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Section 6

TROUBLESHOOTING FLOWCHARTS

Page 27

REPAIR

REPLACE

REPAIR

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

GOOD

TEST 6 – TEST

STATOR DPE

WINDING

TEST 10 –

CHECK ROTOR

ASSEMBLY

TEST 7 – CHECK

SENSING LEADS /

POWER WINDINGS

CHECK VOM FUSES –

VERIFY AMP METER

FUNCTIONS

REPLACE FUSES

– THEN RE-TEST

EITHER OR

BOTH BAD

(PERFORM BOTH TEST 7 & 8)

REPLACE

PRINTED CIRCUIT

BOARD

GO TO PROBLEM 8

TEST 2 – CHECK

STEPPER MOTOR

CONTROL

TEST 12 – CHECK

LOAD VOLTAGE &

FREQUENCY

TEST 13 – CHECK

LOAD WATTS &

AMPERAGE

BAD

GOOD

END TEST

GOOD

Problem 3 – Excessive Voltage/Frequency Droop When Load is Applied

(Underspeed Warning – 4 Flashes on SW1 LED)

NOT OVERLOADED

OVERLOADED

REDUCE LOAD

Default Chapter3
- Table of Contents3
Section 15
Safety5
Generator Fundamentals5
- Magnetism5
- Electromagnetic Fields5
- Electromagnetic Induction5
- A Simple Ac Generator6
- A more Sophisticated Ac Generator6
- Field Boost8
- Generator Ac Connection System8
Section 210
Major Generator Components10
- Rotor Assembly10
- Stator Assembly10
- Brush Holder11
- Excitation CIRCUIT COMPONENTS11
- Crankcase BREATHER12
- Control Panel Component Identification13
- Major Generator Components13
Section 314
Insulation Resistance Tests14
- Effects of Dirt and Moisture14
- Insulation Resistance Testers14
- Drying the Generator14
- Cleaning the Generator14
- Stator Insulation Resistance15
- Test15
- Testing Rotor Insulation16
- The Megohmmeter16
Section 417
Measuring Electricity17
- Meters17
- The vom17
- Measuring Ac Voltage17
- Measuring DC Voltage17
- MEASURING AC Frequency17
- Test17
- Measuring Current18
- Measuring Resistance18
- Test18
- Electrical Units19
- Ohm's Law19
Section 520
Engine DC Control System20
- Introduction20
- Operational Analysis20
- Printed Circuit Board24
- Battery24
- 7.5 Amp Fuse25
- Start-Stop Switch25
- Test25
- Starter Contactor Relay & Starter Motor26
Troubleshooting Flowcharts27
- If Problem Involves Ac Output27
- Problem 427
- High or Low27
  - VOLTAGE & Frequency ARE both HIGH or LOW27
  - Test27
- Problem28
- Generator Produces Zero Voltage or Residual Voltage (5-12VAC)28
- Test28
- Excessive Voltage/Frequency DROOP WHEN LOAD IS APPLIED29
- Test29
- Engine Overspeed Warning Code Flashing on Sw1 Led (4 Flashes)30
- PRIMING FUNCTION DOES NOT Work (GASOLINE MODELS)30
- Test30
- ENGINE will NOT Crank31
- Test31
- ENGINE Cranks but will NOT START (GASOLINE UNITS)32
- Test32
- ENGINE Cranks but will NOT START (LP UNITS)33
- Test33
- Engine Starts Hard and Runs Rough (Gasoline Units)34
- Test34
- Engine Starts Hard and Runs Rough (Lp Units)35
- Test35
- Or Low Oil Pressure Fault (5 Flashes)36
  - Troubleshooting Flowcharts36
  - Test36
- Problem 10 - 7.5 Amp (F1) Fuse Blowing37
- Test37
Section 738
Diagnostic Tests38
- Introduction38
- Check No-Load Voltage and Frequency38
- Check Stepper Motor Control38
- Test38
- Fixed Excitation Test/Rotor Amp Draw39
  - Test39
  - Test40
- Check Field Boost41
- Test Stator DPE Winding41
- Check Sensing Leads/Power Windings42
- Test42
- Check Brush Leads43
- Test43
- Check Brushes & Slip Rings44
- Test44
- Check Main Circuit Breaker45
- Check Load Voltage & Frequency45
- Check Load Watts & Amperage45
- Try Cranking the Engine46
- Check Fuel Pump46
- Check 7.5 Amp Fuse47
- Test47
- Check Battery & Cables47
- Check Power Supply to Printed Circuit Board47
- Check Continuity of Wire 1748
- Test48
- Check Start-Stop Switch48
- Check Power Supply to Wire 5649
- Check Starter Contactor Relay49
- Test49
- Check Starter Contactor50
- Check Starter Motor50
- Test50
- Check Fuel Supply53
- Check Wire 14 Power Supply54
- TEST 27 - Check Wire 1855
- (Gasoline Models)55
- Check Ignition Spark56
- Check Spark Plugs57
- Check and Adjust Ignition Magnetos57
  - Check Valve Adjustment59
  - Check Carburetion60
  - Check Choke Solenoid60
  - Check Engine / Cylinder Leak down Test / Compression Test61
  - Check Oil Pressure Switch62
  - Test Wire 86 for Continuity63
  - Test Oil Temperature Switch63
  - Test Wire 85 for Continuity64
  - Test Choke Heater64
  - Check LPG Fuel Solenoid65
Section 866
Exploded Views / PART NUMBERS66
- Base & Pulley Drawing66
- Enclosure Drawing68
- Control Panel Drawing70
- Engine Accessories Drawing72
- Rv Engine Drawing74
- Rotor and Stator Drawing76
Section 978
Specifications & Charts78
- Major FEATURES and DIMENSIONS78
- Generator Specifications79
- Nominal Resistances of Generator Windings at 68°F79
- Torque Requirements79
Section 1079
Electrical Data80
- Electrical Schematic and Wiring Diagram80
- Electrical Data81

Brand	Generac Power Systems
Model	Guardian 5410
Category	Inverter
Language	English

Generac Power Systems Guardian 5410 User Manual

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