEM cold weather star ting, voltage drop between the bat- ter y and star ter should not exceed 0.12 v olt per 100 amperes of cranking current. Select the batter y cables based on total cab le length and prev ailing ambient temperature. Generally , the longer the cable and the colder the weather , the larger the requir[...]

Section 5 ENGINE DC CONTROL SYSTEM a. With Wire 17 grounded, a Crank Rela y on the circuit board energizes and batter y voltage is delivered to the Star ter Contactor Rela y via Wire 56. The Star ter Contactor Rela y energizes , its contacts close and the Star ter Contactor is energized via wire 16. Its con - tacts close and the engine cranks . b .[...]

Section 6 TROUBLESHOO TING FLO WCHARTS The “Flow Char ts” in this section ma y be used in conjunction with the “Diagnostic T ests” of Section 7. Numbered tests in the Flow Char ts correspond to identically numbered tests of Section 7. Problems 1 through 4 apply to the A C generator only . Beginning with Problem 5, the engine DC control sys-[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 26 REPAIR OR REPLACE THEN RE-TEST REPAIR OR REPLACE REPAIR OR REPLACE REPAIR OR REPLACE REPLACE VOLTAGE REGULATOR TEST 4 – PERFORM FIXED EXCITATION TEST / ROTOR AMP DRAW D A C B Problem 2 – Generator Produces Zero Voltage or Residual Voltage (5-12VAC) RESET TO “ON” OR REPLACE IF BAD TEST 11 – C[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 27 REPAIR OR REPLACE REPAIR OR REPLACE TEST 4 – PERFORM FIXED EXCITATION TEST / ROTOR AMP DRAW Problem 2 – Generator Produces Zero Voltage or ResidualVoltage (5-12VAC) (continued) INSULATION RESISTANCE TEST, PAGE 13 TEST ROTOR INSULATION, PAGE 14 BAD BAD BAD GOOD GOOD E F G TEST 6 – TEST STATOR DPE[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 28 REPLACE BAD SWITCH REPLACE FUEL PUMP IF DEFECTIVE Proble 5 – Priming Function Does Not Work (Gasoline Models) ENGINE CRANKS NORMALLY STILL WON’T PRIME WON’T CRANK GO TO PROBLEM 6 TEST 15 – CHECK FUEL PUMP OPERATION TEST 14 – TRY CRANKING THE ENGINE TEST 20 – CHECK START-STOP SWITCH (SW1) B[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 29 REPLACE DEFECTIVE SWITCH REPLACE BAD ST ARTER CONT AC TO R RELA Y REPLACE ST ARTER M OT OR IF DEFECTIVE REPLACE ST ARTER CONT AC TO R GO TO PROBLEM 10 RECHARGE OR REPLACE BA TTERY – CLEAN, REP AIR OR REPLACE BAD CABLE(S) CHECK WIRING AND WIRE CONNECTIONS . REP AIR, RECONNECT OR REPLACE BAD WIRES AS [...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 30 CLEAN AND REGAP OR REPLACE SPARK PLUG REPLACE BAD SWITCH REPLACE FUEL PUMP REPLACE SOLENOID REPLACE MAGNET OS ADJUST OR REPAIR ADJUST OR REPAIR ADJUST VALVES REPLENISH FUEL SUPPLY O .K. BAD Problem 7 – Engine Cranks But Will Not Start (Gasoline Units) (Overcrank Warning Code on SW1 LED – 3 Flashes[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 31 CLEAN AND REGAP OR REPLACE SPARK PLUG REPLACE BAD SWITCH REPAIR OR REPLACE REPLACE MAGNET OS ADJUST VALVES REPLENISH FUEL SUPPLY O .K. Problem 7 – Engine Cranks But Will Not Start (LP Units) (Overcrank Warning Code on SW1 LED – 3 Flashes) BAD BAD BAD REPAIR OR REPLACE AS NECESSARY BAD BAD BAD GOOD[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 32 ADJUST, REPAIR OR REPLACE AS NECESSARY REPLACE MAGNETOS GOOD Problem 8 – Engine Starts Hard and Runs Rough (Gasoline Units) BAD BAD BAD BAD BAD BAD GOOD GOOD GOOD GOOD GOOD GOOD GOOD TEST 25 – CHECK FUEL SUPPL Y LOW FUEL ENGINE MISS IS APPARENT TEST 29 – CHECK IGNITION SP ARK TEST 30 – CHECK S[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 33 REPLACE MAGNETOS GOOD Problem 8 – Engine Starts Hard and Runs Rough (LP Units) BAD BAD BAD BAD GOOD GOOD GOOD GOOD GOOD TEST 25 – CHECK FUEL SUPPL Y LOW FUEL ENGINE MISS IS APPARENT TEST 29 – CHECK IGNITION SP ARK TEST 30 – CHECK SP ARK PLUGS CLEAN AND REGAP OR REPLACE SPARK PLUG REPAIR OR REP[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 34 Problem 9 – High Oil Temperature Fault (6 Flashes) or Low Oil Pressure Fault (5 Flashes) REPAIR OR REPLACE REPLACE SWITCH HIGH OIL TEMPERA TURE – 6 FLASHES ON SW1 LED TEST 38 – CHECK OIL TEMPERATURE SWITCH CHECK ENGINE OIL LEVEL TEST 39 – CHECK WIRE 85 FOR CONTINUITY GOOD GOOD BAD BAD REPLENIS[...]

Section 6 TROUBLESHOO TING FLO WCHARTS P age 35 REPLACE PRINTED CIRCUIT BOARD INSTALL NEW 7.5 AMP FUSE CHECK THAT FUSE HOLDER IS NOT GROUNDED CHECK WIRE 15 FOR SHORT TO GROUND CHECK REMOTE HARNESS WIRE 15 FOR SHORT TO GROUND CHECK WIRE 56 FOR SHORT TO GROUND CHECK WIRE 90 FOR SHORT TO GROUND CHECK CHOKE SOLENOID AND STARTER CONTACTOR RELAY STARTER [...]

Section 7 DIA GNOSTIC TESTS INTRODUCTION The “Diagnostic T ests” in this chapter may be per - f or med in conjunction with the “Flow Char ts” of Section 6. T est n umbers in this chapter correspond to the numbered tests in the “Flow Char ts”. T ests 1 through 13 are procedures in volving problems with the generator’ s A C output volta[...]

Section 7 DIA GNOSTIC TESTS 4. If no mo vement is seen in Step 3 remove the con- trol panel cover . V er ify the six pin connector (J2) on the Pr inted Circuit Board is seated proper ly , remov e the connector and then replace it and test again. V er ify the dip s witches are correctly set. NO TE: The dip switches on the Printed Circuit Board are f[...]

Section 7 DIA GNOSTIC TESTS 6 0 4 13 13 2 4 22S 11S 15 105 VA C JUMPER WIRE WIRES 4 REMO VED FROM VO LT AG E REGUL AT OR VO LT AG E REGUL AT OR FUSE HOLDER (F1) RED TEST LEAD BLACK TEST LEAD Figure 7-4. – Fix ed Excitation T est, Step B 4 . Disconnect Wire 2 from the V oltage Regulator (VR) and connect one meter test lead to that wire. Disconnect[...]

Section 7 DIA GNOSTIC TESTS 6 0 4 13 13 2 4 22S 11S 15 WIRES 4 REMO VED FROM VO LT AG E REGUL AT OR VO LT AG E REGUL AT OR FUSE HOLDER (F1) RED TEST LEAD BLACK TEST LEAD 1. 11 Amp Figure 7-6. – Fix ed Excitation T est, Step D 7. Re-connect Wire 11S and Wire 22S to the V oltage Regulator . 8. Remov e the jumper wire between Wire 4 and 12 volt supp[...]

Section 7 DIA GNOSTIC TESTS A. Schematic B. Pictor ial 2 26 6 Figure 7-8. – Stator Excitation Winding PROCEDURE: 1. Disconnect Wire 2 from the V oltage Regulator . 2. Disconnect Wire 6 from the V oltage Regulator . 3. Set a V OM to its “Rx1” scale and zero the meter . 4. Connect the V OM test leads across the ter minal ends of Wires 2 and 6. [...]

Section 7 DIA GNOSTIC TESTS A C PO WER WINDING RESIST ANCE * RV45 (Model 5410/5411) A CROSS WIRES: OHMS 11 & 22 0.396 Ω 11S & 22S 0.396 Ω 33 & 44 0.396 Ω A C PO WER WINDING RESIST ANCE * RV55 (Model 5412/5413) A CROSS WIRES: OHMS 11 & 22 0.28 Ω − 0.32Ω 11S & 22S 0.28 Ω − 0.32Ω 33 & 44 0.28 Ω − 0.32Ω A[...]

Section 7 DIA GNOSTIC TESTS 4 0 Figure 7-10. – Brush Leads TEST 9 – CHECK BRUSHES & SLIP RINGS DISCUSSION: Brushes and slip rings are made of special materials that will provide hundreds of hours of service with little wear . Ho we ver , when the generator has been idle for some time, an o xide film can dev elop on the slip rings. This film[...]

Section 7 DIA GNOSTIC TESTS POSITIVE (+) TEST LEAD Figure 7-11. – Rotor Assembly TEST 11 – CHECK MAIN CIRCUIT BREAKER DISCUSSION: The main circuit breaker on the generator panel must be closed or no output to the load will be av ailable . A def ectiv e breaker may not be able to pass current e ven though it is in the “ON” position. CB2 CB1 [...]

Section 7 DIA GNOSTIC TESTS TEST 14 – TR Y CRANKING THE ENGINE DISCUSSION: If t he S ta r t -St op S wi tch o n t he g en er at or p an el i s actuated, but the Fuel Pump does not run (pr iming function doesn’t work), perhaps batter y voltage is not av ailable. PROCEDURE: Hold the Star t-Stop Switch at “ST AR T”. The engine should crank and[...]

P age 45 Section 7 DIA GNOSTIC TESTS TEST 16 – CHECK 7.5 AMP FUSE DISCUSSION: If the panel-mounted 7.5 amp fuse (F1) has blo wn, engine cranking will not be possib le. Figure 7-15. – 7.5 Amp Fuse PROCEDURE: Push In on fuse holder cap and tur n counterclockwise . Then, remov e the cap with fuse. Inspect the Fuse. RESUL TS: If the Fuse element ha[...]

TEST 19 – CHECK CONTINUITY OF WIRE 17 DISCUSSION: A faulty condition in Wire 17 could prev ent the unit from cranking when the Star t-Stop s witch is held in the “St ar t” position. PROCEDURE: 1. Disconnect Wire 17 from its Switch terminal and connect it to frame ground. The engine should crank. If unit cranks, proceed to Step 2. If unit does[...]

Section 7 DIA GNOSTIC TESTS CONTINUITY DEPRESSED AWA Y FROM TERMINAL BEING TESTED 8 1 2 3 7 4 5 6 0000 Figure 7-18. – T est 20, Step 6 RESUL TS: 1. If “Continuity” is not measured in Step 3, repair , reconnect or replace Wire 0 (between Star t-Stop Switch and ground terminal) as necessar y . 2. If the Star t-Stop Switch (SW1) failed any par t[...]

“Infinity” should be measured. Set the Star t-Stop Switch to “ST AR T”. The meter should now read “Continuity”. Shor t to Ground: 3 . Set the V OM to measure resistance (“R x 1” scale). Disconnect Wire 56 from the Star ter Contactor Relay (SCR). Connect one meter test lead to the SCR ter minal from which Wire 56 was just remov ed. C[...]

Section 7 DIA GNOSTIC TESTS be indicated by excessiv e current draw or no RPM. 3. A def ective Starter Motor switch. 4. Broken, damaged or w eak magnets. 5. Star ter drive dirty or binding. DISCUSSION: T est 21 verified that Printed Circuit Board action is deliv ering DC voltage to the Star ter Contactor Relay (SCR). T est 22 verified the operation[...]

Figure 7-23. – Clamp-On Ammeter T ACHOMETER: A tachometer is av ailable from your Generac P ower Systems source of supply . Order as P/N 042223. The tachometer measures from 800 to 50,000 RPM (see Figure 7-24). Figure 7-24. – T achometer TEST BRA CKET: A star ter motor test brac ket ma y be made as shown in Figure 7-25. MET AL STOCK 1/4" T[...]

Section 7 DIA GNOSTIC TESTS TEST 25 – CHECK FUEL SUPPL Y DISCUSSION (GASOLINE MODELS): If the engine cranks but won’t start, don’t o verlook the obvious . The fuel supply may be low . Man y R V gener- ator installations “share” the fuel tank with the v ehicle engine. When such is the case, the Installer may hav e used a generator fuel pic[...]

The g reater the airflow through the carburetor v entur i, the lower the pressure at the v enturi throat. The lower the pressure at the v enturi throat, the greater the dia- phragm mov ement, and the greater the mov ement of the regulator valv e. The more the regulator v alve opens, the greater the gas flow that is propor tional to airflow through [...]

Section 7 DIA GNOSTIC TESTS TEST 27 – CHECK WIRE 18 DISCUSSION: W ir e 1 8 c on t ro l s s e nd i ng t h e S TO P s ig n al t o t he Printed Circuit Board. Coach manuf acturers some - times install a 15 to 30 f oot remote harness. If unit shuts down or will not star t, a possib le ground e xists on Wire 18. PROCEDURE: 1. Disconnect the customer i[...]

3. If “ Continuity” is not measured in Step 5, repair or replace Wire 0 between the Fuel Solenoid and ground terminal. 4. If “ Continuity” is not measured in Step 6, repair or replace Carburetor g round wire. 5. If the Fuel Solenoid operates , proceed to T est 29. TEST 29 – CHECK IGNITION SP ARK DISCUSSION: A problem in the engine ignitio[...]

Section 7 DIA GNOSTIC TESTS Figure 7-34. – Cylinder Balance T est The cylinder balance test will also detect a cylinder that is not functioning. When grounding out one cylin- der there will be no RPM loss. When the other cylin- der is grounded out the engine will stop . TEST 30 - CHECK SP ARK PLUGS DISCUSSION: During T est 29, if spar k jumped th[...]

to Step 2. If the unit does not produce spark or has weak spark go to Step 4. 2. Do the f ollowing: a. Set a V OM to measure resistance. Connect the positive (+) meter test lead to Wire 18A (Wire 18A still remov ed from the J1 connec- tor) Connect the negativ e (-) meter test lead to a clean frame ground. “Infinity” should be measured, or 0.5 t[...]

Section 7 DIA GNOSTIC TESTS 3. If “Infinity” was not measured in Step 15, repair or replace grounded Wire 18A between the J1 Connector and the insulated ter minal stud or def ective insulated terminal stud. 4. If sparking still does not occur after adjusting the ar mature air gap , testing the ground wires and perf or ming the basic flywheel te[...]

P age 58 TEST 33 – CHECK CARBURETION DISCUSSION: If the engine cranks but will not star t, one possible cause of the problem might be the carb uretion system. PROCEDURE: Bef ore making a carb uretion check, be sure the fuel sup- ply tank has an ample supply of fresh, clean gasoline. Check that all shutoff valv es are open and fuel flows freely th[...]

Section 7 DIA GNOSTIC TESTS in its coil, tighten the two scre ws. V erify that the choke solenoid plunger and linkage mov e freely wit hout any dra g or res istanc e th at m a y res tric t mov ement. CHOKE CONTROL RO D CHOKE SOLENOID MO VES VERTICALL Y PLUNGER Figure 7-42. – Choke Solenoid Adjustment 4. Disconnect Connector 3: Set the V OM to mea[...]

DISCUSSION: The Cylinder Leak Down T ester checks the sealing (compression) ability of the engine by measur ing air leakage from the combustion chamber . Compression loss can present many diff erent symptoms. This test is designed to detect the section of the engine where the f ault lies bef ore disassembling the engine . PROCEDURE: 1. Remov e a sp[...]

Section 7 DIA GNOSTIC TESTS Figure 7-44. – Oil Pressure Switch PROCEDURE: 1. Check engine oil lev el. If necessar y , replenish oil le vel to the dipstic k “FULL ” mark. 2. Set a V OM to its “Rx1” scale and zero the meter . 3. Connect the meter test leads across the switch terminals, with engine shut down. The meter should read “ Contin[...]

3 . Connect the test leads of a V OM across the s witch ter minals . The meter should read “Infinity”. 4 . Heat the oil. When oil temperature reach- es approximately 270-284° F ., the switch con - tacts should close and the meter should read “Continuity”. Figure 7-46. – T esting Oil T emperature Switch RESUL TS: 1. If the Oil T emperatur[...]

Section 7 DIA GNOSTIC TESTS RESUL TS: 1 . If Choke Plate is binding in Step 1, repair or rep lace bi nding Ch oke P late. If Bi -Meta l H eater Assembly tests good, go to T est 32. 2. If continuity was not measured in Step 3, repair or replace Wire 14 between the 4-tab Connector and Connector 3. 3. If the resistance value is incorrect in the Shor t[...]

Section 9 Exploded Views P age 64 Base & Pulley – Dra wing No. 0G77 20-B[...]

Section 9 Exploded Views P age 65 ITEM QTY . DESCRIPTION 1 1 TRA Y , 530 R V 2 2 NUT FLANGE 5/16-18 LOCK 3 8 NUT HEX 5/16-18 STEEL 4 12 W ASHER LOCK M8-5/16 5 13 W ASHER FLA T 5/16-M8 ZINC 6 2 SCREW HHC 3/8-24 X 1-1/2 G8 7 1 BEL T V -RIBBED 4L X 43.75" LG 8 2 W ASHER LOCK M10 9 2 W ASHER FLA T 3/8-M10 ZINC 10 1 AL TERNA T OR PULLEY 11 4 VIB MN[...]

P age 66 Enclosure – Dra wing No. 0G388 1-C Section 9 Exploded Views[...]

Section 9 Exploded Views P age 67 ITEM QTY . DESCRIPTION 1 1 ENCLOSURE DOOR 2 2 SLIDE LA TCH, FLUSH 3 1 FO AM ENCLOSURE DOOR 4 23 NUT FLANGE M6-1.0 NYLOK * 26 NUT FLANGE M6-1.0 NYLOK (LP) 5 1 BRA CKET , ENCLOSURE ELECTRIC HTR 6 1 GR OMMET , OIL FIL TER 7 1 U CHANNEL 1/8” 8 1 TRA Y , 530 R V 9 1 GASKET AIR IN BO TTOM DUCT 10 1 PLUG PLASTIC 1.093-1[...]

P age 68 Control P anel – Drawing No. 0G5489-D "A" 51 20 22 9 14 13 12 11 10 15 24 16 17 6 18 21 20 26 52 28 27 25 24 25 23 20 21 REAR VIEW OG3530 2 1 3 7 6 17 19 8 TO "A" 29 30 44 39 33,34 4 35 37 36 36 38 40 32 31 5 47 48 41 43 42 49 50 45 45 12 46 53 54 TO AIRBO X 55 Section 9 Exploded Views[...]

Section 9 Exploded Views P age 69 ITEM QTY . DESCRIPTION 1 1 SCrEW HHC M6-1.0 X 25 G8.8 2 2 SCrEW PLaStItE HI-LOW #10X3/8 3 1 BUSHING SNaP SB-1093-937 4 1 WIrE HarNESS C/PNL FraME 5 1 NUt HEX M6 X 1.0 G8 YEL CHr 6 2 WaSHEr FLa t 1/4-M6 ZINC 7 1 WaSHEr LOCK SPECIaL 1/4" 8 1 FUEL PUMP MOUNtING BraCKEt 9 28.75” HOSE,1/4" SaE30r7 10 1 CLaMP[...]

P age 70 Engine Accessories – Drawing No. 0G77 1 8-B Section 9 Exploded Views[...]

Section 9 Exploded Views P age 71 ITEM QTY . DESCRIPTION 1 1 FraME 3 1 ENGINE WraPPEr, St artEr SIDE 4 8 SCrEW HHFC M8-1.25 X 14 5 1 SNaP BUSHING 6 14 SCrEW CrIMPtItE 10-24 X 1/2 7 1 SHIELD WraPPEr, CYLINDEr #1 8 13 SCrEW HHFC M6-1.0 X 12 G8.8 9 1 ENGINE WraPPEr, BaCK 10 1 Ba CKPLa tE 11 1 aSSY , FL YWHEEL & rING GEar 29D 12 1 aSSY , GrOUND WIr[...]

P age 72 53 0 RV Eng ine – Drawing No. 0G7 7 1 9-B 24 25 23 24,27,28,29,30,31,32,33,34,35,36,39,41 24,27,28,29,30,31,32,33,34,35,39,41,46 1,24,39,44,48 48,49 55 52 53 54 26 37 38 30 31 14 3 22 21 19 32 5 6 2 1 4 7 20 12 10 11 9 8 19 17 15 18 15 16 47 27 28 29 39 36 35 34 33 42 5 41 51 44 43 1 40 13 48 50 49 45 46 Section 9 Exploded Views[...]

Section 9 Exploded Views P age 73 ITEM QTY . DESCRIPTION 1 2 SEaL D 35 X 48.2 2 1 3/8” SQ U arE HEaD PLUG 3 9 SCrEW HHFC M8 – 1.25 X 45 4 1 GEar CO VEr 5 6 SLEEVE DOWEL PIN 6 1 11/32 DIaMEtEr PrESSUrE rELIEF BaLL 7 1 OIL PrESSUrE SPrING 8 1 GEarO tOr, OUtEr 9 1 GEarO tOr, INNEr 10 1 SCrEEN, OIL PICK-UP 11 1 COVEr, GEr Ot Or 12 3 SCrEW , HHFCS M[...]

P age 74 Rotor & Stator – Drawing No. 0G395 3-b 4 3 2 1 5 6 7 5 9 10 11 1 23 12 7 16 17 19 18 13 14 15 21 20 22 Section 9 Exploded Views[...]

Section 9 Exploded Views P age 75 ITEM QTY . DESCRIPTION 1 6 NUt tOP LOCK FL M8-1.25 2 4 W aSHEr, SPrNG CENtEr 3 4 SPrING, GEN. MOUNt 4 2 SUPPOrt , SLIDE 5 4 SLIDE, NYLON 6 2 SCrEW HHC M8-1.25 X 70 G8.8 7 6 W aSHEr FLa t 5/16-M8 ZINC 9 4 StUD , 530 r V St a tOr 10 2 tENSION SPrING 11 2 W aSHEr, SPrING CENtr 12 1 LO WEr BEarING CarrIEr 13 1 rO tOr 1[...]

424.8 [16 3/4"] 29.6 [1 3/16"] BA TTER Y CONNECTION (NEGA TIVE) 50 [1 15/16"] TY P. 469.9 [18 1/2"] AC OUTPUT HARNESS 109.1 [4 5/16"] 543.8 [21 7/16"] FRONT DOOR A CCESS FOR REQUIRED MAINTENANCE 853.4 [33 5/8"] FUEL INLET BA TTER Y CONNECTION (POSITIVE) 3/8"-16 THD . (4 PLACES) REM OT E ST ART CONNECTION 41.1[...]

Section 10 SPECIFICA TIONS & CHAR TS P age 77 TYPE R V 45G/LP R V 55G/LP R V 65G/LP MODEL 5410/5411 5412/5413 5414/5415 WEIGHT 278/281 pounds 285/288 pounds 293/296 pounds TYPE OF RO T OR T wo-pole T wo-pole T wo-pole RA TED W A TTS 4500 5500 6500 RA TED V OL TS 120 120 120 PHASE 1-Phase 1-Phase 1-Phase RA TED MAX. CONTINUOUS CURRENT AMPS (240V[...]

Section 11 ELECTRICAL D A T A P age 78 Electrical Schematic and Wiring Diagram – Drawing No. 0G4221 -B[...]

Section 11 ELECTRICAL D A T A P age 79 Electrical Schematic and Wiring Diagram – Drawing No. 0G4221 -B[...]

PO BOx 297 • WhiteWa ter, Wi 53190 • www .guardiangenerators.com P/N OG7515 reV . a PriNteD iN the USa / 03.08[...]