Generac Power Systems Guardian 5410 User Manual

RV 45/55/65
Diagnostic
RepaiR Manual
Diagnostic
RepaiR Manual
RECREATIONAL VEHICLE GENERATOR
MoDels 5410, 5411, 5412,
5413, 5414 & 5415

Generac Power Systems Guardian 5410 Specifications

General

Start Type	Electric
Voltage	120/240 V
Frequency	60 Hz
Fuel Type	Gasoline/Propane
Warranty	3 years

Summary

Safety Precautions

Section 1: Generator Fundamentals

Section 2: Major Generator Components

Section 3: Insulation Resistance Tests

Stator Short-to-Ground Tests

Test Between Isolated Windings

Test Between Parallel Windings

Testing Rotor Insulation

The Megohmmeter

Testing Stator Insulation

Section 4: Measuring Electricity

Section 5: Engine DC Control System

Circuit Condition: Cranking

Circuit Condition: Running

Circuit Condition: Shutdown

Circuit Condition: Fault Shutdown

Starter Contactor Relay and Motor

Section 6: Troubleshooting Flowcharts

Problem 1: Voltage & Frequency High or Low

Flowchart for diagnosing voltage and frequency issues.

Problem 2: Zero or Residual AC Voltage

Flowchart for troubleshooting zero or low residual AC voltage output.

Problem 3: Excessive Voltage/Frequency Droop

Flowchart for diagnosing voltage/frequency droop under load.

Problem 4: Engine Overspeed Warning

Flowchart for troubleshooting engine overspeed warnings.

Problem 5: Priming Function Not Working

Flowchart for diagnosing priming issues on gasoline models.

Problem 6: Engine Will Not Crank

Flowchart for troubleshooting when the engine fails to crank.

Problem 7: Engine Cranks But Won't Start (Gasoline)

Flowchart for diagnosing engine crank-but-no-start issues in gasoline units.

Problem 7: Engine Cranks But Won't Start (LP)

Flowchart for diagnosing engine crank-but-no-start issues in LP units.

Problem 8: Engine Starts Hard and Runs Rough (Gasoline)

Flowchart for troubleshooting hard starting and rough running in gasoline units.

Problem 8: Engine Starts Hard and Runs Rough (LP)

Flowchart for troubleshooting hard starting and rough running in LP units.

Problem 9: High Oil Temp or Low Oil Pressure Fault

Flowchart for diagnosing high oil temp or low oil pressure faults.

Problem 10: 7.5A (F1) Fuse Blowing

Flowchart for troubleshooting a blown 7.5A fuse.

Section 7: Diagnostic Tests

Test 1: Check No-Load Voltage and Frequency

Procedures to check generator output voltage and frequency at no load.

Test 2: Check Stepper Motor Control

Checks the stepper motor's movement for proper throttle control.

Test 4: Fixed Excitation Test/Rotor Amp Draw

Tests the excitation circuit by applying battery voltage to the rotor.

Test 5: Check Field Boost

Checks if field boost current is delivered to the rotor during cranking.

Test 6: Test Stator DPE Winding

Tests the stator excitation winding for open circuits.

Test 7: Check Sensing Leads/Power Windings

Checks sensing leads and power windings for proper resistance and shorts.

Test 8: Check Brush Leads

Verifies continuity of wires connecting the voltage regulator to the brush terminals.

Test 9: Check Brushes & Slip Rings

Inspects brushes and slip rings for wear, damage, or oxide film.

Test 10: Check Rotor Assembly

Tests the rotor assembly for open or shorted conditions.

Test 11: Check Main Circuit Breaker

Checks if the main circuit breaker is closed and has continuity.

Test 12: Check Load Voltage & Frequency

Checks generator output voltage and frequency under load.

Test 13: Check Load Watts & Amperage

Determines if the generator's rated capacity is exceeded by the applied loads.

Test 14: Try Cranking the Engine

Tests if the engine cranks and the priming function works.

Test 15: Check Fuel Pump

Verifies fuel pump operation and fuel flow to the carburetor.

Test 16: Check 7.5 Amp Fuse

Checks if the 7.5 amp fuse has blown, preventing cranking.

Test 17: Check Battery & Cables

Assesses battery condition and cable connections for proper voltage.

Test 18: Check Power Supply to Printed Circuit Board

Verifies battery voltage is supplied to the PCB for cranking.

Test 19: Check Continuity of Wire 17

Checks continuity of the wire that initiates cranking when grounded.

Test 20: Check Start-Stop Switch

Test 21: Check Power Supply to Wire 56

Test 22: Check Starter Contactor Relay

Test 23: Check Starter Contactor

Test 24: Check Starter Motor

Testing Starter Motor Performance

Test 25: Check Fuel Supply

Test 26: Check Wire 14 Power Supply

Test 27: Check Wire 18

Test 28: Check Fuel Solenoid (Gasoline Models)

Test 29: Check Ignition Spark

Tests for ignition spark using a spark tester.

Cylinder Balance Test

Test 30: Check Spark Plugs

Test 31: Check and Adjust Ignition Magnetos

Checks and adjusts the air gap for ignition magnetos.

Test 32: Check Valve Adjustment

Test 33: Check Carburetion

Test 34: Check Choke Solenoid

Test 35: Check Engine/Cylinder Leak Down Test/Compression Test

Checks engine sealing and compression using leak down and compression tests.

Test 36: Check Oil Pressure Switch

Test 37: Check Wire 86 for Continuity

Test 38: Test Oil Temperature Switch

Test 39: Check Wire 85 for Continuity

Test 40: Test Choke Heater

Test 41: Check LPG Fuel Solenoid

Section 9: Exploded Views

Section 10: Specifications & Charts

Generator Specifications

Nominal Generator Winding Resistances

Torque Requirements

Section 11: Electrical Data

Electrical Schematic and Wiring Diagram

Presents the generator's electrical schematic and wiring diagram.